HP TWIN8 User Manual 4-2015 V9
Contents
1. Plugs 0 030 0 76 NS Pe TT EWI BEN REKE Clean Cooling System dort usewaen peg S COO OOT Remove Condensed Moisture 1 1 LTL LT Reietvaive Setings LL Hydraulics Heavy Duty Maintenance Schedule Foam Air Pre Cieanor TI finineFuslFiter 1 o Spark Pugs 0050 0 76 Eam amp Clean Air Cooling System don t use water HydraulieFluid Relief Valve Settings Hydraulics Clean In dusty conditions or when airborne debris is present clean more often 1 Inspect In dusty conditions or when airborne debris is present inspect the back side of cooler often R Replace For additional maintenance information see the Briggs amp Stratton engine operator s manual that was supplied with the power unit 14 gt HP TWIN3 User Manual STAN LEY MAINTENANCE SEE PAGE 19 FOR REPLACEMENT FILTER PART NUMBERS FUEL FILTER FUEL LINE FROM TANK TO FILTER GG CONNECTION ENGINE OIL HYDRAULIC OIL FILTER See Page 27 COOLER HYDRAULIC FUEL LINE FROM TANK TANK TO FUEL PUMP 5c 7 4 THROTTLE At 4 e CABLE STANLEY HP TWINS FUEL VAP2. JSNUI Iv SLL 0052 9 8 9 dn 050944 61 0 suoneoijdde Aue 10 pesn eq jou 0052 6l pue 004 5 001 06 08 005 001 07 6 FOLS H uo peseq SLL 0052 eJnsse d ov 8 8 101 pesn s yeyo siu SLL 0052 ujog ov 8 8 05 61 001 19 07 6 01 5 4 921 0052 ujog l e GL 0 dn 05 0 dn 07 6 01 5 NE E e oj eunsseJd 6 1 0052 ujog EL e 08 92 001 92 62 91 9 y eJnsseJd daay suon 6 1 0052 ujog OL 8 92 0 dn 92 0 dn 62 91 9 y 95941 S19 YVAN ASN LON OQ plesg JO e nu u uo SSL 0522 u og OL 9 dn OL 04 dn ve SL 6 SSOY SNOMEA 2504 3exong ANN 20 plesg 4 eso SMOUS 1 94 0 Weyo avg ISd uinjoysseid WI HONI SYUILIN 1334 5 asn episu sy45u97 esoH MO WNIID 0 001
3. HP TWIN8 User Manual lt 9 STANLEY 5 TOOL HYDRAULIC SYSTEM REQUIREMENTS TYPE TYPE II RR III Flow Range 4 6 gpm 7 9 gpm 9 10 5 gpm 11 13 gpm 15 23 Ipm 26 34 Ipm 34 40 Ipm 42 49 Ipm Nominal Operating Pressure 1500 psi 1500 psi 1500 psi 1500 psi at the power supply outlet 103 bar 103 bar 103 bar 103 bar System relief valve setting 2100 2250 psi 2100 2250 psi 2200 2300 psi 2100 2250 psi at the power supply outlet 145 155 bar 145 155 bar 152 159 bar 145 155 bar Maximum back pressure 250 psi 250 psi 250 psi 250 psi at tool end of the return hose 17 bar 17 bar 17 bar 17 bar Measured at a max fluid viscosity of 400 ssu 400 ssu 400 ssu 400 ssu at min operating temperature 82 centistokes 82 centistokes 82 centistokes 82 centistokes Temperature Sufficient heat rejection 140 140 140 140 capacity to limit max fluid temperature to 60 C 60 C 60 C 60 C at max expected ambient temperature Min cooling capacity at a temperature 3 hp 5 hp 6 hp 7 hp difference of between ambient and fluid 2 24 kW 3 73 kW 5 22 kW 4 47 kW temps 40 F 40 F 40 F 40 22 22 22 22 Do not operate the tool at temperatures above 140 60 C Operation at higher temperatures can cause operator discomfort at the tool Filter 25 microns 25 microns
4. C ET pr 10 CC 46 16 Ss 3 SS SS SS SSS SSS N Ss BSS SSS SS Ne 24 mounts inside lower frame using fasteners item 10 CC above CONNECTION see pg 27 20 HP TWIN8 User Manual STAN LEY 3 N N co QD 21765 1 PRESSURE SWITCH 40369 59074 leen 71937 71939 72402 72403 CO on N DH WIRE 5 T N FLANGE BOLT 1 4 20 X 1 2 9 N _ RUBBER MOUNT c N HEX FLNG BOLT 3 8 16 X 1 1 2 N N N N STARTER SOLENOID MUFFLER NIN RIER E N 4 N T2413 SOLENOID GROUND STRAP BRIGGS M49 27 HP WASHER 3 8 1 0 N N R 0 3 5 6 7 8 5 6 CAPSCREW 1 4 200 1 2 8 72439 1 WIRE 55 PICTURED 1 1 1 1 1 1 1 1 1 1 FLANGE BOLT 1 4 20 3 4 ji 3 4 2 BEEN 6 2 a 2 81 6 2 a 28 72412 CLAMP25 35 N LER 2 E d LEN a s 2 2 4 2 1 2 2 4 28 1 1 1 1 1 2 1 1 1 1 2 1 1 1 1 2 2 2 2 2 N LEY HP TWIN8 User Manual 4 21 Connects to 10 EE Connects to hose Item lower frame see pg 20 36 at left see FF Connects to hose Item
5. as shown below are used to emphasize all operator maintenance and repair tions which if not strictly followed could result in a life threatening situation bodily injury or damage to equipment This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death This safety alert and signal word indicate an imminently hazardous situation A DANGER which if not avoided will result in death or serious injury This safety alert and signal word indicate a potentially hazardous situation which if not avoided could result in death or serious injury This safety alert and signal word indicate a potentially hazardous situation which if not avoided could result in death or serious injury This signal word indicates a potentially hazardous situation which if not avoid ed may result in property damage This signal word indicates a situation which if not avoided will result in damage to equipment This signal word indicates a situation which if not avoided may result in dam to equipment Always observe safety symbols They are included for your safety and for the protection of the tool LOCAL SAFETY REGULATIONS Enter any local safety regulations here Keep these instructions in an area accessible to the operator and mainte nance personnel A A DANGER
