HDP 502 S 110050

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
Machine no. : B7.02502.0210 http://www.hammelmann.de
Page: 1
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. 04.00190.0006 2 Stück
Battery box no. 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
Page: 2
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
Page: 3
360 04.04611.0065 CONNECTION HOSE 4,00 m

3m
370 04.04475.0160 CLAMP 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. HAMMELMANN GmbH

B7.02502.0210
Machine No. Carl-Zeiss-Str. 6 - 8
Unsere Auftrags-Nr.
KA 222274 D-59302 Oelde
Our Order No.
Tel.: +49 (0)2522/76-0
Bestell-Nr. e-mail: mail@hammelmann.de
I00010227 - Doornbos http: www.hammelmann.de
P. Order No.
Druckregelautomatik Eingangsdrehzahl / Motordrehzahl

---------------------------------------- 1800
Pressure unloader Input speed / Motor r.p.m. min-1
Druckregelventil / Bypassventil 00.05865.0146 + Öldruck
8,0
Pressure relief valve / Bypass valve 00.06428.0029 Oil pressure bar
Anzahl der Tellerfedern Mediumdruck
---------------------------------------- 1000
Number of Disc-springs Medium pressure bar
Schichtung der Tellerfedern Fördermenge
---------------------------------------- 264
Spring pack arrangement Output m 3 /h l/min
Distanzhülse / Steuerdruck Plungerkühlwasser
3,1 bar 11,6 / 32°C
Washer / Control pressure Pisten cooling water l/min / °C
Sicherheitsventil / Berstscheibensicherung Ansprechdruck
Safety valve / Burst disc / / Opening Pressure bar
1400
Druckwächter Öl E-Motor ex 50 Hz
Oil pressure switch D-Motor 60 Hz
Druckwächter Medium Antriebsleistung
478
nicht vorhanden / not installed
Medium pressure switch Motor rating kW

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

Überlast E-Motor Gesamtlaufzeit – Std.
1,75
Overload E-Motor Total – Test – Time hr.
Schaltschrank (ohne Pumpenüberwachung) unter Last
Switchboard (without pump control unit) under Load Std./hr. 1,5
Schaltschrank (Überwachungsgerät, Pumpe-Motor) Geprüft nach EG-Maschinenrichtlinie
Switchboard (control unit, pump-motor) Gerätesicherheitsgesetz
ja / yes
Tested in accordance with E.U. Machine
Betriebsstundenzähler Regulations governing operational nein / no
Operating hours counter safety of equipement.
Bypasssteuerventil Druckwächter Luft ja / yes
Bypass solenoid valve Air pressure sensor nein / no
Umschaltventil / Magnetventil Kühlwassermenge
20
Multi tool valve / Changeover valve Cooling water quantity Ltr./ min.
Temperaturmessung nach Erreichen der Beharrungstemperatur
Temperature measurement only when steady state temperature reached
Nr. Name Datum Zeit IR-Temp IR-Min IR-Max Mat. Name

1 TS1 Temp.Cranks.bear 06.03.2017 13:54:43 56,2 56,2 56,4 Free
2 TS2 Temp.Cranks.bear 06.03.2017 13:54:45 55,9 55,9 56,1 Free
3 TS3 Driveshaft bear. 06.03.2017 13:54:47 56,4 56,4 56,4 Free
4 TS4 Driveshaft bear. 06.03.2017 13:54:52 57,4 57,2 57,5 Free
5 TS5 Oiltemperature 06.03.2017 13:55:00 52,8 52,8 53,5 Free
6 TS6 Oil Cooler out 06.03.2017 13:55:06 43,8 43,5 43,8 Free
7 TS7 Coolingwater inl 06.03.2017 13:55:09 28,2 28,2 28,5 Free
8 TS8 Coolingwater out 06.03.2017 13:55:18 33,9 33,9 34,6 Free
9 TS9 Crank sec.gener. 06.03.2017 13:55:22 53,3 53,1 53,8 Free
10 TS10 Temp.Pisten 06.03.2017 13:55:26 33,8 33,4 34,8 Free
11 TS11 Temp.Crosshead 06.03.2017 13:55:28 54,9 54,7 54,9 Free
12 TS12 Ambient Temp. 06.03.2017 13:55:34 8,7 8,7 9,3 Free
Qualitätsprüfung Der Abnahmeingenieur Datum

Quality Control Test-Engineer Date
Name:
Unterschrift / Signature J. Vöge 07.03.2017

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
Déclaration de conformité CE
EG-Konformitätserklärung EC-Declaration of Conformity
conformément à la directive CE
nach EG-Richtlinie 2006/42/EG, according to E.C. Directive
sur les machines 2006/42/CE,
Anhang II, Nr. 1A 2006/42/EC, Appendix II, No 1A
Annexe II, N° 1A
Hiermit erklären wir, dass die nachstehend We hereby declare that the machine
Par la présente, nous déclarons que la
bezeichnete Maschine in ihrer Konzipierung detailed below has been designed,
conception et la construction ainsi que le
und Bauart sowie in der von uns in Verkehr constructed and tested to fully comply with
modèle mis en circulation de la machine ci-
gebrachten Ausführung den grundlegenden the health and safety requirements of the
dessous correspondent aux exigences de
Sicherheits- und Gesundheitsanforderungen E.C. Directive 2006/42/EC (Directive
base en matière de sécurité et de santé de
der EG-Richtlinie 2006/42/EG (Maschinen- relating to Machinery).
la directive 2006/42/CE sur les machines.
Richtlinie) entspricht.
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.
Bezeichnung der Maschine: Hochdruckpumpenaggregat HDP 502

Machine description: High pressure pump unit HDP 502
Désignation de la machine: Groupe de pompe à haute pression HDP 502
Maschinentyp:
Machine designation: 09.63502.9002
Type de machine:
Maschinen-Nr.:
Machine No.: B7.02502.0210
No de machine:
Weitere, zutreffende EG-Richtlinien: Other appropriate E.C. Directives: Autres directives CE concernées:
EG-Richtlinie 2014/30/EU E.C. Directive 2014/30/EU Directive CE sur la comptabilité

(EMV-Richtlinie) (EMC directive) électromagnétique 2014/30/EU
Angewandte harmonisierte Normen: Used harmonised standards: Normes harmonisées appliquées:
EN 809 EN 1829-1 EN 60204-1 EN 61000-6-2
Angewandte nationale Normen und National standards and technical Normes nationales et spécifications
technische Spezifikationen: specifications: techniques appliquées:
- -
Hersteller-Unterschrift Manufacturer’s signature Signature du fabricant
07.03.2017
TB 008/0106
Datum / Date / Date Geschäftsführer General Manager Gérant

Funktion des Unterzeichners Position of Signatory Fonction du signataire
High pressure pump unit
HDP 502 / S 1100-50

HDP 502 / S 1100-50
2017
Made in Germany
Issue: 03.2017
No.: HDP 502 / S 1100-50 Contents
Page 2, Issue: 03.2017
1 Contents
1 Contents ............................................................................................................................................................ 2
2 Foreword ........................................................................................................................................................... 5
3 Technical data ................................................................................................................................................... 6
3.1 Main dimensions .......................................................................................................................................... 6
3.2 Performance data: High pressure pump ...................................................................................................... 8
3.3 Performance data: Diesel engine................................................................................................................. 8
3.4 Batteries ....................................................................................................................................................... 8
4 Safety ................................................................................................................................................................. 9
4.1 Dangers arising from non observance of safety instructions ....................................................................... 9
4.2 Safety conscious working ............................................................................................................................ 9
4.3 Personnel qualification and training ............................................................................................................. 9
4.4 Precise safety instructions for the operator ................................................................................................. 9
4.5 Danger symbol ........................................................................................................................................... 11
4.6 Safety during inspection, maintenance and repair ..................................................................................... 12
4.7 Forbidden practices ................................................................................................................................... 12
4.8 Additional warnings .................................................................................................................................... 12
5 General.............................................................................................................................................................13
5.1 Introduction ................................................................................................................................................ 13
5.2 Application.................................................................................................................................................. 13
5.3 General permissible operational conditions ............................................................................................... 13
5.4 Copyright .................................................................................................................................................... 14
5.5 Warranty terms........................................................................................................................................... 14
6 Transportation ................................................................................................................................................15
6.1 Packing ...................................................................................................................................................... 15
6.2 Transportation ............................................................................................................................................ 16
6.3 Transport .................................................................................................................................................... 16
6.4 Protection ................................................................................................................................................... 16
7 Construction & Description ...........................................................................................................................17
7.1 Construction ............................................................................................................................................... 17
7.1.1 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 No.: HDP 502 / S 1100-50
7.3.1 Electronic pressure transmitter 04.00829.0093 ...................................................................................... 26

7.3.2 Electronic pressure transmitter 04.00829.0056 ...................................................................................... 27
7.3.3 Solenoid Valve 04.05875.0107 ............................................................................................................... 28
7.3.4 Electronic temperature transmitter 04.05630.0074 ................................................................................ 29
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

No.: HDP 502 / S 1100-50 Contents
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

Foreword No.: HDP 502 / S 1100-50
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
Type: HDP 502 / S 1100-50
Serial no.: B7.02502.0210
Date: 2017
Pos : 5 /xxxxxxx xxxxxx xxxxxx @ 0\mod6_2.doc x @ 1188 @ @ 1

No.: HDP 502 / S 1100-50 Technical data
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

Technical data No.: HDP 502 / S 1100-50
Weight of the pump: approx. 1985 kg

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

No.: HDP 502 / S 1100-50 Technical data
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

Type: HAMMELMANN High pressure pump HDP 502
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

Safety No.: HDP 502 / S 1100-50
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 atten-
tion must be paid to this section "safety" and these instructions must always be readily available to all personnel
concerned. No claims for personal injuries or damages arising from ignorance or non observance of safety
procedures can be accepted.
4.2 Safety conscious working

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

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

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

No.: HDP 502 / S 1100-50 Safety
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.

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.

No.: HDP 502 / S 1100-50 Safety
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.

General 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!

No.: HDP 502 / S 1100-50 General
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.

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 Use no hand hooks
barrow here
Do not use forklifts or

similar transportation
units.

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.

Construction & Description No.: HDP 502 / S 1100-50
Page 17, Issue: 03.2017
Pos : 25 /Aufbau und Besc hrei bung/Ü bers chrift @ 0\mod155_2.doc x @ 1372 @ 1 @ 1
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)

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

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. Description Item No. Description

10 Pump head 100 Drive shaft
20 High pressure discharge 110 Oil dip stick
30 Name plate 120 Oil drain valve
40 Oil pressure gauge 130 Suction chamber drainage
50 Oil pump 140 Suction connection
60 Oil pressure regulator 150 Suction chamber
70 Oil filter 160 Cover plate
80 Oil cooler 170 Mounting holes
90 Oil filler neck 180 Leakage connection

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:

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

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

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.

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 Start display with AdBlue system (e.g. Volvo Stage

IIIb/Tier 4i and Stage IV/Tier 4 f. engine)
0 bar
0 r.p.m. AdBlue fill level display
OFF
 Fig.: Start display

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.

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
Input Dimension
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 IP67 (Connected
IEC 60 529 with connector with
IP 67)

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
Input Dimension
Pressure range 0 – 1600 bar
Burst pressure 4000 bar
Over pressure safety 2300 bar
Pressure connection G½B
Output
Max. ohmic load RA(UB-10V)/0,02A
Response time (10..90%)  1 ms
Permissible temp. medium 0..+80 °C
Perm. temp. ambience -20..+80 °C
Miscellaneous
Power supply UB 10.. 30 V DC

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
IEC 60 529 with female
connectors acc.
corresponding
ingress prot.)

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
Valve Dimension
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 1,6 + 0,4 Nm
M4
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
Electrical connection Switching function

Connector EN 175301-803 A 1 Compressed
Air
Cable Gland PG 11 2 Compressed
Air
Ingress protection IP65 (With suitable 3 Compressed
connector) Air

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
Input Dimension
Measuring range 0°C .. +100 °C
Pressure resistance 40 bar
Vibration resistance 3g
Pressure connection G¼B
Output
Rise time t50 3,3 s
Permissible temp. medium -50 °C .. +150 °C
Perm. temp. ambience -40°C ..+85 °C
Miscellaneous
Power supply UB 10 V .. 35 V DC
Electrical connection Pin connection

Connector M 12x1 1 Signal+
Terminal connection 2-wire 2 n.c.
Wire gauge Depends on 3 Signal-
connector
Diameter of cable Depends on 4 n.c.
connector
IEC 60 529 with connector with
IP 67)

No.: HDP 502 / S 1100-50 Installation & Start up
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.


Installation & Start up No.: HDP 502 / S 1100-50
Page 31, Issue: 03.2017
Pos : 56 /Vorber eitung z ur Inbetri ebnahme/Installation/S-Anlagen/N omogramm @ 0\mod542_2.doc x @ 2296 @ 3 @ 1
8.2.1 Calculating the hose internal diameter (DN)
To determine the internal diameter of the hoses refer to the diagram below. (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 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

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 Series 1 Series 2 Series 2 Series 3 Series 4 Series 4
seriees 0-300 bar 300-1000 bar 300-1000 bar 1000-1500 bar 1500-2500 bar 2500-4000 bar
Design Packing Packing tungsten
packing packing dynamic
seal assembly dynamic dynamic 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
pH 6,5 – 8,5 6,5 – 8,5 6,5 – 8,5 6,5 – 8,5 6,5 – 8,5 6,5 – 8,5
Conductivity Max. 1000 Max. 1000 Max. 1000 Max. 1000 Max. 1000 300 to
µS/cm µS/cm µS/cm µS/cm µS/cm 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
350 mg/l 350 mg/l 350 mg/l 350 mg/l 50 – 175 mg/l 50 – 175 mg/l
(CaCo3) max.
Ammonium (NH4)
0,5 mg/l 0,5 mg/l 0,5 mg/l 0,5 mg/l 0,5 mg/l 0,5 mg/l
max.
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)
50 ppm 50 ppm 50 ppm 50 ppm 50 ppm 50 ppm
max.
Silicate (SiO2/SiO4)
5 mg/l 5 mg/l 5 mg/l 5 mg/l 5 mg/l 5 mg/l
max.
Free carbonic acid
20ppm 20ppm 20ppm 20ppm 20ppm 20ppm
(CO2) max.
Ffree chlorine max. 1 mg/l 1 mg/l 1 mg/l 1 mg/l 1 mg/l 1 mg/l
* depending on type of particle (hardness)
No additives with corrosive effects on nonferrous heavy metals (if to be used consult HAMMELMANN).
In certain cases variations from the above may be possible! HAMMELMANN offers suitable filter systems.

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
german french english american.

mval/kg mmol/l
°dH °f °e ppm
Definition
1 gran CaCO3
28 mg CaO 1 part CaCO3
10 mg 10 mg per gallon 1000 mg
oder 50 mg per million
CaCO3 CaCO3 14,3 mg CaCO3
CaCO3 1 mg CaCO3
per 1000 ml per 1000 ml CaCO3 per per 1000 ml
per 1000 ml per 1000 ml
water water 1000 ml water
water water
water
1 mval/kg 1,0 2,8 5,0 3,5 50,0 0,50

1o dH 0,357 1,0 1,78 1,25 17,8 0,18
1o f 0,2 0,56 1,0 0,7 10,0 0,10
1o e 0,286 0,8 1,43 1,0 14,3 0,14
1 ppm 0,02 0,056 0,1 0,07 1,0 0,01
1 mmol/l 2,00 5,60 10,00 7,02 100 1,0
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.

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 Normally oil cooler supply is from the suction chamber but if the suction water is above
supply 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 Connect the pneumatically control hose (i.e. for pneumatically driven high pressure
line 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.

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

Maximum
Nominal Minimum
Pressure Wrench size Torque Temperature of
diameter Connection fitting Bend Radius
[bar] [mm] [Nm] Medium
[DN] [mm]
[°C]
2500 175
5
3200
M 14 x 1,5 LH direkt 70 200
2500 70
8
3200 250
12 2100 M 20 x 1,5 LH direkt 95 290
290 32
M 18 x 1,5 DKL 50 100 130
530
10
1250 30 150
M 22 x 1,5 DKO 30 70
1600 95
250 27
M 22 x 1,5 DKL 62 100 180
440
Gummi 250
12 1100 M 24 x 1,5 DKO
Polyamid 100
32 33 70
1400 110
M 24 x 1,5 DKO
1800 290
170 36
M 30 x 1,5 DKM 83 100 240
340
1000 280
20
1000 170
M 36 x 2,0 DKO 46 49 70
1400 350
1600 350
140
M 38 x 1,5 DKM 46 105 100 300
25 260
700 M 42 x 2,0 DKO 50 57 100 355
Connection with pressure ring and pressure nut
Pressure ring Pressure nut
2500 175
5
3200
M 14 x 1,5 LH M 30 x 2 32 150 200
2500 70
8
2800 250
12
2100 M 20 x 1,5 LH M 42 x 2 46 205 290

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 H. P. outlet Leakage bore
Pressure nut Pressure ring

Torque = 120 Nm
Pos : 68 /Vorber eitung z ur Inbetri ebnahme/Installation/S-Anlagen/Sc hlauc hsic her ung @ 0\mod176_2.doc x @ 2272 @ @ 1

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.

No.: HDP 502 / S 1100-50 Operation
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 is released. If necessary unlock the emergency stop
button with the key.
 Press keypad 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.

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 (Softkey ) once again.
 Press keypad . 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.

No.: HDP 502 / S 1100-50 Operation
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 (activates softkey ).
 To start the engine 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 imme-
diately 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.

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).

No.: HDP 502 / S 1100-50 Shut down
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 and remove the key for
safekeeping.
 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


0 bar
OFF

Shut down No.: HDP 502 / S 1100-50
Page 43, Issue: 03.2017
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

No.: HDP 502 / S 1100-50 Shut down
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.

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.

No.: HDP 502 / S 1100-50 Maintenance
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 . If after pressing the text remains on display if the fault has not been
eliminated.
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 Remedy
 Batteries exhausted.  Exchange or recharge.

a) Electrical system does not
respond to keypad .  Emergency stop switch is  Release Emergency stop
still engaged. switch
 Batteries low or exhausted.  Recharge or replace.

b) Engine does not respond to the
 Consult HAMMELMANN agent
keypad. .  Control system component
(abroad) or customer services.
failure
dept. (F.R.G.).
 Accessory trigger switch mal-

 Replace.
function.
c) Pumps runs without pressure.
 No oil pressure to bypass
 Check system oil pressure.
cylinder.

Maintenance No.: HDP 502 / S 1100-50
Page 47, Issue: 03.2017
 Replace burst disc. Check why

d) Burst disc rupture.  Maximum pressure exceeded. pressure exceeded.
Remedy fault.
 Engine not achieving required

 See engine handbook.
r.p.m.
 Consult HAMMELMANN agent
 Speed control system defective. (abroad) or customer services.
dept.(F.R.G.)
 Accessory nozzle(s) too large or
 Change nozzle(s).
worn.
 Check oil line and hydraulic
 Bypass leaking water. cylinder for leakage.
Check system pressure.
e) Operating pressure too low.  Change or rework bypass

 Bypass components worn.
components.
 Pump head seals defective.  Change seals.
 Defective suction or pressure
 Change or rework valves.
valve.
 Attention! Do not attempt
close visual inspection until unit
 Leakage at high pressure fittings is shut down!
or hoses.
 Inspect and tighten or replace
as necessary.
 Change piston sleeves. Rework
 Worn piston sleeves.
is possible.
 Worn valves or valve seats.

f) Shock pulses in high pressure  Suction or pressure valve
Change or rework valves and
discharge. sticking.
valve seats if necessary.
g) Excess leakage from inter-
 Low pressure seal fault.  Adjust or replace.
mediate chamber.
 Water entering crank via  Consult HAMMELMANN agent

h) The leakage water or oil dipstick
shows oil water emulsion. defective seal between piston (abroad) or customer services
and crank. dept. (F.R.G:).
 Oil pressure too high.  Adjust oil system pressure.

i) Oil leaks from crank section.
 System over charged with oil.  Drain off.
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.

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”.

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.

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.

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.

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.

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

Page 54, Issue: 03.2017
 Viscosity-Temperature-Diagram for synthetic oils at Poly-  -Olefin - Basis

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

Page 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

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).

Page 58, Issue: 03.2017
 Fig.: Pump head

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

Page 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.

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.

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)
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).

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.

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
Hex. skt. head cap
400
screw
410 Circlip
420 O-ring
430 O-ring
450 O-ring
470 Clamp halves
480 Circlip

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.

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  Fig. Bellows
to the chapter ‚seal assembly‘).
 Use end cut pliers to loosen or snap the hose
clamps (180 und 190). i.e. place the pliers on
the latch joint (A) of the clamp and squeeze
strongly or squeeze and twist.
 Pull down on the bellows (200)
 Use a 60 mm A/F spanner to unscrew the
piston rod (170) and remove it together with
the bellow (200) from the pump intermediate
chamber.
 Take the bellow off the piston rod.
 Slide a new bellow onto the piston rod.
 Loosely slide the hose clamp (190) over the bellow (for later assembly).
 Lay the hose clamp (180) on the crosshead/pump housing (for later assembly).
 Use the 60 mm A/F spanner to screw the piston rod with bellow into the crosshead and tighten to 150 Nm.
 Pull down the bellow and fit over the cylinder bush ensuring that it is not turned into itself. (cast seams should
be vertical).
 Adjust and fasten the hose clamps (180 und 190). The latch joints (A) on both hose clamps must be carefully
compressed with end cut pliers or similar. Ensure that the bellow is seated correctly.
 Connect the plunger to the piston rod as described in ‚Plunger seal assembly’. Repeat the procedure for the
remaining bellows and refit the intermediate chamber cover plates.
Each time you replace the bellows check the surface of each crosshead bore for
signs of corrosion.
Report any signs of corrosion to HAMMELMANN immediately.

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.
Thread size
Material
M6 M 8 M 10 M 12 M 14 M 16 M 18 M 20 M 24
5.6 4.5 11 18 30 48 73 100 140 240
8.8 8.5 21 40 70 110 171 245 345 590

10.9 12 30 60 100 160 250 350 495 850
12.9 15 35 70 120 190 300 405 575 990
A2-70
6,0 15 30 50 85 130 175 250 420
A4-70
Torque (Nm) for various bolts. Any variations from these torque values are indicated on the individual assembly
drawings.

Pressure regulating valve No.: HDP 502 / S 1100-50
00.05865.0146 Page 67, Issue: 03.2017
Pos : 97 /Instandhaltung/Druc kr egel ventil/DR V 00.05865.0146 @ 11\mod_1400674247453_2.doc x @ 89693 @ 12222 @ 1
12 Pressure regulating valve 00.05865.0146
 Fig.: Pressure regulating valve
Item Item
Description Description Item no. Description
no. no.
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

No.: HDP 502 / S 1100-50
Pressure regulating valve
Page 68, Issue: 03.2017 00.05865.0146
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.

00.05865.0146 Page 69, Issue: 03.2017
12.3 Maintenance
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

No.: HDP 502 / S 1100-50
Page 70, Issue: 03.2017 00.05865.0146
 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 O-
ring (25) together.
 Fig. 1
 Remove support ring (70 with O-ring) out of the valve seat ring (60). (Support ring and O-ring are one part
position.)
 Inspection
 Especially examine control piston (30) and valve seat ring (60) for signs of wear or damage. They should be
carefully examined and if worn replaced by new. If wear is slight or there are minor pits in the surface a certain
amount of rework is possible. Rework should be done only by HAMMELMANN.
 Visually inspect all other parts for signs of wear or damage. Replace if necessary.

00.05865.0146 Page 71, Issue: 03.2017
 Reassembling of the pressure regulating valve

 Grease the inner of housing (10) with Stabyl MO 500 (order no. 04.04660.0002)
 Place O-ring (25) onto seal ring
(20) (ref. to fig 2)
 Fig. 2
 Place seal ring (20) with O-ring
(25) onto the special tool (order
no. 01.06224.0137)
 By using the special tool press
the seal ring (20) with O-ring (25)
in the correct position into the
housing (ref. to fig. 3 and 4).
 Fig. 3

No.: HDP 502 / S 1100-50
Page 72, Issue: 03.2017 00.05865.0146
 Fig. 4
 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).
 Fig. 5

00.05865.0146 Page 73, Issue: 03.2017
 Correctly installed seal ring (20),

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

 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.

No.: HDP 502 / S 1100-50
Safety notes for high pressure
Page 74, Issue: 03.2017 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.

Safety notes for high pressure No.: HDP 502 / S 1100-50
hoses Page 75, Issue: 03.2017
13.1 Before using the hose

 Check the working pressure marked on the hose. Never exceed this working pressure.
 Check the hose and the fittings if they are damaged.
 Take out of service hoses with bubbles in the cover, with kinks or uncovered layer of the steel wire. It is not
allowed to repair hose lines with these damages or to use them in other ways. (EN 982)
 Check the fittings if they have rust, cracks (fissures) or worn threads.
 Never plug the relief holes of the fittings, neither intentional nor by dirtying or damages.
 Observe the minimum bend radius at storage and work (look table beyond).
13.2 Use of the hose
 Do not twist the hoses during assembly.
 Regularly check the hoses and fittings as well as the connections and adapters on leakages. In case of
leakages stop the high pressure aggregate immediately. Remove leakage only when the system is switched
off and depressurised. Never tighten fittings under pressure. Observe torque (look table beyond).
 Pay attention to the change of length when working. (Hoses reduce their length under pressure).
 Do not pressurise hoses on reel drums.
 Avoid stress with high temperature from the exterior (e.g. radiant heat at welding or thermal cutting).
 Do not hang the hose across several floors.
Maximum
Nominal Minimum
Pressure Wrench size Torque Temperature of
diameter Connection fitting Bend Radius
[bar] [mm] [Nm] Medium
[DN] [mm]
[°C]
2500 175
5
3200
M 14 x 1,5 LH direkt 70 200
2500 70
8
3200 250
12 2100 M 20 x 1,5 LH direkt 95 290
290 32
M 18 x 1,5 DKL 50 100 130
530
10
1250 30 150
M 22 x 1,5 DKO 30 70
1600 95
250 27
M 22 x 1,5 DKL 62 100 180
440
Gummi 250
12 1100 M 24 x 1,5 DKO
Polyamid 100
32 33 70
1400 110
M 24 x 1,5 DKO
1800 290
170 36
M 30 x 1,5 DKM 83 100 240
340
1000 280
20
1000 170
M 36 x 2,0 DKO 46 49 70
1400 350
1600 350
140
M 38 x 1,5 DKM 46 105 100 300
25 260
700 M 42 x 2,0 DKO 50 57 100 355
Connection with pressure ring and pressure nut
Pressure ring Pressure nut
2500 175
5
3200
M 14 x 1,5 LH M 30 x 2 32 150 200
2500 70
8
2800 250
12
=== Ende der Liste für T extmar ke Inhalt ===
2100 M 20 x 1,5 LH M 42 x 2 46 205 290

No.: HDP 502 / S 1100-50 Index
Page 76, Issue: 03.2017
14 Index
C O
Caractéristiques de puissance ...................................8 Operating the system .............................................. 40
Changing the bellows .............................................. 65 Overnight shut down ............................................... 42
Construction ............................................................ 17 P
Construction High of pressure pump HDP 503 ... 19
Pre-start checks ...................................................... 30
Layout of the S1100-50 ....................................... 17
R
D
Repair and Replacement ........................................ 55
Description
Replacing the burst disc(s) ..................................... 56
Control unit .......................................................... 24
Electronic safety cut out ...................................... 22 S
High pressure installation .................................... 23
Safety
Suction side installation ....................................... 23
The burst disc assembly (safety devices) ........... 22 Additional warnings ............................................. 12
Dieselengine Volvo TAD 1661 VE .......................... 23 Danger symbol .................................................... 11
Dangers arising from non observance of safety
E instructions ............................................................ 9
Forbidden practices ............................................. 12
Extended Shut down ............................................... 43
Personnel qualification and training ...................... 9
F Precise safety instructions for the operator ........... 9
Safety conscious working ...................................... 9
Fault finding and remedy ........................................ 46
Safety during inspection, maintenance and repair
G ............................................................................. 11
General Safety notes for high pressure hoses ..................... 74
Copyright ............................................................. 14 Start up .................................................................... 38
Introduction .......................................................... 13 Stopping the unit ..................................................... 42
Warranty terms .................................................... 14
T
M
To start the high pressure pump unit ...................... 39
Maintenance Torque tables .......................................................... 66
Changing or adjusting the boost pump drive belt 66 Transport
N Packing ................................................................ 15
Protection ............................................................ 16
Notes on installation of connecting armatures ........ 34 Transport ............................................................. 16
Transportation ..................................................... 15

ES2
Microprocessor-Control for Volvo

Engine
ES2-Bediener (Volvo)
2016
Made in Germany
Issue: 04.2016
No.: ES2-Bediener (Volvo) Contents
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

ES 2 – Control No.: ES2-Bediener (Volvo)
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,
Pre heat 1 Multi tool valve 1
Control Off
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
Softkeys (Function menu 13.) 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

Pos: 4 /Aufbau und Beschreibung/ES 2 - Steuerung/Steuerung Einschalten @ 0\mod26_2.docx @ 1648 @ 2 @ 1

No.: ES2-Bediener (Volvo) ES 2 – Control
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:
The last set value will be displayed

Ja yes for 10 sec. The set value can be
Use the set values confirmed or adjustet.
(pressure / speed)
from the previous job Nein The set value will set to minimum
value and displayed for 10 sec.
No The set value can be confirmed or
adjusted.
(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

Pos: 8 /Aufbau und Beschreibung/ES 2 - Steuerung/Start Display Volvo @ 15\mod_1454317675928_2.docx @ 143451 @ @ 1


0 bar
OFF

blocked up.

