Operating instructions High pressure pump unit HDP 502 / S 1100-50 B7.02502.0210 HDP 502 / S 1100-50 2017 Made in Germany Issue: 03.2017 MACHINE CARD Hammelmann GmbH POB 3309, D-59282 Oelde, Germany mail to: mail@hammelmann.de http://www.hammelmann.de Page: 1 Machine no. : B7.02502.0210 Order no. KA 222274 Purchaser Waterkracht B.V., Varsseveld / NL Client no. 10147901 P. O. no./Date I00010227 - Doornbos / 22.11.2016 Machine no. B7.02502.0210 Pump type HDP 502 S 1100 - 50 Code no. 09.63502.9002 Performance data Flow rate Ps 1 l/min 262 Operating pressure Ps 1 bar 1000 Motor speed Ps 1 1/min 1800 Crankshaft speed Ps 1 1/min 465 Piston dia. Ps 1 mm 50 Motor rating req'd Ps 1 kW 478 Performance data diesel engine Make Volvo Type TAD 1672 VE Stufe IV / Tier 4 Final motor no. 2016102431 Voltage V 24 Rating kW 515 R.P.M. 1/min 1800 R.P.M. min. 1/min 900 Battery no. Battery box no. 04.00190.0006 2 Stück 04.01909.0015 2 Stück Battery voltage V 12 Battery capacity Ah 143 Brief instructions Language englisch Paint colour Pump RAL 1018 Frame RAL 7043 Motor Lieferzustand Container RAL 9016 GL Setting of cut-off switches Suction pressure min. bar 2,0 Suction temperature max. °C 40 Oil pressure min. bar 4,0 Oil temperature pump max. °C 75 Different. pres. of filter max bar 1,2 Air pressure min. bar 5,5 Gearing 1 — Gearing 2 — Name plate high pressure pump Machine no. B7.02502.0210 Type no. 09.63502.9002 Year 2017 Motor rating [kW] kW 478 Speed [1/min] 1/min 1800 MACHINE CARD Hammelmann GmbH POB 3309, D-59282 Oelde, Germany mail to: mail@hammelmann.de http://www.hammelmann.de Page: 2 Machine no. : B7.02502.0210 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 262 Pressure reg. valve Ps 1 00.05865.0146 Oil type PAO ISO VG 320 Oil quantity [l] l 42 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 21.02.2017 Person in charge-Sales M. Lettmann Person in charge Kaldewey Date 22.11.2016 Note : Ps = Pressure step Parts list to machine no: B7.02502.0210 Pos Code - No. Description Quantity Unit 1 00.00027.1085 HIGH-PRESSURE PUMP UNIT HDP502; VOLVO TAD1672 STAGE 4 1,00 pc 2 00.00027.1277 HIGH-PRESSURE PUMP UNIT HDP504; VOLVO TAD1672 TIER4 F. 1,00 pc 10 04.04565.0012 NAMEPLATE 1,00 pc 20 00.00743.2221 PISTON SEAL ASSEMBLY, Packing HDP360 - MC D50, 1.4462 3,00 pc 30 00.02515.0350 LINE SUCTION CHAMBER 1,00 pc 50 00.02145.1239 PUMPHEAD - Duplex HDP360-500 D50-55, 1.4462 1,00 pc 55 00.02518.0018 VENT LINE HDP230/330/350/400/550/360-MC 1,00 pc 60 00.05865.0146 PRESSURE REGULATING VALVE 500 L/MIN , 1200 BAR 1.4462 1,00 pc 61 00.00131.0121 CONNECTION G 1 1/2 A T-PIECE 1,00 pc 62 00.06428.0029 MEMBRANE CYLINDER PN 10; D 130 1,00 pc 63 02.00825.0152 HEXAGON SOCKET HEAD SCREW M 12 x 120 4,00 pc 65 04.02860.0056 PRESSURE GAUGE 0-1600 BAR; NG 100; 1,00 pc 66 04.01561.0107 BLOCK BALL VALVE DN 15; PN 16 1,00 pc 70 00.04062.1000 RUPTURE DISC ASSEMBLY G 1/2 A - G 1/2 - 82,0 LG. 1,00 pc 80 04.00829.0056 PRESSURE SENSOR 0-1600 bar; 4-20 mA; G 1/2 A; 1,00 pc 90 08.00200.9201 DISCHARGE FITTING 1,00 pc 100 01.02981.0553 DOUBLE NIPPLE M48X2 - M36X2,0 - 78,0 LG. 1,00 pc 110 04.00742.0048 SEAL RING 36,0 X 30,0 X 3,0 1,00 pc 130 01.04838.0203 SCREW PLUG M48 x 2 1,00 pc 140 04.00742.0050 SEAL RING 42,0 x 36,0 x 3,0 1,00 pc 300 00.00026.1238 UNIT HDP500; VOLVO TAD1672 STUFE 4 1,00 pc 310 04.06200.0031 ANGLE 90°; R 1/4; PN 16 2,00 pc 320 00.02515.0173 OVERFLOW LINE 1,00 pc 330 00.02515.0315 LINE 1,00 pc 335 00.00265.0047 PLATE 1,00 pc 340 04.00995.0129 FILTER BAG 200+10µm,collar dia.=178;L=620 1,00 pc 350 00.05540.0346 WATER TANK 1300L 1,00 pc MACHINE CARD Hammelmann GmbH POB 3309, D-59282 Oelde, Germany mail to: mail@hammelmann.de http://www.hammelmann.de Page: 3 Machine no. : B7.02502.0210 360 04.04611.0065 4,00 m 04.04475.0160 CONNECTION HOSE 3m CLAMP 370 2,00 pc 380 02.01495.0001 SOLID 'C' COUPLING 1,00 pc 390 00.01630.1159 BRACKET 3,00 pc 400 00.05540.0262 FUEL TANK 900L ALU-DIESEL 1,00 pc 405 00.01595.0462 SUPPORT 70L AD-BLUE TANK 1,00 pc 410 08.99109.0050 CONTROL LINE 0-6BAR 1,00 pc 420 04.00829.0093 PRESSURE SENSOR 0-16 BAR; 4-20 mA; G1/4 A; 1,00 pc 430 04.05630.0074 THERMOSTAT 0-100 °C/4-20 mA;G 1/4B; M12x1 1,00 pc 440 00.05630.0012 THERMOSTAT HDP380/500/800/MC 1,00 pc 450 04.01336.0180 CONTROL UNIT ES2 ES2 1,00 pc 460 00.02125.0459 SUPPORT ES-2 1,00 pc 470 00.00640.0234 CONTAINER HDP380-500,20' CONT. KPL 1,00 pc 480 00.00039.0004 KIT FOR DRILLING AGGREGAT; 20'-CONT 1,00 pc 490 00.01880.0065 WEATHER CAP CONTAINER HDP250 1,00 pc 500 00.06020.0143 LIFTING DEVICE PUMP HEAD 1,00 pc 510 00.00753.0015 SOCKET 4-POL 1,00 pc 520 04.04290.0176 SWITCH NOT-AUS 1,00 pc 530 01.03145.0319 PLATE 85 X 85 X 2; BO D40 1,00 pc 540 04.04550.0259 SIGN S1100-50 2,00 pc 550 04.04550.0281 SIGN L=50 2,00 pc >>>end<<< Formblatt FB-K2-11-01 Abnahmeprüfzeugnis / Test Certificate Maschinen-Nr. Machine No. B7.02502.0210 HAMMELMANN GmbH Carl-Zeiss-Str. 6 - 8 Unsere Auftrags-Nr. Our Order No. KA 222274 Bestell-Nr. P. Order No. I00010227 - Doornbos D-59302 Oelde Tel.: +49 (0)2522/76-0 e-mail: mail@hammelmann.de http: www.hammelmann.de Druckregelautomatik Pressure unloader Druckregelventil / Bypassventil Pressure relief valve / Bypass valve Anzahl der Tellerfedern Number of Disc-springs Schichtung der Tellerfedern Spring pack arrangement Distanzhülse / Steuerdruck Washer / Control pressure Sicherheitsventil / Berstscheibensicherung Safety valve / Burst disc Druckwächter Öl Oil pressure switch Druckwächter Medium Medium pressure switch Überlast E-Motor Overload E-Motor Schaltschrank (ohne Pumpenüberwachung) Switchboard (without pump control unit) Schaltschrank (Überwachungsgerät, Pumpe-Motor) Switchboard (control unit, pump-motor) Betriebsstundenzähler Operating hours counter Bypasssteuerventil Bypass solenoid valve Umschaltventil / Magnetventil Multi tool valve / Changeover valve / nicht vorhanden / not installed Medium geprüft / tested Thermostat Öl / Oil Eingangsdrehzahl / Motordrehzahl Input speed / Motor r.p.m. min-1 00.05865.0146 + Öldruck 00.06428.0029 Oil pressure bar Mediumdruck ---------------------------------------Medium pressure bar Fördermenge ---------------------------------------Output m 3 /h l/min Plungerkühlwasser 3,1 bar Pisten cooling water l/min / °C Ansprechdruck / / Opening Pressure bar E-Motor ex D-Motor Antriebsleistung Motor rating kW ---------------------------------------- / 1800 8,0 1000 264 11,6 / 32°C 1400 50 Hz 60 Hz 478 Stromaufnahme (Prüfraum) A Power consumption (Testroom) Volt / Hz / Gesamtlaufzeit – Std. 1,75 Total – Test – Time hr. unter Last under Load Std./hr. 1,5 Geprüft nach EG-Maschinenrichtlinie Gerätesicherheitsgesetz ja / yes Tested in accordance with E.U. Machine nein / no Regulations governing operational safety of equipement. ja / yes Druckwächter Luft Air pressure sensor nein / no Kühlwassermenge 20 Cooling water quantity Ltr./ min. Temperaturmessung nach Erreichen der Beharrungstemperatur Temperature measurement only when steady state temperature reached Nr. 1 2 3 4 5 6 7 8 9 10 11 12 Name TS1 Temp.Cranks.bear TS2 Temp.Cranks.bear TS3 Driveshaft bear. TS4 Driveshaft bear. TS5 Oiltemperature TS6 Oil Cooler out TS7 Coolingwater inl TS8 Coolingwater out TS9 Crank sec.gener. TS10 Temp.Pisten TS11 Temp.Crosshead TS12 Ambient Temp. Qualitätsprüfung Quality Control Datum 06.03.2017 06.03.2017 06.03.2017 06.03.2017 06.03.2017 06.03.2017 06.03.2017 06.03.2017 06.03.2017 06.03.2017 06.03.2017 06.03.2017 Zeit IR-Temp IR-Min IR-Max Mat. Name 13:54:43 56,2 56,2 56,4 Free 13:54:45 55,9 55,9 56,1 Free 13:54:47 56,4 56,4 56,4 Free 13:54:52 57,4 57,2 57,5 Free 13:55:00 52,8 52,8 53,5 Free 13:55:06 43,8 43,5 43,8 Free 13:55:09 28,2 28,2 28,5 Free 13:55:18 33,9 33,9 34,6 Free 13:55:22 53,3 53,1 53,8 Free 13:55:26 33,8 33,4 34,8 Free 13:55:28 54,9 54,7 54,9 Free 13:55:34 8,7 8,7 9,3 Free Der Abnahmeingenieur Test-Engineer Datum Date J. Vöge 07.03.2017 Name: Unterschrift / Signature Dokument wurde auf elektronischem Wege erstellt und ist ohne Unterschrift gültig. This message was electronically generated and is valid without a signature. FB-U3-05-00 Ausgedruckte Exemplare unterliegen nicht der Dokumentenlenkung. Die aktuelle Version befindet sich immer auf dem Server. 1 von 1 HAMMELMANN GmbH Carl-Zeiss-Straße 6-8 59302 Oelde • Germany EG-Konformitätserklärung nach EG-Richtlinie 2006/42/EG, Anhang II, Nr. 1A EC-Declaration of Conformity according to E.C. Directive 2006/42/EC, Appendix II, No 1A Hiermit erklären wir, dass die nachstehend bezeichnete Maschine in ihrer Konzipierung und Bauart sowie in der von uns in Verkehr gebrachten Ausführung den grundlegenden Sicherheits- und Gesundheitsanforderungen der EG-Richtlinie 2006/42/EG (MaschinenRichtlinie) entspricht. We hereby declare that the machine detailed below has been designed, constructed and tested to fully comply with the health and safety requirements of the E.C. Directive 2006/42/EC (Directive relating to Machinery). Déclaration de conformité CE conformément à la directive CE sur les machines 2006/42/CE, Annexe II, N° 1A Par la présente, nous déclarons que la conception et la construction ainsi que le modèle mis en circulation de la machine cidessous correspondent aux exigences de base en matière de sécurité et de santé de la directive 2006/42/CE sur les machines. 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 A zusammenzustellen. according to Annex VII A. technique conformément à l’annexe VII A. Hochdruckpumpenaggregat HDP 502 High pressure pump unit HDP 502 Groupe de pompe à haute pression HDP 502 Bezeichnung der Maschine: Machine description: Désignation de la machine: Maschinentyp: Machine designation: 09.63502.9002 Type de machine: Maschinen-Nr.: B7.02502.0210 Machine No.: No de machine: Weitere, zutreffende EG-Richtlinien: Other appropriate E.C. Directives: Autres directives CE concernées: EG-Richtlinie 2014/30/EU (EMV-Richtlinie) E.C. Directive 2014/30/EU (EMC directive) Directive CE sur la comptabilité électromagnétique 2014/30/EU Angewandte harmonisierte Normen: Used harmonised standards: Normes harmonisées appliquées: EN 809 EN 1829-1 Angewandte nationale Normen und technische Spezifikationen: EN 60204-1 National standards and technical specifications: - EN 61000-6-2 Normes nationales et spécifications techniques appliquées: - Hersteller-Unterschrift Manufacturer’s signature Signature du fabricant Geschäftsführer General Manager Gérant Funktion des Unterzeichners Position of Signatory Fonction du signataire TB 008/0106 07.03.2017 Datum / Date / Date Operating instructions High pressure pump unit HDP 502 / S 1100-50 HDP 502 / S 1100-50 2017 Made in Germany Issue: 03.2017 Operating instructions No.: HDP 502 / S 1100-50 Contents Page 2, Issue: 03.2017 1 Contents 1 Contents ............................................................................................................................................................ 2 2 Foreword ........................................................................................................................................................... 5 3 3.1 3.2 3.3 3.4 Technical data ................................................................................................................................................... 6 Main dimensions .......................................................................................................................................... 6 Performance data: High pressure pump ...................................................................................................... 8 Performance data: Diesel engine................................................................................................................. 8 Batteries ....................................................................................................................................................... 8 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 Safety ................................................................................................................................................................. 9 Dangers arising from non observance of safety instructions ....................................................................... 9 Safety conscious working ............................................................................................................................ 9 Personnel qualification and training ............................................................................................................. 9 Precise safety instructions for the operator ................................................................................................. 9 Danger symbol ........................................................................................................................................... 11 Safety during inspection, maintenance and repair ..................................................................................... 12 Forbidden practices ................................................................................................................................... 12 Additional warnings .................................................................................................................................... 12 5.1 5.2 5.3 5.4 5.5 General.............................................................................................................................................................13 Introduction ................................................................................................................................................ 13 Application.................................................................................................................................................. 13 General permissible operational conditions ............................................................................................... 13 Copyright .................................................................................................................................................... 14 Warranty terms........................................................................................................................................... 14 6.1 6.2 6.3 6.4 Transportation ................................................................................................................................................15 Packing ...................................................................................................................................................... 15 Transportation ............................................................................................................................................ 16 Transport .................................................................................................................................................... 16 Protection ................................................................................................................................................... 16 4 5 6 7 Construction & Description ...........................................................................................................................17 7.1 Construction ............................................................................................................................................... 17 7.1.1 Layout of the S1100- 50 (basic) ............................................................................................................. 17 7.2 Description ................................................................................................................................................. 20 7.2.1 General Description of the High pressure pump .................................................................................... 20 7.2.2 Crank section with pressurised lubrication system ................................................................................ 20 7.2.3 Piston seal assembly ............................................................................................................................. 20 7.2.4 Pump head ............................................................................................................................................. 20 7.2.5 Pressure regulating and overflow valve ................................................................................................. 22 7.2.6 The burst disc assembly (safety devices) .............................................................................................. 22 7.2.7 Electronic safety cut out ......................................................................................................................... 23 7.2.8 High pressure installation ....................................................................................................................... 23 7.2.9 Suction side installation ......................................................................................................................... 23 7.2.10 Container (if fitted).............................................................................................................................. 23 7.2.11 Dieselengine Volvo TAD 1672 VE St. IV Tier 4 final ......................................................................... 23 7.2.12 ES 2 control unit ................................................................................................................................. 24 7.3 Exhaust after treatment .............................................................................................................................. 24 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Contents Operating instructions No.: HDP 502 / S 1100-50 Page 3, Issue: 03.2017 7.3.1 7.3.2 7.3.3 7.3.4 Electronic pressure transmitter 04.00829.0093 ...................................................................................... 26 Electronic pressure transmitter 04.00829.0056 ...................................................................................... 27 Solenoid Valve 04.05875.0107 ............................................................................................................... 28 Electronic temperature transmitter 04.05630.0074 ................................................................................ 29 8 Installation & Start up .................................................................................................................................... 30 8.1 Pre-start checks .......................................................................................................................................... 30 8.2 Installation of pump connections ................................................................................................................ 30 8.2.1 Calculating the hose internal diameter (DN) ........................................................................................... 31 8.2.2 Notes on installation of connecting armatures........................................................................................ 34 8.3 Connecting the high pressure hose(s) ........................................................................................................ 36 9 Operation ......................................................................................................................................................... 38 9.1 Start up ....................................................................................................................................................... 38 9.1.1 Warm up and system checks.................................................................................................................. 38 9.1.2 To start the high pressure pump unit ...................................................................................................... 39 9.2 To start the high pressure pump unit .......................................................................................................... 40 9.3 Operating the system .................................................................................................................................. 40 10 Shut down ....................................................................................................................................................... 42 10.1 Stopping the unit ......................................................................................................................................... 42 10.2 Overnight shut down ................................................................................................................................... 42 10.3 Exhaust after treatment .............................................................................................................................. 42 10.4 Extended shut down ................................................................................................................................... 43 10.4.1 Draining the unit .................................................................................................................................. 43 10.4.2 Venting air from the system after draining for first operation .............................................................. 43 10.4.3 To fill system ....................................................................................................................................... 43 10.4.4 Further actions .................................................................................................................................... 45 10.4.5 Hoses .................................................................................................................................................. 45 10.4.6 Accessories......................................................................................................................................... 45 11 Maintenance .................................................................................................................................................... 46 11.1 Fault finding and remedy ............................................................................................................................ 46 11.1.1 Annunciated faults .............................................................................................................................. 46 11.1.2 Observed faults ................................................................................................................................... 46 11.1.3 Electrical faults .................................................................................................................................... 48 11.2 Maintenance ............................................................................................................................................... 48 11.2.1 Daily inspection and control ................................................................................................................ 48 11.2.2 Maintenance of the water filter............................................................................................................ 48 11.2.3 Checks during operation ..................................................................................................................... 49 11.3 Maintenance of the air pressure installation ............................................................................................... 50 11.3.1 Compressed air tank (if supplied) ....................................................................................................... 50 11.3.2 Compressed air filter ........................................................................................................................... 50 11.4 Oil change ................................................................................................................................................... 51 11.4.1 First oil change after 1000 operating hours ........................................................................................ 51 11.4.2 Next oil changes ................................................................................................................................. 52 11.4.3 Lubrication including oil filter ............................................................................................................... 53 11.4.4 Oil pressure adjustment ...................................................................................................................... 55 11.5 Repair & Replacement ................................................................................................................................ 55 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions No.: HDP 502 / S 1100-50 Contents Page 4, Issue: 03.2017 11.5.1 Replacing the rupture disc up to 1500 bar operating pressure .......................................................... 56 11.6 Maintenance of the pump head 00.02145.1239 (-003) ............................................................................. 57 11.6.1 Disassembly (ref. to fig. pump head) ................................................................................................. 57 11.6.2 Assembling (ref. to fig.: Pump head).................................................................................................. 59 11.7 Maintenance of the piston seal assembly: 00.00743.2221 (-004) ............................................................. 61 11.7.1 Disassembly ....................................................................................................................................... 61 11.7.2 Reassembly ....................................................................................................................................... 62 11.1 Changing the bellows ................................................................................................................................. 65 11.2 Changing or adjusting the boost pump drive belt ...................................................................................... 66 11.3 Torque tables ............................................................................................................................................. 66 12 Pressure regulating valve 00.05865.0146 .....................................................................................................67 Technical Data ....................................................................................................................................................... 68 12.1 Installation (ref. to fig.: Pressure regulating valve) ..................................................................................... 68 12.2 Adjustment ................................................................................................................................................. 68 12.3 Maintenance............................................................................................................................................... 69 13 Safety notes for high pressure hoses ..........................................................................................................74 13.1 Before using the hose ................................................................................................................................ 75 13.2 Use of the hose .......................................................................................................................................... 75 14 Index.................................................................................................................................................................76 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions Foreword No.: HDP 502 / S 1100-50 Page 5, Issue: 03.2017 Pos : 1 /T ec hnis che D aten/Zu di es er Anlei tung/Ü bersc hrift @ 0\mod7_2.doc x @ 1204 @ 1 @ 1 2 Foreword Pos : 2 /T ec hnis che D aten/Zu di es er Anlei tung/Hinweis @ 0\mod3_2.doc x @ 1208 @ @ 1 All personnel who are responsible for the operation and maintenance of the High pressure pump unit HDP 502 / S 1100-50 must: Read and fully understand these instructions, especially the section “Safety“ 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/H erstell eradres se @ 0\mod4_2.doc x @ 1212 @ @ 1 Manufacturer and customer services address: HAMMELMANN GmbH Carl Zeiss Straße 6 - 8 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 x @ 1216 @ @ 1 Pos : 5 /xxxxxxx xxxxxx xxxxxx @ 0\mod6_2.doc x @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Type: HDP 502 / S 1100-50 Serial no.: B7.02502.0210 Date: 2017 Operating instructions No.: HDP 502 / S 1100-50 Technical data Page 6, Issue: 03.2017 Pos : 6 /T ec hnis che D aten/Übersc hrift @ 0\mod8_2.doc x @ 1196 @ 1 @ 1 3 Tech nical dat a Pos : 7 /T ec hnis che D aten/Pumpen/HD P 500/H auptabmes sungen HD P 500 neu @ 9\mod_1360049466827_2.doc x @ 73883 @ 2 @ 1 3.1 Main dimensions Fig.: 1 Main dimensions of the high pressure pump Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Technical data Operating instructions No.: HDP 502 / S 1100-50 Page 7, Issue: 03.2017 Weight of the pump: approx. 1985 kg Pos : 8 /xxxxxxx xxxxxx xxxxxx @ 0\mod6_2.doc x @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions Technical data No.: HDP 502 / S 1100-50 Page 8, Issue: 03.2017 Pos : 9 /T ec hnis che D aten/S1200-50/S 1100-50; 262L,1000bar,1800U,478kW,Vol vo T AD 1672 Stufe IV Tier 4fi nal @ 13\mod_1432713659524_2.doc x @ 116631 @ 222 @ 1 3.2 Performance data: High pressure pump HAMMELMANN High pressure pump HDP 502 Type: Pressure step 1 Flow rate V: 262 l/min. Operating pressure p: 1000 bar Motor speed: 1800 1/min. Crankshaft speed nku: 465 1/min. Piston / Plunger dia. dko: 50 mm Power rating req’d.: 478 kW Rod force: 200 000 N Stroke: 100 mm Weight approx.: 1900 kg 3.3 Performance data: Diesel engine Type: Volvo Type: TAD 1672 VE St. IV Tier 4final Power rating P: 515 kW R.P.M. nmot: 1900 1/min. Engine size: 16100 cm ³ Engine type: 4 stroke direct injection diesel Cylinder Z: 8 Weight approx.: 1650 kg 3.4 Batteries Number of: 2 Volts U: 2 x 12 V = 24 V Capacity Q: 2 x 143 Ah Pos : 10 /xxxxxxxxx xxxxxx xxxx @ 0\mod6_2.doc x @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Safety Operating instructions No.: HDP 502 / S 1100-50 Page 9, Issue: 03.2017 Pos : 11 /Sic herheit/Ü berschrift @ 0 \mod9_2.doc x @ 1220 @ 1 @ 1 4 Saf et y Pos : 12 /Sic herheit/Pumpen @ 0\mod10_2.doc x @ 1224 @ 22222222 @ 1 4.1 Dangers arising from non observance of safety instructions Using the most modern manufacturing techniques HAMMELMANN produce high pressure equipment which is subject to stringent Quality, Function and Safety tests. Even so, improper or unsuitable use of high pressure equipment, or operation by untrained personal can result in accidents leading to: 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 attention 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. Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions Safety No.: HDP 502 / S 1100-50 Page 10, Issue: 03.2017 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. Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions Safety No.: HDP 502 / S 1100-50 Page 11, Issue: 03.2017 Causes of danger are, the jet (cutting power). spray mist (with dangerous chemical additives). loose debris or other items picked up and projected by the force of the jet. 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. Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions Safety No.: HDP 502 / S 1100-50 Page 12, Issue: 03.2017 4.6 Safety during inspection, maintenance and repair The owner shall be responsible for ensuring that all inspection, maintenance and repair works are carried out by competent, fully trained personnel. He shall also ensure that said personnel have read and fully understood this manual. 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. Pos : 13 /xxxxxxxxx xxxxxx xxxx @ 0\mod6_2.doc x @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 General Operating instructions No.: HDP 502 / S 1100-50 Page 13, Issue: 03.2017 Pos : 14 /Allgemeines /Übersc hrift @ 0\mod150_2.doc x @ 1340 @ 2 @ 1 5 Gen er al Pos : 15 /Allgemeines /Pumpen/1. Einl eitung @ 0\mod425_2.doc x @ 4548 @ 2 @ 1 5.1 Introduction Your HAMMELMANN High pressure pump is the product of many years of research, development and testing in the field of high pressure manufacture. 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 x @ 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 x @ 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 m 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! Pos : 18 /xxxxxxxxx xxxxxx xxxx @ 0\mod6_2.doc x @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions General No.: HDP 502 / S 1100-50 Page 14, Issue: 03.2017 Pos : 19 /Allgemeines /Pumpen/4. Ur heberrec ht @ 0\mod428_2.doc x @ 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 x @ 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 (e.g. for change of adjustments). The high pressure pump was used with accessories or fitted with spare parts not supplied by HAMMELMANN. If the damage is caused by: 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. Pos : 21 /xxxxxxxxx xxxxxx xxxx @ 0\mod6_2.doc x @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions Transportation No.: HDP 502 / S 1100-50 Page 15, Issue: 03.2017 Pos : 22 /Allgemeines /Trans port/Übersc hrift Tr ans port @ 0\mod218_2.doc x @ 1348 @ 2 @ 1 6 Tran sport ation Pos : 23 /Allgemeines /Trans port/Trans port Container-Anlagen @ 4\mod_1193824702949_2.doc x @ 20097 @ 2222 @ 1 6.1 Packing Method of packing is determined by method of transport. Fundamentally the pumps and pump aggregates are packed so that they are protected from influences of the environment and transportable. Pay attention to the symbols on the packing, i.e.: This way up Keep away from heat Sling here Keep away from wetness Fragile Centre of gravity Do not add the sack barrow here Use no hand hooks Do not use forklifts or similar transportation units. Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions No.: HDP 502 / S 1100-50 Transportation Page 16, Issue: 03.2017 6.2 Transportation Normally the diesel driven units are supplied without fuel in the tank. The pump and the engine can be drained of the lubricating oil and the cool water after a test procedure. Pay attention to the hints and markings at the system. There are transport arresters fixed to prevent a draining of the fuels. 6.3 Transport In principle applies: Only transport high pressure pump units with empty water tank! Lifting from container units: At the upper lifting points, only with suitable cross beams at the lifting device (crane)! At the lower lifting points, with suitable chains and cross beams at the lifting device (crane)!. See also following sketches. 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 into all water leading parts and into the pistons, plungers, pump heads and other metallic shining parts. That means that a anti-corrosion emulsion is flowed through the pump for a few minutes and the shining parts are sprayed with Optimol D + F. When starting up this procedure has a positive effect because the spraying, i.e. of the piston with Optimol F + D has the effect of lubricating these parts when starting up and this reduces wearing. The anti-corrosion emulsion in the internal of the pump is rinsed after a short operating time and id does not have a negative effect on the cleaning function of the high pressure water. This anti-corrosion emulsion is sufficient for the transport from the factory to the customer. A second protection is necessary if the pumps/ pump units are stored for a longer time. Please ask your HAMMELMANN agent for advice and turn directly to our Hammelmann customer services. The procedure of a second protection can be seen in section "shut down" (paragraph "longer shut downs") of this manual. Pos : 24 /xxxxxxxxx xxxxxx xxxx @ 0\mod6_2.doc x @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Construction & Description Operating instructions No.: HDP 502 / S 1100-50 Page 17, Issue: 03.2017 Pos : 25 /Aufbau und Besc hrei bung/Ü bers chrift @ 0\mod155_2.doc x @ 1372 @ 1 @ 1 7 Constru ction & Description Pos : 26 /Aufbau und Besc hrei bung/Ü bers chrift Konstrukti ver Aufbau @ 0\mod156_2.doc x @ 1376 @ 1 @ 1 7.1 Construction Pos : 27 /Aufbau und Besc hrei bung/S 1100-50/Konstr ukti ver Aufbau HDP 502 Vol vo T AD 1672 Stufe IV Tier 4 final @ 16\mod_1461135163216_2.doc x @ 193913 @ 3 @ 1 7.1.1 Layout of the S1100- 50 (basic) Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions No.: HDP 502 / S 1100-50 Construction & Description Page 18, Issue: 03.2017 Item no. Description Item no. Description 1 HAMMELMANN High pressure pump HDP 504 8 Fine filter with air venting 2 Bypass valve 9 Air filter diesel engine 4 Lifting device for pump head 10 Air pressure container 5 Sound absorber 11 Boost pump 6 Batteries 12 Base frame 7 Diesel engine 13 Engine cooler Pos : 28 /xxxxxxxxx xxxxxx xxxx @ 0\mod6_2.doc x @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Construction & Description Operating instructions No.: HDP 502 / S 1100-50 Page 19, Issue: 03.2017 Pos : 29 /Aufbau und Besc hrei bung/Pumpen/H DP 500/Aufbau HD P 502 auss enl . Öl kühler @ 9\mod_1360835858538_2.doc x @ 74268 @ @ 1 Fig.: Construction of high pressure pump HDP 502 Item No. 10 20 30 40 50 60 70 80 90 Description Pump head High pressure discharge Name plate Oil pressure gauge Oil pump Oil pressure regulator Oil filter Oil cooler Oil filler neck Pos : 30 /xxxxxxxxx xxxxxx xxxx @ 0\mod6_2.doc x @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Item No. 100 110 120 130 140 150 160 170 180 Description Drive shaft Oil dip stick Oil drain valve Suction chamber drainage Suction connection Suction chamber Cover plate Mounting holes Leakage connection Operating instructions No.: HDP 502 / S 1100-50 Construction & Description Page 20, Issue: 03.2017 Pos : 31 /Aufbau und Besc hrei bung/Pumpen/H DP 500/Besc hrei bung HDP 502 D oppel keg el ventil @ 9\mod_1349423108726_2.doc x @ 70195 @ 23333 @ 1 7.2 Description 7.2.1 General Description of the High pressure pump The HDP 502 is a compact, three plunger pump containing the unique HAMMELMANN plunger seal assembly. The special advantage of this pump is the high pressure plunger seal which reduces friction losses and wear to an absolute minimum. 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 crankshaft is an assembly made from hardened and tempered steel. The gearwheels are located on the crankshaft from the inner side near by the outer conrods. The storage of the crankshaft 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 crankshaft 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 there 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: Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Construction & Description Operating instructions No.: HDP 502 / S 1100-50 Page 21, Issue: 03.2017 On the upward stroke of the plunger: Suction valve closes, pressure rises to discharge pressure, discharge valve opens, water is emitted via the discharge line. On the downward stroke of the plunger: Discharge valve closes, pressure drops to suction pressure, suction valve opens, water is drawn in from suction chamber. 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 Crankshaft Pos : 32 /xxxxxxxxx xxxxxx xxxx @ 0\mod6_2.doc x @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions Construction & Description No.: HDP 502 / S 1100-50 Page 22, Issue: 03.2017 Pos : 33 /Aufbau und Besc hrei bung/S-Anlagen/Besc hreibung Druc kr egel ventil @ 0\mod157_2.doc x @ 2184 @ 3 @ 1 7.2.5 Pressure regulating and overflow valve The pressure regulating valve/overflow valve allows a smooth setting of operating pressure from admission pressure to max. 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 min. control pressure air required is 5,5 bar. Setting the wished pressure with the pressure regulating valve (manual adjustment) by: Tension the eccentric lever, pump goes to idle speed Turning the adjusting sleeve » Clockwise => increases the pressure, » Anti-clockwise => decreases the pressure. Relieve the eccentric lever means switch on the pressure, pump goes to working speed. Adjusting sleeve 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 : 34 /Aufbau und Besc hrei bung/S-Anlagen/Besc hreibung Berstsc heibe @ 0\mod158_2.doc x @ 2220 @ 3 @ 1 7.2.6 The burst disc assembly (safety devices) The burst disc assembly is fitted as a protection against over pressurising the pump for instance due to pressure pulse or blocked accessory etc. The actual disc is designed to withstand a certain pressure and then if this pressure is exceeded burst, allowing the water pressure to immediately drop to minimum (feed) pressure. The burst discs fitted will always be designed to burst at a pressure 30 % to 40 % higher than the maximum working pressure. Each burst disc assy. is marked with its burst pressure. Pos : 35 /Aufbau und Besc hrei bung/S-Anlagen/Besc hreibung El ektrisc he Sic herheits abs chaltung @ 0\mod159_2.doc x @ 2188 @ 3 @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Construction & Description Operating instructions No.: HDP 502 / S 1100-50 Page 23, Issue: 03.2017 7.2.7 Electronic safety cut out To prevent over pressurisation the electronic system has a cut out circuit set at 10 % above the stated maximum operating pressure. If activated the complete unit will shut down and the pressure optically displayed. This cannot be adjusted by the operator. Pos : 36 /Aufbau und Besc hrei bung/S-Anlagen/H oc hdr uc ki nstallati on @ 0\mod163_2.doc x @ 2196 @ 3 @ 1 7.2.8 High pressure installation The high pressure installation consists of: Pressure fittings, high pressure hose line, high pressure outlet and connection point for hose arrester. Pos : 37 /Aufbau und Besc hrei bung/S-Anlagen/Vordruc kins tall ation @ 0\mod162_2.doc x @ 2228 @ 3 @ 1 7.2.9 Suction side installation The suction side installation consists of: Boost pump Raises the feed water pressure and prevents pressure loss in the filter Ensures that a minimum feed pressure of 3 bar is available preventing cavitation. Header tank The header tank ensures a constant air free supply for the boost pump. It also takes the oil cooler and bypass water. A float switch ensures that the tank is not over filled when the unit is in bypass mode. A drain cock is provided to empty the tank in freezing conditions. Filter Removes abrasive particles from the feed water to prevent wear. Is fitted with an air vent to prevent back pressure build up. Pressure differential sensor Linked to the filter protects the pump against filter blockage. A pressure gauge and low pressure safety cut-out installed at the suction chamber. An automatic air venting valve to prevent blockage by pressure build up. Suction line and connection. Pos : 38 /Auf bau und Besc hrei bung/S-Anlagen/C ontainer @ 0\mod223_2.doc x @ 2212 @ @ 1 7.2.10 Container (if fitted) The container with lockable maintenance doors has louvered to provide ventilation for the diesel. When closed the system is completely protected from the elements and noise level is reduced to 80 db (A) at 1 metre distance. The unit should only be operated with closed doors. Pos : 39 /Aufbau und Besc hrei bung/S-Anlagen/Vol vo TAD 1672 Stufe IV Ti er 4final @ 13\mod_1432714072305_2.doc x @ 116639 @ 3 @ 1 7.2.11 Dieselengine Volvo TAD 1672 VE St. IV Tier 4 final The Volvo TAD 1672 VE is a 6 cylinder, 4 stroke direct injection, water cooled diesel with a high power output from a very comapct construction. Please refer to the engine manual supplied before using your high pressure pump unit. Pos : 40 /xxxxxxxxx xxxxxx xxxx @ 0\mod6_2.doc x @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions Construction & Description No.: HDP 502 / S 1100-50 Page 24, Issue: 03.2017 Pos : 41 /Aufbau und Besc hrei bung/S-Anlagen/Besc hreibung ES2 Bediengerät @ 1\mod956_2.doc x @ 2236 @ 2 @ 1 7.2.12 ES 2 control unit The processor installed controls the complete pump unit, carries out complex control, monitoring and regulating duties and collects data for various diagnostic functions. Hardware Enlarged graphic display Increased reliability and decreased sensitivity by use of encapsulated SMD technology PCB’s Ventilated plastic housing Flash programme store without buffer battery CAN Bus interface e.g. as interface to exchange data with electronically controlled diesel engine Serial line interface to transfer the operating system over a PC or for data transfer Additional analogue inputs Control of up to 5 multi tool valves with status directly indicated in the graphic display Can be expanded to transfer data by SMS or online connection Compact and robust construction Ability to operate under extreme climatic conditions High resistance to electromagnetic interference Software The operating instructions can be accessed from the control as a Help function More languages available as options (e.g. Chinese, Japanese and others) Emergency programme to enable continued operation when sensors/transmitters are faulty. Constantly active safety relevant monitoring Input of parameters and software updates via ES 2 tools Possible to archive the individual parameter sentences in a PC Damage diagnosis and early warning system Uses clearly recognisable graphic symbols to simplify operation Never bridge the ES2 to operate the unit. A system description is given in the ES2 manual. Pos : 42 /Aufbau und Besc hrei bung/S-Anlagen/Abgas nac hbehandlung Vol vo @ 15\mod_1456399519724_2.doc x @ 146332 @ 3 @ 1 7.3 Exhaust after treatment Automatically exhaust after treatment via the engine control unit. 25.2 V 10 0 bar 0 r.p.m. Start display with AdBlue system (e.g. Volvo Stage IIIb/Tier 4i and Stage IV/Tier 4 f. engine) AdBlue fill level display OFF Fig.: Start display Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Construction & Description Operating instructions No.: HDP 502 / S 1100-50 Page 25, Issue: 03.2017 Function of softkey : activate/deactivate ignition. Pressing once will activate the ignition/stoppage magnet, and the symbol will be shown white on black. If pressed again: Ignition to the engine will be turned off. This function does not affect the starting of the engine. If the ignition is switched off (state after ES2 switched on), the ignition/stoppage magnet output will be activated when the start button is pressed, and then the starter with a delay of approx. 1-2 seconds. If the ignition has already been switched on with the key button, the engine can also be started. The ignition output will stay activated. When switching the engine off, the ignition/stoppage magnet output will always be switched off to stop the engine. The softkey can be helpful for engine service technicians, who can sometimes only access the engine control unit when the ignition is switched on. If the ignition is switched on, the level of the AdBlue tank will be displayed. This can prevent the AdBlue tank from overflowing when AdBlue is being topped up. The fill level of the AdBlue tank should not go below 22%. Top up in good time. If this is not done, there may be a reduction in power by the engine control unit. Only switch off the battery main switch about 2 mins after the ES2 has been turned off. During this time, the AdBlue lines are emptied in order to prevent them from becoming blocked up. Pos : 43 /xxxxxxxxx xxxxxx xxxx @ 0\mod6_2.doc x @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions Construction & Description No.: HDP 502 / S 1100-50 Page 26, Issue: 03.2017 Pos : 44 /Aufbau und Besc hrei bung/Sens oren - M agnetventile/Dr uc kmess umformer 04.00829.0093 (16 bar) @ 12\mod_1414075677654_2.doc x @ 95807 @ 3 @ 1 7.3.1 Electronic pressure transmitter 04.00829.0093 Description The electronic pressure transmitter is specially designed for applications in pressurized oil systems, in water supply systems and, using a second pressure transmitter, in water filtering systems. By deflecting a diaphragm the pressure is transformed into an electrical signal which changes in proportion to the pressure. The pressure transmitter requires no maintenance. Specifications Dimension Input Pressure range 0 – 16 bar Burst pressure 75 bar Over pressure safety 32 bar Pressure connection G¼A Mounting torque 20 Nm Wetted parts Stainless steel Output Signal output 4 .. 20 mA Max. ohmic load (kΩ) RL=(UB-8V)/0,02A Accuracy (of span) ≤ ±0,5 % Response time (10..90%) 3 ms Environmental condition Permissible temp. medium -30..+100 °C Perm. temp. ambience -30..+100 °C Miscellaneous Power supply UB 8.. 30 V DC Weight approx. Ca. 80 g Electrical connection Pin connection Connector M 12x1 1 UB Terminal connection 2-wire 2 n.c. Wire gauge 0,14 mm² 3 0V Diameter of cable 3,4 – 4,3 mm 4 n.c. Ingress protection per IEC 60 529 IP67 (Connected with connector with IP 67) Pos : 45 /xxxxxxxxx xxxxxx xxxx @ 0\mod6_2.doc x @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Construction & Description Operating instructions No.: HDP 502 / S 1100-50 Page 27, Issue: 03.2017 Pos : 46 /Aufbau und Besc hrei bung/Sens oren - M agnetventile/Dr uc kmess umformer 04.00829.0056 (1600 bar) @ 9\mod_1346247725379_2.doc x @ 69169 @ 3 @ 1 7.3.2 Electronic pressure transmitter 04.00829.0056 Description The electronic pressure transmitter is specially designed for superior high pressure applications. By deflecting a diaphragm the pressure is transformed into an electrical signal which changes in proportion to the pressure. The cavitation and peak protection extends the operation time. The pressure transmitter requires no maintenance. Specifications Dimension Input Pressure range 0 – 1600 bar Burst pressure 4000 bar Over pressure safety 2300 bar Pressure connection G½B Mounting torque 50 Nm Wetted parts Stainless steel Output Signal output 4 .. 20 mA Max. ohmic load RA(UB-10V)/0,02A Accuracy (of span) ≤ ±0,5 % Response time (10..90%) 1 ms Environmental condition Permissible temp. medium 0..+80 °C Perm. temp. ambience -20..+80 °C Miscellaneous Power supply UB 10.. 30 V DC Weight approx. Ca. 300 g Electrical connection Plug connection L-connector DIN 175301-803A Terminal connection 2-wire Wire gauge Up to 1,5 mm² Diameter of cable 6 – 8 mm Ingress protection per IEC 60 529 IP65 (Connected with female connectors acc. corresponding ingress prot.) Pos : 47 /xxxxxxxxx xxxxxx xxxx @ 0\mod6_2.doc x @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions Construction & Description No.: HDP 502 / S 1100-50 Page 28, Issue: 03.2017 Pos : 48 /Aufbau und Besc hrei bung/Sens oren - M agnetventile/M agnetventil 04.05875.0107 (Heri on) @ 9\mod_1347615268515_2.doc x @ 69729 @ 3 @ 1 7.3.3 Solenoid Valve 04.05875.0107 Description The electromagnetic actuated, directly controlled, 3/2 poppet valve controls amongst others the air supply of control lines in pressure regulating or bypass valve installations. The connector is equipped with a LED to show the switching status. Using any mounting positions, the one with the solenoid vertical should be preferred. Specifications Dimension Valve Nominal diameter DN 5 Working pressure 0 ... 10 bar Direction of flow any Connection G¼A Mounting torque Solenoid 9 1 Nm Mounting torque fixing bolt M4 1,6 + 0,4 Nm Medium Compressed air Solenoid Voltage 24 VDC Power consumption 16,9 W Fluid temperature -25 °C .. +80 °C Ambient temperature -25° C .. +60 °C Miscellaneous Weight approx. Ca. 800 g Electrical connection Switching function Connector EN 175301-803 A 1 Compressed Air Cable Gland PG 11 2 Compressed Air Ingress protection IP65 (With suitable connector) 3 Compressed Air Pos : 49 /xxxxxxxxx xxxxxx xxxx @ 0\mod6_2.doc x @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions Construction & Description No.: HDP 502 / S 1100-50 Page 29, Issue: 03.2017 Pos : 50 /Aufbau und Besc hrei bung/Sens oren - M agnetventile/T hermos tat 04.05630.0074 (0..100 °C) @ 11\mod_1403677348037_2.doc x @ 90901 @ 3 @ 1 7.3.4 Electronic temperature transmitter 04.05630.0074 Description The electronic temperature transmitter is specially designed for applications in pressurized oil and water supply systems. Semiconductors transform the medium temperature into a proportional electric signal. The temperature transmitter requires no maintenance. Specifications Dimension Input Measuring range 0°C .. +100 °C Pressure resistance 40 bar Vibration resistance 3g Pressure connection G¼B Mounting torque 20 Nm Wetted parts Stainless steel Output Signal output 4 .. 20 mA Accuracy (of span) ≤ ±0,1 % Rise time t50 3,3 s Environmental condition Permissible temp. medium -50 °C .. +150 °C Perm. temp. ambience -40°C ..+85 °C Miscellaneous Power supply UB 10 V .. 