Weir Minerals Netherlands

P.O. Box 249, 5900 AE Venlo, the Netherlands Tel: +31(0)77 3895200
Egtenrayseweg 9, NL-5928 PH Venlo Fax: +31(0)77 3824844
4495 Email: [email protected]
Registration No.: 12032525 WWW: http://www.weirminerals.com

Installation, Operating and

Maintenance Manual

WEIR Pump type : TZPM 1200

WEIR Pump number : 6200981/1+2

WEIR Project name : Atacocha

WEIR Document number : MUI.814.200981.R01.EN

Customer P.O. number :--

Copyright Weir Minerals Netherlands b.v. 2007.

Weir Minerals Netherlands b.v. is the owner of the copyright subsisting in the instructions and drawings stored in this manual. All material of this manual are protected by the Dutch Copyright Law, international
treaty provisions and applicable laws in the country in which it is being used. The material must not be used, reproduced or copied in whole or in part, in any form or by any means, nor may the information
therein contained, which is confidential to Weir Minerals Netherlands b.v be disclosed to any person without the prior written permission of Weir Minerals Netherlands b.v. Furthermore you may not rent, lease,
sublicense or lend the manual and its contents. The manual has been delivered and received on the express condition that it may be used only for the specific purpose for which it has been provided and may
not be used in any way which may injure or cause loss directly or indirectly to Weir Minerals Netherlands b.v. or any related corporation.
Disclaimer.
Except to the extent legislation expressly prohibits the exclusion of provisions as to warranties, Weir Minerals Netherlands b.v. disclaims all warranties as to the instructions and drawings, whether express or
implied, including without limitation any implied warranties of merchantability, fitness for a particular purpose, compatibility with any particular system, or data integrity and the user assumes all responsibility for
the use of the software on its system.
Preface

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1. Preface
Pos: 1.1.2 /GEHO/Preface/General/Diaphragm pumps/Introduction @ 0\mod_1133188276656_31.doc @ 121

This piston diaphragm pump is developed by Weir Minerals Netherlands.

Pos: 1.1.3 /GEHO/Preface/General/Common intro @ 0\mod_1139913202827_31.doc @ 2530

This manual with its user and safety instructions is an integral part of the pump delivery and must be kept in
its neighborhood, accessible for reference at all times.

All persons involved in using and operating this pump and working at this pump must have read and
understood this manual and must comply with it at all times.
We accept no responsibility for damage or disruption caused by disregard of this manual and its instructions.

These operating instructions apply to the GEHO PUMPS equipment during:

Pos: 1.1.4 /GEHO/Preface/General/Purpose - Final @ 0\mod_1139912839316_31.doc @ 2518

Transport
Installation
Operation, start and stop procedure
Maintenance
Pos: 1.1.5 /GEHO/Preface/General/Use @ 0\mod_1133427209923_31.doc @ 246

This equipment, supplied by Weir Minerals Netherlands, is only allowed to be used, according to and
restricted to the technical data. Before exceeding the technical data, a written permission from Weir Minerals
Netherlands is required.
Pos: 1.2 /GEHO/Preface/Project/200981/General overview @ 1\mod_1165846096999_0.doc @ 9138

Pos: 1.3 /GEHO/Heading/H2/#.# Revision form @ 0\mod_1133271476093_31.doc @ 213

1.1 Revision form

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Rev. No. Chapter Description By Checked Date

R00.EN Preliminary release GHH March-02-2007
Manual Transport and Installation
R01.EN All Final issue GHH June-28-2007

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MUI.814.200981.R01.EN 1.1
Contents

Pos: 3 /GEHO/General/Special formats/Table of contents @ 0\mod_1133257649241_31.doc @ 147

2. Contents

1. Preface ....................................................................................... 1.1

1.1 Revision form...............................................................................................1.1

2. Contents..................................................................................... 2.1

3. SAFETY...................................................................................... 3.1
3.1 Safety symbols ............................................................................................3.1
3.2 Important information .................................................................................3.2
3.3 Intended use ................................................................................................3.3
3.4 General safety instructions ........................................................................3.3
3.5 Qualified workers ........................................................................................3.3
3.6 Working on the pump .................................................................................3.3
3.7 Efficient use .................................................................................................3.3
3.8 Safety equipment ........................................................................................3.4
3.8.1 Emergency stop button ............................................................................................. 3.4
3.8.2 Safety covers and safety guards............................................................................... 3.4

4. Technical data ........................................................................... 4.1

4.1 Project information......................................................................................4.1
4.2 Customer information.................................................................................4.1
4.3 Manufacturer information...........................................................................4.1
4.4 Technical data..............................................................................................4.2
4.4.1 Operating characteristics........................................................................................... 4.2
4.4.2 Pump and project data .............................................................................................. 4.3
4.5 Tightening torques......................................................................................4.5
4.5.1 General torques......................................................................................................... 4.5
4.5.2 Foundation bolt torques according to DIN 529 ......................................................... 4.5
4.5.3 Special torques .......................................................................................................... 4.5
4.6 Auxiliary connections and lubrication data .............................................4.7
4.7 Instruments and drawings .........................................................................4.7

5. Description ................................................................................ 5.1

5.1 Introduction..................................................................................................5.1
5.2 Working principle ........................................................................................5.2
5.3 Drive unit ......................................................................................................5.3
5.4 Power end ....................................................................................................5.3
5.4.1 Lubrication unit .......................................................................................................... 5.3

MUI.814.200981.R01.EN 2.1
 Contents

5.5 Liquid end ....................................................................................................5.3

5.5.1 The propelling liquid section.......................................................................................5.4
5.5.2 The slurry section .......................................................................................................5.4
5.5.3 Piston unit ...................................................................................................................5.4
5.5.4 Propelling liquid control system..................................................................................5.5
5.5.5 Flushing unit ...............................................................................................................5.6
5.5.6 Diaphragm housing unit .............................................................................................5.6
5.5.7 Suction valve unit .......................................................................................................5.7
5.5.8 Discharge valve unit ...................................................................................................5.7
5.5.9 Suction pulsation dampener.......................................................................................5.7
5.5.10 Discharge pulsation dampener ..................................................................................5.7
5.5.11 Pressure limitation system .........................................................................................5.7
5.6 Pump control system..................................................................................5.8

6. Transport and installation ........................................................6.1

6.1 Transport and lifting ...................................................................................6.1
6.1.1 Weights and weight limits...........................................................................................6.1
6.1.2 Transport ....................................................................................................................6.2
6.1.3 Pump ..........................................................................................................................6.2
6.1.4 Drive unit.....................................................................................................................6.3
6.1.5 Smaller parts...............................................................................................................6.3
6.2 Installation....................................................................................................6.4
6.2.1 Foundation..................................................................................................................6.4
6.2.2 Drive unit.....................................................................................................................6.6
6.2.3 Safety regulations and instructions for nitrogen.......................................................6.11
6.2.4 Pre-charging the suction pulsation dampener, set-point instructions......................6.12
6.2.5 Pre-charging the discharge pulsation dampener, set-point instructions .................6.14
6.2.6 Pre-charging a pulsation dampener with nitrogen ...................................................6.16
6.2.7 Pre-charging an accumulator with nitrogen .............................................................6.19

7. Operation, Start-up + Start + Stop procedures ......................7.1

7.1 Start-up checklist, working with main power switch OFF ......................7.1
7.1.1 Initial lubrication filling.................................................................................................7.1
7.1.2 Propelling liquid ..........................................................................................................7.2
7.1.3 Air supply unit .............................................................................................................7.2
7.1.4 Pre-charging a pulsation dampener with nitrogen .....................................................7.3
7.1.5 Pre-charging an accumulator with nitrogen ...............................................................7.3
7.2 Start-up checklist, working with main power switch ON........................7.3
7.2.1 Main power switch......................................................................................................7.3
7.2.2 Start-up, electrical check ............................................................................................7.3
7.2.3 Initial power end oil check ..........................................................................................7.3
7.3 Start-up, priming procedure.......................................................................7.4
7.3.1 Priming the slurry section ...........................................................................................7.4
7.3.2 Priming the propelling liquid section...........................................................................7.6
7.4 Operating the GEHO touch panel and pump control system ................7.8
7.5 Start...............................................................................................................7.8
7.5.1 PRE-START check list ...............................................................................................7.8
7.5.2 PRE-START procedure..............................................................................................7.8

2.2 MUI.814.200981.R01.EN
Contents

7.5.3 START procedure by local control ............................................................................ 7.8

7.5.4 START by remote control.......................................................................................... 7.9
7.6 Stop.............................................................................................................7.10
7.6.1 Emergency stop....................................................................................................... 7.10
7.6.2 STOP by remote control.......................................................................................... 7.10
7.6.3 STOP for stand-by................................................................................................... 7.10
7.6.4 STOP for flushing procedure................................................................................... 7.12
7.6.5 STOP for maintenance procedure .......................................................................... 7.13

8. Maintenance .............................................................................. 8.1

8.1 Maintenance safety instructions ...............................................................8.1
8.2 Maintenance checkpoints ..........................................................................8.2
8.3 Location of parts and maintenance checkpoints ....................................8.9
8.4 Description of parts and maintenance checkpoints .............................8.12
8.5 Lubrication system ...................................................................................8.15
8.5.1 Check the oil level.................................................................................................... 8.15
8.5.2 Change the oil filter.................................................................................................. 8.15
8.5.3 Clean the oil sump................................................................................................... 8.15
8.5.4 Replace the pump oil and the oil suction filter......................................................... 8.16
8.5.5 Replace the air filter at the pump frame .................................................................. 8.16
8.6 Propelling liquid system...........................................................................8.16
8.6.1 Replace the air filter at the propelling liquid system................................................ 8.16

9. Troubleshooting........................................................................ 9.1
9.1 Trouble shooting .........................................................................................9.1
9.1.1 Diaphragm pulsation dampener................................................................................ 9.7
9.2 Typical wear phenomena and its causes .................................................9.9
9.2.1 Valves ........................................................................................................................ 9.9
9.2.2 Pump diaphragm ..................................................................................................... 9.10
9.2.3 Pulsation dampener diaphragm .............................................................................. 9.10
9.2.4 Piston ....................................................................................................................... 9.11
9.2.5 Cylinder liner............................................................................................................ 9.11

10. Assembly and disassembly................................................... 10.1

10.1 Special tools ..............................................................................................10.2
10.1.1 Socket wrench ......................................................................................................... 10.2
10.1.2 Air driven hydraulic pump........................................................................................ 10.2
10.2 Valves, discharge angular........................................................................10.3
10.2.1 Valve housing cover ................................................................................................ 10.3
10.2.2 Conical valve ........................................................................................................... 10.4
10.2.3 Valve seat ................................................................................................................ 10.5
10.3 Valves, suction inline................................................................................10.7
10.3.1 Valve housing cover ................................................................................................ 10.7
10.3.2 Conical valve ........................................................................................................... 10.8
10.3.3 Valve seat .............................................................................................................. 10.11

MUI.814.200981.R01.EN 2.3
 Contents

10.3.4 Valve disk .............................................................................................................. 10.12

10.4 Piston unit ................................................................................................10.14
10.4.1 Disassembly .......................................................................................................... 10.14
10.4.2 Assembly ............................................................................................................... 10.16
10.5 Diaphragm housing unit.........................................................................10.18
10.5.1 Disassembly .......................................................................................................... 10.18
10.5.2 Assembly ............................................................................................................... 10.21
10.6 Frame unit ................................................................................................10.23
10.7 Pulsation dampener................................................................................10.24
10.7.1 Diaphragm removing............................................................................................. 10.25
10.7.2 Diaphragm assembly ............................................................................................ 10.25
10.8 Nitrogen filling device.............................................................................10.29
10.9 Drive unit ..................................................................................................10.29

11. Appendix: Parts - Lists and drawings (pump section) .......11.1

12. Appendix: Parts - Lists and drawings (special tools) .........12.1

13. Appendix: Electrical information...........................................13.1

14. Appendix: Catalogue information .........................................14.1

Pos: 4 /--- Section break - Odd page --- @ 0\mod_1136277036628_0.doc @ 765

2.4 MUI.814.200981.R01.EN
SAFETY

Pos: 5.1 /GEHO/Heading/H1/#. SAFETY @ 0\mod_1133270411081_31.doc @ 195

3.
Pos: 5.2 /GEHO/Heading/H2/#.# Safety symbols @ 0\mod_1133271418089_31.doc @ 211
SAFETY
3.1 Safety symbols
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The hazards are classified into various stages.

The table below gives a summary of the signs, classes of risk and signal words used in this manual.
Sign Signal word Definition Consequences
DANGER Dangerous situation Death or serious injuries

WARNING Possible dangerous situation Death or most serious injuries

CAUTION Less dangerous situation Slight or minor injuries

Attention Possible harmful Possible damage to:

The equipment
The environment

Note or Application hints and other useful No signal word indicating a dangerous
Information information or harmful situation

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MUI.814.200981.R01.EN 3.1
 SAFETY

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3.2 Important information

Pos: 5.6 /GEHO/Safety/General/Important information @ 0\mod_1137680237357_31.doc @ 1362

This manual is intended to help you operate this machine safely and effectively. It is intended for use by
people who have followed the training program that this manual accompanies. If you have not followed this
program, but would like to do so, contact your supervisor or training manager.

This machine was designed with safety in mind, and includes features to help prevent injury and damage.
However, all powerful machines can be dangerous if misused. This manual is intended to help you operate
the machine in a safe manner. In this manual, the user is the body with authority over and responsibility for
the machine - usually a company or a corporation. An operator is a person who physically interacts with the
machine and/or the machine's control systems under the direction and with the consent of the machine's
user.

It is your responsibility to operate this machine in accordance with all the safety instructions and procedures
in this manual, and with all other safety procedures in your workplace. It is the user's responsibility to make
sure that the machine is correctly installed, configured, commissioned, operated, serviced and maintained
and that such actions are only carried out by people who have been fully and properly trained for those tasks.
It is also the user's responsibility to make sure that the machine is only used in full accordance with laws (and
regulations, which have the force of law) in the jurisdiction in which the machine is installed.

DANGER
Before attempting to use the machine, read, understand and know all the safety information
in this chapter.
Pay particular attention to all warnings and cautions throughout this manual.
If you do not follow all the warnings and procedures in this manual, then this could lead to
serious injury to yourself or others, including death.
If there is any safety instruction or procedure that you do not understand, then do not use
the machine.
Contact your supervisor and arrange proper training on the use of the machine.
Use of the machine without understanding and following all the safety instructions and
procedures in this manual could lead to serious injury to yourself or others, including death.

WARNING

Never use the machine, until you are sure that the routine checks described is completed
and that the routine preventive maintenance program is up-to-date.
If any part of the machine is known (or suspected) to be defective or wrongly adjusted, then
do not use the machine until a repair has been made.
Operation of the machine with defective or wrongly adjusted components could create
safety hazards. This could lead to fatal or other serious personal injury.

WARNING

Never use the machine until you have received adequate and proper training in its safe and
effective use.
If you are unsure of your ability to use the machine safely and effectively, then do not do so.
The use of the machine without proper and adequate training could lead to fatal or other
serious personal injury.
Never attempt to remove, modify, over-ride or frustrate any safety device on the machine.
Interfering with safety devices could lead to fatal or other serious personal injury.
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3.2 MUI.814.200981.R01.EN
SAFETY

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3.3 Intended use

Pos: 5.9 /GEHO/Safety/Product Safety/Intended use @ 0\mod_1138263117509_31.doc @ 1914

This pump is intended to pump a liquid media only.

The liquid media is specified by the customer.
Refer to the chapter Technical data for a detailed specification.
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3.4 General safety instructions

Pos: 5.11 /GEHO/Safety/Product Safety/General safety instructions @ 0\mod_1133426798361_31.doc @ 244

Always obey local safety regulations and instructions.

Never cause a potentially dangerous situation.
Never touch moving parts.
Never loosen parts under pressure.
Never touch parts with high temperature.
Never touch parts under electrical power.
Never touch parts which contain dangerous or poisonous media.
Pos: 5.12 /GEHO/Heading/H2/#.# Qualified workers @ 0\mod_1133271087294_31.doc @ 203

3.5 Qualified workers

Pos: 5.13 /GEHO/Safety/Product Safety/Qualified workers @ 0\mod_1133271624877_31.doc @ 219

Only personnel who have been given permission are allowed to work with or on the machine.
All personnel must only carry out the work they have been trained to perform.
This applies to both maintenance work and the normal machine operation.
All personnel working with or on the machine must have free access to the applicable manuals.
The operators must be familiar with all situations that may occur so that they can act rapidly and effectively
in the event of emergencies.
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3.6 Working on the pump

Pos: 5.15 /GEHO/Safety/Product Safety/Working on the pump @ 0\mod_1133428079834_31.doc @ 250

Switch off the main power supply and secure the equipment against switching on.
Never loosen any parts containing pressure, hot or dangerous fluids.
Pos: 5.16 /GEHO/Heading/H2/#.# Efficient use @ 0\mod_1133271247864_31.doc @ 207

3.7 Efficient use

Pos: 5.17 /GEHO/Safety/Product Safety/Efficient use @ 0\mod_1133427598361_31.doc @ 248

Apply correct and regular maintenance, according to these operating instructions.

Always use genuine GEHO spare parts and wear parts.
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MUI.814.200981.R01.EN 3.3
 SAFETY

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3.8 Safety equipment

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3.8.1 Emergency stop button

Pos: 5.21 /GEHO/Safety/Product Safety/Emergency stop button @ 0\mod_1137483963358_31.doc @ 1243

Refer to chapter "Start and Stop procedure" for details about the use of the emergency stop button.
According to local regulations an emergency stop button must be provided by the customer.
INFORMATION
An emergency stop situation is defined in the EN 60204 standard.
An emergency stop is a human action in case of emergency, which is determined to stop a
process or movement that could cause an unsafe situation.
An emergency stop has priority towards all functions and controls in all kind of modes.
Reset an emergency stop may not cause an automatic restart.
Functional aspects for switching off at emergency as described in the international
document IEC 60364 or NEC should be observed.
The final customer emergency stop design must be in accordance to the concerning risk
class and all local regulations.
If no MCC (motor control center) hardware is in the manufacturers scope of supply, an
emergency stop will not be added, due to lack of MCC configuration information.
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3.8.2 Safety covers and safety guards

Pos: 5.23 /GEHO/Safety/Product Safety/Safety covers and safety guards @ 0\mod_1137486711069_31.doc @ 1249

The equipment has safety covers and safety guards at all potential unsafe parts.
Safety covers and safety guards must remain in place during operation.
Safety covers and safety guards may only be removed by qualified personnel for maintenance or service
work.
Pos: 6 /--- Section break - Odd page --- @ 0\mod_1136277036628_0.doc @ 765

3.4 MUI.814.200981.R01.EN
Technical data

Pos: 7 /GEHO/Heading/H1/#. Technical data @ 0\mod_1133269719867_31.doc @ 179

4.
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Technical data
4.1 Project information
Pos: 8.2 /GEHO/Technical data sheets/Project information @ 0\mod_1133439392901_31.doc @ 273

WEIR Project information

WEIR Project name Atacocha
WEIR Project number 200981
Customer purchase order number --
Pos: 8.3 /GEHO/Heading/H2/#.# Customer information @ 0\mod_1133443655420_31.doc @ 291

4.2 Customer information

Pos: 8.4 /GEHO/Technical data sheets/Project/200981/Customer information @ 1\mod_1165846379926_31.doc @ 9147

Customer information
Name ATACOCHA
Address Compania Minera Atacocha S.A.
Av. Javier Prado Oeste 980
San Isidro - Lima 27
Pos: 8.5 /GEHO/Heading/H2/#.# Manufacturer information @ 0\mod_1133443515208_31.doc @ 288
Peru

4.3 Manufacturer information

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Manufacturer information
Name Weir Minerals Netherlands b.v.
Address P.O. Box 249
NL5900AE - VENLO, the Netherlands
Phone (+31) 77-3895200
Fax (+31) 77-3824844
E-mail [email protected]
Website http://www.weirminerals.com
Department Installation, Commissioning
Mr. P.C. Karoly
Phone (+31) 77-3895169
Fax (+31) 77-3824844\
Department Spare Parts
Mr. R. Reijnders
Phone (+31) 77-3895236
Fax (+31) 77-3824844
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MUI.814.200981.R01.EN 4.1
 Technical data

Pos: 8.8 /GEHO/Heading/H2/#.# Technical data @ 0\mod_1133270813820_31.doc @ 198

4.4 Technical data

Pos: 8.9 /GEHO/Heading/H3/#.#.# Operating characteristics @ 0\mod_1133443294151_31.doc @ 286

4.4.1 Operating characteristics

Pos: 8.10 /GEHO/Technical data sheets/Project/200981/Operation characteristics @ 1\mod_1165846392976_31.doc @ 9165

Operation characteristics
Location of the equipment Under roof
Liquid to be pumped Slurry, tailings
Specific slurry gravity 1.687 [ - ]
Maximum solid diameter 4 mm
Solid concentration, normal 60%
Solid concentration, maximum Not available
Minimum slurry temperature Not available
Operating slurry temperature Not available
Maximum slurry temperature 80C
Maximum viscosity Not available
Site elevation 3540 masl (meters above sea level)

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4.2 MUI.814.200981.R01.EN
Technical data

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4.4.2 Pump and project data

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Refer for details also to:

- Chapter "Instruments and drawings": 814.200981.00 "Dimensioned outline drawing".
- Chapter "Instruments and drawings": 814.200981.00 "Instrument and equipment list".
- Chapter "Electrical information".
- Chapter "Catalogue information".

GEHO pump 6200981/1+2

Pump Type TZPM 1200
see GEHO PUMPS identification plate
Pump No. 6200981/1 + 6200981/2
see GEHO PUMPS identification plate
Capacity Minimum 20 m3/hour
see GEHO PUMPS identification plate Maximum 197 m3/hour
Stroke rate (stroke per minute of a piston) Minimum 5.7 spm
see GEHO PUMPS identification plate: Maximum 55.7 spm
n (s/min)
Operating discharge pressure Rated 13 900 kPa
see GEHO PUMPS identification plate Maximum 13 900 kPa
Required power Minimum 82 kW
see GEHO PUMPS identification plate Maximum 801 kW
Pump power end ratio direct drive
Piston diameter 260 mm
Piston rod diameter not applicable
Stroke 406.4 mm
Diaphragm size 26.5 liter
Valve size API 11
Suction pulsation dampener, size 1 x 150/64
Discharge pulsation dampener, size 1 x 150/160

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MUI.814.200981.R01.EN 4.3
 Technical data

Pos: 8.15 /GEHO/Heading/H4/Connection - Electrical @ 0\mod_1133446672849_31.doc @ 306

Electrical connection
Pos: 8.16 /GEHO/Technical data sheets/Voltage/Brasil 4160/60/3 - 460/60/3 - 220/60/1 @ 1\mod_1160485842755_31.doc @ 6442

Item Voltage [V] Frequency [Hz] Phases

Main drive 4160 60 3
Auxiliary motors 460 60 3
Control panel 220 60 1
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Pump drive
Pos: 8.18 /GEHO/Technical data sheets/Main E-motor/ABB - HXR 500 LL 4 @ 1\mod_1173110750434_31.doc @ 12598

Main E-motor Refer to "Dimensioned outline drawing"

and "Catalogue information".
Manufacturer ABB
Type / size HXR 500 LL 4
Voltage 4160 V 60 Hz 3 Phases
Speed range 179.2 - 1792 rpm
Power range 88 - 875 kW (1173 HP)
Protection class SF1.15

Pos: 8.19 /GEHO/Technical data sheets/Frequency converter/Allen-Bradley 4160V/160A + 480V/8kVA @ 1\mod_1173112355608_31.doc @ 12602

Frequency converter Refer to "Dimensioned outline drawing"

and "Catalogue information".
Manufacturer Rockwell Automation
Type PowerFlex 7000
Allen-Bradley 4160V/160A + 480V/8kVA
Supply voltage 4160 V/160A 3 phases; 60 Hz

Pos: 8.20 /GEHO/Technical data sheets/Gearbox/Hansen - QHPM3-TRN31.5 @ 1\mod_1172485087208_31.doc @ 12502

Gearbox Refer to "Dimensioned outline drawing"

and "Catalogue information".
Manufacturer Hansen
Type QHPM3-TRN-31.5
Gearbox ratio 31.945
Input speed range 178.9 - 1788 rpm
Output speed range 5.6 - 55.97 rpm
Cooling Oil/air cooling unit
Pos: 8.21 /GEHO/Heading/H4/Shaft coupling @ 0\mod_1133540284412_31.doc @ 341

Shaft couplings
Pos: 8.22 /GEHO/Technical data sheets/Shaft coupling/Flender - RUPEX RWS 400 @ 1\mod_1163595753923_31.doc @ 8568

E-motor / Gearbox Refer to "Catalogue information" for details.

Manufacturer Flender
Type RUPEX RWS400

Pos: 8.23 /GEHO/Technical data sheets/Shaft coupling/Flender - ZAPEX ZWN 545A @ 0\mod_1133540782858_31.doc @ 346

4.4 MUI.814.200981.R01.EN
Technical data

Pump shaft / Gearbox Refer to "Catalogue information" for details.

Manufacturer Flender
Type ZAPEX ZWN 545A

Pos: 8.24 /GEHO/Heading/H2/#.# Tightening torques @ 0\mod_1133269909891_31.doc @ 183

4.5 Tightening torques

Pos: 8.25.1 /GEHO/Heading/H3/#.#.# General torques @ 0\mod_1133270125801_31.doc @ 190

4.5.1 General torques

Pos: 8.25.2 /GEHO/Technical data sheets/General torques/General torques - grade 8.8 @ 0\mod_1133862945227_31.doc @ 392

General = grade 8.8

Size Torque [Nm] Size Torque [Nm]

M8 20 M24 700
M10 50 M27 1040
M12 85 M30 1410
M16 210 M33 1930
M20 400 M36 2470
Pos: 8.26.1 /GEHO/Heading/H3/#.#.# Foundation bolt torques according to DIN 529 @ 0\mod_1133863490701_31.doc @ 397

4.5.2 Foundation bolt torques according to DIN 529

Pos: 8.26.2 /GEHO/Technical data sheets/General torques/Foundation bolt torques - grade 3.6 @ 0\mod_1133863255313_31.doc @ 395

General = grade 3.6

Size Torque [Nm] Size Torque [Nm]

M20 110 M30 380
M24 190 M33 520
M27 280 M36 660
Pos: 8.27.1 /GEHO/Heading/H3/#.#.# Special torques @ 0\mod_1133270014401_31.doc @ 187

4.5.3 Special torques

Pos: 8.27.2 /GEHO/Technical data sheets/Special torques/Diaphragm housing unit/H.832.010.123-M33 @ 2\mod_1178895354267_31.doc @ 13654

Diaphragm housing unit - 832.010.123-M33

Pos: 8.27.3 /GEHO/Technical data sheets/Special torques/A-Specification/A.807.004.886+A.807.004.771-Hydr. @ 0\mod_1138890120655_31.doc @ 2327

A.807.004.886 + A.807.004.771 Part list ID Torque [Nm] Pressure [kPa]

Monitoring rod / diaphragm 015 / 019 140
Diaphragm housing screw 038 = M33 1500
Power end connection nut 040, 044 1965
Diaphragm housing cover nut 045 Use special tool: Use special tool:
pin for cover nut. hydraulic tension unit.
1. Tighten 045
1.1. Pre-tighten 045 Pre-tighten cover nut with 125 000 pre-tighten.
pin, tight by hand.
1.2. Relieve for settling of parts 045 Relieve oil pressure.
1.3. Final-tighten 045 Final-tighten cover nut 125 000 final-tighten.
with pin, tight by hand.
2. Loosening 045 Loosening cover nut with 125 000
pin by hand.

MUI.814.200981.R01.EN 4.5
 Technical data

Pos: 8.27.4 /GEHO/Technical data sheets/Special torques/Discharge valve unit/831.020.358 @ 1\mod_1172573384825_31.doc @ 12522

Discharge valve unit (831.020.358) Part list ID Torque [Nm] Pressure [kPa]
Valve ring lock nut 013 300
Valve cover stud bolt 017 10 000
60 000
115 000
Valve cover nut 019 200 - 400
Connecting nipple / adapter 026 / 027 50
Clamping piece screw 041 / 046 80
Nut 051 1200

Pos: 8.27.5 /GEHO/Technical data sheets/Special torques/Suction valve unit/831.020.359 @ 0\mod_1138379280609_31.doc @ 2059

Suction valve unit (831.020.359) Part list ID Torque [Nm] Pressure [kPa]
Valve ring lock nut 013 300
Valve cover stud bolt 017 115 000
Valve cover nut 019 200 - 400
Connecting nipple / adapter 026 / 027 50
Valve unit lock nut 044 1200 pre-tighten
2400 pre-tighten
3700 final-tighten
Pos: 8.27.6 /GEHO/Technical data sheets/Special torques/Piston unit/835.096.204 @ 1\mod_1173115303413_31.doc @ 12606

Piston unit (835.096.204) Part list ID Torque [Nm] Pressure [kPa]

Piston unit lock nut 006 850
Piston body lock nut 010 2500

Pos: 8.27.7 /GEHO/Technical data sheets/Special torques/Pulsation damper unit/851.010.100 @ 0\mod_1147783310518_31.doc @ 4016

Pulsation damper unit (851.010.100) Part list ID Torque [Nm] Pressure [kPa]
Pulsation dampener flange nut 013 2800
Pulsation dampener cover nut 014 2800

Pos: 8.27.8 /GEHO/Technical data sheets/Special torques/Pulsation damper unit/851.010.104-A.807.004.760 @ 1\mod_1160476865862_31.doc @ 6424

Pulsation dampener unit 150/64 (851.010.104) Part list ID Torque [Nm] Pressure [kPa]
Pulsation dampener cover nut 014 1290

Pos: 8.27.9 /GEHO/Technical data sheets/Special torques/Special tools/897.010.710 @ 0\mod_1143217678540_31.doc @ 2882

Hydraulic pump unit (897.010.710) Part list ID Torque [Nm] Pressure [kPa]
Adapter / connecting nipple 002 / 003 50

Pos: 8.28 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766

4.6 MUI.814.200981.R01.EN
Technical data

Pos: 8.29 /GEHO/Heading/H2/#.# Auxiliary connections and Lubrication data @ 0\mod_1137667733207_31.doc @ 1351

4.6 Auxiliary connections and lubrication data

Pos: 8.30 /GEHO/Technical data sheets/Refer to Utlilty consumption list @ 0\mod_1148974052988_31.doc @ 4381

Refer in chapter "Instruments and drawings" to the Utility consumption list for more information about
auxiliary connections and lubrication data.
Pos: 8.31 /GEHO/Heading/H2/#.# Instruments and drawings @ 0\mod_1133876951146_31.doc @ 421

4.7 Instruments and drawings

Pos: 8.32 /GEHO/Technical data sheets/Project/200981/Instrument and drawings @ 1\mod_1166082493365_31.doc @ 9412

Drawings and lists

Dimensioned outline drawing 814.200981.00
Foundation drawing 814.200981.01
Instrument and equipment list 814.200981.02
P & I diagram 814.200981.03
Packing unit V.814.200981.15
Utility consumption list 814.200981.19
Description of Pump Control System 814.200981.20
Typical Manual of the GEHO Touch Panel 814.200000.20
Flushing/Filling/Drain Connections 814.200000.04
Pos: 9 /--- Section break - Odd page --- @ 0\mod_1136277036628_0.doc @ 765

MUI.814.200981.R01.EN 4.7
Description

Pos: 10.1 /GEHO/Heading/H1/#. Description @ 0\mod_1134483846926_31.doc @ 448

5.
Pos: 10.2.1 /GEHO/Heading/H2/#.# Introduction @ 0\mod_1144834888602_31.doc @ 3092
Description
5.1 Introduction
Pos: 10.2.2 /GEHO/Description/Introduction/Media @ 0\mod_1134634042426_31.doc @ 544

The GEHO piston diaphragm pump is a reciprocating, positive displacement pump, designed to handle
liquids contaminated with solids, like sludges, slurry and mud, particularly where abrasive or aggressive
materials are involved.
Pos: 10.2.3 /GEHO/Description/Introduction/Diaphragm unit @ 0\mod_1134633771977_31.doc @ 542

A rubber diaphragm separates the pumped liquid from the clean propelling liquid.
The pumped liquid has no contact with moving parts, such as the piston, the piston rod or the cylinder liner.
Pos: 10.2.4 /GEHO/Description/Introduction/Wearing and replacement parts @ 0\mod_1134635894018_31.doc @ 574

The wearing and replacement parts are easily accessible for inspection and repair.
Pos: 10.2.5 /GEHO/Heading/H4/Wearing parts @ 0\mod_1134635462418_31.doc @ 560

Wearing parts
Pos: 10.2.6 /GEHO/Description/Introduction/Wearing parts: Definition @ 0\mod_1134639095462_31.doc @ 580

Wearing parts are parts subject to exchange regularly.

