201333-IOM-EN-R02 TZPM2000-Toromocho - EN PDF

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: weir@weirminerals.com
Registration No.: 12032525 WWW: http://www.weirminerals.com
EN = English "Original instructions"
Installation, Operating and Maintenance Manual
Customer purchase order number: R05323-P-028
Project number - name: 201333 - Toromocho
Pump number: 10201333-1-2-3-4-5-6-7-8-9-10
Pump type: TZPM 2000
Document number: 201333-IOM-EN-R02
Copyright © Weir Minerals Netherlands b.v. 2011.

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
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This pump is developed by Weir Minerals Netherlands b.v.

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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.
Scope of this manual

This manual and its user instructions apply to the GEHO PUMPS equipment during:
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• Transport
• Installation
• Operation, start and stop procedure
• Maintenance
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This equipment, supplied by Weir Minerals Netherlands b.v, 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 b.v is required.
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201333-IOM-EN-R01 1.1
Preface
1.1 Revision form

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Rev. No. Chapter Description By Checked Date
EN = "Original instructions" in English.
EN-R00 Preliminary release JOH FVO 31-05-2010

EN-R01 Final release JOH FVO 11-04-2011
4.5.4
EN-R02 Special Torques JVH FVO 05-12-2013
page13
10.12 / Update Diaphragm Unit (WV 12-0049)
page
30,36,40
10.13/
Update Piston Unit (WV 12-0046)
page 53
11.4 / page
Part List and Drawings
19, 20,24,
(WV12-0048), (WV 12-0049), (WV12-0069),
26-28,
(WV13-0013),(WV 13-0035)
14 / page 3 Update Gearbox documentation
Update Main Motor documentation
Add Synchronization Panel documentation
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1.2 201333-IOM-EN-R02
Contents
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2 Contents
1 Preface ....................................................................................... 1.1

1.1 Revision form ................................................................................................ 1.2
2 Contents..................................................................................... 2.1
3 SAFETY ...................................................................................... 3.1

3.1 Safety symbols .............................................................................................. 3.1
3.2 Important information .................................................................................. 3.2
3.3 Efficient use ................................................................................................... 3.3
3.4 Intended use .................................................................................................. 3.3
3.5 General safety instructions ......................................................................... 3.3
3.6 Qualified workers .......................................................................................... 3.3
3.7 Safe working on the pump........................................................................... 3.3
3.8 Safety equipment .......................................................................................... 3.4
3.8.1 Safety related documentation.................................................................................... 3.4
3.8.2 CE conformity ............................................................................................................ 3.4
3.8.3 "EMERGENCY STOP" button .................................................................................. 3.4
3.8.4 Safety covers and safety guards ............................................................................... 3.5
4 Technical data ........................................................................... 4.1

4.1 Manufacturer 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 and identification .................................................................. 4.2
4.5 Tightening torques ....................................................................................... 4.3
4.5.1 General instructions ................................................................................................... 4.3
4.5.2 General torques ......................................................................................................... 4.3
4.5.3 Foundation bolt torques according to DIN 529 ......................................................... 4.4
4.5.4 Special torques .......................................................................................................... 4.5
4.6 Auxiliary connections and lubrication data ............................................ 4.15
4.7 Drawings + lists + instruments ................................................................. 4.15
5 Description ................................................................................ 5.1

5.1 Introduction ................................................................................................... 5.1
5.2 Working principle .......................................................................................... 5.2
5.2.1 Numbering of the diaphragm housings ..................................................................... 5.2
5.2.2 Typical flow of the GEHO TZPM pump ..................................................................... 5.2
5.2.3 Suction stroke ............................................................................................................ 5.3
5.2.4 Discharge stroke ........................................................................................................ 5.3
201333-IOM-EN-R01 2.1
Contents
5.3 Pump control system ................................................................................... 5.4

5.4 Drive unit ........................................................................................................ 5.4
5.5 Power end ...................................................................................................... 5.4
5.5.1 Lubrication unit ...........................................................................................................5.5
5.6 Liquid end ...................................................................................................... 5.5
5.6.1 The propelling liquid section .......................................................................................5.5
5.6.2 The slurry section .......................................................................................................5.5
5.6.3 Piston unit ...................................................................................................................5.6
5.6.4 Flushing unit ...............................................................................................................5.6
5.6.5 Propelling liquid control system ..................................................................................5.7
5.6.6 Pressure limitation system .......................................................................................5.12
5.6.7 Diaphragm housing unit ...........................................................................................5.13
5.6.8 Suction valve unit .....................................................................................................5.14
5.6.9 Discharge valve unit .................................................................................................5.14
5.6.10 Discharge pulsation dampener ................................................................................5.14
5.6.11 Suction air vessel unit...............................................................................................5.14
6 Transport and installation ........................................................6.1

6.1 Transport and lifting ..................................................................................... 6.1
6.1.1 Weights and weight limits ...........................................................................................6.1
6.2 Erecting the installation ............................................................................... 6.2
6.3 Hoisting instructions .................................................................................... 6.2
6.3.1 General .......................................................................................................................6.2
6.3.2 Lifting eye bolts ...........................................................................................................6.2
6.3.3 Smaller parts...............................................................................................................6.2
6.3.4 Transport the packed installation ...............................................................................6.3
6.3.5 Drive unit .....................................................................................................................6.3
6.3.6 Power end...................................................................................................................6.4
6.3.7 Liquid end ...................................................................................................................6.4
6.4 Installation...................................................................................................... 6.5
6.4.1 Foundation ..................................................................................................................6.5
6.4.2 Mount and level the pump end...................................................................................6.6
6.4.3 Mount and level the fluid end .....................................................................................6.7
6.4.4 Auxiliary systems ........................................................................................................6.9
6.4.5 Drive unit ...................................................................................................................6.10
6.5 Safety regulations and instructions for nitrogen ................................... 6.15
6.6 Pre-charging with nitrogen a pulsation dampener (discharge line) .... 6.16
6.6.1 Pre-charging the discharge pulsation dampener, set-point instructions .................6.16
6.6.2 Pre-charging a pulsation dampener with the nitrogen filling device ........................6.19
6.7 Pre-charging an accumulator with nitrogen ........................................... 6.22
7 Operation, Start-up + Start + Stop procedures ......................7.1

7.1 Start-up, working with the GEHO + VFD 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 an accumulator .....................................................................................7.2
7.1.5 Procedure pre-charging a pulsation dampener with nitrogen ...................................7.2
2.2 201333-IOM-EN-R02
Contents
7.2 Start-up checklist, working with the GEHO 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 + GEHO Pump Control System ...... 7.8
7.4.1 Pump operation by local control at the "GEHO HMI PANEL" .................................. 7.8
7.4.2 Pump operation by remote control, supplied by others ............................................ 7.8
7.5 "START" procedures .................................................................................... 7.9
7.5.1 Operation definitions .................................................................................................. 7.9
7.5.2 "PRE-START" check list .......................................................................................... 7.11
7.5.3 "PRE-START" working with the GEHO and "VFD" main power switch "ON" ........ 7.11
7.5.4 "PRE-START" procedure, if "LOCAL" operated ..................................................... 7.12
7.5.5 "PRE-START" procedure, if "REMOTE" operated ................................................. 7.12
7.5.6 "START" procedure, if "LOCAL" operated .............................................................. 7.13
7.5.7 "START" procedure, if "REMOTE" operated .......................................................... 7.13
7.6 "STOP" procedures .................................................................................... 7.14
7.6.1 "EMERGENCY STOP" procedure .......................................................................... 7.14
7.6.2 "STOP" procedure, if "LOCAL" operated ................................................................ 7.15
7.6.3 "STOP" procedure, if "REMOTE" operated ............................................................ 7.15
7.6.4 "STOP" procedure for flushing ................................................................................ 7.16
7.6.5 "STOP" procedure for maintenance........................................................................ 7.17
7.6.6 "STOP" procedure for "EXTENDED SHUT-DOWN" .............................................. 7.19
8 Maintenance .............................................................................. 8.1

8.1 Maintenance safety instructions................................................................. 8.1
8.2 Maintenance: log book ................................................................................. 8.2
8.3 Maintenance: references ............................................................................. 8.2
8.4 Maintenance: checkpoints of pump drive components .......................... 8.2
8.5 Maintenance: daily checkpoints ................................................................. 8.3
8.6 Maintenance: “Hot torque” after initial start-up ..................................... 8.11
8.7 Maintenance: checkpoints 200 hours after initial start-up.................... 8.12
8.8 Maintenance: interval checkpoints .......................................................... 8.14
8.9 Lubrication system ..................................................................................... 8.21
8.9.1 Check the oil level.................................................................................................... 8.21
8.9.2 Oil filter clogging indicator in the discharge line ...................................................... 8.21
8.9.3 Oil filter clogging indicator in the suction line .......................................................... 8.22
8.10 Propelling liquid system ............................................................................ 8.23
8.10.1 Check the Propelling liquid oil level ......................................................................... 8.23
8.10.2 Oil filter clogging indicator in the discharge line ...................................................... 8.23
9 Troubleshooting........................................................................ 9.1
9.1 Trouble shooting ........................................................................................... 9.1
201333-IOM-EN-R01 2.3
Contents
9.2 Trouble shooting at a diaphragm pulsation dampener ........................... 9.7

9.3 Typical wear phenomena and its causes .................................................. 9.9
9.3.1 Valves .........................................................................................................................9.9
9.3.2 Pump diaphragm ......................................................................................................9.10
9.3.3 Pulsation dampener diaphragm ...............................................................................9.10
9.3.4 Piston ........................................................................................................................9.11
9.3.5 Cylinder liner .............................................................................................................9.11
10 Assembly and disassembly ...................................................10.1

10.1 Safety instructions ...................................................................................... 10.1
10.1.1 Lifting eye bolts .........................................................................................................10.2
10.2 General tightening procedure for flanges and gaskets......................... 10.2
10.3 Manual rotation of the pump crankshaft ................................................. 10.3
10.3.1 Manual rotation and locking of the pump shaft with a socket wrench at the gearbox10.3
10.3.2 Balance position of the TZPM crank shaft ...............................................................10.5
10.4 Special tools ................................................................................................ 10.6
10.4.1 Air driven hydraulic pump .........................................................................................10.6
10.4.2 Oil connector caps ....................................................................................................10.6
10.5 Drive unit ...................................................................................................... 10.7
10.6 Frame unit .................................................................................................... 10.7
10.7 Lubrication system ..................................................................................... 10.7
10.7.1 Environment instructions ..........................................................................................10.7
10.7.2 Replace the oil filter element in the discharge line...................................................10.8
10.7.3 Replace the oil filter element in the suction line .......................................................10.9
10.7.4 Replace the pump lubrication oil ..............................................................................10.9
10.7.5 Replace the venting filter at the pump power end ...................................................10.9
10.8 Propelling liquid drain .............................................................................. 10.10
10.8.1 Environment instructions ....................................................................................... 10.10
10.8.2 Propelling liquid drain preparation......................................................................... 10.10
10.8.3 Propelling liquid drain procedure........................................................................... 10.10
10.9 Propelling liquid system .......................................................................... 10.13
10.9.1 Environment instructions ....................................................................................... 10.13
10.9.2 Replace the propelling liquid and the filters .......................................................... 10.13
10.9.3 Replace the oil filter element in the discharge line................................................ 10.14
10.9.4 Disassemble the suction filter at the propelling liquid tank ................................... 10.15
10.9.5 Assemble the suction filter at the propelling liquid tank ........................................ 10.15
10.9.6 Replace the venting filter at the propelling liquid system ...................................... 10.15
10.9.7 2/2 way valves: inspection and preservation ........................................................ 10.16
10.10 Gearbox maintenance .............................................................................. 10.17
10.11 Valves, discharge line and suction line, angular model ...................... 10.18
10.11.1 Valve housing cover .............................................................................................. 10.18
10.11.2 Conical valve ......................................................................................................... 10.20
10.11.3 Valve seat .............................................................................................................. 10.21
10.11.4 Valve guide bush ................................................................................................... 10.26
10.11.5 Valve disk assembly .............................................................................................. 10.27
10.12 Diaphragm housing unit .......................................................................... 10.28
2.4 201333-IOM-EN-R02
Contents
10.12.1 Disassembly .......................................................................................................... 10.28

10.12.2 Cleaning after diaphragm leakage or damage or contamination ......................... 10.32
10.12.3 Assembly ............................................................................................................... 10.36
10.12.4 De-aerating the propelling liquid chamber ............................................................ 10.43
10.13 Piston unit .................................................................................................. 10.44
10.13.2 Disassembly .......................................................................................................... 10.44
10.13.3 Disassembling the piston unit................................................................................ 10.45
10.13.4 Replace procedure for the dust cover rings .......................................................... 10.48
10.13.5 Assembly ............................................................................................................... 10.50
10.13.6 Assembling the piston unit..................................................................................... 10.50
10.13.7 Disassembly and assembly glores cooling jacket................................................. 10.53
10.14 Pulsation dampener ................................................................................. 10.54
10.14.1 Safety instructions ................................................................................................. 10.54
10.14.2 Remove the diaphragm ......................................................................................... 10.55
10.14.3 Assemble the diaphragm....................................................................................... 10.56
10.14.4 Assemble the cover ............................................................................................... 10.60
10.15 Nitrogen filling device .............................................................................. 10.61
11 Appendix: Parts - Lists and drawings (pump section) ....... 11.1

11.1 Safety instructions for parts ...................................................................... 11.1
11.2 Ordering parts ............................................................................................. 11.1
11.3 General the handling and storage conditions ........................................ 11.1
11.3.1 Refer to the handling and storage instructions with the packing ............................ 11.1
11.3.2 General instructions ................................................................................................. 11.1
11.3.3 Storage of synthetic materials ................................................................................. 11.1
11.4 Part List and drawings ............................................................................... 11.3
12 Appendix: Parts - Lists and drawings (special tools)......... 12.1

12.1 Safety instructions for parts ...................................................................... 12.1
12.2 Ordering parts ............................................................................................. 12.1
12.3 Special tools ................................................................................................ 12.3
13 Appendix: Electrical information .......................................... 13.1
14 Appendix: Catalogue information ......................................... 14.1
15 Appendix: PLC Software (electronic format) ....................... 15.1

201333-IOM-EN-R01 2.5
SAFETY
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3
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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 most 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 Note for application hints No signal word indicating a dangerous

Information and other useful information or harmful situation
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201333-IOM-EN-R01 3.1
SAFETY
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3.2 Important information

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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,
then 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 201333-IOM-EN-R02
SAFETY
3.3 Efficient use

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• Apply correct and regular maintenance, according to these manual instructions.

• Always use genuine GEHO spare parts and wear parts.
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3.4 Intended use

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This pump (and/or the pump system components) 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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3.5 General safety instructions

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DANGER
1 Always obey local legislation and local safety regulations and instructions.
2 Never cause a potentially dangerous situation.
3 Never touch moving parts.
4 Never loosen parts under pressure.
5 Never touch parts with high temperature.
6 Never touch parts under electrical power.
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7 Never touch parts which contain dangerous or poisonous media.
3.6 Qualified workers

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• 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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3.7 Safe working on the pump

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• Make sure to be aware of all related safety warnings and instructions and procedures.
• Make sure to be aware of all other parts of the equipment, which are related and involved in securing the
working zone and the equipment.
• Always use personal protective equipment during assembly and disassembly work on the pump.
General working instructions
• Before starting works on the machinery, switch off the involved power supply of that part of the machinery
and secure the equipment against switching on.
• Never loosen any parts that contain pressure or hot or dangerous fluids or gasses.
• Never loosen any parts that are still under mechanical stress.
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201333-IOM-EN-R01 3.3
SAFETY
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3.8 Safety equipment

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3.8.1 Safety related documentation

DANGER
If applicable, then refer to the book "MANUFACTURING DATA RECORDS" ("MDR")
of this pump for the documentation about CE conformity
(as defined by the European "Directive on machinery 98/37/EC and 2006/42/EC")
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and other required safety related documentation.
3.8.2 CE conformity
DANGER
If failing to install and maintain the SAFETY EQUIPMENT in accordance with this manual,
then the installation is no longer in CE-conformity (as defined by the European
"Directive on machinery 98/37/EC and 2006/42/EC") and thus results in:
"... machinery must not be put into service until the final machinery into which it is to be
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incorporated has been declared in conformity with the provisions of this Directive ..."
3.8.3 "EMERGENCY STOP" button

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CE conformity
DANGER
If failing to install and maintain the "EMERGENCY STOP" button equipment in accordance
with this manual,
then the installation is no longer in CE-conformity (as defined by the European "Directive on
machinery 98/37/EC and 2006/42/EC") and thus results in:
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Functional requirements
Refer for the "Emergency stop" procedure to the document "DESCRIPTION OF THE PUMP CONTROL
SYSTEM" in chapter "Technical data".
Operation and procedure
Refer to chapter "Start and Stop procedure" for details about the use of the "EMERGENCY STOP" button.
Safety and legal requirements
An emergency stop button must be provided, according to the CE regulations and according to the local
regulations. The customer must assure this.
It is mandatory to install at least one "EMERGENCY STOP" button, within a short distance of the pump /
machinery / equipment / components / 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.
3.4 201333-IOM-EN-R02
SAFETY
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 manufacturer’s scope of supply,
then an emergency stop will not be added, due to lack of MCC configuration information.
Pos : 5.24 /GEHO/Heading/H 3/#.#.# Safety c overs and s afety g uar ds @ 0\mod_1137486661628_31.doc @ 1247 @ 555
3.8.4 Safety covers and safety guards

Pos : 5.25 /GEHO/Safety/Pr oduct Safety Pump/Safety covers and s afety g uar ds #ins tall ed @ 0\mod_1137486711069_31.doc @ 1249 @ 3
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.
201333-IOM-EN-R01 3.5
SAFETY
3.6 201333-IOM-EN-R02
Technical data
Pos : 7 /GEH O/H eadi ng/H1/#. Technic al data @ 0\mod_1133269719867_31.doc @ 179 @
4 Technical data
Pos : 8.1 /GEH O/H eading/H 2/#.# M anufac tur er infor mation @ 0\mod_1133443515208_31.doc @ 288 @
4.1 Manufacturer information

Pos : 8.2 /GEH O/T ec hnic al data sheets/Proj ect infor mation-EN @ 0\mod_1133439392901_31.doc @ 273 @
WEIR Project information

WEIR Project name Toromocho
WEIR Project number 201333
Customer purchase order number R05323-P-028
Pos : 8.3 /GEH O/H eading/H 2/#.# C ustomer infor mation @ 0\mod_1133443655420_31.doc @ 291 @
4.2 Customer information

Pos : 8.4 /GEH O/T ec hnic al data sheets/Proj ect/201333/Customer i nformati on @ 9\mod_1274773201796_31.doc @ 67724 @
Purchaser information
Name Minera Chinalco Peru S.A.
Purchaser address/bills Av. Santo Toribio 143, Piso 4
San Isidro
Lima 27, Peru
Application information
Site Toromocho site, Peru
Application Tailings slurry
Pos : 8.5 /GEH O/H eading/H 2/#.# M anufac tur er infor mation @ 0\mod_1133443515208_31.doc @ 288 @
4.3 Manufacturer information

Pos : 8.6 /GEH O/T ec hnic al data sheets/M anufac tur er infor mation EN @ 0\mod_1133272928581_31.doc @ 221 @
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 weir@weirminerals.com
Website, internet http://www.weirminerals.com
Department Installation, Commissioning
Phone (+31) 77-3895141
Fax (+31) 77-3824844: V. van der Koelen
Department Spare Parts
Phone (+31) 77-3895236
Fax (+31) 77-3824844: R. Reijnders
Pos : 8.7 /--- Page br eak --- @ 0\mod_1136278659331_0.doc @ 766 @
201333-IOM-EN-R01 4.1
Technical data
Pos : 8.8 /GEH O/H eading/H 2/#.# T ec hnic al data @ 0\mod_1133270813820_31.doc @ 198 @
4.4 Technical data

Pos : 8.9 /GEH O/H eading/H 3/#.#.# Operating c haracteristics @ 0\mod_1133443294151_31.doc @ 286 @
4.4.1 Operating characteristics

Pos : 8.10 /GEHO/Technic al data s heets/Proj ect/201333/Oper ation charac teristic s refer to PD S @ 9\mod_1274773203921_31.doc @ 67758 @
Refer to document PDS.201333 "PUMP DATA SHEET" in chapter "Technical data.

Pos : 8.11 /GEHO/Heading/H 3/#.#.# Pump and proj ect data and i denti ficati on @ 0\mod_1133444066872_31.doc @ 292 @
4.4.2 Pump and project data and identification

Pos : 8.12 /GEHO/Technic al data s heets/Proj ect/201333/GEHO PUMPS data @ 9\mod_1274773202531_31.doc @ 67736 @ 3
Refer for the allowable operating performance and conditions also to the GEHO pump identification plate.
GEHO pump Refer to document PDS.201333 "PUMP DATA SHEET".

Pump No. 101333/1, 101333/2, 101333/3, 101333/4, 101333/5,
see GEHO PUMPS identification plate 101333/6, 101333/7, 101333/8, 101333/9, 101333/10
Pump Type TZPM 2000
see GEHO PUMPS identification plate
Capacity 655.25 m3/h
Operating discharge pressure 8100 kPa (phase 1)
Stroke rate (stroke cycles per minute of a piston) 50.7 s/min
see GEHO PUMPS identification plate:
n (s/min)
Required power 1568 kW (phase 1)
Proj. 814.201333
Date 2010
Refer to the document PDS.201333 "PUMP DATA SHEET"

in chapter "Drawings + lists + instruments" for details about:
• the site conditions,
• the slurry conditions,
• the pump performance data,
• the drive components.
Refer for details also to:

- Document 814.201333.00 "DIMENSIONED OUTLINE DRAWING" in chapter "Instruments and drawings".
- Document 814.201333.02 "INSTRUMENT AND EQUIPMENT LIST" in chapter "Instruments and drawings".
- Document 814.201333.03 "P&I DIAGRAM TPZM 2000" in chapter "Instruments and drawings".
- Chapter "Electrical information".
- Chapter "Catalogue information".
Pos : 8.13 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 @
4.2 201333-IOM-EN-R02
Technical data
Pos : 8.14 /GEHO/Heading/H 4/C onnecti on - El ectric al @ 0\mod_1133446672849_31.doc @ 306 @
4.4.2.1 Electrical connection

Pos : 8.15 /GEHO/Technic al data s heets/Voltage/Peru 4000/60/3 - 380/60/3 - 220/60/1 @ 9\mod_1274787438609_31.doc @ 67789 @
Item Voltage [V] Frequency [Hz] Phases

Main drive 4000 60 3
Auxiliary motors 380 60 3
Control panel 220 60 1
Pos : 8.16 /GEHO/Heading/H 4/Pump dri ve @ 0\mod_1133448795551_31.doc @ 321 @
4.4.2.2 Pump drive

Pos : 8.17 /GEHO/Technic al data s heets/M ain E- motor/R efer to the "Pump Data Sheet" . @ 4\mod_1214554063015_31.doc @ 36605 @
Main E-motor Refer to the document "Pump Data Sheet".

Pos : 8.19 /GEHO/Heading/H 2/#.# Tightening torques @ 0\mod_1133269909891_31.doc @ 183 @
4.5 Tightening torques

Pos : 8.20.1 /GEHO/Heading/H 3/#.#.# Gener al ins truc tions @ 7\mod_1248334427435_31.doc @ 52981 @
4.5.1 General instructions

Pos : 8.20.2 /GEHO/Technical data s heets/Gener al torques/Cl ean and greas e all @ 7\mod_1248334260103_31.doc @ 52990 @
Before assembly of a threaded connection:

• Clean and grease all the threaded sections with a suitable grease.
This accomplishes:
• Proper tightening a prescribed tightening torque.
• Easy assembly and disassembly.
• Preventing corrosion of the threaded sections.
Pos : 8.20.3 /GEHO/Heading/H 3/#.#.# Gener al torques @ 0\mod_1133270125801_31.doc @ 190 @
4.5.2 General torques

Pos : 8.20.4 /GEHO/Technical data s heets/Gener al torques/General torques R 03 grade 8.8 + 10.9 N m @ 10\mod_1286972418734_31.doc @ 72393 @
Size Torque [Nm] Torque [Nm]

property classes, grade 8.8 property classes, grade 10.9
M8 20 25
M10 40 55
M12 70 95
M16 165 230
M20 320 455
M24 550 785
M27 810 1140
M30 1120 1565
M33 1505 2120
M36 1930 2710
M39 2490 3500
M42 3090 4345
M45 3870 5445
M48 4700 6610
M52 6050 8510
Pos : 8.21.1 /GEHO/Heading/H 3/#.#.# F oundati on bolt torques accor ding to D IN 529 @ 0\mod_1133863490701_31.doc @ 397 @
201333-IOM-EN-R01 4.3
Technical data
4.5.3 Foundation bolt torques according to DIN 529

Pos : 8.21.2 /GEHO/Technical data s heets/Gener al torques/F oundation bol t torques - grade 4.6 N m @ 10\mod_1286973259140_31.doc @ 72415 @ 3
General = grade 4.6
Size Torque [Nm] Size Torque [Nm]

M20 120 M33 565
M24 210 M36 725
M27 305 M39 935
M30 420 M42 1160
4.4 201333-IOM-EN-R02
Technical data
Pos : 8.23.1 /GEHO/Heading/H 3/#.#.# Special torques @ 0\mod_1133270014401_31.doc @ 187 @
4.5.4 Special torques

Pos : 8.23.2 /GEHO/Technical data s heets/Speci al torques /INF O - Posi tion numbers @ 1\mod_1166014236919_31.doc @ 9320 @
INFORMATION
Position numbers specified in the list must be ignored,
if they are not listed in the corresponding parts list.
Pos : 8.23.3 /GEHO/Technical data s heets/Speci al torques /Disc harge val ve unit/H.831.020.426 @ 11\mod_1290595563015_31.doc @ 73982 @
Discharge valve unit - 831.020.426

Pos : 8.23.4 /GEHO/Technical data s heets/Speci al torques /A- Specific ati on/A.807.005.176 val ve discharge- hydr-in steps + housi ng_nut @ 12\mod_1301986688859_31.doc @ 84723 @
Step A.807.005.176 Part list ID Torque [Nm] Pressure kPa Rev.

Valve ring lock nut 013/010/011 300
Connecting nipple / adapter 026 / 027 50
Adapter / housing 027 / 001 50
Cap screw for clamping piece 041 / 015 60
Use "LOCTITE" LT243.
Nut stud bolt valve housing / 051 /050 2750
Discharge pipeline
Valve Housing: tightening procedure
1. Clean all sealing surfaces.

2. Place the valve housing and 017 / 001
gasket on the diaphragm
housing. Align the stud bolt and
the valve housing.
3. Tighten the fixation nut of the 023 50
valve housing. Tighten all the nuts to
the valve housing,
use the pin.
4. Make sure that the tap of the bolt 043
is equal to the bottom of the
valve cover.
5. Tighten the strain nut and lock 019 / 020 / Tighten the strain nut
nut to the stud bolt and tension 017 / 009 and tension ring metal
ring. to metal.
Attention:
020 / 019 Make sure that there is
a metal to metal contact
between the strain nut
and lock nut.
6. Tighten the strain-nut to the 020 / 009 400
tension ring.
Attention:
018 Make sure that the
pistons are equal to the
top of the tension ring.
7. Pressurize the hydraulic pump, 009 / 018 Attention: 50 000
this actuates the pistons. The pistons may (500 bar)
protrude up to 4 mm
above the tension ring.
the valve housing,
use the pin.
201333-IOM-EN-R01 4.5
Technical data

tension ring.
018 Attention:
Make sure that the
10. De-pressurize the pistons. 018 0
tension ring.
018 Attention:
Make sure that the
12. Pressurize the hydraulic pump, 003 Attention: 100 000
this actuates the pistons 018 The pistons may (1000 bar)
protrude up to 4 mm
the valve housing,
use the pin.
tension ring
018 Attention:
Make sure that the
protrude up to 4 mm
the valve housing,
use the pin.
Tension ring: tightening procedure
tension ring Attention:
Make sure that there is
between the valve
housing and tension
ring
2. Pressurize the hydraulic pump, 026 / 027 125 000
this actuates the pistons 018 (1250 bar)
3. Lock-nut at the tension ring 019 / 009 400
4. De-pressurize the hydraulic 0
pump
4.6 201333-IOM-EN-R02
Technical data

Tension ring: removal procedure
2. Loosen the lock-nut at the 019 / 009 400 (minimum)
tension ring
Attention:
Turn the lock nut
upwards. Make sure
that there is a metal to
metal contact between
strain nut and lock nut.
3. De-pressurize the pistons 018 0
4. Loosen the tension nut 020 400 (minimum)
Valve Housing: removal procedure
valve cover.
2. Make sure that the pistons are 018
equal to the top of the tension
ring.
3. Turn the lock nut upwards to the 019 / 020 Make sure that there is
strain nut. a metal to metal contact
between strain nut and
lock nut.
4. Screw the strain nut on the stud 020 / 018 Attention:
bolt. Leave a gap of 2 mm
pistons.
6. Loosen the fixation nut of the 023 Attention:
valve housing. Screw the fixation nut at
least 4 mm upwards.
7. Release the pressure until: 018 100 000
(1000 bar)
the valve housing,
use the pin.
10. Screw the strain nut upward 020 / 018 Attention:
Leave a gap of 2 mm
pistons.
least 4 mm upwards.
(500 bar)
201333-IOM-EN-R01 4.7
Technical data

the valve housing,
use the pin.
Leave a gap of 2 mm
pistons.
least 4 mm upwards.
Pos : 8.23.5 /GEHO/Technical data s heets/Speci al torques /Sucti on val ve unit/H .831.020.427 @ 11\mod_1290595756015_31.doc @ 73993 @
Valve unit = 831.020.427

Pos : 8.23.6 /GEHO/Technical data s heets/Speci al torques /A- Specific ati on/A.807.005.177 val ve s ucti on- hydr-in steps + housi ng_nut @ 12\mod_1302082126484_31.doc @ 84862 @

Valve ring lock nut 013/010/011 300
Connecting nipple / adapter 026 / 027 50
Adapter / housing 027 / 001 50
Cap screw for clamping piece 041 / 015 60
Use "LOCTITE" LT243.
Nut stud bolt valve housing / 051 /050 2750
Discharge pipeline
Valve Housing: tightening procedure
1. Clean all sealing surfaces.

2. Tighten the cap screw to the stud 055 / 017 Attention:
bolt Do this until the stud
bolt end hits the cap
screw bottom. Make
sure that the spigot of
the nut sizes well in the
valve housing.
the valve housing,
use the pin.
Attention:
Make sure that the
spigot of the nut sizes
well in the valve
housing.
valve cover.
5. Tighten the strain nut and lock 019 / 020 / Tighten the strain nut
nut to the stud bolt and tension 017 / 009 and tension ring metal
ring. to metal.
4.8 201333-IOM-EN-R02
Technical data

Attention:
020 / 019 Make sure that there is
between the strain nut
and lock nut.
tension ring.
Attention:
018 Make sure that the
7. Pressurize the hydraulic pump, 009 / 018 Attention: 50 000
this actuates the pistons. The pistons may (500 bar)
protrude up to 4 mm
the valve housing,
use the pin.
tension ring.
018 Attention:
Make sure that the
tension ring.
018 Attention:
Make sure that the
protrude up to 4 mm
the valve housing,
use the pin.
tension ring
018 Attention:
Make sure that the
protrude up to 4 mm
the valve housing,
201333-IOM-EN-R01 4.9
Technical data

use the pin.
Tension ring: tightening procedure
tension ring Attention:
Make sure that there is
between the valve
housing and tension
ring.

3. Lock-nut at the tension ring 019 / 009 400
4. De-pressurize the hydraulic 0
pump
Tension ring: removal procedure
2. Loosen the lock-nut at the 019 / 009 400 (minimum)
tension ring
Attention:
Turn the lock nut
upwards. Make sure
that there is a metal to
metal contact between
strain nut and lock nut.
4. Loosen the tension nut 020 400 (minimum)
Valve Housing: removal procedure
valve cover.
2. Make sure that the pistons are 018
equal to the top of the tension
ring.
3. Turn the lock nut upwards to the 019 / 020 Make sure that there is
strain nut. a metal to metal contact
lock nut.
4. Screw the strain nut on the stud 020 / 018 Attention:
bolt. Leave a gap of 2 mm
pistons.
least 4 mm upwards.
4.10 201333-IOM-EN-R02
Technical data

(1000 bar)
the valve housing,
use the pin.
Leave a gap of 2 mm
pistons.
least 4 mm upwards.
(500 bar)
the valve housing,
use the pin.
Leave a gap of 2 mm
pistons.
least 4 mm upwards.
Pos : 8.23.7 /GEHO/Technical data s heets/Speci al torques /Diaphrag m housing unit/H.832.010.324 @ 11\mod_1290596067500_31.doc @ 74006 @
201333-IOM-EN-R01 4.11
Technical data
Diaphragm housing unit - 832.010.324

Pos : 8.23.8 /GEHO/Technical data s heets/Speci al torques /A- Specific ati on/A.807.005.179+A.807.005.175 Di aphr agm housi ng+unit-hydr. @ 11\mod_1291211931890_31.doc @ 79276 @
A.807.005.179 Part list ID Torque [Nm] Pressure [kPa]

Monitoring rod / diaphragm 015/019 140
Use "LOCTITE
NUTLOCK 243"
Bearing bush in clamping bush 018 Use "LOCTITE
NUTLOCK 243"
Nut connection Diaphragm Housing to 046/038 2800
Suction Elbow
Nut connection of corner + middle pieces 047/039 2300
to diaphragm housings
Nut connection blind flange suction elbow 089/090 500

Use the special tool: Use pin ID 013 Use the hydraulic
"HYDR. DIAPHR. COVER pump
MOUNTING" T.897.000.471
Blind plug, after de-aerating the tool 011 50
Assembly procedure: Refer to the parts
Diaphragm housing cover nuts list of the cover.
1 Pressurize with the hydraulic tool. 045 Pre-tighten the 120 000 kPa
nuts with the pin 17 400 psig
2 De-pressurize the hydraulic tool. 0 kPa
3 Pressurize with the hydraulic tool. 045 Final-tighten the 120 000 kPa
nuts with the pin 17 400 psig
Disassembly procedure: Refer to the parts
Diaphragm housing cover nuts list of the cover.
1 Pressurize with the hydraulic tool. 045 Loosen the nuts 120 000 kPa
with the pin 17 400 psig
Pos : 8.23.9 /GEHO/Technical data s heets/Speci al torques /Pis ton unit/H.835.0963.230 @ 11\mod_1291275518515_31.doc @ 79293 @
4.12 201333-IOM-EN-R02
Technical data
Piston unit - 835.0963.230

Pos : 8.23.10 /GEH O/T ec hnic al data s heets /Special torques/A-Specific ation/A.807.005.168 Pis ton unit mech. @ 11\mod_1291275772859_31.doc @ 79306 @
Figure 4.1: Figur e 4.2: Fig ure 4.3: Figure 4.4: Figure 4.5:
A.807.005.168 Piston unit Part list ID Torque [Nm] Pressure [kPa]

Piston unit lock nut 008 1600
Use "LOCTITE 243"
Capscrew Thrust piece / Cylinder liner 026 50
Nut Thrust piece / Glores manifold 027 900
Nut Connection piece / Adapter flange 028 1100
Nut Adapter flange / Piston rod 035 1200

Use "LOCTITE 243"
Nut Stud bolt (corner and middle pieces) 037 450 For the exact
/ Threaded flange sequence ( 1 to 12)
see attached figure.
Nut stud bolt (Glores manifold) / 033 30% = 1600 For the exact
Threaded flange 60% = 3200 sequence ( 13 to 22)
100% = 5400 see attached figure.
Do this for each turn.
Pos : 8.23.11 /GEH O/T ec hnic al data s heets /Special torques/Pulsation damper unit/H .851.010.135= 150/160 @ 10\mod_1285753922671_31.doc @ 72075 @
"PULSATION DAMPER UNIT 150/160" = 851.010.135

Pos : 8.23.12 /GEH O/T ec hnic al data s heets /Special torques/A-Specific ation/A.807.005.148=150/160 puls.damp. @ 10\mod_1285762083312_31.doc @ 72118 @

Valve 007 Use "LOCTITE 542"
Pulsation damper flange screw 013 1800
Pulsation damper cover nut 014 3600
Pos : 8.23.13 /GEH O/T ec hnic al data s heets /Special torques/Propelling liquid unit/H .857.010.174 @ 11\mod_1291300446531_31.doc @ 79320 @
Propelling liquid unit: 857.010.174

Pos : 8.23.14 /GEH O/T ec hnic al data s heets /Special torques/A-Specific ation/A.807.005.174 propelling liqui d uni t - Aquasens or @ 11\mod_1291357711562_31.doc @ 79354 @

Tighten aqua-sensor 058 25 - 30
Pos : 8.23.15 /GEH O/T ec hnic al data s heets /Special torques/Speci al tools/H.897.010.789 @ 11\mod_1291358863750_31.doc @ 79369 @
201333-IOM-EN-R01 4.13
Technical data
Special tool: 897.010.789 , drawing T.897.000.279

= "ASS.VALVE SEAT TOOL" (valve seat pulling tool)
Pos : 8.23.16 /GEH O/T ec hnic al data s heets /Special torques/A-Specific ation/A.807.005.220 adapter/ni ppl e @ 11\mod_1293022914265_31.doc @ 79673 @

Adapter / Connecting Nipple 009 / 008 50
(Adapter / Connecting Nipple) / Cylinder (009 / 008) / 004 50
Assemble the valve seat. Use the hydraulic jack. 005 / 006 / 007 / 40 000
((009 / 008) /
004)
Disassemble the valve seat. Use the hydraulic jack. 005 / 006 / 007 / Maximum of
((009 / 008) / 200 000
Pos : 8.23.17 /GEH O/T ec hnic al data s heets /Special torques/Speci al tools/H.897.010.780-hydr.pump, dr awing T.897.000.318 @ 11\mod_1294049492640_31.doc @ 79706 @
004)
Special tool: "HYDRAULIC PUMP UNIT" = 897.010.780, drawing T.897.000.318

Pos : 8.23.18 /GEH O/T ec hnic al data s heets /Special torques/A-Specific ation/A.807.004.622 H ydr.pump-imp 200 M PA @ 0\mod_1143217678540_31.doc @ 2882 @
A.807.004.622 Part list ID Torque Pressure

Adapter / connecting nipple 002 / 003 50 Nm
37 LB-FT
Hydraulic unit, with hose 002 / 003 maximum
200 000 kPa
2 000 bar
29 000 psig
WARNING: 002 / 004 Non
NEVER pressurize the pump,
if it is not connected with the hose to a tool.
For this can damage the sealing ring at the quick
release connectors ("nipples").
4.14 201333-IOM-EN-R02
Technical data
Pos : 8.25 /GEHO/Heading/H 2/#.# Auxiliar y c onnections and Lubricati on data @ 0\mod_1137667733207_31.doc @ 1351 @
4.6 Auxiliary connections and lubrication data

Pos : 8.26 /GEHO/Technic al data s heets/R efer to Utility c ons umption list @ 0\mod_1148974052988_31.doc @ 4381 @
Refer to the document “UTILITY CONSUMPTION LIST” for more information about auxiliary connections
and lubrication data.
Pos : 8.27 /GEHO/General /Attenti on, Warni ng and Note/Informati on - Chec k lubricant @ 0\mod_1143532829375_31.doc @ 2934 @
INFORMATION
Depending on the oil condition the changing intervals can differ substantially.
• Check the oil regularly for contamination and chemical properties by an authorized
laboratory.
• Always keep reserve oil in stock.
Pos : 8.28 /GEHO/Heading/H 2/#.# Drawi ngs+Lis ts+Instruments @ 0\mod_1133876951146_31.doc @ 421 @
4.7 Drawings + lists + instruments

Pos : 8.29 /GEHO/Technic al data s heets/Proj ect/201333/Instrument and drawi ngs @ 9\mod_1274773203312_31.doc @ 67745 @ 2
Drawings and lists

PDS.201333 "PUMP DATA SHEET"
814.201333.00 "DIMENSIONED OUTLINE DRAWING"
814.201333.01 "FOUNDATION DRAWING"
814.201333.02 "INSTRUMENT LIST"
814.201333.03 "P & I DIAGRAM"
V.814.201333.15 "PACKING UNIT"
814.201333.19 "UTILITY CONSUMPTION LIST"
814.201333.20 "DESCRIPTION OF PUMP CONTROL SYSTEM"
814.2TZPM.24 "TYPICAL MANUAL OF THE GEHO TOUCH PANEL"
814.200000.04 "FLUSHING/FILLING/DRAIN CONNECTIONS"
STO.201333 "STORAGE REQUIREMENTS"
MI.093701 "INSTRUCTION FOR LUBRICATION OIL MONITORING & SAMPLING
201333-IOM-EN-R01 4.15
Description
Pos : 10.1 /GEHO/Heading/H 1/#. D escri ption @ 0\mod_1134483846926_31.doc @ 448 @
5
Pos : 10.2.1 /GEHO/Heading/H 2/#.# Intr oducti on @ 0\mod_1144834888602_31.doc @ 3092 @
Description
5.1 Introduction
Pos : 10.2.2 /GEHO/Des cripti on/Introducti on/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 sludge’s, slurry and mud, particularly where abrasive or aggressive
materials are involved.
Pos : 10.2.3 /GEHO/Des cripti on/Introducti on/Diaphr agm 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.
This enables to use low-wear components to pump at high pressure a solids containing liquid or slurry.
Pos : 10.2.4 /GEHO/Des cripti on/Introducti on/Wearing and repl acement parts @ 0\mod_1134635894018_31.doc @ 574 @
The wearing parts and replacement parts are easily accessible for inspection and repair.
Pos : 10.2.5 /GEHO/Heading/H 4/Wearing parts @ 0\mod_1134635462418_31.doc @ 560 @
5.1.1.1 Wearing parts

Pos : 10.2.6 /GEHO/Des cripti on/Introducti on/Wearing parts : D efini tion @ 0\mod_1134639095462_31.doc @ 580 @
Wearing parts are parts subject to exchange regularly.

