N14882 May, 2011
Universal Hydraulic Oil Cooler
Assembly Instructions (Originating w/Serial Number 50-101)
Model Number: _________________ Serial Number: __________________ Date of Purchase: ________________ Specialized Equipment, Inc.
650 So. Main Street - PO Box 337 - Hector, MN 55342 Business Phone: 320-848-6266 * Fax: 320-848-6269 * Toll Free: 1-800-828-7624
April 2009
LOFTNESS SPECIALIZED EQUIPMENT, INC.
WARRANTY POLICY The warranty policy begins upon delivery of the unit to the original customer. All Loftness products have a one (1) year warranty policy. If any Loftness product is used as a rental unit, the warranty period extends for only 30 days from the delivery date to the original customer. Loftness Specialized Equipment, hereinafter referred to as LOFTNESS, a manufacturer of quality machinery since 1956, warrants new LOFTNESS machinery and/or attachments at the time of delivery to the original purchaser, to be free from defects in material and workmanship when properly set up and operated in accordance with the recommendations set forth in the LOFTNESS Operator’s Manual. LOFTNESS’ liability for any defect with respect to accepted goods shall be limited to repairing the goods at an authorized dealer or other LOFTNESS designated location, or replacing them as LOFTNESS shall elect. The above shall be in accordance with LOFTNESS warranty adjustment policies. This warranty shall not apply to any machine or attachment which shall have been repaired or altered outside the LOFTNESS factory or authorized LOFTNESS dealership or in any way so as in LOFTNESS’ judgment, to affect its stability or reliability, nor which has been subject to misuse, negligence or accident, nor to any machine or attachment which shall not have been operated in accordance with LOFTNESS’ printed instructions or beyond the company recommended machine rated capacity. WARRANTY REQUIREMENTS Warranty registration form must be filled out and returned to Loftness Specialized Equipment to validate all future warranty claims. LIMITATIONS OF WARRANTY All Products – LOFTNESS products are designed to provide years of dependable service when proper use and maintenance is adhered to. The potential for misuse in many applications exists, therefore a limited warranty is provided as follows: All Shredders, Axes, Cutters & Mowers – Rotor Balance: Critical rotor balance can be affected by conditions beyond LOFTNESS’ control, such as the operation of a shredder beyond the Company’s rated capacity, improper knife replacement, missing knives, striking foreign objects, lack of lubrication, etc. Any failure resulting from running in as “out-of-balance” condition, such as, but not limited to bearing and or drive-line failure, metal fatigue, cracks, etc. will be considered abuse and will not be covered under warranty. LOFTNESS may elect to have an area representative evaluate the condition of the machine before warranty is considered. To receive a warranty claim, a return authorization from LOFTNESS must be obtained. The failed part may then be returned in an untampered status. This warranty does not include freight or delivery charges incurred when returning machinery for servicing. Dealer mileage, service calls and pick-up/delivery charges are the customer’s responsibility. EXCLUSIONS OF WARRANTY Except as otherwise expressly stated herein, LOFTNESS makes no representation or warranty of any kind, expressed or implied, and makes no warranty of merchantability in respect to its machinery and/or attachments and makes no warranty that its machinery and/or attachments are fit for any particular purpose. LOFTNESS shall not be liable for incidental or consequential damages for any breach of warranty, including but not limited to inconvenience, rental or replacement equipment, loss of profits or other commercial loss. Upon purchase the buyer assumes all liability, all personal injury and property damage resulting from the handling, possession or use of the goods by the buyer. No agent, employee, or representative of LOFTNESS has any authority to bind LOFTNESS to any affirmation, representation or warranty concerning its machinery and/or attachments except as specifically set forth herein.
650 South Main StreetHector, MN 55342 USA
loftness.com 320-848-6266 US & Canada 800-828-7624
TM
International: 320-848-6266 Fax: 320-848-6269 Parts Fax: 320-848-6055 E-mail: [email protected] Web Address: www.loftness.com
WARRANTY REGISTRATION
Dealer No.:
Dealer Name:
Shipping Address:
Mailing Address:
City: State: Zip:
City:
County:
Phone: Month Day Year
Warranty (Delivered) Date
State: Zip:
Invoice No.:
Model No.: Serial No.:
Part No.:
Dealer Phone:
PLEASE
FOLLOWING INFORMATION MUST BE FILLED IN COMPLETELY FOR WARRANTY:
DEALER PURCHASER
Customer:Last Name:
The machine was properly set up, adjusted and inspectedbefore delivery. The following items were explained to thepurchaser.
