HP18289M Service Manual
Contents
1. ITEM P N QTY DESCRIPTION 52754 1 Hydraulic Tank Kit 1 152774 1 Lid 2 52775 1 Spring 3 01202 1 O Ring 4 140408 1 Filter Element 40080 1 Filter Assy Incl items 1 5 amp 11 13 5 58487 1 Filter Bowl 6 26070 1 Breather Vent 7 140364 1 Elbow 45 8 43688 1 Capscrew 9 58650 1 Tank 10 40133 1 Grip Plate 11 52782 1 Gasket 12 52773 1 Dipstick Bolt 13 52772 1 Dipstick 14 04306 1 Hose 15 58486 1 Filter Head 16 03044 1 Nipple 17 58460 1 Coupling 18 58489 1 Plastic Washer 19 04889 1 Hose Clamp 20 01258 1 O Ring SERVICE KIT P N 43592 03652 1 Lid 1 O Ring 1 Filter Receptacle 1 O Ring 1 1 Breather Element Breather Cover amp 9 o E D Da i 4 24 FIGURE 5A DASH PANEL 8 VALVE ASSEMBLY ITEM P N QTY DESCRIPTION ITEM P N QTY DESCRIPTION 1 25633 2 Swivel Fitting 23 07745 1 Spool Stop Washer 2 24061 2 Male Coupler Body 1 2 in 24 05551 1 Capscrew 3 08425 1 Dash Panel Incl item 12 25 01459 3 Lockwasher 4 20606 1 Hour Meter 26 07753 1 Bar 5 07745 1 Spool Washer 27 07771 1 Valve Spool 6 07820 1 Retaining Ring 28 06988 1 Backup Ring T 00147 1 Nut 29 06989 1 O Ring 8 24291 1 Control Rod 30 07781 1 Valve Block 9 02633 1 On Off Knob 31 05043 2 Relief Valve 10 1 Incl with Item 14 32 00955 1 Pipe Plug 11 1 Incl w2. Failure to do so will cause battery failure USING THE HANDLE BARS The power unit is equipped with retractable handle bars so it can easily be moved at the job site DO NOT lift the power unit with the handle bars extracted 1 To use the handle bars pull each handle bar straight out Twist the bars until locking mechanism engages The power unit may now be pushed about in a wheel barrow manner 2 To retract the handle bars disengage the locking mecha nism then push the bars inward NOTE Use the correct number of personel to lift or hoist the HP18289M Power Unit to and from the trailer The power unit weighs 384 Ibs Using the extracted handle bars to lift the power unit will cause damage STORAGE e Clean the unit thoroughly before storage Do not use water pressure e Always store the unit in a clean and dry facility If the unit will be stored for a prolonged period over 30 days up to 6 months replace the fuel filter then add diesel fuel additive to the fuel tank to prevent the fuel from gumming Be sure to follow the instructions provided with the fuel additive Run engine for a short period to circulate the additive e Check hydraulic reservoir for water If water is found change the oil and circulate it through the tool hose and tool See HYDRAULIC SYSTEM MAINTENANCE earlier in this section e Disconnect tool hoses 12 ROUTINE MAINTENANCE ENGINE MAINTENANCE Follow the maintenance sc
3. fig 1 and wiring will be loose after this procedure and can then be removed with the engine 7 Tie the oil cooler 8 fig 1 and fig 1A to the frame rails of the frame 55 fig 2 or 39 fig 2A so that it will not interfere with removal ofthe engine 8 Disconnect the two wires leading to the hour meter 9 Disconnect the throttle cable 6 fig 2 or fig 2A at the engine 10 Using an Allen wrench loosen the setscrews on the coupling assy 27 28 fig 2 or 16 fig 2A 11 Unscrew and remove the nuts 37 fig 2 or 35 fig 2A and capscrews 20 fig 1 amp fig 1A and washers 12 Slide the engine forward being careful not to entangle the electrical wiring and not to damage other components 13 Remove the coupling sleeve 28 fig 2 or 17 fig 2A 14 Slide the engine out the fuel tank side of the frame SERVICE TO REINSTALL ENGINE 1 Reverse the above procedures to reinstall the engine 2 Install the capscrews 20 fig 1 8 fig 1A so that one washer 21 fig 1A or 36 fig 1 is installed next to the head of the capscrew one washer is installed between the engine mounting bracket and the frame and one washer is installed between the nut 37 fig 2 or 35 fig 2A and the frame Tighten the capscrews and nuts to 20 ft Ib torque 3 After installing the engine adjust the coupling sleeve as follows a Move the coupling flange forward or backwards on the engine drive shaft until the drive shaft is recessed into th
4. 15 seconds Release the glow plug button and turn the start switch to the third start position to crank the engine NOTE Hydraulic fluids are thicker in cold weather It is recommended that the engine be ran at low idle long enough to bring the fluid temperature up to a mini mum of 50 F 10 C or until the top of the hydraulic filter feels warm 3 When the engine is warmed up pull the throttle cable to the full open position and lock it into place This will provide the proper rpm to obtain 8 gpm required to power the hydraulic tools 4 Push the hydraulic tool circuit control lever to the ON position right see Figure 4 Figure 4 Control Panel to ON Position 11 OPERATION TOOL OPERATION 1 With the control lever at the ON position 2 Activate the tool The automatic throttle will increase engine speed to permit proper tool operation When the tool is deactivated the automatic throttle allows the engine to return to idle NOTE 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 tools SHUTDOWN 1 Place the circuit control lever in the OFF position 2 Push the throttle control completely in Allow the engine to idle for approximately one minute and then switch the starter switch to the OFF position 3 Pull the engine STOP knob NOTE The starter switch must be turned to the OFF position
