Page 1
®
User’s Manual
DL09
Hydraulic Drill
This Manual Covers The Following Models:
DL09150
DL09152S
DL09152SN
DL09152SUP
DL09172S
DL09172SN
DL09550D
DL0955001
DL09652
DL0965201
Copyright © 2002 The Stanley Works
OPS USA & CE Version
25077 7/2002 Ver. 2
(Depth Rod Not Pictured)
DANGER
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.
Page 2
Table of Contents
DL09
Hydraulic Drill
SERVICING THE
DL09 HYDRAULIC DRILL:
This manual contains Safety,
Operation, and Troubleshooting
information. Stanley Hydraulic Tools
recommends that servicing of
hydraulic tools, other than routine
maintenance, must be performed
by an authorized and certified
dealer. Please read the DANGER
warning on the cover and the
SAFETY warning below.
Certificate of Conformity
Specifications
General Safety Instructions
Tool Decals and Tags
Hydraulic Hose Requirements
HTMA Requirements
Hydraulic Recommendations
Operating Instructions
Troubleshooting
Parts Illustration
Parts List
3
3
4
5
6
7
8
9
11
13
14
Copyrightc2002 The Stanley Works
All rights reserved.
Under copyright law, this document may
not be copied in whole or in part without
the prior written consent of The Stanley
Works. This exception does not permit
copies to be made for others, whether or
not sold. Under the law, copying includes
translating into another language, format
or medium. This copyright notice must
appear on any permittedcopies.
2
Warranty
SAFETY FIRST
It is the responsibility of the operator and
service technician to read rules and
instructions for safe and proper operation
and maintenance.
A cautious worker using common sense is
the greatest safety device.
16
Page 3
Certificate of Conformity
I, the undersigned:
Winterling, David
Surname and First Names
hereby certify that the construction plant or equipment specified hereunder:
1. Category:
2. Make:
3. Type:
4. Type Serial Number of equipment:
5. Year of manufacture:
Drill
Stanley
DL0955001, & DL0965201
ALL
Stampedon tool
Has been manufactured in conformity with- EEC Type examination as shown:
Directive:
EN792-3
Approved body:
Self
EN28662-1
EN ISO 3744
Date:
6. Special Provisions:
Done at: Date:
2001
None
StanleyHydraulic Tools, Milwaukie, Oregon USA 2002
Date of expiration:
N/A
Signature: Position:
Engineering Manager
Specifications
Drive Size______ 1/2 in./ 1.3 cm 3-Jaw Adjustable
5/8 - 16 THD Chuck
Pressure Range______1000Flow Range_____________4-12 gpm / 15-45 lpm
Optimum Flow________________ 8 gpm / 30 lpm
System Type__open or closed center, HTMA TYPE I-III
Porting_______________________-8 SAE O-ring
Connect Size & Type___ 3/8
Weight_______________________ 6
Overall Length__________________ 9
Width_______________________ 3-1/2
Motor____________________________ Integral
TORQUE (proportional to Oil Pressure) Drill Speed (proportional to Oil Flow)
USA METRIC
4 ft-lb @ 500 psi 5 Nm @ 35 bar
9 ft-lb @ 1000 psi 12 Nm @ 70 bar
14 ft-lb @ 1500 psi 19 Nm @ 105 bar
19 ft-lb @ 2000 psi 26 Nm @ 140 bar
2000 psi / 70-140 bar
in. NPT Male Adapter
lbs. / 2.7 kg
in. / 23 cm
in. / 9 cm
DL09 TORQUE AND DRILL SPEEDS
Drill Torque___20 ft lbs / 27 Nm at 2000 psi/ 140 bar
Drill Speed__________1000 rpm at 8 gpm/ 30 lpm
RPM Range______________________350-1500
Max. Fluid Temp._____________
HTMA Class II___________
30Lpmat 138bar
BHTMACATEGORY
Weighted Vibration Level____________1.2(m/s2)
Sound Pressure Level_Less than 85 dBA @ 1 m
EHTMA Category_____
HYDRAULIC FLOW DRILL SPEED
3 gpm (11.3 lpm) 350 rpm
4 gpm (15 lpm) 475 rpm
6 gpm (23 lpm) 750 rpm
8 gpm (30 lpm) 1000 rpm
10 gpm (38 lpm) 1250 rpm
7-9 gpm @ 2000 psi
30 lpm @ 138 bar
° F / 60° C
140
3
Page 4
General Safety Instructions
Always observe safety symbols. They are included for your safety and the protection of the tool.
DANGER
This safety symbol may appear on
thetool.Itisusedtoalertthe
operator of an action that could
placehim/herorothersinalife
threatening situation.
WARNING
This safety symbol appears in these
instructions to identify an action
that could cause bodily injury to the
operator or other personnel.
This safety symbol appears in these
instructions to identify an action or
condition that could result in
damage to the tool or other
equipment.
