HAMMELMANN HDP 502 / S 1100-50 User manual

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

Machine no. : B7.02502.0210 1Page:
M A C H I N E C A R D
Hammelmann GmbH
POB 3309, D-59282 Oelde, Germany
mail to: [email protected]
http://www.hammelmann.de
Order no. KA 222274
Purchaser Waterkracht B.V., Varsseveld / NL
Client no. 10147901
P. O. no./Date I00010227 - Doornbos / 22.11.2016
Machine no. B7.02502.0210
Pump type HDP 502 S 1100 - 50
Code no. 09.63502.9002
Performance data l/minFlow rate Ps 1 262
barOperating pressure Ps 1 1000
1/minMotor speed Ps 1 1800
1/minCrankshaft speed Ps 1 465
mmPiston dia. Ps 1 50
kWMotor rating req'd Ps 1 478
Performance data diesel engine
Make Volvo
Type TAD 1672 VE Stufe IV / Tier 4 Final
motor no. 2016102431
VVoltage 24
kWRating 515
1/minR.P.M. 1800
1/minR.P.M. min. 900
Battery no. 04.00190.0006 2 Stück
Battery box no. 04.01909.0015 2 Stück
VBattery voltage 12
A
hBattery capacity 143
Brief instructions
Language englisch
Paint colour
Pump RAL 1018
Frame RAL 7043
Motor Lieferzustand
Container RAL 9016 GL
Setting of cut-off switches barSuction pressure min. 2,0
°CSuction temperature max. 40
barOil pressure min. 4,0
°COil temperature pump max. 75
barDifferent. pres. of filter max 1,2
bar
A
ir pressure min. 5,5
Gearing 1 —
Gearing 2 —
Name plate high pressure pump
Machine no. B7.02502.0210
Type no. 09.63502.9002
Year 2017
kWMotor rating [kW] 478
1/minSpeed [1/min] 1800

Machine no. : B7.02502.0210 2Page:
M A C H I N E C A R D
Hammelmann GmbH
POB 3309, D-59282 Oelde, Germany
mail to: [email protected]
http://www.hammelmann.de
°CMax. liquid temp. [°C] 40
mmPiston dia. pres. step 1 [mm] 50
barMax. pressure Ps 1 [bar] 1000
l/minFlow rate Ps 1 [l/min] 262
Pressure reg. valve Ps 1 00.05865.0146
Oil type PAO ISO VG 320
lOil quantity [l] 42
barOil pressure [bar] 4,0
Documentation
Language 1 englisch
Language 1 number of paper 2
Language 1 number of CD 1
Date of delivery 21.02.2017
Person in charge-Sales M. Lettmann
Person in charge Kaldewey
Date 22.11.2016
Parts list to machine no: B7.02502.0210
Pos Code - No. Description Quantity Uni
t
Note : Ps = Pressure step
1 00.00027.1085 1,00 pcHIGH-PRESSURE PUMP UNIT HDP502; VOLVO TAD1672 STAGE 4
2 00.00027.1277 1,00 pcHIGH-PRESSURE PUMP UNIT HDP504; VOLVO TAD1672 TIER4 F.
10 04.04565.0012 1,00 pcNAMEPLATE
20 00.00743.2221 3,00 pcPISTON SEALASSEMBLY, Packing HDP360 - MC D50, 1.4462
30 00.02515.0350 1,00 pcLINE SUCTION CHAMBER
50 00.02145.1239 1,00 pcPUMPHEAD - Duplex HDP360-500 D50-55, 1.4462
55 00.02518.0018 1,00 pcVENT LINE HDP230/330/350/400/550/360-MC
60 00.05865.0146 1,00 pcPRESSURE REGULATING VALVE 500 L/MIN , 1200 BAR 1.4462
61 00.00131.0121 1,00 pcCONNECTION G 1 1/2 AT-PIECE
62 00.06428.0029 1,00 pcMEMBRANE CYLINDER PN 10; D 130
63 02.00825.0152 4,00 pcHEXAGON SOCKET HEAD SCREW M 12 x 120
65 04.02860.0056 1,00 pcPRESSURE GAUGE 0-1600 BAR; NG 100;
66 04.01561.0107 1,00 pcBLOCK BALL VALVE DN 15; PN 16
70 00.04062.1000 1,00 pcRUPTURE DISC ASSEMBLY G 1/2 A - G 1/2 - 82,0 LG.
80 04.00829.0056 1,00 pcPRESSURE SENSOR 0-1600 bar; 4-20 mA; G 1/2 A;
90 08.00200.9201 1,00 pcDISCHARGE FITTING
100 01.02981.0553 1,00 pcDOUBLE NIPPLE M48X2 - M36X2,0 - 78,0 LG.
110 04.00742.0048 1,00 pcSEAL RING 36,0 X 30,0 X 3,0
130 01.04838.0203 1,00 pcSCREW PLUG M48 x 2
140 04.00742.0050 1,00 pcSEAL RING 42,0 x 36,0 x 3,0
300 00.00026.1238 1,00 pcUNIT HDP500; VOLVO TAD1672 STUFE 4
310 04.06200.0031 2,00 pc
A
NGLE 90°; R 1/4; PN 16
320 00.02515.0173 1,00 pcOVERFLOW LINE
330 00.02515.0315 1,00 pcLINE
335 00.00265.0047 1,00 pcPLATE
340 04.00995.0129 1,00 pcFILTER BAG 200+10µm,collar dia.=178;L=620
350 00.05540.0346 1,00 pcWATER TANK 1300L