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 Message flashes in the sec. tact at running engine.
With announcement filling level <10% a warning is
0 bar given, however, the unit is not switched off.
Also other faults can be programed with the same
behaviour as warning.
0 UPM
OFF
Fig.: 5

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 or
25,2 V 10
0 bar Press to increase or
to decrease.
800 RPM
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 or .
25,2 V 10
0 bar Press to increase or
to decrease.
800 RPM
To confirm press or
automatically after 10 secs.
Fig.: 7

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- -5- -6-

No: 99.01402.3750 10.01.05 Machine no. pump date display
V:ES2 201204:I01.00 12:19:19 Software version ES2 time display
Unit: 1002h30 Operating hours unit
Pump: 1113h57 Operating hours pump
Pressure sensor : 4.0 mA Actuell value of pressure transmitter for

controll, approx 4 mA at 0 bar
Engine temperature
Actual: 60C Engine temperature
Max. : 95C
EXIT
Fig.: 9
Press

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 By pressing or select a function

(shown inverse).
3. Language (ENGL) :ENGLISH
Confirm with .
4. Display contrast : 130
5. Display lighting : ON Change value with or .
6. Standby time : OFF 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 Functions which have been deleted at

the factory are designated inactive.
4. Display contrast : 130 These can not be selected (e.g. 1. Idle
5. Display lighting : ON speed delay).
6. Standby time : OFF
EXIT
Fig.: 11
Pos: 27 /Aufbau und Beschreibung/ES 2 - Steuerung/Grundmaske 3 @ 1\mod39_2.docx @ 1668 @ 3 @ 1
-1- -2- -3- -4- -5- -6-

7. Set min pressure : 50bar
7.1. Delay min bar ON :15 s
7.2. Delay min bar OFF : 3 s By pressing or select a function
(shown inverted).
8. Hose length : 20 m
Confirm with .
9. Control type : PRESSURE
Change value with or .
Confirm with
EXIT
Fig.: 12

Page 10, Issue: 04.2016
2.7.1 Selecting of the pressure step

-1- -2- -3- -4- -5- -6-
10. Pressure steps : 2
Max. pressure : 1900 bar
Max. speed : 2100 UPM
11. Emergency programm : OFF By pressing or select a pressure

12. Reports step (shown inverted), if factory adjusted.
13. Function menu Confirm with .

Display changes to input key code.
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
Input key code
(underlined) The digit changes to *. All
Value limit
from 0000 to 9999 digits must be entered
Code confirm
0000 Cancel 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- -4- -5- -6-

10. Pressure step : 2
Max. speed : 1800 UPM By or select one of the in the
factory set pressure steps.
11. Emergency programm : AUS 1, 2, or 3 (shown inverted).
12. Reports
Confirm with .
13. Function menu
Display changes back to pressure step
setting (prior page)
10. Pressure step shown inverted again.
EXIT
Fig.: 15
Press

Page 11, Issue: 04.2016
2.7.2 Teach in function

-1- -2- -3- -4- -5- -6-
14.Pressure to learn :OFF
15.Consumer number: 3
Teach in function to save speed/pressure
16.Consumer 1: 15 l/min
values for multi tool operation.
17.Consumer 2: 13 l/min >Switch multi tool valve (2) to „ON“.
18.Consumer 3: 18 l/min >Set control type (9) to “Teach in”
19.Consumer 4: inaktiv >Pressure to learn (14.) set to „ON“ and
20.Consumer 5: inaktiv 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- -5- -6-
21.Set clock time 12:19:19
Active set value is shown invers
22.Set date 01.10.05
23.Set value source : Keypad Keypad: Setting the set value by using
24.Keypad lock :OFF the keypads of the ES2
25.Remote control inactive (ref.to entering a set value)
26.Modem: inactive
EXIT
Fig.: 17
If external set value active:
-1- -2- -3- -4- -5- -6-
22.Set date 01.10.05
23.Set value source : External Active set value is shown invers
24.Keypad lock :OFF External: The set value is sent over an
25.Remote control inaktive external signal (0 – 10V) to the
26.Modem: inactive ES2.
EXIT
Fig.: 18

Page 12, Issue: 04.2016
25,2 V 10
The start display behaves then as
accompanying represented.
0 bar At pressing from or i.e. at speed
value
800 UPM
Fig.: 19
If variable set value:
-1- -2- -3- -4- -5- -6-
22.Set date 01.10.05
Changing of the source of set value on
23.Set value source : External
menu page 6 by:
24.Keypad lock :OFF
25.Remote control inaktive
By keypads or select point 23.
26.Modem: inactive
set value source and with confirm.
Selecting „Keypads“ or „External“ with
and .
EXIT Confirm desired mode with .
Fig.: 20
2.7.2 Keypad lock

-1- -2- -3- -4- -5- -6-
21. Set clock time: 12:19:19
22. Set date: 01.10.05
23. Set value source : Keypad
24.Keypad lock :OFF Select keypad lock (shown inverse).
25.Remote control inactiv
26.Modem: inactiv Confirm with .
With or select ON
Confirm with
EXIT
Fig.: 21
Press EXIT or after 30 sec. automatically return to basic display.


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

0 bar switch the keypad lock “OFF”. After this the keypad lock
is active.
0 RPM
After pressing one of the keys the following display will
OFF appear.
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 or enter 2 first

Input key Code
Value limit Then go with  to the next digit
from 0000 to 9999 (underlined) The digit changes to *. All
Code confirm digits must be entered.
0000 Cancel The Code is 2002
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- -5- -6-
10. Pressure step : 2 Select 13. Function menu with or
Max. speed : 1800 UPM .
11. Emergency programm : AUS

12. Reports
Status display inputs
13. Function menu

Press .
O2K OWF3TL1D R123456 Than the complete Function menu will be
111 11111111 111111 displayed (ref. to following fig.)
EXIT
Fig.: 24

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 Faults which displayed as FREE 2 / FREE 3 can be
0 = Fault / Condition not fulfill. have unit dependent functions and designations
U=Battery=25.1V at 31.5C Shut off valve test
0=1 >Engine oil pressure
2=1 >FREE2 Starter test
K=1 >Coupling
EXIT Exit menu

0=1 >Oil pressure pump
W=1 >Water feed pressure Pre Heat test
F=1 >Water filter
3=1 >FREE3
T=1 >Water temp. pump.
L=1 >Air pressure
Pressing the softkeys will activate
EXIT functions of the unit (for example:
Shut off valve test) as follows:
Fig.: 25 Press
0=1 >Oil pressure pump

W=1 >Water feed pressure Pressing will display the shut
F=1 >Water filter off valve symbol inverted as long
3=1 >FREE3
T=1 >Water temp. pump. as you keep presssing .
L=1 >Air pressure The same functions with the
starter, as long as you keep
EXIT pressing
Fig.: 26
Press
Pos: 45 /Aufbau und Beschreibung/ES 2 - Steuerung/Funktionsmenü 2 @ 1\mod55_2.docx @ 1680 @ @ 1

1 = Condition OK Faults which displayed as FREE 1 / RES.1 can be
0 = Fault / Condition not fulfill. have unit dependent functions and designations
Voltage = 26,1 V
1= 1 >FREE1
General fault output
D= 1 <Generator fault voltage
R1= 1 >RES.1
R2= 1 >RES.2
R3= 1 >RES.3
R4= 1 >RES.4
R5= 1 >RES.5
R6= 1 >RES.6
EXIT
Fig.: 27

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

Actual- limit value
U=Battery=25.1V at 31.5C
2=1 >FREE2
K=1 >Coupling Same as digital sensor
In addition the actual and limit values of
0= 0.0 < 2.0bar >Öil pressure pump
W= 0.1 < 2.0bar >Water feed pressure
the appropriate sensors indicated.
F= 0.0 > 1.2bar >Water filter For example:
3=1 >FREE3
T=17 > 40C >Water temp. pump
 Air pressure is OK:
L= 6.3 < 5.5bar >Air pressure
Actual value: 6,3 bar
Limit value: < 5,5 bar
EXIT  Pump water temperature is OK:
Actual value: 17° C
Fig.: 28
Limit value: > 40° C
Or at failure of the sensor  Water boost pressure is not OK:
U=Battery=25.1V at 31.5C (if the unit is not running, there is no
fault)
2=1 >FREE2
K=1 >Coupling Actual value: 0,1 bar
Limit value: < 2,0 bar
0= ERROR >Öil pressure pump  Oil pressure pump, fault of the
W= 0.1 < 2.0bar >Water feed pressure
sensor current is < 4 mA (wire
F= 0.0 > 1.2bar >Water filter
3=1 >FREE3
break)
T=17 > 40C >Water temp. pump
L= 6.3 < 5.5bar >Air pressure
EXIT
Fig.: 29
Press

Page 16, Issue: 04.2016
Pos: 50 /Aufbau und Beschreibung/ES 2 - Steuerung/Funktionsmenü 3 @ 1\mod56_2.docx @ 1872 @ @ 1
Pressing =+
Increase engine speed
+ (test)
T/FU = 1,6V
------------------------------------------------------------- Pressing = -
with 0-10V (1.100) Decrease engine speed
-
Uout = 0,03 V
RPM = 0
+ (test)
Actual value OK
At running engine
-----------------------------------------------------
St>V1=1 V2&3=1 V4&5=1 BV=1
- 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
EXIT Status
Multi tool valve /Bypass valve
Fig.: 30
EXIT
Pos: 51 /Aufbau und Beschreibung/ES 2 - Steuerung/Überschrift Fehler Protokoll @ 1\mod58_2.docx @ 1684 @ 2 @ 1
Exit menu and change to start display
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 Fault report

12.2 Read Can fault
12.3 Read CAN data
12.1 Select Fault report
12.4 M-value T1: 1min> 960RPM
12.5 M-value T2: 1h > 1321RPM
<<< Back
EXIT
Fig.: 31
Pos: 53 /Aufbau und Beschreibung/ES 2 - Steuerung/Bestätigung @ 1\mod64_2.docx @ 1884 @ @ 1
Press

Page 17, Issue: 04.2016
Pos: 55 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlerprotokoll @ 1\mod524_2.docx @ 1956 @ @ 1
No Az. Fault
1 0 Engine error
2 0 Low engine oil pressure
3 0 FREE2
4 0 Low pump oil pressure
5 0 Low feed water pressure
Delete fault memory
6 0 Blocked water filter
(only possible with key
7 0 FREE3
code)
8 0 High p.water temp
9 1 Max.pressure exceeded List of all possible faults and their
<<< Back number of (Example)
Select Max. pressure exceeded
EXIT with or .
Fig.: 32 (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 Hour. Mode
1 21.12.00 10:40 1002 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

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 Displays active faults
2 (displays engine electronic faults
3 during operation)
4 The faults are indicated according to
5 standard (SAE J 1939 code) e.g.:
6
7
SPN -> Fault number
8
e.g. 98 = oil level
9 FMI -> fault level
10 e.g. 15 = warning
3 = critical
1 = shut off
EXIT (also ref. to fault indication)
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 =--.- RPM
2>Actual RPM = 800 RPM
3>Set engine torque = --- % Current data of the machine to be
4>Diesel Pressure =--.- bar sent over CAN –Bus
5>Diesel Temp. = --- C Indicated values dependent on the
6>Consumption = --- L/h machine sensor system
7>Coolant temp. = 58 C
Not installed sensors are explained
8>Coolant level = 100 %
as lines.
9>Oil pressure = 0 bar
10>Oil temp. =--.- C
11>
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

Page 19, Issue: 04.2016
2.10 Explanation of the terms/functions at the operators menu

1. 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.
2. Multi gun valve yes/no: Switches the multi gun valve outputs to active or inactive.
3. Language: Select the language which will be displayed at the operators menu.
4. Display contrast: Adjust the contrast setting.
5. Display lighting: Switching the lighting ON/OFF .
6. Standby time: If the set time expires without a signal to close the bypass the unit will shut down.
7. 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.
7.1 Delay min bar ON: Delays switching on the monitoring time of the HP – min.
7.2 Delay min bar OFF: Delays switching off the monitoring time of the HP – min.
8. Hose length: Select either 20m or 100m. The regulation will start depending on what is selected
after the set time.
9. Control mode: If programmed at the factory, changeable between control of engine speed and
control by pressure setting.
10. Pressure steps: Use password to select factory programmed pressure steps.
12. Protocol : Displays the history of faults with dates, times and regularity. Shows values and actual
faults of CAN-Bus
13. Function menu : Displays the status of the total inputs in the ES 2. Enter menu by pressing the
OK (confirm) keypad.
14. Pressure to learn: Start Teach-in-function
15. Consumer number: Adjust the number of consumer (1 . . . 5)
16. Consumer 1:
17. Consumer 2: Adjust the flow rate
18.
Consumer 3: of each consumer
19.
Consumer 4 at multi gun operation.
20.
21. Consumer 5:
22. Set clock: Set the clock time, that will be displayed in ES2
Set date: Set the date, that will be displayed in ES2
24.
25. Lock keypads: Prevents use of the keypads.
26. 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

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 .
 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:
Fault 1
 At electronic engines jump directly to point “12.2 Read CAN fault” over the
Engine fault
button “CAN fault list” and identify the fault over the SPN-no. If
(what to do)
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
Change the filter.
 Fuel filter blocked. On air cooled Deutz engines check
the hand pump filter.
 Fuel tank empty. Fill tank.
Check line, clear or replace as
 Fuel line defective.
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
Engine fault much.
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

Page 21, Issue: 04.2016
Fault identifying over CAN-Bus code no.

Fault 1 12.2 “Read CAN fault” or by fault
 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
 Oil level too low. Top up engine oil or change the oil.
Fault 2
 Oil filter blocked. Change oil filter, possibly change the oil..
Low engine oil
pressure  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
Is this fault set as a warning and a CAN-

Fault 3
(Designation and function depending to Bus is installed, it is possible to jump
Free definable Fault the HPP construction) dirrectly to point “12.2 Read CAN fault”
FREE 2 by pressing the button .
 Drive belt defective (only applicable to Deutz air cooled diesel engines)
 Drive belt is broken, off pulley or
Replace, refit or retension as necessary.
loose.
 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
Open the fast shut down flap.
“Over speed” is reached.
 DEUTZ – engine fault
Identify the fault over the CAN-Bus-SPN-
code “12.2 Read CAN fault”
Call DEUTZ-Service.
 By connection to the diagnostic plug socket (at electronic engines) “12.2 Read
Important! 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
 Oil level too low Top up or change the oil.

 Oil filter blocked. Change oil filter, possibly change the oil
Check oil temperature.
 Oil temperature too high Check coolant water.
Drop in viscosity Observe the oil pressure gauge.
Fault 4
Oil pressure approx. 5 bar.
Low pump oil pressure
If oil pressure is sufficient > 2 bar
check oil pressure switch. If
necessary repair or replace.
 Oil pressure switch defective.
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 Check water supply or water filling level

at the water tank.

Page 22, Issue: 04.2016
Low feed water Check boost pressure gauge. Boost

 Boost pump defective.
pressure 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

Pos: 72 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 6 Wasserfilter verschmutzt @ 1\mod108_2.docx @ 4084 @ @ 1
 Filter bag blocked Replace filter bag

Reset the red button on the differential
pressure switch.
Fault 6 Check differential pressure switch and
Blocked Water filter  Differential pressure switch defective replace as necessary.
Check sensors
 Ref. to technical information

Fault 7
(Designation and function depending Ref. to technical information
FREE 3 to the HPP construction)
Pos: 74 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 8 Wassertemp. Pumpe zu hoch @ 1\mod237_2.docx @ 3996 @ @ 1
 Supply water temperature > 30°C. Check water supply

 Water temperature at feed water tank
Fault 8 Fill with cool water.
too high.
Water temp. too high
 Operation with to much bypass
Drain the bypass-water separately
water.
Pos: 75 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 9 Hochdruck überschritten @ 1\mod109_2.docx @ 4052 @ @ 1
 Pressure has exceeded > 10 % of Check nozzles The nozzles diameter(s)

must be selected to achieve 1200
max. pressure
rpm. Minimum engine speed.
Fault 9
 Wrong nozzle(s) Exchange nozzle(s)
Max. pressure
exceeded  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: 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

Increase standby time or shut off.
Standby time exceeded idle speed exceeded.
Ref. to technical information

Fault 11
(Designation and function depending to Ref. to technical information
FREE 1 the HPP construction)
Pos: 78 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 12 Kurzschluss an Bypass/USV @ 1\mod111_2.docx @ 4056 @ @ 1
Disconnect bypass valve or multi tool

Fault 12 valve
 A fault in the installation indicates +
Short circuit Bypass/MTV signal to the bypass or multi tool Check the whole installation,
valve. Disconnect all units,
fault remains
ES2 defective  exchange

Page 23, Issue: 04.2016
Pos: 79 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 13 Motordrehzahl überschritten @ 1\mod239_2.docx @ 4004 @ @ 1
Only in pressure control mode:

Incorrect (too large) nozzle(s).
 Max. rpm. of the engine has been Too much bypass water (incorrect
Fault 13 exceeded by 10 % or more (5 sec.). PRV setting)
Wear in the bypass / PRV .
Max. rpm exceeded
 After exchanging the linear motor at Readjust the linear motor.

idle speed.
Pos: 80 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 14 Motortemperatur zu hoch @ 1\mod113_2.docx @ 4028 @ @ 1
 High engine temperature Check coolant water level.

 Cooler blocked Check cooler
Fault 14
High engine temp  Ventilator defective Check ventilator
 Air supply or air outlet blocked. Check the openings of air supply and air
outlet.
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.

If 0 mA the bypass socket or wiring to
Fault 15 socket is faulty. Check the socket for
 Pressure sensor defective short circuit.
Defective pressure
sensor 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 Check pneumatic installation
Low air pressure
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.

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.
Check high pressure pipework and hoses
 The minimum allowable pressure is
for leakage.
not achieved
Fault 17 Re-tighten fittings only after
Below min pressure pressure is released and the unit
is shut down!
 The minimum allowable pressure is Check programmed data for minimum
not achieved within a given time (in pressure and make corrections if
the operators menu). necessary.
Pos: 84 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 18 Arbeitsdrehzahl unterschritten @ 1\mod117_2.docx @ 4036 @ @ 1
 Only at speed control Check the power of the engine.

Actual RPM are lower than the Check fuel system.
Fault 18 bypass set RPM Clean diesel filter.
Insufficient engine  Wrong nozzle(s) or defective or
speed blocked
Check nozzle(s) if necessary exchange.
 Incorrect pressure set value entered. Correct the value.

Pos: 86 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 19 Überspannung @ 1\mod118_2.docx @ 4072 @ @ 1
 The alternator is faulty. Repair or replace.

Fault 19
 The power to the unit is in excess of External power source attached. Switch
Voltage overload
33 V DC off and remove immediately.
Pos: 87 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 20 Drahtbruch Temperaturfühler @ 1\mod119_2.docx @ 4040 @ @ 1
Fault 20 Check cable

 Cable or connector fault.
Defective temp. sensor Replace or repair cable.
Pos: 88 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 21 Steuerkabel defekt @ 1\mod120_2.docx @ 4076 @ @ 1
Remove control cable from unit.

 Control cable defective
Repair or replace control cable.
Fault 21
 Short circuit bypass Pull the bypass cable from the socket
Defective control cable
- switch or Check bypass socket, if necessary
- socket repair.
Pos: 89 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 22 Generator defekt @ 1\mod121_2.docx @ 4024 @ @ 1
 V-belt for generator broken or loose Replace or retension as necessary.

Fault 22  Cable of generator loose or
Generator fault defective. Replace or tighten terminals.
 Cable defective.
Pos: 90 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 23 Füllstand Kraftstofftank @ 1\mod122_2.docx @ 4080 @ @ 1
 Diesel tank empty Fill up.
 Diesel filter blocked Check diesel filter

clean or exchange as necessary.
Fault 23  Diesel line/hose blocked or defective Check diesel line, clean or exchange as
necessary.
Diesel fuel level
 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

Page 25, Issue: 04.2016
 V-belt of the generator loose or

Replace or retension as necessary.
broken.
Fault 24  Cable (W) loose or defective. Replace or tighten terminals.
Generator signal fault At registered CAN-Bus call engine
 No speed signal from CAN-Bus.
supplier.
 Pick up sensor defective. Check pick up sensor or replace
Pos: 93 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 25 Kupplung ausgerückt @ 1\mod241_2.docx @ 4012 @ @ 1
Fault 25 Check air pressure > 5 bar.

 Air pressure to low
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 Inputs can be covered according to
unit.
Fault 29
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
 Pressure is higher than the Check parameter 2.3

Fault 32 programmed value for the engine at
Pressure at idle speed idle speed. (Parameter 2.3)
 Bypass or multi tool valve defective Check valve(s),
Pos: 96 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 33 Not-Aus @ 1\mod251_2.docx @ 3976 @ @ 1
Fault 33
Check emergency stop button.
Emergency stop  Emergency stop button pressed.
Check the cable(s).
tripped
Pos: 97 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 34 Not Programm @ 1\mod253_2.docx @ 3968 @ @ 1
Fault 34
 Emergency programme is set to
Emergency progra. active
Set emergency programme to inactive.
activ

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  Diesel differential pressure to high
pressure
Fault 37
 Diesel level low
Diesel level
Fault 38
 Oil level engine low
Oil level engine
Fault 39
 Oil differential pressure to high General CAN - bus warnings of the
Oil differential pressure
engine electronics (undependent
Fault 40 on engine type).
 Engine oil pressure low
Engine oil pressure The engine is only switched off with
stop exit of the engine
Fault 41 electronics.
 Charger pressure to high
Charger pressure Dependent on the obstructed engine
sensors.
Fault 42
 Air inlet pressure low Not installed sensors produce no
Air inlet pressure warning/switching off of the
engine.
Fault 43
 Coolant temperature high
Coolant temperature
Fault 44
 Coolant level low
Coolant level
Fault 45
 Fuel temperature to high
Fuel temperature
Fault 46
 Engine overspeed
Engine over speed
Fault 47  General fault of the engine

Fault CAN Bus 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  Loss of operating relevant Restart the ES2.
Parameter Error parameters.
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
 Nozzles worn
Change nozzles Change nozzles.
 Nozzles damaged.
(Teach-in operation)
Pos: 102 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 50 Hochdruck zu gering @ 4\mod_1207122880373_2.docx @ 23388 @ @ 1

Page 27, Issue: 04.2016
 Nozzles worn.
Fault 50 Change nozzles.
 Max. flow rate of the pump exceeded
High pressure low Check high pressure side.
 Wrong nozzle dia. Selected.
(Teach-in operation) 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
 Wrong pressure step selected and Check set pressure step..
Torque exceeded
high pressure pump overloaded
Pos: 105 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 53 AdBlue Pegel Gering @ 15\mod_1454410687836_2.docx @ 143719 @ @ 1
Fault 53  AdBlue fill level below 1. Warning

Top up AdBlue.
AdBlue level low stage of engine reached.
Pos: 106 /Aufbau und Beschreibung/ES 2 - Steuerung/Fehlermeldungen/Fehler 54 Leistungsreduzierung @ 15\mod_1454410977113_2.docx @ 143727 @ @ 1
 AdBlue fill level below 2. Warning

Fault 54 stage of engine reached. The engine
Top up AdBlue.
Power reduction power can be reduced by the engine
control unit.
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.

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- Change in page 2, point 2 „Multi
1. Idle speed delay : 15s
gun/Teach in“ by pressing
2. Multi gun/Teach in : ON
3. Language (ENGL) :ENGLISH and or in „ON“.
4. Display contrast : 130

5. Display lighting : ON
6. Standby time : OFF
EXIT
Fig.: 38
-1- -2- -3- -4- -5- -6- Select page 3, point 9
7. Set min. Pressure :inactiv
7.1. Delay min bar ON :inactiv By pressing change the control type
7.2. Delay min bar OFF :inactiv
9. Control type : SPEED
EXIT
Fig.: 39
-1- -2- -3- -4- -5- -6- to Teach-in.
7. Set min. Pressure :inactiv
7.1. Delay min bar ON :inactiv Confirm with .
7.2. Delay min bar OFF :inactiv
By pressing EXIT leave menu.

9. Control type : Teach in..
EXIT
Fig.: 40

Page 29, Issue: 04.2016
25,2 V 00
1
00
2
00
3 Start the engine
0 bar
0 UPM
OFF
Fig.: 41
-1- -2- -3- -4- -5- -6- Select page 5, Point 14
14.Pressure to learn : OFF
15.Consumer number : 3 By pressing or change

“pressure to learn” in “ON”
After 15 sec (after engine start). By
operating the 1st consumer bring the unit
19.Consumer 4: inactiv
on high pressure.
20.Consumer 5: inactiv The multi tool valve is closed, in this
connection.
The whole flow rate of water flows out
EXIT about the pressure regulating valve.
Fig.: 42
25,2 V 00
1
00
2
00
3 With the pneumatic pressure-reducer
adjust the air pressure so that the
0 bar desired pressure (water) is reached.
Confirm this value by pressing .

0 UPM Automatically change to page 5 of this
menu.
EXIT
Fig.: 43

Page 30, Issue: 04.2016
-1- -2- -3- -4- -5- -6- Select page 5; Point 15.,
14.Pressure to learn : OFF
confirm with
15.Consumer number : 3
16.Consumer 1: 18 l/min By pressing or admit the

17.Consumer 2: 35 l/min number of consumer.
19.Consumer 4: inaktiv
20.Consumer 5: inaktiv
EXIT
Fig.: 44
-1- -2- -3- -4- -5- -6- The liter amounts refer on by the „Teach
14. Pressure to learn : OFF in“ given pressure.
15. Consumer number : 3 By pressing or adjust the flow

rate in litre per minute of the appropriate
16. Consumer 1: 38 l/min nozzle (consumer). Confirm this value
17. Consumer 2: 38 l/min
18. Consumer 3: 38 l/min with .
19. Consumer 4: inactiv
20. Consumer 5: inactiv
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!

