Stanley HP210BA, HP210B, HP210BK, HP210BBA, HP210BY User Manual

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Page 1

HP210

HYDRAULIC

POWER UNIT

(HP210BA, HP210B, HP210BK,

HP210BBA, HP210BY)

USER MANUAL

Safety, Operation and Maintenance

New Britain, CT 06053

U.S.A.

8111 9 10/2017 Ver. 3

*Model HP210BA & HP210BBA Only

Page 2

DECLARATION OF CONFORMITY

Nuerenberg, David

Directive/Standards

No.

Approved body

Machinery Directive

2006/42/EC:2006

Self

DECLARATION OF CONFORMITY ÜBEREINSTIMMUNGS-ERKLARUNG DECLARATION DE CONFORMITE CEE

Hydraulic Tools

DECLARACION DE CONFORMIDAD

DICHIARAZIONE DI CONFORMITA

______________________________________________________________________

I, the undersigned: Ich, der Unterzeichnende: Je soussigné: El abajo firmante: lo sottoscritto:

hereby declare that the equipment specified hereunder: bestätige hiermit, daß erklaren Produkt genannten Werk oder Gerät: déclare que l’équipement visé ci-dessous: Por la presente declaro que el equipo se especifica a continuación: Dichiaro che le apparecchiature specificate di seguito:

1. Category: Hydraulic Power Unit Kategorie: Catégorie: Categoria: Categoria:

2. Make/Marke/Marque/Marca/Marca Stanley

3. Type/Typ/Type/Tipo/Tipo: GTR20B01 Auto Throttle (HP210BA Manual Throttle)

4. Serial number of equipment: Seriennummer des Geräts: Numéro de série de l’équipement: Numero de serie del equipo: Matricola dell´attrezzatura:

Has been manufactured in conformity with Wurde hergestellt in Übereinstimmung mit Est fabriqué conformément Ha sido fabricado de acuerdo con E’ stata costruita in conformitá con

Surname and First names/Familiennname und Vornamen/Nom et prénom/ Nombre y apellido/Cognome e nome

All

Richtlinie/Standards Directives/Normes Directriz/Los Normas Direttiva/Norme

EN ISO

Noise Directive ISO

6. Special Provisions: None 7. Measurements: Measured Sound Power Level 99 LwA Spezielle Bestimmungen: Messungen Guaranteed Sound Power Level 101 LwA Dispositions particulières: Mesures Measured in accordance to Directive 2000/14/EC, Provisiones especiales: Mediciones Noise related value: Installed Power 13,4 kW Disposizioni speciali: Misurazioni

8. Representative in the Union: Patrick Vervier, Stanley Dubuis 17-19, rue Jules Berthonneau-BP 3406 41034 Blois Cedex, France. Vertreter in der Union/Représentant dans l’union/Representante en la Union/Rappresentante presso l’Unione

Done at/Ort/Fait à/Dado en/Fatto a Stanley Hydraulic Tools, Milwaukie, Oregon USA Date/Datum/le/Fecha/Data 7-21-2016

Signature/Unterschrift/Signature/Firma/Firma

Position/Position/Fonction/Cargo/Posizione North America Quality Manager

2 ► HP210 User Manual

Nr Numéro No n.

12100:2010

2000/14/EC:2005 3744:2010

Prüfung durch Organisme agréé Aprobado Collaudato

Self

AkustikNet (Notified body ID 1585) Bagsvard Hovedgade 141, 2880 Bagsvard, Denmark Certificate #863/2016/001 (Verification 2015-08-06) Valid 12-31-2018

Test Report #07072016GTR20

Page 3

TABLE OF CONTENTS

SAFETY SYMBOLS ..................................................................................................................................................4

SAFETY PRECAUTIONS .......................................................................................................................................... 5

TOOL STICKERS & TAGS ........................................................................................................................................ 6

HOSE TYPES ............................................................................................................................................................7

OPERATION ............................................................................................................................................................ 10

MAINTENANCE & TESTING ..................................................................................................................................12

TROUBLESHOOTING ............................................................................................................................................13

ACCESSORIES.......................................................................................................................................................14

SPECIFICATIONS ................................................................................................................................................... 14

HP210 FRAME PARTS ILLUSTRATION ................................................................................................................. 15

HP210 CONTROL PANEL PARTS ILLUSTRATION ...............................................................................................16

HP210 ENGINE PARTS LIST - FRONT ..................................................................................................................17

HP210 ENGINE PARTS LIST - BACK.....................................................................................................................18

HP210 ENGINE PARTS LIST - BASE .....................................................................................................................19

HOSES, FITTINGS & 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. STANLEY Infrastructure

recommends that servicing of hydraulic tools, other than routine maintenance, must be performed by an authorized

and certied 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 certied dealer, call STANLEY Infrastructure at (503) 659-5660 and ask for a Customer Service Representative.

HP210 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 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 ► HP210 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 specic 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 HP210 power unit.

The HP210 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.

HP210 User Manual ◄ 5

Page 6

74759 Power Unit Dash Decal

TOOL STICKERS & TAGS

76759 Dual Circuit Decal

81163 Dual Circuit Decal (HP210BA)

76783 Emission Control Decal

28322 CE Decal HP210BA HP210BBA

66653 Sound Power Decal HP210BA HP210BBA

6 ► HP210 User Manual

73306 Lifting Point Decal HP210BA HP210BBA

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 certi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 certi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

SEE OTHER SIDE

SIDE 2

THE TAG SHOWN BELOW IS ATTACHED TO “CONDUCTIVE” HOSE.

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

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

HP210 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

tool applications only based on STANLEY tool

8 ► HP210 User Manual

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 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)

(at min. operating temperature)

(at max. expected ambient temperature)

Min. cooling capacity at a temperature

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

(For cold temp. startup and max. dirt-holding capacity)

4-6 gpm 7-9 gpm 9-10.5 gpm 11-13 gpm (15-23 lpm) (26-34 lpm) (34-40 lpm) (42-49 lpm) 1500 psi 1500 psi 1500 psi 1500 psi (103 bar) (103 bar) (103 bar) (103 bar)

2100-2250 psi 2100-2250 psi 2200-2300 psi 2100-2250 psi (145-155 bar) (145-155 bar) (152-159 bar) (145-155 bar)

250 psi 250 psi 250 psi 250 psi (17 bar) (17 bar) (17 bar) (17 bar)

400 ssu* 400 ssu* 400 ssu* 400 ssu* (82 centistokes) (82 centistokes) (82 centistokes) (82 centistokes)

140° F 140° F 140° F 140° F (60° C) (60° C) (60° C) (60° C)

3 hp 5 hp 6 hp 7 hp (2.24 kW) (3.73 kW) (5.22 kW) (4.47 kW) 40° F 40° F 40° F 40° F (22° C) (22° C) (22° C) (22° C)

25 microns 25 microns 25 microns 25 microns 30 gpm 30 gpm 30 gpm 30 gpm (114 lpm) (114 lpm) (114 lpm) (114 lpm)

TYPE I TYPE II

TOOL TYPE

TYPE RR

TYPE III

(premium grade, anti-wear, non-conductive) Viscosity (at min. and max. operating temps)

NOTE:

over a wide range of operating temperatures.

*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:

100-400 ssu* 100-400 ssu* 100-400 ssu* 100-400 ssu* (20-82 centistokes)

CLASSIFICATION

3.5-4.3 gpm 4.7-5.8 gpm 7.1-8.7 gpm 9.5-11.6 gpm 11.8-14.5 gpm (13.5-16.5 lpm) (18-22 lpm) (27-33 lpm) (36-44 lpm) (45-55 lpm) 1870 psi 1500 psi 1500 psi 1500 psi 1500 psi (129 bar) (103 bar) (103 bar) (103 bar) (103 bar)

2495 psi 2000 psi 2000 psi 2000 psi 2000 psi (172 bar) (138 bar) (138 bar) (138 bar) (138 bar)

HP210 User Manual ◄ 9

Page 10

OPERATION

PREPARATION FOR USE

Do not operate HP210 until you have completed the following steps:

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

overll. Use detergent oil classied "For Service SE, SF, SG" as specied 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

quick disconnect ttings (NPT).

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.

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.

USING THE 12 VOLT DC OUTLET

A 12 VDC outlet is available for specic models. The DC

outlet is ON at all times.

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

*Recommended for extreme cold temperatures

INSTALL HYDRAULIC CONNECTIONS

Accessories left in the 12VDC outlet can drain the

battery if the HP210 is not running.

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.

10 ► HP210 User Manual

Page 11

OPERATION

Throttle / Flow Selector Knob

Ignition Switch Flow Switches

CONTROLS

HP210 can provide two 5 GPM/20 LPM circuits (up to 2000 psi/140 bar) or one 10 GPM/40 LPM circuit (up to 2000 psi/140 bar).

HP210BA and HP210BBA CE models can provide two 4 GPM/15 LPM circuits (up to 2000 psi/140 bar) or one 8 GPM/30 LPM circuit (up to 2000 psi/140 bar).

STARTUP

1. Toggle both Flow Switches to the “FLOW OFF” position.

Male Hydraulic

Hose Fitting

Male Hydraulic

Hose Fitting

Female Hydraulic

Hose Fitting

Female Hydraulic

Hose Fitting

CHANGING CIRCUIT FLOW

1. Toggle the Flow Switches to the “FLOW OFF” position.

2. Select the desired circuit ow using the Flow Selector Knob.

3. Toggle the Flow Switches to the desired ow for each circuit.

SHUTDOWN

1. Toggle the Flow Switches to the “FLOW OFF” position.

Note: HP210 will not start unless the Flow Switches are 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.

8. Toggle the Flow Switches to the desired ow for each circuit.

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

GPM/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.

Once the hydraulic oil is warm, you may operate the HP210 as normal.

HP210 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.

• 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 5 GPM/20 LPM circuit

ow.

2. Start the engine and pump the uid, out of the pressure port, into a 5 gal. container.

3. When hydraulic tank is empty, turn the Ignition Switch to the “Off” 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.

• Replace the crankcase oil.

GENERAL

Tests should be performed periodically to ensure HP210 is

operating at maximum efciency. STANLEY Circuit Tester

(part number 04182) can be used to isolate problems in both the engine and hydraulic system.

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 Flow Switch to the “FLOW OFF” position.

2. Set the Flow Selector Knob 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.

• Check oil cooler. Remove debris with air pressure.

BATTERY

• 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.

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.

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 (10, 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 repeat the test.

12 ► HP210 User Manual

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 overlled. 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 (10, page 18).

kink. The hose should have a smooth curve.

21). Replace if necessary.

HP210 User Manual ◄ 13

Page 14

SPECIFICATIONS

Engine: ....................................................................................................................................................18 hp Briggs

Capacity.......................................................................Two 5 GPM/20 LPM Circuits or One 10 GPM/40 LPM Circuit

Capacity (HP210BA & HP210BBA) ...............................Two 4 GPM/15 LPM Circuits or One 8 GPM/30 LPM Circuit

Length:................................................................................................................................................ 36 in. / 91.4 cm

Width: ................................................................................................................................................. 23 in: / 58.4 cm

Height: .............................................................................................................................................. 29.5 in. / 74.9cm

Weight (Wet): Dual Circuit Briggs ...................................................................................................334 lbs / 151.5 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

Nominal Operating Pressure .......................................................................................................... 1500 psi / 103 bar

Relief Valve "crack" setting ............................................................................................................. 2100 psi / 145 bar

Full relief setting ............................................................................................................................. 2500 psi / 172 bar

EHTMA Category...............................................................................................................................................C or E

EHTMA Category (HP210BA & HP210BBA) ..................................................................................................... B or D

HTMA Category .............................................................................................................................Type 1 or Type RR

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, modications 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.

ACCESSORIES

Coupler Male, 3/8 -8 SAE, Parker .....................................................................................................................58857

Coupler Female, 3/8 -8 SAE, Parker ................................................................................................................. 58856

Coupler Male, 3/8 -8 SAE, Aeroquip..................................................................................................................66785

Coupler Female, 3/8 -8 SAE, Aeroquip .............................................................................................................66784

Hose Assy, 50 ft., with couplers (2 wire braid RR) ............................................................................................. 58448

Hose Assy, 50 ft., with couplers ......................................................................................................................... 31848

Hose Assy, 25 ft., with couplers ......................................................................................................................... 31972

Hose Assy, 25 ft., with couplers (2 wire braid RR) ............................................................................................. 58451

Wheel Kit (Converts a Skid Mount unit into a wheeled unit).............................................................................73393

Oil Filter .............................................................................................................................................................18384

Air Filter .............................................................................................................................................................18382

Fuel Filter...........................................................................................................................................................19947

Foam Air Filter ................................................................................................................................................... 18383

Hydraulic Oil Filter .............................................................................................................................................40408

14 ► HP210 User Manual

Page 15

HP210 FRAME PARTS ILLUSTRATION

1 2 3 4 5

ITEM # PART # QTY DESCRIPTION

1. 76755 1 Frame Weldment

76712 1 Frame Weldment

(HP2510B05)

2. 59074 2 Flange Bolt

3. 59079 1 Cooler Guard

4. 60945 2 Washer

5. 15476 2 Capscrew

6. 03906 7 Nut

7. 370502 7 Capscrew

8. 62268 2 Lift Handle

66064 2 Lift Handle (HP2510B05)

9. 23530 2 Flange Bolt

10. 58976 2 Flange Bolt

11. 62267 1 Rear Lift Handle

66063 1 Rear Lift Handle

(HP2510B05)

12. 58916 1 Handle Lock

810

HP210 User Manual ◄ 15

Page 16

HP210 CONTROL PANEL PARTS ILLUSTRATION

22 23

2 3

6 7 8

1819

2021

1617

ITEM # PART # QTY DESCRIPTION

1. 74759 1 Dash Decal

2. 62298 1 Choke Cable Assembly

3. 204332 1 Throttle Knob

4. 17134 1 Nut

5. 76758 1 Throttle Rod

6. 76757 1 Throttle Stop

7. 208887 1 Throttle Cable Assembly

8. 15476 2 Capscrew

9. 79334 1 Manifold

10. 59131 2 Relief Valve

11. 62319 2 Directional Valve and Cap

12. 60958 2 Solenoid Coil

13. 08104 1 Hollow Hex Plug

14. 60960 1 Combiner Valve and Nut

15. 62320 1 Solenoid Coil

16. 81163 1 Dual Circuit Decal

1514

ITEM # PART # QTY DESCRIPTION

72783 1 Dual Circuit Decal, Metric

(HP210BBA)

17. 60962 4 Capscrew

18. 58856 2 3/8in. Female Coupler, -8 SAE

19. 58857 2 3/8in. Male Coupler, -8 SAE

20. 60956 2 Rotary Switch

21. 67899 1 3 Position Rotary Switch

22. 64942 1 12V Receptacle Assembly

23. 60946 1 Hour Meter

24. 28322 1 CE Decal (HP210BBA, HP210BA)

25. 66653 1 Sound Power Decal (HP210BBA, HP210BA)

26. 79312 1 Wire Harness (see page 21)

16 ► HP210 User Manual

Page 17

HP210 ENGINE PARTS LIST - FRONT

19 20

1 2

ITEM # PART # QTY DESCRIPTION

1. 59077 1 Hydraulic Oil Tank

2. 59080 1 Front Grille

3. 17821 4 Capscrew

4. 80986 4 Capscrew

5. 80984 4 Lock Washer

6. 65107 1 Blower Wheel

7. 00111 3 Capscrew

8. 65108 1 Blower Hub

9. 20990 1 Key

10. 59076 1 Bushing

11. 59083 1 Blower Housing

12. 40433 5 Flange Bolt

13. 26831 2 Washer

14. 01213 2 Capscrew

15. 64937 1 Grip Plate

910

4567

1112

ITEM # PART # QTY DESCRIPTION

16. 43687 2 Capscrew

17. 40080 1 Filter Assembly

18. 51292 1 Standard Thread Union

19. 66215 1 Cooler Mount (HP210BY)

20. 59074 2 Flange Bolt (HP210BY)

21. 59095 3 Flange Nut (HP210BY)

22. 60774 1 Hose Clamp (HP210BY)

23. 59075 1 Flange Bolt (HP210BY)

24. - - Provided with Engine (HP210BY)

25. 59091 1 Cooler

26. 62296 2 Weather Strip

HP210 User Manual ◄ 17

Page 18

HP210 ENGINE PARTS LIST - BACK

20 21

23 2324

26 27

28 29

1213

1 2 3

1011

171819

ITEM # PART # QTY DESCRIPTION

1. 62324 1 Heat Shield

66214 1 Heat Shield (HP210BY)

2. 65456 1 Spark Arrester (HP210BA, HP210BBA)

3. 36152 2 Screw

4. 36151 1 Heat Shield

5. 76753 1 Engine with Mufer

76721 1 Engine(HP210BY)

6. 31765 1 Pressure Switch

7. 40433 4 Flange Bolt

8. 62385 2 Stud

9. 07819 1 Square Key

10. 56656 1 Coupling

11. 56655 1 Pump Mount

12. 01459 4 Washer

13. 07860 4 Capscrew

1213

ITEM # PART # QTY DESCRIPTION

14. 18893 2 Flange Nut

15. 371503 1 Nut

16. 27695 1 Pump

17. 73050 1 Fuel Tank

18. 04303 1 Battery

19. 60912 1 Battery Cover

20. 15476 1 Capscrew

21. 60945 1 Washer

22. 71794 1 Fuel Cap

23. 60920 2 Grommet

24. 72401 1 Grommet Connector

25. 60919 1 Fuel Elbow

26. 72317 2 Hose Clamp

27. 62289 1 Fuel Hose

28. 72571 1 Fuel Vapor Hose

29. 72451 2 Hose Clamp

18 ► HP210 User Manual

Page 19

HP210 ENGINE PARTS LIST - BASE

1 2

5 6

8 9

10 11

ITEM # PART # QTY DESCRIPTION

1. 64991 1 Capscrew

2. 56709 1 Cable Clamp

3. 76753 1 Engine

76721 1 Engine (HP210BY)

4. 01212 1 Pipe Plug

5. 12787 4 Flange Nut

6. 24287 1 Hose Clamp

7. 58942 4 Flange Bolt

8. 58917 1 Axle

9. 56633 2 Foam Filled Tires

10. 21318 2 Washer

11. 31240 2 Retaining Ring

12. 21714 2 Handle Bumper

13. 58976 4 Flange Bolt

14. 18893 2 Flange Nut

15. 58975 2 Foot

16. 58897 1 Frame Base Weldment

HP210 User Manual ◄ 19

Page 20

HOSES, FITTINGS & CLAMPS

ITEM # PART # QTY DESCRIPTION

1. 350104 2 Connector

2. 58943 2 Hose

3. 59105 1 Hose Barb

4. 62199 4 Hose Clamp

5. 59089 2 Hose

6. 40364 1 Elbow

7. 58569 1 Elbow

8. 59104 1 Hose Barb

9. 350000 4 Elbow

10. 02773 1 Adapter

20 ► HP210 User Manual

Page 21

MAIN WIRING HARNESS

PART NUMBER 79312

Solenoid Coil

Starter Relay

Solenoid Coil

Flow Switches

Hour Meter

Start Switch

BlackRed

Positive battery

cable to starter

solenoid

(Red)

Engine Kill

(Black)

Black

Fuel Shutoff

(Red)

Oil Pressure

Switch

Battery

HP210 User Manual ◄ 21

Page 22

ELECTRICAL SCHEMATIC

SOLENOID

FUSE

10 A

SWITCH

CIRCUIT 1

WHITE WIRE

SWITCH

CIRCUIT 2

BROWN WIRE

WHITE WIRE

2+5+6

2+4+5

1+3+6

SWITCH

56 4 3 2

2. RUN

3. START

STARTER

RECTIFIER

REGULATOR

STARTER

SOLENOID

1. OFF

CASE GROUND

STARTER

BATTERY

STARTER

RELAY NC

SWITCH

ENGINE OIL

INTERLOCK

HOUR

MAGNETO

METER

87a

FUEL SHUTOFF

CIRCUIT 1

CIRCUIT 2

22 ► HP210 User Manual

Page 23

Page 24

STANLEY Infrastructure

3810 SE Naef Road

Milwaukie, Oregon 97267-5698 USA

(503) 659-5660 / Fax (503) 652-1780

www.stanleyinfrastructure.com