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HPW 250
HPW 220
HPW 300
HPW 320
HPW 360
HPW 420
HPW 460
HPW 520
HPW 800
HPW 1000
HPW 1200
HPW 1600
Congratulations!
You have just purchased DYNASET hydraulic equipment!
The equipment allows you to maximize the productivity and
efficiency of your mobile machine. Read this User Manual
before using your new equipment. It contains important
information that will help you 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
products and customer service.
We are constantly developing and releasing new innovations.
Please visit on our website and social media channels for the
latest news and updates.
Picture 4: Main components of HPW pump .....................................................................................................................11
Picture 5: Operating description of HPW pump 1 ............................................................................................................ 17
Picture 6: Operating description of HPW pump 2 ............................................................................................................ 18
Picture 7: Relation of pumping uid’s ow rate and pressure. ......................................................................................... 19
Picture 8: HPW hydraulic line connection in parallel ....................................................................................................... 19
Picture 9: HPW hydraulic line connection in series .......................................................................................................... 20
Picture 10: Open centre hydraulic system with Load Sensing variable displacement pump ............................................22
Picture 11: Connection gure for open centre hydraulic system with Load Sensing variable displacement pump ...........23
Picture 12: Closed centre hydraulic system with Load Sensing variable displacement pump ..........................................24
Picture 13: Connection gure for closed centre hydraulic system with Load Sensing variable displacement pump .........25
Picture 14: Hydraulic system with xed displacement pump .......................................................................................... 26
Picture 15: Connection gure for hydraulic system with xed discplacement pump ....................................................... 27
Picture 18: Placing HPW high pressure water pumps ...................................................................................................... 29
Picture 23: Connection to the pumping uid intake ........................................................................................................ 32
Picture 24: Installation into pumping uid line ............................................................................................................... 32
Picture 25: Connection to the pumping uid output ....................................................................................................... 33
Picture 26: Starting the HPW pump ................................................................................................................................ 35
Picture 27: HPW pump with water pressure unloader valve ............................................................................................ 36
Picture 28: HPW pump without water pressure unloader valve.......................................................................................36
Picture 29: Stopping the HPW pump ...............................................................................................................................38
Picture 30: Stopping procedure of the HPW pump .......................................................................................................... 38
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1. GENERAL
This manual contains general information about assembly, installation, operation
and maintenance of DYNASET HPW high pressure water pumps.
ATTENTION!
Read this user manual before installation, use or maintenance of the HPW
pump to ensure proper handling, operation and maintenance right from
the beginning. Pay attention to warnings and safety instructions. READ
CHAPTER ”2. SAFETY” for more information.
HIGH PRESSURE WATER PUMPS
GENERAL
1.1. PRODUCT INFORMATION
DYNASET HPW pump converts the hydraulic oil flow of a base machine into high
pressure water. HPW pumps are used for pumping water and other fluids depending on a model. The power of the pump is defined by flow rate and pressure. Actuating power is supplied from the hydraulic system of the base machine or other
hydraulic installation. Pumping fluid can be taken from reservoir or pressurized
supply network. Water can also be taken form natural source such as lake or river.
The relation ship between hydraulic oil flow and pressure to pumping fluid flow
and pressure is linear. HPW pumps can be safely operated in power range of
0-100%.
Most of HPW pumps are self-priming. READ CHAPTER „10. TECHNICAL SPECIFICATIONS“ for specific characteristics of any pump.
NOTE!
The design of HPW pump is protected with an international patent.
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1.2. PRODUCT IDENTIFICATION KEY
Picture 1: Identification key for HPW pumps
1. Product Group HPW Hydraulic Power Washers
2. Maximum water pressure that HPW pump can produce (40-1600 bar).
3. Maximum water flow or other pumping fluid flow that moves through HPW pump
(15-300l/min).
4. Maximum hydraulic oil flow from the base machine required to run HPW pump
(8-350 l/min).
HIGH PRESSURE WATER PUMPS
GENERAL
5. Options (listed below)
Water unloader valve (ST/PA)
The unloader valve directs water flow into bypass when the high pressure
water output is closed or not needed. In HPW200 pumps water unloader valve
is ST-model, other HPW pumps has PA-model.
Flow limiter (VR)
Limits the oil flow from the base machine. This function allowes to use the HPW
pump with partial load instead of maximum flow.
Pressure reducing valve (PA)
Reduces the oil pressure from the base machine. This function gives possibilities to drive HPW pump with partial load instead of maximum pressure.
Load Sensing (LS)
Load Sensing on PT-flange. Senses and provides only the pressure and flow
required by the HPW pump. This function saves significantly energy and customer’s expenses preventing excessive part wear in long term.
Marine (M)
For marine use. Pipes of unloader valve and all bolts are made of stainless steel.
