HP65

OPERATING & MAINTENANCE MANUAL

Build Number : 6C622-225A3

Unit Number : 51852-824-1437

Manufactured by : Hughes Pumps Ltd

Spring Gardens
Washington
West Sussex
RH20 3BS
United Kingdom
Tel +44 (0)1903 892358
Fax +44 (0)1903 892062
sales@hughes-pumps.co.uk
www.hughes-pumps.co.uk

Hughes Sales Order : 44204/1

Customer : Gomotor SAC

Manufactured : July 2024

1. Introduction

2. Safety

3. Specification/scope of supply

4. Installation

5. Avoidance of cavitation

6. Water Tank Requirements

7. Operating Instructions

8. Pump drawings & parts lists

9. Pressure Safety Valve

10. Engine

11. Control Panel

12. Spare parts & tools

13. Maintenance

14. Special Tools

15. Fault finding

16. Ancillary Equipment (if supplied)

Oil cooler
Oil temperature switch
Pump discharge Pressure Gauge
Water Level Switch
Drive coupling

17. Warranty

18. Test certificate

Section 1 – Introduction

lubricated, depending on model & all

include an oil cooler / heat exchanger
mounted on the pump inlet & uses
incoming water to cool the crankcase &
gearbox assembly.

All pumps should incorporate an oil

Failure to follow instructions in this temperature switch, oil pressure switch &
manual may cause damage to the a boost pressure switch to stop the engine
equipment, invalidate warranty or in the event of a fault.
cause personal injury or death.
Water is pumped using three hard
wearing, solid ceramic plungers (five in an
HPS5000 pump) which operate in spring
This pumpset is a specialist piece of loaded, self adjusted packing’s to give
equipment & must be installed, operated & long life. The pumphead & all wetted
maintained in accordance with this components are manufactured in
Operating & Maintenance Manual. corrosion resistant materials suitable for
pumping seawater over many years.
All operators must be trained in the correct These materials are typically 316 or
/ safe operation of the equipment & should duplex stainless steel.
read & fully understand this manual.
Following these instructions will lead to Each cylinder includes an in-line valve
safe, efficient & reliable operation. arrangement which incorporates spring
loaded inlet & outlet valves. This design
There are various build configurations for isolates the pumphead from the effects of
these pumps. alternating stress as each cylinder
operates between inlet & discharge
All pumps are available with SAE engine pressure on each stroke / rpm of the
adaptors to ensure perfect alignment pump.
between the engine & pump whilst giving
a compact installation. A flexible drive Pumps are fitted with a safety valve set at
coupling should be used to reduce the 20% above working pressure to prevent
effect of any vibration in the system. The over-pressure & a pressure gauge. The
pumps can be supplied without an SAE safety valve should be calibrated at 6
adaptor to enable conventional foot month intervals to ensure safe operation.
mounting if required, for example if a
clutch is being installed between the All plunger pumps must be correctly fed
engine & pump. with water to ensure reliable operation,
failure to do so will lead to cavitation which
Each pump has an integral reduction can severely damage internal surfaces of
gearbox to give a pump speed of 350- the pump, crack pressure containing
750rpm depending on model. The pump is components & even damage pump
crankshaft driven where connecting rods bearings, gears or drive couplings.
are attached to crossheads which
reciprocate through oil seals to keep the All Hughes packaged pumpsets are
crankcase & gearbox oil sealed in the carefully designed to ensure the pump is
pump. This part of the pump is virtually fed correctly. A boost pump is always
maintenance free other than for routine oil fitted to supply the high pressure pump
& filter changes (where fitted). The with a positive supply, typically at 2-5 bar,
crankcases are splash or pressure via a high capacity, stainless steel filter
housing fitted with a fine, replaceable filter Section 3 – Specification which outlines
element, typically 50/100 micron rating. what components / options are included.
These ancillary items are available from
Hughes Pumps. Section 3 also includes some specific
suppliers part numbers which can be
If the boost pump is used to lift water great referred to when using the general data
care should be taken in ensuring the sheets throughout this manual Contact
suction hose is correctly sized, is as short Hughes Pumps or the reseller if further
as possible, with minimal connections to information is required.
reduce the possibility of air entrainment
which would lead to cavitation.

It is essential the system is correctly

primed before start up & that boost
pressure & water filter condition are well
maintained. Refer to section 5 of this
manual for more information.

Each system should include a boost

pressure switch to prevent the pump from
running dry / cavitating. This is achieved
by setting the switch at around 0.5 bar to
ensure the pump always has a positive
supply. It is good practice to regularly
check the correct function of this switch.

The pumpset should incorporate a high

pressure control valve to enable the pump
to be started off-load. Starting the pump
against load can overload crankshaft
bearings &/or the engine starter motor.
The pump must be able to start off-load to
ensure correct lubrication of main & big
end bearings before any load is applied.
Most units use a pneumatically actuated
pressure adjusting valve, powered from an
engine mounted compressor to provide
instant off-load facility as well as providing
infinite pressure control & additional over-
pressure protection. Alternatively a
manual ball valve is fitted to provide off-
load start facility. When a manual valve is
used it normally has to be actuated with
the engine at low speed / pump at low
pressure.

This manual is designed to provide all

information required & is generic in nature.
It includes information on various build
options which may or may not be included
with the particular pump in question. For
details on the precise specification refer to
SAFETY

Failure to follow these safety

instructions may cause personal
injury or death.

This code of practice has been prepared to give guidance on the safe use of equipment
used in high pressure applications.

High pressure water jets can cause serious injury. It is the responsibility of both supervisor
and operator of the equipment to observe at all times the recommendations made in this
code of practice. Safety is a joint effort. In the event of an accident occurring from contact
with a high pressure water jet, this must be taken seriously. Even apparently minor injuries
must be referred to a medical department or hospital. The superficial puncture may be quite
small but tissue damage could be extensive and deep.

General Precautions
It is recommended that testing of all high pressure equipment should take place at least
annually. This testing should be 1 ½ times maximum working pressure and this pressure
held for a period of 15 minutes.

Hughes Pumps can provide this service and will provide test certificates for successfully
tested items of equipment.

Check that the operating pressure of the pump does not exceed the working pressure of the
accessory to be used.

Never carry out any examination or attempt maintenance of the pump or its prime mover
whilst the unit is running. Diesel engines should be shut down, and in the case of electric
powered units, ensure full isolation from the electric supply at source.

Hoses must not be used as tow-ropes and jetting guns used as hammers or crowbars etc.

If used, never attempt to tie or wedge the gun trigger, dump lever, or foot valve pedal in the
open position. It is essential to be able to stop jetting immediately the trigger, lever or pedal
is released.

Never connect the pumphead delivery line directly to any accessory, there must be some
type of dump / pressure adjusting valve that enables the pump to be started off-load.

Do not use unspecified hose or equipment.

The high pressure connecting hose (or pipework) and adaptors between the pumphead and
the jetting equipment, must be of the correct type and pressure rating for the application.

Any high pressure connections not in use must be blanked off using either the standard ball
and cap method or the coned swivel plug arrangements. Use of ordinary plugs or caps could
be dangerous.

Never attempt to stop a leak or tighten any connection while pressure remains in the system.

Never connect a stop valve to a high pressure delivery line without ensuring a pressure
adjusting / unloader valve is fitted that is capable of full flow against a closed valve.

Several lengths of delivery hose may be joined together using high pressure adaptors. As
the length of delivery line is increased, the pressure at the discharge nozzle is decreased.

The size of the jets in the accessory is also very important. If they are too small a continuous
high volume of water will be discharged through the dump valve of the pressure adjusting
valve causing excess wear to the valve and possible uneven running. Or if a pressure
adjusting valve is not fitted the pump will go over pressure. Undersize jets will only utilise a
fraction of the power available. If too large a nozzle is used, it may be impossible to achieve
the desired working pressure.

Always use the recommended / original seal types and sealing methods. The importance of
efficient and leak free joints and seals in high pressure water jetting cannot be over-
stressed, both for safety aspects and the maintenance of equipment in efficient working
order.

If a high pressure water seal is allowed to leak for any period of time serious erosion of steel
components adjacent to the leak will occur, rendering the item useless for further service.
This can be very costly, i.e. in the case of a pumphead.

Safety Valves And Bursting Discs

Pumps must be protected by a suitable safety valve. All safety valves used on Hughes
equipment are accurately set and sealed / locked. Do not rely on any safety valves that have
a broken or missing seal. Unauthorised adjustment of these valves could result in the valve
not relieving in an emergency. Safety valves are matched to plunger sizes, so ensure that
the correct valve is being used with a given plunger size. Safety valves should be calibrated
at least every six months to ensure accurate and reliable operation.

If bursting discs are fitted ensure the correct disc is used appropriate to the working pressure
of the pump.

Training and Personnel Protection

Correct training and responsible supervision must be the first consideration.

Each member of the team should wear suitable protective clothing and equipment.

For operators subjected to long periods of noise, it is advisable that ear defenders are worn.
Site Precautions

Extreme caution must be observed to protect operators, any surrounding areas and
observers.

Suitable warning signs or notices prohibiting the entry of unauthorised personnel into the
immediate area surrounding the high pressure pump and any high pressure pipework, must
be displayed.

Before commencing jetting check all hose and pipework connections and fittings to ensure
leak tight joints. It is sufficient just to tighten hose connections etc., to prevent leaks. Over
tightening can cause permanent damage to connections.

Never attempt to tighten any hose connection, nut or fitting while the system is under
pressure.

Pre-Operation Checks
All operations must be controlled by a competent supervisor and all equipment must be
carefully inspected before each operation commences. In particular the following must be
checked:

A pressure gauge must be fitted to the pump and easily read.

All hoses must be in good condition, i.e. blisters or wearing of the outer casing, renders the
hose unserviceable.

All hose couplings must be visually checked for good condition of threads.

All nozzles must be visually checked for good condition particularly where threaded nozzles
are used. All threads must be in good condition

All adaptors & accessories must be visually checked. Threads and seatings must be in good
condition.

Where protective guards are fitted ensure these are in position.

Check safety valves and bursting discs.

If in doubt over any of the above, check with a supervisor. If any item of equipment is
suspect, it must be replaced before work commences.

Electric Motor

All electrical installations must comply with the local safety requirements, eg, I.E.E
Regulations, Health and Safety Act, etc

Check that the electrical rating of the unit is correct for use with the power supply available.
It is important to ascertain that the power supply available is sufficient for the starting and
running of the equipment.
Check that the unit is adequately earthed or bonded.

Extra care must be taken when using electrical equipment in wet conditions.
Specification/Scope of Supply
Pump details

Hughes sales order no : 44204/1

Customer : Gomotor SAC
Manufactured : July 2024

Unit Number : 51852-824-1437

Pump build no. : 6C622-224A3

Pump model : HP65
Max Flow : 50 LPM
Plunger size : 25 mm
Un-loaded RPM (min-max) : 1000-1710 RPM
Loaded/On Pressure RPM (min-max) : 1400-1710 RPM
Gearbox ratio : 2.28:1
Pump speed (min-max) : 438-750 RPM
Absorbed Power : 46 kW
Rated Power : 48 kW

Max Discharge Pressure : 500 Bar

Min Inlet Pressure : 2 Bar
Max Inlet Pressure : 10 Bar
Pumped Media : Clean Water
Max Media Temperature : 40OC
Min Media Temperature : 1 OC

Recommended Pre-Filter size : 50µm

Pre-Filter Part No. : 21571-656
Recommended Main Filter size : -
Main Filter Part No. : -
Bursting Disk/Safety valve : 24715-001
High-pressure Un-loading valve : -
High-pressure control valve : -
Drive Coupling Part No. : 23357-117

Required water flow to oil cooler : N/A

Max water temperature to oil cooler : N/A
Packing bypass collection rate : N/A
Section 4 – Installation Instructions for
Bareshaft Pumps

1. Size of Prime Mover

The prime mover (diesel engine, electric

motor or hydraulic motor) should be
suitably sized to ensure adequate power
Failure to follow these installation is available for the pump. It is good
instructions may cause damage to the practice not to oversize the prime mover,
equipment, invalidate warranty or cause failure to do so could result in the pump
personal injury or death. being overloaded in the event of incorrect
operation.
It is essential the pump is installed
The following calculation is used to
correctly to avoid damage to the
calculate power required.
equipment, to ensure trouble-free
operation & to avoid potentially dangerous
Power (hp) = pressure (bar) x flow (lpm)
occurrences from taking place. The
400
following points are key to correct
installation & are expanded on later in this
To convert hp to kW, multiply x 0.746
section :
1. Size of the prime mover.
Example
2. Alignment.
hp = 320bar x 228lpm = 182.4hp (136kW)
400
3. Drive coupling.

4. Direction of rotation.
2. Alignment
5. Overpressure protection.
The pump must be well aligned with the
prime mover to prevent premature wear or
6. Pressure gauge.
damage to the gearbox bearings & gears.
Failure of these components could lead to
7. Off-load start facility
a catastrophic pump failure. The degree of
misalignment that is acceptable largely
8. Pressure control.
depends on the capability of the flexible
drive coupling, but perfect alignment
9. Oil cooler installation.
should be aimed for. It could be that this
bareshaft pump includes an SAE adaptor
10. Shutdown protection.
which ensures perfect alignment. When
using an SAE adaptor care must be taken
11. Boost pump & filtration
to ensure there is no clash of coupling
halves as the pump is mounted to the
12. Suction pipework.
engine (refer to Section 14).
13. Pulsation damper.
If an SAE adaptor is fitted it is necessary
to support the weight of the pump using a
14. Discharge pipework.
bracket or studs under the two most outer
pump feet. Care should be taken to
15. Accessories.
ensure this bracket or studs do not conflict
with pump feet but are adjusted to suit.
16. Pump Inclination
 5. Overpressure Protection

The pump MUST be fitted with

overpressure protection in the form of a
safety valve or bursting disc. Hughes
Pumps always supply bare shaft pumps
with safety valves which are factory set to
120% of the maximum working pressure
SAE engine adaptor Pump support to prevent system & operator damage in
the event of a blocked nozzle etc. These
If the pump does not have an SAE engine devices should be locked, not tampered
adaptor & is foot mounted, then alignment with & calibrated at 6-month intervals (or
is much more critical. The pump &/or sooner) to check for correct function. If a
prime mover feet will need to be shimmed safety valve has not been called into
accordingly to ensure shafts are in line. operation for a long period it can become
“sticky” & not relieve at the correct
3. Drive Coupling pressure, particularly if working with
seawater. In this situation, more frequent
The drive coupling must be specified to testing is required. Never tamper with or
accommodate any misalignment present by-pass this device.
& be able to absorb the power/torque
being transmitted at the operating speed.
Specialist advice can be sought from
coupling manufacturers or Hughes Pumps
(refer to Section 14). The rotating coupling
& all moving parts must be guarded.

4. Direction of Rotation

The pump input shaft must operate in a

clockwise direction, this is marked with an
arrow cast into the gearbox. If a clutch or
transmission is fitted between the prime
mover & pump, ensure it does not reverse Pressure control valve (7)
the direction of rotation.
Pressure gauge (6)
Electric motors can be wired to rotate
backwards & hydraulic motors can be Safety valve (5)
piped to run backwards so always check
for the correct direction of rotation on 6. Pressure Gauge
initial start-up.
The pump MUST be fitted with a pressure
gauge so operators know what the system
pressure is. It is good practice to always fit
one to the pump head so pressure at the
pump is known. If using very long/small
high-pressure hoses, the pressure at the
end of that line will be less than pump
pressure so it is important to know what
the pump pressure is. Hughes Pumps
always supply bareshaft pumps with
pressure gauges fitted.
7. Off-load Starting 10. Shutdown Protection

There must be a high-pressure valve in The pump MUST be fitted with the
the discharge line that allows the pump to following shutdown protection devices for
be started off-load. This can be a manual any warranty to be valid :
or pneumatic valve & can be supplied by
Hughes Pumps Ltd. Failure to start the • Boost (inlet water) pressure switch
pump off-load can cause extreme • Oil temperature switch
overloading/damage to the pump including • Oil pressure switch
bearing or crankshaft failure.
These devices are relatively low in cost,
are available from Hughes Pumps & will
8. Pressure Control protect the pump from serious damage in
the event of a fault.
Although not essential, a pressure control
valve makes the pump easier to use, is
more flexible & provides additional safety. 11. Boost Pump & Filtration
Whether pneumatically or manually
controlled, this valve is a by-pass valve Most Hughes high-pressure pumps (not
that will spill excess flow to waste to UHP pumps) are capable of operating
reduce the amount of flow pumped to the from a gravity feed, but supplying the
cleaning device. Pneumatic valves provide pump with a positive / boosted inlet will
fingertip control of pressure & pump provide enormous benefits. Firstly a
on/offloading. boosted pressure of 1 to 5 bar will reduce
the possibility of cavitation (see Section
5). Secondly, a positive pressure will
9. Oil Cooler Installation enable a fine filter to be fitted between the
boost pump & high-pressure pump.
Oil coolers are supplied loose with
bareshaft pumps. It is important they are The boost pump should be sized to give a
correctly installed with the oil flow passing minimum of 1 bar at the lowest operating
in the opposite direction to water flow. speed, for example, tick over speed on an
engine. This allows the boost pressure
Oil flow out of oil pump. Oil flow return to pump switch to be set to operate at 0.5 bar.
Hughes Pumps use centrifugal pumps as
boost pumps which are belt driven from an
engine or with a separate electric or
hydraulic motor.

A high capacity filter housing should be

used with a 50 / 100-micron replaceable
element. Water filtration is often a
compromise between providing the best
pump protection & frequency of filter
element changes. A 50-micron element
will provide better pump protection but will
require changing more often than a 100-
water flow micron element.
oil flow

Water flow in Water flow out

 13. Pulsation Damper

Although not essential, a pulsation

damper will make the pump & system run
much smoother, particularly when large
plungers are fitted, which will reduce
vibration, noise & wear & tear.

14. Discharge Pipework

The high-pressure hose used with any

pump must have a safe working pressure
that exceeds the pump working pressure
& should have a 2.5:1 safety margin. All
hoses should be pressure tested & re-
Water filter housing Boost pump certified at 6-month intervals.

Pressure loss needs to be considered, the

12. Suction Pipework smaller & longer the hose is, the greater
the pressure loss. Hughes Pumps can
Suction pipework should be as large supply an excel pressure loss calculator to
(within reason), short & straight as give precise figures. To check the
possible. Optimum flow velocity in suction pressure loss of any existing system, run
pipework is 0.5 to 1.0m/sec. As an the pump set with an open-ended high-
example, to stay under 1.0m/sec the pressure hose, with all pump flow passing
following hose sizes should be used for through it at maximum pump speed.
various standard pump flowrates : Measure what the pump head mounted
pressure gauge is reading – this is the
Pump Flow Line Size pressure loss. The pressure at the end of
Lpm Inch the open ended high pressure hose will be
zero but the pump gauge could be reading
30 1" 100 bar for example. This is the pressure
45 1 1/4" required to force that amount of flow
66 1 1/2" through that particular hose.
120 2"
It is not practical or necessary to eliminate
190 2 1/2"
all pressure loss otherwise the size &
270 3" weight of the hose would become too
480 4" great. How much pressure loss is
760 5" acceptable often depends on balancing
the weight / cost of the hose & whether
Note: The line size may be a different size the pressure that exists at the cleaning
to the inlet port in the pump. Care and device (after pressure loss) is adequately
planning must be used especially if cleaning. If in doubt consult Hughes
different plunger kits are to be used. Pumps.
Consult Hughes Pumps for advice.
15. Accessories
Hughes pumps can supply a wide
selection of nozzles, lances, guns,
peddles and PPE equipment
Recommended Fluid Properties
For optimum service life, Hughes Pump recommends water quality meets the below
specification:

Hard Particle size not to exceed the microns size in Table 1

Total suspended solids not to exceed 50 PPM
pH maintained between 5-9
Viscosity not to exceed 500cP (2500 SSU).
Minimum water temperature is 1°C.
Maximum Water temperature is 40°C with an oil cooler and 55°C with offline cooling.

Pumping liquids with suspended solids are not recommended. Solids can become trapped
in valves and seal. Extra Pre-filters and tanks can help with dirty water conditions. See
Table 1 for recommend filter sizes. When adding pre-filters, add the extra filter upstream of
the recommended filter and use a larger filter size to give progressive filtration. i.e. if using a
10um pre-filter, add a 50um before it. If more filtration is required, a 100um filter can be
added before the 50um

Pressure
Pre Filter um Main Filter um
BAR
3000 10 1
1400 50 25
1000 100 50
400 200 100
250 500 200
Table 1, filter micron size

UHP Pumps can only be used with potable (tap) water unless specifically guided by Hughes
Pumps

Pumping water that is lower in temperature than the atmospheric temperature can cause
condensation at the back of the plunger and on the crosshead. If this freezes, the ice will
possibly damage the oil seals and low-pressure seals.

The maximum Water temperature is 40°C when using an oil cooler and 55°C with offline
cooling. Pumping water at higher temperatures will increase the risk of cavitation and cause
premature wear as the water will be closer to its vapour point.

NOTE: different liquids have different vapour points!

Hughes Pumps recommends that the liquid being pumped be within a range of 5 to 9 (7 pH
is water). Liquids rated above or below this PH may require extra engineering. Hughes
Pumps can provide different seals and metallic parts to meet a range of requirements.
 THIS FORM MUST BE COMPLETED & RETURNED TO HUGHES
PUMPS BEFORE THE PUMP IS STARTED, FOR WARRANTY
VALIDITY TO BE REVIEWED/APPROVED BY HUGHES PUMPS
Bareshaft Pump Commissioning Check List

Description Comments / Readings OK

Hughes
delete as
necessary

Main details
1 Client -
2 Sales order no. -
3 Reference -
4 Pump model (nameplate) -
5 Pump build no. (nameplate) -
6 Input speed (nameplate) -
7 Gearbox ratio (nameplate) -
8 Pump speed (nameplate) -
9 Pump performance (nameplate) -
10 Crankcase serial no. -
11 Pumphead serial no. -

General installation
12 Position Y/N
13 Ambient temp Y/N
14 Adequate cooling Y/N

Prime mover
15 Prime mover model no. Y/N
16 Prime mover power/speed (check max rpm with pump nameplate) Y/N
17 Direction of rotation (when looking at pump input shaft) Y/N

Pump installation
18 SAE housing fitted Y/N
19 Type of drive coupling Y/N
20 Coupling guard fitted Y/N
21 Pump alignment Y/N
22 Pump support Y/N
23 Rigidity of skid Y/N
24 Pump oil level Y/N
25 Pump inclination angle (cannot exceed 7° along axis of crankshaft) Y/N

Suction line
26 Suction hose dia/length Y/N
27 Suction hose material Y/N

2.Bareshaft Pump Installation check list.doc

28 Suction lift/check valve fitted Y/N
29 Boost pump type Y/N
30 Boost pressure, idle speed Y/N
31 Boost pressure, full speed Y/N
32 Bleed facility Y/N
33 Filter type/micron rating Y/N
34 Water supply/quality Y/N
35 Drain facility for system Y/N
36 Check for leaks (connectors must be air tight) Y/N

Oil cooling
37 Oil cooler fitted/correctly Y/N
38 Oil cooler pipework Y/N

High pressure system Y/N

39 Safety valve type/setting Y/N
40 Pressure gauge Y/N
41 Off load starting facility Y/N
42 Pressure adjusting valve Y/N
43 Pulsation damper fitted Y/N
44 HP pipework dia/length Y/N
45 Pressure loss at full speed Y/N

Shutdown protection
46 Oil temperature switch Y/N type setting ˚C Y/N
47 Oil pressure switch Y/N type setting bar Y/N
48 Boost pressure switch Y/N type setting bar Y/N
49 All functioning ok Y/N

Client/Installers Comments
Provide photos where necessary

Inspection carried out by

Date

2.Bareshaft Pump Installation check list.doc

Hughes Pumps Comments

Conclusion

Based on the information Signed

provided above, assumed to be
correct, installation is *approved / Name
not approved by Hughes Pumps.
Date
*delete as appropriate

In the event of any warranty claim, Hughes Pumps may request to inspect the
installation, or request further information/photographs of any element of the
installation potentially associated with the claim.

2.Bareshaft Pump Installation check list.doc

Section 5 – Avoidance of Cavitation

Avoidance of Cavitation

High pressure pumps must be fed with

water correctly. A lack of water supply or
an air leak in the suction line will cause
the pump to cavitate.

Hughes range of pumps have proven to

be more tolerant to cavitation than most
but even so it should be avoided at all
costs.

Cavitation is the formation of vapour

bubbles in the inlet water, formed when
there are restrictions in the supply line, for
example by a blocked water filter which
reduces the supply pressure below
atmospheric. Refer to the following
drawings

Ways To Avoid Cavitation

If the pump is not being fed with sufficient

water or the suction hose is too small,
negative pressure is created in the suction
line. Any loose fitting or clamp will allow
air to be drawn in (known as air
entrainment) which will cause cavitation.
This type of leak is not always visible so it
is important to regularly check that all
connectors in the suction line are tight.

Ensure the system is correctly primed

before start up by bleeding air from the
system.

Early cavitation pitting to a plunger

PART. No. DO NOT SCALE IF IN DOUBT ASK REMOVE ALL BURRS & SHARP EDGES
SK1733
REF. No. Ceramic Plunger Inlet Valve Outlet Valve
Open on 'Suction' stroke Closed on 'Suction' stroke
Vapour bubble

i
)_
/

/ /
///

/:
I
Inlet Manifold
Pump on Suction Stroke:
I
As the plunger moves, pressure inside the cylinder reduces, the Inlet I
Valve opens against the spring and seawater enters. I
I
The reduction in pressure can cause vapour bubbles to form on the I
I
surface of the pump components unless there is sufficient inlet
pressure from the boost pump. r
™ water at High Pressure ISS. DATE REVISIONS T.C.N.

l�/41 water at Low Pressure DRAWN ON

SHEET SIZE �, IHIUGIHIES
�.ii/PUMPS LIMITED

FIRST ASSEMBLY USED ON: ANGLE PROJECTION

A3 High & Ultra High Pressure Technology

UNLESS OTHERWISE STATED: ALL DIMENSIONS IN TITLE MATERIAL & SPECIFICATION THIS DRAWING IS THE PROPERTYOF HUGHES DRAWN GMD DRG. No. ISSUE
MILLIMETERS. WHOLE AND DECIMAL DIMENSIONS± 0.25 0.00
SUCTION STROKE
SKI 733
PUMPS LIMITED AND MAYNOT BE COPIED NOR
± 0.125 ANGULAR± 30'
METRIC THREADS TO BS 3643 B.S.P. THREADS TO BS 21
UNIT
------------+T_ R_EA
_ _T _M_E _N
USED NOR DISCLOSED TO A THIRD PARTYFOR
ANYPURPOSE OTHER THAN THAT FOR WHICH IT
_T___T"F-I N_ I S_ H_ ____---tIS
CHECKED
APPROVED
1
SURFACE FINISH TO BS 1134 1- SUPPLIED, WITHOUT THE EXPRESS WRITTEN
GENERAL DRAWING PRACTICE TO BS 308
NONE NONE AUTHORITYOF HUGHESPUMPS LIMITED 2012©
DATE 08.03.12 SCALE NIA
PART. No. DO NOT SCALE IF IN DOUBT ASK REMOVE ALL BURRS & SHARP EDGES
SK1734 Vapour bubble implodes creating a jet of water that
causes impact damage to the surface of the pump
REF. No.
Ceramic Plunger Inlet Valve Outlet Valve
Closed on 'Discharge' stroke Open on 'Discharge' stroke
Vapour bubble

I
I-

Inlet Manifold
Pump on Discharge Stroke:

As the plunger moves, pressure inside the cylinder increases, closing

the Inlet Valve and opening the Outlet Valve.

The vapour bubbles reduce in size and start to implode rapidly. As

they implode, a jet of water is generated that impacts against the
surface of the pump.
ISS. DATE REVISIONS T.C.N.

� water at High Pressure

l�I water at Low Pressure
DRAWN ON
SHEET SIZE �,
�..ii IHIUGIHIES
PUMPS LIMITED

FIRST ASSEMBLY USED ON: ANGLE PROJECTION

A3 High & Ultra High Pressure Technology

UNLESS OTHERWISE STATED: ALL DIMENSIONS IN TITLE MAT ERIAL & SPECIFICAT ION THIS DRAWING IS THE PROPERTYOF HUGHES DRAWN GMD DRG. No. ISSUE
MILLIMETERS. WHOLE AND DECIMAL DIMENSIONS± 0.25 0.00
DISCHARGE STROKE
SKI 734
PUMPS LIMITED AND MAYNOT BE COPIED NOR
± 0.125 ANGULAR± 30'
METRIC THREADS TO BS 3643 B.S.P. THREADS TO BS 21
UNIT
-----------+T_ R_ E_ A_T _ E
M
USED NOR DISCLOSED TO A THIRD PARTYFOR
ANYPURPOSE OTHER THAN THAT FOR WHICH IT
_ _IS_H____--tIS
_ -NT___"T'""FI N
CHECKED
APPROVED
1
SURFACE FINISH TO BS 1134 1-- SUPPLIED, WITHOUT THE EXPRESS WRITTEN
GENERAL DRAWING PRACTICE TO BS 308
NONE NONE AUTHORITYOF HUGHESPUMPS LIMITED 2012©
DAT E 08.03.12 SCALE NIA
Recommended Fluid Properties
For optimum service life, Hughes Pump recommends water quality meets the below
specification:

Hard Particle size not to exceed the microns size in Table 1

Total suspended solids not to exceed 50 PPM
pH maintained between 5-9
Viscosity not to exceed 500cP (2500 SSU).
Minimum water temperature is 1°C.
Maximum Water temperature is 40°C with an oil cooler and 55°C with offline cooling.

