Manual 38731 PDF

HPS3000 DIESEL DRIVEN PUMPSET
OPERATING & MAINTENANCE MANUAL
Build Number : 51851-769-1263
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 : 38731
Customer : Eastwind Gmbh

Mattentwiete 8
Hamburg
20457
Germany
Manufactured : August 2017

1. Introduction
2. Safety and WJA Code of Practice
3. Specification
4. Avoidance of cavitation
5. Operating instructions
6. Control panel wiring diagram
7. Pumpset part list
8. Pump drawings & parts lists
9. HP Valves
10. Spare parts & tools
11. Maintenance
12. Fault finding
13. Ancillary Equipment
 Oil cooler
 Oil temperature switch
 Boost pump
 Pressure Transmitter
 Drive coupling
 Barrcuda
 Dump Jetting Gun
14. Warranty
15. Test certificate
16. Engine operating and maintenance manual

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
Section 2 – Safety
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.
Hoses must not be used as tow-ropes

and jetting guns used as hammers or
Failure to follow these safety crowbars etc.
instructions may cause personal
injury or death. If used, never attempt to tie or wedge the
gun trigger. It is essential to be able to
stop jetting immediately the trigger is
Introduction released.
This code of practice has been prepared Never direct high pressure water jets at
to give guidance on the safe use of any person or at any objects which may
equipment used in high pressure water be damaged or dislodged due to their
jetting applications. effect.
High pressure water jets can cause On jetting guns without an automatic
serious injury. It is the responsibility of safety catch engagement, care must be
both supervisor and operator of the taken to apply the safety catch in the
equipment to observe at all times the closed position when the gun is not being
recommendations made in this code of used.
practice. Safety is a joint effort. In the
event of an accident occurring from During any cleaning operation, the jetting
contact with a high pressure water jet, this operator must always be under
must be taken seriously. Even apparently observation, or there must be an adequate
minor injuries must be referred to a system of communication with another
medical department or hospital. The person readily placed to give assistance
superficial puncture may be quite small or to shut down the power to the pump.
but tissue damage could be extensive and
deep. A minimum of two men per team is
recommended.
General Precautions
Never connect the pumphead delivery line
It is recommended that testing of all high directly to any accessory, there must be
pressure equipment should take place at some type of dump / pressure adjusting
least every six months. This testing valve that enables the pump to be started
should be 1 ½ times maximum working off-load.
pressure and this pressure held for a
period of 15 minutes. Do not use unspecified hose or
equipment.
Hughes Pumps can provide this service
and will provide test certificates for The high pressure connecting hose and
successfully tested items of equipment. adaptors between the pumphead and the
jetting equipment, must be of the correct
Check that the operating pressure of the type and pressure rating for the
pump does not exceed the working application.
pressure of the accessory to be used.
Any high pressure connections not in use will occur, rendering the item useless for
must be blanked off using either the further service. This can be very costly,
standard ball and cap method or the i.e. in the case of a pumphead.
coned swivel plug arrangements. Use of
ordinary plugs or caps could be Safety Valves And Bursting Discs
dangerous.
Pumps must be protected by a suitable
Never attempt to stop a leak or tighten any safety valve. All safety valves used on
connection while pressure remains in the Hughes equipment are accurately set and
system. sealed / locked. Do not rely on any safety
valves that have a broken or missing seal.
Never connect a stop valve to a high Unauthorised adjustment of these valves
pressure delivery line without ensuring a could result in the valve not relieving in an
pressure adjusting / unloader valve is emergency. Safety valves are matched to
fitted that is capable of full flow against a plunger sizes, so ensure that the correct
closed valve. valve is being used with a given plunger
size. Safety valves should be calibrated at
Several lengths of delivery hose may be least every six months to ensure accurate
joined together using high pressure & reliable operation.
adaptors. As the length of delivery line is
increased, the pressure at the discharge If bursting discs are fitted ensure the
nozzle is decreased. correct disc is used appropriate to the
working pressure of the pump.
The size of the jets in any accessory is
also very important. If they are too small a Training and Personnel Protection
continuous high volume of water will be
discharged through the dump valve of the Correct training and responsible
pressure adjusting valve causing excess supervision must be the first
wear to the valve and possible uneven consideration. Attendance at a suitable
running. Or if a pressure adjusting valve is training course is strongly advised such as
not fitted the pump will go over pressure. that carried out by the UK based Water
Undersize jets will only utilise a fraction of Jetting Association (WJA) which can be
the power available. If too large a nozzle organised by Hughes Pumps.
is used, it may be impossible to achieve
the desired working pressure. Each member of the team should wear
suitable protective clothing and
If a hand-held jetting gun is used, the equipment. This is to protect them from
combination of the selected nozzle and debris removed by the action of the water
desired working pressure must not exceed jet. Protective clothing and equipment
25kg reaction force to the operator. should consist of safety helmet, gloves,
Consult Hughes Pumps if necessary. PVC jacket and trousers, knee length
boots with steel toe caps, goggles, visor or
Always use the recommended / original suitable facial protection. It must be noted
seal types and sealing methods. The that these items will not provide protection
importance of efficient and leak free joints from direct impingement of a high
and seals in high pressure water jetting pressure water jet.
cannot be over-stressed, both for safety
aspects and the maintenance of For operators subjected to long periods of
equipment in efficient working order. noise, it is advisable that ear defenders
are worn.
If a high pressure water seal is allowed to
leak for any period of time serious erosion
of steel components adjacent to the leak
Site Precautions
Extreme caution must be observed to Safety catches on jetting guns must be

protect operators, any surrounding areas checked for correct operation.
and observers.
All nozzles must be visually checked for
Before any high pressure water jetting good condition particularly where threaded
operation can commence, suitable nozzles are used. All threads must be in
barriers must be erected around the good condition
cleaning bay or site.
All adaptors & accessories must be
Suitable warning signs or notices visually checked. Threads and seatings
prohibiting the entry of unauthorised must be in good condition.
personnel into the cleaning area must be
displayed. It is recommended that the Where protective guards are fitted ensure
barriers be erected at minimum distance these are in position.
of 10 metres away from the nozzle
discharge point. Check safety valves and bursting discs.
Before commencing jetting check all hose If in doubt over any of the above, check
connections / fittings to ensure leak tight with a supervisor. If any item of
joints. It is sufficient just to tighten hose equipment is suspect, it must be replaced
connections etc., to prevent leaks. Over before work commences.
tightening can cause permanent damage
to connections. Operation
Never attempt to tighten any hose Ensure any accessory is located in a safe
connection, nut or fitting while the position, facing away from operators
system is under pressure. before the pump is started.
Pre-Operation Checks If a jetting gun is being used, always hold

the gun firmly in both hands. It is the
All operations must be controlled by a supervisors' responsibility to ensure that
competent supervisor and all equipment no operator is subjected to any unsafe or
must be carefully inspected before each unreasonable gun reaction forces.
operation commences. In particular the
following must be checked: End of Shift or Operation
A pressure gauge must be fitted to the Whenever the equipment is left

pump and easily read. unattended, the prime mover must be shut
down.
All hoses must be in good condition, i.e.
blisters or wearing of the outer casing, When a pressure adjusting valve is fitted,
renders the hose unserviceable. the adjusting screw must be fully released.
All hose couplings must be visually At the end of any shift or operation, it is
checked for good condition of threads. strongly advised that all equipment is
disconnected and stored for safe keeping.
Jetting guns must have free operation of It is recommended that all threads be
the trigger. suitably protected and all hose coiled for
storage.
Section 3 – Specification/Scope of Supply
Hughes sales order no. : 38731

Manufactured : July 2017
Pump build no. : 692451-330A1
Pump model : HPS3000 (see Section 7)

Performance : 85 lpm @ 1400 bar
Plunger size : 30 mm
Input speed : 2050 rpm
Gearbox ratio : 5.13:1
Pump speed : 400 rpm
Safety valve : 43742-733 (see Section 9)
High pressure control valve : 43744-914 Pneumatic Regulator

(see Section 9)
Drive coupling part no. : 23357-156 (see Section 13)
Oil temperature switch part no. : 24135-022 (see Section 13)

Oil temperature switch model no. : NT BC 70 BC (see Section 13)
Oil temperature switch serial no. : TBA
HPS3000
High Pressure Triplex Pump
Features
• 431 stainless steel pump head
• Solid ceramic plungers & self
adjusting seals
• Interchangeable plunger kits
• Hardened, alloy steel
crankshaft with heavy duty
steel backed white metal main
bearings, supported between
each connecting rod
• SG iron crankcase with
pressure lubrication, filtration
and oil cooling
• Forged connecting rods with
HPS3000 with optional SAE engine adaptor Uprated performance low friction, shell type big
end bearings and lead bronze
lined small end bushes
Maximum Flowrate 484 lpm at 250 bar • Gear driven, eliminating the
(106.4 igpm / 128.2 usgpm at 3,625 psi) need for belt drive
Maximum Pressure 1400 bar at 85 lpm
(20,300 psi at 18.6 igpm / 22.5 usgpm) • Safety relief valve
Maximum Power 225 kW • Pressure gauge
(300hp)
See overleaf for performance options
Build Options
• 316 stainless/Duplex steel pump
A robust design, the HPS3000 has a aligned installations and enclosing all head for seawater applications
specification producing a heavy duty moving parts.
capability for dealing with the more • Choice of gear ratio to suit
difficult problems in industry and shares For maximum hydraulic efficiency, the diesel engine or electric
critical components with the higher in-line valve arrangement is designed motor drive
rated HPS5000 pump. to minimise the unswept volume and • SAE 1 adaptor housing for
prevents the adverse effects of cyclic flange mounting the pump to a
The close coupled, gear driven power stress within the head block, while diesel engine flywheel housing
end has pressure lubrication, filtration allowing all working components to be or electric motor
and oil cooling. An SAE 1 adaptor easily removed on site for service.
housing is available enabling the pump • Unloader valves
to be flange mounted to a diesel engine This improved design is capable of • Pressure adjusting valves
flywheel housing or electric motor high pressure to high volume with (manual or actuated)
ensuring extremely compact, perfectly outstanding seal, plunger and valve life.
• Selector / Diverter valves
(manual or actuated)
• Bare shaft pump only or
• General Dimensions - typical pump build complete unit build
• Approx weight - 680 kg (with gearbox) • ATEX compliant
646
Shaft Ø50
1180 Key 14 x 9 x 100
370
270
*
840
310
230
300
*
160
383 67
* * * 4 No. Fixing holes
M24 x 50 deep HPS3000 as standard foot mounted version
HPS3000
High Pressure Triplex Pump
Plunger Gear ratio Pump Power Required Nominal Flowrate Max Pressure
Diameter Input Speed (rpm) Speed
mm 1500 1800 2050 rpm kW HP lpm igpm usgpm bar psi
5.13 292 191 216 62 13.6 16.4
30 5.13 351 193 259 74 16.4 19.7 1400 20,300
4.11 365 201 270 77 17.0 20.5
5.13 400 220 295 85 18.6 22.5
5.13 292 180 241 84 18.6 22.4
35 5.13 351 216 290 101 22.3 26.8 1150 16,675
4.11 365 225 301 105 23.2 27.9
5.13 292 185 248 99 21.9 26.4
38 5.13 351 222 297 119 26.3 31.6 1000 14,500
4.11 365 231 309 124 27.3 32.9
5.13 292 184 247 110 24.2 29.2
40 5.13 351 221 296 132 29.1 35.0 900 13,050
4.11 365 230 308 138 30.3 36.5
5.13 292 181 243 140 30.7 37.0
45 5.13 351 218 292 167 36.8 44.4 700 10,150
4.11 365 226 303 174 38.3 46.2
5.13 292 182 244 172 37.9 45.6
50 5.13 351 219 293 207 45.5 54.8 570 8,265
4.11 365 227 305 215 47.3 57.0
5.13 292 182 244 208 45.9 55.2
55 5.13 351 218 293 250 55.0 66.3 470 6,815
4.11 365 227 304 260 57.2 69.0
5.13 292 184 247 248 54.6 65.7
60 5.13 351 221 296 298 65.5 78.9 400 5,800
4.11 365 230 308 310 68.1 82.1
5.13 292 186 250 291 64.0 77.1
65 5.13 351 224 300 349 76.8 92.6 345 5,003
4.11 365 233 312 363 79.9 96.3
5.13 292 182 244 338 74.3 89.5
70 5.13 351 218 292 405 89.1 107.4 290 4,205
4.11 365 227 304 421 92.7 111.7
5.13 292 180 241 388 85.3 102.7
75 5.13 351 216 289 465 102.3 123.3 250 3,625
4.11 365 225 301 484 106.4 128.2
Additional Notes. 1. Flowrates indicated are swept volume & will reduce by approximately 5% at full pressure
2. Other gear ratios are available for specific applications, consult Hughes Pumps Ltd 3. Pump stroke 100mm
Hughes Pumps Limited

