Stanley HP1 Safety, Operation And Maintenance Manual

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Page 1

HP1

COMPACT POWER UNIT

Safety, Operation

and

Maintenance

Manual

OPS/MAINT USA & CE VERSION Printed in U.S.A. 24280 06/97 Ver 3

SERIOUS INJURY OR DEASERIOUS INJURY OR DEA

SERIOUS INJURY OR DEA

SERIOUS INJURY OR DEASERIOUS INJURY OR DEA COULD RESULCOULD RESUL

COULD RESUL

COULD RESULCOULD RESUL IMPROPER REPIMPROPER REP

IMPROPER REP

IMPROPER REPIMPROPER REP OF THIS TOOLOF THIS TOOL

OF THIS TOOL

OF THIS TOOLOF THIS TOOL

REPREP

AIRS AND / OR SERVICE TOAIRS AND / OR SERVICE TO

REP

AIRS AND / OR SERVICE TO

REPREP

AIRS AND / OR SERVICE TOAIRS AND / OR SERVICE TO

THIS TOOL MUST ONLTHIS TOOL MUST ONL

THIS TOOL MUST ONL

THIS TOOL MUST ONLTHIS TOOL MUST ONL DONE BDONE B

DONE B

DONE BDONE B CERTIFIED DEALERCERTIFIED DEALER

CERTIFIED DEALER

CERTIFIED DEALERCERTIFIED DEALER

T FROM THET FROM THE

T FROM THE

T FROM THET FROM THE

AIR OR SERVICEAIR OR SERVICE

AIR OR SERVICE

AIR OR SERVICEAIR OR SERVICE

Y AN AY AN A

UTHORIZED ANDUTHORIZED AND

Y AN A

UTHORIZED AND

Y AN AY AN A

UTHORIZED ANDUTHORIZED AND

Y BEY BE

Y BE

Y BEY BE

THTH

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INDEX

Index (this page) ...................................................................................... 1

Hydraulic Hose Requirements ................................................................. 6

Operation ......................................................................................... 7 - 10

Preparation for Use ........................................................................... 7

Hydraulic Connections ................................................................ 7 - 8

Startup ...................................................................................... 9 - 10

Cold Weather Startup ..................................................................... 10

Tool Operation .................................................................................10

Optional Equipment ............................................................................... 28

Parts Lists ...................................................................................... 19 - 20

Parts Drawings .............................................................................. 21 - 27

Engine Assembly (Fig. 1) ................................................................ 21

Frame Assemblies (Fig. 2) .............................................................. 22

Choke Cable Assembly (Fig. 3) ...................................................... 23

Actuator Assembly (Fig. 4) .............................................................. 23

Dash Panel & Valve Assembly (Fig. 5) ........................................... 24

Hydraulic Tank & Filter Assembly (Fig. 6) ....................................... 25

Hose & Fitting Connections (Fig. 7) ................................................26

Wiring Diagram (Fig. 8) .................................................................. 27

Routine Maintenance ............................................................................. 11

Engine ............................................................................................. 11

Hydraulic System ............................................................................ 11

Storage............................................................................................ 11

Safety Precautions ............................................................................ 2 - 5

Local Safety Regulation .................................................................... 4

Safety Stickers & Tags ......................................................................5

Sales & Service ......................................................................... Last Page

Service Instructions ....................................................................... 12 - 14

Specification & Capacities ..................................................................... 18

Testing & Troubleshooting ............................................................. 15 - 16

Troubleshooting Chart ........................................................................... 17

Warranty ................................................................................................ 29

SERIOUS INJURY OR DEASERIOUS INJURY OR DEA

SERIOUS INJURY OR DEA

SERIOUS INJURY OR DEASERIOUS INJURY OR DEA IMPROPER REPIMPROPER REP

IMPROPER REP

IMPROPER REPIMPROPER REP

REPREP

AIRS AND / OR SERVICE TO THIS EQUIPMENT MUSTAIRS AND / OR SERVICE TO THIS EQUIPMENT MUST

REP

AIRS AND / OR SERVICE TO THIS EQUIPMENT MUST

REPREP

AIRS AND / OR SERVICE TO THIS EQUIPMENT MUSTAIRS AND / OR SERVICE TO THIS EQUIPMENT MUST

ONLONL

Y BE DONE BY BE DONE B

ONL

Y BE DONE B

ONLONL

Y BE DONE BY BE DONE B

DEALERDEALER

DEALER

DEALERDEALER

For the nearest authorized and certified dealer, call Stanley Hydraulic Tools at one of the locations listed on the back of this manual.

