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Weir Minerals Netherlands b.v.

Excellent
Minerals
Solutions

GEHO
TZPM
Training
Weir Minerals Netherlands b.v. Excellent
Minerals
Solutions

TRAINING TZPM

- Basic theory of operation


- Save operation procedures
- Sectional view of the pump with all components active, including
diaphragms, valves, pistons, crankshaft etc.
- Detailed views of the operation of:
* Propelling liquid system
* Relief valve system
* Lubrication system
* Valve operation
- Typical operation features of your specific pump.
- Operational parameters of pumping.

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TRAINING TZPM

INDEX
Total pump system
Frame unit
Lubrication unit
Valve unit
Diaphragm unit
Propelling liquid unit
Piston unit
Vent line unit
Pulsation dampener
Pressure relief unit
Zapex coupling
HMI panel
Maintenance
Priming the slurry section
Priming the propelling liquid section

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TRAINING TZPM

Discharge pulsation dampener


Amortiguador de pulsaciones
Frame unit or drive end
Parte motriz

Discharge valve
Válvula de descarga

Pressure relief unit


Ventline Válvula de control de presión
Sistema de aireación
Pump diaphragm
Diaphragma de la bomba

Piston
Suction valve Pistón
Válvula de succión
Propelling liquid
Fluido propulsor Lubrication unit sump
Sistema de lubricacion
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Drive end

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Water end

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Piston numbering

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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.
The 3 pistons follow each
other at 120° degree
crankshaft angle, as
represented in the figure.

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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).
The slurry must have a minimum
pressure (NPSHr).
This is to overcome the spring load of
the suction valve and fill the diaphragm
chamber properly.
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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).

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Frame unit

 1. Crankshaft
 2. Cross head
4 1 3 2 5
 3. Connecting road
 4. Oil sump
 5. Dust cover

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Frame unit

1. Crankshaft
2. Cross head
3. Connecting road
4 1 3 2 5 4. Oil sump
5. Dust cover
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Lubrication System

Check the oil level


The oil level gauge is located at the side of the power end.
1. Check the oil level gauge.
At initial filling or re-filling, the oil level
should be near level (B).
2. If necessary top-up the lubrication oil during operation, when the
pump is stopped.

Cleanliness of the oil:


Power end:
Cleanness : - /18/14 acc ISO 4406
Changing intervals : after first 200 hours after each 8000 hours or each year
B
When available;
Reduction gear box:
Cleanness : - /l5 /l2 acc ISO 4406

Every 2000 running hours / twice a year or due to a earlier defined sampling period:
 Take an oil sample, just before the discharge filter, when oil pump is running and the oil is at a normal temperature.

WARNING
 The oil is under pressure and can be hot.
Send the oil sample to the laboratory for recommendations and for a time schedule, for replacing the oil.
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Lubrication System

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Lubrication System

Main cranckshaft lubrication points

Dustcover lubrication points

Top crosshead lubrication points

All lubrication points have their


specific orifice size

Bottom crosshead lubrication points

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Lubrication System

1. Pressure gauge
1
2. Electric motor
3. Internal suction filter
4. Hydraulic gear pump
5. Flow sensor 2
6. Oil drain plug
7. Discharge pressure filters
3

7 6 5 4
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Lubrication System Filters

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.

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Lubrication System Filters

Visual clogging indicator

The filter housing is equipped with a


visual clogging indicator.
If the indicator displays, that the oil filter
resistance is too high, than the filter
needs to be replaced urgently.
Always check for abnormal causes for a
clogged filter. Like testing the oil by a
laboratory.

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Lubrication System

1. Keep dust and dirt out of the frame, especially


during maintenance and inspections.
2. If filling new oil, then always use a filter of the
same mesh as the discharge filter.
3. Never store oil drums outside upright and in
direct sunlight, because water will settle on the
top and will enter the drum when the drum is
cooling down.
4. Follow the recommendations for oil change
intervals as given in the laboratory report.
5. Follow the changes of the oil (trends) and try to
handle in time.
6. Be aware of the oil quality of already opened
drums, the water content can be too high.
7. If the average oil temperature is > 55°C,
then contact our WEIR After Market, Service
Application Engineers for recommendations.

