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
Page 2
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.
Page 3
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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4991015005 Date:02/18 Hydrapak Installation, Operating & Maintenance Manual
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
Page 5
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

3.6 Operating Instructions
Please read thoroughly before operating the system.
Noise
Tests conducted by Gardner Denver Drum show noise levels are signicantly
less than 85dB(A).
Safety
Do not operate the Hydrapak with the outer cover removed.
Visual Checks before Starting the System
Make sure any non-spill couplings (if tted) are correctly
connected.
Installation
A lter blockage indicator
gauge on initial start up,
(when cold), may point to the
red sector (lter on full by-
pass). This is normal due to
the high viscosity of oil when
cold. When the system has
warmed up the gauge should
not remain in the red sector.
If the gauge remains in the red
sector after warm up, the lter
element must be replaced.
See section 4.3.
NOTE
Grease or dirt must not be
allowed to enter the internals
of the machine.
CAUTION
It is recommened that ear
protection is worn during
vehicle testing.
IF IN DOUBT CONSULT A GARDNER DENVER DRUM
REPRESENTATIVE.
Starting the System
1. Ensure the handbrake is applied.
2. If a selector valve or reverse ow valve is tted, select
the neutral position.
3. If hydraulic speed control is tted, this should be fully
open.
4. Check oil level. This should be on or slightly below the maximum
level on the sight glass.
5. Depress the clutch and engage the PTO, release the clutch
slowly.
6. Operate the selector valve (if tted) for desired rotation.
7. Close the speed control valve (if tted) to direct the
hydraulic oil through the motor.
8. If a hand throttle is tted, gradually increase to the
required speed.
Stopping the system
1. Reduce engine speed to idle and return all control valves
to the neutral position.
2. Disengage the PTO.
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1
11
10
9
3
4
6
7
2
5
8
12
KEY
1. Hydrapak
2. Suction Line to Pump
3. Hydraulic Motor
4. Motor Case Drain Line
(CD)
5. Pressure Line to Motor
6. Hydraulic Motor
7. Power Take o
8. Pressure Line (P)
9. Return Line (R)
10. Polyhydron Block
Assembly
11. Pressure gauge
12. Throttle valve
3.7 Pressure Relief Valve
The working pressure of hydraulic drive systems is dependant on the
installation and the load upon the system.
Although the normal working pressure range of the Hydrapak is 80-200 bar
(LP) and 200-300 bar (HP version) the units are supplied with the relief valve
preset to allow operation up to 180 bar (LP) and 280 bar (HP version).
If there is a need to increase/decrease these settings up to the maximum
working pressure or reduce them to protect sensitive hydraulic equipment,
follow the instructions in section 3.8.
To set the relief valve, a pressure gauge and a throttle valve must be
connected into the pressure lines as shown in (Fig 7). Refer to Fig 8 for
Relief Valve setting.
For the best protection, the relief valve should be reset to the maximum
working pressure +30 bar on all hydraulic systems.
Installation
Fig. 7 Typical system layout
Setting/adjusting the relief
valve should only be carried
out by a competent person
with the correct equipment.
NOTE
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3.8 Relief Valve Setting Procedure
After draining the system and inserting a throttle valve and pressure gauge
into the system (see g 7):-
1. With the throttle valve fully open, run the system under load at
normal operating speed and measure the normal working pressure.
2. Fully close the Throttle Valve to increase the pressure in the system.
The drive motor will stop and the relief valve will go on full by-pass.
3. Using a 17mm spanner, loosen the locking nut on the relief valve
adjusting screw (item 5).
4. Insert a 3/16” allen key (item4) into the adjusting screw (item
5) and rotate as shown in an anti-clockwise direction to increase the
by-pass pressure so that it is 30 bar above the normal working
pressure.(Fig 8).
5. Drain the system then remove throttle valve and gauge (Fig 7 Items
11 & 12).
Installation
At high operating pressure the
system will heat up rapidly.
Make adjustments quickly
then re-open the Throttle
Valve
CAUTION
Fig. 8 Setting Relief Valve
2
To front of
Hydrapak
1
4
5
3
KEY
1. Relief Valve
2. Polyhydron
Block
3. 10mm Locking
Nut
4. 3/16” Allen key
5. Adjusting Screw
Page 13
4991015005 Date:02/18 Hydrapak Installation, Operating & Maintenance Manual