Spring Gardens, Washington, West Sussex, RH20 3BS UK
Tel: +44 (0) 1903 892358 Fax: +44(0) 1903 892062
www.hughes-pumps.co.uk sales@hughes-pumps.co.uk
In line with the Company’s policy of research and development, alterations in design, dimensions and appearance are incorporated from time to time in order to ensure
that important developments are included at the earliest opportunity. The Company, therefore, reserves the right to alter design, dimensions etc without notice.
Section 4 – 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

As the plunger moves, pressure inside the cylinder reduces, the inlet
valve opens against the spring and water enters.
GENERAL PUMP OPERATING INSTRUCTIONS
All operators must be trained in the correct / safe operation of this equipment & must have read & fully
understood the operating & maintenance manual.
PRE-START CHECKS
 Check pump oil level

 Check engine oil level
 Check engine coolant level
 Check hydraulic reservoir level (if fitted)
 Check fuel tank level (fuel must be clean & free of water)
 Check suction hose for leaks, kinks or damage
 Check condition / change water filter (element must be fitted correctly / sealed in filter housing)
 Check system is not frozen
 Check correct function of boost pressure switch
 Check all high pressure connections are tight
 Ensure any water jetting accessory in a safe position
 Ensure the pump is offload before start up
START UP
 Start the engine & allow to idle / warm up for a few minutes
 Check boost pressure is above 0.5 bar. If not the water filter may be blocked or it may be
necessary to increase engine idle speed slightly.
 Open the valve on the top of the water filter to bleed any air, close when there is a steady flow of
water without air bubbles. It may be necessary to increase engine speed to assist priming.
 Load the pump by switching the air control to the ON position (or actuating the manual dump valve
on the pump if fitted). The pump pressure will be low at this point.
 Raise engine speed to approximately 1500 rpm & check boost pressure is approximately 2-4 bar
(if a manual dump valve is fitted, pump pressure will increase with engine speed)
 Slowly raise pump pressure by using the pressure adjusting/unloader valve
 Pump discharge & boost pressure gauges should be steady. If not shutdown & investigate.
 The pump can be unloaded / loaded by switching the air control switch on / off.
SHUTDOWN
 Unload the pump

 Drain all water from the pump & system
 Where there is a risk of freezing the pump & complete system should be filled with anti-freeze
BOM REFERENCE : 51851‐769‐1263
DESCRIPTION : HPS3000, DIESEL SITE TRAILER WITH OPEN CRASHFRAME
Seq. Product Code Description Quantity

1 PUMP‐ASSEMBLY
2 692451‐330A1 HPS3000/P30/431/5.13:1/TRB/SAE1 1
3 21681‐011 OIL COOLER Bronze Ends ‐ 2" Water 1
4 44211‐050 OIL COOLER HOSE ASSY 2200 1
5 41451‐038 PUMP SUPPORT ASSEMBLY 1
6 48615‐892 PUMP OIL DRAIN FITTINGS FOR HPS 3000 1
7 PUMP‐CONTROLS
8 43742‐733 R/VALVE ‐ LM12 <= 1400 BAR WP (ø8 TC) 1
8 24711‐409 PRESSURE TRANSMITTER, 0 ‐ 1600 BARG, G1/2 A, 4‐20mA 1
9 COMPRESSOR HEADER
10 48615‐922 PNEUMATIC ASSEMBLY 24V COMPRESSOR & G1/4 & 6mm hose 1
12 HP‐VALVE‐ASSEMBLY
13 43744‐914 PNEUMATIC REGULATING VALVE (1400 BAR) 1
14 45117‐208 M24 DKO OUTLET ADAPTOR ASSEMBLY 1
15 DRIVE‐COUPLING
16 23357‐156 COUPLING ASSEMBLY 1
17 25732‐280 M12 x 35 x 1.5p SHCS 12.9HT BZP 8
18 BOOST‐PUMP‐ASSEMBLY
19 23582‐008 BOOST PUMP 2" x 1‐1/2" 1
20 23357‐296 TAPER LOCK BUSH 1610 X 25mm 1
21 23351‐279 BELT TENSIONER WITH SPB 112 PULLEY 1
22 23351‐277 DRIVE PULLEY SPB 112 X A 1
23 23355‐308 DRIVE BELT 1850mm SPB 1
24 41616‐045 BOOST PUMP GUARD (1243) 1
24 41411‐933 BOOST PUMP MOUNTING 1
25 FILTRATION
26 21571‐501 25 MICRON FILTER BAG FOR 21571‐327 1
27 21571‐327 FILTER HOUSING, 316, 2" BSP PORTS 1
28 PC50060 FILTER HOUSING Big Blue 10", 1½", for Filter bags 1
29 21571‐628 100 MICRON FILTER BAG FOR FILTER PC50060 1
29 41455‐058 FILTER BRACKET FOR PC50060 AND 21571‐326 1
29 41435‐788 FILTER BRACKET (21571‐327) 1
30 DIESEL‐ENGINE‐ASSY
31 22651‐144 DOOSAN PU126TI DIESEL ENGINE 1
31 21751‐266 EXHAUST LAGGING MANIFOLD, TURBO DOOSAN PU126TI 22651‐144 1
32 47514‐310 BATTERY ASSEMBLY (AC1230/35) 1
33 41616‐034 ENGINE BELT GUARD 1
34 22659‐118 AIR CLEANER INLET HOOD 1
35 41435‐785 REAR ENGINE FOOT (AC1239) 2
36 41435‐786 FRONT ENGINE FOOT (AC1239) 2
37 48615‐888 OIL DRAIN FOR DOOSAN PU086T ENGINE 1
38 24331‐102 VERNIER CONTROL 1
39 24331‐118 VERNIER THROTTLE CABLE, 2.8m LONG 1
39 24112‐151 BATT MASTER SWITCH 1
40 EXHAUST‐ASSY
41 21751‐267 4" EXHAUST SYSTEM DOOSAN PU126TI 1
42 21751‐226 4" STAINLESS STEEL RAIN CAP 1
42 21751‐262 S235 UBC CLAMP 2
43 FUEL‐TANK‐ASSY
44 45647‐375 Fuel Tank (AC1263) 470 ltr HPS 3000 1
45 25859‐014 FILLER BREATHER 1
46 48615‐891 FUEL LINE FITTINGS ASSEMBLY (AC1239) 1
47 25215‐057 M6 NITRILE PENNY WASHER 54
48 HEADER‐TANK‐ASSY
49 45647‐352 WATER TANK (AC 1216) 1
50 21532‐054 LEVEL SIGHT GAUGE 500mm CENTRES WITH FLOAT 1
50 48615‐917 LOW PRESSURE FITTINGS 1" FEED TO TANK 1
50 48615‐918 LOW PRESSURE FITTINGS 2" TANK TO MAIN FILTER VIA BOOST PUMP 1
50 48615‐919 LOW PRESSURE FITTINGS 3/4" OVER FLOW AND DRAIN 1
50 48615‐920 LOW PRESSURE FITTINGS 1/4" FILTER, BOOST PUMP, COOLER DRAIN 1
52 CONTROL‐PANEL‐ASSY
53 22659‐148 CONTROL PANEL FOR DOOSAN PU0126TI DIESEL ENGINE 1
54 SHUTDOWNS
55 24711‐407 PRESSURE TRANSMITTER, 0 ‐ 10 BARG, G1/4A, 4‐20mA 2
56 48615‐721 LP TEMP SWITCH ASSY (N/C 70') 1
57 23161‐055 3/8" BSP DOWTY SEAL 2
58 23612‐693 1/4" BSPP FEMALE X 1/8" BSPT MALE ADAPTOR 316 SS 1
59 ENCLOSURE
60 41431‐1042 BEDPLATE CRASH FRAME SITE TRAILER (AC1263) 1
61 41431‐1017 SUBFRAME (AC1239) 1
61 26411‐150 ANTI VIBRATION MOUNT 6
62 SITE‐TRAILER‐UNDERGEAR
63 26832‐112 UNBRAKED AXLE (2000kG) 1
64 26832‐113 BRAKED AXLE (2000KG) 26832‐114 WITH BRACKETS 1
65 26832‐067 HANDBRAKE & BRAKE CABLE 1
66 26832‐069 TURNTABLE 1
67 41411‐929 FRONT AXLE MOUNTING 1
68 26832‐063 50mm WELD ON EYE 1
69 26832‐098 5 STUD 6 1/2" PCD WHEEL & 185/70R13 TYRE 4
70 PAINTING 1
71 TESTING
74 MISCELLANEOUS
75 38118‐315 UNIT LABEL 1
76 38118‐156 WARNING LABEL 1
77 17213‐041 SHELL RIMULA RT4 15W/40 20
78 17213‐048 ANTI‐FREEZE Fuchs Maintain Fricofin DP‐35 35
79 38118‐321 ADHESIVE LABEL, HUGHES PUMPS LIMITED logo 194 X 41mm 1

BOM REFERENCE : 692451‐330A1
DESCRIPTION : HPS3000/P30/431/5.13:1/TRB/SAE1

1 47151‐232 CRANKCASE ASSY HPS3000 (100 DIA, VHP, TRB) 1
2 47175‐482 5.13:1 GEARBOX, HPS3000/5000, TRB, EXC C/PLATE 1
3 41611‐303 ADAPTOR HOUSING ASSEMBLY, SAE 1, TRB 1
4 43128‐3069 P30 PLUNGER KIT (1400 BAR) 1
5 43360‐333 PUMP HEAD ASSEMBLY (1400 BAR) 1

BOM REFERENCE : 47151‐232
DESCRIPTION : CRANKCASE ASSY HPS3000 (100 DIA, VHP, TRB)

1 8347 CRANKCASE HPS3000 TRB (HP, 100mm BORE) 1
1 7784 CRANKCASE MODIFICATION 1
2 5632 CRANKSHAFT 3000 1
3 6273 MAIN BEARING FRONT 1
4 6272 MAIN BEARING 3/5000 3
5 6277 KEYPLATE 3/5000 4
6 47114‐127 CON ROD ASSEMBLY 3/5000 3
7 23311‐960 BIG END BEARING 3/5000 3
8 8025 RETAINED CROSSHEAD PIN 3/5000 3
9 25255‐210 SPIRAL RETAINING RING 6
10 7368 CROSSHEAD,(UHP) 3
11 23514‐528 CROSSHEAD OIL SEAL 3
12 25251‐100 INTERNAL CIRCLIP 100mm 3
13 21571‐093 OIL FILTER (FSD 425) 1
14 6279 OIL FILTER STUB 1
15 21573‐008 FILLER BREATHER 1" BSP 1
16 7047 HUGHES LABEL 1
17 25156‐013 DRIVE SCREW No6 x 6.5 4
18 25777‐003 M16 EYEBOLT BS4278 3
19 21673‐008 3/4" BSP MAGNETIC PLUG 1
20 41131‐117 DIPSTICK 3/5000 1
21 17213‐034 GEAR OIL SHELL SPIRAX S2 A 80W/90 35
22 25311‐062 10mm DIA x 32mm DOWEL, H&G STEEL 1
23 6191 OIL PUMP BODY 3/5000 1
24 6192 OIL PUMP CAP 3/5000 1
25 25732‐211 M12 x 95 SHCS 8.8HT 4
26 25732‐212 M8 x 45 SHCS 8.8HT BZP 2
27 25772‐004 M12 x 60 SHCS 8.8HT BZP 2
28 6935 SPLINED HUB 3/5000 1
29 25732‐161 M10 x 60 SHCS 8.8HT BZP 4
30 6283 INNER GEAR, OIL PUMP 1
31 6284 OUTER GEAR, OIL PUMP 1
32 23513‐210 O‐RING 1
33 23513‐208 O‐RING 2
34 23513‐206 O‐RING 2
35 23611‐284 1/2" BSPT SOCKET HEAD PLUG 5
36 23611‐002 1/4" BSPT SKT HEAD PLUG 3
38 6467 ADJUSTING SCREW CAP 1
39 6466 ADJUSTING SCREW 1
40 23455‐067 SPRING 1
41 8115 RELIEF VALVE SPOOL 1
42 21531‐222 PRESSURE GAUGE 0‐150 PSI 1/4" BSPT 1
44 17112‐001 LOCTITE 275 (50ml) 0
45 6463 SHROUD, BY‐PASS 1
46 23312‐059 9/16" DIA BALL EN58J 1
47 23455‐070 CARBON COMPR SPRING 1
48 6226 THRUST WASHER 1
49 6930 MK2 OIL SEAL HOUSING 3
50 23513‐117 O‐RING 1
51 23513‐162 O‐RING,3000/5000 OIL PUMP 1
52 6931 OIL SEAL RETAINER 3
53 38118‐156 WARNING LABEL 1
54 6625 GUARD PLATE 3/5000 1
55 25755‐101 M5 x 8 PAN HEAD POSI SCREW ST/ST A2 5
56 25212‐224 M5 WASHER ST/ST A2 5
57 23611‐320 1/16" NPT SOCKET HEAD PLUG 3
58 23612‐005 3/4" BSP EQUAL MALE ADAPTOR 2
59 23161‐058 3/4" BSP BONDED SEAL 2
60 7757 PONY ROD 3
61 7756 THRUST PAD 3
62 23513‐218 O‐RING 6
63 23513‐108 O‐RING 1