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Lubrication System

8. If the water contents rises above 500ppm,


then you should start actions:
 Question, why the water content is rising and how
is it possible to reduce it or stop it.
 Should you plan a change of lubrication oil.
 If the air humidity around the pump is high or if
the pump is exposed to high temperature changes
(day/night), than replace the air breathers by
desiccant breathers, in order to keep the inside as
dry as possible. Use only desiccant breathers
which included also the dust filters.
9. If the air humidity is extreme or even caustic and
corrosive, then the power end frame (bearings and
crosshead guides can suffer from internal
corrosion. Purging the pump frame with
instrument air can be an option.

Contact for advice our WEIR After Market,


Service Application Engineers for
solutions.
10. If oil samples are investigated on a regular base,
under the same conditions and always the same
laboratory is used, then most laboratories can
help you with saving unexpected costs and shut
down of the pumps.
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Valve unit

 1.Valve housing
2
 2.Valve cover
 3.Conical valve 1
 4.Valve disc 8
10
 5.Valve seat 7
11
 6.Lock nut 9
3
 7.Compression spring
6
 8.Clamping piece
 9.Guide bush 4
 10.Stud bolt with 5
hydraulic tensioning
 11.Hydraulic nipples

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Stud bolt with hydraulic tensioning

Stud bolt

Nuts

Seals

Hydraulic nipple

Cover Piston

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Diaphragm unit

De-aeration
De-aeration channels
Initiators

Cover

Control rod

Diaphragm
Guide bush
Alumina inlay

Diaphragm
housing

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Propelling Liquid System P & ID

1. 2/2 way valves 7 5


2. 3/2 way valves
3. Pilot (globe) valve
6
4. Monitoring rod
5. Diaphragm 10

6. Initiator 4
7. Pressure transmitter
8. Air supply 13
1
9. Flow switch
14
10. Check (non-return) valves
2 3
11. Suction filter
8
12. Gear pump
9
13. Accumulator
14. Gauge 12

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Propelling liquid control

A. Slurry suction line;


B. B. Slurry chamber;
C. Propelling liquid;
D. D. Suction valve;
E. Diaphragm;
F. F. Piston;
G. Piston rod;
H. H. Cylinder liner;
I. Monitoring rod with a position marker for
limitation of the diaphragm stroke;
J. Discharge valve;
K. K. Slurry discharge line
L. Monitoring probes for minimum and
maximum stroke of the diaphragm (for
limitation of the diaphragm stroke)

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Propelling liquid control

1. "AIR" = Compressed air supply


connection
2. Propelling liquid automatic control
system
3. "PLC" = "PROGRAMMABLE LOGIC
CONTROLLER"
4. "FILL" = automatic filling of propelling
liquid, if the position marker (I) at the rod
reaches the minimum probe
5. "DRAIN" = automatic drain of propelling
liquid, if the position marker (I) at the rod
reaches the maximum-probe

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Solutions

Propelling liquid control

The pump is standard equipped with a


patented GEHO propelling liquid automatic
control system:
• It controls and limits the stroke of the
pump diaphragms.
• It regulates the volume of the propelling
liquid within limits.
• It protects the diaphragms against
overstress.
If the normal diaphragm stroke position
changes (as a result of increase or decrease
of propelling liquid), then the position marker
at the monitoring rod reaches the rear or
front monitoring probe.
Then the connected "PLC“
("PROGRAMMABLE LOGIC CONTROLLER")
actuates a fill or drain of propelling liquid.

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2/2 way valves

Inlet valve Outlet valve

Supply manifold Drain manifold

Check
valve
(NRV)
To and from diaphragm housing
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2/2 way valves

1. Distribution block Inlet valve Outlet valve


2. Banjo bolt
3. Valve seat
4. Non-return valve
5. Plug
6. O-ring
7. Seal ring
8. Orifice
9. Gasket
10.Base plate
11.Hex head cap screw

1 7

2 8

3 9

4 10

5
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2/2 way valve

Hex.socket head
Cover
capscrew

Diaphragm Rubber dampening

Spring Valve housing

Filter (breather)
Valve spindle

1e Slide bearing

U-ring 2e Slide bearing

Retaining ring

Orifice
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Piston unit

6
1. Propelling liquid
2. Piston body
3. Cylinder liner
4. Piston rod
5. Drain
6. Flushing nozzle
7. Thrust piece
8. Chevron seals

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Ventline unit

Vent line unit


This is a important unit for de-aeration of the diaphragm
housings, pressure relief - and propelling liquid systems
The unit is connected to the different systems by means
of transparent hoses, which in turn are equipped with a
high pressure needle valve at the point to the systems.
The primary task is to return excess oil with air back to
the sump without spillage.

