AL35 User Manual - Stanley Hydraulic Tools
Contents
1. Operator must start a work area without bystand ers Keep bystanders clear of your work area The operator must be familiar with the work area such as excessive slopes and dangerous terrain conditions Establish a training program for all operators to en sure safe operation Do not operate the alternator unless thoroughly trained or under the supervision of an instructor Always wear safety equipment such as goggles ear and head protection and safety shoes at all times when operating the alternator e Never use tools near energized transmission lines Know the location of buried or covered services be fore starting your work Do not overreach Maintain proper footing and bal ance at all times Do not inspect or clean the alternator while the hy draulic power source is connected Accidental en gagement of the tool can cause serious injury STANLEY Always connect hoses to the alternator hose cou plers before energizing the hydraulic power source Be sure all hose connections are tight Do not operate the alternator at oil temperatures above 140 F 60 C Operation at higher tempera tures can cause higher than normal temperatures at the tool which can result in operator discomfort Never transport or carry the alternator with the unit energized and connected to electrical loads Do not operate a damaged improperly adjusted or incompletely assembled alternator Observe local and national elec2. TEST HOSE FOR MAXIMUM ALLOWABLE CURRENT LEAKAGE IN ACCORDANCE WITH AGE TO GOUELINGS IE ANT OF THESE CONDITIONS ENST REPLACE THE HOSE IMMEDIATELY NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE SAFETY DEPARTMENT INSTRUCTIONS AFTER EACH USE STORE IN A CLEAN DRY AREA FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROP ERLY TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND DO NOT REMOVE THIS TAG Ovl SIHL 3AONA3Y LON OG SEE OTHER SIDE SEE OTHER SIDE SIDE 1 SIDE 2 Shown smaller than actual size THE TAG SHOWN BELOW IS ATTACHED TO CONDUCTIVE HOSE DANGER DANGER DO NOT USE THIS HYDRAULIC HOSE ON OR NEAR ELECTRIC LINES THIS HOSE IS 5 CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAMAGE TO NOT LABELED OR CERTIFIED AS NON CONDUCTIVE USING THIS HOSE ON OR NEAR COUPLINGS IF ANY OF THESE CONDITIONS EXIST REPLACE THE HOSE IMMEDIATELY ELECTRICAL LINES MAY RESULT IN DEATH OR SERIOUS INJURY NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY 6 AFTER EACH USE STORE IN A CLEAN DRY AREA TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND ELEC TRIC LINES 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
3. draulic hose used with the alternator Excess pres sure may cause a leak or burst Check alternator hose couplers and connectors dai ly for leaks Do not feel for leaks with your hands Contact with a leak may result in severe personal injury 6 AL35 User Manual Do not lift or carry the alternator by the hoses Do not abuse the hoses Do not use kinked torn or damaged hydraulic hose Make sure hydraulic hoses are properly connected to the alternator before pressuring the hydraulic system The system pressure hose must always be connected to the alternator IN port The system re turn hose must always be connected to the alterna tor OUT port Reversing the connections may cause reverse tool operation which can result in severe personal injury Do not connect open center hydraulic tools to closed center hydraulic systems This may result in loss of other hydraulic functions powered by the same system and or may cause severe personal injury The AL35 alternator is an open center hy draulic tool To avoid personal injury or equipment damage all tool repair maintenance and service must only be performed by authorized and properly trained per sonnel STANLEY CAUTION 7 9 28 34 LPM DO NOT EXCEED 2000 PSI 140 BAR DO NOT EXCEED SPECIFIED FLOW OR PRESSURE USE CLOSED CENTER TOOL ON CLOSED CENTER SYSTEM USE OPEN CENTER TOOL ON OPEN CENTER SYSTEM CORRECTLY CONNECT HOSES TO TOOL N AND OUT PORTS IMPRO
