Page 1
HP12
HYDRAULIC
POWER UNIT
(HP12B)
USER’S MANUAL
SAFETY, OPERATION AND MAINTENANCE
© 2017 STANLEY Black & Decker, Inc.
New Britain, CT 06053
U.S.A.
81117 1/2019 Ver. 3
Page 2
Page 3
TABLE OF CONTENTS
SAFETY SYMBOLS .................................................................................................................................................4
SAFETY PRECAUTIONS .......................................................................................................................................5
TOOL STICKERS AND TAGS .................................................................................................................................6
HOSE TYPES ..........................................................................................................................................................7
HOSE RECOMMENDATIONS ................................................................................................................................8
HTMA / EHTMA REQUIREMENTS ........................................................................................................................9
OPERATION ..........................................................................................................................................................10
MAINTENANCE & TESTING ................................................................................................................................12
TROUBLESHOOTING ..........................................................................................................................................13
SPECIFICATIONS ................................................................................................................................................. 14
HP12 FRAME PARTS ILLUSTRATION ................................................................................................................15
HP12 CONTROL PANEL ILLUSTRATION ...........................................................................................................16
HP12 ENGINE ILLUSTRATION - FRONT............................................................................................................ 17
HP12 ENGINE ILLUSTRATION - BACK .............................................................................................................. 18
HP12 ENGINE ILLUSTRATION - BASE .............................................................................................................. 19
HOSES, FITTINGS AND CLAMPS ....................................................................................................................... 20
MAIN WIRING HARNESS ..................................................................................................................................... 21
ELECTRICAL SCHEMATIC .................................................................................................................................. 22
To ll out a product warranty validation form, and for information on your warranty,
visit www.stanleyinfrastructure.com and select the Company tab > Warranty.
Note: The warranty validation record must be submitted to validate the warranty.
SERVICING: This manual contains safety, operation and routine maintenance instructions. Servicing of hydraulic
tools, other than routine maintenance, must be performed by an authorized and certied dealer. Please read the
following warning.
SERIOUS INJURY OR DEATH COULD RESULT FROM THE IMPROPER REPAIR OR
SERVICE OF THIS TOOL.
REPAIRS AND / OR SERVICE TO THIS TOOL MUST ONLY BE DONE BY AN
AUTHORIZED AND CERTIFIED DEALER.
For the nearest certied dealer, call STANLEY Infrastructure at (503) 659-5660 and ask for a Customer Service Representative.
HP12 User Manual ◄ 3
Page 4
SAFETY SYMBOLS
Safety symbols and signal words, as shown below, are used to emphasize all operator, maintenance and repair
actions which, if not strictly followed, could result in a life-threatening situation, bodily injury or damage to equipment.
This is the safety alert symbol. It is used to alert you to potential personal injury
hazards. Obey all safety messages that follow this symbol to avoid possible
injury or death.
This safety alert and signal word indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
This safety alert and signal word indicates a potentially hazardous situation
which, if not avoided, could result in death or serious injury.
This safety alert and signal word indicates a potentially hazardous situation
which, if not avoided, could result in death or serious 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
maintenance personnel.
4 ► HP12 User Manual
Page 5
SAFETY PRECAUTIONS
Tool operators and maintenance personnel must always
comply with the safety precautions given in this manual
and on the stickers and tags attached to the equipment.
These safety precautions are given for your safety.
Review them carefully before operating the tool and
before performing general maintenance or repairs.
Supervising personnel should develop additional
precautions relating to the specic work area and local
safety regulations. If so, place the added precautions in
the space provided on page 4.
In addition to this manual, read and understand safety
and operating instructions in the engine “Operation &
Maintenance Instructions” manual furnished with the
HP12 power unit.
The HP12 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 unit. Failure to do so
could result in personal injury or equipment damage.
• Do not inspect hoses and ttings 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 become
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 it is running
or is still hot.
• Do not operate the power unit if gasoline odor is
present.
• 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 protection, head protection and safety shoes at
all times when operating the power unit.
• Do not inspect or clean the power unit while it is
running. Accidental engagement of the unit can
cause serious injury.
• Always use hoses and ttings rated at 2500 psi/172
bar with a 4-to-1 safety factor. Be sure all hose
connections are tight.
• Do not use ammable solvents around the power
unit engine.
• Do not operate the power unit within 3.3 ft/1 m of
buildings, obstructions or ammable objects.