5. DAILY FOR LEAKS DO NOT FEEL FOR LEAKS WITH YOUR HANDS CONTACT WITH A LEAK MAY RESULT IN SEVERE PERSONAL INJURY The safety tag at right is attached to the power unit when shipped from the factory Read and under stand the safety instruc tions listed on this tag before removal We TAG TO BE REMOVED ONLY BY suggest you retain this tag TOOLOPERATOR and attach it to the tool when not in use 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 SAFETY TAG 3 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 OUT HOSE MUST ALWAYS BE CONNECTED TO TOO REVERSING CONNECTIONS MAY CAUSE REVERSE TOOL OPERATION WHICH CAN RESULT IN SEVERE PER SONAL INJURY 4 DONOT 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 IN JURY 5 BYSTANDERS MAY BE INJURED IN YOUR WORK AREA KEEP BYSTANDERS CLEAR OF YOUR WORK AREA 6 WEAR HEARING EYE FOOT HAND AND HEAD PROTEC TION 7 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 OP
6. USING HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE ON OR NEAR ELECTRIC LINES WIPE THE ENTIRE LENGTH OF THE HOSE AND FITTING WITH A CLEAN DRY ABSORBENT CLOTH TO REMOVE DIRT AND MOSISTURE AND TEST HOSE FOR MAXIMUM ALLOWABLE CURRENT LEAKAGE IN ACCORDANCE WITH SAFETY DEPARTMENT INSTRUCTIONS SEE OTHER SIDE SIDE 1 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 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 OH LIFT TOOLS POWER UNITS ETC 5 CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAMAGE TO COUPLINGS IF ANY OF THESE CONDITIONS EXIST REPLACE THE HOSE IMMEDIATELY NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE 6 AFTER EACH USE STORE IN A CLEAN DRY AREA SEE OTHER SIDE SIDE 2 DVL SIHL 3AON3Y LON OG shown smaller than actual size THE TAG SHOWN BELOW IS ATTACHED TO CONDUCTIVE HOSE DO NOT REMOVE THIS TAG 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 LINES MAY RESULT IN DEATH OR SERI
7. s RELIEF VALVES DESCRIPTION The relief valves allow oil to by pass to the reservoir when the system pressure reaches a pre set value The relief valves are set to by pass at a cracking pressure of 2100 2200 psi 148 155 bar While adjustments can be made to the relief settings see TESTING and TROUBLESHOOTING the parts of the relief valves are not serviceable RE ASSEMBLY 1 Reverse the above procedure to reinstall the above components TESTING GENERAL Tests and adjustments should be performed periodically to ensure the power unit is operating at maximum efficiency A hydraulic circuit tester is recom mended for use in isolating 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 given in this section for possible causes Also referto the section on service instructions for repair or replacement of defective parts TESTING H T M A Hydraulic Tool Manufacturers Association TYPE II CIRCUITS An H T M A Type II Circuit is a circuit that produces 8 gpm 30 lpm at 2000 psi 138 bar When the throttle actua tor is set in the full open posi
8. 9 5 in 100 3 cm EEN ENE ail 384 lbs 174 kg F el Tank Capa C e re al ra aa 4 2 gal 15 ltr Estimated Gas Consumption Per Hour i paa tica fed fattes ta atar 1 3 gal 4 ltr Hydrauli Reservor Capacidad 2 7 gal 11 Itr NON 2150 psi 148 bar EE NA SSR OO O I TOO 2500 psi 172 bar C 20 lpm 138 bar or D 30 lom 138 bar Sound Pressure Level 1 Meter anna nrnennnrnnnnnnnn ano nnnnn nn nn aa cnn nn cnn aiaia 100dBA Sound Power Level ictericia 111 dBA LWA Vibration bevel at A a Ce aaa N A 50 ft Dual Hydraulic Hose 1 2 in 1 D Wire Braid with Couplers oooooocccnnccooococnnocooonnnnnnnonnnonononnnnnnnnnnnrncnnnn rn nnnnrcnnnnn non 31848 25 ft Dual Hydraulic Hose 1 2 in 1 D Wire Braid with Couplers nnn nne 31972 Flush Face Coupler Set 1 2 in NPT NSN 4730 01 479 0555 cooooccccnnocccononcnnnnncnnnnnnnnnnnr cc naar rra 24070 Bruning Flush Face Coupler Set 1 2 in NPT i 03974 Flow and Pressure TOSE coraan aculei asi 04182 Adaptor 1 2 in SAE to 3 8 in Male Piper ia 00936 Bushing 1 2 t0 3 4 MN aus tes eset teas lets dei ee eee ei 02151 Hex Nipple 1 2 in Male Pipe lele ne dee en eee eet 04192 Flex Nipple 3 8 IM Male Pipe iii dr ar a na aaa ad Cl 03044 MAAS TOOLS NSN S Military Pavement Breaker Stanley Br6713016 i 3820 012 421 440 Military Hammer Drill Stanley 4 HD45110D cnn ano c crac 5130 01 178 6338 MAAS Post Driver Stanley
9. A ii 26 Wiring Diagram Fig 7A nn nn nn nana 27 Warranty ii eta 28 SERVICING THE STANLEY POWER UNIT This manual contains safety operation and routine mainte nance instructions Stanley Hydraulic Tools recommends that servicing of hydraulic tools other than routine maintenance must be performed by an authorized and certified dealer Please read the follow ing warning SERIOUS INJURY OR DEATH COULD RESULT FROM THE IM PROPER 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 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 equip ment IMPORTANT A DANGER a WARNING A CAUTION AUN NOTICE IMPORTANT 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 situa tion which if not avoided will result in death or serious injury This safety alert and signal word indi
10. ERATION 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 15875 shown smaller then actual size HYDRAULIC HOSE REQUIREMENTS HOSE TYPES Hydraulic hose types authorized for use with Stanley Hydraulic Tools are as follows O Certified non conductive Wire braided conductive 6 Fabric braided not certified or labeled non conductive Hose listed above is the only hose authorized for use near electrical conductors Hoses and 6 listed above are 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 from your Stanley Distributor THE TAG SHOWN BELOW IS ATTACHED TO CERTIFIED NON CONDUCTIVE HOSE O lt E a pal E uy gt o wW ec E o Zz o a 1 FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRIC LINES MAYRESULT IN DEATH OR SERIOUS INJURY FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND ELECTRIC LINES 2 BEFORE
