USER GUIDE

&
SPARE PARTS
MANUAL

UHP
WATER BLASTER
SERIES:

C-2500/21E 50Hz
C-2500/25E 60Hz
 USER’s GUIDE C-2500/21E 50Hz, C-2500/25E 60Hz

Congratulations on your purchase

of the ALTO DEN-SIN® C-2500/21E (50Hz) C-2500/25E (60Hz) UHP
Water-blaster.
To ensure long life and high durability of the product,
we encourage you to read this user’s guide before
operating the equipment.
This user’s guide has been drawn up for:
The user as well as the maintenance technician and the repair technician.

Notice:

The information contained in this user’s guide is subject to

change without notice.
®
ALTO DEN-SIN Singapore Pte Ltd. Make no warranty of
any kind with regard to this material, including, but not limited
to, the implied warranties of merchantability and fitness for a
particular purpose.
®
ALTO DEN-SIN Singapore Pte Ltd. expressly disclaims all
responsibility and liability for the installation, use, purpose,
maintenance, and support of third party products.

This document or part of it may not be photocopied, or in any

other way reproduced, or translated to another language without
®
the prior written consent of ALTO DEN-SIN Singapore Pte
Ltd. Company

November 2001

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 USER’s GUIDE C-2500/21E 50Hz, C-2500/25E 60Hz

TABLE OF CONTENTS
section one
Getting acquainted with your UHP Water-blaster
Fast and efficient cleaning .................................. 4
Specifications...................................................... 4
The key features.................................................. 4
Safety precautions............................................... 4-5
Protective Clothing ............................................. 6
Emergency medical information......................... 7
Unpacking........................................................... 8
Available accessories.......................................... 8
Installation/Setup ................................................ 9-10

section two
Maintenance
Routine inspection ............................................ 10
Lubrication........................................................ 11
Cleaning............................................................ 11
Storage .............................................................. 11

section three
Trouble shooting
Symptom / Cause and correction ...................... 12-13
Repair
Service instructions........................................... 14-17

section four
Spare-part lists
Connection diagram.......................................... 18
Main assembly frame /engine ........................... 19-21
Main assembly water tank ................................ 22-23
Assembly filters ................................................ 24-25
Gauge assembly ................................................ 26-27
Assembly Pump complete ............................... 28-29
Assembly Fluid-end .......................................... 30-31
Assembly Power-end ........................................ 32-35
Wiring diagram ................................................. 36

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 USER’s GUIDE C-2500/21E 50Hz, C-2500/25E 60Hz

Getting acquainted with your Water-blaster

FAST AND EFFICIENT CLEANING

The ALTO DEN-SIN UHP Water-blaster C-2500/21E & C-2500/25E enables you to get
more cleaning done in less time.

This ALTO DEN-SIN coldwater UHP Water-blaster offers you high performance and a
design optimized for heavy duty use. The design of the surrounding frame safeguard the
vital parts during transport and use, and the high performance gives you the opportunity
to solve an array of blasting tasks. The Water-blaster is designed for industrial and for
offshore use. All pump parts fittings and pipes in contact with water are made of non-
corrosive materials. Together with the carbide coated plungers, long life seals and
stainless steel valves, it ensures long life and high durability.

SPECIFICATIONS
MODEL MOTOR MOTOR WORKING FLOW Motor DIMENSIONS WEIGHT
SPEED PRESSURE CAPACITY LxWxH
HP kW RPM PSI BAR GPM L/MIN VOLTAGE MM KG
C-2500/21E 125 92 1450 36.000 2500 5.5 21 415V 50Hz 2380x1400 1700
x1850
C-2500/25E 150 110 1750 36.000 2500 6.6 25 440V 60Hz 2380x1400 1700
x1850

KEY FEATURES

These heavy-duty water blasters are capable of removing any kind of dirt:

Descaling
Surface preparation
Paint and rust removal
Concrete roughening / removal

And with the option for use of accessories even many more jobs are to be dealt with.

Getting acquainted with your Water-blaster

SAFETY PRECAUTIONS

To prevent accidents from happening and to ensure the safety of the person(s) who uses
the equipment and also to protect bystanders and nearby placed inventory or machinery, a
few safety precautions needs attention.

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 USER’s GUIDE C-2500/21E 50Hz, C-2500/25E 60Hz

(Continued)
Operators of a high-pressure water-blaster system must treat the system as they would
treat any other high-speed power cutting tool. Although the water-jet may appear
harmless, it is a very powerful high energy water-stream which potentially can be very
dangerous.

Always connect the main power in a secure way, specially designed with ground to earth
wiring.

Always keep the Water-blaster and the belonging accessories in good working condition.

The operator of the high pressure water blaster must be familiar with the equipment and
trained in the proper use of the machinery. Not least on how to stop the equipment.

When using the blasting equipment and its accessories, eye protection must be worn to
protect against repelling or ricocheting matters causing eye damage.

The protective clothing, footwear, eye and ear protection worn while using the equipment
must be suited for the task to avoid hazard to the operator.