Pos: 10.2.7 /GEHO/Description/Introduction/Wearing parts: List @ 0\mod_1134635624621_31.doc @ 570

These are:
Suction valve
Discharge valve
Pos: 10.2.8 /GEHO/Heading/H4/Replacement parts @ 0\mod_1134635502866_31.doc @ 564

Replacement parts
Pos: 10.2.9 /GEHO/Description/Introduction/Replacement parts: Definition @ 0\mod_1134639331822_31.doc @ 582

Replacement parts are parts subject to be replaced if required.

Pos: 10.2.10 /GEHO/Description/Introduction/Replacement parts: List @ 0\mod_1134635786604_31.doc @ 572

These are:
Pump diaphragm
Pulsation dampener diaphragm
Pos: 10.2.11 /GEHO/Heading/H4/Non-wearing parts @ 0\mod_1134635392998_31.doc @ 555

Non-wearing parts
Pos: 10.2.12 /GEHO/Description/Introduction/TZPM/Non-wearing parts @ 0\mod_1134634939436_31.doc @ 554

Piston
Piston rod
Piston seal rings
Cylinder liner
Pos: 10.3 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766

MUI.814.200981.R01.EN 5.1
 Description

Pos: 10.4.1 /GEHO/Heading/H2/#.# Working principle @ 0\mod_1135000311087_31.doc @ 611

5.2 Working principle

Pos: 10.4.2 /GEHO/Description/Working principle/TZPM/TZPM general @ 2\mod_1176882885858_31.doc @ 13241

The GEHO TZPM pump is a single acting pump with 3 cylinders and 3 pistons.
Each single acting piston uses propelling liquid to drive a diaphragm, which pumps the slurry.
This enables low-wear components to be used and to pump a solids containing liquid or slurry at high
pressure.

1 pump crank shaft drives 3 single acting pistons, driving in total 3 diaphragms.
With every revolution of the pump crank shaft, each piston makes 1 suction stroke and 1 discharge stroke,
so the pump makes in total 3 diaphragm suction strokes and 3 diaphragm discharge strokes.
Pos: 10.4.3 /GEHO/Description/Working principle/TZPM/Suction stroke @ 0\mod_1134999056904_31.doc @ 606

Suction stroke:
The piston (A) moves backward and G
decompresses the propelling liquid (B).
The diaphragm (F) moves backward.
The resulting low pressure in the slurry F
chamber (E) forces
- the discharge valve (G) to close, E
- the suction valve (C) to open.
The slurry fills the slurry chamber (E) of the
diaphragm housing unit through the suction
line (D). C
B A
D

Figure 5.1: Working principle: Stroke 1 Suction phase

Pos: 10.4.4 /GEHO/Description/Working principle/TZPM/Discharge stroke @ 0\mod_1134999494473_31.doc @ 608

Discharge stroke: H
The piston (A) moves forward and compresses
the propelling liquid (B). G
The diaphragm (F) moves forward.
F
The resulting high pressure in the slurry
chamber (E) of the diaphragm housing unit E
forces
- the suction valve (C) to close,
- the discharge valve (G) to open. C
The slurry leaves the slurry chamber (E) through
the discharge line (H).

B A

Figure 5.2: Working principle: Stroke 1 Discharge

phase

Pos: 10.5 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766

5.2 MUI.814.200981.R01.EN
Description

Pos: 10.6.1 /GEHO/Heading/H2/#.# Drive unit @ 0\mod_1134483988099_31.doc @ 452

5.3 Drive unit

Pos: 10.6.2 /GEHO/Description/Drive unit/Gearbox type @ 0\mod_1134639813244_31.doc @ 584

The main E-motor and the gearbox are mounted on a one structure welded base frame.
The mounting surfaces for these components are machined to allow optimum alignment.
Anchoring holes in the bottom of the base frame are provided.
The main E-motor shaft and the gearbox input shaft are connected with a flexible shaft coupling.
The gearbox output shaft and the pump shaft are connected with a gear coupling.
Coupling guards are provided for safety.
Pos: 10.7 /GEHO/Heading/H2/#.# Power end @ 0\mod_1134484023820_31.doc @ 454

5.4 Power end

Pos: 10.8 /GEHO/Description/Power end/Introduction/Introduction @ 0\mod_1136371259991_31.doc @ 916

The power end converts the circular motion of the pump drive into a linear motion of the connecting rod and
crosshead.
Pos: 10.9 /GEHO/Description/Power end/Project/200981 @ 1\mod_1173098497877_31.doc @ 12586

The power end includes the following items:

Cast power end with shaft seals and inspection covers to seal against exterior contamination.
Direct driven crankshaft.
Forged alloy steel crankshaft supported on self-aligning roller bearings.
Heavy duty anti-friction bearings.
Crossheads with replaceable guides.
Crosshead extension/piston rods constructed in sections for simple replacement of the pistons.
Integral pressurized lube oil system.
Piston rod stuffing box to prevent lube oil contamination and leakage.
A turning gear device for manually rotating the pump in an unloaded condition.
Lock-out of the motor driver when the turning gear is engaged.
Pos: 10.10.1 /GEHO/Heading/H3/#.#.# Lubrication unit @ 0\mod_1134568393543_31.doc @ 498

5.4.1 Lubrication unit

Pos: 10.10.2 /GEHO/Description/Power end/Lubrication unit/TZPM/Introduction @ 0\mod_1136372541764_31.doc @ 918

The lubrication unit supplies fresh oil to the bearings, the crosshead liners and the crosshead rod.
Pos: 10.11 /GEHO/Heading/H2/#.# Liquid end @ 0\mod_1134568182139_31.doc @ 492

5.5 Liquid end

Pos: 10.12.1 /GEHO/Description/Liquid end/Introduction/TZPM/Main items - TZPM - Header @ 0\mod_1145875032918_31.doc @ 3323

The TZPM pump consist of the following parts:

Pos: 10.12.2 /GEHO/Description/Liquid end/Introduction/TZPM/Main items - TZPM @ 0\mod_1136360416839_31.doc @ 882

3 Piston units.
3 Diaphragm housing units.
3 Suction valve units.
1 Suction manifold.
3 Discharge valve units.
1 Discharge manifold.
Pos: 10.12.3 /GEHO/Description/Liquid end/Introduction/Main items/ Pulsation dampener - Suction (1) @ 1\mod_1173099006839_31.doc @ 12590

1 Suction pulsation dampener.

Pos: 10.12.4 /GEHO/Description/Liquid end/Introduction/Main items/Pulsation dampener - Discharge (1) @ 0\mod_1135002171112_31.doc @ 623

1 Discharge pulsation dampener.

Pos: 10.12.5 /GEHO/Description/Liquid end/Introduction/Divisions @ 0\mod_1149662408190_31.doc @ 4417

The liquid end is divided by a rubber diaphragm into two mechanically separated sections:
The propelling liquid section.
The slurry section.
Pos: 10.12.6 /GEHO/Description/Liquid end/Introduction/Propelling liquid section/TZPM @ 1\mod_1166113655949_31.doc @ 11322

MUI.814.200981.R01.EN 5.3
 Description

5.5.1 The propelling liquid section

The propelling liquid section is filled with the propelling liquid.
The propelling liquid section consists of:
The piston unit.
The rear side of the diaphragm housing unit.
Pos: 10.12.7 /GEHO/Description/Liquid end/Introduction/Slurry section/Standard @ 0\mod_1149662677848_31.doc @ 4423

5.5.2 The slurry section

Only the slurry section has contact with the pumped liquid.
The slurry section consists of:
The suction valve unit.
The front side of the diaphragm housing unit.
The discharge valve unit.
Pos: 10.12.8 /GEHO/Description/Liquid end/Introduction/Main items/ Pulsation dampener - Suction (1) @ 1\mod_1173099006839_31.doc @ 12590

1 Suction pulsation dampener.

Pos: 10.12.9 /GEHO/Description/Liquid end/Introduction/Main items/Pulsation dampener - Discharge (1) @ 0\mod_1135002171112_31.doc @ 623

1 Discharge pulsation dampener.

Pos: 10.13.1 /GEHO/Heading/H3/#.#.# Piston unit @ 0\mod_1134569925466_31.doc @ 512

5.5.3 Piston unit

Pos: 10.13.2 /GEHO/Description/Liquid end/Piston unit/TZPM/Piston rod - Tapered @ 0\mod_1145878938338_31.doc @ 3329

The piston rod connects the piston and the crosshead rod.
The tapered ends are connected by the rod clamping piece.
Pos: 10.13.3 /GEHO/Description/Liquid end/Piston unit/Piston @ 0\mod_1135242883584_31.doc @ 732

The piston is provided with two sets of roof shaped rings (piston seal rings) and a piston guide ring.
The piston guide ring centers the piston in the cylinder liner.
Pos: 10.13.4 /GEHO/Description/Liquid end/Piston unit/TZPM/Piston seal rings @ 0\mod_1135069059470_31.doc @ 661

The piston seal to the propelling section prevents loss of propelling liquid from the diaphragm housing.
The piston seal ring to the air side prevents drawing in of air or drawing in of flushing liquid.
Pos: 10.13.5 /GEHO/Description/Liquid end/Piston unit/TZPM/Cylinder liner @ 0\mod_1135069465694_31.doc @ 666

The cylinder liner is clamped into the diaphragm housing end by a thrust piece.
Pos: 10.13.6 /GEHO/Description/Liquid end/Piston unit/Resistance and replacement @ 0\mod_1135070106045_31.doc @ 670

The cylinder liner is highly wear resistant. It is not damaged immediately, when as a result of diaphragm
rupture the abrasive solids enter the propelling liquid section.
The piston body and the cylinder liner can be changed quickly and easily.
Pos: 10.14 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766

5.4 MUI.814.200981.R01.EN
Description

Pos: 10.15.1 /GEHO/Heading/H3/#.#.# Propelling liquid control system @ 0\mod_1134632211894_31.doc @ 522

5.5.4 Propelling liquid control system

Pos: 10.15.2 /GEHO/Description/Liquid end/Propelling liquid control system/TZPM/TZPM schematics @ 0\mod_1135261173624_31.doc @ 755

PROPELLING
LIQUID K
AUTOMATIC
CONTROL L
SYSTEM
PLC
FILL DRAIN
J
M
I
H

F E D C B A
Figure 5.3: TZPM pump schematics
A Suction line B Slurry chamber
C Propelling liquid D Suction valve
E Diaphragm F Piston
G Piston rod H Cylinder liner
I Monitoring rod with a position marker J Discharge valve
for limitation of the diaphragm stroke
K Discharge pulsation damper L Discharge line
M Monitoring probes at the monitoring rod, PLC Programmable Logic Controller
for limitation of the diaphragm stroke
Pos: 10.15.3 /GEHO/Description/Liquid end/Propelling liquid control system/TZPM/TZPM Propelling liquid control system @ 2\mod_1175168658938_31.doc @ 12922

The pump is standard equipped with a patented GEHO propelling liquid automatic control system:
It controls and limits the stroke of the pump diaphragms.
It regulates the volume of the propelling liquid within limits.
It protects the diaphragms against overstress.
If the normal diaphragm stroke position changes (as a result of increase or decrease of propelling liquid)
then the monitoring rod reaches the rear or front monitoring probe.
Then the connected PLC (Programmable Logic Controller) actuates a fill or drain of propelling liquid.

Possible causes for (slow, long term) change of the propelling liquid volume at a TZPM pump:
Liquid increase by flush liquid, wiped by the piston sealing rings from the cylinder liner.
Liquid loss at the piston sealing rings from the high pressure chamber.
Liquid loss at other seals.
The patented GEHO propelling liquid automatic control Possible causes:
system prevents:
Overstress of the diaphragm. Increase of propelling liquid volume.
Blow up the diaphragm.
Diaphragm may strike the rear wall of the diaphragm housing. Decrease of propelling liquid volume.

Pos: 10.15.4 /GEHO/Description/Liquid end/Propelling liquid control system/Caution - Release remaining pressure @ 0\mod_1136282494105_31.doc @ 786

MUI.814.200981.R01.EN 5.5
 Description

CAUTION
Before installation or service or maintenance work:
Refer to the concerning chapters.
Stop the auxiliary propelling liquid motor.
Release the pressure from the propelling liquid control system.
The system remains under pressure even after shutting down the pump. The system is
equipped with an accumulator. This accumulator is preloaded with pressurized nitrogen.
Pos: 10.16.1 /GEHO/Heading/H3/#.#.# Flushing unit @ 0\mod_1136284703903_31.doc @ 806

5.5.5 Flushing unit

Pos: 10.16.2 /GEHO/Description/Liquid end/Flushing unit/TZPM/Piston flushing unit @ 0\mod_1136369150107_31.doc @ 908

The piston flushing unit uses the propelling liquid to lubricate the piston and cylinder liner.
Pos: 10.16.3 /GEHO/Description/Liquid end/Flushing unit/Flushing unit - Common @ 0\mod_1136369685006_31.doc @ 912

The propelling liquid for the flushing unit is supplied by the propelling liquid unit.
During normal operation the flushing unit is active. In case of propelling liquid needs to be supplied to the
propelling liquid section, the flow to the flushing unit will be switched off and will be used for the propelling
liquid control unit. Logics in the PLC prevent that the absence of propelling liquid in the flushing unit will not
exceed 1 minute.
Pos: 10.17.1 /GEHO/Heading/H3/#.#.# Diaphragm housing unit @ 0\mod_1134569604134_31.doc @ 504

5.5.6 Diaphragm housing unit

Pos: 10.17.2 /GEHO/Description/Liquid end/Diaphragm housing unit/Common @ 0\mod_1135074606766_31.doc @ 699

The diaphragm housing unit is the central part of the pump.

A rubber diaphragm divides diaphragm housing unit into two sections:
The propelling liquid section.
The slurry section.
The movement of the piston generates an increase and decrease of the pressure in the propelling liquid. The
diaphragm transmits the pressure change into the slurry section. In combination with the connected valves
the slurry will be pumped.
The diaphragm housing unit consists of:
The diaphragm housing.
The diaphragm.
The diaphragm housing cover.
The monitoring rod.
The connecting pieces.
The diaphragm is a preformed molded diaphragm with an O-ring shaped clamping ring. This prevents stress
concentrations in the clamping area.
The diaphragm housing cover clamps the diaphragm at the diaphragm clamping ring. The diaphragm
housing cover and the diaphragm housing have a metal to metal contact. This prevents movement during
pump operation and gives the diaphragm a fixed fitting stress in the clamping area. There is a seal between
the diaphragm housing cover and the diaphragm housing.
The monitoring rod is connected to a cone plate. The cone plate is vulcanized into the diaphragm. The
monitoring rod is part of the propelling liquid control system.
At the propelling liquid section the diaphragm housing unit is connected to:
The power end unit.
Pos: 10.17.3 /GEHO/Description/Liquid end/Diaphragm housing unit/Slurry section/Standard @ 1\mod_1164965667046_31.doc @ 8898

At the slurry section the diaphragm housing unit is connected to:

The suction valve unit at the bottom.
The discharge valve unit at the top.

5.6 MUI.814.200981.R01.EN
Description

Pos: 10.18.1 /GEHO/Heading/H3/#.#.# Suction valve unit @ 0\mod_1134569502477_31.doc @ 502

5.5.7 Suction valve unit

Pos: 10.18.2 /GEHO/Description/Liquid end/Valve units/Suction valve unit @ 0\mod_1137069101509_31.doc @ 1141

The suction valve unit allows the slurry to pass from the suction line to the diaphragm housing unit during the
suction stroke.
The suction valve unit disallows the slurry to pass from diaphragm housing unit to the suction line during the
discharge stroke.
Pos: 10.18.3 /GEHO/Heading/H3/#.#.# Discharge valve unit @ 0\mod_1137069603901_31.doc @ 1146

5.5.8 Discharge valve unit

Pos: 10.18.4 /GEHO/Description/Liquid end/Valve units/Discharge valve unit @ 0\mod_1137069192630_31.doc @ 1143

The discharge valve unit allows the slurry to pass from diaphragm housing unit to the discharge line during
the discharge stroke.
The discharge valve unit disallows the slurry to pass from the discharge line to the diaphragm housing unit
during the suction stroke.
Pos: 10.19 /GEHO/Heading/H3/#.#.# Suction pulsation dampener @ 0\mod_1160051076345_31.doc @ 6400

5.5.9 Suction pulsation dampener

Pos: 10.20 /GEHO/Description/Liquid end/Pulsation dampener/Suction/Introduction @ 0\mod_1160050898959_31.doc @ 6394

The suction pulsation dampener minimizes the pressure variations in the suction line. This achieves a
constant flow in the suction line. A rubber diaphragm separates the pulsation dampener into 2 sections:
The slurry section.
The nitrogen section.
The nitrogen section is pre-charged with nitrogen.
Pos: 10.21 /GEHO/Heading/H3/#.#.# Discharge pulsation dampener @ 0\mod_1134569676478_31.doc @ 506

5.5.10 Discharge pulsation dampener

Pos: 10.22 /GEHO/Description/Liquid end/Pulsation dampener/Discharge/Introduction @ 0\mod_1147765070988_31.doc @ 3941

The discharge pulsation dampener minimizes the pressure variations in the discharge line. This achieves a
constant flow in the discharge line. A rubber diaphragm separates the pulsation dampener into 2 sections:
The slurry section.
The nitrogen section.
The nitrogen section is pre-charged with nitrogen.
Pos: 10.23 /GEHO/Heading/H4/Over pressure alarm @ 0\mod_1136289931970_31.doc @ 828

Over-pressure alarm
Pos: 10.24 /GEHO/Description/Liquid end/Pulsation dampener/Pressure transmitter+ Refer on P&I-skid @ 1\mod_1173174838995_31.doc @ 12616

A pressure measuring point for the pump discharge pressure is located on top of the discharge pulsation
damper.
The pressure indicator is located on the P&I-skid (Process and Instruments skid).
The pressure transmitter results are displayed on the GEHO touch panel.
Refer for details to the "Instrument and equipment list" and chapter "Pressure limitation system".
Pos: 10.25 /GEHO/Description/Liquid end/Pressure transmitter/Pressure transmitter - Common @ 0\mod_1136289605881_31.doc @ 824

The pressure transmitter raises an alarm when the operating pressure exceeds a preset alarm level set-
point.
A further increase of the operating pressure switches off the pump at a second preset level set-point.
Refer for details and set-points to the "Instrument and equipment list".
Pos: 10.26.1 /GEHO/Heading/H3/#.#.# Pressure limitation system @ 0\mod_1134569743995_31.doc @ 508

5.5.11 Pressure limitation system

Pos: 10.26.2 /GEHO/Description/Liquid end/Pressure limitation system/Introduction, Elelectrical - Mechanical @ 0\mod_1136292306374_31.doc @ 852

A pressure limitation system limits the discharge pressure when a pre-determined pressure is exceeded.
Refer for details and set-points to the "Instrument and equipment list".
There are independent systems:
Electrical pressure limitation by stopping the pump drives.
Mechanical pressure limitation by releasing the propelling liquid.
Pos: 10.26.3.1 /GEHO/Heading/H4/Pressure limitation - Electrical @ 0\mod_1136292111124_31.doc @ 846

MUI.814.200981.R01.EN 5.7
 Description

Electrical pressure limitation

Pos: 10.26.3.2 /GEHO/Description/Liquid end/Pressure transmitter/Pressure transmitter - Common @ 0\mod_1136289605881_31.doc @ 824

The pressure transmitter raises an alarm when the operating pressure exceeds a preset alarm level set-
point.
A further increase of the operating pressure switches off the pump at a second preset level set-point.
Refer for details and set-points to the "Instrument and equipment list".
Pos: 10.26.4.1 /GEHO/Heading/H4/Pressure limitation - Mechanical @ 0\mod_1136292155037_31.doc @ 848

Mechanical pressure limitation

Pos: 10.26.4.2 /GEHO/Description/Liquid end/Pressure limitation system/Mechanical @ 0\mod_1136292524278_31.doc @ 854

The mechanical pressure limitation system is a secondary safety system. In some cases the pump does not
stop immediately due to the mass of inertia forces. In that case the discharge pressure still exceeds the
preset trigger level of the electrical pressure limitation system.
A high-pressure manifold connects all diaphragm housing units with a pressure relief valve. The high
pressure manifold is connected to all diaphragm housings with a check valve. The check valve prevents oil
flow between the diaphragm housings. It also holds a constant line pressure at the underside of the relief
valve.
The pressure level in the manifold equals the level of the main pressure spikes in the diaphragm housing
units. The safety valve is a spring-loaded type valve with a special valve disc (soft seal).
Whenever the pressure in the main discharge line exceeds the pressure of the spring, then the safety valve
opens and releases the pressure.
Pos: 10.26.4.3 /GEHO/Description/Liquid end/Pressure limitation system/Actions after actuating @ 0\mod_1136295398521_31.doc @ 860

Actions that follow are:

Immediate stop of all pumping action.
A great amount of propelling liquid will be returned to the storage tank.
The diaphragm moves to the filling position.
Automatic refill of the propelling liquid system.
Pos: 10.26.4.4 /GEHO/Description/Liquid end/Pressure limitation system/Caution - Release pressure @ 0\mod_1136295053785_31.doc @ 858

CAUTION
Before installation or service or maintenance work:
Refer to the concerning chapters.
Release the pressure from the pressure limitation system.
The pressure limitation system remains under pressure even after shut down of the pump.
Pos: 10.27.1 /GEHO/Heading/H2/#.# Pump control system @ 0\mod_1134569924544_31.doc @ 510

5.6 Pump control system

Pos: 10.27.2 /GEHO/Description/Pump control system/Pump control system @ 0\mod_1135075605523_31.doc @ 701

The pump control system monitors and controls the operation.

The pump control system includes:
A PLC (Programmable Logic Controller)
The HMI (Human Machine Interface)
The pump control system monitors the pump alarm and trip parameters. It also monitors the pump
diaphragm position to prevent an overload of the diaphragm.
The pump control system allows a local or remote pump start or pump stop procedure as well as the speed
control.
For maintenance purpose the PLC/HMI allows the manual operation of the propelling liquid fill and outlet
valves.
If required, then the pump parameters can also be made available to the customer control system.
Refer to Chapter Electrical information for a detailed description of the pump control system.
Pos: 11 /--- Section break - Odd page --- @ 0\mod_1136277036628_0.doc @ 765

5.8 MUI.814.200981.R01.EN
Transport and installation

Pos: 12.1 /GEHO/Heading/H1/#. Transport and installation @ 0\mod_1136455268304_31.doc @ 931

6.
Pos: 12.2.1.1 /GEHO/Heading/H2/#.# Transport and lifting @ 0\mod_1136806045785_31.doc @ 973
Transport and installation
6.1 Transport and lifting
Pos: 12.2.1.2 /GEHO/General/Attention, Warning and Note/DANGER - Safety - Obey safety instructions and procedures @ 0\mod_1136886637385_31.doc @ 1007

DANGER
Obey the safety instructions.
Obey the working procedures.

Pos: 12.2.1.3 /GEHO/General/Attention, Warning and Note/Caution - Lifting device - Check for damage @ 0\mod_1136886348800_31.doc @ 1005

CAUTION
Check the lifting devices for damage before use.
Replace damaged parts immediately.
Pos: 12.2.1.4 /GEHO/General/Attention, Warning and Note/Attention - Lifting devices - Weight limits @ 0\mod_1136885967642_31.doc @ 1003

ATTENTION
Make sure to use only lifting devices with suitable weight limitation.

Pos: 12.2.1.5 /GEHO/General/Attention, Warning and Note/Attention - Lifting devices - Protect equipment @ 0\mod_1136886849861_31.doc @ 1009

ATTENTION
Make sure to protect the equipment when using lifting straps or lifting chains.

Pos: 12.2.1.6 /GEHO/General/Attention, Warning and Note/Attention - Lifting locations - Use lifting eyes or flanges @ 0\mod_1136885672808_31.doc @ 1001

ATTENTION
Make sure to use the provided lifting eyes or lifting flanges when hoisting the pump parts.
Pos: 12.2.1.7 /GEHO/Heading/H3/#.#.# Weights and limits @ 0\mod_1137424754577_31.doc @ 1233

6.1.1 Weights and weight limits

Pos: 12.2.1.8 /GEHO/Transport and installation/Transport and lifting/Caution - Weight limits @ 0\mod_1137425074277_31.doc @ 1237

CAUTION
Never exceed the weight limits.
Use the correct transport and lifting gear.
Pos: 12.2.1.9 /GEHO/Transport and installation/Transport and lifting/Weights @ 0\mod_1137424926404_31.doc @ 1235

For the actual transport weights refer to the drawing Packing.

For the actual unit weights refer to the drawing Dimensioned outline.
Pos: 12.2.2 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766

MUI.814.200981.R01.EN 6.1
 Transport and installation

Pos: 12.2.3.1 /GEHO/Heading/H3/#.#.# Transport @ 0\mod_1137408313966_31.doc @ 1177

6.1.2 Transport
Pos: 12.2.3.2 /GEHO/Transport and installation/Transport and lifting/Transport/Transport box @ 0\mod_1137408396926_31.doc @ 1182

To lift the transport box use a crane and lifting

chains.

Figure 6.1: Lifting locations at the transport box

WARNING

Obey the instructions at the transport box.

Pos: 12.2.4 /GEHO/Heading/H3/#.#.# Pump @ 0\mod_1137414488876_31.doc @ 1207

6.1.3 Pump
Pos: 12.2.5 /GEHO/Transport and installation/Transport and lifting/Lifting locations/TZPM/Standard, refer to special tools @ 1\mod_1173178868349_31.doc @ 12620

The power end and liquid end are shipped Refer to the drawing in chapter
preassembled. Part lists and drawings (special tools).
Refer to chapter "Technical data sheets",
drawing "Packing".
Make sure to use the transport support.
Lift the pump at the four lifting points or
flanges.

Pos: 12.2.6 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766

6.2 MUI.814.200981.R01.EN
Transport and installation

Pos: 12.2.7.1 /GEHO/Heading/H3/#.#.# Drive unit @ 0\mod_1136807338183_31.doc @ 987

6.1.4 Drive unit

Pos: 12.2.7.2 /GEHO/Transport and installation/Transport and lifting/Lifting locations/Drive Unit/Drive unit+gearbox+4standard hoistspreadersR01 @ 0\mod_1136808534193_31.doc @ 991

Use standard hoist spreaders (A),

(not in the scope of supply) to avoid damage.
Lift the unit at the 4 frame lifting points (B). B B

B B

Figure 6.2: Lifting locations at the drive unit

Pos: 12.2.8.1 /GEHO/Heading/H3/#.#.# Smaller parts @ 0\mod_1136807299788_31.doc @ 985

6.1.5 Smaller parts

Pos: 12.2.8.2 /GEHO/Transport and installation/Transport and lifting/Lifting locations/Smaller parts @ 0\mod_1136809345700_31.doc @ 995

Lift the smaller parts at the desired lifting locations.

Use lifting straps or a forklift.

WARNING
Refer to the drawing Lifting tools for the exact lifting locations, lifting values and restrictions.
Pos: 12.3 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766

MUI.814.200981.R01.EN 6.3
 Transport and installation

Pos: 12.4 /GEHO/Heading/H2/#.# Installation @ 0\mod_1136888682286_31.doc @ 1015

6.2 Installation
Pos: 12.5.1 /GEHO/Heading/H3/#.#.# Foundation @ 0\mod_1136888827835_31.doc @ 1021

6.2.1 Foundation
Pos: 12.5.2 /GEHO/Transport and installation/Installation/Foundation/Foundation bolt schematics @ 0\mod_1136891863740_31.doc @ 1025

A Steel foundation bolt

B Grout
C Diameter of the foundation bolt
D C B A
D Polyurethane foam
E Free length of the foundation bolt thread
F Diameter () of the anchor pocket E I
G Depth of the anchor pocket
H Height of the Polyurethane foam
I Thickness of the covering grout J H
J Foundation bolt hook
G

Figure 6.3: Schematics of the anchor pocket and the

foundation bolt

Pos: 12.5.3 /GEHO/Transport and installation/Installation/Foundation/Refer to "Dimensioned outline" drawing or "Foundation drawing" @ 0\mod_1136893431935_31.doc @ 1027

Refer to the Dimensioned outline drawing or the Foundation drawing for the exact sizes and locations of
the anchor pockets.

6.4 MUI.814.200981.R01.EN
Transport and installation

Pos: 12.5.4.1 /GEHO/Heading/H4/Mount and level pump @ 0\mod_1136965605812_31.doc @ 1041

Mount and level pump

Pos: 12.5.4.2 /GEHO/Transport and installation/Installation/Foundation/Mount and level/TZPM/Level - TZPM @ 0\mod_1137418638092_31.doc @ 1214

1 Check the foundation according to the

dimensioned outline drawing or foundation
drawing. B
2 Place steel blocks next to each anchor
pocket. Use steel blocks with a thickness
of 50 mm. A A
3 Level the steel blocks in a range of 1 mm.
4 Lift the pump. Use a crane.
5 Put the thread of the foundation bolts into
the borings at the pump.
6 Put the nuts to the foundation bolts.
7 Lower the pump B C
8 Put the pump to the steel blocks.
9 Make sure that the foundation bolts fit into
the anchor pockets.
10 Hook the foundation bolts in their
dedicated position.
11 Tighten the nuts at the foundation bolts
easily by hand.
12 Place a steel block exactly underneath the Figure 6.4: Spirit level positions
leveling bolts of the pump.
13 Remove the piston cover and crosshead
cover.
14 Place a spirit level (C) on the machined
face in direction A-A.
15 Level the pump.
Keep a tolerance of 0.5 mm/m.
Use the leveling bolts.
16 Place a spirit level (C) on the machined
face in direction B-B.
17 Level the pump.
Keep a tolerance of 0.5 mm/m.
Use the leveling bolts.
18 Fill up the space between the pump and
the steel blocks with metal packing shims.
19 Loosen the leveling bolts.
20 Fill the anchor pockets with grout to fix the
foundation bolts in its position according to
figure 5.4
21 Fill the upper section of the anchor pocket
with Polyurethane foam.
22 Put on a top layer of grout.
23 Tighten the nuts at the foundation bolts
when the grout is hardened.
24 Make sure to use the correct torques.
Pos: 12.6 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766

MUI.814.200981.R01.EN 6.5
 Transport and installation

Pos: 12.7.1 /GEHO/Heading/H3/#.#.# Drive unit @ 0\mod_1136807338183_31.doc @ 987

6.2.2 Drive unit

Pos: 12.7.2 /GEHO/Transport and installation/Installation/Drive unit/Gearbox/Overview @ 0\mod_1136990349612_31.doc @ 1091

A Coupling gearbox / pump shaft

B Gearbox
C Coupling gearbox / motor
D Motor
E Motor tighten screws
F Leveling bolts
G Hole for foundation bolts
H Metal packing shim
I Adjustment screws
J Lifting eye
K Safety guard

Figure 6.5: Drive unit with gearbox overview

Pos: 12.7.3 /GEHO/Transport and installation/Installation/Drive unit/Gearbox/Mount @ 0\mod_1136903066579_31.doc @ 1039

1 Place steel blocks (E) next to each anchor

pocket.
2 Lift the pump. B A
Use a crane.
3 Put the thread of the foundation bolts (C)
into the holes at the pump drive base
frame (D).
4 Put the nuts to the foundation bolts.
5 Lower the pump drive base frame
6 Put the pump drive unit to the steel
blocks (E).
7 Make sure that the foundation bolts (C) fit
into the anchor pockets.
8 Hook the foundation bolts in their
dedicated position.
9 Center the gearbox output shaft (A) with
the pump shaft (B).
C D E
10 Level the pump drive unit.
Use the leveling bolts at the base
frame (D). Figure 6.6: Mount the pump drive unit

Pos: 12.7.4 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766

6.6 MUI.814.200981.R01.EN
Transport and installation

Pos: 12.7.5 /GEHO/Heading/H4/Gearbox alignment @ 0\mod_1136967931366_31.doc @ 1045

Gearbox alignment
Pos: 12.7.6 /GEHO/Heading/H5/General @ 0\mod_1136967977522_31.doc @ 1047

General
Pos: 12.7.7 /GEHO/Transport and installation/Installation/Drive unit/General/Introduction @ 0\mod_1136968488297_31.doc @ 1053

Shaft couplings need 3 types of alignment:

axial alignment + angular alignment + radial horizontal and vertical alignment.
Pos: 12.7.8 /GEHO/Transport and installation/Installation/Drive unit/General/Alignment - Axial @ 0\mod_1136969611422_31.doc @ 1055

Axial alignment:
1 Split-up the spacing between both coupling
parts (Snom +/- Ka).
2 Use the adjustment screws at the drive unit
base frame.
3 Make sure that the remaining gap is in
tolerance.
For the correct tolerance values,
see the tables below.