11. HP18289M HYDRAULIC DIESEL POWER UNIT SERIOUS INJURY OR DEATH COULD RESULT FROM IM PROPER REPAIR OR SERVICE OF THIS TOOL REPAIRS AND OR SERVICE TO THIS TOOL MUST ONLY BE DONE BY AN AUTHORIZED AND CERTIFIED DEALER WARNING To avoid serious injury or death 00 Read the Manual Wear Eye ran SAFETY OPERATION AND MAINTENANCE O a SERVICE MANUAL Wear Dust Mask 47351 Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie OR 97267 5698 503 659 5660 Copyright O 2003 The Stanley Works FAX 503 652 1780 OPS SVCE USA 62216 1 2004 Ver 2 www stanley hydraulic tools com TABLE OF CONTENTS Safety Symbols iii 4 Safety Precautions incida iii 5 Tool Stickers amp TagS coomccconnncccnnnccccnnccnoncncnnnnanoncnnnn cnn 6 Hydraulic Hose Requirements rrurnnvvvnnnnvnnnnvvvnnnnnrnnnrvvnnnnrnnnnnnnrnneessnennnnnnr 7 HTMA Requirements nn EE CAKA 8 Operation veronica li 9 Routine Maintenance ii 13 Testing 8 Troubleshooting i 14 SpecifiCatiONS micci n ai iii 16 AGCCOSSOMOS coi a kakene adidas kakao 16 A 17 TOSUNG iii a e alii 20 Parts LISIS ii A dde 21 Parts Drawing cecinere it a kb 21 Engine amp Blower Parts Fig 1A crac 21 Frame Parts Fig 2A ciones 22 Hose Basket Fig 3A 23 Hydraulic Tank Parts Fig 4A 24 Dash Panel amp Valve Assembly Fig BA 25 Hose Fittings amp Clamps Fig 6
12. OUS INJURY 2 FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND 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 CAUSEE BODILY INJECTION AND SEVERE PERSONAL INJURY 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 A SEE OTHER SIDE SIDE 1 5 CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAMAGE TO COUPLINGS IF ANY OF THESE CONDITIONS EXIST REPLACE THE HOSE IMMEDIATELY NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE 6 AFTER EACH USE STORE IN A CLEAN DRY AREA SEE OTHER SIDE SIDE 2 DVL SIHL JAOWSY LON OG The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the shown smaller than actual size HOSE PRESSURE RATING hydraulic system HTMA REQUIREMENTS TOOL CATEGORY HYDRAULIC SYSTEM REQUIREMENTS TYPEII TYPEIII TYPE RR FLOW RATE 4 6 gpm 11 13 gpm 9 10 5 gpm 15 23 Ipm 26 34 lpm 42 49 lpm 34 40 lpm TOOL OPERATING PRESSURE 2000 psi 2000 psi 2000 psi 2000 psi
13. PD48142 nan nn nono rn nana cn cnn nn nn n nr narran 1710 01 468 8021 MAAS Post Puller Stanley 4 PP10100A i 1710 01 468 8024 Hydraulic Power Unit Gasoline Powered Stanley HP18299M 4320 01 450 3557 Hydraulic Power Unit Diesel Powered Stanley HP18289M i 1730 01 342 2183 50 ft Dual Hose Assembly includes Couplers Stanley 31848 4720 01 361 5033 17 SERVICE INSTRUCTIONS GENERAL Service instructions in this section are limited to parts and components other than the engine and hydraulic pump Other major components should be serviced by represen tatives of the respective manufacturers as follows ENGINE Duetz Ruggerini 19 hp Model MD191 The engine should be serviced only by Ruggerini Certified Dealers It is recommended to contact Deutz Corporation for the nearest authorized Ruggerini representative at 1 770 564 7100 HYDRAULIC PUMP ENGINE REMOVAL Most engine servicing can be performed without removing the engine Consult with your Ruggerini Dealer regarding engine repairs 1 Remove both battery connections Remove the battery strap or battery hold down Remove the battery 2 Remove the wheels by first removing one retaining ring slide one washer and wheel off of the axle then pull the other wheel and axle out of the axle brackets FUEL LINES AND FUEL TANK 3 Follow the applicable instructions below to disconnect engine fue
14. ad the Manual rer dl In addition to this manual read and understand safety and operating instructions in the Engine Operation Manual furnished with the power unit The HP18289M Hydraulic Diesel 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 Wear Ear Protection Wear Dust Mask 47351 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 Do not 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 us 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 Do not inspect hoses and fittings for leaks by using bare hands Pin hole leaks can penet
15. andling LOSS TIME Loss of operating time to the user while the tool s is out of service IMPROPER OPERATION Any failure or performance deficiency attributable to a failure to follow the guidelines and or procedures as outlined in the tool s operation and maintenance manual MAINTENANCE Any failure or performance deficiency attributable to not maintaining the tool s in good operating condition as outlined in the Operation and Maintenance Manual HYDRAULIC PRESSURE 8 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 REGISTRATION IS ON RECORD In the event a warranty claim is submi
