Operating Manual: High Pressure Pump P52/54-270-30KW

Operating Manual
High Pressure Pump

P52/54-270-30KW
 Herrenknecht AG, Schlehenweg 2 Eidion: June 2004

77963 Schwanau 2, Tel. 07824 / 3020
Version: 0
Declaration of Conformity
x EC-regulation for machines (98 / 37 / EG)
x EC-regulation for low voltage (73 / 23 / EWG i.d.F. 93 / 68 / EWG)
x EMV - regulation for solenoid compatibility (93 / 97 / EWG)
x EC-regulation for high pressure vessels (97 / 23 / EG)
We herewith confirm that the following described product corresponds to the above menti-
oned regulations because of its conception and construction as well as the carrying out
which is put into circulation by us.
The maintenance schedule is to be followed.
This declaration losses its validity, if a change, repair or overhaul is performed without our
agreement.
Designation of the product High Pressure Pump P52/54-270-30KW

Drawing number 809-20-000-10
Part number 30039109
Year of construction ---
Used harmonized standards:

prEN 12336, Tunnelling machines - safety requirements
DIN EN ISO 12100-T1 and T 2, safety of machinery - basic concepts, and general
principles for design
EN 60 204-1, safety of machinery - electrical equipment
Used national standards and technical specifications
Schwanau
Place PPA. Uwe Breig
Technischer Leiter
BU Utility Tunneling
Sitz der Gesellschaft : Vorsitzender des Aufsichtsrates : Dr. h.c. Lothar Späth
Telefon 07824 - 3020 Schlehenweg 2, Vorstand : Dr. Ing. E.h. Martin Herrenknecht, Vorsitzender
Telefax 07824 - 3403 77963 Schwanau Dipl. Ing. Gebhard Lehmann, Stellvertreter
e-mail : info@herrenknecht.de Registergericht : Lahr HRB 485 Dipl. Ing. Werner Suhm
Betriebswirt ( VWA ) Kurt Stiefel
B:\02-PROJEKTE\Pro_2007\M-1212M_M-1213C\Konfis\Konfi_EN\Konformitätsererklärung_VTM.fm
High Pressure Pump P52/54-270-30KW
Overview Operating Manual
I) Introduction, Safety Instructions
II) Technical Data, Technical Descritption
III) Transport, Connecting
IV) Commissioning, Operation, Trouble Schooting
V) Maintenance, Repair, Storage
VI) Drawings and Part Lists
VII) Diagrams and Part Lists
© Herrenknecht AG, Schlehenweg 2 Edition: June 2004

77963 Schwanau 2, Tel. 07824 / 3020 Version: 0
Overview Operating Manual
Edition: June 2004 © Herrenknecht AG, Schlehenweg 2

Version: 0 77963 Schwanau 2, Tel. 07824 / 3020
1 Introduction................................................................................. 1 - 1
1.1 General Information .................................................................................... 1 - 1
1.2 Information about High Pressure Pump.................................................... 1 - 2
1.2.1 Structure of the Operating Instructions.......................................................... 1 - 2
1.3 Guaranty....................................................................................................... 1 - 3
1.4 Exclusion of Liability................................................................................... 1 - 4
1.5 Environmental Acceptability ...................................................................... 1 - 4
1.6 Copyright Protection ................................................................................... 1 - 5
2 General Safety Instructions....................................................... 2 - 1
2.1 Intended Use ................................................................................................ 2 - 1
2.2 Use and Application .................................................................................... 2 - 1
2.3 Explanation of Symbols .............................................................................. 2 - 2
2.4 Directions for Use Safety Outfit ................................................................. 2 - 3
2.5 Special Symbols .......................................................................................... 2 - 4
2.6 Emergency-Stop and Safety Checks ......................................................... 2 - 5
2.7 Requirements to Operating Personnel ...................................................... 2 - 6
2.8 Operators Engagement ............................................................................... 2 - 8
2.9 Safety for the Operating Personnel ........................................................... 2 - 9
2.10 Allgemeine Sicherheitshinweise für den Betreiber / Bediener ............... 2 -10
2.11 Sicherheitshinweise für Wartungs-, Inspektions- und Montagearbeiten 2 -11
2.12 Electrical Energy ......................................................................................... 2 -13
2.12.1 Electric and Steering Cables ......................................................................... 2 -14
2.13 Oil, Grease and other Chemical Substances ............................................ 2 -14
2.14 Gas, Dust, Steam, Smog ............................................................................. 2 -15
2.15 Safety Equipment ........................................................................................ 2 -16
2.15.1 First aid equipment ........................................................................................ 2 -16
2.15.2 Fire protection................................................................................................ 2 -16
2.16 Reaction when recognize a Danger ........................................................... 2 -17
2.16.1 Rescue of People, First Aid ........................................................................... 2 -17
2.16.2 Fight against Fire........................................................................................... 2 -17

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3 Additional Safety Instructions .................................................. 3 - 1

3.1 Security and Safety Equipment at the VTM/VTA....................................... 3 - 1
3.1.1 Symbols Located at the VTM/VTA ................................................................. 3 - 1
3.2 Warning Signals during Operation of the High Pressure Pump.............. 3 - 1
3.3 Safety Installations ...................................................................................... 3 - 1
3.3.1 Emergency-Stop Buttons ............................................................................... 3 - 1
3.3.2 Additional Information .................................................................................... 3 - 2
3.5 Operation at Temperatures below Zero ..................................................... 3 - 3
3.5.1 Start-up at Temperatures below Zero ............................................................ 3 - 3
3.5.2 High Pressure Pump ...................................................................................... 3 - 3

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Introduction
1 Introduction
1.1 General Information
Before the first putting into operation of the high pressure pump read this
operating manual thoroughly to become acquainted with the tunnelling
equipment and to use it as directed. Observing them helps to avoid risks,
reduce repair costs, downtime and increase reliability and working life of
high pressure pump.
The operating manual contains important references for a safe and proper
operation and maintenance of the high pressure pump.
This operating manual complies with the demand of The
European Union, in particular EG directive 98/37/ EG.
This operating manual is a part of the complete technical documentation.

Ensure that all safety conditions are fulfilled before putting the tunnelling
equipment into operation.
Any work on and with the high pressure pump, shall be executed by
qualified and trained personnel. Statutory minimum age shall be observed.
It is not possible to fulfill guaranty in accordance with our delivery contract
if maintenance work is neglect or improper.
Only original spare parts of Herrenknecht AG ensure quality and
replacement.
All technical information, data and references included in this operating
manual have been updated at the time of going to press and result from our
present and previous experiences and realizations to the best of our
knowledge.
CAUTION
We are not liable for damages and malfunction
resulting from operating faults, non-observance of
this operating manual or improper maintenance. We
explicitly point out that only original spare parts and
original accessory parts released by us shall be used.
WARNING
Pay attention to the following chapters „General
Safety Instructions and Additional Safety
Instructions“ to ensure health of machine operators
and maintenance personnel and the function of the
equipment.
Non observance of these instructions may endanger
manufacturer’s guarantee and liability.

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Introduction
1.2 Information about High Pressure Pump
Project: ---
Year of
Type: AVN
construction
Manufacturer: Herrenknecht AG
High Pressure Pump Part No. 30039109 ---
Operating manual
May 2004
edition:
Version: 0
1.2.1 Structure of the Operating Instructions

Main Parts
• These operating instructions consist of 8 main parts.
Chapters
• Each main part is preceded by a table of contents for the individual
chapters.
Pages
• The pages of each chapter are numbered consecutively.
Example:
I -4 -2
I = Main part
-4 = Chapter
-2 = Page
In main part I chapter 2 "General Safety Instructions" the main points

for accident prevention and environmental protection are summed up. Main
part I chapter 2 is a general part. It contains no information about special
machines.
Illustrations
The illustrations in these operating instructions are intended to clarify the
text passages. They may differ from the actual execution of the machine
without fundamentally altering the factual information.
Modifications
Important modifications to the standard specification of the machine will
be incorporated in each new edition of the operating instructions.

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Introduction
1.3 Guaranty
This operating manual contains all required references and shall be
carefully read prior to commissioning of the high pressure pump. We are not
liable for damages and malfunction resulting from non-observance of
operating instructions.
The guaranty expires e.g. in case of:
• improper use
• non-use of original spare parts and original accessory parts
• conversions unless co-ordinated with Herrenknecht AG.
CAUTION
Original parts and system components are especially
designed for AVN tunnelling equipments:
We explicitly remind you, that a faultless function of
the tunnelling equipment can only be guaranteed, if
the equipment is used with original parts and system
components of Herrenknecht AG.
Herrenknecht AG can not be held liable for any
damages and/or malfunctions resulting of the use of
non-original parts and system components.

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Introduction
1.4 Exclusion of Liability

All technical information, data and references included in this operating
manual have been updated at the time of going to press and result from our
present and previous experiences and realizations to the best of our
knowledge.
We reserve the right to all technical changes which may emerge within the
range of the further development of the assemblies mentioned in this
operating manual. Therefore no claims may be derived from the information,
illustrations and descriptions given in this operating manual.
We are not liable for damages and malfunction resulting from operating
faults, non-observance of this operating manual or improper maintenance.
We explicitly point out that only original spare parts and original accessories
released by us shall be used.
For safety reasons, assembly or use of unreleased spares or accessories
and all arbitrary conversions and changes are not permitted and exclude
any liability of Herrenknecht AG for resulting damages.
Translations are carried out to the best of our knowledge. We are not
liable for any occuring translation faults, not even if the translation was
carried out by us or by our order. Obligatory with only the original
text.Environmental Compatibility.
1.5 Environmental Acceptability

• The national and communal legal instructions for environmental
protection shall be observed.
• Internal regulations shall take into account producer instructions.
• As a rule, never remove any operating and auxiliary material into
canalization, soil or waters.
• To prevent any pollution of the ground water, only biologically
degradable oil shall be used.
• Discarded exchange parts shall be appropriately disposed of.

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Introduction
1.6 Copyright Protection

This operating manual shall be treated confidentially. It is to be used by
authorized personnel only. They may only be passed on by written approval
of Herrenknecht AG. All documents are protected within the meaning of the
copyright law. A passing on as well as copying of documents, even partially,
use and information as to contents is not permitted unless explicitly
admitted. Violations are illicit and liable for damages. We reserve all rights
to exercise industrial patent rights.
Company address:
Herrenknecht AG
Schlehenweg 2
D-77963 Schwanau
Germany
Tel. (0049) 7824/302-0
Fax (0049) 7824/4355

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Introduction

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General Safety Instructions
2 General Safety Instructions

2.1 Intended Use
Only intended use ensures safety in operation of high pressure pump.
Intended use exits only employing the high pressure pump as described
in section „Use and Application“. A different or exceeding use is considered
contrary to this designation. The producer can not be held liable for any
resulting damage. The operating company alone bears the risk.
Intended use includes also observing the operating instructions as well as
observing inspection and maintenance instructions.
2.2 Use and Application

The high pressure pump has been designated for producing high pressure
water for the high pressure nozzles of tunnelling machine’s cutting heads.
The high pressure pump has been constructed in accordance with state-
of-the-art technique and the acknowledged safety requirements. Its use
may yet be a danger to life and limb of operating personnel or any third
party or may result in impairment of the high pressure pump and other
material assets
There fore the high pressure pump shall only be used in technically
faultless condition and only in accordance with its designated use. The
personnel must be aware of safety regulations and risk prevention and must
observe all operating instructions. Any malfunctions or faults, especially
those affecting the safety of the high pressure pump, shall be immediately
repaired.
The use of high pressure pump is not allowed:

• in faulty condition,
• without mounted safety devices,
• with defective or for the working pressure not permissible hydraulic
hoses
• unauthorized changes and conversions of the high pressure pump.