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Discharge pulsation dampener

Connecting
points
for
Cover
auxiliaries

Nitrogen

Diaphragm
Slurry side

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Filling of the dampener

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.
S. Drain valve

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Filling of the 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

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Filling of the dampener

Nitrogen filling device:


E. Pressure gauge pulsation dampener
F. Mounting block
G. Filling valve pulsation dampener
H. Connector of the nitrogen filling device
I. Fixed connection to pulsation dampener
J. Fixed connection to working pressure
transmitter
N. Pulsation dampener

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Filling of the dampener

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.

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Filling of the dampener

3. If the actual pre-charge pressure is lower then


the pre-charge pressure, then follow this
procedure to add nitrogen.
4. Connect the pressure regulator (C) to the
nitrogen bottle (A+B).
5. Connect the safety valve (R) and the relieve
valve (S) to the pressure regulator (C)
6. Connect the hose (D) to the safety valve (R).
7. Connect the hose (D) to the connector (H) of the
nitrogen filling device.

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Filling of the dampener

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.

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Filling of the dampener

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.
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.
9.After finished filling, wait some time to
let the diaphragm set, than repeat the
filling till the pre-charge pressure is
reached again!

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Filling of the accumulator

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
H. Charging unit:
I. Non-return valve (prevents gas to flow out of the accumulator)
J. Shut-off-valve
K. Manual 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.

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Filling of the accumulator

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. Check 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).

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Filling of the accumulator

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 to 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.

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Filling of the accumulator

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 bottle pressure, 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).
6. Connect the hose (G) to the charging unit (H).

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Filling of the accumulator

7. Open the shut-off-valve (J).


8. Open the pressure reducer valve (F) in many small steps,
until the recommended pre-charge pressure is reached at
gauge (E) and gauge (l).
9. When the recommended pre-charge pressure is reached,
then:
10. Close the nitrogen bottle valve (B), so the nitrogen supply is
interrupted.
11. Close the pressure reducer valve (F).
12. Close the shut-off-valve (J), so the accumulator is isolated.
13. 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).

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Solutions

Filling of the accumulator

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).
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.

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Pressure relief unit

WARNING
The oil in the connecting piece remains under pressure
5 even when the pump is idle.
1. Non-return valve unit 4 Behind the non-return valves and before the pressure
2. Connecting piece relief valve.

3. Needle bleed valve 2


3
4. Pressure gauge
5. Pressure relief valve unit 1

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HMI panel

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HMI panel

HMI starting page


1. Language selection
2. Next page

1 2

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HMI panel

HMI overview screen


1. Touch screen buttons
selection
2. Return to last page
3. Indication lights
representing settings 3

2
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HMI panel

HMI overview screen


Touch screen on (1)
“ANALOG VALUES” than
(2) pops-up with
“ACTUAL VALUES”

1
2

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HMI panel

1
HMI overview screen
Touch screen on (1)
“SPEED” than (2) pops-up
with new pop-up with speed 2
setting buttons
“UP” Speed-up
“DOWN” Speed-down
“ZERO” Speed set point
goes down to “0”
Only 2 (two) pop-ups can be
available per screen

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HMI panel

1
HMI propelling liquid screen
1. Touch screen buttons
selection
2. Return to last page 3
3. 15 minutes valve button
needed for priming of the
pump
4. Ability to copy screen to
USB stick.
4
The USB connector is on
the backside of the HMI
inside the cabinet
2
5. Manual filling diapragm
housings
4
5 2
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HMI panel

HMI alarm screen

Alarm list with aluminated


active alarms

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HMI panel

HMI Setpoint set-up screen

Do not change any settings


unless you are absolutely
sure that it necessary to do
so!

