MH-C2 HYDRAPAK
Contents
1. at its option replacing during normal business hours at an authorized service facility of the Company any part which in its judgment proved not to be as warranted within the applicable Warranty Period as follows HYDRAPAK COOLING SYSTEMS Hydrapak coolers consisting of all parts within are warranted for 12 months from date of initial use or 18 months from date of shipment to the first purchaser whichever occurs first Any disassembly or partial disassembly of the Hydrapak or failure to return the funopenedo Hydrapak per Company instructions will be cause for denial of warranty LABOR TRANSPORTATION AND INSPECTION The Company will provide labor by Company representative or authorized service personnel for repair or replacement of any product or part thereof which in the Company amp judgment is proved not to be as warranted Labor shall be limited to the amount specified in the Company labor rate schedule Labor costs in excess of the Company rate schedules caused by but not limited to location or inaccessibility of equipment or labor provided by unauthorized service personnel is not provided for by this warranty Transportation of Company6 choice within the continental United States is covered by this warranty for replacement of any blower which in the Company6 judgment proved not to be as warranted For user locations outside the continental United States the Company will provide transportation by the carrier of its choice t2. PARTS LIST OPERATING AND SERVICE MANUAL MH C2 HYDRAPAK MOBILE HYDRAULIC COOLING SYSTEM 30 3500 PSI 5000 PSI optional HYD 7 600 Version 01 September 17 2014 5 Introduction Your Key To Trouble Free 3 Maintain Hydrapak Reliability And 4 Instructions For Ordering Repair 4 FEN ci et its fat esc cn te 5 SAN save 6 Section 1 Equipment 7 eA AE 5 ENEE E EE 8 Section Initial Startup 12 Section 4 Mantenan cs sce sea a sia ere rere lese 13 Second Paris rir ha te sea ears reir treet cect E N 14 AAT AU EE i a rnc 16 HYD 7 600 Page 1 INDEX Equipment Check Section 1 7 MOT 8 Hydraulic Hoses 8 065 8 Parts List Section 5 14 Initial Startup Procedure Section 3 12 Safety Instructions 6 Installation Section 2 2 8 5189 6 gt 7 Introduction Your Key To Trouble Fre
3. Hg for piston pumps The suction hose must be capable of operating under 28 Hg Vacuum Special attention should be given to applications utilizing a double suction or large diameter piping When excessive loading or insufficient support of the suction piping exists reservoir fatigue fractures loss of oil and decreased hose life are likely to occur 1 For double suction applications if weight and length of pipe work fittings is excessive shorten the piping to reduce vibration and add support brackets to compensate for the added weight Additional support brackets should be attached to a common point with the Hyrdrapak so that flexing of the truck frame and vibration does not induce additional stress on the Hydrapak 2 On direct coupled double suction piping if mounting conditions do not accommodate additional support brackets consider line mounting a pipe Y to fill the need for a double suction When line mounting the Y a single section of large diameter hose can be fitted to the reservoir suction fitting leading into the Y downstream Appropriately sized piping can then exit the Y and lead into the pump inlet sections Always make sure the Y pipe is Supported and consideration is given to the remaining points HYD 7 600 Page 8 Hoses must have proper support near the Hydrapak to reduce loading from hose and fluid weight Unsupported hoses pull on the welded connection fittings of the reservoir and may result in r
4. RING REKE TETEE 2 244010200 244010200 244010200 54 SCREW enna ete bedende 4 751 485 751 485 75LM48S Order by Part Number and Description Reference Numbers are for your convenience only FILTER ELEMENT FOR ITEM 191 VP1119226 HYD 7 600 Page 15 G ardn er WARRANTY HYDRAPAK COOLING SYSTEM ver GENERAL PROVISIONS AND LIMITATIONS Gardner Denver Inc the warrants to each original retail purchaser of its products from the Company or its authorized distributor that such products are at the time of delivery to the Purchaser made with good material and workmanship No warranty is made with respect to 1 product which has been repaired or altered in such way the judgment as to affect the product adversely 2 Any product which has in the judgment been subject to negligence accident improper storage or improper installation or application 3 Any product which has not been operated or maintained in accordance with the recommendations of the Company 4 Components or accessories manufactured warranted and serviced by others 5 Any reconditioned or prior owned product Claims for items described in 4 above should be submitted directly to the manufacturer WARRANTY PERIOD The obligation under this warranty is limited to repairing
