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Dynaset Oy | Menotie 3, 33470 Ylöjärvi | puh. 03 3488 200 | [email protected] | www.dynaset.com

HYDRAULIC ROTARY VANE COMPRESSORS

MAINTENANCE

6. MAINTENANCE

DYNASET HKL compressors are low-maintenance units. Only normally wearing

parts and materials should be replaced either when necessary or in accordance

with a service program.

ATTENTION!

Before beginning any maintenance or repair, ensure that the system

is stopped and depressurized. Make sure that the system can not start

accidentally.

STOP

Depressurize the system completely by loosening the oil filler cap. Little amount of

hot oil may escape from the groove of the oil filler cap when loosing it. Especially if

the compressor has been running recently and there is pressure in the system and

oil is thermally expanded.

Picture 34: Depressurization of the HKL compressor

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Содержание HKL 1300

Страница 1: ...HKL 400 HKL 801 HKL 1300 HKL 1800 HKL 2600 HKL 4100 HKL 5000 HKL 7500 06 18 rev 1 2 HYDRAULIC ROTARY VANE COMPRESSORS USER MANUAL Download PDF version from www Dynaset com manuals Keycode LZ4BYM...

Страница 2: ......

Страница 3: ...u to take the full advance of the technical features avaible in your equipment Please contact us for any feedback you might have on our products Your feedback is important to us for improving our prod...

Страница 4: ...INCIPLES 17 3 1 OPERATING DESCRIPTION 17 3 2 AUTOMATIC RPM CONTROL 20 3 3 LUBRICATION SYSTEM OF COMPRESSOR 20 3 4 PRESSURE AND COMPRESSION RATIO 20 3 5 PNEUMATIC ELECTRIC OFF LOAD VALVE 21 3 6 TEMPERA...

Страница 5: ...2 HYDRAULIC FLUIDS 44 6 3 COMPRESSOR OILS 45 6 4 CLEANING THE COMPRESSOR 46 6 5 OIL LEVEL CHECK 46 6 6 OIL UALITY CHECK 49 6 7 OIL AND OIL FILTER REPLACEMENT 49 6 8 OIL RETURN VALVES REPLACEMENT 52 6...

Страница 6: ...re 15 Connection figure for closed centre hydraulic system with Load Sensing variable displacement pump 29 Picture 16 Hydraulic system with fixed displacement pump 30 Picture 17 Connection figure for...

Страница 7: ...o high quality compressed air and it can be installed in almost any working machine HKL compressors are used topowerforexamplepneumatictools fillingtires airflushing purgeairprotection equipments clea...

Страница 8: ...intake valve and compressor starts to run on off load mode When compressor is stopped restart of compressor is prohibited before compressor chamber pressure is decreased under 3 bars Pneumatic electri...

Страница 9: ...Pressure Code Made in Finland P O W E R E D B Y H Y D R A U L I C S HKL 2600 18 65 O PE 65 l min 12345 6789 Dxxxxxxxxx 210 bar 11 15 Qair 2600 l min Pair 10 bar 1 2 3 4 7 8 5 6 Picture 2 Type plate Th...

Страница 10: ...rvi puh 03 3488 200 info dynaset com www dynaset com HYDRAULIC ROTARY VANE COMPRESSORS GENERAL 1 4 HKL COMPRESSOR LINE UP Picture 3 HKL compressor line up 1 HKL 400 2 HKL 801 HKL 1300 3 HKL 1800 HKL 2...

Страница 11: ...AIN COMPONENTS OF HKL COMPRESSOR Picture 4 Main components of HKL compressor 1 Hydraulic motor 2 Hydraulic pressure line P 3 Hydraulic return line T 4 Oil cooler 5 Fan 6 Compressor block 7 Bracket 8 A...

Страница 12: ...12 Dynaset Oy Menotie 3 33470 Yl j rvi puh 03 3488 200 info dynaset com www dynaset com HYDRAULIC ROTARY VANE COMPRESSORS GENERAL...

Страница 13: ...e severe injuries Always wear appropriate clothing and safety equipment Couplings valves and hoses should be maintained tight and clean to avoid possible leakages of pressure and hot blowouts Hydrauli...

Страница 14: ...pressor beware of machinery parts warmed by hot hydraulic oil WARNING RISK OF BURNS Parts of the unit oil and oil filler cap can be hotter than 80 C Wear personal safety equipment Never aim compressed...