All changed settings will


return to default setting
during power outage of the
cabinet!

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Minerals
Solutions

Maintenance cone valve


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 abrasively 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.

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Solutions

Maintenance cone valve


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.

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Maintenance cone valve


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.

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Maintenance preparation

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.

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Maintenance preparation

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
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Maintenance preparation

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.

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Maintenance preparation

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”).

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

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Maintenance preparation

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).

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Maintenance preparation

CAUTION

• Avoid wasting oil.


• Avoid polluting the oil and the connectors.

Oil connector caps


If disconnecting oil tubes or hoses, then:
• Use connector caps, to close the connection and to avoid waste of oil.

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Maintenance diaphragm housing unit

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).
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.
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).

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Maintenance diaphragm housing unit

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).

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Maintenance diaphragm housing unit

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

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Maintenance diaphragm housing unit

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).
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). As shown in the figure.

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Maintenance diaphragm housing unit

If some pistons heads are 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.
4. Activate the "HYDRAULIC PUMP UNIT", until the
hydraulic oil pushed all those pistons against the
tension-ring-nuts (F).
5. Check the positions of the piston heads.

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Maintenance diaphragm housing unit

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).
3. Open the drain side of the oil-return/de-aerate
valve at the hydraulic pump, 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).

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Maintenance diaphragm housing unit

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.

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Maintenance diaphragm unit

Disassembly
Drain the propelling liquid.
Diaphragm housing cover
1. Use the special tool "DIAPHRAGM COVER LIFTING
DEVICE".
2. Remove the two topmost cover nuts.
3. Remove the two lowest cover nuts.
4. Put the "DIAPHRAGM COVER LIFTING DEVICE" to the
diaphragm cover. Make sure that the threaded bolts fit in
the holes.
5. Tighten the "DIAPHRAGM COVER LIFTING DEVICE"
with two screws.
6. Remove the remaining cover nuts.
7. Remove the diaphragm housing cover. Use the push-off
bolts.
8. Remove the diaphragm housing cover seal ring.

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Maintenance diaphragm unit

Diaphragm
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 lousing (A).
3. Loosen and remove the monitoring rod (C)
from the diaphragm (B).
4. Check the monitoring rod (C) for ab-normal
wear or damage.
5. If necessary, then replace the monitoring rod
(C).
6. Check the diaphragm (B).
7. Mark any indicator of ab-normal wear or failure
or damage.
8. Replace the diaphragm (B), according to the
regular maintenance schedule, or if necessary.

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Maintenance diaphragm unit

Diaphragm housing unit


Schematic overview:
A. "MONITORING ROD"
B. Guide bush lock screw
C. Front "INITIATOR HOUSING"
D. Monitoring rod "CLAMPING BUSH"
E. "DIAPHRAGM"
F. De-aeration boring
G. Diaphragm cover "SEALING RING"
H. "DIAPHRAGM HOUSING"
I. "DIAPHRAGM HOUSING COVER"
J. Diaphragm cover nut
K. Protective cap
L. Sealing ring
M. O-ring

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Maintenance diaphragm unit

Monitoring rod guide bush


Checkpoints
1. Check the guide bush for wear and/or damage.
2. Check the initiator housing for wear and/or
damage.
3. If necessary, than replace the guide bush and or
initiator housing.

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Maintenance diaphragm unit

1. Clean and dry all parts.


2. Install the monitoring rod guide bush (D). Check
the position, the hole for the screw (L) in the
guide bush must be corresponding with the hole
(B) in the housing, as shown in the figure.
3. Use a nut-lock (like LOCTITE 243) at the lock
screw. Lock the guide bush lock screw (B).

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Maintenance diaphragm housing unit

Disassembly
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. Guide bush for the monitoring rod
G. Initiator housing
H. Screw at the covering ring (standard = 3x)
I. Screw for the guide bush (standard = 2x, the
position is 90°turned)
R. De-aeration holes in the housing and in the
filling ring

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Maintenance diaphragm housing unit

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.
3. Drain the diaphragm housing.