Precautions must be made to keep bystanders away from the working range.

Do NOT spray on human bodies nor live animals, the high pressure beam are capable of
making severe injuries.

Do not spray at electrical equipment.

While repairing or maintaining the equipment and it’s accessories always be sure the
machine is turned off, pressure is released and the electric cable disconnected from the
main power supply.

Do not alter or by-pass any of the built in protective and safety interlocks featured on the
equipment.

Notice:
This machine is only to be used for the purposes it is designed for. Any other use shall be
considered improper and therefore potentially dangerous. The manufacturer is not to be
held responsible for any damages caused by improper use.

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 USER’s GUIDE C-2500/21E 50Hz, C-2500/25E 60Hz

SAFETY PRECAUTIONS / PROTECTIVE CLOTHING

The following protective clothing and devices should be worn both by personnel
operating the water blaster system and equipment and by those working nearby:

Eye protection- Operators must wear visors and goggles to

guard against spray and flying debris. A combination of
both goggles and visor is advisable. And will protect the
eyes and the face during both water-blasting as well as
abrasive water-blasting

Head protection- Helmets must be worn at all time by

personnel within the work area.
Helmet material must be able to withstand mechanical
shock exceeding 10G in 8ms without fracturing.

Hand protection- Shear proof gloves must be worn by the

operator at all times. A glove combination of a cloth inner
lining and a water tight outer layer is preferred.
Foot protection- Safety footwear with steel toecaps
minimum 0.5mm (0.02”) thick must be worn. The toecap
must cover at least 30% of the footwear length. Basic safety
footwear must also be equipped with metatarsal guards to
protect the instep. Safety boots are available in other
designs than the illustration.

Hearing protection- Operators and other personnel

exposed to noise levels of more than 90-dBa for more than
1 hour must wear suitable ear protection. Ear plugs or ear
muffs are usually sufficient.

Body protection- Waterproof garments protect the

operator only from spray and flying debris. They do NOT
deflect direct jet impact. Therefore, an operator must take
care never to point a water-jet either at them selves or other
personnel.

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 USER’s GUIDE C-2500/21E 50Hz, C-2500/25E 60Hz

EMERGENCY MEDICAL INFORMATION

Immediate hospital attention should be given personnel who sustain equipment related
injuries while operating the system. In such cases, it is vital that medical personnel be
apprised of all facts relevant to such injuries. Therefore, all operating personnel should be
provided with waterproof emergency medical alert tags or cards, describing the nature of
their work and the possibility of injury inherent in the use of water jetting equipment. The
below example of a standard card can be photo copied, laminated and used as medical
alert tag.

MEDICAL ALERT
This card is to be carried by personnel working with
high-pressure water jetting equipment. Obtain medical treatment
immediately for ANY high-pressure water-jet injuries.

ALTO DEN-SIN Singapore Pte Ltd.

17 Link Road, Singapore 619034
Tel: +65 268 1006 Fax: +65 268 4916

This person has been working with water jetting at pressures up to

55,000 psi (374Mpa, 3,740bar, 3,867 kg/cm 2) with a jet velocity of up to
3,000 fps (914 mps). This should be taken into account during diagnosis.
Unusual infections with microaerophilic organisms occouring at lower
temperatures have been reported. These may be gram-negative pathogens
such as found in sewage. Bacterial swabs and blood cultures may therefore
be helpful. A local poison control centre should be contacted for additional
treatment information and advise.

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 USER’s GUIDE C-2500/21E 50Hz, C-2500/25E 60Hz

Getting acquainted with your Water-blaster

UNPACKING
Free the UHP Water-blaster and it’s accessories from the packing material, if any. For
transport and packing reasons some accessories may be supplied disassembled.

Make sure all components are present:

• Water-blaster machine itself

• High pressure hose(s)
• Trigger gun(s) with lance(s)
• Water inlet hose coupling for 11/2” hose
• Operation manual/Spare-parts book
• Any ordered optional accessories and spare-parts

AVAILABLE ACCESORIES

Accessories
Special nozzles
Extension hoses in various lengths
Drain cleaning equipment
Safety gear

Notice: Always state type of Water-blaster along with the part no.: when
ordering accessories or spare-parts.

Refer to the identification plate on the machine:

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 USER’s GUIDE C-2500/21E 50Hz, C-2500/25E 60Hz

INSTALLATION/SETUP
Installation:
Onboard vessels:
Locate the UHP Water-blaster machine behind the super structure or on the poop deck.
Securely fastened.

Mount the high-pressure hose(s) on to the adaptor located on the cylinder head left side.
(Extension hoses if applicable mounts through a straight connector) Mount the other end
of the hose to the inlet on the gun. Always use two wrenches when tightening the hoses.

Prepare the water supply for the Water-blaster, by attaching a 1.1/2” hose to the supplied
low pressure inlet coupling on the frame. Connect the other end of the water supply hose
to a fresh water tap. Open the tap. To prevent water spill always use the float valve inlet.

