AL35
HYDRAULIC
ALTERNATOR
USER MANUAL
Safety, Operation and Maintenance
© 2014 Stanley Black & Decker, Inc.
New Britain, CT 06053
U.S.A.
16798 8/2014 Ver. 6
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TABLE OF CONTENTS
SAFETY SYMBOLS ..................................................................................................................................................4
SAFETY PRECAUTIONS..........................................................................................................................................5
TOOL STICKERS & TAGS........................................................................................................................................7
HOSE TYPES............................................................................................................................................................8
HOSE RECOMMENDATIONS ..................................................................................................................................9
FIGURE 1. TYPICAL HOSE CONNECTIONS.......................................................................................................9
HTMA REQUIREMENTS.........................................................................................................................................10
OPERATION............................................................................................................................................................ 11
FIGURE 2. DIODE LOCATION ............................................................................................................................12
TOOL PROTECTION & CARE................................................................................................................................13
TROUBLESHOOTING ............................................................................................................................................14
SPECIFICATIONS...................................................................................................................................................15
AL35 PARTS ILLUSTRATION.................................................................................................................................16
AL35 PARTS LIST...................................................................................................................................................17
AL35 MOTOR PARTS ILLUSTRATION...................................................................................................................18
AL35 WIRING DIAGRAM........................................................................................................................................19
IMPORTANT
To fill out a Product Warranty Recording form, and for information on your warranty,
visit Stanleyhydraulics.com and select the Company tab, Warranty.
(NOTE: The warranty recording form 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.
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 certified dealer, call Stanley Hydraulic Tools at the number listed on the back of this
manual and ask for a Customer Service Representative.
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SAFETY SYMBOLS
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
which, if not avoided, will result in death or serious injury.
DANGER
WARNING
CAUTION
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.
CAUTION
NOTICE
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 dam-
age to the equipment.
IMPORTANT
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.
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SAFETY PRECAUTIONS
Tool operators and maintenance personnel must always
•
Always connect hoses to the alternator hose cou-
comply with the safety precautions given in this manual
and on the stickers and tags attached to the tool and
hose.
plers before energizing the hydraulic power source.
Be sure all hose connections are tight.
•
Do not operate the alternator at oil temperatures
above 140 °F/60 °C. Operation at higher tempera-
tures can cause higher than normal temperatures
at the tool which can result in operator discomfort.
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.
•
•
•
Never transport or carry the alternator with the unit
energized and connected to electrical loads.
Do not operate a damaged, improperly adjusted, or
incompletely assembled alternator.
The AL35 Hydraulic Alternator 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.
Observe local and national electrical codes for load
wiring. To prevent electrical shock from faulty equip-
ment, ground the alternator. If ground bonding is
required, connect a length of heavy wire between
the alternator ground terminal and the ground bond
point.
•
•
•
Exercise reasonable caution to prevent electrical
shock; do not operate the alternator with wet hands.
Do not operate the alternator in rain or snow. Do not
let the alternator get thoroughly wet.
Do not connect the alternator to a building circuit.
This could cause damage to the alternator or to
electrical equipment in the building.
•
Operator must start in a work area without bystand-
ers. Keep bystanders clear of your work area. The
operator must be familiar with the work area such as
excessive slopes and dangerous terrain conditions.
•
•
•
Establish a training program for all operators to en-
sure safe operation.
Do not operate the alternator unless thoroughly
trained or under the supervision of an instructor.
Always wear safety equipment such as goggles, ear
and head protection, and safety shoes at all times
when operating the alternator.
•
Never use tools near energized transmission lines.
Know the location of buried or covered services be-
fore starting your work.
•
•
Do not overreach. Maintain proper footing and bal-
ance at all times.
Do not inspect or clean the alternator while the hy-
draulic power source is connected. Accidental en-
gagement of the tool can cause serious injury.
AL35 User Manual ◄ 5
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SAFETY PRECAUTIONS
•
•
•
Do not start the alternator with electrical loads con-
nected and in a power “ON” state.
•
Do not lift or carry the alternator by the hoses. Do
not abuse the hoses. Do not use kinked, torn or
damaged hydraulic hose.
Ensure that the alternator is at operating speed/volt-
age before connecting an electrical load.
•
Make sure hydraulic hoses are properly connected
to the alternator before pressuring the hydraulic
system. The system pressure hose must always be
connected to the alternator IN port. The system re-
turn hose must always be connected to the alterna-
tor OUT port. Reversing the connections may cause
reverse tool operation which can result in severe
personal injury.
Only use hydraulic hose labeled and certified as
non-conductive when using hydraulic tools on or
near electrical lines. Failure to do so may result in
death or serious injury.
