Stac THERMAFLOW SS980H User manual

MODEL SS980
TRANSPORT HYDRAULIC COOLING SYSTEM
Model #:
Serial #:
Installation Date:
Resource Manual
Installation Guide lOperating Procedures lParts Breakdown
STAC INC l ST PAUL MN l800-334-7699
Mobile Hydraulic Systems
®
MODELS
SS980H
SS980HFT

MODEL SS980
INDEX
STEP DESCRIPTION PAGE
Introduction 1
1 Positioning & Mounting 2
2 Installing the PTO & Hyd Pump 2
3 Hydraulic Plumbing 3-5
4 Final Assembly 6
5 Start-Up Procedures 6
System Maintenance 7
Troubleshooting 8
Specifications 9
SS980H Parts Breakdown 10
SS980HFT Parts Breakdown 11
Parts List 12-14
Product Offering 15
Warranty Policy
INSTALLATION GUIDE , OPERATING PROCEDURES & PARTS BREAKDOWN
STAC INC l ST PAUL MN l800-334-7699
Mobile Hydraulic Systems
®

Please read this guide carefully before installing and operating your
THERMAFLOW system.
The THERMAFLOW assembly is designed to cool and filter the oil required to
operate your hydraulic system. The oil is cooled by forcing air across cooling fins on
the heat exchanger. This system utilizes a hydraulic fan motor to force air across the
fins.
The Hydraulic fan motor has an adjustable pressure reducing valve that
automatically cycles the fan “ON” when the hydraulic system is running and “OFF”
when not running. This comes plumbed from the factory.
Because different product pump applications require different speed and power
requirements, your THERMAFLOW system was custom engineered for a particular
application. If the system is operated beyond its designed capacity, overheating and/
or component damage may result.
PAGE 1
INSTALLATION GUIDE , OPERATING PROCEDURES & PARTS BREAKDOWN
STAC INC l ST PAUL MN l800-334-7699
Mobile Hydraulic Systems
®

STEP 1 POSITIONING & MOUNTING
The Model SS980 is designed to mount behind the truck cab across the frame rail sides.
A) Diagram A illustrates the mounting of the SS980 series. Allow a minimum of 4” on both
sides of the unit for proper airflow.
STEP 2 INSTALLING THE PTO & HYDRAULIC PUMP
A) Install the PTO to the transmission and mount the hydraulic pump according to
the instructions included with the PTO.
HELPFUL HINT: If you are using a direct mount hydraulic pump/PTO combination,
be sure that the pump splines are well lubrication with a heavy grease. This grease will
prevent premature spline wear on the PTO and pump shafts. Also available from both
MUNCIE and CHELSEA is a new option for a greaseable shaft. This option allows you
to grease these splines without pulling the pump off the PTO.
DIAGRAM A
INSTALLATION GUIDE , OPERATING PROCEDURES & PARTS BREAKDOWN
PAGE 2
STAC INC l ST PAUL MN l800-334-7699
Mobile Hydraulic Systems
®
FRAME RAILFRAME RAIL

STEP 3 HYDRAULIC PLUMBING
DIAGRAMS B, C, & D show proper plumbing for all SS980 models. Please carefully read the
Helpful Hints and Notes listed below before beginning.
HELPFUL HINT: We recommend the use of minimum 2” suction hose. If the suction
hose is too small the hydraulic pump will cavitate and fail prematurely. A 1” pressure hose
is recommended for flows up to 40 gpm. A 1 1/4” pressure hose is recommended for flows
greater than 40 gpm. The 980 Series has two 2” suction port for high flow and tandem
applications.
NOTE: Be careful not to over tighten NPT threads. It is very easy to crack these
types of ports when tightening fittings.
DIAGRAM B
INSTALLATION GUIDE , OPERATING PROCEDURES & PARTS BREAKDOWN
PAGE 3
STAC INC l ST PAUL MN l800-334-7699
Mobile Hydraulic Systems
®
RETURN LINE
PRESSURE LINE
PRESSURE FOR
HYDRAULIC FAN
INLET LINE
PTO
PRESSURE RELIF VALVE
HYDRAULIC PUMP

