AVANT A35409 Operator'S Manual Download

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Hydraulic Compressor 2013 1

CONTENTS

Foreword...............................................................................................................................4

Designed purpose of use ......................................................................................................5

Safety instructions for using the compressor .........................................................................6

Technical specifications ........................................................................................................9

4.1. Operating conditions......................................................................................................................

4.2. Speed control system and automatic stopping (PNE)...................................................................

4.3. Safety relief valve........................................................................................................................

4.4. Warning labels ............................................................................................................................

4.5. Main components of the compressor ...........................................................................................

Assembly of compressor .....................................................................................................14

5.1. Mounting the compressor to the loader boom ..............................................................................

5.2. Connecting and disconnecting hydraulic fittings ...........................................................................

5.3. Uncoupling and storage of the compressor ..................................................................................

5.4. Installing the rear mount frame ....................................................................................................

Instructions for use ..............................................................................................................18

6.1. Checks before use ......................................................................................................................

6.2. Starting the compressor...............................................................................................................

6.3. Stopping the compressor .............................................................................................................

6.4. Draining air reservoir and storage of compressor .........................................................................

Inspections, maintenance and service.................................................................................20

7.1. Checking hydraulic and pneumatic components ..........................................................................

7.2. Checking the compressor and regular maintenance.....................................................................

7.2.1. Compressor air filter ................................................................................................................

7.3. Cleaning......................................................................................................................................

7.4. Oils .............................................................................................................................................

7.5. Removal from service..................................................................................................................

7.6. Troubleshooting ..........................................................................................................................

Appendix: Original manual for Dynaset HK400/8-23 compressor unit, including EC Declaration of Conformity

The complete manual for the compressor

consists of two parts. The original manual of the

compressor unit is supplied with this manual.

Make sure that also the original manual of the

compressor is also available, cover page shown

in adjacent picture.

Summary of Contents for A35409

Page 1: ... all instructions Keep this manual for later reference Operator s Operator s Operator s Operator s manual for Attachment manual for Attachment manual for Attachment manual for Attachment H Hy yd dr ra au ul li ic c C Co om mp pr re es ss so or r Product number for 300 700 series loaders front mount A35409 for 400 700 series loaders rear mount A35456 ...

Page 3: ...unt frame 17 6 Instructions for use 18 6 1 Checks before use 18 6 2 Starting the compressor 18 6 3 Stopping the compressor 19 6 4 Draining air reservoir and storage of compressor 19 7 Inspections maintenance and service 20 7 1 Checking hydraulic and pneumatic components 20 7 2 Checking the compressor and regular maintenance 21 7 2 1 Compressor air filter 21 7 3 Cleaning 22 7 4 Oils 22 7 5 Removal ...

Page 4: ...is operator s manual the original manual for the attachment and all safety instructions before using the equipment Using the equipment for other purposes or use in any other way than described in this manual is prohibited Keep this manual at hand throughout the service life of the equipment If you sell or transfer the equipment be sure to hand over this manual to the new owner If the manual is los...

Page 5: ...or block directly to other systems by bypassing the integrated reservoir is prohibited Depending on the compressor model it can be attached to the front quick coupling of the loader or it can fitted to the back of the loader with mounting bracket leaving the boom available for another attachment When using the compressor it must be attached and locked to the loader The compressor is intended to pr...

Page 6: ...tors only Ensure that the loader will stay firmly still when leaving the driver s seat even if the loader is parked on an even surface The loader could crawl due to vibration or fault in drive circuit resulting in hazard of being run over by moving loader Always engage the parking brake and use chocks as needed A running loader must not be left unmonitored for long periods Shut down the loader eng...

Page 7: ...can lead to explosion like release of compressed air Never operate the compressor if signs of leaks have been found on the compressor or any pneumatic tool or hose Do not attempt to repair damaged pressure reservoir contact service if needed Transport and operate the compressor when the loader boom is lowered to its lowest position and near the loader for the best stability of the loader Operate t...

Page 8: ...For example when working at construction sites safety helmet is required In dusty conditions wear breathing mask Safe stopping of the equipment in case of disruption of operation before maintenance work or when preparing the compressor for any storage period Always stop the compressor following safe stopping procedure before going near the attachment Never go under a raised loader boom or the atta...

Page 9: ...or is equipped with speed compensator Hydraulic oil pressure with rated output 210 bar Hydraulic oil pressure when running unloaded 50 bar Operating temperatures Standard 5ºC 40ºC Suitable AVANT loader See Table 1 Pressure and compression ratio The rated absolute intake pressure is 1 bar 100 kPa The used reference pressure is barometric pressure at sea level 1 0135 bar which at an altitude of 100 ...

