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HAMMELMANN HDP 502 / S 1100-50 Operating Instructions Manual

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Operating instructions
High pressure pump unit
HDP 502 / S 1100-50
B7.02502.0210
HDP 502 / S 1100-50
2017
Made in Germany
Issue: 03.2017

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Summary of Contents for HAMMELMANN HDP 502 / S 1100-50

  • Page 1 Operating instructions High pressure pump unit HDP 502 / S 1100-50 B7.02502.0210 HDP 502 / S 1100-50 2017 Made in Germany Issue: 03.2017...
  • Page 2 M A C H I N E C A R D Hammelmann GmbH POB 3309, D-59282 Oelde, Germany mail to: mail@hammelmann.de Machine no. : B7.02502.0210 http://www.hammelmann.de Page: Order no. KA 222274 Purchaser Waterkracht B.V., Varsseveld / NL Client no. 10147901 P.
  • Page 3 M A C H I N E C A R D Hammelmann GmbH POB 3309, D-59282 Oelde, Germany mail to: mail@hammelmann.de Machine no. : B7.02502.0210 http://www.hammelmann.de Page: Max. liquid temp. [°C] °C Piston dia. pres. step 1 [mm] Max. pressure Ps 1 [bar]...
  • Page 4 M A C H I N E C A R D Hammelmann GmbH POB 3309, D-59282 Oelde, Germany mail to: mail@hammelmann.de Machine no. : B7.02502.0210 http://www.hammelmann.de Page: 04.04611.0065 CONNECTION HOSE 4,00 04.04475.0160 CLAMP 2,00 02.01495.0001 SOLID 'C' COUPLING 1,00 00.01630.1159...
  • Page 5 Formblatt FB-K2-11-01 Abnahmeprüfzeugnis / Test Certificate Maschinen-Nr. HAMMELMANN GmbH B7.02502.0210 Machine No. Carl-Zeiss-Str. 6 - 8 Unsere Auftrags-Nr. KA 222274 D-59302 Oelde Our Order No. Tel.: +49 (0)2522/76-0 e-mail: mail@hammelmann.de Bestell-Nr. I00010227 - Doornbos http: www.hammelmann.de P. Order No. Druckregelautomatik...
  • Page 6 HAMMELMANN GmbH Carl-Zeiss-Straße 6-8 59302 Oelde • Germany Déclaration de conformité CE EG-Konformitätserklärung EC-Declaration of Conformity conformément à la directive CE nach EG-Richtlinie 2006/42/EG, according to E.C. Directive sur les machines 2006/42/CE, Anhang II, Nr. 1A 2006/42/EC, Appendix II, No 1A Annexe II, N°...
  • Page 7 Operating instructions High pressure pump unit HDP 502 / S 1100-50 HDP 502 / S 1100-50 2017 Made in Germany Issue: 03.2017...

  • Page 8: Table Of Contents

    Operating instructions Contents No.: HDP 502 / S 1100-50 Page 2, Issue: 03.2017 Contents Contents ................................2 Foreword ................................5 Technical data ..............................6 Main dimensions ............................6 Performance data: High pressure pump ...................... 8 Performance data: Diesel engine......................... 8 Batteries ...............................
  • Page 9 Operating instructions Contents No.: HDP 502 / S 1100-50 Page 3, Issue: 03.2017 7.3.1 Electronic pressure transmitter 04.00829.0093 ..................26 7.3.2 Electronic pressure transmitter 04.00829.0056 ..................27 7.3.3 Solenoid Valve 04.05875.0107 ....................... 28 7.3.4 Electronic temperature transmitter 04.05630.0074 ................29 Installation &...
  • Page 10 Operating instructions Contents No.: HDP 502 / S 1100-50 Page 4, Issue: 03.2017 11.5.1 Replacing the rupture disc up to 1500 bar operating pressure ............56 11.6 Maintenance of the pump head 00.02145.1239 (-003) ................57 11.6.1 Disassembly (ref. to fig. pump head) ....................57 11.6.2...

  • Page 11: Foreword

    Pos : 2 /T ec hnis che D aten/Zu di es er Anlei tung/Hinweis @ 0\mod3_2.doc x @ 1208 @ @ 1 All personnel who are responsible for the operation and maintenance of the High pressure pump unit HDP 502 / S 1100-50 must: Read and fully understand these instructions, especially the section “Safety“...

  • Page 12: Technical Data

    Operating instructions Technical data No.: HDP 502 / S 1100-50 Page 6, Issue: 03.2017 Pos : 6 /T ec hnis che D aten/Übersc hrift @ 0\mod8_2.doc x @ 1196 @ 1 @ 1 Tech nical dat a Pos : 7 /T ec hnis che D aten/Pumpen/HD P 500/H auptabmes sungen HD P 500 neu @ 9\mod_1360049466827_2.doc x @ 73883 @ 2 @ 1 3.1 Main dimensions...
  • Page 13 Operating instructions Technical data No.: HDP 502 / S 1100-50 Page 7, Issue: 03.2017 Weight of the pump: approx. 1985 kg Pos : 8 /xxxxxxx xxxxxx xxxxxx @ 0\mod6_2.doc x @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany  D-59302 Oelde  Carl-Zeiss-Straße 6 - 8...

  • Page 14: Performance Data: High Pressure Pump

    Operating instructions Technical data No.: HDP 502 / S 1100-50 Page 8, Issue: 03.2017 Pos : 9 /T ec hnis che D aten/S1200-50/S 1100-50; 262L,1000bar,1800U,478kW,Vol vo T AD 1672 Stufe IV Tier 4fi nal @ 13\mod_1432713659524_2.doc x @ 116631 @ 222 @ 1 3.2 Performance data: High pressure pump...

  • Page 15: Safety

    Pos : 12 /Sic herheit/Pumpen @ 0\mod10_2.doc x @ 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: ...
  • Page 16  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.

  • Page 17: Danger Symbol

    Operating instructions Safety No.: HDP 502 / S 1100-50 Page 11, Issue: 03.2017  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.

  • Page 18: Safety During Inspection, Maintenance And Repair

    Operating instructions Safety No.: HDP 502 / S 1100-50 Page 12, Issue: 03.2017 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.

  • Page 19: General

    Pos : 15 /Allgemeines /Pumpen/1. Einl eitung @ 0\mod425_2.doc x @ 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.

  • Page 20: Copyright

     The equipment was used for purposes under other than our admissible conditions.  The leads at the safety organs are injured (e.g. for change of adjustments).  The high pressure pump was used with accessories or fitted with spare parts not supplied by HAMMELMANN.  If the damage is caused by: ...

  • Page 21: Transportation

    Operating instructions Transportation No.: HDP 502 / S 1100-50 Page 15, Issue: 03.2017 Pos : 22 /Allgemeines /Trans port/Übersc hrift Tr ans port @ 0\mod218_2.doc x @ 1348 @ 2 @ 1 Tran sport ation Pos : 23 /Allgemeines /Trans port/Trans port Container-Anlagen @ 4\mod_1193824702949_2.doc x @ 20097 @ 2222 @ 1 6.1 Packing...

  • Page 22: Transportation

    This anti-corrosion emulsion is sufficient for the transport from the factory to the customer. A second protection is necessary if the pumps/ pump units are stored for a longer time. Please ask your HAMMELMANN agent for advice and turn directly to our Hammelmann customer services. The procedure of a second protection can be seen in section "shut down"...

  • Page 23: Construction & Description

    Operating instructions Construction & Description No.: HDP 502 / S 1100-50 Page 17, Issue: 03.2017 Pos : 25 /Aufbau und Besc hrei bung/Ü bers chrift @ 0\mod155_2.doc x @ 1372 @ 1 @ 1 Constru ction & Description Pos : 26 /Aufbau und Besc hrei bung/Ü bers chrift Konstrukti ver Aufbau @ 0\mod156_2.doc x @ 1376 @ 1 @ 1 7.1 Construction...
  • Page 24 Operating instructions Construction & Description No.: HDP 502 / S 1100-50 Page 18, Issue: 03.2017 Item no. Description Item no. Description HAMMELMANN High pressure pump HDP 504 Fine filter with air venting Bypass valve Air filter diesel engine Lifting device for pump head...
  • Page 25 Operating instructions Construction & Description No.: HDP 502 / S 1100-50 Page 19, Issue: 03.2017 Pos : 29 /Aufbau und Besc hrei bung/Pumpen/H DP 500/Aufbau HD P 502 auss enl . Öl kühler @ 9\mod_1360835858538_2.doc x @ 74268 @ @ 1 ...

  • Page 26: Description

    7.2.1 General Description of the High pressure pump The HDP 502 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 wear to an absolute minimum.
  • Page 27 Operating instructions Construction & Description No.: HDP 502 / S 1100-50 Page 21, Issue: 03.2017  On the upward stroke of the plunger:  Suction valve closes,  pressure rises to discharge pressure,  discharge valve opens,  water is emitted via the discharge line.

  • Page 28: Pressure Regulating And Overflow Valve

    Operating instructions Construction & Description No.: HDP 502 / S 1100-50 Page 22, Issue: 03.2017 Pos : 33 /Aufbau und Besc hrei bung/S-Anlagen/Besc hreibung Druc kr egel ventil @ 0\mod157_2.doc x @ 2184 @ 3 @ 1 7.2.5 Pressure regulating and overflow valve The pressure regulating valve/overflow valve allows a smooth setting of operating pressure from admission pressure to max.

  • Page 29: Electronic Safety Cut Out

    Operating instructions Construction & Description No.: HDP 502 / S 1100-50 Page 23, Issue: 03.2017 7.2.7 Electronic safety cut out To prevent over pressurisation the electronic system has a cut out circuit set at 10 % above the stated maximum operating pressure.

  • Page 30: 2 Control Unit

    Operating instructions Construction & Description No.: HDP 502 / S 1100-50 Page 24, Issue: 03.2017 Pos : 41 /Aufbau und Besc hrei bung/S-Anlagen/Besc hreibung ES2 Bediengerät @ 1\mod956_2.doc x @ 2236 @ 2 @ 1 7.2.12 ES 2 control unit The processor installed controls the complete pump unit, carries out complex control, monitoring and regulating duties and collects data for various diagnostic functions.
  • Page 31 Operating instructions Construction & Description No.: HDP 502 / S 1100-50 Page 25, Issue: 03.2017 Function of softkey : activate/deactivate ignition. Pressing once will activate the ignition/stoppage magnet, and the symbol will be shown white on black. If pressed again: Ignition to the engine will be turned off.

  • Page 32: Electronic Pressure Transmitter 04.00829.0093

    Operating instructions Construction & Description No.: HDP 502 / S 1100-50 Page 26, Issue: 03.2017 Pos : 44 /Aufbau und Besc hrei bung/Sens oren - M agnetventile/Dr uc kmess umformer 04.00829.0093 (16 bar) @ 12\mod_1414075677654_2.doc x @ 95807 @ 3 @ 1 7.3.1 Electronic pressure transmitter 04.00829.0093...

  • Page 33: Electronic Pressure Transmitter 04.00829.0056

    Operating instructions Construction & Description No.: HDP 502 / S 1100-50 Page 27, Issue: 03.2017 Pos : 46 /Aufbau und Besc hrei bung/Sens oren - M agnetventile/Dr uc kmess umformer 04.00829.0056 (1600 bar) @ 9\mod_1346247725379_2.doc x @ 69169 @ 3 @ 1 7.3.2 Electronic pressure transmitter 04.00829.0056...

  • Page 34: Solenoid Valve 04.05875.0107

    Operating instructions Construction & Description No.: HDP 502 / S 1100-50 Page 28, Issue: 03.2017 Pos : 48 /Aufbau und Besc hrei bung/Sens oren - M agnetventile/M agnetventil 04.05875.0107 (Heri on) @ 9\mod_1347615268515_2.doc x @ 69729 @ 3 @ 1 7.3.3 Solenoid Valve 04.05875.0107...

  • Page 35: Electronic Temperature Transmitter 04.05630.0074

    Operating instructions Construction & Description No.: HDP 502 / S 1100-50 Page 29, Issue: 03.2017 Pos : 50 /Aufbau und Besc hrei bung/Sens oren - M agnetventile/T hermos tat 04.05630.0074 (0..100 °C) @ 11\mod_1403677348037_2.doc x @ 90901 @ 3 @ 1 7.3.4 Electronic temperature transmitter 04.05630.0074...

  • Page 36: Installation & Start Up

     Also check for signs of water (emulsion) in oil. If found do not run the pump. Try and determine the cause. If may be necessary to consult HAMMELMANN or their accredited representative before changing the oil.  Check engine oil level and top up if necessary. Never run below min. level.

