HP08 manual-complete-V1 - Tool
Contents
1. iode bala boite dA ai d totu dg 14 19 Safety iet e SO OU S DR RR du E E 2 3 SpecifiCatiOlls e edicta v ettet ttti 13 Tool Stickers amp Tags uia s eto ete c Se vesti eus 4 5 Troubleshooting ki oe RETI IRR RR RI TR es 12 Warranty a RP 20 SERVICING THE HP08 POWER UNIT This manual contains safety operation and routine maintenance instruc tions Stanley Hydraulic Tools recommends that servicing of hydraulic tools and power units other than routine maintenance must be performed by an authorized and certified dealer Please read the following warning 4 DANGER SERIOUS INJURY OR DEATH COULD RESULT FROM THE IMPROPER REPAIR OR SERVICE OF THIS EQUIPMENT REPAIRS AND OR SERVICE TO THIS EQUIPMENT MUST ONLY BE DONE BY AN AUTHORIZED AND CERTIFIED DEALER For the nearest authorized and certified dealer call Stanley Hydraulic Tools 1 800 972 2647 1 503 659 5660 and ask for a Customer Service Representative SAFETY 44 DANGER Do not operate this equipment or associated equipment until the following safety instruc tions have been thoroughly read and under stood Read this manual before installing operating or maintaining this equipment 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 equipment These safety precautions are given for your safety Review them carefully before operating the power unit and bef2. Sound Power evel au uu de enm or Or E eee AUD I ene ERR EE RE Lwa102 ACCESSORIES PART NO DESCRIPTION 41128 Spin on Filter 05008 25 feet of dual hydraulic hose less couplers 24069 HTMA Flush Face Coupler Set with 3 8 NPTF threads male amp female 24070 HTMA Flush Face Coupler Set with 1 2 NPTF threads male amp female 04182 Flow amp Pressure Tester 29085 Flow amp Pressure Tester with Digital Flow amp Temperature Readout 13 HP091523D PARTS LlST NOTE Use Part Number and Part Name when ordering FRAME CHASSIS ASSY ITEM DESCRIPTION PART NO QTY 1 Frame 41172 1 off 2 Rivet 41158 2 off 3 Washer 41204 2 off 4 Handle 41177 1 off 5 Chassis 41165 1 off 6 Chassis Plug 41119 4 off ra Bonded Foot 41130 2 off 8 Wheel 41118 2 off 9 Durlok Bolt 41164 4 off 10 Blanking Plug Bolt 41196 4 off 11 Spring Washer 41210 4 off 12 Universal Mounting Plate 41166 2 off 13 Spring Washer 41210 4 off 14 Set Screw 41198 4 off 15 Plain Washer 41205 4 off ITEM TANK ASSY DESCRIPTION Tank Suction Strainer Bonded Seal Blanking Plug Bolt Sight Glass Float Switch Cap Screw Shakeproof Washer Cowl Filler Breather Unit Set Screw Washer Gasket Pressure Gauge Pressure Gauge Seal Capillary Hose Rivet Oillevel label Nameplate Label HYD OIL Noise Label 102 Operator Warning Icons Label PART NO 41167 41127 41186 41196 41173 41136 41192 41208 41169 41
3. as follows Adjustment a Start engine with cable slack and check flow and pressure as detailed below b Offload the machine by operating the By pass lever c Adjustthe cable tightness by using the Adjuster item 10 until the engine speed drops to 1800 2200 rpm d Lock off Adjuster and check that engine reaches high speed when system pressure is raised e Repeatif settings are not as specified 11 TROUBLE SHOOTING SYMPTOM POSSIBLE FAULT ACTION Engine stops or will not start Fuel tap switched off Switch on fuel tap Fuel line blocked Clean filters pipes Air vent in filter cap blocked Air cleaner blocked Clean or renew element Refer to engine manual for details Engine malfunctions Refer to engine Low engine oil Top up to correct level Refer to engine manual for correct grade Insufficient oil in hydraulic tank Top up to correct level Refer to page 6 item 3 for details Engine ignition switch or connecting Check for earth leak and renew worn wires damaged or damaged parts Hydraulic tank float switch damaged Renew worn or damaged parts Hydraulic oil pressure low Bypass lever is in the BYPASS Set to FLOW position Relief valve set low or worn Check relief valve settingand adjust Check system oil flow Ref page 11 Renew pump as necessary Relief valve set low or worn Checksettingand renew as necessary Thermal valve malfunction Renew valve Hydraulic oil contaminated Drain oil tank and
