Professional Documents
Culture Documents
HDP 72
B3.01072.1592
HDP 72
2013
Made in Germany
Issue: 02.2013
MACHINE CARD
>>>end<<<
HAMMELMANN
Maschinenfabrik GmbH
Zum Sundern 13 – 21
59302 Oelde • Germany
Weitere, zutreffende EG-Richtlinien: Other appropriate E.C. Directives: Directrizes Europeas aplicadas
Angewandte nationale Normen und National standards and technical Normas nacionales y especificaciones
technische Spezifikationen: specifications: aplicadas especialmente:
- -
22.02.2013
TB 008/0106
HDP 72
HDP 72
2013
Made in Germany
Issue: 02.2013
Operating instructions
No.: HDP 72 Contents
Page 2, Issue: 02.2013
1 Contents
1 Contents ............................................................................................................................................................ 2
2 Foreword ........................................................................................................................................................... 5
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
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
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 Oil change ................................................................................................................................................... 37
11.5.1 First oil change after 1000 operating hours ........................................................................................ 37
11.5.2 Next oil changes ................................................................................................................................. 37
11.5.3 Lubrication plan and lubricants ........................................................................................................... 38
11.6 Repair & Replacement................................................................................................................................ 39
11.7 Maintenance of the pump head 00.02145.1089 (-006) .............................................................................. 40
11.7.1 Disassembly (ref. to fig. pump head) .................................................................................................. 40
Operating instructions
No.: HDP 72 Contents
Page 4, Issue: 02.2013
15 Index................................................................................................................................................................. 63
Operating instructions
Foreword No.: HDP 72
Page 5, Issue: 02.2013
All personnel who are responsible for the operation and maintenance of the
High pressure pump HDP 72 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 /T ec hnis che D aten/Zu di es er Anlei tung/Hers tell eradress e @ 0\mod4_2.doc @ 1212 @ @ 1
Type: HDP 72
Date: 2013
D = Piston diameter
PN = Required power rating
n = r.p.m.
P = Operating pressure
Q = Flow rate
n in 1/min PN in kW
D in mm Engine Crank shaft Q in l/min 30 37 45 55 70
n1 n2 p in bar
1500 625 26 600 740 900 1100 1130
22
1500/1800 750 32 500 610 750 910 1130
1500 625 32 500 620 750 920 950
24
1500/1800 750 38 420 520 630 780 950
1500 625 38 430 530 640 780 810
26
1500/1800 750 45 350 440 530 650 810
1500 625 50 320 390 480 590
30
1500/1800 750 59 260 330 400 490 600
1500 625 69 230 290 350 430
35
1500/1800 750 81 190 240 290 360 440
1500 625 91 180 220 270 330
40
1500/1800 750 107 150 180 220 270 340
1500 625 115 140 170 210 260
45
1500/1800 750 135 110 140 170 210 270
1500 625 142 110 130 170 210
50
1500/1800 750 167 90 110 140 170 210
1500 625 172 90 110 140 170
55 1500/1800 750 201 70 90 110 140 180
1800/2150 900 246 60 70 100 120 150
09. X X XX X. X XXX
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.
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
No.: HDP 72 Safety
Page 12, Issue: 02.2013
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.
Operating instructions
Safety No.: HDP 72
Page 13, Issue: 02.2013
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. Anwendungsbereic h @ 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. Eins atzbedi ngungen 40° @ 0\mod721_2.doc @ 4480 @ 2 @ 1
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
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.
Pos : 25 /xxxxxxxxx xxxxxx xxxx @ 0\mod6_2.doc @ 1188 @ @ 1
Operating instructions
No.: HDP 72 Transportation
Page 16, Issue: 02.2013
Pos : 26 /Trans por t/Ü bersc hrift Transport @ 0\mod218_2.doc @ 1348 @ 12222 @ 1
6 Tran sport ation
Pos : 27 /Trans por t/Trans por t Pumpen @ 0\mod216_2.doc @ 1344 @ 2222 @ 1
6.1 Packing
Method of packing is determined by method of transport. At the minimum the pump unit will be protected from the
elements.
This way up Keep away from heat Sling here Keep dry
Fragile handle with Centre of gravity No hand truck here Use no hooks
care
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 /xxxxxxxxx xxxxxx xxxx @ 0\mod6_2.doc @ 1188 @ @ 1
Operating instructions
No.: HDP 72 Construction & Description
Page 18, Issue: 02.2013
Pos : 29 /Aufbau und Besc hrei bung/Ü bersc hrift @ 0\mod155_2.doc @ 1372 @ 1 @ 1
7.1 Construction
Pos : 31 /Aufbau und Besc hrei bung/Pumpen/HD P 70/Aufbau HDP 72 @ 0\mod153_2.doc @ 2088 @ 3 @ 1
Pos : 33 /Aufbau und Besc hrei bung/Pumpen/HD P 70/Besc hrei bung HD P 72 (Doppel kegel ventil) @ 8\mod_1345035100285_2.doc @ 68516 @ 2233333333 @ 1
7.2 Description
The HDP 72 is a compact, three 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 apparations of
wear to an absolute minimum. That guarantees a long working time under highest pressures.
The crank section is precision built to withstand heavy loads. Its function is to transmit the rotary motion of the drive
shaft to an oscillating motion at the pump plungers. The transmission works via three pump plungers turned by
120° with conrods and crossheads. The crankshaft is an assembly made from hardened and tempered steel. The
canted 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 an oil pump, an oil cooler, oil filter and an oil pressure
manometer. It supplies all bearings and sliding faces with filtered oil. 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
special seals and a rotary shaft seal at the drive shaft .
Check the oil pressure! The ideal oil pressure should be between 3 and 6 bar. A safety shut
off is carried out at 2 bar.
The piston seal assembly is the piston or plunger sealing. The piston or plunger sealing is made by packings. The
arrangement of the packings is so designed that the packings are self adjusted. If their is a higher leakage
observed change the packings. Any high pressure leakage flows back into the suction chamber. The piston
respectively the plunger is made by solid ceramics.
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
No.: HDP 72 Construction & Description
Page 20, Issue: 02.2013
Druckwasser
Suction water
Pos : 35 /Aufbau und Besc hrei bung/S-Anlagen/Beschr eibung Druc kr egel ventil @ 0\mod157_2.doc @ 2184 @ 131222222 @ 1
The pressure regulating valve/overflow valve allows a smooth setting of operating pressure from admission
pressure to max. operating overpressure. That makes an optimal use of the energy source.
The drive can happen pneumatic or manual.
Regulators are available in various forms for a variety of operating pressures and flow rates.
Mobile units with pneumatic pressure regulating valves are usually supplied with control air pressure from a
compressor in the system. On stationary units the local air pressure can be used from an internal pneumatic
circular pipeline. The max. control pressure air required is 4 bar.
