Gardner Denver MH3 HYDRAPAK Operation, Maintenance And Installation Manual

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Page 1

OPERATION, MAINTENANCE

and INSTALLATION

MANUAL

40 G.P.M. 3500 P.S.I.

MH3 HYDRAPAK

February 3, 2015

999042002 VERSION: 03

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SAFETY Do not work under the vehicle when the engine is running. Do not work on hydraulic system when the engine is running. Do not go near leaks when engine is running.

• high pressure oil easily punctures skin causing serious injury, gangrene or death.

•

• if injured, seek emergency medical help.

• Immediate surgery is required to remove oil.

• do not use finger or skin to check for leaks.

• lower load or relieve hydraulic pressure before

loosening fittings.

A serious or fatal injury can occur . . .

• if you lack proper training.

• if you fail to follow proper procedures.

• if you do not use proper tools and safety equipment.

• if you assemble components improperly.

• if you use incompatible components.

• if you use worn-out or damaged

components. Read, understand and follow this manual.

• Get proper training.

• Learn and follow safe operating procedures.

• Use proper tools and safety equipment.

• Use proper components in good condition.

INITIAL HYD. SYS. START UP : (2 people

1. Hydraulic oil: Non-foaming. We recommend Shell Tellus “T” series ISO 32 or equivalent.

2. Fill the Hydrapak with the above listed hydraulic oil. Use a paint filter as a strainer while filling.

3. After Hydrapak is filled, check for hydraulic system leaks.

4. Slowly raise the clutch while the engine is running to engage the P.T.O. and pump. Stop when level drops in the Hydrapak tank to just below the dip stick.

5. Disengage the P.T.O. (press clutch all the way in) Re-fill Hydrapak and repeat step 4 until oil level in tank does not drop while the P.T.O. is engaged.

PRECAUTIONS:

required)

MAINTENANCE:

1. Change hydraulic oil filter every 6 months*

2. Change hydraulic oil every 6 months*

3. Check oil level each week. Check with system off. (should be between the marks on the dip stick)

4. Visually check the system each week - all fittings, hoses and Hydrapak mounting.

5. Grease PTO / Pump spline every 3 months ( grease every month for high duty cycle applications)

* An oil analysis program is

recommended.

NORMAL

OPERATION:

VISUAL CHECKS BEFORE STARTING SYSTEM:

1. Check that the oil level is between the marks on the dipstick.

2. Remove any obstructions from radiator and fan.

STARTING SYSTEM:

1. Ensure brake is applied.

2. Ensure control valves are in neutral position.

3. Engage PTO per manufacturers instructions.

4. Oil level may drop if air is trapped in

system. Stop the system and top off tank if necessary.

5. Operate the valving slowly

6. To stop the system, follow steps in reverse.

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POWER TAKE OFF & HYDRAULIC

1. Mount power take off,and brace hydraulic pump per manufacturers instructions.

2. Ensure that the female spline of power take off is filled with grease.

PUMP:

3. Mount hydraulic pump to P.T.O. using only capscrews provided. Note : To avoid premature spline wear of the pump and PTO from

manufacturer

for the correct engine speed (based on

application)

torsional vibration consult

that will reduce

torsional vibration.

the

engine

SUCTION LINE INSTALLATION GUIDELINES:

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, is the weight and length of pipe work (fittings) is excessive? If so, 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.

MOUNTING

HYDRAPAK: Behind the cab is the preferred mounting method. Frame rail mount is the secondary choice.

1. Drill 7/16” dia. holes as shown in Fig.1. Use the capscrews, washers and nuts supplied to mount the Hydrapak.

2. Be sure to allow 4” of space between radiator and any solid obstruction that will effect air flow into radiator.

3. Radiator must be shielded from rocks and road debris. HYDRAULIC HOSES &

1. Do not use thread tape or pipe dope as this will contaminate the hydraulic system.

2. All hoses are customer supplied. Fit all hoses as per separate system drawings provided by Drum.

3. All high pressure hoses must have a working pressure rating equal to or higher than the hydraulic system relief valve

setting.

4. The suction hose must be suitable for 28”Hg vacuum service.

5. 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 reservoir stress fractures and shortened hose life.

6. 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.

7. 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.