35 V DC Weight approx. Ca. 100 g Electrical connection Pin connection Connector M 12x1 1 Signal+ Terminal connection 2-wire 2 n.c. Wire gauge Depends on connector 3 Signal- Diameter of cable Depends on connector 4 n.c. Ingress protection per IEC 60 529 IP67 (Connected with connector with IP 67) Pos : 51 /xxxxxxxxx xxxxxx xxxx @ 0\mod6_2.doc x @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions Installation & Start up No.: HDP 502 / S 1100-50 Page 30, Issue: 03.2017 Pos : 52 /Vorber eitung z ur Inbetri ebnahme/Installation/Ü bers chrift @ 0 \mod168_2.doc x @ 1380 @ 1 @ 1 8 Installation & St art up Pos : 53 /Vorber eitung z ur Inbetri ebnahme/Installation/S-Anlagen/Kontrollen vor der Inbetriebnahme @ 0\mod169_2.doc x @ 2256 @ 2 @ 1 8.1 Pre-start checks Check pump oil level and top up if necessary. Never run below min. level. Also check for signs of water (emulsion) in oil. If found do not run the pump. Try and determine the cause. If may be necessary to consult HAMMELMANN or their accredited representative before changing the oil. Check engine oil level and top up if necessary. Never run below min. level. Check condition and tension of belt drives. (Refer to the motor manual) Unscrew the filter housing and check condition. If dirty clean the filter housing and fit new filter cartridge. Pos : 54 /Vorber eitung z ur Inbetri ebnahme/Installation/S-Anlagen/Installati on der Ansc hl uss armaturen @ 0\mod541_2.doc x @ 2292 @ 3 @ 1 8.2 Installation of pump connections 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 suction line is as free as possible of elbows, T-pieces, restrictions and other turbulence causing items. The water flows has a low reed velocity and unhindered flow. Feed velocity: max. 1 m/sec. Needed admission pressure: - min. 3 bar - max. 10 bar Other values require our written permission. Refer to the following diagram to determine the size of suction line. Pos : 55 /xxxxxxxxx xxxxxx xxxx @ 0\mod6_2.doc x @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Installation & Start up Operating instructions No.: HDP 502 / S 1100-50 Page 31, Issue: 03.2017 Pos : 56 /Vorber eitung z ur Inbetri ebnahme/Installation/S-Anlagen/N omogramm @ 0\mod542_2.doc x @ 2296 @ 3 @ 1 8.2.1 Calculating the hose internal diameter (DN) To determine the internal diameter of the hoses refer to the diagram below. (Fig.) 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 Flow velocity in appetence: Suction side: 0.5 m/s Pressure side: 5,0 m/s Not taken into consideration: The resistance of pipes, bends, valves, The viscosity and the effects of temperature on viscosity and other influencing factors. Flow rate depending on the intermediate diameter ID: Following data are normally the rules. DN 10 max. rate of flow 50 l/min DN 12 max. rate of flow 80 l/min DN 20 max. rate of flow 200 l/min DN 25 max. rate of flow 300 l/min DN 32 max. flow rate 500 l/min at a hose length of approx. 20 m. Pos : 57 /Vorber eitung z ur Inbetri ebnahme/Installation/S-Anlagen/Wass erqualitäten @ 0\mod543_2.doc x @ 2300 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions Installation & Start up No.: HDP 502 / S 1100-50 Page 32, Issue: 03.2017 To prolong the life of wearing parts such as valves, nozzles, control pistons etc. it is recommended to: Ensure the medium is as clean as possible, filter out abrasive particles in the medium. (ref. to the water quality for high pressure pumps) Water quality for high pressure pumps Pump seriees Series 1 0-300 bar Series 2 300-1000 bar Series 2 300-1000 bar Series 3 1000-1500 bar Series 4 1500-2500 bar Series 4 2500-4000 bar packing packing dynamic Packing dynamic Packing dynamic tungsten carbide Filtration degree 75 µm 50 µm 10 µm 10 µm 1 µm 1 µm Total hardness * 0 – 20° dH 0 – 20° dH 0 – 20° dH 0 – 20° dH 3 – 15° dH 3 – 15° dH 6,5 – 8,5 6,5 – 8,5 6,5 – 8,5 6,5 – 8,5 6,5 – 8,5 6,5 – 8,5 Max. 1000 µS/cm Max. 1000 µS/cm Max. 1000 µS/cm Max. 1000 µS/cm Max. 1000 µS/cm 300 to 1000 µS/cm Max. content solids 200 mg/l 200 mg/l 50 mg/l 50 mg/l 20 mg/l 20 mg/l Calcium carbonate (CaCo3) max. 350 mg/l 350 mg/l 350 mg/l 350 mg/l 50 – 175 mg/l 50 – 175 mg/l Ammonium (NH4) max. 0,5 mg/l 0,5 mg/l 0,5 mg/l 0,5 mg/l 0,5 mg/l 0,5 mg/l Iron (Fe) max. 0,5 mg/l 0,5 mg/l 0,5 mg/l 0,5 mg/l 0,5 mg/l 0,5 mg/l Chloride (Cl) max. 100 ppm 100 ppm 100 ppm 100 ppm 100 ppm 100 ppm Sulphate (SO4) max. 100 ppm 100 ppm 100 ppm 100 ppm 100 ppm 100 ppm Phosphate (PO3) max. 50 ppm 50 ppm 50 ppm 50 ppm 50 ppm 50 ppm Silicate (SiO2/SiO4) max. 5 mg/l 5 mg/l 5 mg/l 5 mg/l 5 mg/l 5 mg/l Free carbonic acid (CO2) max. 20ppm 20ppm 20ppm 20ppm 20ppm 20ppm Ffree chlorine max. 1 mg/l 1 mg/l 1 mg/l 1 mg/l 1 mg/l 1 mg/l Design seal assembly pH Conductivity * depending on type of particle (hardness) No additives with corrosive effects on nonferrous heavy metals (if to be used consult HAMMELMANN). In certain cases variations from the above may be possible! HAMMELMANN offers suitable filter systems. Pos : 58 /xxxxxxxxx xxxxxx xxxx @ 0\mod6_2.doc x @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions Installation & Start up No.: HDP 502 / S 1100-50 Page 33, Issue: 03.2017 Pos : 59 /Vorber eitung z ur Inbetri ebnahme/Installation/S-Anlagen/H ärtegrade und Ei nheiten @ 0\mod172_2.doc x @ 2280 @ @ 1 Conversion table for the various hardness degrees and units Hardness degrees and units mval/kg german °dH french °f english °e american. ppm mmol/l 28 mg CaO oder 50 mg CaCO3 per 1000 ml water 10 mg CaCO3 per 1000 ml water 10 mg CaCO3 per 1000 ml water 1 gran CaCO3 per gallon 14,3 mg CaCO3 per 1000 ml water 1 part CaCO3 per million 1 mg CaCO3 per 1000 ml water 1000 mg CaCO3 per 1000 ml water 1,0 0,357 0,2 0,286 0,02 2,00 2,8 1,0 0,56 0,8 0,056 5,60 5,0 1,78 1,0 1,43 0,1 10,00 50,0 17,8 10,0 14,3 1,0 100 0,50 0,18 0,10 0,14 0,01 1,0 Definition 1 mval/kg 1o dH 1o f 1o e 1 ppm 1 mmol/l 3,5 1,25 0,7 1,0 0,07 7,02 Pos : 60 /Vorber eitung z ur Inbetri ebnahme/Installation/S-Anlagen/Hi nweis Filter (Ablager ungen) @ 0\mod544_2.doc x @ 2304 @ @ 1 The pump can become contaminated due to: - An extremely high feed velocity. - Connecting a seldom used supply line. - Taking supply from a fire hydrant. Before connecting the supply to the pump allow the water to run freely for a minute or so. Before every starting: Control the water filter in front of the pump regularly for cleanliness and change the filter insert - 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 Never clean the filter insert. Rechange by new. Only use original HAMMELMANN-spare parts! A blocked filter can cause cavitation and damage the pump. Cavitation damages at high pressure pumps are excluded from the guarantee. Pos : 61 /xxxxxxxxx xxxxxx xxxx @ 0\mod6_2.doc x @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions No.: HDP 502 / S 1100-50 Installation & Start up Page 34, Issue: 03.2017 Pos : 62 /Vorber eitung z ur Inbetri ebnahme/Installation/S-Anlagen/Leitungen ansc hliess en neu @ 0 \mod546_2.doc x @ 2312 @ 2 @ 1 8.2.2 Notes on installation of connecting armatures Only put components (high pressure hoses, connections etc.) into the high pressure side if they can withstand the pressure and the flow rate. Look at the registration on the components. Regularly check the high pressure hoses, fittings and jetting (i.e. nozzles, spray bar) for signs of leakage. In the case of leakage stop the high pressure pump system immediately. Remove leakage only when the system is switched off and depressurised. The HDP 502 / S 1100-50 connections for instance are: Suction hose Before connecting the water supply (hose) onto the high pressure pump (suction connection) rinse the suction hose. Remove protective cap from the suction coupling and ensure that the coupling is clean. Let the water run for one minute or so. Then connect the water inlet line with the suction coupling. High pressure hose Remove hose protection from H.P. water 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 hose. The cleaning, greasing and hose arrester procedure should be observed when fitting hose extensions. Separate oil cooler supply Normally oil cooler supply is from the suction chamber but if the suction water is above 35° a separate supply with a lower temperature must be provided. Bypass line Connect the bypass hose/line (onto the pressure regulating or bypass valve). The bypass line is used to dispose of the water when the consumer is closed and the pump is running without pressure. Connect the line with a suitable drain channel or collecting place. Cool water line Connect the cooling water hose. Connect the line with a suitable drain channel or collecting place. Piston cooling Never close off the piston cooling drain hose/line. The cooling water must be enable to flow freely away. If necessary run the hose to a suitable container or similar. Control cable Remove protective cap from electrical connector. Ensure they are clean and dry before connecting. Pneumatically control line Connect the pneumatically control hose (i.e. for pneumatically driven high pressure pistol) onto the push lock connection of the unit. Ensure that connections are in order and clean. Never connect or disconnect control cable when system is > LIVE <. Extremely dangerous! Never tighten up leaky hoses under pressure. Remove leakage only when the system is switched off and depressurised. Pos : 63 /xxxxxxxxx xxxxxx xxxx @ 0\mod6_2.doc x @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions Installation & Start up No.: HDP 502 / S 1100-50 Page 35, Issue: 03.2017 Pos : 64 /Vorber eitung z ur Inbetri ebnahme/Installation/S-Anlagen/Anzugs momente für H oc hdr uc ks chl äuc he @ 0\mod540_2.doc x @ 2288 @ @ 1 Torque for high pressure hoses Nominal diameter [DN] Pressure [bar] 2500 3200 2500 3200 2100 290 530 1250 1600 250 440 5 8 12 10 12 1100 1400 1800 170 340 1000 1000 1400 1600 140 260 700 20 25 Connection fitting Wrench size [mm] Torque [Nm] 8 12 2500 3200 2500 2800 2100 Minimum Bend Radius [mm] 175 M 14 x 1,5 LH direkt 70 M 20 x 1,5 LH direkt 95 70 200 250 290 M 18 x 1,5 DKL 32 50 100 130 M 22 x 1,5 DKO 30 30 70 150 95 M 22 x 1,5 DKL 27 62 100 180 32 33 70 Gummi 250 Polyamid 100 110 290 36 83 100 240 M 24 x 1,5 DKO M 24 x 1,5 DKO M 30 x 1,5 DKM M 36 x 2,0 DKO 46 49 70 280 170 350 350 M 38 x 1,5 DKM 46 105 100 300 100 355 M 42 x 2,0 DKO 50 57 Connection with pressure ring and pressure nut Pressure ring Pressure nut 5 Maximum Temperature of Medium [°C] 175 M 14 x 1,5 LH M 30 x 2 32 150 M 20 x 1,5 LH M 42 x 2 46 205 Pos : 65 /xxxxxxxxx xxxxxx xxxx @ 0\mod6_2.doc x @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 70 200 250 290 Operating instructions Installation & Start up No.: HDP 502 / S 1100-50 Page 36, Issue: 03.2017 Pos : 66 /Vorber eitung z ur Inbetri ebnahme/Installation/S-Anlagen/M ontage H oc hdr uc ksc hlauc h @ 0\mod174_2.doc x @ 2284 @ 2 @ 1 8.3 Connecting the high pressure hose(s) Connect high pressure hose(s), hose arresters and carabiner hooks as shown in figs 5.1. and 5.2. (ref. to table torque for high pressure hoses) Run the assembled hose(s) out to jetting area and position ready for start up and system checks. ensure that no grit or dirt can adhere to the last connector. Do not fit the accessory yet. Fig. Hose connections Compression sleeve H. P. outlet Arrester Carabiner Hose conn. Nut When connecting hose(s) ensure that the control distance (5 mm 1) is adhered to. Ensure that the carabiner is hooked on the ring. Make a second check of all high pressure connections and hose arresters. Pos : 67 /Vorber eitung z ur Inbetri ebnahme/Installation/S-Anlagen/Sc hlauc hansc hlüsse @ 0\mod175_2.doc x @ 2248 @ @ 1 Fig. Hose connections High pressure hose Pressure nut Torque = 120 Nm H. P. outlet Leakage bore Pressure ring Pos : 68 /Vorber eitung z ur Inbetri ebnahme/Installation/S-Anlagen/Sc hlauc hsic her ung @ 0\mod176_2.doc x @ 2272 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Installation & Start up Operating instructions No.: HDP 502 / S 1100-50 Page 37, Issue: 03.2017 Fig. Accessory to hose and hose to hose safety connections The wire hose arresters fitted to all HDP 502 / S 1100-50 hoses and accessories are to prevent the hose from wiplashing in the event of a bad or faulty connection: Between the high pressure outlet and hose, at hose to hose connection between hose and the jetting accessory. Pos : 69 /xxxxxxxxx xxxxxx xxxx @ 0\mod6_2.doc x @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions Operation No.: HDP 502 / S 1100-50 Page 38, Issue: 03.2017 Pos : 70 /Betri eb/Übersc hrift @ 0\mod178_2.doc x @ 1400 @ 2 @ 1 9 Oper ation Pos : 71 /Betri eb/S- Anl agen/Betri eb mit ES2-Dies el @ 1\mod1040_2.doc x @ 2324 @ 22323 @ 1 9.1 Start up The HDP 502 / S 1100-50 is fully automatic and once the desired pressure has been set controlled entirely by electronic signal from the accessory. When the trigger(s) is/are disengaged the engine speed will automatically drop to idle r.p.m. With the accessory trigger(s) engaged the engine speed will automatically increase from idle to a speed necessary to provide the required pressure. Safety regulations demand that a unit should never be operated above its stated maximum operating pressure. Ref. to machine card or pump name plate for the max. operating pressure. Never exceed the max. operating pressure In the case of accident, equipment failure or leakage operate the emergency stop button immediately. 9.1.1 Warm up and system checks It is necessary to run the pump and make some system checks before fitting the accessory. 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. At start up: Under high pressure the high pressure hose shortens. Ensure the control over the consumer (i.e. spray gun). A spray gun that lies on the floor can jump up and break when falling down again. Unlock and open control panel door. If existing, activate battery switch Unlock and ensure that the emergency stop button button with the key. Press keypad is released. If necessary unlock the emergency stop to activate the basic display. Basic display appears. Ensure that it shows: pressure is indicated as zero on the left of display ( 30 bar tolerance of display – ref. to the ES2 manual. r.p.m. are displayed as zero on the left of display, voltage and the fuel gauge (Tank %) on the right of display indicates that there is sufficient fuel. Use branded grade of diesel with less than 0,5 % sulphur content. Ensure that cleanliness is observed when filling. Non observance could alter oil change intervals. There is no “low fuel“ cut-out. Fuel display should be checked regularly. Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions Operation No.: HDP 502 / S 1100-50 Page 39, Issue: 03.2017 Using an external power source to start the HP unit can damage the ES2 microprocessor. When charging the batteries ensure that the emergency stop switch is depressed and locked. The ES2 microprocessor contains, electronic components that will be damaged if subjected to excessive voltage of > 36 V. To operate the high pressure pump unit with the ES2 microprocessor refer to the ES2 manual. 9.1.2 To start the high pressure pump 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! Under no circumstances even if unpressurised! Open water supply to the pump. Check the water admission pressure (min. 3 bar) and Release the emergency stop button . Press keypad (Softkey activates) again to activate diesel pre-heat. Pre heat period ends after 15 secs. or when the engine starts. During this period the display will indicate: Pre-heat time elapsing from 15 to 0 secs. Battery voltage min. 24 V It is possible to repeat the pre-heat period by pressing Press keypad (Softkey ) once again. . The starter is automatically switched off if the engine has started. Depending on operational mode (set in factory) the display will indicate: pressure Diesel idle r.p.m. Battery voltage and fuel volume (%) The pump unit must be switched off and all lines depressurised before attempting to check hose connections and leakage points! Observe 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 (ref. to the ES2 manual). Press keypad . Depress and lock emergency stop button Turn off the water supply. Lower and lock sound proof cover. Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 . Operating instructions Operation No.: HDP 502 / S 1100-50 Page 40, Issue: 03.2017 You may now connect the accessory: To do so: Remove protective cap from accessory high pressure connector. Ensure that it is clean and then smear threads with Molykote. Check high pressure hose connector once again and make connection (ref. to the table: torque for high pressure hoses). If fitting further accessory, i.e.: Rotorjet to pistol repeat inspection, Molykote and connection check procedure). 9.2 To start the high pressure pump 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! Under no circumstances even if unpressurised! Panel operator should turn on water supply and wait of a sign from the jetting operator, which indicates that the water comes free of blow holes out of the jetting tool. Pre-heat press keypad To start the engine (activates softkey press keypad ). . Jetting operator can now engage trigger(s) and commence blasting. The operator in the control panel should observe the values of engine speed or pressure. Pressure must climb gradually up to the selected level. 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 immediately press the emergency stop button. For reasons of safety pull off the ignition key and protect it in a safe place. 9.3 Operating the system Monitoring during operation The panel operator should remain in position and observe both the panel and jetting operator. In the case of accident, equipment failure or leakage operate the emergency stop button immediately. Remove the ignition key for safety reasons. Monitor the pressure at display. Pressure is also a function of accessory nozzle diameter. If 1400 bar max. is reached at idle or low r.p.m. the nozzle is too small. If 1400 bar cannot be achieved at max. engine r.p.m. the nozzle is too large. (Refer to nozzle selection tables) Monitor engine r.p.m. at the display. Every time the jetting operator releases the accessory trigger(s) the engine speed should decrease to idle speed. Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions Operation No.: HDP 502 / S 1100-50 Page 41, Issue: 03.2017 Regularly check the high pressure hoses, fittings and jetting (i.e. nozzles, spray bar) for signs of leakage. In the case of leakage stop the high pressure pump system immediately. Remove leakage only when the system is switched off and depressurised. During pauses in work (lunch break, end of shift, etc.) and when the unit is shut down, unlock and raise soundproof cover to check the amount of leakage water at the pump. A plastic container is placed at the base of the pump to collect the leakage. A little leakage is normal and necessary. Excessive leakage amounts indicate that seals need adjusting or replacing (see section ”Maintenance”). To check the service functions of the system (user's menu) during operation see operating instructions of the ES2 control. With running engine it is not to be activated possibly in the functional menu, e.g., the pre-heat. Prevent the access to the ES2 control for unauthorised, while you conclude (close) the door, or set the keys barrier “ON” (see operating instructions ES2). The symbol is indicated on the basic display. If the unit is equipped with a battery switch, do not deactivate it when the motor is running. If the unit shut down automatically the fault will appear at the display in clear text. For safety depress and lock emergency stop button before commencing repair. Remove the key and keep it. Only then begin with the removal of the fault or the disturbance (see operating instructions of the ES2 control). Pos : 72 /xxxxxxxxx xxxxxx xxxx @ 0\mod6_2.doc x @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions Shut down No.: HDP 502 / S 1100-50 Page 42, Issue: 03.2017 Pos : 73 /Auß erbetriebnahme/Ü bersc hrift @ 0\mod182_2.doc x @ 1408 @ 2 @ 1 10 Shut do wn Pos : 74 /Auß erbetriebnahme/S- Anl agen/Abs chalten & Übernac ht Stillstand ES2 @ 1\mod1041_2.doc x @ 2328 @ 22 @ 1 10.1 Stopping the unit These instructions cover stopping the unit and overnight shut down. If there is any danger of overnight freezing the system should be completely drained and it can be charged with anti-freeze solution. The jetting operator should release the accessory trigger(s). The engine r.p.m. drops to idle speed. Let the engine run for 2 to 3 minutes at idle speed until it cools down. Press keypad . If it is intended to shut down the unit, press and lock the emergency switch safekeeping. and remove the key for If existing, don’t use the battery switch within two minutes of shutting off the engine. If the unit shall be out of operation for more than one week, switch off the battery to prevent them discharging. 10.2 Overnight shut down Unlock and open sound dampening cover. Carry out daily inspection. Close and lock damping cover. Remove key for safekeeping. Disconnect arrester, water and electrical connections at the jetting accessory. Store the accessory in accordance with instructions provided. Either plug/cap the hose connections or place polythene bag over them and secure with adhesive tape. Cap the electrical connector. Disconnect the high pressure hose(s) and arresters. Clean threaded connectors and smear with Molykote 1000 anti-seize. Protect 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 insulation for damage while reeling onto drum. Cap the connector at the pump unit. Disconnect suction, bypass and cooling water hoses. Clean couplings at the pump unit and replace protective caps. The suction hose connections should also be cleaned, and protected if necessary. Lock control panel door and remove key for safekeeping. Pos : 75 /Aufbau und Besc hrei bung/S-Anlagen/Abgas nac hbehandlung Vol vo @ 15\mod_1456399519724_2.doc x @ 146332 @ 3 @ 1 10.3 Exhaust after treatment Automatically exhaust after treatment via the engine control unit. 25.2 V 10 0 bar Start display with AdBlue system (e.g. Volvo Stage IIIb/Tier 4i and Stage IV/Tier 4 f. engine) 0 r.p.m. AdBlue fill level display OFF Fig.: Start display Function of softkey : activate/deactivate ignition. Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Shut down Operating instructions No.: HDP 502 / S 1100-50 Page 43, Issue: 03.2017 Pressing once will activate the ignition/stoppage magnet, and the symbol will be shown white on black. If pressed again: Ignition to the engine will be turned off. This function does not affect the starting of the engine. If the ignition is switched off (state after ES2 switched on), the ignition/stoppage magnet output will be activated when the start button is pressed, and then the starter with a delay of approx. 1-2 seconds. If the ignition has already been switched on with the key button, the engine can also be started. The ignition output will stay activated. When switching the engine off, the ignition/stoppage magnet output will always be switched off to stop the engine. The softkey can be helpful for engine service technicians, who can sometimes only access the engine control unit when the ignition is switched on. If the ignition is switched on, the level of the AdBlue tank will be displayed. This can prevent the AdBlue tank from overflowing when AdBlue is being topped up. The fill level of the AdBlue tank should not go below 22%. Top up in good time. If this is not done, there may be a reduction in power by the engine control unit. Only switch off the battery main switch about 2 mins after the ES2 has been turned off. During this time, the AdBlue lines are emptied in order to prevent them from becoming blocked up. Pos : 76 /Auß erbetriebnahme/S- Anl agen/Länger e Auß erbetri ebnahme @ 0\mod183_2.doc x @ 2336 @ 1333233 @ 1 10.4 Extended shut down Whenever an extended shut down is envisaged the Aquajet 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. 10.4.1 Draining the unit To drain the system open the cocks on the boost pump and on the filter. ¼ to ½ a turn with 12 mm A/F spanner is sufficient. Close supply connection. Run the pump AT IDLE SPEED for a few seconds and then stop. This is not critical when preparing for emulsion but is essential when protecting against freezing! 10.4.2 Venting air from the system after draining for first operation With the engine stopped close all drain cocks. Unscrew vent plugs at the boost pump. Open suction connection and fit suction hose. Turn on water supply (i.e.: Hydrant) and wait until water is flowing freely from the boost pump vents. Turn off water supply and refit vent plugs. Turn on water supply again and start the unit. 10.4.3 To fill system For anti-corrosion we recommend the following: 89 % clean fresh water 10 % Shell 9156 or equivalent 1 % ESKAPHOR EM 96 or equivalent Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions Shut down No.: HDP 502 / S 1100-50 Page 44, Issue: 03.2017 With the engine stopped almost fill the header tank with water via the suction connection. Unscrew the header tank cover and add the correct amount of anti-corrosion fluids. Remove the suction hose and close the suction connection with the screw cap. Fit a short length of H.P. hose to the pressure outlet and place the free end in the header tank. Run the pump AT IDLE SPEED for 2 or 3 minutes allowing the emulsion to circulate through the system. Observe the emulsion in the tank and if necessary add more Shell Donax C. Stop the pump. Remove hose from H.P. water connection. Clean, grease and cap the connection. Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions Shut down No.: HDP 502 / S 1100-50 Page 45, Issue: 03.2017 Schematic of emulsion flow Item Description 1 High pressure pump 2 Suction chamber 3 Filter 4 Boost pump 5 Suction line 6 Emulsion 7 High pressure hose 8 Supply connection 10.4.4 Further actions Remove intermediate chamber cover plates and thoroughly clean and dry the whole chamber. Spray the exposed plungers with Optimol F + D fluid. Do not spray or lubricate tungsten carbide plungers in any way. Remove the leakage water container. Empty it and store it separately. Disconnect and remove the batteries to store. Top up with distilled water. Close and lock the sound dampening cover. Make sure that all unit keys are kept in a secure place. 10.4.5 Hoses Before undertaking the greasing and protection procedure described previously thoroughly dry the connections 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. 10.4.6 Accessories Thoroughly clean and dry all accessories paying particular attention to connectors. Grease and protect threads as described previously. Ensure electrical connectors are capped or protected. They must be completely dry. (Repeat for cable drum) Remove all nozzles for separate storage. Grease nozzle holder threads 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. Decommissioning after shut down should be preceded by internal checks as described previously in this manual. Once batteries and leakage water container have been replaced the draining procedure as in the page before should be observed to remove emulsion/anti-freeze. Pos : 77 /xxxxxxxxx xxxxxx xxxx @ 0\mod6_2.doc x @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions Maintenance No.: HDP 502 / S 1100-50 Page 46, Issue: 03.2017 Pos : 78 /Instandhaltung/Ü bersc hrift @ 0\mod185_2.doc x @ 1416 @ 2 @ 1 11 Mainten an ce Pos : 79 /Instandhaltung/S- Anl agen/Störungen & Wartung ES2 Dies el @ 1\mod1042_2.doc x @ 2352 @ 23332333 @ 1 11.1 Fault finding and remedy All maintenance and inspection work should only be done when system is switched off and released! Whenever a fault is observed or suspected, emergency stop the unit immediately! Before examination of the High pressure unit or before maintenance works and repairs, shut down and relieve the complete high pressure system. Depress and lock emergency stop button . Remove key for safekeeping. Recommendation: The keeping of the key by the man, i.e. that man which works at the high pressure unit carries the key on himself. 11.1.1 Annunciated faults The unit is protected against extensive damage by automatic safety cut-outs. The unit will stop immediately and the fault will appear in clear text on the panel display. Press keypad and lock for safety. The fault finding and remedy is described in the operating instructions of the ES2. Faults, possible reasons as well as remedies are described there. After removal of the fault, the fault text can only be removed from display screen by pressing keypad eliminated. . If after pressing the text remains on display if the fault has not been Using an external power source as an auxiliary starter when the ES2 is on can interfere with the electronic control system. 11.1.2 Observed faults The following faults are either immediately obvious or will be picked up during routine monitoring by the operator. These faults will not be announced in clear text at the panel screen. Faults Possible causes a) Electrical system does not respond to keypad . Remedy Batteries exhausted. Emergency stop switch still engaged. Exchange or recharge. is . c) Pumps runs without pressure. Release Emergency stop switch Batteries low or exhausted. Recharge or replace. Control system component failure Consult HAMMELMANN agent (abroad) or customer services. dept. (F.R.G.). Accessory trigger switch malfunction. Replace. No oil pressure to bypass cylinder. Check system oil pressure. b) Engine does not respond to the keypad. Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions Maintenance No.: HDP 502 / S 1100-50 Page 47, Issue: 03.2017 d) Burst disc rupture. e) Operating pressure too low. Maximum pressure exceeded. Replace burst disc. Check why pressure exceeded. Remedy fault. Engine not achieving required r.p.m. See engine handbook. Speed control system defective. Consult HAMMELMANN agent (abroad) or customer services. dept.(F.R.G.) Accessory nozzle(s) too large or worn. Change nozzle(s). Bypass leaking water. Check oil line and hydraulic cylinder for leakage. Check system pressure. Bypass components worn. Change or rework bypass components. Pump head seals defective. Change seals. Defective suction or pressure valve. Change or rework valves. Leakage at high pressure fittings or hoses. Attention! Do not attempt close visual inspection until unit is shut down! Inspect and tighten or replace as necessary. Worn piston sleeves. Change piston sleeves. Rework is possible. Suction or pressure valve sticking. Worn valves or valve seats. Change or rework valves and valve seats if necessary. g) Excess leakage from intermediate chamber. Low pressure seal fault. Adjust or replace. h) The leakage water or oil dipstick shows oil water emulsion. Water entering crank via defective seal between piston and crank. Consult HAMMELMANN agent (abroad) or customer services dept. (F.R.G:). Oil pressure too high. Adjust oil system pressure. System over charged with oil. Drain off. f) i) Shock pulses in high pressure discharge. Oil leaks from crank section. The engine starts, runs for a short time and then cuts out. If repeated effort is to start the engine are made a number of differing fault indications can appear one after the other. “Alternator fault” or “Engine oil pressure low” or “Pump oil pressure low”” Possible reason: The diesel engine is not receiving any or not enough fuel. Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions No.: HDP 502 / S 1100-50 Maintenance Page 48, Issue: 03.2017 Fill fuel tank. Clean the fuel filter or fit new if necessary. Bleed air from the fuel system. 11.1.3 Electrical faults Electrical / electronic faults are normally those as listed in annunciated faults. Or they occur as a result of a break down in signal from accessory to the unit. These are to be stated (are to be found out) with a test device. Any faults or misadjustments that appear to originate in the electric control and monitoring system must be referred to HAMMELMANN or their approved agent. This normally means referring the problem to HAMMELMANN or their accredited agent. It could be helpful to bring connection diagrams or drawings etc. 11.2 Maintenance 11.2.1 Daily inspection and control Check the following: Check pump and engine oil level. Top up if necessary. Intermediate chamber of the pump (optic). Only remove cover plate 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. 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. Check condition of batteries, tyres, etc. Refer to the operating instructions provided for care of trailer and engine. 11.2.2 Maintenance of the water filter Daily check the cleanness of the water filter and cartridge. To get an access stop the unit, close off the water supply and: Open the filter drain clock by a ¼ to ½ turn. Loosen the ring screws on the filter and turn the screws downwards. Remove the cover and the filter cartridge housing. 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. 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 and the ES2-control displays “Filter blocked”. Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Maintenance Operating instructions No.: HDP 502 / S 1100-50 Page 49, Issue: 03.2017 11.2.3 Checks during operation During operation of the pump we recommend that you check the condition of certain essential components for: Excessive or unusual noise, vibration i.e. (Valves tapping, pulsation in the discharge lines etc), Uneven heating in areas of the pump head (Valve block), Pulsation in the suction side assembly or rapid flickering at the pressure gauge, Temperature increase at the plunger cooling water outlet, Leakage at the low pressure seal sets (of the hp seal set assemblies), Excessive or unexpected discharge from the pressure regulating valve (Bypass valve) All the above indicate that the pump is in urgent need of repair or maintenance which must be carried out in accordance with the instructions provided. Pos : 80 /xxxxxxxxx xxxxxx xxxx @ 0\mod6_2.doc x @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions Maintenance No.: HDP 502 / S 1100-50 Page 50, Issue: 03.2017 Pos : 81 /Instandhaltung/Pumpen/Wartung Luftfilter- Behälter @ 16\mod_1458564431004_2.doc x @ 149459 @ 233 @ 1 11.3 Maintenance of the air pressure installation At external compressed air supply of high pressure pump unit, use only factory filtered compressed air! 11.3.1 Compressed air tank (if supplied) Before start to work, at least daily drain compressed air tank. 11.3.2 Compressed air filter Before start to work, at least daily drain compressed air filter Visually check the condition of the filter cartridge. If necessary clean (wash out) or replace. To do this unscrew the plastic cap and unscrew the nut from the bracket and remove the cartridge. Assembly in reverse order. In the case of units with air pressure monitoring, the unit will switch off if the filter is dirty. In the case of units with ES2 control, the warning "air pressure too low" will be shown on the display and stored, and the high pressure will be switched off. See operating manual for the ES2 control. Pos : 82 /xxxxxxxxx xxxxxx xxxx @ 0\mod6_2.doc x @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions Maintenance No.: HDP 502 / S 1100-50 Page 51, Issue: 03.2017 Pos : 83 /Instandhaltung/Pumpen/HD P 500/Öl wechs el HD P 500 - S4 GX 320 @ 7\mod_1313764542149_2.doc x @ 49326 @ 23232 @ 1 11.4 Oil change 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. 11.4.1 First oil change after 1000 operating hours Item no. Description 1 Oil drain valve 2 Oil drain valve oil cooler 3 Dip stick 4 Oil filler neck 5 Oil cooler 6 Oil drain valve oil cooler 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. 42 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. If the oil is drained from the crank section, then drain the oil from the oil cooler and oil filter. Unscrew the oil drain plug (2). The oil comes out of the oil cooler. Remove the protective cap (10) from oil filter and then 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. Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions No.: HDP 502 / S 1100-50 Maintenance Page 52, Issue: 03.2017 If the crank case, oil filter and oil cooler are completely drained unscrew the hoses from the oil drain valves (1 and 6) Screw the protective caps/plugs back on the oil drain valves. 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. 11.4.2 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. Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions Maintenance No.: HDP 502 / S 1100-50 Page 53, Issue: 03.2017 11.4.3 Lubrication including oil filter Quantity of oil: 42 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 Fuchs Renolyin Unisysn CLP ÖL 320 Mobil Mobil SHC 632 Mobilgear SHC XMP 320 Optimol Optigear Synthetic A 320 PANOLIN Tecsynth 320 Petro-Canada Enduratex* Synthetic EP 320 Shell Omala S4 GX 320 Total Carter SH 320 OMV OMV gear SHG 320 By using other oils as here listed consult your supplier. Note! Polyalphaolefin gear oils of different manufactures can be mixed slightly (max. 5%) with another, e.g. at oil refill. Only small quantities (max. 5%) should be refilled, in order not to change the characteristics of the original gear oil. At the changing from mineral oil to polyalfaolefin the crank case must not be rinsed before new filling. The remaining residue of the mineral oil, after a complete draining of the crank case, is compatible with the polyalfaolefin. Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions Maintenance No.: HDP 502 / S 1100-50 Page 54, Issue: 03.2017 Viscosity-Temperature-Diagram for synthetic oils at Poly- -Olefin - Basis Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Maintenance Operating instructions No.: HDP 502 / S 1100-50 Page 55, Issue: 03.2017 11.4.4 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 4 bar even when the unit is warm. A pressure gauge is fitted to the unit. If the oil pressure fall below 4 bar the high pressure pump would be shut off automatically to prevent damages of the crank section. Make adjustment on the oil pressure regulator (ref. to fig.: Oil change, item 8). To do so: Remove protective cap and loosen the counter nut. Use screw driver to adjust the oil pressure. Tighten the adjuster screw to increase pressure or unscrew to reduce pressure. Pos : 84 /Instandhaltung/Pumpen/Ins tandsetz ungs arbeiten @ 0\mod188_2.doc x @ 1480 @ 2 @ 1 11.5 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 HAMMELMANN directly. The unit should be switched off, the panel cover locked and the key removed for safekeeping before attempting to commence repairs. Pos : 85 /xxxxxxxxx xxxxxx xxxx @ 0\mod6_2.doc x @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions Maintenance No.: HDP 502 / S 1100-50 Page 56, Issue: 03.2017 Pos : 86 /Instandhaltung/Pumpen/Austaus ch Berstsc heibe bis 1500 bar ab 03.2011 @ 6\mod_1299838371271_2.doc x @ 45089 @ 3 @ 1 11.5.1 Replacing the rupture disc up to 1500 bar operating pressure When the burst disc is destroyed, unscrew the high pressure line from the connection piece (40) and then: Fit a spanner SW 36 onto the connection piece (10). Unscrew the connection piece (40) with a spanner SW 27 and pull it completely out with the plug (30) and the rupture disc (50). Grease the outer thread of the connection piece (40) carefully with Molykote1000 (order no. 04.02750.0011) Position the plug (30) on the end of the connection piece (40). Use grease Stabyl MO 500 (order No. 04.04660.0002) to fix the plug there. Grease the rupture disc (50) with Stabyl MO 500 and place it onto the plug (30). Screw connection piece (40) together with plug and disc into the connection piece (10) and tighten up with 110 Nm. Grease the outer thread of the high pressure line with Molykote1000 and connect it with the connection piece again. Item no. Description 10 Connection piece 20 Seal ring 30 Plug 40 Connection piece 50 Rupture disc Pos : 87 /xxxxxxxxx xxxxxx xxxx @ 0\mod6_2.doc x @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Maintenance Operating instructions No.: HDP 502 / S 1100-50 Page 57, Issue: 03.2017 Pos : 88 /Instandhaltung/Pumpen/Pumpenkopf/PK 1239 HDP 360- 500 (DKV) @ 9\mod_1367571631332_2.doc x @ 76551 @ 233 @ 1 11.6 Maintenance of the pump head 00.02145.1239 (-003) The pump head is subject to minor wearing. Maintenance is required, i.e. if a decrease of pressure or a restless run of the pump is determined. 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. 11.6.1 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). Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions Maintenance No.: HDP 502 / S 1100-50 Page 58, Issue: 03.2017 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 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Maintenance Operating instructions No.: HDP 502 / S 1100-50 Page 59, Issue: 03.2017 Inspection Check the valve seat ring (150). If damaged or worn, replace it. It is possible that the circular seat face could have been deformed or worn by impact of the valve (30). If it is greatly worn or deformed so much that a good seat is no longer possible then discard and replace with new. 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. 11.6.2 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. Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions Maintenance No.: HDP 502 / S 1100-50 Page 60, Issue: 03.2017 Assemble the pump head (valve housing) on the crank section or suction chamber. To do so: Lightly grease the supporting surfaces of pump head/seal assembly. 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. Pos : 89 /xxxxxxxxx xxxxxx xxxx @ 0\mod6_2.doc x @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Maintenance Operating instructions No.: HDP 502 / S 1100-50 Page 61, Issue: 03.2017 Pos : 90 /Instandhaltung/Pumpen/Dic htungssatz/DS 2221 HDP 360/480/750 @ 7\mod_1306845678721_2.doc x @ 47064 @ 233 @ 1 11.7 Maintenance of the piston seal assembly: 00.00743.2221 (-004) The pump unit must be switched off and all lines depressurised before attempting to check hose connections and leakage points or making inspection and remedy! Use only correctly sized suitable tools. 11.7.1 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). Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions Maintenance No.: HDP 502 / S 1100-50 Page 62, Issue: 03.2017 Remove the flange (30) from the casing (10). Pull out the bushing (300) from the casing (10). Remove ring’s (190 and 110) and packings (130) from the casing (10). 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. 11.7.2 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. Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Maintenance Operating instructions No.: HDP 502 / S 1100-50 Page 63, Issue: 03.2017 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 400 Hex. skt. head cap screw 410 Circlip 420 O-ring 430 O-ring 450 O-ring 470 Clamp halves 480 Circlip Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions Maintenance No.: HDP 502 / S 1100-50 Page 64, Issue: 03.2017 Reassemble the seal assemblies and the pump head Lightly grease the supporting surfaces of the crank section/seal assembly. Insert the complete seal assembly with the piston (20) in the pump housing. Ensure that the O-rings (60) are not pressed out of the grooves and damaged. 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. Pos : 91 /xxxxxxxxx xxxxxx xxxx @ 0\mod6_2.doc x @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions Maintenance No.: HDP 502 / S 1100-50 Page 65, Issue: 03.2017 Pos : 92 /Instandhaltung/Pumpen/HD P 500/Austaus ch Faltenbalg @ 8 \mod_1333541215787_2.doc x @ 56469 @ 1 @ 1 11.1 Changing the bellows At every maintenance work at the plunger seal assembly or after 4000 operating hours or at least once in a year the bellows needs to be changed. The mounting clips should also be changed (damaged during removal). Proceed as follows: Loosen the plunger from the piston rod (refer to the chapter ‚seal assembly‘). Fig. Bellows 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 : 93 /xxxxxxxxx xxxxxx xxxx @ 0\mod6_2.doc x @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions Maintenance No.: HDP 502 / S 1100-50 Page 66, Issue: 03.2017 Pos : 94 /Instandhaltung/S- Anl agen/Keilriemen Vordr uc kpumpe wechsel n @ 0\mod195_2.doc x @ 2348 @ 1 @ 1 11.2 Changing or adjusting the boost pump drive belt Changing the drive belts is necessary when it is stretched, frayed and of course broken. Change as follows: Use a 17 mm A/F spanner to loosen the four boot pump fixing bolts. With the same spanner loosen the counter nuts and then with a 6 mm allen key loosen the tensioning bolts. Slide the boost pump towards the engine. If not already off, remove the damaged belt. Place the new belt over the engine and boost pump pulley wheels. Pull the boost pump away from the engine as far as possible. Hand tighten the four pump fixing bolts. Tension the belt by means of the tensioning bolts (6 mm allen key). There should be about 10 mm play in the centre of the belt with normal thumb pressure. Tighten the counter nuts. Tighten the four fixing bolts with the 17 mm A/F spanner. Check the play again and adjust if necessary. Pos : 95 /Instandhaltung/Pumpen/Anzugs momente @ 0\mod194_2.doc x @ 1476 @ 2 @ 1 11.3 Torque tables Tightening torque (in Nm) for various bolted joints. Material Thread size 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 12.9 15 35 70 120 190 300 405 575 990 A2-70 A4-70 6,0 15 30 50 85 130 175 250 420 Torque (Nm) for various bolts. Any variations from these torque values are indicated on the individual assembly drawings. Pos : 96 /xxxxxxxxx xxxxxx xxxx @ 0\mod6_2.doc x @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions Pressure regulating valve 00.05865.0146 No.: HDP 502 / S 1100-50 Page 67, Issue: 03.2017 Pos : 97 /Instandhaltung/Druc kr egel ventil/DR V 00.05865.0146 @ 11\mod_1400674247453_2.doc x @ 89693 @ 12222 @ 1 12 Pressure regulating valve 00.05865.0146 Fig.: Pressure regulating valve Item no. Description Item no. Description Item no. Description 10 Housing 50 Ring 110 Circlip 20 Seal ring 60 Valve seat ring 120 Plug 25 O-ring 70 Support ring with O-ring 130 Disc 30 Control piston 80 Reduction piece 140 Spring 35 Bracket 90 Seal ring 160 Cylinder ring Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions Pressure regulating valve 00.05865.0146 No.: HDP 502 / S 1100-50 Page 68, Issue: 03.2017 Technical Data Max. operating pressure: 1200 bar Flow rate max.: 500 l/min. Diameter nominal: DN 17 Weight approx.: 10.5 kg 12.1 Installation (ref. to fig.: Pressure regulating valve) Grease fixing screws (hex. socket head screw M12 x 120, 10.9, order no.: 02.00825.0152) 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 (50) doesn’t fall apart and is in correct position. Set the fixing screws in place and tighten. Tighten the hex socket cap head screws (in a few steps) crosswise (Torque 90 Nm) ensuring that the valve is absolutely parallel with the pump head. Tighten to 90 Nm. Lightly grease the connection armature (order no.: 00.00131.0121) with Molykote 1000 and tighten into the valve. Screw membrane cylinder (for example no.: 00.06428.0025) or adjusting sleeve (for example: 00.01754.0028) onto the pressure regulating valve by hand. Tighten membrane cylinder only by hand! Under no circumstances with a tool. Connect the pneumatically control line onto the membrane cylinder If necessary remove plug (120) and screw pressure gauge (i.e. order no.: 04.02860.0009) with seal ring into the housing (req. torque = 100 Nm). 12.2 Adjustment The pressure regulating valve allows a smooth increase of pressure from suction pressure to max. operating pressure That makes an optimal use of the energy source. 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. Increasing the air pressure increases the operating pressure. Decreasing the air pressure decreases the operating pressure. Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Pressure regulating valve 00.05865.0146 Operating instructions No.: HDP 502 / S 1100-50 Page 69, Issue: 03.2017 12.3 Maintenance The pump unit must be switched off and all lines depressurised before attempting to check hose connections and leakage points or making inspection and remedy! 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 pres. reg. valve. Loosen the 4 hexagon socket cap head screws crosswise. Support the valve so that it doesn't fall apart. Remove the valve from the pump head. Disassembling of the pressure regulating valve Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions Pressure regulating valve 00.05865.0146 No.: HDP 502 / S 1100-50 Page 70, Issue: 03.2017 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 (140). Push control piston (30) and valve seat ring (60) out of the housing (10) By using a screw driver remove the bracket (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 bracket (35), seal (20) and Oring (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. Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Pressure regulating valve 00.05865.0146 Operating instructions No.: HDP 502 / S 1100-50 Page 71, Issue: 03.2017 Reassembling of the pressure regulating valve Grease the inner of housing (10) with Stabyl MO 500 (order no. 04.04660.0002) Place O-ring (25) onto seal ring (20) (ref. to fig 2) Fig. 2 Fig. 3 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). Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions Pressure regulating valve 00.05865.0146 No.: HDP 502 / S 1100-50 Page 72, Issue: 03.2017 Fig. 4 Fig. 5 Slide the bracket (35) (ref. to fig 5) onto the special tool and then into the housing (10). (Ensure correct positioning) (Ref. to fig. 6). Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Pressure regulating valve 00.05865.0146 Operating instructions No.: HDP 502 / S 1100-50 Page 73, Issue: 03.2017 Correctly installed seal ring (20), O-ring (25) and bracket (35) (ref. to. Fig 6) Fig. 6 Remove the tool out of the housing. Slide the control pin (30) into the housing (10). Insert spring (140) into the housing. Place disc (130) onto the spring (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. Pos : 98 /xxxxxxxxx xxxxxx xxxx @ 0\mod6_2.doc x @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions No.: HDP 502 / S 1100-50 Page 74, Issue: 03.2017 Safety notes for high pressure hoses Pos : 99 /Sic herheit/Sc hlauc hsicherheit @ 0\mod416_2.doc x @ 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. Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions Safety notes for high pressure hoses No.: HDP 502 / S 1100-50 Page 75, Issue: 03.2017 13.1 Before using the hose Check the working pressure marked on the hose. Never exceed this working pressure. Check the hose and the fittings if they are damaged. Take out of service hoses with bubbles in the cover, with kinks or uncovered layer of the steel wire. It is not allowed to repair hose lines with these damages or to use them in other ways. (EN 982) Check the fittings if they have rust, cracks (fissures) or worn threads. Never plug the relief holes of the fittings, neither intentional nor by dirtying or damages. Observe the minimum bend radius at storage and work (look table beyond). 13.2 Use of the hose Do not twist the hoses during assembly. Regularly check the hoses and fittings as well as the connections and adapters on leakages. In case of leakages stop the high pressure aggregate immediately. Remove leakage only when the system is switched off and depressurised. Never tighten fittings under pressure. Observe torque (look table beyond). Pay attention to the change of length when working. (Hoses reduce their length under pressure). Do not pressurise hoses on reel drums. Avoid stress with high temperature from the exterior (e.g. radiant heat at welding or thermal cutting). Do not hang the hose across several floors. Nominal diameter [DN] Pressure [bar] 2500 3200 2500 3200 2100 290 530 1250 1600 250 440 5 8 12 10 12 1100 1400 1800 170 340 1000 1000 1400 1600 140 260 700 20 25 Connection fitting Wrench size [mm] Torque [Nm] 8 12 2500 3200 2500 2800 2100 Minimum Bend Radius [mm] 175 M 14 x 1,5 LH direkt 70 M 20 x 1,5 LH direkt 95 70 200 250 290 M 18 x 1,5 DKL 32 50 100 130 M 22 x 1,5 DKO 30 30 70 150 95 M 22 x 1,5 DKL 27 62 100 180 32 33 70 Gummi 250 Polyamid 100 110 290 36 83 100 240 M 24 x 1,5 DKO M 24 x 1,5 DKO M 30 x 1,5 DKM M 36 x 2,0 DKO 46 49 70 280 170 350 350 M 38 x 1,5 DKM 46 105 100 300 100 355 M 42 x 2,0 DKO 50 57 Connection with pressure ring and pressure nut Pressure ring Pressure nut 5 Maximum Temperature of Medium [°C] 175 M 14 x 1,5 LH M 30 x 2 32 150 M 20 x 1,5 LH M 42 x 2 46 205 === Ende der Liste für T extmar ke Inhalt === Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 70 200 250 290 Operating instructions Index No.: HDP 502 / S 1100-50 Page 76, Issue: 03.2017 14 Index C O Caractéristiques de puissance ...................................8 Changing the bellows .............................................. 65 Construction ............................................................ 17 Construction High of pressure pump HDP 503 ... 19 Layout of the S1100-50 ....................................... 17 Operating the system .............................................. 40 Overnight shut down ............................................... 42 D Description Control unit .......................................................... 24 Electronic safety cut out ...................................... 22 High pressure installation .................................... 23 Suction side installation ....................................... 23 The burst disc assembly (safety devices) ........... 22 Dieselengine Volvo TAD 1661 VE .......................... 