•
Before using hose labeled and certified as non‑con-
ductive, 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.
•
•
Do not connect open-center hydraulic tools to
closed-center hydraulic systems. This may result
in loss of other hydraulic functions powered by the
same system and/or may cause severe personal
injury. The AL35 alternator is an open‑center hy‑
draulic tool.
•
•
A hydraulic leak or burst may cause oil injection into
the body or other severe personal injury.
Do not exceed specified flow and pressure for the
alternator. Excess flow or pressure may cause a
leak or burst.
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 exceed the rated working pressure of hy-
draulic hose used with the alternator. Excess pres-
sure may cause a leak or burst.
Check alternator hose couplers and connectors dai-
ly for leaks. Do not feel for leaks with your hands.
Contact with a leak may result in severe personal
injury.
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TOOL STICKERS & TAGS
12735
AL35 Name Tag
03763
GPM Sticker
NOTE:
D A N G E R
D A N G E R
THE INFORMATION LISTED
ON THE STICKERS SHOWN,
MUST BE LEGIBLE AT ALL
TIMES.
1. 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 OR SERIOUS INJURY.
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 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
PERSONAL INJURY.
BEFORE USING HOSE LABELEDAND CERTIFIEDAS 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.
REPLACE DECALS IF
THEY BECOME WORN OR
DAMAGED. REPLACEMENTS
ARE AVAILABLE FROM
YOUR LOCAL STANLEY
DISTRIBUTOR.
2. A HYDRAULIC LEAK OR BURST MAY CAUSE OIL INJEC-
TION INTO THE BODY OR CAUSE OTHER 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 SYSTEMAND/OR SEVERE PERSONAL INJURY.
A. DO NOT EXCEED SPECIFIED FLOW AND PRESSURE
FOR THIS TOOL. EXCESS FLOW OR PRESSURE MAY
CAUSE A LEAK OR BURST.
5. BYSTANDERS MAY BE INJURED IN YOUR WORK AREA.
KEEP BYSTANDERS CLEAR OF YOUR WORK AREA.
B. DO NOT EXCEED RATED WORKING PRESSURE OF
HYDRAULIC HOSE USED WITH THIS TOOL. EXCESS
PRESSURE MAY CAUSE A LEAK OR BURST.
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.
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.
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
I M P O R T A N T
I M P O R T A N T
READ OPERATION MANUAL AND
SAFETY INSTRUCTIONS FOR THIS
READ OPERATION MANUAL AND
SAFETY INSTRUCTIONS FOR THIS
TOOL BEFORE USING IT.
removal. We suggest you retain this tag and
TOOL BEFORE USING IT.
attach it to the tool when not in use.
USE ONLY PARTS AND REPAIR
PROCEDURES APPROVED BY
STANLEY AND DESCRIBED IN THE
OPERATION MANUAL.
USE ONLY PARTS AND REPAIR
PROCEDURES APPROVED BY
STANLEY AND DESCRIBED IN THE
OPERATION MANUAL.
TAG TO BE REMOVED ONLY BY
TOOL OPERATOR.
TAG TO BE REMOVED ONLY BY
TOOL OPERATOR.
SEE OTHER SIDE
SEE OTHER SIDE
SAFETY TAG P/N 15875 (Shown smaller then actual size)
AL35 User Manual ◄ 7
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HOSE TYPES
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, single 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
D A N G E R
D A N G E R
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.
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.
FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROP-
ERLY TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND
ELECTRIC LINES.
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.
2. BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS NON-CONDUCTIVE
ON OR NEAR ELECTRIC LINES. WIPE THE ENTIRE LENGTH OF THE HOSE AND FIT-
TING 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.
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.
SEE OTHER SIDE
SEE OTHER SIDE
SIDE 1
SIDE 2
(Shown smaller than actual size)
THE TAG SHOWN BELOW IS ATTACHED TO “CONDUCTIVE” HOSE.
D A N G E R
D A N G E R
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.
5. CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKSABRASIONS, 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.
2. FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY
TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND ELEC-
TRIC LINES.
6. AFTER EACH USE STORE IN A CLEAN DRY AREA.
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.