DIAGRAM C
STEP 3 HYDRAULIC PLUMBING (Continued)
INSTALLATION GUIDE , OPERATING PROCEDURES & PARTS BREAKDOWN
PAGE 4
STAC INC l ST PAUL MN l800-334-7699
Tandem System
w/Dual Relief
Mobile Hydraulic Systems
®
INLET LINE
PRESSURE LINES
TANDEM
HYDRAULIC PUMP
RETURN 1
RETURN 2
PRESSURE 1
PRESSURE 2
PTO
PRESSURE RELIEF VALVE
PRESSURE FOR
HYDRAULIC FAN

DIAGRAM D
STEP 3 HYDRAULIC PLUMBING (Continued)
INSTALLATION GUIDE , OPERATING PROCEDURES & PARTS BREAKDOWN
PAGE 5
STAC INC l ST PAUL MN l800-334-7699
SYSTEM 1
PRESSURE LINE
SYSTEM 2
PRESSURE LINE
RETURN LINE
INLET LINE 1
INLET LINE 2
PTO
SYSTEM 2 PRESSURE LINE
SYSTEM 1 PRESSURE LINE
TANDEM HYDRAULIC PUMP
SS980HFT Plumbing
Mobile Hydraulic Systems
®

STEP 4 Final Assembly
A) Complete all hydraulic plumbing.
B) Make sure suction lines are supported to prevent tank cracking.
C) Fill the reservoir until the oil level gets to the top blue line on the site level gage.
D) Set relief valve for system requirements.
NOTE: After the initial start up procedure you will need to add oil due to the hydraulic
lines filling up to capacity.
NOTE: Over-filling the reservoir will cause the oil to expand up through the breather
assembly when the oil warms up.
NOTE: We recommend using a high grade of hydraulic oil with a Pour Point of -50 F.
This will ensure proper oil flow during extreme cold weather operation. Use of
synthetic hydraulic oils is also recommended. Recommended Oil: AW32MV or
equivalent.
STEP 5 START-UP PROCEDURES
The following steps are to ensure that the THERMAFLOW assembly is operating properly.
NOTE: Before engaging the PTO, make sure that all hydraulic lines are plumbed and
properly tightened.
1) Slowly engage the PTO with engine at idle speed.
NOTE: Watch the oil level in the reservoir. Be ready to add more oil as needed to
maintain the oil level between the level indication lines on the site level gage.
2) Check for hydraulic leaks and repair as needed.
3) Check for fan operation.
4) Carefully Tach the product pump speed.
5) Slowly increase the engine speed until desired product pump speed is obtained.
6) Run system for at least five minutes to ensure that system is sufficiently cooling the
hydraulic oil. Using a Hydraulic Flow Meter Kit, set required pressure and flow rates to system
requirements.
7) Slow engine to idle and disengage the PTO.
8) System is ready for operation.
INSTALLATION GUIDE , OPERATING PROCEDURES & PARTS BREAKDOWN
PAGE 6
STAC INC l ST PAUL MN l800-334-7699
Mobile Hydraulic Systems
®

System Maintenance
Hydraulic
Fluid:
l Drain and replace hydraulic oil every 6 to 12 months depending on use.
l Recommended Fluid: AW32MV or equivalent.
Filter:
l Remove 4 cap screws on top of filter housing.
l Remove filter cartridge and spring.
l Replace with new filter cartridge and spring Part Number 975331.
l Apply anti-seize to cap screws and tighten.
Pump:
l Inspect periodically for leaks.
l Check hoses for signs of wear.
Motor:
l Inspect periodically for leaks.
l Check hoses for signs of wear.
PTO
l Grease output shaft every 6 to 12 months depending on use.
l If PTO does not have a grease zerk on output shaft, remove direct mount
hydraulic pump and grease the output shaft using a high quality gear lube.
INSTALLATION GUIDE , OPERATING PROCEDURES & PARTS BREAKDOWN
PAGE 7
STAC INC l ST PAUL MN l800-334-7699
Mobile Hydraulic Systems
®