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

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

Page 33, Issue: 04.2016
-1- -2- -3- -4- -5- -6-

21. Set clock time
22. Set date
24.Keypad lock :inaktiv

25.Remote control :inaktiv
26.Modem :OFF Select point 26 and confirm. It follows
EXIT
Fig.: 51
The PIN interrogation of the Sim card

(is provided by the card supplier) give,
Select PIN e.g., 5846 as follows and confirm.
Vallue limits
With or assign the digit.
from 0000 to 9999
Confirm code Then go with  to the next digit
0000 cancel (underlined) The digit changes to *. All
PIN OFF
digits must be entered
→ Select „Code confirm“ and
Fig.: 52
-1- -2- -3- -4- -5- -6-

21. Set clock time
22. Set date
SIM Card without PIN:
24.Keypad lock :inactiv The value 0000 can be confirmed. Then
25.Remote control :inactiv in the list next to the PIN display select
26.Modem :ON
“PIN OFF” and confirm with
Switch the ES2 off and then on again.
EXIT
Fig.: 53

Page 34, Issue: 04.2016
-1- -2- -3- -4- -5- -6-

21. Set clock time
22. Set date
24.Keypad lock :inaktiv With this announcement there works the

25.Remote control :inaktiv modem, should appear (NET NO) in the
26.Modem :ON announcement switch off control 1 x and
restart.
also ref. to technical information,
ES2 – Modem (04.01336.0193)
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 ===

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 Pre-heat ..................................................................... 6
Entering a value – units with pressure control ........... 7 S
Entering a value – units with speed control ............... 7
Switch control ON ...................................................... 3
F Switch OFF the keypad lock .................................... 14
Fault indication......................................................... 21 T
Fault report .............................................................. 17
Teach in function ..................................................... 12
Function menu ......................................................... 14
W
K
Working with multi gun valve and Teach in ............. 30
Keypad lock ............................................................. 13

0 1 2 3 4 5 6 7 8 9
06.2016 Überwachung Wassertank mit IMB-Geber Blatt 6.( ifm und S19 auf, Blatt 6a)
Änderungen:
Kennzeichnung der Vovo-Sicherung falls vorhanden Blatt 1a.
weitere Änderungen siehe 03.2016 Anschluss Volvo-Steuergeräte, Volvo Pin 5 + 6 überarbeitet, Blatt 1
Blatt 7, Änderungshistorie 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
40poliger Anschlussstecker
-ES2/40 = 40 pole connection plug ES2 - Leitstungsteil
ES2 - power part
24 poliger Anschlussstecker
-ES2/24 = 24 pole connection plug
ES2/40 1a 1b 10a 10b 1c 6c 6d 9c 9a 9b 9d 10c 10d
-W_40pol
41x1 1 2 3 40 26 4 5 6 7 8 9 10 11
1C / 3.0
emergency stop / main switch
NOT-AUS / HAUPTSCHALTER
-X5 1 2 3 4 41 6 7 8 9
11
geschaltete +24V
switched +24V
-S01
Sammelstörung
general alarm
11 21 12
safety switch gear

SICH.-SCHALTER
start relais
Vorglühen
Startrelais
Zündung
pre heat
Ignition
-S1 X5 5
GETRIEBE
12 22 S22/BN
-S04
04.04310.0024 S21/WH
-X5 37 X5 39
11
-S02
external emergency stop loop

1 12
externer NOT-AUS Kreis

-F1 X5 40
C8A 2
Zuleitung
GND / 2.6 XNA C
input lead
11
+24V 0V
1.a.7 -S03
12
XNA D
VOLVO_EMS
RD BK BU/RD GN BU/RD GN
EMS 2
oder EMS 2.2 / EMS 2.3
VOLVO_8pol 4 3 5 6 or 5 6
only: TAD9xxVE, TAD164xVE (not -B)
Batterieplus
batterie plus
Batterieminus
batterie minus
Batterie nach Schlüssel**
Zusatz-Abstellsignal**
Batterie nach Schlüssel*
Zusatz-Abstellsignal*
batterie after key**
extra stop**
batterie after key*
extra stop*
EMS 2.2 / EMS 2.3: EMS 2:
Pin 5: Pin 5:
* Ab Motoren mit EMS2.2/2.3: ** Bei Motoren mit EMS2:
Abstellung bei Spannungsverlust keine Abstellung bei Spannungsverlust!
Motorüberwachung sowie START und STOP des Dieselmotors * From engines with EMS2.2/2.3: ** At engines with ESM2:
Die Absicherung seitens Volvo erfolgt durch Shut down if voltage goes down No shut down if voltage goes down
erfolgen vom Motorsteuergerät.
eine Kfz-Klingensicherung im Kabelbaum. Pin 6: Pin 6:
Die Kommunikation mit der ES2 wird mittels CAN-Bus ausgeführt. * Programmierung: "energized to stop", ** Programmierung: "energized to run"
engine monitoring and also start and stop of the diesel engine ab Volvo Software-Architektur nur bei Motoren mit EMS 2 erforderlich
Power supply is fused by Volvo with a are done by the engine controller itself. EMS 2.2 / 2.3 fest eingestellt ** Programming: "energized to run"
blade fuse in the Volvo harness The communication with the ES2 is made by CAN bus.
* Programming: "energized to stop", only for engines with EMS 2 required
from Volvo software-structure
EMS 2.2 / 2.3 permanently set
EMS = Engine Management System
1.a
® Leistungsteil =
Datum
Bearb.
04.01.2012
Barenhoff
File name: 00.06700.0809
HAMMELMANN power part
Z-Nr.: 00.06700.0809 +
Gepr 16.06.2016 KK für ES2 mit elektr. VOLVO GmbH Blatt 1
Änderung Datum Name Urspr Ersatz von Ersetzt durch Carl-Zeiss-Straße 6-8 D-59302 Oelde von 18
0 1 2 3 4 5 6 7 8 9
*fuse behind compressor (only motor type:TAD1643 VE StufeII/4)

Sicherungen VOR dem Batterieschalter
25 mm²
Ladegerät Funksteuerung /
Telematic-System /
Standheizung /
5A 15A
Standheizung_ /
5A 5A
Nach Bedarf
Batterieladegerät /
belegen
15A
Batterieschalter
Battery switch bajonet fuse
00.01808.0392
Beleuchtung /
falls vorhanden 25 mm² 70 mm² 70 mm²
8A
if fitted
HAMMELMANN
VOLVO
+
Volvo fuse *
- +24V / 1.1
BAT
24V M
+
- 0V / 1.2
70 mm²
Batterien Anlasser
batteries Starter
04.04550.0517
Aufkleber für Batterieschalter in der Nähe anbringen!
"...frühestens 2 Minuten nach dem Motor-Stopp abschalten..."
1 2
® Anschluss Batterie und Batterieschalter =
Datum
Bearb.
04.01.2012
Barenhoff
File name: 00.06700.0809
HAMMELMANN Connection of barrery and battery switch
Z-Nr.: 00.06700.0809 +
Gepr 06.06.2016 KK für ES2 mit elektr. VOLVO GmbH Blatt 1.a
0 1 2 3 4 5 6 7 8 9
ES2 - Überwachung Motor

ES2 - monitoring enging
-ES2/40 3b 5b 4a 3a 6a 3c
-W_40pol
41x1 12 13 14 15 16 17
-X5 10 11 12 13 14 15
temperature sensor engine
oil pressure switch engine

Temperaturfühler Motor
-R3
Öldruckschalter Motor
VOLVO EMS-FEHLER
** Fehler "FREI 2" wird ausgelöst,
VOLVO EMS-FAULT
Generator D+
Generator D+
Generator W
Generator W
sobald via CAN-Bus eine aktive
(FREE 2)
(FREI 2)
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. 1.2 / GND GND / 3.0
No connection at terminal 12 necessary!
** ab ES2-Software ES2_030815.bin
EMS = Engine Management System Einstellung FREI 2:

Signallogik: NO
Aktion: Warnung
(alternativ with B2)

(Alternativ zu B2)
Speichern: bei Error
tank sensor
Tankgeber
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 3
® Überwachung MOTOR =
Datum
Bearb.
04.01.2012
Barenhoff
File name: 00.06700.0809
HAMMELMANN monitoring engine
Z-Nr.: 00.06700.0809 +
0 1 2 3 4 5 6 7 8 9
ES2 - Überwachung Pumpe

ES2 - monitoring of pump
-ES2/40 4c 4b 5a 4d 5d 5c 6b 1d
-W_40pol
41x1 18 19 20 21 22 23 24 25
1.2 /1C 1C / 4.1

2.7 / GND GND / 4.1
-X5 3 16 PE 3 17 PE 3 18 PE 3 19 PE 3 20 PE 3 21 PE 3 22 PE 3 23 PE
-WB5 BN BU SH -WB6 BN BU SH -WB7 BN BU SH -WB8 BN BU SH -WB10 BN BU SH -WB11 BN BU SH
-B5 1+ 3-
-B6 1+ 3-
-B7 1+ 3-
-B8 1+ 3-
-B10 1+ 3-
-B11 1+ 3-
0-16bar 0-16bar 0-16bar 0-100°C 0-100°C 0-16bar
>2bar >2bar >1,2bar <70°C <40°C >5,5bar
4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA
Kupplung oder externer Sollwert

clutch or external set value
Wassertemperatur Pumpe
water temperature Pump
water boost pressure Pump
oil pressure Pump
Wasservordruck Pumpe
oil temperature pump

Öldruck Pumpe
Filter Differenzdruck
air pressure
ÖLTEMP. PUMPE
filter diff. press.
Luftdruck
FREE 1
FREI 1
(FREE 3)
(FREI 3)
2 4
® Überwachung PUMPE =
Datum
Bearb.
04.01.2012
Barenhoff
File name: 00.06700.0809
HAMMELMANN monitoring pump
Z-Nr.: 00.06700.0809 +
0 1 2 3 4 5 6 7 8 9
ES2 - Regelungsfunktionen
4mA - 0bar
ES2 - control functions
20mA - ...bar
CAN high
CAN low
110% max. Druck --> Abschaltung
110% max pressure --> cut off
-ES2/40 3d 8A 8B ES2/24 24 23
-W_40pol W_24pol
41x1 27 28 29 12x1 1 2
3.9 / 1C 1C / 5.0
3.9 / GND GND / 5.0
-X5 3 24 PE -X5 25 26 -X5 56 57
Stellmotor
-WB10 BN BU SH servomotor
VOLVO_EMS
-B1 1+ 2-
WH/YE GY/YE WH WH/BK
0-xxxxbar
4-20mA
-VOLVO_8pol 1 2 7 8
J1587A
CAN high
CAN low
J1587B
J1939
Druckaufnehmer
Pressure transducer
3 5
® Regelungsfunktionen =
Datum
Bearb.
04.01.2012
Matzel
File name: 00.06700.0809
HAMMELMANN control function
Z-Nr.: 00.06700.0809 +
0 1 2 3 4 5 6 7 8 9
Zeitdiagramm ES2 - Bypassventil und Umschaltventile

Bypass Schaltung: A1
time diagram
of bypass circuit: 500ms
ES2 - bypass and multi gun valves
A2
Y
t
-X1 = Bypasssteckdose 4 pol ITT
-ES2/40 2a 2b 7a 7b 2c 2d 7c 8c 8d 7d
-W_40pol
41x1 30 31 32 33 34 35 36 37 38 39
A1 A2 Y
1C
4.2 / 1C / 6.0
4.2 / GND GND / 6.0
-X5 3 2 27 28 29 29 30 -X5 3 2 31 32 33 -X5 3 2 34 35 36
-X1 A B D C -Y0 -Y1 -X2 A B D C -Y2 -X3 A B D C -Y3
-Y0.1
2 2 2 2 2
multi gun valve 1
multi gun valve 2
multi gun valve 3

Umschaltventil 1
Umschaltventil 2
Umschaltventil 3
Bypass / Pistole 1 Pistole 2 Pistole 3
bypass valve 2
Bypassventil 2
bypass valve
Bypassventil
bypass / gun 1 Gun 2 Gun 3
Bypass-Schlüsselschalter Bypass-Schlüsselschalter Bypass-Schlüsselschalter

bypass key switch bypass key switch bypass key switch
* falls an der * falls an der

Anlage vorhanden Anlage vorhanden
* if installed at * if installed at
the machine the machine
4 6
® Bypassventil und Umschaltventile =
Datum
Bearb.
04.01.2012
Matzel
File name: 00.06700.0809
HAMMELMANN bypass valve and multi gun valves
Z-Nr.: 00.06700.0809 +
0 1 2 3 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 Res.2 Res.3 Res.4 Res.5 Res.6
-ES2/24 5 6 7 8 9 19
W_24pol
12x1 3 4 5 6 7 8
5.9 / 1C 1C / 6a.0
5.9 / GND GND / 6a.0
-X5 3 2 81 PE 3 82 PE 3 83 PE 3 84 PE 3 PE 85 3 PE 86
1 2 3
-WB19 1 2 3
A B C
-WB15 WH BN YE
A B C
Verlängert mit
Deutsch-Stecker
00.06700.0969
Verlängert mit
-B15 -WB16 BN BU SH -WB17 BN BU SH Deutsch-Stecker
LED's:
1 2 4 -WB2 GN BK VO
refer to
BR WS GN
grün >195µS
rot <150µS
gelb = 195-150µS
+24V 0V +OUT2
LOW bei
<150µS -B19 +24V 0V +OUT -B2
-B16 -B17 Tanksensor
0-100°C
1+ 3-
0-100°C
1+ 3- + - 0-10V
Bedia ITS 60
< 95°C < 60°C
Leitfähigkeitsmesszelle
conductivity sensor IMB
4-20mA 4-20mA
00.01327.0002 OPG 04
0-200µS Alternativ siehe Blatt 6a
DE: ABSPERRKLAPPE ZU
EN: AIR SHUTOFF FLAP
oiltemperature gearing
Öltemperatur Getriebe
ÖKW-TEMP.ZU HOCH
F: SECU.ETOUFFOIR
OCW-TEMP. HIGH
Demineral. water
Dieseltank Geber
fuel level sensor
Wassertank min.
water tank min.
VE-Wasser
ÖKW-TEMP. = Öl Kühler Wasser Temperatur

OCW-TEMP. = Oil Cooler Water Temperature
Bei Ausgführung mit Hartmetalldichtungssatz Bei Ausgführung mit Schaltgetriebe Bei Ausgführung Heißwasseranlage Bei Ausgführung Luftabsperrklappe
* falls an der * falls an der * falls an der * falls an der

Anlage vorhanden Anlage vorhanden Anlage vorhanden Anlage vorhanden
* if installed at * if installed at * if installed at * if installed at
the machine the machine the machine the machine
5 6a
® Reserve Überwachungen =
Datum
Bearb.
04.01.2012
Barenhoff
File name: 00.06700.0809
HAMMELMANN reserve monitoring
Z-Nr.: 00.06700.0809 +
0 1 2 3 4 5 6 7 8 9
ES2 - Reserve Überwachungs-Funktionen

ES2 - reserve monitoring funktions
oder
Res.1 Res.2 Res.3 Res.4 Res.5 or Res.5 Res.6
-ES2/24 5 6 7 8 9 9 19
W_24pol
12x1 3 4 5 6 7 7
6.9 /1C 1C / 6b.0

6.9 / GND GND / 6b.0
-X5 3 2 81 PE 3 82 PE 3 83 PE 3 84 PE 3 85 PE 3 PE 85 3 86 PE
04.01030.0033 1 2 3
1 2 1 3 2 1 2
A B C
1 2
Verlängert mit
Deutsch-Stecker Verlängert mit
Deutsch-Stecker
BN/RT
-WB19 BN BU BK
Betriebsbereit
S10 S13
-S19
Störung
WH
-B19
Kl_1 24V 0V Kl_2 /6.6
1+ 3- 4 OUT
COM C O * ggf. Ausführung mit
ifm-Wassertankschalter
S11 S12 siehe Folgeseite / -B19
* could be with ifm

ifm water tank switch LMT 121
refer to following page / -B19
Anstatt Schwimmerschalter -S19
ES2-Parameter: "digital zu Ub"
Fehler Vorfilter
Fault prefilter
air dampers
Luftklappen
Wassertank min.
water tank min.
Wassertank min.
water tank min.
Einstellung Res. 4:
Signallogik: NC
Aktion: Motor Stop
Speichern: bei Error
Bei Ausgführung mit Container-Jalousie Bei Ausgführung mit Vorfilter (Bollfilter)

Bei Ausgführung mit Schwimmerschalter-S19 Bei Ausgführung mit ifm-Wassertankschalter
* falls an der * falls an der * falls an der * falls an der

Anlage vorhanden Anlage vorhanden Anlage vorhanden Anlage vorhanden
* if installed at * if installed at * if installed at * if installed at
the machine the machine the machine the machine
6 6b
® Reserve Überwachungen Sonderausführungen =
Datum
Bearb.
04.01.2012
Barenhoff
File name: 00.06700.0809
HAMMELMANN Z-Nr.: 00.06700.0809 +
Gepr 16.06.2016 KK für ES2 mit elektr. VOLVO GmbH Blatt 6a
0 1 2 3 4 5 6 7 8 9
+24V Batterie /
Zündung
Ignition
6a.9 /1C 1C /
6a.9 / GND GND /
7 2 -X5 3 -X5 1
-WM1
3x1 1 2
(3) (1)
A1 30
-K5
+ - 04.03440.0028 A2 87 87a
M
-M1 (2) 3AUF 2AB
/6b.4 WH RD
24V / ca. 0,9A
M
-M1
/6b.1
1
BK
Elektrische Kraftstoffpumpe
-X5 2 -X5 2
Electric Fuel Pump
Jalousie Motor
Louvre motor
87
30 /6b.4
87a
Option
Bei Ausgführung mit externem niedrigen Dieseltank
* falls an der
Anlage vorhanden
* if installed at
the machine
6a 7
® Sonderausführungen =
Datum
Bearb.
04.01.2012
Matzel
File name: 00.06700.0809
HAMMELMANN Z-Nr.: 00.06700.0809 +
Gepr 09.01.2017 KK für ES2 mit elektr. VOLVO GmbH Blatt 6b
0 1 2 3 4 5 6 7 8 9
Änderungen: 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 8
® Änderungshistorie =
Datum
Bearb.
04.01.2012
Matzel
File name: 00.06700.0809
HAMMELMANN Z-Nr.: 00.06700.0809 +
0 1 2 3 4 5 6 7 8 9
Ohne Externen Not-Aus =

2,5 Brücke von X5.5 nach X5.41
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
PE
-X5
-F1
16 17 18 19 20 21 22 23 24 25 81 82 83 84 85 86
1 1 3 3 3 4 5 7 7 9 9 11 13 15 26 27 27 29 29 31 33 35 40 42 56 56
PE
PE
3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3
2 2 2 2 2 2 2 2 6 8 8 10 12 14 28 28 30 32 34 36 37 37 39 41 57 57
PE PE PE PE PE PE PE PE PE PE PE PE PE PE PE PE
7 10
® Klemmenplan =
Datum
Bearb.
04.01.2012
Barenhoff
File name: 00.06700.0809
HAMMELMANN Terminal diagram
Z-Nr.: 00.06700.0809 +
0 1 2 3 4 5 6 7 8 9
Steckerplan F22_001
-W_24pol
Leistenbezeichnung
Kabelname
Kabelname
=+-ES2/24
24 poliger Anschlussstecker
24 pole connection plug
Geräteanschluss
bezeichnung
Anschluss
Anschluss
Kabeltyp
Kabeltyp
Stecker-
Brücke
Funktionstext Zielbezeichnung Zielbezeichnung Seite / Spalte
VE-Wasser
5 -X5 81 3 /6.1
Demineral. water
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

Wassertank min.
9 -X5 85 7 /6.7
water tank min.
17 -ES2/24 21 /1.2
= 18 -ES2/24 20 /1.3
Dieseltank Geber
19 -X5 86 8 /6.8
fuel level sensor
20 -ES2/24 18 /1.3
= 21 -ES2/24 17 /1.3
CAN low 23 -X5 57 2 /4.7
CAN high 24 -X5 56 1 /4.7
8 11
Datum 22.06.2016 GmbH Steckerplan =+-ES2/24 =
Bearb. Barenhoff Plug diagram =+-ES2/24 +
Gepr KK für ES2 mit elektr. VOLVO 00.06700.0809 Blatt 10
Änderung Datum Name Urspr ????????????????????????????
Ersatz von Ersetzt durch Blatt 18
0 1 2 3 4 5 6 7 8 9
Steckerplan F22_001
-W_40pol
Leistenbezeichnung
Kabelname
Kabelname
=+-ES2/40
Geräteanschluss
bezeichnung
Anschluss
Anschluss
Kabeltyp
Kabeltyp
Stecker-
Brücke
Batterieplus
1a -X5 1 1 /1.1
batterie plus
= 1b -X5 1 2 /1.1
geschaltete +24V
1c -X5 3 26 /1.2
switched +24V
FREI 1
1d -X5 23 25 /3.8
FREE 1
Bypass / Pistole 1
2a -X5 27 30 /5.1
bypass / gun 1
= 2b -X5 28 31 /5.1
Pistole 2
2c -X5 31 34 /5.5
Gun 2
= 2d -X5 32 35 /5.5
Tankgeber (Alternativ zu B2)
3a -X5 13 15 /2.6
tank sensor (alternativ with B2)
Temperaturfühler Motor
3b -X5 10 12 /2.1
temperature sensor engine
Generator W
3c -X5 15 17 /2.8
Generator W
Druckaufnehmer
3d -X5 24 27 /4.2
Pressure transducer
VOLVO EMS-FEHLER (FREI 2)
4a -X5 12 14 /2.3
VOLVO EMS-FAULT (FREE 2)
Wasservordruck Pumpe
4b -X5 17 19 /3.2
water boost pressure Pump
Öldruck Pumpe
4c -X5 16 18 /3.1
oil pressure Pump
ÖLTEMP. PUMPE (FREI 3)
4d -X5 19 21 /3.4
oil temperature pump (FREE 3)
Filter Differenzdruck
5a -X5 18 20 /3.3
filter diff. press.
Öldruckschalter Motor
5b -X5 11 13 /2.2
oil pressure switch engine
Wassertemperatur Pumpe
5c -X5 21 23 /3.6
water temperature Pump
Kupplung oder externer Sollwert
5d -X5 20 22 /3.5
clutch or external set value
Generator D+
6a -X5 14 16 /2.7
Generator D+
Luftdruck
6b -X5 22 24 /3.7
air pressure
6c -X5 4 4 /1.3
safety switch gear 6d -X5 41 5 /1.4
Bypassventil
7a -X5 29 32 /5.2
bypass valve
Umschaltventil 1
7b -X5 30 33 /5.4
multi gun valve 1
Umschaltventil 2
7c -X5 33 36 /5.6
multi gun valve 2
Umschaltventil 3
7d -X5 36 39 /5.9
multi gun valve 3
Stellmotor
8A -X5 25 28 /4.4
servomotor
= 8B -X5 26 29 /4.4
Pistole 3
8c -X5 34 37 /5.8
Gun 3
= 8d -X5 35 38 /5.8
Zündung
9a -X5 7 7 /1.6
Ignition
Sammelstörung
9b -X5 8 8 /1.7
general alarm
Startrelais
9c -X5 6 6 /1.5
start relais
10 11.a
0 1 2 3 4 5 6 7 8 9
Steckerplan F22_001
-W_40pol
Leistenbezeichnung
Kabelname
Kabelname
=+-ES2/40
Geräteanschluss
bezeichnung
Anschluss
Anschluss
Kabeltyp
Kabeltyp
Stecker-
Brücke
Sammelstörung
9d -X5 8 9 /1.7
general alarm
Batterieminus
10a -X5 2 3 /1.2
batterie minus
= 10b -X5 2 40 /1.2
Vorglühen
10c -X5 9 10 /1.8
pre heat
= 10d -X5 9 11 /1.8
11 13
Gepr KK für ES2 mit elektr. VOLVO 00.06700.0809 Blatt 11.a
0 1 2 3 4 5 6 7 8 9
Steckerplan F22_001
Leistenbezeichnung
Kabelname
Kabelname
=+-X1
Bypasssteckdose 4 pol ITT
Geräteanschluss
bezeichnung
Anschluss
Anschluss
Kabeltyp
Kabeltyp
Stecker-
Brücke
Bypass / Pistole 1
A -X5 3 /5.1
bypass / gun 1
= B -X5 2 /5.1
= C -X5 28 /5.1
= D -X5 27 /5.1
11.a 14
Datum 07.12.2015 GmbH Steckerplan =+-X1 =
Bearb. Matzel Plug diagram =+-X1 +
0 1 2 3 4 5 6 7 8 9
Kabelplan F09_001
Kabelname Kabeltyp Aderzahl Querschnitt Kabellänge Funktionstext

=+-W_24pol 12 1 VE-Wasser
Demineral. water
Funktionstext QVW Zielbezeichnung von Anschluss Ader Zielbezeichnung nach 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 VE-Wasser
/6.1 -ES2/24 5 3 -X5 81 /6.1
Demineral. water 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
/6.5
DE: ABSPERRKLAPPE ZU EN: AIR SHUTOFF FLAP F: SECU.ETOUFFOIR -ES2/24 8 6 -X5 84 /6.5 DE: ABSPERRKLAPPE ZU EN: AIR SHUTOFF FLAP F: SECU.ETOUFFOIR
Wassertank min. Wassertank min.
/6.7 -ES2/24 9 7 -X5 85 /6.7
water tank min. water tank min.
Dieseltank Geber Dieseltank Geber
/6.8 -ES2/24 19 8 -X5 86 /6.8
fuel level sensor fuel level sensor
13 15
Datum 22.06.2016 GmbH Kabelplan =+-W_24pol =
Bearb. Barenhoff Cable diagram =+-W_24pol +
0 1 2 3 4 5 6 7 8 9
Kabelplan F09_001

=+-W_40pol 41 1 Batterieplus
batterie plus
Batterieplus Batterieplus
/1.1 -ES2/40 1a 1 -X5 1 /1.1
batterie plus batterie plus
= /1.1 -ES2/40 1b 2 -X5 1 /1.1 =
Batterieminus Batterieminus
/1.2 -ES2/40 10a 3 -X5 2 /1.2
batterie minus batterie minus
Brücken für Anlagentyp Diesel Brücken für Anlagentyp Diesel
/1.3 -ES2/40 6c 4 -X5 4 /1.3
bridges for diesel machines bridges for diesel machines
safety switch gear /1.4 -ES2/40 6d 5 -X5 41 /1.4 safety switch gear
Startrelais Startrelais
/1.5 -ES2/40 9c 6 -X5 6 /1.5
start relais start relais
Zündung Zündung
/1.6 -ES2/40 9a 7 -X5 7 /1.6
Ignition Ignition
Sammelstörung Sammelstörung
/1.7 -ES2/40 9b 8 -X5 8 /1.7
general alarm general alarm
= /1.7 -ES2/40 9d 9 -X5 8 /1.7 =
Vorglühen Vorglühen
/1.8 -ES2/40 10c 10 -X5 9 /1.8
pre heat pre heat
= /1.8 -ES2/40 10d 11 -X5 9 /1.8 =
Temperaturfühler Motor Temperaturfühler Motor
/2.1 -ES2/40 3b 12 -X5 10 /2.1
temperature sensor engine temperature sensor engine
Öldruckschalter Motor Öldruckschalter Motor
/2.2 -ES2/40 5b 13 -X5 11 /2.2
oil pressure switch engine oil pressure switch engine
VOLVO EMS-FEHLER (FREI 2) VOLVO EMS-FEHLER (FREI 2)
/2.3 -ES2/40 4a 14 -X5 12 /2.3
VOLVO EMS-FAULT (FREE 2) VOLVO EMS-FAULT (FREE 2)
Tankgeber (Alternativ zu B2) Tankgeber (Alternativ zu B2)
/2.6 -ES2/40 3a 15 -X5 13 /2.6
tank sensor (alternativ with B2) tank sensor (alternativ with B2)
Generator D+ Generator D+
/2.7 -ES2/40 6a 16 -X5 14 /2.7
Generator D+ Generator D+
Generator W Generator W
/2.8 -ES2/40 3c 17 -X5 15 /2.8
Generator W Generator W
Öldruck Pumpe Öldruck Pumpe
/3.1 -ES2/40 4c 18 -X5 16 /3.1
oil pressure Pump oil pressure Pump
Wasservordruck Pumpe Wasservordruck Pumpe
/3.2 -ES2/40 4b 19 -X5 17 /3.2
water boost pressure Pump water boost pressure Pump
Filter Differenzdruck Filter Differenzdruck
/3.3 -ES2/40 5a 20 -X5 18 /3.3
filter diff. press. filter diff. press.
ÖLTEMP. PUMPE (FREI 3) ÖLTEMP. PUMPE (FREI 3)
/3.4 -ES2/40 4d 21 -X5 19 /3.4
oil temperature pump (FREE 3) oil temperature pump (FREE 3)
Kupplung oder externer Sollwert Kupplung oder externer Sollwert
/3.5 -ES2/40 5d 22 -X5 20 /3.5
clutch or external set value clutch or external set value
Wassertemperatur Pumpe Wassertemperatur Pumpe
/3.6 -ES2/40 5c 23 -X5 21 /3.6
water temperature Pump water temperature Pump
Luftdruck Luftdruck
/3.7 -ES2/40 6b 24 -X5 22 /3.7
air pressure air pressure
FREI 1 FREI 1
/3.8 -ES2/40 1d 25 -X5 23 /3.8
FREE 1 FREE 1
geschaltete +24V geschaltete +24V
/1.2 -ES2/40 1c 26 -X5 3 /1.2
switched +24V switched +24V
Druckaufnehmer Druckaufnehmer
/4.2 -ES2/40 3d 27 -X5 24 /4.2
Pressure transducer Pressure transducer
14 15.a
0 1 2 3 4 5 6 7 8 9
Kabelplan F09_001

=+-W_40pol 41 1 Batterieplus
batterie plus
Stellmotor Stellmotor
/4.4 -ES2/40 8A 28 -X5 25 /4.4
servomotor servomotor
= /4.4 -ES2/40 8B 29 -X5 26 /4.4 =
Bypass / Pistole 1 Bypass / Pistole 1
/5.1 -ES2/40 2a 30 -X5 27 /5.1
bypass / gun 1 bypass / gun 1
= /5.1 -ES2/40 2b 31 -X5 28 /5.1 =
Bypassventil Bypassventil
/5.2 -ES2/40 7a 32 -X5 29 /5.2
bypass valve bypass valve
Umschaltventil 1 Umschaltventil 1
/5.4 -ES2/40 7b 33 -X5 30 /5.4
multi gun valve 1 multi gun valve 1
Pistole 2 Pistole 2
/5.5 -ES2/40 2c 34 -X5 31 /5.5
Gun 2 Gun 2
= /5.5 -ES2/40 2d 35 -X5 32 /5.5 =
/5.6 -ES2/40 7c 36 -X5 33 /5.6
Pistole 3 Pistole 3
/5.8 -ES2/40 8c 37 -X5 34 /5.8
Gun 3 Gun 3
= /5.8 -ES2/40 8d 38 -X5 35 /5.8 =
/5.9 -ES2/40 7d 39 -X5 36 /5.9
Batterieminus Batterieminus
/1.2 -ES2/40 10b 40 -X5 2 /1.2
batterie minus batterie minus
15
Gepr KK für ES2 mit elektr. VOLVO 00.06700.0809 Blatt 15.a
1 2 3 4 5 6 7 8 9 10 11 12
939
Abgasaustritt Abgasnachbehandlungssystem:
HD Anschluss O 127 exhaust SCR6 Schalldämpfer mit Katalysator,
Druckregelventil discharge connection Hebevorrichtung für Pumpenkopf Dosiermodul, Temperatur6 und NOx6Geber
pressure regulating valve lifting device for pump head emissions aftertreatment system:
A SCR muffler with catalytic converter, A
dosing system, temp and NOx sensor
B B
2559
2271
C C
895
Z
69 0
D 1230 D
1020 6Z
1300 M20;20 tief Sauganschluss Vordruckpumpe; DN50, PN16 Klemmenkasten
200 800 800 800 M20;20 depth suction connection boost pump, DN50, PN16 terminal box
2800 1660
001
99,5 3120
001
6Y 0 Y
3219,5 Massenschwerpunkt
Massenschwerpunkt centre of gravity
6X 0 X centre of gravity
E E
F F
1597 Kühlerfläche
123
radiator surface
G G
001
Massenschwerpunkt/
Centre of Gravity
X Y Z
HDP 502 mit VOLVO TAD1672VE STAGE IV, TIER4final 1020 69 895
* Artikel6Nr. Format DIN
00.00027.1085
alle Ecken und Kanten gratfrei
ß Mit Betriebsdruck signiert
ß Mit Auftrags-Nr. signiert
ZeichFreig A1
Zul.Abweichung
1:10
260
ß Mit Teile-Nr. - Rev. signiert Maßstab Gewicht in kg

werden, und sie darf durch den Empfänger oder Dritte auch
f.Maße ohne
5200.0000
Ohne unsere vorherige Zustimmung darf diese Zeichnung
ß Härte geprüft Toleranzangabe

nicht in anderer Weise mißbräuchlich benutzt werden.
weder vervielfältigt noch Dritten zugänglich gemacht
ISO 2768 6 mH
Verwendungszweck Halbzeug Werkstoff *
H 001
Oberfläche nach
DIN ISO 1302 H
Datum Name Benennung
905 Kühlerfläche Bearb 25.03.2014 Brunnert
radiator surface Gepr. 23.02.2015 Barton
Norm 23.02.2015 Krabus HOCHDRUCKPUMPENAGGREGAT
Zeichnungs6Nr. Revision Blatt
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
001 1 von
1 Bl.
1 2 3 4 5 6 7 8 9 10 11 12
6058 2438
2746 1400 123 Luftaustrittsgitter
Durchgangsbreite 260 Lufteintrittsgitter air outlet louvre
passage width air inlet louvre
A A
A
ca. 2733
2591
B B
92
Erdungsanschluss 355
115
290 2259
Erdungsanschluss earthing connection 2050 1805,5
earthing connection Ad Blue Tank Durchführung f. Schläuche, M10
C M10 Inhalt: ca. 70 L Anschlussmöglichkeit:
6058 C
Ad Blue tank Füllanschluss Wassertank Pneumatikanschluss G1/4, Überströmanschluss G1 1/2
capacit: approx. 70 L 5853
Wetterkappe demontierbar C6Kupplung DIN14307 lead6in tubes for hoses,
rain cap removable 961 supply connection water tank Connection options:
c6coupling DIN14307 pneumatic connection G1/2, overflow line connection G1 1/2
D D
1065
E E
Z
0
800 800 800 530 17
6Z
Dieseltank Wassertank
2690 Montageklappe zur Inhalt: ca.900L Inhalt: ca.1300L 0
6Y Y
Kühlerreinigung fuel tank water tank 1230
0 mounting cover for capacity: approx.900l capacity: approx. 1300l
6X X cleaning cooler 2250
F F
270°
öffnend/
opening
270°
G öffnend/ G
opening
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
00.00027.1277
180° ß Mit Betriebsdruck signiert