Start-up/Operation:
Switch on the Booster pump, if the machine has been complete drained, loosen the air
bleed screw on the booster pump until booster pressure occurs. Through the clear pump
cover check that the cooling spray are directed into the 3 holes at the cylinder back-plates.
At the front of the un-loader loosen the hexagon contra nut and loosen the hexagon screw
to allow the pump to start up without pressure load. Switch on main motor and allow it a
few seconds for the star delta connection to switch over automatically. The Water-blaster
is now ready for operation. Get a firm grip with both hands on the Spray-gun(s) handle
and the lance. Press the trigger(s) and get a second operator to tighten the hexagon screw
at the front of the un-loader until the desired pressure is reached and water dump-back to
tank stops.

Shut down:
Shot down the high-pressure pump by pressing the stop button. Then turn of the booster
pump. After shut down of the Water-blaster, always release the pressure inside the high-
pressure hoses by pulling the trigger on the spray-gun(s). Again loosen the contra nut on
the un-loader and loosen the pressure adjusting screw.

Notice Correct power supply, voltage and cycle:

Make sure your local power supply specifications are in accordance with the motors need.
Refer to the ID-plate located at the coupling-cover on the Water-blaster machine.
Salt-water:
When running the Water-blaster on salt/sea-water supply, the machine MUST always be
flushed with fresh-water at the end of each use. More frequent filter change is
recommended. Running the machine on salt-water supply may shorten the life of the
pump and pump parts.

Filter maintenance and filter change:

The pre-inlet filter, mounted on the water tank is flushable by opening the ball-valve at
the bottom of the black filter housing while water inlet supply pressure is maintained. The
filter fiber cartridges inside the twin stainless steel booster pump filters are not flushable
and should be replaced with new cartridges (Part no: 700520206) when clogged. The two
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 USER’s GUIDE C-2500/21E 50Hz, C-2500/25E 60Hz

booster-pump pressure gauges, one before and one after the twin filters should indicate
approximately the same pressure when running the machine. When the gauge after the
filters, the one closest to the inlet at the pump-head shows significantly lower pressure
than the gauge at the booster pump, before the filters, it indicates a pressure drop through
the filters and their cartridges should be replaced. Always replace both filter cartridges.
Clogged filters may inflict cavitation in the high-pressure pump leading to severe damage
of the pump.

ROUTINE MAINTENANCE
Subject Matter / How to do
Daily Check water-filter inside the water-tank.
Inspection Check oil level on Water-blaster pump.
Check for air-bubbles in the suction hose between tank and pump.
If air-bubbles are present tighten the hoseclamps.
Check high pressure connections for leakage.
Check high pressure hoses for wear and cracks.
Check the power cord for wear and cracks.

Notice: To prevent damage on hoses and cord, be careful not to let

the high-pressure hoses rub against sharp edges eg. Man-holes or
squeezed in door openings etc. Replace if necessary.

Ensure that the inlet water temperature is below 60°C (140°F)

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 USER’s GUIDE C-2500/21E 50Hz, C-2500/25E 60Hz

ROUTINE MAINTENANCE
Subject Matter / How to do
Lubrication Oil renewal on the pump crankcase is to be completed the first time
after no more than 100 hours of use. Oil renewal is hereafter to be
completed in every 500 hours of use.

Recommended Oil:
Good automotive quality SAE 15-40W
Oil capacity: 15 liters. Or to the mark.

Pump grease into the front and rear grease nipple of the motor at
approximately 500 running hours interval. Use a good quality ball
bearing grease.

Renewal of oil: Turn off the Water-blaster. Open the hexagon screw
on the side at the bottom of the pump crankcase. Allow the oil to
drain into a waste oil-tray. Remount the hexagon screw and add oil
through the oil inlet on top of the pump until the level point of the
oil control glass has been reached
Notice: Dispose the used in a proper manner.

Cleaning Use a damp cloth to wipe the machine Do not use detergent
cleaning chemicals. To prevent electrical shock do NOT clean the
machine with high pressure.

Occasionally clean the fan cover positioned at the back of the

engine, as well as the cylinders to ensure sufficient airflow for
cooling.

Storage Be sure the water-blaster is kept frost-free, if not possible, empty

the pump-system for water completely and flush the pump-system
with antifreeze fluids. Disconnect the battery.

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 USER’s GUIDE C-2500/21E 50Hz, C-2500/25E 60Hz

TROUBLE SHOOTING/REPAIR
Symptom Cause and correction
Motor will not start. Low water level in tank. Level switch in water tank is stuck.
Pressure switch on booster pump line is stuck. Fan-belt is
broken. Battery is flat.

Fill up water tank through the correct inlet. Shake level switch
in water tank. Dismantle and lubricate pressure switch with
silicone grease. Replace fan belt. Charge battery

The pressure drops The pre-filter on the water tank is clogged or the water supply
and the Water- from the tap is insufficient. The twin booster pump filters are
blaster works clogged. Air in the booster-pump.
irregularly. No
booster-pump Flush the pre-filter.
pressure The machine should always suck from the water-tank.
Replace both filter cartridges. Repair the booster pump.

