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Operating instructions

High pressure pump

HDP 254B3.01254.0377 HDP 254 2013

Made in Germany Issue: 04.2013

Machine no. : B3.01254.03771Page:

M A C H I N E C A R D

Hammelmann Maschinenfabrik GmbHPOB 3309, D-59282 Oelde, Germanymail to: [email protected]://www.hammelmann.de

Order no. KA 162380Purchaser DEN- JET NORDIC A/S, Arden / DKClient no. 11117601P. O. no./Date 7756 / 12.03.2013Machine no. B3.01254.0377Pump type HDP 254Code no. 09.00254.1140Performance data

l/minFlow rate Ps 1 63barOperating pressure Ps 1 20001/minMotor speed Ps 1 20001/minCrankshaft speed Ps 1 619mmPiston dia. Ps 1 20kWMotor rating req'd Ps 1 244l/minFlow rate Ps 2 52barOperating pressure Ps 2 24001/minMotor speed Ps 2 16501/minCrankshaft speed Ps 2 511mmPistion dia. Ps 2 20kWMotor rating req'd. Ps 2 241

Brief instructionsLanguage englischPump RAL 1018Name plate high pressure pumpMachine no. B3.01254.0377Type no. 09.00254.1140Year 2013

kWMotor rating [kW] 2441/minSpeed [1/min] 2000°CMax. liquid temp. [°C] 40mmPiston dia. pres. step 1 [mm] 20mmPiston dia. pres. step 2 [mm] 20barMax. pressure Ps 1 [bar] 2000barMax. pressure Ps 2 [bar] 2400l/minFlow rate Ps 1 [l/min] 63l/minFlow rate Ps 2 [l/min] 52

Pressure reg. valve Ps 1 ---Oil type PAO VG 320

lOil quantity [l] 22,5barOil pressure [bar] 2

DocumentationLanguage 1 englischLanguage 1 number of paper 2Language 1 number of CD 1Date of delivery 11.04.2013Person in charge-Sales M. LettmannPerson in charge H.- J. SchulteDate 13.03.2013

Machine no. : B3.01254.03772Page:

M A C H I N E C A R D


Parts list to machine no: B3.01254.0377

Pos Code - No. Description Quantity Unit

Note : Ps = Pressure step

1 00.03223.2845 1,00 pcHIGH-PRESSURE PUMP HDP25010 01.04565.0037 1,00 pcNAMEPLATE20 00.02350.0793 1,00 pcCRANK SECTION HDP250 I=3,2330 00.04246.0080 1,00 pcSUCTION CHAMBER HDP250 D17,5-5540 00.02516.0182 1,00 pcOIL LINE HDP25050 00.02515.0314 1,00 pcLINE HDP120/170/25060 04.03070.0035 22,50 lOIL SHELL OMALA HD 32070 00.00743.2152 5,00 pcPISTON SEAL ASSEMBLY HDP120/170/250 D2080 00.02515.0379 2,00 pcLINE HDP40-80/120-250/360-75090 01.06224.0082 1,00 pcTOOLS, SET100 00.02145.1133 1,00 pcPUMP HEAD HDP250 D17,5-20105 00.02518.0022 1,00 pcVENT LINE HDP234110 00.00792.0012 1,00 pcSPLITTING NOZZLE M 30x2 A -166,5 LG120 02.00301.0005 2,00 pcLIFTING EYE NUT M 20

>>>end<<<

Abnahmeprüfzeugnis Test certificate

QC - 049/05.08 Seite 1 von 1

Maschinen-Nr. Machine No. B3.01254.0377 HAMMELMANN

Maschinenfabrik GmbH Zum Sundern 13-21 D-59302 Oelde Tel.: 02522/76-0 e-mail: [email protected] http: www.hammelmann.de

Unsere Auftrags-Nr. Our Order No. KA 162380

Bestell-Nr. P. Order No. 7756

Druckregelautomatik Pressure unloader --------------------------------------- Eingangsdrehzahl / Motordrehzahl

Input speed / Motor r.p.m. min-1 2000 / 1650

Druckregelventil / Bypassventil Pressure relief valve / Bypass valve --------------------------------------- Öldruck

Oil pressure bar 7,0

Anzahl der Tellerfedern Number of Disc-springs --------------------------------------- Mediumdruck

Medium pressure bar 2000 / 2400

Schichtung der Tellerfedern Spring pack arrangement --------------------------------------- Fördermenge

Output

m 3 /h

l/min 69 / 56

Distanzhülse / Steuerdruck Washer / Control pressure --------------------------------------- Plungerkühlwasser

Pisten cooling water l/min / °C 8,2 / 18°C

Sicherheitsventil / Berstscheibensicherung Safety valve / Burst disc

/ / Ansprechdruck Opening Pressure bar -----------------

Druckwächter Öl Oil pressure switch E-Motor ex

D-Motor 50 Hz 60 Hz

Druckwächter Medium Medium pressure switch Antriebsleistung

Motor rating kW 244 / 241

Thermostat Öl / Oil Medium / / Stromaufnahme (Prüfraum) A Power consumption (Testroom) Volt / Hz

/

Überlast E-Motor Overload E-Motor Gesamtlaufzeit – Std.

Total – Test – Time hr. 2,5

Schaltschrank (ohne Pumpenüberwachung) Switchboard (without pump control unit) unter Last

under Load Std./hr. 2,25

Schaltschrank (Überwachungsgerät, Pumpe-Motor) Switchboard (control unit, pump-motor) Geprüft nach EG-Maschinenrichtlinie

Gerätesicherheitsgesetz Tested in accordance with E.U. Machine Regulations governing operational safety of equipement.

ja / yes nein / no Betriebsstundenzähler

Operating hours counter

Bypasssteuerventil Bypass solenoid valve Druckwächter Luft

Air pressure sensor ja / yes nein / no

Umschaltventil / Magnetventil Multi tool valve / Changeover valve Kühlwassermenge

Cooling water quantity Ltr./ min. 13

Temperaturmessung nach Erreichen der Beharrungstemperatur Temperature measurement only when steady state temperature reached

Qualitätsprüfung Quality Control

Der Abnahmeingenieur Test-Engineer

Datum Date

Name:

Unterschrift / Signature

G.Conradi

08.04.2013

Dokument wurde auf elektronischem Wege erstellt und ist ohne Unterschrift gültig. This message was electronically generated and is valid without a signature.

gepr

üft /

test

ed

nich

t vor

hand

en /

not i

nsta

lled

Nr. Name Datum Zeit IR-Temp IR-Min IR-Max Mat. Name1 TS1 Temp.Cranks.bear 05.04.2013 11:23:57 56,8 56,3 56,9 Free2 TS2 Temp.Cranks.bear 05.04.2013 11:24:01 56,7 56,0 56,7 Free3 TS3 Driveshaft bear. 05.04.2013 11:24:05 59,0 58,6 59,0 Free4 TS4 Driveshaft bear. 05.04.2013 11:24:08 59,5 59,5 59,7 Free5 TS5 Oiltemperature 05.04.2013 11:24:16 56,8 56,5 57,2 Free6 TS6 Oil Cooler out 05.04.2013 11:24:21 51,6 51,3 51,7 Free7 TS7 Coolingwater inl 05.04.2013 11:24:25 17,3 17,3 17,6 Free8 TS8 Coolingwater out 05.04.2013 11:24:31 23,3 23,0 23,3 Free9 TS9 Crank sec.gener. 05.04.2013 11:24:36 55,8 55,8 56,5 Free

10 TS10 Temp.Pisten 05.04.2013 11:24:53 38,0 37,1 38,0 Free11 TS11 Temp.Crosshead 05.04.2013 11:25:02 65,4 65,0 65,4 Free12 TS12 Ambient Temp. 05.04.2013 11:25:07 21,4 21,4 21,7 Free

HAMMELMANN Maschinenfabrik GmbH Zum Sundern 13 – 21 59302 Oelde • Germany Einbauerklärung nach EG-Richtlinie 2006/42/EG, Anhang II, Nr. 1B

Declaration of Incorporation according to E.C. Directive 2006/42/EC, Appendix II, No 1B

Déclaration d’incorporation conformément à la directive 2006/42/CE, Annexe II, N° 1B

Hiermit erklären wir, dass die nachstehend bezeichnete Maschine eine unvollständige Maschine nach Artikel 2g ist. Sie ist ausschließlich zum Einbau in oder zum Zusammenbau mit einer anderen Maschine oder Ausrüstung vorgesehen.

We hereby declare that the machine detailed below is partly completed machinery according to Article 2g. It is exclusively intended for incorporation in or with other machinery or equipment.

Par la présente, nous déclarons que la machine désignée ci-dessous est une machine incomplète conformément à l’article 2g. Elle est exclusivement prévue d’être incorporé dans une autre machine ou équipement ou de faire partie d’un assemblage.

Die Abteilung Normung/Dokumentation ist bevollmächtigt, die technischen Unterlagen nach Anhang VII B zusammenzustellen.

The department Standards/Documents is authorised to compile the technical file according to Annex VII B.

Le service Standardisation/Documentation est autorisé à compiler la documentation technique conformément à l’annexe VII B.

Diese unvollständige Maschine darf erst dann in Betrieb genommen werden, wenn festgestellt wurde, dass die Maschine, in die diese unvollständige Maschine eingebaut wurde, den Bestimmungen der Maschinen-richtlinie entspricht.

This partly completed machinery must not be put into service until the final machinery into which it is to be incorporated, has been declared in conformity with the provisions of the machine directive.

Cette machine incomplète ne doit pas être mis en service avant que la machine dans laquelle la machine incomplète a été incorporée soit conforme aux dispositions de la directive CE sur les machines.

Bezeichnung der Maschine: Hochdruckpumpe HDP 254 Machine description: High pressure pump HDP 254 Désignation de la machine: Pompe à haute pression HDP 254 Maschinentyp:

09.00254.1140 Machine designation: Type de machine:

Maschinen-Nr.:

B3.01254.0377 Machine No.:

No de machine:

Weitere, zutreffende EG-Richtlinien: Other appropriate E.C. Directives: Autres directives CE concernées:

EG-Richtlinie 2004/108/EG (EMV-Richtlinie)

E.C. Directive 2004/108/EC (EMC directive)

Directive CE sur la comptabilité électromagnétique 2004/108/CE

Angewandte harmonisierte Normen: Used harmonised standards: Normes harmonisées appliquées:

EN 809 EN 60204-1 EN 61000-6-2

Angewandte nationale Normen und technische Spezifikationen:

National standards and technical specifications:

Normes nationales et spécifications techniques appliquées:

- -

Hersteller-Unterschrift Manufacturer’s signature Signature du fabricant

08.04.2013

Datum / Date / Date Geschäftsführer Managing director Gérant

Funktion des Unterzeichners Position of Signatory Fonction du signataire

TB 0

08/0

106

Operating instructions

High pressure pump

HDP 254

HDP 254 2013

Made in Germany Issue: 04.2013

Operating instructions Contents No: HDP 254

Page 2, Issue: 04.2013

Copyright of Hammelmann Maschinenfabrik GmbH

Germany • D-59302 Oelde • Zum Sundern 13 - 21

1 Contents

1 Contents ............................................................................................................................................................ 2

2 Foreword ........................................................................................................................................................... 5

3 Technical data ................................................................................................................................................... 6

3.1 Main dimensions .......................................................................................................................................... 6

3.2 Performance data, High Pressure Pump ..................................................................................................... 7

3.3 Order Code Key ........................................................................................................................................... 8

3.4 Machine number key .................................................................................................................................... 9

4 Safety ............................................................................................................................................................... 10

4.1 Dangers arising from non observance of safety instructions ..................................................................... 10

4.2 Safety conscious working .......................................................................................................................... 10

4.3 Personnel qualification and training ........................................................................................................... 10

4.4 Precise safety instructions for the operator ............................................................................................... 10

4.5 Danger symbol ........................................................................................................................................... 12

4.6 Safety during inspection, maintenance and repair ..................................................................................... 13

4.7 Forbidden practices ................................................................................................................................... 13

4.8 Additional warnings .................................................................................................................................... 13

5 General............................................................................................................................................................. 14

5.1 Introduction ................................................................................................................................................ 14

5.2 Application .................................................................................................................................................. 14

5.3 General permissible operational conditions ............................................................................................... 14

5.4 Copyright .................................................................................................................................................... 15

5.5 Warranty terms........................................................................................................................................... 15

6 Transportation ................................................................................................................................................ 16

6.1 Packing ...................................................................................................................................................... 16

6.2 Transportation ............................................................................................................................................ 17

6.3 Transport .................................................................................................................................................... 17

6.4 Protection ................................................................................................................................................... 17

7 Construction & Description ........................................................................................................................... 18

7.1 Construction ............................................................................................................................................... 18

7.2 Description ................................................................................................................................................. 19

7.2.1 General description of the pump ............................................................................................................ 19

7.2.2 Crank section with pressurised lubrication system ................................................................................ 19

7.2.3 Piston seal assembly ............................................................................................................................. 19

7.2.4 Pump head ............................................................................................................................................. 19

8 Installation & Start up ..................................................................................................................................... 21

8.1 Connecting the driver ................................................................................................................................. 21

Contents Operating instructions No.: HDP 254




8.2 Suction (feed) side installation .................................................................................................................... 21

8.3 Calculating the suction and discharge hose internal diameters (DN) ........................................................ 23

8.4 Connections to the ultra high pressure pump outlet (discharge side) ........................................................ 26

8.5 Installation of hoses, pipe work and cables ................................................................................................ 26

9 Operation ......................................................................................................................................................... 29

9.1 Pre-start checks .......................................................................................................................................... 29

9.2 To start the unit ........................................................................................................................................... 29

9.3 Setting the operating pressure.................................................................................................................... 30

9.3.1 by manually operated pressure regulating valve .................................................................................... 30

9.3.2 by pneumatically operated pressure regulating valve ............................................................................ 30

9.3.3 by setting the r.p.m. of the drive engine ................................................................................................. 30

10 Shut down ....................................................................................................................................................... 31

10.1 Stopping the unit ......................................................................................................................................... 31

10.2 Overnight shut down ................................................................................................................................... 31

10.3 Extended shut down (14 days and longer) ................................................................................................. 32

10.3.1 Draining the pump .............................................................................................................................. 32

10.3.2 Protecting the high pressure pump ..................................................................................................... 32

10.3.3 Filling the pump unit with anti-corrosion emulsion or anti-freeze solution. ......................................... 32

10.3.4 Equipment required for filling a pump unit if no suction installation is available ................................. 33

10.3.5 Method of filling the pump with anti-corrosion emulsion or anti-freeze solution using an external membrane pump ................................................................................................................................................. 33

10.3.6 Other protective measures ................................................................................................................. 33

11 Maintenance .................................................................................................................................................... 35

11.1 Fault finding and remedy ............................................................................................................................ 35

11.2 Maintenance ............................................................................................................................................... 36

11.3 Daily inspection ........................................................................................................................................... 36

11.4 Water filter inspection ................................................................................................................................. 36

11.5 Checks during operation ............................................................................................................................. 37

11.6 Oil change ................................................................................................................................................... 38

11.6.1 First oil change after 1000 operating hours ........................................................................................ 38

11.6.2 Next oil changes ................................................................................................................................. 39

11.6.3 Lubrication including oil filter ............................................................................................................... 40

11.6.4 Oil pressure adjustment ...................................................................................................................... 42

11.7 Repair & Replacement ................................................................................................................................ 42

11.8 Maintenance of the pump head 00.02145.1133 (-007) .............................................................................. 43

11.8.1 Disassembly (see fig.: Pump head & point: Piston seal assembly).................................................... 43

11.8.2 Assembling (ref. to fig.: Pump head) .................................................................................................. 45

Operating instructions Contents No: HDP 254




11.9 The plunger seal assembly 00.00743.2152 (-011) .................................................................................... 47

11.9.1 Disassembly ....................................................................................................................................... 47

11.9.2 Reassembly ....................................................................................................................................... 50

11.10 Changing the bellows ............................................................................................................................. 52

11.11 Torque tables ......................................................................................................................................... 52

12 Splitting nozzle 00.00792.0012 ...................................................................................................................... 54

12.1 Technical Data ........................................................................................................................................... 54

12.2 Description ................................................................................................................................................. 54

12.3 Installation .................................................................................................................................................. 54

12.4 Adjustment ................................................................................................................................................. 54

12.5 Maintenance ............................................................................................................................................... 55

12.5.1 Disassembly ....................................................................................................................................... 55

12.5.2 Reassembly ....................................................................................................................................... 55

12.5.3 Replacing the wearing parts: Bushing (10) and control pin (60) ........................................................ 55

13 Safety notes for high pressure hoses .......................................................................................................... 56

13.1 Before using the hose ................................................................................................................................ 57

13.2 Use of the hose .......................................................................................................................................... 57

14 Index................................................................................................................................................................. 58

Foreword Operating instructions No.: HDP 254




Pos: 1 /Technische D aten/Zu di eser Anlei tung/Überschrift @ 0\mod7_2.doc @ 1204 @ 1 @ 1 2 Foreword Pos: 2 /Technische D aten/Zu di eser Anlei tung/Hinweis @ 0\mod3_2.doc @ 1208 @ @ 1

All personnel who are responsible for the operation and maintenance of the High pressure pump HDP 254 must: Read and fully understand these instructions, especially the section “Safety“ before attempting to operate. Ensure that these instructions are always readily available to all personnel concerned.