FITTINGS:

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4”

16.0”

5.50”

BEHIND THE MOUNT

CAB

Suction hose sizing

0 to 19 gpm hyd. flow use 1-1/4”

20 to 25 gpm hyd. flow use 1-1/2”

26 to 40 gpm hyd. flow use 2”

chart

IDEAL SUCTION

behind cab on fabricated

mounting bracket

suction hose

CONDITION

EXAMPLE

Refer to specific system schematic for details on

your system

ONL

open space required

Fig. 1

Low pressure return from hydraulic

FRAME RAIL MOUNT

Note: for severe duty off applications Hydrapak rail. Use # 507044228 bracket mount Hydrapak to Consult factory for

directly

hydraulic motor and valving

do not

High pressure to

motor and valving

Note: 4” of space (shown above)

Radiator must be shielded from

road

mount

to the

frame

frame.

assistance.

must be maintained between

radiator and any obstructions.

rocks and road debris.

suction hose see High pressure from hydraulic pump to Hydrapak

Power take off & hydraulic pump

EXAMPLE Refer to specific system schematic for details on your system

ONLY.

chart

hydraulic motor and valving

High pressure to

Low pressure return from hydraulic

Note: See

specific

motor and valving

system

circuit

drawing for complete

hydraulic plumbing information

Power take off & hydraulic pump

suction hose see

High pressure from hydraulic pump to Hydrapak

chart

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TRAILER MOUNTED HYDRAPAK

SUCTION HOSE SIZING 0 to 15 gpm hyd. flow use 1-1/4” 15 to 23 gpm hyd. flow use 1-1/2” 23 to 40 gpm hyd. flow use 2” This hose sizing chart is based on of 15 feet. For The bottom of the Hydrapak The maximum pumps.Consult

To hydraulic pump inlet

routing

of the

Detail 3 is the best possible mounting configuration. The mounting of the Hydrapak as shown will help to improve the suction conditions. This type of Hydrapak mounting will provide good system performance provided that there are no rises in the suction line above the Hydrapak reservior. Note: pressure drop calculations must be performed on the specific system and corresponding tractor unit to insure acceptable suction conditions. Consult factory for

CHART:

suction

recommended

lines that have an over-all length that is more than 15 feet Consult the factory for

suction

reservior

the factory for

Detail 1 is the worst possible suction condition. This mounting may cause severe hydraulic pump cavitation which will reduce the hydraulic pump life. The hydraulic system as shown in this mounting configuration will operate very poorly or not at all.

DETAIL1

Detail 2 is a possible choice for hydraulic mounting. The straight line run on the suction line is acceptable. Caution must be taken with the routing of the suction line to insure that there are no rises in the suction line that are above the Hydrapak oil reservior. Note: pressure drop calculations must be performed on the specific system and corresponding tractor unit to insure acceptable suction c Consult factory for

DETAIL 2

DETAIL 3

application assistance.

suction

line must be done to avoid excessive pressure drop. Elbows

vacuum at the

assistance

line on trailer and

suction

will cause excessive pressure drop in the

line on trailer and

mounting

the Hydrapak as shown in

hydraulic

application assistance.

tractor.

“detail

pump inlet is 5” Hg for gear pumps and 2”Hg for

3”and having an over-all

suction line.

onditions.

,reducers,and

suction assistance.

line rises above

piston

line

length

the

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ITEM DESCRIPTION PART NO. QTY.

1 MAINFRAME

50008021

8 1 2” NPTF

SUCTION

HYDRAULIC

FAN

MOTOR

300001228

1 3 GROMMET

521070206

1 4 HOSE

ASSY.

FAN

MANIFOLD

407021216

NOT

SHOWN

HYD.