• Do not reverse tool rotation direction by changing
uid ow direction.
• Allow power unit engine to cool before storing in an
enclosed space.
• Always keep critical tool markings, such as labels
and warning stickers, legible.
• To avoid personal injury or equipment damage,
all tool repair, maintenance and service must only
be performed by authorized and properly trained
personnel.
• Be sure all hoses are connected for correct ow
direction to and from the tool being used.
HP12 User Manual ◄ 5
Page 6
The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the
hydraulic system. There are three types of hydraulic hose that meet this requirement and are authorized for use with
STANLEY hydraulic tools. They are:
Certi ed non-conductive — constructed of thermoplastic or synthetic rubber inner tube, synthetic ber braid
reinforcement, and weather resistant thermoplastic or synthetic rubber cover. Hose labeled certifi ed non-
conductive is the only hose authorized for use near electrical conductors.
Wire-braided (conductive) — constructed of synthetic rubber inner tube, single or double wire braid
reinforcement, and weather resistant synthetic rubber cover. This hose is conductive and must never be used
near electrical conductors.
Fabric-braided (not certi ed or labeled non-conductive) — constructed of thermoplastic or synthetic rubber
inner tube, synthetic ber braid reinforcement, and weather resistant thermoplastic or synthetic rubber cover.
This hose is not certifi ed non-conductive and must never be used near electrical conductors.
HOSE SAFETY TAGS
To help ensure your safety, the following DANGER tags are attached to all hose purchased from STANLEY. DO
NOT REMOVE THESE TAGS.
If the information on a tag is illegible because of wear or damage, replace the tag immediately. A new tag may be
obtained from your STANLEY Distributor.
THE TAG SHOWN BELOW IS ATTACHED TO “CERTIFIED NON-CONDUCTIVE” HOSE
THE TAG SHOWN BELOW IS ATTACHED TO “CONDUCTIVE” HOSE.
(Shown smaller than actual size)
SIDE 1
DANGER
1. FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON-CONDUCTIVE
WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRIC LINES MAY RESULT 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 MOISTURE AND TEST
HOSE FOR MAXIMUM ALLOWABLE CURRENT LEAKAGE IN ACCORDANCE WITH SAFETY
DEPARTMENT INSTRUCTIONS.
SEE OTHER SIDE
SIDE 2
DO NOT REMOVE THIS TAG
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 DAM-
AGE 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
DANGER
DO NOT REMOVE THIS TAG
DANGER
(Shown smaller than actual size)
SIDE 2
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.
DANGER
DO NOT REMOVE THIS TAG
DANGER
SIDE 1
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 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 ELEC-
TRIC 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 CAUSE 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.
DO NOT REMOVE THIS TAG
DANGER
SEE OTHER SIDE
SEE OTHER SIDE
TOOL STICKERS AND TAGS
74759 Power Unit Dash Decal
76748 Single Circuit Decal
82516 Emissions Decal
6 ► HP12 User Manual
Page 7
HOSE TYPES
The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the
hydraulic system. There are three types of hydraulic hose that meet this requirement and are authorized for use with
STANLEY hydraulic tools. They are:
Certi ed non-conductive — constructed of thermoplastic or synthetic rubber inner tube, synthetic ber braid
reinforcement, and weather resistant thermoplastic or synthetic rubber cover. Hose labeled certifi ed non-
conductive is the only hose authorized for use near electrical conductors.
Wire-braided (conductive) — constructed of synthetic rubber inner tube, single or double wire braid
reinforcement, and weather resistant synthetic rubber cover. This hose is conductive and must never be used
near electrical conductors.
Fabric-braided (not certi ed or labeled non-conductive) — constructed of thermoplastic or synthetic rubber
inner tube, synthetic ber braid reinforcement, and weather resistant thermoplastic or synthetic rubber cover.
This hose is not certifi ed non-conductive and must never be used near electrical conductors.
HOSE SAFETY TAGS
To help ensure your safety, the following DANGER tags are attached to all hose purchased from STANLEY. DO
NOT REMOVE THESE TAGS.
If the information on a tag is illegible because of wear or damage, replace the tag immediately. A new tag may be
obtained from your STANLEY Distributor.