4. transmission hoses and replenish with clean oil Replace filters Engine speed remains at idle when P O D Cylinder seized in retracted Check cylinder and replace P O D tools are operated position unit as necessary P O D Cable adjustment incorrect Re adjust as per page 11 Throttle lever incorrectly set at low Reset engine speed and lock throttle speed lever Engine speed remains at full when P O D Cylinder seized in extended Check cylinder and replace P O D off load bypass position unit as necessary P O D Cable adjustment incorrect Re adjust as per page 11 12 SPECIFICATIONS Capacity coim dere dan lwe ee sea ae WW ut depa dyn pope ada ede One 20 1pm 5 28gpm circuit Pressure Range nu IL UT eect ect elec ne devan dese WT ede eee AWG 70 140 bar 1000 2000 psi EngimeRbMt nun yn Y GY GYW O en 3600 RPM COuplers i GY eee YF eee i tee dt EHTMA HTMA Flush Face Type Male amp Female Weight withorl eu we Y WY A A en heehee 66 kg 145 lbs XX kg Overall eneth u te rne Pe Wb t eii 75 cm 29 5 in Overall Width iet ates RO eal ot tete E PPP Ves GY yddyd YU I FN de de 53 cm 20 9 in COyerallHeight6 eed erae urere re ee apte ise cs itt eet Tees 57 cm 22 5 in mi OD PE ibn dead mei ER Honda 9 0 hp Fuel TANK Capacity ee kak teste ie duabus FRAN vete rae E 6 1 6 gal Oli Reservoir Capacity aeter GU GI DD GYD 6 2 Itr 1 6 gal 20 1pm 138 bar
5. 176 41195 41203 41139 41115 41116 41117 41159 41628 41218 41223 41222 41224 QTY 1 off 1 off 1 off 1 off 1 off 1 off 1 off 1 off 1 off 1 off 8 off 8 off 1 off 1 off 1 off 1 off 12 off 1 off 1 off 1 off 1 off 1 off 15 VALVE BLOCK ASSY 3 4 5 29 28 i 642 24 16 20 19 POD ASSY DESCRIPTION Spool amp Block Matched Pair O Ring Grub Screw Boss Lever Knob Dowel Pin Relief valve seal kit Relief Valve Male Male Adaptor Bonded Seal Bonded Seal Adaptor Bonded Seal Q R C Carrier Q R C Probe H P Feed Pipe Nut Adaptor Circlip Filter Spigot Filter Can Set Screw Shakeproof Washer Clamping Plate T v Capsule Washer Gasket PART NO 41161 41188 41200 41140 41141 41121 41211 41627 41153 41213 41183 41185 41214 41184 41132 41131 41182 41126 41214 41216 41122 41128 41197 41209 41135 41120 41138 41137 QTY 1 off 1 off 1 off 1 off 1 off 1 off 1 off 1 off 1 off 1 off 1 off 2 off 2 off 3 off 1 off 1 off 1 off 1 off 1 off 1 off 1 off 1 off 4 off 4 off 1 off 1 off 1 off 1 off 16 ITEM eooNuoouonoON DESCRIPTION Cooler Cooler Guard Nut Washer Set Screw Cooler Return Pipe Nut Nut Coolerfeed Pipe ORing Cap Screw Washer Set Screw Shakeproof Washer COOLER ASSY PART NO
6. 41163 41168 41191 41203 41195 41178 41125 41125 41179 41187 41192 41204 41194 41207 GTY 1 off 1 off 6 off 8 off 6 off 1 off 1 off 1 off 1 off 2 off 1 off 1 off 2 off 2 off 17 ITEM oouoonoON DESCRIPTION Engine Spacer Grub Screw Extension Shaft Shakeproof Washer Bolt Fan Grub Screw Drive Coupling Stud Coupling Bonded Seal Pump Adaptor Suction Hose Adaptor Cap Screw Shakeproof Washer Nut Washer Pump Plate Back Up Ring Jubilee clip Suction Hose Compact Elbow Bolt ShakeproofWasher Key Engine Honda Label Speed Control Lever PUMP ASSY QTY 1 off 2 off 1 off 1 off 1 off 1 off 1 off 1 off 1 off 2 off 1 off 1 off 1 off 4 off 4 off 3 off 3 off 1 off 2 off 2 off 1 off 1 off 4 off 4 off 1 off 1 off 1 off 18 ITEM fO DESCRIPTION Spacer U Ring Grub Screw Spring Bonded Seal Body End Cap Nut Adjuster Cable Assy Cable Clamp Cable Support Bracket Sold as complete 41113 POD Assembly P O D ASSY PART NO 41144 41147 41143 41199 41134 41185 41142 41145 41189 41146 41148 41150 41149 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 shi