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Maintenance diaphragm housing unit

Preparation of the propelling liquid system


CAUTION
• De-pressurize the propelling liquid system,
before starting works on the pump.
DANGER
• Do this procedure only during shut-down and
lock-out of the pump.
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.

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Maintenance diaphragm housing unit

Diaphragm
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 from the diaphragm
housing (A).
3. Loosen and remove the monitoring rod (C)
from the diaphragm .
4. Check the monitoring rod (C) for ab-normal
wear or damage.
5. If necessary, then replace the monitoring rod
(C).
6. Check the diaphragm (B).
7. Mark any indicator of ab-normal wear or failure
or damage.
8. Replace the diaphragm (B), according to the
regular maintenance schedule, or if necessary.

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Maintenance diaphragm unit

Diaphragm-rod unit
1. Loosen the monitoring rod from the diaphragm.
2. Remove the monitoring rod.
3. Check the monitoring rod for ab-normal wear or
damage.
4. Replace the monitoring rod, if necessary.

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Maintenance diaphragm unit

Diaphragm-rod unit
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).

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Maintenance diaphragm housing unit

Cleaning after diaphragm leakage or damage


or contamination
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.

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Maintenance diaphragm housing unit

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.

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Maintenance diaphragm housing unit

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.
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.

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Maintenance diaphragm unit

Assembly
ATTENTION
After a diaphragm leakage or damage or
contamination, before starting the assembly, it is
essential to clean and dry all parts.
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.

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Maintenance diaphragm unit

Diaphragm housing cover Preparation


1. Check the diaphragm housing cover seal.
2. If necessary, 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.

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Maintenance diaphragm unit

Mounting
5. Use the "DIAPHRAGM COVER LIFTING DEVICE".
6. Screw the push-off bolts back in 0-position.
7. Check that the cover is hoisted perfectly vertical.
8. Put the diaphragm housing cover to the diaphragm
housing. Make sure that the threaded bolts fit in the
holes.
9. Tighten the most left en right diaphragm cover nut.
10. Screw evenly, until the cover sits flat on the housing via
its raised face (check for even clearance all around).
11. Un-tighten the two hoisting bracket screws.
12. Remove the "DIAPHRAGM COVER LIFTING DEVICE".

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Maintenance diaphragm unit

13. Tighten the diaphragm cover nuts.


Use the sequence as displayed here.
Refer to chapter "Special torques" for the
correct torque.

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Maintenance Initiator

Initiator coupling nuts at the back of the diaphragm housings

Check initiators every trimester by means of a


magnet.
This must be done during standstill of the pump!
Screw the initiator coupling nuts (6x) hand tight and
then loosen about 45 degrees.

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Maintenance gearbox

Greasing the bearings and labyrinth seals


The bearings and labyrinth seals need periodical
greasing.
• Check, how many grease nipples there are at the gear box
(indicated on the nameplate).
• Add grease into the nipples.
Grease nipple at shaft ends (The photo shows a
schematic arrangement for more versions)
Cooling
If applicable, check regularly the fans, air-oil coolers, oil
to water coolers or cooling coils.
It is important that the generated heat in the gearbox due
friction and churning of the oil can be dissipated.
Air filter
Clean or replace the air filter, at the top of the gearbox.

Refer to chapter "Maintenance" for the frequency of


maintenance works.
Refer to chapter "Catalogue Information", "Gearbox" for
details about the gearbox maintenance, oil change and re-
greasing.

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Solutions

Maintenance diaphragm failures

Normal wear by fatigue


Problem:
When the diaphragm is broken by fatigue it shows near the clamping edge a crack and mostly
more surfaces cracks, especially at the propelling liquid side.
Possible cause:
Fatigue; diaphragm has reached end of lifetime
Solution / checkpoints:
Replace diaphragm by new one. No further actions required.