16. as pump damage may occur 3 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 13 TESTING amp TROUBLESHOOTING GENERAL Tests and adjustments should be performed periodically to ensure the power unit is operating at maximum efficiency Stanley Circuit Tester Part Number 04182 is recom mended 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 given in this section for possible causes TESTING THE 8 GPM CIRCUIT To test the circuit proceed as follows 1 Set the Circuit Control Lever to the OFF position 2 Connect the Stanley Circuit Tester across two hose ends where the tool would normally be connected 3 Fully open the tester restrictor valve counter clockwise 4 Start the engine and allow it to run until warm 5 Pull the engine throttle control completely OUT so that the engine is running at full RPM 6 Move the Circuit Control Lever to the ON positi
17. 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 155bar 145 155bar 145 155bar 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 Sufficient heat rejection capacity to limit max fluid temperature to at max expected ambient temperature Min cooling capacity 3 hp 5 hp 7 hp 6 hp at a temperature difference of 2 24 kW 3 73 kW 4 47 kW 5 22 kW between ambient and fluid temps 40 F 40 F 40 F 40 F 22 C 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 25 microns 25 microns 25 microns 25 microns Min full flow filtration 30 gpm 30 gpm 30 gpm 30 gpm Sized for flow of at least 114 lpm 114 lpm 114 lpm 114 lpm For cold temp startup and max dirt holding 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
18. cate a potentially hazardous situation which if not avoided could result in death or serious injury This safety alert and signal word indicate a potentially hazardous situation which if not avoided may result in minor or moderate injury This signal word indicates a potentially hazardous situation which if not avoided may result in property damage This signal word indicates a situation which if not avoided will result in damage to the equipment This signal word indicates a situation which if not avoided may result in damage to the equipment Always observe safety symbols They are included for your safety and for the protection of the tool LOCAL SAFETY REGULATIONS Enter any local safety regulations here Keep these instructions in an area accessible to the operator and mainte nance personnel SAFETY PRECAUTIONS Tool operators and maintenance personnel must always comply with the safety A WARNING precautions given in this manual and on the stickers and tags attached to the equipment To avoid serious injury or death 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 on page 4 Re
19. e coupling flange bore 435 inches Tighten the setscrews b Adjust the coupling flange on the pump until the coupling sleeve has 1 32 1 16 inch end play BLOWER HUB BLOWER WHEEL INLET RING amp BLOWER HOUSING 1 Remove the engine as described earlier in this section 2 To remove the blower wheel remove the five screws 31 fig 1 or fig 1A around the housing inlet ring 30 fig 1 or 1A and remove the ring 3 Remove the blower wheel 26 fig 1 or 24 fig 1A with the blower hub it may be required to remove the three hub screws and use them as jack screws in the adjacent holes 25 fig 1 or 1A by loosening the set screws on the coupler flange 28 fig 1 or 1A 4 Remove the four capscrews 14 fig 1 or 1A holding the blower housing 16 fig 1 or 1A to the engine Remove the housing RE ASSEMBLY 1 Reverse the above procedure to reinstall the above components and observe the following added procedures a Install capscrews which hold the blower housing to the engine using Loctite 242 b Install capscrews which hold the blower wheel to the blower hub using Loctite 680 and torque to 80 100 Ib in 18 OIL COOLER 1 Remove the top grille 8 fig 2 or 47 fig 2A 2 Remove the hoses 3 8 9 fig 6 or 6A 3 Remove the fasteners that retain the cooler mounts 6 10 fig 1 or 1A and the cooler brace 12 fig 1 or 1A and remove the mounts and brace The switch box 7 fig 1 and wiring will be loo
20. he 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 will cause the engine RPM to remain at full load if AUTO is selected on the automatic throttle Also see HYDRAULIC HOSE REQUIREMENTS earlier in this manual QUICK DISCONNECT COUPLERS H T M A 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 1 Quick disconnect couplings and hose fittings are selected so that addi tional fittings such as reducer or adapter fittings are not required If adapter fittings are used they must be approved steel hydraulic fittings meeting a minimum operating pressure rating of 2500 psi 172 bar Do not use galvanized pipe fittings or black pipe fittings Use thread tape or pipe joint compound when installing quick disconnect couplings to hose or tool fittings Follow the instructions furnished with the selected thread sealant DO NOT OVERTIGHTEN THE FITTINGS 5 BATTERY The supplied 12 Volt DC no maintenance dry cell battery is fully charged The battery is air transportable and is suitable for cold weather applications 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 pr