7. ARRY TOOL BY THE HOSES DO NOT AS NON CONDUCTIVE WHEN USING HYDRAULIC TOOLS ON ABUSE HOSE DO NOT USE KINKED TORN OR DAMAGED OR NEAR ELECTRICAL LINES MAY RESULT IN DEATH OR SERI HOSE OUS INJURY 3 MAKE SURE HYDRAULIC HOSES ARE PROPERLY CONNECTED BEFORE USING HOSE LABELED AND CERTIFIED AS NON CON TO THE TOOL BEFORE PRESSURING SYSTEM SYSTEM PRES DUCTIVE ON OR NEAR ELECTRIC LINES BE SURE THE HOSE IS SURE HOSE MUST ALWAYS BE CONNECTED TO TOOL IN PORT The safety tag p n 158 75 at right MAINTAINED AS NON CONDUCTIVE THE HOSE SHOULD BE SYSTEMRETURNHOSE MUST ALWAYS BE CONNECTED TO TOOL REGULARLY TESTED FOR ELECTRIC CURRENT LEAKAGE IN OUT PORT REVERSING CONNECTIONS MAY CAUSE REVERSE ACCORDANCE WITH YOUR SAFETY DEPARTMENT INSTRUC TOOL OPERATION WHICH CAN RESULT IN SEVERE PERSONAL is attached to the power unit TIONS INJURY i 2 AHYDRAULIC LEAK OR BURST MAY CAUSE OIL INJECTION 4 DONOT CONNECT OPEN CENTER TOOLS TO CLOSED CENTER when shipp ed from the factory INTO THE BODY OR CAUSE OTHER SEVERE PERSONAL INJURY HYDRAULIC SYSTEMS THIS MAY RESULT IN LOSS OF OTHER HYDRAULIC FUNCTIONS POWERED BY THE SAME SYSTEM AND Read and understand the safety DONOTEXCEED SPECIFIED FLOW AND PRESSURE FOR OR SEVERE PERSONAL INJURY THIS TOOL EXCESS FLOWOR PRESSURE MAY CAUSE A i s LEAKORBURST 5 BYSTANDERS MAY BE INJURED IN YOUR WORK AREA KEEP BY instructions listed on this tag STANDERS CLEAR OF YOURWORK AREA DO NOT EXCEED RATED WORKING PRESSUR
8. E OF HYDRAU LICHOSE USEDWITH THIS TOOL EXCESS PRESSURE MAY 6 WEAR HEARING EYE FOOT HAND AND HEAD PROTECTION before removal We suggest you De ei Dn A 3 7 TO AVOID PERSONAL INJURY OR EQUIPMENT DAMAGE ALL TOOL retain this tag and attach it to the CHECK TOOL HOSE COUPLERS AND CONNECTORS DAILY REPAIR MAINTENANCE AND SERVICE MUST ONLY BE PER FORLEAKS DO NOT FEEL FOR LEAKS WITH YOUR HANDS FORMED BY AUTHORIZED AND PROPERLY TRAINED PERSON i CONTACT WITHALEAK MAY RESULTIN SEVERE PERSONAL NEL power unit when not in use INJURY IMPORTANT IMPORTANT READ OPERATION MANUAL AND READ OPERATION MANUAL AND SAFETY INSTRUCTIONS FOR THIS SAFETY INSTRUCTIONS FOR THIS TOOL BEFORE USING IT TOOL BEFORE USING IT USE ONLY PARTS AND REPAIR USE ONLY PARTS AND REPAIR PROCEDURES APPROVED BY PROCEDURES APPROVED BY STANLEY AND DESCRIBED IN THE STANLEY AND DESCRIBED IN THE OPERATION MANUAL OPERATION MANUAL TAG TO BE REMOVED ONLY BY TAG TO BE REMOVED ONLY BY TOOL OPERATOR TOOL OPERATOR SEE OTHER SIDE SEE OTHER SIDE SAFETY TAG P N 15875shown smaller than actual size HYDRAULIC HOSE REQUIREMENTS HOSE TYPES Hydraulic hose types authorized for use with Stanley Hydraulic Tools are as follows 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 and listed above ar
9. E TO USEASTRAINER DO NOT OVERFILL The following oils are recommended for use ISO VG T32 SPEC for use in ambient tempertures below 32Degrees Centigrade ISO VG T46 SPEC for use in ambient tempertures above 32Degrees Centigrade 4 HYDRAULIC CONNECTIONS Facing the control valve the left hand male quick disconnect fitting is the pressure FLUID OUT fitting The right hand female quick disconnect fitting is the return FLUID IN fitting 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 E H T M A H T M A HYDRAULIC TOOL MANUFACTURERS ASSOCIATION quick disconnect fittings NPT type threads see next page Longer hoses are not recommended If small diameter or