IP16 User Manual - Stanley Hydraulic Tools
Contents
1. ate dee 8 in 20 cm piene EL 9 in 23 cm STAN LEY IP16 User Manual lt 13 14 IP16 User Manual STAN LEY ZU gt 5 DESCRIPTION 1 _ MOTOR ASSY INCL ITEMS 1 15 O RING 7 32 x 11 32 x 1 18 1 _ MOTOR HOUSING INCL ITEM 2 O RING URETHANE o o wo e 1 O RING 3 1 2x3 5 8x116 O RING 3 3 4 x 3 3 8 x 1 46 1 omwszas zaze es i seo 1 ferororsusne 1 i t 6 m mn E 2 o IE ajoj gt A 0883 9861 1 incu 18 48 6 HIGH PRESSURE COUPLER H e ae o e EM 9 a o 1 1 1 1 1 1 1 1 1 1 1 1 1 ojo EN gt N gt ojo eld 2 2 5 2 ADAPTOR FITTING GPM PRESSURE STICKER CAPSCREW 10 32 x 3 8 IN SOCKET WARNING STICKER sd EAD DANGER STICKER MARA CAUTION TAG UNIT SHIPPED W O OIL BUSHING NAMEPLATE STICKER 2 CAPSCREW 10 32 x 1 IN SOCKET HEAD 2 THRUST WASHER PLASTIC PLUG SAE8 NOT SHOWN THRUST BEARING SEAL KIT INDICATES PART OF KIT ROLL PIN 1 8 x 1 IN 2 pm N ojo o 2 2 2 2 22. sed uo peseq syjBue SSL 0922 ujog OL 9 dn 0 04 dn ve SL 6 SSOY SNOMEA JO 2504 3exong ANN 104 plesg 4 SMOUS 1 y 0 yeu avg ISd uinjoysseid WI HONI SYUILIN 1334 Ido 5 UIN J9jouuelq episu sy45u97 esoH MO PNI 0 1001 STANLEY 8 gt IP16 User Manual HTMA TOOL TYPE HYDRAULIC SYSTEM REQUIREMENTS TYPE TYPE Il TYPERR TYPE III Flow Range 4 6 gpm 7 9 gpm 9 10 5 gpm 11 13 gpm 15 23 Ipm 26 34 Ipm 34 40 Ipm 42 49 Ipm Nominal Operating Pressure 1500 psi 1500 psi 1500 psi 1500 psi at the power supply outlet 103 bar 103 bar 103 bar 103 bar System relief valve setting 2100 2250 psi 2100 2250 psi 2200 2300 psi 2100 2250 psi at the power supply outlet 145 155 bar 145 155 bar 152 159 bar 145 155 bar Maximum back pressure 250 psi 250 psi 250 psi 250 psi at tool end of the return hose 17 bar 17 bar 17 bar 17 bar Measured at a max fluid viscosity of 400 ssu 400 ssu 400 ssu 400 ssu at min operating temperature 82 centistokes 82 centistokes 82 centistokes 82 centistokes Temperature Sufficient heat rejection 140 F 140 F 140 F 140 capacity to limit max fluid temperature to 60 C 60 C 60 C 60 C at max
3. 911 0092 792 02 8 001 92 09 67 9L L SLL 0092 eJnsseJg 6l vIe 921 0092 6l vIe 8 dn 92 0 dn 09 67 9L EL 821 0082 9 8 9 LISP IVS Aq 195 se 8 0082 mes vor Jo Jsnw 09 08 002 001 6r gE EL OL SLL 0052 8 6l vIe Bunes WEIS S SZL 0052 Uny 6L m WU ne rw jenbe Buom m 0082 9i 979 e 15291 JSNUI oineJp u Iv SLL 0092 9 8 9 dn og 01 dn er oL 18410 Aue 10 pesn eq jou pjnous SIL 0097 6l ve pue 00 5 00 oineup 06 0 00 001 Ov 6l 901 9 H ejuejs uo peseq SLL 0092 aiNssald ov 8 8 40J pesn aq SI yeyo siu SLL 0092 ujog ov 8 8 0 91 001 19 Ov 6l FOLS d 811 0092 ujog l e GL dn 09 dn 0 6 FOLS TN TN E uunuuluiu e oj eunsseJd 921 0092 ujog EL e 08 92 001 92 62 91 9 ainssaid oui daay papuaju ae suon 811 0092 ujog OL 8 92 dn 92 0 dn 62 91 9 95941 Jed SYOLONGNOD 1V9IN1L9414 YVAN ASN LON OQ 2 JO plesg Kwd6
4. 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 6 IP16 User Manual _ DANGER Fallure to use hydraulic hose labeled and certified as non conductive when using hydraulic tools on or near electric Ines may result In death or serious Injury For proper and safe operation read owners manual mwke sure that you have been properly trained In correct procedures required for work ELECTROCUTION HAZARD or around electric lines 12412 Warning Sticker Electrical DO NOT OPERATE THIS PRODUCT UNLESS BOTH HIGH PRESSURE HYDRAULIC LINES ARE CONNECTED THROUGH AN DPEN CENTER VALVE USE ONLY COMPONENTS RATED FOR 10 000 PSI MINIMUM WORKING PRESSURE FAILURE TO 00 50 MAY RESULT IN COMPONENT FAILURE AND SERIOUS PERSONAL INJURY OR DEATH 12891 Danger Sticker 10515 Caution Tag SHIPPED W O OIL Not shown DANGER ae 2 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 O