TH COULD RESULTH COULD RESUL

TH COULD RESUL

TH COULD RESULTH COULD RESUL

AIR OR SERVICE OF THIS EQUIPMENTAIR OR SERVICE OF THIS EQUIPMENT

AIR OR SERVICE OF THIS EQUIPMENT

AIR OR SERVICE OF THIS EQUIPMENTAIR OR SERVICE OF THIS EQUIPMENT

Y AN AY AN A

Y AN A

Y AN AY AN A

UTHORIZED AND CERTIFIEDUTHORIZED AND CERTIFIED

UTHORIZED AND CERTIFIED

UTHORIZED AND CERTIFIEDUTHORIZED AND CERTIFIED

T FROM THET FROM THE

T FROM THE

T FROM THET FROM THE

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SAFETY PRECAUTIONS

Do not operate this equipment or associated equipment until the following safety instructions have been thoroughly read and understood! Read this manual before installing, operating or maintaining this equipment.

Tool operators and maintenance personnel must always comply with the safety precautions given in this manual and on the stickers and tags attached to the equipment.

These safety precautions are given for your safety. Review them carefully before operating the 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 5.

In addition to this manual, read and understand safety and operating instructions in the Engine Operation Manual furnished with the power unit.

GENERAL SAFETY PRECAUTIONS

The HP1 Compact Hydraulic Power Unit will provide safe and dependable service if operated in accordance with the instructions given in this manual. Read and understand this manual and any stickers and tags attached to the Power Unit. Failure to do so could result in personal injury or equipment damage.

• Operators must start in a work area without bystanders. The operator must be familiar with all prohibited work areas such as excessive slopes and dangerous terrain conditions.

• 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 and head protection, and safety shoes at all times when operating the power unit and a hydraulic tool.

• Do not inspect or clean the power unit while the unit is running.

• Always use hoses and fittings rated at 2500 psi/172 bar with a 4 to 1 safety factor. Be sure all hose

connections are tight.

• Make 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 penetrate the

skin.

• Never operate the power unit in a closed space. Inhalation of engine exhaust can be fatal.

• Do not operate a damaged or improperly adjusted power unit.

• 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.

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• Always wear appropriate safety equipment such as goggles, ear protection, and toe guards. Certain

tools used in conjunction with the power unit may require other safety equipment such as breathing filters.

• Keep clear of hot engine exhaust.

• Do not add fuel to the power unit while the power unit is running or is still hot.

• Do not operate the power unit if gasoline odor is present.

• Do not use flammable solvents around the power unit engine.

• Do not operate the power unit within 3.3 ft/1 m of buildings, obstructions, or flammable objects.

• Do not reverse grinding wheel rotation direction by changing fluid flow direction.

• Allow the engine to cool before storing the power unit in an enclosure.

• To avoid personal injury or equipment damage, all tool repair, maintenance and service must only be performed by authorized and properly trained personnel.

SAFETY SYMBOLS

Safety symbols are used to emphasize all operator, maintenance and repair actions which, if not strictly followed, could result in a life-threatening situation, bodily injury or damage to equipment.

DANGER

This safety symbol may appear on the tool. It is used to alert the operator of an action that could place him/her or others in a life threatening situation.

This safety symbol appears in these instructions to identify an action that could cause bodily injury to the operator or other personnel.

IMPORTANT

This safety symbol appears in these instructions to identify an action or condition that could result in damage to the tool or other equipment.

Always observe safety symbols. They are included for your safety and for the protection of the tool.

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LOCAL SAFETY REGULATIONS

Enter any local safety regulations here. Keep these instructions in an area accessible to the operator and maintenance personnel.

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SAFETY STICKERS & TAGS

0110

CHOKE PULL DECAL

EXHAUST FUMES STICKER

EXHAUST STICKER

WEIGHT STICKER

DO NOT OPERATE THE PUMP WITHOUT WATER. OPERATING THE PUMP WITHOUT WATER WILL SEVERLY DAMAGE THE PUMP.