  • Page 37: Calculating The Hose Internal Diameter (Dn)

    Operating instructions Installation & Start up No.: HDP 502 / S 1100-50 Page 31, Issue: 03.2017 Pos : 56 /Vorber eitung z ur Inbetri ebnahme/Installation/S-Anlagen/N omogramm @ 0\mod542_2.doc x @ 2296 @ 3 @ 1 8.2.1 Calculating the hose internal diameter (DN) To determine the internal diameter of the hoses refer to the diagram below.
  • Page 38 1 mg/l * depending on type of particle (hardness) No additives with corrosive effects on nonferrous heavy metals (if to be used consult HAMMELMANN). In certain cases variations from the above may be possible! HAMMELMANN offers suitable filter systems. Pos : 58 /xxxxxxxxx xxxxxx xxxx @ 0\mod6_2.doc x @ 1188 @ @ 1 ...
  • Page 39 1500 bar every 50 operating hours Never clean the filter insert. Rechange by new. Only use original HAMMELMANN-spare parts! A blocked filter can cause cavitation and damage the pump. Cavitation damages at high pressure pumps are excluded from the guarantee.

  • Page 40: Notes On Installation Of Connecting Armatures

    In the case of leakage stop the high pressure pump system immediately. Remove leakage only when the system is switched off and depressurised. The HDP 502 / S 1100-50 connections for instance are: Before connecting the water supply (hose) onto the high pressure pump (suction ...
  • Page 41 Operating instructions Installation & Start up No.: HDP 502 / S 1100-50 Page 35, Issue: 03.2017 Pos : 64 /Vorber eitung z ur Inbetri ebnahme/Installation/S-Anlagen/Anzugs momente für H oc hdr uc ks chl äuc he @ 0\mod540_2.doc x @ 2288 @ @ 1 ...

  • Page 42: Connecting The High Pressure Hose(S)

    Operating instructions Installation & Start up No.: HDP 502 / S 1100-50 Page 36, Issue: 03.2017 Pos : 66 /Vorber eitung z ur Inbetri ebnahme/Installation/S-Anlagen/M ontage H oc hdr uc ksc hlauc h @ 0\mod174_2.doc x @ 2284 @ 2 @ 1 8.3 Connecting the high pressure hose(s)
  • Page 43 Fig. Accessory to hose and hose to hose safety connections The wire hose arresters fitted to all HDP 502 / S 1100-50 hoses and accessories are to prevent the hose from wiplashing in the event of a bad or faulty connection: ...

  • Page 44: Operation

    Pos : 71 /Betri eb/S- Anl agen/Betri eb mit ES2-Dies el @ 1\mod1040_2.doc x @ 2324 @ 22323 @ 1 9.1 Start up The HDP 502 / S 1100-50 is fully automatic and once the desired pressure has been set controlled entirely by electronic signal from the accessory.

  • Page 45: To Start The High Pressure Pump Unit

    Operating instructions Operation No.: HDP 502 / S 1100-50 Page 39, Issue: 03.2017 Using an external power source to start the HP unit can damage the ES2 microprocessor. When charging the batteries ensure that the emergency stop switch is depressed and locked.

  • Page 46: To Start The High Pressure Pump Unit

    Operating instructions Operation No.: HDP 502 / S 1100-50 Page 40, Issue: 03.2017  You may now connect the accessory: To do so:  Remove protective cap from accessory high pressure connector. Ensure that it is clean and then smear threads with Molykote.
  • Page 47 Operating instructions Operation No.: HDP 502 / S 1100-50 Page 41, Issue: 03.2017 Regularly check the high pressure hoses, fittings and jetting (i.e. nozzles, spray bar) for signs of leakage. In the case of leakage stop the high pressure pump system immediately.

  • Page 48: Shut Down

    Operating instructions Shut down No.: HDP 502 / S 1100-50 Page 42, Issue: 03.2017 Pos : 73 /Auß erbetriebnahme/Ü bersc hrift @ 0\mod182_2.doc x @ 1408 @ 2 @ 1 Shut do wn Pos : 74 /Auß erbetriebnahme/S- Anl agen/Abs chalten & Übernac ht Stillstand ES2 @ 1\mod1041_2.doc x @ 2328 @ 22 @ 1 10.1 Stopping the unit...

  • Page 49: Extended Shut Down

    Operating instructions Shut down No.: HDP 502 / S 1100-50 Page 43, Issue: 03.2017 Pressing once will activate the ignition/stoppage magnet, and the symbol will be shown white on black. If pressed again: Ignition to the engine will be turned off.
  • Page 50 Operating instructions Shut down No.: HDP 502 / S 1100-50 Page 44, Issue: 03.2017  With the engine stopped almost fill the header tank with water via the suction connection.  Unscrew the header tank cover and add the correct amount of anti-corrosion fluids.

  • Page 51: Further Actions

    Operating instructions Shut down No.: HDP 502 / S 1100-50 Page 45, Issue: 03.2017  Schematic of emulsion flow Item Description High pressure pump Suction chamber Filter Boost pump Suction line Emulsion High pressure hose Supply connection 10.4.4 Further actions ...

  • Page 52: Maintenance

    Operating instructions Maintenance No.: HDP 502 / S 1100-50 Page 46, Issue: 03.2017 Pos : 78 /Instandhaltung/Ü bersc hrift @ 0\mod185_2.doc x @ 1416 @ 2 @ 1 Mainten an ce Pos : 79 /Instandhaltung/S- Anl agen/Störungen & Wartung ES2 Dies el @ 1\mod1042_2.doc x @ 2352 @ 23332333 @ 1 11.1 Fault finding and remedy...
  • Page 53 Operating instructions Maintenance No.: HDP 502 / S 1100-50 Page 47, Issue: 03.2017  Replace burst disc. Check why d) Burst disc rupture.  Maximum pressure exceeded. pressure exceeded. Remedy fault.  Engine not achieving required  See engine handbook.

  • Page 54: Electrical Faults

    Any faults or misadjustments that appear to originate in the electric control and monitoring system must be referred to HAMMELMANN or their approved agent. This normally means referring the problem to HAMMELMANN or their accredited agent. It could be helpful to bring connection diagrams or drawings etc.

  • Page 55: Checks During Operation

    Operating instructions Maintenance No.: HDP 502 / S 1100-50 Page 49, Issue: 03.2017 11.2.3 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), ...

  • Page 56: Maintenance Of The Air Pressure Installation

    Operating instructions Maintenance No.: HDP 502 / S 1100-50 Page 50, Issue: 03.2017 Pos : 81 /Instandhaltung/Pumpen/Wartung Luftfilter- Behälter @ 16\mod_1458564431004_2.doc x @ 149459 @ 233 @ 1 11.3 Maintenance of the air pressure installation At external compressed air supply of high pressure pump unit, use only factory filtered compressed air! 11.3.1 Compressed air tank (if supplied)

  • Page 57: Oil Change

    Operating instructions Maintenance No.: HDP 502 / S 1100-50 Page 51, Issue: 03.2017 Pos : 83 /Instandhaltung/Pumpen/HD P 500/Öl wechs el HD P 500 - S4 GX 320 @ 7\mod_1313764542149_2.doc x @ 49326 @ 23232 @ 1 11.4 Oil change...

  • Page 58: Next Oil Changes

    Operating instructions Maintenance No.: HDP 502 / S 1100-50 Page 52, Issue: 03.2017  If the crank case, oil filter and oil cooler are completely drained unscrew the hoses from the oil drain valves (1 and 6) Screw the protective caps/plugs back on the oil drain valves.

  • Page 59: Lubrication Including Oil Filter

     Quality of oil: Polyalfaolefin (PAO) CLP according to DIN 51517 – 3 ISO 12925 CKD ANSI/AGMA 9005 – E02  Hammelmann first fill: AVIA Syntogear PE 320 Alternative oils Manufacturer CLP 320 / ISO VG 320 Avia Syntogear PE 320...
  • Page 60 Operating instructions Maintenance No.: HDP 502 / S 1100-50 Page 54, Issue: 03.2017 Viscosity-Temperature-Diagram for synthetic oils at Poly-  -Olefin - Basis   Copyright Hammelmann GmbH Germany  D-59302 Oelde  Carl-Zeiss-Straße 6 - 8...

  • Page 61: Oil Pressure Adjustment

    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.

  • Page 62: Replacing The Rupture Disc Up To 1500 Bar Operating Pressure

    Operating instructions Maintenance No.: HDP 502 / S 1100-50 Page 56, Issue: 03.2017 Pos : 86 /Instandhaltung/Pumpen/Austaus ch Berstsc heibe bis 1500 bar ab 03.2011 @ 6\mod_1299838371271_2.doc x @ 45089 @ 3 @ 1 11.5.1 Replacing the rupture disc up to 1500 bar operating pressure When the burst disc is destroyed, unscrew the high pressure line from the connection piece (40) and then: ...

  • Page 63: Maintenance Of The Pump Head 00.02145.1239 (-003)

    Operating instructions Maintenance No.: HDP 502 / S 1100-50 Page 57, Issue: 03.2017 Pos : 88 /Instandhaltung/Pumpen/Pumpenkopf/PK 1239 HDP 360- 500 (DKV) @ 9\mod_1367571631332_2.doc x @ 76551 @ 233 @ 1 11.6 Maintenance of the pump head 00.02145.1239 (-003) 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.
  • Page 64 Operating instructions Maintenance No.: HDP 502 / S 1100-50 Page 58, Issue: 03.2017  Fig.: Pump head Item no. Description Item no. Description Valve housing Bushing Spring Set screw Valve Screw in piece Cylinder ring Tappet Hexagon socket head screw...

  • Page 65: Assembling (Ref. To Fig.: Pump Head)

    Operating instructions Maintenance No.: HDP 502 / S 1100-50 Page 59, Issue: 03.2017  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.
  • Page 66 Operating instructions Maintenance No.: HDP 502 / S 1100-50 Page 60, Issue: 03.2017  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.

  • Page 67: Maintenance Of The Piston Seal Assembly: 00.00743.2221 (-004)

    Operating instructions Maintenance No.: HDP 502 / S 1100-50 Page 61, Issue: 03.2017 Pos : 90 /Instandhaltung/Pumpen/Dic htungssatz/DS 2221 HDP 360/480/750 @ 7\mod_1306845678721_2.doc x @ 47064 @ 233 @ 1 11.7 Maintenance of the piston seal assembly: 00.00743.2221 (-004) 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.

  • Page 68: Reassembly

    Operating instructions Maintenance No.: HDP 502 / S 1100-50 Page 62, Issue: 03.2017  Remove the flange (30) from the casing (10).  Pull out the bushing (300) from the casing (10).  Remove ring’s (190 and 110) and packings (130) from the casing (10).
  • Page 69 Operating instructions Maintenance No.: HDP 502 / S 1100-50 Page 63, Issue: 03.2017  Fig.: Piston seal assembly Item No. Description Casing Piston Flange Glyd-Ring O-ring Ring Support ring Packings Bushing Ring Bushing O-ring Hex. skt. head cap screw Circlip...
  • Page 70 Operating instructions Maintenance No.: HDP 502 / S 1100-50 Page 64, Issue: 03.2017  Reassemble the seal assemblies and the pump head  Lightly grease the supporting surfaces of the crank section/seal assembly.  Insert the complete seal assembly with the piston (20) in the pump housing. Ensure that the O-rings (60) are not pressed out of the grooves and damaged.

  • Page 71: Changing The Bellows

    Each time you replace the bellows check the surface of each crosshead bore for signs of corrosion. Report any signs of corrosion to HAMMELMANN immediately. Pos : 93 /xxxxxxxxx xxxxxx xxxx @ 0\mod6_2.doc x @ 1188 @ @ 1 Copyright Hammelmann GmbH...

  • Page 72: Changing Or Adjusting The Boost Pump Drive Belt

    Operating instructions Maintenance No.: HDP 502 / S 1100-50 Page 66, Issue: 03.2017 Pos : 94 /Instandhaltung/S- Anl agen/Keilriemen Vordr uc kpumpe wechsel n @ 0\mod195_2.doc x @ 2348 @ 1 @ 1 11.2 Changing or adjusting the boost pump drive belt ...
  • Page 73 Operating instructions Pressure regulating valve No.: HDP 502 / S 1100-50 00.05865.0146 Page 67, Issue: 03.2017 Pos : 97 /Instandhaltung/Druc kr egel ventil/DR V 00.05865.0146 @ 11\mod_1400674247453_2.doc x @ 89693 @ 12222 @ 1 Pressure regulating valve 00.05865.0146 Fig.: Pressure regulating valve ...

  • Page 74: Pressure Regulating Valve 00.05865.0146

    Operating instructions Pressure regulating valve No.: HDP 502 / S 1100-50 00.05865.0146 Page 68, Issue: 03.2017 Technical Data 1200 bar  Max. operating pressure: 500 l/min.  Flow rate max.: DN 17  Diameter nominal: 10.5 kg  Weight approx.: 12.1...