Setting the wished pressure with the pressure regulating valve (manual adjustment) by:
Turning the eccentric lever
Setting of the air pressure with the help of the pressure air:
The operating pressure is directly proportional to the control air pressure with which the pressure
regulating valve is admitted.
Increasing the air pressure means setting a higher operating pressure.
Decreasing of air pressure means setting a lower operating pressure.
Pos : 36 /Aufbau und Besc hrei bung/Pumpen/Besc hreibung Sic herheits ventil @ 0\mod433_2.doc @ 5712 @ 233322222 @ 1
The safety valve prevents the high pressure pump from accidentally exceeding the maximum permitted operating
pressure. It is set at the maximum permitted operating pressure and secured by locking wire at our works. If the
pump pressure exceeds the set pressure then the safety valve opens and the medium emits pressureless. If the
safety valve has operated it should be tested to ensure that it is sealing under pressure. If it is not it must be
replaced. The seat stud / guide piece can be refurbished and the valve reset at our works. Repair and resetting is
only permitted at our works.
Pos : 37 /xxxxxxxxx xxxxxx xxxx @ 0\mod6_2.doc @ 1188 @ 22 @ 1
Operating instructions
No.: HDP 72 Installation & Start up
Page 22, Issue: 02.2013
Pos : 38 /Vorber eitung z ur Inbetri ebnahme/Installation/Ü bers chrift @ 0\mod168_2.doc @ 1380 @ 122222222333333 @ 1
8 Installation & St art up
Pos : 39 /Vorber eitung z ur Inbetri ebnahme/Installation/Pumpen/Vorbereitung zur Inbetriebnahme allgemein @ 0\mod415_2.doc @ 5672 @ 2222222222333333333 @ 1
The driver power must be transmitted to the pump by a flexible coupling (not HDP 10 & 20 which are belt
driven).
When selecting the coupling please refer to the manufacturer’s literature AND THE DRIVER
MANUFACTURER’S TECHNICAL DATA;
Check the adjustments of the coupling particularly alignment and if necessary readjust.
The preferred direction of rotation of the pump is marked on the crank housing (on the right side seen from the
front on the drive shaft).
To prolong the life or wearing parts such as valves, control pistons etc. it is recommended
that you ensure 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 pressure sensor (with
monitoring) to immediately switch off the high pressure pump in the case of a blocked
filter.
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 your Hammelmann agent or from Hammelmann
customer services.
Filters are available from HAMMELMANN to eliminate abrasive particles larger than 10 µ
and concentrations of 20 mg/l.
When used in high pressure washing- or de-burring machines etc. follow our specific
instructions for these applications.
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 an output 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 an output 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.
Fig.: Diagram
The pressure loss represented here is related to 1 m length and increases linearly with increasing hose / pipe
length (theoretical values).
Operating instructions
No.: HDP 72 Installation & Start up
Page 26, Issue: 02.2013
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.
Piston cooling
Never close off the piston cooling drain hose/line. The 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 outside 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 often the case in
production processes) should be flexible enough to counter the effects of discharge pulsation.
Torque for high pressure hoses
Nominal dia. in mm Connection thread Spanner size in mm Torque in Nm
10 M 18 x 1,5 DKL 22 50
12 M 22 x 1,5 DKL 27 62
20 M 30 x 1,5 DKM 36 83
25 M 38 x 1,5 DKM 46 105
10 M 22 x 1,5 DKO 27 30
12 M 24 x 1,5 DKO 32 33
20 M 36 x 2,0 DKO 46 49
25 M 42 x 2,0 DKO 50 57
Connection with pressure screw and pressure ring
Pressure screw
5 M 14 x 1,5 links 70
M 30 x 2 (32mm A/F)
Pressure screw
8 M 14 x 1,5 LH 70
M 30 x 2 (32mm A/F)
Pressure screw
12 M 20 x 1,5 LH 70
M 42 x 2 (46mm A/F)
30
50 SAE 2” 6000 psi 300
(4 x M 20)
Operating instructions
No.: HDP 72 Installation & Start up
Page 28, Issue: 02.2013
Bypass line
The standard bypass connection is a ”push fit” connector on the Hammelmann pressure regulating valve or
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 pressure regulating valve or bypass valve.
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.
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
No.: HDP 72 Operation
Page 30, Issue: 02.2013
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.
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 : 43 /xxxxxxxxx xxxxxx xxxx @ 0\mod6_2.doc @ 1188 @ 22 @ 1
Operating instructions
Shut down No.: HDP 72
Page 31, Issue: 02.2013
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.
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.
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.
10.3.3 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.
Operating instructions
Shut down No.: HDP 72
Page 33, Issue: 02.2013
10.3.4 Equipment required for filling a pump unit if no suction installation is available
10.3.5 Method of filling the pump with anti-corrosion emulsion or anti-freeze solution
using an external membrane pump
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”.
Pos : 46 /xxxxxxxxx xxxxxx xxxx @ 0\mod6_2.doc @ 1188 @ 222333 @ 1
Operating instructions
Maintenance No.: HDP 72
Page 35, Issue: 02.2013
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!
Pressure too low. Valve set(s) seals defective. Fit new seals.
Suction valves can be reground
Damaged suction and pressure or replaced. Damaged discharge
valve(s). valves should be replaced.
Check condition of valve springs.
Replace burst disc. Check why
Burst disc rupture. Maximum pressure exceeded. pressure exceeded. Remedy
fault.
Pump noisy. Suction side medium shortage. Check suction side installation.
Extreme pulsation, H. P. discharge Suction or pressure valve(s)
Rework or renew as necessary.
line. sticking.
Water leaking form suction chamber Low pressure seal pack(s)
Replace seals.
/ intermediate chamber. defective.
Defective seal(s) at plunger rod / Check seals and bellows if
Oil leaks into the intermediate crosshead. necessary renew.
chamber.
Too much oil in crank. Drain oil to correct level.
Check sealings and rotary shaft
Oil leaks from the crank case. If necessary renew sealings.
seals at the crank housing.
Oil emulsion emits from breather. Medium entering crank section. Change the oil, including
cleaning /changing the filter,
renew the seals. (ref. to oil
Dipstick shows signs of emulsion. Medium in crank section. change). Check the bellows. If
necessary renew.
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
No.: HDP 72 Maintenance
Page 36, Issue: 02.2013
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.
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.
Procedure:
Change the oil, when pump is warm (oil drains better).
Drain the oil with the oil drain thread. Use a piece of a hose if necessary.
A collecting tank is necessary for catching the oil (4,3 litres).
Lay a rag or equivalent under the oil filter and then unscrew the housing. Take out filter cartridge and exchange
with a new (order no. 04.00995.0153). Reassemble the housing with the new filter cartridge.
Examine old oil for formation of emulsion.
Clean the thread of the oil hose and grease with Molykote 1000.
Screw the vent plug of the oil drain valve and reassemble the oil hose.
Fill the crank housing with new oil.