4. DRY ENVIRONMENTS GA ID 12 MONTH INTERVALS If the unit is operated or stored in a clean and dry envi ronment the electrical contacts rotor and stator should Figure 2 Diode Location be inspected and cleaned every 12 months or more fre quently as deemed necessary No other preventative maintenance is required COLD WEATHER OPERATION If the breaker 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 400 ssu 82 centistokes be fore use Damage to the hydraulic system or breaker can result from use with fluid that is too viscous or thick 12 AL35 User Manual STAN LEY In addition to the Safety Precautions found in this manual observe the following for equipment protection and care Make sure all couplers are wiped clean before con nection The hydraulic circuit control valve must be in the OFF position when coupling or uncoupling hydrau lic tools Failure to do so may result in damage to the quick couplers and cause overheating of the hy draulic system Always store the tool in a clean dry space safe from damage or pilferage Make sure the circuit PRESSURE hose with male quick disconnect is connected to the IN port The circuit RETURN hose with female quick disconnect is connected to the opposite port Do not reverse cir cuit flow This can cause damag
5. OTHER SEVERE PERSONAL INJURY DO NOT EXCEED SPECIFIED FLOW AND PRESSURE FOR THIS TOOL EXCESS FLOW OR PRESSURE MAY CAUSE A LEAK OR BURST DO NOT EXCEED RATED WORKING PRESSURE OF HYDRAULIC HOSE USED WITH THIS TOOL EXCESS PRESSURE MAY CAUSE ALEAK OR BURST CHECK TOOL HOSE COUPLERS AND CONNECTORS DAILY FOR LEAKS DO NOT FEEL FOR LEAKS WITH YOUR HANDS CONTACT WITH A LEAK MAY RESULT IN SEVERE PERSONAL INJURY D DO NOT LIFT OR CARRY TOOL BY THE HOSES DO NOT ABUSE HOSE DO NOT USE KINKED TORN OR DAMAGED HOSE MAKE SURE HYDRAULIC HOSES ARE PROPERLY CON NECTED TO THE TOOL BEFORE PRESSURING SYSTEM SYSTEM PRESSURE HOSE MUST ALWAYS BE CON NECTED TO TOOL IN PORT SYSTEM RETURN HOSE MUST ALWAYS BE CONNECTED TO TOOL OUT PORT REVERSING CONNECTIONS MAY CAUSE REVERSE TOOL OPERATION WHICH CAN RESULT IN SEVERE PERSONAL INJURY DO NOT CONNECT OPEN CENTER TOOLS TO CLOSED CENTER HYDRAULIC SYSTEMS THIS MAY RESULT IN LOSS OF OTHER HYDRAULIC FUNCTIONS POWERED BY THE SAME SYSTEM AND OR SEVERE PERSONAL INJURY BYSTANDERS MAY BE INJURED IN YOUR WORK AREA KEEP BYSTANDERS CLEAR OF YOUR WORK AREA WEAR HEARING EYE FOOT HAND AND HEAD PRO TECTION TO AVOID PERSONAL INJURY OR EQUIPMENT DAMAGE ALL TOOL REPAIR MAINTENANCE AND SERVICE MUST ONLY BE PERFORMED BY AUTHORIZED AND PROPERLY TRAINED PERSONNEL IMPORTANT READ OPERATION MANUAL AND SAFETY INSTRUCTIONS FOR THIS TOOL BEFORE USING IT USE ONLY PARTS AND REPAIR PRO
6. Tools recommends that servicing of hydraulic tools other than routine maintenance must be performed by an authorized and certified dealer Please read the following warning SERIOUS INJURY OR DEATH COULD RESULT FROM THE IMPROPER REPAIR OR SERVICE OF THIS TOOL REPAIRS AND OR SERVICE TO THIS TOOL MUST ONLY BE DONE BY AN AUTHORIZED AND CERTIFIED DEALER For the nearest authorized and certified dealer call Stanley Hydraulic Tools at the number listed on the back of this manual and ask for a Customer Service Representative STAN LEY AL35 User Manual 4 3 Safety symbols and signal words as shown below are used to emphasize all operator maintenance and repair ac tions which if not strictly followed could result in a life threatening situation bodily injury or damage to equipment This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death This safety alert and signal word indicate an imminently hazardous situation DANGER which if not avoided will result in death or serious injury This safety alert and signal word indicate a potentially hazardous situation which if not avoided could result in death or serious injury This safety alert and signal word indicate a potentially hazardous situation which if not avoided could result in death or serious injury This signal word indicates a potentia