DESCRIPTION : 5.13:1 GEARBOX, HPS3000/5000, TRB, EXC C/PLATE

1 Seq. Product Code Description Quantity
2 25732‐213 M20 x 38 (40) SHCS 8.8HT 14
4 7466 GEAR 77T ‐ 3/5000 1
5 25732‐210 M20 x 100 SHCS 8.8HT 4
7 7465 15T PINION ‐ 3/5000 1
8 23411‐133 PARALLEL KEY 1
9 23515‐131 OIL SEAL 1
10 23317‐299 TAPER ROLLER BEARING 2
11 23513‐115 O‐RING 1
12 23513‐117 O‐RING 2
13 21673‐009 1/2" BSPT MAGNETIC PLUG 1
14 8352 SPRING GUIDE, HPS3000/5000, TRB 1
15 23457‐016 DISC SPRING (112 x 57 x 3) 1

DESCRIPTION : ADAPTOR HOUSING ASSEMBLY, SAE 1, TRB

1 8351 ADAPTOR HOUSING SAE1, HPS3000/5000, TRB 1
2 25765‐092 M12 x 40 HEX BOLT 8.8HT STEEL BZP 14
3 25218‐224 M12 S/C SPRING WASHER ST/ST A2 14
4 7091 STABILISER STUD 3/5000 2
5 25218‐310 M20 S/C SPRING WASHER STEEL BZP 2
6 6295 STABILISER SPACER 2
7 25781‐120 M20 HEX FULL NUT GR8.8 BZP 2
8 8361 COVER PLATE, SAE1 ADAPTOR HOUSING, HPS3000/5000 1
9 25754‐130 M5 x 8 PAN HEAD SLOTTED SCREW ST/ST A2 3
10 25715‐042 M6 x 10 SKT SETSCREW ST/ST A2 3
11 25212‐224 M5 WASHER ST/ST A2 3

DESCRIPTION : P30 PLUNGER KIT (1400 BAR)

6 7763 GLAND NUT 3
7 23513‐033 O‐RING 3
8 23514‐544 LOW PRESSURE SEAL 3
9 7764 PRESSURE CYLINDER 3
10 7765 GUIDE BAND HOUSING 3
11 33157‐530 30mm GUIDE BAND 6
12 23513‐139 O‐RING 3
13 7766 SEAL BACK UP RING 3
14 23552‐018 REAR GUIDE RING 3
15 23514‐295 30MM PACKING RING (PRE‐FORM) 6
16 23552‐019 FRONT GUIDE RING 3
17 7767 SPRING RING 3
18 5961 30mm PACKING SPRING 3
19 7768 SPRING CAGE 3
20 7769 INLET SPRING GUIDE 3
21 7780 INLET SPRING 3
22 44213‐011 DISCHARGE ASSEMBLY 1
23 47110‐053 PLUNGER HOLDER ASSEMBLY 3
24 7773 INLET VALVE 3

DESCRIPTION : PUMP HEAD ASSEMBLY (1400 BAR)

1 7820 PUMPHEAD (1400 BAR) EN57 1
2 7581 INLET MANIFOLD 3000 1
3 25732‐219 M10 x 80 SHCS HTS. 8
4 23513‐332 O‐RING 3
5 7772 VALVE SEATING CARTRIDGE 3
6 7774 OUTLET VALVE 3
7 7781 OUTLET VALVE SPRING 3
8 7777 RETAINING PLATE 3
9 23513‐121 O‐RING 3
10 23513‐121X AX‐RING 3
11 23514‐827 SLEEVE INNER SEAL 3
12 23514‐828 SLEEVE OUTER SEAL 3
13 7782 HEAD STUDS (HPS5000 UHP) 8
14 6408 M24 HEAD NUT 8
15 25732‐265 M16 X 2.0 X 55 LONG SHCS,grade 12.9 plated (umbrako) 24
16 23513‐238 O' RING 3
17 23611‐527 PLUG SKT HD 1/4"NPT, ST STL, 3/4" TAPER 3
18 47131‐703 VALVE STOP ASSEMBLY 3

DESCRIPTION : R/VALVE ‐ LM12 <= 1400 BAR WP (ø8 TC)

1 8191 STEPPED VALVE SEAT, LM12 1
2 35237‐105 RELIEF VALVE BODY 1
3 25311‐250 5mm DIA x 24mm DOWEL, GROOVED 1
4 23312‐225 8mm DIA TUNGSTEN NICKEL BALL 1
5 8100 BALL GUIDE 1
6 23457‐006 DISC SPRING 20
7 8101 SPRING GUIDE 1
8 8102 SETTING PLUG 1
9 25254‐038 EXTERNAL CIRCLIP 38mm 2
10 23513‐128 O‐RING 2
11 34229‐128 COLLAR 1

DESCRIPTION : PNEUMATIC REGULATING VALVE (1400 BAR)

1 8192 VALVE BODY WITH THREADED RETAINER (1400 BAR) 1
2 7750 12mm DIA STEM 1
3 7822 SEAT (1400 BAR) 1
4 8193 UPPER STEM GUIDE (12mm, THREADED BODY) 1
5 7823 LOWER STEM GUIDE 1
6 23651‐014 DOUBLE ACTING COMPACT CYLINDER 2
7 23651‐015 SINGLE ACTING COMPACT CYLINDER 1
8 7710 CYLINDER SPACER 2
9 7718 M8 STUD ST/ST A2 4
10 25784‐109 M8 DOMED NUT ST/ST A2 4
11 7719 SPACER 4
12 7711 BUTTON 1
13 23514‐543 12MM ROD SEAL 1
14 23512‐015 O‐RING 1
15 23512‐015X AX‐RING 1
16 23512‐104 O‐RING 20.60 ID x 2.40 1
17 23512‐104X AX RING 20.60 ID x 2.40 2
18 8194 THREADED RETAINER (1400 BAR VALVE BODY) 1
19 24537‐111 BANJO BOLT N/R 1
20 24537‐112 BANJO BOLT R/O 1
21 7712 MANIFOLD BLOCK 1
22 25733‐003 M14 x 110 SHCS 12.9HT BZP 4
23 7709 LOCATION RING 1
24 23512‐112 O‐RING 1
25 23612‐429 1 1/2" BSP HEX NIPPLE ST/ST 150LB 1
26 23616‐858 1 1/2" BSP EQUAL TEE ST/ST 150LB 1
27 23612‐232 1 1/2" BSP HOSE TAIL ST/ST 150LB 1
28 23611‐833 1 1/2" BSPT PLUG ST/ST EN58J 1
32 23612‐540 1 1/2" BSP MALE/FEMALE UNION ST/ST 150LB 1

Section 10 – Spare Parts & Tools
Hughes sales order no. : 38731

Manufactured : July 2017
Pump build no. : 692451-330A1
Pump model : HPS3000
Description Part No. Suggested Stock
Spare Parts - Pump
Pumphead seal kit (seals) : 43360-333/SK 1

Pumphead repair kit (seals & valves) : 43360-333/RK 1
Plunger seal kit (seals) : 43128-3069/SK 1

Plunger repair kit (seals & plungers) : 43128-3069/RK 1
Crosshead seals : 23514-528 3

Oil filter (if fitted) : 21571-093 3
Pressure Adjusting / Dump Valve
Seal kit (seals) : 43744-914/SK 1

Repair kit (seals, seat & stem) : 43744-914/RK 1
Filtration
25 Micron Filter bag : 21571-501 6

100 Micron filter bag : 21571-628 6
Tools
Pure Goop anti seize compound : 17111-005 1

Pumphead tool kit (cartridge extractor) : inc in pumphead 1
Pumphead tool kit , part number : 48161-042
Plunger kit tool kit : n/a 1
Crosshead oil seal removal tool : T1050 1
Pressure Adjusting / Dump Valve tool kit : 43744-914/TK 1
Spanner for 3” suction hose : not fitted 1
Maintenance
Maintenance Schedule
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).
MAINTENANCE SCHEDULE
Every 3 months
Every 6 months
(2000 hours)
(1000hours)
Every week
Maintenance Task
(500hours)
Every year
(12 hours)
(40 hours)
Every day
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 pumphead x

Inspect valves in pumphead x
Inspect pumphead 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 pumphead x

Change plungers x
Remove pump from engine, change oil seal, inspect x
bearings, gears & drive coupling (3)
(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 need to be replaced more frequently as pressure increases.
For engine maintenance refer to engine manual

Lubricating Oil
The correct grade of oil must be used

& changed at correct intervals.
Historically Hughes have specified

EP90 Extreme Pressure Gear Oil for
use in crankcases & gearboxes. This
seems to have become more of a
generic term in recent times leading to
difficulty in identifying the correct oil
Listed below is a selection of oils we

have identified as suitable. Key points
Gearbox drain plug Crankcase drain plug
are they conform to API GL-5 :
 Shell Spirax S2 A 80W-90 After refilling to the correct level, run

the pump for 30 seconds without load.
 BP Energear Hypo 90
Stop the pump and re-check the oil
 Statoil Loadway EP 150
level. Top up as necessary, taking into
 Geartex EP-B 85W-90 consideration the oil cooler & oil hoses
 Chevron RPM Universal Gear will have taken some oil from the pump
Lubricant SAE 80W-90, 85W- crankcase.
140
In the event of a major crankcase strip-
If in doubt consult Hughes Pumps. down, thoroughly flush the oil cooler &
There have been instances where hoses before re-fitting
incorrect oil has been fitted leading to
pump failure If oil becomes emulsified (white in
colour), the possible causes are :
Oil & filter should be changed after 50
hours from new, then at 500 hour  Plunger seals leaking badly &
intervals thereafter penetrating the oil seals
 Oil cooler allowing inlet water
Most pumps have separate drain
into the oil circuit due to a
plugs in the crankcase & gearbox.
leaking O-ring seal or cracked
Use both.
end cover damaged by freezing
 Water/rain penetrating the filler
breather (unlikely)
 Condensation, if this is the
cause then more frequent oil
changes are required
Do not continue to use the pump if

there is evidence of water in the oil,
otherwise severe damage could occur.