When cleaning the oil filter with solvents or equivalent (i.e. fuel)!
Solvents can be harmful to health! Pay attention to the instructions of the solvent
manufacturer (i.e. warning on the packing)!
Never fill solvents into tanks or bottles of foods or drinks. When drying with pressure air:
Do not hold bodily parts in the pressure air jet.
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.
Operating instructions
No.: HDP 72 Maintenance
Page 38, Issue: 02.2013
Alternative oils
Product
Producer
CLP 150 / ISO VG 150
Avia Syntogear PE 150
Addinol Eco Gear 150 S
Aral Degol PAS 150
BP Enersyn EP-XF 150
Castrol Alphasyn EP 150
Optimol Optigear Synthetic A 150
Esso Spartan Synth EP 150
Fuchs Renolyin Unisyn CLP OIL 150
Mobil SHC 629
Mobil
Mobilgear SHC XMP 150
PANOLIN Tecsynth 150
Enduratex* Synthetic
Petro-Canada
EP 150
Shell Omala S4 GX 150
Total Carter SH 150
OMV OMV gear SHG 150
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.
Operating instructions
Maintenance No.: HDP 72
Page 39, Issue: 02.2013
The unit should be switched off, the panel cover locked and the key removed for
safekeeping before attempting to commence repairs.
Pos : 51 /Instandhal tung/Pumpen/Pumpenkopf/PK 1089 HDP 40/70 (DKV) @ 5\mod_1233662307821_2.doc @ 29114 @ 22222333333 @ 1
At every removing / disassembly of the pump head / valve housing check the torque
of item 500. If necessary retighten.
Be extremely careful when removing the valve seat rings (150). Making the slightest scratch
or mark will eventually cause the component to crack.
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) for scratches, pitting or cracks. Replace if any of these are evident.
Examine the screw in piece (500) and tappet (550 and 510) for signs of wear, if damaged exchange it.
The supporting surface between the valve seats (150) and the sleeves of the seal assembly and to the pump
housing should be smooth. Exchange scratched parts.
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. Grease all slide ways carefully
(grease always means Stabyl MO 500 - order no. 04.04660.0002).
Assembly of the pump head
Grease the bore surfaces of the valve housing (10) with water repellent grease.
If necessary place the tappet (510) and spring (20) into the screw in piece (500).
Lightly grease the thread of the screw in piece (500) with Molykote 1000 (order no. 04.02750.0011) and screw
into the housing. Tighten to 250 Nm.
If necessary insert the bushing (160) in the sleeve of the seal assembly.
Insert spring (140) with tappet (550) in the bush (160).
Grease the cylinder rings (40) and carefully install it into the valve seat ring (150).
Coat internal and external surfaces of valve seat ring (150) with grease. Grease suction valve (30) and place it
into the valve seat ring (150). Place the valve seat ring (150) into the sleeve of the piston seal assembly.
Grease pressure valve (30) and place it into the valve seat ring (150).
If necessary place the O-ring (50) into the spacer ring (550).
Build in the other valve sets this way.
Operating instructions
Maintenance No.: HDP 72
Page 43, Issue: 02.2013
Assemble the pump head (valve housing) on the crank section or suction chamber. To do so:
Lightly grease the supporting surfaces of pump head/seal assembly.
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. Screw nuts (520) on the stud bolts (530)
by your hand.
Sketch pump head
Then working crosswise with torque wrench
and 27 mm socket tighten down nuts (520).
Req. torque = 240 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.
11.8.1 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.
Disassembly of the seal assembly (ref. to fig.: Loosen the piston & fig.: Piston seal assembly)
Disconnect high pressure line / hoses and all other parts.
Remove pump head and lay it on a workbench or similar (ref. to chapter pump head).
The casing bills of the seal assembly lay bare now.
(Ref. to fig.: Loosen the piston) Remove the cover plate of the intermediate chamber.
(Ref. to fig.: Loosen the piston) Remove the circlips from the clamp halves with the help of circlip pliers.
(Ref. to fig.: Loosen the piston) Remove the clamp halves. The pistons are now loosened from the piston rod.
Fig.: Loosen the piston
Item no. Description
1 Set screws
2 Intermediate chamber
4 Piston rod
20 Piston
360 O-ring
470 Clamp halves
480 Circlip
Unscrew the seal ring holder (30) from the casing (10). Fix the casing carefully into a vice with protective
cheeks so that nothing gets damaged. By using a 65 mm A/F spanner unscrew the seal ring holder.
Remove bushing (300) the ring (110) packings (130) and bushing (150) from the casing (10).
Remove the O-rings (60) from the grooves of the seal ring holder.
Remove spring pack (100), ring (380), lantern ring (290), packings (40) and back ring (120) from the seal ring
holder (30).
11.8.2 Reassembly
Clean and examine all parts for wearing and scratching. Replace with new parts if necessary. Renew packings
and seals.
When doing assembly grease all sliding parts (like packings etc.) with Stabyl MO 500 (order no.
04.04660.0002).
Insert back ring (120), packings (40), lantern ring (290), ring (380) and spring pack (100) into the seal ring
holder. The join in the packings should be at 180o when correctly positioned. Lightly grease all parts with
Stabyl MO 500.
If the spring pack is not fitted, act as follows. Press the single springs with water pump pliers or equivalent into
the ring. Then place the second ring and press this in with the help of a vice.
Lightly grease the inner surfaces of the casing (10). Slide bushing (150) into the casing.
Install packings (130) with ring (110) into the casing (10). The join in the packings should be at 180° when
correctly positioned. Slide the bushing (300) into the casing.
Lightly grease the threaded surfaces of the seal ring holder with Silver Goop (order no. 04.00982.0010). Screw
the preassembled seal ring holder (30) with the preassembled casing (10). Fix the casing carefully into a vice
with protective cheeks so that nothing gets damaged. Then tighten up the seal ring holder with a 65 mm torque
wrench. For the req. torque ref. to drawing 00.00743.1989.
Insert the O-rings (60) in the grooves of seal ring holders (30).
Insert the O-rings (60) in the grooves of seal ring holders (30).
Lightly grease all parts of the inner seal assembly and slide the piston (20) in the seal assembly.
Do the same with other seal assemblies.
Insert the complete casing (10) with piston (20) in the pump housing. Ensure that the piston (20) does not fall
away.
Press the casing (10) in its seat in the pump housing. Ensure that the O-rings (60) are not pressed out of their
grooves.
Slide the piston (20) onto the piston rod. Press the clamp halves (470) on the connection and fix it with light hits
(plastic tip hammer). Fix the clamp halves (470) with circlips (480).
Operating instructions
No.: HDP 72 Maintenance
Page 46, Issue: 02.2013
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/Dic htungss atz/Pac kungsei nbau @ 0\mod192_2.doc @ 3256 @ 22122 @ 1
Operating instructions
No.: HDP 72 Maintenance
Page 48, Issue: 02.2013
After long pump shut down periods (> 1/2 year) the packings must be renewed.