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2.3 Explanation of Symbols

In this operating manual the following symbols and notes warn against
possible damage of persons or property or refer to working aids:
DANGER
Indicates death, severe personal injury in case of
non-observance of instructions.
WARNING
Warning in case of non-observance of instructions
may be a risk of personal injury or substantial
damage to the equipment or damage of particular
assemblies.
CAUTION
Warning in case non-observance of instructions may
lead to damage of the equipment or damage of
particular assemblies.
DANGER
Warning of dangerous electrical voltage.
NOTE
Important or additional information concerning machine or
documentation.
Instructions attached directly to the high pressure pump must always be

complied with and be kept in perfectly legible condition at all times.

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2.4 Directions for Use Safety Outfit

In this manual occuppations which require the wearing of safety outfits are
marked with the signs shown below.
Wear safety goggles Wear safety helmet
Wear ear protection Wear safety gloves
Wear safety shoes Wear safety clothing
Waer face screen Wear respirator

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2.5 Special Symbols

In this manual occuppations which expose particualr risks are marked with
the signs shown below.
Falling loads Danger of slipping
Falling tools Danger of falling
Hot surfaces Danger of stumbling
Hot liquids Danger of hand injuri
Laser beams Danger of squeezing
Ban on smoking Ban on open fire

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2.6 Emergency-Stop and Safety Checks

Check daily all
• Emergency Stop buttons
• safety equipment
see also chapter special safety instructions.

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2.7 Requirements to Operating Personnel

• Any work on and with the high pressure pump shall be executed by
reliable and qualified persons only. Statutory minimum age limits shall be
observed.
• Each person in charge with transport, assembly, commissioning,
operation, maintenance, and repair work shall have thoroughly read and
understood
• the operating manual,
• the safety instructions and
• the safety regulations of particular chapters and paragraphs.
• Individual responsibilities of personnel for operation, set-up, maintenance
and repair shall be clearly determined.
• Make sure that only authorized personnel work on the high pressure
pump.
• Define the responsibility of the machine operator. He shall be given the
authority to refuse instructions by any third party which are contrary to
safety.
• Persons to be trained shall only work on the high pressure pump while
being permanently supervised by an experienced person.
• Any work on the electrical system of the high pressure pump shall only
be carried out by a skilled electrician.
It is required that the electrical plant is commissioned, maintained and
repaired by qualified personnel and that these activities are supervised
and controlled by responsible specialists. Qualified personnel are
persons who have been authorized by the person responsible for the
safety of the plant because of their education, experience and training as
well as their knowledge of standards, regulations, conditions at work and
accident prevention regulations, to carry out all required activities and to
recognise and avoid all possible risks.
• The prohibition of employment of non-qualified persons working on
highvoltage installations has been settled by standard IEC 364.
• Only persons with a special knowledge and experience in hydraulics may
carry out works on hydraulic installations.

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Occupation
compressed air regulation

Putting into operation
hydraulic equipment
electrical equipment
Trouble searching
Trouble shooting
Trouble shooting
Trouble shooting
Trouble shooting
Maintenance
mechanical
Operation
Transport
Disposal
Repairs
Machine operator
Skilled mechanics
Skilled electrician
Personal which is special trained

to hydraulic
Personal which is special trained
to compressed air
Superiors with corresponding
competence

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2.8 Operators Engagement

• The complete operating manual must always be at hand in the control
container of the high pressure pump.
• In addition to the operating instructions the operating company of the
high pressure pumpshall observe all statutory or otherwise obligatory
regulations for accident prevention and environmental protection and
must instruct operating personnel accordingly. See these additions as a
part of this manual and observe them.
• The operating instructions shall be supplemented by instructions
including supervising and reporting duties, working procedures and
information about operating personnel employed.
• The operating personnel must have read the operating manual, in
particular the chapter dealing with health, safety and welfare
requirements, prior to work starting.
• Make known all security installations, their function and operation.
• Regularly check whether operating personnel are carrying out the work
in accordance with operating instructions and are observing risk and
safety factors.
ATTENTION
Pay attention to all the local regulations of tunnelling,
prevention of accidents, electric and environmental
regulations and other necessary regulations.

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2.9 Safety for the Operating Personnel

The following personal safety outfit must be worn when working:
Safety helmet Safety shoes
Safety gloves Safety clothing
Ear protection
On principle in all areas of the high pressure pump

• Wear only close-fitting safety clothing. Put neckerchief or scarfs inside
clothing.
• Long hair shall be secured in a hair-net.
• Wear no jewelry, including rings.
• When carrying out activities which require further safety outfit in
accordance with accident prevention regulations, e.g. glasses,
respiratory protection mask etc. must be worn.
• All signs, attached to the high pressure pump, orders or prohibitions must
be observed by all means.
• It shall be guaranteed that all requirements to operating personnel
settled in this operating manual and in the operating instructions of the
producers of particular units and machine parts (see appendix) are
fulfilled.

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2.10 General Safety notes for the Operator
DANGER
High pressure pumps and high pressure systems are
under pressur during operation.
Keep away in safe distance.
• Secure hot or cold equipment part against contact. This must be

provided by costumer.
• Protection against contact of moving parts (e.g. coupling) must not be
removed during operation.
• Observe legal requirements.
• Eliminate electrical danger ( see according regulations, e.g. VDE or local
power companies).

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2.11 Safety Instructions for Personnel for Maintenance, Inspection and

Installation
DANGER
High pressure water from the nozzles can lead to
heavy injury.
Do not carry out cleaning works during test run.
Keep away from the cutting head of the tunnelling
machine during test run.
• The maintenance works may only be executed by instructed persons

with the corresponding special knowledge (see „Requirements to
Operating Personnel“) .
• Observe terms for inspection and maintenance activities including
information about exchange of subassemblies or components in
accordance with operating instructions.
• Before starting special and maintenance works nominate a supervisor
and give information to the operating personnel.
• Use producer-released original spare parts and original accessory parts
only.
• Use appropriate equipment and material only (grease, oil, detergents).
• Secure maintenance area spacious if necessary.
• In case the high pressure pump has been completely stopped for
maintenance and repair works, it must be secured against unexpected
restart.
• In case a motor has been stopped for maintenance and repair work, it
must be secured against restart.
• Use appropriate ladders or lifting platforms when carrying out
maintenance works on places which are higher than your body.
• Working in high areas use appropriate safety equipment such as safety
belts or stages.
• Clean machine parts, especially connections and screw fittings, prior to
maintenance activity. Never use any aggressive detergents. Use lint-free
cleaning rags.
• Before cleaning the machine with water, high-pressure cleaner or other
detergents, cover or tape up all openings which - for safety or functional
reasons - must be protected against penetration of liquids and
detergents. Special care must be taken with electrical motors and
switchgear cabinets.
• After cleaning, completely remove all covers and tapes.

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• Always tighten bolted connections loosened during maintenance work

using the appropriate torque setting.
• Clean all handles, steps, handrails, platforms, landings and ladders after
maintenance work.
• Any safety installations removed for set-up, maintenance or repair work
must be reassembled and checked immediately, having completed all
works.
• Before starting work on lines which may be under pressure (e.g. feed-
and slurry lines, hydraulic lines, compressed air lines or oxygen lines)
ensure that the lines are depressurized. Stop pumps or compressor and
secure against unexpected restart.
• Pressure in a line may be the cause of a hydraulic cylinder, a pressure
accumulator or other components under load. Secure hydraulic cylinder
and other components under load against move and depressurize the
pressure accumulator.
• Secure heavy machine parts against tip over and fall down before
remove screws and bolts.
• Keep switch gear cabinets closed. Open only the necessary door for
maintenance works. Close open doors at once when leaving working
place or when maintenance work is finished.
• Ensure that all operating and auxiliary material as well as exchanged
replacement parts are disposed of safely and with minimum
environmental impact.

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2.12 Electrical Energy
DANGER
Before starting the high pressure pump must be
grounded appropriately
DIN 100 / VDE 0100 PART 410 and
DIN 100 / VDE 0100 PART 540!
CAUTION
Check that contact screws are firmly fixed before
putting the equipment into operation.
• Work on the electrical system or equipment may only be carried out by a

professional electrician.
• Secure working area with a red-white safety chain and a warning sign.
Use insulated tools only.
• Observe valid accident prevention measures when carrying out works on
live appliances (e.g. VBG4).
• Necessary works on live parts shall only be carried out in the presence of
a second party to cut off power supply by operating the emergency stop
switch or main switch in case of emergency. The second party must be
familiar with resuscitation measures.
• The electrical equipment shall be inspected and checked in regular
intervals. Defects such as loose connections or scorched cables must be
immediately repaired.
• Handle appliances in a way that no construction elements are deformed
and/or insulation clearances changed.
• Avoid any contact with electronic construction elements (static
discharge!).
• Use an appropriate measuring instrument with an internal resistance of
at least 10 kW for measurements of signal voltages.
• Components on which inspection, maintenance and repair work is to be
carried out must be stopped if appropriate. Before starting any work,
check whether de-energized parts are voltage-free.

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• Use only original fuses with the specified current rating, to immediately
stop the tunnel-boring machine in case of any problems with the
electrical energy supply.
• Before starting works on high-voltage assemblies and after cutting off the
power supply, the feeder must be grounded and components, such as
condensers, must be short-circuited by a grounding rod.
• Never modify the electrical plant without consultation of Herrenknecht
AG and the written approval of Herrenknecht AG.
2.12.1 Electric and Steering Cables
DANGER
Ensure there are no current flowing through the
cables before you disconnect them.
Danger: Electrical voltage!
2.13 Oil, Grease and other Chemical Substances

• When handling oil, grease and other chemical substances, observe the
product-related safety instructions.
• Be careful when handling hot operating and auxiliary material (risk of
burning or scalding).
• Due to increased danger from fire anf slippery surfaces, clean oil and
grease from surfaces immediately.
WARNUNG
Be careful when handling hot operating and auxiliary
material.
Risk of burning or scalding.
Use safety outfit.

