Operating Instructions: High Pressure Pump

Operating instructions
High pressure pump
HDP 382
B3.01382.0011
HDP 382
2013
Made in Germany
Issue: 05.2013
MACHINE CARD
Hammelmann Maschinenfabrik GmbH

POB 3309, D-59282 Oelde, Germany
mail to: mail@hammelmann.de
Machine no. : B3.01382.0011 http://www.hammelmann.de
Page: 1
Order no. KA 162384

Purchaser DEN- JET NORDIC A/S, Arden / DK
Client no. 11117601
P. O. no./Date 7756 / 12.03.2013
Machine no. B3.01382.0011
Pump type HDP 382
Code no. 09.00382.1170
Performance data
Flow rate Ps 1 l/min 204
Operating pressure Ps 1 bar 1000
Motor speed Ps 1 1/min 1800
Crankshaft speed Ps 1 1/min 490
Piston dia. Ps 1 mm 50
Motor rating req'd Ps 1 kW 380
Brief instructions
Language englisch
Paint colour
Pump RAL 1018
Name plate high pressure pump
Machine no. B3.01382.0011
Type no. 09.00382.1170
Year 2013
Motor rating [kW] kW 380
Speed [1/min] 1/min 1800
Max. liquid temp. [°C] °C 40
Piston dia. pres. step 1 [mm] mm 50
Max. pressure Ps 1 [bar] bar 1000
Flow rate Ps 1 [l/min] l/min 204
Pressure reg. valve Ps 1 00.05893.0032
Oil type PAO VG 320
Oil quantity [l] l 38
Oil pressure [bar] bar 4,0
Documentation
Language 1 englisch
Language 1 number of paper 2
Language 1 number of CD 1
Date of delivery 26.04.2013
Person in charge-Sales M. Lettmann
Person in charge H.- J. Schulte
Person in charge H.- J. Schulte / 04.04.2013
Date 18.03.2013
MACHINE CARD
Hammelmann Maschinenfabrik GmbH

POB 3309, D-59282 Oelde, Germany
Machine no. : B3.01382.0011 http://www.hammelmann.de
Page: 2
Note : Ps = Pressure step
Parts list to machine no: B3.01382.0011
Pos Code - No. Description Quantity Unit

1 00.03223.3254 HIGH-PRESSURE PUMP HDP380 1,00 pc
10 01.04565.0037 NAMEPLATE 1,00 pc
20 00.02350.1078 CRANK SECTION HDP380 I=3,66 1,00 pc
30 00.04246.0184 SUCTION CHAMBER HDP360-500 D28 - 65 1,00 pc
40 04.03070.0035 OIL SHELL OMALA HD 320 38,00 l
50 00.00743.2221 PISTON SEAL ASSEMBLY HDP360/480/750 D50 3,00 pc
60 00.02515.0350 LINE SUCTION CHAMBER 1,00 pc
70 00.02145.1239 PUMPHEAD HDP360-500 D50-55 1,00 pc
80 00.05893.0032 PRESSURE REGULATING VALVE CPL. 500 L/MIN (NW17); 500-1200 BAR 1,00 pc
85 01.05240.0030 PLUG G 1/2; 2350 bar 1,00 pc
90 02.00301.0007 RING NUT M30;GALZN;MAX.BEL.3600/2600KG 2,00 pc
>>>end<<<
Abnahmeprüfzeugnis
Test certificate
Maschinen-Nr. HAMMELMANN
B3.01382.0011 Maschinenfabrik GmbH
Machine No.
Zum Sundern 13-21
Unsere Auftrags-Nr.
KA 162384
Our Order No. D-59302 Oelde
Tel.: 02522/76-0
Bestell-Nr. e-mail: mail@hammelmann.de
7756
P. Order No. http: www.hammelmann.de
Druckregelautomatik Eingangsdrehzahl / Motordrehzahl

--------------------------------------- -1 1800
Pressure unloader Input speed / Motor r.p.m. min
Druckregelventil / Bypassventil Öldruck
00.05893.0032 7,0
Pressure relief valve / Bypass valve Oil pressure bar
Anzahl der Tellerfedern Mediumdruck

--------------------------------------- 1000
Number of Disc-springs Medium pressure bar
Schichtung der Tellerfedern Fördermenge
--------------------------------------- 3 202
Spring pack arrangement Output m /h l/min
Distanzhülse / Steuerdruck Plungerkühlwasser
3,2 bar 9,0 / 23°C
Washer / Control pressure Pisten cooling water l/min / °C
Sicherheitsventil / Berstscheibensicherung Ansprechdruck

Safety valve / Burst disc / / Opening Pressure bar
-----------------
Druckwächter Öl E-Motor ex 50 Hz
Oil pressure switch D-Motor 60 Hz
Druckwächter Medium Antriebsleistung
nicht vorhanden / not installed
380
Medium pressure switch Motor rating kW
geprüft / tested
Stromaufnahme (Prüfraum) A
Thermostat Öl / Oil Medium / / Power consumption (Testroom) Volt / Hz /
Überlast E-Motor Gesamtlaufzeit – Std.

2,25
Overload E-Motor Total – Test – Time hr.
Schaltschrank (ohne Pumpenüberwachung) unter Last

Switchboard (without pump control unit) under Load Std./hr. 2,0
Schaltschrank (Überwachungsgerät, Pumpe-Motor) Geprüft nach EG-Maschinenrichtlinie
Switchboard (control unit, pump-motor) Gerätesicherheitsgesetz
ja / yes
Tested in accordance with E.U. Machine
Betriebsstundenzähler Regulations governing operational nein / no
Operating hours counter safety of equipement.
Bypasssteuerventil Druckwächter Luft ja / yes
Bypass solenoid valve Air pressure sensor nein / no
Umschaltventil / Magnetventil Kühlwassermenge
20
Multi tool valve / Changeover valve Cooling water quantity Ltr./ min.
Temperaturmessung nach Erreichen der Beharrungstemperatur
Temperature measurement only when steady state temperature reached
No. Name Date Time IR-Temp IR-Min IR-Max Material Name

1 TS1 Temp.Cranks.bear 06.05.2013 14:12:20 65,7 65,0 65,9 Free
2 TS2 Temp.Cranks.bear 06.05.2013 14:12:24 65,5 64,2 65,8 Free
3 TS3 Driveshaft bear. 06.05.2013 14:12:30 64,5 63,1 64,5 Free
4 TS4 Driveshaft bear. 06.05.2013 14:12:33 64,8 63,5 64,8 Free
5 TS5 Oiltemperature 06.05.2013 14:12:38 67,5 67,3 67,5 Free
6 TS6 Oil Cooler out 06.05.2013 14:12:52 56,1 56,1 56,6 Free
7 TS7 Coolingwater inl 06.05.2013 14:12:57 24,3 24,3 24,3 Free
8 TS8 Coolingwater out 06.05.2013 14:13:04 28,8 28,8 29,2 Free
9 TS9 Crank sec.gener. 06.05.2013 14:13:07 67,2 65,9 67,2 Free
10 TS10 Temp.Pisten 06.05.2013 14:13:15 34,4 34,3 37,2 Free
11 TS11 Temp.Crosshead 06.05.2013 14:13:20 62,2 60,8 62,4 Free
12 TS12 Ambient Temp. 06.05.2013 14:13:24 23,8 23,8 24,0 Free
Qualitätsprüfung Der Abnahmeingenieur Datum

Quality Control Test-Engineer Date
Name:
Unterschrift / Signature T.Hundsrucker 07.05.2013

Dokument wurde auf elektronischem Wege erstellt und ist ohne Unterschrift gültig.
This message was electronically generated and is valid without a signature.
QC - 049/05.08 Seite 1 von 1

HAMMELMANN
Maschinenfabrik GmbH
Zum Sundern 13 – 21
59302 Oelde • Germany
Einbauerklärung Declaration of Incorporation Déclaration d’incorporation

nach EG-Richtlinie 2006/42/EG, according to E.C. Directive conformément à la directive
Anhang II, Nr. 1B 2006/42/EC, Appendix II, No 1B 2006/42/CE, Annexe II, N° 1B
Par la présente, nous déclarons que la
Hiermit erklären wir, dass die nachstehend We hereby declare that the machine
machine désignée ci-dessous est une
bezeichnete Maschine eine unvollständige detailed below is partly completed
machine incomplète conformément à
Maschine nach Artikel 2g ist. Sie ist machinery according to Article 2g. It is
l’article 2g. Elle est exclusivement prévue
ausschließlich zum Einbau in oder zum exclusively intended for incorporation in or
d’être incorporé dans une autre machine ou
Zusammenbau mit einer anderen Maschine with other machinery or equipment.
équipement ou de faire partie d’un
oder Ausrüstung vorgesehen.
assemblage.
Die Abteilung Normung/Dokumentation ist The department Standards/Documents is Le service Standardisation/Documentation
bevollmächtigt, die technischen Unterlagen authorised to compile the technical file est autorisé à compiler la documentation
nach Anhang VII B zusammenzustellen. according to Annex VII B. technique conformément à l’annexe VII B.
Diese unvollständige Maschine darf erst

This partly completed machinery must not Cette machine incomplète ne doit pas être
dann in Betrieb genommen werden, wenn
be put into service until the final machinery mis en service avant que la machine dans
festgestellt wurde, dass die Maschine, in die
into which it is to be incorporated, has been laquelle la machine incomplète a été
diese unvollständige Maschine eingebaut
declared in conformity with the provisions of incorporée soit conforme aux dispositions
wurde, den Bestimmungen der Maschinen-
the machine directive. de la directive CE sur les machines.
richtlinie entspricht.
Bezeichnung der Maschine: Hochdruckpumpe HDP 382
Machine description: High pressure pump HDP 382
Désignation de la machine: Pompe à haute pression HDP 382
Maschinentyp:
Machine designation: 09.00382.1170
Type de machine:
Maschinen-Nr.:
Machine No.: B3.01382.0011
o
N de machine:
Weitere, zutreffende EG-Richtlinien: Other appropriate E.C. Directives: Autres directives CE concernées:
EG-Richtlinie 2004/108/EG E.C. Directive 2004/108/EC Directive CE sur la comptabilité

(EMV-Richtlinie) (EMC directive) électromagnétique 2004/108/CE
Angewandte harmonisierte Normen: Used harmonised standards: Normes harmonisées appliquées:
EN 809 EN 60204-1 EN 61000-6-2
Angewandte nationale Normen und National standards and technical Normes nationales et spécifications
technische Spezifikationen: specifications: techniques appliquées:
- -
Hersteller-Unterschrift Manufacturer’s signature Signature du fabricant
07.05.2013
TB 008/0106
Datum / Date / Date Geschäftsführer Managing director Gérant

Funktion des Unterzeichners Position of Signatory Fonction du signataire
High pressure pump
HDP 382
HDP 382
2013
Made in Germany
Issue: 05.2013
No: HDP 382 Contents
Page 2, Issue: 05.2013
1 Contents
1 Contents ............................................................................................................................................................ 2
2 Foreword ........................................................................................................................................................... 5
3 Technical data ................................................................................................................................................... 6

3.1 Performance Data: High pressure pump ..................................................................................................... 6
3.2 Main dimensions .......................................................................................................................................... 7
4 Safety ................................................................................................................................................................. 9
4.1 Dangers arising from non observance of safety instructions ....................................................................... 9
4.2 Safety conscious working ............................................................................................................................ 9
4.3 Personnel qualification and training ............................................................................................................. 9
4.4 Precise safety instructions for the operator ................................................................................................. 9
4.5 Danger symbol ........................................................................................................................................... 11
4.6 Safety during inspection, maintenance and repair ..................................................................................... 12
4.7 Forbidden practices ................................................................................................................................... 12
4.8 Additional warnings .................................................................................................................................... 12
5 General............................................................................................................................................................. 13
5.1 Introduction ................................................................................................................................................ 13
5.2 Application.................................................................................................................................................. 13
5.3 General permissible operational conditions ............................................................................................... 13
5.4 Copyright .................................................................................................................................................... 14
5.5 Warranty terms........................................................................................................................................... 14
6 Transportation ................................................................................................................................................ 15
6.1 Packing ...................................................................................................................................................... 15
6.2 Transportation ............................................................................................................................................ 16
6.3 Transport .................................................................................................................................................... 16
6.4 Protection ................................................................................................................................................... 16
7 Construction & Description ........................................................................................................................... 17

7.1 Construction ............................................................................................................................................... 17
7.2 Description ................................................................................................................................................. 18
7.2.1 General Description of the high pressure pump .................................................................................... 18
7.2.2 Crank section with pressurised lubrication system ................................................................................ 18
7.2.3 Piston seal assembly ............................................................................................................................. 18
7.2.4 Pump head ............................................................................................................................................. 18
7.2.5 Pressure regulating and overflow valve ................................................................................................. 20
8 Installation & Start up..................................................................................................................................... 21

8.1 Connecting the driver ................................................................................................................................. 21
8.2 Suction (feed) side installation ................................................................................................................... 21
Copyright Hammelmann Maschinenfabrik GmbH
Germany • D-59302 Oelde • Zum Sundern 13 - 21

Contents No.: HDP 382
8.3 Calculating the suction and discharge hose internal diameters (DN) ........................................................ 23
8.4 Connections to the high pressure pump outlet (discharge side) ................................................................ 25
8.5 Installation of hoses, pipe work and cables ................................................................................................ 25
9 Operation ......................................................................................................................................................... 28
9.1 Pre-start checks .......................................................................................................................................... 28
9.2 To start the unit ........................................................................................................................................... 28
9.3 Setting the operating pressure.................................................................................................................... 29
9.3.1 by manually operated pressure regulating valve .................................................................................... 29
9.3.2 by pneumatically operated pressure regulating valve ............................................................................ 29
9.3.3 by setting the r.p.m. of the drive engine ................................................................................................. 29
10 Shut down ....................................................................................................................................................... 30

10.1 Stopping the unit ......................................................................................................................................... 30
10.2 Overnight shut down ................................................................................................................................... 30
10.3 Extended shut down (14 days and longer) ................................................................................................. 31
10.3.1 Draining the pump .............................................................................................................................. 31
10.3.2 Protecting the high pressure pump ..................................................................................................... 31
10.3.3 Filling the pump unit with anti-corrosion emulsion or anti-freeze solution. ......................................... 31
10.3.4 Equipment required for filling a pump unit if no suction installation is available ................................. 32
10.3.5 Method of filling the pump with anti-corrosion emulsion or anti-freeze solution using an external
membrane pump ................................................................................................................................................. 32
10.3.6 Other protective measures ................................................................................................................. 32
11 Maintenance .................................................................................................................................................... 34
11.1 Fault finding and remedy ............................................................................................................................ 34
11.2 Maintenance ............................................................................................................................................... 35
11.3 Daily inspection ........................................................................................................................................... 35
11.4 Water filter inspection ................................................................................................................................. 35
11.5 Checks during operation ............................................................................................................................. 36
11.6 Oil change ................................................................................................................................................... 37
11.6.1 First oil change after 1000 operating hours ........................................................................................ 37
11.6.2 Next oil changes ................................................................................................................................. 38
11.6.3 Lubrication including oil filter............................................................................................................... 39
11.6.4 Oil pressure adjustment ...................................................................................................................... 41
11.7 Repair & Replacement................................................................................................................................ 41
11.8 Maintenance of the pump head 00.02145.1239 ......................................................................................... 42
11.8.1 Disassembly (ref. to fig. pump head) .................................................................................................. 42
11.8.2 Assembling (ref. to fig.: Pump head) .................................................................................................. 44
11.9 Maintenance of the piston seal assembly: 00.00743.2221 (-004) .............................................................. 46

No: HDP 382 Contents
11.9.1 Disassembly ....................................................................................................................................... 46

11.9.2 Reassembly ....................................................................................................................................... 47
11.1 Changing the bellows ................................................................................................................................. 50
11.2 Torque tables ............................................................................................................................................. 50
11.3 Instructions for fitting packings................................................................................................................... 52
12 Pressure regulating valve 00.05893.0032 ..................................................................................................... 53

12.1 Technical Data ........................................................................................................................................... 53
12.2 Installation (ref. to fig.: Complete pressure regulating valve) .................................................................... 56
12.3 Adjustment ................................................................................................................................................. 56
12.4 Maintenance............................................................................................................................................... 56
13 Safety notes for high pressure hoses .......................................................................................................... 63

13.1 Before using the hose ................................................................................................................................ 64
13.2 Use of the hose .......................................................................................................................................... 64
14 Index................................................................................................................................................................. 65

Foreword No.: HDP 382
Pos : 1 /T ec hnis che D aten/Zu di es er Anlei tung/Übersc hrift @ 0\mod7_2.doc @ 1204 @ 1 @ 1

2 Foreword
Pos : 2 /T ec hnis che D aten/Zu di es er Anlei tung/Hinweis @ 0\mod3_2.doc @ 1208 @ @ 1
All personnel who are responsible for the operation and maintenance of the
High pressure pump HDP 382 must:
Read and fully understand these instructions, especially the section “Safety“
before attempting to operate.
Ensure that these instructions are always readily available to all personnel
concerned.
Pos : 3 /T ec hnis che D aten/Zu di es er Anlei tung/Hers tell eradress e @ 0\mod4_2.doc @ 1212 @ @ 1
Manufacturer and customer services address:

HAMMELMANN Maschinenfabrik GmbH
Zum Sundern 13 – 21 • 59302 Oelde • Germany
P. O. Box 33 09 • 59282 Oelde • Germany
Telephone: +49 (0) 25 22 76-0
Telefax: +49 (0) 25 22) 76-4 44
e-mail: mail@hammelmann.de
http://www.hammelmann.de
Pos : 4 /T ec hnis che D aten/Zu di es er Anlei tung/Maschi nennummer @ 0\mod5_2.doc @ 1216 @ @ 1
Type: HDP 382
Serial no.: B3.01382.0011
Date: 2013
Pos : 5 /xxxxxxx xxxxxx xxxxxx @ 0\mod6_2.doc @ 1188 @ @ 1

No: HDP 382 Technical data
Pos : 6 /T ec hnis che D aten/Übersc hrift @ 0\mod8_2.doc @ 1196 @ 1 @ 1
3 Tech nical dat a
Pos : 7 /T ec hnis che D aten/Pumpen/HD P 380/HD P 382 - 204 L, 1000 bar, 380 kW @ 9\mod_1361781141958_2.doc @ 74482 @ 22 @ 1
3.1 Performance Data: High pressure pump

Type: HAMMELMANN High pressure pump HDP 382
Pressure step 1
Flow rate V: 204 l/min.
Operating pressure p: 1000 bar
Crank shaft r.p.m. n2: 490 1/min.
Piston / Plunger diameter: 50 mm
Power rating: 380 kW
Rod force: 200 000 N
Stroke: 75 mm
Weight approx.: 1694 kg
 Average piston speed at a crank shaft r.p.m. of:
 340 1/min. 0,86 m/sec.