ZeichFreig A1
öffnend/opening Zul.Abweichung
ß Mit Teile-Nr. - Rev. signiert Maßstab
1:20 Gewicht in kg
f.Maße ohne
90° 12040.0000

ISO 2768 6 mH
H arretierbar/lockable Oberfläche nach
H
A Bearb
DIN ISO 1302
Datum
28.01.2015 Pieper
Name Benennung
Massenschwerpunkt/ Gepr. 23.02.2015 Barton

Centre of Gravity
Norm 23.02.2015 Krabus HOCHDRUCKPUMPENAGGREGAT
Massenschwerpunkt / center of mass X Y Z Zeichnungs6Nr. Revision Blatt
1 2 3 4 5 6 7 8
2663
9
11 1063
Zust Änderung Datum Name
D659302 OELDE
CAD6Zeichnung
00.00027.1277 1
Ers.durch Ers.für
000 1 von
1 Bl.
PARTS LIST (41)
Parts-list no.: 00.00743.2221 HAMMELMANN GmbH

Drawing no. : 00.00743.2221-1 POB 3309, D-59282 Oelde, Germany
Description : PISTON SEAL ASSEMBLY, Packing http://www.hammelmann.de
HDP360 - MC D50, 1.4462 Date : 06.03.2017
Page : 1
DwgPos Item Code-No. Description 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 10 130 110 190 300 30 120 40 410 400 360 480 470 450
A
150 20
1 1 1 1 2 1 1 1 2 1 1 10 1 2 2 8
A
B B
C C
A
420 430 60
D 1 1 2 D
10 1
6 7 Sonderausführung
E Betriebsdruck max. 1000 bar E
* Artikel-Nr. Format DIN
00.00743.2221
4 3 004
Schrauben Pos. 400 mit integriertem Schmiermittel
ZeichFreig
Zul.Abweichung
A3
1:1,5 Gewicht in kg
f.Maße ohne
und in angegebener Reihenfolge ohne Fett 30.6100

ISO 2768 - mH
angezogen:
Verwendungszweck
Oberfläche nach
Halbzeug Werkstoff *
HDP360/480/750 D50,0 DIN ISO 1302
F 8 5 1. Stufe: Anziehdrehmoment Ma = 80 Nm
2. Stufe: Anziehdrehmoment Ma = 160 Nm
Bearb
Gepr.
02.03.2011 Sander
08.10.2012 EHelmig F
3. Stufe: Anziehdrehmoment Ma = 240 Nm 004 Stücklistenänderung 08.10.2012 Wei
Norm 09.10.2012 Krabus DICHTUNGSSATZ
2 9 003 Pos. 150 geändert in Bz 06.05.2011 JMue Zeichnungs-Nr. Revision Blatt
1 2 3 4
002
001
Zust
Pos. geändert
Stücklistenänderung
Änderung
30.03.2011
16.03.2011
Datum
San
Pöts
Name
D-59302 OELDE
CAD-Zeichnung
00.00743.2221-1
Ers.durch Ers.für
004 1 von
1 Bl.
PARTS LIST (41)

Description : PUMPHEAD - Duplex http://www.hammelmann.de
HDP360-500 D50-55, 1.4462 Date : 06.03.2017
Page : 1

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
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 3 4 5 6 7 8
7 1
A 3 5
530
A 8
A
310 1
5 7
3
A3A 2
520 90
8 24
4 2
8 6
10 6 4 2 8
B
1
A B
20
3 Pos.520 (Skt. SW46) mit MoS2 gefettet und in Schrauben Pos. 90 mit integriertem Schmiermittel
500 angegebener Reihenfolge angezogen: und in angegebener Reihenfolge ohne Fett
3 30 angezogen:
6 1. Stufe: Anziehdrehmoment Ma= 200 Nm
510 2. Stufe: Anziehdrehmoment Ma= 800 Nm 1. Stufe: Anziehdrehmoment Ma = 80 Nm
3 2. Stufe: Anziehdrehmoment Ma = 160 Nm
C 3. Stufe: Anziehdrehmoment Ma = 240 Nm C
003
150
3
D D
40
550 6
3
Sonderausführung Duplex
E 160 140 Betriebsdruck max. 1070 bar E
3 3 * Artikel3Nr. Format DIN
00.02145.1239
Pos.500 (Skt. SW24) Anziehdrehmoment 250Nm

ZeichFreig A3
Zul.Abweichung
1:1,5 Gewicht in kg
f.Maße ohne
153.0000

ISO 2768 3 mH
Verwendungszweck
Oberfläche nach
HDP3603500 ø50355 DIN ISO 1302
Bearb 15.03.2013 Poetschke
F Gepr. 24.04.2014 Hartmann F
Norm 24.04.2014 Krabus PUMPENKOPF
003 Pos. 150 geä. 24.04.2014 Som Zeichnungs3Nr. Revision Blatt
1 2 3 4
002 Stücklistenänderung
Zust Änderung
31.07.2013 Wei
01.07.2013 Wei
Datum Name
D359302 OELDE
CAD3Zeichnung
00.02145.1239 1
Ers.durch Ers.für
003 1 von
1 Bl.
PARTS LIST (41)

Description : PRESSURE REGULATING VALVE http://www.hammelmann.de
500 L/MIN , 1200 BAR 1.4462 Date : 06.03.2017
Page : 1

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 4 5 6 7 8
175
A3A P
Anziehdrehmoment Ma = 200 Nm
Tightening torque Ma = 200 Nm
A 130
1
140
1
10
1
35
1
30
1
50
1
60
1
70
1
160
1
80
1
Couple de serrage Ma = 200 Nm
A A
144
B B
T
(M63 x 2)
(G1 1/2)
132
C C
110 Z Skt. SW 55
1
Z Y T G 1 1/2
D D
2:1 ß 2:1
Skt. SW 19
90 120
Betriebsdruck max. 1200 bar/ 4462
A
3 2 Volumenstrom max. 500 l/min
Nennweite DN 17 P
25 Anziehdrehmoment Ma = 100 Nm Keramikausführung
E 20 Tightening torque Ma = 100 Nm Hochdruckdichtung DN 20 / 4x M12 / 60 x 60 E
1 1 Couple de serrage Ma = 100 Nm * Artikel3Nr. Format DIN
00.05865.0146
Max. operating pressure 1200 bar/ 4462
Max. flow rate 500 l/min X
ZeichFreig A3
X Zul.Abweichung
Nominal diameter 17 mm ß Mit Teile-Nr. - Rev. signiert Maßstab
1:1 Gewicht in kg
f.Maße ohne
10.5032

Ceramic design
ISO 2768 3 mH
High pressure seal Oberfläche nach
DIN ISO 1302
10.12.2013 Schaefer
PRESSURE REGULATING VALVE
Pression de service maximale 1200 bar/ 4462 Bearb
SOUPAPE REGULATRICE DE PRESSION
F Débit maximal 500 l/min Gepr. 14.03.2014 Heinrichsmei F
Largeur nominale DN 17
Norm 18.03.2014 Krabus DRUCKREGELVENTIL
1:5 Version céramique Zeichnungs3Nr. Revision Blatt
1 2 3
Joint haute pression
4
001 Zeichnung aktualisiert
Zust Änderung
13.03.2014 Schä
Datum Name
D359302 OELDE
CAD3Zeichnung
00.05865.0146 1
Ers.durch Ers.für
001 1 von
1 Bl.
PARTS LIST (41)

Description : MEMBRANE CYLINDER http://www.hammelmann.de
PN 10; D 130 Date : 06.03.2017
Page : 1

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
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 110 100 80 40 30 20 A
1 1 1 1 1 1
A
X
X
DN6
B B
90
1
70
1
(M63 x 2)
C C
19 8
120
O
1
D 50 60 10 D
1 8 1 A
Anziehdrehmoment 10 Nm
A-A
Wirkdurchmesser: 130 mm
Betriebsdruck : max. 10 bar ß
E Medium : Luft, Öl E
00.06428.0029
ZeichFreig_PDF A3
X Zul.Abweichung
ß Mit Teile-Nr. signiert Maßstab
1:2 Gewicht in kg
f.Maße ohne
5.5000

ISO 2768 - mH
Verwendungszweck
Oberfläche nach
DIN ISO 1302
008 Signierungsort geändert 02.07.2009 Pae Bearb 28.05.2002 PSchoening
F 007 Pos.120 hinzu 22.10.2007 Pöts Gepr. 02.07.2009 Poetschke F
006
005
00.05877.0065 entf.
Stkl. geä.
27.04.2007 PS Norm
12.04.2006 Pöts
03.07.2009 Szustkowski MEMBRANZYLINDER
004 Darstellung geänd. 02.07.2003 PS Zeichnungs-Nr. Revision Blatt
1 2 3 4
003
002
Zust
Darst. geä.
Pos.200,210,220 entf.
Änderung
12.05.2003 Pöts
05.02.2003 Som
Datum Name
D-59302 OELDE
CAD-Zeichnung
00.06428.0029-1
Ers.durch Ers.für
008 1 von
1 Bl.
PARTS LIST (41)

Description : RUPTURE DISC ASSEMBLY http://www.hammelmann.de
G 1/2 A - G 1/2 - 82,0 LG. Date : 06.03.2017
Page : 1

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
50 50 04.04062.1000 RUPTURE DISC 3 1,000 pc
>>>end<<<
p_dbgs01.p
1 2 3 4 5 6 7 8
A A
A A
B ca. 82 B
20 6kt. SW36 19
A-A 6kt. SW27
2:1
C C
(G1/2 A)
(G1/2)
D 004 D
Anziehdrehmoment 100 Nm 1x 04.04062.1000 montiert, Anziehdrehmoment 110 Nm 004
20 torque: 100 Nm 10 30 50 2x 04.04062.1000 für Ersatz beigelegt. 40 torque: 110 Nm
1 1 1 3 1
Betriebsdruck: 1000bar operating pressure: 14500psi

E 004
®
Berstdruck: 1400bar burst pressure: 20300psi E
Typenschild wird an part no.: 04.04062.1000
00.04062.1000
Berstscheibe ange- operating
pressure:
burst
1000 bar / 14500 psi ß Mit Betriebsdruck signiert
ZeichFreig_PDF A3
drahtet! pressure: 1400 bar / 20300 psi Zul.Abweichung
1:1 Gewicht in kg
f.Maße ohne
Mat.: ................. Torque: 0.4340

110 ISO 2768 - mH

Ser.No: ................. Nm
Verwendungszweck
Oberfläche nach
DIN ISO 1302
Bearb 13.01.1992 Wewer
F Gepr. 11.03.2011 Sommerkamp F
004 Darstellung geä. 10.03.2011 Pöts
Norm 11.03.2011 Krabus BERSTSCHEIBE
003 Anzugsmoment geändert 04.04.2005 Gut Zeichnungs-Nr. Revision Blatt
1 2 3 4
002
001
Zust
Darstellung geä.
Anziehdrehmoment
Änderung
11.06.2003 Pöts
07.05.2001 Wew
Datum Name
D-59302 OELDE
CAD-Zeichnung
00.04062.1000-1
Ers.durch Ers.für
004 1 von
1 Bl.
PARTS LIST (41)

Description : DISCHARGE FITTING http://www.hammelmann.de
Date : 06.03.2017
Page : 1

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 50
240
A A
4
20
(M16) (M12) 4
30
4
003
B B
60
90
55
40
1
(Festigkeitsklasse 10) 55
(Property class 10)
85
C (Festigkeitsklasse 10.9) C
(Skt. SW 22 ) Anziehdrehmoment Ma = 100 Nm 10 (Property class 10.9)
Tightening torque Ma = 100 Nm Druckregelventile 00.05893.xxxx 1
Pressure regulating valve 00.05893.xxxx
D D
Betriebsdruck max. 1800 bar

Max. operating pressure 1800 bar
1:5
E E
Artikel-Nr. Format DIN
08.00200.9201
85
ZeichFreig A3
Zul.Abweichung Maßstab
1:1 Gewicht in kg
f.Maße ohne
6.0165
Toleranzangabe
ISO 2768 - mH
Verwendungszweck
Oberfläche nach
DIN ISO 1302
(M48 x 2) Datum Name Benennung
F
Bearb
Gepr.
25.01.1995 T.GERNDT
23.11.2015 Oberscheidt DISCHARGE FITTING F
Norm 24.11.2015 Krabus ARMATUR (DRUCKSEITIG)
003 Stückliste Pos. 30 23.11.2015 Will Zeichnungs-Nr. Revision Blatt
1 2 3 4
002 Solid Edge Zng. erstellt
001 Stkl. u. Betr.drk. geä.
Zust Änderung
10.04.2008 PS
07.09.2005 Pöts
Datum Name
D-59302 OELDE
CAD-Zeichnung
08.00200.9201-1
Ers.durch Ers.für
003 1 von
1 Bl.
PARTS LIST (41)

Drawing no. : POB 3309, D-59282 Oelde, Germany
Description : UNIT http://www.hammelmann.de
HDP500; VOLVO TAD1672 STUFE 4 Date : 07.03.2017
Page : 1

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
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
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
>>>end<<<
p_dbgs01.p
PARTS LIST (41)

Description : CRANK SECTION http://www.hammelmann.de
HDP500 I=3,889 Date : 06.03.2017
Page : 1

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
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
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
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
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
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)

HDP500 I=3,889 Date : 06.03.2017
Page : 2

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
610 610 00.01015.0020 OIL FILTER 1 1,000 pc
620 620 01.03535.1261 TUBE 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)

HDP500 I=3,889 Date : 06.03.2017
Page : 3

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
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 3 4 5 6 7 8 9 10 11 12
1350 B6B A6A B 190

3 A
3
200 290 270 300
Anziehdrehmoment 3 1 4 2
A Ma = 250 Nm A
Skt.SW60 180
3 1130
970 1
950 170 2
3
90
D 3 1320 50 1120
30 3 4 4 4
160
2 6
150 1000 1110 1120 1300 1310
40 3 1 1 4 4 4
8 610
140 300
50 3 1 2 1100
B 8 1 B
130 270
3 530
70 4 1
3 630
100 320
3 2 2 900
120
3 C 620 C 570
1
2 1 E
110
3 370
60
F 28
260
C 1 360 C
1 1
80 480 240
3 2 D 1
1380
1
1390
1
10 E 1090 290
1 1 1
20
2
670
Anziehdrehmoment M24 2 590 1020
450 Nm, Iskt.SW19 250 1
1 1
D Anziehdrehmoment M27 690 D
650 Nm, Iskt. SW19 2 250
1
680
2 230
Anziehdrehmoment
Ma = 125 Nm 220 1
1 210 215
Skt.SW24
B F 650
1
A
1 1
1030
1
1040
2
1050
1
1060
1
Z
E 1360 C6C 560 550 540 510 500 800 D6D 1220 960 990 E
Y 2 2 2 1 1 1 1 2 1 1
1370
2 1:2
810
1
440 470 490 430
Y
F6F 1 1 1 7 1210
1
1200 1170 1180 1160 1230 750 1080 980 1070 990
1 1 1 1 1 1 1 1 1 1
F Z 1210
1
F
1:2
T 1240
1
770
710 1
1 930
1
G G
T
1:2 E6E
880
1
730 740 890
2 1 1 Blatt 1 von 2
870 Achtung : * Artikel6Nr. Format DIN
00.02350.1167
1 6 vor der kompletten Montage , Pos.90

ZeichFreig A1
Zul.Abweichung
auf 6196°C abgekühlt und ins Gehäuse

1:4 Gewicht in kg
f.Maße ohne
860 1506.0000

ISO 2768 6 mH
1 Verwendungszweck Halbzeug Werkstoff *
H Pos.10 eingeschrumpft HDP500 i=3,889 Oberfläche nach
DIN ISO 1302
H
850 6 Übergang vom Ring Pos.90 zum Bearb 10.06.2013 Sander
1 Gepr. 10.03.2015 Hartmann
1020 1250 270 1020 1290 810 1280 1270 720 Gehäuse mit Seevenax beschichtet. Norm 11.03.2015 Krabus KURBELTRIEB
004 Stücklistenänderung 05.03.2015 Wei
1 1 4 1 2 2 2 2 2 003 Stücklistenänderung 19.12.2014 Pla Zeichnungs6Nr. Revision Blatt
1 2 3 4 5 6 7 8 9
002
001
Zust
Stkl Pos.330 geä (Blatt2)
Änderung
05.03.2014
08.10.2013
Datum
Wei
Pöts
Name
D659302 OELDE
CAD6Zeichnung
00.02350.1167 1
Ers.durch
004
Ers.für 00.02350.098661
1 von
1 Bl.
1 2 3 4 5 6 7 8 9 10 11 12
A A
990 960
1 1
390
B 1
B
980
1 940
3
790 1070 410
1 1 004
1
400
1260 004
1
1
380
770 1
C 1 330 C
1
350
1
340
1
D D
E E
F F
G G
Blatt 2 von 2
00.02350.1167
ZeichFreig A1
Zul.Abweichung
1:4 Gewicht in kg
f.Maße ohne
1506.0000

ISO 2768 6 mH
H HDP500 i=3,889 Oberfläche nach
DIN ISO 1302 H
Bearb 10.06.2013 Sander
Gepr. 10.03.2015 Hartmann
004 Stücklistenänderung 05.03.2015 Wei

Norm 11.03.2015 Krabus KURBELTRIEB
003 Stücklistenänderung 19.12.2014 Pla Zeichnungs6Nr. Revision Blatt
1 2 3 4 5 6 7 8 9
002
001
Zust
Stkl Pos.330 geä (Blatt2)
Änderung
05.03.2014
08.10.2013
Datum
Wei
Pöts
Name
D659302 OELDE
CAD6Zeichnung
00.02350.1167 1
Ers.durch
004
Ers.für 00.02350.098661
1 von
1 Bl.
PARTS LIST (41)

Description : OIL COOLER http://www.hammelmann.de
HDP480 Date : 06.03.2017
Page : 1

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 O 200
630 ±0,5 O 180
12 a O 0,2 A M12
a O 0,2 A
Schweißnaht-ø154,5 mm max.
Demontage A ß
( G3/4 )
Öl ein
( G3/4 ) Schweißnaht
G3/4
002 A
55
B B
X
-0,2
-0,1
O 152,5
O 150
55
60°
( 6x
ß
)
( G1/2 )
( G3/4 )
Ölablass
G3/4
002
60 10
002
50 20 40 30
M12
Demontage
A
C C
1 1 1 1 1 1
ß
X 002
Öl aus
G3/4
ß
G1/4 Aufkleber : Hammelmann
optionaler Anschluss Art.-Nr. : 00.02198.0025
Baujahr :
Bestell-Nr.:
D ß D
Wasser aus
G1/2
ß
Wasser ein
O13 G1/2
Befestigungsbohrung
E Mantel hydrostatisch mit 45 bar abgedrückt E

Rippenrohrwendel bei Fertigungsprozess
mit 25 bar Luft unter Wasser abgedrückt
ß signieren
002 Lackierung erfolgt auftragsbezogen!
* Rippenrohr aus CuNi 10Fe 1Mn Artikel-Nr. Format DIN
X
00.02198.0025
ZeichFreig A2
Zul.Abweichung
1:2 Gewicht in kg
f.Maße ohne
19.0500

ISO 2768 - mH
Verwendungszweck
Oberfläche nach
F HDP480 DIN ISO 1302 F
Bearb 11.03.2009 Hunke
Gepr. 24.10.2012 EHelmig
Norm 25.10.2012 Krabus OELKUEHLER
Zeichnungs-Nr. Revision Blatt
1 2 3 4 5
002 Stkl-, Maßänd,Text hinzu 24.10.2012 Pöts
001 Text komplett geändert 19.08.2009 Hun
Zust Änderung Datum Name
D-59302 OELDE
CAD-Zeichnung
00.02198.0025-1
Ers.durch Ers.für
002 1 von
1 Bl.
PARTS LIST (41)

Description : OIL FILTER http://www.hammelmann.de
HDP360/480/750 Date : 06.03.2017
Page : 1

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 2 3 4 5 6 7 8
A 004 004 A
50 30 90 40 60 10 20
1 1 1 1 2 1 1 80
1
B B
C C
D 60 D
70
1 2
440
ca. 443
Betriebsdruck max. 30 bar

E Prüfdruck max. 45 bar E
00.01015.0020
ZeichFreig A3
Zul.Abweichung
1:1.5 Gewicht in kg
f.Maße ohne
13.0000

ISO 2768 - mH
Verwendungszweck
Oberfläche nach
HDP360/480/750 DIN ISO 1302
Bearb 02.03.2009 Hunke
F Gepr. 27.07.2016 Hartmann F
004 Stkl. geä. 26.07.2016 Pöts
Norm 28.07.2016 Krabus OELFILTER
003 Stücklistenänderung 12.12.2014 Waw Zeichnungs-Nr. Revision Blatt
1 2 3 4
002
001
Zust
Pos.40 geändert
Änderung
24.06.2014
12.04.2011
Datum
San
Pöts
Name
D-59302 OELDE
CAD-Zeichnung
00.01015.0020-1
Ers.durch Ers.für
004 1 von
1 Bl.
PARTS LIST (41)

Description : SUCTION CHAMBER http://www.hammelmann.de
HDP360-500 D28 - 65 Date : 06.03.2017
Page : 1

10 10 01.04246.0224 SUCTION CHAMBER 1 1,000 pc
20 20 01.04380.1080 DISC 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
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
1 2 3 4 5 6 7 8
80 640
1 10
1
40
A 8 A
45
°
50
8
W
22,5°
358
70
180
2
B 90 B
20 2
12
30 O 180
12 Saugraum bei Montage mit Kurbeltrieb
mit Kleber "TEROKAL 3 2444"
(04.02056.0005) umlaufend angedichtet.
9 7 1 3 5 11
C C
12 6 4 2 8 10
D D
Schrauben Pos. 30 mit integriertem Schmiermittel
001 und in angegebener Reihenfolge ohne Fett
angezogen:
W 1. Stufe: Anziehdrehmoment Ma = 200 Nm
2. Stufe: Anziehdrehmoment Ma = 800 Nm
E E
Bronze Saugraum mit 1x DIN DN100 ; PN16

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

ISO 2768 3 mH
Verwendungszweck Halbzeug Werkstoff*
F HDP3603500 D28360 Oberfläche nach
DIN ISO 1302 2.0975 F
Bearb 23.04.2012 Sander
Gepr. 28.02.2013 EHelmig
Norm 28.02.2013 Krabus SAUGRAUM
Zeichnungs3Nr. Revision Blatt
1 2 3 4 5
001 Text geändert
Zust Änderung
28.02.2013 San
Datum Name
D359302 OELDE
CAD3Zeichnung
00.04246.0184 1
Ers.durch Ers.für
001 1 von
1 Bl.
PARTS LIST (41)

Description : DRIVE http://www.hammelmann.de
HDP480; DEUTZ TCD 2015 V08 Date : 06.03.2017
Page : 1

20 20 00.02250.0432 COUPLING 1 1,000 pc
30 30 00.01642.0386 PROTECTION 1 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
60 30
10 1
50
10
B 003 B
(O 466,7 )
(O 438,2 )
C C
40
8
286,5
25,4
D D
003
38 (Volvo)
29 (Deutz)
20
1
E E

ZeichFreig 00.00120.1244 A2
Zul.Abweichung
1:4 Gewicht in kg
f.Maße ohne
ß Härte geprüft 47.0000
Toleranzangabe
ISO 2768 - mH
Verwendungszweck
Oberfläche nach
F HDP 500 DIN ISO 1302 F
268,5 Datum Name Benennung
Bearb 11.01.2006 Schueppen
Gepr. 17.12.2015 Barton
Norm 17.12.2015 Krabus ANTRIEB
003 Maße Volvo nachgetrg. 16.12.2015 Fra Zeichnungs-Nr. Revision Blatt
1 2 3 4 5
002 Maß 466,7 nachgetr.
001 Pos.10 entfällt
Zust Änderung
14.03.2007 Schü
18.01.2007 Schü
Datum Name
D-59302 OELDE
CAD-Zeichnung
00.00120.1244-1
Ers.durch Ers.für
003 1 von
1 Bl.
PARTS LIST (41)

Description : COUPLING http://www.hammelmann.de
HDP480; CAT C-18 Date : 06.03.2017
Page : 1

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 7 8
SAE14 Kupplungs-Bestell-Nr.:
A 286,5 A
70 im Lieferumfang
CM-5000-SCE-14-65078
enthalten (Pos.50)
32,5
30 60 Shore Silicon
1
Drehschwingungsberechnung: TVA-Nr. 05015
B O 13 Anziehdrehmoment 280Nm B
10 Tightening torque
1 Couple de serrage
203 20 22 JS9
1
167
A
im Lieferumfang 75
C enthalten (Pos.60,70) C
12
+0,2
11,5
(8x45°)
90,4
O 438,2 ±0,2
-0,1
A
O 466,7
O 85 H7
O 154
O 115
D 31 D
Nut nach DIN 6885-1
40 205
1
298
Passmaß Abmaße Höchstmaß Mindestmaß
+0,026
22 JS9 -0,026 22,026 21,974
+0,035
E 85 H7 0,000 85,035 85,000 E
00.02250.0432
70 Gewindestift 1 DIN 914 M20x25 45H - Lieferumfang ß Mit Betriebsdruck signiert
ZeichFreig_PDF A3
60 Zylinderschraube 12 ISO 4762-10.9 M16x50 - Lieferumfang Zul.Abweichung
1:1.5 Gewicht in kg
f.Maße ohne
50 Stützscheibe 8 DIN 988 SS13x19x1,5 - Lieferumfang 40.0000

ISO 2768 - mH
Verwendungszweck
Oberfläche nach
40 Kupplungsring 1 C45 04.03465.0031 04-02999-02 HDP 480 mit CAT C-18 DIN ISO 1302
30 Kupplungsflansch 1 GkAlSi12(Cu) 04.01063.0009 04-01147-01 Bearb 18.03.2005 Schueppen
F 20 Kupplungsnabe 1 C45 04.02251.0121 04-03952-02 Gepr. 06.07.2009 Barton F
10 Kupplungselement 1 Silicon 04.03490.0043 04-03390-05
Norm 07.07.2009 Szustkowski KUPPLUNG
003 "Nur f. Ersatz" entfällt 02.07.2009 Schü Zeichnungs-Nr. Revision Blatt
Pos. Benennung Stck. Werkstoff Hammelmann-Nr. Centa-Nr.
1 2 3 4
002 Nur für Ersatz
001 Zeichng. auf Solid Edge
Zust Änderung
21.04.2009 Schü
25.10.2006 Hun
Datum Name
D-59302 OELDE
CAD-Zeichnung
00.02250.0432-1
Ers.durch Ers.für
003 1 von
1 Bl.
PARTS LIST (41)

Description : SUCTION SIDE FITTING http://www.hammelmann.de
HDP250/360,VOLVO (STAGE 3B) Date : 06.03.2017
Page : 1