6. tank cap and fittings frequently for cracks or leaks Replace if necessary e Clean the fuel cap area of dirt and debris Replacement parts must the same and installed in the same position as the original parts HYDRAULIC SYSTEM MAINTENANCE e Check hydraulic fluid level daily Add fluid per specifications in this manual See HYDRAULIC FLUID under the section titled PRE OPERATION page 11 Remove condensed moisture from the hydraulic fluid by pumping the hydraulic fluid into a 5 gal 20 L container through the pressure hose Make sure the engine is at idle when performing this procedure When the hydraulic reservoir is empty turn the engine off immediately Allow the fluid to sit long enough for the water to settle to the bottom of the container Slowly pour the fluid back into the hydraulic tank avoiding the water at the bottom of the container Each day check hydraulic lines and fittings for leaks kinks etc Do not use your hand to perform this check STANLEY Change the hydraulic filter element every 200 hours of operation Change more often if cold moist or dusty conditions exist e Check oil cooler for debris Remove debris with air pressure BATTERY MAINTENANCE If the power unit is not in use for two or more months check the battery once a month and charge if the bat tery voltage is below 12 5V Charge at 1 3A for 5 10 hours If the battery voltage is below 12 0V charge
7. 37 at left see JJ Connects to Item 7 below Connects to back of control block item 26 Below Connects to item 24 on pg 20 inside See page 26 for lower frame close up of Control Block See pg 20 for mounting location 38 of Item 26 Control Block Connects to lower fittings on Hyd tank 22 gt HP TWIN8 User Manual STANLEY 04313 RETAINING RING 203232 COOLER FILTER 06988 2 RING 018 04306X20 25 06989 O RING 203233 HOSE COOLER BLOCK 10793 2 HSHCS 3 8 16 X 1 1 4 04306X30 00 40364 ELBOW 45 3 4 SAE TO 3 4 Wez 40 203246 42 203247 2 HOSE TANK PUMP fod all 11 44 12 45 13 PARTSNOLONGERUSED fag 49 204840 1 THOSE BLOCK FILTER 7 COUPLER PUMP FAN NOTE BUSHING TAPER LOCK 5 8 CONTROL BLOCK ASSEMBLY 203051 reder Item 1 thru 4 10 16 18 26 28 thru 30 26 203049 1 CONTROL BLOCK DUAL SEE NOTE FOR COMPLETE COUPLER SET 72396 INCLUDES MALE AND ASSEMBLY FEMALE 31 203063 2 8 SAE 1 2 ORFS 71 1 JPartnoronGERUSED 203067 HOUSING BLOWER 9 LEY HP TWIN8 User Manual 4 23 DD CONNECTION Mounts to Lower Frame see Fastener DD pg 20 NOTE Complete Upper Frame Assembly P N 206975 Includes the Following Items 4 thru 7 and Items 11 thru 14 e 20926 2 FASTENER 1 4 TURN ow fo 200220 2 _ RETAINER 14 TURN o
8. A WARNING a CAUTION CAUTION NOTICE IMPORTANT 4 gt HP TWIN8 User Manual STAN LEY Tool operators and maintenance personnel must always comply with the safety precautions given in this manual and on the stickers and tags attached to the tool and hose These safety precautions are given for your safety Re view them carefully before operating the tool and before performing general maintenance or repairs Supervising personnel should develop additional pre cautions relating to the specific work area and local safety regulations If so place the added precautions in the space provided in this manual The HP TWINS Hydraulic Power Unit will provide safe and dependable service if operated in accordance with the instructions given in this manual Read and under stand this manual and any stickers and tags attached to the tool and hoses before operation Failure to do so could result in personal injury or equipment damage Operator must start in a work area without bystand ers The operator must be familiar with all prohibited work areas such as excessive slopes and danger ous terrain conditions Establish a training program for all operators to en sure safe operation Do not operate the power unit unless thoroughly trained or under the supervision of an instructor Always wear safety equipment such as goggles ear protection breathing protection head protection and safety shoes at all times when operating th