 410 1/min. 1,03 m/sec.
 490 1/min. 1,23 m/sec.
Pos : 8 /xxxxxxx xxxxxx xxxxxx @ 0\mod6_2.doc @ 1188 @ @ 1

Technical data No.: HDP 382
Pos : 9 /T ec hnis che D aten/Pumpen/HD P 380/H auptabmes sungen HD P 380 neu @ 9\mod_1358774065291_2.doc @ 73222 @ 222 @ 1
3.2 Main dimensions

 Fig.1 : Main dimensions of the high pressure pump

No: HDP 382 Technical data
Weight of the pump approx.: 1690 kg

Pos : 10 /xxxxxxxxx xxxxxx xxxx @ 0\mod6_2.doc @ 1188 @ @ 1

Safety No.: HDP 382
Pos : 11 /Sic herheit/Ü berschrift @ 0\mod9_2.doc @ 1220 @ 1 @ 1

4 Saf et y
Pos : 12 /Sic herheit/Pumpen @ 0\mod10_2.doc @ 1224 @ 22222222 @ 1
4.1 Dangers arising from non observance of safety instructions

Using the most modern manufacturing techniques HAMMELMANN produce high pressure equipment which is
subject to stringent Quality, Function and Safety tests. Even so, improper or unsuitable use of high pressure
equipment, or operation by untrained personal can result in accidents leading to:
 Danger of death or injury.
 Costly damages claims.
All personnel who are responsible for the operation and maintenance of high pressure equipment must, before they
attempt operation be fully conversant with and completely understand the contents of this manual. Particular atten-
tion must be paid to this section "safety" and these instructions must always be readily available to all personnel
concerned. No claims for personal injuries or damages arising from ignorance or non observance of safety
procedures can be accepted.
4.2 Safety conscious working

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

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

 The operation of water jetting equipment should only be entrusted to personnel who are,
 fully conversant with the operation procedure.
 fully aware of the inherent dangers.
 Dangers are for instance,
 reaction force.
 cutting power of the jet.
 hose shortening when pressurised.
 working close to electrical sources or machinery.
 In the case of bare shaft pumps never connect a driver that can exceed the pump max. power rating as given
on the name plate.
 A pump unit must always be fitted with a mains cut-off / ignition switch system.
 An emergency switch is an essential component of any pump unit.

No: HDP 382 Safety
Page 10, Issue: 05.2013
 Before each operation the employer should ensure that a competent or trained person has checked,
 that units and / or equipment are in good condition and
 that the important elements, i.e.: safety devices, hoses, hose connections etc. are in good order.
 Any fault should be remedied before using the equipment.
 Follow precisely all start up/shut down procedures given in the operating instructions
During operation regularly check the hoses, fittings and jetting accessories (i.e.: nozzles,
spray bar) for signs of leakage. In the case of leakage stop the pump unit immediately.
Do not attempt a close visual inspection of leakage while the pump is running.
 Use only the correct tools, i.e.: ensure that you have the correct spanner size to fit connection nuts etc.
Do not vary the pump pressure unless you have informed the accessory / machine operator
that you are about to do so.
 Upon shut down ensure that all elements of the equipment are depressurised (atmospheric pressure).
 When using two or more consumers (i.e.: spray guns) from a single pump unit,
 care shall be taken to ensure that the pressure regulating valve or unloader is correctly set so that the
operation of any consumer (i.e.: spray gun) will not cause a sudden pressure change and / or excessive
reaction forces.
 Never use accessories, i.e.: hoses, spray pistols etc. above the maximum specified operating pressure.
The maximum pressure of any system is only equal to the maximum pressure rating of the lowest rated
component therein.
 Position hoses,
 so that they are not clamped or kinked and cannot chafe against sharp edges.
 Interfering with safety elements is strictly forbidden! Damaging, e.g. the locking wire or seal coating will
invalidate the guarantee and will release us from any liability in the event of accident or injury.
 Use only accessories and spares from HAMMELMANN or their approved suppliers. Use of parts that are not
marked as tested or that are supplied without a test certificate can be dangerous. Think of your own safety.
(Also see guarantee conditions)
 The employer must ensure,
 that the workplace is cleared, offers a firm footing and there is no possibility of tripping.
 Trailing lines, loose debris and tools do not make a safe workplace.
 The jetting operator must ensure,
 that there is no danger to neighbouring workers, and that the workplace is closed off with barriers.
 signs are erected to prohibit unauthorised entry i.e.: Danger! High pressure water.

Safety No.: HDP 382
Page 11, Issue: 05.2013
 Causes of danger are,

 the jet (cutting power).
 spray mist (with dangerous chemical additives).
 loose debris or other items picked up and projected by the force of the jet.
 Avoid contact with any spray arrangement:
 Do not place your hand or other bodily parts in front of a pressurised nozzle.
 Never under any circumstances point an accessory (i.e.: pistol) at other persons even when depressurised.
 Hazards to your health are,
 the properties of the liquid (Wet, high temp, caustic etc.)
 the high pressure (i.e.: cutting power of the jet, possible impact damage to tissue and bacterial infection).
 To work with liquid jets the employer should ensure that all operatives wear protective clothing, i.e.:
 Protective suit,
 Safety helmet,
 Flexible closed gloves,
 Slip proof safety boots with foot and shin protection.,
 Ear protectors,
 Respiratory protector,
 Safety glasses or full face visor.
Operatives ignoring the employers instruction to wear any of the above do so at their own
risk!
In the event that a person is struck by a waterjet they must immediately report to or be
taken to a doctor. Even seemingly minor injuries can have serious consequences! Liquids
can be injected into body tissue leaving no obvious external damage!
4.5 Danger symbol
This symbol, always indicates an important safety instruction. You must read,
understand and follow the instruction precisely!
Failure to follow such an instruction can result in extreme danger to persons and
damage to property.

No: HDP 382 Safety
Page 12, Issue: 05.2013
4.6 Safety during inspection, maintenance and repair

The owner shall be responsible for ensuring that all inspection, maintenance and repair works are carried out by
competent, fully trained personnel. He shall also ensure that said personnel have read and fully understood this
manual.
Before commencing such works all safety and shut down instructions herein must be observed. Before starting
such works on diesel engine driven units disconnect the battery cables. In case of e-motor driven units cut-off
tension / unplug mains plug. Before restarting follow the instructions given in the section “Installation”.
4.7 Forbidden practices

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

 When this high pressure equipment (i.e.: rotary joint, pistol etc.) is built into a high pressure system you must
also refer to the safety and operation instructions of the other high pressure elements before use!
Other elements are for instance:
 Drive, Pump, Spray head or Spray bar, Surface cleaners, etc.
 If using a diesel or petrol powered unit in an enclosed area ensure that there is sufficient ventilation and that
exhaust gases are vented to atmosphere.
 In the event that other high pressure accessories (i.e.: hoses) are used in conjunction with this unit then the
relevant manufacturer's or supplier's operation instructions should be observed and followed in all cases.
 If your pump unit is mounted on a roadworthy trailer you must ensure that the towing vehicle is suitable for the
weight! See construction and description section for trailer details.
 Drivers must ensure that towing vehicle and trailer are in a roadworthy condition and that they comply with local
traffic regulations.

General No.: HDP 382
Page 13, Issue: 05.2013
Pos : 14 /Allgemeines /Übersc hrift @ 0\mod150_2.doc @ 1340 @ 1 @ 1

5 Gen er al
Pos : 15 /Allgemeines /Pumpen/1. Einl eitung @ 0\mod425_2.doc @ 4548 @ 2 @ 1
5.1 Introduction
Your HAMMELMANN High pressure pump is the product of many years of research, development and testing in
the field of high pressure manufacture.
Modern design and production procedures allow us to place the highest demands on the quality of our products.
For you, this means:
 High precision manufacture,
 high reliability and
 efficiency.
Pos : 16 /Allgemeines /Pumpen/2. Anwendungsbereic h @ 0\mod426_2.doc @ 4552 @ 2 @ 1
5.2 Application
There are many applications for HAMMELMANN High and Ultra high pressure pumps, i.e.:
 Liquid dosing and transportation.
 Hydrogenation and cracking processing.
 Decoring and cleaning castings.
 Water jet cutting.
 Building, bridge, highway renovations.
 General high pressure cleaning
 of flat surfaces,
 transportation and production plants,
 of the inside and outside of pipes and tanks etc.
Use only HAMMELMANN accessories designed for the maximum pressure of your high
pressure pump (unit).
If you have any questions concerning accessories or special application techniques please contact
HAMMELMANN or an accredited agent.
Pos : 17 /Allgemeines /Pumpen/3. Eins atzbedi ngungen 40° @ 0\mod721_2.doc @ 4480 @ 2 @ 1
5.3 General permissible operational conditions

Unless otherwise stated in writing (contractually) by HAMMELMANN the following operational conditions apply:
 Use only clean medium. Any solids must not exceed a max. particle size of 10 µm or a concentration of
50 mg/l. (Ensure suitable filtration is installed). Medium supply temperature must not exceed 40°C. The max.
permissible feed velocity is 1 m/sec. at a necessary admission pressure of min. 3 bar to max. 10 bar.
Before attempting to introduce any cleaning fluids obtain written approval from
HAMMELMANN!
Cleaning fluids should not attack the non-ferrous heavy metal (bronze)!
Under no circumstances introduce cleaning fluids containing Amine or Phosphate!

No: HDP 382 General
Page 14, Issue: 05.2013
Pos : 19 /Allgemeines /Pumpen/4. Ur heberrecht @ 0\mod428_2.doc @ 4560 @ 2 @ 1
5.4 Copyright
The copyright of these operating instructions is the property of HAMMELMANN GmbH. These instructions contain
technical descriptions and illustrations that may not be electronically stored or reproduced in whole or in part or be
passed to third parties in any form whatsoever without the written permission of the owners.
We are protected by law against contravention of the above and will take appropriate action if necessary.
Pos : 20 /Allgemeines /Pumpen/5. Gar antiebedi ngung en @ 0\mod430_2.doc @ 4564 @ 2 @ 1
5.5 Warranty terms

Corresponding to our general business conditions we guarantee a warranty of 24 months or 2000 operating hours,
excluding normal wearing parts.
The guarantee would be invalidated if:
 The equipment was used for purposes under other than our admissible conditions.
 The leads at the safety organs are injured.
 The high pressure pump was used with accessories or fitted with spare parts not supplied by HAMMELMANN.
 If the damage is caused by:
 Improper use.
 Ignoring the maintenance instructions.
 Use beyond the provided operative range.
 Unsuitable flow medium.
 Faulty installation.
 Incorrectly or not professionally positioned pipe lines.
 Unauthorized changes or reconstruction’s.
 Cavitation
If there is the need of a Guarantee Claim Application can be demanded from HAMMELMANN.
The contents of the operating instructions and product documentation shall not become part of or
modify any prior or existing agreement, commitment or relationship. All the obligations of
HAMMELMANN result from the sale contracts which is also the complete and only valid
guaranteed rules. Any statements contained herein do not create new warranties or modify the
existing warranty.

Transportation No.: HDP 382
Page 15, Issue: 05.2013
Pos : 22 /Trans por t/Ü bersc hrift Transport @ 0\mod218_2.doc @ 1348 @ 1 @ 1

6 Tran sport ation
Pos : 23 /Trans por t/Trans por t Pumpen @ 0\mod216_2.doc @ 1344 @ 2222 @ 1
6.1 Packing
Method of packing is determined by method of transport. At the minimum the pump unit will be protected from the
elements.
Packing symbols (for example).
This way up Keep away from heat Sling here Keep dry
Fragile handle with Centre of gravity No hand truck here Use no hooks
care
Do not use forklifts or

similar transportation
units

No: HDP 382 Transportation
Page 16, Issue: 05.2013
6.2 Transportation
 Normally a pump unit will be transported without fuel in the tank. Sometimes the pump and engine will have
been drained of oil and in some cases the cooling system will also be drained.
Please check the pump unit for notices as to its delivery condition.
 For safety precautions will have been taken to stop leakage of fuel, oil etc. during transportation.
6.3 Transport
If your pump unit is mounted on a roadworthy trailer you must ensure that the towing
vehicle is suitable for the weight! See construction and description section for trailer
details.
Drivers must ensure that towing vehicle and trailer are in a roadworthy condition and that
they comply with local traffic regulations.
Only lift trailers with a suitable lifting device on the lifting point!
6.4 Protection
All pumps and pump units only leave our works when they have undergone a strict test procedure. At the end of
the test an anti corrosion emulsion is introduced and the pump is run for a minute. This is to ensure that all water
bearing parts such as plunger, pump head etc. are completely protected against corrosion. As an extra precaution
all exposed polished metal parts are sprayed with Optimol F + D protective fluid.
The above precautions do not hinder the initial start up of the pump. The coating of F + D in fact acts as a lubricant
and prevents wear. The anti corrosion emulsion is very quickly flushed out by the high pressure water.
The protection process is suitable for the transport period between our works and reaching the customer. If the
pump is to be stored for an indefinite period of time before operation further precautions will be needed. Please ask
you HAMMELMANN agent for advice. Our recommendations can be found in the section “Shut down” paragraph 3.

Construction & Description No.: HDP 382
Page 17, Issue: 05.2013
Pos : 25 /Aufbau und Besc hrei bung/Ü bersc hrift @ 0\mod155_2.doc @ 1372 @ 1 @ 1
7 Constru ction & Description

Pos : 26 /Aufbau und Besc hrei bung/Ü bersc hrift Konstrukti ver Aufbau @ 0\mod156_2.doc @ 1376 @ 2 @ 1
7.1 Construction
Pos : 27 /Aufbau und Besc hrei bung/Pumpen/HD P 380 neu/Aufbau HDP 382 @ 7\mod_1325579078883_2.doc @ 53173 @ @ 1
 Fig.: Construction of high pressure pump HDP 382
Item No. Description Item No. Description

10 Pump head 90 Oil filler neck
20 High pressure discharge 100 Drive shaft
30 Name plate 110 Oil dip stick
40 Oil pressure gauge 120 Oil drain valve
50 Oil pump 130 Suction chamber draining
60 Oil pressure regulator 140 Suction connection
70 Oil filter 150 Suction chamber
80 Oil cooler 160 Cover plate
170 Mounting holes

No: HDP 382 Construction & Description
Page 18, Issue: 05.2013
Pos : 29 /Aufbau und Besc hrei bung/Pumpen/HD P 380 neu/Besc hrei bung HD P 382 (D oppel keg el ventil) @ 9\mod_1355747039213_2.doc @ 72489 @ 23333 @ 1
7.2 Description
7.2.1 General Description of the high pressure pump
The HDP 382 is a compact, three plunger pump containing the unique HAMMELMANN piston/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. That guarantees a long working time under highest pressures.
7.2.2 Crank section with pressurised lubrication system
The crank section is precision built to withstand heavy loads. Its function is to transmit the rotary motion of the drive
shaft to an oscillating motion at the pump plungers. The transmission works via three pump plungers turned by
120° with conrods and crossheads. The crank shaft is an assembly made from hardened and tempered steel. The
gear-wheels are located on the crankshaft from the inner side near by the outer conrods. The storage of the crank
shaft is carried out by two roller bearings which are located from the outside near the outer conrods. Conrods have
bush bearings both ends running on hardened, polished surfaces at the crankshaft and gudgeon pins.
The pressurised oil lubrication system consists of an oil pump, an oil cooler, an oil filter and an oil pressure
manometer. It supplies all bearing and sliding places with filtered oil. Conrod bearings are lubricated via oil
channels in the crank shaft and the gudgeon pins via channels in the con-rods. The crank mechanism is sealed
with special gaskets and the motor shaft by a rotary shaft seal.
Observe the oil pressure! The ideal oil pressure should be between 4 and 6 bar. A safety
shut off is carried out at 4 bar.
7.2.3 Piston seal assembly
The piston seal assembly is the piston or plunger sealing. The piston or plunger sealing is made by packings. The
arrangement of the packings is so designed that the packings are self adjusted. If their is a higher leakage
observed change the packings. Every leakage goes back into the suction chamber. The piston respectively the
plunger is made by solid ceramics.
7.2.4 Pump head
The high grade stainless steel pump head is not subjected to alternating stress, therefore the risk of fatigue
cracking is eliminated. Pressurised areas have been reduced to an absolute minimum resulting in a
correspondingly small load. The uncomplicated design allows easy access to suction and discharge valves
It operates as follows:

Construction & Description No.: HDP 382
Page 19, Issue: 05.2013
 On the suction stroke of the plunger

 pressure valve closes,
 pressure rises from flow pressure to suction pressure,
 suction valve opens,
 suction of the medium out of the low-pressure cylinder (inlet chamber).
 On the downward stroke of the plunger
 closes the suction valve
 pressure drops from suction pressure to valve opening pressure,
 pressure valve opens,
 flowing in the pressure line.
 Fig.: Function
Suction water
Discharge water
Item no. Description Item no. Description

A Pressure chamber E Sleeve
B Pressure valve F Plunger
C Suction valve G Conrod
D Suction chamber H Crank shaft

No: HDP 382 Construction & Description
Page 20, Issue: 05.2013
Pos : 31 /Aufbau und Besc hrei bung/S-Anlagen/Beschr eibung Druc kr egel ventil @ 0\mod157_2.doc @ 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. operating overpressure. That makes an optimal use of the energy source.
The drive can happen pneumatic or manual.
Regulators are available in various forms for a variety of operating pressures and flow rates.
Mobile units with pneumatic pressure regulating valves are usually supplied with control air pressure from a
compressor in the system. On stationary units the local air pressure can be used from an internal pneumatic
circular pipeline. The max. control pressure air required is 4 bar.
 Setting the wished pressure with the pressure regulating valve (manual adjustment) by:
 Turning the eccentric lever
» Clockwise => increases the pressure,
» Anti-clockwise => decreases the pressure.

 Tension the eccentric lever, pump goes to idle speed
 Setting of the air pressure with the help of the pressure air:
 The operating pressure is directly proportional to the control air pressure with which the pressure
regulating valve is admitted.
 Increasing the air pressure means setting a higher operating pressure.
 Decreasing of air pressure means setting a lower operating pressure.
Pos : 32 /xxxxxxxxx xxxxxx xxxx @ 0\mod6_2.doc @ 1188 @ 3 @ 1

Installation & Start up No.: HDP 382
Page 21, Issue: 05.2013
Pos : 33 /Vorber eitung z ur Inbetri ebnahme/Installation/Ü bers chrift @ 0\mod168_2.doc @ 1380 @ 1 @ 1

8 Installation & St art up
Pos : 34 /Vorber eitung z ur Inbetri ebnahme/Installation/Pumpen/Vorbereitung zur Inbetriebnahme allgemein @ 0\mod415_2.doc @ 5672 @ 1122222 @ 1
8.1 Connecting the driver

If the high pressure pump is to be driven by an:
 Electric motor (with or without variable frequency drive) or a diesel engine :
Electric motors should always have a main isolating switch. If one is not fitted please
install one!
Electrical installation should only be carried out by qualified technicians!
If an electric motor with a variable frequency drive is employed with a speed range of zero
to maximum a separate electrically powered oil pump must be installed. For speed ranges
starting above zero please consult Hammelmann.
Adhere to the installation instructions and the operating instructions of the electric motor /
diesel engine manufacturer!
Pos : 36 /Vorber eitung z ur Inbetri ebnahme/Installation/Proz ess pumpen/2a. Kupplung @ 3\mod1769_2.doc @ 8432 @
 The driver power must be transmitted to the pump by a flexible coupling (not HDP 10 & 20 which are belt
driven).
 When selecting the coupling please refer to the manufacturer’s literature AND THE DRIVER
MANUFACTURER’S TECHNICAL DATA;
 Check the adjustments of the coupling particularly alignment and if necessary readjust.
 The preferred direction of rotation of the pump is marked on the crank housing (on the right side seen from the
front on the drive shaft).
8.2 Suction (feed) side installation

 The pumped medium can only emit from the pump smoothly under high pressure if:
 The medium is totally free from air or gas bubbles.
 The correct volume of medium is available.
 The suction (feed) line is as free as possible of elbows, T-pieces, restrictions and other items that cause
turbulence.
 The medium has a low feed velocity and unhindered flow.
 Feed velocity: » max. 1m/sec
 Feed pressure: » min. 3 bar
» max.6 bar
Operation with other parameters requires our written permission. If you install a boost
pump the inlet pressure of the boost pump must not exceed 3 bar. Install a pressure
reducing valve if necessary.
A boost pump for a diesel engine powered unit will be belt driven. Refer to the diesel
engine manufacturer’s instructions for installing PTO driven ancillary equipment.
A boost pump for an electrically powered unit must be driven by an independent electric
motor. It must be wired to the control panel so that when the main pump motor is started
the boost pump motor starts before the main pump motor and when the main motor is
stopped the boost pump motor stops after the main pump motor.