7. between black white and red red wires No continuity from black white to red wire or any wire to ground If a short is found replace the stator Low output Hyrevz motor speed too slow Check for proper flow of 7 9 gpm 26 34 Ipm Unbalanced or excessive load Balance load between circuits load should not exceed rated capacity High backpressure Check for excessive backpressure over 250 psi 17 bar Couplers hoses blocked Locate and remove blockage Oil too hot cold Above 150 F 66 C Check power source for proper oil or below 50 F 10 C temperature Bypass cooler to warm oil or provide cooler to maintain proper temperature Relief valve set too low Adjust relief valve to 2000 psi 145 bar Alternator overheats Overloaded Reduce electrical load load should not exceed rated capacity Air intake plugged or covered Clear air intake Windings covered with dirt Clean windings Output too high Motor over speeding Check power unit for proper flow 7 9 gpm 26 34 Ipm 14 AL35 User Manual STAN LEY The AL35 is a hydraulic motor powered electrical alternator designed to provide power for lights small power tools and small appliances It produces 3500 watts of power at a nominal 120 240 volts AC single phase at 60 Hz frequency The unit requires hydraulic power delivered at 7 9 gallons per minute gpm with pressure up to 2000 pounds per square inch psi 3500 W 120 240 V 60 Hz at 8
8. yeyo SUL 03 001 AL35 User Manual lt 9 STANLEY HTMA EHTMA REQUIREMENTS HTMA TOOL TYPE HYDRAULIC SYSTEM REQUIREMENTS TYPE I TYPE II Ill Flow Range 4 6 gpm 7 9 gpm 9 10 5 gpm 11 13 gpm 15 23 Ipm 26 34 Ipm 34 40 Ipm 42 49 Ipm Nominal Operating Pressure 1500 psi 1500 psi 1500 psi 1500 psi at the power supply outlet 103 bar 103 bar 103 bar 103 bar System relief valve setting 2100 2250 psi 2100 2250 psi 2200 2300 psi 2100 2250 psi at the power supply outlet 145 155 bar 145 155 bar 152 159 bar 145 155 bar Maximum back pressure 250 psi 250 psi 250 psi 250 psi at tool end of the return hose 17 bar 17 bar 17 bar 17 bar Measured at a max fluid viscosity of 400 ssu 400 ssu 400 ssu 400 ssu at min operating temperature 82 centistokes 82 centistokes 82 centistokes 82 centistokes Temperature Sufficient heat rejection 140 F 140 140 F 140 F capacity to limit max fluid temperature to 60 C 60 C 60 C 60 C at max expected ambient temperature Min cooling capacity at a temperature 3 hp 5 hp 6 hp 7 hp difference of between ambient and fluid 2 24 kW 3 73 kW 5 22 kW 4 47 kW temps 40 F 40 F 40 F 40 F NOTE 22 C 22 C 22 C 22 C Do not operate the tool at oil temperatures above 140 F 60 C Operation at higher temperatures can cause operator disco
9. 6 0 00 001 07 6 901 9 g l 009 ainsseld QL 8 6 g l 009 ujog QL 8 6 06 6 001 19 07 61 901 9 g l 009 ujog EL ZIL GL 0 dn OG 0 dn Of 6L 901 9 g l 009 EL ZIL 08 92 001 92 65 91 9 7 g l 009 OL 8 5 g 0 dn Gz 0 dn 65 91 or SYOLONGNOD 71991419373 YVAN ISN LON OQ plejg 49914 40 9JIM BAHONPUOD SSL 0922 ujog OL 8 5 0 dn OL 0 dn 78 91 6 1 syon L Joyang ANN 404 plesg J3QI4 paye uva ISd WIN HONI SYILIN 1333 eunssaJg Buom episu sy45u97 esoH MOI 4 PRESSURE LISP IVS yoy yas se suoneoyioads 10 jsnui esou Bunes 1 UIS S S xew jenbe eJnsseJd Bulyjom WNUIUIU e jseo je JSNUI esou oineJp U Iv suoneoidde Aue J0J pesn aq jou pjnoys pue sjueujeJinbeJ joo sjoop H ejueis uo Ajuo joo oineJp u 104 pesn eq SI yeyo siu eoueuuojied joo eJnsue eunsseud oeq eJnsseJd eui uunjeJ dee 0 pepusju suoi 1 eseu Jed SJe 49d suojje6 uo peseq sujBue esou snoueA JO sJejeulelp esou uunuululuJ SMOYS eui