Pos: 3 /Technische D aten/Zu di eser Anlei tung/Hers tell eradresse @ 0\mod4_2.doc @ 1212 @ @ 1

Manufacturer and customer services address: HAMMELMANN Maschinenfabrik GmbH

Zum Sundern 13 – 21 • 59302 Oelde • Germany

P. O. Box 33 09 • 59282 Oelde • Germany

Telephone: +49 (0) 25 22 76-0

Telefax: +49 (0) 25 22) 76-4 44

e-mail: [email protected]

http://www.hammelmann.de

Pos: 4 /Technische D aten/Zu di eser Anlei tung/Maschi nennummer @ 0\mod5_2.doc @ 1216 @ @ 1

Type: HDP 254

Serial no.: B3.01254.0377

Date: 2013

Pos: 5 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.doc @ 1188 @ @ 1

mailto:[email protected]

Operating instructions Technical data No: HDP 254




Pos: 6 /Technische D aten/Überschrift @ 0\mod8_2.doc @ 1196 @ 1 @ 1 3 Technical dat a Pos: 7 /Technische D aten/Pumpen/HD P 120/H auptabmessungen @ 0\mod12_2.doc @ 1456 @ 2 @ 1

3.1 Main dimensions

Fig. 1: Main dimensions of the high pressure pump

Weight of the pump: approx. 390 kg Pos: 8 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.doc @ 1188 @ @ 1

Technical data Operating instructions No.: HDP 254




Pos: 9 /Technische D aten/Pumpen/HD P 250/Leis tungsdaten HD P 254; 63 L; 2000 bar; 244kW; 52 L; 2400 bar; 241kW @ 9\mod_1365583814221_2.doc @ 75854 @ 22 @ 1

3.2 Performance data, High Pressure Pump

Make: HAMMELMANN High Pressure Pump HDP 254

Pressure step 1 Pressure step 2

Flow rate 63 l/min. 52 l/min.

Operating pressure: 2000 bar 2400 bar

Max. liquid temp.: 40° C 40° C

Crankshaft r.p.m.: 619 1/min 511 1/min

Piston/plunger dia.: 20 mm 20 mm

Rod force: 82 000 N 82 000 N

Stroke: 75 mm 75 mm

Req. motor rating: 244 kW 241 kW

Average piston speed at a crankshaft r.p.m. of:

385 1/min = 0,97 m/sec 465 1/min = 1,16 m/sec 555 1/min = 1,39 m/sec


Operating instructions Technical data No: HDP 254




Pos: 11 /Technische Daten/Pumpen/Aussage der Bestellnummer @ 0\mod413_2.doc @ 1428 @ 2 @ 1

3.3 Order Code Key

Key for code numbers for high pressure pumps and units.

09. X X XX X. X XXX Pos: 12 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.doc @ 1188 @ @ 1

to identify performance data (see performance table)

to identify design of water end

1 = Uniflow / piston 2 = Labyrinth 3 = Dynamic ceramic plunger 4 = Dynamic tung. carbide plunger 5 = Process pumps 6 = Sewer cleaning pump 7 = Packing 8 = Free 9 = Special design (according machine card)

to identify type of pump (power end) 02 = HDP 20 08 = HDP 86 17 = HDP 170 40 = HDP 400 03 = HDP 30 11 = HDP 110 19 = HDP 196 48 = HDP 480 04 = HDP 40 12 = HDP 120 23 = HDP 230 55 = HDP 550 05 = HDP 50 14 = HDP 146 25 = HDP 250 75 = HDP 750 07 = HDP 70 16 = HDP 160 38 = HDP 380 MC = HDP MC

to identify type of drive

0 = Without motor 5 = Freq. translation adj. 0 - 1800 1/min.

1 = Electric motor 400 V, 50 Hz / 460 V, 60 Hz 6 = Electric motor with special voltage

2 = Diesel engine, air cooled 7 = Electric motor free issued

3 = Diesel engine, water cooled 8 = Diesel engine free issued

4 = Freq. translation adj. 800 - 1800 1/min. 9 = Special drive according parts list

to identify type of assembly

0 = Bare shaft pump 1 = Short frame for electronic motor 2 = Long frame for e-motor + hose reel etc. 3 = Diesel on frame without fuel tank 4 = Diesel on frame, with fuel tank 6 = S 1000, S 1500, Aquajet units 9 = Special frames

to identify gear ratio

Technical data Operating instructions No.: HDP 254




Pos: 13 /Technische Daten/Pumpen/Aussage der Maschi nennummer @ 0\mod414_2.doc @ 1432 @ 2 @ 1

3.4 Machine number key

The machine number provides the following information:

XX. XX XXX. XXXX Pos: 14 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.doc @ 1188 @ @ 1

Internal number

Pump type i. e. for High pressure pump 072 = HDP 72 127 = HDP 127 174 = HDP 174 232 = HDP 232 353 = HDP 353

Free

Year of

i. e. 90 = 1990 A0 = 2000 A1 = 2001 A2 = 2002 A3 = 2003 etc. B0 = 2010 B1 = 2011 etc.

Operating instructions Safety No: HDP 254

Page 10, Issue: 04.2013



Pos: 15 /Sicherheit/Ü berschrif t @ 0\mod9_2.doc @ 1220 @ 1 @ 1 4 Saf et y Pos: 16 /Sicherheit/Pumpen @ 0\mod10_2.doc @ 1224 @ 22222222 @ 1

4.1 Dangers arising from non observance of safety instructions

Using the most modern manufacturing techniques HAMMELMANN produce high pressure equipment which is subject to stringent Quality, Function and Safety tests. Even so, improper or unsuitable use of high pressure equipment, or operation by untrained personal can result in accidents leading to:

Danger of death or injury.

Costly damages claims.

All personnel who are responsible for the operation and maintenance of high pressure equipment must, before they attempt operation be fully conversant with and completely understand the contents of this manual. Particular atten-tion must be paid to this section "safety" and these instructions must always be readily available to all personnel concerned. No claims for personal injuries or damages arising from ignorance or non observance of safety procedures can be accepted.

4.2 Safety conscious working

Always observe accident prevention rules (e.g. in Great Britain - "Health and Safety at Work Act”)! Refer to local statutory or recommended codes of practice for the use of water jetting equipment. If no codes of practice are in place in your country you are advised to obtain and adopt those of another country.

4.3 Personnel qualification and training

Only trained personnel should be entrusted with operation, maintenance, inspection and repair of high pressure water equipment. The owners of the equipment are responsible for ensuring that all personnel concerned are fully trained and conversant with the contents of this manual. If necessary, training courses should be arranged.

4.4 Precise safety instructions for the operator

The operation of water jetting equipment should only be entrusted to personnel who are,

fully conversant with the operation procedure.

fully aware of the inherent dangers.

Dangers are for instance,

reaction force.

cutting power of the jet.

hose shortening when pressurised.

working close to electrical sources or machinery.

In the case of bare shaft pumps never connect a driver that can exceed the pump max. power rating as given on the name plate.

A pump unit must always be fitted with a mains cut-off / ignition switch system.

An emergency switch is an essential component of any pump unit.

Safety Operating instructions No.: HDP 254

Page 11, Issue: 04.2013



Before each operation the employer should ensure that a competent or trained person has checked,

that units and / or equipment are in good condition and

that the important elements, i.e.: safety devices, hoses, hose connections etc. are in good order.

Any fault should be remedied before using the equipment.

Follow precisely all start up/shut down procedures given in the operating instructions

During operation regularly check the hoses, fittings and jetting accessories (i.e.: nozzles, spray bar) for signs of leakage. In the case of leakage stop the pump unit immediately.

Do not attempt a close visual inspection of leakage while the pump is running.

Use only the correct tools, i.e.: ensure that you have the correct spanner size to fit connection nuts etc.

Do not vary the pump pressure unless you have informed the accessory / machine operator that you are about to do so.

Upon shut down ensure that all elements of the equipment are depressurised (atmospheric pressure).

When using two or more consumers (i.e.: spray guns) from a single pump unit,

care shall be taken to ensure that the pressure regulating valve or unloader is correctly set so that the operation of any consumer (i.e.: spray gun) will not cause a sudden pressure change and / or excessive reaction forces.

Never use accessories, i.e.: hoses, spray pistols etc. above the maximum specified operating pressure. The maximum pressure of any system is only equal to the maximum pressure rating of the lowest rated component therein.

Position hoses,

so that they are not clamped or kinked and cannot chafe against sharp edges.

Interfering with safety elements is strictly forbidden! Damaging, e.g. the locking wire or seal coating will invalidate the guarantee and will release us from any liability in the event of accident or injury.

Use only accessories and spares from HAMMELMANN or their approved suppliers. Use of parts that are not marked as tested or that are supplied without a test certificate can be dangerous. Think of your own safety. (Also see guarantee conditions)

The employer must ensure,

that the workplace is cleared, offers a firm footing and there is no possibility of tripping.

Trailing lines, loose debris and tools do not make a safe workplace.

The jetting operator must ensure,

that there is no danger to neighbouring workers, and that the workplace is closed off with barriers.

signs are erected to prohibit unauthorised entry i.e.: Danger! High pressure water.

Operating instructions Safety No: HDP 254

Page 12, Issue: 04.2013



Causes of danger are,

the jet (cutting power).

spray mist (with dangerous chemical additives).

loose debris or other items picked up and projected by the force of the jet.

Avoid contact with any spray arrangement:

Do not place your hand or other bodily parts in front of a pressurised nozzle.

Never under any circumstances point an accessory (i.e.: pistol) at other persons even when depressurised.

Hazards to your health are,

the properties of the liquid (Wet, high temp, caustic etc.)

the high pressure (i.e.: cutting power of the jet, possible impact damage to tissue and bacterial infection).

To work with liquid jets the employer should ensure that all operatives wear protective clothing, i.e.:

Protective suit,

Safety helmet,

Flexible closed gloves,

Slip proof safety boots with foot and shin protection.,

Ear protectors,

Respiratory protector,

Safety glasses or full face visor.

Operatives ignoring the employers instruction to wear any of the above do so at their own risk!

In the event that a person is struck by a waterjet they must immediately report to or be taken to a doctor. Even seemingly minor injuries can have serious consequences! Liquids can be injected into body tissue leaving no obvious external damage!

4.5 Danger symbol

This symbol, always indicates an important safety instruction. You must read, understand and follow the instruction precisely!

Failure to follow such an instruction can result in extreme danger to persons and damage to property.

Safety Operating instructions No.: HDP 254

Page 13, Issue: 04.2013



4.6 Safety during inspection, maintenance and repair

The owner shall be responsible for ensuring that all inspection, maintenance and repair works are carried out by competent, fully trained personnel. He shall also ensure that said personnel have read and fully understood this manual.

Before commencing such works all safety and shut down instructions herein must be observed. Before starting such works on diesel engine driven units disconnect the battery cables. In case of e-motor driven units cut-off tension / unplug mains plug. Before restarting follow the instructions given in the section “Installation”.

4.7 Forbidden practices

Operating , maintenance and repair procedures other than described herein or unauthorised design modifications are forbidden on safety grounds. The manufacturer cannot be held responsible for any consequences arising from the fitting of unauthorised spare parts or accessories.

4.8 Additional warnings

When this high pressure equipment (i.e.: rotary joint, pistol etc.) is built into a high pressure system you must also refer to the safety and operation instructions of the other high pressure elements before use! Other elements are for instance:

Drive, Pump, Spray head or Spray bar, Surface cleaners, etc.

If using a diesel or petrol powered unit in an enclosed area ensure that there is sufficient ventilation and that exhaust gases are vented to atmosphere.

In the event that other high pressure accessories (i.e.: hoses) are used in conjunction with this unit then the relevant manufacturer's or supplier's operation instructions should be observed and followed in all cases.

If your pump unit is mounted on a roadworthy trailer you must ensure that the towing vehicle is suitable for the weight! See construction and description section for trailer details.

Drivers must ensure that towing vehicle and trailer are in a roadworthy condition and that they comply with local traffic regulations.


Operating instructions General No: HDP 254

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Pos: 18 /Allgemeines /Überschrift @ 0\mod150_2.doc @ 1340 @ 1 @ 1 5 General Pos: 19 /Allgemeines /Pumpen/1. Einl eitung @ 0\mod425_2.doc @ 4548 @ 2 @ 1

5.1 Introduction

Your HAMMELMANN High pressure pump is the product of many years of research, development and testing in the field of high pressure manufacture.

Modern design and production procedures allow us to place the highest demands on the quality of our products. For you, this means:

High precision manufacture,

high reliability and

efficiency. Pos: 20 /Allgemeines /Pumpen/2. Anwendungsbereich @ 0\mod426_2.doc @ 4552 @ 2 @ 1

5.2 Application

There are many applications for HAMMELMANN High and Ultra high pressure pumps, i.e.:

Liquid dosing and transportation.

Hydrogenation and cracking processing.

Decoring and cleaning castings.

Water jet cutting.

Building, bridge, highway renovations.

General high pressure cleaning

of flat surfaces,

transportation and production plants,

of the inside and outside of pipes and tanks etc.

Use only HAMMELMANN accessories designed for the maximum pressure of your high pressure pump (unit).

If you have any questions concerning accessories or special application techniques please contact HAMMELMANN or an accredited agent. Pos: 21 /Allgemeines /Pumpen/3. Einsatzbedi ngungen 4er Serie @ 0\mod470_2.doc @ 4544 @ 2 @ 1

5.3 General permissible operational conditions

Unless otherwise stated in writing (contractually) by HAMMELMANN the following operational conditions apply:

Use only clean water. Any solids must not exceed a max. particle size of 1 µm or a concentration of 50 mg/l. (Ensure suitable filtration is installed). Water supply temperature must not exceed 40°C. Do not use demineralised or completely desalted water.

The max. permissible feed velocity is 1 m/sec. at a necessary admission pressure of min. 3 bar to max. 10 bar.

Before attempting to introduce any cleaning fluids obtain written approval from HAMMELMANN! Cleaning fluids should not attack the nonferrous heavy metal (bronze)! Under no circumstances introduce cleaning fluids containing Amine or Phosphate.

Pos : 22 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.doc @ 1188 @ @ 1

General Operating instructions No.: HDP 254

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5.4 Copyright

The copyright of these operating instructions is the property of HAMMELMANN GmbH. These instructions contain technical descriptions and illustrations that may not be electronically stored or reproduced in whole or in part or be passed to third parties in any form whatsoever without the written permission of the owners.

We are protected by law against contravention of the above and will take appropriate action if necessary. Pos: 24 /Allgemeines /Pumpen/5. Gar antiebedi ngung en @ 0\mod430_2.doc @ 4564 @ 2 @ 1

5.5 Warranty terms

Corresponding to our general business conditions we guarantee a warranty of 24 months or 2000 operating hours, excluding normal wearing parts.

The guarantee would be invalidated if:

The equipment was used for purposes under other than our admissible conditions.

The leads at the safety organs are injured.

The high pressure pump was used with accessories or fitted with spare parts not supplied by HAMMELMANN.

If the damage is caused by:

Improper use.

Ignoring the maintenance instructions.

Use beyond the provided operative range.

Unsuitable flow medium.

Faulty installation.

Incorrectly or not professionally positioned pipe lines.

Unauthorized changes or reconstruction’s.

Cavitation

If there is the need of a Guarantee Claim Application can be demanded from HAMMELMANN.

The contents of the operating instructions and product documentation shall not become part of or modify any prior or existing agreement, commitment or relationship. All the obligations of HAMMELMANN result from the sale contracts which is also the complete and only valid guaranteed rules. Any statements contained herein do not create new warranties or modify the existing warranty.


Operating instructions Transportation No: HDP 254

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6.1 Packing

Method of packing is determined by method of transport. At the minimum the pump unit will be protected from the elements.

Packing symbols (for example).