Page 10: ...y exceeds 90 contact service 4 2 Speed control system and automatic stopping PNE Speed control system The speed control valve integrated to the hydraulic system of the compressor regulates the rotating speed of the compressor so that the maximum input can be exceeded by 10 to 20 l min as shown in the figure on the left This will help to achieve the best performance of the compressor The speed cont...

Page 11: ...ts the hydraulic circuit to free circulation with valve 4 2 when the pre set air pressure level is reached in valve 4 13 More detailed component descriptions can be found from the operator s manual of the compressor unit 4 3 Safety relief valve The safety relief valve 5 4 shown in figure on previous page must be an original part in good condition Check the condition of the safety relief valve visu...

Page 12: ...s are available via your retailer or contact information provided on the cover of this manual The warning labels contain important safety information and they help to identify and remember the hazards related to the equipment Replace any damaged or missing warning label with new one A46771 A46772 A46803 Only when the compressor is installed to the rear of the loader Identification plate of the att...

Page 13: ... identification plate 10 Power Pack rear mount frame A35546 11 Frame tilt locking 12 Hydraulic hose stand 13 Rear mount frame fitting brackets 14 Rear mount frame screws Decal Warning message A46771 Read instructions before use A46803 Crushing hazard moving and locking frame mechanism Keep fingers away from between frame components when tilting the mounting frame Attachment identification plate Ta...

Page 14: ...ns provided in the following pages Also remember the safety instructions in Section 3 and the instructions provided in the operator s manual of the loader Step 1 Lift the quick attach plate locking pins up and turn them so that they are locked in the upper position If your loader is equipped with a hydraulic attachment locking system see additional instructions about the use of the locking system ...

Page 15: ...stem is under pressure or if the control lever of the auxiliary hydraulics control lever is locked on Connecting or disconnecting the hydraulic couplings while the system is pressurized may lead to unintended movements of the attachment or ejection of high pressure fluid which can cause serious burns or other injuries Keep the fittings as clean as possible use the protective caps for the quick cou...

Page 16: ...re in the hydraulic system of the attachment shut down the loader engine and move the auxiliary hydraulics control lever of the loader to it s extreme positions before disconnecting the couplings If the fittings will not connect to the loader the residual pressure must be released The residual pressure must be released before handling the rotating components of the attachment and before storage of...

Page 17: ... the counterweight or light bumper 5 Tighten fitting bolts and make sure the frame is locked upright 6 Connect hydraulic hoses to rear outlet on the loader Make sure that the hoses will not abrade against sharp corners and make sure that the hoses are not close to the exhaust of the loader or other hot points Height adjustment of the rear mount frame The frame is adjusted by removing the pin locki...

Page 18: ...oader 6 1 Checks before use Operate the compressor only when the loader is parked and the boom is lowered Ensure that during use the compressor is in upright position Check the condition of the compressor leakages cleanliness cooling fan and oil level See list of checks in Chapter 7 2 and other instructions regarding maintenance service and checks in chapter 7 Only use tools that are in good condi...

Page 19: ...ndoors or in poorly ventilated areas the exhaust fumes can reach toxic levels and lead to suffocation Operating the loader indoors is prohibited 6 3 Stopping the compressor Stop the compressor whenever compressed air is not needed The compressor must be stopped by turning the auxiliary hydraulics control lever to its neutral position or by turning off the loader if needed The compressor must never...

Page 20: ...te skin and cause serious injuries Seek medical attention immediately in case hydraulic fluid penetrates the skin Wash any part of body that has been in contact with hydraulic oil carefully with water and soap Hydraulic fluid is also harmful to the environment and any leak to the environment must be prevented Operate the attachment only with type of hydraulic oil that is accepted for use in Avant ...

Page 21: ...g hydraulic components must be left for professional service technicians When handling hydraulic components special attention to safety is needed and installation work is allowed only for qualified persons The speed control valve system of the compressor does not include user serviceable components The manufacturer or its representative is not responsible for damages losses or injuries resulted fr...

Page 22: ... oil pan The oil level must be between the lower edge and the middle of the sight glass Oil type Viscosity Operating temperature Change interval maximum Oil volume Multi grade SAE 10W 30 5ºC 40ºC 500 h 12 m SAE 10W 25ºC 20ºC 500 h 3 m SAE 30 5ºC 30ºC 500 h 3 m Diesel engine oil API CC MIL L 2104 MIL L 46152 B SAE 40 5ºC 40ºC 500 h 3 m 0 91 l The first oil change must be made after a maximum of 150...

Page 23: ...hin specifications Adjust as needed 3 2 Fault in hydraulic system Check the condition of hydraulic motor and possibility of internal leaks Contact service to check or repair hydraulic motor 3 Air pressure does not reach set level 3 3 Clogged air filter or intake manifold Check clean and or replace 4 1 Air connector damaged or tool failure Check and fix possible fault 4 2 Speed control damaged or a...