In this connection, if necessary, carefully remove any deposits on the plungers. Take care
not to scratch or damage them.
Installation of packings
If supplied in uncut lengths measure and cut as required. Especially pre cut packings for each seal assembly
set are available from HAMMELMANN.
Check the length of cut sealings if necessary.
The packings extend slightly when they are pressed, so leave a gap when fitting.
The cut should be made at an angle of 45°. In the fitted condition the cut should go downwards, not sideways.
Coat packings with MoS2
Determining the length Cutting angle
Thread size
Material
M6 M 8 M 10 M 12 M 14 M 16 M 18 M 20 M 24
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.
Pos : 58 /xxxxxxxxx xxxxxx xxxx @ 0\mod6_2.doc @ 1188 @ 112222 @ 1
Operating instructions
No.: HDP 72
Pressure regulating valve
Page 50, Issue: 02.2013 00.05893.0031
Pos : 59 /Instandhal tung/Druc kr egel ventil/DRV 00.05893.0031 @ 6\mod_1289476104619_2.doc @ 41768 @ 1112222 @ 1
12 Pressur e r egulating valve 00.05893.0031
1
Adjustment pressure 0 - 500 bar
Operating pressure max.: 1200 bar
Flow rate max.: 500 l/min.
Nominal diameter: DN 17
Quantity of oil filling for dampening: 0,3 l
Oil quality: ISO VG 68 DIN 51519
Factory filling: Aral Konit SAE 20 W 20
Weight approx.: 20 kg
1
Dependent on the control air pressure, which is given on the membrane cylinder (ref. to diagram)
12.3 Adjustment
The pressure regulating valve allows a smooth increase of pressure from suction pressure to max. operating
pressure.
Adjust the operating pressure via the control air pressure. The operating pressure is directly proportional to the
control air pressure with which the pressure regulating valve is admitted (ref. to diagram).
Increasing the air pressure ⇒ increases the operating pressure.
Decreasing the air pressure ⇒ decreases the operating pressure.
12.4 Maintenance
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!
Disassembly
Operating instructions
No.: HDP 72
Pressure regulating valve
Page 56, Issue: 02.2013 00.05893.0031
Remove ring (50) from housing (10).
Carefully clamp the pressure regulating valve (housing) in a vice so that the reduction piece (80) is over the top
and that nothing would be damaged.
Unscrew the reduction piece (80) out of the housing (10). Remove housing from vice. If necessary remove
cylinder ring (160) from the reduction piece (80).
Using circlip pliers remove circlip (110) from control piston.
Remove disc (130) and spring disc (140).
Push control piston (30) and valve seat ring (60) out of the housing (10)
By using a screw driver remove the holder (35)
from the housing (10). (Ref. to fig. 1) Thereby
do not damage the housing.
Afterwards remove support ring (20) with 'O'-
ring (25) from the housing (10).
Always exchange holder (35), seal (20) and O-
ring (25) together.
Fig. 1
Remove support ring (70 with ‘O’-ring) out of the valve seat ring (60). (Support ring and O-ring are one part
position.)
Inspection
Especially examine control piston (30) and valve seat ring (60) for signs of wear or damage. They should be
carefully examined and if worn replaced by new. If wear is slight or there are minor pits in the surface a certain
amount of rework is possible. Rework should be done only by HAMMELMANN.
Visually inspect all other parts for signs of wear or damage. Replace if necessary.
Operating instructions
Pressure regulating valve No.: HDP 72
00.05893.0031 Page 57, Issue: 02.2013
Fig. 2
Place seal ring (20) with O-ring
(25) onto the special tool (order
no. 01.06224.0137)
By using the special tool press
the seal ring (20) with O-ring (25)
in the correct position into the
housing (ref. to fig. 3 and 4).
Fig. 3
Operating instructions
No.: HDP 72
Pressure regulating valve
Page 58, Issue: 02.2013 00.05893.0031
Fig. 4
Fig. 5
Operating instructions
Pressure regulating valve No.: HDP 72
00.05893.0031 Page 59, Issue: 02.2013
Fig. 6
It is strictly forbidden to manipulate safety elements! Damage, i.e. to the lead seals or the
safety varnish can lead to the loss of all warranty claims.
Technical Data
Operating pressure: 400 - 700 bar
Connections: 2 x G ½“
Nominal width: DN 4,3
Weight approx.: 3,6 kg
Operating pressure Theoretical flow rate (L/min) at
(bar) nozzle coefficient 0,67
400 318
500 355
600 390
700 421
Ignoring these notes can invalidate all claims for injuries or damages.
Secure the high pressure hose at the equipment
every time with hose protections!
15 Index
S Transportation ...................................................... 17
Safety
Additional warnings .............................................. 13
1 2 3 4 5 6 7 8 9 10 11 12
120 314
60 157 55
A M16 : 28 tief A
M12 : 21 tief
X Y
60
55
45 °
O 139,7
B Schrauben M16 B
50 screws
Saugraum Entwässerung
suction chamber drainage
Öleinfüllstutzen
oil filler cap
788,5
CoM y= 6 4,49 CoM x= 6 5,96 Ölkühler
oil cooler
713
713
C C
Ölmessstab
91 dip stick
565
413
CoM z= 339,63
Öldruckmanometer
D oil pressure gauge D
253
235
220
123,95
15
30
30
22,5
80 38 O 17 22,5
236 208 Ölablassventil
E 266 286 oil outlet valve E
314 495
28
23,1 60,10
0,5 x 45°
255 19,4
151 0
2,5 60,1
94
F F
O
80 10
17
+0,05
O 36 H7
+0,1
O 42 0
O 26 0
M48 x 2
O 20
O 30
14
O 50 k6
Passfeder / key
A 14x9x80 DIN688561
Y
X 1:1
236
G
1:1 G
00.03223.1052
alle Ecken und Kanten gratfrei
208 ß Mit Betriebsdruck signiert Krabus A1
ß Mit Auftrags-Nr. signiert
Zul.Abweichung
ß Mit Teile-Nr. signiert Maßstab
1:3 Gewicht in kg
werden, und sie darf durch den Empfänger oder Dritte auch
f.Maße ohne
204.1000
Ohne unsere vorherige Zustimmung darf diese Zeichnung
ISO 2768 6 mH
Verwendungszweck Halbzeug Werkstoff *
H HDP 70 Oberfläche nach
DIN ISO 1302 H
Datum Name Benennung
Bearb 12.09.2012 Poetschke
Gepr. 13.09.2012 EHelmig
Norm 13.09.2012 Krabus HOCHDRUCKPUMPE
Zeichnungs6Nr. Revision Blatt
>>>end<<<
p_dbgs01.p
1 2 3 4 5 6 7 8 9 10 11 12
Anziehdrehmoment
Ma = 5 Nm
B6B A6A
A 40
4
30
4 20 A A
50
1 2 B
Anziehdrehmoment
Ma = 100 Nm 90
3
60 220
1 100 1
3
110
3 120
150 3
B 3 230 B
130 1
3
160
auf 6196 °C abge6 3
kühlt und einge6
schrumpft 140 20
3 2
370
500
170 C 1 C
3
1 590
1
510
C 1 C
180
520 3 450 580
1 1 1
10 300
1
D D 260
1
1
540
320 550
1
D 2 330 2 D
1 570
310 1 560
,
1 1
290
470 1
1
460
1
Anziehdrehmoment
Ma = 45 Nm
B 002
A
Anziehdrehmoment Anziehdrehmoment
210 Ma = 8,5 Nm 200 190 Ma=30Nm 350 280
E 18 1 1 10 1 E
F 440 430 F
2 2
D6D
420
1:1
1
G G
410
C6C 600
1 1
Vor Montage bitte Einbau von Pos.130 beachten!!!
