Post Driver
Contents
1. Remote ON OFF Valve Model 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 OOOO Read Wear Wear Prud The Breathing Hearing Manual Protection Protection Preis Copyright 2001 The Stanley Works OPS amp SERVICE USA 17472 01 03 Ver 2 PD45 Post Driver Valve In Handle Model Safety Operation and Service User s Manual STANLEY Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie OR 97267 5698 USA Phone 503 659 5660 Fax 503 652 1780 Table of Contents PD45 Post Driver SERVICING THE PD45 Post Driver This manual contains Safety Operation Service and Troubleshooting information 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 DANGER warning on the cover and the SAFETY warning below Copyright 2001 The Stanley Works All rights reserved Under copyright law this document may not be copied in whole or in part without the prior written consent of The Stanley Works This exception does not permit copies to be made for others whether or not sold Under the law copying includes translating into another language format or medium This copyright notice must appear on any permitted copies Specifications Safety Symb2. Tool gets hot Hot fluid going through tool Check power unit Be sure flow rate is not too high causing part of the fluid to go through the relief valve Provide cooler to maintain proper fluid temperature 140 F 60 C max Check relief valve a Eliminate Eliminate flow control devices control devices Oil coe on Lower piston seal failure Replace seal post Refer to Page 7 Hydraulic Power Source Check 13 Charging the Accumulator Accumulator Testing Procedure To check or charge the accumulator the following equipment is required e Accumulator tester Part Number 02835 e Charging kit assembly Part Number 31254 includes a regulator hose and fittings e NITROGEN bottle with an 800 psi 56 bar minimum charge A Remove the charging valve plug from the post driver B Holding the chuck end of Stanley tester Part Number 02835 turn the gauge fully counter clockwise to ensure the stem inside the chuck is completely retracted C Thread the tester onto the charging valve of the tool accumulator Do not advance the guage end into the chuck end Turn as a unit Seat the chuck on the accumulator charging valve and hand tighten only D Advance the valve stem by turning the guage end clockwise until pressure is read on the guage charging pressure should be 500 700 psi 34 38 bar E Ifpressure is OK unscrew the gauge end from the chuck to retract the stem then unscrew the entire test
3. 20387 Plunger 12100 Steel Ball 3 8 Dia G 00899 HHCS 1 4 20 UNC x 1 2 G 20386 Cover Plate 04374 Lock Nut 5 8 18 20390 Lift Strap 20384 Spacer 370351 HHCS 5 8 11 UNC x 1 3 4 20385 Pilot Ring 02003 O Ring 2 013 R16 20398 Support Washer 3 4 Tr 08016 Retaining Ring 3 4 Ex 12139 Side Rod 08087 Side Rod 00293 O Ring 2 115 R170 04056 Rod Wiper 5 16 x 9 160 01362 O Ring 2 011 R160 04057 Bushing 04077 Valve Spool OC 04058 Spring 07479 Accumulator Diaphragm 350000 Straight Thread 45 EL 15195 Hose Assy 15 in 15196 Hose Assy 14 in 04381 Back Up Ring 04379 O Ring 2 145 R170 04378 Porting Block 07481 Piston 15191 Adaptor Block 04387 Rod Wiper 04780 Back up Washer 04386 Cup Seal 02022 O Ring 2 228 R160 J O O1 B ND n 04383 Flow Sleeve Tube A supplied With Item 1 07385 Flow Sleeve B Supplied With Item 24 04605 Push Pin 02900 Roll Pin 04382 Automatic Valve 04571 Push Pin Q Denotes Part in Seal Kit 07480 Automatic Valve Body 11588 Accumulator Valve Block 20396 Valve Top Plate 20392 Trigger Assy 00038 Nut 1 4 20 Plain 20399 Oval Pt Set Screw 1 4 12143 Upper Anvil Stop 15183 Anvil Bushing 12146 Spring 15189 Anvil 15182 Handle Bar 15194 Set Screw 15170 Post Driver Foot 20388 Valve Actuator Housing 48962 Decal Name Tag LPH30 24059 Male Coupler 24058 Female Coupler O Ring O Ring O Ring For item 1 O Ring For item 24 O Ring Rod Wiper O Ring Backup Ring
4. This Tag attached to Certified Non Conductive hose shown smaller than actual size p n 27987 1 FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE WHEN ING 4 HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING ABRASION CUTTING OR CONTACT HYDRAULIC TOOLS ON OR NEAR ELECTRIC ES MAY RESULT IN DEATH OR SERIOUS INJUR WITH HIGH TEMPERATURE SURFACES DO NOT USE IF KINKED DO NOT USE HOSE TO PULL OR FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY TRAINED IN LIFT TOOLS POWER UNITS ETC CORRECT PROCEDURES REQUIRED FOR Wonk ON OR AROUND ELECTRIC LINES CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAMAGE TO BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE ON OR NEAR COUPLINGS IF ANY OF THESE CONDITIONS EXIST REPLACE THE HOSE IMMEDIATELY ELECTRIC LINES WIPE THE ENTIRE LENGTH OF THE HOSE AND FITTINGS WITH A CLEAN NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE DRY ABSORBENT CLOTH TO REMOVE DIRT AND MOISTURE AND TEST HOSE FOR MAXIMUM ALLOWABLE CURRENT LEAKAGE IN ACCORDANCE WITH SAFETY DEPARTMENT INSTRUCTIONS 6 AFTER EACH USE STORE IN A CLEAN DRY AREA DO 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 POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT CONTACT DURING USE CONTACT Sr THE BURST CAN CAUSE BODILY INJECTION AND SEVERE PERSONAL INJURY SEE OTHER SIDE