Page 24: ......

Page 25: ...e 3 FIN 33470 Ylöjärvi FINLAND Tel 358 3 3488200 Fax 358 3 3488222 MAY CHANGE WITHOUT PRIOR NOTICE July 2013 JLe 1 21 MAY CHANGE WITHOUT PRIOR NOTICE HYDRAULIC COMPRESSOR HK400 8 23_PNE OPERATING INSTRUCTIONS HK400 8 23_PNE HYDRAULIC COMPRESSOR ...

Page 26: ...stem with variable displacement pump 7 8 3 Hydraulic system with constant placement pump 8 8 4 Connetion to the air supply system 8 9 OPERATION 9 10 MAINTENANCE 10 10 1 Compressor block maintenance 10 10 2 Oil level check 10 11 OUTLINE DIMENSIONS AND CONNECTIONS 12 12 PARAMETERS 13 13 MAIN ASSEMBLY 14 13 1 HYDRAULIC MOTOR ASSEMBLY 14 13 2 HYDRAULIC MOTOR PNE ASSEMBLY 15 13 3 PNE ASSEMBLY 15 13 4 C...

Page 27: ...the blow gun Always wear appropriate clothing and safety equipment such as goggles ear protection and safety shoes at all times when operating the compressor When operating the compressor beware of machinery parts warmed by hot hydraulic oil EXTERME CLEANLINESS MUST BE MAINTAINED WHEN CARRYING OUT ANY SERVICE REPAIR DISSASSEMBLING OF HK COMPRESSOR AND HYDRAULIC SYSTEM THIS IS CRUCIAL TO ENSURE SAF...

Page 28: ...MATICS 2 COMPRESSOR BLOCK 2 1 INTAKE FILTER 2 1 X Y COMPRESSOR BLOCK S BUILT IN SAFETY VALVES 3 5 OFF LOAD VALVE 4 FRAME RESERVOIR 4 3 PRESSURE GAUGE 4 5 SAFETY VALVE 5 COOLING FAN 3 5 4 5 4 3 5 DYNASET hydraulic compressor of HK series is mobile unit comprised of a hydraulic motor with incorporated automatic rotation speed control valve except S models and 2 piston compressor block Compressor blo...

Page 29: ... PNEUMATIC CUT OFF PNE OPTIONAL Provides operation control in accordance with pre adjusted maximum and minimum pressure limits in automatic mode When there is no air consumption compressor being on pneumatic cut off halts the unit switching over the hydraulics to the free circulation Simultaneously the pressure in a hose between compressor block and frame reservoir is being let off making compress...

Page 30: ...t 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 unit s p...

Page 31: ...r all other functions Furthermore pump s control works together with DYNASET PV SAE priority valve 1 OPEN CENTRE HYDRAULIC SYSTEM WITH VARIABLE DISPLACEMENT PUMP LS valve HK S M P T AUTOMATIC ROTATION SPEED CONTROL VALVE 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 VA...

Page 32: ...ressure control type VKV 90 3 4 CONNECTION TO THE AIR SUPPLY SYSTEM It is recommended to install distribution valve to a pressure line near the compressor in order to the unit with a blow gun when necessary 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 compressor s connection should be at...

Page 33: ...pressor 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 9 21 MAY CHANGE WITHOUT PRIOR NOTI...

Page 34: ...ge must indicate zero The compressor block and fan guards should be checked on a daily basis and cleaned when necessary To clean the unit use blow gun with a REASONABLE DELIBERATION Clogged and dirty cooling ribs may cause compressor s overheating At least once a week drain the condensate from the frame reservoir Prior to launching the procedure stop the compressor Water drain valve s knob should ...

Page 35: ...T PRIOR NOTICE ATTENTION OIL LEVEL IN A RUNNING COMPRESSOR UNIT MUST BE BETWEEN THE BOTTOM OF THE SIGHTGLASS MIN AND RED POINT MAX IN THE CENTRE OF IT OIL LEVEL CHECK MAX MIN HYDRAULIC COMPRESSOR HK400 8 23_PNE July 2013 JLe ...

Page 36: ... 400 415 395 325 11 37 0 9 OUTLINE DIMENSIONS HYDRAULIC AND COMPRESSED AIR CONNECTIONS B W H A L Ø D AP HYDRAULIC FLOW l min max 40 HYDRAULIC PRESSURE bar max 250 AIR FLOW l min max 400 AIR PRESSURE bar max 8 WEIGHT kg 37 CONNECTIONS HYDRAULICS COMPRESSED AIR P T D AP pressure return drain BSP 1 2 BSP 1 2 BSP 1 2 A A T 1 2 P 5 7 1 July 2013 JLe ...