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Solutions

Maintenance diaphragm failures


Blown up diaphragm
Problem:
A blown up diaphragm by to 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.
Possible cause:
 To much propelling liquid due to wrong start-up procedure
 Defect outlet initiator
 Mal-function of 2/2-way valves.
Solution / checkpoints:
 Use correct start-up procedure
 check initiators
 check propelling liquid system

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Solutions

Maintenance diaphragm failures

Damage at the propelling liquid side of the diaphragm


Problem:
If rubber has loosened at the in-vulcanised cone-plate area the pump was probably running with
insufficient propelling liquid and the cone-plate has touched the rear wall of the diaphragm housing.
Possible cause:
 Insufficient propelling liquid
Solution / checkpoint:
 Mal-function of 2/2-way valves
 Mal function of 3/2-way valves
 Leakage propelling liquid system
 Defect filling initiator
 Discharge valve

Teared-off in-vulcanised cone- late in


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

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Solutions

Maintenance diaphragm failures

Hole at top (12 O clock) of diaphragm


Problem:
Hole at the top of the diaphragm.
Possible cause:
Loose monitoring rod
Solution / checkpoint:
Torque and glue monitoring rod

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Solutions

Maintenance diaphragm failures

Crack at lower side (5 or 7 O clock) of diaphragm


Problem:
Crack at lower side of diaphragm at 5 or 7 O clock.
Possible cause:
Slurry settling
Solution / checkpoint:
Check flushing procedure

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Solutions

Maintenance diaphragm failures

Crack at bottom (6 O clock) of diaphragm


Problem:
Crack at bottom (6 O clock) of diaphragm
Possible cause:
Suction pressure to low
Solution / checkpoint:
Check suction pressure

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Minerals

Maintenance Solutions

Pulsation dampener diaphragm

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.

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Solutions

Maintenance Zapex coupling

1. Grease the surface of the DUO-rings (B) and


the groves in cover rings (A).
Recommended lubrication grease:
> "Shell Alvania RL3".
> "Mobil Mobilux EP3".
2. Mount the DUO sealing rings (B) proper in the
cover rings (A).
3. 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".

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Maintenance Zapex coupling

4. Clean and dry the sealing surfaces (D) of the


coupling parts.
5. Cover the sealing surfaces (D) of the coupling
parts with a sealing compound.
Recommended sealing compound:
"LOCTITE 5922 Flange Sealant".
6. 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.
7. Assemble the coupling covers (E) and cover
rings (A) together.

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Maintenance Zapex coupling

Coupling oil filling:


1. 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).
2. Remove the two top screw plugs (D1+D2).
3. Measure the correct oil/grease quantity with a
measuring beaker.
4. Fill the coupling with the recommended oil.
5. Screw in all screw plugs (D) with
fitted/integrated sealing rings.
6. Check that the coupling cover does not leak, by
rotating the shaft.
Safety protection:
7. Mount the safety guard.

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Maintenance main valves

Disassembly
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.
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.
7. Loosen all the outside lock-nuts (D).

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Maintenance main valves

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).

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Maintenance main valves

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.
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.

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Maintenance main valves

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.
9. Open the drain side of the oil-return/de-aerate
valve at the hydraulic 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.

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Maintenance main valves

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).
14. Re-tighten the outside lock-nuts (D). These lock-nuts
(E) maintain during operation the tightening force in
stud (C).
15. 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.
16. Disconnect the high pressure hose from the
hydraulic connector nipple (E). Put the protecting
guard to the connector nipple (E).

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Maintenance main valves

Disassembly
1 Release the pressure from the slurry section.
2 Remove the valve housing cover.
3 Remove the square gasket.
4 Remove the compression spring.
5 Remove the conical valve.

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Maintenance main valves

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

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Maintenance main valves

Valve seat
Disassembly
Remove the valve seat, using the hydraulic seat connector
1. Remove the valve housing cover.
2. Remove the conical valve.
WARNING
• Re-install the valve housing cover, to prevent getting hit
by a valve seat.
3. Install the valve housing cover.
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.
9. Remove the valve housing cover.
10. Remove the valve seat from the valve housing.

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Maintenance main valves

Remove the valve seat, using a hydraulic special tool set


1. Remove the valve housing cover.
2. Remove the valve and spring.
3. Place puller (E) under the valve seat.
4. Screw the threaded spindle (C) into the puller (E).
5. Put the centering plate (D) with the hydraulic tool (B) to
the valve housing.
6. Tighten the nut (A) until the hydraulic tool (B) is
compressed in its final position.
7. Connect the hydraulic pump to the connector of the
hydraulic tool (B).
8. Pressurize the pump until the valve seat is loose.
9. Depressurize the pump.
10. Remove the pump.
11. Remove the valve seat.