CAUTION
This tool will provide safe and dependable service if operated in accordance with the instructions
given in this manual. Read and understand this manual and any stickers and tags attached to the
tool and hoses before operation. Failure to do so could result in personal injury or equipment
damage.
A Operator must start in a work area without bystanders. The operator must be familiar with all prohibited
work areas such as excessive slopes and dangerous terrain conditions.
Establish a training program for all operators to ensure safe operations.
A
Do not operate the tool unless thoroughly trained or under the supervision of an instructor.
A
Always wear safety equipment such as goggles, head protection, and safety shoes at all times when
A
operating the tool.
Do not inspect or clean the tool while the hydraulic power source is connected. Accidental engagement of
A
the tool can cause serious injury.
Do not operate this tool without first reading the Operating Instructions.
A
Do not install or remove this tool while the hydraulic power source is connected. Accidental engagement
A
of the tool can cause serious injury.
Never operate the tool if you cannot be sure that underground utilities are not present. Underground
A
electrical utilities present an electrocution hazard. Underground gas utilities present an explosion hazard.
Other underground utilities may present other hazards.
Do not wear loose fitting clothing when operating the tool. Loose fitting clothing can get entangled with
A
the tool and cause serious injury.
Supply hoses must have a minimum working pressure rating of 2500 psi/175 bar.
A
Be sure all hose connections are tight.
A
The hydraulic circuit control valve must be in the “OFF” position when coupling or uncoupling the tool.
A
Wipe all couplers clean before connecting. Failure to do so may result in damage to the quick couplers
and cause overheating. Use only lint-free cloths.
Do not operate the tool at oil temperatures above 140 F/60 C. Operation at higher oil temperatures can
A
°°
cause operator discomfort and may cause damage to the tool.
Do not operate a damaged, improperly adjusted, or incompletely assembled tool.
A
To avoid personal injury or equipment damage, all tool repair, maintenance and service must only be
A
performed by authorized and properly trained personnel.
Do not exceed the rated limits of the tool or use the tool for applications beyond its design capacity.
A
Always keep critical tool markings, such as labels and warning stickers legible.
A
Always replace parts with replacement parts recommended by Stanley Hydraulic Tools.
A
Check fastener tightness often and before each use daily.
A
When working near electrical conductors, always assume that all conductors are energized and that insulation,
A
Clothing and hoses can conduct electricity. Use hose labeled and certified as non-conductive.
4
Page 5
Tool Decals & Tags
A model sticker is attached to the tool. Neverexceed the flow and pressure levels specified onthis
sticker. The information listed on the model sticker must be legible at all times. Replace this
sticker if it becomes worn or damaged. A replacement is available from your local Stanley
distributor.
28323
“CE” Decal
(CE Models only)
28788
Manual Sticker
(Not used on all models)
15211
Danger Sticker
Failureto use hydraulic hose labeled and certified as
non-conductivewhen using hydraulic tools on or
nearelectric lines may result in death or serious
injury.
Forproper and safe operation read owners manual
andmake sure that you have been properly trained in
correctprocedures required for work on or around
ELECTROCUTION
electriclines.
HAZARD
DANGER
7-10GPM/ 24-36 LPM
DONOT EXCEED 2000 PSI/ 140 BAR
nn
DONOT EXCEED SPECIFIED FLOW OR PRESSURE. USECLOSED-CENTER
n
TOOLON CLOSED-CENTER SYSTEM. USEOPEN-CENTERTOOL ON OPEN-
n
CENTERSYSTEM. CORRECTLYCONNECTHOSES TO TOOL "IN" AND "OUT"
n
PORTS. IMPROPER HANDLING, USE OR MAINTENANCE OF TOOL COULD
RESULTINA LEAK, BURST OR OTHER TOOL FAILURE. CONTACT AT A LEAK
ORBURST CAN CAUSE OIL INJECTION INTO THE BODY. FAILURE TO
OBSERVETHESE PRECAUTIONS CAN RESULT IN SERIOUS PERSONAL
INJURY.
n
n
DL09
29149
Rotation Direction Sticker
(Not used on all models)
Stanley Hydraulic Tools
3810 SE Naef Rd
®
Milwaukie, Oregon 97267
Model No.
DL09
15-45 lpm/4-12 gpm
140 bar/2000 psi
28769
DL09 Model Sticker
RPM Sticker
29148
(Not used on all models)
30Lpm at 138bar
BHTMA CATEGORY
11207
Circuit Type “D” Decal
(Not used on all models)
The SAFETY TAG, P/N 15875, shown at right, smaller
than actual size, 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.
DANGER DANGER
1. FAILURE TO USE HYDRAULIC HOSE
CERTI-FIED AS NON-CONDUCTIVE
HYDRAULIC TOOLS ON OR NEAR ELECTRICAL LINES
MAYRESULTIN DEATHOR SERIOUSINJURY.