No: HDP 382 Installation & Start up
Page 22, Issue: 05.2013
To prolong the life or wearing parts such as valves, control pistons etc. it is recommended
that you ensure the medium is as clean as possible. There is no substitute for adequate,
efficient filtration. Solids, especially abrasive solids in the medium will curtail the working
life of wearing parts. Install a suitably sized filter system between the boost pump and the
suction chamber of the high pressure pump. A blocked medium filter can cause cavitation
and damage the pump. Damage to the pump caused by cavitation is excluded from the
guarantee. Therefore, we recommend the installation of a pressure sensor (with
monitoring) to immediately switch off the high pressure pump in the case of a blocked
filter.
If you are not sure how to design a pipe work system to prevent ingress of air, ingress of
foreign matter, high medium velocity etc. especially if you intend to re-circulate the medium
then do not hesitate to seek advice from your Hammelmann agent or from Hammelmann
customer services.
Filters are available from HAMMELMANN to eliminate abrasive particles larger than 10 µ
and concentrations of 20 mg/l.
 Water quality for high pressure pumps
Type 2 + 7 Type 3 Type 4

Max. particle size / Filtration
10 µm 10 µm 1 µm
degree
Max. content solids 50 mg/l 50 mg/l 20 mg/l
Max. total hardness 20°dH 20°dH 3 - 10°dH
Max. hardness (CaCO3) 350 mg/l 350 mg/l 50 – 175 mg/l
Max. content iron (Fe) 0.5 mg/l 0.5 mg/l 0.5 mg/l
Max. content chlorine (Cl) 100 ppm 100 ppm 100 ppm
Max. content sulphate
100 ppm 100 ppm 100 ppm
(SO4)
Max. content phosphate
50 ppm 50 ppm 50 ppm
(PO3)
Free chlorine 1 mg/l 1 mg/l 1 mg/l
pH 6,5 – 8,5 6,5 – 8,5 6,5 – 8,5
* Dependant upon type of particle (hardness)
No additives with corrosive effect on non-ferrous heavy metals (if to be used consult HAMMELMANN).
In certain cases variations from the above may be possible! HAMMELMANN offer suitable filter systems.
When used in high pressure washing- or de-burring machines etc. follow our specific
instructions for these applications.
The pump can become contaminated due to:

- An extremely high feed velocity.
- Connecting a seldom used supply line.
- Taking supply from a fire hydrant.

Page 23, Issue: 05.2013
8.3 Calculating the suction and discharge hose internal diameters (DN)
To determine the internal diameter of the hoses refer to the diagram below.
 Example 1 (--------)
 A speed of v = 0.45 m/s and an output of Q = 150 l/min. The straight connection between these two values
on the scales results in the hoses DN 80 on the centre scale.
 Example 2 (_____)
 A speed of v = 5,5 m/s and an output of Q = 66 l/min. The straight connection between these two values on
the scales results in the hoses DN 16 on the centre scale.
 Fig.: Diagram
 Optimum flow velocities:

 Suction (feed) side: 0.5 m/s
 Pressure (discharge) side: 5,0 m/s
 Not taken into consideration:
 The resistance of pipes, bends, valves.
 The viscosity and the effects of temperature on viscosity and other influencing factors.

Page 24, Issue: 05.2013
 Fig. Pressure losses in hoses and pipe work
The pressure loss represented here is related to 1 m length and increases linearly with increasing hose / pipe
length (theoretical values).

Page 25, Issue: 05.2013
8.4 Connections to the high pressure pump outlet (discharge side)

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

Before installing any ancillary items it is, especially in the case of fixed stationary pump
units, important to address the issue of positioning.
A fixed, stationary pump unit with pipe work must be positioned to comply with the good
engineering practices for suction and discharge installations as described in these
instructions. Additionally the floor or plinth must be as level, flat and smooth as possible.
Never anchor a stationary unit directly to the floor or plinth. Always use anti-vibration
mountings between the pump unit base frame and the floor/plinth. Ensure that the unit has
adequate ventilation.
A mobile pump unit employing suction and discharge hoses must be positioned on as flat
and level ground as possible. If the unit is built into any form of enclosure (sound damping
cover etc.) ensure that it is positioned so that air intakes and air exhaust outlets are not
blocked off by walls or vehicles etc. Mobile pump units must have the handbrake engaged
and / or wheel chocks deployed before making any connections.
The following connections can be made to a high pressure pump unit dependent upon the scope of the unit build:
 Suction hose / pipe work (between water supply point and the pump)
 Oil cooler water out to waste or back to tank
 Piston cooling
 Highest pressure hose / pipe work line
 Bypass line hose / pipe work to waste or back to tank.
 Burst disc over pressure safety device outlet tube to waste.
 Control cable for electrically actuated bypass from manual tools (i.e. water blasting gun).
 Control systems. Connect pressure and temperature transmitter (sensor). Check the functions at test run.
 Pneumatic control lines (hoses) i.e. control line to membrane cylinder of bypass or pressure regulating valve, or
to pneumatically powered or actuated accessories (water blasting gun).
 Notes on connecting the ancillaries.
 Suction hose / pipe work
 To install a suction hose remove protective cap (if fitted) from the supply line connection and ensure that
the connection is clean. Let the water run for a minute or two to flush out any residue then turn off the
supply and connect the suction (feed) hose to the supply line.
 Turn on the supply again and flush the suction hose until the water is completely clean. Turn the supply off
and connect the free end of the hose to the pump suction connection.
 On fixed installations with permanently installed suction pipe work you must ensure that the complete
system is clean and free from fabrication debris before making the final connection to the pump unit.
 Oil cooler line

Page 26, Issue: 05.2013
 This is a push fit hose connection on the cooler. The cooling water emits without pressure and can be run
to waste or back to the pump suction side tank (if fitted)
 Separate oil cooler supply
 Normally the oil cooler supply is from the suction chamber but if the suction water is above 35°C a
separate supply with a lower temperature must be provided.
On fixed installations do not feed bypass or oil cooler water back to another return line unless that
return line is also without pressure.
 Piston cooling
 Never close off the piston cooling drain hose/line. The cooling water must be able to flow freely away. If
necessary run the hose to a suitable container or similar.
 High pressure hose / pipe work
 To fit a high pressure hose remove the protective cap or threaded plug from the H.P. pump water
discharge connection. Ensure the mating thread is clean and then smear with Molykote (1000 anti-
seize) grease. Remove the cap from the hose outside and repeat the cleaning and greasing
procedure. Connect the high pressure hose and tighten to a torque value as per the table below. This
procedure should be followed when fitting hose extensions and the consumer (water blasting gun etc.).
 The cleaning and greasing procedure should be applied threaded fittings in permanent high pressure
pipe work such as ring lines for high pressure water blasting with several discharge points around the
plant, ship, automobile paint spray line etc. We recommend that you fit a length of high pressure hose
between the pump discharge fitting and the ring line connector to damp the inherent pulsation from the
pump and reduce vibration in the line. Ring lines should be attached to structures with cushioned pipe
clamps. Discharge pipe work connected directly to the pump discharge (as often the case in
production processes) should be flexible enough to counter the effects of discharge pulsation.
Torque for high pressure hoses
Nominal dia. in mm Connection thread Spanner size in mm Torque in Nm
10 M 18 x 1,5 DKL 22 50
12 M 22 x 1,5 DKL 27 62
20 M 30 x 1,5 DKM 36 83
25 M 38 x 1,5 DKM 46 105
10 M 22 x 1,5 DKO 27 30
12 M 24 x 1,5 DKO 32 33
20 M 36 x 2,0 DKO 46 49
25 M 42 x 2,0 DKO 50 57
Connection with pressure screw and pressure ring
Pressure screw
5 M 14 x 1,5 links 70
M 30 x 2 (32mm A/F)
Pressure screw
8 M 14 x 1,5 LH 70
M 30 x 2 (32mm A/F)
Pressure screw
12 M 20 x 1,5 LH 70
M 42 x 2 (46mm A/F)
30
50 SAE 2” 6000 psi 300
(4 x M 20)

Page 27, Issue: 05.2013
For your own safety:

Check all hose and pipe work connections for tightness a second time.
 Bypass line
 The standard bypass connection is a ”push fit” connector on the Hammelmann pressure regulating valve or
bypass valve. We recommend a clear plastic hose held in place by a hose clip. The bypass line is used to
dispose of the water when the consumer is closed and the pump is running without pressure. The water
can run to waste or back to the pump suction side tank (if fitted).
 Burst disc outlet
 In the event of a burst disc rupture medium will emit from the burst disc assembly initially at high velocity.
We recommend fitting a steel (Ermeto type) tube between the burst disc assembly and the pump unit base
frame. The burst disc assembly is attached to the Hammelmann pressure regulating valve or bypass valve.
 Control cable
 If you have installed an electrical bypass control system for use with Hammelmann four pole, electrically
actuated blasting tools or key switch remove the protective caps from plugs and sockets. Ensure they are
clean and dry before connecting.
Never connect or disconnect a cable when the pump unit is running!
 Pneumatic control line

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

No: HDP 382 Operation
Page 28, Issue: 05.2013
Pos : 36 /Betri eb/Übersc hrift @ 0\mod178_2.doc @ 1400 @ 1 @ 1
9 Oper ation
Pos : 37 /Betri eb/Pumpen/Inbetri ebnahme / Betri eb @ 0\mod417_2.doc @ 5676 @ 1122333 @ 1
9.1 Pre-start checks

 Check the pump oil level and top up if necessary. The oil level should not be below
the minimum shown on the dip stick.
 Also check if there is water i the oil (emulsion). If found determine and dispose of
the cause. Then change the oil and start (see section "Maintenance", paragraph "oil
change")
 On diesel driven units: Check the oil level of the diesel engine and top up if
necessary.
 Check the condition of the filter housing and inlet. If dirty clean the filter housing and
fit new filter cartridge.
Before start up:
Remember that when working with hand hold accessories attached to hoses the operative
should have a firm grip on the accessory and a sure footing before start up! If a hose is
pressurised and not controlled it could whiplash causing damage or injury.
9.2 To start the unit

The jetting operator should have a good foothold and firm control of the jetting tool but
with the trigger(s) in the “OFF” position.
High pressure water is a highly effective cutting tool and therefore dangerous!
Never point a pistol, lance etc. at other personnel under any circumstances even if
unpressurised!
 Open water supply to the pump.
 the water admission pressure (min. 3 bar) and
 Release the emergency stop button .
 Starting the engine.
 Check the oil pressure!
 At 2 bar min. oil pressure turn the high pressure water on.
 Check previously values (r.p.m. or pressure dependent of the control). If necessary adjust the values
(dependent of the control or pressure regulating valve).
 Jetting operator can now engage trigger(s) and commence blasting.
 During operating a second operator should control the manometers of the pump, i.e. if the pressure always
increases continuously, and he should also oversee the jetting operator.
In the event of accident, machine problem, signs of leakage the pump operator must imme-
diately press the emergency stop button. For reasons of safety pull off the ignition key and
protect it in a safe place.

Operation No.: HDP 382
Page 29, Issue: 05.2013
9.3 Setting the operating pressure
9.3.1 by manually operated pressure regulating valve
 Increasing pressure: by turning the eccentric lever clockwise.

 Decreasing pressure: by turning the eccentric lever anti-clockwise.
 Relieve the eccentric lever means take away the pressure and tension the eccentric lever means the pump is
at idle speed.
9.3.2 by pneumatically operated pressure regulating valve
 When the pressure regulating valve is charged with air the pump is running under pressure.
 The maximum control air pressure is 4 bar. At a control air pressure of 4 bar the max. operating pressure is set.
 Reducing the control air pressure reduces the discharge pressure of the pump.
 Closing the air supply returns the pump to idle speed.
9.3.3 by setting the r.p.m. of the drive engine
 With diesel powered units or thyristor controlled electric powered units it is possible, in conjunction with a
suitable control system, to regulate the operating pressure by adjusting the driver speed. This is only possible
when using diesel engines with i.e. automatically operated pressure regulating valve, pressure absorption’s
and regulating motors.
 When the motor is fully loaded the max. control air pressure is set from the operator so that the max. operating
pressure stands in line.
 The operator can set the operating pressure by setting the r.p.m.
 max. motor r.p.m. => max. operating pressure
 min. r.p.m. => min. operating pressure or pump running at idle speed
When using pressure regulating valves the blower output is set on bypass and the r.p.m. is set back to idle speed if
the consumer is turned off (i.e. by releasing the trigger of the spray gun).

No: HDP 382 Shut down
Page 30, Issue: 05.2013
Pos : 39 /Auss erbetri ebnahme/Ü bersc hrift @ 0\mod182_2.doc @ 1408 @ 1 @ 1
10 Shut do wn
Pos : 40 /Auss erbetri ebnahme/Pumpen/Auss erbetriebnahme allgemein @ 0\mod418_2.doc @ 5704 @ 11223333 @ 1
These instructions cover stopping the unit, overnight shut down and extended shutdown. If the pump unit is located
outside and there is any danger of overnight freezing the complete pump unit must be drained and charged with
anti-freeze solution.
10.1 Stopping the unit

 On a diesel engine powered unit:
 Deactivate the consumer (blasting gun, key switch etc.) so that the pump is bypassing and running at idle
speed.
 Allow the engine to run freely at idle speed for 2 or 3 minutes to cool it down.
 Switch off the engine.
 Actuate the consumer to drain the remaining water from the discharge side.
 Operate the emergency stop button. If it is the lockable type lock it and remove the key for safe keeping.
 Shut off the suction (feed) line.
 On an electric motor powered unit:
 Deactivate the consumer and open the bypass.
 Switch off the motor.
 Operate the emergency stop button. If it is the lockable type lock it and remove the key for safe keeping.
 Isolate or unplug the mains power supply.
NOTE! Electrically powered, fixed installation pumps that are part of a production process
or that are installed as part of a machine in a process will normally have local or remote
controls or both. Follow the plant and/or machine manufacturer’s stopping procedures.
10.2 Overnight shut down

 Carry out the daily inspection (see section "Maintenance").
 If the pump is built into water blasting unit the following actions may be necessary depending upon the
configuration of the unit.
 Disconnect hose arrester, water and electrical connections (if fitted) at the water blasting tool and store them
carefully. Either plug/cap the hose connections or place polythene bag over them and secure with adhesive
tape.
 Disconnect the high pressure hoses and the hose arresters. Clean threaded connectors and smear with
Molykote (1000 anti-seize) and protect them as described above. Inspect hose covering for damage before
storing.
 Clean high pressure connections at the pump, smear with Molykote and fit protective caps.
 Disconnect the control cable and fit a cap on the plug. Inspect isolation of the cables for damage (while reeling
onto cable drum). Cap the connector at the pump.
 Disconnect suction, bypass and cool water hoses. Clean couplings and protect with caps. The suction hose
connections should also be cleaned, and protected if necessary.
 If the operator’s panel is fitted with a cover close it, lock it and remove the key for safekeeping.
 During an overnight shutdown without risk of freezing there is no need to drain the unit if you have been
pumping drinking quality water. If there is any danger of freezing the pump must be protected (see sections
protecting the pump onwards).

Shut down No.: HDP 382
Page 31, Issue: 05.2013
10.3 Extended shut down (14 days and longer)

Whenever an extended shut down is envisaged the pump and its accessories should be stored in a heated, dry
atmosphere if possible. Several precautions should be taken to ensure that a future start up is trouble free.
Firstly the procedures for overnight shut down should be carried out except that the high pressure discharge,
overflow discharge and oil cooler discharge outlets should not be capped but left open.
10.3.1 Draining the pump
 If fitted drain the buffer tank, oil cooler, filter and boost pump. On HAMMELMANN supplied boost pumps oil
coolers and filters, ¼ to ½ turn with a 12 mm A/F spanner is sufficient.
 Open the overflow, and high pressure connections.
 Ensure the suction connection is fully closed off.
 Run the pump at idle speed for a few seconds, so that the remaining water can flow out of the pump easier.
This is not critical when rinsing with emulsion but is essential when protecting against freezing.
 It is not possible to drain a pump unit completely so draining alone does not offer 100% protection against
corrosion or frost damage. The oil cooler is particularly susceptible to freezing so unscrew the oil cooler hose
and blast through with compressed air.
10.3.2 Protecting the high pressure pump
As anti-corrosion emulsion we recommend: (NOTE! This is not anti-freeze.)

 90 % clean fresh water
 10% Shell 9156 or equivalent
As anti-freeze we recommend:
 Glysantin G48 or any other commercial anti-freeze engine coolant in a solution as recommended by the
manufacturer. Anti-freeze also acts as a corrosion inhibitor. Anti-freeze can be drained for reuse at the end
of the shutdown period.
Do not use windscreen washing / de-icing fluids.
10.3.3 Filling the pump unit with anti-corrosion emulsion or anti-freeze solution.
 Depending upon the size of the pump unit you will need 100 litres to 200 litres of solution.
 Fill the buffer tank (if there is no suction side installation on the pump unit) with the solution.
 Start the engine/motor.
 Observe that the solution is emitting the high pressure discharge, bypass, oil cooler return and plunger cooling
 Close all drains.
 Stop the engine /motor.
 Close the high pressure discharge.

No: HDP 382 Shut down
Page 32, Issue: 05.2013
10.3.4 Equipment required for filling a pump unit if no suction installation is available
 Following items should be prepared for protecting the pump:

 Membrane pump (electric or manual) with a min. pressure of 1,5 bar.
 Lengths of hose to connect membrane pump to suction connection.
 Length of hose to fit to the high pressure discharge.
 An emulsion container.
10.3.5 Method of filling the pump with anti-corrosion emulsion or anti-freeze solution
using an external membrane pump
 Close filter drain cock (if fitted).

 Ensure hose connection is clean, smear with grease and connect to the high pressure discharge.
 Fit a suction hose to the membrane pump. Open the pump suction connection and fit hose between it and the
membrane pump.
 Fill container with emulsion/solution.
 Place the free ends of the membrane suction hose and the high pressure discharge hose into the container.
 Operate the membrane pump.
 Observe the overflow and oil cooler connections. When undiluted emulsion/solution is emitting close both these
off.
 Continue pumping. Remove the high pressure discharge hose from container and observe until undiluted
emulsion/solution is emitted. Place hose back into the container.
 Continue pumping for a minute or so. The emulsion/solution can be strengthened if necessary.
i.e.: add more Shell 9156 to the emulsion.
 Stop pumping. Remove the hose from suction connection and cap/close the connection.
 Remove the hose from the high pressure discharge. Clean, grease and cap both discharge and hose
connections.
10.3.6 Other protective measures
 Shut downs for a half year or longer.

Additionally drain the pump oil at operating temperature. Completely fill the crank section of the pump with
Aral Konit SAE 20W20 (or comparable) preserving oil. (The procedure of changing the oil can be seen in
section "Maintenance").
 Seal the dipstick opening.
 Remove intermediate chamber cover plate. Clean and thoroughly dry the chamber. Spray the exposed
plungers with Optimal F + D fluid. Do not spray or lubricate tungsten carbide plungers in any way.
 On diesel units disconnect the battery leads. Check battery acid level and top up if necessary.
 Also on diesel units completely fill the fuel tank and observe the engine manufacturer’s shutdown instructions.