5. leaks Lower load and or relieve hydraulic pressure before loosening fittings Do not operate unit without all body panels and quards in place Never bypass safety devices Failure to observe these notices could result in damage to equipment e Stop the PTO and engine if nay repairs or adjustments on or around the Hydrapak are required e Ensure proper rotation of blower prior to start up Failure to do so may result in damage to the hydraulic pump HYD 7 600 Page 6 SECTION 1 Before uncrating check the packing slip carefully to be sure the parts been received All accessories are listed as separate items on the packing slip and small important accessories such as relief valves can be overlooked or lost After every item on the packing slip has been checked off uncrate carefully Register a claim with the carrier for lost or damaged equipment Customers are cautioned to provide adequate protection warning and safety equipment necessary to protect personnel against hazards involved in installation and operation of this equipment in the system or facility STORAGE Your Gardner Denver Hydrapak was packaged at the factory with adequate protection to permit normal storage for up to six 6 months If the unit is to be stored under adverse conditions or for extended periods of time the following additional measures should be taken to prevent damage 1 Store the cooler in clea
6. 1 1118076 1118076 1118076 17 EDGE TRIM irene 6 80 ft 1118156 1118156 1118156 18 VPN 1 1119238 1119238 1119238 519 1 1118077 1118077 1118077 20 GROMMET sauser 1 1118154 1118154 1118154 21 FITTING HYD 1 302095219 302095219 302095219 22 FITTING HYDHOSE BARB 1 302183205 302183205 302183205 23 FLING AYD ELBOW 1 302099201 302099201 302099201 24 RELUEFRVAVE 1 303000008 303000008 1132940 25 FITTING HYD ADAPTER 1 302065207 302065207 302065207 26 FITTING HYD 1 302005200 302005200 302005200 27 FAN file 1 VP1118078 VP1118078 VP1118078 28 FITTING HYD PLUG aa 1 302123205 302123205 302123205 29 ETING PEW 1 302123204 302123204 302123204 30 PUTING HYD PLUG olsen 1 302123203 302123203 302123203 31 FLOW 05 5 5 de 1 VP11180891 VP11180891 VP11180891 32 FITTING HYD ADAPTER A A 1 302065234 302065234 302065234 33 GROMET uviss 2 VP118153 VP118153 VP118153 34 FITTIN
7. G HYDHOSE BARB 1 302183200 302183200 302183200 35 FITTING HYDHOSE BARB 1 302183206 302183206 302183206 36 EOS E vaere Dee 1 310030223 310030223 310030223 37 Ledelse desert 1 310030224 310030224 310030224 38 HOSE ASSEMBLY 1 407021218 407021219 407021219 39 FITTING HYD HOSE BARB 545 1 302170206 302170206 302170206 40 STRIP FOAM 6 00 1118157 1118157 1118157 41 FITTING HYD APAPTER air 1 305061200 305061200 305061200 42 EITTING KHYD ADAPTER redet 1 302065235 302065235 302065235 43 SIDE PANE 2 1119224 1119224 1119224 44 WASHER RUBBER 4 VP1118151 VP1118151 VP1118151 45 FITTING PLUG 1 64 5 64 5 64 5 46 SCREW sauene 4 75A10Z 75A10Z 75A10Z 47 NET Ve 6 236105400 236105400 236105400 48 FRAME ASSEMBLY vane 1 CC1118050 CC1118050 CC1118050 49 HOSE Pg 2 299070218 299070218 299070218 50 HOSE CLAMP At 4 299070207 299070207 299070207 51 tee a 1 1118083 1118083 1118083 52 EE en ee 24 75LM47S 75LM47S 75LM47S 53 RETAINING
8. Gardner Denver service year in and year out IMPORTANT GARDNER DENVER TELEPHONE NUMBERS YOUR AUTHORIZED GARDNER DENVER DISTRIBUTION NAME TELEPHONE FAX CONTACT THANKS6 FOR THE PRIVILEGE OF SERVING YOU WITH DEPENDABLE GARDNER DENVER QUALITY HYD 7 600 Page 3 MAINTAIN HYDRAPAK RELIABILITY AND PERFORMANCE WITH GENUINE GARDNER DENVER PARTS AND SUPPORT SERVICES Factory genuine parts manufactured to design tolerances are developed for optimum dependability specifically for your Hydrapak Design and material innovations are born from years of experience with hundreds of different applications When you specify factory genuine parts you are assured of receiving parts that incorporate the most current design advancements manufactured in our state of the art factory under exacting quality standards Your AUTHORIZED DISTRIBUTOR offers all the backup you require A worldwide network of authorized distributors provides the finest product support in the industry INSTRUCTIONS FOR ORDERING REPAIR PARTS For pricing and ordering information contact your nearest AUTHORIZED FACTORY DISTRIBUTOR When ordering parts specify MODEL and SERIAL NUMBER see nameplate on unit Rely upon the knowledge and experience of you AUTHORIZED DISTRIBUTOR and let them assist you in making the proper parts selection for your Hydrapak To Contact Gardner Denver or locate your local distributor Visit www contactgd com mobi