BEFORE USING HOSE
NON- CONDUCTIVE
BESURE THE HOSEIS . T HE
HOSE SHOULD BE REGULARLY TESTED FOR ELECTRIC CURRENT
LEAKAGE IN ACCORDANCE WITH YOUR SAFETY DEPARTMENT
INSTRUCTIONS.
2. A HYDRAULIC LEAK OR BURST MAY CAUSE OIL
INJECTIONINTO THE BODYOR CAUSEOTHER SEVERE P ERSONAL
INJURY.
A. DO NOT EXCEED SPECIFIED FLOW AND
PRESSURE FOR THIS TOOL. EXCESS FLOW OR
PRESSUREMAY CAUSEA LEAK ORBURST.
B. DO NOT EXCEED RATED WORKING PRESSURE
OF HYDRAULIC HOSE USED WITH THIS TOOL.
EXCESS PRESSURE MAY CAUSE A LEAK OR
BURST.
C. CHECK TOOL, HOSE, COUPLERS &
CONNECTORS DAILY FOR
LEAKS. DO NOT FEEL FOR LEAKS WITH
YOUR HANDS. CONTACT WITH A LEAK MAY
RESULTIN SEVEREPERSONAL INJURY.
ON OR NEAR ELECTRIC LINES.
MAINTAINEDAS NON- COND UCTIV E
LABELED AND
WHEN USING
LABELED AND CERTIFIED AS
D. DO NOT LIFT OR CARRY TOOL BY THE HOSES. DO NOT ABUSE
HOSE.DO NOT USEKINKED, TORNOR DAMAGED HOSES.
3. MAKE SURE HYDRAULIC HOSES ARE PROPERLY
CONN-ECTED TO THE TOOL BEFORE PRESSURIZING
SYSTEM. SYSTEM PRESSURE HOSE MUST ALWAYS
BE CONNECTED TO TOOL “IN” PORT. SYSTEM
RETURN HOSE MUST ALWAYS BE CONNECTED AT
TOOL “OUT” PORT. REVERSING CONNECTIONS MAY
CAUSE REVERSE TOOL OPERATION WHICH CAN
CAUSESEVERE PERSONAL INJURY.
4. DO NOT CONNECT CLOSED-CENTER TOOLS TO
OPEN-CENTER HYDRAULIC SYSTEMS. THIS MAY
CAUSE EXTREME SYSTEM HEAT AND/OR SEVERE
PERSONALINJURY.
DONOT CONNECT OPEN-CENTERTOOLS TO CLO S ED -C E NT ER
HYDRAULIC SYSTEMS. THIS MAY RESULT IN LOSS OF OTHER
HYDRAULIC FUNCTIONS POWERED BY THE SAME SYSTEM AND/OR
SEVEREPERSONAL INJURY.
5. BYSTANDERS MAY BE INJURED IN YOUR WORK
AREA. KEEP BYSTANDERS CLEAR OF YOUR WORK
AREA.
6. WEAR HEARING,EYE, FOOT,HAND ANDHEAD PROTECTION.
7. TO AVOIDPERSONAL INJURYOR EQUIPMENT DAMAGE, ALL TOOL
REPAIR,MAINTENANCE AND SERVICE MUST BE
PERFORMEDBY AUTHORIZED A ND P R O PE R LY
TRAINEDPERSONNEL.
IMPORTANT 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
(517) (517)15875 15875
OPERATOR.
SEE OTHER SIDE SEE OTHER SIDE
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.
5
Page 6
Hydraulic Hose Requirements
HOSE TYPES
Hydraulic hose types authorized for usewithStanleyHydraulicTools areas follows:
Certified non-conductive
Wire-braided(conductive)
Fabric-braided (not certified or labeled non-conductive)
Hose listed above is the only hoseauthorizedfor use near electrical conductors.
Hoses and listed above are and be nearelectricalconductors.
HOSE SAFETY TAGS
To help ensure your safety, the following DANGER tags are attached to all hoses purchased from Stanley
Hydraulic Tools. DO NOT REMOVE THESE TAGS.
If the information in a tag is illegible because of wear or damage, replace the tag immediately. A new tag
may be obtained at no charge from yourStanley Distributor.
This Tag attached to “Certified Non-Conductive” hose.
conductive must never
(shown smaller than actual size) p/n 27987
DO NOT REMOVE THIS TAG
DANGER
1.
FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON-CONDUCTIVE WHEN USING
HYDRAULIC TOOLS ON OR NEAR ELECTRIC LINES MAY RESULTIN 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.
BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS NON-CONDUCTIVE ON OR NEAR
2.
ELECTRIC LINES, WIPE THE ENTIRE LENGTH OF THE HOSE AND FITTINGS WITH A CLEAN,
DRY,ABSORBENT CLOTH TO REMOVE DIRT AND MOISTURE AND TEST HOSE FOR MAXIMUM
ALLOWABLE CURRENT LEAKAGE IN ACCORDANCE WITH SAFETY DEPARTMENTINSTRUCTIONS.
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 BODILYINJECTION AND SEVERE PERSONAL INJURY.
