934-Resource-Manual-1-up-Revised-10.15

Transcription

Installation Guide
Resource Manual

Operating Procedures

Parts Breakdown
MODEL 934
MOBILE HYDRAULIC COOLING SYSTEMS
MODELS AVAILABLE IN BOTH VERSIONS
SS/BK934ER
SS/BK934EV
SS/BK934HR
SS/BK934HV
SS/BK934E
Model #:
Serial #:
Electric Fan with Relief Valve
Electric Fan with Control Valve
Hydraulic Fan with Relief Valve
Hydraulic Fan with Control Valve
Electric Fan with No Valve
Installation Date:
STAC INC
 ST PAUL MN

800-334-7699
INSTALLATION GUIDE , OPERATING PROCEDURES & PARTS BREAKDOWN
MODEL 934
INDEX
S
TEP
DESCRIPTION
PAGE
Introduction
1
1
Positioning & Mounting
2
2
Installing the PTO & Hyd Pump
2
3
Electrical Wiring
3-4
4
Hydraulic Plumbing
5-6
5
Final Assembly
7
6
Start-Up Procedures
8
System Maintenance
9
Troubleshooting
10
Specifications
11
SS/BK934ER Parts Breakdown
12
SS/BK934EV Parts Breakdown
13
SS/BK934HR Parts Breakdown
14
SS/BK934HV Parts Breakdown
15
SS/BK934E Parts Breakdown
16
Parts List
17
Product Offering
18
Notes
19
Warranty Policy
STAC INC
 ST PAUL MN

800-334-7699
Please read this guide carefully before installing and operating your MODEL 934
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 either an electric or hydraulic fan motor to force air
across the fins. The fan motor options and control valve options are described below.
The Model 934 has 2 fan motor options, Electric or Hydraulic. The Electric fan motor
option has a 12VDC cooling fan which is operated with a temperature control switch.
This switch gets wired into keyed power. When the key is turned on, the switch will be
ready to activate the fan when the oil temperature gets to 110°F. When the oil
temperature falls to 105°F the fan will turn off.
The Hydraulic fan motor option has a fixed pressure compensated flow control that
automatically cycles the fan “ON” when the hydraulic system is running and “OFF”
when not running. This option comes plumbed from the factory.
Models 934(E)(H)R comes with a standard relief valve system. While Models 934(E)
(H)V have the optional control valve system installed. This control valve system will
allow the operator to start, stop, and change rotation of the product pump by simply
shifting the control valve. This control valve is integrally mounted and plumbed within
the cabinet to save frame rail space, lower installation times, and to reduce hose and
fitting costs.
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.
STAC INC
 ST PAUL MN
PAGE 1

800-334-7699
STEP 1 POSITIONING & MOUNTING
The Model 934 is designed to mount on the frame rail, either on the driver or passenger sides.
A) Follow Diagram A for proper mounting and shock mount assembly.
NOTE: You will need a minimum of 6 1/2" clearance to remove the filter when mounting
under the bunk.
ALL MOUNTING
ARE SUPPLIED
NOTE: FASTENERS
IN THE MOUNTING KIT.
1/2-13 GRADE 8 NYLOC NUT
(QTY:4)
PART #: 600550
1/2-13 GRADE 8 BOLT
(QTY:4)
RUBBER SHOCK MOUNT
(300200 QTY:4)
MINIMUM HEIGHT
REQUIREDBETWEEN
TOP OF FILTER AND
BUNK TO REMOVE
THE FILTER ELEMENT
IS 6-1/2 INCHES
1/2 GRADE 8 WASHER
(QTY:8)
FRAME RAIL
TOP VIEW
SPACER
(934032 QTY:4)
DIAGRAM A
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.
STAC INC
 ST PAUL MN
PAGE 2