Center body and heads stainless steel (AIS)
The center body and the heads of the pump are made of stainless steel.
Center body and heads aluminium bronze (AB)
The center body and the heads of the pump are made of aluminium bronze.
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HIGH PRESSURE WATER PUMPS
GENERAL
Under water use (SUB)
For under water use. The center body and the heads are made of stainless steel
or aluminium. Plugs are made of stainless steel, bolts are made of stainless
steel or with special coating.
Seals for hot fluids and specific chemicals (HOT)
Seals are made to tolerate hot fluids and some specific chemicals.
Load Sensing Control (LSC)
Automatic Load Sensing Control on PT-flange. It is useful when hydraulic flow
and pressure is occasionally needed. Off-state drives main hydraulic pump via
LS-line to 0 ° angle and on-state drives hydraulic pump to full angle, producing
maximum oil flow to the HPW pump. This function saves significantly energy
and customer’s expenses preventing excessive part wear in long term.
1.3. TYPE PLATE
Picture 2: Type plate
The products type plate shows the following information.
1. Product identification key
2. Product code
3. Serial number
4. Maximum hydraulic flow
7. Output water flow
rate and pressure.
8. Manufacturer’s contact information
5. Maximum hydraulic pressure
6. Production month / year
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1.4. HPW PUMP LINEUP
HIGH PRESSURE WATER PUMPS
GENERAL
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Picture 3: HPW pump line-up
1. HPW 200
2. HPW 420
3. HPW 220
4. HPW 520
5. HPW 250
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6. HPW 90
7. HPW 180
8. HPW 460 /
HPW 320
9. HPW 130
10. HPW 800
11. HPW 1000
12. HPW 1200
13. HPW 1600
14. HPW 300 /
HPW 360
1.5. MAIN COMPONENTS OF HPW PUMP
Picture 4: Main components of HPW pump
HIGH PRESSURE WATER PUMPS
GENERAL
1. Body
2. Head right
3. Head left
4. PT-flange
5. Suction manifold
6. Discharge manifold
7. Hydraulic pressure line (P)
8. Hydraulic tank line (T)
9. Pumping fluid intake (S)
10. Pumping fluid outlet (WP)
11. Pressure gauge
12. Water unloader valve
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HIGH PRESSURE WATER PUMPS
GENERAL
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2. SAFETY
2.1. SAFETY PRECAUTIONS
ATTENTION!
Operators and maintenance personnel must always comply with local
safety regulations and precautions in order to close out the possibility of
damages and accidents.
The pressure in both hydraulic oil and water circuits of HPW pump is considerably
high. Keep the condition of your equipment and hydraulic system under constant
observation.
HIGH PRESSURE WATER PUMPS
SAFETY
WARNING
HIGH PRESSURE WATER AND OIL!
Can cause severe injuries.
Always wear appropriate clothing
and safety equipment.
Couplings, valves and hoses need to be kept tight and clean to avoid possible
leakages. Leaks in the hydraulic system must be repaired immediately to avoid
injuries caused by high pressure blowouts.
In order to avoid accidents, it is not allowed to clean or inspect HPW unit when
hydraulic fluid circuit is pressurized. Prior to any cleaning, inspection and service,
hydraulic system of your base machine must be stopped and all hydraulic fluid
circuits must be depressurized.
Prevent nozzles, water circuit and pipeline from freezing. Draining and air flushing
of the water circuit have to performed before ambient temperature reaches 0°C
or lower.
2.2. SAFETY EQUIPMENT
Always wear appropriate clothing and safety equipment such as safety goggles,
safety shoes and ear protection when operating the HPW pump.
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2.3. OPERATING SAFETY
When operating the HPW pump, beware of the unit parts warmed by hot hydraulic oil.
RISK OF BURNS!
The unit parts and hydraulic oil can
be hotter than 80 °C!
Wear personal safety equipment!
HIGH PRESSURE WATER PUMPS
SAFETY
WARNING
Never aim high pressure water at a person.
WARNING
HIGH PRESSURE WATER!
Never aim high pressure water at a person.
This can cause severe injuries.
ATTENTION!
Do not exceed the maximum pressure, temperature or load.
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2.4. MAINTENANCE SAFETY
READ OPERA
ATTENTION
Installation and service of hydraulic equipment must be performed by
qualified and experienced personnel only.
NOTE!
When carrying out any maintenance to HPW pump keep the components
of the system clean. This is to ensure safe, reliable and longlife operation of
your equipment.
HIGH PRESSURE WATER PUMPS
SAFETY
Hydraulic system of the base machine should be maintained according to the service program.
2.5. WARNING LABELS
Product recipient is obligated to place warning labels on the DYNASET product.
Attach labels to visible and appropriate place onto or close to DYNASET product where it’s easily seen. Clean surface with solvent detergent before attaching
labels.