Machine no. : B7.02502.0210 3Page:
M A C H I N E C A R D
Hammelmann GmbH
POB 3309, D-59282 Oelde, Germany
mail to: [email protected]
http://www.hammelmann.de
360 04.04611.0065 4,00 mCONNECTION HOSE
3m
370 04.04475.0160 2,00 pcCLAMP
380 02.01495.0001 1,00 pcSOLID 'C' COUPLING
390 00.01630.1159 3,00 pcBRACKET
400 00.05540.0262 1,00 pcFUEL TANK 900LALU-DIESEL
405 00.01595.0462 1,00 pcSUPPORT 70LAD-BLUE TANK
410 08.99109.0050 1,00 pcCONTROL LINE 0-6BAR
420 04.00829.0093 1,00 pcPRESSURE SENSOR 0-16 BAR; 4-20 mA; G1/4 A;
430 04.05630.0074 1,00 pcTHERMOSTAT 0-100 °C/4-20 mA;G 1/4B; M12x1
440 00.05630.0012 1,00 pcTHERMOSTAT HDP380/500/800/MC
450 04.01336.0180 1,00 pcCONTROL UNIT ES2 ES2
460 00.02125.0459 1,00 pcSUPPORT ES-2
470 00.00640.0234 1,00 pcCONTAINER HDP380-500,20' CONT. KPL
480 00.00039.0004 1,00 pcKIT FOR DRILLING
A
GGREGAT; 20'-CONT
490 00.01880.0065 1,00 pcWEATHER CAP CONTAINER HDP250
500 00.06020.0143 1,00 pcLIFTING DEVICE PUMP HEAD
510 00.00753.0015 1,00 pcSOCKET 4-POL
520 04.04290.0176 1,00 pcSWITCH NOT-AUS
530 01.03145.0319 1,00 pcPLATE 85 X 85 X 2; BO D40
540 04.04550.0259 2,00 pcSIGN S1100-50
550 04.04550.0281 2,00 pcSIGN L=50
>>>end<<<