Pumping liquids with suspended solids are not recommended. Solids can become trapped
in valves and seal. Extra Pre-filters and tanks can help with dirty water conditions. See
Table 1 for recommend filter sizes. When adding pre-filters, add the extra filter upstream of
the recommended filter and use a larger filter size to give progressive filtration. i.e. if using a
10um pre-filter, add a 50um before it. If more filtration is required, a 100um filter can be
added before the 50um

Pressure
Pre Filter um Main Filter um
BAR
3000 10 1
1400 50 25
1000 100 50
400 200 100
250 500 200
Table 1, filter micron size

UHP Pumps can only be used with potable (tap) water unless specifically guided by Hughes
Pumps

Pumping water that is lower in temperature than the atmospheric temperature can cause
condensation at the back of the plunger and on the crosshead. If this freezes, the ice will
possibly damage the oil seals and low-pressure seals.

The maximum Water temperature is 40°C when using an oil cooler and 55°C with offline
cooling. Pumping water at higher temperatures will increase the risk of cavitation and cause
premature wear as the water will be closer to its vapour point.

NOTE: different liquids have different vapour points!

Hughes Pumps recommends that the liquid being pumped be within a range of 5 to 9 (7 pH
is water). Liquids rated above or below this PH may require extra engineering. Hughes
Pumps can provide different seals and metallic parts to meet a range of requirements.
PART. No. DO NOT SCALE IF IN DOUBT ASK REMOVE ALL BURRS & SHARP EDGES
1345 REQUIREMENTS FOR WATER TANKS TANK FILLER BREATHER, MUST ALLOW SUITABLE
AIR FLOW AND STOP THE INGRESS OF DIRT,
REF. No. - IT CAN ALSO BE USED TO APPLY ANTIFREEZE
OR INHIBITOR INTO THE SYSTEM.
FOR HIGH FLOW PUMPS SNORKELS ARE ACCEPTABLE
LID MUST BE SECURELY FASTENED
AND STOP THE INGRESS OF DIRT. A-A ( 1 : 14 )

OVERFLOW OTHER RETURN FEEDS TO TANK

I.E. UNLOADER VALVE, PRESSURE
A

AIR GAP 100mm

REGULATOR OR SAFETY VALVE

1" HIGH FLOW

STOPCOCK

VOLUME !
USEABLE
PUMP FEED TO BE
20mm MIN OFF THE
TANK BOTTOM TO
STOP DEBRIS BEING
DRAWN INTO THE
BAFFLE CUT OUT ON
PUMP
THE OPPOSITE END
TO THE INLET FEED.
SIGHT LEVEL GAUGE ENSURE THE HOLE
PRE-FILTER
OR TRANSMITTER CAN IS BIG ENOUGH TO
SEE TABLE FOR
BE USED NOT RESTRICTED
TABLE 1 MICRON RATING
Pump Flow THE FLOW!
Line Size
TANKS ARE REQUIRED AS THEY PROTECT AGAINST THE INLET SUPPLY
BECOMING INTERRUPTED, AND THEY ALSO HELP TO REMOVE ANY Lpm Inch
ENTRAINED AIR FROM THE MEDIA.

THE TANK LOCATION SHOULD BE ABOVE THE INTAKE OF THE PUMP AND
30
45
1"
1 1/4"
A
AS CLOSE AS POSSIBLE WITH A MAXIMUM LINE LENGTH OF 1.5M. THE 66 1 1/2" WATER FEED
LINE SIZE MUST BE EQUAL OR GRATER THEN THE LINE SIZE SHOWN ON 120 2" USABLE VOLUME OF THE TANK MUST BE SIZED TO 5 X THE MAXIMUM
TABLE 1 . RESTRICTIONS SUCH AS ELBOWS MUST BE KEPT TO A
190 2 1/2" CAPACITY OF THE PUMP
MINIMUM.
270 3"
DRAWINGS SHOWN ARE TYPICAL DESIGNS FOR HUGHES PUMPS SYSTEM
IF A BOOST PUMP IS USED, THE LINE LENGTH CAN BE INCREASED BUT 480 4" REQUIREMENTS, AND CAN BEE SEEN AS A BASIC MINIMUM.
THE LINE SIZE MUST REMAIN THE SAME. BOOST PUMPS MUST BE FITTED
ON ALL PUMPS OPERATING OVER 1000 BAR OR OVER 100 LPM 760 5"
ACCELERATED HEAD CALCULATIONS CAN BE COMPLETED ON REQUEST.

HUGHES PUMPS CAN NOT BE HELD RESPONSIBLE FOR DAMAGE CAUSED

TO PUMPS BY INADEQUATE WATER FEED CONDITIONS.
THE BAFFLE MUST SEPARATE ALL
FEEDS INTO THE TANK FROM IF IN DOUBT ASK
THE PUMP SUPPLY TO STOP ANY
ENTRAINED AIR FROM BEING
DRAWN IN BY THE PUMP

PUMP FEED

PRE-FILTER MICRON RATING MAIN PUMP FILTER MICRON RATING

Pressure BAR Main Filter um Pressure BAR Main Filter um
ISS. DATE REVISIONS T.C.N.

{ {
3000 10 3000 1
MANDATORY 1400 50 1400 25
1000 100 1000 50
400 200 400 100 DRAWN ON
250 250 250 200 SHEET SIZE
PUMPS LIMITED

- FIRST ANGLE PROJECTION

A3 High & Ultra High Pressure Technology
FIRST ASSEMBLY USED ON: SHEET 1 of 1 Washington W. Sussex RH20 3BS U.K. Tel.+44 (0) 1903 892358 Fax.+44 (0) 1903 892062 E.mail www.hughes-pumps.co.uk

UNLESS OTHERWISE STATED : ALL DIMENSIONS IN TITLE MATERIAL & SPECIFICATION THIS DRAWING IS THE PROPERTY OF HUGHES DRAWN EH DRG. No. ISSUE
MILLIMETERS. WHOLE AND DECIMAL DIMENSIONS ± 0.25 0.00
GAD - PUMPS LIMITED AND MAY NOT BE COPIED NOR
± 0.125 ANGULAR ± 30' CHECKED
METRIC THREADS TO BS 3643 B.S.P. THREADS TO BS 21
UNIT TREATMENT FINISH
USED NOR DISCLOSED TO A THIRD PARTY FOR
ANY PURPOSE OTHER THAN THAT FOR WHICH IT IS
APPROVED
1345 1

SURFACE FINISH TO BS 1134 SUPPLIED, WITHOUT THE EXPRESS WRITTEN

GENERAL DRAWING PRACTICE TO BS 8888 AUTHORITY OF HUGHES PUMPS LIMITED 2020 ã
41561 - - DATE 11/10/2017 SCALE 1 : 14
Quick Start Guide
These instructions are general & apply to all pump sets.

All operators must be trained in the correct/safe operating of this equipment and must have read
& fully understand the operating & maintenance manual.

This document is to be used as a reminder of the daily checks and start-up / shut down procedures
and does not replace the manual!

DAILY CHECKS
Check the pump oil level using the Dip Stick at the back of the pump if required use API GL 5
80W-90
Check engine oil using dipstick
Check engine coolant level,
Check fuel tank is filled with clean, uncontaminated diesel.

PRE-START CHECKS
Ensure that the high-pressure pump unit is in a suitable location relative to the proposed
area for water jetting.
Ensure the pump unit is on a level ground
Check the condition of the water filter element and change it if necessary. The filter
elements must be changed at regular intervals to ensure the pump is not starved of water.
Ensure the system is not frozen
Check all drain valves are closed
Check suction line for damage and flush thoroughly
Connect water feeds to the water supply tank
Check that all high-pressure accessories and hoses are rated to 3000 bar or greater
Connect a high-pressure hose to the outlet of the pump with a wip check
Check all high-pressure connections are tight

DO NOT connect any high-pressure accessories to the high-pressure hose at this stage.

Open all isolation valves to the feed tank supply

Check all feed and return lines for leaks
Close the battery isolator
Turn the key to power on the panel,

MIN RPM 1400

MAX RPM 1710

MAX PRESSURE 500 BAR

Page 1 of 2 R1.0
PRIMING THE PUMP SET
Open vent valve on top of the main filter housing to the pump
Start the engine & allow the engine to idle/warm-up for a few minutes.
During this time note the flow of water coming out the filter bleed, the stream should
become steady and long.
Close the filter bleed valve
If the engine stops after 10-20 seconds, low boost pressure will be the likely cause. If so,
restart the engine as above & immediately increase engine speed to 1200 rpm and
open the vent valve on top of the filter.
If the problem persists check/change the water filter element

RUNNING
With an operator correctly handling the high-pressure accessory, or with the high-pressure
accessory correctly fastened to its operating apparatus.
Check the pump is offloaded and press the “Start” button on the control panel
Load / pressurise the pump by using the accessory fitted to the pump.
Control the pressure with the engine RPM,

WHEN RUNNING
Regularly monitor the pump set, specifically boost pressure, the stability of boost pressure,
and discharge pressure & for pulsing of low & high-pressure hoses
If any unusual conditions are encountered, immediately shut the pump down

SHUTDOWN
Unload the pump
Turn the key off
At the end of a shift, drain all water from the pump & system
In freezing conditions, the pump set must be protected by filling the water system with anti-
freeze from the suction line, through to the end of the high-pressure hose.

MIN RPM 1400

MAX RPM 1710

MAX PRESSURE 500 BAR

Page 2 of 2 R1.0
Anti-freeze and long term storage procedure

This document is intended to guide the operator in the correct method of anti-freezing and
corrosion inhibiting the pump and complete system.
If a pump set is to be de-commissioned for any length of time, or exposed to sub-zero
conditions, the system must be suitably protected from internal damage by water residue
left in the system.
Local restrictions must be checked for the type of antifreeze and/or corrosion inhibitor that
may be prohibited and any special considerations for the handling, use and storage of these
types of chemicals.
Compatibility with the pump and system must be checked before use, if in doubt ask.

Procedure
Drain the water tank until the level is near the bottom of the level gauge on the tank
(roughly 25mm)
Remove the filler/breather cap from the tank, and add neat antifreeze or inhibitor until the
water visibly changes colour, do not add more than 50% of the contents of the water, ie if
the level is 25mm from the bottom of the gauge, do not allow the level to get more the
50mm!
Fit a hose to the discharge of the pump, WITHOUT any accessories fitted, and place the hose
in the tank, use a wip check or similar to secure the hose in the tank.
Operate the pump and wait for a few seconds to allow the mix to fully flush the system.
Stop the pump and remove the hose, NOTE, the hose will now have antifreeze or inhibitor in
it, dispose of the contents in a suitable container.
The pre-filter will not be protected, drain the housing completely using the fitted valve,
remove the bowl to remove any residual water and re-assemble.

Long term storage

If the system is to be decommissioned for a period of time longer than 1 month, fully drain
every part of the system using the valves fitted to the main pump, boost pump, oil cooler
and filter housings.
For extended storage, ensure the pump set is kept dry, away from damp and moisture.
if the storage location is offshore/damp, fill the crankcase with oil and spray all exposed
plain metal surfaces with a heavy rust inhibitor (Rocal Z30 or similar).
For storage longer than 6 months it is recommended that the pumps are turned over by
hand to stop the bearings and pack bedding in.

Re-commission
If full of fluids, fully drain the system ensuring everything is captured in a suitable container.
Check the filters and change if required, (for long-term storage, change the filters anyway).
Go through the normal pre-start checks, if the crankcase has been filled for storage this will
need to be drained and filled with fresh oil to the correct level.

Page 1 of 1 R 1.0
 Date: 16/07/2024

Time: 12:30:24

BOM 51852-824-1437

Description HP65, OPEN DIESEL UNIT, DS-B

Sequence Product Code Description Quantity UOM

1.00 PUMP-ASSEMBLY 0.00

2.00 6C622-225A3 HP65/P25/2.2:1/SAE3 1.00 Each

3.00 21681-085 OIL COOLER 2" BSP 1.00 Each

4.00 44211-056 OIL COOLER ASSEMBLY 3/8" TO 1" COOLER 1.00 Each

6.00 PUMP-CONTROLS 0.00

7.00 45616-007 BURST DISC HOLDER ASSY 1/2 BSP (1/2" FPB) 1.00 Each

8.00 25213-369 COPPER WASHER 1/2" 2.00 Each

12.00 DRIVE-COUPLING 0.00

13.00 23358-117 COUPLING ASSEMBLY 1.00 Each

16.00 HEADER-TANK-ASSY 0.00

17.00 45647-407 WATER TANK PLASTIC 210 LTR BLUE 1.00 Each

20.00 FILTRATION 0.00

22.00 21571-656 50 MICRON FILTER BAG FOR FILTER PC50060 1.00 Each

24.00 PC50060 FILTER HOUSING Big Blue 10", 1½", for Filter bags 1.00 Each

26.00 21571-440 BOWL REMOVAL SPANNER - SW3 (21571-326) 1.00 Each

27.00 LP-PIPE-WORK 0.00

28.00 48615-1017 LOW PRESSURE FITTINGS 1" FEED TO TANK THROUGH COOLER 1.00 Each

30.00 48615-1013 LOW PRESSURE FITTINGS OVER FLOW AND DRAIN 3/4" & 1/2" E TYPE 1.00 Each

30.10 48615-973 WATER TANK TO PUMP FEED HPS 650 DIRECT 1.00 Each

32.00 DIESEL-ENGINE-ASSY 0.00

33.00 22651-168 JCB ST3A IPU 63KW 1.00 Each

34.00 47514-320 BATTERY CABLES FOR JCB 444 95mm2 12V 1.00 Each

37.00 24331-117 VERNIER THROTTLE CABLE, 2.2m LONG 1.00 Each

38.00 24331-102 VERNIER CONTROL 1.00 Each

39.00 32535-111 THROTTLE CABLE PIN 1.00 Each

15.00 25732-311 M10 X 25 SHCS 12.9HT BZP 20.00 Each

43.00 FUEL-TANK-ASSY 0.00

44.00 45647-410 FUEL TANK 122 LTR PLASTIC BLACK 1.00 Each

50.00 48615-1018 FUEL FITTINGS JCB 444 1.00 Each

51.00 EXHAUST-ASSY 0.00

52.00 21751-292 2 1/2" EXHAUST SILENCER CARBON/ST S150 1.00 Each

52.10 21751-276 UBC S150 EXHAUST SILENCER / SPARK ARRESTOR CLAMP 2.00 Each

52.20 21751-277 2 1/2" EXHAUST RAIN CAP ST/ST 1.00 Each

52.30 21751-279 2 1/2" OD PIPE CLAMP 2.00 Each

52.40 21751-297 2 1/2" EXHAUST SYSTEM JCB 444 1.00 Each

53.00 CONTROL-PANEL-ASSY 0.00

Page 1 of 2
 Date: 16/07/2024

Time: 12:30:24

BOM 51852-824-1437

Description HP65, OPEN DIESEL UNIT, DS-B

Sequence Product Code Description Quantity UOM

54.00 22659-210 CONTROL PANEL JCB 444 ST3A 1.00 Each

55.00 26411-167 BOBBIN TYPE AVM, M8 MxM 4.00 Each

56.00 SHUTDOWNS 0.00

58.00 24135-051 LEVEL SWITCH 3/4" BSPP, WITH CABLE 1.00 Each

59.00 24135-022 TEMPERATURE SWITCH 70 Deg C 3/8" BSP(M) 1.00 Each

60.00 23161-068 3/8" BSP BONDED SEAL ST/ST 1.00 Each

62.00 CHASSIS 0.00

63.00 41440-0042 JCB 444 OPEN FRAME TYPE E 1.00 Each

64.00 26411-150 ANTI VIBRATION MOUNT 4.00 Each

74.00 LABF-MINS RECOVERY IN MINUTES - FITTING 4,800.00 MINUTES

76.00 TESTING 0.00

77.00 MISCELLANEOUS 0.00

78.00 17213-034 GEAR OIL SHELL SPIRAX S2 A 80W/90 3.00 LITRE

79.00 17213-041 SHELL RIMULA RT4 15W/40 7.00 LITRE

80.00 17500-001 ANTI FREEZE 8.00 LITRE

81.00 38118-315 UNIT LABEL 1.00 Each

82.00 38118-156 WARNING LABEL 1.00 Each

85.00 38118-335 ADHESIVE LABEL, HUGHES PUMPS LIMITED logo 500 x 147mm 2.00 Each

9.00 33876-324 ADAPTOR M22 x 1/2" BSP 1000bar 1.00 Each

7.10 24715-001 BURSTING DISC (9,500 PSI) (1/2" FPB) 1.00 Each

9.10 21531-115 PRESSURE GAUGE 0-14,000 PSI / 0-1000 BAR 1/2"BSPP 1.00 Each

9.20 25213-389 GAUGE WASHER 1/2" COPPER 1.00 Each

9.30 25213-317 COPPER WASHER M22 2.00 Each

9.40 31674-411 PLUG (M22 x 1.5 P) 1.00 Each

58.10 23161-071 3/4" BSP BONDED SEAL ST/ST 2.00 Each

18.00 36138-417 Ratchet Strap Stainless Steel 25mm wide 4M 4.00 Each

35.00 22211-012 BATTERY 12V AMP-125 COLD CRANKING 1.00 Each

36.00 22211-014 BATTERY BOX 1.00 Each

75.00 LABT-HRS RECOVERY IN HOURS - TEST BAY 3.00 HOURS

86.00 38118-349 UNIT KEYRING 1.00 Each

87.00 25152-015 DRIVE SCREW ST/ST 4.00 Each

14.00 25632-360 3/8" 16 UNC x 1" SHCS 12.9HT 8.00 Each

88.00 25732-235 M8 x 70 SHCS ST/ST A2 6.00 Each

Page 2 of 2
PART. No. DO NOT SCALE IF IN DOUBT ASK REMOVE ALL BURRS & SHARP EDGES
1437 1803

REF. No. - FUEL TANK A ( 1 : 15 )

122 LTR

=1055=

130
16 x n11

50
A
=1290=

WATER LEVEL SWITCH

PRESSURE GAUGE
BURST DISK HOLDER
CONTROL PANEL

1872
1404
ENGINE SPEED
CONTROL

260 260

647 456 647

BATTERY PRE-FILTER PUMP DISCHARGE
50um WATER FEED 1/2" BSP
12V
1" BSP

ENGINE JCB 444 TC

PUMP BUILD 6C622-225A3
PLUNGER DIA (mm) 25
INPUT SPEED (rpm) 1710
GEARBOX RATIO 2.28 WATER TANK AVM TYPE CHANGED FROM
PUMP SPEED (rpm) 750 210 LRT 2 19/06/24 EH
BUFFER TO FIXED
FLOW (lpm) 50 ISS DATE DESCRIPTION ENG
PRESSURE (bar) 500 REVISION HISTORY
ABSORBED POWER (kW) 46
RATED POWER (kW) 48
MASS (Kg) 980 DRAWN ON
OIL TYPE API-6L-5 (80W/90) SHEET SIZE
PUMPS LIMITED
OIL QUANTITY (L) 6
FIRST ANGLE PROJECTION
A3 High & Ultra High Pressure Technology
FIRST ASSEMBLY USED ON: 44204 SHEET 1 of 1 Washington W. Sussex RH20 3BS U.K. Tel.+44 (0) 1903 892358 Fax.+44 (0) 1903 892062 E.mail www.hughes-pumps.co.uk

UNLESS OTHERWISE STATED : TITLE MATERIAL & SPECIFICATION DRG. No. ISSUE
ALL DIMENSIONS IN MILLIMETERS. THIS DRAWING IS THE PROPERTY OF HUGHES DRAWN EH
WHOLE AND DECIMAL DIMENSIONS ± 3.0 / 0.00 ± 1.0 GAD PUMP FRAME - PUMPS LIMITED AND MAY NOT BE COPIED NOR
CHECKED PC
ANGULAR ± 30'
METRIC THREADS TO BS 3643 B.S.P. THREADS TO BS 21 UNIT TREATMENT FINISH
USED NOR DISCLOSED TO A THIRD PARTY FOR
ANY PURPOSE OTHER THAN THAT FOR WHICH IT IS
APPROVED
1437 2

SURFACE FINISH TO BS 1134 SUPPLIED, WITHOUT THE EXPRESS WRITTEN

HP65 - - AUTHORITY OF HUGHES PUMPS LIMITED 2024 ã
GENERAL DRAWING PRACTICE TO BS 8888 DATE 22/04/2024 SCALE 0.03
 Date: 16/07/2024

Time: 12:31:31

BOM 6C622-225A3

Description HP65/P25/2.2:1/SAE3

Sequence Product Code Description Quantity UOM

1.00 43128-604 25mm P/KIT.OMEGAT 1.00 Each

2.00 43360-626 FL/HD ASSY, 650, BSPP 1.00 Each

3.00 47151-544 650 CRANKCASE ASSY 1.00 Each

4.00 47175-1036 G/B ASSY 2.285:1 MK5 1.00 Each

5.00 41611-517 A/HSG.ASSY.SAE3 650 1.00 Each

Page 1 of 1
 Date: 16/07/2024

Time: 12:32:47

BOM 43128-604

Description 25mm P/KIT.OMEGAT

Sequence Product Code Description Quantity UOM

1.00 5399 ADAPTOR 20-30mm 3.00 Each

2.00 6991 PRESS.CYL.25mm 500>> 3.00 Each

3.00 5926 M10 x 140 PLUNGER BOLT ST/ST HEX HEAD 3.00 Each

4.00 5703 25mm PACKING SPRING 3.00 Each

5.00 43128-604/RK 25mm x 105mm long CERAMIC PLUNGER 3.00 Each

6.00 43128-604/SK INLET SPRING 3.00 Each

7.00 5710 25mm DIA SPRING RING 3.00 Each

8.00 43128-604/SK PACKING RING 25 6.00 Each

9.00 43128-604/SK 25mm SEPARATING RING 6.00 Each

10.00 5945 GUIDE BAND HOUSING 3.00 Each

11.00 43128-604/SK 25 G/BAND x10 WIDE 3.00 Each

12.00 43128-604/SK ROD SEAL SET 25mm 3.00 Each

13.00 43128-604/SK O-RING 9.00 Each

14.00 43128-604/SK AX-RING 3.00 Each

15.00 43128-604/SK COPPER WASHER 17 x 10 x 2 3.00 Each

16.00 43128-604/RK PLUNGER DOWEL (316) 3.00 Each

17.00 43128-604/SK O-RING 3.00 Each

18.00 43128-604/SK AX-RING 3.00 Each

19.00 1015/1 PLUNGER BAFFLE 316 3.00 Each

Page 1 of 1
 Date: 16/07/2024

Time: 12:33:42

BOM 43360-626

Description FL/HD ASSY, 650, BSPP

Sequence Product Code Description Quantity UOM

1.00 6832/1 HEAD NUT M13 NiAl BRONZE 8.00 Each

2.00 23513-135 O-RING 3.00 Each

3.00 23513-135X AX-RING 3.00 Each

4.00 8209 FL/HD 650 (431/ M22 & 1/2" BSPP) 1.00 Each

5.00 6831 HEADSTUD M13 x 240 8.00 Each

6.00 5986 OUTLET SPRING 3.00 Each

7.00 5370/B OUTLET VALVE(N/AL/B) 3.00 Each

8.00 5478 VALVE CARTRIDGE(500) 3.00 Each

9.00 23513-121 O-RING 3.00 Each

10.00 23513-121X AX-RING 3.00 Each

11.00 5377/B INLET VALVE (H.P.) 3.00 Each

12.00 5368 VALVE STOP (MK3) 316 3.00 Each

13.00 23513-116 O-RING 3.00 Each

14.00 23611-892 1/4" BSPP HEX HEAD PLUG 316 3.00 Each

15.00 23611-005 1" BSPT SKT HEAD PLUG ST/ST 3.00 Each

16.00 23161-053 1/4" BSP BONDED SEAL 3.00 Each

22.00 LABF-MINS RECOVERY IN MINUTES - FITTING 45.00 MINUTES

21.00 23626-801 STEM TAILPIECE O/D12 1.00 Each

18.00 23626-737 ELBOW ADPTR.12mm x 3/8" BSP Brass 1.00 Each

19.00 23626-739 SLEEVE O/D12 1.00 Each

20.00 23626-740 TUBING NUT O/D 12 1.00 Each

Page 1 of 1
 Date: 16/07/2024

Time: 12:34:24

BOM 47151-544

Description 650 CRANKCASE ASSY

Sequence Product Code Description Quantity UOM

1.00 7295 CRANKCASE, SG.IRON, 650 1.00 Each

2.00 6635 CAP, OIL PUMP 1.00 Each

3.00 25724-082 M6 x 20 HEX SETSCREW 8.8HT STEEL BZP 4.00 Each

4.00 25218-222 M6 S/C SPRING WASHER ST/ST A2 4.00 Each

5.00 6233 BODY OIL PUMP 1.00 Each

6.00 25732-212 M8 x 45 SHCS 8.8HT BZP 4.00 Each

7.00 23583-024 MINI IMPELLER SET 1.00 Each

9.00 23317-326 ROLLER BEARING 2.00 Each

10.00 5474 500 C/SHAFT (PL/EXT) 1.00 Each

11.00 47114-124 CONNECTING ROD ASSY 650/850 PUMP 3.00 Each

13.00 21673-009 1/2" BSPT MAGNETIC PLUG 1.00 Each

14.00 23311-958 BIG END BEARING 400/650 3.00 PAIR

15.00 5927 500/850 MAIN BEARING 2.00 Each

16.00 5373 KEYPLATE 500/850 2.00 Each

17.00 47114-131 CROSSHEAD 3.00 Each

18.00 23514-529 U-SEAL 45x30 3.00 Each

19.00 25251-050 INTERNAL CIRCLIP 50mm 3.00 Each

20.00 21573-008 FILLER BREATHER 1" BSP 1.00 Each

21.00 23513-123 O-RING 1.00 Each

22.00 43312-129 650 DIPSTICK (MOULDED) 1.00 Each

23.00 23513-108 O-RING 1.00 Each

24.00 5929 500 MK5 B/HOUSING 1.00 Each

25.00 25732-169 M8 x 20 SHCS 10.9HT BZP 4.00 Each

26.00 25152-015 DRIVE SCREW ST/ST 4.00 Each

27.00 23611-002 1/4" BSPT SKT HEAD PLUG 3.00 Each

28.00 23513-240 O-RING 2.00 Each

29.00 23513-041 O-RING 1.00 Each

30.00 23513-113 O-RING 1.00 Each

31.00 5994 KEY 10 x 8 x 50 1.00 Each

32.00 5646 SEAL HOUSING GACO 3.00 Each

34.00 6674 CRANKSHAFT DRIVE PLUG 1.00 Each

35.00 6932 CORE PLUG 650 1.00 Each

36.00 23611-003 3/8" BSPT SKT HEAD PLUG 1.00 Each

37.00 8709 FINGER GUARD PLATE HPS650 1.00 Each

39.00 17213-034 GEAR OIL SHELL SPIRAX S2 A 80W/90 4.00 LITRE

40.00 7047 HUGHES PUMP LABEL 1.00 Each

Page 1 of 2
 Date: 16/07/2024

Time: 12:34:24

BOM 47151-544

Description 650 CRANKCASE ASSY

Sequence Product Code Description Quantity UOM

41.00 SK1166 OIL DASHPOT 1.00 Each

42.00 38118-336 OIL WARNING LABEL 1.00 Each

43.00 8029 RETAINED CROSSHEAD PIN 650/850 3.00 Each

44.00 25255-212 SPIRAL RETAINING RING 6.00 Each

45.00 23612-461 3/8" BSPP X BSPT M/M ADAPTOR 2.00 Each

46.00 LABF-MINS RECOVERY IN MINUTES - FITTING 180.00 MINUTES

Page 2 of 2
 Date: 16/07/2024

Time: 12:35:10

BOM 47175-1036

Description G/B ASSY 2.285:1 MK5

Sequence Product Code Description Quantity UOM

10.00 21673-009 1/2" BSPT MAGNETIC PLUG 1.00 Each

20.00 5610 650 GEARBOX HOUSING 1.00 Each

30.00 25732-169 M8 x 20 SHCS 10.9HT BZP 8.00 Each

40.00 7322 GEAR 48T - 650/850 MK5 1.00 Each

50.00 25714-309 M8 x 10 GRUB SCREW STEEL 2.00 Each

60.00 23317-733 NEEDLE BEARING 1.00 Each

70.00 7323 PINION 21T - 650/850 MK5 1.00 Each

80.00 23314-276 BEARING 1.00 Each

90.00 23515-117 OIL SEAL 1.00 Each

100.00 25311-549 8mm DIA x 20mm DOWEL, H&G STEEL 2.00 Each

110.00 6011 KEY 8 x 7 x 50 1.00 Each

120.00 23513-115 O-RING 2.00 Each

130.00 23513-110 O-RING 1.00 Each

Page 1 of 1
 Date: 16/07/2024

Time: 12:35:58

BOM 41611-517

Description A/HSG.ASSY.SAE3 650

Sequence Product Code Description Quantity UOM

10.00 5223 ADAPTOR HOUSING SAE3 1.00 Each

20.00 6594 SLEEVE MK3 G/B 2.00 Each

30.00 6595 STABILISER STUD 2.00 Each

40.00 25781-165 M8 HEX FULL NUT ST/ST A2 2.00 Each

50.00 25727-025 M8 x 25 HEX SETSCREW 8.8HT STEEL BZP 10.00 Each

60.00 25218-402 M8 S/C SPRING WASHER ST/ST A2 12.00 Each

Page 1 of 1
PART. No. DO NOT SCALE IF IN DOUBT ASK REMOVE ALL BURRS & SHARP EDGES
45616-007
REF. No. 45616-003

2
A-A ( 1 : 1 ) A

1 A

PARTS LIST
ITEM QTY PART NUMBER DESCRIPTION
1 1 8433 BODY
2 1 5839 R1 RETAINER
3 1 5840 R1 COLLAR
ISS. DATE REVISIONS T.C.N.