THE TAG SHOWN BELOW IS ATTACHED TO “CERTIFIED NON-CONDUCTIVE” HOSE
DANGER
1. FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON-CONDUCTIVE
WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRIC LINES MAY RESULT 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 MOISTURE AND TEST
HOSE FOR MAXIMUM ALLOWABLE CURRENT LEAKAGE IN ACCORDANCE WITH SAFETY
DEPARTMENT INSTRUCTIONS.
DO NOT REMOVE THIS TAG
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 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.
(Shown smaller than actual size)
DANGER
DANGER
SEE OTHER SIDE
SIDE 2
THE TAG SHOWN BELOW IS ATTACHED TO “CONDUCTIVE” HOSE.
DANGER
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
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.
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, 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
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.
(Shown smaller than actual size)
DANGER
SEE OTHER SIDE
SIDE 2
DO NOT REMOVE THIS TAG
DO NOT REMOVE THIS TAG
HP12 User Manual ◄ 7
Page 8
Min. Working Pressure
USE
Press/Return)
(
HOSE RECOMMENDATIONS
Certi ed Non-Conductive Hose - Fiber Braid - for Utility Bucket Trucks
Oil Flow Hose Lengths Inside Diameter
GPM LPM FEET METERS INCH MM PSI BAR
4-9 15-34 up to 10 up to 3 3/8 10 Both 2250 155
Conductive Hose - Wire Braid or Fiber Braid -DO NOT USE NEAR ELECTRICAL CONDUCTORS
4-6 15-23 up to 25 up to 7.5 3/8 10 Both 2500 175
4-6 15-23 26-100 7.5-30 1/2 13 Both 2500 175
5-10.5 19-40 up to 50 up to 15 1/2 13 Both 2500 175
5-10.5 19-40 51-100 15-30 5/8 16 Both 2500 175
5/8 16 Pressure 2500 175
3/4 19 Return 2500 175
5-10.5 19-40 100-300 30-90
10-13 38-49 up to 50 up to 15 5/8 16 Both 2500 175
5/8 16 Pressure 2500 175
3/4 19 Return 2500 175
10-13 38-49 51-100 15-30
3/4 19 Pressure 2500 175
1 25.4 Return 2500 175
10-13 38-49 100-200 30-60
5/8 16 Pressure 2500 175
3/4 19 Return 2500 175
13-16 49-60 up to 25 up to 8
3/4 19 Pressure 2500 175
1 25.4 Return 2500 175
13-16 49-60 26-100 8-30
PRESSURE
<<< FLOW
RETURN
FLOW >>>
Figure 1. Typical Hose Connections
Tool to Hydraulic Circuit Hose
Recommendations
The chart to the right shows recommended
minimum hose diameters for various
hose lengths based on gallons per minute
(GPM)/liters per minute (LPM). These
recommendations are intended to keep return
line pressure (back pressure) to a minimum
acceptable level to ensure maximum tool
performance.
This chart is intended to be used for hydraulic
8 ► HP12 User Manual
tool applications only based on STANLEY tool
operating requirements and should not be
used for any other applications.
All hydraulic hose must have at least a
rated minimum working pressure equal to
the maximum hydraulic system relief valve
setting.
All hydraulic hose must meet or exceed
speci cations as set forth by SAE J517.
Page 9
HTMA / EHTMA REQUIREMENTS
HTMA / EHTMA REQUIREMENTS
TOOL TYPE
HTMA
HYDRAULIC SYSTEM REQUIREMENTS
Flow range
Nominal 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 uid viscosity of:
(At minimum operating temperature)
Temperature: Su cient heat rejection capacity to limit
maximum uid temperature to:
(At maximum expected ambient temperature)
Minimum cooling capacity at a temperature di erence of
between ambient and uid temps
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 minimum full- ow ltration 25 microns 25 microns 25 microns 25 microns
Sized for ow of at least:
(For cold temp startup and maximum dirt-holding capacity)
Hydraulic uid, petroleum based (premium grade, antiwear, non-conductive) Viscosity (at minimum and maximum
operating temps)
Note: When choosing hydraulic uid, the expected oil temperature extremes that will be experienced in service determine the most
suitable temperature viscosity characteristics. Hydraulic uids with a viscosity index over 140 will meet the requirements over a wide
range of operating temperatures.