4.1 Schedule
Always ensure the Hydrapak and hydraulic system are well maintained by
following the maintenance instructions outlined below:
4
Maintenance
If air is drawn into the system
it may cause damage to the
hydraulic equipment.
NOTE
Every Day
• Check the reservoir oil level and top up if necessary.
First 50 hours
• For best practice and to maximise the life of system
equipment, the hydraulic oil should ideally be changed for
the rst time.
Every 3 Months
• All bolts attaching the PTO to the gearbox, the pump
to the PTO and the motor to the cargo pump are to be
checked and tightened where necessary.
• Check for external damage and possible bulging of hoses
under pressure. Replace worn hoses.
• Check for oil leaks in the system and tighten the pipeline
connections where necessary.
• Check the reservoir oil level and top up as required.
• Check the radiator for dirt and possible blockage. Blow
clear using compressed air.
Every 9 months
• Replace Filter Element.
Every 12 months
• Replace hydraulic oil. See page 7, point 4
Suction Hose
Special attention should be paid to the suction hose, Hydrapak
to hydraulic pump. A leak due to a damaged or loose connection
will allow air to be drawn into the system when it is operating and
very quickly damage the pump. The suction hose must be able to
withstand vacuum conditions up to 6”Hg.
Power Take O, Pump and Motor
Refer to manufacturers recommendations.
Page 14
4991015005 Date:02/18 Hydrapak Installation, Operating & Maintenance Manual

4.2 Removing The Outer Cover
1. Unscrew and remove the 3 x M6 button head screws (item 2) and
washers (item 3) from the front face of the outer cover.
2. The cover is now free to be pulled away from the aluminium tank
Fig. 9.
Maintenance
Fig. 9 Removing the Outer Cover
1
23
Filler cap no longer needs to
be removed to take the outer
cover o.
NOTE
KEY
1. Outer Cover
2. M6 Button Head Screw x 3
3. Retaining Washer x 3
Page 15
4991015005 Date:02/18 Hydrapak Installation, Operating & Maintenance Manual

4.3 Changing The Filter Element
The life expectancy of the lter element is approximately 9 months. Gardner
Denver Drum recommends that the lter condition is checked on a regular
basis.
The cooler is tted with a lter condition gauge (6) which is located at the
front of the outer cover of the Hydrapak. When the needle of the gauge has
reached the ‘Red’ section of the gauge the lter element will need changing.
1. Unscrew Filler Cap (1) and remove, then unscrew and remove lter
retaining nut (2).
2. Remove Strainer Disc (3) from the sealing ring and remove the
spring (4) located on top of the lter element .
3. Withdraw the lter element (5) from the Hydrapak reservoir. The
lter is a non-serviceable item and must be replaced at the end of its
service life.
Re-tting a new Filter Element is a reversal of the above.
Maintenance
Spring tension is released
during this operation.
CAUTION
6
1
2
3
4
5
Fig. 10 Changing the Filter Element
When re-tting the Filler Cap,
do not use excessive force.
Hand Tight only to avoid
distortion of the tank.
CAUTION
When replacing the new lter
element, ensure it is located
into the housing at the bottom
of the tank.
NOTE
Key
1. Filler Cap
2. Retaining Nut
3. Strainer Disc
4. Spring
5. Filter Element
6. Filter Condition Gauge
Take care not to drop any
components or contamination
into the tank.
CAUTION
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2. Insucient Pressure in the System
Symptoms Remedy/Solution
Pump will not prime - See 1a and 1b
Relief valve opening below - Adjust the setting using a
setting. pressure gauge, change Relief
valve if necessary
Hydraulic motor/pump is worn or - Repair or replace unit
has excessive external damage
Lack of power from engine - Examine for possible faults in
system specication and
engine management system
Pump has not been primed - See pump installation
instructions
4.4 Fault Finding
1. Noisy system
Symptoms Remedy/Solution
a. Cavitation of pump due to :-
Low oil supply - Top up oil
Incorrect grade of oil - Replace with correct grade
oil.
Suction line restriction - Remove restriction
Sharp bend in suction line - Modify design / line length
b. Air entering system due to :-
Leakage in suction line - Inspect and tighten pipe
connections
Low oil level - Replenish / Top up
Leaking packings, pump shaft - Check and replace as
necessary seals etc.
c. Mechanical errors due to :-
Worn or damaged pump - Repair or replace pump
Worn or damaged motor - Repair or replace unit(s)
Failure of P.T.O. - Repair or replace as necessary
d. Vibrating pipes due to :-
Cavitation of pump - (see Cavitation of pump)
Resonance of system - Introduce exible piping at
critical points and/or fasten
pipes
Unstable relief valve - Check setting/examine.
Replace as necessary
Maintenance
When performing any type of
maintenance or fault nding,
ensure all rotating parts etc.
are guarded or isolated for
inspection.
CAUTION
Unless all the components
of a functioning hydraulic
system are kept in a good
working condition, operational
problems are likely to occur.
NOTE
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4991015005 Date:02/18 Hydrapak Installation, Operating & Maintenance Manual