This way up Keep away from heat Sling here Keep dry

Fragile handle with

care Centre of gravity No hand truck here Use no hooks

Do not use forklifts or similar transportation

units

Transportation Operating instructions No.: HDP 254

Page 17, Issue: 04.2013



6.2 Transportation

Normally a pump unit will be transported without fuel in the tank. Sometimes the pump and engine will have been drained of oil and in some cases the cooling system will also be drained.

Please check the pump unit for notices as to its delivery condition.

For safety precautions will have been taken to stop leakage of fuel, oil etc. during transportation.

6.3 Transport

If your pump unit is mounted on a roadworthy trailer you must ensure that the towing vehicle is suitable for the weight! See construction and description section for trailer details.

Drivers must ensure that towing vehicle and trailer are in a roadworthy condition and that they comply with local traffic regulations.

Only lift trailers with a suitable lifting device on the lifting point!

6.4 Protection

All pumps and pump units only leave our works when they have undergone a strict test procedure. At the end of the test an anti corrosion emulsion is introduced and the pump is run for a minute. This is to ensure that all water bearing parts such as plunger, pump head etc. are completely protected against corrosion. As an extra precaution all exposed polished metal parts are sprayed with Optimol F + D protective fluid.

The above precautions do not hinder the initial start up of the pump. The coating of F + D in fact acts as a lubricant and prevents wear. The anti corrosion emulsion is very quickly flushed out by the high pressure water.

The protection process is suitable for the transport period between our works and reaching the customer. If the pump is to be stored for an indefinite period of time before operation further precautions will be needed. Please ask you HAMMELMANN agent for advice. Our recommendations can be found in the section “Shut down” paragraph 3. Pos: 28 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.doc @ 1188 @ @ 1

Operating instructions Construction & Description No: HDP 254

Page 18, Issue: 04.2013



Pos: 29 /Aufbau und Beschrei bung/Ü berschrift @ 0\mod155_2.doc @ 1372 @ 1 @ 1 7 Construction & Description Pos : 30 /Aufbau und Beschrei bung/Ü berschrift Konstrukti ver Aufbau @ 0\mod156_2.doc @ 1376 @ 2 @ 1

7.1 Construction Pos : 31 /Aufbau und Beschrei bung/Pumpen/HD P 250/Aufbau HD P 254 @ 1\mod779_2.doc @ 6024 @ @ 1

Fig.: Construction of the high pressure pump HDP 254

Item no. Description Item no. Description

10 High pressure discharge 90 Oil drain valve

20 Pump head 120 Oil dip stick

30 Nameplate 130 Suction connection

40 Oil pressure gauge 140 Suction chamber

50 Oil pump 150 Cover plate

60 Oil pressure regulator 160 Drive shaft

80 Oil cooler / Oil filter combination 170 Mounting holes


Construction & Description Operating instructions No.: HDP 254

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7.2 Description

7.2.1 General description of the pump

The high pressure pump HDP 254 is a compact, five plunger pump containing the unique HAMMELMANN plunger seal assembly. The special advantage of this pump is the high pressure plunger seal which reduces friction losses and apparitions of wear to an absolute minimum. That guarantees a long working time under highest pressures.

7.2.2 Crank section with pressurised lubrication system

The crank section is precision built to withstand heavy loads. The rotary motion of the drive shaft transmits to an oscillating motion at the pump plungers via five 72° offsets with conrods and crossheads. The crankshaft is an assembly made from ductile, hardened and tempered steel. The helical gear wheels are located in the middle area of the crankshaft. The storage of the crankshaft is carried out by two roller bearings on the ends of the crankshaft Conrods have bush bearings both ends running on hardened, polished surfaces at the crankshaft and gudgeon pins.

The pressurised oil lubrication system consists of oil pump, oil cooler – filter combination and oil pressure gauge. Conrod bearings are lubricated via oil channels in the crankshaft and the gudgeon pins via channels in the con-rods. The crank section is sealed with O-rings and gaskets and the drive shaft by a rotary shaft seal.

Observe the oil pressure! The ideal oil pressure should be between 3 and 6 bar. A safety shut off is carried out at 2 bar.

7.2.3 Piston seal assembly

This further development of the low wear labyrinth seal features a unique, replaceable labyrinth insert. The insert is subjected to dynamic force which maintains the seal between it and the plunger. This metal to metal seal is particularly suitable for high and ultra high pressures. The small sealing area reduces friction on the plunger and combines good mechanical efficiency with very high volumetric efficiency.

The plungers are machined from tempered non rusting stainless steel and offer a long working life under maximum load.

7.2.4 Pump head

The pump head housing is machined from a single block of high grade stainless steal and is free of alternating stress and therefore not subject to fatigue cracking. The uncomplicated suction and discharge valve sets allow easy maintenance.

It operates as follows:

Operating instructions Construction & Description No: HDP 254

Page 20, Issue: 04.2013



On the downward stroke of the plunger:

closes the suction valve,

pressure drops from suction pressure to valve opening pressure,

pressure valve opens,

flowing in the pressure line.

On the suction stroke of the plunger:

pressure valve closes,

pressure rises from flow pressure to suction pressure,

suction valve opens,

suction of the medium from the low-pressure part (suction chamber).

Fig.: Functional description


A Pressure chamber E Sleeve

B Pressure valve F Plunger

C Suction valve G Conrod

D Suction chamber H Crankshaft


Suction water

Discharge water

Installation & Start up Operating instructions No.: HDP 254

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Pos: 35 /Vorber eitung zur Inbetri ebnahme/Installation/Ü berschrift @ 0\mod168_2.doc @ 1380 @ 321 @ 1 8 Installation & St art up Pos: 36 /Vorber eitung zur Inbetri ebnahme/Installation/Pumpen/Vorbereitung zur Inbetriebnahme 4er Serie @ 1\mod990_2.doc @ 5624 @ 2322222 @ 1

8.1 Connecting the driver

The high pressure pump can be driven by:

Electric motor (with or without variable frequency drive)

Diesel engine

Electric motors should be always have a main isolating switch. If one is not fitted please install one! Electrical installation should only be carried out by qualified technicians!

If an electric motor with a variable frequency drive is employed with a speed range of zero to maximum a separate electrically powered oil pump must be installed. For speed ranges starting above zero please consult Hammelmann.

Adhere to the installation instructions to the operating instructions of the electric motor / diesel engine manufacturer!

The driver power must be transmitted to the pump by a flexible coupling.

Checks the adjustments of the coupling, if necessary readjust.

Pump direction of rotation is marked on the housing (normally clockwise).

8.2 Suction (feed) side installation

The pumped medium can only emit from the pump smoothly under high pressure if:

The medium is totally free from air or gas bubbles.

The correct volume of medium is available.

The suction line is as free as possible of elbows, T-pieces, restrictions and other items that cause turbulence.

The water flows has a low feed velocity and unhindered flow.

Feed velocity: » max. 1m/sec

Feed pressure: » min. 3 bar » max.16 bar in the pump suction chamber.

Operation with other parameters requires our written permission. If you install a buffer tank, boost pump, filter arrangement the ideal feed line pressure prior to the tank is 5 to 6 bar and the boost pressure to the filter must be under the maximum operating pressure of the filter (10 bar if using a Hammelmann filter). Install a pressure reducing valve in the feed line if necessary.

The boost pump for a diesel engine powered unit will be belt driven. Refer to the diesel engine manufacturer’s instructions for installing PTO driven ancillary equipment.

A boost pump for an electrically powered unit must be driven by an independent electric motor. It must be wired to the control panel so that when the main pump motor is started the boost pump motor starts before the main pump motor and when the main motor is stopped the boost pump motor stops after the main pump motor.

Operating instructions Installation & Start up No: HDP 254

Page 22, Issue: 04.2013



To prolong the life of wearing parts such as valves, control pistons etc. you must ensure that the medium is as clean as possible. There is no substitute for adequate, efficient filtration. Solids, especially abrasive solids in the medium will curtail the working life of wearing parts. Install a suitably sized filter system between the boost pump and the suction chamber of the high pressure pump. A blocked medium filter can cause cavitation and damage the pump. Damage to the pump caused by cavitation is excluded from the guarantee. Therefore we recommend the installation of a low pressure cut off (with monitoring) to immediately switch off the high pressure pump in the case of a blocked filter. Any suction side cut outs installed must be set at 2 bar.

If you are not sure how to design a pipe work system to prevent ingress of air, ingress of foreign matter, high medium velocity etc. especially if you intend to re-circulate the medium then do not hesitate to seek advice from you Hammelmann agent or from Hammelmann customer services.

Filters are available from HAMMELMANN to eliminate abrasive particles larger than 1µ and concentrations above 50 mg/l.

Water quality for series 4 ultra high pressure pumps.

Type 4

Max. particle size / Filtration degree 1 µm

Max. content solids 20 mg/l

Max. total hardness 3 - 10°dH

Max. hardness (CaCO3) 50 - 175 mg/l

Max. content iron (Fe) 0.5 mg/l

Max. content chlorine (Cl) 100 ppm

Max. content sulphate (SO4) 100 ppm

Max. content phosphate (PO3) 50 ppm

Free chlorine 1 mg/l

pH 6,5 – 8,5

* Depending on type of particle (hardness) No additives with corrosive effect on non-ferrous heavy metals (if to be used consult HAMMELMANN). In certain cases variations from the above may be possible! HAMMELMANN offer suitable filter systems.

When used in high pressure washing de-burring machines or cutting tables etc. follow our specific the instructions for these applications.

The water hardness for 4 series pumps (ultra high pressure pumps) must not exceed 10° German hardness! If the water is harder a water softening unit must be installed. However, in that case ensure that the quality does not fall below 5° German hardness.

Observe the minimum electric conductivity of 300 µS/cm.


Page 23, Issue: 04.2013



Conversion table for the various hardness degrees and units

Definition

Hardness degrees and units

mval/kg German °dH

French °f

English °e

American. ppm mmol/l

28 mg CaO oder 50 mg

CaCO3 per 1000 ml

water

10 mg CaCO3

per 1000 ml water

10 mg CaCO3

per 1000 ml water

1 gran CaCO3 per gallon 14,3 mg

CaCO3 per 1000 ml water

1 part CaCO3 per million

1 mg CaCO3 per 1000 ml

water

1000 mg CaCO3

per 1000 ml water

1 mval/kg 1o dH 1o f 1o e 1 ppm 1 mmol/l

1,0 0,357 0,2 0,286 0,02 2,00

2,8 1,0 0,56 0,8 0,056 5,60

5,0 1,78 1,0 1,43 0,1 10,00

3,5 1,25 0,7 1,0 0,07 7,02

50,0 17,8 10,0 14,3 1,0 100

0,50 0,18 0,10 0,14 0,01 1,0

The pump can become contaminated due to:

An extremely high feed velocity.

Connecting a seldom used supply line.

Taking supply from a fire hydrant.

8.3 Calculating the suction and discharge hose internal diameters (DN)

To determine the internal diameter of the hoses refer to the diagram below.

Example 1 (--------)

A speed of v = 0.45 m/s and a flow rate of Q = 150 l/min. The straight connection between these two values on the scales results in the hoses DN 80 on the centre scale.

Example 2 (_____)

A speed of v = 5,5 m/s and a flow rate of Q = 66 l/min. The straight connection between these two values on the scales results in the hoses DN 16 on the centre scale.

Discharge hoses for series 4 pumps are generally limited to 5 mm and 8 mm internal diameters. For large series 4 pumps with relatively high discharge flow rates it will probably be necessary to use multiple discharge hoses to prevent significant pressure loss. This must be taken into consideration when selecting discharge fittings. Discharge hose connections to the pump, connections between hose lengths and connections to the consumer(s) should be anchored with some form of hose arresting device. Hammelmann can supply UHP hoses complete with arresters installed or can supply arresters separately to fit most types of UHP hose on the market.


Page 24, Issue: 04.2013



Fig.: Diagram

Optimum flow velocities:

Suction side: 0.5 m/s

Pressure side: 5,0 m/s

Not taken into consideration:

The resistance of pipes, bends, valves.

The viscosity and the effects of temperature on viscosity and other influencing factors.

Friction between hose / pipe work internal wall.


Page 25, Issue: 04.2013



Fig. Pressure loss in hoses and pipe work.

The pressure loss represented here is related to 1 m length and increases linearly with increasing hose / pipe length /theoritical values).


Page 26, Issue: 04.2013



8.4 Connections to the ultra high pressure pump outlet (discharge side)

All components on the ultra high pressure outlet (discharge) side (hoses, fittings, pipe work etc.) must be designed to safely withstand the pump maximum operating pressure and flow rate. Carefully check the performance parameters marked on the components before installing them. Please contact your Hammelmann agent or Hammelmann customer services if you require advice on permanent discharge pipe work.

Hammelmann have designed a wide range of discharge fittings and accessories specifically for use with series 4 UHP pumps. Please contact you Hammelmann agent or Hammelmann sales department if you require advice on the selection of discharge side fittings and accessories.

8.5 Installation of hoses, pipe work and cables

Before installing any ancillary items it is, especially in the case of fixed stationary pump units, important to address the issue of positioning.

A fixed, stationary pump unit with pipe work must be positioned to comply with the good engineering practices for suction and discharge installations as described in these instructions. Additionally the floor or plinth must be as level, flat and smooth as possible. Never anchor a stationary unit directly to the floor or plinth. Always use anti-vibration mountings between the pump unit base frame and the floor/plinth. Ensure that the unit has adequate ventilation.

A mobile pump unit employing suction and discharge hoses must be positioned on as flat and level ground as possible. If the unit is built into any form of enclosure (sound damping cover etc.) ensure that it is positioned so that air intakes and air exhaust outlets are not blocked off by walls or vehicles etc. Mobile pump units must have the handbrake engaged and / or wheel chocks deployed before making any connections.

The following connections can be made to a series 4 high pressure pump unit:

Suction hose / pipe work (between water supply point and the pump.

Oil cooler water out to waste or back to tank.

Plunger cooling.

Highest pressure discharge hose / pipe work line.

Bypass line hose / pipe work to waste or back to tank.

Burst disc over pressure safety device outlet tube to waste.

Control cable for electrically actuated bypass from manual tools (i.e. water blasting gun).

Control system and monitoring systems. Connect pressure and temperature transmitter (sensor). Check the functions at test run.

Pneumatic control lines (hoses) (i.e. control line to membrane cylinder of bypass or pressure regulating valve, or to pneumatically powered or actuated accessories (i.e. water blasting gun).


Page 27, Issue: 04.2013



Notes on connecting the ancillaries.

Suction hose / pipe work.

To install a suction hose remove the protective cap (if fitted) from the supply line connection and ensure that the connection is clean. Let the water run for a minute or two to flush out any residue and then turn off the supply and connect the suction (feed) hose to the supply line.

Turn on the supply again and flush the suction hose until the water is completely clean. Turn the supply off and connect the free end of the hose to the pump suction connection.

On fixed installations with permanently installed suction pipe work you must ensure that the complete system is clean and free from fabrication debris before making the final connection to the pump unit.

Oil cooler line.

This is a push fit hose connection on the cooler. The cooling water emits without pressure and can be run to waste or back to the pump suction side tank (if fitted).

Separate oil cooler supply.

Normally the oil cooler supply is from the suction chamber but if the suction water is above 35°C a separate supply with a lower temperature must be provided.

On fixed installations do not feed bypass or oil cooler water back to another return line unless that return line is also without pressure.

Plunger cooling.

Never close off the plunger cooling drain hose/ line. The plunger cooling water must be able to flow freely away. If necessary run the hose to a suitable container or similar.

High pressure hose / pipe work

To fit a high pressure hose remove the protective cap or threaded plug from the H.P. pump water discharge connection. Ensure the mating thread is clean and then smear with Molykote (1000 anti-seize) grease. Remove the cap from the hose and repeat the cleaning and greasing procedure. Connect the high pressure hose and tighten to a torque value as per the table below. This procedure should be followed when fitting hose extensions and the consumer (water blasting gun etc.).

The cleaning and greasing procedure should be applied threaded fittings in permanent high pressure pipe work such as ring lines for high pressure water blasting with several discharge points around the plant, ship, automobile paint spray line etc. We recommend that you fit a length of high pressure hose between the pump discharge fitting and the ring line connector to damp the inherent pulsation from the pump and reduce vibration in the line. Ring lines should be attached to structures with cushioned pipe clamps. Discharge pipe work connected directly to the pump discharge (as is often the case in production processes) should be flexible enough to counter the effects of discharge pulsation.


Page 28, Issue: 04.2013



Torques for ultra high pressure hoses with pressure screw and pressure ring

Nominal i/d Connection thread Spanner size in mm Torque in Nm

5 M 14 x 1,5 LH Pressure screw M 30 x 2 (A/F 32) 70



For your own safety: Check all hoses and pipe work connections for tightness a second time.

