Drum HYDRAPAK User manual

HYDRAPAK
OIL COOLER
Installation,
Operating &
Maintenance
Manual
(Original Instructions)
4991015005
February 2018

Contents
Chapter Page
1 Health & Safety
Health & Safety.....................................................................3
2 General
2.1 Product General Description...........................................4
2.2 Identication.........................................................................4
2.3 Available Models..................................................................4
2.4 Dimensions & Operating Environment .......................5
3 Installation
3.1 General Instructions ...........................................................6
3.2 Mounting Hydrapak .......................................................6-7
3.2 Pipe Connection Diagrams ..............................................8
3.3 Hydraulic System (Hoses) .................................................9
3.5 Hydraulic Fittings.............................................................. 10
3.6 Operating Instructions ................................................... 11
3.7 Pressure Relief Valve ........................................................ 12
3.8 Relief Valve Setting Procedure.....................................13
4 Maintenance Instructions
4.1 Schedule .............................................................................. 14
4.2 Removing the Outer Cover ...........................................15
4.3 Changing the Filter Element.........................................16
4.4 Fault Finding.................................................................17-18
4.5 Spare Parts Diagrams ................................................19-22
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4991015005 Date:02/18 Hydrapak Installation, Operating & Maintenance Manual

Health & Safety
1READ THE WHOLE MANUAL BEFORE COMMENCING
INSTALLATION.
Static electricity
Any equipment must be installed in accordance with prevailing local earthing
legislation.
Hydrapak
The Hydrapak has internal moving parts some of which may be accessed through
the air inlet and outlet apertures. Do not place any objects into these openings as
personal injury could result.
Noise
Gardner Denver Drum’s own noise tests show maximum noise levels to be
typically less than 85dB(A). Other truck / equipment noise levels are likely to
be greater.
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4991015005 Date:02/18 Hydrapak Installation, Operating & Maintenance Manual

General
2.1 Product General Description
The Hydrapak is a lightweight, compact oil cooler combining the reservoir,
lter, control and safety equipment required in a hydraulic system within one
assembly. This replaces large, heavy oil tanks and separate ancillaries.
The compact shape and size of the cooler make it ideal for mounting in small
spaces on any chassis.
All variations can dissipate 8kW of heat for a 40°C temperature rise in a 45°C
ambient automatically (without the need to adjust the fan speed).
All versions contain the following integral equipment:-
Oil reservoir (11 litres)
Cooling fan, radiator and hydraulic fan motor
Relief valve
10 micron lter (return) Rating = 10 Beta 2
Easily replaced paper lter element
Filter / radiator bypass valve
Oil level sight glass
Filter blockage indicator
Suction elbow and pipe kit
Compact size = 340(W) x 607 (H) x 375(D) mm
Low weight = 17kg (dry)
Low oil capacity = 11 Litres
After mounting, the installer simply has to connect the cooler to the
hydraulic pump and motor without sizing / arranging any other equipment.
2.2 Identication
The body number of the machine is shown on the body number label which
is located on the underside of the Hydrapak on the polyhydron block.
2.3 Available Models
The Hydrapak is available in two pressure variations (200 and 300 bar
maximum), and three ow versions (60,100, and 140 litre/min).
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2

General
2.4 Dimensions & Operating Environment
Dimensions
See Fig 1a.
Operating environment
The permissible/foreseen operating environment is as follows:
Mounting Points
6 off Ø13
Filter Element
240
98
170100
27
6
143
607
375
340
280
Filter element
removal height
Fig 1a. Hydrapak general dimensions
Heat dissipation = 8kW for a 40°C Temp Rise
Resistant to tropical rain in operation and transit
Ambient temperature range -30 to +45°C
Truck Mounted, Worldwide, All seasons
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4991015005 Date:02/18 Hydrapak Installation, Operating & Maintenance Manual

Installation
3.1 General Instructions
Handling- The bare machine weighs 17Kg, therefore it is recommended that
the machine is lifted with a suitable crane & sling. The machine must be lifted
using the mounting points provided.
Storing- Store the unit in a dry, heated building. Handle the machine with
care.
3.2 Mounting the Hydrapak
The new Hydrapak has 6 mounting points.
When installing the Hydrapak use holes 1, 2 ,5 and 6.
When replacing older Hydrapak 2’s with a Hydrapak, holes 1,2,3 and 4 are
used but holes 5 & 6 may also be used for extra support. This makes inter-
changing units easier when installing. See Fig 1b.
3
1
3
5
2
4
6
Fig. 1b. Mounting points.
Use 4 mounting points when
installing the Hydrapak.
NOTE
Anti - Vibration pads should
be used to isolate the cooler
from vehicle vibration.
NOTE
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4991015005 Date:02/18 Hydrapak Installation, Operating & Maintenance Manual