10. AL35 HYDRAULIC ALTERNATOR USER MANUAL Safety Operation and Maintenance 2014 Stanley Black amp Decker Inc New Britain CT 06053 U S A 16798 8 2014 Ver 6 SAFETY SYMBOLS Lan aner 4 SAFETY PRECAUTIONSOS tte ei ett rite td etre a a aid 5 TOOL STICKERS amp TAGS unnarennet een een EHER Feen 7 HOSE 8 HOSE RECOMMENDATIONS medie 9 FIGURE 1 TYPICAL HOSE CONNECTIONS 22 0 2 aan 9 ATMA REQUIREMENTS EE E 10 M 11 FIGURE 2 DIDODE EOGATION iiie tenu ea en HERE EI tert 12 TOOL PROTECTION amp GARE een unse i ce eg n d d dende 13 TROUBLESHOOTING tiber uos het oti a aaa cen terere eee das eR ir ees esie ce Pei ded etes 14 gt E le 15 AL35 PARTS ILLUSTRATIONS iiit etti de 16 SHE ET 17 35 MOTOR PARTS IEEUS TRAT ION neo tu engen 18 WIRING DIAGRAM u sen nennen nun dia es d waa 19 IMPORTANT To fill out a Product Warranty Recording form and for information on your warranty visit Stanleyhydraulics com and select the Company tab Warranty NOTE The warranty recording form must be submitted to validate the warranty SERVICING This manual contains safety operation and routine maintenance instructions Stanley Hydraulic
11. CEDURES APPROVED BY STANLEY AND DESCRIBED IN THE OPERATION MANUAL TAG TO BE REMOVED ONLY BY TOOL OPERATOR SEE OTHER SIDE IMPORTANT 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 SAFETY TAG P N 15875 Shown smaller then actual size AL35 User Manual 4 7 The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the hy draulic system There are three types of hydraulic hose that meet this requirement and are authorized for use with Stanley Hydraulic Tools They are Certified non conductive constructed of thermoplastic or synthetic rubber inner tube synthetic fiber braid reinforcement and weather resistant thermoplastic or synthetic rubber cover Hose labeled certified non conductive is the only hose authorized for use near electrical conductors Wire braided conductive constructed of synthetic rubber inner tube single or double wire braid reinforce ment and weather resistant synthetic rubber cover This hose is conductive and must never be used near electrical conductors Fabric braided not certified or labeled non conductive constructed of thermoplastic or synthetic rubber in ner tube synthetic fiber braid reinforcement and weather resistant thermoplastic or
12. MOTOR ASSEMBLY P N 21446 PART ITEM NO QTY DESCRIPTION 00120 CAPSCREW 1 4 20 x 2 1 4 HSH 07386 1 GEAR HOUSING ASSEMBLY INCLUDES ITEMS 3 amp 4 00713 DOWEL PIN 06316 BUSHING 00178 O RING 73309 IDLER SHAFT 06853 DRIVE GEAR Dea 5 BEEN INCLUDES ITEM 4 ho oe NNNM LENIN a Jooros e fosen 118 0016 RETAINING RING Indicates part of Seal Kit 07388 1 10 11 12 13 14 15 16 18 18 AL35 User Manual STAN LEY Use clean solvent In well ventilated areas Avoid prolonged Inhalation of vapors and prolonged or repeated contact with skin Keep away from heat or open flame MOVE NAAS SV NMVHG WHV STYNINYHL WIOVILdNOWH ALON NUS OMY PI THM 9M PIG ATA OMY PI OMY PI ATA OMY PI D lau D a H d o W 91 OMY z a wi8 OMY VI LHM OMY VI gt b 4 1 OMV VI S gt S LHM OMY VI 9 9 PI 2 LU NHD DMV PI gt 8 9 OMY VI I gt gt AL35 User Manual lt 19 STANLEY STANLEY Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie Oregon 97267 5698 USA 503 659 5660 Fax 503 652 1780 www stanleyhydraulics com
13. PER HANDLING USE OR OTHER MAINTENANCE OF TOOL COULD RESULT IN ALEAK BURST OR OTHER TOOL FAILURE CONTACT AT A LEAK OR BURST CAN CAUSE OIL INJECTION INTO THE BODY FAILURE TO OBSERVE THESE PRECAUTIONS CAN RESULT IN SERSQUS PERSONAL INJURY 03763 GPM Sticker NOTE THE INFORMATION LISTED ON THE STICKERS SHOWN MUST BE LEGIBLE AT ALL TIMES REPLACE DECALS IF THEY BECOME WORN OR DAMAGED REPLACEMENTS ARE AVAILABLE FROM YOUR LOCAL STANLEY DISTRIBUTOR The safety tag P N 15875 at right is attached to the tool when shipped from the factory Read and understand the safety instructions listed on this tag before removal We suggest you retain this tag and attach it to the tool when not in use STANLEY Stanley Hydraulic Tools 3810 SE Naef Rd 224 Milwaukie Oregon 97267 U S A Model No 26 34 LPM 7 9 GPM AL35 140 BAR 2000 PSI 12735 AL35 Name Tag DANGER DANGER ae 2 FAILURE TO USE HYDRAULIC HOSE LABELED AND CER TIFIED 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 CONDUCTIVE THE HOSE SHOULD BE REGULARLY TESTED FOR ELECTRIC CUR RENT LEAKAGE IN ACCORDANCE WITH YOUR SAFETY DEPARTMENT INSTRUCTIONS HYDRAULIC LEAK OR BURST MAY CAUSE OIL INJEC TION INTO THE BODY OR CAUSE