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2.14 Gas, Dust, Steam, Smog
CAUTION
There is unrestricted ban on smoking.
• During welding, grinding and torch works ther is fire and explosion
hazard. Because of that it is essential to provide the accorsing fire fight
mediums during such works and to nominate a supervisory person, who
initiate the required measures if required.
• Before welding, grinding and torch works clean the parts that have to be
machined and their surrounding of dust and other combustble mediums
and provide for sufficient ventilation.
• During weldingworks electrode holder and earth have to fit on the same
component part in distance as short as possible.
• By operation in crowded rooms consider the national rules.

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2.15 Safety Equipment

2.15.1 First aid equipment
It is customers responsibility to provide safety and first aid equipment such
as safety helmet, first aid box and stretcher etc. This equipment has to be
available in the job site office or control container.
CAUTION
Safety and first aid equipment have to be checked
weekly for orderly function and completeness.
Safety and first aid equipment have to be ready on
hand every time.
2.15.2 Fire protection

Two types of fire extinguishers may be used at the high pressure pump:
Powder or CO2 fire extinguishers.
Fire extinguishers have to be installed by the customer

and their location have to be signed. Ensure maintenance
and inspection of the fire extinguishers within the pre-
scribed time limit.

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2.16 Reaction when recognize a Danger

When recognize any danger stop the high pressure pump using the next
emergency stop button.
2.16.1 Rescue of People, First Aid

Pay attention to your self protection when carrying out first aid. Call a
doctor at once.
2.16.2 Fight against Fire

• Extinguishing fire at the hydraulic system use only fire extinguishers
which are permissible to hydraulic fire.
• Extinguishing fire at the electrical system use only fire extinguishers
which are permissible to electrical fire.

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Additional Safety Instructions
3 Additional Safety Instructions

3.1 Security and Safety Equipment at the VTM/VTA
3.1.1 Symbols Located at the VTM/VTA
Fire Extinguisher
First Aid Located at all
Located at all places where a fire
places where First- extingusher is
Aid-Equipment is installed. This sign
installed. must be positioned
from the customer.
Ban on Smoking Electrical Voltage

At the entire Located at all
equipment. electrical cabinets.
3.2 Warning Signals during Operation of the High Pressure Pump

• Faults of the pump are shown by illumination of a red lamp.
3.3 Safety Installations

Never manipulate
• EMERGENCY-STOP Installations
• Other safety installations such as pressure relieve valves, overload
protection of electric motors etc.
3.3.1 Emergency-Stop Buttons

The equipment can be stopped by "EMERGENCY-STOP" - button on the
following points:
• remote control
• control tableau at the switch gear cabinet

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3.3.2 Additional Information

• All electric lines and Electric motors have to be protected against
overload and short-circuit. The adjusted values must not be changed.
• The operator of the tunneling equipment is responsible for power supply
and industrial-/cooling water supply (max 20°).

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3.4 Special Risks at the VTM/VTA

• In principal it is not allowed to cross any kind of barriers. If crossing is
necessary to carry out maintenance works use appropriate safety
equipment such as safety belts or stages or shut down tunneling
equipment.
• Pay attention to the special safety rules for cranes and hoist units.
• Never work or stand under suspended loads.
3.5 Operation at Temperatures below Zero

Operation at temperatures below zero or if temperature will fall below
zero.
3.5.1 Start-up at Temperatures below Zero

• Inside temperature of switchgear cabinet has to average +10° C.
3.5.2 High Pressure Pump

• Completely drain, thoroughly insulate or heat the high pressure lines and
the high pressure pump.

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1 Technical Data ............................................................................ 1 - 1

2 General Information ................................................................... 2 - 1

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Technical Data
1 Technical Data
High Pressure Pump P52/54-270-30kw-PN270-1-O
Electric motor
Drive power 30 kW
Voltage 400 V
Frequency 50 Hz
Speed 1000 min-1
Weight approx. 265 kg
Plunger pump
Maximum presssure 270 bar

Maximum output 53 l
Maximum water temperature 60 °C
Transport Dimensions
Length L 1350 mm
Width B 800 mm
Height H 1285 mm

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Technical Data

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General Information
2 General Information
The high pressure pump is a completely mounted attachement consisting
of a pump, drive motor with coupling and coupling protection, base frame.
electric switch gear cabinet, water filter, ball valves, pressure gauges and
unloader valve.
This high-pressure pump is designed for use with the AVN/AVT range of
equipment to deliver high pressure water jetting to assist in the production
rate of the machine in various ground conditions.
The high pressure pump has been constructed in accordance with state-
of-the-art technique and the acknowledged safety requirements. Its use
may yet be a danger to life and limb of operating personnel or any third
party or may result in impairment of the high pressure pump and other
material assets
There fore the high pressure pump shall only be used in technically
faultless condition and only in accordance with its designated use. The
personnel must be aware of safety regulations and risk prevention and must
observe all operating instructions. Any malfunctions or faults, especially
those affecting the safety of the high pressure pump, shall be immediately
repaired.

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General Information

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1 Transport..................................................................................... 1 - 1
1.1 Safety Instructions ...................................................................................... 1 - 1
1.1.1 Lifting Points .................................................................................................. 1 - 2
1.1.2 Table of Load Carrying Capacity in kg .......................................................... 1 - 3
1.2 Transport and Installation of the High Pressure Pump ........................... 1 - 4
1.3 Particular Risks ........................................................................................... 1 - 5
1.3.1 Remove Package .......................................................................................... 1 - 5
1.3.2 Cleaning bright Steel Surfaces ...................................................................... 1 - 5
2 Connecting.................................................................................. 2 - 1
2.1 Electrical Connection.................................................................................. 2 - 1
2.2 Water Connecton......................................................................................... 2 - 2

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III - 0 - 2 77963 Schwanau 2, Tel. 07824 / 3020
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Transport
1 Transport
1.1 Safety Instructions
DANGER
Prior to lifting any section of the machine, the site
operator must ensure the lifting equipment used is
safely installed on firm ground, with adequate
capacity to lift the required load and all site safety
precautions are observed.
• Principally observe safety warnings of the producer prior to

commissioning of lifts and hoist plants.
• When exchanging heavy machine parts, see to it that they are carefully
fastened to lifts and secured.
• Use only appropriate and technically faultless hoists as well as load
carrying devices with a sufficient capacity.
• Reliably secure loads.
NOTE
Dimensions and Weights see technical data.
• Order only experienced personnel to deal with the slinging of the loads.
DANGER
Never work or stand under suspended loads.

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Transport
DANGER
Improper slinging of loads, damaged ropes, chains
and slings may cause serious accidents.
CAUTION
Wear your personal safety
equipment during all
transportation work.
1.1.1 Lifting Points
DANGER
Fix lifting equipment only to the designated lifting
points (red-marked).
Using other lifting points may result in parts falling off

the equipment.
Not using the designated lifting points may also result
in exclusion of liability.
Use only suitable lifting points for transport of the equipment. All lifting
points are marked red.

III - 1 - 2 77963 Schwanau 2, Tel. 07824 / 3020
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Transport
1.1.2 Table of Load Carrying Capacity in kg

multi-rope slinging chain DIN 5688 - 8 grade 8 (Grade 80)
2- cords 4- cords
tunnelling machine with 2 e.g. Container, settlement
suspension brackets tank, jacking frame
tunnelling machine with 4
suspension brackets
angle of inclination β 0 - 45° 45 - 60° 0 - 45° 45 - 60°
capacity factor 1,4 1 2,1 1,5
chain - nominal diameter in mm The specified values obtain to symmetrical load
6 1400 1000 2100 1500
7* 2200 1600 3300 2400
8 2800 2000 4250 3000
10 4500 3200 6700 4750
13 7100 5000 10000 7500
16 11200 8000 17000 11800
18 14000 10000 21200 15000
19* 16000 11300 24000 17000
20 18000 12500 26500 18000
22 21200 15000 32000 22400
26 28000 20000 40000 30000
32 45000 32000 63000 47000
*chains - nominal diameter, not standard
NOTE
The length of the chains must be selected to reach an
angle of inclination "β" between 0 and 45 degrees.
The best security will be reached using an angle of
inclination "β" between 0 and 45 degrees.

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Transport
1.2 Transport and Installation of the High Pressure Pump
NOTE
Only suspend the high pressure pump at the designated
suspension shackles.
CAUTION
Pay ateention to the high pressure pump to be
installed horizontal and on surface stable in
accordance with the operating loads.
The pump always has to be installed stable and
secure.

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Transport
1.3 Particular Risks

1.3.1 Remove Package
Parts of the High Pressur pump are packed in wooden boxes. Remove
packaging at job site. Secure producing nails.
Job site takes the responsibility for dumping or reuse the wood.
1.3.2 Cleaning bright Steel Surfaces

If bright steel surfaces are protected with preservation wax, clean them
with thinners and cloths. Pay attention to sufficient ventilation.
Collect used cloths and dispose of it in accordance with the environmental
regulations.
WARNING
Hazardous gases are expected, when working with
thinners.
Wear safety outfit such as safety goggles, safety
gloves, safety shoes, safety clothing and respirator
when working with thinners.

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Transport

III - 1 - 6 77963 Schwanau 2, Tel. 07824 / 3020
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Connecting
1 Connecting
1.1 Electrical Connection
DANGER
Work on the electrical system and equipment of the
high pressure pump may only be carried out by a
skilled electrician or by instructed personnel under
the supervision and guidance of a skilled electrician
and in accordance with electrical engineering rules
and regulations.
Before starting the equipment take a measurement of
insulation of the main switch cabinet and the lead!
Pay attention to national rules.
DANGER
Faulty connections endanger the electrical and
electronic equipment as well as increasing the risk of
accident for personal.
CAUTION
Check direction of rotation of pumps and electric
motors.
Wrong direction of rotation can destroy the
components.
• The pump must be supplied by a suitable electric power pack.

• Dimensions of the connection cable in accordance with the nominal
current of the motor (see connection cable and plug installed at the
pump).

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Connecting
1.2 Water Connecton

• For operating the pump clean water (quality of drinking water) is
required.
DANGER
On no account may inflammable or explosive media
be pumped.
• The supply lines have to be sufficiently calculated and should have a

flexible part to compensate vibrations of the unit.
• Check the pre-pressure, too.
CAUTION
Guarantee that there is enough water for operating
the pump.
Hoses that are too small cannot supply enough water
to the pump.
Formation of air bubbles in the lines of the pump and
cavitation can occur.
DANGER
Cavitation and/or compression of gases lead to
uncontrollable pressure-kicks which can ruin pump
and unit parts and also be dangerous to the operator
or anyone standing nearby.