21. hedule and general mainte nance instructions in the engine maintenance and opera tion manual furnished with the power unit Normal mainte nance includes Inspect the air filter daily Clean foam air cleaner every 3 months or 50 hours at a minimum e Replace dry air filter every 200 hours of operation e Replace fuel filter every 100 hours of operation e Replace spark plugs every 300 hours or every year Change engine oil after first 50 hours of operation then after every 200 hours of operation If engine has been operating under heavy load or in high ambient tempera ture moist or dusty conditions then change the oil every 25 hours of operation e Change oil filter when engine oil is changed e Check oil level daily e Remove dirt and debris from engine with a cloth or brush daily Do not use water spray e Clean air cooling system every 100 hours of operation HYDRAULIC SYSTEM MAINTENANCE e Check hydraulic fluid level daily Add fluid per specifica tions in this manual See HYDRAULIC FLUID under the section titled OPERATING INSTRUCTIONS Each day check hydraulic lines and fittings for leaks kinks etc Do not use your hand to perform this check e Change the hydraulic filter element every 200 hours of operation Change more often if cold moist or dusty condi tions exist e Check oil cooler for debris Remove debris with air pressure e Make sure the suction hose from the hydraulic tank to the i
22. 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 require ments 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 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 diesel engine lube oil to MIL L 2104D with S 3 MIL L 45199B detergent grade IMPORTANT The engine oil sump must never be overfilled Overfilling can cause the engine to overheat and cause crankshaft seal damage 2 ENGINE FUEL LEVEL Check the fuel level If low fill with DF 1 or DF 2 diesel fuel A S T M D975 66T No 1 or 2 dark Shut the engine off before attempting to add fuel to the fuel tank Do not remove the fuel cap while the engine is running Do not add fuel to the tank while the engine is hot Do not fill the fuel tank to a point of overflowing 3 HYDRAULIC FLUID Check the dip stick in the hydraulic fluid reservoir for the proper fiuid le
23. ick 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 compat ible with H T M A HYDRAULIC TOOL MANUFAC OPERATION CONTROL PANEL ee El PRESSURE RETURN H T M A 1 2 INCH FEMALE QUICK DISCONNECT COUPLER H T M A 1 2 INCH MALE QUICK DISCONNECT COUPLER 1 2 INCH MALE PIPE HOSE END 1 2 INCH I D HOSE 25 FT 4 LONG WITH 2500 PSI 172 BAR RATING AND 4 TO 1 SAFETY FACTOR P N 31848 50 ft HOSE amp COUPLER ASSEMBLY RETURN PRESSURE 1 2 INCH MALE PIPE HOSE END H T M A 1 2 INCH 4 FEMALE QUICK DISCONNECT COUPLER E H T M A 1 2 INCH MALE e QUICK DISCONNECT COUPLER ADAPTER 3 8 INCH MALE PIPE x 8 SAE O RING RETURN PRESSURE TOOL Figure 1 Hydraulic Connections 10 TURERS ASSOCIATION quick disconnect fittings NPT type threads See Figure 1 Longer hoses may be used when necessary but can effect the operation of the engine automatic throttle due to fluid resistance in the hose If small diameter or long hoses are used or if restrictive fittings are con nected to t
24. ing it into a container 2 Remove the grille 19 fig 2 or 5 fig 2A by removing the 4 capscrews 9 fig 2 or 3 fig 2A 3 Remove the hoses 6 amp 9 fig 6 or 6A by loosening the hose clamps 4 The hydraulic tank can now be removed by removing the 2 capscrews 32 fig 2 or 23 fig 2A and the tank support tab 29 fig 2 or 26 fig 2A 5 On model HP18289M the filter assembly 5 fig 4A is removed by first removing the capscrews 8 fig 4A Hold the grip plate in place with your fingers to prevent it from falling into the tank For the model HP20271A the filter assembly is removed by first removing the breather and the dipstick bolt 12 fig 4A RE ASSEMBLY 1 Reinstall the components and complete assembly to the frame by reversing the above procedures DASH PANEL amp VALVE ASSY 1 If it is necessary to remove the valve assembly the battery must first be removed in order to gain access to the hose fittings and wiring located on the back of the panel 2 After the hoses are removed the valve assembly may be 19 removed by first removing the capscrews 15 fig 2 or 3 fig 2A and 27 fig 5A Then remove the capscrews 19 fig 5A holding the valve to the dash panel VALVE SPOOL 1 To remove the valve spool remove the retaining rings 6 fig 5A and pull the valve spool out of the valve body 2 Inspect the finish of the valve spool and bores of the valve block If scored or scratched replace the part
25. it control lever to the ON position 7 Slowly close the restrictor valve while watching the pressure gauge When the gauge reaches 2000 psi continue to close the restrictor and watch closely for a small drop in pressure This small drop in pressure should occur between 2100 2300 psi 145 158 bar and indicates the pressure at which the relief valve cracks open Continue to close the restrictor The pressure should not exceed 2500 psi 172 bar when the restrictor is fully closed If the above settings are incorrect the relief valve requires adjustment or replacement as follows a Remove the top grille b Remove the capscrews holding the dash panel in place and tilt the dash panel forward to gain access to the relief valve c Remove the cap to the relief valve and note the screw slot The relief valve is adjusted by turning the screw clockwise to increase pressure or counter clockwise to decrease pressure Adjust the relief valve until a cracking pressure of approximately 2100 2300 psi 145 158 bar is achieved and then repeat the test d If cracking pressure between 2100 2300 psi 145 158 bar cannot be achieved and or if a maximum pressure of 2500 psi 172 bar cannot be achieved replace the relief valve and repeat the test FIGURE 1A ENGINE 8 BLOWER PARTS DESCRIPTION Filter Bracket Supplied with Item 19 Capscrew Capscrew Supplied with Item 19 Capscrew Lock Washer Cooler Mount Fuel Filter Bracket Oil Co