FUEL STICKER

SAFETY TAG Do not remove until read)

HYDRAULIC OIL STICKER

BATTERY CHARGE TAG (Do not remove until read)

COUPLER STICKER

BR87, BR37, CH18

101

SOUND POWER LEVER STICKER

MANUAL STICKER

SERIAL NO. LOCATION (At top of dash panel)

CAUTION STICKER (If Equipped with Water Pump Kit)

The safety tag at right is attached to the power unit 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

1. FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED 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 CURRENT LEAKAGE IN ACCORDANCE WITH YOUR SAFETY DEPARTMENT INSTRUCTIONS.

2. A HYDRAULIC LEAK OR BURST MAY CAUSE OIL INJECTION INTO THE BODY OR CAUSE OTHER SEVERE PERSONAL INJURY.

A DO NOT EXCEED 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 HYDRAU

LIC HOSE USED WITH THIS TOOL. EXCESS PRESSURE MAY CAUSE A LEAK OR BURST.

C 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.

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

15875

DANGER

D DO NOT LIFT OR CARRY TOOL BY THE HOSES. DO NOT

ABUSE HOSE. DO NOT USE KINKED, TORN OR DAMAGED HOSE.

3. MAKE SURE HYDRAULIC HOSES ARE PROPERLY CONNECTED TO THE TOOL BEFORE PRESSURING SYSTEM. SYSTEM PRESSURE HOSE MUST ALWAYS BE CONNECTED 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.

4. 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.

5. BYSTANDERS MAY BE INJURED IN YOUR WORK AREA. KEEP BYSTANDERS CLEAR OF YOUR WORK AREA.

6. WEAR HEARING, EYE, FOOT, HAND AND HEAD PROTECTION.

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 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

15875

SAFETY TAG

(shown smaller then actual size)

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HYDRAULIC HOSE REQUIREMENTS

HOSE TYPES

Hydraulic hose types authorized for use with Stanley Hydraulic Tools are as follows:

Hose listed above is the only hose authorized for use near electrical conductors.

Hoses and listed above are conductive and must never be used near electrical conductors.

Certified non-conductive

Wire-braided (conductive)

Fabric-braided (not certified or labeled non-conductive)

To help ensure your safety, the following DANGER tags are attached to all hose purchased from Stanley. 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 at no charge from your Stanley Distributor.

CERTIFIED NON-CONDUCTIVE HOSE

This tag is attached to all certified non-conductive hose.

D A N G E R

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 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.

DO NOT REMOVE THIS TAG

SEE OTHER SIDE

D A N G E R

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 OR 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

DO NOT REMOVE THIS TAG

SIDE 1 SIDE 2

AND 1 WIRE-BRAIDED AND FABRIC-BRAIDED (NOT CERTIFIED OR LABELED NON-CON-

DUCTIVE) HOSE

This tag is attached to all conductive hose.

D A N G E R

1 DO NOT USE THIS HYDRAULIC HOSE IN 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 SERIOUS 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.

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.

DO NOT REMOVE THIS TAG

SEE OTHER SIDE

SIDE 1 SIDE 2

HOSE PRESSURE RATING

The rated working pressure of the hydraulic hose must be equal or higher than the relief valve setting on the hydraulic system.

(shown smaller then actual size)

6. AFTER EACH USE STORE IN A CLEAN DRY AREA.

(shown smaller then actual size)

D A N G E R

SEE OTHER SIDE

DO NOT REMOVE THIS TAG

Page 8

OPERATING INSTRUCTIONS

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

IMPORTANT

Do not start the Engine with the

Always check the oil level before starting tne engine. Make sure the oil level is at the FULL MARK on the dipstick. Do not overfill. Use detergent oil classified "For Service SE, SF, SG" as specified in the engine operating and maintenance manual.

trottle control set at 5 or 8 gpm/ 19 or 30 lpm.

Flash Point (ASTM D-92) 340°F/171°C Minimum

Rust Inhibition (ASTM D-665 A & 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, allow moisture to settle out and resist biological growth that may occur in cool operating hydraulic circuits. These fluids are recommended by Stanley. 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

2. ENGINE FUEL LEVEL

Check the fuel level. If low, fill with un-leaded gasoline with a minimum of 85 octane.

