STANLEY HP1 COMPACT POWER UNIT
Safety, Operation and Maintenance Manual
Copyright © 1998 The Stanley Works. All rights reserved.
OPS/MAINT USA & CE VERSION. Printed in U.S.A. 24280 06/97 Ver 3.
⚠️ DANGER
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.
An illustration of the Stanley HP1 Compact Power Unit shows its engine, hydraulic tank, wheels, and control panel area.
The unit displays European Conformity (CE) mark and other certification marks.
INDEX
This manual covers the following topics:
- Hydraulic Hose Requirements
- Operation (Preparation for Use, Hydraulic Connections, Startup, Cold Weather Startup, Tool Operation, Optional Equipment)
- Parts Lists & Drawings (Engine Assembly, Frame Assemblies, Choke Cable Assembly, Actuator Assembly, Dash Panel & Valve Assembly, Hydraulic Tank & Filter Assembly, Hose & Fitting Connections, Wiring Diagram)
- Routine Maintenance (Engine, Hydraulic System, Storage)
- Safety Precautions (General, Local Safety Regulation, Safety Stickers & Tags)
- Sales & Service
- Service Instructions
- Specification & Capacities
- Testing & Troubleshooting (Troubleshooting Chart)
- Warranty
SAFETY PRECAUTIONS
Do not operate this equipment or associated equipment until the following safety instructions have been thoroughly read and understood! Read this manual before installing, operating or maintaining this equipment.
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 specific work area and local safety regulations. If so, place the added precautions in the space provided on page 5. In addition to this manual, read and understand safety and operating instructions in the Engine Operation Manual furnished with the power unit.
GENERAL SAFETY PRECAUTIONS
The HP1 Compact 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 Power Unit. Failure to do so could result in personal injury or equipment damage.
- Operators 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, eye protection, hearing 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 the unit is running.
- Always use hoses and fittings rated at 2500 psi/172 bar with a 4 to 1 safety factor. Be sure all hose connections are tight.
- Make sure all hoses are connected for correct flow direction to and from the tool being used.
- Do not inspect hoses and fittings 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 get entangled in the working parts of the power unit.
- Keep all parts of your body away from the working parts of the power unit.
- Always wear appropriate safety equipment such as goggles, ear protection, and toe guards. Certain tools used in conjunction with the power unit may require other safety equipment such as breathing filters.
- 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 flammable solvents around the power unit engine.
- Do not operate the power unit within 3.3 ft/1 m of buildings, obstructions, or flammable objects.
- Do not reverse grinding wheel rotation direction by changing fluid flow direction.
- Allow the engine to cool before storing the power unit in an enclosure.
- To avoid personal injury or equipment damage, all tool repair, maintenance and service must only be performed by authorized and properly trained personnel.
SAFETY SYMBOLS
Safety symbols 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.
- ⚠️ DANGER: This safety symbol may appear on the tool. It is used to alert the operator of an action that could place him/her or others in a life-threatening situation.
- ❗ WARNING: This safety symbol appears in these instructions to identify an action that could cause bodily injury to the operator or other personnel.
- ℹ️ IMPORTANT: This safety symbol appears in these instructions to identify an action or condition that could result in damage to the tool or other 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.
SAFETY STICKERS & TAGS
Various stickers and tags are applied to the unit for safety and identification. These include:
- EXHAUST FUMES STICKER
- EXHAUST STICKER
- FUEL STICKER
- CHOKE PULL DECAL
- SAFETY TAG (Do not remove until read)
- COUPLER STICKER
- SOUND POWER LEVER STICKER
- WEIGHT STICKER (Indicating 102 KG / 225 LBS)
- MANUAL STICKER
- SERIAL NO. LOCATION (At top of dash panel)
- HYDRAULIC OIL STICKER
- BATTERY CHARGE TAG (Do not remove until read)
A CAUTION sticker is present if the unit is equipped with a Water Pump Kit, stating: DO NOT OPERATE THE PUMP WITHOUT WATER. OPERATING THE PUMP WITHOUT WATER WILL SEVERELY DAMAGE THE PUMP.
The DANGER/IMPORTANT safety tag attached when shipped from the factory contains detailed safety instructions. It is recommended to retain this tag and attach it to the tool when not in use. The tag includes the following points:
- DANGER Section 1: Failure to use non-conductive hydraulic hose near electrical lines may result in death or serious injury. Ensure proper training and maintenance for non-conductive hoses.
