HKL Ope Manual Eng

June 2014 JLe
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HKL HYDRAULIC COMPRESSORS
HKL
HYDRAULIC COMPRESSORS
OPERATING INSTRUCTIONS
HKL 400/8 - 24 (33)

HKL 801/8 - 26
HKL 1300/8-38 (46)
HKL 1800/8-46
HKL 2600/8-65 (82)
HKL 4100/8-113
HKL 5000/8-135
HKL 7500/8-132+12
HKL 7500/8-176+12
HKL 1800 / 8 - 46 -
O - PE
HYDRAULIC VANE COMPRESSOR

MAXIMUM DISCHARGE, L/MIN
MAXIMUM DISCHARGE PRESSURE, BAR
NOMINAL HYDRAULIC FLOW, L/MIN
CONTROL SOLENOID VALVE FOR OFF-LOAD VALVE
AIR-TO-ELECTRIC OFF-LOAD CONTROL VALVE
DYNASET OY, Menotie 3,

FIN-33470 Yljrvi, FINLAND
Tel.: +358 3 3488200

1
E-mail: info @dynaset.com

Fax: +358 3 3488222
MAY CHANGE WITHOUT PRIOR NOTICE
June 2014 JLe
DEAR CUSTOMER!
Thank you for choosing Dynaset product from Finland. We appreciate your product expertise and
are convinced, our product is efficient and profitable for you.
This product is high technology design with latest hydraulic R&D knowledge bringing high
performance in compact size, providing long lasting reliable use for customers all over the world.
TABLE OF CONTENTS
1.
SAFETY PRECAUTIONS AND WARNING STICKERS
2.
GENERAL NOTES
3.
CONSTRUCTION
4.
PERFORMANCE
4.1 Lubrication system of the compressor
4
5
5.
PRESSURE AND COMPENSATION RATIO
6.
AIR AND OIL TEMPERATURES
7.
AIR HUMIDITY
8.
INSTALLATION
9.1 Open centre hydraulic system with variable displacement pump
9.2 Closed centre hydraulic system with variable displacement pump
9.3 Hydraulic system with constant placement pump
9.4 Hydraulic compressor without automatic speed control valve
9.5 Connection to the air supply system
7-9
8
8
9
9
9
9.
OPERATION
10.1 Off-load mode
10
11
10. HYDRAULIC FLUIDS
11
11. COMPRESSOR OILS
11
12. COMPRESSOR MAINTENANCE