III - 1 - 2 77963 Schwanau 2, Tel. 07824 / 3020
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IV) Commissioning Opertion, Trouble Shooting
1 Operating Elements, Alarm and Indicating Devices ............... 1 - 1

1.1 Gear Switch Cabinet.................................................................................... 1 - 1
1.1.1 Tableau Switch Gear Cabinet........................................................................ 1 - 1
1.2 Remote Control............................................................................................ 1 - 3
1.2.1 Tableau Remote Control ............................................................................... 1 - 3
2 Commissioning........................................................................... 2 - 1
2.1 First Commissioning ................................................................................... 2 - 1
2.1.1 Power supply ................................................................................................. 2 - 1
2.1.2 High Pressure................................................................................................ 2 - 1
2.2 Commissioning............................................................................................ 2 - 2
2.2.1 Putting in Operation Crew ............................................................................. 2 - 2
2.2.2 Test run ......................................................................................................... 2 - 2
2.3 Daily Commissioning .................................................................................. 2 - 3
3 Operation..................................................................................... 3 - 1
3.1 Operating the High Pressure Pump ........................................................... 3 - 1
3.2 Operation during Pipe Change................................................................... 3 - 1
3.3 Decommissioning........................................................................................ 3 - 1
4 Trouble Shooting........................................................................ 4 - 1

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IV - 0 - 2 77963 Schwanau 2, Tel. 07824 / 3020
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Operating Elements, Alarm and Indicating Devices
1 Operating Elements, Alarm and Indicating Devices

1.1 Gear Switch Cabinet
1 Main Switch
2 „Emergency-Stop“
3 Pump On
4 Pump Off
Remote Control /
5
Switch Gear Cabinet
6 Fault Phase Sequence
7 Fault Temperature
8 Fault Water Pressure
1.1.1 Tableau Switch Gear Cabinet
Function
Pos.1:
Turn to ON to switch on the main supply voltage.
Turn to OFF to switch off the main supply voltage.
CAUTION
The main switch is equipped with a locking to prevent
unintentional restart of the pumpduring repair or
maintenance works.
Turn the main switch in position OFF and install a
padlock.
The key of the padlock has to be removed and carried
by the maintenance personnel.

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Function
Pos. 2:
By pressing the emergency stop button, all equipment
will be stopped.
Twist to reset before attempting to start again.
Check daily to correct function.
Pump ON Pos. 3:
Press push button to switch on the high pressure pump.
Button illuminates during operation.
Pump OFF Pos. 4:

Press push button to switch off the high pressure pump.
Button illuminates when an error occurs.
Intern / Extern Pos. 5:

Turn in position Intern: The high pressure pump can be
controlled from switch gear cabinet tableau.
Turn in position Extern: The high pressure pump can be
controlled from remote control tableau.
Fault Phase Pos. 6:

Sequence Illuminates when direction of rotation of the motor is
wrong.
Fault Pos. 7:
Temperature Illuminates when temperature is wrong.
Fault Water Pos. 8:

Pressure Illuminates when water pressure is too high.

IV - 1 - 2 77963 Schwanau 2, Tel. 07824 / 3020
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1.2 Remote Control
1 „Emergency-Stop“
2 Fault Temperature
3 Fault Pump
4 Operation Pump
5 Pump off
6 Pump on
1.2.1 Tableau Remote Control
Function
Pos. 2:
By pressing the emergency stop button, all equipment
will be stopped.
Twist to reset before attempting to start again.
Check daily to correct function.
Fault Pos. 7:
Temperature Illuminates when temperature is wrong.
Fault Pump Pos. 3:

Illuminates when pump has a fault.
Operation Pos. 4:
Pump Illuminates when pump is in operation.

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Function
Pump on Pos. 5:
Press push button to switch on the high pressure
pump.
Button illuminates during operation.
Pump off Pos. 6:

Press push button to switch off the high pressure
pump.
Button illuminates when pump has a fault.

IV - 1 - 4 77963 Schwanau 2, Tel. 07824 / 3020
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Commissioning
2 Commissioning
2.1 First Commissioning
NOTE
See every new job site using this tunneling equipment as
first commissioning.
Therefore at every new job site pay attention to this
chapter.
2.1.1 Power supply

• Take care that the necessary power supply for the tunneling equipment
is secured.
• Check for correct voltage.
• Take care that the necessary cable dimension are kept.
• Check all signal and supply cables for correct connection and damages.
Change damaged cables.
• Check all fuses and Emergency stops for a correct function.
2.1.2 High Pressure

• Check direction of rotation of electric motors.
• Check screw joints and hydraulic lines for tightness.
• Check hoses to be not stressed to torsion and tension
• Check to required oil level
• Check to troublefree water supply
• All parts on the pressure side of the unit are vented, with pressure at
zero
CAUTION
Before commissioning the shut-off devices of the
suction and pressure lines have to be opened (vent
the unit).

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Commissioning
2.2 Commissioning
2.2.1 Putting in Operation Crew
• For safety there should only people stay in that area who are directly
concerned with putting the equipment into operation.
CAUTION
It has to be ensured that all people are teached about
possible risks, when they are present in the area of
putting the equipment into operation.
CAUTION
High pressure water from the nozzles can lead to
heavy injury.
Do not carry out cleaning works during test run.
Keep away from the cutting head of the tunnelling
machine during test run.
2.2.2 Test run

Before starting a test run, the following things should once again be
inspected:
• All parts cleaned and neatly assembled?
• Equipment secure and horizontal installed?
• All connections firmly tightened and all devices correctly connected
according to the hydraulic diagram?
• Driving motor and pump correctly connected? (Observe the direction of
rotation of the pump.)?
• Prescribed filters correctly installed in the direction of flow?
During test running pay attention to the following:

• Monitor control and measuring instruments.
• Listen for noises

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Commissioning
CAUTION
After switching on the pump check the direction of
rotation of the motor and the operation conditions.
Monitor the pressure build-up at the pressure gauge.
2.3 Daily Commissioning
NOTE
Putting the equipment into operation after pipe changing
is also part of the daily commissioning.
Before work begins, carry out the following checks:

• Check all signal and supply cables for correct connection and damages.
Change damaged cables.
• Check all fuses and Emergency stops for a correct function.
• Check screw joints and hydraulic lines for tightness.

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Commissioning

IV - 2 - 4 77963 Schwanau 2, Tel. 07824 / 3020
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Operation
3 Operation
3.1 Operating the High Pressure Pump
• Open the ball valve of the supply line.
• Fill up the water filter and the lines with water. Check all lines to be
vented.
• Switch on the high pressure pump by pressing the START-button at the
switch gear cabinet tableau.
After reaching the initial pressure the discharge valve can be opened.
3.2 Operation during Pipe Change

• Close the discharge valve. Because of increase of pressure in the lines
the unloader-valve switches to by-pass function.
If there is a longer standstill the pump will be switched off by a
temperature switch to prevent overheating of the electric motor and the
pump.
3.3 Decommissioning
• Switch off the power supply
• Open shut-off devices and blow off the pressure from system.

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Operation

IV - 3 - 2 77963 Schwanau 2, Tel. 07824 / 3020
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Trouble Shooting
4 Trouble Shooting
The following list does not claim completeness. The cause for malfunction
occurring most commonly in practice are included in this list.
Problem Cause Procedure

Pump will not operate • Motor is verloaded and the • Check motor and operating
motor protection switch or coil conditions
earthing contact activated. • Start the unit without load/
• Pump works against closed pressure
valves
Delivery pressure • Water supply problem. • Open the valves of the water
decreasing • Filter blockage lines
• Supply hose is leaking • Change water filter

• Change the sieve of the filter
• Replace damaged hose
Pump running noisy, • Supply hose crushed. • Check supply hose, clean or
erratic pressure, • Pump damaged. replace
pressure gauge erratic • Call Herrenknecht Service
• Low feed water pressure/flow
dept
Operating pressure will • Consumer load too powerful • Reduce consumer
not reached
Pump, noisy and gearbox • Low oil level • Check oil level, refill
hot • Relief valve faulty • Check valve, change

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Trouble Shooting

IV - 4 - 2 77963 Schwanau 2, Tel. 07824 / 3020
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1 Maintenance................................................................................ 1 - 1
1.2 General Information .................................................................................... 1 - 2
1.3 Removal........................................................................................................ 1 - 3
1.4 Structure of Maintenance Plan ................................................................... 1 - 3
2 Maintenance Plan ....................................................................... 2 - 1
2.1 Daily Maintenance Works ........................................................................... 2 - 1
2.2 Maintenance Works after the first 50 Operating Hours ........................... 2 - 1
2.3 Maintenance Works after every 500 Operating Hours / 6 Months .......... 2 - 1
2.4 Cleaning Material......................................................................................... 2 - 2
2.5 Lubricating Oil ............................................................................................. 2 - 2
3 Maintenance Works.................................................................... 3 - 1
3.2 Requirements of Operating Personnel ...................................................... 3 - 2
3.3 High Pressure Pump - Gear oil level.......................................................... 3 - 3
3.4 Water Filter ................................................................................................... 3 - 4
3.4.1 Filter............................................................................................................... 3 - 4
3.4.2 Filter Element Change at the Water FilterPN16 ............................................ 3 - 4
4 Repair Works .............................................................................. 4 - 1
4.2 Requirements of Operating Personnel ...................................................... 4 - 2
4.3 To Check Valves .......................................................................................... 4 - 3
4.4 To Check Seals and Plunger Pipe.............................................................. 4 - 4
4.5 To Dismantle Gear ....................................................................................... 4 - 6
4.6 Zusammenbau ............................................................................................. 4 - 7
5 Bolt Tightening Torques ............................................................ 5 - 1

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6 Storage........................................................................................ 6 - 1
6.1 Storage of High Pressure Pump ................................................................. 6 - 1
6.2 Storage of High Pressue Hoses.................................................................. 6 - 1
6.3 Storage of Electrical Parts .......................................................................... 6 - 3
6.3.1 Switch Gear Cabinets .................................................................................... 6 - 3
6.3.2 Electrical Cables ............................................................................................ 6 - 3
7 Spare Parts ................................................................................. 7 - 1
7.1 Stocking Spare Parts ................................................................................... 7 - 1
8 Spare Part Drawing.................................................................... 8 - 1
9 Branchadress Herrenknecht AG .............................................. 9 - 1
9.1 Europe........................................................................................................... 9 - 1
9.2 Middle East ................................................................................................... 9 - 1
9.3 Amerika ........................................................................................................ 9 - 2
9.4 Asia................................................................................................................ 9 - 2
9.5 Australia........................................................................................................ 9 - 2

V-0-2 77963 Schwanau 2, Tel. 07824 / 3020
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Maintenance
1 Maintenance
WARNING
Maintenance works may only be done, if pump is at
stand still and if it is out of operation.
Repair works may only be
executed by instructed persons
with the corresponding
knowledge.
Necessary repair works on live
equipment, put up a signe to the
main switch of control panel that
“START“ or “STOP“ of any
function of the equipment is
forbidden.
WARNING
Observe all safety instructions of the operating
manual.
WARNING
Catch production facilities in suitable containers.
Remove production facilities which where run out at
once.
Danger of slipping!

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Maintenance
1.2 General Information

All maintenance works may only be carried out by instructed persons with
corresponding special knowledge (see chapter „General Safety
Instructions“).
These persons must have thoroughly read and understood this operating
manual.
Before maintenance works at the high pressure pump make sure that the
pressure lines of the pump are depressurised. Close the suction line.
Prevent an unexpected restart of the pump (remove the plug, remove
fuse).
CAUTION
Observe all terms for inspections and maintenance
work including the information about exchange of
subassemblies and components.
CAUTION
Use only producer-released original spare parts and
original accessory parts as well as appropriate
operating means and operating material.