Bypass line

The standard bypass connection is a “push fit” connector on the Hammelmann bypass valve. We recommend a clear plastic hose held in place by a hose clip. The bypass line is used to dispose of the water when the consumer is closed and the pump is running without pressure. The water can run to waste or back to the pump suction side tank (if fitted).

Burst disc outlet

In the event of a burst disc rupture medium will emit from the burst disc assembly initially at high velocity. We recommend fitting a steel (Ermeto type) tube between the burst disc assembly and the pump unit base frame. The burst disc assembly is attached to the Hammelmann bypass valve.

Electric control cable

If you have installed an electrical bypass control system for use with Hammelmann four pole electrically actuated blasting tools or key switch remove the protective caps from plugs and sockets. Ensure they are clean and dry before connecting.

Never connect or disconnect a cable when a system is running!

Pneumatic control line

Connect the pneumatic control hose (i.e. for pneumatically driven high pressure blasting gun) onto the push lock connection of the unit. Ensure that connections are in order and clean.


Operation Operating instructions No.: HDP 254

Page 29, Issue: 04.2013



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9.1 Pre-start checks

Check the pump oil level and top up if necessary. The oil level should not be below the minimum shown on the dip stick.

Also check if there is water i the oil (emulsion). If found determine and dispose of the cause. Then change the oil and start (see section "Maintenance", paragraph "oil change")

On diesel driven units: Check the oil level of the diesel engine and top up if necessary.

Check the condition of the filter housing and inlet. If dirty clean the filter housing and fit new filter cartridge.

Before start up:

Remember that when working with hand hold accessories attached to hoses the operative should have a firm grip on the accessory and a sure footing before start up! If a hose is pressurised and not controlled it could whiplash causing damage or injury.

9.2 To start the unit

The jetting operator should have a good foothold and firm control of the jetting tool but with the trigger(s) in the “OFF” position.

High pressure water is a highly effective cutting tool and therefore dangerous!

Never point a pistol, lance etc. at other personnel under any circumstances even if unpressurised!

Open water supply to the pump.

the water admission pressure (min. 3 bar) and

Release the emergency stop button .

Starting the engine.

Check the oil pressure!

At 2 bar min. oil pressure turn the high pressure water on.

Check previously values (r.p.m. or pressure dependent of the control). If necessary adjust the values (dependent of the control or pressure regulating valve).

Jetting operator can now engage trigger(s) and commence blasting.

During operating a second operator should control the manometers of the pump, i.e. if the pressure always increases continuously, and he should also oversee the jetting operator.

In the event of accident, machine problem, signs of leakage the pump operator must imme-diately press the emergency stop button. For reasons of safety pull off the ignition key and protect it in a safe place.

Operating instructions Operation No: HDP 254

Page 30, Issue: 04.2013



9.3 Setting the operating pressure

9.3.1 by manually operated pressure regulating valve

Increasing pressure: by turning the eccentric lever clockwise.

Decreasing pressure: by turning the eccentric lever anti-clockwise.

Relieve the eccentric lever means take away the pressure and tension the eccentric lever means the pump is at idle speed.

9.3.2 by pneumatically operated pressure regulating valve

When the pressure regulating valve is charged with air the pump is running under pressure.

The maximum control air pressure is 4 bar. At a control air pressure of 4 bar the max. operating pressure is set.

Reducing the control air pressure reduces the discharge pressure of the pump.

Closing the air supply returns the pump to idle speed.

9.3.3 by setting the r.p.m. of the drive engine

With diesel powered units or thyristor controlled electric powered units it is possible, in conjunction with a suitable control system, to regulate the operating pressure by adjusting the driver speed. This is only possible when using diesel engines with i.e. automatically operated pressure regulating valve, pressure absorption’s and regulating motors.

When the motor is fully loaded the max. control air pressure is set from the operator so that the max. operating pressure stands in line.

The operator can set the operating pressure by setting the r.p.m.

max. motor r.p.m. => max. operating pressure

min. r.p.m. => min. operating pressure or pump running at idle speed

When using pressure regulating valves the blower output is set on bypass and the r.p.m. is set back to idle speed if the consumer is turned off (i.e. by releasing the trigger of the spray gun). Pos: 40 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.doc @ 1188 @ @ 1

Shut down Operating instructions No.: HDP 254

Page 31, Issue: 04.2013



Pos: 41 /Ausserbetri ebnahme/Ü berschrift @ 0\mod182_2.doc @ 1408 @ 222122333 @ 1 10 Shut down Pos: 42 /Ausserbetri ebnahme/Pumpen/Ausserbetriebnahme allgemein @ 0\mod418_2.doc @ 5704 @ 2222223333333 @ 1

These instructions cover stopping the unit, overnight shut down and extended shutdown. If the pump unit is located outside and there is any danger of overnight freezing the complete pump unit must be drained and charged with anti-freeze solution.

10.1 Stopping the unit

On a diesel engine powered unit:

Deactivate the consumer (blasting gun, key switch etc.) so that the pump is bypassing and running at idle speed.

Allow the engine to run freely at idle speed for 2 or 3 minutes to cool it down.

Switch off the engine.

Actuate the consumer to drain the remaining water from the discharge side.

Operate the emergency stop button. If it is the lockable type lock it and remove the key for safe keeping.

Shut off the suction (feed) line.

On an electric motor powered unit:

Deactivate the consumer and open the bypass.

Switch off the motor.

Operate the emergency stop button. If it is the lockable type lock it and remove the key for safe keeping.

Isolate or unplug the mains power supply.

NOTE! Electrically powered, fixed installation pumps that are part of a production process or that are installed as part of a machine in a process will normally have local or remote controls or both. Follow the plant and/or machine manufacturer’s stopping procedures.

10.2 Overnight shut down

Carry out the daily inspection (see section "Maintenance").

If the pump is built into water blasting unit the following actions may be necessary depending upon the configuration of the unit.

Disconnect hose arrester, water and electrical connections (if fitted) at the water blasting tool and store them carefully. Either plug/cap the hose connections or place polythene bag over them and secure with adhesive tape.

Disconnect the high pressure hoses and the hose arresters. Clean threaded connectors and smear with Molykote (1000 anti-seize) and protect them as described above. Inspect hose covering for damage before storing.

Clean high pressure connections at the pump, smear with Molykote and fit protective caps.

Disconnect the control cable and fit a cap on the plug. Inspect isolation of the cables for damage (while reeling onto cable drum). Cap the connector at the pump.

Disconnect suction, bypass and cool water hoses. Clean couplings and protect with caps. The suction hose connections should also be cleaned, and protected if necessary.

If the operator’s panel is fitted with a cover close it, lock it and remove the key for safekeeping.

During an overnight shutdown without risk of freezing there is no need to drain the unit if you have been pumping drinking quality water. If there is any danger of freezing the pump must be protected (see sections protecting the pump onwards).

Operating instructions Shut down No: HDP 254

Page 32, Issue: 04.2013



10.3 Extended shut down (14 days and longer)

Whenever an extended shut down is envisaged the pump and its accessories should be stored in a heated, dry atmosphere if possible. Several precautions should be taken to ensure that a future start up is trouble free. Firstly the procedures for overnight shut down should be carried out except that the high pressure discharge, overflow discharge and oil cooler discharge outlets should not be capped but left open.

10.3.1 Draining the pump

If fitted drain the buffer tank, oil cooler, filter and boost pump. On HAMMELMANN supplied boost pumps oil coolers and filters, ¼ to ½ turn with a 12 mm A/F spanner is sufficient.

Open the overflow, and high pressure connections.

Ensure the suction connection is fully closed off.

Run the pump at idle speed for a few seconds, so that the remaining water can flow out of the pump easier. This is not critical when rinsing with emulsion but is essential when protecting against freezing.

It is not possible to drain a pump unit completely so draining alone does not offer 100% protection against corrosion or frost damage. The oil cooler is particularly susceptible to freezing so unscrew the oil cooler hose and blast through with compressed air.

10.3.2 Protecting the high pressure pump

As anti-corrosion emulsion we recommend: (NOTE! This is not anti-freeze.)

90 % clean fresh water

10% Shell 9156 or equivalent

As anti-freeze we recommend:

Glysantin G48 or any other commercial anti-freeze engine coolant in a solution as recommended by the manufacturer. Anti-freeze also acts as a corrosion inhibitor. Anti-freeze can be drained for reuse at the end of the shutdown period.

Do not use windscreen washing / de-icing fluids.

10.3.3 Filling the pump unit with anti-corrosion emulsion or anti-freeze solution.

Depending upon the size of the pump unit you will need 100 litres to 200 litres of solution.

Fill the buffer tank (if there is no suction side installation on the pump unit) with the solution.

Start the engine/motor.

Observe that the solution is emitting the high pressure discharge, bypass, oil cooler return and plunger cooling

Close all drains.

Stop the engine /motor.

Close the high pressure discharge.

Shut down Operating instructions No.: HDP 254

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10.3.4 Equipment required for filling a pump unit if no suction installation is available

Following items should be prepared for protecting the pump:

Membrane pump (electric or manual) with a min. pressure of 1,5 bar.

Lengths of hose to connect membrane pump to suction connection.

Length of hose to fit to the high pressure discharge.

An emulsion container.

10.3.5 Method of filling the pump with anti-corrosion emulsion or anti-freeze solution using an external membrane pump

Close filter drain cock (if fitted).

Ensure hose connection is clean, smear with grease and connect to the high pressure discharge.

Fit a suction hose to the membrane pump. Open the pump suction connection and fit hose between it and the membrane pump.

Fill container with emulsion/solution.

Place the free ends of the membrane suction hose and the high pressure discharge hose into the container.

Operate the membrane pump.

Observe the overflow and oil cooler connections. When undiluted emulsion/solution is emitting close both these off.

Continue pumping. Remove the high pressure discharge hose from container and observe until undiluted emulsion/solution is emitted. Place hose back into the container.

Continue pumping for a minute or so. The emulsion/solution can be strengthened if necessary. i.e.: add more Shell 9156 to the emulsion.

Stop pumping. Remove the hose from suction connection and cap/close the connection.

Remove the hose from the high pressure discharge. Clean, grease and cap both discharge and hose connections.

10.3.6 Other protective measures

Shut downs for a half year or longer. Additionally drain the pump oil at operating temperature. Completely fill the crank section of the pump with Aral Konit SAE 20W20 (or comparable) preserving oil. (The procedure of changing the oil can be seen in section "Maintenance").

Seal the dipstick opening.

Remove intermediate chamber cover plate. Clean and thoroughly dry the chamber. Spray the exposed plungers with Optimal F + D fluid. Do not spray or lubricate tungsten carbide plungers in any way.

On diesel units disconnect the battery leads. Check battery acid level and top up if necessary.

Also on diesel units completely fill the fuel tank and observe the engine manufacturer’s shutdown instructions.

Operating instructions Shut down No: HDP 254

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Hoses

Before undertaking the greasing and protection procedure described previously thoroughly dry the connections carefully using compressed air.

Take extra care when capping or protecting with polythene. Do not coil too tightly. Ensure there are no kinks in the hose.

Accessories

Thoroughly clean and dry all accessories. Pay particular attention to the connectors. Grease and protect threads as described above.

Ensure electrical connectors are capped or protected. They must be completely dry (Repeat for the cable drum).

Remove all nozzles for separate storage. Grease the threads of the nozzle holders and protect against ingress of dirt.

A light film of protective fluid spray can be applied to metal surfaces.

Do not use any protective fluids that could penetrate and damage seals, bearings etc.

Re-commissioning after shut down should be preceded by checks as described previously in this manual.

The draining procedures (re-fit batteries on diesel units) described previously should be carried out to remove the emulsion/anti-freeze solution. Drain preserving oil and refill with normal oil as described in the section “Maintenance” paragraph “oil change”.


Maintenance Operating instructions No.: HDP 254

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Pos: 44 /Instandhal tung/Ü berschrift @ 0\mod185_2.doc @ 1416 @ 221223333 @ 1 11 Maintenance Pos: 45 /Instandhal tung/Pumpen/Störungen und Wartung @ 0\mod419_2.doc @ 1496 @ 222222233233 @ 1

The pump unit must be switched off and all lines depressurised before attempting to check hose connections and leakage points or making inspection and remedy!

11.1 Fault finding and remedy

Faults Possible causes Remedy

Pressure too low.

Pump is sucking air. Locate leakage and repair.

Pressure regulating valve is leaking or incorrectly set. Eliminate leakage or reset.

Valve set(s) seals defective. Fit new seals.

Damaged suction and pressure valve(s).

Suction valves can be reground or replaced. Damaged discharge valves should be replaced. Check condition of valve springs.

Burst disc rupture. Maximum pressure exceeded. Replace burst disc. Check why

pressure exceeded. Remedy fault.

Pump noisy. Suction side medium shortage. Check suction side installation.

Extreme pulsation, H. P. discharge line.

Suction or pressure valve(s) sticking. Rework or renew as necessary.

Water leaking form suction chamber / intermediate chamber.

Low pressure seal pack(s) defective. Replace seals.

Oil leaks into the intermediate chamber.

Defective seal(s) at plunger rod / crosshead.

Check seals and bellows if necessary renew.

Too much oil in crank. Drain oil to correct level.

Oil leaks from the crank case. Check sealings and rotary shaft seals at the crank housing. If necessary renew sealings.

Oil emulsion emits from breather. Medium entering crank section. Change the oil, including cleaning /changing the filter, renew the seals. (ref. to oil change). Check the bellows. If necessary renew.

Dipstick shows signs of emulsion. Medium in crank section.

Causes of air or gas bubbles (cavitation) in the pump

Suction side line with bad flow characteristics.

Fluctuating or insufficient supply of medium.

Too short or too small a diameter suction side supply line.

The temperature of the medium is too high in relation to the pressure. For instance the boiling point of water considerably decreases in a vacuum. i.e.: the boiling point is at 70°C at 3 m water column vacuum. (10 m water collumn = 1 bar) (for damages of cavitation there is no warranty)

Operating instructions Maintenance No: HDP 254

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11.2 Maintenance

The crank section with its rotating and sliding parts should be carefully maintained. It is important to regularly check the oil level and top up as necessary and to change the oil.

11.3 Daily inspection

Check the following:

Check pump and engine oil level (diesel engine). Top up if necessary. Never run below min. level.

Check the intermediate chamber for excess leakage water.

Only remove chamber cover plates when the pump unit is stopped.

Also check for signs of water (emulsion) in oil. If found do not run the pump, check the reason and remedy the fault. This is normally means referring the problem to HAMMELMANN or their accredited agent.

Check the water filter for dirt.

Check the condition of the filter housing and of the filter insert. If necessary clean or replace.

Check condition and tension of all belt drives.

All other parts of a high pressure pump unit, i. e. drive motor.

11.4 Water filter inspection

At the daily inspection you must check the water filter, if there are any signs of dirt or blockage the filter must be replaced and the filter housing must be cleaned. To get an access stop the unit, close off the water supply and:

Detach water supply hose from connection.

Open the filter drain clock ½ a turn using 12 mm A/F spanner.

Loosen the ring screws on the filter and turn the screws upwards.

Remove the cover and the filter cartridge.

Take out and check the filter cartridge. The changing of the cartridge is necessary.

At high pressure pumps with a operating pressure up to 1500 bar every 100 operating hours.

At high pressure pumps with a operating pressure over 1500 bar every 50 operating hours.

Reassemble in reverse order. Only use original HAMMELMANN filter cartridges.

Check the differential pressure after starting the unit. The differential pressure does not exceed 1,25 bar. If a differential pressure control is installed (option) the high pressure pump unit will be shut of at 1,25 bar differential pressure.


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11.5 Checks during operation

During operation of the pump we recommend that you check the condition of certain essential components for:-

Excessive or unusual noise, vibration i.e. (Valves tapping, pulsation in the discharge lines etc),

Uneven heating in areas of the pump head (Valve block),

Pulsation in the suction side assembly or rapid flickering at the pressure gauge,

Temperature increase at the plunger cooling water outlet,

Leakage at the low pressure seal sets (of the hp seal set assemblies),

Excessive or unexpected discharge from the pressure regulating valve (Bypass valve)

All the above indicate that the pump is in urgent need of repair or maintenance which must be carried out in accordance with the instructions provided. Pos: 46 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.doc @ 1188 @ @ 1


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Pos: 47 /Instandhal tung/Pumpen/HD P 250/Öl wechsel HD P 250 PAO 320 / S4 GX 320 @ 7\mod_1302872607816_2.doc @ 46123 @ 22233333333 @ 1

11.6 Oil change

Observe environmental regulations! When working on or with the equipment, it is imperative to observe all requirements in regards to waste-disposal and proper recycling. Especially during installation, repair or maintenance, water damaging agents such as lubricating grease and oil hydraulic fluid, cooling agents, solvent-containing cleaning agents must not leak into the ground or into the sewage system! Such materials must be stored, transported, contained and recycled in suitable containers.