Blatt 1 von 2
* Artikel6Nr. Format DIN
00.02350.1136
alle Ecken und Kanten gratfrei
ß Mit Betriebsdruck signiert
ß Mit Auftrags-Nr. signiert
Krabus A1
Zul.Abweichung
ß Mit Teile-Nr. - Rev. signiert Maßstab
1:2 Gewicht in kg
werden, und sie darf durch den Empfänger oder Dritte auch
f.Maße ohne
132.6960
Ohne unsere vorherige Zustimmung darf diese Zeichnung
ISO 2768 6 mH
Verwendungszweck Halbzeug Werkstoff *
H HDP 70 i=2,3913 Oberfläche nach
DIN ISO 1302 H
Datum Name Benennung
Bearb 10.08.2012 Sander
Gepr. 11.09.2012 EHelmig
Norm 12.09.2012 Krabus KURBELTRIEB
Zeichnungs6Nr. Revision Blatt
1 2 3 4 5 6 7 8 9
002 Pos.350 geä.
001 Pos.200 geändert
Zust Änderung
11.09.2012 Pöts
15.08.2012 San
Datum Name
D659302 OELDE
CAD6Zeichnung
00.02350.1136 1
Ers.durch
002
Ers.für 00.02350.081961
1 von
1 Bl.
1 2 3 4 5 6 7 8 9 10 11 12
A A
B B
530
1
C C
D 490 D
1
480
1
002
Anziehdrehmoment
350 Ma=30Nm
10
E E
F F
G G
Blatt 2 von 2
* Artikel6Nr. Format DIN
00.02350.1136
alle Ecken und Kanten gratfrei
ß Mit Betriebsdruck signiert
ß Mit Auftrags-Nr. signiert
Krabus A1
Zul.Abweichung
ß Mit Teile-Nr. - Rev. signiert Maßstab
1:2 Gewicht in kg
werden, und sie darf durch den Empfänger oder Dritte auch
f.Maße ohne
132.6960
Ohne unsere vorherige Zustimmung darf diese Zeichnung
ISO 2768 6 mH
Verwendungszweck Halbzeug Werkstoff *
H HDP 70 i=2,3913 Oberfläche nach
DIN ISO 1302 H
Datum Name Benennung
Bearb 10.08.2012 Sander
Gepr. 11.09.2012 EHelmig
Norm 12.09.2012 Krabus KURBELTRIEB
Zeichnungs6Nr. Revision Blatt
1 2 3 4 5 6 7 8 9
002 Pos.350 geä.
001 Pos.200 geändert
Zust Änderung
11.09.2012 Pöts
15.08.2012 San
Datum Name
D659302 OELDE
CAD6Zeichnung
00.02350.1136 1
Ers.durch
002
Ers.für 00.02350.081961
1 von
1 Bl.
PARTS LIST (41)
>>>end<<<
p_dbgs01.p
1 2 3 4 5 6 7 8
80
278 1
A A
90°
10
1
40
4
45 °
50
4
190
B B
70
95
1
60
2 30
8
C O 139,7 C
Saugraum bei Montage mit Kurbeltrieb
002 mit Kleber "TEROKAL 3 2444"
(04.02056.0005) umlaufend abgedichtet.
