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P110 Operator Manual

1. Failure to use the correct spark plug could result in a warranty that will not be considered Clean the unit thoroughly before storage Do not use water pressure Always store the unit in a clean and dry facility If the 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 a short period to circulate the additive Replace crankcase oil with new oil 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 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 P110 User Manual 4 13 CONTROLLER The ICS programmable controller is an electronic engine governor that provides a means of controlling and limiting engine speed by adjusting the fuel control lever with a proportional actuator The controller is factory programmable and has no manual adjustments A flashing LED indicates the fault condition CALIBRATION Calibration and programming can only be done by the factory TROUBLESHOOTING GUIDELINES Please follow the checklist below to troubleshoot your ICS controller 1 Check battery voltage for stability and correct val
2. RED WIRE P TERMINAL CONTROLLER ORANGE WIRE S TERMINAL Ed esel YELLOW WIRE TERMINAL ENGINE PRESS SWITCH WIRING DETAIL P110 User Manual 4 23 LIMITED WARRANTY POLICY This limited warranty is offered for 90 days 30 days if product is used in rental from date of original purchase on ICS manufactured parts Components not manufactured by ICS will be covered for the period and according to the provisions of each manufacturer s warranty During the warranty period ICS will replace or at its option repair for the original purchaser only free of charge any product or part manufactured by ICS which is found upon examination by ICS to be defective in material and or workmanship The purchaser shall be responsible for all transportation charges and any cost of removing any part submitted for replacement under this warranty This war ranty does not cover any failure caused by accident abuse misuse improper maintenance normal wear neglect damage caused by stale or improper fuel mix or operation under conditions not specified by ICS There are other warranties expressed or implied There is no implied warranty of merchantability and no implied warranty of fitness for a particular purpose Replacement or repair is the exclusive remedy and ICS disclaims all liability for incidental and consequential damages of any kind POWER UNITS amp GAS FUEL DRIVEN EQUIPME
3. 110 HYDRAULIC POWER UNIT ICS SAFETY OPERATION AND MAINTENANCE USER MANUAL TN 125 Blount Inc g 4909 SE International Way Portland Or n 97222 unt Inc WWW C y com Copyright 2012 ICS Blo NOTES 2 gt P110 User Manual TABLE OF CONTENTS SAFETY SYMBOL EE AE ER OR EE OE EE tede OR LIE 4 SAFETY PREGCAUTIOING nitet ER EE EE ER EE a 5 TOOL STICKERS amp TAGS e OE RE ER 6 HOSEREOUIREMENTS erit o cette 7 EE RR A EE AA 8 eg rep M m 9 ROUTINE MAINTENANGE EE N EE tede RO RE N 13 PROGRAMMABLE CONTROLLER trn Eu RR ARR LR FL ee tang FR ee een RAE ied 14 FAULT CODES ETT 15 TESTING amp TROUBLESHOOTING tote int e etd etta nere tht er edet see Id rh aide ven d Ee egg EER 16 TROUBLESHOOTING Fac EE RE RE EE EE ER 17 SPECIFICATIONS EE OE 18 BRIGGS ENGINE ASSEMBLY a 19 BRIGGS ENGINE PARTS LIS T EE EE een ee usas 20 P110 FRAME PARTS ito ER sites Eee E croce RE OO N EE EE 21 HOSE FHITIINGS amp GEAMPS tere eere dan atender tuer c a eder den fin es ee ane 22 P110 WIRINGIHARNESS Ee en Ee ER ER ee eit iate totes ee etes tu tetur te reine 23
4. amp Oo ISOH D Iz 08 gt 0Z e i ge J 99 j ANIONZ 5 v 99 NO 3SOH MOdVA a v ifl OL LOANNOO Nr Sz 226 SN M S LE Cg 82 i 8 9p 19 59 22 92 9p 7 S M s N 9 x n gt P o es m oh e 1 4 2 gt x v9 LI al N ES 1 r 2 om _ 82 H EL ASSY 3NION3 30 Luvd 8 Ed 7 S a 18 x d 89 99 ASSY MO ue 39VXNI131LLONHL 30 1NVd NI9N3 OL ef 9 82 v OL 18 v BRIGGS ENGINE PARTS LIST gt AR e EO AIR Eur 2 2 EN 2 Em E N oO a A 3 EM N gt gt THROTTLE LEVER 2 HEX FLANGE BOLT ANGLE BRACKET WELDMENT ROTARY ACTUATOR ACTUATOR BRACKET olo Alo 1 E N A Go z s HEX FLANGE BOLT 12 N o o EN N D oo IE zx FEE Eee ____ SESS s2 o s f 5 ____ se Joo BEE se o EN so o LEN ____