9. HOSE TO PULL OR LIFT TOOLS POWER UNITS ETC NEEDS OTHER SIDE HESIN TE SEE OTHERSDE SIDE 1 SIDE 2 Shown smaller than actual size 8 gt HP TWIN8 User Manual STAN LEY 9v SIHL LON OG lt X H w gt 12 suonoeuuo 210 17 4 lt lt lt xuz NENNEN lt lt TITI NUNLIU RETURN RETURN gt gt gt Er El JYNSSIYd PRESSURE HYDRAULIC CIRCUIT PRESSURE GLb 0052 792 06 8 001 92 09 67 91 SLL 0052 eJnsse d 61 vIe 921 0092 61 vIe 8 dn 92 o dn 09 67 9L EL 92 0082 9 8 9 LISP IVS Aq yas se 0082 mes j Jo snu 09 0 002 001 6 88 10 SLL 0052 8 6l vIe WEIS S SLL 0052 Uny 6L m ne rw jenbe ainsseid Buom m 0082 15551 9i 979 e 15291
10. Hydraulic Tools DO NOT REMOVE THESE TAGS If the information on a tag is illegible because of wear or damage replace the tag immediately A new tag may be obtained from your Stanley Distributor THE TAG SHOWN BELOW IS ATTACHED TO CERTIFIED NON CONDUCTIVE HOSE DANGER DANGER 1 FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE IMPROPER USE WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRIC LINES MAY RESULT IN OR HANDLING OF HOSE COULD RESULT IN BURST OR OTHER HOSE FAILURE DEATH OR SERIOUS INJURY KEEP HOSE AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT CONTACT DURING USE CONTACT AT THE BURST CAN CAUSE BODILY INJECTION AND SEVERE PERSONAL INJURY ELECTRIC LINES HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING ABRASION CUTTING OR CONTACT WITH HIGH TEMPERATURE SURFACES DO NOT USE IF KINKED DO NOT BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE USE HOSE TO PULL OR LIFT TOOLS POWER UNITS ETC ON OR NEAR ELECTRIC LINES WIPE THE ENTIRE LENGTH OF THE HOSE AND FIT CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAM TING WITH A CLEAN DRY ABSORBENT CLOTH TO REMOVE DIRT AND MOISTURE AND TEST HOSE FOR MAXIMUM ALLOWABLE CURRENT LEAKAGE IN ACCORDANCE WITH AGO SOUPEINSS I ANY OF CONDITIONS ENST REPLACE THE IMMEDIATELY NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE SAFETY DEPARTMENT INSTRUCTI
11. To avoid personal injury or equipment damage all tool repair maintenance and service must only be performed by authorized and properly trained per sonnel Do not operate the machine on excessive slopes or unstable terrain where tip over is a hazard Do not exceed the rated limits of the equipment or use the equipment for applications beyond its de sign capacity Be aware of surrounding hazards Noise created by the Power Unit and the tools it operates may mask early indications of approaching hazards HP TWIN8 User Manual lt 5 e Warning Hydraulic fluid under pressure could cause skin injection injury If you are injured by hydraulic fluid get medical attention immediately observant of the hydraulic hoses lying about the work area they can be a tripping hazard Use proper lifting techniques when handling the power unit and do not over reach Only use the Power Unit in well ventilated areas DO NOT operate in explosive atmospheres in closed environments or near flammable substances Always be well rested and mentally alert when op erating the Power Unit and tools DO NOT operate if affected by medications drugs or alcohol Keep clear of hot engine parts and exhaust Do not operate tools if oil temperature exceeds 140 F 60 C Operation at high temperatures can cause higher than normal temperatures at the tools which can result in operator discomfort or injury Disconnect battery
12. at 1 3A for 12 18 hours let the battery sit for 1 2 hours and check the voltage If the voltage is not 12 5V or greater replace the battery Always charge using a charger as rated as close to 1 3A as possible Checking battery voltage and charging can be done through the 12V marine plug on the battery cover when using an appropriate adapter STORAGE Clean the unit thoroughly before storage Do not use water pressure Always store the unit in a clean and dry facility e unit will be stored for a prolonged period over 30 days add a fuel additive to the fuel tank to prevent the fuel from gumming Run engine for 2 minutes to circulate the additive throughout the fuel System When storing fuel or equipment with fuel in the tank store away from appliances that have pilot lights or other ignition sources they can ignite fuel vapors Replace crankcase oil with new oil e Remove spark plugs and pour approximately 1 ounce 30 ml of engine oil into each cylinder Replace spark plugs and crank the engine slowly to distribute the oil e Check hydraulic reservoir for water If water is found change the oil and circulate it through the tool hose and tool See HYDRAULIC SYSTEM MAINTENANCE earlier in this section Disconnect tool hoses HP TWINS8 User Manual lt 13 Standard Maintenance Schedule werte T amp T