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_______________________________________________________________________
Energear Hypo 90
Extreme-Pressure Automotive Monograde Gear Oil
________________________________________________________________________________
Energear Hypo 90 is designed for use in hypoid, For synchronized manual gearboxes, it should be
bevel and spiral gear units, axles and final drives used only if API GL-5 performance level is explicitly
operating under severe conditions. recommended for such units.
________________________________________________________________________________
• High safety margin against foaming and • Provides effective wear protection even under
corrosion; severe load conditions ensuring longer component
life and allowing it to be used in the final drives of
• Reasonable viscosity/temperature and cold flow most vehicles in a wide range of operating
properties temperatures.
• Compatible with the conventional seal materials

used with mineral oils.
________________________________________________________________________________
GL-5
• MAN 342 Type M1
• MB Approval 235.0
• ZF TE-ML 05A, 16C, 17B, 19B, 21A
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
___________________________________________________________________________
________________________________________________________________________________
SAE 90
Density at 15°C ASTM D1298 Kg/m3 898
Kinematic Viscosity / 100 °CASTM D445 mm²/s 16.9
40 °C ASTM D445 mm²/s 195
Viscosity Index ASTM D2270 - 91
Pour Point ASTM D97 °C -21
Flash Point (COC) ASTM D92 °C 220
Phosphorus ICP % mass 0.11
________________________________________________________________________________
________________________________________________________________________________
Date Created: 02/02/1996 12:38:19 Last Modified:14/11/2008
STATOIL LOADWAY EP 150
Gear - industrial
APPLICATIONS CHARACTERISTICS
LoadWay EP 150 is recommended for all types of industrial LoadWay EP 150 is a mineral-oil-based oil for gearboxes used
gearboxes for operating temperatures up to +80 °C. Below in heavy-duty applications. It is intended for extreme heavy-
this temperature, no harmful oxidation products or deposits duty use at normal temperatures. The oil contains additives to
are formed. inhibit wear, corrosion, oxidation and foaming. Other
important features of LoadWay EP 150 are very rapid water
ADVANTAGES separation and air release, and its excellent filterability.
LoadWay EP 150 handles heavy loads without allowing
gearbox components to wear down. The product provides
very rapid water separation and air release, and is highly
filterable. This translates into high levels of operational safety
and reliability.
TYPICAL INSPECTIONS
CHARACTERISTICS METHODS UNITS

ISO VG - - 150
Density at 15 °C ASTM D 4052 kg/m³ 890
Viscosity at 40 °C ASTM D 445 mm²/s 148
Viscosity at 100 °C ASTM D 445 mm²/s 15
Viscosity Index ASTM D 2270 - 98
Pour Point ASTM D 97 °C -18
Flash Point COC ASTM D 92 °C 230
Demulsibility ASTM D 1401 min 5
Air release ISO DIS 9120 min 4
FZG micropitting test FVA 54/I-IV GFT High >10
FZG A/16.6/90 DIN 51354-2 FLS >12
FE 8 D 7,5/80-80. Rollers DIN 51819-3 mg 0
TESTS AND APPROVALS HANDLING AND STORAGE

Classified as DIN 51517-CLP.
Classified as ISO-L-CKC per ISO 6743-6. Avoid skin contact.
AGMA 9005-E02 (EP), AIST 224, SEB 181226 Wash thoroughly with soap and water, after skin
David Brown S1.53.101Type E contact.
Approved: Flender BA 7300 Dispose of used oils properly.
Performance level: Hansen Transmissions, Metso Drives Safety data sheet available for professional user on
(Santasalo), Tetra Pack, Renk, Scana Volda, Heimdal request.
Propulsion, Sandvik Rock Processing S 223.365.00,
Andritz V5 204 602
The right to change product specifications is reserved.
Statoil Lubricants, 118 88 Stockholm.

Customer service tel 08-429 68 50, fax 08-429 68 51, email: smobest@statoil.com
2009-06-08
Statoil Lubricants, 118 88 Stockholm.
Customer service tel 08-429 68 50, fax 08-429 68 51, email: smobest@statoil.com
RPM® UNIVERSAL GEAR LUBRICANTS
SAE 80W-90, 85W-140
PRODUCT DESCRIPTION The sulfur-phosphorus extreme pressure additives in

RPM Universal Gear Lubricants minimize the spalling
RPM® Universal Gear Lubricants are recommended for and wear of gears by creating a microthin sacrificial
use in spiral bevel and hypoid differentials, power film on the surface of the gear teeth which is actually
dividers, and oil-lubricated steering axle wheel softer than the gears themselves. Frictional heat and
bearings. pressures between tooth surfaces cause the sulfur-
phosphorus to react with the surface of the gear teeth
CUSTOMER BENEFITS at the point of contact, thus creating the sacrificial film.
RPM Universal Gear Lubricants deliver value through: The highly refined base stocks and various inhibitors in
the additive package help assure a well-balanced
• Long gear life — Extreme pressure properties lubricant and long gear and bearing life.
protect hypoid and other types of gears from
scuffing and wear.
APPLICATIONS
• Rust and corrosion protection — Effective
inhibitor package protects against rusting or RPM Universal Gear Lubricants are recommended for
corrosion of gear and bearing surfaces. use in spiral bevel and hypoid differentials, power
dividers, and oil-lubricated steering axle wheel
• Excellent foam inhibition — Foaming minimized bearings.
by use of foam inhibitor.
• Long lubricant life — Outstanding thermal and Their multiviscosity characteristics allow their use in
oxidation stability allow high temperature operation equipment operating over a broad ambient
with long lubricant life. temperature range. This means good cold flow
properties and gear protection.
• Seal Protection — Formulated to protect against oil
seal deterioration. RPM Universal Gear Lubricants:
• meet the requirements of API Service
FEATURES Categories MT-1, GL-4 and GL-5
RPM Universal Gear Lubricants are multipurpose • are qualified for SAE J 2360 (formerly known as
lubricants. MIL-PRF-2105E)
• have Mack GO-J approval (active on Mack web site)
They are made from paraffinic base stocks and contain
a carefully balanced additive package to provide gear
protection and long lubricant life.
The sulfur-phosphorus extreme pressure additive
technology used in RPM Universal Gear Lubricants
provides exceptional thermal and oxidation stability.
In addition, this lubricant is fortified with rust and
corrosion inhibitors, a foam inhibitor, and a pour point
depressant.
Product(s) manufactured in the USA.

Always confirm that the product selected is consistent with the original equipment manufacturer's recommendation for the equip-
ment operating conditions and customer's maintenance practices.
A Chevron company product 27 April 2011

GL-100
© 2008-2011 Chevron U.S.A. Inc. All rights reserved.
Chevron, the Chevron Hallmark and RPM are trademarks owned by Chevron Intellectual Property LLC. All other trademarks are
property of their respective owners.
11-25
RPM® Universal Gear Lubricants — Continued
TYPICAL TEST DATA
SAE Grade 80W-90 85W-140

Product Number 225040 225039
MSDS Number 7234 7234
API Gravity 28.0 24.8
Density @ 15.6°C(60°F)
kg/l(lb/gal) 0.8871(7.40) 0.9053(7.56)
Viscosity, Kinematic
cSt at 40°C 145 341
cSt at 100°C 14.2 25.0
Viscosity, Brookfield
cP at -12°C — 123,000
cP at -26°C 81,000 —
Viscosity Index 95 95
Flash Point, °C(°F) 218(421) 226(439)
Pour Point, °C(°F) -33(-27) -15(+5)
Minor variations in product typical test data are to be expected in normal manufacturing.
Always confirm that the product selected is consistent with the original equipment manufacturer's recommendation for the equip-
ment operating conditions and customer's maintenance practices.
27 April 2011
GL-100
11-26
Fault Finding
Introduction
Many operating faults can be traced to

easily corrected errors in setting up or  Is the dump valve by-passing
operating the equipment. It is a natural
tendency to start dismantling the pump  Is the engine/motor speed correct
when the equipment is not operating
properly, thinking that the problem must  Are there any low or high pressure
be in faulty or worn out parts. hose leaks
It has been our experience over many  Is there a leak on the accessories
years that many faults are rectified outside
of the pump and it cannot be emphasised  Are the accessory nozzles worn or
too strongly to first check on the most damaged
obvious of problems, for example :
 Is the pump getting sufficient water A check on the above examples could
cover many of the difficulties likely to be
 Is the suction pipework blocked or experienced. However, if these checks
leaking prove negative, then the following
diagnostic chart of symptoms / cause /
 Are the inlet strainer(s) blocked action will be of assistance to locate the
problem.
 Have the hoses been connected up
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
Accessory connector(s) Tighten

leaking
High pressure hose or Tighten / Replace

connector leaking
Dump valve by-passing Adjust valve or overhaul

(if fitted)
Check for compressed air
leaks / adjust pressure
Water starvation to pump Check pump set is correctly

primed
Check / change water filter

element
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
High pressure pump leaking Inspect / replace plunger

externally from the underside seals
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 (if fitted) air 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 Copper washer(s) on plunger Replace
bolt allowing leak down
centre of plunger
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
Motor shuts down Low boost pressure Check / change water filter
Check pumpset is primed
Check for problems in

suction pipework
Pump fault Check pump warning lamps

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
Non rotation of pump Broken drive coupling Replace
Broken gear(s) Seek advice from Hughes

Pressure Vacuum Level Flow Temperature Displays
Temperature Switch NTBC
FEATURES 51
______________________________
Aluminium body for maximum heat
conductivity.
Standard DIN Plug - rotatable
3/8" or 1/2" BSPP thread as stand-
97
18.5
ard
12
N/O or N/C electrical contacts 27mm AF
25
Protected to IP65
Anodized body
Ideal for water or oil applications Ø11
Up to 10 bar maximum pressure
NT BC 50 C A
Model: NTBC
Contact type
Switch set-point A = NO contact
30°C ± 5°C C = NC contact
40°C ± 5°C
50°C ± 5°C
60°C ± 5°C T HREAD
70°C ± 5°C B 3/8" BSP
80°C ± 5°C
C 1/2" BSP
90°C ± 7°C
100°C ± 7°C D M22x1.5
105°C ± 7°C
Technical data
Switch electrical rating 220Vac/1A res (0.5A ind) Body material Anodized Aluminium
Protection IP65 (DIN 40050) Hysteresis 5 degC
Contacts (choice) N/O or N/C Maximum temperature 120°C

Cable gland Pg9 (DIN 43650) Choice of threads 1/2" or 3/8" BSP& M22x1.5
WARNING
This pump is fitted with an SAE engine

adaptor which makes for a compact, perfectly
aligned pump / engine installation.
Due to having to assemble the pump to the

engine in a “blind” manner, it is vital the drive
coupling is correctly positioned on the pump
input shaft to avoid a clash of the coupling
halves which could lead to severe damage to
the pump.
Refer to drive coupling installation

instructions.
If in doubt consult Hughes Pumps Ltd.

®
CENTAFLEX -A
highly flexible couplings
Catalog CF-A-E-15-07
Power Transmission
Leading by innovation
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CENTAFLEX®
The success of a coupling system
CENTAFLEX, the original from the inventor! the perimeter. During assembly, the knurl points press
into the aluminium and result in a highly stressable com-
This successfull coupling has been developed and inter- bination giving a positive and friction locking connection.
nationally been patented by CENTA Transmissions and
brought to the market in 1970. Since then a unique suc-
The materials
cess story on the world market began. More than 100.000
couplings are produced every year, with still growing vol- Precision diecast aluminium parts, vulcanised into high
ume. Totally six million couplings have been installed and quality rubber; high tensile selfsecuring screws and steel
are performing reliably. Beside the original production in hubs machined all over.
Germany, the couplings are produced under license by:
Miki Pulley Co. in Japan The hubs
CENTA Andino in Brazil.
The hubs have very simple cylindrical or flat mating faces
Further ten CENTA subsidiaries and 30 agencies with without cams or recesses.
broad know-how provide worldwide sales and service and This means that other existing elements (e.g. flywheels,
make the CENTAFLEX the most successfull couplings of its brake discs, clutches, pulleys, gears etc.) can easily be
kind on the world market. used as hubs. All that is necessary in such cases is to drill
and tap a few holes for fastening the rubber element. The
simple, easily manufactured form of the hubs permits the
The idea manufacture of many special designs, such as elongated
A high quality coupling element which - with very little hubs.
effort - enables a highly flexible coupling to be “custom
built” for almost any purpose. The CENTAFLEX contains The CENTAFLEX system
a highly elastic element which is extensively flexible in
any direction, and upon which an entire coupling system An entire system with the most varied designs and hubs
is based. This coupling system embodies a combination was developed, based on the advantages described
of numerous positive characteristics, with a versatil- above. In addition there are hundreds of special designs.
ity of design from common components, not previously This catalog describes only the important highly flexible
achieved. designs of the CENTAFLEX system. Apart from these, sev-
eral varieties with higher torsional stiffness of the elastic
element have been developed, which provide – with the
The principle same connecting dimensions and hubs – for further inter-
A prestressed polygon shaped rubber element with metal esting designs in other areas of applications:
parts vulcanised in. The important innovation is that the
screws connecting the rubber element with the hubs CENTAFLEX type H torsionally stiff, for diesel hydraulic
are alternately arranged axially and radially. The radial drives
screws fulfill 2 tasks: CENTAFLEX type X torsionally very stiff, angularly flex-
ible free of play and backlash.
• connecting
the rubber element to the hub Every good elastic coupling has 4-way flexibility:
• producing a preload by radial compression
of the rubber column 1. torsional elasticity
2. radial flexibility
Preload pressure stress in the rubber element consider- 3. axial flexibility
ably raises the capacity of the coupling, since it com- 4. angular flexibilty
pensates for the tensile stress which otherwise occurs
in operation. Under compressive stress the capacity of
rubber is multiplied. In addition, the CENTAFLEX-A is uniquely flexible in
Transmission of the peripheral force from the bonded application, i.e. capable of modification and adap-
aluminium segments to the hubs is by friction. The stress tion; CENTAFLEX therefore has 5-way flexibility.
in the screws is therefore purely tensile and in no way a
flexional or shearing stress. For better frictional engage-
ment, the cylindrical hubs for most sizes are knurled on
® CENTAFLEX is a registered trademark of CENTA Antriebe
CF-A-2 CENTA Power Transmission leading by innovation