11.6.1 First oil change after 1000 operating hours

Item no. Description

1 Oil drain valve

2 Oil drain oil cooler/filter

3 Oil filter/cooler combination

4 Hexagon screw plug

5 Dip stick

6 Oil pressure gauge

7 Oil pump

8 Oil pressure regulator

9 Oil filler neck

Fig.: Oil change

Change the oil, when pump is warm (oil drains better).

At every oil change it is necessary to change the oil filter cartridge.

Place rags or equivalent under the oil drain valves.

Collecting trays are necessary for catching the oil from the crank case (approx. 22,5 litres) and oil filter/cooler.

(Ref. to fig oil change) Remove the cap from the oil filler neck (9)

Unscrew the protective cap of the oil drain valve (1). Use the first drain hose which are fitted with threaded connector. Place the free end in the collecting tray. The oil comes out of the crank section, as soon as the oil drain hose gets screwed.

Examine old oil for signs of emulsion.

By using a 24 mm or 41 mm wrench unscrew the hexagon screw plug (4) from the oil filter/cooler combination and remove it.

Remove the plug from the bottom of the oil filter/cooler combination (2). The oil comes out of the oil filter/cooler combination, as soon as the plug gets unscrewed.

If the crank case and oil filter/cooler combination are completely drained unscrew the hose from the oil drain valves (1). Screw the protective cap back on the oil drain valve (1) and the plug (2) back into the oil filter/cooler.


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Fig. Oil filter

(Ref. to fig. oil filter) Pull the complete oil filter insert (order no.: 04.00995.0156) out of the filter/cooler housing.

Unscrew the hexagon nut (1) from the bottom of the oil filter insert and remove it with the spring (2) from the thread rod (3).

Pull off the oil filter cartridge (04.00995.0155) from the thread rod (3) and change by new.

Clean the magnet (4).

Reassembling in reverse order.

Insert the new oil filter into the oil filter/cooler housing and replace the hexagon screw plug (4)

Fill the crank housing with new oil (approx. 22,5 liter) over the oil filler neck (orange cap) until the oil level at the dip stick is between the two markings.

Close the oil filler neck with the cap.

Do not overfill.

11.6.2 Next oil changes

After 4000 operating hours or min. once in a year. If 4000 hours are not reached in a year, it is possible to check the oil quality. If the oil is in good condition it can be further used up to 4000 hours. Oil check every year.

In extreme operating conditions, i.e.: dirt or water ingress, radiated heat, etc. more frequent oil changes are necessary. A special change schedule is advisable.


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11.6.3 Lubrication including oil filter

Quantity of oil: 22,5 liter

Quality of oil: Polyalfaolefin (PAO) CLP according to DIN 51517 – 3 ISO 12925 CKD ANSI/AGMA 9005 – E02

Hammelmann first fill: Shell Omala S4 GX 320

Alternative oils

Manufacturer CLP 320 / ISO VG 320

Avia Syntogear PE 320

Addinol Eco Gear 320 S

Aral Degol PAS 320

BP Enersyn HTX 320

Castrol Alphasyn EP 320

Esso Spartan Synth EP 320

Fuchs Renolyin Unisysn CLP ÖL 320

Mobil Mobil SHC 632

Mobilgear SHC XMP 320

Optimol Optigear Synthetic A 320

PANOLIN Tecsynth 320

Petro-Canada Enduratex* Synthetic EP 320

Shell Omala S4 GX 320

Total Carter SH 320

OMV OMV gear SHG 320

By using other oils as here listed consult your supplier.

Note! Polyalphaolefin gear oils of different manufactures can be mixed slightly (max. 5%) with another, e.g. at oil refill. Only small quantities (max. 5%) should be refilled, in order not to change the characteristics of the original gear oil.

At the changing from mineral oil to polyalfaolefin the crank case must not be rinsed before new filling. The remaining residue of the mineral oil, after a complete draining of the crank case, is compatible with the polyalfaolefin.


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Viscosity-Temperature-Diagram for synthetic oils at Poly- α -Olefin - Basis


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11.6.4 Oil pressure adjustment

The pressure of the oil pump has been set in our works. For a good oil supply and a long working life of the bearings the oil pressure should never fall below 3 bar even when the unit is warm. A pressure gauge is fitted to the unit.

If the oil pressure fall below 2 bar the high pressure pump would be shut off automatically to prevent damages of the crank section.

Make adjustment on the oil pressure regulator (ref. to fig.: Oil change, item 8). To do so:

Remove protective cap and loosen the counter nut.

Use screw driver to adjust the oil pressure.

Tighten the adjuster screw to increase pressure

or

unscrew to reduce pressure Pos: 48 /Instandhal tung/Pumpen/Ins tandsetzungsarbeiten @ 0\mod188_2.doc @ 1480 @ 222222 @ 1

11.7 Repair & Replacement

The following section “Repair & Replacement” contains information enabling you to carry out repairs to the high pressure section of the pump. Only competent trained technicians should undertake these repairs and only genuine HAMMELMANN parts should be used.

For specialised training in pump repair and operation please consult your HAMMELMANN agent or HAMMEL-MANN directly.

The unit should be switched off, the panel cover locked and the key removed for safekeeping before attempting to commence repairs.

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11.8 Maintenance of the pump head 00.02145.1133 (-007)

The pump head is subject to minor wearing. Maintenance is required, i.e. if a decrease of pressure or a restless run of the pump is determined.

Before beginning to work ensure that the medium supply is switched off.

Care for cleanliness at the workplace! Dirt or i.e. little swarfs can affect the function of the pump if they i.e. get into the valve guide or similar.

11.8.1 Disassembly (see fig.: Pump head & point: Piston seal assembly)

Disassembly of the pump head

Remove the pump head of the crank section or suction chamber.

To do so: If necessary disconnect and remove all hoses and parts from the pump head.

Working crosswise use 32 mm socket and torque wrench to remove the head retaining nuts (520).

Loosen the cylinder screws (90) with a 14 mm allen key and pull them out. By that the pump head is loosened from the seal assembly.

Lift the pump head (valve housing) from the crank section and turn it by 180°. If necessary do it with two men or a suitable lifting device. Ensure that no pump head parts fall away.

Disassemble the pump head on a workbench or in a vice if possible. Always lay the parts in order of the removal and in individual sets. Mark them with a felt-tip pen if necessary. The following instructions are for one valve set.

Disassembly of the pump head

The valve guide (500) remains either in the valve (10) housing or on the valve (30). If necessary remove valve guide (50) from valve housing.

Or remove the valve (30) with valve guide (500) and spring (20) from the valve seat ring (150). Then remove the valve (30) and spring (20) from the valve guide (500).

Remove O-ring (60) from the valve guide (500)

Remove valve seat ring (150) from the casing of the seal assembly.

If necessary remove the seal rings (40) from the valve seat ring (150).

Remove valve (120) and spring (140) from the casing of piston seal assembly.

If necessary remove flat seal (100) from the pump head housing or from the pump housing.


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Fig.: Pump head


10 Valve housing 120 Valve

20 Spring 140 Spring

30 Valve 150 Valve seat ring

40 Seal ring 500 Valve guide

60 O-ring 520 Hexagon nut

90 Hex. skt. cap head screw 530 Stud bolt

100 Flat seal


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Inspection

Check the valve seat ring (150). If damaged or worn, replace it. It is possible that the circular seat face could have been deformed or worn by impact of the valve (30). If it is greatly worn or deformed so much that a good seat is no longer possible then discard and replace with new.

Check valve (30 and 120) for scratches, pitting or cracks. Replace if any of these are evident.

Examine valve guide (500) for signs of wear or damage. Replace if necessary.

The supporting surface between the valve seats (150) and the casings of the seal assembly and to the pump housing should be smooth. Exchange scratched parts.

11.8.2 Assembling (ref. to fig.: Pump head)

Clean all parts including new spare parts for the reassembling thoroughly with a degreasing fluid and remove all felt-tip markings if necessary. Lay these parts in order of their assembly.

Do not use grease at reassembly!

Assembly of the pump head

Place O-ring (60) into the valve guide (500).

Insert the valve guide (500) in the valve housing if necessary.

Place spring (140) and valve (120) into the casing of piston seal assembly. Place valve (120) onto the spring (140).

Crefully fit seal ring (40) into the valve seat ring (150).

Place valve seat (150) onto the piston seal assembly.

Place valve (30) into the valve seat (150).

Place spring (20) onto the valve (30).

Repeat the above procedure for the other remaining valve sets.

Place the flat seal (100) on the pump housing (crank section) if necessary.

Assemble the pump head (valve housing) on the crank section or suction chamber. To do so:

Carefully place the pump head (valve housing) onto the pump housing. Ensure that no parts fall away or shift.

Lightly grease the threads of the stud bolts (530) with Molykote 1000 (order no. 04.02750.0011). Screw nuts (520) on the stud bolts (530) by your hand.

Don’t grease the thread of the hex. skt. head cap screws (90).

They are provided with an integrated lubricant.

Screw the valve housing and the casings of the seal assembly by using cylinder screws. The required torque is 240 Nm. Tighten down in three steps in according to fig.: sketch pump head.


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Then working crosswise with torque wrench and 46 mm socket tighten down nuts (520). Req. torque = 450 Nm Do not tighten with the max. torque immediately. Tighten it up in order of the sketch again and again in several phases and check if the pump head constantly lays everywhere on the suction chamber.

Reassemble all lines and add-on pieces.

Fig.: Sketch pump head

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11.9 The plunger seal assembly 00.00743.2152 (-011)

The pump unit must be switched off and all lines depressurised before attempting to check hose connections and leakage points or making inspection and remedy!

Use only correctly sized suitable tools.

11.9.1 Disassembly

Clear an area of workbench or, if no bench available, lay a sheet of material (paper, cardboard etc.) ready to accept dismantled parts. The parts should always be laid out in the order of disassembly and in the individual sets.

Ensure that your workbench is absolutely clean before commencing work. Foreign parti-cles, i.e.: metal etc. will cause serious damage to the plunger seal assembly if inadvertently assembled.

Disassembly of the plunger seal assembly

Disconnect high pressure line/hoses and all other parts.

For disassembly of the pump head ref. to point pump head. Have a felt tip pen available so that the pump head parts can be removed and marked (not on sliding or sealing surfaces) in the correct order.

Remove the cover plates from the intermediate chamber

Use circlip pliers to remove circlip (480).

Remove the clamp halves (470) by hand.

Now the plunger from plunger seal set (20) is loosened from the piston rod.


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Fig.: Plunger seal assembly

Item. Description

10 Casing

20 Plunger seal set

30 Flange

40 Seal ring

60 O-ring

120 Support ring

300 Bushing

360 O-ring

400 Hexagon socket head screw

410 Circlip

420 O-ring

430 O-ring

440 Spring casing

470 Clamp

480 Circlip

490 O-ring


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Fig. Plunger set

The parts of the plunger set are engraved with a batch number and a unique serial number. Check the markings! Only assemble matched parts. Do not interchange!

Do not touch the plunger surface with bare hands!

Screw two hex. socket head screws (90 from pump head) into the threaded bores of the casing (10) and using a suitable lifting device lift the complete plunger seal assembly from the pump housing. Normally the plunger will emerge with the plunger seal assembly but make sure that it is not damaged or drops out completely during the lifting operation.

Ref. to fig. plunger set. The plunger set comprises plunger (10), bushing (20), 3 x seal ring (30) and O-ring (40). One seal ring is built into the plunger seal assembly and two spare matched seal rings are in a groove in the plunger connection bush behind the O-ring (40).

Remove the plunger of the plunger seal set (20) from the casing (10).

Slide the O-ring (360) from the plunger connection bush.

Place the casing (10) in a protected vice ensuring that you not deform or damage it.

Using a 10 mm Allen key loosen and then remove the eight hex. socket cap head screws (400) from the casing (10).

Remove the flange (30) from the casing (10).

Pull out the bushing (300) and bushing (20 from plunger set 20) from the casing (10).

Remove seal ring (30 from plunger set 20) from the casing (10). Do not use any sharp or pointed tool to remove the seal ring. Ensure that you do not damage (scratch) the bush or casing. Do not discard the seal ring.

If necessary pull out the spring casing (440) from the casing (10).

If necessary remove the O-ring’s (450 and 460) from the casing (10).

By using a circlip pliers remove the circlip (410) from the flange (30).

Remove support ring (120) and seal ring (40) with O-ring (490) from the flange (30).

If necessary remove second support ring (120) from the flange (30).


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Remove the O-rings (60) from the grooves of the flange (30). Have new available for reassembly.

Repeat the above procedure for the remaining plunger seal assemblies.

11.9.2 Reassembly

Clean and examine all parts for wearing and scratching. Replace with new parts if necessary. Sealing components must be discarded and replaced with new.

When assembling grease all sliding parts with Stabyl MO 500 (order no. 04.04660.0002)

Lightly grease the internal bore of flange (30).

Place the support ring (120) and seal ring (40) with O-ring (490) into the flange (30).

Place the second support ring (120) into the flange (30).

Using circlip pliers, fit the circlip (410) into the groove of the flange (30).

Lightly grease the internal bore formed by these pre-assembled parts.

Insert O-rings (60) into the grooves of the flange (30).

If it was removed during disassembly slide the spring casing (440) back into the casing.

Ref. to fig. plunger set: Remove O-ring (40) and take a new seal ring (30) from the plunger connection bush. Place the used seal ring (30) into the plunger connection bush and close the groove with the O-ring (40). The cylinder rings are provided with a bar code e.g. 2 blue lines. Always use seal rings with identical bar code for a plunger set. If all 3 seal rings were used, then exchange the complete plunger set. Place the new seal ring (30 from plunger set 20) into the groove of the casing (10). Do not use grease!

Slide bushing (20 from plunger seal set 20) into the casing (10). Do not use grease!

Lightly grease the bushing (300) and slide into the casing (10). Lightly grease the grooves of O-rings (420 and 430) with Stabyl MO 500 and place the O-rings (420 and 430) into the grooves of the casing.

Place the casing (10) in a protected vice ensuring that you do not deform or damage it.

Don’t grease the thread of the hex. skt. head cap screws (400).

They are provided with an integrated lubricant.

Place the pre-assembled flange (30) onto the casing (10). Screw the hexagon socket head screws (400) by hand into the flange (30) and casing (10). Use a 10 mm allen key to tighten down the screws into the casing. The req. torque = 100 Nm. For tightening sequence ref. to fig. plunger seal assembly.

Slide the O-ring (360) over the plunger (10 from plunger set 20) connection bush and seat in position.

Carefully slide the plunger (10 from plunger set 20) into the seal assembly. It should slide in without the need for force.

Slide the plunger in and out several times by hand to check that it will operate smoothly when reinstalled.

Repeat the above procedure for the remaining plunger seal assemblies..


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Refitting the pump head and plunger seal assembly

Lightly grease the internal bores of the suction chamber, crank housing and the outside of each plunger seal assembly.

Place the circlips (480) over the piston rods to be fixed later.

Set by set lower the complete plunger seal assembly down through the suction chamber. Take great care that the O-rings (60)) correctly seated in their grooves and that the plungers cannot drop out. Ensure that the threaded holes in the casing (10) (for the hex. skt head screws (90) from pump head) are correctly in position. Push the plungers down towards their mating piston rods and ensure they are correctly vertically aligned.

Assemble the pump head parts as described previously.

From the intermediate chamber pull the plunger down so that the connection bush sits on the piston rod.

Place the half shells (470) onto the plunger connection bush. With one hand hold the clamp halves tight (470) and with the second hand fit the circlip (480) into the groove.

Reconnect all the items previously dismantled from the pump head.

Test procedure

Spray the plungers with Optimol F+D fluid. Regular applications of F+D fluid prevents build up of scale on the plungers and prolongs working life.

Refit cover plates on the intermediate chamber.

Start-up and run for 15 to 20 minutes, observing noise, vibration and that leakage from low pressure seal pack is not excessive.

If the test is satisfactory stop the pump, depress and lock emergency stop button. Pos: 53 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.doc @ 1188 @ 2233 @ 1


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11.10 Changing the bellows

At every high pressure seal change or at least once in the year the bellows must be changed. In this occasion also the hose clamps should be replaced.

Fig. Bellows

Loosen the piston / plunger from the piston rod (ref. to chapter: Seal assembly).

Loosen the hose clamp (180) and roll up the bellow (170).