13. retest Check both the 5 and 8 gallon flow settings and then follow the same procedure to test the other circuit each circuit has its own relief valve STANLEY See Defective spark plugs Remove plugs check gap clean or replace Low Engine Oil Check Oil Level Flow Control Levers in the Move the levers to the off position position Fluid blowing out of fluid reservoir Hydraulic tank overfilled Correct the fluid level vent Pump suction leak Check suction connections Tighten if necessary Hydraulic tool won t operate Flow control lever s not in the ON Check that the flow control lever s position are in the ON position Incorrect hose connection to tool Make sure the tool hose circuit goes from left pressure fitting to tool and back to the right fitting return Fluid always flows from the male to female fittings Quick disconnect fittings defective Detach from hose connect set together and check for free flow Hydraulic fluid level low Check for correct fluid level Fill using the recommended fluid Relief valve stuck open Adjust or replace valve Suction hose kinked Make sure suction hose from fluid reservoir to pump inlet has a smooth curve Tool is defective Refer to tool manual STAN LEY HP TWIN8 User Manual 4 17 go Agnes nce et 27 hp OHV Briggs amp Stratton Engine Output Capacity Dual 5 or Dual 8 Circuits Two
14. terat eus tu et da ae cen S N AA ER N 21 HYDRAULIG GROUP ILLUS TRATION nasz itta rte et t tnde certant e ce deer a Da 22 HYDRAULIC GROUP PARTS LIST is su xuye iate dan alya testet ta ee 23 UPPER FRAME ILLUSTRATION AND PARTS 24 HYDRAULIC FLOW RE 25 CONTROL BLOCK DETAIL re tenente Dor cere bed Dea cd 26 HYDRAULIC amp FUEL TANKS sinir 27 To fill out Product Warranty Validation form and for information on your warranty visit Stanleyhydraulics com and select the Company tab Warranty NOTE The warranty Validation record must be submitted to validate the warranty SERVICING This manual contains safety operation and routine maintenance instructions Stanley Hydraulic Tools recommends that servicing of hydraulic tools other than routine maintenance must be performed by an authorized and certified dealer Please read the following warning SERIOUS INJURY OR DEATH COULD RESULT FROM THE IMPROPER REPAIR OR SERVICE OF THIS TOOL REPAIRS AND OR SERVICE TO THIS TOOL MUST ONLY BE DONE BY AN AUTHORIZED AND CERTIFIED DEALER For the nearest authorized and certified dealer call Stanley Hydraulic Tools at 503 659 5660 and ask for a Customer Service Representative STAN LEY HP TWIN8 User Manual lt 3 Safety symbols signal words
15. the unit 1 ENGINE CRANKCASE OIL LEVEL Always check the oil level before starting the engine Make sure the oil level is at the FULL MARK on the dipstick Do not overfill Use detergent oil classified For Service SF SG SH SJ or higher as specified in the engine operators manual Do not use special additives Outdoor temperatures deter mine the proper oil viscosity for the engine Use the chart to select the best viscosity for the outdoor temperature range expected m z 5 a Below 40 F 4 C the use of SAE 30 will result in hard starting Above 80 F 27 C the use of 10W 30 may cause increased oil consumption Check oil level more frequently 2 ENGINE FUEL LEVEL Check the fuel level If low fill with clean fresh unleaded gasoline with a minimum of 87 octane Gasoline with up to 10 ethanol gasohol is acceptable 3 HYDRAULIC CONNECTIONS The recommended hose length is 25 ft 8 m with a 1 2 inch 12 7 mm inside diameter The hoses must have a working pressure rating of at least 2500 psi 175 bar Each hose end must have male thread ends compatible with HTMA HYDRAULIC TOOL MANUFACTURERS ASSOCIATION quick disconnect fittings NPT type threads See pages 8 and 9 STANLEY QUICK DISCONNECT COUPLERS HTMA approved quick disconnect couplings are installed to hydraulic hoses so that the direction of oil flow is always from the male to the female quick disconnect as