Shut down No.: HDP 382
Page 33, Issue: 05.2013
 Hoses
 Before undertaking the greasing and protection procedure described previously thoroughly dry the connections
carefully using compressed air.
 Take extra care when capping or protecting with polythene. Do not coil too tightly. Ensure there are no kinks in
the hose.
 Accessories
 Thoroughly clean and dry all accessories. Pay particular attention to the connectors. Grease and protect
threads as described above.
 Ensure electrical connectors are capped or protected. They must be completely dry (Repeat for the cable
drum).
 Remove all nozzles for separate storage. Grease the threads of the nozzle holders and protect against ingress
of dirt.
 A light film of protective fluid spray can be applied to metal surfaces.
 Do not use any protective fluids that could penetrate and damage seals, bearings etc.
 Re-commissioning after shut down should be preceded by checks as described previously in this manual.
 The draining procedures (re-fit batteries on diesel units) described previously should be carried out to remove
the emulsion/anti-freeze solution. Drain preserving oil and refill with normal oil as described in the section
“Maintenance” paragraph “oil change”.

No: HDP 382 Maintenance
Page 34, Issue: 05.2013
Pos : 42 /Instandhal tung/Ü bersc hrift @ 0\mod185_2.doc @ 1416 @ 1 @ 1
11 Mainten an ce
Pos : 43 /Instandhal tung/Pumpen/Störungen und Wartung @ 0\mod419_2.doc @ 1496 @ 122222 @ 1
The pump unit must be switched off and all lines depressurised before attempting to check
hose connections and leakage points or making inspection and remedy!
11.1 Fault finding and remedy
Faults Possible causes Remedy

 Pump is sucking air.  Locate leakage and repair.
 Pressure regulating valve is
 Eliminate leakage or reset.
leaking or incorrectly set.
Pressure too low.  Valve set(s) seals defective.  Fit new seals.
 Suction valves can be reground
 Damaged suction and pressure or replaced. Damaged discharge
valve(s). valves should be replaced.
Check condition of valve springs.
 Replace burst disc. Check why
Burst disc rupture.  Maximum pressure exceeded. pressure exceeded. Remedy
fault.
Pump noisy.  Suction side medium shortage.  Check suction side installation.
Extreme pulsation, H. P. discharge  Suction or pressure valve(s)
 Rework or renew as necessary.
line. sticking.
Water leaking form suction chamber  Low pressure seal pack(s)
 Replace seals.
/ intermediate chamber. defective.
 Defective seal(s) at plunger rod /  Check seals and bellows if
Oil leaks into the intermediate crosshead. necessary renew.
chamber.
 Too much oil in crank.  Drain oil to correct level.
 Check sealings and rotary shaft
Oil leaks from the crank case.  If necessary renew sealings.
seals at the crank housing.
Oil emulsion emits from breather.  Medium entering crank section.  Change the oil, including
cleaning /changing the filter,
renew the seals. (ref. to oil
Dipstick shows signs of emulsion.  Medium in crank section. change). Check the bellows. If
necessary renew.
 Causes of air or gas bubbles (cavitation) in the pump
 Suction side line with bad flow characteristics.
 Fluctuating or insufficient supply of medium.
 Too short or too small a diameter suction side supply line.
 The temperature of the medium is too high in relation to the pressure. For instance the boiling point of water
considerably decreases in a vacuum. i.e.: the boiling point is at 70°C at 3 m water column vacuum. (10 m water
collumn = 1 bar)
(for damages of cavitation there is no warranty)

Maintenance No.: HDP 382
Page 35, Issue: 05.2013
11.2 Maintenance
The crank section with its rotating and sliding parts should be carefully maintained. It is important to regularly check
the oil level and top up as necessary and to change the oil.
11.3 Daily inspection

 Check the following:
 Check pump and engine oil level (diesel engine). Top up if necessary. Never run below min. level.
 Check the intermediate chamber for excess leakage water.
Only remove chamber cover plates when the pump unit is stopped.
 Also check for signs of water (emulsion) in oil. If found do not run the pump, check the reason and remedy
the fault. This is normally means referring the problem to HAMMELMANN or their accredited agent.
 Check the water filter for dirt.
 Check the condition of the filter housing and of the filter insert. If necessary clean or replace.
 Check condition and tension of all belt drives.
 All other parts of a high pressure pump unit, i. e. drive motor.
11.4 Water filter inspection

At the daily inspection you must check the water filter, if there are any signs of dirt or blockage the filter must be
replaced and the filter housing must be cleaned.
To get an access stop the unit, close off the water supply and:
 Detach water supply hose from connection.
 Open the filter drain clock ½ a turn using 12 mm A/F spanner.
 Loosen the ring screws on the filter and turn the screws upwards.
 Remove the cover and the filter cartridge.
 Take out and check the filter cartridge.
The changing of the cartridge is necessary.

 At high pressure pumps with a operating pressure up to 1500 bar every 100 operating hours.
 At high pressure pumps with a operating pressure over 1500 bar every 50 operating hours.
 Reassemble in reverse order. Only use original HAMMELMANN filter cartridges.
 Check the differential pressure after starting the unit.
The differential pressure does not exceed 1,25 bar. If a differential pressure control is installed (option) the high
pressure pump unit will be shut of at 1,25 bar differential pressure.

Page 36, Issue: 05.2013
11.5 Checks during operation

During operation of the pump we recommend that you check the condition of certain essential components for:-
Excessive or unusual noise, vibration i.e. (Valves tapping, pulsation in the discharge lines etc),
Uneven heating in areas of the pump head (Valve block),
Pulsation in the suction side assembly or rapid flickering at the pressure gauge,
Temperature increase at the plunger cooling water outlet,
Leakage at the low pressure seal sets (of the hp seal set assemblies),
Excessive or unexpected discharge from the pressure regulating valve (Bypass valve)
All the above indicate that the pump is in urgent need of repair or maintenance which must be carried out in
accordance with the instructions provided.

Page 37, Issue: 05.2013
Pos : 45 /Instandhal tung/Pumpen/HD P 380/Öl wec hs el HD P 380 - PAO 320 / S4 GX 320 @ 7\mod_1325579420066_2.doc @ 53193 @ 222323 @ 1
11.6 Oil change

Observe environmental regulations!
When working on or with the equipment, it is imperative to observe all requirements in
regards to waste-disposal and proper recycling.
Especially during installation, repair or maintenance, water damaging agents such as
lubricating grease and oil hydraulic fluid, cooling agents, solvent-containing cleaning
agents must not leak into the ground or into the sewage system! Such materials must be
stored, transported, contained and recycled in suitable containers.
11.6.1 First oil change after 1000 operating hours
Item no. Description

1 Oil drain valve
2 Oil drain oil cooler
3 Dip stick
4 Oil filler neck
5 Oil cooler
6 Oil drain valve oil filter
7 Oil filter
8 Oil pressure regulator
9 Oil pump
10 Hexagon screw plug
11 Oil pressure gauge
 Fig.: Oil change

 Change the oil, when pump is warm (oil drains better).
 At every oil change it is necessary to change the oil filter cartridge.
 Place rags or equivalent under the oil drain valves.
 Collecting trays are necessary for catching the oil from the crank case (approx. 38 litres), oil filter and oil cooler.
 (Ref. to fig oil change) Remove the cap from the oil filler neck (4)
 Unscrew the protective cap of the oil drain valve (1). Use the first drain hose which are fitted with threaded
connector. Place the free end in the collecting tray. The oil comes out of the crank section, as soon as the oil
drain hose gets screwed.
 Examine old oil for signs of emulsion.
 Unscrew the protective cap of the oil drain valve (2). Use the second drain hose which are fitted with threaded
connector. Place the free end in the collecting tray. The oil comes out of the crank section, as soon as the oil
drain hose gets screwed.
 By using a 24 mm or 41 mm wrench unscrew the hexagon screw plug (10) from the oil filter and remove it.
 Remove the protective cap from the drain valve (6) on the bottom of the oil filter. Use the drain hose with one
end fitted with threaded connector. Place free end in the collecting tray.
 The oil comes out of the oil filter, as soon as the oil drain hose gets screwed.

Page 38, Issue: 05.2013
 If the crank case, oil filter and oil cooler are completely drained unscrew the hoses from the oil drain valves
(1, 2 and 6) Screw the protective caps back on the oil drain valves.
 Fig. Oil filter

 (Ref. to fig. oil filter) Pull the complete oil filter insert (order no.: 04.00995.0177) out of the filter housing.
 Unscrew the hexagon nut (1) from the bottom of the oil filter insert and remove it with the spring (2) from the
thread rod (3).
 Pull off the oil filter cartridge (04.00995.0176) from the thread rod (3) and change by new.
 Clean the magnet (4).
 Reassembling in reverse order.
 Insert the new oil filter into the oil filter housing and replace the hexagon screw plug (9)
 Fill the crank housing with new oil (approx. 45 liter) over the oil filler neck (orange cap) until the oil level at the
dip stick is between the two markings.
 Close the oil filler neck with the cap.
Do not overfill.
11.6.2 Next oil changes
 After 4000 operating hours or min. once in a year. If 4000 hours are not reached in a year, it is possible to
check the oil quality. If the oil is in good condition it can be further used up to 4000 hours. Oil check every year.
 In extreme operating conditions, i.e.: dirt or water ingress, radiated heat, etc. more frequent oil changes are
necessary. A special change schedule is advisable.

Page 39, Issue: 05.2013
11.6.3 Lubrication including oil filter
 Quantity of oil: 38 liter

 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
Addinol Eco Gear 320 S
Aral Degol PAS 320
BP Enersyn HTX 320
Castrol Alphasyn EP 320
Esso Spartan Synth EP 320
Renolyin Unisysn
Fuchs
CLP ÖL 320
Mobil SHC 632
Mobil
Mobilgear SHC XMP 320
Optimol Optigear Synthetic A 320
PANOLIN Tecsynth 320
Enduratex* Synthetic
Petro-Canada
EP 320
Shell Omala S4 GX 320
Total Carter SH 320
OMV OMV gear SHG 320
By using other oils as here listed consult your supplier.
Note! Polyalphaolefin gear oils of different manufactures can be mixed slightly (max. 5%) with another, e.g. at oil
refill. Only small quantities (max. 5%) should be refilled, in order not to change the characteristics of the original
gear oil.
At the changing from mineral oil to polyalfaolefin the crank case must not be rinsed before new filling. The
remaining residue of the mineral oil, after a complete draining of the crank case, is compatible with the
polyalfaolefin.

Page 40, Issue: 05.2013
 Viscosity-Temperature-Diagram for synthetic oils at Poly- α -Olefin - Basis

Page 41, Issue: 05.2013
11.6.4 Oil pressure adjustment
The pressure of the oil pump has been set in our works. For a good oil supply and a long working life of the
bearings the oil pressure should never fall below 3 bar even when the unit is warm. A pressure gauge is fitted to
the unit.
If the oil pressure fall below 2 bar the high pressure pump would be shut off automatically to prevent damages of
the crank section.
Make adjustment on the oil pressure regulator (ref. to fig.: Oil change, item 6). To do so:
 Remove protective cap and loosen the counter nut.
 Use screw driver to adjust the oil pressure.
 Tighten the adjuster screw to increase pressure
or
 unscrew to reduce pressure
Pos : 46 /Instandhal tung/Pumpen/Ins tandsetzungs arbeiten @ 0\mod188_2.doc @ 1480 @ 2223333 @ 1
11.7 Repair & Replacement

The following section “Repair & Replacement” contains information enabling you to carry out repairs to the high
pressure section of the pump. Only competent trained technicians should undertake these repairs and only genuine
HAMMELMANN parts should be used.
For specialised training in pump repair and operation please consult your HAMMELMANN agent or HAMMEL-
MANN directly.
The unit should be switched off, the panel cover locked and the key removed for
safekeeping before attempting to commence repairs.

Page 42, Issue: 05.2013
Pos : 48 /Instandhal tung/Pumpen/Pumpenkopf/PK 1239 HDP 360- 500 (DKV) @ 9\mod_1367571631332_2.doc @ 76551 @ 3233 @ 1
11.8 Maintenance of the pump head 00.02145.1239

The pump head is subject to minor wearing. Maintenance is required, i.e. if a decrease of pressure or a restless run
of the pump is determined.
Before beginning to work ensure that the medium supply is switched off.
Care for cleanliness at the workplace! Dirt or i.e. little swarfs can affect the function of the
pump if they i.e. get into the valve guide or similar.
11.8.1 Disassembly (ref. to fig. pump head)
At every removing/disassembly of the pump head/valve housing check the torque of

item 500. If necessary retighten!
 Disassembly of the pump head

 Remove the pump head of the crank section or suction chamber.
 To do so: If necessary disconnect and remove all hoses and parts from the pump head.
 By using a 14 mm Allen key unscrew the hex. socket head screws (90). Thereby the casings from piston seal
assembly are now loosened.
 Working crosswise use 32 mm socket and torque wrench to remove the head retaining nuts (520).
 Lift the pump head (valve housing) from the crank section and turn it by 180°. If necessary do it with two men
or a suitable lifting device. Ensure that no pump head parts fall away.
 Disassemble the pump head on a workbench or in a vice if possible.
Always lay the parts in order of the removal and in individual sets. Mark them with a felt-tip pen if necessary.
 Disassembly of the pump head
The following instructions are made for one valve set.
Be extremely careful when removing the valve seat rings (150). Making the slightest scratch
or mark will eventually cause the component to crack.
 The following instructions are made for one valve set.

 Remove valve seat ring (150) from the sleeve of the seal assembly. Ensure that the suction valve (30) does not
fall away. Remove the pressure valve (30) from the valve seat (150). Remove the suction valve (30) from the
valve seat ring (150) or from the tappet (550).
 If necessary remove the cylinder rings (40) from the valve seat ring (150).
 Remove tappet (550), spring (140) and if necessary the bushing (160) from the seal assembly (casing).
 By using a 24 mm spanner unscrew if necessary the screw in piece (500) out of the valve housing and remove
the tappet (510) with spring (20) from the valve housing (10).

Page 43, Issue: 05.2013
 Fig.: Pump head
Item no. Description Item no. Description

10 Valve housing 160 Bushing
20 Spring 310 Set screw
30 Valve 500 Screw in piece
40 Cylinder ring 510 Tappet
90 Hexagon socket head screw 520 Hexagon nut
140 Spring 530 Stud bolt
150 Valve seat ring 550 Tappet

Page 44, Issue: 05.2013
 Inspection
 Check the valve seat ring (150). If damaged or worn, replace it. It is possible that the circular seat face could
have been deformed or worn by impact of the valve (30). If it is greatly worn or deformed so much that a good
seat is no longer possible then discard and replace with new.
 Check valve (30) for scratches, pitting or cracks. Replace if any of these are evident.
 Examine the screw in piece (500) and tappet (510 and 550) for signs of wear, if damaged exchange it.
 The supporting surface between the valve seats (150) and the casings of the seal assembly and to the pump
housing should be smooth. Exchange scratched parts.
11.8.2 Assembling (ref. to fig.: Pump head)
 Clean all parts including new spare parts for the reassembling thoroughly with a degreasing fluid and remove
all felt-tip markings if necessary. Lay these parts in order of their assembly. Grease all slide ways carefully
(grease always means Stabyl MO 500 (order no. 04.04660.0002).
 Assembly of the pump head
 Grease the bore surfaces of the valve housing (10) with water repellent grease.
 If necessary place the tappet (510) and spring (20) into the screw in piece (500).
 Lightly grease the thread of the screw in piece (500) with Molykote 1000 (order no. 04.02750.0010) and screw
into the housing. Tighten to 250 Nm.
 If necessary insert the bushing (160) in the sleeve of the seal assembly.
 Insert spring (140) with tappet (550) in the bush (160).
 Grease the cylinder rings (40) and carefully install it into the valve seat ring (150).
 Coat internal and external surfaces of valve seat ring (150) with grease. Grease suction valve (30) and place it
into the valve seat ring (150). Place the valve seat ring (150) into the sleeve of the piston seal assembly.
The arrow marker must point to the pump head (valve housing)!
 Grease pressure valve (30) and place it into the valve seat ring (150).
 Build in the other valve sets this way.

Page 45, Issue: 05.2013
 Assemble the pump head (valve housing) on the crank section or suction chamber. To do so:
 Lightly grease the supporting surfaces of pump head/seal assembly.
 Carefully place the pump head (valve housing) onto the pump housing. Ensure that no parts fall away or shift.
 Lightly grease the threads of the stud bolts (530) with Molykote 1000 (order no. 04.02750.0010). Screw nuts
(520) on the stud bolts (530) by your hand.
Don’t grease the thread of the hex. skt. head cap screws (90).
They are provided with an integrated lubricant.
 By using the hex. socket head screws (90) fix the valve housing and the casings of the piston seal assembly.
The required torque = 240 Nm. Tighten down in three steps accordingly to the sketch.
 Sketch pump head
 Then working crosswise with torque wrench and 32 mm socket tighten down nuts (520). Req. torque = 800 Nm
Do not tighten with the max. torque immediately. Tighten it up in order of the sketch in two steps and check if
the pump head constantly lays everywhere on the suction chamber.
 Reassemble all lines and add-on pieces.

Page 46, Issue: 05.2013
Pos : 50 /Instandhal tung/Pumpen/Dic htungss atz/DS 2221 HDP 360/480/D S 2221 HDP 360/480/750 @ 7\mod_1306845678721_2.doc @ 47064 @ 2223333 @ 1
11.9 Maintenance of the piston seal assembly: 00.00743.2221 (-004)

Use only correctly sized suitable tools.
11.9.1 Disassembly
 Clear an area of workbench or, if no bench available, lay a sheet of material (paper, cardboard etc.) ready to
accept dismantled parts. The parts should always be laid out in the order of disassembly and in the individual
sets.
Ensure that your workbench is absolutely clean before commencing work.
 Disassembly of the seal assembly (ref. to fig.: Loosen the piston & fig.: Piston seal assembly)
 Disconnect high pressure line/hoses and all other parts.
 Disassemble pump head parts as described under point pump head and lay them cleaned down on a
workbench or similar. Mark the parts i.e. with a felt-tip to know from which valve set they originate.
 The casing bills of the seal assembly lay bare now.
 (Ref. to fig.: Loosen the piston) Unscrew nuts (1) from the stud bolts and remove the cover plate (2) from the
pump intermediate chamber.
 Remove the circlips (480) with circlip pliers for outer circlips.
 Remove the clamp halves (470) by hand.
 Fig.: Disassembly of the piston
Item No. Description
1 Set screws
2 Intermediate chamber
4 Piston rod
20 Piston
360 O-ring
470 Clamp halves
480 Circlip
 The pistons are now loosened from the piston rod.

 Pull out the complete casing (10) from the pump housing i.e. screw two screwings (50) from the pump head in
the thread borings of the casing and pull out the pistons from the pump housing with the help of these screws.
if necessary use fitting lifting tools. Ensure that the piston (20) does not get damaged or does not lost.
 Pull out the piston (20) from the casing (10).
 Fix the casing (10) in a vice with soft cheeks. Ensure that the casing does not get damaged.
 Unscrew the cylinder screws (400) with an inner hexagon key SW 14 and by that separate the flange (30) and
the casing (10).