Loosen the piston rod (160) with a spanner and remove the bellow (170) from the intermediate chamber.

Then remove the bellow from the piston rod.

Slide a new bellow over the piston rod.

Open the hose clamp (30) widely and slackly slide it over the bellow (to be fixed later).

Put the bellow (180) onto the crosshead / pump housing (to be fixed later).

Using the spanner screw the piston rod with the bellow into the crosshead.

Pull the bellow down to the crosshead, ensuring that the bellow doesn’t twisted (the cast noses must be straight).

Fix the hose clamps (180 and 30). Carefully tighten the screws of the hose clamps with a torque of 1 Nm. For connecting the piston with the piston rod (ref. to chapter seal assembly and recommended). Reconnect the cover from the intermediate chamber.

Each time the bellows are replaced check the surfaces of the crosshead bores for signs of corrosion.

Inform HAMMELMANN immediately if there are any signs of corrosion. Pos : 55 /Instandhal tung/Pumpen/Anzugsmomente @ 0\mod194_2.doc @ 1476 @ 22222113333333333 @ 1

11.11 Torque tables Tightening torque (in Nm) for various bolted joints.

Material Thread size

M 6 M 8 M 10 M 12 M 14 M 16 M 18 M 20 M 24

5.6 4,5 11 18 30 48 73 100 140 240

8.8 8,5 21 40 70 110 171 245 345 590

10.9 12 30 60 100 160 250 350 495 850

12.9 15 35 70 120 190 300 405 575 990

NIRO (A2-70) 2,5 6 10 18 29 44 62 85 150

Torque (Nm) for various bolts. Any variations from these torque values are indicated on the individual assembly drawings.


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Operating instructions Splitting nozzle 00.00792.0012 No: HDP 254

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Pos: 57 /Instandhal tung/Spaltdüse/00.00792.0012 @ 4\mod_1203681483127_2.doc @ 22683 @ 2222123233332322222333 @ 1 12 Splitting nozzle 00.00792.0012

12.1 Technical Data

Operating pressure max.: 3000 bar

Flow rate: 1 - 150 l/min.

Equivalent nozzle dia.: 0,5 – 3,7 mm

Weight approx.: 2,1 kg

Connection thread: Inlet: M 30x2(A), Outlet: G ¾“ (I)

12.2 Description The splitting nozzle acts as a flow diverter when a part or all of the water needs to be diverted away from the end consumer nozzle(s). Following the principle of an energy dissipater the water flows via an adjustable gap where its kinetic energy is converted to heat and the water is emitted at atmospheric pressure. The bolt (item 80) sets the position of the conical control pin (item 60) within the conical bushing (10) which determines the gap surface area defining the amount of flow diverted. The gap simulates a nozzle. Screwing the bolt in = smaller equivalent nozzle diameter – higher pressure Unscrewing the bolt = larger equivalent nozzle diameter – lower pressure

12.3 Installation

Do not close the bypass! Not designed to shut off pressurised water! (The conical pin will jam in the conical bushing)

When installing the splitting nozzle ensure that the bolt (80) is unscrewed to expose 13 mm of thread between nut (100) and the bolt head.

Lightly grease the connection thread with Molykote 1000 (Order no.: 04.02750.0011).

Only screw in using the spanner flats of the housing (90). Torque to 250 Nm.

12.4 Adjustment With the pump depressurised hold the splitter housing (90)

firm with the spanner and adjust the gap by means of the bolt (80).

Secure this adjustment with the nut (100).

Setting under pressure is permissable to max. 500 bar - do not adjust repeatedly. With pressures over 500 bar: Only adjust when the splitting nozzle is not under pressure.

Should the bolt (80) be screwed in so tight that the control pin (60) jams in the bushing (10) the splitting nozzle will have to be dismantled.

If the splitting nozzle needs to be dismantled it is absolutely essential that the pump is depressurised, switched off and the engine/motor isolated.

Once the splitting nozzle has been removed unscrew the bolt (80) at least 13 mm. Then take a plastic drift and hammer and loosen the control (60).

Make sure the control pin moves freely and then reinstall the splitting nozzle.

If operational pressure drops check the consumer for nozzle wear.

M

O.K.

Wrong

Splitting nozzle 00.00792.0012 Operating instructions No.: HDP 254

Page 55, Issue: 04.2013



12.5 Maintenance

Before commencing any maintenance work ensure that the pump is depressurised, switched off and the engine / motor isolated.

12.5.1 Disassembly

With the spanner flats of the housing (110) disconnect the complete splitting nozzle from the pump unit.

Using circlip pliers remove circlip (30) from control piston.

Remove water connection (40) from the housing (90).

Remove the ’O’-rings (50) from the water connection (40).

Place the housing (90) by the spanner flats in a protected vice with the bolt (80) upwards.

If necessary loosen the nut (100) and remove the bolt (80).

Unscrew the nipple (90) from the housing.

Remove the housing from the vice and slide out the control pin (60).

Take the ’O’-ring (70) out of the groove in the control pin (60).

Use a plastic drift to push the bushing (10) out of the housing.

Remove the ’O’-ring (20) from the housing.

12.5.2 Reassembly

Always use new ’O’-rings when reassembling the splitting nozzle. All parts should be lightly greased with Gleitmo 500.

Fit the O-ring (20) into the groove in the housing (90).

Push the bushing (10) into the housing.

Fit the ’O’-ring (70) into the groove of the control pin (60) and slide the assembled pin into the housing.

Place the housing (90) at the spanner flats in a protected vice.

Screw the bolt (80) together with the nut (100) into the housing (90).

Place the ’O’-ring (50) in the water connection (40) and slide the assembly onto the housing.

Fix the water connection (40) in place with the circlip (30).

12.5.3 Replacing the wearing parts: Bushing (10) and control pin (60)

It is not necessary to dismantle the splitting nozzle to replace the above parts. For this it is sufficient to proceed as follows:

Unscrew the bolt (80) together with the nut (100) from the housing (90).

Use a plastic drift to push the control pin (60) out of the housing and then push the bushing (10) out of the opposite end. Fit NEW ’O’-rings (items 20 and 70).


Operating instructions Safety notes for high pressure hoses

No: HDP 254

Page 56, Issue: 04.2013



Pos: 59 /Sicherheit/Schlauchsicherheit @ 0\mod416_2.doc @ 1244 @ 1112222 @ 1 13 Saf et y notes for h igh p ressure hoses

Ignoring these notes can invalidate all claims for injuries or damages.

Secure the high pressure hose at the equipment every time with hose protections!

Secure connections of high pressure hoses every time with hose protections !

Secure the high pressure hose every time with hose protections at the working tool!

Never tighten fittings of high pressure hoses under pressure !

Avoid looping ! After looping during work, shut down the high pressure equipment and carefully remove loop.

Avoid twisting (torsion) of high pressure hose.

Avoid tension, never pull HP-equipment with high pressure hose.

Do not bend high pressure hoses or pull them around sharp edges. At work on edges or several floors coat hose or edge. Do not bend fitting.

Never put weight on the high pressure hose. Use hose bridges, when you have to drive over hoses.

Safety notes for high pressure hoses

Operating instructions No.: HDP 254

Page 57, Issue: 04.2013



13.1 Before using the hose

Check the working pressure marked on the hose. Never exceed this working pressure.

Check the hose and the fittings if they are damaged.

Take out of service hoses with bubbles in the cover, with kinks or uncovered layer of the steel wire. It is not allowed to repair hose lines with these damages or to use them in other ways. (EN 982)

Check the fittings if they have rust, cracks (fissures) or worn threads.

Never plug the relief holes of the fittings, neither intentional nor by dirtying or damages.

Observe the minimum bend radius at storage and work (look table beyond).

13.2 Use of the hose

Do not twist the hoses during assembly.

Regularly check the hoses and fittings as well as the connections and adapters on leakages. In case of leakages stop the high pressure aggregate immediately. Remove leakage only when the system is switched off and depressurised. Never tighten fittings under pressure. Observe torque (look table beyond).

Pay attention to the change of length when working. (Hoses reduce their length under pressure).

Do not pressurise hoses on reel drums.

Avoid stress with high temperature from the exterior (e.g. radiant heat at welding or thermal cutting).

Do not hang the hose across several floors.

Nominal diameter

[DN] Pressure

[bar] Connection fitting Torque [Nm]

Maximum Temperature of

Medium [°C]

Minimum Bend Radius [mm]

5 2500 M 14x1,5 LH 70 70 150 5 3200 M 14x1,5 LH 70 70 200 8 2500 M 14x1,5 LH 70 70 200 8 2800 M 14x1,5 LH 70 70 250 10 330 M 18x1,5 DKL 50 100 130 10 500 M 18x1,5 DKL 50 100 130 10 710 M 18x1,5 DKL 50 100 150 10 1250 M 22x1,5 DKO 30 100 150 10 1500 M 22x1,5 DKO 30 100 150 12 290 M 22x1,5 DKL 62 100 180 12 470 M 22x1,5 DKL 62 100 180 12 660 M 22x1,5 DKL 62 100 200 12 1100 M 24x1,5 DKO 33 100 200 12 1400 M 24x1,5 DKO 33 100 200 12 1800 M 24x1,5 DKO 33 70 300 12 2500 M 14x1,5 LH 70 70 350 20 190 M 30x1,5 DKM 83 100 240 20 350 M 30x1,5 DKM 83 100 240 20 900 M 36x2,0 DKO 49 100 280 20 1000 M 36x2,0 DKO 49 100 280 20 1400 M 36x2,0 DKO 49 100 350 25 150 M 38x1,5 DKM 105 100 300 25 290 M 38x1,5 DKM 105 100 300 25 700 M 42x2,0 DKO 57 100 355

=== Ende der Liste für Textmar ke Inhalt ===

Operating instructions Index No: HDP 254

Page 58, Issue: 04.2013



14 Index

C

Construction ............................................................ 18

G

General

Copyright ............................................................. 15

Introduction .......................................................... 14

Warranty terms .................................................... 15

L

Leistungsdaten ...........................................................7

M

Maintenance

Changing the bellows .......................................... 52

R

Repair and Replacement ........................................ 42

S

Safety

Additional warnings ............................................. 13

Danger symbol .................................................... 12

Dangers arising from non observance of safety instructions ....................................................... 10

Forbidden practices ............................................. 13

Personnel qualification and training .................... 10

Precise safety instructions for the operator ......... 10

Safety conscious working .................................... 10

Safety during inspection, maintenance and repair ......................................................................... 13

Spaltdüse 00.00792.0007 ....................................... 54

T

Torque tables .......................................................... 52

Transportation

Packing ................................................................ 16

Protection ............................................................ 17

Transport ............................................................. 17

Transportation ..................................................... 17

H

1 2

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Gewicht in kg

Format DIN

Revision

Zust Änderung

Verwendungszweck

Name

NameDatum CAD6Zeichnung

Gepr.Norm

BearbDatum

Ers.fürErs.durch

Zeichnungs6Nr.

Benennung

Halbzeug

Artikel6Nr.

Maßstab

Blatt

von

Bl.

*

AZul.Abweichungf.Maße ohne

ToleranzangabeISO 2768 6 mH

Oberfläche nachDIN ISO 1302

1122.1680

00.03223.2845�1

HOCHDRUCKPUMPE

00.03223.2845

1

1

1:51

Sander19.03.201219.03.2012

GlittKrabus

000

Krabus

HDP250

D659302 OELDE

13.03.2012

430

480

80134,35

25

340

Ölmessstabdip stick

149,335

558

125

Öleinfüllstutzenoil filler cap

120

8100

183

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834,5

1017

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60

60140

132,5

M20, 30 tief

Öleinfüllstutzenoil filler cap

834,5

1021

,18

Saugraumentwässerungsuction chamber drainage

Schrauben M16screws

Sauganschluss DN100 PN16suction connection

Passfeder / keyA20x12x100 DIN 6885

O8,

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4,24CoM y=24

7,48

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649

Ölkühler6Filter Kombinationoilcooler6filter unit

Kühlwassereintrittcooling water in

Kühlwasseraustrittcooling water out

Blatt 1 von 2

ß Mit Teile-Nr. - Rev. signiertHärte geprüftß

Mit Betriebsdruck signiertalle Ecken und Kanten gratfrei

Mit Auftrags-Nr. signiertßß

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O 100

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Revision

Zust Änderung

Verwendungszweck

Name


Gepr.Norm

BearbDatum

Ers.fürErs.durch

Zeichnungs6Nr.

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1122.1680

00.03223.2845�1

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00.03223.2845

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GlittKrabus

000

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HDP250

D659302 OELDE

13.03.2012




*

Blatt 2 von 2

O 1319Schwenkbereich für optionale Hebevorrichtungslewing radius withoptional lifting device

optionale Hebevorrichtung optional lifting device(00.06020.0131)

Erforderliche Höhenmaße für die Demontage: x1: manuelle Demontage des Pumpenkopfes x2: Demontage von Pumpenkopf und Dichtungssatz mit optionaler Hebevorrichtung

height required for disassembly: x1: manual disassembly of the pump head x2: disassembly of pump head and seal assembly with the use of the optional lifting device

1325

x1

1515

x2

500730

763,5

1124

,5

189,5

Drawing no. : 00.02350.0793-100.02350.0793Parts-list no.:

CRANK SECTIONDescription :Date :Page :

09.04.20131

PARTS LIST (41)


DwgPos Item Code-No. Description Quantity No/Unit Unit

HDP250 I=3,23

1 1,001010 CRANK HOUSING pc00.01256.0181

2 0,852020 GASKET CORD m04.00708.0026

1 1,003030 COVER PLATE pc01.00266.0077

1 1,004040 COVER PLATE pc01.00266.0078

8 1,005050 HEX-SOCKET SET SCREW pc02.00888.0016

8 1,006060 HEXAGON THIN NUT pc02.00314.0008

1 1,007070 CRANKSHAFT pc00.06161.0106

5 1,008080 CONNECTING ROD pc00.03270.0021

5 1,009090 BEARING SHELL (PAIR) pr.04.04277.0025

5 1,00100100 STRAIGHT PIN pc02.00957.0107

5 1,00110110 CROSSHEAD pc01.02140.0051

5 1,00120120 GUDGEON PIN pc01.00410.0007

10 1,00130130 BORE CIRCLIP pc02.01766.0006

5 1,00140140 RING pc01.03465.1028

2 1,00150150 STRAIGHT PIN pc02.00957.0103

5 1,00170170 BELLOWS pc01.01170.0012

5 1,00180180 HOSE CLAMP pc04.04482.0158

5 1,00190190 HOSE CLAMP pc04.04482.0156

1 1,00200200 COVER pc01.00665.0498

2 1,00210210 PIPE pc00.03535.0246

28 1,00220220 HEXAGON SOCKET HEAD SCREW pc02.00825.0289

1 1,00230230 PINION SHAFT pc01.06180.0142

1 1,00240240 FEATHER KEY pc02.01651.0076

2 1,00250250 BORE CIRCLIP pc02.01766.0050

1 1,00260260 SELF-ALIGNING ROLLER BEARING pc02.01657.0362

1 1,00270270 CYLINDRICAL ROLLER BEARING pc02.01998.0653

1 1,00280280 COUPLING pc01.02250.0022


1 1,00300300 OIL PUMP pc04.03235.0167


2 1,00320320 TENSION BOLT pc02.01786.0002

2 1,00330330 STRAIGHT PIN pc02.00957.0019

2 1,00340340 SET SCREW pc01.05172.0036

1 1,00350350 ELBOW FITTING pc02.01255.0042

1 1,00360360 COVER pc04.00665.0024

1 1,00370370 HOSE LINER pc04.05682.0086

1 1,00380380 DRAIN VALVE pc04.05866.0006

1 1,00390390 RETAINER RING pc04.00740.0033

1 1,00400400 CONNECTION PIECE pc04.05300.0011

2 1,00410410 BUSHING pc01.00525.0715

4 1,00420420 O-RING pc04.00730.0093

1 1,00430430 CONNECTION pc04.05993.0448

1 1,00440440 CONNECTION pc04.05993.0511

1 1,00450450 PIPE pc01.03535.1201

1 1,00460460 CONNECTION pc04.05993.0512


CRANK SECTIONDescription :Date :Page :

09.04.20132

PARTS LIST (41)



HDP250 I=3,23

5 1,00470470 PISTON ROD pc01.05060.0111

1 1,00500500 COVER pc01.00665.0499

1 1,00510510 ROTARY SHAFT SEAL pc04.00736.0065

1 1,00520520 OIL DIPSTICK pc04.05000.0025

1 1,00530530 O-RING pc04.00730.0014

1 1,00540540 HEADED LINER pc01.00530.0148

1 1,00550550 CONTROL PIN pc01.05180.0070

1 1,00560560 ADJUSTING SCREW pc01.04723.0028

1 1,00570570 COIL SPRING pc04.00946.0117

1 1,00580580 O-RING pc04.00730.0041

1 1,00590590 HEXAGON NUT pc02.00311.0106

1 1,00600600 PLUG pc04.05240.0047

1 1,00610610 THREADED CONNECTION pc04.05993.0788

1 1,00620620 PLUG pc04.05993.0756

8 1,00630630 WASHER pc02.00421.0005

5 1,00650650 SEAL RING pc01.00742.0397

p_dbgs01.p

>>>end<<<

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Verwendungszweck

Name


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BearbDatum

Ers.fürErs.durch

Zeichnungs6Nr.