SEE OTHER SIDE
DO NOT REMOVE THIS TAG
Side 1 Side 2
This Tag attached to “Conductive” hose.
(shown smaller than actual size) p/n 29144
DANGER
1.
DO NOT USE THIS HYDRAULIC HOSE ON OR NEAR ELECTRIC LINES. THIS HOSE IS NOT
LABELED OR CERTIFIED AS NON-CONDUCTIVE. USING THIS HOSE ON OR NEAR ELECTRIC LINES
MAY RESULTIN DEATH OR SERIOUS INJURY.
FOR PROPER AND SAFE OPERATION, MAKE SURE THAT YOU HAVE BEEN PROPERLY TRAINED IN
2.
CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND ELECTRIC LINES.
DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE. IMPROPER USE OR HANDLING OF
3.
HOSE COULD RESULT IN BURST OR OTHER HOSE FAILURE.KEEP HOSE AS FAR AWAY AS
POSSIBLE FROM BODY AND DO NOT PERMIT CONTACT DURING USE. CONTACT AT THE
BURST CAN CAUSE BODILYINJECTION AND SEVERE PERSONAL INJURY.
4.
HANDLE AND ROUTE HOSE CAREFULLY TO AVOIDKINKING, ABRASION, CUT TING OR CONTACT
WITH HIGH TEMPERATURE SURFACES. USE IF KINKED. USE HOSE TO PULL OR
LIFT TOOLS, POWER UNITS, ETC.
DO NOT REMOVE THIS TAG
DO NOT DO NOT
SEE OTHER SIDE
Side 1 Side 2
DANGER
4.
HANDLE AND ROUTE HOSE CAREFULLY TO AVOIDKINKING, ABRASION, CUT TING OR CONTACT
WITH HIGH TEMPERATURE SURFACES. USE IF KINKED. USE HOSE TO PULL OR
LIFT TOOLS, POWER UNITS, ETC.
CHECK ENTIRE HOSE FOR CUTS, CRACKS, LEAKS, ABRASIONS, BULGES OR DAMAGE TO
5.
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.
DO NOT DO NOT
SEE OTHER SIDE
DANGER
CHECK ENTIRE HOSE FOR CUTS, CRACKS, LEAKS, ABRASIONS, BULGES OR DAMAGE TO
5.
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
DO NOT REMOVE THIS TAG
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.
6
Page 7
HTMA Requirements
NOTE: These are general hydraulic system requirements. See tool specification page for tool
specific requirements.
Tool Category
C
Hydraulic System
Requirements
20Lpm at 138bar
BHTMA CATEGORY
Type I
30Lpm at 138bar
BHTMA CATEGORY
Type II
40Lpm at 138bar
EHTMA CATEGORY
Type III
Flow rate
Tool Operating Pressure
(at the power supply outlet)
System relief valve setting
(at the power supply outlet)
Maximum back pressure
(at tool end of the return hose)
Measured at a max. fluid viscosity of:
(at min. operating temperature)
Temperature
Sufficient heat rejection capacity
to limit max. fluid temperature to:
(at max. expected ambient temperature)
Min. cooling capacity
at a temperature difference of
between ambient and fluid temps
NOTE: Do not operate the tool at oil
temperatures above 140
at higher temperatures can cause operator
discomfort at the tool.
° F (60° C). Operation
4-6
gpm 7-9 gpm 10.5-11.6 gpm 11-13 gpm
(15-23 lpm) (26-34 lpm) (36-44 lpm) (42-49 lpm)
2000 psi
(138 bar) (138 bar) (138 bar) (138 bar)
2100-2250 psi
(145-155 bar)
200 psi
(14 bar)
400 ssu*
(82 centistokes)
°F °F °F °F
140 140 140 140
3hp 5hp 6hp 7hp
40 40 40 40
(60° C) (60° C) (60° C) (60° C)
(2.24 kW) (3.73 kW) (4.47 kW) (5.22 kW)
(22° C) (22° C) (22° C) (22° C)
°F °F °F °F
2000 psi 2000 psi 2000 psi
2100-2250 psi 2100-2250 psi 2100-2250 psi
(145-155 bar) (145-155 bar) (145-155 bar)
200 psi 200 psi 200 psi
(14 bar) (14 bar) (14 bar)
400 ssu* 400 ssu* 400 ssu*
(82 centistokes) (82 centistokes) (82 centistokes)
Filter
Min. full-flow filtration
Sized for flow of at least:
(For cold temp. startup and max. dirt-holding
capacity)
Hydraulic fluid
Petroleum based
(premium grade, anti-wear, non-conductive)
Viscosity
(at min. and max. operating temps)
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
25 microns 25 microns 25 microns 25 microns
18 gpm 30 gpm 35 gpm 40 gpm
100-400 100-400 100-400 100-400
(20-82 centistokes) (20-82 centistokes) (20-82 centistokes) (20-82 centistokes)
(68 lpm) (114 lpm) (132 lpm) (151 lpm)
ssu* ssu* ssu* ssu*
7
Page 8
Hydraulic Recommendations
SPECIFICATIONS
Fluids for Mobile Hydraulic
Tool Circuits
The specification listed here will
provide good all season operation
if your circuit is of proper design
and normal maintenance is performed.