Pos : 10.2.7 /GEHO/Des cripti on/Introducti on/Wearing parts : List @ 0\mod_1134635624621_31.doc @ 570 @
These are:
• Suction valve
• Discharge valve
Pos : 10.2.8 /GEHO/Heading/H 4/R epl ac ement parts @ 0\mod_1134635502866_31.doc @ 564 @
5.1.1.2 Replacement parts

Pos : 10.2.9 /GEHO/Des cripti on/Introducti on/Replac ement parts : D efi nition @ 0\mod_1134639331822_31.doc @ 582 @
Replacement parts are parts subject to be replaced, if required.

Pos : 10.2.10 /GEH O/D escri ption/Introduc tion/R epl ac ement parts: Lis t @ 0\mod_1134635786604_31.doc @ 572 @
These are:
• Pump diaphragm
• Pulsation dampener diaphragm
Pos : 10.2.11 /GEH O/H eadi ng/H4/Non- wearing par ts @ 0\mod_1134635392998_31.doc @ 555 @
5.1.1.3 Non-wearing parts

Pos : 10.2.12 /GEH O/D escri ption/Introduc tion/TZ PM/N on- wearing parts @ 0\mod_1134634939436_31.doc @ 554 @
• Piston
• Piston rod
• Piston seal rings
• Cylinder liner
201333-IOM-EN-R01 5.1
Description
Pos : 10.4.1 /GEHO/Heading/H 2/#.# Wor ki ng pri ncipl e @ 0\mod_1135000311087_31.doc @ 611 @
5.2 Working principle

Pos : 10.4.2 /GEHO/Des cripti on/Wor ki ng principl e/TZ PM/TZ PM gener al @ 6\mod_1234867089317_31.doc @ 47582 @
5.2.1 Numbering of the diaphragm housings
Figure 5.1:
5.2.2 Typical flow of the GEHO TZPM pump

Each single acting piston moves the propelling
liquid to drive the connected diaphragm,
which then pumps the slurry.
With 1 revolution of the crankshaft,

3 pistons make in total
3 diaphragm suction strokes and
3 diaphragm discharge strokes.
The total pump flow is the combined flow from

the 3 diaphragm housings.
Figure 5.2: Typical flow of a GEHO TZPM pump
The 3 pistons follow each other at 120° degree
crankshaft angle, as represented in the figure.
Pos : 10.4.3 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 @
5.2 201333-IOM-EN-R02
Description
Pos : 10.4.4 /GEHO/Des cripti on/Wor ki ng principl e/TZ PM/Suc tion str oke @ 0\mod_1134999056904_31.doc @ 606 @
5.2.3 Suction stroke

The piston (A) moves backward and
decompresses the propelling liquid (B).
The diaphragm (F) moves backward.
The resulting low pressure in the slurry
chamber (E) forces
• the discharge valve (G) to close,
• the suction valve (C) to open.
The slurry fills the slurry chamber (E) of the
diaphragm housing unit through the suction
line (D).
Figure 5.3: Working principle: Suction stroke

(The figure shows a general schematic arrangement,
applicable for more versions.)
Pos : 10.4.5 /GEHO/Des cripti on/Wor ki ng principl e/TZ PM/Disc harge str oke @ 0\mod_1134999494473_31.doc @ 608 @ 3
5.2.4 Discharge stroke

The piston (A) moves forward and compresses
the propelling liquid (B).
The diaphragm (F) moves forward.
The resulting high pressure in the slurry
chamber (E) of the diaphragm housing unit
forces
• the suction valve (C) to close,
• the discharge valve (G) to open.
The slurry leaves the slurry chamber (E) through
the discharge line (H).
Figure 5.4: Working principle: Discharge stroke

201333-IOM-EN-R01 5.3
Description
Pos : 10.6.1 /GEHO/Heading/H 2/#.# Pump c ontrol s ystem @ 0\mod_1134569924544_31.doc @ 510 @
5.3 Pump control system

Pos : 10.6.2 /GEHO/Des cripti on/Pump c ontr ol s ystem/Pump c ontrol s ystem @ 0\mod_1135075605523_31.doc @ 701 @
The pump control system monitors and controls the operation.

The pump control system includes:
• GEHO HMI PANEL (HMI = "Human Machine Interface").
• A PLC (Programmable Logic Controller).
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 GEHO HMI+PLC 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 : 10.7.1 /GEHO/Heading/H 2/#.# Dri ve unit @ 0\mod_1134483988099_31.doc @ 452 @
5.4 Drive unit

Pos : 10.7.2 /GEHO/Des cripti on/Drive unit/Gearbox type @ 0\mod_1134639813244_31.doc @ 584 @
• The main electric 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 electric 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 : 10.8 /GEHO/Heading/H 2/#.# Power end @ 0\mod_1134484023820_31.doc @ 454 @
5.5 Power end

Pos : 10.9 /GEHO/Descripti on/Power end/Intr oducti on/Introducti on @ 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 and piston.
Pos : 10.10 /GEHO/D escri ption/Power end/Proj ect/201333=TZPM 2000 @ 9\mod_1274789146078_31.doc @ 67811 @
The power end includes the following items:

• Cast power end with shaft seals and inspection covers to seal against exterior contamination.
• Piston rod stuffing box to prevent lube oil contamination and leakage
• Direct driven crankshaft i.e. without drive shaft and gearing.
• 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.
• 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 : 10.11.1 /GEH O/H eadi ng/H3/#.#.# Lubric ati on unit @ 0\mod_1134568393543_31.doc @ 498 @
5.4 201333-IOM-EN-R02
Description
5.5.1 Lubrication unit

Pos : 10.11.2 /GEH O/D escri ption/Power end/Lubric ati on unit/TZ PM/Lubric ation methods @ 8\mod_1256563912308_31.doc @ 56021 @
Two lubrication methods are applied:

1 The Splash lubrication.
2 The force feed lubrication system.
The Splash lubrication of the crankshaft bearings, affected by their own movement in the oil sump.
The force feed lubrication system lubricate points that are difficult to reach by the splashed oil such as the
bearings of the drive shaft and the crankshaft, the upper and lower side of the crosshead liners and the
crosshead bearings.
CAUTION
The force feed lubrication system is a system that remains under pressure even after shut
down the pump.
Pos : 10.12 /--- Pag e break --- @ 0\mod_1136278659331_0.doc @ 766 @
Pos : 10.13 /GEHO/H eadi ng/H2/#.# Liqui d end @ 0\mod_1134568182139_31.doc @ 492 @

Shut off the lubrication pump, before carrying out maintenance and repair activities.
5.6 Liquid end

Pos : 10.14.1 /GEH O/D escri ption/Liqui d end/Intr oducti on/TZ PM/M ain items - TZPM - Header @ 0\mod_1145875032918_31.doc @ 3323 @
The GEHO TZPM pump consist of the following parts:

Pos : 10.14.2 /GEH O/D escri ption/Liqui d end/Intr oducti on/TZ PM/M ain 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 : 10.14.3 /GEH O/D escri ption/Liqui d end/Intr oducti on/M ain items /Pulsation dampener - Disc harge (3) @ 7\mod_1246276706206_31.doc @ 51942 @
• 3 Discharge pulsation dampeners.

Pos : 10.14.4 /GEH O/D escri ption/Liqui d end/Intr oducti on/M ain items /Air vess el - Suc tion @ 0\mod_1145981103040_31.doc @ 3414 @
• 1 Suction air vessel.

Pos : 10.14.5 /GEH O/D escri ption/Liqui d end/Intr oducti on/Di visions @ 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 : 10.14.6 /GEH O/D escri ption/Liqui d end/Intr oducti on/Pr opelling liqui d s ecti on/TZ PM @ 1\mod_1166113655949_31.doc @ 11322 @
5.6.1 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 : 10.14.7 /GEH O/D escri ption/Liqui d end/Intr oducti on/Sl urr y s ecti on/Standar d @ 0\mod_1149662677848_31.doc @ 4423 @
5.6.2 The slurry section

Only the slurry section has contact with the pumped liquid.
The slurry section consists of:
• The slurry front side of the diaphragm housing unit.
• The suction valve unit.
• The discharge valve unit.
Pos : 10.14.8 /GEH O/D escri ption/Liqui d end/Intr oducti on/M ain items /Air vess el - Suc tion @ 0\mod_1145981103040_31.doc @ 3414 @
• 1 Suction air vessel.

Pos : 10.14.9 /GEH O/D escri ption/Liqui d end/Intr oducti on/M ain items /Pulsation dampener - Disc harge (3) @ 7\mod_1246276706206_31.doc @ 51942 @
• 3 Discharge pulsation dampeners.

201333-IOM-EN-R01 5.5
Description
Pos : 10.16 /GEHO/D escri ption/Liqui d end/Piston unit/Proj ect/201333 Pis ton uni t @ 12\mod_1302525901390_31.doc @ 85032 @
5.6.3 Piston unit

The piston is connected to the crosshead by means of the:
– Crosshead rod;
– Connection piece;
– Piston rod.
The piston is provided with 2 sets of piston seal rings (chevron roof shaped rings) and a piston guide ring.
The piston guide ring centers the piston in the cylinder liner.
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.
The front side of the piston moves the propelling liquid. Refer to chapter "propelling liquid control system" for
the description how the volume of the propelling liquid in this compartment is monitored and controlled.
The cylinder liner is positioned between the trust piece and the corner pieces.
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.
The cylinder liner is positioned inside a cooling jacket. In the current application, the cooling jacket is not
used. In a future application called "Glores system" , the cooling jacket ensures the lifespan of the seals in the
piston unit.
Pos : 10.17.1 /GEH O/H eadi ng/H3/#.#.# Flus hing unit @ 0\mod_1136284703903_31.doc @ 806 @
5.6.4 Flushing unit

Pos : 10.17.2 /GEH O/D escri ption/Liqui d end/Fl ushi ng unit/TZPM /Pis ton fl us hing uni t @ 0\mod_1136369150107_31.doc @ 908 @
The piston flushing unit uses the propelling liquid to lubricate the piston and cylinder liner.
Pos : 10.17.3 /GEH O/D escri ption/Liqui d end/Fl ushi ng unit/Flus hi ng unit - C ommon @ 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.
If propelling liquid needs to be supplied to the propelling liquid section,
then 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.
5.6 201333-IOM-EN-R02
Description
Pos : 10.19.1 /GEH O/H eadi ng/H3/#.#.# Propelling liquid contr ol s ys tem @ 0\mod_1134632211894_31.doc @ 522 @
5.6.5 Propelling liquid control system

Pos : 10.19.2 /GEH O/H eadi ng/H5/H5 Refer enc es @ 10\mod_1288253105484_31.doc @ 72842 @
References
Pos : 10.19.3 /GEH O/D escri ption/Liqui d end/Propelling liqui d c ontrol s ystem/TZ PM/R efer to " Start-up, pri ming proc edur e" @ 6\mod_1234953648836_31.doc @ 47661 @ 5
NOTE
Refer to chapter "Start-up, priming procedure" for details about
• how to do a save initial start of the automatic system,
after a drain of the propelling liquid.
Pos : 10.19.4 /GEH O/D escri ption/Liqui d end/Propelling liqui d c ontrol s ystem/C aution - R el eas e r emai ning pres sur e @ 0\mod_1136282494105_31.doc @ 786 @
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 : 10.19.5 /GEH O/D escri ption/Liqui d end/Propelling liqui d c ontrol s ystem/General functi ons prop.liquid TZPM+Z PM @ 10\mod_1288344581984_31.doc @ 72921 @
5.6.5.1 General functions

The pump is standard equipped with the patented GEHO propelling liquid automatic control system.
It provides during operation a full automatic control of the required quantity of propelling liquid between the
piston and the diaphragm.
• 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 position marker at the monitoring rod reaches the rear or front monitoring probe.
Then the connected "PLC" ("PROGRAMMABLE LOGIC CONTROLLER") actuates a fill or a drain of
propelling liquid.
The patented GEHO propelling liquid automatic control system Possible causes:
prevents:
Overstress of the diaphragm. Increase of propelling
Blow up the diaphragm. liquid volume.
Diaphragm may strike the rear wall of the diaphragm housing. Decrease of propelling
liquid volume.
Possible causes for a (slow, long term) change of the propelling liquid volume in diaphragm housing:
• 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.
Pos : 10.19.6 /--- Pag e br eak --- @ 0\mod_1136278659331_0.doc @ 766 @ 4
201333-IOM-EN-R01 5.7
Description
Pos : 10.19.7 /GEH O/H eadi ng/H4/#.#.#.# Over view @ 1\mod_1165494429019_31.doc @ 9072 @
5.6.5.2 Overview
Pos : 10.19.8 /GEH O/D escri ption/Liqui d end/Propelling liqui d c ontrol s ystem/TZ PM/TZ PM sc hematics @ 0\mod_1135261173624_31.doc @ 755 @
Figure 5.5: GEHO TZPM pump schematics

(The figure shows a general schematic arrangement, applicable for more versions.)
A Slurry 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 Slurry discharge line
L Monitoring probes for minimum and maximum stroke of the diaphragm (for limitation of the diaphragm stroke)
1 "AIR" = Compressed air supply connection

2 Propelling liquid automatic control system
3 "PLC" = "PROGRAMMABLE LOGIC CONTROLLER"
4 "FILLING" = automatic filling of propelling liquid,
if the position marker (I) at the rod reaches the minimum-probe ZSL
5 "OUTLET" = automatic drain of propelling liquid,
if the position marker (I) at the rod reaches the maximum-probe ZSH
Pos : 10.19.9 /--- Pag e br eak --- @ 0\mod_1136278659331_0.doc @ 766 @
5.8 201333-IOM-EN-R02
Description
Pos : 10.19.10 /GEH O/D escripti on/Liquid end/Pr opelling liqui d c ontrol s ystem/TZ PM/TZ PM Pr opelling liqui d c ontrol s ystem R 02 @ 2\mod_1175168658938_31.doc @ 12922 @
5.6.5.3 Working principle of the filling valves + outlet valves
Figure 5.6: Propelling liquid automatic control system
1 ZSH (switch high) monitoring probe for the outlet of propelling liquid
2 ZSL (switch low) monitoring probe for filling of propelling liquid
3 Diaphragm
4 Monitoring rod
5 Magnet to trigger the switches
6 Piston
7 HV = hydraulic valve for filling of propelling liquid.
HV1 = valve for filling diaphragm housing 1.
8 HV = hydraulic valve for outlet of propelling liquid.
HV5 = valve for outlet diaphragm housing 1.
Normal pumping conditions
Under normal pumping conditions the magnet (5) in the diaphragm rod (4) moves between the monitoring
probes (1) ZSH (switch high) and (2) ZSL (switch low), without actuating them.
Filling by the ZSL switch high
If there is too less propelling liquid in the propelling liquid chamber,
then the magnet actuates monitoring probe ZSL (switch low),
which gives an impulse to an input of the GEHO control box.
Due to this impulse, an output will activate a solenoid valve SV, which activates a pneumatic main valve HV,
for a certain time propelling liquid will be added to the propelling liquid chamber.
Outlet by the ZSH switch low
If there is too much propelling liquid in the propelling liquid chamber,
then the magnet actuates monitoring probe ZSH (switch high),
which gives an impulse to an input of the GEHO control box.
Due to this impulse an output will activate a solenoid valve SV, which activates a pneumatic main valve HV,
for a certain time and propelling liquid will be drained from the propelling liquid chamber.
201333-IOM-EN-R01 5.9
Description
5.6.5.4 Propelling liquid/flushing unit with filling/outlet valves
Figure 5.7: Propelling liquid valves
1 Filling valves HV1 + HV2 + HV3 5 Outlet valves HV5 + HV6 + HV7
(2/2 way hydraulic valve) (2/2 way hydraulic valve) for outlet of oil from
for filling oil into the propelling liquid chamber. the propelling liquid chamber.
2 Compressed air supply for actuating the 6 Compressed air supply for actuating the
hydraulic valves (1). hydraulic valves (5).
The air comes from SV1 + SV2 + SV3 The air comes from SV5 + SV6 + SV7
(solenoid valves 3/2 way, NC = normal closed). (solenoid valves 3/2 way, NC = normal closed).
3 Filling flow into the propelling liquid chamber. 7 Outlet flow from the propelling liquid chamber.
4 Propelling liquid supply from the accumulator. 8 Return of oil to the propelling liquid tank.
5.6.5.5 Automatic propelling liquid pressure control

WARNING
The propelling liquid system remains under pressure during operation of the pump and during
shut down of the pump, by this accumulator.
This is indicated at the pressure gauge.
• Relieve the pressure at this system, by opening the 3-way drain valve at the accumulator
line, before working on it.
The pressure in the propelling liquid accumulator is regulated by switching the "FLUSHING VALVE" SV15 of
the propelling liquid pump.
The position of the valve SV15 is controlled by the pressure transmitter PT6 (connected to the PLC).
During steady pump operation this system flushes continuously the pump pistons.
If the pressure in the propelling liquid accumulator drops below a preset value,
then the SV15 valve closes and the oil flows into the accumulator.
If this action exceeds 60 seconds,
then the SV15 valve will switch back to flush the pistons for 5 seconds.
5.10 201333-IOM-EN-R02
Description
Flow monitoring at the propelling liquid pump

A flow indicator/switch FISLL is installed in the discharge line of this propelling liquid/flushing pump in order to
monitor insufficient oil flow.
The switch may generate an alarm signal.
5.6.5.6 Propelling liquid supply valve HV9

The propelling liquid supply valve HV9 supplies the filling valves with propelling liquid from the propelling
liquid pump system and prevents the diaphragm housings to be overfilled
(for instance caused by leaking filling valves when the main pump is stopped).
The propelling liquid supply valve HV9 is actuated by the main motor running signal or manually by push
button (see document 814.2TZPM.24) when the pump is not running.
After manual operation of the HV9 valve, this valve will stay open for 15 minutes.
5.6.5.7 Automatic outlet program

Program cycle
The automatic outlet program improves the lifetime of the diaphragms.
After startup and a speed > 5 SPM (=speed in revolutions per minute of the pump crankshaft)
an automatic outlet program for the diaphragm housings will start.
8/10/12 minutes after starting the automatic outlet program the outlet valves will be active during 0.5 second
in a time cycle of 5, 9 and 13 seconds.
This cycle will be repeated until a filling monitoring probe ZSL of the related diaphragm house is active,
then for a certain time propelling liquid will be added to the propelling liquid chamber.
Automatic repeat
After this, the automatic outlet program will repeat the outlet cycle every hour.
If during the automatic outlet program a fill monitoring probe ZSL is activated,
then the program will switch directly to the next cycle for the related diaphragm house.
5.6.5.8 Propelling liquid failure detection

If at running pump, the fill or outlet system is not able to correct the amount of propelling liquid, within a time
of 3 minutes, then the fill/outlet failure detection will be activated.
Because the fill or outlet valves are only active for a certain time, an off delay timer of 15 seconds is
programmed to extend this signal, which energizes the 3 minutes failure on delay timer.
This means that at a speed greater then 4 SPM the valve action will reactivate the off delay timer within 15
seconds and in this way the 3 minute on delay timer for propelling liquid failure will stay active.
The propelling liquid failure detection is not active at a pump speed below 4 SPM.
Pos : 10.20 /--- Pag e break --- @ 0\mod_1136278659331_0.doc @ 766 @ 455544544554
201333-IOM-EN-R01 5.11
Description
Pos : 10.21.1 /GEH O/H eadi ng/H3/#.#.# Pressur e li mitation s ystem @ 0\mod_1134569743995_31.doc @ 508 @
5.6.6 Pressure limitation system

Pos : 10.21.2 /GEH O/D escri ption/Liqui d end/Press ure limi tati on s ys tem/Introducti on, Elel ectric al - Mechani cal @ 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 document "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 : 10.21.3.1 /GEH O/H eadi ng/H4/Pr ess ure li mitation - El ectrical @ 0\mod_1136292111124_31.doc @ 846 @
5.6.6.1 Electrical pressure limitation

Pos : 10.21.3.2 /GEH O/D escription/Liquid end/Press ure trans mitter/Pres sur e tr ansmi tter - 2-s tep overpr essur e @ 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 document "INSTRUMENT AND EQUIPMENT LIST".
NOTE
If the operating pressure is below the precharge pressure of the discharge dampener or air
vessel,
then the pressure transmitter and the pressure gauge will indicate the precharge pressure
(not the lower pump operating pressure).
Refer to chapter "Precharging with nitrogen a pulsation dampener (discharge line)" for dampener precharge
instructions.
Pos : 10.21.4.1 /GEH O/H eadi ng/H4/Pr ess ure li mitation - Mec hanic al @ 0\mod_1136292155037_31.doc @ 848 @
5.6.6.2 Mechanical pressure limitation

Pos : 10.21.4.2 /GEH O/D escription/Liquid end/Press ure limitati on s ys tem/Mec hanic al @ 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.
If the pressure in the main discharge line exceeds the pressure of the spring,
then the safety valve opens and releases the pressure.
Pos : 10.21.4.3 /GEH O/D escription/Liquid end/Press ure limitati on s ys tem/Ac tions 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 : 10.21.4.4 /GEH O/D escription/Liquid end/Press ure limitati on s ys tem/Cauti on - Rel ease pr ess ure @ 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.
5.12 201333-IOM-EN-R02
Description
Pos : 10.23.1 /GEH O/H eadi ng/H3/#.#.# Di aphr agm housing unit @ 0\mod_1134569604134_31.doc @ 504 @
5.6.7 Diaphragm housing unit

Pos : 10.23.2 /GEH O/D escri ption/Liqui d end/Di aphrag m housi ng unit/T ZPM high pr essur e >= 160 bar @ 3\mod_1196415416094_31.doc @ 19927 @
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 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 filling ring
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.
The filling ring is used by high pressure performances and increases the lifespan of the diaphragm housing.
At the propelling liquid section the diaphragm housing unit is connected to:
• The power end unit.
Pos : 10.23.3 /GEH O/D escri ption/Liqui d end/Di aphrag m housi ng unit/Slurr y sec tion/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.
201333-IOM-EN-R01 5.13
Description
Pos : 10.25.1 /GEH O/H eadi ng/H3/#.#.# Sucti on val ve unit @ 0\mod_1134569502477_31.doc @ 502 @
5.6.8 Suction valve unit

Pos : 10.25.2 /GEH O/D escri ption/Liqui d end/Val ve uni ts/Suction val ve 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 : 10.25.3 /GEH O/H eadi ng/H3/#.#.# Di scharge val ve uni t @ 0\mod_1137069603901_31.doc @ 1146 @
5.6.9 Discharge valve unit

Pos : 10.25.4 /GEH O/D escri ption/Liqui d end/Val ve uni ts/Disc harge val ve 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 : 10.26 /GEHO/H eadi ng/H3/#.#.# Discharge pulsation dampener @ 0\mod_1134569676478_31.doc @ 506 @
5.6.10 Discharge pulsation dampener

Pos : 10.27 /GEHO/D escri ption/Liqui d end/Puls ati on 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 nitrogen section, pre-charged with nitrogen.
Pos : 10.28 /GEHO/D escri ption/Liqui d end/Puls ati on dampener /Pr essur e trans mitter+ Refer on P&I-s ki d @ 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 : 10.29.1 /GEH O/H eadi ng/H3/#.#.# Sucti on air vess el uni t @ 0\mod_1134632576428_31.doc @ 526 @
5.6.11 Suction air vessel unit

Pos : 10.29.2 /GEH O/D escri ption/Liqui d end/Air vessel units/Sucti on/Standard- manual air filling @ 0\mod_1137071003724_31.doc @ 1148 @
The suction air vessel unit minimizes the pressure variations in the suction line.
This achieves a constant flow in the suction line.
For most applications the air content in the suction air vessel will not reduce during pump operation even
after a long period.
In case of an application where air is being transported out of the vessel,
then it may be required to install an air filling line to the top of the vessel to allow manually air filling during
pump operation.
Pos : 11 /--- Secti on br eak - Odd pag e --- @ 0\mod_1136277036628_0.doc @ 765 @
5.14 201333-IOM-EN-R02
Transport and installation
Pos : 12.1 /GEHO/Heading/H 1/#. Tr ansport and i nstallation @ 0\mod_1136455268304_31.doc @ 931 @
6
Pos : 12.2.1.1 /GEHO/Heading/H 2/#.# Trans port and lifti ng @ 0\mod_1136806045785_31.doc @ 973 @
6.1 Transport and lifting

Pos : 12.2.1.2 /GEHO/General /Attenti on, Warning and Note/DAN GER - Safety - Obey s afety i nstr ucti ons and proc edur es @ 0\mod_1136886637385_31.doc @ 1007 @
DANGER
• Obey the safety instructions.
• Obey the working procedures.
Pos : 12.2.1.3 /GEHO/General /Attenti on, Warning and Note/Cauti on - Li fting device - Chec k 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 /Attenti on, Warning and Note/Attenti on - Lifting devic es - Weight li mits @ 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 /Attenti on, Warning and Note/Attenti on - Lifting devic es - Protec t eq uipment @ 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 /Attenti on, Warning and Note/Attenti on - Lifting l oc ati ons - Us e lifti ng 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/H 3/#.#.# Weights and li mits @ 0\mod_1137424754577_31.doc @ 1233 @
6.1.1 Weights and weight limits

Pos : 12.2.1.8 /GEHO/Trans port and ins tall ati on/Transport and lifti ng/Cauti on - Weight limi ts @ 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/Trans port and ins tall ati on/Transport and lifti ng/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 DRAWING”.
Pos : 12.2.2 /GEHO/General /Attenti on, Warni ng and Note/War ning - R efer to " PAC KING" @ 0\mod_1137404858107_31.doc @ 1159 @
WARNING
• Refer to the drawings "PACKING" in chapter "Drawings + Lists + Instruments"
for the lifting values and restrictions.
Pos : 12.2.3 /GEHO/General /Attenti on, Warni ng and Note/War ning - H oisti ng facilities @ 6\mod_1234794998618_31.doc @ 47513 @
WARNING
• Refer to the drawing “HOISTING FACILITY” in chapter "Special tools"
for the lifting locations and recommended tools.
Pos : 12.2.4 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 @
201333-IOM-EN-R01 6.1
Pos : 12.2.5 /GEHO/Trans port and install ati on/Installati on/## Erec ting the Ins tallation @ 5\mod_1225119340834_31.doc @ 39879 @
6.2 Erecting the installation
ATTENTION
Before starting erecting the installation, make sure to follow the agreements made between
your company and Weir Minerals Netherlands b.v.
WARNING
Strictly adhere to all instructions as given in chapter "Safety" in front of this manual.
For safe operation and handling, obey to the instructions in this chapter along with the correct
Pos : 12.2.6 /GEHO/Heading/H 2/#.# H oisting Ins truc tions @ 5\mod_1225119514302_31.doc @ 39887 @
working sequence.
6.3 Hoisting instructions

Pos : 12.2.7 /GEHO/Trans port and install ati on/Transport and lifti ng/### Chec k,, hoisting belts @ 5\mod_1225120147893_31.doc @ 39895 @
6.3.1 General
ATTENTION
• Check always, that the hoisting belts do not touch and damage vulnerable parts of the
pump (like instruments, hoses and piping).
Pos : 12.2.8 /GEHO/Trans port and install ati on/Transport and lifti ng/### lifti ng eyes @ 5\mod_1221653262294_31.doc @ 38469 @
6.3.2 Lifting eye bolts

WARNING
The heavy parts of the pumps are provided with one or more lifting eye bolts,
or have the possibility to install a lifting eye for transportation purposes.
• Always transport these parts by using these eyes.
Table according to DIN 580 "LIFTING EYE BOLTS": Working Load Limit (= WLL) [kg]
Size M8 M10 M12 M16 M20 M24 M27 M30 M33 M36 M42 M56 M64
(metric thread)
only for 1 eye 140 230 340 700 1200 1800 2500 3600 4300 5100 7000 11500 16000
bolt, hoisting
upwards
for 2 or more 95 170 240 500 830 1270 1800 2600 3100 3700 5000 8300 11000
eye bolts
together
• If 2 or more lifting eye bolts are used, then the minimum hoisting angle is 45 degrees, as shown in the
figure.
Pos : 12.2.9.1 /GEHO/Heading/H 3/#.#.# Smaller parts @ 0\mod_1136807299788_31.doc @ 985 @
6.3.3 Smaller parts

Pos : 12.2.9.2 /GEHO/Trans port and ins tall ati on/Transport and lifti ng/Lifting l ocations/Small er parts @ 0\mod_1136809345700_31.doc @ 995 @ 3
• Lift the smaller parts at the desired lifting locations.

• Use lifting straps or a forklift.
Error ! U nkno wn switch ar gum ent.

6.2 201333-IOM-EN-R02
Pos : 12.2.11.1 /GEH O/H eadi ng/H3/#.#.# Transport the pac ked i nstallation @ 0\mod_1137408313966_31.doc @ 1177 @
6.3.4 Transport the packed installation

Pos : 12.2.11.2 /GEH O/Tr ansport and i nstallation/Tr ans port and lifting/Tr ans port/Tr ans port box @ 0\mod_1137408396926_31.doc @ 1182 @
WARNING
• Obey the instructions at the transport box.

• To lift the transport box, use a crane and
lifting chains.
• For fastening the hoisting chains
(in case the pump is packed),
follow the pictured instructions on both
sides of the box.
Figure 6.1: Lifting locations at the transport box

Pos : 12.2.12 /GEH O/General/Attenti on, War ning and N ote/Warni ng - Refer to "PACKING" @ 0\mod_1137404858107_31.doc @ 1159 @
WARNING
• Refer to the drawings "PACKING" in chapter "Drawings + Lists + Instruments"
for the lifting values and restrictions.
Pos : 12.2.13.1 /GEH O/H eadi ng/H3/#.#.# Dri ve uni t @ 0\mod_1136807338183_31.doc @ 987 @
6.3.5 Drive unit

Pos : 12.2.13.2 /GEH O/Tr ansport and i nstallation/Tr ans port and lifting/Lifti ng loc ati ons/Dri ve Unit/Dri ve unit+gearbox+1hoists preaders $01 @ 0\mod_1136808534193_31.doc @ 991 @
1 Use a standard hoist spreader (A) to avoid

damage (not in the scope of supply).
2 Lift the unit at the 4 frame lifting points (B).
If this kind of hoist spreader is not available, then:

1 Disconnect coupling (C) between the motor
and the gearbox.
2 Dis-assemble the motor and gearbox from the
frame.
3 Hoist separately the motor and the gearbox
and the frame at their hoisting points.
Figure 6.2: Lifting locations at the drive unit

201333-IOM-EN-R01 6.3
Pos : 12.2.15.1 /GEH O/H eadi ng/H3/#.#.# Power end @ 0\mod_1136806759712_31.doc @ 979 @
6.3.6 Power end

Pos : 12.2.15.2 /GEH O/Tr ansport and i nstallation/Tr ans port and lifting/Lifti ng loc ati ons/TZ PM/Power end - 2000 ... @ 0\mod_1137413287899_31.doc @ 1204 @
Refer for the required tools to drawing

"HOISTING FACILITY" in chapter “Part lists and
drawings (special tools)”.
Make sure to use the required transport

supports.
Lift the power end at the four lifting flanges (B).

The lifting flanges (B) are included in the set of
special tools.
Figure 6.3: Lifting locations at the power end.

(The figure shows a schematic arrangement for more
versions)
Pos : 12.2.16.1 /GEH O/H eadi ng/H3/#.#.# Liqui d end @ 0\mod_1136807235275_31.doc @ 983 @
6.3.7 Liquid end

Pos : 12.2.16.2 /GEH O/Tr ansport and i nstallation/Tr ans port and lifting/Lifti ng loc ati ons/TZ PM/Liq uid end - 2000 ... @ 0\mod_1137400242761_31.doc @ 1152 @
Refer for the required tools to drawing

"HOISTING FACILITY" in chapter “Part lists and
drawings (special tools)”.
Make sure to use the required transport

supports.
Use the hoisting beam (A) and the transport

beam (B) to lift the liquid end.
The hoisting beam (A) and the transport
beam (B) are included in the set of special tools.
Figure 6.4: Lifting locations at the liquid end

versions)
6.4 201333-IOM-EN-R02
Pos : 12.4 /GEHO/Heading/H 2/#.# Installation @ 0\mod_1136888682286_31.doc @ 1015 @
6.4 Installation
Pos : 12.5 /GEHO/Heading/H 3/#.#.# F oundati on @ 0\mod_1136888827835_31.doc @ 1021 @
6.4.1 Foundation
Pos : 12.6 /GEHO/Trans port and installati on/Installati on/Foundati on/Foundati on bolt sc hematics @ 0\mod_1136891863740_31.doc @ 1025 @
A Steel foundation bolt

B Grout
C Diameter of the foundation bolt
D Polyurethane foam
E Free length of the foundation bolt thread
F Diameter (Ø) of the anchor pocket
G Depth of the anchor pocket
H Height of the Polyurethane foam
I Thickness of the covering grout
J Angle iron
Figure 6.5: Schematics of the anchor pocket and the

foundation bolt
Pos : 12.7 /GEHO/Trans port and installati on/Installati on/Foundati on/Refer to "Di mensioned outli ne" dr awing or "Foundati on dr awing" @ 0\mod_1136893431935_31.doc @ 1027 @
Refer to the “DIMENSIONED OUTLINE” drawing and/or the “FOUNDATION DRAWING” for the exact sizes
and locations of the anchor pockets.
201333-IOM-EN-R01 6.5
Pos : 12.9 /GEHO/Heading/H 4/#.#.# Mount and level the pump end @ 11\mod_1294149571375_31.doc @ 79734 @
6.4.2 Mount and level the pump end

Pos : 12.10 /GEHO/Tr ansport and ins tallation/Ins tall ation/F oundation/M ount and l evel /CAUT ION C hec k part numbers @ 6\mod_1234530747188_31.doc @ 47430 @ 3
CAUTION
• Check, before assembling, that the parts numbers are matching with the pump numbers.
Some parts, like the suction line and the discharge line, are sometimes made fitting for
one pump number, and labeled accordingly.
Pos : 12.11 /GEHO/Tr ansport and ins tallation/Ins tall ation/F oundation/M ount and l evel /TZPM /Level pump end - TZ PM >= 2000 or Diaphrag m housi ng >= 70 liter glores @ 11\mod_1291905083859_31.doc @ 79609 @
1 Check the foundation, according to the

"DIMENSIONED OUTLINE DRAWING"
and/or the "FOUNDATION DRAWING".
2 Place steel blocks next to each anchor
pocket.
Use steel blocks with a thickness of
50 mm.
3 Level the steel blocks in a range of 1 mm.
4 Lift the pump.
Use a crane.
5 Remove the power end transport support.
7 Put the thread of the foundation bolts into
the borings at the pump.
8 Put the nuts to the foundation bolts.
9 Lower the pump
10 Put the pump to the steel blocks.
11 Make sure that the foundation bolts fit into
the anchor pockets.
12 Hook the foundation bolts in their Figure 6.6: Spirit level positions
dedicated position.
13 Tighten the nuts at the foundation bolts by hand.
14 Place exactly below all leveling bolts of the pump a plane steel block.
Use steel blocks with a thickness of about 40 mm.
15 Remove 1 cover of a piston cover and crosshead chamber.
16 Place a spirit level (C) on the machined face in direction A-A.
17 Level the pump.
Keep a tolerance of 0.5 mm/m.
Use the leveling bolts.
18 Place a spirit level (C) on the machined face in direction B-B.
19 Level the pump.
20 Fill up the space between the pump and the steel blocks with metal packing shims.
21 Check that the base frame rests on the packing shims.
22 Loosen and remove all leveling bolts.
23 Fill the lower section of all anchor pockets,
to fix all foundation bolts in their position.
Refer to the drawing of the anchor pocket.
24 Fill the upper section of all anchor pockets with polyurethane foam.
25 Put on a top layer of grout.
26 When the grout is hardened, then tighten all nuts at the foundation bolts.
Make sure to use the correct torques.
Refer to chapter "Tightening torques".
Pos : 12.12 /GEHO/H eadi ng/H4/#.#.# Mount and l evel the flui d end @ 11\mod_1294149656468_31.doc @ 79746 @
6.6 201333-IOM-EN-R02
6.4.3 Mount and level the fluid end

Pos : 12.13 /GEHO/Tr ansport and ins tallation/Ins tall ation/F oundation/M ount and l evel /TZPM /Pr oject/201333 Level fl uid end - TZ PM >= 2000 or Diaphr agm housing >= 70 liter glores @ 12\mod_1302521676703_31.doc @ 85004 @ 3
1 Apply anti-seize grease on thread,

cylindrical parts, guide pins, slots in frame
and thread in Glores manifold.
2 Mount the two guide pins. Use a hand
spanner. (See: T.814.201333.50).
ATTENTION
The guide pins should remain
in place during assembly and
operation of the pump.
3 Mount the eight stud bolts into the power
end frame. (See: T.845.000.495).
4 Mount the three piston units into the fluid
end except the connecting piece. (See:
T.835.000.206)
5 Assemble the three o-rings into the Glores
manifold. Lubricate the o-rings with grease.
6 Connect the fluid end section to a hoisting
device. Refer to the packing drawing for
the estimated weight. (See:
V.814.201333.15).
7 Connect the hoisting device (A) to the hoisting
beam (C). Use a sling (B).
8 Mount two hoisting eyes (F) to the Glores
manifold.
9 Connect a hoisting chain to the two hoisting
eyes and the hoisting device
10 Also connect three chain hoists (D, E) to the
hoisting chain (G).
• One chain hoist, with a capacity of 10 tons, for
the vertical leveling Figure 6.7: Hoisting and leveling fluid end with Glores
manifold.
• Two chain hoists, both a capacity of 6 tons,
for the horizontal leveling.
11 Level the fluid end horizontally (H) within a
deviation of 0.5 mm/mtr.
12 Level the fluid end vertically (V) within +/- 0-5
mm.
Figure 6.8: Leveling and assembly of the fluid end on

the foundation.
201333-IOM-EN-R01 6.7
13 Put the anchor bolts into the pockets

14 Move the fluid end section with small steps against the power end section, the foundation and over the
studs. To accomplish this use a hoisting device.
15 Visual check the left and right side of the power end if the guide pins are in line with the inserts.
16 When the guide pins hit the slots then the fluid end section must be leveled exactly within 0.5mm/mtr to
the power end.
17 From now on, move the fluid end section with help of the nuts (pos 162).
18 Use the four outer nuts to move the fluid end gradually against the power end section.
19 Continuously check the alignment of the Glores manifold and power end frame. The clearance
between Glores manifold and power end frame must be equal (within 0.1 mm) on all positions.
20 Check the position of the three o-rings during this proces.
21 Do this until the power end and fluid end are steel on steel.
22 Finally torque all eight nuts with 12500 Nm.
23 Check the foundation, according to the "DIMENSIONED OUTLINE DRAWING" and/or the
"FOUNDATION DRAWING".
24 Place steel blocks next to each anchor pocket. Use steel blocks with a thickness of 50 mm.
26 The fluid end is still hanging in the hoisting device.
27 Put the thread of the foundation bolts into the borings at the fluid end.
29 Make sure that the foundation bolts fit into the anchor pockets.
30 Hook the foundation bolts in their dedicated position.
31 Tighten the nuts at the foundation bolts by hand.
32 Place exactly below all leveling bolts of the fluid end plane steel blocks with a thickness of about
40 mm.
33 Tighten all level bolts until they make contact with the steel blocks.
34 Check the level. Place a spirit level (C) on the fluid end frame direction A-A and direction B-B).
35 If necessary level the pump.
36 Fill up the space between the fluid end and the steel blocks with metal packing shims.
37 Check that the base frame of the fluid end rests on the packing shims.
38 Loosen and remove all leveling bolts.
39 Disconnect the fluid end section from the hoisting device
40 Fill the lower section of all anchor pockets, to fix all foundation bolts in their position.
41 Fill the upper section of all anchor pockets with polyurethane foam.
42 Put on a top layer of grout.
43 When the grout is hardened, then tighten all nuts at the foundation bolts.
Make sure to use the correct torques.
Refer to chapter "Tightening torques".
Pos : 12.14 /GEHO/Tr ansport and ins tallation/Ins tall ation/Auxiliar y s ystems/Auxili ar y s ys tems @ 3\mod_1203946338903_31.doc @ 26331 @
6.8 201333-IOM-EN-R02
6.4.4 Auxiliary systems

1 Mount the support (A) and the pre-
assembled auxiliary system to the pump
power end.
2 Slide the drip pan (B) between the legs of
the support (A).
3 Level the drip pan (B).
Use steel shims.
4 Connect the drip pan (B) to the support.
Use two brackets (C).
5 Under fill the drip pan (B) with grout.
6 Place the propelling liquid tank (D) over the Figure 6.9: Auxiliary system connections
drip pan (B). (The figure shows a schematic arrangement for
7 Lock the position of the propelling liquid more versions)
tank (D).
8 Assemble the tubing between the auxiliary system support and the pump:
• Suction line (hydraulic hose) propelling liquid system (E).
• Fill / drain line (F) to each diaphragm house.
• Vent line (G) to side of power end and the propelling liquid tank.
• Nitrogen line (H) to the pulsation dampener(s).
• Drain line (I) flushing box to the propelling liquid tank.
• Drain line (J) pump relief valve to the flushing box.
9 Connect the electrical wiring to the lubrication unit and the drive unit.
10 Connect the instrument airline (K) to the 3/2 valves.
201333-IOM-EN-R01 6.9
Pos : 12.16.1 /GEH O/H eadi ng/H3/#.#.# Dri ve uni t @ 0\mod_1136807338183_31.doc @ 987 @
6.4.5 Drive unit

Pos : 12.16.2 /GEH O/Tr ansport and i nstallation/Ins tall ation/Dri ve uni t/Gearbox/Over vi ew @ 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 6.10: Drive unit with gearbox overview

Pos : 12.16.3 /GEH O/Tr ansport and i nstallation/Ins tall ation/Dri ve uni t/Gearbox/M ount @ 0\mod_1136903066579_31.doc @ 1039 @
6.4.5.1 Mount the drive unit

1 Place steel blocks (E) next to each anchor
pocket.
2 Lift the drive unit.
Use a crane.
3 Put the thread of the foundation bolts (C)
into the holes at the pump drive base
frame (D).
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).
10 Level the pump drive unit. Figure 6.11: Mount the drive unit
Use the leveling bolts at the base (The figure shows a general schematic arrangement,
frame (D). applicable for more versions.)
6.10 201333-IOM-EN-R02
Pos : 12.16.5 /GEH O/H eadi ng/H4/Gear box alignment @ 0\mod_1136967931366_31.doc @ 1045 @
6.4.5.2 Gearbox alignment

Pos : 12.16.6 /GEH O/H eadi ng/H5/H5 General @ 0\mod_1136967977522_31.doc @ 1047 @
General
Pos : 12.16.7 /GEH O/Tr ansport and i nstallation/Ins tall ation/Dri ve uni t/Gener al/Introducti on @ 0\mod_1136968488297_31.doc @ 1053 @ 5
Shaft couplings need 3 types of alignment:

axial alignment + angular alignment + radial alignment (horizontal and vertical).
Pos : 12.16.8 /GEH O/Tr ansport and i nstallation/Ins tall ation/Dri ve uni t/Gener al/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 6.12: Axial misalignment.