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790.7000

00.02350.0793�1

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00.02350.0793

1

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Wewer28.02.201301.03.2013

EHelmigKrabus

004001 Ölpumpe v. 0128 in 0167 03.07.2007 Wew002 Pos.310 / 450003 Stücklistenänderung 01.04.2011 Pöts004 Stücklistenänderung 28.02.2013 Wei

Krabus

HDP250 i=3,23

D659302 OELDE

17.10.2006

17.07.2007 Wew

A

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B

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2701

2801

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3202

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*

Vor der Montage Einbau von Pos.140 beachten !

Anziehdrehmoment 450 Nm



Blatt 1 von 2

2601

202

3001

6308


6505

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Werkstoff

Gewicht in kg

Format DIN

Revision

Zust Änderung

Verwendungszweck

Name


Gepr.Norm

BearbDatum

Ers.fürErs.durch

Zeichnungs6Nr.

Benennung

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Artikel6Nr.

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790.7000

00.02350.0793�1

KURBELTRIEB

00.02350.0793

1

1

1:3.51

Wewer28.02.201301.03.2013

EHelmigKrabus

004001 Ölpumpe v. 0128 in 0167 03.07.2007 Wew002 Pos.310 / 450003 Stücklistenänderung 01.04.2011 Pöts004 Stücklistenänderung 28.02.2013 Wei

Krabus

HDP250 i=3,23

D659302 OELDE

17.10.2006

17.07.2007 Wew

6101

6201




*

Vor der Montage Einbau von Pos.140 beachten !

Blatt 2 von 2


SUCTION CHAMBERDescription :Date :Page :

09.04.20131

PARTS LIST (41)



HDP250 D17,5-55

1 1,001010 SUCTION CHAMBER pc01.04246.0091

14 1,002020 DISC pc01.04380.1088

14 1,003030 HEXAGON HEAD SCREW pc01.04710.0053

8 1,004040 STUD BOLT pc02.00788.0060

8 1,005050 HEXAGON NUT pc02.00309.0009

2 1,006060 CONNECTION pc04.05993.0802

2 1,007070 THREADED CONNECTION pc04.05993.0788

p_dbgs01.p

>>>end<<<

2

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3 4

2

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Werkstoff

Gewicht in kg

Format DIN

Revision

Zust Änderung

Verwendungszweck

Name


Gepr.Norm

BearbDatum

Ers.fürErs.durch

Zeichnungs3Nr.

Benennung

Halbzeug

Artikel3Nr.

Maßstab

Blatt

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Bl.

*




140.0670

00.04246.0080�1

SAUGRAUM

2.0975

00.04246.0080

1

1

1:42

Wewer21.01.201321.01.2013

EHelmigKrabus

004001 Pos.20 geändert 24.05.2004 Wew002 Ansicht ergänzt003 Schrauben / Scheiben 11.10.2006 Wew004 Text geändert u. zugefügt 15.01.2013 San

Krabus

HDP250

D359302 OELDE

04.09.2003

11.10.2004 Gut

O 180

22,5°

45°

138,

7

101

2014

3014

408

508

602

702

1

24

37

86

59

10

11

12

13

14

Bronze Saugraum mit 1x DIN DN100 ; PN16

257

696

W

W

Schrauben Pos. mit integriertem Schmiermittelund in angegebener Reihenfolge ohne Fettangezogen:

1. Stufe: Anziehdrehmoment Ma = Nm2. Stufe: Anziehdrehmoment Ma = Nm

200600

30




*

Saugraum bei Montage mit Kurbeltriebmit Kleber "TEROKAL 3 2444"(04.02056.0005) umlaufend angedichtet.


OIL LINEDescription :Date :Page :

09.04.20131

PARTS LIST (41)



HDP250

1 1,001010 OIL COOLER pc00.02198.0018

1 1,002020 PIPE pc00.03535.0257

1 1,003030 PIPE pc00.03535.0258

1 1,004040 PRESSURE GAUGE pc04.02860.0073

1 1,005050 CONNECTION pc04.05993.0704

1 1,006060 CONNECTION pc04.05993.0713

1 1,007070 CONNECTION pc00.05993.0031

1 1,008080 TUBE FITTING pc04.05993.0668

2 1,009090 TUBE FITTING pc04.05993.0575

2 1,00100100 PLUG pc04.05993.0750

1 1,00110110 TUBE FITTING pc04.05993.1042

2 1,00120120 CONNECTION pc04.05993.0410

1 1,00130130 TUBE FITTING pc04.05993.0616

1 1,00140140 TUBE FITTING pc04.05993.0700

p_dbgs01.p

>>>end<<<

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Name


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BearbDatum

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13.2850

00.02516.0182�1

OELLEITUNG

00.02516.0182

1

1

1:53

Heitmann23.12.201103.01.2012

EHelmigKrabus

005001 Pos.110 geändert 29.07.2004 Heit002 Darstellung angepaßt003 Solid Edge Zeichnung 14.10.2008 Stau004 Pos.70 und 80 vertauscht 13.08.2009 Hun005 Darstellung angepasst 23.12.2011 Wei

Krabus

HDP250

D359302 OELDE

28.04.2004

10.02.2005 Heit

101

201

301

401

501

601

701

801

902

1002

1101

1401

1301

1202




*

Verrohrung aus 1.0309


OIL COOLERDescription :Date :Page :

09.04.20131

PARTS LIST (41)



HDP120/170/250

1 1,001010 HOUSING pc01.01240.0470

1 1,002020 COVER pc01.00665.0515

1 1,003030 FLANGE pc01.01055.1028

1 1,004040 HEXAGON HEAD SCREW PLUG pc01.04838.0216

1 1,005050 FINNED TUBE pc04.03575.0003

1 1,006060 PIPE pc01.03535.0979

1 1,007070 TUBE FITTING pc04.05993.1031

1 1,008080 FILTER pc04.00995.0156

1 1,009090 O-RING pc04.00730.0416


3 1,00110110 LOCK WASHER pc02.00380.0005

3 1,00120120 WASHER pc02.00421.0005

p_dbgs01.p

>>>end<<<

2

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10.1400

00.02198.0018�1

OELKUEHLER

00.02198.0018

1

1

1:22

Heitmann06.08.201207.08.2012

EHelmigKrabus

009003 Pos.80 hinzugefügt 02.10.2002 Heit004 Pos.100/110/120 hinzugef.005 Pos.70 geändert 29.07.2004 Heit006 Zeichng. auf Solid Edge 08.05.2007 Hun007 Texte zugefügt 22.09.2008 Hun008 Texte signieren 02.11.2009 Hun009 Darst. Pos.80 korr. 06.08.2012 Pöts

Krabus

HDP 120/170/250

D359302 OELDE

13.03.2002

28.04.2004 Heit

A

A

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125

9

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93

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(G3/8)

401

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101

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1

301

701

1003

1103

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X*

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ArmaturanschlußG 1/4

ArmaturanschlußG 1/4

Öl Ein

Öl Aus

X

Ansicht X

Wasser Ein Wasser Aus

Öl Überwachung

Hersteller : HammelmannTyp : 00.02198.0018Leistung : 6 KWWerkstoff : ALU3Mantel 3.2341 Rohre Kupfer/NickelKühlmedium : WasserDurchfluß (Wasser) : 13 l/minDurchfluß (Öl) : max. 26 l/min

AnschlüsseKühlung Ein : G 3/8Kühlung Aus : G 3/8Öl Ein : G 1/2Öl Aus : G 1/2Öl Überwachung : G 1/22x Armaturanschl. : G 1/4

Auslegungsdruck : 16 barBetriebsdruck : 536 bar

Oel Ein

Oel Aus

signieren mit ß

ß

ß

ßß ß

Aufkleber : Hammelmann Art.3Nr. : 00.02198.0018 Baujahr : Bestell3Nr.:

ß

Ölablaßschraube

009


PISTON SEAL ASSEMBLYDescription :Date :Page :

09.04.20131

PARTS LIST (41)



HDP120/170/250 D20

1 1,001010 CASING pc01.01750.0882

1 1,002020 PLUNGER pc00.03280.0027

1 1,003030 FLANGE pc01.01055.0963

1 1,004040 SEAL RING pc01.03468.0160

2 1,006060 O-RING pc04.00730.0392

2 1,00120120 SUPPORT RING pc01.03512.0311

1 1,00300300 BUSHING pc01.00525.0640

1 1,00360360 O-RING pc04.00730.0248


1 1,00410410 CIRCLIP pc01.03501.0029

1 1,00420420 O-RING pc04.00730.0379

1 1,00430430 O-RING pc04.00730.0193

1 1,00440440 SPRING SLEEVE pc01.01755.0066

2 1,00470470 CLAMP pc01.01990.0009

1 1,00480480 SHAFT CIRCLIP pc02.01765.0042

1 1,00490490 O-RING pc04.00730.0117

p_dbgs01.p

>>>end<<<

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12.2354

00.00743.21521

DICHTUNGSSATZ

00.00743.2152

1

1

1:1,53

voege15.03.201315.03.2013

BoroschKrabus

011005 Pos. 440 neu, 150 raus 10.03.2011 Som006 Pos. 400 neu007 Text Pos. 400 16.08.2011 Som008 Text hinzu / geä. 05.09.2012 Pöts009 Stücklistenänderung 27.09.2012 Wei010 Stücklistenänderung 23.10.2012 Wei011 Pos. 490, 40 neu 12.03.2013 Som

Krabus

HDP120/170/250 ø20,0

D359302 OELDE

12.01.2009

20.05.2011 Som

1

2

34

5

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201

301

401

602

1202

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4008

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*

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O88

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,9

251,5

279( ca. )

Ausführung nach Werksnormblatt 00.00743.000031

Schrauben Pos. mit integriertem Schmiermittelund in angegebener Reihenfolge ohne Fett

angezogen:

1. Stufe: Anziehdrehmoment Ma = Nm2. Stufe: Anziehdrehmoment Ma = Nm3. Stufe: Anziehdrehmoment Ma = Nm

3070100

400

011

4901

011


PUMP HEADDescription :Date :Page :

09.04.20131

PARTS LIST (41)



HDP250 D17,5-20

1 1,001010 VALVE HOUSING pc01.01305.0605

5 1,002020 COIL SPRING pc04.00946.0045

5 1,003030 VALVE pc01.05860.0397

10 1,004040 SEAL RING pc01.00742.0347

5 1,006060 O-RING pc04.00730.0076


1 1,00100100 FLAT SEAL pc01.00709.0129

5 1,00120120 VALVE pc01.05860.0396

5 1,00140140 COIL SPRING pc04.00946.0030

5 1,00150150 VALVE SEAT RING pc01.03528.0438

5 1,00500500 VALVE GUIDE pc01.01109.0073

12 1,00520520 HEXAGON NUT pc02.00318.0005

12 1,00530530 STUD BOLT pc01.04756.0015

p_dbgs01.p

>>>end<<<

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89.1630

00.02145.1133�1

PUMPENKOPF

00.02145.1133

1

1

1:13

Wallmeyer25.10.201226.10.2012

EHelmigKrabus

007001 Pos.60 zugefügt 06.01.2009 Hun002 Einheitsdarstellung003 Derhmoment 27.09.2010 Som004 Stücklistenänderung 20.05.2011 Pöts005 Text entfernt 20.12.2011 Wei006 Text 12.07.2012 Som007 Stücklistenänderung 22.10.2012 Wei

Krabus

HDP250 ø17,5 3 ø20

D359302 OELDE

16.09.2008

03.08.2010 San

1

2

3

4

5

6

9 7 1 3 5 11

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101

205

305

4010

9030

5005

52012

53012

1505

605

Pos.520 (Skt. SW32) mit MoS2 gefettet und inangegebener Reihenfolge angezogen:

1. Stufe: Anziehdrehmoment Ma= 100 Nm2. Stufe: Anziehdrehmoment Ma= 300 Nm3. Stufe: Anziehdrehmoment Ma= 450 Nm

Betriebsdruck max. 3000 bar




*

1001

1405

1205

Schrauben Pos. mit integriertem Schmiermittelund in angegebener Reihenfolge ohne Fettangezogen:

1. Stufe: Anziehdrehmoment Ma = Nm2. Stufe: Anziehdrehmoment Ma = Nm3. Stufe: Anziehdrehmoment Ma = Nm

80160240

90007

007


SPLITTING NOZZLEDescription :Date :Page :

09.04.20131

PARTS LIST (41)



M 30x2 A -166,5 LG

1 1,001010 BUSHING pc01.00525.0548

1 1,002020 O-RING pc04.00730.0076

1 1,003030 SHAFT CIRCLIP pc02.01765.0047

1 1,004040 WATER CONNECTION pc01.00067.0055

2 1,005050 O-RING pc04.00730.0172

1 1,006060 CONTROL PIN pc01.05180.0055

1 1,007070 O-RING pc04.00730.0056


1 1,009090 HOUSING pc01.01240.0425

1 1,00100100 HEXAGON NUT pc01.02805.0144

p_dbgs01.p

>>>end<<<

Shell Omala S4 GX 320Version 1.0

Effective Date 01/12/2011

Safety Data Sheet

Regulation 1907/2006/EC

1/7 Print Date 01/14/2011 MSDS_DE

1. IDENTIFICATION OF THE SUBSTANCE/PREPARATION AND COMPANY/UNDERTAKING

Material Name : Shell Omala S4 GX 320 Uses : Gear lubricant. Product Code : 001D7852 Manufacturer/Supplier : Shell Deutschland Oil GmbH

Suhrenkamp 71-77 D-22335 Hamburg

Telephone : (+49) 40 6324-6255 Fax : (+49) 40 6321-051 Email Contact for MSDS

: If you have any enquiries about the content of this MSDS please email [email protected]

Emergency Telephone Number

: +49 (0)40 6324-5110

2. HAZARDS IDENTIFICATION

EC Classification : Not classified as dangerous under EC criteria.

Health Hazards : Not expected to be a health hazard when used under normal conditions. Prolonged or repeated skin contact without proper cleaning can clog the pores of the skin resulting in disorders such as oil acne/folliculitis. Used oil may contain harmful impurities.

Signs and Symptoms : Oil acne/folliculitis signs and symptoms may include formation of black pustules and spots on the skin of exposed areas. Ingestion may result in nausea, vomiting and/or diarrhoea.

Safety Hazards : Not classified as flammable but will burn. Environmental Hazards : Not classified as dangerous for the environment.

3. COMPOSITION/INFORMATION ON INGREDIENTS

Preparation Description : Blend of polyolefins and additives. Hazardous Components

Chemical Identity CAS EINECS Symbol(s) R-phrase(s) Conc. Long-chain alkyl amine

T, C, N

R22; R34; R43; R23/24; R48/20; R50/53

0,10 - 0,24 %

Additional Information : Refer to chapter 16 for full text of EC R-phrases.

HAMMELMANN Code no.: 04.03070.0035



Safety Data Sheet



4. FIRST AID MEASURES

General Information : Not expected to be a health hazard when used under normal conditions.

Inhalation : No treatment necessary under normal conditions of use. If symptoms persist, obtain medical advice.

Skin Contact : Remove contaminated clothing. Flush exposed area with water and follow by washing with soap if available. If persistent irritation occurs, obtain medical attention.

Eye Contact : Flush eye with copious quantities of water. If persistent irritation occurs, obtain medical attention.

Ingestion : In general no treatment is necessary unless large quantities are swallowed, however, get medical advice.

Advice to Physician : Treat symptomatically. 5. FIRE FIGHTING MEASURES

Clear fire area of all non-emergency personnel. Specific Hazards : Hazardous combustion products may include: A complex

mixture of airborne solid and liquid particulates and gases (smoke). Carbon monoxide. Unidentified organic and inorganic compounds.

Suitable Extinguishing Media

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

Unsuitable Extinguishing Media

: Do not use water in a jet.

Protective Equipment for Firefighters

: Proper protective equipment including breathing apparatus must be worn when approaching a fire in a confined space.