12.1 HKL service table
12.2 Compressor block intake air filter
12.2 Oil level check and change
12.3 Oil return valves
12.4 AIr/Oil separator
12.5 Pressure regulator
12-14
12
12
13
13
14
14
13. TROUBLE SHOOTING
15-16
14. SOLENOID CONTROL VALVE FOR OFF-LOAD VALVE (O)
17
15. AIR TO ELECTRIC (PE) CONTROL FOR OFF-LOAD VALVE
18-19
16. PRODUCT DISPOSAL
20
17. PARAMETERS
21-22
18. MANUFACTURERS LIMITED WARRANTY
23
19. DECLARATION OF CONFORMITY
24
20. NOTES
25
June 2014 JLe
SAFETY PRECAUTIONS
The pressure in both hydraulic and compressed air circuits of HK-compressor is considerably high. There at the
technical condition of your equipment should be under constant scrutiny. Operators and maintenance personnel
must always comply with local safety regulations and precautions in order to close out the possibility of damages
and accidents.
Especially couplings, valves and hoses should be maintained tight and clean as well as kept under constant
observation avoid possible leakages of pressure and hot blowouts. Hydraulic leakages must be rectified immediately
to avoid user and bystander injuries. Follow all your local safety instructions related to the high pressure
hydraulics.
In order to exclude possible accidents, it is not allowed to clean or inspect HK-compressor and pneumatic tools
when hydraulic or/and pneumatic circuit is pressurized. Prior to any cleaning, inspection and service hydraulic
system of your carrier machine must be stopped and both hydraulic and pneumatic circuits dissipated, for
instance, by opening the blow gun.
Always wear appropriate clothing and safety equipment such as goggles, ear protection and safety shoes at all
times when operating by the compressor. When operating the compressor, beware of machinery parts warmed
by hot hydraulic oil.
EXTERME CLEANLINESS MUST BE MAINTAINED WHEN CARRYING OUT ANY DISASSEMBLING OR REPAIR OF
HKL-COMPRESSOR AND HYDRAULIC SYSTEM. THIS IS CRUCIAL TO ENSURE SAFE, RELIABLE AND LONG-LIFE
OPERATION OF YOUR EQUIPMENT.
Hydraulic system of a carrier machine should be maintained according to the service program.
All installation and service of both hydraulic and electric equipment must be performed by qualified and
experienced personnel only.
WARNING STICKERS
Dynaset dispatch department includes one (1) warning sticker bag per one (1) main product.
Product recipient is obligated to fix determinate warning sticker to Dynaset product.
Attach sticker to visible and appropriate place or close to Dynaset product where its easily seen.
Before attaching sticker clean surface with solvent detergent.
READ OPERATING INSTRUCTIONS.
GENERAL CAUTION.
BEWARE OF HOT SURFACE. USE EAR PROTECTOR.
BEWARE OF PRESSURE AIR.
June 2014 JLe
GENERAL NOTES
DYNASET hydraulic compressors are compact and integrated all-in-one units, especially designed for mobile
installation. The only power source is a hydraulic system to provide compressor with required hydraulic fluid
flow at demanded pressure.
DYNASET hydraulic compressor transforms hydraulic power into a high quality compressed air.
Designed to meet regular compressed air demands, HK hydraulic compressors are used to power pneumatic
tools, for cleaning, flushing etc.
CONSTRUCTION
Utilizing compact rotary vane technique, DYNASET hydraulic compressor of HKL-series is mobile unit
comprised of a hydraulic motor with incorporated automatic rotation speed control valve (up to HKL 1800)
and rotary vane compressor block. Compressor block includes stator-rotor unit, cooling and lubrication
systems, oil separator as well as unloading pressure regulator, attached to the air intake.
Hydraulic motors and compressors shafts are coupled when rotor runs inside of stator eccentrically.
10
VANE COMPRESSOR BLOCK
7
1.
INTAKE AIR FILTER
2.
INTAKE/SERVO VALVES
3.
OIL CHAMBER
4.
COMPRESSION CHAMBER
5.
OIL COOLER
6.
OIL FILTER
7.
AIR / OIL LABYRINTH
8.
COMPRESSED AIR
9.
ROTOR
10.
OIL SEPARATOR
11.
OIL RETURN VALVE
12.
MINIMUM PRESSURE /
-NON RETURN VALVE
12
11
9
5
PERFORMANCE
When compressors rotor is revolved by a hydraulic motor, air is taken through a filter into a compression
chamber consisting of a stator and rotor.
The rotor is provided with longitudinal slots in which vanes slide. Vanes are pushed against the stator by
centrifugal force, generated by rotation. During compressors rotation air is being compressed through the
construction in volume comprised by walls of rotor, stator and vanes.
Pressurization, cooling and lubrication are ensured by oil, injected into a compression chamber due the
pressure differential between compression chamber and oil sump. Thereat, separate oil pump is not
required.
The compressed air/oil mixture is discharged from the rotor-stator unit passing through a labyrinth, where
most of the oil is separated from the air due to the continuous changes of direction.
The remaining oil is trapped at the separators inlet and furthers on filter element condensates it by
coalescing effect. The recovered oil returns to the intake.
The oil-free compressed air leaves the compressor through a minimum pressure / non-return valve. The
valve prevents the air from leaving the compressor until the necessary internal pressure will be achieved in
order to ensure proper hermetization and cooling. The same valve also prevents the compressed air,
already contained in the system, to return into the compressor.
The fan, mounted on a motor shaft and placed inside of an oil cooler, maintains the proper temperature of
the compressor oil and compressed air.
The quantity of air, aspirated by the compressor is regulated / limited by the intake valve, hydraulically
controlled by servo valve.
June 2014 JLe
... PERFORMANCE
7
16
23
16
15
21 22
18
2
P
T
S
10
13
11
17
12
14
30
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
COMPRESSOR BLOCK
OIL SUMP, PRIMARY SEPARATION
INTAKE FILTER
INTAKE VALVE
AIR / OIL SEPARATOR
MINIMUM PRESSURE / NON-RETURN VALVE
SAFETY VALVE 12 BAR
VACUUM RELIEF VALVE
OIL DRAIN VALVE
OIL RETURN VALVE
THERMOSTATIC BY-PASS VALVE
OIL COOLER
13.
14.
15.
16.
17.
18.
21.
22.
23.
30.
OIL FILTER
SERVOVALVE
THERMOSTAT
PILOT OPERATED CHECK VALVE OF
PE-CONTROL VALVE (23) (OPTIONAL)
OFF-LOAD VALVE (O)
OIL LEVEL INDICATOR
AFTERCOOLER (OPTIONAL)
CONDENSATE SEPARATOR (OPTIONAL)
PE-CONTROL VALVE FOR OFF-LOAD VALVE
(OPTIONAL)
HYDRAULIC SOLENOID VALVE
SAFETY VALVE:
Protects compressor against internal overpressure. The safety valve is adjusted to 12 bar.
SERVOVALVE:
Limits the maximum operational pressure during compressors continuous operation by closing the
intake valve according to the increase of an internal pressure. The valve operates together with the
OFF-LOAD VALVE.
THERMOSTATIC BY-PASS VALVE:
Forwards warming the oil to the operational temperature before opening the oil circulation through the
cooler.
OFF-LOAD VALVE (O, with or without a SOLENOID CONTROL VALVE ):
When activated, drops compressors load and discharges internal pressure.
AIR-TO-ELECTRIC (PE-) CONTROL VALVE FOR OFF-LOAD VALVE :
Provides operation control in accordance with pre-adjusted maximum and minimum pressure limits
in automatic mode.
PE-valve and solenoid control valve for off-load valve are recommended when compressor is to be
started under pressure (for instance, air tank in pressure line) or compressor is operated intermittently.
i.e. stopped and restarted depending on a compressed air consumption.
The devices decompress the pressure line enabling easy restart of the compressor.
LUBRICATION SYSTEM OF THE COMPRESSOR
COMPRESSOR OIL PERFOMS FOLLOWING FUNCTIONS:
1. LUBRICATION
Pressure differential (see above) makes the oil spread along grooves to the surfaces to be
lubricated. Separate oil pump not required.
2. HERMETIZATION
Oil, injected into the stator, seals rotor blades against stators wall and lubricates them.
3. COOLING
Compressor oil removes the compression heat from the stator.
4. CAPACITY CONTROL
Off-load automatics (servo valve - off-load valve) adjusts compressors flow rate according to
the air consumption hydraulically using compressor oil.
June 2014 JLe
PRESSURE AND COMPRESSION RATIO

The rated absolute intake pressure is 1 bar (100 000 Pa). (NOTE! The reference barometric pressure
at 0 m above sea level is 1,0135 bar, when at 1000 m above sea level it drops to approx. 0,9 bar).
When the discharge (operational) pressure of HKL-compressor is 8 bar, compression ratio is equal to:
operational pressure + barometric pressure
barometric pressure
8 + 1,0135
= 8,89
1,0135
The compression ratio for unit of 12 bar is calculated in the same way.
AIR AND OIL TEMPERATURES