Troubleshooting
Safety First!
Think about it before you do it. Our systems use controlled fluid pressure and converts it to rotational
movement. This means that the system pressure operates as high as 5000 psi. A pin hole leak of fluid at this
pressure can be dangerous. Use caution when loosening fittings, system pressure can be maintained for a
period of time after shutdown.
Troubleshooting
Always inspect the things easiest to eliminate first. Look for faulty linkage or wiring that controls the PTO,
pump or motor. Look at the fluid level and appearance of the oil. Check temperatures and pressures.
Excessive Heat:
lClean air passages through heat exchanger.
lCheck fan operation.
lCheck setting of relief valve.
lCheck temperature of suction line vs outlet line temperature. If the outlet temperature is noticeably hotter,
the pump is cavitating.
lCheck for contamination in relief valve. Clean and replace.
lCheck for added flow controls. If a flow control has been added to the system, excess heat can be
generated by the added restriction to flow.
Loss of Motor Speed:
lCheck oil level.
lEnsure recommended engine idle speed is maintained.
lCheck output pressure of the pump. If system pressure cannot be maintained, attempt to adjust the relief
valve setting to max system pressure. If this does not make a noticeable change, make sure to return
relief setting to original position and bring the pump and motor to a hydraulic specialist for bench testing
and possible replacement.
Excessive Noise:
lCheck oil level. Fill to proper level.
lEnsure use of recommended oil type and weight.
lEnsure suction line to pump is at least 1 1/2”.
lEnsure there is no restriction in suction line.
Oil Discoloration:
lEnsure suction line connections are tight.
lEnsure oil is free from water and contaminants. Drain and refill with recommended oil and replace filter.
lEnsure use of recommended oil type and weight.
INSTALLATION GUIDE , OPERATING PROCEDURES & PARTS BREAKDOWN
PAGE 8
STAC INC l ST PAUL MN l800-334-7699
Mobile Hydraulic Systems
®

Specifications
Max Flow Rate: 60 gpm
Max Pressure: 5000 psi
Reservoir: 9.4 gal
Weight: 100 lbs
Suction Line: Two, 2”
Pressure Lines: 1 Inch
Warranty: 2 years
Oil - The recommended oil is
AW32MV or equivalent. AW32MV is
a supreme performance anti-wear
hydraulic oil engineered for wide
temperature range applications. It
exhibits optimum flow characteristics at
sub-zero temperatures and is resistant
to shearing and viscosity loss so that
system efficiency is maintained and
internal pump leakage is minimized
at high operating temperatures and
pressures.
INSTALLATION GUIDE , OPERATING PROCEDURES & PARTS BREAKDOWN
PAGE 9
STAC INC l ST PAUL MN l800-334-7699
Mobile Hydraulic Systems
®

MODEL SS980H
INSTALLATION GUIDE , OPERATING PROCEDURES & PARTS BREAKDOWN
PAGE 10
STAC INC l ST PAUL MN l800-334-7699
9
1
18
29
28
19
2
14
24
15
16
10
7
17
12
6
11
5
27
13
6
5
13
8
3
23
22
2
26
15
25
20
21
4
ITEM NO. PART NUMBER DESCRIPTION Without Bolts/QTY.
1 P575923 980 FILTER HOUSING 1
2975416
20MJIC-20MORB 90° 2
3975730
20MJIC-24MORB 1
4980020
980 HEAT EXCHANGER HOUSING 1
5300200
SHOCK MOUNT 6
6300032
SPACER 6
7980000
980 TANK SS 1
8980650
980 FAN GUARD 1
9600332 BREATHER 1
10 975334 SITE PLUG 1
11 300410M 8MORB PLUG 1
12 980030 980 TRAY 1
13 980071 980 LEG 2
14 6801-08-08 8MORB-8MJIC 90° 1
15 7400-08-14 8MJIC-14MM 2
16 980300 980 HEATEXCHANGER 1
17 300710 1/4 IN NPT PLUG 1
18 934835 ECJ STEEL BODY PR V 1
19 934836 PR CART PR V 1
20 150908 8MORB-8MORB ADJUSTABLE 1
21 6400-08-06 8MJIC-6MORB STRAIGHT 1
22 980891 980 FILTER RETURN HOSE 1
23 980893 980891 HOSE SLEEVE 1
24 980894 980 FAN RETURN HOSE 1
25 980980 980 VALVE DRAIN HOSE 1
26 980040 980 SCREEN 1
27 2700LN-08-08 8MJIC-8MJIC BULKHEAD 1
28 6400-08-08 8MJIC-8MORB STRAIGHT 1
29 980898 980 FAN PRESSURE HOSE 1
Mobile Hydraulic Systems
®