TING
INSTRUCTIONS.
PRESSURE SPLATTERS.
BEWARE OF HIGH
KEEP FROM
FREEZING.
USE EAR PROTECTION
AND SAFETY
GOGGLES.
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HIGH PRESSURE WATER PUMPS
SAFETY
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3. OPERATING PRINCIPLES
3.1. OPERATING DESCRIPTION
The patented HPW-pump utilizes the reciprocal motion of the hydraulic piston.
HIGH PRESSURE WATER PUMPS
OPERATING PRINCIPLES
Picture 5: Operating description of HPW pump 1
HPW-pump is driven by hyraulic flow through the hydraulic ports (P) and (T).
Hydraulic flow moves the piston assembly (1) into its extreme position. After
exteme position reached, reversal valve (2) inside the piston assembly changes
the direction of hydraulic flow and the piston assembly starts to move into the
opposite direction.
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HIGH PRESSURE WATER PUMPS
OPERATING PRINCIPLES
Picture 6: Operating description of HPW pump 2
Move of the piston assembly creates pressure and suction. Pump self-primes from
water supply line (S) and generates pressure into pressure line (WP). When piston
assembly moves away from head it creates underpressure (3) and water (or other
pumping fluid) is sucked through intake valve (4) into head.
When water piston moves towards the head, it creates pressure (5) and water is
pushed through pressure valve (6) into pumping fluid outlet (WP).
NOTE !
Most of HPW-pumps are self-priming. Specific characteristics of any pump
can be verified according to parameters, READ CHAPTER „10. TECHNICAL
SPECIFICATIONS“.
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HIGH PRESSURE WATER PUMPS
OPERATING PRINCIPLES
The relation ship between hydraulic oil flow and pressure to pumping fluid flow
and pressure is linear.
Picture 7: Relation of pumping fluid’s flow rate and pressure.
HPW pumps can be safely operated in power range of 0-100%.
3.2. HYDRAULIC CONNECTION IN PARALLEL AND SERIES
Hydraulic lines of multiple HPW pumps can be connectec in parallel to get
maximum output pressure and double the output flow. Use flow contoller valves
when high pressure water pumps are connected in parallel.
Picture 8: HPW hydraulic line connection in parallel
NOTE!
Hydraulic oil flow required in parallel connection is the maximum
hydraulic oil flow of the HPW pump multiplied by the count of the pumps.
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HIGH PRESSURE WATER PUMPS
OPERATING PRINCIPLES
Hydraulic lines of multiple HPW pumps can be connectec in series to get higher
output flow in small hydraulic flow. Maximum output pressure is divided by the
count of the pumps in series connction.
Picture 9: HPW hydraulic line connection in series
3.3. PUMPING FLUID CONNECTION IN PARALLEL AND SERIES
Pumping fluid lines of multiple HPW pumps can also be connected in parallel or
in series.
NOTE!
If pumps with different pressure level is used, the pump which has lower
nominal pressure, must be protected with for example check valve.
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HIGH PRESSURE WATER PUMPS
4. INSTALLATION
4.1. BEFORE INSTALLATION
ATTENTION!
Read the instructions before installing the DYNASET product!
4.1.1. HYDRAULIC SYSTEM OF A BASE MACHINE
INSTALLATION
Base machines have different type 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 variable displacement pump
• Hydraulic system with fixed displacement pump
Before installing the DYNASET product, find out the type of the hydraulic system of your machine.
If you are unsure of the hydraulic system, please contact the base machine
manufacturer.
Next three paragraphs describe the hydraulic systems in more detail.
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HIGH PRESSURE WATER PUMPS
INSTALLATION
OPEN CENTRE HYDRAULIC SYSTEM WITH LOAD SENSING VARIABLE
DISPLACEMENT PUMP
Picture 10: Open centre hydraulic 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 centered. It provides an
open return path to tank and the fluid is not pumped into a high pressure. In Load
Sensing variable-displacement pump, the flow rate and output pressure adjusts
automatically based on the load of the hydraulic system.
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HIGH PRESSURE WATER PUMPS
INSTALLATION
Picture 11: Connection 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. DYNASET LSV Load
sensing valve
3. Base machines variable
displacement pump
4. Open centre directional control valves
5. Oil cooler
6. Oil filter
7. Oil tank
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HIGH PRESSURE WATER PUMPS
INSTALLATION
CLOSED CENTRE HYDRAULIC SYSTEM WITH LOAD SENSING VARIABLE
DISPLACEMENT PUMP
Picture 12: 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 pump can rest when the oil is not required to operate a function. In Load Sensing variable-displacement pump, the flow rate and
output pressure adjusts automatically based on the load of the hydraulic system.