  • Page 75: Maintenance

    Operating instructions Pressure regulating valve No.: HDP 502 / S 1100-50 00.05865.0146 Page 69, Issue: 03.2017 12.3 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! ...
  • Page 76 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.
  • Page 77 Operating instructions Pressure regulating valve No.: HDP 502 / S 1100-50 00.05865.0146 Page 71, Issue: 03.2017  Reassembling of the pressure regulating valve  Grease the inner of housing (10) with Stabyl MO 500 (order no. 04.04660.0002)  Place O-ring (25) onto seal ring (20) (ref.
  • Page 78 Operating instructions Pressure regulating valve No.: HDP 502 / S 1100-50 00.05865.0146 Page 72, Issue: 03.2017  Fig. 4  Slide the bracket (35) (ref. to fig 5) onto the special tool and then into the housing (10). (Ensure correct positioning) (Ref.
  • Page 79 Operating instructions Pressure regulating valve No.: HDP 502 / S 1100-50 00.05865.0146 Page 73, Issue: 03.2017  Correctly installed seal ring (20), O-ring (25) and bracket (35) (ref. to. Fig 6)  Fig. 6  Remove the tool out of the housing.

  • Page 80: Safety Notes For High Pressure Hoses

    Operating instructions Safety notes for high pressure No.: HDP 502 / S 1100-50 hoses Page 74, Issue: 03.2017 Pos : 99 /Sic herheit/Sc hlauc hsicherheit @ 0\mod416_2.doc x @ 1244 @ 122 @ 1 Saf et y n otes for h igh p ressure ho ses Ignoring these notes can invalidate all claims for injuries or damages.

  • Page 81: Before Using The Hose

    Operating instructions Safety notes for high pressure No.: HDP 502 / S 1100-50 hoses Page 75, Issue: 03.2017 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.

  • Page 82: Index

    Operating instructions Index No.: HDP 502 / S 1100-50 Page 76, Issue: 03.2017 Index Caractéristiques de puissance ........8 Operating the system ..........40 Changing the bellows ..........65 Overnight shut down ..........42 Construction ............17 Construction High of pressure pump HDP 503 ... 19 Pre-start checks ............
  • Page 83 Operating instructions Microprocessor-Control for Volvo Engine ES2-Bediener (Volvo) 2016 Made in Germany Issue: 04.2016...
  • Page 84 Working with multi gun valve and „Teach in“ ..................... 28     2.13 Modem connection ............................. 31     2.13.1 Description of blink code of ES2-modem ................... 34 Index ................................35      Copyright Hammelmann GmbH Germany  D-59302 Oelde  Carl-Zeiss-Straße 6 - 8...

  • Page 85: 2 - Control

    General fault test Help 4 Consumer 4 Delete error memory 5 Consumer 5 Pos: 4 /Aufbau und Beschreibung/ES 2 - Steuerung/Steuerung Einschalten @ 0\mod26_2.docx @ 1648 @ 2 @ 1 Copyright Hammelmann GmbH Germany  D-59302 Oelde  Carl-Zeiss-Straße 6 - 8...

  • Page 86: Switch Control On

    Pos: 6 /Aufbau und Beschreibung/ES 2 - Steuerung/Start Display (mit Vorglühen) @ 1\mod35_2.docx @ 1852 @ @ 1 25,2 V 0 bar Start display Fig.: 3 Pos: 7 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.docx @ 1188 @ @ 1  Copyright Hammelmann GmbH Germany  D-59302 Oelde  Carl-Zeiss-Straße 6 - 8...

  • Page 87: Exhaust After Treatment

    Only switch off the battery main switch about 2 mins after the ES2 has been turned off. During this time, the AdBlue lines are emptied in order to prevent them from becoming blocked up. Pos: 9 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.docx @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany  D-59302 Oelde  Carl-Zeiss-Straße 6 - 8...

  • Page 88: Pre-Heat

    Also other faults can be programed with the same behaviour as warning. Fig.: 5 Pos: 13 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.docx @ 1188 @ @ 1  Copyright Hammelmann GmbH Germany  D-59302 Oelde  Carl-Zeiss-Straße 6 - 8...

  • Page 89: Entering A Set Value

    25,2 V 0 bar Press to increase or to decrease. To confirm press automatically after 10 secs. Fig.: 7 Pos: 17 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.docx @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany  D-59302 Oelde  Carl-Zeiss-Straße 6 - 8...

  • Page 90: Operators Menu

    Pos: 22 /Aufbau und Beschreibung/ES 2 - Steuerung/Seite vorblättern @ 1\mod36_2.docx @ 1664 @ @ 1 Press Pos: 23 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.docx @ 1188 @ @ 1  Copyright Hammelmann GmbH Germany  D-59302 Oelde  Carl-Zeiss-Straße 6 - 8...
  • Page 91 9 . C o n t r o l t y p e : P R E S S U R E Change value with Confirm with EXIT Fig.: 12 Pos: 28 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.docx @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany  D-59302 Oelde  Carl-Zeiss-Straße 6 - 8...

  • Page 92: Selecting Of The Pressure Step

    Pos: 32 /Aufbau und Beschreibung/ES 2 - Steuerung/Seite vorblättern @ 1\mod36_2.docx @ 1664 @ @ 1 Press Pos: 33 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.docx @ 1188 @ @ 1  Copyright Hammelmann GmbH Germany  D-59302 Oelde  Carl-Zeiss-Straße 6 - 8...

  • Page 93: Teach In Function

    (0 – 10V) to the 2 6 . M o d e m : i n a c t i v e ES2. EXIT Fig.: 18 Copyright Hammelmann GmbH Germany  D-59302 Oelde  Carl-Zeiss-Straße 6 - 8...

  • Page 94: Keypad Lock

    ON Confirm with EXIT Fig.: 21 EXIT Press or after 30 sec. automatically return to basic display. Pos: 37 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.docx @ 1188 @ @ 1  Copyright Hammelmann GmbH Germany  D-59302 Oelde  Carl-Zeiss-Straße 6 - 8...

  • Page 95: Switch Off The Keypad Lock

    1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 EXIT Fig.: 24 Pos: 42 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.docx @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany  D-59302 Oelde  Carl-Zeiss-Straße 6 - 8...

  • Page 96: Digital Sensor

    > R E S . 5 R 6 = 1 > R E S . 6 EXIT Fig.: 27 Pos: 46 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.docx @ 1188 @ @ 1  Copyright Hammelmann GmbH Germany  D-59302 Oelde  Carl-Zeiss-Straße 6 - 8...

  • Page 97: Analogue Sensor

    Fig.: 29 Pos: 48 /Aufbau und Beschreibung/ES 2 - Steuerung/Seite vorblättern @ 1\mod36_2.docx @ 1664 @ @ 1 Press Pos: 49 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.docx @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany  D-59302 Oelde  Carl-Zeiss-Straße 6 - 8...

  • Page 98: Fault Report

    Fig.: 31 Pos: 53 /Aufbau und Beschreibung/ES 2 - Steuerung/Bestätigung @ 1\mod64_2.docx @ 1884 @ @ 1 Press Pos: 54 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.docx @ 1188 @ @ 1  Copyright Hammelmann GmbH Germany  D-59302 Oelde  Carl-Zeiss-Straße 6 - 8...
  • Page 99 - H o s e l e n g t h > 2 0 m Press to access list of remedies EXIT Fig.: 34 Pos: 60 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.docx @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany  D-59302 Oelde  Carl-Zeiss-Straße 6 - 8...
  • Page 100 1 1 > EXIT Fig.: 37 Pos: 64 /Aufbau und Beschreibung/ES 2 - Steuerung/Erklärung der Begriffe/Funktionen Bedienermenü ohne Not @ 5\mod_1260525302849_2.docx @ 33303 @ 2 @ 1  Copyright Hammelmann GmbH Germany  D-59302 Oelde  Carl-Zeiss-Straße 6 - 8...

  • Page 101: Explanation Of The Terms/Functions At The Operators Menu

    Remote control: Enables receipt of serial data, for example from a SPS or a PC (remote control) Modem: Activation of the far maintenance about modem Pos: 65 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.docx @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany  D-59302 Oelde  Carl-Zeiss-Straße 6 - 8...

  • Page 102: Fault Indication

    Check in function menu of the ES2. Check wiring connections, if necessary replace or refit.  Nozzle inserts to small. Check and replace if necessary  Consumer closed. Open consumer  Copyright Hammelmann GmbH Germany  D-59302 Oelde  Carl-Zeiss-Straße 6 - 8...
  • Page 103 Pos: 71 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 5 Wasservordruck zu klein @ 1\mod106_2.docx @ 4048 @ @ 1 Check water supply or water filling level Fault 5 at the water tank. Copyright Hammelmann GmbH Germany  D-59302 Oelde  Carl-Zeiss-Straße 6 - 8...
  • Page 104  A fault in the installation indicates + Check the whole installation, Short circuit Bypass/MTV signal to the bypass or multi tool Disconnect all units, valve. fault remains ES2 defective  exchange  Copyright Hammelmann GmbH Germany  D-59302 Oelde  Carl-Zeiss-Straße 6 - 8...
  • Page 105 The engine will continue to run at idle (no air pressure can be built up without a running engine!) The warning will disappear however as soon as the air pressure is OK again.  Cleaning air filter. Copyright Hammelmann GmbH Germany  D-59302 Oelde  Carl-Zeiss-Straße 6 - 8...
  • Page 106  Sensor defective Check sensor, exchange as necessary. Pos: 91 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 24 Keine Gen. Impulse @ 1\mod240_2.docx @ 4008 @ @ 1  Copyright Hammelmann GmbH Germany  D-59302 Oelde  Carl-Zeiss-Straße 6 - 8...
  • Page 107 Pos: 97 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 34 Not Programm @ 1\mod253_2.docx @ 3968 @ @ 1 Fault 34  Emergency programme is set to Emergency progra. Set emergency programme to inactive. active activ Pos: 98 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.docx @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany  D-59302 Oelde  Carl-Zeiss-Straße 6 - 8...
  • Page 108 Change nozzles Change nozzles.  Nozzles damaged. (Teach-in operation) Pos: 102 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 50 Hochdruck zu gering @ 4\mod_1207122880373_2.docx @ 23388 @ @ 1  Copyright Hammelmann GmbH Germany  D-59302 Oelde  Carl-Zeiss-Straße 6 - 8...
  • Page 109 4. Turn on the ES2 control . Wait after appearance of the basic display approx. 10 sec. Start afterwards the engine. Pos: 108 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.docx @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany  D-59302 Oelde  Carl-Zeiss-Straße 6 - 8...

  • Page 110: Working With Multi Gun Valve And „Teach In

    : 2 0 m 9 . C o n t r o l t y p e : T e a c h i n . . EXIT Fig.: 40  Copyright Hammelmann GmbH Germany  D-59302 Oelde  Carl-Zeiss-Straße 6 - 8...
  • Page 111 0 bar desired pressure (water) is reached. Confirm this value by pressing 0 UPM Automatically change to page 5 of this menu. EXIT Fig.: 43 Copyright Hammelmann GmbH Germany  D-59302 Oelde  Carl-Zeiss-Straße 6 - 8...
  • Page 112 The total sum of the flow rates of all consumers can N O T exceed the max. flow rate of the high pressure pump unit! Pos: 110 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.docx @ 1188 @ @ 1  Copyright Hammelmann GmbH Germany  D-59302 Oelde  Carl-Zeiss-Straße 6 - 8...

  • Page 113: Modem Connection

    Beschreibung/ES 2 - Steuerung/Bestätigung @ 0\mod64_1.doc @ 1883 Shipment of the ES2 modem Identifying the condition of the modem over the flushing code. Fig.: 46 Connect ES2 modem and ES2 Control Fig.: 47 Copyright Hammelmann GmbH Germany  D-59302 Oelde  Carl-Zeiss-Straße 6 - 8...
  • Page 114 By pressing of the yellow button the SIM box opens. Fig.: 48 Attach SIM card into the lade box. Fig.: 49 Attach the SIM card and slide it until to the arrester. Fig.: 50  Copyright Hammelmann GmbH Germany  D-59302 Oelde  Carl-Zeiss-Straße 6 - 8...
  • Page 115 : i n a c t i v 2 6 . M o d e m “PIN OFF” and confirm with Switch the ES2 off and then on again. EXIT Fig.: 53 Copyright Hammelmann GmbH Germany  D-59302 Oelde  Carl-Zeiss-Straße 6 - 8...

  • Page 116: Description Of Blink Code Of Es2-Modem

    Connection to net OK, calling possible orange Short ON, long OFF Modem is called/net connection OK orange Constant ON === Ende der Liste für Textmarke Inhalt ===  Copyright Hammelmann GmbH Germany  D-59302 Oelde  Carl-Zeiss-Straße 6 - 8...