long hoses are used or if restrictive fittings are con nected to the supply and return ports the pressure required to push the fluid through the system and back to the hydraulic tank will be higher If the pressure is too high this may cause the engine to stall Also see HYDRAULIC HOSE REQUIREMENTS earlier in this manual 5 GENERAL The HP08 Power Unit provides one hydraulic tool circuit with an oil flow of 5 28 gpm 20 Ipm up to 2250 psi 155 bar Oil flow is regulated by sliding the throttle lever to the full throttle position QUICK DISCONNECT COUPLERS E H T M A H T M A approved quick dis
10. G FOR 25 FEET STANLEY P N 05008 HYDRAULIC HOSES 1 2 INCH MALE PIPE HOSE END E H T M A H T M A QUICK DISCONNECT COUPLER STANLEY P N 24070 COUPLER SET male amp female E H T M A H T M A QUICK DISCONNECT COUPLER STANLEY P N 24069 COUPLER SET male amp female STANLEY P N 00936 ADAPTER NOTE AS REQUIRED DO NOT OVERTIGHTEN THE FITTINGS PRE START CHECKS In addition to checking the fluid levels mentioned previously the following should be observed 1 Ensure that the Power Unit is standing on stable ground or where necessary that it is suitable chocked for stability CAUTION DO NOT OPERATE THE MACHINE AT AN ANGLE OF GREATER THAN 20 DEGREES FROM HORIZONTAL OTHERWISE THE ENGINE LUBRICATING SYSTEM MAY FAIL CAUSING EXTENSIVE DAMAGE TO THE ENGINE 2 Ensure that the engine exhaust is not obstructed and that there is adequate ventilation to disperse the exhaust gases 3 Ensure that the transmission hoses are positioned to avoid damage by vehicles etc and that they will not be understrain when the accessory tool is in use CAUTION ENSURE THAT THE HOSE COUPLINGS TO THEACCESSORY TOOLARE THOROUGHLY CLEANED BEFORE CONNECTING FAILURE TO DO SO MAY CAUSE DAMAGETOTHE SEALS WARNING NEVERATTEMPT TOADD FUEL OR OIL WHEN THE ENGINE IS RUNNING USE ONLY THE CORRECT GRADEAND DO NOT OVERFILL STARTING THE ENGINE NOTE REFER TO THE ENGINE MANUAL FOR DETAILS ALWAYS ENSURE THAT THE BYPASS LEVER IS IN THE BYPASS PO
11. HP081523D Hydraulic Power Unit Safetu Operation and Routine Maintenance User s Manual DANGER SERIOUS INJURY OR DEATH COULD RESULT FROM THE IMPROPER RE PAIR OR SERVICE OF THIS TOOL Please stick REPAIRS AND OR SERVICE TO THIS serial number TOOL MUST ONLY BE DONE BY AN AUTHORIZED AND CERTIFIED label here oe 90 STANLEY 3810 SE Naef Road Copyright 9 2000 The Milwaukie OR 97267 5698 USA Stanley Works Pre 503 659 5660 OPS USA CE VERSION Fax 503 652 1780 41217 11 00 Ver 1 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 COPYRIGHTO 2000 The Stanley Works 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 excep tion 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 CONTENTS Accessories PM 13 Hydraulic Hose Requirements sinini ii EEEE 5 Operation sss mre ost iat bare de ors Ud et 4 8 Routine Maintenance co ate eate Ser ten RP RE x od genes 9 11 Parts E
12. NTATION 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 obligation of Stanley thereunder is in lieu of all other warranties expressed or implied including merchantability or fitness for a particular purpose except for that provided herein There is no other warranty This warranty gives the purchaser specific legal rights and other rights may be available which might vary depending upon applicable law 20 Stanley Hydraulic Tools 3810 S E Naef Road Milwaukie Oregon 97267 5698 Phone 503 659 5660 Fax 503 652 1780