5. Cup Seal Rod Wiper 18 i REMOTE ON OFF VALVE MODEI JANUARY 2003 17 NOTE Use Part Number and Description when ordering A Supplied With Item 34 O Denotes Part in Seal Kit O Ring O Ring O Ring For item 1 O Ring For item 24 O Ring Rod Wiper O Ring Backup Ring Cup Seal Rod Wiper PD45131 Item Part J O O1 B ND 15190 11588 04374 00293 15188 07493 20499 07479 04381 04379 04378 04571 04382 04605 04383 12139 02022 04386 04780 04387 370351 15191 15189 15170 15182 15194 04058 07480 07481 07485 12146 12143 15183 350000 15195 15196 00026 02900 15197 03044 19693 13568 13567 01003 10536 24058 24059 16070 38631 38629 11499 PD45 Parts List Description Top Plate Accumulator Valve Block Locknut 5 8 18 O ring 11 16x7 8x3 32 115 R170 Valve Spool Male O ring Plug Charge Valve Accumulator Diaphragm Back Up Ring O ring 2 9 16x2 3 4x3 32 R170 Porting Block Push Pin Automatic Valve Push Pin Flow Sleeve Tube Side Rod O Ring 2 1 4x2 1 2x1 8 228 R160 Cup Seal Washer Rod Wiper Capscrew 5 8 11x1 3 4 Hex HD Adapter Block Anvil Post Driver Foot Handle Bar Set Screw 3 8 16 x 1 2 Spring Automatic Valve Body Piston Flow Sleeve Spring Upper Anvil Stop Anvil Bushing 45 Elbow 8 V50X S Hose Assy Aeroquip FG1055HHG0150 Hos
6. LOCAL SAFETY REGULATIONS Enter any local safety regulations here Keep these instructions in an area accessible to the operator and maintenance personnel General Safety Instructions Read the Manual Tool operators and maintenance personnel must always comply with the safety precautions ca given in this manual and on the stickers and tags attached to the tool and hose Q These safety precautions are given for your safety Review them carefully before operating Perd the tool and before performing general maintenance or repairs Supervising personnel should develop additional precautions relating to the specific work area and local safety regulations If so place the added precautions in the space provided Wise Ean Wear Dust Mask on page 5 Protection This tool will provide safe and dependable service if operated in accordance with the instructions given in this manual Read and understand 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 A gt gt e b be Operator must start in a work area without bystanders The operator must be familiar with all prohibited work areas such as excessive slopes and dangerous terrain conditions Establish a training program for all operators to ensure safe operations Do not operate the tool unless thoroughly trained or under the supervision of an instructor Always w
7. hydraulic hose must be equal to or higher than the relief valve setting on the hydraulic system These are general hydraulic system requirements See tool specifications page for tool specific requirements HTMA Requirements Tool D Category 8 Hydraulic System Requirements Type Type II Type Ill Type RR Flow rate 4 6 GPM 15 23 7 9 GPM 26 34 11 13 GPM 42 49 9 10 5 GPM 34 40 Tool Operating Pressure lpm Lpm lpm lpm at thie power supply outst 2000 psi 138 bar 2000 psi 138 bar 2000 psi 138 ba 2000 psi 138 bar yom relief eee 2100 2250 2100 2250 2100 2250 2200 2300 at tha power supply outet 145 155 bar 145 155 bar 145 155 bar 152 159 bar Maximum back pressure at tool end of the return hose 250 psi 250 psi 250 psi 250 psi 17 bar 17 bar 17 bar 17 bar Measured at a max fluid viscosity of at min operating temperature 400 SSU 400 SSU 400 SSU 400 SSU 82 centistokes 82 centistokes 82 centistokes 82 centistokes Temperature Sufficient heat rejection capacity to limit max fluid temperature to 140 F 60 C 140 F 60 C 140 F 60 C 140 F 60 C at max expected ambient temperature Min cooling capacity 3 hp 2 24kW 5 hp 3 73 kW 7 hp 5 22 kW 6 hp 4 5 kW at a temperature difference of 40 F 22 C 40 F 22 C 40 F 22 C 40 F 22 C between ambient and fluid temps NOTE Do not operate the tool at oil temperatures above 140 F 60
8. in 25 ft Ib 34 Nm increments to 75 ft Ib 100 Nm maximum 23 Install the handle bars using two 5 8 11 x 1 3 4 inch hex head capscrews Tighten the capscrews to 90 ft 1b 120 Nm Tighten the setscrews 24 Install the pigtail hose and valve assemblies 25 Remove the post driver from the vise Troubleshooting This section describes how to find and resolve problems users may experience If a situation occurs that is not covered call your Stanley Customer Service representative for assistance AWARNING Inspecting the tool or installing parts with the hydraulic hoses connected can result in severe personal injury or equipment damage To prevent accidental startup disconnect the hydraulic power before beginning any inspection or installation task Ifsymptoms of poor performance develop the following chart can be used as a guide to correct the problem When diagnosing faults in operation of the tool always check that the hydraulic power source is supplying the correct hydraulic flow and pressure to the tool as listed in the table Use a flowmeter known to be accurate Check the flow with the hydraulic oil temperature at least 80 F 27 C Symptom Possible Cause Solution Tool does not run Power unit not functioning Check power source for proper flow and pressure 7 9 gpm 26 34 lpm 2000 psi 140 bar Couplers or Hoses blocked Pressure and return line hoses Be sure hoses are connected to reversed at ports their pr