800-334-7699
STEP 3 ELECTRICAL WIRING (Models with Electric Fan)
Models having a 12 VDC fan motor can be wired two different ways. Listed below are these
options.
OPTION #1 - FAN SWITCH WIRED HOT
This option wires the temp switch so that when the key is turned on it has power going
to it.
ELECTRICAL CONNECTIONS
10 Gauge RED WIRE: Connect to the positive (+) 12VDC battery terminal (20
Amps) through circuit breaker (150153) provided in electrical kit (934525TC).
10 Gauge BLACK WIRE: Connect to the truck frame or to the negative (-) battery
terminal.
18 Gauge RED WIRE: Connect to a keyed power source.
For further illustration follow DIAGRAM B on Page 4.
NOTE: We recommend that the power supply be taken directly from a battery post or similar high current location.
OPTION #2 - TEMP SWITCH WIRED THROUGH AN AIR SWITCH
This option wires the temp switch so that you will only be able to run the fan when the
PTO is engaged. PTO disengaged fan “OFF”, PTO engaged fan “ON” via an air switch.
ELECTRICAL CONNECTIONS
10 Gauge RED WIRE: Connect to the positive (+) 12VDC battery terminal (20
Amps) through circuit breaker (150153) provided in electrical kit (934525TC).
10 Gauge BLACK WIRE: Connect to truck frame or to negative (-) battery
terminal.
18 Gauge RED WIRE: Connect to air switch and to positive (+) 12VDC battery
terminal with recommended 5 amp fuse.
For further illustration follow DIAGRAM C on Page 4.
NOTE: We recommend that the power supply be taken directly from a battery
post or similar high current location.
STAC INC
 ST PAUL MN
PAGE 3

800-334-7699
STEP 3 ELECTRICAL WIRING (CONTINUED)
Diagram B & C below illustrates proper electrical wiring for Models 934ER, 934EV, & 934E.
BATTERY
CIRCUIT BREAKER
10 GAUGE RED WIRE
18 GAUGE RED WIRE
10 GAUGE BLACK WIRE
FRAME GROUND
KEYED POWER
DIAGRAM B
Above electrical schematic illustrates the proper wiring diagram for Option 1.
TO PTO
AIR LINES
TO PTO SWITCH
AIR SWITCH
18 GAUGE RED WIRE
5 AMP FUSE
(RECOMENDED)
10 GAUGE BLACK WIRE
10 GAUGE RED WIRE
CIRCUIT BREAKER
FRAME GROUND
BATTERY
DIAGRAM C
Above electrical schematic illustrates the proper wiring diagram for Option 2.
STAC INC
 ST PAUL MN
PAGE 4

800-334-7699
STEP 4 HYDRAULIC PLUMBING
DIAGRAMS D & E show proper plumbing for Models 934ER, 934EV, 934HR & 934HV. Please carefully read the Helpful Hints and Notes listed below before beginning.
HELPFUL HINT: We recommend the use of 1 1/2” suction hose for all applications,
especially if the THERMAFLOW Assembly will be operated in cold weather. If the suction hose is too small the hydraulic pump will cavitate and fail prematurely. 3/4” pressure hose recommended for flows up to 25 gpm. 1” pressure hose recommended for flows greater
than 25 gpm.
NOTE: Be careful not to over tighten NPT threads. It is very easy to crack these
types of ports when tightening fittings.
PRESSURE LINE FROM PUMP
MAY BE CONNECTED TO
EITHER FITTING
PRESSURE
INLET LINE
PRESSURE LINE
HYDRAULIC PUMP
PTO
RETURN FROM SYSTEM
PRESSURE TO SYSTEM
DIAGRAM D
Hydraulic plumbing diagram for THERMAFLOW MODEL 934ER & 934HR
STAC INC
 ST PAUL MN
PAGE 5

800-334-7699
STEP 4
HYDRAULIC PLUMBING (Continued)
PRESSURE OUT/RETURN IN
PRESSURE IN
INLET LINE
PRESSURE LINE
HYDRAULIC PUMP
DIAGRAM E
Hydraulic plumbing diagram for THERMAFLOW MODEL 934EV & 934HV
STAC INC
 ST PAUL MN
PAGE 6

800-334-7699
PTO
STEP 5 Final Assembly
A) Complete all hydraulic plumbing.
B) Fill the reservoir until the oil level gets to the top black line on the site level gage.
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: MOBIL DTE10-32 or equivalent.
1
5
3
ITEM
NO.
PART NUMBER
DESCRIPTION
1
300330ORC
COVER O-RING
2
300330OREC
CANISTER O-RING
3
300330ORE
ELEMENT O-RING
4
300330ORH
FILTER HEAD O-RING
5
300331
300330 ELEMENT
300330
FILTER ASSEMBLY
WHEN ORDERING A NEW ELEMENT, PART
NUMBER 300331 IT INCLUDES A NEW SPRING
AND ONE 300330ORE
2
DIAGRAM F
4
STAC INC
Filter assembly procedures for all Model 934 Thermaflow's.
 ST PAUL MN
PAGE 7