  • Page 117: Index

    Fault report .............. 17 Teach in function ............. 12 Function menu ............14 W  K  Working with multi gun valve and Teach in ..... 30 Keypad lock ............. 13 Copyright Hammelmann GmbH Germany  D-59302 Oelde  Carl-Zeiss-Straße 6 - 8...
  • Page 118 Volvo software-structure EMS 2.2 / 2.3 permanently set EMS = Engine Management System ® Datum 04.01.2012 00.06700.0809 Leistungsteil 00.06700.0809 Z-Nr.: HAMMELMANN File name: Bearb. Barenhoff power part KK für ES2 mit elektr. VOLVO GmbH Gepr 16.06.2016 Blatt Carl-Zeiss-Straße 6-8 D-59302 Oelde Änderung...
  • Page 119 Batterieladegerät belegen Batterieschalter Battery switch bajonet fuse 00.01808.0392 Beleuchtung falls vorhanden 25 mm² 70 mm² 70 mm² if fitted HAMMELMANN VOLVO Volvo fuse * +24V / 1.1 / 1.2 70 mm² Batterien Anlasser batteries Starter 04.04550.0517 Aufkleber für Batterieschalter in der Nähe anbringen! "...frühestens 2 Minuten nach dem Motor-Stopp abschalten..."...
  • Page 120 The communication with the ES2 is made by CAN bus ® Datum 04.01.2012 00.06700.0809 Überwachung MOTOR 00.06700.0809 Z-Nr.: HAMMELMANN File name: Bearb. Barenhoff monitoring engine KK für ES2 mit elektr. VOLVO GmbH Gepr 06.06.2016 Blatt Carl-Zeiss-Straße 6-8 D-59302 Oelde...
  • Page 121 >5,5bar 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA ® Datum 04.01.2012 00.06700.0809 Überwachung PUMPE 00.06700.0809 Z-Nr.: HAMMELMANN File name: Bearb. Barenhoff monitoring pump KK für ES2 mit elektr. VOLVO GmbH Gepr 02.06.2016 Blatt Carl-Zeiss-Straße 6-8 D-59302 Oelde Änderung Datum Name Urspr...
  • Page 122 WH/BK 0-xxxxbar 4-20mA -VOLVO_8pol J1939 Druckaufnehmer Pressure transducer ® Datum 04.01.2012 00.06700.0809 Regelungsfunktionen 00.06700.0809 Z-Nr.: HAMMELMANN File name: Bearb. Matzel control function KK für ES2 mit elektr. VOLVO GmbH Gepr 27.02.2016 Blatt Carl-Zeiss-Straße 6-8 D-59302 Oelde Änderung Datum Name Urspr...
  • Page 123 * if installed at the machine the machine ® Datum 04.01.2012 00.06700.0809 Bypassventil und Umschaltventile 00.06700.0809 Z-Nr.: HAMMELMANN File name: Bearb. Matzel bypass valve and multi gun valves KK für ES2 mit elektr. VOLVO GmbH Gepr 07.12.2015 Blatt Carl-Zeiss-Straße 6-8 D-59302 Oelde Änderung...
  • Page 124 * if installed at the machine the machine the machine the machine ® Datum 04.01.2012 00.06700.0809 Reserve Überwachungen 00.06700.0809 Z-Nr.: HAMMELMANN File name: Bearb. Barenhoff reserve monitoring KK für ES2 mit elektr. VOLVO GmbH Gepr 22.06.2016 Blatt Carl-Zeiss-Straße 6-8 D-59302 Oelde Änderung...
  • Page 125 * if installed at the machine the machine the machine the machine ® Datum 04.01.2012 00.06700.0809 Reserve Überwachungen Sonderausführungen 00.06700.0809 Z-Nr.: HAMMELMANN File name: Bearb. Barenhoff KK für ES2 mit elektr. VOLVO GmbH Gepr 16.06.2016 Blatt Carl-Zeiss-Straße 6-8 D-59302 Oelde Änderung Datum...
  • Page 126 * falls an der Anlage vorhanden * if installed at the machine ® Datum 04.01.2012 00.06700.0809 Sonderausführungen 00.06700.0809 Z-Nr.: HAMMELMANN File name: Bearb. Matzel KK für ES2 mit elektr. VOLVO GmbH Gepr 09.01.2017 Blatt Carl-Zeiss-Straße 6-8 D-59302 Oelde Änderung Datum...
  • Page 127 10.2012 Leitfähigkeitssensor ergänzt, Reserve 1, Seite 6 01.2012 Erste Ausführung mit elektronischem VOLVO mit SCR ® Datum 04.01.2012 00.06700.0809 Änderungshistorie 00.06700.0809 Z-Nr.: HAMMELMANN File name: Bearb. Matzel KK für ES2 mit elektr. VOLVO GmbH Gepr 09.01.2017 Blatt Carl-Zeiss-Straße 6-8 D-59302 Oelde Änderung...
  • Page 128 Ohne Externen Not-Aus = Brücke von X5.5 nach X5.41 ® Datum 04.01.2012 00.06700.0809 Klemmenplan 00.06700.0809 Z-Nr.: HAMMELMANN File name: Bearb. Barenhoff Terminal diagram KK für ES2 mit elektr. VOLVO GmbH Gepr 15.06.2016 Blatt Carl-Zeiss-Straße 6-8 D-59302 Oelde Änderung Datum Name...
  • Page 129 Steckerplan F22_001 Leistenbezeichnung =+-ES2/24 24 poliger Anschlussstecker 24 pole connection plug Funktionstext Zielbezeichnung Zielbezeichnung Seite / Spalte VE-Wasser /6.1 Demineral. water Öltemperatur Getriebe oiltemperature gearing /6.3 ÖKW-TEMP.ZU HOCH OCW-TEMP. HIGH /6.4 DE: ABSPERRKLAPPE ZU EN: AIR SHUTOFF FLAP F: SECU.ETOUFFOIR /6.5 Wassertank min.
  • Page 130 Steckerplan F22_001 Leistenbezeichnung =+-ES2/40 40poliger Anschlussstecker 40 pole connection plug Funktionstext Zielbezeichnung Zielbezeichnung Seite / Spalte Batterieplus /1.1 batterie plus /1.1 geschaltete +24V /1.2 switched +24V FREI 1 /3.8 FREE 1 Bypass / Pistole 1 /5.1 bypass / gun 1 /5.1 Pistole 2 /5.5...
  • Page 131 Steckerplan F22_001 Leistenbezeichnung =+-ES2/40 40poliger Anschlussstecker 40 pole connection plug Funktionstext Zielbezeichnung Zielbezeichnung Seite / Spalte Sammelstörung /1.7 general alarm Batterieminus /1.2 batterie minus /1.2 Vorglühen /1.8 pre heat /1.8 Datum 16.06.2016 GmbH Steckerplan =+-ES2/40 Bearb. Barenhoff Plug diagram =+-ES2/40 KK für ES2 mit elektr.
  • Page 132 Steckerplan F22_001 Leistenbezeichnung =+-X1 Bypasssteckdose 4 pol ITT Funktionstext Zielbezeichnung Zielbezeichnung Seite / Spalte Bypass / Pistole 1 /5.1 bypass / gun 1 /5.1 /5.1 /5.1 11.a Datum 07.12.2015 GmbH Steckerplan =+-X1 Bearb. Matzel Plug diagram =+-X1 KK für ES2 mit elektr. VOLVO Gepr 00.06700.0809 Blatt...
  • Page 133 Kabelplan F09_001 Kabelname Kabeltyp Aderzahl Querschnitt Kabellänge Funktionstext =+-W_24pol VE-Wasser Demineral. water Funktionstext Zielbezeichnung von Anschluss Ader Zielbezeichnung nach Anschluss Funktionstext CAN high /4.7 -ES2/24 /4.7 CAN high CAN low /4.7 -ES2/24 /4.7 CAN low VE-Wasser VE-Wasser /6.1 -ES2/24 /6.1 Demineral.
  • Page 134 Kabelplan F09_001 Kabelname Kabeltyp Aderzahl Querschnitt Kabellänge Funktionstext =+-W_40pol Batterieplus batterie plus Funktionstext Zielbezeichnung von Anschluss Ader Zielbezeichnung nach Anschluss Funktionstext Batterieplus Batterieplus /1.1 -ES2/40 /1.1 batterie plus batterie plus /1.1 -ES2/40 /1.1 Batterieminus Batterieminus /1.2 -ES2/40 /1.2 batterie minus batterie minus Brücken für Anlagentyp Diesel Brücken für Anlagentyp Diesel...
  • Page 135 Kabelplan F09_001 Kabelname Kabeltyp Aderzahl Querschnitt Kabellänge Funktionstext =+-W_40pol Batterieplus batterie plus Funktionstext Zielbezeichnung von Anschluss Ader Zielbezeichnung nach Anschluss Funktionstext Stellmotor Stellmotor /4.4 -ES2/40 /4.4 servomotor servomotor /4.4 -ES2/40 /4.4 Bypass / Pistole 1 Bypass / Pistole 1 /5.1 -ES2/40 /5.1 bypass / gun 1...
  • Page 136 Abgasaustritt Abgasnachbehandlungssystem: O 127 exhaust HD Anschluss SCR6 Schalldämpfer mit Katalysator, discharge connection Dosiermodul, Temperatur6 und NOx6Geber Druckregelventil Hebevorrichtung für Pumpenkopf pressure regulating valve emissions aftertreatment system: lifting device for pump head SCR muffler with catalytic converter, dosing system, temp and NOx sensor 1230 1020 M20;...
  • Page 137 6058 2438 1400 2746 Luftaustrittsgitter Lufteintrittsgitter Durchgangsbreite air outlet louvre air inlet louvre passage width Erdungsanschluss 2259 Erdungsanschluss earthing connection 2050 1805,5 Ad Blue Tank earthing connection Durchführung f. Schläuche, Inhalt: ca. 70 L 6058 Anschlussmöglichkeit: Ad Blue tank Füllanschluss Wassertank Pneumatikanschluss G1/4, Überströmanschluss G1 1/2 5853 capacit: approx.
  • Page 138 PARTS LIST (41) Parts-list no.: 00.00743.2221 HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany Drawing no. : 00.00743.2221-1 mail to: mail@hammelmann.de Description : PISTON SEAL ASSEMBLY, Packing http://www.hammelmann.de HDP360 - MC D50, 1.4462 Date 06.03.2017 Page DwgPos Item Code-No. Description Quantity No/Unit Unit 01.01750.0898...
  • Page 139 Sonderausführung Betriebsdruck max. 1000 bar Artikel-Nr. Format DIN 00.00743.2221 alle Ecken und Kanten gratfrei ZeichFreig ß Mit Betriebsdruck signiert ß Mit Auftrags-Nr. signiert Schrauben Pos. mit integriertem Schmiermittel Zul.Abweichung 1:1,5 Maßstab Gewicht in kg ß Mit Teile-Nr. - Rev. signiert f.Maße ohne 30.6100 und in angegebener Reihenfolge ohne Fett...
  • Page 140 PARTS LIST (41) Parts-list no.: 00.02145.1239 HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany Drawing no. : 00.02145.1239-1 mail to: mail@hammelmann.de Description : PUMPHEAD - Duplex http://www.hammelmann.de HDP360-500 D50-55, 1.4462 Date 06.03.2017 Page DwgPos Item Code-No. Description Quantity No/Unit Unit 01.01305.0760...
  • Page 141 Schrauben Pos. mit integriertem Schmiermittel Pos.520 (Skt. SW46) mit MoS gefettet und in und in angegebener Reihenfolge ohne Fett angegebener Reihenfolge angezogen: angezogen: 1. Stufe: Anziehdrehmoment Ma= 200 Nm 1. Stufe: Anziehdrehmoment Ma = 2. Stufe: Anziehdrehmoment Ma= 800 Nm 2.
  • Page 142 PARTS LIST (41) Parts-list no.: 00.05865.0146 HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany Drawing no. : 00.05865.0146-1 mail to: mail@hammelmann.de Description : PRESSURE REGULATING VALVE http://www.hammelmann.de 500 L/MIN , 1200 BAR 1.4462 Date 06.03.2017 Page DwgPos Item Code-No. Description Quantity No/Unit Unit 01.01240.0603...
  • Page 143 Anziehdrehmoment Ma = 200 Nm Tightening torque Ma = 200 Nm Couple de serrage Ma = 200 Nm Skt. SW 55 G 1 1/2 2: 1 2: 1 ß Skt. SW 19 Betriebsdruck max. 1200 bar/ 4462 Volumenstrom max. 500 l/min Nennweite DN 17 Anziehdrehmoment Ma = 100 Nm Keramikausführung...
  • Page 144 PARTS LIST (41) Parts-list no.: 00.06428.0029 HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany Drawing no. : 00.06428.0029-1 mail to: mail@hammelmann.de Description : MEMBRANE CYLINDER http://www.hammelmann.de PN 10; D 130 Date 06.03.2017 Page DwgPos Item Code-No. Description Quantity No/Unit Unit 01.06415.0074...
  • Page 145 Anziehdrehmoment 10 Nm Wirkdurchmesser: 130 mm Betriebsdruck : max. 10 bar ß Medium : Luft, Öl Artikel-Nr. Format DIN alle Ecken und Kanten gratfrei 00.06428.0029 ZeichFreig_PDF ß Mit Betriebsdruck signiert ß Mit Auftrags-Nr. signiert Zul.Abweichung Maßstab Gewicht in kg ß Mit Teile-Nr.
  • Page 146 PARTS LIST (41) Parts-list no.: 00.04062.1000 HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany Drawing no. : 00.04062.1000-1 mail to: mail@hammelmann.de Description : RUPTURE DISC ASSEMBLY http://www.hammelmann.de G 1/2 A - G 1/2 - 82,0 LG. Date 06.03.2017 Page DwgPos Item Code-No.
  • Page 147 6kt. SW36 6kt. SW27 2: 1 1x 04.04062.1000 montiert, Anziehdrehmoment 110 Nm Anziehdrehmoment 100 Nm 2x 04.04062.1000 für Ersatz beigelegt. torque: 110 Nm torque: 100 Nm Betriebsdruck: 1000bar operating pressure: 14500psi Berstdruck: 1400bar burst pressure: 20300psi ® Artikel-Nr. Format DIN Typenschild wird an 04.04062.1000 part no.:...
  • Page 148 PARTS LIST (41) Parts-list no.: 08.00200.9201 HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany Drawing no. : 08.00200.9201-1 mail to: mail@hammelmann.de Description : DISCHARGE FITTING http://www.hammelmann.de Date 06.03.2017 Page DwgPos Item Code-No. Description Quantity No/Unit Unit 01.05332.0141 MANIFOLD 1,000 01.04756.0061 THREADED STUD 1,000 02.00318.0003...
  • Page 149 (M12) (M16) (Festigkeitsklasse 10) (Property class 10) (Festigkeitsklasse 10.9) (Property class 10.9) Anziehdrehmoment Ma = 100 Nm (Skt. SW Druckregelventile 00.05893. x xxx Tightening torque Ma = 100 Nm Pressure regulating valve 00.05893.xxxx Betriebsdruck max. 1800 bar 1: 5 Max. operating pressure 1800 bar Artikel-Nr.
  • Page 150 PARTS LIST (41) Parts-list no.: 00.00026.1238 HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany Drawing no. : mail to: mail@hammelmann.de Description : UNIT http://www.hammelmann.de HDP500; VOLVO TAD1672 STUFE 4 Date 07.03.2017 Page DwgPos Item Code-No. Description Quantity No/Unit Unit 00.02350.1167 CRANK SECTION...
  • Page 151 PARTS LIST (41) Parts-list no.: 00.02350.1167 HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany Drawing no. : 00.02350.1167-1 mail to: mail@hammelmann.de Description : CRANK SECTION http://www.hammelmann.de HDP500 I=3,889 Date 06.03.2017 Page DwgPos Item Code-No. Description Quantity No/Unit Unit 00.01256.0206 CRANK HOUSING 1,000 04.00708.0026...
  • Page 152 PARTS LIST (41) Parts-list no.: 00.02350.1167 HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany Drawing no. : 00.02350.1167-1 mail to: mail@hammelmann.de Description : CRANK SECTION http://www.hammelmann.de HDP500 I=3,889 Date 06.03.2017 Page DwgPos Item Code-No. Description Quantity No/Unit Unit 01.06180.0180 PINION SHAFT 1,000 02.01651.0073...