9. performance deficiency attributable to excess hydraulic pressure excess hydraulic back pressure excess hydraulic flow excessive heat or incorrect hydraulic fluid REPAIRS OR ALTERATIONS Any failure or performance deficiency attributable to repairs by anyone which in Stanley s sole judgement caused or contributed to the failure or deficiency MIS APPLICATION Any failure or performance deficiency attributable to mis application Mis application is defined as usage of products for which they were not originally intended or usage of products in such a matter which exposes them to abuse or accident without first obtaining the written consent of Stanley PERMISSION TO APPLY ANY PRODUCT FOR WHICH IT WAS NOT ORIGINALLY INTENDED CAN ONLY BE OBTAINED FROM STANLEY ENGINEERING WARRANTY REGISTRATION STANLEY ASSUMES NO LIABILITY FOR WARRANTY CLAIMS SUBMITTED FOR WHICH NO TOOL REGISTRA TION IS ON RECORD In the event a warranty claim is submitted and no tool registration is on record no warranty credit will be issued without first receiving documentation which proves the sale of the tool or the tools first date of usage The term DOCUMENTATION as used in this paragraph is defined as a bill of sale or letter of intent from the first retail customer A WARRANTY REGISTRATION FORM THAT IS NOT ALSO ON RECORD WITH STANLEY WILL NOT BE ACCEPTED AS DOCUMENTATION NO ADDITIONAL WARRANTIES OR REPRESENTATIONS This limited warranty and the oblig
10. square and up to 2 5 8 inch diameter round post without requiring adapters If you are driving one of these types of post orient the post into the tightest fit in the post driver foot 2 Ifyou are driving smaller square or round post insert the adapter to the post driver foot using two 1 2 hex head capscrews Connecting Hoses 1 Wipe all hose couplers with a clean lint free cloth before making connections 2 Connect the hoses from the hydraulic power source to the tool fittings or quick disconnects It is a good practice to connect return hoses first and disconnect them last to minimize or avoid trapped pressure within the tool 3 Ifhose couplers are used observe the arrow on the coupler to ensure that the flow is in the proper direction The female coupler on the tool hose is the inlet pressure coupler 4 Move the hydraulic power source on off control valve to the ON position to operate the tool Note If uncoupled hoses are left in the sun pressure increase inside the hoses may make them difficult to connect When possible connect the free ends of the operating hoses together Tool Operation 1 Observe all safety precautions 2 Install the appropriate adapter as required 3 Place the post driver foot firmly on the surface to be driven 4 Press the lever assembly on handle to start the post driver Note On Remote ON OFF Valve Models Place the post driver on off control valve in The ON position
11. AD OPERATION MANUAL AND SAFETY INSTRUCTIONS FOR THIS The SAFETY TAG P N 15875 shown at right smaller TOOEBEROREISINGITS than actual size is attached to the tool when shipped Je QURE AND REPAIR from the factory Read and understand the safety TANLEY AND DESCRIBED INTHE instructions listed on this tag before removal We x Fi TAG TO BE REMOVED ONLY BY TOOL suggest you retain this tag and attach it to the tool OPERATOR SEE OTHER SIDE 15875 whennotinuse READ OPERATION MANUAL AND SAFETY INSTRUCTIONS FOR THIS TOOL BEFORE USING IT USE ONLY PARTS AND REPAIR PROCEDURES APPROVED BY STANLEY AND DESCRIBED IN THE OPERATION MANUAL TAG TO BE REMOVED ONLY BY TOOL OPERATOR SEE OTHER SIDE 15875 Hydraulic Hose Requirements HOSE TYPES Hydraulic hose types authorized for use with Stanley Hydraulic Tools are as follows Q Certified non conductive Wire braided conductive Fabric braided not certified or labeled non conductive Hose listed above is the only hose authorized for use near electrical conductors Hoses O and listed above are conductive and must never be near electrical conductors HOSE SAFETY TAGS To help ensure your safety the following DANGER tags are attached to all hoses purchased from Stanley Hydraulic Tools DO NOT REMOVE THESE TAGS If the information in a tag is illegible because of wear or damage replace the tag immediately A new tag may be obtained at no charge from your Stanley Distributor