5. fluid reservoir to pump inlet has a smooth curve Solenoid not working Check solenoid operation and electrical connections Tool is defective Refer to tool manual P110 User Manual 4 17 SPECIFICATIONS EDONG RT 23 hp Briggs OE One 8 gpm 30 Ipm Circuit or One 12 gpm 45 lpm Circuit Lengte TIR PERMIT 36 in 91 4 cm M 23 in 58 4 cm ele t PULS 29 5 in 74 9cm Weight Wet Single Circuit Briggs eite itr true erra rixa a ere EHE E ERR Paar Ge Ee Fera d dedu 330 155 149 6 kg Fuel 6 gal 22 7 ltr Estimated Gas Consumption Per Hour ss 1 3 gal 4 Itr Hydraulic Reservor WERE Gee na Santee duse 3 gal 11 Itr Reliet Valve Crack SSe einer uu er mar gr ne c vd Evi o tetes tt 2100 psi 145 bar sr RE EE MO uu n toe Peto divum te tu RE EE 2500 psi 172 bar HTMA Category N D 30 Ipm 138 bar or 45 Ipm 138 bar 18 P110 User Manual o q gt n 8v 7 LLI D 2 2 0 ge ZEE79 N d 81989 o erue lt T ze ee 26 oc Ov NE 5 OD NO 31114 110 OL le x MED gt ANS ul wo 0 OD 3NION3 OL HNVL 71314
6. AUTO OFF When the throttle control switch is in the AUTO OFF position the engine speed is held to maintain 8 gpm 30 or 12 gpm 45 Ipm depending on which position the operator has selected with the flow selector switch When a tool is not being used the engine will not return to idle until either the flow selector switch is turned to the OFF position or the throttle control switch is turned to AUTO ON may be necessary to reset Controller At times it may be necessary to reset the controller This could happen if a fault occurs in the controller For example excessive engine speed If a fault does occur the power unit will return to an idle and the operator will have no control of the unit To reset the controller simply turn off the power unit and restart it STARTUP Before starting the engine make sure the flow selector Switch is in the OFF position NOTE The power unit will not start if the flow control switch is not in the OFF position Pull choke knob out and move the Throttle Control Switch to the auto idle off or the auto idle on position whichever mode of operation the operator prefers Ensure the flow selector switch is in the OFF position Turn the Ignition Switch to the START position After the engine starts release the switch Gradually push in the choke knob as the engine begins to idle smoothly Allow the engine to warm up Connect hoses and the tool as des
7. not overfill Use detergent oil classified For Service SE SF SG as specified in the engine operating and maintenance manual See engine manual for oil viscosity grade 2 SPARK PLUG On power units equipped with Briggs amp Stratton Engines ONLY Champion RC12YC or equivalent can be used Incorrect type spark plugs can produce radio frequency interference that will corrupt and damage the controller Failure to use the correct spark plug could result in a warranty that will not be considered 3 ENGINE FUEL LEVEL Check the fuel level If low fill with unleaded gasoline with a minimum of 85 octane 4 HYDRAULIC FLUID Check the dip stick in the hydraulic fluid reservoir for the proper fluid level Use fluids meeting the following specifications VISCOSITY FLUID THICKNESS U S METRIC 50 F 450 550 Maximum 10 95 C S 100 F 130 200 550 140 F 85 550 Minimum 38 C 27 42 C S 60 16 5 C S Min Pour Point 10 F 23 C Minimum for cold startup Viscosity Index ASTM D 2220 140 Minimum Demulsibility ASTM D 1401 30 Minutes Maximum Flash Point ASTM D 92 340 F 171 Minimum Rust Inhibition ASTM D 665 A amp B Pass Oxidation ASTM D 943 1000 Hours Minimum Pump Wear Test ASTM D 2882 60 mg Maximum The following fluids work over a wide temperature range allow moisture to settle out and resist biological growth that may occur in cool operating hydraulic circuits These fl
