Dynaset HGV Power Box Series User manual

HGV Basic 3,5
HGV Basic 6,5
HGV Basic 10
HGV Basic 12
HGV Basic 15
HGV Basic 20
HGV Power Box 3,5
HGV Power Box 6,5
HGV Power Box 10
HGV Power Box 15
HGV Power Box 20
06/18 rev 1.2
HGV POWER BOX / HGV BASIC
VARIABLE HYDRAULIC GENERATOR SYSTEMS
USER MANUAL
Download PDF version from www.Dynaset.com/manuals Keycode: B36FKP

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Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: [phone] | [email protected] | www.dynaset.com
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.
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Dynaset Oy | Menotie 3, 33470 Ylöjärvi | puh. 03 3488 200 | [email protected] | www.dynaset.com
VARIABLE HYDRAULIC GENERATOR SYSTEM
TABLE OF CONTENTS
1. GENERAL 9
1.1. PRODUCT INFORMATION 9
1.2. PRODUCT IDENTIFICATION 9
1.2.1. HGV POWERBOX 9
1.2.2. HGV BASIC 10
1.3. TYPE PLATES 11
1.4. DYNASET HGV POWER BOX SYSTEMS LINE-UP 12
1.5. DYNASET HGV BASIC SYSTEMS LINE-UP 12
1.6. MAIN ASSEMBLY COMPONENTS OF HGV POWER BOX SYSTEM 13
1.7. MAIN ASSEMBLY COMPONENTS OF HGV BASIC SYSTEMS 14
1.7.1. MAIN ASSEMBLY COMPONENTS OF HGV PUMP 14
1.7.2. MAIN ASSEMBLY COMPONENTS OF HGV GENERATOR 15
1.7.3. MAIN ASSEMBLY COMPONENTS OF HGV COOLER 16
1.7.4. MAIN ASSEMBLY COMPONENTS OF HGV TANK 16
1.8. MAIN ASSEBLY OF THE ELECTRIC CENTRAL 17
1.9. IP(Ingress Protection) CLASSIFICATION 17
1.10. VOLTAGE AND FREQUENCY 18
1.11. HYDRAULIC EQUIPMENT 20
1.12. ELECTRIC EQUIPMENT 20
1.12.1. SINGLE-PHASE SOCKET PLUG TYPE 21
2. SAFETY 25
2.1. SAFETY PRECAUTIONS 25
2.2. SAFETY EQUIPMENT 26
2.3. OPERATING SAFETY 26
2.4. MAINTENANCE SAFETY 27
2.5. WARNING LABELS 28
3. OPERATING PRINCIPLES 29
3.1. OPERATING DESCRIPTION 29
3.2. AUTOMATIC HYDRAULIC FLOW CONTROL 30
4. INSTALLATION 31
4.1. BEFORE INSTALLATION 31
4.1.1. BASE MACHINE 31
4.1.2. HYDRAULIC FLUIDS 32
4.1.3. IP CODE REQUIREMENTS 32

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VARIABLE HYDRAULIC GENERATOR SYSTEM
TABLE OF CONTENTS
4.2. INSTALLING DYNASET HGV POWERBOX SYSTEM 32
4.2.1. HYDRAULIC PUMP & HPTO 32
4.2.2. POWER BOX PLACEMENT AND INSTALLATION MEASUREMENTS 33
4.3. INSTALLING HGV BASIC SYSTEM 35
4.3.1. HYDRAULIC PUMP & DYNASET HPTO 35
4.3.2. HYDRAULIC GENERATOR 35
4.3.3. COOLER 35
4.3.4. OIL TANK 36
4.3.5. ELECTRIC CENTRAL 36
4.4. HYDRAULIC AND ELECTRIC CONNECTIONS 37
4.5. ADJUSTING THE PUMP RPM 42
4.6. OUTPUT FREQUENCY CHECK AT START-UP 42
4.7. OUTPUT FREQUENCY ADJUSTING 43
5. OPERATION 47
5.1. STARTING AND STOPPING THE HGV SYSTEM. 47
5.2. AMBIENT TEMPERATURE 48
6. MAINTENANCE 49
6.1. MAINTENANCE INTERVALS 49
6.2. HYDRAULIC FLUIDS 50
6.3. CLEANING HGV GENERATOR 50
6.4. TEST SAFETY DEVICES 50
6.5. OIL LEVEL CHECK 51
6.6. OIL CHANGE 52
6.7. OIL FILTER CHANGE 53
6.8. TROUBLESHOOTING 54
7. MANUFACTURER’S LIMITED WARRANTY 57
8. PRODUCT DISPOSAL 59
9. DECLARATION OF CONFORMITY 61
10. TECHNICAL SPECIFICATIONS 63

