MACHINE CARD

Hammelmann Maschinenfabrik GmbH

POB 3309, D-59302 Oelde, Germany
mail to: mail@hammelmann.de
Machine no. : A3.01234.0263 http://www.hammelmann.de
Page: 1

Order no. KA 37629/1

Purchaser Hammelmann Corp., Dayton / USA
Client no. 10133501
P. O. no./Date 202259 / 16.06.2003
Machine no. A3.01234.0263
Pump type HDP 234
Code no. 09.43234.2000
Performance data
Flow rate Ps 1 l/min 29
Operating pressure Ps 1 bar 3500
Motor speed Ps 1 1/min 2150
Crankshaft speed Ps 1 1/min 550
Piston dia. Ps 1 mm 15
Motor rating req'd Ps 1 kW 224
Performance data diesel engine
Make Caterpillar
Type C9
motor no. CLJ 02322
Voltage V 24
Rating kW 250
R.P.M. 1/min 2150
Battery no. 04.00190.0003 2 Stück
Battery box no. 00.01909.0006 2 Stück
Battery voltage V 12
Battery capacity Ah 135
Brief instructions
Language englisch
Paint colour
Pump RAL 5005
Frame RAL 5005
Name plate high pressure pump
Machine no. A3.01234.0263
Type no. 09.43234.2000
Year 2003
Motor rating [kW] kW 224
Speed [1/min] 1/min 2150
Max. liquid temp. [°C] °C 40
Piston dia. pres. step 1 [mm] mm 15
Max. pressure Ps 1 [bar] bar 3500
Flow rate Ps 1 [l/min] l/min 29
Pressure reg. valve Ps 1 00.05907.0022
Oil type BM 320
Oil quantity [l] 20,0
Oil pressure [bar] 2,0
Person in charge VK / Hü
Date 28.08.2003
MACHINE CARD

Hammelmann Maschinenfabrik GmbH

POB 3309, D-59302 Oelde, Germany
mail to: mail@hammelmann.de
Machine no. : A3.01234.0263 http://www.hammelmann.de
Page: 2

Note : Ps = Pressure step

Parts list to machine no: A3.01234.0263

Pos Code - No. Description Quantity Unit

10 01.04565.0037 NAME PLATE 1,00 pc

20 00.00743.1817 PISTON SEAL ASSEMBLY HDP124/174/254 D15 5,00 pc
30 01.06224.0081 TOOLS, SET 1,00 pc
40 00.02515.0199 LINE HDP 110/160/350/400 2,00 pc
50 00.02145.0965 PUMPHEAD HDP234 D15 1,00 pc
60 00.02518.0022 VENT LINE HDP234 1,00 pc
70 00.00135.1559 ANSCHLUSSARMATUR(DRUCKSEITIG) HDP 70/120/170/250 1,00 pc
80 00.05907.0022 BYPASS VALVE DN 5; PN 4000 BAR 1,00 pc
90 04.00829.0029 PRESSURE SENSOR 0-4000BAR;4-20MA;M14X1.5LH; 1,00 pc
100 00.04062.3500 RUPTURE DISC ASSEMBLY M30X2 A - G 1/2 - 92,0 LG. 1,00 pc
110 04.05992.0311 PRESSURE RING M14 x 1.5 LH 4,00 pc
120 04.05992.0351 PRESSURE SCREW M30 x 2 4,00 pc
130 04.05992.0604 PLUG M 14x1,5 LH 3,00 pc
300 00.00026.1026 AGGREGAT S-ANLAGE-23; CAT C9 1,00 pc
310 04.00995.0132 FILTER BAG 1,00 pc
320 00.00134.0195 CONNECTION FITTING, SUCTION SI HDP160,230, CAT 3126B, CAT C9 1,00 pc
330 08.99109.0051 CONTROL LINE 1,00 pc
340 04.05630.0026 CUT OFF SWITCH, THERMOSTAT 1,00 pc
350 08.00229.5026 CUT OFF SWITCH 1,00 pc
360 00.01336.0039 CONTROL UNIT 1,00 pc
370 08.01320.0003 SUPPORT 1,00 pc
380 08.00229.6005 KEY OPERATED SWITCH 1,00 pc

>>>end<<<
Operating Instructions

for

Microprocessor - Control
ES1
from machine no.: 1000
from prog. no.: D327

Using an external power source to start the HP unit can da-

mage the ES1 microprocessor.
When charging the batteries ensure that the emergency stop
switch is depressed and locked.
The ES1 microprocessor contains electronic components that
will be damaged if subjected to excessive voltage of > 36 V.

The maximum ambient temperature should not exceed 50 oC.

Protect the ES1 against direct sun light.

Made in Germany

Issue: 01/2003
 Operating instructions
No. BES10X-E
Page 2 of 20 Issue 01/2003 Contents

Manufacturer and Customer Services address

HAMMELMANN Maschinenfabrik GmbH

Zum Sundern 13 - 21, Postfach 33 09

D-59302 Oelde • Germany

Telephone: (0 25 22) 76-0

Telex: 89455 hpump d

Telefax: (0 25 22) 7 64 44

Type: ES1

Machine no.:

Year of manufacture:

Contents:

1. Switch and keypad functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3

2. Control modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
3. Normal operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
3.1. On/off control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
3.2. Pre-heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
3.3. Starting the diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
3.4. Entering a value - Units with speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
3.5. Entering a value - Units with pressure control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
3.6. High pressure operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 6
4. User’s menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 6
4.1. Function menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 10
5. Fault indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 13

© Copyright of Hammelmann Maschinenfabrik GmbH

Germany • D-59302 Oelde • Zum Sundern 13 - 21
 Operating instructions
No. BES1-11-E
Construction and description Issue 01/2003 Page 3 of 20

1. Switch and keypad functions

◆ Fig.: 1.1. Control panel with basic display

Emergency stop / Main switch.

Press once: Control voltage on. Press again: Pre-heat activated.

Starts engine, Basic display appears.

Press once: Switches off motor. Press again: Switches off control voltage (press for 2 sec)

Changes menu.

Confirms status, enters data and resets display.

Selector keypad: Increases set value or selects next display.

Selector keypad: Decreases set value or returns to previous display.

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Germany • D-59302 Oelde • Zum Sundern 13 - 21
 Operating instructions
No. BES1-11-E
Page 4 of 20 Issue 01/2003 Construction and description

2. Control modes
The ES1 is available in four control mode configurations.

● Without parameter selection

➨ In this control mode the ES1 cannot influence either the selection of engine r.p.m. or of discharge
pressure. It functions only as a monitoring unit.

● Speed control
➨ The diesel engine r.p.m. can be selected by the operator
(but not exceeding max. r.p.m. set in the factory).

● Pressure control
➨ The discharge pressure can be selected by the operator
(but not exceeding max. pressure set in the factory).

● Control mode select

➨ Speed or Pressure control can be selected by the users menu.

Depending upon your pump unit there are variations in basic display. If no
pressure sensor is installed then actual r.p.m., fuel % remaining and battery
voltage are displayed.

If your pump unit is fitted with a pressure sensor then the actual pressure is
displayed in p.s.i. or bar (programmed to customer’s instructions).

Once the keypads are activated the display lighting illuminates. The lighting de-energises auto-
matically 30 secs. after last keypad operation.
Attention! Do not use as last keypad operation.
At temperatures under freezing point a fault can be indicated at the display. This has no effect
upon the control functions and the display soon returns to normal thanks to the integrated heating
system.

3. Normal operation
Under normal operational conditions the following instructions are integrated into the pump unit operational procedures.

3.1. On / off control

The unit is started by unlocking and releasing the Emergency stop/Main switch . At this point the ES1 takes over

contol and monitoring functions. Pressing keypad activates the basic display (see fig 1.1.). The unit is switched off
by pressing keypad .

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Germany • D-59302 Oelde • Zum Sundern 13 - 21
 Operating instructions
No. BES1-11-E
Construction and description Issue 01/2003 Page 5 of 20

For safety during maintenance, servicing etc. at the pump or during work breaks and at shift end the Emergency stop/
Main switch should be depressed and locked. The key should be removed and kept by a responsible person.

3.2. Pre-heat

A double press of keypad activates the pre-heat for diesel and the display shows:-

After a max. of 15 secs. or when the engine starts the display returns to basic.
If further pre-heat time is necessary press yet again to obtain a another 15 secs.
The engine management servo motor will open the throttle to max. (For better
starting in cold conditions)

3.3. Starting the diesel

Pressing the keypad activates the starter via a solenoid.

The starter automatically cuts out once the engine fires.

3.4. Entering a value - units with speed control

If the pump unit is fitted with a speed control the operator can set the max. r.p.m. (within the limit set in the factory). Pressing
keypad or will display the previously set r.p.m.

Pressing keypads or will increase or decrease r.p.m. setting. Display

returns to basic by pressing or automatically after 5 secs.

Variations of ± 30 r.p.m. are possible at the display.

3.5. Entering a value - units with pressure control

If the pump unit is fitted with a pressure control the operator can set the max. pressure (within the limit set in the factory).
Pressing keypad or will display the previous pressure setting.

Pressing keypads or will increase or decrease the pressure setting.

Display returns to basic by pressing or automatically after 5 secs.

Variations of ± 435 psi (30 bar) are possible at the display.

By pressing keypad in the Pressure set value menu the Pressure set value minimum menu is entered. By pressing
keypad or the minmum Pressure set value can be defined.

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Germany • D-59302 Oelde • Zum Sundern 13 - 21
 Operating instructions
No. BES1-11-E
Page 6 of 20 Issue 01/2003 Construction and description

The pump unit engine can only be run at above 1200 r.p.m. If r.p.m. under load drops below 1200
r.p.m. for any reason (ie: incorrect water nozzle fitted to H.P. tool) the pump until will shut down
after 15 secs. and the pump unit will shut down. The display will indicate ,,Insufficient engine
speed”.

3.6. High pressure operation

If the electrical command is given from a pistol, footswitch or remote control unit for the pump to run in high pressure water
mode the engine r.p.m. will increase from idle speed until max. set r.p.m. or pressure value is achieved. This function is
not active until 10 secs. after the ES1 is switched on.

4. Users menu
The users menu allows the operator to make certain checks or select certain parameters. Exit from basic display into users
menu is achieved by pressing keypad . If you want to go straight to particular menu display ie: ,,Multi - gun” which is
3rd in sequence press rapidly 3 times or keep depressed. The menu displays will appear rapidly in sequence.
Release IMMEDIATELY the required display appears.

● Hours run display and machine-no.

The first display to appear shows the total hours the unit has run (ie: inclusive
diesel at idle speed) and the machine-no.
This display cannot be altered.

● Speed control override

By pressing keypad again the Speed control override display appears (if programmed into the ES1 at the factory).

By pressing keypad or an engine "run on" time of between 1 and 30

secs. can be entered. This enables the lance operator to signal (release trigger
etc.) the pump to bypass but to maintain the engine r.p.m. at the set speed. Once
the lance is inserted into the next tube and the bypass is signalled to close the
pressure IMMEDIATELY rises to operational level.
Entering value "0" sec. overrides this function. For continuos speed override press

up to 30 s and press again. The symbol ∞ will appear.

● Multi-gun valve

By pressing keypad again the Multi-gun display appears. By pressing

or you can select "yes" or "no" (if multi-gun valve(s) fitted). This allows
the choice of working with multi-gun valve(s) or over the normal bypass valve.

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Germany • D-59302 Oelde • Zum Sundern 13 - 21
 Operating instructions
No. BES1-11-E
Construction and description Issue 01/2003 Page 7 of 20

● Bypass switch - Control

Press keypad and in the next display the status of the bypass switch is given.

This display is used mainly to diagnose breaks in the signal wiring. A correctly
connected bypass switch can only have the status 10 or 01, never 00 or 11.
The status of bypass switches 1, 2 and 3 are displayed from left to right.
10 means the bypass switches are off and 01 means they are on.
If the bypass switch display signal 00 then the control cable is damaged. If 11 is
displayed there is a short circuit in the cable or in the cable socket on the frame.

● Pressure sensor - Control

Pressing keypad calls up the display used to check the condition of the pressure sensor.

It displays the actual current emitted. At "0" pressure (psi/bar) and ambient temp
approx. 20 - 21 oC a reading between 3.9 and 4.1 mA should appear.
Readings under 3.5 mA indicate foreign influences at the pressure sensor, ie:
signal disturbance, low temperature.
At a value of ≤ 3,2 mA the control unit cut out and the display will indicate
"Pressure sensor fault".

● Engine temp. max.

Once again press keypad to display the actual and max. engine tempera-
ture.

The actual engine temperature appears on the left of the display:

- for range 120 oC max. from 60 oC and upwards
- for range 150 oC max. from 70 oC and upwards and
- for range 250 oC max. from 125 oC and upwards. This display cannot be
altered.

● Monitoring and unit cut out if set pressure not achieved

In this menu (if programmed into the ES1 at the factory) a percentage of the HP
value from 0% to 100% of the pressure set value can be entered so that the unit
will automatically shut down if pressure drop from set exceeds the percentage
entered. Percentage is entered by using the arrowed keypads.
e.g.: Pressure set value = 1000 bar
Set min pressure 90% = shutdown at 900 bar.

In this menu (if programmed into the ES1 at the factory) at time of 0 to 59 sec.
and 1 to 30 min. can be entered by using the arrowed keypads. If over this period
of time the high Pressure value is less than the minimum set value the unit will
automatically shut down. "Below min. pressure" will appear on the display.

© Copyright of Hammelmann Maschinenfabrik GmbH

Germany • D-59302 Oelde • Zum Sundern 13 - 21
 Operating instructions
No. BES1-11-E
Page 8 of 20 Issue 01/2003 Construction and description

Display contrast

The next press of keypad allows you to adjust the display contrast to suit ambient light conditions.

By pressing keypad or you can adjust contrast setting between

values 1 and 16.

Hose length

Press keypad to access "Hose length" display (if programmed into the ES1 at the factory).

By pressing keypad or you can select "20 m" or "< 100 m" or in
other words short or long hose operation. The "Max pressure exceeded" cut out
function is influenced by the hose length, diameter, elasticity and by the choice
of nozzle. You can use a longer hose at a setting of "20 m" as long as no over
pressure cut out occurs. If this situation arises then select " < 100 m".

Language

Press keypad to access language display and choose English or German.

R 327 Switch from German to English and vice versa by pressing keypads or
. In the left corner the prog. vers. will disaper (e .g. R327).

Standby - Time

The next operation of keypad will bring up the "Standby - Time" display. (If programmed into the ES1 at the factory).

By pressing keypad or a standby time of between 0 and 30 mins.

can be entered or ∞ constant running. If the set time expires without a signal to
close the bypass the unit will shut down. "Standby time exceeded" will appear
on the display. Entering ∞ constant running overrides the standby function.

Control mode select

Press keypad mode again to be able to select mode of control (If programmed into the ES1 at the factory).

Using keypads or you can selsct either "speed control" or "pressure

control". This menu can only be accessed when the diesel engine is not running.
Having changed from one mode to the other the required value (... r.p.m.
or ... p.s.i.) must also be entered.

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Germany • D-59302 Oelde • Zum Sundern 13 - 21
 Operating instructions
No. BES1-11-E
Construction and description Issue 01/2003 Page 9 of 20

● Pressure step

Press keypad to obtain "Pressure Step" display (if entered into the ES1 at
the factory). The actual pressure setting will appear. The "Pressure step" function
is for use with pump units supplied with conversion kits (pumphead, p.s.a.,
regulator etc.) to change the pump performance parameters.

The max. pressures will have been programmed into the ES1 to match the
conversion kits supplied. Gaining entry and changing is only possible with a pass
code!

Press keypads and simultaneously and then release followed

by to enable pass code entry. The display will show a row of numbers and
letters with a cursor under one of them. The pass code is 1 2 3. Position the
cursor under each of these in turn using keypads or and enter using
.

Use or to call up the correct pressure step and then exit this sub
menu by pressing keypad .

● Fault log

Use or to scroll through the most recent 100 faults registered by the
ES1. Pressing ACK will display the fault code no. identifying the actual fault. Press
again or wait 30 sec. to return to fault log display. The time that the fault
occured (unit hours run) will appear on the bottom right of the display. The
following table lists the Fault code nos. and their corresponding fault descriptions.