13. REMOVE DIRT AND MOSISTURE AND TEST HOSE FOR MAXIMUM 5 CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAMAGE TO ALLOWABLE CURRENT LEAKAGE IN ACCORDANCE WITH SAFETY DEPARTMENT COUPLINGS IF ANY OF THESE CONDITIONS EXIST REPLACE THE HOSE IMMEDIATELY NEVER INSTRUCTIONS USE TAPE ORANY DEVICE TOATTEMPT TO MEND THE HOSE SIHL 3AOW3M LON OG 6 AFTER EACH USE STORE IN A CLEAN DRY AREA DO NOT REMOVE THIS SEE OTHER SIDE SEE OTHER SIDE SIDE 1 shown smaller than actual size SIDE 2 The tag shown below is attached to conductive hose DANGER DANGER 1 DO NOT USE THIS HYDRAULIC HOSE ON OR NEAR ELECTRIC LINES THIS HOSE IS NOT LABELED OR CERTIFIED AS NON CONDUCTIVE USING THIS HOSE ON OR NEAR ELECTRICAL 5 CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAMAGE TO LINES MAY RESULT IN DEATH OR SERIOUS INJURY COUPLINGS IF ANY OF THESE CONDITIONS EXIST REPLACE THE HOSE IMMEDIATELY NEVER 2 FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY TRAINED IN LD RENEE EE SU ERE TO MENDO ERTS CORRECT PROCEDURES REQUIRED FOR WORK ON ORAROUND ELECTRIC LINES 3 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 DIRECT CONTACT DURING USE CONTACT AT THE BURST CAN CAUSE BODILY INJECTION AND SEVERE PERSONAL INJURY 6 AFTEREACH USE
14. SITION 1 Open the fuel tap 2 Close the choke on the carburetor 3 Set the engine ignition switch to ON 4 Start the Engine by pulling on the recoil starter rope 5 As the engine warms up gradually return the choke to OPEN NOTE THE HP08 POWER PACKIS FITTED WITHA POWER ON DEMAND DEVICEAND THE ENGINE WILLRUN AT IDLE SPEED UNTILPRESSURE IS GENERATEDINTHE HYDRAULIC SYSTEM OPERATING CHECKS Before commencing operation with a tool connected the following checks should be carried out 1 Bypass lever is in the FLOW position 2 Check that there is no excessive engine vibrations 3 Ensure that there are no hydraulic leaks from hoses or couplings 4 Check that the filter condition indicator is not within the clogging sector When this sector is indicated the return line filter should be replaced Depending on the ambient temperature optimum performance is usually achieved after 5 10 minutes operation this is the time required for the hydraulic oil to reach its correct operating temperature STOPPING THE ENGINE NOTE REFER TO THE ENGINE MANUAL FOR DETAILS 1 Set the bypass lever to the BYPASS position 2 Set the ignition switch to OFF 3 Switch off the fuel tap ROUTINE MAINTENANCE a on an 300 hrs Complete Unit Keep all areas clean and free from dust debris etc ple Check security of all fasteners especially on engine mounts Wheels and Feet Examine for da
15. STORE IN ACLEAN DRY AREA SIHL JAOWJY LON OG 4 HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING 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 SEE OTHER SIDE o m ul gt o z oJ a SIDE 1 shown smaller than actual size SIDE 2 HOSE PRESSURE RATING The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the hydraulic system OPERATION PREPARATION FOR USE Do not operate the power unit until you have read the engine operating and maintenance instructions manual furnished with 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 SD SE SF SG as specified in the engine operating and maintenance manual 2 ENGINE FUEL LEVEL Check the fuel level If low fill with unleaded gasoline with a minimum of 85 octane Do not mix oil with gasoline 3 HYDRAULIC FLUID Check the sight gauge on the hydraulic fluid reservoir for the proper fiuid level If the sight gauge indicates the fluid level is low add hydraulic fluid to the hydraulic oil tank via the filler on the top NOTE WHEN TOPPING UP THE HYDRAULIC TANK ITISADVISABL