5. Overheating
Symptoms Remedy/Solution
Relief valve setting too low - Adjust setting using a pressure
allowing oil by-pass directly gauge - See Setting Section
to tank
Radiator blocked with road dirt - Clean/remove obstruction
or obstructed reducing cooling
Radiator fan not working - Replace fan motor/ investigate
for fan interference
Hydraulic motor/pump is worn - Repair or replace unit
and has excessive internal
leakage
Flow too high for Hydrapak - Reduce P.T.O. speed
(maximum 140 litres/min.)
Incorrect motor / pump type - Replace with higher eciency
used equipment
4. Erratic Operation of Motor
Symptoms Remedy/Solution
Entrapped air causing - Ensure that oil in system is
uctuating pump delivery clear from bubbles and foam
(See 1a)
Inconsistant P.T.O. speed - Check PTO spec,condition,
engine speed & engine
management system
Air pocket in system - Remove air from system by
bleeding
3. Pump Deliveries Low or No Fluid
Symptoms Remedy/Solution
Low oil level - Examine for cause of loss of
oil and top up
Suction line restricted or closed - See 1a
Pump running in reverse - Check rotation of pump and
P.T.O.
Incorrect oil having too high a - Change oil
viscosity
P.T.O. running too slow - Check speed
Maintenance
When handling hot Relief
Valves wear heat resistant
gloves.
CAUTION
Only a small amount of water
will cause this eect and will
not result in short term system
damage.
NOTE 6. Oil Condition
Symptoms Remedy/Solution
Oil looks milky (caused by water - Check for leaks, particulary
entering the system) in cooler
Page 18
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Maintenance
Item Description ............................................................Part Number.........................................Qty
1 Reservoir (Standard)...........................................8901314000-2......................................1
2 Filter Support ........................................................6460614240-2......................................1
3 Filter Element........................................................6828914000-2......................................1
4 Retaining Washer ................................................7924200000-2......................................3
5 Radiator...................................................................8770314000-2......................................1
6 Filter Retaining Nut.............................................6701814240-2......................................1
7 Strainer Disc...........................................................6289014240-2......................................1
8 Sealing Ring...........................................................7080814605-2......................................1
9 Filler Cap .................................................................6260003898-2......................................1
10 Filter Tie Rod..........................................................8850814240-2......................................1
11 Outer Cover ...........................................................8842615000-2......................................1
12 Radiator Outlet Hose..........................................6471714004-2......................................1
13 Radiator Inlet Hose ..............................................6471614000-2......................................1
14 Hose Clip.................................................................H62007002402....................................4
15 St/St Hex Head M6 x 16.....................................M470067016-7 ....................................3
16 M8 Dowty Washer ...............................................H79039008212....................................1
17 M8 Domed Nut.....................................................M230087000-2 ....................................1
18 Sightglass Kit ........................................................6482900000-2......................................1
19 Fan Motor Assembly...........................................H16560010002....................................1
20 Cap Head Screw M6 x 20 ..................................M450067020-9 ....................................2
21 Fan Impeller...........................................................3301400000-2......................................1
24 Sealing Tape 6mm x 25mm x 0.6m ...............8820100000-2......................................1
25 Motor Supply Pipe .............................................6474400000-2......................................1
- Motor Supply Pipe .............................................6473600000-2......................................1
26 Cover Securing Grommet.................................8251100000-2......................................2
27 Spring ......................................................................8871714000-2......................................1
28 Serial No. Plate......................................................6726200451-2......................................1
29 Sight Glass Gasket...............................................6405115000-2......................................1
30 Polyhydron Valve Block Assembly.................8501114001-2......................................1
31 Radiator Support Grommet.............................8250914000-2......................................2
32 Adaptor 1/4”BSP x 14mm ................................H69188002402....................................1
33 Dowty Washer.......................................................H79044008212....................................1
34 Copper Washer .....................................................7902100401-2......................................2
35 Cork Gasket............................................................6404915000-2......................................1
36 Clamp Plate............................................................8614214240-2......................................1
37 Restrictor/Assy Filter...........................................8023600000-2......................................1
38 Fan Nut....................................................................6701714001-2......................................1
39 M12 Plain Washers ..............................................M600120000-2 ....................................2
41 Grub Screw Special.............................................SK894/14 ...............................................1
42 ‘GD’ Logo.................................................................6729700000-2......................................1
43 Drive Screws..........................................................M510038006-2 ....................................2
44 Filter ‘Blocking Indicator....................................H41222000012....................................1
45 Bulkhead Fitting...................................................6916800000-2......................................1
4.4 Spare Parts Diagrams
**
# Refer to page 21 for
spares sheet1
*Standard Units Only
** High Pressure Units
Only
*** Cryogenics only
#
*
***
**
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Maintenance
11
38
21
5
36
35
19 34 20
39
39
44
45
26
42
4
15
24
24
30
31
31
18 29
13
14
12
33
32
25
41
3
7
43
10
28
16
17
1
9
6
7
8
27
3
2
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