Formblatt FB-K2-11-01
FB-U3-05-00 Ausgedruckte Exemplare unterliegen nicht der Dokumentenlenkung. Die aktuelle Version befindet sich immer auf dem Server. 1 von 1
Abnahmeprüfzeugnis / Test Certificate
Maschinen-Nr.
Machine No. B7.02502.0210 HAMMELMANN GmbH
Carl-Zeiss-Str. 6 - 8
D-59302 Oelde
Tel.: [phone]
e-mail: m[email protected]
http: www.hammelmann.de
Unsere Auftrags-Nr.
Our Order No.
KA 222274
Bestell-Nr.
P. Order No. I00010227 - Doornbos
Druckregelautomatik
Pressure unloader
---------------------------------------- Eingangsdrehzahl / Motordrehzahl
Input speed / Motor r.p.m. min
-1
1800
Druckregelventil / Bypassventil
Pressure relief valve / Bypass valve
00.05865.0146 +
00.06428.0029
Öldruck
Oil pressure bar
8,0
Anzahl der Tellerfedern
Number of Disc-springs
---------------------------------------- Mediumdruck
Medium pressure bar
1000
Schichtung der Tellerfedern
Spring pack arrangement
---------------------------------------- Fördermenge
Output
m
3
/h
l/min
264
Distanzhülse / Steuerdruck
Washer / Control pressure
3,1 bar
Plungerkühlwasser
Pisten cooling water l/min / °C
11,6 / 32°C
Sicherheitsventil / Berstscheibensicherung
Safety valve / Burst disc
/ / Ansprechdruck
Opening Pressure bar
1400
Druckwächter Öl
Oil pressure switch
E-Motor
ex
D-Motor
50 Hz
60 Hz
Druckwächter Medium
Medium pressure switch
Antriebsleistung
Motor rating kW
478
Thermostat Öl / Oil Medium / / Stromaufnahme (Prüfraum)
A
Power consumption (Testroom) Volt / Hz
/
Überlast E-Motor
Overload E-Motor
Gesamtlaufzeit – Std.
Total – Test – Time hr.
1,75
Schaltschrank (ohne Pumpenüberwachung)
Switchboard (without pump control unit)
unter Last
under Load Std./hr.
1,5
Schaltschrank (Überwachungsgerät, Pumpe-Motor)
Switchboard (control unit, pump-motor)
Geprüft nach EG-Maschinenrichtlinie
Gerätesicherheitsgesetz
Tested in accordance with E.U. Machine
Regulations governing operational
safety of equipement.
ja / yes
nein / no
Betriebsstundenzähler
Operating hours counter
Bypasssteuerventil
Bypass solenoid valve
Druckwächter Luft
Air pressure sensor
ja / yes
nein / no
Umschaltventil / Magnetventil
Multi tool valve / Changeover valve
Kühlwassermenge
Cooling water quantity Ltr./ min.
20
Temperaturmessung nach Erreichen der Beharrungstemperatur
Temperature measurement only when steady state temperature reached
Nr. Name Datum Zeit IR-Temp IR-Min IR-Max Mat. Name
1TS1 Temp.Cranks.bear 06.03.2017 13:54:43 56,2 56,2 56,4 Free
2TS2 Temp.Cranks.bear 06.03.2017 13:54:45 55,9 55,9 56,1 Free
3TS3 Driveshaft bear. 06.03.2017 13:54:47 56,4 56,4 56,4 Free
4TS4 Driveshaft bear. 06.03.2017 13:54:52 57,4 57,2 57,5 Free
5TS5 Oiltemperature 06.03.2017 13:55:00 52,8 52,8 53,5 Free
6TS6 Oil Cooler out 06.03.2017 13:55:06 43,8 43,5 43,8 Free
7TS7 Coolingwater inl 06.03.2017 13:55:09 28,2 28,2 28,5 Free
8TS8 Coolingwater out 06.03.2017 13:55:18 33,9 33,9 34,6 Free
9TS9 Crank sec.gener. 06.03.2017 13:55:22 53,3 53,1 53,8 Free
10 TS10 Temp.Pisten 06.03.2017 13:55:26 33,8 33,4 34,8 Free
11 TS11 Temp.Crosshead 06.03.2017 13:55:28 54,9 54,7 54,9 Free
12 TS12 Ambient Temp. 06.03.2017 13:55:34 8,7 8,7 9,3 Free
Qualitätsprüfung
Quality Control Der Abnahmeingenieur Test-Engineer Datum Date
Name:
Unterschrift / Signature
J. Vöge 07.03.2017
Dokument wurde auf elektronischem Wege erstellt und ist ohne Unterschrift gültig.
This message was electronically generated and is valid without a signature.
geprüft / tested
nicht vorhanden / not installed

HAMMELMANN GmbH
Carl-Zeiss-Straße 6-8
59302 Oelde •Germany
EG-Konformitätserklärung
nach EG-Richtlinie 2006/42/EG,
Anhang II, Nr. 1A
EC-Declaration of Conformity
according to E.C. Directive
2006/42/EC, Appendix II, No 1A
Déclaration de conformité CE
conformément à la directive CE
sur les machines 2006/42/CE,
Annexe II, N° 1A
Hiermit erklären wir, dass die nachstehend
bezeichnete Maschine in ihrer Konzipierung
und Bauart sowie in der von uns in Verkehr
gebrachten Ausführung den grundlegenden
Sicherheits-
und Gesundheitsanforderungen
der EG-Richtlinie 2006/42/EG (Maschinen-
Richtlinie) entspricht.
We hereby declare that the machine
detailed below has been designed,
constructed and tested to fully comply with
the health and safety requirements of the
E.C. Directive 2006/42
/EC (Directive
relating to Machinery).
Par la présente, n
ous déclarons que la
conception et la construction ainsi que le
modèle mis en circulation de la machine ci-
dessous correspondent aux exigences de
base en matière de sécurité et de s
anté de
la directive 2006/42/CE sur les machines.
Die Abteilung Normung/Dokumentation ist
bevollmächtigt, die technischen Unterlagen
nach Anhang VII A zusammenzustellen.
The department Standards/Documents is
authorised to compile the technical file
according to Annex VII A.
Le service Standardisation/Documentation
es
t autorisé à compiler la documentation
technique conformément à l’annexe VII A.
Bezeichnung der Maschine:
Hochdruckpumpenaggregat HDP 502
Machine description:
High pressure pump unit HDP 502
Désignation de la machine:
Groupe de pompe à haute pression HDP 502
Maschinentyp:
09.63502.9002
Machine designation:
Type de machine:
Maschinen-Nr.: B7.02502.0210
Machine No.:
Node machine:
Weitere, zutreffende EG-Richtlinien: Other appropriate E.C. Directives: Autres directives CE concernées:
EG-Richtlinie 2014/30/EU
(EMV-Richtlinie) E.C. Directive 2014/30/EU (EMC directive) Directive CE sur la comptabilité électromagnétique 2014/30/EU
Angewandte harmonisierte Normen: Used harmonised standards: Normes harmonisées appliquées:
EN 809 EN 1829-1 EN 60204-1 EN 61000-6-2
Angewandte nationale Normen und
technische Spezifikationen: National standards and technical specifications: Normes nationales et spécifications techniques appliquées:
- -
Hersteller-Unterschrift Manufacturer’s signature Signature du fabricant
07.03.2017
Datum / Date / Date Geschäftsführer General Manager Gérant
Funktion des Unterzeichners Position of Signatory Fonction du signataire
TB 008/0106