16. c tank breather indicate air is present in the lines Keep all suction line fittings and clamps tight Hydraulic system wear is noted by increased heat during tool operation reduced tool performance and eventual system breakdown e Operate with the fluid temperature at 50 140 F 10 60 C for improved seal and hose life and maximum efficiency REMOVING CONDENSED MOISTURE FROM HYDRAULIC FLUID Condensation is a frequent problem with cool mobile hydraulic circuits This condition occurs in moist or cold climates When warm air in the hydraulic tank draws moisture from the cooler air outside water accumulates in the tank To remove water from the hydraulic system use the PRESSURE hose without the quick disconnect coupler attached Run the engine at the idle setting and pump the fluid into a clean 5 gal 20 Itr container Turn the engine OFF as soon as the hydraulic tank reservoir is empty DO NOT operate the engine with an empty hydraulic tank as pump damage may occur 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 STORAGE Clean the unit thoroughly before storage Do not use water pressure e Always store the unit in a clean and dry facility e Ifthe unit will be stored for a prolonged period over 30 days add a fuel additive to the fuel tank to prevent the f
17. connect couplings are installed to hydraulic hoses so that the direction of oil flow is always from the male to the female quick disconnect as shown on the next page 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 sealant compound or bonded seals when installing quick disconnect couplings to hose or tool fittings Follow the instructions furnished with the selected thread sealant Valve block on hydraulic unit PRESSURE PRESSURE RETURN TOOL HYDRAULIC HOSE amp FITTING CONNECTIONS 1 2 INCH BONDED SEAL STANLEY P N 41185 ADAPTER 1 2 x 3 8 INCH MALE PIPE STANLEY P N 41214 3 8 INCH BONDED SEAL STANLEY P N 41184 E H T M A H T M A QUICK DISCONNECT COUPLER STANLEY P N 41132 COUPLER CARRIER or STANLEY P N 41131 COUPLER PROBE E H T M A H T M A QUICK DISCONNECT COUPLER STANLEY P N 24070 COUPLER SET male amp female 1 2 INCH MALE PIPE HOSE END 1 2 INCH I D HOSE 25 FT LON
18. e 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 Hydraulic Tools DO NOT REMOVE THESE TAGS If the information on a tag is illegible because of wear or damage replace the tag immediately Anew tag may be obtained at no charge 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 WHEN 3 DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE IMPROPER USE OR HANDLING USING HYDRAULIC TOOLS ON OR NEAR ELECTRIC LINES MAYRESULT IN DEATH OR SERIOUS OF HOSE COULD RESULT IN BURST OR OTHERHOSE FAILURE KEEP HOSE AS FAR AWAY AS INJURY POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT CONTACT DURING USE CONTACT AT THE FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY TRAINED IN BURST CAN CAUSE BODILY INJECTION AND SEVERE PERSONAL INJURY CORRECT PROCEDURES REQUIRED FOR WORK ON ORAROUND ELECTRIC LINES 4 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 2 BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE ON OR LIFT TOOLS POWER UNITS ETC NEAR ELECTRIC LINES WIPE THE ENTIRE LENGTH OF THE HOSE AND FITTING WITH A CLEAN DRY ABSORBENT CLOTH TO
19. edures 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 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 DOCUME
20. jury or equipment damage all tool repair maintenance and service must only be performed by authorized and properly trained personnel LOCAL SAFETY REGULATIONS Enter any local safety regulations here Keep these instructions in an area accessible to the operator and mainte nance personnel SAFETY SYMBOLS Safety symbols are used to emphasize all operator maintenance and repair actions which if not strictly followed could result in a life threatening situation bodily injury or damage to eguipment Pw FX Rem This safety symbol may appear This safety symbol appears in This