DRAWN ON
1/2" BSPP BOTTOM SEALING SHEET SIZE
PUMPS LIMITED
1/2" RUPTURE DISK
FIRST ASSEMBLY USED ON: 1276 FIRST ANGLE PROJECTION
A3 High & Ultra High Pressure Technology
Washington W. Sussex RH20 3BS U.K. Tel.+44 (0) 1903 892358 Fax.+44 (0) 1903 892062 E.mail www.hughes-pumps.co.uk

UNLESS OTHERWISE STATED : ALL DIMENSIONS IN TITLE MATERIAL & SPECIFICATION THIS DRAWING IS THE PROPERTY OF HUGHES DRAWN EH DRG. No. ISSUE
MILLIMETERS. WHOLE AND DECIMAL DIMENSIONS ± 0.25 0.00
B/DISC HOLDER ASSY - PUMPS LIMITED AND MAY NOT BE COPIED NOR
± 0.125 ANGULAR ± 30'
METRIC THREADS TO BS 3643 B.S.P. THREADS TO BS 21
USED NOR DISCLOSED TO A THIRD PARTY FOR
ANY PURPOSE OTHER THAN THAT FOR WHICH IT IS
CHECKED
45616-007 1
SURFACE FINISH TO BS 1134 UNIT TREATMENT FINISH SUPPLIED, WITHOUT THE EXPRESS WRITTEN APPROVED
GENERAL DRAWING PRACTICE TO BS 8888
1276 - - AUTHORITY OF HUGHES PUMPS LIMITED 2017 ã
DATE 10/11/17 SCALE 1:1
 JCB 444 DIESELMAX UN III 63kW (84hp) IPU Engine

FUEL SYSTEM MODEL DATA

Injection System Mechanical Certification Model TC-63
Brake Specific Fuel Consumption (BSFC) @ Full Load Rated Speed (FLRS) g / kW / hr 248 Gross Rated Power kW (hp) 63 (84)
BSFC @ Peak Torque g / kW / hr 227 Emissions Level UN III (Stage IIIA / Tier 3 Equivalent)
Max. Fuel Inlet Temperature Measured Before Engine Mounted Fuel Filter. °C (°F) 80 (176) Rated Speed rpm 2200
Max. Fuel System Back Pressure Measured at Engine Spill Line Outlet From Engine kPa (PSI) 8 (1.16) Peak Torque Nm (lbf-ft) 362 (267)
Max. Fuel Inlet Depression Measured at Inlet to Fuel Lift Pump kPa (PSI) 10 (1.5) Peak Torque Speed rpm 1200
Nominal Fuel Inlet Flow to Pump @ FLRS litre/h (gal/h) - Nominal Displacement litres 4.4
Heat Rejection to Returned Fuel kW (hp) - Idle Speed (With engine at normal operating temperature) rpm 900
Nominal Fuel Return Flow to Tank @FLRS litre/h (gal/h) - Max. No Load Governed Speed rpm 2420
Engine Fuel Pre Filter micron 20 Dimensions (L x W x H) (Engine Only) mm (in) 814(32) x 591(23.3) x 879(34.6)
Engine Fuel Main Filter micron 7 Bore mm (in) 103 (4.06)
Stroke mm (in) 132 (5.20)

ENGINE LUBRICATION
Engine Oil Pressure @ FLRS kPa (PSI) 490 (71.1)
Max. Continuous Oil Temperature °C (°f) 125 (257)
Max. Intermittent Oil Temperature °C (°f) 135 (275)
Oil Capacity litres (gals) 14 (3.1)
Oil SAE Classification (as supplied from factory) SAE 10W40
Min. Required Oil Grade API CH4

POWER & TORQUE

Speed (r/min) 1000 1100 1200 1300 1400 1600 1800 2000 2200
Power (kW) 36.9 41.5 45.5 49.1 52.5 57.6 61.3 62.8 63.0

Power (hp) 49 56 61 66 70 77 82 84 84

Torque (Nm) 352 360 362 361 358 344 325 300 274

Engine Technical Data

 JCB 444 DIESELMAX UN III 63kW (84hp) IPU Engine

ENGINE BREATHING ENGINE COOLING

Max. Rise Over Ambient at Inlet to Turbocharger °C (°F) 20 (36) Heat to Coolant @ Rated Condition, 25°c Ambient kW (hp) thermal 46.4 (62.2)
Max. Induction Depression @ FLRS, Clean Filter kPa (PSI) 5 (0.73) Heat to Coolant @ Peak Torque, 25°c Ambient kW (hp) thermal -
Min. Induction Depression @ FLRS, Clean Filter kPa (PSI) - Radiator Flow @ Rated Speed (cab heater off) l/min (gal/h) 240 (3167.6)
Max. Induction Depression @ FLRS, Dirty Filter kPa (PSI) 8 (1.16) Radiator Flow @ Peak Torque (cab heater off) l/min (gal/h) 162 (2138.1)
Air Requirement For Combustion / CAC Mass Flow @ FLRS, 25°c Ambient kg/h (Lb/h) 352.8 (777.8) Max. Coolant System Pressure Drop Between T.Stat Outlet and Coolant Inlet kPa (PSI) 70 (10.2)
Air Requirement For Combustion / CAC Mass Flow @ Peak Torque, 25°c Ambient kg/h (Lb/h) - Min. Coolant Fill Rate l/min (gal/h) 10 (132)
Engine Compressor Outlet Temperature @ FLRS 25°C Ambient °C (°F) 93 (199.4) Max. Coolant Temperature °C (°F) 110 (230)
Engine Compressor Outlet Temperature @ Peak Torque 25°C Ambient °C (°F) - Max. Managed Coolant Temperature °C (°F) 110 (230)
Max. Engine Compressor Outlet Temperature @ Limiting Ambient Temperature (LAT) °C (°F) - Thermostat Opening Temperature °C (°F) 88 (190.4)
Turbocharger Boost Pressure @ FLRS kPa abs (PSI abs) N/A Coolant Temperature Warning Threshold °C (°F) 112 (233.6)
Max. Turbocharger Boost Pressure kPa abs (PSI abs) - Coolant Capacity Engine Only litres (gals) 7 (1.5)
CAC Outlet Temperature @ FLRS, 25°C Ambient °C (°F) N/A
CAC Outlet Temperature @ Peak Torque, 25°C Ambient °C (°F) N/A MASS / GEOMETRY
Heat Rejection to CAC @ FLRS 25°C Ambient kW (hp) thermal N/A Direction of Rotation (viewed from crank nose) Clockwise
Heat Rejection to CAC @ Peak Torque 25°C Ambient kW (hp) thermal N/A Approximate Weight (Engine Only, Dry) kg (lb) 465 (1025.2)
CAC System (comp. outlet to intake manifold inlet) Max. Pressure Drop @ FLRS kPa (PSI) N/A Max. Bending Moment on Standard Flywheel Housing Nm (lbf-ft) 1400 (1032.6)
CAC System (comp. outlet to intake manifold inlet) Min. Pressure Drop @ FLRS kPa (PSI) N/A Mass Moment of Inertia kgm² (lbft²) 0.22866 (5.4262)
Centre of Gravity: x (distance from rear face of standard FH2 flywheel housing) mm (in) 367 (14.49)

EXHAUST & EGR Centre of Gravity: y (distance to left of crank centreline, viewed from rear) mm (in) -6 (-0.23)
Exhaust Mass Flow @ FLRS kg/h (Lb/h) 367.2 (809.5) Centre of Gravity: z (height above centreline of crank) mm (in) 143 (5.63)
Exhaust Mass Flow @ peak torque kg/h (Lb/h) 273.6 (603.2)
Max. Allowable Exhaust Back Pressure @ FLRS kPa (PSI) 15 (2.2) OTHER TEMPERATURE LIMITS
Min. Allowable Exhaust Back Pressure @ FLRS kPa (PSI) - Max. Engine ECU Case Temperature °C (°F) N/A
Turbocharger Turbine Outlet Gas Temperature @ FLRS °C (°F) 559 (1038) Max. Alternator Air Inlet Temperature °C (°F) 110 (230)
Max. EGR Actuator Skin Temperature °C (°F) N/A
©2020 JCB Power Systems. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission
from JCB Power Systems. All references in this publication to operating weights, sizes, capacities and other performance measurements are provided for guidance only and may vary dependant upon the exact specification of engine. They should not
therefore be relied upon in relation to suitability for a particular application. Guidance and advice should always be sought from your JCB Distributer. JCB reserves the right to change specifications without notice.
Illustrations and specifications shown may include optional equipment and accessories. The JCB logo is a registered trademark of J C Bamford Excavators Ltd.

Engine Technical Data

Version V3.0 15/09/2020
 JCB Dieselmax Engine
Installation Manual

EEC/EPA Stage 2 / Tier 2 & EEC/EPA Stage 3a / 3

Mechanical Fuel Injection Engines

Part No. 320/A9162-1

 This manual contains original instructions, verified by the manufacturer (or their authorised representative).
The original language is British English.

Copyright 2014 © JCB Power Systems Ltd.

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted
in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission
from JCB Power Systems Ltd.

www.jcb.com
 JCB Dieselmax Engine Installation Manual

Contents

1. Safety ............................................................................................................................ 6
1.1 Safety Notices ...................................................................................................... 6
1.2 General Safety ..................................................................................................... 6
2. Installation .................................................................................................................... 8
2.1 Engine Model ....................................................................................................... 8
2.2 Using this Installation Manual .............................................................................. 8
3. Cooling System ............................................................................................................ 9
3.1 Introduction .......................................................................................................... 9
3.2 System Performance ........................................................................................... 9
3.3 Cooling Capability – Limiting Ambient Temperature ........................................... 9
3.4 Coolant System ................................................................................................... 9
3.5 Cooling System Types ....................................................................................... 11
3.5.1 Shunt Cooling System ........................................................................ 11
3.5.2 Recovery Cooling System .................................................................. 11
3.6 Component Design ............................................................................................ 13
3.6.1 Header Tank ....................................................................................... 13
3.6.2 Pressure Cap ..................................................................................... 13
3.6.3 Cooling System Pipework .................................................................. 14
3.6.4 Radiator .............................................................................................. 15
3.6.5 Fan ..................................................................................................... 16
4. Intake System ............................................................................................................. 19
4.1 Introduction ........................................................................................................ 19
4.2 Charge Air Cooler .............................................................................................. 20
4.3 Induction System Performance ......................................................................... 20
4.3.1 Air Cleaner ......................................................................................... 20
4.3.2 Inlet Depression ................................................................................. 21
4.3.3 Service Indicator ................................................................................. 21
4.3.4 Temperature ....................................................................................... 21
4.3.5 Intake Manifold Temperature on Charge Air Cooled Engines ........... 21
4.3.6 Pressure Drop across the Charge Air Cooling System ...................... 21
4.3.7 Weight of Unsupported Pipes Attached to the Turbo ......................... 21
4.3.8 Noise Emissions ................................................................................. 21
4.4 Induction System Installation ............................................................................. 22
4.4.1 Ducting ............................................................................................... 22
4.4.2 Charge Air Cooler Pipes and Hoses .................................................. 22
4.4.3 Hose Clamping Requirements ........................................................... 23
4.4.4 Air Filter Box ....................................................................................... 23

© JCB Power Systems Ltd. 320/A9162-1 Page 3 of 56

JCB Dieselmax Engine Installation Manual

5. Crankcase Ventilation (CCV) .................................................................................... 24

5.1 Stage 2 / Tier 2 (NA) Dieselmax Engines (Closed Loop CCV) ......................... 24
5.2 Stage 3a / Tier 3 Dieselmax Engines (Open Loop CCV) .................................. 24
6. Exhaust System ......................................................................................................... 25
6.1 Overview ............................................................................................................ 25
6.2 Performance ...................................................................................................... 26
6.2.1 Backpressure ..................................................................................... 26
6.2.2 Noise Emissions ................................................................................. 26
6.3 Exhaust Installation............................................................................................ 26
6.3.1 Turbocharger Mounting ...................................................................... 26
6.3.2 Exhaust Mounting ............................................................................... 26
6.3.3 Flexible Elements ............................................................................... 27
6.3.4 Materials ............................................................................................. 27
6.3.5 Pipe Sizes and Bends ........................................................................ 27
6.3.6 Water Protection ................................................................................. 27
7. Fuel System ................................................................................................................ 28
7.1 Fuel System Overview ....................................................................................... 28
7.2 Installation of the Fuel System .......................................................................... 29
7.2.1 Fuel Tank ........................................................................................... 29
7.2.2 Fuel Feed Pipe (Suction Pipe) ........................................................... 29
7.2.3 Fuel Pump .......................................................................................... 29
7.2.4 Injector Leak Off Return to Fuel Tank ................................................ 29
7.2.5 Fuel Filters and Water Separators ..................................................... 30
7.2.6 Fuel Temperature ............................................................................... 31
7.2.7 Fuel Lubricity Additive Dosing Filters ................................................. 31
8. Engine Mounting and Noise Reduction ................................................................... 32
8.1 Overview ............................................................................................................ 32
8.2 Performance ...................................................................................................... 35
8.2.1 Minimum First Bending (Beam) Frequency of the Powertrain ........... 35
8.2.2 Allowable Installation Angles .............................................................. 35
8.2.3 Control of Engine Movement .............................................................. 35
8.2.4 Control of Rigid Modes of Vibration ................................................... 35
8.2.5 Isolation of Engine Vibration............................................................... 36
8.2.6 Noise Shields ..................................................................................... 37
8.3 Installation .......................................................................................................... 38
8.3.1 Bump Stop Clearances ...................................................................... 38
8.3.2 Fool Proofing of Mounts (Poka-Yoke) ................................................ 38
8.3.3 Mount Positions Relative to the Engine ............................................. 38
8.3.4 Mount Positions Relative to the Equipment ....................................... 38
8.3.5 Protection of the Mounts .................................................................... 38
8.3.6 Noise Shields ..................................................................................... 38

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 JCB Dieselmax Engine Installation Manual

9. Electrical System ....................................................................................................... 40

9.1 Overview ............................................................................................................ 40
9.2 Performance ...................................................................................................... 40
9.3 Voltage Capability .............................................................................................. 40
9.4 Electromagnetic Compatibility ........................................................................... 41
9.5 Cold Start Strategy ............................................................................................ 41
9.6 Battery................................................................................................................ 41
9.6.1 Installation .......................................................................................... 41
9.6.2 Earthing .............................................................................................. 41
9.6.3 Battery Isolators ................................................................................. 41
9.7 Starter Motor ...................................................................................................... 42
9.7.1 Starter Motor Earthing Requirements ................................................ 42
9.8 Alternator ........................................................................................................... 42
9.9 Wiring ................................................................................................................. 43
9.10 Earthing ............................................................................................................ 43
9.11 Switches and Sensors ....................................................................................... 43
9.12 Hour meter ......................................................................................................... 43
9.13 Specimen Wiring Diagram ................................................................................. 44
9.14 Cold Start and Boost Pressure Switch Harness ................................................ 44
10. Power Take-Offs ......................................................................................................... 46
10.1 Positions of Power Take-Offs ............................................................................ 46
10.2 Performance of Power Take Offs ...................................................................... 47
10.3 Front End Accessory Drive (FEAD) ................................................................... 48
10.3.1 Torsional Vibration ............................................................................. 48
11. Engine Speed Control System.................................................................................. 49
12. Fluids and Ambient Temperature: Fuel, Lubricant and Coolant........................... 50
12.1 Overview ............................................................................................................ 50
12.2 Fuel ............................................................................................................ 50
12.3 Lubricant ............................................................................................................ 51
12.4 Dipsticks ............................................................................................................ 52
12.5 Coolant ............................................................................................................ 52
13. Hostile Environment Precautions ............................................................................ 53
13.1 General Provisions ............................................................................................ 53
13.1.1 Cold Climates ..................................................................................... 53
13.1.2 Wading ............................................................................................... 53
13.1.3 Operation in Explosive Atmospheres ................................................. 53
14. Accessibility ............................................................................................................... 54
15. Installation Approval Limits ...................................................................................... 55

© JCB Power Systems Ltd. 320/A9162-1 Page 5 of 56

JCB Dieselmax Engine Installation Manual

1. Safety
1.1 Safety Notices
There are safety notices in this manual. Each notice starts with a signal word. The meanings
of the signal words are given below.

The safety alert system also helps to identify important safety messages in this manual and
on the engine. When you see the danger, warning and caution symbols you must be alert as
your safety is involved.

Symbol Description
DANGER!

W The signal word 'DANGER' shows a hazardous situation

which, if not avoided, will result in death or serious injury.

WARNING!

W The signal word 'WARNING' shows a hazardous situation

which, if not avoided, could result in death or serious
injury.
CAUTION!

W The signal word 'CAUTION' shows a hazardous situation

which, if not avoided, could result in minor or moderate
injury.
NOTICE!

C The signal word 'NOTICE' shows a hazardous situation

which, if not avoided, could result in machine damage.
NOTE:

N Notes give additional information, hints and tips that help you to
use your product.

1.2 General Safety

Clothing
You can be injured if you do not wear the correct clothing. Loose clothing can get caught in
the machinery.

Keep cuffs fastened. Do not wear a necktie or scarf. Keep long hair restrained. Remove
rings, watches and personal jewelry.

Alcohol and Drugs

It is extremely dangerous to install or operate the engine when under the influence of alcohol
or drugs. Do not consume alcoholic drinks or take drugs before or while operating the
engine. Be aware of medicines which can cause drowsiness.

Feeling Unwell
Do not install or operate the engine if you are feeling unwell. By doing so you could be a
danger to yourself and those you work with.

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 JCB Dieselmax Engine Installation Manual

Mobile Phones
Switch off your mobile phone before entering an area with a potentially explosive
atmosphere. Sparks in such an area could cause an explosion or fire resulting in death or
serious injury.

Lifting Equipment
You can be injured if you use incorrect or faulty lifting equipment. You must identify the
weight of the item to be lifted then choose lifting equipment that is strong enough and
suitable for the job. Make sure that lifting equipment is in good condition and complies with
all local regulations.

Raised Equipment
Never walk under or work under raised equipment unless it is supported by a mechanical
device. Equipment which is supported only by a hydraulic device can drop and injure you if
the hydraulic system fails or if the control is operated (even with the engine stopped).

Make sure that no-one goes near the engine while you install or remove the mechanical
device.

Raised Engine
Never position yourself or any part of your body under a raised engine which is not correctly
supported. If the engine moves unexpectedly you could become trapped and suffer serious
injury or be killed.

Engine Modifications
This engine is manufactured in compliance with legislative and other requirements. It must
not be altered in any way which could affect or invalidate any of these requirements. For
advice consult your JCB dealer.

Clothing and Personal Protective Equipment (PPE)

Do not wear loose clothing or jewelry that can get caught on controls or moving parts. Wear
protective clothing and personal safety equipment issued or called for by the job conditions,
local regulations or as specified by your employer.

© JCB Power Systems Ltd. 320/A9162-1 Page 7 of 56

JCB Dieselmax Engine Installation Manual

2. Installation
2.1 Engine Model
This Installation Manual gives information for the following JCB Dieselmax engines:

• SA

• SB

• SC

• SD

• SF

The JCB Dieselmax engines meet EEC/EPA emissions regulations at either Stage 2 / Tier 2
or Stage 3a / Tier 3, depending on the specification.

2.2 Using this Installation Manual

This manual is arranged to give a good understanding of the JCB Dieselmax engine and
guidance on its safe integration into equipment. The main purpose of the manual is to help
engineers and designers specialising in installing JCB Dieselmax engines into equipment. It
gives advice on good practice together with requirements to ensure expected operation and
engine longevity. Adherence to the advice contained in this manual will help ensure
acceptance of the installation by JCB Power Systems.

Fully read this manual before you install the engine into equipment. You must give particular
attention to all the safety aspects of the installation. It is the engine installer’s responsibility to
ensure that users of equipment are provided with adequate instruction for safe operation of
the equipment – including an Operator’s Manual, warnings, and labeling as required.

References to the ‘left’ side and the ‘right’ side of the engine are when viewed from the
flywheel end of the engine.

All equipment, whether mobile or static, can be hazardous. When the engine is correctly
installed, operated and maintained it can be safe to work with, but when it is not it can
become a danger. The engine installer must design the installation to avoid hazards to the
operator and other persons. These hazards may include component edges, surfaces and
angles.

Throughout this manual there are safety messages. Please read and understand these
safety messages before you install the engine into equipment.

N NOTE: For more advice and guidance consult JCB Power Systems Applications
department.

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 JCB Dieselmax Engine Installation Manual

3. Cooling System
3.1 Introduction
This chapter gives guidance on how to install the engine cooling system in a particular
application. If you need any more advice please contact JCB Power Systems Applications
department.

W WARNING! The cooling system is pressurised when the coolant is hot. When
you remove the cap, hot coolant can spray out and burn you. Make sure that
the engine is cool before you work on the cooling system.

W WARNING! Antifreeze can be harmful. Obey the manufacturer’s instructions

when you handle full strength or diluted antifreeze.

The JCB Dieselmax engine must be cooled using a liquid cooling system to maintain the
correct operating temperature. You must design the system to allow for thermal expansion of
the coolant, without losses, including provision to prevent coolant loss even after shutdown
at high temperature. There must be provision for bleeding of entrained air using a small
internal diameter hose to flow fluid to the air volume at the highest point in the circuit.

The engine uses a thermostat to maintain the operating temperature of the engine. When the
engine is below normal operating temperature the thermostat is closed and coolant is
pumped around the engine only. When the engine is at operating temperature the thermostat
opens and allows coolant to flow out of the engine into the radiator top hose, through the
radiator and draw back into the engine by the coolant pump.

3.2 System Performance

You need to test the performance of the cooling system to make sure that you meet the
performance requirements we specify.

3.3 Cooling Capability – Limiting Ambient Temperature

You need to consider the capability of the cooling system in the complete equipment
Engineering Sign-off procedure, with respect to the expected operating environment. The
cooling system must give enough cooling performance in all of the expected ambient
temperatures. Please read the appropriate JCB standard on cooling system requirements for
more guidance on cooling system design and performance requirements.

There are maximum limits for coolant and lubricating oil temperature which must not be
exceeded. See the Technical Data Sheet for specific values.

3.4 Coolant System

2
A robust pressure control cap of 1 bar (14.5 lb/in ) is needed. You must route the relief flow
from the pressure cap safely. Ideally you need to route the relief flow to a separate reservoir
or to a safe position on the equipment.

The restriction to coolant flow from engine outlet to engine inlet must not exceed 700 mbar.

You must use a minimum concentration of 30% antifreeze and corrosion inhibitor. Antifreeze
and corrosion inhibitor must be ethylene glycol based to ASTM D6210.

We recommend that it is possible to fill the coolant system at 10 litres/min to 95% of the total
volume on the initial fill.

© JCB Power Systems Ltd. 320/A9162-1 Page 9 of 56

JCB Dieselmax Engine Installation Manual

Following the installation requirements gives adequate de-aeration. You must make sure that
air is removed from any cab heater circuits. If the header tank is the correct size and there is
coolant inside it, the system will continue to operate normally.

You must consider the following when you want to install cooling fans on the fan belt driven
fan pulley:

• Maximum power absorption

• Maximum mass

• Maximum overhang

N NOTE: For specific advice on fan suitability please contact JCB Power Systems
Applications department.

You must keep the alternator air inlet temperature at the rear of the unit below pre-
determined limits in maximum ambient temperatures. See the Technical Data Sheet for
specific values.

To demonstrate that the system is fit for purpose you need to do the following tests:

• Cooling trials

• Hot shut down – no coolant loss

• Initial fill – 95% of total coolant volume on initial fill at 10 litres/min

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 JCB Dieselmax Engine Installation Manual

3.5 Cooling System Types

A shunt cooling system is preferred. However, you can use alternative types of cooling
system arrangements in particular circumstances, such as where there are severe
installation space constraints.

3.5.1 Shunt Cooling System

A shunt cooling system is strongly recommended for all applications to help avoid pump
cavitation and to maintain cooling performance. This must be arranged using a radiator with
a separate pressurised header tank, as shown in Figure 1.

A small proportion of coolant flow, which may contain some air, tends to flow into the header
tank through the bleed hose, where any air separates and the de-aerated coolant flows back
down the bottom-hose file hose (or shunt line). The bottom-hose fill hose internal diameter is
critical for the pressurised fill system used in production and you must maintain it at the
internal diameter stated.

Figure 1: Shunt cooling system schematic

3.5.2 Recovery Cooling System

The recovery cooling system can be used where severe installation constraints prevent the
use of a separate header tank used in the shunt system.

N NOTE: This system is non-preferred, giving inferior de-aeration performance when

compared to the shunt arrangement, with remote (expansion) header tank.

You must design the radiator to accommodate most of the coolant expansion inside its own
header tank. Any coolant overflow from this system is expelled through the radiator pressure
cap, through a tube or hose and captured in a suitably positioned unpressurised recovery
bottle, or tank. As the coolant in the system cools down, contraction begins to take place and
the expelled coolant is returned from the recovery bottle through the two-way radiator
pressure cap and back into the header tank of the main radiator so it recovers the lost
coolant volume.

© JCB Power Systems Ltd. 320/A9162-1 Page 11 of 56

JCB Dieselmax Engine Installation Manual

A typical system, as shown in Figure 2, has the following components:

1. Reservoir and mount

2. Connecting tube and hose

3. Hose clamps to make air tight connections

4. Pressure-vacuum cap tightly sealed at the top of the radiator filler neck

If items 3 and 4 are not maintained air-tight, the coolant will not be drawn back into the
radiator on engine cool down.

The radiator is filled cold and topped up after running.

You must use the correct mark and size of the recovery tank for the system to be effective
once in service. Radiator header tank design also becomes a critical factor for the system to
work correctly.

N NOTE: Please contact JCB Power Systems Applications department for specific
advice on this subject.

The recovery hose must be sufficiently rigid that it does not collapse under the vacuum
created when drawing fluid back from the recovery bottle on engine cool down. This vacuum
can be reduced by limiting the height difference between the recovery bottle and the
pressure cap.

Figure 2: Typical coolant recovery cooling system layout

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3.6 Component Design

3.6.1 Header Tank

Figure 3 shows the basic design principles for the header tank. The working volume of the
header tank must be at least 25% of the volume of the total cooling system (including the
cab heater, radiator and hoses). This allows for expansion of the coolant with temperature
rise and gives provision for drops in the coolant level due to de-aeration. Critically, the tank
must have at least an equivalent volume of coolant to the volume of air trapped in the system
during normal fill. In some machines this may mean that a larger capacity tank is necessary.
Typically, the tank needs to be filled to two thirds volume with coolant when cold. The main
principles are shown in Figure 3.

For a typical cooling system of volume 24 litres, the header tank must have a volume of at
least 6 litres with 4 litres of coolant and 2 litres of available expansion. The volume between
the MIN and MAX lines (volume B on Figure 3) is normally about 1.5 litres.

N NOTE: These figures may vary depending on specific installation requirements.

Tank construction must be suitable for maximum expected under bonnet temperatures (air
temperatures over 80ºC are not uncommon) and be capable of withstanding the fluctuations
in coolant pressure at operating temperature (refer to the Technical Data Sheet). The tank
material must be clear or translucent so that it allows you to check the fluid level.

We also recommend that you incorporate a suitable coolant level switch into the design of
the header tank.

You must install the header tank so that the minimum mark is above the radiator top tank
and the highest point of top hose.

3.6.2 Pressure Cap

You must use a pressure cap with a 1 bar rating.

Figure 3: Header tank design principles

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3.6.3 Cooling System Pipework

The radiator inlet and outlet pipes must be a minimum internal diameter of 38 mm.

The shunt line, or ‘bottom hose fill pipe’, must have a minimum internal diameter of 24 mm.
You must make sure that this pipe is always below the minimum coolant level when the
machine is operating on its maximum gradient.

The engine to cab heater and return hose must have a minimum internal diameter of 16 mm.

The bleed hose, or vent line, must have a minimum internal diameter of 8 mm. This hose
must be connected at the highest point in the cooling circuit, typically in the radiator top
hose, and flow to the header tank above the maximum coolant level in all operating
conditions.

All pipework must be designed with rounded bends to help maintain smooth flow through the
system and prevent unnecessary restrictions.

Pipework between the engine and the radiator must be sufficiently flexible to allow for
relative movement between the engine and radiator.

Hoses of less than 150 mm length tend to have insufficient flexibility and can be difficult to
install. Hoses of greater than 450 mm can be susceptible to vibration induced failure so you
need to clip them.

Arrange the shunt line (or bottom-hose fill hose) and bleed hose so that there are no “high”
points or “low” points in which air could be trapped.

You need to bead all pipe ends to reduce the risk of pipes blowing off according to SAE
standard J1231. The minimum expected bead is shown in Figure 4 and Table 1.

Figure 4: Minimum expected pipe beadings

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Table 1: Dimensions (reference for Figure 4 above)

Hose Dash Tube OD Tube OD A B C

Size Nominal Nominal ±0.25 Reference Nominal Drill
mm in mm mm mm
-3 4.76 3/16 5.58 0.41 3.2
-4 6.35 1/4 7.37 0.51 4.8
-5 7.94 5/16 9.16 0.61 6.4
-6 9.52 3/8 10.95 0.71 7.5
-7 11.11 7/16 12.45 0.71 9.1
-8 12.7 1/2 14.22 0.76 10.3
-9 14.29 9/16 15.75 0.76 11.1
-10 15.88 5/8 17.55 0.84 12.7
-12 19.05 3/4 20.83 0.89 15.9
-16 25.4 1 26.92 0.76 21.4
-20 31.75 1-1/4 34.44 1.35 27.8
-24 38.1 1-1/2 41.25 1.57 34.1
-32 50.8 2 54.51 1.85 46.8

3.6.4 Radiator

The radiator must be of an aluminium construction with moulded tanks and a separate
header and expansion tank. The frontal area must be as large as the machine packaging
permits to allow for a large diameter fan running at a lower speed, giving reduced drive
power and lower noise. A square radiator gives the maximum efficiency by minimising the
upswept area of the core.