- DANGER Section 2: Hydraulic leaks or bursts can cause oil injection or severe personal injury. Do not exceed specified flow and pressure. Check hose couplers and connectors daily for leaks, and do not feel for leaks with hands.
- DANGER Section 2A: Do not exceed specified flow and pressure for this tool.
- DANGER Section 2B: Do not exceed the rated working pressure of the hydraulic hose used with this tool.
- DANGER Section 2C: 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.
- DANGER Section 2D: Do not lift or carry the tool by the hoses. Do not abuse hose. Do not use kinked, torn, or damaged hose.
- DANGER Section 3: Ensure hydraulic hoses are properly connected to the tool before pressurizing the system. System pressure hose must connect to the "IN" port, and return hose to the "OUT" port. Reversing connections may cause reverse tool operation and severe personal injury.
- DANGER Section 4: Do not connect open-center tools to closed-center hydraulic systems, as this may result in loss of other hydraulic functions or severe personal injury.
- DANGER Section 5: Keep bystanders clear of your work area.
- DANGER Section 6: Wear hearing, eye, foot, hand, and head protection.
- DANGER Section 7: All tool repair, maintenance, and service must only be performed by authorized and properly trained personnel.
- IMPORTANT Section: Read Operation Manual and Safety Instructions before using the tool. Use only parts and repair procedures approved by Stanley. Tag to be removed only by tool operator.
Similar detailed safety instructions are provided on the reverse side of the tags.
HYDRAULIC HOSE REQUIREMENTS
Hydraulic hose types authorized for use with Stanley Hydraulic Tools are:
- Certified non-conductive
- Wire-braided (conductive)
- Fabric-braided (not certified or labeled non-conductive)
Only hose type 1 is authorized for use near electrical conductors. Hoses 2 and 3 are conductive and must never be used near electrical conductors.
Stanley attaches DANGER tags to all hoses purchased from Stanley to ensure safety. These tags must not be removed. If a tag becomes illegible, obtain a replacement from your Stanley Distributor.
1 CERTIFIED NON-CONDUCTIVE HOSE
This tag is attached to all certified non-conductive hose. It contains DANGER warnings regarding electrical lines, proper training, cleaning and testing of the hose, and handling to prevent bursts or injury. It also provides IMPORTANT instructions on usage and maintenance.
2 AND 3 WIRE-BRAIDED AND FABRIC-BRAIDED (NOT CERTIFIED OR LABELED NON-CONDUCTIVE) HOSE
This tag is attached to all conductive hose. It contains DANGER warnings against use near electrical lines and instructions on proper handling, pressure ratings, and maintenance to prevent bursts or injury. It also provides IMPORTANT instructions on usage and maintenance.
HOSE PRESSURE RATING
The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the hydraulic system.
OPERATING INSTRUCTIONS
PREPARATION FOR USE
Do not operate the power unit until you have read the engine operating and maintenance instructions manual furnished with the unit.
1. ENGINE CRANKCASE OIL LEVEL
IMPORTANT: Do not start the Engine with the throttle control set at 5 or 8 gpm/19 or 30 lpm.
Always check the oil level before starting the engine. Make sure the oil level is at the FULL MARK on the dipstick. Do not overfill. Use detergent oil classified "For Service SE, SF, SG" as specified in the engine operating and maintenance manual.
2. ENGINE FUEL LEVEL
Check the fuel level. If low, fill with unleaded gasoline with a minimum of 85 octane.
3. HYDRAULIC FLUID
Check the sight pipe in the hydraulic fluid reservoir for the proper fluid level. Proper fluid level is indicated when the center section of the sight pipe is dark. If the center section of the sight pipe is not dark, add hydraulic fluid. Use fluids meeting the following specifications:
Viscosity (Fluid Thickness)
| U.S. | METRIC |
|---|---|
| 50°F 450 SSU Maximum | 10°C 95 Centistokes |
| 100°F 130-200 SSU | 38°C 27-42 C.S. |
| 140°F 85 SSU Minimum | 60°C 16.5 C.S. Minimum |
PourPoint: -10°F/-23°C Minimum (for cold startup)
Viscosity Index (ASTM D-2220): 140 Minimum
Demulsibility (ASTM D-1401): 30 Minutes Maximum
Flash Point (ASTM D-92): 340°F/171°C Minimum
Rust Inhibition (ASTM D-665 A & B): Pass
Oxidation (ASTM D-943): 1000 Hours Minimum
Pump Wear Test (ASTM D-2882): 60 mg Maximum
The following fluids work well over a wide temperature range, allow moisture to settle out and resist biological growth that may occur in cool operating hydraulic circuits. These fluids are recommended by Stanley. Other fluids that meet or exceed the specifications of these fluids may also be used:
- Chevron AW-MV-32
- Exxon "Univis" J-26
- Mobil D.T.E. 13
- Gulf "Harmony" AW-HVI-150-32
- Shell "Tellus" T-32
- Texaco "Rando" HD-AZ
- Union "Unax" AW-WR-32
4. HYDRAULIC CONNECTIONS
Facing the panel control valve, the far right-hand male quick disconnect fitting is the pressure (FLUID OUT) fitting. The left-hand female quick disconnect fitting is the return (FLUID IN) fitting.