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Characteristics and advantages of the CENTAFLEX-couplings

• Simple, compact, smoothface design • The rubber element can easily be fitted and disman-
• Low weight, low moment of inertia tled without the use of special tools or tension bands
• High performance, high speed range, large bores per- • The coupling can be very easily aligned, relying on
mitted, ruptureproof line of sight or with the aid of a straight edge, without
• Large angle of twist with progressive characteristic any special templates or gauges
curve (approx. 6–8° at nominal torque) • The elements can be dismantled transversely without
• High elasticity and considerable flexibility in any direc- any axial displacement
tion (radial, axial, angular) with low counter forces on • By slackening the radial screws, the drive can easily
shafts and bearings. Therefore the shafts do not have be seperated and rotated without dismantling
to be aligned accurately • No axial reaction forces are imposed on shafts and
• The action of the CENTAFLEX coupling is shock and bearings due to the transmission of torque
vibration absorbing • Rubber elements are available in various shorehard-
• The torque is transmitted absolutely free from play, ness grades. This permits variation of the torsional
uniformly, free from noise, and electrically insulating stiffness within wide limits and its adaption to the
• The coupling requires no maintenance, the rubber vibrational requirements of each drive system
parts suffer no wear, providing long useful life with no • The rubber elements are available in various materi-
dirt produced by rubber particles als:
• The rubber element is air flushed all around; the heat Standard: natural rubber
generated is easily conducted away and the rubber Special materials: Perbunan, Neoprene and Silicone
element remains cool for high temperatures.
NEW !
Split CENTAFLEX-element Series AR. In case that the
flexible element is damaged, then the split spare element
can be wrapped around the cylindrical hub. Therefore no
hub or components must be disturbed. Extremely simple
exchange of the element within minutes.
The fasteners, overall dimensions and the rating of the
element remain unchanged.
A further CENTA innovation, protected by patents.

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CENTAFLEX coupling
design types
Type 0 and 0-S
The rubber element for customers’ “own
designed” special applications. Available in vari-
ous shorehardness grades and materials.
Type 1 and 1-S

Element with cylindrical hub for existing drive
elements, e.g. flywheels, pulleys, brake discs,
friction clutches, universal joints, freewheels,
gears.
Type 2 and 2-S

Complete shaft couplings for all areas of
mechanical engineering. After removing the
axial screws, coupled machines can be removed
radially, as with “three-part” couplings.
Type 3 and 3-S

Flanged couplings for combustion engines and
many other applications. The simple adaptor
plate can be adapted to fit any standard or non-
standard flywheel or other component.

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Type S
Design “S” is a plug-in variation for applications where axial movement or “blind” assembly in a housing
is required. Design “S” is available for all design types and sizes of CENTAFLEX. In addition, there are
special designs available with extended socket bolts for applications requiring large axial movement or
the provision of facilities to change V-belts.
Universal joint shaft, type G

Highly elastic universal joint shafts for any assem-
bly length and for a variety of applications.
Connecting pieces can be varied as required, and
are adaptable. With short assembly length they
are suitable for speeds up to 3000 rpm.
Never surpassed for simplicity and economic pric-
ing!
Universal joint shaft, type GZ

Highly elastic universal joint shafts with accurate,
maintenance-free centering of the central part for
applications with very high speeds and/or long
shaft lengths.
CENTAFLEX design H
Torsionally stiff, plug-in, high temperature and
oil-resistant design series, specially designed for
diesel hydraulic drives. Numerous design types
identical to those previously described, and with
further special designs.
Detailed description is given in catalog CF-H.
CENTAFLEX design X
Torsionally very stiff design series, free from play
or backlash, but axially and angularly flexible. This
series is temperature and oil resistant. Plug-in
types suitable for blind fitting, or axially stiff types
are available. This series is especially suitable for
torsionally stiff universal joint shafts identical to
the above design type G.
Detailed description is given in catalog CF-X.

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A 1.0 Performance table
Centaflex size 1 2 4 8 12 16 22 25 28 30 50 80 90 140 200 250 400 Remarks*
Pos. Description Symbol Unit

Nominal
1 TKN Nm 10 20 50 100 140 200 275 315 420 500 700 900 1100 1700 2400 3000 5000
Torque
Maximum
2 TKmax Nm 25 60 125 280 360 560 750 875 1200 1400 2100 2100 3150 4900 6000 8750 12500
Torque
TKN degree 6° 6° 5° 5° 3° 5° 3° 5° 3° 5° 3° 3° 5° 3° 3° 3° 3°
Angle
3
of Twist
TKmax degree 17° 17° 12° 14° 7.5° 14° 7.5° 14° 7.5° 14° 7.5° 7.5° 14° 7.5° 7.5° 7.5° 7.5°
4 Max speed nmax min-1 10000 8000 7000 6500 6500 6000 6000 5000 5000 4000 4000 4000 3600 3600 3000 3000 2500
Angular dependant
5 ∆KW degree 3° 3° 3° 3° 2° 3° 2° 3° 2° 3° 2° 2° 3° 2° 2° 2° 2°
Elasticity upon speed
6 Axial Elasticity ∆Ka mm 2 3 3 4 4 5 5 5 5 5 5 3 5 5 5 5 5
Radial Ela- depedant
7 ∆Kr mm 1.5 1.5 1.5 2 2 2 2 2 2 2 2 1.5 2 2 2 2 2
sticity upon speed
Cont. Oscilla-
8 TKW Nm 5 10 20 40 50 80 100 125 150 200 300 320 450 700 960 1250 2000
ting Torque
Allowable
9 PKV W 6 10 15 25 30 40 50 68 75 80 90 100 120 150 170 200 250
Energy Loss
CTdyn Nm/rad 90 180 550 900 2700 2000 6100 2800 7500 4800 12000 16000 10500 26500 38700 43000 75000 50 Shore
Dyn. Torsional
10
Stiffness
CTdyn Nm/rad 140 290 850 1500 4400 3400 9000 4500 12000 7800 19000 25000 16000 40000 60000 67000 120000 60 Shore
11 Axial Stiffness ca N/mm 38 22 75 75 250 100 500 140 550 190 650 850 220 650 900 1150 1300
Radial Stiff-
12 cr N/mm 150 150 500 500 1000 500 1300 600 1400 750 2200 2900 1000 2300 3100 4100 6000
ness
Angular Nm/
13 cw 0.3 0.3 2.4 3.6 9.0 5.0 12.0 7.0 17.0 9.0 26.0 34.0 17.0 38.0 48.0 68.0 88.0
Stiffness degree
Figures given for lines 3, 11, 12, 13 are values for a shore hardness of 60° measured statically (cdyn = Cstat ∙ 1,3)
Nominal Torque TKN: Torque which can be transmitted throughout the entire permitted speed range.
Max. Torque TKmax: Torque which may be applied for short periods 105 times, pulsating in the same direction of rotation, or 5 x 104 alternating.
Continuously Torque TKW: Amplitude of continuously permissable torque fluctuation at max. frequency of 10 Hz and a basic load up to nominal Torque TKN.
* Larger sizes up to 1250 Nm are available, please consult us.
A 1.1. Starting up Factor

Z ≤ 120 120 < Z≤ 240 > 240
SZ 1,0 1,3 1,6 A 1.6 Temperature factor
Z= start frequency per hour
A 1.2. Frequency Factor

in Hz ≤ 10 > 10
Sf 1
A 1.3. Shore Hardness

Conversion Factor U A 1.7 Permissible angular and radial
Shore 50 60 70 75 misalignment
permissible angular and parallel offset misalignment
u 0,7 1 1,6 2,3 is dependant upon the speed when utilising the
nominal torque capacity. % of line 5 or 7
A 1.4. Surge or Pulse Factor A 1.5. Resonance Factor VR

Relative Damping Factor D
SA/SL
1,6 Light starting load Natural Rubber (NR)
1,9 Medium starting load Shore Hardn. VR D
2,2 heavy starting load 50 10 0,6

60 8 0,78

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Coupling selection Total mass moment of inertia
drive side JA kgm²
The CENTAFLEX-coupling must be suitable dimensioned load side JL kgm²
to prevent the stresses: Dyn. torsional stiffness of the coupling
a) Nominal torque TKN CTdyn Nm/rad (Table A 1.0-9)
b) Maximum torque TKmax
c) Continuously oscillating torque TKW Determining the resonance speed of the ith order
from exeeding the permissible values in any operational
state. The following formulae will be helpful. 30 JA + JL
nR = CTdyn ∙ rpm
∙i JA ∙ JL
Stress due to the torque
i = number of oscillations generated per revolution
The permissible nominal torque at all operating tempe-
ratures must be at least as great as the nominal torque
Distance from resonance
of the drive or load side.
Where there is considerable oscillation generated, the
TAN ∙ St ≤ TKN ≥ TLN ∙ St resonance can be placed outside the operating speed
range by the appropriate selection of the coupling tor-
Factors of influence: sional stiffness. The following applies for the required
Nominal torque drive side TAN Nm resonance distance:
load side TLN Nm nB
= 1,5 . . . . 2
Temperature factor St (diagram A 1.6) nR
Passing through resonance
Performance formula:
The permissible max. torque TKmax must not be
P KW
TAN | TKN | TLN = 9555 ∙ Nm exceeded while running through the resonance.
n R.P.M. Factors of influence:
Stress due to torque pulses: generating torque
The permissible max. torque of the coupling must at all drive side TAi Nm
operating temperatures be at least as great as the tor- load side TLi Nm
que pulses TAS and TLS (Nm) occuring in operation. Resonance factor VR (Table A 1.5)
Factors of influence : Drive side oscillation generation
TKmax ≥ MA ∙ TAi ∙ VR ∙ SZ ∙ St Nm
start-up factor Sz (Table A 1.1)
pulse factor
Load side oscillation generation
drive side SA (Table A 1.4)
load side SL TKmax ≥ ML ∙ TLi ∙ VR ∙ SZ ∙ St Nm
Mass factor JL
drive seite MA MA= Continuously oscillating torque
JA + JL
For the operating frequency, the oscillating torque must
JA be compared with the permissible continuously oscilla-
load side ML ML= ting torque of the coupling. The continuously oscillating
J + JL
torque existing is dependant upon the amplifying factor
outside the resonance.
Drive side pulse
Amplifying factor V outside the resonance.
TKmax ≥ MA ∙ TAS ∙ SA ∙ SZ ∙ St Nm 1
approximation formula: V ≈
|1 - (n/nR)2|
Load side pulse Drive side oscillation generation
TKmax ≥ ML ∙ TLS ∙ SL ∙ SZ ∙ St Nm TKW ≥ MA ∙ TAi ∙ V ∙ St ∙ Sf Nm
Stress due to a periodic oscillating torque Load side oscillation generation

Position of resonance (resonance speed)
TKW ≥ ML ∙ TLi ∙ V ∙ St ∙ Sf Nm
For easier calculation, the existing unit is best reduced
to a 2-mass torsional oscillating system if possible. Frequency factor Sf (Table A 1.2)
JA JL We shall be pleased to carry out torsional vibration cal-
culations for you in our offices.
CTdyn
All data, dimensions and information of this catalog are given without
guarantee.
Amendments and improvements may be made without notice.
This technical document has legal protection (copyright).