Страница 15: ...sure safe reliable and longlife operation of your equipment Hydraulic system of a base machine should be maintained according to the service program 2 5 WARNING LABELS Warning labels are included with...

Страница 16: ...16 Dynaset Oy Menotie 3 33470 Yl j rvi puh 03 3488 200 info dynaset com www dynaset com HYDRAULIC ROTARY VANE COMPRESSORS SAFETY...

Страница 17: ...OPERATING INSTRUCTIONS 3 OPERATING PRINCIPLES 3 1 OPERATING DESCRIPTION Picture 5 Operating description Air intake 1 Therotorofhydrauliccompressorsaredrivenbyhydraulicmotor Therotationof rotor creates...

Страница 18: ...internal surface of the stator by centrifugal force generated by rotation 4 Compressioniscreatedbythereductioninvolumeofthecompressionchambers formed by the stator the vanes and the rotor during rotat...

Страница 19: ...When supply line is closed and preset air pressure is reached compressor starts to run automatically in off load mode Pneumatically controlled intake valve is closed and compressor s internal pressur...

Страница 20: ...differential makes the oil spread along grooves to the surfaces to be lubricated Separate oil pump is not needed 2 HERMETIZATION Injectedoilsealsrotorbladesagainststator swallandlubricates them 3 COO...

Страница 21: ...p with an air discharging from compressor s reservoir until the pressure in chamber achieves the pre adjusted value for the opening of a pressure switch 3 bar When pressure switch 23 3 opens it de ene...

Страница 22: ...ure switch when installing compressor Picture 11 Temperature switch Temperature switch prevents compressor over heating Temperature switch stops the compressor when fixed switching temperature of 110...

Страница 23: ...mum pressure non return valve 7 Safety valve 12 bar 8 Vacuum relief valve 9 Oil drain valve 10 Oil return valve 11 Thermostatic By pass valve 12 Oil cooler 13 Oil filter 14 Servo valve 15 Temperature...

Страница 24: ...24 Dynaset Oy Menotie 3 33470 Yl j rvi puh 03 3488 200 info dynaset com www dynaset com HYDRAULIC ROTARY VANE COMPRESSORS OPERATING INSTRUCTIONS...

Страница 25: ...pe of hydraulic systems Most common hydraulic systems in mobile machinery are Open centre hydraulic system with Load Sensing variable displacement pump Closed centre hydraulic system with Load Sensing...

Страница 26: ...ydraulic system with Load Sensing variable displacement pump In open centre hydraulic system the flow is returned to tank through the control valves open centre that is when the control valve is cente...

Страница 27: ...ection figure for open centre hydraulic system with Load Sensing variable displacement pump 1 DYNASET hydraulic equipment 2 DYNASET Priority valve PV SAE 2 1 DYNASET PC SAE pressure compensator 2 2 DY...

Страница 28: ...UMP Picture 14 Closed centre hydraulic system with Load Sensing variable displacement pump In a closed centre hydraulic system the oil flow is stopped from the pump when control valve is centered The...

Страница 29: ...LLATION Picture 15 Connection figure for closed centre hydraulic system with Load Sensing variable displacement pump 1 DYNASET hydraulic equipment 2 DYNASET LSV Load sensing valve 3 DYNASET Shuttle va...

Страница 30: ...HYDRAULIC SYSTEM WITH FIXED DISPLACEMENT PUMP Picture 16 Hydraulic system with fixed displacement pump In hydraulic system which has the fixed displacement pump the oil flow from the pump is fixed Ev...

Страница 31: ...Picture 17 Connection figure for hydraulic system with fixed discplacement pump 1 DYNASET hydraulic equipment 2 DYNASET Priority valve PV SAE 2 1 DYNASET PC SAE pressure compensator 2 2 DYNASET LSV Lo...

Страница 32: ...d to enable easy installation of your DYNASET hydraulic product DYNASET LOAD SENSING VALVE Picture 18 Load Sensing valve LSV DYNASET LSV Load Sensing valves are made for installations in a closed cent...

Страница 33: ...ressor NOTE When positioning the HKL compressor note the maximum inclinations and ensure that required oil cooling capacity of hydraulic system is sufficient READ CHAPTER 10 TECHNICAL SPECIFICATIONS f...