1. Allow a minimum space of 280 mm above the Hydrapak ller cap to
allow removal of the lter element when servicing.
2. When retting ller cap, only tighten by hand. Do not use excessive
force as this will cause the tank to distort.
3. During installation it is important to make sure that the air inlet and
outlet ducts (shown below Fig 2) are not obstructed,
allowing a free ow of air for maximum cooling.
4. Typically ISO VG46 hydraulic oil will be suitable but the correct
viscosity for the hydraulic pump and motor (see manufacturers
instructions) will also suce for the Hydrapak. Ensure that the oil
level coincides approximately with the mid point of the sight glass.
Run the unit for 1 minute then top up the oil level if necessary.
5. When the Hydrapak is sharing the same mounting uprights with a
compressor it is recommended that a deector plate is installed to
divert the hot air discharged away from the compressor. See Fig 2.
Installation
KEY
1. Chassis Frame
2. M12 Bolt
3. Anti-vibration Pad
4. M12 Washer
5. M12 Nut
6. Filler Cap
7. Typical Compressor Installation
8. Deector Plate
Fig. 2 Airow direction incorporating typical compressor installation.
1
AIR INLET
6
Mounting Points
7
8
HOT AIR OUT
2
3
4
5
Do not use excessive force
when tightening the Filler Cap.
CAUTION
Do not distort tank when
tting, ensuring tank is
secured using Anti-Vibration
pads as illustrated.
NOTE
When the Hydrapak is to be
used on cryogenic’s, specialist
hydraulic oils are used. The
Motor supply hose should be
changed accordingly.
See page 19 & 20 for correct
part number.
CAUTION
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4991015005 Date:02/18 Hydrapak Installation, Operating & Maintenance Manual

1
2
9
3
4
7
5
6
8
1. Hydrapak
2. Suction Line to Pump
3. Hydraulic Motor
4. Motor Case Drain line (CD)
5. Pressure Line to Motor
6. Hydraulic Pump
7. Power Take O
8. Pressure sensing Line (P) to relief
valve
9. Return line (R)
Fig 3a shows typical installation. Fig. 3b shows a typical tractor/trailer
installation with non-spill couplings.
3.3 Pipe Connection Diagrams
Installation
Fig. 3a Typical Installation
10
10
Fig.3b Tractor / Trailer installation
10. Non-spill Couplings
When installing the hydrapak and hydraulic
system, ensure that the pump and motor are
mounted below the oil level of the Hydrapak
reservoir.
NOTE
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4991015005 Date:02/18 Hydrapak Installation, Operating & Maintenance Manual

3.4 Hydraulic Hoses
Always make sure that any Hydraulic Hoses tted into the Oil Cooler system
are of the correct length to suit the positioning of the equipment being
installed.
Allow for the movement of the PTO/Gearbox in relation to the Hydrapak
when tting the hydraulic hoses. See Fig 4, a and b.
Installation
DO NOT Install hydraulic
hoses that are too long and
may ‘kink’ when tted.
CAUTION
Install the Hydrapak a safe
distance away from the
vehicle exhaust or other heat
producing equipment. See Fig
5.
NOTE
Fig. 4a. Hose Lengths too short 4b. Too long.
Fig. 5 Vehicle exhaust / heat producing equipment
a
b
DO NOT Install hoses that are
too short and will be stretched
when tted.
CAUTION
The Hydrapak body must
not be distorted or heavily
stressed when mounting.
NOTE
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4991015005 Date:02/18 Hydrapak Installation, Operating & Maintenance Manual

3.5 Hydraulic Fittings
Leakage from any hydraulic tting could cause air to be drawn into the
system, which may cause damage to the hydraulic equipment.
Hose and end ttings should be of the appropriate pressure ratings :-
SAE 100R2 - Low and Medium Pressure Hose
SAE 100R10 - High Pressure Hose
Only use crimp hydraulic ttings with high pressure hose. Always use the
correct size ttings.
The suction elbow can be orientated in any of three positions to
accommodate dierent pipe layouts.
See Fig 6 for schematic layout.
Installation
Fig. 6 Schematic Diagram
Suction
Case Drain
Return Pressure
FR
R
P
CD RAD2
RAD1
6
1
7
2
5
4
3
KEY
1. Restrictor Assembly -*(if tted)
2. Fan Motor
3. Radiator
4. System Relief Valve
5. Return Line Return Valve
6. Filter Restriction Indicator
7. Return Filter
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4991015005 Date:02/18 Hydrapak Installation, Operating & Maintenance Manual