Time
Fault code Fault description
Fault code
Fault no. 1 Engine problem
2 Engine oil pressure low
3 Freely definable fault 2
4 Pump oil pressure low
5 Feed water pressure low
6 Water filter blocked
7 No water in tank or at idle speed
8 Water temp. high
9 Max pressure exceede

© Copyright of Hammelmann Maschinenfabrik GmbH

Germany • D-59302 Oelde • Zum Sundern 13 - 21
 Operating instructions
No. BES1-11-E
Page 10 of 20 Issue 01/2003 Construction and description

Fault code Fault description

10 Standby-time exceeded
11 Freely definable fault 1
12 Electronic overload
13 Max. r.p.m. exceeded
14 Engine temp. high
15 Press. sensor or bypass-cable fault
16 Air pressure low
17 Below min. pressure
18 Insufficient engine speed
19 Overload voltage
20 Temperature sensor-cable fault
21 Control-cable fault
22 Alternator fault
23
24

● Average r.p.m. (if factory programmed)

Displays two average engine r.p.m. readings n1 and n2 taken while the pump is under pressure over pre set times t1 and
t2.

Set the required time in the display (... s/m/h) with the keypads "up and down"
and then confirm with the keypad "ACK" corresponding to the times t1 and t2.
The times t1 and t2 can be selected as:-
t1 = 1,2,3 . . . 59 sec./ 1, 10, 20, 30, 40, 50, min. / 1, 2, 3, ... 24 hrs.
t2 = 1, 2, 3, ... 24 hrs.

Changing the t1 or t2 settings immediately wipes the display cancels the

calculated average r.p.m. the display will show four dashes until the newly
entered time has eleapsed and the new average r.p.m. n1 or n2 is calculated.
The average r.p.m. is constantly calculated over the pre set times t1 and t2 while
the unit is running under pressure.

4.1. Function menus

The function menus have some programmes enabling you to check various functions of the unit circuitry.
The function menus can be entered at the end of the user menu by pressing keypad once the following display has

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 Operating instructions
No. BES1-11-E
Construction and description Issue 01/2003 Page 11 of 20

appeared.

Press to return to basic display.

Press to call up function menu 1.

● Function menu 1: Input control.

Here the status of various circuit inputs are digitally displayed.

The letters are abbreviations for:

O Engine oil pressure 1 = ok 0 = not ok

2 Freely definable fault 2 1 = ok 0 = not ok
K Coupling (limit switch) 1 = coupled 0 = uncoupled

O Pump oil pressure 1 = ok 0 = not ok

W Feed water pressure 1 = ok 0 = not ok
F Water filter 1 = ok 0 = not ok
3 Freely definable fault 3 1 = ok 0 = not ok
T Water temp. pump 1 = ok 0 = not ok
L Air pressure 1 = ok 0 = not ok
H H.P. water below min. press. 1 = ok inactive 0 = not ok
B Bypass overflow 1 = ok inactive 0 = not ok
1 Freely definable fault 1 1 = ok 0 = not ok

In the following menus you can physically check or visually confirm that various elements of the unit are functioning correctly.
Once the function display appears, pressing keypad will result in the word "live" and the actual battery voltage
appearing. The ES1 is "on" in this mode but nothing is running due to an automatic cut-out system, ie: when you are in
function menu 3 - "starter", pressing will turn the starter but the motor will not start. To access the next function
menu press keypad . To return to basic display from any function menu press the keypad .

● Function menu 2: Pre-heat

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Germany • D-59302 Oelde • Zum Sundern 13 - 21
 Operating instructions
No. BES1-11-E
Page 12 of 20 Issue 01/2003 Construction and description

● Function menu 3: Starter

Starter turns
Pressing "ACK" and "ON" will
activate the start solenoid enabling
the engine to start. The engine will run
for as long as you keep pressing "ON".
Release "ACK" immediately the engine
Start solenoid function indicated,
starts to avoid damaging the gener-
engine starts, flickering line
ator!
indicates generator pulses
● Function menu 4: Shut off valve

Valve is activated
Function menu 5: Servo motor (fuel system bi-magnet)

Pressing keypad activates

servo motor in direction accelerate
(display showes "live + ").

Pressing keypad activates

servo motor in direction decelerate
(display showes "live - ").

● Function menu 6: Compressor

● Function menu 7: Hours run display Compressor motor activated

with no air in tank

It shows the hours and minutes the pump has run at pressure and the total time
the unit has run (ie: inclusive diesel at idle speed). This display cannot be altered.
Note: This menu is not shown in programme versions V 203 onwards.

Press keypad to return to basic display.

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Germany • D-59302 Oelde • Zum Sundern 13 - 21
 Operating instructions
No. BES1-11-E
Construction and description Issue 01/2003 Page 13 of 20

5. Fault indication
If a fault occurs in the pump unit during operation the following sequence is automatically activated:

● The bypass opens and the unit runs without pressure.

● The diesel r.p.m. fall to idle speed.
● The fault is indicated in clear text on the display.
● The engine cuts out after X secs. (X = set in the factory)
(Exception: Fault code 16 - The engine runs at idle speed)

Upon automatic cut out of the engine: Read and note the cause of the fault at the display and then press and lock
the emergency stop button . Carry out the necessary repair and then release the emergency stop button .
Follow the normal start procedure. If the repair is effective the unit will run normally and the fault text can be removed from
the display by pressing . If the fault has not been eliminated the engine will stop again after 10 secs.

Indicated faults are:

● Fault code 1

Cancel the fault indication "Engine problem" by pressing and press to start the enigine.
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:-

❍ Fuel filter blocked. ➨Change the filter.

On air cooled Deutz engines check the hand pump filter.
❍ Fuel tank empty. ➨Fill tank.
❍ Fuel line defective ➨Check line, clear or replace as necessary.
❍ Air in the fuel system ➨Check fuel level,
Check that fuel line is airtight.
Ensure that tank (unit) is not tilted too much.
The suction line must be at the bottom of the tank.
❍ Start solenoid not functioning ➨Check in function menu 4. If display does not show live
check wiring connections.
❍ Nozzle inserts too small ➨Check and replace if necessary.
❍ Consumer closed ➨Open consumer

The fault "Engine problem" can also display when:

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 Operating instructions
No. BES1-11-E
Page 14 of 20 Issue 01/2003 Construction and description

❍ At idle speed: ➨Speed drops below set idle r.p.m. (not control related)
❍ When pump is pressurised: ➨Speed drops below min. set
working speed of 1000 r.p.m. (not control related).

● Fault code 2

❍ Oil level too low. ➨Top up engine oil or change the oi

❍ Oil filter blocked. ➨Change oil filter, possibly change the oil.
❍ Oil pressure switch S3 defective. ➨Check pressure switch S3 and repair or replace if
necessary.

❶ These faults can be displayed if the engine runs too slowly or if it cuts out
altogether. Check the engine and fuel supply system for faults.

● Fault code 3

Possible faults for freely definable fault 2

● Drive belt defective (only applicable to DEUTZ air cooled diesel engines)

❍ Drive belt is broken, off pulley, or loose.

➨Replace, refit or retension as necessary.
or
➨ECM of the CAT-engine shows a fault. Identify the fault by
● CAT - engine fault the flash code. Carry out the necessary repair or call
CAT-Service.
❍ At machines with fast stopping flap "Over speed" is
➨Shortly shut of the ES1 by pressing the emergency stop
reached.
button. After restarting open the fast stopping flap.
or
➨EMR of the DEUTZ-engine shows a fault. Call DEUTZ-
● DEUTZ - engine fault
Service.

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 Operating instructions
No. BES1-11-E
Construction and description Issue 01/2003 Page 15 of 20

● Fault code 4
❶

❍ Oil level too low. ➨Top up or change the oil.

❍ Oil filter blocked. ➨Change oil filter, possibly change the oil.
❍ Oil pressure switch S5 defective. ➨Check oil pressure gauge. Oil pressure should be approx.
5 bar.
➨If oil pressure is sufficient (> 2 bar) check oil pressure
switch S5. If necessary repair or replace.

● Fault code 5

❍ Belt drive broken or loose. ➨Check boost pressure gauge. (Under load boost pressure
should be higher than 3 bar).
❍ Water filter blocked. ➨Clean or exchange water filter.
❍ Water pressure switch S6 defective. ➨Repair or replace as necessary.

● Fault code 6

❍ Filter bag blocked ➨Clean or replace filter bag.

❍ Differential pressure switch S7
➨Reset the red button on the differential pressure switch.
defective.
❍ ➨Check differential pressure switch S7 and replace as
necessary.

© Copyright of Hammelmann Maschinenfabrik GmbH

Germany • D-59302 Oelde • Zum Sundern 13 - 21
Operating instructions
No. BES1-11-E
Page 16 of 20 Issue 01/2003 Construction and description

● Fault code 7

Possible faults for freely definable fault 3:

3 No water in tank/ idle speed

There are two monitoring systems:

1. Float switch.
2. Low pressure switch (only on S Class units up until Sep-
tember 1997). To point 1:
➨Check water supply (must be approx 1bar)
➨Check float switch and replace if necessary.
❍ Water tank empty. To point 2:
❍ Float switch defective or 0,5 bar pressure switch de- ➨Check boost pressure. Should be > 0.5 bar at idle speed.
fective. If ok. remove defective switch and bridge connections.
(switch not installed on current units)

● Fault code 8

❍ Supply water temperature too high (max. 30 ° C). ➨If a higher water temperature than 30 ° C is required please
contact Hammelmann or Hammelmann dealer.
❍ Bypass water/ oil cooler return water is increasing ➨Remove bypass water / oil cooler hoses from tank and
temperature in water tank. drain them separately.

● Fault code 9

❍ Pressure has exceeded 10 % of max. pressure. ➨The nozzle diameter(s) must be selected to achieve 1200
rpm. minimum diesel engine speed.
❍ Wrong nozzle diameter has been selected. ➨Exchange nozzles.
❍ Nozzles are blocked ➨Clean or exchange nozzle
❍ Hose length > 20 m. ➨In computer menu change "Hose length" from "20 m" to
"100 m". The diesel engine will accelerate slower avoiding
over pressure.

© Copyright of Hammelmann Maschinenfabrik GmbH

Germany • D-59302 Oelde • Zum Sundern 13 - 21
 Operating instructions
No. BES1-11-E
Construction and description Issue 01/2003 Page 17 of 20

● Fault code 10

❍ If the unit is run on standby for too long a period it will

➨Change "standby-time" in users menu to constant running
automatically shut down.
(symbol ∞ indicates) if automatic cut out is not required.

● Fault code 11

● Multi tool valve defective:

❍ Valve mechanically damaged ➨Repair or replace valve

❍ Control line defective ➨Check for damaged cable or connections.

● Pump oil temp. too high

❍ Feed water temp. too high. ➨Check the water temp. If necessary apply external cooling.
If the unit has a water tank charge with cold water.
❍ Cooling water line defective. ➨Check and remedy.
❍ Ambient temp. too high. ➨Cool externally, provide shadow.

● Fault code 12

❍ Short circuit between connection A + B bypass- ➨Remove bypass cable and check connections. Repair if
switch including the connector on the unit necessary.
❍ Internal fault in the ES1 control ➨Disconnect multi tool valve (if installed) and check
connectors.
❍ A fault in the installation indicates + signal to the ➨Check socket for bypass cable. If it can be turned open
bypass- or multi tool valve. and check the wiring connections. Repair wiring
connections if necessary.
➨Check the whole installation for wiring faults, short circuits
etc.
➨If the fault remains indicated with bypass cable
disconnected and wiring continuity proven the ES1 is
faulty.

© Copyright of Hammelmann Maschinenfabrik GmbH

Germany • D-59302 Oelde • Zum Sundern 13 - 21
Operating instructions
No. BES1-11-E
Page 18 of 20 Issue 01/2003 Construction and description

● Fault code 13

❍ The maximum r.p.m. of the ENGINE has been excee- ➨Only in pressure control mode:
ded by 10 % or more. Incorrect (too large) nozzle(s).
Too much bypass water (incorrect PRV setting).
Wear in the bypass / PRV.
➨This failure can only occur when the pump is unloaded or
after a change of linear motor.
➨Readjust the linear motor in accordance with the
instructions.

● Fault code 14

❍ Max. permissible engine temperature has been achie-

➨Check coolant level and top up if necessary.
ved.
➨Check the fan V-belt. Adjust as
necessary.
➨Check radiator for dirt and clean if necessary.
➨Ensure that air inlet and outlet grilles are open.
➨Reposition the unit if air inlet is close to a temperature
source (e.g. air outlet of another unit).

● Fault code 15

❍ It is unlikely that the presssure transducer is defective. ➨Check the 4mA in the "USERS MENU"
❍ The current of transducer should be approx. 4 mA. ➨If approx. 4 mA the bypass cable is faulty. Repair.
If 0 mA the bypass socket or wiring to socket is faulty.
Repair. If neither of the above check the transducer. If
voltage is approx 22 volts but 4 mA current is not present
replace the transducer.

© Copyright of Hammelmann Maschinenfabrik GmbH

Germany • D-59302 Oelde • Zum Sundern 13 - 21
 Operating instructions
No. BES1-11-E
Construction and description Issue 01/2003 Page 19 of 20

● Fault code 16 Attention!

If a high pressure command is in place, e.g.
keyswitch in position "I" it should be returned to
position "0" so that the fault display will
automatically cancel once the air supply is back
in place.

❍ The minimum air pressure of 5 bar is not available. ➨Check pneumatic installation for leakage and eliminate if
found. If the air pressure gauge will indicate 5 bar, check
the S11 switch and if necessary replace switch S11.

● Fault code 17

❍ The minimum allowable pressure is not achieved due

➨Check nozzles for wear and replace if necessary.
to nozzle wear.
❍ The minimum allowable pressure is not achieved due ➨Check high pressure pipework and hoses for leakage.
to leakage in the high pressure pipework or hose ATTENTION! Re-tighten fittings only after pressure is
connections. released and the unit is shut down!
❍ The minimum allowable pressure is not achieved wit-
➨Check programmed data for minimum pressure and make
hin a given time (in the user’s menu you can adjust
corrections if necessary.
"min. pressure after ? sec./min.").

● Fault code 18

❍ The minimum allowable engine speed under load has

not been achieved (1200 min-1) (only possible if pres- ➨Wrong nozzle selected.
sure control is programmed)
➨Incorrect pressure set value entered.
➨Engine not producing enough power (e.g. 1200 r.p.m
exceeded but set pressure cannot be achieved). Refill
diesel tank, clean diesel filter and check fuel system for
leakage.
If necessary have the engine (turbo charger) inspected by
an expert.

© Copyright of Hammelmann Maschinenfabrik GmbH

Germany • D-59302 Oelde • Zum Sundern 13 - 21
Operating instructions
No. BES1-11-E
Page 20 of 20 Issue 01/2003 Construction and description

● Fault code 19

❍ The power to the unit is in excess of 33V. DC. (permit-

➨The alternator is faulty. Repair or replace.
ted power is between 20 and 30 V. DC.)
➨External power source attached. Switch off and remove
immediately.
ATTENTION using an external power source as an auxilliary
starter when the ES1 is on can interfere with the electronic
control system.

● Fault code 20

❍ Cable or connector fault ➨Replace or repair cable.

● Fault code 21

❍ Control cable defective. ➨Remove control cable from unit.

➨If 4 mA is indicated, control cable is defective. Repair

● Fault code 22
❶

❍ V-belt for alternator broken or loose. ➨Replace or retension as necessary.

❍ Cable on terminal W (Deutz/Volvo) or terminal R (Ca-
➨Replace or tighten terminals.
terpillar) of alternator loose or defective.
❍ Cable on terminal D+ of alternator loose or defective. ➨Replace or tighten terminals.
❍ Cable defective. ➨Replace or tighten terminals.

For all described faults one general rule applies: The reason for a fault display appearing can also
be due to a defective sensor or interference with a sensor.
If you cannot find any reason for a fault display appearing it could be that the multi pin connector
has been incorrectly fitted and that one or more pins have been bent. Always ensure that the pins
are correctly located and the connector is parallel to the socket before finally pressing home.