TYPE I TYPE II TYPE RR TYPE III
4-6 GPM
(15-23 LPM)
1500 psi
(103 bar)
2100-2250 psi
(145-155 bar)
250 psi
(17 bar)
400 ssu*
(82 centistokes)
140° F
(60° C)
3 hp
(2.24 kW)
40° F
(22° C)
30 GPM
(114 LPM)
100-400 ssu
(20-82
centistokes)
7-9 GPM
(26-34 LPM)
1500 psi
(103 bar)
2100-2250 psi
(145-155 bar)
250 psi
(17 bar)
400 ssu*
(82 centistokes)
140° F
(60° C)
5 hp
(3.73 kW)
40° F
(22° C)
30 GPM
(114 LPM)
100-400 ssu
(20-82
centistokes)
9-10.5 GPM
(34-40 LPM)
1500 psi
(103 bar)
2200-2300 psi
(152-159 bar)
250 psi
(17 bar)
400 ssu*
(82 centistokes)
140° F
(60° C)
6 hp
(5.22 kW)
40° F
(22° C)
30 GPM
(114 LPM)
100-400 ssu
(20-82
centistokes)
11-13 GPM
(42-49 LPM)
2100-2250 psi
(145-155 bar)
(82 centistokes)
100-400 ssu
centistokes)
1500 psi
(103 bar)
250 psi
(17 bar)
400 ssu*
140° F
(60° C)
7 hp
(4.47 kW)
40° F
(22° C)
30 GPM
(114 LPM)
(20-82
*SSU = Saybolt Seconds Universal
EHTMA
HYDRAULIC SYSTEM
REQUIREMENTS
Flow range
Nominal operating pressure
(At the power supply outlet)
System relief valve setting
(At the power supply outlet)
Note: These are general hydraulic system requirements. See tool speci cation page for tool speci c requirements.
B
3.5-4.3 GPM
(13.5-16.5
LPM)
1870 psi
(129 bar)
2495 psi
(172 bar)
C
4.7-5.8 GPM
(18-22 LPM)
1500 psi
(103 bar)
2000 psi
(138 bar)
CLASSIFICATION
D
7.1-8.7 GPM
(27-33 LPM)
1500 psi
(103 bar)
2000 psi
(138 bar)
9.5-11.6 GPM
(36-44 LPM)
1500 psi
(103 bar)
2000 psi
(138 bar)
HP12 User Manual ◄ 9
11.8-14.5 GPM
(45-55 LPM)
1500 psi
(103 bar)
2000 psi
(138 bar)
Page 10
OPERATION
PREPARATION FOR USE
Do not operate HP12 until you have completed the
following steps:
H.T.M.A. approved quick disconnect couplings are installed
to hydraulic hoses so that the direction of oil ow is always
from the male to the female coupling. Additional ttings,
such as reducers or adapter ttings, are not required.
READ THE ENGINE “OPERATING & MAINTENANCE
INSTRUCTIONS” MANUAL.
CHECK ENGINE CRANKCASE OIL LEVEL
Check the oil level before starting the engine. Make sure
the oil level is at the FULL MARK on the dipstick. Do not
overll. Use detergent oil classied "For Service SE, SF,
SG" as specied in the engine “Operating & Maintenance
Instructions” manual. See the “Operating & Maintenance
Instructions” manual for oil viscosity grade.
CHECK ENGINE FUEL LEVEL
If fuel level is low, ll with unleaded gasoline (85 octane
minimum).
CHECK HYDRAULIC FLUID
Ensure there is hydraulic uid in the hydraulic oil tank.
Below is a list of recommended oils.
Brand Biodegradable Description
CITGO No Hydurance AW32
AMS Oil No HVH 32
Exxon Mobil No Univis HVI26*
Exxon Mobil No DTE 10 Excel
Shell No S2 V 32
Chevron No Rando HDZ 32
Conoco Phillips No Unax AW-WR-32
Clarion (CITGO) Yes Green Bio 32
Exxon Mobil Yes EAL 224H
Chevron Yes Clarity AW32
Terresolve Yes Envirologic 132
Shell Yes Naturelle HF-E-32
If adapter ttings are used, they must be approved steel
hydraulic ttings meeting a minimum operating pressure
rating of 2500 psi/172 bar. Do not use galvanized pipe
ttings or black pipe ttings.
Use thread tape or pipe joint compound when installing
quick disconnect couplings to hose or tool ttings. Follow
the instructions furnished with the selected thread sealant.
DO NOT OVERTIGHTEN THE FITTINGS.
Connect the pressure hose to the bottom (male) tting.