Pos : 12.16.9 /GEH O/Tr ansport and i nstallation/Ins tall ation/Dri ve uni t/Gener al/Alignment - Ang ular @ 0\mod_1136976079252_31.doc @ 1059 @ 5
Angular alignment:
1 Align both couplings parts (∆S=S1-S 2).
base frame.
3 Make sure that the misalignment ∆S is in
tolerance.
For correct tolerance values,
Error! Unknown switch argument.

Figure 6.13: Angular misalignment.
Pos : 12.16.10 /GEH O/Trans por t and i nstallati on/Installation/Dri ve unit/General/Alignment - R adi al ESCO @ 0\mod_1136978990869_31.doc @ 1063 @ 5
Radial alignment (horizontal and vertical):

1 Align both coupling parts in horizontal and
vertical position (∆K r).
base frame.
3 Make sure that the remaining gap is in
tolerance.
For the correct tolerance values,
Figure Error! No text of specified style in document..14:

Radial misalignment.
Pos : 12.16.11 /--- Page br eak --- @ 0\mod_1136278659331_0.doc @ 766 @ 5
201333-IOM-EN-R01 6.11
Pos : 12.16.12 /GEH O/H eading/H 5/H 4 Gearbox - pump s haft - Pre- alignment @ 0\mod_1136968077676_31.doc @ 1049 @
6.4.5.3 Pre-alignment of the gearbox and the pump shaft

Pos : 12.16.13 /GEH O/Gener al/Attention, Warni ng and N ote/N ote - R efer alignment i nfor mati on @ 0\mod_1136979880428_31.doc @ 1067 @ 4
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 : 12.16.14 /GEH O/Trans por t and i nstallati on/Installation/Dri ve unit/Gear box - Pumpshaft/Pre alignment pr oc edure @ 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 (∆K r).
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 : 12.16.15 /GEH O/Trans por t and i nstallati on/Installation/Dri ve unit/Gear box - Pumpshaft/Alignment tol eranc es/Z APEX Z WN 780, no i nternal gear @ 10\mod_1276243729771_31.doc @ 68703 @
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-S 2 [mm] ∆Kr [mm] ∆S + ∆Kr [mm]
780 25 -0 / +3.0 ≥0.52 max. 1.04 ≤ 1.01 ≤ 1.01
0.05° ≤ angle ≤ 0.10°
Pos : 12.16.16 /GEH O/Gener al/Attention, Warni ng and N ote/N ote (2) Alignment limi ts @ 0\mod_1136975969234_31.doc @ 1057 @
NOTE
To improve lifetime performance of the teeth of the coupling parts,
an intentional angular mis-alignment (in a static condition) is recommended.
(2)
Minimum limits (lower value) of mis-alignment values are based upon minimum 0.05° angle.
Maximum limits (higher value) of mis-alignment values are based upon maximum 0.10° angle.
In operation a maximum of 10 fold is allowed
Pos : 12.16.17 /GEH O/H eading/H 5/H 4 Gearbox - pump s haft - Fi nal alignment @ 0\mod_1136984882160_31.doc @ 1074 @
(= maximum 1.00° angle of all mis-alignments together, per one coupling half).
6.4.5.4 Final alignment of the gearbox and the pump shaft

Pos : 12.16.18 /GEH O/Trans por t and i nstallati on/Installation/Dri ve unit/Gear box - Pumpshaft/Z APEX Z WN Fi nal alignment pr oc edure @ 0\mod_1136984368161_31.doc @ 1072 @ 4
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.
Coupling assembly:
Refer to document "Catalogue information", "Drive unit", "Coupling" for manufacturer information about
> the physical shape of the coupling,
> the assembly of the coupling,
6.12 201333-IOM-EN-R02
> how to make the coupling oil leak proof,

> filling the coupling with oil.
Refer to document "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
the cover rings (A).
6 Insert generously grease in the ring-
shaped space (C) between the sealing lips
of the DUO-rings (B). To seal properly
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.
Figure 6.15: Coupling assembly and sealing
8 Cover the sealing surfaces (D) of the coupling parts with a sealing compound.
Recommended sealing compound: "LOCTITE 5922 Flange Sealant".
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.
ATTENTION
If the cover ring (A) is designed as an two-split cover ring then use the "match marking" on
both the cover rings. Do this to avoid deformation of the DUO-rings (B).
10 Assemble the coupling covers (E) and cover rings (A) together.
Coupling oil filling:
11 Rotate the coupling,
until the oil screw plugs are in the position,
as shown in the 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
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. Figure 6.16: Coupling oil filling
Pos : 12.16.19 /--- Page br eak --- @ 0\mod_1136278659331_0.doc @ 766 @
201333-IOM-EN-R01 6.13
Pos : 12.16.20 /GEH O/H eading/H 5/H 4 M otor - Gearbox @ 0\mod_1136968126046_31.doc @ 1051 @
6.4.5.5 Motor and gearbox

Pos : 12.16.21 /GEH O/Gener al/Attention, Warni ng and N ote/N ote - R efer alignment i nfor mati on @ 0\mod_1136979880428_31.doc @ 1067 @ 4
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 : 12.16.22 /GEH O/Trans por t and i nstallati on/Installation/Dri ve unit/M otor - Gearbox/Alignment pr oc edure @ 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 (∆K r).
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 : 12.16.23 /GEH O/Trans por t and i nstallati on/Installation/Dri ve unit/M otor - Gearbox/Alignment toler ances /RUPEX R WS 450- 500 @ 0\mod_1147848228883_31.doc @ 4071 @
Alignment tolerance values for couplings:
Size Axial Axial Angular Radial

[mm] distance mis-alignment mis-alignment mis-alignment
Snom [mm] ∆K a [mm] ∆S=S 1-S 2 [mm] ∆Kr [mm]
FLENDER 5.5 ± 1.5 ≤ 0.10 ≤ 0.10
RUPEX RWS
450 - 500
6.14 201333-IOM-EN-R02
Pos : 12.18 /GEHO/Tr ansport and ins tallation/Ins tall ation/Ni trogen filling/## Safety reg ulations and i nstr ucti ons for ni trogen @ 0\mod_1156234263710_31.doc @ 5734 @
6.5 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 (N 2) 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.
201333-IOM-EN-R01 6.15
Pos : 12.20 /GEHO/H eadi ng/H2/#.# Pr e-charging with ni trogen a puls ati on dampener (disc harg e line) @ 5\mod_1231340599275_31.doc @ 45123 @
6.6 Pre-charging with nitrogen a pulsation dampener (discharge line)

Pos : 12.21 /GEHO/H eadi ng/H3/#.#.# Pre-c harging the disc harge puls ati on dampener, s et-point instructions @ 1\mod_1173202078632_31.doc @ 12640 @
6.6.1 Pre-charging the discharge pulsation dampener, set-point instructions

Pos : 12.22 /GEHO/Tr ansport and ins tallation/Ins tall ation/Ni trogen filling/Pre-c harging/#### Dis charge pul sati on dampener, pre-c harge defi nitions @ 0\mod_1156257465577_31.doc @ 5764 @
discharge
6.6.1.1 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
pressure many factors menu:
"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
6.6.1.2 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 limit of
the diaphragm. The pressure limit of the diaphragm is indicated in chapter "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.
6.16 201333-IOM-EN-R02
201333-IOM-EN-R01 6.17
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 document "INSTRUMENT AND EQUIPMENT LIST" for details about the "discharge pulsation
dampener".
Refer to document "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
but NEVER more then the diaphragm and the dampener
limit, as indicated in document
"INSTRUMENT AND EQUIPMENT LIST".
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.
If the operating pressure decreases,
then this can cause wear and damage to the diaphragm and metal insert,
by continuously hammering at the dampener bottom.
If working with relatively constant pump pressures,
then 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").
If operating the pump with widely varying pressures,
then 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").
6.18 201333-IOM-EN-R02
Pos : 12.24 /GEHO/H eadi ng/H3/#.#.# Pre-c harging a pulsation dampener with the nitrog en filling devic e @ 1\mod_1173344002199_31.doc @ 12672 @
6.6.2 Pre-charging a pulsation dampener with the nitrogen filling device

Pos : 12.25 /GEHO/Tr ansport and ins tallation/Ins tall ation/Ni trogen filling/Pre-c harging/#### D ampener-Nitrogen R 03 bottl e+c harging equipment 2+ mor e c onnecti ons old fig. @ 3\mod_1203094745983_31.doc @ 26234 @
6.6.2.1 Nitrogen bottle with charging equipment
DANGER
• Usually not in the scope of supply of Weir Minerals are the 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 bottle
B Nitrogen bottle valve
R Safety relieve,
to protect the pulsation dampener against
overload.
Relieve pressure depends on the maximum
allowed pressure of the pulsation dampener.
Nitrogen pressure regulator unit:

C Pressure regulator
C1 Pressure gauge indicating the bottle pressure
C2 Pressure gauge indicating the actual filling
pressure in the hose
C3 Pressure reducer valve
D High pressure hose
Nitrogen filling device:

E Pressure gauge pulsation dampener
F Filling valve pulsation dampener
G Fixed connection to working pressure
transmitter
H High pressure hose connection
I Fixed connection to pulsation dampener
N Pulsation dampener
Figure 6.17: Pre-charging the pulsation dampener with

the nitrogen filling device
The figures show a general schematic arrangement,
applicable for more versions with 2 or more pulsation
dampeners.
201333-IOM-EN-R01 6.19
Pos : 12.27 /GEHO/Tr ansport and ins tallation/Ins tall ation/Ni trogen filling/Pre-c harging/#### Pulsation dampener pr e-charging proc edure using the nitrogen filling devic e on P&I s kid @ 2\mod_1183376823646_31.doc @ 14362 @
6.6.2.2 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 document "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 (N 2), 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
6.6.2.3 Pre-charge pressure check

1 Read the actual pre-charge pressure of the pulsation dampener (N) at its pressure indicator (E) on the
mounting block (F).
2 If the pre-charge pressure is higher then the desired pre-charge pressure, then:
• Slowly open the filler valve (G).
• Check the actual pre-charge pressure of the pulsation dampener (N) at its pressure indicator (E).
• Repeat this pulsation venting, until the recommended pre-charge pressure is reached.
• Close the filler valve (G) when pre-charge pressure is reached.
3 If the actual pre-charge pressure is lower then the pre-charge pressure,
then follow this procedure to add nitrogen.
6.6.2.4 Preparation
1 Connect the pressure regulator (C) to the nitrogen bottle (A+B).
2 Connect the safety valve (R) and the relieve valve (S) to the pressure regulator (C)
3 Connect the hose (D) to the safety valve (R).
4 Connect the hose (D) to the connector (H) of the nitrogen filling device.
6.20 201333-IOM-EN-R02
6.6.2.5 Nitrogen pre-charge filling

1 Check that the relieve valve (S) is closed.
2 Set the nitrogen pressure regulator (C) with the pressure relieve valve (C3) to the according dampener
pre-charge pressure.
3 Open the nitrogen bottle valve slowly (B).
• Check at the gauge (C1) the pressure in the bottle, it has to be more than the recommended pulsation
dampener pressure.
• Check at the gauge (C2) that the pressure is zero.
4 Open the pulsation dampener filler valve (G).
5 Flush the hose (D) for a short time by opening the pressure relieve valve (C3).
6 Close the pressure relieve valve (C3).
The actual filling is now started.
DANGER
Prevent fast filling.
It will cause icing at the valves and the hose.
7 Open the pressure reducer valve (C3) in many small steps,

until the recommended pre-charge pressure is reached at the gauge (C2) and gauge (E).
8 Close the pulsation dampener filler valve (G), when the pre-charge pressure is reached.
6.6.2.6 Disconnect
1 Interrupt the nitrogen supply by closing the nitrogen bottle valve (B).
2 Open the drain valve (S).
The hose pressure will drop to pressure zero.
3 Close the pressure reducer valve (C3).
4 Disconnect the pressure regulator (C) from the nitrogen bottle (A+B).
5 Disconnect the safety valve (R) and relieve valve (S).
6 Disconnect the hose (D) from the connector (H) of the nitrogen filling device.
201333-IOM-EN-R01 6.21
Pos : 12.29 /GEHO/H eadi ng/H2/#.# Pr e-charging the acc umulator with nitr ogen @ 5\mod_1231340368299_31.doc @ 45103 @
6.7 Pre-charging an accumulator with nitrogen

Pos : 12.30 /GEHO/Tr ansport and ins tallation/Ins tall ation/Ni trogen filling/Pre-c harging/#### Ni trogen bottl e+charging eq uipment+ac cumulator+s afety val ve @ 4\mod_1210236627950_31.doc @ 29246 @
6.7.1.1 Nitrogen bottle with charging equipment, accumulator

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 manual valve
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
Figure 6.18: Nitrogen bottle with charging equipment

H Charging unit:
I Non-return valve (prevents gas to flow out of the accumulator)
J Shut-off-valve
KManual valve for pressure relief
L Pressure gauge indicating the actual filling pressure
M Accumulator
N 3/2 manual ball valve, with drain side to release the pressure at the fluid side of the accumulator
O Safety relieve valve, to protect the accumulator against pressure overload.
The relieve pressure depends on the maximum allowed pressure of the accumulator and the charging
equipment.
6.22 201333-IOM-EN-R02
Pos : 12.32 /GEHO/Tr ansport and ins tallation/Ins tall ation/Ni trogen filling/Pre-c harging/#### Acc u-N2- pre-c harging proc edur e with s afety val ve @ 1\mod_1169741590336_31.doc @ 12010 @
6.7.1.2 Accumulator pre-charging procedure

DANGER
Refer to chapter "Safety regulations and instructions for nitrogen".
DANGER
ACCUMULATOR INSTRUCTIONS
Refer to document "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,
then that leads to a wrong combination of nitrogen volume and pressure.
That will affect the function of the accumulator.
6.7.1.3 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 the lay-out details:
• Keep fluid in the piping below the accumulator.
• Prevent that air fills the fluid compartment of the accumulator.
3 Make sure that shut-off-valve (J) is closed.
4 Make sure 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 the 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 use the filling procedure below.
6.7.1.4 Filling preparation

1 Close the pressure reducer valve (F).
2 Connect the pressure reducer (C) to nitrogen bottle (A+B).
3 Connect the hose (G) to pressure reducer (C).
4 Open the nitrogen bottle valve (B) slowly.
• Check at the gauge (D) the pressure in the bottle,
it has to be more than the recommended accumulator pressure.
• Make sure that the pressure at the gauge (E) 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).
201333-IOM-EN-R01 6.23
6 Connect the hose (G) to the charging unit (H).
6.7.1.5 Nitrogen pre-charge filling

1 Open the shut-off-valve (J).
2 Open the 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, because it will cause icing at the valves and the hose.
3 If the recommended pre-charge pressure is reached, then:

4 Close the nitrogen bottle valve (B), so the nitrogen supply is interrupted.
5 Close the pressure reducer valve (F).
6 Close the shut-off-valve (J), so the accumulator is isolated.
7 To release the nitrogen pressure in the hose:
Open the pressure relief valve (K).
• Make sure that the pressure is zero at the gauge (L).
• Make sure that the pressure is zero at the gauge (E).
6.7.1.6 Disconnect the nitrogen supply line

1 Make sure, that nitrogen bottle valve (B) is closed.
2 Disconnect the pressure regulator (C) from nitrogen bottle (A+B).
3 Disconnect the hose (G) pressure regulator (C+O).
4 Disconnect the hose (G) from charging unit (H).
6.7.1.7 Return to operation.

1 If charging unit (H) stays at the accumulator, then:
• Leave the 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 the 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 the 3/2 ball valve (N), to allow fluid pressure at the fluid side of the accumulator.
Pos : 13 /--- Secti on br eak - Odd pag e --- @ 0\mod_1136277036628_0.doc @ 765 @ 444444
6.24 201333-IOM-EN-R02
Operation, Start-up + Start + Stop procedures
Pos : 14.1 /GEHO/Heading/H 1/#. Operation, Start- up + Start + Stop proc edur es @ 0\mod_1136455316013_31.doc @ 933 @
7 Operation, Start-up + Start + Stop procedures

Pos : 14.2 /GEHO/Heading/H 2/## Start- up chec klis t, GEH O + VFD main power s witc h OFF @ 2\mod_1173875659029_31.doc @ 12732 @
7.1 Start-up, working with the GEHO + VFD 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 switches against "unwanted switch-on".
VFD = "VARIABLE FREQUENCY CONVERTER DEVICE" that regulates the speed of the
main motor.
Pos : 14.3 /GEHO/Start and Stop/C ommon/Warni ng - H eavy parts - Us e hoisti ng eye @ 1\mod_1165935566336_31.doc @ 9221 @ 2
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/H 3/#.#.# Initial lubrication filling @ 1\mod_1171376311244_31.doc @ 12412 @
7.1.1 Initial lubrication filling

Pos : 14.5 /GEHO/Start and Stop/C ommon/Lubric ati on - Initial @ 1\mod_1165995657192_31.doc @ 9251 @
If applicable, then check and perform an initial lubrication filling of the following parts.
7.1.1.1 Gear box (if applicable):

1 Check the oil level in the gearbox.
2 If the gearbox has an oil cooling system and/or oil filters,
then check the oil level again, immediately after starting the oil circulation, to ensure, that the circulation
system is filled properly.
3 If necessary, then add or drain oil until the right level is reached.
Refer to chapter "Appendix: Catalogue information" for details about the procedure.
Refer to document "UTILITY CONSUMPTION LIST" for details about the oil type and oil quantity.
7.1.1.2 Tooth coupling between gearbox and pump shaft (if applicable):
Refer to chapter "Installation", "Drive unit" for details.
Refer to chapter "Appendix: Catalogue information" for details about the procedure.
7.1.1.3 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 document "UTILITY CONSUMPTION
LIST" for details about the oil type and oil
quantity.
6 Check the oil level gauge.
At initial filling or re-filling, the oil level
should be near level (B).
7 Close all covers.
Figure 7.1: Correct oil filling level at the oil level gauge
201333-IOM-EN-R01 7.1
Working with the main power switch ON at the GEHO control box:
8 Check the direction of rotation of the lubrication pump.
Refer to chapter "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
at the oil level gauge, near level (A).
If necessary, then fill additional oil until level (A).
11 Check the lubrication system.
Continue working with the main power switch OFF at the GEHO control box.
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7.1.2 Propelling liquid

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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.
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7.1.3 Air supply unit

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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 a 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 requirements.
Refer to document "UTILITY CONSUMPTION LIST" in chapter "Technical data" 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.
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7.1.4 Pre-charging an accumulator

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The accumulator of the propelling liquid system must be pre-charged with gas.
Refer to document "INSTRUMENT AND EQUIPMENT LIST" for the correct pre-charge pressure.
Refer to document "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 : 14.12 /GEHO/H eadi ng/H3/#.#.# Procedure pre-c harging a pulsation dampener with nitrogen @ 0\mod_1156314333839_31.doc @ 5777 @
7.1.5 Procedure pre-charging a pulsation dampener with nitrogen

Pos : 14.13 /GEHO/Start and Stop/C ommon/Pre-c harge puls ation dampener, r efer to i nstallati on @ 1\mod_1169653974927_31.doc @ 11992 @
Refer to chapter "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.
7.2 201333-IOM-EN-R02
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eparation
7.2 Start-up checklist, working with the GEHO main power switch ON
DANGER
• Make sure that the power of the main motor and its VFD is switched OFF.
• Secure the main power switch of the main motor and its VFD against "unwanted switch-
on".
VFD = "Variable Frequency converter Device " that regulates the speed of the main motor.
ATTENTION
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7.2.1 Main power switch

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DANGER
From this step on, to proceed the "Start, preparation check list", electric main power supply is
needed only at the GEHO Pump Control System and its GEHO HMI PANEL.
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DANGER
While working on the pump, it is not permitted to start the pump.
• If working during maintenance or service,
then set the main motor power switch to the 0-position (OFF) and lock the switch.
• Secure the main motor power switch against "unwanted switch-on",
until the pump system is safe to run.
• NEVER switch on the main motor power switch, until the pump system is safe to run.
Operation at the GEHO HMI PANEL

1 Check that the pump EMERGENCY STOP SYSTEM is operational.
2 Check, that the pump system is safe to switch on and run.
3 Switch the main switch at the "GEHO HMI PANEL" to the 1-position (= ON).
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7.2.2 Start-up, electrical check

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1 Ask an authorized electrician to check that the auxiliary electric motors turn in the direction,
as indicated on the motor cover or on the pump power end.
2 If a motor turns in the wrong direction,
then change the electrical connections.
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7.2.3 Initial power end oil check

1 Check the oil level at the power end.
Refer to chapter "Initial lubrication filling".
201333-IOM-EN-R01 7.3
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eparation
7.3 Start-up, priming procedure

ATTENTION
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7.3.1 Priming the slurry section

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7.3.1.1 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 document "UTILITY CONSUMPTION LIST" for the required flush water quality and
quantity and pressure.
7.3.1.2 Procedure filling the slurry section with flush water and de-aeration
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 document "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).
7.4 201333-IOM-EN-R02
6 Close the drain valve (B).

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 document "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 c hapter, to pri me the pr opelling liquid s ecti on.
201333-IOM-EN-R01 7.5
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7.3.2 Priming the propelling liquid section

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ATTENTION
Refer to document "UTILITY CONSUMPTION LIST" for the required flush water quality and
quantity and pressure.
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 document "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 pump.
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 filling
valve (K) for 15 minutes.
Refer to document "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, then repeat the steps 7 and 8 until all vent valves (E) of the diaphragms are closed.
10 After de-aeration, as long as a filling valve 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;
7.6 201333-IOM-EN-R02
• the corresponding filling valves will close, the filling will stop;
• at the GEHO touch panel the corresponding diaphragm position light (ZSL) will turn off.
11 If necessary, then repeat step 7 until at the GEHO touch panel all position lights of all diaphragms are
off.
Positioning of the diaphragms in relation to the pistons:

ATTENTION
Avoid that the pump rotates without lubrication.
12 Start the lubrication pump.
13 Check that the lubrication system delivers the oil quantity.
14 Rotate the pump crankshaft manually.
DANGER
• Make sure that the power of the drive motor is switched off.
Refer for details to the chapter "Manual rotation of the pump".

15 If at the GEHO touch panel one of the lights of switch (ZSH) or (ZSL) of the diaphragm position is lit,
then stop rotation of the pump.
• If indicator (M) meets switch (ZSL), so related switch light is lit,
then 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,
then the propelling liquid automatic control system will drain propelling liquid,
until the switch light is off.
16 Wait until this switch light is off.
17 Repeat steps 10 to 12 until no switch lights light up during rotation of the pump.
18 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
19 Close the drain valve (B) in the discharge line.
20 Close the flush water valve (D) of the flushing water connection in the suction line.
21 Stop the flush water supply.
22 Open the main valve (C) in the suction line.
23 Open the main valve (A) in the discharge line.
201333-IOM-EN-R01 7.7
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7.4 Operating the GEHO Touch Panel + GEHO Pump Control System
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Refer to document "TYPICAL MANUAL OF THE GEHO HMI PANEL" in chapter "Technical data" for
operating the "GEHO HMI PANEL".
Refer to document "DESCRIPTION OF THE PUMP CONTROL SYSTEM" in chapter "Technical data" for
operating the GEHO Pump Control System.
7.4.1 Pump operation by local control at the "GEHO HMI PANEL"

The pump can be operated at the "GEHO HMI PANEL" in a "LOCAL" mode = local stand alone operation.
The procedures in this manual cover the operation of the pump at the "GEHO HMI PANEL" in its "LOCAL"
mode.
7.4.1.1 Selection "LOCAL" or "REMOTE" at the "GEHO HMI PANEL"

Check at the "GEHO HMI PANEL" which actual operation mode is active:
■ "LOCAL" = local operation mode at the "GEHO HMI PANEL".
■ "REMOTE" = remote operation mode at a remote control device.
How to switch from local control (= "LOC.") to remote control (= "REM.") and back:
• Push at the "GEHO HMI PANEL" the field button "LOC.REM." to switch from local control mode to remote
control mode and back.
7.4.2 Pump operation by remote control, supplied by others

The "GEHO HMI PANEL" control box has connections for remote control options.
WARNING
Remote control is usually not in the scope of supply of Weir Minerals and has to be provided
by the customer.
Refer to the user manual and safety instructions of the supplier of the remote control.
Refer for details of the remote control options at the GEHO to document
"DESCRIPTION OF THE PUMP CONTROL SYSTEM" and document
"TYPICAL MANUAL OF THE GEHO HMI PANEL".
Selection "LOCAL" or "REMOTE" at the remote control device

Pump operation at the remote control device

7.8 201333-IOM-EN-R02
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7.5 "START" procedures

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7.5.1 Operation definitions

Main motor "RAMP-UP" and "RAMP-DOWN" procedure at the "VFD"
The speed of the electric main motor is controlled by a "VFD" (= "Variable Frequency converter Device").
At this "VFD" the minimum and the maximum speed of the main motor is locked in its pre-settings.
These pre-settings can not be overruled at the "GEHO TOUCH PANEL" or at a remote control device.
If the "VFD" is not in the scope of supply of Weir Minerals,
then the supplier has to assure the correct settings at the "VFD".
• The "MAXIMUM SPEED LIMITATION" is part of the "Intended use" specification of the pump,
to protect the main motor and the transmission parts and the pump against overload.
Refer for details to chapter "Technical data" and to the "GEHO pump identification plate" at the pump.
• The "MINIMUM SPEED LIMITATION" is part of the "RAMP-UP" and "RAMP-DOWN" procedure at the
"VFD".
The "MINIMUM SPEED LIMITATION" is NOT part of the "Intended use" specification of the pump,
it is a recommendation to avoid pump speeds below this level.
How to operate the main motor "RAMP-UP" and "RAMP-DOWN" procedure at the "GEHO TOUCH PANEL":
• Push the "START" button = the "VFD" performs the "VFD RAMP-UP" procedure,
to start the motor from "STOP" to the "MINIMUM SPEED LIMITATION".
• Push the "STOP" button = the "VFD" performs the "VFD RAMP-DOWN" procedure,
to stop the motor from the "MINIMUM SPEED LIMITATION" to "STOP".
ATTENTION
The "VFD" performs the "RAMP-UP" and "RAMP-DOWN" procedures independently.
These procedures can only be operated by "EMERGENCY STOP" or "START" or "STOP"
commands, these procedures can not be influenced by other operation means.
"ACTUAL SPEED' at the "GEHO TOUCH PANEL"

The "ACTUAL SPEED" displayed at the "GEHO TOUCH PANEL" gives the real speed of the pump
("SPM" = "Strokes Per Minute" = revolutions of the pump crank shaft).
"SPEED-SETPOINT" signal
The "SPEED-SETPOINT" displayed at the "GEHO TOUCH PANEL" indicates the desired speed of the main
motor (so it can be different form the "ACTUAL SPEED" value).
It can be set with the display buttons "UP", "DOWN" and "ZERO" at the "GEHO TOUCH PANEL".
ATTENTION
The "VFD" will ignore:
• a "SPEED SETPOINT" higher then the "MAXIMUM SPEED LIMITATION" set at the
"VDF",
• a "SPEED SETPOINT" lower then the "MINIMUM SPEED LIMITATION" set at the
"VDF".
"ZERO" button at the "GEHO TOUCH PANEL"
• If the "SPEED-SETPOINT" at the "GEHO TOUCH PANEL" is set to zero,
and the "MINIMUM SPEED LIMITATION" at the "VFD" is also set to zero,
then the motor and the pump remain in a "stand-by idle status".
(= "0 SPM" at the "GEHO TOUCH PANEL" = zero "Strokes Per Minute"
= zero revolutions per minute of the pump crank shaft.)
201333-IOM-EN-R01 7.9
7.10 201333-IOM-EN-R02
7.5.2 "PRE-START" check list

DANGER
If the pump is operated, then the operator has to assure:
1 that the pump can run safely,
2 that the pump can deliver its flow safely,
3 that the pump will not run dry.
• NEVER start the main motor, if one of the checks below fails.
Control systems:
1 Check the air supply and the air pressure.
Refer to document "UTILITY CONSUMPTION LIST" for details about quality and quantity and
pressure.
2 Check the pre-charge pressure of the diaphragm pulsation dampeners.
Propelling liquid section:

3 Check that the propelling liquid sections are filled.
4 Check that the propelling liquid sections are de-aerated.
5 Check that the propelling liquid de-aeration valves are closed.
Slurry section at the pump:

6 Check that the slurry end is filled and de-aerated.
Slurry lines of the pump system:

7 Check that all slurry line flushing valves are closed.
8 Check that all slurry line drain valves are closed.
9 Check that the slurry line main suction valve is open.
10 Check that the slurry line main discharge valve is open.
7.5.3 "PRE-START" working with the GEHO and "VFD" main power switch "ON"
1 Check that the pump "EMERGENCY STOP SYSTEM" is operational.
2 Check that the main power switch of the GEHO pump system is switched "ON".
3 Switch "ON" the main power switches of the "VFD" (Variable Frequency Drive) and the main motor.
201333-IOM-EN-R01 7.11
7.5.4 "PRE-START" procedure, if "LOCAL" operated

Use this procedure only, if the pump system is ready to operate.
1 Push the "START/STOP" button at the "GEHO TOUCH PANEL".
2 Push the "PRE-START" button at the "GEHO TOUCH PANEL".
The electrical "PRE-START" procedure performs:
2.1 Start of all auxiliary systems.
2.2 Check of the electrical "PRE-START" conditions.
The main motor can only start, if all pre-conditions are fulfilled.
Refer for details to the document "LOGIC DIAGRAM" in chapter "Electrical information",
and the document "DESCRIPTION OF THE PUMP CONTROL SYSTEM in chapter "Technical data".
2.3 During the "PRE-START" procedure the "COMMON ALARM" lamp flashes.
2.4 If the "PRE-START" procedure is finished successfully and the pump is ready to run, then:
• the "COMMON ALARM" lamp stops flashing,
• "PUMP READY TO RUN" is displayed at the "GEHO TOUCH PANEL".
Go to the "START" procedure.
2.5 If the "PRE-START" procedure fails for the pump is not ready to run, then:
• the "COMMON ALARM" lamp keeps flashing,
• the concerned alarms are displayed at the panel.
Check the reasons for the alarms and solve the causes.
Repeat this "PRE-START" procedure.
7.5.5 "PRE-START" procedure, if "REMOTE" operated

During "REMOTE" operation, the "GEHO TOUCH PANEL" displays:
7.12 201333-IOM-EN-R02
7.5.6 "START" procedure, if "LOCAL" operated

1 Check the "SPEED-SETPOINT" at the "GEHO TOUCH PANEL".
Push the button "ANALOG VALUES" to check the "SPEED SETPOINT".
2 Change the "SPEED SETPOINT" value with the buttons "UP" and "DOWN".
3 Push the "START" button at the "GEHO TOUCH PANEL".
4 The "VFD" starts the "RAMP-UP" procedure,
the main motor starts and runs up
first phase to the value of the "MINIMUM SPEED LIMITATION" at the VFD,
second phase to value of the "SPEED-SETPOINT" speed.
4.1 Push the button "ANALOG VALUES" to check the "SPEED SETPOINT" and the "ACTUAL SPEED".
4.2 If at the "VFD" the "MINIMUM SPEED LIMITATION" is set to zero,
then the motor will only speed up by pushing the "UP" button.
Changing the speed of the pump:

1 Change the "SPEED SETPOINT":
Push the "UP" button or "DOWN" button at the "GEHO TOUCH PANEL".
ATTENTION
The "Variable Frequency converter Device" (= "VFD") will ignore:
• A "SPEED SETPOINT" higher then the "MAXIMUM SPEED LIMITATION" set at the
"VDF".
• A "SPEED SETPOINT" lower then the "MINIMUM SPEED LIMITATION" set at the
"VDF".
2 Check that the "ACTUAL SPEED" follows the "SPEED SETPOINT" value.
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7.5.7 "START" procedure, if "REMOTE" operated

INFORMATION
If applicable, refer to the manual of the supplier of the remote control system.
Refer also to document "DESCRIPTION OF THE PUMP CONTROL SYSTEM" in chapter
"Technical data" for details about remote control.
• Push the button "LOC.REM." to switch from local control to remote control and back.
During "REMOTE" operation, the "GEHO TOUCH PANEL" displays:

The "ACTUAL SPEED" of the pump.
201333-IOM-EN-R01 7.13
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7.6 "STOP" procedures

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7.6.1 "EMERGENCY STOP" procedure

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"CE" conformity
DANGER
An emergency shut down button has to be present within a short distance of the pump.
DANGER
When failing to install and maintain the "EMERGENCY STOP" button equipment in
accordance with this manual, then the installation is no longer in "CE"-conformity (as defined
by the European "Directive on machinery 98/37/EC and 2006/42/EC") and thus results in:
Refer to chapter "Safety equipment" for details about requirements of the "EMERGENCY STOP" system.
"EMERGENCY STOP" signal

In case of an "EMERGENCY STOP":
DANGER
• The "EMERGENCY STOP" overrules all other operation options.
• The electrical supply of all pump auxiliary motors will shut-down immediately.
• The "VFD" (="Variable Frequency converter Device") stops the main motor.
Refer for details to the manual of the VFD system in "Appendix: Catalogue information".
• The pump system (motor + transmission + pump) will without power supply stop
(coast to rest, wasting its dynamic energy).
• The pump control system (with the "GEHO TOUCH PANEL") remains operational,
but as long as the "EMERGENCY STOP" status remains,
all operation options of the motors are blocked.
DANGER
After an "EMERGENCY STOP":
• Refer to the manual of the "EMERGENCY STOP" system of the supplier of that system for
procedures how to handle an "EMERGENCY STOP" and how to start again.
• 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.
7.14 201333-IOM-EN-R02
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7.6.2 "STOP" procedure, if "LOCAL" operated

ATTENTION
This "STOP" button procedure is preferred:
• For longer operation interruptions, to switch off all auxiliary systems of the pump.
• For a normal stop, that does not require an "EMERGENCY STOP".
If the pump is stopped with the "STOP" button,
then start the pump with the "PRE-START" button, to start all auxiliary systems.
To stop the pump:

1 If the pump runs in the "REMOTE" mode,
to switch the control in the "LOCAL" mode,
then push the "LOCAL" or "REMOTE" button at the "GEHO TOUCH PANEL".
2 Push the "STOP" or "STOP" button at the "GEHO TOUCH PANEL".
3 Push the "STOP" button at the "GEHO TOUCH PANEL".
The automatic "STOP" program contains:
3.1 The "VFD" stops the main motor with the "RAMP-DOWN" procedure.
3.2 All auxiliary systems will stop.
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7.6.3 "STOP" procedure, if "REMOTE" operated

INFORMATION
If applicable, refer to the user manual and safety instructions of the supplier of the remote
control.
• Push at the "GEHO TOUCH PANEL" the button "LOC.REM." to switch from "LOCAL"
control to "REMOTE" control and back.
Refer also to document "DESCRIPTION OF THE PUMP CONTROL SYSTEM" in chapter
"Technical data" for details about the remote control.
201333-IOM-EN-R01 7.15
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7.6.4 "STOP" procedure for flushing

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7.6.4.1 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 drawing "FLUSHING/FILLING/DRAIN CONNECTIONS" in chapter "Technical data"
for details, how this may be arranged on the pump system.
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7.6.4.2 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 documents "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.
7.16 201333-IOM-EN-R02
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7.6.5 "STOP" procedure for maintenance

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DANGER
Before working on the pump system, it is necessary to:
• Flush the pump 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 all pump system main switches, to prevent un-intentional starting.
7.6.5.1 Pump, switch off procedure

1 Flush the pump slurry section with clean water for at least 5 minutes.
Refer to chapter "Stop for flushing procedure".
2 Push the "STOP" button at the "GEHO TOUCH PANEL".
Refer for details to document "DESCRIPTION OF THE PUMP CONTROL SYSTEM" in chapter "Technical
Data".
During this stop the slurry section of the pump remains filled with clean flush water,
the pump remains ready to re-start.
7.6.5.2 Slurry section, de-pressurize and drain procedure

for working on the valves and pump diaphragm and piping.
ATTENTION
• AVOID to disconnect or switch off the air pressure at this phase of the procedure.
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, then depressurize the discharge pulsation dampener.
7 If applicable, then depressurize the suction pulsation dampener.
7.6.5.3 De-pressurize the pump auxiliary systems.