© Copyright of Hammelmann Maschinenfabrik GmbH

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

for

High pressure pump

HDP 234

Made in Germany

Stand: 09/2003
 Operating instructions
No.: B2340X-E
Page 2 of 2 Issue 09/2003 Index

All personnel who are responsible for the Operation and

maintenance of the high pressure pump HDP 234 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.

Manufacturer and customer services address:

HAMMELMANN Maschinenfabrik GmbH

Zum Sundern 13 - 21, POB 3309

D-59302 Oelde • Germany
Telephone: (02522) 76-0
Telex: 89455 hpump d
Telefax: (02522) 76444

Type: HDP 234

Serial no.: A2.01233.0263

Date: 2002

Contents:

Index:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. B2340 X E

Technical Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. B2340 0 E
Safety: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. BHDP0 1 E
Generall:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. BHDP0 2 E
Transportation:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. BHDP0 3 E
Construction and description: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. B2340 4 E
Installation and start up: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. B2340 5 E
Operation: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. B2340 6 E
Shut down: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. B2340 7 E
Maintenance: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. B2340 8 E
Appendix:
 Operating Instructions
No.: B23400-E
Technical Data Issue 09/2003 Page 1 of 4

Contents

1. Main dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1

2. Performance data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2
3. Order code key. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3
4. Machine number key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4

1. Main dimensions

■ Fig. 1.1.: Main dimensions of the High Pressure Pump

Weight of the pump: approx. 630 kg

 Operating Instructions
No.: B23400-E
Page 2 of 4 Issue 09/2003 Technical Data

2. Performance data

The following table shows the possible pump performances. The performance data of your pump can be taken from
the machine card or the pump nameplate

D = Plunger dia.
PN = Power rating
n = r.p.m.
p = Operating pressure
Q = Flow rate
n in 1/min PN in kW
D in mm Q in l/min 110 132 160 200 230
Motor Crank shaft
p in bar
1500 385 24 2500 2950 - - -
15 1500/1800 455 29 2100 2500 3000 - -
1800/2150 550 25 1750 2100 2500 3000 -
1500 385 33 1800 2200 2650 3000 -
17,5 1500/1800 455 39 1550 1850 2250 2800 3000
1800/2150 550 47 1300 1500 1850 2300 2650
1500 385 43 1400 1700 2000 2500 2600
20 1500/1800 455 51 1200 1400 1700 2150 2500
1800/2150 550 62 1000 1200 1400 1800 2000

Rod force F = 82 000 N

Stroke h = 75 mm

Average piston speed

at a crank shaft r.p.m. of:
385 1/min = 0,96 m/sec
455 1/min = 1,14 m/sec
550 1/min = 1,38 m/sec
 Operating Instructions
No.: B23400-E
Technical Data Issue 09/2003 Page 3 of 4

3. Order Code Key

Key for code numbers for high pressure pumps and units.

09. X X XX X. X XXX

to identify performance data (see performance table)

to identify gear ratio

to identify design of water end

1 = Piston type (packings) max 300 bar

2 = Plunger type (Labyrinth) max. 1000 bar
3 = Plunger type (Labyrinth) max. 1500 bar
4 = Plunger type (Labyrinth) max. 2500 bar
5 = Process pumps
6 = Sewer cleaning pumps

to identify type of pump (power end)

02 = HDP 20 06 = HDP 60 12 = HDP 120 35 = HDP 350

03 = HDP 30 08 = HDP 80 16 = HDP 160 55 = HDP 550
05 = HDP 50 11 = HDP 110 23 = HDP 230 95 = HDP 950

to identify type of drive

0 = without drive
1 = Electric motor 380 V, 50 Hz - 440 V, 60 Hz
2 = Diesel egine, air cooled
3 = Diesel engine, water cooled
4 = Electric motor 500 V, 50 Hz
5 = Thyristor control
9 = Special drive

to identify type of assembly

0 = Bare shaft pump

1 = Short frame for electric motor
2 = Long frame for e- motor + hose reel etc.
3 = Diesel on frame without fuel tank
4 = Diesel on frame with fuel tank
6 = S 1000, S 1500, S 2500series units
9 = Special frames
 Operating Instructions
No.: B23400-E
Page 4 of 4 Issue 09/2003 Technical Data

4. Machine number key

The machine number provides the following information:

XX. XX XXX. XXXX

Internal number

Pump type

ie: for High Pressure Pump

052 = HDP 52
164 = HDP 164
234 = HDP 234
352 = HDP 352

Free

Year of manufacture

ie: 90 = 1990
 Operating instructions
No.: BHDP01-E
Safety Issue 09/2003 Page 1 of 4

Contents:

1. Dangers arising from non observance of safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1

2. Safety conscious working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
3. Personnel qualification and training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
4. Precise safety instructions for the operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2
5. Danger symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
6. Safety during Inspection, maintenance and repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
7. Forbidden practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
8. Additional warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4

1. Dangers arising from non observance of safety instructions

Using the most modern manufacturing techniques HAMMELMANN produce high pressure equipment which is subject to
stringent Quality, Function and Safety tests. Even so, improper or unsuitable use of high pressure equipment, or operation
by untrained personal can result in accidents leading to:

❍ Danger of death or injury

❍ Costly damages claims.

All personnel who are responsible for the operation and maintenance of high pressure equipment must, before they attempt
operation be fully conversant with and completely understand the contents of this manual. Particular attention must be
paid to this section "safety" and these instructions must always be readily available to all personnel concerned. No claims
for personal injuries or damages arising from ignorance or non observance of safety procedures can be accepted.

2. Safety conscious working

Always observe accident prevention rules (eg. 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.

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.
 Operating instructions
No.: BHDP01-E
Page 2 of 4 Issue 09/2003 Safety

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.

❍ 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, ie: 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 (ie: nozzles, spray bar)
for signs of leakage. In the case of leakage stop the pump unit imediately.
Do not attempt a close visual inspection of leakage while the pump is running.

❍ Use only the correct tools, ie: 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 (ie: sprayguns) 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 (ie: spraygun) will not cause a sudden pressure change and / or excessive reaction forces.

❍ Never use accessories, ie: 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.
 Operating instructions
No.: BHDP01-E
Safety Issue 09/2003 Page 3 of 4

❍ 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)

❍ Interfering with safety elements is strictly forbidden! Damaging, eg. the locking wire or seal coating will invalidate the
guarantee and will release us from any liability in the event of accident or injury.

❍ 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 neighboring workers, and that the workplace is closed off with barriers.
➨ signs are erected to prohibit unauthorised entry ie: Danger! High pressure water.

❍ Causes of danger are,

➨ the jet (cutting power).
➨ spray mist (with dangerous chemical addatives).
➨ 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 (ie: 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 (ie: cutting power of the jet, possble impact damage to tissue and bacterial infection).

❍ To work with liquid jets the employer should ensure that all operatives wear protective clothing, ie:
➨ 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!
 Operating instructions
No.: BHDP01-E
Page 4 of 4 Issue 09/2003 Safety

5. Danger symbol

This symbol, always indicates an important safety instruction. You must read under-
stand and follow the instruction precisely!
Failure to follow such an instruction can result in extreme danger to persons and
damage to property.

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 competant,
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".

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.

8. Additional warnings

❍ When this high pressure equipment (ie: 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 (ie: 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.
 Operating Instructions
No. BHDP02-E
General Issue 09/2003 Page 1 of 2

Contents:
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
2. Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
3. General permissible operational conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
4. Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2
5. Guarantee conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2

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 manufacturing processes allow us to offer the very highest quality
products.
This means for you:

❍ High precision manufacture,

❍ High reliability and
❍ Efficiency

2. Application

There are many applications for HAMMELMANN High and Ultra high pressure pumps, ie:

❍ Liquid dosing and transportation.

❍ Hydrogenation and cracking processing.
❍ Hydraulic mine support, power packs.
❍ Decoring and cleaning castings.
❍ Water jet cutting.
❍ Building, bridge, highway renovation.
❍ General high pressure cleaning
➨ of flat surfaces
➨ transportation and production plant
➨ pipework, sewers, tanks, heat exchangers etc. etc.

3. General permissible operational conditions

Unless otherwise stated in writing (contractually) by HAMMELMANN the following operational conditions apply:

❍ Use only clean water. Any solids must not exceed a max. particle size of 1 µm and a concentration of 50
mg/l. (Ensure suitable filtration is installed). Water supply temperature must not exceed 40° C.
❍ The max. permissible supply water velocity is 1 m/sec. at a boost pressure of min. 3 bar, max. 8 bar.
 Operating Instructions
No. BHDP02-E
Page 2 of 2 Issue 09/2003 General

Before attempting to introduce any additives such as cleaning fluids obtain written approval from
HAMMELMANN ! Some fluids will attack the labyrinth material (bronze).
Under no circumstances intruce cleaning fluids containing Amine or Phosphate.

4. Copyright
The copyright to these operating instructions is the property of HAMMELMANN GmbH. These instructions contain
technical descriptions and illustrations that may not be electronically stored nor 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.

5. Guarantee conditions
The high pressure pump is guaranteed for a period of 12 months from date of delivery or 1000 operating hours whichever
occurs sooner except for wearing parts. See our "General terms of business" for other guarantee conditions. The guarantee
would be invalidated for instance if:

❍ The equipment was used for purposes other than intended by us.
❍ A motor / engine is fitted with a higher power rating than stated on the pump name plate.
❍ If the safety devices fitted have been maladjusted or disconnected.
❍ If the machine was used with accessories or fitted with spares not supplied by HAMMELMANN.
❍ Damage is caused by:
➨ Improper use.
➨ Ignoring the maintenance instructions.
➨ Use other than described in these operating instructions.
➨ Unsuitable flow medium.
➨ Faulty installation.
➨ Incorrectly positioned or sized hoses, pipework etc.
➨ Unauthorised design modifications.
➨ Cavitation (ie: suction installation allows air into pump).

If required a Guarantee Claim Application form is available from us or our accredited agent.

The contents of the operating instructions and product documentation shall not become part of
or modify any prior or existing agreement, commitment or relationship. The sales contract contains
the entire obligations of HAMMELMANN.The warranty contained in the contract between the parties
is the sole warranty of HAMMELMANN. Any statements contained herein do not create new
warranties or modify the existing warranty.
 Operating instructions
No.: BHDP03-E
Transportation Issue 09/2003 Page 1 of 2

Contents

1. Packing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
2. Transportation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2
3. Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2

1. Packing

Method of packing is determined by method of transport. At the minimum the pump or pump unit will be protected from
the elements.

Packing symbols

This way up Keep away from heat Sling here Keep dry

Fragile Centre of gravity No hand truck here Use no hooks

Handle with care
 Operating instructions
No.: BHDP03-E
Issue 09/2003 Page 2 of 2 Transportation

2. Transportation

Normally a pump unit will be transported without fuel in the tank. Sometimes the pump and engine will have been drained
of oil and in some cases the cooling system will also be drained.

Please check the pump unit for notices as to its delivery condition.

For safety precautions will have been taken to stop leakage of fuel, oil etc. during transportation.

3. Protection

All pumps and pump units only leave our works when they have undergone a strict test procedure. At the end of the test
an anti corrosion emulsion is introduced and the pump is run for a minute. This is to ensure that all water bearing parts
such as plungers, pumphead etc. are completly protected against corrosion. As an extra precaution all exposed polished
metal parts are sprayed with Optimol F + D protective fluid.

The above precautions do not hinder the initial start up of the pump. The coating of F + D in fact acts as a lubricant and
prevents wear. The anti corrosion emulsion is very quickly flushed out by the high pressure water.

The protection process is suitable for the transport period between our works and reaching the customer. If the pump is
to be stored for an indefinite period of time before operation further precautions will be needed. Please ask your
HAMMELMANN agent for advice. Our recommendations can be found in the section "shut down" paragraph 3.
 Operating Instructions
No.: B23404-E
Construction and Description Issue 09/2003 Page 1 of 4

Inhalt

1. Construction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2
2.1. General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2
2.2. Crank section with pressurised oil lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2
2.3. Plunger seal assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2
2.4. Pump head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2
2.5. Pressure regulating and overflow valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
2.6. Burst disc safety device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4

1. Construction

Fig. 4.1.: High pressure pump

Item Description Item Description

10 Pumphead 100 Oil cooler a. oil filter
20 High pressure discharge 110 Dip stick
30 Nameplate 120 Oil filler cap
40 Oil pressure gauge 130 Suction connection
50 Oil pump 140 Suction chamber
60 Oil pressure regulator 150 Cover plate
70 Oil line 160 Drive shaft
80 Oil filter 170 Mounting holes
90 Oil drain valve
 Operating Instructions
No.: B23404-E
Page 2 of 4 Issue 09/2003 Construction and Description

2. Description

2.1. General

The HDP 234 is a compact, five plunger pump containing the unique HAMMELMANN patented plunger seal assembly. This
seal arrangement reduces wear to an absolute minimum resulting in long working life at high pressure.

2.2. Crank section with pressurised oil lubrication system

The crank section is precision built to withstand heavy loads. The rotary motion of the drive shaft transmits to an oscillating
motion at the pump plungers via five 72o offsets with conrods and crossheads. The crankshaft is an assembly made from
ductile, hardened and tempered steel. The helical gear wheels are innersides near the outsides conrods located. One roller
bearing is positioned on the middle of the crankshaft and two roller bearings are outside near the helical gear wheels.
Conrods have bush bearings both ends running on hardened, polished surfaces at the crankshaft and gudgeon pins.

The crankshaft is an assembly made from ductile, hardened and tempered steel. The helical gear wheels are located on
the left and right side of the crank shaft. . Conrods have bush bearings both ends running on hardened, polished surfaces
at the crankshaft and gudgeon pins.

The pressurised oil lubrication system consists of oil pump, oil filter, oil pressure gauge and oil cooler. Conrod bearings
are lubricated via oil channels in the crankshaft and the gudgeon pins via channels in the conrods. The crank section is
sealed with "O"-rings and gaskets and the drive shaft by a rotary shaft seal.

Minimum oil pressure, 3 bar.

2.3. Plunger Seal Assembly

This further development of the low wear labyrinth seal features a unique, replaceable labyrinth insert. The insert is subjected
to dynamic force which maintains the seal between it and the plunger. This metal to metal seal is particularly suitable for
high and ultra high pressures. The small sealing area reduces friction on the plunger and combines good mechanical
efficiency with very high volumetric effieciency.

2.4. Pumphead

The pumphead housing is machined from a single block of high grade stainless steal and features in line valve sets. It is
free of alternating stress and therefore not subject to fatigue cracking. The uncomplicated suction and discharge valve
sets allow easy maintenance.

The principle of operation is as follows:

 Operating Instructions
No.: B23404-E
Construction and Description Issue 09/2003 Page 3 of 4

❍ 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

❍ 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

Fig. 4.2.: Principle of operation

Item Description Item Description

A Pressure chamber E Sleeve
B Discharge valve F Plunger
C Suction valve G Conrod
D Suction chamber H Crank shaft
 Operating Instructions
No.: B23404-E
Page 4 of 4 Issue 09/2003 Construction and Description

2.5. Pressure regulating and overflow valve

The pressure regulating valve allows a smooth increase of pressure from suction pressure to max. operating pressure
thereby making optimal use of the energy source.
The regulators can be supplied for either manual adjustment or pneumatic adjustment.

Regulators are available in various forms for a variety of operating pressures and flow rates. Pneumatic types on self
contained or mobile units are supplied by a mini compressor built onto the unit. On stationary "in plant" units the local air
supply can be used. The max. control air pressure required is 4 bar.

❍ Manual adjustment of pressure.

➨ Turn the eccentric lever

» Clockwise => increases the pressure
» Anti-clockwise => decreases the pressure
➨ Tension the eccentric lever (lever action)
» pump goes to idle speed.

❍ Pneumatic adjustment of pressure.

➨ The operating pressure is directly proportional to the control air pressure fed to the pressure regulator.
➨ Increasing the air pressure increases the operating pressure.
➨ Decreasing the air pressure decreases the operating pressure.