(Periodic filter change,
draining of condensate, etc.
Recommended Fluid
s
ITEM U.S.A. METRIC
Viscosity (Fluid Thickness) 50 F 450 SSU Max 10 C 95 Centistokes Max.
Viscosity (Fluid Thickness) 100 F 130-225 SSU 38 C 27-42 Centistokes
Viscosity (Fluid Thickness) 140 F 85 SSE Min. 60 C 16.5 Centistokes Min.
Pour Point (Min. for cold startup) -10 F 23 C
Viscosity Index (ASTM D2220) 140 Minimum
Demulsibility (ASTM D1401) 30 Minutes Max.
Flash Point (ASTM D92) 340 F Min.
Rust Inhibition (ASTM D665 A&B) Pass
Oxidation (ASTM D943) 1000 Hours Min.
Pump Wear Test (ASTM D2882) 60 mg Max.
°°
°°
°°
°°
°
RECOMMENDED FLUIDS
BRAND BIODEGRADABLE DESCRIPTION
AMS-Oil No Hydraulic Fluid MN 150 SSU, 100 V.I.
The fluids listed here work well
over a wide temperature range at
start-up, allow moisture to settle
out, and resist biological growth
likely in cool-operating hydraulic
Circuits.
These fluids are recommended by
Stanley Hydraulic Tools for use in
our tools. Other fluids that meet or
exceed the specifications of these
fluids may also be used.
Chevron No AW-MV-32
Exxon No “Univis” J-26
Mobil No D.T.E. 13
Gulf No “Harmony” AW-HVI-1 50-32
Shell No “Lo-Hydraul” 32
Sun No “Sunvis” 805 MG
Texaco No “Rando” HD-AZ
Union No “Unax” AW-WR-32
Mobil Yes EAL 224H
Texaco Yes BioStar 32
Terresole Yes EnviroLogic 132
Shell Yes Naturelle HF-E-32
Pennzoil Yes Pennzsafe Sl200
P/N 15596 04/98 .5M
Page 9
Operating Instructions
CAUTION
Make certain that the chuck has been securely mounted.
Check Power Source
1. Using a calibrated flowmeter and pressure
gauge during the intial set-up, check that the
hydraulic power source develops a flow of 412 gpm/ 15-45 lpm at 1000-2000 psi/ 70-140
bar.
2. Make certain that the hydraulic power source
is equipped with a relief valve set to open at
2100 psi/ 145 bar maximum.
Connect Hoses
1. Wipe all hose couplers with a clean lint-free
cloth before making connections.
2. Connect hoses from the hydraulic power
supply to the tool quick disconnects. It is a
good practice to connect the return hose first
and disconnect it last to minimize or avoid
trapped pressure within the drill.
3. Observe the arrow on hose couplers to ensure
that the flow is in the proper direction. The
male coupler on the circuit hose end is the
supply (pressure) coupler.
4. Make sure the circuit PRESSURE hose (with
male quick disconnect) is connected to the
port at the back of the drill handle. The circuit
RETURN hose (with female quick disconnect)
is connected to the port closest to the trigger.
5. Move the hydraulic circuit control valve to the
position to direct hydraulic flow to the
ON
drill.
NOTE: If uncoupled hoses are left in the
sun, pressure increase inside the hose
may result in making them difficult to
connect. Whenever possible, connect the
free ends of the hoses together.
Drill Operation
1. Observe all safety precautions.
2. Place the selected drill bit fully into the chuck.
Center the bit and tighten the chuck using the
key provided. Remove the key and store away
from the drill.
3. Momentarily press the trigger to ensure that
the drill bit rotates clockwise and runs true.
4. Select a work position that gives secure
footing and balance while operating the drill.
5. Press the drill against the work and squeeze
the trigger.
The drilling method used is determined by the
material being drilled and the size and depth
requirements of the hole.
Ductile material such as metal or wood is drilled
efficiently when a steady down force is applied to
the drill center to cause the bit to slice chips of
material from the hole bottom. When drilling in
metal, use a cutting lubricant to prolong bit life
and reduce the amount of force required to drill
effectively.
Large drill holes are more productively created
from small drill holes. Drill bits are incrementally
selected to enlarge the hole until the desired hole
size is obtained. Each bit selected must always be
too large to thread and jam into an existing hole;
otherwise the bit may break and endanger the
operator.
9
Page 10
Operating Instructions
Cold Weather Operation
Damage to the hydraulic system or tool can result
from use with fluid that is too viscous or thick.