23 E Extended Shut down ............................................... 43 F Fault finding and remedy ........................................ 46 G General Copyright ............................................................. 14 Introduction .......................................................... 13 Warranty terms .................................................... 14 M Maintenance Changing or adjusting the boost pump drive belt 66 N Notes on installation of connecting armatures ........ 34 P Pre-start checks ...................................................... 30 R Repair and Replacement ........................................ 55 Replacing the burst disc(s) ..................................... 56 S Safety Additional warnings ............................................. 12 Danger symbol .................................................... 11 Dangers arising from non observance of safety instructions ............................................................ 9 Forbidden practices ............................................. 12 Personnel qualification and training ...................... 9 Precise safety instructions for the operator ........... 9 Safety conscious working ...................................... 9 Safety during inspection, maintenance and repair ............................................................................. 11 Safety notes for high pressure hoses ..................... 74 Start up .................................................................... 38 Stopping the unit ..................................................... 42 T To start the high pressure pump unit ...................... 39 Torque tables .......................................................... 66 Transport Packing ................................................................ 15 Protection ............................................................ 16 Transport ............................................................. 16 Transportation ..................................................... 15 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions ES2 Microprocessor-Control for Volvo Engine ES2-Bediener (Volvo) 2016 Made in Germany Issue: 04.2016 Operating instructions No.: ES2-Bediener (Volvo) Contents Page 2, Issue: 04.2016 1 Contents 1 Contents ............................................................................................................................................................ 2 2 ES 2 – Control ................................................................................................................................................... 3 2.1 Control panel with basic display................................................................................................................... 3 2.2 Switch control ON ........................................................................................................................................ 4 2.3 Exhaust after treatment................................................................................................................................ 5 2.4 Pre-heat ....................................................................................................................................................... 6 2.5 Engine START ............................................................................................................................................. 6 2.5.1 Tank warning............................................................................................................................................ 6 2.6 Entering a set value ..................................................................................................................................... 7 2.7 Operators menu ........................................................................................................................................... 8 2.7.1 Selecting of the pressure step ............................................................................................................... 10 2.7.2 Teach in function .................................................................................................................................... 11 2.7.1 External set value / set value parameter ............................................................................................... 11 2.7.2 Keypad lock............................................................................................................................................ 12 2.7.3 Switch OFF the keypad lock .................................................................................................................. 13 2.8 Function menu ........................................................................................................................................... 13 2.8.1 Digital sensor ......................................................................................................................................... 14 2.8.2 Analogue sensor .................................................................................................................................... 15 2.9 Fault report ................................................................................................................................................. 16 2.10 Explanation of the terms/functions at the operators menu ........................................................................ 19 2.11 Fault indication ........................................................................................................................................... 20 2.12 Working with multi gun valve and „Teach in“ ............................................................................................. 28 2.13 Modem connection ..................................................................................................................................... 31 2.13.1 Description of blink code of ES2-modem ........................................................................................... 34 3 Index ................................................................................................................................................................ 35 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions ES 2 – Control No.: ES2-Bediener (Volvo) Page 3, Issue: 04.2016 Pos: 1 /Aufbau und Beschreibung/ES 2 - Steuerung/Überschrift ES2 - Steuerung @ 0\mod23_2.docx @ 1644 @ 1 @ 1 2 ES 2 – Control Pos: 2 /Aufbau und Beschreibung/ES 2 - Steuerung/Bedieneroberfläche @ 0\mod21_2.docx @ 1832 @ 2 @ 1 2.1 Control panel with basic display Display Tank level display Pressure display R.P.M. display Keypads Softkeys OFF Allocation fields Fig.: 1 The keypads take over the functions of the softkeys via the allocation fields. Pos: 3 /Aufbau und Beschreibung/ES 2 - Steuerung/Bedeutung der Tasten und Softkeys @ 0\mod25_2.docx @ 1836 @ @ 1 Meaning of Keypads, Softkeys and Symbols Key pads Softkeys Symbole Control On Engine Start Battery Engine Start Engine Stop Bypass valve Engine Stop, Control Off Pre heat 1 Multi tool valve 1 OK (confirm) Previous page 2 Multi tool valve 2 Selection/Increasing Next page 3 Multi tool valve 3 Selection/Decreasing Cursor left 4 Multi tool valve 4 Cursor right 5 Multi tool valve 5 Operating instructions 1 Consumer 1 Shut off valve test OK (confirm) 2 Consumer 2 Starter test Exit 3 Consumer 3 General fault test Help 4 Consumer 4 Delete error memory 5 Consumer 5 Softkeys (Function menu 13.) Pos: 4 /Aufbau und Beschreibung/ES 2 - Steuerung/Steuerung Einschalten @ 0\mod26_2.docx @ 1648 @ 2 @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions ES 2 – Control No.: ES2-Bediener (Volvo) Page 4, Issue: 04.2016 2.2 Switch control ON Unlock and release Press Pos: 5 /Aufbau und Beschreibung/ES 2 - Steuerung/Sicherheitsabfrage @ 5\mod_1234853767778_2.docx @ 29373 @ @ 1 After switching on the ES2 the start side is covered by a safety request: Ja Use the set values (pressure / speed) from the previous job yes The last set value will be displayed for 10 sec. The set value can be confirmed or adjustet. No The set value will set to minimum value and displayed for 10 sec. The set value can be confirmed or adjusted. Nein (Ref. also to entering set value point 2.5) Fig.: 2 Pos: 6 /Aufbau und Beschreibung/ES 2 - Steuerung/Start Display (mit Vorglühen) @ 1\mod35_2.docx @ 1852 @ @ 1 25,2 V 10 0 bar Start display 0 RPM OFF Fig.: 3 Pos: 7 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.docx @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions ES 2 – Control No.: ES2-Bediener (Volvo) Page 5, Issue: 04.2016 Pos: 8 /Aufbau und Beschreibung/ES 2 - Steuerung/Start Display Volvo @ 15\mod_1454317675928_2.docx @ 143451 @ @ 1 2.3 Exhaust after treatment Automatically exhaust after treatment via the engine control unit. 25.2 V 10 0 bar 0 r.p.m. Start display with AdBlue system (e.g. Volvo Stage IIIb/Tier 4i and Stage IV/Tier 4 f. engine) AdBlue fill level display OFF Fig.: Start display Function of softkey : activate/deactivate ignition. Pressing once will activate the ignition/stoppage magnet, and the symbol will be shown white on black. If pressed again: Ignition to the engine will be turned off. This function does not affect the starting of the engine. If the ignition is switched off (state after ES2 switched on), the ignition/stoppage magnet output will be activated when the start button is pressed, and then the starter with a delay of approx. 1-2 seconds. If the ignition has already been switched on with the key button, the engine can also be started. The ignition output will stay activated. When switching the engine off, the ignition/stoppage magnet output will always be switched off to stop the engine. The softkey can be helpful for engine service technicians, who can sometimes only access the engine control unit when the ignition is switched on. If the ignition is switched on, the level of the AdBlue tank will be displayed. This can prevent the AdBlue tank from overflowing when AdBlue is being topped up. The fill level of the AdBlue tank should not go below 22%. Top up in good time. If this is not done, there may be a reduction in power by the engine control unit. Only switch off the battery main switch about 2 mins after the ES2 has been turned off. During this time, the AdBlue lines are emptied in order to prevent them from becoming blocked up. Pos: 9 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.docx @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions ES 2 – Control No.: ES2-Bediener (Volvo) Page 6, Issue: 04.2016 Pos: 10 /Aufbau und Beschreibung/ES 2 - Steuerung/Vorglühen @ 0\mod29_2.docx @ 1840 @ 2 @ 1 2.4 Pre-heat Press 25,2 V 10 0 bar Pre-heat time (i.e.. t = 15 sec.) count down to 0 secs. 15, 14, 13, . . . . . 0 s 13 s Press again = repeat pre-heat time Fig.: 4 Pos: 11 /Aufbau und Beschreibung/ES 2 - Steuerung/Motor Starten @ 0\mod30_2.docx @ 1652 @ 2 @ 1 2.5 Engine START Press Pos: 12 /Aufbau und Beschreibung/ES 2 - Steuerung/Warnmeldung @ 3\mod1976_2.docx @ 1612 @ 3 @ 1 2.5.1 Tank warning 25,2 V 10 Filling level fuel tank 0 bar 0 UPM Message flashes in the sec. tact at running engine. With announcement filling level <10% a warning is given, however, the unit is not switched off. Also other faults can be programed with the same behaviour as warning. OFF Fig.: 5 Pos: 13 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.docx @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions ES 2 – Control No.: ES2-Bediener (Volvo) Page 7, Issue: 04.2016 Pos: 14 /Aufbau und Beschreibung/ES 2 - Steuerung/Überschrift Sollwerteinstellung @ 0\mod31_2.docx @ 1844 @ 2 @ 1 2.6 Entering a set value For control modes ref. to fig. 12, point 9 Pos: 15 /Aufbau und Beschreibung/ES 2 - Steuerung/Drucksollwert @ 0\mod32_2.docx @ 1656 @ @ 1 Entering a set value – units with pressure control Press 25,2 V or 10 0 bar Press 800 RPM to increase or to decrease. To confirm press or automatically after 10 secs. Fig.: 6 Pos: 16 /Aufbau und Beschreibung/ES 2 - Steuerung/Drehzahlsollwert @ 0\mod33_2.docx @ 1848 @ @ 1 Entering a set value – units with speed control Press 25,2 V or . 10 0 bar 800 RPM Fig.: 7 Pos: 17 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.docx @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Press to increase or to decrease. To confirm press or automatically after 10 secs. Operating instructions ES 2 – Control No.: ES2-Bediener (Volvo) Page 8, Issue: 04.2016 Pos: 18 /Aufbau und Beschreibung/ES 2 - Steuerung/Überschrift Benutzermenü @ 1\mod34_2.docx @ 1660 @ 2 @ 1 2.7 Operators menu Pos: 19 /Aufbau und Beschreibung/ES 2 - Steuerung/Start Display (mit Vorglühen) @ 1\mod35_2.docx @ 1852 @ @ 1 25,2 V 10 0 bar Start display 0 RPM OFF Fig.: 8 Pos: 20 /Aufbau und Beschreibung/ES 2 - Steuerung/Seite vorblättern @ 1\mod36_2.docx @ 1664 @ @ 1 Press Pos: 21 /Aufbau und Beschreibung/ES 2 - Steuerung/Grundmaske 1 @ 1\mod38_2.docx @ 1856 @ @ 1 -1- -2- -3- -4- No: 99.01402.3750 V:ES2 201204:I01.00 Unit: 1002h30 Pump: 1113h57 Pressure sensor Engine temperature Actual: 60C Max. : 95C : 4.0 mA -5- -610.01.05 12:19:19 Machine no. pump Software version ES2 Operating hours unit Operating hours pump date display time display Actuell value of pressure transmitter for controll, approx 4 mA at 0 bar Engine temperature EXIT Fig.: 9 Pos: 22 /Aufbau und Beschreibung/ES 2 - Steuerung/Seite vorblättern @ 1\mod36_2.docx @ 1664 @ @ 1 Press Pos: 23 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.docx @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions ES 2 – Control No.: ES2-Bediener (Volvo) Page 9, Issue: 04.2016 Pos: 24 /Aufbau und Beschreibung/ES 2 - Steuerung/Grundmaske 2 @ 1\mod48_2.docx @ 1860 @ @ 1 -1- -2- -3- -4- -5- -6- 1. Idle speed delay : OFF 2. Multi tool valve : ON 3. Language (ENGL) :ENGLISH 4. Display contrast 5. Display lighting : 130 : ON 6. Standby time : OFF By pressing or (shown inverse). Confirm with select a function . Change value with or . Confirm with EXIT Fig.: 10 Pos: 25 /Aufbau und Beschreibung/ES 2 - Steuerung/Grundmaske 2 a @ 1\mod521_2.docx @ 1948 @ @ 1 -1- -2- -3- -4- -5- -6- 1. Idle speed delay : inactive 2. Multi tool valve : ON 3. Language (ENGL) :ENGLISH 4. Display contrast 5. Display lighting : 130 : ON 6. Standby time : OFF Functions which have been deleted at the factory are designated inactive. These can not be selected (e.g. 1. Idle speed delay). EXIT Fig.: 11 Pos: 26 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.docx @ 1188 @ @ 1 Pos: 27 /Aufbau und Beschreibung/ES 2 - Steuerung/Grundmaske 3 @ 1\mod39_2.docx @ 1668 @ 3 @ 1 -1- -2- -3- -4- -5- 7. Set min pressure 7.1. Delay min bar ON 7.2. Delay min bar OFF -6: 50bar :15 s : 3 s 8. Hose length : 20 m 9. Control type : PRESSURE By pressing or (shown inverted). Confirm with . Change value with Confirm with EXIT Fig.: 12 Pos: 28 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.docx @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 select a function or . Operating instructions ES 2 – Control No.: ES2-Bediener (Volvo) Page 10, Issue: 04.2016 Pos: 29 /Aufbau und Beschreibung/ES 2 - Steuerung/Grundmaske 4 @ 1\mod54_2.docx @ 1868 @ 3 @ 1 2.7.1 Selecting of the pressure step -1- -2- -3- -4- 10. Pressure steps Max. pressure Max. speed -5- -6: 2 : 1900 bar : 2100 UPM 11. Emergency programm 12. Reports By pressing or select a pressure step (shown inverted), if factory adjusted. : OFF Confirm with . Display changes to input key code. 13. Function menu EXIT Fig.: 13 Pos: 30 /Aufbau und Beschreibung/ES 2 - Steuerung/Passwort Druckstufe @ 3\mod1930_2.docx @ 1596 @ @ 1 With or assign the digit. Then go with to the next digit (underlined) The digit changes to *. All Input key code Value limit from 0000 to 9999 Code confirm Cancel digits must be entered 0000 Select „Code confirm“ and The code is: 1, 2, 3, 0 or: 0, 1, 2, 3 Display changes to prior page. → Fig.: 14 Pos: 31 /Aufbau und Beschreibung/ES 2 - Steuerung/Grundmaske 4a Druckstufe auswählen @ 3\mod1931_2.docx @ 1600 @ @ 1 -1- -2- -3- 10. Pressure step Max. pressure Max. speed 11. Emergency programm 12. Reports 13. Function menu -4- -5- -6: 2 : 2500 bar : 1800 UPM : AUS By or select one of the in the factory set pressure steps. 1, 2, or 3 (shown inverted). Confirm with . Display changes back to pressure step setting (prior page) 10. Pressure step shown inverted again. EXIT Fig.: 15 Pos: 32 /Aufbau und Beschreibung/ES 2 - Steuerung/Seite vorblättern @ 1\mod36_2.docx @ 1664 @ @ 1 Press Pos: 33 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.docx @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions ES 2 – Control No.: ES2-Bediener (Volvo) Page 11, Issue: 04.2016 Pos: 34 /Aufbau und Beschreibung/ES 2 - Steuerung/Grundmaske 5 @ 1\mod1004_2.docx @ 1984 @ 3 @ 1 2.7.2 Teach in function -1- -2- -3- -4- -5- 14.Pressure to learn :OFF 15.Consumer 16.Consumer 17.Consumer 18.Consumer 19.Consumer 20.Consumer 3 15 l/min 13 l/min 18 l/min inaktiv inaktiv number: 1: 2: 3: 4: 5: -6Teach in function to save speed/pressure values for multi tool operation. >Switch multi tool valve (2) to „ON“. >Set control type (9) to “Teach in” >Pressure to learn (14.) set to „ON“ and confirm At running unit set the flow rates (ref. to appendix „Teach in“) EXIT Fig.: 16 Pos: 35 /Aufbau und Beschreibung/ES 2 - Steuerung/Ext. Sollwert / Sollwertvorgabe @ 5\mod_1260355836103_2.docx @ 33277 @ 3 @ 1 2.7.1 External set value / set value parameter If external set value inactive: -1- -2- -3- -4- 21.Set clock time 22.Set date 23.Set value source 24.Keypad lock 25.Remote control 26.Modem: -5- -6- 12:19:19 01.10.05 : Keypad :OFF inactive inactive Active set value is shown invers Keypad: Setting the set value by using the keypads of the ES2 (ref.to entering a set value) EXIT Fig.: 17 If external set value active: -1- -2- -3- 21.Set clock time 22.Set date 23.Set value source 24.Keypad lock 25.Remote control 26.Modem: EXIT Fig.: 18 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 -4- -5- -6- 12:19:19 01.10.05 : External :OFF inaktive inactive Active set value is shown invers External: The set value is sent over an external signal (0 – 10V) to the ES2. Operating instructions ES 2 – Control No.: ES2-Bediener (Volvo) Page 12, Issue: 04.2016 25,2 V The start display behaves then as accompanying represented. 10 0 bar At pressing from value 800 UPM or i.e. at speed Fig.: 19 If variable set value: -1- -2- -3- -4- 21.Set clock time 22.Set date 23.Set value source 24.Keypad lock 25.Remote control 26.Modem: -5- -6- 12:19:19 01.10.05 : External :OFF inaktive inactive Changing of the source of set value on menu page 6 by: By keypads or select point 23. set value source and with confirm. Selecting „Keypads“ or „External“ with and EXIT . Confirm desired mode with . Fig.: 20 Pos: 36 /Aufbau und Beschreibung/ES 2 - Steuerung/Grundmaske 6 @ 3\mod1932_2.docx @ 1604 @ 3 @ 1 2.7.2 Keypad lock -1- -2- -3- 21. Set clock time: 22. Set date: 23. Set value source 24.Keypad lock 25.Remote control 26.Modem: -4- -512:19:19 01.10.05 : Keypad :OFF inactiv inactiv -6- Select keypad lock (shown inverse). Confirm with . With select ON or Confirm with EXIT Fig.: 21 Press EXIT or after 30 sec. automatically return to basic display. Pos: 37 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.docx @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions ES 2 – Control No.: ES2-Bediener (Volvo) Page 13, Issue: 04.2016 Pos: 38 /Aufbau und Beschreibung/ES 2 - Steuerung/Start display mit Schloss @ 1\mod1005_2.docx @ 1988 @ @ 1 25,2 V 10 The symbol will flash for 30 sec. time allowing you to switch the keypad lock “OFF”. After this the keypad lock is active. 0 bar 0 RPM After pressing one of the keys the following display will appear. OFF Fig.: 22 Pos: 39 /Aufbau und Beschreibung/ES 2 - Steuerung/Password Tastensperre aufheben @ 1\mod1006_2.docx @ 1992 @ 3 @ 1 2.7.3 Switch OFF the keypad lock With Input key Code Value limit from 0000 to 9999 Code confirm 0000 or enter 2 first Then go with to the next digit (underlined) The digit changes to *. All digits must be entered. The Code is 2002 Cancel Select „Code confirm“ and → Fig.: 23 Changing to start display without symbol. Within 30 sec. select the menu line 24 and switch the keypad lock „OFF“ Pos: 40 /Aufbau und Beschreibung/ES 2 - Steuerung/Überschrift Funktionsmenü @ 1\mod51_2.docx @ 1864 @ 2 @ 1 2.8 Function menu Pos: 41 /Aufbau und Beschreibung/ES 2 - Steuerung/Funktionsmenü auswählen @ 1\mod52_2.docx @ 1676 @ @ 1 Select 13. Function menu -1- -2- -3- -4- 10. Pressure step Max. pressure Max. speed 11. Emergency programm 12. Reports 13. Function menu O2K OWF3TL1D 111 11111111 EXIT Fig.: 24 Pos: 42 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.docx @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 -5- -6: 2 : 2500 bar : 1800 UPM : AUS R123456 111111 Select 13. Function menu with or . Status display inputs Press . Than the complete Function menu will be displayed (ref. to following fig.) Operating instructions ES 2 – Control No.: ES2-Bediener (Volvo) Page 14, Issue: 04.2016 Pos: 43 /Aufbau und Beschreibung/ES 2 - Steuerung/Funktionsmenü 1 Digitale Geber @ 1\mod49_2.docx @ 1672 @ 3 @ 1 2.8.1 Digital sensor Status of inputs Meaning 1 = Condition OK 0 = Fault / Condition not fulfill. Faults which displayed as FREE 2 / FREE 3 can be have unit dependent functions and designations U=Battery=25.1V at 31.5C 0=1 2=1 K=1 >Engine oil pressure >FREE2 >Coupling 0=1 W=1 F=1 3=1 T=1 L=1 >Oil pressure pump >Water feed pressure >Water filter >FREE3 >Water temp. pump. >Air pressure Shut off valve test Starter test EXIT Exit menu Pre Heat test Pressing the softkeys will activate functions of the unit (for example: Shut off valve test) as follows: EXIT Fig.: 25 Press 0=1 W=1 F=1 3=1 T=1 L=1 >Oil pressure pump >Water feed pressure >Water filter >FREE3 >Water temp. pump. >Air pressure EXIT Pressing will display the shut off valve symbol inverted as long as you keep presssing . The same functions with the starter, as long as you keep pressing Fig.: 26 Pos: 44 /Aufbau und Beschreibung/ES 2 - Steuerung/Seite vorblättern @ 1\mod36_2.docx @ 1664 @ @ 1 Press Pos: 45 /Aufbau und Beschreibung/ES 2 - Steuerung/Funktionsmenü 2 @ 1\mod55_2.docx @ 1680 @ @ 1 Status of inputs Meaning 1 = Condition OK 0 = Fault / Condition not fulfill. Faults which displayed as FREE 1 / RES.1 can be have unit dependent functions and designations Voltage = 26,1 V 1= 1 D= 1 R1= 1 R2= 1 R3= 1 R4= 1 R5= 1 R6= 1 >FREE1 <Generator fault voltage >RES.1 >RES.2 >RES.3 >RES.4 >RES.5 >RES.6 General fault output EXIT Fig.: 27 Pos: 46 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.docx @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions ES 2 – Control No.: ES2-Bediener (Volvo) Page 15, Issue: 04.2016 Pos: 47 /Aufbau und Beschreibung/ES 2 - Steuerung/Funktionsmenü 1 Analoge Geber @ 3\mod1942_2.docx @ 1608 @ 3 @ 1 2.8.2 Analogue sensor Status of inputs Meaning Actual- limit value U=Battery=25.1V at 31.5C 0=1 2=1 K=1 >Engine oil pressure >FREE2 >Coupling 0= 0.0 < 2.0bar W= 0.1 < 2.0bar F= 0.0 > 1.2bar 3=1 T=17 > 40C L= 6.3 < 5.5bar >Öil pressure pump >Water feed pressure >Water filter >FREE3 >Water temp. pump >Air pressure EXIT Same as digital sensor In addition the actual and limit values of the appropriate sensors indicated. For example: Air pressure is OK: Actual value: 6,3 bar Limit value: < 5,5 bar Pump water temperature is OK: Actual value: 17° C Limit value: > 40° C Fig.: 28 Or at failure of the sensor U=Battery=25.1V at 31.5C 0=1 2=1 K=1 >Engine oil pressure >FREE2 >Coupling 0= ERROR W= 0.1 < 2.0bar F= 0.0 > 1.2bar 3=1 T=17 > 40C L= 6.3 < 5.5bar >Öil pressure pump >Water feed pressure >Water filter >FREE3 >Water temp. pump >Air pressure EXIT Fig.: 29 Pos: 48 /Aufbau und Beschreibung/ES 2 - Steuerung/Seite vorblättern @ 1\mod36_2.docx @ 1664 @ @ 1 Press Pos: 49 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.docx @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Water boost pressure is not OK: (if the unit is not running, there is no fault) Actual value: 0,1 bar Limit value: < 2,0 bar Oil pressure pump, fault of the sensor current is < 4 mA (wire break) Operating instructions ES 2 – Control No.: ES2-Bediener (Volvo) Page 16, Issue: 04.2016 Pos: 50 /Aufbau und Beschreibung/ES 2 - Steuerung/Funktionsmenü 3 @ 1\mod56_2.docx @ 1872 @ @ 1 Pressing + T/FU = 1,6V ------------------------------------------------------------with 0-10V (1.100) Uout = 0,03 V RPM = 0 Actual value OK ----------------------------------------------------St>V1=1 V2&3=1 V4&5=1 BV=1 EXIT + - Pressing - =+ Increase engine speed (test) = - Decrease engine speed (test) At running engine This function can be used e.g. for warm up the engine or to check the r.p.m. adjusting of the ES2. In this menu it isn’t possible to start high pressure Status Multi tool valve /Bypass valve Fig.: 30 EXIT Exit menu and change to start display Pos: 51 /Aufbau und Beschreibung/ES 2 - Steuerung/Überschrift Fehler Protokoll @ 1\mod58_2.docx @ 1684 @ 2 @ 1 2.9 Fault report Select 12. Reports at the operators menu. Pos: 52 /Aufbau und Beschreibung/ES 2 - Steuerung/12 Protokolle @ 1\mod523_2.docx @ 1952 @ @ 1 12 Reports 12.1 12.2 12.3 12.4 12.5 Fault report Read Can fault Read CAN data M-value T1: 1min> 960RPM M-value T2: 1h > 1321RPM 12.1 Select Fault report <<< Back EXIT Fig.: 31 Pos: 53 /Aufbau und Beschreibung/ES 2 - Steuerung/Bestätigung @ 1\mod64_2.docx @ 1884 @ @ 1 Press Pos: 54 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.docx @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions ES 2 – Control No.: ES2-Bediener (Volvo) Page 17, Issue: 04.2016 Pos: 55 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlerprotokoll @ 1\mod524_2.docx @ 1956 @ @ 1 No Az. 1 2 3 4 5 6 7 8 9 <<< Back 0 0 0 0 0 0 0 0 1 Fault Engine error Low engine oil pressure FREE2 Low pump oil pressure Low feed water pressure Blocked water filter FREE3 High p.water temp Max.pressure exceeded Delete fault memory (only possible with key code) List of all possible faults and their number of (Example) Select Max. pressure exceeded EXIT with Fig.: 32 or . (also ref. to fault indication) Pos: 56 /Aufbau und Beschreibung/ES 2 - Steuerung/Bestätigung @ 1\mod64_2.docx @ 1884 @ @ 1 Press Pos: 57 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehler Protokoll Beispiel @ 1\mod60_2.docx @ 1688 @ @ 1 Max. pressure exceeded No Date Time 1 21.12.00 10:40 Hour. 1002 Mode STOP back to previous fault report page. ? change to “Help page” (causes) EXIT ? Fig.: 33 Pos: 58 /Aufbau und Beschreibung/ES 2 - Steuerung/Fragezeichen Betätigen @ 1\mod534_2.docx @ 1976 @ @ 1 Press Pos: 59 /Aufbau und Beschreibung/ES 2 - Steuerung/Ursachen @ 1\mod528_2.docx @ 1968 @ @ 1 Causes - > 10% above max. permissable pressure - Incorrect nozzle (s) fitted to tool(s) - Nozzle(s) blocked - Hose length > 20 m Press to access list of remedies EXIT Fig.: 34 Pos: 60 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.docx @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions ES 2 – Control No.: ES2-Bediener (Volvo) Page 18, Issue: 04.2016 Pos: 61 /Aufbau und Beschreibung/ES 2 - Steuerung/Behebung @ 1\mod529_2.docx @ 1972 @ @ 1 Remedy > Check nozzle(s) fitted. Do not operate at below 1200 r.p.m > Replace nozzle(s) > Clean or replace nozzle(s) > Change hose length from 20 m to 100 m (Point 10). = back to causes. EXIT to leave this menu. EXIT Fig.: 35 Pos: 62 /Aufbau und Beschreibung/ES 2 - Steuerung/Aktive Fehler von CAN-Bus @ 1\mod525_2.docx @ 1960 @ @ 1 Select at the fault report menu “12.2 Read CAN Fault” Active Faults from CAN-Bus/DM2 1 2 3 4 5 6 7 8 9 10 Displays active faults (displays engine electronic faults during operation) The faults are indicated according to standard (SAE J 1939 code) e.g.: SPN -> Fault number e.g. 98 = oil level FMI -> fault level e.g. 15 = warning 3 = critical 1 = shut off (also ref. to fault indication) EXIT Fig.: 36 Pos: 63 /Aufbau und Beschreibung/ES 2 - Steuerung/CAN Daten @ 1\mod526_2.docx @ 1964 @ @ 1 At fault report select “12.3 Read CAN data” CAN Data 1>Set RPM 2>Actual RPM 3>Set engine torque 4>Diesel Pressure 5>Diesel Temp. 6>Consumption 7>Coolant temp. 8>Coolant level 9>Oil pressure 10>Oil temp. 11> =--.= 800 = --=--.= --= --= 58 = 100 = 0 =--.- RPM RPM % bar C L/h C % bar C Current data of the machine to be sent over CAN –Bus Indicated values dependent on the machine sensor system Not installed sensors are explained as lines. EXIT Fig.: 37 Pos: 64 /Aufbau und Beschreibung/ES 2 - Steuerung/Erklärung der Begriffe/Funktionen Bedienermenü ohne Not @ 5\mod_1260525302849_2.docx @ 33303 @ 2 @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions ES 2 – Control No.: ES2-Bediener (Volvo) Page 19, Issue: 04.2016 2.10 Explanation of the terms/functions at the operators menu 1. 2. 3. 4. 5. 6. 7. 7.1 7.2 8. 9. 10. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 24. 25. 26. Idle speed delay: The engine stays at working speed after the bypass opens for the length of time set so that the tool operator can pause without the engine dropping to idle speed. Multi gun valve yes/no: Switches the multi gun valve outputs to active or inactive. Language: Select the language which will be displayed at the operators menu. Display contrast: Adjust the contrast setting. Display lighting: Switching the lighting ON/OFF . Standby time: If the set time expires without a signal to close the bypass the unit will shut down. Set min. pressure: Sets the minimum high pressure value (in bar) that the unit should not run below. The minimum high pressure value is changing automatically when changing the set value. The difference will stay. Delay min bar ON: Delays switching on the monitoring time of the HP – min. Delay min bar OFF: Delays switching off the monitoring time of the HP – min. Hose length: Select either 20m or 100m. The regulation will start depending on what is selected after the set time. Control mode: If programmed at the factory, changeable between control of engine speed and control by pressure setting. Pressure steps: Use password to select factory programmed pressure steps. Protocol : Displays the history of faults with dates, times and regularity. Shows values and actual faults of CAN-Bus Function menu : Displays the status of the total inputs in the ES 2. Enter menu by pressing the OK (confirm) keypad. Pressure to learn: Start Teach-in-function Consumer number: Adjust the number of consumer (1 . . . 5) Consumer 1: Consumer 2: Adjust the flow rate Consumer 3: of each consumer Consumer 4 at multi gun operation. Consumer 5: Set clock: Set the clock time, that will be displayed in ES2 Set date: Set the date, that will be displayed in ES2 Lock keypads: Prevents use of the keypads. Remote control: Enables receipt of serial data, for example from a SPS or a PC (remote control) Modem: Activation of the far maintenance about modem Pos: 65 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.docx @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions ES 2 – Control No.: ES2-Bediener (Volvo) Page 20, Issue: 04.2016 Pos: 66 /Aufbau und Beschreibung/ES 2 - Steuerung/Überschrift Fehlermeldungen @ 1\mod98_2.docx @ 1808 @ 2 @ 1 2.11 Fault indication Pos: 67 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 1 Motorstörung @ 1\mod99_2.docx @ 4044 @ @ 1 Fault indication after switching on the ES2 Cause: 24 pole-plug is missing (bridge in the plug), therefore the control is missing the information whether it is a diesel or an electrical driven unit. Remedy: Check the 24 pole plug! Bridge: 17 – 21 and 18 – 20 for diesel unit Bridge: 16 – 18 and 21 – 22 for electrical units Fault display Cancel the fault indication “Engine fault” by pressing Fault 1 Engine fault (what to do) . Press It is possible the fault code 22 “Generator fault” will be displayed. If you cannot start the engine again and no other fault code no. appears the problem could be one of the following: At electronic engines jump directly to point “12.2 Read CAN fault” over the button “CAN fault list” and identify the fault over the SPN-no. If necessary call the engine supplier. Important! During connection to the diagnostic plug socket (at electronic engines) the page 12.2 “Read CAN fault” or page 12.3 “Read CAN data” can be called into the ES2, so that the engine control equipment is current-fed at stopped unit (shut off valve – output is energized) The engine speed is for 3 sec. under the min. engine speed independent shut off the engine by (for example): Causes Remedy Fuel filter blocked. Change the filter. On air cooled Deutz engines check the hand pump filter. Fuel tank empty. Fill tank. Fuel line defective. Check line, clear or replace as necessary.. Air in the fuel system. Check fuel level. Check that fuel line is airtight. Fault 1 Ensure that tank (unit) is not tilted too much. Engine fault The suction line must be at the bottom of the tank. Start solenoid not functioning. Check in function menu of the ES2. Check wiring connections, if necessary replace or refit. Nozzle inserts to small. Check and replace if necessary Consumer closed. Open consumer Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions ES 2 – Control No.: ES2-Bediener (Volvo) Page 21, Issue: 04.2016 Fault identifying over CAN-Bus code no. 12.2 “Read CAN fault” or by fault Fault 1 Cut off by engine electronic Engine fault indication press CAN-Button If necessary call engine supplier. . Pos: 68 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 2 Öldruck Motor @ 1\mod100_2.docx @ 4096 @ @ 1 Fault 2 Low engine oil pressure Oil level too low. Top up engine oil or change the oil. Oil filter blocked. Change oil filter, possibly change the oil.. Oil pressure switch defective. Check pressure switch and repair or replace if necessary. Pos: 69 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 3 Freidefinierbarer Fehler 2 @ 1\mod235_2.docx @ 4064 @ @ 1 Fault 3 Free definable Fault FREE 2 (Designation and function depending to the HPP construction) Is this fault set as a warning and a CANBus is installed, it is possible to jump dirrectly to point “12.2 Read CAN fault” by pressing the button . Drive belt defective (only applicable to Deutz air cooled diesel engines) Drive belt is broken, off pulley or loose. Replace, refit or retension as necessary. CAT – engine fault Identify the fault by the flash code or by SPN-code “12.2 Read CAN fault” Or if necessary call CAT-Service. At machines with fast shut down flap “Over speed” is reached. Open the fast shut down flap. DEUTZ – engine fault Identify the fault over the CAN-Bus-SPNcode “12.2 Read CAN fault” Call DEUTZ-Service. Important! By connection to the diagnostic plug socket (at electronic engines) “12.2 Read Can fault” or the page “12.3 “Read CAN data” can be called into the ES2, so that the engine control equipment is current - fed. Pos: 70 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 4 Öldruck Pumpe zu gering @ 1\mod105_2.docx @ 4100 @ @ 1 Fault 4 Oil level too low Top up or change the oil. Oil filter blocked. Change oil filter, possibly change the oil Oil temperature too high Drop in viscosity Low pump oil pressure Oil pressure switch defective. Check oil temperature. Check coolant water. Observe the oil pressure gauge. Oil pressure approx. 5 bar. If oil pressure is sufficient > 2 bar check oil pressure switch. If necessary repair or replace. Check sensors Sensor power 4 mA If necessary replace sensor. Pos: 71 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 5 Wasservordruck zu klein @ 1\mod106_2.docx @ 4048 @ @ 1 Fault 5 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Check water supply or water filling level at the water tank. Operating instructions ES 2 – Control No.: ES2-Bediener (Volvo) Page 22, Issue: 04.2016 Low feed water pressure Boost pump defective. Check boost pressure gauge. Boost pressure > 3 bar. Belt drive broken or loose Check drive belt tension, adjust or change it. Waterfilter blocked. Exchange water filter. Repair or replace as necessary Water pressure switch defective. Check sensors Sensor power 4 mA If necessary replace sensor. Pos: 72 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 6 Wasserfilter verschmutzt @ 1\mod108_2.docx @ 4084 @ @ 1 Filter bag blocked Reset the red button on the differential pressure switch. Fault 6 Blocked Water filter Replace filter bag Differential pressure switch defective Check differential pressure switch and replace as necessary. Check sensors Sensor power 4 mA If necessary replace sensor. Pos: 73 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 7 Freidefinierbarer Fehler 3 @ 1\mod236_2.docx @ 4060 @ @ 1 Fault 7 FREE 3 Ref. to technical information (Designation and function depending to the HPP construction) Ref. to technical information Supply water temperature > 30°C. Check water supply Pos: 74 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 8 Wassertemp. Pumpe zu hoch @ 1\mod237_2.docx @ 3996 @ @ 1 Fault 8 Water temp. too high Water temperature at feed water tank Fill with cool water. too high. Operation with to much bypass water. Drain the bypass-water separately Pressure has exceeded > 10 % of max. pressure Check nozzles The nozzles diameter(s) must be selected to achieve 1200 rpm. Minimum engine speed. Wrong nozzle(s) Exchange nozzle(s) Nozzle(s) are blocked Clean or exchange nozzle(s). Hose length > 20 m In operators menu (point 10) change „20 m“ to „100 m“. Pos: 75 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 9 Hochdruck überschritten @ 1\mod109_2.docx @ 4052 @ @ 1 Fault 9 Max. pressure exceeded Pos: 76 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 10 Max. Standby-Zeit @ 1\mod110_2.docx @ 4088 @ @ 1 Fault 10 The time setting (standby time) at idle speed exceeded. Standby time exceeded Increase standby time or shut off. Pos: 77 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 11 Freidefinierbarer Fehler 1 @ 1\mod238_2.docx @ 4000 @ @ 1 Fault 11 FREE 1 Ref. to technical information (Designation and function depending to the HPP construction) Ref. to technical information Pos: 78 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 12 Kurzschluss an Bypass/USV @ 1\mod111_2.docx @ 4056 @ @ 1 Fault 12 A fault in the installation indicates + Short circuit Bypass/MTV signal to the bypass or multi tool valve. Disconnect bypass valve or multi tool valve Check the whole installation, Disconnect all units, fault remains ES2 defective exchange Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions ES 2 – Control No.: ES2-Bediener (Volvo) Page 23, Issue: 04.2016 Pos: 79 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 13 Motordrehzahl überschritten @ 1\mod239_2.docx @ 4004 @ @ 1 Max. rpm. of the engine has been exceeded by 10 % or more (5 sec.). Fault 13 Max. rpm exceeded Only in pressure control mode: Incorrect (too large) nozzle(s). Too much bypass water (incorrect PRV setting) Wear in the bypass / PRV . After exchanging the linear motor at idle speed. Readjust the linear motor. High engine temperature Check coolant water level. Cooler blocked Check cooler Ventilator defective Check ventilator Air supply or air outlet blocked. Check the openings of air supply and air outlet. Pos: 80 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 14 Motortemperatur zu hoch @ 1\mod113_2.docx @ 4028 @ @ 1 Fault 14 High engine temp Pos: 81 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 15 Druckaufnehmer defekt @ 1\mod114_2.docx @ 4092 @ @ 1 Check the. 4 mA in the operators menu. Fault 15 Pressure sensor defective Defective pressure sensor If 0 mA the bypass socket or wiring to socket is faulty. Check the socket for short circuit. If bypass socket is O.K If voltage is approx. 22 volts but 4 mA current is not present replace the transducer. Pos: 82 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 16 Luftdruck zu gering @ 1\mod115_2.docx @ 4032 @ @ 1 Shut off high pressure air pressure > 5 bar, automatically reset fault. Fault 16 Min. air pressure < 5 bar Low air pressure Check pneumatic installation Check pressure switch/sensor sensor power 4 mA if necessary exchange. If an air filter is dirty, the air flow will be is reduced. This will result in the air pressure behind the filter crashing briefly when the high pressure is activated, since only a small amount of air can flow through the filter. If it takes too long for the air pressure behind the filter to stabilise, a unit with air pressure monitoring will switch off giving an appropriate error message "air pressure too low". Only one warning will be shown on the display of the ES2 and the high pressure will be switched off. The engine will continue to run at idle (no air pressure can be built up without a running engine!) The warning will disappear however as soon as the air pressure is OK again. Cleaning air filter. Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions ES 2 – Control No.: ES2-Bediener (Volvo) Page 24, Issue: 04.2016 Pos: 83 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 17 Hochdruck zu gering @ 1\mod116_2.docx @ 4068 @ @ 1 Check nozzle(s) for wear and replace if necessary. Fault 17 The minimum allowable pressure is not achieved Check high pressure pipework and hoses for leakage. Re-tighten fittings only after pressure is released and the unit is shut down! Below min pressure The minimum allowable pressure is not achieved within a given time (in the operators menu). Check programmed data for minimum pressure and make corrections if necessary. Check the power of the engine. Fault 18 Only at speed control Actual RPM are lower than the bypass set RPM Insufficient engine speed Wrong nozzle(s) or defective or blocked Check nozzle(s) if necessary exchange. Incorrect pressure set value entered. Correct the value. The alternator is faulty. Repair or replace. The power to the unit is in excess of 33 V DC External power source attached. Switch off and remove immediately. Cable or connector fault. Check cable Replace or repair cable. Control cable defective Remove control cable from unit. Short circuit bypass - switch or - socket Pull the bypass cable from the socket V-belt for generator broken or loose Replace or retension as necessary. Cable of generator loose or defective. Replace or tighten terminals. Pos: 84 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 18 Arbeitsdrehzahl unterschritten @ 1\mod117_2.docx @ 4036 @ @ 1 Check fuel system. Clean diesel filter. Pos: 85 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.docx @ 1188 @ @ 1 Pos: 86 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 19 Überspannung @ 1\mod118_2.docx @ 4072 @ @ 1 Fault 19 Voltage overload Pos: 87 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 20 Drahtbruch Temperaturfühler @ 1\mod119_2.docx @ 4040 @ @ 1 Fault 20 Defective temp. sensor Pos: 88 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 21 Steuerkabel defekt @ 1\mod120_2.docx @ 4076 @ @ 1 Fault 21 Defective control cable Repair or replace control cable. Check bypass socket, if necessary repair. Pos: 89 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 22 Generator defekt @ 1\mod121_2.docx @ 4024 @ @ 1 Fault 22 Generator fault Cable defective. Pos: 90 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 23 Füllstand Kraftstofftank @ 1\mod122_2.docx @ 4080 @ @ 1 Fault 23 Diesel fuel level Diesel tank empty Fill up. Diesel filter blocked Check diesel filter clean or exchange as necessary. Diesel line/hose blocked or defective Check diesel line, clean or exchange as necessary. Air in diesel line Air venting of the diesel line. Unit is not on level ground. Relocate Sensor defective Check sensor, exchange as necessary. Pos: 91 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 24 Keine Gen. Impulse @ 1\mod240_2.docx @ 4008 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions ES 2 – Control No.: ES2-Bediener (Volvo) Page 25, Issue: 04.2016 Fault 24 Generator signal fault V-belt of the generator loose or broken. Replace or retension as necessary. Cable (W) loose or defective. Replace or tighten terminals. No speed signal from CAN-Bus. At registered CAN-Bus call engine supplier. Pick up sensor defective. Check pick up sensor or replace Air pressure to low Check air pressure > 5 bar. Pos: 92 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.docx @ 1188 @ @ 1 Pos: 93 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 25 Kupplung ausgerückt @ 1\mod241_2.docx @ 4012 @ @ 1 Fault 25 Clutch disengaged Check hoses. Pos: 94 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 26 - 31 Reserve 1 - 6 @ 3\mod1979_2.docx @ 4104 @ @ 1 Fault 26 Res. 1 Fault 27 Res. 2 Fault 28 Res. 3 Fault 29 Inputs can be covered according to unit. Res. 4 Fault 30 Res. 5 Fault 31 Res. 6 Pos: 95 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 32 Druck im Leerlauf @ 1\mod250_2.docx @ 3972 @ @ 1 Fault 32 Pressure at idle speed Pressure is higher than the programmed value for the engine at idle speed. (Parameter 2.3) Check parameter 2.3 Bypass or multi tool valve defective Check valve(s), Emergency stop button pressed. Check emergency stop button. Pos: 96 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 33 Not-Aus @ 1\mod251_2.docx @ 3976 @ @ 1 Fault 33 Emergency stop tripped Check the cable(s). Pos: 97 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 34 Not Programm @ 1\mod253_2.docx @ 3968 @ @ 1 Fault 34 Emergency progra. activ Emergency programme is set to active Pos: 98 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.docx @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Set emergency programme to inactive. Operating instructions ES 2 – Control No.: ES2-Bediener (Volvo) Page 26, Issue: 04.2016 Pos: 99 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 35 bis 47 CAN-Bus Warnungen @ 1\mod1007_2.docx @ 3964 @ @ 1 Fault 35 Diesel filter dirty Diesel filter dirty Fault 36 Diesel differential pressure Fault 37 Diesel level Fault 38 Oil level engine Fault 39 Oil differential pressure Fault 40 Engine oil pressure Fault 41 Charger pressure Fault 42 Air inlet pressure Fault 43 Coolant temperature Fault 44 Coolant level Fault 45 Fuel temperature Fault 46 Engine over speed Fault 47 Fault CAN Bus Diesel differential pressure to high Diesel level low Oil level engine low Oil differential pressure to high Engine oil pressure low Charger pressure to high Air inlet pressure low General CAN - bus warnings of the engine electronics (undependent on engine type). The engine is only switched off with stop exit of the engine electronics. Dependent on the obstructed engine sensors. Not installed sensors produce no warning/switching off of the engine. Coolant temperature high Coolant level low Fuel temperature to high Engine overspeed General fault of the engine electronics Pos: 100 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 48 Parameter Error @ 3\mod1980_2.docx @ 4108 @ @ 1 Quit fault display with Fault 48 Parameter Error Loss of operating relevant parameters. . Restart the ES2. The parameter sentence is automatically reproduced. Pos: 101 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 49 Düsen wechseln @ 4\mod_1207122308454_2.docx @ 23383 @ @ 1 Fault 49 Change nozzles (Teach-in operation) Nozzles worn Nozzles damaged. Change nozzles. Pos: 102 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 50 Hochdruck zu gering @ 4\mod_1207122880373_2.docx @ 23388 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions ES 2 – Control No.: ES2-Bediener (Volvo) Page 27, Issue: 04.2016 Nozzles worn. Fault 50 High pressure low (Teach-in operation) Max. flow rate of the pump exceeded Wrong nozzle dia. Selected. Change nozzles. Check high pressure side. Never retighten under pressure! Leackage of high pressure Pos: 103 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 51 DRV verschlissen @ 15\mod_1454410288594_2.docx @ 143703 @ @ 1 Fault 51 (Only for unused mode of operation "cutting unit") PRV worn Pos: 104 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 52 Drehmoment überschritten @ 15\mod_1454410422440_2.docx @ 143711 @ @ 1 Monitoring for different pressure phases. Fault 52 Torque exceeded Wrong pressure step selected and high pressure pump overloaded Check set pressure step.. Pos: 105 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 53 AdBlue Pegel Gering @ 15\mod_1454410687836_2.docx @ 143719 @ @ 1 Fault 53 AdBlue level low AdBlue fill level below 1. Warning stage of engine reached. Top up AdBlue. AdBlue fill level below 2. Warning stage of engine reached. The engine power can be reduced by the engine control unit. Top up AdBlue. Pos: 106 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 54 Leistungsreduzierung @ 15\mod_1454410977113_2.docx @ 143727 @ @ 1 Fault 54 Power reduction Pos: 107 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Hinweis Abschaltung des Motors @ 4\mod2330_2.docx @ 4112 @ @ 1 In the ES2 indicated CAN warnings can lead to the disconnection of the engine by the engine electronics. In the display of the ES2 the fault 1 "engine fault” or fault 3 "CAT / Deutz engine fault" is indicated. The exact fault cause can be read about the ES2, page 4, point 12 "protocols", 12.2" CAN faults" as a number SPN select. e.g. SPN = 100 => Oil pressure SPN = 107 => Air filter SPN = 110 => Cooling water To delete the faults in the engine control device go forward as follows: 1. Switch off the ES2 control. 2. Remove selected fault. 3. Make the engine electronics for approx. 20 sec. without tension. 4. Turn on the ES2 control . Wait after appearance of the basic display approx. 10 sec. Start afterwards the engine. Pos: 108 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.docx @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions ES 2 – Control No.: ES2-Bediener (Volvo) Page 28, Issue: 04.2016 Pos: 109 /Aufbau und Beschreibung/ES 2 - Steuerung/Anhang Arbeiten mit Umschaltventil und TEACH IN @ 4\mod_1196254260960_2.docx @ 20976 @ 2 @ 1 2.12 Working with multi gun valve and „Teach in“ -1- -2- -3- -4- -5- -6- 1. Idle speed delay : 15s 2. Multi gun/Teach in : ON 3. Language (ENGL) :ENGLISH 4. Display contrast 5. Display lighting : 130 : ON 6. Standby time : OFF Change in page 2, point 2 „Multi gun/Teach in“ by pressing and or in „ON“. EXIT Fig.: 38 -1- -2- -3- -4- -5- 7. Set min. Pressure 7.1. Delay min bar ON 7.2. Delay min bar OFF -6:inactiv :inactiv :inactiv 8. Hose length : 20 m 9. Control type : SPEED Select page 3, point 9 By pressing change the control type EXIT Fig.: 39 -1- -2- -3- -4- -5- 7. Set min. Pressure 7.1. Delay min bar ON 7.2. Delay min bar OFF -6- to Teach-in. :inactiv :inactiv :inactiv Confirm with 8. Hose length : 20 m 9. Control type : Teach in.. . By pressing EXIT leave menu. EXIT Fig.: 40 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions ES 2 – Control No.: ES2-Bediener (Volvo) Page 29, Issue: 04.2016 25,2 V 1 2 00 Start the engine 3 00 00 0 bar 0 UPM OFF Fig.: 41 -1- -2- -3- -4- -5- 14.Pressure to learn : OFF 15.Consumer number : 3 16.Consumer 17.Consumer 18.Consumer 19.Consumer 20.Consumer 18 l/min 35 l/min 123 l/min inactiv inactiv 1: 2: 3: 4: 5: EXIT -6- Select page 5, Point 14 By pressing or change “pressure to learn” in “ON” After 15 sec (after engine start). By operating the 1st consumer bring the unit on high pressure. The multi tool valve is closed, in this connection. The whole flow rate of water flows out about the pressure regulating valve. Fig.: 42 25,2 V 1 00 2 00 3 00 0 bar 0 UPM EXIT Fig.: 43 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 With the pneumatic pressure-reducer adjust the air pressure so that the desired pressure (water) is reached. Confirm this value by pressing . Automatically change to page 5 of this menu. Operating instructions ES 2 – Control No.: ES2-Bediener (Volvo) Page 30, Issue: 04.2016 -1- -2- -3- -4- -5- 14.Pressure to learn : OFF 15.Consumer number : 3 16.Consumer 17.Consumer 18.Consumer 19.Consumer 20.Consumer 18 l/min 35 l/min 123 l/min inaktiv inaktiv 1: 2: 3: 4: 5: -6- Select page 5; Point 15., confirm with By pressing or number of consumer. admit the EXIT Fig.: 44 -1- -2- -3- -4- -5- 14. Pressure to learn : OFF 15. Consumer number : 3 16. 17. 18. 19. 20. 