1 Safety relief valve:
Open the drain valve at the relief valve,
to relief the liquid pressure at the connecting piping between the propelling liquid chambers and the
safety relief valve.
2 Propelling liquid system:
Open the 3-way-drain valve at the pressure accumulator,
to relief the pressure at the connecting piping of the propelling liquid system.
201333-IOM-EN-R01 7.17
7.6.5.4 Stop the air supply

To disconnect or 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.
De-pressurize the slurry suction line and slurry discharge line at the pump(s):
1 Close the main suction valve in the slurry line.
2 Close the main discharge valves in the slurry line.
3 Open the drain valve in the slurry discharge line.
4 Stop and dis-connect the air supply.
7.6.5.5 Switch off the electric main supply to all related parts
DANGER
1 Switch off all electric main switches for the pump system and the main motor and its
"VFD".
2 Lock all electric main switches, to prevent un-intentional starting.
7.18 201333-IOM-EN-R02
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7.6.6 "STOP" procedure for "EXTENDED SHUT-DOWN"

This procedure is recommended to preserve a pump for a temporary "EXTENDED SHUT-DOWN" for more
then 3 weeks up to 6 months.
If a pump should be shut-down or de-commissioned for a period longer then 6 months,
then contact in advance the service department of Weir Netherlands b.v.
ATTENTION
• Contact the OEM suppliers for their instructions for the drive components
(like motor, gearbox, V-belt, coupling, transformer).
Recommendation for the crankshaft turning intervals:
1 Immediately or short after the stop of pumping slurry:
Flush the pump with clean water for at least 5 minutes at minimum speed.
Refer to the flushing procedure.
2 Repeat this every 4 weeks.
If possible, then run the pump with the motor power.
If not possible, then turn the crankshaft with help of the manual provisions.
Preservation procedure
DANGER
Do this work only during shut-down and lock-out of the pump
(refer to chapter "Maintenance safety instructions").
1 Add an anti-corrosion additive agent to the lubrication oil, fill it into the pump power end oil sump,
to achieve an inside preservation of the pump power end components, during running of the lubrication
pump.
We recommend "Shell VSI 8235" for a use at 2% volume solution (avoid higher concentrations).
Crankshaft turning procedure by the motor
1 If installed, then switch on the oil heaters, at least 10 minutes before starting.
2 Refer to the according chapters for the "PRE-START checklist" and to start the lubrication pump.
3 Flush the pump with clean water for at least 5 minutes at minimum speed.
Refer to the flushing procedure.
Crankshaft turning procedure by manual provisions
Refer to the chapter "Special tools", "Socket wrench".
1 Check that the pump crankshaft can turn freely and pump water, without pressurizing the discharge
line (with an open flushing valve in the discharge line).
2 If installed, then switch on the oil heaters, at least 10 minutes before start-up.
3 Use the normal procedures to start the lubrication pump.
4 Run the lubrication pump for at least 5 minutes.
Check at an open side cover, that the bearings and crosshead are lubricated.
5 Turn the crankshaft around (minimum 2 complete revolutions), by the manual provisions, according to
chapter "Socket wrench".
6 Stop the lubrication pump.
Preservation of the pump parts
1 Shut-down and lock-out the pump.
2 Coat the machined surfaces with a preservation agent.
We recommend "Cortec VCI-369D" (or "Castrol Rustillo DWX-32" or equal).
"Cortec VCI-369D" is compatible with the recommended lubrication oil, so it does not require to be
removed, before putting the pump into operation again.
3 Refer to chapter "2/2 way valves: inspection and preservation" for the preservation of these valves.
4 Replace the air filter at the power end by a plug, to avoid loss of the agent by evaporation.
5 Clean the pump at the outside.
6 Before the next start of the pump, a de-aeration of the propelling liquid system and a priming of the
pump are required.
Refer to the according procedures.
201333-IOM-EN-R01 7.19
Maintenance
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8 Maintenance
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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 and hot parts and parts under pressure.
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 "STOP for maintenance procedure"
(including de-pressurizing and draining the slurry section and dampeners).
• Lock-out power the supply to the main motor and its VFD
"Variable Frequency converter Device".
• Lock-out power the supply to the lubrication oil motor.
• Lock-out power the supply to the propelling liquid motor.
• Lock-out power the supply to all auxiliary motor(s) of the gearbox (if applicable).
• Lock-out power the supply to the GEHO HMI TOUCH 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.
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201333-IOM-EN-R01 8.1
Maintenance
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_31.doc @ 84888 @
8.2 Maintenance: log book
ATTENTION
• Use a log book, to achieve a proper operation and maintenance history.
As part of a plant quality assurance plan, we recommend to use a log book with operation and
maintenance checklist sheets.
Copies of the following pages can be used to achieve this.
8.3 Maintenance: references
Refer for the allowable performance data to chapter "TECHNICAL DATA":

• PDS.201333 "PUMP DATA SHEET".
Refer for the location and technical data of the maintenance checkpoints to chapter "Technical data":
• 814.201333.00 "DIMENSIONED OUTLINE DRAWING",
• 814.201333.02 "INSTRUMENT AND EQUIPMENT LIST",
• 814.201333.03 "P&I DIAGRAM TZPM 1200",
and chapter "Appendix: Parts - Lists and drawings (pump section)".
Refer for operation of the "GEHO HMI TOUCH PANEL" to

chapter "Technical data":
• 814.2TZPM.24 "TYPICAL MANUAL OF THE GEHO HMI TOUCH PANEL TZPM",
• 814.201333.20 "DESCRIPTION OF THE PUMP CONTROL SYSTEM",
chapter "Appendix: Electrical information":
• Electric drawings: S.814.201333.05 + S.814.201333.06 + S.814.201333.07 + S.814.201333.09.
8.4 Maintenance: checkpoints of pump drive components

Refer to chapter “Appendix: Catalog information”, for documents about the pump components and their
maintenance.
8.2 201333-IOM-EN-R02
Maintenance
8.5 Maintenance: daily checkpoints

Log.nr. Date Pump number Operation hours Performed by Done
Rem.
_ _ . _ _. _ _ _ _ 10201333/ __
Daily 1 General function inspection with a running pump:
check-
points
CAUTION
During operation, with running pump,
(to achieve a diagnosis of the pump performance).
Refer to chapter "Maintenance safety instructions".
1.1 "GEHO HMI TOUCH PANEL":

Daily Checkpoint Location Check / Action Done
check- Rem.
points
Alarm check Pump Control: Push the alarm button for a manual check
"GEHO HMI TOUCH PANEL" of the alarm light.
T.814.201333.49 -001 Refer to the documents
814.2TZPM.24 + 814.201333.20
in chapter "Technical data".
General "GEHO HMI TOUCH PANEL" Check all performance data.

performance Refer to the documents
check 814.2TZPM.24 + 814.201333.20
Slurry flow "GEHO HMI TOUCH PANEL" Check for a correct relation between the
pump speed and the slurry flow rate.
Refer to the documents
814.2TZPM.24 + 814.201333.20
201333-IOM-EN-R01 8.3
Maintenance
1.2 General status + performance:

check- Rem.
points
General round 814.201333.00 Check for changes in running noise.
check All units + Check for abnormal:
systems + temperatures, contamination,
piping + vibrations, filters.
connections Check for leaks of air, oil, slurry.
"Discharge pressure transmitter Check for no alarms at the
working pressure": T.814.201333.44 - "GEHO HMI TOUCH PANEL".
pressure 002=PIT3 Check the trend graphs at the
transmitter, "GEHO HMI TOUCH PANEL".
connected to the Displayed at the Check the slurry discharge pressure.
top of the "GEHO HMI TOUCH
discharge PANEL". Refer for the allowed discharge
pulsation 814.2TZPM.24 + pressure to:
dampener. 814.201333.20 > the GEHO PUMP identification plate.
In chapter "TECHNICAL DATA":
> PDS.201333 "PUMP DATA SHEET",
> 814.201333.02 "INSTRUMENT AND
EQUIPMENT LIST".
Refer for the pre-charge pressure of the
dampener to document 814.201333.02
"INSTRUMENT AND EQUIPMENT
LIST" in chapter "Technical Data".
"Discharge pressure gauge Check that the pressure is
working pressure": T.818.080.219 -022 corresponding with the pressure,
pressure gauge, =PI3A, PI3B, PI3C given by the pressure transmitter,
connected to the mentioned above.
top of the
discharge
pulsation
dampeners.
"Suction working pressure transmitter Check the slurry suction pressure.
pressure": T.851.000.470 -014=PI8
pressure gauge, Refer for the allowed suction pressure
connected to the (maximum pressure and minimum
top of the suction NPSH required) to:
air vessel. In chapter "TECHNICAL DATA":
> PDS.201333 "PUMP DATA SHEET",
> 814.201333.02 "INSTRUMENT AND
EQUIPMENT LIST".
8.4 201333-IOM-EN-R02
Maintenance
1.3 Air supply (for the solenoid valves of the "Propelling liquid unit")
check- Rem.
points
Air supply: T.857.000.251 - 65=PI7 Check the pressure.
pressure gauge Refer for the allowed pressure
to document 814.201333.19
"UTILITY CONSUMPTION LIST"
in chapter "Technical Data".
Air supply: T.814.201333.44 - Check that the pressure is corresponding
pressure 01=PIT7 with the pressure,
transmitter Display at the given by the air pressure gauge,
"GEHO HMI TOUCH mentioned above.
PANEL" Check for no alarms at the
814.2TZPM.24 + "GEHO HMI TOUCH PANEL".
814.201333.20
Air supply: T.857.000.251 - 110 Check the air supply.
filter-regulator Check for leaks.
Check for abnormal:
noise, temperatures, vibrations, filter
contamination.
If applicable and necessary:
• Drain the filter.
• Replace the filter.
• Add suitable oil.
Air supply unit NOT IN THE SCOPE Check the air supply pressure.
OF SUPPLY OF Refer for the allowable air quality
"WEIR MINERALS to document 814.201333.19
NETHERLANDS B.V." "UTILITY CONSUMPTION LIST"
201333-IOM-EN-R01 8.5
Maintenance
1.4 Drive unit: T.814.201333.16

check- Rem.
points
Gearbox 814.201333.31 Check the level at oil sight glass.
= T.814.201333.16 -001 Check for abnormal:
noise, vibrations, temperatures,
= LI10 contamination.
Gearbox = TE10J Check for no alarms at the
lubrication oil Display at the "GEHO HMI TOUCH PANEL".
temperature "GEHO HMI TOUCH
sensor PANEL"
814.2TZPM.24 +
814.201333.20
Gearbox bearing = TE10A-I Check for no alarms at the
temperature Display at the "GEHO HMI TOUCH PANEL".
sensor "GEHO HMI TOUCH
PANEL"
814.2TZPM.24 +
814.201333.20
Gearbox cooling Check for leaks.
system: Check for abnormal: noise, vibrations,
- oil pressure = PI10 temperatures, pressure, contamination
- oil temperature = TI10 and flow.
- oil flow = FISLL10 Refer to the instructions of the supplier.
- filter = PDSH10
contamination
Coupling 814.201333.33 Check for changes in the running noise.
pump / gearbox = T.814.201333.16 -003 Check for oil leakage under the safety
cover. This coupling is filed with oil,
lost of oil causes faster wear of its teeth.
Electric Motor 814.201333.30 Refer to the instructions of the supplier.
= T.814.201333.16 -004
Frequency NOT IN THE SCOPE Refer to the instructions of the supplier.
converter (VFD = OF SUPPLY OF
variable frequency "WEIR MINERALS
converter device) NETHERLANDS B.V."
Transformer Not applicable
8.6 201333-IOM-EN-R02
Maintenance
1.5 Lubrication unit: T.814.201333.48

check- Rem.
points
Lubrication oil: T.845.000.495 -138 Check the level at the oil sight glass.
level in the = LI2
frame sump
Lubrication oil T.814.201333.48 - 075 = Check for no alarms at the
temperature TE2 "GEHO HMI TOUCH PANEL".
sensor Display at the
"GEHO HMI TOUCH
PANEL"
814.2TZPM.24 +
814.201333.20
Pressure T.814.201333.48 -015 Check the pressure.
gauge in the = PI2
oil discharge
line
Lubrication oil T.814.201333.48 - 120 Check that the pressure is corresponding
pressure = PIT2 with the pressure,
transmitter Display at the given by the air pressure gauge,
"GEHO HMI TOUCH mentioned above.
PANEL" Check for no alarms at the
814.2TZPM.24 + "GEHO HMI TOUCH PANEL".
814.201333.20
Oil flow sensor T.814.201333.48 -100 Check that the LED’s status is green.
= FISLL2 No alarms at the
"GEHO HMI TOUCH PANEL".
814.2TZPM.24 + 814.201333.20
Oil filter in the T.814.201333.48 -020 Check visual the clogging indicator,
discharge line -021 it should be green.
If necessary, then switch over to the other
oil filter, and replace during shut-down the
clogged filter element.
suction line -017 If the vacuum pressure is between -0.7
and -1.0 bar,
then replace the filter element. Do this
during shut-down.
201333-IOM-EN-R01 8.7
Maintenance
1.6 Propelling liquid unit: T.857.000.251

check- Rem.
points
Propelling T.857.000.251 -152 Check the level at the oil sight glass.
liquid level in = LI6
the tank
discharge line -021 it should be green.
If necessary, then switch over to the other
oil filter, and replace during shut-down the
clogged filter element.
Flow sensor T.857.000.251 -100 Check that the LED’s status is green.
= FISLL6 No alarms at the
814.2TZPM.24 + 814.201333.20
gauge = PI6 Refer for the allowable pressure to
document 814.201333.02
"INSTRUMENT AND EQUIPMENT LIST"
Pressure T.814.201333.44 -001 Check that the pressure is corresponding
transmitter = PIT6 with the pressure, given by the pressure
gauge, mentioned above.
No alarms at the
814.2TZPM.24 + 814.201333.02
De-aeration T.832.000.245 -070 (3x) Vent each diaphragm chamber,
valves of until no air is released.
propelling T.814.201333.52 -002 Watch at the transparent hose for air
liquid at each =FI 6A+6B+6C bubbles.
diaphragm During the start-up period, some air can
house appear.
Air bubbles after the start-up period may
indicate leakage in the propelling liquid
system.
De-aeration T.853.000.284 -018 (1x) Open the needle valve, to vent the safety
vent of valve line, until no air is released.
propelling T.814.201333.52 -002 Watch at the transparent hose for air
liquid = FI5 bubbles.
at the During the start-up period, some air can
pressure appear.
limitation unit Air bubbles after the start-up period may
indicate leakage in the propelling liquid
system.
Safety relief T.853.000.284 -001 Check for no oil leakage inside the safety
valve = PSV5 relief valve, by unscrewing the drain plug
+ drain plug in the (pressure-less side of the) relieve
(for leakage valve.
inspection) During operation, no propelling liquid
should flow or leak.
8.8 201333-IOM-EN-R02
Maintenance

gauge = PI5 Refer for the allowable pressure to
document 814.201333.02
"INSTRUMENT AND EQUIPMENT LIST"
Solenoid 3/2 T.857.000.251 Check for no air leakage.
way air valves - 055 (2x) = HEV9,
HEV15
- 050 (6x) = HEV1,
HEV2,
HEV3, HEV5,
HEV6, HEV7
2/2 way oil Check for no air or oil leakage.
valves: T.853.000.240 -001
= propelling = HV1, HV2, HV3
liquid filling
valves
= propelling = HV5, HV6, HV7
liquid outlet
valves
= propelling T.853.000.240 -001
liquid supply
valves = HV9
= piston T.853.000.240 -014
lubrication
supply = HV15
valve / change
over valve
Sequence for Maximum once per 5 minutes.
actuation of If available/applicable:
the filling Check at the "GEHO HMI TOUCH
valves + outlet PANEL" the history of the propelling liquid
valves valves actuation frequency.
814.2TZPM.24 + 814.201333.20
If the frequency is increasing,
then search for causes.
Like leakage at the piping or wear at the
piston seals.
201333-IOM-EN-R01 8.9
Maintenance
1.7 Frame unit: T.845.000.495

check- Rem.
points
Air propelling T.845.000.495 -140 Check the air conditioner.
liquid unit. When the indicator granules are light
Air lubrication orange then replace the complete filter.
unit.
1.8 Slurry section:

check- Rem.
points
Slurry T.820.201333 No abnormal or extreme noise inside the
discharge + -025 = T.831.000.516 valve housings.
suction valves -026 = T.831.000.515
Covers of T.820.201333 No leakage of slurry through the covers.
discharge -025= T.831.000.516
valve
housings, -026 = T.831.000.515
suction valve
housings, -030 = T.832.000.245
pump
diaphragm
housings
Pulsation T.820.201333 No leakage of slurry through the covers.
dampener in -060 = T.851.000.420
the discharge
line
Air vessel in T.820.201333 No leakage of slurry through the covers.
the suction line -090 = T.851.000.470
8.10 201333-IOM-EN-R02
Maintenance
8.6 Maintenance: “Hot torque” after initial start-up

Rem.
_ _ . _ _. _ _ _ _ 10201333/ __
Interval 1 Maintenance checkpoints during shut-down
“Hot torque” DANGER
after initial Only during shut-down and lock-out of the pump
start-up Refer to chapter "Maintenance safety instructions".
Checkpoint Location Check / Action Done

Rem.
Torque’s of all Re-tighten.
flanges, For the correct torque,
covers, refer to chapter "Tightening torques".
bolts and
nuts
201333-IOM-EN-R01 8.11
Maintenance
8.7 Maintenance: checkpoints 200 hours after initial start-up

Rem.
_ _ . _ _. _ _ _ _ 10201333/ __
Interval 1 Maintenance checkpoints during operation
200 hours CAUTION
after initial During operation, with running pump.
start-up Refer to chapter "Maintenance safety instructions".
1.1 Daily checkpoints
Do the daily checkpoints, with a running pump, before doing the maintenance work
checkpoints. (to achieve a diagnosis of the pump performance)
2 Maintenance checkpoints during shut-down
DANGER
Only during shut-down and lock-out of the pump.
2.1 Frame unit T.845.000.495: Lubrication oil replacement

Refer for details to chapter "Assembly and disassembly".
Rem.
Frame: T.845.000.495 -001 Drain the lubrication oil.
lubrication oil Clean the oil sump carefully.
sump
T.814.201333.48 -010 Inspect the suction strainer (inside the
frame). Clean, if necessary.
T.814.201333.48 -017 Replace the oil filter element in the
suction line.
T.814.201333.48 -021 Replace the oil filter element in the
discharge line.
Refer for specifications to
document 814.201333.02
Fill the sump with new oil.
Refer for the correct oil quality and
quantity to document 814.201333.19
"UTILITY CONSUMPTION LIST"
T.845.000.495 -138 Check oil level at the oil sight glass.
8.12 201333-IOM-EN-R02
Maintenance
2.2 Drive unit: T.814.201333.16

Rem.
Gearbox: oil 814.201333.31 Replace the oil.
= T.814.201333.16 -001 Refer to "Catalogue information",
"Gearbox" for manual instructions of the
manufacturer.
- Clean the magnet drain plug.
Gearbox: Refer for the correct oil quality and
oil quality and quantity to document 814.201333.19
quantity "UTILITY CONSUMPTION LIST"
Gearbox: oil = LI10 Check the oil level at the oil dipstick / oil
level glass , immediately after start-up, to
ensure, that the gearbox is filled
properly.
Gearbox cooling Replace the oil filter element in the
system gearbox cooling system.
Refer for specifications to
document 814.201333.02
201333-IOM-EN-R01 8.13
Maintenance
8.8 Maintenance: interval checkpoints

Rem.
_ _ . _ _. _ _ _ _ 10201333/ __
Interval legend
2000 = After each operating period of 2000 working hours,
or after 3 months of operation, whatever comes first.
Done
1 General function inspection of a running pump Rem.
CAUTION
During operation, while running.
Refer to chapter "Maintenance Safety Instructions".
1.1 Daily checkpoints

2000 Do the daily checkpoints, with a running pump, before doing the maintenance work
checkpoints (to achieve a diagnosis of the pump performance).
2. Maintenance checkpoints during shut-down
DANGER
Only during shut-down and lock-out of the pump.
2.1 Lubrication oil sample

To achieve reliable and economical performance of the pump,
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.
Refer for the procedure to document MI.093701 "MAINTENANCE INSTRUCTION FOR
LUBRICATION OIL MONITORING AND SAMPLING" in chapter "Technical Data".
Interval Checkpoint Location Check / Action Done
Rem.
2000 Frame unit: T.845.000.495 -136 Do the oil quality laboratory check.
lubrication oil Take an oil sample at the probe plug
sump between the pump and the filter.
lubrication Send it in to the oil supplier laboratory, for
system a recommendation of a time schedule for
replacing the oil.
Depending on the result,

if necessary:
Replace the oil and the oil filters.
Refer for instructions and details to the
table for "200 hours interval".
2.2 "DRIVE UNIT": T.814.201333.16
8.14 201333-IOM-EN-R02
Maintenance

Rem.
2000 Gearbox 814.201333.31 Refer to the instructions of the supplier.
+ cooling system = T.814.201333.16 -001 Refer to “Appendix: Catalogue
information”, "Drive unit", "Gearbox".
2000 Gearbox: oil Do the oil quality laboratory check.
Take an oil sample and send it in to the
oil supplier laboratory, for a
recommendation of a time schedule for
replacing the oil.
if necessary:
Replace the oil filter elements.
Refer for instructions and details to the
table for the "200 hours interval".
2000 Gearbox Grease at the grease nipples the seals
of the output shaft and/or the input
shaft.
Refer to the manual of the gearbox, to
the related sticker on the gearbox and
to the lay-out drawing of the gearbox.
4000 Gearbox Replace the air filter.
2000 Coupling 814.201333.32 Refer to the instructions of the supplier.

motor / gearbox = T.814.201333.16 -002 Refer to “Catalog information”,
"Drive unit", "Coupling".
4000 Check the coupling alignment.
Refer for details to chapter "Transport
and installation", "Drive unit".
Re-align, if necessary.
2000 Coupling 814.201333.33 Refer to the instructions of the supplier.

pump / gearbox = T.814.201333.16 -003 Refer to “Catalog information”,
"Drive unit", "Coupling".
4000 Check the coupling alignment.
Re-align, if necessary.
8000 Replace the oil in the ZAPEX coupling.

Refer to "Catalogue information",
"Drive unit" for manual instructions of
the manufacturer.
Refer for the correct oil quality and
quantity to document 814.201333.19
"UTILITY CONSUMPTION LIST" in
chapter "Technical Data".
Motor 814.201333.30 Refer to the instructions of the supplier.
= T.814.201333.16 -004
201333-IOM-EN-R01 8.15
Maintenance
Frequency NOT IN THE SCOPE OF Refer to the instructions of the supplier.

converter SUPPLY OF
(VFD = variable "WEIR MINERALS
frequency NETHERLANDS B.V."
converter
device)
Transformer Not applicable
Air supply NOT IN THE SCOPE OF Refer to the instructions of the supplier.
SUPPLY OF Refer for the details about the air supply
"WEIR MINERALS to 814.201333.19
NETHERLANDS B.V." "UTILITY CONSUMPTION LIST"
2.3 "FRAME UNIT" T.845.000.495

Rem.
4000 Check the drive T.845.000.495 - 118 Visual outside inspection:
shaft seals No oil should leak at the outside end of
the pump drive shaft.
Record sign’s of wear damages.
If necessary, contact the Service
Department of "WEIR MINERALS
NETHERLANDS B.V."
4000 Frame unit T.845.000.495 Remove the frame main cover and the
frame inspection covers.
Check the Visual inside inspection:
moving parts. Record sign’s of wear or damages or
corrosion
at the crankshaft +crossheads + guides
+ bearings.
If necessary, contact the Service
NETHERLANDS B.V."
4000 Crosshead rod T.845.000.495 Visual inspection:
seals in the dust See, detail X: Check for no oil leakage between the
cover -080 crankshaft frame and the piston
-081 chamber.
If necessary, then contact the Service
NETHERLANDS B.V."
8000 Piston adapter T.845.000.495 -046 Check the required tightening torque,
flange / T.835.000.206 -012 according to chapter "Tightening
connection torques".
piece Re-tighten, if required.
8000 Air vent/filter of T.845.000.495 -140 (1x) Replace the air vent/filter.
the lubrication oil Refer for specifications to
sump, located document 814.201333.02
on inspection "INSTRUMENT AND EQUIPMENT
cover. LIST" in chapter "Technical Data".
8.16 201333-IOM-EN-R02
Maintenance
2.4 "PISTON UNIT": T.835.000.206

Rem.
4000 Piston seals Check at the
"GEHO HMI TOUCH PANEL" in the
"TRENDS GRAPH" menu the filling
frequency.
Refer to the document 814.2TZPM.24
A high filling frequency can indicate
leakage at the piston seals.
"SET OF ROOF T.835.000.206 Visual inspection:
SHAPED RINGS" -009+011 Check for no propelling liquid leakage
(chevrons) from the pump cylinder to the piston
chamber.
Replace, if required.
Refer for instructions and details to
chapter "Assembly and disassembly",
"Piston unit".
If necessary, then contact the Service
NETHERLANDS B.V."
8000 Piston rod T.835.000.206 -001 Inspect the surface of the piston rod.
"Piston unit".
8000 Piston body and T.835.000.206 Inspect the surface of the piston body.
retaining plates - 002 Inspect the retaining plates. Inspect if
- 003 the retaining bolts are bent.
"Piston unit".
8000 O-ring piston body. T.835.000.206 Inspect the o-ring of the piston body.
- 029 Replace, if required.
8000 Cylinder liner T.835.000.206 -006 Inspect the surface of the cylinder liner.
"Piston unit".
8000 Piston body lock nut T.835.000.206 -010 Check the required tightening torque,
according to chapter "Tightening
torques".
Re-tighten, if required.
8000 Nuts piston body / T.835.000.206 -005 Check the required tightening torque,
retaining plates according to chapter "Tightening
torques".
8000 Nuts connection piece T.835.000.206 -012 Check the required tightening torque,
/ adaptor flange -015 according to chapter "Tightening
torques".
201333-IOM-EN-R01 8.17
Maintenance
2.5 Propelling liquid replacement

Refer for details to chapter "Assembly and disassembly".
Rem.
8000 Propelling liquid T.857.000.251 Do the oil quality laboratory check.
system and oil tank Take an oil sample and send it in to
the oil supplier laboratory, for a
recommendation of a time schedule
for replacing the oil.
if necessary:
"Propelling liquid system".
8000 Propelling liquid T.857.000.251 -040 Check the pre-charge pressure.
accumulator Refer for specifications to
document 814.201333.02
chapter "Pre-charging an accumulator
with nitrogen".
8000 2/2 way oil valves T.853.000.240 Check at the "GEHO HMI TOUCH
= propelling liquid - 001 PANEL" in the "TRENDS GRAPH"
filling + outlet + supply = HV1, HV2, HV3 menu the filling frequency.
(TZPM: + flushing) = HV5, HV6, HV7 A high filling frequency can indicate
= HV9 leakage in these valves.
- 014
= HV15
= T.857.000.251
- 070 = HV15
Inspect the functions.
2/2 way oil valves T.853.000.240 -002 Replace parts, if there is any leakage
valve seat: between the valves and valves seats.
2/2 way oil valves spindle / slide Refer to chapter
spindle / seal guide bearings: "2/2 way valves: inspection and
T.853.000.068 preservation".
-001
-014
T.853.000.110
-001
-014
2.6 Slurry section: T.820.201333
Rem.
4000 Covers of the No leakage of slurry through cover
discharge valve T.820.201333 seals or flanges.
housings, -025
= T.831.000.516
(3x)
the suction valve -026
housings, = T.831.000.515
(3x)
8.18 201333-IOM-EN-R02
Maintenance
the pump diaphragm -

housings 030= T.832.000.245
(3x)
8000 Slurry chambers: discharge valves, Carefully clean and inspect the slurry
suction valves, chambers.
diaphragm Watch for internal wear or cracks during
chambers, valve maintenance intervals.
discharge manifolds, In high wear cases,
suction manifolds, check the wall thickness and record
pulsation cavies.
dampeners Contact for spare parts in time the
Service Department of "WEIR
MINERALS NETHERLANDS B.V.".
8000 Pump diaphragm T.832.000.245 -019 Replace the pump diaphragms.
(3x) Refer for instructions and details to
chapter "Assembly and disassembly".
2000 Pulsation T.851.000.420 Visual outside inspection:
dampener(s) in the T.820.201333 -060 No leakage of slurry.
discharge line
Check the nitrogen precharge pressure
(= the pressure at the pressure gauge,
with no pressure under the diaphragm).
Check for no leakage of nitrogen at the
cover and the connecting parts.
8000 Replace the pulsation dampener
diaphragm.
chapter "Assembly and disassembly".
Pre-charge the pulsation dampener,
refer to chapter "Transport and
installation".
2000 Air vessel in the T.851.000.470 Visual outside inspection:
suction line T.820.201333 -090 No leakage of slurry.
2.7 General equipment check
Rem.
4000 Instrumentation Refer to the Clean and calibrate and reset all
drawing 814.201333 instrumentation parts.
.03 Check the set-points, according to
"P&I DIAGRAM" document 814.201333.02
201333-IOM-EN-R01 8.19
Maintenance
3. Maintenance checkpoints during the "Start-up" procedure

Refer to the related chapters in this manual.
3.1 Electrical Installation: T.814.201333.49

Function checks, after the previous maintenance work is done:
Rem.
4000 Initiator union nuts at T.814.201333.49 - Check the initiator union nuts.
the diaphragm 005 Refer for details to chapter "Initiator
housings (3x2 initiators) union nuts at the diaphragm housings".
-ZSH1-2-3
-ZSL1-2-3
4000 Check the function of T.814.201333.49 - Check the transfer signal of the
the diaphragm stroke 005 initiators to the PLC.
control system. (3x2 initiators) Check, after one signal from an initiator
Refer for the function -ZSH1-2-3 to the PLC, that the filling valve and the
details to chapter -ZSL1-2-3 outlet/drain valve are actuated.
"Start-up, priming T.832.000.245 -015
procedure". (3x monitoring rod)
4000 Indication of the stroke "GEHO HMI Check for correct indication of these
positions at the TOUCH PANEL" actions on the
"GEHO HMI TOUCH 814.2TZPM.24 "GEHO HMI TOUCH PANEL"
PANEL" + 814.201333.20 operation screen and events list.
4000 Working of the T.857.000.251 Check the functions.
the propelling liquid - 055(2x) Maximum once per 5 minutes.
filling valves, = SV9, SV15 If available/applicable:
the outlet/drain valves - 050 (6x) Check at the
= SV1, SV2, SV3, "GEHO HMI TOUCH PANEL"
SV5, SV6, SV7. the history of the propelling liquid valves
(= air-solenoid actuation frequency.
valves)
-070
(= propelling liquid /
flush unit) =
T.853.000.240
-001
= T.853.000.068
-014
T.853.000.110
(= oil valves).
Refer for the
function details to
chapter
"Start-up, priming
procedure".
If the frequency is increasing,
then search for causes.
Like leakage at the piping or wear at the
piston seals or a left open vent valve.
8.20 201333-IOM-EN-R02
Maintenance
Pos : 22 /GEHO/Heading/H 2/#.# Lubrication s ystem @ 0\mod_1152094184716_31.doc @ 5126 @
8.9 Lubrication system

Pos : 23 /GEHO/Mai ntenance/CAUT ION during operation @ 6\mod_1235988366046_31.doc @ 47921 @
CAUTION
MAINTENANCE CHECKPOINTS
During operation, with running or stand-by pump.
Pos : 24 /GEHO/As sembl y and Dis ass embl y_during loc k- out/Proc edur es _during loc k-out/Lubric ati on s ystem/### Chec k the oil level @ 0\mod_1138630463309_31.doc @ 2208 @
8.9.1 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, then fill up the lubrication oil.
LIST" in chapter “Technical data”, for the correct
oil type quality and the estimated oil quantity.
Figure 8.1: Lubrication oil level gauge

Pos : 25 /GEHO/Heading/H 5/H 5 Disc harge filter @ 8\mod_1260358440906_31.doc @ 57715 @
Discharge filter
Pos : 26 /GEHO/As sembl y and Dis ass embl y_during loc k- out/Proc edur es _during loc k-out/Lubric ati on s ystem/C hange the dis charge oil filter/### D ouble oil filter resistanc e indic ator-disc harge line @ 5\mod_1220425203165_31.doc @ 37881 @ 5
8.9.2 Oil filter clogging indicator in the discharge line

Refer to the document "INSTRUMENT AND EQUIPMENT LIST" in chapter "Technical data", "Drawings +
lists + instruments" and also to chapter "Catalogue information" for the specification of the oil filer and for
details and specifications of the filter housing.
8.9.2.1 Visual clogging indicator

The filter housing is equipped with a visual
clogging indicator.
Under normal operation conditions, the indicator
will show an empty or a green display, like
shown in the figure.
If the indicator displays red,
then the oil filter resistance is too high and needs
to be replaced urgently.
Always check for abnormal causes for a clogged

filter.
Like testing the oil by a laboratory.
Figure 8.2: Oil filter with visual clogging indicator
Pos : 27 /GEHO/Heading/H 5/H 5 Suc tion filter @ 8\mod_1260358408562_31.doc @ 57705 @ 34
201333-IOM-EN-R01 8.21
Maintenance
Suction filter
Pos : 28 /GEHO/As sembl y and Dis ass embl y_during loc k- out/Proc edur es _during loc k-out/Lubric ati on s ystem/C hange the dis charge oil filter/### si ngle oil filter vis ual anal ogue with s cal e cl ogging indicator-suction li ne @ 8\mod_1260349580890_31.doc @ 57676 @ 5
8.9.3 Oil filter clogging indicator in the suction line

Refer to document "INSTRUMENT AND EQUIPMENT LIST" in chapter "Technical data" and also to chapter
"Catalogue information" for the specification of the oil filer and for details and specifications of the filter
housing.
8.9.3.1 Visual analogue scale indicator

analogue scale indication.
Under normal operation conditions,
the indicator will show a vacuum pressure
between 0 and -0.7 bar.
If the vacuum pressure is between -0.7 and -1.0
bar,
then change the filter element.
filter.
Figure 8.3: Oil filter with visual analogue scale clogging

indicator
8.22 201333-IOM-EN-R02
Maintenance
Pos : 30 /GEHO/Heading/H 2/#.# Propelling liqui d s ystem @ 0\mod_1152094190955_31.doc @ 5132 @
8.10 Propelling liquid system

Pos : 31 /GEHO/Mai ntenance/CAUT ION during operation @ 6\mod_1235988366046_31.doc @ 47921 @
CAUTION
MAINTENANCE CHECKPOINTS
During operation, with running or stand-by pump.
Pos : 32 /GEHO/As sembl y and Dis ass embl y_during loc k- out/Proc edur es _during loc k-out/Propelling liquid s ystem- mai ntenanc e oil /### Chec k the pr opelling lqui d level @ 11\mod_1296031306031_31.doc @ 80572 @
8.10.1 Check the Propelling liquid oil level

The propelling liquid oil level gauge is located at
the propelling liquid tank.
1 Check the Propelling liquid oil level (A) at
the oil level gauge.
2 When the propelling liquid oil level reached
the minimal propelling liquid oil level (A)
then fill up the propelling liquid tank. The
minimal propelling liquid oil level is equal to
a quarter of the total readout.
LIST" in chapter “Technical data”, for the correct
propelling liquid oil type quality and the estimated
propelling liquid oil quantity.
Figure 8.4: Propelling liquid oil level gauge

Pos : 33 /GEHO/Heading/H 5/H 5 Disc harge filter @ 8\mod_1260358440906_31.doc @ 57715 @ 3
Discharge filter
Pos : 34 /GEHO/As sembl y and Dis ass embl y_during loc k- out/Proc edur es _during loc k-out/Lubric ati on s ystem/C hange the dis charge oil filter/### D ouble oil filter resistanc e indic ator-disc harge line @ 5\mod_1220425203165_31.doc @ 37881 @ 5
8.10.2 Oil filter clogging indicator in the discharge line

lists + instruments" and also to chapter "Catalogue information" for the specification of the oil filer and for
8.10.2.1 Visual clogging indicator

clogging indicator.
Under normal operation conditions, the indicator
will show an empty or a green display, like
shown in the figure.
If the indicator displays red,
then the oil filter resistance is too high and needs
to be replaced urgently.

filter.
Figure 8.5: Oil filter with visual clogging indicator
201333-IOM-EN-R01 8.23
Troubleshooting
Pos : 36 /GEHO/Heading/H 1/#. Tr oubl eshooting @ 0\mod_1152772213698_31.doc @ 5244 @
9 Troubleshooting
Pos : 37 /GEHO/Troubles hooti ng/Attention - Tr ouble s hooti ng @ 0\mod_1138615626939_31.doc @ 2139 @ 1
ATTENTION
• Do not hesitate to contact the Weir Minerals Service Department,
if problems occur during trouble shooting.
• 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 : 38 /GEHO/Troubles hooti ng/## Troubl e s hooti ng tabl e (T)ZPM-gear dri ve @ 1\mod_1169136012360_31.doc @ 11845 @
9.1 Trouble shooting

POWER END:
Lubrication system:
Problem/symptom Possible cause Remedy
Noise in the lubrication oil Low oil level in the power end See chapter "Maintenance".
pump. sump.
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,
through its pressure relieve then replace the discharge 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
insufficient oil flow line. points.
(check reading of the oil Oil pump is not running. Check electric connections.
pressure). 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,
through its pressure relieve then replace the discharge filter.
valve, oil and pump get hot.
Suction pipe to oil pump leaks. Tighten connections.
Filter valves closed. Open valves.
Relief valve in the oil pump Check or replace.
clogged.
Relief valve in the oil pump Check or replace.
leaking.
No oil flow at some lubrication Check and clean orifices at the
points. lubrication points.
201333-IOM-EN-R01 9.1
Troubleshooting
Abnormal mechanical noise:

Hammering noise synchronous Malfunction of lubrication system Check the lubrication system.
with dead points of the 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 the worn
crosshead guides, crosshead parts.
bearing, connecting rod bearing,
crankshaft bearing or other.
Power end bearings damaged. Check for temperature rise and
replace if necessary.
Abnormal noise is continuous Malfunction of lubrication Check the lubrication system.
(frequency more than 500 Hz) system.
Power end gears See the general note.
worn/damaged.
Power end bearings damaged. Check for temperature rise and
replace if necessary.
Overheating:
Overheating of the lubrication Malfunction of lubrication Check lubrication system and
oil system. settings or relief valves,
(maximum temperature 80°C). see document "INSTRUMENT AND
EQUIPMENT LIST".
Incorrect setting or worn parts. Correct setting or replace worn parts.
Gears worn. Replace.
Overheating of the crosshead Malfunction of lubrication Check the lubrication system.

liner. system.
Damaged running surfaces. Replace the damaged parts.
Overheating of the bearing Bearings damaged. Replace the bearings.

housing.
Wandered settings or worn Correct the settings or replace.
bearings.
9.2 201333-IOM-EN-R02
Troubleshooting
LIQUID END:
Propelling liquid section:
Propelling liquid filling: Leakage in filling pipe. Tighten connections.
Filling valves too often in Leakage of outlet valve. Replace the outlet valve parts.
operation. Too low air pressure. See chapter "Maintenance".
Filling valve malfunction. Check or replace the valve or the
valve parts.
Leakage of the cylinder liner seal. Check and replace, if necessary.
Pump diaphragm rupture Replace the diaphragm.
(this will cause a knocking noise in the
pump chamber during the discharge
stroke).
Air in the propelling liquid chamber. De-aerate the propelling liquid
chambers.
Piston seal rings leaking. Replace the seal rings.
Leakage in the propelling liquid Repair the leakage’s.
chamber.
Leaking of the safety valves or valve Check and replace if necessary.
seats.
Propelling liquid drain: Leakage of the filling valve. Check and replace the filling valve or
Outlet valves to often in seat.
operating. Rupture diaphragm of the filling valve. Check and replace.
Outlet valves to often in Too low air pressure. Re-adjust the air pressure.
operating Malfunction of the outlet valve. Check and replace if necessary.
Leakage of the cylinder liner seals. Check and replace.
Leakage of the piston seals. Check and replace.
Propelling liquid pump is Leaking of the propelling liquid piping. Tighten the connections.
starting too often. Leaking of the pressure relief valve. Check the set-points and replace the
worn parts.
Propelling liquid accumulator not proper Check the pre-charging.
pre-charged.
Drain valve is leaking. Check and replace.
Damaged running surfaces. Replaced the damaged parts.
Diaphragm rupture. "Timing": Problems to synchronize the For repair and cleaning, refer to
movements of each piston stroke with chapter "Assembly and disassembly",
the diaphragm stroke. "Diaphragm housing unit".
"Priming": Propelling liquid chamber To synchronize the movements of
was not proper filled with oil. each piston stroke with the
diaphragm stroke, refer to chapter
"Start-up, priming procedure".
Settlement of sediment in the Clean the diaphragm housing.
diaphragm housing. Follow the suitable flushing
procedure before the pump stop.
Overfilling by the propelling liquid Check proper functioning of all pump
system. initiators or diaphragm position
transmitters with help of a magnet.
201333-IOM-EN-R01 9.3
Troubleshooting

Filling valve alarm Pressure limitation system is leaking. Check the suction filter,
by 3 minutes time relay. system pressure
(see chapter "Maintenance")
and filter cartridge for damage.
Discharge valve is leaking in such an Replace the valve and valve seat.
extent that slurry under pressure flows
back (during the suction stroke) via the
leaking discharge valve.
Non-return valve in pipe connection Check, clean or replace the non-

between filling valve and propelling return valve.
liquid chamber is clogged or damaged.
The filling valve does not open while Check the diaphragm stroke control
there is an electric signal. system.
Too low air pressure. Re-adjust the air pressure.
Pneumatic plug valve is closed. Check the globe valve and the air
pressure.
Oil level in the propelling liquid tank too For correct quantity,
low. see chapter "Maintenance".
No pressure in the propelling liquid feed Check operating of the propelling

system. liquid pump.
Check the suction line for air leakage
and clogging.
Outlet valve alarm Piping system from outlet valve to the Clean or replace.
by 3 minutes time relay. propelling liquid tank is clogged or
damaged.
Non-return valve in pipe between the Clean or replace.

outlet valve and the propelling liquid
tank is clogged or damaged.
Outlet valve alarm by 3 Much air is left in the propelling liquid De-aerating the propelling liquid
minutes time relay chamber after maintenance work. chamber.
The outlet valve does not open while Check the diaphragm stroke control
there is an electric signal. system.
Diaphragm is leaking and acts as a Change the diaphragm and clean the
non-return valve. total propelling liquid system.
9.4 201333-IOM-EN-R02
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 a mechanical source.
If the noise seems general and difficult to locate,
then the source might be a fluid knock.
During the discharge stroke Partially blocking of suction Check the permitted lifting of suction
excessive vibrations or valve(s). valve.
knocking due to not complete (Partially) blocked suction line. Check the clogged or not completely
filling of one or more pump opened valves in the 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 the propelling liquid
discharge valves. chamber(s). chambers.
Air in slurry chamber De-aerating the slurry chamber.
Hammering noise near of just Suction feed pressure too low. Increase the suction pressure.
behind mid-stroke. Slurry temperature too high. Cooling of the 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 Air level in Air vessel too low. Manually add a small amount of air
chamber. until the hammering noise is
This collapsing causes a disappeared.
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 the seal ring / valve seat.
dead points. worn (resulting in mechanical
noise).
Loose piston/cylinder liner. Tighten the connection.
For the correct torque, see chapter
"Maintenance".
Suction or discharge valve, Check and replace.
valve guide or valve spring
worn.
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, replace if necessary.
then the 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.
201333-IOM-EN-R01 9.5
Troubleshooting

Hammering noise in the Surge pressure well, cause by fluid Reduce the pump speed.
suction line, once per separation (void) and following
crankshaft revolution. collapsing in the pump chamber.
Suction pressure too low. Increase the suction pressure.
Propelling liquid chamber not De-aerate the propelling liquid

completely filled. chambers.
Surge pressure well in suction line, Check the suction valve.

caused by malfunctioning of one
suction valve.
AIR SUPPLY UNIT:

Air pressure is low. Compression failure. Check the air supply.
Air line is leaking. Tighten the connections.
Reducing valve on the air-conditioning Open the reducing valve.

device closed.
9.6 201333-IOM-EN-R02
Troubleshooting
Pos : 40 /GEHO/Troubles hooti ng/## Di aphr agm pulsation dampener @ 0\mod_1156318158348_31.doc @ 5783 @
9.2 Trouble shooting at a diaphragm pulsation dampener
Problem/symptom Possible causes and solutions
Safety
DANGER: Avoid breathing in nitrogen.
Make sure that the pulsation dampener is depressurized before

loosening the pulsation dampener cover.
Always loosen the cover nuts controlled.
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.
ATTENTION If the liquid pressure at the pulsation dampener bottom is higher then
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.