The radiator must allow a 5°C, or 20%, margin for blockage while still being capable of
achieving full ambient capability. The full ambient capability for Europe is 41°C and for the
rest of the world 46°C. For example, to sell a machine into the rest of the world territories,
the ambient temperature achieved during the cooling trial tests must be at least 51°C (that is
46°C ambient temperature plus 5°C margin).

For construction type machinery, radiator designs must not be more than 9 fins per inch. For
agricultural applications use 5.5 fins per inch as a guide. However, these figures are
influenced by overall cooling package design. Fin designs without louvers are advisable to
help prevent premature blockage.

The coolant circuit, and therefore the radiator, must take advantage of thermo-siphoning
(flow due to natural convection) on hot shutdown. This reduces the likelihood of localised
boiling in the cylinder head and therefore reduces coolant expansion during hot shutdown
events, see Figure 5.

Route the engine hot water outlet to the top of the radiator and route the engine cold water
inlet to the bottom of the radiator. This arrangement allows convection to encourage the flow
of hot water out of the engine and cold water into the engine.

Figure 5: Radiator top and bottom hose connections to take advantage of thermo syphoning

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3.6.5 Fan

W WARNING! Do not work on the cooling pack while the engine is running.
Rotating parts can cause injury.

Use as large a diameter fan as possible to give the necessary level of airflow with minimum
fan speed. As a general rule, a tip speed of around 60-65 m/s gives a good performance.

To maintain cooling performance, you must match the correct fan with the radiator and you
need to take great care in design to give good airflow.

To maximise cooling efficiency, the fan must be designed to maximise smooth air flow. A
Venturi style shroud gives best results. See Figure 6 for recommended installation details.

Figure 6: Fan installation details

To avoid recirculation of hot air from the engine compartment, you need to attach baffles
between the machine bodywork and the radiator so that only fresh cool air is drawn across
the radiator and not air from the engine compartment. Recirculation of cooling air has a
detrimental effect on cooling performance.

Important: Fans are a significant source of off-highway equipment noise. You must
consider this to comply with regulations.

Fan noise is one of the most significant sources of noise on many off-highway machines.
Therefore, you must chose a fan which achieves the requirements of the EC Directive on
noise emissions from machines used out of doors (2005/88/EC) or other relevant legislation
depending on the application.

Fan noise is a function of fan speed and fan efficiency. You normally get the best results by
specifying the most efficient fan available. This allows lower fan speeds and results in lower
noise during operation. The enclosure around the fan and cowling in front of the radiator can
also have a significant influence on the noise so you need to give as much shielding as
necessary to achieve the cooling requirements.

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If more significant reductions in fan noise become necessary then you may consider viscous
fan couplings (bi-metallic or electronically controlled). Although these fan drives do not
reduce the peak noise, the overall noise rating, as measured according to Directive
2005/88/EC, is likely to be significantly reduced with a viscous fan coupling fitted.

Ring fans have been used to help reduce fan noise on road vehicles. However, the danger of
fan failure due to vibration caused by a build-up of dirt on the inside of the ring makes them
generally unsuitable for off-highway machines unless they can be protected from the risk of
dirt build-up.

For machines that may be required to wade, you need to install the fan above the expected
high water line, if possible. There are three possible fan positions. The standard two are 262
mm above the crankshaft centre-line and 356 mm above the crankshaft centre-line, as
shown in Figure 7. If there is a risk of the fan dipping below the water line then the fan must
have aluminium blades mounted on a steel hub, instead of being made of plastic, to avoid
the risk of the fan blades shattering.

You can fit a cooling fan in one of two positions on the front of the engine, see Figure 7. You
must make sure that the rated speed of the fan is not exceeded in any running conditions of
the equipment. Basic limits of 7.5 kW (at 2200 engine rpm) and 4.3 kg of mass at an
overhang of 103 mm (from the fan mounting fan to the centre of mass of the fan) apply. For
applications that need more than this you need to ask JCB Power Systems Applications
department for advice. Fan pulleys are made in diameters to enable fan to engine speed
ratios of 0.85:1, 1:1, 1.16:1, 1.25:1 and 1.375:1.

When using low voltage DC electrical systems, an electrically driven fan is unfeasible due to
the power requirement of the cooling fan (up to 7.5 kW). The subsequent motor and
alternator size would be impractical.

For indirect fan drive applications, use an aramid construction belt for the FEAD system.

N NOTE: Contact JCB Power Systems Applications department for more information.

All installations that need a reversible fan, you need to consult JCB Power Systems for
guidance on the suitability of the components.

W WARNING! You must adequately guard the fan, belt, pulleys, flywheel and
other moving equipment. You must earth these guards to stop the build-up of
static electricity. You must make sure that operators of the engine cannot get
any part of their body anywhere near moving components.

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Figure 7: Alternative fan positions

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4. Intake System
4.1 Introduction

C NOTICE! Dirt or water ingress may cause engine damage.

You must fit an air intake system that consists of a dry type air cleaner with a safety element
as shown in Figure 8 and a cleaner restriction indicator as shown in Figure 9. Air is drawn
from a cool location and piped to the engine intake through a leak-free, low pressure drop
system. Inlet ducting must be leak-free throughout the life of the equipment and must not
degrade in any way that could release debris into the engine. Intakes with cyclonic-style pre-
filters are often appropriate on off-highway equipment. The intake must stop induction of
water during running. You do this by carefully positioning the intake orifice and, in particular
circumstances, such as on machines with specific wading requirements, you may need to
include water separation features in the system upstream of the filter element.

Figure 8: Example of an appropriate air cleaner for off-highway equipment

Figure 9: Example of an appropriate filter restriction indicator

C NOTICE! If the quality of the air intake system is poor it severely affects the
engine performance and durability.

You need to test the intake system to make sure that it meets the performance requirements
(see engine technical data) for air cleaner efficiency, inlet depression and temperature. You
must also make sure you control the engine noise emissions.

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4.2 Charge Air Cooler

You must be careful when you specify the pipework and installation of the Charge Air Cooler
(CAC). The charge air system must be capable of withstanding high pressures and
temperatures. You need to test the CAC system to make sure it meets performance
requirements (see engine technical data), for temperature and pressure drop. The total
unsupported mass attached to the turbocharger must not exceed 2.5 kg, and first resonant
frequency must be greater than 150 Hz. The effective static bending moment applied to the
turbocharger must be less than 7.5 Nm.

You can install charge air coolers in series, as shown in Figure 10, or in parallel. When
installed in series, the air must pass through the charge air cooler first.

Figure 10: Typical charge air cooler installation and associated hoses

4.3 Induction System Performance

You need to test the air intake performance to make sure that it meets all of the performance
requirements described below. The following subsections explain the limits that apply to the
JCB Dieselmax engine range.

4.3.1 Air Cleaner

The efficiency of the air cleaner must be 99.99% or better when tested in accordance with
ISO 5011 (SAE coarse dust). Airflow must be steady and at least equal to the airflow of the
engine at rated power. With the correct arrangement, you can achieve air cleaner
efficiencies of 99.999%.

When you specify a suitable air cleaner, you need to take into account its robustness in its
environment and operator maintenance practices. Engine failures due to dust ingress are
usually a result of operator abuse when cleaning the filtration element. Therefore, you need
to use cleaners that make use of a protective mesh or advanced design to guard the filtration
element. A good example of this is the Donaldson power core.

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4.3.2 Inlet Depression

With a new air filter, the depression across the intake system must be measured with the
engine at rated speed and load to ensure it complies with the prescribed limits in the relevant
engine Technical Data Sheet. The purpose of this test relates to the emissions compliance of
the engine. Please refer to JCB Power Systems Applications department for specific advice.

For turbocharged and turbocharged air cooled engines it must be measured at the intake to
the turbocharger.

4.3.3 Service Indicator

You must fit a service indicator (similar to the one shown in Figure 9) to show when the inlet
depression, at the manifold or turbocharger, has risen to 80 mbar.

4.3.4 Temperature

The air inlet temperature at the intake manifold or turbo inlet must be no more than 20°C
above ambient when tested under the operating conditions of the machine. Testing of this
parameter is necessary as part of the approval process for the engine installation.

4.3.5 Intake Manifold Temperature on Charge Air Cooled Engines

Please refer to the specific engine Technical Data Sheet for the relevant intake air
temperature limits measured at the intake manifold. The results of these tests are critical for
the Installation Approval Process. Please refer to the JCB Power Systems Applications
department for specific advice.

4.3.6 Pressure Drop across the Charge Air Cooling System

Please refer to the relevant engine Technical Data Sheet for the pressure drop limits
measured across the charge air cooler. The results of these tests are critical for the
Installation Approval Process. Please refer to the JCB Power Systems Applications
department for specific advice.

4.3.7 Weight of Unsupported Pipes Attached to the Turbo

Any mass attached to the turbo housing will reduce the first natural frequency of vibration of
the turbocharger. The total unsupported mass, including unsupported exhaust pipe must not
exceed a static figure of 2.5 kg.

The static moment applied by the charge air cooler piping must not exceed 7.5 Nm.

4.3.8 Noise Emissions

Important: Air intake systems are a significant source of noise, so you must consider
this to make sure you comply with regulations.

The air intake can be a significant source of noise, both in terms of in-cab refinement and
also in relation to the Equipment Used Out of Doors Directive 2005/88/EC. Your design must
avoid acoustic resonances in the pipework that may be excited by engine firing frequencies.
You must select the position of the exhaust orifice and the direction in which it points to avoid
the measurement positions identified in the Directive. You must not install the exhaust close
to, or pointing towards, one of the measuring positions. You must make sure that the air
cleaner volume and the cleaner element give enough attenuation of higher frequency noise
emissions.

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4.4 Induction System Installation

4.4.1 Ducting

Hose diameters must generally be a minimum of 70 mm internal diameter but certainly large
enough to achieve the minimum specified induction system depression.

Ducting between the air cleaner and the engine inlet must be leak free up to 100 mbar of
depression and capable of maintaining this performance throughout the life of the machine.
The ducting must not degrade in any way that could release debris into the engine.

Turbocharger inlet ducting must be supported when their weight would impose a static
moment of 7.5 Nm or more on the turbo housing.

N NOTE: The total unsupported mass attached to the turbo housing must be less
than a static figure of 2.5 kg. There must be a straight section of pipe equal to at
least two times the pipe diameter immediately before the turbo inlet.

You must support any pipework of extended length by using appropriate brackets to make
sure that it shows no significant structural resonances below 150 Hz.

Use rigid pipes of aluminium, stainless steel, aluminised steel or plastic with clean and
smooth internal surfaces. Associated hose connections must be truly circular and have a
smooth external finish for at least 25 mm at each connection. The pipes must be strong
enough to resist deformation by the hose clamps and must be beaded as per SAE standard
J1231.

All hoses must conform to SAE J 2140 or equivalent standard.

Use reinforced hump hoses for connecting ducting to the engine and air cleaner. These must
be designed to accommodate the relative movement without inducing loads into the system.

You must not use reinforced convoluted types of wire.

4.4.2 Charge Air Cooler Pipes and Hoses

Piping and hoses in the charge air cooler system must maintain their properties over a wide
temperature range, typically from -40ºC to +190ºC. They must withstand a pressure that is
greater than the engine boost pressure and lower than the maximum depression (–80 mbar)
to avoid collapse when the engine is being driven on the overrun. As a guide, you must test
hoses to 2 times boost pressure and 1.5 times maximum depression.

N NOTE: Please refer to the specific engine Technical Data Sheet for the relevant
figures.

On the cool side of the charge air cooler, use aluminised steel tubes with neoprene hoses.

On the hot side, you need to use stainless steel tubes with reinforced silicon rubber or
reinforced Vamac hoses.

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4.4.3 Hose Clamping Requirements

For naturally aspirated engines, you must use worm drive clamps as detailed in JCB
Standard 2201/0000 and tighten them to the specified torques.

For charge cooled engines, you must use T-bolt sprung energised hose clamps as shown in
JCB Standard PART/0013 for all hoses on pipes which are not fully supported (to restrict
movement and prevent blowing off) and on all hoses of greater than 60 mm internal diameter
in the high pressure system. For pipes of 60 mm internal diameter and below, you must use
spring energised worm drive clamps in the high pressure system. Use worm drive clips in the
low-pressure side of the system.

4.4.4 Air Filter Box

You need to use a two-stage air cleaner with a safety element, in which the first part is a
cyclonic design to separate out much of the dirt before it reaches the disposable element,
with the safety element providing a level of back-up protection on the clean side of the
disposable element.

The air cleaner box must be configured such that accumulated dirt in the box cannot fall into
the engine during normal service activities.

The inlet orifice must generally be protected from rain and larger debris by a suitable cap
with a coarse screen. This must be designed so that it does not get clogged easily and does
not cause any significant restriction to airflow. The inlet must also be configured such that
particles of water from spray are separated before they reach the air cleaner.

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5. Crankcase Ventilation (CCV)

W WARNING! Breathing the engine crankcase gases can harm you and
possibly kill you.

5.1 Stage 2 / Tier 2 (NA) Dieselmax Engines (Closed Loop CCV)

The naturally aspirated Stage 2 / Tier 2 Dieselmax engines (Closed Loop CCV) operate with
the CCV gases routed into the induction system. You must provide a well-sealed tube to take
gases from the outlet stub on the rocker cover (to suit 22 mm internal diameter hose) into the
induction hose. The tube must not have any low points and must be tolerant to oils.

Figure 11: Typical arrangement of a closed crank case ventilation system for
naturally aspirated T2 engines

5.2 Stage 3a / Tier 3 Dieselmax Engines (Open Loop CCV)

The Stage 3a / Tier 3 (turbocharged) and Stage 2 (Turbocharged) Tier 2 Dieselmax Engines
(Open Loop CCV) operate with the CCV gases routed to the atmosphere. You must provide
a tube to take gases from the outlet stub on the rocker cover (to suit 22 mm internal diameter
hose) to an appropriate location, away from the air cleaner, and operator environment, inlets.
The tube must also not have any low points and must be tolerant to oils. A typical example is
shown in Figure 12.

Figure 12: Open loop crank case ventilation outlet for turbocharged T3 engines

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6. Exhaust System
6.1 Overview

W WARNING! Be aware of the hot exhaust system even with the engine
stopped.

W WARNING! Breathing the engine exhaust gases can harm and possibly kill
you. Do not operate the engine in closed spaces without making sure there is
good ventilation. If possible, fit an exhaust extension. If you begin to feel
drowsy, stop the engine at once and get into fresh air.

You must fit an exhaust system. The purpose of the exhaust system is to pipe hot, noxious
gases to a safe outlet position and to quieten the noise carried by the exhaust gas. You must
take care with the selection of the materials used and the mounting of the exhaust system to
make sure it is durable and effective.

The design of the exhaust system can have a negative effect on engine performance if it is
too restrictive or the outlet position allows exhaust gas to be drawn into the air intake.

Design considerations also need to include corrosion resistance, pipe sizes and bends,
flexible elements and thermal expansion.

Packaging of the exhaust pipework and silencer also needs careful consideration due to their
high temperature and high levels of vibration.

Off-highway equipment employs several different exhaust mounting strategies including

engine mounted silencers, equipment mounted silencers and cab mounted silencers. Each
approach requires special consideration in relation to accommodation of relative movement
between sections of the exhaust system, methods of mounting and noise emission.

You must make sure that vibrations transmitted to the equipment operator and other people
are minimised as vibration is uncomfortable and can be damaging to health.

Where there is risk of access to the hot components on the engine, you must make sure that
appropriate warnings are made on the equipment and in the equipment operating manual.

The position of the outlet also needs consideration to make sure that the exhaust gases are
directed away from the operator and other people.

C NOTICE! Water ingress may cause engine damage.

The exhaust system must be designed to prevent water ingress. Heat from exhausts and
turbo chargers can be a source of ignition or can melt adjacent components.

Consider the position of the exhaust system in relation to fuel system components, cables,
plastics, hoses, wiring, soundproofing and to oil and fuel fillers.

You must make allowances for combustible airborne material such as chaff, sawdust, paper.

You must use insulating jackets or heat shields to protect against fires or heat damage.

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6.2 Performance
You must test the exhaust system to make sure it meets performance requirements for
backpressure, vibration levels, exhaust manifold and turbocharger mounting loads (see
Technical Data Sheet).

6.2.1 Backpressure

The exhaust backpressure, measured on a straight section of pipe close to the turbocharger
outlet, must not exceed the specified limits shown in the Technical Data Sheet.

6.2.2 Noise Emissions

N NOTE: Exhaust systems are a significant source of off-highway equipment noise.

You must take this into account and make sure you comply with regulations.

The exhaust is a significant source of noise and can be a major contributor to the noise
emissions assessed under Directive 2005/88/EC for Equipment Used Out of Doors. You
must position the exhaust orifice and the direction in which it points carefully. You must not
install the exhaust close to of the measuring positions or point it towards one of these
positions.

6.3 Exhaust Installation

6.3.1 Turbocharger Mounting

The total unsupported mass attached to the manifold and turbocharger must not exceed
2.5 kg, and the effective static bending moment applied to the turbocharger must be less
than 7.5 Nm. In common with all additional structural elements on the engine, it is important
that the first resonant frequency of the exhaust components fixed to the engine is greater
than 150 Hz. You can normally achieve this by keeping the total unsupported weight on the
turbo housing, including charge air cooler piping, below a static figure of 2.5 kg. However, it
is good practice to support the exhaust system so that it does not impose any additional
weight onto the turbocharger outlet.

The system must allow for engine movement and thermal expansion so that, under the worst
case conditions, the load imposed on the turbocharger housing stays below 7.5 Nm of
applied (static) torque.

You must consider the positioning of any flexible elements. For chassis, or cab mounted
muffler systems, at least one flexible element will be required to protect the turbo from loads
due to thermal expansion and relative movement between the engine and the machine.

Typically, engine mounted muffler systems do not need a flexible element. However, in this
case the first natural frequency of vibration of the whole system must be above 150 Hz.

6.3.2 Exhaust Mounting

The exhaust must be supported so that the stresses generated in the exhaust due to thermal
expansion, engine vibration, (cab vibration if the muffler is mounted to the cab) and vibration
induced through operation of the machine do not exceed the capability of the materials used.

For engine mounted muffler systems there are a number of tapped M10 holes on the
cylinder head to which you can attach brackets. For this kind or arrangement you must keep
the brackets as short and stiff as possible to make sure that the system does not have any
resonances below 150 Hz.

Vibration from the exhaust can be a source of noise in the cab. This is a particular issue with
A-pillar mounted systems so you must be very careful with these types of mounting systems.

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Use appropriate anti-vibration mounts where you have to attach the exhaust to bodywork or
chassis.

6.3.3 Flexible Elements

You must fit flexible elements in a position so that that they will compress longitudinally to
accommodate thermal expansion. Equally, you need to install a flexible element to allow for
relative movement between the engine and the machine. Figure 13 shows possible solutions
for a chassis mounted muffler system or a cab mounted muffler system. With cab mounted
muffler systems, you must to take into account the movement across the cab mounts as well
as the movement across the engine mounts.

The expansion coefficient for steel is approximately 1 mm per metre of pipe per 100ºC
temperature rise. So, for example, a 2 metre pipe might be expected to expand by over 5
mm. You must allow for this by using a mounting system that allows for such expansion, or
include flexible bellows that allows for the compression without transmitting excessive forces
back into the manifold or support brackets.

6.3.4 Materials

Exhaust gas contains corrosive chemicals, as well as water vapour, so the materials you
select for the exhaust have a significant effect on the life of the system.

6.3.5 Pipe Sizes and Bends

The exhaust pipe must be at least a nominal 60 mm internal diameter, including pipework
inside the silencer.

Avoid sharp bends as they increase restriction. Make all bends around as large a radius as
possible and avoid mitred joint type bends if possible.

Restriction is inversely proportional to the 5th power of the pipe diameter so, if you need a
complex routing with many bends for package reasons, a small increase in pipe diameter
can help to compensate for the restriction caused by the bends.

6.3.6 Water Protection

The system must not allow water to drain back into the engine, or to fill with rainwater. Any
vertical exhaust stack must be protected from rain by fitting a rain cap or using a bend to
bring the outlet back to the horizontal.

Figure 13: Typical provision of flexible elements in cab mounted and

chassis mounted exhaust designs

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7. Fuel System
7.1 Fuel System Overview

W WARNING! Fuel is flammable so keep naked flames away from the fuel
system. Stop the engine immediately if you suspect a fuel leak. Do not smoke
while refuelling or working on the fuel system. Do not refuel with the engine
running. Completely wipe off any spilt fuel which could cause a fire. There
could be a fire and injury if you do not follow these precautions.

C NOTICE! Do not allow the engine to run out of fuel. If you do not follow these
instructions it could seriously damage the fuel injection equipment and may
be expensive to repair.

C NOTICE! Do not allow dirt to enter the fuel system. Before you disconnect
any part of the fuel system, thoroughly clean around the connection. When a
component has been disconnected, for example a fuel pipe, always fit
protective caps and plugs to prevent dirt ingress. If you do not follow these
instructions it will lead to dirt entering the fuel system. Dirt in the fuel system
will seriously damage the fuel injection equipment and may be expensive to
repair.

The fuel system included on the JCB Dieselmax engine meets the required legislated
emission standards.

The engine needs a supply of clean fuel and a return line back to the fuel tank. The system
is designed to allow high bypass fuel flow and can deliver full flow return to tank.

Materials used for all components and pipe fittings in the fuel system must be resistant to
diesel fuel. Copper, bronze, brass, tin, lead and zinc coatings can cause deposit formations
which will damage components in the fuel system.

Parts of the fuel system which the engine installer needs to provide are normally the
following:

• Fuel tank

• Fuel feed hoses and pipework

• Pre fuel filtration and water agglomerator

• Fuel return to fuel tank

The engine installer must make sure that these parts are adequately earthed to prevent the
build-up of static electricity.

You need to test the fuel system to make sure that it meets the performance requirements
for depression at lift pump inlet, fuel return backpressure and fuel temperature (see the
Technical Data Sheet).

Under maximum flow conditions the depression at the lift pump and the maximum back
pressure in the fuel return line (at the engine outlet) must not exceed the limit specified in the
Technical Data Sheet. However it is good practice to ensure that these values are kept as
low as possible.

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7.2 Installation of the Fuel System

7.2.1 Fuel Tank

You need to install the fuel tank in a position between 0.7 m above the engine and 0.7 m
below the engine. You measure the position from the fuel outlet position on the tank to the
fuel inlet position on the engine. The fuel tank must also incorporate a drain plug so you can
drain and flush the tank to remove sediment and water that typically build up in the fuel tanks
of off-highway equipment.

Install the fuel feed to the engine pipe centrally inside the fuel tank, at a height above the
bottom of the tank so that 5% of the tank’s volume lies below the bottom of the suction pipe
with the machine on a flat and level surface. This makes sure that the fuel feed pipe does not
become blocked and water ingress is reduced to the fuel filter and sedimenter.

Fuel tanks must ideally be of 1:1 aspect ratio. If possible, avoid shallow tanks. If you have to
install a shallow tank, you can reduce the risk of fuel starvation when the machine is inclined
by fitting baffles.

Install the return pipe to avoid the return fuel being directly drawn back into the fuel feed
pipe. You can do this by separating the two by approximately 300 mm and by baffling.

Vent the tank to prevent the formation of a vacuum as fuel is used up. The vent must not
allow ingress of dirt or water to the fuel tank.

Incorporate a drain plug in the fuel tank so that you can flush the tank to remove sediment
and water that typically build up in diesel storage systems.

Install the fuel tank so that any relative movement of the mounting locations is not
transmitted into the tank structure and that stresses in the tank are within the material’s
capabilities when the full tank is subjected to operating loads.

7.2.2 Fuel Feed Pipe (Suction Pipe)

You must make the suction pipe from materials that are resistant to fuel oil and from
materials that can operate safely up to 100ºC and tolerate the inlet depression for the
engine. In applications where it is necessary to use a remote tank, you need to construct the
suction pipe so that it does not collapse under the suction pressure required to draw fuel
from the tank.

Connection to the engine is done using quick release connectors as described in SAE
standard J2044.

In applications where it is necessary to use a remote tank, you must construct the suction
pipe so that it does not collapse under the suction pressure needed to draw fuel from the
tank.

Use an internal diameter of 8 mm to allow for a fuel flow rate of up to 100 Litres/hour.

The hose and pipework must give a smooth flow to the engine without any sharp bends or
rising loops. You need to clip the hose and pipework at intervals to prevent chafing and to
avoid fatigue failures due to resonant vibration.

7.2.3 Fuel Pump

Do not adjust engine idle speed. Reducing idle speed will result in excessive vibration which
could cause severe damage to the engine and machine.

7.2.4 Injector Leak Off Return to Fuel Tank

Connection from the engine is done using a quick release connector, as described in SAE
Standard J2044.

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This pipe must conform to the requirements of the fuel feed pipe. With exception that the fuel
return hose must have an internal diameter of at least 6.0 mm and must follow the most
direct route back to tank, avoiding sharp bends and restrictive adaptors. Avoid close
proximity of fuel pipes and hoses to hot surfaces such as exhaust pipes.

7.2.5 Fuel Filters and Water Separators

You need a machine-mounted agglomerator for the JCB Dieselmax range of engines. You
must install this onto the equipment chassis, close to the engine and in a warm position.
However, not in a hot position, that is to say, not adjacent to the exhaust system. The
efficiency of the water separation must be a minimum of 95% (measured to SAE J1839).

For mechanical engines, you need to install an integral filter media of rating 30 microns
minimum to give adequate protection for the lift pump while avoiding premature blocking.

The water agglomerator must include a water present detector which lights a warning on the
in cab engine control panel.

You need to install the agglomerator above the maximum fill level of the tank to avoid fuel
syphoning when servicing.

It is good practice to fit a strainer and gauze to the filler neck of the fuel tank to stop large
items blocking fuel feed pipes.

Water separation requirements vary depending on fuel quality. Where the fuel does not
comply with EN590 you may need to install an additional water separator. JCB Power
Systems Applications Department can give advice on expected regional fuel conditions.

See Figure 14 below for a schematic of the recommended fuel filtration.

Figure 14: Example fuel filtration schematics for mechanical fuel injection systems

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7.2.6 Fuel Temperature

W WARNING! Do not install the fuel pipes and hoses close to hot surfaces such
as the exhaust pipes.

Diesel fuels have a cloud point at which wax crystals begin to form. Below this temperature,
problems may result from these crystals partially or completely blocking the system. It is
possible to install an electric heater adjacent to the engine mounted fuel filter for extreme
temperature situations.

N NOTE! Refer to JCB Power Systems Applications department for more advice.

7.2.7 Fuel Lubricity Additive Dosing Filters

A lubricity additive dosing filter unit is available for use with low lubricity fuels. Diesel fuel
specification EN590 states a lubricity limit of 460 µm (wear scar diameter), for fuels with
wear scar values higher than 500 µm, fitment of a lubricity dosing filter is recommended.

N NOTE: Please contact JCB Power Systems Applications Department for more
information and advice on installation and expected regional fuel conditions.

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8. Engine Mounting and Noise Reduction

8.1 Overview

W WARNING! Poor engine mount design may lead to excessive operator

environment noise and vibration levels resulting in personal injury.

C NOTICE! Poor engine or powertrain mount design may cause engine

damage.

Figure 15 and Figure 16 show two types of engine mount layout:

• Type 1 – In-line engine and torque converter and gearbox

• Type 2 – In-line engine and hydrostatic transmission

Figure 15: Typical 4-point mount. Torque converter and gearbox 'T-Bar' attached to gearbox

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Figure 16: Typical 4 point mount. Hydrostatic system, mounts attached to SAE flanges

Type 1 and Type 2 engine mount layouts both use a four point mount system with mounts
located towards the front of the engine and rear mount located off the transmission housing.

The purpose of the engine mount system is to locate the engine while reducing the vibration
transmitted into the equipment structure. In addition, the mounts protect the engine from any
relative movement of the chassis-side mount positions due, for example, to flexure of the
chassis as the machine travels over rough ground. This is particularly important for machines
with a more flexible chassis. Generally, engine mount specification involves reconciling the
conflicting requirements for restricting engine movement and providing isolation.

A compromise is needed to achieve the refinement targets while keeping engine movement
within the limits prescribed by clearances to bodywork and other components. It is also
important to make sure that rigid body modes of vibration of the powertrain do not coincide
with sources of vibration input, such as engine firing frequency or modes of the whole
machine.

Many off-highway engine mount systems have only received limited development in respect
of vibration isolation. In practice, common mounts are generally used at all mount positions
and these positions are largely dictated by package restrictions. The largest single factor
affecting vibration isolation can often be ensuring the bump stops are free and that there are
no fouls between the engine, or its associated pipes and hoses, and chassis/body. Adequate
isolation can be achieved using four identical mounts located as described in Figure 8 for the
Type 1 layout, as long as the machine was assembled such that the design-intent bump stop
clearances were achieved.

W CAUTION! You must make sure that vibrations transmitted to the equipment
operator and other people are minimised as vibration is uncomfortable and
can be damaging to health.

If significantly improved isolation is required then the standard approach may need
modifying. Typically, you can achieve good engine isolation with a four-point mount system
in which the rear mounts carry around 70%-80% of the weight of the powertrain, allowing the

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front mounts to be relatively soft. Install the mounts to allow the powertrain to roll about its
torque-roll axis, which leads to the front mounts being mounted close to the front of the
engine and as high on the block as possible, with the rear mounts being mounted close to
the flywheel position. However, this kind of configuration can lead to increased engine
movement so you need to be careful, particularly with clearance between the fan tip and
radiator shroud.