38 l/min 38 l/min 38 l/min inactiv inactiv Consumer Consumer Consumer Consumer Consumer 1: 2: 3: 4: 5: -6- The liter amounts refer on by the „Teach in“ given pressure. By pressing or adjust the flow rate in litre per minute of the appropriate nozzle (consumer). Confirm this value with . EXIT Fig.: 45 The total sum of the flow rates of all consumers can N O T exceed the max. flow rate of the high pressure pump unit! Pos: 110 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.docx @ 1188 @ @ 1 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions ES 2 – Control No.: ES2-Bediener (Volvo) Page 31, Issue: 04.2016 Pos: 111 /Aufbau und Beschreibung/ES 2 - Steuerung/Service Einstellung: Modem Anschluss @ 4\mod_1207827395897_2.docx @ 23681 @ 23 @ 1 2.13 Modem connection au und Beschreibung/ES 2 - Steuerung/Bestätigung @ 0\mod64_1.doc @ 1883 Shipment of the ES2 modem Identifying the condition of the modem over the flushing code. Fig.: 46 Connect ES2 modem and ES2 Control Fig.: 47 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions No.: ES2-Bediener (Volvo) ES 2 – Control Page 32, Issue: 04.2016 By pressing of the yellow button the SIM box opens. Fig.: 48 Attach SIM card into the lade box. Fig.: 49 Attach the SIM card and slide it until to the arrester. Fig.: 50 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions ES 2 – Control No.: ES2-Bediener (Volvo) Page 33, Issue: 04.2016 -1- -2- -3- -4- -5- -6- 21. Set clock time 22. Set date 24.Keypad lock 25.Remote control 26.Modem :OFF :inaktiv :inaktiv Select point 26 and confirm. It follows EXIT Fig.: 51 The PIN interrogation of the Sim card (is provided by the card supplier) give, e.g., 5846 as follows and confirm. Select PIN Vallue limits from 0000 to 9999 Confirm code cancel With or assign the digit. Then go with to the next digit (underlined) The digit changes to *. All 0000 PIN OFF digits must be entered → Select „Code confirm“ and Fig.: 52 -1- -2- -3- -4- -5- 21. Set clock time 22. Set date 24.Keypad lock 25.Remote control 26.Modem :ON :inactiv :inactiv -6SIM Card without PIN: The value 0000 can be confirmed. Then in the list next to the PIN display select “PIN OFF” and confirm with Switch the ES2 off and then on again. EXIT Fig.: 53 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions ES 2 – Control No.: ES2-Bediener (Volvo) Page 34, Issue: 04.2016 -1- -2- -3- -4- -5- -6- 21. Set clock time 22. Set date 24.Keypad lock 25.Remote control 26.Modem :ON With this announcement there works the modem, should appear (NET NO) in the announcement switch off control 1 x and restart. also ref. to technical information, ES2 – Modem (04.01336.0193) :inaktiv :inaktiv EXIT Fig.: 54 2.13.1 Description of blink code of ES2-modem State of Modems LED colour blink-time Modem OFF off no Start up of modem red Blinking and flash up Connecting of modem to net orange ON/OFF even Stay in this state possibly no/wrong PIN insert orange ON/OFF even Connection to net OK, calling possible orange Short ON, long OFF Modem is called/net connection OK orange Constant ON === Ende der Liste für Textmarke Inhalt === Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 Operating instructions Index No.: ES2-Bediener (Volvo) Page 35, Issue: 04.2016 3 Index B O Basic display .............................................................. 3 Operators menu ......................................................... 8 E P Engine Start ............................................................... 6 Entering a value – units with pressure control ........... 7 Entering a value – units with speed control ............... 7 Pre-heat ..................................................................... 6 F Fault indication......................................................... 21 Fault report .............................................................. 17 Function menu ......................................................... 14 K Keypad lock ............................................................. 13 Copyright Hammelmann GmbH Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8 S Switch control ON ...................................................... 3 Switch OFF the keypad lock .................................... 14 T Teach in function ..................................................... 12 W Working with multi gun valve and Teach in ............. 30 1 0 3 2 4 5 6 7 8 Änderungen: weitere Änderungen siehe Blatt 7, Änderungshistorie 9 06.2016 Überwachung Wassertank mit IMB-Geber Blatt 6.( ifm und S19 auf, Blatt 6a) Kennzeichnung der Vovo-Sicherung falls vorhanden Blatt 1a. 03.2016 Anschluss Volvo-Steuergeräte, Volvo Pin 5 + 6 überarbeitet, Blatt 1 Anschluss Wassertank und Dieseltank mit Deutsch-Steckern 02.2016 Überwachung Wassertank mit ifm-Geber -B19 nachgetragen, Blatt 6a 02.2016 Belegung Reserveeingänge, Blatt 6 und 6a ES2/24 17 21 18 20 01.2016 Änderung der Belegung "Sicherungsblock vor dem Bat.Schalter" Brücken für Anlagentyp Diesel bridges for diesel machines ES2 - Leitstungsteil ES2 - power part 40poliger Anschlussstecker -ES2/40 = 40 pole connection plug 24 poliger Anschlussstecker -ES2/24 = 24 pole connection plug ES2/40 1b 10a 10b 1c 6c 6d 9c 9a 9b 9d 10c 10d 1 2 3 40 26 4 5 6 7 8 9 10 11 4 41 6 7 8 1C / 3.0 3 -X5 22 5 S22/BN -S04 04.04310.0024 S21/WH X5 37 39 11 -S02 12 1 -F1 X5 C8A 2 Zuleitung input lead GND / 2.6 C 11 0V +24V XNA 40 -S03 1.a.7 12 XNA D Vorglühen pre heat 12 12 X5 Sammelstörung general alarm -S1 -S01 Zündung Ignition 21 11 9 11 Startrelais start relais 2 externer NOT-AUS Kreis external emergency stop loop 1 SICH.-SCHALTER GETRIEBE safety switch gear -X5 geschaltete +24V switched +24V NOT-AUS / HAUPTSCHALTER emergency stop / main switch -W_40pol 41x1 1a VOLVO_EMS BU/RD GN EMS 2 3 5 Batterieminus batterie minus Batterie nach Schlüssel** batterie after key** Die Absicherung seitens Volvo erfolgt durch eine Kfz-Klingensicherung im Kabelbaum. Power supply is fused by Volvo with a blade fuse in the Volvo harness 6 only: TAD9xxVE, TAD164xVE (not -B) Motorüberwachung sowie START und STOP des Dieselmotors erfolgen vom Motorsteuergerät. Die Kommunikation mit der ES2 wird mittels CAN-Bus ausgeführt. engine monitoring and also start and stop of the diesel engine are done by the engine controller itself. The communication with the ES2 is made by CAN bus. Zusatz-Abstellsignal** extra stop** 4 Batterieplus batterie plus VOLVO_8pol BU/RD oder or GN EMS 2.2 / EMS 2.3 5 6 Zusatz-Abstellsignal* extra stop* BK Batterie nach Schlüssel* batterie after key* RD EMS = Engine Management System EMS 2.2 / EMS 2.3: EMS 2: Pin 5: Pin 5: * Ab Motoren mit EMS2.2/2.3: Abstellung bei Spannungsverlust * From engines with EMS2.2/2.3: Shut down if voltage goes down ** Bei Motoren mit EMS2: keine Abstellung bei Spannungsverlust! ** At engines with ESM2: No shut down if voltage goes down Pin 6: Pin 6: * Programmierung: "energized to stop", ab Volvo Software-Architektur EMS 2.2 / 2.3 fest eingestellt * Programming: "energized to stop", from Volvo software-structure EMS 2.2 / 2.3 permanently set ** Programmierung: "energized to run" nur bei Motoren mit EMS 2 erforderlich ** Programming: "energized to run" only for engines with EMS 2 required 1.a Änderung Datum Name Datum 04.01.2012 Bearb. Barenhoff Gepr 16.06.2016 Urspr File name: 00.06700.0809 HAMMELMANN KK für ES2 mit elektr. VOLVO Ersatz von GmbH Ersetzt durch Carl-Zeiss-Straße 6-8 D-59302 Oelde ® Leistungsteil power part Z-Nr.: 00.06700.0809 = + Blatt von 1 18 1 0 3 2 4 5 6 7 8 9 *fuse behind compressor (only motor type:TAD1643 VE StufeII/4) Sicherungen VOR dem Batterieschalter Ladegerät Funksteuerung / Telematic-System / 25 mm² Standheizung / 5A 15A 5A 5A Standheizung_ / Nach Bedarf belegen Batterieladegerät / 15A Batterieschalter Battery switch bajonet fuse 00.01808.0392 Beleuchtung / falls vorhanden if fitted 25 mm² 70 mm² 8A 70 mm² HAMMELMANN VOLVO + Volvo fuse * - +24V / 1.1 BAT 24V M + - 0V / 1.2 70 mm² Batterien batteries Anlasser Starter 04.04550.0517 Aufkleber für Batterieschalter in der Nähe anbringen! "...frühestens 2 Minuten nach dem Motor-Stopp abschalten..." 1 Änderung 2 Datum Name Datum 04.01.2012 Bearb. Barenhoff Gepr 06.06.2016 Urspr File name: 00.06700.0809 HAMMELMANN KK für ES2 mit elektr. VOLVO Ersatz von GmbH Ersetzt durch Carl-Zeiss-Straße 6-8 D-59302 Oelde ® Anschluss Batterie und Batterieschalter Connection of barrery and battery switch Z-Nr.: 00.06700.0809 = + Blatt von 1.a 18 1 0 3 2 4 5 6 7 8 9 ES2 - Überwachung Motor ES2 - monitoring enging 5b 4a 3a 6a 3c 12 13 14 15 16 17 10 11 12 13 14 15 Öldruckschalter Motor oil pressure switch engine Generator D+ Generator D+ Generator W Generator W -W_40pol 41x1 -X5 VOLVO EMS-FEHLER (FREI 2) VOLVO EMS-FAULT (FREE 2) 3b Temperaturfühler Motor temperature sensor engine -ES2/40 -R3 ** Fehler "FREI 2" wird ausgelöst, sobald via CAN-Bus eine aktive Fehlerlapme vom Motor gelesen wird. Kein Anschluss an Klemme 12 nötig! 2 ** Fault message "FREE 2" is activated, in case of an active engine fault lamp read from the CAN interface. No connection at terminal 12 necessary! 1.2 / GND GND / 3.0 ** ab ES2-Software ES2_030815.bin Einstellung FREI 2: Signallogik: NO Aktion: Warnung Speichern: bei Error Tankgeber (Alternativ zu B2) tank sensor (alternativ with B2) EMS = Engine Management System Motorüberwachung sowie START und STOP des Dieselmotors erfolgen vom Motorsteuergerät. Die Kommunikation mit der ES2 wird mittels CAN-Bus ausgeführt engine monitoring and also start and stop of the diesel engine are done by the engine controller itself. The communication with the ES2 is made by CAN bus 1.a Änderung 3 Datum Name Datum 04.01.2012 Bearb. Barenhoff Gepr 06.06.2016 Urspr File name: 00.06700.0809 HAMMELMANN KK für ES2 mit elektr. VOLVO Ersatz von GmbH Ersetzt durch Carl-Zeiss-Straße 6-8 D-59302 Oelde ® Überwachung MOTOR monitoring engine Z-Nr.: 00.06700.0809 = + Blatt von 2 18 1 0 3 2 4 5 6 7 8 9 ES2 - Überwachung Pumpe ES2 - monitoring of pump -ES2/40 -W_40pol 41x1 4c 4b 5a 4d 5d 5c 6b 1d 18 19 20 21 22 23 24 25 1C GND 1C / 4.1 GND / 4.1 1.2 / BU SH 1+ 3- -WB6 -B6 0-16bar >2bar PE BN BU SH 1+ 3- -WB7 -B7 0-16bar >1,2bar 4-20mA Öldruck Pumpe oil pressure Pump 3 18 PE BN BU SH 1+ 3- 4-20mA Wasservordruck Pumpe water boost pressure Pump 4-20mA 17 -WB8 -B8 0-100°C <70°C 3 19 PE BN BU SH 1+ 3- 3 20 PE -WB10 -B10 0-100°C <40°C 4-20mA 3 21 PE BN BU SH 1+ 3- -WB11 -B11 0-16bar >5,5bar 4-20mA 3 22 PE BN BU SH 1+ 3- 3 23 PE 4-20mA FREI 1 FREE 1 BN 3 Luftdruck air pressure PE Wassertemperatur Pumpe water temperature Pump -B5 0-16bar >2bar 16 Kupplung oder externer Sollwert clutch or external set value -WB5 3 ÖLTEMP. PUMPE (FREI 3) oil temperature pump (FREE 3) -X5 Filter Differenzdruck filter diff. press. 2.7 / 2 Änderung 4 Datum Name Datum 04.01.2012 Bearb. Barenhoff Gepr 02.06.2016 Urspr File name: 00.06700.0809 HAMMELMANN KK für ES2 mit elektr. VOLVO Ersatz von GmbH Ersetzt durch Carl-Zeiss-Straße 6-8 D-59302 Oelde ® Überwachung PUMPE monitoring pump Z-Nr.: 00.06700.0809 = + Blatt von 3 18 3 2 4 5 -W_40pol 41x1 CAN high 3d 8A 8B 27 28 29 25 26 1C GND 8 9 ES2/24 W_24pol 12x1 24 23 1 2 56 57 WH/YE GY/YE WH WH/BK 1 2 7 8 1C / 5.0 GND / 5.0 3.9 / 3.9 / 7 ES2 - Regelungsfunktionen ES2 - control functions 4mA 0bar 20mA - ...bar 110% max. Druck --> Abschaltung 110% max pressure --> cut off -ES2/40 6 CAN low 1 0 -X5 -WB10 3 24 PE BN BU SH -X5 -X5 Stellmotor servomotor VOLVO_EMS -B1 0-xxxxbar 1+ 2- J1587B CAN low CAN high -VOLVO_8pol J1587A 4-20mA J1939 Druckaufnehmer Pressure transducer 3 Änderung 5 Datum Name Datum 04.01.2012 Bearb. Matzel Gepr 27.02.2016 Urspr File name: 00.06700.0809 HAMMELMANN KK für ES2 mit elektr. VOLVO Ersatz von GmbH Ersetzt durch Carl-Zeiss-Straße 6-8 D-59302 Oelde ® Regelungsfunktionen control function Z-Nr.: 00.06700.0809 = + Blatt von 4 18 1 0 3 2 Zeitdiagramm Bypass Schaltung: 4 5 500ms A2 7 8 9 ES2 - Bypassventil und Umschaltventile ES2 - bypass and multi gun valves A1 time diagram of bypass circuit: 6 Y t -X1 = Bypasssteckdose 4 pol ITT -X2 = Bypasssteckdose 4 pol ITT -X3 = Bypasssteckdose 4 pol ITT -ES2/40 -W_40pol 41x1 2a 2b 7a 7b 2c 2d 7c 8c 8d 7d 30 31 32 33 34 35 36 37 38 39 A1 A2 Y 1C 4.2 / GND 1C / 6.0 GND / 6.0 4.2 / -X5 -X1 3 A 2 B 27 28 D C 29 29 30 -Y0 -Y1 -X5 3 2 31 32 -X2 A B D C 33 -Y2 -X5 3 2 -X3 A B 34 35 D C 36 -Y3 -Y0.1 * falls an der Anlage vorhanden * if installed at the machine Pistole 2 Gun 2 Bypass-Schlüsselschalter bypass key switch 2 Umschaltventil 3 multi gun valve 3 2 Umschaltventil 2 multi gun valve 2 2 Umschaltventil 1 multi gun valve 1 Bypass-Schlüsselschalter bypass key switch 2 Bypassventil 2 bypass valve 2 Bypass / Pistole 1 bypass / gun 1 Bypassventil bypass valve 2 Pistole 3 Gun 3 Bypass-Schlüsselschalter bypass key switch * falls an der Anlage vorhanden * if installed at the machine 4 Änderung 6 Datum Name Datum 04.01.2012 Bearb. Matzel Gepr 07.12.2015 Urspr File name: 00.06700.0809 HAMMELMANN KK für ES2 mit elektr. VOLVO Ersatz von GmbH Ersetzt durch Carl-Zeiss-Straße 6-8 D-59302 Oelde ® Bypassventil und Umschaltventile bypass valve and multi gun valves Z-Nr.: 00.06700.0809 = + Blatt von 5 18 1 0 3 2 4 5 6 7 8 9 ES2 - Reserve Überwachungs-Funktionen ES2 - reserve monitoring funktions Fehlermeldung: 1xStop, dann Warnung Fault message: 1xStop, than warning Res.1 -ES2/24 W_24pol 12x1 Res.2 Res.3 Res.4 Res.5 5 6 7 8 9 Res.6 19 3 4 5 6 7 8 1C GND 1C / 6a.0 GND / 6a.0 5.9 / 3 2 81 PE 3 82 PE 3 83 PE 3 84 PE 3 -WB19 1 LED's: grün >195µS rot <150µS gelb = 195-150µS YE 2 4 +24V 0V -WB16 BN BU -WB17 SH BN BU refer to 00.06700.0969 -B15 BN SH +OUT2 LOW bei <150µS Leitfähigkeitsmesszelle -B16 1+ 0-100°C < 95°C conductivity sensor -B17 3- 4-20mA 00.01327.0002 0-200µS 1+ 0-100°C < 60°C 85 1 2 3 A B C Verlängert mit Deutsch-Stecker BR WS GN -B19 +24V 0V +OUT 3- 3 PE 86 1 2 3 A B C Verlängert mit Deutsch-Stecker -WB2 GN BK VO -B2 Tanksensor Bedia ITS 60 + - 0-10V IMB OPG 04 4-20mA VE-Wasser Demineral. water Öltemperatur Getriebe oiltemperature gearing Alternativ siehe Blatt 6a DE: ABSPERRKLAPPE ZU EN: AIR SHUTOFF FLAP F: SECU.ETOUFFOIR WH ÖKW-TEMP.ZU HOCH OCW-TEMP. HIGH -WB15 PE Dieseltank Geber fuel level sensor -X5 Wassertank min. water tank min. 5.9 / ÖKW-TEMP. = Öl Kühler Wasser Temperatur OCW-TEMP. = Oil Cooler Water Temperature Bei Ausgführung mit Hartmetalldichtungssatz Bei Ausgführung mit Schaltgetriebe * falls an der Anlage vorhanden * if installed at the machine Bei Ausgführung Heißwasseranlage * falls an der Anlage vorhanden * if installed at the machine Bei Ausgführung Luftabsperrklappe * falls an der Anlage vorhanden * if installed at the machine * falls an der Anlage vorhanden * if installed at the machine 5 Änderung 6a Datum Name Datum 04.01.2012 Bearb. Barenhoff Gepr 22.06.2016 Urspr File name: 00.06700.0809 HAMMELMANN KK für ES2 mit elektr. VOLVO Ersatz von GmbH Ersetzt durch Carl-Zeiss-Straße 6-8 D-59302 Oelde ® Reserve Überwachungen reserve monitoring Z-Nr.: 00.06700.0809 = + Blatt von 6 18 0 1 3 2 4 5 6 7 8 9 ES2 - Reserve Überwachungs-Funktionen ES2 - reserve monitoring funktions Res.1 -ES2/24 W_24pol 12x1 oder or Res.2 Res.3 Res.4 Res.5 5 6 7 8 9 Res.5 9 3 4 5 6 7 7 Res.6 19 1C GND 1C / 6b.0 GND / 6b.0 6.9 / 6.9 / -X5 3 2 81 PE 3 82 PE 3 83 1 2 PE 3 84 PE 1 3 2 3 04.01030.0033 85 PE 1 2 1 3 PE 85 1 2 3 A B C BN BU BK 1+ 3- 4 OUT 2 3 S13 Kl_1 24V 0V Störung S10 Kl_2 COM S11 C Betriebsbereit Verlängert mit Deutsch-Stecker BN/RT 86 PE Verlängert mit Deutsch-Stecker -WB19 -S19 WH -B19 O * ggf. Ausführung mit ifm-Wassertankschalter siehe Folgeseite / -B19 S12 /6.6 ifm LMT 121 * could be with ifm water tank switch refer to following page / -B19 Anstatt Schwimmerschalter -S19 Bei Ausgführung mit Container-Jalousie * falls an der Anlage vorhanden * if installed at the machine Einstellung Res. 4: Signallogik: NC Aktion: Motor Stop Speichern: bei Error Bei Ausgführung mit Vorfilter (Bollfilter) Bei Ausgführung mit Schwimmerschalter-S19 * falls an der Anlage vorhanden * if installed at the machine * falls an der Anlage vorhanden * if installed at the machine Wassertank min. water tank min. Wassertank min. water tank min. Luftklappen air dampers Fehler Vorfilter Fault prefilter ES2-Parameter: "digital zu Ub" Bei Ausgführung mit ifm-Wassertankschalter * falls an der Anlage vorhanden * if installed at the machine 6 Änderung 6b Datum Name Datum 04.01.2012 Bearb. Barenhoff Gepr 16.06.2016 Urspr File name: 00.06700.0809 HAMMELMANN KK für ES2 mit elektr. VOLVO Ersatz von GmbH Ersetzt durch Carl-Zeiss-Straße 6-8 D-59302 Oelde ® Reserve Überwachungen Sonderausführungen Z-Nr.: 00.06700.0809 = + Blatt von 6a 18 0 3 2 4 5 6 7 8 9 Zündung Ignition +24V Batterie / 1 1C GND 1C / GND / 6a.9 / 6a.9 / -WM1 3x1 7 2 1 2 + - -X5 -X5 3 (3) (1) A1 30 -K5 04.03440.0028 M -M1 1 A2 87 87a 3AUF WH (2) /6b.4 24V / ca. 0,9A 2AB RD M -M1 /6b.1 1 -X5 87 87a -X5 2 30 /6b.4 2 Jalousie Motor Louvre motor Elektrische Kraftstoffpumpe Electric Fuel Pump BK Option Bei Ausgführung mit externem niedrigen Dieseltank * falls an der Anlage vorhanden * if installed at the machine 6a Änderung 7 Datum Name Datum 04.01.2012 Bearb. Matzel Gepr 09.01.2017 Urspr File name: 00.06700.0809 HAMMELMANN KK für ES2 mit elektr. VOLVO Ersatz von GmbH Ersetzt durch Carl-Zeiss-Straße 6-8 D-59302 Oelde ® Sonderausführungen Z-Nr.: 00.06700.0809 = + Blatt von 6b 18 0 1 Änderungen: 3 2 4 5 6 7 8 9 06.2016 Anschluss für Jalosie Motor nachgetragen (Blatt 6b) 06.2016 Überwachung Wassertank mit IMB-Geber Blatt 6.( ifm und S19 auf, Blatt 6a) Kennzeichnung der Vovo-Sicherung falls vorhanden Blatt 1a. 03.2016 Anschluss Volvo-Steuergeräte, Volvo Pin 5 + 6 überarbeitet, Blatt 1 Anschluss Wassertank und Dieseltank mit Deutsch-Steckern 02.2016 Überwachung Wassertank mit ifm-Geber -B19 nachgetragen, Blatt 6a 02.2016 Belegung Reserveeingänge, Blatt 6 und 6a 01.2016 Änderung der Belegung "Sicherungsblock vor dem Bat.Schalter" 18.12.2015 Erweiterung: Sich.-Schalter Getriebe -S04 (Bl.1) 12.2015 Anschluss Bollfilter ergänzt (Res. 4) 10.2015 Anschluss Sicherungsblock vor dem Bat.-Schalter ergänzt 08.2015 Fehler FREI 2 wird von CAN-Nachricht ausgelöst, Seite 2 Kommentar an Volvo-Pin6 hinzugefügt 06.2015 Belegung CAN-Bus korrigiert, Seite 4 02.2015 Beschreibung für Pin 6 von Volvo angepasst, Seite 1 07.2014 Bezeichnung Dieseltankgeber, Seite 6 06.2014 Abfrage Öltemperatur, Seite 6 11.2013 externe Not-Aus Schalter, Seite 1 Brücke falls nicht benötigt, Seite 7 Klemmenbezeichnung für CAN Bus, Seite 4 08.2013 CAN-Bus-Aderfarben berichtigt, Seite 4 Bypasssteckdosen berichtigt, Seite 5 06.2013 CAN-Bus-Aderfarben getauscht, Seite 4 11.2012 Motoransteuerung für Stufe II Motoren ergänzt, Volvo Pin 6, Seite 1 Batterieschalter dargestellt, Seite 1a Anschluss Stellmotor, Klemmennummern korrigiert, Seite 4 10.2012 Leitfähigkeitssensor ergänzt, Reserve 1, Seite 6 01.2012 Erste Ausführung mit elektronischem VOLVO mit SCR 6b Änderung 8 Datum Name Datum 04.01.2012 Bearb. Matzel Gepr 09.01.2017 Urspr File name: 00.06700.0809 HAMMELMANN KK für ES2 mit elektr. VOLVO Ersatz von GmbH Ersetzt durch Carl-Zeiss-Straße 6-8 D-59302 Oelde ® Änderungshistorie Z-Nr.: 00.06700.0809 = + Blatt von 7 18 1 0 3 2 4 5 6 7 8 9 Ohne Externen Not-Aus = Brücke von X5.5 nach X5.41 2,5 2 2 2 2 2 2 2 2 6 8 8 10 12 14 3 3 3 3 3 3 3 3 3 3 28 28 30 32 34 36 37 37 39 41 57 57 3 3 3 3 3 3 1 1 3 3 3 4 5 7 7 9 9 11 13 15 16 17 18 19 20 21 22 23 24 25 26 27 27 29 29 31 33 35 40 42 56 56 81 82 83 84 85 86 PE -F1 -X5 PE 16 1 1 3 3 3 4 5 7 7 9 9 11 13 17 18 19 20 21 22 23 24 25 81 26 15 27 27 29 29 31 33 35 40 42 56 82 83 84 85 86 56 PE PE 3 2 2 2 2 2 2 2 2 6 8 8 10 12 3 3 3 3 3 3 3 3 3 14 28 PE PE PE PE PE PE PE PE PE 28 30 32 34 36 37 37 39 41 57 PE 3 3 3 3 3 3 PE PE PE PE PE PE 57 7 Änderung 10 Datum Name Datum 04.01.2012 Bearb. Barenhoff Gepr 15.06.2016 Urspr File name: 00.06700.0809 HAMMELMANN KK für ES2 mit elektr. VOLVO Ersatz von GmbH Ersetzt durch Carl-Zeiss-Straße 6-8 D-59302 Oelde ® Klemmenplan Terminal diagram Z-Nr.: 00.06700.0809 = + Blatt von 8 18 1 0 2 3 4 5 6 7 8 9 Steckerplan F22_001 24 poliger Anschlussstecker 24 pole connection plug Kabeltyp Anschluss Geräteanschluss 5 Brücke Steckerbezeichnung Anschluss Zielbezeichnung VE-Wasser Demineral. water -W_24pol =+-ES2/24 Kabeltyp Funktionstext Kabelname Kabelname Leistenbezeichnung Zielbezeichnung Seite / Spalte -X5 81 3 /6.1 Öltemperatur Getriebe oiltemperature gearing 6 -X5 82 4 /6.3 ÖKW-TEMP.ZU HOCH OCW-TEMP. HIGH 7 -X5 83 5 /6.4 DE: ABSPERRKLAPPE ZU EN: AIR SHUTOFF FLAP F: SECU.ETOUFFOIR 8 -X5 84 6 /6.5 9 -X5 85 7 /6.7 17 -ES2/24 21 18 -ES2/24 20 19 -X5 86 20 -ES2/24 18 = 21 -ES2/24 17 CAN low 23 -X5 57 2 /4.7 CAN high 24 -X5 56 1 /4.7 Wassertank min. water tank min. Brücken für Anlagentyp Diesel bridges for diesel machines = Dieseltank Geber fuel level sensor Brücken für Anlagentyp Diesel bridges for diesel machines /1.2 /1.3 8 /6.8 /1.3 /1.3 8 11 Datum 22.06.2016 Bearb. Barenhoff Gepr Änderung Datum Name Urspr GmbH KK für ES2 mit elektr. VOLVO ???????????????????????????? Ersatz von Ersetzt durch = Steckerplan =+-ES2/24 Plug diagram =+-ES2/24 + 00.06700.0809 Blatt 10 Blatt 18 1 0 2 3 4 5 6 7 8 9 Steckerplan F22_001 40poliger Anschlussstecker 40 pole connection plug Kabeltyp Anschluss = Geräteanschluss 1a Brücke Steckerbezeichnung Anschluss Zielbezeichnung Batterieplus batterie plus -W_40pol =+-ES2/40 Kabeltyp Funktionstext Kabelname Kabelname Leistenbezeichnung Zielbezeichnung Seite / Spalte -X5 1 1b 1 /1.1 -X5 1 2 /1.1 geschaltete +24V switched +24V FREI 1 FREE 1 Bypass / Pistole 1 bypass / gun 1 1c -X5 3 26 /1.2 1d -X5 23 25 /3.8 2a -X5 27 30 /5.1 = 2b -X5 28 31 /5.1 Pistole 2 Gun 2 2c -X5 31 34 /5.5 = 2d -X5 32 35 /5.5 3a -X5 13 15 /2.6 3b -X5 10 12 /2.1 3c -X5 15 17 /2.8 3d -X5 24 27 /4.2 4a -X5 12 14 /2.3 4b -X5 17 19 /3.2 4c -X5 16 18 /3.1 4d -X5 19 21 /3.4 5a -X5 18 20 /3.3 5b -X5 11 13 /2.2 5c -X5 21 23 /3.6 5d -X5 20 22 /3.5 6a -X5 14 16 /2.7 6b -X5 22 24 /3.7 6c -X5 4 4 /1.3 6d -X5 41 5 /1.4 7a -X5 29 32 /5.2 7b -X5 30 33 /5.4 7c -X5 33 36 /5.6 7d -X5 36 39 /5.9 8A -X5 25 28 /4.4 = 8B -X5 26 29 /4.4 Pistole 3 Gun 3 8c -X5 34 37 /5.8 = 8d -X5 35 38 /5.8 9a -X5 7 7 /1.6 9b -X5 8 8 /1.7 9c -X5 6 6 /1.5 Tankgeber (Alternativ zu B2) tank sensor (alternativ with B2) Temperaturfühler Motor temperature sensor engine Generator W Generator W Druckaufnehmer Pressure transducer VOLVO EMS-FEHLER (FREI 2) VOLVO EMS-FAULT (FREE 2) Wasservordruck Pumpe water boost pressure Pump Öldruck Pumpe oil pressure Pump ÖLTEMP. PUMPE (FREI 3) oil temperature pump (FREE 3) Filter Differenzdruck filter diff. press. Öldruckschalter Motor oil pressure switch engine Wassertemperatur Pumpe water temperature Pump Kupplung oder externer Sollwert clutch or external set value Generator D+ Generator D+ Luftdruck air pressure Brücken für Anlagentyp Diesel bridges for diesel machines safety switch gear Bypassventil bypass valve Umschaltventil 1 multi gun valve 1 Umschaltventil 2 multi gun valve 2 Umschaltventil 3 multi gun valve 3 Stellmotor servomotor Zündung Ignition Sammelstörung general alarm Startrelais start relais 10 11.a Datum 16.06.2016 Bearb. Barenhoff Gepr Änderung Datum Name Urspr GmbH KK für ES2 mit elektr. VOLVO ???????????????????????????? Ersatz von Ersetzt durch = Steckerplan =+-ES2/40 Plug diagram =+-ES2/40 + 00.06700.0809 Blatt 11 Blatt 18 1 0 2 3 4 5 6 7 8 9 Steckerplan F22_001 40poliger Anschlussstecker 40 pole connection plug Kabeltyp Anschluss Geräteanschluss Brücke Steckerbezeichnung Anschluss Zielbezeichnung Sammelstörung general alarm Batterieminus batterie minus -W_40pol =+-ES2/40 Kabeltyp Funktionstext Kabelname Kabelname Leistenbezeichnung Zielbezeichnung Seite / Spalte 9d -X5 8 9 /1.7 10a -X5 2 3 /1.2 = 10b -X5 2 40 /1.2 Vorglühen pre heat 10c -X5 9 10 /1.8 = 10d -X5 9 11 /1.8 11 13 Datum 16.06.2016 Bearb. Barenhoff Gepr Änderung Datum Name Urspr GmbH KK für ES2 mit elektr. VOLVO ???????????????????????????? Ersatz von Ersetzt durch = Steckerplan =+-ES2/40 Plug diagram =+-ES2/40 + 00.06700.0809 Blatt 11.a Blatt 18 1 0 2 3 4 5 6 7 8 9 Steckerplan F22_001 =+-X1 Bypasssteckdose 4 pol ITT Kabeltyp Anschluss Geräteanschluss Zielbezeichnung Brücke Steckerbezeichnung Anschluss Kabeltyp Funktionstext Kabelname Kabelname Leistenbezeichnung Zielbezeichnung Bypass / Pistole 1 bypass / gun 1 A -X5 = B = C = D Seite / Spalte 3 /5.1 -X5 2 /5.1 -X5 28 /5.1 -X5 27 /5.1 11.a 14 Datum 07.12.2015 Bearb. Matzel Gepr Änderung Datum Name Urspr GmbH KK für ES2 mit elektr. VOLVO ???????????????????????????? Ersatz von Ersetzt durch = Steckerplan =+-X1 Plug diagram =+-X1 + 00.06700.0809 Blatt 13 Blatt 18 1 0 2 3 4 5 6 7 8 9 Kabelplan F09_001 Kabelname Kabeltyp Aderzahl Querschnitt 12 1 =+-W_24pol Funktionstext QVW Zielbezeichnung von Anschluss Ader Zielbezeichnung nach Funktionstext Kabellänge VE-Wasser Demineral. water Anschluss QVW Funktionstext CAN high /4.7 -ES2/24 24 1 -X5 56 /4.7 CAN high CAN low /4.7 -ES2/24 23 2 -X5 57 /4.7 CAN low VE-Wasser Demineral. water /6.1 -ES2/24 5 3 -X5 81 /6.1 VE-Wasser Demineral. water Öltemperatur Getriebe oiltemperature gearing /6.3 -ES2/24 6 4 -X5 82 /6.3 Öltemperatur Getriebe oiltemperature gearing ÖKW-TEMP.ZU HOCH OCW-TEMP. HIGH /6.4 -ES2/24 7 5 -X5 83 /6.4 ÖKW-TEMP.ZU HOCH OCW-TEMP. HIGH -ES2/24 8 6 -X5 84 /6.5 /6.5 DE: ABSPERRKLAPPE ZU EN: AIR SHUTOFF FLAP F: SECU.ETOUFFOIR Wassertank min. water tank min. Dieseltank Geber fuel level sensor /6.7 -ES2/24 9 7 -X5 85 /6.7 /6.8 -ES2/24 19 8 -X5 86 /6.8 DE: ABSPERRKLAPPE ZU EN: AIR SHUTOFF FLAP F: SECU.ETOUFFOIR Wassertank min. water tank min. Dieseltank Geber fuel level sensor 13 15 Datum 22.06.2016 Bearb. Barenhoff Gepr Änderung Datum Name Urspr GmbH KK für ES2 mit elektr. VOLVO ???????????????????????????? Ersatz von Ersetzt durch = Kabelplan =+-W_24pol Cable diagram =+-W_24pol + 00.06700.0809 Blatt 14 Blatt 18 1 0 2 3 4 5 6 7 8 9 Kabelplan F09_001 Kabelname Kabeltyp Aderzahl Querschnitt 41 1 =+-W_40pol Funktionstext QVW Zielbezeichnung von Anschluss Ader Zielbezeichnung nach Funktionstext Kabellänge Batterieplus batterie plus Anschluss QVW Funktionstext Batterieplus batterie plus /1.1 -ES2/40 1a 1 -X5 1 /1.1 Batterieplus batterie plus = /1.1 -ES2/40 1b 2 -X5 1 /1.1 = /1.2 -ES2/40 10a 3 -X5 2 /1.2 /1.3 -ES2/40 6c 4 -X5 4 /1.3 /1.4 -ES2/40 6d 5 -X5 41 /1.4 /1.5 -ES2/40 9c 6 -X5 6 /1.5 /1.6 -ES2/40 9a 7 -X5 7 /1.6 /1.7 -ES2/40 9b 8 -X5 8 /1.7 /1.7 -ES2/40 9d 9 -X5 8 /1.7 = Vorglühen pre heat Batterieminus batterie minus Brücken für Anlagentyp Diesel bridges for diesel machines safety switch gear Startrelais start relais Zündung Ignition Sammelstörung general alarm = Vorglühen pre heat /1.8 -ES2/40 10c 10 -X5 9 /1.8 = /1.8 -ES2/40 10d 11 -X5 9 /1.8 Temperaturfühler Motor temperature sensor engine Öldruckschalter Motor oil pressure switch engine VOLVO EMS-FEHLER (FREI 2) VOLVO EMS-FAULT (FREE 2) Tankgeber (Alternativ zu B2) tank sensor (alternativ with B2) Generator D+ Generator D+ Generator W Generator W Öldruck Pumpe oil pressure Pump Wasservordruck Pumpe water boost pressure Pump Filter Differenzdruck filter diff. press. ÖLTEMP. PUMPE (FREI 3) oil temperature pump (FREE 3) Kupplung oder externer Sollwert clutch or external set value Wassertemperatur Pumpe water temperature Pump Luftdruck air pressure FREI 1 FREE 1 geschaltete +24V switched +24V Druckaufnehmer Pressure transducer /2.1 -ES2/40 3b 12 -X5 10 /2.1 /2.2 -ES2/40 5b 13 -X5 11 /2.2 /2.3 -ES2/40 4a 14 -X5 12 /2.3 /2.6 -ES2/40 3a 15 -X5 13 /2.6 /2.7 -ES2/40 6a 16 -X5 14 /2.7 /2.8 -ES2/40 3c 17 -X5 15 /2.8 /3.1 -ES2/40 4c 18 -X5 16 /3.1 /3.2 -ES2/40 4b 19 -X5 17 /3.2 /3.3 -ES2/40 5a 20 -X5 18 /3.3 /3.4 -ES2/40 4d 21 -X5 19 /3.4 /3.5 -ES2/40 5d 22 -X5 20 /3.5 /3.6 -ES2/40 5c 23 -X5 21 /3.6 /3.7 -ES2/40 6b 24 -X5 22 /3.7 /3.8 -ES2/40 1d 25 -X5 23 /3.8 /1.2 -ES2/40 1c 26 -X5 3 /1.2 /4.2 -ES2/40 3d 27 -X5 24 /4.2 Batterieminus batterie minus Brücken für Anlagentyp Diesel bridges for diesel machines safety switch gear Startrelais start relais Zündung Ignition Sammelstörung general alarm = Temperaturfühler Motor temperature sensor engine Öldruckschalter Motor oil pressure switch engine VOLVO EMS-FEHLER (FREI 2) VOLVO EMS-FAULT (FREE 2) Tankgeber (Alternativ zu B2) tank sensor (alternativ with B2) Generator D+ Generator D+ Generator W Generator W Öldruck Pumpe oil pressure Pump Wasservordruck Pumpe water boost pressure Pump Filter Differenzdruck filter diff. press. ÖLTEMP. PUMPE (FREI 3) oil temperature pump (FREE 3) Kupplung oder externer Sollwert clutch or external set value Wassertemperatur Pumpe water temperature Pump Luftdruck air pressure FREI 1 FREE 1 geschaltete +24V switched +24V Druckaufnehmer Pressure transducer 14 15.a Datum 16.06.2016 Bearb. Barenhoff Gepr Änderung Datum Name Urspr GmbH KK für ES2 mit elektr. VOLVO ???????????????????????????? Ersatz von Ersetzt durch = Kabelplan =+-W_40pol Cable diagram =+-W_40pol + 00.06700.0809 Blatt 15 Blatt 18 1 0 2 3 4 5 6 7 8 9 Kabelplan F09_001 Kabelname Kabeltyp Aderzahl Querschnitt 41 1 =+-W_40pol Funktionstext QVW Zielbezeichnung von Anschluss Ader Zielbezeichnung nach Funktionstext Kabellänge Batterieplus batterie plus Anschluss QVW Funktionstext Stellmotor servomotor /4.4 -ES2/40 8A 28 -X5 25 /4.4 Stellmotor servomotor = /4.4 -ES2/40 8B 29 -X5 26 /4.4 = Bypass / Pistole 1 bypass / gun 1 /5.1 -ES2/40 2a 30 -X5 27 /5.1 Bypass / Pistole 1 bypass / gun 1 = /5.1 -ES2/40 2b 31 -X5 28 /5.1 = /5.2 -ES2/40 7a 32 -X5 29 /5.2 /5.4 -ES2/40 7b 33 -X5 30 /5.4 /5.5 -ES2/40 2c 34 -X5 31 /5.5 /5.5 -ES2/40 2d 35 -X5 32 /5.5 /5.6 -ES2/40 7c 36 -X5 33 /5.6 /5.8 -ES2/40 8c 37 -X5 34 /5.8 /5.8 -ES2/40 8d 38 -X5 35 /5.8 /5.9 -ES2/40 7d 39 -X5 36 /5.9 /1.2 -ES2/40 10b 40 -X5 2 /1.2 Bypassventil bypass valve Umschaltventil 1 multi gun valve 1 Pistole 2 Gun 2 = Umschaltventil 2 multi gun valve 2 Pistole 3 Gun 3 = Umschaltventil 3 multi gun valve 3 Batterieminus batterie minus Bypassventil bypass valve Umschaltventil 1 multi gun valve 1 Pistole 2 Gun 2 = Umschaltventil 2 multi gun valve 2 Pistole 3 Gun 3 = Umschaltventil 3 multi gun valve 3 Batterieminus batterie minus 15 Datum 16.06.2016 Bearb. Barenhoff Gepr Änderung Datum Name Urspr GmbH KK für ES2 mit elektr. VOLVO ???????????????????????????? Ersatz von Ersetzt durch = Kabelplan =+-W_40pol Cable diagram =+-W_40pol + 00.06700.0809 Blatt 15.a Blatt 18 1 2 Druckregelventil pressure regulating valve A 4 3 5 6 7 8 9 11 10 12 939 Abgasaustritt exhaust O 127 HD Anschluss discharge connection Abgasnachbehandlungssystem: SCR6 Schalldämpfer mit Katalysator, Dosiermodul, Temperatur6 und NOx6Geber emissions aftertreatment system: SCR muffler with catalytic converter, dosing system, temp and NOx sensor Hebevorrichtung für Pumpenkopf lifting device for pump head A B 2271 2559 B C 895 C Z 69 D 1230 1300 1020 200 800 800 800 2800 99,5 3219,5 0 D 6Z M20;20 tief M20;20 depth 001 001 6Y 0 Y Massenschwerpunkt centre of gravity Massenschwerpunkt centre of gravity X Klemmenkasten terminal box Sauganschluss Vordruckpumpe; DN50, PN16 suction connection boost pump, DN50, PN16 1660 3120 6X 0 E F F 123 1597 Kühlerfläche radiator surface E G 001 G Massenschwerpunkt/ Centre of Gravity X Y Z 1020 69 895 HDP 502 mit VOLVO TAD1672VE STAGE IV, TIER4final alle Ecken und Kanten gratfrei ß Mit Betriebsdruck signiert ß Mit Auftrags-Nr. signiert ß Mit Teile-Nr. - Rev. signiert ß Härte geprüft 260 Ohne unsere vorherige Zustimmung darf diese Zeichnung weder vervielfältigt noch Dritten zugänglich gemacht werden, und sie darf durch den Empfänger oder Dritte auch nicht in anderer Weise mißbräuchlich benutzt werden. H 00.00027.1085 ZeichFreig Zul.Abweichung f.Maße ohne Toleranzangabe ISO 2768 6 mH Verwendungszweck 001 Format DIN Artikel6Nr. * Maßstab 905 Kühlerfläche radiator surface Bearb Gepr. Norm 1:10 Gewicht in kg 5200.0000 Halbzeug Oberfläche nach DIN ISO 1302 Datum A1 Name 25.03.2014 Brunnert 23.02.2015 Barton 23.02.2015 Krabus Werkstoff Benennung HOCHDRUCKPUMPENAGGREGAT Zeichnungs6Nr. 1 2 3 4 5 6 7 8 9 001 D6Motor ausgetauscht Zust Änderung 04.02.2015 pie Datum Name D659302 OELDE CAD6Zeichnung * 00.00027.1085 1 Ers.durch Ers.für Revision 001 Blatt 1 von 1 Bl. H 1 2 4 3 5 6 7 6058 8 9 11 10 12 2438 1400 Durchgangsbreite passage width 2746 123 260 Luftaustrittsgitter air outlet louvre Lufteintrittsgitter air inlet louvre A A ca. 2733 2591 A B 92 B C Erdungsanschluss earthing connection M10 Ad Blue Tank Inhalt: ca. 70 L Ad Blue tank capacit: approx. 70 L Wetterkappe demontierbar rain cap removable Durchführung f. Schläuche, Anschlussmöglichkeit: Pneumatikanschluss G1/4, Überströmanschluss G1 1/2 lead6in tubes for hoses, Connection options: pneumatic connection G1/2, overflow line connection G1 1/2 Füllanschluss Wassertank C6Kupplung DIN14307 supply connection water tank c6coupling DIN14307 961 Erdungsanschluss earthing connection M10 2259 355 115 290 2050 1805,5 C 6058 5853 D 1065 D E E Z 0 800 800 800 2690 6X 0 530 17 Dieseltank Inhalt: ca.900L fuel tank capacity: approx.900l Montageklappe zur Kühlerreinigung mounting cover for cleaning cooler X Wassertank Inhalt: ca.1300L water tank capacity: approx. 1300l 6Y 0 1230 2250 6Z Y F F 270° öffnend/ opening 270° öffnend/ opening G G 6 Gewicht des Hochdruckpumpenaggregates (siehe Schriftfeld) inkl. 900L Diesel (ca.765kg) und 70L Ad Blue (ca. 76kg)! Weight of the high pressure pump unit (see title block) incl. 900l fuel (approx. 765kg) and 70L Ad Blue (approx. 76kg)! 6 HDP 504 mit VOLVO6Dieselmotor Typ TAD 1672 VE ( Stufe IV / Tier 4 Final ) in einem 20'6Container Ohne unsere vorherige Zustimmung darf diese Zeichnung weder vervielfältigt noch Dritten zugänglich gemacht werden, und sie darf durch den Empfänger oder Dritte auch nicht in anderer Weise mißbräuchlich benutzt werden. H alle Ecken und Kanten gratfrei ß Mit Betriebsdruck signiert ß Mit Auftrags-Nr. signiert ß Mit Teile-Nr. - Rev. signiert ß Härte geprüft 180° öffnend/opening 90° arretierbar/lockable 1 2 3 4 5 6 Zul.Abweichung f.Maße ohne Toleranzangabe ISO 2768 6 mH 7 8 Bearb Gepr. Norm Massenschwerpunkt/ Centre of Gravity X Y Z 2663 11 1063 9 Maßstab A1 1:20 Gewicht in kg 12040.0000 Halbzeug Oberfläche nach DIN ISO 1302 Datum Massenschwerpunkt / center of mass 00.00027.1277 ZeichFreig Verwendungszweck A Format DIN Artikel6Nr. * Name 28.01.2015 Pieper 23.02.2015 Barton 23.02.2015 Krabus Werkstoff Benennung HOCHDRUCKPUMPENAGGREGAT Zeichnungs6Nr. Zust Änderung Datum Name D659302 OELDE CAD6Zeichnung * 00.00027.1277 1 Ers.durch Ers.für Revision 000 Blatt 1 von 1 Bl. H PARTS LIST (41) Parts-list no.: 00.00743.2221 Drawing no. : 00.00743.2221-1 Description : PISTON SEAL ASSEMBLY, Packing HDP360 - MC D50, 1.4462 DwgPos Item Code-No. Description HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany mail to: mail@hammelmann.de http://www.hammelmann.de Date : 06.03.2017 Page : 1 Quantity No/Unit Unit 10 10 01.01750.0898 CASING 1 1,000 pc 20 20 00.02110.0374 PISTON 1 1,000 pc 30 30 01.01055.1386 FLANGE 1 1,000 pc 40 40 04.00731.0052 GLYD RING 1 1,000 pc 60 60 04.00730.0510 O-RING 2 1,000 pc 110 110 01.03465.1424 RING 2 1,000 pc 120 120 01.03512.0306 SUPPORT RING 2 1,000 pc 130 130 04.00739.0032 PACKING 1 1,000 set 150 150 01.00525.0801 BUSHING 1 1,000 pc 190 190 01.03465.1430 RING 1 1,000 pc 300 300 01.00525.1092 BUSHING 1 1,000 pc 360 360 04.00730.0218 O-RING 1 1,000 pc 400 400 02.00825.0206 HEXAGON SOCKET HEAD SCREW 10 1,000 pc 410 410 02.01766.0034 BORE CIRCLIP 1 1,000 pc 420 420 04.00730.0505 O-RING 1 1,000 pc 430 430 04.00730.0379 O-RING 1 1,000 pc 450 450 04.00730.0076 O-RING 8 1,000 pc 470 470 01.01990.0014 CLAMP 2 1,000 pc 480 480 01.03501.0025 SHAFT CIRCLIP 2 1,000 pc >>>end<<< p_dbgs01.p 1 2 3 4 5 6 7 8 A-A 004 A 10 1 150 1 130 1 20 1 110 2 190 1 300 1 30 1 120 2 40 1 410 1 400 10 360 1 480 2 470 2 A 450 8 A B B C C A 420 1 D 10 430 1 60 2 D 1 6 7 Sonderausführung E E Betriebsdruck max. 1000 bar Artikel-Nr. * F Ohne unsere vorherige Zustimmung darf diese Zeichnung weder vervielfältigt noch Dritten zugänglich gemacht werden, und sie darf durch den Empfänger oder Dritte auch nicht in anderer Weise mißbräuchlich benutzt werden. 4 3 5 8 9 2 1 2 004 Schrauben Pos. 400 mit integriertem Schmiermittel und in angegebener Reihenfolge ohne Fett angezogen: 1. Stufe: Anziehdrehmoment Ma = 80 Nm 2. Stufe: Anziehdrehmoment Ma = 160 Nm 3. Stufe: Anziehdrehmoment Ma = 240 Nm 3 4 alle Ecken und Kanten gratfrei ß Mit Betriebsdruck signiert ß Mit Auftrags-Nr. signiert ß Mit Teile-Nr. - Rev. signiert ß Härte geprüft Zul.Abweichung f.Maße ohne Toleranzangabe ISO 2768 - mH Datum Bearb Gepr. Norm Stücklistenänderung Pos. 150 geändert in Bz Pos. geändert Stücklistenänderung Änderung Maßstab 08.10.2012 06.05.2011 30.03.2011 16.03.2011 Datum Wei JMue San Pöts Name A3 1:1,5 Gewicht in kg 30.6100 Halbzeug Oberfläche nach DIN ISO 1302 HDP360/480/750 D50,0 004 003 002 001 Zust 00.00743.2221 ZeichFreig Verwendungszweck Format DIN Name 02.03.2011 Sander 08.10.2012 EHelmig 09.10.2012 Krabus Werkstoff Benennung F DICHTUNGSSATZ Revision Zeichnungs-Nr. D-59302 OELDE CAD-Zeichnung * 00.00743.2221-1 Ers.durch Ers.für 004 Blatt 1 von 1 Bl. PARTS LIST (41) Parts-list no.: 00.02145.1239 Drawing no. : 00.02145.1239-1 Description : PUMPHEAD - Duplex HDP360-500 D50-55, 1.4462 DwgPos Item Code-No. Description HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany mail to: mail@hammelmann.de http://www.hammelmann.de Date : 06.03.2017 Page : 1 Quantity No/Unit Unit 10 10 01.01305.0760 VALVE HOUSING 1 1,000 pc 20 20 04.00946.0283 COIL SPRING 3 1,000 pc 30 30 01.05860.0291 VALVE 6 1,000 pc 40 40 01.00742.0212 SEAL RING 6 1,000 pc 90 90 02.00825.0276 HEXAGON SOCKET HEAD SCREW 24 1,000 pc 140 140 04.00946.0287 COIL SPRING 3 1,000 pc 150 150 01.03528.0472 VALVE SEAT RING 3 1,000 pc 160 160 01.00525.1164 BUSHING 3 1,000 pc 310 310 02.00888.0305 HEXAGON SOCKET SET SCREW 2 1,000 pc 500 500 01.05317.0023 SCREWED SOCKET 3 1,000 pc 510 510 01.05195.0039 TAPPET 3 1,000 pc 520 520 02.00318.0011 HEXAGON NUT 8 1,000 pc 530 530 01.04756.0110 THREADED STUD 8 1,000 pc 550 550 01.05195.0045 TAPPET 3 1,000 pc >>>end<<< p_dbgs01.p 1 2 4 5 7 A 1 310 2 A3A 1 90 24 520 8 4 10 1 B 6 20 3 500 3 5 7 8 6 3 5 2 8 A 2 A 1. Stufe: Anziehdrehmoment Ma= 200 Nm 2. Stufe: Anziehdrehmoment Ma= 800 Nm 8 3 4 Pos.520 (Skt. SW46) mit MoS2 gefettet und in angegebener Reihenfolge angezogen: 30 6 510 3 C 6 7 530 8 A 3 B Schrauben Pos. 90 mit integriertem Schmiermittel und in angegebener Reihenfolge ohne Fett angezogen: 1. Stufe: Anziehdrehmoment Ma = 80 Nm 2. Stufe: Anziehdrehmoment Ma = 160 Nm 3. Stufe: Anziehdrehmoment Ma = 240 Nm C 003 150 3 D D 40 6 550 3 140 3 160 3 Betriebsdruck max. 1070 bar E Zul.Abweichung f.Maße ohne Toleranzangabe ISO 2768 3 mH Datum Bearb Gepr. Norm 2 3 4 Maßstab 24.04.2014 Som 31.07.2013 Wei 01.07.2013 Wei Datum Name A3 1:1,5 Gewicht in kg 153.0000 Werkstoff Halbzeug Oberfläche nach DIN ISO 1302 HDP3603500 ø50355 003 Pos. 150 geä. 002 Stücklistenänderung 001 Stücklistenänderung Zust Änderung 00.02145.1239 ZeichFreig Verwendungszweck 1 Format DIN Artikel3Nr. * alle Ecken und Kanten gratfrei ß Mit Betriebsdruck signiert ß Mit Auftrags-Nr. signiert ß Mit Teile-Nr. - Rev. signiert ß Härte geprüft Pos.500 (Skt. SW24) Anziehdrehmoment 250Nm Ohne unsere vorherige Zustimmung darf diese Zeichnung weder vervielfältigt noch Dritten zugänglich gemacht werden, und sie darf durch den Empfänger oder Dritte auch nicht in anderer Weise mißbräuchlich benutzt werden. E F Sonderausführung Duplex Name 15.03.2013 Poetschke 24.04.2014 Hartmann 24.04.2014 Krabus Benennung F PUMPENKOPF Zeichnungs3Nr. D359302 OELDE CAD3Zeichnung * 00.02145.1239 1 Ers.durch Ers.für Revision 003 Blatt 1 von 1 Bl. PARTS LIST (41) Parts-list no.: 00.05865.0146 Drawing no. : 00.05865.0146-1 Description : PRESSURE REGULATING VALVE 500 L/MIN , 1200 BAR 1.4462 DwgPos Item Code-No. Description HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany mail to: mail@hammelmann.de http://www.hammelmann.de Date : 06.03.2017 Page : 1 Quantity No/Unit Unit 10 10 01.01240.0603 HOUSING 1 1,000 pc 20 20 01.03468.0158 SEAL RING 1 1,000 pc 25 25 04.00734.0113 O-RING 1 1,000 pc 30 30 01.02123.0147 CONTROL PISTON 1 1,000 pc 35 35 01.01595.0182 BRACKET 1 1,000 pc 50 50 01.03465.0786 SEAL RING 1 1,000 pc 60 60 01.03528.0305 VALVE SEAT RING 1 1,000 pc 70 70 04.00737.1018 SUPPORT RING 1 1,000 pc 80 80 01.05320.0508 REDUCTION PIECE 1 1,000 pc 90 90 04.00706.0028 SEAL RING 3 1,000 pc 110 110 01.03501.0028 SHAFT CIRCLIP 1 1,000 pc 120 120 01.05240.0037 PLUG 2 1,000 pc 130 130 01.04380.1135 DISC 1 1,000 pc 140 140 04.00946.0260 COIL SPRING 1 1,000 pc 160 160 04.00742.0043 SEAL RING 1 1,000 pc >>>end<<< p_dbgs01.p 1 2 3 A 140 1 10 1 5 6 7 8 175 A3A 130 1 4 35 1 30 1 50 1 P 60 1 70 1 160 1 Anziehdrehmoment Ma = 200 Nm Tightening torque Ma = 200 Nm Couple de serrage Ma = 200 Nm 80 1 A A 144 B B (G1 1/2) Y 132 (M63 x 2) T C C Z 110 1 Skt. SW 55 Z 2:1 D Y 2:1 ß Skt. SW 19 90 3 F 25 1 20 1 Ohne unsere vorherige Zustimmung darf diese Zeichnung weder vervielfältigt noch Dritten zugänglich gemacht werden, und sie darf durch den Empfänger oder Dritte auch nicht in anderer Weise mißbräuchlich benutzt werden. E 120 2 T G 1 1/2 A Betriebsdruck max. 1200 bar/ 4462 Volumenstrom max. 500 l/min Nennweite DN 17 Keramikausführung Hochdruckdichtung Anziehdrehmoment Ma = 100 Nm Tightening torque Ma = 100 Nm Couple de serrage Ma = 100 Nm P DN 20 / 4x M12 / 60 x 60 X X alle Ecken und Kanten gratfrei ß Mit Betriebsdruck signiert ß Mit Auftrags-Nr. signiert ß Mit Teile-Nr. - Rev. signiert ß Härte geprüft Zul.Abweichung f.Maße ohne Toleranzangabe ISO 2768 3 mH Verwendungszweck 1:5 1 2 3 4 Maßstab Bearb Gepr. Norm A3 1:1 Gewicht in kg 10.5032 Werkstoff Halbzeug Oberfläche nach DIN ISO 1302 Datum Pression de service maximale 1200 bar/ 4462 Débit maximal 500 l/min Largeur nominale DN 17 Version céramique Joint haute pression 00.05865.0146 ZeichFreig Name 10.12.2013 Schaefer 14.03.2014 Heinrichsmei 18.03.2014 Krabus 13.03.2014 Schä Datum Name D359302 OELDE CAD3Zeichnung * Benennung PRESSURE REGULATING VALVE SOUPAPE REGULATRICE DE PRESSION F DRUCKREGELVENTIL Zeichnungs3Nr. 001 Zeichnung aktualisiert Zust Änderung E Format DIN Artikel3Nr. * Max. operating pressure 1200 bar/ 4462 Max. flow rate 500 l/min Nominal diameter 17 mm Ceramic design High pressure seal D 00.05865.0146 1 Ers.durch Ers.für Revision 001 Blatt 1 von 1 Bl. PARTS LIST (41) Parts-list no.: 00.06428.0029 Drawing no. : 00.06428.0029-1 Description : MEMBRANE CYLINDER HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany mail to: mail@hammelmann.de http://www.hammelmann.de Date : 06.03.2017 Page : 1 PN 10; D 130 DwgPos Item Code-No. Description Quantity No/Unit Unit 10 10 01.06415.0074 CYLINDER 1 1,000 pc 20 20 04.00946.0216 COIL SPRING 1 1,000 pc 30 30 01.02110.0449 PISTON 1 1,000 pc 40 40 04.02727.0007 DIAPHRAGM 1 1,000 pc 50 50 01.00665.0362 COVER 1 1,000 pc 60 60 02.00825.0019 HEXAGON SOCKET HEAD SCREW 8 1,000 pc 70 70 04.02990.0093 REDUCTION NIPPLE 1 1,000 pc 80 80 04.05878.0029 CHECK VALVE 1 1,000 pc 90 90 04.00706.0026 SEAL RING 1 1,000 pc 100 100 04.05993.0956 TUBE FITTING 1 1,000 pc 110 110 04.05993.0838 TUBE FITTING 1 1,000 pc 120 120 00.00222.0099 CONTAINER 1 1,000 pc >>>end<<< p_dbgs01.p 1 2 3 4 5 6 7 8 ca. 209 A 110 1 100 1 80 1 40 1 30 1 A 20 1 A X DN6 X B B 90 1 (M63 x 2) 70 1 C 19 8 C D O 120 1 50 1 A-A 60 8 Anziehdrehmoment 10 Nm 10 1 D A Wirkdurchmesser: 130 mm Betriebsdruck : max. 10 bar Medium : Luft, Öl E ß Artikel-Nr. * Ohne unsere vorherige Zustimmung darf diese Zeichnung weder vervielfältigt noch Dritten zugänglich gemacht werden, und sie darf durch den Empfänger oder Dritte auch nicht in anderer Weise mißbräuchlich benutzt werden. F X alle Ecken und Kanten gratfrei ß Mit Betriebsdruck signiert ß Mit Auftrags-Nr. signiert ß Mit Teile-Nr. signiert ß Härte geprüft Zul.Abweichung f.Maße ohne Toleranzangabe ISO 2768 - mH 2 3 4 Signierungsort geändert Pos.120 hinzu 00.05877.0065 entf. Stkl. geä. Darstellung geänd. Darst. geä. Pos.200,210,220 entf. Änderung Maßstab 02.07.2009 Pae Bearb 22.10.2007 Pöts Gepr. 27.04.2007 PS Norm 12.04.2006 Pöts 02.07.2003 PS 12.05.2003 Pöts 05.02.2003 Som Datum Name A3 1:2 Gewicht in kg 5.5000 Halbzeug Oberfläche nach DIN ISO 1302 Datum 008 007 006 005 004 003 002 Zust Format DIN 00.06428.0029 ZeichFreig_PDF Verwendungszweck 1 E Name 28.05.2002 PSchoening 02.07.2009 Poetschke 03.07.2009 Szustkowski Werkstoff Benennung F MEMBRANZYLINDER Revision Zeichnungs-Nr. D-59302 OELDE CAD-Zeichnung * 00.06428.0029-1 Ers.durch Ers.für 008 Blatt 1 von 1 Bl. PARTS LIST (41) Parts-list no.: 00.04062.1000 Drawing no. : 00.04062.1000-1 Description : RUPTURE DISC ASSEMBLY G 1/2 A - G 1/2 - 82,0 LG. DwgPos Item Code-No. Description HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany mail to: mail@hammelmann.de http://www.hammelmann.de Date : 06.03.2017 Page : 1 Quantity No/Unit Unit 10 10 01.05300.0488 CONNECTION PIECE 1 1,000 pc 20 20 04.00706.0002 SEAL RING 1 1,000 pc 30 30 04.01946.0001 SEALING CONE 1 1,000 pc 40 40 01.05300.0489 CONNECTION PIECE 1 1,000 pc 50 50 04.04062.1000 RUPTURE DISC 3 1,000 pc >>>end<<< p_dbgs01.p 1 2 3 4 5 A 6 7 8 A A A ca. 82 B B 6kt. SW36 20 19 A-A 2:1 6kt. SW27 C (G1/2) (G1/2 A) C D 20 1 E Anziehdrehmoment 100 Nm torque: 100 Nm 10 1 Betriebsdruck: 1000bar Berstdruck: 1400bar 004 Typenschild wird an Berstscheibe angedrahtet! part no.: operating pressure: burst pressure: Mat.: Ser.No: 1400 bar / 20300 psi Torque: 110 Nm Zul.Abweichung f.Maße ohne Toleranzangabe ISO 2768 - mH Verwendungszweck 3 4 E 004 003 002 001 Zust Darstellung geä. Anzugsmoment geändert Darstellung geä. Anziehdrehmoment Änderung Maßstab Datum Name A3 1:1 Gewicht in kg 0.4340 Halbzeug Oberfläche nach DIN ISO 1302 10.03.2011 Pöts 04.04.2005 Gut 11.06.2003 Pöts 07.05.2001 Wew Format DIN 00.04062.1000 ZeichFreig_PDF Datum 2 004 Artikel-Nr. alle Ecken und Kanten gratfrei ß Mit Betriebsdruck signiert ß Mit Auftrags-Nr. signiert ß Mit Teile-Nr. signiert ß Härte geprüft 1000 bar / 14500 psi Anziehdrehmoment 110 Nm torque: 110 Nm operating pressure: 14500psi burst pressure: 20300psi Bearb Gepr. Norm 1 40 1 * 04.04062.1000 ................. ................. 1x 04.04062.1000 montiert, 2x 04.04062.1000 für Ersatz beigelegt. 50 3 30 1 ® Ohne unsere vorherige Zustimmung darf diese Zeichnung weder vervielfältigt noch Dritten zugänglich gemacht werden, und sie darf durch den Empfänger oder Dritte auch nicht in anderer Weise mißbräuchlich benutzt werden. F D 004 Name 13.01.1992 Wewer 11.03.2011 Sommerkamp 11.03.2011 Krabus Werkstoff Benennung F BERSTSCHEIBE Revision Zeichnungs-Nr. D-59302 OELDE CAD-Zeichnung * 00.04062.1000-1 Ers.durch Ers.für 004 Blatt 1 von 1 Bl. PARTS LIST (41) Parts-list no.: 08.00200.9201 Drawing no. : 08.00200.9201-1 Description : DISCHARGE FITTING DwgPos Item Code-No. HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany mail to: mail@hammelmann.de http://www.hammelmann.de Date : 06.03.2017 Page : 1 Description Quantity No/Unit Unit 10 10 01.05332.0141 MANIFOLD 1 1,000 pc 20 20 01.04756.0061 THREADED STUD 4 1,000 pc 30 30 02.00318.0003 HEXAGON NUT 4 1,000 pc 40 40 01.03465.0786 SEAL RING 1 1,000 pc 50 50 01.00525.0438 BUSHING 4 1,000 pc >>>end<<< p_dbgs01.p 1 2 3 4 5 6 7 8 105 60 A 240 50 4 A 20 4 (M16) (M12) 30 4 003 B 90 55 60 B 40 1 (Festigkeitsklasse 10) (Property class 10) 55 85 C Anziehdrehmoment Ma = 100 Nm Tightening torque Ma = 100 Nm (Skt. SW 22 ) 10 1 Druckregelventile 00.05893.xxxx Pressure regulating valve 00.05893.xxxx C (Festigkeitsklasse 10.9) (Property class 10.9) D D 1:5 Betriebsdruck max. 1800 bar Max. operating pressure 1800 bar E E F Ohne unsere vorherige Zustimmung darf diese Zeichnung weder vervielfältigt noch Dritten zugänglich gemacht werden, und sie darf durch den Empfänger oder Dritte auch nicht in anderer Weise mißbräuchlich benutzt werden. 85 Artikel-Nr. Zul.Abweichung f.Maße ohne Toleranzangabe ISO 2768 - mH Datum Bearb Gepr. Norm 2 3 4 003 Stückliste Pos. 30 002 Solid Edge Zng. erstellt 001 Stkl. u. Betr.drk. geä. Zust Änderung Maßstab 23.11.2015 Will 10.04.2008 PS 07.09.2005 Pöts Datum Name A3 1:1 Gewicht in kg 6.0165 Halbzeug Oberfläche nach DIN ISO 1302 (M48 x 2) 1 08.00200.9201 ZeichFreig Verwendungszweck Format DIN Name 25.01.1995 T.GERNDT 23.11.2015 Oberscheidt 24.11.2015 Krabus Werkstoff Benennung DISCHARGE FITTING ARMATUR (DRUCKSEITIG) Zeichnungs-Nr. D-59302 OELDE CAD-Zeichnung * 08.00200.9201-1 Ers.durch Ers.für F Revision 003 Blatt 1 von 1 Bl. PARTS LIST (41) Parts-list no.: 00.00026.1238 Drawing no. : Description : UNIT HDP500; VOLVO TAD1672 STUFE 4 DwgPos >>>end<<< p_dbgs01.p Item Code-No. Description HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany mail to: mail@hammelmann.de http://www.hammelmann.de Date : 07.03.2017 Page : 1 Quantity No/Unit Unit 10 00.02350.1167 CRANK SECTION 1 1,000 pc 20 00.04246.0184 SUCTION CHAMBER 1 1,000 pc 30 00.03370.0689 BASE FRAME 1 1,000 pc 40 00.00120.1244 DRIVE 1 1,000 pc 50 04.02759.0581 DIESEL ENGINE 1 1,000 pc 70 00.00657.0209 SOUND ABSORBER 1 1,000 pc 80 00.06700.0809 CONTROL UNIT 1 1,000 pc 90 01.00273.0073 MOUNTING 1 1,000 pc 100 00.01808.0275 INSTALLATION MATERIAL 1 1,000 pc 110 00.01808.0349 INSTALLATION MATERIAL 1 1,000 pc 120 04.00829.0093 PRESSURE SENSOR 3 1,000 pc 130 08.00229.6005 KEY OPERATED SWITCH 1 1,000 pc 140 00.00134.0389 SUCTION SIDE FITTING 1 1,000 pc 145 00.00134.0152 SUCTION SIDE FITTING 1 1,000 pc 150 00.01808.0416 INSTALLATION MATERIAL 1 1,000 pc 160 04.00190.0006 BATTERY 2 1,000 pc 170 04.01909.0015 BATTERY RACK 2 1,000 pc 180 04.03070.0035 OIL 42 1,000 l 190 04.03070.0007 OIL 10W-40 38 1,000 l 200 04.04871.0004 ANTIFREEZE FLUID 70 1,000 l 210 04.04590.0121 HOSE 1 1,200 m 220 04.04590.0054 HOSE 1 1,000 m 230 04.03200.0062 SHOCK ABSORBER 8 1,000 pc 240 02.00450.0005 SQUARE TAPER WASHER 8 1,000 pc 250 02.00671.0167 HEXAGON HEAD SCREW 8 1,000 pc 260 04.00222.0027 container 1 1,000 pc 270 00.04290.0128 SWITCH 1 1,000 pc 280 04.01634.0001 UREA 1 30,000 l PARTS LIST (41) Parts-list no.: 00.02350.1167 Drawing no. : 00.02350.1167-1 Description : CRANK SECTION HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany mail to: mail@hammelmann.de http://www.hammelmann.de Date : 06.03.2017 Page : 1 HDP500 I=3,889 DwgPos Item Code-No. Description Quantity No/Unit Unit 10 10 00.01256.0206 CRANK HOUSING 1 1,000 pc 20 20 04.00708.0026 GASKET CORD 2 0,736 m 30 30 01.00266.0084 COVER PLATE 2 1,000 pc 40 40 02.00888.0018 HEXAGON SOCKET SET SCREW 8 1,000 pc 50 50 02.00314.0007 HEXAGON THIN NUT 12 1,000 pc 60 60 00.06161.0139 CRANK SHAFT 1 1,000 pc 70 70 00.03270.0032 CONNECTING ROD 3 1,000 pc 80 80 01.02390.0049 BEARING 3 1,000 pc 90 90 01.03465.1341 RING 3 1,000 pc 100 100 01.00554.0194 CYLINDRICAL BUSHING 3 1,000 pc 110 110 01.04380.0541 DISC 3 1,000 pc 120 120 02.00825.0282 HEXAGON SOCKET HEAD SCREW 3 1,000 pc 130 130 04.00730.0508 O-RING 3 1,000 pc 140 140 01.02140.0060 CROSSHEAD 3 1,000 pc 150 150 01.00410.0008 GUDGEON PIN 3 1,000 pc 160 160 02.01766.0034 BORE CIRCLIP 6 1,000 pc 170 170 01.05060.0147 PISTON ROD 3 1,000 pc 180 180 04.04482.0165 HOSE CLAMP 3 1,000 pc 190 190 04.04482.0164 HOSE CLAMP 3 1,000 pc 200 200 01.01170.0019 BELLOWS 3 1,000 pc 210 210 04.05866.0012 OIL DRAIN VALVE 1 1,000 pc 215 215 04.05300.0027 CONNECTION PIECE 1 1,000 pc 220 220 04.05993.0702 CONNECTION 1 1,000 pc 230 230 04.05993.1106 TUBE FITTING 1 1,000 pc 240 240 04.05993.0542 CONNECTION 1 1,000 pc 250 250 01.03535.1163 PIPE 1 1,000 pc 260 260 04.03235.0134 OIL PUMP 1 1,000 pc 270 270 04.05993.0707 CONNECTION 4 1,000 pc 290 290 04.05993.0448 CONNECTION 2 1,000 pc 300 300 04.05993.0511 CONNECTION 2 1,000 pc 320 320 02.00957.0103 STRAIGHT PIN 2 1,000 pc 330 330 04.05000.0014 OIL DIPSTICK 1 1,000 pc 340 340 01.00530.0148 HEADED LINER 1 1,000 pc 350 350 04.00730.0014 O-RING 1 1,000 pc 360 360 01.00665.0668 COVER 1 1,000 pc 370 370 02.00825.0281 HEXAGON SOCKET HEAD SCREW 28 1,000 pc 380 380 02.01255.0042 ELBOW FITTING 1 1,000 pc 390 390 04.00665.0024 COVER 1 1,000 pc 400 400 04.02978.0058 DOUBLE NIPPLE 1 1,000 pc 410 410 01.03535.1484 TUBE 1 1,000 pc 430 430 02.00825.0288 HEXAGON SOCKET HEAD SCREW 7 1,000 pc 440 440 02.01651.0090 FEATHER KEY 1 1,000 pc 470 470 02.01651.0036 FEATHER KEY 1 1,000 pc 480 480 01.05172.0036 SET SCREW 2 1,000 pc 490 490 01.02745.0020 DRIVER 1 1,000 pc PARTS LIST (41) Parts-list no.: 00.02350.1167 Drawing no. : 00.02350.1167-1 Description : CRANK SECTION HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany mail to: mail@hammelmann.de http://www.hammelmann.de Date : 06.03.2017 Page : 2 HDP500 I=3,889 DwgPos Item Code-No. Description Quantity No/Unit Unit 500 500 01.06180.0180 PINION SHAFT 1 1,000 pc 510 510 02.01651.0073 FEATHER KEY 1 1,000 pc 530 530 00.02198.0025 OIL COOLER 1 1,000 pc 540 540 04.00736.0052 ROTARY SHAFT SEAL 1 1,000 pc 550 550 01.03535.1066 PIPE 2 1,000 pc 560 560 02.01657.0817 SELF-ALIGNING ROLLER BEARING 2 1,000 pc 570 570 04.05993.1094 TUBE FITTING 1 1,000 pc 590 590 04.05300.0011 CONNECTION PIECE 1 1,000 pc 610 610 00.01015.0020 OIL FILTER 1 1,000 pc 620 620 01.03535.1261 TUBE 2 1,000 pc 630 630 02.00825.0272 HEXAGON SOCKET HEAD SCREW 2 1,000 pc 650 650 01.00665.0667 COVER 1 1,000 pc 670 670 01.00525.0777 BUSHING 2 1,000 pc 680 680 04.00730.0093 O-RING 2 1,000 pc 690 690 04.00730.0133 O-RING 2 1,000 pc 710 710 04.05896.0002 FLOW REGULATOR 1 1,000 pc 720 720 04.05993.0402 TUBE FITTING 2 1,000 pc 730 730 04.05993.0410 CONNECTION 2 1,000 pc 740 740 04.05993.0750 SCREW PLUG 1 1,000 pc 750 750 01.03535.1468 TUBE 1 1,000 pc 770 770 04.05993.1029 TUBE FITTING 2 1,000 pc 790 790 04.05993.0023 FITTING 1 1,000 pc 800 800 04.02860.0073 PRESSURE GAUGE 1 1,000 pc 810 810 04.05993.0704 CONNECTION 3 1,000 pc 850 850 01.05180.0071 CONTROL PIN 1 1,000 pc 860 860 04.00946.0117 COIL SPRING 1 1,000 pc 870 870 04.00730.0041 O-RING 1 1,000 pc 880 880 01.04723.0030 ADJUSTING SCREW 1 1,000 pc 890 890 02.00307.0024 HEXAGON NUT 1 1,000 pc 900 900 04.05240.0136 PLUG 1 1,000 pc 930 930 04.01777.0005 PROTECTIVE SLEEVE 1 1,000 pc 940 940 04.05682.0086 HOSE LINER 3 1,000 pc 950 950 04.00730.0520 O-RING 3 1,000 pc 960 960 00.05993.0057 TUBE FITTING 2 1,000 pc 970 970 04.05215.0063 PLUG 2 1,000 pc 980 980 01.03535.1206 PIPE 2 1,000 pc 990 990 04.05993.0101 CONNECTION 3 1,000 pc 1000 1000 01.03535.1169 PIPE 1 1,000 pc 1020 1020 04.05993.0431 TUBE FITTING 3 1,000 pc 1030 1030 04.02251.0126 COUPLING HALF 1 1,000 pc 1040 1040 04.03490.0057 COUPLING RING 2 1,000 pc 1050 1050 04.05336.0003 INTERMEDIATE PIECE 1 1,000 pc 1060 1060 04.02251.0125 COUPLING HALF 1 1,000 pc 1070 1070 00.05993.0058 TUBE FITTING 2 1,000 pc 1080 1080 04.05993.1161 TUBE FITTING 1 1,000 pc PARTS LIST (41) Parts-list no.: 00.02350.1167 Drawing no. : 00.02350.1167-1 Description : CRANK SECTION HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany mail to: mail@hammelmann.de http://www.hammelmann.de Date : 06.03.2017 Page : 3 HDP500 I=3,889 DwgPos Item Code-No. Description Quantity No/Unit Unit 1090 1090 04.05993.1015 TUBE FITTING 1 1,000 pc 1100 1100 01.03535.1461 TUBE 1 1,000 pc 1110 1110 01.01630.0138 BRACKET 1 1,000 pc 1120 1120 02.00421.0007 WASHER 8 1,000 pc 1130 1130 04.05993.0924 THREADED CONNECTION 1 1,000 pc 1160 1160 04.05993.1165 CONNECTION 1 1,000 pc 1170 1170 04.03497.0012 CUTTING RING 1 1,000 pc 1180 1180 04.02833.0038 CAP NUT 1 1,000 pc 1200 1200 01.03535.1465 TUBE 1 1,000 pc 1210 1210 04.05993.0011 TUBE FITTING 2 1,000 pc 1220 1220 01.03535.1453 TUBE 2 1,000 pc 1230 1230 04.05993.0845 fitting 1 1,000 pc 1240 1240 01.03535.1308 TUBE 1 1,000 pc 1250 1250 04.05993.1016 TUBE FITTING 1 1,000 pc 1260 1260 01.03535.1309 TUBE 1 1,000 pc 1270 1270 04.05993.0700 TUBE FITTING 2 1,000 pc 1280 1280 04.05993.0713 CONNECTION 2 1,000 pc 1290 1290 04.01548.0001 DRAIN VALVE 2 1,000 pc 1300 1300 02.00434.0007 WASHER 4 1,000 pc 1310 1310 02.00825.0290 HEXAGON SOCKET HEAD SCREW 4 1,000 pc 1320 1320 02.00825.0799 HEXAGON SOCKET HEAD SCREW 4 1,000 pc 1350 1350 01.00742.0399 SEAL RING 3 1,000 pc 1360 1360 04.00730.0462 O-RING 2 1,000 pc 1370 1370 01.05194.0127 STRAIGHT PIN 2 1,000 pc 1380 1380 04.00740.0017 RETAINER RING 1 1,000 pc 1390 1390 01.05214.0059 PLUG 1 1,000 pc >>>end<<< p_dbgs01.p 1 2 4 3 5 6 B6B 1350 3 7 8 B A6A 950 3 30 2 50 8 B 1000 1 610 1 140 3 300 2 130 3 70 3 120 3 C 630 2 C 620 2 110 3 C 480 2 80 3 1320 4 50 4 1120 4 1110 1 1120 4 1300 4 A 1310 4 B 530 1 320 2 900 1 570 1 E 370 28 F 60 1 300 2 1100 1 270 4 100 3 270 4 1130 1 970 2 160 6 150 3 40 8 290 1 170 3 D 12 A 180 3 90 3 11 10 190 3 200 3 Anziehdrehmoment Ma = 250 Nm Skt.SW60 A 9 D 260 1 360 1 240 1 1380 1 1390 1 1090 1 290 1 E 10 1 C 20 2 D Anziehdrehmoment M24 450 Nm, Iskt.SW19 Anziehdrehmoment M27 650 Nm, Iskt. SW19 250 1 220 1 1030 1 E F 1050 1 1160 1 1230 1 750 1 470 1 F C6C 490 1 560 2 550 2 540 1 510 1 500 1 Y 430 7 D 250 1 230 1 210 1 A 800 1 D6D 1220 2 960 1 990 1 1070 1 990 1 215 1 Z E 810 1 1210 1 1080 1 980 1 Z 1:2 F 1210 1 T 1240 1 770 1 930 1 G G T 1:2 E6E 730 2 880 1 890 1 740 1 Blatt 1 von 2 Achtung : 870 1 Ohne unsere vorherige Zustimmung darf diese Zeichnung weder vervielfältigt noch Dritten zugänglich gemacht werden, und sie darf durch den Empfänger oder Dritte auch nicht in anderer Weise mißbräuchlich benutzt werden. 