* How to operate machine properly as shown in the owner’s manual.
* The importance of safety precaution, safety equipment and preventative maintenance.
* Loftness Warranty for this machine.
I have received and reviewed the operator’s manual for theabove machine and understand the proper and safe operationas well as the applicable warranty outlined therein.
A customer’s manual is included with each machine.
The unit was delivered to me in satisfactory condition.
First
Mailing Address:
Middle Initial
Dealer’s Signature
Date
xPurchaser’s Signature
Date
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Customer Copy
650 South Main StreetHector, MN 55342 USA
loftness.com 320-848-6266 US & Canada 800-828-7624
TM
International: 320-848-6266 Fax: 320-848-6269 Parts Fax: 320-848-6055 E-mail: [email protected] Web Address: www.loftness.com
WARRANTY REGISTRATION
Dealer No.:
Dealer Name:
Shipping Address:
Mailing Address:
City: State: Zip:
City:
County:
Phone: Month Day Year
Warranty (Delivered) Date
State: Zip:
Invoice No.:
Model No.: Serial No.:
Part No.:
Dealer Phone:
PLEASE
FOLLOWING INFORMATION MUST BE FILLED IN COMPLETELY FOR WARRANTY:
DEALER PURCHASER
Customer:Last Name:
The machine was properly set up, adjusted and inspectedbefore delivery. The following items were explained to thepurchaser.
* How to operate machine properly as shown in the owner’s manual.
* The importance of safety precaution, safety equipment and preventative maintenance.
* Loftness Warranty for this machine.
I have received and reviewed the operator’s manual for theabove machine and understand the proper and safe operationas well as the applicable warranty outlined therein.
A customer’s manual is included with each machine.
The unit was delivered to me in satisfactory condition.
First
Mailing Address:
Middle Initial
Dealer’s Signature
Date
xPurchaser’s Signature
Date
x
Loftness Copy
Specialized Equipment, Inc.
650 So. Main St. - PO Box 337 - Hector, MN 55342 Business Phone: 320-848-6266 * Fax: 320-848-6269 * Toll Free: 1-800-828-7624
Dear Customer: Thank you for your decision to purchase an Oil Cooler, attached to a skid-steer, from Loftness Specialized Equipment, Inc. It has been designed to provide years of profitable and dependable service. To ensure maximum performance of your Oil Cooler, it is mandatory that you thoroughly study the owner’s manual and follow its recommendations. Proper operation and maintenance are essential to maintain and maximize the life of the machine and to prevent damage or injury. It is the owner’s responsibility to:
Operate and maintain this Oil Cooler in a safe manner and in accordance with all applicable local, state, and federal codes, regulations and/or laws, and in compliance
with on-product labeling and these instructions.
Make sure that all personnel have read this owner’s manual and thoroughly understand safe and correct operating, installation, and maintenance procedures.
Provide impact-resistant shielding on the power unit to protect the operator from the possible dangers of flying debris.
Make sure the Oil Cooler is set-up correctly before being placed in service. It should be serviced at regular intervals thereafter, in accordance with procedures outlined in this manual.
Fulfill all warranty obligations so as not to void the warranties. The warranty section at the beginning of this manual outlines the warranty policy of Loftness Specialized Equipment, Inc.
Loftness Specialized Equipment, Inc. reserves the right to make product improvements to the equipment at any time. We welcome you to the satisfied family of Loftness equipment owners. Gloria Nelson, President Steve Nelson, Vice-President Dave Nelson, Vice-President
May, 2011
WARNING
Because of the potential safety hazard to eyes from hydraulic leaks and/or flying debris, “USE OF PROTECTIVE EYEWEAR IS ABSOLUTELY MANDATORY” for operator and others in the work area.