  • Page 153 PARTS LIST (41) Parts-list no.: 00.02350.1167 HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany Drawing no. : 00.02350.1167-1 mail to: mail@hammelmann.de Description : CRANK SECTION http://www.hammelmann.de HDP500 I=3,889 Date 06.03.2017 Page DwgPos Item Code-No. Description Quantity No/Unit Unit 1090 1090 04.05993.1015...
  • Page 154 1350 Anziehdrehmoment Ma = 250 Nm Skt.SW60 1130 1320 1120 1110 1120 1300 1310 1000 1100 1380 1390 1090 Anziehdrehmoment M24 1020 450 Nm, Iskt.SW19 Anziehdrehmoment M27 650 Nm, Iskt. SW19 Anziehdrehmoment Ma = 125 Nm Skt.SW24 1030 1040 1050 1060 1220 1360...
  • Page 155 1070 1260 Blatt 2 von 2 Artikel6Nr. Format DIN alle Ecken und Kanten gratfrei 00.02350.1167 ß Mit Betriebsdruck signiert ZeichFreig ß Mit Auftrags-Nr. signiert Zul.Abweichung Maßstab 1: 4 Gewicht in kg ß Mit Teile-Nr. - Rev. signiert f.Maße ohne 1506.0000 Toleranzangabe ß...
  • Page 156 PARTS LIST (41) Parts-list no.: 00.02198.0025 HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany Drawing no. : 00.02198.0025-1 mail to: mail@hammelmann.de Description : OIL COOLER http://www.hammelmann.de HDP480 Date 06.03.2017 Page DwgPos Item Code-No. Description Quantity No/Unit Unit 01.01055.1331 FLANGE 1,000 01.03535.1258...
  • Page 157 ß Schweißnaht-ø154,5 mm max. Öl ein Schweißnaht G3/4 ß Ölablass G3/4 Demontage ß Öl aus G3/4 ß G1/4 Aufkleber : Hammelmann optionaler Anschluss Art.-Nr. : 00.02198.0025 Baujahr : Bestell-Nr.: ß Wasser aus G1/2 ß Wasser ein O 13 G1/2 Befestigungsbohrung Mantel hydrostatisch mit 45 bar abgedrückt...
  • Page 158 PARTS LIST (41) Parts-list no.: 00.01015.0020 HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany Drawing no. : 00.01015.0020-1 mail to: mail@hammelmann.de Description : OIL FILTER http://www.hammelmann.de HDP360/480/750 Date 06.03.2017 Page DwgPos Item Code-No. Description Quantity No/Unit Unit 00.01240.0378 HOUSING 1,000 04.00995.0177...
  • Page 159 Betriebsdruck max. 30 bar Prüfdruck max. 45 bar Artikel-Nr. Format DIN alle Ecken und Kanten gratfrei 00.01015.0020 ZeichFreig ß Mit Betriebsdruck signiert ß Mit Auftrags-Nr. signiert Zul.Abweichung Maßstab 1: 1 .5 Gewicht in kg ß Mit Teile-Nr. signiert f.Maße ohne 13.0000 ß...
  • Page 160 PARTS LIST (41) Parts-list no.: 00.04246.0184 HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany Drawing no. : 00.04246.0184-1 mail to: mail@hammelmann.de Description : SUCTION CHAMBER http://www.hammelmann.de HDP360-500 D28 - 65 Date 06.03.2017 Page DwgPos Item Code-No. Description Quantity No/Unit Unit 01.04246.0224...
  • Page 161 O 180 Saugraum bei Montage mit Kurbeltrieb mit Kleber "TEROKAL 3 2444" (04.02056.0005) umlaufend angedichtet. Schrauben Pos. mit integriertem Schmiermittel und in angegebener Reihenfolge ohne Fett angezogen: 1. Stufe: Anziehdrehmoment Ma = 2. Stufe: Anziehdrehmoment Ma = Bronze Saugraum mit 1x DIN DN100 ; PN16 Artikel3Nr.
  • Page 162 PARTS LIST (41) Parts-list no.: 00.00120.1244 HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany Drawing no. : 00.00120.1244-1 mail to: mail@hammelmann.de Description : DRIVE http://www.hammelmann.de HDP480; DEUTZ TCD 2015 V08 Date 06.03.2017 Page DwgPos Item Code-No. Description Quantity No/Unit Unit 00.02250.0432...
  • Page 163 O 530 286,5 25,4 38 (Volvo) 29 (Deutz) Artikel-Nr. Format DIN alle Ecken und Kanten gratfrei 00.00120.1244 ß Mit Betriebsdruck signiert ZeichFreig ß Mit Auftrags-Nr. signiert Zul.Abweichung Maßstab 1: 4 Gewicht in kg ß Mit Teile-Nr. - Rev. signiert f.Maße ohne 47.0000 ß...
  • Page 164 PARTS LIST (41) Parts-list no.: 00.02250.0432 HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany Drawing no. : 00.02250.0432-1 mail to: mail@hammelmann.de Description : COUPLING http://www.hammelmann.de HDP480; CAT C-18 Date 06.03.2017 Page DwgPos Item Code-No. Description Quantity No/Unit Unit 04.03490.0043 COUPLING RING 1,000 04.02251.0121...
  • Page 165 04.03490.0043 04-03390-05 003 "Nur f. Ersatz" entfällt 02.07.2009 Schü Zeichnungs-Nr. Revision Blatt Pos. Benennung Stck. Werkstoff Hammelmann-Nr. Centa-Nr. 00.02250.0432-1 002 Nur für Ersatz 21.04.2009 Schü D-59302 OELDE 001 Zeichng. auf Solid Edge 25.10.2006 Hun CAD-Zeichnung Zust Änderung Ers. d urch Ers.
  • Page 166 PARTS LIST (41) Parts-list no.: 00.00134.0389 HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany Drawing no. : 00.00134.0389-1 mail to: mail@hammelmann.de Description : SUCTION SIDE FITTING http://www.hammelmann.de HDP250/360,VOLVO (STAGE 3B) Date 06.03.2017 Page DwgPos Item Code-No. Description Quantity No/Unit Unit 00.00131.0143...
  • Page 167 DN50 Artikel-Nr. Format DIN alle Ecken und Kanten gratfrei 00.00134.0389 ZeichFreig_PDF ß Mit Betriebsdruck signiert ß Mit Auftrags-Nr. signiert Zul.Abweichung 1: 5 Maßstab Gewicht in kg ß Mit Teile-Nr. - Rev. signiert f.Maße ohne 54.0000 Toleranzangabe ß Härte geprüft ISO 2768 - mH Halbzeug Werkstoff Verwendungszweck...
  • Page 168 PARTS LIST (41) Parts-list no.: 00.00134.0152 HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany Drawing no. : 00.00134.0152-1 mail to: mail@hammelmann.de Description : SUCTION SIDE FITTING http://www.hammelmann.de HDP 380, 500, 800 Date 06.03.2017 Page DwgPos Item Code-No. Description Quantity No/Unit Unit 00.00995.0058...
  • Page 169 Vorschweißflansch DN100; PN16; DIN-ISO 2633 ( O 18) 1: 2 Sauganschluß Artikel-Nr. Format DIN Losflansch DN65; DIN 2642 00.00134.0152 alle Ecken und Kanten gratfrei ZeichFreig_PDF ß Mit Betriebsdruck signiert ß Mit Auftrags-Nr. signiert Zul.Abweichung 1: 7 .5 Maßstab Gewicht in kg ß...
  • Page 170 PARTS LIST (41) Parts-list no.: 00.00995.0058 HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany Drawing no. : 00.00995.0058-1 mail to: mail@hammelmann.de Description : FILTER http://www.hammelmann.de FILTER 300LTR/MIN Date 06.03.2017 Page DwgPos Item Code-No. Description Quantity No/Unit Unit 00.00222.0082 CONTAINER 1,000 01.00665.0419...
  • Page 171 1,25 (+/-10%) Differenzdruck max. bar max.70 Betriebstemperatur °C Durchflussmenge l/min Inhalt Liter Hammelmann Maschinenfabrik GmbH Zum Sundern 13-21 59302 Oelde Germany Losflansch DN65 ; PN10 Telefon 02522/76-0 Telefax 02522/76444 Anschlussmaße nach DIN 2642 Artikel-Nr. Format DIN alle Ecken und Kanten gratfrei 00.00995.0058...
  • Page 172 PARTS LIST (41) Parts-list no.: 00.00134.0160 HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany Drawing no. : mail to: mail@hammelmann.de Description : CONNECTION FITTING, SUCTION SI http://www.hammelmann.de HDP400 Date 06.03.2017 Page DwgPos Item Code-No. Description Quantity No/Unit Unit 04.00709.0019 FLAT SEAL 1,000 02.01272.0310...
  • Page 173 Vorschweißflansch C100x114,3-1.4571; PN16 DIN 2633 204,5 (R 1/2) alle unbemaßten Schweißnähte a=3 Oberflächenbehandlung nach Hammelmann WN 3501 Schweißnähte sind zu passivieren durch: bürsten, strahlen oder beizen. Artikel-Nr. Format DIN alle Ecken und Kanten gratfrei 00.00134.0160 ß Mit Betriebsdruck signiert ZeichFreig ß...
  • Page 174 PARTS LIST (41) Parts-list no.: 00.05540.0346 HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany Drawing no. : 00.05540.0346-1 mail to: mail@hammelmann.de Description : WATER TANK http://www.hammelmann.de 1300L Date 06.03.2017 Page DwgPos Item Code-No. Description Quantity No/Unit Unit 00.05540.0345 TANK 1,000 04.00709.0017...
  • Page 175 1200 1: 2 ,5 (G2) 1: 1 2 1230 DN 50 Tankinhalt ca. 1300 l Artikel-Nr. Format DIN alle Ecken und Kanten gratfrei 00.05540.0346 ZeichFreig ß Mit Betriebsdruck signiert ß Mit Auftrags-Nr. signiert Zul.Abweichung Maßstab 1: 2 0 Gewicht in kg ß...
  • Page 176 PARTS LIST (41) Parts-list no.: 00.05540.0345 HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany Drawing no. : 00.05540.0345-1 mail to: mail@hammelmann.de Description : TANK http://www.hammelmann.de CA.1300L Date 06.03.2017 Page DwgPos Item Code-No. Description Quantity No/Unit Unit 00.05540.0289 TANK 1,000 04.02978.0046 DOUBLE NIPPLE 1,000 00.05880.0007...
  • Page 177 G2 A O 15 1200 Entleerungsanschluss 1230 G1 1/2 1250 Sauganschluss Schlauchtülle Ø76, 1 1: 5 Tankinhalt ca. 1300 l Artikel-Nr. Format DIN alle Ecken und Kanten gratfrei 00.05540.0345 ZeichFreig ß Mit Betriebsdruck signiert ß Mit Auftrags-Nr. signiert Zul.Abweichung Maßstab 1: 1 0 Gewicht in kg ß...
  • Page 178 PARTS LIST (41) Parts-list no.: 00.05880.0007 HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany Drawing no. : 00.05880.0007-1 mail to: mail@hammelmann.de Description : float valve http://www.hammelmann.de 2" SCHWIMMERV.+KUGEL Date 06.03.2017 Page DwgPos Item Code-No. Description Quantity No/Unit Unit 04.05880.0021 FLOAT VALVE 1,000 04.05880.0020...
  • Page 179 Ventil geschlossen Original 300mm Messingstange mit Brenner erwärmen bis gute Verformbarkeit gegeben Artikel-Nr. Format DIN alle Ecken und Kanten gratfrei 00.05880.0007 ß Mit Betriebsdruck signiert ZeichFreig ß Mit Auftrags-Nr. signiert Zul.Abweichung Maßstab 1: 5 Gewicht in kg ß Mit Teile-Nr. - Rev. signiert f.Maße ohne 6.7000 ß...
  • Page 180 PARTS LIST (41) Parts-list no.: 00.00131.0183 HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany Drawing no. : 00.00131.0183-1 mail to: mail@hammelmann.de Description : ARMATURE http://www.hammelmann.de ARMATURE Date 06.03.2017 Page DwgPos Item Code-No. Description Quantity No/Unit Unit 02.01276.0314 FLANGE 1,000 02.01276.0164 WELDING NECK FLANGE 1,000 04.00426.0076...
  • Page 181 90° ( O 17,5) DN50 1: 4 (G2 1/2"A) Artikel-Nr. Format DIN alle Ecken und Kanten gratfrei 00.00131.0183 ZeichFreig_PDF ß Mit Betriebsdruck signiert ß Mit Auftrags-Nr. signiert Zul.Abweichung Maßstab Gewicht in kg ß Mit Teile-Nr. - Rev. signiert f.Maße ohne 2.4000 ß...
  • Page 182 PARTS LIST (41) Parts-list no.: 00.05540.0262 HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany Drawing no. : 00.05540.0262-1 mail to: mail@hammelmann.de Description : FUEL TANK http://www.hammelmann.de 900L ALU-DIESEL Date 06.03.2017 Page DwgPos Item Code-No. Description Quantity No/Unit Unit 00.05540.0261 TANK 1,000 04.00075.0030...
  • Page 183 1260 1230 1280 1340 (M12) 1: 2 0 Alu-Dieseltank Inhalt ca.900L Artikel-Nr. Format DIN alle Ecken und Kanten gratfrei 00.05540.0262 ZeichFreig ß Mit Betriebsdruck signiert ß Mit Auftrags-Nr. signiert Zul.Abweichung Maßstab 1: 1 0 Gewicht in kg ß Mit Teile-Nr. - Rev. signiert f.Maße ohne 177.0000 ß...
  • Page 184 PARTS LIST (41) Parts-list no.: 08.99109.0050 HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany Drawing no. : 08.99109.0050-1 mail to: mail@hammelmann.de Description : CONTROL LINE http://www.hammelmann.de 0-6BAR Date 06.03.2017 Page DwgPos Item Code-No. Description Quantity No/Unit Unit 04.01002.0104 filter 1,000 04.05875.0107...
  • Page 185 T G1 1/2 0 - 6 bar Artikel-Nr. Format DIN 08.99109.0050 ZeichFreig Zul.Abweichung Maßstab 1: 5 Gewicht in kg Magnetventil 24 VDC f.Maße ohne 2.6000 Pos. 50 und Pos. 100 je nach Einbausituation Toleranzangabe Solenoid valve 24 VDC ISO 2768 - mH Halbzeug Werkstoff variabel montiert...
  • Page 186 PARTS LIST (41) Parts-list no.: 00.05630.0012 HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany Drawing no. : 00.05630.0012-1 mail to: mail@hammelmann.de Description : THERMOSTAT http://www.hammelmann.de HDP380/500/800/MC Date 06.03.2017 Page DwgPos Item Code-No. Description Quantity No/Unit Unit 04.05630.0074 THERMOSTAT 1,000 01.05993.0057 TUBE FITTING 1,000 04.00706.0035...
  • Page 187 VKA-Verschlusskegel 22 mit O-Ring 1: 1 Artikel-Nr. Format DIN alle Ecken und Kanten gratfrei 00.05630.0012 ZeichFreig ß Mit Betriebsdruck signiert ß Mit Auftrags-Nr. signiert Zul.Abweichung Maßstab 1: 2 Gewicht in kg ß Mit Teile-Nr. signiert f.Maße ohne 0.1900 ß Härte geprüft Toleranzangabe ISO 2768 - mH Halbzeug...
  • Page 188 PARTS LIST (41) Parts-list no.: 00.06020.0143 HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany Drawing no. : 00.06020.0143-1 mail to: mail@hammelmann.de Description : LIFTING DEVICE http://www.hammelmann.de PUMP HEAD Date 06.03.2017 Page DwgPos Item Code-No. Description Quantity No/Unit Unit 00.01630.1145 BRACKET 1,000 02.00421.0009...
