Stanley Black & Decker AL35 Automobile Parts User Manual

User manual for the device Stanley Black & Decker AL35 Automobile Parts

Stanley Black & Decker AL35 Automobile Parts User Manual

Extracts of contents

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AL35HYDRAULICALTERNATORUSER MANUALSafety, Operation and Maintenance© 2014 Stanley Black & Decker, Inc.New Britain, CT 06053U.S.A.16798 8/2014 Ver. 6

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TABLE OF CONTENTSSAFETY SYMBOLS...................................................................................................................................................4SAFETY PRECAUTIONS...........................................................................................................................................5TOOL STICKERS & TAGS.........................................................................................................................................7HOSE

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SAFETY SYMBOLSSafety 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 injuryhazards. Obey all safety messages that follow this symbol to avoid possibleinjury or death.DANGERThis safety alert and signal word indicate an imminently hazardous situa

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SAFETY PRECAUTIONSTool operators and maintenance personnel must alwayscomply with the safety precautions given in this manualand on the stickers and tags attached to the tool andhose.• Always connect hoses to the alternator hose couplers before energizing the hydraulic power source.Be sure all hose connections are tight.• Do not operate the alternator at oil temperaturesabove 140 °F/60 °C. Operation at higher temperatures can cause higher than normal temperaturesat the tool which can res

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SAFETY PRECAUTIONS• Do not start the alternator with electrical loads connected and in a power “ON” state.• Ensure that the alternator is at operating speed/voltage before connecting an electrical load.• Only use hydraulic hose labeled and certified asnon‑conductive when using hydraulic tools on ornear electrical lines. Failure to do so may result indeath or serious injury.• Before using hose labeled and certified as non‑conductive, be sure the hose is maintained as nonconductive

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TOOL STICKERS & TAGS12735AL35 Name Tag03763GPM StickerNOTE:THE INFORMATION LISTEDON THE STICKERS SHOWN,MUST BE LEGIBLE AT ALLTIMES.REPLACE DECALS IFTHEY BECOME WORN ORDAMAGED. REPLACEMENTSARE AVAILABLE FROMYOUR LOCAL STANLEYDISTRIBUTOR.The safety tag (P/N 15875) at right isattached to the tool when shipped fromthe factory. Read and understand thesafety instructions listed on this tag beforeremoval. We suggest you retain this tag andattach it to the tool when not in use.D A N G E R1. FAILURE TO U

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HOSE TYPESThe 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 withStanley Hydraulic Tools. They are:Certified non-conductive — constructed of thermoplastic or synthetic rubber inner tube, synthetic fiber braidreinforcement, and weather resistant thermoplastic or synthetic rubber cover. Hose labeled certified nonconductive i

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All hydraulic hose must meet or exceedspecifications as set forth by SAE J517.All hydraulic hose must have at least a ratedminimum working pressure equal to the maximum hydraulic system relief valve setting.This chart is intended to be used for hydraulictool applications only based on Stanley Hydraulic Tools tool operating requirements andshould not be used for any other applications.The chart to the right shows recommendedminimum hose diameters for various hoselengths based on gallons per minut

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HTMA / EHTMA REQUIREMENTSHTMA / EHTMA REQUIREMENTSHTMAHYDRAULIC SYSTEM REQUIREMENTSTYPE INominal Operating Pressure(at the power supply outlet)4-6 gpm(15-23 lpm)1500 psi(103 bar)TOOL TYPETYPE IITYPE RR7-9 gpm(26-34 lpm)1500 psi(103 bar)9-10.5 gpm(34-40 lpm)1500 psi(103 bar)System relief valve setting(at the power supply outlet)2100-2250 psi(145-155 bar)2100-2250 psi(145-155 bar)2200-2300 psi(152-159 bar)2100-2250 psi(145-155 bar)Maximum back pressure(at tool end of the return hose)250 psi(17 bar

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OPERATIONThe recommended hose size is .500 inch/12 mm I.D. upto 50 ft/15 m long and .625 inch/16 mm I.D. minimum upto 100 ft/30 m.OPERATION PROCEDURES1. Observe all safety precautions.PRE-OPERATION PROCEDURESCAUTIONELECTRICAL GROUNDIf required, ground the electrical load and alternator atthe ground lug on the alternator frame, lower right (asviewed from the front).CHECK POWER SOURCE1. Using a calibrated flowmeter and pressure gauge,check that the hydraulic power source develops aflow of 7–9 gp