The recommended hose length is 25 ft/8 m with a 1/2 inch/12.7 mm inside diameter. The hoses must have a working pressure rating of at least 2500 psi/175 bar. Each hose end must have male thread ends compatible with H.T.M.A. (HYDRAULIC TOOL MANUFACTURERS ASSOCIATION).
An illustration (Figure 1) shows the hydraulic connections. It depicts the control panel with RETURN and PRESSURE ports, H.T.M.A. 1/2 inch female and male quick disconnect couplers, and 1/2 inch male pipe hose ends. It also shows a 1/2 inch I.D. hose with a 2500 PSI/172 BAR RATING AND 4 TO 1 SAFETY FACTOR, and an adapter (3/8 INCH MALE PIPE x -8 SAE O-RING).
Longer hoses may be used when necessary, but can affect the operation of the engine automatic throttle due to fluid resistance. If small diameter or long hoses are used, or if restrictive fittings are connected to the supply and return ports, the pressure required to push the fluid through the system and back to the hydraulic tank will be higher. If the pressure is too high, this will cause the engine RPM to remain at full load if "AUTO" is selected on the automatic throttle. Also see "HYDRAULIC HOSE REQUIREMENTS" earlier in this manual.
QUICK DISCONNECT COUPLERS
H.T.M.A. approved quick disconnect couplings are installed to hydraulic hoses so that the direction of oil flow is always from the male to the female quick disconnect as shown in Figure 1. Quick disconnect couplings and hose fittings are selected so that additional fittings such as reducer or adapter fittings are not required.
If adapter fittings are used, they must be approved steel hydraulic fittings meeting a minimum operating pressure rating of 2500 psi/172 bar. Do not use galvanized pipe fittings or black pipe fittings.
Use thread tape or pipe joint compound when installing quick disconnect couplings to hose or tool fittings. Follow the instructions furnished with the selected thread sealant. DO NOT OVERTIGHTEN THE FITTINGS.
5. BATTERY
The supplied 12 Volt DC battery has been partially dry charged. Before using, it must first be filled with battery electrolyte at a specific density of 1.240 to 1.260. Fill each cell to its upper level indicator and then charge at a 2 Amp rate for at least 12 to 15 hours. After charging, check the electrolyte level and fill as required.
Also, make sure the battery cables are tight and charging circuit functions are operating properly.
THROTTLE CONTROL (See Figure 2)
IMPORTANT: Do not start the Engine with the throttle control set at 5 or 8 gpm/19 or 30 lpm.
The throttle control permits the operator to select one of 3 operating modes after the engine has warmed up. For startup, the throttle control should be set on "AUTO".
- AUTO - Engine speed varies with hydraulic circuit pressure to maintain a constant 8.5 gpm/32 lpm. When a tool is not being used the engine will return to idle automatically.
- 5 - Engine speed is held at part throttle to maintain 5 gpm/19 lpm. When a tool is not being used the engine will not return to idle until the faspin is removed.
- 8 - Engine speed is held at full throttle to maintain 8.5 gpm/32 lpm. When a tool is not being used the engine will not return to idle until the faspin is removed.
Typical conditions requiring the "8" position are:
- When operating an alternator, fluid flow must be constant to produce the required voltage and frequency, even when load requirements are light.
- When operating drills or grinders or diamond saws, tool rpm must be maintained even when load requirements are light.
Figure 2 illustrates the Throttle Control Settings. It shows the control with labels for BASE, CYLINDER LEVER, FASPIN, and GOVERNOR LEVER. The three modes are depicted: AUTO, HOLD 5 GPM, and HOLD 8 GPM, showing the positions of the cylinder lever and faspin.
STARTUP - See "PANEL CONTROLS" - Figure 3
- Assure the circuit control lever is in the "OFF" position.