  • Page 189 1: 3 Anzugsdrehmoment 16Nm 1: 5 1: 1 0 Tragkraft max. 500kg Artikel-Nr. Format DIN alle Ecken und Kanten gratfrei 00.06020.0143 ß Mit Betriebsdruck signiert ZeichFreig ß Mit Auftrags-Nr. signiert Zul.Abweichung Maßstab 1: 8 Gewicht in kg ß Mit Teile-Nr. - Rev. signiert f.Maße ohne 39.5000 ß...
  • Page 190 HAMMELMANN Artikel-Nr. / Code no. / Référénce no.: 04.00995.0177 Einbausatz / Insert / Partie intérieur IN-AGB1-125 Insert filters Einbaufilter Parties intérieur es intégrées Type I/Model IN-AGB Flow rate: up to 2000 l/min Nennvolumenstrom: bis 2000 l/min Débit: jusqu’à 2000 l/min...
  • Page 191 HAMMELMANN Artikel-Nr. / Code no. / Référénce no.: 04.00995.0177 Einbausatz / Insert / Partie intérieur IN-AGB1-125...
  • Page 192 HAMMELMANN Artikel-Nr. / Code no. / Référénce no.: 04.00995.0177 Einbausatz / Insert / Partie intérieur IN-AGB1-125 SYMBOL EXPLANATION SYMBOL DESCRIPTION UNIT Aluminium Port dimension (BSP/G) Inch Element Fluid compatibility Fµ Filter fineness Micron XW Media type - Glass fibre XX Media type - Cellulose...
  • Page 193 HAMMELMANN Artikel-Nr. / Code no. / Référénce no.: 04.00995.0177 Einbausatz / Insert / Partie intérieur IN-AGB1-125 COMPANY PROFILE UNTERNEHMENS PROFIL PROFIL DE L’ENTREPRISE Parker Arlon ist ein führender Parker Arlon is a leading designer and Parker Arlon est un des tous premiers...
  • Page 194 HAMMELMANN Artikel-Nr. / Code no. / Référénce no.: 04.00995.0177 Einbausatz / Insert / Partie intérieur IN-AGB1-125 ASSEMBLY PARTS TEILE-LISTE PIECES DETACHEES ITEM NUMBER BESCHREIBUNG TEIL NUMMER DESCRIPTION DESCRIPTION NUMÉRO DE PART Top-spring Feder Ressort supérieur Insert Einbausatz Partie intérieure Insert seal O-ring Einbausatz Joint de partie intérieure...
  • Page 195 HAMMELMANN Artikel-Nr. / Code no. / Référénce no.: 04.00995.0177 Einbausatz / Insert / Partie intérieur IN-AGB1-125 INSTALLATION DIMENSIONS EINBAU-ABMESSUNGEN ENCOMBREMENT MOUNTING ARRANGEMENT TYPE TYPE IN-AGB1-30 IN-AGB1-60 IN-AGB1-90 IN-AGB1-120 IN-AGB1-125 IN-AGB2-170 IN-AGB2-230 IN-AGB2-300 IN-AGB3-270 IN-AGB3-390 IN-AGB3-500 IN-AGB4-600 13.5 IN-AGB4-800 13.5 IN-AGB4-1000 13.5...
  • Page 196 HAMMELMANN Artikel-Nr. / Code no. / Référénce no.: 04.00995.0177 Einbausatz / Insert / Partie intérieur IN-AGB1-125 ∆p/Q GRAPHS ∆p/Q KENNLINIEN ∆p/Q COURBES DE DÉBIT T- -elements T2-elements ν = 32cSt FLUID/FLUID/FLUIDE T3-elements T3D-elements T3E-elements T4-elements T5-elements T5A-elements T6A-elements T8A-elements T8C-elements...
  • Page 197 HAMMELMANN Artikel-Nr. / Code no. / Référénce no.: 04.00995.0177 Einbausatz / Insert / Partie intérieur IN-AGB1-125 ∆p/Q GRAPHS ∆p/Q KENNLINIEN ∆p/Q COURBES DE DÉBIT T3-elements T3D-elements T2-elements T4-elements T5-elements T3E-elements T6A-elements T5A-elements T8A-elements T8C-elements T10-elements T11-elements T13-elements T14-elements T12-elements ∆p CALCULATION ∆p KALKULATION...
  • Page 198 HAMMELMANN Artikel-Nr. / Code no. / Référénce no.: 04.00995.0177 Einbausatz / Insert / Partie intérieur IN-AGB1-125 ORDERING INFORMATION / BESTELLDATEN / COMMENT PASSER VOTRE COMMANDE Variety/ Diffuser/ Seal material/ Ausfuhrung/ Auslaufrohr/ Dichtungen/ Variante code Bac d’ecoulement code Joints code IN-AGB 1-30...
  • Page 199 HAMMELMANN Artikel-Nr. / Code no. / Référénce no.: 04.00995.0177 Einbausatz / Insert / Partie intérieur IN-AGB1-125 ORDERING INFORMATION / BESTELLDATEN / COMMENT PASSER VOTRE COMMANDE Parker Filtration BV Parker Hannifin plc Parker Hannifin Oy Parker Arlon Filter Division Europe HQ...
  • Page 200 HAMMELMANN Artikel-Nr. / Code no. / Référénce no.: 04.00995.0177 Einbausatz / Insert / Partie intérieur IN-AGB1-125 Insert filter Einbaufilter Parties intérieur es intégrées Model IN-AGB FEATURES AND BENEFITS • Designed for return line filtration • Flow direction from in to out •...
  • Page 201 00.02250.0432 - Coupling / Kupplung...
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  • Page 225 HAMMELMANN Artikel-Nr. / Code no. / Réference no.: 04.03070.0007 Safety Data Sheet according to Regulation (EC) No. 1907/2006 (REACH) Printed 10.07.2009 Revision 07.01.2008 (GB) Version 2.0 SRS TFX ! 1. IDENTIFICATION OF THE SUBSTANCE/PREPARATION AND OF THE COMPANY/UNDERTAKING Name of product...
  • Page 226 HAMMELMANN Artikel-Nr. / Code no. / Réference no.: 04.03070.0007 Safety Data Sheet according to Regulation (EC) No. 1907/2006 (REACH) Printed 10.07.2009 Revision 07.01.2008 (GB) Version 2.0 SRS TFX 5. FIRE-FIGHTING MEASURES Suitable extinguishing media Foam Dry powder Carbon dioxide sand...
  • Page 227 HAMMELMANN Artikel-Nr. / Code no. / Réference no.: 04.03070.0007 Safety Data Sheet according to Regulation (EC) No. 1907/2006 (REACH) Printed 10.07.2009 Revision 07.01.2008 (GB) Version 2.0 SRS TFX 8. EXPOSURE CONTROLS/PERSONAL PROTECTION Ingredients with occupational exposure limits to be monitored...
  • Page 228 HAMMELMANN Artikel-Nr. / Code no. / Réference no.: 04.03070.0007 Safety Data Sheet according to Regulation (EC) No. 1907/2006 (REACH) Printed 10.07.2009 Revision 07.01.2008 (GB) Version 2.0 SRS TFX 11. TOXICOLOGICAL INFORMATION Acute toxicity/Irritability/Sensitization Value/Validation Species Method Remark > 5000 mg/kg LD 50 acute oral >...
  • Page 229 HAMMELMANN Artikel-Nr. / Code no. / Réference no.: 04.03070.0007 Safety Data Sheet according to Regulation (EC) No. 1907/2006 (REACH) Printed 10.07.2009 Revision 07.01.2008 (GB) Version 2.0 SRS TFX ! 15. REGULATORY INFORMATION Remarks for classification The product does not require a hazard warning label in accordance with EC directives/German regulations on dangerous substances.
  • Page 230 04.03070.0035 Shell Omala S4 GX 320 Version 2.0 Effective Date 04.12.2012 Regulation 1907/2006/EC Safety Data Sheet SECTION 1. IDENTIFICATION OF THE SUBSTANCE/MIXTURE AND OF THE COMPANY/UNDERTAKING 1.1 Product Identifier Material Name Shell Omala S4 GX 320 Product Code 001D7852 1.2 Relevant identified uses of the substance or mixture and uses advised against Product Use Gear lubricant.
  • Page 231 Shell Omala S4 GX 320 Version 2.0 Effective Date 04.12.2012 Regulation 1907/2006/EC Safety Data Sheet Labeling according to Directive 1999/45/EC EC Symbols No Hazard Symbol required EC Classification Not classified as dangerous under EC criteria. EC Risk Phrases Not classified. EC Safety Phrases Not classified.
  • Page 232 Shell Omala S4 GX 320 Version 2.0 Effective Date 04.12.2012 Regulation 1907/2006/EC Safety Data Sheet Chemical Name Hazard Class & Category Hazard Statement Long-chain alkyl amine Acute Tox., 4; Acute Tox., 3; Acute H302; H331; H311; H314; Tox., 3; Skin Corr., 1B; Skin Sens., 1; H317;...
  • Page 233 Shell Omala S4 GX 320 Version 2.0 Effective Date 04.12.2012 Regulation 1907/2006/EC Safety Data Sheet treatment needed SECTION 5. FIRE FIGHTING MEASURES Clear fire area of all non-emergency personnel. 5.1 Extinguishing Media Foam, water spray or fog. Dry chemical powder, carbon dioxide, sand or earth may be used for small fires only.
  • Page 234 Shell Omala S4 GX 320 Version 2.0 Effective Date 04.12.2012 Regulation 1907/2006/EC Safety Data Sheet sections see Chapter 8 of this Material Safety Data Sheet. For guidance on disposal of spilled material see Chapter 13 of this Material Safety Data Sheet. SECTION 7.
  • Page 235 Shell Omala S4 GX 320 Version 2.0 Effective Date 04.12.2012 Regulation 1907/2006/EC Safety Data Sheet No biological limit allocated. PNEC related information Data not available 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.
  • Page 236 Shell Omala S4 GX 320 Version 2.0 Effective Date 04.12.2012 Regulation 1907/2006/EC Safety Data Sheet controls. Educate and train workers in the hazards and control measures relevant to normal activities associated with this product. Ensure appropriate selection, testing and maintenance of equipment used to control exposure, e.g. personal protective equipment, local exhaust ventilation.
  • Page 237 Shell Omala S4 GX 320 Version 2.0 Effective Date 04.12.2012 Regulation 1907/2006/EC Safety Data Sheet dependent on the exact composition of the glove material. Body protection Skin protection not ordinarily required beyond standard issue work clothes. Respiratory Protection No respiratory protection is ordinarily required under normal conditions of use.
  • Page 238 Shell Omala S4 GX 320 Version 2.0 Effective Date 04.12.2012 Regulation 1907/2006/EC Safety Data Sheet n-octanol/water partition : > 6 (based on information on similar products) coefficient (log Pow) Dynamic viscosity : Data not available Kinematic viscosity : Typical 312,7 mm2/s at 40 °C / 104 °F Vapour density (air=1) : >...
  • Page 239 Shell Omala S4 GX 320 Version 2.0 Effective Date 04.12.2012 Regulation 1907/2006/EC Safety Data Sheet Likely Routes of Skin and eye contact are the primary routes of exposure Exposure although exposure may occur following accidental ingestion. Acute Oral Toxicity Expected to be of low toxicity: LD50 > 5000 mg/kg , Rat Acute Dermal Toxicity Expected to be of low toxicity: LD50 >...
  • Page 240 Shell Omala S4 GX 320 Version 2.0 Effective Date 04.12.2012 Regulation 1907/2006/EC Safety Data Sheet SECTION 12. ECOLOGICAL INFORMATION Basis for Assessment 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.
  • Page 241 Shell Omala S4 GX 320 Version 2.0 Effective Date 04.12.2012 Regulation 1907/2006/EC Safety Data Sheet 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.
  • Page 242 Shell Omala S4 GX 320 Version 2.0 Effective Date 04.12.2012 Regulation 1907/2006/EC Safety Data Sheet Product Name Not applicable. Special Precaution Not applicable. Additional Information : MARPOL Annex 1 rules apply for bulk shipments by sea. SECTION 15. REGULATORY INFORMATION The regulatory information is not intended to be comprehensive.
  • Page 243 Shell Omala S4 GX 320 Version 2.0 Effective Date 04.12.2012 Regulation 1907/2006/EC Safety Data Sheet Not classified. Harmful if swallowed. R23/24 Toxic by inhalation and in contact with skin. Causes burns. May cause sensitisation by skin contact. R48/20 Harmful: danger of serious damage to health by prolonged exposure through inhalation.
  • Page 244 Shell Omala S4 GX 320 Version 2.0 Effective Date 04.12.2012 Regulation 1907/2006/EC Safety Data Sheet ADN = European Agreement concerning the international carriage of dangerous goods by inland waterways (ADN) DFG = Federal Institute of Hydrology EG = European Community EN = European Norm IBC = Intermediate Bulk Container ISO = International Standards Organisation...
  • Page 245 Shell Omala S4 GX 320 Version 2.0 Effective Date 04.12.2012 Regulation 1907/2006/EC Safety Data Sheet EWC = European Waste Code GHS = Globally Harmonised System of Classification and Labelling of Chemicals IARC = International Agency for Research on Cancer IATA = International Air Transport Association IC50 = Inhibitory Concentration fifty IL50 = Inhibitory Level fifty IMDG = International Maritime Dangerous Goods...
  • Page 246 Shell Omala S4 GX 320 Version 2.0 Effective Date 04.12.2012 Regulation 1907/2006/EC Safety Data Sheet SDS Regulation Regulation 1907/2006/EC as amended by Regulation (EU) 453/2010 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.
  • Page 247 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 SuperNova SIHI Programme Range: ZLND Volute casing pump complying with EN 733 / DIN 24255 Operating instructions Safety issues Chapter 1 Safety instructions and compliance Intended application Chapter 2 Application, description Planning the installation...
  • Page 248 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Safety issues Page 1 of 3 Chapter 1 Safety • the identification plate This operating manual gives basic instructions, and that these are kept legible. which must be observed during installation, Qualification training operation and maintenance of the pump. It is...
  • Page 249 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Safety issues Page 2 of 3 Chapter 1 Compliance with regulations operative again. Prior to re-starting the machine, relating to safety at work the instructions listed under “first commissioning” When operating the pump the safety instructions are to be observed.
  • Page 250 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Safety issues Page 3 of 3 Chapter 1 1.7.3 Monitoring technical 1.10 Warranty / guarantee parameters Sterling Fluid Systems guarantee satisfactory When using pumps in areas with an explosion operation if: • the pump is installed and operated in...