Figure 6.7: Axial misalignment.

Pos: 12.7.9 /GEHO/Transport and installation/Installation/Drive unit/General/Alignment - Angular @ 0\mod_1136976079252_31.doc @ 1059

Angular alignment:
1 Align both couplings parts (S=S1-S2).
2 Use the adjustment screws at the drive unit
base frame.
3 Make sure that the misalignment S is in
tolerance.
For correct tolerance values,
see the tables below.

Figure 6.8: Angular misalignment.

Pos: 12.7.10 /GEHO/Transport and installation/Installation/Drive unit/General/Alignment - Radial @ 0\mod_1136978990869_31.doc @ 1063

Radial alignment:
1 Align both coupling parts in horizontal and
vertical position (Kr).
2 Use the adjustment screws at the drive unit
base frame.
3 Make sure that the remaining gap is in
tolerance.
For the correct tolerance values,
see the tables below.

Figure 6.9: Radial misalignment.

Pos: 12.7.11 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766

MUI.814.200981.R01.EN 6.7
 Transport and installation

Pos: 12.7.12 /GEHO/Heading/H5/Gearbox - pump shaft - Pre-alignment @ 0\mod_1136968077676_31.doc @ 1049

Pre-alignment of the gearbox and the pump shaft

Pos: 12.7.13 /GEHO/General/Attention, Warning and Note/Note - Alignment information @ 0\mod_1136979880428_31.doc @ 1067

NOTE
Refer to chapter Catalogue information, "Drive unit" for details about
> safety instructions,
> coupling alignment methods and mis-alignment limits,
> coupling assembly and maintenance.
Pos: 12.7.14 /GEHO/Transport and installation/Installation/Drive unit/Gearbox - Pumpshaft/Pre alignment procedure @ 0\mod_1136983950690_31.doc @ 1069

Align the gearbox to the pump shaft:

1 Refer to the table below for the alignment tolerance values.
2 Adjust the spacing between both coupling parts (Snom Ka).
3 Align both coupling parts in horizontal and vertical direction (Kr).
4 Align the angle between the gearbox shaft and motor shaft (S).

Attach the unit base frame to the foundation:

5 Fill the space between the steel blocks and the drive unit base frame with metal packing shims.
6 Loosen the leveling bolts.
7 Fix all foundation bolts in position.
8 Wait until the grout is hardened.
9 Tighten all foundation bolts with the correct tightening torques.
Pos: 12.7.15 /GEHO/Transport and installation/Installation/Drive unit/Gearbox - Pumpshaft/Alignment tolerances/ZAPEX ZWN 545, no internal gear @ 1\mod_1173171186122_31.doc @ 12612

Alignment tolerance values for FLENDER ZAPEX ZWN type couplings:

Size Pump Axial Angular Radial Combined
[mm] direct driven mis-alignment mis-alignment(2) mis-alignment mis-alignment
Snom [mm] Ka [mm] S=S1-S2 [mm] Kr [mm] S + Kr [mm]
545 16 -0 / +2.0 0.38 S 0.76 0.71 0.71
Pos: 12.7.16 /GEHO/Transport and installation/Installation/Drive unit/Gearbox - Pumpshaft/Alignment tolerances/Footnote 2 - Minimal error 0.05 @ 0\mod_1138607113643_31.doc @ 2085

(2)
Lower limits (minimum) are based upon angular alignment error to be intentional minimal 0.05.
Pos: 12.7.17 /GEHO/General/Attention, Warning and Note/Note - Alignment @ 0\mod_1136975969234_31.doc @ 1057

NOTE
Alignment values are based upon a recommended intentional angular mis-alignment in a static
condition of minimum 0.1 (to improve lifetime performance of the teeth of the coupling parts).
In operation a maximum of 10 fold is allowed.
Pos: 12.7.18 /GEHO/Heading/H5/Gearbox - pump shaft - Final alignment @ 0\mod_1136984882160_31.doc @ 1074

Final alignment of the gearbox and the pump shaft

Pos: 12.7.19 /GEHO/Transport and installation/Installation/Drive unit/Gearbox - Pumpshaft/ZAPEX ZWN Final alignment procedure @ 0\mod_1136984368161_31.doc @ 1072

CAUTION
Premature wear and resulting damage to the coupling can be caused by:
> incorrect alignment of the coupling,
> incorrect assembly of the coupling,
> incorrect sealing or lubricant of the coupling,
> incorrect greasing of the DUO sealing rings.

Re-aligning:
1 Re-align the gearbox to the pump shaft as described before.

Attaching the gearbox:

2 Fill the space between the gearbox and the base frame.
Use metal packing shims or modify the installed spacer plates.
3 Tighten the gearbox to the drive unit base frame.

6.8 MUI.814.200981.R01.EN
Transport and installation

Coupling assembly:
Refer to "Catalogue information", "Drive unit", "Coupling" for manufacturer information about
> the physical shape of the coupling,
> the assembly of the coupling,
> how to make the coupling oil leak proof,
> filling the coupling with oil.
Refer to "Utility consumption list" for details about oil type and oil quantity.
4 Grease the surface of the DUO-rings (B)
and the groves in cover rings (A).
Recommended lubrication grease:
> Shell Alvania RL3.
> Mobil Mobilux EP3.
5 Mount the DUO sealing rings (B) proper in D D D
the cover rings (A). F E EF
6 Insert generously grease in the ring- A A
shaped space (C) between the sealing lips B B
of the DUO-rings (B). To seal properly C C
during operation, the DUO-ring sealing lips
have to float on a generous grease film.
Recommended lubrication grease:
> Shell Alvania RL3.
> Mobil Mobilux EP3.
7 Clean and dry the sealing surfaces (D) of
the coupling parts.
8 Cover the sealing surfaces (D) of the
coupling parts with a sealing compound. Figure 6.10: Coupling assembly
Recommended sealing compound:
Flange Sealant Loctite 5922.
9 Position carefully the cover rings (A) with
the DUO-rings (B) on the pre-greased
coupling shafts.
Assure right position of the DUO-rings
sealing lips.
10 Assemble the coupling covers (E) and
cover rings (A) together.

Coupling oil filling:

11 Rotate the coupling, until the oil screw D1 = Filling plug D2 = Ventilation plug
plugs are in the position, as shown in the 60 60
figure (D1 = filling plug, D2 = ventilation
plug, D3 = drain plug).
12 Remove the two top screw plugs (D1+D2).
13 Measure the correct oil/grease quantity 30
with a measuring beaker.
14 Fill the coupling with the recommended oil.
15 Screw in all screw plugs (D) with
fitted/integrated sealing rings.
16 Check that the coupling cover does not
leak, by rotating the shaft.

Safety protection:
17 Mount the safety guard. D3 = Drain plug

Pos: 12.7.20 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766

Figure 6.11: Coupling oil filling

MUI.814.200981.R01.EN 6.9
 Transport and installation

Pos: 12.7.21 /GEHO/Heading/H5/ Motor - Gearbox @ 0\mod_1136968126046_31.doc @ 1051

Motor and gearbox

Pos: 12.7.22 /GEHO/General/Attention, Warning and Note/Note - Alignment information @ 0\mod_1136979880428_31.doc @ 1067

NOTE
Refer to chapter Catalogue information, "Drive unit" for details about
> safety instructions,
> coupling alignment methods and mis-alignment limits,
> coupling assembly and maintenance.
Pos: 12.7.23 /GEHO/Transport and installation/Installation/Drive unit/Motor - Gearbox/Alignment procedure @ 0\mod_1136985418902_31.doc @ 1081

Align the motor to the gearbox:

1 Refer to the table below for the alignment tolerance values.
2 Adjust the spacing between both coupling parts (Snom Ka).
3 Align both coupling parts in horizontal and vertical direction (Kr).
4 Align the angle between the gearbox shaft and motor shaft (S).
Attach the motor on the unit base frame:
5 Modify the metal packing shims if necessary.
6 Tighten the motor to the drive unit base frame.
7 Month the safety guards.
Pos: 12.7.24 /GEHO/Transport and installation/Installation/Drive unit/Motor - Gearbox/Alignment tolerances/Rupex 285-400 @ 1\mod_1163702343801_31.doc @ 8692

Alignment tolerance values for FLENDER RUPEX couplings:

Size Axial Axial Angular Radial
[mm] distance mis-alignment mis-alignment mis-alignment
Snom [mm] Ka [mm] S=S1-S2 [mm] Kr [mm]
285 - 400 4.5 1.5 0.10 0.10
Pos: 12.8 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766

6.10 MUI.814.200981.R01.EN
Transport and installation

Pos: 12.9 /GEHO/Transport and installation/Installation/Nitrogen filling/Safety regulations for nitrogen @ 0\mod_1156234263710_31.doc @ 5734

6.2.3 Safety regulations and instructions for nitrogen

DANGER
SAFETY
Before using a nitrogen bottle equipment:
Working with a nitrogen bottle equipment is only allowed to authorized and instructed
workers.
Inform about all local legal and insurance policy regulations and safety instructions.
Inform about all local labor conditions about working with a nitrogen bottle equipment.
Strictly obey to those regulations and safety instructions.
Refer to the safety instructions of the nitrogen bottle supplier,
about how to handle nitrogen, its equipment, and what to do in emergency cases.

DANGER
NITROGEN
Leaking nitrogen (N2) causes lack of oxygen:
Prevent breathing in nitrogen.
Be aware of the risk of suffocation, caused by to much nitrogen in the air.
Prevent nitrogen escaping from the equipment into the working environment.
Assure in small rooms good ventilation, because of risks of nitrogen leakage.
Assure free escape routes, because of risks of nitrogen leakage.
DANGER
NITROGEN EQUIPMENT INSTRUCTIONS
The supply of a nitrogen bottle is not in the scope of Weir Minerals.
Refer to "Catalogue information" for instructions and information of the manufacturer about
safe and proper user of the nitrogen bottle and nitrogen charging equipment.
If the nitrogen charging equipment is not in the scope of Weir Minerals,
then refer to instructions and information of the manufacturer about safe and proper use.
Make sure that the maximum pressure in the nitrogen bottle does not exceed the maximum
permitted pressure of the pressure regulator.
Make sure that the equipment is in good condition.
Pos: 12.10 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766

MUI.814.200981.R01.EN 6.11
 Transport and installation

Pos: 12.11 /GEHO/Heading/H3/#.#.# Pre-charging the suction pulsation dampener, set-point instructions @ 1\mod_1173202054425_31.doc @ 12636

6.2.4 Pre-charging the suction pulsation dampener, set-point instructions

Pos: 12.12 /GEHO/Transport and installation/Installation/Nitrogen filling/Pre-charging/Suction pulsation dampener pre-charge @ 1\mod_1173084644396_31.doc @ 12574
discharge

Suction pulsation dampener pre-charge set-point instructions

The suction pulsation dampener minimizes the pressure variations in the suction line. This achieves a
constant flow in the suction line. A rubber diaphragm separates the pulsation dampener into 2 sections:
The slurry section.
The nitrogen section, pre-charged with nitrogen.
Suction pulsation dampener pre-charge set-point instructions
DANGER

Safety limits:
To prevent over-stressing the dampener system and the diaphragm:
NEVER pre-charge the pulsation dampener with more then the dampener system,
maximum pressure.
The maximum pressure is indicated on the pulsation dampener identification plate.
NEVER pre-charge the pulsation dampener with more then the maximum pressure for the
diaphragm limit.
The diaphragm limit pressure is indicated in the "Technical data".

ATTENTION

Functional limits:
To prevent dampener diaphragm damage during pressure still-stand of the pump
and hammering of the diaphragm against the bottom of the dampener:
NEVER pre-charge the pulsation dampener with more then 80% of the maximum pump
suction pressure.
To prevent hammering of the diaphragm against the top of the dampener:
NEVER let the pre-charge pressure drop below 30% of the maximum pump suction
pressure.
Excessive pressure pulsations and heavy vibrations are caused by insufficient pre-charge
pressure.

ATTENTION
The pre-charge pressure may change due to temperature influence:
Temperature fluctuation of the slurry.
Temperature differences between the slurry and the environment.
These effects require re-adjustment of the pre-charge pressure.

6.12 MUI.814.200981.R01.EN
Transport and installation

Refer to the "Instrument and equipment list" for details about the "suction pulsation dampener".
Refer to the "Instrument and equipment list" for the dampener pre-charge "set-point" recommendation for
installation, to start with.
Refer to the Installation and maintenance instructions, before working on a GEHO pulsation damper.
The pre-charge pressure is application dependent.
Operating conditions Recommended pre-charge set-point Result
Percentage of maximum suction
pressure
80% = maximum pre-charge limit, to protect the diaphragm and
but not more than the diaphragm limit dampener
constant suction pressure 60% to 65% optimal operation
widely varying suction pressure 30% to 35% optimal operation
30% = minimum pre-charge limit to protect the diaphragm and
dampener
Pos: 12.13 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766

MUI.814.200981.R01.EN 6.13
 Transport and installation

Pos: 12.14 /GEHO/Heading/H3/#.#.# Pre-charging the discharge pulsation dampener, set-point instructions @ 1\mod_1173202078632_31.doc @ 12640

6.2.5 Pre-charging the discharge pulsation dampener, set-point instructions

Pos: 12.15 /GEHO/Transport and installation/Installation/Nitrogen filling/Pre-charging/Discharge pulsation dampener pre-charge @ 0\mod_1156257465577_31.doc @ 5764
discharge

Discharge pulsation dampener pre-charge definitions

Definitions Comment Refer to
pump system, maximum allowed pressure for pump identification plate
maximum pressure the pump system
pump system, operating pressure will change pump discharge pressure indicator
"normal" pump operating during operation, depending on + GEHO Touch Panel, graphics menu:
pressure many factors "ACTUAL VALUE"
pump system, operating pressure maximum, pump discharge pressure indicator
maximum pump operating that occurs while operating + GEHO Touch Panel, graphics menu
pressure "HIGHEST VALUE"
dampener system, maximum allowed pressure for dampener system identification plate
maximum system pressure the dampener system + chapter "Technical data"
dampener, maximum allowed pressure for Instrument and equipment list
range this part + pulsation dampener identification plate
dampener, recommendation to start with by Instrument and equipment list
pre-charge set-point installation, + after pre-charging, read the pressure
may need re-adjustment, indicator on the dampener
depending on operation (only if there is no pressure at the slurry
conditions side of the diaphragm)
dampener, pre-charge limit to prevent Instrument and equipment list
diaphragm limit extrusion of the diaphragm + chapter "Technical data"
material at the dampener in-/out-
let

Discharge pulsation dampener pre-charge set-point instructions

DANGER
Safety limits:
To prevent over-stressing the dampener system and the diaphragm:
NEVER pre-charge the pulsation dampener with more then the dampener system,
maximum pressure.
The maximum pressure is indicated on the pulsation dampener identification plate.
NEVER pre-charge the pulsation dampener with more then the maximum pressure for the
diaphragm limit.
The diaphragm limit pressure is indicated in the "Technical data".

ATTENTION
Functional limits:
To prevent dampener diaphragm damage during pressure still-stand of the pump
and hammering of the diaphragm against the bottom of the dampener:
NEVER pre-charge the pulsation dampener with more then 80% of the maximum pump
operating pressure.
To prevent hammering of the diaphragm against the top of the dampener:
NEVER let the pre-charge pressure drop below 30% of the maximum pump operating
pressure.
Excessive pressure pulsations and heavy vibrations are caused by insufficient pre-charge
pressure.

6.14 MUI.814.200981.R01.EN
Transport and installation

ATTENTION
The pre-charge pressure may change due to temperature influence:
Temperature fluctuation of the slurry.
Temperature differences between the slurry and the environment.
These effects require re-adjustment of the pre-charge pressure.

The pre-charge pressure is application dependent.

Refer to the "Instrument and equipment list" for details about the "discharge pulsation dampener".
Refer to the "Instrument and equipment list" for the dampener pre-charge "set-point" recommendation for
installation, to start with.

Operating conditions Recommended pre-charge set-point Result

Percentage of operating pressure
80% = maximum pre-charge limit, to protect the diaphragm and
but not more than the diaphragm limit dampener
constant operating pressure 60% to 65% optimal operation
widely varying operating pressure 30% to 35% optimal operation
30% = minimum pre-charge limit to protect the diaphragm and
dampener

NOTE
High dampener pre-charge pressure (related to the operating pressure) gives the best
dampening results. But if the operating pressure decreases, this can cause wear and damage
to the diaphragm and metal insert by continuously hammering the dampener bottom.
When working with relatively constant pump pressures, the GEHO diaphragm pulsation
dampeners are to be charged at 60%-65% of the pumps normal operating pressure
(see GEHO Touch Panel, menu Graphics: "ACTUAL VALUE").
When operating the pump with widely varying pressures, it can be necessary to pre-charge the
pulsation dampener at 30%-35% of the pumps maximum operating pressure
(see GEHO Touch Panel, menu Graphics: "HIGHEST VALUE").
Pos: 12.16 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766

MUI.814.200981.R01.EN 6.15
 Transport and installation

Pos: 12.17 /GEHO/Heading/H3/#.#.# Pre-charging a pulsation dampener with nitrogen @ 0\mod_1156314333839_31.doc @ 5777

6.2.6 Pre-charging a pulsation dampener with nitrogen

Pos: 12.18 /GEHO/Transport and installation/Installation/Nitrogen filling/Pre-charging/Nitrogen bottle+charging equipment @ 1\mod_1169738002506_31.doc @ 12006

Nitrogen bottle with charging equipment

DANGER
Usually not in the scope of supply of Weir Minerals are nitrogen filling equipment parts
(nitrogen bottle, pressure reducer, safety valve and drain valve).
Check that they are in accordance with local standards and safety regulations.

A Nitrogen (N2) bottle

B Nitrogen bottle main valve A B C C1 C2 C3 D E F G H I

C Pressure reducer:
C1 Pressure gauge, indicating the bottle pressure
C2 Pressure gauge, indicating the actual filling
pressure in the hose
C3 Pressure reducer valve

D Safety relieve valve,

to protect the pulsation dampener against
overload.
Relieve pressure depending on the maximum
allowed pressure of the pulsation dampener.
E Drain valve

F Charging hose Figure 6.12: Nitrogen bottle with charging

for high pressure nitrogen charging equipment

G Filler valve
H Pressure gauge
(at the top of the dampener or at the P&I-skid
panel), indicating
> during filling: the actual nitrogen filling
pressure,
> during pump operation: the pump discharge
pressure.
I Pulsation dampener
Pos: 12.19 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766

6.16 MUI.814.200981.R01.EN
Transport and installation

Pos: 12.20 /GEHO/Transport and installation/Installation/Nitrogen filling/Pre-charging/Pulsation dampener pre-charging procedure @ 0\mod_1156240668870_31.doc @ 5740

Pulsation dampener pre-charging procedure

DANGER
Refer to chapter "Safety regulations and instructions for nitrogen".

DANGER
INSTRUCTIONS ABOUT FILLING A PULSATION DAMPENER WITH NITROGEN (N2)
Refer to "Instrument and equipment list" and the begin of this chapter,
for the recommended pre-charge set-point pressure of a pulsation dampener.
Always pre-charge the GEHO pulsation dampeners with nitrogen gas (N2), before operating
the pump.
ONLY use nitrogen gas (N2) to pre-charge the dampener.
NEVER use oxygen (or air containing oxygen) to pre-charge the dampener.
There is a risk of explosion.
ONLY use an appropriate pressure regulator to pre-charge the pulsation dampener.
Be aware of the risk, that the dampener pressure gauge indicates a wrong pressure.
The pressure sensing opening may be clogged. The pulsation dampener may be under
pressure, even when the dampener pressure gauge indicates no pressure.
Risk of explosion of the dampener.
An external fire will increase the nitrogen pressure inside the pulsation dampener.
The designed pressure can be exceeded.

DANGER
Before starting the dampener pre-charge procedure:
Make sure that there is no pressure at all connections of the pulsation dampener.
Make sure that there is no liquid at the slurry side of the diaphragm.
Measuring pre-charge pressure with liquid or pressure at the slurry side of the diaphragm
gives wrong indications about the pre-charge situation.
NEVER change the nitrogen charge of the dampener during operation of the pump, for
measured pressure values will not relate to the nitrogen volume in the dampener.

Pre-charge pressure check

1 Read the actual pre-charge pressure of the pulsation dampener at its pressure gauge (H) (at the top of the
dampener or at the P&I-skid).
2 If the pre-charge pressure is higher then the recommended pre-charge pressure, then
Vent a little amount of nitrogen by opening filler valve (G) a few seconds just a little and fast closing.
Check the actual pre-charge pressure of the pulsation dampener at its pressure gauge (H).
Repeat this pulsation venting, until the recommended pre-charge pressure is reached.
3 If the actual pre-charge pressure is lower then the pre-charge pressure,
then follow the procedure to add nitrogen.
Filling preparation
1 Close drain valve (E).
2 Close pressure reducer valve (C3) to pressure zero at gauge (C2).
3 Connect pressure reducer (C) to nitrogen bottle (A+B).
4 Connect hose (F) to pressure reducer (C).
5 Open nitrogen bottle valve (B) slowly.
- Check at gauge (C1) the bottle pressure, it has to be more than the recommended dampener pre-charge

MUI.814.200981.R01.EN 6.17
 Transport and installation

pressure.
- Check at gauge (C2) that the pressure is zero and valve (C3) is closed.
6 Flush short the hose clean
- open little a second and immediately close pressure reducer valve (F).
7 Connect hose (F) to filler valve (G).
Nitrogen pre-charge filling
1 Open filler valve (G).
2 Open pressure reducer valve (F) in many small steps, until the recommended pre-charge pressure is
reached at gauge (C2) and gauge (G).
DANGER
Prevent fast filling, it will cause icing at the valves and the hose.

3 When the recommended pre-charge pressure is reached, then:

4 Close nitrogen bottle valve (B), so the nitrogen supply is interrupted.
5 Close filler valve (G), so the pulsation dampener is isolated.
6 To release the nitrogen pressure in the hose:
Open drain valve (E) slowly, until the pressure at gauge (C2) is zero.
Nitrogen will escape (E).
7 Disconnect hose (F) from filler valve (G).
Pos: 12.21 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766

6.18 MUI.814.200981.R01.EN
Transport and installation

Pos: 12.22 /GEHO/Heading/H3/#.#.# Pre-charging the accumulator with nitrogen @ 1\mod_1166006986593_31.doc @ 9291

6.2.7 Pre-charging an accumulator with nitrogen

Pos: 12.23 /GEHO/Transport and installation/Installation/Nitrogen filling/Pre-charging/Nitrogen bottle+charging equipment+valve @ 1\mod_1170063773322_31.doc @ 12032

Nitrogen bottle with charging equipment

DANGER
Nitrogen bottle and pressure reducer are usually not in the scope of supply of Weir Minerals.
Check that they are in accordance with local standards and safety regulations.

A Nitrogen (N2) bottle

B Nitrogen bottle main valve A B C D E F G H I J K L M N

C Pressure reducer:
D Pressure gauge, indicating the bottle pressure
E Pressure gauge, indicating the actual filling
pressure in the hose
F Pressure reducer valve

G Charging hose
for high pressure nitrogen charging

H Charging unit:
I Non-return valve
(prevents gas to flow out of the accumulator)
J Shut-off-valve
Figure 6.13: Nitrogen bottle with charging
K Pressure relief valve equipment
L Pressure gauge indicating the actual filling
pressure

M Accumulator
N 3/2 ball valve, with drain side to release the
pressure at the fluid side of the accumulator
Pos: 12.24 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766

MUI.814.200981.R01.EN 6.19
 Transport and installation

Pos: 12.25 /GEHO/Transport and installation/Installation/Nitrogen filling/Pre-charging/Accu-N2-pre-charging procedure @ 1\mod_1169741590336_31.doc @ 12010

Accumulator pre-charging procedure

DANGER
Refer to chapter "Safety regulations and instructions for nitrogen".

DANGER
ACCUMULATOR INSTRUCTIONS
Refer to "Instrument and equipment list" for the correct pre-charge pressure of the
accumulator.

CAUTION
Prior to each testing, topping-up or re-charging the accumulator with nitrogen,
de-pressurize the fluid side of the accumulator.
If pressure remains at the fluid side of the accumulator, that leads to a wrong combination of
nitrogen volume and pressure. That will affect the function of the accumulator.
Primer pre-charge pressure check
1 Shut down the pump for maintenance.
2 Open the drain side of 3/2 ball valve (N) to drain pressure at the fluid side of the accumulator.
Depending on lay-out details:
- Keep fluid in the piping below the accumulator
- Avoid that air fills the fluid compartment of the accumulator.
3 Check that shut-off-valve (J) is closed.
4 Check that relieve valve (K) is closed.
5 Remove the protection cap at the top of the accumulator (M).
Mount charging unit (H) on accumulator (M).
6 Open shut-off-valve (J).
7 Read the actual pre-charge pressure of the accumulator with the pressure gauge (L).
If the accumulator is filled with a higher pressure than recommended,
then release the pressure until the recommended value.
8 Open the pressure relief valve (K)a few seconds just a bit.
This will allow nitrogen to escape, reducing the pressure in the accumulator.
Repeat this, until the recommended pre-charge pressure is reached.
9 If the pressure is according to the recommended value, then
- Close the drain side of 3/2 ball valve (N) to allow fluid pressure at the fluid side of the accumulator.
- The pressure check procedure is finished.
10 If the accumulator is filled with a lower pressure than recommended,
then follow the filling procedure below.
Filling preparation
1 Close the pressure reducer valve (F).
2 Connect pressure reducer (C) to nitrogen bottle (A+B).
3 Connect hose (G) to pressure reducer (C).
4 Open nitrogen bottle valve (B) slowly.
- Check at gauge (D) the bottle pressure, it has to be more than the recommended accumulator pressure.
- Check at gauge (E) that the pressure is zero and the valve (F) is closed.
5 Flush the hose clean short by open little a second and immediately close pressure reducer valve (F).
6 Connect hose (G) to charging unit (H).

6.20 MUI.814.200981.R01.EN
Transport and installation

Nitrogen pre-charge filling

1 Open shut-off-valve (J).
2 Open pressure reducer valve (F) in many small steps until the recommended pre-charge pressure is
reached at gauge (E) and gauge (l).
DANGER
Prevent fast filling, it will cause icing at the valves and the hose.

3 When the recommended pre-charge pressure is reached, then:

4 Close nitrogen bottle valve (B), so the nitrogen supply is interrupted.
5 Close pressure reducer valve (F).
6 Close shut-off-valve (J), so the accumulator is isolated.
7 To release the nitrogen pressure in the hose:
Open pressure relief valve (K).
Nitrogen will escape from the hose.
- Check at gauge (L) that the pressure is zero.
- Check at gauge (E) that the pressure is zero.
Disconnect the nitrogen supply line
1 Check, that nitrogen bottle valve (B) is closed.
2 Disconnect pressure regulator (C) from nitrogen bottle (A+B).
3 Disconnect hose (G) pressure regulator (C).
4 Disconnect hose (G) from charging unit (H).
Return to operation.
1 If charging unit (H) stays at the accumulator, then:
- Leave shut-off-valve (J) shut.
- Read the fluid pressure only at the pressure gauge at the fluid side, not at gauge (I).
- Check for leakages on valve (J) and its connection to the accumulator, using a leak detector spray.
2 If removing charging unit (H), then:
- Disconnect charging unit (H) from accumulator (M).
- Check for leakages on the accumulator top, using a leak detector spray.
- Mount the protection cap at the top of the accumulator (M).
3 Close the drain side of 3/2 ball valve (N) to allow fluid pressure at the fluid side of the accumulator.
Pos: 13 /--- Section break - Odd page --- @ 0\mod_1136277036628_0.doc @ 765

MUI.814.200981.R01.EN 6.21
Operation, Start-up + Start + Stop procedures

Pos: 14.1 /GEHO/Heading/H1/#. Operation, Start-up + Start + Stop procedures @ 0\mod_1136455316013_31.doc @ 933

7. Operation, Start-up + Start + Stop procedures

Pos: 14.2 /GEHO/Heading/H2/#.# Start-up checklist, main power switch OFF @ 2\mod_1173875659029_31.doc @ 12732
Preparation

7.1 Start-up checklist, working with main power switch OFF

ATTENTION
Use this procedure, to make the pump system ready for operation
(at first at installation, and after working on the pump).
Secure the main power switch against "unwanted switch-on".
Pos: 14.3 /GEHO/Start and Stop/Common/Warning - Heavy parts - Use hoisting eye @ 1\mod_1165935566336_31.doc @ 9221

WARNING
The heavy parts of the pumps are provided with a hoisting eye or have the possibility to install
a hoisting eye for transportation purposes.
Always transport these parts by using these hoisting eyes.
Pos: 14.4 /GEHO/Heading/H3/#.#.# Initial lubrication filling @ 1\mod_1171376311244_31.doc @ 12412

7.1.1 Initial lubrication filling

Pos: 14.5 /GEHO/Start and Stop/Common/Lubrication - Initial @ 1\mod_1165995657192_31.doc @ 9251

If applicable, perform and check an initial lubrication filling of the following parts.
Gear box (if applicable):
Refer to "Catalogue information" for details about the procedure, the oil type and oil quantity.
Tooth coupling between gearbox and pump shaft (if applicable):
1 Remove the protection cover.
2 Fill the coupling with oil.
3 Mount the protection cover.
Refer to "Catalogue information" for details about the procedure, the oil type and oil quantity.

Power end:
Working with the main power switch OFF:
1 Clean the power end side, if necessary.
2 Open the main covers.
3 Open the side covers.
4 Clean the crosshead liners.
5 Fill the oil sump with oil.
Use a combined oil-filter/oil-water-
separator to clean the oil.
Refer to "Utility consumption list" for details about
the oil type and oil quantity.
6 Check the oil level gauge.
B
At initial filling or re-filling, the oil level
should be near level (B).
7 Close all covers.
A

Figure 7.1: Correct oil filling level at the oil level gauge

MUI.814.200981.R01.EN 7.1
 Operation, Start-up + Start + Stop procedures

Working with the main power switch ON:

8 Check the turning direction of the lubrication pump.
Refer to "Start-up, electrical check".
9 Start the lubrication pump.
10 Check the oil level gauge.
After 5 minutes, oil is distributed in the lubrication system and the oil level should be about half
height (A) at the oil level gauge.
If necessary, fill additional oil until level (A).
11 Check the lubrication system.
Pos: 14.6 /GEHO/Heading/H3/#.#.# Propelling liquid @ 1\mod_1166007118791_31.doc @ 9297

7.1.2 Propelling liquid

Pos: 14.7 /GEHO/Start and Stop/Propelling liquid - Initial @ 1\mod_1165936154067_31.doc @ 9227

1 Open the propelling liquid tank cover.

2 Clean the propelling liquid tank.
3 Fill the propelling liquid tank to the upper liquid level.
4 Check the liquid level at the liquid level gauge.
5 Close the propelling liquid tank cover.
Pos: 14.8 /GEHO/Heading/H3/#.#.# Air supply unit @ 0\mod_1146140424938_31.doc @ 3465

7.1.3 Air supply unit

Pos: 14.9 /GEHO/Start and Stop/Common/Air supply check @ 1\mod_1165998689770_31.doc @ 9254

ATTENTION
Air pressure must ALWAYS be available, even when the slurry pump is not in operation.
Without air pressure, the pump system will stop immediately by an pressure alarm or soon by
an electric operation control alarm.
Because the air valves are spring-opened, air pressure is necessary to avoid liquid-loss or
liquid-overfilling in the propelling liquid chambers.

