PARTS LIST
OPERATING AND
HYD
-7-
600
MH
-
C2
SERVICE MANUAL
HYDRAPAK
MOBILE
HYDRAULIC COOLING
SYSTEM
30 G.P.M. – 3500 PSI
(5000 PSI optional)
Version: 01
September 17, 2014
TABLE OF CONTENTS
Introduction Your Key To Trouble Free Service ........................................................................................ 3
Maintain Hydrapak Reliability And Performance ....................................................................................... 4
Instructions For Ordering Repair Parts ..................................................................................................... 4
Foreword ................................................................................................................................................. 5
Safety Instructions ................................................................................................................................... 6
Section 1, Equipment Check .................................................................................................................... 7
Section 2, Installation............................................................................................................................... 8
Section 3, Initial Startup Procedure ........................................................................................................ 12
Section 4, Maintenance ......................................................................................................................... 13
Section 5, Parts List ............................................................................................................................... 14
Warranty ............................................................................................................................................... 16
HYD-7-600 Page 1
INDEX
Equipment Check, Section 1 ............................ 7
Hydraulic Hoses & Fittings ............................... 8
Initial Startup Procedure, Section 3 .................12
Installation, Section 2....................................... 8
Introduction Your Key To Trouble Free Service 3
Maintenance, Section 4 ..................................13
LIST OF ILLUSTRATION
Figure 2-1 – Air Flow Direction And Outline .................................................................................................... 10
Figure 2-2 – Air Flow Direction And Outline .................................................................................................... 11
Mounting .......................................................... 8
Parts List Section 5 ........................................ 14
Safety Instructions ........................................... 6
Storage ............................................................ 7
Warranty ........................................................ 16
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
Gardner Denver® service… year in and year out.
IMPORTANT GARDNER DENVER® TELEPHONE NUMBERS
YOUR AUTHORIZED GARDNER DENVER DISTRIBUTION
NAME: ____________________________
TELEPHONE: ____________________________
FAX: ____________________________
CONTACT: ____________________________
THANKS…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 Hydrapak 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/mobile
or
call: (217)222-5400
HYD-7-600 Page 4
FOREWORD
Gardner Denverâ Hydrapak are the product of advanced engineering and skilled manufacturing. To 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.
· High pressure oil easily punctures skin causing serious injury, infection or death.
· If injured, seek emergency medical help immediately.
· Immediate surgery is required to remove oil.
· Do not use finger or skin to check for leaks.
· Lower load and/or relieve hydraulic pressure before loosening fittings.
· Do not operate unit without all body panels and guards in place. Never bypass safety
devices.
Failure to observe these notices could result in damage to equipment.
· Stop the PTO and engine if nay repairs or adjustments on or around the Hydrapak are
required.
· 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
EQUIPMENT CHECK
Before uncrating, check the packing slip carefully to be sure all the parts have 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 a clean, 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 ½” bolt 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 & FITTINGS
All high pressure hoses & fittings must have a working pressure rating equal to or higher thank
the hydraulic system relief valve setting.
· 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 & ROUTING
· 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” 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
3. 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.
4. 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.
5. 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
HYD-7-600 Page 10
FIGURE 2-1 – AIR FLOW DIRECTION AND OUTLINE
HYD-7-600 Page 11
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 Hydrapak lid to access in-tank filter. Remove cap and filter element.
2. Fill reservoir with Shell Tellus “T” series 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.
5. Disengage P.T.O. (press clutch all the way in). Repeat steps 1-4 until oil level does not drop
while the P.T.O is engaged.
6. Check entire hydraulic system for leaks.
NOTICE
· 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 ½ of sight glass.
3. Visually check the system each week – all fittings, hoses, and Hydrapak mounting.
4. Grease P.T.O. / Pump spline every 3 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 – MH-C2
See page 15 for Parts List.
HYD-7-600 Page 14
Order by Part Number and Description. Reference Numbers are for your convenience only.
Ref.
No.
Description
1 RESERVOIR ............................................................................................................ 1 CC1118064 CC1118064 CC1118064
2 SCREW .................................................................................................................... 2 BB1126663 BB1126663 BB1126663
3 RECPTACLE, 1/ 4 TURN ........................................................................................ 4 BB1126665 BB1126665 BB1126665
4
STUD,
5
SPRING ............................................................................................
6
RETAINER, 1/ 4 TURN ....................................................................................
7
NI
8
COUPLING ........................................................................................
9
GAUGE-OIL
10
FAN GUARD ..............................................................................................
11
HOSE ................................................................................................
12
FAN MOTOR ..............................................................................................
13
CONTROL BLO
14
CHECK VALVE,
15
PLATE, TOP HEAT EXCHANGE
16
OIL COOLE
17
EDGE TRIM ......................................................................................
18 LI
*19
FILTER, IN-TAN
20 GROMMET ........................................................................................
21
FITTING, HYD ELBOW .....................................................................................
22
FITTING, HYD HOSE BARB ELBOW .........................................................
23
FITTING, HYD ELBOW .....................................................................................
24
RELIEF VALVE...................................................................
25
FITTING, HYD ADAPTER .......................................................
26
FITTING, HYD TEE...............................................................
27 FA
28
FITTING, HYD PLU
29
FITTING, HYD PLU
30
FITTING, HYD PLU
31
FLOW CONTRO
32
FITTING, HYD ADAPTER .......................................................