Due to the possible danger of flying debris, it is “ABSOLUTELY MANDATORY that IMPACT-RESISTANT SHIELDING” be provided on the power unit to protect the operator. The owner is responsible for providing the operator protection devices on the power unit.
Flying debris can gather on the skid-steer and needs to be cleaned off, especially around the radiator and oil cooler screens, engine compartment and exhaust areas. Periodic cleaning will help prevent the possibility of fire.
TABLE OF CONTENTS
LOFTNESS UNIVERSAL HYDRAULIC OIL COOLER
Page Loftness Universal Oil Cooler…………………...……… 1 Preparing to Install…………………..…………………… 1 Step 1: Mounting the Oil Cooler…...……………….….. 2 Step 2: Connecting the Hydraulics…………………….. 6 Step 3: Installing Fan Wire Harness…………………… 12 Check and Verify Fan Operation……………………….. 14 Check Clearances, Hardware & Hydr. Connections…..14 Cleaning the Cooler……………………………………… 15 Operation………………………………………….………. 15 Original Cooler Systems A, B, C (Diagrams)…………. 17 Loftness Cooler Positions #1, #2 (Diagrams)…………. 18 Cooler Parts List…..………………………………………19 Oil Cooler Parts Identifcation……………………………. 20
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LOFTNESS UNIVERSAL OIL COOLER: 1. Thank you for purchasing the Loftness Universal Hydraulic Oil Cooler 94,000 BTU kit. The universal cooler and protective box where designed to be used where more hydraulic cooling is needed in mobile equipment. With a little ingenuity, the universal cooler can be adapted to a variety of applications.
2. There are three basics steps to installing the Loftness Universal Oil Cooler: A. Physically mounting the cooler and protective box to the machine. B. Connecting the cooler inlet and outlet ports to the proper location in the hydraulic system. C. Wiring the fan to the electrical system.
3. This guide is designed to help you decide the best way to incorporate the Loftness Universal Oil Cooler to your machine. You will need to know a little information about your machine’s hydraulic and electrical systems. Most of the information can be obtained with observation. The operator’s manual is another source of information along with the help of your local dealer.
PREPARING TO INSTALL: 4. The Loftness Universal Oil Cooler consists of the oil cooler/protective box, oil cooler core, electric fan, fan controller/reverser, by-pass check valve, temp sensor, wire harness, inlet and outlet ports, slide out screen, removable top, and hinged shroud. The kit also included an external by-pass check valve for protecting the existing coolers if needed. Refer to pages 20-21 for a complete parts listing.
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5. The Loftness Universal Oil Cooler and instructions were developed to fit those applications where Loftness has not yet designed a custom mount kit.
This guide and your design skills will be used in constructing brackets to attach the cooler to the machine, routing hoses, and wiring up the electrical fan.
These tasks are not overly complicated, but will require some planning, ingenuity, time and materials on your behalf.
6. Prepare the work area and skid steer. Your work area should allow you to raise and lock the boom arms on the skid steer. Make sure the skid steer will not have to be moved during installation. The hydraulics and battery will be disconnected at various stages in the assembly. An overhead hoist is recommended.
STEP 1: MOUNTING THE OIL COOLER:
7. The first step is to determine the best location to physically mount the oil cooler.
The cleanest, coolest air available will deliver the best oil cooling results. The oil cooler draws air in from the bottom and blows it out the top.
The oil cooler is approximately 31” long x 30” wide x 16” tall and weighs around 220 lbs.
8. The skid steer roof is a prime location for the oil cooler. Cool, clean air is available and the cooler is not blocking the operator’s line of sight. It will add 16” plus to the height of the machine, which could be an issue if low clearance is needed. Behind the operator’s cab or on top of a forestry package are also places to consider.
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9. IMPORTANT: Make sure you- (1) do not block any operator emergency escape routes, (2) do not severely limit the operator’s vision, (3) do not block access to any machine service areas, (4) do not interfere with operation of the boom arms. Using a cardboard box the approximate size of the cooler may help you in quickly determining the best location for the oil cooler. The oil cooler ports will point towards the rear of the machine.