12. Ban SEE OTHER SIDE GE DO NOT REMOVE THIS TAG OVL SIHL SAOWSY LON OG ey Side 1 Side 2 This Tag attached to Conductive hose shown smaller than actual size p n 29144 1 DO NOT USE THIS HYDRAULIC HOSE ON OR NEAR ELECTRIC LINES THIS HOSE IS NOT CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAMAGE TO LABELED OR CERTIFIED AS NON CONDUCTIVE USING THIS HOSE ON OR NEAR ELECTRIC LINES COUPLINGS IF ANY OF THESE CONDITIONS EXIST REPLACE THE HOSE IMMEDIATELY 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 TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND ELECTRIC LINES AFTER EAGE USE STORE NA CLEAN DRY AREA DO 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 CONTACT DURING USE CONTACT AT THE BURST CAN CAUSE BODILY INJECTION AND SEVERE PERSONAL INJURY HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING ABRASION CUTTING OR CONTACT WITH HIGH TEMPERATURE SURFACES DO NOT USE IF KINKED DO NOT USE HOSE TO PULL OR LIFT TOOLS POWER UNITS ETC SEE OTHER SIDE Ban SEE OTHER SIDE DS DO NOT REMOVE THIS TAG SVL SIHL SAOWSY LON OG y Side 1 Side 2 HOSE PRESSURE RATING The rated working pressure of the
13. C Operation at higher temperatures can cause operator discomfort at the tool Filter 25 microns 25 microns 25 microns 25 microns Min full flow filtration 30 GPM 114 Ipm 30 GPM 114 1pm 30GPM 114Ipm 30 GPM 114 Ipm sized for flow of at least For cold temp startup and max dirt holding capacity Hydraulic fluid Petroleum based premium grade anti wear non conductive Viscosity at min and max operating temps 100 400 SSU 100 400 SSU 100 400 SSU 100 400 SSU 20 82 centistokes 20 82 centistokes 20 82 centistokes 20 82 centistokes 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 NOTE These are general hydraulic system requirements See tool Specification page for tool specific requirements Operating Instructions Pre Operation Procedures Check the power source 1 Using a calibrated flowmeter and pressure guage check that the hydraulic power source develops a flow of 7 9 gpm 26 34 lpm at 2000 psi 140 bar 2 Make certain the hydraulic power source is equipped with a relief valve set to open at 2100 2250 psi 140 bar Installing Adapters 1 The post hammer is designed to drive No 1 thought No 4 sign post 2 1 2 inch
14. STED FOR ELECTRIC CURRENT LEAKAGE IN ACCORDANCE WITH YOUR SAFETY DEPARTMENT INSTRUCTIONS 2 A HYDRAULIC LEAK OR BURST MAY CAUSE OIL TRU EGTIONINTO THE BOD OR DAUSE OTHER SEVERE PERSONAL A DO NOT EXCEED SPECIFIED FLOW A PRESSURE FOR THIS TOOL EXCESS FLOW PRESSURE MAY CAUSE A LEAK OR BURST B DO NOT EXCEED RATED WORKING PRESSURE OF HYDRAULIC HOSE USED WITH THIS TOOL EU v PRESSURE MAY CAUSE A LEAK OR D DO NOT LIFT OR CARRY TOOL BY THE HOSES DO NOT ABUSE HOSE DO NOT USE KINKED TORN OR DAMAGED HOSES 3 MAKE SURE HYDRAULIC HOSES ARE PROPERLY CONN ECTED TO THE TOOL BEFORE PRESSURIZING SYSTEM SYSTEM PRESSURE HOSE MUST ALWAYS BE CONNECTED TO TOOL IN PORT SYSTEM RETURN HOSE MUST ALWAYS BE CONNECTED AT TOOL OUT PORT REVERSING CONNECTIONS MAY CAUSE REVERSE TOOL OPERATION WHICH CAN CAUSE SEVERE PERSONAL INJURY DO NOT CONNECT CLOSED CENTER OPEN CENTER HYDRAULIC SYSTEMS CAUSE EXTREME SYSTEM HEAT AND 0 PERSONAL INJURY DONOT CONNECT OPEN CENTERTOOLSTO CLO SE D CE NT ER HYDRAULIC SYSTEMS THIS MAY RESULT IN LOSS OF OTHER HYDRAULIC FUNCTIONS POWERED BY THE SAME SYSTEM AND OR SEVERE PERSONAL INJURY 5 BYSTANDERS MAY BE INJURED IN YOUR WORK AREA KEEP BYSTANDERS CLEAR OF YOUR WORK 6 WEAR HEARING EYE FOOT HAND AND HEAD PROTECTION 7 TO AVOID PERSONAL INJURY OR EQUIPMENT DAMAGE ALL TOOL REPAIR MAINTENANCE AND SERVICE MUST BE PERFORMED BY AUTHORIZED AND PR OP ER LY TRAINED PERSONNEL IMPORTANT IMPORTANT RE
15. an arbor press and an aluminum disc or accumulator cylinder puller Part Number 05640 to protect the flow sleeve push the flow sleeve with seven holes on its end facing up until it is FLUSH with the tube Be sure to lubricate the entire bore of the flow sleeve tube prior to assembly 5 Install four 1 4 x 1 1 2 inch 6 4 mm x 38 mm push pins with ground face end up in the flow sleeve 6 Install two 3 16 x 1 1 4 inch 5 mm x 32 mm push pins with ground face end up in the automatic valve body Install the automatic valve small diameter first into the automatic valve body IMPORTANT The push pins must be installed such that the flat ground faces bear on the flange of the automatic valve 7 Place the automatic valve body with proper roll pin alignment and with the side holes up on top of the flow sleeve Allow the automatic valve to drop and pilot into the bore of the flow sleeve Service Instructions Continued 8 Use an aluminum disc or accumulator cylinder puller Part Number 05640 to protect parts and push the automatic valve body into the flow sleeve tube until the valve body shoulder stops on top of the flow sleeve tube 9 Install the piston small end first into the flow sleeve assembly from the automatic valve body end 10 Install the porting block into the flow sleeve assembly with proper roll pin alignment 11 Place the accumulator valve block in a bench vise being careful not to over tighten and