V-1-2 77963 Schwanau 2, Tel. 07824 / 3020
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Maintenance
1.3 Removal
Make sure that all operating and auxiliary material as well as exchange
parts are removed securely and with minimal environmental impact.
As a rule, never remove any operating and auxiliary material into
canalization, soil or waters.
• Collect and remove all oils.
• See to it that reusable exchange parts are being recycled.
NOTE
Collect production facility eg. transmission
oil, hydraulic oil and grease and dispose it in
accordance with the environmental
regulations (EG-directive 75/439/EG and
decrees in accordance to § 5a, 5b AbfG and
decrees for used oil).
1.4 Structure of Maintenance Plan

The maintenance works described in the maintenance plan must be
carried out to guarantee the reliable and secure operation of the tunneling
equipment and to reduce downtime.
Periodically maintenance works are described in the maintenance plan.
The maintenance works are arranged by intervals
• Daily Maintenance Works
• Maintenance Works after the first 50 Operating Hours
• Maintenance Works after every 500 Operating Hours / 6 months
Most of the maintenance works are described in the maintenance plan.
For a detailed description see chapter „Maintenance Works“ and „Repair
Works“.
NOTE
If the operating hours designated in the maintenance
plan are reached before the according time intervals
(daily, weekly..) maintenance work has to be carried out
without reaching the time interval.

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Maintenance

V-1-4 77963 Schwanau 2, Tel. 07824 / 3020
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Maintenance Plan
2 Maintenance Plan
2.1 Daily Maintenance Works
Assembly Locality Maintenance works Consumption material

High pressure Check gear oil levelmotor.
pump Top up if necessary. 3,5 l Gear oil
Check gear oil condition for ARAL DEGOL BMB 220
condensation, change MH Art. No. 29700011
High pressure immediately if evident.
pump Check contamination of the
Water filter Filter according to diagram
filter, Change if necessary.
Check equipment to
Valves, Sealings,
sealness. Change damaged See spare part drawing
Plunger pipe
parts.
2.2 Maintenance Works after the first 50 Operating Hours

3,5 l Gear oil
High pressure
High pressure Change oil. ARAL DEGOL BMB 220
pump
pump MH Art. No. 29700011
Water filter Change filter. Filter according to diagram
2.3 Maintenance Works after every 500 Operating Hours / 6 Months

3,5 l Gear oil
High pressure High pressure
Change oil. ARAL DEGOL BMB 220
pump pump
MH Art. No. 29700011

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Maintenance Plan
2.4 Cleaning Material
Cleaning Material Use

Water High pressure pump
2.5 Lubricating Oil
Manufacturer Part No. Use

ARAL DEGOL BMB 220 29700011 Gearbox pump
CAUTION
Oil check only when pump is at standstill.

V-2-2 77963 Schwanau 2, Tel. 07824 / 3020
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Maintenance Works
3 Maintenance Works
Before starting repair works put the pump out of operation. It must be
secured against unexpected restart. Set the main switch to OFF and secure
with a padlock. Remove the key.
WARNING
Maintenance works may only be carried out, if pump
is at stand still and if it is out of operation.
knowledge.
equipment, put up a sign at the
forbidden.
WARNING
Exchanging heavy machine parts, ensure they are
carefully fastened and secure.
Use only appropriate and technically faultless hoists
as well as load-carrying devices with a sufficient
capacity.
• When exchanging heavy machine parts, ensure that they are carefully
fastened to lifts and are secure.
• Do not store heavy machine parts in unstable places.
• Secure heavy parts reliable also for a short time of storage.
• Use only appropriate and technically faultless hoists as well as load-
carrying devices with a sufficient capacity.
• Principally observe safety warnings of the producer prior to
commissioning of lifts and hoist plants.
• Always pay attention to the sequence of the working steps during
disassembling or assembling machine parts.

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Maintenance Works
CAUTION
Never start disassembly / assembly with a part before
the disassembly / assembly of the previous part is
finished.
• Inspect all works to ensure that repairs will be carried out correctly, after
they are finished.
• Before the machine will be put into operation again, check all
adjustments by a test run.
3.2 Requirements of Operating Personnel

Repair works may only be executed by instructed persons with the
corresponding special knowledge (see Chapter “General safety
instructions“).

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Maintenance Works
3.3 High Pressure Pump - Gear oil level
1 High pressure pump

2 Sight glass
3 oil-level indicator
4 Oil drain plug
5 Oil level
Procedure
• Discharge pressure from the system.
• Make the unit safe, disconnect from the electricity supply
• Open oil drain plug and drain the oil.
• Close the oil drain plug.
• Fill the gearbox with new oil of the specified type via the opening of the
oil-level indicator. Necessary oil level is reached when sight glass ias
filled half-full.
• Replace the oil-level indicator
WARNING
Before maintenance works start the pump must be
depressurised. Suction line has to be closed.
The equipment must be secured against unexpected
restart (Set the main switch to OFF and secure with a
padlock. Remove the key).

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Maintenance Works
3.4 Water Filter

3.4.1 Filter
• Regular maintenenance is supposition for a faultless operation of the
filter. The frequency of change results from contamination of the water
with particle. The filterJ should be changed every 6 months at the latest.
• Non-observance can lead to filter obstruction. Decrease of pressure and
sinking water flow can occur.
3.4.2 Filter Element Change at the Water FilterPN16

Procedur:
1 ventilating valve
2 filter cloth
3 support body
4 O-ring
5 filter bowl
6 spigot nut
1) Close the valve in front of and behind the filter.

2) Open the ventilating valve (1).
3) Unscrew the spigot nut (6), remove the filter bowl (5) and rinse.
(Wrench for loosening the spigot nut (5) on demand.)
4) Remove filter insert downward.
5) Install a new filer insert.
6) Screw the filter bowl (5) with the nut (6), pay attention to correct seat of
the o-ring (4) in the groove of the filter bowl (5).
7) Slowly open the valves and close the vetilating valve (1) when water is
escaping there.
Visual chack to sealness

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Repair Works
4 Repair Works
Before starting repair works put the equipment out of operation. It must be
secured against unexpected restart.
WARNING
Repair works may only be done, if pump stand is at
still and if it is out of operation.
knowledge.
equipment, put up a sign to the
forbidden.
WARNING
Exchanging heavy machine parts, see to it that they
are carefully fastened to lifts and secured.
Use only appropriate and technically faultless hoists
as well as load-carrying devices with a sufficient
capacity.
• When exchanging heavy machine parts, see to it that they are carefully
fastened to lifts and secured.
• Do not store heavy machine parts at unstable places.
• Secure heavy parts reliable also for a short time of storage.
• Use only appropriate and technically faultless hoists as well as load-car-
rying devices with a sufficient capacity.
• Principally observe safety warnings of the producer prior to commission-
ing of lifts and hoist plants.
• Always pay attention to the sequence of the working steps during disas-
sembling or assembling machine parts.

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Repair Works
CAUTION
Never start disassembly / assembly a new part before
the disassembly / assembly of the previous part is
finished.
Inspect all works to ensure that repairs will be done correctly after they are
finished.
Before the machine will be put into operation again, check all adjustments
by a test run.
4.2 Requirements of Operating Personnel

Repair works may only be executed by instructed persons with the
corresponding special knowledge (see Chapter “General safety
instructions“).

V-4-2 77963 Schwanau 2, Tel. 07824 / 3020
Version: 0
Repair Works
4.3 To Check Valves
1) Screw off tension plugs

2) Remove O-ring.
3) Take out discharge valves, pulling them upwards out of the valve casing
with snap-ring tongs or any other pull-off device.
4) Then remove suction valves in the same way.
5) Loosen valve seats from spacer pipe by lightly hitting the valve plate
with a plastic stick.
6) Check sealing surface and replace worn parts.
7) Reassemble with new 0-rings if possible and oil them before installing.
8) Tighten up tension plugs to 145NM.

77963 Schwanau 2, Tel. 07824 / 3020 V-4-3
Version: 0
Repair Works
4.4 To Check Seals and Plunger Pipe
1) Loosen the 8 nuts

2) Pull off valve casing to the front.
3) Pull seal sleeves out of guides in crankcase.
4) Remove seal case from seal sleeve.
5) Check plunger surface and seals.
6) Change worn seals.
7) lf plunger pipe is worn out, loosen tension screws and pull off plunger
pipe to the front.
8) Clean front surface of plunger thoroughly.
9) Then place new plunger pipe carefully through the oiled seals and push
seal sleeve with plunger pipe into the crankcase guide.
10) Turn gear until the plunger comes up against the plunger pipe.
11) Put a new copper gasket onto tension screw.
12) Put a thin coat of glue (Loctite) on the gasket and tighten screw to
30Nm.

V-4-4 77963 Schwanau 2, Tel. 07824 / 3020
Version: 0
Repair Works
CAUTION
Care must be taken that no glue gets between the
plunger pipe and the centring sleeve.
The plunger pipe should not be strained by eccentric
tightening of the tension screw or through damage to
front surface of plunger, otherwise it will probably
break.
Tighten the fixing nuts for the valve casing evenly at
80 Nm.

77963 Schwanau 2, Tel. 07824 / 3020 V-4-5
Version: 0
Repair Works
4.5 To Dismantle Gear
1) After removiang valve casing and plunger pipe, drain oil.

2) Screw off gear cover and bearing cover.
3) Loosen con rod screws and push the front of the con rod forward as far
as possible into the crosshead guide.
CAUTION
Connecting rods are marked for identification.
Do not twist con rod halves.
Con rod is to be reinstalled in the same position on
shaft journals.
4) Turning the crankshaft slightly, hit it out carefully to the side with a rub-
ber hammer.
CAUTION
Do not band the con rod shanks. Check shaft and con
rod surfaces, shaft seals and taper roller bearings.

V-4-6 77963 Schwanau 2, Tel. 07824 / 3020
Version: 0
Repair Works
4.6 Reassemble
1) Using a soft tool, press in the outer bearing ring till the outer edge lines
up with the outer edge of the bearing hole.
2) Screw off bearing cover together with shaft seal and o-ring.
3) Fit shaft through bearing hole on the opposite side.
4) Press in outer bearing and tension it inwards with the bearing cover,
keeping the shaft in vertical position and turning slowly so that the taper
rollers of the bearings touch the edge of the outer bearing ring. Adjust
axial bearing clearance to at least 0.lmm and maximum 0.15mm by
placing fitting discs (20A) under the bearing cover.
CAUTION
After assembly has been completed, the shaft should
turn easily with very little clearance.
Tighten con rod screws to 35Nm.