3. HYDRAULIC FLUID

Check the sight pipe in the hydraulic fluid reservoir for the proper fiuid level. Proper fluid level is indicated when the center section of the sight pipe is dark. If the center section of the sight pipe is not dark, add hydraulic fluid. Use fluids meeting the following specifications.

Viscosity (Fluid Thickness)

U.S. METRIC

50°F 450 SSU Maximum 10°C 95 Centistokes 100°F 130-200 SSU 38°C 27-42 C.S. 140°F 85 SSU Minimum 60°C 16.5 C.S. Minimum

PourPoint -10°F/-23°C Minimum (for cold startup)

Viscosity Index (ASTM D-2220) 140 Minimum

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 quick disconnect fitting is the return (FLUID IN) fitting.

The recommended hose length is 25 ft/8 m with a 1/2 inch/12.7 mm inside diameter. The hoses must have a working pressure rating of at least 2500 psi/175 bar. Each hose end must have male thread ends compatible with H.T.M.A. (HYDRAULIC TOOL MANUFACTURERS ASSOCIATION)

5. BATTERY

The supplied 12 Volt DC battery has been partially dry charged. Before using, it must first be filled with battery electrolyte at a specific density of

1.240 to 1.260. Fill each cell to its upper level indicator and then charge at a 2 Amp rate for at least 12 to 15 hours. After charging, check the electrolyte level and fill as required.

Demulsibility (ASTM D-1401) 30 Minutes Maximum

Also, make sure the battery cables are tight and charging circuit functions are operating properly.

Page 9

quick disconnect fittings (NPT type threads). (See Figure 1.)

CONTROL PANEL

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 LONG WITH 2500 PSI/ 172 BAR RATING AND 4 TO 1 SAFETY FACTOR

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 connected to the supply and return ports, the pressure required to push the fluid through the system and back to the hydraulic tank will be higher. If the pressure is too high, this 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 additional fittings such as reducer or adapter fittings are not required.

1/2 INCH MALE PIPE HOSE END

H.T.M.A. 1/2 INCH FEMALE QUICK DISCONNECT COUPLER

H.T.M.A. 1/2 INCH MALE QUICK DISCONNECT COUPLER

ADAPTER, 3/8 INCH MALE PIPE x -8 SAE O-RING

RETURN

PRESSURE

If adapter fittings are used, they must be

PRESSURERETURN

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.

TOOL

Figure 1. Hydraulic Connections

Page 10

Do not charge the battery with a standard automotive battery charger. This type of charger produces a charging amperage higher than 2 amps. Charging the battery with amperage higher than 2 amps will damage the battery.

6. THROTTLE CONTROL (See Figure 2)

The throttle control permits the operator to select one of 3 operating modes after the engine has warmed up. For startup, the throttle control should be set on "AUTO".

a. AUTO - Engine speed varies with hydraulic circuit pressure to maintain a constant 8.5 gpm/32 lpm. When a tool is not being used the engine will return to idle automatically.

b. 5 - Engine speed is held at part throttle to maintain 5 gpm/19 lpm. When a tool is not being used the engine will not return to idle until the faspin is removed.

CYLINDER LEVER

FASPIN

AUTO

HOLD 5 GPM

BASE

GOVERNOR LEVER

c. 8 - Engine speed is held at full throttle to maintain 8.5 gpm/32 lpm. When a tool is not being used the engine will not return to idle until the faspin is removed.

Typical conditions requiring the "8" position are:

• When operating an alternator, fluid flow must be constant to produce the required voltage and frequency, even when load requirements are light.

• When operating drills or grinders or diamond saws, tool rpm must be maintained even when load requirements are light.

HOLD 8 GPM

Figure 2. Throttle Control Settings

STARTUP - See "PANEL CON-

TROLS" - Figure 3

1. Assure the circuit control lever is in the "OFF" position.

2. Select the "AUTO" throttle operating mode by positioning the governor lever to the cylinder lever and inserting the faspin as shown in figure 2.

Page 11

ON/OFF SWITCH

OFF

ENGINE

TOOL

RETURN

HOSE

OFF

Stanley Hydraulic Tools

MILWAUKIE, OREGON

TOOL

PRESSURE

HOSE

HP1 COMPACT POWER UNIT

3. If the tools and tool hoses are cold, it is recommended to allow hydraulic fluid to circulate through the tool hoses until warm before using the tool.