10 10 00.00131.0143 CONNECTION FITTING 1 1,000 pc
20 20 00.02515.0211 LINE 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
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 7 8
10
20 1
A 1 A
30
1
70 60 50
B 4 4 4 B
40
1
130
1 DN50
80
C 1 C
150 140
3 3
90 100
180 190 200 1 1
12 6 6 170
2
160
D 1 D
E 110 120 E
1 1 * Artikel-Nr. Format DIN
00.00134.0389
ZeichFreig_PDF A3
Zul.Abweichung
1:5 Gewicht in kg
f.Maße ohne
54.0000

ISO 2768 - mH
Verwendungszweck
Oberfläche nach
HDP250/360 mit VOLVO DIN ISO 1302
Bearb 10.05.2011 Brunnert
F Gepr. 11.05.2011 Barton F
Norm 11.05.2011 Krabus ANSCHLUSSARMATUR(SAUGSEITIG)
1 2 3 4 Zust Änderung Datum Name

D-59302 OELDE
CAD-Zeichnung
00.00134.0389-1
Ers.durch Ers.für
000 1 von
1 Bl.
PARTS LIST (41)

Description : SUCTION SIDE FITTING http://www.hammelmann.de
HDP 380, 500, 800 Date : 06.03.2017
Page : 1

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
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
1 2 3 4 5 6 7 8
22,5°
50
( O 180 Vorschweißflansch 4
) DN100; PN16; DIN-ISO 2633 20
A 1 70 A
5
2
(O18)
15
60
8
445
100
110 X
B 2
4
1:2 B
010
1075
965
10
1
655
C 30 C
520
1
D X D
331 30 268
292
E E
Sauganschluß * Artikel-Nr. Format DIN
Losflansch DN65; DIN 2642
00.00134.0152
ZeichFreig_PDF A3
713,5

Zul.Abweichung
1:7.5 Gewicht in kg
596
f.Maße ohne
43.0000

ISO 2768 - mH
Verwendungszweck
Oberfläche nach
DIN ISO 1302
010 Pos.100 Menge 3 in 2 10.03.2010 Schü Bearb 26.01.2006 Schueppen
F 90
009 Pos.-Änderung 29.10.2009 Schü Gepr. 11.03.2010 Barton F
1
008
007
Solid-Edge Fehler
Solid-Edge Zchng. erst.
05.09.2006 Schü Norm
26.01.2006 Schü
12.03.2010 Szustkowski ANSCHLUSSARMATUR(SAUGSEITIG)
006 Positionsänderung 09.05.2005 Gut Zeichnungs-Nr. Revision Blatt
1 2 3 4
005
004
Zust
Pos.40 & 80 entfällt
Änderung
02.03.2005 Maa
23.02.2005 Gut
Datum Name
D-59302 OELDE
CAD-Zeichnung
00.00134.0152-1
Ers.durch Ers.für
010 1 von
1 Bl.
PARTS LIST (41)

Description : FILTER http://www.hammelmann.de
FILTER 300LTR/MIN Date : 06.03.2017
Page : 1

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
>>>end<<<
p_dbgs01.p
1 2 3 4 5 6 7 8
120 60
3 20
1 1
A 190 A
3 30
1
50 70
3 1
100
B 1 B
O 114,3
176
169 90
40 1
3 80
963
160 1
2 10
1:10
655
C 200 1 Filterbeutel (04.00995.XXXX) C

1 gehört nicht zur Baugruppe!
520
Typenschild ausgefüllt!
210
4
00.00995.0058
01.04565.0017
Artikel-Nr.
Baujahr / Serien-Nr.
D Betriebsdruck max. bar 10 D

Differenzdruck max. bar 1,25 (+/-10%)
Betriebstemperatur °C max.70
Durchflussmenge l/min 300
Inhalt Liter 25
268
110
1 A-A Hammelmann Maschinenfabrik GmbH
Zum Sundern 13-21 59302 Oelde Germany
Losflansch DN65 ; PN10 Telefon 02522/76-0 Telefax 02522/76444
Anschlussmaße nach DIN 2642 (O 14 )

E 220 E
006
1 * Artikel-Nr. Format DIN
00.00995.0058
(O11)
ZeichFreig A3
Zul.Abweichung
1:5 Gewicht in kg
f.Maße ohne
30.2000

ISO 2768 - mH
Verwendungszweck
Oberfläche nach
300l/min DIN ISO 1302
Bearb 16.12.1994 HEINR.
F 11.06.2012 Wei Gepr. 12.06.2012 Willems F
30
005
004
Solid-Edge Zchng. erst.
Pos.40 geändert
05.09.2006 Schü Norm
25.04.2005 Gut
13.06.2012 Krabus FILTER
A A 003
002
001
Typenschild geändert
Konvertierungsfehler
Diffdr. + Entl.-V.
29.06.2004 Gut
22.12.1999 Hein
17.11.1999 Sys D-59302 OELDE
Zeichnungs-Nr.
00.00995.0058-1
Revision
006
Blatt
1 von
1 Bl.
1 2 3 4 Zust Änderung Datum Name CAD-Zeichnung Ers.durch Ers.für
PARTS LIST (41)

Drawing no. : POB 3309, D-59282 Oelde, Germany
Description : CONNECTION FITTING, SUCTION SI http://www.hammelmann.de
HDP400 Date : 06.03.2017
Page : 1

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 6 7 8
10 20 Vorschweißflansch
1 1 C100x114,3-1.4571; PN16
A DIN 2633 A
30
2
40
B 1 B
445
( 114,3 x 3,6 )
60
C C
417
D D
004
50
1 204,5
(R 1/2) alle unbemaßten Schweißnähte a=3
004 Oberflächenbehandlung nach Hammelmann WN 3501
Schweißnähte sind zu passivieren durch:
bürsten, strahlen oder beizen.
E E
X alle Ecken und Kanten gratfrei
(R 1/4) Zul.Abweichung
1:5 Gewicht in kg
f.Maße ohne
Toleranzangabe
ISO 2768 - mH
Verwendungszweck
Oberfläche nach
DIN ISO 1302
Bearb 06.06.2001 Maas
F Gepr. 12.07.2012 Krabus F
004 Pos.50 Halbzeug geändert 09.07.2012 Jan
Norm 12.07.2012 Krabus ANSCHLUSSARMATUR(SAUGSEITIG)
003 Pos.40 aktualisiert 10.03.2010 Schü Zeichnungs-Nr. Revision Blatt
1 2 3 4
002
001
Zust
Maße korr.
Maßnachtrag
Änderung
16.10.2009
20.01.2003
Datum
Pöts
Maa
Name
D-59302 OELDE
CAD-Zeichnung
00.00134.0160-1
Ers.durch Ers.für
004 1 von
1 Bl.
PARTS LIST (41)

Description : WATER TANK http://www.hammelmann.de
1300L Date : 06.03.2017
Page : 1

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
60 60 02.00421.0007 WASHER 6 1,000 pc
80 80 04.04590.0125 HOSE 1 3,000 m
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
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 3 4 5 6 7 8
830 1200 150
A
130
1 Y 1
40 A
1:2,5 10 50
1
1 (G2) 1 160
1
O 14
400 400 153 X

B
1:12 B
354
Z X
C C
Y 80
1
1230
120
Z
D 2 1:3 D
858
60 70
6 6
DN 50
E Tankinhalt ca. 1300 l E
1250

X
00.05540.0346
20 90
ZeichFreig A3
1 4 ß Mit Teile-Nr. - Rev. signiert Zul.Abweichung Maßstab
1:20 Gewicht in kg
f.Maße ohne
264.0000

ISO 2768 - mH
30 100 Verwendungszweck
Oberfläche nach
DIN ISO 1302
1 4 Datum Name Benennung
Bearb 31.03.2016 OFranke
F 110 Gepr. 05.04.2016 Barton F
4 Norm 05.04.2016 Krabus TANK

D-59302 OELDE
CAD-Zeichnung
00.05540.0346-1
Ers.durch Ers.für
000 1 von
1 Bl.
PARTS LIST (41)

Description : TANK http://www.hammelmann.de
CA.1300L Date : 06.03.2017
Page : 1

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
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 6 7 8
355 352
50 40
A
1 1
X A
400 400
G2 A
75
240 230
1 1
B B
1340
10
60 1
1
250 180 20 200

1 1 2 1
C 190 C
59
44
1
1200 O 15
1230 Entleerungsanschluss
1250 G1 1/2
Sauganschluss 830
Schlauchtülle Ø76,1 850
D D
110 100 90 70 80
1 1 1 2 2
E E
120 X 150
2
130
1:5 1
160 Tankinhalt ca. 1300 l
2 1 *
Artikel-Nr. Format DIN
140 170 ß Mit Betriebsdruck signiert

2 1 Zul.Abweichung
1:10 Gewicht in kg
f.Maße ohne
240.0000

ISO 2768 - mH
Verwendungszweck Halbzeug Werkstoff*
F
Oberfläche nach
DIN ISO 1302 1.4301 F
Norm 05.04.2016 Krabus TANK
1 2 3 4 5 Zust Änderung Datum Name

D-59302 OELDE
CAD-Zeichnung
00.05540.0345-1
Ers.durch Ers.für
000 1 von
1 Bl.
PARTS LIST (41)

Description : float valve http://www.hammelmann.de
2" SCHWIMMERV.+KUGEL Date : 06.03.2017
Page : 1

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
20 68
1
G 2A
A A
Ventil geschlossen
10
B 1 B
ca. 405
ca. 18°
n til offen
V e
C C
150°
69
ca .
R 50
D D
Original 300mm Messingstange mit Brenner erwärmen

bis gute Verformbarkeit gegeben
E E
Zul.Abweichung
1:5 Gewicht in kg
f.Maße ohne
Toleranzangabe
ISO 2768 - mH
Verwendungszweck
Oberfläche nach
DIN ISO 1302
F Gepr. 01.07.2015 Brunnert F
Norm 02.07.2015 Krabus SCHWIMMERVENTIL

D-59302 OELDE
CAD-Zeichnung
00.05880.0007-1
Ers.durch Ers.für
000 1 von
1 Bl.
PARTS LIST (41)

Description : ARMATURE http://www.hammelmann.de
ARMATURE Date : 06.03.2017
Page : 1

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 6 7 8
23 90°
A 3,5 A
45 °
20
1 O 16
30 5 (O17,5)
1
B DN50 B
5
O 12
C C
40
1 10
226
1
50
D D
1
1:4
(G2 1/2"A)
99
E E
X
00.00131.0183
ZeichFreig_PDF A3
Zul.Abweichung
1:2 Gewicht in kg
f.Maße ohne
2.4000

ISO 2768 - mH
Verwendungszweck
Oberfläche nach
DIN ISO 1302
Bearb 12.11.1996 Franke
Norm 25.08.2010 Krabus ANSCHLUSSARMATUR
1 2 3 4
001 Solid-Edge Zchng. erst.
Zust Änderung
20.08.2010 Schü
Datum Name
D-59302 OELDE
CAD-Zeichnung
00.00131.0183-1
Ers.durch Ers.für
001 1 von
1 Bl.
PARTS LIST (41)

Description : FUEL TANK http://www.hammelmann.de
900L ALU-DIESEL Date : 06.03.2017
Page : 1

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
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
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 7 8
20
10 1
1 30
A 1 A
40 150
1 1 010
816
632
50
1
B B
Z
1230 1260
1280 1340
400 400 140 130 120
C (M12) C
7 14 7 80 90
25
60°
Z 6 6
15
1:20
225
5
350
25
500
D D
550
350
O 15
100 70
110
1 2
1
1230
40
60
350
Alu-Dieseltank 2
E Inhalt ca.900L E
550
00.05540.0262
ZeichFreig A3
Zul.Abweichung
1:10 Gewicht in kg
f.Maße ohne
177.0000

ISO 2768 - mH
Verwendungszweck
Oberfläche nach
200
DIN ISO 1302

010 Stückliste geändert 14.01.2016 Bru Bearb 06.06.2011 Brunnert
F 009 Ansicht aktualisiert 14.11.2013 Bru Gepr. 14.01.2016 Barton F
008 Ansicht aktualisiert 19.06.2013 Bru Norm 14.01.2016 Krabus TANK
(M12)
200 007 Flach hinzu 28.05.2013 Jac

006 Stücklistenänderung 12.04.2013 Bru Zeichnungs-Nr. Revision Blatt
1250
1 2 3 4
005
004
Zust
Pos.80:Stahl in Edelstahl
Änderung
15.03.2013
10.12.2012
Datum
Bru
Fra
Name
D-59302 OELDE
CAD-Zeichnung
00.05540.0262-1
Ers.durch Ers.für
010 1 von
1 Bl.
PARTS LIST (41)

Description : CONTROL LINE http://www.hammelmann.de
0-6BAR Date : 06.03.2017
Page : 1

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
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
B 1 P B
40 2
1
40 1 3
1
20
1
C C
0 - 6 bar
90
1
70 40 50 100
1 1 1 1
100 009
1
D D
009
10 50
1 1
009 009
E 100 40 60 E
1 1 1 Artikel-Nr. Format DIN
Zul.Abweichung
Magnetventil 24 VDC
Maßstab
1:5 Gewicht in kg
f.Maße ohne
Pos. 50 und Pos. 100 je nach Einbausituation 2.6000
Toleranzangabe
variabel montiert Solenoid valve 24 VDC Verwendungszweck ISO 2768 - mH

Oberfläche nach
Arrangement of item 50 and item 100 may vary Electrovanne 24 VCC DIN ISO 1302
according to installation. 009 Leitungsfilter nachgetrg. 24.02.2016 Fra Bearb

Datum Name CONDUITE
Benennung
15.09.1998 SCHUEPPEN
F L’arrangement des pos. 50 et 100 est variable Regelbereich 0 - 6 bar 008 Pos. 60 geändert 18.04.2012 PS Gepr. 04.03.2016 Barton CONTROL LINE F
au gré de l’installation. Range of adjustment 0 - 6 bar
Plage de réglage : 0 - 6 bar
007
006
Pos.40 geändert
Schaltbild geä.
04.02.2011 Fra Norm
09.06.2008 Pöts
04.03.2016 Krabus LEITUNG
005 Pos.-Änderung 14.05.2007 Schü Zeichnungs-Nr. Revision Blatt
1 2 3 4
004
003
Zust
Pos.10 entfällt
Kompl. überarb.
Änderung
09.06.2005 Schü
14.06.2004 Pöts
Datum Name
D-59302 OELDE
CAD-Zeichnung
08.99109.0050-1
Ers.durch Ers.für
009 1 von
1 Bl.
PARTS LIST (41)

Description : THERMOSTAT http://www.hammelmann.de
HDP380/500/800/MC Date : 06.03.2017
Page : 1

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 3 4
A 30 20
10
1 001 1 1
001
B
(M 12 )
VKA-Verschlusskegel 22 mit O-Ring

C
001
86
1:1
00.05630.0012
ZeichFreig A4
Zul.Abweichung
ß Mit Teile-Nr. signiert
ß Härte geprüft
f.Maße ohne
Toleranzangabe
ISO 2768 - mH
Maßstab
1:2 Gewicht in kg
0.1900
Oberfläche nach
HDP360/480/750

DIN ISO 1302

Norm 27.01.2016 Krabus THERMOSTAT
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
001 1 von
1 Bl.
PARTS LIST (41)

Description : LIFTING DEVICE http://www.hammelmann.de
PUMP HEAD Date : 06.03.2017
Page : 1

10 10 00.01630.1145 BRACKET 1 1,000 pc
20 20 02.00421.0009 WASHER 8 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
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
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
240 240 04.01671.0007 CLAMP-LEVER 2 1,000 pc
250 250 01.03200.0022 SHOCK ABSORBER 1 1,000 pc
>>>end<<<
p_dbgs01.p
1 2 3 4 5 6 7 8
A 80
1 A 200
1
230
2
220
2
210
2
90
2
150
4
A
Y 140 A
2
130
110 4
1 120
2
100
1 X 190
B 1 B
180
3 002
240
X Y
933
170 2
002
3
1:3
796
160
6
50
1
260
1
1:3
70
C 2 C
Anzugsdrehmoment 16Nm
60
1
min.
5
792
min
D 250 40 10 D
.
30 20
O
1 1 4 8 1
25
A-A
1:5
1:10
E Tragkraft max. 500kg E
384

Zul.Abweichung
1:8 Gewicht in kg
f.Maße ohne
Toleranzangabe
ISO 2768 - mH
Verwendungszweck
Oberfläche nach
DIN ISO 1302
792 Bearb 11.01.2013 Janzen
Norm 22.06.2016 Krabus VORRICHTUNG
1 2 3 4
002 Pos.170, 180 geändert.
001 Stückliste geändert
Zust Änderung
22.06.2016 Jan
01.03.2013 Jan
Datum Name
D-59302 OELDE
CAD-Zeichnung
00.06020.0143-1
Ers.durch Ers.für
002
00.06020.0131-1
1 von
1 Bl.
HAMMELMANN Artikel-Nr. / Code no. / Référénce no.: 04.00995.0177
Einbausatz / Insert / Partie intérieur IN-AGB1-125
Insert filters
Einbaufilter
Parties intérieur es intégrées
Type I/Model IN-AGB
Model IN-AGB
Flow rate:
up to 2000 l/min
Nennvolumenstrom:
bis 2000 l/min
Débit:
jusqu’à 2000 l/min
MBC 009 rev 7-05-03
Global Filtration Technology

Member of Parker Hannifin Corporation
SYMBOL EXPLANATION
SYMBOL DESCRIPTION UNIT

AL Aluminium
Cd Port dimension (BSP/G) Inch
E Element #
Fc Fluid compatibility #
Fµ Filter fineness Micron
XW Media type - Glass fibre
XX Media type - Cellulose
S Media type - Steel mesh
Ft Functional test #
GDL Media type HPFE Low pr. #
H Housing #
Mh Material filter housing #
Mwc Max. water content ppm
NA Not applicable
Orq On request #
Pb Burst pressure bar
Pi Indicator setting bar
P0 By-pass setting bar
POM Plastic
Pw Max. working pressure bar
Qd Flow direction #
Sm Seal material #
Std Standard #
SYMBOL ERKLÄRUNG
SYMBOL BESCHREIBUNG EINHEIT

AL Aluminium
Cd Anschluß (BSP/G) Inch
E Element #
Fc Fluid Verträglichkeit #
Fµ Filterfeinheit Micron
XW Filtermedia Glasfaser
XX Filtermedia Zellulose
S Filtermedia Edelstahlgewebe
Ft Funktionstest #
GDL Filtermedia HPFE Niederdruck #
H Filtergehäuse #
Mh Werkstoff Filtergehäuse #
Mwc Max. Wassergehalt ppm
NA Nicht zutreffend
Orq Auf Anfrage #
Pb Berstdruck bar
Pi Indikatoranzeige bar
P0 By-pass Öffnungsdruck bar
POM Plastik
Pw Max. Nenndruck bar
Qd Durchfluß Richtung #
Sm Dichtungsmaterial #
Std Standard #
EXPLICATION DE SYMBOLE
SYMBOLE DESCRIPTION UNITÉ

AL Aluminium
Cd Raccordements (BSP/G) Inch
E Élément #
Fc Compatibilité des fluides #
Fµ Finesses de filtration Micron
XW Fibre de verre
XX Cellulose
S Toile métallique inox.
Ft Test normalisé utilisé #
GDL Média type HPFE haute #
efficacité basse pression
H Corps de filtre #
Mh Matière du corps de filtre #
Mwc Taux d’eau max. ppm
NA Non applicable
Orq Sur demande #
Pb Pression d’éclatement bar
Pi Tarage de l’indicateur bar
P0 Tarage de by-pass bar
POM Plastique
Pw Max. pression de service bar
Qd Sens du débit #
Sm Matière de joints #
Std Standard #
COMPANY PROFILE UNTERNEHMENS PROFIL PROFIL DE L’ENTREPRISE
Parker Arlon is a leading designer and Parker Arlon ist ein führender 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 La société propose des solutions stan-
semi-standard and tailor-made solutions Anwendung finden. dards, semi-standards et personnalisées
that meet all requirements. The product Mit seinen Standards, Halbstandards pour toutes les demandes.
portfolio encompasses a wide variety of und kundenorientierten Lösungen bedient La gamme de produits comprend une
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® De plus, Parker Arlon assure un service
lysis services. Filter und AQUASAFE® wasserabsorbieren- d’analyse d’huile.
den Elementen. Zusätzlich bietet Parker
In-depth know-how and experience, Arlon einen Ölanalyse-Service an. Un grand savoir-faire et une longue
combined with an awareness of market expérience, ainsi qu’une connaissance des
demands and customer requirements are 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 Parker Arlon est certifié ISO9001 et
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 Qualität und Umwelt-Verantwortung kom-
and manufacturing facilities located in men durch technische Effizienz, Parker Arlon a ses bureaux d’études,
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
exporte 90% de sa production dans le

Parker Filtration BV is part of the Parker Arlon vereint Engineering, monde entier.
Parker Hannifin Corporation – the world’s Forschung & Entwicklung sowie
largest motion and control company, Produktion am Standort in Arnheim, Parker Filtration BV appartient au
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. dans la fabrication de composants pour le
Parker Filtration BV ist Teil der Parker contrôle des mouvements et des fluides.
Hannifin Corporation, einer der interna-
tional führenden Anbieter auf dem Gebiet
der Antriebstechnik.
2
ASSEMBLY PARTS TEILE-LISTE PIECES DETACHEES
ITEM NUMBER
TEIL NUMMER DESCRIPTION BESCHREIBUNG DESCRIPTION
NUMÉRO DE PART
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 INFORMATIONS TECHNIQUES
AGB-4-600 m: 13,0 kg
FILTER/FILTER/FILTRE GENERAL/ALGEMEIN/GÉNÉRALES
AGB-4-800 m: 14,0 kg
Q max IN-AGB-1 = 125 l/min AGB-4-1000 m: 16,8 kg Ft: ISO 2941
Q max IN-AGB-2 = 300 l/min AGB-4-1500 m: 21,4 kg ISO 2942
Q max IN-AGB-3 = 500 l/min AGB-4-2000 m: 28,3 kg ISO 2943
Q max IN-AGB-4 = 2000 l/min ISO 3724
Sm: NBR, CR, FPM ISO 3968
T: –40 0C/+120 0C ISO 4572
Pb: 10 bar
Fc: Oil type; Öl Type; Type d’huile
BY-PASS/BY-PASS/BY-PASS MEDIA/MEDIUM/MÉDIUM HH - HL - HLP - HV
HETG - HEPG - HEES
P0: 0,8 / 1,5 bar Qd: In/Out; Innen/Aussen; Intérieur/Extérieur HFA (mineral base) - HFB - HFC
HFA (synthetic base) - Orq Please
INSERT/EINBAUSATZ/PARTIE INTÉRIEUR Fµ XW: GDL 1 - 3 - 6 - 10 - 20µm contact Parker Arlon
Fµ S: 40 - 120µm
AGB-1-30 m: 0,5 kg Fµ XX: 10µm nom
AGB-1-60 m: 0,6 kg
AGB-1-90 m: 0,8 kg MWc: 500 ppm
AGB-1-120 m: 0,9 kg
AGB-1-125 m: 1,1 kg
AGB-2-170 m: 2,1 kg
AGB-2-230 m: 2,2 kg
AGB-2-300 m: 2,4 kg
AGB-3-270 m: 2,8 kg
AGB-3-390 m: 3,0 kg
AGB-3-500 m: 3,6 kg
FILTRATION EFFICIENCY ABSCHEIDE RATE EFFICACITÉ DE FILTRATION
MEDIA MICRON FILTRATION RATIO

FILTERMEDIA MIKRON FILTER FEINHEIT
MÉDIA MICRON NIVEAU DE FILTRATION
− − − − − − − −
β X ≥75 β3 β6 β 10 β 12 β 20 β 25 β 55
GDL1 1 400 4000 >5000 >5000 >5000 >5000 >5000
GDL3 3 ≥75 1000 >5000 >5000 >5000 >5000 >5000
GDL6 6 8 ≥75 1000 >5000 >5000 >5000 >5000
GDL10 10 5 17 ≥75 >200 >5000 >5000 >5000
GDL20 20 N/A 2 8 10 ≥75 >5000 >5000
XX10 33 N/A N/A 2.6 3.5 6 23 >5000
3
INSTALLATION DIMENSIONS EINBAU-ABMESSUNGEN ENCOMBREMENT
MOUNTING ARRANGEMENT
TYPE
TYP A B H h d x y s p C D E F G
TYPE
IN-AGB1-30 87 79 122 35 20 4 6 45 20 88 85 80 4 12
IN-AGB1-60 87 79 173 35 20 4 6 45 20 88 85 80 4 12
IN-AGB1-90 87 79 217 35 20 4 6 45 20 88 85 80 4 12
IN-AGB1-120 87 79 267 35 20 4 6 45 20 88 85 80 4 12
IN-AGB1-125 87 79 381 35 20 4 6 45 20 88 85 80 4 12
IN-AGB2-170 125 116 284 48 25 5 8 77 42 126 122 117 5 15
IN-AGB2-230 125 116 360 48 25 5 8 77 42 126 122 117 5 15
IN-AGB2-300 125 116 559 48 25 5 8 77 42 126 122 117 5 15
IN-AGB3-270 150 138 325 62 30 7 12 100 55 151 149 139 5 18
IN-AGB3-390 150 138 405 62 30 7 12 100 55 151 149 139 5 18
IN-AGB3-500 150 138 595 62 30 7 12 100 55 151 149 139 5 18
IN-AGB4-600 230 216 505 100 40 13.5 12 142 60 231 227 217 6 20
IN-AGB4-800 230 216 615 100 40 13.5 12 142 60 231 227 217 6 20
IN-AGB4-1000 230 216 720 100 40 13.5 12 142 60 231 227 217 6 20
IN-AGB4-1500 230 216 1000 100 40 13.5 12 142 60 231 227 217 6 20
IN-AGB4-2000 230 216 1265 100 40 13.5 12 142 60 231 227 217 6 20
AGB 3 AGB 4
TYPE
TYP K L M U V Q R
TYPE
IN-AGB3-270 290 110 175 106 55 178

IN-AGB3-390 370 110 175 106 55 178
IN-AGB3-500 560 120 175 106 55 178
IN-AGB4-600 445 183 239 145 60 250.5 2.5
IN-AGB4-800 555 183 239 145 60 250.5 2.5
IN-AGB4-1000 660 183 239 145 60 250.5 2.5
IN-AGB4-1500 940 183 239 145 60 250.5 2.5
IN-AGB4-2000 1205 183 239 145 60 250.5 2.5
4
∆p/Q GRAPHS ∆p/Q KENNLINIEN ∆p/Q COURBES DE DÉBIT
T- -elements T2-elements
FLUID/FLUID/FLUIDE ν = 32cSt
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 T14-elements T-elements
5
∆p/Q GRAPHS ∆p/Q KENNLINIEN ∆p/Q COURBES DE DÉBIT
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 T14-elements
∆p CALCULATION ∆p KALKULATION CALCUL ∆p
FLUID/FLUID/FLUIDE A: FLUID/FLUID/FLUIDE B:
νa = 32cSt / γ = 0.87 νb = 46cSt / γ = 1.1
∆p E = 0.5 bar ∆p E = (46/32)x0.5 = 0.72 bar

∆p H = 0.1 bar ∆p H = (1.1/0.87)x0.1 = 0.13 bar
∆p Tot. A = 0.6 bar ∆p Tot.B = 0.85 bar
6
ORDERING INFORMATION / BESTELLDATEN / COMMENT PASSER VOTRE COMMANDE
1 3 4
Variety/ Diffuser/ Seal material/
Ausfuhrung/ Auslaufrohr/ Dichtungen/
Variante code Bac d’ecoulement code Joints code
IN-AGB 1-30 30 No Diffuser Buna (NBR) B
Ohne Auslaufrohr -
IN-AGB 1-60 60 Sans bac d’ecoulement Neoprene (CR) N
IN-AGB 1-90 90 Diffuser for ≥ 3-270 Viton (FPM) V
IN-AGB 1-120 120 Auslaufrohr für ≥ 3-270 T
Bac d’ecoulement pour ≥ 3-270
IN-AGB 1-125 125
IN-AGB 2-170 170
5
IN-AGB 2-230 230
By-pass setting/
IN-AGB 2-300 300
By-pass Öffnungsdruck/
IN-AGB 3-270 270
By-pass code
IN-AGB 3-390 390
0.8 bar 08
IN-AGB 3-500 500
1.5 bar 15
IN-AGB 4-600 600
blocked B
IN-AGB 4-800 800
IN-AGB 4-1000 1000
IN-AGB 4-1500 1500
IN-AGB 4-2000 2000
2
Element/ Nominal Filtration fineness absolute/ Filterfeinheit Absolut/ Finesse de filtration absolue
Element/ Cellulose/ Stainless steel mesh/
Élément Zellulose/ LEIF ® Rostfrei Metallgewebe/
Cellulose − Toile métallique inoxydable
HPFE glass fibre/ HPFE Glasfaser/ HPFE fibre de verre β X ≥ 75
10µm 3µm 6µm 10µm 20µm 40µm
code code code code code code
IN-AGB 1-30 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 1-120 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 2-300 TXX5A-10 TXWL5A-3 TXWL5A-6 TXWL5A-10 TXWL5A-20 ST5A-40
IN-AGB 3-500 TXX8C-10 TXWL8C-3 TXWL8C-6 TXWL8C-10 TXWL8C-20 ST8C-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 TXW14-6 TXW14-10 TXW14-20 ST14-40
Ordering example element Ordering example filter

Bestellbeispiel Element Bestellbeispiel Filter
Exemple de commande de l’élément 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. Note: Filter with LEIF ® element and sleeve.
Ersatz LEIF ® -Element ohne Filterkorb. Filter mit LEIF ® -Element und Filterkorb.
Pièce detachée l’élément LEIF®: sans enveloppe métallique. Filtre avec l’élément LEIF ® et enveloppe métallique.
7
ORDERING INFORMATION / BESTELLDATEN / COMMENT PASSER VOTRE COMMANDE
Parker Filtration BV Parker Hannifin plc Parker Hannifin Oy

Parker Arlon Filter Division Europe HQ Finn-Filter
Filter Division Europe Shaw Cross Business Park Filter Division Europe
Stieltjesweg 8 Dewsbury, West Yorkshire Salmentie 260
6827 BV Arnhem WF12 7 RD UK FIN - 31700 Urjala As.
The Netherlands Phone: +44 1924 487000 Finland
Phone: +31 26 3760376 Fax: +44 1924 487038 Phone: +358 3 54100
Fax: +31 26 3643620 E-mail: Fax: +358 3 5410100
E-mail: arlon@parker.com filtrationinfo@parker.com finnfilter@parker.com
www.parkerarlon.nl www.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
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-pass-
Konstruktion
• 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
HAMMELMANN Artikel-Nr. / Code no. / Réference no.: 04.03070.0007
Safety Data Sheet according to Regulation (EC) No.
1907/2006 (REACH)
Printed 10.07.2009
Revision 07.01.2008 (GB) Version 2.0
SRS TFX
! 1. IDENTIFICATION OF THE SUBSTANCE/PREPARATION AND OF THE COMPANY/UNDERTAKING
Name of product 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 Name [% weight] Classification
68649-42-3 Zinkalkyldithiophosphat. <2 N, Xi,R38-41-51/53
alkyliertes Phenol < 1,5 N, R51/53
91648-65-6 substituiertes Thiadiazol. < 0,15 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.
1907/2006 (REACH)
Printed 10.07.2009
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
1907/2006 (REACH)
Printed 10.07.2009
SRS TFX
8. EXPOSURE CONTROLS/PERSONAL PROTECTION

Ingredients with occupational exposure limits to be monitored
CAS No Name Code [mg/m3] [ppm] Spitzenb. Remark
oil mist 8 hours 5 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 Remark
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
Solubility in water insoluble
Viscosity 1 kinematic ca. 13,8 mm2/s 100 °C DIN 51562
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.
1907/2006 (REACH)
Printed 10.07.2009
SRS TFX
11. TOXICOLOGICAL INFORMATION
Acute toxicity/Irritability/Sensitization
Value/Validation Species Method Remark
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 non-sensitising
respiratory system
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 Method of analysis Method Validation
Physico-chemical
degradability The product is slightly soluble in water. It can be largely eliminated from the water by abiotic processes, e.g.
mechanical separation.
Biological not readily degradable

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

1907/2006 (REACH)
Printed 10.07.2009
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/ Accident regulation, appendix I: not specified
remarks
! 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

Version 2.0
Effective Date 04.12.2012
Regulation 1907/2006/EC
Safety Data Sheet
SECTION 1. IDENTIFICATION OF THE SUBSTANCE/MIXTURE AND OF THE

COMPANY/UNDERTAKING
1.1 Product Identifier
Material Name : Shell Omala S4 GX 320

Product Code : 001D7852
1.2 Relevant identified uses of the substance or mixture and uses advised against
Product Use : Gear lubricant.
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 : Shell Deutschland Oil GmbH

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

Fax : (+49) 40 6321-051
Email Contact for : If you have any enquiries about the content of this SDS please
Safety Data Sheet 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 R-phrase(s)
Not classified as dangerous under EC criteria.;
Sensitiser not sufficient to : Contains alkylamine. May produce an allergic reaction.

classify
2.2 Label Elements

1/17
Print Date 26.12.2012 000000019336
MSDS_DE
Version 2.0
Safety Data Sheet
Labeling according to Directive 1999/45/EC
EC Symbols : No Hazard Symbol required
EC Classification : Not classified as dangerous under EC criteria.