10. When positioning the oil cooler, keep in mind that the bottom screen slides forward and the top shroud pivots up for cleaning. The hoses will attach to the ports in the back of the oil cooler.
11. The picture at left shows a typical roof mount bracket for the oil cooler. When designing your brackets avoid drilling holes into or welding onto the roof or cab structure. This could weaken the cab rollover and falling object protection. Drilling holes could also cause water leaks into the cab. Welding directly onto the cab may make the mount removal difficult.
12. Look for holes, tabs and lugs already on the structure which could be used as mounting points. If drilling holes can not be avoided, look for tabs, lugs and overhangs which can be modified without affecting the main cab structure.
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13. The picture at left shows a breakdown of the main components of the mounting brackets for this example. The ears can be designed to mount to the inside or the outside of the oil cooler legs.
14. The inside width dimension for the cooler legs is 29-1/8 inches.
15. The length dimension to the outside holes for the cooler is 29-1/8 inches. The distance between the holes on each leg is 1-1/2 inches. The lower mount holes are designed to take a ½ inch bolt.
16. The photo at left shows an example of holding down the bracket with a U-bolt.
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17. The photo at left shows the mount brackets being clamped through the overhang window grating in the front.
18. Design and build the mount brackets to fit your machine, taking the above points into consideration. Test fit the final design with the parts tack welded together where necessary. When the test fit looks good, finish welding and paint the brackets. Install the competed brackets and fasten them securely. Do not tighten hardware completely until all parts are in place.
19. Slide bottom screen completely out of cooler box to prevent damage to screen. Use two straps to attached cooler box to overhead hoist as shown. The cooler weighs 220 lbs. Attached straps to over hoist, raise cooler slightly off the ground and make sure the cooler is secure.
20. With cooler securely attached to hoist, raise cooler to the proper height and position over the mounts. Note: The hydraulic ports will face towards the rear of the skid steer.
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21. Attach legs of cooler box to the mount ears using 1/2 bolts and locknuts. Attach all four corners of cooler to mount. The hydraulic ports will face towards the rear of the skid steer.
22. With the hardware not completely tight, make any necessary adjustments to the cooler and mount for a proper fit. Tighten all mounting hardware to the proper specs when you are satisfied with the fit.
23. Raise loader arms slowly and check clearances for cab, cooler and mount. Lower arms and adjust mounting if necessary. Recheck clearances after making adjustments. If the cab tilts for service, make sure this is still possible with the cooler attached. With arms lowered, tighten all mounting hardware to the proper specifications.
STEP 2: CONNECTING THE HYRDRAULICS: 24. This next section will include routing the hoses, disconnecting and reconnecting the hydraulics.
Make sure skid steer will not have to be started or moved.
Keep the arms lowered to the ground if possible. If the arms need to be raised for access to the hydraulics, make sure the mechanical boom lock is engaged.
Disconnect battery for safety.
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25. The first step is locate the existing parts of the current cooling system. Open up the back of the skid steer and identify the following parts: a. Skid Steer Hydraulic Oil Cooler b. Engine Coolant Radiator
26. Identify the following ports on the skid steer hydraulic oil cooler. a. Oil Inlet Port coming from the control valves. b. Oil Outlet Port going to the hydraulic tank.
27. Follow the hoses attached to the inlet and outlet ports on the skid steer oil cooler(s) and locate the following parts: a. Hydraulic oil filter. b. Hydraulic oil tank reservoir. c. Hydraulic check valve or pressure relief valve (if any).
28. Refer to the diagrams on page 18 to aid you determining the layout of the current cooling system for your machine. Your machine may have one or two current oil coolers. If it has two oil coolers, they may be in parallel or series. (see diagrams page 18) The oil coolers may be stacked in front of the engine radiator, in back of the radiator, along side of the radiator, or straddling the radiator (front and back).
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29. There are basically two locations to put the new Loftness Universal Oil Cooler (see diagram on page 19). Position #1: In front (ahead) of the original oil coolers so the hot oil will enter the Loftness Universal Oil Cooler first and the original oil coolers second. Position #2: Behind the original oil coolers so the hot oil will enter the original oil coolers first and the Loftness Universal Oil Cooler second.