TOOL OPERATION

1. With the engine running smoothly, move the control lever to 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.

3. If automatic throttle operation is not desired, change the throttle control to "5 or 8".

RETURN QUICK DISCONNECT

PRESSURE QUICK DISCONNECT

Figure 3. Control Panel

3. Position the ON/OFF switch to the "ON" position.

4. Pull the choke lever out.

5. Push the circuit control lever to the "START" position.

6. After the engine starts, allow the engine to warm up until it runs smoothly with the choke released.

IMPORTANT

Do not start the Engine with the trottle control set at 5 or 8 gpm/ 19 or 30 lpm.

SHUTDOWN

1. Place the circuit control lever in the "OFF" position.

2. If the throttle control is in the "5" or "8" position, change it to the "AUTO" position.

3. Allow the engine to idle for approximately one minute and then switch the ON/OFF switch to the "OFF" position.

OPTIONAL WATER PUMP KIT

DO NOT OPERATE THE PUMP WITHOUT WATER. OPERATING THE PUMP WITHOUT WATER WILL SEVERLY DAMAGE THE PUMP.

COLD WEATHER STARTUP

1. Use the procedures described under "STARTUP" and then follow the procedure below.

2. Hydraulic fluids are thicker in cold weather, therefore, it is recommended that the engine be run at low idle long enough to bring the fluid temperature up to a minimum of 50°F/10°C or until the top of the hydraulic filter feels warm.

If the power unit will be operated without need of the water pump, unpin the water pump and remove it.

Page 12

ROUTINE MAINTENANCE

ENGINE MAINTENANCE

Follow the maintenance schedule and general maintenance instructions in the engine maintenance and operation manual furnished with the power unit. Normal maintenance includes:

• Service foam air pre-cleaner every 25 hours of operation.

• Service air paper cartridge every 100 hours of operation.

• Replace in-line fuel filter every 100-300 hours or sooner if required.

• Replace spark plugs every 100 hours of operation.

• Change engine oil after first 5 hours of operation, then after every 50 hours of operation. If engine has been operating under heavy load or in high ambient temperature, change the oil every 25 hours of operation.

• Change oil filter when engine oil is changed.

• Check oil level daily.

• Remove dirt and debris from engine with a cloth or brush daily. Do not use water spray.

• Clean air cooling system every 100 hours of operation.

avoiding the water at the bottom of the container.

• Each day, check hydraulic lines and fittings for leaks, kinks, etc. Do not use your hand to perform this check.

• Change the hydraulic filter element every 200 hours of operation. Change more often if cold, moist or dusty conditions exist.

• Check oil cooler for debris. Remove debris with air pressure.

STORAGE

• Clean the unit thoroughly before storage. Do not use water pressure.

• Always store the unit in a clean and dry facility.

• If the unit will be stored for a prolonged period (over 30 days), add a fuel additive to the fuel tank to prevent the fuel from gumming. Run engine for a short period to circulate the additive.

• Replace crankcase oil with new oil.

• Remove spark plugs and pour approximately 1 ounce (30 ml) of engine oil into each cylinder. Replace spark plugs and crank the engine slowly to distribute the oil.

HYDRAULIC SYSTEM MAINTENANCE

• Check hydraulic fluid level daily. The center of the sight pipe on the reservoir must be dark. If it is not dark, fluid must be added. Add fluid per specifications in this manual. (See "HYDRAULIC FLUID" under the section titled "OPERATING INSTRUCTIONS".

• Remove condensed moisture from the hydraulic

fluid by pumping the hydraulic fluid into a 5 gal/20 ltr container through the pressure hose. Make sure the engine is at idle when performing this procedure. When the hydraulic reservoir is empty turn the engine off immediately.

• Allow the fluid to sit long enough for the water to settle to the bottom of the container. Slowly pour the fluid back into the hydraulic tank,

• Check hydraulic reservoir for water. If water is found, change the oil and circulate it through the tool hose and tool. (See "HYDRAULIC SYSTEM MAINTENANCE" earlier in this section).

• Disconnect tool hoses.