In applications where heavy transient duty cycles are expected, another mounting technique
which offers very good isolation and limited fan movement outside of its normal swept
volume is available. This relies on the use of inclined sandwich mounts at the front of the
engine which you can angle to act as a single mount positioned on the axis of minimum roll
inertia. This better allows the dynamic disturbances to be dissipated by doing work in
overcoming the inertial mass of the engine instead of being reacted and transmitted into the
support structure. Because the engine is being allowed to move about its roll centre, fan
movement outside of its normal swept volume is reduced. This allows a smaller fan tip
clearance and therefore improves cooling performance. Figure 17 illustrates this principal.

Figure 17: Using inclined front mounts to simulate a single mount

on the axis of minimum roll inertia

Whatever the configuration, you must design the engine mounts so they give low stiffness in
the neutral position and then give progressively higher stiffness as powertrain movement
increases through the use of well-designed bump stops or snubbers. It is very important that
the engine mounts give physical restraints that stop engine movement becoming large
enough to allow clashes between engine components and the bodywork or chassis.
However, you must make sure the mounts can be set in production so that the design intent
bump-stop clearances are achieved.

Consider the static stiffness and the damping that the mount gives. A particular level of
damping is necessary to help control engine movement but too much damping results in
poor isolation and problems with mount durability. Damping is often described in terms of the
“phase angle”. Typically, natural rubbers have a phase angle of between 6° and 8°. This can
be expected to give acceptable damping and good durability.

The brackets which attach to the engine also need careful consideration. As a general rule,
the body and engine side brackets must be at least ten times the stiffness of the mount,
when considered as an elastic cantilever from the side of the main structure. It must also be
free of resonances up to 150 Hz.

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8.2 Performance
You need to test the engine mount system to make sure that it conforms to the following
performance requirements:

• Stationary bending moment applied to the flywheel housing.

• Resonant bending frequencies of the powertrain.

• Control of engine movement.

• Control of rigid body modes of vibration.

• Isolation of engine vibration.

8.2.1 Minimum First Bending (Beam) Frequency of the Powertrain

The first bending frequency of the engine and gearbox system must be above 150 Hz. If the
frequency is below 150 Hz it will typically show up on the 2nd order vibration levels,
measured at three positions along the powertrain, during a full load sweep through the
engine speed range. If the bending frequency is excited within the engine speed range then
it will show as a distinct peak. If the bending frequency lies below 150 Hz but above the
frequencies excited within the engine speed range then it will show up as high levels at the
top end of the engine speed range.

Off-highway equipment must generally meet noise legislation appropriate to the territory of
operation. In order to achieve legislated limits on noise emissions it may be necessary to
apply noise shields around the engine. You must make sure that adequate airflow is
maintained.

N NOTE: Cooling fans are one of the most significant sources of noise on Off-
highway equipment.

8.2.2 Allowable Installation Angles

We recommend that you install the engine horizontally. However, small installed installation
angles are allowed when necessary (sub 5 degrees) without impacting the 35 degree
machine gradeability.

8.2.3 Control of Engine Movement

Engine movement must not exceed 10 mm at the fan when subjected to normal operating
loads and abuse loads such as “shuttling” and rough terrain operations. You can normally
achieve this by allowing 3 mm of rebound travel and 5 mm of compression. You need to
install rebound washers and snubbers to make sure that rebound travel is limited to 3 mm.
Compression snubbers may be necessary if the mount stiffness is insufficient to limit
compression travel during abuse loading.

8.2.4 Control of Rigid Modes of Vibration

The fundamental bounce, pitch and roll modes of the powertrain must be below 18 Hz
(assuming a 750 rpm idle speed). However, you must avoid installed natural frequencies
similar to other machine components such as cab mounts, track frequencies, and so on.

Avoid coincidence of rigid body modes by locating the pitch, bounce and roll modes at
different frequencies within the prescribed band.

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8.2.5 Isolation of Engine Vibration

Mounts chosen to meet the rigid body requirements above will give adequate isolation if
installed correctly. Because of the small amount of allowable engine movement, the mounts
may need bump stops to limit the amount of movement at the mount. In practice, all the
allowable travel could be taken up in production tolerances unless appropriate adjustment is
provided to enable bump stop clearances to be set in machine build.

In addition, the design of the bump stops needs careful consideration. Rebound washers, or
other form of travel limiter must be fitted as standard. Compression bump-stops may be
required depending on whether the mount stiffness is sufficient to limit engine movement and
prevent the fan fouling the shroud during extreme loading. In off-highway machines there is
likely to be frequent impacting on the bump-stops. They must therefore be designed to
provide a rapidly increasing stiffness, rather than a hard, metal-to-metal contact. The design
of Figure 18 shows a classic approach. Typically up to 6000 bump-stop impacts may be
expected so the design needs to be able to accommodate this level of activity without
significant degradation.

To ensure effective isolation of vibration, you need to consider the mount brackets and the
structure to which the mounts attach on the machine. Mount brackets must be 10 times
stiffer than the rubber mounts and free of resonances up to 150 Hz. The structure to which
the mounts attach on the machine must be as stiff and have as much mass as possible and
must also be free of resonances up to 150 Hz.

C NOTICE! If using engine mounts with stepped rebound washers as described

in Figure 18, make sure that the washer is assembled in the correct
orientation.

Figure 18: Typical engine mount design illustrating good practice in bump stop design

You can normally meet this requirement by designing short “stubby” brackets. You can
design long “spindly” brackets that are physically strong enough (that is their stresses are
well below yield) but still have resonances at frequencies that the engine will excite. See
Figure 19. In this situation the in-cab refinement will suffer and there may be a fatigue issue
affecting durability. Applying a modal load case to the FE model can be done very simply
and will identify any resonances. However, it is important that the constraints match reality
and the bracket is modelled with its fasteners.

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Figure 19: Examples of good (left) and bad (right) bracket design

8.2.6 Noise Shields

Off-highway equipment must generally meet current EC regulations relating to equipment

used out of doors (2005/88/EC). Responsibility lies with the customer to make sure that the
equipment conforms to all of the current and applicable noise legislation.

You must make sure that engine noise and engine ancillary noise does not cause the
machine to fail the test. You must pay particular attention to the position of fans and
hydraulic components such as pumps, valves, and so on and the noise paths from these
components to the outside. Avoiding clear line of sight between a noisy component and the
measurement position is very helpful in avoiding problems with noise compliance and you
also need to consider component isolation.

For higher frequency noises, local shielding with noise absorbent backing material can be
very effective. Simple barriers are helpful, but as sound reflects well off hard surfaces, their
effect can be improved by using noise absorbent backing materials. Applying noise
absorbent materials to existing panels inside the engine bay also helps reduce noise levels.

Fan noise is one of the most significant sources of noise on off-road equipment so you must
select a fan which is compatible with achieving the requirements of the EC Directive.

Fan noise is a function of fan speed and fan efficiency. Best results are normally obtained by
specifying the most efficient fan available. This allows lower fan speeds and results in lower
noise operation. However, the enclosure around the fan and cowling in front of the radiator
can also have a significant influence on the noise and you must provide as much shielding
as is consistent with achieving cooling requirements. If more significant reductions in fan
noise become necessary then viscous fan couplings (bi-metallic or electronically controlled)
may be considered. Whilst such fan drives do nothing to reduce the peak noise, the way that
the machine is tested means that lower results will be recorded with a viscous fan coupling
fitted.

Ring fans have been used to help reduce fan noise on road vehicles. However, the danger of
fan failure due to vibration caused by a build-up of dirt on the inside of the ring makes them
generally unsuitable for off-highway equipment unless you can protect ring fans from the risk
of dirt build-up.

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8.3 Installation

8.3.1 Bump Stop Clearances

It is essential that you achieve the intended bump-stop clearances in the machine. If you do
not give adequate bump-stop clearance it leads to excessive in-cab noise and vibration and
may allow the engine to move in such a way that it could cause a clash. Excessive loading of
an individual bump-stop could lead to fatigue failures.

You need to provide adjustment to allow the mounts to be levelled during machine build,
taking up any misalignment due to production tolerances. You do this before the fan cowl
clearance is set.

8.3.2 Fool Proofing of Mounts (Poka-Yoke)

It is normal practise in JCB to specify the same part for all mount locations. In this case no
fool-proofing is necessary. However, if a mount system is specified in which different parts
are used, then the design must be fool-proofed such that it is not possible to fit the wrong
mount by mistake.

8.3.3 Mount Positions Relative to the Engine

The distance that the compliant element of the mount is away from the centre of gravity of
the engine and transmission unit affects the pitch and roll frequencies. Increasing the
distance increases the frequency. You can use this effect to tune the pitch and roll
frequencies relative to the vertical frequency.

8.3.4 Mount Positions Relative to the Equipment

The nearer the mount is to the main structure of the equipment the easier it is to ensure that
all the brackets are resonance free up to 150 Hz. In general, attaching the engine mounts to
heavy and stiff parts of the main structure is one of the most important aspects of achieving
good vibration isolation.

Where the mounts are attached to chassis sections, such as a conventional C-section, you
must make sure the load is reacted through the centroid of the section to avoid introducing
unnecessary twisting into the section, unless the section is stiff enough for any twist to be
negligible.

8.3.5 Protection of the Mounts

The mounts will deteriorate if they are exposed to diesel oil, engine oil or hydraulic fluids.
While some “misting” is inevitable in an engine bay area you need to avoid locating mounts
where they could be exposed to regular or constant exposure to such fluids. Generally you
can do this by keeping fluid fill, drip paths and mount locations separated and avoiding
placing mounts in locations where fluids could pool.

The rubber elements of the mount degrade faster if they are exposed to temperatures above
70ºC. If mounts are located close to hot parts of the engine, such as the exhaust pipe and
the turbocharger, you must protect them with heat shields. If temperatures higher than 70ºC
are unavoidable, then you need to consult the mounting supplier’s about special high
temperature rubbers.

8.3.6 Noise Shields

Noise shields must be of a form in which acoustically absorbent material is mounted to a

rigid backing material. This could be an existing panel or a new panel introduced specifically
to control noise.

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All materials must be durable and resistant to fuel and lubricating oil, while also being
suitable for operation in temperatures of up to 120°C. Where shielding needs to pass close
to the exhaust, you need to apply additional thermal protection to the noise shield.

The noise shields work in two ways. They are a physical barrier to sound waves escaping
from the engine bay and they also absorb sound energy. Unless the engine bay is
completely acoustically sealed, which is not practical, the amount of absorption area
available is critical to the effectiveness of the installation.

Attach all of the noise panels securely to the surrounding structure with fasteners that are
sufficient to hold the shields in position, regardless of equipment activities, for the expected
life of the equipment.

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9. Electrical System
9.1 Overview

W WARNING! Battery electrolyte is toxic and corrosive. Do not breathe the

gases given off by the battery. Keep the electrolyte away from your clothes,
skin, mouth and eyes. Wear safety glasses.

W WARNING! Batteries give off explosive gases. Keep flames and sparks away
from the battery. Do not smoke close to the battery. Make sure there is good
ventilation in closed areas where batteries are being used or charged. Do not
check the battery charge by shorting the terminals with metal, use a
hydrometer or voltmeter.

W WARNING! Understand the electrical circuit before connecting or

disconnecting an electrical component. A wrong connection can cause injury
and damage.

W WARNING! Injury may occur when lifting batteries. Do not lift heavy objects
on your own. Use lifting equipment or the help of an assistant.

The basic electrical system consists of the following:

• Battery or batteries (24 V systems)

• Starter motor

• Alternator

• Key-switch

• Various sensor and relay devices.

Always use proprietary parts that are properly matched to the requirements of the engine
and which have been proven to be durable in the application being considered. Make sure
that the earth paths are short as this gives reliable operation and avoids EMC problems.

You may need additional devices for operation in low temperatures, such as below -12°C
ambient. A 1000 W block heater is available in both 110 V and 240 V formats. Block heaters
will be most efficient in terms of engine core temperature when left on overnight. However,
they show a significant benefit after four hours of operation. The offered block heater is not
thermostatically controlled and does not suit continuous operation.

9.2 Performance
You need to test the electrical system to make sure it conforms to the performance
requirements for voltage overload, EMC emissions, cranking speeds, alternator loads,
earthing, cold start strategy and warning devices.

9.3 Voltage Capability

All system components must be capable of withstanding a 50% voltage overload. This
means that for a 12 V system, all components must be capable of safe operation at voltages

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up to 18 V. For a 24 V system the limit is 36 V. (See JCB standard 00140, section 12).
A minimum of 6.5 V must be seen at the ECU to avoid ECU brown out.

9.4 Electromagnetic Compatibility

Electromagnetic emissions for the electrical system of the machine must be tested.

N NOTE: It is the manufacturers’ responsibility to make sure that the machine

conforms to the overall EMC limit.

9.5 Cold Start Strategy

The grid heater (when supplied) is located in an aperture in the inlet manifold. Its use
depends upon ambient temperature and available cranking speed in the machine. The
maximum allowable preheat time is 30 seconds. Extending this time may result in damage to
the grid heater element. Tests have proved that no more than 20 seconds is necessary.

Sometimes it may be beneficial for the grid heater to stay energised whilst cranking. Some
post heat (after start) may also help to reduce white smoke under severe cold conditions
(maximum 5 minutes post heat).

JCB can provide a separate automatic grid heater control for mechanical engines.

9.6 Battery

W WARNING! You must always remove the negative battery lead before you do
any work on the equipment or engine. You must also make sure that all
appropriate warnings, and or, labels advise accordingly.

Use only one battery for 12 V systems. You need two batteries for 24 V systems. Each
battery must have a minimum rating of 900 CCA (SAE) / 145 Ahr.

9.6.1 Installation

You must support the battery or batteries on a carrier that holds the battery flat and level
under normal load conditions. The battery carrier must have sufficient strength to hold the
battery in place under all conceivable conditions, including equipment roll over. Make the
bracket sufficiently stiff that it does not suffer from significant resonant vibration under normal
operating conditions.

It is important that the battery compartment is open to the atmosphere to avoid a build-up of
dangerous gases. You can improve the battery performance and life by protecting it from
large variations in temperature (either excessive heat or excessive cold). The battery
temperature must stay below 50°C at all times. Take account of maintenance of the batteries
when you design and locate the battery carrier.

9.6.2 Earthing

The negative terminal of the battery must be earthed to the main chassis (through a battery
isolator, where required). Earth leads must be kept as short as possible and of minimum
2
diameter 95 mm .

9.6.3 Battery Isolators

The use of a battery isolator allows you to completely isolate the electrical system from the
equipment battery, or batteries. You must make sure that the battery isolator hardware is
sized in accordance with the expected current demand and that it has good environmental
protection. You must make sure that the contacts in the isolator are of a good, robust design

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and offer minimal resistance. You must install the isolator as close as possible to the battery
and make sure that the operator can access the isolator easily.

N NOTE: The battery isolator must not be used to shut down the machine.

9.7 Starter Motor

The geared motor on the JCB Dieselmax engine is rated at 4.2 kW for the 12 V and 24 V
systems.

The starter motor’s cranking speed varies depending on a range of different conditions such
as ambient temperature, parasitic loads and available battery charge. To ensure a reliable
start in cold climate conditions tests have shown that particular cranking speeds must be
attained (see Table 2). For successful operation below -30ºC, you need full winterisation.

Table 2: Cold start strategies

Temperature (°C) Start Aid Mean crank speed

required (rpm)
-30 Block heater plus 10 seconds preheat 90 – 100
(and on whilst cranking)
-20 10 seconds preheat 90 – 100
(and on whilst cranking)
-12 No aid 100 – 110

9.7.1 Starter Motor Earthing Requirements

Route the battery negative cable directly from the switched terminal of the isolator (or directly
from battery negative if no isolator fitted) to the earth stud on the rear casing of the starter
motor. This keeps the voltage drop at the starter motor to a minimum and makes sure that a
high integrity earth connection is maintained throughout the equipment’s life.

A separate earth cable is also needed to earth the equipment chassis. You must connect the
earth cable from the starter motor earth stud or the switched side of the isolator (if fitted) to
the chassis. Use an appropriate fastener where all paint has been removed at the point of
2
connection. The minimum recommended cable cross-section is 95 mm .

9.8 Alternator
The alternator is direct mounted to the engine and is driven by the FEAD system. You do not
need to adjust the alternator belt as a sprung tensioner is included in the FEAD system.

The alternator rating must be more than 25% above the maximum continuous load. The
standard 95 Amp alternators will normally be sufficient for a 12 V system. The 24 V
alternators are rated at 55 Amp. The alternator charging lamp must be of a 3 watt rating to
give the correct level of excitation to the alternator upon initial start-up.

A W terminal is provided on the alternator for engine speed indication. The frequency is 6
pulses per alternator revolution. The alternator speed is dependent on the effective alternator
pulley diameter. Table 3 shows the speed ratios. This signal incorporates a filter network to
enable a stable tachometer response, which limits voltage output from the terminal to 1.5
Volts.

Table 3: Alternator speed ratios

Effective Diameter (mm) Alternator: Engine speed ratio

50 3.113:1
56.2 2.787:1

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The starter motor also needs to be earthed to the chassis, normally by a braided earth strap,
attached by ring terminal, typically under an appropriate M8 fastener into the powertrain
assembly. The connection to the chassis must be made using a bolted connection in which
all paint has been removed from the chassis at the point of connection.

9.9 Wiring
All wiring in the engine bay must have insulation that can withstand temperatures up to
100°C (Class B wiring to ISO Standard 6722). The wiring must also be resistant to diesel,
moisture and lubricating oil.

Battery cables must be as short as possible. The minimum recommended cross-section is

2
95 mm .

The starter motor must be earthed to the equipment chassis and also directly back to battery
negative with a cable of adequate cross-section. The minimum recommended cross-section
2
is 95 mm .
2
The alternator wiring must have a cross sectional area of at least 16 mm for 24 V systems
2
and 25 mm for 12 V systems dependent upon the alternator specification. See JCB
Standards 00127 & 00137.

9.10 Earthing
Voltage drop on a 12 V system between any earth, or component negative terminal and the
negative terminal of the battery must not be greater than 0.5 V, measured whilst cranking.
Similarly, the voltage drop between any component positive terminal and the battery’s
positive terminal must not be greater than 0.5 V under similar conditions. In each case, for
24 V systems a limit of 1.0 V is used instead of 0.5 V. You need to account for the voltage
drop across battery isolators, where fitted.

9.11 Switches and Sensors

All engine related switches and sensors must be of the insulated earth type.

If the application needs an emergency stop please contact JCB Power Systems Applications
department for more information and advice.

9.12 Hour meter

You must install an hour meter to record the machine and engine hours.

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9.13 Specimen Wiring Diagram

Figure 20 shows a typical wiring diagram for the mechanical JCB Dieselmax engine,
including the minimum acceptable provision of warning devices.

Figure 20: Example mechanical engine specimen wiring diagram

9.14 Cold Start and Boost Pressure Switch Harness

The electrical cold start advance (CSA) system on the 448 G-TCA differs significantly from
other JCB Dieselmax G-Drive units. The DC Stage 2 engine is fitted or supplied with a boost
pressure switch and boost pressure switch harness. The engine installer, OEM or distributor
must note the following:

C NOTICE! The boost pressure switch, item A (see Figure 21), installed on the
charge cooler pipe is critical to the control of the engine. The boost pressure
switch must stay connected at all times to the boost pressure switch
harness, item B.

C NOTICE! Manufacturers must connect their harness using only the two
sockets, items E and F, on the boost pressure harness. This arrangement
must be maintained at all times in the finished generating set.

If you do not comply with these notices, it will invalidate the Warranty Agreement and the
JCB Customer Acceptance Standards. You must never remove the boost pressure switch
harness or bypass it in the operation of the equipment.

For more advice and guidance please contact JCB Power Systems Applications department.

Page 44 of 56 320/A9162-1 © JCB Power Systems Ltd.

 JCB Dieselmax Engine Installation Manual

Figure 21: Boost pressure switch harness schematic

Item Part No. Description Comment

A 320/09635 Boost pressure switch Do not disconnect
B 320/09636 Boost pressure switch harness
C - Cold start advance switch Do not disconnect
D - Cold start advance solenoid Do not disconnect
E - Connector (NN) Customer connection – 2 way DT04
F - Connector (MF) Customer connection – 2 way DT04
G - Relay Chassis mounted

Table 4: Key to boost pressure switch harness schematic

© JCB Power Systems Ltd. 320/A9162-1 Page 45 of 56

JCB Dieselmax Engine Installation Manual

10. Power Take-Offs

10.1 Positions of Power Take-Offs

W CAUTION! Operating the engine PTOs beyond their design limits may result
in engine damage or personal injury.

The four Power Take-Off (PTO) points are provided on the JCB Dieselmax engine, as shown
in Figure 22. These PTO points and maximum loadings are as follows:

• PTO No. 1 – Flywheel. Full load engine torque at rated speed

• PTO No. 2 – Crank Nose. 60 kW / 260 Nm at rated engine speed

• PTO No. 3 – RHS gear case. 60 kW / 205 Nm max. at 1.268x engine speed

• PTO No. 4 – LHS gear case. 15 kW / 40 Nm max. at 1.625x engine speed

PTO No. 3 & PTO No. 4 are mounted to the gear casing by two-bolt flanges to the SAE
standard J744 pattern. PTO No. 3 conforms to the SAE B standard, while PTO No. 4
conforms to the SAE A standard. A four bolt-boss has been provided on the cylinder block
adjacent to PTO No. 3 to allow for supplementary support brackets if required, as shown in
Figure 23. Devices attached to both PTO No. 3 and PTO No. 4 must carry their own gears.
For gear details please contact JCB Power Systems Applications department.

PTOs operate in the anti-clockwise direction when viewed from the rear of the engine.

A flange to SAE standard J1946 (size code 1410, Type S) is provided on the crank nose for
provision of PTO No. 2.

The alternator is direct mounted to the RHS of the engine and driven by the FEAD system.

Provision has been made for the direct mounting of an air-conditioning compressor to the
lower LHS of the engine. The FEAD is capable of driving this type of compressor.

Figure 22: Positions of Power Take-Offs

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 JCB Dieselmax Engine Installation Manual

Figure 23: Supplementary support bosses

10.2 Performance of Power Take Offs

You must make the following considerations about the PTOs:

• PTO No. 1 loading with belt or chain drive

• PTO No. 2 maximum unsupported weight and bending moment

• Mass and support of PTO No. 3 & PTO No. 4

You must make sure that, in common with all other structures attached to the engine, the
PTO-driven device has a primary resonant frequency greater than 150 Hz. Bosses have
been provided at various positions on the engine to which you can attach additional support
brackets, if necessary.

PTO No. 3 has been evaluated successfully with cast iron hydraulic pumps with no additional
support and a calculated bending moment of up to 33 Nm.

N NOTE: Please consult JCB Power Systems Applications department for specific
information and advice.

© JCB Power Systems Ltd. 320/A9162-1 Page 47 of 56

JCB Dieselmax Engine Installation Manual

10.3 Front End Accessory Drive (FEAD)

W WARNING! The engine has rotating parts. You must make sure that you give
a clear warning to stop anyone starting the engine when someone is working
on the FEAD due to risk of personal injury.

The FEAD gives drive for the cooling fan, water pump, alternator, and an air conditioning
compressor. The alternator is direct mounted to the RHS of the engine and driven by the
FEAD system. You must allow for the direct mounting of an air conditioning compressor to
the lower left-hand side of the engine.

10.3.1 Torsional Vibration

The JCB Dieselmax engine gives generally refined torsional vibration characteristics. The
crank is exceptionally stiff giving very low levels of wind-up between the crank pulley and the
flywheel.

Torsional vibrations must not present a problem for transmissions (manual and torque
converter) and hydrostatic pumps typically used in construction equipment and attached to
PTO No. 1.

There may be instances, particularly in respect of devices attached to PTO No. 2 and
devices that need particular limits on torsional vibration, where care needs to be taken to
ensure the engine characteristics are appropriate. In such cases cyclic velocity curves are
available from JCB Power Systems on request.

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 JCB Dieselmax Engine Installation Manual

11. Engine Speed Control System

You must arrange the engine speed control system to allow full travel to the engine speed
control lever, within its stops, while giving acceptable pedal forces. You need to use a cable
system which allows for movement across the engine and cab mounts. Install an over-travel
spring to stop excessive loads on the engine speed control lever, as shown in Figure 24.

Use a guideline figure of 100 g for any throttle lever attachments, brackets and so on,
connected to the main throttle arm of the Delphi DP210 pump.

The force required to operate the speed control lever to wide open throttle is approximately
40 N.

The travel of the speed control lever from minimum to maximum engine speed is
approximately 30°.

N NOTE: Please contact JCB Power Systems Applications department for more
information.

Figure 24: Example of a typical cable system

© JCB Power Systems Ltd. 320/A9162-1 Page 49 of 56

JCB Dieselmax Engine Installation Manual

12. Fluids and Ambient Temperature: Fuel, Lubricant and

Coolant
12.1 Overview

C NOTICE! If you do not use JCB recommended fluids it may result in engine
damage.

The quality of fluids used in an engine can have a significant effect on the engine
performance and durability. You must select fluids appropriate for the engine and the climatic
conditions in which the equipment is to be used. The JCB Dieselmax engine has been
developed to operate using particular quality fuels, lubricants and coolant. If you use other
fluids then you must consult JCB Power Systems Applications department confirm that they
are acceptable.

12.2 Fuel
The following fuel grades are preferred and may be used with no restrictions or conditions:

• EN590 Diesel Fuel Types – Auto, C0, C1, C2, C3, C4

• ASTM D975-91 Class USDF1, USDF2, USDFA, 2-2DA

• BS 2869 Class A2

• JIS K2204 (1992) Grades 1, 2, 3 and Special Grade 3

The following fuels are not preferred and may be used but may lead to reduced FIE life, loss
of performance or both:

• ASTM D975-91 Class 1-1DA

• JP7 (MIL T38219 XF63)

• NATO F63

The following fuels are not preferred and may be used only with appropriate additives and
will lead to reduced FIE life, loss of performance or both:

• AVTUR FS11 (NATO F34, JP8, MIL T83133, DEF STAN 91-87, DERD 2463)

• AVCAT FS11 (NATO F44, JP5, MIL T5624, DERD 2452, AVTOR)

• JET A1 (NATO F35, DEF STAN 91-91, DERD 2494)

• AVCAT (NATO F43, JP5 without additives)

• JET A (ASTM D1655)

• ASTM D3699 Kerosene

Fuels which have been modified by the inclusion of water and alcohol emulsions, such as
Elf-Aquazole and Lubrizol-Purinox, may contribute to premature failure of engines or
components. You must consult JCB Power Systems Applications department before you use
these fuels.

Biodiesels can cause serious problems for engines. JCB Dieselmax Stage 3a / Tier 3
engines have been developed to run with biodiesels up to 20% mix (B20), but NOT with
higher biodiesel proportion. The biodiesel content of this mix must be to ASTM D6751, DIN
51606, or ISO 14214 standards. Using a B20 blend of biodiesel requires caution and
additional servicing of the engine is required. You must consult JCB Power Systems

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 JCB Dieselmax Engine Installation Manual

Applications department for more guidance. Biodiesel is very problematic to store. Fuel in
storage has to be very carefully managed to ensure that it does not deteriorate during this
period.

Regardless of fuel specification, dirt, air and water content may have a detrimental effect on
engine performance and longevity. You must take care with the fuel system to give
appropriate filtration and water separation. You must install drains on the tank to allow
periodic cleaning.

The engine is rated according to ISO14396 with a fuel inlet temperature of 40°C. Higher fuel
temperatures will reduce the power output so the maximum must not exceed 80°C.

No warranty liability will be accepted for failure of fuel injection equipment where the failure is
attributed to the quality and grade of the fuel used.

12.3 Lubricant
See the Engine Operator’s Manual for a statement on preferred lubricants.

You must select the lubricant viscosity based on the lowest ambient temperature at which
the equipment is started and the maximum ambient temperature at which it operates.

Table 8 gives guidance on suitable oils for ambient temperature ranges.

You must change the oil and the oil filter at the specified service intervals. For oil change
intervals refer to the Service Manual. The oil filter is installed with the flange facing
downwards.

Do not allow oil to come into contact with the FEAD belt.

Table 8: Ambient temperature ranges for typical oil viscosity grades

Oil Viscosity Min Temp (ºC) Max Temp (ºC)

SAE 0W30 -40 +30
SAE 0W20 -40 +10
SAE 5W20 -30 +10
SAE 5W40 -30 +46
SAE 10W30 -20 +40
SAE 15W40 -15 +50

© JCB Power Systems Ltd. 320/A9162-1 Page 51 of 56

JCB Dieselmax Engine Installation Manual

12.4 Dipsticks
The dipstick is located on the left-hand side of the JCB Dieselmax engine, as shown in
Figure 25. You must make sure that the dipstick is accessible to the equipment operator.

There are various dipstick options available. Please contact JCB Power Systems
Applications department for more information.

Figure 25: Location of a standard dipstick on a Dieselmax engine

12.5 Coolant
Use JCB Universal Antifreeze as this antifreeze contains all of the necessary additives to
give appropriate protection for the engine. Use a minimum concentration of 30% antifreeze
and corrosion inhibitor. You must choose the concentration to give protection to the lowest
expected ambient temperature. Table 9 shows the concentration you need to use depending
on the ambient temperature. The JCB Dieselmax engine only coolant volume is 7 litres and
must be ethylene based to ASTM D6210.

Table 9: Antifreeze concentration to protect at different ambient temperatures

Protection to Antifreeze
Concentration
-15ºC 30%
-23ºC 40%
-37ºC 50%
-51ºC 60%

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 JCB Dieselmax Engine Installation Manual

13. Hostile Environment Precautions

The JCB Dieselmax engine has been designed for use in a wide range of conditions. Normal
environments are described as temperate and tropical, and are defined in terms of the
following:

• Temperate - Ambient temperatures between -20ºC and +40ºC

• Tropical - Ambient temperatures between -20ºC and +46ºC

Normal environment covers operation above sea level, up to and including 3000 metres
elevation.

Special provisions for operation in hostile environments have been made. You can consult
JCB Power Systems Applications department about any application that falls outside what is
considered to be normal environments.