If the tool is to be used during cold weather, preheat
the hydraulic fluid at low engine speed. Follow
steps 1 through 5 (connect hoses) page#9ofthe
operating instructions. With the hoses connected to
the power supply and to the tool, turn the circuit on
DO NOT OPERATE THE TOOL)
( and allow the
hydraulic oil to preheat with the engine at low
speed. Preheat the hydraulic fluid until the
temperature is at or above 50
centistokes) when using the normally recommended
fluids.
Open Center/ Closed Center Setup
(OC/CC)
° F/10° C (400 ssu/82
The adjustment for open center/ closed center is
obtained by a flat screw slot located at front of tool.
To adjust from OC to CC or vice ver-sa hold on to
the trigger keeping it from being depressed. While
using a flat screw driver push in and rotate the
selector to the desired Open Center or Closed Center
position (see illustration on this page).
Note: Make sure that the four notches on the
selector lock into the four cutouts in the trigger.
For Closed Center operation turn the selector so that
the slot is in the horizontal position (as shown in the
illustration below). For Open Center operation
rotate the selector until the slot is in the vertical
position.
10
Page 11
Troubleshooting
This section describes how to find and resolve problems users may experience.If a situation occurs that is not covered,
call your Stanley Customer Servicerepresentative for assistance.
WARNING
Inspecting the tool or installing parts with the hydraulic hoses connected can result in severe personal injury or equipment
damage.
To prevent accidental startup, disconnect the hydraulic power before beginning any inspection or installation task.
If symptoms of poor performance develop, the following chart can beused as a guide to correct the problem.
When diagnosing faultsin operation of the tool, always check that the hydraulic power source is supplying the correct
hydraulic flow and pressure to the tool as listed in the table. Use a flowmeter known to be accurate. Check the flow
with the hydraulic oil temperature at least 80° F/27° C.
Symptom Possible Cause Solution
Tool will not start. Power not being supplied. Check to make certain that both
hoses are connected.
Turn hydraulic circuit control valve
ON.
Defective quick disconnects.
Check each quick disconnect
separately. Replace as necessary.
Low drilling
Relief valve setting too low. Set relief valve at 2100 psi/ 145 bar.
torque.
Fluid restriction in hose or valve.
Excess flow and pressure loss.
Locate and remove restriction.
Use correct fluid.
Fluid not warmed-up. Preheat
system.
Hoses too long for hose I.D. Use
shorter hose.
Hoses I.D. too small for hose
length. Use larger I.D. hose.
Low tool speed. Fluid flow rate is too low. Check circuit flow rate.
Tool speed too
high.
Oil leaks around
gear housing.
Fluid flow rate is excessive. Check circuit flow rate; add a
proper flow control valve.
Hydraulic pressure and return
hoses reversed.
Correct hose connections. Pressure
should be to the handle port away
from the trigger, return is near the
trigger, or see your Authorized
Dealer for servicing.
Main shaft seal o-ring leaking.
See your Authorized Dealer for
servicing.
11
continued
Page 12
Troubleshooting
Symptom Possible Cause Solution
Oil gets hot,
power unit
working hard.
Oil leaks at
reversing spool.
Oil leak at motor
cap face.
Open center tool on a closed center
circuit and vice versa.
Circuit relief set too low. Adjust relief valve to 2100 psi/ 145
Too much oil going through tool. Adjust flow for 12 gpm/ 45 lpm
Damaged o-rings. Replace as required.
Wrong hydraulic fluid. Circuit too
hot.
Fasteners loose. Tighten to specification (see service
Face o-ring worn or missing.
Motor cap/ main housing damaged. See your Authorized Dealer.
Use tools to match circuit.
bar.
maximum, or less.
See OPERATING INSTRUCTIONS
for correct fluid/ circuit
specifications.
manual.
See your Authorized Dealer.
12
Page 13
DL09 Parts Illustration
13
Page 14
NOTE:
Part Number
Use and
Description
when ordering.
DL09 Parts List
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
DescriptionDescriptionPartPartItem
1
38676
2
38685
3
15211
4
08175
5
26655
24412
6
09623
7
09622
00753
8
09687
00111
9
09621
09778
09624
27628
08163
08162
00354
08165
09779
08161
08440
08166
06635
20767
13995
18206
00146
26297
00231
00145
20770
01262
24271
05207
00713
27559
20790
20758
00026
20782
20760
20769
28769
28323
28788
28316
29149
20781
01605
06617
29313
24161
23175
23174
20783
02178
Depth Guage Rod (ModelsDL09172S,DL09172SN, & DL09152S Only)Shipped uninstalled.
Thumb Screw (ModelsDL09172S,DL09172SN, & DL09152S Only)Shipped uninstalled.