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Maintenance main valves

Assembly
Install the valve seat, using a mechanical tool
1. Clean the valve seat.
2. Clean the bore in the valve housing.
3. Make sure that they are free of dust, paint, or oil.
4. Insert new O-rings into the grooves at the valve seat.
5. Insert valve seat (D) into the bore in the valve housing.
6. Put valve seat tool (C) to the valve seat.
7. Tap valve seat tool (B+C) until the valve seat (D) fits. Use
a hammer (A).
8. Remove the valve seat tool.
9. Make sure that the valve seat is mounted correctly and
tight.
If you can pull out the valve seat by hand, then inspect
the surfaces of the housing and the valve, and repeat
this procedure.

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Minerals
Solutions

Maintenance main valves

Valve guide bush

Overview

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

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Solutions

Maintenance main valves

Disassembly
Use the procedure below, to remove the valve guide
bush from the clamping piece.
Check the guide bush:
1. Remove the valve housing cover.
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 (A) 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.

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Maintenance main valves

Assembly
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.

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Maintenance main valves

Valve disk assembly


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).

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).

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Maintenance main valves

5. Put the valve nut wrench (A) to the assembled valve (B).
6. Tighten the valve disc lock nut.
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.

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Solutions

Priming slurry section

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).

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Solutions

Priming 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.
5. Open the drain valve (B) in the
discharge line.
Wait until flush water discharges
from the drain valve (B).
6. Close the drain valve (B).

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Minerals
Solutions

Priming slurry section

De-aerating the liquid chambers and


positioning the diaphragms in
starting position:
1. Partly open drain valve (B) in the
discharge line, to maintain
pressure in the slurry section.
The pressure of the flush water must
be high enough to force the
propelling liquid to escape through
non-return-valve (F).
2. 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.
3. Check at the GEHO touch panel,
that the lights of switch (ZSL) of all
pistons light on.

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Minerals
Solutions

Priming propelling liquid section

1. Open the flush water connection


(D) in the suction line.
2. Partly open the drain valve (B) in
the discharge line, to maintain
pressure in the slurry section.
• 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).
3. Start at the GEHO touch panel the
propelling liquid pump.
4. Open the vent valves (E) in the
propelling liquid section of all
diaphragms.

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Priming propelling liquid section

5. Open the vent valve (G) to de-aerate the


common line at safety relief valve (H)
of the propelling liquid system.
6. Push at the GEHO touch panel the
button "MAIN SUPPLY VALVE", to
open the main supply filling valve (K)
for 15 minutes.
7. Close the vent valves (E) and (G), if the
propelling liquid, that discharges
through valve (F), contains no air
bubbles.
8. If necessary, then repeat the steps 6
and 7 until all vent valves (E) of the
diaphragms are closed.

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Priming propelling liquid section

9. 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;
• the corresponding filling valves will
close, the filling will stop;
• at the GEHO touch panel the
corresponding diaphragm
position light (ZSL) will turn
off.
10. If necessary, then repeat step 6 until
at the GEHO touch panel all
position lights of all
diaphragms are off.
11. Start the lubrication pump.
12. Check that the lubrication system
delivers the oil quantity.
13. Rotate the pump crankshaft
manually. 122
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Solutions

Priming propelling liquid section

14. 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.
15. Wait until this switch light is off.
16. Repeat steps 9 to 11 until no switch
lights light up during rotation of the
pump

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Solutions

Priming propelling liquid section

17. 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
18. Close the drain valve (B) in the discharge
line.
19. Close the flush water valve (D) of the
flushing water connection in the suction line.
20. Stop the flush water supply.
21. Open the main valve (C) in the suction line.
22. Open the main valve (A) in the discharge
line.