14. USE CONTACT AT THE BURST CAN CAUSE BODILY INJECTION AND SEVERE PERSONAL INJURY HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING CUTTING OR CONTACT WITH HIGH TEMPERATURE SURFACES DO NOT USE IF KINKED DO NOT USE HOSE TO PULL OR LIFT TOOLS POWER UNITS ETC DO NOT REMOVE THIS TAG Ovl SIHL SAONAIY LON OG EMEND SEE OTHER SIDE EEE SSeO SE Lx SEE OTHER SIDE SIDE 1 SIDE 2 Shown smaller than actual size 8 gt AL35 User Manual STAN LEY RETURN HYDRAULIC CIRCUIT PRESSURE suonoeuuo eoid 4 lt lt lt MO 14 SN 1 gt gt gt RETURN EE JYNSSIYd g l 009 GZ L 05 8 001 92 09 67 9L EL g l 009 einsseld 61 vIe g l 009 6l vIe 8 0 dn gz dn 09 67 9L EL g l 009 e nssald QL 8 6 g l 009 uny 792 09 0 002 001 67 85 L OL g l 009 einsseld 61 vIe g l 009 61 vIe 06 6 001 19 67 85 61 01 g l 009 e nssald QL 8 6 g l 009 QL 8 6 GL 0 dn OG 0 dn 67 85 L OL g l 009 UJnj9M 6l vie 0
15. e to internal seals Always replace hoses couplings and other parts with replacement parts recommended by Stanley Hydraulic Tools Supply hoses must have a mini mum working pressure rating of 2500 psi 172 bar Do not exceed the rated flow see Specifications in this manual for correct flow rate and model number Rapid failure of the internal seals may result Always keep critical tool markings such as warning stickers and tags legible Do not force a small breaker to do the job of a large breaker STANLEY Keep tool bit sharp for maximum breaker perfor mance Make sure that tool bits are not chipped or rounded on the striking end Never operate a breaker without a tool bit or without holding it against the work surface This puts exces sive strain on the breaker foot Tool repair should be performed by experienced personnel only Make certain that the recommended relief valves are installed in the pressure side of the system Do not use the tool for applications for which it was not intended AL35 User Manual lt 13 PROBLEM CAUSE REMEDY Tool does not run Power unit not functioning Check power unit for power flow and pressure 7 9 gpm 26 34 Ipm 2000 psi 140 bar Loss of residual magnetism Flash and Field Refer to section in this manual Short circuit in rotor filed or diodes Return to an authorized service center Shorted AC or exciter stator Check with Ohmmeter Continuity should windings exist
16. g and 625 inch 16 mm 1 0 minimum up to 100 ft 30 m PRE OPERATION PROCEDURES ELECTRICAL GROUND If required ground the electrical load and alternator at the ground lug on the alternator frame lower right as viewed from the front CHECK POWER SOURCE 1 Observe all safety precautions Do not connect or otherwise apply power to an electrical load until the alternator has come up to speed 1 Using a calibrated flowmeter and pressure gauge 2 Move the hydraulic circuit control to the ON posi check that the hydraulic power source develops a tion As the alternator comes up to speed a maxi flow of 7 9 gpm 26 34 Ipm at 2000 psi 140 bar mum electrical load of 3500 W single phase 60 Hz 2 Make certain the hydraulic power source is equipped alternating current at 120 volts becomes available with a relief valve set to open at 2100 psi 145 bar 3 Connect the electrical loads maximum CONNECT 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 discon nect them last to minimize or avoid trapped pressure within the tool 3 Observe flow indicators stamped on hose couplers to ensure that fluid flow is in the proper direction The female coupler on the tool hose is the inlet cou pler 4 Move the hydraulic circuit control va