8. 2 es o foo 70 MEE 2 Em ME id EE He ELE E ES ed so o Ie CD N 20 gt P110 User Manual CD CD CD CD NI T m A P110 FRAME PARTS LIST Emm o s franesrmnx ICS P110 User Manual 4 21 HOSE FITTINGS 4 CLAMPS LIST o TY DESCRIPTION MANIFOLD ASSY SINGLE CIRCUIT HOSE BARB 3 4 IN HOSE x 3 4 IN PIPE HOSE CLAMP ELBOW 45 STRAIGHT THREAD ADAPTER ELBOW 90 HOSE CONNECTOR STRAIGHT THREAD ELBOW 45 HOSE HOSE HOSE BARB 3 4 IN HOSE x 3 4 IN PIPE T FA gt ajA jv Nj gt 3 22 gt P110 User Manual P110 WIRING HARNESS THROTTLE CONTROL SWITCH NOTE PLUG BEHIND SWITCH WITH BLUE amp YELLOW WIRES GOES TO SWITCH ON TOP FLOW CONTROL SWITCH HOUR METER SWITCH MANIFOLD ASSY BLACK TO STARTER SOLENOID RELAY 62301 SUPPLIED W 62293 HARNESS POSITIVE BATTERY CABLE TO STARTER SOLENOID GROUND WIRES BLACK TO ACTUATOR RED GREEN MAGNETO WIRE ON ENGINE GRAY WIRE g OIL PR SSURE FUEL SHUTOFF SWITCH RED WIRE FA S
9. E O RING PRESSURE RETURN Figure 2 Hydraulic Connections b OPERATION Controls This unit is equipped with an advanced propor tional engine control system It provides a means of controlling engine speed by adjusting the fuel control lever with an actuator The Power Unit provides one circuit with an oil flow of 8 gpm 30 Ipm up to 2000 psi 140 bar or 12 gpm 45 Ipm up to 2000 psi 140 bar with a factory programmed electronic governed engine throttle THROTELE CONTRO SWITCH IGNITION swircH FLOW SELECTOR SWITCH Figure 3 Control Panel One hydraulic tool can be connected to the tool circuit The circuit is activated by turning the flow control switch to either the 8 gpm 30 Ipm or 12 gpm 45 Ipm setting THROTTLE CONTROL The throttle control permits the operator to select one of 2 operating modes after the engine has warmed up When starting the engine make sure the flow selector switch is in the OFF position The throttle control switch can be set in either the AUTO IDLE ON or AUTO IDLE OFF positions AUTO ON When the throttle control switch is in the AUTO ON position the oil flow is regulated automatically when the trigger on the tool is activated When the tool is not being used the engine will return to idle automatically after a 10 second delay This setting will produce 8 gpm 30 Ipm or 12 gpm 45 lpm depending on which position the operator has selected with the flow selector switch
10. ED is working 2 are multiple faults the LED will flash them all in sequence Count the flash codes to determine the fault conditions 3 If there are no faults the LED will flash once at reset and from then on indicate the detection of engine speed A continuous ON LED indicates that a valid engine speed is being sensed 4 The controller will attempt to shut down for some faults and will not permit starting after reset with faults 1 5 and 8 b FAULT CODES EE Shutdown Corrective Action Unit not calibrated Have engine serviced by an Authorized Service Center Engine speed excessive Have engine serviced by an Authorized Service Center Engine speed unusually low Have engine serviced by an Authorized Service Center Engine shutdown due to Have engine serviced by an Authorized Service Center engine protection input Have engine serviced by an Authorized Service Center Factory settings lost External pot out of range Have engine serviced by an Authorized Service Center Accelerator position idle Have engine serviced by an Authorized Service Center switch conflict Controller unit failed Have engine serviced by an Authorized Service Center Limiting excessive actuator Have engine serviced by an Authorized Service Center current Engine speed input signal Active only in Auto crank mode Check speed sensor missing wiring Check starter motor Auto crank unable to start Check fuel engine A
11. LIMITED WARRANTY POLICY itte ttti etae he teet ea re ttti aad c net x ves n Se une d de een va 24 SERVICING THE ICS POWER UNIT This manual contains safety operation and routine maintenance instructions ICS 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 visit our website www icsbestway com or call 1 800 321 1240 and ask for a Customer Service Representative P110 User Manual 4 3 SAFETY SYMBOLS Safety symbols and signal words as shown below 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 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 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
12. NT A1 Federal Emission Component Compliance 40CFR part 1060 120 ICS 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 components whose failure would not in crease 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 24 gt P110 User Manual 1 5 The best way to cut concrete ICS Blount Inc 4909 SE International Way Portland Oregon 97222 www icsbestway com Part Number 69403