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

Operating instructions
Contents
No.: HDP 502 / S 1100-50
Page 2, Issue: 03.2017
Copyright Hammelmann GmbH
Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8
1 Contents
1Contents ............................................................................................................................................................2
2Foreword ...........................................................................................................................................................5
3Technical data...................................................................................................................................................6
3.1 Main dimensions .......................................................................................................................................... 6
3.2 Performance data: High pressure pump...................................................................................................... 8
3.3 Performance data: Diesel engine................................................................................................................. 8
3.4 Batteries ....................................................................................................................................................... 8
4Safety .................................................................................................................................................................9
4.1 Dangers arising from non observance of safety instructions....................................................................... 9
4.2 Safety conscious working ............................................................................................................................ 9
4.3 Personnel qualification and training ............................................................................................................. 9
4.4 Precise safety instructions for the operator ................................................................................................. 9
4.5 Danger symbol ........................................................................................................................................... 11
4.6 Safety during inspection, maintenance and repair..................................................................................... 12
4.7 Forbidden practices ................................................................................................................................... 12
4.8 Additional warnings .................................................................................................................................... 12
5General.............................................................................................................................................................13
5.1 Introduction ................................................................................................................................................ 13
5.2 Application.................................................................................................................................................. 13
5.3 General permissible operational conditions............................................................................................... 13
5.4 Copyright.................................................................................................................................................... 14
5.5 Warranty terms........................................................................................................................................... 14
6Transportation ................................................................................................................................................15
6.1 Packing ...................................................................................................................................................... 15
6.2 Transportation ............................................................................................................................................ 16
6.3 Transport.................................................................................................................................................... 16
6.4 Protection ................................................................................................................................................... 16
7Construction & Description ...........................................................................................................................17
7.1 Construction ............................................................................................................................................... 17
7.1.1 Layout of the S1100- 50 (basic)............................................................................................................. 17
7.2 Description ................................................................................................................................................. 20
7.2.1 General Description of the High pressure pump.................................................................................... 20
7.2.2 Crank section with pressurised lubrication system ................................................................................ 20
7.2.3 Piston seal assembly ............................................................................................................................. 20
7.2.4 Pump head............................................................................................................................................. 20
7.2.5 Pressure regulating and overflow valve ................................................................................................. 22
7.2.6 The burst disc assembly (safety devices) .............................................................................................. 22
7.2.7 Electronic safety cut out......................................................................................................................... 23
7.2.8 High pressure installation....................................................................................................................... 23
7.2.9 Suction side installation ......................................................................................................................... 23
7.2.10 Container (if fitted).............................................................................................................................. 23
7.2.11 Dieselengine Volvo TAD 1672 VE St. IV Tier 4 final ......................................................................... 23
7.2.12 ES 2 control unit................................................................................................................................. 24
7.3 Exhaust after treatment.............................................................................................................................. 24