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HIGH PRESSURE WATER PUMPS
INSTALLATION
Picture 13: 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 valve
4. Base machines variable
displacement pump
5. Closed centre directional control valves
6. Oil cooler
7. Oil filter
8. Oil tank
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HIGH PRESSURE WATER PUMPS
HYDRAULIC SYSTEM WITH FIXED DISPLACEMENT PUMP
INSTALLATION
Picture 14: Hydraulic system with fixed displacement pump
In hydraulic system which has the fixed displacement pump, the oil flow from the
pump is fixed. Every stroke of the hydraulic motor moves the same amount of oil.
The output flow is function of the motor’s rpm and pump’s displacement.
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HIGH PRESSURE WATER PUMPS
INSTALLATION
Picture 15: 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 Load
sensing valve
3. Base machines fixed displacement pump
4. Open centre directional control valves
5. Oil cooler
6. Oil filter
7. Oil tank
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4.1.2. DYNASET VALVES
DYNASET valves are designed to enable easy installation of your DYNASET hydraulic product.
DYNASET LOAD SENSING VALVE
HIGH PRESSURE WATER PUMPS
INSTALLATION
Picture 16: Load sensing valve LSV
DYNASET LSV load sensing valves are made for installations in a closed centre
hydraulic systems.
DYNASET PRIORITY VALVE
Picture 17: Priority valve PV-SAE
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DYNASET PV- SAE priority valve enables the installations of the DYNASET products
into any hydraulic system.
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HIGH PRESSURE WATER PUMPS
4.2. INSTALLING DYNASET HYDRAULIC PRODUCT
4.2.1. PLACING DYNASET HYDRAULIC PRODUCT
Place DYNASET hydraulic product where there is an easy access to the unit. Ensure
proper ventilation.
INSTALLATION
Picture 18: Placing HPW high pressure water pumps
NOTE!
When positioning the HPW pump note the maximum inclinations and
ensure that required oil cooling capacity of hydraulic system is sufficient.
READ CHAPTER „10. TECHNICAL SPECIFICATIONS“ for specific cooling capcities.
4.2.2. INSTALLING DYNASET VALVES
Installation instructions can be found in DYNASET LSV or DYNASET PV SAE installation manual.
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4.2.3. CONNECTING HYDRAULIC HOSES
Connect pressure- (P) and return (T) lines of a hydraulic system to the corresponding hydraulic ports of the DYNASET unit.
HIGH PRESSURE WATER PUMPS
INSTALLATION
Picture 19: Connecting hydraulic hoses
NOTE!
Location of P- and T-ports variates between different DYNASET hydraulic
equipment.
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 or using
flow limiter valve. DYNASET PV-SAE priority valve is recommended.
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Picture 20: Base machine’s pumps
Generally DYNASET products T-line is to be connected directly to the return line
of a hydraulic system.
If oil cooler is used between HPW pump and oil tank the return hydraulic prerssure
should be under 5 bar.
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HIGH PRESSURE WATER PUMPS
INSTALLATION
Picture 21: Return line connection
ATTENTION!
Ensure that the filtering degree and cooling capacity of the hydraulic
system are sufficient. READ CHAPTER „10. TECHNICAL SPECIFICATIONS“ for
more information.
4.2.4. HYDRAULIC FLUIDS
To use proper hydraulic fluid READ CHAPTER „6.2. Hydraulic fluids“ for more
information.
4.3. INSTALLING HPWPUMP
4.3.1. MAXIMUM INCLINATIONS
Pump should be mounted on sufficiently horizontal surface to enable proper working of leakage detecting holes, which are found either on bottom surface or side
faces of pump housing (depends on model).
Picture 22: Leakage detecting holes
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HIGH PRESSURE WATER PUMPS
4.3.2. CONNECTION TO THE PUMPING FLUID INTAKE
Connect water supply line pipe to the intake port (S).
Picture 23: Connection to the pumping fluid intake
INSTALLATION
When installing HPW pump into pumping fluid line note following things:
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Picture 24: Installation into pumping fluid line
1. Intake filter for pumping fluid.
2. Air separator for pumping fluid.
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HIGH PRESSURE WATER PUMPS
INSTALLATION
3. Pumping fluid intake line hose diameter.
4. Pumping fluid intake line can be pressurised, maximum feed pressure can be typically 16 bar.
5. Pumping fluid temperature, typically between 5 to 70 °C
6. Most HPW pumps can be used as self-priming and the head of a pumping fluid
intake line is typically 3 m as maximum.
NOTE!
READ CHAPTER „10. TECHNICAL SPECIFICATIONS“ for specific characteristics of your HPW pump.
4.3.3. CONNECTION TO THE PUMPING FLUID OUTPUT
Connect the water or other pumping fluid output line to the water pressure port
(WP).