INSTALLATION GUIDE , OPERATING PROCEDURES & PARTS BREAKDOWN
MODEL SS980HFT
PAGE 11
STAC INC l ST PAUL MN l800-334-7699
9
1
3
23
22
2
26
10
7
17
12
11
6
5
13
36
3
30
13
5
6
31
32
37
34
25
4
15
16
215
24
14
8
21
20
18
35
33
19
ITEM NO. PART NUMBER DESCRIPTION Without Bolts/QTY.
1 P575923 980 FILTER HOUSING 1
2975416
20MJIC-20MORB 90° 2
3975730
20MJIC-24MORB 2
4980020
980 HEAT EXCHANGER HOUSING 1
5300200
SHOCK MOUNT 6
6300032
SPACER 6
7980000
980 TANK SS 1
8980650
980 FAN GUARD 1
9600332 BREATHER 1
10 975334 SITE PLUG 1
11 300410M 8MORB PLUG 1
12 980030 980 TRAY 1
13 980071 980 LEG 2
14 6801-08-08 8MORB-8MJIC 90° 1
15 7400-08-14 8MJIC-14MM 2
16 980300 980 HEATEXCHANGER 1
17 300710 1/4 IN NPT PLUG 1
18 934835 ECJ STEEL BODY PR V 1
19 934836 PR CART PR V 1
20 150908 8MORB-8MORB ADJUSTABLE 1
21 6400-08-06 8MJIC-6MORB STRAIGHT 1
22 980891 980 FILTER RETURN HOSE 1
23 980893 980891 HOSE SLEEVE 1
24 980894 980 FAN RETURN HOSE 1
25 980980 980 VALVE DRAIN HOSE 1
26 980040 980 SCREEN 1
30 800422 HFT MANIFOLD 1
31 980425 980 MANIFOLD MOUNT ASSY 1
32 300410 8MORB PLUG 1
33 150912 6MJIC-8MORB STRAIGHT 1
34 6408-04 4MORB PLUG 2
35 980986 980HFT FAN PRESSURE HOSE 1
36 980729 980HFT MANIFOLD TUBE 1
37 6801-6-8 6MJIC-8MORB 90° 1
Mobile Hydraulic Systems
®

Parts List
INSTALLATION GUIDE , OPERATING PROCEDURES & PARTS BREAKDOWN
PAGE 12
STAC INC l ST PAUL MN l800-334-7699
Item No. Part Number Description
1 P575923 980 FILTER HOUSING
2 975416 20MJIC-20MORB 90°
3 975730 20MJIC-24MORB
4 980020 980 HEAT EXCHANGER HOUSING
5 300200 SHOCK MOUNT
6 300032 SPACER
7 980000 980 TANK SS
8 980650 980 FAN GUARD
9 600332 BREATHER
10 975334 SITE PLUG
11 300410M 8MORB PLUG
12 980030 980 TRAY
13 980071 980 LEG
14 6801-08-08 8MORB-8MJIC 90°
15 7400-08-14 8MJIC-14MM
16 980300 980 HEATEXCHANGER
17 300710 1/4 IN NPT PLUG
18 934835 ECJ STEEL BODY PR V
19 934836 PR CART PR V
20 150908 8MORB-8MORB ADJUSTABLE
21 6400-08-06 8MJIC-6MORB STRAIGHT
22 980891 980 FILTER RETURN HOSE
23 980893 980891 HOSE SLEEVE
24 980894 980 FAN RETURN HOSE
25 980980 980 VALVE DRAIN HOSE
26 980040 980 SCREEN
27 2700LN-08-08 8MJIC-8MJIC BULKHEAD
28 150912 6MJIC-8MORB STRAIGHT
29 980891 980 FAN PRESSURE HOSE
Mobile Hydraulic Systems
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INSTALLATION GUIDE , OPERATING PROCEDURES & PARTS BREAKDOWN
PAGE 13
STAC INC l ST PAUL MN l800-334-7699
Parts List
30 800422 HFT MANIFOLD
31 980425 980 MANIFOLD MOUNT ASSY
32 300410 8MORB PLUG
33 150912 6MJIC-8MORB STRAIGHT
34 6408-04 4MORB PLUG
35 980986 980HFT FAN PRESSURE HOSE
36 980729 980HFT MANIFOLD TUBE
37 6801-06-08 6MJIC-8MORB 90°
Mobile Hydraulic Systems
®