6. ACCIDENTAL RELEASE MEASURES

Avoid contact with spilled or released material. For guidance on selection of personal protective equipment see Chapter 8 of this Material Safety Data Sheet. See Chapter 13 for information on disposal. Observe the relevant local and international regulations. Protective measures : Avoid contact with skin and eyes. Use appropriate containment

to avoid environmental contamination. Prevent from spreading or entering drains, ditches or rivers by using sand, earth, or other appropriate barriers.

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

Additional Advice : Local authorities should be advised if significant spillages cannot be contained.




Safety Data Sheet



7. HANDLING AND STORAGE

General Precautions : Use local exhaust ventilation if there is risk of inhalation of vapours, mists or aerosols. Properly dispose of any contaminated rags or cleaning materials in order to prevent fires. Use the information in this data sheet as input to a risk assessment of local circumstances to help determine appropriate controls for safe handling, storage and disposal of this material.

Handling : Avoid prolonged or repeated contact with skin. Avoid inhaling vapour and/or mists. When handling product in drums, safety footwear should be worn and proper handling equipment should be used.

Storage : Keep container tightly closed and in a cool, well-ventilated place. Use properly labelled and closeable containers. Storage Temperature: 0 - 50°C / 32 - 122°F

Recommended Materials : For containers or container linings, use mild steel or high density polyethylene.

Unsuitable Materials : PVC. Additional Information : Polyethylene containers should not be exposed to high

temperatures because of possible risk of distortion. Storage class: 10 Fire hazard classification: B

8. EXPOSURE CONTROLS/PERSONAL PROTECTION

If the American Conference of Governmental Industrial Hygienists (ACGIH) value is provided on this document, it is provided for information only.

Occupational Exposure Limits Exposure Controls : The level of protection and types of controls necessary will vary

depending upon potential exposure conditions. Select controls based on a risk assessment of local circumstances. Appropriate measures include: Adequate ventilation to control airborne concentrations. Where material is heated, sprayed or mist formed, there is greater potential for airborne concentrations to be generated.

Personal Protective Equipment

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

Respiratory Protection : No respiratory protection is ordinarily required under normal conditions of use. In accordance with good industrial hygiene practices, precautions should be taken to avoid breathing of material. If engineering controls do not maintain airborne concentrations to a level which is adequate to protect worker health, select respiratory protection equipment suitable for the specific conditions of use and meeting relevant legislation. Check with respiratory protective equipment suppliers. Where




Safety Data Sheet



air-filtering respirators are suitable, select an appropriate combination of mask and filter. Select a filter suitable for combined particulate/organic gases and vapours [boiling point >65 °C (149 °F)] meeting EN14387.

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

Eye Protection : Wear safety glasses or full face shield if splashes are likely to occur. Approved to EU Standard EN166.

Protective Clothing

: Skin protection not ordinarily required beyond standard issue work clothes.

Monitoring Methods : Monitoring of the concentration of substances in the breathing zone of workers or in the general workplace may be required to confirm compliance with an OEL and adequacy of exposure controls. For some substances biological monitoring may also be appropriate.

Environmental Exposure Controls

: Minimise release to the environment. An environmental assessment must be made to ensure compliance with local environmental legislation.

9. PHYSICAL AND CHEMICAL PROPERTIES

Appearance : Amber. Liquid at room temperature. Odour : Slight hydrocarbon. pH : Not applicable. Initial Boiling Point and Boiling Range

: > 280 °C / 536 °F estimated value(s)

Pour point : Typical -42 °C / -44 °F Flash point : Typical 252 °C / 486 °F (COC) Lower / upper Flammability or Explosion limits

: Typical 1 - 10 %(V)

Auto-ignition temperature : > 320 °C / 608 °F Vapour pressure : < 0,5 Pa at 20 °C / 68 °F (estimated value(s)) Density : Typical 883 kg/m3 at 15 °C / 59 °F Water solubility : Negligible. n-octanol/water partition coefficient (log Pow)

: > 6 (based on information on similar products)

Kinematic viscosity : Typical 312,7 mm2/s at 40 °C / 104 °F Vapour density (air=1) : > 1 (estimated value(s)) Evaporation rate (nBuAc=1) : Data not available




Safety Data Sheet



10. STABILITY AND REACTIVITY

Stability : Stable. Conditions to Avoid : Extremes of temperature and direct sunlight. Materials to Avoid : Strong oxidising agents. Hazardous Decomposition Products

: Hazardous decomposition products are not expected to form during normal storage.

11. TOXICOLOGICAL INFORMATION

Basis for Assessment : Information given is based on data on the components and the toxicology of similar products.

Acute Oral Toxicity : Expected to be of low toxicity: LD50 > 5000 mg/kg , Rat Acute Dermal Toxicity : Expected to be of low toxicity: LD50 > 5000 mg/kg , Rabbit Acute Inhalation Toxicity : Not considered to be an inhalation hazard under normal

conditions of use. Skin Irritation : Expected to be slightly irritating. Prolonged or repeated skin

contact without proper cleaning can clog the pores of the skin resulting in disorders such as oil acne/folliculitis.

Eye Irritation : Expected to be slightly irritating. Respiratory Irritation : Inhalation of vapours or mists may cause irritation. Sensitisation : Not expected to be a skin sensitiser. Repeated Dose Toxicity : Not expected to be a hazard. Mutagenicity : Not considered a mutagenic hazard. Carcinogenicity : Components are not known to be associated with carcinogenic

effects. Reproductive and Developmental Toxicity

: Not expected to be a hazard.

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

12. ECOLOGICAL INFORMATION

Ecotoxicological data have not been determined specifically for this product. Information given is based on a knowledge of the components and the ecotoxicology of similar products. Acute Toxicity : Poorly soluble mixture. May cause physical fouling of aquatic

organisms. Expected to be practically non toxic: LL/EL/IL50 > 100 mg/l (to aquatic organisms) (LL/EL50 expressed as the nominal amount of product required to prepare aqueous test extract).

Mobility : Liquid under most environmental conditions. Floats on water. If it enters soil, it will adsorb to soil particles and will not be mobile.

Persistence/degradability : Expected to be not readily biodegradable. Major constituents are expected to be inherently biodegradable, but the product contains components that may persist in the environment.




Safety Data Sheet



Bioaccumulation : Contains components with the potential to bioaccumulate. Other Adverse Effects : Product is a mixture of non-volatile components, which are not

expected to be released to air in any significant quantities. Not expected to have ozone depletion potential, photochemical ozone creation potential or global warming potential.

13. DISPOSAL CONSIDERATIONS

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

Container Disposal : Dispose in accordance with prevailing regulations, preferably to a recognised collector or contractor. The competence of the collector or contractor should be established beforehand.

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

EU Waste Disposal Code (EWC): 13 02 06 synthetic engine, gear and lubricating oils. Classification of waste is always the responsibility of the end user.

14. TRANSPORT INFORMATION

ADRThis material is not classified as dangerous under ADR regulations. RIDThis material is not classified as dangerous under RID regulations. ADNRThis material is not classified as dangerous under ADNR regulations. IMDG This material is not classified as dangerous under IMDG regulations. IATA (Country variations may apply) This material is not classified as dangerous under IATA regulations.

15. REGULATORY INFORMATION

The regulatory information is not intended to be comprehensive. Other regulations may apply to this material.

EC Classification : Not classified as dangerous under EC criteria.




Safety Data Sheet



EC Symbols : No Hazard Symbol required EC Risk Phrases : Not classified.EC Safety Phrases : Not classified.

Chemical Inventory Status EINECS : All components

listed or polymer exempt.

TSCA : All components listed.

National Legislation Water Pollution Class : WGK 1 - low hazard to waters (appendix 4, VwVwS,

preparations). Sensitiser not sufficient to classify

: Contains alkylamine. May produce an allergic reaction.

Other Information : Technische Anleitung Luft: Product not listed by name.

Observe section 5.2.5 in connection with section 5.4.9 16. OTHER INFORMATION

R-phrase(s)

Not classified. R22 Harmful if swallowed. R23/24 Toxic by inhalation and in contact with skin. R34 Causes burns. R43 May cause sensitization by skin contact. R48/20 Harmful: danger of serious damage to health by prolonged exposure through

inhalation. R50/53 Very toxic to aquatic organisms, may cause long-term adverse effects in the

aquatic environment. MSDS Version Number

: 1.0

MSDS Effective Date : 01/12/2011

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

MSDS Regulation : Regulation 1907/2006/EC MSDS Distribution : The information in this document should be made available to

all who may handle the product. Disclaimer : This information is based on our current knowledge and is

intended to describe the product for the purposes of health, safety and environmental requirements only. It should not therefore be construed as guaranteeing any specific property of the product.


BEKA Gear pump

Type FL 11 C

Article-No. 3030 011050046

Installation, operation and maintenance instruction


Madams

Hervorheben

Zentralschmiertechnik

BAIER + KÖPPEL

K 3000.1091.1 GB

D--91253 Pegnitz -- Postfach 1320 -- Telefon 09241/729--0 -- FAX 09241/72950

Instructions for use and maintenanceGear pumps

Taking the unit into operation

InstallationThe gear pump may be installed in vertical as well as in horizontal position. Angular bases and pump sup-ports required for that purposeare available. For direct---drive operation the pump is equipped with an ela-stic clutch. Belt and cogwheel drive assemblies as well as axial loads to the shaft are not acceptable. Wheninstalling the pump, the piping assembly connected to it has to be taken into account. Tensions due to incor-rectly installed tubes or to misalignment of the drive motor should be avoided. Any misalignment of the shaftshould not exceed 0,2 mm. Even if some manufacturers of drive clutches state that a greater misalignmentcan be compensated by the clutch, the restoring force of the clutch generates some radial load on the shaftsto be connected, and this may result in damages to the pump. Impacts on the shaft end are not acceptableat all, as they might result in serious damage to the pump.

Piping assembliesWhen designing the size of a piping assembly, at has to be made sure that the acceptable flow speeds willnot be exceeded. In the suction pipe, they should not exceed 1,5 m/sec., and in the pressure pipe theyshould not exceed 5 m/sec. (for more details, please consult the manufacturer). Before installation, anypiping assembly should be cleaned carefully. The suction pipe has to be perfectly airproof, and it shouldbe arranged as straight as possible, its end always being placed a few centimeters below of the minimumoil level in the tank. The maximum suction lift should be restricted to a maximum of approx. 1 m. For thepiping assembly seamless precision steel tubes as per DIN 2391 are recommended.

Range of viscosityThe range of viscosity at operation should be between 15 and 800 mm2/s, as per graph 1 attached hereto.The range of use of an oil may be clarified by reading the table of viscosities and temperatures. To this effect,two viscosity values --- for ex. for 20° and 50° C --- must be entered into the graph. The point of intersectionof the straight line passing through these points, with the lines for maximum and minimum viscosity, indica-tes the temperature limits of the oil concerned.Attention: mind lubricant recommendation of manufacturer!

Oil quantity --- Oil temperatureThe oil quantity required in the storage tank depends on the conditions of operation. In case of intermittentoperation, a quantity will be satisfactory which corresponds to two times the total flow rate per minute ofthe pump. For continous operation, a quantity of oil of 3 or 4 times that reserve has to be provided. Theservice temperature should be in the range from ---10° to +80° C (refer to diagram 1). The ideal range oftemperature is from 30° up to 50° C. Under particular circumstances, installation of an oil cooler may berequired in order to keep the temperature within certain limits.

FiltrationIt is recommended to install a filter having a maximum mesh size of 0,100 mm and magnetic separatingdevice. An additional suction filter with a mesh size of 0,100 up to 0,200 mm will protect the pump againstcoarse dirt. It should be cleaned at regular intervals in order to prevent the suction vacuum pressure fromfalling below the specified limits, as this might lead to damages by cavitation.


Madams

Hervorheben


BAIER + KÖPPEL

K 3000.1091.2 GB


Maximum pressureThe pump must be protected against excessive pressure, by means of a pressure restrictor valve. Settingof that pressure restrictor valve effected by using a pressure gauge for control.

Speed --- Sense of rotationAccording to the size of the type concerned, the minimum service speed is approx. 500 r.p.m. The nominalspeed is 1400 r.p.m. All performance data stated in the leaflet are based on these ratings. In that leaflet, youwill find also the maximum speeds of the individual types. Normal sense of rotation is clockwise, and markedby an arrow. When the unit is taken into operation, the correct sense of rotation of the electrical motor shouldbe checked by turning it ”ON” for a short period of time (maximum 5 seconds) before the line is filled withfluid for the first time.

ClutchThe diameter tolerance of the shaft end is j6. The diameter tolerance of the clutch hub should be in accordan-ce to H7.

Start---up operationIt will be usefull to fill the pump and the suction with pressure fluid by manual rotation, before putting themotor into operation. After that, the pump should be set to ”supply” condition, by turning the motor ”ON”.In doing so, watch the fluid level in the tank until bleeding of the system is positively finished, in order to makesure that the fluid level does not decrease to an amount less than the minimum suction limit. After the firststart ---up operation (in depressurized condition), the system should be turned ”OFF” again, in order to allowseparation of air dissolved in the oil. Operation of the pump in pressurized condition is acceptable only ifthe pressure fluid does not contain any bubbles.

Maintenance

GeneralThe gear pump is lubricated by the oil and, therefore, does not require any maintenance. Care and servicework are restricted to keeping the hydraulic oil perfectly clean, to checking the oil level and the temperature,and to cleaning of the filters. In this context we recommend that our detailed instructions for operation andservice of pipe filters should be complied with. In order to preclude any corosion, the pump should be filledwith oil if it is kept on stock for a substantial period of time (more than one year).

Malfunctions and remedies

Even if all instructions and notes of advice are strictly complied with, a malfunction may occur in some orother case. The remarks listed here---below are to help you to identify and eliminate the fault, taking intoaccount the symptoms actually detected.


Madams

Hervorheben


BAIER + KÖPPEL

K 3000.1091.3 GB


2.1 Air has entered the suction pipe. Refer to items 1.1.2 and 1.1.3

2.2 Pressure relief valve does not close as it is Clean the pressure relief valve,damaged, or the spring is broken. or replace the defective spring.

2.3 Bresakage of tube underneath the tank cover, Repair the defectiveness.or threaded tube connections not tightened inthe proper way.

2.4 Substantial wear of the pump. Have the pump repaired by the factory.

Malfunction No. 1: The pump does not supply fluid.

Possible reasons Remedies

Malfunction No. 2: The pump supplies fluid, but there is lack of pressure,or pressure is not satisfactory

Remedies


Possible reasons

1.2 Supply is interrupted even if the drive system is okay.

1.1 The pump does not suck--- in any fluid

1.1.1 The plug was not removed from the suction pipe. Remove the plug.

1.1.2 Leakage of the suction pipe. Re--- tighten the screwed joints; seal the threads.

1.1.3 Suction pipe is too short, or oil level in the tank Extend the suction pipe,is too low. top up with oil.

1.1.4 Flow resistance in the suction pipe is too high Increase the tube diameter; straighten the suction pipe;(excessive depressiopn). clean the suction filter; reduce the intake height.

1.1.5 Wrong sense of rotationof the motor assembly. Correct the sense of rotation.

1.1.6 Pressure pipe closed by the valve, or under Change over the depressurized circulation, or bleedpre--- load, so that bleeding of the pump is the pump by opening the pressure socket.impossible.

1.1.7 Excessive viscosity of the pressure fluid, or Fill the system using a pressure fluid, the viscosity ofexcessive cooling of the pressure fluid. which is suitable for the service temperature.

1.2.1 Destroyed clutch. Replace the clutch.

1.2.2 Pump shaft shorn off. Have the unit repaired by the factory.

1.2.3 Leakage of the suction pipe. Refer to item 1.1.2

1.2.4 Oil level in the tank is lower than the minimum Top up with pressure fluid.required for suction.


Madams

Hervorheben


BAIER + KÖPPEL

K 3000.1091.4 GB



Malfunction No. 3: Excessive pump noise

800

25

20

15---30 ---20 ---10 0 10 20 30 40 50 60 70 80 90 100 110 120 130

100

150

200

300

400500600

90807060

50

40

30

Viscosity mm2/s ( cSt )

Temperature ( ° C )

Graph 1

3.1 Air is taken in by the pump. Refer to items 1.1.2 and 1.1.3

3.2 Defective shaft seal. Install a new shaft seal.

3.3 Cavitation in the pump. Refer to items 1.1.4 and 1.1.7

3.4 Clutch is defective or misaligned. New clutch, or re---align the clutch.

3.5 Pump is defective. Have the pump repaired by the factory.


Madams

Hervorheben


Madams

Hervorheben