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OPERATIONPREVENTATIVE MAINTENANCESCHEDULEIN DIRTY OR MOIST ENVIRONMENTS90 DAY INTERVALSIf the unit is operated or stored in a dirty, moist, or saltmoisture environment, the electrical contacts, rotor andstator should be inspected and cleaned every 90 days ormore frequently as deemed necessary.Positive andNegativeDiodesIN CLEAN, DRY ENVIRONMENTS12 MONTH INTERVALSIf the unit is operated or stored in a clean and dry environment, the electrical contacts, rotor, and stator shouldbe inspected and clea

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TOOL PROTECTION & CARENOTICEIn addition to the Safety Precautions found inthis manual, observe the following for equipmentprotection 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 tothe quick couplers and cause overheating of the hydraulic system.• Always store the tool in a clean dry space, safe fromdamage or pilfera

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TROUBLESHOOTINGPROBLEMTool does not run.No electrical output.CAUSEREMEDYPower unit not functioning.Check power unit for power flow andpressure (7-9 gpm/26-34 lpm, 2000psi/140 bar.Couplers or hoses blocked.Remove restriction.Hyrevz motor failure.Inspect and repair.Hydraulic lines not connected.Connect lines.Open circuit breaker.Reset circuit breaker.Faulty receptacle.Replace receptacle.Loose/broken wires.Locate and repair.Loss of residual magnetism.Flash and Field. Refer to section in thismanual.

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SPECIFICATIONSThe AL35 is a hydraulic motor powered electrical alternator, designed to provide power for lights, small powertools, and small appliances. It produces 3500 watts of power at a nominal 120/240 volts AC single phase at 60 Hzfrequency. The unit requires hydraulic power delivered at 7–9 gallons per minute (gpm) with pressure up to 2000pounds per square inch (psi).Capacity.......................................................................................... 3500 W 120/240 V, 60 Hz

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2316 ► AL35 User Manual1234August 19981461312AL35 ALTERNATOR78952115262230161718282221103119203635232543372724323840412022213942AL35 PARTS ILLUSTRATION

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AL35 PARTS LISTITEMPARTNO.QTYDESCRIPTIONITEMPARTNO.QTYDESCRIPTION1151001VOLTMETER38126221MOUNTING BRACKET—TALL043534ESNA NUT2COM*4PHILLIPS HEAD MACHINE SCREW393COM*4WASHER40214461HYREVZ MOTOR ASSEMBLY1RECEPTACLE PANEL41037861STICKER, GPM42009362ADAPTOR45151011RECEPTACLE, 30 A, 120 V6151031RECEPTACLE, 15 A, 240 V7——INCLUDED WITH ITEM 18151061CIRCUIT BREAKER, 30 A9352351CAPACITOR10057344CAPSCREW, 3/8-16 × 2 HEX HEAD11——NO ITEM12151021RECEPTACLE, 15 A, 120 V13151051CIRCUIT BREAKER, 15 A1

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AL35 MOTOR PARTS ILLUSTRATIONAL35 MOTOR ASSEMBLY P/N 21446ITEMPARTNO.QTYDESCRIPTION1001208CAPSCREW, 1/4-20 × 2-1/4 HSH2073861GEAR HOUSING ASSEMBLY(INCLUDES ITEMS 3 & 4)3007132DOWEL PIN4063164BUSHING5001781O-RING *6733091IDLER SHAFT7068532DRIVE GEAR92143210006691QUAD RING *11001711O-RING *12198841SEAL GLAND13001701RETAINING RING14007081RETAINING RING15001481BEARING16068812NEEDLE ROLLER17068761DRIVE SHAFT18001661RETAINING RINGBEARING HOUSING ASSEMBLY(INCLUDES ITEM 4)* Indicates part of Seal Kit 0

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WSILVER115V30ANEMAL530R14 AWG WHT30A14 AWG WHTXGOLDGSILVERGOLD14 AWG BLKGOLD15AGNDGOLD14 AWG BLK1. RECEPTACLE TERMINALS ARE DRAWNAS SEEN FROM THE BACK.14 AWG GRN14 AWG BLK14 AWG GRN14 AWG BLK14 AWG GRN14 AWG BLK14 AWG BLK(P) 114 AWG BLK(P) 214 AWG WHT(P) 314 AWG WHT(P) 414 AWG WHT(P) 514 AWG BLK(P) 614 AWG GRN16 AWG RED16 AWG RED12345678P1CAPACITOR14 AWG GRN(P) 89J1112245GND6TO FRAME3AL35 WIRING DIAGRAMUse clean solvent In well ventilated areas. Avoid prolonged Inhalation of vapors and prolonged

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Stanley Hydraulic Tools3810 SE Naef RoadMilwaukie, Oregon 97267-5698 USA(503) 659-5660 / Fax (503) 652-1780www.stanleyhydraulics.com

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