13. and fluid temps 40 F 40 F 40 F 22 C 22 C 22 C NOTE Do not operate the tool at oil temperatures above 140 F 60 C Operation at higher temperatures can cause operator discomfort at the tool FILTER Min full flow filtration 25 microns 25 microns 25 microns 25 microns Sized for flow of at least 30 gpm 30 gpm 30 gpm 30 gpm For cold temp start up and max dirt holding 114 Ipm 114 Ipm 114 Ipm 114 Ipm capacity HYDRAULIC FLUID 100 400 ssu 100 400 ssu 100 400 ssu 100 400 ssu Petroleum based 20 82 centistokes Premium grade anti wear non conductive 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 NOTE These are general hydraulic system requirements See tool Specification page for tool specific requirements 8 gt P110 User Manual 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
14. and pressure tester across two hose ends where the tool would normally be connected 4 Fully open the tester restrictor valve counterclockwise Start the engine and allow it to run until warm 6 Switch the flow selector switch to 8 or 12 depending on which flow you are testing 7 With the engine at the programed speed the test flow gauge should read 7 9 gpm 26 5 34 Ipm or 11 13 gpm 41 6 49 lpm 8 Slowly turn the restrictor valve clockwise while watching the pressure gauge The flow rate should stay at 7 9 gpm 26 5 34 lpm or 11 13 gpm 41 6 49 as the pressure gauge reaches 2100 2200 psi 148 155 bar 16 P110 User Manual At 2100 2200 psi 148 155 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 the relief valve must be re set as follows a Therelief valve is located on the right side of the unit just behind the dash panel It protrudes out from the manifold assembly Use a open end or box end wrench to loosen the nut on the relief valve b Usean Allen wrench to adjust the relief valve Turn clockwise to raise the pressure and counterclockwise to reduce the pres
15. atal Do not operate a damaged improperly adjusted power unit 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 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 To avoid personal injury or equipment damage all tool repair maintenance and service must only be performed by authorized and properly trained personnel P110 User Manual 4 5 TOOL STICKERS amp TAGS ICS Dash Sticker Single Circuit Sticker ICS Dash Sticker Single Circuit Sticker 6 gt P110 User Manual N HOSE REQUIREMENTS Hydraulic hose types authorized for use with ICS are as follows Certified non conductive Hose labeled certified non conductive is the only hose authorized for use near electrical conductors Wire braided conductive This hose is conductive and must never be used near electrical conducto
16. cribed on pages 9 and 10 FOR 8 GPM OPERATION For 8 gpm operation select mode of operation with the Throttle Control switch either auto idle on or the auto idle off position Move the flow selector switch to the 8 gpm position When finished operating the tool move the flow selector switch to the OFF position FOR 12 GPM OPERATION For 12 gpm operation select mode of operation with the Throttle Control Switch either auto idle on or the auto idle off position Move the flow selector switch to the 12 gpm position When finished operating the tool move the flow selector switch to the OFF position P110 User Manual 4 11 COLD WEATHER STARTUP 1 Use the procedures described under STARTUP and then follow the procedure below Hydraulic 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 10 If the 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 SHUTDOWN 1 Ensure the flow selector switch in the OFF position center position Unless already at idle the power unit should return to idle This may take a few seconds for the unit to react due to a built in program delay Allow the engine to idle for approximately one minute and move the Ignition Switch to the OFF pos