Check that pressure and quality and quantity of the compressed air supply meet the required standards.
Refer to "Technical data", "Utility consumption list" for details about the compressed air supply.
Check that the air supply line is flushed clean, before connecting it to the pump system.
Connect the compressed air supply.
Pos: 14.10 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766

7.2 MUI.814.200981.R01.EN
Operation, Start-up + Start + Stop procedures

Pos: 14.11 /GEHO/Heading/H3/#.#.# Pre-charging a pulsation dampener with nitrogen @ 0\mod_1156314333839_31.doc @ 5777

7.1.4 Pre-charging a pulsation dampener with nitrogen

Pos: 14.12 /GEHO/Start and Stop/Common/Pre-charge pulsation dampener, refer to installation @ 1\mod_1169653974927_31.doc @ 11992

Refer to "Transport and installation", "Pre-charging the pulsation dampener" for the procedure.
Check that the pulsation dampener is pre-charged with nitrogen, according to the procedure.

Pos: 14.13 /GEHO/Heading/H3/#.#.# Pre-charging the accumulator with nitrogen @ 1\mod_1166006986593_31.doc @ 9291

7.1.5 Pre-charging an accumulator with nitrogen

Pos: 14.14 /GEHO/Start and Stop/Common/Pre-charge accumulator-gas @ 1\mod_1170093129172_31.doc @ 12048

The accumulator of the propelling liquid system must be pre-charged with gas.
Refer to the "Instrument List" for the correct pre-charge pressure.
Refer to the "Utility consumption list" for the gas quality.
Refer to the chapter "Installation" for the pre-charging procedure and set-point.
Refer to the chapter "Transport and installation", "Pre-charging the accumulator" for the procedure.
Pos: 14.15 /GEHO/Heading/H2/#.# Start-up checklist, main power switch ON @ 2\mod_1173875689375_31.doc @ 12737
eparation

7.2 Start-up checklist, working with main power switch ON

ATTENTION
Use this procedure, to make the pump system ready for operation
(at first at installation, and after working on the pump).
Pos: 14.16 /GEHO/Heading/H3/#.#.# Main power switch @ 1\mod_1166007056288_31.doc @ 9294

7.2.1 Main power switch

Pos: 14.17 /GEHO/Start and Stop/Common/Start-up, main power supply @ 1\mod_1170157413431_31.doc @ 12075

From this step on, electric main power supply is needed to proceed the "Start, preparation check list".
Pos: 14.18 /GEHO/Start and Stop/Common/Start-up, main power switch @ 1\mod_1165998832165_31.doc @ 9257

DANGER
While working on the pump, it is not permitted to start the pump.
Secure the main power switch against "unwanted switch-on", until the pump system is safe
to run.
DO NOT switch on the main power switch, until the pump system is safe to run.
Set the main power switch to 0-position (OFF) only in case of working during maintenance
or service.
1 Check, that the pump system is safe to switch on and run.
2 Switch the main power switch on the control panel to 1-position (ON).

Pos: 14.19 /GEHO/Heading/H3/#.#.# Start-up, electrical check @ 1\mod_1170159443932_31.doc @ 12080

7.2.2 Start-up, electrical check

Pos: 14.20 /GEHO/Start and Stop/Common/Start-up, electric check @ 1\mod_1170159737562_31.doc @ 12084

1 Ask an authorized electrician to check that the auxiliary electric motors turn in the direction, as indicated
on the motor cover.
2 If a motor turns in the wrong direction, then change the electrical connections.
Pos: 14.21 /GEHO/Start and Stop/Common/Start-up, power end oil check @ 2\mod_1173876188272_31.doc @ 12742

7.2.3 Initial power end oil check

1 Check the oil level at the power end.
Refer to chapter "Initial lubrication filling".
Pos: 14.22 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766

MUI.814.200981.R01.EN 7.3
 Operation, Start-up + Start + Stop procedures

Pos: 14.23 /GEHO/Heading/H2/#.# Start-up, priming procedure @ 2\mod_1175856788072_31.doc @ 13082

eparation

7.3 Start-up, priming procedure

ATTENTION
Use this procedure, to make the pump system ready for operation
(at first at installation, and after working on the pump).
Pos: 14.24 /GEHO/Heading/H3/#.#.# Priming the slurry section @ 1\mod_1166006925672_31.doc @ 9288

7.3.1 Priming the slurry section

Pos: 14.25 /GEHO/Start and Stop/TZPM/Priming the slurry section @ 1\mod_1166001286915_31.doc @ 9269

Targets of priming the slurry section:

1. De-aeration of the slurry section, by filling water via a flushing water connection (D) in the suction line and
draining the water through valve (B) in the discharge line.
2. De-aeration of each propelling liquid chamber through valves (E) and (G) and (F).
3. To obtain a controlled starting position for filling all propelling liquid chambers, the flush water pressure will
force the diaphragm against the rear wall of the diaphragm housing, where position marker (M) meets
switch (ZSL).
ATTENTION
Refer to "Utility consumption list" for the flush water quality and quantity and pressure.

Procedure filling the slurry section with flush water and de-aeration

PROPELLING
LIQUID
AUTOMATIC
CONTROL
SYSTEM PI

ZSH PLC FILL DRAIN B A

ZSL DISCHARGE LINE

E E E
M

SUCTION LINE D
F G H
Figure 7.2: Filling and de-aerating the slurry section
1 Start up the air unit (needed for proper function of the propelling liquid system).
Closing the slurry section:
2 Close the main valve (C) in the suction line.
3 Close the main valve (A) in the discharge line.
De-aerating the slurry section:
4 Open valve (D) of the flush water connection to the suction line.
Refer to "Utility consumption list" for the flush water quality and quantity and pressure.
5 Open the drain valve (B) in the discharge line.
Wait until flush water discharges from the drain valve (B).
6 Close the drain valve (B).

7.4 MUI.814.200981.R01.EN
Operation, Start-up + Start + Stop procedures

De-aerating the propelling liquid chambers and

positioning the diaphragms in starting position:
7 Partly open drain valve (B) in the discharge line, to maintain in the slurry section a pressure, as
specified in the "Utility consumption list".
> The pressure of the flush water must be high enough to force the propelling liquid to escape through
non-return-valve (F).
8 Open the vent valves (E) of all propelling liquid chambers
(located on the rear side top of the diaphragm housing).
The flush water pressure moves all diaphragms in the priming start position (ZSL).
Position marker (M) of each diaphragm rod meets switch (ZSL) and at the GEHO touch panel its light
will light on.
9 Check at the GEHO touch panel, that the lights of switch (ZSL) of all pistons light on.
10 Continue with the next chapter, to prime the propelling liquid section.
11 Continue with the next chapter, to prime the propelling liquid section.
Pos: 14.26 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766

MUI.814.200981.R01.EN 7.5
 Operation, Start-up + Start + Stop procedures

Pos: 14.27 /GEHO/Heading/H3/#.#.# Priming the propelling liquid section @ 2\mod_1175857268341_31.doc @ 13087

7.3.2 Priming the propelling liquid section

Pos: 14.28 /GEHO/Start and Stop/TZPM/Priming the propelling liquid section @ 1\mod_1166001870053_31.doc @ 9272

ATTENTION
Refer to "Utility consumption list" for the flush water quality and quantity and pressure.

PROPELLING
LIQUID
AUTOMATIC
CONTROL
SYSTEM PI

ZSH PLC FILL DRAIN B A

ZSL DISCHARGE LINE

E E E
M

SUCTION LINE D
F G H
Figure 7.3: Schematics of the TZPM propelling liquid section
De-aeration of the propelling liquid section:
1 Refer to the previous chapter to fill the slurry section with flush water and to move each diaphragm with
rod indicator (M) in its priming start position (ZSL).
2 Open the flush water connection (D) in the suction line.
3 Partly open the drain valve (B) in the discharge line, to maintain in the slurry section a pressure, as
specified in the "Utility consumption list".
> A diaphragm needs pressure at both sides, to move properly.
> The pressure of the flush water must be high enough to force the propelling liquid to escape through
non-return-valve (F).
4 Start at the GEHO touch panel the propelling liquid automatic control system.
5 Open the vent valves (E) in the propelling liquid section of all diaphragms.
6 Open the vent valve (G) to de-aerate the common line at safety relief valve (H) of the propelling liquid
system.
7 Push at the GEHO touch panel the button "MAIN SUPPLY VALVE", to open the main supply valve
(SV9). The filling valve (HV9) opens for 15 minutes.
Refer to "P&I Diagram" for details about the propelling liquid automatic control system.
Refer to the GEHO touch panel and its manual for details about how operation conditions are displayed at
the panel.
8 Close the vent valves (E) and (G), if the propelling liquid, that discharges through valve (F), contains no
air bubbles.
9 If necessary, repeat the steps 7 and 8 until all vent valves (E) of the diaphragms are closed.
10 After de-aeration, as long as filling valve (HV9) is open,
> propelling liquid will be filled into the pump chambers;
> the diaphragms will leave the ZSL start position;
> until the monitoring rods of the diaphragms de-activate the ZSL indicators;
> the corresponding filling valves (HV) will close, the filling will stop;
> at the GEHO touch panel the corresponding diaphragm position light (ZSL) will turn off.
11 If necessary, repeat step 7 until at the GEHO touch panel all position lights of all diaphragms are off.

7.6 MUI.814.200981.R01.EN
Operation, Start-up + Start + Stop procedures

Positioning of the diaphragms in relation to the pistons:

12 Rotate the pump crankshaft manually.
Make sure that the power of the drive motor is switched off.
Refer for details to chapter "Manual rotation of the pump".
13 Stop rotation of the pump, if at the GEHO touch panel one of the lights of switch (ZSH) or (ZSL) of the
diaphragm position is lit.
> If indicator (M) meets switch (ZSL), so related switch light is lit,
than the propelling liquid system will fill propelling liquid, until the indicator light is off.
> If indicator (M) meets switch (ZSH), so related switch light is lit,
than the propelling liquid automatic control system will drain propelling liquid,
until the switch light is off.
14 Wait until this switch light is off.
15 Repeat steps 10 to 12 until no switch lights light up during rotation of the pump.
16 Turn the pump crankshaft another 2 turns, to check that no switch lights light up.
So all chambers are filled properly with propelling liquid and piston rod indicator (M) of the diaphragm
moves properly between switch (ZSL) and switch (ZSH) .
Arranging PRE-START of the pump
17 Close the drain valve (B) in the discharge line.
18 Close the flush water valve (D) of the flushing water connection in the suction line.
19 Stop the flush water supply.
20 Open the main valve (C) in the suction line.
21 Open the main valve (A) in the discharge line.
PRE-START procedure
The pump system is now ready for the PRE-START procedure.
Pos: 14.29 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766

MUI.814.200981.R01.EN 7.7
 Operation, Start-up + Start + Stop procedures

Pos: 14.30 /GEHO/Heading/H2/#.# Operating touch panel and control system @ 1\mod_1169830993137_31.doc @ 12026

7.4 Operating the GEHO touch panel and pump control system
Pos: 14.31 /GEHO/Start and Stop/Common/Operating touch panel and pump control system @ 1\mod_1169830665787_31.doc @ 12021

Refer to chapter "Technical data", "Typical Manual of the GEHO Touch Panel" for operating the GEHO
Touch Panel.
Refer to chapter "Technical data", "Description of the pump control system" for operating the GEHO Pump
Control System.
Pos: 14.32 /GEHO/Heading/H2/#.# Start @ 1\mod_1165935124304_31.doc @ 9209

7.5 Start
Pos: 14.33 /GEHO/Start and Stop/Common/START + Pre-start procedure @ 1\mod_1170848561800_31.doc @ 12151

7.5.1 PRE-START check list

DANGER
NEVER start the main motor, if one of the checks below fails.

1 Check that the slurry end is filled and de-aerated.

2 Check that all slurry end flushing valves are closed.
3 Check that all slurry end drain valves are closed.
4 Check that the propelling liquid sections are filled.
5 Check that the propelling liquid sections are de-aerated.
6 Check that the propelling liquid de-aeration valves are closed.
7 Check the air supply pressure.
Refer to "Utility consumption list" for details about quality and quantity and pressure.
8 Check the pre-charge pressure of the diaphragm pulsation dampeners.
9 Check that the main suction valve is open.
10 Check that the main discharge valve is open.

7.5.2 PRE-START procedure

Use this procedure only, if the pump system is ready to operate.
Refer for operation details to "Description of the pump control system" and "Typical Manual of the GEHO
Touch Panel".
1 Push the PRE-START button at the GEHO touch panel.
The electrical PRE-START procedure contains:
1.1 Start of all auxiliary systems.
1.2 Check of the electrical PRE-START conditions.
The main motor can only start, if all pre-conditions are fulfilled.
Refer for details to the electrical "Logic diagram" and "Description of the pump control system".
1.3 The pump is ready to run, if the lamp "PUMP READY TO RUN" lights up at the GEHO touch panel.

7.5.3 START procedure by local control

Refer for details to "Description of the pump control system" and "Typical Manual of the GEHO Touch Panel".
If local operation, then:
1 Check the pre-set speed at the GEHO touch panel.
2 Push the ZERO button at the GEHO touch panel.
3 Push the UP button to start from speed zero.
The pump will start and run up to turn at the pre-set speed.
4 Check the actual speed at the GEHO touch panel.

If remote control operation, then:

7.8 MUI.814.200981.R01.EN
Operation, Start-up + Start + Stop procedures

1 Check the pre-set speed at the GEHO touch panel.

2 Check remote signal for preset speed.
3 Push the START button at the GEHO touch panel.
The pump will start and run up to turn at the pre-set speed.
4 Check the actual speed at the GEHO touch panel.

INFORMATION
If the pre-set speed is set at zero, then the pump remains in a stand-by idle status.
(= "0 SPM" at the GEHO touch panel = zero strokes per minute
= zero revolutions per minute of the crankshaft.)
The pump system needs a minimum speed to run.
Refer for details to "GEHO pump identification plate" and chapter "Technical data".
Pos: 14.34 /GEHO/Start and Stop/Common/START, remote control @ 1\mod_1170863453339_31.doc @ 12161

7.5.4 START by remote control

INFORMATION
If applicable, refer to the manual of the remote control system of the supplier .
Push the button LOC.REM. to switch from local control to remote control and back.
Refer also to chapter "Technical data", "Description of the Pump Control System" for details
about remote control.
Pos: 14.35 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766

MUI.814.200981.R01.EN 7.9
 Operation, Start-up + Start + Stop procedures

Pos: 14.36 /GEHO/Heading/H2/#.# Stop @ 1\mod_1165935157213_31.doc @ 9212

7.6 Stop
Pos: 14.37 /GEHO/Heading/H3/#.#.# Emergency stop @ 1\mod_1166006853944_31.doc @ 9285

7.6.1 Emergency stop

Pos: 14.38 /GEHO/Start and Stop/Common/Emergency stop @ 1\mod_1166005615179_31.doc @ 9281

Refer to chapter "Safety equipment" for details about requirements of the emergency stop system.
It is mandatory to install an EMERGENCY STOP button within a short range of the pump installation.
The installation of the EMERGENCY STOP system is not within the scope of the contract between the
customer and Weir Minerals Netherlands. Responsible for the installation of the EMERGENCY STOP button
is the customer as stated in the written contract.

DANGER
Fail to install an EMERGENCY STOP button will result in an illegal use of the pump
installation.

In case of an EMERGENCY STOP:

The electrical supply of the main motor and all auxiliary motors will shut-down immediately.
The pump system (motor + gear box + pump) will run down (wasting its dynamic energy).

DANGER
After an EMERGENCY STOP:
Make sure, that the reason for the EMERGENCY STOP is attended and solved,
before starting the pump again.

After an EMERGENCY STOP, the pump system is ready for a regular PRE-START procedure.
Pos: 14.39 /GEHO/Start and Stop/Common/STOP by remote control @ 1\mod_1170863607721_31.doc @ 12166

7.6.2 STOP by remote control

INFORMATION
If applicable, refer to the manual of the remote control system of the supplier.
Push the button LOC.REM. to switch from local control to remote control and back.
Refer also to chapter "Technical data", "Description of the Pump Control System" for details
about remote control.
Pos: 14.40 /GEHO/Heading/H3/#.#.# STOP for stand-by @ 1\mod_1170094105925_31.doc @ 12052

7.6.3 STOP for stand-by

Pos: 14.41 /GEHO/Start and Stop/Common/STOP for stand-by @ 1\mod_1170094694626_31.doc @ 12064

Refer for details to "Description of the pump control system" and "Typical Manual of the GEHO Touch Panel".

ATTENTION
Keep the pump system in the stand-by modus, ready to start again:
DO NOT switch off the auxiliary motors.
DO NOT switch off the air pressure.
This prevents that the propelling liquid sections are overfilled or discharged.
DO NOT switch off the electric power supply.
During stand-by status the slurry section of the pump remains filled with slurry.

7.10 MUI.814.200981.R01.EN
Operation, Start-up + Start + Stop procedures

ZERO button procedure

ATTENTION
The ZERO button procedure is preferred:
For short operation interruptions.
For quick re-starting requirements after a short operating interruption.
For starting with the UP button.

ATTENTION
A pump motor at ZERO status will draw electric energy and may tray to drift slightly.
So the ZERO status is only recommended for short interruptions.

DANGER
If the minimum speed setting of the VFD (Variable Frequency Drive) 0 (= more then zero
revolutions per minute), then the main motor does not stop.

1 Push the ZERO button at the GEHO touch panel, to stop the pump.
The automatic ZERO program contains:
1.1 The main motor runs down to the minimum revolution stand-by status (this depends on the minimum
speed setting of the VFD (Variable Frequency Drive)).
1.2 All auxilary systems of the pump system remain in action or stand-by, ready to start pumping again.

STOP button procedure

ATTENTION
The STOP button procedure is preferred:
For longer interruptions.
For starting with the PRE-START button.

1 Push the STOP button at the GEHO touch panel, to stop the pump.
The automatic STOP program contains:
1.1 The main motor runs down and stop.
1.2 All auxiliary systems will stop.
Pos: 14.42 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766

MUI.814.200981.R01.EN 7.11
 Operation, Start-up + Start + Stop procedures

Pos: 14.43 /GEHO/Heading/H3/#.#.# STOP for flushing @ 1\mod_1170094128268_31.doc @ 12056

7.6.4 STOP for flushing procedure

Pos: 14.44 /GEHO/Start and Stop/Flushing slurry section, general @ 1\mod_1169569488886_31.doc @ 11969

Flushing the slurry section, general recommendations

ATTENTION
Flush the slurry section, if the pump may get out of operation for a longer time.
If the pump system stops for a longer period, then:
the slurry may get clogged,
so starting up may need more time and energy and cause troubles.
the slurry may get acid,
so this may result to damage to the inner surfaces of the pump slurry section.
The decision to flush depends on:
the quality of the slurry,
the period of still stand,
general experience and operating and precaution arguments.

The flushing connections are not in the scope of supply of this pump system.
Refer to chapter "Technical data" drawing 814.200000.04 "Flushing/Filling/Drain Connections"
for details, how this may be arranged on the pump system.

Pos: 14.45 /GEHO/Start and Stop/Common/STOP, flushing procedure @ 1\mod_1170094728267_31.doc @ 12072

Flushing the slurry section procedure

1 Keep the pump system running at minimum speed.
2 Flush the pump with clean water for at least 5 minutes.
3 Stop the pump at the GEHO touch panel.
Refer for details to "Description of the pump control system" and "Typical Manual of the GEHO Touch Panel".
The slurry section of the pump remains filled with clean flush water.
At the end of the flushing procedure the pump is in the right position for starting.

ATTENTION
Keep the pump system in the ready-to-start modus:
DO NOT switch off the air pressure.
This prevents that the propelling liquid sections get discharged.
DO NOT switch off the electric power supply.
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7.12 MUI.814.200981.R01.EN
Operation, Start-up + Start + Stop procedures

Pos: 14.47 /GEHO/Heading/H3/#.#.# STOP for maintenance procedure @ 1\mod_1170094160937_31.doc @ 12060

7.6.5 STOP for maintenance procedure

Pos: 14.48 /GEHO/Start and Stop/Common/STOP, maintenance procedure @ 1\mod_1170094711772_31.doc @ 12068

DANGER
Before working on the pump system, it is necessary to:
Flush the slurry section with clean water.
Stop the pump system.
De-pressurize the slurry section.
De-pressurize the pump auxiliary systems.
Switch off all power supply.
Lock the pump system main switch, to prevent un-intentional starting.
Pump, switch off procedure
1 Flush the pump with clean water for at least 5 minutes.
Refer to chapter "Stop for flushing procedure".
2 Push the STOP button at the GEHO touch screen panel.
Refer for details to chapter "Technical Data sheets", "Description of the pump control system".
During this stop the slurry section of the pump remains filled with clean flush water, ready to re-start.
Slurry section, de-pressurize and drain procedure
for working on the valves and pump diaphragm and piping.
ATTENTION
DO NOT switch off the air pressure at this phase.
This prevents that the propelling liquid sections get discharged.
1 Close the main valve in the discharge lines.
2 Close the main valve in the suction lines.
3 Open the drain plug in the discharge line.
4 Open the drain plug of the slurry section.
5 Open the drain plug of the suction section.
6 If applicable, depressurize the discharge pulsation dampener.
7 If applicable, depressurize the suction pulsation dampener.
Stop air supply
To switch off the air pressure, obey the procedure below.
ATTENTION
Stop the air only with this procedure.
This procedure prevents that the propelling liquid sections get discharged.
1 Close the main suction valve.
2 Close the main discharge valves.
3 Open the discharge drain valve.
4 Stop and dis-connect the air supply.
Switch off electric main supply
1 Switch off the electric main switch.
2 Lock the electric main switch against not-intentional starting.
Pos: 15 /--- Section break - Odd page --- @ 0\mod_1136277036628_0.doc @ 765

MUI.814.200981.R01.EN 7.13
Maintenance

Pos: 16 /GEHO/Heading/H1/#. Maintenance @ 0\mod_1136455430617_31.doc @ 937

8. Maintenance
Pos: 17 /GEHO/Maintenance/Project/Maintenance safety @ 1\mod_1171287274515_31.doc @ 12350

8.1 Maintenance safety instructions

ATTENTION
Do not hesitate to contact the Service Department of Weir Minerals, if problems occur
during maintenance or repair activities.

DANGER
Strictly obey to all instructions as given in the chapter "Safety" of this manual.
The correct working sequence along with the data in this manual is of the utmost
importance for safe operation and handling.
Only authorized and properly trained people are allowed to do maintenance work with the
pumps.
Only use original and undamaged GEHO parts.

DANGER
MAINTENANCE CHECKPOINTS during operation, with running pump:
Prevent contact with moving parts.

DANGER
MAINTENANCE CHECKPOINTS during shut-down and lock-out of the pump:
For safe working on the pump it is essential that the installation is locked out from all energy
sources.
For stopping the pump, refer to Chapter "Start and stop".
Lock-out power supply to main motor.
Lock-out power supply to lubrication oil motor.
Lock-out power supply to propelling liquid motor.
Lock-out power supply to relief valve motor.
Lock-out power supply to control panel.
Lock pump isolation valves in closed position.

Disconnect the air supply only, when working on the air-actuated valves.

INFORMATION
The below mentioned maintenance checkpoints are rough guidelines.
The real maintenance intervals have to be determined based on actual performance during
operation. This especially valid for the high wear parts.
Inspection of these parts should take place at least monthly until the real wear live has been
determined.

INFORMATION
Refer to chapter "Assembly and disassembly" for maintenance and (dis)assembling of valves,
valve seats, diaphragms, piston, cylinder and cylinder liner.

Pos: 18 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766

MUI.814.200981.R01.EN 8.1
 Maintenance

Pos: 19 /GEHO/Maintenance/Project/200981 TZPM1200 gear drive: checkpoints @ 2\mod_1177675403330_31.doc @ 13562

0

8.2 Maintenance checkpoints

ATTENTION
As part of a plant quality assurance plan, we recommend to use a log book with maintenance
checklist sheets to achieve a maintenance history.

MAINTENANCE CHECKPOINTS
Interval Checkpoint Location Check / Action
Daily During operation, with running pump
checkpoints (refer to "Maintenance safety instructions"):

General performance, status and condition

GEHO Touch Panel:
General performance X4= Check the data at the GEHO Touch Panel, refer
check GEHO to chapter "Technical data", "Manual of the GEHO
Touch Touch Panel".
Panel Check on flow in relation to pump speed.
Alarm check X4 Push the alarm button for a manual alarm check.
General round check:
All units, Check on abnormal:
systems, temperatures, filters, contamination, vibrations.
piping Check for changes in running noise.
Check on leaks of: air, oil, slurry.
Drive unit:
Gearbox oil level 814.31.1 Between marks of dipstick.
Gearbox oil cooler 814.31.2 Check on leaks and abnormal:
noise, temperatures, filters, contamination,
vibrations.
Coupling pump-shaft / 814.33 Check for oil leakage under the safety cover.
gearbox Check for changes in running noise.
Power end:
Oil level in sump 845.1 Between marks of oil sight glass.
Lubrication oil pressure 845.2 Check pressure
Lubrication oil flow 845.6 Flow sensor indicator LEDs status green.
Lubrication oil temperature X4 Temperature below 80C at sensor 845.3.
Propelling liquid unit:
Propelling liquid level in 857.2 Check level at oil sight glass.
tank
Propelling liquid pressure 857.14 Refer to chapter "Technical Data" for allowable
pressure.
No alarms on Touch Panel.
Propelling liquid 828.1 Vent each diaphragm chamber until no air is
de-aeration vents at each (3x) released.
diaphragm house Watch at the transparent tube for air bubbles.
During the start-up period, some air can appear.
Air bubbles after the start-up period may indicate
leakage in the propelling liquid system.
Propelling liquid 853.2 Vent the pressure limitation unit no air is released.
de-aeration vent at the (1x) Watch at the transparent tube for air bubbles.
pressure limitation unit During the start-up period, some air can appear.
Air bubbles after the start-up period may indicate
leakage in the propelling liquid system.

8.2 MUI.814.200981.R01.EN
Maintenance

MAINTENANCE CHECKPOINTS
Interval Checkpoint Location Check / Action
continued from
previous page
Propelling liquid No oil leakage.
filling valves 857.HV
1+2+3
and outlet valves 857.HV
5+6+7
Sequence for actuation Maximum once per 5 minutes.
of the filling valves 857.HV If available/applicable:
1+2+3 Check at the X4= GEHO Touch Panel the history
and outlet valves 857.HV of the propelling liquid valves actuation
5+6+7 frequency.
If the frequency is increasing, search for causes,
like leakage at the piping or wear at the piston
seals.
Safety relief valve 853.1 Watch at the transparent tube for oil flow.
During operation, no propelling liquid should flow
or leak.
Slurry section:
Discharge pressure X4 Refer to chapter "Technical Data" for allowable
pressure.
Check for no alarms at the GEHO Touch Panel.
Check trend graph at the GEHO Touch Panel.
Slurry flow X4 Check for not correct relation between the pump
speed and slurry flow.
Slurry valves: No extreme noise inside the valve housings.
discharge valves 831.1 (3x)
suction valves 831.2 (3x)
Covers of pump No leakage of slurry through covers.
discharge valve 831.1 (3x)
housings, 831.2 (3x)
suction valve housings, 832.1
diaphragm housings
Dampener diaphragm 832.1 No leakage of through covers.
housing and cover Check pressure indicator.

MUI.814.200981.R01.EN 8.3
 Maintenance

MAINTENANCE CHECKPOINTS
Interval Checkpoint Location Check / Action
Hot torque During shut-down and lock-out of the pump
after initial (refer to "Maintenance safety instructions"):
start-up
Torques of all flanges, Re-tighten.
covers, bolts and nuts For correct torque, refer to chapter "Technical
Data".

MAINTENANCE CHECKPOINTS
Interval Checkpoint Location Check / Action
200 hours During operation, with running pump
after initial (refer to "Maintenance safety instructions"):
start-up

Do the daily checkpoints

During shut-down and lock-out of the pump
(refer to "Maintenance safety instructions"):

Drive unit
Gearbox 814.31.1 Replace the oil.
Refer to chapter "Technical Data", "Utility
consumption list" for correct oil quality and
quantity.
Refer to "Catalogue information", "Gearbox" for
manual instructions.
Power end:
Power end lubrication oil replacement:
Lubrication oil tank 845 Replace the oil.
Refer to chapter "Technical Data", "Utility
consumption list" for correct oil quality and
quantity.
Refer to "Catalogue information", "Drive unit",
"Gearbox" for manual instructions of the
manufacturer.
Lubrication oil tank 845 Drain the lubrication oil.
Carefully clean the oil sump.
Lubrication oil tank 845.4 Replace suction oil filter.
845.7 Replace discharge oil filter.
Refer to "Instrument and equipment list" for
specifications.
Lubrication oil tank 845 Fill the carter with new oil.
Refer to chapter "Technical Data", "Utility
consumption list" for correct oil quality and
quantity.

8.4 MUI.814.200981.R01.EN
Maintenance

INFORMATION
To achieve reliable and economical pump performance, we recommend regular oil quality
checks by an oil laboratory.
Oil change intervals depend on the operation conditions and oil quality and oil quantity.
We recommend for normal conditions an oil check interval of 2000 working hours or 3 month.

MAINTENANCE CHECKPOINTS
Interval Checkpoint Location Check / Action
After each operating Oil in gearbox 814.31.1 Do the oil quality laboratory check.
period of 2000 working Take an oil sample and send it in to the
hours oil supplier laboratory, for a recommen-
(or 3 months of dation of a time schedule for replacing
operation, whatever the oil.
comes first)
Depending on the result, if necessary:
Replace the oil.
Refer for instructions and details to the
table for 200 hours interval.
Power end:
Lubrication oil tank 845 Do the oil quality laboratory check.
Take an oil sample and send it in to the
oil supplier laboratory, for a recommen-
dation of a time schedule for replacing
the oil.
Depending on the result, if necessary:
Replace the oil.
Refer for instructions and details to the
table for 200 hours interval.

MUI.814.200981.R01.EN 8.5
 Maintenance

MAINTENANCE CHECKPOINTS
Interval Checkpoint Location Check / Action
After each operating During operation, with running pump
period of 4000 working (refer to "Maintenance safety instructions"):
hours
(or year of
Do the daily checkpoints
operation,
whatever comes first) Electrical Installation:
Check function of the Initiators transfer signal to PLC.
diaphragm stroke control Filling outlet valve actuated after signal
system: from initiator to PLC.
Indication on Touch X4 Check for indication on Touch Panel.
Panel.
Working of initiators, 832.2 Maximum once per 5 minutes.
propelling liquid 832.3 If available/applicable:
filling valves, 857.SV Check at X4 (= GEHO Touch Panel)
outlet/drain valves 857.HV the history of the propelling liquid valves
actuation frequency.
If the frequency is increasing, search for
causes, like leakage at the piping or
wear at the piston seals.
Slurry section:
Covers of No leakage of slurry through covers.
discharge valve housings, 831.1
suction valve housings, 831.2
diaphragm housings 832
During shut-down and lock-out of the pump
(refer to "Maintenance safety instructions"):

General:
Instrumentation Calibrate and reset all instrumentation
parts and check set-points according to
the "Instrument list", refer to chapter
"Technical Data".
Power end:
Check drive shaft 845. Record signs of wear damages.
If necessary, contact the Service
Department of Weir Minerals
Netherlands b.v.
Piston rod seals in the dust 835.5 No oil leakage from the crankshaft frame
cover 835.6 to the piston chamber.
Piston seals 835.3 No propelling liquid leakage from the
pump cylinder to the piston chamber.
Drive unit
Motor 814.30 Refer to Catalog information,
"Drive unit", "Motor".
Gearbox 814.31.1 Refer to Catalog information,
"Drive unit", "Gearbox".
Gearbox cooler 814.31.2 Refer to Catalog information,
"Drive unit".
Coupling motor / gearbox 814.32 Refer to Catalog information,
"Drive unit", "Coupling".
Coupling pump / gearbox 814.33 Refer to Catalog information,
"Drive unit", "Coupling".