The Water-blaster is .Gun valve is stuck

running at high
pressure when
trigger is released. Inspect clean and change the gun repair kit.

The Water-blaster Leakage from: hose connections, trigger-gun. The pump sucks
does not reach the air. The high-pressure nozzle is worn. Plunger packings worn
proper working out.
pressure when the
spray-gun handle is Turn of the water-blaster. Inspect for leakage. Replace the
activated. nozzle. Inspect/repair the gun. Repair Trigger gun. Change
packings.

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 USER’s GUIDE C-2500/21E 50Hz, C-2500/25E 60Hz

TROUBLE-SHOOTING
(continued)
Symptom Cause and correction
The Water-blaster There is dirt in the valves.
works with
approximately 2/3 of Turn off the Water-blaster. Dismantle cylinder assembly as
the maximum described below, remove the dirt and check to ensure the inlet
pressure, and the valve discs and the discharge valve pins are movable and fits
high-pressure hose is tightly.
vibrating

Excessive water Packing is worn

leakage shooting out
behind the cylinder Replace packings. (See below)
assemblies.

Noisiness The pump sucks air. One or more valve springs are broken or
down. Extraneous matter in the valves.
Inspect the low-pressure water supply. Replace springs. Clean
the valves.

Water in the oil The Oil-seal is worn out. High moisture in the air (condensing
inside the crankcase) The seals are completely worn out.

Check or replace the oil-seals.

Renewal of the crankcase oil more often.
Replace the seals.

Notice:
For any further inconveniences, not mentioned in this user’s guide or any damages of the
machine, we strongly suggest you to make contact with your dealer for the repair or
possible replacement of any original spare-parts.

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 USER’s GUIDE C-2500/21E 50Hz, C-2500/25E 60Hz

SERVICE & REPAIR INSTRUCTIONS

Inspection and Replacement of valves and high-pressure plunger packings:

Disassembling: (pos. refers to page: 30 if not stated otherwise)

Stop the machine and disconnect main cable

Remove the pump cover and the spray-bar cover (pos: 33, 31 page 23) IMPORTANT:
First unscrew the plunger (pos 24) at the back of the cylinder from the plunger-adaptor
(pos: 20) Then loosen the screws (pos: 15, 16) holding the cylinder assemblies in an even
and alternating manner, the screws are tightened hard. Remove the top screws (pos: 16)
completely and push back the lower ones (pos: 15). Slide out the cylinder assembly, be
careful not to loose any parts. Pull out the plunger from the back of the cylinder. Remove
the Throat bushing, packing spring & packing adaptor (pos: 31, 30 & 29) from the front.
Knock out the packing assembly (pos: 25, 26, 27, 28) with the packing removing tool
(Order part no: 953510) or with a piece of plastic rod or suitable piece of round wood
from the front of the cylinder. Inspect the plungers for wear (scratches / grooves / pitting)
replace if necessary. Inspect the back-up rings for inside wear. Replace packings (pos: 27
& 28) (and back-up ring (pos: 25, 26) if necessary).

Inspect the 3 O-rings (pos: 34, 35, 36) on the valve cartridge (pos: 33) If valve wear is
suspected place the valve cartridge in a wise clamping on the flat part of the discharge
valve-pin (pos: 37) and carefully unscrew the valve stop nut (pos: 41) with a suitable pipe
wrench. Inspect the suction valve disc (pos: 39) for wear and pitting. Replace if
necessary. Temporary field repair of the suction valve-disc can be carried out by sanding
it on fine emery-paper on a flat surface. Make sure the valve spring (pos: 40) is not
broken. Gently assembly back the valve cartridge, clean all parts especially the threads
and apply a drop of “Lock-tite” on the thread of the discharge valve-pin. Do not apply
excessive force when tightening the valve stop nut, but make sure the nut is screwed on
completely. Do not forget to put back the valve spring.

Reassembling: (pos. refers to page: 30 if not stated otherwise)

Clean all parts and lubricate O-rings, plunger and packings with silicone grease (Silicon
grease can be ordered as part no.: 953008) From the rear of the cylinder, push in 1) the
back-up ring (pos: 25, 26) its chamfered side facing to the rear of the cylinder. 2) From
the front of the cylinder, insert the white packing and the black/gold packing (pos: 27
&28). 3) Then the Packing adaptor (pos: 29), its chamfered side facing to the rear of the
cylinder towards the packings. 4) Slide in the packing spring (pos: 30) and the throat
bushing (pos: 31) with its thin walled side facing front of the cylinder, leaving room for
the valves to move. Put the 3 O-rings (pos: 34, 35 & 36) back in the grooves in the valve
cartridge assembly (pos: 33) keep them in place with a little silicone grease. Lubricate the
cylinder assembly screws (pos: 15, 16) with copper-slip (order part no.: 953015) on the
thread and under the heads to allow high torque.