800-334-7699
STEP 6 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 black and red lines on the site level gage.
2) Check for hydraulic leaks and fix as needed.
3) Check for fan operation (Electric & Hydraulic).
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. If you have a Hydraulic Flow Meter Kit set required pressure and flow rates
as needed.
7) Slow engine to idle and disengage the PTO.
8) System is ready for operation.
STAC INC
 ST PAUL MN
PAGE 8

800-334-7699
System Maintenance
Hydraulic
Fluid:
Drain and replace hydraulic oil every 6 to 12 months depending on use.
Recommended Fluid: MOBIL DTE10-32 or equivalent.
Filter:
Remove 4 cap screws (10mm) on top of filter housing.
Remove filter cartridge and spring.
Replace with new filter cartridge and spring Part Number 300331
Apply anti-seize to cap screws and tighten.
Pump:
Inspect periodically for leaks.
Check hoses for signs of wear.
Motor:
Inspect periodically for leaks.
Check hoses for signs of wear.
PTO:
Grease output shaft every 6 to 12 months depending on use.
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.
STAC INC
 ST PAUL MN
PAGE 9

800-334-7699
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 around 2000 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:
 Clean air passages through heat exchanger
 Check fan operation
 Check setting of relief valve
 Check temperature of suction line vs outlet line temperature. If the outlet temperature is noticeably hotter, the pump is
cavitating.
 Check for contamination in relief valve. Clean and replace.
 Check 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:
 Check oil level.
 Ensure recommended engine idle speed is maintained.
 Check 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:
 Check oil level. Fill to proper level
 Ensure use of recommended oil type and weight
 Ensure suction line to pump is at least 1 1/2”
 Ensure there is no restriction in suction line.
Oil Discoloration:
 Ensure suction line connections are tight.
 Ensure oil is free from water and contaminants. Drain and refill with recommended oil and replace filter.
 Ensure use of recommended oil type and weight
STAC INC
 ST PAUL MN
PAGE 10

800-334-7699
Specifications
Max Flow Rate:
Max Pressure
Reservoir:
Weight
Suction Line
Pressure Lines
Warranty
30 gpm
3000/5000 psi
3.5 gal
79 lbs
1.5 Inch
3/4 Inch
2 years
Oil - The recommended oil is
MOBIL DTE10-32 or equivalent.
Mobil DTE 10-32 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.
STAC INC
 ST PAUL MN
PAGE 11

800-334-7699
MODEL SS934ER/BK934ER
9
ITEM N
1
2
3
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
9
1
16
?
16
19
7
7
19
5
5
8
8
13
13
2
2
14
15
11
10
15
11
10
3
3
17
12
18
12
6
18
21
20
21
STAC INC
 ST PAUL MN
PAGE 12

22
21
6
21
22
21
21
800-334-7699
20
MODEL SS934EV/BK934EV
9
ITEM NO
1
2
3
4
5
7
8
9
10
11
12
13
14
15
16
17
18
19
21
22
23
24
25
9
1
16
1
16
7
19
57
19
5
8
13
13
2
14
2
15
11
8
14
15
11
10
3
10
3
17
12
18
12
4
21
21
21
STAC INC
 ST PAUL MN
PAGE 13

18
4
22
22
23
21
21
17
25
24
21
800-334-7699
23
25
24
16
MODEL SS934HR/BK934HR
17
1
7
1
9
5
34
2
11
16
19
29
17
29
7
9
11
6
2
19
28
5
30
ITEM NO.
1
2
3
5
6
7
309
11
12
13
14
15
16
17
19
20
21
22
26
27
28
29
30
38
31
32
33
34
35
22
26
6
28
13
3
15
32
33
41
30
12
22
26
13
3
27
21
35
14
15
20
32
33
21
30
31
21
35
12
27
20
21
31
STAC INC
 ST PAUL MN
PAGE 14