16. ation of Stanley thereunder is in lieu of all other warranties expressed or implied including merchantability or 20 For additional Sales amp Service information contact STANLEY Stanley Hydraulic Tools Division of the Stanley Works 3810 SE Naef Road Milwaukie OR 97267 USA Tel 503 659 5660 Fax 503 652 1780
17. d or incompletely assembled tool To avoid personal injury or equipment damage all tool repair maintenance and service must only be performed by authorized and properly trained personnel Do not exceed the rated limits of the tool or use the tool for applications beyond its design capacity Always keep critical tool markings such as labels and warning stickers legible Always replace parts with replacement parts recommended by Stanley Hydraulic Tools Check fastener tightness often and before each use daily Tool Decals amp Tags AName Tag Sticker is attached to the tool Never exceed the flow and pressure levels specified on this sticker The information listed on the name tag sticker must be legible at all times Replace this sticker if it becomes worn or damaged A replacement is available from your local Stanley distributor M Stanley Hydraulic Tools Division of the Stanley Works 3810 S E NAEF ROAD Milwaukie Oregon 97267 U S A SSdHd N39OMLIN ISd 009 3V8 Zr OHO YOLVINNNDOV ISd 0002 0051 Nd9 6 NdI 46 92 MOT M43AIMQ IS0d Sydd yg 0y S0I 1 FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTI FIED AS NON CONDUCTIVE WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRICAL LINES MAY RESULT IN DEATH OR SERIOUS INJURY BEFORE USING HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE ON OR NEAR ELECTRIC LINES BE SURE THE HOSE IS MAINTAINED AS NON CONDUC TIVE THE HOSE SHOULD BE REGULARLY TE
18. distort the block 12 Push the flow sleeve assembly into the accumulator valve block It may be necessary to tap on the end of the flow sleeve tube with a rubber or plastic hammer Be sure to tap on opposite sides to make sure the assembly seats properly 13 Remove the accumulator valve block from the vise and clamp on the flow sleeve tube with the IN and OUT ports facing up 14 Replace in the following order the spring and valve spool into the valve spool bore 15 Install the bushing two o rings and rod wiper on the valve spool 16 Install the four balls and plunger in the valve actuator housing Thoroughly lubricate the balls with multipurpose grease prior to installation Install the cover plate using the two 1 4 20 x 1 2 hex head capscrews 17 Apply a light coating of WD 40 lubricant to the accumulator diaphragm and install in the accumulator bore 18 Slide the adapter block post driver foot assembly over the piston Align the handle bar mounting bosses 90 from the hose ports and seat the assembly into the flow sleeve tube with a plastic or rubber hammer 19 Place the top plate onto the accumulator valve block 20 Install the o ring and pilot ring in the bore of the valve top plate 11 21 Install the spacer strap and assembled actuator housing on the two side rods as shown in the exploded view illustration at the back of this manual 22 Secure the top plate Tighten alternate side rods
19. e Assy Aeroquip FG1055HHG0140 O ring Roll Pin Name Tag Hex Nipple 3 8 NPT Danger Sricker Back Up Ring A5 568 015 O ring 9 16x11 16x1 16 015 R24 On Off Valve Button Selector Screw Female Coupler 3 8 NPT Male Coupler 3 8 NPT Retaining Ring Valve Spool Valve Body Assy Adaptor 1 2 SAE to 3 8 NPTF QTY PO HS Sa mm mm AH Ha RH aH Ha a ha ha D Ha Pp wy AH AH D _ D ND NN ND ND NN 18 Accessories NOTE Use Part Number and Description when ordering Service Tools NOTE Use Part Number and Description when ordering 19 Part Part Description Adapter 1 3 4 in Square Post Adapter 2 in Round Pipe Adapter 2 1 4 in Square Post Adapter 2 in Square Post Description Tamper Sleeve Tool O ring Tool Kit Flow Sleeve Removal Tube Flow Sleeve Removal Tool Accumulator Cylinder Puller Warranty Stanley Hydraulic Tools hereinafter called Stanley subject to the exceptions contained below warrants new hydraulic tools for a period of one year from the date of sale to the first retail purchaser or for a period of 2 years from the shipping date from Stanley whichever period expires first to be free of defects in material and or workmanship at the time of delivery and will at its option repair or replace any tool or part of a tool or new part which is found upon examination by a Stanley authorized service outlet or by Stanley s factory