7 1 3 5
D D
6 4 2 8
Schrauben Pos. 30 mit integriertem Schmiermittel
002
und in angegebener Reihenfolge ohne Fett
E angezogen: E
1. Stufe: Anziehdrehmoment Ma = 80 Nm
2. Stufe: Anziehdrehmoment Ma = 160 Nm
3. Stufe: Anziehdrehmoment Ma = 265 Nm
Sonderausführung
Bronze Saugraum mit ANSI3Flansch Lochbild
* Artikel3Nr. Format DIN
00.04246.0096
alle Ecken und Kanten gratfrei
ß Mit Betriebsdruck signiert
ß Mit Auftrags-Nr. signiert
Krabus A2
Zul.Abweichung
ß Mit Teile-Nr. - Rev. signiert Maßstab
1:2 Gewicht in kg
werden, und sie darf durch den Empfänger oder Dritte auch
f.Maße ohne
25.3900
Ohne unsere vorherige Zustimmung darf diese Zeichnung
ISO 2768 3 mH
Verwendungszweck Halbzeug Werkstoff *
F HDP 40/70 Oberfläche nach
DIN ISO 1302 2.0975 F
Datum Name Benennung
Bearb 06.11.2012 Wewer
Gepr. 09.01.2013 EHelmig
Norm 09.01.2013 Krabus SAUGRAUM
Zeichnungs3Nr. Revision Blatt
1 2 3 4 5
002 Texte geändert und zugef. 07.01.2013 San
001 Zeichnung in SolidEdge
Zust Änderung
06.11.2012 Pöts
Datum Name
D359302 OELDE
CAD3Zeichnung
00.04246.0096 1
Ers.durch Ers.für
002 1 von
1 Bl.
PARTS LIST (41)
>>>end<<<
p_dbgs01.p
1 2 3 4 5 6 7 8
60 50 40 30 20 10 70 80
A 1 1 1 1 1 1 1 1 A
B B
90
1
C C
D D
E E
* Artikel3Nr. Format DIN
00.02516.0235
alle Ecken und Kanten gratfrei
ß Mit Betriebsdruck signiert
ß Mit Auftrags-Nr. signiert
Krabus A3
Zul.Abweichung
ß Mit Teile-Nr. signiert Maßstab
1:2 Gewicht in kg
werden, und sie darf durch den Empfänger oder Dritte auch
f.Maße ohne
1.4781
Ohne unsere vorherige Zustimmung darf diese Zeichnung
ISO 2768 3 mH
Verwendungszweck
Oberfläche nach
Halbzeug Werkstoff *
HDP 70 DIN ISO 1302
Datum Name Benennung
Bearb 11.09.2007 Wewer
F Gepr. 11.09.2007 Glitt F
Norm 13.09.2007 Szustkowski OELLEITUNG
Zeichnungs3Nr. Revision Blatt
>>>end<<<
p_dbgs01.p
1 2 3 4 5 6 7 8
A3A
(ca. 218,5 )
A A
209
008
10
1
20
1
150
1
130
1
110
1
300
1
60
2
120
2
360
1
480
1
470
2
A
B B
O 74,5
O 84
C C
D
100
1
380
1
290
1
40
2
30
1
Gewinde Pos.30 mit "Silver Goop"
(04.00982.0010) gefettet und in
A D
angegebenem Drehmoment angezogen:
Anziehdrehmoment 500 Nm
Sonderausführung
E Betriebsdruck max. 440 bar E
* Artikel3Nr. Format DIN
alle Ecken und Kanten gratfrei
ß Mit Betriebsdruck signiert
ß Mit Auftrags-Nr. signiert
Krabus 00.00743.1989 A3
Zul.Abweichung Maßstab
1:1 Gewicht in kg
ß Mit Teile-Nr. - Rev. signiert
werden, und sie darf durch den Empfänger oder Dritte auch
f.Maße ohne
ß Härte geprüft 5.3418
Ohne unsere vorherige Zustimmung darf diese Zeichnung
Toleranzangabe
nicht in anderer Weise mißbräuchlich benutzt werden.
weder vervielfältigt noch Dritten zugänglich gemacht
ISO 2768 3 mH
Verwendungszweck
Oberfläche nach
Halbzeug Werkstoff *
HDP 40/70 ø35 DIN ISO 1302
Datum Name Benennung
008 Stücklistenänderung 11.05.2012 Wei Bearb 02.08.2005 Wallmeyer
F 007 Einheitsdarstellung 02.03.2011 San Gepr. 21.05.2012 Sommerkamp F
006
005
Pos.200 entf. 150 hinzu
Pos.120 geändert
22.09.2008 Stau Norm
11.02.2008 Hun
22.05.2012 Krabus DICHTUNGSSATZ
004 Pos.470 u. 480 zugefügt 12.03.2007 Hun Zeichnungs3Nr. Revision Blatt
1 2 3 4
003
002
Zust
Zeichng. auf Solid Edge
Drehmoment geaendert
Änderung
28.02.2007 Hun
20.09.2005 Wal
Datum Name
D359302 OELDE
CAD3Zeichnung
00.00743.1989 1
Ers.durch Ers.für
008 1 von
1 Bl.
PARTS LIST (41)
>>>end<<<
p_dbgs01.p
1 2 3 4 5 6 7 8
A
7 1 3 5
A A
530
8
520
A3A 10
B 8 1
6 4 2 8 B
20
A
500 3 Pos.520 (Skt. SW27) mit MoS2 gefettet und in
3 angegebener Reihenfolge angezogen:
510 1. Stufe: Anziehdrehmoment Ma= 80 Nm
3 30
6
2. Stufe: Anziehdrehmoment Ma= 160 Nm
C 3. Stufe: Anziehdrehmoment Ma= 240 Nm C
150
3
D 40 D
6
160
3 550
3
140
3
E Betriebsdruck max. 600 bar E
* Artikel3Nr. Format DIN
Pos.500 (Skt. SW24) Anziehdrehmoment 250Nm
00.02145.1089
alle Ecken und Kanten gratfrei
ß Mit Betriebsdruck signiert
ß Mit Auftrags-Nr. signiert
Krabus A3
Zul.Abweichung
ß Mit Teile-Nr. signiert Maßstab
1:1 Gewicht in kg
werden, und sie darf durch den Empfänger oder Dritte auch
f.Maße ohne
26.0830
Ohne unsere vorherige Zustimmung darf diese Zeichnung
ISO 2768 3 mH
Verwendungszweck
Oberfläche nach
Halbzeug Werkstoff *
HDP 40/70 Ø30335 DIN ISO 1302
Datum Name Benennung
Bearb 22.02.2007 Borosch
F 006 Text entfernt 19.12.2011 Wei Gepr. 20.12.2011 Glitt F
005
004
Druck geändert
Einheitsdarstellung
09.08.2011 Wei Norm
25.08.2010 San
20.12.2011 Szustkowski PUMPENKOPF
003 Anziehdrehmoment geändert22.02.2010 Bor Zeichnungs3Nr. Revision Blatt
1 2 3 4
002
001
Zust
Nur für ø 30 3 35 gültig 05.11.2009 Bor
Pos.geändert
Änderung
11.01.2008 Wew
Datum Name
D359302 OELDE
CAD3Zeichnung
00.02145.1089 1
Ers.durch Ers.für
006
00.96050.000331
1 von
1 Bl.
PARTS LIST (41)
>>>end<<<
p_dbgs01.p
1 2 3 4 5 6 7 8
Membranzylinder O95
524 Membrane cylinder O95
Cylindre a membrane O95
Anschluss Berstscheibensicherung G 1/2 1800
Connection rupture disc G 1/2
A Raccord disque a l'eclatement G 1/2 1600 A
Betriebsdruck (bar)
Couple de serrage Ma = 200 Nm
1000
800
S
O 165
600
400
(DN 6)
200
B 0
0 1 2 3 4 5 6 8 B
Druckluft Steuerdruck (bar) (+/3 0,3 bar)
Anziehdrehmoment Ma = 90 Nm Compressed air controll pressure (bar) (+/3 0,3 bar)
40 La pression de traitement d'air (bar) (+/3 0,3 bar)
4 Tightening torque Ma = 90 Nm
P Couple de serrage Ma = 90 Nm
Anschraublochbild 60 mm x 60 mm (M12)
Hole pattern 60 mm x 60 mm (M12)
Configuration de percage 60 mm x 60 mm (M12)
C C
Hochdruckmanometer gehört nicht zur Baugruppe Manometer3 Druckbereich (bar)
Manometerauswahl gemäß Maschinenkarte Gauge pressure range (bar)
High pressure gauge not part of shown assembly Portée de pression du manomètre (bar)
Selection of gauge according to machine card
Le manomètre haute pression ne fait pas partie Druck (bar) Anzeigebereich (bar) Teile3 Nr.:
d‘ ensemble des components Pressure (bar) Range (bar) Part no.:
Séléction de manomètre selon de carte de machine Pression (bar) Portée d'affichage (bar) Référence:
Z
20
1
10
1
50
1
60
1
70
1 100
300
0 3 160 bar
0 3 400 bar
04.02860.0001
04.02860.0003
1:5
2:1 450
750
0 3 600 bar
0 3 1000 bar
04.02860.0004
04.02860.0009
D Anziehdrehmoment Ma = 100 Nm
1150 0 3 1600 bar 04.02860.0056 D
Tightening torque Ma = 100 Nm 1500 0 3 2000 bar 04.02860.0091
Couple de serrage Ma = 100 Nm 1800 0 3 2500 bar 04.02860.0117
ß
30
Y 1
Z 2:1
368
Y
T G 1 1/2
S
E E
Betriebsdruck max. 1200 bar
Volumenstrom max. 500 l/min
Nennweite DN17 P
Keramikausführung DN 20 / 4x M12 / 60 x 60
Hochdruckdichtung
* Artikel3Nr. Format DIN
Max. operating pressure 1200 bar
00.05893.0031
alle Ecken und Kanten gratfrei
f.Maße ohne
20.2000
Ohne unsere vorherige Zustimmung darf diese Zeichnung
Toleranzangabe
Ceramic design ß Härte geprüft
nicht in anderer Weise mißbräuchlich benutzt werden.
weder vervielfältigt noch Dritten zugänglich gemacht
ISO 2768 3 mH
Verwendungszweck Halbzeug Werkstoff *
F O 40 High pressure seal Oberfläche nach
DIN ISO 1302 F
271 171 Datum Name PRESSURE REGULATING VALVE CPL.