Connect the return hose to the top (female) tting.
*Recommended for extreme cold temperatures
INSTALL HYDRAULIC CONNECTIONS
STANLEY recommends you use hose lengths of 25 ft/8 m
with 1/2 inch/12.7 mm inside diameter. Hoses must have a
working pressure rating of at least 2500 psi/175 bar. Hose
ends must have male threads compatible with H.T.M.A.
quick disconnect ttings (NPT).
10 ► HP12 User Manual
Page 11
OPERATION
CONTROLS
Throttle / Flow
Selector Knob
Ignition Switch Flow Switch
Female Hydraulic
Hose Fitting
Male Hydraulic
Hose Fitting
1. Toggle the Flow Switch to the “FLOW OFF” position
HP12 can provide one 8 GPM/30 LPM circuit, one 10
GPM/40 LPM circuit or one 12 GPM/45 LPM circuit.
STARTUP
1. Toggle the Flow Switch to the "FLOW OFF" position.
Note: HP12 will not start unless the Flow Switch is in
the "FLOW OFF" position.
2. Pull the choke knob out
3. Select the desired ow using the Flow Selector Knob.
4. Turn the Ignition Switch to the "START" position. After
the engine starts, release the switch.
5. Gradually push in the choke knob as the engine begins
to idle smoothly.
6. Allow the engine to warm up.
7. Connect hoses and the tool.
2. Select the desired circuit ow using the Flow Selector
Knob.
3. Toggle the Flow Switch to the “FLOW ON” position.
SHUTDOWN
1. Toggle the Flow Switch to the “FLOW OFF” position.
2. Allow the engine to idle for approximately one minute
3. Turn the Ignition Switch to the “OFF” position.
COLD WEATHER STARTUP
Hydraulic uid becomes thicker in cold weather. STANLEY
recommends that the engine be run at a low idle (5
GMP/20 LPM setting) long enough to bring the uid
temperature up to a minimum of 50°F/10°C. Allow the
hydraulic uid to circulate through the tool hoses until they
are warm.
8. Toggle the Flow Switch to the “FLOW ON” position.
CHANGING CIRCUIT FLOW
Once the hydraulic oil is warm, you may operate the HP12
as normal.
HP12 User Manual ◄ 11
Page 12
MAINTENANCE & TESTING
ENGINE MAINTENANCE SCHEDULE
Follow the maintenance instructions provided in the engine
“Operating & Maintenance Instructions” manual.
HYDRAULIC SYSTEM MAINTENANCE
• Check hydraulic uid level daily and ll if needed.
GENERAL
Tests should be performed periodically to ensure HP12 is
operating at maximum eciency. STANLEY Circuit Tester
,part number 04182, can be used to isolate problems in
both the engine and hydraulic system.
• Check hydraulic lines and ttings daily for leaks, kinks
or damage. Do not use your hand to perform this
check.
• Remove condensed moisture from the hydraulic uid:
1. Set the ow selector to a 8 GPM/20 LPM ow.
2. Start the engine and pump the uid, out of the
male hose tting, into a 5 gal. container.
3. When hydraulic tank is empty, turn the Ignition
Switch to the “O” position.
4. Let the water settle to the bottom of the
container.
5. Pour the hydraulic uid back into the tank, being
careful to not disturb the water sitting at the
bottom of the container.
• Change the hydraulic lter every 200 hours of
operation. Change more often if used in cold, moist or
dusty conditions.
• Check oil cooler. Remove debris with air pressure.
BATTERY
TESTING THE HYDRAULIC CIRCUIT
Test to ensure the hydraulic pump is supplying the correct
ow and pressure, and that the system relief valve is
operating properly. Before testing, make sure the engine is
warm and operating smoothly.
1. Turn the ow selector switch to the “OFF” position.
2. Set the ow control to the ow you would like to test.
3. Connect the STANLEY Circuit Tester to the tool hoses.
4. Fully open the tester restrictor valve (counterclockwise).
5. Start the engine.
6. The test ow gauge should read +/- 1 GPM of the
selected ow.
7. Slowly turn the restrictor valve clockwise while
watching the pressure gauge. The ow rate should not
change as the pressure reaches 2100-2200 psi/148155 bar.
• Do not charge the battery with an automotive battery
charger. Charging at higher than 2 amps will damage
the battery.
• If the engine stalls during operation, set the ignition
switch to the “OFF” position to preserve battery charge.