2.6. Burst disc safety device

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 disc fitted will always be designed
to burst at a pressure approx. 30% higher than the max. operating pressure. In the case for instance of 800 bar max.
operating pressure the burst pressure will be 1040 bar. Each burst disc is marked with its burst pressure.
 Operating Instructions
No. B23405-E
Installation Issue 09/2003 Page 1 of 6

Contents

1. Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
2. Connecting the driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
3. Suction side installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2
4. Calculating hose internal diameters (DN). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3
5. Pressure side installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
6. Connecting hoses and cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5

1. Positioning

When positioning a pump unit stationary or mobile employ good engineering practice.

❍ The floor or parking surface must be as flat as possible.

❍ Never fix a stationary unit directly to a floor. Always use anti-vibration mountings between the
base frame and floor.
❍ Ensure ease of access for operation and maintenance.
❍ Mobile units should be braked or chocked to prevent movement.

2. Connecting the driver

❍ The pump can be driven by

➨ Electric motor (with or without thyristor control)
➨ Diesel engine

The driver should never be so powerful that it exceeds the max. power rating on the pump
nameplate.
Electric motors should always have a main isolating switch and an overload cut-out switch.
Electrical installation should only be carried out by qualified technicans.

❍ Power should be transmitted to the pump by:

➨ Flexible coupling

❍ When selecting the coupling please refer to manufacturers literature AND THE DRIVER MANUFACTU-
RERS TECHNICAL DATA.
❍ Pump direction of rotation is marked on the housing.

© Copyright of Hammelmann Maschinenfabrik GmbH

Germany • D-59302 Oelde • Zum Sundern 13 - 21
 Operating Instructions
No. B23405-E
Page 2 of 6 Issue 09/2003 Installation

3. Suction side installation

❍ The pumped medium can only emit from the pump smoothly under high pressure if:
➨ The correct quantity of medium is available.
➨ The medium is totally free from air or gas bubbles..
➨ The suction side installation is as free as possible of elbows, T-pieces, restrictions and other
turbulence causing items.
➨ When the medium has a low feed velocity and unhindered flow.
➨ Max. feed velocity: » 1m/sec
➨ Max. feed pressure: » 6 bar
➨ Min. feeed pressure » 3 bar

During operation with a boost pump the max. inlet pressure at the boost pump must not
exceed 3 bar. At higher pressures a pressure reducing valve has to be preconnected.

Other conditions require our written permission.

Refer to the diagram on the following page to determine the size of suction line.

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.

Filters are available from HAMMELMANN to eliminate abrasive particles larger than 10 micron and in concentrations of
50 mg/l.

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 it to run freely for a minute or so.

If a filter is fitted check it for cleanliness before each operation.

A blocked filter can cause cavitation and damage the pump. Ideally a filter with a pressure differential sensor should be
fitted to stop the unit immediately other filter element becomes blocked.

The water hardness must not exceed 10° German hardness !

If the water is harder a water softening unit must be installed. However, in that case ensure that
the water quality does not fall below 5° German hardness.

© Copyright of Hammelmann Maschinenfabrik GmbH

Germany • D-59302 Oelde • Zum Sundern 13 - 21
 Operating Instructions
No. B23405-E
Installation Issue 09/2003 Page 3 of 6

Conversion table for the various hardness degrees and units

Hardness degrees and units

german french english american.

mval/kg o o o mmol/l
dH f e ppm

Definition
1 gran CaCO3
28 mg CaO 1 part CaCO3
10 mg per gallon
oder 50 mg 10 mg CaCO3 per million 100 mg CaCO3
CaCO3 14,3 mg
CaCO3 per 1000 ml 1mg CaCO3 per 1000 ml
per 1000 ml CaCO3 per
per 1000 ml water per 1000 ml water
water 1000 ml
water water
water

1 mval/kg 1,0 2,8 5,0 3,5 50,0 0,50

1o odH 0,357 1,0 1,78 1,25 17,8 0,18
1 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

4. Calculating hose internal diameter (DN)

To determine the internal diameter of the hoses you require refer to the diagram (Fig. 5.1.) below.

❍ Example 1 (------)

A speed of v = 0,45 m/s and an output of Q = 150 l/min. The straight connection between these two
values on the scales results in the hoses DN 80 on the centre scale.

❍ Example 2 ( )
➨ A speed of v = 5,5 m/s and an output of Q = 66 l/min. The straight connection between these two values
on the scales results in the hoses DN 16 on the centre scale.
❍ optimum flow speeds:
➨ suction side: 0,5 m/s 1 cm2 = 0,155 sq. in. 1 m/s = 3,28 ft/s
➨ pressure side: 5,0 m/s 1 l/min = 0,22 gal/min GB = 0,264 gal/min US

❍ Not included in the calculation are:

➨ The resistance of pipes, bends, valves etc.
➨ The viscosity and the effects of temperature on viscosity.
➨ other influencing factors.

© Copyright of Hammelmann Maschinenfabrik GmbH

Germany • D-59302 Oelde • Zum Sundern 13 - 21
 Operating Instructions
No. B23405-E
Page 4 of 6 Issue 09/2003 Installation

■ Fig.: 5.1. Hose calculation diagramm

5. Pressure side installation

All components on the high pressure side (hoses, fittings etc.) must be designed to safely
withstand the pump max. operating pressure and flow rate. Carefully check performance para-
meters marked on the components before fitting.

During operation regularly check the hoses, fittings and jetting accessories for signs of leakage.
In the case of leakage stop the emergency stop button immediately.
Do not attempt a close visual inspection of leakage while the pump is running.

Use HAMMELMANN discharge fittings between the pumphead and high pressure hoses/pipework.

❍ A rule of thumb for discharge fittings between the pumphead and high pressure hoses/pipework is:

➨ DN 10 maximum output 50 l/min

➨ DN 12 maximum output 80 l/min
➨ DN 20 maximum output 200 l/min
➨ DN 25 maximum output 300 l/min
➨ DN 32 maximum output 500 l/min

© Copyright of Hammelmann Maschinenfabrik GmbH

Germany • D-59302 Oelde • Zum Sundern 13 - 21
 Operating Instructions
No. B23405-E
Installation Issue 09/2003 Page 5 of 6

6. Connecting hoses and cables

The following connections can be made to a high pressure pump unit.

❍ Control cable (for electrically actuated bypass from hand tools)

❍ High pressure hose/pipework line
❍ Suction hose/pipework
❍ Overflow hose/pipework (Bypass line)
❍ Oil cooler (water out to waste/tank)

❍ Notes on making connections

❍ Suction hose
➨ Remove protective cap (if fitted) from suction connection and ensure connection is clean. Also check
the hose end fitting for cleanliness. Let the supply run for a minute or two to flush out any residue,
turn it off and then make the connection.

❍ Bypass line
➨ The standard bypass connection is to a brass "push fit" connector on the pressure regulating valve.
We recommend a clear plastic hose held in place by a hose clip. The bypass line is used to dispose
of the overflow water and bypass water when the consumer is closed and the pump is running without
pressure. The water can be run waste or back to a tank (if fitted) on the suction side.

❍ Oil cooler line

➨ This is a push fit connection on the cooler. The cooling water is emitted without pressure and can be
run to waste or back to a tank.

❍ Seperate oil cooler supply

➨ Normally oil cooler water supply is from the suction chamber but if the suction water is above 35o C
a seperate supply with a lower temperature must be provided.

On fixed installations do not feed bypass or oil cooler water back to a tank via another return line
unless the return line is also without pressure.

❍ High pressure hose

➨ Remove protective plastic cap or threaded plug from discharge fitting. Ensure the mating thread is
clean and then smear with Molykote 1000 anti-seize grease. Remove the cap from the hose and
repeat the cleaning and greasing procedure. Connect the hose and tighten to a torque of 115 Nm.
This procedure should be followed when fitting hose extensions and the consumer (spray pistol etc.).
Connect hose arresters if supplied. The cleaning and greasing procedure should also be applied if
fitting permanent high pressure pipework.

For your own safety:

Check all hose/pipework connections a second time.
The pump unit must be switched off and all lines de-pressurised before attempting to check hose
conections and leakage points.

© Copyright of Hammelmann Maschinenfabrik GmbH

Germany • D-59302 Oelde • Zum Sundern 13 - 21
 Operating Instructions
No. B23405-E
Page 6 of 6 Issue 09/2003 Installation

❍ Electric control cable

➨ Remove the protective caps from cable, control cabinet and accessory.
Plugs and sockets. Ensure they are clean and dry before connecting.

Always fit the cable at this point.

Never connect or disconnect a cable when a system is live!

❍ Special notes on hose safety

Ensure that high pressure hoses are positioned so that they do not rub,
chafe or snag against any objects that could damage them (hoses may
be sheathed for extra protection).

Do not allow the hose to ’kink’.

This will crease the lining, expand the metal braid and eventually cause
a "blow out".
Do not lay hoses in the path of vehicles, fork lifts etc.

DURING OPERATION
Regulary check the hoses for signs of leakage.

In the case of leakage operate the emergency stop button

immediately!

Do not attempt a close visual inspection of leakage while the pump is

running.

Leakage at connectors indicates that the connection requires tighte-

ning or replacing. In the latter case fit a new hose
immediately and have the faulty hose repaired by a specialist.

Distortion of the protective outer sheath indicates a fault in the inner

high pressure construction. The hose should be replaced immediately!

If the fault has occured at or reasonably close to the end fitting the
hose can be cut and fitted with a new connector by a specialist.
IMPORTANT!
All repaired hoses must be pressure tested and a test certificate issued
before re-use!!!

Leakage holes in connection should not be closed off either intentio-

nally or by accidental damage.

© Copyright of Hammelmann Maschinenfabrik GmbH

Germany • D-59302 Oelde • Zum Sundern 13 - 21
 Operating Instructions
No. B23406-E
Operation Page 1 of 2 Issue 09/2003

Contents

1. Pre-start checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1

2. Start up and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
3. Setting the operating pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2
4. Operation monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2

1. Pre-start checks:

❍ Check the pump oil level and top up if necessary. Never run the pump if the oil level
shown on the dipstick is below minimum level..

❍ Also check for signs of water (emulsion) in oil. if found do not run the pump! Try and
determine the cause. If you can eliminate the fault drain the old oil and refill in accordance
with the instructions given in "Maintenance" section 2.2.

❍ On diesel driven units also check the engine oil level.

❍ If a filter is fitted check and ensure the housing and element are clean. change element if necessary.

Before start up:

Remember that when working with hand hold accessories attached to hoses the operative should
have a firm grip of the accessory and a sure footing before start up! If a hose is pressurised and
not controlled it could whiplash causing damage or injury.

2. Start up and control

❍ The complete system should be free of air before start up:

➛ Turn on the medium supply and open the consumer (piston, nozzle etc.) Allow the medium to flow
until it is emerging bubble free from consumer
❍ Check that:
➛ There is a minimum supply pressure of 3 bar (gauge on the suction chamber)
➛ If a filter is fitted the air bleed valve is open.
❍ Release the emergency stop button.
❍ Ensure that the pressure regulator (manual) is turned fully clockwise with the lever tensioned and then start
the engine/motor.
❍ Check the oil pressure!
❍ When the oil pressure reaches min 2 bar the pump is ready to run under pressure.
 Operating Instructions
No. B23406-E
Page 2 of 2 Issue 09/2003 Operation

3. Setting the operating pressure

◆ by manual pressure regulating valve.
❍ Turn the eccentric lever clockwise to increase the pressure to required operating pressure and then untension
the lever.
❍ The pressure can be increased by turning the lever in anti- clockwise direction.
❍ The pressure can be increased or decreased at any time within operating parameters by turning the lever
one way or other.
❍ To return pump to idle speed at any time, simply tension the lever.
◆ by pneumatic pressure regulating valve.
❍ When the pressure regulating valve membrane cylinder is charged with air the pump is running under pressure.
❍ Maximum air pressure is 4 bar which will produce max operating pressure at the pump.
❍ Reducing the air pressure to the regulating valve reduces the discharge pressure of the pump.
❍ Closing the air supply to regulating valve returns the pump to idle speed.
◆ by controlling the r.p.m. of the drive engine/ e-motor
❍ With diesel powered units or thyristor controlled electric powered units it is possible, in conjunction with a
suitable control system, to regulate the operating pressure by adjusting the driver speed. This is only possible
when using a pneumatic pressure regulator, a pressure sensor and a servo motor or pneumatic cylinder
control device.
❍ The system is set up so that max. r.p.m. of the driver produces max. operating pressure at the pump.
» Max. r.p.m. => max. operating pressure.
» Min. r.p.m. => min. operating pressure or pump is running at idle speed.

With this pressure regulating system switching at the end user (ie: letting go of the pistol trigger) causes the driver speed
to drop to idle as the water is switched to bypass.

4. Operation monitoring
◆ Monitoring during operation
❍ The operator of the accessory is solely responsible for the jetting function.
❍ A second operator must monitor the pump as to maintaining the operation pressure. He should continually
check the pressure gauge, suction pressure, oil pressure etc. He should also oversee the jetting operator.

In the event of accident, machine problem, signs of leakage the pump operator must immediately
press the emergency stop button.
Switch off ignition and remove the key or on electric units isolate the motor from mains.

❍ During any break in working (ie. lunchtime) take the opportunity to check the leakage water collecting in the
pump intermediate chamber. A little leakage is normal but large amounts indicate that the aramit- graphite
low pressure seals need adjusting or replacing (see section "Maintenance").
 Operating Instructions
No.: B23407-E
Shut down Issue 09/2002 Page 1 of 4

Contents

1. Stopping the unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1

2. Overnight shut down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
3. Extended shut down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2

These instructions cover stopping the unit and overnight shut down. If there is any danger of overnight freezing the system
should be completely drained. The system can be charged with anti-freeze solution if preferred.

1. Stopping the unit

❍ Switch the pump to idle speed.

❍ On diesel powered units allow the engine to run at idle speed for 2 to 3 minutes until it cools down.

❍ Switch off the driver

❍ Relieve any residual pressure in the system by opening the consumer.

❍ Depress the emergency stop button, Switch off the ignition and remove the key. On E-motor units operate
the isolating switch.

2. Overnight shut down

❍ Carry out daily inspection.

❍ Disconnect arrester, water and electrical connections at the jetting accessory. Store the accessory in
accordance with instructions provided. Either plug/cap the high pressure 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 sheath for damage before storing

❍ Clean high pressure connections at the pump. Smear with Molykote and fit protective plugs.

❍ Disconnect the electrical cable and cap the connectors. Inspect insulation for damage while reeling onto
drum. Cap the connector at the pump unit.

❍ Disconnect suction, bypass and cooling water hoses. Clean couplings and protect. The suction hose
connections should also be cleaned and protected if necessary.

❍ Lock the operators panel and remove the key for safekeeping

❍ If there is any danger of freezing overnight the pump must be protected (see para. 3).
 Operating Instructions
No.: B23407-E
Page 2 of 4 Issue 09/2003 Shut down

3. Extended Shut down (14 days or longer)

Whenever an extended shut down is envisaged the pump and its accessories should be stored in a heated, dry atmosphere
if possible. Several precautions should be taken to ensure that a future start up is trouble free.
Firstly the procedures for overnight shut down should be carried out except that the high pressure discharge, overflow
discharge and oil cooler discharge outlets should not be capped but left open.

◆ Draining the pump

❍ If fitted drain the filter and boost pump. On Hammelmann supplied units, 1/4 to 1/2 turn with a 12 mm A/F
spanner is sufficient.

❍ Ensure the suction connection is fully closed off.

❍ Run the pump at idle speed for a few seconds and then stop. This is not critical when preparing for
anti-corosion emulsion but is essential when protecting against freezing.

◆ Protecting the pump

● As anti- corrosion emulsion we recommend the following:

- 89% clean fresh water

- 10% Shell Donax C or equivalent
- 1% ESKAPHOR EM 96 or equivalent

● Items required fill the system are:

- Membrane pump (electric or manual) with a min. pressure of 1,5 bar.

- Lengths of hose to connect membrane pump to suction connection.
- Length of hose to fit to the high pressure discharge.
- An emulsion container.
 Operating Instructions
No.: B23407-E
Shut down Issue 09/2002 Page 3 of 4

◆ Method of filling the pump with anti-corrosion emulsion or anti-freeze solution using an external membrane
pump

❍ Close filter drain cock (if fitted).

