Hammelmann HDP 72 High Pressure Pump Instruction Manual – Operation, Maintenance & Safety Guide PDF

Description

Hammelmann HDP 72 High Pressure Pump Instruction Manual

Full factory instruction manual for the Hammelmann HDP 72 high-pressure plunger pump, published by Hammelmann GmbH for machine number C0.01072.3344 (pump type 09.11072.1099, built in 2020, manual version 01.2020). The document takes an operator or maintenance technician through every stage of the pump’s working life — installation, first commissioning, day-to-day pressure regulation, scheduled servicing, and complete overhaul of the pump head and plunger seal set. All torque values, oil quantities, safety warnings and electrical references are reproduced exactly as printed in the original manual.

File Details

• Manual type: Instruction / operating and maintenance manual (Manuel d’instructions)
• Manufacturer: Hammelmann GmbH, Carl-Zeiss-Straße 6–8, 59302 Oelde, Germany
• Machine: HDP 72 high-pressure plunger pump
• Machine number: C0.01072.3344
• Reference number: 09.11072.1099
• Year of construction: 2020
• Manual version: 01.2020
• Original language: French
• Format: PDF
• Length: 239 pages

Chapters Covered

• Preface and general instructions
• Technical specifications — main dimensions, power data, order number, machine number
• Safety — dangers of non-compliance, responsible behaviour, personnel qualification, protective measures for the operator, specific dangers, safety during maintenance, inspection and assembly, prohibition of modification, other dangers
• Safety instructions for electric motors — general risks, intended use, transport and storage, assembly, electrical connection, operation, warranty
• General information — introduction, application range, admissible operating conditions, copyright, warranty conditions
• Transport — packaging, shipping, transport, storage
• Construction & description — HDP 72 construction, crank drive with oil circulation lubrication, sealing system, pump head, pressure regulating valve, safety rupture disc, piston cooling system, solenoid valve 04.05875.0107, electronic pressure transmitters, electronic temperature transmitter
• JetControl pump control — description, program structure, starting and stopping the high-pressure pump, general information, actual values, settings, error memory, functions
• Preparation for installation — installation, motor connection, low-pressure inlet connection, DN specification, high-pressure outlet connection, mounting pipes and cables
• Operation — pre-commissioning checks, commissioning procedure, adjusting service pressure via manual valve, pneumatic valve or engine speed
• Shutdown — decommissioning, overnight shutdown, prolonged shutdowns (15 days and more), draining water, storage, corrosion-protection filling
• Maintenance — faults and remedies, maintenance schedule, daily checks, water filter maintenance, in-service checks, compressed-air system maintenance, oil change intervals, lubrication table, maintenance operations, rupture disc replacement, pump head maintenance, seal set overhaul, bellows replacement, aramid-graphite packing installation, tightening torques
• Pressure regulating valve 00.05893.0046 — technical data, installation, adjustment, maintenance
• Safety instructions for high-pressure hoses
• Index

The manual covers the HDP 72 as a complete motor-pump unit, including the electric drive motor (AC type 250 M-4, 55 kW, 400/690 V, 50 Hz, 1500 rpm, IP 55 with three PTC thermistors), the oil lubrication circuit with filter and oil cooler, the suction chamber, the ceramic plunger seal set, the pump head with suction and discharge valves, the pressure regulating valve, the safety rupture disc, the pneumatic control circuit and the JetControl electronic control panel with its five-button LCD interface.

Technical Drawings and Component Documentation Included

In addition to the main instruction chapters, this PDF contains the complete technical appendix that ships with the HDP 72 unit:

• Main dimensions drawing (page 11) with suction connection DN 65 / PN 16
• Functional principle diagram of the pump head with suction valve, discharge valve, plunger, connecting rod and crank drive
• Exploded views and cross-sections of the crank drive (Embiellage HDP 70-2, i = 2.0385 right-hand), suction chamber, oil line, seal set, pump head, vent line, pressure regulating valve, membrane cylinder, rupture disc assembly, drive coupling and oil filter
• Electrical schematics for control unit MK SD 55 kW (drawing 48.80220.1407) — incoming power, control voltages, emergency stop circuit, star-delta motor starting, by-pass control, analogue sensor monitoring, signal exchange, PLC modules, terminal plans for strips X1, X2, X3 and X4, and the complete parts lists for the cabinet
• KTR ROTEX coupling manual (type 75) covering assembly, alignment tolerances and ATEX-relevant checks
• HYDAC in-line filter LF/LFF manual — filter sizing, element part numbers, maintenance and spare parts
• EMMEGI oil/water heat exchanger instructions — installation, water and oil circuit cleaning, selection coefficients
• BAIER + KÖPPEL gear pump service instructions (type FL 5.6 B + C) — commissioning, oil selection, filtration, troubleshooting
• Hemme Vent-1 air vent valve technical information
• Safety data sheets for the recommended lubricants (Shell Omala S4 GXV 150, Aral Konit 20W-20)
• EU Declaration of Conformity (2006/42/EC, 2014/30/EU) for the HDP 72 unit

Specifications at a Glance

• Pump type: HDP 72 high-pressure plunger pump
• Plunger diameter: 26 mm
• Maximum pressure: 650 bar
• Flow rate: 45 l/min
• Crankshaft speed: 750 rpm
• Motor speed: 1500 rpm
• Drive power: 55 kW (54 kW required)
• Pump oil: PAO VG 150, 4.3 litres
• Minimum oil pressure: 2.0 bar
• Maximum pump oil temperature: 70 °C
• Minimum feed pressure: 2.0 bar
• Maximum feed temperature: 40 °C
• Maximum filter differential pressure: 1.2 bar
• Minimum air pressure: 3.0 bar
• Pump weight: approx. 215 kg
• Pressure regulating valve: 00.05893.0046, 500 l/min (NW 17), 500–1200 bar

What This Hammelmann HDP 72 Instruction Manual Enables You to Do

With this Hammelmann HDP 72 instruction manual on hand you can install and align the pump correctly, commission it without risking cavitation or dry running, set the service pressure through the manual or pneumatic regulating valve, diagnose pressure loss, unusual noise, overheating and leaks using the fault table, replace the rupture disc, overhaul the pump head valves, rebuild the plunger seal set, replace the bellows, and carry out the oil change at the correct interval with the correct grade. It also lets you read and fault-find the JetControl panel, interpret the electrical schematics for the MK SD 55 kW control cabinet, and check the coupling, filter, heat exchanger and gear pump against their manufacturer instructions.

Correct procedures and the exact torque values, clearances and oil quantities matter on a 650-bar plunger pump: getting them wrong damages seals, valves and the crank drive, and can create a high-pressure water-jet hazard. This HDP 72 instruction manual is the reference the manufacturer expects to be followed.

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