Picture 25: Connection to the pumping fluid output
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HIGH PRESSURE WATER PUMPS
INSTALLATION
34
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5. OPERATION
5.1. STARTING THE HPW PUMP
ATTENTION!
Check all hoses and couplings in hydraulic and pumping fluid circuits
before use to ensure there are no leaks or damages.
Ensure that there is water or other pumping fluid available in intake line.
When the engine of base machine is running and hydraulic flow is available, the
HPW pump can be started by opening the hydraulic control valve.
HIGH PRESSURE WATER PUMPS
OPERATION
Picture 26: Starting the HPW pump
ATTENTION !
Never put your hand, fingers or body directly in front of the spray nozzle!
The spray nozzle attached to a pressure tool determines the flow rate and the
pressure when operating parameters of hydraulic circuit meet the HPW pump’s
requirements.
Correct size of the spray nozzle of pressure tool is a very important step for ensuring the optimal water jet or hydro-demolition power in each application.
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HIGH PRESSURE WATER PUMPS
OPERATION
5.2. ADJUSTING FLOW RATE AND PRESSURE OF PUMPING FLUID
5.2.1. ADJUSTING FLOW RATE AND PRESSURE WITH WATER UNLOADER
VALVE
Picture 27: HPW pump with water pressure unloader valve
1. The water unloader valve is used to adjust the desired maximum output pressure limit. The adjusting knob is tightened to increase pressure and loosened to
decrease pressure.
2. Whereupon the adjusted maximum pressure limit is being reached, water
unloader valve circulaters the water within the pump and prevents the output
pressure to rise over the limit.
NOTE!
Do not use unloader mode continuously over 5 minutes.
5.2.2. ADJUSTING FLOW RATE AND PRESSURE WITHOUT WATER
UNLOADER VALVE
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Picture 28: HPW pump without water pressure unloader valve
1. The water pressure and flow are adjusted by adjusting corresponding parameters in the hydraulic circuit.
2. In circuits based on fixed displacement pump closing the water pressure line
opens the pressure relief valve in hydraulic system.
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HIGH PRESSURE WATER PUMPS
OPERATION
NOTE!
Hydraulic fluid circulation through pressure relief valve causes heating of
oil and hydraulic system!
3. In circuits based on variable displacement hydraulic pump closing the water
pressure line adjusts hydraulic pump’s swashplate at 0° angle. Hydraulic pump
produces flow only for self-lubrication and self-flushing.
5.3. PUMPING FLUIDS
Most liquids, which can be transferred by pumping, can be pumped also with
HPW pump.
Water based fluids and seawater can be pumped without any special arrangements, however the pump must be flushed and cleaned thoroughly after a working shift with clean fresh water. Same rule applies when pumping gelatinous
fluids, flush HPW pump with clean fresh water or suitable solvent. Solvents, fuels
and oils can be pumped without any special arrangements.
Fluids with abrasives or high content of solids can be pumped as well, but should
be kept in mind, that HPW pump’s service lifetime is considerably shortened.
Note that DYNASET HDF-pump series is especially designed for pumping abrasive
fluids. If pumping solution is aggressive to NBR-rubber, special seals must be used.
When HPW pump is going to be used as a self-priming unit with a special or high
viscosity liquid, the flow and self-priming conditions should be valuated. If the
self-priming property can not be reached, pumping liquid is to be fed with certain
pressure, or the pump should be used at lower hydraulic flow. READ CHAPTER „10.
TECHNICAL SPECIFICATIONS“ for specific values of your HPW pump.
HPW-models made of special materials are available by request.
NOTE!
HPW pump can be run dry unlimited time without any harm, because
self-lubricating sealing and circulating hydraulic oil prevent the pump
from overheating.
NOTE!
Maximum pumping fluid temperature is 70 °C in standard models and
100 °C in HOT models. Do not exceed the maximum temperature.
NOTE!
Maximum pumping fluid temperature in self-priming is 45 °C.
Temperatures over 45 °C requires feed.
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5.4. WORKING IN COLD TEMPERATURES
To prevent pipes and HPW pump from freezing in cold season, pump and pumping fluid output line should be dewatered after a working shift. Detach the intake
hose from HPW pump and run it dry for a while until all water is removed from
water circuit.
5.5. STOPPING THE HPW PUMP
HPW pump is stopped by shutting off the hydraulic flow.
HIGH PRESSURE WATER PUMPS
OPERATION
Picture 29: Stopping the HPW pump
High pressure can remain in closed pressure circuit. Release water pressure to
avoid unexpected water discharges and injuries. If spray gun or similar tool has
been used, pull the trigger for some time after the pump has stopped.