77963 Schwanau 2, Tel. 07824 / 3020 V-4-7
Version: 0
Repair Works

V-4-8 77963 Schwanau 2, Tel. 07824 / 3020
Version: 0
Bolt Tightening Torques
5 Bolt Tightening Torques

Extract of Herrenknecht prescription A-MBQ002 A-GW002 A-FS003
A-MT005: controlled preloading of screws and studs.
Great unsafeness is connected when tensioning screws. Therefore
greatest pains is absolutely necessary.
• Practically new screws, smooth surface of the thread, thread and head
supporting surface lightly oiled,
• Pairing of material: steel / steel,
• No dirt, no rest of colour or corrosion on the contact surfaces,
• No contact between the shaft of the bolt and the drill hole,
• Screws are tightened in a diagonal sequence for two times
have an influence on the clamping force of the screw connection.
Dimensions Bolt tightening torques in Nm at Dimensions Bolt tightening torques in Nm at

(standard strength of (standard strength of
thread) 5.6 8.8 10.9 12.9 thread) 5.6 8.8 10.9 12.9
M5 2,5 5,7 8,1 9,7 M27 415 910 1300 1500
M6 4,3 9,9 14 16,5 M30 570 1250 1800 2100
M7 7,1 16,5 23 27 M33 780 1700 2400 2800
M8 10,5 24 34 40 M36 980 2150 3100 3600
M10 21 44 64 75 M39 1250 2800 3950 4650
M12 35 75 110 130 M42 1550 3450 4900 5800
M14 56 120 175 205 M45 1950 4300 6100 7100
M16 85 180 265 310 M48 2400 5200 7400 8700
M18 120 260 370 430 M52 3000 6700 9500 11100
M20 165 360 520 600 M56 3800 8300 11800 13900
M22 220 485 690 810 M60 4630 10100 14400 17000
M24 285 630 890 1050
Notice:
Screw condition „lightly oiled“ means that head / nut supporting surface
and the flanks of the threads which are in operation are sprinkled with a thin
oil film. Usable oils are transmission oils according to ISO VG 100 up to ISO
VG220.
Creeping oils are not allowed.
The specified bolt tensioning torques are not applied for HV-bolts and HV-
nuts according to DIN 6914 and DIN 6915 (bolts and nuts with big width
across glats). Also the table is not applied for screws and nuts which are
safed with adhesives.

77963 Schwanau 2, Tel. 07824 / 3020 V-5-1
Version: 0
Bolt Tightening Torques

V-5-2 77963 Schwanau 2, Tel. 07824 / 3020
Version: 0
Storage
6 Storage
6.1 Storage of High Pressure Pump
• Drain the pump completely when it is stored for longer than 3 month
• If temperatures below zero are expected, drain the pump completely to
prevent damages at the pump
Therefor open a deep screw and empty the lines and the pump.
CAUTION
Formation of ice in the pump or the lines of the pump
leads to destruction of pump and lines.
6.2 Storage of High Pressue Hoses

When storing hydraulic hoses pay attention to the following points:
• Store hydraulic hoses in a cool, dry and almost dust free place, prevent
direct sun-radiation and UV radiation, shield heatings near hydraulic
hoses.
• Do not store elastomere at temperatures below -10°C. May be there are
different guidance values for thermoplastics. Don’t store near ozone
formating lighting fixtures or electric instruments with spark fomation.
Ozone formating lighting fixtures are e.g. fluorescent sources of light and
quicksilver-steam-lamps.
• Wrap hydraulic hoses in a plastic awning for dust-free storage.
• Temperatures between +15°C and +25°C and a relative atmospheric
humidity below 65% are convenient contions ro store hydraulic hoses.
• Do not allow the hoses to come into contact with other substances and
materials which may damage them.
• Store hydraulic hoses stress free, lying and closed. Pay attention to the
minimum bending radius given by the manufacturer when storing the
hydraulic hoses in rings.
• Do not store hydraulic hoses for more than 2 years.

77963 Schwanau 2, Tel. 07824 / 3020 V-6-1
Version: 0
Storage
Feature
Hydraulic hoses must be signed durable and continuously with the follow-
ing specifications in a distance of maximum 50 cm.
• Manufacturer,
• Type,
• Nominal diameter,
• Date of manufacture (quarter and year).
Eg. “1 Q 83“ means the first quarter in the year 1983.
Hoses have to be indicated clearly recognizable and permanent with the
following points:
• License plate of the producer of the hoses
• Date of production (Month and Year),
• Maximum permissible dynamic operating pressure.
CAUTION
Do not store hydraulic hoses for more then 4 years
and hydraulic hose lines for more then 2 years.

V-6-2 77963 Schwanau 2, Tel. 07824 / 3020
Version: 0
Storage
6.3 Storage of Electrical Parts

6.3.1 Switch Gear Cabinets
Switch gear cabinets are to be water tight. To prevent condenced water on
the base of temperature variations fill the switch gear cabinets with dry cells
according to DIN55473-A+B.
CAUTION
The quantity of dry cell has to be adjusted to the
volume of the switch gear cabinets.
6.3.2 Electrical Cables

To store electrical cables pay attention to following rules:
• Store electrical cables in a cool and dry place. Prevent direct sun-
radiation and UV radiation to electrical cables.
• Avoid temperature variations
Temperature variations may result in development of condenced water in
the cables.
• Store electrical cables with plug and socket only, with plug and socket
connected together.
• Do not fall short of the minimum bending radius (1,5 x d) when storing
electrical cables in rings. (d = outside diameter of the cable).

77963 Schwanau 2, Tel. 07824 / 3020 V-6-3
Version: 0
Storage

V-6-4 77963 Schwanau 2, Tel. 07824 / 3020
Version: 0
Spare Parts
7 Spare Parts
Ordering Spare Parts
When ordering spare parts please write the description, order number
(Teilenummer) and the number of parts on your order list.
Send your order to the following address by using the password
"Ersatzteilservice".
Herrenknecht AG
Schlehenweg 2
77963 Schwanau
Tel: 07824 / 3020
Fax: 07824 / 3403
Example::
Baukastenstückliste STLDISPO22
Modular parts list 27.02.03
Part Number 30015368 MISCHBODENKOPF drawing number: 973-01-012-00

CUTTING HEAD
Part-
Pos Bezeichnung designation quantity E/V
Number
1 30015276 MISCHBODENKOPF CUTTING HEAD 1,00 ST
2 30015328 SCHLEISSRING WEAR RING 1,00 ST
3 25604753 WERKZEUGHALTERSATZ BUCKET 5,00 ST
. . . . .
. . . . .
. . . . .
101 29602757 SCHNEIDROLLE 3-FACH CUTTER DISC 5,00 ST V
102 29603137 SCHNEIDROLLE 3-FACH CUTTER DISC 2,00 ST V
explanantion: E=spare part, V=wearing part
7.1 Stocking Spare Parts

Parts, marked with “E“ or "V" on the parts list, are wear parts.
To ensure running of the equipment it is recommended to stock these
parts as spare parts in your store.

77963 Schwanau 2, Tel. 07824 / 3020 V-7-1
Version: 0
Spare Parts

V-7-2 77963 Schwanau 2, Tel. 07824 / 3020
Version: 0
Spare Part Drawing
8 Spare Part Drawing

77963 Schwanau 2, Tel. 07824 / 3020 V-8-1
Version: 0
Spare Part Drawing
Modular parts list
Part No.: 23500810 High Pressure Pump
Pos. Part No. Designatopn Qty.
20 23900810 CONTROL 1.00 ST
21 23903763 Wellenschutz 1.00 ST
25 23904010 Head 3.00 ST
29 23904011 Bush 3.00 ST
30 23904012 Scraper 3.00 ST
31 28101037 Seal 3.00 ST
40 23903207 Sleeve 6.00 ST
41 23904014 Spring 3.00 ST
42 23904013 Pressure Ring 3.00 ST
44 23903053 O-ring 9.00 ST
49 23904015 Screw 8.00 ST
100 23902976 Set 1.00 ST
101 23902975 Sealing Set 1.00 ST
102 28100854 Seal 2.00 ST
103 28002431 O-ring 2.00 ST
104 23903656 Washer 3.00 ST
105 23904016 Nut 8.00 ST
106 23904017 Washer 8.00 ST
107 29903479 Plunger 1.00 ST

I-8-2 77963 Schwanau 2, Tel. 07824 / 3020
Version: 0
Branchadress Herrenknecht AG
9 Branchadress Herrenknecht AG
9.1 Europe
Herrenknecht AG Herrenknecht International Ltd.
Schlehenweg 2 Wearfield
77963 Schwanau Southwick Riverside
Deutschland Sunderland
Gesch. 1: +49 (7824) 302 0 SR 5 2 TA
Vereinigtes Königreich
Gesch. 1: +44 (191) 54 89 191
Fax geschäftl.: +44 (191) 54 89 292
Herrenknecht France S.A.R.L. Herrenknecht Ibérica S.A.

Espace Lumière Bâtiment 3 Paseo de la Castellana 192-14 D
2, rue Emile Pathé 28046 Madrid
78400 Châtou Spanien
Frankreich Gesch. 1: +34 (91) 345 26 97
Gesch. 1: +33 (1) 300 960 30 Fax geschäftl.: +34 (91) 359 20 32
Fax geschäftl.: +33 (1) 300 960 35 E-Mail: herrenknecht@ctv.es
Herrenknecht Schweiz AG Herrenknecht Nederland B.V.

Im Grund Meentwal 1
6474 Amsteg 3432 GL Nieuwegein
Schweiz Niederlande
Gesch. 1: +41 (41) 884 80 80 Gesch. 1: +31 (30) 6000333
Fax geschäftl.: +41 (41) 884 80 89 Fax geschäftl.: +31 (30) 6000955
Herrenknecht & Grindat AG Herrenknecht Tunneling Service Russia

Mottastrasse 27 Birjusinka 4
3005 Bern 107497 Moskau
Schweiz Russland
Gesch. 1: +41 (31) 3510 249 Gesch. 1: +7 (095) 462 38 78
Fax geschäftl.: +41 (31) 35 13 791 Fax geschäftl.: +7 (095) 462 57 44
E-Mail: Info@herrenknecht.ru
9.2 Middle East

Herrenknecht AG - IRAN Herrenknecht AG Middle East
6th floor Jebel Ali Free Zone LOB 4F27
#32, Ahmad Ghasir (Bokharest) St. Po. Box 61251
1513755511 Tehran Dubai
Iran Vereinigte Arabische Emirate
Gesch. 1: +98 (21) 872 77 15 Gesch. 1: +971 (4) 8811200
Fax geschäftl.: +98 (21) 872 85 14 Fax geschäftl.: +971 (4) 8871011
E-Mail: herrenknecht-ir@cydexia.com E-Mail: emirates@herrenknecht.de