17. gpm 30 Input OT e EE E A E A DO EE REE 240 V 15 A 120 V 20 A 120 V 15 A Duplex Pressure Range u ae E Ea E EEE NETE 2000 psi 140 bar FIOW R ngen nt knr ed E EA 7 9 gpm 26 34 Ipm Optimum 8 gpm 30 PONDO UR 10 SAE O ring Connect Sze and i era a a nee 1 2 NPT Pipe Fitting e 70 1b 31 8 kg Overall Length 22 19 inches 47 9 cm Wah cR 9 inches 22 7 cm ge tes 10 inches 25 4 cm Stanley Hyrevz P N 21446 STAN LEY AL35 User Manual 4 15 AL35 ALTERNATOR 16 AL35 User Manual STAN LEY PART PART ITEM NO QTY DESCRIPTION ITEM NO QTY DESCRIPTION 1 15100 COM COM a COM indicates common parts available through local INCLUDED WITH ITEM 1 sources 4 OUTBOARD BEARING BRACKET ASSY amp ror 1 MOUNTING BRACKET SHORT gt _ CAPSCREW shoas 1 MoTORADAPTOR 15101 15103 1510 3523 05734 OT 10 12 13 14 15 16 17 18 19 15102 15105 1269 12735 26604 COM COM 26607 20 21 22 23 24 25 26 27 28 05351 00429 03031 12628 21315 00171 35237 12690 30 31 32 3523 2660 12694 olo wo e N N A 35 36 37 20051 02688 05325 STAN LEY AL35 User Manual lt 17 AL35
18. lly hazardous situation which if not avoid ed may result in property damage This signal word indicates a situation which if not avoided will result in damage NOTICE to the equipment This signal word indicates a situation which if not avoided may result in dam IMPORTANT age to the equipment Always observe safety symbols They are included for your safety and for the protection of the tool LOCAL SAFETY REGULATIONS Enter any local safety regulations here Keep these instructions in an area accessible to the operator and mainte nance personnel 4 gt AL35 User Manual STAN LEY Tool operators and maintenance personnel must always comply with the safety precautions given in this manual and on the stickers and tags attached to the tool and hose These safety precautions are given for your safety Re view them carefully before operating the tool and before performing general maintenance or repairs Supervising personnel should develop additional pre cautions relating to the specific work area and local safety regulations If so place the added precautions in the space provided in this manual The AL35 Hydraulic Alternator will provide safe and de pendable service if operated in accordance with the in structions 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
19. lve to the ON position to operate the tool NOTE If uncoupled hoses are left in the sun pressure in crease within the hoses may make them difficult to connect When possible connect the free ends of the hoses together Do not exceed the alternator s rated 3500 W capacity NOTE Output voltage is proportional to the RPM of the hy draulic motor FLASHING THE FIELD This procedure establishes residual magnetism in the field windings to provide start up excitation and proper output voltage levels 1 2 3 Stop the alternator Remove the receptacle panel Using a 12 volt automotive battery touch the posi tive lead to the positive diode set with the white or silver band located on the rotor assembly At the same time touch the negative lead to the negative diode Hold the leads against the diodes for 2 4 seconds NOTE Do not reverse the polarity of the leads This may cause damage to the diodes or the rotor or both 4 Replace the receptacle panel and start the alterna tor AL35 User Manual lt 11 STANLEY PREVENTATIVE MAINTENANCE SCHEDULE IN DIRTY OR MOIST ENVIRONMENTS 90 DAY INTERVALS If the unit is operated or stored in a dirty moist or salt moisture environment the electrical contacts rotor and Negative stator should be inspected and cleaned every 90 days or Diodes SEAN Positive and more frequently as deemed necessary R k gt AWS IN CLEAN