STORAGE
• Clean the unit thoroughly. Do not pressure wash.
• Always store the unit in a clean and dry location.
• If storing for over 30 days, add an additive to the fuel
tank to prevent the fuel from gumming. Run the engine
to circulate the additive.
• Replace crankcase oil.
12 ► HP12 User Manual
8. At 2100-2200 psi/148-155 bar, the relief valve should
begin to open. The ow rate should start to drop
because the relief valve is allowing uid to bypass to
the hydraulic uid tank. The relief valve is preset at the
factory. If it does not open within the above range, the
relief valve must be reset as follows:
a. The relief valve is located on the right side of the
unit, behind the dash panel (7, page 16). Use a
wrench to loosen the nut on the relief valve.
b. Use an Allen wrench to adjust the relief valve.
Turn clockwise to raise the opening pressure, and
counterclockwise to reduce the opening pressure.
c. Tighten the nut and test again.
Page 13
TROUBLESHOOTING
Problem Cause Remedy
Engine will not start. Flow Switch is not in the “FLOW OFF”
position.
Battery is not connected. Check the battery cables for continuity
Weak battery charge. Test the battery voltage and charge if
No Fuel. Ensure the power unit is cool, then add
Fuel lter is plugged. Replace the fuel lter.
Defective spark plugs. Remove the spark plugs and check the
Hydraulic uid is blowing out
of the uid reservoir vent.
The hydraulic tool connected
to the power unit will not
operate.
Hydraulic uid tank is overlled. Remove hydraulic uid from the tank.
Hydraulic pump is leaking. Check the pump connections (see page
The Flow Selector Knob is not in the
proper position for the connected tool.
The tool is not properly connected to
the power unit.
The quick disconnect ttings are
defective.
The hydraulic uid level in the reservoir
is too low.
Make sure the Flow Switch is in the
“FLOW OFF” position before attempting
to start the power unit.
and re-attach to the battery.
necessary. If the battery will not hold a
charge, replace.
fuel.
gap. Replace if necessary.
20). Tighten if necessary.
Ensure that the Flow Selector Knob is
positioned for the correct uid ow for
your tool.
Check the connection hoses from
the power unit to the tool. Ensure the
pressure and the return hoses are in the
proper ports on the tool.
Disconnect the ttings from the hose
and ensure there is free ow from each
end of the ttings.
Check the uid level in the hydraulic
uid tank. Add more uid if necessary.
The pump coupling is defective. Power down the unit and check the
The relief valve is stuck open. Adjust the valve or replace if necessary
Suction hoses are kinked. Visually check the suction hose for a
The solenoid is not working. Check electrical connections (see page
The attached tool is defective. Refer to the tool manual.
coupling between the hydraulic pump
and the engine (4, page 18).
(7, page 16).
kink. The hose should have a smooth
curve.
21). Replace if necessary.
HP12 User Manual ◄ 13
Page 14
SPECIFICATIONS
Engine: ....................................................................................................................................................23 hp Briggs
Capacity.................................... One 8 GPM/30 LPM Circuit, One 10 GPM/40 LPM or One 12 GPM/45 LPM Circuit
Length:................................................................................................................................................ 36 in. / 91.4 cm
Width: ................................................................................................................................................. 23 in: / 58.4 cm
Height: ............................................................................................................................................. 29.5 in. / 74.9 cm
Weight (Wet): Single Circuit Briggs ................................................................................................330 lbs / 149.6 kg
Fuel Tank Capacity: ........................................................................................................................... 5.5 gal. / 20.8 ltr
Estimated Gas Consumption Per Hour ...................................................................................................1.3 gal / 4 ltr
Hydraulic Reservoir Capacity: ................................................................................................................. 3 gal. / 11 ltr
Relief Valve setting ......................................................................................................................... 2100 psi / 145 bar
Full relief setting .............................................................................................................................2500 psi / 172 bar
HTMA Category ............................................"D" (30 LPM @ 138 bar) or "E" (45 LPM @ 138 bar)
Nominal Pressure ............................................................................................................................. 1500 psi/103 bar
Max Pressure ...................................................................................................................................2000 psi/138 bar
POWER UNITS,TRACHORSE & GAS/FUEL DRIVEN EQUIPMENT: A1. Federal Emission Component Compliance
40CFR part 1060.120 STANLEY warrants all fuel system emission components for 2 years from the date of original
purchase provided there has been no abuse, neglect, modications or improper maintenance.