16. 25 microns 25 microns Min full flow filtration 30 gpm 30 30 gpm 30 gpm ee e lpm dirt holding capacity Hydraulic fluid Petroleum based 100 400 ssu 100 400 ssu 100 400 ssu 100 400 ssu premium grade anti wear non conductive 20 82 centistokes Viscosity at min and max operating temps NOTE When choosing hydraulic fluid the expected oil temperature extremes that will be experienced in service determine the most suitable temperature viscosity characteristics Hydraulic fluids with a viscosity index over 140 will meet the requirements over a wide range of operating temperatures SSU Saybolt Seconds Universal EHTMA CLASSIFICATION HYDRAULIC SYSTEM unm A A A A Flow Range 3 5 4 3 gpm 4 7 5 8 gpm 7 1 8 7 gpm 9 5 11 6 gpm 11 8 14 5 gpm 13 5 16 5 lpm 18 22 Ipm 27 33 Ipm 36 44 Ipm 45 55 Ipm Nominal Operating Pressure 1870 psi 1500 psi 1500 psi 1500 psi 1500 psi at the power supply outlet 129 bar 103 bar 103 bar 103 bar 103 bar System relief valve setting 2495 psi 2000 psi 2000 psi 2000 psi 2000 psi at the power supply outlet 172 bar 138 bar 138 bar 138 bar 138 bar NOTE These are general hydraulic system requirements See tool specification page for tool specific requirements 10 gt HP TWIN8 User Manual STAN LEY PREPARATION FOR USE Do not operate the power unit until you have read the engine operating and maintenance instructions manual furnished with
17. 5 gpm 20 Circuits or Two 8 gpm 30 Ipm Circuits E 37 5 in 95 25 Dp 25 75 in 65 4 cm le a Te 30 in 76 2cm Weight Wet n 360 165 163 kg Fuel Tank Capacity a kk 4 7 gal 17 8 Itr Estimated Gas Consumption Per Hour en een aa 2 5 gal 9 4 Itr Hydraulic Reservoir k ka ke nenne 3 2 gal 12 1 Itr Relief Valve Crack Setting tdeo eiat eee m a 2100 psi 145 bar Full Relief Setting 2500 psi 172 bar Nominal AN nnn 1500 103 Pressure oreet ia uc Rav eus Poire Ex ede 2000 psi 138 bar eed Open Center Category M RE h R V 1 2 A POWER UNITS GAS FUEL DRIVEN EQUIPMENT A1 Federal Emission Component Compliance 40CFR part 1060 120 Stanley warrants all fuel system emission components for 2 years from the date of original purchase provided there has been no abuse neglect modifications or improper maintenance Components covered The emission related warranty covers all components whose failure would increase the evaporative emissions Your emission related warranty does not cover compo
18. ONS AFTER EACH USE STORE IN A CLEAN DRY AREA FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROP ERLY TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND DO NOT REMOVE THIS TAG SIHL LON OG SEE OTHER SIDE SEE OTHER SIDE SIDE 1 SIDE 2 Shown smaller than actual size THE TAG SHOWN BELOW IS ATTACHED TO CONDUCTIVE HOSE DANGER DANGER NOT USE THIS HYDRAULIC HOSE OR NEAR ELECTRIC LINES THIS HOSE IS 5 CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAMAGE NOT LABELED OR CERTIFIED AS NON CONDUCTIVE USING THIS HOSE ON OR NEAR COUPLINGS IF ANY OF THESE CONDITIONS EXIST REPLACE THE HOSE IMMEDIATELY ELECTRICAL LINES MAY RESULT IN DEATH OR SERIOUS INJURY NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY 6 AFTER EACH USE STORE IN A CLEAN DRY AREA TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND ELEC TRIC LINES NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE IMPROPER USE OR HANDLING OF HOSE COULD RESULT IN BURST OR OTHER HOSE FAILURE KEEP HOSE AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT CONTACT DURING USE CONTACT AT THE BURST CAN CAUSE BODILY INJECTION AND SEVERE PERSONAL INJURY HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING CUTTING OR CONTACT WITH HIGH TEMPERATURE SURFACES DO NOT USE IF KINKED DO NOT USE
19. OR LINE FROM CARBON CANISTER TO ENGINE CONNECTION See Page 27 QUICK ENGINE ENGINE OIL CHECK amp OIL DRAIN AIR CLEANER FILL DIP STICK FUEL TANK SPARK PLUG HYDRAULIC HP TWINS OIL COOLER STAN LEY HP TWIN8 User Manual 4 15 GENERAL Tests and adjustments should be performed periodically to ensure the power unit is operating at maximum efficiency Use a calibrated flow and pressure tester This tester can be used to isolate problems in both the engine and hydraulic system prior to any power unit disassembly TESTING THE HYDRAULIC CIRCUIT The following tests can be performed to ensure that the hydraulic pump is supplying the correct flow and pressure and that the system relief valve is operating properly During these tests make sure the engine is warm and operating smoothly If test results are not as specified refer to the troubleshooting table in this section for possible causes TESTING THE 5 OR 8 GPM CIRCUIT To test the circuit proceed as follows Throttle Control Lever Flow Control Lever s 1 Install a calibrated flow and pressure tester across the two hose ends where the tool would normally be connected 2 Set both flow control levers to the OFF down position 3 Set the throttle control lever to the far left for 5 GPM after the engine is started you can leave the lever in this position if you are testing the 5 GPM circuit or move the lever to the far right to tes