safety symbol appears in on the tool It is used to alert these instructions to identify these instructions to identify the operator of an action that an action that could cause an action or condition that could place him her or others bodily injury to the operator or could result in damage to the in a life threatening situation other personnel tool or other equipment Always observe safety symbols They are included for your safety and for the protection of the tool DECALS STICKERS amp TAGS MODEL No amp OPERATING ENGINE MODEL No LOCATED WORK ORDER amp SERIAL No MSTRUCTIONS RIGHT SIDE OF CRANKCASE LOCATED TOP LEFT CORNER OF TANK FRONT a t LX LCD ae Tea A m NN DANGER DANGER 1 FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED D DONOT LIFT OR C
21. kmanship 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 delivery 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 proc
22. mage Transmission Examine for leaks or damage Hoses IL Me a Bawemnm pe Greene EE EI 1 Change Oil Service Refer to notes on next page and manufacturers instructions Return line filter Replace as shown or when indicator needle stays in red zone Hydraulic pipes amp Examine for oil leaks connectors i Externally clean using compressed air DO NOT USE A WIRE BRUSH ENGINE MAINTENANCE Follow the maintenance schedule and general maintenance instructions in the engine maintenance and operation manual furnished with the power unit Normal maintenance includes e Service air cleaner cartridge every 50 hours of operation Clean sediment cup every 50 hours or sooner if required e Replace the spark plug every 100 hours of operation e Change engine oil after first 20 hours of operation then after every 100 hours of operation If engine has been operating under heavy load or in high ambient temperature change the oil every 25 hours of operation e Check oil level daily e Remove dirt and debris from engine with a cloth or brush daily Do not use water spray HYDRAULIC SYSTEM MAINTENANCE Observe the following for maximum performance and service life from the hydraulic system e Always keep hydraulic system and fluids clean e Keep water out of fluid e Keep air out of hydraulic lines Hydraulic system overheating and foam at the hydrauli
23. ore 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 on page 3 In addition to this manual read and understand safety and operating instructions in the Engine Operation Manual furnished with the power unit GENERAL SAFETY PRECAUTIONS The HP08 Hydraulic Power Unit will provide safe and dependable service if operated in accordance with the instruc tions given in this manual Read and understand this manual and any stickers and tags attached to the power unit Read and understand the engine manual furnished with the unit Failure to do so could result in personal injury or equipment damage Operators 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 e Establish a training program for all operators to ensure safe operation Do not operate the power unit unless thoroughly trained or under the supervision of an instructor e Always wear safety equipment such as goggles ear and head protection and safety shoes at all times when operating the power unit and a hydraulic tool Do not inspect or clean the power unit while the unit is running Always use hoses and fittings rated at 2500 psi 172 bar with a 4 to 1 safety factor Be sure all hose connec
24. pping 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 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 wor