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 USER’s GUIDE C-2500/21E 50Hz, C-2500/25E 60Hz

(Continued)
Push the plunger (pos: 24) in from behind. Slide the cylinder assembly back in place
ensuring the O-rings still sits correct. Lightly hand torque the cylinder screws in an
alternating manner until the whole cylinder assembly is correctly seated in its place.
Alternating torque the cylinder screws to the correct torque in 3 increasing steps.
IMPORTANT: Finish of by screwing back the plunger (pos: 24) into the plunger adaptor
(pos: 20) The pump may needs turning by hand to enabling positioning of the pony-rods
back into the crankcase so easy assembling is possible.
Mount back the spray-bar cover and the clear inspection cover.

Torque specifications:

Cylinder head securing screws (pos: 15, 16 page 25) .......... 450 Nm (45 kgm) (300 lbs.ft)
Plunger (pos: 24 page 25)........................................................... 40 Nm (4 kgm) (29 lbs.ft)
Connecting rod securing screws (pos: 15 page 27) ................. 68 Nm (6.8 kgm) (50 lbs.ft)
Main bearing cap screws (pos: 9, 23 page 27, 28) ............... 570 Nm (57 kgm) (420 lbs.ft)

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 USER’s GUIDE C-2500/21E 50Hz, C-2500/25E 60Hz

MOUNTING AND SERVICE INSTRUCTION

SELF ALIGNING SOLID CARBIDE PLUNGERS

PARTS LIST
Pos Part/No: Qty: Description:
01 700680111 1 Carbide Plunger Ø5/8”
02 700680114 1 Plunger Clamp
03 700680113 1 Thrust Disc
04 700540447 2 Opening Spring
05 700680112 1 Plunger Adaptor
06 700680115 1 Belville Disc Spring
07 700510185 2 Spring Washer Ø10
08 700510181 2 Screw M10x40

MOUNTING & SERVICE INSTRUCTIONS:

Mounting:
Start (Please refer to above sketch) by mounting the Belville Disc spring (06) over the
Plunger Adaptor (05) Notice that the Belville Disc Spring must be mounted in the right
direction: The inner diameter must face the recess on the Plunger Adaptor, the flared
outer diameter must face towards the threaded end of the Plunger Adaptor. When the
Belville Disc Spring is mounted in the correct way it will give a calculated tension to the
plunger assembly allowing for self alignment.
Place the Thrust Disc (03) in the Plunger Clamp (02) the curved side facing towards the
Plunger Adaptor, the tapered sides aligned with the inside taper of the Plunger Clamp.
Lubricate the parts well with grease. (Do NOT use copper grease)
Mount the two Opening Springs (04) in the slots inside the Plunger clamp. (Continues:)

(Continued)
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 USER’s GUIDE C-2500/21E 50Hz, C-2500/25E 60Hz

Assemble the Plunger Clamp over the Plunger Adaptor using the two Spring Washer
Ø10 (07) and the two Screw M10x40 (08)
Screw the assembled parts into the Pony Rod (not shown) on the pump and tighten.
Mount the cylinder assembly with the Carbide Plunger (01) inserted through the packing
assembly. Tighten the cylinder assembly to the specified torque.

Open up the Plunger Clamp by loosening the Screw M10x40, push the Plunger into the
plunger clamp and tighten the two Screw M10x40 alternatively until the Plunger Clamp
is closed firmly.
Repeat the above steps for the remaining two plungers.

When dismantling for service: Loosen the two Screw M10x40 until the Plunger Clamp is
so loose the Plunger can be pushed out freely. It is not necessary to dismantle the plunger
clamp entirely.

Inspection / Service:
Always stop the pump entirely before inspection and service are carried out.
The self aligning plunger assembly is designed to work with a light tension from the
Belville Disc Spring.

Inspect daily to ensure that the assembly have enough tension to maintain the self
alignment.
By hand: Try to turn the Plunger Clamp around the axis, resistance should be felt. If the
Plunger Clamp turns very freely without any resistance at all, or even have slack,
dismantling and inspection of the Belville Disc Spring and the Thrust Disc must be
carried out. If there is evidence of wear replace the worn parts.
In order to ensure correct self aligning to take place during operation, the assembly must
be kept lubricated with grease at regular intervals. Do not use copper grease.

Notice:
The Carbide Plunger must be handled with care during at all times.
Although the Carbide Plunger is very long lasting, it is a very hard and very strong
material, it is in danger of chipping if exposed to sharp blows.

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 USER’s GUIDE C-2500/21E 50Hz, C-2500/25E 60Hz

Connection Diagram.

AIR SUPPLY
& AIR PILOT HOSES
AIR SUPPLY

ROTATING UHP GUN

SUPPLY HOSE
AIR OPERATED
DUMP
UNLOADER

UHP PUMP
DISCHARGE HOSE

UHP PUMP
max: 40.000 PSI ~ 2800 Bar.