77963 Schwanau 2, Tel. 07824 / 3020 V-9-1
Version: 0
Branchadress Herrenknecht AG
9.3 Amerika
Herrenknecht Corporation Herrenknecht Tunnelling Systems USA
201 Clay Street NW Suite# A2 Inc.
Auburn, WA 98001 P O Box 11288
Vereinigte Staaten von Amerika Tacoma, WA 98411-0288
Gesch. 1: +1 (253) 804 6511 Vereinigte Staaten von Amerika
Fax geschäftl.: +1 (253) 804 6507 Gesch. 1: +1 (253) 4 76 47 00
Fax geschäftl.: +1 (253) 4 76 47 70
Herrenknecht Argentina
Bartolomé Mitre 921 piso 2 depto. 27
1036 Buenos Aires
Argentinien
Gesch. 1: +54 (11) 4394 3243
Fax geschäftl.: +54 (11) 4394 3243
9.4 Asia
Herrenknecht ASIA Ltd Herrenknecht Asia-Pacific Pte.
Federal Express Building Appartement 602
12/621 Moo 15 Soi Sornhirun Building Chunjiang 1050
Bangna Trad Road, Bangplee Zhong Shan Nan Yi Lu
Samut Prakarn 10540 Shanghai 200023
Thailand China
Gesch. 1: +66 (2) 7450843 Fax geschäftl.: +86 (21) 630 31 721
Fax geschäftl.: +66 (2) 7450845
Herrenknecht Asia-Pacific Pte. Herrenknecht Asia-Pacific

Room 1407, No. 3 Building, Xinhua Road
Xi Luo Yuan No. 3 Section, Lane 569 Number 158
Feng Tai District Block 7 Room 503
Beijing 100077 Shanghai 200052
China China
Fax geschäftl.: +86 (10) 8726 0301 E-Mail: zhbn@public4.sta.net.cn
9.5 Australia
Herrenknecht Australia Pty. Ltd
2 Mosaic Street West
Shelley, Perth
Western, Australia 6148
Australien
Gesch. 1: +61 (8) 945 766 15
Fax geschäftl.: +61 (8) 945 767 15

V-9-2 77963 Schwanau 2, Tel. 07824 / 3020
Version: 0
Designation Part-No. Drawing No.
High pressure pump 30039109 809-20-000-10

Tubing 30031759 809-20-000-12

77963 Schwanau 2, Tel. 07824 / 3020 VI - 1
Version: 0

VI - 2 77963 Schwanau 2, Tel. 07824 / 3020
Version: A
2007-11-27
Baukastenstückliste
Modular parts list
Projekt M-976 Project M-976

Teilenummer 30039109 Part Number 30039109
HOCHDRUCKAGGREGAT AGGREGATE
Zeichnungsnr. 809-20-000-10 D drawing number 809-20-000-10 D
Pos. Part Bezeichnung Designation Quantity E/V

number
1 30039090 GRUNDGESTELL BASE FRAMEWORK 1,00 ST
2 25632099 SCHUTZABDECKUNG COVER 1,00 ST
3 30031759 VERROHRUNG 1,00 ST
100 27900062 DECKPLATTE VZ. PLATE 4,00 ST
101 27400300 SCHELLENHÄLFTE DN60/BG.6S CLAMP 8,00 ST
102 26600097 SCHALTSCHRANK SWITCHGEAR CABINET 1,00 ST
103 27900100 DECKPLATTE VZ. PLATE 1,00 ST
104 27400538 SCHELLENHÄLFTE DN42/BG.5S CLAMP 2,00 ST
200 24000179 SCHEIBE WASHER 4,00 ST

B13-140HV-DIN125
201 24000266 SECHSKANTSCHRAUBE HEXAGON HEAD SCREW 4,00 ST
M12X40-8.8-DIN933
B17-140HV-DIN125
M16X40-8.8-DIN933
B8,4-140HV-DIN125
M8X20-8.8-DIN933
page 1 / 2
2007-11-27
Modular parts list

HOCHDRUCKAGGREGAT AGGREGATE
Zeichnungsnr. 809-20-000-10 D drawing number 809-20-000-10 D

number
206 24000103 SECHSKANTMUTTER NUT M8 4,00 ST

M8-8-DIN934
M12X100-8.8-DIN931
300 25253543 HOCHDRUCKAGGREGAT DIAGRAM 1,00 ST
301 25154810 ELEKTROAUSRÜSTUNG PUMPEN EQUIPMENT 1,00 ST
Explanation: E=spare part, V=wearing part
page 2 / 2
2007-11-27
Modular parts list

VERROHRUNG
Zeichnungsnr. 809-20-000-12 B drawing number 809-20-000-12 B

number
2 16110050 GEWINDEROHR-W-FVZ THREADED PIPE 0,38 M
100 27402184 C-ANSCHLUSS CONNECTION 1,00 ST
101 27600057 MUFFENKUGELHAHN BALL VALVE 2" 1,00 ST
102 24100074 T-STÜCK FVZ T-PIECE 2,00 ST
103 24100080 ROHRDOPPELNIPPEL FVZ NIPPLE 2,00 ST
104 24100081 ROHRDOPPELNIPPEL FVZ NIPPLE 1,00 ST
106 24100319 REDUZIERMUFFE FVZ REDUCER 1,00 ST
107 27302573 HYDRAULIKSCHLAUCH 42L HOSE 1,00 ST
108 27301600 HYDRAULIKSCHLAUCH 25S HOSE / L=600 1,00 ST
page 1 / 3
2007-11-27
Modular parts list

VERROHRUNG

number
109 27403819 EINSCHRAUBVERSCHRAUBUNG PIPE FITTING 1,00 ST
110 23500810 HOCHDRUCKPUMPE HIGH PRESSURE PUMP 1,00 ST
111 27102138 DRUCKSCHALTER PRESSURE SWITCH 1,00 ST
112 23001722 MOTOR BG225M ELECTRIC MOTOR 1,00 ST
113 23700335 KUPPLUNG ROTEX COUPLING 1,00 ST
114 27001227 WASSERFILTER WATER FILTER 1,00 ST
115 27500080 MANOMETER TYP213.53 PRESSURE GAUGE TYPE213.53 1,00 ST
116 24100166 REDUZIERSTÜCK FVZ REDUCING PART 1,00 ST
119 27403218 L-ANSCHLUSSSTUTZEN L-CONNECTION PIECE 2,00 ST
120 27403470 KONUS-REDUZIERANSCHLUSS CONE-REDUCTION FITTING 1,00 ST
121 27403356 ZWISCHENSTUTZEN GERADE CONNECTION PIECE STRAIGHT 1,00 ST
122 27403358 ZWISCHENSTUTZEN GERADE CONNECTION PIECE STRAIGHT 1,00 ST
123 27600033 BLOCKKUGELHAHN DN20 BALL VALVE W/LEVER/ 1,00 ST
page 2 / 3
2007-11-27
Modular parts list

VERROHRUNG

number
124 27103066 ÜBERDRUCKVENTIL VALVE 1,00 ST
125 24100034 WINKEL 90GRAD FVZ ANGLE 3,00 ST
126 27403467 KONUS-REDUZIERANSCHLUSS CONE-REDUCTION FITTING 1,00 ST
127 27500152 MANOMETER TYP213.40 PRESSURE GAUGE TYPE213.40 1,00 ST
128 27403642 WINKELVERSCHRAUBUNG SCREWED JOINT 1,00 ST
129 27403821 EINSCHRAUBVERSCHRAUBUNG SCREW FITTING 1,00 ST
130 24100019 WINKEL 90GRAD FVZ ELLBOW 90° 1,00 ST
132 27403580 T-VERSCHRAUBUNG T-FITTING 1,00 ST
133 24100048 VERSCHRAUBUNG FVZ SCREW FITTING 1,00 ST
Explanation: E=spare part, V=wearing part
page 3 / 3
Designation Part-No. Drawing No.
High pessuring Diagram 25253543 809-20-000-15

Electrical equipment pump 25151242 1441-556-002
Electrical equipment 25153602

77963 Schwanau 2, Tel. 07824 / 3020 VII - 1
Version: 0

VII - 2 77963 Schwanau 2, Tel. 07824 / 3020
Version: 0
2007-11-27
STLDISPO68 Strukturstückliste
Modular parts list
693595

Artikelnummer 25253543 Part number 25253543
HOCHDRUCKAGGREGAT P52/54-270-30KW-PN270-1-0 DIAGRAM
Zeichnungsnr. 809-20-000-15 B Drawing number 809-20-000-15 B
Pos BMK Path Part Bezeichnung Designation Drawing number Quantity

Number
1 27402184 C-ANSCHLUSS CONNECTION 1,00ST
2 27001227 WASSERFILTER WATER FILTER 1,00ST
3 23001722 MOTOR BG225M ELECTRIC MOTOR 1,00ST
4 23700335 KUPPLUNG ROTEX COUPLING 1,00ST
5 23500810 HOCHDRUCKPUMPE HIGH PRESSURE PUMP 1,00ST
5.31 D1-D3 28101037 RADIALWELLENDICHTRING ROTARY SHAFT SEAL RING 3,00ST
5.101 D4 23902975 DICHTSATZ SEALING SET 1,00ST
5.102 D5-D6 28100854 RADIALWELLENDICHTRING ROTARY SHAFT SEAL 2,00ST
5.103 D7-D8 28002431 O-RING O-RING 2,00ST
5.109 D9 28900798 DICHTUNG SEAL 1,00ST
5.21 Z1 23900810 PRESSENSTEUERUNG CONTROL 1,00ST
5.40 Z11-Z16 23903207 MANSCHETTE SLEEVE 6,00ST
5.41 Z17-Z19 23904014 DRUCKFEDER PRESSURE SPRING 3,00ST
5.42 Z20-Z22 23904013 DRUCKRING PRESSURE RING 3,00ST
page 1 / 9
2007-11-27
Modular parts list
693595


Number
5.44 Z23-Z31 23903053 O-RING O-RING 9,00ST
5.25 Z2-Z4 23904010 KREUZKOPF CROSSHEAD 3,00ST
5.49 Z32-Z39 23904015 STIFTSCHRAUBE STUD BOLT 8,00ST
5.100 Z40 23902976 VENTILSATZ VALVE SET 1,00ST
5.104 Z41-Z43 23903656 PASSSCHEIBE WASHER 3,00ST
5.105 Z44-Z51 23904016 SECHSKANTMUTTER HEXAGON NUT 8,00ST
5.106 Z52-Z59 23904017 SCHEIBE DISC 8,00ST
5.29 Z5-Z7 23904011 ZENTRIERHÜLSE CENTERING SLEEVE 3,00ST
5.107 Z60 29903479 PLUNGERWECHSELSATZ PLUNGER REPLACEMENT KIT 1,00ST
5.108 Z61 23906575 GLEITLAGERBLEUEL KPL. CONNECTING ROD ASSY 1,00ST
5.110 Z62 29903733 DICHTUNGSKASSETTE SEAL-CASSETTE 1,00ST
5.111 Z63 29904383 STÜTZRING THRUST RING 1,00ST
5.112 Z64 29904384 STÜTZRING THRUST RING 1,00ST
5.30 Z8-Z10 23904012 ÖLABSTREIFER OIL SCRAPER 3,00ST
page 2 / 9
2007-11-27
Modular parts list
693595