Benennung
Pression de service maximale 1200 bar Bearb 05.11.2010 PSchoening
SOUPAPE REGULATRICE DE PRESSION AU COMPLET
16.03.2012 Oberscheidt
T Débit maximal 500 l/min Gepr.
Norm 16.03.2012 Krabus DRUCKREGELVENTIL KPL.
Largeur nominale DN 17
Version céramique Zeichnungs3Nr. Revision Blatt
Joint haute pression
1 2 3 4 5
001 Positionen nachgetragen
Zust Änderung
12.03.2012 PS
Datum Name
D359302 OELDE
CAD3Zeichnung
00.05893.0031 1
Ers.durch Ers.für
001 1 von
1 Bl.
PARTS LIST (41)
>>>end<<<
p_dbgs01.p
1 2 3 4 5 6 7 8
175
A3A Anzugsdrehmoment Ma = 200 Nm
A 130 140 10 35 30 50
P 60 70 160 80
Tightening torque Ma = 200 Nm
Couple de serrage Ma = 200 Nm A A
1 1 1 1 1 1 1 1 1 1
144
B B
T
(M63 x 2)
(G1 1/2)
133
C C
110 Z Skt. SW 55
1
Y
Z 2:1 T G 1 1/2
D D
2:1 ß
Skt. SW 19
90 120
A
Betriebsdruck max. 1200 bar
3 2 Volumenstrom max. 500 l/min
Nennweite DN17 P
25 20 Anzugsdrehmoment Ma = 100 Nm Keramikausführung
E Tightening torque Ma = 100 Nm Hochdruckdichtung DN 20 / 4x M12 / 60 x 60 E
1 1 Couple de serrage Ma = 100 Nm * Artikel3Nr. Format DIN
00.05865.0125
alle Ecken und Kanten gratfrei
Max. operating pressure 1200 bar
Max. flow rate 500 l/min X
ß Mit Betriebsdruck signiert
ß Mit Auftrags-Nr. signiert
Krabus A3
X Zul.Abweichung
Nominal diameter 17 mm ß Mit Teile-Nr. - Rev. signiert Maßstab
1:1 Gewicht in kg
werden, und sie darf durch den Empfänger oder Dritte auch
f.Maße ohne
10.4200
Ohne unsere vorherige Zustimmung darf diese Zeichnung
ISO 2768 3 mH
Verwendungszweck Halbzeug Werkstoff *
High pressure seal Oberfläche nach
DIN ISO 1302
Datum Name Benennung
26.08.2010 Oberscheidt
PRESSURE REGULATING VALVE
Pression de service maximale 1200 bar Bearb
SOUPAPE REGULATRICE DE PRESSION
F Débit maximal 500 l/min Gepr. 15.03.2012 Oberscheidt F
Largeur nominale DN 17 004 Texte hinzu 14.03.2012 PS
Norm 15.03.2012 Krabus DRUCKREGELVENTIL
1:5 Version céramique 003 Druck in 1200 bar 12.03.2012 PS Zeichnungs3Nr. Revision Blatt
1 2 3
Joint haute pression
4
002
001
Zust
Text berichtigt
Stückliste
Änderung
05.11.2010
21.09.2010
Datum
PS
Os
Name
D359302 OELDE
CAD3Zeichnung
00.05865.0125 1
Ers.durch Ers.für
004
00.96120.001031
1 von
1 Bl.
PARTS LIST (41)
>>>end<<<
p_dbgs01.p
1 2 3 4 5 6 7 8
ca. 218
A3A ca. 177
A A
110 100 90 80 70 30
1 1 1 1 1 1
A
B 10 B
009 1
ß
C C
M63 x 2
165
O
D D
120 50 40 60 20
A
1 1 1 8 1
00.06428.0025
alle Ecken und Kanten gratfrei
ß Mit Betriebsdruck signiert
ß Mit Auftrags-Nr. signiert
Krabus A3
009 X Zul.Abweichung
ß Mit Teile-Nr. - Rev. signiert Maßstab
1:2 Gewicht in kg
werden, und sie darf durch den Empfänger oder Dritte auch
f.Maße ohne
5.1800
Ohne unsere vorherige Zustimmung darf diese Zeichnung
ISO 2768 3 mH
Verwendungszweck
Oberfläche nach
Halbzeug Werkstoff *
DIN ISO 1302
Datum Name Benennung
009 Signierung/3ort hinzu 08.12.2010 Pöts Bearb 11.12.2001 Sommerkamp
F 008 Teilenr sign. entfällt 09.06.2010 Pöts Gepr. 10.12.2010 Oberscheidt F
007
006
Pos. 120 hinzu
00.05877.0065 entf.
17.10.2007 Pöts Norm
27.04.2007 PS
13.12.2010 Krabus MEMBRANZYLINDER
005 Stkl. geä. 12.04.2006 Pöts Zeichnungs3Nr. Revision Blatt
1 2 3 4
004
003
Zust
Stkl. geä.
Pos.80,210 geändert
Änderung
04.03.2003 Pöts
28.03.2002 Som
Datum Name
D359302 OELDE
CAD3Zeichnung
00.06428.0025 1
Ers.durch Ers.für
009 1 von
1 Bl.
PARTS LIST (41)
>>>end<<<
p_dbgs01.p
1 2 3 4 5 6 7 8
gefettet
006
15
150
1
B B
(G1/2)
Anziehdrehmoment Ma = 120Nm
150
1
6kt. SW30
Anziehdrehmoment Ma = 120Nm 8kt. SW60 6kt. SW32
je nach Einstellung ca. 223
C C
83
51
D D
Typenschild plombiert
T
Betriebsdruck theoretische Durchflußmenge
(bar) bei Düsenfaktor 0,67 Druckbereich 400 bar bis 700 bar
(l/min) Nennweite: DN 6
400 318 Ansprechdruck darf nur durch
Sicherheitsventil
Fa. Hammelmann eingestellt werden.