Страница 34: ...PECIFICATIONS Picture 22 P line operational hydraulic flow In case of hydraulic flow being too high The flow must be reduced either by dropping down the rotation speed of base machine s hydraulic pump...

Страница 35: ...hydraulic system are sufficient READ CHAPTER 10 TECHNICAL SPECIFICATIONS for more information 4 2 4 HYDRAULIC FLUIDS To use proper hydraulic fluid READ CHAPTER 10 TECHNICAL SPECIFICATIONS for more in...

Страница 36: ...system or consumer with a proper fitting and cut off valve options Picture 26 Air supply system connection The inner diameter of pipe hose used for compressor s connection should be at least equal to...

Страница 37: ...with compressor oil Only in special cases compressor is delivered without compressor oil The oil level must be over the top point of a sight glass when standing still and over the mid point when comp...

Страница 38: ...ydraulic flow achieves the functional minimum rate which is approx a half of the nominal value The nominal discharge is achieved when the compressor is rotated by hydraulic flow adequate to the nomina...

Страница 39: ...ressed air delivered by a HKL compressor must not be used as the breathing air even if purified and filtered HKL compressor is designed to compress athmospheric air only and must not be used with any...

Страница 40: ...for corresponding oils Picture 31 Operating in extreme ambient temperatures 5 4 AIR HUMIDITY When operating compressor in high humidity ambient conditions the water condensation must be taken account...

Страница 41: ...run at off load mode few minutes Oil circulation is proper when the termorstatic valve is open NOTE When starting HKL compressor in cold ambient temperatures It s recommended that compressor air supp...

Страница 42: ...42 Dynaset Oy Menotie 3 33470 Yl j rvi puh 03 3488 200 info dynaset com www dynaset com HYDRAULIC ROTARY VANE COMPRESSORS OPERATION...

Страница 43: ...ervice program ATTENTION Before beginning any maintenance or repair ensure that the system is stopped and depressurized Make sure that the system can not start accidentally STOP Depressurize the syste...

Страница 44: ...m for leaks x Change air intake filter o x Clean oil return filters x Change oil oil filter and oil return filters x Change air oil separating element x o Check change if necessary x Change NOTE All i...

Страница 45: ...special hydraulic fluids with DYNASET equipment please contact the nearest DYNASET representative for more information 6 3 COMPRESSOR OILS RotoroilF2compressoroilisrecommendedasmostpreferablelubricant...

Страница 46: ...ation Check and clean your HKL compressor after every work shift The compressor block and oil cooler should be checked on a daily basis and cleaned when necessary To clean the unit use blow gun Clogge...

Страница 47: ...a horizontal position 2 Wait for one minute at standstill 3 Checktheoillevelfromtheoillevelsightglass Withthecompressoratastandstill and without pressure in the chamber the oil level must be above the...

Страница 48: ...essor requires oil fill up slowly open the oil filler cap NOTE Hot oil expands in volume As a result oil may escape when the screw plug is opened at the maximum oil level In this case close the oil fi...

Страница 49: ...ressor must be at operating temperature when changing the oil It helps oil draining from the drain hole Compressor must be stopped during oil change NOTE Make sure to use recommended compressor oil Ad...

Страница 50: ...com HYDRAULIC ROTARY VANE COMPRESSORS MAINTENANCE 1 Slowly open the oil filler cap and place a suitable container under drain valve 2 Carefully open the oil drain valve drain the used oil and close t...

Страница 51: ...ATTENTION Dispose of the old oil filter in accordance with the applicable regulations 4 Install new oil filter 5 Add oil up to the maximum level and screw the oil cap firmly onto the filler neck 6 St...

Страница 52: ...y by loosening the oil filler cap 9 Check the oil level and top up the missing oil quantity up to the maximum level if needed 6 8 OIL RETURN VALVES REPLACEMENT Oil return filters should be cleaned at...

Страница 53: ...essed air if there is a lot of crust on the sintered filter replace it 3 Assemble oil return valves in opposite order Remember always to replace the O ring 4 NOTE Be careful with the tightening of the...

Страница 54: ...IC ROTARY VANE COMPRESSORS MAINTENANCE 1 Remove AP line connection return oil line connections and O PE switch connection 2 Unscrew air oil separator screw and lift air oil separator 3 Remove the air...