Danger Sticker (Not used on Models )
Ball Bearing
Gear Housing
Gear Housing (Model ONLY)
Lockwasher # 10
Capscrew 10-24x1-1/4 HSH Stainless
Capscrew 10-24x1-1/4 HSH (Model ONLY)
Capscrew 10-24x2 HSH Stainless
Capscrew 10-24x1-1/2 Hex Socket head (Model ONLY)
Shaft Seal
Seal Nut
Chuck 3 Jaw Adjustable, 5/8-16 THD (All Models Except DL09172S & DL09172SN)
Chuck 3 Jaw Adjustable, 5/8-16 THD (Used on Models DL09172S & DL09172SN only)
Bearing Keeper
Shaft Keeper
O-ring 1/2 x 11/16 x 3/32 - 112
Planet Gear Assembly
Output Shaft
Planet Shaft
Retaining Ring
Ring Gear
Retaining Ring
Seal Back-up Washer
Back-up Ring - 112
Capscrew 5/16-18x1-3/4 HSH STNLS
Capscrew 5/16-18x1-3/4 HEX SOC HEAD (Model ONLY)
Capscrew 5/16-18x1-3/4 ZNC PLT (Model DL09152SN ONLY)
Lockwasher 5/16 High Collar
Lockwasher 5/16 High Collar (Model ONLY)
Motor Cap Assy (Includes Items 28 & 29)
O-ring 1-3/4 x 1-7/8 x 1/16 - 031
Main Shaft
Bushing
Dowel Pin
Main Housing Assy (Includes Items 28,31,32)
Main Housing Assy (Models DL09550D, , & ONLY) (Includes Items 28,
31,32)
Bushing
O-ring
Idler Shaft
Bushing
Idler Gear Assy (Includes Item 34)
DL09 Model Number Sticker
CE Sticker (Models ONLY)
Manual Sticker (Models 1 ONLY)
CN Sticker (Model DL09152SN ONLY)
Rotation Direction Sticker (Models ONLY)
Spring Cap
O-ring 1/2 x 5/8 x 1/16 - 014
Spring
Valve Spool Assy-OC/CC
Valve Spool-OC (Model ONLY)
Capscrew 12-24x3/8 Hex Soc Flat Head
Capscrew 12-24x3/8 Hex Soc Flat Head (Models ONLY)
Stop Washer
Wiper Seal
DL09150
DL0955001 & DL0965201
DL0965201 & DL095500
DL09150
DL0955001 & DL0965201
DL09150
DL09150
DL09150
DL09150
DL09150 DL0955001
DL0955001 & DL0965201
DL09150, DL09550D, & DL0955001
Qty.
1
1
1
1
1
1
3
3
3
3
2
1
1
1
1
1
1
2
2
1
2
1
1
1
1
1
6
6
6
6
6
1
1
1
2
2
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
14
Page 15
NOTE:
Part Number
Use and
Description
when ordering.
DL09 Parts List (Continued)
DescriptionDescriptionPartPartItem Qty.
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
----
----
----
20786
01604
00106
34893
12100
03709
08130
18919
14019
14028
14024
24411
14022
07724
06971
00936
28234
24058
03972
24059
03973
06345
12621
07970
11207
26299
11191
29456
Seal Cap
O-ring .755x.949x.097 -012 R16
O-ring 3/8x1/2x1/16 -012 R16
Reversing Spool
Steel Ball 3/8 Dia. (Not Used on Model )
DL09150
SAE Plug -5 Hex Soc Head
Cross Handle (Not Used On Models )
Pin To Socket Adaptor (Not Used On Model )
DL09150, DL09550D, & DL0955001
DL09150
Spool End Socket (Not Used On Model DL09150)
Retaining Ring
Trigger
Trigger (Model ONLY)
Trigger Guard (Not Used On Model )
DL09150
DL09150
Locknut 10-24 STNLS
Locknut 10-24 (Used On Model DL09152SN ONLY)
Adaptor Fitting (Used On Models , & DL09550D ONLY)
Hose Whip (Not Used On Models , & DL09550D)
Female Coupler Body 3/8”(Not Used On Models
DL0955001
&)
Female Coupler Body (Used On Model ONLY)
Male Coupler Body 3/8”(Not Used On Models , DL09550D, ,
DL09150, DL0955001
DL09150, DL0955001
DL09150, DL09550D, DL09652
DL0955001
DL09150 DL09652
& DL0955001)
Male Coupler Body (Used On Model ONLY)
DL0955001
Plastic Plug ( Not Illustrated)
Seal Gasket
Spirol Pin 3/16x1-3/8
Circuit Type “D” Decal
Lockout Kit (shipped unassembled) Not Used On Model
Chuck Key used on 3/8 chuck All Models except
C
huck Key used on ½ chuck (Used on models DL09172S & DL09172SN ONLY)
( DL09172S & DL09172SN)
DL09150
2
2
4
1
2
2
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
2
1
1
1
1
1
1
A Supplied with Item # 53
Seal Kit P/N 25078
00026
00106
00354
00717
01262
01604
01605
02003
02178
03364
08928
09621
13995
12621
25079
Note: No Male or Female Couplers are Provided with Models DL09150,
DL09652, & DL09550D.