❍ Ensure hose connection is clean, smear with grease and connect to the high pressure discharge.

❍ Fit a suction hose to the membrane pump. Open the pump suction connection and fit hose between it and
the membrane pump.

❍ Fill container with emulsion/solution.

❍ Place the free ends of the membrane suction hose and the high pressure discharge hose into the container.

❍ Operate the membrane pump.

❍ Observe the overflow and oil cooler connections. When undiluted emulsion/solution is emitting close both
these off.

❍ Continue pumping. Remove the high pressure discharge hose from container and observe until undiluted
emulsion/solution is emitted. Place hose back into the container.

❍ Continue pumping for a minute or so. The emulsion/solution can be strengthened if necessary. ie: add more
Shell Donax to the emulsion.

❍ Stop pumping. Remove the hose from suction connection and cap/ close the connection.

❍ Remove the hose from the high pressure discharge. Clean, grease and cap both discharge and hose
connections.

Pump units with boost pump fitted can be filled with emulsion/solution via the boost pump.

◆ Other protection hints

❍ Drain the crank section oil (when pump is warm) and fill with preserving oil. See "Maintenance" section for oil
change.

❍ Remove intermediate chamber cover plate. Clean and thoroughly dry the chamber. Spray the exposed
plungers with Optimol F + D fluid.

❍ On diesel units disconnect the battery leads. Check battery acid level and top up if necessary.
 Operating Instructions
No.: B23407-E
Page 4 of 4 Issue 09/2003 Shut down

◆ Hoses

❍ Before undertaking the greasing and protection procedure described previously thoroughly dry the connec-
tions using compressed air.

❍ Take extra care when capping or protecting with polythene.

❍ Do not coil too tightly. Ensure there are no kinks in the hose.

◆ Accessories

❍ Thoroughly clean and dry all accessories 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.

Recommissioning after shut down should be preceded by checks as described previously in this manual.
The draining procedures (re-fit batteries on diesel units) described previously should be carried out to remove the emulsion/
anti-freeze solution. Drain preserving oil and refill with normal oil as described in the section "Maintenance" para. oil
changes.
 Operating instructions
No. B23408-E
Maintenance Issue 09/2003 Page 1 of 14

Contents:

1. Fault finding and remedy: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1

2. Inspection: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3
2.1. Daily inspection: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3
2.2. Oil change: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3
2.2.1. First oil change after 1000 operating hours: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3
2.2.2. Next oil changes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
2.2.3. Lubrication including oil filter: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
2.3. Pump oil pressure adjustment: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
3. Repair and replacement: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 6
3.1. Replacing the burst disc: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 6
3.2. The pumphead: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 7
3.3. The piston seal assembly: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 10

1. Fault finding and remedy

The pump unit must be switched off and all lines de-pressurised before attempting to
check hose connections and leakage points or making inspection and remedy!

Whenever a fault is observed or suspected, emmergency stop the unit immediately!

Close and lock panel cover before inspection and remedy. Remove the key for safekee-
ping. The key must be kept by the operator!

Fault Possible causes Remedy

➨Pump is sucking air. Locate leakage and repair.

➨Pressure regulating valve leaking or Eliminate leakage or reset.
incorrectly set.

➨Valve set(s) seals defective Fit new seals

❍ Pressure too low
Suction valves can be reground or
➨Damaged suction or discharge replaced. Damaged discharge valves
valve(s). should be replaced. Check condition of
valve springs.

➨Leakage from pumphead Fit new pumphead/ sandwich plate

seals
Check suction side installation.
❍ Pump noisy. ➨Suction side medium shortage.

Rework or renew as necessary.

❍ Extreme pulsation, H.P. ➨Suction or pressure valve(s) sticking.
discharge line.
 Operating instructions
No. B23408-E
Page 2 of 14 Issue 09/2003 Maintenance

Fault Possible causes Remedy

❍ Water leaking from suction Replace Aramid graphite

chamber/ intermediate ➨Low pressure seal pack(s) defective. seals.
chamber.

➨Defective seal(s) at plunger rod/

crosshead. Replace seals
❍ Oil leaks into the interme-
diate chamber.
➨Too much oil in crank. Drain oil to correct level.

❍ Oil leaks from the crank ➨Seals between crankcase sections Replace seals.
case. defective.

❍ Oil emulsion emits from bre- ➨Medium entering crank section. Change the oil, clean the filter, renew the
ather. seals (see 2.2.).

❍ Dipstick shows signs of ➨Medium in crank section Change the oil, clean the filter, renew the
emulsion. seals (see 2.2.).

➨Control bore in control plunger of

pressure regulating valve or bypass Check and thorough clean bore.
control blocked.
❍ No pressure
➨Adjusting screw on solenoid valve mis.
adjusted. Re-adjust.

Cases of air or gas bubbles (cavitation) in the pump.

❍ Suction side line with bad flow characterstics.

❍ Fluctuating or insufficient supply of medium.
❍ Too short or too small a diameter suction side supply line.
❍ The temperature of the medium is too high in relation to the pressure. For instance the boiling point of water
considerably decreases in a vacuum. ie: the boiling point is at 70o C at 3m water column vacuum. (10m water
collumn = 1 bar)
 Operating instructions
No. B23408-E
Maintenance Issue 09/2003 Page 3 of 14

2. Inspection

2.1. Daily inspection

● Check the following:

➨ Check pump and engine oil level. Top up if necessary. Never run below min. level.
➨ Check the intermediate chamber for excess leakage water.

Only remove chamber cover plates when the pump unit is stopped.

➨ Also check for signs of water (emulsion) in oil. If found do not run the pump, check the reason and
remedy the fault. This is normally means refering the problem to Hammelmann or their accredited
agent.
➨ Check the filter and the filter housing, clean or replace if necessary.

2.2. Oil change

2.2.1. First oil change after 1000 operating hours

Old oil should be placed in a suitable storage tank for further disposal and never be allowed to
run to ground waste or into sewerage. Spillages should be mopped up immediately.
Protect the enviroment!
❍ It is advisable to drain the oil when it is warm.
❍ A receptacle to collect the oil (20 litre) is required.
❍ Place cotton waste or similar under the drain valve and position the receptacle.
❍ Use a hose with one end fitted with threaded connector. Place the free end in the receptacle.
❍ Unscrew the oil drain valve cap. The oil will start to drain immediately so screw the hose onto the valve as
quickly as possible.
❍ Examine old oil for signs of water ingress.
Cleaning fluids can be dangerous!
Observe all instructions and warnings on the manufactures packaging
Never put cleaning fluid in food or drink containers.
If using spray fluids never spray onto skin.
❍ At every oil change clean or change the oil filter:
❍ For external oil filter: Place rags or similar under the filter and unscrew the filter housing.
❍ Remove the cartridge and discard. Fit a new cartridge and reassemble.
❍ Disconnect the hose from the drain valve.
❍ Refit the drain valve cap.
Operating instructions
No. B23408-E
Page 4 of 14 Issue 09/2003 Maintenance

❍ Unscrew the oil filler cap (above oil pump) and refill with clean new oil.

Check oil level by this job. Do not overfill!

2.2.2. Next Oil changes

❍ After 2000 operating hours

❍ or once in a year
❍ In extreme operating conditions, ie: dirt or water ingress, radiated heat etc. more frequent oil changes are
necessary. A special change schedule is advisable.

2.2.3. Lubrication including oil filter

❍ Quantity: 20 litres
❍ Grade: Optigear BM 320

Alternative oils to Optigear BM 320 are

Maker Product

Aral DEGOL BG 320

Agip BLASIA 320
BP BP Energol GR - XP 320
Castrol ALPHA SP 320
DEA FALVON CLP 320
ELF REDUCTELF SP 320
Esso SPARTAN 320
ICI Tribol 1100/320
Klüber GEM 1 - 320
Mobil Mobilgear 632
Westfalen Lastan X 320

protection oil: Aral Konit SAE 20 W 20

 Operating instructions
No. B23408-E
Maintenance Issue 09/2003 Page 5 of 14

Viscosity / Temperature diagramm

mm2/s = cSt
Viscosity υ

o
C
Temperature ϑ

The factory filled oil is suitable for ambient temperatures between 0 oC and 30 oC. Where temperatures are higher or where
other factors such enclosing the pump can have influence regular checks should be made. If during normal operation the
temperature at the oil cooler outlet exceeds 50 oC then another oil type is necessary. Refer to the Viscosity / Temperature
diagramm. At the measured temperature the oil should have a minimum viscosity of 180 cSt.
If in doubt another solution is to fit a second oil cooler in line with the original to maintain a lower oil temperature.

2.3. Pump oil pressure adjustment

The pump oil pressure has been set in our works at
6 bar. It should never fall below 3 bar even when the
unit is hot. A pressure gauge is fitted onto the crank
section.

Use screw driver to adjust the oil pressure:

❍ Remove protective cap from oil pres-

sure adjuster.
❍ Tighten the adjuster screw to increase
pressure

or

❍ unscrew to reduce pressure. ■ Fig. 8.1: Oil pressure adjustment

 Operating instructions
No. B23408-E
Page 6 of 14 Issue 09/2003 Maintenance

3. Repair and Replacement

The following section Repair and replacement contains information enabling you to carry out repairs to the high pressure
section of the pump. Only competent trained technicans should undertake these repairs and only genuine HAMMELMANN
parts should be used.

For specialised training in pump repair and operation please consult your HAMMELMANN agent or HAMMELMANN directly.

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

3.1. Replacing the burst disc

The burst disc is positioned at the flange of the bypass valve.

❍ Unscrew the drain pipe from the elbow.

❍ Unscrew the elbow from the burst disc holder (40).
❍ Fit a 36 mm A/F spanner to the housing (10).
❍ Using a 27 mm A/F spanner unscrew the holder (40) and withdraw complete with seating cone (30)
and disc (20).
❍ Apply a considerable amount of Gleitmo 500 grease to the male threaded end of the holder (40).
❍ Position the seating cone (30) on the end of the holder (40) using grease to keep it in place.
❍ Apply grease to the new disc (20) and position it over the seating cone (30).
❍ Screw holder (40) complete with cone and disc into the housing (10) and tighten to not more than 60 Nm.
❍ Smear the male thread of the elbow with molykote anti-seize and screw into the holder (40).
❍ Smear the thread of the drain pipe with Molykote anti-seize and screw into the elbow.

■ Fig. 8.2.: Replacing the burst disc

Item. Description

10 Housing

20 Burst disc

30 Seating cone

40 Burst disc holder

50 Seal ring
 Operating instructions
No. B23408-E
Maintenance Issue 09/2003 Page 7 of 14

3.2. The pumphead

The pumphead contains wearing water bearing parts that require inspection and rework/replacement from time to time.

A mechanical fault is often indicated by a high temperature rise at one or more of the three valve sets. A temperature rise
between suction and pressurised water of 10 oC measured at the head housing is however quite normal.

Before commencing ensure that the suction water supply is turned off

Ensure that your workbench is absoluteliy clean before commencing work. Foreign particles, ie:
metal etc. will cause serious damage to valve components if inadvertantly assembled into the
pumphead.

❏ Removing the pumphead and the plunger seal assembly (see Fig. 8.3, 8.6 and 8.7)

❍ Disconnect bypass valves hoses and remove the bypass valve.

❍ Disconnect all lines/hoses and other parts from pumphead.
❍ Working crosswise use 32 mm socket and torque wrench to remove the head retaining nuts (520)
❍ Use 14 mm allen key to remove the cap head screws (90).
❍ Carefully lift of pumphead. It should be removed to clean bench and placed upside down. Have a felt tip pen
available so that the valve sets can be removed and marked in the correct order.
❍ The parts of the pumphead will stay in the valve housing or will stay on the pump housing. Ensure that the
pumphead parts does not fall appart. Place a cloth or paper over the exposed pump housing as protection.

❏ Disassembly (see Fig. 8.3.)

❍ If you do not have a workbench clear a suitable area nearby and 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.
❍ The following instructions are for one valve set and for the possibility that the parts stay on the pumphousing.
Be extremely careful when removing the valve seat rings (150). Making the slightest scratch or
mark will eventually cause the component to crack.

❍ Remove valve guide (190), spring (20) and valve (30).

❍ Remove valve seat (150).
❍ Remove the gasket rings (40) from the valve seat (150).
❍ Remove valve (120) and spring (140) out of the sleeve from the piston seal assy.
❍ If necessary remove gasket (540) from the pump housing or valve housing (10).
Operating instructions
No. B23408-E
Page 8 of 14 Issue 09/2003 Maintenance

■ Fig. 8.3a.: The pumphead

Torque = 360 Nm

The sl eeve bel ongs to the P.S.A

Item. Description Item. Description

10 Valve housing 140 Spring
20 Spring 150 Valve seat ring
30 Valve 190 Valve guide
40 Gasket ring 520 Hexagon nut
90 Hex. socket head screw 530 Stud bolt
120 Valve 540 Gasket
 Operating instructions
No. B23408-E
Maintenance Issue 09/2003 Page 9 of 14

❏ Inspection (see Fig. 8.3.)

❍ Inspect the valves (120). Any cracked valves should be discarded and replaced with new. Valves worn on
one face may be reversed for reassembly. If both sides are worn discard and fit new. Reworking of valves is
not possible!
❍ Inspect valve seat rings (150). If damaged or cracked discard and fit new. 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.
❍ Inspect the valves (30) for scoring, cracks or pitting. Discard and replace with new if necessary.
❍ The mating face of the valve guides (190) should be smooth. Scored parts should be discarded and replaced.

❏ Reassembly (see Fig. 8.3.)

Ensure that all parts to be reassembled including new replacements have been thoroughly cleaned with degreasing fluid
and that any felt tip markings applied to facilitate rework have been removed. Place all parts in position and in correct
order of assembly. All sliding parts should be smeared with grease. Use Gleitmo 500 (Order-No. 04.04660.0002).

❍ Coat the bore surfaces in the block (10) with waterproof grease (grease refers to Molykote Gleitmo 500 MoS2
in these instructions - Order-No. 04.04660.0002).
❍ Place the gasket (540) onto the crankcase.
❍ Place spring (140) into the sleeve of the piston seal assy.
❍ Grease valve (120) and place it onto the spring (140).
❍ Lightly grease the gasket rings (40) and place in the valve seat ring (150).
❍ Coat internal and external surfaces of valve seat (150) with grease and place onto the pump housing (p.s.a.).
❍ Grease valve (30) and place it over the valve seat (150).
❍ Place the spring (20) onto the valve (30).
❍ Lightly grease the valve guide (190) and place it in the bore of the valve housing.
❍ Repeat the above procedure for the remaining two valve sets.

❏ Refitting the pumphead

❍ Lightly coat the head bolts with Molykote anti-seize grease and then slide the pumphead (valve housing) over
the stud bolts (530). Hand tighten the retaining nuts (520). Ensure that all parts of the pumphead are in correct
position and that no parts are lost.
❍ Lightly grease the hex. skt. cap hd. screws (90) with Molykote anti-seize and screw up hand tight (req. torque
180 Nm). Refer to fig. 8.4. Tighten down in the order shown in the sketch repeating three times and then
apply 180 Nm to each screw.
❍ Use the 32 mm A/F Torque wrench to tighten down the valve housing (10). The req. torque is 360 Nm but
do not tighten to this immediately. Refer to fig. 8.5. Tighten down in the order shown in the sketch repeating
two or three times until you are certain the head is absolutely parallel to the housing and then apply 360 Nm
to each nut.
❍ Turn the pump by hand to ensure that the plungers move freely in the sleeves.
❍ Reconnect bypass valve and hoses.
❍ Smear threads of high pressure discharge connection with Molykote anti seize.
❍ Use 32 mm spanner head on spigot T.W. and tighten high pressure connection to 140 Nm.
 Operating instructions
No. B23408-E
Page 10 of 14 Issue 09/2003 Maintenance

❍ Smear threads of connection with Molykote anti-seize and with 19 mm A/F spanner make pressure differential
assy. connection.
❍ Refit the burst disc safety device pipework.
❍ Observing all operational and safety procedures described in section 3, set the unit up for testing. Run for
10 to 15 minutes at 1500 bar and monitor carefully for excess noise or vibration. If everything is in order
continue for 5 more minutes at the maximum pressure. If test is successful, pump unit may be returned to
normal operational duties.