17. 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 NOTICE damage to equipment This signal word indicates a situation which if not avoided may result in IM damage to equipment 4 DANGER a WARNING a CAUTION CAUTION NOTICE _ IMPORTANT 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 maintenance personnel 4 gt P110 User Manual SAFETY PRECAUTIONS 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 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 in this manual In addition to this manual read and understand safe
18. ition 12 P110 User Manual b ROUTINE MAINTENANCE STORAGE ENGINE MAINTENANCE Follow the maintenance schedule and general maintenance instructions in the engine maintenance and operation manual furnished with the power unit HYDRAULIC SYSTEM MAINTENANCE e Check hydraulic fluid level daily Add fluid per specifications in this manual See HYDRAULIC FLUID under the section titled OPERATING INSTRUCTIONS e Remove condensed moisture from the hydraulic fluid by pumping the hydraulic fluid into a 5 gal 20 I 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 e Each day check hydraulic lines and fittings for leaks kinks etc Do not use your hand to perform this check 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 SPARK PLUG On power units equipped with Briggs amp Stratton Engines ONLY Champion RC12YC or equivalent can be used Incorrect type spark plugs can produce radio frequency interference that will corrupt and damage the controller
19. rs Fabric braided not certified or labeled non conductive This hose is not certified non conductive and must never be used near electrical conductors 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 P110 User Manual 4 7 HTMA REQUIREMENTS TOOL CATEGORY ar HYDRAULIC SYSTEM pom EE REOUIREMENTS TYPE Il FLOW RATE 4 6 gpm 7 9 gpm 11 13 gpm 9 10 5 gpm 15 23 Ipm 26 34 42 49 Ipm 34 40 TOOL OPERATING PRESSURE 2000 psi 2000 psi 2000 psi 2000 psi At the power supply outlet 138 bar 138 bar 138 bar 138 bar SYSTEM RELIEF VALVE SETTING 2100 2250 psi 2100 2250 psi 2100 2250 psi 2200 2300 psi At the power supply outlet 145 155 bar 145 155 bar 145 155 bar 152 159 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 140 F 140 F Sufficient heat rejection capacity 60 C 60 C to limit max fluid temperature to At max expected ambient temperature Min cooling capacity 5 hp 7 hp 6 hp at a temperature difference of 3 73 kW 4 47 kW 5 22 kW between ambient
20. sure c Tighten the nut and retest N TROUBLESHOOTING Gauss Soin Engine will not start Flow selector switch not in the OFF Make sure the flow selector switch position is in the OFF position when starting Battery not connected Attach battery cables check wires Weak battery Test battery charge or replace No fuel Add fuel Fuel filter plugged Replace fuel filter Defective spark plugs Remove plugs check gap clean or replace 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 selector switch not switched Check that the flow selector switch ON is set to 8 or 12 gpm 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 Pump coupling defective With the engine not running Check the coupling between the pump and engine that it is engaged and is not damaged Caution Keep hands clear of rotating objects Relief valve stuck open Adjust or replace valve Suction hose kinked Make sure suction hose from
21. ty and operating instructions in the Engine Operation Manual furnished with the power unit The Hydraulic Power Unit 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 Power Unit Failure to do so could result in personal injury or equipment damage 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 operation Donot operate the power unit unless thoroughly trained or under the supervision of an instructor Always wear safety equipment such as goggles ear 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 it is running 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 connections are tight Be sure all hoses are connected for correct flow direction to and from the tool being used KJ Do not inspect hoses and fittings for leaks by using bare hands Pin hole leaks can penetrate the skin NEVER OPERATE THE POWER UNIT INA CLOSED SPACE Inhalation of engine exhaust can be f
