IP16
HYDRAULIC
INTENSIFIER
USER MANUAL
Safety, Operation and Maintenance
© 2014 Stanley Black & Decker, Inc.
New Britain, CT 06053
U.S.A.
10413 9/2014 Ver. 3
WARNING
TABLE OF CONTENTS
SAFETY SYMBOLS ..................................................................................................................................................4
SAFETY PRECAUTIONS .......................................................................................................................................... 5
TOOL STICKERS & TAGS ........................................................................................................................................6
HOSE TYPES ............................................................................................................................................................ 7
HOSE RECOMMENDATIONS ..................................................................................................................................8
FIGURE 1. TYPICAL HOSE CONNECTIONS .......................................................................................................8
HTMA REQUIREMENTS ...........................................................................................................................................9
OPERATION ............................................................................................................................................................10
TOOL PROTECTION & CARE ................................................................................................................................ 11
TROUBLESHOOTING ............................................................................................................................................12
SPECIFICATIONS ................................................................................................................................................... 13
IP16 PARTS ILLUSTRATION .................................................................................................................................. 14
IP16 PARTS LIST ....................................................................................................................................................15
IMPORTANT
To ll out a Product Warranty Validation form, and for information on your warranty,
visit Stanleyhydraulics.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 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.
IP16 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 ► IP16 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 IP16 Hydraulic Intensier 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 dangerous terrain conditions.
• Establish a training program for all operators to ensure safe operation.
• Do not operate the tool unless thoroughly trained or
under the supervision of an instructor.
• Always wear safety equipment such as goggles,
ear, head protection, and safety shoes at all times
when operating the tool.
• Do not inspect or clean the tool while the hydraulic
power source is connected. Accidental engagement
of the tool can cause serious injury.
• Inlet and outlet hydraulic hoses must be capable of
10,000/700 bar working pressure. They must be t-
ted with hose guards at each end to help prevent
kinks and sharp bends near the ttings. If these requirements are not met, replace the hoses immediately with the correct type before operating the
intensier.
• Be sure all hose connections are tight and inspect
hoses for correct pressure rating and for kinks, cuts
swelled areas and damage from abrasion. Replace
if necessary.
• Check that all ttings, connectors and quick disconnects are rated at 10,000 psi/700 bar working pressure and that they are in good working condition.
Replace any improper or damaged components be-
fore operating the intensier.
• Do not operate the tool at oil temperatures above
140 °F/60 °C. Operation at higher oil temperatures
can cause operator discomfort and may damage the
tool.
• Do not operate a damaged, improperly adjusted, or
incompletely assembled tool.
• Do not operate the intensier unless both high-pressure hoses are connected.
• 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 attempt to locate hydraulic leaks by feeling
around hoses and ttings with bare hands. Pinhole
leaks can penetrate the skin. To inspect for leaks,
depressurize the system, clean around suspected
area, repressurize the system and visually check for
leaks.
• Always keep critical tool markings, such as labels
and warning stickers legible.
• Always replace parts with replacement parts recommended by Stanley Hydraulic Tools.
• Avoid using tightly curled or twisted hoses.
IP16 User Manual ◄ 5
TOOL STICKERS & TAGS
DANGER
Failure to use hydraulic hose labeled and certified
as non-conductive when using hydraulic toolson
or near electric lines mayresultin deathor
serious injury.
Forproper and safe operationreadownersmanual
and mwke sure that you have been properly
trained in correct procedures requiredforwork
ELECTROCUTION
on or around electric lines.
HAZARD
03783
GPM Sticker 3–9 2000 PSI
10146
IP16 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.
12412
Warning Sticker—Electrical
12891
Danger Sticker
10515
Caution Tag—“SHIPPED W/O OIL”
(Not shown)
1. FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED 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 CURRENT 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.
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.
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.
6 ► IP16 User Manual
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.
IMPORTANT
READ OPERATION MANUAL AND
SAFETY INSTRUCTIONS FOR THIS
USE ONLY PARTS AND REPAIR
PROCEDURES APPROVED BY
STANLEY AND DESCRIBED IN THE
TAG TO BE REMOVED ONLY BY
SEE OTHER SIDE
SAFETY TAG P/N 15875 (Shown smaller then actual size)
TOOL BEFORE USING IT.
OPERATION MANUAL.
TOOL OPERATOR.
SEE OTHER SIDE
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
IP16 User Manual ◄ 7
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.
8 ► IP16 User Manual
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.
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)
TOOL TYPE
TYPE I TYPE II
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 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
IP16 User Manual ◄ 9
IMPORTANT
IMPORTANT
OPERATION
PRE-OPERATION PROCEDURES
FILL RESERVOIR
Mil-H 5606 Hydraulic Oil must not be used in the
reservoir of the intensier.
1.
Remove the vent plug from the top of the intensier.
Fill with clean hydraulic oil ltered to 10 microns or
less. Fill to top of high pressure pump as viewed
from the ller hole.