■ Fig. 8.4. Tightening sequence ■ Fig. 8.5.: Sketch Pumphead

1. Step: torque = 60 Nm
2. Step: torque = 120 Nm
3. Step: torque = 180 Nm

3.3. The piston seal assembly

The piston seal assembly contains wearing parts that require inspection and replacement from time to time. Before
commencing ensure that the suction water is turned off.

❏ Disassembly of the plunger seal assembly (see Fig. 8.6. and Fig. 8.7.)

❍ To remove the p.s.a. from the pump housing ref. also to removing the pumphead

❏ Removing the pumphead and the plunger seal assembly

(see Fig. 8.3, 8.6 and 8.7)

❍ Disconnect bypass valves hoses and remove the bypass valve.

❍ Disconnect the pipe from the burst disc assy.
❍ With 32 mm spanner hd. on spigot T.W. remove high pressure discharge pipe from the connector.
❍ Working crosswise use 32 mm socket and torque wrench to remove the head retaining nuts.
❍ Ref. to fig 8.6 and remove the retaining nuts from the studs (1).
❍ Remove the cover plates.
 Operating instructions
No. B23408-E
Maintenance Issue 09/2003 Page 11 of 14

❍ Use circlip pliers to remove circlip (5).

❍ Remove the clamp halves (3) by hand.
❍ Working crosswise to remove the head retaining nuts.
❍ Use 14 mm allen key to remove the cap head screws (90 from the pumphead).
❍ Carefully lift of pumphead (valve housing). It should be removed to clean bench and placed upside down.
Ensure that no parts fall apart.
❍ Remove the parts from the pumphead as described at point 3.2.
❍ Have a felt tip pen available so that the valve sets can be removed and marked in the correct order.

■ Fig. 8.6.: Disassembly of the p.s.a.

Item Description
1 Studs with retaining nuts
2 Intermediate chamber
3 Half shells (clamps)
4 Piston rod
5 Circlip
20 Piston
360 O-Ring
Operating instructions
No. B23408-E
Page 12 of 14 Issue 09/2003 Maintenance

■ Fig. 8.7.: Plunger seal assembly

Item. Description
10 Sleeve
20 Plunger
30 Flange
40 Glyd-ring
60 O-Ring
120 Support ring
360 ’O’-ring
370 Gasket ring
390 Bush
Hex. skt. cap hd.
400
screw
410 Circlip
440 Bushing

1. Step: torque = 30 Nm
2. Step: torque = 75 Nm
3. Step: torque = 100 Nm
 Operating instructions
No. B23408-E
Maintenance Issue 09/2003 Page 13 of 14

❏ Disassembly of the sleeves (10)

❍ Use two head cap screws (90 from pumphead) to pull out the complete sleeves from pump housing.
❍ Normally the plunger (20) will get out of the chamber together with the sleeves (10). Ensure that the plunger
does not fall appart.
❍ Remove the plunger (20) from the sleeves (10).
❍ Slide the ’O’-ring (360) off the plunger.
❍ Remove the screws (400) and seperate the sleeve and the flange (30).
❍ Remove the bushings (390 and 440 and the gasket ring (370) from the sleeve (10).

❏ Disassembly of the flange (30), change the glyd ring (40)

❍ Remove ’O’-ring (60) from the groove of the flange.

❍ With a circlip plieres remove the circlip (410) from the flange (30).
❍ Remove support ring (120) and glyd-ring (40).
❍ If necessary remove second support ring (120) from the flange.
❍ Clean all parts thoroughly and check for wear or scratches. Replace parts as necessary. Seals should be
replaced by new.

❏ Reassembly of the flange (30), change the glyd ring (40)

❍ If necessary insert support ring (120) into the flange (30).

❍ Place glyd-ring (40) into the flange (30).
❍ Place second support ring (120) into the flange (30).
❍ Grease support rings (120) and glyd ring (40) with Gleitmo 500.
❍ Secure this parts with circlip (410).
❍ Fit ’O’-ring (60) to the grooves of the flange. Grease flange (30) with Gleitmo 500.

❏ Reassembly of the sleeve (10)

❍ Place the gasket ring (370) into the sleeve.

❍ Fit bushings (390 and 440) into the sleeve.
❍ Place the flange (30) onto the sleeve and fix with the screws (400) (req. torque = 100 Nm). For tightening
sequence ref. to fig. 8.7.
❍ Slide the ’O’-ring (360) over the plunger and seat in position.
❍ Lightly grease the plunger (20) and slide into the flange and sleeve.
❍ Lightly grease the complete sleeve (10).

❏ Refitting plunger seal assembly and the pumphead

❍ By using the two cap head screws (90 from p.h.) slide the
complete sleeve into the pump housing. Ensure that the plunger does not fall apart. Take great care that the
O-rings (60) remain correctly seated in their grooves.
❍ Lay the circlip (5) on the holder to be fixed later.
Operating instructions
No. B23408-E
Page 14 of 14 Issue 09/2003 Maintenance

❍ Lightly grease the crankcase/pumphead mating faces.

❍ Fit the valve housing over the mounting stud bolts.
❍ Lightly coat the head bolts with Molykote anti-seize grease and then hand tighten the retaining nuts.
❍ Grease the threads of hex. skt. cap hd. screws (90) with Molykote anti-seize (MoS2) and tighten it in 3 steps
in accordance to the sketch (ref. to fig. 8.4) req. torque = 180 Nm).
❍ Use the 32 mm A/F Torque wrench to tighten down the head. The max. torque required is 360 Nm but do
not tighten to this immediately. Refer to fig. 8.5. Tighten down in the order shown in the sketch repeating two
or three times until you are certain the head is absolutely parallel to the housing and then apply 360 Nm to
each nut.
❍ (See fig. 8.6.) Place the clamp halves over the plunger and holder and hold tight.
❍ Use circlip pliers to position circlip (3). Ensure that it is correctly seated in the groove.
❍ Turn the pump by hand to ensure that the plungers move freely in the sleeves.
❍ Reconnect bypass valve hoses.
❍ Smear threads of high pressure discharge connection with Molykote anti seize.
❍ Use 32 mm spanner head on spigot T.W. and tighten high pressure connection to 140 Nm.
❍ Smear threads of connection with Molykote anti-seize and with 19 mm A/F spanner make pressure differential
assy. connection.
❍ Refit the burst disc safety device pipework.
❍ Observing all operational and safety procedures described in section 3, set the unit up for testing. If test is
successful, pump unit may be returned to normal operational duties.

❏ Test procedure

❍ Observing all operational and safety procedures set the unit up for testing.
❍ Spray exposed pistons with Optimol F + D fluid.
❍ Run for 10 to 15 minutes at 1500 bar and monitor carefully for excess noise or vibration.
❍ If everything is in order continue for 5 more minutes at the maximum pressure.
❍ If the test is satisfactory stop the pump and lock emergency stop removing for safety.
❍ Refer to fig 8.6. and refit cover plates onto studs (1) with nuts provided.
PARTS LIST (41)

Parts-list no.: 00.00743.1817 Hammelmann Maschinenfabrik GmbH

Drawing no. : 00.00743.1817-1 POB 3309, D-59302 Oelde, Germany
mail to: mail@hammelmann.de
Description : PISTON SEAL ASSEMBLY http://www.hammelmann.de
HDP124/174/254 D15 Date : 01.09.2003
Page : 1

DwgPos Item Code-No. Description Quantity No/Unit Unit

10 10 01.01750.0666 CASING 1 1,00 pc
20 20 00.03280.0006 PLUNGER SEAL (SET) 1 1,00 pc
30 30 01.01055.1011 FLANGE 1 1,00 pc
40 40 04.00731.0015 GLYD-RING 1 1,00 pc
60 60 04.00730.0392 O-RING 2 1,00 pc
120 120 01.03512.0314 SUPPORT RING 2 1,00 pc
360 360 04.00730.0248 O-RING 1 1,00 pc
370 370 01.00742.0161 GASKET RING 1 1,00 pc
390 390 01.00525.0600 BUSHING 1 1,00 pc
400 400 02.00825.0215 HEXAGON SOCKET HEAD CAP SCREW 9 1,00 pc
410 410 01.03501.0031 BORE CIRCLIP 1 1,00 pc
440 440 01.00529.0034 BUSHING 1 1,00 pc

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

Parts-list no.: 00.02145.0965 Hammelmann Maschinenfabrik GmbH

Drawing no. : 00.02145.0965-1 POB 3309, D-59302 Oelde, Germany
mail to: mail@hammelmann.de
Description : PUMPHEAD http://www.hammelmann.de
HDP234 D15 Date : 01.09.2003
Page : 1

DwgPos Item Code-No. Description Quantity No/Unit Unit

10 10 01.01305.0582 VALVE HOUSING 1 1,00 pc
20 20 04.00946.0520 COIL SPRING 5 1,00 pc
30 30 01.05860.0283 VALVE 5 1,00 pc
40 40 01.00742.0170 GASKET RING 10 1,00 pc
90 90 02.00825.0206 HEXAGON SOCKET HEAD CAP SCREW 30 1,00 pc
120 120 01.05860.0284 VALVE 5 1,00 pc
140 140 04.00946.0519 COIL SPRING 5 1,00 pc
150 150 01.03528.0353 VALVE SEAT RING 5 1,00 pc
190 190 01.01109.0078 VALVE GUIDE 5 1,00 pc
520 520 02.00318.0005 HEXAGON NUT 12 1,00 pc
530 530 01.04756.0015 STUD BOLT 12 1,00 pc
540 540 01.00709.0112 gasket 1 1,00 pc

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

Parts-list no.: 00.02518.0022 Hammelmann Maschinenfabrik GmbH

Drawing no. : 00.02518.0022-1 POB 3309, D-59302 Oelde, Germany
mail to: mail@hammelmann.de
Description : VENT LINE http://www.hammelmann.de
HDP234 Date : 01.09.2003
Page : 1

DwgPos Item Code-No. Description Quantity No/Unit Unit

10 10 01.05993.0022 TUBE FITTING 5 1,00 pc
20 20 01.05172.0034 SET SCREW 5 1,00 pc
30 30 04.05993.0879 TUBE FITTING 1 1,00 pc
40 40 07.54571.0103 STEEL TUBE 4 0,10 m
50 50 04.05993.0880 TUBE FITTING 4 1,00 pc
70 70 04.05993.0404 TUBE FITTING 1 1,00 pc
80 80 04.04590.0069 HOSE 1 1,00 m

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

Parts-list no.: 00.00135.1559 Hammelmann Maschinenfabrik GmbH

Drawing no. : 00.00135.1559-1 POB 3309, D-59302 Oelde, Germany
mail to: mail@hammelmann.de
Description : CONNECTION FITTING, DELIVERY S http://www.hammelmann.de
HDP 70/120/170/250 Date : 16.09.2003
Page : 1

DwgPos Item Code-No. Description Quantity No/Unit Unit

10 10 02.00318.0005 HEXAGON NUT 4 1,00 pc
20 20 01.04756.0015 STUD BOLT 4 1,00 pc
30 30 01.01055.1086 FLANGE 1 1,00 pc
40 40 01.00742.0170 GASKET RING 2 1,00 pc
50 50 01.01597.0651 SEAL RING HOLDER 1 1,00 pc

>>>end<<<
p_dbgs01.p
 Technical information
Bypass valve 00.05907.0022 No. 00.05907.0022-E.doc
Issue 09/2003, Page 1 of 3

The following supplementary information is a guide only. You are still obliged to read and
follow the instructions in the pump operation manual particularly the section „Safety“.
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.
You should never under any circumstances attempt to repair a bypass valve or adjust its
connections when it is attached to a pressurised system. Use only the correct tools.
To work with liquid jets the employer should ensure that all operatives wear protective
clothing! Signs are erected to prohibit unauthorised entry!

Technical Data
m Operating pressure max.: 4000 bar
m Flow rate from.: 50 l/min
m Control medium: air/ oil
m Control pressure max.: 7 bar
m Control pressure min.: 5 bar
m Weight approx.: 13 kg

n Fig.1: Bypass valve

Pos. Description Pos. Description

A Control air / oil connection 90 Hex. skt. cap head screw
B Bypass water connection 100 O-ring
10 Membrane cylinder 110 Ring
20 O-Ring 120 Ring
50 Housing 130 Control pin
80 Ring

Copyright of Hammelmann Maschinenfabrik GmbH

Germany • D-59302 Oelde • Zum Sundern 13 - 21
Technical information
No. 00.05907.0022-E.doc
Bypass valve 00.05907.0022
Page 2 of 3, Issue 09/2003

Installation (ref. to fig. 1)

m Lightly grease the threads of hexagon socket cap head screws (90) (M16 x60; 12.9; order no.:
02.00825.0181) with Molykote 1000 (order no.: 04.02750.0011).
m Carefully place the valve in the correct position and press against the pumphead. (Bypass-connection
(B) should be faced downwards). Ensure that the ring (120) doesn’t lost and is in correct position.
m Tighten the hex skt. cap head screws (90)(in a few steps) crosswise (Torque 180 Nm) ensuring that the
valve is absolutely parallel with the pumphead.

Tighten membrane cylinder only by hand! Not with a tool.

m Connect the pneumatically (or oil) control line onto the membrane cylinder.
m Lightly grease the connection armature (Bypass hose) with Molykote anti -seize and tighten into the
valve (connection B).

Maintenance

The pump unit must be switched off and all lines depressurised before attempting to check
hose connections and leakage points or making inspection and remedy!

m Remove the bypass valve from pumphead.

m Loosen the 4 hexagon socket cap head screws (90) crosswise. Support the valve and remove the
screws Remove the complete valve to a clean workbench. Ensure that the ring (120) doesn’t lost.
Remove the ring (120).

< Disassembly

m Clamp the housing (50) flange in a vice so that the valve is vertical.
m Unscrew the membrane cylinder (10) (only by hand) from the housing (50) and lift off.
m Push the control pin (130) and ring (110) out of the housing (50).
m Pull the Ring (80) out of the housing (50) and remove O-ring (20).
m Remove the O-ring (100). Unclamp the housing (50) and lay on bench. The bypass valve is now
disassembled.

< Inspection

m Examine the O-rings (20 and 100) in the housing (50) to ensure that it is not damaged and is seated
correctly. Renew if necessary.
m The ring (110) is subjected to wear at the pin mating face. Initially it can be reversed for reassembly. If
both sides are worn a certain amount of rework is possible.
m The control pin (130) will wear at the ring (110) end. Initially the pin can be reversed for reassembly. If
both ends are worn rechange.

Copyright of Hammelmann Maschinenfabrik GmbH

Germany • D-59302 Oelde • Zum Sundern 13 - 21
 Technical information
Bypass valve 00.05907.0022 No. 00.05907.0022-E.doc
Issue 09/2003, Page 3 of 3

< Reassembly

m Lightly grease the inner surfaces of the Housing (50) with (Gleitmo 500) and place housing (50)
vertically in vice.
m Place the O-rings (20 and 100) into the grooves of the housing (50).
m Slide the ring (80) into the housing (50).
m Smear control pin (130) surfaces with grease (Gleitmo 500) and fit control pin (130) into the housing
(50).
m Position ring (110) into the housing (50).
m Smear the male thread of housing (50) with anti-seize.
m Screw on membrane cylinder (10) hand tight.

Tighten membrane cylinder only by hand. Not with a tool!

m Liberally smear the ring(120) with anti-seize and position in the Pumphead.
m For installation of the valve ref. to the top of the page.

