AL35
HYDRAULIC
ALTERNATOR
USER MANUAL
Safety, Operation and Maintenance
© 2014 Stanley Black & Decker, Inc.
New Britain, CT 06053
U.S.A.
16798 8/2014 Ver. 6
WARNING
IMPORTANT
TABLE OF CONTENTS
SAFETY SYMBOLS ..................................................................................................................................................4
SAFETY PRECAUTIONS .......................................................................................................................................... 5
TOOL STICKERS & TAGS ........................................................................................................................................7
HOSE TYPES ............................................................................................................................................................ 8
HOSE RECOMMENDATIONS ..................................................................................................................................9
FIGURE 1. TYPICAL HOSE CONNECTIONS .......................................................................................................9
HTMA REQUIREMENTS .........................................................................................................................................10
OPERATION ............................................................................................................................................................ 11
FIGURE 2. DIODE LOCATION ............................................................................................................................12
TOOL PROTECTION & CARE ................................................................................................................................13
TROUBLESHOOTING ............................................................................................................................................14
SPECIFICATIONS ................................................................................................................................................... 15
AL35 PARTS ILLUSTRATION ................................................................................................................................. 16
AL35 PARTS LIST ...................................................................................................................................................17
AL35 MOTOR PARTS ILLUSTRATION ...................................................................................................................18
AL35 WIRING DIAGRAM ........................................................................................................................................ 19
To ll out a Product Warranty Recording form, and for information on your warranty,
visit Stanleyhydraulics.com and select the Company tab, Warranty.
(NOTE: The warranty recording form must be submitted to validate the warranty).
SERVICING: This manual contains safety, operation, and routine maintenance instructions. Stanley Hydraulic Tools
recommends that 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 authorized and certied dealer, call Stanley Hydraulic Tools at the number listed on the back of this
manual and ask for a Customer Service Representative.
AL35 User Manual ◄ 3
DANGER
WARNING
CAUTION
CAUTION
NOTICE
IMPORTANT
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 indicate an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
This safety alert and signal word indicate a potentially hazardous situation
which, if not avoided, could result in death or serious injury.
This safety alert and signal word indicate 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 ► AL35 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 tool and
hose.
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 pre-
cautions relating to the specic work area and local
safety regulations. If so, place the added precautions in
the space provided in this manual.
The AL35 Hydraulic Alternator will provide safe and dependable service if operated in accordance with the instructions given in this manual. Read and understand
this manual and any stickers and tags attached to the
tool and hoses before operation. Failure to do so could
result in personal injury or equipment damage.
• Operator must start in a work area without bystand-
ers. Keep bystanders clear of your work area. The
operator must be familiar with the work area such as
excessive slopes and dangerous terrain conditions.
• Establish a training program for all operators to en-
sure safe operation.
• Do not operate the alternator unless thoroughly
trained or under the supervision of an instructor.
• Always wear safety equipment such as goggles, ear
and head protection, and safety shoes at all times
when operating the alternator.
• Never use tools near energized transmission lines.
Know the location of buried or covered services before starting your work.
• Do not overreach. Maintain proper footing and bal-
ance at all times.
• Do not inspect or clean the alternator while the hy-
draulic power source is connected. Accidental engagement of the tool can cause serious injury.
• Always connect hoses to the alternator hose couplers before energizing the hydraulic power source.
Be sure all hose connections are tight.
• Do not operate the alternator at oil temperatures
above 140 °F/60 °C. Operation at higher temperatures can cause higher than normal temperatures
at the tool which can result in operator discomfort.
• Never transport or carry the alternator with the unit
energized and connected to electrical loads.
• Do not operate a damaged, improperly adjusted, or
incompletely assembled alternator.
• Observe local and national electrical codes for load
wiring. To prevent electrical shock from faulty equipment, ground the alternator. If ground bonding is
required, connect a length of heavy wire between
the alternator ground terminal and the ground bond
point.
• Exercise reasonable caution to prevent electrical
shock; do not operate the alternator with wet hands.
• Do not operate the alternator in rain or snow. Do not
let the alternator get thoroughly wet.
• Do not connect the alternator to a building circuit.
This could cause damage to the alternator or to
electrical equipment in the building.
AL35 User Manual ◄ 5
SAFETY PRECAUTIONS
• Do not start the alternator with electrical loads connected and in a power “ON” state.