26. ith Item 14 33 04868 1 Elbow Fitting 90 12 21698 1 Control Panel Decal 34 5 1 Incl with Item 4 13 24060 2 Femal Coupler Body 35 gt 2 Incl with Item 4 14 No Item 36 a 1 Incl with Item 4 15 07793 1 Steel Ball 37 01403 1 O Ring 16 07754 1 Spring 38 07794 1 Backup Ring 17 01212 2 Pipe Plug 39 00140 1 Quad Ring 18 21693 1 Control Valve Stop 19 27931 2 Capscrew 20 01298 6 Lockwasher 21 07792 1 Elbow Fitting 45 22 01539 1 Elbow Fitting 25 FIGURE 6A HOSES FITTINGS amp CLAMPS DESCRIPTION 90 Elbow Hose Clamp Hose Cooler Supply Hose Assy Hose Suction Hose Clamp Sleeve Suction Tube Suction Hose Cooler Return Hose Fuel Return Hose Clamp Hose Fuel Supply 26 FIGURE 7A WIRING DIAGRAM ide GLOW PLUGS TO STATOR BLACK YELLOW BROWN BLACK Va VOLTAGE REGULATOR HOUR METER ME RED IN BLACK Fire s CIRCUIT GREEN a BREAKER aan START som C Pp ee ee SWITCH nee per 7 GLOW PLUG SWITCH RED WHITE l Mm Mm MN WHITE 8 r OIL PRESS SENDER SWITCH BOX c CONNECTIONS VIEWED MN Mm TE FROM FRONT OF FN SWITCH BOX BATTERY BLACK DESCRIPTION Wire Assy Black Wire Assy Green Wire Assy Black Circuit Breaker Glow Plug Switch Wire Assy White 27 WARRANTY Stanley Hydraulic Tool
27. l lines Model HP18289M The hoses at the fuel tank must be disconnected Obtain the following materials for plugging the fuel tank ports and the fuel hoses a Two short lengths 2 to 3 inches of fuel hose one with 1 4 inch inside diameter and one with 1 8 inch inside diam eter b Four plug fittings or wood dowels to plug one end of each of the short hoses and also the ends of the hoses disconnected from the fuel tank 17 Using the fittings or the wood dowels plug one end of each of the short hoses c Thoroughly clean the exterior of the connections of the fuel supply line 12 fig 6A and the fuel return line 10 fig 6A where they are connected to the fuel tank Disconnect one fuel line at a time quickly plugging the fuel line and the tank port with the wood dowels or fittings and the short hose lengths to minimize spillage Wipe up any spillage using appropriate disposal methods Model HP18289M The fuel tank must be removed in order to remove the engine a Disconnect the hoses 13 amp 14 fig 6A and plug them with a plug fittings or wood dowels b Remove the 3 capscrews 23 fig 2A that secure the tank to the frame Remove the fuel tank 4 Remove the air cleaner cover and air cleaner 5 Remove the top grille 8 fig 2 or 47 fig 2A 6 Remove the fasteners that retain the cooler mounts 6 8 10 fig 1 8 fig 1A and the cooler brace 12 fig 1 and fig 1A and remove the mounts and brace The switch box 7
28. nlet manifold is clamped securely This reduces the risk of pump cavitation All pump fittings should be tight e Keep air out of the hydraulic lines Hydraulic system overheating and foam at the hydraulic tank breather indicates air is present in the lines Keep all suction line fittings and clamps tight e Hydraulic system wear is noted by increased heat during tool operation reduced tool performance and eventual system breakdown Operate with the fluid temperature at 50 140 F 10 60 C for improved seal and hose life and maximum efficiency FILLING THE RESERVOIR 1 Make sure the engine is stopped before opening the filler cap Fill slowly with the recommended fluid as listed in the Operation section of this manual 2 Add fluid as needed 3 Secure the filler cap before restarting the engine REMOVING CONDENSED MOISTURE FROM HYDRAULIC FLUID Condensation is a frequent problem with cool 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 1 To remove water from the hydraulic system use the PRESSURE hose without the quick disconnect coupler attached Start the engine and let it run at the idle speed Pump the fluid into a clean 5 gal 20 ltr container 2 Turn the engine OFF as soon as the hydraulic tank reservoir is empty DO NOT operate the engine with an empty hydraulic tank
29. oduces a charging amperage higher than 2 amps Charging the battery at higher than 2 amps will damage the battery OPERATION STARTUP SEE CONTROL PANEL FIGURE 2 1 Before starting the engine assure the hydraulic circuit control lever is in the TOOL OFF position left and the throttle cable is fully depressed Figre 2 Control Panel 2 Turn the three position starter switch clockwise until the engine begins to crank When the engine starts release the switch The switch will default to the ON 2nd position as shown in Figure 3 Oil Battery Pressure Charge Glow Plug Light i Light Buttons vtu START 3 Position Figure 3 Engine Control Panel 3 When the engine is warmed up pull the throttle cable to the full open position and lock it into place This will provide the proper rpm to obtain 8 gpm 30 Ipm required to power the hydraulic tools 4 Push the hydraulic tool circuit control lever to the ON position right see Figure 4 OIL PRESSURE LIGHT A problem with the engine oil lubricating system exists if the oil pressure light remains on after the engine has started Shutdown the engine and then have the lubricating system serviced by a qualified technician COLD WEATHER STARTUP 1 Before starting the engine assure the hydraulic circuit control lever is in the TOOL OFF position left and the throttle cable is fully depressed 2 Press and hold the glow plug switch for 10