20. e flow sleeve removal tube and continue pushing on the flow sleeve until it drops out 15 Remove the cup seal washer and rod wiper from the adapter block using proper o ring tools to avoid damage to sealing surfaces 16 Remove two 5 8 11 x 1 3 4 hex head capscrews and slowly lift the adapter block off of the post driver foot 17 Remove the spring 18 Remove the anvil from the post driver foot 19 Loosen the two 3 8 16 x 1 2 setscrews and remove the handle bars from the post driver foot if necessary PRIOR TO ASSEMBLY Clean all parts with a degreasing solvent Ensure that all seals exposed during disassembly are replaced with new parts Apply clean grease or o ring lubricant to all parts during assembly 10 Obtain Seal Kit Part Number 04595 so that all seals exposed during disassembly can be replaced Note For orientation of parts identified in the following procedures see the parts list exploded view illustration at the back of this manual POST DRIVER ASSEMBLY Note Steps preceded by an asterisk apply to valve in handle models only 1 Coat the anvil with anti seize compound and install the anvil into the post driver foot Place the spring on the anvil 2 Using Loctite 242 secure the adapter block to the post driver foot with two 5 8 11 x 1 3 4 inch hex head capscrews Tighten the capscrews to 90 ft Ib 120 Nm 3 Install the rod wiper washer and cup seal into the adapter block 4 Using
21. e tool Obtain Seal Kit Part Number 04595 to replace all seals exposed during disassembly Note the orientation of the seals before removing them Install new seals in the same position as the original seals POST DRIVER DISASSEMBLY Note Steps preceded by an apply to valve in handle models only 1 Secure the post driver in a bench vise with the IN and OUT ports up clamping on the flow sleeve tube between the side rods Soft vise jaws are recommended 2 Remove the pigtail hose assemblies Note The post driver is full of hydraulic fluid and will drip from the ports when the hoses are removed 3 Remove the male o ring plug from the top plate and Discharge the Accumulator 9 WARNING Discharge Accumulator 4 Spread the retaining ring and slide out the lever assembly Be careful not to lose the washer or retaining ring 5 Remove two 5 8 11 x 1 3 4 inch hex head capscrews and four side rods securing the top plate to the accumulator valve block 6 Remove the top plate to expose the accumulator diaphragm and valve spool 7 Remove the valve actuator housing spacer and lift strap 8 Remove the accumulator diaphragm valve spool and spring from the accumulator block taking care not to damage the valve spool s surfaces 9 Remove the rod wiper two o rings and bushing from the valve spool 10 Remove the accumulator valve block from the flow sleeve tube by tapping on the unde
22. ear safety equipment such as goggles head protection and safety shoes at all times when operating the tool Do not inspect or clean the tool while the hydraulic power source is connected Accidental engagement of the tool can cause serious injury Do not operate this tool without first reading the Operating Instructions Do not install or remove this tool while the hydraulic power source is connected Accidental engagement of the tool can cause serious injury Never operate the tool if you cannot be sure that underground utilities are not present Underground electrical utilities present an electrocution hazard Underground gas utilities present an explosion hazard Other underground utilities may present other hazards Do not wear loose fitting clothing when operating the tool Loose fitting clothing can get entangled with the tool and cause serious injury Supply hoses must have a minimum working pressure rating of 2500 psi 175 bar Be sure all hose connections are tight The hydraulic circuit control valve must be in the OFF position when coupling or uncoupling the tool Wipe all couplers clean before connecting Failure to do so may result in damage to the quick couplers and cause overheating Use only lint free cloths Do not operate the tool at oil temperatures above 140 F 60 C Operation at higher oil temperatures can cause operator discomfort and may cause damage to the tool Do not operate a damaged improperly adjuste
23. epair actions which if not strictly followed could result in a life threatening situation bodily injury or damage to equipment IMPORTANT unb 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 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 may result in minor or moderate injury This signal word indicates a potentially hazardous situation which if not avoided may result in property damage This signal word indicates a situation which if not avoided will result in damage to the equipment This signal word indicates a situation which if not avoided may result in damage to the equipment Always observe safety symbols They are included for your safety and for the protection of the tool SOME HYDRAULIC FLUIDS ARE FLAMMABLE NEVER ALLOW THESE HYDRAULIC FLUIDS TO COME IN CONTACT WITH AN OPEN FLAME IF A HOSE WERE TO BURST OR IF A TOOL LEAK OCCURS NEXT TO AN OPEN FLAME THESE HYDRAULIC FLUIDS WILL IGNITE AND COULD RESULT IN SERIOUS INJURY OR DEATH