5. expected ambient temperature Min cooling capacity at a temperature 3 hp 5 hp 6 hp 7 hp difference of between ambient and fluid 2 24 kW 3 73 kW 5 22 kW 4 47 kW temps 40 F 40 F 40 F 40 F NOTE 22 22 22 22 C 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 25 microns 25 microns 25 microns 25 microns Min full flow filtration 30 gpm 30 gpm 30 gpm 30 gpm o spm lpm dem dirt holding capacity Hydraulic fluid Petroleum based 100 400 ssu 100 400 ssu 100 400 ssu 100 400 ssu premium grade anti wear non conductive 20 82 centistokes Viscosity at min and max operating temps NOTE When choosing hydraulic fluid the expected oil temperature extremes that will be experienced in service determine the most suitable temperature viscosity characteristics Hydraulic fluids with a viscosity index over 140 will meet the requirements over a wide range of operating temperatures SSU Saybolt Seconds Universal EHTMA CLASSIFICATION HYDRAULIC SYSTEM TT A A A A Flow Range 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 Ipm 18 22 Ipm 27 33 Ipm 36 44 Ipm 45 55 Ipm Nominal Operating Pressure 1870 psi 1500 psi 1500 psi 1500 psi 1500 psi at the power supply outlet 129 bar 103 bar 103 bar 103 bar 103 bar System relief valve setting 2495 ps
6. PERSONAL INJURY 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 BYSTANDERS MAY BE INJURED IN YOUR WORK AREA KEEP BYSTANDERS CLEAR OF YOUR WORK AREA WEAR HEARING EYE FOOT HAND AND HEAD PRO TECTION 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 STANLEY The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the hy draulic system There are three types of hydraulic hose that meet this requirement and are authorized for use with Stanley Hydraulic Tools They are Certified non conductive constructed of thermoplastic or synthetic rubber inner tube synthetic fiber braid reinforcement and weather resistant thermoplastic or synthetic rubber cover Hose labeled certified non conductive is the only hose authorized for use near electrical conductors Wire braided conductive constructed of synthetic rubber inner tube singl
7. 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 certified dealer call Stanley Hydraulic Tools at the number listed on the back of this manual and ask for a Customer Service Representative STAN LEY IP16 User Manual lt 3 Safety symbols and signal words as shown below are used to emphasize all operator maintenance and repair ac tions 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 A DANGER 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 NOTICE to the equipment This signal
8. word indicates a situation which if not avoided may result in dam IMPORTANT age 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 A A DANGER a WARNING CAUTION NOTICE IMPORTANT 4 gt IP16 User Manual STAN LEY 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 specific work area and local safety regulations If so place the added precautions in the space provided in this manual The IP16 Hydraulic Intensifier will provide safe and de pendable service if operated in accordance with the in structions 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 a work area without bystand ers The operator must be familiar with all prohibited work areas such as exce
9. 2 THRUST WASHER BEARING RETAINING RING PUMP ASSY INCL ITEMS 34 38 4 CAPSCREW 1 4 20 x 1 1 2 IN SOCKET HEAD w N o 1 4 5 6 7 8 9 1 3 4 3 3 e 3 I w EU STAN LEY IP16 User Manual lt 15 STANLEY Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie Oregon 97267 5698 USA 503 659 5660 Fax 503 652 1780 www stanleyhydraulics com