22. ue The LED will turn on for one second when the controller is first powered up 2 Check the actuator linkage for binding and backlash CHECKING PERFORMANCE CONTROL ELECTRONIC GOVERNOR STATIC CHECK To determine whether a governor problem is being caused by the actuator or the control module perform the following static check exactly in order shown A pair of jumper wires and a known good 12 volt battery is required 14 P110 User Manual 1 Disconnect red and green wires from the control module to actuator 2 Attach jumper wires from battery to RED and GREEN wires to actuator a Attach 12 volt positive to RED wire b Attach 12 volt negative to GREEN wire 3 Actuator should move throttle lever to wide open position a If actuator does not move it is defective Replace b If actuator moves throttle to wide open position the module is defective Replace Note Before replacing the actuator verify signal inputs to module see ICS Electrical Trouble shooting guide TechHELP 032807 Contact a customer service representative FAULT CODES The ICS controller is capable of identifying certain fault conditions and alerting the user to them A flashing LED indicates the fault conditions The current fault code list is shown on the following page Please note the following 1 When power is first applied to the controller the LED will flash just once for one second to indicate that the L
23. uids are recommended by ICS Other fluids that meet or exceed the specifications of these fluids may also be used Chevron AW MV 32 Exxon Univis J 26 Mobil D T E 13 Gulf Harmony AW HVI 150 32 e Shell Tellus T 32 Texaco Rando HD AZ Union Unax AW WR 32 e Terresolve EnviroLogic 132 5 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 Figure 2 Figure 1 Control Panel Facing the control panel the bottom male quick disconnect fitting is the PRESSURE FLUID OUT fitting The top female quick disconnect fitting is the RETURN FLUID IN fitting see Figure 1 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 shown in Figure 2 Quick disconnect couplings and hose fittings are selected so that additional fittings such as reducer or adapter fittings are not required P110 User Manual 4 9 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 gal
24. uxiliary output is shorted No Check the lamp or relay hooked to the output If fault is still present have engine serviced by an authorized Service Center 13 Auxiliary output 2 is shorted No Check the lamp or relay hooked to the output If fault is still present have engine serviced by an authorized Service Center 14 Actuator disconnected or No Check actuator wiring and actuator resistance open circuit Resistance should be less than 10 ohms P110 User Manual 4 15 TESTING 8 TROUBLESHOOTING GENERAL 9 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 8 HTMA TYPE II CIRCUIT OR THE 12 TYPE CIRCUIT To test the circuit proceed as follows 1 Setthe flow selector switch to the OFF center position 2 Setthe throttle control switch to AUTO OFF position 3 Use a calibrated flow
25. vanized 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 6 BATTERY The supplied 12 Volt DC battery is a non spillable maintenance free battery and is fully charged Make sure the battery cables are tight and charging circuit functions are operating properly Do not charge the battery with a standard automotive battery charger This type of charger produces a charging amperage higher than 2 amps Charging the battery at higher than 2 amps will damage the battery 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 sure the ignition switch is returned to the OFF position 10 P110 User Manual CONTROL PANEL PRESSURE RETURN HTMA 1 2 INCH FEMALE QUICK DISCONNECT COUPLER HTMA 1 2 INCH MALE QUICK DISCONNECT COUPLER 1 2 INCH MALE PIPE HOSE END 1 2 INCH I D HOSE 25 FT LONG WITH 2500 PSI 172 BAR RATING AND 4 TO 1 SAFETY FACTOR PRESSURE RETURN 1 2 INCH MALE PIPE HOSE END HTMA 1 2 INCH FEMALE QUICK DISCONNECT COUPLER HTMA 1 2 INCH MALE QUICK DISCONNECT COUPLER ADAPTER 3 8 INCH MALE PIPE x 8 SA

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