30. oler NO ITEM Cooler Mount NO ITEM Cooler Brace Sheet Metal Screw Capscrew Washer Blower Housing Att SH HSH AP ap O 001 a Square Key Engine Ruggerini MD191 Capscrew Washer also used in Fig 2 Capscrew Spacer Blower Wheel Blower Hub QD Bushing Capscrew Supplied with Item 26 Coupling Assy Inlet Ring Gasket Inlet Ring Tapping Screw ESNA Nut also used in Fig 2 OMNDANRKVNRN 4 A A ANNO Der XH OH N DESCRIPTION Stop Cable Handle Grip Capscrew Washer Grille Assy Throttle Cable Warning Sticker Lockwasher Plug Capscrew Lock Washer Elbow 90 Elbow 90 Hydraulic Pump Key Included with pump Coupling Assy Incl items 17 Part of Item 16 Hydraulic Tank Battery Hold Down FIGURE 2A FRAME 4 N WO NASUIN k o PARTS SAT SEEFIGURE3 DESCRIPTION Battery Battery Pad Vibration Mount Capscrew Washer Capscrew Tank Support Washer Capscrew Capscrew Locknut NO ITEM ESNA Nut also used in Fig 1 Carry Handle Capscrew Locknut Washer also used in Fig 1 ITEM NNNN 2 OnNANMNNH H SEE FIGURE 4A DESCRIPTION Tank Support Axle Frame Weldment Handle Tube Wheel Foam Filled Washer Retaining Ring Fuel Tank Fuel Tank Cap Supplied with Item 44 Top Grille Decal Hyd Fluid Washer Nut Washer Bumper Grommet FIGURE 4A HYDRAULIC TANK PARTS
31. on 7 With the engine at high speed the test flow gauge should read at least 8 gpm 30 Ipm 8 Slowly turn the restrictor valve clockwise while watching the pressure gauge The flow rate should stay at 8 9 gpm 30 34 lpm as the pressure gauge reaches 2100 2200 psi 148 155 bar 9 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 reset as follows a Access to the relief valve can be gained through the top of the power unit between the dash panel and top grille If more room is required remove the dash panel Use a open end or box end wrench to remove the cap on the relief valve b Use an Allen wrench to adjust the relief valve Turn clockwise to raise the pressure and counterclockwise to reduce the pressure c Replace the cap and test for 2100 2200 psi 148 155 bar as described above d Repeat the above test with the hoses and tester connected to the other circuit 14 TROUBLESHOOTING PROBLEM Engine will not run CAUSE Battery not connected REMEDY Attach battery cables check wires Weak battery Test batter
32. rate the skin NEVER OPERATE THE POWER UNIT IN A CLOSED SPACE Inhalation of engine exhaust can be fatal Do not operate a damaged improperly adjusted power unit 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 lables 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 TOOL STICKERS amp TAGS 15875 SAFETY TAG shown below Do not remove until read CERTAIN PARTS OF THE POWER UNIT DANGER OPERATE UNIT ONLY INA WILL BE HOT WELL VENTILATED AREA ENGINES PRODUCE CARBON AVOID CONTACT WITH MONOXIDE WHICH IS AN THOSE PARTS TO ODORLESS DEADLY POISON PREVENT INJURY 28046 28047 CARBON MONOXIDE DECAL HOT PARTS DECAL located on dash panel located on da
33. s hereinafter called Stanley subject to the exceptions contained below warrants new hydraulic tools for a period of one year from the date of sale to the first retail purchaser or for a period of 2 years from the shipping date from Stanley whichever period expires first to be free of defects in material and or workmanship at the time of delivery and will at its option repair or replace any tool or part of a tool or new part which is found upon examination by a Stanley authorized service outlet or by Stanley s factory 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 part
34. s which are not approved for warranty credit will be the responsi bility of the individual SEALS amp DIAPHRAGMS Seals and diaphragms installed in new tools are warranted to be free of defects in material and or workmanship for a period of 6 months after the date of first usage or for a period of 2 years from the shipping date from Stanley whichever period expires first CUTTING ACCESSORIES Cutting accessories such as breaker tool bits are warranted to be free of defects in material and or workmanship at the time of 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 h
35. se after this procedure 4 Lift the cooler out RE ASSEMBLY 1 Reverse the above procedure to reinstall the cooler HYDRAULIC PUMP 1 First remove the hydraulic fluid from the tank by either pumping it out with a portable drill pump or draining it into a container 2 Remove the grille 19 fig 2 or 5 fig 2A 3 Disconnect the pressure hoses and inlet manifold at the pump 3 Remove the 2 capscrews 21 fig 2 or 10 fig 2A and then remove the pump RE ASSEMBLY 1 Reverse the above procedure to reinstall the pump and observe the following step a Insure the coupling sleeve is installed correctly see REINSTALL ENGINB FUEL TANK 1 If the fuel tank contains fuel take extreme precautions to remove the fuel into approved containers Do not attempt to service the fuel tank in unventilated areas or in areas containing electric or natural gas appliances which may start up unexpectantly or in shop areas where grinding or welding is present all of which can ignite the fuel vapors SERVICE 2 Follow step 3 under ENGINE REMOVAL to disconnect and plug the fuel lines To remove the tank first remove the 3 capscrews 23 fig 2A and tank support 37 fig 2A at the top of the fuel tank only Slide the tank out RE ASSEMBLY 1 Reverse the above procedures to reinstall the fuel tank HYDRAULIC TANK 1 First remove the hydraulic fluid from the tank by either pumping it out with a portable drill pump or drain