10. AT YOU HAVE BEEN PROPERLY 6 AFTER EACH USE STORE IN A CLEAN DRY AREA TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND ELEC TRIC LINES 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 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 Ovl SIHL LON OG EMEND SEE OTHER SIDE m TEE SEE OTHERSDE __ SIDE 1 SIDE 2 Shown smaller than actual size STAN LEY IP16 User Manual lt 7 suonoeuuo esoH 4 lt lt lt ____ lt MM NUNLIU RETURN RETURN gt gt gt Er El JYNSSIYd HYDRAULIC CIRCUIT PRESSURE PRESSURE
11. IP16 HYDRAULIC INTENSIFIER USER MANUAL Safety Operation and Maintenance 2014 Stanley Black amp Decker Inc New Britain CT 06053 U S A 10413 9 2014 Ver 3 SAFETY SYMBOLS ur 4 SAFETY PRECAUTIONS 2 2 nad janes serbe dn t el ese d er et RR e ee dee Ru e zn DLL eR ER Hd c epe da 5 TOOL STICKERS amp E enden 6 HOSE TYPES sudanesiske 7 HOSERECOMMENDATIONS uekte 8 FIGURE 1 TYPICAL HOSE CONNECTIONS 2 0 2 aan 8 REQUIREMENTS eee tus esee tpe es curn cir ur et ean AES 9 OPERATION cae 10 TOOL PROTECTION amp GARE tei Pa ana rn dash ied etc t cete tele 11 TROUBLESHOOTING uvenn u aa aan adada ia 12 SPECIFICATIONS cU 13 IP16 PARTS ILLUSTRATION 22 28 Ha ee ee Er iii 14 PAS PARTS LIST unga kom TTE 15 IMPORTANT To fill 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 certified dealer Please read the following warning SERIOUS INJURY OR DEATH COULD
12. R 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 A HYDRAULIC LEAK OR BURST MAY CAUSE OIL INJEC TION INTO THE BODY OR CAUSE OTHER SEVERE PERSONAL INJURY DO NOT EXCEED SPECIFIED FLOW AND PRESSURE FOR THIS TOOL EXCESS FLOW OR PRESSURE MAY CAUSE A LEAK OR BURST DO NOT EXCEED RATED WORKING PRESSURE OF HYDRAULIC HOSE USED WITH THIS TOOL EXCESS PRESSURE MAY CAUSE A LEAK OR BURST 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 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 D DO NOT LIFT OR CARRY TOOL BY THE HOSES DO NOT ABUSE HOSE DO NOT USE KINKED TORN OR DAMAGED HOSE MAKE SURE HYDRAULIC HOSES ARE PROPERLY CON NECTED TO THE TOOL BEFORE PRESSURING SYSTEM SYSTEM PRESSURE HOSE MUST ALWAYS BE CON NECTED 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
13. S DO NOT USE IF KINKED DO NOT BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE USE HOSE TO PULL OR LIFT TOOLS POWER UNITS ETC ON OR NEAR ELECTRIC LINES WIPE THE ENTIRE LENGTH OF THE HOSE AND FIT CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAM TING WITH A CLEAN DRY ABSORBENT CLOTH TO REMOVE DIRT AND MOISTURE AND TEST HOSE FOR MAXIMUM ALLOWABLE CURRENT LEAKAGE IN ACCORDANCE WITH AGE TO GOUELINGS IE ANT OF THESE CONDITIONS ENST REPLACE THE HOSE IMMEDIATELY NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE SAFETY DEPARTMENT INSTRUCTIONS AFTER EACH USE STORE IN A CLEAN DRY AREA FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROP ERLY TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND DO NOT REMOVE THIS TAG Ovl SIHL LON OG SEE OTHER SIDE SEE OTHER SIDE SIDE 1 SIDE 2 Shown smaller than actual size THE TAG SHOWN BELOW IS ATTACHED TO CONDUCTIVE HOSE DANGER DANGER DO NOT USE THIS HYDRAULIC HOSE ON OR NEAR ELECTRIC LINES THIS HOSE IS 5 CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAMAGE TO NOT LABELED OR CERTIFIED AS NON CONDUCTIVE USING THIS HOSE ON OR NEAR COUPLINGS IF ANY OF THESE CONDITIONS EXIST REPLACE THE HOSE IMMEDIATELY ELECTRICAL LINES MAY RESULT IN DEATH OR SERIOUS INJURY NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE FOR PROPER AND SAFE OPERATION MAKE SURE TH