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Solutions

Maintenance piston unit

Piston unit

A. "PISTON ROD"
B. "THRUST PIECE"
C. Threaded bolts
D. Piston "GUIDE RING"
E. 2x chevron piston seals
"SET OF ROOF SHAPED RINGS"
F. Piston "NUT"
G. "RETAINING PLATE"
H. "CYLINDER LINER"

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Solutions

Maintenance piston unit

1. Remove the top cover plate of the piston unit.


2. Move the "PISTON UNIT" to the most forward position.

DANGER
• Before going on, make sure, that the crankshaft is
blocked against rotating, to avoid risks during working.

3. Remove the "CLAMPING PIECE" between "PISTON


ROD" and "CROSSHEAD ROD".
4. Move the crosshead to the most backward position.
5. If applicable, then disconnect the flushing pipes.
6. Remove the lock nuts at the "THRUST PIECE".
7. Remove the upper threaded bolts.
8. Remove the "THRUST PIECE".

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Solutions

Maintenance piston unit

1. Put a suitable hoisting belt around the piston unit.


2. Make sure that the hoisting belt is NOT below the two
lower threaded bolts.
3. Tension the hoisting belt.
4. Turn the crankshaft, to move the "CROSSHEAD" to the
most forward position.
5. Install the "CLAMPING PIECE" between "PISTON ROD"
and "CROSSHEAD ROD".

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Maintenance piston unit

Remove the piston unit

Use the special tool "PULLING DEVICE CIL.LINER"


(= cylinder liner pulling tool).

1. Place the cylinder liner pulling tool to the piston unit.


2. Pull the piston unit out of the bore, by moving the
crosshead backwards.
3. Remove the cylinder liner pulling tool.
4. Remove the "CLAMPING PIECE" between "PISTON ROD"
and "CROSSHEAD ROD".
5. Remove the piston unit.

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Maintenance piston unit

Assembly

Preparation

1. Replace the piston "GUIDE RING", if necessary.


2. Replace the chevron piston seals, "SET OF ROOF
SHAPED RINGS", if necessary.
3. Check the "CYLINDER LINER" for grooves.
Replace the cylinder liner, if necessary.
4. Lubricate to the chevron piston seals.
5. Lubricate the "CYLINDER LINER" surface.
6. Put the piston assembly into the "CYLINDER LINER".

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Maintenance piston unit

Install the piston unit

1. Check the seal ring (A) at the corner-piece / middle-piece.


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

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Maintenance piston unit

Final works

1. Install the "THRUST RING".


2. Tighten the lock nuts at the "THRUST PIECE".
Refer to chapter "Special torques" for the correct torque.
3. Install the flushing pipes, if applicable.
4. Move the "CROSSHEAD" forwards.
Make sure the "CROSSHEAD ROD" touches the "PISTON ROD".
5. Assemble the "CLAMPING PIECE" at the "CROSSHEAD ROD"
and "PISTON ROD".
6. If available/applicable:
Grease the "CYLINDER LINER".
Use the grease nipple.

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Priming

Priming the slurry section

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).
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Solutions

Priming

1. Close the main valve (C) in the suction line.


2. Close the main valve (A) in the discharge line.

De-aerating the slurry section:


3. Open valve (D) of the flush water connection to the suction line.
4. Open the drain valve (B) in the discharge line.
Wait until flush water discharges from the drain valve (B).
5. Close the drain valve (B). 133
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Priming

De-aerating the propelling liquid chambers and positioning the diaphragms in starting position:
6. 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).
7. 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.
8. Check at the GEHO touch panel, that the lights of switch (ZSL) of all pistons light on.
9. Continue with the next chapter, to prime the propelling liquid section. 134
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Solutions

Priming

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 135 (F).
Weir Minerals Netherlands b.v. Excellent
Minerals
Solutions

Priming

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.
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.

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Priming

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;
• 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.
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Priming

Positioning of the diaphragms in relation to the pistons (timing of the pump):

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. 138
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Priming

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
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(ZSH).
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Minerals
Solutions

Priming

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. 140
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Priming

NOTE!
Make sure that the air pressure remains above 450kPa (4,5bar) at all times.
When it goes below the 400kPa or there has been an air pressure trip alarm, than steps
12 to 23 have to be repeated again.
This is because the 2/2-way valves are in a failsafe position, when there is still pressure
left in the slurry side, the diaphragms will go back to their start positions.
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Solutions

TRAINING TZPM

Questions?

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