1020 1 650 1 710 1 H 590 1 1060 1 1360 2 440 1 F6F 1180 1 1040 2 B Y 1:2 1370 2 1170 1 690 2 680 2 Anziehdrehmoment Ma = 125 Nm Skt.SW24 1200 1 670 2 6 vor der kompletten Montage , Pos.90 auf 6196°C abgekühlt und ins Gehäuse Pos.10 eingeschrumpft 6 Übergang vom Ring Pos.90 zum Gehäuse mit Seevenax beschichtet. 860 1 1020 1 1 1250 1 270 4 2 1290 2 1020 1 3 4 810 2 1280 2 1270 2 5 850 1 720 2 6 7 8 9 Format DIN Artikel6Nr. * alle Ecken und Kanten gratfrei ß Mit Betriebsdruck signiert ß Mit Auftrags-Nr. signiert ß Mit Teile-Nr. - Rev. signiert ß Härte geprüft Zul.Abweichung f.Maße ohne Toleranzangabe ISO 2768 6 mH Verwendungszweck Datum Bearb Gepr. Norm Stücklistenänderung Stücklistenänderung Stücklistenänderung Stkl Pos.330 geä (Blatt2) Änderung Maßstab 05.03.2015 19.12.2014 05.03.2014 08.10.2013 Datum Wei Pla Wei Pöts Name Name 10.06.2013 Sander 10.03.2015 Hartmann 11.03.2015 Krabus 1:4 Gewicht in kg 1506.0000 Werkstoff * Benennung KURBELTRIEB Zeichnungs6Nr. D659302 OELDE CAD6Zeichnung A1 Halbzeug Oberfläche nach DIN ISO 1302 HDP500 i=3,889 004 003 002 001 Zust 00.02350.1167 ZeichFreig 00.02350.1167 1 Ers.durch Revision 004 Ers.für 00.02350.098661 Blatt 1 von 1 Bl. H 1 2 3 4 5 6 7 8 9 11 10 12 A A 990 1 960 1 390 1 B 980 1 790 1 940 3 1070 1 1260 1 004 410 1 004 400 1 380 1 770 1 C B C 330 1 350 1 340 1 D D E E F F G G Blatt 2 von 2 alle Ecken und Kanten gratfrei ß Mit Betriebsdruck signiert ß Mit Auftrags-Nr. signiert ß Mit Teile-Nr. - Rev. signiert ß Härte geprüft Ohne unsere vorherige Zustimmung darf diese Zeichnung weder vervielfältigt noch Dritten zugänglich gemacht werden, und sie darf durch den Empfänger oder Dritte auch nicht in anderer Weise mißbräuchlich benutzt werden. H Zul.Abweichung f.Maße ohne Toleranzangabe ISO 2768 6 mH Datum Bearb Gepr. Norm 2 3 4 5 6 7 8 9 Stücklistenänderung Stücklistenänderung Stücklistenänderung Stkl Pos.330 geä (Blatt2) Änderung Maßstab 05.03.2015 19.12.2014 05.03.2014 08.10.2013 Datum Wei Pla Wei Pöts Name Name 10.06.2013 Sander 10.03.2015 Hartmann 11.03.2015 Krabus 1:4 Gewicht in kg 1506.0000 Werkstoff * Benennung KURBELTRIEB Zeichnungs6Nr. D659302 OELDE CAD6Zeichnung A1 Halbzeug Oberfläche nach DIN ISO 1302 HDP500 i=3,889 004 003 002 001 Zust 00.02350.1167 ZeichFreig Verwendungszweck 1 Format DIN Artikel6Nr. * 00.02350.1167 1 Ers.durch Revision 004 Ers.für 00.02350.098661 Blatt 1 von 1 Bl. H PARTS LIST (41) Parts-list no.: 00.02198.0025 Drawing no. : 00.02198.0025-1 Description : OIL COOLER HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany mail to: mail@hammelmann.de http://www.hammelmann.de Date : 06.03.2017 Page : 1 HDP480 DwgPos Item Code-No. Description Quantity No/Unit Unit 10 10 01.01055.1331 FLANGE 1 1,000 pc 20 20 01.03535.1258 TUBE 1 1,000 pc 30 30 01.01055.1332 FLANGE 1 1,000 pc 40 40 04.03575.0005 FINNED TUBE 1 1,000 pc 50 50 01.03535.1348 TUBE 1 1,000 pc 60 60 01.05214.0055 PLUG 1 1,000 pc >>>end<<< p_dbgs01.p 1 2 3 4 5 6 7 8 A-A A A 660 ±1 630 ±0,5 a O 0,2 A Schweißnaht-ø154,5 mm max. Schweißnaht A A ß Öl ein G3/4 X B 55 O 150 O 152,5 -0,1 -0,2 002 B M12 Demontage 55 ( G3/4 ) a O 0,2 A ( G3/4 ) 12 O 200 O 180 60° ( 6x ( G1/2 ) ( G3/4 ) 60 1 C ) 002 50 1 20 1 40 1 A M12 Demontage 002 10 1 ß Ölablass G3/4 30 1 X C ß Öl aus G3/4 002 ß Aufkleber : Hammelmann Art.-Nr. : 00.02198.0025 Baujahr : Bestell-Nr.: G1/4 optionaler Anschluss ß Wasser aus G1/2 D ß Wasser ein G1/2 O13 Befestigungsbohrung E D E Mantel hydrostatisch mit 45 bar abgedrückt Rippenrohrwendel bei Fertigungsprozess mit 25 bar Luft unter Wasser abgedrückt ß signieren 002 Lackierung erfolgt auftragsbezogen! * Rippenrohr aus CuNi 10Fe 1Mn alle Ecken und Kanten gratfrei ß Mit Betriebsdruck signiert ß Mit Auftrags-Nr. signiert ß Mit Teile-Nr. signiert ß Härte geprüft Artikel-Nr. F Ohne unsere vorherige Zustimmung darf diese Zeichnung weder vervielfältigt noch Dritten zugänglich gemacht werden, und sie darf durch den Empfänger oder Dritte auch nicht in anderer Weise mißbräuchlich benutzt werden. X Zul.Abweichung f.Maße ohne Toleranzangabe ISO 2768 - mH Datum Bearb Gepr. Norm 1 2 3 4 5 Maßstab A2 1:2 Gewicht in kg 19.0500 Halbzeug Oberfläche nach DIN ISO 1302 HDP480 002 Stkl-, Maßänd,Text hinzu 24.10.2012 Pöts 001 Text komplett geändert 19.08.2009 Hun Name Datum Zust Änderung 00.02198.0025 ZeichFreig Verwendungszweck Format DIN Name 11.03.2009 Hunke 24.10.2012 EHelmig 25.10.2012 Krabus Werkstoff Benennung OELKUEHLER Revision Zeichnungs-Nr. D-59302 OELDE CAD-Zeichnung * 00.02198.0025-1 Ers.durch Ers.für 002 Blatt 1 von 1 Bl. F PARTS LIST (41) Parts-list no.: 00.01015.0020 Drawing no. : 00.01015.0020-1 Description : OIL FILTER HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany mail to: mail@hammelmann.de http://www.hammelmann.de Date : 06.03.2017 Page : 1 HDP360/480/750 DwgPos Item Code-No. Description Quantity No/Unit Unit 10 10 00.01240.0378 HOUSING 1 1,000 pc 20 20 04.00995.0177 FILTER 1 1,000 pc 30 30 01.04838.0236 SCREW PLUG 1 1,000 pc 40 40 04.00734.0423 O-RING 1 1,000 pc 50 50 04.05240.0150 PLUG 1 1,000 pc 60 60 04.05993.0512 CONNECTION 2 1,000 pc 70 70 04.05993.1042 SCREW PLUG 1 1,000 pc 80 80 04.05866.0013 DRAIN VALVE 1 1,000 pc 90 90 01.03465.1517 RING 1 1,000 pc >>>end<<< p_dbgs01.p 1 A 50 1 2 004 004 30 1 90 1 3 4 5 6 7 8 A 40 1 60 2 10 1 20 1 80 1 B B C C D D 60 2 70 1 440 ca. 443 Betriebsdruck max. 30 bar Prüfdruck max. 45 bar E E Artikel-Nr. * Ohne unsere vorherige Zustimmung darf diese Zeichnung weder vervielfältigt noch Dritten zugänglich gemacht werden, und sie darf durch den Empfänger oder Dritte auch nicht in anderer Weise mißbräuchlich benutzt werden. F alle Ecken und Kanten gratfrei ß Mit Betriebsdruck signiert ß Mit Auftrags-Nr. signiert ß Mit Teile-Nr. signiert ß Härte geprüft Zul.Abweichung f.Maße ohne Toleranzangabe ISO 2768 - mH Datum Bearb Gepr. Norm 1 2 3 4 Stkl. geä. Stücklistenänderung Pos.40 geändert Stücklistenänderung Änderung Maßstab 26.07.2016 12.12.2014 24.06.2014 12.04.2011 Datum Pöts Waw San Pöts Name A3 1:1.5 Gewicht in kg 13.0000 Halbzeug Oberfläche nach DIN ISO 1302 HDP360/480/750 004 003 002 001 Zust 00.01015.0020 ZeichFreig Verwendungszweck Format DIN Name 02.03.2009 Hunke 27.07.2016 Hartmann 28.07.2016 Krabus Werkstoff Benennung F OELFILTER Zeichnungs-Nr. D-59302 OELDE CAD-Zeichnung * 00.01015.0020-1 Ers.durch Ers.für Revision 004 Blatt 1 von 1 Bl. PARTS LIST (41) Parts-list no.: 00.04246.0184 Drawing no. : 00.04246.0184-1 Description : SUCTION CHAMBER HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany mail to: mail@hammelmann.de http://www.hammelmann.de Date : 06.03.2017 Page : 1 HDP360-500 D28 - 65 DwgPos Item Code-No. Description Quantity No/Unit Unit 10 10 01.04246.0224 SUCTION CHAMBER 1 1,000 pc 20 20 01.04380.1080 DISC 12 1,000 pc 30 30 02.00825.0226 HEXAGON SOCKET HEAD SCREW 12 1,000 pc 40 40 02.00788.0060 STUD BOLT 8 1,000 pc 50 50 02.00309.0009 HEXAGON NUT 8 1,000 pc 70 70 04.05993.0788 THREADED CONNECTION 5 1,000 pc 80 80 04.00730.0539 O-RING 1 1,000 pc 90 90 02.00957.0103 STRAIGHT PIN 2 1,000 pc >>>end<<< p_dbgs01.p 2 80 1 4 5 6 7 8 640 10 1 A ° 45 40 8 A 3 50 8 22,5° W 358 1 B 180 70 2 B 90 2 20 12 O 180 30 12 Saugraum bei Montage mit Kurbeltrieb mit Kleber "TEROKAL 3 2444" (04.02056.0005) umlaufend angedichtet. 7 9 1 3 11 5 C C 12 6 D 001 W 8 2 4 10 D Schrauben Pos. 30 mit integriertem Schmiermittel und in angegebener Reihenfolge ohne Fett angezogen: 1. Stufe: Anziehdrehmoment Ma = 200 Nm 2. Stufe: Anziehdrehmoment Ma = 800 Nm E E Bronze Saugraum mit 1x DIN DN100 ; PN16 alle Ecken und Kanten gratfrei ß Mit Betriebsdruck signiert ß Mit Auftrags-Nr. signiert ß Mit Teile-Nr. - Rev. signiert ß Härte geprüft Ohne unsere vorherige Zustimmung darf diese Zeichnung weder vervielfältigt noch Dritten zugänglich gemacht werden, und sie darf durch den Empfänger oder Dritte auch nicht in anderer Weise mißbräuchlich benutzt werden. F Format DIN Artikel3Nr. * 00.04246.0184 ZeichFreig Zul.Abweichung f.Maße ohne Toleranzangabe ISO 2768 3 mH Verwendungszweck Maßstab Datum Bearb Gepr. Norm 1:5 Gewicht in kg 253.7640 * 2.0975 Halbzeug Oberfläche nach DIN ISO 1302 HDP3603500 D28360 A2 Name 23.04.2012 Sander 28.02.2013 EHelmig 28.02.2013 Krabus Werkstoff Benennung SAUGRAUM Zeichnungs3Nr. 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 Revision 001 Blatt 1 von 1 Bl. F PARTS LIST (41) Parts-list no.: 00.00120.1244 Drawing no. : 00.00120.1244-1 Description : DRIVE HDP480; DEUTZ TCD 2015 V08 DwgPos Item Code-No. Description HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany mail to: mail@hammelmann.de http://www.hammelmann.de Date : 06.03.2017 Page : 1 Quantity No/Unit Unit 20 20 00.02250.0432 COUPLING 1 1,000 pc 30 30 00.01642.0386 PROTECTION 1 1,000 pc 40 40 02.00825.0079 HEXAGON SOCKET HEAD SCREW 8 1,000 pc 50 50 02.00421.0006 WASHER 10 1,000 pc 60 60 02.00654.0033 HEXAGON SCREW 10 1,000 pc >>>end<<< p_dbgs01.p 1 2 3 4 5 6 7 8 A A O 530 30 1 60 10 50 10 B B (O 466,7 ) (O 438,2 ) 003 C C 40 8 286,5 25,4 D D 38 (Volvo) 003 29 (Deutz) 20 1 E E alle Ecken und Kanten gratfrei ß Mit Betriebsdruck signiert ß Mit Auftrags-Nr. signiert ß Mit Teile-Nr. - Rev. signiert ß Härte geprüft Ohne unsere vorherige Zustimmung darf diese Zeichnung weder vervielfältigt noch Dritten zugänglich gemacht werden, und sie darf durch den Empfänger oder Dritte auch nicht in anderer Weise mißbräuchlich benutzt werden. F Zul.Abweichung f.Maße ohne Toleranzangabe ISO 2768 - mH Datum Bearb Gepr. Norm 1 2 3 4 5 Maßstab 16.12.2015 Fra 14.03.2007 Schü 18.01.2007 Schü Datum Name A2 1:4 Gewicht in kg Halbzeug Oberfläche nach DIN ISO 1302 HDP 500 003 Maße Volvo nachgetrg. 002 Maß 466,7 nachgetr. 001 Pos.10 entfällt Zust Änderung 00.00120.1244 ZeichFreig Verwendungszweck 268,5 Format DIN Artikel-Nr. * Name 11.01.2006 Schueppen 17.12.2015 Barton 17.12.2015 Krabus Werkstoff * Benennung ANTRIEB Zeichnungs-Nr. D-59302 OELDE CAD-Zeichnung 47.0000 00.00120.1244-1 Ers.durch Ers.für Revision 003 Blatt 1 von 1 Bl. F PARTS LIST (41) Parts-list no.: 00.02250.0432 Drawing no. : 00.02250.0432-1 Description : COUPLING HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany mail to: mail@hammelmann.de http://www.hammelmann.de Date : 06.03.2017 Page : 1 HDP480; CAT C-18 DwgPos Item Code-No. Description Quantity No/Unit Unit 10 10 04.03490.0043 COUPLING RING 1 1,000 pc 20 20 04.02251.0121 COUPLING HALF 1 1,000 pc 30 30 04.01063.0009 COUPLING FLANGE 1 1,000 pc 40 40 04.03465.0031 RING 1 1,000 pc >>>end<<< p_dbgs01.p 1 2 3 4 5 6 SAE14 70 im Lieferumfang enthalten (Pos.50) 32,5 O 13 Drehschwingungsberechnung: TVA-Nr. 05015 Anziehdrehmoment 280Nm Tightening torque Couple de serrage 10 1 B 203 20 1 167 im Lieferumfang enthalten (Pos.60,70) C C +0,2 90,4 31 O 115 O 154 (8x45°) A 12 Nut nach DIN 6885-1 A O 85 H7 D 205 40 1 298 Passmaß Abmaße 22 JS9 +0,026 -0,026 +0,035 0,000 E 85 H7 Ohne unsere vorherige Zustimmung darf diese Zeichnung weder vervielfältigt noch Dritten zugänglich gemacht werden, und sie darf durch den Empfänger oder Dritte auch nicht in anderer Weise mißbräuchlich benutzt werden. 70 60 50 40 30 20 10 Pos. 1 Gewindestift 1 DIN 914 M20x25 45H Zylinderschraube 12 ISO 4762-10.9 M16x50 Stützscheibe 8 DIN 988 SS13x19x1,5 Kupplungsring 1 C45 Kupplungsflansch 1 GkAlSi12(Cu) Kupplungsnabe 1 C45 Kupplungselement 1 Silicon Benennung Stck. Werkstoff 2 04.03465.0031 04.01063.0009 04.02251.0121 04.03490.0043 Hammelmann-Nr. 3 Lieferumfang Lieferumfang Lieferumfang 04-02999-02 04-01147-01 04-03952-02 04-03390-05 Centa-Nr. 4 Höchstmaß Mindestmaß 22,026 21,974 85,035 85,000 Artikel-Nr. * F 22 JS9 75 11,5 O 438,2 ±0,2 -0,1 O 466,7 D A 60 Shore Silicon 30 1 B 8 Kupplungs-Bestell-Nr.: CM-5000-SCE-14-65078 286,5 A 7 alle Ecken und Kanten gratfrei ß Mit Betriebsdruck signiert ß Mit Auftrags-Nr. signiert ß Mit Teile-Nr. signiert ß Härte geprüft Zul.Abweichung f.Maße ohne Toleranzangabe ISO 2768 - mH Verwendungszweck Datum Bearb Gepr. Norm 003 "Nur f. Ersatz" entfällt 002 Nur für Ersatz 001 Zeichng. auf Solid Edge Zust Änderung Maßstab 02.07.2009 Schü 21.04.2009 Schü 25.10.2006 Hun Datum Name A3 1:1.5 Gewicht in kg 40.0000 Halbzeug Oberfläche nach DIN ISO 1302 HDP 480 mit CAT C-18 Format DIN 00.02250.0432 ZeichFreig_PDF Name 18.03.2005 Schueppen 06.07.2009 Barton 07.07.2009 Szustkowski Werkstoff * Benennung F KUPPLUNG Revision Zeichnungs-Nr. D-59302 OELDE CAD-Zeichnung E 00.02250.0432-1 Ers.durch Ers.für 003 Blatt 1 von 1 Bl. PARTS LIST (41) Parts-list no.: 00.00134.0389 Drawing no. : 00.00134.0389-1 Description : SUCTION SIDE FITTING HDP250/360,VOLVO (STAGE 3B) DwgPos Item Code-No. Description HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany mail to: mail@hammelmann.de http://www.hammelmann.de Date : 06.03.2017 Page : 1 Quantity No/Unit Unit 10 10 00.00131.0143 CONNECTION FITTING 1 1,000 pc 20 20 00.02515.0211 LINE 1 1,000 pc 30 30 00.00131.0279 CONNECTION FITTING 1 1,000 pc 40 40 04.00709.0020 SEAL RING 1 1,000 pc 50 50 02.00654.0335 HEXAGON HEAD BOLT 4 1,000 pc 60 60 02.00421.0009 WASHER 4 1,000 pc 70 70 02.00309.0009 HEXAGON NUT 4 1,000 pc 80 80 04.03226.0769 CENTRIFUGAL PUMP 1 1,000 pc 90 90 02.01255.0485 MALLEABLE CAST IRON FITTING 1 1,000 pc 100 100 04.01548.0001 DRAIN VALVE 1 1,000 pc 110 110 02.00888.0308 HEXAGON SOCKET SET SCREW 1 1,000 pc 120 120 01.03460.0291 V-BELT DISC 1 1,000 pc 130 130 01.01642.0099 PROTECTIVE COVER 1 1,000 pc 140 140 02.00421.0004 DISC 3 1,000 pc 150 150 02.00671.0148 HEXAGON HEAD SCREW 3 1,000 pc 160 160 04.04205.0023 SPANNER 1 1,000 pc 170 170 04.03459.0362 NARROW V-BELT 2 1,000 pc 180 180 02.00421.0007 WASHER 12 1,000 pc 190 190 02.00671.0124 HEXAGON SCREW 6 1,000 pc 200 200 02.00309.0007 HEXAGON NUT 6 1,000 pc >>>end<<< p_dbgs01.p 1 2 3 4 5 6 8 10 1 20 1 A 7 A 30 1 70 4 B 60 4 50 4 B 40 1 130 1 C 150 3 180 12 190 6 200 6 80 1 140 3 C 90 1 100 1 170 2 D 110 1 E 160 1 D 120 1 E Artikel-Nr. * alle Ecken und Kanten gratfrei ß Mit Betriebsdruck signiert ß Mit Auftrags-Nr. signiert ß Mit Teile-Nr. - Rev. signiert ß Härte geprüft Ohne unsere vorherige Zustimmung darf diese Zeichnung weder vervielfältigt noch Dritten zugänglich gemacht werden, und sie darf durch den Empfänger oder Dritte auch nicht in anderer Weise mißbräuchlich benutzt werden. F DN50 00.00134.0389 ZeichFreig_PDF Zul.Abweichung f.Maße ohne Toleranzangabe ISO 2768 - mH Verwendungszweck Maßstab Datum Bearb Gepr. Norm A3 1:5 Gewicht in kg 54.0000 Halbzeug Oberfläche nach DIN ISO 1302 HDP250/360 mit VOLVO Format DIN Name 10.05.2011 Brunnert 11.05.2011 Barton 11.05.2011 Krabus Werkstoff Benennung 1 2 3 4 Zust Änderung Datum Name F ANSCHLUSSARMATUR(SAUGSEITIG) Revision Zeichnungs-Nr. D-59302 OELDE CAD-Zeichnung * 00.00134.0389-1 Ers.durch Ers.für 000 Blatt 1 von 1 Bl. PARTS LIST (41) Parts-list no.: 00.00134.0152 Drawing no. : 00.00134.0152-1 Description : SUCTION SIDE FITTING HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany mail to: mail@hammelmann.de http://www.hammelmann.de Date : 06.03.2017 Page : 1 HDP 380, 500, 800 DwgPos Item Code-No. Description Quantity No/Unit Unit 10 10 00.00995.0058 FILTER 1 1,000 pc 20 20 00.00134.0160 CONNECTION FITTING, SUCTION SI 1 1,000 pc 30 30 04.04475.0134 CLAMP 1 1,000 pc 50 50 02.00654.0327 HEXAGON HEAD BOLT 4 1,000 pc 60 60 02.00421.0006 WASHER 8 1,000 pc 70 70 01.00265.0851 PLATE 2 1,000 pc 90 90 04.02860.0073 PRESSURE GAUGE 1 1,000 pc 100 100 02.00805.0305 HEXAGON HEAD SCREW PLUG 2 1,000 pc 110 110 02.00309.0006 HEXAGON NUT 4 1,000 pc >>>end<<< p_dbgs01.p 2 3 4 5 6 7 22,5° Vorschweißflansch DN100; PN16; DIN-ISO 2633 ( O 180 ) A 8 50 4 20 1 70 2 15 (O18) A 5 1 445 60 8 B B 1075 010 965 X 1:2 110 4 100 2 655 10 1 30 1 C 520 C X D 331 D 30 268 292 E F Sauganschluß Losflansch DN65; DIN 2642 Artikel-Nr. * alle Ecken und Kanten gratfrei ß Mit Betriebsdruck signiert ß Mit Auftrags-Nr. signiert ß Mit Teile-Nr. signiert ß Härte geprüft 596 Ohne unsere vorherige Zustimmung darf diese Zeichnung weder vervielfältigt noch Dritten zugänglich gemacht werden, und sie darf durch den Empfänger oder Dritte auch nicht in anderer Weise mißbräuchlich benutzt werden. 713,5 E Zul.Abweichung f.Maße ohne Toleranzangabe ISO 2768 - mH 90 1 1 2 3 4 Pos.100 Menge 3 in 2 Pos.-Änderung Solid-Edge Fehler Solid-Edge Zchng. erst. Positionsänderung Stücklistenänderung Pos.40 & 80 entfällt Änderung Maßstab 10.03.2010 Schü Bearb 29.10.2009 Schü Gepr. 05.09.2006 Schü Norm 26.01.2006 Schü 09.05.2005 Gut 02.03.2005 Maa 23.02.2005 Gut Datum Name A3 1:7.5 Gewicht in kg 43.0000 Halbzeug Oberfläche nach DIN ISO 1302 Datum 010 009 008 007 006 005 004 Zust 00.00134.0152 ZeichFreig_PDF Verwendungszweck Format DIN Name 26.01.2006 Schueppen 11.03.2010 Barton 12.03.2010 Szustkowski Werkstoff Benennung F ANSCHLUSSARMATUR(SAUGSEITIG) Revision Zeichnungs-Nr. D-59302 OELDE CAD-Zeichnung * 00.00134.0152-1 Ers.durch Ers.für 010 Blatt 1 von 1 Bl. PARTS LIST (41) Parts-list no.: 00.00995.0058 Drawing no. : 00.00995.0058-1 Description : FILTER HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany mail to: mail@hammelmann.de http://www.hammelmann.de Date : 06.03.2017 Page : 1 FILTER 300LTR/MIN DwgPos Item Code-No. Description Quantity No/Unit Unit 10 10 00.00222.0082 CONTAINER 1 1,000 pc 20 20 01.00665.0419 COVER 1 1,000 pc 30 30 04.00730.0504 O-RING 1 1,000 pc 40 40 01.05194.0117 STRAIGHT PIN 3 1,000 pc 50 50 02.00503.0110 EYEBOLT 3 1,000 pc 60 60 02.00301.0002 RING NUT 3 1,000 pc 70 70 04.00946.0124 COIL SPRING 1 1,000 pc 80 80 00.02166.0003 FILTER HOLDER 1 1,000 pc 90 90 01.03478.0257 SUPPORT RING 1 1,000 pc 100 100 00.00273.0012 PLATE 1 1,000 pc 110 110 04.01561.0107 BLOCK BALL VALVE 1 1,000 pc 120 120 04.05866.0011 AIR VENT VALVE 1 1,000 pc 160 160 04.05993.0802 CONNECTION 2 1,000 pc 190 190 02.00421.0006 WASHER 3 1,000 pc 200 200 01.04565.0017 NAMEPLATE 1 1,000 pc 210 210 04.02970.0016 RIVET 4 1,000 pc 220 220 04.05993.0924 THREADED CONNECTION 1 1,000 pc >>>end<<< p_dbgs01.p 1 2 3 4 5 6 60 3 120 1 A 70 1 O 114,3 100 1 169 655 80 1 963 160 2 10 1 1:10 Filterbeutel (04.00995.XXXX) gehört nicht zur Baugruppe! Typenschild ausgefüllt! 210 4 01.04565.0017 D 00.00995.0058 Artikel-Nr. Baujahr / Serien-Nr. Betriebsdruck max. bar Differenzdruck max. bar Betriebstemperatur °C Durchflussmenge l/min Losflansch DN65 ; PN10 Anschlussmaße nach DIN 2642 220 1 006 Artikel-Nr. * alle Ecken und Kanten gratfrei ß Mit Betriebsdruck signiert ß Mit Auftrags-Nr. signiert ß Mit Teile-Nr. - Rev. signiert ß Härte geprüft Zul.Abweichung f.Maße ohne Toleranzangabe ISO 2768 - mH A 2 3 4 006 005 004 003 002 001 Zust Stücklistenänderung Solid-Edge Zchng. erst. Pos.40 geändert Typenschild geändert Konvertierungsfehler Diffdr. + Entl.-V. Änderung Maßstab Datum Name A3 1:5 Gewicht in kg 30.2000 Halbzeug Oberfläche nach DIN ISO 1302 Bearb 11.06.2012 Wei Gepr. 05.09.2006 Schü Norm 25.04.2005 Gut 29.06.2004 Gut 22.12.1999 Hein 17.11.1999 Sys Format DIN 00.00995.0058 ZeichFreig Datum 30 Ohne unsere vorherige Zustimmung darf diese Zeichnung weder vervielfältigt noch Dritten zugänglich gemacht werden, und sie darf durch den Empfänger oder Dritte auch nicht in anderer Weise mißbräuchlich benutzt werden. E 300l/min 1 D Hammelmann Maschinenfabrik GmbH Zum Sundern 13-21 59302 Oelde Germany Telefon 02522/76-0 Telefax 02522/76444 Verwendungszweck A Liter 10 1,25 (+/-10%) max.70 300 25 (O 14 ) (O11) F Inhalt A-A 110 1 268 E C 520 200 1 B 90 1 40 3 C A 30 1 50 3 176 8 20 1 190 3 B 7 Name 16.12.1994 HEINR. 12.06.2012 Willems 13.06.2012 Krabus Werkstoff Benennung F FILTER Revision Zeichnungs-Nr. D-59302 OELDE CAD-Zeichnung * 00.00995.0058-1 Ers.durch Ers.für 006 Blatt 1 von 1 Bl. PARTS LIST (41) Parts-list no.: 00.00134.0160 Drawing no. : Description : CONNECTION FITTING, SUCTION SI HDP400 DwgPos Item Code-No. Description HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany mail to: mail@hammelmann.de http://www.hammelmann.de Date : 06.03.2017 Page : 1 Quantity No/Unit Unit 10 10 04.00709.0019 FLAT SEAL 1 1,000 pc 20 20 02.01272.0310 WELDING NECK FLANGE 1 1,000 pc 30 30 04.00426.0079 ELBOW 2 1,000 pc 40 40 00.00134.0079 SUCTION SIDE FITTING 1 1,000 pc 50 50 07.54571.0745 STEEL TUBE 1 0,060 m >>>end<<< p_dbgs01.p 1 2 3 4 5 10 1 A 6 7 8 Vorschweißflansch C100x114,3-1.4571; PN16 DIN 2633 20 1 30 2 A 40 1 B ( 114,3 x 3,6 ) 445 B C 60 C 417 D 004 D 50 1 204,5 (R 1/2) alle unbemaßten Schweißnähte a=3 004 E Oberflächenbehandlung nach Hammelmann WN 3501 Schweißnähte sind zu passivieren durch: bürsten, strahlen oder beizen. E * X Ohne unsere vorherige Zustimmung darf diese Zeichnung weder vervielfältigt noch Dritten zugänglich gemacht werden, und sie darf durch den Empfänger oder Dritte auch nicht in anderer Weise mißbräuchlich benutzt werden. F (R 1/4) Artikel-Nr. alle Ecken und Kanten gratfrei ß Mit Betriebsdruck signiert ß Mit Auftrags-Nr. signiert ß Mit Teile-Nr. signiert ß Härte geprüft Zul.Abweichung f.Maße ohne Toleranzangabe ISO 2768 - mH Datum 1 2 3 4 Pos.50 Halbzeug geändert Pos.40 aktualisiert Maße korr. Maßnachtrag Änderung Maßstab 09.07.2012 10.03.2010 16.10.2009 20.01.2003 Datum Jan Schü Pöts Maa Name A3 1:5 Gewicht in kg 11.7000 Halbzeug Oberfläche nach DIN ISO 1302 Bearb Gepr. Norm 004 003 002 001 Zust 00.00134.0160 ZeichFreig Verwendungszweck Format DIN Name 06.06.2001 Maas 12.07.2012 Krabus 12.07.2012 Krabus Werkstoff Benennung F ANSCHLUSSARMATUR(SAUGSEITIG) Revision Zeichnungs-Nr. D-59302 OELDE CAD-Zeichnung * 00.00134.0160-1 Ers.durch Ers.für 004 Blatt 1 von 1 Bl. PARTS LIST (41) Parts-list no.: 00.05540.0346 Drawing no. : 00.05540.0346-1 Description : WATER TANK HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany mail to: mail@hammelmann.de http://www.hammelmann.de Date : 06.03.2017 Page : 1 1300L DwgPos Item Code-No. Description Quantity No/Unit Unit 10 10 00.05540.0345 TANK 1 1,000 pc 20 20 04.00709.0017 FLAT SEAL 1 1,000 pc 30 30 00.00131.0183 ARMATURE 1 1,000 pc 40 40 04.01561.0151 BLOCK BALL VALVE 1 1,000 pc 50 50 00.00131.0341 CONNECTION FITTING 1 1,000 pc 60 60 02.00421.0007 WASHER 6 1,000 pc 70 70 02.00671.0120 HEXAGON HEAD SCREW 6 1,000 pc 80 80 04.04590.0125 HOSE 1 3,000 m 90 90 02.00671.0154 HEXAGON HEAD SCREW 4 1,000 pc 100 100 02.00421.0009 WASHER 4 1,000 pc 110 110 02.00309.0009 HEXAGON NUT 4 1,000 pc 120 120 04.04482.0137 HOSE CLAMP 2 1,000 pc 130 130 04.01561.0107 BLOCK BALL VALVE 1 1,000 pc 150 150 04.04475.0081 CLAMP 1 1,000 pc 160 160 04.02976.0021 WELDING NIPPLE 1 1,000 pc >>>end<<< p_dbgs01.p 1 2 Y 1:2,5 130 1 4 5 6 830 7 1200 400 40 1 50 1 (G2) 400 8 150 1 10 1 O 14 A 3 A 160 1 X 1:12 153 B 354 B Z X C C Y 1230 80 1 Z 1:3 120 2 D D 858 60 6 70 6 DN 50 Ohne unsere vorherige Zustimmung darf diese Zeichnung weder vervielfältigt noch Dritten zugänglich gemacht werden, und sie darf durch den Empfänger oder Dritte auch nicht in anderer Weise mißbräuchlich benutzt werden. F 1250 E 20 1 30 1 90 4 100 4 110 4 E Tankinhalt ca. 1300 l Artikel-Nr. * X alle Ecken und Kanten gratfrei ß Mit Betriebsdruck signiert ß Mit Auftrags-Nr. signiert ß Mit Teile-Nr. - Rev. signiert ß Härte geprüft 00.05540.0346 ZeichFreig Zul.Abweichung f.Maße ohne Toleranzangabe ISO 2768 - mH Verwendungszweck Maßstab Datum A3 1:20 Gewicht in kg 264.0000 Halbzeug Oberfläche nach DIN ISO 1302 Bearb Gepr. Norm Format DIN Name 31.03.2016 OFranke 05.04.2016 Barton 05.04.2016 Krabus Werkstoff Benennung F TANK Zeichnungs-Nr. 1 2 3 4 Zust Änderung Datum Name D-59302 OELDE CAD-Zeichnung * 00.05540.0346-1 Ers.durch Ers.für Revision 000 Blatt 1 von 1 Bl. PARTS LIST (41) Parts-list no.: 00.05540.0345 Drawing no. : 00.05540.0345-1 Description : TANK HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany mail to: mail@hammelmann.de http://www.hammelmann.de Date : 06.03.2017 Page : 1 CA.1300L DwgPos Item Code-No. Description Quantity No/Unit Unit 10 10 00.05540.0289 TANK 1 1,000 pc 20 20 04.02978.0046 DOUBLE NIPPLE 2 1,000 pc 40 40 00.05880.0007 float valve 1 1,000 pc 50 50 04.06200.0017 ANGLE 1 1,000 pc 60 60 04.04306.0153 LIMIT SWITCH 1 1,000 pc 70 70 04.06195.0018 ANGLE 2 1,000 pc 80 80 04.05682.0051 HOSE LINER 2 1,000 pc 90 90 04.05993.0440 TUBE FITTING 1 1,000 pc 100 100 04.06195.0020 ANGLE 1 1,000 pc 110 110 04.05993.0825 CONNECTION 1 1,000 pc 120 120 04.05993.0404 TUBE FITTING 2 1,000 pc 130 130 04.05993.0742 CONNECTION 2 1,000 pc 140 140 04.06195.0016 ANGLE 2 1,000 pc 150 150 04.05993.0402 TUBE FITTING 1 1,000 pc 160 160 04.06195.0017 ANGLE 1 1,000 pc 170 170 04.05993.0731 CONNECTION 1 1,000 pc 180 180 04.06200.0025 ANGLE 1 1,000 pc 190 190 00.00131.0208 CONNECTION FITTING 1 1,000 pc 200 200 04.04495.0021 SLIDE 1 1,000 pc 230 230 04.04611.0064 CONNECTION HOSE 1 0,000 m 240 240 04.04482.0129 CLAMP 1 1,000 pc 250 250 04.05214.0028 PLUG 1 1,000 pc >>>end<<< p_dbgs01.p 1 2 3 4 5 355 7 8 352 40 1 50 1 A 6 X 400 A 400 G2 A 75 240 1 B 1340 B 230 1 10 1 60 1 250 1 20 2 200 1 C 44 190 1 59 C 180 1 O 15 1200 1230 1250 Entleerungsanschluss G1 1/2 830 850 Sauganschluss Schlauchtülle Ø76,1 D D 110 1 100 1 90 1 70 2 80 2 E 120 2 130 2 140 2 Ohne unsere vorherige Zustimmung darf diese Zeichnung weder vervielfältigt noch Dritten zugänglich gemacht werden, und sie darf durch den Empfänger oder Dritte auch nicht in anderer Weise mißbräuchlich benutzt werden. F E X 1:5 150 1 160 1 170 1 Tankinhalt ca. 1300 l Artikel-Nr. * alle Ecken und Kanten gratfrei ß Mit Betriebsdruck signiert ß Mit Auftrags-Nr. signiert ß Mit Teile-Nr. - Rev. signiert ß Härte geprüft 00.05540.0345 ZeichFreig Zul.Abweichung f.Maße ohne Toleranzangabe ISO 2768 - mH Verwendungszweck Maßstab Bearb Gepr. Norm A2 1:10 Gewicht in kg 240.0000 * 1.4301 Halbzeug Oberfläche nach DIN ISO 1302 Datum Format DIN Name 31.03.2016 OFranke 05.04.2016 Barton 05.04.2016 Krabus Werkstoff Benennung TANK Zeichnungs-Nr. 1 2 3 4 5 Zust Änderung Datum Name D-59302 OELDE CAD-Zeichnung 00.05540.0345-1 Ers.durch Ers.für Revision 000 Blatt 1 von 1 Bl. F PARTS LIST (41) Parts-list no.: 00.05880.0007 Drawing no. : 00.05880.0007-1 Description : float valve 2" SCHWIMMERV.+KUGEL DwgPos Item Code-No. Description HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany mail to: mail@hammelmann.de http://www.hammelmann.de Date : 06.03.2017 Page : 1 Quantity No/Unit Unit 10 10 04.05880.0021 FLOAT VALVE 1 1,000 pc 20 20 04.05880.0020 FLOAT VALVE 1 1,000 pc >>>end<<< p_dbgs01.p 1 2 3 4 5 6 7 8 68 A G 2A 20 1 A Ventil geschlossen B ca. 405 ca. 18° B 10 1 offen l i t n e V C C 150° ca . 69 R 50 D D Original 300mm Messingstange mit Brenner erwärmen bis gute Verformbarkeit gegeben E E Artikel-Nr. * Ohne unsere vorherige Zustimmung darf diese Zeichnung weder vervielfältigt noch Dritten zugänglich gemacht werden, und sie darf durch den Empfänger oder Dritte auch nicht in anderer Weise mißbräuchlich benutzt werden. F alle Ecken und Kanten gratfrei ß Mit Betriebsdruck signiert ß Mit Auftrags-Nr. signiert ß Mit Teile-Nr. - Rev. signiert ß Härte geprüft 00.05880.0007 ZeichFreig Zul.Abweichung f.Maße ohne Toleranzangabe ISO 2768 - mH Verwendungszweck Maßstab Datum 1:5 Halbzeug Oberfläche nach DIN ISO 1302 Bearb Gepr. Norm Format DIN Name 30.06.2015 OFranke 01.07.2015 Brunnert 02.07.2015 Krabus A3 Gewicht in kg 6.7000 Werkstoff Benennung F SCHWIMMERVENTIL Zeichnungs-Nr. 1 2 3 4 Zust Änderung Datum Name D-59302 OELDE CAD-Zeichnung * 00.05880.0007-1 Ers.durch Ers.für Revision 000 Blatt 1 von 1 Bl. PARTS LIST (41) Parts-list no.: 00.00131.0183 Drawing no. : 00.00131.0183-1 Description : ARMATURE HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany mail to: mail@hammelmann.de http://www.hammelmann.de Date : 06.03.2017 Page : 1 ARMATURE DwgPos Item Code-No. Description Quantity No/Unit Unit 10 10 02.01276.0314 FLANGE 1 1,000 pc 20 20 02.01276.0164 WELDING NECK FLANGE 1 1,000 pc 30 30 04.00426.0076 ELBOW FITTING 1 1,000 pc 40 40 04.05320.0026 REDUCTION PIECE 1 1,000 pc 50 50 04.02976.0002 WELDING NIPPLE 1 1,000 pc >>>end<<< p_dbgs01.p 1 2 3 4 5 3,5 B 8 A 45 ° 20 1 30 1 7 90° 23 A 6 O 16 5 (O17,5) B DN50 5 O 12 C C 40 1 226 10 1 50 1 D D 1:4 (G2 1/2"A) 99 E E Artikel-Nr. * F Ohne unsere vorherige Zustimmung darf diese Zeichnung weder vervielfältigt noch Dritten zugänglich gemacht werden, und sie darf durch den Empfänger oder Dritte auch nicht in anderer Weise mißbräuchlich benutzt werden. X alle Ecken und Kanten gratfrei ß Mit Betriebsdruck signiert ß Mit Auftrags-Nr. signiert ß Mit Teile-Nr. - Rev. signiert ß Härte geprüft 00.00131.0183 ZeichFreig_PDF Zul.Abweichung f.Maße ohne Toleranzangabe ISO 2768 - mH Verwendungszweck Maßstab Datum A3 1:2 Gewicht in kg 2.4000 Halbzeug Oberfläche nach DIN ISO 1302 Bearb Gepr. Norm Format DIN Name 12.11.1996 Franke 20.08.2010 Barton 25.08.2010 Krabus Werkstoff Benennung 1 2 3 4 20.08.2010 Schü Datum Name D-59302 OELDE CAD-Zeichnung F ANSCHLUSSARMATUR Revision Zeichnungs-Nr. 001 Solid-Edge Zchng. erst. Zust Änderung * 00.00131.0183-1 Ers.durch 001 Ers.für Blatt 1 von 1 Bl. PARTS LIST (41) Parts-list no.: 00.05540.0262 Drawing no. : 00.05540.0262-1 Description : FUEL TANK HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany mail to: mail@hammelmann.de http://www.hammelmann.de Date : 06.03.2017 Page : 1 900L ALU-DIESEL DwgPos Item Code-No. Description Quantity No/Unit Unit 10 10 00.05540.0261 TANK 1 1,000 pc 20 20 04.00075.0030 LEVEL INDICATOR 1 1,000 pc 30 30 04.05955.0003 TANK CAP 1 1,000 pc 40 40 00.05300.0128 CONNECTION PIECE 1 1,000 pc 50 50 04.05993.0756 PLUG 1 1,000 pc 60 60 04.01454.0023 RUBBER GASKET 2 1,180 m 70 70 04.01454.0023 RUBBER GASKET 2 1,280 m 80 80 02.00671.0117 HEXAGON HEAD SCREW 6 1,000 pc 90 90 01.05013.0231 STEEL BAR 6 1,000 pc 100 100 00.03355.0377 FRAME 1 1,000 pc 110 110 01.05308.0067 CLAMP PIECE 1 1,000 pc 120 120 02.00671.0126 HEXAGON SCREW 7 1,000 pc 130 130 02.00421.0007 WASHER 14 1,000 pc 140 140 02.00309.0007 HEXAGON NUT 7 1,000 pc 150 150 04.01002.0092 FILTER 1 1,000 pc >>>end<<< p_dbgs01.p 1 2 3 4 5 6 8 20 1 10 1 A 7 30 1 50 1 B 150 1 010 632 816 40 1 A B Z C 1260 1340 1230 1280 400 400 25 (M12) 140 7 130 14 120 7 90 6 1:20 25 5 225 350 15 Z 500 550 D 350 1230 O 15 350 D 60° 80 6 C 70 2 60 2 E Artikel-Nr. 550 * alle Ecken und Kanten gratfrei ß Mit Betriebsdruck signiert ß Mit Auftrags-Nr. signiert ß Mit Teile-Nr. - Rev. signiert ß Härte geprüft Zul.Abweichung f.Maße ohne Toleranzangabe ISO 2768 - mH Verwendungszweck (M12) 200 1250 1 2 3 4 Stückliste geändert Ansicht aktualisiert Ansicht aktualisiert Flach hinzu Stücklistenänderung Stücklistenänderung Pos.80:Stahl in Edelstahl Änderung Maßstab 14.01.2016 14.11.2013 19.06.2013 28.05.2013 12.04.2013 15.03.2013 10.12.2012 Datum Bru Bru Bru Jac Bru Bru Fra Name Bearb Gepr. Norm A3 1:10 Gewicht in kg 177.0000 Halbzeug Oberfläche nach DIN ISO 1302 Datum 010 009 008 007 006 005 004 Zust Format DIN 00.05540.0262 ZeichFreig 200 Ohne unsere vorherige Zustimmung darf diese Zeichnung weder vervielfältigt noch Dritten zugänglich gemacht werden, und sie darf durch den Empfänger oder Dritte auch nicht in anderer Weise mißbräuchlich benutzt werden. 40 100 1 Alu-Dieseltank Inhalt ca.900L E F 110 1 Name 06.06.2011 Brunnert 14.01.2016 Barton 14.01.2016 Krabus Werkstoff Benennung F TANK Zeichnungs-Nr. D-59302 OELDE CAD-Zeichnung * 00.05540.0262-1 Ers.durch Ers.für Revision 010 Blatt 1 von 1 Bl. PARTS LIST (41) Parts-list no.: 08.99109.0050 Drawing no. : 08.99109.0050-1 Description : CONTROL LINE HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany mail to: mail@hammelmann.de http://www.hammelmann.de Date : 06.03.2017 Page : 1 0-6BAR DwgPos Item Code-No. Description Quantity No/Unit Unit 10 10 04.01002.0104 filter 1 1,000 pc 20 20 04.05875.0107 SOLENOID VALVE 1 1,000 pc 40 40 04.05993.0956 TUBE FITTING 6 1,000 pc 50 50 04.05993.0838 TUBE FITTING 3 1,000 pc 60 60 04.03400.0010 PRESSURE REGULATOR 1 1,000 pc 70 70 04.02860.0065 PRESSURE GAUGE 1 1,000 pc 80 80 04.04590.0121 HOSE 4 1,000 m 90 90 04.00657.0010 SOUND ABSORBER 1 1,000 pc 100 100 04.05993.0837 TUBE FITTING 3 1,000 pc >>>end<<< p_dbgs01.p 1 2 3 4 5 6 7 8 A A T G1 1/2 80 4 S 009 50 1 B P 40 1 B 2 1 40 1 20 1 3 C C 0 - 6 bar 90 1 70 1 40 1 100 1 100 1 50 1 009 D 10 1 50 1 009 009 E 100 1 40 1 E 60 1 Artikel-Nr. Ohne unsere vorherige Zustimmung darf diese Zeichnung weder vervielfältigt noch Dritten zugänglich gemacht werden, und sie darf durch den Empfänger oder Dritte auch nicht in anderer Weise mißbräuchlich benutzt werden. Pos. 50 und Pos. 100 je nach Einbausituation variabel montiert Arrangement of item 50 and item 100 may vary according to installation. L’arrangement des pos. 50 et 100 est variable au gré de l’installation. 1 2 3 Magnetventil 24 VDC Solenoid valve 24 VDC Electrovanne 24 VCC Regelbereich 0 - 6 bar Range of adjustment 0 - 6 bar Plage de réglage : 0 - 6 bar 4 Zul.Abweichung f.Maße ohne Toleranzangabe ISO 2768 - mH Verwendungszweck Leitungsfilter nachgetrg. Pos. 60 geändert Pos.40 geändert Schaltbild geä. Pos.-Änderung Pos.10 entfällt Kompl. überarb. Änderung Maßstab 24.02.2016 Fra Bearb 18.04.2012 PS Gepr. 04.02.2011 Fra Norm 09.06.2008 Pöts 14.05.2007 Schü 09.06.2005 Schü 14.06.2004 Pöts Datum Name A3 1:5 Gewicht in kg 2.6000 Halbzeug Oberfläche nach DIN ISO 1302 Datum 009 008 007 006 005 004 003 Zust Format DIN 08.99109.0050 ZeichFreig F D 009 Name 15.09.1998 SCHUEPPEN 04.03.2016 Barton 04.03.2016 Krabus Werkstoff CONDUITE CONTROL LINE Benennung F LEITUNG Zeichnungs-Nr. D-59302 OELDE CAD-Zeichnung * 08.99109.0050-1 Ers.durch Ers.für Revision 009 Blatt 1 von 1 Bl. PARTS LIST (41) Parts-list no.: 00.05630.0012 Drawing no. : 00.05630.0012-1 Description : THERMOSTAT HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany mail to: mail@hammelmann.de http://www.hammelmann.de Date : 06.03.2017 Page : 1 HDP380/500/800/MC DwgPos Item Code-No. Description Quantity No/Unit Unit 10 10 04.05630.0074 THERMOSTAT 1 1,000 pc 20 20 01.05993.0057 TUBE FITTING 1 1,000 pc 30 30 04.00706.0035 SEAL RING 1 1,000 pc >>>end<<< p_dbgs01.p 1 2 A B 10 1 4 20 1 30 1 001 (M 12 ) 001 3 VKA-Verschlusskegel 22 mit O-Ring C 86 001 D 1:1 alle Ecken und Kanten gratfrei ß Mit Betriebsdruck signiert ß Mit Auftrags-Nr. signiert ß Mit Teile-Nr. signiert ß Härte geprüft Ohne unsere vorherige Zustimmung darf diese Zeichnung weder vervielfältigt noch Dritten zugänglich gemacht werden, und sie darf durch den Empfänger oder Dritte auch nicht in anderer Weise mißbräuchlich benutzt werden. Format DIN Artikel-Nr. * 00.05630.0012 ZeichFreig Zul.Abweichung f.Maße ohne Toleranzangabe ISO 2768 - mH Verwendungszweck Maßstab Datum Bearb Gepr. Norm 1:2 Gewicht in kg 0.1900 Werkstoff Halbzeug Oberfläche nach DIN ISO 1302 HDP360/480/750 A4 Name 19.12.2007 OFranke 27.01.2016 Barton 27.01.2016 Krabus Benennung THERMOSTAT Zeichnungs-Nr. 001 Pos.10,30 Zust Änderung 27.01.2016 Fra Datum Name D-59302 OELDE CAD-Zeichnung * 00.05630.0012-1 Ers.durch Ers.für Revision 001 Blatt 1 von 1 Bl. PARTS LIST (41) Parts-list no.: 00.06020.0143 Drawing no. : 00.06020.0143-1 Description : LIFTING DEVICE HAMMELMANN GmbH POB 3309, D-59282 Oelde, Germany mail to: mail@hammelmann.de http://www.hammelmann.de Date : 06.03.2017 Page : 1 PUMP HEAD DwgPos Item Code-No. Description Quantity No/Unit Unit 10 10 00.01630.1145 BRACKET 1 1,000 pc 20 20 02.00421.0009 WASHER 8 1,000 pc 30 30 02.00671.0135 HEXAGON HEAD SCREW 4 1,000 pc 40 40 00.01630.1274 BRACKET 1 1,000 pc 50 50 01.03465.1497 RING 1 1,000 pc 60 60 01.03544.0047 spacer-pipe 1 1,000 pc 70 70 01.03544.0048 spacer-pipe 2 1,000 pc 80 80 00.01630.1273 BRACKET 1 1,000 pc 90 90 01.03595.0135 ROLL 2 1,000 pc 100 100 04.06208.0007 CABLE WINCH 1 1,000 pc 110 110 02.01751.0001 WIRE ROPE 1 5,000 m 120 120 02.00314.0005 HEXAGON THIN NUT 2 1,000 pc 130 130 02.00436.0002 DISC 4 1,000 pc 140 140 02.00654.0382 HEXAGON SCREW 2 1,000 pc 150 150 04.05240.0047 PLUG 4 1,000 pc 160 160 02.00421.0006 WASHER 6 1,000 pc 170 170 02.00314.0004 HEXAGON THIN NUT 3 1,000 pc 180 180 02.00671.0114 HEXAGON HEAD SCREW 3 1,000 pc 190 190 01.05013.0128 FLAT STEEL 1 1,000 pc 200 200 01.05308.0043 CLAMP PIECE 1 1,000 pc 210 210 02.00734.0114 COUNTERSUNK SCREW 2 1,000 pc 220 220 02.00421.0103 WASHER 2 1,000 pc 230 230 02.00314.0210 HEXAGON THIN NUT 2 1,000 pc 240 240 04.01671.0007 CLAMP-LEVER 2 1,000 pc 250 250 01.03200.0022 SHOCK ABSORBER 1 1,000 pc 260 260 02.00825.0047 HEXAGON SOCKET HEAD SCREW 1 1,000 pc >>>end<<< p_dbgs01.p 1 2 3 A 4 5 A 80 1 Y A 6 200 1 230 2 220 2 7 8 210 2 90 2 150 4 140 2 130 4 120 2 110 1 X 100 1 C 002 240 2 002 B X 1:3 933 180 3 170 3 160 6 190 1 796 B A 50 1 260 1 70 2 Y 1:3 C Anzugsdrehmoment 16Nm min. 60 1 5 792 30 4 10 1 20 8 D 25 40 1 O 250 1 . min D A-A 1:5 E E Tragkraft max. 500kg 384 Ohne unsere vorherige Zustimmung darf diese Zeichnung weder vervielfältigt noch Dritten zugänglich gemacht werden, und sie darf durch den Empfänger oder Dritte auch nicht in anderer Weise mißbräuchlich benutzt werden. F 1:10 Artikel-Nr. * alle Ecken und Kanten gratfrei ß Mit Betriebsdruck signiert ß Mit Auftrags-Nr. signiert ß Mit Teile-Nr. - Rev. signiert ß Härte geprüft Zul.Abweichung f.Maße ohne Toleranzangabe ISO 2768 - mH 1 2 Datum Bearb Gepr. Norm 3 4 Maßstab 22.06.2016 Jan 01.03.2013 Jan Datum Name A3 1:8 Gewicht in kg 39.5000 Halbzeug Oberfläche nach DIN ISO 1302 792 002 Pos.170, 180 geändert. 001 Stückliste geändert Zust Änderung 00.06020.0143 ZeichFreig Verwendungszweck Format DIN Name 11.01.2013 Janzen 22.06.2016 Barton 22.06.2016 Krabus Werkstoff Benennung F VORRICHTUNG Zeichnungs-Nr. D-59302 OELDE CAD-Zeichnung * 00.06020.0143-1 Ers.durch Ers.für Revision Blatt 1 von 1 Bl. 00.06020.0131-1 002 HAMMELMANN Artikel-Nr. / Code no. / Référénce no.: 04.00995.0177 Einbausatz / Insert / Partie intérieur IN-AGB1-125 Insert filters Einbaufilter Parties intérieur es intégrées Model IN-AGB Type I/Model IN-AGB Flow rate: up to 2000 l/min Nennvolumenstrom: bis 2000 l/min Global Filtration Technology Member of Parker Hannifin Corporation MBC 009 rev 7-05-03 Débit: jusqu’à 2000 l/min HAMMELMANN Artikel-Nr. / Code no. / Référénce no.: 04.00995.0177 Einbausatz / Insert / Partie intérieur IN-AGB1-125 HAMMELMANN Artikel-Nr. / Code no. / Référénce no.: 04.00995.0177 Einbausatz / Insert / Partie intérieur IN-AGB1-125 SYMBOL EXPLANATION SYMBOL DESCRIPTION AL Cd E Fc Fµ Aluminium Port dimension (BSP/G) Element Fluid compatibility Filter fineness XW Media type - Glass fibre XX Media type - Cellulose S Media type - Steel mesh Functional test Media type HPFE Low pr. Housing Material filter housing Max. water content Not applicable On request Burst pressure Indicator setting By-pass setting Plastic Max. working pressure Flow direction Seal material Standard Ft GDL H Mh Mwc NA Orq Pb Pi P0 POM Pw Qd Sm Std UNIT Inch # # Micron # # # # ppm # bar bar bar bar # # # SYMBOL ERKLÄRUNG SYMBOL BESCHREIBUNG AL Cd E Fc Fµ Aluminium Anschluß (BSP/G) Element Fluid Verträglichkeit Filterfeinheit XW Filtermedia Glasfaser XX Filtermedia Zellulose S Filtermedia Edelstahlgewebe Funktionstest Filtermedia HPFE Niederdruck Filtergehäuse Werkstoff Filtergehäuse Max. Wassergehalt Nicht zutreffend Auf Anfrage Berstdruck Indikatoranzeige By-pass Öffnungsdruck Plastik Max. Nenndruck Durchfluß Richtung Dichtungsmaterial Standard Ft GDL H Mh Mwc NA Orq Pb Pi P0 POM Pw Qd Sm Std EINHEIT Inch # # Micron # # # # ppm # bar bar bar bar # # # EXPLICATION DE SYMBOLE SYMBOLE DESCRIPTION AL Cd E Fc Fµ Aluminium Raccordements (BSP/G) Élément Compatibilité des fluides Finesses de filtration XW Fibre de verre XX Cellulose S Toile métallique inox. Test normalisé utilisé Média type HPFE haute efficacité basse pression Corps de filtre Matière du corps de filtre Taux d’eau max. Non applicable Sur demande Pression d’éclatement Tarage de l’indicateur Tarage de by-pass Plastique Max. pression de service Sens du débit Matière de joints Standard Ft GDL H Mh Mwc NA Orq Pb Pi P0 POM Pw Qd Sm Std UNITÉ Inch # # Micron # # # # ppm # bar bar bar bar # # # HAMMELMANN Artikel-Nr. / Code no. / Référénce no.: 04.00995.0177 Einbausatz / Insert / Partie intérieur IN-AGB1-125 COMPANY PROFILE Parker Arlon is a leading designer and UNTERNEHMENS PROFIL Parker Arlon ist ein führender PROFIL DE L’ENTREPRISE Parker Arlon est un des tous premiers manufacturer of filters for hydraulic and Entwickler und Hersteller von concepteurs et fabricants mondiaux de lubricating oil systems used in mobile and Filtrationsprodukten für Hydraulik- und filtres hydrauliques et de lubrification pour industrial applications throughout the Schmierölsysteme, welche weltweit auf l’industrie et les applications mobiles. world. The company offers standard, dem Mobil- und Industrie-Sektor ihre semi-standard and tailor-made solutions Anwendung finden. that meet all requirements. The product Mit seinen Standards, Halbstandards La société propose des solutions standards, semi-standards et personnalisées pour toutes les demandes. portfolio encompasses a wide variety of und kundenorientierten Lösungen bedient indicators, 3-way ball valves and filter ele- die Firma eine Vielzahl von Anforderungen. grande variété d’indicateurs, des vannes 3 ments, including the innovative LEIF® Die Produktpalette umfasst eine breite voies sphériques, d’éléments filtrants tels Low Environmental Impact Filter and Vielfalt von Indikatoren, 3-Wege-Kugel- les innovants LEIF® filtre écologique et AQUASAFE® water absorption elements. hähnen und Filterelementen einschließlich AQUASAFE®, élément absorbant l’eau. In addition, Parker Arlon provides oil ana- der innovativen, umweltfreundlichen LEIF® lysis services. Filter und AQUASAFE® wasserabsorbieren- La gamme de produits comprend une De plus, Parker Arlon assure un service d’analyse d’huile. den Elementen. Zusätzlich bietet Parker In-depth know-how and experience, Arlon einen Ölanalyse-Service an. combined with an awareness of market demands and customer requirements are Un grand savoir-faire et une longue expérience, ainsi qu’une connaissance des Der langjährige know-how und besoins du marché et des clients sont les the foundation of Parker Arlon’s customer- Erfahrung zusammen mit der bases de l’approche client de Parker Arlon. oriented approach. The company is pur- Wahrnehmung hoher Kunden- und La société explore de nouveaux domaines, suing new standards, not only in filtration Marktansprüche ist die Grundlage für die non seulement dans l’efficacité de filtra- efficiency and customer service, but also kundenorientierte Ausprägung von Parker tion et le service client, mais aussi dans la in environmental consciousness. Parker Arlon. Die Umsetzung neuester Standards prise de conscience environnementale. Arlon is ISO 9001 and ISO 14001 certi- zeigt sich gleichermaßen in der Qualität fied. Quality & environment are conveyed unserer Produkte, einem hohen Niveau an ISO14001. Qualité et environnement se through technical efficiency, consistency, Kundenservice, wie in der Verfolgung traduisent par efficacité technique, qualité long lifecycles and cost efficiency. umwelt- politischer Aspekte. Parker Arlon constante, longues durées de vie et effica- ist ISO 9001 und 14001 zertifiziert. cité économique. Parker Arlon has engineering, R&D Parker Arlon est certifié ISO9001 et Qualität und Umwelt-Verantwortung kom- and manufacturing facilities located in men durch technische Effizienz, Arnhem, the Netherlands, and exports Konsistenz, lange Lebenszyklen und Recherche et Développement et usine de 90% of its products around the world. Kosteneffizienz zum Ausdruck. production à Arnhem en Hollande, et Parker Arlon a ses bureaux d’études, exporte 90% de sa production dans le Parker Filtration BV is part of the Parker Arlon vereint Engineering, Forschung & Entwicklung sowie largest motion and control company, Produktion am Standort in Arnheim, manufacturing and supplying components Niederlande. 90% der Produkte werden in groupe Parker Hannifin Corporation, la and systems for just about anything that die ganze Welt exportiert. plus grande société du monde spécialisée moves. Parker Filtration BV appartient au dans la fabrication de composants pour le Parker Filtration BV ist Teil der Parker Hannifin Corporation, einer der international führenden Anbieter auf dem Gebiet der Antriebstechnik. 2 monde entier. Parker Hannifin Corporation – the world’s Global Filtration Technology contrôle des mouvements et des fluides. HAMMELMANN Artikel-Nr. / Code no. / Référénce no.: 04.00995.0177 Einbausatz / Insert / Partie intérieur IN-AGB1-125 ASSEMBLY PARTS TEILE-LISTE ITEM NUMBER TEIL NUMMER NUMÉRO DE PART DESCRIPTION BESCHREIBUNG DESCRIPTION 1 Top-spring Feder Ressort supérieur 2 Insert Einbausatz Partie intérieure 3 Insert seal O-ring Einbausatz Joint de partie intérieure 4 By-pass seal By-pass Dichtung Joint de by-pass 5 Filter element Filterelement Élément de filtrant 6.1 Tank seal AGB-3 Behälter Dichtung AGB-3 Joint de réservoir AGB-3 6.2 Tank seal AGB-4 Behälter Dichtung AGB-4 Joint de réservoir AGB-4 7 Element seal O-ring Element Joint de l’élément 8 By-pass set By-pass Satz Ensemble by-pass 9 Funnel/diffuser Auslaufrohr Bac d’écoulement TECHNICAL INFORMATION TECHNISCHE BESCHREIBUNG FILTER/FILTER/FILTRE Q Q Q Q max max max max IN-AGB-1 IN-AGB-2 IN-AGB-3 IN-AGB-4 = = = = 125 300 500 2000 l/min l/min l/min l/min –40 0C/+120 0C T: P0: 0,8 / 1,5 bar INSERT/EINBAUSATZ/PARTIE INTÉRIEUR AGB-1-30 AGB-1-60 AGB-1-90 AGB-1-120 AGB-1-125 AGB-2-170 AGB-2-230 AGB-2-300 AGB-3-270 AGB-3-390 AGB-3-500 AGB-4-600 AGB-4-800 AGB-4-1000 AGB-4-1500 AGB-4-2000 GDL1 GDL3 GDL6 GDL10 GDL20 XX10 13,0 14,0 16,8 21,4 28,3 kg kg kg kg kg Sm: NBR, CR, FPM Pb: 10 bar m: m: m: m: m: m: m: m: m: m: m: 0,5 0,6 0,8 0,9 1,1 2,1 2,2 2,4 2,8 3,0 3,6 kg kg kg kg kg kg kg kg kg kg kg Qd: In/Out; Innen/Aussen; Intérieur/Extérieur Fµ XW: Fµ S: Fµ XX: GDL 1 - 3 - 6 - 10 - 20µm 40 - 120µm 10µm nom MWc: GENERAL/ALGEMEIN/GÉNÉRALES Ft: ISO ISO ISO ISO ISO ISO 2941 2942 2943 3724 3968 4572 Fc: Oil type; Öl Type; Type d’huile HH - HL - HLP - HV HETG - HEPG - HEES HFA (mineral base) - HFB - HFC HFA (synthetic base) - Orq Please contact Parker Arlon 500 ppm FILTRATION EFFICIENCY MEDIA FILTERMEDIA MÉDIA m: m: m: m: m: INFORMATIONS TECHNIQUES MEDIA/MEDIUM/MÉDIUM BY-PASS/BY-PASS/BY-PASS 3 PIECES DETACHEES ABSCHEIDE RATE MICRON MIKRON MICRON − β X ≥75 − β3 − β6 1 3 6 10 20 33 400 ≥75 8 5 N/A N/A 4000 1000 ≥75 17 2 N/A EFFICACITÉ DE FILTRATION FILTRATION RATIO FILTER FEINHEIT NIVEAU DE FILTRATION − − − β 10 β 12 β 20 >5000 >5000 1000 ≥75 8 2.6 >5000 >5000 >5000 >200 10 3.5 Global Filtration Technology >5000 >5000 >5000 >5000 ≥75 6 − β 25 − β 55 >5000 >5000 >5000 >5000 >5000 23 >5000 >5000 >5000 >5000 >5000 >5000 HAMMELMANN Artikel-Nr. / Code no. / Référénce no.: 04.00995.0177 Einbausatz / Insert / Partie intérieur IN-AGB1-125 INSTALLATION DIMENSIONS EINBAU-ABMESSUNGEN ENCOMBREMENT MOUNTING ARRANGEMENT TYPE TYP TYPE IN-AGB1-30 IN-AGB1-60 IN-AGB1-90 IN-AGB1-120 IN-AGB1-125 IN-AGB2-170 IN-AGB2-230 IN-AGB2-300 IN-AGB3-270 IN-AGB3-390 IN-AGB3-500 IN-AGB4-600 IN-AGB4-800 IN-AGB4-1000 IN-AGB4-1500 IN-AGB4-2000 A B H h d x y s p C D E F G 87 87 87 87 87 125 125 125 150 150 150 230 230 230 230 230 79 79 79 79 79 116 116 116 138 138 138 216 216 216 216 216 122 173 217 267 381 284 360 559 325 405 595 505 615 720 1000 1265 35 35 35 35 35 48 48 48 62 62 62 100 100 100 100 100 20 20 20 20 20 25 25 25 30 30 30 40 40 40 40 40 4 4 4 4 4 5 5 5 7 7 7 13.5 13.5 13.5 13.5 13.5 6 6 6 6 6 8 8 8 12 12 12 12 12 12 12 12 45 45 45 45 45 77 77 77 100 100 100 142 142 142 142 142 20 20 20 20 20 42 42 42 55 55 55 60 60 60 60 60 88 88 88 88 88 126 126 126 151 151 151 231 231 231 231 231 85 85 85 85 85 122 122 122 149 149 149 227 227 227 227 227 80 80 80 80 80 117 117 117 139 139 139 217 217 217 217 217 4 4 4 4 4 5 5 5 5 5 5 6 6 6 6 6 12 12 12 12 12 15 15 15 18 18 18 20 20 20 20 20 AGB 3 AGB 4 TYPE TYP TYPE K L M U V Q 290 370 560 110 110 120 175 175 175 106 106 106 55 55 55 178 178 178 445 555 660 940 1205 183 183 183 183 183 239 239 239 239 239 145 145 145 145 145 60 60 60 60 60 250.5 250.5 250.5 250.5 250.5 IN-AGB3-270 IN-AGB3-390 IN-AGB3-500 IN-AGB4-600 IN-AGB4-800 IN-AGB4-1000 IN-AGB4-1500 IN-AGB4-2000 4 Global Filtration Technology R 2.5 2.5 2.5 2.5 2.5 HAMMELMANN Artikel-Nr. / Code no. / Référénce no.: 04.00995.0177 Einbausatz / Insert / Partie intérieur IN-AGB1-125 ∆p/Q GRAPHS ∆p/Q COURBES DE DÉBIT T- -elements T2-elements T3D-elements T3E-elements T4-elements T5-elements T5A-elements T6A-elements T8A-elements T8C-elements T10-elements T11-elements T12-elements T13-elements T14-elements T-elements FLUID/FLUID/FLUIDE ν = 32cSt T3-elements 5 ∆p/Q KENNLINIEN Global Filtration Technology HAMMELMANN Artikel-Nr. / Code no. / Référénce no.: 04.00995.0177 Einbausatz / Insert / Partie intérieur IN-AGB1-125 ∆p/Q GRAPHS ∆p/Q KENNLINIEN T2-elements T3-elements T3D-elements T3E-elements T4-elements T5-elements T5A-elements T6A-elements T8A-elements T8C-elements T10-elements T11-elements T12-elements T13-elements ∆p CALCULATION 6 ∆p/Q COURBES DE DÉBIT ∆p KALKULATION FLUID/FLUID/FLUIDE A: νa = 32cSt / γ = 0.87 FLUID/FLUID/FLUIDE B: νb = 46cSt / γ = 1.1 ∆p E = ∆p H = ∆p Tot. A = ∆p E = (46/32)x0.5 = 0.72 bar ∆p H = (1.1/0.87)x0.1 = 0.13 bar ∆p Tot.B = 0.85 bar 0.5 bar 0.1 bar 0.6 bar Global Filtration Technology T14-elements CALCUL ∆p HAMMELMANN Artikel-Nr. / Code no. / Référénce no.: 04.00995.0177 Einbausatz / Insert / Partie intérieur IN-AGB1-125 ORDERING INFORMATION / BESTELLDATEN / COMMENT PASSER VOTRE COMMANDE 1 3 Variety/ Diffuser/ Ausfuhrung/ Auslaufrohr/ Variante 30 IN-AGB 1-60 60 IN-AGB 1-90 90 Seal material/ Dichtungen/ Bac d’ecoulement code IN-AGB 1-30 4 No Diffuser Ohne Auslaufrohr Sans bac d’ecoulement IN-AGB 1-120 120 IN-AGB 1-125 125 IN-AGB 2-170 170 IN-AGB 2-230 230 IN-AGB 2-300 300 IN-AGB 3-270 270 IN-AGB 3-390 390 IN-AGB 3-500 500 IN-AGB 4-600 600 IN-AGB 4-800 800 Joints code - Diffuser for ≥ 3-270 Auslaufrohr für ≥ 3-270 Bac d’ecoulement pour ≥ 3-270 B Neoprene (CR) N Viton (FPM) V T 5 By-pass setting/ By-pass Öffnungsdruck/ By-pass 08 1.5 bar 15 blocked B IN-AGB 4-1500 1500 IN-AGB 4-2000 2000 2 Element/ Nominal Element/ Cellulose/ Élément Zellulose/ LEIF ® Rostfrei Metallgewebe/ Cellulose − HPFE glass fibre/ HPFE Glasfaser/ HPFE fibre de verre β X ≥ 75 Toile métallique inoxydable Filtration fineness absolute/ Filterfeinheit Absolut/ Finesse de filtration absolue Stainless steel mesh/ 10µm 3µm 6µm 10µm 20µm code code code code code code TXX-10 TXWL-3 TXWL-6 TXWL-10 TXWL-20 ST-40 IN-AGB 1-60 TXX2-10 TXWL2-3 TXWL2-6 TXWL2-10 TXWL2-20 ST2-40 IN-AGB 1-90 TXX3-10 TXWL3-3 TXWL3-6 TXWL3-10 TXWL3-20 ST3-40 IN-AGB 1-120 TXX3D-10 TXWL3D-3 TXWL3D-6 TXWL3D-10 TXWL3D-20 ST3D-40 IN-AGB 1-125 TXX3E-R-10 TXWL3E-3 TXWL3E-6 TXWL3E-10 TXWL3E-20 ST3E-R-40 IN-AGB 2-170 TXX4-10 TXWL4-3 TXWL4-6 TXWL4-10 TXWL4-20 ST4-40 IN-AGB 2-230 TXX5-10 TXWL5-3 TXWL5-6 TXWL5-10 TXWL5-20 ST5-40 IN-AGB 2-300 TXX5A-10 TXWL5A-3 TXWL5A-6 TXWL5A-10 TXWL5A-20 ST5A-40 IN-AGB 3-270 TXX6A-10 TXWL6A-3 TXWL6A-6 TXWL6A-10 TXWL6A-20 ST6A-40 40µm IN-AGB 3-390 TXX8A-10 TXWL8A-3 TXWL8A-6 TXWL8A-10 TXWL8A-20 ST8A-40 IN-AGB 3-500 TXX8C-10 TXWL8C-3 TXWL8C-6 TXWL8C-10 TXWL8C-20 ST8C-40 IN-AGB 4-600 TXX10-10 TXWL10-3 TXWL10-6 TXWL10-10 TXWL10-20 ST10-40 IN-AGB 4-800 TXX11-10 TXWL11-3 TXWL11-6 TXWL11-10 TXWL11-20 ST11-40 IN-AGB 4-1000 TXX12-10 TXWL12-3 TXWL12-6 TXWL12-10 TXWL12-20 ST12-40 IN-AGB 4-1500 TXX13-R-10 TXWL13-R-3 TXWL13-R-6 TXWL13-R-10 TXWL13-R-20 ST13-R-40 In case of non LEIF ®, delete L in code/ Im falle von keine LEIF ®, L streichen im Code/ Si pas de LEIF ®, supprimer L en code IN-AGB 4-2000 TXX14-10 TXW14-3 Ordering example element Bestellbeispiel Element Exemple de commande de l’élément ST14-40 TXW14-20 Ordering example filter Bestellbeispiel Filter Exemple de commande de filtre 2 4 Std 1 2 3 4 5 TXW8A-20 B IN 390 TXW8A-20 T B B Note: Spare LEIF ® element: no sleeve included. Ersatz LEIF ® -Element ohne Filterkorb. Pièce detachée l’élément LEIF®: sans enveloppe métallique. 