14. aking hose connections 3 Connect hydraulic lines from the parent circuit to the intensifier inlet fitting Make certain the P pres sure and T tank hoses are connected to their respective ports If incorrectly connected high pres sure output will not be obtained 10 IP16 User Manual NOTE High pressure couplings must be used for the high pressure connections at the output side of the in tensifier 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 intensifier NOTE If uncoupled hoses are left in the sun pressure in crease within the hoses may make them difficult 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 intensifier 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 intensifier relief valve as required NOTE Higher flows and or high back pressure will in crease the output pressure Adjust the output relief valve under the flow and operating conditions the tool will be used under The load valve locks the tool outlet and is to be use
15. d to hold the tool in a fixed 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 fluid at low engine speed When using the nor mally recommended fluids fluid temperature should be at or above 50 F 10 C 400 ssu 82 centistokes before use STANLEY 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 con nection The hydraulic circuit control valve must be in the OFF position when coupling or uncoupling hydrau lic tools Failure to do so may result in damage to the quick couplers and cause overheating of the hy draulic 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 intensifier must have a minimum working pressure rating of 2500 psi 172 bar Supply hoses from the intensifier 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 certified non conductive Never allow the working pressure of the inten
16. d at ports proper ports No oil in reservoir Fill reservoir to proper level High pressure relief valve stuck Test and adjust as specified in Service open section Motor to pump hose leaking Remove and replace hose Intensifier turned over with vent Return intensifier to upright position assembly down Oil mist from center of motor Rear drive shaft seal bad Replace shaft seal located behind shaft housing assembly bushing in motor housing assembly Oil leaking from vent assembly Oil reservoir over filled Reduce oil level to the top of the high pressure pump as viewed through the vent assembly port while the intensifier is in the horizontal position Reservoir must have room for oil expansion Defective shaft seal Seal is located Turn off intensifier Remove vent in the oil seal plate between the assembly and turn on intensifier motor housing assembly and pump Operate compression tool or cutter If oil housing reservoir fills up and overflows replace the shaft seal 12 gt IP16 User Manual STAN LEY Output Pressure ae EP 10 000 psi 700 Bar Input cte eet e ae Up to 2500 psi 176 Bar edet eee 4 10 gpm 15 38 Ipm AT UU 3 8 NPT Connect SIze and Typen une PMID RE DLL deeds 3 8 NPT WoD nens 29 6 Ibs 13 4 kg Length with occ ice rer ee 18 in 46 cm aom
17. e or double wire braid reinforce ment and weather resistant synthetic rubber cover This hose is conductive and must never be used near electrical conductors Fabric braided not certified or labeled non conductive constructed of thermoplastic or synthetic rubber in ner tube synthetic fiber braid reinforcement and weather resistant thermoplastic or synthetic rubber cover This hose is not certified 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 DANGER 1 FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE IMPROPER USE WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRIC LINES MAY RESULT IN OR HANDLING OF HOSE COULD RESULT IN BURST OR OTHER HOSE FAILURE DEATH OR SERIOUS INJURY 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 ELECTRIC LINES HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING ABRASION CUTTING OR CONTACT WITH HIGH TEMPERATURE SURFACE
