Stanley Black & Decker HP TWIN8 User Manual
HYDRAULIC
POWER UNIT
USER MANUAL
Safety, Operation and Maintenance
© 2013 Stanley Black & Decker, Inc.
New Britain, CT 06053
U.S.A.
72464 5/2014 Ver. 6
2 ► HP TWIN8 User Manual
WARNING
IMPORTANT
TABLE OF CONTENTS
SAFETY SYMBOLS ..................................................................................................................................................4
SAFETY PRECAUTIONS .......................................................................................................................................... 5
TOOL STICKERS ......................................................................................................................................................7
HOSE TYPES ............................................................................................................................................................ 8
HOSE RECOMMENDATIONS ..................................................................................................................................9
HTMA \ EHTMA REQUIREMENTS ......................................................................................................................... 10
PRE-OPERATION ................................................................................................................................................... 11
CONTROLS .............................................................................................................................................................12
START-UP ...............................................................................................................................................................12
MAINTENANCE ......................................................................................................................................................13
BATTERY MAINTENANCE ...............................................................................................................................13
CIRCUIT TESTING .................................................................................................................................................16
TROUBLESHOOTING ............................................................................................................................................17
SPECIFICATIONS ................................................................................................................................................... 18
ACCESSORIES.......................................................................................................................................................19
LOWER FRAME ILLUSTRATION ...........................................................................................................................20
LOWER FRAME PARTS LIST.................................................................................................................................21
HYDRAULIC GROUP ILLUSTRATION ................................................................................................................... 22
HYDRAULIC GROUP PARTS LIST ........................................................................................................................ 23
UPPER FRAME ILLUSTRATION AND PARTS LIST ..............................................................................................24
HYDRAULIC FLOW ................................................................................................................................................25
CONTROL BLOCK DETAIL ..................................................................................................................................... 26
HYDRAULIC & FUEL TANKS ..................................................................................................................................27
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 (503) 659-5660 and ask for a
Customer Service Representative.
HP TWIN8 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 avoid-
ed, 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 mainte-
nance personnel.
4 ► HP TWIN8 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. Re-
view 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 HP TWIN8 Hydraulic Power Unit will provide safe
and dependable service if operated in accordance with
the instructions given in this manual. Read and understand this manual and any stickers and tags attached
to the 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 bystanders. The operator must be familiar with all prohibited
work areas such as excessive slopes and danger-
ous 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, breathing protection, head protection,
and safety shoes at all times when operating the
power unit and a hydraulic tool.
• Do not inspect or clean the power unit while it is run-
ning. 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 con-
nections are tight.
• Be sure all hoses are connected for correct ow di-
rection to and from the tool being used.
• 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, improperly adjusted
power unit.
• Do not wear loose clothing or unbound long hair
when operating the tool. Loose items can get entangled with the tool and cause serious injury.
• 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 the power
unit is running or is still hot.
• Do not operate the power unit if gasoline odor is
present.
• 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.
• Do not operate the machine on excessive slopes or
unstable terrain where “tip over” is a hazard.
• Do not exceed the rated limits of the equipment or
use the equipment for applications beyond its de-
sign capacity.
• Be aware of surrounding hazards. Noise created by
the Power Unit and the tools it operates may mask
early indications of approaching hazards.
HP TWIN8 User Manual ◄ 5
SAFETY PRECAUTIONS
• Warning: Hydraulic uid under pressure could cause
skin injection injury. If you are injured by hydraulic
uid, get medical attention immediately.
• Be observant of the hydraulic hoses lying about the
work area, they can be a tripping hazard.
• Use proper lifting techniques when handling the
power unit, and do not over-reach.
• Only use the Power Unit in well-ventilated areas. DO
NOT operate in explosive atmospheres, in closed
environments or near ammable substances.
• Always be well-rested and mentally alert when operating the Power Unit and tools. DO NOT operate if
affected by medications, drugs or alcohol.
• Keep clear of hot (engine) parts and exhaust.
• Do not operate tools if oil temperature exceeds 140
°F/60 °C. Operation at high temperatures can cause
higher than normal temperatures at the tools which
can result in operator discomfort or injury.
• Disconnect battery before servicing electrical com-
ponents. Electrocution or burns could result from
improper contact.
• Loading and unloading of the power unit is danger-
ous. Never attempt to load or unload the power unit
without loading ramps, loading dock or an over head
crane. Loading ramps must be strong enough, have
a low angle, and correct height. Load and unload the
power unit on a level surface. Never attempt to load
or unload the power unit if the ramp incline exceeds
15 degrees. Failure to follow these instructions may
result in serious injury or death.
• Warning: Use of this tool on certain materials
during demolition could generate dust potentially
containing a variety of hazardous substances
such as asbestos, silica or lead. Inhalation of dust
containing these or other hazardous substances
could result in serious injury, cancer or death.
Protect yourself and those around you. Research
and understand the materials you are cutting.
Follow correct safety procedures and comply with
all applicable national, state or provisional health
and safety regulations relating to them, including,
if appropriate arranging for the safe disposal of the
materials by a qualied person.
6 ► HP TWIN8 User Manual
TOOL STICKERS
LOGO, TWIN8 DECAL P/N-205044
DASH, TWIN8, DECAL P/N-205043
STANLEY, HYD TANK, DECAL P/N-205049
LOGO TWIN8, HYD TANK DECAL P/N-205046
SAFETY, TWIN8, DECAL P/N-205047
STANLEY, FUEL TANK DECAL P/N-205048
LOGO, TWIN8, FUEL TANK DECAL P/N-205045
HP TWIN8 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 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
8 ► HP TWIN8 User Manual
HOSE RECOMMENDATIONS
Min. Working Pressure
USE
(Press/Return)
Certied Non-Conductive Hose - Fiber Braid - for Utility Bucket Trucks
5/8 16 Pressure 2500 175
3/4 19 Return 2500 175
5/8 16 Pressure 2500 175
3/4 19 Return 2500 175
3/4 19 Pressure 2500 175
1 25.4 Return 2500 175
5/8 16 Pressure 2500 175
3/4 19 Return 2500 175
3/4 19 Pressure 2500 175
1 25.4 Return 2500 175
HYDRAULIC CIRCUIT
PRESSURE RETURN
PRESSURE
<<< FLOW
RETURN
FLOW >>>
Conductive Hose - Wire Braid or Fiber Braid -DO NOT USE NEAR ELECTRICAL CONDUCTORS
Oil Flow Hose Lengths Inside Diameter
Tool to Hydraulic Circuit Hose
4-9 15-34 up to 10 up to 3 3/8 10 Both 2250 155
4-6 15-23 up to 25 up to 7.5 3/8 10 Both 2500 175
lengths based on gallons per minute (gpm)/
liters per minute (lpm). These recommenda-
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
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
5-10.5 19-40 100-300 30-90
tool applications only based on Stanley Hy-
10-13 38-49 up to 50 up to 15 5/8 16 Both 2500 175
draulic Tools tool operating requirements and
should not be used for any other applications.
GPM LPM FEET METERS INCH MM PSI BAR
Recommendations
The chart to the right shows recommended
minimum hose diameters for various hose
10-13 38-49 51-100 15-30
10-13 38-49 100-200 30-60
13-16 49-60 up to 25 up to 8
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.
13-16 49-60 26-100 8-30
Figure 1. Typical Hose Connections
HP TWIN8 User Manual ◄ 9
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