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0 1
Dimensions,
Basic Design
Types
0, 1, 2,
0-S, 1-S, 2-S.
d1 d2
Centaflex d3 A B B1 C1 E G L1 L2 L3 M N1 N2 S TS
min. max. min. max.
1 8 19 8 25 56 24 7 7 26 22 11 24 24 50 M6 30 36 2 10
2 10 26 12 38 85 24 8 8 32 20 10 28 28 60 M8 40 55 4 14
4 12 30 15 45 100 28 8 8 34 24 12 30 30 64 M8 45 65 4 14
8 12 38 18 55 120 32 10 10 46 28 14 42 42 88 M 10 60 80 4 17
12 12 38 18 55 122 32 10 10 46 28 14 42 42 88 M 10 60 80 4 17
16 15 48 20 70 150 42 12 12 56 36 18 50 50 106 M 12 70 100 6 19
22 15 48 20 70 150 42 12 12 56 36 18 50 50 106 M 12 70 100 6 19
25 15 55 20 85 170 46 14 14 61 40 20 55 55 116 M 14 85 115 6 22
28 15 55 20 85 170 46 14 14 61 40 20 55 55 116 M 14 85 115 6 22
30 20 65 25 100 200 58 16 16 74 50 25 66 66 140 M 16 100 140 8 25
50 20 65 25 100 200 58 16 16 74 50 25 66 66 140 M 16 100 140 8 25
80 20 65 25 100 205 65 16 16 75.5 61 30.5 66 66 141.5 M 16 100 140 4 25
90 30 85 30 110 260 70 19 20 88 62 31 80 80 168 M 20 125 160 8 32
140 30 85 30 110 260 70 11 20 88 62 31 80 80 168 M 20 125 160 8 32
200 35 105 35 110 300 80 11 20 102 72 36 94 90 192 M 20 145 160 8 32
22.5
250 40 115 40 130 340 85 11 20 108 77 54.5 100 100 208 M 20 160 195 8 32
28.5
400 40 120 40 140 370 105 25 28 135 95 66.5 125 125 260 M 24 170 200 10 45
Larger sizes up to 1250 Nm are available, please consult us.
Typical examples of application for CENTAFLEX-couplings
The CENTAFLEX couplings have been proven in many equipment as well as a very wide range of industrial
areas of mechanical engineering. The major area of applications. The photographs illustrate some typical
application lies with diesel driven stationary and mobile examples of application:

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2 1-S 2-S
Weight [kg] Mass moment of Inertia [kg∙cm2]

T R P O TK/Division Centaflex
Type 0 Type 1 Type 2 Type 1/S Type 2/S Type 0 Type 1 Type 2 Type 1/S Type 2/S
10.5 6.5 18 5 44/2x180° 0.06 0.21 0.47 0.24 0.49 0.35 0.75 1.6 0.86 1.7 1
13.5 8.5 12 14.2 68/2x180° 0.15 0.46 1.06 0.49 1.09 1.25 2.5 7.3 3.3 8.1 2
13.5 8.5 17 18.5 80/3x120° 0.21 1.31 2.31 0.70 1.70 3.3 5.0 11.3 6.5 12.8 4
16.5 10.5 20.5 20.5 100/3x120° 0.32 1.35 3.45 1.44 3.54 7.0 15.0 41.0 18.6 44.6 8
16.5 10.5 20.5 20.5 100/4x90° 0.35 1.45 3.55 1.56 3.66 8.4 18.2 44.2 20.0 46.1 12
18.5 12.5 23.5 25.2 125/3x120° 0.65 2.28 6.16 2.33 6.21 23.4 42.5 118.8 49.1 125.4 16
18.5 12.5 23.5 25.2 125/4x90° 0.70 2.52 6.42 2.62 6.62 26.6 50.4 126.5 70.2 146.3 22
21.5 14.5 26.0 27.0 140/3x120° 0.84 3.59 9.31 3.77 9.49 50.2 90.7 215.0 102.7 227.0 25
21.5 14.5 26.0 27.0 140/4x90° 0.95 3.79 9.51 4.05 9.76 55.6 102.4 247.8 113.2 258.5 28
24.5 16.5 34.5 34.5 165/3x120° 1.43 5.66 15.21 6.02 15.57 102.0 200.0 545.5 220.4 565.9 30
24.5 16.5 34.5 34.5 165/4x90° 1.60 6.04 15.60 6.50 16.05 104.0 205.0 550.5 253.4 598.9 50
24.5 16.5 34.5 34.5 165/4x90° 2.10 6.85 16.60 7.25 17.00 131.8 240.3 585.5 263.9 609.1 80
30.5 20.5 45.5 47.0 215/3x120° 3.30 11.55 28.67 12.23 29.35 450.0 657.5 1630.1 759.2 1731.8 90
30.5 20.5 45.5 47.0 215/4x90° 3.65 12.33 29.45 13.22 30.36 572.0 770.0 1742.6 873.0 1845.6 140
30.5 20.5 44.5 45.5 250/4x90° 5.75 13.13 33.16 14.07 34.11 1356.0 1598.0 3050.0 1686.0 3129.0 200
30.5 20.5 60.0 59.0 280/4x90° 7.10 18.98 44.42 20.01 45.44 1754.0 2404.0 5264.0 2529.0 5389.0 250
42.5 24.5 72.0 77.0 300/4x90° 11.25 26.58 57.23 29.34 59.95 3380.0 4485.0 9130.0 4683.0 9328.0 400
©photo by Pfaff
Boat drives, mechanical conveying and handling, agri- nes for the most varied applications, lifting elements
cultural machinery, front power take-off on diesel engi- or platforms.

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CENTAFLEX
Universal Joint Shafts
The CENTAFLEX universal joint shafts
are proven, extremely simple, versati-
le and torsionally highly elastic.
They dampen noise, torsional oscillati-
on and shock.
They compensate for considerable
axial, radial and angular misalign-
ment.
The lengths are not standardised, but
made individually in accordance with
G customers’ requirements; but they
are, nonetheless very moderately pri-
ced. The connecting parts (hubs) can
also be adapted to suit requirements.
CENTAFLEX universal joint shafts
require no maintenance whatsoever;
the centre part can be removed radi-
ally (transversely) without displacing
the coupled machines.
Design G
GZ This is the simplest design type; the
centre part is centered only by the
TKN d
Size A B C D H L2 N2 R T TK M ZH8 CENTAFLEX elements. Suit-able for
[Nm] Vorb. max.
1 10 24 7 5 56 8 25 13 24 36 30 1.5 44 2 x M6 52 short and medium lengths and for
2 20 24 8 5 85 12 38 14 28 55 40 1.5 68 2 x M8 80 speeds up to approx. 1500 rpm.
4 50 28 8 5 100 15 45 16 30 65 45 1.5 80 3 x M8 95
Please also see the diagram on page
8 100 32 10 5 120 18 55 18 42 80 60 1.5 100 3 x M10 115
12 140 32 10 5 122 18 55 18 42 80 60 1.5 100 4 x M10 115
11 for additional information.
16 200 42 12 5 150 20 70 24 50 100 70 1.5 125 3 x M12 145
22 275 42 12 5 150 20 70 24 50 100 70 1.5 125 4 x M12 145
25 315 46 14 5 170 20 85 26 55 115 85 1.5 140 3 x M14 165
Design GZ
28 420 46 14 5 170 20 85 26 55 115 85 1.5 140 4 x M14 165
Here, the centre assembly is accu-
30 500 58 16 5 200 25 100 33 66 140 100 1.5 165 3 x M16 195
50 700 58 16 5 200 25 100 33 66 140 100 1.5 165 4 x M16 195
rately located on the centering plate
80 900 65 16 5 205 25 100 34.5 66 140 100 1.5 165 4 x M16 195 and maintenance free bearings. This
90 1100 70 19 5 260 30 110 39 80 160 125 1.5 215 3 x M20 250 design is suitable for long lengths
140 1700 70 19 5 260 30 110 39 80 160 125 1.5 215 4 x M20 250
and/or high speeds. The centre
200 2400 80 19 10 300 35 110 44 90 160 145 1.5 250 4 x M20 290
250 3000 85 19 10 340 40 130 46 100 195 160 1.5 280 4 x M20 330 assembly can be withdrawn without
400 5000 105 25 10 370 40 140 57 125 200 170 1.5 300 4 x M24 360 disturbing the driving or driven hubs.
Please state dimension „L“ upon order. In cases of doubt, the decision whe-
ther to chose design G or GZ should
be left to us, since a clear demarcati-
on is difficult.
The sectional drawing on the left

shows one of the many special de-
signs, with an adaptor plate for a
diesel engine and with extensive axial
movement permitted by means of
long socket bolts.

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Selection of CENTAFLEX
Universal Joint Shafts:
Torque capacity is in accordance
with the table on page 6.
Due to the use of two CENTAFLEX
elements, the values of axial ela-
sticity and for the angle of twist
are doubled, the values for torsio-
nal stiffness and the axial spring
values are halved.
Permissible angular misalignment
is shown in diagram A 1.7 and the
following formula:
Design G:
a = tan A (L- 2H)
a = parallel offset (mm)
Design GZ:
a = tan A [L-2 (H+C)]
Speed [rpm]
L; H and C as in dimension table.
Distance between shafts ends length L [mm]

The maximum permissible length
for the centre part is dependant on
the speed and can be found in the The dotted line gives an appro- Examples of typical applications:
diagram on the right. ximate indication as to whether Screw Jacks, compressors, engi-
type G or GZ should be used ne test benches
on short shafts, but only in (Size 16 GZ; n= 7200 rpm).
respect of speed, not of length. Other applications: Boat drives,
We recommend that all shafts diesel drives for centrifugal
regardless of length are of the pumps, air conditioning, con-
GZ type if they run at speeds struction machinery, general
above those indicated by the dot- mechanical engineering.
ted line.
© by MTU
CF-A-400-G with carbon fibre tube on HMS CF-A in marine application. CF-A-16 double in the PTO for hydraulic pumps on MTU
Albion. engine Series 2000 Common Rail.

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CENTAFLEX-couplings for diesel engines
This is the central point of appli-
cation for CENTAFLEX. We supp-
ly suitable CENTAFLEX couplings Type
for practically any diesel or petrol
engine, to suit the flywheel side
3-S-SAE
as well as for the power take-off
at the front end of the crankshaft,
e.g. Caterpillar, Detroit, Deutz,
Dorman, Ford, Gardner, Hatz,
Leyland, Lister, MAN, Perkins,
Petter, Rolls Royce, VW and many
others.
The number of the existing assem-
bly drawings is so great that it is
not possible to include them in a
brochure.
The type most extensively used
for diesel engine flywheels is SAE
standard J620. The dimensional
d1 Appropriate
sheet shows appropriate couplings Size
min. max.
d3 A3 C3 L1 N1 S TK / Division
SAE-Flange
for the plug-in (blind fitting) design 8 12 38 120 38 52 42 60 4 100 / 3 x 120° 6½" 7½"
(e.g. for generator drives). 16 15 48 150 48 62 50 70 6 125 / 3 x 120° 6½" 7½" 8"
For Deutz and Perkins engines, 25 15 55 170 52 67 55 85 6 140 / 3 x 120° 8"
flywheels with tapped holes are 25 15 55 170 56 71 55 85 6 140 / 3 x 120° 10"
available for CENTAFLEX couplings. 30 20 65 200 68 84 66 100 8 165 / 3 x 120° 10" 11½"
50 20 65 200 68 84 66 100 8 165 / 4 x 90° 10" 11½"
This enables couplings to be fitted
90 30 85 260 80 98 80 125 8 215 / 3 x 120° (10") 11½" 14"
direct - without and adaptor plate-
140 30 85 260 80 98 80 125 8 215 / 4 x 90° (10") 11½" 14"
with types 1 and 1-S, and results
200 35 105 300 90 112 94 145 8 250 / 4 x 90° 11½" 14" 16"
in particularly compact and econo- 250 40 115 340 95 118 100 160 8 280 / 4 x 90° 11½" 14" 16"
mically priced couplings. 400 40 120 370 115 150 125 170 10 300 / 4 x 90° 14" 16" 18"
Please ask for our detailed offer for
your specific requirements.
Nominal Mass moment of

DA weight
SAE DT Dj d2 Z* Inertia
1 Deutz F3-6L912 f7 [kg]
Size J [kgcm2]
available for engines 208, 210, 6½" 215.9 200.02 180 9 6 2.60 147
511, 912, 913 and 413 7½" 241.3 222.25 200 9 8 3.25 228
8" 263.52 244.47 220 11 6 3.90 328
2 Perkins 3, 4, 6 and 8 cylinders 10" 314.32 295.27 270 11 8 7.20 966
Perkins part-no. 31221322 11½" 352.42 333.37 310 11 8 9.60 1584
14" 466.72 438.15 405 13 8 19.40 5421
3 Intermediate couplings for uni- 16" 517.5 489 450 13 8 24.60 8272
versal joint shafts.
Example of coupling reference CF 30-3-S-SAE 10 * Z = No. of holes

