Dynaset HPW 90 User manual

HPW 90
HPW 130
HPW 180
HPW 200
HPW 250
HPW 220
HPW 300
HPW 320
HPW 360
HPW 420
HPW 460
HPW 520
HPW 800
HPW 1000
HPW 1200
HPW 1600
rev 1.4 07/19
HIGH PRESSURE WATER PUMPS
USER MANUAL
Download PDF version from www.Dynaset.com/manuals Keycode: DM4YRG

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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, FI-33470 Ylöjärvi, Finland | tel: [phone] | [email protected] | www.dynaset.com
HIGH PRESSURE WATER PUMPS
TABLE OF CONTENTS
1. GENERAL 7
1.1. PRODUCT INFORMATION 7
1.2. PRODUCT IDENTIFICATION KEY 8
1.3. TYPE PLATE 9
1.4. HPW PUMP LINEUP 10
1.5. MAIN COMPONENTS OF HPW PUMP 11
2. SAFETY 13
2.1. SAFETY PRECAUTIONS 13
2.2. SAFETY EQUIPMENT 13
2.3. OPERATING SAFETY 14
2.4. MAINTENANCE SAFETY 15
2.5. WARNING LABELS 15
3. OPERATING PRINCIPLES 17
3.1. OPERATING DESCRIPTION 17
3.2. HYDRAULIC CONNECTION IN PARALLEL AND SERIES 19
3.3. PUMPING FLUID CONNECTION IN PARALLEL AND SERIES 20
4. INSTALLATION 21
4.1. BEFORE INSTALLATION 21
4.1.1. HYDRAULIC SYSTEM OF A BASE MACHINE 21
4.1.2. DYNASET VALVES 28
4.2. INSTALLING DYNASET HYDRAULIC PRODUCT 29
4.2.1. PLACING DYNASET HYDRAULIC PRODUCT 29
4.2.2. INSTALLING DYNASET VALVES 29
4.2.3. CONNECTING HYDRAULIC HOSES 30
4.2.4. HYDRAULIC FLUIDS 31
4.3. INSTALLING HPWPUMP 31
4.3.1. MAXIMUM INCLINATIONS 31
4.3.2. CONNECTION TO THE PUMPING FLUID INTAKE 32
4.3.3. CONNECTION TO THE PUMPING FLUID OUTPUT 33

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HIGH PRESSURE WATER PUMPS
TABLE OF CONTENTS
5. OPERATION 35
5.1. STARTING THE HPW PUMP 35
5.2. ADJUSTING FLOW RATE AND PRESSURE OF PUMPING FLUID 36
5.3. PUMPING FLUIDS 37
5.4. WORKING IN COLD TEMPERATURES 38
5.5. STOPPING THE HPW PUMP 38
6. MAINTENANCE 39
6.1. MAINTENANCE INTERVAL 39
6.2. HYDRAULIC FLUIDS 40
6.3. CLEANING THE HPW PUMP 40
6.4. REPLACING WATER VALVES 41
6.5. REPLACING PUMP SEALS 43
6.6. BOLT TIGHTENING TORQUES 49
6.7. TROUBLESHOOTING 50
7. MANUFACTURER’S LIMITED WARRANTY 53
8. PRODUCT DISPOSAL 55
9. DECLARATION OF CONFORMITY 57
10. TECHNICAL SPECIFICATIONS 59

Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: [phone] | [email protected] | www.dynaset.com
HIGH PRESSURE WATER PUMPS
TABLE OF PICTURES
Picture 1: Identication key for HPW pumps..................................................................................................................... 8
Picture 2: Type plate..........................................................................................................................................................9
Picture 3: HPW pump line-up.......................................................................................................................................... 10
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 16: Load sensing valve LSV.................................................................................................................................. 28
Picture 17: Priority valve PV-SAE..................................................................................................................................... 28
Picture 18: Placing HPW high pressure water pumps...................................................................................................... 29
Picture 19: Connecting hydraulic hoses........................................................................................................................... 30
Picture 20: Base machine’s pumps .................................................................................................................................. 30
Picture 21: Return line connection .................................................................................................................................. 31
Picture 22: Leakage detecting holes................................................................................................................................ 31
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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Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: [phone] | [email protected] | www.dynaset.com
HIGH PRESSURE WATER PUMPS
GENERAL
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.
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 depend-
ing on a model. The power of the pump is defined by flow rate and pressure. Actu-
ating 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 SPECIFICA-
TIONS“ for specific characteristics of any pump.
NOTE!
The design of HPW pump is protected with an international patent.

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HIGH PRESSURE WATER PUMPS
GENERAL
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.Maximumwaterfloworotherpumping fluidflowthatmovesthroughHPWpump
(15-300l/min).
4.Maximum hydraulic oil flow from the base machine required to run HPW pump
(8-350 l/min).
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 possibili-
ties 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 custo-
mer’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
5. Maximum hydraulic pressure
6. Production month / year
7. Output water flow
rate and pressure.
8. Manufacturer’s con-
tact information

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HIGH PRESSURE WATER PUMPS
GENERAL
1.4. HPW PUMP LINEUP
Picture 3: HPW pump line-up
1. HPW 200
2. HPW 420
3. HPW 220
4. HPW 520
5. HPW 250
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

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HIGH PRESSURE WATER PUMPS
GENERAL
1.5. MAIN COMPONENTS OF HPW PUMP
Picture 4: Main components of HPW pump
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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HIGH PRESSURE WATER PUMPS
SAFETY
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.
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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HIGH PRESSURE WATER PUMPS
SAFETY
2.3. OPERATING SAFETY
When operating the HPW pump, beware of the unit parts warmed by hot hydrau-
lic oil.
WARNING
RISK OF BURNS!
The unit parts and hydraulic oil can
be hotter than 80 °C!
Wear personal safety equipment!
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.

15
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HIGH PRESSURE WATER PUMPS
SAFETY
2.4. MAINTENANCE SAFETY
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.
Hydraulic system of the base machine should be maintained according to the ser-
vice 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 prod-
uct where it’s easily seen. Clean surface with solvent detergent before attaching
labels.
USE EAR PROTECTION
AND SAFETY
GOGGLES.
READ OPERA
TING
INSTRUCTIONS.
BEWARE OF HIGH
PRESSURE SPLATTERS.
KEEP FROM
FREEZING.

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HIGH PRESSURE WATER PUMPS
SAFETY

17
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HIGH PRESSURE WATER PUMPS
OPERATING PRINCIPLES
3. OPERATING PRINCIPLES
3.1. OPERATING DESCRIPTION
The patented HPW-pump utilizes the reciprocal motion of the hydraulic piston.
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“.

19
Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: [phone] | [email protected] | www.dynaset.com
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.