Страница 55: ...www dynaset com HYDRAULIC ROTARY VANE COMPRESSORS MAINTENANCE 4 Install new air oil separation element to the air oil separator Grease the o rings check and clean the surfaces 5 Install air oil separa...

Страница 56: ...with the system running 6 10 REPLACING THE AIR FILTER ELEMENT ATTENTION Dirt and dust particles must not be permitted to get into the air inlet of the compressor module 1 Screw off the knob remove the...

Страница 57: ...ng to the applicable regulations 2 Carefully remove dust from the filter housing 3 Insert new filter element and install filter cover 6 11 ADJUST THE OFF LOAD PRESSURE Compressor s output pressure is...

Страница 58: ...adjusting screw to increase pressure loosen the adjusting screw to decrease pressure Use separate pressure gauge in pressure line when making the adjustement Nominal output pressure Servo valve s sett...

Страница 59: ...set com www dynaset com HYDRAULIC ROTARY VANE COMPRESSORS MAINTENANCE NOTE If hysteresis locking nut and pilot valve are on factory settings phases 1 5 can be skipped 1 Open the hysteresis lock nut 18...

Страница 60: ...3488 200 info dynaset com www dynaset com HYDRAULIC ROTARY VANE COMPRESSORS MAINTENANCE 3 Start gently to loosen valve from 14mm SW rotate counter clockwive until valve feels loose 4 Tighten 14mm SW...

Страница 61: ...Start the compressor 7 Start closing the air supply lines valve slowly until the air pressure is desired For example 8 bar it depends on what pressure servo valve is set on servo valve pressure should...

Страница 62: ...set com www dynaset com HYDRAULIC ROTARY VANE COMPRESSORS MAINTENANCE 10 Start to open pilot valve adjusting knob on the top of the pilot valve until compressor goes on free flow state and pressure st...

Страница 63: ...e are sufficient Adjust when necessary Check the hydraulic motor for possible leakage Replace damaged parts if necessary Air pressure in delivery line disrupts compressor s start Depressurize the syst...

Страница 64: ...possible malfunction in pneumatic executor Check and repair Sevo valve s failure or incorrect setting i e adjusted pressure is lower than setting of minimum pressure non return valve Check and repair...

Страница 65: ...imary to the seller of the product Contact must be made as soon as possible latest thirty 30 days after the problem was identified Seller and or manufacturer technical staff determines the nature of t...

Страница 66: ...of maintenance Cost of maintenance adjustments installation or startup Coating hydraulic oil quick couplings and interconnection hoses internal or external to system assemblies Products altered or mod...

Страница 67: ...sponsible way Do not dispose used oils electrical components batteries or any other hazardous waste with normal waste They are harmful for the environment and can be recycled for re use Contact your l...

Страница 68: ...68 Dynaset Oy Menotie 3 33470 Yl j rvi puh 03 3488 200 info dynaset com www dynaset com HYDRAULIC ROTARY VANE COMPRESSORS PRODUCT DISPOSAL...

Страница 69: ...y of machines Machine directive 2006 42 EC LVD directive 2014 35 EU EMC directive 2014 30 EU RoHS directive 2011 65 EU PED directive 2014 68 EU Applied conformity standards CEN EN ISO 4413 EN ISO 4413...

Страница 70: ...70 Dynaset Oy Menotie 3 33470 Yl j rvi puh 03 3488 200 info dynaset com www dynaset com HYDRAULIC ROTARY VANE COMPRESSORS DECLARATION OF CONFORMITY...

Страница 71: ...ow min l min gmp 10 2 64 14 3 70 20 5 28 23 6 08 23 6 08 Oil flow max l min gmp 35 9 25 37 9 77 60 15 85 66 17 44 66 17 44 Pressure at nominal flow bar psi 120 1740 210 3046 210 3046 170 2466 210 3046...

Страница 72: ...10 83 74 19 55 74 19 55 90 23 77 Oil flow max l min gmp 65 17 17 82 21 66 113 29 85 135 35 66 150 39 63 Pressure at nominal flow bar psi 210 3046 170 2466 210 3046 210 3046 260 3771 Pressure max bar p...

Страница 73: ...DYNASET OY all rights reserved...

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