INSTALLATION GUIDE , OPERATING PROCEDURES & PARTS BREAKDOWN
PAGE 14
STAC INC l ST PAUL MN l800-334-7699
Parts List
Mobile Hydraulic Systems
®
2
4
1
3
5
ITEM NO. PART NUMBER DESCRIPTION
1 975330ORC 975330 CANISTER O-RING
2 975330OREC 975330 FILTER COVER O-RING
3 975330ORH 975330 FILTER HEAD O-RING
4 975331 980 FILTER ELEMENT
5 975332 0-60 PSI FILTER GAUGE
975330K 980 FILTER ASSEMBLY

Product Offering
Fans
Spal
Multi-Wing
Fittings
Tompkins
Stucci
Ryco
Heat Exchangers
Thermal Transfer
Flat Plate
AKG
Hydraulic Motors
Eaton/Charlynn
Muncie
Permco
Hydro Leduc
PTO’s
Muncie
Pumps
Muncie
Parker
Permco
Hydro Leduc
INSTALLATION GUIDE , OPERATING PROCEDURES & PARTS BREAKDOWN
PAGE 15
STAC INC l ST PAUL MN l800-334-7699
Mobile Hydraulic Systems
®

The THERMAFLOW SS980 Series Hydraulic Cooler is warranted against any
defect in material and workmanship which existed at the time of sale, by STAC Inc.
according to the following provisions, subject to the requirements that the Cooler
must be used only in accordance with the catalogue and package instructions.
The cooler is warranted for a period of TWO Years from the date of installation. If
during the warranty period the cooler fails to operate to STAC’s specifications due
to a defect in any part in material or workmanship that existed at the time of sale by
STAC Inc., the defective part will be repaired or replaced, at STAC Inc.’s discretion,
at no charge, if the defective part is returned to STAC Inc. with transportation
prepaid.
The above warranty shall terminate if any alterations or repairs are made to the
System other than at an authorized dealer or if the cooler is used on any equipment
other than the equipment upon which it is first installed.
THE FORGOING WARRANTIES ARE IN LIEU OF ALL OTHER OBLIGATIONS
AND LIABILITIES, INCLUDING NEGLIGENCE AND ALL WARRANTIES OF
MERCHANTABILITY AND SUITABILITY, EXPRESSED OR IMPLIED AND STATE
STAC INC.’S ENTIRE AND EXCLUSIVE LIABILITY AND BUYER’S EXCLUSIVE
REMEDY FOR ANY CLAIM OF DAMAGES IN CONNECTION WITH THE SALE,
REPAIR OR REPLACEMENT OF THE ABOVE GOODS, THEIR DESIGN,
INSTALLATION OR OPERATION. STAC INC. WILL IN NO EVENT BE LIABLE
FOR ANY DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL
DAMAGES WHATSOEVER, AND OUR LIABILITY UNDER NO CIRCUMSTANCES
WILL EXCEED THE CONTRACT PRICE FOR THE GOODS FOR WHICH
LIABILITY IS CLAIMED.
60 West Sycamore Street • St. Paul, MN 55117
800-334-7699 • 763-235-7822 Fax
Web: www.thermaflow.com
Inc.
THERMAFLOW WARRANTY
Thermaflow is a registered trademark of STAC, Inc. All Rights Reserved. Form 980901 Rev: 10/19
Mobile Hydraulic Systems
®