EC Risk Phrases : Not classified.
EC Safety Phrases : Not classified.
2.3 Other Hazards
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.
SECTION 3. COMPOSITION/INFORMATION ON INGREDIENTS
3.1 Substance
Material Name : Not applicable.
3.2 Mixtures
Mixture Description : Blend of polyolefins and additives.
Hazardous Components
Classification of components according to Regulation (EC) No 1272/2008
Chemical Name CAS No. EC Number REACH Registration Conc.

No.
Long-chain alkyl amine Not available Not available Not available / Not 0,10 - 0,24%
applicable.
2/17
Print Date 26.12.2012 000000019336
MSDS_DE
Version 2.0
Safety Data Sheet
Chemical Name Hazard Class & Category Hazard Statement

Long-chain alkyl amine Acute Tox., 4; Acute Tox., 3; Acute H302; H331; H311; H314;
Tox., 3; Skin Corr., 1B; Skin Sens., 1; H317; H373; H410;
STOT RE, 2; Aquatic Chronic, 1;
Classification of components according to 67/548/EEC
Chemical Name CAS No. EC REACH Symbol(s) R-phrase(s) Conc.

Number Registration
No.
Long-chain alkyl Not available Not Not available T, C, N R22; R23/24; 0,10 -
amine available / Not R34; R43; 0,24%
applicable. R48/20;
R50/53
Additional Information : 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 : Not expected to be a health hazard when used under normal
conditions.
Inhalation : No treatment necessary under normal conditions of use. If
symptoms persist, obtain medical advice.
Skin Contact : Remove contaminated clothing. Flush exposed area with water
and follow by washing with soap if available. If persistent
irritation occurs, obtain medical attention.
Eye Contact : Flush eye with copious quantities of water. If persistent
irritation occurs, obtain medical attention.
Ingestion : In general no treatment is necessary unless large quantities
are swallowed, however, get medical advice.
Self-protection of the first : When administering first aid, ensure that you are wearing the
aider appropriate personal protective equipment according to the
incident, injury and surroundings.
4.2 Most important : Oil acne/folliculitis signs and symptoms may include formation
symptoms and effects, of black pustules and spots on the skin of exposed areas.
both acute and delayed Ingestion may result in nausea, vomiting and/or diarrhoea.
4.3 Indication of any : Notes to doctor/physician:
immediate medical Treat symptomatically.
attention and special
3/17
Print Date 26.12.2012 000000019336
MSDS_DE
Version 2.0
Safety Data Sheet
treatment needed
SECTION 5. FIRE FIGHTING MEASURES
Clear fire area of all non-emergency personnel.
5.1 Extinguishing Media : Foam, water spray or fog. Dry chemical powder, carbon
dioxide, sand or earth may be used for small fires only.
Unsuitable Extinguishing : Do not use water in a jet.
Media
5.2 Special hazards : Hazardous combustion products may include: A complex
arising from the mixture of airborne solid and liquid particulates and gases
substance or mixture (smoke). Carbon monoxide. Unidentified organic and inorganic
compounds.
5.3 Advice for firefighters : 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, : 6.1.1 For non emergency personnel: Avoid contact with skin
Protective Equipment and and eyes.
Emergency Procedures
6.1.2 For emergency responders: Avoid contact with skin and
eyes.
6.2 Environmental : Use appropriate containment to avoid environmental
Precautions contamination. Prevent from spreading or entering drains,
ditches or rivers by using sand, earth, or other appropriate
barriers.
6.3 Methods and Material : Slippery when spilt. Avoid accidents, clean up immediately.
for Containment and Prevent from spreading by making a barrier with sand, earth or
Cleaning Up other containment material. Reclaim liquid directly or in an
absorbent. Soak up residue with an absorbent such as clay,
sand or other suitable material and dispose of properly.
Additional Advice : Local authorities should be advised if significant spillages
cannot be contained.
6.4 Reference to other : For guidance on selection of personal protective equipment
4/17
Print Date 26.12.2012 000000019336
MSDS_DE
Version 2.0
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 : 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.
7.1 Precautions for Safe : Avoid prolonged or repeated contact with skin. Avoid inhaling
Handling 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.
7.2 Conditions for safe : Store at ambient temperature.
storage, including any
incompatibilities
Refer to section 15 for any additional specific legislation
covering the packaging and storage of this product.
Recommended Materials : For containers or container linings, use mild steel or high
density polyethylene.
Unsuitable Materials : PVC.
7.3 Specific end use(s) : Not applicable
Additional Information : 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
Version 2.0
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
Version 2.0
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 : The provided information is made in consideration of the PPE
Equipment 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.
Eye Protection : Wear safety glasses or full face shield if splashes are likely to
occur. Approved to EU Standard EN166.
Hand Protection : Where hand contact with the product may occur the use of
gloves approved to relevant standards (e.g. Europe: EN374,
US: F739) made from the following materials may provide
suitable chemical protection: PVC, neoprene or nitrile rubber
gloves. Suitability and durability of a glove is dependent on
usage, e.g. frequency and duration of contact, chemical
resistance of glove material, 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
Version 2.0
Safety Data Sheet
dependent on the exact composition of the glove material.

Body protection : Skin protection not ordinarily required beyond standard issue
work clothes.
Respiratory Protection : No respiratory protection is ordinarily required under normal
conditions of use. 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.
Thermal Hazards : Not applicable.
Environmental Exposure Controls

Environmental exposure : Minimise release to the environment. An environmental
control measures assessment must be made to ensure compliance with local
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 : Amber. Liquid at room temperature.
Odour : Slight hydrocarbon.
Odour threshold : Data not available
pH : Not applicable.
Initial Boiling Point and : > 280 °C / 536 °F estimated value(s)
Boiling Range
Pour point : Typical -42 °C / -44 °F
Flash point : Typical 252 °C / 486 °F (COC)
Upper / lower Flammability : Typical 1 - 10 %(V)
or Explosion limits
Auto-ignition temperature : > 320 °C / 608 °F
Vapour pressure : < 0,5 Pa at 20 °C / 68 °F (estimated value(s))
Relative Density : Typical 0,883 at 15 °C / 59 °F
Density : Typical 883 kg/m3 at 15 °C / 59 °F
Water solubility : Negligible.
Solubility in other solvents : Data not available
8/17
Print Date 26.12.2012 000000019336
MSDS_DE
Version 2.0
Safety Data Sheet
n-octanol/water partition : > 6 (based on information on similar products)

coefficient (log Pow)
Dynamic viscosity : Data not available
Kinematic viscosity : Typical 312,7 mm2/s at 40 °C / 104 °F
Vapour density (air=1) : > 1 (estimated value(s))
Evaporation rate (nBuAc=1) : Data not available
Decomposition : Data not available
Temperature
Flammability : Data not available
Oxidizing Properties : Data not available
Explosive Properties : Not classified
9.2 Other Information

Electrical conductivity : This material is not expected to be a static accumulator.
Other Information : not a VOC

Volatile organic compound : 0%
SECTION 10. STABILITY AND REACTIVITY
10.1 Reactivity : The product does not pose any further reactivity hazards in
addition to those listed in the following sub-paragraph.
10.2 Chemical stability : No hazardous reaction is expected when handled and stored
according to provisions.
10.3 Possibility of :
Hazardous Reactions Reacts with strong oxidising agents.
10.4 Conditions to Avoid : Extremes of temperature and direct sunlight.
10.5 Incompatible : Strong oxidising agents.
Materials
10.6 Hazardous : Hazardous decomposition products are not expected to form
Decomposition Products 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
Version 2.0
Safety Data Sheet
Likely Routes of : Skin and eye contact are the primary routes of exposure
Exposure although exposure may occur following accidental ingestion.
Acute Oral Toxicity : Expected to be of low toxicity: LD50 > 5000 mg/kg , Rat
Acute Dermal Toxicity : Expected to be of low toxicity: LD50 > 5000 mg/kg , Rabbit
Acute Inhalation Toxicity : Not considered to be an inhalation hazard under normal
conditions of use.
Skin corrosion/irritation : Expected to be slightly irritating. Prolonged or repeated skin
contact without proper cleaning can clog the pores of the skin
resulting in disorders such as oil acne/folliculitis.
Serious eye : Expected to be slightly irritating.
damage/irritation
Respiratory Irritation : Inhalation of vapours or mists may cause irritation.
Respiratory or skin : For respiratory and skin sensitisation: Not expected to be a
sensitisation sensitiser.
Aspiration Hazard : Not considered an aspiration hazard.
Germ cell mutagenicity : Not considered a mutagenic hazard.

Carcinogenicity : Not expected to be carcinogenic.
Reproductive and : Not expected to be a hazard.
Developmental Toxicity
Summary on evaluation of the CMR properties

Carcinogenicity : This product does not meet the criteria for classification in
categories 1A/1B.,
Mutagenicity : This product does not meet the criteria for classification in
categories 1A/1B.
Reproductive Toxicity : This product does not meet the criteria for classification in
(fertility) categories 1A/1B.
Specific target organ : Not expected to be a hazard.

toxicity - single exposure
Specific target organ : Not expected to be a hazard.
toxicity - repeated
exposure
Additional Information : Used oils may contain harmful impurities that have
accumulated during use. The concentration of such impurities
will depend on use and they may present risks to health and
the environment on disposal. ALL used oil should be handled
with caution and skin contact avoided as far as possible.
Classifications by other authorities under varying regulatory
frameworks may exist.
10/17
Print Date 26.12.2012 000000019336
MSDS_DE
Version 2.0
Safety Data Sheet
SECTION 12. ECOLOGICAL INFORMATION
Basis for Assessment : Ecotoxicological data have not been determined specifically for
this product. Information given is based on a knowledge of the
components and the ecotoxicology of similar products. Unless
indicated otherwise, the data presented is representative of the
product as a whole, rather than for individual component(s).
12.1 Toxicity
Acute Toxicity : Poorly soluble mixture. May cause physical fouling of aquatic
organisms. Expected to be practically non toxic: LL/EL/IL50 >
100 mg/l (to aquatic organisms) LL/EL50 expressed as the
nominal amount of product required to prepare aqueous test
extract.
12.2 Persistence and : Expected to be not readily biodegradable. Major constituents

degradability are expected to be inherently biodegradable, but the product
contains components that may persist in the environment.
12.3 Bioaccumulative : Contains components with the potential to bioaccumulate.
Potential
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 : This mixture does not contain any REACH registered
vPvB assesment substances that are assessed to be a PBT or a vPvB.
12.6 Other Adverse : Product is a mixture of non-volatile components, which are not
Effects 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
Version 2.0
Safety Data Sheet
applicable regulations. Do not dispose into the environment, in

drains or in water courses.
Container Disposal : Dispose in accordance with prevailing regulations, preferably to
a recognised collector or contractor. The competence of the
collector or contractor should be established beforehand.
Local Legislation : Disposal should be in accordance with applicable regional,
national, and local laws and regulations.
EU Waste Disposal Code (EWC): 13 02 06 synthetic engine,
gear and lubricating oils. Classification of waste is always the
responsibility of the end user.
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
Inland waterways transport (ADN):

CDNI Inland Water Waste : NST 3411 Mineral Lubricanting Oils
Agreement
Sea transport (IMDG Code):

Air transport (IATA):

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
Version 2.0
Safety Data Sheet
Product Name : Not applicable.

Special Precaution : Not applicable.
Additional Information : MARPOL Annex 1 rules apply for bulk shipments by sea.
SECTION 15. REGULATORY INFORMATION
The regulatory information is not intended to be comprehensive. 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 : Product is not subject to Authorisation under REACh.
restrictions on use
Recommended : This product must not be used in applications other than those
Restrictions on Use recommended in Section 1, without first seeking the advice of
(Advice Against) the supplier.
Chemical Inventory Status
EINECS : All components

listed or polymer
exempt.
TSCA : All components
listed.
National Legislation
Water Pollution Class : WGK 1 - low hazard to waters (appendix 4, VwVwS,

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

Observe section 5.2.5 in connection with section 5.4.9
15.2 Chemical Safety : No Chemical Safety Assessment has been carried out for this
Assessment substance/mixture by the supplier.
SECTION 16. OTHER INFORMATION
R-phrase(s)
13/17
Print Date 26.12.2012 000000019336
MSDS_DE
Version 2.0
Safety Data Sheet
Not classified.
R22 Harmful if swallowed.
R23/24 Toxic by inhalation and in contact with skin.
R34 Causes burns.
R43 May cause sensitisation by skin contact.
R48/20 Harmful: danger of serious damage to health by prolonged exposure through
inhalation.
R50/53 Very toxic to aquatic organisms, may cause long-term adverse effects in the
aquatic environment.
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.
Other Information
Abbreviations and : Acute Tox. = Acute toxicity

Acronyms 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
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
Version 2.0
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
Version 2.0
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 : The information in this document should be made available to

all who may handle the product.
SDS Version Number : 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
Version 2.0
Safety Data Sheet
SDS Regulation : Regulation 1907/2006/EC as amended by Regulation (EU)

453/2010
Disclaimer : This information is based on our current knowledge and is
intended to describe the product for the purposes of health,
safety and environmental requirements only. 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*
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!
Safety instructions marked with included in this Operating Instructions and in the
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: In the search to improve continuously its products,  (Sterling Fluid Systems BV) 2001
www. sterlingfluidsystems.com Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice
Type 32-200
Safety issues Page 1 of 3 Chapter 1
1. Safety • the identification plate

This operating manual gives basic instructions, and that these are kept legible.
which must be observed during installation,
operation and maintenance of the pump. It is 1.2 Qualification and training of
therefore imperative that this manual is read by personnel
the responsible personnel / operator(s) prior to The personnel responsible for operation,
assembly and commissioning. It must always be maintenance, inspection and assembly must be
kept available at the site of pump installation. adequately qualified. The scope of responsibility
It is not only the general safety instructions and supervision of the personnel must be exactly
contained in this chapter “Safety” which must be defined by plant management. If the staff do not
observed, but also the specific information have the necessary knowledge, they must be
provided in the other chapters. trained and instructed. This task may be
performed by the machine manufacturer or
1.1 Identification of safety supplier on behalf of the plant management.
symbols in the operating Moreover, plant management must ensure that
instructions the contents of the operation instructions are fully
Safety symbols are given in these operating understood by plant operators and other relevant
instructions. Non compliance with these would personnel such as maintenance staff.
affect safety and are identified by the following
symbol 1.3 Hazards in case of non
compliance with safety
instructions
Non compliance with the safety instructions may
result in risk to personnel as well as to the
Danger symbol as per DIN 4844-W9 environment and the pump/pump set and result in
(ISO 3864 - B.3.1) the loss of any right to claim damages.
For example, non-compliance may result from, or
Or in case of danger of electric current with: lead to, the following:
• failure of important functions of the pump/pump
set/plant
• failure of specified procedures of maintenance
and repair
Danger symbol as per DIN 4844 W-8 • exposure of people to electrical, mechanical
(ISO 3864 - B.3.6) and chemical hazards
The word • danger to the environment owing to hazardous
ATTENTION substances being released.
identifies those safety regulations where non-

compliance 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
products at any time without prior notice.
Type 32-200
1.4 Compliance with regulations operative again. Prior to re-starting the machine,
relating to safety at work the instructions listed under “first commissioning”
When operating the pump the safety instructions are to be observed.
contained in this manual, the relevant national
accident prevention regulations and any other 1.7 Safety instructions for the use in
service and safety instructions issued by plant areas with explosion hazard
management must be observed.
1.5 Safety instructions relating to

operation
• If high or low temperature pump/pump set In this section information is given for operation in
components involve hazards, steps must be areas where an explosion hazard exists.
taken to avoid accidental contact.
• Guards for moving parts (e.g. couplings) must 1.7.1 Complete pump sets
not be removed from the pump/pump set while If the pump is combined with other mechanical or
in operation. electrical components in one set, the category of
• Any leakage of hazardous (e.g. explosive, the complete unit will correspond, based upon the
toxic, hot) fluids (e.g. from the shaft seal) must Directive 94/9/EC, only to that category with which
be drained safely so as to prevent any risk to all of its components comply.
persons or the environment. Statutory
regulations are to be complied with. Note:
• Hazards from electricity are to be avoided by These comments are of particular importance
the user (see for example the VDE- when pumps, which conform to a given category
specifications and the bye-laws of the local of Directive 94/9/EC, are powered by a driver
power supply utilities). which is not in the same category.
Although the pump may bear the Ex sign, the set
1.6 Safety instructions relevant for should not be used in areas with an explosion
maintenance, inspection and hazard when the motor is not classified for this
assembly work application.
It is the plant manegement’s responsibility to This means that plant management personnel
ensure that all maintenance, inspection and should always check that all elements of the set
assembly work is performed by authorized comply with the Directive 94/9/EC.
personnel who have adequately familiarised
themselves with the subject matter by studying 1.7.2 Execution of coupling guards
this manual in detail. Coupling guards that are to be used in areas with
Any work on the machine must only be performed an explosion hazard, have to fulfil one of the
when it is at a standstill. It is imperative that the following criteria:
procedure for shutting down the machine • consist of non-sparking material, e.g. brass.
described in this manual is followed. • if they consist of sparking material, e.g. steel
Pumps and pump sets, which convey hazardous sheet, they must be designed in such a way
media, must be decontaminated. that the rotating parts will not come in contact
On completion of the work all safety and with any part of the guard if errors, that could
protective guards must be re-installed and made be foreseen, are committed by the user, e.g if
a person steps on the guard.
Type 32-200
1.7.3 Monitoring technical 1.10 Warranty / guarantee

parameters Sterling Fluid Systems guarantee satisfactory
When using pumps in areas with an explosion operation if:
risk, the operator must check the following • the pump is installed and operated in
parameters regularly: compliance with these instructions and in
• leakage of shaft seals operating conditions approved by Sterling Fluid
• bearing temperature Systems
• that the pump is always filled with liquid during • modifications are only undertaken with Sterling
operation Fluid Systems’ written agreement.
• 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.
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.
Type 32-200
Intended application Page 1 of 3 Chapter 2
2. Application 2.3 Construction and mode of

The pump is to be used only for the operating operation
conditions stated by the customer and confirmed ZLND pumps are horizontal, single-stage volute
by the supplier. Guarantee is assumed within the casing pumps with nominal outputs and flange
scope of the Sterling Fluid Systems conditions dimensions meeting EN 733 / DIN 24255. Their
of sale. back pull out construction allows the disassembly
Appropriate application and operating conditions of the complete bearing unit towards the drive
are contained in the attached data sheets. side without removing the pump casing from the
pipework.
ZLND pumps are preferably used when pure or
2.1 Warning of misuse 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.
Type 32-200
2.4 Description
Type
size Hydraulic + Bearing Shaft seal Material design Casing gasket
A• First hydraulic 041: Self-sealed, uncooled packing rings 0B: Cast iron GG25
B• Second hydraulic 2: confined flat
D• Double volute 052: Uncooled packing rings, external seal liquid 0C: Cast iron GG25, gasket of EWP
Bronze G-CuSn10 impeller 210 material
BJ3,C23,AF3,AX3,AY3,A93:SiC/Carbon, EPDM
0E: Cast iron GG25,
• B Two ball bearings
BJS,C2S,AFS, AXS,AYS,A9S: SiC/ SiC, Viton Stainless steel 1.4408 imp. 4: confined flat
greased for life (2Z)
gasket of PTFE
• C Two ball bearings oil BJJ,C2J,AFK,AXK,AYK,A9K: SiC/Carbon, Viton 4B: Stainless steel 1.4408
ZLND lubricated
• 2 Oil lubrication
32125 configurations with CLO
to • S One double row
300500 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 Alternatively Alternatively
A 32125 to 200315, 250315 041,052,BJ3,C23,AF3,AX3,AY3,A93,BJS,C2S,
D 200400 to 300500 AFS,AXS,AYS,A9S,BJJ,C2J,AFK,AXK,AYK,A9K 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
Type 32-200
Example of a pump designation: 2.5 Shaft sealing

Depending on the application, different shaft
1-3 4 5-7 8-10 11 12 13-15 16-17 18 sealing executions are offered (see 2.4)
ZLND 125 250 A C 041 OB 2 • a stuffing box with lantern ring (executions
041, 052, and optionally 051) or mechanical
Casing gasket
seals according to DIN 24960 are utilised in
Construction the following cases:
Shaft sealing • if the pump draws from a suction line,
Bearings:B,C,S,T or 2 • if the pump is fed by a feed line with a
Hydraulic: A/B/D pressure of less than 0.5 bar or
• if the pumped liquid is at or near its boiling
Impeller size
point.
Nominal discharge Provision of the sealing liquid is as follows:
• 041: Internal self sealing ISO 5199 plan 01
• 052: External self sealing ISO 5199 plan 08
Pump series
• 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).
Type 32-200
Planning the installation Page 1 of 2 Chapter 3
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
ATTENTION
transition pieces.
• Note the arrows on the pump branches

indicating the direction of flow. Flow straightener
• 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. Connection of eccentric pipe transitions
• Support the pipework in order to avoid
distortions at the pump components (risk of It is recommended that a filter is installed in front
damage to pump components) of the pump with a filter surface of at least 3 times
• Avoid abrupt changes of cross section and the pipe cross section (approx. 100 meshes/cm²).
direction.
• Where different diameter pipework is to be The suction opening of the suction line should be
used, connection should be by eccentric well below the liquid level, and a strainer should
transition pieces. This will avoid the formation be used.
of air pockets in the pipework. The strainer must be far enough from the bottom
• For difficult pumping on the suction side, to to avoid excessive inlet losses, which could impair
stabilise the flow, a pipe length 15 times the pumping performance. It is advisable to check that
diameter of the suction branch should be there is no leakage.
installed before the suction branch. 7
• The flow rate in the suction line or inflow line, 6
must not exceed 2 - 3 m/s. 4

3 1 2
3.1.1 Suction line / inflow line

See the sketches below for the optimum layout of 1 Eccentric reducer ( suction line ) or
pump installation for flow and suction lift concentric reducer ( feed line )
operation. 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 suction lift operation
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.
Type 32-200
Unpacking, storage, transport Page 1 of 2 Chapter 4
4. Unpacking, storage, handling 4.4 Handling

The pump or pump set must be lifted and handled
4.1 Safety measures as shown in the following sketches.
• 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. Pump without motor
• 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.
4.2 Unpacking
Before unpacking, a visual check of the packing is
recommended. If transport damage is visible, the
Pump set
extent should be noted on the receipt or on the
delivery note. Potential claims must be lodged
immediately with the carriers or the insurance
4.5 Protection against corrosion
In general, a protective coating is only applied to
company.
the following executions: OB, OC and OE.
4.3 Interim storage
If the pump or the pump unit is not installed
4.5.1 Removal of protective coating
To remove the protective coating, the pump
immediately after delivery, it must be stored free
should be filled and drained several times using
from vibration in a dry room.
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.
www.sterlingfluidsystems.com Sterling Fluid Systems reserves the right to modify its
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.
Type 32-200
Installing the pump Page 1 of 3 Chapter 5
5. Installing the pump
5.1 Requirements 5.4.3 Base, foundation

The pump and the pump set, must have been The pump must be installed on a flat floor or
unpacked and handled as described in Chapter 4. foundation free from vibration. In case of doubt
use vibration dampening feet.
5.2 Use of trained staff The pump set must be correctly mounted on the
Only appropriately trained staff must undertake foundations. To avoid distortion of the pump set
the work described in this chapter. and/or the foundation, parallel shims must be
used between the base plate and foundation.
5.3 Safety measures 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 )
• Connect the pipework carefully to prevent the - the foundation dimensions.
pumped liquid escaping during operation and The following preparatory work must be carried
endangering operating personnel. out before to placing the pump:
• Ensure that the suction or inflow line, and the - roughen and clean foundation surface
discharge line are closed by valves. - remove shuttering/cores from the anchor
• Ensure that all electrical connections are holes
“dead”. Otherwise, there is a risk of electric - blow the anchor holes clean
shock. - check the position and dimensions of
• Pay attention to relevant internal plant the anchor holes against the arrangement
regulations. drawing.
• Avoid accidental contacts with hot
components. 5.4.4 Installation of the set
ATTENTION
• Remove the protective coating by following The complete set mounted on the base plate must
the instructions of Chapter 4. Otherwise there be placed on the foundation with its foundation
is a danger of contamination . (rag) bolts hanging below the baseplate.
5.4.5 Space required

5.4 General information The space required for the pump set is set out in
the foundation plan or installation drawing.
5.4.1 Assembly tools Ensure easy access to the shut-off and regulation
Special tools are not required for assembly and valves as well as to any measuring instruments.
installation.
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.
Type 32-200
5.4.6 Position
In principle the ZLND pumps are installed half of the N-EUPEX B ( FLENDER ) coupling
horizontally. must be 2 - 3 mm (see fig.).
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 re-
aligned, 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.
5.5 Motor In any event, the operating instructions of the
Before assembly check the direction of rotation of coupling manufacturer must be followed, since the
the motor (indicated by an arrow on the pump coupling is a component incorporated by Sterling
casing). If this is not possible the direction of Fluid Systems.
rotation of the complete unit can only be checked ruler
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 Alignment of the set
Place shims under the base plate on both sides of

