Flexible couplings are often viewed as simple mechanical components, until repeated failures begin causing vibration, downtime, backlash or expensive drivetrain damage.
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In reality, coupling wear patterns can reveal far more about a system than many people realise.

What appears to be a failed coupling may actually indicate:

» misalignment.
» torsional shock.
» excessive backlash.
» overload conditions.
» vibration issues.
» incorrect coupling selection.
» or wider drivetrain design problems.

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At jbj Techniques, we regularly support engineers investigating mechanical power transmission issues across industrial machinery, marine systems, renewable energy, transport, heavy plant and processing industries.

Very often, the coupling itself is not the root cause of the failure, it is simply the first visible symptom of a wider system issue.

Understanding the behaviour of the complete drivetrain is where engineering experience becomes critical.

Over the years, we have published technical discussions covering:
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» torque-related failure patterns
» coupling elastomer analysis
» torsional wind-up and backlash
» coupling selection and application tools
» and practical drivetrain problem-solving

Because successful coupling selection is rarely just about torque capacity alone.

It involves understanding:
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» dynamic loading.
» start-up conditions.
» vibration behaviour.
» shaft movement.
» environmental factors.
» service life expectations.
» and the operational realities of the application.

At jbj Techniques, engineering beyond product supply means helping customers understand not just which coupling to use, but why problems occur in the first place.

Explore more: https://www.jbj.co.uk/couplings.html

Electrification of refuse lorries ~ quiet hydraulic solutions for modern waste vehicles.
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As the waste management industry moves towards vehicle electrification, manufacturers are facing a new set of engineering challenges. One of the most significant is the need to maintain hydraulic performance while dramatically reducing operating noise. This was exactly the challenge presented in a recent refuse lorry electrification project, where a customer required a quiet tandem gear pump solution capable of operating under demanding conditions.
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The challenge of electrified refuse vehicles

As the waste management industry moves towards vehicle electrification, manufacturers are facing a new set of engineering challenges. One of the most significant is the need to maintain hydraulic performance while dramatically reducing operating noise. This was exactly the challenge presented in a recent refuse lorry electrification project, where a customer required a quiet tandem gear pump solution capable of operating under demanding conditions.

Traditional refuse collection vehicles rely heavily on diesel engines, which naturally mask much of the hydraulic system noise. However, with the transition to electric drivetrains, hydraulic noise becomes far more noticeable, particularly during early morning residential collections where noise pollution is a growing concern.

The customer required a tandem gear pump solution that would:

» Deliver reliable hydraulic performance for refuse collection operations.
» Operate with exceptionally low noise levels.
» Function at speeds beyond the standard rated maximum speed of the pump.
» Integrate with a variable-speed pump drive system.

To meet the acoustic requirements of the application, conventional external gear pumps were not suitable. Instead, the project focused on the use of ELIKA low-noise, high efficiency gear pumps from Marzocchi Pompe.

Meanwhile at the other end of the spectrum an unlikely application of a Marzocchi gear pump supplied by jbj Techniques, feeding kerosine into the afterburner of this jet powered VW at 180 litres/min, 160 psi (11.03 bar), delivered in 10 second bursts.

The transition from diesel power to electric drive systems is creating new engineering challenges across many industries. Retrofitting diesel-powered equipment for electrification is rarely straightforward.
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While the objective may sound straightforward, replacing an internal combustion engine with an electric motor, the reality is often considerably more complex, particularly where existing driveline systems, mounting arrangements and operational flexibility must be retained.

A project undertaken by jbj Techniques involved supporting the clean-energy retrofit of heavy equipment by replacing a diesel engine with a 250kW D355 frame electric motor.

The challenge was not simply mounting the new motor.

The customer needed to retain compatibility with an existing SAE 1 / SAE 14 over-centre clutch arrangement while preserving the option to revert back to diesel power in the future if operational requirements changed.

To achieve this, jbj Techniques designed and manufactured a bespoke 800 mm diameter cast iron bellhousing together with a custom coupling arrangement that converted the electric motor shaft to an SAE 14 flange configuration. This ensured full mechanical compatibility between the new electric drive system and the existing rotating equipment.

Projects such as this demonstrate how successful electrification often depends on far more than selecting a suitable motor.


Critical considerations can include:
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» driveline compatibility,
» torsional characteristics,
» mounting integrity,
» alignment accuracy,
» thermal behaviour,
» future serviceability,
» and operational flexibility.

The project also highlighted the value of combining design engineering with in-house manufacturing capability.

The 230kg cast iron housing was produced using UK-sourced castings and machined on jbj Techniques' Puma V8300M CNC machining centre, capable of handling components up to 800mm diameter. Inspection was undertaken using a Keyence XM-5000 handheld CMM system, allowing rapid in-process verification directly at the machine.

At jbj Techniques, projects often begin with a component requirement but develop into a broader engineering solution involving mechanical integration, bespoke manufacturing and system-level problem solving.

From couplings, bellhousings and hydraulic systems through to complete drivetrain integration challenges, our focus remains the same: understanding the application, understanding the system, and engineering practical solutions that work reliably in the real world.

If your application is suffering from:
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» rising oil temperatures
» reduced component life
» unreliable operation
» excessive thermal load
» or recurring overheating issues

there is usually a wider thermal management problem affecting system reliability.
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In high-demand industrial environments, heat can quickly become one of the biggest causes of:
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» reduced efficiency
» premature wear
» oil degradation
» unexpected failures
» and costly downtime

The challenge is not simply adding a cooler. It is understanding how heat moves through the complete system.
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At jbj Techniques, cooling projects often involve helping customers identify:
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» where thermal energy is being generated,
» airflow and pressure limitations,
» oil flow inefficiencies,
» environmental operating constraints,
» and long-term thermal loading issues.