7 TXW14-10 TXW14-6 Note: Filter with LEIF ® element and sleeve. Filter mit LEIF ® -Element und Filterkorb. Filtre avec l’élément LEIF ® et enveloppe métallique. Global Filtration Technology code 0.8 bar IN-AGB 4-1000 1000 IN-AGB 1-30 code Buna (NBR) HAMMELMANN Artikel-Nr. / Code no. / Référénce no.: 04.00995.0177 Einbausatz / Insert / Partie intérieur IN-AGB1-125 ORDERING INFORMATION / BESTELLDATEN / COMMENT PASSER VOTRE COMMANDE Parker Filtration BV Parker Arlon Filter Division Europe Stieltjesweg 8 6827 BV Arnhem The Netherlands Phone: +31 26 3760376 Fax: +31 26 3643620 E-mail: arlon@parker.com www.parkerarlon.nl Parker Hannifin plc Filter Division Europe HQ Shaw Cross Business Park Dewsbury, West Yorkshire WF12 7 RD UK Phone: +44 1924 487000 Fax: +44 1924 487038 E-mail: filtrationinfo@parker.com www.parker.com Parker Hannifin Oy Finn-Filter Filter Division Europe Salmentie 260 FIN - 31700 Urjala As. Finland Phone: +358 3 54100 Fax: +358 3 5410100 finnfilter@parker.com www.finnfilter.fi Due to continuous product improvement published data and specifications are subject to change without notice. / Aufgrund Produkt-Verbesserungen können Daten und Spezifikationen ohne Mitteilung geändert werden. / En fonction de l’évolution technique du matériel, nous nous réservons le droit de modifier cette documentation sans préavis. 8 Global Filtration Technology HAMMELMANN Artikel-Nr. / Code no. / Référénce no.: 04.00995.0177 Einbausatz / Insert / Partie intérieur IN-AGB1-125 Insert filter Einbaufilter Parties intérieur es intégrées Model IN-AGB FEATURES AND BENEFITS • • • • • • • Designed for return line filtration Flow direction from in to out Magnetic pre-filtration Simple and effective full flow by-pass Wide range of removal ratings: • GDL - glass fibre • XX - cellulose • S - stainless steel wire mesh Funnel or diffuser to avoid foaming Option: LEIF ® MERKMALE UND VORTEILE • • • • • • • Model für Rücklauffilterung Durchflussrichtung von innen nach aussen Magnetische Vorfilterung Einfache und effektive By-passKonstruktion Filterfeinheiten in: • GDL - Glasfaser • XX - Zellulose • S - Edelstahlgewebe Auslaufrohr zur Verhütung von Schaumbildung Option: LEIF ® AVANTAGES ET BÉNÉFICES • • • • • • • Pour filtration sur circuit de retour Sens de filtration de l’intérieur vers l’extérieur Préfiltration magnétique Dérivation by-pass simple et efficace Gamme étendue de finesses de filtration en: • Fibre de verre - GDL • Cellulose - XX • Maille en acier inoxydable - S Bac d’écoulement anti-mousse en option Option: LEIF ® 00.02250.0432 - Coupling / Kupplung 00.02250.0432 - Coupling / Kupplung 00.02250.0432 - Coupling / Kupplung 00.02250.0432 - Coupling / Kupplung 00.02250.0432 - Coupling / Kupplung 00.02250.0432 - Coupling / Kupplung 00.02250.0432 - Coupling / Kupplung 00.02250.0432 - Coupling / Kupplung 00.02250.0432 - Coupling / Kupplung 00.02250.0432 - Coupling / Kupplung 00.02250.0432 - Coupling / Kupplung 00.02250.0432 - Coupling / Kupplung 00.02250.0432 - Coupling / Kupplung 00.02250.0432 - Coupling / Kupplung 00.02250.0432 - Coupling / Kupplung 00.02250.0432 - Coupling / Kupplung 00.02250.0432 - Coupling / Kupplung 00.02250.0432 - Coupling / Kupplung 00.02250.0432 - Coupling / Kupplung 00.02250.0432 - Coupling / Kupplung 00.02250.0432 - Coupling / Kupplung 00.02250.0432 - Coupling / Kupplung 00.02250.0432 - Coupling / Kupplung 00.02250.0432 - Coupling / Kupplung HAMMELMANN Artikel-Nr. / Code no. / Réference no.: 04.03070.0007 Safety Data Sheet according to Regulation (EC) No. 1907/2006 (REACH) Printed Revision 10.07.2009 07.01.2008 (GB) Version 2.0 SRS TFX ! 1. IDENTIFICATION OF THE SUBSTANCE/PREPARATION AND OF THE COMPANY/UNDERTAKING Name of product SRS TFX Manufacturer/distributor SRS Schmierstoff Vertrieb GmbH Neuenkirchener Straße 8, D-48499 Salzbergen Postbox 11 65, D-48497 Salzbergen Phone 05976 - 945-0 E-Mail Daniela.Heber@hansen-rosenthal.de Advice Abt. Produktsicherheit: Dipl. Ing. Daniela Heber Phone 040-78110820 Emergency advice Gift-Informationszentrum Nord (Göttingen) Phone 0551-19240 Recommended intended purpose(s) Motor oil 2. HAZARDS IDENTIFICATION Special hazards information for humans and environment The product is not classified as hazardous/is not a hazardous preparation and therefore exempt from labelling. 3. COMPOSITION/INFORMATION ON INGREDIENTS Chemical characterization Highly refined mineral oil, with additives Hazardous ingredients CAS No EC No 68649-42-3 91648-65-6 Name [% weight] Classification Zinkalkyldithiophosphat. alkyliertes Phenol substituiertes Thiadiazol. <2 < 1,5 < 0,15 N, Xi,R38-41-51/53 N, R51/53 Xi,R43 Additional advice If oil mist is generated, the oil mist exposure limits should be applied (see section 8). 4. FIRST AID MEASURES General information Remove contaminated soaked clothing immediately. In case of inhalation In the event of symptoms refer for medical treatment. In case of skin contact In case of contact with skin wash off immediately with soap and water. Consult a doctor if skin irritation persists. In case of eye contact In case of contact with eyes rinse thoroughly with plenty of water and seek medical advice. In case of ingestion Do not induce vomiting. Call for a doctor immediately. Physician's information / possible dangers In case of swallowing or vomiting of product there is danger of penetration into the lungs. Treatment (Advice to doctor) Treat symptoms. HAMMELMANN Artikel-Nr. / Code no. / Réference no.: 04.03070.0007 Safety Data Sheet according to Regulation (EC) No. 1907/2006 (REACH) Printed Revision 10.07.2009 07.01.2008 (GB) Version 2.0 SRS TFX 5. FIRE-FIGHTING MEASURES Suitable extinguishing media Foam Dry powder Carbon dioxide sand Water spray jet water mist Extinguishing media which must not be used for safety reasons Full water jet Special exposure hazards arising from the substance or preparation itself, combustion products, resulting gases Soot and other organic products. Nitrogen oxides (NOx) Carbon monoxide (CO) Sulphur dioxide (SO2) Special protective equipment for fire-fighters Use breathing apparatus with independent air supply ( isolated ). Additional information Cool endangered containers with water spray jet. 6. ACCIDENTAL RELEASE MEASURES Personal precautions Use breathing apparatus if exposed to vapours/aerosol with filter Typ A2, A2/P2 or ABEK. Use personal protective clothing. Environmental precautions Do not discharge into the drains/surface waters/groundwater. Prevent spread over a wide area (e.g. by containment or oil barriers). Do not discharge into the subsoil/soil. Methods for cleaning up Take up with absorbent material (e.g. oil binder). After taking up the material dispose according to regulation. Additional Information no 7. HANDLING AND STORAGE Advice on safe handling Avoid formation of oil dust. Advice on protection against fire and explosion Do not smoke. Requirements for storage rooms and vessels Only use containers that are approved specifically for the substance/product. Advice on storage compatibility Do not store together with oxidizing agents. Further information on storage conditions To be store under control of light and temperature conditions. Storage group 10 Fire class B HAMMELMANN Artikel-Nr. / Code no. / Réference no.: 04.03070.0007 Safety Data Sheet according to Regulation (EC) No. 1907/2006 (REACH) Printed Revision 10.07.2009 07.01.2008 (GB) Version 2.0 SRS TFX 8. EXPOSURE CONTROLS/PERSONAL PROTECTION Ingredients with occupational exposure limits to be monitored CAS No Name Code [mg/m3] oil mist 8 hours 5 [ppm] Spitzenb. Remark TWA, 5 h Respiratory protection Respiratory equipment in case of nebulosity or aerosol: Use a mask with a filter type A2, A2/P2 or ABEK. Hand protection Use safety gloves of following materials:: NBR (nitrile) / neopren / viton (permeationslevel 5 - 6), Cat. II according to norm EN 388 Eye protection Safety goggles with side protection. In case of increased risk add protective face shield Skin protection Oil-resistant and hardly inflammable protective clothing. General protective measures Do not inhale vapours. Avoid contact with eyes and skin It is recommended to use safety clothing, safety gloves and safety googles/safe screen. Hygiene measures Clean skin thoroughly after working. Cloths contaminated with product should not be kept in trouser pockets. At work do not eat, drink, smoke or take drugs. Keep away from food and drink. 9. PHYSICAL AND CHEMICAL PROPERTIES Form Colour Odour liquid brownish mild Important health, safety and environmental information Value Temperature at Method pourpoint ca. -42 °C DIN/ISO 3016 Flash point ca. 230 °C DIN ISO 2592 Lower explosion limit ca. 0,45 Vol-% DIN 51649 Upper explosion limit ca. 4,5 Vol-% DIN 51649 Vapour pressure < 0,01 kPa 20 °C calculated Density ca. 874 kg/m3 15 °C DIN 51757 insoluble Solubility in water Viscosity 1 kinematic Remark ca. 13,8 mm2/s Additional information The data are subject to usual tolerances. 10. STABILITY AND REACTIVITY Conditions to avoid No hazardous reactions known. Materials to avoid Reactions with strong oxidising agents. 100 °C DIN 51562 HAMMELMANN Artikel-Nr. / Code no. / Réference no.: 04.03070.0007 Safety Data Sheet according to Regulation (EC) No. 1907/2006 (REACH) Printed Revision 10.07.2009 07.01.2008 (GB) Version 2.0 SRS TFX 11. TOXICOLOGICAL INFORMATION Acute toxicity/Irritability/Sensitization Value/Validation Species LD 50 acute oral > 5000 mg/kg rat LD 50 acute dermal > 3000 mg/kg rabbit Irritability skin non-irritant Irritability eye non-irritant Skin sensitization non-sensitizing Sensitization respiratory system non-sensitising Method Remark Experiences made from practice Frequent contact specially if dried out may cause skin and eye irritations. 12. ECOLOGICAL INFORMATION Data on elimination (persistence and degradability) Elimination rate Physico-chemical degradability Method of analysis Method Validation The product is slightly soluble in water. It can be largely eliminated from the water by abiotic processes, e.g. mechanical separation. not readily degradable Biological degradability General regulation Do not allow uncontrolled leakage of product into the environment. 13. DISPOSAL CONSIDERATIONS Waste code No. Name of waste 13 02 05* mineral-based non-chlorinated engine, gear and lubricating oils Wastes marked with an asterisk are considered to be hazardous waste pursuant to Directive 91/689/EEC on hazardous waste. Recommendations for the product The disposal code is just a recommendation. Contact your local experts to obtain information about use or disposal of the material involved. The indication about disposal refers to the product and its residues. If the product is mixed with other materials or preparations an individual evaluation should be necessary. Recommendations for packaging Contaminated packaging should be emptied as far as possible and after appropiate cleaning may be taken for reuse. 14. TRANSPORT INFORMATION Land and inland navigation transport ADR/RID No hazardous material as defined by the prescriptions. Marine transport IMDG No hazardous material as defined by the prescriptions. Air transport ICAO/IATA-DGR HAMMELMANN Artikel-Nr. / Code no. / Réference no.: 04.03070.0007 Safety Data Sheet according to Regulation (EC) No. 1907/2006 (REACH) Printed Revision 10.07.2009 07.01.2008 (GB) Version 2.0 SRS TFX ! 15. REGULATORY INFORMATION Remarks for classification The product does not require a hazard warning label in accordance with EC directives/German regulations on dangerous substances. Special labelling for certain preparations Enthält substituiertes Thiadiazol. Kann allergische Reaktionen hervorrufen. National regulations Decree for case of interference/ remarks Accident regulation, appendix I: not specified ! Technical instruction air remarks 5.2.5. Organische Stoffe Water hazard class 2 Mixture-WGK Based on "Verwaltungsvorschrift wassergefährdender Stoffe (VwVwS)" from 27 Juli 2005 16. OTHER INFORMATION Further information Above information corresponds to our present knowledge and experience. It is not a guarantee that no errors or incomplete data may be contained. Sources of key data used DGMK-Bericht 400-1 , 400-2 , 400-7 Concawe-Report " Health aspects of lubricants " 1/1983 Wording of the R-phrases specified in chapter 3 (not the classification of the formulation!) R 38 Irritating to skin. R 41 Risk of serious damage to eyes. R 43 May cause sensitisation by skin contact. R 51/53 Toxic to aquatic organisms, may cause long-term adverse effects in the aquatic environment. 04.03070.0035 Shell Omala S4 GX 320 Version 2.0 Effective Date 04.12.2012 Regulation 1907/2006/EC Safety Data Sheet SECTION 1. IDENTIFICATION OF THE SUBSTANCE/MIXTURE AND OF THE COMPANY/UNDERTAKING 1.1 Product Identifier Material Name Product Code : : Shell Omala S4 GX 320 001D7852 1.2 Relevant identified uses of the substance or mixture and uses advised against Product Use : Gear lubricant. Uses Advised Against : This product must not be used in applications other than those recommended in Section 1, without first seeking the advice of the supplier. 1.3 Details of the Supplier of the safety data sheet Manufacturer/Supplier Telephone Fax Email Contact for Safety Data Sheet : Shell Deutschland Oil GmbH Suhrenkamp 71-77 D-22335 Hamburg : : : (+49) 40 6324-6255 (+49) 40 6321-051 If you have any enquiries about the content of this SDS please email lubricantSDS@shell.com 1.4 Emergency Telephone Number : (+49) 30 3068 6790 (Giftnotruf Berlin) SECTION 2. HAZARDS IDENTIFICATION 2.1 Classification of the substance or mixture 1999/45/EC Hazard Characteristics Not classified as dangerous under EC criteria.; Sensitiser not sufficient to classify : R-phrase(s) Contains alkylamine. May produce an allergic reaction. 2.2 Label Elements 1/17 Print Date 26.12.2012 000000019336 MSDS_DE Shell Omala S4 GX 320 Version 2.0 Effective Date 04.12.2012 Regulation 1907/2006/EC Safety Data Sheet Labeling according to Directive 1999/45/EC EC Symbols : No Hazard Symbol required EC Classification EC Risk Phrases EC Safety Phrases : : : Not classified as dangerous under EC criteria. Not classified. Not classified. 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. Safety Hazards : Not classified as flammable but will burn. Environmental Hazards : Not classified as dangerous for the environment. 2.3 Other Hazards SECTION 3. COMPOSITION/INFORMATION ON INGREDIENTS 3.1 Substance Material Name : Not applicable. : Blend of polyolefins and additives. 3.2 Mixtures Mixture Description Hazardous Components Classification of components according to Regulation (EC) No 1272/2008 Chemical Name Long-chain alkyl amine CAS No. EC Number Not available Not available REACH Registration No. Not available / Not applicable. Conc. 0,10 - 0,24% 2/17 Print Date 26.12.2012 000000019336 MSDS_DE Shell Omala S4 GX 320 Version 2.0 Effective Date 04.12.2012 Regulation 1907/2006/EC Safety Data Sheet Chemical Name Long-chain alkyl amine Hazard Class & Category Acute Tox., 4; Acute Tox., 3; Acute Tox., 3; Skin Corr., 1B; Skin Sens., 1; STOT RE, 2; Aquatic Chronic, 1; Hazard Statement H302; H331; H311; H314; H317; H373; H410; Classification of components according to 67/548/EEC Chemical Name CAS No. EC Number Long-chain alkyl Not available amine Additional Information : Not available REACH Symbol(s) R-phrase(s) Registration No. Not available T, C, N R22; R23/24; / Not R34; R43; applicable. R48/20; R50/53 Conc. 0,10 0,24% Refer to Ch 16 for full text of R- and H- phrases. This mixture does not contain any REACH registered substances that are assessed to be a PBT or a vPvB. SECTION 4. FIRST AID MEASURES 4.1 Description of First Aid Measures General Information : Inhalation : Skin Contact : Eye Contact : Ingestion : Self-protection of the first aider : 4.2 Most important symptoms and effects, both acute and delayed 4.3 Indication of any immediate medical attention and special : : Not expected to be a health hazard when used under normal conditions. No treatment necessary under normal conditions of use. If symptoms persist, obtain medical advice. Remove contaminated clothing. Flush exposed area with water and follow by washing with soap if available. If persistent irritation occurs, obtain medical attention. Flush eye with copious quantities of water. If persistent irritation occurs, obtain medical attention. In general no treatment is necessary unless large quantities are swallowed, however, get medical advice. When administering first aid, ensure that you are wearing the appropriate personal protective equipment according to the incident, injury and surroundings. 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. Notes to doctor/physician: Treat symptomatically. 3/17 Print Date 26.12.2012 000000019336 MSDS_DE Shell Omala S4 GX 320 Version 2.0 Effective Date 04.12.2012 Regulation 1907/2006/EC Safety Data Sheet treatment needed SECTION 5. FIRE FIGHTING MEASURES Clear fire area of all non-emergency personnel. 5.1 Extinguishing Media : Unsuitable Extinguishing Media 5.2 Special hazards arising from the substance or mixture : 5.3 Advice for firefighters : : Foam, water spray or fog. Dry chemical powder, carbon dioxide, sand or earth may be used for small fires only. Do not use water in a jet. Hazardous combustion products may include: A complex mixture of airborne solid and liquid particulates and gases (smoke). Carbon monoxide. Unidentified organic and inorganic compounds. Proper protective equipment including chemical resistant gloves are to be worn; chemical resistant suit is indicated if large contact with spilled product is expected. Self-Contained Breathing Apparatus must be worn when approaching a fire in a confined space. Select fire fighter's clothing approved to relevant Standards (e.g. Europe: EN469). SECTION 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. Observe the relevant local and international regulations. 6.1 Personal Precautions, Protective Equipment and Emergency Procedures : 6.2 Environmental Precautions : 6.3 Methods and Material for Containment and Cleaning Up : Additional Advice : 6.4 Reference to other : 6.1.1 For non emergency personnel: Avoid contact with skin and eyes. 6.1.2 For emergency responders: 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. 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. Local authorities should be advised if significant spillages cannot be contained. For guidance on selection of personal protective equipment 4/17 Print Date 26.12.2012 000000019336 MSDS_DE Shell Omala S4 GX 320 Version 2.0 Effective Date 04.12.2012 Regulation 1907/2006/EC Safety Data Sheet sections see Chapter 8 of this Material Safety Data Sheet. For guidance on disposal of spilled material see Chapter 13 of this Material Safety Data Sheet. SECTION 7. HANDLING AND STORAGE General Precautions : 7.1 Precautions for Safe Handling : 7.2 Conditions for safe storage, including any incompatibilities : Recommended Materials : Unsuitable Materials 7.3 Specific end use(s) Additional Information : : : Use local exhaust ventilation if there is risk of inhalation of vapours, mists or aerosols. 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. 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. Properly dispose of any contaminated rags or cleaning materials in order to prevent fires. Keep container tightly closed and in a cool, well-ventilated place. Use properly labelled and closeable containers. Store at ambient temperature. Refer to section 15 for any additional specific legislation covering the packaging and storage of this product. For containers or container linings, use mild steel or high density polyethylene. PVC. Not applicable Polyethylene containers should not be exposed to high temperatures because of possible risk of distortion. Storage class according to TRGS 510: 10 Fire hazard classification: B SECTION 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. 8.1 Control Parameters Occupational Exposure Limits Biological Exposure Index (BEI) 5/17 Print Date 26.12.2012 000000019336 MSDS_DE Shell Omala S4 GX 320 Version 2.0 Effective Date 04.12.2012 Regulation 1907/2006/EC Safety Data Sheet No biological limit allocated. PNEC related information : Data not available Monitoring Methods : Monitoring of the concentration of substances in the breathing zone of workers or in the general workplace may be required to confirm compliance with an OEL and adequacy of exposure controls. For some substances biological monitoring may also be appropriate. Validated exposure measurement methods should be applied by a competent person and samples analysed by an accredited laboratory. Examples of sources of recommended exposure measurement methods are given below or contact the supplier. Further national methods may be available. National Institute of Occupational Safety and Health (NIOSH), USA: Manual of Analytical Methods http://www.cdc.gov/niosh/ Occupational Safety and Health Administration (OSHA), USA: Sampling and Analytical Methods http://www.osha.gov/ Health and Safety Executive (HSE), UK: Methods for the Determination of Hazardous Substances http://www.hse.gov.uk/ Institut für Arbeitsschutz Deutschen Gesetzlichen Unfallversicherung (IFA), Germany. http://www.dguv.de/inhalt/index.jsp L'Institut National de Recherche et de Securité, (INRS), France http://www.inrs.fr/accueil 8.2 Exposure Controls General Information : 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. Define procedures for safe handling and maintenance of 6/17 Print Date 26.12.2012 000000019336 MSDS_DE Shell Omala S4 GX 320 Version 2.0 Effective Date 04.12.2012 Regulation 1907/2006/EC Safety Data Sheet controls. Educate and train workers in the hazards and control measures relevant to normal activities associated with this product. Ensure appropriate selection, testing and maintenance of equipment used to control exposure, e.g. personal protective equipment, local exhaust ventilation. Drain down system prior to equipment break-in or maintenance. Retain drain downs in sealed storage pending disposal or for subsequent recycle. Always observe good personal hygiene measures, such as washing hands after handling the material and before eating, drinking, and/or smoking. Routinely wash work clothing and protective equipment to remove contaminants. Discard contaminated clothing and footwear that cannot be cleaned. Practice good housekeeping. Occupational Exposure Controls Personal Protective Equipment : Eye Protection : Hand Protection : The provided information is made in consideration of the PPE directive (Council Directive 89/686/EEC) and the CEN European Committee for Standardisation (CEN) standards. Personal protective equipment (PPE) should meet recommended national standards. Check with PPE suppliers. Wear safety glasses or full face shield if splashes are likely to occur. Approved to EU Standard EN166. 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, 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. For continuous contact we recommend gloves with breakthrough time of more than 240 minutes with preference for > 480 minutes where suitable gloves can be identified. For short-term/splash protection we recommend the same, but recognise that suitable gloves offering this level of protection may not be available and in this case a lower breakthrough time may be acceptable so long as appropriate maintenance and replacement regimes are followed. Glove thickness is not a good predictor of glove resistance to a chemical as it is 7/17 Print Date 26.12.2012 000000019336 MSDS_DE Shell Omala S4 GX 320 Version 2.0 Effective Date 04.12.2012 Regulation 1907/2006/EC Safety Data Sheet Body protection : Respiratory Protection : Thermal Hazards : dependent on the exact composition of the glove material. Skin protection not ordinarily required beyond standard issue work clothes. 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 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. Not applicable. Environmental Exposure Controls : Minimise release to the environment. An environmental Environmental exposure assessment must be made to ensure compliance with local control measures environmental legislation. Information on accidental release measures are to be found in section 6. SECTION 9. PHYSICAL AND CHEMICAL PROPERTIES 9.1 Information on basic physical and chemical properties Appearance Odour Odour threshold pH Initial Boiling Point and Boiling Range Pour point Flash point Upper / lower Flammability or Explosion limits Auto-ignition temperature Vapour pressure Relative Density Density Water solubility Solubility in other solvents : : : : : Amber. Liquid at room temperature. Slight hydrocarbon. Data not available Not applicable. > 280 °C / 536 °F estimated value(s) : Typical -42 °C / -44 °F : Typical 252 °C / 486 °F (COC) : Typical 1 - 10 %(V) : : : : : : > 320 °C / 608 °F < 0,5 Pa at 20 °C / 68 °F (estimated value(s)) Typical 0,883 at 15 °C / 59 °F Typical 883 kg/m3 at 15 °C / 59 °F Negligible. Data not available 8/17 Print Date 26.12.2012 000000019336 MSDS_DE Shell Omala S4 GX 320 Version 2.0 Effective Date 04.12.2012 Regulation 1907/2006/EC Safety Data Sheet n-octanol/water partition coefficient (log Pow) Dynamic viscosity Kinematic viscosity Vapour density (air=1) Evaporation rate (nBuAc=1) Decomposition Temperature Flammability Oxidizing Properties : Data not available : Data not available Explosive Properties : Not classified 9.2 Other Information Electrical conductivity Other Information Volatile organic compound : > 6 (based on information on similar products) : : : : : Data not available Typical 312,7 mm2/s at 40 °C / 104 °F > 1 (estimated value(s)) Data not available Data not available : This material is not expected to be a static accumulator. : not a VOC : 0% SECTION 10. STABILITY AND REACTIVITY 10.1 Reactivity 10.2 Chemical stability 10.3 Possibility of Hazardous Reactions 10.4 Conditions to Avoid 10.5 Incompatible Materials 10.6 Hazardous Decomposition Products : The product does not pose any further reactivity hazards in addition to those listed in the following sub-paragraph. : No hazardous reaction is expected when handled and stored according to provisions. : Reacts with strong oxidising agents. : Extremes of temperature and direct sunlight. : Strong oxidising agents. : Hazardous decomposition products are not expected to form during normal storage. SECTION 11. TOXICOLOGICAL INFORMATION 11.1 Information on Toxicological effects Basis for Assessment : Information given is based on data on the components and the toxicology of similar products. Unless indicated otherwise, the data presented is representative of the product as a whole, rather than for individual component(s). 9/17 Print Date 26.12.2012 000000019336 MSDS_DE Shell Omala S4 GX 320 Version 2.0 Effective Date 04.12.2012 Regulation 1907/2006/EC Safety Data Sheet Likely Routes of Exposure Acute Oral Toxicity Acute Dermal Toxicity Acute Inhalation Toxicity : : : Skin corrosion/irritation : Serious eye damage/irritation Respiratory Irritation Respiratory or skin sensitisation Aspiration Hazard : Germ cell mutagenicity Carcinogenicity Reproductive and Developmental Toxicity : : : Skin and eye contact are the primary routes of exposure although exposure may occur following accidental ingestion. Expected to be of low toxicity: LD50 > 5000 mg/kg , Rat Expected to be of low toxicity: LD50 > 5000 mg/kg , Rabbit Not considered to be an inhalation hazard under normal conditions of use. 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. Expected to be slightly irritating. : Inhalation of vapours or mists may cause irritation. For respiratory and skin sensitisation: Not expected to be a sensitiser. Not considered an aspiration hazard. : : : Not considered a mutagenic hazard. Not expected to be carcinogenic. Not expected to be a hazard. Summary on evaluation of the CMR properties : This product does not meet the criteria for classification in Carcinogenicity categories 1A/1B., : This product does not meet the criteria for classification in Mutagenicity categories 1A/1B. : This product does not meet the criteria for classification in Reproductive Toxicity categories 1A/1B. (fertility) Specific target organ toxicity - single exposure Specific target organ toxicity - repeated exposure Additional Information : Not expected to be a hazard. : Not expected to be a hazard. : 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. Classifications by other authorities under varying regulatory frameworks may exist. 10/17 Print Date 26.12.2012 000000019336 MSDS_DE Shell Omala S4 GX 320 Version 2.0 Effective Date 04.12.2012 Regulation 1907/2006/EC Safety Data Sheet SECTION 12. ECOLOGICAL INFORMATION Basis for Assessment : 12.1 Toxicity Acute Toxicity 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. Unless indicated otherwise, the data presented is representative of the product as a whole, rather than for individual component(s). : 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. 12.2 Persistence and degradability : 12.3 Bioaccumulative Potential : 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. Contains components with the potential to bioaccumulate. 12.4 Mobility in Soil : Liquid under most environmental conditions. If it enters soil, it will adsorb to soil particles and will not be mobile. Floats on water. 12.5 Result of PBT and vPvB assesment : This mixture does not contain any REACH registered substances that are assessed to be a PBT or a vPvB. 12.6 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. SECTION 13. DISPOSAL CONSIDERATIONS 13.1 Waste Treatment Methods 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 11/17 Print Date 26.12.2012 000000019336 MSDS_DE Shell Omala S4 GX 320 Version 2.0 Effective Date 04.12.2012 Regulation 1907/2006/EC Safety Data Sheet Container Disposal : Local Legislation : applicable regulations. Do not dispose into the environment, in drains or in water courses. Dispose in accordance with prevailing regulations, preferably to a recognised collector or contractor. The competence of the collector or contractor should be established beforehand. 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. SECTION 14. TRANSPORT INFORMATION Land transport (ADR/RID): ADR This product is not classified as dangerous for this mode of transport. Therefore 14.1 UN Number, 14.2 UN Proper Shipping name, 14.3 Transport hazard class(es), 14.4 Packing group, 14.5 Environmental hazards, 14.6 Special precautions for user do not apply. RID This product is not classified as dangerous for this mode of transport. Therefore 14.1 UN Number, 14.2 UN Proper Shipping name, 14.3 Transport hazard class(es), 14.4 Packing group, 14.5 Environmental hazards, 14.6 Special precautions for user do not apply. Inland waterways transport (ADN): This product is not classified as dangerous for this mode of transport. Therefore 14.1 UN Number, 14.2 UN Proper Shipping name, 14.3 Transport hazard class(es), 14.4 Packing group, 14.5 Environmental hazards, 14.6 Special precautions for user do not apply. CDNI Inland Water Waste : NST 3411 Mineral Lubricanting Oils Agreement Sea transport (IMDG Code): This product is not classified as dangerous for this mode of transport. Therefore 14.1 UN Number, 14.2 UN Proper Shipping name, 14.3 Transport hazard class(es), 14.4 Packing group, 14.5 Environmental hazards, 14.6 Special precautions for user do not apply. Air transport (IATA): This product is not classified as dangerous for this mode of transport. Therefore 14.1 UN Number, 14.2 UN Proper Shipping name, 14.3 Transport hazard class(es), 14.4 Packing group, 14.5 Environmental hazards, 14.6 Special precautions for user do not apply. 14.7 Transport in bulk according to Annex II of MARPOL 73/78 and the IBC Code Pollution Category : Not applicable. Ship Type : Not applicable. 12/17 Print Date 26.12.2012 000000019336 MSDS_DE Shell Omala S4 GX 320 Version 2.0 Effective Date 04.12.2012 Regulation 1907/2006/EC Safety Data Sheet Product Name Special Precaution : : Not applicable. Not applicable. Additional Information : MARPOL Annex 1 rules apply for bulk shipments by sea. SECTION 15. REGULATORY INFORMATION The regulatory information is not intended to be comprehensive. Other regulations may apply to this material. 15.1 Safety, health and environmental regulations/legislation specific for the substance or mixture Other regulatory Information : Authorisations and/or restrictions on use Product is not subject to Authorisation under REACh. Recommended Restrictions on Use (Advice Against) : This product must not be used in applications other than those recommended in Section 1, without first seeking the advice of the supplier. EINECS : TSCA : All components listed or polymer exempt. All components listed. Chemical Inventory Status National Legislation Water Pollution Class : WGK 1 - low hazard to waters (appendix 4, VwVwS, preparations). Other Information : 15.2 Chemical Safety Assessment : Technische Anleitung Luft: Product not listed by name. Observe section 5.2.5 in connection with section 5.4.9 No Chemical Safety Assessment has been carried out for this substance/mixture by the supplier. SECTION 16. OTHER INFORMATION R-phrase(s) 13/17 Print Date 26.12.2012 000000019336 MSDS_DE Shell Omala S4 GX 320 Version 2.0 Effective Date 04.12.2012 Regulation 1907/2006/EC Safety Data Sheet R22 R23/24 R34 R43 R48/20 R50/53 Not classified. Harmful if swallowed. Toxic by inhalation and in contact with skin. Causes burns. May cause sensitisation by skin contact. Harmful: danger of serious damage to health by prolonged exposure through inhalation. Very toxic to aquatic organisms, may cause long-term adverse effects in the aquatic environment. CLP Hazard Statements H302 Harmful if swallowed. H311 Toxic in contact with skin. H314 Causes severe skin burns and eye damage. H317 May cause an allergic skin reaction. H331 Toxic if inhaled. H373 May cause damage to organs or organ systems through prolonged or repeated exposure. H410 Very toxic to aquatic life with long lasting effects. Additional Information : No Exposure Scenario annex is attached to this safety data sheet. It is a non-classified mixture containing hazardous substances as detailed in Section 3; relevant information from Exposure Scenarios for the hazardous substances contained have been integrated into the core sections 1-16 of this SDS. : Acute Tox. = Acute toxicity Asp. Tox. = Aspiration hazard Aquatic Acute = Acute hazards to the aquatic environment Aquatic Chronic = Hazardous to the aquatic environment Long-term Hazard Eye Dam. = Serious eye damage/eye irritation Flam. Liq. = Flammable liquids Skin Corr. = Skin corrosion/irritation Skin Sens. = Skin sensitizer STOT SE = Specific target organ toxicity - single exposure STOT RE = Specific target organ toxicity - repeated exposure Other Information Abbreviations and Acronyms The standard abbreviations and acronyms used in this document can be looked up in reference literature (e.g. scientific dictionaries) and/or websites. 14/17 Print Date 26.12.2012 000000019336 MSDS_DE Shell Omala S4 GX 320 Version 2.0 Effective Date 04.12.2012 Regulation 1907/2006/EC Safety Data Sheet ADN = European Agreement concerning the international carriage of dangerous goods by inland waterways (ADN) DFG = Federal Institute of Hydrology EG = European Community EN = European Norm IBC = Intermediate Bulk Container ISO = International Standards Organisation MAK = Maximum workplace concentration OECD = Organisation for economic cooperation and development OEL = Occupational Exposure Limits PSA = Personal protective equipment TRGS = Technical rules for hazardous substances VO = Regulation VOC = Volatile Organic Compounds VwVwS = Water administrative pollutants WGK = Water Hazard Class ACGIH = American Conference of Governmental Industrial Hygienists ADR = European Agreement concerning the International Carriage of Dangerous Goods by Road AICS = Australian Inventory of Chemical Substances ASTM = American Society for Testing and Materials BEL = Biological exposure limits BTEX = Benzene, Toluene, Ethylbenzene, Xylenes CAS = Chemical Abstracts Service CEFIC = European Chemical Industry Council CLP = Classification Packaging and Labelling COC = Cleveland Open-Cup DIN = Deutsches Institut fur Normung DMEL = Derived Minimal Effect Level DNEL = Derived No Effect Level DSL = Canada Domestic Substance List EC = European Commission EC50 = Effective Concentration fifty ECETOC = European Center on Ecotoxicology and Toxicology Of Chemicals ECHA = European Chemicals Agency EINECS = The European Inventory of Existing Commercial Chemical Substances EL50 = Effective Loading fifty ENCS = Japanese Existing and New Chemical Substances Inventory 15/17 Print Date 26.12.2012 000000019336 MSDS_DE Shell Omala S4 GX 320 Version 2.0 Effective Date 04.12.2012 Regulation 1907/2006/EC Safety Data Sheet EWC = European Waste Code GHS = Globally Harmonised System of Classification and Labelling of Chemicals IARC = International Agency for Research on Cancer IATA = International Air Transport Association IC50 = Inhibitory Concentration fifty IL50 = Inhibitory Level fifty IMDG = International Maritime Dangerous Goods INV = Chinese Chemicals Inventory IP346 = Institute of Petroleum test method N° 346 for the determination of polycyclic aromatics DMSO-extractables KECI = Korea Existing Chemicals Inventory LC50 = Lethal Concentration fifty LD50 = Lethal Dose fifty per cent. LL/EL/IL = Lethal Loading/Effective Loading/Inhibitory loading LL50 = Lethal Loading fifty MARPOL = International Convention for the Prevention of Pollution From Ships NOEC/NOEL = No Observed Effect Concentration / No Observed Effect Level OE_HPV = Occupational Exposure - High Production Volume PBT = Persistent, Bioaccumulative and Toxic PICCS = Philippine Inventory of Chemicals and Chemical Substances PNEC = Predicted No Effect Concentration REACH = Registration Evaluation And Authorisation Of Chemicals RID = Regulations Relating to International Carriage of Dangerous Goods by Rail SKIN_DES = Skin Designation STEL = Short term exposure limit TRA = Targeted Risk Assessment TSCA = US Toxic Substances Control Act TWA = Time-Weighted Average vPvB = very Persistent and very Bioaccumulative SDS Distribution : SDS Version Number : The information in this document should be made available to all who may handle the product. 2.0 SDS Effective Date : 04.12.2012 SDS Revisions : A vertical bar (|) in the left margin indicates an amendment from the previous version. 16/17 Print Date 26.12.2012 000000019336 MSDS_DE Shell Omala S4 GX 320 Version 2.0 Effective Date 04.12.2012 Regulation 1907/2006/EC Safety Data Sheet SDS Regulation : Disclaimer : Regulation 1907/2006/EC as amended by Regulation (EU) 453/2010 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. 17/17 Print Date 26.12.2012 000000019336 MSDS_DE HAMMELMANN Code no.: 04.03226.0769 Type 32-200 SIHISuperNova Programme Range: ZLND Volute casing pump complying with EN 733 / DIN 24255* Operating instructions Safety issues Chapter 1 Safety instructions and compliance Intended application Chapter 2 Application, description Planning the installation Chapter 3 Requirements, piping system, accessories Unpacking, storage, transport Chapter 4 Supply, interim storage, corrosion protection Installing the pump Chapter 5 Assembly at site, tools, checks Start-up and shut-down Chapter 6 Important requirements Maintenance, dismantling, assembly Chapter 7 Intervals, cleaning Troubleshooting Chapter 8 If something does not work Technical data Chapter 9 Dimensions, permissible values Annex Chapter 10 Technical data, dimensions table, sectional drawings * With certain exceptions – see Technical Catalogue Attention: Both the pump and/or the pump set must be installed and commissioned by qualified technical personnel only and these installation, commissioning and operating instructions must be strictly observed. Failure to do so could result in: • danger to you and your colleagues, • the pump or the pump unit may be damaged, Note that the manufacturer is not liable for damages resulting from failure to observe these instructions. Please be aware of your responsibility to your colleagues when working on the pump or the pump set! included in this Operating Instructions and in the Safety instructions marked with Supplementary Operating Instructions, which must be attached to this Operating Instruction, have to be considered in particular when operating this pump in potentially explosive atmospheres! For local contact details: www. sterlingfluidsystems.com In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice (Sterling Fluid Systems BV) 2001 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Safety issues 1. Page 1 of 3 Safety This operating manual gives basic instructions, which must be observed during installation, operation and maintenance of the pump. It is therefore imperative that this manual is read by the responsible personnel / operator(s) prior to assembly and commissioning. It must always be kept available at the site of pump installation. It is not only the general safety instructions contained in this chapter “Safety” which must be observed, but also the specific information provided in the other chapters. 1.1 Identification of safety symbols in the operating instructions Safety symbols are given in these operating instructions. Non compliance with these would affect safety and are identified by the following symbol Danger symbol as per DIN 4844-W9 (ISO 3864 - B.3.1) Or in case of danger of electric current with: Danger symbol as per DIN 4844 W-8 (ISO 3864 - B.3.6) The word ATTENTION Chapter 1 • the identification plate and that these are kept legible. 1.2 Qualification personnel and training The personnel responsible for operation, maintenance, inspection and assembly must be adequately qualified. The scope of responsibility and supervision of the personnel must be exactly defined by plant management. If the staff do not have the necessary knowledge, they must be trained and instructed. This task may be performed by the machine manufacturer or supplier on behalf of the plant management. Moreover, plant management must ensure that the contents of the operation instructions are fully understood by plant operators and other relevant personnel such as maintenance staff. 1.3 Hazards in compliance instructions case with of non safety Non compliance with the safety instructions may result in risk to personnel as well as to the environment and the pump/pump set and result in the loss of any right to claim damages. For example, non-compliance may result from, or lead to, the following: • failure of important functions of the pump/pump set/plant • failure of specified procedures of maintenance and repair • exposure of people to electrical, mechanical and chemical hazards • danger to the environment owing to hazardous substances being released. identifies those safety regulations where noncompliance may pose a danger to the pump and its function. It is imperative that the appropriate safety information is attached to the pump/pump set, for example: • an arrow indicating the direction of rotation • symbols indicating fluid connections For local contact details: www. sterlingfluidsystems.com of In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice. (Sterling Fluid Systems BV) 2001 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Safety issues 1.4 Page 2 of 3 Compliance with regulations relating to safety at work When operating the pump the safety instructions contained in this manual, the relevant national accident prevention regulations and any other service and safety instructions issued by plant management must be observed. 1.5 Safety instructions relating to operation • If high or low temperature pump/pump set components involve hazards, steps must be taken to avoid accidental contact. • Guards for moving parts (e.g. couplings) must not be removed from the pump/pump set while in operation. • Any leakage of hazardous (e.g. explosive, toxic, hot) fluids (e.g. from the shaft seal) must be drained safely so as to prevent any risk to persons or the environment. Statutory regulations are to be complied with. • Hazards from electricity are to be avoided by the user (see for example the VDEspecifications and the bye-laws of the local power supply utilities). 1.6 Safety instructions relevant for maintenance, inspection and assembly work It is the plant manegement’s responsibility to ensure that all maintenance, inspection and assembly work is performed by authorized personnel who have adequately familiarised themselves with the subject matter by studying this manual in detail. Any work on the machine must only be performed when it is at a standstill. It is imperative that the procedure for shutting down the machine described in this manual is followed. Pumps and pump sets, which convey hazardous media, must be decontaminated. On completion of the work all safety and protective guards must be re-installed and made For local contact details: www. sterlingfluidsystems.com Chapter 1 operative again. Prior to re-starting the machine, the instructions listed under “first commissioning” are to be observed. 1.7 Safety instructions for the use in areas with explosion hazard In this section information is given for operation in areas where an explosion hazard exists. 1.7.1 Complete pump sets If the pump is combined with other mechanical or electrical components in one set, the category of the complete unit will correspond, based upon the Directive 94/9/EC, only to that category with which all of its components comply. Note: These comments are of particular importance when pumps, which conform to a given category of Directive 94/9/EC, are powered by a driver which is not in the same category. Although the pump may bear the Ex sign, the set should not be used in areas with an explosion hazard when the motor is not classified for this application. This means that plant management personnel should always check that all elements of the set comply with the Directive 94/9/EC. 1.7.2 Execution of coupling guards Coupling guards that are to be used in areas with an explosion hazard, have to fulfil one of the following criteria: • consist of non-sparking material, e.g. brass. • if they consist of sparking material, e.g. steel sheet, they must be designed in such a way that the rotating parts will not come in contact with any part of the guard if errors, that could be foreseen, are committed by the user, e.g if a person steps on the guard. In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice. (Sterling Fluid Systems BV) 2001 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Safety issues Page 3 of 3 1.7.3 Monitoring technical parameters 1.10 When using pumps in areas with an explosion risk, the operator must check the following parameters regularly: • leakage of shaft seals • bearing temperature • that the pump is always filled with liquid during operation • that the pump does not operate against a closed valve for any length of time. The operator must ensure that pumps, which show evidence of abnormal operation, are switched off and not started again until the cause of the abnormal operation has been eliminated. Chapter 1 Warranty / guarantee Sterling Fluid Systems guarantee satisfactory operation if: • the pump is installed and operated in compliance with these instructions and in operating conditions approved by Sterling Fluid Systems • modifications are only undertaken with Sterling Fluid Systems’ written agreement. 1.7.4 Avoiding external damage In areas with a risk of explosion the operator must ensure that the pumps and or pump set is not subjected to external impacts e.g by heavy objects. 1.8 Unauthorized alterations and production of spare parts Modifications may be made to the pump/pump set only after consultation with,and written approval from, the manufacturer. Using spare parts and accessories authorized by the manufacturer are in the interests of safety. Use of other parts may exempt the manufacturer from any liability. 1.9 Unauthorized mode of operation The reliability of the pump/pump set can only be guaranteed if it is used in the manner intended and in accordance with the instructions of this manual. The specified limit values must under no circumstances be exceeded. For local contact details: www. sterlingfluidsystems.com In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice. (Sterling Fluid Systems BV) 2001 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Intended application 2. Page 1 of 3 Application 2.3 The pump is to be used only for the operating conditions stated by the customer and confirmed by the supplier. Guarantee is assumed within the scope of the Sterling Fluid Systems conditions of sale. Appropriate application and operating conditions are contained in the attached data sheets. 2.1 • Warning of misuse Chapter 2 Construction and mode of operation ZLND pumps are horizontal, single-stage volute casing pumps with nominal outputs and flange dimensions meeting EN 733 / DIN 24255. Their back pull out construction allows the disassembly of the complete bearing unit towards the drive side without removing the pump casing from the pipework. ZLND pumps are preferably used when pure or turbid liquids, not containing solid particles, are to be handled. Impurities up to a grain size of 3 mm can be handled, but shorten the service life. The pump may only be used for the application(s) stated. Otherwise hazards for people and environment may arise. ATTENTION • Do not exceed fluid density stated. Otherwise, there is a the danger of motor overload. The pump must not be operated beyond its characteristic curve – otherwise there is a danger of cavitation and motor damage. • 2.2 Accessories The accessories included in the scope of supply are indicated in the delivery note or in the order confirmation. The corresponding operating and installation instructions are also indicated in the Annex relating to accessories. If it is intended to mount other accessories on the pump or on the pump set, please inform the manufacturer in advance in order that appropriate technical advice can be given. For local contact details: www. sterlingfluidsystems.com In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice (Sterling Fluid Systems BV) 2001 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Intended application Page 2 of 3 Chapter 2 2.4 Description Type size ZLND 32125 to 300500 Shaft seal 041: Self-sealed, uncooled packing rings Hydraulic + Bearing A• First hydraulic B• Second hydraulic D• Double volute Material design 0B: Cast iron GG25 052: Uncooled packing rings, external seal liquid 0C: Cast iron GG25, Bronze G-CuSn10 impeller BJ3,C23,AF3,AX3,AY3,A93:SiC/Carbon, EPDM 0E: Cast iron GG25, Stainless steel 1.4408 imp. BJS,C2S,AFS, AXS,AYS,A9S: SiC/ SiC, Viton • B Two ball bearings greased for life (2Z) • C Two ball bearings oil BJJ,C2J,AFK,AXK,AYK,A9K: SiC/Carbon, Viton lubricated Casing gasket 2: confined flat gasket of EWP 210 material 4: confined flat gasket of PTFE 4B: Stainless steel 1.4408 • 2 Oil lubrication configurations with CLO • S One double row angular contact bearing plus one ball bearing, grease lubricated • T One double row ball bearing plus ball bearing, oil lubricated Alternatively A or B 32160, 32200 A 32125 to 200315, 250315 D 200400 to 300500 041,052,BJ3,C23,AF3,AX3,AY3,A93,BJS,C2S, AFS,AXS,AYS,A9S,BJJ,C2J,AFK,AXK,AYK,A9K Alternatively Alternatively 0B, 0C, 0E, 4B 2, 4 Alternatively B, C, 2, S or T Codes AX3, AXS, AXK: are equivalent to AF3, AFS, AFK respectively plus quench Codes AY3, AYS, AYK: are equivalent to AF3, AFS, AFK respectively plus heating Codes A93, A9S, A9K: are equivalent to AF3, AFS, AFK respectively plus external flushing For local contact details: www. sterlingfluidsystems.com In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice (Sterling Fluid Systems BV) 2001 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Intended application Page 3 of 3 2.5 Example of a pump designation: 1-3 4 5-7 8-10 11 12 13-15 16-17 18 ZLND 125 250 A C 041 OB 2 Casing gasket Construction Shaft sealing Bearings:B,C,S,T or 2 Hydraulic: A/B/D Impeller size Nominal discharge Pump series Chapter 2 Shaft sealing Depending on the application, different shaft sealing executions are offered (see 2.4) • a stuffing box with lantern ring (executions 041, 052, and optionally 051) or mechanical seals according to DIN 24960 are utilised in the following cases: • if the pump draws from a suction line, • if the pump is fed by a feed line with a pressure of less than 0.5 bar or • if the pumped liquid is at or near its boiling point. Provision of the sealing liquid is as follows: • 041: Internal self sealing ISO 5199 plan 01 • 052: External self sealing ISO 5199 plan 08 • 051: External self sealing ISO 5199 plan 09 • Mechanical seal: ISO 5199 plan 02. API plan 11 • Mechanical seal execution plus external flushing: ISO 5199 plan 08, API plan 32 Mechanical seal execution plus quench: ISO 5199 plan 09. API plan 62. ATTENTION Section 2.4 does not contain the codes for all variations of mechanical seals. Where the code is not included or replaced by QQQ, consult the relevant data sheet of the mechanical seal supplier (e.g. special execution of the mechanical sealing in a back to back position). For local contact details: www. sterlingfluidsystems.com In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice (Sterling Fluid Systems BV) 2001 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Planning the installation Page 1 of 2 3.0 Planning the installation 3.1 Piping system Ensure that air pockets cannot be created. Unequal nominal widths of the suction branch and suction line must be compensated by eccentric transition pieces. ATTENTION • • • • • • • • • Chapter 3 Note the arrows on the pump branches indicating the direction of flow. Choose nominal widths of the pipelines according to the nominal widths of the pump branches or larger ones with the corresponding reductions. Flange sealing must not protrude on the inside. Ensure that the pipework is clean before installing of the pump. Support the pipework in order to avoid distortions at the pump components (risk of damage to pump components) Avoid abrupt changes of cross section and direction. Where different diameter pipework is to be used, connection should be by eccentric transition pieces. This will avoid the formation of air pockets in the pipework. For difficult pumping on the suction side, to stabilise the flow, a pipe length 15 times the diameter of the suction branch should be installed before the suction branch. The flow rate in the suction line or inflow line, must not exceed 2 - 3 m/s. Flow straightener Connection of eccentric pipe transitions It is recommended that a filter is installed in front of the pump with a filter surface of at least 3 times the pipe cross section (approx. 