Contents
Operating instructions
No.: HDP 502 / S 1100-50
Page 3, Issue: 03.2017
Copyright Hammelmann GmbH
Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8
7.3.1 Electronic pressure transmitter 04.00829.0093......................................................................................26
7.3.2 Electronic pressure transmitter 04.00829.0056......................................................................................27
7.3.3 Solenoid Valve 04.05875.0107...............................................................................................................28
7.3.4 Electronic temperature transmitter 04.05630.0074 ................................................................................29
8Installation & Start up ....................................................................................................................................30
8.1 Pre-start checks..........................................................................................................................................30
8.2 Installation of pump connections ................................................................................................................30
8.2.1 Calculating the hose internal diameter (DN)...........................................................................................31
8.2.2 Notes on installation of connecting armatures........................................................................................34
8.3 Connecting the high pressure hose(s)........................................................................................................36
9Operation.........................................................................................................................................................38
9.1 Start up .......................................................................................................................................................38
9.1.1 Warm up and system checks..................................................................................................................38
9.1.2 To start the high pressure pump unit......................................................................................................39
9.2 To start the high pressure pump unit..........................................................................................................40
9.3 Operating the system..................................................................................................................................40
10 Shut down .......................................................................................................................................................42
10.1 Stopping the unit.........................................................................................................................................42
10.2 Overnight shut down...................................................................................................................................42
10.3 Exhaust after treatment ..............................................................................................................................42
10.4 Extended shut down ...................................................................................................................................43
10.4.1 Draining the unit..................................................................................................................................43
10.4.2 Venting air from the system after draining for first operation..............................................................43
10.4.3 To fill system .......................................................................................................................................43
10.4.4 Further actions ....................................................................................................................................45
10.4.5 Hoses..................................................................................................................................................45
10.4.6 Accessories.........................................................................................................................................45
11 Maintenance....................................................................................................................................................46
11.1 Fault finding and remedy ............................................................................................................................46
11.1.1 Annunciated faults ..............................................................................................................................46
11.1.2 Observed faults...................................................................................................................................46
11.1.3 Electrical faults....................................................................................................................................48
11.2 Maintenance ...............................................................................................................................................48
11.2.1 Daily inspection and control................................................................................................................48
11.2.2 Maintenance of the water filter............................................................................................................48
11.2.3 Checks during operation.....................................................................................................................49
11.3 Maintenance of the air pressure installation ...............................................................................................50
11.3.1 Compressed air tank (if supplied) .......................................................................................................50
11.3.2 Compressed air filter...........................................................................................................................50
11.4 Oil change...................................................................................................................................................51
11.4.1 First oil change after 1000 operating hours ........................................................................................51
11.4.2 Next oil changes .................................................................................................................................52
11.4.3 Lubrication including oil filter...............................................................................................................53
11.4.4 Oil pressure adjustment......................................................................................................................55
11.5 Repair & Replacement................................................................................................................................55

Operating instructions
Contents
No.: HDP 502 / S 1100-50
Page 4, Issue: 03.2017
Copyright Hammelmann GmbH
Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8
11.5.1 Replacing the rupture disc up to 1500 bar operating pressure.......................................................... 56
11.6 Maintenance of the pump head 00.02145.1239 (-003) ............................................................................. 57
11.6.1 Disassembly (ref. to fig. pump head) ................................................................................................. 57
11.6.2 Assembling (ref. to fig.: Pump head).................................................................................................. 59
11.7 Maintenance of the piston seal assembly: 00.00743.2221 (-004) ............................................................. 61
11.7.1 Disassembly....................................................................................................................................... 61
11.7.2 Reassembly ....................................................................................................................................... 62
11.1 Changing the bellows................................................................................................................................. 65
11.2 Changing or adjusting the boost pump drive belt ...................................................................................... 66
11.3 Torque tables ............................................................................................................................................. 66
12 Pressure regulating valve 00.05865.0146.....................................................................................................67
Technical Data ....................................................................................................................................................... 68
12.1 Installation (ref. to fig.: Pressure regulating valve)..................................................................................... 68
12.2 Adjustment ................................................................................................................................................. 68
12.3 Maintenance............................................................................................................................................... 69
13 Safety notes for high pressure hoses ..........................................................................................................74
13.1 Before using the hose ................................................................................................................................ 75
13.2 Use of the hose .......................................................................................................................................... 75
14 Index.................................................................................................................................................................76

Foreword
Operating instructions
No.: HDP 502 / S 1100-50
Page 5, Issue: 03.2017
Copyright Hammelmann GmbH
Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8
Pos: 1/T echnische Daten/Zu dies erAnlei tung/Überschrift @ 0\m od7_2.docx @ 1204 @ 1@ 1
2 Foreword
Pos: 2 /Tec hnisch e D aten/Zu di eser A nleitung/Hi nweis @0\ mod3 _2.doc x @ 1208 @ @ 1
All personnel who are responsible for the operation and maintenance of the
High pressure pump unit HDP 502 / S 1100-50 must:
Read and fully understand these instructions, especially the section “Safety“
before attempting to operate.
Ensure that these instructions are always readily available to all personnel
concerned.
Pos: 3 /Tec hnisch e D aten/Zu di eser A nleitung/H erstell eradres se @ 0\ mod4 _2.docx @ 1212 @ @ 1
Manufacturer and customer services address:
HAMMELMANN GmbH
Carl Zeiss Straße 6 - 8 59302 Oelde Germany
P. O. Box 33 09 59282 Oelde Germany
Telephone: [phone]
Telefax: [phone]
e-mail: m[email protected]
http://www.hammelmann.de
Pos: 4 /Tec hnisch e D aten/Zu di eser A nleitung/Ma schi nennumm er @ 0 \mod 5_2.doc x @ 1216 @ @ 1
Type:
HDP 502 / S 1100-50
Serial no.:
B7.02502.0210
Date:
2017
Pos: 5/ xxxxxxxxxxxxxxxxxxx @ 0\ mod6_2.docx @ 1188 @ @ 1