- Select the "AUTO" throttle operating mode by positioning the governor lever to the cylinder lever and inserting the faspin as shown in figure 2.
- Position the ON/OFF switch to the "ON" position.
- Pull the choke lever out.
- Push the circuit control lever to the "START" position.
- After the engine starts, allow the engine to warm up until it runs smoothly with the choke released.
Figure 3 shows the Control Panel with labels for ON/OFF SWITCH (ENGINE/TOOL ON/OFF), RETURN HOSE, PRESSURE HOSE, HP1 COMPACT POWER UNIT, RETURN QUICK DISCONNECT, and PRESSURE QUICK DISCONNECT.
COLD WEATHER STARTUP
- Use the procedures described under "STARTUP" and then follow the procedure below.
- Hydraulic fluids are thicker in cold weather, therefore, it is recommended that the engine be run at low idle long enough to bring the fluid temperature up to a minimum of 50°F/10°C or until the top of the hydraulic filter feels warm.
- If the tools and tool hoses are cold, it is recommended to allow hydraulic fluid to circulate through the tool hoses until warm before using the tool.
TOOL OPERATION
- With the engine running smoothly, move the control lever to the "ON" position.
- Activate the tool. The automatic throttle will increase engine speed to permit proper tool operation. When the tool is deactivated, the automatic throttle allows the engine to return to idle.
- If automatic throttle operation is not desired, change the throttle control to "5 or 8".
SHUTDOWN
- Place the circuit control lever in the "OFF" position.
- If the throttle control is in the "5" or "8" position, change it to the "AUTO" position.
- Allow the engine to idle for approximately one minute and then switch the ON/OFF switch to the "OFF" position.
OPTIONAL WATER PUMP KIT
CAUTION: DO NOT OPERATE THE PUMP WITHOUT WATER. OPERATING THE PUMP WITHOUT WATER WILL SEVERELY DAMAGE THE PUMP.
If the power unit will be operated without need of the water pump, unpin the water pump and remove it.
ROUTINE MAINTENANCE
ENGINE MAINTENANCE
Follow the maintenance schedule and general maintenance instructions in the engine maintenance and operation manual furnished with the power unit. Normal maintenance includes:
- Service foam air pre-cleaner every 25 hours of operation.
- Service air paper cartridge every 100 hours of operation.
- Replace in-line fuel filter every 100-300 hours or sooner if required.
- Replace spark plugs every 100 hours of operation.
- Change engine oil after first 5 hours of operation, then after every 50 hours of operation. If the engine has been operating under heavy load or in high ambient temperature, change the oil every 25 hours of operation.
- Change oil filter when engine oil is changed.
- Check oil level daily.
- Remove dirt and debris from engine with a cloth or brush daily. Do not use water spray.
- Clean air cooling system every 100 hours of operation.
HYDRAULIC SYSTEM MAINTENANCE
- Check hydraulic fluid level daily. The center of the sight pipe on the reservoir must be dark. If it is not dark, fluid must be added. Add fluid per specifications in this manual. (See "HYDRAULIC FLUID" under the section titled "OPERATING INSTRUCTIONS".)
- Remove condensed moisture from the hydraulic fluid by pumping the hydraulic fluid into a 5 gal/20 ltr container through the pressure hose. Make sure the engine is at idle when performing this procedure. When the hydraulic reservoir is empty, turn the engine off immediately.
- Allow the fluid to sit long enough for the water to settle to the bottom of the container. Slowly pour the fluid back into the hydraulic tank, avoiding the water at the bottom of the container.
- Each day, check hydraulic lines and fittings for leaks, kinks, etc. Do not use your hand to perform this check.
- Change the hydraulic filter element every 200 hours of operation. Change more often if cold, moist, or dusty conditions exist.
- Check oil cooler for debris. Remove debris with air pressure.
STORAGE
- Clean the unit thoroughly before storage. Do not use water pressure.
- Always store the unit in a clean and dry facility.
- If the unit will be stored for a prolonged period (over 30 days), add a fuel additive to the fuel tank to prevent the fuel from gumming. Run engine for a short period to circulate the additive.
- Replace crankcase oil with new oil.
- Remove spark plugs and pour approximately 1 ounce (30 ml) of engine oil into each cylinder. Replace spark plugs and crank the engine slowly to distribute the oil.
- Check hydraulic reservoir for water. If water is found, change the oil and circulate it through the tool hose and tool. (See "HYDRAULIC SYSTEM MAINTENANCE" earlier in this section).
- Disconnect tool hoses.