Picture 30: Stopping procedure of the HPW pump
1. Shut off hydraulic flow.
2. Pull the trigger of spray gun to let the pressure out the system.
3. Ensure that there is no pressure left in the system from the pressure gauge.
38
NOTE!
Clean the pump completely after work, if special pumping fluid is used!
READ CHAPTER „5.3. Pumping fluids“ or contact your supplier for use of
special pumping fluids.
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6. MAINTENANCE
DYNASET HPW pumps are low-maintenance pumps. In normal operating conditions HPW pump does not require any other service, except replacement of sealings or occasionally replacement of water valves. It depends on content of abrasives in pumping fluid, as well as on cleanliness of hydraulic oil.
ATTENTION!
Before beginning any maintenance or repair, ensure that the system is
stopped and completely depressurized. Make sure that the system can not
start accidentally.
HIGH PRESSURE WATER PUMPS
MAINTENANCE
6.1. MAINTENANCE INTERVAL
All maintenance must be complied with as they are scheduled in this manual.
The following table provides maintenance schedule for DYNASET HPW pumps.
CHECK POINTS
Observe leakage detactors x
Clean HPW pumpx
Change water intake lterx
Change sealingsx
Check constantly whether the fluid dropping from pump’s leakage detectors is
growing. Replace sealing in proper time to exclude intermixing of hydraulic oil
and pumping fluid.
DailyAfter daily
use
Every 3
months
Every 1500 hours
or if necessary
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39
6.2. HYDRAULIC FLUIDS
Wide range of standard hydraulic fluids can be used with DYNASET hydraulic
equipment. Depending on the operating temperature, following mineral hydraulic oils are recommended:
Mineral hydraulic oilOperation temperature up to
ISO VG 32S 60 °C
ISO VG 46S70 °C
ISO VG 68S80 °C
NOTE!
Recommended oil viscosity is between 10 to 35 cSt when operating at normal operating temperature.
HIGH PRESSURE WATER PUMPS
MAINTENANCE
Synthetic and bio-oils can also be used if their viscosity characteristics and lubricating efficiency are similar to the 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 base machine.
For the hydraulic fluid change interval follow the base machine’s maintenance
instructions.
To use special hydraulic fluids with DYNASET equipment, please contact the nearest DYNASET representative for more information.
6.3. CLEANING THE HPW PUMP
ATTENTION!
Keep the HPW pump clean to enable its safe and longlife operation. Check
and clean your HPW pump after every work shift.
40
Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: +358 3 3488 200 | info@dynaset.com | www.dynaset.com
6.4. REPLACING WATER VALVES
1. Remove screws from the head.
2. Pull out the head.
HIGH PRESSURE WATER PUMPS
MAINTENANCE
3. Remove water valves and O-rings.
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41
HIGH PRESSURE WATER PUMPS
MAINTENANCE
ATTENTION!
The pressure valve’s spring has less turns than the suction valve’s spring.
Do not mix up the valves when re-assembling the pump!
1. Suction valve2. Pressure valve
4. Install new suction (1) and pressure (2) valves.
5. Install the head. Tighten heads bolts across, see chapter READ CHAPTER „6.6.
Bolt tightening torques“
42
6. Repeat the operation to the other head.
Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: +358 3 3488 200 | info@dynaset.com | www.dynaset.com
6.5. REPLACING PUMP SEALS
1. Remove screws from the head.
2. Pull out the head and remove water valves.
HIGH PRESSURE WATER PUMPS
MAINTENANCE
3. Remove the other head and water valves.
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43
HIGH PRESSURE WATER PUMPS
MAINTENANCE
4. Turn the pump frame into a vertical position.
5. Use rubber hammer and special tool to remove piston assembly with cylinder
and sealing flanges from the pump.
44
6. Remove the sealing flanges from the piston assembly.
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HIGH PRESSURE WATER PUMPS
7. Remove seals and o-rings from the sealing flanges.
8. Remove the piston assembly from the cylinder.
MAINTENANCE
9. Remove seal from the piston assembly and o-ring from the cylinder.
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45
HIGH PRESSURE WATER PUMPS
MAINTENANCE
10. Install new o-ring to the cylinder, new o-ring and seal to the piston assembly.
11. Install the piston assembly to the cylinder. Use vaseline or mineral oil on the
seal and mating surfaces to make installation easy.
12. Install new o-rings and seals to the sealing flanges. First install o-rings and
then the seals. Compress the seal into a kidney shape, place it into groove and
push it back to normal shape. Avoid making sharp bends on the seal.
46
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HIGH PRESSURE WATER PUMPS
MAINTENANCE
ATTENTION!
Seals of the sealing flange differs from each other, make sure that correct
seal is installed into correct place.
13. Install sealing flanges into the piston assembly. Use lubricant to make the installation easy.
14. Lubricate mating surfaces of the piston assembly and insert it to the body.
Place the special tool in the top of the piston assembly.
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47
HIGH PRESSURE WATER PUMPS
NOTE!
Make sure that the piston assembly is installed correctly.
15. Use rubber hammer to install piston assembly into the body.
MAINTENANCE
16. Remove seals from the heads.
48
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HIGH PRESSURE WATER PUMPS
MAINTENANCE
17. Install new seals into the heads.
18. Install water valves. READ CHAPTER „6.4. Replacing water valves“.
NOTE!
DYNASET recommends replacing the water valves at the same time as the
pump seals.
19. Install both heads into the body. Tighten heads bolts across, see chapter READ
CHAPTER „6.6. Bolt tightening torques“
20. Test run the pump and make sure that there are no leakages.
6.6. BOLT TIGHTENING TORQUES
BOLTTIGHTENING TORQUE
M6 8.8, SS9 Nm (6.5 lb ft)
M88.8, SS22 Nm (16.0 lb ft)
M108.8, SS45 Nm (33.0 lb ft)
M1012.975 Nm (55.0 lb ft)
M128.8, SS75 Nm (55.0 lb ft)
M1212.9135 Nm (99.5 lb ft)
M168.8, SS180 Nm (133.0 lb ft)
M1612.9300 Nm (221.0 lb ft)
*SS = Stainless Steel
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49
6.7. TROUBLESHOOTING
Performing the maintenance tasks requires a qualified hydraulic mechanic. Please,
contact DYNASET authorized workshop or dealer for more maintenance information.
FAILUREREASONCORRECTIVE ACTION
HIGH PRESSURE WATER PUMPS
MAINTENANCE
Hydraulic ow not
sucient or no hydraulic
ow at all.
Hydraulic pressure too low. Adjust the hydraulic pressure.
Enable or adjust the hydraulic
ow.
HPW pump does not work.
Hydraulic ow reversed.
Hydraulic piston damaged
mechanically.
FAILUREREASONCORRECTIVE ACTION
Water intake and pressure
valves are open (jammed
with debris) or damaged.
HPW pump works, but does
not deliver water ow.
FAILUREREASONCORRECTIVE ACTION
HPW pump does not receive
pumping uid
Regulator’s unloader
valve opens from intake
to pressure (models with
water pressure unloader
valve).
Intake hose detached or
hose breathes.
Water supply line clogged.
Suction head to high.
Check and reconnect hydraulic
hoses. Pressure hose should be
connected to P-port and return
hose to T-port.
Replace damaged part.
Check water valves and clean
them thoroughly or replace when
damaged.
Check the valve and repair failure.
Check and x the hose and
connectors.
Check strainer or water lter and
clean thoroughly.
Check the performance with
pressurized water supply when
possible.
50
FAILUREREASONCORRECTIVE ACTION
Nozzle clogged.
Water pressure line blocked.
Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: +358 3 3488 200 | info@dynaset.com | www.dynaset.com
Regulator’s check valve
damaged, pressure line
blocked (models with
water pressure unloader
valve).
Check the nozzle and clean
thoroughly.
Check the valve and repair failure.
HIGH PRESSURE WATER PUMPS
MAINTENANCE
FAILUREREASONCORRECTIVE ACTION
Insucient hydraulic ow
or pressure.
Adjust the hydraulic ow to the
demanded level at required
pressure.
Water ow rate too small
FAILUREREASONCORRECTIVE ACTION
Water pressure too low
Nozzle of your pressure
tool undersized.
Pressure loss in delivery
hose.
Insucient hydraulic ow
or pressure.
Nozzle of pressure tool
oversized.
Wear-out of nozzle.Replace the nozzle.
Insucient water supply.
Water pressure unloader
valve set too low (models
with water pressure
unloader valve).
Verify the nozzle sizing and
replace with proper one.
Verify the hose sizing and replace
with proper one.
Adjust the hydraulic pressure to
the demanded level at required
hydraulic oil ow.
Pressure loss should be minimized
- Do not use hoses of too small
diameter or/and of an excessive
length.
Verify the nozzle sizing and
replace with proper one.
Check and x the problem.
Use pressurised water supply if
available.
Check and re-adjust to
specication.
FAILUREREASONCORRECTIVE ACTION
Intence pulsating of water
pressure.
Some of water intake and
pressure valves are open or
damaged.
Water intake line breathes
causing pump cavitation.
Water intake line’s diameter
to small, resulting in pump
cavitation.
Excessive hydraulic ow,
when HPW-pump runs too
fast.
Filter clogged or too small.
Check water valves, clean
thoroughly or repair.
Check water intake line and x the
problem.
Verify the hose sizing and replace
with proper one.
Adjust the hydraulic ow to the
demanded level.
Clean lter or replace lter of
correct size.