RADIATOR

308011209

1 6 RADIATOR

BLANKING

PLATE

540063209

1 7 RADIATOR

BY-

PASS

CHECK

304059203

1 8 HYD.RELIEF

VALVE

303000208

2500

PSI 8 HYD.RELIEF

VALVE

303000210

3000

PSI 9 HYDRAULIC

PLUG

SOCKET

HEAD

302123206

2 # 4

ORBM

HYDRAULIC

PLUG

SOCKET

HEAD

302123200

1 # 8

ORBM

11 HYDRAULI

C MANIFOLD

311003202

1 12 # 10-32

GR.5

PLATED

NUT

236103000

1 13 MANIFOLD

CHECK

VALVE

DISC

532111202

NOT

SHOWN

14 MANIFOLD

CHECK

VALVE

SPRING

517000204

1 NOT SHOWN

15 MANIFOLD

CHECK

VALVE

WASHER

532112200

1 NOT SHOWN

16 MANIFOLD

CHECK

VALV

GUIDE

BOLT

212103040

1 NOT SHOWN

17 FAN

50602220

6 1

RETAININ

G RING FOR FAN

244010200

2 19

FAN

MOTOR

FLOW

CONTROL

304060209

1 20

HYDRAULI

C FITTING

302065207

1 # 16

ORBM

X # 16

JICM

HYDRAULIC

TEE FITTING

302005200

1 # 12 JICM

X # 12

ORBM

X # 12

JICM

22 FILLER

BREATHER

CAP

30900120

2 1

23 FAN

GRILL

GUARD

521022201

1 24 MAGNETIC

DRAIN

PLUG

258208208

1 # 8

NPTM

HYDRAULIC

FILTER

306000206

SPIN

STYLE

CAP

SCREW

75A10Z

5/16-18 X 1 GR5

PLATED

NYLOCK

NUT

236105400

5/16-18 PLATED

LOCK

WASHER

405757

5/16 GR 5 S.S. 29 LOCK

WSHER

240004400

1/4 GR 5 PLATED

FLAT

WAHER

240404000

1/4 GR 5 PLATED

NYLOCK

NUT

299123200

1/4-20 GR 5 PLATED

32 HYDRULI

C ELBO

W FITTING

302095219

1 # 6

ORBM

X # 4

JICM

33 HOSE

CLAMP

WORM

TYPE

299070211

2 NOT SHOWN

HOSE

CLAMP

SLOTLESS

WORM

299070207

NOT

SHOWN

HOSE

CLAMP

CONSTANT

TENSION

29907021

6 2 NOT

SHOWN

HYDRAULIC

ELBOW

FITTING

302183203

1 # 16 HOSE

BARB

X # 20

ORBM

HYDRAULIC

FITTING

302170205

1 # 8

HOSE

BARB

X # 6

NPTM

38 HYDRAULI

C HOSE

310010208

1/2” FAN MTR

. RETUR

N NOT

SHOWN

39 HYDRAULI

C HOSE

310030211

1 1” MANIFOL

D TO

RADIATO

R NOT

SHOWN

HYDRAULIC

HOSE

310030212

1 1” RADIATOR

TO TANK

NOTSHOWN

HYDRAULIC

ELBOW

FITTING

302183202

1 # 8

HOSE

BARB

X # 6

ORBM

HYDRAULIC

ELBOW

FITTING

302180204

1 # 12 HOSE

BARB

X # 12

MPTM

SPEE

D NUTS

299120204

1/4-20 44 CAP

SCREW

214004216

1/4-20 X 1 S.S. HEX

HEAD

CAP

SCREW

214304

212 7 1/4-20 X 3/4

S.S. BTN HEAD

CAP

SCREW

212303216

6 # 10-32 X 1

S.S. BTN

HEAD

HYDRAULIC

HOSE

310030217

RADIATOR

CHECK

TANK

NOT

SHOWN

CAP SCREW

405766

5/16-1/8 X 7/8 S.S.

SIGHT GLASS

307058205

NOT

SHOWN

RIVET

299061200

NOT SHOWN

FOAM RUBBER

015001200

NOT SHOWN

PARTS LIST

MAINFRAME

500080217

1-1/2 CODE 61 SUCTION

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Hydrapak Optional Equipment

409030201 HYD TEST POINT PLUG ASSY 5000psiw/ADP 703000210 KIT PRESSURE CAP OPTION MH SERIES

717000200 HEATER KIT HYDRAPAK TANK 12 vdc MOBILE 717001200 HEATER KIT HYDRAPAK TANK 12 vac STATIC 309072200 HYD FLLR CAP THREADED (NON-VENTED) 303011200 HYD RELIEF VALVE 65 PSI 1” NPTF 309001203 HYD FILLER/BREATHER CAP LOCKIN

MH3 HYDRAPAK

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47 (6)

31 (4) 45 (7)

26 (8)

27 (4)

43 (3)

29 (3)

45 (7)

41 37

29 (2)

44 (2)

28 (8)