Page 47, Issue: 05.2013
 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).
 Pull out the bushing (150) from the casing (10).
 If necessary remove the O-ring (450) from the casing (10).
 If necessary remove the O-rings (420 and 430) from the flange (30).
 Remove the circlip (410) from the flange (30) with the help of circlip pliers.
 Remove the support ring (120) and the glyd-ring (40) from the flange.
 If necessary remove the second support ring (120) from the flange (30).
 Remove the O-rings (60) from the grooves of the flange (30) and prepare new ones.
11.9.2 Reassembly
 Clean and examine all parts for wearing and scratching. Replace with new parts if necessary. Sealings need
renewed.
 When assembling grease all sliding parts with Stabyl MO 500 (order no. 04.04660.0002) and the threads of the
screws with Molykote1000 (order no. 04.02750.0011). Now the actual assembly can be started.
 Lightly grease the inner of the flange (30).
 Insert the support ring (120) and the glyd-ring (40) in the flange.
 Place the second support ring (120) onto the Glyd-ring (40).
 Fix these parts by inserting the circlip (410).
 Lightly grease the inner of all parts.
 Assemble the O-rings (60) in the grooves of the flange (30).
 Insert O-rings (420 and 430) into the grooves of the flange (30).
 Lightly grease the inner surfaces of the casing (10).
 Lightly grease the bushing (150) and slide it in the casing (10).
 Install packing’s (130) and ring’s (110 and 190) in the casing (10). The join in the packing’s should be at 180°
when correctly positioned. (ref. to point: Assembling of packings)
 Lightly grease the bushing (300) and slide it in the casing (10).
 Then fix the casing (10) in a vice with protective cheeks.
Don’t grease the thread of the hex. skt. head cap screws (400).
They are provided with an integrated lubricant.
 Place the hex. skt. head cap screws (400) and the preassembled flange (30) on the casing (10). Screw the
hex.skt cap head screws in the casing and tighten the screws up with a dynamometric key (inner hexagon SW
14) in three steps with 240 Nm as shown in fig.: Piston seal assembly.
 Slide the O-ring (360) over the piston (20) in its position.
 Lightly grease the inner of the complete seal assembly and slide the piston (20) in the seal assembly.
 Repeat the instructions named above for the other seal assemblies.

Page 48, Issue: 05.2013
 Fig.: Piston seal assembly
Item No. Description

10 Casing
20 Piston
30 Flange
40 Glyd-Ring
60 O-ring
110 Ring
120 Support ring
130 Packings
150 Bushing
190 Ring
300 Bushing
360 O-ring
Hex. skt. head cap
400
screw
410 Circlip
420 O-ring
430 O-ring
450 O-ring
470 Clamp halves
480 Circlip

Page 49, Issue: 05.2013
 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. Ensure that the threaded bores in the casing (10) (for the hex.
skt. head screws (90) from pump head) are correctly in position.
 (Ref. to fig.: Loosen the piston) Place the circlips (480) over the piston rods to be fixed later.
 Press the piston (20) down on the piston rod and slide the peg of the piston in the piston rod.
 Assemble the parts of the pump head as described under point pump head.
 (Ref. fig: Loosen the piston) Press the clamp halves (470) on piston and piston rod.
 Hold the clamp halves with one hand and install the circlip (480) with the other hand by using circlip pliers.
Ensure that the circlip seats correctly in the groove.
 Reassemble all lines and add-on pieces.
 Test procedure
 Spray the piston with Optimol F + D. Regularly spraying of the piston with Optimol F + D prevents deposits and
extends the standing time!
 Start the pump and let it run for 5 to 10 minutes. Ensure that there are no excessive sounds or vibrations and
no excessive leakage.
 If the test procedure was successful, stop the pump and replace the cover plates.

Page 50, Issue: 05.2013
Pos : 52 /Instandhal tung/Pumpen/HD P 360/Austaus ch Faltenbalg @ 2\mod1655_2.doc @ 7964 @ 22233 @ 1
11.1 Changing the bellows

At every high pressure seal change or at least once in the year the bellows must be changed. The mounting clips
should also be changed (damaged during removal). Proceed as follows:
 Loosen the plunger from the piston rod (refer Fig. Bellows
to the chapter ‚seal assembly‘).
 Use end cut pliers to loosen or snap the hose
clamps (180 und 190). i.e. place the pliers on
the latch joint (A) of the clamp and squeeze
strongly or squeeze and twist.
 Pull down on the bellows (200)
 Use a 60 mm A/F spanner to unscrew the
piston rod (170) and remove it together with
the bellow (200) from the pump intermediate
chamber.
 Take the bellow off the piston rod.
 Slide a new bellow onto the piston rod.
 Loosely slide the hose clamp (190) over the bellow (for later assembly).
 Lay the hose clamp (180) on the crosshead/pump housing (for later assembly).
 Use the 60 mm A/F spanner to screw the piston rod with bellow into the crosshead and tighten to 150 Nm.
 Pull down the bellow and fit over the cylinder bush ensuring that it is not turned into itself. (cast seams should
be vertical).
 Adjust and fasten the hose clamps (180 und 190). The latch joints (A) on both hose clamps must be carefully
compressed with end cut pliers or similar. Ensure that the bellow is seated correctly.
 Connect the plunger to the piston rod as described in ‚Plunger seal assembly’. Repeat the procedure for the
remaining bellows and refit the intermediate chamber cover plates.
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 : 53 /Instandhal tung/Pumpen/Anzugs momente @ 0\mod194_2.doc @ 1476 @ 222 @ 1
11.2 Torque tables

Tightening torque (in Nm) for various bolted joints.
Thread size
Material
M6 M 8 M 10 M 12 M 14 M 16 M 18 M 20 M 24
5.6 4,5 11 18 30 48 73 100 140 240
8.8 8,5 21 40 70 110 171 245 345 590
10.9 12 30 60 100 160 250 350 495 850

Page 51, Issue: 05.2013
12.9 15 35 70 120 190 300 405 575 990
NIRO
(A2-70)
2,5 6 10 18 29 44 62 85 150
Torque (Nm) for various bolts. Any variations from these torque values are indicated on the individual assembly
drawings.

Page 52, Issue: 05.2013
Pos : 55 /Instandhal tung/Pumpen/Dic htungss atz/Pac kungsei nbau @ 0\mod192_2.doc @ 3256 @ 2212222 @ 1
11.3 Instructions for fitting packings

After long pump shut down periods (> 1/2 year) the packings must be renewed.
In this connection, if necessary, carefully remove any deposits on the plungers. Take care
not to scratch or damage them.
 Installation of packings
 If supplied in uncut lengths measure and cut as required. Especially pre cut packings for each seal assembly
set are available from HAMMELMANN.
 Check the length of cut sealings if necessary.
 The packings extend slightly when they are pressed, so leave a gap when fitting.
 The cut should be made at an angle of 45°. In the fitted condition the cut should go downwards, not sideways.
 Coat packings with MoS2
 Determining the length  Cutting angle
Standard values for an example of fitting
∅ in mm up to 30 31 to 60 61 to 100 101 and ...
Space in mm 0,5 1 1,5 2
 Running in the new packing

When using new packings spray the plungers with Optimol F + D.
Measure the temperature of the plungers after approx. 2 min. The difference to the medium
temperature should not exceed 20°.
If necessary stop the pump, cool it down and restart. Regularly spraying of the plungers
with Optimol F +D prevents disposits and extends the standing time!
F + D order no. 04.04660.0006
MoS 2 (Stabyl MO 500) order no. 04.04660.0002

Pressure regulating valve No.: HDP 382
00.05893.0032 Page 53, Issue: 05.2013
Pos : 57 /Instandhal tung/Druc kr egel ventil/DRV 00.05893.0032 @ 6\mod_1289481807383_2.doc @ 41774 @ 11222222 @ 1

12 Pressur e r egulating valve 00.05893.0032
12.1 Technical Data
 Operating pressure max.: 1000 bar

 Flow rate max.: 500 l/min.
 Nominal diameter: DN 17
 Quantity of oil filling for dampening: 0,3 l
 Oil quality: ISO VG 68 DIN 51519
Factory filling: Aral Konit SAE 20 W 20
 Weight approx.: 20,2 kg
Alternative oils for dampers

Texaco Ursatex SAE 20 W 20 Mobil Oil AG Mobilgear 626
Ursa Super LA SAE 20 W 20 Mobil D.T.E. Oil Heavy Medium
Auriga EP 68 BP Energol DS B20
Westfalen Multina 68 Energol EM 68
Lastan X 68 Energol GR-XP 68
Lastan N 68 Energol RC 68
Kresto 68 Shell Vitrea 68
Tonna Oel T 68
Tellus Oel C 68

No: HDP 382
Pressure regulating valve
Page 54, Issue: 05.2013 00.05893.0032
 Fig.: Complete pressure regulating valve
Item Description Item Description Item Description Item Description

10 Pre. reg. valve 30 Connection armatur 50 Double nipple 70 Reducing socket
Membrane Hex. socket head
20 40 60 Seal ring
cylinder screw

00.05893.0032 Page 55, Issue: 05.2013
Pressure gauge selection in accordance with the

machine card
bar Normal range Code no.:
100 0 - 160 04.02860.0001
300 0 - 400 04.02860.0003
450 0 – 600 04.02860.0004
750 0 – 1000 04.02860.0009
1150 0 - 1600 04.02860.0056
1500 0 – 2000 04.02860.0091
1800 0 - 2500 04.02860.0117
 Diagram: Operating pressure as a function of the control air pressure

No: HDP 382
Page 56, Issue: 05.2013 00.05893.0032
12.2 Installation (ref. to fig.: Complete pressure regulating valve)

 Lightly grease the threads of hexagon socket cap head screws (Item 40; M12 x 120; 10.9) with Molykote 1000
(order no.: 04.02750.0011).
 Carefully place the valve in the correct position and press against the pump head. Ensure that the ring
(item 50, ref. to fig.: Pressure regulating valve 00.05865.0125) doesn’t fall apart and is in correct position.
 Set the fixing screws in place and tighten. Tighten the hex skt. cap head screws (in a few steps) crosswise
(Torque 90 Nm) ensuring that the valve is absolutely parallel with the pump head.
 Lightly grease the connection armature (item 30) with Molykote 1000 and tighten into the valve.
 Screw membrane cylinder (item 20) onto the pressure regulating valve by hand.
Tighten membrane cylinder only by hand!

Not with a tool.
 Connect the pneumatically control line onto the membrane cylinder.

 (Ref. to fig.: Pressure regulating valve) If necessary remove plug (120) and screw pressure gauge with seal
ring (90) into the housing (grease the thread with Molykote 1000).
12.3 Adjustment
 The pressure regulating valve allows a smooth increase of pressure from suction pressure to max. operating
pressure.
 Adjust the operating pressure via the control air pressure. The operating pressure is directly proportional to the
control air pressure with which the pressure regulating valve is admitted (ref. to diagram).
 Increasing the air pressure ⇒ increases the operating pressure.
 Decreasing the air pressure ⇒ decreases the operating pressure.
12.4 Maintenance
 Removing the pressure regulating valve from the pump head

 Remove pneumatically control line/hose, membrane cylinder (by hand), pressure gauge and connection
armature from the pressure regulating valve.
 Loosen the 4 hexagon socket cap head screws crosswise. Support the valve so that it doesn't fall apart.
Remove the screws and the complete valve from the pump head.

00.05893.0032 Page 57, Issue: 05.2013
 Fig.: Pressure regulating valve 00.05865.0125
Item no. Description Item no. Description Item no. Description

10 Housing 50 Ring 120 Plug
20 Seal ring 60 Valve seat ring 130 Disc
Support ring with
25 O-ring 70 140 Disc spring
O-ring
30 Control piston 80 Reduction piece 150 Circlip
35 Holder 90 Seal ring 160 Cylinder ring

No: HDP 382
Page 58, Issue: 05.2013 00.05893.0032
 Disassembling of the pressure regulating valve

00.05893.0032 Page 59, Issue: 05.2013
 Remove ring (50) from housing (10).

 Carefully clamp the pressure regulating valve (housing) in a vice so that the reduction piece (80) is over the top
and that nothing would be damaged.
 Unscrew the reduction piece (80) out of the housing (10). Remove housing from vice. If necessary remove
cylinder ring (160) from the reduction piece (80).
 Using circlip pliers remove circlip (110) from control piston.
 Remove disc (130) and spring disc (140).
 Push control piston (30) and valve seat ring (60) out of the housing (10)
 By using a screw driver remove the holder (35)
from the housing (10). (Ref. to fig. 1) Thereby
do not damage the housing.
 Afterwards remove support ring (20) with 'O'-
ring (25) from the housing (10).
 Always exchange holder (35), seal (20) and O-
ring (25) together.
 Fig. 1
 Remove support ring (70 with ‘O’-ring) out of the valve seat ring (60). (Support ring and O-ring are one part
position.)
 Inspection
 Especially examine control piston (30) and valve seat ring (60) for signs of wear or damage. They should be
carefully examined and if worn replaced by new. If wear is slight or there are minor pits in the surface a certain
amount of rework is possible. Rework should be done only by HAMMELMANN.
 Visually inspect all other parts for signs of wear or damage. Replace if necessary.

No: HDP 382
Page 60, Issue: 05.2013 00.05893.0032
 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. to fig 2)
 Fig. 2
 Place seal ring (20) with O-ring
(25) onto the special tool (order
no. 01.06224.0137)
 By using the special tool press
the seal ring (20) with O-ring (25)
in the correct position into the
housing (ref. to fig. 3 and 4).
 Fig. 3

00.05893.0032 Page 61, Issue: 05.2013
 Fig. 4
 Slide the holder (35) (ref. to

fig 5) onto the special tool and
then into the housing (10).
(Ensure correct positioning) (Ref.
to fig. 6).
 Fig. 5

No: HDP 382
Page 62, Issue: 05.2013 00.05893.0032
 Correctly installed seal ring (20),

O-ring (25) and holder (35) (ref.
to. Fig 6)
 Fig. 6
 Remove the tool out of the housing.

 Slide the control pin (30) into the housing (10).
 Insert spring disc (140) into the housing. Place disc (130) onto the spring disc (140) and press this down, so
that you can fit the circlip (110) into the groove of the control piston (30).
 Place the support ring (70 and O-ring; one part) into the valve seat ring (for correct positioning ref. to fig 1!).
 Slide the valve seat ring (60) into the housing (10).
 Fit cylinder ring (160) into the reducing piece (80).
 Lightly grease the reduction piece (80) with Molykote 1000 (order no. 04.02750.0011) and screw into the
housing.
 Carefully clamp the housing in a protected vice and screw the reduction piece (80) into the housing; req. torque
= 200 Nm. Afterwards remove the pres. reg. valve from the vice.
 For installation ref. to the instructions above.

Safety notes for high pressure No.: HDP 382
hoses Page 63, Issue: 05.2013
Pos : 59 /Sic herheit/Sc hlauc hsicherheit @ 0\mod416_2.doc @ 1244 @ 122 @ 1

13 Saf et y n otes for h igh p ressure ho ses
Ignoring these notes can invalidate all claims for injuries or damages.
Secure the high pressure hose at the equipment
every time with hose protections!
Secure connections of high pressure hoses every

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

hose protections at the working tool!
Never tighten fittings of high pressure hoses under

pressure !
Avoid looping ! After looping during work, shut

down the high pressure equipment and carefully
remove loop.
Avoid twisting (torsion) of high pressure hose.
Avoid tension, never pull HP-equipment with high

pressure hose.
Do not bend high pressure hoses or pull them

around sharp edges. At work on edges or several
floors coat hose or edge. Do not bend fitting.
Never put weight on the high pressure hose. Use

hose bridges, when you have to drive over hoses.

No: HDP 382
Safety notes for high pressure
Page 64, Issue: 05.2013 hoses
13.1 Before using the hose
 Check the working pressure marked on the hose. Never exceed this working pressure.
 Check the hose and the fittings if they are damaged.
 Take out of service hoses with bubbles in the cover, with kinks or uncovered layer of the steel wire. It is not
allowed to repair hose lines with these damages or to use them in other ways. (EN 982)
 Check the fittings if they have rust, cracks (fissures) or worn threads.
 Never plug the relief holes of the fittings, neither intentional nor by dirtying or damages.
 Observe the minimum bend radius at storage and work (look table beyond).
13.2 Use of the hose

 Do not twist the hoses during assembly.
 Regularly check the hoses and fittings as well as the connections and adapters on leakages. In case of
leakages stop the high pressure aggregate immediately. Remove leakage only when the system is switched
off and depressurised. Never tighten fittings under pressure. Observe torque (look table beyond).
 Pay attention to the change of length when working. (Hoses reduce their length under pressure).
 Do not pressurise hoses on reel drums.
 Avoid stress with high temperature from the exterior (e.g. radiant heat at welding or thermal cutting).
 Do not hang the hose across several floors.
Maximum
Nominal Minimum Bend
Pressure Torque Temperature of
diameter Connection fitting Radius
[bar] [Nm] Medium
[DN] [mm]
[°C]
5 2500 M 14x1,5 LH 70 70 150
5 3200 M 14x1,5 LH 70 70 200
8 2500 M 14x1,5 LH 70 70 200
8 2800 M 14x1,5 LH 70 70 250
10 330 M 18x1,5 DKL 50 100 130
10 500 M 18x1,5 DKL 50 100 130
10 710 M 18x1,5 DKL 50 100 150
10 1250 M 22x1,5 DKO 30 100 150
10 1500 M 22x1,5 DKO 30 100 150
12 290 M 22x1,5 DKL 62 100 180
12 470 M 22x1,5 DKL 62 100 180
12 660 M 22x1,5 DKL 62 100 200
12 1100 M 24x1,5 DKO 33 100 200
12 1400 M 24x1,5 DKO 33 100 200
12 1800 M 24x1,5 DKO 33 70 300
12 2500 M 14x1,5 LH 70 70 350
20 190 M 30x1,5 DKM 83 100 240
20 350 M 30x1,5 DKM 83 100 240
20 900 M 36x2,0 DKO 49 100 280
20 1000 M 36x2,0 DKO 49 100 280
20 1400 M 36x2,0 DKO 49 100 350
25 150 M 38x1,5 DKM 105 100 300
25 290 M 38x1,5 DKM 105 100 300
=== Ende der Liste für T extmar ke Inhalt ===
25 700 M 42x2,0 DKO 57 100 355

Index No.: HDP 382
Page 65, Issue: 05.2013
14 Index
C S
Changing the bellows .............................................. 50 Safety

Construction ............................................................. 17 Additional warnings .............................................. 12
Construction High pressure pump HDP 382 ........... 17 Danger symbol ..................................................... 11
G Dangers arising from non observance of safety

instructions ......................................................... 9
General
Forbidden practices .............................................. 12
Copyright .............................................................. 14
Personnel qualification and training ....................... 9
Introduction .......................................................... 13
Precise safety instructions for the operator ............ 9
Warranty terms..................................................... 14
Safety conscious working....................................... 9
I Safety during inspection, maintenance and repair
.......................................................................... 12
Instruction for fitting packings .................................. 52
T
L
Torque tables ........................................................... 50
Leistungsdaten .......................................................... 6
Transportation
P
Packing................................................................. 15
Pressure regulating valve 00.05893.0032 ............... 53 Protection ............................................................. 16
R Transport .............................................................. 16
Repair and Replacement ......................................... 41 Transportation ...................................................... 16

1 2 3 4 5 6 7 8 9 10 11 12
354
178
660
A 173 A
M12 6 26 Tiefe 330 55 M16 6 28 Tiefe
60
Z X
60
55
22,5°
45
°
B Saugraum Entwässerung Sauganschluss DN100 PN16 B
suction chamber drainage suction connection
O 180
Schrauben M16
screws
Ölmessstab
dip stick
Öldruckmanometer
oil pressure gauge
C C
250 Ölkühler /6 filter

1494 oil cooler 6 filter unit
CoM y= 1,51 CoM x= 10,16
1401
1391
Öleinfüllstutzen
oil filler cap
1096
1096
D D
CoM z= 621,79
515
506
400
E E
52
40
O 28 172,9 550 155 155 Ölablassventil

oil outlet valve
520 610 639,5
570 1069
F X Z
29
F
550 228
1:1 2,5 0
60,1
1:2
23,1 0
60,1
68 160 19,4
100 8
( O 70 m6 )
+0,05
,5
+0,1
0
R 0 ,5
M48 x 2
O 20
O 36
O 35
20 P9
O 42
O 26
R0
G G
Passfeder / key
A20 x 12 x 100 DIN 688561
520
Massenschwerpunkt / center of mass