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”.
201333-IOM-EN-R01 9.7
Troubleshooting
Problem/symptom Possible causes and solutions
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, or heavy vibrations. Check the pre-charge pressure.
Refer to chapter “Pre-charging the diaphragm pulsation dampener”.
Filling valve leakage.

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.

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.
9.8 201333-IOM-EN-R02
Troubleshooting
Pos : 42 /GEHO/Troubles hooti ng/## T ypic al wear (T)ZPM @ 1\mod_1169136581763_31.doc @ 11849 @
9.3 Typical wear phenomena and its causes
9.3.1 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 abrasivity 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 (2) (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, or 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.
201333-IOM-EN-R01 9.9
Troubleshooting
9.3.2 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-vulcanized 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.
9.3.3 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 in-vulcanized 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 201333-IOM-EN-R02
Troubleshooting
9.3.4 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

Possible causes:
• The piston guide ring is worn (mostly lower side).
• 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.
9.3.5 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).
201333-IOM-EN-R01 9.11
Assembly and disassembly
Pos : 44.1 /GEHO/Heading/H 1/#. Ass embl y and disas sembl y @ 0\mod_1136455386113_31.doc @ 935 @
10 Assembly and disassembly

Pos : 44.2 /GEHO/As sembl y and Dis ass embl y_during loc k- out/General/## Introducti on - Safety notes (T)Z PM @ 0\mod_1145882820736_31.doc @ 3352 @
10.1 Safety instructions

ATTENTION
• Do not hesitate to contact the Service Department of Weir Minerals Netherlands b.v.,
if problems occur during maintenance or repair activities.
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.
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
For safe working on the pump, it is mandatory,
that the installation is locked out from all energy sources:
Pump lock-out procedure
• Stop the pump, refer to chapter "Operation".
• Lock-out the power supply to the main motor, lock the main switch.
• Lock-out the power supply to the lubrication oil motor.
• Lock-out the power supply to the propelling liquid motor.
• Lock-out the power supply to the control panel.
• Lock-out the power supply of all other applicable components.
• Stop and dis-connect the air supply only, when working on the air-actuated valves.
Refer to chapter "Operation", "STOP for maintenance procedure".
DANGER
For safe work on the pump parts, this is mandatory:
Slurry section isolation and drain procedure
1 Close and secure the pump isolation valves in the discharge line.
2 Close and secure the pump isolation valves in the suction line.
3 Flush clean the pump slurry section.
Refer to chapter "Operation", "STOP for maintenance procedure".
DANGER
For safe work on the pump parts at the propelling liquid section, this is mandatory:
1 Drain the propelling liquid at the diaphragm.
Refer to chapter "Assembly and disassembly", "Propelling liquid drain".
201333-IOM-EN-R01 10.1
DANGER
Hydraulic tool pressurizing procedure

If tools are operated hydraulically, then:
• Use only suitable tools and parts for this work.
• Before pressurizing a hydraulic tool:
Check the hydraulic pump, all the hoses, nipples and tools,
and de-aerate all the parts and tools.
• During pressurizing and 1 minute after reaching pressure level,
no person is allowed to be in front of the tool.
Always stay aside.
• Watch the pressure gauge.
If the pressure does not build-up steady,
then the stud bolts are not stretching equally.
If the pistons come out further (without adding oil),
then this indicates that the stud bolts are failing.
If this happens, then:
• Relief the oil pressure, replace these stud bolts by new ones and restart the procedure.
Pos : 44.3 /GEHO/Trans port and installati on/Trans port and lifti ng/### lifti ng eyes @ 5\mod_1221653262294_31.doc @ 38469 @ 2555
10.1.1 Lifting eye bolts

WARNING
The heavy parts of the pumps are provided with one or more lifting eye bolts,
or have the possibility to install a lifting eye for transportation purposes.
• Always transport these parts by using these eyes.
Table according to DIN 580 "LIFTING EYE BOLTS": Working Load Limit (= WLL) [kg]
Size M8 M10 M12 M16 M20 M24 M27 M30 M33 M36 M42 M56 M64
(metric thread)
only for 1 eye 140 230 340 700 1200 1800 2500 3600 4300 5100 7000 11500 16000
bolt, hoisting
upwards
for 2 or more 95 170 240 500 830 1270 1800 2600 3100 3700 5000 8300 11000
eye bolts
together
• If 2 or more lifting eye bolts are used, then the minimum hoisting angle is 45 degrees, as shown in the
figure.
Pos : 44.4 /GEHO/Technic al data s heets/Gener al torques/A.807.005.119 = ## tighteni ng proc edure @ 7\mod_1254137193726_31.doc @ 54812 @ 3
10.2 General tightening procedure for flanges and gaskets

DANGER
Refer for the recommended procedure to document WEIR - A.807.005.119 in chapter
"Catalogue information".
10.2 201333-IOM-EN-R02
Pos : 44.6 /GEHO/Heading/H 2/#.# M anual rotati on of the pump cr ankschaft @ 0\mod_1145881352537_31.doc @ 3343 @
10.3 Manual rotation of the pump crankshaft

Pos : 44.7 /GEHO/As sembl y and Dis ass embl y_during loc k- out/General/M anual rotati on/###(T)ZPM-gearbox-R01=MANU AL CR ANK UN IT vi a gearbox soc ket wrenc h+bl oc kade tool @ 0\mod_1145881095763_31.doc @ 3340 @
10.3.1 Manual rotation and locking of the pump shaft with a socket wrench at the gearbox
Manual rotation the pump shaft is required for:
• For "priming" of the pump during the start-up procedure.
• For turning a piston in a necessary position during inspection or maintenance.
• For assembling or dis-assembling of several components within the pump.
DANGER
Be aware that the un-balance of the crankshaft-assembly causes un-stable positions.
This un-balance causes a torque at the crankshaft, that will vary during rotation and can trigger
unexpected sudden rotation of the crankshaft.
There is a risk of a "run-away" of the pump crankshaft, turning forwards or backwards,
causing movement of the connected parts in the pump frame (like crossheads and rods and
pistons) and turning parts in the drive train (like couplings, gearbox and motor).
Preparation for rotation during the "priming" procedure
Refer to the chapter "Start-up, priming procedure".
Preparation for rotation during work on the pump
1 Switch-off the power from the main motor and lock the switch.
DANGER
• Make sure that the main motor can not be operated during the maintenance work.
2 Open the drain valve of the discharge line and the suction line,
to release the pressure from the slurry section.
Be aware that some static slurry pressure can remain at the diaphragm and the pistons,
due to open or leaking discharge valves or suction valves.
3 Opening the drain valves of every propelling liquid section,
to release the oil pressure from the pistons and the related forces from the crankshaft.
Procedure rotation at the gearbox and locking
1 Remove the safety guard from the non-driven end of the primer high speed gearbox shaft.
This will actuate the electric switch and will inhibit the start of the electric main motor.
2 Start the lubrication pump, to assure lubrication during turning of the pump shaft.
Check that the lubrication system delivers the oil pressure and oil quantity.
DANGER
Fore safety reasons, NEVER do this work alone. •
Be aware, that the crankshaft can start to rotate to a rest position. •
The rotation tool shall always be operated with a tight grip and shall be locked firm, •
to prevent uncontrolled crankshaft movement.
• To avoid the risk of a crankshaft run-away, never use a tool in the ratchet position.
3 Use the "LOCKING PLATE TOOL"
Refer to the documentation of the gearbox for details
of the construction.
LA "LOCKING PLATE TOOL" (or flense)
delivered separately.
LB Locking bolts provision
LC Hexagon shaft extension (or keyway) at the
primer high speed gearbox shaft.
This is normally hidden under the safety guard.
The figure shows a schematic arrangement for more
Figure 10.1: Locking plate,
versions. Depending on the supplier of the gearbox for blocking the gearbox against rotation
and its construction, the details can be different.
201333-IOM-EN-R01 10.3
4 Mounth the "LOCKING PLATE TOOL" (LA) over the hexagon (C) (or keyway) at the gearbox.
5 Use the special tool "MANUAL CRANK UNIT".
Refer to chapter "Parts - List and drawings (special tools)" for details of this tool.
A Socket wrench
B Socket, fitting on the hexagon of the shaft
C Hexagon at the primer shaft of the gearbox
(normally hidden under the safety guard)
The figure shows a schematic arrangement for more

versions. Depending on the supplier of the gearbox
and its construction, the details can be different.
Figure 10.2: Special tool "MANUAL CRANK UNIT"
6 Put the socket (B) on the socket wrench (A).

7 Put the "MANUAL CRANK UNIT" on the hexagon shaft extension (C) of the gearbox.
8 Manually rotate with the socket wrench (A) the pump crankshaft into the required position.
Position the "LOCKING PLATE TOOL" (LA) above the locking bolts provisions (LB).
9 Make sure, that one person keeps with the socket wrench (A) the gearbox shaft under control,
while an other person secures the "LOCKING PLATE TOOL" with bolts (LB) on the gearbox,
according to the details of the gearbox drawing.
Refer to the documentation of the gearbox for details of the construction.
10 Depending on the further working process, if no rotation of the pump crankshaft is needed,
then stop the lubrication pump.
Procedure unlocking
1 Start the lubrication pump, to assure lubrication during turning of the pump shaft.
Check that the lubrication system delivers the oil pressure and oil quantity.
2 Use the special tool "MANUAL CRANK UNIT".
Put the socket (B) on the socket wrench (A).
3 Put the "MANUAL CRANK UNIT" on the hexagon shaft extension (C) of the gearbox.
4 Make sure, that one person keeps with the socket wrench (A) the gearbox shaft under control,
while an other person removes the bolts (LB) from the "LOCKING PLATE TOOL" (LA) on the gearbox.
DANGER
Fore safety reasons, NEVER do this work alone. •
•
Be aware, that the tool can be under tension, due to torques from the shaft, from forces
somewhere in the drive line.
• Be aware, that the crankshaft can start to rotate to a rest position.
5 If necessary, turn with the socket wrench the crankshaft in its stable balance position.
Refer for details to the related chapter.
6 Remove the "MANUAL CRANK UNIT".
7 Remove the "LOCKING PLATE TOOL" (LA).
8 Mount the safety guard at the non-driven end of the high speed gearbox shaft.
9 Depending on the further working process, if no rotation of the pump crankshaft is needed,
then stop the lubrication pump.
10.4 201333-IOM-EN-R02
Pos : 44.9 /GEHO/As sembl y and Dis ass embl y_during loc k- out/General/M anual rotati on/### TZ PM cr ankshaft bal anc e @ 8\mod_1258633343546_31.doc @ 56833 @
10.3.2 Balance position of the TZPM crank shaft

DANGER
Be aware that the un-balance of the crankshaft-assembly causes un-stable positions.
This un-balance causes a torque on the crankshaft, that will vary during rotation and can
trigger unexpected sudden rotation of the crankshaft.
There is a possibility of a "run-away" of the pump crankshaft, turning forwards or backwards,
causing movement of the connected parts in the pump frame (like crossheads and rods and
pistons) and turning parts in the drive train (like couplings, gearbox and motor).
• Only work on the crankshaft, the couplings and the pistons,
if the un-balanced dead weight of the crankshaft is in its lowest position,
or if the crankshaft is blocked safely against rotation.
• For safety reasons, NEVER do this work alone.
DANGER
Always first make sure, that there are no additional forces from the pistons or from the drive
train, before turning a crankshaft in its balance position.
1 Switch of the power from the main motor and lock the switch.
2 Drain the slurry section. Refer to the related chapter.
3 Drain the propelling liquid section. Refer to the related chapter.
Figure 10.3: TZPM balance position of the crankshaft

(if there are no additional forces from the pistons or from the drive train)
A Crankshaft of the TZPM pump, the viewpoint is from the driven shaft side
B Gravity centre of the crankshaft
C Threaded hole points downwards, indicating the gravity centre of the crankshaft
(the holes are made for handling the crankshaft during assembly)
D+E Threaded holes
Procedure
1 Remove the cover of the crankshaft compartment of the frame.
2 Find the threaded hole (C) at the crankshaft in the ring. Refer to the figure above for the viewpoint.
3 Turn the crankshaft, until the threaded hole (C) points downwards, as shown in the figure above.
DANGER
Only if the threaded hole (C) points downwards (as shown above),
then the gravity center of the crankshaft is under the center line of the crankshaft,
in a stable balance position (if there are no additional forces from the pistons or the drive train).
This position is required for working:
• on the coupling between the gearbox and the pump,
• on internal parts of the pump frame, like crankshaft, crossheads, rods and pistons.
In any other position, the crankshaft is NOT in balance, and can start turning by itself.
201333-IOM-EN-R01 10.5
Pos : 44.11 /GEHO/H eadi ng/H2/#.# Special tools @ 1\mod_1166540615553_31.doc @ 11465 @
10.4 Special tools

Pos : 44.12 /GEHO/Ass embl y and Dis ass embl y_during l oc k- out/Gener al/H ydraulic pump unit/### Air dri ven hydraulic pump @ 0\mod_1156403099735_31.doc @ 5821 @ 2
10.4.1 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”).
10.4.1.1 Legend
A Hydraulic connector
B High pressure hose
C Operating handle
D Air pressure supply connector
E Hydraulic pressure gauge
10.4.1.2 Operating instructions

1 Connect the hydraulic connector (A) to the
according quick release connector
(“nipple”).
2 Pressurize the hydraulic pump.
3 Turn the operating handle (C) to pressurize
the tool to be operated.
4 Check the pressure gauge (E).
Refer to chapter “Technical data”, "Special
torques" for the appropriate pressure.
Figure 10.4: Air driven hydraulic pump
Pos : 44.13 /GEHO/Ass embl y and Dis ass embl y_during l oc k- out/Gener al/### Oil connec tor caps at (T)ZPM pump @ 4\mod_1214468883644_31.doc @ 36433 @ 344
10.4.2 Oil connector caps

CAUTION
• Avoid wasting oil.
• Avoid polluting the oil and the connectors.
If dis-connecting oil tubes or hoses, then:
• Use connector caps, to close the
connection and to avoid waste of oil.
Figure 10.5: Oil connector caps

10.6 201333-IOM-EN-R02
Pos : 44.15.1 /GEH O/H eadi ng/H2/#.# Drive unit @ 0\mod_1134483988099_31.doc @ 452 @
10.5 Drive unit

Pos : 44.15.2 /GEH O/Ass embl y and Dis ass embl y_during l oc k- out/Dri ve unit/Dis ass embl y and ass embl y @ 1\mod_1168951193156_31.doc @ 11775 @
ATTENTION
Refer to chapter "Catalogue information" for information about assembly and disassembly of
drive unit parts.
Pos : 44.16.1 /GEH O/H eadi ng/H2/#.# Frame unit @ 0\mod_1146735364754_31.doc @ 3598 @
10.6 Frame unit

Pos : 44.16.2 /GEH O/General/Attenti on, War ning and N ote/Infor mation - Fr ame unit - Contact Weir Mi ner als @ 1\mod_1165496458248_31.doc @ 9075 @
INFORMATION
• For major maintenance work on the frame unit,
please contact the service department of Weir Minerals Netherlands b.v.
Pos : 44.18 /GEHO/H eadi ng/H2/#.# Lubric ati on s ystem @ 0\mod_1152094184716_31.doc @ 5126 @
10.7 Lubrication system

Pos : 44.19 /GEHO/Ass embl y and Dis ass embl y_during l oc k- out/Pr oc edures _duri ng loc k- out/## Pr opelling liqui d dr ain/### Envir onment instructions @ 8\mod_1255956478091_31.doc @ 55821 @
10.7.1 Environment instructions

ATTENTION
• Make sure that the storage and/or disposal of the oil is according to the local
environmental regulations.
• Before re-using the oil, check the oil quality for contamination and chemical properties.
Options:
• External full oil diagnosis by an authorized laboratory.
• Internal oil diagnosis with an on-site analysis equipment.
Like a "Shell LubeClinic On-site analysis" set.
• Internal optical diagnosis of the oil.
Look for changes of the oil and contaminations in the oil, caused by a leaking
diaphragm.
Like the oil color, solids from the slurry, fluid from the slurry, or water from the flushing
water.
201333-IOM-EN-R01 10.7
Pos : 44.21 /GEHO/H eadi ng/H5/H5 Discharge filter @ 8\mod_1260358440906_31.doc @ 57715 @
Discharge filter
Pos : 44.22 /GEHO/Ass embl y and Dis ass embl y_during l oc k- out/Pr oc edures _duri ng loc k- out/Lubrication s ystem/C hange the disc harge oil filter/### Replace the double dis charge oil filter during l oc k- out @ 0\mod_1152097825089_31.doc @ 5144 @ 5
10.7.2 Replace the oil filter element in the discharge line

Refer to the "INSTRUMENT AND EQUIPMENT LIST" in chapter "Technical data", "Drawings + lists +
instruments" and also to chapter "Catalogue information" details of the oil filer and the filter housing.
DANGER
1 Lock-out of oil pump.
2 Before replacing one filter element,
relieve the pressure in that filter housing,
by switching over the handle to the that filter.
The other filter can be under pressure, so do not work at that filter.
• The filter-housing and the filter and the oil can still be very hot.
10.7.2.1 Replace filter A

1 Set the lever to position (A).
2 Remove the filter cover.
3 Remove the old filter.
4 Install the new filter.
5 Clean the filter cover.
6 Check the O-ring.
If necessary, then replace the O-ring.
7 Install the filter cover.
Figure 10.6: Double oil filter: replace filter A

10.7.2.2 Replace filter B

1 Set the lever to position (B).
6 Check the O-ring.
Figure 10.7: Double oil filter: replace filter B

Pos : 44.23 /GEHO/H eadi ng/H5/H5 Sucti on filter @ 8\mod_1260358408562_31.doc @ 57705 @ 344
10.8 201333-IOM-EN-R02
Suction filter
Pos : 44.24 /GEHO/Ass embl y and Dis ass embl y_during l oc k- out/Pr oc edures _duri ng loc k- out/Lubrication s ystem/### R epl ac e the si ngel oil filter el ement in the suc tion line @ 7\mod_1254728656649_31.doc @ 55103 @ 5
┐┐┐
10.7.3 Replace the oil filter element in the suction line

DANGER
• Do this procedure only during shut-down and lock-out of the pump.
instruments", and also to the chapter "Catalogue information" for the specification of the oil filer and for
1 Stop the pump.
2 If available/applicable, then isolate the filter by closing the valves before and/or behind the filter.
3 Put a barrel under the filter.
4 Loosen the filter cover.
8
If available/applicable, then open the valves before and/or behind the filter.
Pos : 44.26 /GEHO/Ass embl y and Dis ass embl y_during l oc k- out/Pr oc edures _duri ng loc k- out/Lubrication s ystem/### R epl ac e the pump l ubric ation oil @ 8\mod_1260346407281_31.doc @ 57665 @
10.7.4 Replace the pump lubrication oil
10.7.4.1 Remove the oil

1 Open the frame unit cover.
2 Drain the oil through the oil drain valve,
ore use a pump.
3 Remove the remaining oil from the oil sump.
10.7.4.2 If applicable, clean and/or replace parts inside the pump frame
4 Clean the oil sump.
Refer to document "INSTRUMENT AND EQUIPMENT LIST" in chapter "Technical data",
"Drawings + lists + instruments" and also to chapter "Catalogue information"
for the specification of the replaceable parts.
5 If a "SUCTION STRAINER" is installed (instead of a filter), then clean this part.
10.7.4.3 Replace all oil filters in the oil suction line and oil discharge line
Refer to the concerning chapters in this section of the manual.
10.7.4.4 Fill the oil in the pump frame

Refer to chapter "Start and stop procedure", "Initial lubrication filling" for the procedure.
1 Fill in the new oil. Use a pump.
2 After replacing the oil, check the liquid level at the level gauge.
3 After starting-up the pump, check again the oil level at the level gauge.
4 If necessary, then add or drain oil.
Pos : 44.28 /GEHO/Ass embl y and Dis ass embl y_during l oc k- out/Pr oc edures _duri ng loc k- out/Fr ame unit- mai ntenance oil/### Replace the venti ng filter-top-nofig @ 2\mod_1174995485185_31.doc @ 12836 @
10.7.5 Replace the venting filter at the pump power end

Refer to document "INSTRUMENT AND EQUIPMENT LIST" in chapter "Technical data", "Drawings + lists +
instruments" and also to chapter "Catalogue information" for details and specifications of the air filter.
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.
201333-IOM-EN-R01 10.9
Pos : 44.30.1 /GEH O/H eadi ng/H2/#.# Propelling liquid dr ain @ 7\mod_1255089725997_31.doc @ 55208 @
10.8 Propelling liquid drain

Pos : 44.30.2 /GEH O/Ass embl y and Dis ass embl y_during l oc k- out/Pr oc edures _duri ng loc k- out/## Pr opelling liquid dr ain/### Environment instruc tions @ 8\mod_1255956478091_31.doc @ 55821 @

ATTENTION
Options:
diaphragm.
water.
Pos : 44.30.3 /GEH O/H eadi ng/H3/#.#.# Propelling liquid dr ain pr eparation @ 7\mod_1255090251455_31.doc @ 55238 @ 3
10.8.2 Propelling liquid drain preparation

Pos : 44.30.4 /GEH O/Ass embl y and Dis ass embl y_during l oc k- out/Pr oc edures _duri ng loc k- out/## Pr opelling liquid dr ain/Pr opelling liquid dr ain pr eparation @ 7\mod_1255089532001_31.doc @ 55179 @
Clean the slurry section

1 Do the ""STOP" procedure for flushing", to avoid dried slurry in the slurry section.
Refer to that procedure in chapter "Operation".
Pos : 44.30.5 /GEH O/H eadi ng/H3/#.#.# Propelling liquid dr ain pr ocedure @ 7\mod_1255090131941_31.doc @ 55219 @ 5
10.8.3 Propelling liquid drain procedure

Pos : 44.30.6 /GEH O/Ass embl y and Dis ass embl y_during l oc k- out/Pr oc edures _duri ng loc k- out/D ANGER onl y during s hut-down mai n pump motor @ 7\mod_1255090729382_31.doc @ 55247 @
DANGER
• Do this procedure only during shut-down and lock-out of the main pump motor.
Lock and tag the power supply of this main motor of the pump.
• Keep in operation (do not turn off):
• The "GEHO HMI TOUCH PANEL", to monitor the display functions.
• The air supply, to operate the pneumatic assisted valves.
De-pressurize the propelling liquid system

DANGER
1 Make sure that the propelling liquid pump is shut down.
Lock and tag the power supply of this oil pump.
• If applicable, the following procedure can be used for one single diaphragm or for all diaphragms
together at the same time.
10.10 201333-IOM-EN-R02
Pos : 44.30.8 /GEH O/Ass embl y and Dis ass embl y_during l oc k- out/Pr oc edures _duri ng loc k- out/## Pr opelling liquid dr ain/(T)ZPM Propelli ng liquid drai n proc edur e @ 7\mod_1255089590562_31.doc @ 55189 @
10.8.3.1 Drain the contaminated propelling liquid into a container

ATTENTION
For the draining of the contaminated propelling liquid oil,
this procedure drains as much as possible oil into the disposal container.
Use this procedure, if the works are related to:
• leakage of slurry though the diaphragm into the propelling liquid,
• by collecting the oil for disposal,
• and to avoid contamination in the oil tank.
1 Place a (suitable large enough clean) container under the drain plug(s) of the propelling liquid
chamber(s).
2 Make sure, that there is no pressure in the propelling liquid chamber(s).
If applicable, relief the pressure from the slurry side of the diaphragm.
3 Open the drain plug(s) of the propelling liquid chamber(s).
The oil will drain into the container.
4 Apply a flush-water pressure of 200-300 kPa (2-3 bar / 29-44 psig) on the slurry side of the
diaphragms.
5 The flush-water pressure pushes the diaphragms back into their rear position.
The oil in the pump chamber will drain, through the drain hole(s), into the container.
6 Monitor at the "GEHO HMI TOUCH PANEL" the filling lights
(= indicating the position of the diaphragm monitoring rod).
When a filling light are lit, then the diaphragm is in its rear position.
7 Wait until no oil comes out of the drain holes.
8 Open the vent valve at the "PRESSURE LIMITATION UNIT", to de-pressurize this unit.
9 Place a (suitable large enough clean) container under the drain plug of the "PRESSURE LIMITATION
UNIT".
10 Open the drain plug of the "PRESSURE LIMITATION UNIT", to drain this unit.
CAUTION
The tubes between the vent valves at the diaphragm housing and the non-return valve
can still contain some remaining oil pressure (50 kPa / 0.5 bar / 7.3 psig).
11 Open for a short period one vent valve at the diaphragm housing, to relief the pressure.
Flushing the oil piping

1 Open the propelling liquid "FILLING VALVE" (located at the hydraulic skid).
Refer to the "P&I DIAGRAM" for the functions and location and tagging of these valves.
These valves can be operated at the "GEHO HMI TOUCH PANEL" in a manual service mode.
Pushing the button "PROPELLING LIQUID SUPPLY VALVE 15 MINUTES"
opens for 15 minutes the line from the oil pump to the propelling liquid chambers.
This action relieves the pressure from the oil side of the accumulator and drains the oil, through the
"FILLING VALVE", the piping, the propelling liquid chamber and the drain holes, into the container.
2 Start for 1 minute the propelling liquid pump, to flush the piping to the propelling liquid chambers.
DANGER
• Stop the propelling liquid pump.
Lock and tag the power supply of this oil pump.
3 Wait until no oil comes out of the drain holes.
201333-IOM-EN-R01 10.11
10.8.3.2 Drain the clean propelling liquid into the oil tank
ATTENTION
For re-use of the clean propelling liquid oil,
this procedure drains as much as possible oil via the flushing compartment into the oil tank.
Use this procedure only, if you can assume, that the propelling liquid is clean and not
contaminated (like for regular inspections or maintenance works).
1 Remove cover above the flushing compartment, to watch the oil flow from several units,
via this compartment to the oil tank.
2 Open the vent valve at the "PRESSURE LIMITATION UNIT" (to de-pressurize and drain this unit).
The oil flows through the piping into the oil tank.
3 Open the 3/2 outlet / release valve(s) (near the accumulator) of the propelling liquid section,
to de-pressurize the oil pump discharge side of the propelling liquid system.
This also drains the oil side of the accumulator, through the piping, into the oil tank.
The propelling liquid chambers remain filled.
4 Apply a flush-water pressure of 200-300 kPa (2-3 bar / 29-44 psig) on the slurry side of the
diaphragms.
5 Open the propelling liquid "OUTLET VALVES" (located at the hydraulic skid).
Refer to the "P&I DIAGRAM" for the functions and location and tagging of these valves.
These valves can be operated at the "GEHO HMI TOUCH PANEL" in a manual service mode.
Pushing the button "MANUAL OUT" opens the line from the propelling liquid chambers to the oil tank.
6 The flush-water pressure pushes the diaphragms back into their rear position.
The oil in the pump chamber will drain, through the "OUTLET VALVES", into the oil tank.
7 Monitor at the "GEHO HMI TOUCH PANEL" the filling lights
(= indicating the position of the diaphragm monitoring rod).
When a filling light is lit, then the diaphragm is in its rear position.
8 Wait until no oil flows into the oil tank.
Drain the remaining clean propelling liquid into a container

9 Place a (suitable large enough clean) container under the drain plugs of the propelling liquid chambers.
10 Open the drain plug(s) of the propelling liquid chamber(s).
The oil will drain into the container.
11 Wait until no more oil comes out of the drain holes.
CAUTION
The tubes between the vent valves at the diaphragm housing and the non-return valve
can still contain some remaining oil pressure (50 kPa / 0.5 bar / 7.3 psig).
12 Open for a short period one vent valve at the diaphragm housing, to relief the pressure.
10.8.3.3 Oil treatment

1 For a diagnosis of possible problems and causes, inspect the oil in the container for contaminations of
solids (from slurry) or water (from a leaking diaphragm).
2 If the oil in the container is not contaminated,
then you can filter and re-use the oil in the container.
If the oil in the container is contaminated,
then dispose it, according to the local environmental regulations.
10.8.3.4 Propelling liquid filling + start-up

Refer to chapter "Replace the propelling liquid + the suction filter" for details to re-fill the oil tank.
Refer to chapter "Start-up, priming procedure" to fill the propelling liquid chambers.
10.12 201333-IOM-EN-R02
Pos : 44.32 /GEHO/H eadi ng/H2/#.# Pr opelling liquid s ys tem @ 0\mod_1152094190955_31.doc @ 5132 @
10.9 Propelling liquid system

Pos : 44.33 /GEHO/Ass embl y and Dis ass embl y_during l oc k- out/Pr oc edures _duri ng loc k- out/## Pr opelling liqui d dr ain/### Envir onment instructions @ 8\mod_1255956478091_31.doc @ 55821 @

ATTENTION
Options:
diaphragm.
water.
Pos : 44.34 /GEHO/Ass embl y and Dis ass embl y_during l oc k- out/Pr oc edures _duri ng loc k- out/Propelli ng liquid s ystem-maintenanc e oil/### R eplac e the propelli ng liquid+filters @ 0\mod_1152098068238_31.doc @ 5152 @ 3
10.9.2 Replace the propelling liquid and the filters

Propelling liquid drain
Refer to chapter "Propelling liquid drain" for a save and proper procedure.
Replace the propelling liquid

1 Open the propelling liquid tank drain valve.
2 Open the propelling liquid tank cover.
4 If applicable, replace the propelling liquid filter in the oil tank.
If applicable, replace the propelling liquid filter in the suction line.
If applicable, replace the propelling liquid filter in the discharge line.
Refer to document "INSTRUMENT AND EQUIPMENT LIST" in chapter “Technical data”, for details.
5 Fill in the new propelling liquid.
Refer to document "UTILITY CONSUMPTION LIST" in chapter “Technical data”, for the correct oil type,
quality and quantity.
6 After replacing the liquid, check the liquid level at the level gauge.
7 Close the propelling liquid tank cover.
8 After starting-up the pump, check again the liquid level at the level gauge.
9 If necessary, then add or drain liquid.
Pos : 44.35 /GEHO/H eadi ng/H5/H5 Discharge filter @ 8\mod_1260358440906_31.doc @ 57715 @ 355
201333-IOM-EN-R01 10.13
Discharge filter
Pos : 44.36 /GEHO/Ass embl y and Dis ass embl y_during l oc k- out/Pr oc edures _duri ng loc k- out/Lubrication s ystem/C hange the disc harge oil filter/### Replace the double dis charge oil filter during l oc k- out @ 0\mod_1152097825089_31.doc @ 5144 @ 5
10.9.3 Replace the oil filter element in the discharge line

instruments" and also to chapter "Catalogue information" details of the oil filer and the filter housing.
DANGER
1 Lock-out of oil pump.
2 Before replacing one filter element,
relieve the pressure in that filter housing,
by switching over the handle to the that filter.
The other filter can be under pressure, so do not work at that filter.
• The filter-housing and the filter and the oil can still be very hot.
10.9.3.1 Replace filter A

1 Set the lever to position (A).
6 Check the O-ring.
Figure 10.8: Double oil filter: replace filter A

10.9.3.2 Replace filter B

1 Set the lever to position (B).
6 Check the O-ring.
Figure 10.9: Double oil filter: replace filter B

Pos : 44.37 /GEHO/H eadi ng/H5/H5 Sucti on filter @ 8\mod_1260358408562_31.doc @ 57705 @ 344
10.14 201333-IOM-EN-R02
Suction filter
Pos : 44.38 /GEHO/Ass embl y and Dis ass embl y_during l oc k- out/Pr oc edures _duri ng loc k- out/Propelli ng liquid s ystem-maintenanc e oil/(Dis)as semble ins truc tion propelling liqui de s ucti on filter in tank @ 5\mod_1221134876001_31.doc @ 38422 @ 5
10.9.4 Disassemble the suction filter at the propelling liquid tank

1 Stop the pump.
2 Drain the propelling liquid.
Use the drain valve on the propelling liquid tank.
3 Loosen the cover of the propelling liquid tank.
4 Remove the propelling liquid suction filter.
ATTENTION
• Do not loosen the filter at the filter connecting port.
• Always disassemble the filter by loosen the stud coupling in the piping.
By doing this, the end cap and connecting port of the filter will not be damaged.
6 Check the seal ring on the propelling liquid tank.
Replace the seal ring, if necessary.
10.9.5 Assemble the suction filter at the propelling liquid tank

1 Clean the propelling liquid suction filter.
2 Install the propelling liquid suction filter.
ATTENTION
• Do not tighten the filter at the filter connecting port.
• Always assemble the filter by tighten the stud coupling in the piping.
By doing this, the end cap and connecting port of the filter will not be damaged.
3 Close the drain valve on the propelling liquid tank.
4 Install the propelling liquid tank cover.
5 Open the inspection cover on the top of pump.
6 Add propelling liquid oil in the propelling liquid chamber.
Refer to chapter "Operation" for proper filling.
7
Close the inspection cover on top of the pump.
Pos : 44.40 /GEHO/Ass embl y and Dis ass embl y_during l oc k- out/Pr oc edures _duri ng loc k- out/Propelli ng liquid s ystem-maintenanc e oil/### R eplac e proliq venting filter @ 0\mod_1152098314051_31.doc @ 5168 @
10.9.6 Replace the venting filter at the propelling liquid system

DANGER
lists + instruments" and also to chapter "Catalogue information" for details and specifications of the air filter.
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.
201333-IOM-EN-R01 10.15
Pos : 44.42 /GEHO/Ass embl y and Dis ass embl y_during l oc k- out/Pr oc edures _duri ng loc k- out/Propelli ng liquid s ystem-maintenanc e oil/### 2/2 way val ves: ins pection and pr es ervati on @ 6\mod_1234348023224_31.doc @ 47301 @
10.9.7 2/2 way valves: inspection and preservation

1 Dis-connect the air supply.
2 De-pressurize the propelling liquid piping,
by opening the 3-way valve at the
accumulator.
Refer for the location to the drawing "P&I
DIAGRAM".
3 Remove the filter (002).
4 Inspect the filter (002).
If the filter (002) is clogged, then clean it
with a duster blow gun blaster.
5 Assemble the filter (002).
6 Remove the valve covers (003) and the
valve internals.
7 Clean the air chambers up and below the
diaphragm (005).
Figure 10.10: 2/2 way valves inspection and

conservation
8 Coat the air chambers below the diaphragm (005) with a suitable anti-corrosion agent.
We recommend "Cortec VCI-369D".
If the covers (003) are not coated,
then coat them the same way.
9 Inspect the internals, especially the wear parts:
Slide bearings (001 + 011, Valve spindle (014) and U-ring (013).
If required, then replace the worn parts.
10 Grease all internals with suitable bearing grease.
11 Fill the space between the two slide bearings (001 + 011) and Valve spindle (014) with suitable grease.
12 Assemble the valves.
13 Before the next start of the pump, a de-aeration of the propelling liquid system and a priming of the
pump is required. Refer to the according procedures.
Pos : 44.43 /GEHO/Ass embl y and Dis ass embl y_during l oc k- out/Pr oc edures _duri ng loc k- out/#### Initi ator coupling nuts at the diaphrag m housings @ 5\mod_1220445788139_31.doc @ 37905 @ 3
10.16 201333-IOM-EN-R02
10.9.7.1 Initiator coupling nuts at the diaphragm housings

DANGER
The initiator coupling nuts at the diaphragm housings should not be tightened, to avoid heat expansion
forces.
1 Screw every initiator coupling nut hand-
tight and then loosen about 45 degrees.
Figure 10.11: Initiator coupling nuts at the

diaphragm housings
(The figure shows a general schematic
os: 44.44 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 @ 4
arrangement, applicable for more versions.)
Pos : 44.45 /GEHO/Ass embl y and Dis ass embl y_during l oc k- out/Pr oc edures _duri ng loc k- out/## Gear box neutr aal: Refer to catal ogue @ 3\mod_1195199009727_31.doc @ 19641 @
10.10 Gearbox maintenance

Refer to chapter "Maintenance" for the frequency of maintenance works.
Refer to chapter "Catalogue Information", "Gearbox" for details about the gearbox maintenance and the
grease quality and quantity.
201333-IOM-EN-R01 10.17
Pos : 44.47 /GEHO/H eadi ng/H2/#.# Val ves, disc harge and s ucti on angul ar @ 5\mod_1227199312782_31.doc @ 44212 @
10.11 Valves, discharge line and suction line, angular model

Pos : 44.48.1.1 /GEH O/H eadi ng/H3/#.#.# Val ve housing c over @ 0\mod_1147174241226_31.doc @ 3690 @
10.11.1 Valve housing cover

Pos : 44.48.1.2 /GEH O/Ass embl y and Dis ass embl y_during l oc k-out/Val ve unit/Conic al val ves /Val ve housing cover/H ydraulic/R emove, Standar d, Ang elar @ 0\mod_1147163606938_31.doc @ 3669 @
10.11.1.1 Disassembly
Preparation
DANGER
1 Flush and drain the slurry section.
2 Close and secure the isolation valves in the slurry suction line and discharge line, to
isolate the working area.
Refer to the chapter "Safety instructions".
3 Drain the valve.
4 Remove the protection guard from the
connecting nipple (E) at the valve housing
cover (A).
5 Connect the high pressure hose to the
connecting nipple (E) and to the hydraulic
pump unit.
6 Pressurize the hydraulic pump unit.
Refer to chapter “Technical data”,
“Special torques” for the correct pressure.
7 Loosen all the outside lock-nuts (D).
Refer to chapter “Technical data”, “Special
torques” for the correct torque.
Figure 10.12: Schematics of a hydraulic operated valve

cover
8 Screw all the lock-nuts (D) against the hexagon surface of the inside strain-nuts (B).
9 Open the drain side of the oil-return/de-aerate valve at the hydraulic pump,
to de-pressurize the hydraulic system.
Check this at the pressure gauge of the pump.
10 Disconnect the high pressure hose from the hydraulic connector nipple (E).
Put the protecting guard to the connector nipple (E).
Remove the valve cover

11 Loosen all the inside strain-nuts (B).
12 Unscrew all the inside strain-nuts (B).
13 Lift the valve housing cover (A).
If necessary, then use the push-off bolts (G).
14 Remove the valve housing cover (A).
Use a lifting device.
Use the lifting eye (F).
Pos : 44.48.1.3 /GEH O/Ass embl y and Dis ass embl y_during l oc k-out/Val ve unit/Conic al val ves /Val ve housing cover/H ydraulic/Ins tall, Standard, Angul ar @ 0\mod_1147165917235_31.doc @ 3679 @ 455
10.18 201333-IOM-EN-R02
10.11.1.2 Assembly
Preparation
1 Clean and grease all the sealing surfaces
and threat surfaces with suitable grease.
2
ATTENTION
Make sure that all the push-off
bolts (G) at the valve cover (A) are
unscrewed and free from any
contact with the top of the valve
housing.
Ensure a metal to metal fit between
the valve housing cover and valve
housing.
Figure 10.13: Schematics of the hydraulic operated

valve cover
Place the valve cover

3 Insert a new square gasket into the valve housing cover (A).
4 Fit the valve housing cover (A) to the valve housing (H).
Use a lifting device. Use the lifting eye (F).
Make sure that the gasket stays well in place.
5 Screw by hand all the outside lock-nuts (D) against the hexagon surface of the strain-nuts (B).
6 Screw by hand all the inside strain-nuts (B) (including the lock-nut (D)) on the valve studs (C) against
the pistons.
Apply the stud tension
7 Remove the protection guard from the nipple (E) at the valve cover (A).
8 Connect the high pressure hose to the hydraulic connector nipple (E) and to the hydraulic high-
pressure pump.
so the oil can flow back from the pistons to the hydraulic pump sump.
10 Tighten all the inside strain-nuts (B).
This will push the pistons into their start position against the cover, and the cover against the
housing.
Refer to chapter “Technical data”, “Special torques” for the correct torque.
11 Pre-tighten all the outside lock-nuts (D) by hand to the cover, to secure the start position of the cover.
12 Close the oil-return/de-aerate valve at the hydraulic pump.
13 Pressurize the pistons with the hydraulic pump, to tension the stud (C).
Refer to chapter “Technical data”, “Special torques” for the correct pressures.
14 Re-tighten the outside lock-nuts (D).
These lock-nuts (E) maintain during operation the tightening force in stud (C).
Refer to chapter “Technical data”, “Special torques” for the correct torque.
to de-pressurize the hydraulic system.
Check this at the pressure gauge of the pump.
16 Disconnect the high pressure hose from the hydraulic connector nipple (E).
Put the protecting guard to the connector nipple (E).
201333-IOM-EN-R01 10.19
Pos : 44.48.3.1 /GEH O/H eadi ng/H3/#.#.# C onical val ve @ 0\mod_1147176114890_31.doc @ 3735 @
10.11.2 Conical valve

Pos : 44.48.3.2 /GEH O/Ass embl y and Dis ass embl y_during l oc k-out/Val ve unit/Conic al val ves /Val ve/#### Remove, Angular, Standar d @ 1\mod_1161247034668_31.doc @ 6533 @
1 Release the pressure from the slurry
section.
2 Remove the valve housing cover.
Refer to chapter "Remove the valve housing
cover".
3 Remove the square gasket.
4 Remove the compression spring.
5 Remove the conical valve.
Figure 10.14: Remove the conical valve

housing versions)
Pos : 44.48.3.3 /GEH O/Ass embl y and Dis ass embl y_during l oc k-out/Val ve unit/Conic al val ves /Val ve/R emove, Angular , API 13+ @ 1\mod_1162205697332_31.doc @ 6713 @ 4
Valve lifting tool
ATTENTION
Make sure to use the valve lifting tool to remove the valve from the valve housing.
1 Put the valve lifting tool (B) to the valve.