Do not ll to top of hole. An air space is required for
hydraulic oil expansion as oil temperature increases.
2.
An over-full reservoir will cause oil leakage from the
vent plug as the oil heats. If this condition occurs,
remove the vent plug and lower oil level to the point
specied.
CHECK HYDRAULIC POWER SOURCE
1. Using a calibrated owmeter and pressure gauge,
check that the hydraulic power source develops a
ow of 4–10 gpm/15–38 lpm at 1000–2000 psi/70–
140 bar.
2. Make certain the hydraulic power source is equipped
with a relief valve set to open at 2100–2300 psi/145–
159 bar maximum.
3. Check that the hydraulic circuit matches the tool for
open-center (OC) operation.
CONNECT HOSES
1. Remove the thread protectors and valve caps from
the intensier.
2. Wipe all hose couplers with a clean lint-free cloth
before making hose connections.
3. Connect hydraulic lines from the parent circuit to the
intensier inlet tting. Make certain the “P” (pressure) and “T” (tank) hoses are connected to their
respective ports. If incorrectly connected, high pressure output will not be obtained.
NOTE:
High-pressure couplings must be used for the highpressure connections at the output side of the in-
tensier.
4. Connect the tool to be used (stretcher, cutter, etc,)
to the unit. Refer to the applicable Operation Manual
for detailed connection procedures.
5. Move the hydraulic circuit control valve to the ON
position to operate the intensier.
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
operating hoses together.
TOOL OPERATION
1. Observe all safety precautions
2. Activate the parent circuit to energize the intensier.
Pressure should now be available at the pressure
port of the tool. At this time, the control valve and
tool are ready for operation.
3. Verify operating pressure requirements of tool being
used and adjust intensier relief valve as required.
NOTE:
Higher ows and/or high back-pressure will increase the output pressure. Adjust the output relief
valve under the ow and operating conditions the
tool will be used under.
The load valve locks the tool outlet and is to be used
to hold the tool in a xed position. The pressure gauge
reads on the tool side of the valve to monitor the load.
COLD WEATHER OPERATION
If the tool is to be used during cold weather, preheat the
hydraulic uid at low engine speed. When using the normally recommended uids, uid temperature should be
at or above 50 °F/10 °C (400 ssu/82 centistokes) before
use.
10 ► IP16 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.
• Always replace hoses, couplings and other parts
with replacement parts recommended by Stanley
Hydraulic Tools. Supply hoses to the intensier must
have a minimum working pressure rating of 2500
psi/172 bar. Supply hoses from the intensier to the
tool couplings and other high-pressure parts, must
have a minimum working pressure rating of 10,000
psi/700 bar.
• All hoses must have an oil resistant inner surface
and an abrasion resistant outer surface. Whenever
near electrical conductors, use clean hoses labeled
and certied non-conductive.
• Never allow the working pressure of the intensier
or tool to exceed 10,000 psi/690 bar.
• Always keep critical tool markings, such as warning
stickers and tags legible.
• Make sure that the compression tool, cutter, etc. to
be operated is rated at 10,000 psi/690 bar. If other
than 10,000 psi/700 bar, the intensier relief valve
must be adjusted to the pressure for the tool being
operated.
• Operate the intensier within its rated capacity.
• Do not use the intensier for applications for which it
was not designed.
• Tool repair should be performed by experienced
personnel only.
• Never connect or disconnect couplers or port connections with hydraulic pressure in the hose.
• Always check high-pressure couplers for leaks and
damage before operating the system at maximum
rated pressure.
• When the intensier is not in use, attach thread protectors and install valve caps.
IP16 User Manual ◄ 11
TROUBLESHOOTING
If symptoms of poor performance develop, the following chart can be used as a guide to correct the problem.
When diagnosing faults in operation of the intensier, always check that the hydraulic power source is supplying the
correct hydraulic ow and pressure to the intensier as listed in the table. Use a ow meter known to be accurate.
Check the ow with the hydraulic uid temperature at least 80 °F/27 °C.
PROBLEM CAUSE SOLUTION
No output. Couplers or hoses blocked. Remove obstruction.
Input pressure and return line
hoses reversed at ports.
No oil in reservoir. Fill reservoir to proper level.
High-pressure relief valve stuck
open.
Motor to pump hose leaking. Remove and replace hose.
Intensier turned over with vent
assembly down.
Oil mist from center of motor
housing assembly.
Oil leaking from vent assembly. Oil reservoir over lled. Reduce oil level to the top of the high-
Rear drive shaft seal bad. Replace shaft seal located behind shaft
Defective shaft seal. Seal is located
in the oil seal plate between the
motor housing assembly and pump
housing.
Be sure hoses are connected to the
proper ports.
Test and adjust as specied in Service
section.
Return intensier to upright position.
bushing in motor housing assembly.
pressure pump as viewed through the
vent assembly port while the intensier
is in the horizontal position. (Reservoir
must have room for oil expansion.)
Turn off intensier. Remove vent
assembly and turn on intensier.