25. the flow rate is between 18 and 20l min Adjust the engine speed to give the correct flow DO NOT EXCEED 3600 RPM on load speed If correct flow cannot be obtained within max engine speed then the pump must be suspect replace as necessary POWER ON DEMAND P O D ADJUSTMENT The P O D Cylinder and Cable Assy are designed as a cartridge that can be disassembled completely without disturbing any other part of the Power Pack See diagram for breakdown of parts a Slacken the P O D End Cap Item 8 and unscrew fully b Pull down the Nut Cable to extract the Spring Item 5 and Piston Item 3 for examination NOTE To connect a new Cable the piston can be withdrawn sufficiently to reveal the Grub Screw Item 4 which clamps the cable to the piston allowing access without extracting the U Ring Item 2 from the body c The P O D Body Item 7 can be unscrewed from the Valve Block for examination if desired d Cable can only be removed from the Tank by removal of the Clamps Item 12 These clamps are plastic and cannot be removed without damage Replace the clamps upon reassembly NOTE Reassembly is the reverse of the above procedure However care should be taken when fitting the U Ring Item 2 into the bore of the Body Item 7 Standard cable length allows for the cable to be pushed fully home into the piston before clamping by the Grub Screw Item 4 When unit is fully reassembled Adjuster item 10 can be adjusted
26. tions are tight and that tools are operated at the extremity of the transmission hoses connecting the tool to the power unit Make sure all hoses are connected for correct flow direction to and from the tool being used and that the hydraulic power suppy is compatible with the tool to be used It is DANGEROUS to use a hydraulic tool with an incompatible flow rate and pressure 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 or improperly adjusted power unit e Never wear loose clothing that can get entangled in the working parts of the power unit Keep all parts of your body away from the working parts of the power unit e Always wear appropriate safety equipment such as goggles ear protection and toe guards Certain tools used in conjunction with the power unit may reguire other safety eguipment such as breathing filters 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 1 m of buildings obstructions or flammable objects Allow the engine to cool before storing the power unit in an enclosure e To avoid personal in
27. uel from gumming Run engine for a short period to circulate the additive Replace crankcase oil with new oil Remove the spark plug and pour approximately 1 ounce 30 ml of engine oil into the cylinder Replace the spark plug 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 HY DRAULIC SYSTEM MAINTENANCE earlier in this section Disconnect tool hoses Allow the water to settle from the fluid overnight Install a new filter if dirty 10 ROUTINE CHECKS AND ADJUSTMENTS SYSTEM PRESSURE AND FLOW CHECKS 1 Connect a suitable hydraulic test unit to the powerpack The unit should comprise a high pressure flowmeter O 50 l min 13 21 gal min a gauge O 200 bar 0 3OO0psi a temperature gauge and a load valve 2 Connect the test unit to the power pack with the load valve and the By Pass lever in the by pass position and start the power pack Allow the engine to warm up set the by pass lever to the flow position Close the load valve completely and check that the relief valve setting is correct Refer to Section 2 The hydraulic oil will tend to get quite hot during this operation and therefore the checking should be carried out as quickly as possible and the load valve opened before excessive temperatures are reached 3 Carefully close the load valve to raise the pressure to 100 Bar Check that
Download Pdf Manuals
Related Search