* Artikel6Nr. Format DIN
alle Ecken und Kanten gratfrei
ß Mit Betriebsdruck signiert
ß Mit Auftrags-Nr. signiert
Krabus 00.03223.3254 A1
Zul.Abweichung
ß Mit Teile-Nr. - Rev. signiert Maßstab
1:5 Gewicht in kg
werden, und sie darf durch den Empfänger oder Dritte auch
f.Maße ohne
ß Härte geprüft 1694.0000
Ohne unsere vorherige Zustimmung darf diese Zeichnung
Toleranzangabe
nicht in anderer Weise mißbräuchlich benutzt werden.
weder vervielfältigt noch Dritten zugänglich gemacht
ISO 2768 6 mH
Verwendungszweck Halbzeug Werkstoff *
H HDP380 Oberfläche nach
DIN ISO 1302 H
Datum Name Benennung
Bearb 16.10.2012 Poetschke
Gepr. 16.10.2012 EHelmig
Norm 17.10.2012 Szustkowski HOCHDRUCKPUMPE
Zeichnungs6Nr. Revision Blatt
1 2 3 4 5 6 7 8 9 Zust Änderung Datum Name

D659302 OELDE
CAD6Zeichnung
00.03223.3254 1
Ers.durch Ers.für
000 1 von
2 Bl.
1 2 3 4 5 6 7 8 9 10 11 12
optionale Hebevorrichtung
optional lifting device
(00.06020.0131)
A A
B B
1976
x2
1786,5
x1
C C
1025
D D
398
473
E E
703
O 1350
Schwenkbereich für
optionale Hebevorrichtung
slewing radius with Erforderliche Höhenmaße für die Demontage:
optional lifting device x1: manuelle Demontage des Pumpenkopfes
x2: Demontage von Pumpenkopf mit optionaler Hebevorrichtung
F
height required for disassembly: F
x1: manual disassembly of the pump head
x2: disassembly of pump head with the use of the optional lifting device
G G
00.03223.3254
Krabus A1
1:57
ß Mit Teile-Nr. - Rev. signiert Zul.Abweichung Maßstab Gewicht in kg
f.Maße ohne
1694.0000
ß Härte geprüft Toleranzangabe

ISO 2768 6 mH
H HDP380 Oberfläche nach
DIN ISO 1302 H
Norm 17.10.2012 Szustkowski HOCHDRUCKPUMPE
1 2 3 4 5 6 7 8 9 Zust Änderung Datum Name

D659302 OELDE
CAD6Zeichnung
00.03223.3254 1
Ers.durch Ers.für
000 2 von
2 Bl.
PARTS LIST (41)
Parts-list no.: 00.02350.1078 Hammelmann Maschinenfabrik GmbH

Drawing no. : 00.02350.1078-1 POB 3309, D-59282 Oelde, Germany
Description : CRANK SECTION http://www.hammelmann.de
HDP380 I=3,66 Date : 08.05.2013
Page : 1
DwgPos Item Code-No. Description Quantity No/Unit Unit

10 10 00.01256.0207 CRANK HOUSING 1 1,00 pc
20 20 04.00708.0026 GASKET CORD 2 0,71 m
30 30 01.00266.0084 COVER PLATE 1 1,00 pc
35 35 01.00266.0085 COVER PLATE 1 1,00 pc
40 40 02.00888.0018 HEX-SOCKET SET SCREW WITH FLAT 8 1,00 pc
50 50 02.00314.0007 HEXAGON THIN NUT 8 1,00 pc
60 60 00.06161.0122 CRANK SHAFT 1 1,00 pc
70 70 00.03270.0033 CONNECTING ROD 3 1,00 pc
80 80 01.02390.0049 BEARING 3 1,00 pc
90 90 01.03465.1341 RING 3 1,00 pc
100 100 01.00554.0195 CYLINDER BUSHING 3 1,00 pc
110 110 01.04380.0541 DISC 3 1,00 pc
130 130 04.00730.0508 O-RING 3 1,00 pc
140 140 01.02140.0060 CROSSHEAD 3 1,00 pc
150 150 01.00410.0008 GUDGEON PIN 3 1,00 pc
160 160 02.01766.0034 BORE CIRCLIP 6 1,00 pc
170 170 01.05060.0148 PISTON ROD 3 1,00 pc
180 180 04.04482.0165 HOSE CLAMP 3 1,00 pc
190 190 04.04482.0164 HOSE CLAMP 3 1,00 pc
200 200 01.01170.0019 BELLOWS 3 1,00 pc
210 210 04.05866.0012 OIL DRAIN VALVE 1 1,00 pc
215 215 04.05300.0027 CONNECTION PIECE 1 1,00 pc
220 220 04.05993.0702 CONNECTION 1 1,00 pc
230 230 04.05993.1106 TUBE FITTING 1 1,00 pc
240 240 04.05993.0542 CONNECTION 1 1,00 pc
250 250 01.03535.1113 PIPE 1 1,00 pc
260 260 04.03235.0134 OIL PUMP 1 1,00 pc
270 270 04.05993.0707 CONNECTION 4 1,00 pc
290 290 04.05993.0448 CONNECTION 2 1,00 pc
300 300 04.05993.0511 CONNECTION 3 1,00 pc
310 310 04.05993.0512 CONNECTION 1 1,00 pc
320 320 02.00957.0103 STRAIGHT PIN 2 1,00 pc
330 330 04.05000.0019 OIL DIPSTICK 1 1,00 pc
340 340 01.00530.0148 HEADED LINER 1 1,00 pc
350 350 04.00730.0014 O-RING 1 1,00 pc
360 360 01.00665.0678 COVER 1 1,00 pc
370 370 02.00825.0281 HEXAGON SOCKET HEAD SCREW 28 1,00 pc
380 380 02.01255.0042 ELBOW FITTING 1 1,00 pc
390 390 04.00665.0024 COVER 1 1,00 pc
400 400 01.03469.0263 SPACER RING 1 1,00 pc
410 410 04.00730.0341 O-RING 3 1,00 pc
440 440 02.01651.0090 FEATHER KEY 1 1,00 pc
470 470 02.01651.0036 FEATHER KEY 1 1,00 pc
PARTS LIST (41)

HDP380 I=3,66 Date : 08.05.2013
Page : 2

480 480 01.05172.0036 SET SCREW 2 1,00 pc
490 490 01.02745.0019 DRIVER 1 1,00 pc
500 500 01.06180.0161 PINION SHAFT 1 1,00 pc
510 510 02.01651.0076 FEATHER KEY 1 1,00 pc
530 530 00.02198.0025 OIL COOLER 1 1,00 pc
540 540 04.00736.0091 ROTARY SHAFT SEAL 1 1,00 pc
550 550 01.03535.1091 PIPE 2 1,00 pc
560 560 02.01657.0376 SELF-ALIGNING ROLLER BEARING 2 1,00 pc
570 570 04.05993.1094 TUBE FITTING 1 1,00 pc
580 580 04.05866.0013 DRAIN VALVE 1 1,00 pc
590 590 04.05300.0011 CONNECTION PIECE 1 1,00 pc
610 610 00.01015.0020 OIL FILTER 1 1,00 pc
620 620 01.03535.1261 TUBE 2 1,00 pc
640 640 04.05993.1042 TUBE FITTING 1 1,00 pc
650 650 01.00665.0677 COVER 1 1,00 pc
670 670 01.00525.0777 BUSHING 2 1,00 pc
680 680 04.00730.0093 O-RING 2 1,00 pc
690 690 04.00730.0133 O-RING 2 1,00 pc
710 710 04.05896.0002 FLOW REGULATOR 1 1,00 pc
720 720 04.05993.0402 TUBE FITTING 2 1,00 pc
730 730 04.05993.0410 CONNECTION 2 1,00 pc
740 740 04.05993.0750 PLUG 1 1,00 pc
750 750 07.50309.0228 PIPE 1 0,06 m
770 770 04.05993.1029 TUBE FITTING 2 1,00 pc
790 790 04.05993.0023 FITTING 1 1,00 pc
800 800 04.02860.0073 PRESSURE GAUGE 1 1,00 pc
810 810 04.05993.0704 CONNECTION 3 1,00 pc
820 820 00.05993.0058 TUBE FITTING 2 1,00 pc
850 850 01.05180.0071 CONTROL PIN 1 1,00 pc
860 860 04.00946.0117 COIL SPRING 1 1,00 pc
870 870 04.00730.0041 O-RING 1 1,00 pc
880 880 01.04723.0030 ADJUSTING SCREW 1 1,00 pc
890 890 02.00307.0024 HEXAGON NUT 1 1,00 pc
900 900 04.05240.0136 PLUG 1 1,00 pc
930 930 04.01777.0007 PROTECTIVE SLEEVE 1 1,00 pc
940 940 04.05682.0086 HOSE LINER 4 1,00 pc
950 950 04.00730.0520 O-RING 3 1,00 pc
960 960 00.05993.0059 TUBE FITTING 2 1,00 pc
970 970 04.05215.0063 PLUG 2 1,00 pc
980 980 01.03535.1205 PIPE 2 1,00 pc
990 990 04.05993.0101 CONNECTION 3 1,00 pc
1000 1000 01.03535.1094 PIPE 1 1,00 pc
1020 1020 04.05993.0431 TUBE FITTING 2 1,00 pc
1030 1030 04.02251.0126 COUPLING HALF 1 1,00 pc
PARTS LIST (41)

HDP380 I=3,66 Date : 08.05.2013
Page : 3

1040 1040 04.03490.0057 COUPLING RING 2 1,00 pc
1050 1050 04.05336.0003 INTERMEDIATE PIECE 1 1,00 pc
1060 1060 04.02251.0125 COUPLING HALF 1 1,00 pc
1080 1080 04.05993.1161 TUBE FITTING 1 1,00 pc
1100 1100 07.50309.0228 PIPE 1 0,66 m
1110 1110 01.01630.0138 BRACKET 1 1,00 pc
1120 1120 02.00434.0007 WASHER 4 1,00 pc
1130 1130 04.05993.0924 THREADED CONNECTION 1 1,00 pc
1160 1160 04.05993.1165 CONNECTION 1 1,00 pc
1170 1170 04.03497.0012 CUTTING RING 1 1,00 pc
1180 1180 04.02833.0038 CAP NUT 1 1,00 pc
1200 1200 07.50309.0228 PIPE 1 0,07 m
1210 1210 04.05993.0011 TUBE FITTING 2 1,00 pc
1220 1220 07.50309.0105 pipe 2 0,05 m
1230 1230 04.05993.0845 fitting 1 1,00 pc
1240 1240 01.03535.1324 TUBE 1 1,00 pc
1250 1250 04.05993.1016 TUBE FITTING 1 1,00 pc
1260 1260 01.03535.1323 TUBE 1 1,00 pc
1270 1270 04.05993.0700 TUBE FITTING 2 1,00 pc
1280 1280 04.05993.0713 CONNECTION 2 1,00 pc
1290 1290 04.01548.0001 DRAIN VALVE 2 1,00 pc
1300 1300 02.00421.0007 WASHER 8 1,00 pc
1320 1320 02.00825.0799 HEXAGON SOCKET HEAD CAP SCREW 4 1,00 pc
1330 1330 02.00314.0007 HEXAGON THIN NUT 4 1,00 pc
1350 1350 01.00742.0399 SEAL RING 3 1,00 pc
>>>end<<<
p_dbgs01.p
1 2 3 4 5 6 7 8 9 10 11 12
290 270 300
50
8 B6B 1350 A6A B A
1 1 1
Anziehdrehmoment 3 1130
Ma=70Nm 40 190 1
A 8 3 A
620 1320 1300 1330
35 2 200
1 150 4 4 4
3
3
90
3 140
610 D 180 970
Anziehdrehmoment
Ma = 100 Nm
1 3 Anziehdremoment 1
3 Ma=250 Nm 1110 1120 1300 1310
950 310
3 170 Skt SW60 1 4 4 4
30 640 3 1
1 Anziehdrehmoment
130 1 Ma=100Nm
160 1000
3 1
Anziehdrehmoment 6
70 1100
B Ma=100Nm 300 1 B
3 1
630
110 2 530
3 1
Anziehdrehmoment 270
Ma=100Nm 420 100 2
3 3 C 320
C 2
10 570
1 1
C C
60 480
1 2
Anziehdrehmoment
Ma=30Nm 430 260
80 670 4 1
3 2
680 290 300
240 1 1
2
20 1
2 690 360
2
D 1
D 250 D
1
Anziehdrehmoment M24
450 Nm, Iskt. SW19 590 580
Anziehdrehmoment M27 650 1 1
650 Nm, Iskt. SW19 1
Anziehdrehmoment 125 Nm
Skt. SW24 Z
B Anziehdrehmoment
Ma=100Nm 370 230 220 360
A
1030 1040 1050 1060 210 215
1 2 1 1 28 1 1 1 1 1
E
Y
004 004 004 004
C6C 560
2
550
2
540
1
400
1 800 D6D 1220 990 960
E
1:2 160 1 2 1 1
004
Y 810
1
440 470 490 430
Anziehdrehmoment
Ma=30Nm X 1210
1 1 1 3 1
990 820
980 1 1
1
1200 1170 1180 1160 1230 750 1080
F 1 1 1 1 1 1 1 1210 F
1 900
1
Z 1240
1 880
1:2 770 1
1 890
930 410 510 500
1 3 1 1 1
710 870
1 1
G
T Wellenschutzhülse mit Montagewerkzeug aufziehen .
860
1
G
T 1:2 Montageflansch nach der Montage an der vorgezeichneten
Linie abtrennen und komplett entfernen. 850
730 160 1
2
740
1
X Artikel6Nr. Format DIN
*
00.02350.1078
ß Mit Betriebsdruck signiert Krabus A1
2:1 Achtung :
ß Mit Teile-Nr. - Rev. signiert Zul.Abweichung Maßstab
1:3.5 Gewicht in kg
f.Maße ohne
1196.0000

H 6 vor der kompletten Montage , Pos.90 Verwendungszweck

HDP 380 i=3,66
ISO 2768 6 mH
Oberfläche nach
DIN ISO 1302
Halbzeug Werkstoff *
H
auf 6196°C abgekühlt und ins Gehäuse Bearb
Datum
26.08.2011 Poetschke
Name Benennung
1020 1250 270 1020 Pos.10 eingeschrumpft Gepr. 27.03.2013 EHelmig

1 1 1 1 1290 810 1280 1270 720
6 Übergang vom Ring Pos.90 zum 004 Stücklistenänderung 26.03.2013 Wei
Norm 27.03.2013 Krabus KURBELTRIEB
2 2 2 2 2 003 Stücklistenänderung 04.03.2013 Wei Zeichnungs6Nr. Revision Blatt
Gehäuse mit Seevenax beschichtet. 002 Pos.210 geändert
001
22.11.2012
18.06.2012
San
Wei D659302 OELDE 00.02350.1078 1 004 1 von
2 Bl.
1 2 3 4 5 6 7 8 9 Zust Änderung Datum Name CAD6Zeichnung Ers.durch Ers.für
1 2 3 4 5 6 7 8 9 10 11 12
A A
990 960
1 1 970 390
1 1
B B
980 380
1 1
790 820
1 1 330
940 1
4 340
1
1260
1 350
C 1 C
770
1
D D
E E
F F
G G
00.02350.1078
Krabus A1
Zul.Abweichung
1:3.5 Gewicht in kg
f.Maße ohne
1196.0000

ISO 2768 6 mH
H HDP 380 i=3,66 Oberfläche nach
DIN ISO 1302 H
004 Stücklistenänderung 26.03.2013 Wei

Norm 27.03.2013 Krabus KURBELTRIEB
003 Stücklistenänderung 04.03.2013 Wei Zeichnungs6Nr. Revision Blatt
1 2 3 4 5 6 7 8 9
002 Pos.210 geändert
001
Zust Änderung
22.11.2012
18.06.2012
Datum
San
Wei
Name
D659302 OELDE
CAD6Zeichnung
00.02350.1078 1
Ers.durch Ers.für
004 2 von
2 Bl.
PARTS LIST (41)

Description : OIL FILTER http://www.hammelmann.de
HDP360/480/750 Date : 08.05.2013
Page : 1

10 10 00.01240.0378 HOUSING 1 1,00 pc
20 20 04.00995.0177 FILTER 1 1,00 pc
30 30 01.04838.0216 HEXAGON HEAD SCREW PLUG 1 1,00 pc
40 40 04.00730.0416 O-RING 1 1,00 pc
50 50 04.05240.0150 PLUG 1 1,00 pc
>>>end<<<
p_dbgs01.p
1 2 3 4 5 6 7 8
A 001
A
50 30 40 10 20
1 1 1 1 1
(G3/4)
B B
(G3/4)
C C
(G3/4)
D (G1/2) D
435
ca. 440
Betriebsdruck max. 30 bar

E Prüfdruck max. 45 bar E
00.01015.0020
Krabus A3
Zul.Abweichung
ß Mit Teile-Nr. signiert Maßstab
1:1.5 Gewicht in kg
f.Maße ohne
13.0000

ISO 2768 3 mH
Verwendungszweck
Oberfläche nach
HDP360/480/750 DIN ISO 1302
Bearb 02.03.2009 Hunke
F Gepr. 12.04.2011 Glitt F
Norm 12.04.2011 Krabus OELFILTER
1 2 3 4
001 Stücklistenänderung
Zust Änderung
12.04.2011 Pöts
Datum Name
D359302 OELDE
CAD3Zeichnung
00.01015.0020 1
Ers.durch Ers.für
001 1 von
1 Bl.
PARTS LIST (41)

Description : SUCTION CHAMBER http://www.hammelmann.de
HDP360-500 D28 - 65 Date : 08.05.2013
Page : 1

10 10 01.04246.0224 SUCTION CHAMBER 1 1,00 pc
20 20 01.04380.1080 DISC 12 1,00 pc
40 40 02.00788.0060 STUD BOLT 8 1,00 pc
50 50 02.00309.0009 HEXAGON NUT 8 1,00 pc
70 70 04.05993.0788 THREADED CONNECTION 5 1,00 pc
80 80 04.00730.0539 O-RING 1 1,00 pc
90 90 02.00957.0103 STRAIGHT PIN 2 1,00 pc
>>>end<<<
p_dbgs01.p
1 2 3 4 5 6 7 8
80 640
1 10
1
40
A 8 A
45
°
50
8
W
22,5°
358
70
180
2
B 90 B
20 2
12
30 O 180
12 Saugraum bei Montage mit Kurbeltrieb
mit Kleber "TEROKAL 3 2444"
(04.02056.0005) umlaufend angedichtet.
9 7 1 3 5 11
C C
12 6 4 2 8 10
D D
Schrauben Pos. 30 mit integriertem Schmiermittel
001 und in angegebener Reihenfolge ohne Fett
angezogen:
W 1. Stufe: Anziehdrehmoment Ma = 200 Nm
2. Stufe: Anziehdrehmoment Ma = 800 Nm
E E
Bronze Saugraum mit 1x DIN DN100 ; PN16

00.04246.0184
Krabus A2
Zul.Abweichung
1:5 Gewicht in kg
f.Maße ohne
253.7640

ISO 2768 3 mH
Verwendungszweck Halbzeug Werkstoff*
F HDP3603500 D28360 Oberfläche nach
DIN ISO 1302 2.0975 F
Bearb 23.04.2012 Sander
Norm 28.02.2013 Krabus SAUGRAUM
1 2 3 4 5
001 Text geändert
Zust Änderung
28.02.2013 San
Datum Name
D359302 OELDE
CAD3Zeichnung
00.04246.0184 1
Ers.durch Ers.für
001 1 von
1 Bl.
PARTS LIST (41)

Description : PISTON SEAL ASSEMBLY http://www.hammelmann.de
HDP360/480/750 D50 Date : 08.05.2013
Page : 1

