Stanley HP210 Hydraulic Power Unit
User Manual: Safety, Operation and Maintenance
This manual provides essential information for the safe operation, maintenance, and troubleshooting of the Stanley HP210 Hydraulic Power Unit. It covers models HP210BA, HP210B, HP210BK, HP210BBA, and HP210BY.
IMPORTANT: To validate your product warranty, visit www.stanleyinfrastructure.com, select the Company tab, then Warranty. A warranty validation record must be submitted.
SERVICING WARNING: Repairs and/or service to this tool must only be performed by an authorized and certified dealer. Improper repair or service can result in serious injury or death.
Declaration of Conformity
Stanley Hydraulic Tools declares that the Hydraulic Power Unit, models HP210BA and GTR20B01, manufactured in conformity with Directive 2000/14/EC (Noise Directive) and Directive 2006/42/EC (Machinery Directive), and relevant standards such as EN ISO 12100:2010 and ISO 3744:2010. Measured Sound Power Level: 99 LwA. Guaranteed Sound Power Level: 101 LwA. Installed Power: 13.4 kW.
Safety Symbols and Precautions
This manual utilizes various safety symbols and signal words to highlight potential hazards:
- DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
- WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
- CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury or property damage.
- NOTICE/IMPORTANT: Indicates a situation which, if not avoided, may result in damage to the equipment.
Always observe safety symbols. Operators and maintenance personnel must comply with all safety precautions in this manual and on equipment stickers/tags. Ensure all operators are trained and wear appropriate safety equipment, including goggles, ear protection, head protection, and safety shoes.
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. Keep clear of hot engine exhaust. Do not add fuel while the unit is running or hot. Do not operate if gasoline odor is present. Do not use flammable solvents around the engine.
Tool Stickers & Tags
Various decals are affixed to the unit for identification and safety:
- 74759 Power Unit Dash Decal
- 76759 Dual Circuit Decal
- 28322 CE Decal (HP210BA, HP210BBA)
- 66653 Sound Power Decal (HP210BA, HP210BBA)
- 73306 Lifting Point Decal (HP210BA, HP210BBA) - Indicates a lifting capacity of 330 lb / 150 kg.
Emission Control Information: This equipment meets U.S. EPA EVAP standards.
Hose Types and Recommendations
Use hydraulic hoses with a rated working pressure equal to or higher than the relief valve setting (2500 psi / 172 bar minimum). Authorized hose types include:
- Certified non-conductive: For use near electrical conductors.
- Wire-braided (conductive): Must not be used near electrical conductors.
- Fabric-braided (not certified non-conductive): Must not be used near electrical conductors.
Hose Safety Tags: Do not remove safety tags attached to hoses. Replace illegible tags immediately.
Tool to Hydraulic Circuit Hose Recommendations: The manual provides a chart detailing recommended minimum hose diameters based on flow rate (GPM/LPM) and hose length to minimize back pressure. All hoses must meet or exceed SAE J517 specifications.
HTMA / EHTMA Requirements
The manual outlines requirements for hydraulic systems based on HTMA (Hydraulic Tool Manufacturers Association) and EHTMA (European Hydraulic Tool Manufacturers Association) classifications. These include flow ranges, nominal operating pressure, system relief valve settings, maximum back pressure, fluid viscosity, and cooling capacity.
EHTMA Categories:
- Category B: 15 lpm at 138 bar
- Category C: 20 lpm at 138 bar
- Category D: 30 lpm at 138 bar
- Category E: 40 lpm at 138 bar
- Category F: 50 lpm at 138 bar
Operation
Preparation for Use:
- Read the engine "Operating & Maintenance Instructions" manual.
- Check engine crankcase oil level. Use detergent oil classified "For Service SE, SF, SG".
- Check engine fuel level. Use unleaded gasoline (85 octane minimum).
- Check hydraulic fluid level. Recommended fluids are listed in the manual, including biodegradable options.
- Install hydraulic connections using hoses with a minimum working pressure rating of 2500 psi / 175 bar and compatible quick disconnect fittings (NPT). Use thread tape or pipe joint compound, but do not overtighten.
Using the 12 Volt DC Outlet:
A 12 VDC outlet is available on specific models. Note that accessories left in the outlet can drain the battery if the HP210 is not running.
Controls:
The HP210 can provide two 5 GPM/20 LPM circuits or one 10 GPM/40 LPM circuit, each up to 2000 psi/140 bar.
Startup Procedure:
- Toggle both Flow Switches to "FLOW OFF".
- Pull the choke knob out.
- Select desired flow using the Flow Selector Knob.
- Turn the Ignition Switch to "START".
- Gradually push in the choke knob as the engine idles smoothly.
- Allow the engine to warm up.
- Connect hoses and the tool.
- Toggle the Flow Switches to the desired flow for each circuit.
Changing Circuit Flow:
- Toggle both Flow Switches to "FLOW OFF".
- Select the desired circuit flow using the Flow Selector Knob.
- Toggle the Flow Switches to the desired flow for each circuit.
Shutdown Procedure:
- Toggle the Flow Switches to "FLOW OFF".
- Allow the engine to idle for approximately one minute.
- Turn the Ignition Switch to "OFF".
Cold Weather Startup:
In cold weather, hydraulic fluid thickens. Run the engine at a low idle (5 GPM/20 LPM setting) until the fluid reaches at least 50°F / 10°C. Circulate fluid through the tool hoses until they are warm before normal operation.
Maintenance & Testing
Engine Maintenance Schedule:
Follow the instructions in the engine "Operating & Maintenance Instructions" manual.