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51
HIGH PRESSURE WATER PUMPS
MAINTENANCE
FAILUREREASONCORRECTIVE ACTION
Adjust the hydraulic pressure
up as much as necessary to
enable proper operation of water
Closing the water pressure
line does not drop pressure
to free circulaiton mode.
Hydraulic system starts to
run through the pressure
relief
valve, emitting excessive
heat.
Insucient hydraulic
pressure in relation to
pumping uid pressure,
adjusted with water
pressure unloader valve.
Defective water pressure
unloader valve (models
with water pressure
unloader valve).
pressure unloader valve.
Note that the maximum hydraulic
pressure should not be overrun!
If boosting the hydraulic pressure
is not possible, the water unloader
pressure setting should be
dropped.
Repair or replace water pressure
unloader valve.
FAILUREREASONCORRECTIVE ACTION
Sealings and water pistons
wear o repeatedly.
Leakages.
Broken lter.Check and replace lter.
Filter missing totally.
Hydraulic oil leakages.
Pumping uid leakages.
Hyraulic oil-pumping uid
leakage.
Install lter. Always must use lter,
even with clear tap water.
Check the tightness of component
mating, tighten screws.
Replace sealings of pumps mated
surfaces if necessary.
Check and tighten couplings.
Replace if necessary.
Check the tightness of component
mating, tighten screws.
Replace sealings of pumps mated
surfaces if necessary.
Check and tighten couplings.
Replace if necessary.
If the draining from leakage
detectors exceeds rate of 10
drops per minute, pump’s sealings
should be replaced.
The rule applies to dropping of
hydraulic uid, pumping uid and
their commixture.
52
Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: +358 3 3488 200 | info@dynaset.com | www.dynaset.com
HIGH PRESSURE WATER PUMPS
7. MANUFACTURER’S 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 Exclusions from warranty.
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. Warranty period
Warranty period is twenty four (24) 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 manufacturer’s warranty.
WARRANTY
4. Warranty procedures
Immediately upon identifying a problem which purchaser believes to be a failure
subject to the product’s 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.
5. 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 purchaser’s cost, adequately packed for
shipment, to the DYNASET OY or to other location authored by DYNASET OY.
Shipment documents must contain:
• Purchaser’s name and contact information
• Receipt of original purchase
• WRN code
• Problem description
Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: +358 3 3488 200 | info@dynaset.com | www.dynaset.com
53
HIGH PRESSURE WATER PUMPS
WARRANTY
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:
• 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.
• Cost of maintenance, adjustments, installation or startup.
• Coating, hydraulic oil, quick couplings and interconnection hoses (internal or
external to system assemblies).
• Products altered or modified in a manner not authorized by DYNASET OY in
writing.
• Products which have been repaired during warranty period by others than
DYNASET OY or its authorized workshop.
• 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.
• Telephone or other communications expense.
• Product that is used in exceptional conditions, considered to cause excessive
wear and tear.
• Faults caused by nature phenomenon’s like flood, thunder, etc.
Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: +358 3 3488 200 | info@dynaset.com | www.dynaset.com
8. PRODUCT DISPOSAL
Dispose and recycle all DYNASET products and their packaging environmentally
responsible 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 local waste recycling facility for more information about recycling
hazardous waste.
NOTE!
Always act according to the waste legislation, regulations and
recommendations in waste disposal and waste recycling issued by your
local authorities.
HIGH PRESSURE WATER PUMP
PRODUCT DISPOSAL
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55
HIGH PRESSURE WATER PUMP
PRODUCT DISPOSAL
56
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HIGH PRESSURE WATER PUMPS
DECLARATION OF CONFORMITY
9. DECLARATION OF CONFORMITY
We hereby declare that the design and manufacture of the product stated below
are in conformity with the provisions of the European Parliament and Councils on
the harmonization of the laws of Member States on the safety of machines.
Machine directive 2006/42/EC
LVD directive 2014/35/EU
EMC directive 2014/30/EU
RoHS directive 2011/65/EU
Applied conformity standards:
CEN EN ISO 4413: EN ISO 4413:2010 Hydraulic fluid power -
General rules and safety requirements for systems and their
components.
EN60204-1 Safety of machinery – Electrical equipment of
machines.
Manufacturer: DYNASET OyMenotie 3, FI-33470 Ylöjärvi, Finland
Product group: HIGH PRESSURE WATER PUMPS
Product: HPW High pressure water pumps
If the device has been modified by someone other than the manufacturer or
without the manufacturer’s permission, this declaration is not valid.
Timo Nieminen
R&D Manager
Ylöjärvi, Finland 20.04.2016
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57
HIGH PRESSURE WATER PUMPS
DECLARATION OF CONFORMITY
58
Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: +358 3 3488 200 | info@dynaset.com | www.dynaset.com
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