The following is required a = a1 and b = b1
the foundation bolts, 10 mm from the base plate
edge. Use a spirit level to align the set.
5.8 Checking before installation
If necessary, place shims between the foundation
Before installing the pump on the plant, the
bolts to prevent the base plate from sagging. Care
following points must be checked:
should be taken to minimize distortion of the base
1. is the electrical current to the drive motor
plate during installation. The location of the driver
switched off?
must not be higher than that of the pump. The
2. are suction and discharge lines emptied and
max. deviation from the shaft centre line is ± 0.1
closed by valves?
mm.
3. Is it possible to rotate the pump easily by
The foundation bolts should be embedded in
hand (for this purpose turn the fan of the
concrete using quick-setting grout.
motor or the coupling)?
4. Have the latest internal/plant instructions been
5.7 Coupling
observed?.
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
Type 32-200
5.9 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.
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. • If there is no bypass line, do not run the
to the instructions of Chapter 5. pump with the control valve closed for any
length of time.
6.2 Use of trained staff • Safety measures should be taken by the
Only appropriately trained staff must carry out the end user to ensure (for example by
work described in this chapter. means of a relief valve) that the
permissible pump casing pressure is not
6.3 Safety measures exceeded during operation
• Repeat the alignment of the coupling at
operating temperature. Re-align the pump
or the motor, if necessary.
• Electrical connections must be made 6.4 Electrical connection

according to the European Regulations and The motor must be connected at set out in the
Directives for the Standards in Industry and in circuit diagram in the terminal box.
compliance with the instructions of the local
power supply utilities of the country 6.5 Checks before switching-on
concerned. Before switching on the pump unit, the following
• Only appropriately authorized personnel may points should be checked:
carry out this work. 1. is all pipework connected and are the unions
tight?
ATTENTION 2. is the pump including the pipework filled
properly?
• Fill the pump correctly; otherwise the shaft 3. is the shut-off valve in the discharge line
seal could be destroyed. closed?
• Fill the supply lines correctly. 4. is the shut-off valve in the suction line
• Check the direction of rotation only when the completely opened?
pump is filled. 5. is the motor ready for operation?
• Fill the pump slowly if hot media are being 6. is the direction of rotation of the motor
pumped in order to avoid distortions or heat correct?
shock. (check by running the motor for a short time)
• When handling explosive, toxic, hot, 7. is the coupling aligned exactly?
crystalline or corrosive media, ensure that 8. has the shaft seal been installed?
there is no risk to people or the environment. 9. are the supply lines, if any, to the shaft seal
• Control the output at constant speed at the open?
discharge side only. The valve at the suction 10. in the case of oil lubrication - has the bearing
side must always be completely open during housing been correctly filled with oil?
operation to avoid the risk of cavitation. 11. is the gland finger slightly tight?.
For local contact details: In the search to improve continuously its products,  (Sterling Fluid Systems) 2001
Type 32-200
6.7 Switching frequency
Size Permissible number of

starts equally spaced
per hour
32-125, 32-160, 32-200, 32-250,
40-125, 40-160, 40-200, 40-250,
50-125, 50-160, 50-200, 65-125,
65-160, 65-200, 65-250, 80-160, 15
80-200, 80-250,100-160,
Fasten gland nuts 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,
6.6 Start-up operation 150-315, 150-400, 150-500, 8
200-250, 200-315, 200-400,
For starting proceed as follows: 200-500, 250-300, 250-315,
1. open fully the valve on the suction side 250-400, 250-500, 300-400, 300-500
2. close the valve on the discharge side

3. switch on the motor
4. check the pressure gauges at the pressure 6.8 Special instructions
measuring points During operation the following points must be
If the pumping pressure does not increase observed:
consistently with increasing speed, switch off the - control the speed and the delivery head
motor again and vent the pump one more. - ensure that the pump runs without vibration
5. After reaching operating speed, regulate the - control the liquid level in the suction line and/or
operating point of the pump by adjusting the inflow tank
valve in the discharge line (see technical data - control the bearing temperature (max.
for permissible range of operation). temperature 100 °C)
6. For “running in” the packing, the gland should - control the pressure in the supply lines according
be tightened only slightly (even in the case of to the following limits:
considerable leakage initially). After approx. External flushing:
30 minutes tighten the gland to such an extent • Impeller size 125
that it leaks only slightly. Check it several Buffer pressure = pW + 0,5 bar
times, until leakage from the packing is about • Rest of impeller sizes:
20 to 40 drops a minute. In extreme operating Buffer pressure = pW + H + 2,5 bar
conditions and high temperatures this rate • Flow = 0,1 – 0,2 m3/h
may be higher. pW = suction pressure, in bar
H = differential pressure of pump, in bar
Pumping against a closed valve in the discharge
line is permitted only if a minimum output via a Quench
bypass line is guaranteed. Maximum pressure = 4 bar
Heating
Maximum pressure = 4 bar, with
water steam to 140 ˚C
Type 32-200
- 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. When handling explosive, toxic, hot, crystalline or
If the pump is equipped with code 052 or code corrosive media, ensure that people and the
051, the supply lines to the stuffing box have to be environment are not endangered. Even if the
open before the pump is started. pump has been drained using the threaded plug
Executions with mechanical seal: 90.30, residues can remain in the pump. For
During running-in slight leakage may occur. If the transport, the pump must be free from any
pump is equipped with an external flush, quench dangerous material. In case of extended periods
or heating, the flush, quench or heating supply out of service, protect the pump against corrosion.
has to be switched on before the pump is started.
The mechanical seal must be allowed to cool
before the next re-start.
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.
Type 32-200
Maintenance, dismantling, assembly Page 1 of 10 Chapter 7
7. Maintenance, dismantling, grease nipple

assembly
7.1 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 Grease lubrication:
undertake the work described in this chapter. The bearings receive their first engreasing at the
supplier plant.
Only authorised personnel must undertake
electrical work associated with maintenance of the Grease amount per ball bearing:
pump/pump set.
bearing housing 55: (shaft end diameter at the
driving side 50 mm) 30 gramme
7.3 Safety measures
bearing housing 65: (shaft end diameter at the
driving side 60 mm) 40 gramme
lubrication low activity middle and high

intervals activity
for grease n ≤ 1500 1/min 1500 < n ≤ 3000 1/min
lubrication every 5000 hours every 2500 hours
• For explosive, toxic, hot, crystalline as well as at the latest after 12 months
different pumping media ensure that people
and the environment are not endangered. After about 10000 hours of activity or the latest
• Flush the pump with clean liquid before after two years, the bearings have to be
dismantling. disassembled, washed and refilled with grease.
• The working place for disassembly or Under extremely unfavourable circumstances (wet
assembly must be clean. or dusty environment or high temperatures of the
• Before reinstallation, the pump must be free of environment) the lubrication intervals have to be
any dangerous material. chosen considerably shorter.
For renewing or adding lubrication grease, only
lithium soap bearing grease have to be utilised
7.4 Maintenance and inspection (e.g. Mobilux 2, Shell Aero Grease 16, Esso
The pump requires only limited maintenance. Unirex N3).
7.4.1 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.
Type 32-200
7.4.2 Bearing with oil lubrication Oil change intervals

The pump is supplied empty (no oil). Before the If the bearings are new, change the oil after about
initial start up, pour oil into the oil inlet hole until 200 hours and subsequently annually. These
the oil level reaches the mark on the dipstick. 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
Oil filling
should be renewed about every six months.
Oil properties:
Operating Ambient temp.
temp. of < 0ºC
bearing up
to 80ºC
n≤1500 n>1500
rpm rpm
Type of lubrication CL68 CL46 CL22

DIN 51517
t Kinematic viscocity
2
61.2 to 41.8 to 19.8 to
at 50ºC in mm /s 74.8 50.8 24.2
Oil drainage Constant level oiler
Neutralisation figure Maximum 0.15 mg KOH/g
Ash ( as Ash Oxide ) Maximum 0.02% weight
As an additional accessory, it is possible to Water content Maximum 0.1% weight
connect a constant level oiler. In this case, the Suitable motor oil SAE 20 and 20W SAE 10W
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. Oil quantities:
Subsequently the oil reservoir should be filled with Bearing Bracket Oil ( litre )
oil and put into its correct position. 25 0.22

The bearing housing will be supplied with oil from 35 0.38
the constant level oiler with the correct amount as 45 0.57
long as there is oil in the reservoir. 55 1.50
See sketch of oiling system below 65 2.00
1. Oil reservoir
2. Screw-in elbow ATTENTION
3. Fill in oil here
4. Never fill with oil here, always use the oil inlet The lubricating oil must be extremely pure,
hole. resistant to ageing, must have good viscosity-
temperature behaviour, good water separating
properties and corrosion protection.
Type 32-200
7.4.3 Stuffing box 7.4.4 Mechanical seal

If leakage makes it necessary, the packing rings The mechanical seal should have little or no
should be retightened. After extended periods and visible leakage. Where there is considerable
frequent retightening, the packing rings gradually leakage, check the mechanical seal. To do this, it
lose their shape and elasticity. We therefore is necessary to dismantle the rotating part(s).
recommend replacing the packing material at 43.30 16.10
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
50.40 21.10
carefully from the shaft seal chamber. The shaft

and shaft protection sleeve must not be
damaged. 7.4.5 Drive motor
Otherwise perfect sealing cannot be guaranteed The drive motor must be maintained according to
and the shaft sleeve would then need replacing. the instructions of the manufacturer.
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 7.5 Dismantling
into a ring form.
Push the packing rings as well as the lantern ring 7.5.1 Preparation for the dismantling
by means of the gland into the shaft seal
chamber. The cut joints should be staggered by Proceed as follows:
180°. Tighten the nuts at the gland steadily until • disconnect power to the motor
resistance is felt when rotating the pump shaft by • drain the plant, at least within the pump area,
hand. Remove the gland again and fasten the i.e. between the valves on the suction- and
nuts slightly. If the pump is removed in order to discharge side
carry out repacking, it is useful to push the • if necessary, disconnect any measuring
packing rings in the delivered condition, that probes or control devices and remove them
means closed over the shaft sleeve. • drain liquid from the pump by means of the
drain plug
Lantern ring
• 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
Packing rings 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.
Type 32-200
• dismantle guard coupling, pump feet and

coupling. Design with stuffing box
1. Remove the Allen head screws 91.40 and
7.5.2 Replacement parts detach the casing cover 16.10.
The item numbers necessary for ordering spare 1. Detach hexagonal nuts 92.01 and studs
parts are provided in the component parts list in 90.21.
the Annex. 2. Loosen hexagonal screws 90.23 and detach
packing housing 45.10 and gland 45.20 with
7.5.3 Dismantling the pump the pressure ring 45.70.
• For executions with bearing housings 25,35 3. Detach packing ring 46.10 and lantern ring
and 45. 45.80.
10.20 40.00 90.10
4. Detach the shaft sleeve 52.40.
16.10 40.05 45.10 90.23 45.70 52.40 91.40
46.10 45.80 92.01 45.20 90.21 55.40 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 1. Detach the distance ring 50.40.
tool. 2. Remove the rotating part of the mechanical
2. Remove the hexagonal screws 90.10. seal 43.30.
3. Remove the back pull out unit from the volute 3. Remove the Allen head screws 91.40 and
casing 10.20. detach the casing cover 16.10.
90.13 68.10 92.20 23.00 94.01 50.40 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.
Type 32-200
Design with quench (AX3, AXS, AXK) Bearing design B, C or 2 :

Detach the cover 16.50, O-ring 41.23 and lip 1. Release hexagonal screws 90.11, remove
seals 42.11. V-seal 42.20 in case of grease lubrication,
dismantle bearing cover 36.00 and flat gasket
16.10 41.23 42.11 16 .50 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.
Design with heating (AY3, AYS, AYK) 50.70 42.20 42.10 33.00 91.60 40.02 42.10 36.00 90.11 42.20 94.00
Detach the cover 16.50, O-rings 41.22 and

41.23.
16.10 41.22 41.23 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:
90.80
10.20 90.20 40.00 92.00 92.06
90.30 50.20 56.00
Type 32-200
1. Mark the position of all parts with a colour pen Design with a mechanical seal:
or scribing tool in order to be able to 1. Loosen hexagonal screws 90.24 and withdraw
reassemble the pump correctly. the mechanical seal cover 47.10 with the flat
2. Unscrew hexagonal nuts 92.00. gasket 40.06, static part of the mechanical
3. Withdraw pull out assembly from the volute seal 43.30 with pin 56.10.
casing 10.20. Withdraw the flat gasket 40.00. 2. Remove the shaft sleeve 52.30 with the
The wear ring 50.20, if it is necessary can be distance ring 50.40, the rotating part of the
removed. mechanical seal 43.30 and the flat gasket
40.01.
92.20
93.00 40.03 23.00 94.01 16.10 90.22 92.02
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
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: 56.00 50.21 56.10 90.24
1. Remove hexagonal nuts 92.01 and studs Bearing design S or T :

90.21. 1. Release the thrower 50.70
2. Detach the gland 45.20, the packing ring 2. Release hexagonal screws 90.11 and 90.14,
46.10 and the lantern ring 45.80. dismantle bearing covers 36.00, 36.01 and flat
3. Detach shaft sleeve 52.40 and flat gasket gaskets 40.02. Remove the lip seals 42.10.
40.01. 3. Release hexagonal screws 90.12, remove
4. Detach the pin 56.00 and then, the wear ring washer 93.01 and dismantle the pump foot
50.21 18.30.
16.10 90.22 46.10 45.80 45.20 40.01 52.40
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 42.10 40.02 50.70 33.00 93.21 40.02 42.10 36.00 63.60 94.00 90.11
18.30 93.01 90.12

56.00 50.21 90.21 55.40 92.01
Type 32-200
5. Pull out complete shaft with both ball bearings 7.7 Assembly
32.10 and 32.11 and circlip 93.21. 7.7.1 Tightening torque
When tightening the bolts the following torques
32.11 21.00 93.21 32.10
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
7.6 Post dismantling activities 7.7.2 Pump assembly

Proceed as follows:
7.6.1 Hints for cleaning. Bearing design B, C or 2 :
• Clean all parts. • For executions with bearing housings 25,35
• Clean the clearances and sealing surfaces and 45:
with an appropriate liquid. 1. Prior to installing bearings, the support
washer for ball bearing 50.50 must be
7.6.2 Points to be checked replaced, (only bearing housing 25). Install
The following pump components, if installed, must ball bearings (use new ball bearings, if
be checked: necessary). Before installation, the ball
• Mechanical seal : If the running faces are bearings must be heated to 80ºC in an oil
damaged or worn, replace the mechanical bath.
seal. (Only bearing design C or 2).
• Shaft and shaft sleeve : Check the shaft 2. For a pump with oil lubrication, using a tool,
within the stuffing box. If the shaft has worn press lip seal 42.10 in the bearing housing
badly and is grooved, a new shaft or shaft 33.00. When lip seals are used, the lip should
sleeve should be used. point towards the drive end.
• Clearances : The difference in diameter 32.10 50.50 21.00 50.50 32.10
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.
3. Insert the shaft assembly into the bearing
housing from the drive end towards non-drive
end.
Type 32-200
4. Attach the bearing cover 36.00, with its radial • For executions with mechanical seal:
seal inserted, if it is oil lubricated, and the flat
gasket 40.02;( the lip of the radial seal ring 7. Insert the static part of the mechanical seal
should point towards the non drive end). Then 43.30, with the pin 56.10 if any, in the casing
fasten hexagonal screws 90.11. In case of cover 16.10.
grease lubrication, mount the V- seals 42.20
43.30 16.10 56.10
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 42.10 36.00 90.11 42.20 94.00
18.30 93.01 90.12
6. Fasten pump foot 18.30 and insert the thrower

50.70.
Design with quench (AX3, AXS, AXK)
• For executions with stuffing box: Insert the lip seals 42.11 and the O-ring 41.23 in
the cover 16.50.
7. Position the shaft sleeve 52.40 on the shaft. 41.23 42.11 16 .50
16.10
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 52.40
Attach the cover 16.50 and casing cover 16.10.
16.10 1 6 . 50
46.10 45.80 92.01 45.20 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.
Type 32-200
Design with heating (AY3, AYS, AYK) 10.20 40.00 90.10
Insert the O-rings 41.22 and 41.23 in the cover

16.50.
16.10 41.22 41.23 16. 50
90.30
Bearing design S or T :
Attach the cover 16.50 and casing cover 16.10.
• For executions with bearing housings 55 and
16.10 16.50
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
8. Attach the bearing housing 33.00 and the on the external ring of the oil seals. The lips
casing cover 16.10. should point towards the bearing after
9. Insert the rotating part of the mechanical seal installation. Pay attention to the bearing
43.30 and the distance ring 50.40. covers to avoid fitting them incorrectly.
10. Insert the key 94.01, impeller 23.00 and
tighten the impeller nut 92.20. Attach the 32.11 21.00 93.21 32.10
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 91.40
4. Install the bearing cover of the pump side with

68.10 90.13 the flat gasket 40.02 and the grease nipple
11. Insert the gasket 40.00 between the pull out 63.60 if any.
unit and volute casing. Tighten hexagonal
screws 90.10.
Type 32-200
5. When fitting the rotating unit in the bearing • For executions with mechanical seal:
housing 33.00, the circlip 93.21 must be 9. Install the mechanical seal cover 47.10 with
inserted in the groove in the bearing housing. the mechanical seal stationary part 43.30 and
6. Insert the bearing cover 36.01 with the flat its pin 56.10 if any, then place the flat gasket
gasket 40.02 and the grease nipple 63.60 if 40.06 and hexagonal screws 90.24.
any. 10. Insert the shaft sleeve 52.30 with the rotating
7. Mount the plug 67.20, the oil level sight glass part of the mechanical seal 43.30 and the
64.20 and the constant level oiler ( CLO ) distance ring 50.40.
63.80, where oil lubrication is used. 11. In the casing cover 16.10, insert the wear ring
8. Fasten pump foot 18.30 and insert the thrower 50.21 with grub screws 56.00 and the studs
50.70. 90.22.
90.14 36.01 63.60 42.10 40.02 50.70 33.00 93.21 40.02 42.10 36.00 63.60 94.00 90.11
40.01 52.30 50.40 43.30 16.10 90.22 40.06 47.10
18.30 93.01 90.12
• For executions with stuffing box:
9. Mount the shaft sleeve 52.40 on to the shaft 56.00 50.21 56.10 90.24
unit.
12. Join the casing cover 16.10, the bearing
10. In the casing cover, insert one of the packing
housing 33.00 and fasten hexagonal nuts
rings 46.10, the lantern ring 45.80, the
92.02.
remaining packing rings and finally the gland
45.20. 92.20
93.00 40.03 23.00 94.01 16.10 90.22 92.02
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 46.10 45.80 45.20 40.01 52.40
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.
56.00 50.21 90.21 55.40 92.01 16. Insert flat gasket 40.00 between the unit and
the volute casing 10.20. Tighten hexagonal
nuts 92.00.
Type 32-200
Troubleshooting Page 1 of 1 Chapter 8
8. Help in case of trouble
8.1 Use of trained staff

Trouble shooting must be undertaken only by appropriately trained personnel.
8.2 Symptoms, causes and remedies
Symptom Cause Remedy

Output too low - Back pressure too high. Check the plant for contamination.
Regulate anew the operating point.
- Pump or pipework, resp., not completely Vent and fill the pump as well as the
filled. suction or inflow line.
- Suction lift too high or positive suction Check the liquid levels, open the shut-off
head too low. valves on the suction side.
Clean the filters and dirt traps installed on
the suction side.
- Sealing gap too large because of wear. Replace worn parts.
- Wrong direction of rotation. Change the motor connection.
- Casing or suction line leaks. Replace the casing seal.
Check the flange connections.
Pump does not prime or only - Pump casing, shaft seal, foot valve or Replace the casing seal.
suction line leaks. Check the shaft seal.
intermittently Check the flange connections..
the suction side.
- Loose or jammed parts in the Open and clean the pump.
pump.
Pump leaks - Casing bolts not correctly Check the tightening torque of the casing
tightened. bolts.
- Mechanical seal leaks. Check the seal surfaces and elastomere of
the mechanical seal. In case of damages
exchange mechanical seal.
- Stuffing box leaks. Check the condition of the stuffing box. If
possible, retighten the stuffing box, if not,
replace it.
- Seals defective. Replace the seals.
Temperature of the pump - Pump or pipework not completely filled. Vent and fill the pump as well as the
suction line or inflow line.
increases
the suction side.
- Stuffing box overtightened. Loosen the stuffing box.
- Pump is run against closed valve. Open the shut-off valve on discharge side.
Pump runs noisily - Pump or pipework not completely filled. Vent and fill the pump as well as the
suction line or inflow line.
the suction side.
- Pump is not properly levelled or is Check the pump installation
distorted.
- Foreign material in the pump. Dismantle and clean the pump.
Motor protection switch - Pump is not properly levelled or is Check the pump installation.
distorted.
switches off.
- Operating conditions outside of Refer to pump operating conditions stated
performance range of pump. in technical data.
- Loose or jammed parts in the pump. Open and clean the pump.
For local contact details: In the search to improve continuously its products,  (Sterling Fluid Systems BV 2001)
Type 32-200
Technical data Page 1 of 3 Chapter 9
9. Technical Data
For technical information about the pump or pump Direction of rotation:
set, which is not described in this chapter, see the Clockwise seen from the drive end of the pump.
specific data sheet. Note that data relating to a Materials of construction, and of shaft seals:
specific order may conflict with information See Chapter 2.4.
provided here. In any such case, the order Vibrations:
specific information will override data provided in ZLND range pumps comply with VDI 2056 and
the general technical documentation. ISO 5199 Class K for pumps with a driving power
Pressure component operating limits: of up to 15 kW and Class M with a driving power
of more than 15 kW
Material Temperature Pressure Sizes Noise levels:
-40ºC to 120ºC 16 bar All The noise levels of the pump comply with the
4B
120ºC to 170ºC 14 bar All Directive 001/30 - 1992 of the EUROPUMP
16 bar 32125 to 80315
-20ºC to 120ºC
10 bar 80400 to 300500 Commission.
0B/0C/0E
14 bar 150500
14 bar 32125 to 80315
The following table provides approximate values:
120ºC to 170ºC
9 bar 80400 to 300500
8 bar 150500
Shaft sealing operating limits: LWA (dB)
Shaft sealing execution Temperature range

041, 052 -40°C to + 110°C
BJ3, BJS, BJJ -20°C to + 120°C
AF3, AX3, AY3, A93 -30°C to +150°C
AFS,AXS,AYS,A9S,AFK,AXK,AYK,A9K -20°C to + 180°C
C23, C2S, C2J -40ºC to + 150ºC
P (kW)
ATTENTION
pump without motor
Note that additional noise can be generated by:
• All indicated operating limits are not valid
• the driver.
for all liquids which can be pumped. See
• a possible misalignment of the coupling.
technical data or delivery note.
• 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
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.
• Material execution 0B / 0C / 0E:
DN Fy Fz Fx ∑F My Mz Mx ∑M
flanges (N) (N) (N) (N) (Nm) (Nm) (Nm) (Nm)
32 400 500 440 780 360 420 520 760
40 400 500 440 780 360 420 520 760
50 540 660 600 1040 400 460 560 820
Top branch z-Axis
65 820 1000 900 1580 460 520 640 940

80 820 1000 900 1580 460 520 640 940
100 1080 1340 1200 2100 500 580 700 1040
125 1620 2000 1800 3140 700 820 1000 1460
150 1620 2000 1800 3140 700 820 1000 1460
200 2160 2680 2400 4180 920 1060 1300 1920
250 2700 3340 2980 5220 1260 1460 1780 2620
300 3220 4000 3580 6260 1720 1980 2420 3560
50 600 540 660 1040 400 460 560 820
65 900 820 1000 1580 460 520 640 940
80 900 820 1000 1580 460 520 640 940
End branch x-Axis
100 1200 1080 1340 2100 500 580 700 1040

125 1800 1620 2000 3140 700 820 1000 1460
150 1800 1620 2000 3140 700 820 1000 1460
200 2400 2160 2680 4180 920 1060 1300 1920
250 2980 2700 3340 5220 1260 1460 1780 2620
300 3580 3220 4000 6260 1720 1980 2420 3560
350 4180 3760 4660 7300 2200 2540 3100 4560
• Material execution 4B:

Multiply by ƒ = 1,536; which is the relationship of
E – modules between 1.4408 and GG-25.
Type 32-200
Techical Data Page 3 of 3 Chapter 9
Maximum permissible speeds at 50 Hz:
Max. speed Max. speed Max. speed Max speed

Size rpm Size rpm Size rpm Size rpm
4) 4)
32125 32160 32250 40315 50315
4) 4)
32200 40125 40250 65315 80315 150500 200315
40160 40200 3600 50250 3000 80400 100315 1800 200400 200500 1500
50125 50160 65250 100400 125250 250300 250315
50200 65125 80250 125315 125400 250400 250500
1) 2) 3)
65160 65200 100250 150200 150250 300400 300500
1) 2)
80160 80200 125200 150315 150400
100160 100200 200250
1) 2) 3)
For material specification 4B:the max. speed changes to : 3000 rpm 1800 rpm 1500 rpm
4)
In material specification 0E and 4B max. speed 3000 rpm
Operating range:
(Continuous operation)
Sizes
32125 to 80400
100315 to100400
0,3 Qopt < Q < 1,1 Qopt
125315 to 125400
150250 to 150500
100160 to 100250
125200 to 125250
0,5 Qopt < Q < 1,1 Qopt
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.
Type 32-200
Annex Page 1 of 14 Chapter 10
10. Annex
10.1 Connections
Connections for bearing brackets 25, 35 and 45.
u m1 ufo u m1 u k6
1)
Only for Impellers ∅125
u k7
ufo um1
u k4
u s ufo us u k5 u k3
u k8
u k4
u k5 u k6
u k8 u k7
u k3
u k1
u k2
ueo u io
ueo uio uAL ue um2 u k1 u eo u io

u k2
um1 : Pressure gauge. Only available on request uk1 : Quench Inlet
um2 : Pressure gauge. Only available on request uk2 : Heating Inlet
ue : Drainage uk3 : 051 Inlet (Stuffing box)
ueo : Oil drainage uk4 : 052 External sealing (Stuffing box)
uio : Constant level oiler (CLO) uk5 : External Flushing
ufo : Oil filling uk6 : Quench Outlet
uAL : Drainage for leakage. Threaded hole only available on request uk7 : Heating Outlet
us : Sensor uk8 : 051 Outlet (Stuffing box)
Size um1 um2 ue ueo uio ufo uAL us uk1 uk2 uk3 uk4 uk5 uk6 uk7 uk8
321251)
32160
32200
32250
401251)
40160
40200 G1/4
40250
40315
501251)
50160
50200 G1/8
50250
50315
651251)
65160
65200
65250
65315
80160 G1/4
80200
80250
80315 G1/4 ∅15.65 ∅13 M8
80400 G1 / 4
100160
100200 G3/8
100250 G1/8
100315
100400 G1 / 4
125200
G1/8
125250
125315
G1 / 4
125400
150200
G1/8
150250
150315
150400 G1 / 4
200250
Drawings are indicative only.
For local contact details: In the search to improve continuously its products, © (Sterling Fluid Systems BV) 2001
Type 32-200
Connections for bearing brackets 55 and 65
um1 um3 ufo um1
ufo
uk4
uk8
uk9
View X
uk3
uio umo ueo uAL ue um2 ueo uio umo