Filled with specified compressor oil or corresponding, (ref. to COMPRESSOR OILS) unit is operated without
any particular arrangements within ambient temperature range -5 C... + 40 C. If ambient temperature drops
below -5 C or raises over + 45 C, fill the compressor with synthetic oil or be kindly requested to contact
DYNASETs representative.
According to the standard EN 1012-1 the maximum accepted temperature of oil is +100 C. In normal operational
conditions at ambient temperature of +20 C compressor oils temperature levels to 80 - 85 C.
The temperature of the delivered compressed air exceeds ambient temperature by approx. 5 - 10 C.
AIR HUMIDITY
Compressor can be operated at the relative humidity up to 90%, provided that the ambient temperature is
within the above range. If air humidity exceeds 90%, please contact DYNASETs representative.
June 2014 JLe
INSTALLATION
DYNASET hydraulic compressor can be placed deliberately ensuring free air intake, sufficient cooling and an
easy access to the unit. Position of a compressor should be horizontal. To protect compressor against overheating,
do not allow the warmed cooling air to be directed by cooling fan back to the compressor block. Compressors
location should be chosen as far as possible from any source of dust and heat. Protective cover against weather
and season impacts is recommended.
Intake air should not contain any smoke, toxic or flammable gas/vapor. When necessary, intake pipe can be
fitted (the pipe should be measured properly in order to avoid load loss).
DYNASET hydraulic compressor works installed into an original hydraulic system of any carrier machine.
Additionally, return line must be connected to a hydraulic oil tank directly in the shortest possible way in order
to keep return oil pressure under 5 bar. Generally DYNASETs T-line is to be connected directly to the return
line of a hydraulic system, when hydraulic fluid flows to the tank only through the return filter and cooler.
Both filtering degree and cooling capacity of a hydraulic system should be sufficient (ref. to PARAMETERS).
P
T
It is possible to use DYNASET either as a mobile compressor and connect hydraulic power
with quick couplings, or make a fixed installation on a carrier machine.
To put DYNASET compressor into operation only pressure- (P) and return (T) lines of a
hydraulic system are to be connected to the units corresponding hydraulic ports. The
proper connection ensures correct rotation direction of the compressor and, by that, an
appropriate cooling of the compressor block. Rotation in opposite direction is not allowed.
Furthermore, cross-connection of hydraulic hoses damages hydraulic motors shaft seal.
Ensure that the oil flow is sufficient to run the unit, i.e. at least the nominal flow must be available.
At the oil flow less that demanded nominal rate, compressors delivery will be below the nominal. If the oil
flow is so excessive, that the automatic speed control valve is unable to handle it, the unit could be damaged.
In the latter case the oil flow is to be reduced either by dropping down the rotation speed of hydraulic pump
or using flow limiter valve. DYNASET priority valve is recommended.
After having been connected to the hydraulic system, DYNASET hydraulic compressor is to be started by directing
the oil flow to the units pressure port by means of control valve - manual or solenoid. Even simple ball valve
or three-way valve can be used.
To ensure DYNASETs proper operation, the hydraulic pressure must be set to the level, at which at least the
nominal power output is achieved (ref. to PARAMETERS). Lower hydraulic pressure reduces compressed air
pressure. Maximum hydraulic pressure is 250 bar (ref. to PARAMETERS). If the hydraulic system main pressure
is higher, service pressure relief valve must be used.
Ensure also that your machine oil cooling is working properly when DYNASET is in operation.
June 2014 JLe
... INSTALLATION
DYNASET hydraulic compressors are designed for easy integration into hydraulic system of any type.
OPEN CENTRE HYDRAULIC SYSTEM WITH VARIABLE DISPLACEMENT PUMP
1.
The demanded hydraulic flow is to be ensured and controlled with a DYNASET PRESSURE COMPENSATED
PRIORITY VALVE.
DYNASET PV SAE 3/4 - 1 1/4 -XX lpm - 12/24 V
priority valve includes following components:
1.
AUTOMATIC
Sandwich-mounted pressure
ROTATION SPEED
CONTROL VALVE
compensator with SAE-flange
specification;
T P
2.
S
Solenoid valve 12/24V;
M
3.
Flow limiter;
4.
Pressure relief valve.
PV-SAE valve
PV SAE priority valve is designed for the

installation to main pressure line
between SAE-flanges of main hydraulic
pump. Pre-adjusted, independent from
other functions and priorised hydraulic
flow for DYNASET-unit comes from the
solenoid valve.
B
LS
LS
CF
HKL
T
The rest of hydraulic pumps capacity is available for all other

functions. Furthermore, pumps control works together with
DYNASET PV SAE priority valve.
ALSO AVAILABLE for open centre hydraulic systems with variable displacement pump: PRIORITY VALVE PV SAE - 1 - 12/24 V.
DYNASET PRIORITY VALVE enables trouble-free operation of your DYNASET-unit simultaneously with other
hydraulic executors.
2.
CLOSED CENTRE HYDRAULIC SYSTEM WITH VARIABLE DISPLACEMENT PUMP

The demanded hydraulic flow is to be ensured and controlled with a DYNASET
PRESSURE COMPENSATED LOAD SENSING (LS) VALVE.
AUTOMATIC
ROTATION SPEED
CONTROL VALVE
S
M
DYNASET LS-valve includes following

components:
1.
Flow limiter;
2.
Solenoid valve 12/24V;
3.
Pressure relief valve;
4.
Shuttle valve (OPTIONAL).
DYNASET LOAD SENSING VALVES:
LSV 40, LSV 60, LSV 95 and LSV 150
HKL
LS-valve
LS-connection, pressure relief, max. hydraulic

flow 40, 60, 95 ja 150 l/min respectively.
DYNASET FLOW LIMITERS to the pressure line:

VR 40 PK - 1/2, max. 35 l/min, with pressure compensation;
VR 95 PK - 3/4, max. 95 l/min, with pressure compensation.
VRD 180 PK - 1, max. 180 l/min, with pressure compensation.
ALSO AVAILABLE for closed centre hydraulic systems with variable displacement pump:
DYNASET SOLENOID VALVE to the pressure line for remote starting.
SV 70 NC - 1/2 - 12 / 24 V
max 70 l/min with LS -connection;
SV 150 NC 1 - 12 / 24 V
max 150 l/min with LS -connection.
June 2014 JLe
... INSTALLATION
3.
HYDRAULIC SYSTEM WITH CONSTANT DISPLACEMENT PUMP

AUTOMATIC
ROTATION SPEED
CONTROL VALVE
The demanded oil flow is to be ensured with

proper hydraulic pump choice. In systems with
redundant hydraulic flow an installation with
DYNASET PRIORITY VALVE is recommended.
Installation with a standard pressure compensated
3-way valve should be avoided in order to close off
potential waving in hydraulic system.
ALSO AVAILABLE for hydraulic systems with

constant displacement pump:
DYNASET FREE CIRCULATION VALVE with solenoid
and pressure control, type VKV 903/4.
HKL 400 - 1800
HYDRAULIC COMPRESSORS WITHOUT AUTOMATIC SPEED CONTROL VALVE:
HKL 2600 - 5000
T
HKL 400 - 1800
HKL 2600 - 7500
When installing a compressor of given type to a hydraulic system, is to kept in mind that the allowed
nominal hydraulic flow should not be exceeded (Qhy_nom = Qhy_max).
CONNECTION TO THE AIR SUPPLY SYSTEM