Temperature and altitude affect the engine’s performance so you must consider this when
you pick an engine’s type and rating.

13.1 General Provisions

13.1.1 Cold Climates

Provision has been made for the installation of an engine block heater (mains powered,
screwed into the oil cooler housing on the LHS of the block) for operation in cold climates.
Provision has also been made in the inlet manifold for the installation of a grid heater for
improved cold start.

• The engine block heater is rated at 1000 watts.

• The grid heater is rated at 1200 watts.

13.1.2 Wading

The engine is capable of wading for intermittent, short durations up to the centre line of the
crankshaft without modification, although you must make sure that the fan can still operate
properly under these conditions. For greater depths or duration consult JCB Power Systems
Applications department.

13.1.3 Operation in Explosive Atmospheres

For operation in explosive atmospheres, such as in mining applications, you may need to fit
spark arrestors, an air-flow limiting valve or both of these devices.

© JCB Power Systems Ltd. 320/A9162-1 Page 53 of 56

JCB Dieselmax Engine Installation Manual

14. Accessibility

W WARNING! You can be injured if you use faulty lifting equipment. Make sure
that lifting equipment is in good condition. Make sure that lifting tackle
complies with all local regulations and is suitable for the job. Make sure that
lifting equipment is strong enough for the job.

Figure 26 shows the positions of the main engine components you need to access regularly.
You must make sure that you can easily and safely do all maintenance activities, such as
checking and filling the fluids, draining and so on. You must give appropriate advice and
warning to operators and other persons.

The engine has lifting eyes to lift the weight of the engine only. You must use an approved
type of lifting equipment which can lift the engine safely.

Figure 26: Position of regularly accessed items on the engine

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 JCB Dieselmax Engine Installation Manual

15. Installation Approval Limits

In addition to the guidelines covered in this manual, you must do satisfactory testing to make
sure that the limits for the following fluid temperatures and pressures are not exceeded
during all operation duties of the equipment:

• Maximum coolant temperature

• Maximum oil temperature

• Inlet restriction

• Inlet temperature

• Charge air cooler out temperature

• Charge air cooler restriction

• Exhaust back pressure

• Fuel intake restriction

• Fuel intake temperature

• Fuel return backpressure

The limits listed are shown in the appropriate JCB Dieselmax Technical Data Sheet.

© JCB Power Systems Ltd. 320/A9162-1 Page 55 of 56

JCB Dieselmax Engine Installation Manual

Page 56 of 56 320/A9162-1 © JCB Power Systems Ltd.

 Panel Wiring
0.5mm2 16/.2 Tri-Rated 11amps
1.5mm2 30/0.25 Tri-Rated 21 amps
Unless Noted Otherwise
NOTE:
All Relays 12V

RL2/1 CB2
28 1 10A 20

IN6 - IP Engine High Temperature

CR0403 Controller Module

IN1- IP Engine Temperature Res

Display CR0451

IN7 IP Engine Low Oil Pressure

IN2 IP Low Tank Level Switch

CAN CAN

IN4 IP High Pump Temp

P/N1 VBBS B+ve 12vdc
P/N1 VBB1 B+ve 12vdc

P/N1 VBB2 B+ve 12vdc

IN0 IP Speed Sense Alt

IN3 IP Outlet Pressure

wh -ve +ve Hi Lo

OP4 OP POwer Hold

OP1 OP Glow Plugs

P/N1 GNDB-ve 0vdc
VBBS 3 2 4 5

IN5 IP9 POwer ON

IN9 IP Oil Pressure

OP3 OP Fuel ETR
IP10 Estop Active

OP6 OP Alt Warn

bu
GND
bk

IP8 Crank
bu wh bk gy
CAN H

VBBS
gy

GND

GND
CAN L
120R

Programming
OFF - ON
1 2 Port
11
28 28 20 0
S1
26 4 33 7 44 27 73 10 0 13 16 23 2 pin deutsch
1K
sockets

PB1
Start 33

Emergency
Stop
RL1 RL2 PB2
7

0 0

28
CB1
16A
2

27 73
2 Resistor
Diode

180R
1N4001 7 Watts
RL1/1

2 2 0 5 5 7 8 9 10 11 0 13 20 16 20 23 0 20
2 2 0 5 6 7 8 9 10 11 12 13 15 16 22 23 24 25

19 Way Deutsch
Plug 20 16 20 23 0 20 6 Way Deutsch
14 18 12 1 2 8 10 7 5 6 3 9 15 13 1 2 3 4 5 6
Plug
6 Way
2 2 0 5 5 7 8 9 10 11 0 13
20 16 20 23 0 20

JCB 1 2 3
Length
Length 3.5M
Harness 2M 2M

First 2M in Conduit

7 7
55 77

B+ 1
Ring 0 20
Battery +s Fuel Cold W+
+ D+
Speed Warning
-ve +ve THIRD ANGLE PROJECTION
-
ETR Start Sense
-
Light

Starter Solenoid Engine Low High Engine 24v

DIMENSIONAL TOLERANCES UNLESS OTHERWISE STATED
Alternator Engine Oil Engine Temp 2 Switched
motor
Pressure Temp Sensor Tank Supply DIMENSIONAL RANGE
Level VALUES IN
Switch Switch MILLIMETERS
OVER 120 315 1000 2000 4000+
Switch Temperature Switch UP TO 120 315 1000 2000 4000
Closed Healthy TOLERANCE 1.0 1.5 2.0 3.0 4.0 5.0
Open on RIsing DRAWINGS AND DESIGNS CONTAINED
Temperature Fault HEREON ARE THE PROPERTY OF
SPECIALIST INSTRUMENTS LTD.
THEY MUST NOT BE COPIED OR CONVEYED
TO A THIRD PARTY WITHOUT WRITTEN
CONSENT FROM SPECIALIST INSTRUMENTS LTD.

Din Plugs (Positive term 1 Signal Term 2) and 2 Pin Deutsch Socket attached (Positive term 1 Signal Term 2).

Confidentiality & Copyright Specialist Instruments Ltd. 2010

This document and contents are property of

Specialist Instruments Ltd. (SIL)
The document is provided for information purposes and must not SPECIALIST INSTRUMENTS LTD.
be copied or distributed without written permission from SIL.
Unit 18 Tel: +44 (0)1722 321221
Lancaster Road Email: tech@specialistinstruments.com
Sarum Business Park
Salisbury Website: www.specialistinstruments.com
Wiltshire
SP4 6FB
Customer :
TITLE.
Engine : Hughes JCB444 mechanical panel

DRAWN: CHECKED: ISSUE DRAWN: CHECKED: ISSUE DRAWN: CHECKED: ISSUE

DATE: DATE: DATE:

DRAWING No.
1st Issue 1st Issue 1st Issue
Match new IP to software Addition of a resister and
removal
For Production 20HP2403_300_1.2
Sheet 1 of 1
SPARE PARTS & TOOLS

Hughes Pumps Sales Order No : 44204/1

Customer : Gomotor

Manufactured : October 2022

Pump build no. : 6C622-225A3

Pump model : HP65

Description Part No. Suggested Stock

Spare Parts - Pump

Pump Head seal kit : 43360-626/SK 1
Pump Head repair kit : 43360-626/RK 1

Plunger Kit seal kit : 43128-604/SK 1

Plunger Kit repair kit : 43128-604/RK 1

Crosshead seals : 23514-529 3

Oil filter : - 1

Burst Disc
Burst disc (45,000 psi) : 45616-007 3

Unloader Valve (Pneumatic) 3000 bar

Diaphragm : - 1
Repair Kit : - 1

Filtration / Boost Pump

50-micron water filter element : 21571-656 12
1-micron water filter element : - 12
Boost pump gasket kit : - 1
Boost pump seal kit : - 1

Tools
Pure Goop anti-seize compound : 17111-005 1
Plunger kit tool kit : - 1
Pump Head Tool kit : - 1
Crosshead oil seal removal tool : T1033 1
Crosshead oil seal fitting tool : T1033 -
Regulating valve Tool kit : -
Maintenance

Failure to follow these maintenance

instructions may cause damage to the
equipment, invalidate warranty or cause
personal injury or death.

The following are guidelines, frequency of

maintenance depends on various factors
including level of filtration, degree of
cavitation the pump has been exposed to,
pressure & flow (speed) operated at & the
quality of maintenance.

On a high pressure pump / system,

preventative maintenance is most cost
effective & reduces downtime. If a leak
(external or internal) is allowed to
continue, severe damage can occur to
“non-wear” items. Service the pump
before it fails. Ant-seize compound may have prevented this damage

Refer to the engine manual for 3. Only carry out maintenance in clean
maintenance schedule. conditions.

General Notes On Maintenace 4. Stock basic spare parts (filter elements,

pump seal kits, repair kits boost pump
1. Torque figures on high pressure pumps seals etc). This will reduce downtime.
and valves are critical. Refer to pump
drawings for correct figures. Failure to
use correct torque figures could
severely damage the pump &/or cause
personal injury.

2. Pumpheads & most fittings are

manufactured in stainless steel.
Threads in this material are prone to
“galling”, or seizing, even if only finger
tight. Anti-seize compound (eg Pure
Goop) must be used on threads,
(available from Hughes Pumps).
 To replace the lubrication oil for the
crankcase and gearbox, remove both drain
Only a qualified pump engineer can carry plugs.
out maintenance on the pump.
Once completely drained, refit the drain
They must fully understand the contents plugs and secure tightly.
of this manual before attempting to begin
any work. Remove the filler/ breather from the top,
using a funnel fill to the correct
Do not allow unqualified measurement (table 1.4) with the correct
personnel to work on or grade of lubricant.
near the pump as this
raises the risk of injury. Table 1.4 Pump oil capacitates

If your pump requires maintenance, please Model Capacity (litres)

contact Hughes Pumps where we can
arrange for a professional service engineer HPS400 4.5
to come and work on site.
HPS650 4.5
9.1 MAINTENANCE SCHEDULE HPS1000 6.0
HPS2200/UB30 18.0
For pump servicing intervals, please see
HPS3000 32.0
table 1.5.
HPS5000 47.0
9.2 LUBRICATION OILS
NOTE: Be careful not to overfill the pump.
Check the crankcase and gearbox oil level
using the dipstick (fig. 1.9). Only check the
Use either one of the following suitable
oil level when the pump is level and turned
lubrication oils when replacing the oil:
off.
- Shell Spirax S2 A 80W-90
- BP Energear Hypo 90
- Statoil Loadway EP 150
- Geartex EP-B 85W-90
- Chevron RPM Universal Gear
Lubricant SAE 80W-90, 85W-140

All of these lubrication oils comply with API

GL-5.

Using alternative oils will

affect pump performance,
Figure 1.9- Pump lubrication
locations. invalidating any warranty.
For information on how to dispose of oils in 9.3 TESTING
a correct and safe method, see section 6.2.
Hughes Pumps recommends that testing
Failure to dispose of oils of all high-pressure equipment should take
correctly and safely can place every six months.
have environmental
impacts and server fines. The test should be 1 ½ times the maximum
working pressure and this pressure held for
Once full, refit the filler/ breather. Hughes a period of 15 minutes.
Pumps recommends an oil change after
the first 50 hours then every 500 hours Hughes Pumps provide test certificates for
after that. all successfully tested items of equipment.

9.4 FAULT FINDING

When you have changed the oil, run the
pump for 30 seconds. Stop the pump and
It has been our experience in over many
re-check the oil level. Top up as
years that in 70 - 80% of the problems
necessary, taking into account the oil
encountered are rectified outside of the
cooler and oil hoses will have taken some
pump. Some errors may include:
oil from the pump crankcase.
- Has someone half closed the supply
In the event of a major crankcase strip-
valve?
down, thoroughly flush the oil cooler and
hoses before re-fitting.
- Has an incorrectly sized nozzle been
fitted to the gun or spray bar?
If the oil has become emulsified (white in
colour), meaning water has contaminated
- Is the inlet strainer blocked?
the crankcase, the possible causes are:
- Is the water supply on?
 Plunger seals leaking badly and
penetrating the oil seals.
- Are the connections secure and tight,
ensuring no air can get into the system?
 Oil cooler allowing inlet water into the oil
circuit due to leaking O-ring seals or
A check on just the above examples covers
cracked end cover damaged by
20% of the difficulties likely to be
freezing.
experienced.
 Condensation, if this is the cause then
However, if these checks prove negative
more frequent oil changes are required.
then check the fault finding diagnostics
chart to resolve any issues.
Contact Hughes Pumps
immediately if there is
evidence of emulsification.
Table 1.5 Pump servicing/ maintenance intervals.

Every year (2000

Every 3 months

Every 6 months
Every week (40
Every day (12

(1000hours)
(500hours)
Maintenance Task

hours)

hours)

hours)
Check pump oil level x
Check engine oil & coolant level x
Check hydraulic tank level (if fitted) x
Check fuel tank level x
Check water strainer is clear x
Check non-return valve operates ok x
Check suction line for leaks/damage x
Check/replace water filter x
Check pump & engine for oil/water leaks x
Check condition of high pressure hoses x
Change oil in pump crankcase & gearbox (1) x
Change pump oil filter (2) x
Change seal kit in pneumatic dump valve x
Inspect seat/stem in pneumatic dump valve x
Change seal kit in pump head x
Inspect valves in pump head x
Inspect pump head for signs of wear x
Change plunger seal kit x
Inspect plungers x
Change crosshead oil seals x
Change/reverse seat & stem in dump valve x
Recalibrate safety relief valve x
Change valves in pump head x
Change plungers x
Remove pump from engine, change oil seal,
x
inspect bearings, gears & drive coupling (3)
Change boost pump transmission belt and Pre - Tensioner x

(1) First oil change at 50 hours

(2) First oil filter change at 50 hours
(3) It is unlikely these items will require attention at this time

NOTE: The figures above are based on pumps operating up to 500 bar. Plunger seals,
plungers, valves etc. may need replacing more frequently as pressure increases.

For engine maintenance refer to engine manual

NOTE: Some pumps may have different
arrangements/ components to the  Replace ‘O’ & ‘AX’ rings where
illustrations showed in this guide; please necessary.
refer to the drawings and BOM listed in this
 Check for any signs of cracks or
manual and do not rely exclusively on damage to the components. Replace
these instructions shown. where necessary.

If your pump requires maintenance,  Mark all components to assist with re-
please contact Hughes Pumps where assembly instructions.
we can arrange for a professional
NOTE: Failure to reassemble components
engineer to come and work on site. back to their original positions can lead to
mechanical failure.
PUMP SERVICING INSTRUCTIONS

Instructions before carrying out Failure to follow these set

maintenance on the pump: instructions can lead to the
failure of the pump.

 Isolate the prime mover/ power supply.


 Shut-off the pump inlet feed.

 Isolate and release all residual

pressure in the system by operating
valves in the discharge line.

 Disconnect all external hoses/ fittings

and services to the pump.

 Sign off the area so that unauthorised

personnel cannot enter the area.

 Check that you have any specialist

Hughes Pumps tooling you may need
for the job at hand.

Please contact Hughes Pumps if you

require any tools.

Instructions whilst carrying out

maintenance on the pump:

 Store all components in a safe place.

 Clean all components that have

become dirty over use/ time.
Torque
The fixing torque is noted on the parts or on the sec�onal drawings, if in doubt ask. For highly
torqued systems it is recommended that the fixings are progressively �ghtened in 3 equal steps to
ensure the final torque is met and evenly distributed among all the fixings.

I.E. if the final torque is 300Nm, first �ghten to 100Nm, then 200Nm and finally 300Nm.

Once the final torque has been achieved, all fixings must be re-checked, to ensure all fixings are
evenly �ghtened. “Spongy” or loose bolts must be inves�gated and replaced.

There are some special cases (UB30) where there are strict and clear instruc�ons on how to
assemble and torque the assembly.

To torque correctly work crosswise with the torque wrench as denoted in the sketch.
Do not �ghten to the maximum torque immediately. Tighten it up in steps as above, again and again
in several phases and check if the parts lay flat end even against each other.

Note, a fluid head is shown but any bolt sequence requiring �ghtening will follow the same or similar
cross patern.

Unless otherwise stated, all torque values given are lubricated values, the recommended lubricants
are:

BP Energear Hypo SAE90

BP Energrease LC2
An�-seize compound - Pure Goop
 Previous Name: Shell Spirax A 80W-90

Shell Spirax S2 A 80W-90

High quality, GL-5 axle oil
Spirax S2 A 80W-90 is blended for use in a wide variety of automotive axle units
subjected to heavy duty conditions.

Applications
• Automotive transmissions, differentials
• Moderate to heavily loaded gear sets in
stationary and ancillary equipment Specification and Approvals
• Hypoid gear axles API Service Classification GL-5
• Motorcycle gear units separate from the
engine Advice
• Other automotive transmission units Advice on applications not covered in this leaflet
operating under high speed/shock load, may be obtained from your Shell Representative.
high speed/low torque and low
speed/high torque conditions. Health and Safety
Guidance on Health and Safety are available on
Performance Features and Benefits the appropriate Material Safety Data Sheet, which
can be obtained from your Shell representative.
• Comprehensive components
Specially selected additives impart good anti-
wear, anti-rust characteristics and oxidation Protect the environment
stability. Take used oil to an authorised collection point. Do
not discharge into drains, soil or water
• High quality base oils
Maintains low temperature flow in the designed
temperature range, resists oxidation, and
maintains oil film between gears.

Typical Physical Characteristics

Spirax S2 A 80W-
80W-90
SAE Viscosity grade SAE J 306 80W-90
Kinematic Viscosity ISO 3104
at 40°C mm2/s 146
2
at 100°C mm /s 14.7
Viscosity Index ISO 2909 100
Density at 15°C kg/m3 ISO 12185 904
Flash Point COC °C ISO 2592 175
Pour Point °C ISO 3016 -27

These characteristics are typical of current production. Whilst future production will conform to Shell's
specification, variations in these characteristics may occur.

Shell Lubricants – 001D8276 23/02/2010

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SECTION 1. PRODUCT AND COMPANY IDENTIFICATION

Product name : Shell Spirax S2 A 80W-90

Product code : 001D8276

Manufacturer or supplier's details

Supplier : Viva Energy Australia Pty Ltd
(Formerly: The Shell Company of Australia)
(ABN 46 004 610 459)
720 Bourke Street
Docklands
Victoria 3008
Australia
Telephone : +61 (0)3 8823 4444
Telefax : +61 (0)3 8823 4800

Emergency telephone : 1800 651 818 (Australia). ; POISONS INFORMATION

number CENTRE: 13 11 26 (Australia).

Recommended use of the chemical and restrictions on use

Recommended use : Transmission oil.

SECTION 2. HAZARDS IDENTIFICATION

GHS Classification
Based on available data this substance / mixture does not meet the classification criteria.
GHS label elements
Hazard pictograms : No Hazard Symbol required

Signal word : No signal word

Hazard statements : PHYSICAL HAZARDS:

Not classified as a physical hazard under GHS criteria.
HEALTH HAZARDS:
Not classified as a health hazard under GHS criteria.
ENVIRONMENTAL HAZARDS:
Not classified as an environmental hazard under GHS criteria.

Precautionary statements :
Prevention:
No precautionary phrases.

Response:
No precautionary phrases.

Storage:
No precautionary phrases.

Disposal:

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No precautionary phrases.

Other hazards which do not result in classification

Prolonged or repeated skin contact without proper cleaning can clog the pores of the skin
resulting in disorders such as oil acne/folliculitis.Used oil may contain harmful impurities.Not
classified as flammable but will burn.

SECTION 3. COMPOSITION/INFORMATION ON INGREDIENTS

Chemical nature : Highly refined mineral oils and additives.

The highly refined mineral oil contains <3% (w/w) DMSO-
extract, according to IP346.

: * contains one or more of the following CAS-numbers: 64742-

53-6, 64742-54-7, 64742-55-8, 64742-56-9, 64742-65-0,
68037-01-4, 72623-86-0, 72623-87-1, 8042-47-5, 848301-69-
9, 68649-12-7, 151006-60-9, 163149-28-8.

Hazardous components
Chemical name CAS-No. Classification Concentration
[%]
Interchangeable low Not Assigned Asp. Tox.1; H304 0 - 90
viscosity base oil
(<20,5 cSt @40°C) *
Alkyl polysulphide ** Not Assigned Aquatic Chronic4; <5
H413
Dialkyl polysulphide 68937-96-2 Skin Sens.1B; H317 < 3.3
Aquatic Chronic4;
H412
Alkenyl amine Not Assigned Acute Tox.4; H302 0.1 - 0.99
Asp. Tox.1; H304
Skin Corr.1; H314
STOT SE3; H335
STOT RE2; H373
Aquatic Acute1;
H400
Aquatic Chronic1;
H410
** polymer exempt.
For explanation of abbreviations see section 16.

SECTION 4. FIRST-AID MEASURES

If inhaled : No treatment necessary under normal conditions of use.

If symptoms persist, obtain medical advice.

In case of skin contact : Remove contaminated clothing. Flush exposed area with
water and follow by washing with soap if available.

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If persistent irritation occurs, obtain medical attention.

In case of eye contact : Flush eye with copious quantities of water.

Remove contact lenses, if present and easy to do. Continue
rinsing.
If persistent irritation occurs, obtain medical attention.

If swallowed : In general no treatment is necessary unless large quantities

are swallowed, however, get medical advice.

Most important symptoms : Oil acne/folliculitis signs and symptoms may include formation
and effects, both acute and of black pustules and spots on the skin of exposed areas.
delayed Ingestion may result in nausea, vomiting and/or diarrhoea.

Protection of first-aiders : When administering first aid, ensure that you are wearing the
appropriate personal protective equipment according to the
incident, injury and surroundings.

Notes to physician : Treat symptomatically.

SECTION 5. FIRE-FIGHTING MEASURES

Suitable extinguishing media : Foam, water spray or fog. Dry chemical powder, carbon
dioxide, sand or earth may be used for small fires only.

Unsuitable extinguishing : Do not use water in a jet.

media

Specific hazards during : Hazardous combustion products may include:

firefighting A complex mixture of airborne solid and liquid particulates and
gases (smoke).
Carbon monoxide may be evolved if incomplete combustion
occurs.
Unidentified organic and inorganic compounds.

Specific extinguishing : Use extinguishing measures that are appropriate to local

methods circumstances and the surrounding environment.

Special protective equipment : Proper protective equipment including chemical resistant

for firefighters gloves are to be worn; chemical resistant suit is indicated if
large contact with spilled product is expected. Self-Contained
Breathing Apparatus must be worn when approaching a fire in
a confined space. Select fire fighter's clothing approved to
relevant Standards (e.g. Europe: EN469).

Hazchem Code : NONE

SECTION 6. ACCIDENTAL RELEASE MEASURES

Personal precautions, : Avoid contact with skin and eyes.

protective equipment and

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emergency procedures
Environmental precautions : Use appropriate containment to avoid environmental
contamination. Prevent from spreading or entering drains,
ditches or rivers by using sand, earth, or other appropriate
barriers.

Local authorities should be advised if significant spillages

cannot be contained.

Methods and materials for : Slippery when spilt. Avoid accidents, clean up immediately.
containment and cleaning up Prevent from spreading by making a barrier with sand, earth
or other containment material.
Reclaim liquid directly or in an absorbent.
Soak up residue with an absorbent such as clay, sand or other
suitable material and dispose of properly.

Additional advice : For guidance on selection of personal protective equipment

see Chapter 8 of this Safety Data Sheet.
For guidance on disposal of spilled material see Chapter 13 of
this Safety Data Sheet.

SECTION 7. HANDLING AND STORAGE

General Precautions : Use local exhaust ventilation if there is risk of inhalation of

vapours, mists or aerosols.
Use the information in this data sheet as input to a risk
assessment of local circumstances to help determine
appropriate controls for safe handling, storage and disposal of
this material.

Advice on safe handling : Avoid prolonged or repeated contact with skin.

Avoid inhaling vapour and/or mists.
When handling product in drums, safety footwear should be
worn and proper handling equipment should be used.
Properly dispose of any contaminated rags or cleaning
materials in order to prevent fires.

Avoidance of contact : Strong oxidising agents.

Product Transfer : Proper grounding and bonding procedures should be used

during all bulk transfer operations to avoid static accumulation.

Storage
Other data : Keep container tightly closed and in a cool, well-ventilated
place.
Use properly labeled and closable containers.

Store at ambient temperature.

Packaging material : Suitable material: For containers or container linings, use mild
steel or high density polyethylene.
Unsuitable material: PVC.

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Container Advice : Polyethylene containers should not be exposed to high
temperatures because of possible risk of distortion.

SECTION 8. EXPOSURE CONTROLS AND PERSONAL PROTECTION

Components with workplace control parameters

Components CAS-No. Value type Control Basis
(Form of parameters /
exposure) Permissible
concentration
Oil mist, mineral Not Assigned TWA (Mist) 5 mg/m3 AU OEL
Oil mist, mineral Not Assigned TWA (Mist) 5 mg/m3 Australia.
Workplace
Exposure
Standards for
Airborne
Contaminant
s.
Oil mist, mineral Not Assigned TWA (Mist) 5 mg/m3 OSHA Z-1
Oil mist, mineral Not Assigned TWA 5 mg/m3 ACGIH
(Inhalable
fraction)
Biological occupational exposure limits
No biological limit allocated.

Monitoring Methods
Monitoring of the concentration of substances in the breathing zone of workers or in the general
workplace may be required to confirm compliance with an OEL and adequacy of exposure
controls. For some substances biological monitoring may also be appropriate.
Validated exposure measurement methods should be applied by a competent person and
samples analysed by an accredited laboratory.
Examples of sources of recommended exposure measurement methods are given below or
contact the supplier. Further national methods may be available.
National Institute of Occupational Safety and Health (NIOSH), USA: Manual of Analytical Methods
http://www.cdc.gov/niosh/
Occupational Safety and Health Administration (OSHA), USA: Sampling and Analytical Methods
http://www.osha.gov/
Health and Safety Executive (HSE), UK: Methods for the Determination of Hazardous Substances
http://www.hse.gov.uk/
Institut für Arbeitsschutz Deutschen Gesetzlichen Unfallversicherung (IFA) , Germany
http://www.dguv.de/inhalt/index.jsp
L'Institut National de Recherche et de Securité, (INRS), France http://www.inrs.fr/accueil

Engineering measures : The level of protection and types of controls necessary will
vary depending upon potential exposure conditions. Select
controls based on a risk assessment of local circumstances.
Appropriate measures include:
Adequate ventilation to control airborne concentrations.

Where material is heated, sprayed or mist formed, there is

greater potential for airborne concentrations to be generated.

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General Information:
Define procedures for safe handling and maintenance of
controls.
Educate and train workers in the hazards and control
measures relevant to normal activities associated with this
product.
Ensure appropriate selection, testing and maintenance of
equipment used to control exposure, e.g. personal protective
equipment, local exhaust ventilation.
Drain down system prior to equipment break-in or
maintenance.
Retain drain downs in sealed storage pending disposal or
subsequent recycle.
Always observe good personal hygiene measures, such as
washing hands after handling the material and before eating,
drinking, and/or smoking. Routinely wash work clothing and
protective equipment to remove contaminants. Discard
contaminated clothing and footwear that cannot be cleaned.
Practice good housekeeping.

Personal protective equipment

Protective measures
Personal protective equipment (PPE) should meet recommended national standards. Check with
PPE suppliers.

Respiratory protection : No respiratory protection is ordinarily required under normal

conditions of use.
In accordance with good industrial hygiene practices,
precautions should be taken to avoid breathing of material.
If engineering controls do not maintain airborne
concentrations to a level which is adequate to protect worker
health, select respiratory protection equipment suitable for the
specific conditions of use and meeting relevant legislation.
Check with respiratory protective equipment suppliers.
Where air-filtering respirators are suitable, select an
appropriate combination of mask and filter.
Select a filter suitable for the combination of organic gases
and vapours and particles [Type A/Type P boiling point >65°C
(149°F)].

Hand protection
Remarks : Where hand contact with the product may occur the use of
gloves approved to relevant standards (e.g. Europe: EN374,
US: F739) made from the following materials may provide
suitable chemical protection. PVC, neoprene or nitrile rubber
gloves Suitability and durability of a glove is dependent on
usage, e.g. frequency and duration of contact, chemical
resistance of glove material, dexterity. Always seek advice
from glove suppliers. Contaminated gloves should be
replaced. Personal hygiene is a key element of effective hand
care. Gloves must only be worn on clean hands. After using
gloves, hands should be washed and dried thoroughly.

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Application of a non-perfumed moisturizer is recommended.

For continuous contact we recommend gloves with

breakthrough time of more than 240 minutes with preference
for > 480 minutes where suitable gloves can be identified. For
short-term/splash protection we recommend the same but
recognize that suitable gloves offering this level of protection
may not be available and in this case a lower breakthrough
time maybe acceptable so long as appropriate maintenance
and replacement regimes are followed. Glove thickness is not
a good predictor of glove resistance to a chemical as it is
dependent on the exact composition of the glove material.
Glove thickness should be typically greater than 0.35 mm
depending on the glove make and model.

Eye protection : If material is handled such that it could be splashed into eyes,
protective eyewear is recommended.

Skin and body protection : Skin protection is not ordinarily required beyond standard
work clothes.
It is good practice to wear chemical resistant gloves.

Thermal hazards : Not applicable

Environmental exposure controls

General advice : Take appropriate measures to fulfill the requirements of
relevant environmental protection legislation. Avoid
contamination of the environment by following advice given in
Section 6. If necessary, prevent undissolved material from
being discharged to waste water. Waste water should be
treated in a municipal or industrial waste water treatment plant
before discharge to surface water.
Local guidelines on emission limits for volatile substances
must be observed for the discharge of exhaust air containing
vapour.

SECTION 9. PHYSICAL AND CHEMICAL PROPERTIES

Appearance : Liquid at room temperature.