20. TANK DECAL P N 205049 ADANGER ADANGER ADANGER INHALATION HAZARD OIL INJECTION HOT SURFACE SAFETY TWIN8 DECAL 205047 STAN LEY HP TWIN8 User Manual lt 7 The rated working pressure of the hydraulic hose must equal to or higher than the relief valve setting hy draulic system There are three types of hydraulic hose that meet this requirement and are authorized for use with Stanley Hydraulic Tools They are Certified non conductive constructed of thermoplastic or synthetic rubber inner tube synthetic fiber braid reinforcement and weather resistant thermoplastic or synthetic rubber cover Hose labeled certified non conductive is the only hose authorized for use near electrical conductors Wire braided conductive constructed of synthetic rubber inner tube single or double wire braid reinforce ment and weather resistant synthetic rubber cover This hose is conductive and must never be used near electrical conductors Fabric braided not certified or labeled non conductive constructed of thermoplastic or synthetic rubber in ner tube synthetic fiber braid reinforcement and weather resistant thermoplastic or synthetic rubber cover This hose is not certified non conductive and must never be used near electrical conductors HOSE SAFETY TAGS To help ensure your safety the following DANGER tags are attached to all hose purchased from Stanley
21. TWIN HYDRAULIC POWER UNIT USER MANUAL Safety Operation and Maintenance 2013 Stanley Black amp Decker Inc New Britain CT 06053 U S A 72464 4 2015 Ver 9 2 gt HP TWIN8 User Manual STAN L EY SAFETY SYMBOL 4 SAFETY PRECAUTIONS iseia na canted ren t ean nh aa e ebd ebd cnc enda 5 TOOE STEKER See 7 HOSE TYPES kasa un 8 HOSE RECOMMENDATIONS i arana zarek an RR E Ka Ke e A erk d AA AR S KA WEL 9 RI MA ERTMA REQ REMEN LS Hela d ce et kde a tear cn re tea exe era 10 PRE OPERATION ETE 11 CONTROL Sot HU ROT 12 START UP eee 12 MAINTENANCE es 13 BATTERY MAINTENANCE unter 13 CIRCUIT icm 16 TROUBLESHOOTING ss iya x land ii ker yan Kerik Ai KE SERR ke W ia Wa Al A rn 17 SPECIFICATIONS i yaka ka aoii an dik ya yaaa la aa din aka a k ARA n Van We n kuye ak 18 ACCESSORIES m CEU ET 19 LOWER FRAME ILLUSTRATION aient pet iet naked 20 LOWER FRAME PARTS LEIST ia irte
22. before servicing electrical com ponents Electrocution or burns could result from improper contact e Loading and unloading of the power unit is danger ous Never attempt to load or unload the power unit without loading ramps loading dock or an over head crane Loading ramps must be strong enough have a low angle and correct height Load and unload the power unit on a level surface Never attempt to load or unload the power unit if the ramp incline exceeds 15 degrees Failure to follow these instructions may result in serious injury or death e Warning Use of this tool on certain materials during demolition could generate dust potentially containing a variety of hazardous substances such as asbestos silica or lead Inhalation of dust containing these or other hazardous substances could result in serious injury cancer or death Protect yourself and those around you Research and understand the materials you are cutting Follow correct safety procedures and comply with all applicable national state or provisional health and safety regulations relating to them including if appropriate arranging for the safe disposal of the materials by a qualified person 6 gt HP TWIN8 User Manual STAN LEY LOGO TWIN8 DECAL 205044 DASH TWIN8 DECAL 205043 STANLEY FUEL TANK DECAL P N 205048 HP TWINS IHI2 TWINS LOGO TWIN8 HYD TANK DECAL 205046 LOGO TWIN8 FUEL TANK DECAL P N 205045 STANLEY HYD