Compressor can be connected to the air supply system (or consumer) with a proper fitting and cut-off valve
(options). The internal diameter of pipe / hose used for compressors connection should be at least equal to
AP-port to keep the pressure drop minimal. The length of a pipeline, laid with the pipe of same diameter as
AP-port, can be 50 m as maximum. For longer lines use larger diameter.
Moisture separator to the pressure line is

optional.
S
M
It is recommended to install distribution valve to

a pressure line near the compressor in order to
clean oil cooler and filter with a blow gun when
necessary.
June 2014 JLe
10
OPERATION
Prior to starting the compressor check whether the unit is filled with oil. In non-operating and depressurized
compressor oil level is over the top point of sight glass. When necessary top up with the same oil as the unit
is filled with. Replace and tighten the filler plug (Ref. to the instructions below).
Open the cut-off valve in compressors pressure line. Ensure from compressors pressure gauge that the unit
is decompressed - when pressurized, compressor may start with difficulty*).
With carriers engine running HKL-compressor is started with a hydraulic control valve. Compressor starts to
produce usable compressed air when hydraulic flow achieves the functional minimum rate, which is approx.
a half of the nominal value (Ref.to the units nameplate as well as to the PARAMETRS). The nominal
discharge is achieved when the compressor is rotated by hydraulic flow adequate to the nominal rotation
speed.
ATTENTION !
The minimum allowed rotation speed of rotary vane compressor is 1200 rpm, corresponding to the
minimum hydraulic flow - refer to pages 21 and 22 of the manual.
*)
When the compressor is to be started under pressure (for instance, air reservoir in pressure line) or the unit
is used intermittently stopping and restarting it several times according to the air demand, following
accessories are recommended:
* solenoid control valve for off-load valve;
* pressure switch.
COMPRESSORS EQUIPPED WITH AN AUTOMATIC ROTATION SPEED CONTROL VALVE
HKL400 - HKL1800
Qhy_nom = Qhy_calc + 2 l/min

Qhy_calc - CALCULATED CONSTANT FLOW
Qhy_nom - NOMINAL FLOW
Qpi,
Qpi,
nom
Qpi,
min
l/min
DISCHARGE
Compressor being rotated at full output,

automatic rotation speed control valve keeps
rotation speed constant when incoming
hydraulic oil flow (Qhy) can vary from
nominal demanded flow (Qnom) up to value
exceeding Qnom by 10 20 l/min depending
on compressor size.
CONTROL RANGE*
Qmax
Qmin
Qnom
Qhy,
l/min
HYDRAULIC FLOW
COMPRESSORS WITHOUT AN AUTOMATIC ROTATION SPEED CONTROL VALVE

HKL2600 - HKL5000
Hydraulic flow rate marked on the compressors

nameplate is an absolute maximum and should
not be exceeded in any circumstances.
A redundant hydraulic flow causes compressors
overspeeding and may damage it.
Qpi,
nom
Qpi,
min
l/min
DISCGARGE
Qpi,
Q hy_nom = Q hy_max
0
OFF-LOAD MODE
Qhy,
Qmin
Qnom = Qmax
l/min
HYDRAULIC FLOW
Compressed air is consumed according to the demand, when compressors delivery levels within 0 l/min
to the maximum. If the compressed air is not used while compressor is running, off-load automatics (=
OFF-LOAD VALVE + SERVOVALVE) closes the intake valve and sets compressors internal pressure to 1 - 2
bar (to prevent compressor oil from drain into the air filter) when the output drops to 0 l/min.
When the compressed air is consumed, off-load automatic controls the intake valve according to the
current air demand.
June 2014 JLe
11
... OPERATION
ATTENTION !
The compressor must be operated neither in smoky environment nor in conditions where toxic or flammable
vapors could be aspirated.
Compressors maximum pressure must not be exceeded in any circumstances.
Compressed air delivered by a HKL-compressor must not be used as the breathing air, even if purified and
filtered. HKL-compressor is designed for air only and must not be used with any other gas.
If the compressor is connected to the distribution network or consumer with a flexible hose, ensure that the
hose is of proper diameter and pressure class. Damaged or worn hose should be replaced immediately.
The sound-proof enclosure (if used) should be closed when compressor is in the operation.
Check the compressors oil fill periodically: when the unit is in operation, the oil level must be over the
midlevel of the sight glass .
NEVER REMOVE THE OIL FILLER PLUG WHEN THE COMRESSOR IS RUNNING OR PRESSURIZED !
HYDRAULIC FLUIDS
Wide range of standard hydraulic fluids can be used with the DYNASET hydraulic equipment.
Depending on the operating temperature, following mineral hydraulic oils are recommended:
ISO VG 32S
for oils operation temperature up to 70 C;
ISO VG 46S
for oils operation temperature up to 80 C;
ISO VG 68S
for oils operation temperature up to 90 C.
Synthetic and bio-oils can be used as well if their viscosity characteristics and lubricating efficiency are
corresponding to above mineral oils. Automatic transmission fluids and even engine oils can be used,
provided that they are allowed to be used in hydraulic system of your carrier machine.
To use special hydraulic fluids a with DYNASET equipment, please be kindly requested to contact nearest
DYNASET representative for an advice.
COMPRESSOR OILS
ROTOROIL F4 compressor oil is recommended as most preferable lubricant. If ROTOROIL lubricants are not
available it is allowed to replace them with high quality rotary vane compressor oils of same viscosity class
supplied by other manufacturers, see table below. Pay attention to long-life oil exchange interval and life
span. All Dynaset compressors are equipped with thermostat for unexpected overheating and damages.
QUALITY
AMBIENT
TEMPERATURE
OIL CHANGE
MAX, HOURS
SUPPLIER
DETAILS
ROTOROIL 8000 F4
Corena S4R
Rarus SHC 1020
- 30 ... + 45C
- 10 ... + 45C
- 10 ... + 45C
2.500 or 12 months
2.500 or 12 months
2.500 or 12 months
Dynaset
Shell
Exxon Mobil
synthetic oil
synthetic oil
synthetic oil
ATTENTION !
Do not mix together lubricants neither of different specification nor of different brand!
COMPRESSOR MAINTENANCE
DYNASET hydraulic compressors are low-maintenance units. Only normally wearing parts and materials
should be replaced either when necessary or in accordance with a service program.
Refer also to the TROUBLESHOOTING section.
Prior to starting any maintenance or repair, ensure that the compressor is completely depressurised.
The pressure gauge in oil separator housing must indicate zero.
June 2014 JLe
12
COMPRESSOR MAINTENANCE
DYNASET HKL-SERIES SERVICE TABLE
Neglecting recommended services may cause device malfunction and Dynaset warranty is anymore valid.
Perform given maintenance in time according to next table.
CHECK POINTS
Check oil level
Clean compressor air intake filter
Clean oil cooler and air after cooler
Clean oil return valve filters
Change air intake filter
Tighten nuts and screws fixing the
wires in the electric control panel
and in the motor terminal board
Replace oil return valve filters
Change oil filter: FG
Change oil filter: F2 or F4
Oil change: Rotoroil 8000: FG
Oil change: Rotoroil 8000: F2 or F4
After
the
first
50 h
Weekly
or
every
50 h
O
O
O
O
Monthly Every 3
months
or
or
every
100 h
500 h
Every 6 Every 12 Every 12