800-334-7699
PART NUMBER
DESCRIP
BLK =
934 BLACK M
300330
FILTER ASS
34
300334
SITE GL
300410
8MORB
300416
16MJIC-16M
300730
12MJIC-12MOR
ITEM
NO. PAR
375418
16MJIC-16MOR
600332
BREAT
1
934000/934000BLK
934 TA
2 934 LEFT
934010/934010BLK
934020/934020BLK
3 934 RIGH
934030/934030BLK
934 CO
5
934040
6934 VALVE
934050/904050BLK
934
7 SUPPORT
934300
934
9 HEAT EXC
934728
934 TU
11
93400
300702
3000 PSI
REL
12
93401
300708
12MJIC-12M
13
93402
934714
12MORB-12FJ
14
93403
150510
HYD FAN M
15
150904
6MJIC-12FJIC
16
93405
150908
8MORB-8MORB
17
150912
6MJIC-8MOR
196MJIC-8M
600732
20
600734
12MJIC-12MJIC
21 FLOW CO
600830
22HYD FAN M
934850
26FAN RETUR
934892
27 FAN INLE
934894
14
28
29
30
31
32
33
34
35
38
MODEL SS934HV/BK934HV
1
17
29
1
16
7
5
19
9
29
11
16
9
17
7
2
19
13
5
36
4
11
30
2
13
22
26
33
36
4
30
22
32
15
36
30
3
26
28
33
37
27
32
21
28
23
15
3
30
25
12
21
21
36
21
14
37
38
24
23
14
25
12
21
21
STAC INC
 ST PAUL MN
PAGE 15
24

800-334-7699
ITEM
NO.
1
2
3
4
5
7
9
11
12
13
14
15
16
17
19
21
22
23
300330
300334
300410
300412
300416
375418
600332
934000/934000BLK
934010/934010BLK
934020/934020BLK
934030/934303BLK
934040
934050/934050BLK
934300
934728
300708
934714
934070
24
934708
26
150510
25
934722
28
29
30
32
33
34
36
37
150908
150912
600732
600830
934850
934892
934890
934720
BLK =
PART NUMBER
1
1
8M
MODEL SS934E
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
9
19
16
1
16
7
19
7
5
19
5
8
8
13
13
2
2
14
15
11
15
10
11
3
14
10
3
17
12
12
18
18
6
STAC INC
 ST PAUL MN
PAGE 16
17

4
6
800-334-7699
4
Parts List
Item
Part Number
Description
Item
Part Number
Description
1
300330
600/934 FILTER ASSEMBLY
21
300708
12MJIC-12MORB 90°
2
300334
SITE GLASS
22
934714
12MORB-FJIC SWIVEL
3
300410
8MORB PLUG
23
934070
934722 VALVE HANDLE
4
300412
12MORB PLUG
24
934708
12MJIC-12MORB 90° LONG NECK
5
300416
16MJIC-16MORB 90°
25
934722
DIRECTIONAL CONTROL VALVE
6
300730
12MJIC-12MORB STRAIGHT
26
150510
HYD FAN MOTOR
7
375418
27
150904
6MJIC-12FJIC REDUCER
8
600306
11” FAN
28
150908
8MORB-8MORB ADJUSTABLE
9
600332
BREATHER
29
150912
10
800515
TEMP SWITCH
30
600732
11
934000/934000BLK
934 TANK
31
600734
12MJIC-12MJIC-12MORB TEE
12
934010/934010BLK
934 LEFT SIDE
32
600830
FLOW CONTROL
13
934020/934020BLK
934 RIGHT SIDE
33
934850
HYD FAN MOTOR MOUNT
14
934030/934030BLK
934 COVER
34
934892
FAN RETURN HOSE
15
934040
934 VALVE BRACKET
35
934894
FAN INLET HOSE
16
934050/934050BLK
934 SUPPORT BRACKET
36
934890
FAN INLET HOSE
17
934300
934 HEAT EXCHANGER
37
934720
6MJIC-6ORB STRAIGHT
18
934535
934 ELECTRICAL HARNESS
38
600820
HYDRAULIC FAN BLADE
19
934728
934 TUBE
BLK =
934 BLACK MODEL PART
20
300702
3000 PSI RELIEF VALVE
STAC INC
 ST PAUL MN
PAGE 17

800-334-7699
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
STAC INC
 ST PAUL MN
PAGE 18

800-334-7699
Notes
STAC INC
 ST PAUL MN
PAGE 19

800-334-7699
THERMAFLOW WARRANTY
The THERMAFLOW 934 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.
Inc.
60 West Sycamore Street, St. Paul MN 55117
800-334-7699 • 763-235-7822 Fax
Web: www.thermaflow.com
Thermaflow is a registered trademark of STAC, Inc. All Rights Reserved.
Form 934901 Rev: 10/2015

934-Resource-Manual-1-up-Revised-10.15

Transcription

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