100 meshes/cm²). The suction opening of the suction line should be well below the liquid level, and a strainer should be used. The strainer must be far enough from the bottom to avoid excessive inlet losses, which could impair pumping performance. It is advisable to check that there is no leakage. 7 4 3 1 6 2 4 3.1.1 Suction line / inflow line See the sketches below for the optimum layout of pump installation for flow and suction lift operation. 1 Eccentric reducer ( suction line ) or concentric reducer ( feed line ) 5 2 Shut-off valve 3 Suction line 4 Bend Pump installation 5 Foot valve with suction strainer 6 Check valve 7 Regulating valve positive suction head operation For local contact details: www. sterlingfluidsystems.com suction lift operation In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice. (Sterling Fluid Systems BV) 2001 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Planning the installation Page 2 of 2 Chapter 3 A shut-off valve should be installed in the feed line. It must be closed for maintenance work. It should be installed in order to avoid air pockets forming in the spindle cap, i.e. with the spindle in a horizontal position or pointing vertically downward. 3.1.2 Discharge line For flow regulation, a valve must be installed behind the pump. If non-return valves are used, they should close smoothly. Pressure shocks must be avoided. 3.1.3 Inlet and outlet connections The various connecting points are shows in the drawings. (See Annex, Chapter 10, point 10.1). 3.1.4 Pressure control For consistent control of pressure, it is advisable to install in the pipework a measuring point in front of, and behind the pump. 3.2 Electrical connections For the drive motor a mains connection is required which complies with the European Regulations and Directives for the Standards in Industry and with the instructions of the local power supply utilities of the country concerned. For local contact details: www. sterlingfluidsystems.com In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice. (Sterling Fluid Systems BV) 2001 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Unpacking, storage, transport Page 1 of 2 Chapter 4 4. Unpacking, storage, handling 4.4 4.1 Safety measures The pump or pump set must be lifted and handled as shown in the following sketches. • • • • • • • 4.2 Never stay below the suspended load. Keep a safe distance while the load is being transported. Use only approved lifting appliances, which are in good condition. Adjust the length of the lifting appliances in such a way that the pump and/ or the pump set, is suspended horizontally. Do not use the eyebolts on the pump components for lifting the assembled pump or the complete set. Do not remove documents, which are attached to the pump. Do not remove the protection covers from the pump suction/discharge. Otherwise, there may be a risk of contamination. Pump without motor Unpacking Before unpacking, a visual check of the packing is recommended. If transport damage is visible, the extent should be noted on the receipt or on the delivery note. Potential claims must be lodged immediately with the carriers or the insurance company. 4.3 Handling Interim storage If the pump or the pump unit is not installed immediately after delivery, it must be stored free from vibration in a dry room. For local contact details: www.sterlingfluidsystems.com Pump set 4.5 Protection against corrosion In general, a protective coating is only applied to the following executions: OB, OC and OE. 4.5.1 Removal of protective coating To remove the protective coating, the pump should be filled and drained several times using appropriate agents, e.g. solvent naphtha, diesel oil or alkaline detergent. Flush with water, if necessary. The pump must be installed and started up immediately afterwards. In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice (Sterling Fluid Systems BV) 2001 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Unpacking, storage, transport Page 2 of 2 Chapter 4 4.5.2 Renewing corrosion protection If the pump has been supplied with a protective coating and has to be stored, a new protective coating should be applied after six months. For suitable protective coatings, contact Sterling Fluid Systems. For local contact details: www.sterlingfluidsystems.com In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice (Sterling Fluid Systems BV) 2001 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Installing the pump Page 1 of 3 5. Installing the pump 5.1 Requirements 5.4.3 Base, foundation The pump and the pump set, must have been unpacked and handled as described in Chapter 4. 5.2 Use of trained staff Only appropriately trained staff must undertake the work described in this chapter. 5.3 • • • • • • Chapter 5 Safety measures Connect the pipework carefully to prevent the pumped liquid escaping during operation and endangering operating personnel. Ensure that the suction or inflow line, and the discharge line are closed by valves. Ensure that all electrical connections are “dead”. Otherwise, there is a risk of electric shock. Pay attention to relevant internal plant regulations. Avoid accidental contacts with hot components. ATTENTION Remove the protective coating by following the instructions of Chapter 4. Otherwise there is a danger of contamination . The pump must be installed on a flat floor or foundation free from vibration. In case of doubt use vibration dampening feet. The pump set must be correctly mounted on the foundations. To avoid distortion of the pump set and/or the foundation, parallel shims must be used between the base plate and foundation. Prior to installing, checks should be made with regard to: - possible damage to the pump or the pump set that may occur in transit - ease of running ( check that the shaft is free to rotate by hand ) - the foundation dimensions. The following preparatory work must be carried out before to placing the pump: - roughen and clean foundation surface - remove shuttering/cores from the anchor holes - blow the anchor holes clean - check the position and dimensions of the anchor holes against the arrangement drawing. 5.4.4 Installation of the set The complete set mounted on the base plate must be placed on the foundation with its foundation (rag) bolts hanging below the baseplate. 5.4.5 Space required 5.4 General information 5.4.1 Assembly tools Special tools are not required for assembly and installation. The space required for the pump set is set out in the foundation plan or installation drawing. Ensure easy access to the shut-off and regulation valves as well as to any measuring instruments. 5.4.2 Permissible ambient conditions The ambient temperature can be from -20 °C to +60 °C. The atmospheric humidity should be as low as possible in order to avoid corrosion. For local contact details: www.sterlingfluidsystems.com In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice (Sterling Fluid Systems BV) 2001 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Installing the pump Page 2 of 3 Chapter 5 5.4.6 Position In principle the ZLND pumps are installed horizontally. 5.5 Motor Before assembly check the direction of rotation of the motor (indicated by an arrow on the pump casing). If this is not possible the direction of rotation of the complete unit can only be checked only if the pump is filled. In any event, the operating instructions of the motor manufacturer must be followed, since the motor is generally incorporated by STERLING FLUID SYSTEMS into the pump set. 5.6 ruler Alignment of the set Place shims under the base plate on both sides of the foundation bolts, 10 mm from the base plate edge. Use a spirit level to align the set. If necessary, place shims between the foundation bolts to prevent the base plate from sagging. Care should be taken to minimize distortion of the base plate during installation. The location of the driver must not be higher than that of the pump. The max. deviation from the shaft centre line is ± 0.1 mm. The foundation bolts should be embedded in concrete using quick-setting grout. 5.7 half of the N-EUPEX B ( FLENDER ) coupling must be 2 - 3 mm (see fig.). If other manufacturer’s couplings are used, follow the manufacturer’s instructions. After installation on the foundation and connecting the pipework, the coupling alignment must be checked and realigned, if necessary. Moreover, after reaching the operating temperature the alignment of the coupling must be checked again. The coupling requires a guard that meets DIN 31001 in order to avoid accidental contact during operation. In any event, the operating instructions of the coupling manufacturer must be followed, since the coupling is a component incorporated by Sterling Fluid Systems. Coupling Install the coupling avoiding hard blows, if necessary in warm condition. Arrange the pump and motor on a level base. The shaft ends must be aligned exactly. The distance between each For local contact details: www.sterlingfluidsystems.com The following is required a = a1 and b = b1 5.8 Checking before installation Before installing the pump on the plant, the following points must be checked: 1. is the electrical current to the drive motor switched off? 2. are suction and discharge lines emptied and closed by valves? 3. Is it possible to rotate the pump easily by hand (for this purpose turn the fan of the motor or the coupling)? 4. Have the latest internal/plant instructions been observed?. In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice (Sterling Fluid Systems BV) 2001 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Installing the pump 5.9 Page 3 of 3 Chapter 5 Mounting the pump and installation into pipework The following instructions must be carried out: 1. remove the protective covers from the pump flanges and the auxiliary pipework connections. 2. correctly insert the flange seals. 3. connect the suction or feed line. 4. connect the discharge line The pump must be aligned with the pipework. The pipework must be supported so that distortion cannot occur when connecting the pump. 5.10 Final work The following final steps must be undertaken: 1. check the tightness of the connecting flanges. 2. check for easy running of the pump (for that purpose turn the motor fan or the coupling). 3. check the coupling alignment. 4. install the coupling guard. 5.11 Hydrostatic pressure test When subjecting the piping system to a hydrostatic pressure test, exclude the pump from the pressure test. If it is not possible to test the pipework without the pump, ensure that foreign material cannot enter the pump. • • The max. permissible pressure for a pressure test is 1.3 times the nominal pump pressure. The nominal pump pressure is indicated in the technical data sheet. For local contact details: www.sterlingfluidsystems.com In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice (Sterling Fluid Systems BV) 2001 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Starp-up and shut-down Page 1 of 3 Chapter 6 6. Start-up and shut-down operations 6.1 Requirements The pump or the pump set, must be installed acc. to the instructions of Chapter 5. • 6.2 • Use of trained staff Only appropriately trained staff must carry out the work described in this chapter. 6.3 Safety measures • • • Electrical connections must be made according to the European Regulations and Directives for the Standards in Industry and in compliance with the instructions of the local power supply utilities of the country concerned. Only appropriately authorized personnel may carry out this work. ATTENTION • • • • • • Fill the pump correctly; otherwise the shaft seal could be destroyed. Fill the supply lines correctly. Check the direction of rotation only when the pump is filled. Fill the pump slowly if hot media are being pumped in order to avoid distortions or heat shock. When handling explosive, toxic, hot, crystalline or corrosive media, ensure that there is no risk to people or the environment. Control the output at constant speed at the discharge side only. The valve at the suction side must always be completely open during operation to avoid the risk of cavitation. For local contact details: www. sterlingfluidsystems.com 6.4 If there is no bypass line, do not run the pump with the control valve closed for any length of time. Safety measures should be taken by the end user to ensure (for example by means of a relief valve) that the permissible pump casing pressure is not exceeded during operation Repeat the alignment of the coupling at operating temperature. Re-align the pump or the motor, if necessary. Electrical connection The motor must be connected at set out in the circuit diagram in the terminal box. 6.5 Checks before switching-on Before switching on the pump unit, the following points should be checked: 1. is all pipework connected and are the unions tight? 2. is the pump including the pipework filled properly? 3. is the shut-off valve in the discharge line closed? 4. is the shut-off valve in the suction line completely opened? 5. is the motor ready for operation? 6. is the direction of rotation of the motor correct? (check by running the motor for a short time) 7. is the coupling aligned exactly? 8. has the shaft seal been installed? 9. are the supply lines, if any, to the shaft seal open? 10. in the case of oil lubrication - has the bearing housing been correctly filled with oil? 11. is the gland finger slightly tight?. In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice. (Sterling Fluid Systems) 2001 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Starp-up and shut-down Page 2 of 3 Chapter 6 6.7 Switching frequency Size Fasten gland nuts 6.6 Start-up operation For starting proceed as follows: 1. open fully the valve on the suction side 2. close the valve on the discharge side 3. switch on the motor 4. check the pressure gauges at the pressure measuring points If the pumping pressure does not increase consistently with increasing speed, switch off the motor again and vent the pump one more. 5. After reaching operating speed, regulate the operating point of the pump by adjusting the valve in the discharge line (see technical data for permissible range of operation). 6. For “running in” the packing, the gland should be tightened only slightly (even in the case of considerable leakage initially). After approx. 30 minutes tighten the gland to such an extent that it leaks only slightly. Check it several times, until leakage from the packing is about 20 to 40 drops a minute. In extreme operating conditions and high temperatures this rate may be higher. Pumping against a closed valve in the discharge line is permitted only if a minimum output via a bypass line is guaranteed. Permissible number of starts equally spaced per hour 32-125, 32-160, 32-200, 32-250, 40-125, 40-160, 40-200, 40-250, 50-125, 50-160, 50-200, 65-125, 65-160, 65-200, 65-250, 80-160, 80-200, 80-250,100-160, 100-200, 100-250, 100-315, 125-200, 150-200, 150-250 40-315, 50-250, 50-315, 65-315, 80-315, 80-400, 100-400, 125-250, 125-315, 125-400, 150-315, 150-400, 150-500, 200-250, 200-315, 200-400, 200-500, 250-300, 250-315, 250-400, 250-500, 300-400, 300-500 6.8 15 8 Special instructions During operation the following points must be observed: - control the speed and the delivery head - ensure that the pump runs without vibration - control the liquid level in the suction line and/or inflow tank - control the bearing temperature (max. temperature 100 °C) - control the pressure in the supply lines according to the following limits: External flushing: • Impeller size 125 Buffer pressure = pW + 0,5 bar • Rest of impeller sizes: Buffer pressure = pW + H + 2,5 bar • Flow = 0,1 – 0,2 m3/h pW = suction pressure, in bar H = differential pressure of pump, in bar Quench Maximum pressure = 4 bar Heating Maximum pressure = 4 bar, with water steam to 140 ˚C For local contact details: www. sterlingfluidsystems.com In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice. (Sterling Fluid Systems) 2001 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Starp-up and shut-down Page 3 of 3 - shaft seal Executions with stuffing box: For correct operation of the shaft seal a slight leakage (20 - 40 drops per minute) is essential. If the leakage is reduced too much by retightening the packing, it will be destroyed. If the pump is equipped with code 052 or code 051, the supply lines to the stuffing box have to be open before the pump is started. Executions with mechanical seal: During running-in slight leakage may occur. If the pump is equipped with an external flush, quench or heating, the flush, quench or heating supply has to be switched on before the pump is started. The mechanical seal must be allowed to cool before the next re-start. Chapter 6 When handling explosive, toxic, hot, crystalline or corrosive media, ensure that people and the environment are not endangered. Even if the pump has been drained using the threaded plug 90.30, residues can remain in the pump. For transport, the pump must be free from any dangerous material. In case of extended periods out of service, protect the pump against corrosion. ATTENTION For executions with stuffing box: If the leakage increases considerably and cannot be adjusted by retightening the gland, the packing is worn and must be replaced by a new one. For executions with mechanical seal: If the initial leakage does not disappear within 5 minutes of operation, stop the pump, dismantle the seal and check for damage of the seal faces and auxiliary sealing. 6.9 Shutting-down Before shutting down close the valve on the discharge side. After shutting down, all valves may be closed. The valves of the auxiliary pipework connections, (quench, heating, external flush, code 052, code 051), have to be closed in the last place. If there is a risk of very low ambient temperatures, remove the pump and then drain it using the threaded plug 90.30. For local contact details: www. sterlingfluidsystems.com In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice. (Sterling Fluid Systems) 2001 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Maintenance, dismantling, assembly Page 1 of 10 7. Maintenance, dismantling, assembly 7.1 Chapter 7 grease nipple Requirements The pump or the pump set must have been shut down in the manner described in Chapter 6. 7.2 Use of trained staff Only appropriately trained and skilled staff should undertake the work described in this chapter. Only authorised personnel must undertake electrical work associated with maintenance of the pump/pump set. 7.3 Grease lubrication: The bearings receive their first engreasing at the supplier plant. Grease amount per ball bearing: bearing housing 55: (shaft end diameter at the driving side 50 mm) Safety measures 30 gramme bearing housing 65: (shaft end diameter at the driving side 60 mm) lubrication intervals • • • • For explosive, toxic, hot, crystalline as well as different pumping media ensure that people and the environment are not endangered. Flush the pump with clean liquid before dismantling. The working place for disassembly or assembly must be clean. Before reinstallation, the pump must be free of any dangerous material. 7.4 Maintenance and inspection The pump requires only limited maintenance. 7.4.1 low activity 40 gramme middle and high activity for grease n ≤ 1500 1/min 1500 < n ≤ 3000 1/min lubrication every 5000 hours every 2500 hours at the latest after 12 months After about 10000 hours of activity or the latest after two years, the bearings have to be disassembled, washed and refilled with grease. Under extremely unfavourable circumstances (wet or dusty environment or high temperatures of the environment) the lubrication intervals have to be chosen considerably shorter. For renewing or adding lubrication grease, only lithium soap bearing grease have to be utilised (e.g. Mobilux 2, Shell Aero Grease 16, Esso Unirex N3). Bearing with grease lubrication The pumps with bearing brackets 25, 35 and 45 use an antifriction bearing, lubricated for service life, on the drive side and on the pump side. The pumps with bearing brackets 55 and 65 must be greased through grease nipples 63.60. For local contact details: www.sterlingfluidsystems.com In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice. (Sterling Fluid Systems BV) 2001 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Maintenance, dismantling, assembly 7.4.2 Bearing with oil lubrication The pump is supplied empty (no oil). Before the initial start up, pour oil into the oil inlet hole until the oil level reaches the mark on the dipstick. Oil filling Page 2 of 10 Chapter 7 Oil change intervals If the bearings are new, change the oil after about 200 hours and subsequently annually. These intervals only apply if the bearing temperature does not exceed 50 ºC. If the bearing temperature during operation is above 50 ºC but below 80 ºC and/or if there is danger of contamination, the oil should be renewed about every six months. Oil properties: Operating temp. of bearing up to 80ºC n>1500 n≤1500 rpm rpm CL68 CL46 CL22 at 50ºC in mm /s 61.2 to 74.8 41.8 to 50.8 19.8 to 24.2 Neutralisation figure Ash ( as Ash Oxide ) Water content Maximum 0.15 mg KOH/g Maximum 0.02% weight Maximum 0.1% weight Suitable motor oil SAE 20 and 20W Type of lubrication DIN 51517 t Kinematic viscocity 2 Oil drainage Ambient temp. < 0ºC Constant level oiler As an additional accessory, it is possible to connect a constant level oiler. In this case, the bearing support must be filled with oil through the oil inlet hole, until the oil is visible in the screw-in elbow, the oil reservoir having been removed. Subsequently the oil reservoir should be filled with oil and put into its correct position. The bearing housing will be supplied with oil from the constant level oiler with the correct amount as long as there is oil in the reservoir. See sketch of oiling system below 1. Oil reservoir 2. Screw-in elbow 3. Fill in oil here 4. Never fill with oil here, always use the oil inlet hole. For local contact details: www.sterlingfluidsystems.com SAE 10W Oil quantities: Bearing Bracket 25 35 45 55 65 Oil ( litre ) 0.22 0.38 0.57 1.50 2.00 ATTENTION The lubricating oil must be extremely pure, resistant to ageing, must have good viscositytemperature behaviour, good water separating properties and corrosion protection. In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice. (Sterling Fluid Systems BV) 2001 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Maintenance, dismantling, assembly Chapter 7 7.4.4 Mechanical seal 7.4.3 Stuffing box If leakage makes it necessary, the packing rings should be retightened. After extended periods and frequent retightening, the packing rings gradually lose their shape and elasticity. We therefore recommend replacing the packing material at regular intervals. As a typical indication, after an operating time of approx. 2500 hours or when the gland has been retightened by approximately half the width of a packing ring. Repacking When repacking, the stuffing box rings used up, as well as, the lantern ring are to be removed carefully from the shaft seal chamber. The shaft and shaft protection sleeve must not be damaged. Otherwise perfect sealing cannot be guaranteed and the shaft sleeve would then need replacing. If the pump is installed, cut soft packing rings diagonally, bend them in a spiral shape, position them on the pump shaft and bend them carefully into a ring form. Push the packing rings as well as the lantern ring by means of the gland into the shaft seal chamber. The cut joints should be staggered by 180°. Tighten the nuts at the gland steadily until resistance is felt when rotating the pump shaft by hand. Remove the gland again and fasten the nuts slightly. If the pump is removed in order to carry out repacking, it is useful to push the packing rings in the delivered condition, that means closed over the shaft sleeve. Lantern ring Packing rings For local contact details: www.sterlingfluidsystems.com Page 3 of 10 The mechanical seal should have little or no visible leakage. Where there is considerable leakage, check the mechanical seal. To do this, it is necessary to dismantle the rotating part(s). 43.30 16.10 50.40 21.10 7.4.5 Drive motor The drive motor must be maintained according to the instructions of the manufacturer. 7.5 Dismantling 7.5.1 Preparation for the dismantling Proceed as follows: • disconnect power to the motor • drain the plant, at least within the pump area, i.e. between the valves on the suction- and discharge side • if necessary, disconnect any measuring probes or control devices and remove them • drain liquid from the pump by means of the drain plug • dismantle shaft seal supply lines, if any. If oil lubricated bearings are used, drain the oil from the bearing housing. • the pump casing must not be detached from the pipe union • remove motor mounting bolts and move the motor so that there is sufficient space to remove the back pull out unit. When using a spacer coupling repositioning of the motor is not necessary. In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice. (Sterling Fluid Systems BV) 2001 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Maintenance, dismantling, assembly • Page 4 of 10 dismantle guard coupling, pump feet and coupling. 7.5.2 Replacement parts The item numbers necessary for ordering spare parts are provided in the component parts list in the Annex. 7.5.3 Dismantling the pump • For executions with bearing housings 25,35 and 45. 10.20 40.00 90.10 Chapter 7 Design with stuffing box 1. Remove the Allen head screws 91.40 and detach the casing cover 16.10. 1. Detach hexagonal nuts 92.01 and studs 90.21. 2. Loosen hexagonal screws 90.23 and detach packing housing 45.10 and gland 45.20 with the pressure ring 45.70. 3. Detach packing ring 46.10 and lantern ring 45.80. 4. Detach the shaft sleeve 52.40. 16.10 40.05 46.10 45.80 45.10 90.23 92.01 45.20 45.70 90.21 52.40 55.40 91.40 92.01 90.30 Design with a mechanical seal 1. Mark the position of the parts in relation to each other by a coloured pencil or a scribing tool. 2. Remove the hexagonal screws 90.10. 3. Remove the back pull out unit from the volute casing 10.20. 1. Detach the distance ring 50.40. 2. Remove the rotating part of the mechanical seal 43.30. 3. Remove the Allen head screws 91.40 and detach the casing cover 16.10. 90.13 68.10 50.40 92.20 23.00 94.01 43.30 16.10 91.40 68.10 90.13 4. Remove flat gasket 40.00. 5. Remove hexagonal screws 90.13 and remove protective screen 68.10. 6. Loosen impeller nut 92.20. 7. Remove impeller 23.00 and key 94.01. For local contact details: www.sterlingfluidsystems.com In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice. (Sterling Fluid Systems BV) 2001 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Maintenance, dismantling, assembly Design with quench (AX3, AXS, AXK) Detach the cover 16.50, O-ring 41.23 and lip seals 42.11. 16.10 42.11 41.23 16 .50 Design with heating (AY3, AYS, AYK) Detach the cover 16.50, O-rings 41.22 and 41.23. 16.10 41.22 41.23 Page 5 of 10 Chapter 7 Bearing design B, C or 2 : 1. Release hexagonal screws 90.11, remove V-seal 42.20 in case of grease lubrication, dismantle bearing cover 36.00 and flat gasket 40.02. Remove the lip seal 42.10 if pump is oil lubricated. 2. Release the thrower 50.70 3. Undo hexagonal screws 90.12, remove washer 93.01 and dismantle the pump foot 18.30. 4. For oil lubricated pumps, remove the oil dip stick 91.60 and remove the constant level oiler (CLO) 63.80 if any. 50.70 42.20 42.10 33.00 91.60 40.02 42.10 36.00 90.11 42.20 94.00 16. 50 18.30 93.01 90.12 5. Pull out complete shaft 21.00 with both ball bearings 32.10 and support washers for ball bearing 50.50 if any. 6. Remove ball bearings 32.10 and support washers for ball bearing 50.50. 32.10 50.50 21.00 50.50 32.10 4. Remove the static part of the mechanical seal 43.30 and pin 56.10. 43.30 16.10 56.10 • For executions with bearing housings 55 and 65: 10.20 90.30 For local contact details: www.sterlingfluidsystems.com 40.00 90.20 50.20 In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice. 90.80 92.00 92.06 56.00 (Sterling Fluid Systems BV) 2001 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Maintenance, dismantling, assembly Page 6 of 10 1. Mark the position of all parts with a colour pen or scribing tool in order to be able to reassemble the pump correctly. 2. Unscrew hexagonal nuts 92.00. 3. Withdraw pull out assembly from the volute casing 10.20. Withdraw the flat gasket 40.00. The wear ring 50.20, if it is necessary can be removed. 92.20 93.00 40.03 23.00 94.01 16.10 90.22 92.02 Chapter 7 Design with a mechanical seal: 1. Loosen hexagonal screws 90.24 and withdraw the mechanical seal cover 47.10 with the flat gasket 40.06, static part of the mechanical seal 43.30 with pin 56.10. 2. Remove the shaft sleeve 52.30 with the distance ring 50.40, the rotating part of the mechanical seal 43.30 and the flat gasket 40.01. 3. Loosen grub screw 56.00. 4. Detach the pin 56.00 and then, the wear ring 50.21. 40.01 52.30 50.40 43.30 16.10 90.22 40.06 47.10 56.00 50.21 56.10 90.24 4. Loosen impeller nut 92.20 and helicoil 93.00. 5. Remove impeller 23.00, key 94.01 and flat gasket 40.03. Unscrew hexagonal nuts 92.02 and detach the casing cover 16.10. Design with a stuffing box: 1. Remove hexagonal nuts 92.01 and studs 90.21. 2. Detach the gland 45.20, the packing ring 46.10 and the lantern ring 45.80. 3. Detach shaft sleeve 52.40 and flat gasket 40.01. 4. Detach the pin 56.00 and then, the wear ring 50.21 16.10 90.22 46.10 45.80 45.20 40.01 52.40 Bearing design S or T : 1. Release the thrower 50.70 2. Release hexagonal screws 90.11 and 90.14, dismantle bearing covers 36.00, 36.01 and flat gaskets 40.02. Remove the lip seals 42.10. 3. Release hexagonal screws 90.12, remove washer 93.01 and dismantle the pump foot 18.30. 4. For oil lubricated pumps, remove the plug 67.20 and the constant level oiler (CLO) 63.80 if any. 90.14 36.01 63.60 56.00 50.21 90.21 For local contact details: www.sterlingfluidsystems.com 55.40 42.10 40.02 92.01 In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice. 50.70 33.00 18.30 93.21 93.01 40.02 42.10 36.00 63.60 94.00 90.11 90.12 (Sterling Fluid Systems BV) 2001 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Maintenance, dismantling, assembly Page 7 of 10 5. Pull out complete shaft with both ball bearings 32.10 and 32.11 and circlip 93.21. 32.11 7.6 21.00 93.21 32.10 Post dismantling activities 7.6.1 Hints for cleaning. • • Clean all parts. Clean the clearances and sealing surfaces with an appropriate liquid. 7.6.2 Points to be checked The following pump components, if installed, must be checked: • Mechanical seal : If the running faces are damaged or worn, replace the mechanical seal. • Shaft and shaft sleeve : Check the shaft within the stuffing box. If the shaft has worn badly and is grooved, a new shaft or shaft sleeve should be used. • Clearances : The difference in diameter between impeller clearance area and casing or cover clearance area should be 0.3 mm to 0.5 mm. In the case of excessive wear in the clearance area, wear rings must be installed. • Radial seal ring : If the radial seal ring is damaged, it must be replaced. For local contact details: www.sterlingfluidsystems.com Chapter 7 7.7 Assembly 7.7.1 Tightening torque When tightening the bolts the following torques must be used: Thread M8 M10 M12 M16 M20 M24 M30 M36 Torque 12 25 40 90 175 300 500 700 Nm Nm Nm Nm Nm Nm Nm Nm 7.7.2 Pump assembly Proceed as follows: Bearing design B, C or 2 : • For executions with bearing housings 25,35 and 45: 1. Prior to installing bearings, the support washer for ball bearing 50.50 must be replaced, (only bearing housing 25). Install ball bearings (use new ball bearings, if necessary). Before installation, the ball bearings must be heated to 80ºC in an oil bath. (Only bearing design C or 2). 2. For a pump with oil lubrication, using a tool, press lip seal 42.10 in the bearing housing 33.00. When lip seals are used, the lip should point towards the drive end. 32.10 50.50 21.00 50.50 32.10 3. Insert the shaft assembly into the bearing housing from the drive end towards non-drive end. In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice. (Sterling Fluid Systems BV) 2001 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Maintenance, dismantling, assembly Page 8 of 10 • 4. Attach the bearing cover 36.00, with its radial seal inserted, if it is oil lubricated, and the flat gasket 40.02;( the lip of the radial seal ring should point towards the non drive end). Then fasten hexagonal screws 90.11. In case of grease lubrication, mount the V- seals 42.20 in the shaft and lean one against the bearing housing 33.00. Insert the key 94.00. 5. Insert the oil dip stick 91.60 and the CLO 63.80 if any. 50.70 42.20 42.10 33.00 91.60 40.02 18.30 93.01 42.10 36.00 90.11 42.20 Chapter 7 For executions with mechanical seal: 7. Insert the static part of the mechanical seal 43.30, with the pin 56.10 if any, in the casing cover 16.10. 43.30 16.10 56.10 94.00 90.12 6. Fasten pump foot 18.30 and insert the thrower 50.70. • Design with quench (AX3, AXS, AXK) Insert the lip seals 42.11 and the O-ring 41.23 in the cover 16.50. For executions with stuffing box: 7. Position the shaft sleeve 52.40 on the shaft. 8. Insert the packing housing 45.10 with the gasket 40.05 in the casing cover 16.10. 9. Install one of the packing rings 46.10 in the packing housing, the lantern ring 45.80 and then, the remaining packing rings. 10. Fasten hexagonal screws 90.23 , fix the studs 90.21 and hexagonal nuts 92.01. 16.10 40.05 45.10 90.23 45.70 16.10 41.23 42.11 16 .50 52.40 Attach the cover 16.50 and casing cover 16.10. 16.10 46.10 45.80 92.01 45.20 1 6 . 50 90.21 55.40 92.01 11. Finally, install the pressure ring 45.70 and the gland 45.20. Fix the washer 55.40 and the following hexagonal nuts 92.01. 12. Adjust the stuffing box as described in Chapter 7.4.3. For local contact details: www.sterlingfluidsystems.com In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice. (Sterling Fluid Systems BV) 2001 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Maintenance, dismantling, assembly Page 9 of 10 Design with heating (AY3, AYS, AYK) Insert the O-rings 41.22 and 41.23 in the cover 16.50. 16.10 41.22 41.23 Chapter 7 10.20 40.00 90.10 16. 50 90.30 Bearing design S or T : • For executions with bearing housings 55 and 65: Carry out the following steps: 1. Fit the shaft unit. 2. If the shaft is to be fitted with new bearings, they should be heated in an oil bath to a temperature of 80º C before assembling. First, install the ball bearing 32.11, then the circlip 93.21 and finally ball bearing 32.10. Make sure that the bearing is pressed home against the shoulders of the shaft. 3. If the lip seals have been removed, they must be exchanged. The lip seals should be fitted into the bearing cover with a bush, pressing on the external ring of the oil seals. The lips should point towards the bearing after installation. Pay attention to the bearing covers to avoid fitting them incorrectly. Attach the cover 16.50 and casing cover 16.10. 16.10 16.50 8. Attach the bearing housing 33.00 and the casing cover 16.10. 9. Insert the rotating part of the mechanical seal 43.30 and the distance ring 50.40. 10. Insert the key 94.01, impeller 23.00 and tighten the impeller nut 92.20. Attach the protective screens 68.10 with the hexagonal screws 90.13. 90.13 68.10 92.20 23.00 94.01 50.40 43.30 16.10 33.00 68.10 90.13 11. Insert the gasket 40.00 between the pull out unit and volute casing. Tighten hexagonal screws 90.10. For local contact details: www.sterlingfluidsystems.com 32.11 21.00 93.21 32.10 91.40 4. Install the bearing cover of the pump side with the flat gasket 40.02 and the grease nipple 63.60 if any. In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice. (Sterling Fluid Systems BV) 2001 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Maintenance, dismantling, assembly 5. When fitting the rotating unit in the bearing housing 33.00, the circlip 93.21 must be inserted in the groove in the bearing housing. 6. Insert the bearing cover 36.01 with the flat gasket 40.02 and the grease nipple 63.60 if any. 7. Mount the plug 67.20, the oil level sight glass 64.20 and the constant level oiler ( CLO ) 63.80, where oil lubrication is used. 8. Fasten pump foot 18.30 and insert the thrower 50.70. 90.14 36.01 63.60 42.10 40.02 50.70 33.00 18.30 • 93.21 93.01 40.02 42.10 36.00 63.60 94.00 90.11 Chapter 7 • For executions with mechanical seal: 9. Install the mechanical seal cover 47.10 with the mechanical seal stationary part 43.30 and its pin 56.10 if any, then place the flat gasket 40.06 and hexagonal screws 90.24. 10. Insert the shaft sleeve 52.30 with the rotating part of the mechanical seal 43.30 and the distance ring 50.40. 11. In the casing cover 16.10, insert the wear ring 50.21 with grub screws 56.00 and the studs 90.22. 40.01 52.30 50.40 43.30 16.10 90.22 40.06 47.10 56.00 50.21 56.10 90.24 90.12 For executions with stuffing box: 9. Mount the shaft sleeve 52.40 on to the shaft unit. 10. In the casing cover, insert one of the packing rings 46.10, the lantern ring 45.80, the remaining packing rings and finally the gland 45.20. 11. Fix the studs 90.21, the washers 55.40 and the nuts 92.01. Adjust the stuffing box as described in Chapter 7.4.3. 12. Mount the wear rings 50.21 with grub screws 56.00. 16.10 90.22 56.00 Page 10 of 10 50.21 46.10 45.80 90.21 For local contact details: www.sterlingfluidsystems.com 55.40 12. Join the casing cover 16.10, the bearing housing 33.00 and fasten hexagonal nuts 92.02. 92.20 93.00 40.03 23.00 94.01 16.10 90.22 92.02 45.20 40.01 52.40 92.01 Finally: 13. Insert the flat gasket 40.01, keys 94.01, impeller 23.00 and flat gasket 40.03. 14. Tighten the impeller nut 92.20 with the helicoil 93.00. 15. Insert the wear ring 50.20 with grub screws 56.00 and then, insert studs 90.20. 16. Insert flat gasket 40.00 between the unit and the volute casing 10.20. Tighten hexagonal nuts 92.00. In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice. (Sterling Fluid Systems BV) 2001 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Troubleshooting Page 1 of 1 8. Help in case of trouble 8.1 Use of trained staff Chapter 8 Trouble shooting must be undertaken only by appropriately trained personnel. 8.2 Symptoms, causes and remedies Symptom Output too low Cause - Back pressure too high. - Pump or pipework, resp., not completely filled. - Suction lift too high or positive suction head too low. - Sealing gap too large because of wear. - Wrong direction of rotation. - Casing or suction line leaks. Pump does not prime or only intermittently - Pump casing, shaft seal, foot valve or suction line leaks. - Suction lift too high or positive suction head too low. Pump leaks - Loose or jammed parts in the pump. - Casing bolts not correctly tightened. - Mechanical seal leaks. - Stuffing box leaks. Temperature of the pump increases - Seals defective. - Pump or pipework not completely filled. - Suction lift too high or positive suction head too low. Pump runs noisily - Stuffing box overtightened. - Pump is run against closed valve. - Pump or pipework not completely filled. - Suction lift too high or positive suction head too low. Motor protection switch switches off. For local contact details: www.sterlingfluidsystems.com - Pump is not properly levelled or is distorted. - Foreign material in the pump. - Pump is not properly levelled or is distorted. Remedy Check the plant for contamination. Regulate anew the operating point. Vent and fill the pump as well as the suction or inflow line. Check the liquid levels, open the shut-off valves on the suction side. Clean the filters and dirt traps installed on the suction side. Replace worn parts. Change the motor connection. Replace the casing seal. Check the flange connections. Replace the casing seal. Check the shaft seal. Check the flange connections.. Check the liquid levels, open the shut-off valves on the suction side. Clean the filters and dirt traps installed on the suction side. Open and clean the pump. Check the tightening torque of the casing bolts. Check the seal surfaces and elastomere of the mechanical seal. In case of damages exchange mechanical seal. Check the condition of the stuffing box. If possible, retighten the stuffing box, if not, replace it. Replace the seals. Vent and fill the pump as well as the suction line or inflow line. Check the liquid levels, open the shut-off valves on the suction side. Clean the filters and dirt traps installed on the suction side. Loosen the stuffing box. Open the shut-off valve on discharge side. Vent and fill the pump as well as the suction line or inflow line. Check the liquid levels, open the shut-off valves on the suction side. Clean the filters and dirt traps installed on the suction side. Check the pump installation Dismantle and clean the pump. Check the pump installation. - Operating conditions outside of performance range of pump. - Loose or jammed parts in the pump. Refer to pump operating conditions stated in technical data. Open and clean the pump. In the search to improve continuously its products, (Sterling Fluid Systems BV 2001) Sterling Fluid Systems reserves the right to modify its products at any time without prior notice. HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Technical data 9. Page 1 of 3 Technical Data For technical information about the pump or pump set, which is not described in this chapter, see the specific data sheet. Note that data relating to a specific order may conflict with information provided here. In any such case, the order specific information will override data provided in the general technical documentation. Pressure component operating limits: Material 4B Temperature -40ºC to 120ºC Pressure 16 bar Sizes All 120ºC to 170ºC 14 bar 16 bar 10 bar 14 bar 14 bar 9 bar 8 bar All 32125 to 80315 80400 to 300500 150500 32125 to 80315 80400 to 300500 150500 -20ºC to 120ºC 0B/0C/0E 120ºC to 170ºC Shaft sealing operating limits: Direction of rotation: Clockwise seen from the drive end of the pump. Materials of construction, and of shaft seals: See Chapter 2.4. Vibrations: ZLND range pumps comply with VDI 2056 and ISO 5199 Class K for pumps with a driving power of up to 15 kW and Class M with a driving power of more than 15 kW Noise levels: The noise levels of the pump comply with the Directive 001/30 - 1992 of the EUROPUMP Commission. The following table provides approximate values: LWA (dB) Shaft sealing execution 041, 052 BJ3, BJS, BJJ AF3, AX3, AY3, A93 AFS,AXS,AYS,A9S,AFK,AXK,AYK,A9K C23, C2S, C2J Temperature range -40°C to + 110°C -20°C to + 120°C -30°C to +150°C -20°C to + 180°C -40ºC to + 150ºC P (kW) ATTENTION • Chapter 9 pump without motor All indicated operating limits are not valid for all liquids which can be pumped. See technical data or delivery note. Note that additional noise can be generated by: • the driver. • a possible misalignment of the coupling. • pipework (note: the larger the pipe diameter, the lower the pipe noise). Flange locations: Axial suction flange, discharge flange radially upwards. Flanges: Material design 4B: Complies with DIN 2543 PN16. Material design 0B, 0C, 0E : DIN 2533 PN16 / 2532 PN101) Flanges drilled according to ANSI 150 can be supplied. 1) 150-200,150-250 and 200-250 For local contact details: www.sterlingfluidsystems.com In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice. (Sterling Fluid Systems BV) 2001 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Technical data Page 2 of 3 Chapter 9 Permissible branch forces and moments: Values according to ISO/DIN 5199 – Class II (1997) – Annex B, Family Nº 2 for mounting on sheet metal baseplates and frames without grouting for pumping temperatures up to 110 ºC and up to 120 ºC for grouted baseplates / frames. End branch x-Axis Top branch z-Axis • Material execution 0B / 0C / 0E: DN flanges 32 40 50 65 80 100 125 150 200 250 300 50 65 80 100 125 150 200 250 300 350 Fy (N) 400 400 540 820 820 1080 1620 1620 2160 2700 3220 600 900 900 1200 1800 1800 2400 2980 3580 4180 Fz (N) 500 500 660 1000 1000 1340 2000 2000 2680 3340 4000 540 820 820 1080 1620 1620 2160 2700 3220 3760 Fx (N) 440 440 600 900 900 1200 1800 1800 2400 2980 3580 660 1000 1000 1340 2000 2000 2680 3340 4000 4660 ∑F (N) 780 780 1040 1580 1580 2100 3140 3140 4180 5220 6260 1040 1580 1580 2100 3140 3140 4180 5220 6260 7300 My (Nm) 360 360 400 460 460 500 700 700 920 1260 1720 400 460 460 500 700 700 920 1260 1720 2200 Mz (Nm) 420 420 460 520 520 580 820 820 1060 1460 1980 460 520 520 580 820 820 1060 1460 1980 2540 Mx (Nm) 520 520 560 640 640 700 1000 1000 1300 1780 2420 560 640 640 700 1000 1000 1300 1780 2420 3100 ∑M (Nm) 760 760 820 940 940 1040 1460 1460 1920 2620 3560 820 940 940 1040 1460 1460 1920 2620 3560 4560 • Material execution 4B: Multiply by ƒ = 1,536; which is the relationship of E – modules between 1.4408 and GG-25. For local contact details: www.sterlingfluidsystems.com In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice. (Sterling Fluid Systems BV) 2001 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Techical Data Page 3 of 3 Chapter 9 Maximum permissible speeds at 50 Hz: Size Max. speed rpm 32125 32160 32200 40125 40160 40200 50125 50160 50200 65125 1) 65160 65200 1) 80160 80200 100160 100200 3600 Max. speed rpm Size 32250 40250 50250 65250 80250 2) 100250 2) 125200 4) 3000 1) For material specification 4B:the max. speed changes to : 3000 rpm 4) In material specification 0E and 4B max. speed 3000 rpm Max. speed rpm Size Max speed rpm 4) 40315 50315 4) 4) 65315 80315 80400 100315 100400 125250 125315 125400 3) 150200 150250 150315 150400 200250 2) Size 1800 rpm 1800 3) 150500 200315 200400 200500 250300 250315 250400 250500 300400 300500 1500 1500 rpm Operating range: (Continuous operation) Sizes 32125 to 80400 0,3 Qopt < Q < 1,1 Qopt 100315 to100400 125315 to 125400 150250 to 150500 100160 to 100250 0,5 Qopt < Q < 1,1 Qopt 125200 to 125250 150200 200500 to 300500 0,7 Qopt < Q < 1,2 Qopt 200250 to 200400 This operating range is applicable if waterlike liquids are pumped. If liquids having distinctly different physical properties are handled, it may be necessary to narrow the permissible operating range. See the specific performance curve for more details. For local contact details: www.sterlingfluidsystems.com In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice. (Sterling Fluid Systems BV) 2001 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Annex 10. Page 1 of 14 Chapter 10 Annex 10.1 Connections Connections for bearing brackets 25, 35 and 45. u m1 1) u k6 u k7 u m1 ufo Only for Impellers ∅125 ufo u s ufo u k4 u k5 u k8 us um1 u k3 u k4 u k5 u k8 u k6 u k7 u k3 u k1 u k2 ueo ueo uio um1 um2 ue ueo uio ufo uAL us Size 321251) 32160 32200 32250 401251) 40160 40200 40250 40315 501251) 50160 50200 50250 50315 651251) 65160 65200 65250 65315 80160 80200 80250 80315 80400 100160 100200 100250 100315 100400 125200 125250 125315 125400 150200 150250 150315 150400 200250 uAL ue um2 u eo u k1 u k2 u io : Pressure gauge. Only available on request : Pressure gauge. Only available on request : Drainage : Oil drainage : Constant level oiler (CLO) : Oil filling : Drainage for leakage. Threaded hole only available on request : Sensor um1 um2 ue ueo uio ufo uAL us u io uk1 : Quench Inlet uk2 : Heating Inlet uk3 : 051 Inlet (Stuffing box) uk4 : 052 External sealing (Stuffing box) uk5 : External Flushing uk6 : Quench Outlet uk7 : Heating Outlet uk8 : 051 Outlet (Stuffing box) uk1 uk2 uk3 uk4 uk5 uk6 uk7 G1/4 G1/8 G1/4 G1/4 ∅15.65 ∅13 M8 G1 / 4 G3/8 G1/8 G1 / 4 G1/8 G1 / 4 G1/8 G1 / 4 Drawings are indicative only. For local contact details: www.sterlingfluidsystems.com In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice © (Sterling Fluid Systems BV) 2001 uk8 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Annex Page 2 of 14 Chapter 10 Connections for bearing brackets 55 and 65 um1 ufo um3 um1 ufo uk4 uk8 uk9 View X X uk3 ue uio umo ueo uAL um1 um2 ue ueo uio ufo uAL ueo uAL um2 : Self sealing connection : Pressure/vacuum gauge. Only available on request : Drainage : Oil drainage : Constant level oiler : Oil filling : Drainage for leakage Size 150500 200315 200400 200500 250300 250315 250400 250500 300400 300500 um1 G1/4 um2 ue G1/2 For local contact details: www.sterlingfluidsystems.com ueo G1/2 G1/4 uio G1/4 ufo ∅20 um3 : uk3 : uk4 : uk8 : umo : uk9 : uAL G1/2 um3 G1/2 uk3 G1/4 In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice uio umo Pressure gauge connection 051 Inlet (Stuffing box) 052 External sealing (Stuffing box) 051 Outlet (Stuffing box) Oil level control 041 inlet (Stuffing box) uk4 G1/4 uk8 G1/4 umo G3/4 uk9 G1/4 © (Sterling Fluid Systems BV) 2001 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Annex 10.2 Page 3 of 14 Chapter 10 Table of Dimensions a d x f l 2 D øk DN 2 d 2 h d 1 k6 2 t u h DN 1 øk D 1 c m s 2 w m 1 b s 1 2 110 n 2 n 1 All dimensions in mm Size 32125 32160 32200 322501) 40125 40160 40200 40250 403151) 50125 50160 50200 50250 503151) 65125 65160 65200 65250 65315 80160 80200 80250 80315 804001) 1001601) 100200 100250 100315 100400 1252001) 125250 125315 125400 1502001) 1502501) 150315 150400 2002501) BB 25 25 25 25 25 25 25 25 35 25 25 25 25 35 25 25 25 35 35 25 35 35 35 45 35 35 35 35 45 35 35 45 45 35 35 45 45 45 DN2 32 32 32 32 40 40 40 40 40 50 50 50 50 50 65 65 65 65 65 80 80 80 80 80 100 100 100 100 100 125 125 125 125 150 150 150 150 200 Pump dimensions DN1 a f h1 50 80 360 112 50 80 360 132 50 80 360 160 50 100 360 180 65 80 360 112 65 80 360 132 65 100 360 160 65 100 360 180 65 125 470 225 65 100 360 132 65 100 360 160 65 100 360 160 65 100 360 180 65 125 470 225 80 100 360 160 80 100 360 160 80 100 360 180 80 100 470 200 80 125 470 225 100 125 360 180 100 125 470 180 100 125 470 200 100 125 470 250 125 125 530 280 125 125 470 200 125 125 470 200 125 140 470 225 125 140 470 250 125 140 530 280 150 140 470 250 150 140 470 250 150 140 530 280 150 140 530 315 200 160 470 280 200 160 470 280 200 160 530 280 200 160 530 315 200 160 590 280 h2 140 160 180 225 140 160 180 225 250 160 180 200 225 280 180 200 225 250 280 225 250 280 315 355 280 280 280 315 355 315 355 355 400 400 400 400 450 400 b 50 50 50 65 50 50 50 65 65 50 50 50 65 65 65 65 65 80 80 65 65 80 80 80 80 80 80 80 100 80 80 100 100 100 100 100 100 100 c 15 15 15 15 15 15 15 15 18 15 15 15 15 17 15 15 15 15 18 15 15 18 18 18 18 18 18 18 18 18 18 18 18 20 20 18 18 22 m1 100 100 100 125 100 100 100 125 125 100 100 100 125 125 125 125 125 160 160 125 125 160 160 160 160 160 160 160 200 160 160 200 200 200 200 200 200 200 Foot dimensions m2 n1 n2 70 190 140 70 240 190 70 240 190 95 320 250 70 210 160 70 240 190 70 265 212 95 320 250 95 345 280 70 240 190 70 265 212 70 265 212 95 320 250 95 345 280 95 280 212 95 280 212 95 320 250 120 360 280 120 400 315 95 320 250 95 345 280 120 400 315 120 400 315 120 435 355 120 360 280 120 360 280 120 400 315 120 400 315 150 500 400 120 400 315 120 400 315 150 500 400 150 500 400 150 550 450 150 500 400 150 550 450 150 550 450 150 500 400 s1* M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M16 M16 M12 M12 M16 M16 M16 M16 M16 M16 M16 M20 M16 M16 M20 M20 M20 M20 M20 M20 M20 s2* M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 w 260 260 260 260 260 260 260 260 340 260 260 260 260 340 260 260 260 340 340 260 340 340 340 370 340 340 340 340 370 340 340 370 370 340 340 370 370 430 x 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140 180 d1 24 24 24 24 24 24 24 24 32 24 24 24 24 32 24 24 24 32 32 24 32 32 32 42 32 32 32 32 42 32 32 42 42 32 32 42 42 42 End shaft l 50 50 50 50 50 50 50 50 80 50 50 50 50 80 50 50 50 80 80 50 80 80 80 110 80 80 80 80 110 80 80 110 110 80 80 110 110 110 1) Transnorm pump sizes, not included in DIN 24255 / EN 733. Flanges drilled according to ANSI 150 on request. *Holes for bolts of the dimensions indicated. For local contact details: www.sterlingfluidsystems.com In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice © (Sterling Fluid Systems BV) 2001 t 27 27 27 27 27 27 27 27 35 27 27 27 27 35 27 27 27 35 35 27 35 35 35 45 35 35 35 35 45 35 35 45 45 35 35 45 45 45 u 8 8 8 8 8 8 8 8 10 8 8 8 8 10 8 8 8 10 10 8 10 10 10 12 10 10 10 10 12 10 10 12 12 10 10 12 12 12 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Annex Page 4 of 14 Chapter 10 Table of Dimensions x f a l d2 DN2 øk D h2 d2 t d 1k6 u h1 DN1 øk D c m 2 s b s 2 1 140 n 2 n 1 w m 1 All dimensions in mm Size 1505001) 2003151) 2004001) 2005001) 2503001) 2503151) 2504001) 2505001) 3004001) 3005001) BB 55 55 55 55 55 55 65 65 65 65 DN2 150 200 200 200 250 250 250 250 300 300 Pump dimensions DN1 a f h1 200 180 670 400 250 200 670 355 250 180 670 355 250 200 670 425 300 305 655 425 300 250 670 375 300 250 720 400 300 250 720 450 350 300 720 425 350 300 720 480 h2 500 450 500 560 550 560 600 670 670 670 b 100 100 100 100 120 120 120 120 120 140 c 22 22 22 22 28 28 29 32 30 32 m1 200 200 200 200 240 240 240 240 250 250 Foot dimensions m2 n1 n2 150 640 540 150 550 450 150 550 450 150 660 560 190 700 600 190 620 520 190 700 600 190 750 650 190 760 660 190 840 720 s1* M20 M20 M20 M20 M20 M20 M20 M20 M24 M24 s2* M16 M16 M16 M16 M16 M16 M16 M16 M16 M16 w 489 489 489 489 474 489 508 503 508 508 x 180 180 180 180 180 180 180 180 180 180 d1 50 50 50 50 50 50 602) 602) 602) 602) End shaft l t 115 53.5 115 53.5 115 53.5 115 53.5 115 53.5 115 53.5 145 64 145 64 145 64 145 64 u 14 14 14 14 14 14 18 18 18 18 1) Transnorm pump sizes, not included in DIN 24255 / EN 733. Flanges drilled according to ANSI 150 on request. For these sizes the clearance corresponds to M6. *Holes for bolts of the dimensions indicated. 