Colour : amber
Odour : Slight hydrocarbon
Odour Threshold : Data not available
pH : Not applicable
pour point : -27 °C / -17 °FMethod: ISO 3016

Melting / freezing point Data not available

Initial boiling point and boiling : > 280 °C / 536 °Festimated value(s)
range
Flash point : 175 °C / 347 °F

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Method: ISO 2592

Evaporation rate : Data not available

Flammability (solid, gas) : Data not available

Upper explosion limit : Typical 10 %(V)

Lower explosion limit : Typical 1 %(V)

Vapour pressure : < 0.5 Pa (20 °C / 68 °F)

estimated value(s)
Relative vapour density : > 1estimated value(s)
Relative density : 0.904 (15 °C / 59 °F)

Density : 904 kg/m3 (15.0 °C / 59.0 °F)

Method: ISO 12185

Solubility(ies)
Water solubility : negligible
Solubility in other solvents : Data not available

Partition coefficient: n- : log Pow: > 6(based on information on similar products)

octanol/water
Auto-ignition temperature : > 320 °C / 608 °F

Decomposition temperature : Data not available

Viscosity
Viscosity, dynamic : Data not available
Viscosity, kinematic : 146 mm2/s (40.0 °C / 104.0 °F)
Method: ISO 3104

14.7 mm2/s (100 °C / 212 °F)

Method: ISO 3104

Explosive properties : Not classified

Oxidizing properties : Data not available

Conductivity : This material is not expected to be a static accumulator.

SECTION 10. STABILITY AND REACTIVITY

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Reactivity : The product does not pose any further reactivity hazards in
addition to those listed in the following sub-paragraph.

Chemical stability : Stable.

Possibility of hazardous : Reacts with strong oxidising agents.

reactions
Conditions to avoid : Extremes of temperature and direct sunlight.

Incompatible materials : Strong oxidising agents.

Hazardous decomposition : No decomposition if stored and applied as directed.

products

SECTION 11. TOXICOLOGICAL INFORMATION

Basis for assessment : Information given is based on data on the components and
the toxicology of similar products.Unless indicated otherwise,
the data presented is representative of the product as a
whole, rather than for individual component(s).

Exposure routes : Skin and eye contact are the primary routes of exposure
although exposure may occur following accidental ingestion.

Acute toxicity
Product:
Acute oral toxicity : LD50 rat: > 5,000 mg/kg
Remarks: Low toxicity:
Based on available data, the classification criteria are not met.

Acute inhalation toxicity : Remarks: Based on available data, the classification criteria
are not met.

Acute dermal toxicity : LD50 Rabbit: > 5,000 mg/kg

Remarks: Low toxicity:
Based on available data, the classification criteria are not met.

Skin corrosion/irritation
Product:
Remarks: Slightly irritating to skin., Prolonged or repeated skin contact without proper cleaning
can clog the pores of the skin resulting in disorders such as oil acne/folliculitis., Based on
available data, the classification criteria are not met.

Serious eye damage/eye irritation

Product:
Remarks: Slightly irritating to the eye., Based on available data, the classification criteria are not
met.

Respiratory or skin sensitisation

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Product:
Remarks: Not a skin sensitiser.
Based on available data, the classification criteria are not met.

Components:
Dialkyl polysulphide:
Remarks: Experimental data has shown that the concentration of potentially sensitising
components present in this product does not induce skin sensitisation.
May cause an allergic skin reaction in sensitive individuals.

Chronic toxicity
Germ cell mutagenicity
Product:
: Remarks: Non mutagenic, Based on available data, the
classification criteria are not met.
Carcinogenicity
Product:

Remarks: Not a carcinogen., Based on available data, the classification criteria are not met.

Remarks: Product contains mineral oils of types shown to be non-carcinogenic in animal skin-
painting studies., Highly refined mineral oils are not classified as carcinogenic by the
International Agency for Research on Cancer (IARC).

Material GHS/CLP Carcinogenicity Classification

Highly refined mineral oil No carcinogenicity classification.

Reproductive toxicity

Product:
:
Remarks: Not a developmental toxicant., Does not impair
fertility., Based on available data, the classification criteria are
not met.

STOT - single exposure

Product:
Remarks: Based on available data, the classification criteria are not met.

STOT - repeated exposure

Product:

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Remarks: Based on available data, the classification criteria are not met.

Aspiration toxicity
Product:
Not an aspiration hazard.

Further information
Product:
Remarks: Used oils may contain harmful impurities that have accumulated during use. The
concentration of such impurities will depend on use and they may present risks to health and the
environment on disposal., ALL used oil should be handled with caution and skin contact avoided
as far as possible.

Remarks: Slightly irritating to respiratory system.

SECTION 12. ECOLOGICAL INFORMATION

Basis for assessment : Ecotoxicological data have not been determined specifically
for this product.
Information given is based on a knowledge of the components
and the ecotoxicology of similar products.
Unless indicated otherwise, the data presented is
representative of the product as a whole, rather than for
individual component(s).(LL/EL/IL50 expressed as the
nominal amount of product required to prepare aqueous test
extract).

Ecotoxicity
Product:
Toxicity to fish (Acute :
toxicity) Remarks: LL/EL/IL50 > 100 mg/l
Practically non toxic:
Based on available data, the classification criteria are not met.

Toxicity to crustacean (Acute :

toxicity) Remarks: LL/EL/IL50 > 100 mg/l
Practically non toxic:
Based on available data, the classification criteria are not met.

Toxicity to algae/aquatic :
plants (Acute toxicity) Remarks: LL/EL/IL50 > 100 mg/l
Practically non toxic:
Based on available data, the classification criteria are not met.

Toxicity to fish (Chronic : Remarks: Data not available

toxicity)
Toxicity to crustacean : Remarks: Data not available
(Chronic toxicity)
Toxicity to microorganisms : Remarks: Data not available

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(Acute toxicity)

Components:
Alkenyl amine :
M-Factor : 1
Persistence and degradability
Product:
Biodegradability : Remarks: Not readily biodegradable., Major constituents are
inherently biodegradable, but contains components that may
persist in the environment.

Bioaccumulative potential
Product:
Bioaccumulation : Remarks: Contains components with the potential to
bioaccumulate.

Partition coefficient: n- : log Pow: > 6Remarks: (based on information on similar

octanol/water products)
Mobility in soil
Product:
Mobility : Remarks: Liquid under most environmental conditions., If it
enters soil, it will adsorb to soil particles and will not be
mobile.
Remarks: Floats on water.
Other adverse effects
no data available
Product:
Additional ecological : Does not have ozone depletion potential, photochemical
information ozone creation potential or global warming potential., Product
is a mixture of non-volatile components, which will not be
released to air in any significant quantities under normal
conditions of use.
Poorly soluble mixture., Causes physical fouling of aquatic
organisms.
Mineral oil does not cause chronic toxicity to aquatic
organisms at concentrations less than 1 mg/l.

SECTION 13. DISPOSAL CONSIDERATIONS

Disposal methods
Waste from residues : Recover or recycle if possible.
It is the responsibility of the waste generator to determine the
toxicity and physical properties of the material generated to
determine the proper waste classification and disposal
methods in compliance with applicable regulations.
Do not dispose into the environment, in drains or in water
courses

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Waste product should not be allowed to contaminate soil or

ground water, or be disposed of into the environment.
Waste, spills or used product is dangerous waste.

Contaminated packaging : Dispose in accordance with prevailing regulations, preferably

to a recognized collector or contractor. The competence of
the collector or contractor should be established beforehand.
Disposal should be in accordance with applicable regional,
national, and local laws and regulations.

Local legislation
Remarks : Disposal should be in accordance with applicable regional,
national, and local laws and regulations.

SECTION 14. TRANSPORT INFORMATION

National Regulations
ADG
Not regulated as a dangerous good
International Regulations

IATA-DGR
Not regulated as a dangerous good
IMDG-Code
Not regulated as a dangerous good
Transport in bulk according to Annex II of MARPOL 73/78 and the IBC Code
Not applicable for product as supplied. MARPOL Annex 1 rules apply for bulk shipments by sea.

Special precautions for user

Remarks : Special Precautions: Refer to Section 7, Handling & Storage,
for special precautions which a user needs to be aware of or
needs to comply with in connection with transport.

SECTION 15. REGULATORY INFORMATION

Safety, health and environmental regulations/legislation specific for the substance or

mixture
Standard for the Uniform : No poison schedule number allocated
Scheduling of Medicines and
Poisons

The regulatory information is not intended to be comprehensive. Other regulations may apply to
this material.
Product classified as per Work Health Safety Regulations – Implementation of the Globally
Harmonized System of Classification and Labelling of Chemicals (GHS) 2012 and SDS prepared

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as per national model code of practice for preparation of safety data sheet for Hazardous
chemicals 2011 based on Globally Harmonized Classification version 3.
National Model Code of Practice for the Labelling of Workplace Hazardous Chemicals (2011).
Australian Code for the Transport of Dangerous Goods by Road and Rail (ADG code). Standard
for the Uniform Scheduling of Medicines and Poisons (SUSMP).
Other international regulations
The components of this product are reported in the following inventories:
EINECS : All components listed or polymer exempt.
TSCA : All components listed.
AIIC : All components listed.

SECTION 16. OTHER INFORMATION

Full text of H-Statements

H302 Harmful if swallowed.
H304 May be fatal if swallowed and enters airways.
H314 Causes severe skin burns and eye damage.
H317 May cause an allergic skin reaction.
H335 May cause respiratory irritation.
H373 May cause damage to organs through prolonged or repeated exposure.
H400 Very toxic to aquatic life.
H410 Very toxic to aquatic life with long lasting effects.
H412 Harmful to aquatic life with long lasting effects.
H413 May cause long lasting harmful effects to aquatic life.
Full text of other abbreviations
Acute Tox. Acute toxicity
Aquatic Acute Short-term (acute) aquatic hazard
Aquatic Chronic Long-term (chronic) aquatic hazard
Asp. Tox. Aspiration hazard
Skin Corr. Skin corrosion
Skin Sens. Skin sensitisation
STOT RE Specific target organ toxicity - repeated exposure
STOT SE Specific target organ toxicity - single exposure

AICS - Australian Inventory of Chemical Substances; ANTT - National Agency for Transport by
Land of Brazil; ASTM - American Society for the Testing of Materials; bw - Body weight; CMR -
Carcinogen, Mutagen or Reproductive Toxicant; DIN - Standard of the German Institute for
Standardisation; DSL - Domestic Substances List (Canada); ECx - Concentration associated with
x% response; ELx - Loading rate associated with x% response; EmS - Emergency Schedule;
ENCS - Existing and New Chemical Substances (Japan); ErCx - Concentration associated with
x% growth rate response; ERG - Emergency Response Guide; GHS - Globally Harmonized
System; GLP - Good Laboratory Practice; IARC - International Agency for Research on Cancer;
IATA - International Air Transport Association; IBC - International Code for the Construction and
Equipment of Ships carrying Dangerous Chemicals in Bulk; IC50 - Half maximal inhibitory
concentration; ICAO - International Civil Aviation Organization; IECSC - Inventory of Existing
Chemical Substances in China; IMDG - International Maritime Dangerous Goods; IMO -
International Maritime Organization; ISHL - Industrial Safety and Health Law (Japan); ISO -
International Organisation for Standardization; KECI - Korea Existing Chemicals Inventory; LC50 -
Lethal Concentration to 50 % of a test population; LD50 - Lethal Dose to 50% of a test population
(Median Lethal Dose); MARPOL - International Convention for the Prevention of Pollution from
Ships; n.o.s. - Not Otherwise Specified; Nch - Chilean Norm; NO(A)EC - No Observed (Adverse)

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Effect Concentration; NO(A)EL - No Observed (Adverse) Effect Level; NOELR - No Observable
Effect Loading Rate; NOM - Official Mexican Norm; NTP - National Toxicology Program; NZIoC -
New Zealand Inventory of Chemicals; OECD - Organization for Economic Co-operation and
Development; OPPTS - Office of Chemical Safety and Pollution Prevention; PBT - Persistent,
Bioaccumulative and Toxic substance; PICCS - Philippines Inventory of Chemicals and Chemical
Substances; (Q)SAR - (Quantitative) Structure Activity Relationship; REACH - Regulation (EC)
No 1907/2006 of the European Parliament and of the Council concerning the Registration,
Evaluation, Authorisation and Restriction of Chemicals; SADT - Self-Accelerating Decomposition
Temperature; SDS - Safety Data Sheet; TCSI - Taiwan Chemical Substance Inventory; TDG -
Transportation of Dangerous Goods; TSCA - Toxic Substances Control Act (United States); UN -
United Nations; UNRTDG - United Nations Recommendations on the Transport of Dangerous
Goods; vPvB - Very Persistent and Very Bioaccumulative; WHMIS - Workplace Hazardous
Materials Information System

Date of preparation or review : 26.11.2019

Further information
Training advice : Provide adequate information, instruction and training for
operators.

Other information : A vertical bar (|) in the left margin indicates an amendment
from the previous version.

Sources of key data used to : The quoted data are from, but not limited to, one or more
compile the Safety Data sources of information (e.g. toxicological data from Shell
Sheet Health Services, material suppliers’ data, CONCAWE, EU
IUCLID date base, EC 1272 regulation, etc).

The information provided in this Safety Data Sheet is correct to the best of our knowledge,
information and belief at the date of its publication. The information given is designed only as a
guidance for safe handling, use, processing, storage, transportation, disposal and release and is
not to be considered a warranty or quality specification. The information relates only to the
specific material designated and may not be valid for such material used in combination with any
other materials or in any process, unless specified in the text.

AU / EN

15 / 15 800001005777
AU
PART. No. DO NOT SCALE IF IN DOUBT ASK REMOVE ALL BURRS & SHARP EDGES
21571-327 Air Bleed port
REF. No.
Main Filter Bag Replacement Procedure

Slide the basket & filter bag as far into

housing as it will go ensuring it sits below
Insert the filter bag
the housing inlet port & sits squarely with
into the filter basket.
no gaps around the outside.

O-ring seal
Water in

F
Filtered Water out Ensure the seal has no
wrinkles or deformities

MAIN PUMP FILTER

MICRON RATING
Pressure Main Filter
F(1:3) BAR um
3000 1
1400 25
All pumps are supplied with a water inlet pressure switch, if the pump constantly 1000 50
shuts down during start up, the most likely cause is a blocked filter bag. Ensure the filter is fully down 400 100
and below the inlet 250 200
With the pump off, isolate and drain the system, remove the filter housing lid and
remove the filter and basket

Whilst the filter housing is open, it is prone to contamination ensure all care is
taken to ensure no debris enters the housing whilst it is open.
ISS. DATE REVISIONS T.C.N.
Do not wash filter bags, always replace with new!

Always replace filters with the same micron rating, the only time a micron rating DRAWN ON
SHEET SIZE
can be changed is when a plunger kit is changed to a different one. PUMPS LIMITED

FIRST ANGLE PROJECTION

A3 High & Ultra High Pressure Technology
FIRST ASSEMBLY USED ON: SHEET 1 of 1 Washington W. Sussex RH20 3BS U.K. Tel.+44 (0) 1903 892358 Fax.+44 (0) 1903 892062 E.mail www.hughes-pumps.co.uk

UNLESS OTHERWISE STATED : ALL DIMENSIONS IN TITLE MATERIAL & SPECIFICATION THIS DRAWING IS THE PROPERTY OF HUGHES DRAWN EH DRG. No. ISSUE
MILLIMETERS. WHOLE AND DECIMAL DIMENSIONS ± 0.25 0.00
FILTER HOUSING - PUMPS LIMITED AND MAY NOT BE COPIED NOR
± 0.125 ANGULAR ± 30' CHECKED
METRIC THREADS TO BS 3643 B.S.P. THREADS TO BS 21
UNIT TREATMENT FINISH
USED NOR DISCLOSED TO A THIRD PARTY FOR
ANY PURPOSE OTHER THAN THAT FOR WHICH IT IS
APPROVED
21571-327 1
SURFACE FINISH TO BS 1134 SUPPLIED, WITHOUT THE EXPRESS WRITTEN
GENERAL DRAWING PRACTICE TO BS 8888 AUTHORITY OF HUGHES PUMPS LIMITED 2020 ã
DATE 14/09/2015 SCALE 1 : 6
PART. No. DO NOT SCALE IF IN DOUBT ASK REMOVE ALL BURRS & SHARP EDGES
T1033/T1043 REMOVAL RE-FITTING
REF. No.
SEAL HOUSING OIL SEAL

M10 BOLT
SEAL REMOVAL TOOL

M4 BOLT

DO NOT USE THE

RETAINING PLATE M4 BOLTS!
NOTE: CIRCLIP
NEWER PUMPS REQUIRE 4 BOLTS
OLDER PUMPS REQUIRE 3 BOLTS
THE REMOVAL TOOL SUITES BOTH

• REMOVE THE PUMP FROM THE ENGINE, ELECTRICALLY DRIVEN PUMPS CAN REMAIN FITTED PUMP TOOL OIL SEAL
• REMOVE THE PUMP HEAD AND PLUNGER KITS HPS400/650/850 T1033 23514-529
• DRAIN THE OIL FROM THE CRANKCASE HPS1000/1500 T1043 23514-530
• TURN THE PUMP OVER BY HAND UNTIL THE CROSSHEAD IS CLOSE TO THE SEAL HOUSING
• FIX THE REMOVAL TOOL TO THE SEAL HOUSING USING THE BOLTS SUPPLIED.
• ENSURE THE TOOL IS SQUARE AND LEVEL TO THE CROSSHEAD. ISS DATE DESCRIPTION ENG
REVISION HISTORY
• TURN THE PUMP OVER BY HAND TO PUSH THE HOUSING OUT.
• REMOVE THE SEAL AND INSPECT THE HOUSING, CLEAN AWAY ANY SEALANT AND OIL
• REPLACE THE SEAL AND APPLY LOCTITE 518 TO THE OUTSIDE DIAMETER DRAWN ON
• SLIDE THE ASSEMBLY DOWN THE CROSSHEAD SHEET SIZE
PUMPS LIMITED
• ATTACH THE REMOVAL TOOL TO THE CROSSHEAD AND TURN THE PUMP OVER BY HAND TO PUSH THE HOUSING IN
FIRST ANGLE PROJECTION
A3 High & Ultra High Pressure Technology
FIRST ASSEMBLY USED ON: SHEET 1 of 1 Washington W. Sussex RH20 3BS U.K. Tel.+44 (0) 1903 892358 Fax.+44 (0) 1903 892062 E.mail www.hughes-pumps.co.uk

UNLESS OTHERWISE STATED : TITLE MATERIAL & SPECIFICATION DRG. No. ISSUE
ALL DIMENSIONS IN MILLIMETERS. THIS DRAWING IS THE PROPERTY OF HUGHES DRAWN EH
WHOLE AND DECIMAL DIMENSIONS ± 3.0 / 0.00 ± 1.0 OIL SEAL REMOVAL TOOL PUMPS LIMITED AND MAY NOT BE COPIED NOR
CHECKED
ANGULAR ± 30'
METRIC THREADS TO BS 3643 B.S.P. THREADS TO BS 21 UNIT TREATMENT FINISH
USED NOR DISCLOSED TO A THIRD PARTY FOR
ANY PURPOSE OTHER THAN THAT FOR WHICH IT IS
APPROVED
T1033/T1043
SURFACE FINISH TO BS 1134 SUPPLIED, WITHOUT THE EXPRESS WRITTEN
GENERAL DRAWING PRACTICE TO BS 8888 HPS 400/650/850/1000 AUTHORITY OF HUGHES PUMPS LIMITED 2020 ã
DATE 25/08/2015 SCALE 1 : 2
Fault Finding

Introduction

Many operating faults can be traced to • Is the dump valve by-passing

easily corrected errors in setting up or
operating the equipment. It is a natural • Is the engine speed correct
tendency to start dismantling the pump
when the equipment is not operating • Is the diesel fuel supply clean &
properly, thinking that the problem must adequate
be in faulty or worn out parts.
• Are there any low or high pressure
It has been our experience over many hose leaks
years that many faults are rectified outside
of the pump and it cannot be emphasised • Is there a leak on the accessory
too strongly to first check on the most
obvious of problems, for example : • Are the accessory nozzles worn or
damaged
• Is the pump getting sufficient water
A check on the above examples could
• Is the suction hose kinked, blocked or cover many of the difficulties likely to be
leaking experienced. However, if these checks
prove negative, then the following
• Are the inlet strainer(s) blocked diagnostic chart of symptoms / cause /
action will be of assistance to locate the
• Have the hoses been connected up problem.
properly and to the right connections
If this is unsuccessful then contact the
factory or reseller for further advice.
Fault Finding Chart

Symptom Possible Cause Recommended Action

Low Discharge Pressure Nozzles too large Fitter smaller ones

Nozzles leaking / worn Tighten / replace

High pressure hose or Tighten or replace

connector leaking

Engine speed too low Increase if necessary

Dump valve by-passing Adjust valve or overhaul

Check for compressed air

leaks / adjust pressure

Water starvation to pump Check pump set is correctly

primed

Check / change water filter

elements

Check for any air leaks, kinks

or damage to suction hose

Check suction hose is not

blocked

Check for air leaks

throughout suction side of
boost pump

Inspect / replace plunger

seals

High pressure pump leaking Inspect / replace seals

externally from the underside

Pump valve cartridge o-rings Inspect / replace

leaking internally / externally

Pump inlet / outlet valve Inspect / replace

springs worn or broken

Pump valves leaking Inspect / replace

Insufficient air pressure on Increase pressure / check for

dump valve leaks
Symptom Possible Cause Recommended Action
Discharge Pressure Gauge Pump is cavitating Carry out same checks as
Unsteady shown for “water starvation
to pump” above

Inspect pump valves &

springs, replace as
necessary
Boost Pressure Gauge Pump is cavitating Carry out same checks as
Unsteady shown for “water starvation
to pump” above

Inspect pump valves &

springs, replace as
necessary
Slow drip of water from air A slow drip is normal No action required
gap on underside of pump
Fast drip / continuous flow of Plunger seals worn Replace
water from air gap on
underside of pump
Worn or cracked plunger(s) Replace
Oil leak from air gap on Crosshead oil seal(s) leaking Replace
underside of pump
Crosshead(s) scored Polish / replace
Oil leak from underside of Input gear oil seal leaking Replace
pump SAE housing
Engine crankshaft oil seal Consult engine manufacturer
leaking
Engine speed low / erratic & Blocked fuel filter(s) Replace
under powered
Inspect fuel for
contamination
Engine shuts down Low boost pressure Check / change water filter

Check pumpset is primed

Check for problems in

suction hose

High pump oil temperature Inspect pump

Low pump oil pressure Check pressure is above 2

bar

Engine fault Check readout on control

panel
Noise from pump crankcase Worn / damaged bearings Seek advice from Hughes
Noise from pump gearbox Worn / damaged bearings Seek advice from Hughes

Worn / damaged gears Seek advice from Hughes

Symptom Possible Cause Recommended Action
Non rotation of pump Broken drive coupling Replace

Broken gear(s) Seek advice from Hughes

[507] Bimetallic Thermostat SPDT Contacts

Part Number
Threads (X3) Temperature
02 3/8” G From 35º to 85ºC
507 21 05 M14x 1,5 With intervals of 5ºC
07 M22x 1,5
ATEX version available on request 08 1/2” G

Case Brass (on request stainless steel)

Electrical conditions SPDT (exchange contact)
Differential 15 / 20K
Intervention tolerance +/- 5K
Electrical characteristics 5(4) A / 14Vdc
4(3) A / 30Vdc
5 (3) A / 125Vac
5 (1) A / 250Vac
Max ambient temp. +85ºC
Number of cycles 100.000
Number of cycles/ minute max 5
Snap action contact
Temp. change rate 1÷2 K/min
Tightening torque max 40 Nm
Connection Faston male 6,3 x 0,8 and ground
Protection degree IP65
With connector according to UNI EN 175301-803 (DIN43650)
Max pressure 80 bar (other ranges available)
Weight ~ 100 gr

Distributed by: PVL Ltd - Crowborough, East Sussex, TN6 2NQ, UK

T: +44 (0)1892 664499 F: +44(0)1892 663690 E: sales@pvl.co.uk W: www.pvl.co.uk
 Operating 1. Safety gauge, it must be protected against being blocked
instructions EN WARNING!
by debris and dirt. With safety pressure gauges
(see k) there must be a free space of > 15 mm
Before installation, commissioning and
behind the blow-out back.
operation, ensure that the appropriate
After installation, open the vent valve (if available)
Pressure gauges pressure gauge has been selected in
or set from CLOSE to OPEN. With
terms of measuring range, design and
models 4 and 7, do not open the
suitable wetted material (corrosion) for the specific
flange mounting screws. The version
measuring conditions. In order to guarantee the
of the vent valve depends on the
measurement accuracy and long-term stability
Examples: model and can deviate from the above illustration!
specified, the corresponding load limits must be
observed. Requirements for the installation point
Only qualified persons authorised by the plant If the line to the measuring instrument is not
manager are permitted to install, maintain and adequately stable, a measuring instrument holder
service the pressure gauges. should be used for fastening (and possibly via a
Model 732.14, flexible capillary). If vibrations cannot be avoided
For hazardous media such as oxygen, acetylene,
overpressure safety by means of suitable installation, instruments
flammable or toxic gases or liquids, and refrigera-
up to 400 bar with liquid filling should be used. The instruments
tion plants, compressors, etc., in addition to all
Model 432.56, should be protected against coarse dirt and wide
standard regulations, the appropriate existing
overpressure safety fluctuations in ambient temperature.
codes or regulations must also be followed.
up to 100 bar Note for model 732.14, for front bezel mounting:
From pressure gauges which do not correspond The front bezel serves as centring and as the
Model 213.40 to a safety version per EN 837 highly pressurised aperture in the mounting panel. Securing and thus
media might leak out through the possibly burst- the weight-bearing must be made via the pressure
ing window in case of a component failure. For connection piping.
gaseous media and working pressures > 25 bar a
pressure gauge with safety version S3 is recom- 3. Permissible ambient and operating
mended per EN 837-2. temperatures
After an external fire, pressure media can leak out, When mounting the pressure gauge it must be
Notes per current pressure equipment directive particularly at soft solder joints. All instruments ensured that, taking into consideration the influ-
„„ The pressure gauges are defined as “pressure must be checked and, if necessary, replaced ence of convection and heat radiation, no deviation
accessories” before recommissioning the plant. above or below the permissible temperature limits
„„ The volume of the “pressure-bearing housings” of can occur. Observe the influence of temperature
Non-observance of the respective regulations on the indication accuracy!
WIKA pressure gauges is < 0.1 L
can cause serious injuries and/or damage to the
„„ The pressure gauges carry CE marking for fluid
equipment. 4. Storage
group 1 per annex II, diagram 1 when their permis-
sible working pressure is > 200 bar 2. Mechanical connection To protect the pressure gauges from mechanical
damage keep them in the original packaging until
Instruments that do not carry the mark are manufactured In accordance with the general technical regula- installation.
per article 4, paragraph 3 “sound engineering practice”. tions for pressure gauges (e.g. EN 837-2). When Protect the measuring instruments from humidity
screwing the instruments in, the force required to and dust.
Applicable standards (depending on model) do this must not be applied through the case, but Storage temperature range: -40 ... +70 °C
EN 837-1 Bourdon tube pressure gauges, dimensions, only through the spanner flats provided for this Storage temperature range model
metrology, requirements and testing purpose, and using a suitable tool. PG23LT: -70 ... +70 °C
EN 837-2 Selection and installation recommendations For parallel threads, use flat gaskets, lens-type
for pressure gauges sealing rings or WIKA profile sealings at the 5. Maintenance and repairs
EN 837-3 Diaphragm and capsule pressure gauges, The pressure gauges are maintenance-free.
dimensions, metrology, requirements and Regular checks should be carried out to ensure
testing Installation with the measurement accuracy. Checks or recalibra-
Specifications: See data sheet at www.wika.de open-ended tions must only be carried out by qualified skilled
spanner personnel with the appropriate equipment. When
Subject to technical modifications. dismounting, close the vent valve (if available).
© WIKA Alexander Wiegand SE & Co. KG 2009 Sealing of the pressure gauge connections
WARNING! Residual media in
Sealing in dismounted pressure gauges can
Spanner flats the thread result in a risk to persons, the environ-
 ment and equipment. Take sufficient
Sealing face  precautionary measures.
sealing face . With tapered threads (e.g. NPT
WIKA Alexander Wiegand SE & Co. KG threads), sealing is made in the threads  using
Alexander-Wiegand-Straße 30 additional sealing materials, e.g. PTFE tape
2408976.06 12/2016

63911 Klingenberg/Germany (EN 837-2).

Tel. +49 9372 132-0 The torque depends on the sealing used. In order
Fax +49 9372 132-406 to orientate the measuring instrument so that it
info@wika.de can be read as well as possible, a connection with
www.wika.de clamp socket or union nut should be used.
When a blow-out device is fitted to a pressure
 
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All rights reserved

¤E.J. Bowman (Birmingham) Ltd, reserve the right to change specification and technical alteration without prior notice.

No part of this guide may be reproduced or transmitted in any form or by any means including reproduction or recording without written
permission from ¤E.J. Bowman (Birmingham) Ltd.

 
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Three Pass Bowman
Heat Exchangers

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 Mechatronic
pressure measurement

OEM compact pressure switch

With settable hysteresis
Model PSM02
WIKA data sheet PV 34.82

Applications
■■ Hydraulics and mobile hydraulics
■■ Pneumatics
■■ Plastics injection moulding machines
■■ General machine building and plant construction
■■ Media: Compressed air, neutral and self-lubricating fluids,
neutral gases

Special features
■■ High reproducibility
■■ Compact design
■■ Setting ranges from 0.2 … 2 bar to 40 … 400 bar
■■ Long service life due to high-quality micro switch
■■ Settable hysteresis

OEM compact pressure switch, with settable

hysteresis, model PSM02

Description

Model PSM02 screw-in pressure switches in a diaphragm or

piston variant open or close a circuit, depending on whether
the pressure is dropping or rising. Two adjustment screws
enable easy and convenient on-site setting of the required
switch point and hysteresis. Optionally, WIKA offers its
customers the factory setting of switch point and hysteresis.