Operate compression tool or cutter. If oil
reservoir lls up and overows, replace
the shaft seal.
12 ► IP16 User Manual
SPECIFICATIONS
Output Pressure ............................................................................................................................10,000 psi/700 Bar
Input Pressure ........................................................................................................................ Up to 2500 psi/176 Bar
Flow Range ............................................................................................................................... 4–10 gpm/15–38 lpm
Porting ............................................................................................................................................................3/8 NPT
Connect Size and Type ................................................................................................................................. 3/8 NPT
Weight ................................................................................................................................................29.6 lbs/13.4 kg
Length (with couplers) ............................................................................................................................. 18 in./46 cm
Width ......................................................................................................................................................... 8 in./20 cm
Height ........................................................................................................................................................ 9 in./23 cm
IP16 User Manual ◄ 13
IP16 PARTS ILLUSTRATION
14 ► IP16 User Manual
IP16 PARTS LIST
PART
ITEM
NO. QTY DESCRIPTION
09853 1 MOTOR ASSY (INCL ITEMS 1–15)
1 09868 1 MOTOR HOUSING (INCL ITEM 2)
2 05207 1 BUSHING
3 13996 2 O-RING 1/2 × 11/18 × 3/32 *
4 01257 1 O-RING 3-1/2 × 3-5/8 × 1/16 *
5 05641 1 O-RING 2-3/8 × 2-1/2 × 1/16 *
6 09594 1 GEROTOR
7 09839 1 GEROTOR BUSHING
8 09844 1 OIL SEAL PLATE
9 09895 1 GEROTOR
10 09850 1 PUMP HOUSING
11 09901 6 FLANGE NUT
12 09900 1 DOWEL PIN
13 09867 1 DRIVE PIN
14 09838 1 DRIVE SHAFT
15 09883 6 CAPSCREW 10-24 × 3 IN SOCKET HEAD
09861 1 LOW PRESSURE VALVE ASSY
16 09841 1 LOW-PRESSURE VALVE
17 02436 1 CHECK BALL
18 09893 1 SPRING
19 09892 1 SETSCREW
20 09898 1 MALE CONNECTOR
21 00936 2 ADAPTOR FITTING
22 09886 3 CAPSCREW, 10-32 × 3/8 IN SOCKET
23 09871 1 WOBBLE PLATE HOUSING
24 05207 1 BUSHING
25 09882 2 CAPSCREW 10-32 × 1 IN SOCKET HEAD
26 09877 2 THRUST WASHER
27 09878 1 THRUST BEARING
28 01851 1 ROLL PIN 1/8 × 1 IN
29 09845 1 WOBBLE PLATE
30 09879 1 THRUST WASHER
31 08148 1 THRUST BEARING
32 09840 1 THRUST WASHER
33 09881 1 BEARING
34 00077 1 RETAINING RING
15283 1 PUMP ASSY (INCL ITEMS 34–38)
35 08253 4 CAPSCREW 1/4-20 × 1-1/2 IN SOCKET
36 09847 1 PISTON BLOCK
37 09836 4 PISTON
38 09866 1 CHECK BALL BLOCK ASSY
39 09869 1 MANIFOLD ASSY
(INCL 15–18)
HEAD
(INCL ITEM 23)
HEAD
PART
ITEM
NO. QTY DESCRIPTION
40 09884 1 O-RING 7/32 × 11/32 × 1/18 *
41 09887 1 O-RING URETHANE *
42 09870 1 HOSE
43 09898 1 MALE CONNECTOR
44 00149 1 O-RING 3-3/4 × 3-3/8 × 1/16 *
45 09883 6 CAPSCREW 10-32 × 3 IN SOCKET HEAD
46 09857 1 END PLATE ASSY
47 09842 1 VALVE CAP
48 00012 1 O-RING *
09862 1 HIGH-PRESSURE UNLOADING VALVE
49 09891 1 SETSCREW
50 09843 1 VALVE BODY
51 09837 1 PINTAL UNLOADING VALVE
52 09309 1 SPRING
53 09834 1 ADJUSTING PLUG
54 09835 1 SEAL WASHER *
55 05337 1 HIGH-PRESSURE NIPPLE
56 05148 1 HEX NIPPLE
57 05338 1 HIGH-PRESSURE COUPLER
58 09865 1 VENT ASSY (INCL O-RING)
59 11720 1 SIGHT GLASS
60 03364 1 O-RING .414 × .558 × .072
61 03783 1 GPM/PRESSURE STICKER
62 12412 1 WARNING STICKER
63 12891 1 DANGER STICKER
64 10515 1 CAUTION TAG, UNIT SHIPPED W/O OIL
65 10146 1 NAMEPLATE STICKER
66 11718 1 PUMP CASE
— 06345 2 PLASTIC PLUG, SAE8 (NOT SHOWN)
— 14785 1 SEAL KIT (* INDICATES PART OF KIT)
ASSY
IP16 User Manual ◄ 15
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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