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USER’s GUIDE C-2500/21E 50Hz, C-2500/25E 60Hz

MAIN ASSEMBLY
C-2500/21E C-2500/25E

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 USER’s GUIDE C-2500/21E 50Hz, C-2500/25E 60Hz

MAIN ASSEMBLY SPARE-PARTS LIST

C-2500/21E C-2500/25E
Pos: Part no.: Qty.: Description:
1 530349 1 El-box complete C-2500/25E 60Hz
1 530348 El-box complete C-2500/21E 50Hz
2 530101 3 Cable gland PG21
3 530363 1 Cable for Booster pump
4 530356 4 Cable gland star/delta
5 951526 7x1m Cable star/delta
6 530355 1 Cable gland main cable
7 951525 15m Main cable
8 510004 28 Lock nut M8
9 510005 28 Washer M8
10 510017 4 Rubber element M8
11 520241 1 Discharge pipe set
12 510131 5 U-bolt 1.1/2”
13 540266 2 Ball valve 1”
14 530332 1 Pressure switch
15 540268 2 Hose nipple 1/4”
16 540306 1 Low-Pressure gauge
17 540140 1 T-joint 1/4”
18 540197 1 Nipple 1/4”
19 520224 2 Connection Suction/Discharge pipe sets
20 600203 4 O-ring
21 510117 4 Rubber foot
22 510030 20 Bolt M8
23 520286 1 Frame
24 520280 1 Stop for Water-tank
25 510068 2 Lock nut M12
26 510067 2 Washer M12
27 510164 1 Stud bolt M12 for Water-tank stop
28 520287 1 Suction pipe set
29 520103 1 Coupling motor TL 280 complete
30 520105 1 Coupling half motor end
31 520107 1 Taper lock bush motor
32 520108 1 Rubber element
33 520106 1 Taper lock bush pump
34 520104 1 Coupling half bush pump
35 520289 1 Cover coupling
36 530233 1 Motor C-2500/25E 60Hz
36 530232 1 Motor C-2500/21E 50Hz
37 510095 4 Bolt 7/8” x 3”
38 510056 4 Washer 7/8”
39 510097 4 Spring washer 7/8”
40 510096 4 Nut
41 540264 4 Hose clip 1”
42 520291 2 Hose 1” x 600mm
(continues)

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 USER’s GUIDE C-2500/21E 50Hz, C-2500/25E 60Hz

MAIN ASSEMBLY SPARE-PARTS LIST

C-2500/21E C-2500/25E
(continued)
Pos: Part no.: Qty.: Description:
43 540299 2 Hose nipple 1”
44 540561 1 Elbow 1.1/4”
45 540562 1 T-joint 1.1/4”
46 540563 1 Nipple 1.1/4”
47 530412 1 Booster pump Grundfos
48 540480 1 Hose nipple 1.1/2” – 1.1/4”
49 540262 2 Hose clip 1.1/2”
50 520244 1 Suction Hose 1.1/2” x 1000mm

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USER’s GUIDE C-2500/21E 50Hz, C-2500/25E 60Hz

WATER TANK ASSEMBLY

C-2500/21E C-2500/25E

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 USER’s GUIDE C-2500/21E 50Hz, C-2500/25E 60Hz

WATER TANK ASSEMBLY SPARE-PARTS LIST

C-2500/21E C-2500/25E
Pos: Part no.: Qty.: Description:
1 700540303 1 Water inlet coupling female
2 700540302 1 Water inlet coupling male
3 700540341 1 Nipple 1.1/2” x 1.1/2”
4 700540579 1 Socket 1.1/2”
5 700540565 3 Hose nipple 1.1/2”
6 700510130 1 U-bolt
7 700540262 3 Hose clip 1.1/2”
8 700520244 1 Supply hose 1.1/2” x 1.5m
9 700540564 1 Elbow 1.1/2”
10 700520122 1 Filter inlet 1.1/2” complete w. filter insert and o-ring
11 700520201 1 O-ring
12 700520123 1 Filter insert “blue” 50 mesh
13 700540479 1 Nipple 1”
14 700540266 1 Ball valve 1”
15 700540299 1 Hose nipple 1”
16 700510004 4 Lock nut M8
17 700510005 4 Washer M8
18 700520138 1 Bracket for tank filter
19 700510127 2 Bolt M8 x 110
20 700510107 2 Bolt M8 x 20
21 700510005 2 Washer
22 700520135 1 Float inlet valve 1.1/2”
23 700520136 2 Ball for float valve
24 700520052 1 Ball holder
25 700510057 2 Nut M8
26 700510166 1 Stud bolt M8
27 700520244 1 Suction hose 1.1/2” x 1m
28 700520237 1 Lid for water tank
29 700540566 1 Elbow 2”
30 700530145 1 Level switch water tank
31 700530010 2 Cable gland
32 700540567 1 Hose nipple 2”
33 700540263 1 Hose clip 2”
34 700520245 1 Hose overflow 2” x 1.5m
35 700520236 1 Water tank complete w. lid
36 700520340 6 Rubber dampener