Components Covered: The emission-related warranty covers all components whose failure would increase
the evaporative emissions. Your emission-related warranty does not cover components whose failure would not
increase evaporative emissions. Coverage under this warranty extends only to the following parts; fuel tank, fuel
cap, fuel hose and vapor hose from the fuel tank to the engine and any connectors that are apart of the fuel system.
The equipment is designed, built, and equipped so it conforms at the time of sale to the ultimate purchaser and each
subsequent purchaser and is in compliance with 40 C.F.R. 1060.120 standards. The equipment is free from defects
in materials and workmanship that may keep it from meeting these requirements.
14 ► HP12 User Manual
Page 15
HP12 FRAME PARTS ILLUSTRATION
1
2
2 3
5 6
9
812
9
7
4
8 9
8
11
ITEM # PART # QTY DESCRIPTION
1. 76755 1 Frame Weldment
2. 59075 2 Hex Flange Bolt
3. 59079 1 Cooler Guard
4. 59095 2 Hex Flange Nut
5. 60945 2 Washer
6. 15476 2 Hex Head Capscrew
7. 23530 2 Rear Hex Flange Bolt
8. 03906 7 Locknut
9. 370502 7 Hex Head Capscrew
10. 62268 2 Lift Handle
11. 62267 1 Rear Lift Handle
12. 58916 1 Handle Lock
10
HP12 User Manual ◄ 15
Page 16
HP12 CONTROL PANEL ILLUSTRATION
14
1
2
3
5
6
4
7
89
15
16
17
18
1011
1213
ITEM # PART # QTY DESCRIPTION
1. 74759 1 Dash Decal
2. 62298 1 Choke Cable Assembly
3. 60959 1 Directional Valve with Cap
4. 60958 1 Solenoid Coil
5. 08104 2 Hollow Hex Plug
6. 76711 1 Manifold
76722 Manifold Assembly (Items 3-7)
7. 59131 1 Relief Valve
8. 58856 1 3/8in. Female Coupler, -8 SAE
9. 58857 1 3/8in. Male Coupler, -8 SAE
10. 60962 4 Capscrew
11. 76748 1 Single Circuit Decal
12. 60955 1 2 Position Rotary Switch
13. 67899 1 3 Position Rotary Switch
14. 60946 1 Hour Meter
15. 204332 1 Throttle Knob
16. 76705 1 Throttle Adjustment Plate
17. 76791 3 Setscrew
18. 76702 3 Socket Head Cap Screw
19. 76785 2 Shoulder Bolt
20. 12175 8 Washer
21. 02259 4 Washer
22. 00719 2 Nut
19 20
21 22
31
30
29
ITEM # PART # QTY DESCRIPTION
23. 76779 1 Outer Throttle Plate Assembly
24. 02146 2 Hex Head Cap Screw
25. 76700 1 Inner Throttle Plate
26. 20334 1 Nut
27. 210854 1 Ball Detent
28. 01214 1 Washer
29. 00038 2 Nut
30. 00046 2 Washer
31. 208887 1 Throttle Cable Assembly
32. 76710 1 Wire Harness (see page 21)
21
23
24
25
282726
16 ► HP12 User Manual
Page 17
HP12 ENGINE ILLUSTRATION - FRONT
25
24
23
26
3
20 21 22
19
18
1
4
5
6 7
2
3
ITEM # PART # QTY DESCRIPTION
1. 59074 2 Flange Bolt
2. - - Provided as Part of Engine
3. 59095 3 Nut
4. 59091 1 Oil Cooler
5. 59077 1 Hydraulic Oil Tank
6. 59080 1 Front Grille
7. 17821 4 Button Head Capscrew
8. 80986 4 Hex Head Capscrew
9. 80984 4 Lock Washer
10. 65107 1 Blower Wheel
11. 00111 3 Capscrew
12. 65108 1 Blower Hub
13. 20990 1 Key
14. 59076 1 Bushing
121314151617
ITEM # PART # QTY DESCRIPTION
15. 62296 2 Weather Strip
16. 59083 1 Blower Housing
17. 40433 5 Flange Bolt
18. 26831 2 Washer
19. 01213 2 Hex Head Capscrew
20. 51292 1 Standard Thread Union
21. 60774 1 Hose Clamp
22. 59075 1 Flange Bolt
23. 64937 1 Grip Plate
24. 43687 2 Capscrew
25. 40080 1 Filter Assembly
26. 66215 1 Cooler Mount
891011
HP12 User Manual ◄ 17
Page 18
HP12 ENGINE ILLUSTRATION - BACK
18
1617
19 20 21
23
22
25
24
26
27
1 2
3
4
5
6 7
8
1415
ITEM # PART # QTY DESCRIPTION
1. 66214 1 Heat Shield
2. 36152 2 Hex Washer Screw
3. 56655 1 Pump Mount
4. 56656 1 Coupling
5. 07819 1 Square Key
6. 62385 2 Stud
7. 31765 1 Pressure Switch
8. 69387 1 1/8in NPT Elbow Fitting
9. 40433 4 Flange Bolt
10. 01459 4 Washer
11. 07860 4 Hex Head Capscrew
12. 68561 1 Pump
13. 73050 1 Fuel Tank
14. 04303 1 Battery
13
12
ITEM # PART # QTY DESCRIPTION
15. 60921 1 Battery Cover
16. 60945 1 Washer
17. 15476 1 Hex Head Cap Screw
18. 71794 1 Fuel Tank Cap
19. 60920 2 Grommet
20. 60919 1 Fuel Elbow
21. 62289 1 Fuel Hose
22. 72317 2 Hose Clamp
23. 72571 1 Fuel Vapor Hose
24. 72451 3 Hose Clamp
25. 350104 1 Connector
26. 18893 2 Flange Nut
27. 371503 1 Nut
91011
18 ► HP12 User Manual
Page 19
HP12 ENGINE ILLUSTRATION - BASE
1
13
14
12
11
2
4
3
5
6
7
8
ITEM # PART # QTY DESCRIPTION
1. 76721 1 Engine
2. 12787 4 Flange Nut
3. 58897 1 Frame Base Weldment
4. 58976 4 Flange Bolt
5. 58975 2 Foot
6. 56633 2 Wheel and Tire
7. 21318 2 Washer
8. 31240 2 Retaining Ring
9. 21714 2 Handle Bumper
10. 58917 1 Axle
11. 18893 2 Flange Nut
12. 58942 4 Flange Bolt
13. 24287 1 Hose Clamp
14. 01212 1 Pipe Plug
910
HP12 User Manual ◄ 19
Page 20
HOSES, FITTINGS AND CLAMPS
1 2
3
10
11
4
12
9
5
2
8
7
22
6
5
ITEM # PART # QTY DESCRIPTION
1. 58943 1 Hose
2. 62199 4 Hose Clamp
3. 69384 4 Hose Clamp
4. 69383 2 Hose
5. 40364 2 45° Elbow Fitting
6. 59105 1 Hose Barb
7. 59089 1 Hose
8. 59088 1 Hose
9. 58569 1 90° Elbow Fitting
10. 350000 1 45° Fitting
11. 02773 1 Adapter
12. 350104 1 Connector
20 ► HP12 User Manual
Page 21
MAIN WIRING HARNESS
PART NUMBER 76710
Starter Relay
Solenoid Coil
Start Switch
Flow Switch
Black
Hour Meter
BlackRed
Positive battery
cable to starter
solenoid
(Red)
Starter Solenoid
(Green)
Engine Kill
(Black)
Red
Fuel Shuto
(Red)
Battery
Oil Pressure
Switch
HP12 User Manual ◄ 21
Page 22
SOLENOID
CIRCUIT 1
ELECTRICAL SCHEMATIC
FUSE
10 A
WHITE WIRE
1
2+5+6
2+4+5
1+3+6
SWITCH
56 4 3 2
2. RUN
3. START
STARTER
1. OFF
RECTIFIER
REGULATOR
STARTER
SOLENOID
CASE GROUND
STARTER
M
BATTERY
STARTER
RELAY NC
INTERLOCK
NC
NO
SWITCH
ON / OFF
CIRCUIT 1
WHITE WIRE
SWITCH
ENGINE OIL
FUEL SHUTOFF
HOUR
METER
MAGNETO
22 ► HP12 User Manual
Page 23
Page 24
STANLEY Infrastructure
6430 SE Lake Road
Portland, Oregon 97222 USA
(503) 659-5660 / Fax (503) 652-1780
www.stanleyinfrastructure.com
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