Operating instructions
Technical data
No.: HDP 502 / S 1100-50
Page 6, Issue: 03.2017
Copyright Hammelmann GmbH
Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8
Pos: 6/T echnische Daten/Übersc hrift @ 0\mod8_2.docx @ 1196 @ 1 @ 1
3 Technical dat a
Pos: 7 /Tec hnisch e D aten/P umpen/HD P 500/H aupta bmessunge n HD P 500n eu @ 9\mod_136004 9466827_ 2.docx @ 7 3883 @2 @ 1
3.1 Main dimensions
Fig.: 1 Main dimensions of the high pressure pump

Technical data
Operating instructions
No.: HDP 502 / S 1100-50
Page 7, Issue: 03.2017
Copyright Hammelmann GmbH
Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8
Weight of the pump: approx. 1985 kg
Pos: 8/ xxxxxxxxxxxxxxxxxxx @ 0\ mod6_2.docx @ 1188 @ @ 1

Operating instructions
Technical data
No.: HDP 502 / S 1100-50
Page 8, Issue: 03.2017
Copyright Hammelmann GmbH
Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8
Pos: 9 /Tec hnisch e D aten/S 1200-50/ S 110 0-50; 262 L,1000bar, 1800U, 478kW, Volvo T AD 1672 Stu fe IV Tier 4final @ 13\mod_14 32713659524_2.d ocx@ 116 631 @ 222@ 1
3.2 Performance data: High pressure pump
Type:
HAMMELMANN High pressure pump HDP 502
Pressure step 1
Flow rate V:
262 l/min.
Operating pressure p:
1000 bar
Motor speed:
1800 1/min.
Crankshaft speed nku:
465 1/min.
Piston / Plunger dia. dko:
50 mm
Power rating req’d.:
478 kW
Rod force:
200 000 N
Stroke:
100 mm
Weight approx.:
1900 kg
3.3 Performance data: Diesel engine
Type:
Volvo
Type:
TAD 1672 VE St. IV
Tier 4final
Power rating P:
515 kW
R.P.M. nmot:
1900 1/min.
Engine size:
16100 cm ³
Engine type:
4 stroke direct injection diesel
Cylinder Z:
8
Weight approx.:
1650 kg
3.4 Batteries
Number of:
2
Volts U:
2 x 12 V = 24 V
Capacity Q:
2 x 143 Ah
Pos: 10 /xxxxxxxxxxxxxxxxxxx @ 0\mod6_2.docx @ 1188 @ @ 1

Safety
Operating instructions
No.: HDP 502 / S 1100-50
Page 9, Issue: 03.2017
Copyright Hammelmann GmbH
Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8
Pos: 11 /Sicherheit/Überschrif t@ 0 \mod9_2.docx @ 1220 @ 1 @ 1
4 Safet y
Pos: 12 /Sicherheit/Pump en@ 0\ mod10_2.docx @ 1224 @ 22222222 @ 1
4.1 Dangers arising from non observance of safety instructions
Using the most modern manufacturing techniques HAMMELMANN produce high pressure equipment which is
subject to stringent Quality, Function and Safety tests. Even so, improper or unsuitable use of high pressure
equipment, or operation by untrained personal can result in accidents leading to:
Danger of death or injury.
Costly damages claims.
All personnel who are responsible for the operation and maintenance of high pressure equipment must, before they
attempt operation be fully conversant with and completely understand the contents of this manual. Particular atten-
tion must be paid to this section "safety" and these instructions must always be readily available to all personnel
concerned. No claims for personal injuries or damages arising from ignorance or non observance of safety
procedures can be accepted.
4.2 Safety conscious working
Always observe accident prevention rules (e.g. in Great Britain - "Health and Safety at Work Act”)! Refer to local
statutory or recommended codes of practice for the use of water jetting equipment. If no codes of practice are in
place in your country you are advised to obtain and adopt those of another country.
4.3 Personnel qualification and training
Only trained personnel should be entrusted with operation, maintenance, inspection and repair of high pressure
water equipment. The owners of the equipment are responsible for ensuring that all personnel concerned are fully
trained and conversant with the contents of this manual. If necessary, training courses should be arranged.
4.4 Precise safety instructions for the operator
The operation of water jetting equipment should only be entrusted to personnel who are,
fully conversant with the operation procedure.
fully aware of the inherent dangers.
Dangers are for instance,
reaction force.
cutting power of the jet.
hose shortening when pressurised.
working close to electrical sources or machinery.
In the case of bare shaft pumps never connect a driver that can exceed the pump max. power rating as given
on the name plate.
A pump unit must always be fitted with a mains cut-off / ignition switch system.
An emergency switch is an essential component of any pump unit.