23
USER’s GUIDE C-2500/21E 50Hz, C-2500/25E 60Hz

FILTER ASSEMBLY
C-2500/21E C-2500/25E

24
 USER’s GUIDE C-2500/21E 50Hz, C-2500/25E 60Hz

FILTER ASSEMBLY SPARE-PARTS LIST

C-2500/21E C-2500/25E

Pos: Part no.: Qty.: Description:

1 700520147 2 Filter element 20”
2 700520197 2 Filter housing 20”
3 700520207 2 O-ring filter housing
4 700540560 4 Hose nipple 1” x ¾”
5 700520208 1 O-ring
6 700540559 2 Elbow ¾”
7 700540264 8 Hose clip 1”
8 700520291 2 Hose 1” x 600mm
9 700510011 12 Lock nut M8
10 700510005 24 Washer flat M8
11 700510030 8 Bolt M8x25
12 700520230 1 Bracket for 20” filter
13 700510051 8 Bolt M6x20
14 700510033 8 Spring washer M6
15 700510023 8 Flat washer M6
16 700530112 8 Spacer Ø7x8mm

25
USER’s GUIDE C-2500/21E 50Hz, C-2500/25E 60Hz

PUMP COUPLING ASSEMBLY

C-2500/21E C-2500/25E

26
 USER’s GUIDE C-2500/21E 50Hz, C-2500/25E 60Hz

PUMP COUPLING ASSEMBLY SPARE-PARTS LIST

C-2500/21E C-2500/25E
Pos: Part no.: Qty.: Description:
1 700680104 1 Pump complete C-2500/21E C-2500/25e
2 700680065 1 Fluid end complete 36K Psi w. Outlet fittings 700540572
3 700540572 2 Pump Outlet fitting UHP
4 700540564 2 Elbow 1.1/2”
5 700540565 2 Hose nipple 1.1/2”
6 700540262 4 Hose clip 1.1/2”
7 700520243 2 Inlet Hose 1.1/2” x 0.45m
8 700510080 4 Bolt 5/8”x 2.5”
9 700510081 8 Washer Flat 5/8”
10 700510116 4 Lock Nut 5/8”
11 700650281 1 Pump Power-end
12 700540388 2 Collar 9/16”
13 700540387 2 Gland Nut 9/16”
14 700540355 1 Nipple 9/16” x 4”
15 700540382 1 Fitting UHP 9/16” – 3/8”
16 700540477 2 Rupture Disc 43K Psi
17 700540386 2 Rupture Disc assembly without Rupture disc
18 700550771 2 Mushroom Head 3/8”
19 700540474 1 Pipe for High pressure Gauge 3/8”
20 700540390 2 Gland nut 3/8”
21 700540391 2 Collar 3/8”
22 700510067 2 Washer Flat M12
23 700510129 3 Bolt Hex M12x25
24 700680067 1 Bracket for Spray-cover
25 700680066 1 Spray-cover
26 700510010 2 Knob Screw M8
27 700680109 1 Cover for Cover-Spray
28 700540199 2 Hose clip ¼”
29 700540582 1 Hose ¼” x 1000mm
30 700540268 1 Hose Nipple ¼”
31 700540238 1 Elbow ¼”
32 700540354 1 Cross connection UHP

27
USER’s GUIDE C-2500/21E 50Hz, C-2500/25E 60Hz

GAUGE ASSEMBLY
C-2500/21E C-2500/25E

28
 USER’s GUIDE C-2500/21E 50Hz, C-2500/25E 60Hz

GAUGE ASSEMBLY SPARE-PARTS LIST

C-2500/21E C-2500/25E
Pos: Part no.: Qty.: Description:
1 700540653 1 Gauge 0-40Kpsi (400Bar)
2 700650060 1 Copper seal
3 700540699 1 Adaptor ½”
4 700540702 1 Bleed Screw
5 700060107 1 O-ring
6 700540698 1 Piston
7 700540701 1 Step-seal set
8 700540700 1 V-seal
9 700540697 1 Housing gauge converter
3-9 700540696 1 Gauge converter complete
1-9 700540705 1 Gauge converter complete w. gauge
10 700540703 1 U-bolt
11 700510004 2 M8 nut
12 700520429 1 Bracket