2 Put the bolt (C) through the hole in the
valve lifting tool (B) and the boring in the
valve shaft (A).
3 Secure the bolt (C) with a nut.
4 Use a lifting device to remove the
valve (A).
Figure 10.15: The valve lifting tool for large valves.
Pos : 44.48.3.4 /--- Page br eak --- @ 0\mod_1136278659331_0.doc @ 766 @
10.20 201333-IOM-EN-R02
Pos : 44.48.3.5 /GEH O/Ass embl y and Dis ass embl y_during l oc k-out/Val ve unit/Conic al val ves /Val ve/#### Install, Ang ular @ 1\mod_1161247316353_31.doc @ 6535 @
10.11.2.2 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 chapter "Install the valve housing cover".
Figure 10.16: Insert the conical valve

Pos : 44.48.5.1 /GEH O/H eadi ng/H3/#.#.# Val ve seat @ 0\mod_1147176079227_31.doc @ 3732 @
10.11.3 Valve seat

Pos : 44.48.5.2 /GEH O/Ass embl y and Dis ass embl y_during l oc k-out/Val ve unit/Conic al val ves /Val ve s eat/Angul ar/R emove H ySeat ang ular @ 0\mod_1147180524829_31.doc @ 3774 @
Remove the valve seat, using the hydraulic seat connector
Refer to chapter "Valve housing cover", "Disassembly".
2 Remove the conical valve.
Refer to chapter "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 chapter "Valve housing cover", "Assembly".
4 Remove the protection guard from the hydraulic connector.
5 Connect the hydraulic pump unit to the connector at the valve housing.
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.
Refer to chapter "Valve housing cover", "Disassembly".
10 Remove the valve seat from the valve housing.
Pos : 44.48.5.3 /GEH O/Ass embl y and Dis ass embl y_during l oc k-out/Val ve unit/Conic al val ves /Val ve s eat/Angul ar/R emove H yTool API 15+ @ 11\mod_1291644518609_31.doc @ 79473 @
201333-IOM-EN-R01 10.21
Remove the valve seat,

using a hydraulic special tool set
Refer to chapter "Remove the valve cover".
2 Remove the valve and spring.
Refer to chapter "Remove the valve".
3 Mount a eye-bolt (K) in the hoisting pin (L).
4 Mount the hoisting pin (L) in the puller
block (A).
5 Use a lifting tool. Use both eye-bolts (K) to
lift and position the puller bloc (A)
underneath the valve seat (N).
6 Disassemble the hoisting pin (L) out of the
puller bloc (A).
7 Use a lifting tool to hoist the connecting
rod (C).
8 Mount the connecting rod (C) in the puller
bloc (A).
9 Put bloc (B) to the connecting rod (C) and
valve housing (M). Use a lifting tool. Use
both eye-bolts (K) to lift bloc (B).
10 Put the hydraulic jack (assembly of D, E, F,
G, I and H) to the connecting rod (C) and Figure 10.17: Using the hydraulic valve seat tool.
bloc (B). (The figure shows a schematic arrangement for more
tool versions)
ATTENTION A Puller bloc
The piston (E) of the hydraulic B Bloc
jack must be equal to the C Connecting rod
cylinder (D). Otherwise U-ring (F) D Cylinder
can be damaged. E Piston
F U- ring (bottom)
11 Put the nut (J) to the connecting rod (C) G U-ring (top)
and hand-fasten the nut to the hydraulic H Connecting nipple
jack. Make sure that puller bloc (A) is firmly I Adapter
fixed against the underside of the valve J Nut
seat (N). K Eye-bolt
12 Connect the hydraulic pump to the L Hoisting pin
connecting nipple (H) of the hydraulic jack. M Valve housing
13 Pressurize the pump, until the valve N Valve seat
seat (N) is loose. O O-ring (2x)
Refer to chapter "Technical data", "Special
torques" for the maximum allowable pressure on
the Hydraulic jack.
14 Depressurize the pump.
15 Remove the pump.
16 Un-tighten nut (J).
17 Remove nut (J) and the hydraulic
jack (assembly of D, E, F, G, I and H).
18 Use a lifting device for bloc (B). Use both
eye-bolts (K) to lift bloc (B)
19 Remove bloc (B).
10.22 201333-IOM-EN-R02
20 Connect valve hoisting tool (Q) to the

connecting rod (R).
21 Connect a lifting device to the valve
housing tool (Q).
22 Position the hoisting assembly (Puller
bloc (A), connecting rod (R), valve hoisting
tool (Q) and valve seat (N) exactly above
the center of the valve housing (M).
23 Pull the valve seat (N) out of the bore of
the valve housing (M).
24 Lift the valve seat (N), the connecting
rod (R) and valve hoisting tool (Q) on two
wooden bars (P).
25 Disconnect and remove the valve hoisting
tool (Q), the connecting rod (R) and puller
bloc (A).
Figure 10.18: Using the special hoisting tool.
A Puller bloc B Strip

C Valve seat D Cylinder
assembly tool
E Piston F U- ring (bottom)
G U-ring (top) H Connecting nipple
I Adapter J Nut
K Eye-bolt L Hoisting pin
M Valve housing N Valve seat
O O-ring (2x) P Wooden bars
Q Valve hoisting R Connecting rod
tool
Pos : 44.48.5.4 /--- Page br eak --- @ 0\mod_1136278659331_0.doc @ 766 @ 5
201333-IOM-EN-R01 10.23
Pos : 44.48.5.5 /GEH O/H eadi ng/H4/#.#.#.# Ass embl y @ 0\mod_1147174319423_31.doc @ 3693 @
10.11.3.2 Assembly
Pos : 44.48.5.6 /GEH O/Ass embl y and Dis ass embl y_during l oc k-out/Val ve unit/Conic al val ves /Val ve s eat/Angul ar/Install H ydrTool API 15+ @ 11\mod_1291716716137_31.doc @ 79526 @
Install the valve seat (angular valve units),

using a hydraulic special tool set
1 Put the valve seat (N) on two wooden
bars (P). Use a lifting device.
2 Clean the valve seat (N).
3 Insert new O-rings (O) in the grooves at
the valve seat.
4 Clean the bore in the valve housing (M).
5 Make sure that the valve seat (N) and the
bore in the valve housing (M) are free of
dust, paint and oil.
6 Put the puller bloc (A) underneath the
valve seat (N).
7 Mount the connecting rod (R) in the puller
bloc (A)
8 Connect the valve hoisting tool (Q) to the
connecting rod (R).
9 Connect a lifting device to the valve
housing tool (Q).
10 Position the hoisting assembly (Puller
bloc (A), connecting rod (R), valve hoisting
tool (Q) and valve seat (N) exactly above
the center of the valve housing (M).
11 Insert the valve seat (N) in the bore of the
valve housing (M).
Figure 10.19: Using the special hoisting tool.

ATTENTION
Do this in a controlled manner to
avoid damaging the o-rings (O). A Puller bloc B Strip
C Valve seat D Cylinder
assembly tool
12 Check if the position of the valve seat (N) E Piston F U- ring (bottom)
is correct. G U-ring (top) H Connecting nipple
13 Check if the o-rings (O) are in position. I Adapter J Nut
14 When the valve seat (N) is in place then K Eye-bolt L Hoisting pin
disassemble the connecting rod (R). M Valve housing N Valve seat
Remove the connecting rod (R). Use a O O-ring (2x) P Wooden bars
lifting device. Q Valve hoisting R Connecting rod
15 Connect the lifting device to the eye- tool
bolt (K) connected on the puller bloc (A).
16 Remove the puller bloc (A).
10.24 201333-IOM-EN-R02
17 Put the valve seat assembly tool (C) to the

valve seat (N). Use a lifting device.
18 Put the hydraulic jack (assembly of D, E, F,
G, I and H) on top of the valve seat
assembly tool (C).
19 Put the strip (B) onto the 2 threaded ends
of the valve housing (M). Use a lifting
device.
20 Mount and hand-tighten nuts (J).
Make sure that the position of the valve
seat assembly tool (C) and hydraulic jack
is positioned in the middle of strip (B).
ATTENTION
The piston (E) of the hydraulic
jack must be equal to the
cylinder (D). Otherwise U-ring (F)
can be damaged.
21 Connect the hydraulic pump to the

connecting nipple (H) of the hydraulic jack.
22 Pressurize the pump, until a metal to metal
contact between the valve seat (N) and the
bore of valve housing (M) is achieved.
Refer to chapter "Technical data", "Special Figure 10.20: Using the hydraulic valve seat tool.
torques" for the correct pressure (The figure shows a general schematic arrangement,
23 Depressurize the pump.
24 Remove the pump.
25 Un-tighten the nuts (J). A Puller bloc B Strip
26 Remove the nuts (J), strip (B), hydraulic C Valve seat D Cylinder
jack (assembly of D, E, F, G, I and H) and assembly tool
valve seat assembly tool (C). Use a lifting E Piston F U- ring (bottom)
device. G U-ring (top) H Connecting nipple
27 Make sure that the valve seat is mounted I Adapter J Nut
correctly and tight. K Eye-bolt L Hoisting pin
28 Inspect the surfaces of the housing and the M Valve housing N Valve seat
valve. O O-ring (2x) P Wooden bars
Q Valve hoisting R Connecting rod
tool
201333-IOM-EN-R01 10.25
Pos : 44.50.1 /GEH O/H eadi ng/H3/#.#.# Val ve guide bush @ 1\mod_1165494162006_31.doc @ 9067 @
10.11.4 Valve guide bush

Pos : 44.50.2 /GEH O/H eadi ng/H4/#.#.#.# Over view @ 1\mod_1165494429019_31.doc @ 9072 @
10.11.4.1 Overview
Pos : 44.50.3 /GEH O/Ass embl y and Dis ass embl y_during l oc k- out/Val ve unit/Conic al val ves /Val ve gui de bus h/Standar d/Over vi ew, angul ar @ 1\mod_1165490064608_31.doc @ 9054 @
A Valve seat
B Valve disc
C Conical valve
D Compression spring
E Clamping piece locking screw
F Guide groove for special tool
G Clamping piece
H Valve guide bush
I Valve cover
Figure 10.21: Overview of a valve unit with hydraulic

operated valve cover
Pos : 44.50.4 /GEH O/H eadi ng/H4/#.#.#.# Dis ass embl y @ 0\mod_1147174347836_31.doc @ 3696 @
Pos : 44.50.5 /GEH O/Ass embl y and Dis ass embl y_during l oc k- out/Val ve unit/Conic al val ves /Val ve gui de bus h/Standar d/R emove angul ar-bush r emoval tool @ 1\mod_1165492029621_31.doc @ 9057 @
Use the procedure below, to remove the valve

guide bush from the clamping piece.
Check the guide bush:
2 Turn the valve housing cover until the
clamping piece (A) is visible.
3 Check the inner surface of the guide
bush (D).
4 If the guide bush (D) is worn-out or
damaged, then replace the guide bush (D).
Replace the guide bush:
5 Remove the clamping piece locking screw.
6 Remove the clamping piece (A) from the
valve housing cover.
7 Put the clamping piece (B) into a vice.
8 Put the valve guide bush removal tool (B)
into the grooves (C) of the clamping
piece (A).
9 Remove the valve guide bush (D) from the
clamping piece (A). Use a hammer. Figure 10.22: The valve guide bush removal tool
Pos : 44.50.6 /GEH O/H eadi ng/H4/#.#.#.# Ass embl y @ 0\mod_1147174319423_31.doc @ 3693 @
10.11.4.3 Assembly
Pos : 44.50.7 /GEH O/Ass embl y and Dis ass embl y_during l oc k- out/Val ve unit/Conic al val ves /Val ve gui de bus h/Standar d/Ins tall angular @ 1\mod_1165492511437_31.doc @ 9060 @
1 Heat up the clamping piece to 220°C

2 Put the clamping piece into a vice or press.
3 Put the valve guide bush into the clamping piece.
4 Put the clamping piece to the valve cover.
5 Tighten the clamping piece locking screw.
Refer to chapter "Tightening torques" for the correct torque.
10.26 201333-IOM-EN-R02
Pos : 44.52 /GEHO/Ass embl y and Dis ass embl y_during l oc k- out/Val ve unit/Conic al val ves /Val ve dis k/### Val ve dis k Disas sembl y and ass embl y @ 1\mod_1161260471084_31.doc @ 6573 @
10.11.5 Valve disk assembly
10.11.5.1 Disassemble the valve disk

A Conical valve
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 10.23: The valve
10.11.5.2 Assemble the valve disk

1 Make sure that all valve parts are clean,
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 10.24: The valve
5 Put the valve nut wrench (A) to the

assembled valve (B).
6 Tighten the valve disc lock nut.
Refer to chapter "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 10.25: Assemble the valve with the valve nut

wrench.
201333-IOM-EN-R01 10.27
Pos : 44.54.1 /GEH O/H eadi ng/H2/#.# Diaphr agm housing uni t @ 0\mod_1152094180650_31.doc @ 5123 @
10.12 Diaphragm housing unit

Pos : 44.54.2 /GEH O/H eadi ng/H3/#.#.# Di sass embl y @ 0\mod_1146735769451_31.doc @ 3613 @
10.12.1 Disassembly
Pos : 44.54.3 /GEH O/Ass embl y and Dis ass embl y_during l oc k- out/Diaphrag m housing unit/TZ PM Over vi ew filli ng ring and s pider cl ampi ng bus h @ 11\mod_1294320339781_31.doc @ 79787 @
Overview
A Filling ring
B Covering ring at the filling ring.
C Diaphragm housing.
D Screw at the filling ring.
(standard = 6x)
E Diaphragm
F Clamping bush (spider).
G Initiator housing
H Screw at the covering ring
(standard = 3x)
I Bearing bush for the guiding of the
monitoring rod.
J De-aeration holes in the housing and in the
filling ring. K
K Shim
Figure 10.26: Schematics of a diaphragm

housing with filling ring and (spider) clamping
bush with hydraulic operated cover
(The figure shows a schematic arrangement for
more versions)
Pos : 44.54.4 /GEH O/Ass embl y and Dis ass embl y_during l oc k- out/Gener al/#### Flus h and dr ain and de-pr ess urize the sl urr y s ecti on @ 5\mod_1232031630918_31.doc @ 45431 @ 5
10.12.1.1 Flush and drain and de-pressurize the slurry section

1 Flush and drain the slurry section.
DANGER
2 Close and secure the isolation valves in the slurry suction line and discharge line, to
isolate the working area.
Refer to the chapter "Safety instructions".
3 Drain the diaphragm housing.

Pos : 44.54.5 /GEH O/Ass embl y and Dis ass embl y_during l oc k- out/Diaphrag m housing unit/Di aphrag m housi ng c over/C ommon/#### Dis ass embl y, Preparati on de-pr ess urize+ drai n @ 1\mod_1164881888391_31.doc @ 8826 @
10.12.1.2 Preparation of the propelling liquid system

CAUTION
• De-pressurize the propelling liquid system, before starting works on the pump.
DANGER
1 De-pressurize the accumulator,

by opening the drain valve in the propelling liquid piping.
2 De-pressurize the propelling liquid chambers,
by opening the vent valves of the diaphragm housing units.
3 Open the drain plug of each propelling liquid chamber.
Collect the oil in a bucket.
Pos : 44.54.6 /GEH O/Ass embl y and Dis ass embl y_during l oc k- out/Diaphrag m housing unit/Di aphrag m housi ng c over/H ydr aulic/Loosen, single piston @ 0\mod_1156333407963_31.doc @ 5796 @
10.28 201333-IOM-EN-R02
10.12.1.3 Loosen the diaphragm housing

cover
Preparation
1 Remove the protection cover from the
diaphragm housing unit (D).
2 Remove eventually remaining push-bolds.
3 Use a special tool,
the "HYDRAULIC TENSION RING" (B).
Refer to chapter "Special tools".
4 Place the "HYDRAULIC TENSION
RING" (B) over the stud bolts.
Use an appropriate lifting device.
Use the lifting eye (A).
5 Hand-tighten all nuts (C) at the tension
ring.
Figure 10.27: Install the "HYDRAULIC TENSION RING".
6 Disconnect the protection cap of the
hydraulic quick release connector (E).
7 Connect the hose of the "HYDRAULIC
PUMP UNIT" to the hydraulic quick release
connector (E).
De-aeration procedure (if necessary):

De-aeration is required, if the "HYDRAULIC TENSION RING" (B) is used the first time (= initial use),
or if there is air in the hydraulic canals (so during hydraulic pressurizing the hydraulic system is
compressible).
1 Remove the blind plug (F), to enable the de-aeration of the tool (B).
2 Close the drain side of the oil-return/de-aerate valve at the hydraulic pump.
3 Activate the "HYDRAULIC PUMP UNIT",
until hydraulic oil with no air bubbles leaks out of the hole (F).
4 Tighten the de-aeration hole with the blind plug (F).
201333-IOM-EN-R01 10.29
Legend
A Diaphragm housing cover
B Hydraulic tension ring unit
C Diaphragm housing cover stud bolt
D Diaphragm housing cover nut
E Pin (to turn the cover nut)
F Tension-ring-nut
Figure 10.28: "HYDRAULIC TENSION RING"
Preparation of the hydraulic pistons

ATTENTION
For a proper procedure, the pistons and tension ring nuts (F) and cover-nuts (D) the must be in
their start position.
All piston heads must be even with the top surface of the "HYDRAULIC TENSION RING" (B).
As shown in the figure above.
1 Open the drain valve at the hydraulic pump,

to enable the pistons to move.
2 Screw all the tension-ring-nuts (F) into the position, that the nuts bottom surfaces are even with the
top surface of the "HYDRAULIC TENSION RING" (B).
If some pistons heads where above the ring surface,
then they have been pushed back into their start position with the tension-ring-nuts (F).
If some pistons heads are below the ring surface,
then they must be pushed back into their start position with the hydraulic pump.
3 Close the drain valve at the hydraulic pump.
until the hydraulic oil pushed all those pistons against the tension-ring-nuts (F).
5 Check the positions of the piston heads.
Loosen the diaphragm cover nuts
1 Activate the "HYDRAULIC PUMP UNIT", to pressurize the pistons of the "HYDRAULIC TENSION
RING".
Refer to chapter "Technical data", "Special torques", "Diaphragm housing unit" for the procedure and
pressure.
2 Loosen all diaphragm housing cover nuts (D) with the pin (E).
to relief the hydraulic pressure at the tensioning ring.
4 Disconnect the hydraulic hose.
5 Put the protection cap on the connector.
6 Remove all tension-ring-nut (F).
7 Remove the "HYDRAULIC TENSION RING" (B).
10.30 201333-IOM-EN-R02
Pos : 44.54.8 /GEH O/Ass embl y and Dis ass embl y_during l oc k- out/Diaphrag m housing unit/Di aphrag m housi ng c over/H ydr aulic/R emove, H oisti ng br ac ket @ 1\mod_1164889293953_31.doc @ 8839 @
Remove the diaphragm housing cover

1 Use the special tool set "HOISTING TOOL
DIAPHRAGM COVER".
2 Remove the two topmost cover nuts.
3 Remove the two lowest cover nuts.
4 Put the "HOISTING TOOL DIAPHRAGM
COVER" to the diaphragm cover.
Make sure that the threaded bolts fit in the
holes.
5 Tighten the "HOISTING TOOL
DIAPHRAGM COVER" with two screws.
6 Remove the remaining cover nuts.
7 Remove the diaphragm housing cover.
Use the jack-off screws.
8 Remove the diaphragm housing cover seal
ring.
Figure 10.29: The "HOISTING TOOL DIAPHRAGM

COVER"
Pos : 44.54.9 /GEH O/H eadi ng/H4/#.#.#.# Di aphr agm @ 1\mod_1165394045801_31.doc @ 9030 @
10.12.1.4 Diaphragm
Pos : 44.54.10 /GEH O/Assembl y and Disas sembl y_during loc k-out/Di aphr agm housing unit/Diaphrag m unit/H ydr aulic /Remove @ 1\mod_1165319630222_31.doc @ 8947 @ 4
1 Mark (clearly, with a permanent white

marker) at the diaphragm (B) its top-side
position (=12:00 o-clock)
(to enable diagnosis after removing).
2 Remove the diaphragm (B) from the
diaphragm housing (A).
3 Loosen and remove the monitoring rod (C)
from the diaphragm (B).
4 Check the monitoring rod (C) for abnormal
wear or damage.
5 If necessary, then replace the monitoring
rod (C).
6 Check the diaphragm (B).
7 Mark any indicator of abnormal wear or
failure or damage.
8 Replace the diaphragm (B),
according to the regular maintenance
schedule, or if necessary.
Figure 10.30: Remove the diaphragm

Pos : 44.54.11 /GEH O/Assembl y and Disas sembl y_during loc k-out/Di aphr agm housing unit/Clamping bush/#### Chec k the beari ng bus h @ 11\mod_1294378817500_31.doc @ 79803 @
10.12.1.5 Check the bearing bush

1 Check (visual inspection) the bearing bush / bearing retainer for wear and/or damage.
2 If necessary, then replace the bearing bush / bearing retainer.
201333-IOM-EN-R01 10.31
Pos : 44.54.13 /GEH O/Assembl y and Disas sembl y_during loc k-out/Di aphr agm housing unit/### Ass embl y: Cleaning after diaphr agm leakage @ 5\mod_1231426603303_31.doc @ 45210 @
10.12.2 Cleaning after diaphragm leakage or damage or contamination

INFORMATION
In case of questions or doubt, related to work because of a diaphragm replacement or
diaphragm failure, please do not hesitate to contact the service department of Weir Minerals
Netherlands b.v.
ATTENTION
After leakage of slurry into the propelling liquid camber, hard particles and chemical influences
can result in corrosion and mechanical wear and damage.
• Clean as soon as possible the propelling liquid system totally,
to avoid problems as a result of contamination.
• Clean and dry all parts immediately after dis-assembly, to avoid sticking of slurry.
Using warm flushing water helps to clean away slurry.
Dry all metal surfaces immediately after cleaning.
• The best way to preserve an "out of operation" pump:
after cleaning and drying, fill the propelling liquid chamber and the propelling liquid system
with fresh propelling liquid.
Diagnosis recommendation:
1 Remove the diaphragm and keep it available for inspection and diagnosis.
2 Drain the oil of the propelling liquid system of the involved diaphragm.
3 Do the oil quality laboratory check.
Decide how to proceed, depending on the level of the contamination of this oil.
Draining and inspection and cleaning of the "Propelling liquid chamber":

1 Inspect the propelling liquid chamber behind the diaphragm.
Search for any kind of slurry contamination.
Slurry can settle in lower places and get trapped in clearances between parts and in de-aeration holes.
2 Clean and dry and inspect all surfaces.
3 Clean and dry and inspect all de-aeration holes.
4 Clean and dry and inspect all plugs and connections and joints.
Recommendations for a full cleaning procedure:

1 Open and inspect and clean the propelling liquid tank.
2 Clean the propelling liquid chamber, from the diaphragm opening up to the piston.
3 If applicable, then remove and clean the "FILLING RING" in the diaphragm chamber.
Refer to the procedures in the next chapter.
4 Disconnect the propelling liquid lines, inspect them and flush the lines clean.
5 Open and inspect and clean all propelling liquid 2/2 valves at the inlet side and the outlet side.
6 Open and inspect and clean all non-return valves inside the 2/2 valve block.
7 Open and inspect and clean all non-return valves in the piping (near the 2/2 valves).
8 Replace all filters in the suction line and the discharge line of the propelling liquid pump.
10.32 201333-IOM-EN-R02
Draining and inspection and cleaning of the "PRESSURE LIMITATION SYSTEM":

WARNING
At normal conditions, the highest discharge operating pressure of the pump will remain in the
piping of the "PRESSURE LIMITATION SYSTEM" between the pressure relieve valve and the
non-return valves.
• Always discharge the pressure in the piping, by opening the drain valve,
before working at it or at the connecting valves.
1 To de-pressurize this section, open the vent valve at the piping between the pressure-relieve valve and
the non-return valves.
2 To drain the oil in this section, open the plug and collect it in a bucket.
3 If there is contamination in the propelling liquid,
then remove the piping and open and clean and inspect the non-return valve and the safety relief
valve.
Inspection and cleaning of the piston and liner:

1 Disassemble and clean and inspect the piston unit and its piston seals.
If necessary, then replace the piston seals.
2 Clean and inspect the cylinder liner.
Refer to chapter "Assembly and disassembly", "Piston unit."
Refilling:
1 Replace all the propelling liquid.
2 Replace all propelling liquid suction filters and discharge filters.
3 Re-fill the propelling liquid tank.
Refer to the according chapter for the procedure of replacing the propelling liquid.
Refer to document "UTILITY CONSUMPTION LIST" in chapter "Technical data" for the quality and quantity
of the propelling liquid.
ATTENTION
Remember at the priming phase to re-fill and de-aerate all the drained piping in the propelling
liquid system and pressure limitation system.
201333-IOM-EN-R01 10.33
Pos : 44.54.15 /GEH O/Assembl y and Disas sembl y_during loc k-out/Di aphr agm housing unit/TZ PM Over view filling ring and spi der clamping bush @ 11\mod_1294320339781_31.doc @ 79787 @
Overview
A Filling ring
(standard = 6x)
E Diaphragm
G Initiator housing
(standard = 3x)
monitoring rod.
filling ring.
K
K Shim
Figure 10.31: Schematics of a diaphragm housing with

filling ring and (spider) clamping bush with hydraulic
operated cover

more versions)
10.34 201333-IOM-EN-R02
Pos : 44.54.17 /GEH O/Assembl y and Disas sembl y_during loc k-out/Di aphr agm housing unit/Filling Ring/R emove the filling ring @ 1\mod_1165316258091_31.doc @ 8940 @
10.12.2.1 Remove the filling ring

CAUTION
To avoid injuries and damage of parts:
• Use a special lifting tool to handle the filling ring.
1 Check that the guide bush is removed, for

else, the tool can not fit at the filler ring.
2 Remove the screws (3xD) from the filling
ring.
Refer for the locations to the special lifting
tool.
3 Screw the special lifting tool (A) to the
filling ring (B).
If applicable, than use the special jack-off-
bolds.
4 Remove the remaining filling ring screws
(3xD).
5 Remove the filling ring (B).
If applicable, than use the special jack-off-
bolds.
If the filling ring is stuck,
than use a soft hammer (wood or copper)
to knock at the outside of the ring.
6 Clean and dry all parts and their thread
and the inside of the propelling liquid Figure 10.32: Removing the filling ring with the lifting
tool
chamber.
7 Clean and dry (with high pressure air) the (The figure shows a schematic arrangement for more
versions)
de-aeration holes (2x) in the filling ring.
Check that they are free and no dirt
remains.
Pos : 44.54.18 /GEH O/Assembl y and Disas sembl y_during loc k-out/Di aphr agm housing unit/Filling Ring/R emove the cover ri ng / Application: Clamping bus h (s pider) @ 11\mod_1294384279843_31.doc @ 79815 @
Remove the covering ring

Refer to picture 1.
1 Remove the screws (3xE).
2 Use a jaw puller (A) with a special tool, a
centre plug (C) which is included in the tool
set "HOISTING TOOL").
Put the centre plug (C) to the jaw
puller (A). Put the centre plug (C) against
the center of the guide bush (D) of the
monitoring rod.
3 Put the puller jaws behind the covering
ring (B).
4 Tighten jaw puller (A).
Use a wrench.
If the covering (B) is stuck, than use a soft
hammer (wood or copper). Knock on the
ring until it looses.
Figure 10.33: Remove the cover ring with a jaw puller

Refer to picture 2.
5 Remove the cover ring (B).
6 Clean and dry all parts and their thread.
201333-IOM-EN-R01 10.35
Pos : 44.54.20 /GEH O/H eading/H 3/#.#.# Ass embl y @ 0\mod_1146735726056_31.doc @ 3610 @
10.12.3 Assembly
Pos : 44.54.21 /GEH O/Assembl y and Disas sembl y_during loc k-out/Di aphr agm housing unit/AT TENTION Cl ean all parts @ 5\mod_1231514092064_31.doc @ 45260 @
ATTENTION
After a diaphragm leakage or damage or contamination, before starting the assembly,
it is essential to clean and dry all parts.
Refer to chapter "Cleaning after diaphragm leakage or damage or contamination".
Cleaning
1 Check that all cleaning preparations are done properly.
2 Clean and dry the diaphragm housing.
3 Clean and dry all parts.
4 Clean and dry (with high pressure air) the de-aeration holes at the diaphragm housing (1x),
and (if applicable) the filling ring (2x).
CAUTION
Cleaning all de-aeration holes is essential for proper de-aeration.
Pos : 44.54.22 /GEH O/Assembl y and Disas sembl y_during loc k-out/Di aphr agm housing unit/TZ PM Over view filling ring and spi der clamping bush @ 11\mod_1294320339781_31.doc @ 79787 @
Overview
A Filling ring
(standard = 6x)
E Diaphragm
G Initiator housing
(standard = 3x)
monitoring rod.
filling ring. K
K Shim
Figure 10.34: Schematics of a diaphragm housing with

filling ring and (spider) clamping bush with hydraulic
operated cover

more versions)
10.36 201333-IOM-EN-R02
Pos : 44.54.24 /GEH O/H eading/H 4/Filling ri ng @ 1\mod_1165326308309_31.doc @ 9003 @
10.12.3.1 Filling ring

Pos : 44.54.25 /GEH O/Assembl y and Disas sembl y_during loc k-out/Di aphr agm housing unit/Filling Ring/Ins tall the filling ring @ 1\mod_1165392370371_31.doc @ 9021 @
Install the filling ring

CAUTION
To avoid injuries and damage of parts:
• Use a special lifting tool to handle the filling ring, as shown in the figure.
1 Use the special lifting tool.

Check that the filler ring is balanced in the
hoist perfectly vertical, to enable easy
centering into the housing.
2 Check the position of the filler ring,
the de-aeration holes must be on top,
as shown in the figure.
3 Move carefully the filling ring (B) into the
diaphragm housing.
4 Tighten the filling ring screws (3x).
5 Remove the lifting tool (A).
6 Tighten the remaining filling ring screws
(3x).
Figure 10.35: Install the filling ring with the lifting tool
versions)
Pos : 44.54.26 /GEH O/Assembl y and Disas sembl y_during loc k-out/Di aphr agm housing unit/Clamping bush/#### Install the beari ng bus h @ 11\mod_1294391973718_31.doc @ 79832 @
10.12.3.2 Install the bearing bush

Checkpoints
1 Check, (visual inspection), the bearing bush for wear and/or damage.
2 If necessary, then replace the bearing bush.
201333-IOM-EN-R01 10.37
Install
2 Install the bearing bush (I) into the
clamping bush (spider) (F).
3 Use a nut-lock (LOCKTITE 243) at the
bearing bush (I).
Refer to chapter "Tightening torques" for the
correct torques.
Figure 10.36: Install bearing bush into the clamping

bush
Pos : 44.54.28 /GEH O/Assembl y and Disas sembl y_during loc k-out/Di aphr agm housing unit/Filling Ring/Ins tall the c overing ring @ 1\mod_1165392147668_31.doc @ 9018 @
10.12.3.3 Install the covering ring

2 Put the cover ring into the filling ring.
3 Tighten the covering ring screws (3x).
Refer to chapter "Tightening torques" to the correct torques.
Pos : 44.54.30 /GEH O/Assembl y and Disas sembl y_during loc k-out/Di aphr agm housing unit/#### As sembl y of the 2 i nitiator housi ngs @ 6\mod_1234883771196_31.doc @ 47614 @
10.12.3.4 Assembly of the 2 initiator housings

2 Use new O-rings.
3 Install the O-rings.
10.12.3.5 4 Install the 2 initiator housings. Assembly of the 2 initiator housings

In order to prevent high dynamic loading of the studbolts, 8 shims (K) are placed between the diaphragm
housing and cornerpiece. Because the thickness of these shims has to be very accurate they have been
measured,calculated and machined individually during assembly. In case of disassembly of the shims, make
sure the shims are re-assembled in the same location with same combination of parts. For this reason the
shims and surrounding parts need to be match marked during disassembly.
Spray the surface of the shims with preservation oil before re-assembly.
When the wet-end has been assembled again, the surface of the shims have to prayed with preservation oil.
If the shims have to be replaced by new ones please contact the WEIR Minerals Netherlands service
department.
Pos : 44.54.31 /GEH O/Assembl y and Disas sembl y_during loc k-out/Procedur es _during l oc k-out/#### Ini tiator c oupli ng nuts at the di aphr agm housings @ 5\mod_1220445788139_31.doc @ 37905 @
10.38 201333-IOM-EN-R02
10.12.3.6 Initiator coupling nuts at the diaphragm housings

DANGER
The initiator coupling nuts at the diaphragm housings should not be tightened, to avoid heat expansion
forces.
1 Screw every initiator coupling nut hand-
tight and then loosen about 45 degrees.
Figure 10.37: Initiator coupling nuts at the

diaphragm housings
(The figure shows a general schematic
Pos : 44.54.32 /GEH O/Assembl y and Disas sembl y_during loc k-out/Di aphr agm housing unit/Diaphrag m housing cover/H ydraulic/#### F unc tion c hec k of the i niti ators @ 5\mod_1232039717870_31.doc @ 45440 @ 4
arrangement, applicable for more versions.)
10.12.3.7 Function check of the initiators

Check the fill and outlet functions, operated by the monitoring-rod and its magnet moving under the initiators.
Triggering of these functions is displayed accordingly at the GEHO panel for each rod.
CAUTION
This function check can be done, with only the GEHO panel in operation,
and all other power supply shut-off.
1 Push the monitoring-rod forwards (into the housing), to trigger the fill-function, displayed at the GEHO
panel.
2 Pull the monitoring-rod backwards, to trigger the outlet-function, displayed at the GEHO panel.
3 Proceed only, if this test is perfect repeated 5x.
201333-IOM-EN-R01 10.39
Pos : 44.54.34 /GEH O/H eading/H 4/#.#.#.# M onitoring r od @ 6\mod_1233584025586_31.doc @ 46473 @
10.12.3.8 Monitoring rod

Pos : 44.54.35 /GEH O/Assembl y and Disas sembl y_during loc k-out/Di aphr agm housing unit/Diaphrag m/Closed diaphr agm/Assembling, Monitoring rod_clos ed Diaphrag m_siz e > = 10 l. @ 1\mod_1165320506364_31.doc @ 8950 @
Disass e
1 Clean the thread of monitoring rod (C).