Dynaset Oy | Menotie 3, 33470 Ylöjärvi | puh. 03 3488 200 | [email protected] | www.dynaset.com
VARIABLE HYDRAULIC GENERATOR SYSTEM
TABLE OF PICTURES
Picture 1: HGV PowerBox identification key....................................................................................................................9
Picture 2: HGV Basic identification key ..........................................................................................................................10
Picture 3: HGV PowerBox type plate..............................................................................................................................11
Picture 4: HGV Power box system line-up......................................................................................................................12
Picture 5: HGV Basic system line-up..............................................................................................................................12
Picture 6: HGV PowerBox system’s main components ...................................................................................................13
Picture 7: HGV Basic system’s components....................................................................................................................14
Picture 8: HGV pump’s main components......................................................................................................................14
Picture 9: HGV generator’s main components ...............................................................................................................15
Picture 10: Oil cooler main components........................................................................................................................16
Picture 11: Oil tank main components ..........................................................................................................................16
Picture 12: HGV systems electric central’s components .................................................................................................17
Picture 13: Single phase voltage and frequency map....................................................................................................19
Picture 14: Three phase voltage and frequency world map ...........................................................................................19
Picture 15: Single phase sockets and plugs ...................................................................................................................21
Picture 16: Single phase plug and socket map ..............................................................................................................22
Picture 17: IEC60309 three phase sockets and plugs .....................................................................................................22
Picture 18: NEMA three phase sockets and plugs...........................................................................................................23
Picture 19: Operating principle......................................................................................................................................29
Picture 20: Positioning of the HGV system according the IP23 classification..................................................................32
Picture 21: Hydraulic pump installed to transmissions PTO ...........................................................................................32
Picture 22: Hydraulic pump installed to engines PTO ....................................................................................................33
Picture 23: Palcement of the HGV PowerBox system .....................................................................................................33
Picture 24: HGV Power Box installation measurements.................................................................................................34
Picture 25: 6,5 KVA HG hydraulic generator ..................................................................................................................35
Picture 26: DYNASET Oil cooler .....................................................................................................................................35
Picture 27: Oil Tank........................................................................................................................................................36
Picture 28: Electric central.............................................................................................................................................36
Picture 29: HGV Power Box S hydraulic connections......................................................................................................37
Picture 30: HGV Power Box S hydraulic connections......................................................................................................37
Picture 31: HGV Power box hydraulic schema................................................................................................................38
Picture 32: HGV Power Box electric connections............................................................................................................38
Picture 33: HGV Power box electric schema...................................................................................................................39
Picture 34: HGV basic systems hydraulic connections....................................................................................................40
Picture 35: HGV basic systems hydraulic schema...........................................................................................................41
Picture 36: HGV basic systems electric connections.......................................................................................................41
Picture 37: HGV systems frequency check 1...................................................................................................................43
Picture 38: HGV systems frequency check 2...................................................................................................................43
Picture 39: Adjusting HGV systems frequency 1 ............................................................................................................44
Picture 40: Adjusting HGV systems frequency 2 ............................................................................................................45
Picture 41: Adjusting HGV systems frequency 3 ............................................................................................................45
Picture 42: Starting HGV system 1.................................................................................................................................47
Picture 43: Starting HGV system 2.................................................................................................................................47
Picture 44: Starting HGV system 3.................................................................................................................................47
Picture 45: Power take off in higher temperatures ........................................................................................................48
Picture 46: Testing safety equipment ............................................................................................................................51