months months months
or
or
or
1000 h 1000 h 2500 h
I
I
I
I
I
I
I
I
I
I
Maintenance operations have to be performed at reduced Intervals in case of dusty environments.

NOTE: O = These operations must perform to a new device after the first 50 hours.
Within the first 300 hours of operation: Clean the oil return valves.
NOTE: All installation and service of both hydraulics and electric equipment must
be performing experienced personnel only.
INTAKE AIR FILTER
INTAKE AIR FILTER
In normal operating conditions the filter

element should be replaced after each 1000 h
or with the interval of at least 6 months.
Filter site and cover should be cleaned.
Oil cooler should be checked on a daily

basis and cleaned when necessary. To clean
the cooler use AIR blow gun MODERATELY.
A clogged and dirty cooler causes
compressors overheating.
June 2014 JLe
13
MAINTENANCE
OIL LEVEL CHECK AND CHANGE
FACTORY-FILL OIL
Factory-fill oil must be changed after very first 200
(max.) operation hours.
Further on compressor oil is to be changed according
to the oil quality and service time (ref. to
COMPRESSOR OILS above) or at least once a year.
ENSURE THAT THE COMPRESSOR IS COMPLETELY
DEPRESSURIZED !
Unscrew filler plug (1) slowly.
Attach proper fitting to the oil drain valve (2.1) and
open the valve. Drain the oil into the suitable pan.
(Oil drain valve could be replaced with a discharge
plug 2.2).
Shut off the valve (2.1) or replace and tighten the
plug (2.2) Fill the compressor with oil. Replace and
tighten filler plug 1. DO NOT FORGET GASKETS !
2.1
2.2
ATTENTION !
OIL SHOULD BE CHANGED WHEN THE
COMPESSOR IS WARMED UP TO THE
NORMAL OPERATIONAL TEMPERATURE.
Start the compressor and let it operate few minutes.

Check oil level and top up if necessary.
OIL LEVEL SHOULD BE CHECKED AT EACH STARTING :
Compressor standing still:
OVER THE TOP POINT OF A SIGHT GLAS (3).
Compressor running:
OVER THE MIDLEVEL OF A SIGHT GLAS (3).
OIL FILTER ELEMENT SHOULD BE REPLACED AT EACH OIL CHANGE OR

AT LEAST AFTER EVERY 12 MONTHS.
MODEL
HKL 400/8 - 24 (33)
HKL 801/8 - 26
HKL 1300/8-38 (46)
HKL 1800/8-46
HKL 2600/8-65 (82)
HKL 4100/8-113
HKL 5000/8-135
HKL 7500/8-176+12
OIL FILL
l
2,5
2,0
2,0
3,5
3,5
10
10
19
OIL RETURN VALVES

OIL RETURN VALVE
OIL RETURN VALVE
Oil return filters should be cleaned

at the first oil change.
Further on, oil return filters should
be cleaned after each 500 h or
every three months. Replace oil
return filters after each 2500 h or
at least once a year.
14
June 2014 JLe

MAINTENANCE
AIR / OIL SEPARATOR
In normal ambient conditions oil separator elements should be replaces at each 10 000 operation hours or
when pressure loss or oil consumption increases considerably.
In heavy conditions exchange interval should be shortened.
SEPARATOR ELEMENT
SEPARATOR ELEMENT
HKL 800 - HKL 2600
HKL 4100 - HKL 5000
PRESSURE REGULATION
Compressors output pressure is adjusted and
tested at factory and usually does not
required resetting.
However, if re-adjustment is required, the
procedure is to be made as follows:
1.
Start the compressor.
2.
Shut off the pressure line slowly when air
pressure achieves the maximum. Note the
pressure gauges reading *).
3.
Having removed parts, shown on the sketch,
make the adjustment with the servo valve:
3.1 loosen locknut first
3.2 to increase pressure, tighten the
adjusting screw;
to decrease pressure, loosen the
adjusting screw;
3.3 lock the setting with locknut.
SAFETY VALVE 12 BAR
SERVOVALVE
REF. TO THE DATA SHEETS FOR SPECIFIC UNIT !!!

NOMINAL OUTPUT PRESSURE
OF A HYDRAULIC COMPRESSOR
SERVOVALVES SETTING
bar
bar
8
10
8,5
10,5
ATTENTION !
ONLY THE QUALIFIED PERSONNEL IS
ALLOWED TO MAKE THE SETTING !
*)
A separate pressure gauge should be connected to the pressure line when making
the adjustment.
It is recommended to use the unit comprised of ball valve and pressure gauge as
shown on the alongside sketch.
15
June 2014 JLe