23. e power unit and a hydraulic tool Do not inspect or clean the power unit while it is run ning Accidental engagement of the unit can cause serious injury Always use hoses and fittings rated at 2500 psi 172 bar with a 4 to 1 safety factor Be sure all hose con nections are tight sure all hoses are connected for correct flow di rection to and from the tool being used STANLEY Do not inspect hoses and fittings for leaks by using bare hands Pin hole leaks can penetrate the skin NEVER OPERATE THE POWER UNIT IN A CLOSED SPACE Inhalation of engine exhaust can be fatal Do not operate a damaged improperly adjusted power unit Do not wear loose clothing or unbound long hair when operating the tool Loose items can get en tangled with the tool and cause serious injury Keep all parts of your body away from the working parts of the power unit Keep clear of hot engine exhaust Do not add fuel to the power unit while the power unit is running or is still hot Do not operate the power unit if gasoline odor is present Do not use flammable solvents around the power unit engine Do not operate the power unit within 3 3 ft 1 m of buildings obstructions or flammable objects Do not reverse tool rotation direction by changing fluid flow direction Allow power unit engine to cool before storing in an enclosed space Always keep critical tool markings such as labels and warning stickers legible
24. e the ignition switch is returned to the OFF position COUPLERS HOSE CONNECTIONS Top Male Quick Disconnect Couplers Pressure Fluid Out Bottom Female Quick Disconnect Couplers Return Fluid In Facing the control panel the top 2 male couplers are the PRESSURE FLUID OUT fittings The bottom 2 female quick disconnect couplers are the RETURN FLUID IN Their are two independent circuits one on the left and one on the right each controlled by the adjacent lever 12 gt HP TWINS User Manual Throttle Control Lever Starter Switch Flow Control Lever s In Off Position When the throttle control lever is in the far left position it will produce 5 GPM to both circuits at the same time and with the lever in the far right position will produce 8 GPM to both circuits This allows two tools that can run simultaneously at 5 or 8 GPM The flow control levers when turned ON up position turns on flow to the tool or tools depending on if you are using one or both circuits STARTUP 1 Before starting the engine check the engine oil and hydraulic fluid level Check to make sure the flow Control levers are in the OFF position Down the power unit will not start if the levers are in the UP position ON Connect hoses and the tool as described on page 9 It is not necessary to choke the engine it is equipped with a Electronic Fuel Management System that does not have a manual choke Set
25. nents whose failure would not increase evaporative emissions Coverage under this warranty extends only to the following parts fuel tank fuel cap fuel hose and vapor hose from the fuel tank to the engine and any connectors that are apart of the fuel system The equipment is designed built and equipped so it conforms at the time of sale to the ultimate purchaser and each subsequent purchaser and is in compliance with 40 C F R 1060 120 standards The equipment is free from defects in materials and workmanship that may keep it from meeting these requirements 18 gt HP TWIN8 User Manual STAN LEY ACCESSORIES Coupler Male Parker SAE ierat epe eere PRI eka 72398 Coupler Female Parker SAB sd ean rte nee 72397 Coupler Set amp Female Parker 72396 Flow and Pressure 007 04182 Hose Assy 50 TL with COUplers co aan Re e inan ser k ee dee RE kai dai n 31848 Hose Assy 25 ft Wilh COUPICTS s co deri oer eee tte e e d pee enu Rd 31972 FILTERS ENGINE MODEL HYDRAULIC OIL FILTER AIR FILTER FUEL FILTER OIL FILTER HP28B02 18384 205053 205057 40408 STAN LEY HP TWIN8 User Manual 4 19 5 pressure switch not pictured mounts next to engine oil filter 5 Item 26 control block on pg 22 mounts to backside of this plate ltem 19 mounts inside lower frame on axles
26. shown on page 9 Quick disconnect couplings and hose fittings are selected so that additional fittings such as reducer or adapter fittings are not required If adapter fittings are used they must be approved steel hydraulic fittings meeting a minimum operating pressure rating of 2500 psi 172 bar Do not use galvanized pipe fittings or black pipe fittings Use thread tape or pipe joint compound when installing quick disconnect couplings to hose or tool fittings Follow the instructions furnished with the selected thread sealant DO NOT OVERTIGHTEN THE FITTINGS 3 HYDRAULIC FLUID RECOMMENDED HYDRAULIC OILS Below is a list of recommended oils by brand Biodegradable Description AMsor ma Exxon Mobil No 10 Excel Chewon Rando 40232 Recommended for extreme cold temperatures HP TWIN8 User Manual lt 11 CONTROLS DUAL CIRCUIT 5 BATTERY The supplied 12 Volt DC battery is a sealed non spillable maintenance free battery and is fully charged Make sure the battery cables are tight and charging circuit functions are operating properly A fully charged battery should read 12 8V 13 0V Caution overcharging can harm your battery beyond recovery When using an automatic charger refer to the charger manufacturer s instructions If the engine runs out of gas or dies during operation and the ignition switch is left in the ON or RUN position this could drain the battery Make sur