8.6 MUI.814.200981.R01.EN
Maintenance

MAINTENANCE CHECKPOINTS
Interval Checkpoint Location Check / Action
After each operating During operation, with running pump
period of 8000 working (refer to "Maintenance safety instructions"):
hours
(or 1 year of operation,
Do the daily checkpoints.
whatever comes first)
Do the 4000 hours (or year) checkpoints.
During shut-down and lock-out of the pump
(refer to "Maintenance safety instructions"):

Do the 4000 working hours (or year) checkpoints

Drive unit:
Oil in gearbox 814.31.1 Do the oil quality laboratory check.
Depending on the result, if necessary:
Replace oil.
Refer for instructions and details to the
200 hours interval.
Coupling motor-gearbox. 814.32 Check coupling alignments, refer to
chapter "Installation".
Re-align, if necessary.
Coupling gearbox-pump 814.33 Check coupling alignments, refer to
shaft chapter "Installation".
Re-align, if necessary.
Replace the oil in the ZAPEX coupling.
Refer to "Catalogue information", "Drive
unit" for manual instructions of the
manufacturer.
Refer to chapter "Technical Data",
"Utility consumption list" for details about
oil quality and quantity.
Power end:
Lubrication oil tank 845 Do the oil quality laboratory check.
Take an oil sample and send it in to the
oil supplier laboratory, for a recommen-
dation of a time schedule for replacing
the oil.
Depending on the result, if necessary:
Replace oil.
Refer for instructions and details to the
200 hours interval.
Air vent/filter of oil sump, 845.11 Change the air vent/filter.
located on inspection Refer to Instrument and equipment list
cover for specifications.
Piston nut 835.2 Check the required tightening torque
according to chapter "Technical Data"
and re-tighten if required.
Piston clamping piece 835.15 Check the required tightening torque
according to chapter "Technical Data"
and re-tighten if required.

MUI.814.200981.R01.EN 8.7
 Maintenance

MAINTENANCE CHECKPOINTS
Interval Checkpoint Location Check / Action
continued from
previous page
Propelling liquid unit:
Propelling liquid oil tank 857.1 Do the oil quality laboratory check.
Take an oil sample and send it in to the
oil supplier laboratory, for a recommen-
dation of a time schedule for replacing
the oil.
Propelling liquid oil tank 857.1 Depending on the result, if necessary:
Replace oil.
Refer for instructions and details to the
200 hours interval.
Propelling liquid 857.12 Check the pre-charge pressure.
accumulator
Cylinder liner 835.4 Inspect surface of cylinder liner or
replace.
Piston seals 835.3 Check for no oil leakage.
Filling valves, 857.SV Inspect and replace if there is any
outlet/drain valve: 857.HV leakage between the valves and valves
valve seat seats.
Filling valves, 857.SV Open cover, disassemble valve housing
outlet/drain valves: 857.HV from base plate.
spindle / seal guide Inspect 2/2 diaphragm for perforation or
damage.
Inspect slide bearing and guide ring
between valve spindle and valve
housing.
Replace slide bearing and / guide ring if
required.
Before re-assembly:
fill space between the two guide rings
with suitable grease.
Slurry section:
Slurry chambers: Carefully inspect the slurry chambers.
discharge valves 831.1
suction valves 831.2
diaphragm chamber 832
Pump diaphragm 832.1 Replace the pump diaphragms.
Refer to chapter "Assembly and
disassembly".
Pulsation dampener 851.1 Replace the pulsation dampener
diaphragm 851.2 diaphragm.
For (dis-)assembling instructions, refer
to chapter "Assembly and disassembly".
Pre-charge the pulsation dampener,
refer to chapter "Transport and
installation".
Pos: 20 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766

8.8 MUI.814.200981.R01.EN
Maintenance

Pos: 21 /GEHO/Maintenance/Project/200981 TZPM1200 gear drive: locations @ 2\mod_1176987324937_31.doc @ 13462

8.3 Location of parts and maintenance checkpoints

X4 814.30
= GEHO
TOUCH
814.31
PANEL 814.31.1
814.31.2
814.31.3 (2x)
814.32
814.33
853.1=PSV5
853.2
853.3=PI5

828.1 (3x)

831.1 (3x)
831.2 (3x) X2
845
832.1 845.1=LI2
832.2=ZSH (3x) 845.2=PI2
845.3=TE2
832.3=ZSL (3x) 845.4
845.5=M2
845.6=FISLL2
845.7

857
851.1
851.1.1
851.1.2=PI3+PT3
851.2
851.2.1
851.2.2=PI8

Figure 8.1: Overview

MUI.814.200981.R01.EN 8.9
 Maintenance

857.PI7
857.PT7
857.SV1+2+3
857.SV5+6+7
857.SV9+15
857.HV1+2+3
857.HV5+6+7
857.HV9+15

857.20
857.16
857.14=PI6
857.15=PT6
857.13
857.12
857.11=FISLL
857.10=M6=PUMP

857.1
857.2=LI6
857.3
857.4
857.5

Figure 8.2: Skid panel

8.10 MUI.814.200981.R01.EN
Maintenance

845.10
845.11
845.12
835.5 845.13
835.6 845.14
845.15

835.1 845.16
835.2 845.1
835.3
835.4
Figure 8.3: Piston parts

MUI.814.200981.R01.EN 8.11
 Maintenance

8.4 Description of parts and maintenance checkpoints

X Control units
X2 Terminal box
X4 GEHO Pump control panel
(HMI = Human Machine Interface with touch screen) located near the pump

814.200981.16 Drive unit

814.30 E-Motor
814.31 Gearbox
814.31.1 Gearbox oil level check
814.31.2 Gearbox oil/air cooler unit
814.31.3 (2x) Gearbox oil heater
814.32 Coupling electric motor - gearbox
814.33 Coupling pump shaft - gearbox

828 Leakage and vent-line unit

828.1 (3x) De-aeration vent valves at the diaphragm housing propelling liquid chamber

831 Valve unit

831.1 (3x) Discharge valves
831.2 (3x) Suction valves

832 Diaphragm housing unit

832.1 (3x) Diaphragm (inside the diaphragm unit)
832.2 = ZSH (3x) Initiators for diaphragm monitoring rod
ZSH = end of discharge stroke
832.3 = ZSL (3x) Initiators for diaphragm monitoring rod
ZSL = end of suction stroke

835 Piston unit

835.1 Piston rod
835.2 Piston nut
835.3 Piston seals
835.4 Cylinder liner

8.12 MUI.814.200981.R01.EN
Maintenance

835.5 Wiper ring

835.6 U-ring

845 Pump frame unit

845.1=LI2 Lubrication oil level indicator (oil glass)
845.2=PI2 Lubrication oil pressure indicator
845.3=TE2 Lubrication oil temperature sensor
845.4 Lubrication oil suction filter
845.5=M2 Lubrication oil pump
845.6=FISLL2 Lubrication oil flow sensor
845.7 Lubrication oil discharge filter

845.10 Inspection cover for cylinder/piston unit

845.11 Air vent filter
845.12 Crosshead
845.13 Crosshead guide
845.14 Crosshead rod
845.15 Piston clamping piece
845.16 Drain valve, drain to the propelling liquid tank

851 Pulsation damper system

851.1 Discharge pulsation damper
851.1.1 Discharge pulsation dampener filling unit
851.1.2=PI3+PT3 Pressure gauge for actual discharge working pressure
851.2 Suction pulsation damper
851.2.1 Suction pulsation damper filling valve
851.2.2=PI8 Pressure gauge for actual suction pressure

853 Pressure limitation unit

853.1=PSV5 Pressure limitation safety relief valve
853.2 Pressure limitation de-aeration valve
853.3=PI5 Pressure limitation pressure gauge

857 Propelling liquid system

MUI.814.200981.R01.EN 8.13
 Maintenance

857.1 Propelling liquid tank

857.2=LI6 Propelling liquid level indicator
857.3 Drain flange of the propelling liquid sump
857.4 Suction filter (inside propelling liquid sump)
857.5 Drain plug of waist oil receiving bin
857.10=M6 Propelling liquid oil pump
857.11=FISLL Flow sensor
857.12 Discharge filter, propelling liquid
857.13 Accumulator on supply system propelling liquid
857.14 Pressure gauge for propelling liquid
857.15 Pressure switch for propelling liquid
857.16 Manual valve, 3/2 ball, for manual discharging the accumulator
857.20 Air supply connection

857.HV1+2+3 Valve 2/2 for propelling liquid oil filling

857.HV5+6+7 Valve 2/2 for propelling liquid oil outlet/drain
857.HV9 Valve 2/2 for propelling liquid oil supply
857.HV15 Valve 2/2 for flushing oil
857.PI7 Air supply pressure gauge
857.PT7 Air supply pressure transmitter
857.SV1+2+3 Solenoid valve 3/2 for propelling liquid filling
857.SV5+6+7 Solenoid valve 3/2 for propelling liquid outlet/drain
857.SV9 Solenoid valve 3/2 for propelling liquid oil supply
857.SV15 Solenoid valve 3/2 for flushing oil

Pos: 22 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766

8.14 MUI.814.200981.R01.EN
Maintenance

Pos: 23 /GEHO/Heading/H2/#.# Lubrication system @ 0\mod_1152094184716_31.doc @ 5126

8.5 Lubrication system

Pos: 24 /GEHO/Maintenance/Procedures/Lubrication system/Check the oil level @ 0\mod_1138630463309_31.doc @ 2208

8.5.1 Check the oil level

The oil level gauge is located at the side of the
power end.
1 Check the lubrication oil level (A) at the oil
level gauge.
2 If necessary, fill up the lubrication oil.
Refer to Technical data for the correct oil type.

Figure 8.4: Lubrication oil level gauge

Pos: 25 /GEHO/Maintenance/Procedures/Lubrication system/Change the oil filter/Single oil filter @ 0\mod_1152779323482_31.doc @ 5251

8.5.2 Change the oil filter

1 Set the lever to position (I).
2 Remove the filter cover.
3 Remove the old filter.
4 Install the new filter.
5 Install the filter cover.
6 Set the lever to position (II).

Figure 8.5: Single oil filter with bypass

Pos: 26 /GEHO/Maintenance/Procedures/Frame unit/Clean the oil sump @ 0\mod_1156845386000_31.doc @ 5891

8.5.3 Clean the oil sump

1 Drain the lubrication oil.
Refer to Change the oil section.
2 Open the frame unit cover.
3 Clean the oil sump.
4 Replace the oil filter.
Refer to Replace the oil filter section.
5 Fill in new oil.
Refer to Technical data section for the correct oil type.
Pos: 27 /GEHO/Maintenance/Procedures/Lubrication system/Replace the suction oil filter @ 0\mod_1152098136341_31.doc @ 5155

MUI.814.200981.R01.EN 8.15
 Maintenance

8.5.4 Replace the pump oil and the oil suction filter
Remove the oil
1 Open the frame unit cover.
2 Remove the oil from the oil sump.
Drain the oil through the oil drain valve,
ore use a pump.
Remove the oil filter
1 Loosen the oil filter cover.
2 Remove the oil filter cover.
3 Remove the oil filter from the oil filter housing.
4 Clean:
the oil filter cover.
the oil filter housing.
the oil sump.
Install the oil filter
1 Install a new suction oil filter into the oil filter housing.
2 Install the oil filter cover.
3 Tighten the oil filter cover.
Fill the oil
1 Fill in the new oil. Use a pump.
Refer to chapter "Start and stop procedure", "Initial lubrication filling" for the procedure.
Pos: 28 /GEHO/Maintenance/Procedures/Frame unit/Replace oil air filter-top-nofig @ 2\mod_1174995485185_31.doc @ 12836

8.5.5 Replace the air filter at the pump frame

Refer to "Location of the checkpoints" for the
location.
1 Open the air filter cover.
2 Remove the filter element from the air filter
housing.
3 Insert the new filter element into the air
filter housing.
4 Close the air filter cover.
Pos: 29 /GEHO/Heading/H2/#.# Propelling liquid system @ 0\mod_1152094190955_31.doc @ 5132

8.6 Propelling liquid system

Pos: 30 /GEHO/Maintenance/Procedures/Propelling liquid system/Change proliq air filter @ 0\mod_1152098314051_31.doc @ 5168

8.6.1 Replace the air filter at the propelling liquid system

Refer to "Location of the checkpoints" for the
location.
1 Open the air filter cover.
2 Remove the filter element from the air filter
housing.
3 Insert the new filter element into the air
filter housing.
4 Close the air filter cover.
Pos: 31 /--- Section break - Odd page --- @ 0\mod_1136277036628_0.doc @ 765

8.16 MUI.814.200981.R01.EN
Troubleshooting

Pos: 32 /GEHO/Heading/H1/#. Troubleshooting @ 0\mod_1152772213698_31.doc @ 5244

9. Troubleshooting
Pos: 33 /GEHO/Troubleshooting/Attention - Trouble shouting @ 0\mod_1138615626939_31.doc @ 2139

ATTENTION
Do not hesitate to contact the Service Department of Weir Minerals, if problems occur
during trouble shouting.
Refer to chapter Assembly and disassembly for instructions of replacing parts.
If parts of the power end are damaged in such a way that they have to be replaced, then
follow instructions in chapter "Assembly and disassembly".
Pos: 34 /GEHO/Troubleshooting/Trouble shooting table (T)ZPM-gear drive @ 1\mod_1169136012360_31.doc @ 11845

9.1 Trouble shooting

POWER END
Lubrication system:
Problem/symptom Possible cause Remedy
Noise in lubrication oil pump Low oil level in power end sump See chapter "Maintenance"
Suction filter is clogged Check the suction filter,
if necessary, replace the suction filter
Discharge filter is clogged, Check the discharge filter,
oil circulates inside the pump if necessary, replace the discharge
through its pressure relieve filter
valve, oil and pump get hot
Suction pipe leakage Check and tighten connections
Oil pump damaged Check or replace
Electric motor oil pump Check or replace
damaged
Flow indicator shows Blocked lubrication discharge Check and clean all lubrication points
insufficient oil flow line
(check reading of oil pressure) Oil pump is not running Check electric connections
Oil level power end sump too See chapter "Maintenance"
low
Suction filter is clogged Check the suction filter,
if necessary, replace the suction filter
Discharge filter is clogged, Check the discharge filter,
oil circulates inside the pump if necessary, replace the discharge
through its pressure relieve filter
valve, oil and pump get hot
Suction pipe to oil pump leaks Tighten connections
Filter valves closed Open valves
Relief valve in oil pump clogged Check or replace
Relief valve in oil pump leaking Check or replace
No oil flow at some lubrication Check and clean orifices at the
points lubrication points
Abnormal mechanical noise:
Problem/symptom Possible cause Remedy
Hammering noise synchronous Malfunction of lubrication system Check lubrication system
with dead points of piston Noise caused by loosened
stroke connections and transmitted to
power end:
Loose piston See chapter "Maintenance"
Loose piston rod/crosshead rod See chapter "Maintenance"
connection
Loose crosshead rod/on Tighten the crosshead rod
crosshead
Incorrect settings/worn parts of Correct setting or replace worn parts

MUI.814.200981.R01.EN 9.1
 Troubleshooting

crosshead guides, crosshead

bearing, connecting rod bearing,
crankshaft bearing or other
Power end bearings damaged Check for temperature rise and
replace if necessary

9.2 MUI.814.200981.R01.EN
Troubleshooting

Problem/symptom Possible cause Remedy

Abnormal noise is continuous Malfunction of lubrication system Check lubrication system
(frequency more than 500 Hz) Power end gears worn/damaged See general note
Power end bearings damaged Check for temperature rise and
replace if necessary
Overheating:
Problem/symptom Possible cause Remedy
Overheating of the lubrication Malfunction of lubrication system Check lubrication system and
oil settings or relief valves, see
(maximum temperature 80C) Instrument List
Incorrect setting or worn parts Correct setting or replace worn parts
Gears worn Replace
Overheating of the crosshead Malfunction of lubrication system Check lubrication system
liner Damaged running surfaces Replace damaged parts
Overheating of the bearing Bearings damaged Replace bearings
housing Wandered settings or worn Correct settings or replace
bearings
LIQUID END:
Propelling liquid section:
Problem/symptom Possible cause Remedy
Propelling liquid filling: Leakage in filling pipe Tighten connections
Filling valves too often in Leakage of outlet valve Replace outlet valve parts
operation To low air pressure See chapter "Maintenance"
Filling valve malfunction Check or replace valve or valve parts
Leakage of cylinder liner seal Check and replace if necessary
Pump diaphragm rupture Replace diaphragm
(this will cause a knocking noise
in the pump chamber during
discharge stroke)
Air in the propelling liquid De-aerate propelling liquid chambers
chamber
Piston seal rings leaking Replace seal rings
Leakage in propelling liquid Repair leakages
chamber
Leaking of safety valves or valve Check and replace if necessary
seats
Propelling liquid drain: Leakage of filling valve Check and replace filling valve or
Outlet valves to often in seat
operating Rupture diaphragm of filling Check and replace
valve
Too low air pressure Re-adjust air pressure
Malfunction of outlet valve Check and replace if necessary
Leakage of cylinder liner seals Check and replace
Leakage of piston seals Check and replace

MUI.814.200981.R01.EN 9.3
 Troubleshooting

Problem/symptom Possible cause Remedy

Propelling liquid pump is Leaking of propelling liquid Tighten connections
starting too often piping
Leaking of pressure relief valve Check set-points and replace worn
parts
Drain valve is leaking Check and replace
Damaged running surfaces Replaced damaged parts
Filling valve alarm Pressure limitation system is Check suction filter, system
by 3 minutes time relay leaking pressure
(see chapter "Maintenance")
and cartridge for damage
Discharge valve is leaking in Replace valve and valve seat
such an extent that slurry under
pressure flows back (during the
suction stroke) via the leaking
discharge valve
Non-return valve in pipe Check, clean or replace the non-
connection between filling valve return valve
and propelling liquid chamber is
clogged or damaged
The filling valve does not open Check diaphragm stroke control
while there is an electric signal system
Too low air pressure Re-adjust air pressure
Pneumatic globe valve closed Check globe valve and the air
pressure
Oil level in propelling liquid tank For correct quantity,
too low see chapter "Maintenance"
No pressure in the propelling Check operating of propelling liquid
liquid feed system pump
Check the suction line for air
leakage and clogging
Outlet valve alarm Piping system from outlet valve Clean or replace
by 3 minutes time relay to the propelling liquid tank is
clogged or damaged
Non-return valve in pipe Clean or replace
between outlet valve and
propelling liquid tank is clogged
or damaged
Much air is left in the propelling De-aerating propelling liquid
liquid chamber after chamber
maintenance work
The outlet valve does not open Check diaphragm stroke control
while there is an electric signal system
Diaphragm is leaking and act as Change diaphragm and clean the
a non-return valve total propelling liquid system

9.4 MUI.814.200981.R01.EN
Troubleshooting

SLURRY SECTION: (abnormal noise and/or vibration)

GENERAL:
If the noise coming from the fluid end, then an attempt should be made to localize the source with the aid
of a wrench or a stethoscope.
If the noise can be localized, then it probably is of mechanical source, if it seems general and difficult to
locate, then the source might be a fluid knock.
Problem/symptom Possible cause Remedy
During the discharge stroke Partially blocking of suction Check permitted lifting of suction
excessive vibrations or valve(s) valve
knocking due to not complete (Partially) blocked suction line Checked clogged or not completely
filling of one or more pump opened valves in suction line
chambers during the suction Not completely filled propelling Filling valves in operation
stroke. liquid chamber (see lamps on control panel)
Mostly also knocking in the Air in propelling liquid De-aerating propelling liquid
discharge valves. chamber(s) chambers
Air in slurry chamber De-aerating slurry chamber
Hammering noise near of just Suction feed pressure too low Increase suction pressure
behind mid-stroke. Slurry temperature too high Cooling of slurry
Fluid hammer due to fluid Pulsation dampener not Pre-charge according to chapter
separation (void) following correctly pre-charged "Maintenance"
collapsing in the pump
chamber. This collapsing
causes a hammering noise in
the suction valves and a surge
pressure well in the suction
line. Diagnose by reducing
pump speed.
Hammering noise in the piston Valve seal ring worn / valve seat Replace seal ring / valve seat
dead points worn (resulting in mechanical
noise)
Loose piston/cylinder liner Tighten connection.
For correct torque see chapter
"Maintenance"
Suction or discharge valve, Check and replace
valve guide or valve spring worn

MUI.814.200981.R01.EN 9.5
 Troubleshooting

Problem/symptom Possible cause Remedy

Jetting noise in suction or Slurry leaking under high Check the valves and seats and
discharge valve(s). velocity between the valve(s) replace if necessary
Depending on the severity of and seat will cause wash out
the problem, a decreasing damage to valve(s) and seat or
discharge flow may be valve housing
observed If noise is heard during Check the valves and seats and
discharge stroke, then the replace if necessary
problem is induced in the
suction valve, if heard during
suction stroke, then the problem
is induced in discharge valve
No closing of suction or Check and close the valves
discharge valves
Hammering noise in the Surge pressure well, cause by Reduce pump speed
suction line once per fluid separation (void) and
crankshaft revolution following collapsing in the pump
chamber
Suction pressure too low Increase suction pressure
Propelling liquid chamber not De-aerate propelling liquid chambers
completely filled
Surge pressure well in suction Check suction valve
line, caused by malfunctioning of
one suction valve
AIR SUPPLY UNIT:
Problem/symptom Possible cause Remedy
Air pressure low Compression failure Check air supply
Air line is leaking Tighten connections
Reducing valve on air- Open reducing valve
conditioning device closed
Pos: 35 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766

9.6 MUI.814.200981.R01.EN
Troubleshooting

Pos: 36 /GEHO/Troubleshooting/Diaphragm pulsation dampener @ 0\mod_1156318158348_31.doc @ 5783

9.1.1 Diaphragm pulsation dampener

Problem/symptom Possible causes and solutions

Safety

DANGER: Avoid breathing in nitrogen.

General The pre-charge pressure at the diaphragm pulsation dampener shall be
checked and noted at regular intervals.
Keep a log book for settings and changes of the pre-charge
pressure, so you can compare and observe changes.
The pre-charge pressure will normally be registered at the pressure
gauge.
If there is no liquid pressure at the pulsation dampener bottom,
then the pressure gauge indicates only the pre-charge pressure.
If the liquid pressure at the pulsation dampener bottom is higher then
ATTENTION the pre-charge pressure,
then the pressure gauge indicates also the working pressure at the
liquid site of diaphragm.
Under certain conditions the pressure gauge or filling line can be
damaged or clogged with slurry and may then not indicate the right
pressure. It is therefore important to recognize symptoms associated
with a pre-charge pressure that is too low or too high.
Such symptoms are excessive pressure fluctuations in piping or shock
and vibrations in pump and piping.
Pre-charge pressure to high 1 Check for causes.
Pre-charge pressure to low

DANGER: Avoid breathing in nitrogen.

Determine the reason for any loss of gas and remedy the condition.
1 Do a leakage test.
Refer below to the section Diaphragm outside leakage test.
2 Check for other causes.
Pre-charge pressure loss Determine the reason for any loss of gas and remedy the condition.
1 Do a leakage test.
Refer below to the section Diaphragm outside leakage test.
2 Increase the pre-charge pressure.
Refer to chapter Pre-charging the diaphragm pulsation dampener.

Measuring at the pressure gauge 1 The pressure gauge (manometer) is damaged.

(manometer) excessive pressure Replace the pressure gauge.
fluctuations in the suction line or 2 Pre-charge pressure to low.
discharge line Check the pre-charge pressure.
or heavy vibrations Refer to chapter Pre-charging the diaphragm pulsation dampener.

MUI.814.200981.R01.EN 9.7
 Troubleshooting

Problem/symptom Possible causes and solutions

Filling valve leakage

DANGER: Avoid breathing in nitrogen.

1 Tighten loose threads.
2 Do a outside leakage test.
If there is still a leakage, then:
3 Release the nitrogen pressure carefully by opening slowly the filling
valve.
4 Replace seal ring.
5 Replace filling valve.
Pressure gauge leakage 1 Replace the pressure gauge.
at the gauge cover
or at the lock cover
Pressure gauge leakage 1 Tighten loose threads.
at the thread 2 Replace threaded nipples.
or at the nipples 3 Replace pressure gauge.
Diaphragm leakage

DANGER: Avoid breathing in nitrogen.

Fluid can have clogged the filling valve or the pressure gauge.
1 Release the nitrogen pressure carefully by opening slowly the filling
valve.
2 Replace the diaphragm.
Refer to Replacing the pulsation dampener diaphragm.

Diaphragm pulsation dampener outside leakage test

DANGER: Avoid breathing in nitrogen.

1 Apply a leak detector to the pulsation dampener. Use soapy water.
2 Watch for bubbles.
3 Use the table above to solve the problem.
If the outside leakage test fails and the pressure still drops, then a diaphragm leakage is probably.
Pos: 37 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766

9.8 MUI.814.200981.R01.EN
Troubleshooting

Pos: 38 /GEHO/Troubleshooting/Typical wear @ 1\mod_1169136581763_31.doc @ 11849

9.2 Typical wear phenomena and its causes

9.2.1 Valves

Figure 9.1

Normal wear
The valve seal ring looses material at side 1, and after a longer running period the overhanging material (A) is
worn away. The length of this running period depends on the slurry abrasivty and particle size and has to be
determined by experience. After this running period the seal ring must be turned in order to use side (II) (in
case of using a cone valve) or replaced (in case of using a ball or mushroom valve) because there is no
elastic sealing any more. Installing a suction strainer will increase the wearing life of the valve parts.

Local severe wash-out

Possible causes:
Too long running period with worn valves and/or seats.
Valves do not really close because of too large solid particles or a foreign object.
Worn upper valve guide in which the clearance in one direction is excessive.
Sticking upper or lower guide.
Broken valve spring

Wash outs at the outside diameter of the valve, valve seat and valve disc
Possible causes:
Wash outs at the valve seat outside.
Improper seat installation in the valve housing, e.g. rust at the valve seat, or dirty or greasy surfaces.
Damaged surfaces from valve seat or valve housing bore.
Damaged from O-rings.
Wrong O-ring assembly.

MUI.814.200981.R01.EN 9.9
 Troubleshooting

9.2.2 Pump diaphragm

Normal wear by fatigue:
If the diaphragm is broken by fatigue, then it shows near the clamping edge a crack and mostly more
surfaces cracks, especially at the propelling liquid side.

Blown up diaphragm
A blown up diaphragm by too much propelling liquid shows at the top section of the diaphragm a crack and
some scratches due to deformation of the diaphragm in the discharge valve opening.

Teared-off in-vulcanised cone-plate in diaphragm

The cause might be fluid hammer in the slurry section for extended period or seizing of monitoring rod.

Damage at the propelling liquid side of the diaphragm

If rubber has loosened at the in-vulcanized cone-plate area, then the pump was probably running with
insufficient propelling liquid and the vulcanized valve has touched the rear wall.
Possible causes:
Pump discharge valve leaking, keeping propelling liquid chamber under discharge pressure during suction
stroke.

9.2.3 Pulsation dampener diaphragm

Normal wear by fatigue
If the diaphragm is broken by fatigue, then it shows a crack near the biggest diameter, and perhaps more
local surface cracks.

Damage of the invulcanised valve

Rubber from the diaphragm surface, near the vulcanized valve, lost by striking against the pulsation
dampener inlet.
Possible causes:
Pre-charge pressure of the pulsation dampener was too high.

9.10 MUI.814.200981.R01.EN
Troubleshooting

9.2.4 Piston
Normal wear
Normal worn piston seal rings show an equal wear around the outer diameter, so there is no pre-sealing
effect any more.

Seal rings granulated surface

The rubber was burned by insufficient lubrication and cooling.
Possible causes:
Piston flushing system works insufficiently.
Running of the piston in a dry cylinder liner.

Grooves over the piston seal rings

Possible causes:
Piston was running in a worn grooved cylinder liner.
Propelling liquid chamber was not clean.
Flushing oil is contaminated.
Diaphragm rupture.

Severe wear at a part of the circumference

The piston guide ring is worn (mostly lower side).
Possible causes:
Alignment of the piston rod - crosshead rod was incorrect:
Damaged contact surface.
Dirty contact surface.
Piston flushing pipe partly clogged, which causes insufficient lubrication of the piston seal rings at one
side.

9.2.5 Cylinder liner

Normal wear
A normal worn liner shows a light grooved surface.
The inner diameter is increased, mostly in the center of the piston stroke where the piston velocity is highest.
The wear is raising rapidly when the hard layer in the cylinder liner is worn away.

Grooved cylinder liner after a relatively short operation time.

Possible causes:
Propelling liquid chamber is insufficiently flushed and cleaned after diaphragm rupture.
Propelling liquid in the tank is contaminated and flushing oil is dirty.
Piston guide ring worn, by which the piston body rubs against the cylinder liner.

Severe wear at a part of the circumference

Possible causes:
The piston guide ring was worn (mostly the lower side).
Pos: 39 /--- Section break - Odd page --- @ 0\mod_1136277036628_0.doc @ 765

MUI.814.200981.R01.EN 9.11
Assembly and disassembly

Pos: 40 /GEHO/Heading/H1/#. Assembly and disassembly @ 0\mod_1136455386113_31.doc @ 935

10. Assembly and disassembly

Pos: 41 /GEHO/Assembly and Disassembly/General/Introduction - Safety notes @ 0\mod_1145882820736_31.doc @ 3352

ATTENTION
Do not hesitate to contact the Service Department of Weir Minerals, if problems occur
during maintenance or repair activities.

DANGER
Strictly obey to all instructions as given in the chapter "Safety" of this manual.
The correct working sequence along with the data in this manual is of the utmost
importance for safe operation and handling.
Only authorized and properly trained people are allowed to work with the pumps.
Only use original and undamaged GEHO parts.

DANGER
Lockout checklist
For safe working on the pump it is essential that the installation is locked out from all energy
sources.
For stopping the pump refer to Chapter "Start and stop".
Lockout power supply to main motor.
Lockout power supply to lubrication oil motor.
Lockout power supply to propelling liquid motor.
Lockout power supply to relief valve motor.
Lockout power supply to control panel.
Lock pump isolation valves in closed position.

Stop the air supply only, when working on the air-actuated valves.
Refer to chapter "Stop, maintenance", "Stop air supply".

WARNING
Some tools operate hydraulically:
Check hydraulic pump, hose, nipples and tool and de-aerate,
before pressurizing a hydraulic tool.
During pressurizing and 1 minute after reaching pressure level,
no person is allowed to be in front of the tool, always stay aside.
Watch pressure gauge.
If pressure does not build-up steady, then stud bolts are not stretching equally.
The pistons coming out further indicate the stud bolts are failing.
Relief oil pressure, replace these stud bolts by new ones and restart.

MUI.814.200981.R01.EN 10.1
 Assembly and disassembly

WARNING
The heavy parts of the pumps have a hoisting eye, or have the possibility to install a hoisting
eye for transportation purposes.
Always transport heavy parts by using these hoisting eyes.

INFORMATION

Refer to the drawings in chapter Parts - Lists and drawings (pump section) for correct positions
of the ID numbers, mentioned in the text and not visible figures.
Refer to chapter Parts - Lists and drawings (special tools) for the use of special tools.

Pos: 42 /GEHO/Heading/H2/#.# Special tools @ 1\mod_1166540615553_31.doc @ 11465

10.1 Special tools

Pos: 43 /GEHO/Assembly and Disassembly/General/Manual rotation/via socket wrench @ 0\mod_1145881095763_31.doc @ 3340

10.1.1 Socket wrench

Manual rotation of the pump shaft with a socket wrench.
Refer to chapter "Parts - List and drawings (special tools)" for details of this tool.
Manual rotation the pump shaft is required:
For assembling or disassembling of several components within the pump.
For "priming" of the pump, turning a piston in a necessary position.

DANGER
When the drive shaft is rotated manually, the crankshaft can reach the top dead centre.
There is a possibility of a "running away" crankshaft.
Therefore the lever must be held firmly to resist "runaway".
NEVER do this work alone.
Procedure:
1 Switch-off the power from the main motor.
2 Make sure that the main motor can not be operated during the maintenance work.
3 Opening the drain valve of the discharge line, to release the pump pressure on the slurry section.
4 Remove the safety guard from the non-driven end of the high speed gearbox shaft.
This will actuate the electric switch and will inhibit the start of the electric main motor.
5 Place the socket wrench on the hexagon shaft extension and manually rotate the pump.
After the manual rotation:
6 Remove the socket wrench.
7 Mount the safety guard.
Pos: 44 /GEHO/Assembly and Disassembly/General/Hydraulic pump unit/Air driven @ 0\mod_1156403099735_31.doc @ 5821

10.1.2 Air driven hydraulic pump

Some tools are operated hydraulically.
The air driven oil pump generates a hydraulic pressure, displayed at the pressure gauge.
A high pressure hose is connected to the hydraulic pump.
All hydraulic tools are fitted with quick release connectors (nipples).

10.2 MUI.814.200981.R01.EN
Assembly and disassembly

Legend
A Hydraulic connector
B High pressure hose
C Operating handle A
D Air pressure supply connector
E Hydraulic pressure gauge

Operating instructions
1 Connect the hydraulic connector (A) to the
according quick release connector D
(nipple). B
2 Pressurize the hydraulic pump.
E
3 Turn the operating handle (C) to pressurize
the tool to be operated.
4 Check the pressure gauge (E). C

Refer to chapter Technical data for the

appropriate pressure.
Figure 10.1: Air driven hydraulic pump
Pos: 45 /GEHO/Heading/H2/#.# Valves, discharge angular @ 1\mod_1170947685604_31.doc @ 12232

10.2 Valves, discharge angular

Pos: 46.1.1 /GEHO/Heading/H3/#.#.# Valve housing cover @ 0\mod_1147174241226_31.doc @ 3690

10.2.1 Valve housing cover

Pos: 46.1.2 /GEHO/Assembly and Disassembly/Valve unit/Conical valves/Valve housing cover/Hydraulic/Remove, Standard, Angelar @ 0\mod_1147163606938_31.doc @ 3669

Disassembly A
1 Remove the protection guard from the B
nipple (E) at the valve housing cover (H). C
2 Connect the hose of the hydraulic pump D
unit to nipple (E).
3 Connect the hexagon nipple of the flexible E
hose to the hydraulic pump unit. F
4 Pressurize the hydraulic pump unit. G
Refer to Technical data for the correct H
pressure.
5 Loosen the outside nuts (D).
6 Unscrew the outside nuts (D) to the inside
nuts (B).
7 Depressurize the hydraulic pump unit.
8 Unscrew all nuts.
9 Lift the valve housing cover (A).
Use the push-off screws (G).
10 Remove the valve housing cover (A). Figure 10.2: Schematics of a hydraulic operated valve
Use a lifting device. Use the lifting eye (F). cover
Pos: 46.1.3 /GEHO/Assembly and Disassembly/Valve unit/Conical valves/Valve housing cover/Hydraulic/Install, Standard. Angular @ 0\mod_1147165917235_31.doc @ 3679

MUI.814.200981.R01.EN 10.3
 Assembly and disassembly

Assembly A
1 Clean and grease the sealing surfaces. B
2 Insert a new square gasket into the valve C
housing cover (A). D
3 Fit the valve housing cover (A) to the valve
housing (H). E
4 Connect the hydraulic pump unit to the F
hydraulic connector (E). G
5 Unscrew on the outside nuts (D) to the H
inside nut (B).
6 Hand tighten the nuts (B).
7 Push the pistons back 0-position.
8 Make sure, that the pistons are even with
the valve housing cover (A).
9 Pressurize the hydraulic pump unit.
Refer to chapter Technical data for the correct
pressure.
10 Hand tighten the outside nuts (D). Figure 10.3: Schematics of the hydraulic operated valve
cover
Refer to chapter Special torques for the correct
torque.
11 Depressurize the hydraulic pump unit.
12 Remove the hydraulic pump unit.
13 Put the protecting guard to the hydraulic
connector (E).
Pos: 46.2.1 /GEHO/Heading/H3/#.#.# Conical valve @ 0\mod_1147176114890_31.doc @ 3735

10.2.2 Conical valve

Pos: 46.2.2 /GEHO/Assembly and Disassembly/Valve unit/Conical valves/Valve/Remove, Angular, Standard @ 1\mod_1161247034668_31.doc @ 6533

Disassembly
1 Make sure the pump is not under pressure.
2 Remove the valve housing cover.
Refer to "Remove the valve housing cover".
3 Remove the square gasket.
4 Remove the compression spring.
5 Remove the conical valve.

Figure 10.4: Remove the conical valve

Pos: 46.2.3 /GEHO/Assembly and Disassembly/Valve unit/Conical valves/Valve/Install, Angular @ 1\mod_1161247316353_31.doc @ 6535

10.4 MUI.814.200981.R01.EN
Assembly and disassembly

Assembly
1 Insert the conical valve.
2 Insert the compression spring
3 Install a new square gasket.
4 Install the valve housing cover.
Refer to section "Install the valve housing cover".

Figure 10.5: Insert the conical valve

Pos: 46.3.1 /GEHO/Heading/H3/#.#.# Valve seat @ 0\mod_1147176079227_31.doc @ 3732

10.2.3 Valve seat

Pos: 46.3.2 /GEHO/Assembly and Disassembly/Valve unit/Conical valves/Valve seat/Angular/Remove, hydraulic, angular @ 0\mod_1147180524829_31.doc @ 3774

Disassembly
Remove the valve seat, hydraulically
1 Remove the valve housing cover.
Refer to "Valve housing cover", "Disassembly".
2 Remove the conical valve.
Refer to "Conical valve", "Disassembly".

WARNING

Re-install the valve housing cover,

to prevent getting hit by a valve seat.
3 Install the valve housing cover.
Refer to "Valve housing cover", "Assembly".
4 Remove the protection guard from the hydraulic connector.
5 Connect the hydraulic pump unit to the connector.
6 Pressurize the hydraulic pump unit until the valve seat is loose.
7 Release the pressure from the hydraulic pump unit.
8 Disconnect the hydraulic pump unit.
9 Remove the valve housing cover.
Refer to "Valve housing cover", "Disassembly".
10 Remove the valve seat from the valve housing.
Pos: 46.3.3 /GEHO/Assembly and Disassembly/Valve unit/Conical valves/Valve seat/Angular/Remove, API 11- @ 0\mod_1147178796273_31.doc @ 3763

MUI.814.200981.R01.EN 10.5
 Assembly and disassembly

Remove the valve seat mechanically A

1 Place the puller (H) underneath the valve B
seat (G).
C
2 Put the block (E) to the valve housing.
3 Screw the nut (C) towards the end of the D
drawing pin (A).
4 Slide the counter bush (C) to the nut (B). E
5 Screw the drawing pin (A) into the puller F
block (001).
6 Turn the puller block (001) by 90.
7 Pull the drawing pin (A).
8 Tighten the nut (B).
9 Put the key (D) underneath the counter
G
bush (C).
10 Tap the key (D) until the valve seat is H
loose.
Use a hammer.
11 Remove the valve seat.
Figure 10.6: Using the mechanic valve seat tool.

Pos: 46.3.4 /GEHO/Assembly and Disassembly/Valve unit/Conical valves/Valve seat/Angular/Install, API 12- @ 0\mod_1147179105600_31.doc @ 3769

Assembly
Install the valve seat - Angular valve units A
1 Clean the valve seat.
2 Clean the bore in the valve housing. B
3 Make sure that they are free of dust, paint,
or oil.
4 Insert new O-rings into the grooves at the
valve seat.
5 Insert the valve seat (D) into the bore in the
valve housing.
6 Put the valve seat tool (C) to the valve C
seat.
7 Tap the valve seat tool (B) until the valve D
seat fits.
Use a hammer (A).
8 Remove the valve seat tool.
9 Make sure that the valve seat is mounted
correctly. Figure 10.7: Using the mechanic valve seat tool.
Pull the valve seat by hand.

Pos: 47 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766

10.6 MUI.814.200981.R01.EN
Assembly and disassembly

Pos: 48 /GEHO/Heading/H2/#.# Valves, suction inline @ 1\mod_1170947706445_31.doc @ 12236

10.3 Valves, suction inline

Pos: 49.1.1 /GEHO/Heading/H3/#.#.# Valve housing cover @ 0\mod_1147174241226_31.doc @ 3690

10.3.1 Valve housing cover

Pos: 49.1.2 /GEHO/Assembly and Disassembly/Valve unit/Conical valves/Valve housing cover/Hydraulic/Remove, Standard, Inline @ 1\mod_1171550323234_31.doc @ 12480

Disassembly
1 Remove the protection guard from the
nipple (F) at the valve housing cover (D).
2 Connect the hose of the hydraulic pump
unit to nipple (F).
3 Connect the hexagon nipple of the flexible
hose to the hydraulic pump unit.
4 Pressurize the hydraulic pump unit.
Refer to Technical data for the correct
pressure.
5 Loosen the outside nuts (C).
6 Unscrew the outside nuts (C) to the inside
nuts (D).
7 Depressurize the hydraulic pump unit.
8 Unscrew all nuts.
9 Lift the valve housing cover (B). Figure 10.8: Schematics of a hydraulic operated inline
Use the push-off screws (E). valve cover
10 Remove the valve housing cover (B).
Use the valve housing cover lifting bar.
Pos: 49.1.3 /GEHO/Assembly and Disassembly/Valve unit/Conical valves/Valve housing cover/Hydraulic/Install, Standard. Inline @ 1\mod_1171558792656_31.doc @ 12484

Assembly
1 Clean and grease the sealing surfaces.
2 Insert a new square gasket into the valve
housing cover (B).
3 Cut the jack-off screws (F).
4 Fit the valve housing cover (B) to the valve
housing (A). Use the valve housing cover
lifting bar.
5 Connect the hydraulic pump unit to the
hydraulic connector (F).
6 Unscrew on the outside nuts (C) to the
inside nut (D).
7 Hand tighten the nuts (D).
8 Push the pistons back in 0-position.
9 Make sure, that the pistons are even with
the valve housing cover (B).
10 Pressurize the hydraulic pump unit. Figure 10.9: Schematics of the hydraulic operated inline
valve cover
Refer to chapter Technical data for the correct
pressure.
11 Hand tighten the outside nuts (D).
Refer to chapter Special torques for the correct
torque.
12 Depressurize the hydraulic pump unit.
13 Remove the hydraulic pump unit.
14 Put the protecting guard to the hydraulic
Pos: 49.2 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766
connector (F).

MUI.814.200981.R01.EN 10.7
 Assembly and disassembly

Pos: 49.3 /GEHO/Assembly and Disassembly/Valve unit/Inline, conical/API 11-/Valve housing cover lifting bar, API 7 - API 11 @ 1\mod_1162210456239_31.doc @ 6730

Valve housing cover lifting bar

ATTENTION
Make sure to use the valve housing cover lifting bar when handling the valve housing cover.

1 Loosen the screw (E) so that the ring (C) is

movable.
2 Screw the thread (A) of lifting spindle (B) A B C D E
into the valve housing cover.
3 Set the ring (C) to a groove on the lifting
spindle (A). Make sure that the ring is in
front of the diaphragm housing cover.
4 Tighten the screw (E) to attach the
ring (C).

Figure 10.10: The valve housing cover lifting bar.

Pos: 49.4.1 /GEHO/Heading/H3/#.#.# Conical valve @ 0\mod_1147176114890_31.doc @ 3735

10.3.2 Conical valve

Pos: 49.4.2 /GEHO/Heading/H4/Disassembly @ 0\mod_1147174347836_31.doc @ 3696

Disassembly
Pos: 49.4.3 /GEHO/Assembly and Disassembly/Valve unit/Conical valves/Valve/Remove, Inline, API 7+ @ 1\mod_1162205774047_31.doc @ 6716

1 Make sure the pump is not under pressure.

2 Remove the valve housing cover. A B CD E F
Refer to "Remove the valve housing cover".
3 Remove the pin (D).
4 Put the spring tensioner (F) with the fork
over the clamping piece (C).
5 Put the support of the spring tensioner (F)
to the stud bolt.
6 Pull the lever (F) up to push the clamping
piece (C) and the compression spring (B)
down.

Figure 10.11: Use the spring tensioner

10.8 MUI.814.200981.R01.EN
Assembly and disassembly

7 Pull the valve support (E) and turn the

valve support (E) by 90. E
8 Release the lever slowly.

Figure 10.12: Remove the valve support.

9 Remove the clamping piece.

10 Remove the compression spring.
11 Remove the conical valve.

Figure 10.13: Remove the valve.

Pos: 49.4.4 /GEHO/Heading/H4/Assembly @ 0\mod_1147174319423_31.doc

MUI.814.200981.R01.EN 10.9
 Assembly and disassembly

@ 3693

Assembly
Pos: 49.4.5 /GEHO/Assembly and Disassembly/Valve unit/Conical valves/Valve/Install, Inline, Spring tensioner @ 1\mod_1161247434813_31.doc @ 6539

1 Insert the conical valve (A).

2 Insert the compression spring (B). A B C E
3 Insert the clamping piece (C).
4 Insert the valve support (E).

Figure 10.14: Insert the conical valve

5 Put the support of the spring tensioner (F)

to the stud bolt. A B CD E F
6 Put the spring tensioner (F) with the fork
over the clamping peace (C).
7 Pull the lever (F) up to push the clamping
piece (C) and the compression spring (B)
down.
8 Turn the valve support (E) by 90.
9 Release the spring tensioner slowly.
10 Install the pin (D).
11 Install a new square gasket, if necessary.
12 Install the valve housing cover.
Refer to section "Install the valve housing cover".

Figure 10.15: Assemble the valve support.

Pos: 49.5.1 /GEHO/Heading/H3/#.#.# Valve seat @ 0\mod_1147176079227_31.doc @ 37

10.10 MUI.814.200981.R01.EN
Assembly and disassembly

32

10.3.3 Valve seat

Pos: 49.5.2 /GEHO/Heading/H4/Disassembly @ 0\mod_1147174347836_31.doc @ 3696

Disassembly
Pos: 49.5.3 /GEHO/Assembly and Disassembly/Valve unit/Conical valves/Valve seat/Inline/Remove, hydraulic, inline @ 1\mod_1171469939990_31.doc @ 12452

Remove the valve seat using the valve units hydraulic connector
1 Remove the valve housing cover.
Refer to "Valve housing cover", "Disassembly".
2 Remove the conical valve.
Refer to "Conical valve", "Disassembly".
3 Remove the protection guard from the hydraulic connector.
4 Connect the hydraulic pump unit to the connector.
5 Pressurize the hydraulic pump unit until the valve seat is loose.
6 Release the pressure from the hydraulic pump unit.
7 Disconnect the hydraulic pump unit.
8 Remove the valve seat from the valve housing.
Pos: 49.5.4 /GEHO/Assembly and Disassembly/Valve unit/Conical valves/Valve seat/Inline/Remove, API 11- @ 0\mod_1147176822297_31.doc @ 3759

Remove the valve seat - Inline valve units

1 Place the puller (G) underneath the valve A
seat (F).
2 Put the block (E) to the valve seat (F).
3 Screw the nut (C) towards the end of the B
drawing pin (A). C
4 Slide the counter bush (C) to the nut (B) D
5 Screw the drawing pin (A) into the puller
block (E).
6 Turn the puller block (E) by 90. E
7 Pull the drawing pin (A).
8 Tighten the nut (B). F
9 Put the key (D) underneath the counter
bush (C).
10 Tap the key (D) until the valve seat is
G
loose.
Use a hammer.
11 Remove the valve seat.
Figure 10.16: Using the mechanic valve seat tool.

Pos: 49.5.5 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766

MUI.814.200981.R01.EN 10.11
 Assembly and disassembly

Pos: 49.5.6 /GEHO/Assembly and Disassembly/Valve unit/Conical valves/Valve seat/Inline/Install, API 11- @ 0\mod_1147179965196_31.doc @ 3772

Assembly
Install the valve seat, inline valves A
1 Clean the valve seat.
2 Clean the bore in the valve housing.
3 Make sure that both are free of any dust,
paint or oil. B
4 Insert new O-rings into the grooves at the C
valve seat. D
5 Insert the valve seat (F) into the bore in the
valve housing.
6 Place the valve seat tool (E) to the valve
seat. E
7 Put the block (A) with the threaded rod and F
the nuts (B) into the valve housing.
8 Tighten the nuts (B) by hand.
9 Put the key (D) underneath the counter
bush (C).
10 Tap the key until the valve seat fits. Figure 10.17: Using the mechanic valve seat tool.
Use a hammer.
11 Make sure that the valve seat is mounted
correctly.
Pull the valve seat by hand.
Pos: 50 /GEHO/Assembly and Disassembly/Valve unit/Conical valves/Valve disk/Disassembly and assembly @ 1\mod_1161260471084_31.doc @ 6573

10.3.4 Valve disk

Disassemble the valve disk

A Conical valve A B C
B Valve disc lock nut
C Valve disc

1 Remove the valve disc lock nut (B).

2 Remove the valve disc (C) from the conical
valve (A).

Figure 10.18: The valve

10.12 MUI.814.200981.R01.EN
Assembly and disassembly

Assemble the valve disk

1 Make sure that all valve parts are clean,
X Y A B C
dry and free of lubricant.
2 Put the valve disc (C) to the conical
valve (A).
3 Apply a small amount of grease or soft
soap to the surface (Y) of the valve disc
lock nut (B).

ATTENTION
Do NOT use grease based on
mineral oil

4 Make sure that there is no grease on

surface (X)

Figure 10.19: The valve

5 Put the valve nut wrench (A) to the

assembled valve (B).
A B
6 Tighten the valve disc lock nut.
Refer to "Special torques" for the correct torque.
7 Make sure that the valve disc does not turn
with the valve disc lock nut.
8 Make sure that valve disc lock nut and the
valve disc are in full contact.

Figure 10.20: Assemble the valve with the valve nut

wrench.
Pos: 51 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766

MUI.814.200981.R01.EN 10.13
 Assembly and disassembly

Pos: 52.1 /GEHO/Heading/H2/#.# Piston unit @ 0\mod_1152094187891_31.doc @ 5129

10.4 Piston unit

Pos: 52.2 /GEHO/Assembly and Disassembly/Piston unit/TZPM/Overview @ 1\mod_1163689690473_31.doc @ 8653

A Piston rod
B Thrust ring A B C D E F GH
C Threaded bolts
D Piston guide ring
E Chevron seal rings
F Piston nut
G Retaining plate
H Cylinder liner

Figure 10.21: Piston unit overview

Pos: 52.3 /GEHO/Heading/H3/#.#.# Disassembly @ 0\mod_1146735769451_31.doc @ 3613

10.4.1 Disassembly
Pos: 52.4 /GEHO/Assembly and Disassembly/Piston unit/TZPM/Disassembly @ 1\mod_1161678281536_31.doc @ 6591

Preparation
1 Drain the propelling liquid.
2 Remove the top cover plate of the piston unit.
3 Move the piston unit to the most forward position.
4 Remove the clamping piece between piston rod and crosshead rod.
5 Move the crosshead to the most backward position.
6 Disconnect the flushing pipes, if applicable.
7 Remove the thrust ring lock nuts.
8 Remove the upper threaded bolts.
9 Remove the thrust ring.

10.14 MUI.814.200981.R01.EN
Assembly and disassembly

Securing the piston unit

1 Put a hoisting belt around the piston unit.
2 Make sure that the hoisting belt is NOT
underneath the two lower threaded bolts.
3 Tension the hoisting belt.
4 Move the crosshead to the most forward
position.
5 Install the clamping piece between piston
rod and crosshead rod.

Figure 10.22:

Remove the piston unit

1 Place the cylinder liner pulling tool to the
piston unit.
2 Pull the piston unit out of the bore.
Refer to "Rotate the pump manually.
3 Remove the cylinder liner pulling tool.
4 Remove the clamping piece between
piston rod and crosshead rod.
5 Remove the piston unit.

Figure 10.23:
Pos: 52.5 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766

MUI.814.200981.R01.EN 10.15
 Assembly and disassembly

Pos: 52.6 /GEHO/Heading/H3/#.#.# Assembly @ 0\mod_1146735726056_31.doc @ 3610

10.4.2 Assembly
Pos: 52.7 /GEHO/Assembly and Disassembly/Piston unit/TZPM/Assembly @ 1\mod_1163689511253_31.doc @ 8647

Preparation
1 Replace piston guide ring, if necessary.
2 Replace piston seal ring, if necessary.
3 Check the cylinder liner for grooves.
Replace the cylinder liner if necessary.
4 Lubricate to the piston seals.
5 Lubricate the cylinder liner surface.
6 Put the piston assembly into the cylinder
liner.

Figure 10.24: Lubrication points

Install the piston unit

1 Check the corner-piece / middle-piece seal
ring (A).
Replace if necessary.
2 Lubricate the corner-piece / middle-piece
seal ring (A).
3 Put a hoisting belt to the piston unit (C).
4 Put the piston unit (C) into the cylinder.
5 Put the threaded bolts (B) to the
connection nuts.

C
B
A

Figure 10.25: Install the ppiston unit

10.16 MUI.814.200981.R01.EN
Assembly and disassembly

Final works
1 Install the thrust ring.
2 Tighten the thrust ring lock nuts.
Refer to "Special torques" for the correct torque.
3 Install the flushing pipes, if applicable.
4 Move the crosshead rod forward.
Make sure the crosshead rod touches the
piston rod.
5 Install the clamping piece.
Refer to "Special torques" for the correct torque.
6 Grease the cylinder liner.
Use the grease nipple.

Figure 10.26: Cylinder liner grease nipples

Pos: 53 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766

MUI.814.200981.R01.EN 10.17
 Assembly and disassembly

Pos: 54.1 /GEHO/Heading/H2/#.# Diaphragm housing unit @ 0\mod_1152094180650_31.doc @ 5123

10.5 Diaphragm housing unit

Pos: 54.2 /GEHO/Assembly and Disassembly/Diaphragm housing unit/General/Overview, Hydraulic @ 1\mod_1164882440067_31.doc @ 8833

A Monitoring rod
B Guide bush lock screw A B CD E F GH I J K
C Monitoring rod guide bush
D Front initiator housing
E Diaphragm
F De-aeration boring
G Diaphragm housing
H Diaphragm housing cover
I Diaphragm housing cover seal ring
J Diaphragm housing cover nut
K Protection cover

Figure 10.27: Schematics of a diaphragm housing unit

with hydraulic operated cover
Pos: 54.3 /GEHO/Heading/H3/#.#.# Disassembly @ 0\mod_1146735769451_31.doc @ 3613

10.5.1 Disassembly
Pos: 54.4 /GEHO/Assembly and Disassembly/Diaphragm housing unit/Diaphragm housing cover/Common/Disassembly, Preparation @ 1\mod_1164881888391_31.doc @ 8826

Preparation
1 Close the pump isolation valves in the suction line.
2 Close the pump isolation valves in the discharge line.
3 Open the vent valves of the diaphragm housing units.
4 Drain the propelling liquid.
Pos: 54.5 /GEHO/Assembly and Disassembly/Diaphragm housing unit/Diaphragm housing cover/Hydraulic/Loosen @ 0\mod_1156333407963_31.doc @ 5796

10.18 MUI.814.200981.R01.EN
Assembly and disassembly

Diaphragm housing cover E

Loosen the diaphragm housing cover
1 Remove the protection cover from the
A
diaphragm housing unit (D).
B
2 Place the hydraulic tension ring unit (B) to
the stud bolts.
Use a appropriate lifting device.
Use the lifting eye (A).
3 Reset the hydraulic bolts on the tension D
ring to 0-position.
4 Tighten the tension ring nuts (C). C
5 Connect the hydraulic pump to the quick
release connector (E).
6 Pressurize the hydraulic tension ring unit.
Refer for the correct pressure to chapter
"Technical data", "Special torques", "Diaphragm
housing unit".
Figure 10.28: Install the hydraulic tension ring unit.

Loosen the cover nuts

1 Loosen the diaphragm housing cover
nuts (D) with the pin (E). A
2 Release the pressure from the hydraulic
tension ring unit.
3 Remove the hydraulic pump. C
4 Loosen the tension ring nuts (F). B
5 Remove the hydraulic tension ring unit.
D

Legend
A Diaphragm housing cover E
B Hydraulic tension ring unit
C Diaphragm housing cover stud bolt
D Diaphragm housing cover nut
E Pin
F Tension ring nut F

Figure 10.29: Loosen the diaphragm cover nuts

Pos: 54.6 /GEHO/Assembly and Disassembly/Diaphragm housing unit/Diaphragm housing cover/Hydraulic/Remove, Hoisting bracket @ 1\mod_1164889293953_31.doc @ 8839

MUI.814.200981.R01.EN 10.19
 Assembly and disassembly

Diaphragm housing cover hoisting bracket

1 Remove the two topmost cover nuts.
2 Remove the two lowest cover nuts.
3 Put the diaphragm cover hoisting bracket
to the diaphragm cover.
Make sure that the threaded bolts fit in the
holes.
4 Tighten the diaphragm cover hoisting
bracket with two screws.
5 Remove the remaining cover nuts.
6 Remove the diaphragm housing cover.
Use the jack-off screws.
7 Remove the diaphragm housing cover seal
ring.

Figure 10.30: The diaphragm cover hoisting bracket

Pos: 54.7 /GEHO/Heading/H4/Diaphragm @ 1\mod_1165394045801_31.doc @ 9030

Diaphragm
Pos: 54.8 /GEHO/Assembly and Disassembly/Diaphragm housing unit/Diaphragm unit/Hydraulic/Remove @ 1\mod_1165319630222_31.doc @ 8947

1 Remove the diaphragm unit from the

diaphragm housing (A). A B C
2 Check the diaphragm (B) for damage.
3 Replace the diaphragm (B), if necessary.
4 Check the monitoring rod (C) for damage.
5 Replace the monitoring rod (C), if
necessary.

Figure 10.31: Remove the diaphragm unit

Pos: 54.9 /GEHO/Heading/H4/Monitoring rod guide bush @ 1\mod_1165393535316_31.doc @ 9023

Monitoring rod guide bush

Pos: 54.10 /GEHO/Assembly and Disassembly/Diaphragm housing unit/Guide bush/Remove @ 1\mod_1164897747510_31.doc @ 8875

1 Remove the front initiator housing.

2 Remove the o-ring.
3 Remove the guide bush lock screw.
4 Remove the sealing ring.
5 Remove the monitoring rod guide bush.
6 Check the guide bush for damage.
7 Replace the guide bush, if necessary.

10.20 MUI.814.200981.R01.EN
Assembly and disassembly

Pos: 54.11 /GEHO/Heading/H4/Diaphragm unit @ 1\mod_1165326645033_31.doc @ 9006

Diaphragm unit
Pos: 54.12 /GEHO/Assembly and Disassembly/Diaphragm housing unit/Diaphragm/Closed, Standard/Disassemble, Standard nofig @ 1\mod_1164895298272_31.doc @ 8847
Disassembl

1 Loosen the monitoring rod.

2 Remove the monitoring rod.
Pos: 54.13 /GEHO/Heading/H3/#.#.# Assembly @ 0\mod_1146735726056_31.doc @ 3610

10.5.2 Assembly
Pos: 54.14 /GEHO/Heading/H4/Diaphragm unit @ 1\mod_1165326645033_31.doc @ 9006

Diaphragm unit
Pos: 54.15 /GEHO/Assembly and Disassembly/Diaphragm housing unit/Diaphragm/Closed, Standard/Assemble threated pin nofig @ 1\mod_1165320506364_31.doc @ 8950
Disassembl

1 Clean the thread of monitoring rod.

2 Clean the threaded pin of the diaphragm.
3 Apply a nut-lock (i.e. Loctite 243) to the
threaded pin.
4 Screw the monitoring rod to the threaded
pin.
Refer to "Special torques" for the correct torque.

Pos: 54.16 /GEHO/Heading/H4/Monitoring rod guide bush @ 1\mod_1165393535316_31.doc @ 9023

Monitoring rod guide bush

Pos: 54.17 /GEHO/Assembly and Disassembly/Diaphragm housing unit/Guide bush/Install @ 1\mod_1165322235178_31.doc @ 8992

1 Install the monitoring rod guide bush.

2 Replace the o-ring, if necessary.
3 Install the o-ring.
4 Install the front initiator housing.
5 Replace the sealing ring, if necessary.
6 Install the sealing ring.
7 Lock the guide bush lock screw.
Pos: 54.18 /GEHO/Heading/H4/Diaphragm @ 1\mod_1165394045801_31.doc @ 9030

Diaphragm
Pos: 54.19 /GEHO/Assembly and Disassembly/Diaphragm housing unit/Diaphragm unit/Hydraulic/Install @ 1\mod_1165321911048_31.doc @ 8969

1 Clean the diaphragm area of the

diaphragm housing (A). A B C
2 Grease the clamping edge (C) of the
diaphragm housing (A).

ATTENTION
Use only oil free grease.

3 Install the diaphragm unit (B) to the

diaphragm housing (A).

Figure 10.32: Install the diaphragm unit

Pos: 54.20 /GEHO/Heading/H4/Diaphragm housing cover @ 1\mod_1165393688115_31.doc @ 9026

MUI.814.200981.R01.EN 10.21
 Assembly and disassembly

Diaphragm housing cover

Pos: 54.21 /GEHO/Assembly and Disassembly/Diaphragm housing unit/Diaphragm housing cover/Hydraulic/Install, Hoisting bracket @ 1\mod_1165323498290_31.doc @ 8998

Preparation
1 Check the diaphragm housing cover seal.
2 Replace the diaphragm housing cover
seal, if necessary.
3 Install the diaphragm housing cover seal.
4 Put the diaphragm housing cover to the
diaphragm housing.
Use the diaphragm housing cover hoisting
bracket.
5 Secure the diaphragm housing cover with
four cover nuts.
Use a wrench.
6 Remove the diaphragm housing cover
hoisting bracket.
7 Tighten all other cover nuts hand-tight.

Figure 10.33: The diaphragm cover hoisting bracket

Pos: 54.22 /GEHO/Assembly and Disassembly/Diaphragm housing unit/Diaphragm housing cover/Hydraulic/Tighten @ 1\mod_1165323465060_31.doc @ 8995

10.22 MUI.814.200981.R01.EN
Assembly and disassembly

Hydraulic tension ring unit E

1 Place the hydraulic tension ring unit (B) to
the stud bolts.
Use a appropriate lifting device.
A
Use the lifting eye (A). B
2 Reset the hydraulic bolts on the tension
ring to 0-position.
3 Tighten the tension ring nuts (C).
4 Connect the hydraulic pump to the quick
release connector (E). D

Figure 10.34: Install the hydraulic tension ring unit

Tighten the cover nuts

1 Pressurize the hydraulic tension ring unit.
Refer to "Technical data", "Special torques", A
"Diaphragm housing unit" for the correct
pressure. C
2 Pre-tighten: Tighten all diaphragm housing B
cover nuts (D) with the pin (E) with normal D
hand force torque.
3 Release the pressure from the hydraulic
tension ring unit, to allow settling of the
E
surfaces.
4 Pressurize the hydraulic tension ring unit.
Refer to "Technical data", "Special torques",
"Diaphragm housing unit" for the correct F
pressure.
5 Final-tighten: Tighten all diaphragm
housing cover nuts (D) with the pin (E) with
Figure 10.35: Tighten the diaphragm cover nuts
normal hand force torque.
6 Release the pressure from the hydraulic Legend
tension ring unit.
A Diaphragm housing cover
7 Remove the hydraulic pump. B Hydraulic tension ring unit
8 Loosen the tension ring nuts (F). C Diaphragm housing cover stud bolt
9 Remove the hydraulic tension ring unit. D Diaphragm housing cover nut
E Pin (to turn the cover nut)
Pos: 55.1 /GEHO/Heading/H2/#.# Frame unit @ 0\mod_1146735364754_31.doc @ 3598
F Tension ring nut

10.6 Frame unit

Pos: 55.2 /GEHO/General/Attention, Warning and Note/Information - Frame unit - Contact Weir Minerals @ 1\mod_1165496458248_31.doc @ 9075

INFORMATION
For major maintenance work on the frame unit, please, contact the service department of
GEHO PUMPS, the Netherlands.
Pos: 56 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766

MUI.814.200981.R01.EN 10.23
 Assembly and disassembly

Pos: 57.1 /GEHO/Heading/H2/#.# Pulsation dampener @ 1\mod_1168952826922_31.doc @ 11788

10.7 Pulsation dampener

Pos: 57.2 /GEHO/Assembly and Disassembly/Pulsation damper/Safety instructions/Safety instructions pulsation dampener @ 1\mod_1168953439328_31.doc @ 11799

WARNING
The dampener may be under pressure even when the pressure gauge indicates no pressure.
The pressure sensing opening may be clogged.

WARNING
Do not use oxygen because of explosion danger.

WARNING
The pre-charge pressure may never exceed the maximum allowable pressure as indicated in
the dampener identification plate.

WARNING
Escaping nitrogen may cause lack of oxygen.

WARNING
In case of an external fire the nitrogen pressure inside the dampener will increase and may
exceed the dampener design pressure.

WARNING
In case of in-sufficient pre-charge pressure or nitrogen leakage, the pressure pulsations may
be excessive and may cause heavy vibrations.

WARNING
In case of a very rapid pressure drop in the discharge line, in combination with dislocation of
the dampener diaphragm in relation to the dampener in/outlet opening, a diaphragm rupture
might occur. In this case, the nitrogen can enter the slurry line and pressurize a blocked
section of this slurry line or form a nitrogen bubble under pressure in the slurry line.

WARNING
When discharging the gas pressure through the valve, the escaping nitrogen can push away
the air in the direct environment and can cause lack of oxygen.

WARNING
The dampener may be under pressure even when the pressure gauge indicates no pressure.
The pressure sensing opening (or pressure sensing line) can be clogged.
Pos: 57.3 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766

10.24 MUI.814.200981.R01.EN
Assembly and disassembly

Pos: 57.4 /GEHO/Assembly and Disassembly/Pulsation damper/Disassembly @ 0\mod_1156236790706_31.doc @ 5737

10.7.1 Diaphragm removing

1 Strictly obey the pulsation dampener safety instructions.
Refer to chapter "Pre-charging the discharge pulsation dampener".
2 Open the filler valve slowly, in many small steps, to discharge the nitrogen gas pressure from the pulsation
dampener.
DANGER
Leaking nitrogen (N2) causes lack of oxygen:
Prevent breathing in nitrogen.
Be aware of the risk of suffocation, caused by to much nitrogen in the air.
Prevent nitrogen filling the working environment.
Assure in small rooms good ventilation, because of risks of nitrogen leakage.
Assure free escape routes, because of risks of nitrogen gas.
3 Make sure that the pulsation dampener is depressurized.
4 Loosen the cover nuts. DO NOT remove the cover nuts.
CAUTION
Make sure that the pulsation dampener cover does not come upward against the nuts.
This indicates that pressure has not been completely discharged from the pulsation
dampener.
5 Remove the pulsation dampener cover. Use the lifting eyes and a proper lifting device.
ATTENTION
The lifting eyes on the pulsation dampener cover is only suitable for lifting the pulsation
dampener unit.
6 Remove the old pulsation dampener diaphragm.
7 Inspect the interior of the pulsation dampener.
8 Clean the interior of the pulsation dampener.
Pos: 57.5 /GEHO/Assembly and Disassembly/Pulsation damper/Assembly @ 0\mod_1156228349876_31.doc @ 5731

10.7.2 Diaphragm assembly

1 Clean the surface of the pulsation dampener
housing.
2 Clean the surface of the pulsation dampener
cover.
3 Make sure to remove all stains and remains
from the clamping edges for the diaphragm.
4 Apply a light coating of cup grease in the
diaphragm clamping edge.

CAUTION
Failure to properly lubricate these surfaces may result in a gradual leakage of nitrogen gas and
drop of pre-charge pressure.

INFORMATION
Use the grease Klber Syntheso Pro AA2, article number 006025 to install the diaphragms,
O-rings and seals.

MUI.814.200981.R01.EN 10.25
 Assembly and disassembly

Diaphragm folding, option 1

1 Push the cone outward.

2 Fold the diaphragm.

10.26 MUI.814.200981.R01.EN
Assembly and disassembly

3 Insert the folded diaphragm into the pulsation

dampener housing.

4 Move the diaphragm into position.

5 Make sure that the clamping rim fits in the
shoulder of the dampener housing.

MUI.814.200981.R01.EN 10.27
 Assembly and disassembly

Diaphragm folding, option 2

1 Fold the diaphragm.

2 Insert the diaphragm into the pulsation

dampener housing.

10.28 MUI.814.200981.R01.EN
Assembly and disassembly

3 Move the diaphragm into position.

4 Make sure that the clamping rim fits in the
shoulder of the dampener housing.

The correct position

1 Apply grease to the fitting edges of the cover.
2 Put the cover to the housing.
3 Tighten the nuts with the correct torque.
Refer to chapter Special torques.

Pos: 58.1 /GEHO/Heading/H2/#.# Nitrogen filling device @ 1\mod_1169209240961_31.doc @ 11882

10.8 Nitrogen filling device

Pos: 58.2 /GEHO/Assembly and Disassembly/Nitrogene filling device/Common part @ 1\mod_1169196110656_31.doc @ 11865

Use the nitrogen filling device for the filling of the hydraulic accumulator(s) or the pulsation dampener(s).

Refer to the "Instrument list" for the correct pressure.

Refer to the "Pre-charging the pulsation dampener" for correct filling of pulsation dampener(s) and
accumulator(s)

Pos: 59.1 /GEHO/Heading/H2/#.# Drive unit @ 0\mod_1134483988099_31.doc @ 452

10.9 Drive unit

Pos: 59.2 /GEHO/Assembly and Disassembly/Drive unit/Disassembly and assembly @ 1\mod_1168951193156_31.doc @ 11775

ATTENTION
Refer to chapter "Catalogue information" for information about assembly and disassembly of
drive unit parts.
Pos: 60 /--- Section break - Odd page --- @ 0\mod_1136277036628_0.doc @ 765

MUI.814.200981.R01.EN 10.29
Appendix: Parts - Lists and drawings (pump section)

Pos: 61 /GEHO/Heading/H1/#. Appendix: Parts - Lists and drawings (pump section) @ 1\mod_1169571543393_31.doc @ 11982

11.
Pos: 62 /GEHO/Parts lists/Pump/Project/200981d @ 2\mod_1181048248464_31.doc @ 13771
Appendix: Parts - Lists and drawings (pump section)

Tzpm1200 assembly
Part list number 820.577.200981
Drawing number T.820.200981

ID Item number Description Technical details Qty

005 818.080.559AD Puls.dampener filling un 1
010 828.950.151F Lubrication unit 1
015 828.950.152F Flushing unit 1
020 828.950.153F Ventline unit 1
025 831.020.358B Valve unit 3
026 831.020.359B Valve unit 3
030 832.010.123L Diaphragm housing unit 1
035 835.096.204B Piston unit 3
050 845.010.461F Frame unit 1
060 851.010.100Y Pulsation dampener unit 1
065 853.010.251F Press.limit.regul.unit 1
070 855.010.054L Pressure transmitter un 1
075 857.010.125F Propelling liquid unit 1
080 858.010.117F Electrical unit 1
085 895.577.213A Accessories 1
090 851.010.104F Pulsation dampener unit 1
100 814.200981.16 Drive unit 1
818.030.245 Type plate Ss 1
910.150.031 Round head grooved pin D1476 r2x8 ss 18
818.030.139 Name plate-geho 2
915.020.008 Hexagon nut D934 m3 ss 12
818.030.258 Name plate-weir 1
818.030.257 Name plate-weir 2
913.310.052 Hex.socket head capscrew D84a m3x10 ss 12

MUI.814.200981.R01.EN 11.1
 Appendix: Parts - Lists and drawings (pump section)

11.2 MUI.814.200981.R01.EN
Appendix: Parts - Lists and drawings (pump section)

Puls. dampener filling un

Part list number 818.080.559AD
Drawing number T.818.080.183

ID Item number Description Technical details Qty

001 922.595.211 Threaded reducing piece Red-r1/2/r1/4 1
002 922.985.201 Banjo coupl.w.one bolt P-rswv 6l/r1/4 1
003 913.003.138 Hex.socket head capscrew D912 m6x35 stl 6
004 929.050.091 Welding pipe clamp Sp106pp-dp-as 6
005 730.103.005 Tube R 6x1.5 ***
006 921.510.316 Pressure gauge R100/0-16000kpa 1
007 922.745.262 Adjustable coupling Emasd 12sr 1
008 922.155.062 Male stud coupling Ges 12s/r1/2 1
009 922.945.262 Stud standpipe adaptor Egesd 12s/r1/2-wd 1
010 922.075.209 Plug Vs-r1/4wd 2
011 913.003.248 Hex.socket head capscrew D912 m12x90 stl 2
012 855.100.065 Connecting block 1
013 818.030.026 Type plate 1
014 910.150.029 Round head grooved pin D1476 r2x5 ss 4
015 921.020.062 Valve Npt1/2"-pv4ns-ss 1
016 925.780.610 Nipple 1/2"npt ss 1
018 922.945.253 Stud standpipe adaptor Egesd 6sr-wd 1
019 922.285.254 Bulkhead coupling P-gsv 6s 2
021 922.305.253 Equal elbow coupling P-wv 6s 1
022 922.175.253 Male stud coupling P-gev 6sr-wd 1
023 922.365.201 Bulkhead elbow coupling P-wsv6l 1
024 922.105.253 Straight coupling P-gv 6s 2
025 925.800.610 Adaptor Npt1/2"bi-g1/2"bu 1
026 931.400.223 Sealing ring 22-27-1.5 din7603 1
027 922.135.062 Male connector Ges 12s/1/2npt 1

MUI.814.200981.R01.EN 11.3
 Appendix: Parts - Lists and drawings (pump section)

11.4 MUI.814.200981.R01.EN
Appendix: Parts - Lists and drawings (pump section)

Lubrication unit
Part list number 828.950.151F
Drawing number T.828.900.340

ID Item number Description Technical details Qty

001 950.261.862 Electric motor 1hp 1200rpm 1
002 960.020.619 Coupling Sf2-145tc-nema 1
003 960.020.063 Gear pump (r Sf2/6 rd-12l 1
004 847.900.014 Lantern piece 1
005 816.941.156 Cable duct 1
006 913.003.195 Hex.socket head capscrew D912 m10x20 stl 3
007 913.003.165 Hex.socket head capscrew D912 m8x20 stl 4
008 913.033.196 Hex.socket head capscrew 3/8"x16uncx1 4
010 921.700.832 Suction filter-element 0050s-125-wp 1
011 911.070.333 Stud D938 m16x40 stl 3
012 917.346.040 Lock washer D9021a m16 stl-glv 3
013 999.999.000 Arrow=rotating direction 1
014 910.150.029 Round head grooved pin D1476 r2x5 ss 2
015 921.510.187 Pressure gauge R100/0-1600kpa 1
016 925.800.610 Adaptor Npt1/2"bi-g1/2"bu 1
017 931.400.223 Sealing ring 22-27-1.5 din7603 1
019 928.860.027 Ball valve Sk3-28l25 1
020 921.700.411 Filter housing Lpf240gexxb 1.0 1
021 921.700.831 Filter element 0240d020bn3hc 1
030 929.050.500 Pipe clamp 112-pp 4
031 929.050.501 Pipe clamp 428-pp 6
032 929.050.530 Locking sheet Dp1 4
033 929.050.531 Locking sheet Dp4 16
034 914.003.144 Hexagon bolt D931 m6x65 stl 12
035 914.103.139 Hexagon screw D933 m6 x40 stl 4
047 730.103.103 Tube R 12 x 1.5 ***
048 730.103.213 Tube R 28 x 2 ***
050 971.900.060 Temperature sensor Pt100 1
051 922.945.228 Stud standpipe adaptor Egesd 28lr-wd 2

MUI.814.200981.R01.EN 11.5
 Appendix: Parts - Lists and drawings (pump section)

ID Item number Description Technical details Qty

054 922.155.228 Male stud coupling P-gev 28lr 3
055 922.595.219 Threaded reducing piece Red-r3/4r1 2
057 922.305.228 Equal elbow coupling P-wv 28l 2
058 922.595.230 Threaded reducing piece Red-r1.1/4-wd/r1 2
059 922.805.228 Non-return valve P-rv 28l 374069 1
061 922.455.228 Equal tee coupling P-tv 28l 12
062 922.975.231 Reducing fitting P-redvd 28/12l 12
063 922.155.210 Male stud coupling P-gev 12lr 6
067 828.500.508 Banjo coupling 5
068 828.500.509 Stud adaptor 6
069 922.035.228 Profile ring P-r 28l 1
070 922.015.229 Nut M 28l 1
071 868.053.287 Orifice 3
072 868.053.288 Orifice 5
073 868.053.286 Orifice 3
074 922.915.228 Adjust. male stud elbow P-ewvd 28l 7
080 915.003.040 Hexagon nut D934 m16 stl 3
081 922.935.228 Adj.male t.-stud P-elvd 28l 2
085 922.925.228 Adjustable equal tee P-etvd 28l 1
086 922.435.228 Straight coupling Snv 28l 372945 2
087 922.285.229 Bulkhead coupling P-gsv 28l 2
091 922.095.228 Blanking plug Vs 28l 1
095 917.306.069 Lock washer D125a m36 stl-glv 2
096 914.106.317 Hexagon screw D933 m16x30stl-glv 4
097 870.005.112 Cover 1
098 931.030.375 O-ring R120x4 nbr-70sh 1
100 971.600.003 Flow sensor Si-1002 1
101 922.950.879 T-piece E40080/ql28-18-28 1
102 922.950.880 Adapter E40104 1
116 922.755.062 Manometer coupling Mas 12sr 1
117 922.015.261 Nut M 12s 1
118 922.035.209 Profile ring P-r 12l/s 1

11.6 MUI.814.200981.R01.EN
Appendix: Parts - Lists and drawings (pump section)

Flushing unit
Part list number 828.950.152F
Drawing number T.828.900.335

ID Item number Description Technical details Qty

001 922.945.209 Stud standpipe adaptor Egesd 12l/r1/4-wd 9
002 922.455.209 Equal tee coupling P-tv 12l 6
003 922.305.209 Equal elbow coupling P-wv 12l 3
004 922.945.210 Stud standpipe adaptor Egesd 12lr-wd 3
005 922.975.220 Reducing fitting P-redvd 18/12l 3
006 730.103.108 Tube R 18 x 1.5 ***
007 922.455.217 Equal tee coupling P-tv 18l 2
008 922.305.217 Equal elbow coupling P-wv 18l 1
009 730.103.103 Tube R 12 x 1.5 ***
010 922.155.217 Male stud coupling P-gev 18lr 1
011 922.175.210 Male stud coupling P-gev 12lr-wd 3
012 922.365.219 Bulkhead elbow coupling P-wsv 18l 1

MUI.814.200981.R01.EN 11.7
 Appendix: Parts - Lists and drawings (pump section)

11.8 MUI.814.200981.R01.EN
Appendix: Parts - Lists and drawings (pump section)

Vent-line unit
Part list number 828.950.153F
Drawing number T.828.900.292

ID Item number Description Technical details Qty

001 928.370.305 Banjo coupl.w. one bolt R3/8"- 8x6 1
002 770.570.000 Hose R8-r6 pe ***
003 928.130.005 Male connector Ack- 3/8"-6 4
004 922.945.210 Stud standpipe adaptor Egesd 12lr-wd 5
006 730.103.103 Tube R 12 x 1.5 ***
008 922.880.000 Non-return valve P-rv 12l(0.5 1
010 922.915.209 Adjust. male stud elbow P-ewvd 12l 2
013 928.120.008 Male connector 3/8" - 6 3
014 922.935.209 Adj.male stud t-stud b.t P-elvd 12l 3
015 922.285.210 Bulkhead coupling P-gsv 12l 2

MUI.814.200981.R01.EN 11.9
 Appendix: Parts - Lists and drawings (pump section)

11.10 MUI.814.200981.R01.EN
Appendix: Parts - Lists and drawings (pump section)

Valve unit
Part list number 831.020.358B
Drawing number T.831.000.399

ID Item number Description Technical details Qty

001 023.582.018 Valve housing 1
003 025.582.016 Valve cover 1
010 831.350.259 Conical valve 1
011 831.700.925 Valve ring 1
012 831.150.918 Valve seat 1
013 831.900.051.14 Lock nut 1
014 825.107.043 Compression spring 1
015 831.900.677 Clamping piece 1
016 831.900.530 Guide bush 1.7131 1
017 862.007.527 Stud bolt 4
018 831.900.715 Piston 4
019 831.900.717 Nut 1.7225v 4
020 831.900.716 Nut 1.0503kg 4
021 822.270.004.67 Sealing ring 1
022 931.208.200 Sealing ring B7a,228.6x266wn100 1
023 931.191.175 Sealing ring B7a,195x229wn101 1
024 862.050.191 Nut Nf m42 4
026 960.010.621 Adapter R1/4"xr1/4"-3000b 2
027 960.010.613 Connecting nipple R1/4"/2000 bar 2
034 917.408.055 Retaining ring 55x2 / ph15-7mo 1
038 931.030.409 O-ring R220x4 nbr70-sh 2
039 933.111.066 Rod seal S8-65-75 4
040 933.111.086 Rod seal S8-85-100 4
041 913.020.239 Hex socket head capscrew D912 m12x40 ss 4
042 914.300.040 Ring bolt D580 m16 c15 1
043 914.206.411 Hexagon screw D561a m20x120 stl 2
045 831.900.719 Spacer 1.0503n 1
046 913.020.251 Hex.socket head capscrew D912 m12x120 ss 4
050 862.007.528 Stud bolt 12

MUI.814.200981.R01.EN 11.11
 Appendix: Parts - Lists and drawings (pump section)

ID Item number Description Technical details Qty

051 862.050.013.36 Nut 12
060 971.750.000 Acoustic sensor 1

11.12 MUI.814.200981.R01.EN
Appendix: Parts - Lists and drawings (pump section)

Valve unit
Part list number 831.020.359B
Drawing number T.831.000.400

ID Item number Description Technical details Qty

001 023.582.019 Valve housing 1
003 025.582.015 Valve cover 1
009 831.900.709 Valve support 1
010 831.350.259 Conical valve 1
011 831.700.925 Valve ring 1
012 831.150.918 Valve seat 1
013 831.900.051.14 Lock nut 1
014 825.107.043 Compression spring 1
015 831.900.713 Clamping piece 1
016 831.900.530 Guide bush 1.7131 1
017 862.007.526 Stud bolt 4
018 831.900.715 Piston 4
019 831.900.717 Nut 1.7225v 4
020 831.900.716 Nut 1.0503kg 4
021 822.270.004.67 Sealing ring 1
024 931.191.175 Sealing ring B7a,195x229wn101 1
026 960.010.621 Adapter R1/4"xr1/4"-3000b 2
027 960.010.613 Connecting nipple R1/4"/2000 bar 2
028 931.400.361 Sealing ring 36-42-2 din7603 1
029 831.900.454 Plug 1
033 917.260.134 Clamping sleeve R6x16 din1481-rvs 1
034 917.408.055 Retaining ring 55x2 / ph15-7mo 1
038 931.030.409 O-ring R220x4 nbr70-sh 2
039 933.111.066 Rod seal S8-65-75 4
040 933.111.086 Rod seal S8-85-100 4
041 914.206.411 Hexagon screw D561a m20x120 stl 2
044 862.050.003.36 Nut 4
045 862.007.525 Stud bolt 4
047 831.900.714 Pin 1

MUI.814.200981.R01.EN 11.13
 Appendix: Parts - Lists and drawings (pump section)

ID Item number Description Technical details Qty

060 971.750.000 Acoustic sensor 1

11.14 MUI.814.200981.R01.EN
Appendix: Parts - Lists and drawings (pump section)

Diaphragm housing unit

Part list number 832.010.123L
Drawing number T.832.000.177

ID Item number Description Technical details Qty

002 039.577.005 Diaphragm housing cover 3
003 045.577.005 Diaphragm housing 3
004 832.100.885 Corner piece 1
005 832.100.886 Middle piece 1
006 832.100.887 Corner piece 1
007 832.100.738 Filling ring 3
008 832.100.739 Covering ring 3
012 862.005.143 Initiator housing 6
013 832.100.578 Cover 6
015 832.100.901 Monitoring rod 3
016 832.100.899 Clamping bush 3
019 824.070.013 Diaphragm 3
021 925.530.224 Hexagon head pipe plug G 1" din 910-5.8 3
022 922.085.217 Blanking end Vs-m18x1.5wd 2
030 822.700.010 Sealing ring 3
031 931.031.267 O-ring R55x3 nbr-90sh 6
034 822.190.010 Sealing ring 3
035 931.400.331 Sealing ring 33-39-2 din7603 3
037 862.007.435 Stud bolt 1.7225v 72
039 862.007.531 Stud bolt 48
042 862.007.045.36 Stud bolt 24
044 814.200981.51 Nut 24
045 862.050.002.36 Nut 72
047 862.050.013.36 Nut 48
049 862.005.120 Coupling nut 6
050 914.103.321 Hexagon screw D933 m16x50 stl 24
052 914.223.459 Hexagon set screw D561b m24x200 stl 9
053 816.020.428 Protective cap 3
059 914.103.327 Hexagon screw D933 m16x80 stl 18

MUI.814.200981.R01.EN 11.15
 Appendix: Parts - Lists and drawings (pump section)

ID Item number Description Technical details Qty

063 913.003.196 Hex.socket head capscrew D912 m10x25 stl 6
064 914.483.325 Hexagon bolt D564 m16x70 stl 9
069 917.260.135 Clamping sleeve R6x20 din1481-rvs 6
070 921.050.001 Needle valve G3/8"-ubel717 3
071 922.075.209 Plug Vs-r1/4wd 3
074 922.305.209 Equal elbow coupling P-wv 12l 3
077 922.945.210 Stud standpipe adaptor Egesd 12lr-wd 6

11.16 MUI.814.200981.R01.EN
Appendix: Parts - Lists and drawings (pump section)

Piston unit
Part list number 835.096.204B
Drawing number T.835.000.152

ID Item number Description Technical details Qty

001 063.577.000 Piston rod 1
002 841.252.018 Cylinder liner 1
003 835.152.014 Piston body 1.0503n 1
004 835.352.005 Retaining plate 1.0503n 2
005 862.007.392 Stud bolt 8
006 915.040.059 Hexagon nut Nf m27 din2510 8
007 841.900.296 Thrust piece 1.7225v 1
008 835.900.109 Sealing plate 1
009 931.031.452 O-ring R40.64x5.33 nbr-90 1
010 862.050.127 Nut Nf m48/d2510 1
011 914.103.242 Hexagon screw D933 m12x55 stl 24
012 835.900.160 Guide ring Ptfe 25 1
015 914.300.040 Ring bolt D580 m16 c15 1
020 933.160.220 Set roof-shaped rings L=30 (1170 1
021 933.160.225 Set roof-shaped rings L=40 (1170 1
022 822.260.037 Sealing ring 1

MUI.814.200981.R01.EN 11.17
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11.18 MUI.814.200981.R01.EN
Appendix: Parts - Lists and drawings (pump section)

Frame unit
Part list number 845.010.461F
Drawing number T.845.000.461

ID Item number Description Technical details Qty

001 002.577.007 Frame 1
003 018.632.002 Retaining plate 1.7225v 12
005 066.577.001 Crosshead pin 3
006 068.577.003 Connecting rod 3
008 072A577A001 Crankshaft 1
010 087.577.004 Bearing cover 0.6025 1
013 086.577.000 Pressure plate 1
014 087.577.005 Bearing cover 0.6025 1
015 088.577.001 Pressure plate 3
016 090.577.001 Crosshead guide 6
018 089.577.000 Crosshead rod 3
019 005.577.001 Frame cover 1
020 816.955.503 Locking plate 3
030 931.030.599 O-ring R596.27x7 nbr70sh 2
031 823.030.041 Seal 1
034 823.051.049 Seal 2
035 823.030.040 Seal 3
036 839.100.047 Crosshead 3
037 823.030.028 Seal 3
038 913.053.319 Hex.socket head capscrew D7984 m16x40 stl 54
039 870.001.225 Cover Stl 2
040 870.001.224 Cover Stl 1
041 870.001.187 Cover 2
042 822.020.123 Sealing ring 3
044 870.001.223 Cover W1.0067 3
045 931.030.869 O-ring R455x5 nbr70sh 3
046 816.955.130 Clamping piece 3
059 914.106.317 Hexagon screw D933 m16x30stl-glv 54
062 914.236.529 Hexagon set screw D561a m30x2x100stl 4

MUI.814.200981.R01.EN 11.19
 Appendix: Parts - Lists and drawings (pump section)

ID Item number Description Technical details Qty

063 914.003.449 Hexagon bolt D931 m24x100 stl 6
064 914.106.321 Hexagon screw D933 m16x50stl-glv 24
065 914.103.445 Hexagon screw D933 m24x70 stl 12
066 914.103.407 Hexagon screw D933 m20x80 stl 12
068 914.103.442 Hexagon screw D933 m24x55 stl 9
069 914.106.237 Hexagon screw D933 m12x30stl-glv 32
080 933.101.126 U-ring T20/125-145-16 3
081 933.021.125 Wiper ring 125-137-11nbr-90sh 3
082 911.040.441 Stud bolt D939 m24x50 8.8 18
084 914.103.317 Hexagon screw D933 m16x30 stl 6
085 915.006.055 Hexagon nut D934 m24 stl-glv 18
086 915.003.040 Hexagon nut D934 m16 stl 12
087 913.003.447 Hex.socket head capscrew D912 m24x80 stl 18
089 822.160.023 Sealing ring 3
091 846.100.172 Dust cover housing 3
092 846.100.126 Gasket holder 3
094 815.812.411 Flat bar steel 6
095 911.040.323 Stud bolt M16x60 din939-8.8 12
118 935.022.340 Lipseal Was 300-340-20 1
121 925.546.145 Hexagon head pipe plug 3
126 942.210.668 Spherial roller bearing 23168bk.mb 2
127 942.900.087 Cyl. roller bearing 3
128 942.900.074 Cyl. roller bearing 3
129 942.410.668 Pressure sleeve Ah3168h 2
131 922.155.209 Male stud coupling P-gev 12l/r1/4 6
132 730.103.103 Tube R 12 x 1.5 ***
134 925.720.284 Pipe nipple D2982 g2"x250 stl 1
136 921.150.021 Gate valve G2"-econ290a 1
138 948.790.002 Oil glass G2 2
140 921.700.033 Filter Pi 0114 mic 2
141 942.800.164 Lock nut Hm3164 1
142 816.955.504 Locking plate 1
143 925.016.114 Bend G3/4"-n1 1
144 917.303.034 Lock washer D125a m12 stl 4

11.20 MUI.814.200981.R01.EN
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ID Item number Description Technical details Qty

147 914.103.237 Hexagon screw D933 m12x30 stl 12
148 914.106.315 Hexagon screw D933 m16x20stl-glv 8
149 914.103.195 Hexagon screw D933 m10x20 stl 1
150 948.500.000 Grease nipple D71412 h45/g1/8 3
151 914.106.439 Hexagon screw D933 m24x40stl-glv 2
152 917.500.055 Retaining ring Dubo m24 2
155 921.200.026 Ball valve G2"-eriks 3185 1
156 925.526.145 Double nipple N280 g2 1
157 828.500.559 Pipe nipple 1

MUI.814.200981.R01.EN 11.21
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11.22 MUI.814.200981.R01.EN
Appendix: Parts - Lists and drawings (pump section)

Pulsation dampener unit

Part list number 851.010.100Y
Drawing number T.851.000.293

ID Item number Description Technical details Qty

001 851.500.278 Cover 1
002 851.300.242 Pulsation dampener body 1
006 824.040.008 Diaphragm 1
009 862.007.424 Stud bolt 16
010 922.075.218 Plug Vs-r1/2wd 1
012 914.300.063 Ring bolt D580 m30 c15 1
013 913.513.597 Hex.socket head capscrew D912 m36x85 stl 12
014 862.050.237 Nut Sa194-2h/m36 16
017 818.030.251 Type plate 1
018 818.030.210 Text plate 1
019 910.150.029 Round head grooved pin D1476 r2x5 ss 8
020 851.500.266 Flange A322-gr4140 1
021 931.030.542 O-ring R159.2x5.7nbr-70sh 1
025 822.150.021 Sealing ring 1
028 922.075.209 Plug Vs-r1/4wd 1

MUI.814.200981.R01.EN 11.23
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11.24 MUI.814.200981.R01.EN
Appendix: Parts - Lists and drawings (pump section)

Press.limit.regul.unit
Part list number 853.010.251F
Drawing number T.853.000.200

ID Item number Description Technical details Qty

001 921.300.563 Safety valve 1
002 853.010.239 Non-return valve unit 3
003 862.015.241 Threaded rod 24
004 915.006.040 Hexagon nut D934 m16 stl-glv 24
005 931.190.050 Sealing ring B7a,62x102d2697 8
006 828.551.686 Connecting pipe 1
007 862.015.298 Threaded rod 8
008 931.190.080 Sealing ring B7a-nw80 din 2697 1
009 853.100.609 Connecting block 1
010 922.075.218 Plug Vs-r1/2wd 2
011 816.930.402 Ring Stl 1
012 862.015.251 Threaded rod 8
013 915.006.055 Hexagon nut D934 m24 stl-glv 16
014 816.930.382 Ring 1.0503n 1
015 822.080.049 Gasket R80-r127-2/c4430 2
016 862.015.275 Threaded rod 8
017 915.006.047 Hexagon nut D934 m20 stl-glv 16
018 828.551.687 Drain line 1
019 822.100.024 Sealing ring 1
020 914.103.319 Hexagon screw D933 m16x40 stl 8
021 922.945.262 Stud standpipe adaptor Egesd 12s/r1/2-wd 1
022 922.455.060 Equal tee coupling Ts 12s 1
023 922.945.261 Stud standpipe adaptor Egesd 12sr-wd 1
024 921.050.001 Needle valve G3/8"-ubel717 1
025 922.755.062 Manometer coupling Mas 12sr 1
026 922.015.261 Nut M 12s 2
027 922.035.209 Profile ring P-r 12l/s 2
028 921.520.042 Shock absorber G1/2"-econ1388 1
029 925.800.610 Adaptor Npt1/2"bi-g1/2"bu 1

MUI.814.200981.R01.EN 11.25
 Appendix: Parts - Lists and drawings (pump section)

ID Item number Description Technical details Qty

030 921.510.316 Pressure gauge R100/0-16000kpa 1
031 730.103.103 Tube R 12 x 1.5 ***
032 929.050.500 Pipe clamp 112-pp 1
033 929.050.530 Locking sheet Dp1 1
034 914.103.139 Hexagon screw D933 m6 x40 stl 1
035 931.400.223 Sealing ring 22-27-1.5 din7603 1

11.26 MUI.814.200981.R01.EN
Appendix: Parts - Lists and drawings (pump section)

Non-return valve unit

Part list number 853.010.239
Drawing number T.853.000.105

ID Item number Description Technical details Qty

001 853.100.504 Valve housing 1
002 853.100.503 Valve guide 1
003 853.100.505 Valve 1
004 821.025.052 Ring 1
005 821.025.044 Ring 1
006 917.800.016 Compression spring R32xr2.5x71.5 1
007 913.006.135 Hex.socket head capscrew D912 m6x20 stl-glv 4
008 931.030.890 O-ring R70x3 1