Page 37: ...FRAME RESERVOIR l 4 4 HYDRAULIC POWER REQUIREMENTS Minimum flow l min 12 Maximum flow l min 40 Pressure at nominal flow bar 210 Maximum pressure bar 250 Pressure when unloaded bar 50 HYDRAULIC FLUID REQUIREMENTS Viscosity cSt 10 200 optimi 25 35 Temperature ºC max 70 Filter ratio recommendation um min 25 Cooling capacity recommend min kW 2 OVERALL DIMENSIONS Length mm 455 Width mm 390 Height mm 41...

Page 38: ...400 8 23_PNE MAIN ASSEMBLY 4 HYDRAULIC MOTOR ASSEMBLY 2 1 2 3 2 2 2 4 5 1 2 5 1 1 1 5 2 4 1 5 4 5 6 5 5 1 1 3 1 3 1 3 1 1 3 2 1 3 3 1 1 1 2 5 1 2 1 1 2 4 1 2 9 1 2 8 1 2 2 1 4 1 1 1 1 1 1 2 1 1 4 3 1 4 2 1 2 6 5 2 3 8 1 1 4 1 1 3 5 3 5 3 3 8 1 3 8 2 July 2013 JLe ...

Page 39: ...SSOR HK400 8 23_PNE HYDRAULIC MOTOR PNE ASSEMBLY PNE ASSEMBLY COMPRESSOR BLOCK TUBE ASSEMBLY 4 1 1 2 1 1 2 2 4 2 4 4 4 5 4 8 4 7 4 9 4 10 4 11 4 12 4 13 4 15 4 3 4 14 1 2 2 4 11 4 6 4 12 4 1 4 13 4 15 4 2 3 8 3 4 3 3 3 2 3 5 3 6 4 6 1 1 1 July 2013 JLe ...

Page 40: ...0576 BLOWER WHEEL HK400 1 2 4 0600040575 HALF COUPLING COMPRESSOR SIDE 86 1 2 4 1 8500584230 ALLEN SCREW M10x12 2 2 5 1 8107214000 RUBBER ELEMENT H86 1 3 2 7306953000 CHECK VALVE R3 4 x 1 2 1 3 3 1702520000 ADAPTER 1 2 1 3 4 17024xxxxx ADAPTER 1 2 u 1 2 u 1 3 5 1702940000 FITTING RK3 4u 1 2s 1 3 6 1702370000 ELBOW FITTING R1 2xRK1 2 1 3 8 COMPR BLOCK TUBE ASSEMBLY R08 90 08 520 1 N R08 90 45 1 3 8...

Page 41: ...used with the DYNASET hydraulic equipment Depending on the operating temperature following mineral hydraulic oils are recommended ISO VG 32S for oil s operation temperature up to 70 C ISO VG 46S for oil s operation temperature up to 80 C ISO VG 68S for oil s operation temperature up to 90 C Synthetic and bio oils can be used as well if their viscosity characteristics and lubricating efficiency are...

Page 42: ...ssible leakage Replace motor if necessary 1 4 Let off the pressure from the delivery line prior to staring the compressor Ref to 1 2 1 COMPRESSOR DOES NOT START WHILE CARRIER S ENGINE IS RUNNING AND HYDRAULIC SYSTEM IS ON 2 COMPRESSOR STARTS HARDLY See 1 3 See 1 4 3 AIR PRESSURE DOES NOT ACHIEVE REQUESTED RATE 3 1 Safety valve s failure or incorrect setting 3 2 Failure in hydraulic system 3 3 Inta...

Page 43: ...rt 4 1 Check and repair possible failure 4 2 Check and repair possible failure 4 3 Check and clean port replace filter element 6 COMPRESSOR S OVERHEATING 6 1 Dirty compressor block clogged cooling fan s guard 6 2 High ambient temperature 6 3 Low oil level 6 4 Due to the insufficient cooling capacity of a hydraulic system hydraulic fluid warms the compressor 6 1 Check and clean 6 2 Sufficient venti...

Page 44: ...d or plastics residues from all components Dispose of this waste material can now be recycled Forward the reclaimed materials for recycling Waste material Dispose of waste material from both of the above processes via an authorized disposal company Customer can send us the old Dynaset equipment for reuse or recycling at the purchaser s cost adequately packed for shipment to the DYNASET OY or to ot...

Page 45: ...thorized 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 b...

Page 46: ...tive 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 NUMBER HK 400 8...

Page 47: ...22 MAY CHANGE WITHOUT PRIOR NOTICE NOTES HYDRAULIC COMPRESSOR HK400 8 23_PNE July 2013 JLe ...

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