• Ensure that the alternator is at operating speed/voltage before connecting an electrical load.
• Only use hydraulic hose labeled and certied as
non-conductive when using hydraulic tools on or
near electrical lines. Failure to do so may result in
death or serious injury.
• Before using hose labeled and certied as non‑conductive, be sure the hose is maintained as nonconductive. The hose should be regularly tested
for electric current leakage in accordance with your
safety department instructions.
• A hydraulic leak or burst may cause oil injection into
the body or other severe personal injury.
• Do not exceed specied ow and pressure for the
alternator. Excess ow or pressure may cause a
leak or burst.
• Do not exceed the rated working pressure of hydraulic hose used with the alternator. Excess pressure may cause a leak or burst.
• Check alternator hose couplers and connectors daily for leaks. Do not feel for leaks with your hands.
Contact with a leak may result in severe personal
injury.
• Do not lift or carry the alternator by the hoses. Do
not abuse the hoses. Do not use kinked, torn or
damaged hydraulic hose.
• Make sure hydraulic hoses are properly connected
to the alternator before pressuring the hydraulic
system. The system pressure hose must always be
connected to the alternator IN port. The system return hose must always be connected to the alternator OUT port. Reversing the connections may cause
reverse tool operation which can result in severe
personal injury.
• Do not connect open-center hydraulic tools to
closed-center hydraulic systems. This may result
in loss of other hydraulic functions powered by the
same system and/or may cause severe personal
injury. The AL35 alternator is an open‑center hy‑
draulic tool.
• To avoid personal injury or equipment damage all
tool repair maintenance and service must only be
performed by authorized and properly trained personnel.
6 ► AL35 User Manual
03763
GPM Sticker
TOOL STICKERS & TAGS
12735
AL35 Name Tag
NOTE:
THE INFORMATION LISTED
ON THE STICKERS SHOWN,
MUST BE LEGIBLE AT ALL
TIMES.
REPLACE DECALS IF
THEY BECOME WORN OR
DAMAGED. REPLACEMENTS
ARE AVAILABLE FROM
YOUR LOCAL STANLEY
DISTRIBUTOR.
The safety tag (P/N 15875) at right is
attached to the tool when shipped from
the factory. Read and understand the
safety instructions listed on this tag before
removal. We suggest you retain this tag and
attach it to the tool when not in use.
1. FAILURE TO USE HYDRAULIC HOSE LABELED AND CER-
TIFIED AS NON‑CONDUCTIVE WHEN USING HYDRAULIC
TOOLS ON OR NEAR ELECTRICAL LINES MAY RESULT IN
DEATH OR SERIOUS INJURY.
BEFORE USING HOSE LABELED AND CERTIFIED AS NON‑
CONDUCTIVE ON OR NEAR ELECTRIC LINES BE SURE THE
HOSE IS MAINTAINED AS NON‑CONDUCTIVE. THE HOSE
SHOULD BE REGULARLY TESTED FOR ELECTRIC CUR-
RENT LEAKAGE IN ACCORDANCE WITH YOUR SAFETY
DEPARTMENT INSTRUCTIONS.
2. A HYDRAULIC LEAK OR BURST MAY CAUSE OIL INJECTION INTO THE BODY OR CAUSE OTHER SEVERE
PERSONAL INJURY.
A. DO NOT EXCEED SPECIFIED FLOW AND PRESSURE
FOR THIS TOOL. EXCESS FLOW OR PRESSURE MAY
CAUSE A LEAK OR BURST.
B. DO NOT EXCEED RATED WORKING PRESSURE OF
HYDRAULIC HOSE USED WITH THIS TOOL. EXCESS
PRESSURE MAY CAUSE A LEAK OR BURST.
C. CHECK TOOL HOSE COUPLERS AND CONNECTORS
DAILY FOR LEAKS. DO NOT FEEL FOR LEAKS WITH
YOUR HANDS. CONTACT WITH A LEAK MAY RESULT
IN SEVERE PERSONAL INJURY.
IMPORTANT
READ OPERATION MANUAL AND
SAFETY INSTRUCTIONS FOR THIS
TOOL BEFORE USING IT.
USE ONLY PARTS AND REPAIR
PROCEDURES APPROVED BY
STANLEY AND DESCRIBED IN THE
OPERATION MANUAL.
TAG TO BE REMOVED ONLY BY
TOOL OPERATOR.