30. There are several reasons to put the Loftness Universal Oil Cooler in either Position #1 or Position #2. The following sections will list some of the reasons for Position #1 and Position #2 to help you decide what will work best for your machine.
31. Position #1: Loft. Cooler 1st-Advantages The original coolers will see no increase in back pressure. Position #1 may help the engine radiator run cooler if the original oil coolers are stacked in front of the radiator.
32. Position#1: Loft. Cooler 1st-Disadvantages The Loftness oil cooler will see higher back pressures. The oil may actually be reheated in Position #1 if the original oil coolers are stacked behind the engine radiator.
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33. Position #2: Loft. Cooler 2nd-Advantages The Loftness oil cooler will see lower back pressures. Position #2 will give the best cooling results for the entire hydraulic system.
34. Position #2: Loft. Cooler 2nd-Disadvantages The original oil coolers will see higher back pressures. Position #2 will not help the engine radiator cooling as effectively as Position #1 when the original oil coolers are stacked in front of the radiator.
35. Use the above sections to aid in deciding if Position #1 or Position #2 is best for the Loftness Universal Oil Cooler in your machine. Another point to consider is the location of the fittings of the original oil cooler. It is helpful if the fittings are relatively accessible to connect the Loftness Universal Oil Cooler.
36. The Loftness Universal Oil Cooler has a pressure relief check valve built-in to allow the oil to bypass the cooler if the pressure builds beyond 65 psi. A similar pressure relief check valve should be incorporated with the original oil coolers. Some systems have the relief valve already in place and some do not. Check to see if the original oil coolers have a bypass pressure relief check valve in place. (refer to the diagrams on page 19)
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37. We have included an additional 65 psi pressure relief check valve to be used if your current oil coolers do not have one. An arrow indicates the direction of flow.
If your system does not have a current check valve, measure the pressure drop across all the original coolers at normal operating temps. If the pressure drop is less than 65 psi, than the check valve we supplied will work as a pressure relief check valve. If the measured pressure drop is greater than 65 psi, than the check valve we supplied will not be large enough. An alternative method of bypassing the original coolers will have to be considered.
38. With the Loftness Universal Oil Cooler mounted and the hydraulic connection point determined, the next step is figuring out the hoses and fittings. Hydraulic Hose Specs: Hose Inside Diameter: I.0 inch Working Pressure: 800 psi or greater Minimum Bend Radius: 6 inch Temperature Range: -40ºF to +250ºF Cover: Fiber Braid
39. Hydraulic Fitting Specs: Loft. Inlet Port: JIC Size 16 (1-5/16” Dia) Male Loft. Outlet Port: JIC Size 16 (1-5/16” Dia) Male Check Valve: SAE O-Ring Size 16 (1-5/16”) Female The original cooler fittings will vary by machine. The more popular fittings will be: JIC Size 16 (1-5/16”) and Size 12 (1-1/16”) Flat Face O-Ring Size 16 (1-7/16) Size 12 (1-3/16)
40. Measure from the inlet port of the Loftness Universal Oil Cooler to the start point where you have determined to divert the oil flow. Make sure you measure along the path you want the actual hose to take. This will be your inlet hose.
Do the same thing for the outlet hose, measuring from the outlet port of the Loftness Universal Oil Cooler to the point where the oil will enter back into the main hydraulic system. Be sure to measure along the path you want the hose to take.
Note: If the cab tips forward for service, see sections 45-47 on page 12.
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41. If you need to put in a bypass check valve around the original coolers, you will need to measure a hose for that also.
Remember as you measure to take into account the fittings you will be using. The fittings can shorten or lengthen the required hose depending on the orientation.
Also take into account that the I” ID hydraulic hose cannot make sharp turns. Generous rounded turns are necessary.
42. Hydraulically connect the roof cooler to the skid steer to the predetermined connection point (see previous sections). Route the hoses along one side. Make sure the hoses will not be pinched, kinked, rub on sharp edges, hit moving parts (fan, belts), or rest against hot surfaces (exhaust, muffler, etc).
43. You will need to cut holes in the engine hood or sheet metal as the hoses pass from under the hood up towards the Loftness Universal Oil Cooler. Line the newly cut sheet metal edge with rubber edging.