500 355 EN ISO 4126-1
Nr.: 00.05877.0039 DN 6
E 600 390 Betriebsdruck: bar E
Ansprechdruck: bar
700 421 KA: Baujahr: Einsatz des Ventils ist druck3 und volumenabhängig.
Hammelmann Maschinenfabrik GmbH
Zum Sundern 13-21 D-59302 Oelde
Signierung erfolgt durch nebenstehenden Aufkleber
Druckangabe gemäß Maschinenkarte bzw.
Bestellangaben
T (G1/2)
X ß Mit Betriebsdruck signiert
ß Mit Auftrags-Nr. signiert
Krabus 00.05877.0039 A2
X Zul.Abweichung
ß Mit Teile-Nr. - Rev. signiert Maßstab
1:1 Gewicht in kg
werden, und sie darf durch den Empfänger oder Dritte auch
f.Maße ohne
ß Härte geprüft 3.8100
Ohne unsere vorherige Zustimmung darf diese Zeichnung
Toleranzangabe
nicht in anderer Weise mißbräuchlich benutzt werden.
weder vervielfältigt noch Dritten zugänglich gemacht
ISO 2768 3 mH
Verwendungszweck
Oberfläche nach
Halbzeug Werkstoff *
F DIN ISO 1302 F
Datum Name Benennung
Bearb 10.06.2005 Sommerkamp
P (G1/2) 006 Pos. 20 Teilenr. geänd. 15.10.2010 PS Gepr. 18.10.2010 Heinrichsmei
005
004
Tabelle, Texte
Signierungsangabe
30.10.2009 PS Norm
10.03.2009 Pöts
19.10.2010 Krabus SICHERHEITSVENTIL
003 Zeichnung in SolidEdge 29.11.2007 Pöts Zeichnungs3Nr. Revision Blatt
1 2 3 4 5
002
001
Zust
Tabelle u Typenschild
Pos 130 geändert
Änderung
02.12.2005 Pöts
26.07.2005 Som
Datum Name
D359302 OELDE
CAD3Zeichnung
00.05877.0039 1
Ers.durch Ers.für
006 1 von
1 Bl.
HAMMELMANN Code no.: 04.03070.0034
2. HAZARDS IDENTIFICATION
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
Hazardous Components
1/7
Print Date 02/18/2011 MSDS_DE
HAMMELMANN Code no.: 04.03070.0034
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.
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.
2/7
Print Date 02/18/2011 MSDS_DE
HAMMELMANN Code no.: 04.03070.0034
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 : Personal protective equipment (PPE) should meet
Equipment 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
3/7
Print Date 02/18/2011 MSDS_DE
HAMMELMANN Code no.: 04.03070.0034
4/7
Print Date 02/18/2011 MSDS_DE
HAMMELMANN Code no.: 04.03070.0034
Stability : Stable.
Conditions to Avoid : Extremes of temperature and direct sunlight.
Materials to Avoid : Strong oxidising agents.
Hazardous : Hazardous decomposition products are not expected to form
Decomposition Products during normal storage.
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 : Not expected to be a hazard.
Developmental Toxicity
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.
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.
5/7
Print Date 02/18/2011 MSDS_DE
HAMMELMANN Code no.: 04.03070.0034
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.
ADR
This material is not classified as dangerous under ADR regulations.
RID
This material is not classified as dangerous under RID regulations.
ADNR
This material is not classified as dangerous under ADNR regulations.
IMDG
This material is not classified as dangerous under IMDG regulations.
The regulatory information is not intended to be comprehensive. Other regulations may apply to this
material.
National Legislation
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 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.
7/7
Print Date 02/18/2011 MSDS_DE
HAMMELMANN Code no.: 04.03235.0114
BEKA
Gear pump
Type FL 6 C
Article-No. 3020 006050011
Installation,
operation
and
maintenance
instruction
HAMMELMANN Code no.: 04.03235.0114
K 3000.1091.1 GB
Zentralschmiertechnik
BAIER + KÖPPEL
Installation
The 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. When
installing 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 shaft
should not exceed 0,2 mm. Even if some manufacturers of drive clutches state that a greater misalignment
can be compensated by the clutch, the restoring force of the clutch generates some radial load on the shafts
to be connected, and this may result in damages to the pump. Impacts on the shaft end are not acceptable
at all, as they might result in serious damage to the pump.
Piping assemblies
When designing the size of a piping assembly, at has to be made sure that the acceptable flow speeds will
not be exceeded. In the suction pipe, they should not exceed 1,5 m/sec., and in the pressure pipe they
should not exceed 5 m/sec. (for more details, please consult the manufacturer). Before installation, any
piping assembly should be cleaned carefully. The suction pipe has to be perfectly airproof, and it should
be arranged as straight as possible, its end always being placed a few centimeters below of the minimum
oil level in the tank. The maximum suction lift should be restricted to a maximum of approx. 1 m. For the
piping assembly seamless precision steel tubes as per DIN 2391 are recommended.
Range of viscosity
The 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 intersection
of 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!
Filtration
It is recommended to install a filter having a maximum mesh size of 0,100 mm and magnetic separating
device. An additional suction filter with a mesh size of 0,100 up to 0,200 mm will protect the pump against
coarse dirt. It should be cleaned at regular intervals in order to prevent the suction vacuum pressure from
falling below the specified limits, as this might lead to damages by cavitation.
K 3000.1091.2 GB
Zentralschmiertechnik
BAIER + KÖPPEL
Maximum pressure
The pump must be protected against excessive pressure, by means of a pressure restrictor valve. Setting
of that pressure restrictor valve effected by using a pressure gauge for control.
Clutch
The diameter tolerance of the shaft end is j6. The diameter tolerance of the clutch hub should be in accordan-
ce to H7.
Maintenance
General
The gear pump is lubricated by the oil and, therefore, does not require any maintenance. Care and service
work 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 and
service of pipe filters should be complied with. In order to preclude any corosion, the pump should be filled
with oil if it is kept on stock for a substantial period of time (more than one year).
K 3000.1091.3 GB
Zentralschmiertechnik
BAIER + KÖPPEL
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 bleed
pre ---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 of
excessive cooling of the pressure fluid. which is suitable for the service temperature.
1.2.2 Pump shaft shorn off. Have the unit repaired by the factory.
1.2.4 Oil level in the tank is lower than the minimum Top up with pressure fluid.
required for suction.
Malfunction No. 2: The pump supplies fluid, but there is lack of pressure,
or pressure is not satisfactory
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 in
the proper way.
2.4 Substantial wear of the pump. Have the pump repaired by the factory.
K 3000.1091.4 GB
Zentralschmiertechnik
BAIER + KÖPPEL
Graph 1
200
150
100
90
80
70
60
50
40
30
25
20
15
--- 30 --- 20 --- 10 0 10 20 30 40 50 60 70 80 90 100 110 120 130
Temperature ( ° C )