SEE OTHER SIDE
DANGERDANGER
D. DO NOT LIFT OR CARRY TOOL BY THE HOSES. DO
NOT ABUSE HOSE. DO NOT USE KINKED, TORN OR
DAMAGED HOSE.
3. MAKE SURE HYDRAULIC HOSES ARE PROPERLY CON-
NECTED TO THE TOOL BEFORE PRESSURING SYSTEM.
SYSTEM PRESSURE HOSE MUST ALWAYS BE CONNECTED TO TOOL “IN” PORT. SYSTEM RETURN HOSE
MUST ALWAYS BE CONNECTED TO TOOL “OUT” PORT.
REVERSING CONNECTIONS MAY CAUSE REVERSE
TOOL OPERATION WHICH CAN RESULT IN SEVERE
PERSONAL INJURY.
4. DO NOT CONNECT OPEN‑CENTER TOOLS TO CLOSED‑
CENTER HYDRAULIC SYSTEMS. THIS MAY RESULT IN
LOSS OF OTHER HYDRAULIC FUNCTIONS POWERED BY
THE SAME SYSTEM AND/OR SEVERE PERSONAL INJURY.
5. BYSTANDERS MAY BE INJURED IN YOUR WORK AREA.
KEEP BYSTANDERS CLEAR OF YOUR WORK AREA.
6. WEAR HEARING, EYE, FOOT, HAND AND HEAD PRO-
TECTION.
7. TO AVOID PERSONAL INJURY OR EQUIPMENT DAMAGE,
ALL TOOL REPAIR MAINTENANCE AND SERVICE MUST
ONLY BE PERFORMED BY AUTHORIZED AND PROPERLY
TRAINED PERSONNEL.
IMPORTANT
READ OPERATION MANUAL AND
SAFETY INSTRUCTIONS FOR THIS
TOOL BEFORE USING IT.
USE ONLY PARTS AND REPAIR
PROCEDURES APPROVED BY
STANLEY AND DESCRIBED IN THE
OPERATION MANUAL.
TAG TO BE REMOVED ONLY BY
TOOL OPERATOR.
SEE OTHER SIDE
SAFETY TAG P/N 15875 (Shown smaller then actual size)
AL35 User Manual ◄ 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:
Certied non-conductive — constructed of thermoplastic or synthetic rubber inner tube, synthetic ber braid
reinforcement, and weather resistant thermoplastic or synthetic rubber cover. Hose labeled certied 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 certied 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 certied 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 Hydraulic
Tools. 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 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.
(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
8 ► AL35 User Manual
Min. Working Pressure
USE
(Press/Return)
HOSE RECOMMENDATIONS
Certied 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
13-16 49-60 up to 25 up to 8
3/4 19 Return 2500 175
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 recommenda-
tions are intended to keep return line pressure
(back pressure) to a minimum acceptable lev-
el to ensure maximum tool performance.
This chart is intended to be used for hydraulic
tool applications only based on Stanley Hy-
draulic Tools 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 maxi-
mum hydraulic system relief valve setting.
All hydraulic hose must meet or exceed
specications as set forth by SAE J517.
AL35 User Manual ◄ 9
HTMA / EHTMA REQUIREMENTS
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)
Measured at a max. uid viscosity of:
(at min. operating temperature)
Temperature: Sufcient heat rejection
capacity to limit max. uid temperature to:
(at max. expected ambient temperature)
Min. cooling capacity at a temperature
difference 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
Min. full-ow ltration
Sized for ow of at least:
(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
Hydraulic uid Petroleum based
(premium grade, anti-wear, non-conductive)
Viscosity (at min. and max. 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.
*SSU = Saybolt Seconds Universal
EHTMA
100-400 ssu* 100-400 ssu* 100-400 ssu* 100-400 ssu*
(20-82 centistokes)
CLASSIFICATION
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 specication page for tool specic requirements
B
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)
C
D
10 ► AL35 User Manual
CAUTION
CAUTION
OPERATION
The recommended hose size is .500 inch/12 mm I.D. up
to 50 ft/15 m long and .625 inch/16 mm I.D. minimum up
to 100 ft/30 m.
PRE‑OPERATION PROCEDURES
ELECTRICAL GROUND
If required, ground the electrical load and alternator at
the ground lug on the alternator frame, lower right (as
viewed from the front).
CHECK POWER SOURCE
1. Using a calibrated owmeter and pressure gauge,
check that the hydraulic power source develops a
ow of 7–9 gpm/26–34 lpm at 2000 psi/140 bar.
2. Make certain the hydraulic power source is equipped
with a relief valve set to open at 2100 psi/145 bar
maximum.
CONNECT HOSES
1. Wipe all hose couplers with a clean, lint‑free cloth
before making connections.
2. Connect the hoses from the hydraulic power source
to the tool ttings or quick disconnects. It is a good
practice to connect return hoses rst and discon-
nect them last to minimize or avoid trapped pressure
within the tool.
3. Observe ow indicators stamped on hose couplers
to ensure that uid ow is in the proper direction.
The female coupler on the tool hose is the inlet coupler.
4. Move the hydraulic circuit control valve to the ON
position to operate the tool.
NOTE:
If uncoupled hoses are left in the sun, pressure in‑
crease within the hoses may make them difcult to
connect. When possible, connect the free ends of
the hoses together.
OPERATION PROCEDURES
1. Observe all safety precautions.
Do not connect or otherwise apply power to an
electrical load until the alternator has come up to
speed.
2.
Move the hydraulic circuit control to the “ON” position. As the alternator comes up to speed, a maxi-
mum electrical load of 3500 W, single‑phase 60 Hz
alternating current, at 120 volts becomes available.
3. Connect the electrical loads.
Do not exceed the alternator’s rated 3500 W
capacity.
NOTE:
Output voltage is proportional to the RPM of the hy‑
draulic motor.
FLASHING THE FIELD
This procedure establishes residual magnetism in the
eld windings, to provide start‑up excitation and proper
output voltage levels.
1. Stop the alternator.
2. Remove the receptacle panel.
3. Using a 12 volt automotive battery, touch the positive lead to the positive (+) diode set with the white
or silver band, located on the rotor assembly. At the
same time touch the negative lead to the negative
(-) diode. Hold the leads against the diodes for 2-4
seconds.
NOTE:
Do not reverse the polarity of the leads. This may
cause damage to the diodes or the rotor or both.
4. Replace the receptacle panel and start the alternator.
AL35 User Manual ◄ 11
OPERATION
PREVENTATIVE MAINTENANCE
SCHEDULE
IN DIRTY OR MOIST ENVIRONMENTS
90 DAY INTERVALS
If the unit is operated or stored in a dirty, moist, or salt
moisture environment, the electrical contacts, rotor and
stator should be inspected and cleaned every 90 days or
more frequently as deemed necessary.
IN CLEAN, DRY ENVIRONMENTS
12 MONTH INTERVALS
If the unit is operated or stored in a clean and dry environment, the electrical contacts, rotor, and stator should
be inspected and cleaned every 12 months or more frequently as deemed necessary.
No other preventative maintenance is required.
COLD WEATHER OPERATION
If the breaker is to be used during cold weather, preheat
the hydraulic uid at low engine speed. When using the
normally recommended uid, uid temperature should
be at or above 50 °F/10 °C (400 ssu/82 centistokes) before use.
Damage to the hydraulic system or breaker can result
from use with uid that is too viscous or thick.
Positive and
Negative
Diodes
Figure 2. Diode Location
12 ► AL35 User Manual
NOTICE
TOOL PROTECTION & CARE
In addition to the Safety Precautions found in
this manual, observe the following for equipment
protection and care.
• Make sure all couplers are wiped clean before connection.
• The hydraulic circuit control valve must be in the
“OFF” position when coupling or uncoupling hydraulic tools. Failure to do so may result in damage to
the quick couplers and cause overheating of the hydraulic system.
• Always store the tool in a clean dry space, safe from
damage or pilferage.
• Make sure the circuit PRESSURE hose (with male
quick disconnect) is connected to the “IN” port. The
circuit RETURN hose (with female quick disconnect)
is connected to the opposite port. Do not reverse cir-
cuit ow. This can cause damage to internal seals.
• Always replace hoses, couplings and other parts
with replacement parts recommended by Stanley
Hydraulic Tools. Supply hoses must have a minimum working pressure rating of 2500 psi/172 bar.
• Do not exceed the rated ow (see Specications) in
this manual for correct ow rate and model number.
Rapid failure of the internal seals may result.
• Always keep critical tool markings, such as warning
stickers and tags legible.
• Do not force a small breaker to do the job of a large
breaker.
• Keep tool bit sharp for maximum breaker performance. Make sure that tool bits are not chipped or
rounded on the striking end.
• Never operate a breaker without a tool bit or without
holding it against the work surface. This puts excessive strain on the breaker foot.
• Tool repair should be performed by experienced
personnel only.
• Make certain that the recommended relief valves
are installed in the pressure side of the system.
• Do not use the tool for applications for which it was
not intended.
AL35 User Manual ◄ 13
TROUBLESHOOTING
PROBLEM CAUSE REMEDY
Tool does not run. Power unit not functioning. Check power unit for power ow and
pressure (7-9 gpm/26-34 lpm, 2000
psi/140 bar.
Couplers or hoses blocked. Remove restriction.
Hyrevz motor failure. Inspect and repair.
Hydraulic lines not connected. Connect lines.
No electrical output. Open circuit breaker. Reset circuit breaker.
Faulty receptacle. Replace receptacle.
Loose/broken wires. Locate and repair.
Loss of residual magnetism. Flash and Field. Refer to section in this
manual.
Short circuit in rotor led or diodes. Return to an authorized service center.
Shorted AC or exciter stator
windings.
Low output. Hyrevz motor speed too slow. Check for proper ow of 7‑9 gpm/26‑34
Unbalanced or excessive load. Balance load between circuits, load should
High backpressure. Check for excessive backpressure, over
Couplers/hoses blocked. Locate and remove blockage.
Oil too hot/cold. Above 150°F/66°C
or below 50°F/10°C.
Relief valve set too low. Adjust relief valve to 2000 psi/145 bar.
Motor worn. Inspect; repair/replace.
Output too high. Motor over-speeding. Check power unit for proper ow. 7‑9
Alternator overheats. Overloaded. Reduce electrical load; load should not
Air intake plugged or covered. Clear air intake.
Windings covered with dirt. Clean windings.
Check with Ohmmeter. Continuity should
exist between black/white and red/red
wires. No continuity from black/white to
red wire or any wire to ground. If a short is
found, replace the stator.
lpm.
not exceed rated capacity.
250 psi/17 bar.
Check power source for proper oil
temperature. Bypass cooler to warm
oil; or provide cooler to maintain proper
temperature.
gpm/26-34 lpm.
exceed rated capacity.
14 ► AL35 User Manual
SPECIFICATIONS
The AL35 is a hydraulic motor powered electrical alternator, designed to provide power for lights, small power
tools, and small appliances. It produces 3500 watts of power at a nominal 120/240 volts AC single phase at 60 Hz
frequency. The unit requires hydraulic power delivered at 7–9 gallons per minute (gpm) with pressure up to 2000
pounds per square inch (psi).
Capacity.......................................................................................... 3500 W 120/240 V, 60 Hz at 8 gpm/30 Ipm Input
Outlets . .................................................................................................. 240 V/15 A, 120 V/20 A, 120 V/15 A Duplex
Pressure Range ............................................................................................................................... 2000 psi/140 bar
Flow Range .................................................................................................................................7–9 gpm/26–34 Ipm
Optimum Flow ......................................................................................................................................8 gpm/30 Ipm
Porting ..................................................................................................................................................10 SAE O-ring
Connect Size and Type ..............................................................................................................1/2 NPT Pipe Fitting
Weight ................................................................................................................................................... 70 Ib/31.8 kg
Overall Length ...............................................................................................................................19 inches/47.9 cm
Width ...............................................................................................................................................9 inches/22.7 cm
Height ............................................................................................................................................10 inches/25.4 cm
Motor ................................................................................................................................Stanley Hyrevz P/N 21446
AL35 User Manual ◄ 15
2
4
3
2
5
21
22
16
1
7
8
9
3
14
13
12
6
15
17
18
19
20
22
21
23
25
24
27
40
36
37
35
42
39
21
22
20
32
43
31
10
28
30
26
41
38
AL35 ALTERNATOR
August 1998
AL35 PARTS ILLUSTRATION
16 ► AL35 User Manual
AL35 PARTS LIST
ITEM
1 15100 1 VOLTMETER
2 COM* 4 PHILLIPS HEAD MACHINE SCREW
3 COM* 4 WASHER
4 1 RECEPTACLE PANEL
5 15101 1 RECEPTACLE, 30 A, 120 V
6 15103 1 RECEPTACLE, 15 A, 240 V
7 — — INCLUDED WITH ITEM 1
8 15106 1 CIRCUIT BREAKER, 30 A
9 35235 1 CAPACITOR
10 05734 4 CAPSCREW, 3/8‑16 × 2 HEX HEAD
11 — — NO ITEM
12 15102 1 RECEPTACLE, 15 A, 120 V
13 15105 1 CIRCUIT BREAKER, 15 A
14 12692 4 STATOR BOLT 11" LONG
15 12735 1 NAME TAG
16 26604 1 RECEPTACLE BOX
17 COM* 1 CAPSCREW
18 COM* 1 LOCKWASHER
19 26607 1 OUTBOARD BEARING BRACKET
20 05351 4 FOOT
21 00429 6 HEX NUT 5/16-18
22 03031 6 WASHER 5/16
23 12628 1 MOUNTING BRACKET—SHORT
24 21315 2 CAPSCREW, 5/16‑18 × 1-1/4
25 00171 1 O-RING
26 35237 1 STATOR ASSY
27 12690 1 CAPSCREW
28 12691 1 "C" WASHER
29 — — NO ITEM
30 35236 1 ROTOR ASSEMBLY
31 26606 1 ADAPTER, INBOARD ENGINE END
32 12694 1 GROUNDING LUG
33 — — NO ITEM
34 — — NO ITEM
35 20051 4 NUT, LOCKWASHER 1/4‑20
36 02688 2 CAPSCREW 5/16‑18 × 3/4
37 05325 1 MOTOR ADAPTOR
PART
NO. QTY DESCRIPTION
ASSY
ITEM
38 12622 1 MOUNTING BRACKET—TALL
39 04353 4 ESNA NUT
40 21446 1 HYREVZ MOTOR ASSEMBLY
41 03786 1 STICKER, GPM
42 00936 2 ADAPTOR
PART
NO. QTY DESCRIPTION
COM* indicates common parts available through local
sources
AL35 User Manual ◄ 17
AL35 MOTOR PARTS ILLUSTRATION
AL35 MOTOR ASSEMBLY P/N 21446
ITEM
1 00120 8 CAPSCREW, 1/4‑20 × 2-1/4 HSH
2 07386 1 GEAR HOUSING ASSEMBLY
3 00713 2 DOWEL PIN
4 06316 4 BUSHING
5 00178 1 O-RING *
6 73309 1 IDLER SHAFT
7 06853 2 DRIVE GEAR
9 21432 BEARING HOUSING ASSEMBLY
10 00669 1 QUAD RING *
11 00171 1 O-RING *
12 19884 1 SEAL GLAND
13 00170 1 RETAINING RING
14 00708 1 RETAINING RING
15 00148 1 BEARING
16 06881 2 NEEDLE ROLLER
17 06876 1 DRIVE SHAFT
18 00166 1 RETAINING RING
PART
NO. QTY DESCRIPTION
(INCLUDES ITEMS 3 & 4)
(INCLUDES ITEM 4)
* Indicates part of Seal Kit 07388
18 ► AL35 User Manual
CAPACITOR
TO FRAME
6
GND
5
GOLD
GOLD
GOLD
SILVER
4
3
2
2
1
1
1
2
3
4
5
6
7
8
9
14 AWG BLK(P) 1
14 AWG BLK(P) 2
14 AWG WHT(P) 3
14 AWG WHT(P) 4
14 AWG WHT(P) 5
14 AWG BLK(P) 6
14 AWG GRN(P) 8 14 AWG GRN
J1
P1
16 AWG RED
16 AWG RED
G
X
W
14 AWG GRN
14 AWG WHT
14 AWG BLK
14 AWG BLK
14 AWG GRN
GND
NEMA
L530R
115V
30A
14 AWG BLK
GOLD
SILVER
15A
30A
14 AWG GRN
14 AWG BLK
1. RECEPTACLE TERMINALS ARE DRAWN
AS SEEN FROM THE BACK.
14 AWG BLK
14 AWG WHT
AL35 WIRING DIAGRAM
Use clean solvent In well ventilated areas. Avoid prolonged Inhalation of vapors and prolonged or repeated contact
with skin. Keep away from heat or open ame.
AL35 User Manual ◄ 19
Stanley Hydraulic Tools
3810 SE Naef Road
Milwaukie, Oregon 97267-5698 USA
(503) 659-5660 / Fax (503) 652-1780
www.stanleyhydraulics.com
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