Because effective thermal management is not just about lowering temperature. It is about improving reliability, extending service life and maintaining consistent performance under demanding operating conditions.

Not all engineering problems are immediately visible.

In hazardous-area hydraulic applications, something as seemingly minor as shaft seal temperature can become a critical reliability and safety issue.

Under fluctuating flow and pressure conditions, hydraulic pump shaft seals can experience pulsation and frictional heating. In extreme cases, seal surface temperatures may rise sufficiently to create a potential ignition risk within ATEX-regulated environments.

A recent project led jbj Techniques to develop a bespoke wet mount bellhousing arrangement specifically designed to control hydraulic pump shaft seal temperatures in demanding hazardous-area applications.

The solution integrated:

» a cooled oil reservoir surrounding the seal area.
» controlled oil flow for temperature management.
» compatibility with horizontal or vertical installations.
» ATEX-compliant bellhousing and coupling arrangements.

The objective was not simply to mount a pump to a motor.

It was to understand how the complete hydraulic and mechanical system behaved under real operating conditions and engineer a practical solution that improved both safety and reliability.

Projects such as this demonstrate how effective engineering often goes far beyond component supply alone.

At jbj Techniques, we regularly support customers with applications involving:

» hazardous areas,
» drivetrain integration,
» hydraulic system reliability,
» torsional behaviour,
» bespoke machining,
» and complex mechanical interfaces.

Because sometimes the real engineering challenge is not the component itself but understanding the operating environment around it.
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At jbj Techniques, projects often begin with a component requirement but develop into a broader engineering solution involving mechanical integration, bespoke manufacturing and system-level problem solving.
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In hazardous-area applications, understanding how the complete hydraulic system behaves under real operating conditions is critical to both safety and reliability.

Engineering challenges in these environments rarely begin and end with a single component.

If your fluid power system is experiencing:

» overheating,
» pressure instability,
» cavitation,
» excessive noise,
» reduced efficiency,
» or shortened component life.

the root cause may involve far more than simply replacing a pump or valve.
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In many applications, long-term performance is heavily influenced by:
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» pump selection,
» cooling performance,
» flow characteristics,
» filtration» installation layout,
» duty cycle,
» and overall system integration.
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Small engineering improvements in these areas can often deliver major gains in:
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» reliability,
» efficiency,
» operating temperature,
» controllability,
» energy consumption,
» and component lifespan.
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At jbj Techniques, many customer enquiries begin with a component requirement but develop into a broader discussion about improving overall system performance and reducing operational problems long term.
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Because the most effective fluid power solutions rarely come from focusing on a single component in isolation.

Low Noise, High Efficiency Hydraulic Motor / Triple Pump Assembly

How do you power multiple hydraulic functions from a single hydraulic source without adding complexity?

ELIKA^® hydraulic gear pumps, hydraulic gear motors, and FTP fluid transfer gear pumps are ideal for applications where low noise operation and high efficiency are critical, such as this bespoke hydraulic motor / triple pump assembly engineered by jbj Techniques.

In this application, a Marzocchi hydraulic gear motor drives a triple Marzocchi hydraulic gear pump arrangement comprising three pumps of differing capacities. Each pump provides hydraulic power to an individual function on a road marking vehicle, all from a single hydraulic source.

By optimising pump capacities to suit the demands of each circuit, the assembly generates independent flow for three separate machine functions without the need for a flow divider. This reduces energy losses, improves overall system efficiency, and provides a simpler, more effective hydraulic solution.

For complex hydraulic applications, assemblies can be configured with a single hydraulic motor driving multiple gear pumps of differing displacements, enabling independent flow generation whilst maintaining efficient and reliable system operation.

This complete assembly was designed and built in-house by jbj Techniques to meet a specific customer requirement, demonstrating our ability to develop practical, application-focused hydraulic solutions. Custom adaptors and mounting components were manufactured using our in-house machining facilities, allowing the assembly to be configured precisely to suit the installation requirements.

A motor-pump set consists of a prime mover, such as a petrol engine, diesel engine, electric motor, hydraulic motor, or air motor, connected to a fluid or gas pump via either a coupling alone or a bellhousing and coupling combination. The key advantage of using a bellhousing is that it maintains full concentricity between the prime mover and the connected pump, helping to prevent premature coupling failure caused by shaft-to-shaft misalignment.

The assembly incorporates precision bellhousing and coupling integration to maintain accurate shaft alignment, reducing coupling loads and promoting long-term drivetrain reliability. This approach also enables compact, space-efficient package configurations that simplify installation and ongoing maintenance.

High-quality mechanical and fluid power products are always available directly from our comprehensively stocked warehouse, but we offer far more than component supply alone. Whether you require a single drive component or a complete, complex driveline package, our experienced team works closely with hydraulic engineers and OEM designers to develop reliable, high-performance solutions tailored to the operational demands of the application.
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Key Design Benefits:
» Independent flow generation without the need for flow dividers.
» Reduced energy losses and improved circuit efficiency.
» Optimised pump capacities for individual circuit requirements.
» Precision bellhousing and coupling alignment.
» Reduced coupling loads and improved drivetrain longevity.
» Compact, space-efficient assembly design.
» Simplified installation and maintenance.
» Full approval drawings provided prior to manufacture.
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Providing a solution based upon your application requirements: jbj Techniques can design and build motor-pump assemblies from the extensive stock of hydraulic gear motors and hydraulic gear pumps, creating custom adaptors to mount the gear pumps to the motor using extensive stocks of bellhousings and couplings, supported by our excellent machine shop facilities. Full design drawings are provided for reference and approval before manufacture.