24. er assembly from the tool accumulator charging valve Charging Valve Accumulator Tester P N 02835 Maintenance If pressure is low charge the accumulator as described in the following section F Install the charging valve cap or plug Accumulator Charging Procedure A Perform steps A through D of the accumulator testing procedure above B Connect the chuck of the charging assembly to the charging valve on the accumulator tester or if preferred remove the tester from the tool charging valve and connect the charging assembly chuck directly to the tool charging valve C Adjust the regulator to the charging pressure of 600 psi 42 bar Note It may be necessary to set the regulator at 650 to 700 psi 45 48 bar to overcome any pressure drop through the charging system D Open the valve on the charging assembly hose E When the accumulator is fully charged close the valve on the charging assembly hose and remove the charging assembly chuck from the accumulator tester of tool charging valve F Ifthe accumulator tester has been used be sure to turn the gauge end fully counterclockwise before removing the tester from the charging valve of the tool G Replace the o ring plug Location Of Charging Valve 14 PD45 Parts Illustration PD45132 15 PD45 Parts List PD45132 NOTE Item Part Description QTY Use Part Number and 07493 O Ring Plug Male Description when ordering 20499 Charge Valve
25. in Milwaukie Oregon to be DEFECTIVE IN MATERIAL AND OR WORKMANSHIP EXCEPTIONS FROM WARRANTY NEW PARTS New parts which are obtained individually are warranted subject to the exceptions herein to be free of defects in material and or workmanship at the time of delivery and for a period of 6 months after the date of first usage Seals and diaphragms are warranted to be free of defects in material and or workmanship at the time of delivery and for a period of 6 months after the date of first usage or 2 years after the date of delivery whichever period expires first Warranty for new parts is limited to replacement of defective parts only Labor is not covered FREIGHT COSTS Freight costs to return parts to Stanley if requested by Stanley for the purpose of evaluating a warranty claim for warranty credit are covered under this policy if the claimed part or parts are approved for warranty credit Freight costs for any part or parts which are not approved for warranty credit will be the responsibility of the individual SEALS amp DIAPHRAGMS Seals and diaphragms installed in new tools are warranted to be free of defects in material and or workmanship for a period of 6 months after the date of first usage or for a period of 2 years from the shipping date from Stanley whichever period expires first CUTTING ACCESSORIES Cutting accessories such as breaker tool bits are warranted to be free of defects in material and or workmanship at the time of deli
26. ols General Safety Instructions Tool Decals and Tags Hydraulic Hose Requirements HTMA Requirements Operating Instructions Service Troubleshooting Maintenance Parts Illustration Parts List Accessories Warranty 14 15 amp 17 16 amp 18 19 20 SAFETY FIRST It is the responsibility of the operator and service technician to read rules and instructions for safe and proper operation and maintenance A cautious worker using common sense is the greatest safety device Weight Standard Weight Extended anvil Pressure Range Flow Range Optimum Flow Couplers 7 9 65 lbs 29 5 kg 71 lbs 32 kg 2000 psi 140 bar gpm 26 34 Imp 8 gpm 30 Ipm HTMA Flush Face Per NFPA T3 20 15 ISO 16028 Width Across Handles System Type 3 8 female pipe in 76 cm 10 1 8 in 25 7 cm open center NOTE Specifications Port Size SAE 8 O Ring Hose Whips O Yes Capacity 2 3 and 4 Ib ft U Channel Sign Post 3 and 4 Strong Back Heavy Duty U Channel Sign Post 1 Delineator Post 2 1 2 in 63 5 mm Square Post 2 5 8 in 67 mm Round Post HTMA Class II 7 9 gpm 2000 psi Weights dimensions and operating specifications listed are subject to change without notice Where specifications are critical to your application please consult the factory SAFETY SYMBOLS Safety symbols and signal words as shown below are used to emphasize all operator maintenance and r
27. oper ports Mechanical failure of piston or Disassemble post driver and automatic valve inspect for damaged parts Tool does not hit Power unit not functioning Check power unit for proper flow effectively and pressure 7 9 gpm 26 34 lpm 2000 Em 140 bar Couplers or hoses blocked or hoses blocked Remove restriction restriction Low accumulator charge pressure Recharge accumulator Replace hose will pulse more than normal diaphragm if charge loss continues Fluid too hot above 140 F 60 C Provide cooler to maintain proper oil n 130 F 55 C maximum The anvil is not sliding freely in the Remove clean lubricate and post driver foot replace anvil as required continued Refer to Page 7 Hydraulic Power Source Check 12 Troubleshooting Symptom Possible Cause Solution Tool operates Low gpm supply from power unit Check power source for proper slow flow 7 9 gpm 26 64 lpm High backpressure Check hydraulic system for excessive backpressure over 250 psi 17 bar Orifice blocked Fluid too hot above 140 F 60 C Check power source for proper or too cold below 60 F 16 C fluid temperature Bypass cooler to warm fluid up or provide cooler to maintain proper temperature Relief valve set too low Adjust relief valve to 2100 2250 psi 145 155 bar The anvil is not sliding freely in Remove clean lubricate and the post driver foot replace as required