Dynaset Oy | Menotie 3, 33470 Ylöjärvi | puh. 03 3488 200 | [email protected] | www.dynaset.com
VARIABLE HYDRAULIC GENERATOR SYSTEM
TABLE OF PICTURES
Picture 47: Oil tanks oil level gauge...............................................................................................................................51
Picture 48: Oil change ...................................................................................................................................................52
Picture 49: Oil filter change...........................................................................................................................................53

Dynaset Oy | Menotie 3, 33470 Ylöjärvi | puh. 03 3488 200 | [email protected] | www.dynaset.com
VARIABLE HYDRAULIC GENERATOR SYSTEM
TABLE OF PICTURES

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Dynaset Oy | Menotie 3, 33470 Ylöjärvi | puh. 03 3488 200 | [email protected] | www.dynaset.com
VARIABLE HYDRAULIC GENERATOR SYSTEMS
GENERAL
1. GENERAL
This manual contains general information about assembly, installation, operation
and maintenance of the DYNASET HGV variable hydraulic generator systems.
ATTENTION!
Read this operating manual before the use of HGV variable hydraulic
generator system, to ensure proper handling, operation and maintenance
right from the beginning. Pay particular attention to all warning and safety
instructions.
1.1. PRODUCT INFORMATION
HGV variable hydraulic generator system is a compact and integrated all-in-one
generatorsystemdesignedformobileinstallation.HGVsystemsusebasemachine’s
power source to operate and produce high quality electricity for powering various
electric equipment.
HGV systems come in two forms, PowerBox and Basic. In HGV PowerBox main
components are fitted in to a compact casing. HGV Basic is a component kit that
includes same main components than the PowerBox system but whit out the
compact casing.
1.2. PRODUCT IDENTIFICATION
1.2.1. HGV POWERBOX
HGV PowerBox system has an identification key. The identification key of the
system informs the main specifications of the system. Identification key can be
found from the products type plate which are attached as shown in picture 6.
The HGV PowerBox’s product identification key includes following information.
Picture 1: HGV PowerBox identification key
1. Product Group HGV PowerBox Variable Hydraulic Generators.
2. Presents the box’size class.
3. Nominal power output in kVA
4. Main voltage of the generator.

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VARIABLE HYDRAULIC GENERATOR SYSTEMS
GENERAL
5. NominalHydraulicFlow.Thetheoreticalminimalhydraulicowneededtooperate
the HGV system.
6. Presents the voltage system on the base machine either 12V or 24V.
7. Oil cooler size in kW.
8. Oil tank size 18/36 in liters (4.75/9.5 gal).
1.2.2. HGV BASIC
HGV basic system has an identification key. The identification key of the system
informs the main specifications of the system.
The HGV Basic’s product identification key includes following information.
Picture 2: HGV Basic identification key
1. Product Group HGV Variable Hydraulic Generator System.
2. NominAl Power output. Presents the HG hydraulic generator’s nominal power
output in kVA.
3. Generator’s main voltage, 230 or 400 VAC.
4. Hydraulic nominal flow. Presents the theoretical minimal hydraulic flow needed
to operate the HGV system.
5. electric equipment. Presents the electric equipment on HG hydraulic generator.
READ CHAPTER ”1.12. Electric equipment”for more information..
6. The voltage system on the base machine truck (T) or van (V), either 12V or 24V.
7. Operating method. Presents the if the hydraulic pump is operatable (D) or not
operatable (C) when driving the base machine.
8. Pump size. Presents the the hydraulic pump’s size.
9. Pump rotation direction. Presents the rotation direction of the hydraulic pump.
10. Connection flange. Presents the hydraulic pump’s connection flange type to
the base machine’s engine.