20. mfort at the tool Filter uu 25 microns 25 microns 25 microns 25 microns Min full flow filtration 30 gpm 30 gpm 30 gpm 30 gpm CH m dirt holding capacity Hydraulic fluid Petroleum based 100 400 ssu 100 400 ssu 100 400 ssu 100 400 ssu premium grade anti wear non conductive 20 82 centistokes Viscosity at min and max operating temps NOTE When choosing hydraulic fluid the expected oil temperature extremes that will be experienced in service determine the most suitable temperature viscosity characteristics Hydraulic fluids with a viscosity index over 140 will meet the requirements over a wide range of operating temperatures SSU Saybolt Seconds Universal EHTMA CLASSIFICATION HYDRAULIC SYSTEM mE A A A A Flow Range 3 5 4 3 gpm 4 7 5 8 gpm 7 1 8 7 gpm 9 5 11 6 gpm 11 8 14 5 gpm 13 5 16 5 18 22 Ipm 27 33 Ipm 36 44 Ipm 45 55 Ipm Nominal Operating Pressure 1870 psi 1500 psi 1500 psi 1500 psi 1500 psi at the power supply outlet 129 bar 103 bar 103 bar 103 bar 103 bar System relief valve setting 2495 psi 2000 psi 2000 psi 2000 psi 2000 psi at the power supply outlet 172 bar 138 bar 138 bar 138 bar 138 bar NOTE These are general hydraulic system requirements See tool specification page for tool specific requirements 10 gt AL35 User Manual STAN LEY The recommended hose size is 500 inch 12 mm I D up OPERATION PROCEDURES to 50 ft 15 m lon
21. synthetic rubber cover This hose is not certified non conductive and must never be used near electrical conductors HOSE SAFETY TAGS To help ensure your safety the following DANGER tags are attached to all hose purchased from Stanley Hydraulic Tools DO NOT REMOVE THESE TAGS If the information on a tag is illegible because of wear or damage replace the tag immediately A new tag may be obtained from your Stanley Distributor THE TAG SHOWN BELOW IS ATTACHED TO CERTIFIED NON CONDUCTIVE HOSE DANGER DANGER 1 FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE IMPROPER USE WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRIC LINES MAY RESULT IN OR HANDLING OF HOSE COULD RESULT IN BURST OR OTHER HOSE FAILURE DEATH OR SERIOUS INJURY KEEP HOSE AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT CONTACT DURING USE CONTACT AT THE BURST CAN CAUSE BODILY INJECTION AND SEVERE PERSONAL INJURY ELECTRIC LINES HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING ABRASION CUTTING OR CONTACT WITH HIGH TEMPERATURE SURFACES DO NOT USE IF KINKED DO NOT BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE USE HOSE TO PULL OR LIFT TOOLS POWER UNITS ETC ON OR NEAR ELECTRIC LINES WIPE THE ENTIRE LENGTH OF THE HOSE AND FIT CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAM TING WITH A CLEAN DRY ABSORBENT CLOTH TO REMOVE DIRT AND MOISTURE AND
22. trical codes for load wiring To prevent electrical shock from faulty equip ment ground the alternator If ground bonding is required connect a length of heavy wire between the alternator ground terminal and the ground bond point Exercise reasonable caution to prevent electrical shock do not operate the alternator with wet hands Do not operate the alternator in rain or snow Do not let the alternator get thoroughly wet Do not connect the alternator to a building circuit This could cause damage to the alternator or to electrical equipment in the building AL35 User Manual 4 5 Do not start the alternator with electrical loads con nected and in a power ON state Ensure that the alternator is at operating speed volt age before connecting an electrical load Only use hydraulic hose labeled and certified as non conductive when using hydraulic tools on or near electrical lines Failure to do so may result in death or serious injury Before using hose labeled and certified as non con ductive be sure the hose is maintained as non conductive The hose should be regularly tested for electric current leakage in accordance with your safety department instructions A hydraulic leak or burst may cause oil injection into the body or other severe personal injury Do not exceed specified flow and pressure for the alternator Excess flow or pressure may cause a leak or burst Do not exceed the rated working pressure of hy
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