Copyright of Hammelmann Maschinenfabrik GmbH

Germany • D-59302 Oelde • Zum Sundern 13 - 21
PARTS LIST (41)

Parts-list no.: 00.05907.0022 Hammelmann Maschinenfabrik GmbH

Drawing no. : 00.05907.0022-1 POB 3309, D-59302 Oelde, Germany
mail to: mail@hammelmann.de
Description : BYPASS VALVE http://www.hammelmann.de
DN 5; PN 4000 BAR Date : 01.09.2003
Page : 1

DwgPos Item Code-No. Description Quantity No/Unit Unit

10 10 00.06428.0027 MEMBRANE CYLINDER 1 1,00 pc
20 20 04.00730.0041 O-RING 1 1,00 pc
50 50 01.01240.0471 HOUSING 1 1,00 pc
80 80 01.03465.1069 RING 1 1,00 pc
90 90 02.00825.0181 hexagon socket head screw 4 1,00 pc
100 100 04.00730.0168 O-RING 1 1,00 pc
110 110 01.03465.0625 RING 1 1,00 pc
120 120 01.03465.0624 RING 1 1,00 pc
130 130 01.05180.0041 CONTROL PIN 1 1,00 pc

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

Parts-list no.: 00.06428.0027 Hammelmann Maschinenfabrik GmbH

Drawing no. : 00.06428.0027-1 POB 3309, D-59302 Oelde, Germany
mail to: mail@hammelmann.de
Description : MEMBRANE CYLINDER http://www.hammelmann.de
DM 188 Date : 01.09.2003
Page : 1

DwgPos Item Code-No. Description Quantity No/Unit Unit

10 10 01.00665.0384 COVER 1 1,00 pc
20 20 01.02110.0424 PISTON 1 1,00 pc
30 30 01.06415.0076 CYLINDER 1 1,00 pc
40 40 04.02727.0008 MEMBRANE 1 1,00 pc
50 50 02.00825.0034 HEXAGON SOCKET HEAD SCREW 8 1,00 pc
60 60 04.00946.0216 COIL SPRING 1 1,00 pc
80 80 01.05194.0112 STRAIGHT PIN 1 1,00 pc

>>>end<<<
p_dbgs01.p
 Company standard
No.: BURST3-E
Rupture Disc Assembly Issue 08/2003 Page 1 of 2

Burst disc Illustration 3

01.01946.0003 01.05300.0494 04.04062.xxxx 04.01946.0001 01.05300.0489

For new units please add two rupture

discs as spare.

indicated "Burst Pressure xxxx bar"

For units which are to be equipped with rupture disc no. 00.04062.....
a disc with a nominal pressure 30 - 40 percent higher than the operating pressure has to be applied (for example:
1600 bar operating pressure - rupture disc 2200 bar).
The rupture disc 00.04062.1600 is then to be indicated as follows:-

"Burst Pressure 2200 bar".

The enclosed label for the rupture disc has to be fixed.

The rupture discs must be tested in our workshop with the provided operating pressure, even
in those cases where they are supplied as individual parts.

© Copyright of Hammelmann Maschinenfabrik GmbH

Germany • D-59302 Oelde • Zum Sundern 13 - 21
Company standard
No.: BURST3-E
Page 2 of 2 Issue 08/2003 Rupture Disc Assembly

Rupture Disc
Rupture disc Operating Pressure Burst Pressure
Assembly
bar bar
00.04062 04.04062
1600 1600 1600 2200
1700 1700 1700 2350
1800 1800 1800 2500
1900 1900 1900 2650
2000 2000 2000 2800
2100 2100 2100 2900
2200 2200 2200 3050
2300 2300 2300 3200
2400 2400 2400 3350
2500 2500 2500 3500
2600 2600 2600 3600
2700 2700 2700 3700
2800 2800 2800 3800
2900 2900 2900 3900
3000 3000 3000 4000
3500 3500 3500 4500
3800 3800 3800 4700
4000 4000 4000 5000

Burst disc as illustration 3

© Copyright of Hammelmann Maschinenfabrik GmbH

Germany • D-59302 Oelde • Zum Sundern 13 - 21
PARTS LIST (41)

Parts-list no.: 00.02350.0685 Hammelmann Maschinenfabrik GmbH

Drawing no. : 00.02350.0685-1 POB 3309, D-59302 Oelde, Germany
mail to: mail@hammelmann.de
Description : CRANK SECTION http://www.hammelmann.de
HDP230 I=3,90 RIGHT Date : 01.09.2003
Page : 1

DwgPos Item Code-No. Description Quantity No/Unit Unit

10 10 00.01256.0156 CRANK HOUSING 1 1,00 pc
20 20 04.00708.0026 SEAL 2 0,85 m
30 30 01.04756.0034 STUD BOLT 12 1,00 pc
40 40 02.00318.0005 HEXAGON NUT 12 1,00 pc
50 50 01.00710.0058 FLAT SEAL 1 1,00 pc
60 60 01.01055.0850 BLANK FLANGE 1 1,00 pc
70 70 02.00888.0013 HEX-SOCKET SET SCREW 4 1,00 pc
80 80 02.00309.0010 HEXAGON NUT 4 1,00 pc
90 90 01.00266.0059 PLATE 2 1,00 pc
100 100 02.00888.0016 HEX-SOCKET SET SCREW 8 1,00 pc
110 110 02.00314.0008 HEXAGON THIN NUT 8 1,00 pc
120 120 01.01990.0009 CLAMP 10 1,00 pc
130 130 02.01765.0042 CIRCLIP FOR SHAFTS 5 1,00 pc
140 140 01.01630.0085 SUPPORT 5 1,00 pc
150 150 01.00020.0012 WIPER 5 1,00 pc
160 160 04.00730.0381 O-RING 5 1,00 pc
170 170 04.00730.0373 O-RING 5 1,00 pc
180 180 01.00525.0478 BUSHING 5 1,00 pc
190 190 04.00730.0214 O-RING 5 1,00 pc
200 200 01.02140.0049 CROSSHEAD 5 1,00 pc
210 210 02.01735.0005 PISTON RING 5 1,00 pc
220 220 02.01736.0004 PISTON RING 5 1,00 pc
230 230 01.00410.0007 PISTON BOLT 5 1,00 pc
240 240 02.01766.0006 CIRCLIP FOR BORES 10 1,00 pc
250 250 00.03270.0021 CONNECTING ROD 5 1,00 pc
260 260 04.04277.0025 BEARING SHELL (PAIR) 5 1,00 pr.
270 270 00.06161.0097 CRANK SHAFT 1 1,00 pc
280 280 01.00554.0152 CYLINDER BUSHING 5 1,00 pc
290 290 02.00957.0107 STRAIGHT PIN 5 1,00 pc
300 300 02.01651.0076 FEATHER KEY 1 1,00 pc
310 310 01.06180.0126 PINION SHAFT 1 1,00 pc
320 320 04.00736.0046 OIL-RING 1 1,00 pc
330 330 01.00532.0058 SPACER BUSHING 1 1,00 pc
350 350 02.01657.0367 SELF-ALIGNING ROLLER BEARING 1 1,00 pc
360 360 01.00525.0479 BUSHING 1 1,00 pc
370 370 04.00730.0362 O-RING 1 1,00 pc
380 380 02.01998.0651 RADIAL CYLINDRICAL ROLLER BEAR 1 1,00 pc
390 390 04.00730.0453 O-RING 1 1,00 pc
400 400 01.00532.0059 SPACER BUSHING 1 1,00 pc
410 410 00.00800.0004 THROTTLE 1 1,00 pc
420 420 00.03235.0023 OIL PUMP 1 1,00 pc
430 430 01.00665.0427 COVER 1 1,00 pc
440 440 01.00709.0095 GASKET 2 1,00 pc
450 450 02.00825.0028 HEXAGON SOCKET HEAD CAP SCREW 27 1,00 pc
460 460 01.00665.0426 COVER 1 1,00 pc
470 470 04.05993.0750 PLUG 4 1,00 pc
PARTS LIST (41)

Parts-list no.: 00.02350.0685 Hammelmann Maschinenfabrik GmbH

Drawing no. : 00.02350.0685-1 POB 3309, D-59302 Oelde, Germany
mail to: mail@hammelmann.de
Description : CRANK SECTION http://www.hammelmann.de
HDP230 I=3,90 RIGHT Date : 01.09.2003
Page : 2

DwgPos Item Code-No. Description Quantity No/Unit Unit

480 480 04.00665.0024 COVER 1 1,00 pc
490 490 00.05375.0007 FILLER CAP 1 1,00 pc
500 500 04.05000.0022 OIL DIPSTICK 1 1,00 pc
510 510 01.00530.0148 BUNDLE BUSHING 1 1,00 pc
520 520 04.00730.0014 O-RING 1 1,00 pc
530 530 04.05866.0006 DRAIN VALVE 1 1,00 pc
540 540 04.05300.0011 CONNECTION PIECE 1 1,00 pc
550 550 02.00890.0021 HEX-SOCKET SET SCREW WITH CONE 2 1,00 pc
560 560 04.00730.0093 O-RING 2 1,00 pc
570 570 04.05993.0702 CONNECTION 1 1,00 pc
580 580 01.03535.0867 PIPE 1 1,00 pc
590 590 04.05993.0706 CONNECTION 1 1,00 pc
600 600 01.05300.0598 CONNECTION PIECE 1 1,00 pc
610 610 04.05993.0448 CONNECTION 4 1,00 pc
620 620 04.05993.0440 TUBE FITTING 3 1,00 pc
630 630 04.04590.0071 HOSE 1 0,41 m
640 640 04.05993.0647 TUBE FITTING 1 1,00 pc
650 650 04.04590.0071 HOSE 1 0,34 m
660 660 04.00730.0446 O-RING 5 1,00 pc
670 670 00.03535.0199 PIPE 1 1,00 pc
680 680 02.00830.0008 HEX. SOCKET THIN HEAD CAP SCRE 3 1,00 pc
690 690 04.05993.0410 CONNECTION 3 1,00 pc
700 700 04.05993.0402 TUBE FITTING 4 1,00 pc
710 710 00.05993.0017 TUBE FITTING 1 1,00 pc
720 720 02.00671.0003 HEXAGON HEAD SCREW 5 1,00 pc
730 730 02.00421.0005 WASHER 5 1,00 pc
740 740 02.00671.0104 HEXAGON HEAD SCREW 6 1,00 pc
750 750 01.01630.0087 SUPPORT 1 1,00 pc
760 760 04.02990.0050 REDUCTION NIPPLE 2 1,00 pc
770 770 04.01015.0029 OIL FILTER 1 1,00 pc
780 780 00.02198.0010 OIL COOLER 1 1,00 pc
790 790 04.00730.0438 O-RING 1 1,00 pc
800 800 04.04590.0070 HOSE 1 0,35 m
810 810 04.05993.0499 CONNECTION 1 1,00 pc
820 820 04.05993.0101 CONNECTION 1 1,00 pc
830 830 04.05993.0704 CONNECTION 1 1,00 pc
840 840 04.02860.0073 PRESSURE GAUGE 1 1,00 pc
850 850 02.00825.0051 HEXAGON SOCKET HEAD SCREW 4 1,00 pc
860 860 04.05240.0105 PLUG 1 1,00 pc
870 870 04.02833.0041 CAP NUT 1 1,00 pc
890 890 01.02981.0593 DOUBLE NIPPLE 1 1,00 pc
900 900 04.02833.0072 CAP NUT 2 1,00 pc
910 910 04.03497.0018 CUTTING RING 2 1,00 pc
920 920 04.00946.0293 COIL SPRING 1 0,38 m
930 930 01.05172.0051 HEX-SOCKET SET SCREW 1 1,00 pc
940 940 04.05993.0700 TUBE FITTING 1 1,00 pc
PARTS LIST (41)

Parts-list no.: 00.02350.0685 Hammelmann Maschinenfabrik GmbH

Drawing no. : 00.02350.0685-1 POB 3309, D-59302 Oelde, Germany
mail to: mail@hammelmann.de
Description : CRANK SECTION http://www.hammelmann.de
HDP230 I=3,90 RIGHT Date : 01.09.2003
Page : 3

DwgPos Item Code-No. Description Quantity No/Unit Unit

950 950 04.05993.0429 TUBE FITTING 1 1,00 pc
960 960 04.05993.0614 TUBE FITTING 1 1,00 pc
970 970 04.05993.0852 CONNECTION 1 1,00 pc
980 980 04.05993.0853 CONNECTION 1 1,00 pc
990 990 04.00740.0023 RING 1 1,00 pc

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

Parts-list no.: 00.06161.0097 Hammelmann Maschinenfabrik GmbH

Drawing no. : 00.06161.0097-1 POB 3309, D-59302 Oelde, Germany
mail to: mail@hammelmann.de
Description : CRANK SHAFT http://www.hammelmann.de
HDP230 I=3,905 ; Date : 01.09.2003
Page : 1

DwgPos Item Code-No. Description Quantity No/Unit Unit

20 10 01.03354.0183 GEAR WHEEL 1 1,00 pc
30 20 01.03354.0184 GEAR WHEEL 1 1,00 pc
10 30 01.06161.0033 CRANK SHAFT 1 1,00 pc
50 40 02.01657.0842 SELF-ALIGNING ROLLER BEARING 2 1,00 pc
40 50 02.01657.0843 ROLLER BEARING 1 1,00 pc

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

Parts-list no.: 00.03235.0023 Hammelmann Maschinenfabrik GmbH

Drawing no. : 00.03235.0023-1 POB 3309, D-59302 Oelde, Germany
mail to: mail@hammelmann.de
Description : OIL PUMP http://www.hammelmann.de
26 L/MIN; 1500 U/MIN Date : 01.09.2003
Page : 1

DwgPos Item Code-No. Description Quantity No/Unit Unit

10 10 01.01055.0842 FLANGE 1 1,00 pc
20 20 01.05304.0173 GUIDE PIECE 1 1,00 pc
30 30 04.00946.0326 COIL SPRING 1 1,00 pc
40 40 04.00740.0033 RING 1 1,00 pc
50 50 01.04838.0209 HEXAGON HEAD SCREW PLUG 1 1,00 pc
70 70 04.03354.0027 GEAR WHEEL 1 1,00 pc
80 80 01.01055.0905 FLANGE 1 1,00 pc
90 90 02.01651.0085 FEATHER KEY 1 1,00 pc
120 120 02.00788.0160 STUD BOLT 3 1,00 pc
130 130 02.00266.0101 HEXAGON DOMED CAP NUT 3 1,00 pc
140 140 04.00730.0441 O-RING 1 1,00 pc
150 150 04.00730.0445 O-RING 1 1,00 pc

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

Parts-list no.: 00.00120.1230 Hammelmann Maschinenfabrik GmbH

Drawing no. : 00.00120.1230-1 POB 3309, D-59302 Oelde, Germany
mail to: mail@hammelmann.de
Description : DRIVE http://www.hammelmann.de
HDP230; CAT C9 Date : 01.09.2003
Page : 1

DwgPos Item Code-No. Description Quantity No/Unit Unit

10 10 00.02250.0421 COUPLING 1 1,00 pc
20 20 04.04710.0063 HEXAGON SOCKET HEAD CAP SCREW 8 1,00 pc
30 30 00.01642.0330 PROTECTION 1 1,00 pc
40 40 04.04750.0016 HEXAGON HEAD SCREW 9 1,00 pc
50 50 02.00421.0007 WASHER 9 1,00 pc

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

Parts-list no.: 00.02250.0421 Hammelmann Maschinenfabrik GmbH

Drawing no. : 00.02250.0421-1 POB 3309, D-59302 Oelde, Germany
mail to: mail@hammelmann.de
Description : COUPLING http://www.hammelmann.de
HDP230/CENTA CM 3500-SCA3-14-6 Date : 01.09.2003
Page : 1

DwgPos Item Code-No. Description Quantity No/Unit Unit

10 10 04.03490.0042 COUPLING-RING 1 1,00 pc
20 20 04.01063.0009 COUPLING FLANGE 1 1,00 pc
30 30 04.02251.0112 COUPLING HALF 1 1,00 pc

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

Parts-list no.: 00.01808.0203 Hammelmann Maschinenfabrik GmbH

Drawing no. : 00.01808.0203-1 POB 3309, D-59302 Oelde, Germany
mail to: mail@hammelmann.de
Description : INSTALLATION MATERIAL http://www.hammelmann.de
Date : 01.09.2003
Page : 1