Model PSM02 mechanical pressure switches are employed

wherever compressed air, neutral and self-lubricating fluids
or neutral gases are used and a precisely set hysteresis is
needed.

The high reproducibility of the switch point of ±2 % and

the settability of the hysteresis makes the model PSM02
pressure switches interesting for all customers who place a
value on precision as well as an attractive price.

WIKA data sheet PV 34.82 ∙ 04/2013 Page 1 of 3

Standard version Switch contacts
High-quality snap-action switch, self-cleaning
Case
Steel, galvanised Switching function
Selectable: Normally open, normally closed, change-over
Reproducibility contact
±2 % of full scale value
Switching power
Permissible temperature Switching voltage: DC / AC 24 ... 250 V
Ambient: -20 … +80 °C Switching current: 5 mA ... 4 A
Medium: -20 … +80 °C
Electrical connection
Process connection Angular connector DIN 175301-803 A
Steel, galvanised
G 1/8, G 1/4, 1/8 NPT, 1/4 NPT, R 1/8 or M10 x 1 Switching frequency
max. 100/min
Measuring element
Diaphragm or piston with compression spring Service life
> 2 x 106 switching cycles
Sealing
Diaphragm: NBR or EPDM Ingress protection
Piston: PTFE (dynamic) and NBR, EPDM or Viton® (static) IP 65 (IP 67 with electrical connection M12 x 1 or cable)

Viton® fluoroelastomer is a registered trademark of DuPont Performance Elastomers.

Setting ranges, max. working pressure, measuring principle, hysteresis

Setting Max. working Measuring Hysteresis
ranges pressure principle
in bar in bar
0.2 ... 2 60 Diaphragm

Example:
Hysteresis in bar

With a switch point

of 4 bar, a switch-
0.5 ... 8 back difference
(hysteresis) of a
minimum 0.5 bar
to a maximum of
1 ... 16 1.5 bar can be set.

Switch point in bar

10 ... 30 350 Piston

Example:
10 ... 80 With a switch
Hysteresis in bar

point of 100 bar,

10 ... 160 a switch-back
difference
(hysteresis) of a
20 ... 250 minimum 18 bar
to a maximum of
30 ... 320 28 bar can be set.

40 ... 400 600

Switch point in bar

Options
■■ Factory setting of switch point and hysteresis
■■ Case and process connection from stainless steel
■■ Other process connection
■■ Other materials on request
■■ Electrical connection M12 x 1 or cable
■■ Permissible ambient and medium temperature
-30 ... +100 °C

Page 2 of 3 WIKA data sheet PV 34.82 ∙ 04/2013

 Dimensions in mm
Standard version Option

Electrical connection
M12 x 1 Cable

Weight
approx. 140 g

Adjustment screw for hysteresis

Adjustment screw for switch point

Ordering information
Model / Setting range / Switching function / Process connection / Sealing / Electrical connection / Options
© 2013 WIKA Alexander Wiegand SE & Co. KG, all rights reserved.
The specifications given in this document represent the state of engineering at the time of publishing.
We reserve the right to make modifications to the specifications and materials.

WIKA data sheet PV 34.82 ∙ 04/2013 Page 3 of 3

04/2013 GB

WIKA Alexander Wiegand SE & Co. KG

Alexander-Wiegand-Straße 30
63911 Klingenberg/Germany
Tel. (+49) 9372/132-0
Fax (+49) 9372/132-406
E-mail info@wika.de
www.wika.de
WARRANTY (20.6.12)

INTRODUCTION

The HUGHES Pumps Limited (HUGHES) 2. WARRANTY EXPLANATION

objective is to provide the a) Original parts
distributor/customer with a product that is Subject to the 'Claims Procedure'
fit for its purpose, at a competitive price, being correctly followed, all original
backed by a complete after-sales service parts manufactured by HUGHES that
which includes:- prove defective due to materials or
workmanship, will be repaired or
x Handbooks to assist installation, replaced (at HUGHES discretion)
operation, maintenance and trouble free-of-charge and inclusive of labour
shooting. costs at Hughes Pumps factory (not
x Spares. site labour).
x Service assistance at our factory or
on-site b) Replacement parts
x Training of customer personnel in All replacement parts manufactured
operation and service. by HUGHES are warranted for the
remaining period of the original
1. WARRANTY warranty. The parts will be fitted free-
of-charge and inclusive of labour
a) The warranty period commences on costs at Hughes Pumps factory (not
the date of despatch to the site labour).
distributor/customer (unless otherwise
agreed by prior written agreement). c) The warranty does not include
b) The warranty is ineffective if full consumable items, specifically any
payment for the product (in component included in seal kits,
accordance with agreed terms) has repair kits or insurance kits. For
not been received by HUGHES. example seals/packings, springs,
c) All products manufactured by valves, plungers etc.
HUGHES are warranted for one year
against defects in materials and d) The warranty excludes
workmanship provided that:- products/equipment not of HUGHES
* The products have been installed, manufacture, e.g. electric motors,
used and serviced in accordance diesel engines, hoses, batteries,
with HUGHES instructions. gauges etc. In these cases, the
* No attempt has been made to warranty extends only to that given to
dismantle any faulty warranted HUGHES by its supplier.
product. Disassembly of any
product under warranty without e) In the event of a warranty claim being
written authorization by HUGHES approved and the repair being carried
will automatically make this out at the Hughes factory, HUGHES
warranty void. will cover the freight cost in returning
* Attention is also given to the the goods to the customer/distributor,
WARRANTY EXPLANATION, using an economy freight service.
TRANSIT LOSS/DAMAGE and
CLAIMS PROCEDURE sections. f) Reconditioned or Converted
These terms/conditions do not Pumps/Products
affect statutory rights. The Warranty extends only to
replacement parts manufactured by
HUGHES. These are warranted for
six months against defects in
 materials and workmanship. Any b) Returned parts/products must be sent
faulty parts will be repaired/replaced to HUGHES carriage paid by the
(at HUGHES discretion) free-of- distributor/customer adequately and
charge and inclusive of labour costs safely packaged.
at Hughes Pumps factory (not site
labour). c) Warranty claims must be submitted in
writing for authorization by HUGHES to
g) Distributor Warranty return the parts/products. Any
All claims made by distributors will be parts/products authorised for return and
treated as replacement parts only with not received by HUGHES within 14
labour and transit costs to be borne days of authorization will have their
by the distributor. claim refused.

3. TRANSIT LOSS/DAMAGE d) A written report must accompany all

claims under warranty. The report
a) Products are carefully inspected and must fully describe the installation and
packaged before leaving the factory working practice/conditions leading up
and responsibility for safe delivery is to failure
assumed by the carrier at the time of
despatch. Claim for loss/damage
should, therefore, be made to the
carrier as follows:-

* Concealed Loss/Damage
This is not apparent until the
product has been unpacked. If
loss/damage is evident at
unpacking, make a written request
for inspection by the carrier within
24 hours of the delivery. HUGHES
will fully support the claim.

* Visible Loss/Damage
Note any visible loss/damage at
delivery and describe it fully on the
carrier's delivery note/invoice.
Ensure that it is signed by the
carrier's agent. Failure to
adequately describe the
loss/damage may result in the
carrier refusing to honour a claim
which must be submitted on the
carrier's approved form.

4. CLAIMS PROCEDURE

a) No parts/products are to be returned

without written authorization by
HUGHES. Any parts/products
authorised to return must also follow
the correct procedure.
 N ERD 4
Main Techn ical Parameter
ormal press ure 800
Shell test pressure 8. 4
Test
pressure Tightness test 6. 2
Gas-Tight ness test 0. 6
g Max working temperature -20~ 180 ·c
Applicabl e medium: water,gas,oil , ac id

o. Parts name Material

Cl 1 Body ASTM A351 CF8M
0

C 2 Screen ASTM A276 316 6

3 Cap ASTM A351 CF8M 7

4 Gas ket PTFE 8

L±l

PRESSURE TEMPERATURE RATINGS

S.NO. COMPONENT MATERIAL (BODY)
(BAR) PSI
1 BODY ASTM A351 CF8M (55) 800

'"
2 SCREEN ASTM A276 316
3 CAP ASTM A351 CF8M (48) 700
4 GASKET PTFE (41) 600
2 1/2" - 3"
....
Q)
I\.

"
:::J
en
(34) 500
en
~ (28) 400
TECHNICAL INFORMATION 0...
\
"
"
1) BASIC DESIGN & MANUFACTURE ACCORDING TO ANSI B16.34
(21) 300
2) THREADS TO ISO 228/1 (BSPP) & ANSI 2.1 (NPT)
(14) 200
3) INSPECTION & TESTED ACC. TO API 598
\

"
4) FITTED WITH STAINLESS STEEL 316 SCREEN WITH lMM PERFORATIONS (7) 100
5) 800 PSI (55 BAR) FOR SIZES 1/4" TO 2" (AMBIENT TEMPERATURE)
6) 600 PSI (41 BAR) FOR SIZES 2-1/2" TO 3" (AMBIENT TEMPERATURE)
7) FOR USE WITHIN TEMPERATURE RANGE -29C TO 232C
-20 0 100 200 300 400 500°F
(-29) (-18) (38 ) (93) (149) (204) (260)°C
8) MEDIUM USED WITH STRAINER -WATER, OIL & GAS
Temperature °F(°C)

PRODUCT CODE PROSPECT CODE

SIZE d D H C L CV FACTOR KG EACH
BSPP NPT
1/4 YS04 YS04N 11 11.6 37.8 11 so 6 0.15
3/8 YS06 YS06N 12 14.5 42 12 60 12 0.20
1/2 YS08 YS08N 15 17.5 44.7 14 65 19 0.25
3/4 YS 12 YS12N 20 23 52.1 15 75 37 0.30
1 YS16 YS16N 25 29 65.7 17 90 64 0.45
11/4 YS20 YS20N 32 38 70 19 110 103 0.66
11/2 YS24 YS24N 38 43.5 79.5 19 120 143 0.90
2 YS32 YS32N 48 SS 95.5 22 140 360 1.45
2 1/2 YS40 - 65 69 125 26 190 440 2.00
3 YS48 78 81.5 144.5 28 205 520 3.00

*
***DIMENSIONSS
DIMENSIONS UBJECTT
SUBJECT OC
TO HANGE-
CHANGE -PLEASEC
PLEASE ONTACTU
CONTACT SI
US FC
IF RI
TICAL* *
CRITICAL**

an.
J S STAR *****
CUSTOMER SERVICE
- ~
-l@~
SAME DAY DISPATCH -
□ ROERS PLACED BEFORE 4 : 30PM
~
~
WEALTH OF
INDUSTRY KNOWLEDGE
ONE DFTHE LARGEST
STOCKISTS IN THE UK

CALL: +44 (0)121 665 3900 EMAIL: INFO@NERO.CO.UK

WWW.NERO.CO.UK
UNIT 2, UNION RD, ANGLO AF"Fi!ICAN INDUSTRIAL ESTATE, OLDBURY, WEST MIDLANDS 869 3EX
 vernier control

hands-on
control

Auxiliary hand controls at a glance

The Kongsberg Automotive Vernier Control is the • Fast and Simple Installation - can be

premium mechanical control for setting engine RPM, mounted independently to the dash

controlling regulating valves or for other precise remote and then connected to the cable on

adjustments. This latest design offers a larger grip for the other side of dash or firewall.

easier feel and two internal ball-bearings for smoother • Coarse Adjustment - depress top of

adjustment. grip and pull the Vernier knob out

until an approximate rpm or setting
is achieved.
Applications for the Vernier Control range from
• Fine Adjustment - rotate Vernier knob
generator sets, to manual throttles for warm up, on a
for precise adjustment
wide variety of on and off-road vehicles.
• Adjustable Brake - accurate settings
can be maintained through vibration
or governor back pressure by setting
the correct amount of friction on the
brake.
• Fast Shutdown - simply depress top
of grip and simultaneously push in
the knob for immediate shutdown.
• Recommended for loads up to 20 lbs.
• 3" cable travel. Travel can be reduced
using stop collar.
 Small Size – Engineered Plastics
LS-7 Series–Compact Side Mounts
are the Solution to Many Small Tanks
These low-cost units are ideal for high volume use in small tanks and vessels.
Engineered plastics construction offers broad compatibility in water, oils and
chemicals.
LEVEL SWITCHES – SINGLE POINT

Type 3 Type 5 Type 7

Internal Mounting External Mounting External Mounting

Polypropylene, Nylon or Versaplast™. Polypropylene, Nylon or Versaplast™. Polypropylene or Nylon;

conduit connection.

4-1/4˝
ZIP CORD 3.84˝ 5/8˝ (108 mm) LEAD 1/2˝ NPT
LEADWIRES, (97.5 mm) ZIP CORD STYLE WIRES,
24˝ (16 mm) 4-1/2˝
GASKET 24˝ LEADWIRES 24˝
EXTENDED EXTENDED (114 mm)
(WHITE BUNA N
INCLUDED)
N.O.

N.C.

5/8˝-11 2-7/8˝ 5/8˝ (16 mm)

THREAD (73 mm) WRENCH FLAT
2-7/8˝
2-3/4˝ 19/64˝ (73 mm)
LOCKING NUT (69.8 mm) (7.5 mm)
(NYLON) 5/8˝ HEX
1/2˝ NPT

Common Specifications Approvals Media Compatibility

Switch Rating*: SPST, 20VA UL LS-7
CSA Listed- Media
Lead Wire Gauge: No. 22 AWG Recognized cUL NSF Compatible Types
Material CE File No.
File No. Recognized Std. 61
Mounting Attitude: Horizontal. 30200 Oil, Fuel, Hydrocarbons Nylon
E45168
* See “Electrical Data” on Page X-5 for Broad Range of
Nylon X X X X Polypropylene
more information. Chemicals and Water
Polypropylene X X X X X Limited Chemicals and Water Noryl®
Noryl® X X X Oil, Antifreeze, High
Versaplast™ X X X Temperatures, Corrosive Versaplast™
Fluids, Various Chemicals

Switch Operation
Depending on the mounting position, the float on these switches can rise or lower with the liquid
level. By rotating the switch 180°, the switch operation can be Normally Open or Normally Closed
(except Type 12).
FLOAT PIVOTS STAY ABOVE WATER

Types 3, 5, 7, 10 and 13 Type 12 – N.C. “Drop Float” Design

WATER
FLOAT ARC Normally MAGNET
Normally Open ENVELOPE Closed N.C. ACTUATION RANGE
25˝ to .50˝

45/64˝ REF.
When the switch is mounted
so that the float rises with
When the switch is mounted the liquid level, the switch The LS-7 Type 12 is ideal for use on food warmers,
so that the float lowers with is N.C.
hot water heaters, steam cookers, small boilers or
the liquid level, the switch
is N.O. wherever water evaporation occurs. The switch is
Food
used effectively for either high fluid level alarms or
Warmer
water make up systems. The units are made of Noryl®,
which carries NSF approval for use in potable water,
and are supplied with FDA-approved Buna gaskets.

A-6 Visit www.GemsSensors.com for most current information.

 vernier control

product range and specifications

4 1/4
Easy grip knob designed Brake
Coupling nut disconnects
for fingertip adjustment, release 3/4-16UNF-2A
11/16-16UNF-2A head from cable for fast,
Depress to 6 1/4 turns per inch.
easy installation
release

6 3/16
3" Travel 2 1/4 when
connected

Cable Series Cable Series Part Min. “G”

Series “E” “F”
End Type Part Number Number (cable Bend “A” “B” “C” “D” Thread
Description Dia. Dia.
(cable only) w/head) Radius UNF-2A
30L Open 307141 317341 6” - - - - .26 - -
30L Bulkhead 307142 317342 6” - - 1.88 1.00 .26 .38 -
30L Clamp 307143 317343 6” - - 1.31 - .26 .38 -
30 Bulkhead 307144 317344 8” 8.88 5.00 1.44 .88 .26 .44 .187-32
30 Clamp 307145 317345 8” 8.19 4.31 1.13 .88 .26 .38 .187-32
40 Bulkhead 307146 317346 8” 9.13 5.13 1.76 1.00 .43 .62 .250-28
40 Clamp 307147 317347 8” 8.50 4.50 1.38 1.00 .43 .56 .250-28

Vernier Hardware Part

and Accessories Number
30L Stop Collar 037693
30L Clamp 043229
30L Pivot 047639
30L Pivot 047640
30L Pivot 047641
30L Bulkhead Adapter Kit 300673
30L Clamp Adapter Kit 302485
30C Clamp to Bulkhead Kit 304307
40C Clamp to Bulkhead Kit 304308
Control Head 317310

Length
Measuring and Ordering
• Cable length stamped on the cable is the overall length that is
Length
achieved when the vernier control head is attached to the cable.
• All L-type cables are measured to the point where the core wire exits
the cable conduit.
• Cables with rod-type end fittings are measured to the rod end.
• A Quick Release Vernier Control can be ordered as two separate
items. Use part number 317310 for the Vernier Control Head. PART NUMBERING SYSTEM
Then order the desired cable part number, immediately followed X X X X X X - X X - X X X
by the desired cable length expressed in inches (order in 1 ft.
increments.) Cables over 20 ft. are special order. CABLE SERIES PART NUMBER TRAVEL
CABLE LENGTH
(3" STANDARD)*
In inches (Place 0 in first
position if less than 100")
 - -------------

300 DfA.

ISAE 11.51
(X)
"'

BORE 28,00/28.02 DIA.

PARALLEL KEY\./AY :- 100 DIA.
8 \./IDE X 31.3/31.5 DEEP
ACROSS BORE AND KEY\./AY

I
I
I
l
1 ARRGT LF030HTR60M D3S/F11.5/28K8X66 COUPLING
□
DRA \.IN RPE DATE 15.10.20. DRA \./ING ND RPE/10/20/15/ 4077
TORSIONAL COUPLINGS LF TORSIONAL ASSEMBLY INSTRUCTIONS

Assembly Notes and Instructions - Important Notes

For optimum coupling performance and longevity, the radial and axial screws connecting the element to the hubs or adaptor plate
must be tightened to the torque given in the table below. It is recommended that a torque wrench be used. This is particularly
important with larger couplings. Tightening “by feel” is normally insufficient.

Tightening torques which are too low will inevitably lead to slackening of the screws and consequently lead to undesireable results.

In order to reduce friction between the screw head and the metal insert in the element, it is suggested that a small amount of grease
be applied to the underside of the screw head before assembly. This also reduces the possibility of twisting the element as illustrated
in the diagrams below. It is important that the element be mounted correctly and not be twisted.

Mounting Screws

Each radial and axial mounting screw is treated for corrosion resistance (minimum grade DIN 8.8, SAE Grade 8) and the threads are
coated with micro-encapsulated adhesive. The adhesive is released at assembly and further enhances the performance and safety
of the coupling. For adequate effect, the adhesive should be allowed to harden for 4-5 hours prior to operation.

Radial and Axial Screws L-Loc Screws

Coupling Size
Screw Size Thread Pitch Quantity Torque (Nm) Set Screw Torque (Nm)
LF1 M6 1.00 4 10 - -
LF2 M8 1.25 4 25 - -
LF4 M8 1.25 6 25 - -
LF8 M10 1.50 6 50 M10 30
LF12 M10 1.50 8 50 M10 30
LF16 M12 1.75 6 90 M12 50
LF22 M12 1.75 8 90 M14 70
LF25 M14 2.00 6 140 M14 70
LF28 M14 2.00 8 140 M16 120
LF30 M16 2.00 6 220 M16 120
LF50 M16 2.00 8 220 M16 120
LF80 M16 2.00 8 220 M16 120
LF90 M20 2.50 6 500 M20 200
LF140 M20 2.50 8 500 M20 200
LF250 M20 2.50 12 500 M20 200
LF400 M20/M24 * 8 /4 610/1050 * *
*Contact jbj Techniques Limited technical office, telephone: 01737 767493 or email: info@jbj.co.uk

™
Note: Anaerobic adhesives (such as Loctite , etc,) should NOT be used as they have a detrimental effect on the bond between the
rubber and the insert if dripped or splashed to those areas.
Recommended adhesives are 3M ™ 2353 or Nylok Precote 80 or equivalent. Screws that we provide with this adhesive may be used
up to three times.

Correct Incorrect

S-style Standard
axial screw radial & axial
screw

#DriveLineHarmony 24 www.jbj.co.uk/couplings.html
TORSIONAL COUPLINGS LF TORSIONAL ASSEMBLY INSTRUCTIONS

Models 1,2 and 3

» Place hubs on shafts or the adaptor plate onto the flywheel. If a key is used, ensure it does not extend past the end of the s haft.
» Attach rubber element to the flanged hub or adaptor plate with the axial screws. Hand tighten. Be sure to place a drop of oil or
grease under each screw head to reduce friction and twisting of the element at final assembly.
» Align equipment so the cylindrical hub in the other shaft is placed into the centre of the element. Install the radial screws.
» Tighten all axial screws first then all radial screws to the correct torque shown in the table on the previous page. Tighten set screws if applicable.

Models 1/S, 2/S & 3/S

» As above except:
» Install S-type axial screws on flanged hub or flanged plate to correct torque value.
» Mount the element on the cylindrical hub and fasten with radial screws. Torque these screws to the correct value. Do not forget
to place a drop of oil or grease under the screw head before fastening. Also make sure the hub is set on the shaft with the
correct shaft engagement. Normally the end of the shaft is flush with the end of the hub. Tighten set screws.
» Pilot the hub assembly onto the flanged hub or adaptor plate.

Standard assembly

“S” style assembly

LF Torsional Alignment and Assembly Notes

After assembly the coupling should be aligned HTR Alignment Values (mm)
carefully for long service life. Naturally, the Size Dimension S Dimension Z
higher the speed, the greater the care should 1 2 13.0
be taken in alignment. 2 4 22.5
4 4 27.5
In Model 2, alignment can easily be checked 8 4 30.0
with a straight edge. The outer diameter of the 12 4 31.0
flanged hub must be flush with the element 16 6 40.0
diameter where the radial screws are placed. 22 6 40.0

Check each position for correct alignement. 25 6 42.5

28 6 42.5
In Models 1 and 3 the distance must be
30 8 50.0
measured at each axially bolted point of the
50 8 50.0
rubber element and should be set as
80 4 52.5
accurately as possible to the value “Z” shown
90 8 67.5
here in the table.
140 8 67.5
2 50 8 90.0
In models that use the S-style screws, 400 10 100.0
alignment is normally not required. The
parallel and angular misalignment is small
when the equipment is flange mounted. An example of this would be a hydraulic pump mounted to an SAE engine pump mounting
flange. Hytrel ® Torsional couplings are flange mounted only.

#DriveLineHarmony 25 www.jbj.co.uk/couplings.html
WARRANTY (20.6.12)

INTRODUCTION

The HUGHES Pumps Limited (HUGHES) 2. WARRANTY EXPLANATION

objective is to provide the a) Original parts
distributor/customer with a product that is Subject to the 'Claims Procedure'
fit for its purpose, at a competitive price, being correctly followed, all original
backed by a complete after-sales service parts manufactured by HUGHES that
which includes:- prove defective due to materials or
workmanship, will be repaired or
x Handbooks to assist installation, replaced (at HUGHES discretion)
operation, maintenance and trouble free-of-charge and inclusive of labour
shooting. costs at Hughes Pumps factory (not
x Spares. site labour).
x Service assistance at our factory or
on-site b) Replacement parts
x Training of customer personnel in All replacement parts manufactured
operation and service. by HUGHES are warranted for the
remaining period of the original
1. WARRANTY warranty. The parts will be fitted free-
of-charge and inclusive of labour
a) The warranty period commences on costs at Hughes Pumps factory (not
the date of despatch to the site labour).
distributor/customer (unless otherwise
agreed by prior written agreement). c) The warranty does not include
b) The warranty is ineffective if full consumable items, specifically any
payment for the product (in component included in seal kits,
accordance with agreed terms) has repair kits or insurance kits. For
not been received by HUGHES. example seals/packings, springs,
c) All products manufactured by valves, plungers etc.
HUGHES are warranted for one year
against defects in materials and d) The warranty excludes
workmanship provided that:- products/equipment not of HUGHES
* The products have been installed, manufacture, e.g. electric motors,
used and serviced in accordance diesel engines, hoses, batteries,
with HUGHES instructions. gauges etc. In these cases, the
* No attempt has been made to warranty extends only to that given to
dismantle any faulty warranted HUGHES by its supplier.
product. Disassembly of any
product under warranty without e) In the event of a warranty claim being
written authorization by HUGHES approved and the repair being carried
will automatically make this out at the Hughes factory, HUGHES
warranty void. will cover the freight cost in returning
* Attention is also given to the the goods to the customer/distributor,
WARRANTY EXPLANATION, using an economy freight service.
TRANSIT LOSS/DAMAGE and
CLAIMS PROCEDURE sections. f) Reconditioned or Converted
These terms/conditions do not Pumps/Products
affect statutory rights. The Warranty extends only to
replacement parts manufactured by
HUGHES. These are warranted for
six months against defects in
 materials and workmanship. Any b) Returned parts/products must be sent
faulty parts will be repaired/replaced to HUGHES carriage paid by the
(at HUGHES discretion) free-of- distributor/customer adequately and
charge and inclusive of labour costs safely packaged.
at Hughes Pumps factory (not site
labour). c) Warranty claims must be submitted in
writing for authorization by HUGHES to
g) Distributor Warranty return the parts/products. Any
All claims made by distributors will be parts/products authorised for return and
treated as replacement parts only with not received by HUGHES within 14
labour and transit costs to be borne days of authorization will have their
by the distributor. claim refused.

3. TRANSIT LOSS/DAMAGE d) A written report must accompany all

claims under warranty. The report
a) Products are carefully inspected and must fully describe the installation and
packaged before leaving the factory working practice/conditions leading up
and responsibility for safe delivery is to failure
assumed by the carrier at the time of
despatch. Claim for loss/damage
should, therefore, be made to the
carrier as follows:-

* Concealed Loss/Damage
This is not apparent until the
product has been unpacked. If
loss/damage is evident at
unpacking, make a written request
for inspection by the carrier within
24 hours of the delivery. HUGHES
will fully support the claim.

* Visible Loss/Damage
Note any visible loss/damage at
delivery and describe it fully on the
carrier's delivery note/invoice.
Ensure that it is signed by the
carrier's agent. Failure to
adequately describe the
loss/damage may result in the
carrier refusing to honour a claim
which must be submitted on the
carrier's approved form.

4. CLAIMS PROCEDURE

a) No parts/products are to be returned

without written authorization by
HUGHES. Any parts/products
authorised to return must also follow
the correct procedure.
WARRANTY REGISTRATION

Please complete, detach and return to HUGHES

WARRANTY REGISTRATION Date: / /

Distributor / Customer Name and Address:

.......................................................................................................................................

.......................................................................................................................................

.......................................................................................................................................

Telephone:....................................................................................................................

Fax:..............................................................................................................................

Product Description: .................................................................................................

Pump Build No/Serial No:..........................................................................................

Pump Fluidhead Serial No:........................................................................................

Pump Crankcase Serial No:.......................................................................................

Pump Gearbox Serial No:..........................................................................................

Other product Serial No:............................................................................................

Signature:................................................. Print Name:.............................................

HUGHES Pumps Limited

Spring Gardens
Washington
West Sussex
RH20 3BS
U.K.

Tel +44 (0)1903-892358

Fax +44 (0)1903-892062
 Declaration of Conformity
Manufacturer: Hughes Pumps Ltd
Highfield Works
Spring Gardens
Washington
West Sussex
UK RH20 3BS

Telephone: +44 (0) 1903 892 358

Email: sales@hughes-pumps.co.uk

Signatory:

Date: 25th November 2021

Position: Engineering Manager

Hughes Pumps Ltd

Product: HP40, HP65, HP100, HP120, HP220, HP300, HP500, UB30

Description: High-pressure and Ultra-high pressure Reciprocating Plunger pumps

We hereby declare that the above-stated product in the shipped version complies with the
following regulations:

Supply of Machinery (Safety) Regulations 2008

Machinery Directive 2006 / 42 / EC

Used Harmonised standards:

BS EN 1829-1:2021, High-Pressure Water Jet Machines

Safety Requirements. Part 1: Machines

Important Notes:

1. All safety, operating and installation instructions must be strictly observed in

accordance with the manuals supplied.

2. Where the above-stated product may be considered as partly completed machinery

and is exclusively intended for incorporation in/with other machinery or equipment, this
machinery must not be placed in service until the final machinery in which it is
incorporated has been declared in conformity with the provisions of the machinery
directive.

HP3135 R2
 ORDER
CUSTOMER. GOMOTOR SAC No.
OC/GM/00704/24 SALES ORDER No. 44204
DESCRIPTION COMMENTS

SERIAL Nos - UNIT - AC1437

1 OFF HP65, DIESEL DRIVEN, OPEN SKID MOUNTED, HIGH
PUMPHEAD - 0538
PRESSURE WATER JETTING UNIT.
CRANKCASE - 0522
ENGINE - U2171424
PART No - 51852-824-1437

50 LPM @ 500 BAR

GEARBOX - 2.28:1
PUMP PERFORMANCE INPUT SPEED - 1710 RPM
PUMP SPEED - 750 RPM

HUGHES PUMPS TEST CERTIFICATE Certificate No. TC 9072 Date. 26/07/24

HUGHES Pumps Limited Signed:

I CERTIFY THAT THE EQUIPMENT
Spring Gardens,
DETAILED ABOVE HAS BEEN
Washington, Pulborough
TESTED AND CONFORMS FULLY
West Sussex, RH20 3BS Tel: (01903) 892358
WITH THE SPECIFICATION(S),
Email: enquiries@hughes-pumps.co.uk
DRAWING(S), AND ORDER.
Web: www.hughes-pumps.co.uk