2 Clean the threaded pin (B) of the
diaphragm (A).
3 Apply to the threaded pin (B) a nut-lock
(like "LOCTITE NUTLOCK 243").
4 Screw the monitoring rod (C) to the pump
diaphragm (A).
Refer to chapter "Tightening torques" for the
correct torque.
Figure 10.38: Assembling the monitoring rod and

diaphragm.
Pos : 44.54.36 /GEH O/Assembl y and Disas sembl y_during loc k-out/Di aphr agm housing unit/Diaphrag m unit/H ydr aulic /#### Install @ 1\mod_1165321911048_31.doc @ 8969 @
10.12.3.9 Diaphragm assembly

2 Clean the diaphragm area of the
3 Grease the clamping edge (C) of the
ATTENTION
Use only oil free grease.
4 Install the diaphragm (B) into the

Figure 10.39: Install the diaphragm unit

10.40 201333-IOM-EN-R02
Pos : 44.54.38 /GEH O/H eading/H 4/#.#.#.# Di aphrag m housi ng cover @ 1\mod_1165393688115_31.doc @ 9026 @
10.12.3.10 Diaphragm housing cover

Pos : 44.54.39 /GEH O/Assembl y and Disas sembl y_during loc k-out/Di aphr agm housing unit/Diaphrag m housing cover/H ydraulic/Ins tall, Hoisti ng brac ket @ 1\mod_1165323498290_31.doc @ 8998 @
Preparation
1 Check the diaphragm housing cover seal.
2 If necessary, then replace the diaphragm
housing cover seal.
3 Apply grease at the seal area of the cover
and the housing.
4 Install the diaphragm housing cover seal.
Mounting
5 Use the "DIAPHRAGM HOUSING COVER
HOISTING BRACKET".
Figure 10.40: The "DIAPHRAGM COVER HOISTING

BRACKET"
ATTENTION
6 Make sure that all the push-off bolts (G) at the valve cover (A) are unscrewed and free
from any contact with the top of the valve housing.
Ensure a metal to metal fit between the valve housing cover and valve housing.
7 Check that the cover is hoisted perfectly vertical.
8 Put the diaphragm housing cover to the diaphragm housing.
9 Secure the diaphragm housing cover with four cover nuts.
Use a wrench.
10 Screw evenly, until the cover sits flat on the housing via its raised face (check for even clearance all
around).
11 Remove the "DIAPHRAGM HOUSING COVER HOISTING BRACKET".
Store it, clean and safe and protected.
12 Tighten all other cover nuts hand-tight.
Pos : 44.54.40 /GEH O/Assembl y and Disas sembl y_during loc k-out/Di aphr agm housing unit/Diaphrag m housing cover/H ydraulic/Tighten, single pis ton @ 1\mod_1165323465060_31.doc @ 8995 @ 55
201333-IOM-EN-R01 10.41
10.12.3.11 "HYDRAULIC TENSION RING

UNIT"
Preparation
1 Use a special tool,
the "HYDRAULIC TENSION RING" (B).
Refer to chapter "Special tools".
2 Place the "HYDRAULIC TENSION
RING" (B) over the stud bolts.
Use an appropriate lifting device.
Use the lifting eye (A).
3 Hand-tighten all nuts (C) at the tension
ring.
4 Disconnect the protection cap of the
hydraulic quick release connector (E).
5 Connect the hose of the "HYDRAULIC
PUMP UNIT" to the hydraulic quick release Figure 10.41: Install the "HYDRAULIC TENSION RING"
connector (E).
De-aeration procedure (if necessary):
De-aeration is required, if the "HYDRAULIC TENSION RING" (B) is used the first time (= initial use),
or if there is air in the hydraulic canals,
so during hydraulic pressurizing the hydraulic system is compressible.
1 Remove the blind plug (F), to enable the de-aeration of the tool (B).
until hydraulic oil with no air bubbles leaks out of the hole (F).
3 Tighten the de-aeration hole with the blind plug (F).
Preparation hydraulic pistons

Legend
A Diaphragm housing cover
B Hydraulic tension ring unit
C Diaphragm housing cover stud bolt
D Diaphragm housing cover nut
E Pin (to turn the cover nut)
F Tension ring nut
Figure 10.42: "HYDRAULIC TENSION RING"
10.42 201333-IOM-EN-R02
ATTENTION
For a proper procedure, the pistons and tension-ring-nuts (F) and cover-nuts (D) the must be
in their start position.
All piston heads must be even with the top surface of the "HYDRAULIC TENSION RING" (B).
4 Open the drain valve at the hydraulic pump,
to enable the pistons to move.
5 Screw all the tension-ring-nuts (F) into the position, that the nuts bottom surfaces are even with the
top surface of the "HYDRAULIC TENSION RING" (B). As shown in the figure above.
If some pistons heads where above the ring surface,
then they have been pushed back into their start position by the tension-ring-nuts (F).
If some pistons heads are below the ring surface,
then they must be pushed back into their start position by the hydraulic pump.
6 Close the drain valve at the hydraulic pump.
until the hydraulic oil pushed all those pistons against the tension-ring-nuts (F).
8 Check the positions of the piston heads.
Tighten the diaphragm cover nuts
1 Activate the "HYDRAULIC PUMP UNIT", to pressurize the pistons in the "HYDRAULIC TENSION
RING".
torques and pressure.
2 Pre-tighten:
Tighten all the diaphragm housing cover nuts (D) with the pin (E), apply normal hand force torque.
3 Release the pressure from the "HYDRAULIC TENSION RING",
to allow a settling of the surfaces.
4 Pressurize again the "HYDRAULIC TENSION RING".
5 Final-tighten:
Tighten all diaphragm housing cover nuts (D) with the pin (E) with normal hand force torque.
to relief the hydraulic pressure at the tensioning ring.
7 Remove all tension ring nuts (F).
8 Disconnect the hydraulic hose.
9 Put the protection cap on the hydraulic quick release connector.
10 Remove the "HYDRAULIC TENSION RING" (B).
11 Install the push-off bolds at the cover.
Pos : 44.54.41 /GEH O/Assembl y and Disas sembl y_during loc k-out/Di aphr agm housing unit/### D e-aerati ng the pr opelling liqui d c hamber @ 5\mod_1231513255148_31.doc @ 45251 @ 45555
10.12.4 De-aerating the propelling liquid chamber

ATTENTION
After replacing a diaphragm, it is essential to de-aerate totally the propelling liquid chamber
and all connected piping.
Refer to chapter "Start-up, priming procedure".
201333-IOM-EN-R01 10.43
Pos : 44.56 /GEHO/Ass embl y and Dis ass embl y_during l oc k- out/Pis ton unit/Proj ect/Piston unit 201333 @ 12\mod_1302607518218_31.doc @ 85063 @
10.13 Piston unit

KK
10.13.1.1 Overview piston unit
Figure 10.43: Overview piston unit

A: Cylinder liner O: Hexagon bolts retaining plates
B: Thrust piece P: Supporting ring cylinder liner
C: Glores manifold Q: Set of roof shaped rings
D: Adapter flange R: Piston body lock nut
E: Hexagon nut S: Hoisting points connection piece
F: Hexagon bolt adapter flange / piston rod T: Hexagon cap screws thrust piece / cylinder
G: Piston rod liner
H: O-ring thrust piece / cylinder liner U: O-ring cylinder liner
I: O-ring thrust piece / glores manifold V: Hoisting point adapter flange
J: O-ring piston rod / piston body W: Connection piece
K: Piston body X: Hexagon bolts connection piece / adapter
L: Set of roof shaped rings flange
M: Piston guide ring Y: Hexagon bolts thrust piece / glores manifold
N: Retaining plates
10.13.2 Disassembly
Drain the propelling liquid.

Refer to chapter "Propelling liquid drain" for a safe and proper procedure.
10.44 201333-IOM-EN-R02
10.13.3 Disassembling the piston unit
10.13.3.1 Preparation
1 Remove the top cover plate of the frame unit.
2 Move the "PISTON UNIT" to the most forward position.
DANGER
Refer to chapter "Manual rotation of the pump crankshaft" for the procedure.
• Before proceeding, make sure, that the crankshaft is blocked against rotating,
to avoid risks during working.
10.13.3.2 Disassembling the Connection piece

1 Loosen the hexagon bolts (A1) which connects the adapter flange (B1) and the connection piece
(W).
2 Move the crosshead to the most backward position.
DANGER
• Before going on, make sure, that the crankshaft is blocked against rotating,
3 Attach two lifting eyes (S) to the
connection piece.
4 Use an overhead crane to lift the
connection piece.
5 Attach the hoisting chain / belt to the lifting
eyes and the overhead crane.
6 Loosen the hexagon bolts (X) and
hexagon nut (E) which connect the
connection piece and the piston rod (G).
7 Lift the connection piece out of the frame
unit.
Figure 10.44: Disassembling the connection piece
201333-IOM-EN-R01 10.45
10.13.3.3 Disassemble the piston rod, thrust piece and cylinder liner
Figure 10.45: Hoisting preparations Figure 10.46: special tool "Lifting tool cylinder"
1 Loosen the hexagon bolts (Y) which connect the thrust piece (B) and the glores manifold (C1).
2 Use the special tool "LIFTING TOOL CYLINDER" (A2).
• Use the special tool to lift the piston rod, thrust piece and cylinder liner.
3 Connect the special tool "LIFTING TOOL CYLINDER" to an overhead crane.
• Use two separate hoisting chains / belts (B2).
• Provide one hoisting chain / belt with a lever hoist (C2).
4 Use a level (D2) to obtain a perfect horizontal disassembly starting position.
5 Use the Guide pins (C3) for the perfect position of the "LIFTING TOOL CYLINDER" , the thrust piece
(B) and Glores manifold (C1).
6 Connect the "LIFTING TOOL CYLINDER" to the thrust piece.
WARNING
Use the special tool "LIFTING TOOL CYLINDER" and the co-supplied bracket (B3) when the
piston rod outer contour is equal to the thrust piece opening. Mount the bracket to the adapter
flange (D3) and thrust piece (B). The bracket prevent that the piston rod slides out of the thrust
piece.
7 If Necessary, use the push off bolts (A3).
8 Slowly pull the special tool backwards to the crankshaft.
9 Tip the special hoisting tool with the piston assembly about -45 degrees.
10 Carefully lift the lifting tool and the attached assembly out of the frame unit.
ATTENTION
Make sure that no o-rings (U) and / or Supporting rings (P) left in the cylinder liner cooling
jacket or frame unit
11 Disassemble o-ring thrust piece / glores manifold (I) and o-ring cylinder liner (U).
10.46 201333-IOM-EN-R02
10.13.3.4 Disassemble the piston body and piston rod

The piston assembly is still connected to the overhead crane. Put the piston assembly on a wooden pallet.
1 Disassemble the special tool "LIFTING TOOL CYLINDER".
2 Remove the special tool "LIFTING TOOL CYLINDER" (hoisting tool, bracket (B3) and guide pin (C3).
3 Mount two lifting eyes crosswise to the thrust piece (B).
4 Connect the overhead crane to the two lifting eyes.
5 Hoist the piston assembly vertical.
6 Put a spanner on the hexagon bolt adapter flange / piston rod (F). Loosen the hexagon bolt.
7 Remove the hexagon bolt (F).
8 Install a lifting eye (see position: V) to the adapter flange (D).
9 Connect a overhead crane to the lifting eye.
10 Remove the adapter flange (D).
11 Loosen the hexagon cap screws thrust piece / cylinder liner (T).
12 Remove the thrust piece (B). Use a overhead crane. Use the lifting eyes on to the thrust piece.
13 Put the thrust piece on a wooden pallet.
14 Remove o-ring thrust piece (H).
15 Connect a lifting eye to the piston rod (G).
16 Connect a overhead crane to the lifting eye and pull the piston rod out of the cylinder liner.
17 Put the piston rod on a wooden pallet.
18 Remove piston guide ring (M).
19 Hoist the piston rod until you have reached a good working position.
20 Loosen the hexagon bolts (O) and remove the retaining plates (N).
21 Remove the set of roof shaped rings (L) and (Q).
22 Put a wooden beam on a wooden pallet.
23 Hoist the piston rod (G) on the wooden beam.
24 Disconnect the piston rod from the overhead crane.
25 Put a spanner on the flattened surface of the piston rod. Do this to prevent movement of the piston rod
when un-tighten the Piston body lock nut (R).
26 Put a spanner on the Piston body lock nut (R). Loosen the piston body lock nut.
27 Tighten two hoisting ropes to the piston rod (G).
28 Remove the piston rod. Use a overhead crane.
29 Remove the o-ring (J) between the piston body and piston rod.
30 Connect two lifting eyes to the piston body (K). Use a overhead crane.
31 Remove the piston body (K).
201333-IOM-EN-R01 10.47
10.13.4 Replace procedure for the dust cover rings
10.13.4.1 Overview TZPM type
Figure 10.48: TZPM "DUST COVER"

Figure 10.47: TZPM "CROSSHEAD-ROD"
DETAIL "X" = "DUST COVER" XA "DUST COVER HOUSING"

A "CROSSHEAD" XB "WIPER RING"
B "CROSSHEAD ROD" XC "O-RING"
C "ADAPTER FLANGE" XD "GASKET HOLDER"
D 2 flat bars to tighten the XE "BOLT"
"DUST COVER HOUSING" (XA) XF "SEALING RING"
E "MULTI-JACKBOLT TENSIONER NUT"
F "O-RING DUST COVER HOUSING"
10.13.4.2 Replace and align the rings in the Gasket holder

Remove the rings in the Gasket holder
1 Loosen the Multi-jackbolt tensioner nut (E).
Refer to chapters "Catalogue information" and "Special torques" for the exact procedure and the correct
torques.
2 Remove the Adapter flange (C) from the Crosshead rod (B).
3 Move the Crosshead (A) in its most backward position.
DANGER
• Always block the crankshaft against rotating. Do this to avoid risks during work.
4 Remove the bolts (XE).
5 Remove the Gasket holder (XD) from the Crosshead rod (B).
6 Remove the Wiper ring (XB) and the O-ring (XC) from the Gasket holder (XD).
7 Clean the Gasket holder (XD).
Assemble the Dust cover housing
(If it was removed, then assemble this first.)
1 Put the O-ring (F) to the Dust cover housing (XA).
2 Slide the Dust cover housing (XA) against the frame unit bulkhead.
3 Tighten Dust cover housing (XA). Use the two flat bars (D).
4 If applicable, then connect the lubrication line to the Dust cover housing (XA).
10.48 201333-IOM-EN-R02
Preparation of the rings in the Gasket holder

1 Make sure that the sealing surfaces of the Gasket holder (XD) and the Crosshead rod (B) are free
from dirt and dust and corrosion.
2 Check the Wiper ring (XB) and the O-ring (XC).
Replace them, if necessary.
3 Put the Wiper ring (XB) and the O-ring (XC) into the Gasket holder (XD).
Grease the rings with the normal lubrication oil.
4 Grease the round surface of the Crosshead rod (B) with the normal lubrication oil.
(To protect the rings during sliding on the rod.)
5 Slide carefully and gently the pre-assembled Gasket holder (XD) (with its rings and Sealing ring (XF)
on the Crosshead rod (B) against the Dust cover housing (XA).
Alignment of the Gasket holder and its rings

1 Make sure that the Crosshead (A) is in the middle position of its stroke.
(To achieve for the alignment of the rings a middle position between the "TOP DEAD END" and the
"BOTTOM DEAD END".)
2 Hand-tighten with the bolts the Gasket holder (XD) at the Dust cover housing (XA).
3 Make sure that the Gasket holder (XD) is proper aligned on the Crosshead rod (B).
(to improve the lifetime and functions of these rings).
If necessary, then use the clearance in the bolt-holes of the Gasket holder (XD) for alignment.
If the Dust cover housing (XA) was disassembled, then you may need to re-position it also, to
achieve a proper alignment.
4 Tighten the bolts (XE) at the Gasket holder (XD).
Make sure that during tightening, the parts do not change the position and the alignment.
Install the adapter flange

1 Move the Crosshead (A) in its most backward position.
DANGER
• Always block the crankshaft against rotating. Do this to avoid risks during work.
2 Install the Adapter flange (C) to the Crosshead rod (B).
3 Tighten the Multi-jackbolt tensioner nut.
Refer to chapters "Catalogue information" and "Special torques" for the exact procedure and the correct
torques.
4 If applicable, then connect the l ubric ation li ne to the Dust c over housi ng (XA).
201333-IOM-EN-R01 10.49
10.13.5 Assembly
10.13.6 Assembling the piston unit
10.13.6.1 General preparation

1 Put the cylinder liner (A) in vertical position on a wooden pallet or two wooden beams.
2 Check the cylinder liner for grooves. Replace the cylinder liner, if necessary.
3 Make sure that the internal thread in the cylinder liner for connecting the thrust piece (B) is on top.
10.13.6.2 Assembly piston body and piston rod

1 Connect two lifting eyes to the piston body (K). Use a overhead crane.
2 Put the piston body vertical on a wooden pallet.
3 Put a wooden beam on the wooden pallet.
4 Tighten two hoisting ropes to the piston rod (G).
5 Hoist the piston rod (G) on the wooden beam.
6 Mount o-ring (J) to the piston rod.
7 Slide the piston rod (G) through the piston body (K).
8 Put a spanner on the flattened surface of the piston rod. Do this to prevent movement of the piston rod
when tightening the Piston body lock nut (R).
9 Put a spanner on the Piston body lock nut (R). Tighten the piston body lock nut.
(Use the hydraulic torque wrench and the special help tools.) .
Refer to chapter "Special torques" for the correct tightening torques.
10 Connect a lifting eye to the piston rod (G).
11 Detach the two hoisting ropes.
12 Hoist the piston rod until you have reached a good working position.
13 If necessary, replace the set of roof shaped rings ("CHEVRON "-type piston seals) (L) and (Q).
14 Install the retaining plates (N).
15 Tighten the hexagon bolts (O).
16 If necessary, replace the piston guide ring (M).
17 Lubricate the set of roof shaped rings
("CHEVRON"-type piston seals) (L) and
(Q) with hydraulic oil.
18 Lubricate the cylinder liner (A) surface with
hydraulic oil.
19 Lubricate the piston guide ring (M) with
grease and hydraulic oil to retain in
position.
20 Put an o-ring around the piston guide ring
(M) to hold it into position during the
assembly.
Figure 10.49: Lubrication points
21 Put a wooden plate (minimum thickness: 10 mm) inside the cylinder liner.
22 Lower the piston rod carefully into the cylinder liner.
23 The o-ring assembled to the piston guide ring rolls off. Remove the o-ring.
24 Disassemble the piston rod from the overhead crane.
25 Disassemble the lifting eye from the piston unit.
10.50 201333-IOM-EN-R02
10.13.6.3 Assembly adapter flange , thrust piece and cylinder liner

1 Mount two lifting eyes to the thrust piece (B).
2 Connect a overhead crane to the lifting eyes.
3 Hoist the thrust piece above the cylinder liner.
4 Tighten the hexagon bolts (T) which connect the thrust piece (B) and the cylinder liner (A).
5 Disassemble the thrust piece from the overhead crane.
6 Install a lifting eye (see position: V) to the adapter flange (D).
7 Hoist the adapter flange above the piston rod (G).
8 Install the adapter flange. Tighten the hexagon bolt (F).
9 Put the thrust piece, cylinder liner and piston rod horizontal on the wooden pallet. Use the two lifting
eyes mounted on the thrust piece.
10 Disassemble the thrust piece from the overhead crane.
11 Disassemble the lifting eyes from the thrust piece.
201333-IOM-EN-R01 10.51
10.13.6.4 Preparations piston assembly
Figure 10.50: Special tool "Hoisting tool cylinder" Figure 10.51: Hoisting preparations
1 Mount two guide pins (C3) in the glores manifold.

2 Mount the special tool "LIFTING TOOL CYLINDER" (A2) to the thrust piece.
WARNING
Use the special tool "LIFTING TOOL CYLINDER" and the co-supplied bracket (B3). Mount the
bracket to the adapter flange and thrust piece. The bracket prevents that the piston rod slides
out of the thrust piece.
3 Connect the special tool "LIFTING TOOL CYLINDER" to an overhead crane.
• Use two separate hoisting chains / belts (B2).
• Provide one hoisting chain / belt with a lever hoist (C2).
4 Hoist the special tool and piston assembly.
5 Use al level (D2) to obtain a perfect horizontal assembly starting position. See figure: "Hoisting
preparations".
6 Mount the o-rings cylinder liner (U) and o-ring thrust piece (I).
7 Lubricate the o-rings with grease and hydraulic oil to achieve smooth assembling of the piston
assembly and the cylinder liner.
8 Lubricate on locations where o-rings makes contact with the corner piece and glores manifold.
9 Move the special hoisting tool and piston assembly above the top cover plate of the frame unit.
10 Move the crosshead to the most backward position.
DANGER
• Before going on, make sure, that the crankshaft is blocked against rotating,
11 Tip the special hoisting tool with the piston assembly about -45 degrees.
12 Lower the special tool in the frame unit.
13 Tip the special tool until it is horizontal. Use a level.
14 Slowly push the special tool forward to the glores manifold.
15 Use the guide pin (C3) in the glores manifold to center the thrust piece.
16 Disassemble the special hoisting tool (A2) and if applicable bracket (B3).
10.52 201333-IOM-EN-R02
10.13.6.5 Assembling the piston unit

1 Tighten the thrust piece to the glores manifold. Use the hexagon bolts (Y).
2 Disassemble the two guide pins (C3). Use these two bolt holes for further tightening of the thrust piece
and glores manifold. Use two hexagon bolts (Y).
3 Connect two hoisting eyes to the connection piece (W).
4 Connect the connection piece to an overhead crane.
5 Hoist the connection piece in the frame unit.
6 Mount the connection piece to the piston rod. Use the hexagon bolts (X) and the hexagon nut (E).
7 Move the crosshead to the most forward position.
DANGER
•
Before going on, make sure, that the crankshaft is blocked against rotating,
8 Mount the adapter flange (B1) to the
connection piece.
9 Use the hexagon bolts (A1).
Refer to chapter "Special torques" for the correct
tightening torques.
10 Close the top cover of the frame unit.
Figure 10.52: Disassembling the connection piece
10.13.7 Disassembly and assembly glores cooling jacket

ATTENTION
If there are problems with o-rings and supporting rings used in the connection between the
glores cooling jacket, the glores manifold, corner and middle pieces then:
• Contact the service department of Weir Minerals Netherlands b.v. because this
maintenance work is highly specialized.
201333-IOM-EN-R01 10.53
Pos : 44.58.1 /GEH O/H eadi ng/H2/#.# Pulsation dampener @ 1\mod_1168952826922_31.doc @ 11788 @
10.14 Pulsation dampener

Pos : 44.58.2 /GEH O/H eadi ng/H3/#.#.# Safety i nstr ucti ons @ 7\mod_1249042333469_31.doc @ 53498 @
10.14.1 Safety instructions

Pos : 44.58.3 /GEH O/Ass embl y and Dis ass embl y_during l oc k- out/Puls ation damper/Safety instruc tions/Safety i nstr ucti ons puls ati on dampener @ 1\mod_1168953439328_31.doc @ 11799 @
WARNING
The pre-charge pressure may never exceed the maximum allowed pressure,
as indicated at the dampener identification plate.
WARNING
The dampener may be under pressure, even when the pressure gauge indicates no pressure.
The pressure sensing opening may be clogged.
WARNING
In case of insufficient pre-charge pressure or nitrogen leakage, the pressure pulsations may be
excessive and may cause heavy vibrations.
WARNING
• ONLY use nitrogen to pre-charge a dampener.
• NEVER use oxygen, because of explosion danger.
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 a very rapid pressure drop in the discharge line, in combination with dis-location 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
Escaping nitrogen may cause lack of oxygen.
WARNING
If discharging the gas pressure through the valve,
then the escaping nitrogen can push away the air in the direct environment,
that can cause lack of oxygen.
10.54 201333-IOM-EN-R02
Pos : 44.58.5 /GEH O/Ass embl y and Dis ass embl y_during l oc k- out/Puls ation damper/### Dis ass embl y @ 0\mod_1156236790706_31.doc @ 5737 @
10.14.2 Remove the diaphragm

Preparation
1 Strictly obey the pulsation dampener safety instructions.
Refer to chapter "Pre-charging the discharge pulsation dampener".
2 Open in many short steps the nitrogen filler valve, to discharge the nitrogen gas pressure from the
pulsation dampener. Check this at the pressure gauge.
DANGER
Leaking nitrogen (N 2) causes lack of oxygen:
• 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 only a few turns.
DANGER
DO NOT remove the cover nuts now. •
First make sure that the pulsation dampener cover does not come upward against the •
nuts. This indicates that there is still pressure inside the pulsation dampener.
5 Remove the cover nuts.
Use the lifting eye and a proper lifting device to remove the cover from the pulsation dampener.
ATTENTION
The lifting eye on the pulsation dampener cover is only suitable
• for lifting the cover of the housing and
• for lifting the pulsation dampener unit,
NEVER for hoisting parts, attached to the bottom of the dampener housing.
Remove the diaphragm
1 Mount a hoisting eye bolt (A) at the bottom of the diaphragm.
2 Hoist at the hoisting eye the pulsation dampener diaphragm out of the housing.
DANGER
Keep away your hands, during this action.
3 Inspect the interior of the pulsation

dampener for signs of abnormal wear.
Figure 10.53: Preparation for removal of the diaphragm

201333-IOM-EN-R01 10.55
Pos : 44.58.7 /GEH O/Ass embl y and Dis ass embl y_during l oc k- out/Puls ation damper/### Ass embl e the diaphr agm @ 0\mod_1156228349876_31.doc @ 5731 @
10.14.3 Assemble the diaphragm

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 Clean the diaphragm clamping edge of the
housing.
5 Apply sufficient liquid sealing in the
diaphragm clamping edge of the housing.
Figure 10.54: Clamping edge of the diaphragm
INFORMATION
• Recommendation, use the following liquid sealing types to install the diaphragms,
O-rings and seals:
"Klüber Syntheso Pro AA2, article number 006025".
CAUTION
The liquid sealing is needed for an air-tight sealing between the diaphragm and the metal
parts.
Failure to properly seal these surfaces may result in a gradual leakage of nitrogen gas and
drop of the pre-charge pressure.
10.56 201333-IOM-EN-R02
10.14.3.1 Diaphragm folding, option 1

1 Push the cone outward.
2 Fold the diaphragm.
201333-IOM-EN-R01 10.57
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.
10.58 201333-IOM-EN-R02
10.14.3.2 Diaphragm folding, option 2

1 Fold the diaphragm.
2 Insert the diaphragm into the pulsation

dampener housing.
201333-IOM-EN-R01 10.59
3 Make sure that there is still sufficient sealing

grease in the housing edge for the clamping
rim of the diaphragm.
Figure 10.55: Clamping edge of the diaphragm
4 Move the diaphragm into its position.

5 Make sure that the clamping rim of the
diaphragm fits well in the edge of the
dampener housing.
Figure 10.56:
Pos : 44.58.9 /GEH O/Ass embl y and Dis ass embl y_during l oc k- out/Puls ation damper/### Ass embl e the c over @ 8\mod_1265121781812_31.doc @ 58921 @
10.14.4 Assemble the cover

1 Apply sufficient liquid sealing to the sealing
edges of the diaphragm to the cover.
Figure 10.57: Sealing edge
CAUTION
The liquid sealing is needed for an air-tight sealing between the diaphragm and the metal
parts.
Failure to properly seal these surfaces may result in a gradual leakage of nitrogen gas and
drop of the pre-charge pressure.
10.60 201333-IOM-EN-R02
INFORMATION
Recommendation, use the following liquid sealing types to install the diaphragms, O-rings and
seals:
• "Klüber Syntheso Pro AA2, article number 006025".
2 Put the cover to the housing.

Make sure, that the cover does not push or pull at the diaphragm.
3 Tighten the nuts with the correct torque.
Refer to chapter “Special torques”.
Pos : 44.59 /GEHO/Ass embl y and Dis ass embl y_during l oc k- out/Nitrog ene filling devic e/## Nitrogen filling devic e @ 2\mod_1192101182920_31.doc @ 18265 @ 3
10.15 Nitrogen filling device

• Use the nitrogen filling device for the filling of the hydraulic accumulator(s) and/or the pulsation
dampener(s).
Refer to the document "INSTRUMENT LIST" for the correct pressure.
Refer to the chapter "Pre-charging the pulsation dampener" for the correct filling of the pulsation dampener(s)
and the accumulator(s).
201333-IOM-EN-R01 10.61
10.62 201333-IOM-EN-R02
Appendix: Parts - Lists and drawings (pump section)
Pos : 46.1 /GEHO/Heading/H 1/#. Appendi x: Parts - Lis ts and drawi ngs (pump s ecti on) @ 1\mod_1169571543393_31.doc @ 11982 @
11 Appendix: Parts - Lists and drawings (pump section)

Pos : 46.2 /GEHO/Parts lis ts/## Safety ins truc tions for par ts @ 5\mod_1227872607693_31.doc @ 44431 @
11.1 Safety instructions for parts

DANGER
• Use only genuine GEHO parts.
• Order parts only with their WEIR-GEHO item number.
This is mandatory, to maintain:

• the original safety level, in accordance with the applicable regulations,
• the warranty accountability,
• the general product accountability,
• the original product reliability and durability.
Pos : 46.3 /GEHO/Parts lis ts/## Or deri ng parts + NOT E - Items with ** * @ 1\mod_1165932498812_31.doc @ 9184 @ 2
11.2 Ordering parts

NOTE
If ordering items marked with ***, then specify the quantity.
Ordering and determination of parts:

• Refer to the pump number, as given on the GEHO type plate.
Sample: WEIR pump number = GEHO 7201152/3
• Use the same determination, as given in the parts list.
Pos : 46.4 /GEHO/Parts lis ts/814=Pump/Project/## Gener al storag e c onditi ons #01= zonder preser vati on of pumps @ 5\mod_1231168066513_31.doc @ 44886 @
11.3 General the handling and storage conditions
11.3.1 Refer to the handling and storage instructions with the packing
• Refer to the instructions on the packing or to the documents delivered with the packing.
If available, these specific instructions are additional to the general instructions, as mentioned below.
11.3.2 General instructions

ATTENTION
Always store the pumps and their components
• under dry conditions,
• in a not-aggressive environment,
• protected from direct sun light.
11.3.3 Storage of synthetic materials

• Keep the original sealed package closed as long as possible.
• Close and seal an opened package as soon as possible.
• Protect package and parts against direct sun-light.
• Store the parts in their as-manufactured-shape.
Storage of elastomer materials (spare parts):
• Storage temperature between +5°C / +41°F and +35°C / +95°F at about 85% relative humidity.
Storage of polyurethane materials (valve seat rings):
• Storage temperature between +5°C / +41°F and +25°C / +77°F at about 75% relative humidity.
201333-IOM-EN-R01 11.1
11.2 201333-IOM-EN-R02
Pos : 46.7 /GEHO/Heading/H 2/#.# Part list and drawi ngs @ 3\mod_1204008514007_31.doc @ 26365 @
11.4 Part List and drawings

Pos : 47 /GEHO/Parts lists/814= Pump/Project/201333 04042011 @ 12\mod_1301925292484_0.doc @ 84691 @ 2
TZPM2000 ASSEMBLY DRAWING REVISION: 00

PART LIST NUMBER 820.587.201333
DRAWING NUMBER T.820.201333
ID ITEM NUMBER DESCRIPTION TECHNICAL DETAILS Qty

005 818.080.559BM PULS.DAMPENER FILLING UN 1
010 828.950.126X LUBRICATION UNIT 1
015 828.950.135V FLUSHING-UNIT 1
020 828.950.155V VENTLINE UNIT 1
025 831.020.426A VALVE UNIT 3
026 831.020.427A VALVE UNIT 3
030 832.010.324A DIAPHRAGM HOUSING UNIT 1
032 834.010.016A GLORES-UNIT 1
035 835.0963.230A PISTON UNIT 3
050 845.010.486A FRAME UNIT 1
060 851.010.135A PULSATION DAMPENER UNIT 3
065 853.010.238G PRESS.UNIT REGUL.UNIT 1
070 855.010.054AH PRESSURE TRANSMITTER UN 1
075 857.010.126X PROPELLING LIQUID UNIT 1
080 858.010.118V ELECTRICAL UNIT 1
085 895.587.215A ACCESSORIES 1
090 851.010.144A AIR VESSEL UNIT 1
100 814.201333.16 DRIVE UNIT 1
910.150.031 ROUND HEAD GROOVED PIN D1476 R2X8 SS 6
818.030.272 TYPE PLATE SS 1
910.150.052 ROUND HEAD GROOVED PIN D1476 R3X10 SS 20
818.030.257 NAME PLATE-WEIR 5
818.030.139 NAME PLATE-GEHO 2
795.000.400 BINDING WIRE SS ***
814.201333.27 SET OF TAG PLATES .1
201333-IOM-EN-R01 11.3
11.4 201333-IOM-EN-R02
PULS.DAMPENER FILLING UN DRAWING REVISION: 00

PART LIST NUMBER 818.080.559BM
DRAWING NUMBER T.818.080.219

001 922.590.611 THREADED REDUCING PIECE RED-R1/2/R1/4 SS 3
002 922.980.653 BANJO COUPL.W.ONE BOLT P-RSWV6S (SS 3
003 929.050.503 PIPE CLAMP 106-PP 7
004 913.003.138 HEX.SOCKET HEAD CAPSCREW D912 M6X35 STL 7
005 929.050.530 LOCKING SHEET DP1 7
006 922.100.653 STRAIGHT COUPLING P-GV6S (SS 3
008 855.100.068 MOUNTING BLOC 1
009 922.360.654 BULKHEAD ELBOW COUPLING WSV 6S (SS 5
010 922.280.654 BULKHEAD COUPLING P-GSV 6S 3
011 922.170.653 MALE STUD COUPLING P-GEV6SR-WD (SS 4
012 922.910.653 ADJUST MALE STUD ELBOW P-EWSD6S (SS 3
013 922.070.609 BLANKING END VS-R1/4"WD SS 2
014 921.100.036 GLOBE VALVE G1/2"-ECON355 3
015 922.740.662 ADJUST.COUPLING EMASD 12SR SS 6
016 922.170.562 MALE STUD COUPLING GES12SR/R1/2-WD SS 6
017 922.590.618 THREADED REDUCING PIECE RED-R3/4-WD/R1/2SS 3
018 900.000.046 DUST COVER 3
019 931.400.210 SEALING RING 21-26-1.5 DIN7603 3
020 818.030.026 TYPE PLATE 1
021 910.150.029 ROUND HEAD GROOVED PIN D1476 R2X5 1.4305 4
022 921.510.344 PRESSURE GAUGE R100/0-16000KPA 3
023 730.945.001 PIPE R6X1 A312-316L ***
201333-IOM-EN-R01 11.5
11.6 201333-IOM-EN-R02
LUBRICATION UNIT DRAWING REVISION: 04

PART LIST NUMBER 828.950.126X

001 814.201333.45 ELECTRIC MOTOR 1.5HP-1200RPM 1
002 960.010.630 COUPLING 1
003 960.020.073 GEAR PUMP 1
004 960.020.633 LATERNE PIECE 1
005 816.941.405 SUPPORT 1
008 913.033.236 HEX.SOCKET HEAD CAPSCREW 1/2"X13UNCX1 4
009 915.003.040 HEXAGON NUT D934 M16 STL 4
010 921.700.881 SUCTION STRAINER 1
011 911.070.333 STUD D938 M16X40 STL 4
012 917.346.040 LOCK WASHER D9021A M16 STL-GLV 4
013 999.999.000 ARROW=ROTATING DIRECTION 1
016 921.700.429 FILTERHOUSING LPF280GE XXB1.X 1
017 921.700.872 FILTERELEMENT 0280D1002/HC 1
018 922.950.996 DISTANCE PIPE 1
020 921.700.430 FILTERHOUSING 1
021 921.700.862 FILTERELEMENT 2
025 922.170.628 MALE STUD COUPLING P-GEV28LR-WD SS 3
026 922.010.629 NUT M 28L SS 1
027 922.030.628 PROFILE RING P-R 28L SS 1
028 922.940.628 STUD STAND PIPE ADAPTOR EGESD 28LR-WD SS 2
029 922.930.628 ADJUST.MALE T-STUD P-ELVD 28L SS 2
031 929.050.501 PIPE CLAMP 428-PP 4
033 929.050.531 LOCKING SHEET DP4 12
035 914.003.144 HEXAGON BOLT D931 M6X65 STL 8
036 922.970.631 REDUCING FITTING P-REDVD 28/12L SS 13
037 922.430.609 FEMALE CONNECTOR SNV12L 1
038 922.010.610 NUT M12L SS 1
201333-IOM-EN-R01 11.7

040 922.910.628 ADJUST.MALE STUD ELBOW P-EWVD28L SS 2
041 922.280.629 BULKHEAD COUPLING P-GSV 28L SS 1
042 917.280.069 WASHER SS 1
043 922.450.628 EQUAL TEE COUPLING P-TV 28L SS 12
044 922.970.628 REDUCING FITTING P-REDVD 28/6L 1
045 922.590.630 THREADED REDUCING PIECE RED-R1.1/4/R1 4
046 914.106.196 HEXAGON SCREW D933 M10X25STL-GLV 2
047 917.306.028 WASHER D125A M10 STL-GLV 2
048 922.980.628 BANJO COUPL.W.ONE BOLT O-RSWV 28LR (SS 2
049 922.300.628 EQUAL ELBOW COUPLING P-WV 28L SS 2
051 922.740.659 ADJUSTABLE COUPLING EMASD-10SR-SS 1
054 922.890.617 STUD STAND PIPE ADAPTOR EGESD18L1/2"NPT SS 1
055 868.001.879 DISTANCE BUSHING 2
056 816.941.074 SUPPORT 1.0067 1
057 914.103.243 HEXAGON SCREW D933 M12X60 STL 2
058 922.920.628 ADJUST EQUAL TEE P-ETVD 28L 1
059 922.910.609 ADJUST.MALE STUD ELBOW P-EWVD 12L 2
060 928.860.028 BALL VALVE RKH 28L-254423 1
061 928.860.030 BALL VALVE RKH 12L10 1
062 922.170.610 MALE STUD COUPLING P-GEV 12LR-WD 6
067 828.500.513 BANJO COUPLING 5
068 828.500.514 STUD ADAPTOR 6
071 868.053.287 ORIFICE 3
072 868.053.288 ORIFICE 5
073 868.053.286 ORIFICE 3
075 971.900.095 TEMPERATURE SENSOR 1
076 931.400.210 SEALING RING 21-26-1.5 DIN7603 1
077 814.201333.54 SUPPORT 1
081 960.020.632 ADAPTERFLANGE 1
11.8 201333-IOM-EN-R02

089 922.090.609 BLANKING PLUG VS 12L/S 1
097 870.005.136 COVER 2
098 931.030.375 O-RING R120X4 NBR-70SH 2
100 971.600.008 FLOW SENSOR 1
101 922.950.879 T-PIECE E40080/QL28-18-28 1
102 922.950.880 ADAPTER E40104 1
105 730.945.103 PIPE R12X1.5 A312-316L ***
106 730.945.213 PIPE R28X2-316L ***
107 730.945.001 PIPE R6X1 A312-316L ***
109 816.941.351 SUPPORT 1
110 922.070.628 BLANKING END VS-R1"WD SS 2
120 971.450.099 PRESSURE TRANSMITTER 1
130 971.900.047 HEATING ELEMENT CSN-ERCT/80 1
201333-IOM-EN-R01 11.9
11.10 201333-IOM-EN-R02
FLUSHING-UNIT DRAWING REVISION: 00

PART LIST NUMBER 828.950.135V

001 922.940.609 STUD STAND PIPE DE ADAP EGESD 12L/R1/4-WD 9
002 922.450.609 EQUAL TEE COUPLING P-TV 12L 6
003 922.300.609 EQUAL ELBOW COUPLING P-WV 12L 373388 3
004 922.940.610 STUD STAND PIPE ADAPTOR EGESD 12LR-WD 3
005 922.970.620 REDUCING FITTING PREDVD18/12L374641 3
006 730.945.119 PIPE R18X2 A312-316L ***
007 922.450.617 EQUAL TEE COUPLING P-TV 18L-SS 2
008 922.300.617 EQUAL ELBOW COUPLING P-WV 18L SS 1
009 730.945.101 PIPE R12X2 A312-316L ***
010 922.170.617 MALE CONNECTOR P-GEV 18LR-WD 1
011 922.170.610 MALE STUD COUPLING P-GEV 12LR-WD 3
201333-IOM-EN-R01 11.11
11.12 201333-IOM-EN-R02
VENTLINE UNIT DRAWING REVISION: 02

001 928.370.305 BANJO COUPL.W. ONE BOLT R3/8"- 8X6 4

002 770.528.000 HOSE ***
003 928.130.005 MALE CONNECTOR ACK- 3/8"-6 10
006 730.945.101 PIPE R12X2 A312-316L ***
008 922.800.609 NON-RETURN VALVE P-RV12L SS 1
013 928.120.008 MALE CONNECTOR 3/8" - 6 6
014 922.930.609 ADJ.MALE STUD T-STUD B.T P-ELVD 12LM 9
015 922.280.610 BULKHEAD COUPLING P-GSV 12L 2
201333-IOM-EN-R01 11.13
11.14 201333-IOM-EN-R02
VALVE UNIT DRAWING REVISION: 02

PART LIST NUMBER 831.020.426A

001 023.015.001 VALVE HOUSING 1
003 025.015.000 VALVE COVER 1
009 831.900.973 TENSION RING 1
010 831.350.358 CONICAL VALVE 1
011 831.700.935 VALVE RING 1
012 831.150.998 VALVE SEAT 1
013 831.900.966 LOCK NUT 1
014 825.107.067 COMPRESSION SPRING 1
015 831.900.971 CLAMPING PIECE 1
016 831.900.967 GUIDE BUSH 1
017 862.007.695 STUD BOLT 4
018 853.200.544 PISTON 4
019 831.900.978 LOCK NUT 4
020 831.900.988 LOCK NUT 4
021 822.440.011 SEALING RING 1
023 862.050.329 NUT 4
026 960.010.613 CONNECTING NIPPLE R1/4"/2000 BAR 2
027 960.010.621 ADAPTER R1/4"XR1/4"-3000B 2
038 931.030.645 O-RING R390X4 NBR-70SH 2
039 933.111.097 U-RING T23/R90-R110-14.6 4
040 933.111.123 U-RING T18 4
041 913.020.243 HEX.SOCKET HEAD CAPSCREW D912 M12X60 SS 4
042 913.003.334 HEX.SOCKET HEAD CAPSREW D912 M16X150 STL 6
043 914.206.415 HEXAGON BOLT D561A M20X160STL 4
044 914.300.063 RING BOLT D580 M30 C15 1
045 911.103.515 HEXAGON SOCKET SET SCREW D916 M30X30 STL 2
050 862.007.693 STUD BOLT 16
051 862.050.129 NUT 16
052 931.191.300 SEALING RING B7A-NW300 WN101 2
201333-IOM-EN-R01 11.15
11.16 201333-IOM-EN-R02
VALVE UNIT DRAWING REVISION: 04


001 023.015.001 VALVE HOUSING 1
003 025.015.000 VALVE COVER 1
009 831.900.973 TENSION RING 1
010 831.350.358 CONICAL VALVE 1
011 831.700.935 VALVE RING 1
012 831.150.998 VALVE SEAT 1
013 831.900.966 LOCK NUT 1
014 825.107.067 COMPRESSION SPRING 1
016 831.900.967 GUIDE BUSH 1
017 862.007.695 STUD BOLT 4
018 853.200.544 PISTON 4
019 831.900.978 LOCK NUT 4
020 831.900.988 LOCK NUT 4
021 822.440.011 SEALING RING 1
023 862.050.329 NUT 4
027 960.010.621 ADAPTER R1/4"XR1/4"-3000B 2
038 931.030.645 O-RING R390X4 NBR-70SH 2
039 933.111.097 U-RING T23/R90-R110-14.6 4
040 933.111.123 U-RING T18 4
041 913.020.243 HEX.SOCKET HEAD CAPSCREW D912 M12X60 SS 4
042 913.003.334 HEX.SOCKET HEAD CAPSREW D912 M16X150 STL 6
044 905.400.055 HOISTING EYE 1
045 911.103.515 HEXAGON SOCKET SET SCREW D916 M30X30 STL 2
050 862.007.693 STUD BOLT 16
051 862.050.129 NUT 16
055 862.050.323 CAP NUT 4
201333-IOM-EN-R01 11.17
11.18 201333-IOM-EN-R02
DIAPHRAGM HOUSING UNIT DRAWING REVISION: 01