Hydraulic System Maintenance:
- Check hydraulic fluid level daily and refill as needed.
- Inspect hydraulic lines and fittings daily for leaks, kinks, or damage. Do not use your hand for inspection.
- Remove condensed moisture from hydraulic fluid by pumping fluid into a container, allowing water to settle, and returning the clean fluid to the tank.
- Change the hydraulic filter every 200 hours of operation, or more frequently in adverse conditions.
- Clean the oil cooler with air pressure.
Battery:
Do not charge the battery with an automotive charger exceeding 2 amps, as this can damage the battery. If the engine stalls, turn the Ignition Switch to "OFF" to preserve battery charge.
Storage:
Clean the unit thoroughly (do not pressure wash). Store in a clean, dry location. For storage over 30 days, add a fuel additive and run the engine to circulate it. Replace crankcase oil.
General Testing:
Periodically test the HP210 for maximum efficiency using the Stanley Circuit Tester (part number 04182).
Testing the Hydraulic Circuit:
- Turn the Flow Switch to "FLOW OFF".
- Set the Flow Selector Knob to the desired test flow.
- Connect the Stanley Circuit Tester to the tool hoses.
- Fully open the tester restrictor valve.
- Start the engine.
- Verify the test flow gauge reads +/- 1 GPM of the selected flow.
- Slowly turn the restrictor valve clockwise. The flow rate should remain constant until pressure reaches 2100-2200 psi / 148-155 bar.
- At this pressure, the relief valve should open, causing the flow rate to drop. The relief valve is factory preset. If it does not open within the specified range, it may need adjustment (clockwise to increase pressure, counterclockwise to decrease). Refer to the manual for specific adjustment instructions.
Troubleshooting
| Problem | Cause | Remedy |
| Engine will not start. | Flow Switch not in "FLOW OFF" position. | Ensure Flow Switch is in "FLOW OFF" position. |
| Battery not connected. | Check battery cables and re-attach. | |
| Weak battery charge. | Test and charge battery; replace if it won't hold a charge. | |
| No Fuel. | Ensure unit is cool, then add fuel. | |
| Plugged fuel filter. | Replace fuel filter. | |
| Defective spark plugs. | Check spark plug gap and replace if necessary. | |
| Hydraulic fluid blowing out of reservoir vent. | Hydraulic fluid tank overfilled. | Remove excess hydraulic fluid. |
| Hydraulic pump leaking. | Check and tighten pump connections. | |
| Hydraulic tool will not operate. | Flow Selector Knob not in correct position. | Set Flow Selector Knob for correct fluid flow. |
| Tool not properly connected. | Check hose connections; ensure pressure and return hoses are correct. | |
| Defective quick disconnect fittings. | Inspect fittings for free flow. | |
| Low hydraulic fluid level. | Check and refill hydraulic fluid reservoir. | |
| Defective pump coupling. | Check coupling between pump and engine. | |
| Relief valve stuck open. | Adjust or replace relief valve. | |
| Suction hoses kinked. | Check suction hoses for kinks; ensure smooth curve. | |
| Solenoid not working. | Check electrical connections; replace if necessary. | |
| Attached tool is defective. | Refer to the tool manual. |
Specifications
- Engine: 18 hp Briggs
- Capacity (Flow): Two 5 GPM/20 LPM Circuits or One 10 GPM/40 LPM Circuit
- Dimensions: Length: 36 in. / 91.4 cm, Width: 23 in. / 58.4 cm, Height: 29.5 in. / 74.9 cm
- Weight (Wet): Dual Circuit Briggs: 334 lbs / 151.5 kg
- Fuel Tank Capacity: 5.5 gal. / 20.8 ltr
- Estimated Gas Consumption: 1.3 gal / 4 ltr per hour
- Hydraulic Reservoir Capacity: 3 gal. / 11 ltr
- Nominal Operating Pressure: 1500 psi / 103 bar
- Relief Valve "crack" setting: 2100 psi / 145 bar
- Full relief setting: 2500 psi / 172 bar
- EHTMA Category: C or E
- HTMA Category: Type 1 or Type RR
Emission Control Compliance: Stanley warrants all fuel system emission components for 2 years from the date of original purchase, provided there has been no abuse, neglect, modifications, or improper maintenance. This warranty covers components whose failure would increase evaporative emissions, including the fuel tank, fuel cap, fuel hose, and vapor hose.
Accessories
Available accessories include various male and female quick disconnect couplers (Parker and Aeroquip), hose assemblies of different lengths and types, a wheel kit, and replacement filters (oil, air, fuel, hydraulic).
Parts Illustrations
Detailed illustrations and parts lists are provided for the following components:
- HP210 Frame Parts Illustration
- HP210 Control Panel Parts Illustration
- HP210 Engine Parts List - Front
- HP210 Engine Parts List - Back
- HP210 Engine Parts List - Base
- Hoses, Fittings & Clamps
- Main Wiring Harness
- Electrical Schematic
Each illustration is accompanied by a table listing item numbers, part numbers, quantities, and descriptions.
Main Wiring Harness (Part Number 79312):
Diagram shows connections for solenoid coils, flow switches, start switch, hour meter, battery, starter relay, oil pressure switch, and fuel shutoff.
Electrical Schematic:
Provides a detailed wiring diagram for the unit's electrical system, including circuit switches, diodes, fuses, regulator/rectifier, starter, battery, starter interlock relay, engine oil switch, magnetic pickup, and fuel shutoff.