  • Page 251 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Intended application Page 1 of 3 Chapter 2 Application Construction and mode of operation The pump is to be used only for the operating conditions stated by the customer and confirmed ZLND pumps are horizontal, single-stage volute by the supplier.
  • Page 252 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Intended application Page 2 of 3 Chapter 2 2.4 Description Type size Shaft seal Casing gasket Hydraulic + Bearing Material design 041: Self-sealed, uncooled packing rings 0B: Cast iron GG25 A• First hydraulic 2: confined flat B•...
  • Page 253 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Intended application Page 3 of 3 Chapter 2 Shaft sealing Example of a pump designation: Depending on the application, different shaft sealing executions are offered (see 2.4) 5-7 8-10 11 12 13-15 16-17 18 •...
  • Page 254 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Planning the installation Page 1 of 2 Chapter 3 Planning the installation Piping system Ensure that air pockets cannot be created. Unequal nominal widths of the suction branch and suction line must be compensated by eccentric ATTENTION transition pieces.
  • Page 255 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Planning the installation Page 2 of 2 Chapter 3 A shut-off valve should be installed in the feed line. It must be closed for maintenance work. It should be installed in order to avoid air pockets forming in the spindle cap, i.e.
  • Page 256 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Unpacking, storage, transport Page 1 of 2 Chapter 4 Unpacking, storage, handling Handling The pump or pump set must be lifted and handled Safety measures as shown in the following sketches. • Never stay below the suspended load.
  • Page 257 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Unpacking, storage, transport Page 2 of 2 Chapter 4 4.5.2 Renewing corrosion protection If the pump has been supplied with a protective coating and has to be stored, a new protective coating should be applied after six months.
  • Page 258 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Installing the pump Page 1 of 3 Chapter 5 Installing the pump Requirements 5.4.3 Base, foundation The pump and the pump set, must have been The pump must be installed on a flat floor or unpacked and handled as described in Chapter 4.
  • Page 259 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Installing the pump Page 2 of 3 Chapter 5 5.4.6 Position In principle the ZLND pumps are installed half of the N-EUPEX B ( FLENDER ) coupling horizontally. must be 2 - 3 mm (see fig.).
  • Page 260 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Installing the pump Page 3 of 3 Chapter 5 Mounting the pump and installation into pipework The following instructions must be carried out: 1. remove the protective covers from the pump flanges and the auxiliary pipework connections.
  • Page 261 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Starp-up and shut-down Page 1 of 3 Chapter 6 6. Start-up and shut-down operations Requirements • The pump or the pump set, must be installed acc. If there is no bypass line, do not run the to the instructions of Chapter 5.
  • Page 262 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Starp-up and shut-down Page 2 of 3 Chapter 6 Switching frequency Size Permissible number of starts equally spaced per hour 32-125, 32-160, 32-200, 32-250, 40-125, 40-160, 40-200, 40-250, 50-125, 50-160, 50-200, 65-125, 65-160, 65-200, 65-250, 80-160,...
  • Page 263 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Starp-up and shut-down Page 3 of 3 Chapter 6 - shaft seal Executions with stuffing box: For correct operation of the shaft seal a slight leakage (20 - 40 drops per minute) is essential. If...
  • Page 264 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Maintenance, dismantling, assembly Page 1 of 10 Chapter 7 7. Maintenance, dismantling, grease nipple assembly Requirements The pump or the pump set must have been shut down in the manner described in Chapter 6.
  • Page 265 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Maintenance, dismantling, assembly Page 2 of 10 Chapter 7 7.4.2 Bearing with oil lubrication Oil change intervals The pump is supplied empty (no oil). Before the If the bearings are new, change the oil after about initial start up, pour oil into the oil inlet hole until 200 hours and subsequently annually.
  • Page 266 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Maintenance, dismantling, assembly Page 3 of 10 Chapter 7 7.4.3 Stuffing box 7.4.4 Mechanical seal If leakage makes it necessary, the packing rings The mechanical seal should have little or no should be retightened. After extended periods and visible leakage.
  • Page 267 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Maintenance, dismantling, assembly Page 4 of 10 Chapter 7 • dismantle guard coupling, pump feet and coupling. Design with stuffing box 1. Remove the Allen head screws 91.40 and 7.5.2 Replacement parts detach the casing cover 16.10.
  • Page 268 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Maintenance, dismantling, assembly Page 5 of 10 Chapter 7 Design with quench (AX3, AXS, AXK) Bearing design B, C or 2 : Detach the cover 16.50, O-ring 41.23 and lip 1. Release hexagonal screws 90.11, remove seals 42.11.
  • Page 269 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Maintenance, dismantling, assembly Page 6 of 10 Chapter 7 1. Mark the position of all parts with a colour pen Design with a mechanical seal: or scribing tool in order to be able to 1.
  • Page 270 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Maintenance, dismantling, assembly Page 7 of 10 Chapter 7 Assembly 5. Pull out complete shaft with both ball bearings 7.7.1 Tightening torque 32.10 and 32.11 and circlip 93.21. When tightening the bolts the following torques must be used: 32.11...
  • Page 271 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Maintenance, dismantling, assembly Page 8 of 10 Chapter 7 • 4. Attach the bearing cover 36.00, with its radial For executions with mechanical seal: seal inserted, if it is oil lubricated, and the flat gasket 40.02;( the lip of the radial seal ring...
  • Page 272 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Maintenance, dismantling, assembly Page 9 of 10 Chapter 7 Design with heating (AY3, AYS, AYK) 10.20 40.00 90.10 Insert the O-rings 41.22 and 41.23 in the cover 16.50. 16.10 41.22 41.23 16. 50 90.30 Bearing design S or T : Attach the cover 16.50 and casing cover 16.10.
  • Page 273 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Maintenance, dismantling, assembly Page 10 of 10 Chapter 7 • 5. When fitting the rotating unit in the bearing For executions with mechanical seal: housing 33.00, the circlip 93.21 must be 9. Install the mechanical seal cover 47.10 with inserted in the groove in the bearing housing.
  • Page 274 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Troubleshooting Page 1 of 1 Chapter 8 Help in case of trouble Use of trained staff Trouble shooting must be undertaken only by appropriately trained personnel. Symptoms, causes and remedies Symptom Cause Remedy Output too low - Back pressure too high.
  • Page 275 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Technical data Page 1 of 3 Chapter 9 Technical Data For technical information about the pump or pump Direction of rotation: set, which is not described in this chapter, see the Clockwise seen from the drive end of the pump.
  • Page 276 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Technical data Page 2 of 3 Chapter 9 Permissible branch forces and moments: Values according to ISO/DIN 5199 – Class II (1997) – Annex B, Family Nº 2 for mounting on sheet metal baseplates and frames without grouting for pumping temperatures up to 110 ºC...
  • Page 277 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Techical Data Page 3 of 3 Chapter 9 Maximum permissible speeds at 50 Hz: Max. speed Max. speed Max. speed Max speed Size Size Size Size 32125 32160 32250 40315 50315 32200 40125 40250...
  • Page 278 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Annex Page 1 of 14 Chapter 10 Annex 10.1 Connections Connections for bearing brackets 25, 35 and 45. Only for Impellers ∅125 : Pressure gauge. Only available on request : Quench Inlet : Pressure gauge. Only available on request...
  • Page 279 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Annex Page 2 of 14 Chapter 10 Connections for bearing brackets 55 and 65 View X : Self sealing connection : Pressure gauge connection : Pressure/vacuum gauge. Only available on request : 051 Inlet (Stuffing box)
  • Page 280 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Annex Page 3 of 14 Chapter 10 10.2 Table of Dimensions øk øk All dimensions in mm Size Pump dimensions Foot dimensions End shaft 32125 32160 32200 32250 40125 40160 40200 40250 40315 50125...
  • Page 281 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Annex Page 4 of 14 Chapter 10 Table of Dimensions DN 2 øk d 1 k6 DN 1 øk All dimensions in mm Size Pump dimensions Foot dimensions End shaft 150500 53.5 200315 53.5 200400 53.5...
  • Page 282 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Annex Page 5 of 14 Chapter 10 10.3 Parts list When ordering spare parts give the following information: position number, the complete pump designation and the serial number, which can be found on the nameplate fixed to the pump.
  • Page 283 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Annex Page 6 of 14 Chapter 10 ZLND 32125 to 200250 AB MECHANICAL SEALS 0B 2 68.10 10.20 23.00 50.40 40.00 43.30 16.10 32.10 50.50 33.00 36.00 42.20 21.00 90.13 Mechanical seal code BJ3/BJS/BJJ 92.20...
  • Page 284 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Annex Page 7 of 14 Chapter 10 ZLND 32125 to 200250 AC/A2 MECHANICAL SEALS 0B 2 68.10 10.20 23.00 50.40 43.30 40.00 16.10 42.10 32.10 50.50 63.80 91.60 40.02 36.00 21.00 90.13 Mechanical seal code BJ3/BJS/BJJ 92.20...
  • Page 285 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Annex Page 8 of 14 Chapter 10 ZLND 32125 to 200250 AB STUFFING BOX 0B 2 68.10 10.20 23.00 52.40 40.00 16.10 40.05 90.23 45.70 45.20 32.10 50.50 33.00 36.00 42.20 21.00 90.13 Stuffing box code 92.20 94.01 90.30...
  • Page 286 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Annex Page 9 of 14 Chapter 10 ZLND 32125 to 200250 AC/A2 STUFFING BOX 0B 2 90.23 45.20 32.10 63.80 68.10 10.20 23.00 52.40 40.00 16.10 40.05 45.70 42.10 50.50 91.60 40.02 36.00 21.00 90.13...
  • Page 287 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Annex Page 10 of 14 Chapter 10 ZLND 200315 to 300500 and 150500 AS MECHANICAL SEALS 0B 2 40.03 23.00 43.30 50.70 33.00 32.10 36.00 94.00 90.80 73.10 90.22 73.11 10.20 50.40 16.10 90.34 40.00...
  • Page 288 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Annex Page 11 of 14 Chapter 10 ZLND 200315 to 300500 and 150500 AT/A2 MECHANICAL SEALS 0B 2 40.03 23.00 50.70 67.20 93.21 90.11 94.00 73.11 90.80 73.10 90.22 10.20 50.40 16.10 41.11 90.34 40.00...
  • Page 289 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Annex Page 12 of 14 Chapter 10 ZLND 200315 to 300500 and 150500 AS STUFFING BOX 0B 2 40.03 23.00 50.70 33.00 32.10 36.00 94.00 90.80 73.10 90.22 73.11 10.20 45.80 16.10 41.11 90.34 40.00...
  • Page 290 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Annex Page 13 of 14 Chapter 10 ZLND 200315 to 300500 and 150500 AT/A2 STUFFING BOX 0B 2 40.03 23.00 50.70 67.20 93.21 90.11 94.00 73.11 90.80 73.10 90.22 10.20 45.80 16.10 41.11 90.34 40.00...
  • Page 291 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Annex Page 14 of 14 Chapter 10 COPYRIGHT WARNING Please read this notice The material you are viewing in this document is protected by Copyright and may only be used in accordance with Copyright, Designs and Patent legislation.
  • Page 292 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 SuperNova SIHI Program Supplementary operating instructions in accordance to EC directive 94/9/EC (ATEX) for the intended use in potentially explosive atmospheres of the following pumps types, manufactured by Sterling Fluid Systems (Spain), S.A.: ZLN, ZLK and ZLI (Industrial Pumps)