001 039.109.002 DIAPHRAGM HOUSING COVER 3
002 039.109.001 DIAPHRAGM HOUSING COVER 3
003 045.109.001 DIAPHRAGM HOUSING 3
004 832.101.182 CORNER PIECE 1
005 832.101.183 MIDDLE PIECE 1
006 832.101.184 CORNER PIECE 1
007 832.101.188 RING 3
008 832.101.189 COVERING RING 3
010 828.552.212 SUCTION ELBOW 3
012 814.201333.81 INITIATOR HOUSING 6
013 832.100.512 COVER 1.0503 6
015 832.101.209 MONITORING ROD 3
016 832.101.212 CLAMPING BUSH 3
018 832.101.351 BEARING BUSH 3
019 824.100.001 DIAPHRAGM 50NBR842 3
021 922.090.628 BLANKING PLUG VS 28L 3
022 922.085.217 BLANKING END VS-M18X1.5WD 2
030 822.900.019 SEALING RING 3
031 931.030.248 O-RING R54X3 NBR-70SH 6
034 931.360.315 SEAL SRC DN315 HNBR 6
037 862.007.692 STUD BOLT 72
038 862.007.693 STUD BOLT 48
039 862.007.694 STUD BOLT 48
045 862.050.235 NUT 72
046 862.050.129 NUT 48
047 862.050.010.36 NUT 48
049 862.005.120 COUPLING NUT 6
201333-IOM-EN-R01 11.19

053 816.020.638 PROTECTIVE CAP 3
064 914.483.321 HEXAGON BOLT D564A M16X50 STL 9
069 917.213.135 SPRING TYPE STRAIGHT PIN R6X20 DIN1481 12
070 921.050.001 NEEDLE VALVE G3/8"-UBEL717 3
071 922.075.213 PLUG VS-R3/8WD 3
074 922.300.609 EQUAL ELBOW COUPLING P-WV 12L 373388 3
086 917.200.320 STRAIGHT PIN 16M6X45 DIN7 3
087 931.190.050 SEALING RING B7A,62X102D2697 3
088 927.011.845 BLIND FLANGE 3
089 915.040.055 HEXAGON NUT NF M24 DIN2510 12
090 862.007.231 STUD BOLT 12
091 814.201333.80 SHIM 12
11.20 201333-IOM-EN-R02
GLORES-UNIT DRAWING REVISION: 01


002 922.590.614 THREADED REDUCING PIECE RED-R1/2-WD/R1 SS 2
003 922.070.613 BLANKING END VS-R3/8WD-SS 1
005 834.100.008 MANIFOLD 1
006 921.600.030 VENTING FILTER G1"-EV1028 1
007 922.070.643 BLANKING PLUG VS-R1.1/2 12
032 931.030.381 O-RING R150X4 NBR-70SH 2
033 914.106.609 HEXAGON SCREW D933M36X100STL-GLV 8
034 853.100.652 ADAPTOR FLANGE 2
062 730.945.101 PIPE R12X2 A312-316L ***
063 730.945.213 PIPE R28X2-316L ***
080 922.170.561 MALE STUD COUPLING GES 12SR-2WD 6
081 921.050.054 NEEDLE VALVE E226S-1/2"-BSPF 2
082 922.940.662 STUD STANDPIPE ADAPTOR EGESD 12S/R1/2-WD 1
083 922.170.562 MALE STUD COUPLING GES12SR/R1/2-WD SS 1
087 913.563.316 HEX.SOCKET HEAD CAPSCREW M16X25-SPEC 8
090 862.010.218 GUIDE PIN 2
091 931.031.1006 O-RING R648X7 NBR-90SH 3
092 922.930.628 ADJUST.MALE T-STUD P-ELVD 28L SS 1
093 922.970.631 REDUCING FITTING P-REDVD 28/12L SS 1
097 922.940.661 STUD STAND PIPE ADAPTOR EGESD 12S/R-2D SS 5
098 905.400.053 HOISTING EYE 2
201333-IOM-EN-R01 11.21
11.22 201333-IOM-EN-R02
PISTON UNIT DRAWING REVISION: 03


001 063.587.006 PISTON ROD 1
002 835.188.003 PISTON BODY 1
003 835.388.001 RETAINING PLATE 2
004 841.900.369 THRUST PIECE 1
006 841.288.003 ZYLINDER LINER 1
007 841.288.002 CYL.LINER COOLING JACKET 1
008 862.050.127 NUT NF M48/D2510 1
009 933.160.400 SET ROOF SHAPED RINGS 1
010 835.900.179 GUIDE RING 1
011 933.160.401 SET ROOF SHAPED RINGS 1
012 835.900.227 CONNECTION PIECE 1
015 835.900.228 ADAPTOR FLANGE 1
016 931.031.1005 O-RING R557.66X7 NBR-90SH 2
017 931.031.1003 O-RING R541X7 - NBR-90SH 1
019 931.031.1001 O-RING R481.46X7 NBR-90SH 2
021 933.345.590 SUPPORTING RING 2
024 933.345.500 SUPPORTING RING 1
028 914.003.537 HEXAGON BOLT M30X180 D931 8
029 931.031.452 O-RING R40.64X5.33 NBR-90 1
031 862.007.720 STUD BOLT 12
032 862.007.697 STUD BOLT 10
033 862.050.330 NUT 10
034 868.003.063 THREADED FLANGE 1
035 862.005.417 HEXAGON BOLT M36X160/182,5 1
036 868.003.066 THREADED FLANGE 1
037 862.050.003.36 NUT 12
201333-IOM-EN-R01 11.23
11.24 201333-IOM-EN-R02
FRAME UNIT DRAWING REVISION: 00


001 002.587.020 FRAME 1
003 018.632.001 DISC 1.7225V 12
005 066.587.002 CROSSHEAD PIN 3
006 068.587.004 CONNECTING ROD 3
008 072.587.000 CRANK SHAFT 1
010 081.587.007 BEARING COVER 1
013 086.387.001 PRESSURE PLATE 1
014 081.587.006 BEARING COVER 1
015 088.387.001 PRESSURE PLATE 3
016 090.587.001 CROSSHEAD GUIDE 6
018 089.587.001 CROSSHEAD ROD 3
019 005.587.001 FRAME COVER 1
020 816.955.463 LOCKING PLATE 3
030 931.030.705 O-RING R800X7 NBR-70SH 2
031 823.030.042 SEAL 1
034 823.051.052 SEAL 2
035 823.030.057 JOINT 3
036 839.100.063 CROSSHEAD 3
037 823.030.028 SEAL 3
039 870.001.273 COVER 2
040 870.001.272 COVER 1
041 870.001.196 COVER 2
042 822.020.120 SEALING RING 3
044 870.001.226 COVER 3
045 931.030.860 O-RING R608.8X7 NBR-70SH 3
046 835.900.229 ADAPTER FLANGE 3
047 919.073.080 MULT.JACK.TENSIONER 3
062 914.236.529 HEXAGON SET SCREW D561A M30X2X100STL 4
063 913.003.529 HEX. CAP SREW M30X100 D912 6
201333-IOM-EN-R01 11.25

080 933.101.142 U-RING 3
081 933.021.140 WIPER RING 140-152-11 NBR 3
082 911.040.524 STUD BOLT D939 M30X65 STL 22
086 915.006.063 HEXAGON NUT D934 M30 STL-GLV 22
089 822.180.039 GASKET R180-R225-0.5 3
091 846.100.212 DUST COVER HOUSING 3
092 846.100.210 GASKET HOLDER 3
094 815.812.312 FLAT BAR STEEL 6
095 911.040.321 STUD BOLT M16X50 DIN939-8.8 12
118 935.022.440 LIPSEAL WAS440-480-20 1
121 925.546.145 HEXAGON HEAD PIPE PLUG 3
126 942.900.119 SPHERICAL ROLLER BEARING 2
127 942.900.083 CYL.ROLLER BEARING FAG 809074.H171A 3
128 942.900.096 CYL.ROLLER BEARING 3
129 942.410.996 PRESSURE SLEEVE 2
131 922.155.211 MALE STUD COUPLING P-GEW 12L/R1/2 6
132 730.103.103 TUBE R 12 X 1.5 ***
134 925.720.284 PIPE NIPPLE D2982 G2"X250 STL 1
136 921.150.071 GATE VALVE G2" ECON3290 1
138 948.790.002 OILGLASS G2 2
140 921.700.033 FILTER PI 0114 MIC 2
141 942.800.792 LOCK NUT HM3092 1
142 816.955.464 LOCK WASHER 1
143 925.016.114 BEND G3/4"-N1 1
144 917.303.034 WASHER D125A M12 STL 14
11.26 201333-IOM-EN-R02

152 917.500.063 RETAINING RING DUBO M30 2
153 922.075.218 PLUG VS-R1/2WD 1
155 921.200.026 BALL VALVE G2"-ERIKS 3185 1
156 925.526.145 DOUBLE NIPPLE N280 G2 2
157 828.500.559 PIPE NIPPLE 1
158 925.206.145 ELBOW N90 G2 1
160 900.000.101 CAP R110x107 8
161 862.008.038 STUD BOLT 8
162 919.070.064 NUT CY-M64x6/W 8
163 821.040.037 INSERT 1
164 821.040.038 INSERT 1
201333-IOM-EN-R01 11.27
11.28 201333-IOM-EN-R02
PULSATION DAMPENER UNIT DRAWING REVISION: 00


001 851.500.337 COVER 1
002 851.300.340 PULSATION DAMPENER BODY 1
006 824.040.008 DIAPHRAGM 1
009 862.007.715 STUD BOLT 16
010 922.075.218 PLUG VS-R1/2WD 2
012 905.400.055 HOISTING EYE 1
013 862.007.699 STUD BOLT 12
014 862.050.327 NUT 16
015 915.040.066 HEXAGON NUT NF M33 DIN2510 12
017 818.030.271 TYPE PLATE SS 1
018 818.030.210 TEXT PLATE 1
022 931.190.200 SEALING RING B7A,214X285DIN2697 1
028 922.075.209 PLUG VS-R1/4WD 1
201333-IOM-EN-R01 11.29
11.30 201333-IOM-EN-R02
PRESS.UNIT REGUL.UNIT DRAWING REVISION: 02

PART LIST NUMBER 853.010.238G

001 921.300.706 SAFETY VALVE 1
002 853.010.259 NON-RETURN VALVE UNIT 3
003 828.552.255 CONNECTING PIPE 1
004 931.191.080 SEALING RING B7A,95X121WN101 6
005 862.015.237 THREADED ROD 8.8-VERZ 24
007 816.930.360 RING 1.0503 2
008 914.106.494 HEXAGON BOLT M27X150 8
010 828.552.256 DRAIN LINE 1
011 862.015.285 THREADED ROD 8
013 822.150.023 SEALING RING R150-R212-2 C4430 2
014 911.040.402 STUD BOLT M20X55 DIN939-8.8 8
016 922.170.611 MALE STUD COUPLING P-GEV 12LR-1/2-WD 2
019 922.740.659 ADJUSTABLE COUPLING EMASD-10SR-SS 1
020 921.520.042 SHOCK ABSORBER G1/2"-ECON1388 1
021 931.400.142 SEALING RING 14-18-1.5 DIN7603 1
024 931.191.100 SEALING RING B7A,118X144WN101 4
025 816.930.589 FILLING RING 1
201333-IOM-EN-R01 11.31
11.32 201333-IOM-EN-R02
NON-RETURN VALVE UNIT DRAWING REVISION: 00


001 853.100.561 VALVE HOUSING 1.7225V 1
002 853.100.560 VALVE GUIDE 1.7225V 1
003 853.100.559 VALVE 1.7225V 1
004 821.025.050 RING 1
005 821.025.048 RING 1.0503N 1
006 917.800.018 COMPRESSION SPRING R40X3.2X82 1
007 913.006.167 HEX.SOCKET HEAD CAPSCREW D912 M8X30 STL-GLV 4
008 931.030.375 O-RING R120X4 NBR-70SH 1
201333-IOM-EN-R01 11.33
11.34 201333-IOM-EN-R02
PRESSURE TRANSMITTER UN DRAWING REVISION: 00

PART LIST NUMBER 855.010.054AH

004 922.130.611 MALE CONNECTOR P-GEV 12L/1/2NPT 3
005 922.970.609 REDUCING FITTING PREDVD12/6L 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
008 816.941.167 SUPPORT 2
009 914.106.135 HEXAGON SCREW D933 M6X20 STL-GLV 4
011 925.780.610 NIPPLE 1/2"NPT SS 1
012 925.740.610 SOCKET 1/2"NPT 3000LBS 1
201333-IOM-EN-R01 11.35
11.36 201333-IOM-EN-R02
PROPELLING LIQUID UNIT DRAWING REVISION: 01

PART LIST NUMBER 857.010.126X

001 814.201333.45 ELECTRIC MOTOR 1.5HP-1200RPM 1
002 960.010.630 COUPLING 1
003 960.020.079 GEAR PUMP 1
004 960.020.633 LATERNE PIECE 1
008 913.033.236 HEX.SOCKET HEAD CAPSCREW 1/2"X13UNCX1 4
012 960.020.632 ADAPTERFLANGE 1
014 922.980.617 BANJO COUPL.W.ONE BOLT P-RSWV 18LR (SS 1
017 922.940.617 STUD STAND PIPECONNECTOR EGESD 18LR-WD 2
018 922.930.617 ADJ. MALE STUD T-STUD BT P-ELVD 18L 374598 5
020 921.700.430 FILTERHOUSING 1
021 921.700.862 FILTERELEMENT 2
023 922.880.051 NON RETURN VALVE P RV18L (0.5 2
024 922.910.617 ADJUST.MALE STUD ELBOW P-EWVD 18L SS 1
033 922.290.620 STRAIGHT REDUC.COUPLING P-GV 18/12L SS 1
034 922.170.617 MALE CONNECTOR P-GEV 18LR-WD 1
036 922.450.609 EQUAL TEE COUPLING P-TV 12L 1
037 922.970.609 REDUCING FITTING PREDVD12/6L 1
038 922.930.609 ADJ.MALE STUD T-STUD B.T P-ELVD 12LM 1
040 973.000.015 ACCUMULATOR 13L-330 BAR 1
041 973.900.031 FIXING PIECE 1
201333-IOM-EN-R01 11.37

043 911.040.166 STUD BOLT M8X25 DIN939-8.8 4
046 922.070.613 BLANKING END VS-R3/8WD-SS 4
047 971.400.045 SILENCER R1/4 8
048 922.590.628 THREADED REDUCING PIECE RED-R1.1/4/R1/2 2
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
057 925.716.110 SOCKET NIPPLE 1
058 971.800.001 AQUASENSOR 1
059 868.001.983 ADAPTER 1
062 922.030.609 PROFILE RING P-R 12L-S SS 23
063 922.010.661 NUT M 12S SS 23
064 922.740.609 FEMALE CONNECTOR EMASD 12LR 1
066 816.941.353 SUPPORT 2
068 922.170.618 MALE CONNECTOR P-GEV 18LR 3/4-WD 3
070 853.010.250 PROP.LIQUID/FLUSH.UNIT 1
071 928.370.604 BANJO COUPLING 8
072 770.528.000 HOSE ***
073 928.110.605 MALE CONNECTION R1/4"-8X6-SS 8
077 999.999.000 ARROW=ROTATING DIRECTION 1
079 922.590.625 THREADED REDUCING PIECE RED-R1-WD/R3/4 1
081 922.090.617 BLANKING PLUG VS 18L SS 1
082 922.450.617 EQUAL TEE COUPLING P-TV 18L-SS 1
083 922.590.633 THREADED REDUCING PIECE RED-R1.1/2WD/R3/4 1
084 922.170.611 MALE STUD COUPLING P-GEV 12LR-1/2-WD 1
11.38 201333-IOM-EN-R02

085 922.920.617 ADJUST.EQUAL TEE P-ETVD 18L SS 1
086 922.740.662 ADJUST.COUPLING EMASD 12SR SS 1
089 911.070.237 STUD D938 M12X30 STL 9
090 928.860.039 3/2 BALL VALVE 1
091 922.010.619 NUT M18L 2
092 922.030.617 PROFILE RING P-R18L SS 2
095 922.170.561 MALE STUD COUPLING GES 12SR-2WD 6
096 922.910.560 ADJUST MALE STUD ELBOW EWSD 12S 3
097 922.280.561 BULKHEAD COUPLING GSS 12S 9
098 915.360.047 HEXAGON NUT 2
100 971.600.008 FLOW SENSOR 1
101 922.950.882 T-PIECE E40078/QL18-18-18 1
102 922.950.880 ADAPTER E40104 1
110 971.350.050 FILTER-REGULATOR 1
111 971.350.803 SUPPORT 1
125 928.900.678 H.P. HOSE 1ST25A05A05-650 1
150 816.310.122 TANK 1
151 815.010.870 DRIPPAN 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
156 925.546.145 HEXAGON HEAD PIPE PLUG 1
161 870.005.112 COVER 1
162 931.030.375 O-RING R120X4 NBR-70SH 2
164 921.700.832 SUCTION FILTER-ELEMENT 0050S-125-WP 1
165 922.940.628 STUD STAND PIPE ADAPTOR EGESD 28LR-WD SS 1
169 911.070.327 STUD D938 M16X80 STL 1
170 815.010.949 PI SKID 1
174 911.070.324 STUD D938 M16X65 STL 3
201333-IOM-EN-R01 11.39

177 914.300.040 EYE BOLT D580 M16 1.0401 2
179 816.940.820 SUPPORT 2
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
184 925.206.145 ELBOW N90 G2 1
186 917.950.030 BOLT ADAPTER M16-GLV 4
190 730.945.001 PIPE R6X1 A312-316L ***
191 730.945.101 PIPE R12X2 A312-316L ***
192 730.945.119 PIPE R18X2 A312-316L ***
201 922.950.948 FEMALE METRIC 1
202 922.950.949 FEMALE SWEPT ELBOW 1
203 770.558.317 HOSE R35-R25 ***
204 929.000.000 CLAMP 2
206 922.910.628 ADJUST.MALE STUD ELBOW P-EWVD28L SS 3
211 911.170.325 HEXAGON SOCKET SET SCREW 1
212 915.020.040 HEXAGON NUT D934 M16 1.4301 1
213 917.850.040 WASHER D125B M16 1.4401 2
214 917.040.040 SPRING WASHER B16 D127B-W1.4401 1
260 870.005.138 COVER 1
263 922.070.643 BLANKING PLUG VS-R1.1/2 2
265 816.941.407 SUPPORT 1
266 814.201333.54 SUPPORT 1
11.40 201333-IOM-EN-R02

201333-IOM-EN-R01 11.41
11.42 201333-IOM-EN-R02
PROP.LIQUID/FLUSH.UNIT DRAWING REVISION: 00


001 853.010.241 2/2 WAY VALVE (PA 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 (R8 4
007 931.082.021 MULTISEAL SCPP45-D 7
008 853.100.323 BASE PLATE 3
009 853.100.330 PLUG 3
012 822.030.024 SEALING RING 8
014 853.010.243 2/2 WAY VALVE (HV9 1
015 853.100.535 DISTRIBUTOR BLOCK 1
016 862.005.396 BANJO BOLT (R3 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
201333-IOM-EN-R01 11.43
11.44 201333-IOM-EN-R02
2/2 WAY VALVE (PA) DRAWING REVISION: 01


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
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
201333-IOM-EN-R01 11.45
11.46 201333-IOM-EN-R02
2/2 WAY VALVE (HV9) DRAWING REVISION: 01


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
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
201333-IOM-EN-R01 11.47
11.48 201333-IOM-EN-R02
ELECTRICAL UNIT DRAWING REVISION: 05


001 814.201333.41 CONTROL BOX CPL 1
001 814.201333.37 HMI-PANEL 1
001 814.201333.34 MEMORY CARD 1
002 814.201333.40 TERMINAL BOX 1
003 814.201333.53 TERMINAL BOX 1
004 913.306.074 HEX.SOCKET HEAD CAPSCREW D84A M4X16 STL-GLV 4
005 995.006.630 ADAPTOR PG135 - M20X1.5 6
005 858A101A050 INITIATOR 6
005 995.025.023 BEND PG13 H318 6
006 931.080.085 U-SEAL 8.5-13.4-1.0 4
007 913.400.165 HEX.SOCKET HEAD CAPSCREW D912 M8X20 1.4401 4
008 915.140.025 HEXAGON NUT D934 M8 SS 4
009 917.280.025 WASHER D125A M8 SS 4
010 858.101.051 CABLE CHANNEL 1
012 917.280.040 WASHER D125A M16 1.4401 6
013 995.025.056 UNIVERSAL ELBOW H312-M20X1.5 5
014 995.006.231 REDUCING RING 12
015 995.001.087 CABLE GLAND 12
016 790.000.009 PROTECTION SLEEVE R10 ***
017 858.100.194 CABLE DUCT 1
018 858.100.286 CABLE DUCT 1
019 858.101.004 CABLE CHANNEL 1
023 795.000.501 CABLE ***
025 971.100.055 INITIATOR NI12U-EM18-AP6X 1
026 995.000.192 CABLE GLAND 3
027 795.000.527 CABLE ***
201333-IOM-EN-R01 11.49

028 795.000.528 CABLE ***
029 795.000.502 CABLE ***
030 730.103.213 TUBE R 28 X 2 ***
031 929.050.501 PIPE CLAMP 428-PP 4
033 914.106.141 HEXAGON BOLT D933 M6X50 2
035 868.005.013 DETECTEUR PIECE 1
036 816.941.419 SUPPORT 1
037 862.050.277 HEXAGON SUPPORT 2
038 816.941.141 SUPPORT 1
039 911.040.321 STUD BOLT M16X50 DIN939-8.8 2
040 995.040.010 CABLE TIERAP T 50 R 100
041 995.040.012 CABLE TIERAP 4X140 / NYLON 6.6 100
043 995.001.086 CABLE GLAND 4
044 995.000.190 CABLE GLAND 1
047 790.000.013 PROTECTION SLEEVE ***
048 995.010.022 CONNECTOR 1
049 995.006.232 REDUCING RING 2
050 913.006.197 HEX.SOCKET HEAD CAPSCREW D912 M10X30STL-GLV 2
054 914.106.143 HEXAGON SCREW D933 M6X60 8
11.50 201333-IOM-EN-R02
ACCESSORIES DRAWING REVISION: 01


001 815.010.951 BASE FRAME 1
002 828.552.260 DISCHARGE LINE 1
003 828.552.258 SUCTION LINE 1
004 868.002.234 BLIND FLANGE 1
005 931.208.350 SEALRING B7A -14"-WN100 1
006 862.007.696 REDUCED SHANK BOLT 20
007 915.040.073 HEXAAAGON NUT NF M39 DIN2510 40
008 868.002.233 BLIND FLANGE 2
009 822.350.045 GASKET R438-R340-2 7
012 914.003.445 HEXAGON BOLT M24X70 / D933 48
015 917.300.063 WASHER D125A M30 STL 30
018 917.300.055 WASHER D125A M24 STL 12
019 914.236.533 HEXAGON SET SCREW M30X2X140 D561A-ST 12
021 915.020.040 HEXAGON NUT D934 M16 1.4301 4
022 917.280.040 WASHER D125A M16 1.4401 4
024 816.930.571 SHIM 3
025 816.930.570 SHIM 3
026 816.930.581 SHIM 3
027 816.930.582 SHIM 3
028 816.930.583 SHIM 3
201333-IOM-EN-R01 11.51
11.52 201333-IOM-EN-R02
AIR VESSEL UNIT DRAWING REVISION: 01


001 851.300.374 SUCTION AIR VESSEL 1
002 927.020.150 BLIND FLANGE 6"-150LBS 1
004 822.150.023 SEALING RING R150-R212-2 C4430 1
005 818.030.248 TEXT PLATE 1
006 818.030.249 TEXT PLATE 2
007 922.075.218 PLUG VS-R1/2WD 4
008 910.150.031 ROUND HEAD GROOVED PIN D1476 R2X8 SS 10
009 929.050.500 PIPE CLAMP 112-PP 5
011 914.103.139 HEXAGON BOLT D933 M6 X40 STL 5
012 818.030.142 NAME PLATE-GEHO 1
013 922.750.562 MANOMETER COUPLING MAS 12SR 1
015 730.945.101 PIPE R12X2 A312-316L ***
016 922.010.661 NUT M 12S SS 1
017 922.980.610 BANJO COUPL.W.ONE BOLT P-RSWV 12LR 1
018 922.590.612 THREADED REDUCING PIECE RED-R1/2-WD/R3/8 1
019 922.030.609 PROFILE RING P-R 12L-S SS 1
201333-IOM-EN-R01 11.53
11.54 201333-IOM-EN-R02
DRIVE UNIT DRAWING REVISION: 00


001 814.201333.31 GEAR BOX 1
002 814.201333.32 FLEX.COUPLING 1
003 814.201333.33 GEARCOUPLING 1
004 814.201333.30 ELECTRIC MOTOR 1
007 815.010.955 BASE FRAME 1
014 914.236.533 HEXAGON SET SCREW M30X2X140 D561A-ST 10
015 914.206.328 HEXAGON BOLT D561AM16X90STL-GLV 12
017 915.020.040 HEXAGON NUT D934 M16 1.4301 4
019 917.280.040 WASHER D125A M16 1.4401 4
020 816.930.566 SSHIM 2
021 816.930.567 SHIM 2
022 816.930.568 SHIM 4
023 816.930.569 SHIM 2
024 914.106.850 HEXAGON BOLT D933 M56X220 6
201333-IOM-EN-R01 11.55
11.56 201333-IOM-EN-R02
Appendix: Parts - Lists and drawings (special tools)
Pos : 49.1 /GEHO/Heading/H 1/#. Appendi x: Parts - Lis ts and drawi ngs (speci al tool s) @ 1\mod_1169571568190_31.doc @ 11986 @
12 Appendix: Parts - Lists and drawings (special tools)

Pos : 49.2 /GEHO/Parts lis ts/## Safety ins truc tions for par ts @ 5\mod_1227872607693_31.doc @ 44431 @
12.1 Safety instructions for parts

DANGER
• Use only genuine GEHO parts.
• Order parts only with their WEIR-GEHO item number.
This is mandatory, to maintain:

• the original safety level, in accordance with the applicable regulations,
• the warranty accountability,
• the general product accountability,
• the original product reliability and durability.
Pos : 49.3 /GEHO/Parts lis ts/## Or deri ng parts + NOT E - Items with ** * @ 1\mod_1165932498812_31.doc @ 9184 @ 2
12.2 Ordering parts

NOTE
If ordering items marked with ***, then specify the quantity.
Ordering and determination of parts:

• Refer to the pump number, as given on the GEHO type plate.
Sample: WEIR pump number = GEHO 7201152/3
• Use the same determination, as given in the parts list.
201333-IOM-EN-R01 12.1
12.2 201333-IOM-EN-R02
Pos : 49.6 /GEHO/Heading/H 2/#.# Special tools @ 1\mod_1166540615553_31.doc @ 11465 @
12.3 Special tools

Pos : 50 /GEHO/Parts lists/Speci al tools /Pr ojec t/814.201333.10 04042011 @ 12\mod_1301926485750_0.doc @ 84702 @ 2
SET OF TOOLS
DRAWING NUMBER

001 897.010.783A HYDR.TENSION RING UNIT 1
002 897.010.785 TOOL VALVE NUT 1
003 897.010.786 LIFTING TOOL VALVE 1
004 897.101.313 DISASS.GUIDE BUSH 1
006 897.010.789 DISASS.VALVE SEAT TOOL 1
007 897.050.422 PLATE 1
008 897.010.780A HYDR.PUMP-UNIT 1
009 897.010.788A LIFTING COVER 1
010 897.010.685CG ACCUMUL.FILLING DEVICE 1
011 897.010.790A FILL.RING LIFTING DEVICE 1
012 897.010.689Z HOISTING UNIT 5
013 897.010.773 MANUAL CRANK UNIT 1
014 897.010.791A LIFTING TOOL CYL.LINER 1
015 ELA.000.593 COVERSHEET 1
016 ELA.000.594 KEY RITTAL 1
201333-IOM-EN-R01 12.3
12.4 201333-IOM-EN-R02
HYDR.TENSION RING UNIT DRAWING REVISION: 00


001 897.101.297 TENSION RING 1
002 853.200.544 PISTON 24
003 862.050.240 NUT 1.7258 24
004 933.111.123 U-RING T18 24
005 933.111.097 U-RING T23/R90-R110-14.6 24
006 914.300.055 EYE BOLT D580 M24 1.0401 1
007 960.010.621 ADAPTER R1/4"XR1/4"-3000B 1
011 960.010.624 BLIND PLUG 1
013 897.100.932 PIN 1
201333-IOM-EN-R01 12.5
12.6 201333-IOM-EN-R02
TOOL VALVE NUT DRAWING REVISION: 00


001 897.050.416 VALVE UNIT WRENCH 1
002 897.101.312 PIN 3
005 897.101.362 PIPE 1
201333-IOM-EN-R01 12.7
12.8 201333-IOM-EN-R02
LIFTING TOOL VALVE DRAWING REVISION: 00


001 897.050.417 HOISTING TOOL 1
002 897.101.316 PIN 1
003 917.606.000 SOCKET PIN 2.5 DIN11024 STL 1
201333-IOM-EN-R01 12.9
12.10 201333-IOM-EN-R02
DISASS.VALVE SEAT TOOL DRAWING REVISION: 01


001 897.101.321 PULLER BLOC 1
002 897.101.322 BLOC 1
003 897.101.323 CONNECTING ROD 1
004 853.200.556 CYLINDER 1
005 853.200.552 PISTON 1
006 933.111.072 U-RING T213/R70-R85-11.4 1
007 933.111.099 U-RING T18/R110-R90-12.2 1
009 960.010.621 ADAPTER R1/4"XR1/4"-3000B 1
010 862.050.324 NUT 1
011 914.300.034 EYE BOLT D580 M12 STL 4
012 897.101.324 HOISTING PIN 1
013 897.050.420 ASS.VALVE SEAT TOOL 1
014 897.050.438 STRIP 1
015 915.040.080 HEXAGON NUT NF M56/D2510 2
201333-IOM-EN-R01 12.11
12.12 201333-IOM-EN-R02
HYDR.PUMP-UNIT DRAWING REVISION: 00


001 960.010.041 HYDRAULIC PUMP HF-B300/0-2000BAR 1
002 960.010.623 ADAPTER 1/4"BSP/9/16"-18UN 1
004 928.900.134 HIGH PRESSURE HOSE 2620RED-10000 1
201333-IOM-EN-R01 12.13
12.14 201333-IOM-EN-R02
LIFTING COVER DRAWING REVISION: 00


001 897.050.418 HOISTING TOOL 1
003 914.300.075 RING BOLT 1
004 897.101.320 DISC 1
201333-IOM-EN-R01 12.15
12.16 201333-IOM-EN-R02
ACCUMUL.FILLING DEVICE DRAWING REVISION: 00

PART LIST NUMBER 897.010.685CG

001 973.900.034 ACCUMUL.FILL/CONTROL SET HYDAC 1
003 973.900.901 ADAPTOR 1
004 973.900.908 ADAPTOR 1
006 921.510.325 PRESSURE GAUGE R63/0-16BAR 1
007 922.950.992 MEASURING CONNECTION G1/4"/M16X2 1
008 922.950.993 MEASURING CONNECTION G1/4"/M16X2 1
201333-IOM-EN-R01 12.17
12.18 201333-IOM-EN-R02
FILL.RING LIFTING DEVICE DRAWING REVISION: 01


001 897.050.421 HOISTING TOOL 1
003 914.300.055 EYE BOLT D580 M24 1.0401 1
004 914.206.334 HEXAGON BOLT D561A M16X150 STL 3
006 897.100.819 PLUG 1
007 911.070.337 STUD BOLT D938 M16X180 8.8 1
009 915.350.040 LIFTING EYE NUT M16 DIN582-C15 1
010 911.070.333 STUD D938 M16X40 STL 2
201333-IOM-EN-R01 12.19
12.20 201333-IOM-EN-R02
HOISTING UNIT DRAWING REVISION: 03

PART LIST NUMBER 897.010.689Z

003 897.101.325 HOISTING BEAM 1
005 914.003.842 HEXAGON BOLT D931 M56X130 12
006 897.100.968 SUPPORT STL 1
009 897.101.331 HOISTING TOOL 1
201333-IOM-EN-R01 12.21
12.22 201333-IOM-EN-R02
MANUAL CRANK UNIT DRAWING REVISION: 00


001 980.622.915 SOCKET WRENCH 1
002 980.627.097 SOCKET 32/SL.W.36 1
201333-IOM-EN-R01 12.23
12.24 201333-IOM-EN-R02
LIFTING TOOL CYL.LINER DRAWING REVISION: 00


001 897.050.423 HOISTING TOOL 1
002 897.050.424 BRACE 1
003 914.300.063 RING BOLT D580 M30 C15 2
004 917.300.063 WASHER D125A M30 STL 2
008 897.101.282 GUIDE PIN 2
009 914.206.409 HEXAGON SCREW D561A M20X100 STL 2
201333-IOM-EN-R01 12.25
12.26 201333-IOM-EN-R02
Appendix: Electrical information
Pos : 52 /GEHO/Heading/H 1/#. Appendi x: El ectric al infor mation @ 1\mod_1169571364915_31.doc @ 11974 @
13 Appendix: Electrical information

Pos : 53 /GEHO/El ectric al infor mation/Proj ect/201333 @ 9\mod_1275046390140_31.doc @ 67883 @
Drawing number Description

S.814.201333.05 "LOGIC DIAGRAM"
S.814.201333.06 "CONTROL BOX AND TERMINAL BOX"
S.814.201333.07 "ELECTRICAL INSTALLATION"
S.814.201333.09 "MOTOR CONTROL CIRCUIT"
201333-IOM-EN-R01 13.1
Appendix: Catalogue information
Pos : 55 /GEHO/Heading/H 1/#. Appendi x: Catal ogue i nfor mati on @ 1\mod_1169571471475_31.doc @ 11978 @
14 Appendix: Catalogue information

Pos : 56 /GEHO/Catal ogue i nfor mati on/General ins tructi ons, tighteni ng @ 8\mod_1258016216015_0.doc @ 56511 @ 1
General instructions REFER TO

General tightening procedure for flanges and gaskets A.807.005.119 A
Pos : 57 /GEHO/Catal ogue i nfor mati on/Pr ojec t/201333 - 23112010 @ 11\mod_1290506196953_0.doc @ 73971 @
PULS.DAMPENER FILLING UN (818.080.559BM) T.818.080.219 Refer to

GLOBE VALVE 921.100.036 B
LUBRICATION UNIT (828.950.126X) T.814.201333.48 Refer to

ELECTRIC MOTOR 814.201333.45 C
GEAR PUMP 960.020.073 C
SUCTION STRAINER 921.700.881 C
FILTERHOUSING 921.700.429 C
FILTERELEMENT 921.700.872 C
BALL VALVE 928.860.028 C
BALL VALVE 928.860.030 C
TEMPERATURE SENSOR 971.900.095 C
FLOW SENSOR 971.600.008 C
PRESSURE TRANSMITTER 971.450.099 C
HEATING ELEMENT 971.900.047 C
DIAPHRAGM HOUSING UNIT (832.010.324A) T.832.000.245 Refer to

NEEDLE VALVE 921.050.001 D
GLORES-UNIT (834.010.016A) T.814.201333.50 Refer to

VENTING FILTER 921.600.030 E
NEEDLE VALVE 921.050.054 E
201333-IOM-EN-R01 14.1
FRAME UNIT (845.010.486A) T.845.000.495 Refer to

MULT.JACK.TENSIONER 919.073.080 F
GATE VALVE 921.150.071 F
OILGLASS 948.790.002 F
FILTER 921.700.033 F
BALL VALVE 921.200.026 F
PRESS.UNIT REGUL.UNIT (853.010.238G) T.853.000.284 Refer to

SAFETY VALVE 921.300.706 G
PRESSURE TRANSMITTER UN (855.010.054AH) T.814.201333.44 Refer to

PRESSURE TRANSMITTER 971.450.099 C
PRESSURE TRANSMITTER 971.450.102 H
PROPELLING LIQUID UNIT (857.010.126X) T.857.000.251 Refer to

ELECTRIC MOTOR 814.201333.45 C
GEAR PUMP 960.020.079 I
ACCUMULATOR 973.000.015 I
3/2 WAY VALVE 972.200.065 I
3/2 WAY VALVE 972.200.066 I
3/2 BALL VALVE 928.860.039 I
FLOW SENSOR 971.600.008 C
FILTER-REGULATOR 971.350.050 I
LEVEL INDICATOR 948.790.105 I
BALL VALVE 921.200.026 F
SUCTION FILTER-ELEMENT 921.700.832 I
ELECTRICAL UNIT (858.010.118V) T.814.201333.49 Refer to

PLC TECHNICAL DATA PLC.201333 J
HMI-PANEL 814.201333.37 J
INITIATOR 971.100.055 J
14.2 201333-IOM-EN-R02
DRIVE UNIT (814.201333.16) T.814.201333.16 Refer to

GEAR BOX 814.201333.31 K
FLEX.COUPLING 814.201333.32 L
GEARCOUPLING 814.201333.33 M
ELECTRIC MOTOR 814.201333.30 N
HYDR.PUMP-UNIT (897.010.780A) T.897.000.318 Refer to

HYDRAULIC PUMP 960.010.041 O
ACCUMUL.FILLING DEVICE (897.010.685CG) T.897.000.414 Refer to

ACCUMUL.FILL/CONTROL SET 973.900.034 P
SYNCHRONIZATION PANEL Refer to

SYNCHRONIZATION PANEL 814.201333.55 Q
Documentation to be delivered by next revision !
201333-IOM-EN-R01 14.3
Appendix: PLC Software (electronic format)
Pos : 59 /GEHO/Heading/H 1/#. Appendi x: PLC Software ( electronic for mat) @ 10\mod_1276173469182_31.doc @ 68612 @
15 Appendix: PLC Software (electronic format)

Pos : 60 /GEHO/PLC Software ( electronic for mat)/Infor mation about PLC Softwar e @ 10\mod_1276174908722_31.doc @ 68623 @ 1
INFORMATION
Detailed information about PLC Software (electronic format) is included on the supplied IOM
(Installation, Operating and Maintenance) CD.
=== Ende der Liste für T extmar ke Inhalt ===
201333-IOM-EN-R01 15.1
Appendix: PLC Software (electronic format)
15.2 201333-IOM-EN-R02

201333-IOM-EN-R02 TZPM2000-Toromocho - EN PDF

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201333-IOM-EN-R02 TZPM2000-Toromocho - EN PDF

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Weir Minerals Netherlands

EN = English "Original instructions"

Installation, Operating and Maintenance Manual

Customer purchase order number: R05323-P-028

Project number - name: 201333 - Toromocho

Pump number: 10201333-1-2-3-4-5-6-7-8-9-10

Pump type: TZPM 2000

Document number: 201333-IOM-EN-R02

Copyright © Weir Minerals Netherlands b.v. 2011.

This pump is developed by Weir Minerals Netherlands b.v.

Scope of this manual

1.1 Revision form

Rev. No. Chapter Description By Checked Date

EN = "Original instructions" in English.

EN-R00 Preliminary release JOH FVO 31-05-2010

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

3 SAFETY ...................................................................................... 3.1

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

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

5.3 Pump control system ................................................................................... 5.4

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

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

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

9.2 Trouble shooting at a diaphragm pulsation dampener ........................... 9.7

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

10.12.1 Disassembly .......................................................................................................... 10.28

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

15 Appendix: PLC Software (electronic format) ....................... 15.1

3.1 Safety symbols

The hazards are classified into various stages.

Sign Signal word Definition Consequences

DANGER Dangerous situation Death or most 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:

Note or Note for application hints No signal word indicating a dangerous

Pos : 5.4 /--- Page br eak --- @ 0\mod_1136278659331_0.doc @ 766 @

3.2 Important information

3.3 Efficient use

• Apply correct and regular maintenance, according to these manual instructions.

3.4 Intended use

3.5 General safety instructions

3.6 Qualified workers

3.7 Safe working on the pump

Pos : 5.18 /GEHO/Heading/H 2/#.# Safety equipment @ 0\mod_1137483401931_31.doc @ 1241 @

3.8 Safety equipment

3.8.1 Safety related documentation

3.8.3 "EMERGENCY STOP" button

3.8.4 Safety covers and safety guards

4.1 Manufacturer information

WEIR Project information

4.2 Customer information

4.3 Manufacturer information

4.4 Technical data

4.4.1 Operating characteristics

Refer to document PDS.201333 "PUMP DATA SHEET" in chapter "Technical data.

4.4.2 Pump and project data and identification

GEHO pump Refer to document PDS.201333 "PUMP DATA SHEET".

Refer to the document PDS.201333 "PUMP DATA SHEET"

Refer for details also to: