Stanley HP12 Series, HP12B User Manual
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
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
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
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
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
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
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.
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