10 10 01.01750.0898 CASING 1 1,00 pc
20 20 00.02110.0374 PISTON 1 1,00 pc
30 30 01.01055.1386 FLANGE 1 1,00 pc
40 40 04.00731.0052 GLYD RING 1 1,00 pc
60 60 04.00730.0510 O-RING 2 1,00 pc
110 110 01.03465.1424 RING 2 1,00 pc
120 120 01.03512.0306 SUPPORT RING 2 1,00 pc
130 130 04.00739.0032 PACKINGS 1 1,00 set
150 150 01.00525.0801 BUSHING 1 1,00 pc
190 190 01.03465.1430 RING 1 1,00 pc
300 300 01.00525.1092 BUSHING 1 1,00 pc
360 360 04.00730.0218 O-RING 1 1,00 pc
410 410 02.01766.0034 BORE CIRCLIP 1 1,00 pc
420 420 04.00730.0505 O-RING 1 1,00 pc
430 430 04.00730.0379 O-RING 1 1,00 pc
450 450 04.00730.0076 O-RING 8 1,00 pc
470 470 01.01990.0014 CLAMP 2 1,00 pc
480 480 01.03501.0025 SHAFT CIRCLIP 2 1,00 pc
>>>end<<<
p_dbgs01.p
1 2 3 4 5 6 7 8
A3A
004
A 10 130 110 190 300 30 120 40 410 400 360 480 470 450
A
150 20
1 1 1 1 2 1 1 1 2 1 1 10 1 2 2 8
A
B B
C C
A
420 430 60
D 1 1 2 D
10 1
6 7 Sonderausführung
E Betriebsdruck max. 1000 bar E
00.00743.2221
4 3 004
Schrauben Pos. 400 mit integriertem Schmiermittel
Krabus
Zul.Abweichung
A3
1:1,5 Gewicht in kg
f.Maße ohne
und in angegebener Reihenfolge ohne Fett 30.6100

ISO 2768 3 mH
angezogen:
Verwendungszweck
Oberfläche nach
HDP360/480/750 D50,0 DIN ISO 1302
F 8 5 1. Stufe: Anziehdrehmoment Ma = 80 Nm
Bearb
Gepr.
02.03.2011 Sander
08.10.2012 EHelmig F
3. Stufe: Anziehdrehmoment Ma = 240 Nm 004 Stücklistenänderung 08.10.2012 Wei
Norm 09.10.2012 Krabus DICHTUNGSSATZ
2 9 003 Pos. 150 geändert in Bz 06.05.2011 JMue Zeichnungs3Nr. Revision Blatt
1 2 3 4
002
001
Zust
Pos. geändert
Stücklistenänderung
Änderung
30.03.2011
16.03.2011
Datum
San
Pöts
Name
D359302 OELDE
CAD3Zeichnung
00.00743.2221 1
Ers.durch Ers.für
004 1 von
1 Bl.
PARTS LIST (41)

Description : PUMPHEAD http://www.hammelmann.de
HDP360-500 D50-55 Date : 08.05.2013
Page : 1

10 10 01.01305.0760 VALVE HOUSING 1 1,00 pc
20 20 04.00946.0283 COIL SPRING 3 1,00 pc
30 30 01.05860.0291 VALVE 6 1,00 pc
40 40 01.00742.0212 CYLINDER RING 6 1,00 pc
140 140 04.00946.0287 COIL SPRING 3 1,00 pc
150 150 00.03528.0059 VALVE SEAT RING 3 1,00 pc
160 160 00.00525.0089 BUSHING 3 1,00 pc
310 310 02.00888.0305 HEX-SOCKET SET SCREW WITH FLAT 2 1,00 pc
500 500 00.05317.0002 SCREW IN PIECE 3 1,00 pc
510 510 01.05195.0012 TAPPET 3 1,00 pc
520 520 02.00318.0011 HEXAGON NUT 8 1,00 pc
530 530 01.04756.0110 STUD BOLT 8 1,00 pc
550 550 01.05195.0022 TAPPET 3 1,00 pc
>>>end<<<
p_dbgs01.p
1 2 3 4 5 6 7 8
7 1
A 3 5
530
A 8
A
310 1
5 7
3
A3A 2
520 90
8 24
4 2
8 6
10 6 4 2 8
B
1
A B
20
3 Pos.520 (Skt. SW46) mit MoS2 gefettet und in Schrauben Pos. 90 sind silberfarbig,
500 angegebener Reihenfolge angezogen: mit integriertem Schmiermittel und
3 30 in angegebener Reihenfolge ohne Fett
6 1. Stufe: Anziehdrehmoment Ma= 200 Nm angezogen:
510 2. Stufe: Anziehdrehmoment Ma= 800 Nm
3 1. Stufe: Anziehdrehmoment Ma = 80 Nm
C 2. Stufe: Anziehdrehmoment Ma = 160 Nm C
150
3
D D
40
550 6
3
Sonderausführung Duplex
E 160 140 Betriebsdruck max. 1070 bar E
3 3 * Artikel3Nr. Format DIN
00.02145.1239
Krabus A3
Pos.500 (Skt. SW24) Anziehdrehmoment 250Nm ß Mit Teile-Nr. - Rev. signiert Zul.Abweichung Maßstab
1:1,5 Gewicht in kg
f.Maße ohne
153.0000

ISO 2768 3 mH
Verwendungszweck
Oberfläche nach
HDP3603500 ø50355 DIN ISO 1302
F Gepr. 18.03.2013 Borosch F
Norm 19.03.2013 Krabus PUMPENKOPF
1 2 3 4 Zust Änderung Datum Name

D359302 OELDE
CAD3Zeichnung
00.02145.1239 1
Ers.durch Ers.für
000 1 von
1 Bl.
PARTS LIST (41)

Description : PRESSURE REGULATING VALVE CPL. http://www.hammelmann.de
500 L/MIN (NW17); 500-1200 BAR Date : 08.05.2013
Page : 1

10 10 00.05865.0125 PRESSURE REGULATING VALVE 1 1,00 pc
20 20 00.06428.0029 MEMBRANE CYLINDER 1 1,00 pc
30 30 00.00131.0121 CONNECTION 1 1,00 pc
50 50 01.02978.0137 DOUBLE NIPPLE 1 1,00 pc
60 60 04.00706.0028 SEAL RING 1 1,00 pc
70 70 01.02795.0091 REDUCING SOCKET 1 1,00 pc
>>>end<<<
p_dbgs01.p
1 2 3 4 5 6 7 8
515 Membranzylinder O130

Membrane cylinder O130
Anschluss Berstscheibensicherung G 1/2 Cylindre a membrane O130
Connection rupture disc G 1/2 1800
A Raccord disque a l'eclatement G 1/2 A
1600
Anziehdrehmoment Ma = 200 Nm 1400

Tightening torque Ma = 200 Nm
Pression de service (bar)

Operating pressure (bar)
1200
Couple de serrage Ma = 200 Nm
Betriebsdruck (bar)
1000
800
S
O 198
600
400
(DN 6)
200
B 0 B
0 1 2 3 4 5 6
Druckluft Steuerdruck (bar) (+/3 0,3 bar)
Anziehdrehmoment Ma = 90 Nm Compressed air control pressure (bar) (+/3 0,3 bar)
Tightening torque Ma = 90 Nm La pression de traitement d'air (bar) (+/3 0,3 bar)
P 40 Couple de serrage Ma = 90 Nm
4
Anschraublochbild 60 mm x 60 mm (M12)
Hole pattern 60 mm x 60 mm (M12)
Configuration de percage 60 mm x 60 mm (M12)
C Hochdruckmanometer gehört nicht zur Baugruppe C

Manometerauswahl gemäß Maschinenkarte Manometer3 Druckbereich (bar)
High pressure gauge not part of shown assembly Gauge pressure range (bar)
Selection of gauge according to machine card Portée de pression du manomètre (bar)
Le manomètre haute pression ne fait pas partie Druck (bar) Anzeigebereich (bar) Teile3 Nr.:
20 10 50 60 70 d‘ ensemble des components Pressure (bar) Range (bar) Part no.:
1 1 1 1 1 Séléction de manomètre selon de carte de machine Pression (bar) Portée d'affichage (bar) Référence:
100 0 3 160 bar 04.02860.0001
Z 300 0 3 400 bar 04.02860.0003
2:1 450
750
0 3 600 bar
0 3 1000 bar
04.02860.0004
04.02860.0009 1:5
Anziehdrehmoment Ma = 100 Nm 1150 0 3 1600 bar 04.02860.0056
D Tightening torque Ma = 100 Nm 1500 0 3 2000 bar 04.02860.0091 D
Couple de serrage Ma = 100 Nm 1800 0 3 2500 bar 04.02860.0117
ß
30
Y 1
Z 2:1
368
Y
T G 1 1/2
S
E E
Volumenstrom max. 500 l/min
Nennweite DN17 P
Keramikausführung DN 20 / 4x M12 / 60 x 60
Hochdruckdichtung
Max. operating pressure 1200 bar
00.05893.0032
Max. flow rate 500 l/min

X ß Mit Betriebsdruck signiert
Krabus A3
Nominal diameter 17 mm X ß Mit Teile-Nr. - Rev. signiert Zul.Abweichung Maßstab
1:2 Gewicht in kg
f.Maße ohne
20.2000
Toleranzangabe
Ceramic design ß Härte geprüft
ISO 2768 3 mH
F O 40 High pressure seal Oberfläche nach
DIN ISO 1302 F
262 171 Datum Name PRESSURE REGULATING VALVE CPL.
Benennung
Pression de service maximale 1200 bar Bearb 05.11.2010 PSchoening
SOUPAPE REGULATRICE DE PRESSION AU COMPLET
22.03.2012 Oberscheidt
T Débit maximal 500 l/min Gepr.
Norm 23.03.2012 Krabus DRUCKREGELVENTIL KPL.
Largeur nominale DN 17
Version céramique Zeichnungs3Nr. Revision Blatt
Joint haute pression
1 2 3 4 5
001 Positionen nachgetragen
Zust Änderung
13.03.2012 PS
Datum Name
D359302 OELDE
CAD3Zeichnung
00.05893.0032 1
Ers.durch Ers.für
001 1 von
1 Bl.
PARTS LIST (41)

Description : PRESSURE REGULATING VALVE http://www.hammelmann.de
500 L/MIN (NW17) , 1000 BAR Date : 08.05.2013
Page : 1

10 10 01.01240.0527 HOUSING 1 1,00 pc
20 20 01.03468.0158 SEAL RING 1 1,00 pc
25 25 04.00734.0113 O-RING 1 1,00 pc
30 30 01.02123.0147 CONTROL PISTON 1 1,00 pc
35 35 01.01595.0182 BRACKET 1 1,00 pc
50 50 01.03465.0786 SEAL RING 1 1,00 pc
60 60 01.03528.0305 VALVE SEAT RING 1 1,00 pc
70 70 04.00737.1018 SUPPORT RING 1 1,00 pc
80 80 01.05320.0174 REDUCTION PIECE 1 1,00 pc
90 90 04.00706.0002 SEAL RING 3 1,00 pc
110 110 02.01765.0013 SHAFT CIRCLIP 1 1,00 pc
120 120 01.05240.0030 PLUG 2 1,00 pc
130 130 01.04380.1135 DISC 1 1,00 pc
140 140 04.04380.0037 SPRING WASHER 1 1,00 pc
160 160 04.00742.0043 CYLINDER RING 1 1,00 pc
>>>end<<<
p_dbgs01.p
1 2 3 4 5 6 7 8
175
A3A Anzugsdrehmoment Ma = 200 Nm
A 130 140 10 35 30 50
P 60 70 160 80
Tightening torque Ma = 200 Nm
Couple de serrage Ma = 200 Nm A A
1 1 1 1 1 1 1 1 1 1
144
B B
T
(M63 x 2)
(G1 1/2)
133
C C
110 Z Skt. SW 55
1
Y
Z 2:1 T G 1 1/2
D D
2:1 ß
Skt. SW 19
90 120
A
3 2 Volumenstrom max. 500 l/min
Nennweite DN17 P
25 20 Anzugsdrehmoment Ma = 100 Nm Keramikausführung
E Tightening torque Ma = 100 Nm Hochdruckdichtung DN 20 / 4x M12 / 60 x 60 E
1 1 Couple de serrage Ma = 100 Nm * Artikel3Nr. Format DIN
00.05865.0125
Max. operating pressure 1200 bar
Max. flow rate 500 l/min X
Krabus A3
X Zul.Abweichung
Nominal diameter 17 mm ß Mit Teile-Nr. - Rev. signiert Maßstab
1:1 Gewicht in kg
f.Maße ohne
10.4200

Ceramic design
ISO 2768 3 mH
High pressure seal Oberfläche nach
DIN ISO 1302
26.08.2010 Oberscheidt
PRESSURE REGULATING VALVE
Pression de service maximale 1200 bar Bearb
SOUPAPE REGULATRICE DE PRESSION
F Débit maximal 500 l/min Gepr. 15.03.2012 Oberscheidt F
Largeur nominale DN 17 004 Texte hinzu 14.03.2012 PS
Norm 15.03.2012 Krabus DRUCKREGELVENTIL
1:5 Version céramique 003 Druck in 1200 bar 12.03.2012 PS Zeichnungs3Nr. Revision Blatt
1 2 3
Joint haute pression
4
002
001
Zust
Text berichtigt
Stückliste
Änderung
05.11.2010
21.09.2010
Datum
PS
Os
Name
D359302 OELDE
CAD3Zeichnung
00.05865.0125 1
Ers.durch Ers.für
004
00.96120.001031
1 von
1 Bl.
PARTS LIST (41)

Description : MEMBRANE CYLINDER http://www.hammelmann.de
PN 10; D 130 Date : 08.05.2013
Page : 1

10 10 01.06415.0074 CYLINDER 1 1,00 pc
20 20 04.00946.0216 COIL SPRING 1 1,00 pc
30 30 01.02110.0449 PISTON 1 1,00 pc
40 40 04.02727.0007 DIAPHRAGM 1 1,00 pc
50 50 01.00665.0362 COVER 1 1,00 pc
70 70 04.02990.0093 REDUCTION NIPPLE 1 1,00 pc
80 80 04.05878.0029 CHECK VALVE 1 1,00 pc
90 90 04.00706.0026 SEAL RING 1 1,00 pc
100 100 04.05993.0956 TUBE FITTING 1 1,00 pc
110 110 04.05993.0838 TUBE FITTING 1 1,00 pc
120 120 00.00222.0099 CONTAINER 1 1,00 pc
>>>end<<<
p_dbgs01.p
1 2 3 4 5 6 7 8
ca. 209
A 110 100 80 40 30 20 A
1 1 1 1 1 1
A
X
X
DN6
B B
90
1
70
1
(M63 x 2)
C C
198
120
O
1
D 50 60 10 D
1 8 1 A
Anziehdrehmoment 10 Nm
A3A
Wirkdurchmesser: 130 mm
Betriebsdruck : max. 10 bar ß
E Medium : Luft, Öl E
00.06428.0029
Krabus A3
X Zul.Abweichung
ß Mit Teile-Nr. signiert Maßstab
1:2 Gewicht in kg
f.Maße ohne
5.5000

ISO 2768 3 mH
Verwendungszweck
Oberfläche nach
DIN ISO 1302
008 Signierungsort geändert 02.07.2009 Pae Bearb 28.05.2002 PSchoening
F 007 Pos.120 hinzu 22.10.2007 Pöts Gepr. 02.07.2009 Poetschke F
006
005
00.05877.0065 entf.
Stkl. geä.
27.04.2007 PS Norm
12.04.2006 Pöts
03.07.2009 Szustkowski MEMBRANZYLINDER
004 Darstellung geänd. 02.07.2003 PS Zeichnungs3Nr. Revision Blatt
1 2 3 4
003
002
Zust
Darst. geä.
Pos.200,210,220 entf.
Änderung
12.05.2003 Pöts
05.02.2003 Som
Datum Name
D359302 OELDE
CAD3Zeichnung
00.06428.0029 1
Ers.durch Ers.für
008 1 von
1 Bl.
HAMMELMANN Code no.: 04.03070.0035

Version 1.0
Effective Date 01/12/2011
Regulation 1907/2006/EC
Safety Data Sheet
1. IDENTIFICATION OF THE SUBSTANCE/PREPARATION AND COMPANY/UNDERTAKING
Material Name : Shell Omala S4 GX 320

Uses : Gear lubricant.
Product Code : 001D7852
Manufacturer/Supplier : Shell Deutschland Oil GmbH

Suhrenkamp 71-77
D-22335 Hamburg
Telephone : (+49) 40 6324-6255

Fax : (+49) 40 6321-051
Email Contact for : If you have any enquiries about the content of this MSDS
MSDS please email lubricantSDS@shell.com
Emergency Telephone : +49 (0)40 6324-5110

Number
2. HAZARDS IDENTIFICATION
EC Classification : Not classified as dangerous under EC criteria.
Health Hazards : Not expected to be a health hazard when used under normal
conditions. Prolonged or repeated skin contact without proper
cleaning can clog the pores of the skin resulting in disorders
such as oil acne/folliculitis. Used oil may contain harmful
impurities.
Signs and Symptoms : Oil acne/folliculitis signs and symptoms may include formation
of black pustules and spots on the skin of exposed areas.
Ingestion may result in nausea, vomiting and/or diarrhoea.
Safety Hazards : Not classified as flammable but will burn.
Environmental Hazards : Not classified as dangerous for the environment.
3. COMPOSITION/INFORMATION ON INGREDIENTS
Preparation Description : Blend of polyolefins and additives.
Hazardous Components
Chemical Identity CAS EINECS Symbol(s) R-phrase(s) Conc.

Long-chain alkyl T, C, N R22; R34; 0,10 - 0,24 %
amine R43;
R23/24;
R48/20;
R50/53
Additional Information : Refer to chapter 16 for full text of EC R-phrases.
1/7
Print Date 01/14/2011 MSDS_DE

Version 1.0
Safety Data Sheet
4. FIRST AID MEASURES
General Information : Not expected to be a health hazard when used under normal
conditions.
Inhalation : No treatment necessary under normal conditions of use. If
symptoms persist, obtain medical advice.
Skin Contact : Remove contaminated clothing. Flush exposed area with water
and follow by washing with soap if available. If persistent
irritation occurs, obtain medical attention.
Eye Contact : Flush eye with copious quantities of water. If persistent
irritation occurs, obtain medical attention.
Ingestion : In general no treatment is necessary unless large quantities
are swallowed, however, get medical advice.
Advice to Physician : Treat symptomatically.
5. FIRE FIGHTING MEASURES
Clear fire area of all non-emergency personnel.
Specific Hazards : Hazardous combustion products may include: A complex

mixture of airborne solid and liquid particulates and gases
(smoke). Carbon monoxide. Unidentified organic and inorganic
compounds.
Suitable Extinguishing : Foam, water spray or fog. Dry chemical powder, carbon
Media dioxide, sand or earth may be used for small fires only.
Unsuitable Extinguishing : Do not use water in a jet.
Media
Protective Equipment for : Proper protective equipment including breathing apparatus
Firefighters must be worn when approaching a fire in a confined space.
6. ACCIDENTAL RELEASE MEASURES
Avoid contact with spilled or released material. For guidance on selection of personal protective
equipment see Chapter 8 of this Material Safety Data Sheet. See Chapter 13 for information on
disposal. Observe the relevant local and international regulations.
Protective measures : Avoid contact with skin and eyes. Use appropriate containment
to avoid environmental contamination. Prevent from spreading
or entering drains, ditches or rivers by using sand, earth, or
other appropriate barriers.
Clean Up Methods : Slippery when spilt. Avoid accidents, clean up immediately.
Prevent from spreading by making a barrier with sand, earth or
other containment material. Reclaim liquid directly or in an
absorbent. Soak up residue with an absorbent such as clay,
sand or other suitable material and dispose of properly.
Additional Advice : Local authorities should be advised if significant spillages
cannot be contained.
2/7

Version 1.0
Safety Data Sheet
7. HANDLING AND STORAGE
General Precautions : Use local exhaust ventilation if there is risk of inhalation of

vapours, mists or aerosols. Properly dispose of any
contaminated rags or cleaning materials in order to prevent
fires. Use the information in this data sheet as input to a risk
assessment of local circumstances to help determine
appropriate controls for safe handling, storage and disposal of
this material.
Handling : Avoid prolonged or repeated contact with skin. Avoid inhaling
vapour and/or mists. When handling product in drums, safety
footwear should be worn and proper handling equipment
should be used.
Storage : Keep container tightly closed and in a cool, well-ventilated
place. Use properly labelled and closeable containers. Storage
Temperature: 0 - 50°C / 32 - 122°F
Recommended Materials : For containers or container linings, use mild steel or high
density polyethylene.
Unsuitable Materials : PVC.
Additional Information : Polyethylene containers should not be exposed to high
temperatures because of possible risk of distortion.
Storage class: 10
Fire hazard classification: B
8. EXPOSURE CONTROLS/PERSONAL PROTECTION
If the American Conference of Governmental Industrial Hygienists (ACGIH) value is provided on

this document, it is provided for information only.
Occupational Exposure Limits
Exposure Controls : The level of protection and types of controls necessary will vary
depending upon potential exposure conditions. Select controls
based on a risk assessment of local circumstances.
Appropriate measures include: Adequate ventilation to control
airborne concentrations. Where material is heated, sprayed or
mist formed, there is greater potential for airborne
concentrations to be generated.
Personal Protective : Personal protective equipment (PPE) should meet
Equipment recommended national standards. Check with PPE suppliers.
Respiratory Protection : No respiratory protection is ordinarily required under normal
conditions of use. In accordance with good industrial hygiene
practices, precautions should be taken to avoid breathing of
material. If engineering controls do not maintain airborne
concentrations to a level which is adequate to protect worker
health, select respiratory protection equipment suitable for the
specific conditions of use and meeting relevant legislation.
Check with respiratory protective equipment suppliers. Where
3/7

Version 1.0
Safety Data Sheet
air-filtering respirators are suitable, select an appropriate

combination of mask and filter. Select a filter suitable for
combined particulate/organic gases and vapours [boiling point
>65 °C (149 °F)] meeting EN14387.
Hand Protection : Where hand contact with the product may occur the use of
gloves approved to relevant standards (e.g. Europe: EN374,
US: F739) made from the following materials may provide
suitable chemical protection: PVC, neoprene or nitrile rubber
gloves. Suitability and durability of a glove is dependent on
usage, e.g. frequency and duration of contact, chemical
resistance of glove material, glove thickness, dexterity. Always
seek advice from glove suppliers. Contaminated gloves should
be replaced. Personal hygiene is a key element of effective
hand care. Gloves must only be worn on clean hands. After
using gloves, hands should be washed and dried thoroughly.
Application of a non-perfumed moisturizer is recommended.
Eye Protection : Wear safety glasses or full face shield if splashes are likely to
occur. Approved to EU Standard EN166.
Protective Clothing : Skin protection not ordinarily required beyond standard issue
work clothes.
Monitoring Methods : Monitoring of the concentration of substances in the breathing
zone of workers or in the general workplace may be required to
confirm compliance with an OEL and adequacy of exposure
controls. For some substances biological monitoring may also
be appropriate.
Environmental Exposure : Minimise release to the environment. An environmental
Controls assessment must be made to ensure compliance with local
environmental legislation.
9. PHYSICAL AND CHEMICAL PROPERTIES
Appearance : Amber. Liquid at room temperature.

Odour : Slight hydrocarbon.
pH : Not applicable.
Initial Boiling Point and : > 280 °C / 536 °F estimated value(s)
Boiling Range
Pour point : Typical -42 °C / -44 °F
Flash point : Typical 252 °C / 486 °F (COC)
Lower / upper Flammability : Typical 1 - 10 %(V)
or Explosion limits
Auto-ignition temperature : > 320 °C / 608 °F
Vapour pressure : < 0,5 Pa at 20 °C / 68 °F (estimated value(s))
Density : Typical 883 kg/m3 at 15 °C / 59 °F
Water solubility : Negligible.
n-octanol/water partition : > 6 (based on information on similar products)
coefficient (log Pow)
Kinematic viscosity : Typical 312,7 mm2/s at 40 °C / 104 °F
Vapour density (air=1) : > 1 (estimated value(s))
Evaporation rate (nBuAc=1) : Data not available
4/7

Version 1.0
Safety Data Sheet
10. STABILITY AND REACTIVITY
Stability : Stable.
Conditions to Avoid : Extremes of temperature and direct sunlight.
Materials to Avoid : Strong oxidising agents.
Hazardous : Hazardous decomposition products are not expected to form
Decomposition Products during normal storage.
11. TOXICOLOGICAL INFORMATION
Basis for Assessment : Information given is based on data on the components and the
toxicology of similar products.
Acute Oral Toxicity : Expected to be of low toxicity: LD50 > 5000 mg/kg , Rat
Acute Dermal Toxicity : Expected to be of low toxicity: LD50 > 5000 mg/kg , Rabbit
Acute Inhalation Toxicity : Not considered to be an inhalation hazard under normal
conditions of use.
Skin Irritation : Expected to be slightly irritating. Prolonged or repeated skin
contact without proper cleaning can clog the pores of the skin
resulting in disorders such as oil acne/folliculitis.
Eye Irritation : Expected to be slightly irritating.
Respiratory Irritation : Inhalation of vapours or mists may cause irritation.
Sensitisation : Not expected to be a skin sensitiser.
Repeated Dose Toxicity : Not expected to be a hazard.
Mutagenicity : Not considered a mutagenic hazard.
Carcinogenicity : Components are not known to be associated with carcinogenic
effects.
Reproductive and : Not expected to be a hazard.
Developmental Toxicity
Additional Information : Used oils may contain harmful impurities that have
accumulated during use. The concentration of such impurities
will depend on use and they may present risks to health and
the environment on disposal. ALL used oil should be handled
with caution and skin contact avoided as far as possible.
12. ECOLOGICAL INFORMATION
Ecotoxicological data have not been determined specifically for this product. Information given is
based on a knowledge of the components and the ecotoxicology of similar products.
Acute Toxicity : Poorly soluble mixture. May cause physical fouling of aquatic
organisms. Expected to be practically non toxic: LL/EL/IL50 >
100 mg/l (to aquatic organisms) (LL/EL50 expressed as the
nominal amount of product required to prepare aqueous test
extract).
Mobility : Liquid under most environmental conditions. Floats on water. If
it enters soil, it will adsorb to soil particles and will not be
mobile.
Persistence/degradability : Expected to be not readily biodegradable. Major constituents
are expected to be inherently biodegradable, but the product
contains components that may persist in the environment.
5/7

Version 1.0
Safety Data Sheet
Bioaccumulation : Contains components with the potential to bioaccumulate.
Other Adverse Effects : Product is a mixture of non-volatile components, which are not
expected to be released to air in any significant quantities. Not
expected to have ozone depletion potential, photochemical
ozone creation potential or global warming potential.
13. DISPOSAL CONSIDERATIONS
Material Disposal : Recover or recycle if possible. It is the responsibility of the

waste generator to determine the toxicity and physical
properties of the material generated to determine the proper
waste classification and disposal methods in compliance with
applicable regulations. Do not dispose into the environment, in
drains or in water courses.
Container Disposal : Dispose in accordance with prevailing regulations, preferably to
a recognised collector or contractor. The competence of the
collector or contractor should be established beforehand.
Local Legislation : Disposal should be in accordance with applicable regional,
national, and local laws and regulations.
EU Waste Disposal Code (EWC): 13 02 06 synthetic engine,
gear and lubricating oils. Classification of waste is always the
responsibility of the end user.
14. TRANSPORT INFORMATION
ADR
This material is not classified as dangerous under ADR regulations.
RID
This material is not classified as dangerous under RID regulations.
ADNR
This material is not classified as dangerous under ADNR regulations.
IMDG
This material is not classified as dangerous under IMDG regulations.
IATA (Country variations may apply)

This material is not classified as dangerous under IATA regulations.
15. REGULATORY INFORMATION
The regulatory information is not intended to be comprehensive. Other regulations may apply to this
material.
EC Classification : Not classified as dangerous under EC criteria.

6/7

Version 1.0
Safety Data Sheet
EC Symbols : No Hazard Symbol required

EC Risk Phrases : Not classified.
EC Safety Phrases : Not classified.
Chemical Inventory Status
EINECS : All components
listed or polymer
exempt.
TSCA : All components
listed.
National Legislation
Water Pollution Class : WGK 1 - low hazard to waters (appendix 4, VwVwS,

preparations).
Sensitiser not sufficient to : Contains alkylamine. May produce an allergic reaction.
classify
Other Information : Technische Anleitung Luft: Product not listed by name.

Observe section 5.2.5 in connection with section 5.4.9
16. OTHER INFORMATION
R-phrase(s)
Not classified.
R22 Harmful if swallowed.
R23/24 Toxic by inhalation and in contact with skin.
R34 Causes burns.
R43 May cause sensitization by skin contact.
R48/20 Harmful: danger of serious damage to health by prolonged exposure through
inhalation.
R50/53 Very toxic to aquatic organisms, may cause long-term adverse effects in the
aquatic environment.
MSDS Version Number : 1.0
MSDS Effective Date : 01/12/2011
MSDS Revisions : A vertical bar (|) in the left margin indicates an amendment
from the previous version.
MSDS Regulation : Regulation 1907/2006/EC
MSDS Distribution : The information in this document should be made available to
all who may handle the product.
Disclaimer : This information is based on our current knowledge and is
intended to describe the product for the purposes of health,
safety and environmental requirements only. It should not
therefore be construed as guaranteeing any specific property
of the product.
7/7
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. For direct---drive operation the pump is equipped with an ela-
stic clutch. Belt and cogwheel drive assemblies as well as axial loads to the shaft are not acceptable. When
installing the pump, the piping assembly connected to it has to be taken into account. Tensions due to incor-
rectly installed tubes or to misalignment of the drive motor should be avoided. Any misalignment of the shaft
should not exceed 0,2 mm. Even if some manufacturers of drive clutches state that a greater misalignment
can be compensated by the clutch, the restoring force of the clutch generates some radial load on the shafts
to be connected, and this may result in damages to the pump. Impacts on the shaft end are not acceptable
at all, as they might result in serious damage to the pump.
Piping assemblies
When designing the size of a piping assembly, at has to be made sure that the acceptable flow speeds will
not be exceeded. In the suction pipe, they should not exceed 1,5 m/sec., and in the pressure pipe they
should not exceed 5 m/sec. (for more details, please consult the manufacturer). Before installation, any
piping assembly should be cleaned carefully. The suction pipe has to be perfectly airproof, and it should
be arranged as straight as possible, its end always being placed a few centimeters below of the minimum
oil level in the tank. The maximum suction lift should be restricted to a maximum of approx. 1 m. For the
piping assembly seamless precision steel tubes as per DIN 2391 are recommended.
Range of viscosity
The range of viscosity at operation should be between 15 and 800 mm2/s, as per graph 1 attached hereto.
The range of use of an oil may be clarified by reading the table of viscosities and temperatures. To this effect,
two viscosity values --- for ex. for 20° and 50° C --- must be entered into the graph. The point of intersection
of the straight line passing through these points, with the lines for maximum and minimum viscosity, indica-
tes the temperature limits of the oil concerned.
Attention: mind lubricant recommendation of manufacturer!
Oil quantity --- Oil temperature

The oil quantity required in the storage tank depends on the conditions of operation. In case of intermittent
operation, a quantity will be satisfactory which corresponds to two times the total flow rate per minute of
the pump. For continous operation, a quantity of oil of 3 or 4 times that reserve has to be provided. The
service temperature should be in the range from ---10° to +80° C (refer to diagram 1). The ideal range of
temperature is from 30° up to 50° C. Under particular circumstances, installation of an oil cooler may be
required in order to keep the temperature within certain limits.
Filtration
It is recommended to install a filter having a maximum mesh size of 0,100 mm and magnetic separating
device. An additional suction filter with a mesh size of 0,100 up to 0,200 mm will protect the pump against
coarse dirt. It should be cleaned at regular intervals in order to prevent the suction vacuum pressure from
falling below the specified limits, as this might lead to damages by cavitation.
D -- 91253 Pegnitz -- Postfach 1320 -- Telefon 09241/729-- 0 -- FAX 09241/72950

K 3000.1091.2 GB
BAIER + KÖPPEL
Maximum pressure
The pump must be protected against excessive pressure, by means of a pressure restrictor valve. Setting
of that pressure restrictor valve effected by using a pressure gauge for control.
Speed --- Sense of rotation

According to the size of the type concerned, the minimum service speed is approx. 500 r.p.m. The nominal
speed is 1400 r.p.m. All performance data stated in the leaflet are based on these ratings. In that leaflet, you
will find also the maximum speeds of the individual types. Normal sense of rotation is clockwise, and marked
by an arrow. When the unit is taken into operation, the correct sense of rotation of the electrical motor should
be checked by turning it ”ON” for a short period of time (maximum 5 seconds) before the line is filled with
fluid for the first time.
Clutch
The diameter tolerance of the shaft end is j6. The diameter tolerance of the clutch hub should be in accordan-
ce to H7.
Start ---up operation

It will be usefull to fill the pump and the suction with pressure fluid by manual rotation, before putting the
motor into operation. After that, the pump should be set to ”supply” condition, by turning the motor ”ON”.
In doing so, watch the fluid level in the tank until bleeding of the system is positively finished, in order to make
sure that the fluid level does not decrease to an amount less than the minimum suction limit. After the first
start---up operation (in depressurized condition), the system should be turned ”OFF” again, in order to allow
separation of air dissolved in the oil. Operation of the pump in pressurized condition is acceptable only if
the pressure fluid does not contain any bubbles.
Maintenance
General
The gear pump is lubricated by the oil and, therefore, does not require any maintenance. Care and service
work are restricted to keeping the hydraulic oil perfectly clean, to checking the oil level and the temperature,
and to cleaning of the filters. In this context we recommend that our detailed instructions for operation and
service of pipe filters should be complied with. In order to preclude any corosion, the pump should be filled
with oil if it is kept on stock for a substantial period of time (more than one year).
Malfunctions and remedies

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

K 3000.1091.3 GB
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. Remove the plug.
1.1.2 Leakage of the suction pipe. Re ---tighten the screwed joints; seal the threads.
1.1.3 Suction pipe is too short, or oil level in the tank Extend the suction pipe,
is too low. top up with oil.
1.1.4 Flow resistance in the suction pipe is too high Increase the tube diameter; straighten the suction pipe;
(excessive depressiopn). clean the suction filter; reduce the intake height.
1.1.5 Wrong sense of rotationof the motor assembly. Correct the sense of rotation.
1.1.6 Pressure pipe closed by the valve, or under Change over the depressurized circulation, or bleed
pre ---load, so that bleeding of the pump is the pump by opening the pressure socket.
impossible.
1.1.7 Excessive viscosity of the pressure fluid, or Fill the system using a pressure fluid, the viscosity of
excessive cooling of the pressure fluid. which is suitable for the service temperature.
1.2 Supply is interrupted even if the drive system is okay.

1.2.1 Destroyed clutch. Replace the clutch.
1.2.2 Pump shaft shorn off. Have the unit repaired by the factory.
1.2.3 Leakage of the suction pipe. Refer to item 1.1.2
1.2.4 Oil level in the tank is lower than the minimum Top up with pressure fluid.
required for suction.
Malfunction No. 2: The pump supplies fluid, but there is lack of pressure,
or pressure is not satisfactory

2.1 Air has entered the suction pipe. Refer to items 1.1.2 and 1.1.3
2.2 Pressure relief valve does not close as it is Clean the pressure relief valve,
damaged, or the spring is broken. or replace the defective spring.
2.3 Bresakage of tube underneath the tank cover, Repair the defectiveness.
or threaded tube connections not tightened in
the proper way.
2.4 Substantial wear of the pump. Have the pump repaired by the factory.

K 3000.1091.4 GB
BAIER + KÖPPEL
Malfunction No. 3: Excessive pump noise

3.1 Air is taken in by the pump. Refer to items 1.1.2 and 1.1.3
3.2 Defective shaft seal. Install a new shaft seal.
3.3 Cavitation in the pump. Refer to items 1.1.4 and 1.1.7
3.4 Clutch is defective or misaligned. New clutch, or re ---align the clutch.
3.5 Pump is defective. Have the pump repaired by the factory.
Graph 1
Viscosity mm2/s ( cSt )

800
600
500
400
300
200
150
100
90
80
70
60
50
40
30
25
20
15
--- 30 --- 20 --- 10 0 10 20 30 40 50 60 70 80 90 100 110 120 130
Temperature ( ° C )


Operating Instructions: High Pressure Pump

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Operating Instructions: High Pressure Pump

Uploaded by

Copyright:

Available Formats

Operating instructions

High pressure pump

Hammelmann Maschinenfabrik GmbH

Order no. KA 162384

Hammelmann Maschinenfabrik GmbH

Note : Ps = Pressure step

Parts list to machine no: B3.01382.0011

Pos Code - No. Description Quantity Unit

Druckregelautomatik Eingangsdrehzahl / Motordrehzahl

Anzahl der Tellerfedern Mediumdruck

Sicherheitsventil / Berstscheibensicherung Ansprechdruck

Überlast E-Motor Gesamtlaufzeit – Std.

Schaltschrank (ohne Pumpenüberwachung) unter Last

No. Name Date Time IR-Temp IR-Min IR-Max Material Name

Qualitätsprüfung Der Abnahmeingenieur Datum

Unterschrift / Signature T.Hundsrucker 07.05.2013

QC - 049/05.08 Seite 1 von 1

Einbauerklärung Declaration of Incorporation Déclaration d’incorporation

Diese unvollständige Maschine darf erst

EG-Richtlinie 2004/108/EG E.C. Directive 2004/108/EC Directive CE sur la comptabilité

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

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

Hersteller-Unterschrift Manufacturer’s signature Signature du fabricant

Datum / Date / Date Geschäftsführer Managing director Gérant

High pressure pump

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

7 Construction & Description ........................................................................................................................... 17

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

Copyright Hammelmann Maschinenfabrik GmbH

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

10 Shut down ....................................................................................................................................................... 30

Copyright Hammelmann Maschinenfabrik GmbH

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

11.9.1 Disassembly ....................................................................................................................................... 46

12 Pressure regulating valve 00.05893.0032 ..................................................................................................... 53

13 Safety notes for high pressure hoses .......................................................................................................... 63

Copyright Hammelmann Maschinenfabrik GmbH

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

Pos : 1 /T ec hnis che D aten/Zu di es er Anlei tung/Übersc hrift @ 0\mod7_2.doc @ 1204 @ 1 @ 1

Manufacturer and customer services address:

Type: HDP 382

Serial no.: B3.01382.0011

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

Copyright Hammelmann Maschinenfabrik GmbH

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

3.1 Performance Data: High pressure pump

 Average piston speed at a crank shaft r.p.m. of:

 340 1/min. 0,86 m/sec.

Pos : 8 /xxxxxxx xxxxxx xxxxxx @ 0\mod6_2.doc @ 1188 @ @ 1

Copyright Hammelmann Maschinenfabrik GmbH

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

3.2 Main dimensions

Copyright Hammelmann Maschinenfabrik GmbH

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

Weight of the pump approx.: 1690 kg

Copyright Hammelmann Maschinenfabrik GmbH

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

Pos : 11 /Sic herheit/Ü berschrift @ 0\mod9_2.doc @ 1220 @ 1 @ 1

4.1 Dangers arising from non observance of safety instructions

4.2 Safety conscious working

4.3 Personnel qualification and training

4.4 Precise safety instructions for the operator

Copyright Hammelmann Maschinenfabrik GmbH