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Path of clamping force
CENTALOC®
Clamping Hub
It is well known that all splined steel connections, which clamping screws, the hub can easily be dismantled or re-
are not free from play tend to wear due to “hammering” fitted. This procedure can be repeated as often as may
and fretting corrosion. be required.
Use of the CENTALOC clamping hub does not present
The shaft of hydrostatic pumps for mobile equipment any difficulty at the assembly stage with the blind fitting
nearly always have spline or involute profiles. The una- design type S, H or X. When assembling for example a
voidable play, due to the manufacturing tolerances on motor and pump, the cylindrical coupling hub is simply
the flanks of these profiles between shaft and hub, per- mounted on the pump shaft and locked prior to motor and
mits minor relative movements in operation leading to pump being assembled together. The coupling housing
wear. Even hubs and shafts made from high quality and does not, therefore, require any access holes.
hardened steels cannot solve this problem in its essence,
but can at best only reduce the wear. The problem can The CENTALOC clamp hub can be selected for all design
be solved effectively only when the connection between types of CENTAFLEX. The clamping should preferably be
shaft and hubs is made free from play. arranged in the cylindrical inner hub; but it is also pos-
With this objective in mind, we developed the CENTALOC sible to manufacture flanged hubs with the clamping
clamping hub. This new type of clamp hub has a slot ar- facility.
ranged tangentially to the bore. On the inner part of this
slot, strong forces are applied through one or more set The connecting details and external dimensions of the
screws. The hub is radially pressed inwards in this area, CENTAFLEX coupling are not altered by the CENTALOC
i.e. pressed firmly against the shaft profile. The opposing clamping facility.
reaction forces of the clamping screw are diverted within
the hub causing it to be pressed firmly against the shaft. The patented CENTALOC clamp hub has already been
The hub thus becomes firmly locked against the shaft proved in thousands of hard applications. It is recom-
around its diameter i.e. absolutely free from play. It is mended by major manufacturers of hydraulic pumps.
at the same time also locked axially. The incidental minor This is evidence of the fact that you can expect real so-
deformations of the hub occur within the elastic limit and lutions to your problems for CENTA power transmission
there is no permanent deformation. After slackening the engineers.
® CENTALOC is a registered trademark of CENTA Antriebe

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Fitting instructions for CENTAFLEX-A-couplings

with highly elastic rubber elements. Important notes - observe strictly
The radial and axial screws connecting the rubber element to the hubs the radial screws, otherwise the cylindrical faces between aluminium
must all be tightened to the torque given in the table below, using a insert and hub will not engage on the full area, but only on two corners.
torque wrench. This will inevitably lead to slackening of the screws and subsequent de-
Tightening with a torque wrench is par-ticularly important withthe larger struction of the coupling. If the coupling is supplied in a pre-assembled
sizes. Tightening “by feel” will not do, as experience has proved the state, do not dismantle it, but fit in this condition.
tightening torques in such cases are far too low.
Tightening torques which are too low will inevitably lead to slackening
of the screws in service and consequently to the destruction of the
coupling.
Ensure that on tightening the screws, the aluminium bushes in the rub-
ber part are not twisted at the same time, but sit straight.
In order to reduce friction between the screw head and the aluminium
part, a small amount of grease should be applied under the head of radial
axial
axial
the screw before fitting. If necessary, use a suitable tool for applying radial
counter pressure on the element to prevent twisting of the rubber wrong correct
part during tightening of the screws. This is particularly important with
CENTAFLEX Screw ISO 4762 Anzugsdrehmoment

size (DIN912) [Nm] [in/lbs]
1 M6 10 90
2 M8 25 220
4 M8 25 220
8/12 M 10 50 440
16/22 M 12 85 750
25/28 M 14 140 1250
30 M 16 220 1950
50/80 M 16 220 1950
90/140 M 20 500 4450
200/250 M 20 500 4450
400 M20/24 610/1050 5400/9300
600 M24/27 1050/1550 9300/13800
800 M 22 820 7300
Sequency of Assembly
radial
axial
radial
grease
axial
Standard Design Design S (plug-in or blind fitting type)

Fith the hubs onto the shafts or the adaptor plate onto the flywheel. Fit the hubs onto the shafts or the adaptor plate onto the flywheel.
Fit the rubber element to the flanged hub or flywheel, by means of Fit the axial socket bolts on ot the flange hub or adaptor plate on the
axial screws. This must be carried out before engaging the radial flywheel.
screws in the cylindrical hub. Position the element with the side ha-ving the rubber free face of the
Push the shaft-mounted cylindrical hub inside the rubber element and axial aluminium inserts towards the flange hub and, using the radial
then fasten the rubber element on it with radial screws. During this screws, mount it on the cy-lindrical hub. During this process, the rubber
process, the rubber element is compressed radially and is pre-loaded element is pulled together radially and receives its preload. Then, push
for increased capacity. the coupled elements together and in doing so, carefully slide the cou-
pling with light axial pressure onto the socket bolts. The rubber element
is subjected to a little more radial compression by the socked bolts, and
the pre-load is thus increased. The axial bores in the rubber element
should be smeared lightly with grease beforehand to allow the socket
bolts to slide easily in the inserts.

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Use only the “Inbus Plus” screws pro-vided which are marked on the CENTALOC clamping hub
threads with a micro-encapsulated adhesive which locks the screw in
the thread and secures them reliably against slackening. For adequate If the hubs are equipped with CENTALOC clamping (see page 13), the
effect, the hardening period for this adhesive after bolting up is approxi- clamping screws must be tightened at least to the following tightening
mately 4-5 hours at room temperature (20°C). The coupling should not torques:
be operated before this period has elapsed.
The adhesive will be fully hardened after 24 hours. Higher temperatures After assembly, the coupling should be carefully aligned if the coupled
will speed up the hardening process, at 70°C (using a hot air blower), elements are not already in good alignment by virtue of being spigot
for instance, the hardening will take only 15 minutes. Inbus Plus is tem- located. In the interest of a long service life of the coupling, the higher
perature proof between -80° and +90°C and the screws can be reused the speed, the more meticulous should the alignment be. In design type
up to 3 times max. Any adhesive stripped off during bolting up will settle 2, the alignment can very easily be checked with a straight edge. The
between the hub and the aluminium part, but this will have a beneficial outer diameter of the flange hub must be flush with the outer diameter
effect in that it enhances the friction grip between these parts. of the rubber element in those areas where the radial screws sit: i.e. in
Note: Anaerobic adhesives (such as Loctite, Omnifitic etc.) will loosen different radial positions.
the adhe-sion of the rubber and the insert and will consequently destroy In design types 1 and 3 the distance “Z” must be measured at all axially
the coupling. bolted points of the rubber element (2, 3 or 4 points depending on the
Such adhesives should therefore be avoided if possible. Where the use size) and must be set as accurately as possible to the value “Z” quoted
of this adhesive is unavoidable apply it very sparingly so that no surplus in the table below.
adhesive will moisten the rubber. For spigot located components there is no need to align the coupling.
We cannot accept any complaints concerning rubber parts which have
become defective through the action of adhesives not supplied or recom- Position of cylindrical hubs:
mended by us.
The coupling is completely maintenance-free and does not require The long end of the cylindrical hub, usually identifiably by a chamfer,
any lubrica-tion. Splashing with oil and similar substan-ces should be is normally as shown in the drawing below. However, in some special
avoided, since natural rubber is not oil-resistant. applications, the hub must be reversed. When in doubt, install as shown
However occasional minor contact with oil or grease is not harmful as in the relevant installation drawing.
this oil will be thrown off during rotation of the coupling.
Clamp Screw Tightening torque [Nm]

M 10 30
M 12 50
M 14 70
M 16 120
M 20 200
Installation table: Screw fastener details, dimension “S” between the hubs and dimension “Z”.
CENTAFLEX-A Standard Design Type „S“ Universal joint shaft Universal joint shaft Dimension Dimension
size G GZ/GB „S“ „Z“
Special Bolt Screws radial axial [mm] [mm]
M6x10 M6x10
1 M6 M6x10 M6x10 M6x30 2 13
M6x25 M6x25
2 M8x20 M8 M8x20 M8x20 M8x20 M8x25 4 22,5

4 M8x25 M8 M8x25 M8x25 M8x25 M8x30 4 27,5
8/12 M10x30 M10 M10x30 M10x30 M10x30 M10x35 4 30/31
16/22 M12x35 M12 M12x35 M12x35 M12x35 M12x40 6 40
25/28 M14x40 M14 M14x40 M14x10 M14x10 M14x45 6 42,5
30 M16x50 M16 M16x50 M16x50 M16x50 M16x55 8 50
50/80 M16x50 M16 M16x50 M16x50 M16x50 M16x55 8/4 50/52,5
90 M20x65 M20 M20x65 M20x65 - M20x70 8 67,5
140 M20x65 M20 M20x65 M20x65 - M20x70 8 67,5
200 M20x65 M20 M20x65 M20x65 M20x65 M20x80 8 77,5
250 M20x80 M20 M20x80 M20x80 M20x80 M20x90 8 90
M24x100
400 M24 M20x100 M20x100 M20x100 M24x100 10 100
M20x100
M24x120 M24x100
600 - - M24x120 M27x130 15 135
M27x120 M27x120
M22x140
800 - - M22x140 M22x140 M22x150 17 110
M22x140

CENTA Australia CENTA Norway CENTA Denmark CENTA Sweden
CENTA China CENTA Headquarters Germany CENTA Singapore
CENTA Italy CENTA Netherlands CENTA USA CENTA Great Britain
International service
Subsidiaries
Australia France Japan Singapore

CENTA Transmissions Pty. Ltd. Prud’Homme Miki Pulley Co.Ltd. CENTA TRANSMISSIONS
P.O. Box 6245 Transmissions FAR EAST PTE LTD
1-39-7, Komatsubara 76 Tuas South Avenue 2
South Windsor, NSW 2756 66 Rue des St. Denis
Zama-City, Kanagawa Singapore 637519
Austria B.P. 73
F-93302 Aubervilliers Cedex JAPAN 228-857
Hainzl Industriesysteme GmbH South Africa
Industriezeile 56 Korea Entramarc (PTY) Ltd.
Germany P.O. Box 69189
A-4040 Linz CENTA Antriebe Wooree MEK 2021 Bryanston
Belgium Kirschey GmbH #823, Ocean Tower ZA - Transvaal
Caldic Techniek Belgium N.V. Bergische Str. 7 760-3 Woo 1 Dong
Tollaan 73 D-42781 Haan Spain
Haeundae-Gu, Busan Herrekor S.A.
B-1932 Sint-Stevens-Woluwe
Great Britain Zamoka Lantegialdea
Brazil CENTA Transmissions Ltd. Mexico Oialume Bidea 25, Barrio Ergobia
CENTA Transmissoes Ltda. Thackley Court, CENTA CORP. ES-20116 Astigarraga-Gipuzkoa
Rua Josè Américo Thackley Old Road, 815 Blackhawk Drive Sweden
Cançado Bahia 199 Shipley, Bradford, Westmont, IL 60559, USA CENTA Transmission Sweden AB
Cidade Industrial West Yorkshire, BD18 1BW Metalgatan 21A
32.210-130 Contagem MG Netherlands S-26272 Ängelholm
Greece
Canada CENTA Netherland b.V.
Industry: Marine: Switzerland
CENTA CORP. Kitko S.A. Technava S.A. Nijverheidsweg 4 HAWE – Hydratec AG
815 Blackhawk Drive NL-3251 LP Stellendam Chamerstrasse 172
1, Rodon St. 6,Loudovikou Sq.
Westmont, IL 60559, USA CH-6300 Zug
17121 N.Smymi 18531 Piraeus
New Zealand
Chile Athens Taiwan
Comercial TGC Ltda. Brevini Ltd. ACE Pillar Trading Co., Ltd.
Calle Dr. M. Barros Borgoño 255-263 Hong Kong/China 9 Bishop Croke Place No. 2 Lane 61, Sec. 1.
Casilla 16.800 (P.O. Box) Foilborn Enterprise Ltd. Kuanfu Road, San-Chung City, R.O.C.
East Tamaki
Santiago-Providencia Unit A8-9, 13/F Taipei
Veristrong Industrial Centre PO Box 58-418 - Greenmount
China 34-36 Au Pui Wan Street NZ-Auckland Turkey
CENTA MP ( Shanghai ) Co., Ltd Fotan, Shatin Industry: Marine:
D3-1F , No. 479 Chundong Road Norway FIBA Makina HATKO Teknik
N.T. Hong Kong
Xingzhuang Industry Park CENTA transmisjoner A.S. Sanayi ve Ticaret DON. MUM.
Shanghai, 201108 India LTD.STI. TIC A.S.
P.O.B. 1551
NENCO Ahievran caddesi Acisu Sok. Taslik
Denmark N-3206 Sandefjord
National Engineering Company No:18/1 D:43 34357 Besiktas-
CENTA Transmissioner A/S
J-225, M.I.D.C., Bhosari, Poland Ostim/Ankara Istanbul
A.C. Illums Vej 5
DK-8600 Silkeborg Pune - 411 026 IOW Trade USA
Egypt Israel Sp.z.o.o. CENTA CORP.
Hydraulic Misr Redco Equipment + Industry ul. Zwolenska 17 815 Blackhawk Drive
P.O. Box 418 3. Reval Street Westmont, IL 60559
04-761 Warszawa
Tenth of Ramadan City 67778 Tel Aviv
Portugal
Finland Italy CENTA Antriebe is also
CENTA Transmissioni Srl PINHOL Import Dep.
Movetec Oy represented in:
Hannuksentie 1 Viale A. De Gasperi, 17/19 Avenida 24 de Julho, 174 Bulgaria, Czech Republic, Hungaria,
FIN-02270 ESPOO I-20020 Lainate (Mi) P - LISBOA 1350 Romania and further countries.
Address data are subject to change. Find our up-to-date address database at www.centa.info/contact
D-42755 Haan P.O.B 11 25 Bergische Strasse 7

tel.: ++49-2129-912-0 Fax: ++49-2129-2790
e-mail: centa@centa.de http://www.centa.de
| Force | Pressure | Temperature | Switch
Pressure sensors for industrial applications