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11.28 MUI.814.200981.R01.EN
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Pressure transmitter un
Part list number 855.010.054L
Drawing number T.855.000.089

ID Item number Description Technical details Qty

001 971.450.074 Pressure transmitter Rosemount 1
002 971.450.056 Pressure transmitter 0-16000 kpa 1
003 971.450.055 Pressure transmitter 0-2500kpa 1
004 922.135.211 Male connector P-gev 12l/1/2npt 3
005 922.975.209 Reducing fitting P-redvd 12/6l 3
006 914.900.019 Hexagon screw 1/4"-20unc/l=1/2 6
007 921.520.043 Shock absorber 1/2"npt econ1389 1
008 816.941.166 Support 1
009 816.941.167 Support 1
010 914.106.135 Hexagon screw D933 m6x20 stl-glv 4
011 915.006.022 Hexagon nut D934 m6 stl-glv 4

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11.30 MUI.814.200981.R01.EN
Appendix: Parts - Lists and drawings (pump section)

Propelling liquid unit

Part list number 857.010.125F
Drawing number T.857.000.193

ID Item number Description Technical details Qty

001 950.261.082 Electric motor 1.5hp 1200rpm 1
002 814.200981.42 Coupling 1
003 960.020.063 Gear pump (r Sf2/6 rd-12l 1
004 847.900.022 Latern piece Stl 1
007 913.003.165 Hex.socket head capscrew D912 m8x20 stl 4
008 913.033.236 Hex.socket head capscrew 1/2"x13uncx1 4
010 911.070.236 Stud D938 m12x25 stl 8
011 917.306.034 Lock washer D125a m12 stl-glv 8
012 915.003.034 Hexagon nut D934 m12 stl 2
013 999.999.000 Arrow=rotating direction 1
014 910.150.029 Round head grooved pin D1476 r2x5 ss 2
015 922.155.217 Male stud coupling P-gev 18lr 2
016 922.595.218 Threaded reducing piece Red-r3/4/r1/2 3
018 922.915.209 Adjust. male stud elbow P-ewvd 12l 1
019 922.295.220 Straight reduct.coupling P-gv 18/12l 374536 1
020 921.700.411 Filter housing Lpf240gexxb 1.0 1
021 921.700.831 Filter element 0240d020bn3hc 1
022 922.595.228 Threaded reducing piece Red-r1.1/4/r1/2 2
023 922.945.217 Stud standpipe adaptor Egesd 18lr-wd 6
024 922.365.219 Bulkhead elbow coupling P-wsv 18l 1
025 922.915.217 Adjust. male stud elbow P-ewvd 18l 5
026 922.880.001 Non-return valve P-rv 18l(o.5 2
027 922.455.217 Equal tee coupling P-tv 18l 2
028 922.935.217 Adj.male t.-stud P-elvd 18l 3
029 922.975.220 Reducing fitting P-redvd 18/12l 2
030 922.285.219 Bulkhead coupling P-gsv 18l 2
031 922.155.062 Male stud coupling Ges 12s/r1/2 6
032 922.915.060 Adjust. male stud elbow Ewsd 12s 3
033 922.285.061 Bulkhead coupling Gss 12s 8

MUI.814.200981.R01.EN 11.31
 Appendix: Parts - Lists and drawings (pump section)

ID Item number Description Technical details Qty

034 915.336.047 Hexagon nut D439 b-m20x1.5 2
035 922.945.210 Stud standpipe adaptor Egesd 12lr-wd 3
036 922.305.209 Equal elbow coupling P-wv 12l 1
037 922.455.209 Equal tee coupling P-tv 12l 1
038 922.975.209 Reducing fitting P-redvd 12/6l 1
040 973.000.012 Hydr. accumulator 6l-330bar 1
041 917.306.025 Lock washer D125a m8 stl-glv 2
042 914.103.164 Hexagon screw D933 m8x16 stl 6
045 925.800.603 Adaptor Npt 1/4"bi-g1/4"bu 1
046 931.400.142 Sealing ring 14-18-1.5 din7603 1
047 925.800.610 Adaptor Npt1/2"bi-g1/2"bu 2
048 931.400.223 Sealing ring 22-27-1.5 din7603 2
049 971.400.045 Silencer R1/4 8
050 972.200.065 3/2 way valve Nw6-24vdc-no 6
055 972.200.066 3/2 way valve Nw6-24vdc-nc 2
056 972.900.000 Mounting block R3/'8"-r1/4"-n=8 1
057 925.470.209 Double nipple N245 g1/2"x3/8"stl 1
058 925.206.110 Elbow N90 g1/2" mall.ci 1
059 914.106.132 Haexagon screw D933 m6x10 stl-glv 4
060 921.510.315 Pressure gauge R100/0-2500kpa 1
061 922.755.062 Manometer coupling Mas 12sr 1
062 922.035.209 Profile ring P-r 12l/s 24
063 922.015.261 Nut M 12s 24
065 921.510.223 Pressure gauge R63/0-1600kpa 1
066 922.745.209 Adjustable coupling Emasd 12lr 1
067 929.050.500 Pipe clamp 112-pp 1
068 929.050.530 Locking sheet Dp1 1
069 914.103.139 Hexagon screw D933 m6 x40 stl 1
070 853.010.250 Prop.liquid/flush.unit 1
071 928.370.304 Banjo coupl. w.one bolt R1/4"- 8x6 8
072 770.570.000 Hose R8-r6 pe ***
073 922.075.213 Plug Vs-r3/8wd 4
074 931.400.183 Sealing ring 18-22-1.5 din7603 3
075 914.106.198 Hexagon screw D933 m10x35stl-glv 8

11.32 MUI.814.200981.R01.EN
Appendix: Parts - Lists and drawings (pump section)

ID Item number Description Technical details Qty

077 922.975.217 Reducing fitting P-redvd 18/6l 1
078 928.110.305 Male connector G1/4"-8x6 8
090 928.860.019 3/2 ball valve Bk3-18l13 1
091 922.015.219 Nut M 18l 2
092 922.035.217 Profile ring P-r 18l 2
100 971.600.003 Flow sensor Si-1002 1
101 922.950.882 T-piece E40078/ql18-18-18 1
102 922.950.880 Adapter E40104 1
116 922.595.219 Threaded reducing piece Red-r3/4r1 1
117 922.915.228 Adjust. male stud elbow P-ewvd 28l 1
125 928.900.678 H.p. hose 1st25a05a05-650 1
131 922.435.217 Female connector Snv 18l 372943 1
150 816.310.104 Tank 1
151 815.010.648 Drip pan 1
152 948.790.105 Level indicator Sna254b-s-t-12 1
153 775.542.272 Seal 12x8 ***
154 925.526.145 Double nipple N280 g2 3
155 921.200.026 Ball valve G2"-eriks 3185 1
156 925.530.224 Hexagon head pipe plug G 1" din 910-5.8 1
157 914.103.165 Hexagon screw D933 m8x20 stl 32
158 922.155.228 Male stud coupling P-gev 28lr 1
159 730.103.213 Tube R 28 x 2 ***
160 922.285.229 Bulkhead coupling P-gsv 28l 1
161 870.005.112 Cover 1
162 931.030.375 O-ring R120x4 nbr-70sh 1
163 914.103.317 Hexagon screw D933 m16x30 stl 4
164 921.700.832 Suction filter-element 0050s-125-wp 1
165 922.945.228 Stud standpipe adaptor Egesd 28lr-wd 1
170 814.200981.25 Pi skid 1
171 868.001.841 Distance bushing 4
172 914.106.325 Hexagon screw D933 m16x70stl-glv 4
173 917.306.040 Lock washer D125a m16 stl-glv 4
174 816.940.820 Support 2
176 914.300.040 Ring bolt D580 m16 c15 2

MUI.814.200981.R01.EN 11.33
 Appendix: Parts - Lists and drawings (pump section)

ID Item number Description Technical details Qty

177 914.103.236 Hexagon screw D933 m12x25 stl 8
180 770.556.578 Hose Tw50-nbr/cr-s ***
181 929.000.531 Hose band clamp S62/20skz 2
182 929.300.020 Connecting piece G2"/633-f/ss 2
183 929.300.000 Coupling G2"/633-c/ss 2
185 925.206.145 Elbow N90 g2 2
186 917.950.030 Bolt adapter M16-glv 4
191 730.103.108 Tube R 18 x 1.5 ***
192 730.103.103 Tube R 12 x 1.5 ***
193 730.103.001 Tube R6x1 ***
194 814.200981.50 Pipe R28x2/l=500 1
195 730.103.101 Tube R 12 x 2 ***
210 816.020.474 Protection cover 1
211 911.170.325 Hexagon socket set screw 1
212 915.020.040 Hexagon nut D934 m16 ss 2
213 917.850.040 Lock washer D125b m16 ss 2
214 917.040.040 Spring washer B16 d127b-w1.4401 1
250 928.900.675 H.p.hose 1st25a05a35-350 1
251 922.105.228 Straight coupling P-gv 28l 1
255 922.985.228 Banjo coupl. w. one bolt P-rswv 28lr 2
256 929.050.501 Pipe clamp 428-pp 1
257 929.050.531 Locking sheet Dp4 4
258 914.003.144 Hexagon bolt D931 m6x65 stl 2

11.34 MUI.814.200981.R01.EN
Appendix: Parts - Lists and drawings (pump section)

Prop. liquid/flush. unit

Part list number 853.010.250
Drawing number T.853.000.131

ID Item number Description Technical details Qty

001 853.010.241 2/2 way valve 7
002 853.100.329 Valve seat 7
003 853.100.455 Non-return valve 3
004 931.032.051 O-ring R21x1.5 fpm-80sh 11
005 853.100.525 Distributor block 1
006 862.005.314 Banjo bolt 4
007 931.082.021 Multiseal Scpp45-d 7
008 853.100.323 Base plate 3
009 853.100.330 Plug 3
010 913.003.169 Hex.socket head capscrew D912 m8x40 stl 32
012 822.030.024 Sealing ring 8
014 853.010.243 2/2 way valve 1
015 853.100.535 Distributor block 1
016 862.005.316 Banjo bolt 3
017 853.100.520 Bottom plate 1
018 853.100.518 Plug 1
019 853.100.519 Valve seat 1
020 853.100.517 Valve 1
021 931.082.017 Multiseal Scpp45-c 7

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11.36 MUI.814.200981.R01.EN
Appendix: Parts - Lists and drawings (pump section)

2/2 way valve

Part list number 853.010.241
Drawing number T.853.000.068

ID Item number Description Technical details Qty

001 853.100.387 Slide bearing 1
002 921.700.030 Filter G1/4"-lo.0304-01 1
003 853.100.490 Cover 1
004 853.100.216.64 Dampening 1
005 933.500.001 Diaphragm Bfa70/60-40 1
007 913.003.168 Hex.socket head capscrew D912 m8x35 stl 4
008 853.100.385 Valve housing 1
009 825.102.000.32 Compression spring 1
011 853.100.388 Slide bearing 1
012 917.403.030 Retaining ring D472 r30x1.2 ss 1
013 933.107.023 U-ring 20-30-8 1
014 853.100.391 Valve spindle 1

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11.38 MUI.814.200981.R01.EN
Appendix: Parts - Lists and drawings (pump section)

2/2 way valve

Part list number 853.010.243
Drawing number T.853.000.110

ID Item number Description Technical details Qty

001 853.100.387 Slide bearing 1
002 921.700.030 Filter G1/4"-lo.0304-01 1
003 853.100.490 Cover 1
004 853.100.216.64 Dampening 1
005 933.500.001 Diaphragm Bfa70/60-40 1
007 913.003.168 Hex.socket head capscrew D912 m8x35 stl 4
008 853.100.385 Valve housing 1
009 825.102.000.32 Compression spring 1
011 853.100.388 Slide bearing 1
012 917.403.030 Retaining ring D472 r30x1.2 ss 1
013 933.107.023 U-ring 20-30-8 1
014 853.100.522 Valve spindle 1

MUI.814.200981.R01.EN 11.39
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11.40 MUI.814.200981.R01.EN
Appendix: Parts - Lists and drawings (pump section)

Electrical unit
Part list number 858.010.117F
Drawing number T.814.200981.43

ID Item number Description Technical details Qty

001 814.200981.41 Control box cpl 1
001 814.200981.34 Memory card 1
002 814.200981.40 Terminal box 1
003 814.200981.44 Terminal box 1
004 814.200981.46 Control box cpl 1
004 814.200981.37 Hmi-panel 1
005 858.100.063 Initiator 6
006 816.941.158 Cable duct 1
007 914.103.316 Hexagon screw D933 m16x25 stl 4
010 995.025.023 Bend Pg13 h318 6
011 995.001.050 Hose swivel Pg 13 12
012 790.000.014 Protection sleeve Ins.ro.14.5 ***
013 862.050.241 Nut 1
014 995.006.202 Reducing ring Pg11-pg9 h527 1
015 995.001.052 Hose swivel Pg 9 2
016 790.000.009 Protection sleeve R10 ***
017 862.050.266 Nut 2
018 971.100.055 Initiator Ni12u-em18-ap6x 1
019 995.006.424 Adapter Pg11/m20x1.5 1
020 858.100.221 Cable channel Stl 1
021 858.100.222 Cable channel Stl 1
022 858.100.223 Cable channel Stl 1
023 929.000.917 Clamping ring Stl-glv 1
024 868.005.006 Detector piece 1
025 914.106.194 Hexagon screw D933 m10x16stl-glv 11
026 995.025.026 Bend Pg7 h318 8
027 995.001.056 Union nut Pg7 h203 8
028 790.000.026 Protection hose 481-inw.r7 ***
029 795.000.306 Cable Cy/4x0.34mm2 ***

MUI.814.200981.R01.EN 11.41
 Appendix: Parts - Lists and drawings (pump section)

ID Item number Description Technical details Qty

030 795.000.095 ***
031 816.941.187 Support 1
032 995.006.200 Reducing ring Pg9-pg7 h527 6
033 995.025.021 Bend Pg9 h318 1
034 816.941.141 Support 6
035 913.003.140 Hex.socket head capscrew D912 m6x45 stl 12
036 995.000.190 Cable gland 6
037 995.006.478 Adapter Pg9/m16x1.5 6
038 790.000.013 Protection sleeve ***
040 995.040.010 Cable tierap T 50 r 50
041 995.040.012 Cable tierap 4x140 / nylon 6.6 100
042 931.080.085 U-seal 8.5-13.4-1.0 4
043 913.400.165 Hex.socket head capscrew D912 m8x20 ss316 4
044 915.140.025 Hexagon nut D934 m8 ss 4
045 917.280.025 Lock washer D125a m8 ss 4
046 995.006.208 Reducing ring Pg16-pg11 h527 1
047 995.025.022 Bend Pg11 1
048 995.001.053 Union nut Pg11 1
049 911.040.321 Stud bolt M16x50 din939-8.8 2
050 914.103.317 Hexagon screw D933 m16x30 stl 2
051 858.100.288 Cable channel 3
052 858.100.289 Cable channel 1
053 858.100.290 Cable channel 1
054 858.100.291 Cable duct 1
055 914.106.164 Hexagon screw D933 m8x16 stl-glv 2
057 914.106.195 Hexagon screw D933 m10x20stl-glv 5
058 915.006.028 Hexagon nut D934 m10 stl-glv 4
059 790.000.007 Protection sleeve ***

11.42 MUI.814.200981.R01.EN
Appendix: Parts - Lists and drawings (pump section)

Accessories
Part list number 895.577.213A
Drawing number T.895.577.005

ID Item number Description Technical details Qty

001 815.010.615 Base frame 1
002 828.551.698 Discharge line 1
003 828.551.700 Suction line 1
004 816.941.121 Support 1
005 816.941.162 Support 2
006 828.551.681 Support 1
007 828.500.535 Plug 1
008 862.015.272 Connecting rod 4
009 915.003.075 Hexagon nut D934 m42 stl 8
010 931.400.640 Sealing ring 64-72-2.5 d7603 1
011 828.551.684 Support 1
012 828.551.471 Adaptor 1.0570n 1
013 911.040.690 Stud bolt D939 m42x110stl 4
014 822.150.021 Sealing ring 1
015 927.026.200 Blind flange 8"rf-900lbs stl 1
016 931.208.200 Sealing ring B7a,228.6x266wn100 2
017 862.007.222 Reduced shank bolt 12
018 862.050.010.36 Nut 48
019 862.007.306 Stud bolt M36x181/coat 24
023 868.002.199 Flange spec 1
024 914.003.407 Hexagon bolt D931 m20x80 stl 8
025 915.003.047 Hexagon nut D934 m20 stl 8
026 822.200.059 Sealing ring R270-r204-2 5
027 914.103.402 Hexagon screw D933 m20x55 stl 8
028 914.103.444 Hexagon screw D933 m24x65 stl 36
029 914.103.400 Hexagon screw D933 m20x45 stl 8
030 914.103.439 Hexagon screw D933 m24x40 stl 4
031 914.103.404 Hexagon screw D933 m20x65 stl 12
032 816.930.388 Shim 6

MUI.814.200981.R01.EN 11.43
 Appendix: Parts - Lists and drawings (pump section)

ID Item number Description Technical details Qty

033 914.236.529 Hexagon set screw D561a m30x2x100stl 6
034 911.170.325 Hexagon socket set screw 2
035 915.020.040 Hexagon nut D934 m16 ss 4
036 917.280.040 Lock washer D125a m16 ss 4
037 917.040.040 Spring washer B16 d127b-w1.4401 2
038 815.010.670 Base frame 1
039 914.103.442 Hexagon screw D933 m24x55 stl 6
041 927.020.075 Blind flange 1
042 822.080.049 Gasket R80-r127-2/c4430 1
043 914.103.324 Hexagon screw D933 m16x65 stl 4
044 915.003.040 Hexagon nut D934 m16 stl 4
045 914.466.595 Foundation bolt D529b-m33x800 stl 24
046 915.003.066 Hexagon nut D934 m33 stl 24
047 917.300.066 Losk washer Din 125a m33 stl 24
048 914.466.551 Stone bolt D529b m30x630stl 6
049 915.003.063 Hexagon nut D934 m30 stl 6
050 917.300.063 Lock washer D125a m30 stl 6
051 913.003.528 Hex.socket head capscrew D912 m30x90 stl 8

11.44 MUI.814.200981.R01.EN
Appendix: Parts - Lists and drawings (pump section)

Pulsation dampener unit

Part list number 851.010.104F
Drawing number T.851.000.338

ID Item number Description Technical details Qty

001 851.500.279 Cover 1
002 851.300.249 Pulsation dampener body Sa-395 1
006 824.040.008 Diaphragm 1
007 921.020.062 Valve Npt1/2"-pv4ns-ss 1
008 921.510.187 Pressure gauge R100/0-1600kpa 1
009 862.007.436 Stud bolt 12
012 914.300.063 Ring bolt D580 m30 c15 1
014 862.050.227 Nut Sa194-2h/m30 12
017 818.030.251 Type plate 1
018 818.030.210 Text plate 1
019 910.150.029 Round head grooved pin D1476 r2x5 ss 8
022 931.191.125 Sealing ring B7a nw125 wn101 1
023 925.780.610 Nipple 1/2"npt ss 1
024 922.945.262 Stud standpipe adaptor Egesd 12s/r1/2-wd 2
025 922.755.062 Manometer coupling Mas 12sr 1
026 925.800.610 Adaptor Npt1/2"bi-g1/2"bu 1
028 922.075.209 Plug Vs-r1/4wd 1
029 922.135.062 Male connector Ges 12s/1/2npt 1

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11.46 MUI.814.200981.R01.EN
Appendix: Parts - Lists and drawings (pump section)

Drive unit
Part list number 814.200981.16
Drawing number T.814.200981.16

ID Item number Description Technical details Qty

001 814.200981.31 Gear box 1
002 814.200981.32 Flex.coupling 1
003 814.200981.33 Gear coupling 1
004 814.200981.30 Electric motor 873kwn1738 1
005 814.200981.38 Frequency convertor Pf7000 1
006 815.010.666 Base frame 1
007 816.020.525 Protective cap 1
008 816.020.524 Protective cap 1
009 816.930.423 Shim 2
010 816.930.351 Shim 1.0067 6
011 816.930.422 Shim 2
012 914.106.610 Hexagon bolt D933 m36x110 4
013 914.106.692 Hexagon bolt D933 m42x130 6
014 917.306.069 Lock washer D125a m36 stl-glv 4
015 917.306.075 Lock washer D125a m42 stl-glv 6
016 914.206.327 Hexagon bolt D561a m16x80 8
017 914.236.533 Hexagon set screw M30x2x140 d561a-st 9
018 914.106.195 Hexagon screw D933 m10x20stl-glv 4
019 917.306.028 Lock washer D125a m10 stl-glv 12
020 914.106.197 Hexagon screw D933 m10x30stl-glv 4
021 915.006.028 Hexagon nut D934 m10 stl-glv 4
022 911.170.325 Hexagon socket set screw 2
023 915.020.040 Hexagon nut D934 m16 ss 4
024 917.040.040 Spring washer B16 d127b-w1.4401 2
025 917.280.040 Lock washer D125a m16 ss 4
026 914.206.329 Hexagon screw D561am16x100st-glv 4

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12. Appendix: Parts - Lists and drawings (special tools)

Pos: 65 /GEHO/Parts lists/Special tools/Project/814.200981.10 @ 1\mod_1166628056761_31.doc @ 11505

Set of tools
Part list number 814.200981.10
Drawing number

ID Item number Description Technical details Qty

001 897.010.583E Hydr. mont. diaphr. cover 1
002 897.050.241 Pulling device cyl. liner 1
003 897.010.685AN Accumul. filling device 1
004 897.050.127 Ass. valve seal tool Api-11 1
005 897.010.635 Tool valve nut 1
006 897.050.279 Collect chuck Stl 1
007 897.010.606J Disass. valve seat tool 1
008 897.010.706 Lifting bar unit 1
009 897.010.710 Hydr. pump unit 1
010 897.010.633E Fill ring lifting device 1
011 897.010.588J Lifting cover 1
012 897.010.680B Hoisting unit 1
013 980.622.915 Socket wrench 1
014 980.627.097 Socket 32/sl.w.36 1
015 ELA.000.593 Coversheet 1
016 ELA.000.594 Key Rittal 1

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 Appendix: Parts - Lists and drawings (special tools)

12.2 MUI.814.200981.R01.EN
Appendix: Parts - Lists and drawings (special tools)

Hydr.mont.diaphr.cover
Part list number 897.010.583E
Drawing number T.897.000.296

ID Item number Description Technical details Qty

001 897.100.982 Tension ring 1.7225v 1
002 853.200.514 Clamping bush 24
003 862.050.005.36 Nut 24
004 933.111.065 Rod seal S8-65 24
005 933.111.093 Rod seal Iso-90 24
006 914.300.047 Ring bolt D580 m20 c15 1
007 960.010.621 Adapter R1/4"xr1/4"-3000b 1
008 960.010.613 Connecting nipple R1/4"/2000 bar 1
011 960.010.624 Blind plug 1
013 897.100.932 Pin 1

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 Appendix: Parts - Lists and drawings (special tools)

12.4 MUI.814.200981.R01.EN
Appendix: Parts - Lists and drawings (special tools)

Accumul.filling device
Part list number 897.010.685AN
Drawing number T.814.200981.27

ID Item number Description Technical details Qty

001 973.900.029 Accumul.fill/control set Hydac 1
003 973.900.908 Adaptor 1
005 922.755.254 Manometer coupling P-mav 6sr 1
006 921.510.326 Pressure gauge R63/0-25bar 1

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12.6 MUI.814.200981.R01.EN
Appendix: Parts - Lists and drawings (special tools)

Tool valve nut

Part list number 897.010.635
Drawing number T.897.000.233

ID Item number Description Technical details Qty

001 897.050.222 Valve nut wrench 1
002 897.100.823 Pin 3
003 914.106.237 Hexagon screw D933 m12x30stl-glv 3
004 917.306.034 Lock washer D125a m12 stl-glv 3
005 897.100.824 Pipe 1

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 Appendix: Parts - Lists and drawings (special tools)

12.8 MUI.814.200981.R01.EN
Appendix: Parts - Lists and drawings (special tools)

Disass.valve seat tool

Part list number 897.010.606J
Drawing number T.897.000.293

ID Item number Description Technical details Qty

001 897.100.867 Drawing operation 1
002 897.101.099 Connecting rod 1
003 897.100.950 Block 1.0570 1
004 853.200.528 Clamping bush 1
005 853.200.529 Clamping bush 1
006 933.111.060 Rod seal S8-60 1
007 933.111.045 Rod seal S8-45 1
008 960.010.613 Connecting nipple R1/4"/2000 bar 1
009 960.010.621 Adapter R1/4"xr1/4"-3000b 1
010 915.003.063 Hexagon nut D934 m30 stl 2
011 897.100.951 Flat bar steel 1.0067 2
012 913.356.132 Hex.socket head capscrew D85a m6x10 stl-glv 4
013 897.100.752 Block 1
014 897.101.101 Connecting rod 1
015 897.100.753 Flat bar 2
016 897.100.788 Block 1.7225v 1
017 897.100.754 Contra-block 1
018 897.100.755 Threaded rod M30x320 1

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12.10 MUI.814.200981.R01.EN
Appendix: Parts - Lists and drawings (special tools)

Lifting bar unit

Part list number 897.010.706
Drawing number T.897.000.241

ID Item number Description Technical details Qty

001 897.101.010 Lifting spindle 1
002 897.100.849 Ring 1
003 914.300.034 Ring bolt D580 m12 stl 1
004 911.040.441 Stud bolt D939 m24x50 8.8 1
005 914.206.239 Hexagon screw D561am12x40stl-glv 2

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12.12 MUI.814.200981.R01.EN
Appendix: Parts - Lists and drawings (special tools)

Hydr.pump-unit
Part list number 897.010.710
Drawing number T.897.000.318

ID Item number Description Technical details Qty

001 960.010.036 Hydraulic pump Hf-b225/0-2000bar 1
002 960.010.623 Adapter 1/4"bsp/9/16"-18un 1
003 960.010.613 Connecting nipple R1/4"/2000 bar 1
004 928.900.130 High pressure hose 2620red-5000 1

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12.14 MUI.814.200981.R01.EN
Appendix: Parts - Lists and drawings (special tools)

Fill ring lifting device

Part list number 897.010.633E
Drawing number T.897.000.244

ID Item number Description Technical details Qty

001 897.050.343 Lifting device 1
002 897.100.808 T-nut 1
003 914.300.047 Ring bolt D580 m20 c15 1
004 862.005.319 Boulon 3
005 917.276.047 Lock washer M20 d7349-st-verz 1
006 914.003.323 Hexagon bolt D931 m16x60 stl 3
007 897.100.819 Plug 1
008 914.003.251 Hexagon bolt D931 m12x120 1
009 915.350.034 Lifting eye nut M12 din582-c15 1

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12.16 MUI.814.200981.R01.EN
Appendix: Parts - Lists and drawings (special tools)

Lifting cover
Part list number 897.010.588J
Drawing number T.897.000.198

ID Item number Description Technical details Qty

001 897.050.262 Hosting tool 1
002 914.106.439 Hexagon screw D933 m24x40stl-glv 2
003 914.300.055 Ring bolt D580 m24 c15 1
004 897.100.633 Disc 1

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12.18 MUI.814.200981.R01.EN
Appendix: Parts - Lists and drawings (special tools)

Hoisting unit
Part list number 897.010.680B
Drawing number T.897.000.365

ID Item number Description Technical details Qty

001 897.101.128 Transport beam 2
002 914.106.397 Hexagon screw D933 m20x30stl-glv 12
003 914.103.402 Hexagon screw D933 m20x55 stl 8
004 915.003.047 Hexagon nut D934 m20 stl 24
005 917.300.047 Lock washer D125a m20 stl 32
006 897.101.129 Transport beam 4
007 914.103.530 Hexagon screw D933 m30x110 stl 16
008 917.300.063 Lock washer D125a m30 stl 16
009 915.003.063 Hexagon nut D934 m30 stl 16
010 914.106.407 Hexagon screw D933m20x80 stl-glv 16

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12.20 MUI.814.200981.R01.EN
Appendix: Electrical information

Pos: 67 /GEHO/Heading/H1/#. Appendix: Electrical information @ 1\mod_1169571364915_31.doc @ 11974

13. Appendix: Electrical information

Pos: 68 /GEHO/General/Attention, Warning and Note/DANGER - Safety - Obey safety instructions and procedures @ 0\mod_1136886637385_31.doc @ 1007

DANGER
Obey the safety instructions.
Obey the working procedures.

Pos: 69 /GEHO/Electrical information/Project/200981 @ 1\mod_1171356736158_31.doc @ 12392

Description Drawing number

Logic diagram S.814.200981.05
Control box and terminal box S.814.200981.06
Electrical installation S.814.200981.07
Motor control circuit S.814.200981.09

Pos: 70 /--- Section break - Odd page --- @ 0\mod_1136277036628_0.doc @ 765

MUI.814.200981.R01.EN 13.1
Appendix: Catalogue information

Pos: 71 /GEHO/Heading/H1/#. Appendix: Catalogue information @ 1\mod_1169571471475_31.doc @ 11978

14. Appendix: Catalogue information

Pos: 72 /GEHO/Catalogue information/Project/200981 @ 1\mod_1166628540967_31.doc @ 11509

Pulsation dampener filling unit (818.080.559AD) T.818.080.183 Refer to

Valve 921.020.062 A

Lubrication unit (828.950.151F) T.828.900.340 Refer to

Electric motor 950.261.862 B
Gear pump 960.020.063 B
Suction filter-element 921.700.832 B
Ball valve 928.860.027 B
Filter housing 921.700.411 B
Filter element 921.700.831 B
Flow sensor 971.600.003 B

Valve unit (831.020.358B) T.831.000.399 Refer to

Acoustic sensor 971.750.000 C

Valve unit (831.020.359B) T.831.000.400 Refer to

Acoustic sensor 971.750.000 C

Diaphragm housing unit (832.010.123L) T.832.000.177 Refer to

Needle valve 921.050.001 D

Frame unit (845.010.461F) T.845.000.461 Refer to

Gate valve 921.150.021 E
Oil glass 948.790.002 E
Filter 921.700.033 E
Ball valve 921.200.026 E

Press. limit. regul. unit (853.010.251F) T.853.000.200 Refer to

Safety valve 921.300.563 F
Needle valve 921.050.001 D

Pressure transmitter unit (855.010.054L) T.855.000.089 Refer to

Pressure transmitter 971.450.074 G
Pressure transmitter 971.450.056 G

MUI.814.200981.R01.EN 14.1
 Appendix: Catalogue information

Pressure transmitter unit (855.010.054L) T.855.000.089 Refer to

Pressure transmitter 971.450.055 G

Propelling liquid unit (857.010.125F) T.857.000.193 Refer to

Electric motor 950.261.082 H
Coupling 814.200981.42 H
Gear pump 960.020.063 B
Filter housing 921.700.411 B
Filter element 921.700.831 B
Hydr. accumulator 973.000.012 H
3/2 way valve 972.200.065 H
3/2 ball valve 928.860.019 H
Flow sensor 971.600.003 B
Level indicator 948.790.105 H
Ball valve 921.200.026 H
Suction filter-element 921.700.832 B

Electrical unit (858.010.117F) T.814.200981.43 Refer to

PLC PLC.200981 I

Pulsation dampener unit (851.010.104F) T.851.000.338 Refer to

Valve 921.020.062 J

Drive unit (814.200981.16) T.814.200981.16 Refer to

Gear box 814.200981.31 K
Coupling (flex.) motor - gearbox RUPEX RWS 400 814.200981.32 L
Coupling pump shaft - gearbox ZAPEX ZWN 545 814.200981.33 M
Electric motor 814.200981.30 N
Frequency converter 814.200981.38 O

Accumulator filling device (897.010.685AN) T.814.200981.27 Refer to

Accumulator fill/control set 973.900.029 P

Hydr. pump-unit (897.010.710) T.897.000.318 Refer to

Hydraulic pump 960.010.036 Q
===== Ende der Stckliste =====

14.2 MUI.814.200981.R01.EN