27. t the 8 GPM circuit 16 HP TWINS User Manual 10 Check that the tester restrictor valve is fully open counterclockwise on the flow and pressure tester Start the engine and allow it to run until warm With the throttle control in the far left position the 5 GPM circuit can be tested or moving the lever to the far right will allow testing the 8 GPM circuit a 5 GPM Range 4 6 gpm 15 23 b 8 GPM Range 7 9 gpm 26 5 34 Ipm Slowly turn the restrictor valve clockwise while watching the pressure gauge The flow rate shown above in step 6 should stay at the selected flow range When the pressure reaches 2100 2200 1 145 152 bar the relief valve should begin to open The pressure at which the relief valve just begins to open is commonly referred to as the cracking pressure At the cracking pressure the flow rate should start to drop because the relief valve is allowing fluid to bypass to the hydraulic reservoir The cracking pressure is preset at the factory and if it is not within the above range 2100 2200 psi the relief valve must be re set as follows The relief valves are located on the control block which is directly behind the couplers on the dash panel See item 10 pg 22 for location Use a wrench to loosen the nut on the relief valve Use an Allen wrench to adjust the relief valve Turn clockwise to raise the pressure and counterclockwise to reduce the pressure Tighten the nut and
28. the throttle control lever to the left 5 GPM setting Once the unit starts and is warmed up the lever can be moved to the 8 GPM setting if desired Turn the Ignition Switch to the START position After the engine starts release the switch Allow the engine to warm up Turn on the flow to the tool by lifting the Flow Control Levers up into the on position lift both levers if running two circuits two Tools SHUTDOWN 1 2 Ensure the flow control levers are in the OFF position Down Move the Ignition Switch to the OFF position STANLEY COLD WEATHER STARTUP 1 Use the procedures described under STARTUP and then follow the procedure below 2 fluids are thicker in cold weather Therefore it is recommended that the engine be run at low idle long enough to bring the fluid temperature up to a minimum of 50 F 10 C 3 Ifthe tools and tool hoses are cold it is recommended to allow hydraulic fluid to circulate through the tool hoses until warm before using the tool ENGINE MAINTENANCE Follow the maintenance schedule and general maintenance instructions and emissions control maintenance in the engine operators manual furnished with the power unit Fuel system emissions maintenance e Check the fuel system emissions components once a year to verify that the components are in good condition and do not show signs of leakage If leakage is found replace part e Check fuel lines
29. u i HANDLE ASSEMBIY s eoz uF BRACKET 7 206974 1 UPPER FRAME ASSEMBLY SEE NOTE 24 gt HP TWIN8 User Manual STAN LEY HYDRAULIC FILTER ASSY HYDRAULIC TANK COOLER CONNECTIONS gt STAN LEY HP TWIN8 User Manual 4 25 CONTROL BLOCK ASSEMBLY P N 203051 INCLUDES THE FOLLOWING Item 5 thru 8 13 18 20 25 27 thru 29 and 53 s oasis 2 TRETANNING RING s omme a senes s HOSE CLAMP 26 gt HP TWIN8 User Manual Connects to lower fitting on cooler see JJ pg 22 Connects to upper fitting on cooler see FF pg 22 22 7 P 38 up 2 P d 10 SAE fittings EN Te to pump am 39 20606 27 28 29 30 32 33 34 36 37 38 STANLEY FUEL TANK VAPOR LINE CONNECTION HYDRAULIC TANK BEC LIME HH TO ENGINE SEE CONNECTION GG PAGE 15 HYDRAULIC OIL FILTER P N TO FUEL FILTER PEE 40408 NOT PICTURED OF CONTROL BLOCK ITEM 26 CONNECTS TO TANK MOUNT BRACKET item 52 pg 26 NE E NJ CONNECTS TO CONNECTS TO nn ET MEET EEE EET SIGHT GAUGE 5 WITEMP s 203253 s caPscrew LEY HP TWIN8 User Manual 4 27 STANLEY Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie Oregon 97267 5698 USA 503 659 5660 Fax 503 652 1780 www stanleyhydraulics com
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