28. rside of the valve block with a plastic or rubber hammer Tap on alternate sides to ensure the valve block comes out straight without binding 11 Remove the piston from the flow sleeve assembly 12 Clamp the accumulator valve block in a soft jaw vise with the IN and OUT ports pointing up IMPORTANT Do not over tighten the vise and distort the valve block 13 Remove the porting block from the accumulator valve block with 3 8 16 threaded slide hammer or tamper sleeve tool Part Number 01120 14 To disassemble the flow sleeve assembly proceed as follows A Remove the piston if not previously removed Service Instructions Continued B Place the flow sleeve assembly automatic valve body down on the flow sleeve removal tool part Number 04919 which in turn is placed on the flow sleeve removal tube Part Number 04910 C Using an arbor press and an aluminum disc to protect the flow sleeve push on the flow sleeve to remove the automatic valve body from the flow sleeve tube IMPORTANT Use a rag in the bottom of the removal tube to protect the auto matic valve body when it drops out D The automatic valve four 1 4 x 1 1 2 inch 6 4 mm push pins from the flow sleeve and two 3 16 x 1 1 4 inch 5 mm x 32 mm push pins from the automatic valve body will come out E To remove the flow sleeve from the flow sleeve tube remove the automatic valve body and associated parts from within th
29. to start the post driver Note Adequate down pressure is very important 5 When the post is fully set in the ground release the lever assembly on handle Cold Weather Operation If the post hammer is to be used during cold weather preheat the hydraulic fluid at low engine speed When using the normally recommended fluid fluid temperature should be at or above 50 F 10 C 400ssu 82 centistrokes before use Damage to the hydraulic system or post driver can result from use with fluid that is too viscous or thick Service Instructions Good maintenance practices will keep the post driver on the job and increase its service life The single most important maintenance practice is to keep the hydraulic fluid clean at all times Contaminated hydraulic fluid causes rapid wear and or failure of internal parts Follow the procedures contained in the HYDRAULIC SYSTEM REQUIREMENTS section of this manual to ensure peak performance from the post driver Never disassemble the post driver unless proper troubleshooting procedures have isolated the problem to an internal part Then only disassemble it to the extent necessary to replace the defective part KEEP CONTAMINANTS SUCH AS DIRT AND GRIT AWAY FROM INTERNAL PARTS AT ALLTIMES Always determine and correct the cause of the problem prior to reassembly Further wear and tool failure can result if the original cause is not corrected PRIOR TO DISASSEMBLY Clean the exterior of th
30. very only ITEMS PRODUCED BY OTHER MANUFACTURERS Components which are not manufactured by Stanley and are warranted by their respective manufacturers a Costs incurred to remove a Stanley manufactured component in order to service an item manufactured by other manufacturers ALTERATIONS amp MODIFICATIONS Alterations or modifications to any tool or part All obligations under this warranty shall be terminated if the new tool or part is altered or modified in any way NORMAL WEAR Any failure or performance deficiency attributable to normal wear and tear such as tool bushings retaining pins wear plates bumpers retaining rings and plugs rubber bushings recoil springs etc INCIDENTAL CONSEQUENTIAL DAMAGES To the fullest extent permitted by applicable law in no event will STANLEY be liable for any incidental consequential or special damages and or expenses FREIGHT DAMAGE Damage caused by improper storage or freight handling LOSS TIME Loss of operating time to the user while the tool s is out of service IMPROPER OPERATION Any failure or performance deficiency attributable to a failure to follow the guidelines and or procedures as outlined in the tool s operation and maintenance manual MAINTENANCE Any failure or performance deficiency attributable to not maintaining the tool s in good operating condition as outlined in the Operation and Maintenance Manual HYDRAULIC PRESSURE amp FLOW HEAT TYPE OF FLUID Any failure or
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