44. The adjacent photo shows the inlet and outlet ports on the roof cooler.
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45. If your cab tilts forward for service and you mounted the Loftness Universal Oil Cooler on the cab roof, you may discover that the hoses will be too long when the cab is down or too short when the cab is up. One solution is to install quick couplers where the hoses connect to the Loftness Universal Oil Cooler.
46. The adjacent photo shows the inlet and outlet ports with quick couplers installed on the Loftness Universal Oil Cooler. Quick couplers for the Loftness Universal Oil Cooler are available from Loftness.
47. With quick couplers installed, you can disconnect the hoses from the Loftness Universal Oil Cooler before tilting the cab forward for service. Connect the inlet hose into the outlet hose whenever they are disconnected from the oil cooler. This will allow for continued oil flow.
STEP 3: INSTALLING FAN WIRE HARNESS: 48. Locate the wire bundle at the back of the cooler as shown.
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49. Run the fan wire bundle down the back of the cab with the hoses, through the cut slots in the hood and into the engine compartment.
50. Inside the engine compartment, run the roof fan wire bundle to the fuse box of the skid steer.
51. Black Wire (Cooler) = Ground Yellow Wire (Cooler) = On/Off Ignition Red Wire (Cooler) = Power Splice the black wire (Cooler) into a ground wire from the fuse box. There may be a common ground wire junction stud.
52. Black Wire (Cooler) = Ground Yellow Wire (Cooler) = On/Off Ignition Red Wire (Cooler) = Power Splice the yellow wire (Cooler) into an ignition switched wire from the fuse box. Protect the yellow wire (Cooler) with an inline 5 amp fuse/holder. This will allow the roof cooler electric fan to only run when the ignition is switched on.
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53. Black Wire (Cooler) = Ground Yellow Wire (Cooler) = On/Off Ignition Red Wire (Cooler) = Power Splice the red wire (Cooler) into a power wire (hot wire) from the fuse box. Protect the red wire (Cooler) with an inline 30 amp fuse/holder.
CHECK & VERIFY FAN OPERATION:
54. To verify the fan operation, the temp sensor must be by-passed. By-pass the temp sensor by disconnecting it from the control box green wires. Reconnect the green wires of the control box into each other to form a loop.
Reconnect the battery. Turn on the ignition key without starting the engine.
The roof cooler fan should start after a 30 second delay if the temp sensor is by-passed.
Turn ignition switch off. Reconnect the temp sensor.
CHECK CLEARANCES, HARDWARE & HYDRAULIC CONNECTIONS: 55. Raise cab and check that the hoses from the roof cooler do not pinch against the cab or hood structure. Double check that all hardware is tightened to the proper specs.
56. Recheck all the hydraulic connections before operation.
Start engine and function loader arms slowly.
Carefully observe for any hydraulic leaks using proper hydraulic techniques.
Caution: Do not use exposed skin to test for hydraulic leaks. High pressure oil can be injected into the skin. If oil is injected into the skin, seek immediate medical attention as serious side affects and death can occur.
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CLEANING THE COOLER: 57. The bottom screen pulls out for easy cleaning.
58. The top unbolts for access to the fan, fan controller, temperature sensor, check valve and cooler core.
59. The fan and shroud top pivot up for access to the cooler fins and core.
OPERATION: 60. In typical operation, the temp sensor (if installed) will turn the fan on when the hydraulic oil temperature reaches 140ºF. Once operating, the fan will run for 30 seconds in the reverse direction blowing air down and cleaning off the lower screen. After 30 seconds, the fan will stop, pause and change direction. (Continued on next page)
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Next the fan will run for 10 minutes in the forward direction blowing air up and out through the top.
The fan will repeat this reversing cycle every 10 minutes.
The temp sensor will turn the fan off if the hydraulic oil temp falls below 130-125ºF.
www.loftness.com
Loftness Specialized Equipment, Inc.650 So. Main Street • PO Box 337 • Hector, MN 55342Tel: 320.848.6266 • Fax: 320.848.6269 • Toll Free: 1.800.828.7624
Printed in USA© Loftness 2008