33 GROMMET ........................................................................................
34
FITTING, HYD HOSE BARB ELBOW .........................................................
35
FITTING, HYD HOSE BARB ELBOW .........................................................
36
HOSE ................................................................................................
37
HOSE ................................................................................................
38
HOSE ASSEMBLY ....................................................................
39
FITTING, HYD HOSE BARB .......................................................
40
STRIP, FOAM ..................................................................................................... 6.00
41
FITTING, HYD ADAPTER .......................................................
42
FITTING, HYD ADAPTER .......................................................
43
SIDE PANE
44
WASHER, RUBBER ISOLATOR ...........................................
45
FITTING, PLUG ......................................................................
46
SCREW ...................................................................................
47
NUT .........................................................................................
48
FRAME ASSEMBLY ...............................................................
49
HOSE CLAMP ........................................................................
50
HOSE CLAMP ........................................................................
51
FITTING PLUG .......................................................................
52
SCREW ...................................................................................
53
RETAINING RING ..................................................................
54
SCREW ...................................................................................
1/ 4 TURN ................................................................................................
PPL
E...............................................................................
LEVEL
R .......................................................................
D ...............................................................................................................
N ..........................................................................................................................
L ............................................................................
SIGHT
CK ............................................................................
BYPASS .....................................................
K..............................................................................
G.........................................................................
G.........................................................................
G.........................................................................
L .......................................................................
GLASS ...........................................
R ..........................................
MODEL
704010100
704010102
Qty.
6.80
24 75LM47S 75LM47S 75LM47S
704010103
MH-C2
4
BB
4
4
1
1
1
1
1
1
1
1
1
1
ft VP1118156 VP1118156 VP1118156
1
1
1
1 302095219 302095219 302095219
1 302183205 302183205 302183205
1 302099201 302099201 302099201
1 303000008 303000008 BB1132940
1 302065207 302065207 302065207
1 302005200 302005200 302005200
1 VP1118078 VP1118078 VP1118078
1 302123205 302123205 302123205
1 302123204 302123204 302123204
1 302123203 302123203 302123203
1 VP11180891 VP11180891 VP11180891
1 302065234 302065234 302065234
2 VP118153 VP118153 VP118153
1 302183200 302183200 302183200
1 302183206 302183206 302183206
1 310030223 310030223 310030223
1 310030224 310030224 310030224
1 407021218 407021219 407021219
1 302170206 302170206 302170206
ft VP1118157 VP1118157 VP1118157
1 305061200 305061200 305061200
1 302065235 302065235 302065235
2 BB1119224 BB1119224 BB1119224
4 VP1118151 VP1118151 VP1118151
1 64AC5 64AC5 64AC5
4 75A10Z 75A10Z 75A10Z
6 236105400 236105400 236105400
1 CC1118050 CC1118050 CC1118050
2 299070218 299070218 299070218
4 299070207 299070207 299070207
1 VP1118083 VP1118083 VP1118083
2 244010200 244010200 244010200
4 75LM48S 75LM48S 75LM48S
1128040 BB
BB
1126667 BB
BB
1126666 BB
63G7
S
64BK5S
40P11
VP1118159 VP1118159 VP1118159
310030226 310030226
300001228 300001228
VP1118079 BB1121067 BB1121067
304059203 304059203
CC
1118158 CC
VP1118076 VP1118076 VP1118076
VP1119238 VP1119238 VP1119238
VP1118077 VP1118077 VP1118077
VP1118154 VP1118154 VP1118154
MODEL
704010104
704010105
MH-C2
1128040 BB
1126667 BB
1126666 BB
63G7
S
64BK5S
40P11
1118158 CC
MODEL
704010100
MH-C2
1128040
1126667
1126666
63G7
S
64BK5S
40P11
310030226
300001228
304059203
1118158
* FILTER ELEMENT FOR ITEM 19 – VP1119226
HYD-7-600 Page 15
WARRANTY
COPYRIGHT© 2005 Gardner Denver, Inc.
HYDRAPAK COOLING SYSTEM
GENERAL PROVISIONS AND LIMITATIONS
Gardner Denver®, Inc. (the “Company”) warrants to each original retail purchaser (“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. Any product which has been repaired or altered in such a way, in the Company’s judgment, as to affect the product adversely.
2. Any product which has, in the Company’s 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 Company’s obligation under this warranty is limited to repairing or, 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 “unopened”
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’s judgment is proved not to be as warranted. Labor shall be limited to the amount specified in the
Company’s 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 Company’s choice, within the continental United States, is covered by this warranty for replacement of any blower which
in the Company’s 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, to and from the nearest Authorized Distributor and the Company’s 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, IM PLIED OR STATUTORY, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR IMPLIED WARRANTY OF FITNESS FOR A PART ICULAR PURPOSE.
THE REMEDY PROVIDED UNDER THIS WARRANTY SHALL BE THE SOLE, EXCLUSIVE AND ONLY REM EDY AVAILABLE T O 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 warranty shall not be effective as to any claim which is not presented within 30 days after the date upon which the product is
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.
claimed
COPYRIGHT© 2012 Gardner Denver, Inc
.
For additional information, contact your local representative or visit:
www.contactgd.com/blowers
©2014 Gardner Denver, Inc. Printed in U.S.A.
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