  • Page 293: General Objective

    HAMMELMANN Code no.: 04.03226.0769 Type 32-200 General Objective Pumping systems can be operated in hazardous areas. It is the obligation of the operator to define the zone and to select the pump with the correct category for this zone. The pump installation and operation must take the Operating Instructions into accounts that are described in these supplementary operating instructions.

  • Page 294: Safety Instructions For Maintenance, Inspection And Installation Work

    HAMMELMANN Code no.: 04.03226.0769 Type 32-200 2.4 Safety instructions for installation work, inspection operation and maintenance The operator is responsible to assure that all installation work, inspection, operation and maintenance must be carried out by authorised and qualified specialist personnel, which is thoroughly familiarised with the pump operating instructions and these supplementary operating instructions.

  • Page 295: Unauthorised Modes Of Operation

    HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Instructions concerning operation and maintenance 5.1 Unauthorised modes of operation The warranty relating to the operating reliability and safety of the unit supplied is only valid if the equipment is used in accordance with its designated use as described in the following sections of this supplementary operating manual and the pump-specific operating manual.

  • Page 296: Pump Operating Mode

    HAMMELMANN Code no.: 04.03226.0769 Type 32-200 5.7 Pump operating mode Make sure that the pump is always started up with the suction-side shut-off valve fully open and the discharge-side shut-off valve slightly open. However, the pump can also be started up against a closed swing check valve. Only after the pump has reached full rotational speed shall the discharge-side shut-off valve be adjusted to comply with the duty point.
  • Page 297 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Because of the very close contact between pumps and motors in close coupled design (ZLK and ZLI, Industrial Pumps; ZTK and ZTI, Thermal Oil Pumps; and ZLI, Hot Water Pumps), there is a thermal influence between pump and motor.
  • Page 298 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Sterling Fluid Systems (Spain), S.A. Vereda de los Zapateros, s/n 28223 Pozuelo de Alarcon (Madrid) España Phone: 0034 91 7091310, Fax: 0034 91 7159700 Declaration of Conformity In the sense of the EU Directive 98/37/EC, Appendix II B...
  • Page 299 HAMMELMANN Code no.: 04.03235.0134 K 3000.1091.1 GB Zentralschmiertechnik BAIER + KÖPPEL Instructions for use and maintenance Gear pumps Taking the unit into operation 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.

  • Page 300: Maintenance

    HAMMELMANN Code no.: 04.03235.0134 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 that pressure restrictor valve effected using pressure gauge control. Speed --- Sense of rotation According to the size of the type concerned, the minimum service speed is approx.
  • Page 301 HAMMELMANN Code no.: 04.03235.0134 K 3000.1091.3 GB Zentralschmiertechnik BAIER + KÖPPEL Malfunction No. 1: The pump does not supply fluid. 1.1 The pump does not suck ---in any fluid Possible reasons Remedies 1.1.1 The plug was not removed from the suction pipe.
  • Page 302 HAMMELMANN Code no.: 04.03235.0134 K 3000.1091.4 GB Zentralschmiertechnik BAIER + KÖPPEL Malfunction No. 3: Excessive pump noise Possible reasons Remedies Air is taken in by the pump. Refer to items 1.1.2 and 1.1.3 Defective shaft seal. Install a new shaft seal.
  • Page 303 HAMMELMANN Code no.: 04.03235.0134...
  • Page 304 SAFETY DATA SHEET Coolant VCS Ready Mixed 21485015 Date of issue : 2012-01-26. Version : 1.01 IDENTIFICATION OF THE SUBSTANCE/MIXTURE AND OF THE COMPANY/UNDERTAKING 1.1 Product identifier Product name Coolant VCS Ready Mixed : 21485015 Product no. 1.2 Relevant identified uses of the substance or mixture and uses advised against Product use Coolant and antifreeze.
  • Page 305 Coolant VCS Ready Mixed 21485015 COMPOSITION/INFORMATION ON INGREDIENTS See Section 16 for the See Section 16 for the full text of the R-phrases full text of the H declared above. statements declared above. There are no additional ingredients present which, within the current knowledge of the supplier and in the concentrations applicable, are classified as hazardous to health or the environment and hence require reporting in this section.
  • Page 306 Coolant VCS Ready Mixed 21485015 6. ACCIDENTAL RELEASE MEASURES 6.4 Reference to other : See Section 1 for emergency contact information. sections See Section 8 for information on appropriate personal protective equipment. See Section 13 for additional waste treatment information. HANDLING AND STORAGE 7.1 Precautions for safe handling Protective measures...
  • Page 307 Coolant VCS Ready Mixed 21485015 PHYSICAL AND CHEMICAL PROPERTIES Initial boiling point and >175°C (>347°F) boiling range Closed cup: >115°C (>239°F) Flash point : Not available. Evaporation rate : Not available. Flammability (solid, gas) Burning time : Not applicable. Not applicable. Burning rate Upper/lower flammability or : Not available.
  • Page 308 Coolant VCS Ready Mixed 21485015 TOXICOLOGICAL INFORMATION General Repeated or prolonged contact with the preparation may cause removal of natural fat from the skin, resulting in non-allergic contact dermatitis and absorption through the skin. Developmental effects : Contains material which can cause birth defects. Other information Not available.
  • Page 309 Coolant VCS Ready Mixed 21485015 REGULATORY INFORMATION 15.1 Safety, health and environmental regulations/legislation specific for the substance or mixture EU Regulation (EC) No. 1907/2006 (REACH) Annex XIV - List of substances subject to authorisation Substances of very high concern None of the components are listed. Other EU regulations Classification and labeling have been determined according to EU Directives 67/548/EEC and Product use...
  • Page 310 HAMMELMANN Code no.: 04.05866.0011 Type S-050 S-050 AUTOMATIC AIR RELEASE VALVE "SEGEV" PAT. PEND PAT. PEND Lightweight, small dimensions, simple and reliable structure. The body is made of high strength plastic, and all operating parts are made of specially selected corrosion resistant materials.
  • Page 311 HAMMELMANN Code no.: 04.05866.0011 Type S-050 PARTS LIST AND SPECIFICATION Part Material Body Reinforced Nylon Rolling Seal Rubber E.P.D.M Clamping Stem Reinforced Nylon Float Foamed Polypropylene O-Ring BUNA-N Base Reinforced Nylon or Brass ASTM B124 AUTOMATIC AIR DISCHARGE CHART Flow m...

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