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7) Appendix
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HP25 GERUPRESS
1. Instructions 2. Instructions for use II. How to work with the high pressure pump
I. HOW TO TEST A HIGH PRESSURE PUMP TO SEE Start again with position 2.) to 7.).
The GERUPRESS provides high static pressures for using them IF IT WORKS Now pull and turn on the relief valve H to get the right oil
in combination with hydraulic tightening device. Because of its pressure:
specification the GERUPRESS is not suitable supporting large 2 bar air pressure ≈ 500 bar oil pressure.
delivery ranges under high pressure. Neither the capacity of the 1.) Check if the pressure gauges A and I are intact and Then connect the high pressure tubes to the hose
oil pump nor the range of hydraulic oil do not allow operating control the position of the indicators. Both indicators connection K.
under these circumstances. In its specified application, the should be on zero.
Continue with position 10.) to 14.)
GERUPRESS works exclusively with the medium compressed 2.) Control the oil level (by locking at oil level controller B) Remove the high pressure tubes from the hose connection
air. 3.) If the oil level is too low, fill in oil an follow these
The function of the GERUPRESS is based on a proportional K when you are finished.
instructions:
working oil pump. The absolute maximum output pressure is 4.1. Choose the quality of the oil according to the
secured by a security valve (adjustable) in the low pressure
instructions on sign C. BE CAREFULL: Hydraulic tubes can only be
circle (cf. risk analysis).
For operating, the compressed air (pressure < 15 bar) have to 4.2. Open the oil admission socket D to fill in the oil by attached or removed if the
be connected to the GERUPRESS, the gauges have to be turning to the left . relief valve E is open. The
checked and the operating lever have to be shift (operating). 4.3. Fill in the oil until the oil level controller B indicates oil pressure gauge A has
Now, the pump starts working until the adjusted value of the that the tank has been filled up threequarters (¾). then dropped to 0 bar.
output pressure has been reached. 4.4. Now close the oil admission socket D by turning it to
It is possible to adjust the output pressure by the pressure the right .
limitation valve until either the requested value is pointed on the
gauge or the maximum pressure of 1500 bar is reached.
4.) Close the relief valve E and turn it to the right as far as it 3. Risk analysis
For set off (high pressure is no longer necessary) the operating will go.
a) The oil pump is working as pressure translator, thus
lever have to be shift back in “0”-position. For ventilation of ducts 5.) Now turn lever F (=start lever) into position II. improper output pressures cannot be reached because
the manual ventilation valve has to be opened. 6.) Connect the compressed air-tube to the compressed-air the lower operating pressure is limited.
Disconnect high pressure tubes only while ventilation valve connection G. b) Improper absolute output pressures will be lock out by a
open. additional pressure reducing valve in the low pressure
circle.
D BE CAREFULL: never use more than the c) Leaks or duct cracks in the high pressure circle including
C maximum of 15 bar! no healthy risks for operators.
d) Duct crack cause a breakdown of the output pressure.
e) Is the determined output pressure not available after a
A F 7.) Pull and turn the pressure control valve H to the right as short time, a damage of the GERUPRESS is probably
far as it will go (until you feel a resistance). occurred. In this case, put the gadget out of operation,
8.) Check the air pressure on the pressure gauge I (There disconnect the connect air tubes. Otherwise the gadget
M I should be an air pressure of at least 6 bar). will get dirty by hydraulic oil.
9.) Put start lever F into position I. f) Pay attention while closing of the cover. Prohibit
10.) The pump starts working and should build up a pressure • damaging (operating level in „1“, cover
G of up to 1.500 bar (if it doesn’t, please check the air cannot be closed)
pressure). • wounding
g) Sufficient lubrication of the oil pump and providing with
11.) When the oil pressure gauge A shows a pressure of
H 1.500 bar turn lever F back into position II.
hydraulic oil is ensured by mounting the pump into the oil
tank. In case of a pump leakage, the gadget and the
12.) The pressure shown on oil pressure gauge A shouldn’t operator is protected by the casing of the tank.
K E fall. This means that the pump is in working order.
13.) Open the relief valve E by turning it to the left. BE CAREFULL: Disconnect high pressure
14.) The pressure shown on oil pressure gauge A now drops tubes only while ventilation
B L to 0 bar. valve open.
1 / 2 Copyright by GERUS Apparatebau GmbH & Co.KG, Engelschalkstraße 16, D - 86316 Friedberg
3/9
HP25 GERUPRESS
4. How to exchange the oil at 5. Technical data 6. After-sales service and self-
the high pressure pump help
Air pressure (pB): 1,5 – 7,0 bar (pBmax = 15,0 bar)
If the pressure at oil pressure gauge A doesn’t remain
constant and drops (as described under point 13.), the pump
Oil can be removed by opening the oi screw L and by lifting the is not air-tight.
pump on the opposite side of the pump. Output pressure (pA): 1500 bar (max. pressure for
In most cases, this is due to the fact that the O-rings are
permanent operating) old/worn-out. It is possible to exchange the O-rings. A
complete set of O-rings (article-no. 11.49015-0067) is
enclosed in the pump.
BE CAREFULL : the oil starts running out as Test pressure (pprüf): 1600 bar (test operating) The packet of spare parts can be taken out by opening the
soon as you have loosened front plate M. An explosion drawing of the pump is also
the screw! included.