DwgPos Item Code-No. Description Quantity No/Unit Unit

10 10 00.02125.0370 SUPPORT 1 1,00 pc
20 20 04.00433.0007 COMPRESSED AIR VESSEL 40,0L 1 1,00 pc
30 30 02.00380.0006 SPRING LOCK WASHER 4 1,00 pc
40 40 02.00671.0113 HEXAGON HEAD SCREW 4 1,00 pc
50 50 04.00706.0020 SEAL RING 4 1,00 pc
60 60 04.00433.0025 TUBE FITTING 1 1,00 pc
70 70 04.02978.0047 DOUBLE NIPPLE 1 1,00 pc
80 80 02.01257.0001 T-PIECE 1 1,00 pc
90 90 04.05993.0840 CONNECTION 1 1,00 pc
100 100 04.05993.0837 TUBE FITTING 1 1,00 pc
110 110 04.05877.0035 SAFETY VALVE 1 1,00 pc
120 120 04.02860.0005 PRESSURE GAUGE 1 1,00 pc
130 130 04.05993.0615 TUBE FITTING 2 1,00 pc
140 140 04.05993.0194 CONNECTION 1 1,00 pc
150 150 04.05993.0616 TUBE FITTING 1 1,00 pc
160 160 07.50309.0156 PIPE 1 1,50 m
170 170 04.05876.0010 NON RETURN VALVE 1 1,00 pc
180 180 04.05993.0130 CONNECTION 1 1,00 pc
190 190 02.01590.0104 MUFF 1 1,00 pc
200 200 04.05993.0701 FITTING 1 1,00 pc
210 210 04.05993.0402 TUBE FITTING 1 1,00 pc
220 220 04.04590.0070 HOSE 1 1,50 m
230 230 04.04475.0104 CLAMP 2 1,00 pc
240 240 02.00825.0073 HEXAGON SOCKET HEAD CAP SCREW 2 1,00 pc
250 250 04.02279.0011 COUPLING 1 1,00 pc
260 260 04.05866.0008 DRAIN VALVE 1 1,00 pc
270 270 04.05993.0614 TUBE FITTING 1 1,00 pc
280 280 07.50309.0104 PIPE 1 1,50 m
290 290 04.00433.0011 PRESSURE RING 2 1,00 pc
300 300 04.05993.0326 TUBE FITTING 1 1,00 pc

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

Parts-list no.: 00.00073.0001 Hammelmann Maschinenfabrik GmbH

Drawing no. : 00.00073.0001-1 POB 3309, D-59302 Oelde, Germany
mail to: mail@hammelmann.de
Description : PRESSURE SENSOR http://www.hammelmann.de
DIFFERENTAL PRESSURE Date : 01.09.2003
Page : 1

DwgPos Item Code-No. Description Quantity No/Unit Unit

10 10 04.00073.0013 pressure indicator 1 1,00 pc
20 20 04.05993.0977 TUBE FITTING 4 1,00 pc
40 40 01.00426.0087 ELBOW 2 1,00 pc

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

Parts-list no.: 00.00134.0141 Hammelmann Maschinenfabrik GmbH

Drawing no. : 00.00134.0141-1 POB 3309, D-59302 Oelde, Germany
mail to: mail@hammelmann.de
Description : FEED WATER ASSEMBLY http://www.hammelmann.de
08.98190.0004+FILTER(300L) Date : 01.09.2003
Page : 1

DwgPos Item Code-No. Description Quantity No/Unit Unit

10 10 00.00995.0058 FILTER 1 1,00 pc
20 20 08.98190.0004 CONNECTION ARMATURE 1 1,00 pc
30 30 07.70038.0541 HOLLOW SECHON 1 0,45 m
40 40 04.04475.0134 CLAMP 1 1,00 pc
50 50 01.05013.0003 FLAT STEEL 1 1,00 pc
60 60 02.00671.0116 HEXAGON HEAD SCREW 4 1,00 pc
70 70 02.00380.0006 SPRING LOCK WASHER 4 1,00 pc
80 80 02.00309.0006 HEXAGON NUT 4 1,00 pc

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

Parts-list no.: 00.00995.0058 Hammelmann Maschinenfabrik GmbH

Drawing no. : 00.00995.0058-1 POB 3309, D-59302 Oelde, Germany
mail to: mail@hammelmann.de
Description : FILTER http://www.hammelmann.de
FILTER 300LTR/MIN Date : 01.09.2003
Page : 1

DwgPos Item Code-No. Description Quantity No/Unit Unit

10 10 00.00222.0082 CONTAINER 1 1,00 pc
20 20 01.00665.0419 COVER 1 1,00 pc
30 30 04.00730.0504 O-RING 1 1,00 pc
40 40 02.00935.0101 CENTER-GROOVED DOWEL PIN 3 1,00 pc
50 50 02.00503.0110 EYEBOLT 3 1,00 pc
60 60 02.00301.0002 RING NUT 3 1,00 pc
70 70 04.00946.0124 COIL SPRING 1 1,00 pc
80 80 00.02166.0003 FILTER HOLDER 1 1,00 pc
90 90 01.03478.0257 SUPPORT-RING 1 1,00 pc
100 100 00.00273.0012 PLATE 1 1,00 pc
110 110 04.01561.0107 BALL VALVE 1 1,00 pc
120 120 04.05866.0011 AIR VENT VALVE 1 1,00 pc
160 160 04.05993.0802 CONNECTION 2 1,00 pc
190 190 02.00421.0006 WASHER 3 1,00 pc
200 200 01.04565.0017 NAME PLATE 1 1,00 pc
210 210 04.02970.0016 RIVET 4 1,00 pc

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

Parts-list no.: 08.98190.0004 Hammelmann Maschinenfabrik GmbH

Drawing no. : 08.98190.0004-1 POB 3309, D-59302 Oelde, Germany
mail to: mail@hammelmann.de
Description : CONNECTION ARMATURE http://www.hammelmann.de
HDP110, 160, 180, 330 Date : 01.09.2003
Page : 1

DwgPos Item Code-No. Description Quantity No/Unit Unit

10 10 00.00134.0057 CONNECTION ARMATURE 1 1,00 pc
20 20 02.00805.0205 HEXAGON SOCKET SCREW PLUG 2 1,00 pc
30 30 02.00805.0210 HEXAGON SOCKET SCREW PLUG 1 1,00 pc
40 40 04.00710.0029 GASKET 1 1,00 pc
50 50 04.02860.0005 PRESSURE GAUGE 1 1,00 pc

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

Parts-list no.: 08.00229.5021 Hammelmann Maschinenfabrik GmbH

Drawing no. : POB 3309, D-59302 Oelde, Germany
mail to: mail@hammelmann.de
Description : CUT OFF SWITCH http://www.hammelmann.de
HDP20-550 Date : 01.09.2003
Page : 1

DwgPos Item Code-No. Description Quantity No/Unit Unit

10 04.06218.0053 PRESSURE GUARD 1 1,00 pc
20 04.05993.0727 TUBE FITTING 1 1,00 pc
30 04.05993.0742 CONNECTION 1 1,00 pc
40 04.02990.0074 REDUCTION NIPPLE 1 1,00 pc

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

Parts-list no.: 08.00229.5023 Hammelmann Maschinenfabrik GmbH

Drawing no. : 08.00229.5023-1 POB 3309, D-59302 Oelde, Germany
mail to: mail@hammelmann.de
Description : CUT OFF SWITCH http://www.hammelmann.de
Date : 01.09.2003
Page : 1

DwgPos Item Code-No. Description Quantity No/Unit Unit

10 10 04.06218.0053 PRESSURE GUARD 1 1,00 pc
20 20 04.05993.0709 TUBE FITTING 1 1,00 pc
30 30 04.05993.0713 CONNECTION 1 1,00 pc

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

Parts-list no.: 00.00657.0082 Hammelmann Maschinenfabrik GmbH

Drawing no. : 00.00657.0082-1 POB 3309, D-59302 Oelde, Germany
mail to: mail@hammelmann.de
Description : SOUND ABSORBER http://www.hammelmann.de
HDP230; CAT C9 Date : 01.09.2003
Page : 1

DwgPos Item Code-No. Description Quantity No/Unit Unit

10 10 00.01630.0853 BRACKET 1 1,00 pc
20 20 00.02530.0073 LINE 1 1,00 pc
30 30 01.00710.0067 FLAT SEAL 1 1,00 pc
40 40 00.00657.0076 SOUND ABSORBER 1 1,00 pc
50 50 04.01815.0013 ISOLATION 1 1,00 pc
60 60 02.00884.0118 SLOTTED SET SCREW WITH FLAT PO 8 1,00 pc
70 70 02.00309.0403 HEXAGON NUT 8 1,00 pc
80 80 02.00421.0103 WASHER 8 1,00 pc
90 90 02.00671.0113 HEXAGON HEAD SCREW 4 1,00 pc
100 100 02.00421.0006 WASHER 4 1,00 pc

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

Parts-list no.: 00.00134.0195 Hammelmann Maschinenfabrik GmbH

Drawing no. : 00.00134.0195-1 POB 3309, D-59302 Oelde, Germany
mail to: mail@hammelmann.de
Description : CONNECTION FITTING, SUCTION SI http://www.hammelmann.de
HDP160,230, CAT 3126B, CAT C9 Date : 01.09.2003
Page : 1

DwgPos Item Code-No. Description Quantity No/Unit Unit

10 10 04.03226.0728 CENTRIFUGAL PUMP 1 1,00 pc
20 20 01.03460.0309 V-BELT DISC 1 1,00 pc
30 30 04.03459.0355 V-BELT 1 1,00 pc
40 40 00.01642.0318 PROTECTION 1 1,00 pc
50 50 04.06200.0015 ANGLE 1 1,00 pc
60 60 04.02981.0030 DOUBLE NIPPLE 1 1,00 pc
70 70 04.04611.0064 CONNECTION HOSE 1 1,50 m
80 80 00.00131.0217 CONNECTION FITTING 1 1,00 pc
90 90 04.04475.0159 CLAMP 2 1,00 pc
100 100 00.04205.0005 SPANNER 1 1,00 pc
110 110 02.00888.0308 HEX-SOCKET SET SCREW 1 1,00 pc
120 120 02.00671.0107 HEXAGON HEAD SCREW 4 1,00 pc
130 130 02.00421.0005 WASHER 4 1,00 pc
140 140 02.00380.0005 POSITIVE PATTERN LOCK WASHER 4 1,00 pc
150 150 02.00309.0005 HEXAGON NUT 4 1,00 pc
160 160 04.01548.0001 DRAIN VALVE 1 1,00 pc
190 190 02.00671.0101 HEXAGON HEAD SCREW 4 1,00 pc
200 200 02.00421.0004 disc 4 1,00 pc

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

Parts-list no.: 00.00131.0217 Hammelmann Maschinenfabrik GmbH

Drawing no. : 00.00131.0217-1 POB 3309, D-59302 Oelde, Germany
mail to: mail@hammelmann.de
Description : CONNECTION FITTING http://www.hammelmann.de
DN65 Date : 01.09.2003
Page : 1

DwgPos Item Code-No. Description Quantity No/Unit Unit

10 10 02.01276.0315 FLANGE 1 1,00 pc
20 20 02.01276.0165 WELDING NECK FLANGE 1 1,00 pc
30 30 04.05320.0046 REDUCTION PIECE 1 1,00 pc
40 40 04.02976.0008 nipple 1 1,00 pc
50 50 04.00709.0018 FLAT SEAL 1 1,00 pc
60 60 02.00671.0154 HEXAGON HEAD SCREW 4 1,00 pc
70 70 02.00421.0009 WASHER 4 1,00 pc
80 80 02.00309.0009 HEXAGON NUT 4 1,00 pc

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

Parts-list no.: 00.04205.0005 Hammelmann Maschinenfabrik GmbH

Drawing no. : 00.04205.0005-1 POB 3309, D-59302 Oelde, Germany
mail to: mail@hammelmann.de
Description : SPANNER http://www.hammelmann.de
Date : 01.09.2003
Page : 1

DwgPos Item Code-No. Description Quantity No/Unit Unit

10 10 01.00530.0156 BUNDLE BUSHING 1 1,00 pc
20 20 04.03613.0001 TENSION ROLLER 1 1,00 pc
30 30 04.04205.0013 spanner 1 1,00 pc
40 40 02.00314.0004 HEXAGON THIN NUT 1 1,00 pc
50 50 02.00654.0012 HEXAGON HEAD BOLT 1 1,00 pc
60 60 02.00440.0005 WASHER 1 1,00 pc
70 70 02.00671.0113 HEXAGON HEAD SCREW 1 1,00 pc
80 80 02.00380.0006 SPRING LOCK WASHER 1 1,00 pc

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

Parts-list no.: 08.99109.0051 Hammelmann Maschinenfabrik GmbH

Drawing no. : 08.99109.0051-1 POB 3309, D-59302 Oelde, Germany
mail to: mail@hammelmann.de
Description : CONTROL LINE http://www.hammelmann.de
Date : 01.09.2003
Page : 1

DwgPos Item Code-No. Description Quantity No/Unit Unit

10 10 04.05993.0842 TUBE FITTING 2 1,00 pc
20 20 04.05875.0107 MAGNETIC VALVE 1 1,00 pc
40 40 04.05993.0840 CONNECTION 1 1,00 pc
50 50 04.05993.0838 TUBE FITTING 1 1,00 pc
60 60 04.04590.0121 HOSE 1 1,00 m

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

Parts-list no.: 08.00229.5026 Hammelmann Maschinenfabrik GmbH

Drawing no. : POB 3309, D-59302 Oelde, Germany
mail to: mail@hammelmann.de
Description : CUT OFF SWITCH http://www.hammelmann.de
Date : 01.09.2003
Page : 1

DwgPos Item Code-No. Description Quantity No/Unit Unit

10 04.06218.0057 PRESSURE GUARD 1 1,00 pc
20 04.05993.0709 TUBE FITTING 1 1,00 pc
30 04.05993.0499 CONNECTION 1 1,00 pc

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

Parts-list no.: 08.01320.0003 Hammelmann Maschinenfabrik GmbH

Drawing no. : 08.01320.0003-1 POB 3309, D-59302 Oelde, Germany
mail to: mail@hammelmann.de
Description : SUPPORT http://www.hammelmann.de
Date : 01.09.2003
Page : 1

DwgPos Item Code-No. Description Quantity No/Unit Unit

10 10 01.03145.0332 PLATE 1 1,00 pc
20 20 02.00671.0113 HEXAGON HEAD SCREW 6 1,00 pc
30 30 02.00380.0006 SPRING LOCK WASHER 6 1,00 pc
40 40 01.05017.0002 U-STEEL 1 1,00 pc
50 50 01.05013.0016 FLAT STEEL 1 1,00 pc
60 60 04.03200.0003 SHOCK ABSORBER 2 1,00 pc
70 70 02.00830.0027 hexagon socket head screw 4 1,00 pc
80 80 01.05013.0021 FLAT STEEL 1 1,00 pc
90 90 01.04475.0005 CLAMP 1 1,00 pc
100 100 02.00421.0004 disc 4 1,00 pc
110 110 01.04475.0004 CLAMP 2 1,00 pc
120 120 01.00525.0427 BUSHING 2 1,00 pc
130 130 02.00825.0046 hexagon socket head screw 2 1,00 pc
140 140 02.00314.0003 PREVAILING TORQUE TYPE HEXAGON 2 1,00 pc

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

Parts-list no.: 08.00229.6005 Hammelmann Maschinenfabrik GmbH

Drawing no. : 08.00229.6005-1 POB 3309, D-59302 Oelde, Germany
mail to: mail@hammelmann.de
Description : KEY OPERATED SWITCH http://www.hammelmann.de
Date : 01.09.2003
Page : 1

DwgPos Item Code-No. Description Quantity No/Unit Unit

10 10 04.04290.0161 SWITCH 1 1,00 pc
20 20 04.05976.0102 ELECTRIC CONNECTION 1 1,00 pc
30 30 04.03500.0021 REDUCTION RING 1 1,00 pc
40 40 00.05101.0002 PLUG 1 1,00 pc
50 50 04.01864.0447 CABLE 1 2,00 m
60 60 04.04550.0084 SIGN 1 1,00 pc
70 04.01759.0006 SLEEVE 1 3,00 pc
80 04.01864.0323 cable 1 0,10 m

>>>end<<<
p_dbgs01.p