uAL
um1 : Self sealing connection um3 : Pressure gauge connection

um2 : Pressure/vacuum gauge. Only available on request uk3 : 051 Inlet (Stuffing box)
ue : Drainage uk4 : 052 External sealing (Stuffing box)
ueo : Oil drainage uk8 : 051 Outlet (Stuffing box)
uio : Constant level oiler umo : Oil level control
ufo : Oil filling uk9 : 041 inlet (Stuffing box)
uAL : Drainage for leakage
Size um1 um2 ue ueo uio ufo uAL um3 uk3 uk4 uk8 umo uk9
150500
200315
200400
200500
250300
250315 G1/4 G1/2 G1/2 G1/4 G1/4 ∅20 G1/2 G1/2 G1/4 G1/4 G1/4 G3/4 G1/4
250400
250500
300400
300500
Type 32-200
10.2 Table of Dimensions
a f x
d l
2
D
øk
DN
2
d
2
h
2
d
1
k6 t
u
h
1
DN
1
øk c
D
m s s
2 2 1
w b 110
m
1 n
2
n
1
All dimensions in mm
Size BB Pump dimensions Foot dimensions End shaft
DN2 DN1 a f h1 h2 b c m1 m2 n1 n2 s1* s2* w x d1 l t u
32125 25 32 50 80 360 112 140 50 15 100 70 190 140 M12 M12 260 100 24 50 27 8
32160 25 32 50 80 360 132 160 50 15 100 70 240 190 M12 M12 260 100 24 50 27 8
32200 25 32 50 80 360 160 180 50 15 100 70 240 190 M12 M12 260 100 24 50 27 8
322501) 25 32 50 100 360 180 225 65 15 125 95 320 250 M12 M12 260 100 24 50 27 8
40125 25 40 65 80 360 112 140 50 15 100 70 210 160 M12 M12 260 100 24 50 27 8
40160 25 40 65 80 360 132 160 50 15 100 70 240 190 M12 M12 260 100 24 50 27 8
40200 25 40 65 100 360 160 180 50 15 100 70 265 212 M12 M12 260 100 24 50 27 8
40250 25 40 65 100 360 180 225 65 15 125 95 320 250 M12 M12 260 100 24 50 27 8
403151) 35 40 65 125 470 225 250 65 18 125 95 345 280 M12 M12 340 100 32 80 35 10
50125 25 50 65 100 360 132 160 50 15 100 70 240 190 M12 M12 260 100 24 50 27 8
50160 25 50 65 100 360 160 180 50 15 100 70 265 212 M12 M12 260 100 24 50 27 8
50200 25 50 65 100 360 160 200 50 15 100 70 265 212 M12 M12 260 100 24 50 27 8
50250 25 50 65 100 360 180 225 65 15 125 95 320 250 M12 M12 260 100 24 50 27 8
503151) 35 50 65 125 470 225 280 65 17 125 95 345 280 M12 M12 340 100 32 80 35 10
65125 25 65 80 100 360 160 180 65 15 125 95 280 212 M12 M12 260 100 24 50 27 8
65160 25 65 80 100 360 160 200 65 15 125 95 280 212 M12 M12 260 100 24 50 27 8
65200 25 65 80 100 360 180 225 65 15 125 95 320 250 M12 M12 260 140 24 50 27 8
65250 35 65 80 100 470 200 250 80 15 160 120 360 280 M16 M12 340 140 32 80 35 10
65315 35 65 80 125 470 225 280 80 18 160 120 400 315 M16 M12 340 140 32 80 35 10
80160 25 80 100 125 360 180 225 65 15 125 95 320 250 M12 M12 260 140 24 50 27 8
80200 35 80 100 125 470 180 250 65 15 125 95 345 280 M12 M12 340 140 32 80 35 10
80250 35 80 100 125 470 200 280 80 18 160 120 400 315 M16 M12 340 140 32 80 35 10
80315 35 80 100 125 470 250 315 80 18 160 120 400 315 M16 M12 340 140 32 80 35 10
804001) 45 80 125 125 530 280 355 80 18 160 120 435 355 M16 M12 370 140 42 110 45 12
1001601) 35 100 125 125 470 200 280 80 18 160 120 360 280 M16 M12 340 140 32 80 35 10
100200 35 100 125 125 470 200 280 80 18 160 120 360 280 M16 M12 340 140 32 80 35 10
100250 35 100 125 140 470 225 280 80 18 160 120 400 315 M16 M12 340 140 32 80 35 10
100315 35 100 125 140 470 250 315 80 18 160 120 400 315 M16 M12 340 140 32 80 35 10
100400 45 100 125 140 530 280 355 100 18 200 150 500 400 M20 M12 370 140 42 110 45 12
1252001) 35 125 150 140 470 250 315 80 18 160 120 400 315 M16 M12 340 140 32 80 35 10
125250 35 125 150 140 470 250 355 80 18 160 120 400 315 M16 M12 340 140 32 80 35 10
125315 45 125 150 140 530 280 355 100 18 200 150 500 400 M20 M12 370 140 42 110 45 12
125400 45 125 150 140 530 315 400 100 18 200 150 500 400 M20 M12 370 140 42 110 45 12
1502001) 35 150 200 160 470 280 400 100 20 200 150 550 450 M20 M12 340 140 32 80 35 10
1502501) 35 150 200 160 470 280 400 100 20 200 150 500 400 M20 M12 340 140 32 80 35 10
150315 45 150 200 160 530 280 400 100 18 200 150 550 450 M20 M12 370 140 42 110 45 12
150400 45 150 200 160 530 315 450 100 18 200 150 550 450 M20 M12 370 140 42 110 45 12
2002501) 45 200 200 160 590 280 400 100 22 200 150 500 400 M20 M12 430 180 42 110 45 12
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.
Type 32-200
Table of Dimensions
a f x
l
d2
DN2 øk D
h2
d2
d 1k6 t
u
h1
DN1
øk
D
c
m s s
2 b 2 1
w 140
m n
1 2
n
1
All dimensions in mm
Size BB Pump dimensions Foot dimensions End shaft
DN2 DN1 a f h1 h2 b c m1 m2 n1 n2 s1* s2* w x d1 l t u
1505001) 55 150 200 180 670 400 500 100 22 200 150 640 540 M20 M16 489 180 50 115 53.5 14
2003151) 55 200 250 200 670 355 450 100 22 200 150 550 450 M20 M16 489 180 50 115 53.5 14
2004001) 55 200 250 180 670 355 500 100 22 200 150 550 450 M20 M16 489 180 50 115 53.5 14
2005001) 55 200 250 200 670 425 560 100 22 200 150 660 560 M20 M16 489 180 50 115 53.5 14
2503001) 55 250 300 305 655 425 550 120 28 240 190 700 600 M20 M16 474 180 50 115 53.5 14
2503151) 55 250 300 250 670 375 560 120 28 240 190 620 520 M20 M16 489 180 50 115 53.5 14
2504001) 65 250 300 250 720 400 600 120 29 240 190 700 600 M20 M16 508 180 602) 145 64 18
2505001) 65 250 300 250 720 450 670 120 32 240 190 750 650 M20 M16 503 180 602) 145 64 18
3004001) 65 300 350 300 720 425 670 120 30 250 190 760 660 M24 M16 508 180 602) 145 64 18
3005001) 65 300 350 300 720 480 670 140 32 250 190 840 720 M24 M16 508 180 602) 145 64 18
1)
Transnorm pump sizes, not included in DIN 24255 / EN 733. Flanges drilled according to ANSI 150 on request.
2)
For these sizes the clearance corresponds to M6.
*Holes for bolts of the dimensions indicated.
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 140 150 165 185 200 220 250 285 340 405 460 520 580 220 250 285 340
k 100 110 125 145 160 180 210 240 295 355 410 470 525 180 210 240 295
d2 x number 18x4 18x4 18x4 18x4 18x8 18x8 18x8 22x8 22x12 26x12 26x12 26x16 30x16 18x8 18x8 22x8 22x8
Type 32-200
10.3 Parts list
When ordering spare parts give the following

information: position number, the complete pump
designation and the serial number, which can be
found on the nameplate fixed to the pump.
Pos. Nr. Description Pos. Nr. Description
10.20 Volute casing 64.20 Oil level sight glass

10.200 Casing plug 67.20 Plug
10.201 Hexagonal screw 68.10 Protection screen
10.202* O-ring 70.30 Pipe
16.10 Casing cover 73.10 Compression nut
16.50 Cover 73.11 Screw connection
18.30 Pump foot 90.10 Hexagonal screw
21.00* Shaft 90.11 Hexagonal screw
23.00* Impeller 90.12 Hexagonal screw
32.10* Ball bearing 90.13 Hexagonal screw
32.11* Ball bearing 90.14 Hexagonal screw
33.00 Bearing housing 90.20 Stud
36.00 Bearing cover 90.21 Stud
36.01 Bearing cover 90.22 Stud
40.00* Flat gasket 90.23 Hexagonal screw
40.01* Flat gasket 90.24 Hexagonal screw
40.02* Flat gasket 90.25 Stud
40.03* Flat gasket 90.30 Threaded plug
41.22* O-ring 90.41 Grub screw
41.23* O-ring 90.80 Hexagonal screw
42.10* Lip seal 91.40 Allen head screw
42.11* Lip seal 91.60 Dip stick
42.20* V – seal 92.00 Hexagonal nut
43.30* Mechanical seal 92.01 Hexagonal nut
45.10 Packing housing 92.02 Hexagonal nut
45.20 Gland 92.06 Hexagonal nut
45.70* Pressure ring 92.20* Impeller nut
45.80* Lantern ring 93.00* Helicoil
46.10* Packing ring 93.01 Washer
47.10* Mechanical seal cover 93.21* Circlip
50.20* Wear ring 94.00* Key
50.21* Wear ring 94.01* Key
50.40* Distance ring 94.02* Key
50.50* Support washer for ball bearing 99.99 Plastic plug
50.70* Thrower
52.30* Shaft sleeve * Recommended spare parts
52.40* Shaft sleeve
55.40 Washer
56.00 Grub screw
56.10 Pin
63.60 Grease nipple
63.80 Constant level oiler
Type 32-200
ZLND 32125 to 200250 AB

MECHANICAL SEALS 0B 2
68.10
10.20 23.00 50.40 40.00 43.30 16.10 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 91.40 50.70 18.30 93.01 90.12 90.11 94.00
Mechanical Seal Mechanical Seal

code AF3/AFS/AFK code C23/C2S/C2J
10.20 23.00 50.40 43.30 40.00 16.10 56.10 10.20 23.00 50.40 43.30 40.00 16.10

code AX3/AXS/AXK code AY3/AYS/AYK
10.20 23.00 50.40 43.30 40.00 16.10 99.99 41.23 56.10 42.11 16.50 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
Type 32-200
ZLND 32125 to 200250 AC/A2

68.10
10.20 23.00 50.40 43.30 40.00 16.10 90.13 42.10 32.10 50.50 63.80 91.60 40.02 36.00 21.00

BJ3/BJS/BJJ
92.20 94.01 90.30 90.10 91.40 50.70 33.00 63.81 90.31 18.30 93.01 90.12 90.11 94.00

code AF3/AFS/AFK code C23/C2S/C2J
10.20 23.00 50.40 43.30 40.00 16.10 56.10 10.20 23.00 50.40 43.30 40.00 16.10

code AX3/AXS/AXK code AY3/AYS/AYK
10.20 23.00 50.40 43.30 40.00 16.10 99.99 41.23 56.10 42.11 16.50 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
Type 32-200
ZLND 32125 to 200250 AB

STUFFING BOX 0B 2
68.10
10.20 23.00 52.40 40.00 16.10 40.05 90.23 45.70 45.20 90.13 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 45.80 40.00 99.99 92.01 45.70 55.40

23.00 45.10 16.10 40.05 46.10 45.20 90.21
Type 32-200
ZLND 32125 to 200250 AC/A2

STUFFING BOX 0B 2
90.23 45.20 68.10 32.10 63.80

10.20 23.00 52.40 40.00 16.10 40.05 45.70 90.13 42.10 50.50 91.60 40.02 36.00 21.00
Stuffing box code

041
92.20 94.01 45.10 46.10 45.80 92.01 91.40 90.21 33.00 63.81 90.31 18.30 93.01 90.12 90.11 94.00
90.30 90.10 55.40 50.70
Stuffing box
code 052
10.20 52.40 45.80 40.00 99.99 92.01 45.70 55.40

23.00 45.10 16.10 40.05 46.10 45.20 90.21
Type 32-200
ZLND 200315 to 300500 and 150500 AS

40.03 23.00 43.30 90.80 73.10 90.22 73.11 50.70 33.00 32.10 36.00 94.00
10.20 50.40 16.10 90.34 40.00 92.06 41.10 70.30 92.02 41.11 47.10 36.01 93.21 63.60 21.00

BJ3/BJS/BJJ
40.01 90.30 90.24 90.14 18.30 90.12 90.11

92.20 94.01 50.20 50.21 52.30 90.20 40.06 32.11 93.01 40.02 42.10
93.00 56.00 56.00 92.00
Shaft seal Shaft seal

Code AF3/AFS/AFK Code C23/C2S/C2J
50.40 23.00 40.00 73.11 47.10 56.10 50.40 23.00 40.00 73.11 47.10 52.30
10.20 43.30 16.10 40.06 41.11 90.24 52.30 10.20 43.30 16.10 40.06 41.11 90.24
Type 32-200
ZLND 200315 to 300500 and 150500 AT/A2

40.03 23.00 73.11 90.80 73.10 90.22 50.70 67.20 93.21 90.11 94.00
10.20 50.40 16.10 41.11 90.34 40.00 92.06 41.10 70.30 92.02 47.10 90.14 32.11 33.00 32.10 21.00

BJ3/BJS/BJJ
40.01 90.30 43.30 90.24 36.01 64.20 18.30 90.12 36.00

92.20 94.01 50.20 50.21 52.30 90.20 40.06 90.31 63.80 93.01 40.02 42.10
93.00 56.00 56.00 92.00
Shaft seal Shaft seal

Code AF3/AFS/AFK Code C23/C2S/C2J
50.40 23.00 40.00 73.11 47.10 56.10 50.40 23.00 40.00 73.11 47.10 52.30
10.20 43.30 16.10 40.06 41.11 90.24 52.30 10.20 43.30 16.10 40.06 41.11 90.24
Type 32-200
ZLND 200315 to 300500 and 150500 AS

STUFFING BOX 0B 2
40.03 23.00 73.11 90.80 73.10 90.22 50.70 33.00 32.10 36.00 94.00
10.20 45.80 16.10 41.11 90.34 40.00 92.06 41.10 70.30 92.02 45.20 36.01 93.21 63.60 21.00
Stuffing box code 041
40.01 46.10 90.14 18.30 90.12 90.11

92.20 94.01 50.20 90.30 50.21 52.40 90.20 55.40 90.21 32.11 93.01 40.02 42.10
93.00 56.00 56.00 92.00 92.01
Shaft seal
Code 052
45.80 23.00 40.00 55.40 90.21

10.20 46.10 16.10 90.33 45.20 92.01 52.40
Type 32-200
ZLND 200315 to 300500 and 150500 AT/A2

STUFFING BOX 0B 2
40.03 23.00 73.11 90.80 73.10 90.22 50.70 67.20 93.21 90.11 94.00
10.20 45.80 16.10 41.11 90.34 40.00 92.06 41.10 70.30 92.02 45.20 90.14 32.11 33.00 32.10 21.00
Stuffing box code 041
40.01 90.30 46.10 36.01 64.20 18.30 90.12 36.00

92.20 94.01 50.20 50.21 52.40 90.20 55.40 90.21 90.31 63.80 93.01 40.02 42.10
93.00 56.00 56.00 92.00 92.01
Shaft seal
Code 052
45.80 23.00 40.00 55.40 90.21

10.20 46.10 16.10 90.33 45.20 92.01 52.40
Type 32-200
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.
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 Safety issues 2
2.1 Identification of safety symbols in the supplementary operating instructions 2
2.2 Compliance with regulations 2
2.3 Qualification and training of personnel 2
2.4 Safety instructions for maintenance, inspection and installation work 3
3 Instructions referring to design of pump and accessories 3
3.1 General 3
3.2 Pump pressure containment components 3
3.2 Coupling, coupling guard 3
3.4 Belt drive 3
4 Instructions referring to installation and start-up of pump sets 3

4.1 Coupling 3
4.2 Connection to power supply 3
4.3 Earthing 3
4.4 Belt drive 3
5 Instructions concerning operation and servicing 3
5.1 Unauthorised modes of operation 3
5.2 Explosion protection 3
5.3 Pump filled and vented 4
5.4 Marking 4
5.5 Fluid pumped 4
5.6 Checking of direction of rotation (see also pump-specific operating manual) 4
5.7 Pump operating mode 5
5.8 Temperature limits 5
5.9 Maintenance 6
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
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 non-
sparking 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
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
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 Specific heat of liquid [J / kg K]

2
g Acceleration due to gravity [m /s]
H Pump head [m]
Tf Temperature of fluid handled [º C]
To Temperature of casing surface [º C]
η Pump efficiency [-]
∆ϑ 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 Permissible Max. permissible fluid

as per EN 13463-1: surface temperature for compliance
temperature with temperature class
T5 100 º C 80 º C
T4 135 º C 115 º C
T3 200 º C 180 º C
T2 300 º C 280 º C
T1 450 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
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
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 1127 - 1
EN 292 part 1 EN 13463 - 1
EN 292 part 2 prEN 13463 - 5
In the actual version.
National technical standards and specifications used, in particular:
UNE-EN 809 UNE-EN 1127-1

UNE-EN 292-1 UNE-EN 13463 - 1
UNE-EN 292-2
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

K 3000.1091.1 GB
Zentralschmiertechnik
BAIER + KÖPPEL
Instructions for use and maintenance

Gear pumps
Taking the unit into operation
Installation
The gear pump may be installed in vertical as well as in horizontal position. Angular bases and pump sup-
ports required for that purposeare available. For direct---drive operation the pump is equipped with an ela-
stic clutch. Belt and cogwheel drive assemblies as well as axial loads to the shaft are not acceptable. When
installing the pump, the piping assembly connected to it has to be taken into account. Tensions due to incor-
rectly installed tubes or to misalignment of the drive motor should be avoided. Any misalignment of the shaft
should not exceed 0,2 mm. Even if some manufacturers of drive clutches state that a greater misalignment
can be compensated by the clutch, the restoring force of the clutch generates some radial load on the shafts
to be connected, and this may result in damages to the pump. Impacts on the shaft end are not acceptable
at all, as they might result in serious damage to the pump.
Piping assemblies
When designing the size of a piping assembly, at has to be made sure that the acceptable flow speeds will
not be exceeded. In the suction pipe, they should not exceed 1,5 m/sec., and in the pressure pipe they
should not exceed 5 m/sec. (for more details, please consult the manufacturer). Before installation, any
piping assembly should be cleaned carefully. The suction pipe has to be perfectly airproof, and it should
be arranged as straight as possible, its end always being placed a few centimeters below of the minimum
oil level in the tank. The maximum suction lift should be restricted to a maximum of approx. 1 m. For the
piping assembly seamless precision steel tubes as per DIN 2391 are recommended.
Range of viscosity
The range of viscosity at operation should be between 15 and 800 mm2/s, as per graph 1 attached hereto.
The range of use of an oil may be clarified by reading the table of viscosities and temperatures. To this effect,
two viscosity values --- for ex. for 20° and 50° C --- must be entered into the graph. The point of intersection
of the straight line passing through these points, with the lines for maximum and minimum viscosity, indica-
tes the temperature limits of the oil concerned.
Attention: mind lubricant recommendation of manufacturer!
Oil quantity --- Oil temperature

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

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

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

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

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

K 3000.1091.3 GB
BAIER + KÖPPEL
Malfunction No. 1: The pump does not supply fluid.

1.1 The pump does not suck ---in any fluid
Possible reasons Remedies

1.1.1 The plug was not removed from the suction pipe. Remove the plug.
1.1.2 Leakage of the suction pipe. Re ---tighten the screwed joints; seal the threads.
1.1.3 Suction pipe is too short, or oil level in the tank Extend the suction pipe,
is too low. top up with oil.
1.1.4 Flow resistance in the suction pipe is too high Increase the tube diameter; straighten the suction pipe;
(excessive depressiopn). clean the suction filter; reduce the intake height.
1.1.5 Wrong sense of rotationof the motor assembly. Correct the sense of rotation.
1.1.6 Pressure pipe closed by the valve, or under Change over the depressurized circulation, or bleed
pre ---load, so that bleeding of the pump is the pump by opening the pressure socket.
impossible.
1.1.7 Excessive viscosity of the pressure fluid, or Fill the system using a pressure fluid, the viscosity of
excessive cooling of the pressure fluid. which is suitable for the service temperature.
1.2 Supply is interrupted even if the drive system is okay.

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

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

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

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

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

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 Telephone no.: : +46-31-66 67 50
SE 405 08 Gothenburg
Sweden
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
Product definition : Mixture
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 : Harmful

Risk phrases : R22- Harmful if swallowed.
Safety phrases : 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
Substance/mixture : Mixture
Classification
Ingredient name Identifiers % 67/548/EEC Regulation (EC) No. Type
1272/2008 [CLP]
ethanediol EC: 203-473-3 30 - 60 Xn; R22 Acute Tox. 4, H302 [1] [2]
CAS: 107-21-1 STOT RE 2, H373o
Index: 603-027-00-1
Hexanoic acid, 2-ethyl-, EC: 243-283-8 1-5 Repr. Cat. 3; R63 Repr. 2, H361d [1]
sodium salt CAS: 19766-89-3
Date of issue : 2012-01-26. 1/6

Coolant VCS Ready Mixed 21485015
See Section 16 for the See Section 16 for the
full text of the R-phrases full text of the H
declared above. statements declared
above.
There are no additional ingredients present which, within the current knowledge of the supplier and in the concentrations
applicable, are classified as hazardous to health or the environment and hence require reporting in this section.
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.
Skin contact : Wash with soap and water. Get medical attention if symptoms occur.
Eye contact : In case of contact with eyes, rinse immediately with plenty of water. Get medical attention if
symptoms occur.
Ingestion : Call medical doctor or poison control centre immediately. (Coolant. Contains ethylene glycol)
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 : 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
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 : Recommended:, alcohol-resistant foam, CO2, powders
Not suitable : Do not use water jet.
5.2 Special hazards arising from the substance or mixture
Hazardous combustion : Decomposition products may include the following materials:
products Hydrocarbon.
carbon oxides
5.3 Advice for firefighters
Special precautions for : Fire-fighters should wear appropriate protective equipment and self-contained breathing apparatus
fire-fighters (SCBA) with a full face-piece operated in positive pressure mode.

6.1 Personal precautions, protective equipment and emergency procedures
For non-emergency : Refer to protective measures listed in sections 7 and 8.
personnel
For emergency responders : 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".
6.2 Environmental : Avoid dispersal of spilt material and runoff and contact with soil, waterways, drains and sewers.
precautions 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 : 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.
Date of issue : 2012-01-26. 2/6


6.4 Reference to other : See Section 1 for emergency contact information.
sections See Section 8 for information on appropriate personal protective equipment.
See Section 13 for additional waste treatment information.
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 : Wash hands, forearms and face thoroughly after handling chemical products, before eating,
occupational hygiene smoking and using the lavatory and at the end of the working period. Wash contaminated clothing
before reusing.
7.2 Conditions for safe : Keep container tightly closed in a cool, well- ventilated place. Do not store in unlabelled
storage, including any containers.
incompatibilities
7.3 Specific end use(s)
Recommendations : Coolant and antifreeze.
Industrial sector specific : Not available.
solutions
8. EXPOSURE CONTROLS/PERSONAL PROTECTION

8.1 Control parameters
Occupational exposure limits
Ingredient name Occupational exposure limits
ethanediol 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 Type Exposure Value Population Effects
ethane-1,2-diol DNEL Long term Dermal 106 mg/kg Workers Systemic
bw/day
DNEL Long term Inhalation 35 mg/m³ Workers Local
DNEL Long term Dermal 53 mg/kg Man via the Systemic
bw/day environment
DNEL Long term Inhalation 7 mg/m³ Man via the Local
environment
Predicted effect concentrations
No PECs available.
8.2 Exposure controls

Appropriate engineering : Provide adequate ventilation. Where reasonably practicable, this should be achieved by the use
controls 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 : In case of insufficient ventilation, wear suitable respiratory equipment.
Hand protection : For prolonged or repeated handling, use gloves : neoprene , nitrile , natural rubber (latex) , or
PVC .
Eye protection : Use safety eyewear designed to protect against splash of liquids.
Environmental exposure : Do not allow to enter drains or watercourses.
controls

9.1 Information on basic physical and chemical properties
Appearance
Physical state : Liquid.
Colour : Yellow.
Odour : Slight
Odour threshold : Not available.
pH : Not available.
Melting point/freezing point : Not available.
Date of issue : 2012-01-26. 3/6


Initial boiling point and : >175°C (>347°F)
boiling range
Flash point : Closed cup: >115°C (>239°F)
Evaporation rate : Not available.
Flammability (solid, gas) : Not available.
Burning time : Not applicable.
Burning rate : Not applicable.
Upper/lower flammability or : Not available.
explosive limits
Vapour pressure : Not available.
Vapour density : Not available.
Relative density : 1,04
Density : 1,04 g/cm3 [20°C (68°F)]
Solubility : Easily soluble in the following materials: cold water and hot water.
Partition coefficient: n- : Not available.
octanol/water
Auto-ignition temperature : Not available.
Decomposition : Not available.
temperature
Viscosity : Not available.
Explosive properties : Not available.
Oxidising properties : 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 : No specific data.
10.5 Incompatible materials : Reactive or incompatible with the following materials:
acids
oxidizing materials
10.6 Hazardous : Decomposition products may include the following materials:
decomposition products Hydrocarbon.
carbon oxides

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
Inhalation : No specific data.
Skin contact : No specific data.
Eye contact : May cause eye irritation.
Ingestion : No specific data.
Relevant information for the mixture and/or the ingredients is presented below.
Acute toxicity
Product/ingredient name Result Species Dose Exposure
ethanediol LDLo Oral Human 786 mg/kg -
Harmful or fatal if swallowed. Ingestion: kidney abnormalities Contains material which can cause
birth defects.
Teratogenicity
Product/ingredient name Result Species Dose Exposure
Hexanoic acid, 2-ethyl-, sodium Positive - - -
salt
Potential chronic health effects
Date of issue : 2012-01-26. 4/6


General : Repeated or prolonged contact with the preparation may cause removal of natural fat from the
skin, resulting in non-allergic contact dermatitis and absorption through the skin.
Developmental effects : Contains material which can cause birth defects.
Other information : Not available.
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 : Not available.
coefficient (KOC)
Mobility : Water-soluble liquid
12.5 Results of PBT and vPvB assessment
PBT : Not applicable.
vPvB : Not applicable.
12.6 Other adverse effects : 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 Waste designation
16 01 14* antifreeze fluids containing dangerous substances
Packaging
Methods of disposal : Waste packaging should be recycled. Incineration or landfill should only be considered when
recycling is not feasible.
Special precautions : 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)
14.4 Packing group - - -

14.5 Environmental No. No. No.
hazards
14.6 Special Not available. Not available. Not available.
precautions for
user
14.7 Transport in bulk : Not available.

according to Annex II of
MARPOL 73/78 and the IBC
Code
Date of issue : 2012-01-26. 5/6

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 : R63- Possible risk of harm to the unborn child.
phrases R22- Harmful if swallowed.
Full text of classifications : Repr. Cat.3 - Toxic to reproduction Category 3
[DSD/DPD] Xn - Harmful
Full text of abbreviated H : H302 Harmful if swallowed.
statements H361d Suspected of damaging the unborn child.
H373o May cause damage to organs through prolonged or repeated exposure if swallowed.
Full text of classifications : Acute Tox. 4, H302 ACUTE TOXICITY: ORAL - Category 4
[CLP/GHS] Repr. 2, H361d TOXIC TO REPRODUCTION [Unborn child] - Category 2
STOT RE 2, H373o 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.

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
Upon ordering, please specify: model, size, working pressure, threads

ECS0502000
standard and type of liquid.
A.R.I Flow Control Accessories

Kfar Charuv, 12932 Israel Tel. 972-6-6761988 Fax. 972-6-6763402 http://arivalves.com
Type S-050
A PARTS LIST AND SPECIFICATION

1
No. Part Material
1. Body Reinforced Nylon

2
2. Rolling Seal Rubber E.P.D.M
3. Clamping Stem Reinforced Nylon
3 4. Float Foamed Polypropylene
5. O-Ring BUNA-N
4
6. Base Reinforced Nylon
or Brass ASTM B124
5
B
AUTOMATIC AIR DISCHARGE CHART
20
Pressure Bar
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" 0.65 Brass Base
* Orifice size Area: 12mm2

HDP 502 S 110050

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

HDP 502 S 110050

Uploaded by

Copyright:

Available Formats

Operating instructions

High pressure pump unit

HDP 502 / S 1100-50

Order no. KA 222274

Max. liquid temp. [°C] °C 40

Note : Ps = Pressure step

Parts list to machine no: B7.02502.0210

Pos Code - No. Description Quantity Unit

360 04.04611.0065 CONNECTION HOSE 4,00 m

Abnahmeprüfzeugnis / Test Certificate

Maschinen-Nr. HAMMELMANN GmbH

Druckregelautomatik Eingangsdrehzahl / Motordrehzahl

Medium pressure switch Motor rating kW

Power consumption (Testroom) Volt / Hz

Nr. Name Datum Zeit IR-Temp IR-Min IR-Max Mat. Name

Qualitätsprüfung Der Abnahmeingenieur Datum

Unterschrift / Signature J. Vöge 07.03.2017

Die Abteilung Normung/Dokumentation ist The department Standards/Documents is Le service Standardisation/Documentation

Bezeichnung der Maschine: Hochdruckpumpenaggregat HDP 502

EG-Richtlinie 2014/30/EU E.C. Directive 2014/30/EU Directive CE sur la comptabilité

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

EN 809 EN 1829-1 EN 60204-1 EN 61000-6-2

Hersteller-Unterschrift Manufacturer’s signature Signature du fabricant

Datum / Date / Date Geschäftsführer General Manager Gérant

High pressure pump unit

HDP 502 / S 1100-50

 Copyright Hammelmann GmbH

7.3.1 Electronic pressure transmitter 04.00829.0093 ...................................................................................... 26

Copyright Hammelmann GmbH

 Copyright Hammelmann GmbH

Manufacturer and customer services address:

Pos : 4 /T ec hnis che D aten/Zu di es er Anlei tung/Maschi nennummer @ 0 \mod5_2.doc x @ 1216 @ @ 1

Type: HDP 502 / S 1100-50

Serial no.: B7.02502.0210

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

Copyright Hammelmann GmbH

3.1 Main dimensions

 Copyright Hammelmann GmbH

Weight of the pump: approx. 1985 kg

Copyright Hammelmann GmbH

3.2 Performance data: High pressure pump

3.3 Performance data: Diesel engine

 Copyright Hammelmann GmbH

4.1 Dangers arising from non observance of safety instructions

4.2 Safety conscious working

4.3 Personnel qualification and training

4.4 Precise safety instructions for the operator

Copyright Hammelmann GmbH

 Copyright Hammelmann GmbH

 Causes of danger are,

4.5 Danger symbol

Copyright Hammelmann GmbH

4.6 Safety during inspection, maintenance and repair

4.7 Forbidden practices

Operating , maintenance and repair procedures other than described herein or

4.8 Additional warnings

 Copyright Hammelmann GmbH

5.3 General permissible operational conditions

Copyright Hammelmann GmbH

5.5 Warranty terms

 Copyright Hammelmann GmbH

Pay attention to the symbols on the packing, i.e.:

Do not use forklifts or