It is recommendable to have the pump overhauled by its
Gadget connections:
Output pressure CEJN high pressure coupling
manufacturer
Use oil admission socket D to fill in the oil. Oil level gauge B (type series 116)
indicates how much oil you have filled in. The pump should be Air pressure compr. air conn. ∅ 9 mm
filled up to three quarters ( ¾). GERUS APPARATEBAU GmbH & Co. KG,
Masses: Engelschalkstraße 16
empty: 26,50 kg
D-86316 Friedberg
filled: 30,50 kg
BE CAREFULL: Only use oils with the Tel.: 0049 – (0)821 - 588 662-0
following specifications: FAX: 0049 – (0)821 - 588 662-10
Dimensions: E-Mail:[email protected]
height: 402 mm
oil quality: anti-corrosion oil, length: 431 mm
viscosity approx. 13 mm² / s = cSt / 20° C width: 315 mm
Volume of tank: 7 l (dm³)
We advise you to exchange the oil every three years because
Performance and consumption of air:
otherwise the pump might be damaged due to residues of dirt.
0,53 m³/min for 6 bar compr.air ≡ 0,37 dm³/min for 1000 bar
1,23 m³/min for 6 bar compr.air ≡ 0,90 dm³/min for 0 bar
2 / 2 Copyright by GERUS Apparatebau GmbH & Co.KG, Engelschalkstraße 16, D - 86316 Friedberg
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1 2 3 4 5 6
001-015-020 001-100-010
11.49015-2038 11.49015-0083
A A
62 G1/4
35 (2x)
294
294
B B
70,5
G 1/2
G 1/4
(2x)
(2x)
70,5 135 G1/2 (2x) 135
C C
134 162,5 134 162,5
for high pressure pump GERUPRESS for nozzle test bench GERUPRESS
für Hochdruckpumpe GERUPRESS für Düsenprüfstand GERUTEST
Maße ohne Toleranzangabe: B, mittel, nach DIN ISO 2768 Kanten nach DIN 6784 Oberfl. n. DIN ISO 1302
M: 1:2
P-Air = 1,5....10 bar P-Luft = 1,5....10 bar Werkstoff:
P-max = 1500 bar P-max = 1500 bar Datum Name
Transmission ratio 1:244 Übersetzung 1:244 Bearb. 06.11.2007 Völk
V = 2cm³ / lifting cycle V = 2cm³ / Hubspiel
Gepr. HD-Pumpe - komplett
Norm
D D
LP125-8E 1
GmbH & Co.KG A3
Status Änderungen Datum Name Urspr. Ers. f.: Ers. d.:
1 Zeichnung ist Eigentum der Fa. GERUS GmbH & Co.KG. Gebrauch durch Dritte u. Vervielfälltigung nur mit schriftlicher Einwilligung.
1 2 3 4 5 6
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1
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EG-Konformitätserklärung EC-Declaration of Conformity
Wir, die Firma We, the company
GERUS Apparatebau GmbH&CO.KG GERUS Apparatebau GmbH&CO.KG
Engelschalkstrasse 16, 86316 Friedberg, Engelschalkstrasse 16, 86316 Friedberg,
Deutschland, Germany,
erklären hiermit, dass die nachfolgend declare hereby that the following described
bezeichnete Maschine aufgrund ihrer machine in its conception, construction
Konzipierung und Bauart sowie in der von and form put by us into circulation is
uns in Verkehr gebrachten Ausführung in accordance with all the relevant essential
den einschlägigen Sicherheits-und health and safety requirements of the
Gesundheitsanforderungen den nach- following EC directives.
folgenden angeführten EG-Richtlinien
entspricht.
Maschinenrichtlinie 2006/42/EG Machinery directive 2006/42/EC
EMV-Richtlinie 2004/108/EG EMC directive 2004/108/EC
Bezeichnung der Maschine: Druckluftbetriebene hydr. Hochdruckpumpe
Description of the machine: Airdriven hydr. high pressure pump
Typ: GERUPRESS HP25
Type:
Serien-Nr.: HP25-
Serial No.:
Angewandte harmonisierte Normen: EN 12100, EN 60204
Applied harmonized standards:
Bevollmächtigter für techn.Dokumentation: Dipl.Ing. H. Müschenborn
Authorized person for techn.documentation:
Ort und Datum: Friedberg, 25.07.2011
Place and date:
Name und Position des Unterzeichners: Dipl.Ing. R. Schroll, Geschäftsführer
Name and position of signer: Dipl.Ing. R. Schroll, Business manager
Unterschrift des Unterzeichners
Signature of signer
8/9
GERUS
Precautions for Protecting
the Inhaled AironGeneral
Safety Instructionses
REACH Erklärung REACH Declaration
Wir, die Firma We, the company
GERUS Apparatebau GmbH&CO.KG GERUS Apparatebau GmbH&CO.KG
Engelschalkstrasse 16, 86316 Friedberg, Engelschalkstrasse 16, 86316 Friedberg,
Deutschland, Germany,
erklären hiermit, dass wir als Hersteller declare hereby that as a manufacturer of
von Maschinen und Werkzeugen zur machines and tools for overhauling and
Überholung und Instandsetzung von maintenance of large bore engines we
Großmotoren von der Verordnung nur are only concerned by the regulation as
als nachgeschalteter Anwender betroffen downstream user and, therefore, we are
sind und daher nicht zur Registrierung not bound to register or pre-register.
und Vorregistrierung verpflichtet sind.
Beim Gebrauch unserer Maschinen werden Under normal use of our machines, no
Keine Schadstoffe im Rahmen von Artikel harmful substances within the scope of
7.1 und 7.2 der Verordnung freigesetzt Article 7.1 and 7.2 of the regulation are
released.
General Safety Instructions
Ort und Datum: Friedberg, 03.11.2011
Place and date:
Name und Position des Unterzeichners: Dipl.Ing. R. Schroll, Geschäftsführer
Name and position of signer: Dipl.Ing. R. Schroll, Business manager
Unterschrift des Unterzeichners
Signature of signer
4 (37)
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