36. sh panel DIESEL FUEL ONLY 32331 DIESEL FUEL ONLY DECAL located on fuel tank SERIAL NO LOCATION At top of dash panel 35686 HYDRAULIC FLUID DECAL located on hydraulic tank filter block i ana Ao HYDRAULIC VALVE 28988 EXHAUST FUMES STICKER BATTERY CHARGE TAG DANGER Do not remove until read D DO NOT LIFT OR CARRY TOOL BY THE HOSES DO NOT ABUSE HOSE DO NOT USE KINKED TORNOR DAMAGEDHOSE CHECK HYDRAULIC FLUID LEEL WITH ENGINE AT IDLE ADD FLUID WHEN ENGINE IS OFF 1 FAILURE TO USE HYDRAULIC HOSE LABELED AND CER TIFIED AS NON CONDUCTIVE WHEN USING HYDRAU LIC TOOLS ON OR NI ELECTRICAL LINES MAY RE Il EAR SULT IN DEATH OR SERIOUS INJURY BEFORE Syed HOSE LABELED AND CERTIFIED AS NON CONDI IVE ON OR NEAR ELECTRIC DUSA ve SURETHE HOSE IS MAINTAINED AS NON CONDI THE HOSE SHOULD BE REGULARLY TESTED FOREL aro TRIC CURRENT LEAKAGE IN ACCORDANCE WITH YOUR SAFETY DEPARTMENT INSTRUCTIONS A HYDRAULIC LEAK OR BURST MAY CAUSE OIL INJEC TION INTO THE BODY OR CAUSE OTHER SEVERE PER SONAL INJURY A_DONOTEXCEED SPECIFIED FLOW AND PRESSURE FOR THIS TOOL EXCESS FLOW OR PRESSURE MAY CAUSE A LEAK OR BURST B DO NOT EXCEED RATED WORKING PRESSURE OF HY DRAULIC HOSE USED WITH THIS TOOL EXCESS PRES SURE MAYCAUSE A LEAK OR BURST CHECK TOOL HOSE COUPLERS AND CONNECTORS 51297 CHECK HYDRAULIC FLUID DECAL located on dash panel C
37. tion the power unit produces 8 gpm 30 Ipm at 2000 psi 138 bar 1 Set the circuit control lever to the OFF position 2 Connect the circuit tester across the tool hose ends 3 Fully open the tester restrictor valve 4 Start the engine and allow it to run until warm 5 Set the engine Throttle Control to the full open position 6 Place the circuit control lever to the ON position With the engine at high speed the test flow gauge should read 8 9 gpm 30 34 Ipm 7 Slowly close the restrictor valve while watching the pressure gauge The flow rate should begin at 8 gpm 30 lpm and will drop slightly as the pressure gauge rises At a pressure of 2000 psi 138 bar the flow rate should read 8 gpm 30 Ipm If it does not the throttle governor may require adjustment If a pressure of 2000 psi 138 bar cannot be obtained the relief valve may require adjustment Test the relief valve according to the instructions located later in this manual 20 TESTING amp SETTING THE RELIEF VALVE The relief valve is set to crack open at approximately 2100 2300 psi 145 158 bar and should be fully open at 2500 psi 172 bar These settings are tested as follows 1 Set the circuit control lever to the OFF position 2 Connect the circuit tester across the tool hose ends 3 Fully open the tester restrictor valve 4 Start the engine and allow it to run until warm 5 Set the engine Throttle Control to the FULL OPEN position 6 Place the circu
38. tted and no tool registration is on record no warranty credit will be issued without first receiving documentation which proves the sale of the tool or the tools first date of usage The term DOCUMENTATION as used in this paragraph is defined as a bill of sale or letter of intent from the first retail customer A WARRANTY REGISTRATION FORM THAT IS NOT ALSO ON RECORD WITH STANLEY WILL NOT BE ACCEPTED AS DOCUMENTATION NO ADDITIONAL WARRANTIES OR REPRESENTATIONS This limited warranty and the 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 28 Stanely Hydraulic Tools i Y 3810 SE Naef Road S AN LE Milwaukie Oregon 503 659 5660 Fax 503 652 1780 www stanley hydraulic tools com
39. vel Proper fluid level is indicated when the center section of the dipstick shows oil If the center section of the dipstick does not show add hydraulic fluid NOTE Do not over fill the hydraulic tank Oil will rise and leak from the tank breather Use fluids meeting the following specifications VISCOSITY FLUID THICKNESS U S METRIC 50 F 450 SSU Maximum 100 F 130 200 SSU 140 85 SSU Minimum 10 C 95 C S 38 27 42 C S 60 C 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 C 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 well over a wide temperature range at startup Allow moisture to settle out and resist biological growth that may occur in cool operating hydraulic circuits These fluids are recommended by Stanley Hydraulic Tools 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 Shell Tellus T 32 Texaco Rando HD AZ Union Unax AW WR 32 Terresolve EnviroLogic 132 4 HYDRAULIC CONNECTIONS Facing the panel control valve the far right hand male quick disconnect fitting is the pressure FLUID OUT fitting The left hand female qu
40. y charge or replace No fuel Add Fuel Fuel filter plugged Replace fuel filter Fluid blowing out of fluid reservoir vent Defective pump seal Replace pump seal Hydraulic tank overfilled Correct the fluid level Hydraulic tool won t operate Control lever setting incorrect Set control lever to TOOL ON Incorrect hose connection to tool Make sure the tool hose goes from pressure fitting to tool and back to the return fitting 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 Check coupling between pump and blower The coupler should slide only 03 06 in 80 1 60 mm inches between blower and pump Relief valve stuck open Adjust or replace valve Incorrect throttle setting Pull throttle completely out so that engine runs at full rpm SPECIFICATIONS a ela AATE cedo redde res auge eras Duetz Ruggerini MD191 2 cylinder diesel 19 hp Engine kube System uuttuasskev bilie ila cai I aaa Pressure Lube Capacitan ia iti libia 8 gpm 2000 psi 30 Ipm 138 bar Lona eee eed det eee a eee a ceo iaia 35 5 in 90 cm VUE RR E bedende eget OO CT LIO 24 in 61 cm Height with hose basket astice hver ad dekke ian 3
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