9. ODEL MODEL MODEL 704010100 704010104 704010100 704010102 704010105 Ref 704010103 No Description Qty MH C2 MH C2 MH C2 1 1 1118064 1118064 1118064 2 2 1 126663 1 126663 1 126663 3 ee 4 1 126665 1 126665 1 126665 4 PS Jt cers Ore re PTE 4 BB1128040 BB1128040 BB1128040 5 SPRING cet et 4 BB1126667 BB1126667 BB1126667 6 RETAINER RIN An 4 BB1126666 BB1126666 BB1126666 7 NIPP UE ise 1 63675 63675 63675 8 COUP E EEE 1 64BK5S 64BK5S 64BK5S 9 GAUGE OIL LEVEL SIGHT GLASS 1 40P11 40P11 40P11 10 FAN GUARD pda 1 VP1118159 VP1118159 VP1118159 11 MOSE vrede 1 310030226 310030226 310030226 12 FANT BS 1 300001228 300001228 300001228 13 CONTROL B kO GK are Le 1 1118079 1121067 1121067 14 CHECK VALVE BYPASS 1 304059203 304059203 304059203 15 PLATE TOP HEAT EXCHANGER 1 CC1118158 CC1118158 CC1118158 16 COOLER 51 ae eee rs
10. ak lid to access in tank filter Remove cap and filter element 2 Fill reservoir with Shell Tellus ISO 32 hydraulic oil or equivalent until oil appears in sight glass 3 Replace filter element and cap 4 Slowly raise clutch while engine is running to engage P T O and pump to draw some oil from reservoir into suction line Stop after a couple seconds Disengage P T O press clutch all the way Repeat steps 1 4 until oil level does drop while the P T O is engaged 6 Check entire hydraulic system for leaks Do not over fill oil in reservoir Doing so may create excessive pressure inside reservoir and result in oil leaks and or filter damage A minimum system operating pressure of 1300 psi is recommended Operating below 1300 psi may result in undesired surging of fan motor and reduced performance HYD 7 600 Page 12 SECTION 4 MAINTENANCE 1 Change hydraulic oil and filter every 6 months 2 Check oil level each week with system OFF Oil should be visible in lower of sight glass 3 Visually check the system each week all fittings hoses Hydrapak mounting 4 Grease P T O Pump spline every months grease every month for high duty cycle applications NOTICE An oil analysis program is recommended HYD 7 600 Page 13 SECTION 5 PARTS LIST 2 See page 15 for Parts List HYD 7 600 Page 14 M
11. e Service 3 Ls LEE EV EE 16 Maintenance Section 4 13 LIST OF ILLUSTRATION Figure 2 11 Air Flow Direction And 10 Figure 2 2 Air Flow Direction And Outline 11 HYD 7 600 Page 2 INTRODUCTION YOUR KEY TO TROUBLE FREE SERVICE Thank your for investing in Gardner Denver quality The Gardner Denver reputation for rugged dependability has been earned by over 50 years of service in demanding industrial operations where downtime cannot be tolerated and efficient performance is expected Your Gardner Denver Hydrapak is a precision engineered cooling system that has been carefully manufactured and thoroughly tested at the state of the art Gardner Denver Manufacturing Facility in Sedalia Missouri As with other precision machinery there are several relatively simple installation operation and maintenance procedures that you must observe to assure optimum cooler performance There is no guesswork in the manufacture of your highly advanced Gardner Denver Hydrapak and there must be none in preparing the cooler to get the job done in the field The purpose of this manual is to help you properly install operate and maintain your Gardner Denver Hydrapak It is essential that you review all sections of this manual in preparation for installing your Hydrapak Follow the instructions carefully and you will be rewarded with trouble free
12. eservoir stress fractures and shortened hose life Proper installation of the hoses should include a slight bend in the hoses near the connections This allows them to flex reduce vibration stress and hose shrinkage under load All hoses should use the largest bend radius possible to reduce pressure drop and loading Always follow the hose manufacturer s recommendations for hose duty and bend radius If an excessively tight bend is required consider using a section of rigid pipe such as a street 90 with increased pipe diameter HYD 7 600 Page 9 OL 009 RETURN LINI OPTIONAI RETURN LINE INLET 16 SUCTION PORT FIGURE 2 1 AIR FLOW DIRECTION AND OUTLINE RELIEF VALVE HIGH PRESSURE INLET SAE 12 MOUNTING STUDS 142 13 UNC AUXILLARY PORT HIGH PRESSURE SAE 06 HIGH PRESSURE INLET OPTIONAL SAE 12 AIR DISCHARGE LL 009 INLET FIGURE 2 2 AIR FLOW DIRECTION AND OUTLINE SECTION 3 INITIAL STARTUP PROCEDURE This startup procedure should be followed during the initial installation and after any shutdown periods or after the Hydrapak has been worked on or moved to new location NOTICE Two people are required for initial start up procedure Ensure all hydraulic connections to Hydrapak are tight before performing initial startup procedure Ensure Hydrapak is in level position so oil level in sight glass is accurate 1 Remove Hydrap
13. le call 217 222 5400 HYD 7 600 4 Gardner Denver Hydrapak are the product of advanced engineering and skilled manufacturing be assured of receiving optimum service from this machine the owner must exercise care in its operation and maintenance This book is written to give the operator and maintenance department essential information for day to day operation maintenance and adjustment Careful adherence to these instructions will result in economical operation and minimum downtime Danger indicate a hazardous situation that if not avoided will result in dath or serious injury Warning indicate a hazardous situation that if not avoided could result in death or serious injury Caution indicate a hazardous situation that if not avoided could result in minor or moderate injury NOTICE Notice indicates information considered import but not hazard related HYD 7 600 Page 5 SAFETY INSTUCTIONS Failure to observe these SAFETY INSTRUCTIONS could result in death or serious injury Do not work under the vehicle when engine and or PTO are running Do not work on the hydraulic system when engine and or PTO is running Do not go near oil leaks when engine is running e High pressure oil easily punctures skin causing serious injury infection or death If injured seek emergency medical help immediately e Immediate surgery is required to remove oil Do not use finger or skin to check for
14. n dry heated if possible area 2 Make certain inlet and discharge air ports are tightly covered to prevent foreign material from entering the hydraulic system 3 All hydraulic fittings are zinc coated but should also be protected against rust and corrosion 4 In high humidity or corrosive environments additional measures may be required to prevent corrosion of an hub and aluminum control block HYD 7 600 Page 7 SECTION 2 INSTALLATION MOUNTING Drilling clearance holes for 2060 size is required to mount the Hydrapak see bolt pattern on page 11 Mounting hardware includes rubber isolation washers flat washers lock washers and hex huts HYDRAULIC HOSES amp FITTINGS Suction line rotation must not rise above the oil level height in reservoir at any location This may cause severe hydraulic pump cavitation which will reduce the hydraulic pump life Do not use thread tape or sealant on hydraulic fittings as this can contaminate hydraulic system NOTICE SUCTION LINE SIZING amp ROUTING e Pressure drop calculations must be performed on the specific system and corresponding tractor unit to insure acceptable suction conditions The routing of the suction line must be done to avoid excessive pressure drop Elbows reducers and line rises above the bottom of Hydrapak reservoir will cause excessive pressure drop in suction line The maximum recommended vacuum at the hydraulic pump inlet is 5 Hg For gear pumps and 2
15. o and from the nearest Authorized Distributor and the designated facility The Company may require the return of any blower or part claimed not to be as warranted to one of its facilities as designated by the Company transportation prepaid by Purchaser to establish a claim under this warranty Replacement parts provided under the terms of the warranty are warranted for the remainder of the Warranty Period of the product upon which installed to the same extent as if such parts were original components thereof DISCLAIMER THE FOREGOING WARRANTY IS EXCLUSIVE AND IT IS EXPRESSLY AGREED THAT EXCEPT AS TO TITLE THE COMPANY MAKES NO OTHER WARRANTIES EXPRESSED IMPLIED OR STATUTORY INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE THE REMEDY PROVIDED UNDER THIS WARRANTY SHALL BE THE SOLE EXCLUSIVE AND ONLY REMEDY AVAILABLE TO THE PURCHASER AND IN NO CASE SHALL THE COMPANY BE SUBJECT TO ANY OTHER OBLIGATIONS OR LIABILITIES UNDER NO CIRCUMSTANCES SHALL THE COMPANY BE LIABLE FOR ANY SPECIAL INDIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES EXPENSES LOSSES OR DELAYS HOWSOEVER CAUSED No statement representation agreement or understanding oral or written made by any agent distributor representative or employee of the Company which is not contained in this Warranty will be binding upon the Company unless made in writing and executed by an officer of the Company This warrant
16. y shall not be effective as to any claim which is not presented within 30 days after the date upon which the product is claimed not to have been as warranted Any action for breach of this warranty must be commenced within one year after the date upon which the cause of action occurred Any adjustment made pursuant to this warranty shall not be construed as an admission by the Company that any product was not as warranted 2012 Gardner Denver Inc Gardner nver For additional information contact your local representative or visit www contactgd com blowers 2014 Gardner Denver Inc Printed in U S A Member 08 9 ST CAGI Cas 150 5 PARTNER 42 Please recycle after use
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