O-ring 3/16 x 5/16 x 1/16 - 008
O-ring 3/8 x 1/2 x 1/16 - 012
O-ring ½ x 11/16 x 3/32 - 112
O-ring 2-112 R16
O-ring 1-3/4 x 1-7/8 x 1/16 - 031
O-ring .755 x .949 x .097 -910
O-ring 1/2x5/8x1/16-014
O-ring 2-113 R16
Wiper Seal 3/8 x 5/8 x 1/8
O-ring 3-905 R17
Back-up Ring
Shaft Seal
Back-up Ring - 112
Seal Gasket
INST. For seal kit
2
4
2
1
1
2
1
1
2
2
1
1
1
1
1
15
Page 16
Warranty
Stanley Hydraulic Tools (hereinafter called “Stanley”), subject to the exceptions contained below, warrants new hydraulic tools for a period of one
year from the date of sale to the first retail purchaser, or for a period of 2 years from the shipping date from Stanley, whichever period expires first,
to be free of defects in material and/or workmanship at the time of delivery, and will, at its option, repair or replace any tool or part of a tool, or new
part, which is found upon examination by a Stanley authorized service outlet or by Stanley’s factory in Milwaukie, Oregon to be DEFECTIVE IN
MATERIAL AND/OR WORKMANSHIP.
EXCEPTIONS FROM WARRANTY
NEW PARTS:
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:
credit, are covered under this policy if the claimed part or parts are approved for warranty credit. Freight costs for any part or parts which are not
approved for warranty credit will be the responsibility of the individual.
SEALS & DIAPHRAGMS:
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:
the time of delivery only.
ITEMS PRODUCED BY OTHER MANUFACTURERS:
manufacturers.
ALTERATIONS & MODIFICATIONS:
new tool or part is altered or modified in any way.
NORMAL WEAR:
bumpers, retaining rings and plugs, rubber bushings, recoil springs, etc.
INCIDENTAL/CONSEQUENTIAL DAMAGES:
incidental, consequential or special damages and/or expenses.
FREIGHT DAMAGE:
New parts which are obtained individually are warranted, subject to the exceptions herein, to be free of defects in material and/or
Freight costs to return parts to Stanley, if requested by Stanley for the purpose of evaluating a warranty claim for warranty
Seals and diaphragms installed in new tools are warranted to be free of defects in material and/or workmanship for a
Cutting accessories such as breaker tool bits are warranted to be free of defects in material and or workmanship at
Components which are not manufactured by Stanley and are warranted by their respective
a. Costs incurred to remove a Stanley manufactured component in order to service an item manufactured by other
manufacturers.
Alterations or modifications to any tool or part. All obligations under this warranty shall be terminated if the
Any failure or performance deficiency attributable to normal wear and tear such as tool bushings, retaining pins, wear plates,
To the fullest extent permitted by applicable law, in no event will STANLEY be liable for any
Damage caused by improper storage or freight handling.
LOSS TIME:
IMPROPER OPERATION:
the tool’s operation and maintenance manual.
MAINTENANCE:
Operation and Maintenance Manual.
HYDRAULIC PRESSURE & FLOW, HEAT, TYPE OF FLUID:
excess hydraulic back-pressure, excess hydraulic flow, excessive heat, or incorrect hydraulic fluid.
REPAIRS OR ALTERATIONS:
or contributed to the failure or deficiency.
MIS-APPLICATION:
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:
TION IS ON RECORD. In the event a warranty claim is submitted and no tool registration is on record, no warranty credit will be issued without first
receiving documentation which proves the sale of the tool or the tools’ first date of usage. The term “DOCUMENTATION” as used in this
paragraph is defined as a bill of sale, or letter of intent from the first retail customer. A WARRANTY REGISTRATION FORM THAT IS NOT ALSO ON
RECORD WITH STANLEY WILL NOT BE ACCEPTED AS “DOCUMENTATION”.
This limited warranty and the obligation of Stanley thereunder is in lieu of all other warranties, expressed or implied including merchantability or
Loss of operating time to the user while the tool(s) is out of service.
Any failure or performance deficiency attributable to a failure to follow the guidelines and/or procedures as outlined in
Any failure or performance deficiency attributable to not maintaining the tool(s) in good operating condition as outlined in the
Any failure or performance deficiency attributable to excess hydraulic pressure,
Any failure or performance deficiency attributable to repairs by anyone which in Stanley’s sole judgement caused
Any failure or performance deficiency attributable to mis-application. “Mis-application” is defined as usage of products for
STANLEY ASSUMES NO LIABILITY FOR WARRANTY CLAIMS SUBMITTED FOR WHICH NO TOOL REGISTRA-
NO ADDITIONAL WARRANTIES OR REPRESENTATIONS
16
Page 17
For additional Sales & Service information, contact:
®
Stanley Hydraulic Tools
Division of the Stanley Works
3810 SE Naef Road
Milwaukie, OR 97267 USA
Tel: (503) 659-5660
Fax: (503) 652-1780
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