Operating instructions
Safety
No.: HDP 502 / S 1100-50
Page 10, Issue: 03.2017
Copyright Hammelmann GmbH
Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8
Before each operation the employer should ensure that a competent or trained person has checked,
that units and / or equipment are in good condition and
that the important elements, i.e.: safety devices, hoses, hose connections etc. are in good order.
Any fault should be remedied before using the equipment.
Follow precisely all start up/shut down procedures given in the operating instructions
During operation regularly check the hoses, fittings and jetting accessories (i.e.: nozzles,
spray bar) for signs of leakage. In the case of leakage stop the pump unit immediately.
Do not attempt a close visual inspection of leakage while the pump is running.
Use only the correct tools, i.e.: ensure that you have the correct spanner size to fit connection nuts etc.
Do not vary the pump pressure unless you have informed the accessory / machine operator
that you are about to do so.
Upon shut down ensure that all elements of the equipment are depressurised (atmospheric pressure).
When using two or more consumers (i.e.: spray guns) from a single pump unit,
care shall be taken to ensure that the pressure regulating valve or unloader is correctly set so that the
operation of any consumer (i.e.: spray gun) will not cause a sudden pressure change and / or excessive
reaction forces.
Never use accessories, i.e.: hoses, spray pistols etc. above the maximum specified operating pressure.
The maximum pressure of any system is only equal to the maximum pressure rating of the lowest rated
component therein.
Position hoses,
so that they are not clamped or kinked and cannot chafe against sharp edges.
Interfering with safety elements is strictly forbidden! Damaging, e.g. the locking wire or seal coating will
invalidate the guarantee and will release us from any liability in the event of accident or injury.
Use only accessories and spares from HAMMELMANN or their approved suppliers. Use of parts that are not
marked as tested or that are supplied without a test certificate can be dangerous. Think of your own safety.
(Also see guarantee conditions)
The employer must ensure,
that the workplace is cleared, offers a firm footing and there is no possibility of tripping.
Trailing lines, loose debris and tools do not make a safe workplace.
The jetting operator must ensure,
that there is no danger to neighbouring workers, and that the workplace is closed off with barriers.
signs are erected to prohibit unauthorised entry i.e.: Danger! High pressure water.

Safety
Operating instructions
No.: HDP 502 / S 1100-50
Page 11, Issue: 03.2017
Copyright Hammelmann GmbH
Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8
Causes of danger are,
the jet (cutting power).
spray mist (with dangerous chemical additives).
loose debris or other items picked up and projected by the force of the jet.
Avoid contact with any spray arrangement:
Do not place your hand or other bodily parts in front of a pressurised nozzle.
Never under any circumstances point an accessory (i.e.: pistol) at other persons even when depressurised.
Hazards to your health are,
the properties of the liquid (Wet, high temp, caustic etc.)
the high pressure (i.e.: cutting power of the jet, possible impact damage to tissue and bacterial infection).
To work with liquid jets the employer should ensure that all operatives wear protective clothing, i.e.:
Protective suit,
Safety helmet,
Flexible closed gloves,
Slip proof safety boots with foot and shin protection.,
Ear protectors,
Respiratory protector,
Safety glasses or full face visor.
Operatives ignoring the employers instruction to wear any of the above do so at their own
risk!
In the event that a person is struck by a waterjet they must immediately report to or be
taken to a doctor. Even seemingly minor injuries can have serious consequences! Liquids
can be injected into body tissue leaving no obvious external damage!
4.5 Danger symbol
This symbol, always indicates an important safety instruction. You must read,
understand and follow the instruction precisely!
Failure to follow such an instruction can result in extreme danger to persons and
damage to property.