18. etely assembled tool Do not operate the intensifier unless both high pres sure 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 per sonnel Do not attempt to locate hydraulic leaks by feeling around hoses and fittings 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 recom mended by Stanley Hydraulic Tools Avoid using tightly curled or twisted hoses IP16 User Manual lt 5 CAUTION 3 9 GPM 11 34 LPM DO NOT EXCEED 2000 PSI 140 BAR DO NOT EXCEED SPECIFIED FLOW OR PRESSURE USE CLOSED CENTER TOOL ON CLOSED CENTER SYSTEM USE OPEN CENTER TOOL ON OPEN CENTER SYSTEM CORRECTLY CONNECT HOSES TO TOOL IN AND OUT PORTS IMPROPER HANDLING USE OR OTHER MAINTENANCE OF TOOL COULD RESULT INALEAK BURST OR OTHER TOOL FAILURE CONTACT AT ALEAK OR BURST CAN CAUSE OIL INJECTION INTO THE BODY FAILURE TO OBSERVE THESE PRECAUTIONS CAN RESULT IN SERIOUS PERSONAL INJURY 03783 GPM Sticker 3 9 2000 PSI Stanley Hydraulic Tools 3810 SE Naef Rd Milwaukie Oregon 97267 U S A Model No IP16 10146 IP16 Name Tag NOTE
19. i 2000 psi 2000 psi 2000 psi 2000 psi at the power supply outlet 172 bar 138 bar 138 bar 138 bar 138 bar NOTE These are general hydraulic system requirements See tool specification page for tool specific requirements STAN LEY IP16 User Manual lt 9 PRE OPERATION PROCEDURES FILL RESERVOIR IMPORTANT Mil H 5606 Hydraulic Oil must not be used in the reservoir of the intensifier 1 Remove the vent plug from the top of the intensifier Fill with clean hydraulic oil filtered to 10 microns or less Fill to top of high pressure pump as viewed from the filler hole IMPORTANT Do not fill 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 specified CHECK HYDRAULIC POWER SOURCE 1 Using a calibrated flowmeter and pressure gauge check that the hydraulic power source develops a flow of 4 10 gpm 15 38 Ipm 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 intensifier 2 Wipe all hose couplers with a clean lint free cloth before m
20. sifier or tool to exceed 10 000 psi 690 bar Always keep critical tool markings such as warning stickers and tags legible STANLEY 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 intensifier relief valve must be adjusted to the pressure for the tool being operated Operate the intensifier within its rated capacity Do not use the intensifier for applications for which it was not designed Tool repair should be performed by experienced personnel only Never connect or disconnect couplers or port con nections 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 intensifier is not in use attach thread pro tectors and install valve caps IP16 User Manual lt 11 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 intensifier always check that the hydraulic power source is supplying the correct hydraulic flow and pressure to the intensifier as listed in the table Use a flow meter known to be accurate Check the flow with the hydraulic fluid temperature at least 80 F 27 C PROBLEM CAUSE SOLUTION No output Couplers or hoses blocked Remove obstruction Input pressure and return line Be sure hoses are connected to the hoses reverse
21. ssive slopes and danger ous terrain conditions Establish a training program for all operators to en sure safe operation Do not operate the tool unless thoroughly trained or under the supervision of an instructor e 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 fit ted with hose guards at each end to help prevent kinks and sharp bends near the fittings If these re quirements are not met replace the hoses imme diately with the correct type before operating the intensifier 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 STANLEY Check that all fittings connectors and quick discon nects are rated at 10 000 psi 700 bar working pres sure and that they are in good working condition Replace any improper or damaged components be fore operating the intensifier 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 incompl
Download Pdf Manuals
Related Search