TROUBLESHOOTING
1.
COMPRESSOR DOES
NOT START WHILE
CARRIERS ENGINE IS
RUNNING AND
HYDRAULIC SYSTEM IS
ON.
2.
COMPRESSOR STARTS
HARDLY
3.
AIR PRESSURE DOES
NOT ACHIEVE
REQUESTED RATE.
1.1
Malfunction of compressors
hydraulic control valve.
1.2
Compressors excessive internal
pressure.
1.1
Check and repair.
1.2
Check the minimum pressure/non return valve and
repair possible blowing.
1.3
Failure in hydraulic system.
1.3.1
Check whether the hydraulic fluid flow and pressure
are sufficient. Adjust when necessary.
1.3.2
Check the hydraulic motor for possible leakage.
Replace motor if necessary.
1.4
Air pressure in delivery line
disrupts compressors start.
1.4
Let off the pressure from the delivery line prior to
staring the compressor.
It is recommended to install the solenoid control
valve for off-load valve, especially if the pneumatic
system is provided with an air reservoir.
See 1.3
See 1.4
3.1
Servo valves incorrect setting.
3.1
Check and adjust servo valve when necessary.
3.2
Safety valve opens due to the
either the failure or incorrect
setting of servo valve.
3.2.
Check and adjust servo valve.
3.3
Failure in hydraulic system.
3.3.1
Check whether the hydraulic fluid flow and pressure
are sufficient. Adjust when necessary.
3.3.2
Check the hydraulic motor for possible leakage.
Replace motor if necessary.
3.4
Air intake filter is clogged.
3.4
Check and replace.
3.5
Oil separators filter element(s)
clogged.
3.5
Check and clean / replace filter element(s).
June 2014 JLe
16
... TROUBLESHOOTING
4.
COMPRESSOR DOES
NOT PRODUCE
COMPRESSED AIR =
RUNS UNLOADED
5.
EXCESSIVE OIL
CONSUMPTION
6.
COMPRESSORS
OVERHEATING.
4.1
Delivery line closed (i.e.
OPEN/CLOSE valve is damaged) or
possible malfunction in pneumatic
executor.
4.2
Servovalves failure or incorrect
setting (i.e. adjusted to the
pressure lower than setting of
minimum pressure / non return
valve).
4.3
Air intake valve does not open.
4.1
Check and repair possible failure.
5.1
Filters of the oil return valves are
clogged.
5.1
Check and clean / replace valves.
5.2
Oil separators filter element(s)
clogged.
5.2.
Check and clean / replace filter element(s).
6.1
Dirty oil cooler.
6.1
Clean the oil cooler.
6.2
High ambient temperature.
6.2
Sufficient ventilation is to be arranged.
6.3
Low oil level.
6.3
Add compressor oil to the required level.
6.4
Due to the seizure of thermostatic
by-pass valve, compressor oil does
not circulate through oil cooler.
6.4
Check and repair the valve.
6.5
Due to the insufficient cooling
capacity of a hydraulic system
hydraulic fluid warms the
compressor.
6.5
DYNASET OY offers wide range of hydraulic
components including oil coolers !
4.2.
Check and repair possible failure.
4.3
Check the valve and repair failure. Check also the
whole valve block to order to find out and repair
possible malfunctions.
ATTENTION !
HKL-compressor is equipped with a
thermostat, which is to be used for stopping
the compressor when the units temperature
achieves thermostats constant set value.
Thermostat is to be connected to the stop
valve or alarm lamp in the Customers system
by Customer themselves.
June 2014 JLe
17
SOLENOID CONTROL VALVE FOR OFF-LOAD VALVE (O)

The valve being activated,
compressors load and internal
pressure are dissipated.
Prior the installation
remove air filters cover.
PLUG R 1/8
PLUG M5
HKL 800 - HKL 2600
ATTENTION !
In HKL 4100 and HKL 5000
the connection is placed
on the right side of the
compressor block.
A.
The offload valve (17) is to be attached into the connection (1) of R
1/8 in oil separator (on the same side with AP-connection). Tightening
glue is used to make joint hermetic. Prior to the installation remove the
plug 1/8 from the connection port.
B.
From-valve-to-compressor unload air tube (2) (6/4 teflon) is installed to
the connection M5 (3) with a swivel fitting and tightening glue as shown
on sketches above. Prior to the installation remove the plug M5 from
the connection port.
The unload air tube is laid under the oil separator between
compressors housing and air filter cover.
Installation kit includes all necessary fittings and the nylon tube.
The valve is equipped with a pre-installed fitting 1/8.
June 2014 JLe
18
AIR-TO-ELECTRIC (PE-, 23) CONTROL VALVE FOR OFF-LOAD VALVE

PE-control valve provides operation control in accordance with pre-adjusted by an incorporated pressure
switch maximum and minimum pressure limits in automatic mode.
23
16
23.3
PE-CONTROL VALVE FOR OFF-LOAD

VALVE IS COMPRISED OF TWO BASIC
ASSEMBLIES:
POS 16
Pilot operated check valve
23.1
POS 23
PE-control valve, including following
components:
23.1
LOCKNUT OF
PILOT VALVE
pilot valve (4 - 10 (13) bar)
23.2
needle valve to adjust filling
time interval of air chamber 23.4
IP65
HYSTERESIS
LOCK
23.2
23.3
pressure switch, pre-adjusted
at factory (3 bar)
23.4
air chamber
Filling times for air chamber 23.4,

pre-adjusted at factory:
HKL 1300
14 - 15 sec
HKL 2600
.....
20 sec
HKL 5000
40 - 45 sec
PRESSURE SWITCH 23.3:

Contacts 1-2: NC, used when compressor is run
as stand-alone unit
Contacts 1-4: NO, used when compressor is
installed to a Customers system with several
executive units;
Control voltage max. 250 V
Pressure max. 10 bar
ATTENTION !
PILOT VALVEs (23.1) HYSTERESIS IS ADJUSTED
AT FACTORY ! DO NOT RE-ADJUST !
June 2014 JLe
19
AIR-TO-ELECTRIC CONTROL VALVE (PE-, 23) FOR OFF-LOAD VALVE
When there is no air consumption compressor being on (i.e. delivery line is closed), air pressure in
compressors reservoir achieves its maximum, opening a pilot valve (23.1) and activating the off-load
mode.
Pilot operated check valve (16) opens and sends a signal to a compressor servov alve, which closes the air
intake valve.
An air chamber (23.4) is filled up with an air discharging from compressors reservoir until the pressure in
chamber achieves the pre-adjusted value for the opening of a pressure switch (3 bar). Pressure switch 23.3
opens de-energizing the solenoid valve (30) when the unit stops.
As soon as the compressed air is requested by a pneumatic consumer, i.e. delivery line is open - pressure in
air chamber (23.4) drops less than 3 bar, when the pressure switch closes, re-energizing the solenoid valve
(30) and restarting the compressor.
23
23.4
23.3
23.2
3 BAR
TIME
23.1
PRESSURE
16
+V
(30) HYDR.
SOLENOID
If the compressed air is requested the off-load mode being on, PE-valve drops the pressure in compressors
reservoir to the pre-adjusted value (set from the pilot valve to 5 - 6,5 bar depending on the unit size)
opening the compressors intake valve, and the unit passes into the operation directly from the unloaded
mode.
June 2014 JLe
20
PRODUCT DISPOSAL
Conform to waste legislation, regulations and recommendations in waste disposal and waste recycling
issued by local authorities.
1. Precondition:
Product is permanently useless or beyond repair.
Before transportation get off all used agent (oil, cooling liquid) and dirty filters.
Items requiring special handling can normally be done by authorized waste management facility,
if not:
Separating the base materials, iron, copper, steel, electronics, removing paint, polyester resin,
and insulation tape and/or plastics residues from all components.
This waste material can now be recycled.
2. Deliver the recycling material to waste management facility.
Note! Customer can send the DYNASET equipment for reuse or recycling to the Dynaset Oy or to
other location determinate by Dynaset representative.
Customer pays shipping cost.
Equipment must be adequately packed for shipment.
Shipment documents must contain purchasers name and contact information.
June 2014 JLe
21
HKL-COMPRESSORS, STANDARD DISCHARGE PRESSURE OF 8 BAR *
PARAMETERS
HKL - VANE COMPRESSORS

HKL 400 /8 -24
-33
DISCHARGE CHARACTERISTICS
Flow rate at ref. conditions*,
max. l/min
Maximum pressure
bar
HKL 801/8 -26
400
8
HKL 1300/8 -38

-46
HKL 1800/8 -46
800
8
1300
8
1800
8
COMPRESSED AIR CONNECTION AP
BSP 12
BSP 1/2
BSP 1/2
BSP 3/4
HYDRAULIC CONNECTIONS
Pressure line
Return line
Drain line
BSP 1/2
BSP 1/2
NO
BSP 1/2
BSP 1/2
NO
BSP 1/2
BSP 1/2
NO
BSP 1/2
BSP 1/2
NO
20
60
210
120
14
37
210
250
140
2,8
10 - 200 / optimum 25 - 35
max. 70 **
min. 25
2,2
3,2
P
T
DR
HYDRAULIC POWER REQUIREMENTS

Minimum flow
l/min
Maximum flow
l/min
Pressure at nominal flow
bar
Maximum pressure
bar
Pressure when unloaded
bar
10
35
210
14
55
170
250
140
23
66
170
130
23
66
210
250
150
250
150
HYDRAULIC FLUID REQUIREMENTS

Viscosity
cSt
Temperature
C
Filter ratio, recommendation um
Cooling capacity, recommend. kW
OVERALL DIMENSIONS
Length
Width
Height
mm
mm
mm
525
250
325
640
390
540
640
390
540
750
390
600
WEIGHT
kg
30
50
55
95
* According to ISO 1217(1996) at discharge pressure of 6 bar.

** REF. TO HYDRAULIC FLUIDS
*) models of 7 - 13 bar discharge pressure available by request
June 2014 JLe
22
HKL-COMPRESSORS, STANDARD DISCHARGE PRESSURE OF 8 BAR *
PARAMETERS
HKL - VANE COMPRESSORS

HKL 2600/8 -65
-82
DISCHARGE CHARACTERISTICS
Flow rate at ref. conditions*,
max. l/min
Maximum pressure
bar
HKL 4100/8-113
2600
8
4100
8
HKL 5000/8-135
5000
8
COMPRESSED AIR CONNECTION AP
BSP 3/4
BSP 1
BSP 1
HYDRAULIC CONNECTIONS
Pressure line
Return line
Drain line
BSP 3/4
BSP 1
NO
BSP 3/4
BSP 1
NO
BSP 3/4
BSP1
NO
74
113
200
250
145
74
135
180
250
150
P
T
DR
HYDRAULIC POWER REQUIREMENTS

Minimum flow
l/min
Maksimum flow
l/min
Pressure at nominal flow
bar
Maximum pressure
bar
Pressure when unloaded
bar
33
65
210
41
82
170
250
50
135
HKL 7500/8 -132 + 12

-176 + 12
7500
8
BSP 1 1/4
BSP 1
BSP 1
T15
72 + 12
144
260
280
200
96 + 12
188
200
250
150
HYDRAULIC FLUID REQUIREMENTS

Viscosity
cSt
Temperature
C
Filter ratio, recommendation um
Cooling capacity, recommend. kW
OVERALL DIMENSIONS
Length
Width
Height
mm
mm
mm
790
390
600
870
495
770
870
495
770
1100
850
820
1100
850
820
WEIGHT
kg
103
185
185
325
330
6,8
9,4
10 - 200 / optimum 25 - 35
max. 70 **
min. 25
11,3
* According to ISO 1217(1996) at discharge pressure of 6 bar.

** REF. TO HYDRAULIC FLUIDS
*) models of 7 - 13 bar discharge pressure available by request
June 2014 JLe
23
MANUFACTURERS LIMITED WARRANTY
1.
Warranty coverage
All hydraulic accessories manufactured by
DYNASET OY are subject to the terms and
conditions of this limited warranty. Products are
warranted to the original purchaser to be free from
defects in materials or workmanship. Exclusions
from warranty are explained in item 8.
2.
Beginning of warranty period

Warranty period begins from the delivery date of
the product. Delivery is considered to be done on
the date when installation has been accomplished
or purchaser has taken the product in use.
Product is considered as taken in use at the date
when DYNASET OY has delivered the product to
purchaser, unless separately agreed otherwise by
written agreement.
3.
4.
5.
Warranty period
Warranty period is twelve (12) months based on
maximum of 2000 hours usage during this time
period. In cases where the system is provided
complete with certain special components (e.g.
drive unit), those components are considered as a
subject to their manufacturers warranty.
Warranty procedures
Immediately upon identifying a problem which
purchaser believes to be a failure subject to the
products limited warranty, purchaser must contact
primary 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 the problem primarily by phone or
e-mail. Purchaser commits to give necessary
information and to perform routine diagnostic
procedures in order to determine the nature of the
problem and necessary procedures.
Warranty repairs
If the product is found to be defective during the
warranty period, DYNASET OY will, at its option,
either repair the product, author it to be repaired at
its authorized workshop or exchange the defective
product. If the product must be repaired elsewhere
than premises of DYNASET OY or authorized
workshop, all costs excluded from this warranty
(traveling and waiting hours, daily allowance,
traveling expenses and uninstallation/reinstallation
costs) will be charged from the purchaser.
If the problem is not covered by this limited
warranty, DYNASET OY has the right to charge
purchaser of troubleshooting and repairing.
6.
Delivery terms of warranty repair