29
USER’s GUIDE C-2500/21E 50Hz, C-2500/25E 60Hz

PUMP FLUID-END ASSEMBLY

C-2500/21E C-2500/25E

30
 USER’s GUIDE C-2500/21E 50Hz, C-2500/25E 60Hz

PUMP FLUID-END ASSEMBLY SPARE-PARTS LIST

C-2500/21E C-2500/25E
Pos: Part no.: Qty.: Description:
1 700520293 1 Hose 1”
2 700540264 1 Hose clip 1”
3 700540245 1 Nipple ¾” NPT 1”hose
4 700510167 9 Bolt M6 x 10 HEX
5 700680096 1 Plate bottom for box for UHP fluid end
6 700510161 4 Dowel pin ø1/2” x1”
7 700510160 4 Bolt ¾” UNC x 3” Allen
8 700680095 1 Plate rear for UHP fluid end
9 700510140 8 Bolt M24 x 80 Allen
10 700680094 2 Plate side for UHP fluid end
11 700680084 3 Back plate
12 700680085 1 Manifold 36 K
13 700540572 2 Outlet fitting UHP
14 700510159 4 Bolt ¾” UNC x 5” Allen
15 700680054 6 Tie bolt 15”
16 700680053 6 Tie bolt 14”
17 700680115 3 Bellville Spring Washer
18 700680112 3 Plunger Adaptor for Floating Plunger AJ
19 700680113 3 Thrust Disc for Floating Plunger
20 700680114 3 Clamp for Floating Plunger
21 700540447 6 Spring
22 700510035 6 Spring Washer M10
23 700510181 6 M10x40 Allen Head Screw SS
24 700680111 3 5/8” Floating Plunger AJ
25 700680110 3 Ø 5/8” Support Ring
26 700680005 3 Back-up ring for 5/8” - 1.3/8” UHP
27 700680011 3 Packing white 5/8” - 1.3/8”
28 700680031 3 Packing black 5/8” - 1.3/8”
29 700680008 3 Packing adaptor 5/8” - 1.3/8” AJ
30 700680059 3 Spring for packing, UHP
31 700680007 3 Throat bushing 5/8” - 1.3/8” AJ
32 700680061 3 Cylinder UHP 1.3/8” bore
33 700680068 3 Valve cartridge assembly
34 700680049 3 O-ring manifold end outer
35 700680013 3 O-ring manifold end inner
36 700680060 3 O-ring cylinder end
37 700680056 3 Discharge valve pin
38 700680086 3 Valve cartridge
39 700680057 3 Valve disc suction
40 700680058 3 Spring for valve, UHP
41 700680021 3 Valve stop nut
42 700540695 3 Grease Nipple
1-42 700680065 1 Fluid end complete 36 K Psi

31
 USER’s GUIDE C-2500/21E 50Hz, C-2500/25E 60Hz

PUMP POWER-END ASSEMBLY PART 1

C-2500/21E C-2500/25E

32
 USER’s GUIDE C-2500/21E 50Hz, C-2500/25E 60Hz

PUMP POWER-END ASSEMBLY PART 2

C-2500/21E C-2500/25E

33
 USER’s GUIDE C-2500/21E 50Hz, C-2500/25E 60Hz

PUMP POWER-END ASSEMBLY SPARE-PARTS LIST

C-2500/21E C-2500/25E
Pos.: Part. No.: Qty.: Description.
1 700650267 1 Crankcase
2 700650105 2 Lifting eye
3 700650034 1 Gasket for crankcase cover
4 700510157 8 Socket head screw for crankcase cover
5 700650223 3 Connecting rod and cap
6 700650273 8 Washer retainer for cap bearing
7 700650228 4 Tab washer
8 700650271 1 Filler cap
9 700650229 4 Hexagon head bolt
10 700650245 1 Bearing location strip
11 700650232 1 Main bearing
12 700650222 1 Cover for crankcase
13 700650230 3 Big end connecting rod bearing
14 700650113 6 Tab washer
15 700650112 6 Connecting rod bolt
16 700650087 3 Gudgeon pin bearing
17 700650224 3 Gudgeon pin
18 700650264 3 Oilseal
19 700650272 3 Crosshead ponyrod
20 700650263 3 Oilseal scraper
21 700650261 3 Seal carrier
22 700650265 3 O-ring
23 700650249 1 Hexagon head bolt
24 700650233 1 Cap
25 700650268 1 Crankshaft
26 700540056 1 Bonded seal
27 700650113 1 Magnetic drain plug
28 700650059 1 Oil level glass
29 700650274 1 Taper roller bearing
30 700650275 1 Taper roller bearing
31 700650242 1 Adjustable ring
32 700650241 1 Pinion bearing retaining plate
33 700650121 4 Nylon locking slug
34 700650277 1 Key
35 700650269 1 Pinion gear 3.48:1
36 700650240 1 Oil seal
37 700650106 4 Socket head cap screw
38 700650278 1 Key
39 700650237 1 Circlip
40 700650270 1 Gear wheel 3.48:1
41 700650235 1 Cap
42 700650234 1 Main bearing
(continues)

34
 USER’s GUIDE C-2500/21E 50Hz, C-2500/25E 60Hz

PUMP POWER-END ASSEMBLY SPARE-PARTS LIST

C-2500/21E C-2500/25E
(continued)
Pos.: Part. No.: Qty.: Description.
43 700650262 3 Pony rod sleeve
44 700650276 6 Gudgeon Pin pad
45 700540097 1 Plug
46 700540314 1 Bonded seal
47 700510009 4 Screw
48 700650250 4 Dowel
49 700510003 6 Screw filler cap

35
USER’s GUIDE C-2500/21E 50Hz, C-2500/25E 60Hz

WIRING DIAGRAM
C-2500/21E C-2500/25E

36