Model P3297
Non linearity 0.5% (option 0.25%)

Standard output: 4...20 mA; 2-wire
or 0...5 VDC; 3-wire
or 0...10 VDC; 3-wire
or 0.5...4.5 VDC; 3-wire
or 0.5...4.5 VDC ratiometric
Description Features
Robustness and long-term stability during operation O Measuring range from 0...1 bar to 0...600 bar
are the strengths of this compact pressure sensor O Medium wetted parts of stainless steel
for general industrial applications.
O High EMC protection according to EN 61 326
O Compact instrument size

The materials and technologies used make these
O No internal sealing elements
sensors suitable for applications with aggerssive
media. Welded connections between pressure cell O Highly resistance to shock and vibration
and process connection require no sealing O For dynamic or static measurements
elements and make the measuring system
particularly resistant to mechanical shock and Measuring range
vibration. The compact design makes these
sensors interesting for room critical applications. Gauge pressure 0…1 bar to 0…600 bar
-1…0 bar to -1…+24 bar
A wide variety of electrical connections and

Applications
pressure ports simplifies the adaptation to different
applications. The pressure sensor is internationally Hydraulics and pneumatics
certified and ready for global deployment.
Pumps and compressors
The pressure sensors comply with electromagnetic
Building automation
compatibility requirements (EMC) as per EN 61326.
Test stand construction
Machine and apparatus construction
Model: P3297
tecsis GmbH DE 708 k

Carl-Legien Str. 40-44 02/2016
D-63073 Offenbach / Main Sales National Sales International e-Mail: info@tecsis.de
Tel.: +49(0) 69 / 5806-0 Fax: +49(0) 69 / 5806-7788 Fax: +49(0) 69 / 5806-7788 Internet: www.tecsis.de p. 1 / 4
Technical Data
Model P3297
Pressure type positive and negative gauge pressure
absolut pressure on request
- Measuring range [bar] 0...1 bar to 0…600 bar
-1..0 bar to -1…+24 bar
- overrange limit [bar] x2
- burst pressure [bar] x6
Sensor element piezoresistive to 0..6 bar, thin film as of 0..10 bar
Output signal 4...20 mA 2- wire
0...5 VDC 3- wire
1...5 VDC 3- wire
0...10 VDC 3- wire
0.5...4.5 VDC 3- wire
0.5...4.5 VDC ratiometric
1)
Non linearity d 0.5% of F.S.; option: 0.25% of F.S.
2) 3)
Accuracy d 1.0% of F.S.; option: 0.5% of F.S.
Zero Drift d 0,5% of F.S. (typ.), d 0,8% of F.S. (max.)
Non-repeatability d 0.1% of F.S.
Long-term Drift d 0.1% of F.S. (by reference conditions)
Material
not wetted parts stainless steel 316L, HNBR, PA
medium wetted parts stainless steel 316L (from 0…10 bar rel. 13-8PH)
Pressure connection G 1/4 according to DIN 3852-E
G 1/4 according to EN 837
G 1/2 according to EN 837
1/4 NPT
1/2 NPT, other pressure connection on request
Electrical connection connector DIN EN 175301-803 Form A with junction box
connector DIN EN 175301-803 Form C with junction box
circular plug-in connector M12x1 (4-pin)
cable outlet: 2m, other electrical connection on request
Power supply / load
4...20 mA 8...30 VDC RA [:] d (UB [V] – 8V) / 0.02A
0…1...5 V 8...30 VDC > max. output / 1 mA
0...10 V 14...30 VDC > max. output / 1 mA
0.5 ... 4.5 V 8…30 VDC > max. output / 1 mA
0.5 ... 4.5 V ratiometric 5 VDC ± 10% RA > 4.5k:
Reponse time d 4ms within 10% to 90% of F.S.
RoHS-conformity yes
Approval according to cULus
CE-conformance 2004/108/EWG interference emission and interference resistance to EN 61 326
interference emission limit class B
97/23/EG pressure gauge code
Electrical protections polarity, overvoltage and short-circuit protection
Ingress protection Plug DIN EN 175301-803: IP 65
(per IEC 60529)4 Circular Connectors M12x1: IP 67
Cable output: IP 67
Temperature influence d 1% typ. d 2.5% max.in range 0…80°C
Temperature ranges
compansated range 0...80°C
storage -20...80°C (Option: -30..100°C)
media 0...80°C (Option: -30..100°C)
ambient 0...80°C (Option: -30..100°C)
Load capacity
shock (mechanical) 500g acc. to IEC 60068-2-27
vibration (under resonance) 10g acc. to IEC 60068-2-6
Weight approx. 80g
1)
According to IEC 61298-2
2)
Including non linearity, hysteresis, non repeatability, variation of zero point and finale value (is equal to error according to IEC 61298-2).
3)
By option: accuracy 0.5% and signal 0…5V is accuracy 0.6%
4)
The specified protection class (according to IEC 60529) only applies when plugged in using mating connectors with corresponding
protection.
DE 708 k
p. 2 / 4
Dimension (mm)
Case
connector according to DIN connector according to DIN circular plug-in connector
Cable outlet
EN 175301 – 803 Form A EN 175301 – 803 Form C M12x1
A
clamping range clamping range
Pressure connections
G 1/2 B G 1/4 B G 1/8 B G 1/2 DIN 3852-E
G 1/4 A DIN 3852-E 1/2 NPT 1/4 NPT R 1/2
R 3/8 R 1/4 G 1/4 female 1/4 NPT female
M20 x 1,5
DE 708 k
p. 3 / 4
Electrical connector
Two-wire system
Connector according to DIN EN 175301-803 Form A with Connector according to DIN EN 175301-803 Form C
junction box with junction box
UB / S+ UB / S+
1
1
3 3 2
2
0V / S-
0V / S-
E-005
E-001
Circular plug-in connector M12x1 Cable outlet
UB / S+ UB / S+
braun
brown
4 3
1 2
0V / S- blau
blue
0V / S-
E-015
E-033
Three-wire system
Connector according to DIN EN 175301-803 Form A with Connector according to DIN EN 175301-803 Form C
junction box with junction box
UB UB
S+
S+
0V / S- 0V / S-
E-002 E-006
Circular plug-in connector M12x1 Cable outlet
UB UB brown
braun
S+
4 3
1 2
S+ black
schwarz
0V / S- blau
0V / S-bluegrün
E-034 E-017
Modifications reserved
DE 708 k
p. 4 / 4
WATER JETTING GUNS
DUMP & DRY SHUT
10,000 - 15 - 20,000 PSI
Fast and easy change of wear
parts in a cartridge type
repair kit
Dump:
A dump gun closes off the un-pressurized
dump port when triggered and releases the
flow when the trigger handle is released.
The gun works without an un-loader or
relief-valve.
Integrated hose swivel

gives freedom of movement
Dry Shut:
A dry shut gun opens for water flow
when triggered and shuts off when
Safety latch can be released the trigger handle is released.
without loosening the grip
The gun works together with an
un-loader or relief-valve.
Technical details: Max Pressure:* Max Flow:* Size: Weight:

LxWxH [Kg / Lbs]
[Bar / Psi] [L/min / Gpm] [mm]
Model:
DRY SHUT 750 Bar 60 L/min 2,8 kg
1150x35x250
10.000 Psi 10.000 Psi 16 Gpm 6,16 Lbs
DUMP 750 Bar 60 L/min 3,0 kg

10.000 Psi 1150x35x250
Shoulder rest for reduced 10.000 Psi 16 Gpm 6,6 Lbs
fatigue
DRY SHUT 1000 Bar 60 L/min 2,8 kg
16 Gpm 1150x35x250
15.000 Psi 15.000 Psi 6,16 Lbs

15.000 Psi 15.000 Psi 16 Gpm 1150x35x250 6,6 Lbs
1400 Bar 60 L/min 2,8 kg

DRY SHUT
20.000 Psi 20.000 Psi 16 Gpm 1150x35x250 6,16 Lbs

20.000 Psi 20.000 Psi 16 Gpm 1150x35x250 6,6 Lbs
Adjustable side handle for All models are CE marked * The back-thrust of pressure and flow should not exceed 25 Kg
ease of use
Website: www.hughes-pumps.co.uk
Email: sales@hughes-pumps.co.uk
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
 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
 Spares. site labour).
 Service assistance at our factory or
on-site b) Replacement parts
 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

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HPS3000 DIESEL DRIVEN PUMPSET

OPERATING & MAINTENANCE MANUAL

Build Number : 51851-769-1263

Manufactured by : Hughes Pumps Ltd

Hughes Sales Order : 38731

Customer : Eastwind Gmbh

Manufactured : August 2017

2. Safety and WJA Code of Practice

6. Control panel wiring diagram

7. Pumpset part list

8. Pump drawings & parts lists

10. Spare parts & tools

12. Fault finding

13. Ancillary Equipment

15. Test certificate

16. Engine operating and maintenance manual

lubricated, depending on model & all

All pumps should incorporate an oil

It is essential the system is correctly

Each system should include a boost

The pumpset should incorporate a high

This manual is designed to provide all

Never carry out any examination or

Hoses must not be used as tow-ropes

Extreme caution must be observed to Safety catches on jetting guns must be

Pre-Operation Checks If a jetting gun is being used, always hold

A pressure gauge must be fitted to the Whenever the equipment is left

Hughes sales order no. : 38731

Manufactured : July 2017

Pump build no. : 692451-330A1

Pump model : HPS3000 (see Section 7)

Safety valve : 43742-733 (see Section 9)

High pressure control valve : 43744-914 Pneumatic Regulator

Drive coupling part no. : 23357-156 (see Section 13)

Oil temperature switch part no. : 24135-022 (see Section 13)

30 5.13 351 193 259 74 16.4 19.7 1400 20,300

4.11 365 201 270 77 17.0 20.5

5.13 400 220 295 85 18.6 22.5

5.13 292 180 241 84 18.6 22.4

35 5.13 351 216 290 101 22.3 26.8 1150 16,675

4.11 365 225 301 105 23.2 27.9

5.13 292 185 248 99 21.9 26.4

38 5.13 351 222 297 119 26.3 31.6 1000 14,500

4.11 365 231 309 124 27.3 32.9

5.13 292 184 247 110 24.2 29.2

40 5.13 351 221 296 132 29.1 35.0 900 13,050

4.11 365 230 308 138 30.3 36.5

5.13 292 181 243 140 30.7 37.0

45 5.13 351 218 292 167 36.8 44.4 700 10,150

4.11 365 226 303 174 38.3 46.2

5.13 292 182 244 172 37.9 45.6

50 5.13 351 219 293 207 45.5 54.8 570 8,265

4.11 365 227 305 215 47.3 57.0

5.13 292 182 244 208 45.9 55.2

55 5.13 351 218 293 250 55.0 66.3 470 6,815

4.11 365 227 304 260 57.2 69.0

5.13 292 184 247 248 54.6 65.7

60 5.13 351 221 296 298 65.5 78.9 400 5,800

4.11 365 230 308 310 68.1 82.1

5.13 292 186 250 291 64.0 77.1

65 5.13 351 224 300 349 76.8 92.6 345 5,003

4.11 365 233 312 363 79.9 96.3

5.13 292 182 244 338 74.3 89.5