26 REF

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WARRANTY

WARRANTY: The Seller warrants the goods sold hereunder against defects in workmanship or materials under normal and proper installation for a period of twelve (12) months from the date of delivery. BUYER’S SOLE AND EXCLUSIVE REMEDY UNDER THIS WARRANTY IS FOR THE REPAIR OR REPLACEMENT AT SELLER’S OPTION, WITHOUT CHARGE TO BUYER EXCEPT FOR SHIPPING EXPENSES, AT THE OFFICE OF THE SELLER IN LOUISVILLE, KENTUCKY, OF ANY PART WHICH HAS PROVEN TO BE DEFECTIVE AT THE TIME IT WAS DELIVERED. ANY GOODS UNDER WARRANTY MUST BE RETURNED TO THE SELLER’S OFFICE FOR INSPECTION BY THE SELLER AND, IF ANY SUCH GOODS ARE FOUND TO BE DEFECTIVE, FOR REPAIR OR REPLACEMENT. ALL FREIGHT AND EXPENSES OF SHIPMENT TO AND FROM THE SELLER’S OFFICE SHALL BE BORNE BY THE BUYER. THE SELLER IS NOT RESPONSIBLE FOR ANY EXPENSES OF ANY NATURE INCURRED FOR ANY REPAIRS TO ALTERATIONS MADE BY OTHERS TO THE GOODS OR ANY OTHER EQUIPMENT WITHOUT THE PREVIOUS WRITTEN CONSENT OF THE SELLER. SHOULD THE GOODS BE PARTIALLY OR FULLY INSTALLED, ALTERED, STRIPPED, REPAIRED, SERVICED, OR MAINTAINED BY ANY PERSON OTHER THAN AUTHORIZED AGENTS AND EMPLOYEES OF THE SELLER, WITHOUT THE PREVIOUS CONSENT OF THE SELLER, OR MISUSED IN ANY WAY, THIS WARRANTY SHALL BE VOID. THIS WARRANTY CONSTITUTES THE ONLY WARRANTY BY THE SELLER OF THE GOODS AND IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, WARRANTIES OF MERCHANTABILITY OR WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT SHALL SELLER BE LIABLE FOR BUYER’S ATTORNEY’S FEES.

NO CONSEQUENTIAL DAMAGES: UNDER NO CIRCUMSTANCES SHALL THE SELLER BE LIABLE FOR (A) ANY DAMAGE, INJURY, BREAKAGE OR LOSS OF ANY KIND WHATSOEVER, (B) ANY LOSS OF INCOME, OR (C) ANY CONSEQUENTIAL LOSS.

NO TORT LIABILITY: SELLER DISCLAIMS ANY LIABILITY FOR CLAIMS BASED ON SELLER’S NEGLIGENCE OR STRICT LIABILITY IN TORT. PARTS: This Warranty and all disclaimers and limitations of liability shall apply to all parts sold to Buyer. TRAINING AND SUPERVISION: The buyer hereby assumes the affirmative duty to properly educate, instruct and supervise its employees and all others,

except employees of the Seller, in the safe, proper use and operation of the goods. The Buyer agrees to indemnify the Seller for any damages paid by the latter as a result of the Buyer’s failure to perform this affirmative duty.

The goods are not designed or intended for use with every substance. If the material which the Buyer contemplates transferring with the goods has corrosive or polymerizing or other properties which may result in unsatisfactory or dangerous operations, the Seller has no liability or responsibility for performance of the goods.

RETURN OF GOODS: No goods supplied may be returned to the Seller for credit without the Seller’s prior written authorization before transportation thereof commences and in such cases transportation must be prepaid and the Buyer’s name, address, original order number and the Seller’s invoice number must be clearly marked on the shipping tag.

If any goods are returned to the Seller for repair or under warranty and no instructions are received within two months after Seller receives the goods for repair or sends notice to Buyer of the disallowance of a warranty claim, the Seller reserves the right to scrap the goods returned, and no subsequent claim for any costs or losses will be accepted.

APPLICABLE LAW AND VENUE: The rights and obligations of the parties hereunder shall be governed in all respects, including all questions of construction and performance of this order, by the laws of Kentucky. All disputes concerning this order shall be resolved in an appropriate state or federal court located in Louisville, Kentucky.

MODIFICATION OR RESCISSION: This warranty can only be modified or rescinded by a written agreement signed by an officer of both the Buyer and the Seller.

For additional information, contact your local representative or visit: www.contactgd.com/compressors

Part #

999042002

Revision 03

February 3, 2015