If the product is found possible to be defective
under this limited warranty and it needs to be
repaired, DYNASET OY gives Warranty Return
Number (WRN). Items being returned must be
shipped, at the purchasers cost, adequately
packed for shipment, to the DYNASET OY or to
other location authored by DYNASET OY.
Shipment documents must contain:
Purchasers name and contact information
Receipt of original purchase
WRN code
Problem description
7.
Warranty of repaired product

Warranty period of the product repaired under this
limited warranty continues to the end of original
warranty period.
8.
Exclusions from warranty

This warranty shall not apply to:
a.
Failures due to normal wear and tear,
improper installation, misuse, abuse, negligence,
purchaser selection of improper product to intended
use, accident, improper filtration of hydraulic oil or
intake water or lack of maintenance
b.
Cost of maintenance, adjustments, installation
or startup
c.
Coating, hydraulic oil, quick couplings and
interconnection hoses (internal or external to system
assemblies)
d.
Products altered or modified in a manner not
authorized by DYNASET OY in writing
e.
Products which have been repaired during
warranty period by others than DYNASET OY or its
authorized workshop
f.
Costs of any other damage or loss, whether
direct, indirect, incidental, special or consequential,
arising out of the use of, or the inability to use, the
product
g.
Telephone or other communications expense
h.
Product that is used in exceptional conditions,
considered to cause excessive wear and tear
i.
Faults caused by nature phenomenons like
flood, thunder, etc.
DYNASET OY, all rights reserved
24
June 2014 JLe

EC DECLARATION OF CONFORMITY
We hereby declare that the below-reference product design, structure and our
manufacture form fulfills relevant, fundamental safety and health requirements
with the provisions in the Council Directive on mutual approximation of laws of the
Member States on the safety of machines.
- Machine directive 2006/42/EC

- Directive 97/23/EC European standards Pressure equipment.
- LVD directive 2006/95/EC
Apply conformity standards:
- CEN EN ISO 4413: EN ISO 4413:2010
Hydraulic fluid power - General rules and safety requirements for systems
and their components.
If device has changed by someone other than at the hands of manufacturer or his
permission, this declaration is not valid.
PRODUCT:
HYDRAULIC COMPRESSOR
TYPE NUMBERS:
HKL400/8-24-xxx, HKL400/10-24,
HKL801/8-26-xxx,
HKL1300/8-38-xxx, HKL1300/8-46-xxx,
HKL1800/8-46-xxx,
HKL2600/8-65-xxx, HKL2600/8-82-xxx,
HKL4100/8-113-xxx,
HKL5000/8-135-xxx,
HKL7500/8-176+12-xxx (xxx + xx)
YLJRVI 26.07.2012
DYNASET Oy
Timo Nieminen
R&D Manager
25
June 2014 JLe

NOTES

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June 2014 JLe

HKL HYDRAULIC COMPRESSORS

HKL 400/8 - 24 (33)

HYDRAULIC VANE COMPRESSOR

DYNASET OY, Menotie 3,

Tel.: +358 3 3488200

E-mail: info @dynaset.com

June 2014 JLe

HKL HYDRAULIC COMPRESSORS

SAFETY PRECAUTIONS AND WARNING STICKERS

PRESSURE AND COMPENSATION RATIO

AIR AND OIL TEMPERATURES

10. HYDRAULIC FLUIDS

11. COMPRESSOR OILS

12. COMPRESSOR MAINTENANCE

13. TROUBLE SHOOTING

14. SOLENOID CONTROL VALVE FOR OFF-LOAD VALVE (O)

15. AIR TO ELECTRIC (PE) CONTROL FOR OFF-LOAD VALVE

16. PRODUCT DISPOSAL

18. MANUFACTURERS LIMITED WARRANTY

19. DECLARATION OF CONFORMITY

MAY CHANGE WITHOUT PRIOR NOTICE

June 2014 JLe

HKL HYDRAULIC COMPRESSORS

READ OPERATING INSTRUCTIONS.

MAY CHANGE WITHOUT PRIOR NOTICE

June 2014 JLe

HKL HYDRAULIC COMPRESSORS

VANE COMPRESSOR BLOCK

MAY CHANGE WITHOUT PRIOR NOTICE

June 2014 JLe

HKL HYDRAULIC COMPRESSORS

MAY CHANGE WITHOUT PRIOR NOTICE

June 2014 JLe

HKL HYDRAULIC COMPRESSORS

PRESSURE AND COMPRESSION RATIO

AIR AND OIL TEMPERATURES

MAY CHANGE WITHOUT PRIOR NOTICE

June 2014 JLe

HKL HYDRAULIC COMPRESSORS

MAY CHANGE WITHOUT PRIOR NOTICE

June 2014 JLe

HKL HYDRAULIC COMPRESSORS

OPEN CENTRE HYDRAULIC SYSTEM WITH VARIABLE DISPLACEMENT PUMP

PV SAE priority valve is designed for the

The rest of hydraulic pumps capacity is available for all other

CLOSED CENTRE HYDRAULIC SYSTEM WITH VARIABLE DISPLACEMENT PUMP

DYNASET LS-valve includes following

LS-connection, pressure relief, max. hydraulic

DYNASET FLOW LIMITERS to the pressure line:

MAY CHANGE WITHOUT PRIOR NOTICE

June 2014 JLe

HKL HYDRAULIC COMPRESSORS

HYDRAULIC SYSTEM WITH CONSTANT DISPLACEMENT PUMP

The demanded oil flow is to be ensured with

ALSO AVAILABLE for hydraulic systems with

HKL 400 - 1800

HYDRAULIC COMPRESSORS WITHOUT AUTOMATIC SPEED CONTROL VALVE:

HKL 2600 - 5000

HKL 2600 - 7500

CONNECTION TO THE AIR SUPPLY SYSTEM

Moisture separator to the pressure line is

It is recommended to install distribution valve to