Operating instructions
Safety
No.: HDP 502 / S 1100-50
Page 12, Issue: 03.2017
Copyright Hammelmann GmbH
Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8
4.6 Safety during inspection, maintenance and repair
The owner shall be responsible for ensuring that all inspection, maintenance and repair works are carried out by
competent, fully trained personnel. He shall also ensure that said personnel have read and fully understood this
manual.
Before commencing such works all safety and shut down instructions herein must be observed. Before starting
such works on diesel engine driven units disconnect the battery cables. In case of e-motor driven units cut-off
tension / unplug mains plug. Before restarting follow the instructions given in the section “Installation”.
4.7 Forbidden practices
Operating , maintenance and repair procedures other than described herein or
unauthorised design modifications are forbidden on safety grounds. The manufacturer
cannot be held responsible for any consequences arising from the fitting of unauthorised
spare parts or accessories.
4.8 Additional warnings
When this high pressure equipment (i.e.: rotary joint, pistol etc.) is built into a high pressure system you must
also refer to the safety and operation instructions of the other high pressure elements before use!
Other elements are for instance:
Drive, Pump, Spray head or Spray bar, Surface cleaners, etc.
If using a diesel or petrol powered unit in an enclosed area ensure that there is sufficient ventilation and that
exhaust gases are vented to atmosphere.
In the event that other high pressure accessories (i.e.: hoses) are used in conjunction with this unit then the
relevant manufacturer's or supplier's operation instructions should be observed and followed in all cases.
If your pump unit is mounted on a roadworthy trailer you must ensure that the towing vehicle is suitable for the
weight! See construction and description section for trailer details.
Drivers must ensure that towing vehicle and trailer are in a roadworthy condition and that they comply with local
traffic regulations.
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General
Operating instructions
No.: HDP 502 / S 1100-50
Page 13, Issue: 03.2017
Copyright Hammelmann GmbH
Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8
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5 Gener al
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5.1 Introduction
Your HAMMELMANN High pressure pump is the product of many years of research, development and testing in
the field of high pressure manufacture.
Modern design and production procedures allow us to place the highest demands on the quality of our products.
For you, this means:
High precision manufacture,
high reliability and
efficiency.
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5.2 Application
There are many applications for HAMMELMANN High and Ultra high pressure pumps, i.e.:
Liquid dosing and transportation.
Hydrogenation and cracking processing.
Decoring and cleaning castings.
Water jet cutting.
Building, bridge, highway renovations.
General high pressure cleaning
of flat surfaces,
transportation and production plants,
of the inside and outside of pipes and tanks etc.
Use only HAMMELMANN accessories designed for the maximum pressure of your high
pressure pump (unit).
If you have any questions concerning accessories or special application techniques please contact
HAMMELMANN or an accredited agent.
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5.3 General permissible operational conditions
Unless otherwise stated in writing (contractually) by HAMMELMANN the following operational conditions apply:
Use only clean medium. Any solids must not exceed a max. particle size of 10 m or a concentration of
50 mg/l. (Ensure suitable filtration is installed). Medium supply temperature must not exceed 40°C. The max.
permissible feed velocity is 1 m/sec. at a necessary admission pressure of min. 3 bar to max. 10 bar.
Before attempting to introduce any cleaning fluids obtain written approval from
HAMMELMANN!
Cleaning fluids should not attack the non-ferrous heavy metal (bronze)!
Under no circumstances introduce cleaning fluids containing Amine or Phosphate!
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Operating instructions
General
No.: HDP 502 / S 1100-50
Page 14, Issue: 03.2017
Copyright Hammelmann GmbH
Germany D-59302 Oelde Carl-Zeiss-Straße 6 - 8
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5.4 Copyright
The copyright of these operating instructions is the property of HAMMELMANN GmbH. These instructions contain
technical descriptions and illustrations that may not be electronically stored or reproduced in whole or in part or be
passed to third parties in any form whatsoever without the written permission of the owners.
We are protected by law against contravention of the above and will take appropriate action if necessary.
Pos: 20 /Allgemeines /Pumpen/5. Garantie bedingungen @ 0\m od430_2.doc x@ 45 64@ 2 @ 1
5.5 Warranty terms
Corresponding to our general business conditions we guarantee a warranty of 24 months or 2000 operating hours,
excluding normal wearing parts.
The guarantee would be invalidated if:
The equipment was used for purposes under other than our admissible conditions.
The leads at the safety organs are injured (e.g. for change of adjustments).
The high pressure pump was used with accessories or fitted with spare parts not supplied by HAMMELMANN.
If the damage is caused by:
Improper use.
Ignoring the maintenance instructions.
Use beyond the provided operative range.
Unsuitable flow medium.
Faulty installation.
Incorrectly or not professionally positioned pipe lines.
Unauthorized changes or reconstruction’s.
Cavitation
If there is the need of a Guarantee Claim Application can be demanded from HAMMELMANN.
The contents of the operating instructions and product documentation shall not become part of or
modify any prior or existing agreement, commitment or relationship. All the obligations of
HAMMELMANN result from the sale contracts which is also the complete and only valid
guaranteed rules. Any statements contained herein do not create new warranties or modify the
existing warranty.
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