2) Flange connections to DIN 2501 PN 16 DIN 2501 PN 10 DN2/DN1 32 40 50 65 80 100 125 150 200 250 300 350 400 100 125 150 200 D k d2 x number 140 100 18x4 150 110 18x4 165 125 18x4 185 145 18x4 200 160 18x8 220 180 18x8 250 210 18x8 285 240 22x8 340 295 22x12 405 355 26x12 460 410 26x12 520 470 26x16 580 525 30x16 220 180 18x8 250 210 18x8 285 240 22x8 340 295 22x8 For local contact details: www.sterlingfluidsystems.com In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice © (Sterling Fluid Systems BV) 2001 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Annex 10.3 Page 5 of 14 Chapter 10 Parts list When ordering spare parts give the following information: position number, the complete pump designation and the serial number, which can be found on the nameplate fixed to the pump. Pos. Nr. Description Pos. Nr. 10.20 Volute casing 10.200 Casing plug 10.201 Hexagonal screw 10.202* O-ring 16.10 Casing cover 16.50 Cover 18.30 Pump foot 21.00* Shaft 23.00* Impeller 32.10* Ball bearing 32.11* Ball bearing 33.00 Bearing housing 36.00 Bearing cover 36.01 Bearing cover 40.00* Flat gasket 40.01* Flat gasket 40.02* Flat gasket 40.03* Flat gasket 40.05* Flat gasket 40.06* Flat gasket 41.10* Flat gasket 41.11* Flat gasket 41.22* O-ring 41.23* O-ring 42.10* Lip seal 42.11* 42.20* 43.30* 45.10 45.20 45.70* 45.80* 46.10* 47.10* 50.20* 50.21* 50.40* 50.50* 50.70* 52.30* 52.40* 55.40 56.00 56.10 63.60 63.80 Lip seal V – seal Mechanical seal Packing housing Gland Pressure ring Lantern ring Packing ring Mechanical seal cover Wear ring Wear ring Distance ring Support washer for ball bearing Thrower Shaft sleeve Shaft sleeve Washer Grub screw Pin Grease nipple Constant level oiler For local contact details: www.sterlingfluidsystems.com 64.20 67.20 68.10 70.30 73.10 73.11 90.10 90.11 90.12 90.13 90.14 90.20 90.21 90.22 90.23 90.24 90.25 90.30 90.31 90.32 90.33 90.34 90.41 90.80 91.40 91.60 92.00 92.01 92.02 92.06 92.20* 93.00* 93.01 93.21* 94.00* 94.01* 94.02* 99.99 Description Oil level sight glass Plug Protection screen Pipe Compression nut Screw connection Hexagonal screw Hexagonal screw Hexagonal screw Hexagonal screw Hexagonal screw Stud Stud Stud Hexagonal screw Hexagonal screw Stud Threaded plug Threaded plug Threaded plug Threaded plug Threaded plug Grub screw Hexagonal screw Allen head screw Dip stick Hexagonal nut Hexagonal nut Hexagonal nut Hexagonal nut Impeller nut Helicoil Washer Circlip Key Key Key Plastic plug * Recommended spare parts In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice © (Sterling Fluid Systems BV) 2001 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Annex Page 6 of 14 Chapter 10 ZLND 32125 to 200250 AB MECHANICAL SEALS 0B 2 10.20 23.00 50.40 40.00 43.30 16.10 68.10 90.13 32.10 50.50 33.00 36.00 42.20 21.00 Mechanical seal code BJ3/BJS/BJJ 92.20 94.01 90.30 90.10 Mechanical Seal code AF3/AFS/AFK 10.20 23.00 50.40 43.30 40.00 16.10 91.40 56.10 Mechanical Seal code AX3/AXS/AXK 10.20 23.00 50.40 43.30 40.00 16.10 99.99 41.23 56.10 42.11 16.50 50.70 18.30 93.01 90.12 90.11 94.00 Mechanical Seal code C23/C2S/C2J 10.20 23.00 50.40 43.30 40.00 16.10 Mechanical Seal code AY3/AYS/AYK 10.20 23.00 50.40 43.30 40.00 16.10 99.99 41.23 41.22 56.10 16.50 Mechanical Seal code A93/A9S/A9K 10.20 23.00 50.40 43.30 40.00 16.10 99.99 56.10 For local contact details: www.sterlingfluidsystems.com In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice © (Sterling Fluid Systems BV) 2001 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Annex Page 7 of 14 Chapter 10 ZLND 32125 to 200250 AC/A2 MECHANICAL SEALS 0B 2 10.20 23.00 50.40 68.10 40.00 16.10 90.13 43.30 42.10 32.10 50.50 63.80 91.60 40.02 36.00 21.00 Mechanical seal code BJ3/BJS/BJJ 92.20 94.01 90.30 Mechanical Seal code AF3/AFS/AFK 10.20 23.00 50.40 43.30 40.00 16.10 90.10 91.40 50.70 Mechanical Seal code AX3/AXS/AXK 10.20 23.00 50.40 43.30 40.00 16.10 99.99 41.23 56.10 42.11 16.50 For local contact details: www.sterlingfluidsystems.com 63.81 90.31 18.30 93.01 90.12 90.11 94.00 Mechanical Seal code C23/C2S/C2J 10.20 23.00 50.40 43.30 40.00 16.10 56.10 10.20 23.00 50.40 33.00 Mechanical Seal code AY3/AYS/AYK 10.20 23.00 50.40 43.30 40.00 16.10 99.99 41.23 41.22 56.10 16.50 Mechanical Seal code A93/A9S/A9K 43.30 40.00 16.10 99.99 56.10 In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice © (Sterling Fluid Systems BV) 2001 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Annex Page 8 of 14 Chapter 10 ZLND 32125 to 200250 AB STUFFING BOX 0B 2 10.20 23.00 68.10 40.00 16.10 40.05 90.23 45.70 45.20 90.13 52.40 32.10 50.50 33.00 36.00 42.20 21.00 Stuffing box code 041 92.20 94.01 90.30 45.10 46.10 45.80 92.01 90.10 91.40 55.40 90.21 50.70 18.30 93.01 90.12 90.11 94.00 Stuffing box code 052 10.20 52.40 23.00 For local contact details: www.sterlingfluidsystems.com 45.80 45.10 40.00 16.10 99.99 92.01 45.70 55.40 40.05 46.10 45.20 90.21 In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice © (Sterling Fluid Systems BV) 2001 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Annex Page 9 of 14 Chapter 10 ZLND 32125 to 200250 AC/A2 STUFFING BOX 0B 2 10.20 23.00 52.40 40.00 16.10 40.05 90.23 45.20 68.10 45.70 90.13 32.10 42.10 63.80 50.50 91.60 40.02 36.00 21.00 Stuffing box code 041 90.21 92.20 94.01 91.40 33.00 63.81 90.31 18.30 93.01 90.12 90.11 94.00 45.10 46.10 45.80 92.01 90.30 90.10 50.70 55.40 Stuffing box code 052 10.20 52.40 23.00 For local contact details: www.sterlingfluidsystems.com 45.80 45.10 40.00 16.10 99.99 92.01 45.70 55.40 40.05 46.10 45.20 In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice 90.21 © (Sterling Fluid Systems BV) 2001 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Annex Page 10 of 14 Chapter 10 ZLND 200315 to 300500 and 150500 AS MECHANICAL SEALS 0B 2 40.03 23.00 43.30 90.80 50.40 90.34 40.00 92.06 16.10 10.20 73.10 41.10 50.70 33.00 32.10 36.00 94.00 90.22 73.11 70.30 92.02 41.11 47.10 63.60 36.01 93.21 21.00 Mechanical seal code BJ3/BJS/BJJ 92.20 93.00 94.01 50.20 56.00 40.01 90.30 50.21 56.00 52.30 90.20 92.00 50.40 23.00 40.00 56.10 73.11 47.10 10.20 43.30 16.10 40.06 41.11 90.24 52.30 www.sterlingfluidsystems.com 90.24 18.30 90.12 90.11 90.14 32.11 93.01 42.10 40.02 Shaft seal Code C23/C2S/C2J Shaft seal Code AF3/AFS/AFK For local contact details: 40.06 50.40 23.00 40.00 52.30 73.11 47.10 10.20 43.30 16.10 40.06 41.11 90.24 In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice © (Sterling Fluid Systems BV) 2001 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Annex Page 11 of 14 Chapter 10 ZLND 200315 to 300500 and 150500 AT/A2 MECHANICAL SEALS 0B 2 10.20 40.03 50.40 23.00 73.11 90.80 16.10 41.11 90.34 40.00 92.06 73.10 41.10 90.22 70.30 92.02 50.70 67.20 93.21 90.11 94.00 47.10 90.14 32.11 33.00 32.10 21.00 Mechanical seal code BJ3/BJS/BJJ 92.20 93.00 94.01 50.20 56.00 40.01 90.30 50.21 56.00 52.30 43.30 90.20 92.00 40.06 90.24 36.01 50.40 23.00 40.00 73.11 47.10 56.10 43.30 16.10 40.06 41.11 90.24 52.30 For local contact details: www.sterlingfluidsystems.com 18.30 90.12 36.00 64.20 63.80 93.01 40.02 42.10 Shaft seal Code C23/C2S/C2J Shaft seal Code AF3/AFS/AFK 10.20 90.31 10.20 50.40 23.00 40.00 52.30 73.11 47.10 43.30 16.10 40.06 41.11 90.24 In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice © (Sterling Fluid Systems BV) 2001 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Annex Page 12 of 14 Chapter 10 ZLND 200315 to 300500 and 150500 AS STUFFING BOX 0B 2 10.20 40.03 23.00 90.80 73.11 45.80 16.10 41.11 90.34 40.00 92.06 73.10 41.10 90.22 70.30 92.02 45.20 50.70 33.00 32.10 36.00 94.00 36.01 93.21 63.60 21.00 Stuffing box code 041 92.20 93.00 94.01 50.20 56.00 40.01 90.30 50.21 56.00 46.10 90.20 52.40 92.00 55.40 90.21 92.01 90.14 18.30 90.12 90.11 32.11 93.01 40.02 42.10 Shaft seal Code 052 45.80 23.00 40.00 10.20 46.10 16.10 90.33 For local contact details: www.sterlingfluidsystems.com 45.20 55.40 90.21 92.01 In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice 52.40 © (Sterling Fluid Systems BV) 2001 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Annex Page 13 of 14 Chapter 10 ZLND 200315 to 300500 and 150500 AT/A2 STUFFING BOX 0B 2 10.20 40.03 45.80 23.00 73.11 90.80 73.10 16.10 41.11 90.34 40.00 92.06 41.10 50.70 67.20 93.21 90.11 94.00 90.22 33.00 32.10 21.00 70.30 92.02 45.20 90.14 32.11 Stuffing box code 041 92.20 93.00 94.01 50.20 56.00 40.01 90.30 50.21 56.00 46.10 90.20 52.40 92.00 55.40 90.21 92.01 36.01 90.31 18.30 90.12 36.00 64.20 63.80 40.02 42.10 93.01 Shaft seal Code 052 45.80 23.00 40.00 10.20 46.10 16.10 90.33 For local contact details: www.sterlingfluidsystems.com 55.40 90.21 45.20 92.01 In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice 52.40 © (Sterling Fluid Systems BV) 2001 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Annex Page 14 of 14 Chapter 10 COPYRIGHT WARNING Please read this notice The material you are viewing in this document is protected by Copyright and may only be used in accordance with Copyright, Designs and Patent legislation. You are not permitted to copy - either in full or in part - nor substantially extract, reproduce or re-use any of the contents of this document in any material form or in any medium without permission from the Copyright holders or their assignees. Any unlawful use of the material in this document may result in claims for civil remedies, including an injunction to restrain further use and a claim for damages; or may result in criminal penalties. For local contact details: www.sterlingfluidsystems.com In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice © (Sterling Fluid Systems BV) 2001 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 SIHI SuperNova Program Supplementary operating instructions in accordance to EC directive 94/9/EC (ATEX) for the intended use in potentially explosive atmospheres of the following pumps types, manufactured by Sterling Fluid Systems (Spain), S.A.: ZLN, ZLK and ZLI (Industrial Pumps) ULN (Self Priming Pumps) ZTN, ZTK and ZTI (Thermal Oil Pumps) ZHN, ZDN, ZEN and ZLI (Hot Water Pumps) These supplementary operating instructions give only general instructions for the use of pumps in conditions that need explosion protection. The operating instructions of the specific pump must be taken into consideration as well. Contents Page 1 General objective 2 2 2.1 2.2 2.3 2.4 Safety issues Identification of safety symbols in the supplementary operating instructions Compliance with regulations Qualification and training of personnel Safety instructions for maintenance, inspection and installation work 2 2 2 2 3 3 3.1 3.2 3.2 3.4 Instructions referring to design of pump and accessories General Pump pressure containment components Coupling, coupling guard Belt drive 3 3 3 3 3 4 4.1 4.2 4.3 4.4 Instructions referring to installation and start-up of pump sets Coupling Connection to power supply Earthing Belt drive 3 3 3 3 3 5 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 Instructions concerning operation and servicing Unauthorised modes of operation Explosion protection Pump filled and vented Marking Fluid pumped Checking of direction of rotation (see also pump-specific operating manual) Pump operating mode Temperature limits Maintenance 3 3 3 4 4 4 4 5 5 6 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 1 General Objective Pumping systems can be operated in hazardous areas. It is the obligation of the operator to define the zone and to select the pump with the correct category for this zone. The pump installation and operation must take the Operating Instructions into accounts that are described in these supplementary operating instructions. They contain important information for safe and reliable pump operation in hazardous areas. This information plus all information given for all components of the system (e.g. the operating instructions for the pump) are of vital importance to avoid risks. These supplementary operating instructions do not take into account national nor local regulations; the operator must ensure that such regulations are strictly observed by all, including the personnel in charge of the installation. For any further information or instructions exceeding the scope of this manual or in case of damage please contact Sterling Fluid Systems nearest customers service. 2 Safety issues These supplementary operating instructions contain fundamental information concerning all actions with pumping systems, when operated in hazardous areas like: installation, inspection, operation, monitoring and maintenance. Therefore these – and all other instructions with related to safety must be known and available with easy access to all personnel, which is involved in the above stated actions. Not only must the general safety instructions established in this chapter on ”Safety issues” be complied with, but also the safety instructions outlined under specific headings as well as the safety instructions contained in the specific operating manual of the specific pump. 2.1 Identification of safety symbols in the supplementary operating instructions In these supplementary operating instructions the safety instructions related to explosion protection are marked with: The sign is used to highlight safety instructions where non-compliance may pose a damage to the pump and its functions. 2.2 Compliance with regulations It is imperative to comply with the safety instructions contained in these supplementary operating instructions, the operating instructions of the pump type concerned, the relevant national and international explosion protection regulations, health and safety regulations and the operator’s own internal work, operation and safety regulations. Ex symbol relates to additional requirements, which must be complied with when the pump is operated in hazardous areas. In addition the following must be observed: If the pumps / units are located in hazardous areas, it is imperative to make sure that the correct category of pump and equipment is selected and that unauthorised modes of operation are prevented. Non-compliance may result in first: increased risk of explosion and second: the specified temperature limits might be exceeded. Non-compliance with these safety instructions may also result in the loss of any rights to claim damages. In addition to the hazards indicated in the operating manual of the relevant pump type, Non-compliance may also result in hazards to persons by explosion. 2.3 Qualification and training of personnel The personnel responsible for or involved in the installation, the operation, maintenance and inspection of the pump and the unit must be adequately qualified to carry out these works in hazardous areas. The scope of responsibility and supervision of the personnel must be exactly defined by plant management. If the staff does not have the necessary knowledge, they must be trained and instructed. The pump manufacturer or supplier on behalf of the plant management may perform this task. Moreover, plant management must ensure that the contents of the operation instructions are fully understood by plant operators and other relevant personnel such as maintenance staff. Page 2 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 2.4 Safety instructions for installation work, inspection operation and maintenance The operator is responsible to assure that all installation work, inspection, operation and maintenance must be carried out by authorised and qualified specialist personnel, which is thoroughly familiarised with the pump operating instructions and these supplementary operating instructions. If necessary, additional explosion protection regulations must be considered. 3 Instructions concerning design of pump and accessories 3.1 General The pumps and the accessories for installations in hazardous areas must comply with the relevant category of mechanical and electrical equipment. Some details are pointed out below: 3.2 Pump pressure containment components For handling inflammable fluids, the pump pressure containment components must be made of ductile material. 3.3 Coupling, coupling guard The accident prevention regulations require, that pump drives must not be operated without a coupling guard. If a customer specifically decides, not to include a coupling guard in our delivery, then the operator must provide such coupling guard himself. The coupling must be selected and sized in accordance with the instructions of the coupling manufacturer. It is important to make sure that the materials selected for coupling and coupling guard are nonsparking in the event of mechanical contact. Sterling Fluid Systems scope of supply meets this requirement. In hazardous areas coupling guards must be of non-sparking material, whereby the coupling material must be considered. 3.4 Belt drives Belts must include some electrically conductive material. 4 Instructions concerning installation and start-up of pump sets In addition to the normal installation instructions, the specific criteria for explosion proof are listed below: 4.1 Coupling The coupling must be installed, started-up and operated in accordance with the operating instructions of the coupling manufacturer. Misalignment of the coupling may result in inadmissible temperatures at the coupling and pump and motor bearings. It has to be ensured, that the half couplings are correctly aligned at all times. 4.2 Connection to power supply Only a properly trained electrician must effect connection to the power supply. The available main voltage must be checked against the data on the motor rating plate and an appropriate start-up method must be selected. It is strongly recommend to use a motor protection device (motor protection switch). In hazardous areas, compliance with national and local regulations form an additional requirement for electrical connections. 4.3 Earthing To eliminate risks due to electrostatic charging, the pump set must be earthed directly or through an earthing line. 4.4 Belt drive Belt-driven pump sets must always be earthed. The condition of the belts must be checked regularly. Page 3 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 5 Instructions concerning operation and maintenance 5.1 Unauthorised modes of operation The warranty relating to the operating reliability and safety of the unit supplied is only valid if the equipment is used in accordance with its designated use as described in the following sections of this supplementary operating manual and the pump-specific operating manual. The limits stated in the data sheet must not be exceeded under any circumstances. Any operation of the pump outside the permissible operating range and any unauthorised modes of operation may result in the specified temperature limits being exceeded (see section 5.8). 5.2 Explosion protection If the pumps / units are installed in hazardous areas where compliance with EC directive 94/9/EC is required, the measures and instructions given in the following sections 5.3 to 5.9 must be carried out with no excuse, to ensure explosion protection. 5.3 Pump filled and vented Especially dry running of a pump results in friction and non-allowed temperature rise. Therefore precautions have to be taken to prevent dry running. It is necessary that the system of suction and discharge lines and thus the wetted pump internals including seal chamber and auxiliary systems are completely filled with the fluid to be handled at all times during pump operation, so that an explosive atmosphere is prevented. If the operator cannot warrant this condition, appropriate monitoring devices must be used. Improper installation (e.g. vertical installation) may impair the self-venting properties of the seal chamber, so that gas bubbles may be collected in the pump and cause the mechanical seal to run dry. High negative pressure on the suction side (e.g. due to clogged suction-side strainers or low system pressure) may result in air intake at the shaft seal forming gas bubbles in the pump. This may also cause the mechanical seal to run dry. Suitable monitoring facilities shall be installed, if necessary. For design-inherent reasons, however, it is not always possible to exclude the existence of a certain residual volume not filled with liquid after the pump has been filled prior to start of operation. However, once the motor is started up the pumping effect will immediately fill this volume with pumped fluid. It is imperative to make sure that the seal chambers and auxiliary seal systems are properly vented from air and filled with liquid. 5.4 Marking The Ex marking on the pump only refers to the pump part, i.e. the coupling and motor must be considered separately. The coupling must have an EC Declaration of Manufacturer and the EC marking. The driver must be treated separately. Example of marking on the pump part: CE Ex II 2 G c T1 - T5 The safety instructions published in section 5.8 must be complied with. 5.5 Fluid handled Abrasive particles in the fluid handled may erode the casing walls to such an extent that fluid may escape. When handling inflammable media, it has to be ensured that the fluid does not contain any abrasive particles, or that the pump is regularly checked with respect to erosion. 5.6 Checking the direction of rotation (see also pump-specific operating manual) If the explosion hazard also exists during the installation phase, the direction of rotation must never be checked by starting up the unfilled pump unit, even for a short period, to prevent temperature increases resulting from contact between rotating and stationary components. If it is not possible to fill the pump, the direction of rotation must be checked with the pump / motor coupling removed. Page 4 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 5.7 Pump operating mode Make sure that the pump is always started up with the suction-side shut-off valve fully open and the discharge-side shut-off valve slightly open. However, the pump can also be started up against a closed swing check valve. Only after the pump has reached full rotational speed shall the discharge-side shut-off valve be adjusted to comply with the duty point. Pump operation with closed shut-off valves in the suction and / or discharge pipes is not permitted. In this case, there is a risk of the pump casing reaching a high surface temperatures after a very short time, due to a rapid temperature rise in the pumped fluid inside the pump. Additionally, the resulting rapid pressure build-up inside the pump may cause excessive stresses on the pump materials and even cause it to burst. The minimum flows indicated in the relevant pump operating manuals refer to water and water-like liquids. Longer operating periods with these liquids and at the flow rates indicated will not cause an additional increase in the temperatures on the pump surface. However, if the physical properties of the fluids handled are different from water, it is essential to check if an additional heat build-up may occur and if the minimum flow rate must therefore be increased. The calculation formula below can be used to check if an additional heat build-up may lead to a dangerous temperature increase at the pump surface. To = Tf + ∆ϑ ∆ϑ = ((g * H) / (c * η))*(1 - η) c g H Tf To η ∆ϑ Specific heat of liquid [J / kg K] 2 Acceleration due to gravity [m /s] Pump head [m] Temperature of fluid handled [º C] Temperature of casing surface [º C] Pump efficiency [-] Temperature difference [º C] 5.8 Temperature limits In normal pump operation, the highest temperatures are to be expected on the surface of the pump casing, at the shaft seal, at the bearing areas and at the pump shaft end in close coupled executions. Unless the pump is equipped with an additional heating facility, the surface temperature at the pump casing will correspond to the temperature of the fluid handled, assuming that the pump surface is freely exposed to the atmosphere. In any case, responsibility for compliance with the specified fluid temperature (operating temperature) lies with the plant operator. The maximum permissible fluid temperature depends on the temperature class to be complied with. The following limits for the maximum permissible fluid temperature must be observed for the individual temperature classes as per EN13463-1 given below (temperature increase in the shaft seal area, if any, has been taken into consideration): Temperature classes as per EN 13463-1: Permissible surface temperature Max. permissible fluid temperature for compliance with temperature class T5 T4 T3 T2 T1 100 º C 135 º C 200 º C 300 º C 450 º C 80 º C 115 º C 180 º C 280 º C Temperature limit of pump Safety note: The permissible operating temperature of the pump in question is indicated in the technical data. If the pump is to be operated at a higher temperature, the technical data are missing or if the pump is part of a pool of pumps, the maximum permissible operating temperature must be requested from the pump manufacturer. Page 5 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Because of the very close contact between pumps and motors in close coupled design (ZLK and ZLI, Industrial Pumps; ZTK and ZTI, Thermal Oil Pumps; and ZLI, Hot Water Pumps), there is a thermal influence between pump and motor. Especially for motors with protection type EExe (increased safety) the possibility exists that the declaration of conformity looses its validity, as for the EC type examination an ambient temperature of 40°C is taken as a basis. This admissible ambient temperature could be exceeded in the area of the motor flange when pumping hot liquids. In the event of fluid temperature above 80ºC, the temperature category of the unit / set is determined by the pump not by the motor. The motor is usually rated for continuous operation at the data indicated in the technical data. Frequent motor start-ups may result in increased surface temperatures at the motor. Contact the motor manufacturer, if necessary. Based on ambient temperatures of max. 40 º C and assuming that the pump unit is properly serviced and operated and that the surfaces in the bearing area are freely exposed to the atmosphere, compliance with temperature class T4 is warranted for surfaces in the area of the rolling element bearings. If temperature classes T5 (100ºC) and T6 (85ºC) have to be complied with, special measures may have to taken with regard to bearing temperature. In such cases, and if ambient temperatures are higher, contact the manufacturer. Operator’s errors or malfunctions may result in substantially higher temperatures. Please refer to section 5.1 in this context. Mechanical seals may exceed the specified temperature limits if run dry. Dry running may not only result from an inadequately filled seal chamber, but also from excessive gas content in the fluid pumped. Pump operation outside the specified operating range may also result in dry running. Shaft seals shall be regularly checked for leakage. The above stated and also stated in other paragraphs related to the mechanical seal, is also applicable for any shaft sealing execution (i.e. packing rings, lip seal rings, etc.) In any case the operator has the responsibility to check the real compatibility between the normal leakage of the fluid and the atmosphere in the case of shaft sealing made by packing rings. It has to be verified, that V-rings are properly fitted to the shaft. Only proper contact should be exist between the sealing lip and the shaft. 5.9 Maintenance Only a pump set, which is properly operated and maintained in perfect technical condition, will give safe and reliable operation. This also applies to the reliable function of the rolling element bearings whose actual lifetime largely depends on the operating mode and operating conditions. Regular checks of the lubricant and the running noises will prevent the risk of excessive temperatures as a result of bearings running hot or defective bearing seals. The correct function of the shaft seal must be checked regularly. Any auxiliary systems installed must be monitored, if necessary, to make sure they function correctly. Static sealing elements shall be regularly checked for leakage. The coupling guard and any other guards of fast rotating components must be regularly checked for deformation and sufficient distance from rotating elements. Regularly verify the correct position and the status of plastic components exposed to the atmosphere. It is strongly recommended to draw up a maintenance schedule, which includes the above-mentioned points. In case of repair only original Sterling Fluid Systems spare parts must be used, which comply with the corresponding EC Directives. Sterling Fluid Systems In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice For local contact details: www. sterlingfluidsystems.com Page 6 HAMMELMANN Code no.: 04.03226.0769 Type 32-200 Sterling Fluid Systems (Spain), S.A. Vereda de los Zapateros, s/n 28223 Pozuelo de Alarcon (Madrid) España Phone: 0034 91 7091310, Fax: 0034 91 7159700 Declaration of Conformity In the sense of the EU Directive 98/37/EC, Appendix II B Herewith we declare that the pumps of the series ZLN in the version supplied by us comply with the following relevant regulations: EU Machine Directive 98/37/EC, Appendix I No. 1 EU Directive 94/9/EC, Group II, category 2, atmosphere G (Ex II 2 G c T1-T5) And that is destined for installation in a machine / assembly with other machines to form a single machine and that it may not be commissioned until it has been determined that the machine in which this pump is to be installed or with which this pump is to be assembled complies with the clauses of the EU Machine Directive in the version of 98/37/EC and 94/9/EC. Harmonised standards used, in particular: EN 809 EN 292 part 1 EN 292 part 2 EN 1127 - 1 EN 13463 - 1 prEN 13463 - 5 In the actual version. National technical standards and specifications used, in particular: UNE-EN 809 UNE-EN 292-1 UNE-EN 292-2 UNE-EN 1127-1 UNE-EN 13463 - 1 Unauthorised alterations of the pump unit and any use not in accordance with valid regulations and / or intended use result in a loss of validity of this declaration. Sterling Fluid Systems, (Spain), S.A. Business Unit Manager J. A. Cobo June 10, 2003 HAMMELMANN Code no.: 04.03235.0134 K 3000.1091.1 GB Zentralschmiertechnik BAIER + KÖPPEL Instructions for use and maintenance Gear pumps Taking the unit into operation Installation The gear pump may be installed in vertical as well as in horizontal position. Angular bases and pump supports required for that purposeare available. For direct---drive operation the pump is equipped with an elastic 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 incorrectly 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, indicates 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 HAMMELMANN Code no.: 04.03235.0134 K 3000.1091.2 GB Zentralschmiertechnik BAIER + KÖPPEL Maximum pressure The pump must be protected against excessive pressure, by means of a pressure restrictor valve. Setting 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 accordance 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. D -- 91253 Pegnitz -- Postfach 1320 -- Telefon 09241/729-- 0 -- FAX 09241/72950 HAMMELMANN Code no.: 04.03235.0134 K 3000.1091.3 GB Zentralschmiertechnik BAIER + KÖPPEL Malfunction No. 1: The pump does not supply fluid. 1.1 The pump does not suck ---in any fluid Possible reasons Remedies 1.1.1 The plug was not removed from the suction pipe. 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 is too low. Extend the suction pipe, top up with oil. 1.1.4 Flow resistance in the suction pipe is too high (excessive depressiopn). Increase the tube diameter; straighten the suction pipe; 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 pre ---load, so that bleeding of the pump is impossible. Change over the depressurized circulation, or bleed the pump by opening the pressure socket. 1.1.7 Excessive viscosity of the pressure fluid, or excessive cooling of the pressure fluid. Fill the system using a pressure fluid, the viscosity of which is suitable for the service temperature. 1.2 Supply is interrupted even if the drive system is okay. Possible reasons Remedies 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 required for suction. Top up with pressure fluid. Malfunction No. 2: The pump supplies fluid, but there is lack of pressure, or pressure is not satisfactory Possible reasons Remedies 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 damaged, or the spring is broken. Clean the pressure relief valve, or replace the defective spring. 2.3 Bresakage of tube underneath the tank cover, or threaded tube connections not tightened in the proper way. Repair the defectiveness. 2.4 Substantial wear of the pump. Have the pump repaired by the factory. D -- 91253 Pegnitz -- Postfach 1320 -- Telefon 09241/729-- 0 -- FAX 09241/72950 HAMMELMANN Code no.: 04.03235.0134 K 3000.1091.4 GB Zentralschmiertechnik BAIER + KÖPPEL Malfunction No. 3: Excessive pump noise Possible reasons Remedies 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 ) D -- 91253 Pegnitz -- Postfach 1320 -- Telefon 09241/729-- 0 -- FAX 09241/72950 HAMMELMANN Code no.: 04.03235.0134 SAFETY DATA SHEET Coolant VCS Ready Mixed 21485015 Date of issue : 2012-01-26. Version : 1.01 1. IDENTIFICATION OF THE SUBSTANCE/MIXTURE AND OF THE COMPANY/UNDERTAKING 1.1 Product identifier Product name : Coolant VCS Ready Mixed 4 Product no. : 21485015 1.2 Relevant identified uses of the substance or mixture and uses advised against Product use : Coolant and antifreeze. 1.3 Details of the supplier of the safety data sheet Supplier : AB Volvo Penta SE 405 08 Gothenburg Sweden Telephone no.: : +46-31-66 67 50 E-mail address : sds@volvo.com 1.4 Emergency telephone number Emergency phone : +46-31-66 67 50 (during office hours) 2. HAZARDS IDENTIFICATION 2.1 Classification of the substance or mixture : Mixture Product definition Classification according to Directive 1999/45/EC [DPD] The preparation is classified as dangerous according to Directive 1999/45/EC and its amendments. Classification : Xn; R22 Human health hazards : Harmful if swallowed. See section 11 for toxicological information and section 12 for ecotoxicological information. See Section 16 for the full text of the R phrases or H statements declared above. 2.2 Label elements Hazard symbol or symbols Indication of danger Risk phrases Safety phrases : : Harmful : R22- Harmful if swallowed. : S2- Keep out of the reach of children. S13- Keep away from food, drink and animal feeding stuffs. S24/25- Avoid contact with skin and eyes. S46- If swallowed, seek medical advice immediately and show this container or label. Hazardous ingredients : ethanediol 2.3 Other hazards Other hazards which do not : Not available. result in classification 3. COMPOSITION/INFORMATION ON INGREDIENTS Substance/mixture : Mixture Classification Ingredient name ethanediol Hexanoic acid, 2-ethyl-, sodium salt Date of issue Identifiers EC: 203-473-3 CAS: 107-21-1 Index: 603-027-00-1 EC: 243-283-8 CAS: 19766-89-3 : 2012-01-26. % 67/548/EEC Regulation (EC) No. 1272/2008 [CLP] Type 30 - 60 Xn; R22 Acute Tox. 4, H302 STOT RE 2, H373o [1] [2] 1-5 Repr. Cat. 3; R63 Repr. 2, H361d [1] 1/6 Coolant VCS Ready Mixed 21485015 3. COMPOSITION/INFORMATION ON INGREDIENTS See Section 16 for the See Section 16 for the full text of the R-phrases full text of the H statements declared declared above. above. There are no additional ingredients present which, within the current knowledge of the supplier and in the concentrations applicable, are classified as hazardous to health or the environment and hence require reporting in this section. Type [1] Substance classified with a health or environmental hazard [2] Substance with a workplace exposure limit [3] Substance meets the criteria for PBT according to Regulation (EC) No. 1907/2006, Annex XIII [4] Substance meets the criteria for vPvB according to Regulation (EC) No. 1907/2006, Annex XIII Occupational exposure limits, if available, are listed in Section 8. 4. FIRST AID MEASURES 4.1 Description of first aid measures Inhalation : If inhaled, remove to fresh air. : Wash with soap and water. Get medical attention if symptoms occur. Skin contact Eye contact : In case of contact with eyes, rinse immediately with plenty of water. Get medical attention if symptoms occur. : Call medical doctor or poison control centre immediately. (Coolant. Contains ethylene glycol) Ingestion Wash out mouth with water. If affected person is conscious, give plenty of water to drink. Do not induce vomiting unless directed to do so by medical personnel. Protection of first-aiders : Not applicable 4.2 Most important symptoms and effects, both acute and delayed Potential acute health effects Inhalation Skin contact Eye contact Ingestion : Slightly irritating to the respiratory system. Long-term exposure may cause headache, nausea or weakness. : Defatting to the skin. : Slightly irritating to the eyes. : Harmful if swallowed. May be fatal if swallowed. Exposure can cause stomach pains, vomiting and diarrhoea. loss of consciousness or coma Over-exposure signs/symptoms Inhalation : No specific data. Skin contact : No specific data. Eye contact : May cause eye irritation. Ingestion : No specific data. 4.3 Indication of any immediate medical attention and special treatment needed Specific treatments : No specific treatment. See Section 11 for more detailed information on health effects and symptoms. 5. FIRE-FIGHTING MEASURES 5.1 Extinguishing media Suitable Not suitable : Recommended:, alcohol-resistant foam, CO2, powders : Do not use water jet. 5.2 Special hazards arising from the substance or mixture Hazardous combustion : Decomposition products may include the following materials: Hydrocarbon. products carbon oxides 5.3 Advice for firefighters Special precautions for fire-fighters : Fire-fighters should wear appropriate protective equipment and self-contained breathing apparatus (SCBA) with a full face-piece operated in positive pressure mode. 6. ACCIDENTAL RELEASE MEASURES 6.1 Personal precautions, protective equipment and emergency procedures : Refer to protective measures listed in sections 7 and 8. For non-emergency personnel For emergency responders 6.2 Environmental precautions : If specialised clothing is required to deal with the spillage, take note of any information in Section 8 on suitable and unsuitable materials. See also the information in "For non-emergency personnel". : Avoid dispersal of spilt material and runoff and contact with soil, waterways, drains and sewers. Inform the relevant authorities if the product has caused environmental pollution (sewers, waterways, soil or air). 6.3 Methods and materials for containment and cleaning up Spill Date of issue : Contain and collect spillage with non-combustible, absorbent material e.g. sand, earth, vermiculite or diatomaceous earth and place in container for disposal according to local regulations (see section 13). Do not allow to enter drains or watercourses. If the product contaminates lakes, rivers, or sewers, inform the appropriate authorities in accordance with local regulations. : 2012-01-26. 2/6 Coolant VCS Ready Mixed 21485015 6. ACCIDENTAL RELEASE MEASURES 6.4 Reference to other sections : See Section 1 for emergency contact information. See Section 8 for information on appropriate personal protective equipment. See Section 13 for additional waste treatment information. 7. HANDLING AND STORAGE 7.1 Precautions for safe handling Protective measures : Avoid contact with eyes, skin and clothing. Avoid exposure during pregnancy. Wash thoroughly after handling. Avoid contact of spilt material and runoff with soil and surface waterways. Advice on general occupational hygiene 7.2 Conditions for safe storage, including any incompatibilities 7.3 Specific end use(s) Recommendations Industrial sector specific solutions : Wash hands, forearms and face thoroughly after handling chemical products, before eating, smoking and using the lavatory and at the end of the working period. Wash contaminated clothing before reusing. : Keep container tightly closed in a cool, well- ventilated place. Do not store in unlabelled containers. : Coolant and antifreeze. : Not available. 8. EXPOSURE CONTROLS/PERSONAL PROTECTION 8.1 Control parameters Occupational exposure limits Ingredient name ethanediol Occupational exposure limits EU OEL (Europe, 4/2006). Absorbed through skin. Notes: Indicative Limit value: 20 ppm 8 hour(s). Limit value: 52 mg/m³ 8 hour(s). Short term limit value: 40 ppm 15 minute(s). Short term limit value: 104 mg/m³ 15 minute(s). Derived effect levels Product/ingredient name ethane-1,2-diol Type Exposure DNEL Long term Dermal DNEL DNEL Long term Inhalation Long term Dermal DNEL Long term Inhalation Value 106 mg/kg bw/day 35 mg/m³ 53 mg/kg bw/day 7 mg/m³ Population Effects Workers Systemic Workers Man via the environment Man via the environment Local Systemic Local Predicted effect concentrations No PECs available. 8.2 Exposure controls Appropriate engineering controls : Provide adequate ventilation. Where reasonably practicable, this should be achieved by the use of local exhaust ventilation and good general extraction. If workers are exposed to concentrations above the exposure limit, they must use appropriate, certified respirators. Individual protection measures Hygiene measures : Wash hands, forearms and face thoroughly after handling chemical products, before eating, smoking and using the lavatory and at the end of the working period. Personal protective equipment Respiratory protection Hand protection Eye protection Environmental exposure controls : In case of insufficient ventilation, wear suitable respiratory equipment. : For prolonged or repeated handling, use gloves : neoprene , nitrile , natural rubber (latex) , or PVC . : Use safety eyewear designed to protect against splash of liquids. : Do not allow to enter drains or watercourses. 9. PHYSICAL AND CHEMICAL PROPERTIES 9.1 Information on basic physical and chemical properties Appearance : Liquid. Physical state : Yellow. Colour : Slight Odour Odour threshold : Not available. : Not available. pH Melting point/freezing point : Not available. Date of issue : 2012-01-26. 3/6 Coolant VCS Ready Mixed 21485015 9. PHYSICAL AND CHEMICAL PROPERTIES Initial boiling point and boiling range : >175°C (>347°F) Flash point : Closed cup: >115°C (>239°F) Evaporation rate Flammability (solid, gas) Burning time Burning rate Upper/lower flammability or explosive limits : : : : : Not available. Not available. Not applicable. Not applicable. Not available. Vapour pressure Vapour density Relative density Density Solubility Partition coefficient: noctanol/water Auto-ignition temperature Decomposition temperature Viscosity Explosive properties Oxidising properties : : : : : : Not available. Not available. 1,04 1,04 g/cm3 [20°C (68°F)] Easily soluble in the following materials: cold water and hot water. Not available. : Not available. : Not available. : Not available. : Not available. : Not available. 9.2 Other information No additional information. 10. STABILITY AND REACTIVITY 10.1 Reactivity : No specific test data related to reactivity available for this product or its ingredients. 10.2 Chemical stability : Stable under recommended storage and handling conditions (see section 7). 10.3 Possibility of hazardous : Under normal conditions of storage and use, hazardous reactions will not occur. reactions 10.4 Conditions to avoid 10.5 Incompatible materials 10.6 Hazardous decomposition products : No specific data. : Reactive or incompatible with the following materials: acids oxidizing materials : Decomposition products may include the following materials: Hydrocarbon. carbon oxides 11. TOXICOLOGICAL INFORMATION 11.1 Information on toxicological effects Potential acute health effects Inhalation : Slightly irritating to the respiratory system. Long-term exposure may cause headache, nausea or weakness. Skin contact : Defatting to the skin. Eye contact : Slightly irritating to the eyes. Ingestion : Harmful if swallowed. May be fatal if swallowed. Exposure can cause stomach pains, vomiting and diarrhoea. loss of consciousness or coma Over-exposure signs/symptoms : No specific data. Inhalation Skin contact : No specific data. : May cause eye irritation. Eye contact : No specific data. Ingestion Relevant information for the mixture and/or the ingredients is presented below. Acute toxicity Product/ingredient name ethanediol Result Species LDLo Oral Human Dose 786 mg/kg Exposure - Harmful or fatal if swallowed. Ingestion: kidney abnormalities Contains material which can cause birth defects. Teratogenicity Product/ingredient name Result Hexanoic acid, 2-ethyl-, sodium Positive salt Species - Dose - Exposure - Potential chronic health effects Date of issue : 2012-01-26. 4/6 Coolant VCS Ready Mixed 21485015 11. TOXICOLOGICAL INFORMATION General Developmental effects Other information : Repeated or prolonged contact with the preparation may cause removal of natural fat from the skin, resulting in non-allergic contact dermatitis and absorption through the skin. : Contains material which can cause birth defects. : Not available. 12. ECOLOGICAL INFORMATION 12.1 Toxicity Environmental effects : Ecotoxicological data on the substances included in this product show that the product is not classified as harmful to the environment. 12.2 Persistence and degradability Not available. 12.3 Bioaccumulative potential Not available. 12.4 Mobility in soil Soil/water partition coefficient (KOC) : Not available. Mobility : Water-soluble liquid 12.5 Results of PBT and vPvB assessment PBT vPvB 12.6 Other adverse effects : Not applicable. : Not applicable. : No known significant effects or critical hazards. 13. DISPOSAL CONSIDERATIONS 13.1 Waste treatment methods Product Methods of disposal : Waste must be disposed of in accordance with federal, state and local environmental control regulations. Hazardous waste : This product is listed as Hazardous by the EU Directive on hazardous waste. Dispose of according to all national and local applicable regulations. European waste catalogue (EWC) Waste code 16 01 14* Waste designation antifreeze fluids containing dangerous substances Packaging Methods of disposal Special precautions : Waste packaging should be recycled. Incineration or landfill should only be considered when recycling is not feasible. : This material and its container must be disposed of in a safe way. Care should be taken when handling emptied containers that have not been cleaned or rinsed out. Empty containers or liners may retain some product residues. Avoid dispersal of spilt material and runoff and contact with soil, waterways, drains and sewers. 14. TRANSPORT INFORMATION ADR/RID IMDG IATA 14.1 UN number Not regulated. Not regulated. Not regulated. 14.2 UN proper shipping name 14.3 Transport hazard class(es) - - - - - - No. No. Not available. Not available. 14.4 Packing group 14.5 Environmental No. hazards 14.6 Special precautions for user Not available. 14.7 Transport in bulk according to Annex II of MARPOL 73/78 and the IBC Code Date of issue : Not available. : 2012-01-26. 5/6 Coolant VCS Ready Mixed 21485015 15. REGULATORY INFORMATION 15.1 Safety, health and environmental regulations/legislation specific for the substance or mixture EU Regulation (EC) No. 1907/2006 (REACH) Annex XIV - List of substances subject to authorisation Substances of very high concern None of the components are listed. Other EU regulations Product use : Classification and labeling have been determined according to EU Directives 67/548/EEC and 1999/45/EC (including amendments) and take into account the intended product use. - Consumer applications, Industrial applications. 16. OTHER INFORMATION Full text of abbreviated R phrases : R63- Possible risk of harm to the unborn child. R22- Harmful if swallowed. Full text of classifications [DSD/DPD] : Repr. Cat.3 - Toxic to reproduction Category 3 Xn - Harmful Full text of abbreviated H statements : H302 H361d H373o Full text of classifications [CLP/GHS] : Acute Tox. 4, H302 Repr. 2, H361d STOT RE 2, H373o Harmful if swallowed. Suspected of damaging the unborn child. May cause damage to organs through prolonged or repeated exposure if swallowed. ACUTE TOXICITY: ORAL - Category 4 TOXIC TO REPRODUCTION [Unborn child] - Category 2 SPECIFIC TARGET ORGAN TOXICITY (REPEATED EXPOSURE): ORAL [kidneys] - Category 2 History Date of issue / Date of : 2012-01-26. revision Version : 1.01 Conforms to 1907/2006/EC, Article 31 Indicates information that has changed from previously issued version. HAMMELMANN Code no.: 04.05866.0011 Type S-050 S-050 AUTOMATIC AIR RELEASE VALVE "SEGEV" PAT. PEND Lightweight, small dimensions, simple and reliable structure. The body is made of high strength plastic, and all operating parts are made of specially selected corrosion resistant materials. A.R.I patent, Rolling Seal Mechanism: ∞ Dramatically reduces the possibility of obstruction by debris. ∞ Discharges high air flow rates upto 160 m3/h. ∞ One size orifice for a wide pressure range (up to 16 bar). ∞ Self cleaning mechanism. Working pressure range: 0.2-16 bar (3-230 psi). Available in 1/2" (15mm), 3/4" (20mm), 1" (25mm) BSPT/NPT threaded. Option S-050-VAC: vacuum check. Available as a valve that will only release air from the system and will not admit air to the system in vacuum condition. Ordering A.R.I ECS0502000 Upon ordering, please specify: model, size, working pressure, threads standard and type of liquid. Flow Control Accessories Kfar Charuv, 12932 Israel Tel. 972-6-6761988 Fax. 972-6-6763402 http://arivalves.com HAMMELMANN Code no.: 04.05866.0011 Type S-050 PARTS LIST AND SPECIFICATION A 1 2 3 4 No. Part Material 1. Body Reinforced Nylon 2. Rolling Seal Rubber E.P.D.M 3. Clamping Stem Reinforced Nylon 4. Float Foamed Polypropylene 5. O-Ring BUNA-N 6. Base Reinforced Nylon or Brass ASTM B124 5 B 6 AUTOMATIC AIR DISCHARGE CHART Pressure Bar 20 10 0 50 100 150 200 3 Flow m /h DIMENSIONS AND WEIGHTS Nominal Size A B Weight Kg 15mm 20mm 25mm 75 140 0.3 Plastic Base 1/2", 3/4", 1" * Orifice size Area: 12mm2 0.65 Brass Base