Number
6 27500152 MANOMETER TYP213.40 PRESSURE GAUGE TYPE213.40 1,00ST
7 26400526 TEMPERATURSCHALTER TEMPERATURE SWITCH 1,00ST
8 27103066 ÜBERDRUCKVENTIL VALVE 1,00ST
8.1 27901600 REPARATURSATZ ÜBERDRUCKVENTIL REPAIR KIT 1,00ST
9 27600057 MUFFENKUGELHAHN BALL VALVE 2" 1,00ST
9.1 Z1 27902544 SCHALTGRIFF ZU KUGELHAHN 2" HANDLE 1,00ST
10 27102138 DRUCKSCHALTER PRESSURE SWITCH 1,00ST
11 27402189 REDUZIERSTUTZEN CONNECTION PIECE 1,00ST
12 27500080 MANOMETER TYP213.53 PRESSURE GAUGE TYPE213.53 2,00ST
13 27600033 BLOCKKUGELHAHN DN20 BALL VALVE W/LEVER/ 1,00ST
15 25151242 ELEKTROAUSRÜSTUNG PUMPEN EQUIPMENT 1,00ST
15.1 26000503 TRANSFORMATOR 1PH-MULTI 100VA TRANSFORMER 1PH-MULTI 100VA 1,00ST
15.2 26600052 HAUPTSCHALTER SWITCH 1,00ST
15.3 26600060 RELAISFASSUNG 11-POL. RELAY HOLDER 11 PIN 1,00ST
page 3 / 9
2007-11-27
Modular parts list
693595


Number
15.8 26600081 RELAIS 11-POL. 3 WECHSLER RELAY 11-PIN 3 CHANGER 1,00ST
15.13 26600097 SCHALTSCHRANK SWITCHGEAR CABINET 1,00ST
15.14 26600164 SCHALTELEMENT 1Ö/1S SWITCH ELEMENT 1NO/1NC 1,00ST
15.15 26600176 HILFSTASTER 1Ö AUXILIARY SWITCH 1Ö 1,00ST
15.16 26600176 HILFSTASTER 1Ö AUXILIARY SWITCH 1Ö 1,00ST
15.17 26600177 HILFSTASTER 1S AUXILIARY SWITCH 1S 1,00ST
page 4 / 9
2007-11-27
Modular parts list
693595


Number
15.18 26600191 LEISTUNGSSCHÜTZ CONTACTOR 1,00ST
15.19 26600207 ZEITRELAIS STERN-DREIECK TIME RELAY 1,00ST
15.20 26600248 LEISTUNGSSCHÜTZ 18,5KW POWER CONTACTOR 18,5KW 1,00ST
15.21 26600248 LEISTUNGSSCHÜTZ 18,5KW POWER CONTACTOR 18,5KW 1,00ST
15.22 26600503 LEERGEHÄUSE-STEUERBIRNE HOUSING 1,00ST
15.23 26600536 DRUCKTASTER+SCHUTZKAPPE KEY 1,00ST
15.24 26600537 DRUCKTASTER+SCHUTZKAPPE KEY 1,00ST
15.25 26600589 ANZEIGESCHILD "LEERSCHILD" SHIELD 1,00ST
15.31 26600859 FLACHAUTOMAT CIRCUIT BREAKER 1,00ST
page 5 / 9
2007-11-27
Modular parts list
693595


Number
15.32 26600864 LAMPENBLOCK BLOCK 1,00ST
15.35 26601160 PILZTASTER BUTTON 1,00ST
15.36 26601228 NOT-AUS-SCHALTER EMERGENCY LINE BREAKER 1,00ST
15.37 26601302 FRONTELEMENT ROT ELEMENT 1,00ST
15.38 26601302 FRONTELEMENT ROT ELEMENT 1,00ST
15.39 26601303 FRONTELEMENT GRÜN ELEMENT 1,00ST
15.40 26601541 MOTORSCHUTZSCHALTER 1-1,6A MOTOR - CIRCUIT SWITCH 1,00ST
15.41 26601761 MOTORSCHUTZSCHALTER PROTECTIVE MOTOR SWITCH 1,00ST
15.42 26601765 HILFSSCHALTER 1 ÖFFNER AUXILIARY SWITCH 1 OPENER 1,00ST
15.43 26601775 DREHANTRIEB F.LEISTUNGSSCH. ROTARY DRIVE FOR POWER CONTACT 1,00ST
15.44 26601776 HANDGRIFF F.LEISTUNGSSCHALTER HANDLE FOR POWER SWITCH 1,00ST
15.45 26602161 ZEITRELAIS TIME RELAY 1,00ST
page 6 / 9
2007-11-27
Modular parts list
693595


Number
15.46 26602911 PHASENFOLGERELAIS PHASE BALANCE RELAY 1,00ST
15.47 26900551 STECKER 63A 5POL PLUG 63A 5PIN 1,00ST
15.48 26900747 NOT-AUS-SCHILD EMERGENCY STOP SHIELD 1,00ST
15.49 26901826 KALOTTE ROT SPHERICAL CAP RED 1,00ST
15.50 26902092 GLÜHLAMPE LIGHT BULB 1,00ST
15.51 26902475 DRUCKTASTER MIT ML24V 22,5MM PUSH BUTTON WITH INDICATOR LAM 1,00ST
15.51.1 Z1 26901819 LEUCHTTASTER TH25 ILLUMINATED PUSH BUTTON 1,00ST
15.51.2 Z2 26901821 KONTAKTELEMENT 1S,1Ö CONTACT ELEMENT 1NC 1NO 1,00ST
15.51.3 Z3 26902092 GLÜHLAMPE LIGHT BULB 1,00ST
15.51.4 Z4 26901826 KALOTTE ROT SPHERICAL CAP RED 1,00ST
15.51.5 Z5 26901245 STECKVERTEILER DISTRIBUTOR 1,00ST
15.52 26902476 DRUCKTASTER MIT ML24V 22,5MM PUSH BUTTON WITH INDICATOR LAM 1,00ST
15.52.1 26901819 LEUCHTTASTER TH25 ILLUMINATED PUSH BUTTON 1,00ST
15.52.2 26901821 KONTAKTELEMENT 1S,1Ö CONTACT ELEMENT 1NC 1NO 1,00ST
page 7 / 9
2007-11-27
Modular parts list
693595


Number
15.52.3 26902092 GLÜHLAMPE LIGHT BULB 1,00ST
15.52.4 26902091 KALOTTE GRÜN SPHERICAL CAP GREEN 1,00ST
15.53 26903641 MELDELEUCHTE SIGNAL LAMP 1,00ST
15.54 26903646 MELDELEUCHTE 22,5MM SIGNAL LAMP RED 22,5MM 1,00ST
15.54.2 26901826 KALOTTE ROT SPHERICAL CAP RED 1,00ST
15.54.3 26903641 MELDELEUCHTE SIGNAL LAMP 1,00ST
15.55 26903646 MELDELEUCHTE 22,5MM SIGNAL LAMP RED 22,5MM 1,00ST
15.55.2 26901826 KALOTTE ROT SPHERICAL CAP RED 1,00ST
15.55.3 26903641 MELDELEUCHTE SIGNAL LAMP 1,00ST
15.56 26902087 KNEBEL-SCHALTER 2STELL. 0-1 TOMMY SWITCH 1,00ST
16 27400537 SCHELLENHÄLFTE DN35/BG.5S CLAMP 2,00ST
17 27400539 SCHWEISSPLATTE PLATE 1,00ST
page 8 / 9
2007-11-27
Modular parts list
693595


Number
18 27900100 DECKPLATTE VZ. PLATE 1,00ST
19 27403301 AUFSCHRAUBVERSCHRAUBUNG SCREW FITTING 1,00ST
20 27403793 EINSCHRAUBVERSCHRAUBUNG PIPE FITTING 1,00ST
21 27303090 HYDRAULIKSCHLAUCH 18L HOSE 1,00ST
page 9 / 9

Operating Manual: High Pressure Pump P52/54-270-30KW

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Operating Manual: High Pressure Pump P52/54-270-30KW

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Operating Manual

High Pressure Pump

 Herrenknecht AG, Schlehenweg 2 Eidion: June 2004

x EC-regulation for machines (98 / 37 / EG)

x EC-regulation for low voltage (73 / 23 / EWG i.d.F. 93 / 68 / EWG)

x EMV - regulation for solenoid compatibility (93 / 97 / EWG)

x EC-regulation for high pressure vessels (97 / 23 / EG)

Designation of the product High Pressure Pump P52/54-270-30KW

Used harmonized standards:

Used national standards and technical specifications

I) Introduction, Safety Instructions

II) Technical Data, Technical Descritption

III) Transport, Connecting

IV) Commissioning, Operation, Trouble Schooting

V) Maintenance, Repair, Storage

VI) Drawings and Part Lists

VII) Diagrams and Part Lists

© Herrenknecht AG, Schlehenweg 2 Edition: June 2004

Edition: June 2004 © Herrenknecht AG, Schlehenweg 2

I) Introduction, Safety Instructions

© Herrenknecht AG, Schlehenweg 2 Edition: June 2004

3 Additional Safety Instructions .................................................. 3 - 1

Edition: June 2004 © Herrenknecht AG, Schlehenweg 2

This operating manual is a part of the complete technical documentation.

© Herrenknecht AG, Schlehenweg 2 Edition: June 2004

1.2 Information about High Pressure Pump

1.2.1 Structure of the Operating Instructions

In main part I chapter 2 "General Safety Instructions" the main points

Edition: June 2004 © Herrenknecht AG, Schlehenweg 2

© Herrenknecht AG, Schlehenweg 2 Edition: June 2004

1.4 Exclusion of Liability

1.5 Environmental Acceptability

Edition: June 2004 © Herrenknecht AG, Schlehenweg 2

1.6 Copyright Protection

© Herrenknecht AG, Schlehenweg 2 Edition: June 2004

Edition: June 2004 © Herrenknecht AG, Schlehenweg 2

2 General Safety Instructions

2.2 Use and Application

The use of high pressure pump is not allowed:

© Herrenknecht AG, Schlehenweg 2 Edition: June 2004

2.3 Explanation of Symbols

Instructions attached directly to the high pressure pump must always be

Edition: June 2004 © Herrenknecht AG, Schlehenweg 2

2.4 Directions for Use Safety Outfit

Wear safety goggles Wear safety helmet

Wear ear protection Wear safety gloves

Wear safety shoes Wear safety clothing

Waer face screen Wear respirator

© Herrenknecht AG, Schlehenweg 2 Edition: June 2004

2.5 Special Symbols

Falling loads Danger of slipping

Falling tools Danger of falling

Hot surfaces Danger of stumbling

Hot liquids Danger of hand injuri

Laser beams Danger of squeezing

Ban on smoking Ban on open fire

Edition: June 2004 © Herrenknecht AG, Schlehenweg 2

2.6 Emergency-Stop and Safety Checks

© Herrenknecht AG, Schlehenweg 2 Edition: June 2004

2.7 Requirements to Operating Personnel

Edition: June 2004 © Herrenknecht AG, Schlehenweg 2

compressed air regulation

Personal which is special trained