SEE OTHER SIDE
SEE OTHER SIDE
SIDE 1
SIDE 2
(Shown smaller than actual size)
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HOSE RECOMMENDATIONS
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HTMA / EHTMA REQUIREMENTS
HTMA / EHTMA REQUIREMENTS
HTMA
TOOL TYPE
HYDRAULIC SYSTEM REQUIREMENTS
TYPE I
TYPE II
TYPE RR
9-10.5 gpm
(34-40 lpm)
1500 psi
TYPE III
11-13 gpm
(42-49 lpm)
1500 psi
4-6 gpm
7-9 gpm
Flow Range
(15-23 lpm)
1500 psi
(103 bar)
(26-34 lpm)
1500 psi
(103 bar)
Nominal Operating Pressure
(at the power supply outlet)
(103 bar)
(103 bar)
2100-2250 psi
(145-155 bar)
2100-2250 psi
(145-155 bar)
2200-2300 psi
(152-159 bar)
2100-2250 psi
(145-155 bar)
System relief valve setting
(at the power supply outlet)
250 psi
(17 bar)
250 psi
(17 bar)
250 psi
(17 bar)
250 psi
(17 bar)
Maximum back pressure
(at tool end of the return hose)
400 ssu*
400 ssu*
400 ssu*
400 ssu*
Measured at a max. fluid viscosity of:
(82 centistokes) (82 centistokes) (82 centistokes) (82 centistokes)
(at min. operating temperature)
Temperature: Sufficient heat rejection
capacity to limit max. fluid temperature to:
(at max. expected ambient temperature)
140° F
(60° C)
140° F
(60° C)
140° F
(60° C)
140° F
(60° C)
Min. cooling capacity at a temperature
3 hp
5 hp
6 hp
7 hp
difference of between ambient and fluid
temps
(2.24 kW)
40° F
(3.73 kW)
40° F
(5.22 kW)
40° F
(4.47 kW)
40° F
NOTE:
(22° C)
(22° C)
(22° C)
(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
30 gpm
(114 lpm)
25 microns
30 gpm
(114 lpm)
25 microns
30 gpm
(114 lpm)
25 microns
30 gpm
(114 lpm)
Min. full-flow filtration
Sized for flow of at least:
(For cold temp. startup and max.
dirt-holding capacity)
Hydraulic fluid Petroleum based
(premium grade, anti-wear, non-conductive)
Viscosity (at min. and max. operating temps)
100-400 ssu*
100-400 ssu*
(20-82 centistokes)
100-400 ssu*
100-400 ssu*
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
CLASSIFICATION
EHTMA
HYDRAULIC SYSTEM
REQUIREMENTS
C
B
D
Flow Range
3.5-4.3 gpm
(13.5-16.5 lpm) (18-22 lpm)
1870 psi
(129 bar)
4.7-5.8 gpm
7.1-8.7 gpm
(27-33 lpm)
1500 psi
9.5-11.6 gpm
(36-44 lpm)
1500 psi
11.8-14.5 gpm
(45-55 lpm)
1500 psi
Nominal Operating Pressure
(at the power supply outlet)
1500 psi
(103 bar)
(103 bar)
(103 bar)
(103 bar)
System relief valve setting
(at the power supply outlet)
2495 psi
(172 bar)
2000 psi
(138 bar)
2000 psi
(138 bar)
2000 psi
(138 bar)
2000 psi
(138 bar)
NOTE: These are general hydraulic system requirements. See tool specification page for tool specific requirements
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OPERATION
The recommended hose size is .500 inch/12 mm I.D. up
to 50 ft/15 m long and .625 inch/16 mm I.D. minimum up
to 100 ft/30 m.
OPERATION PROCEDURES
1. Observe all safety precautions.
PRE‑OPERATION PROCEDURES
CAUTION
ELECTRICAL GROUND
If required, ground the electrical load and alternator at
the ground lug on the alternator frame, lower right (as
viewed from the front).
Do not connect or otherwise apply power to an
electrical load until the alternator has come up to
speed.
CHECK POWER SOURCE
1. Using a calibrated flowmeter and pressure gauge,
check that the hydraulic power source develops a
flow of 7–9 gpm/26–34 lpm at 2000 psi/140 bar.
2. Move the hydraulic circuit control to the “ON” posi-
tion. As the alternator comes up to speed, a maxi-
mum electrical load of 3500 W, single‑phase 60 Hz
alternating current, at 120 volts becomes available.
2. Make certain the hydraulic power source is equipped
with a relief valve set to open at 2100 psi/145 bar
maximum.
3. Connect the electrical loads.
CONNECT HOSES
CAUTION
1. Wipe all hose couplers with a clean, lint‑free cloth
before making connections.
Do not exceed the alternator’s rated 3500 W
2. Connect the hoses from the hydraulic power source
to the tool fittings or quick disconnects. It is a good
practice to connect return hoses first and discon-
nect them last to minimize or avoid trapped pressure
within the tool.
capacity.
NOTE:
Output voltage is proportional to the RPM of the hy‑
draulic motor.
3. Observe flow indicators stamped on hose couplers
to ensure that fluid flow is in the proper direction.
The female coupler on the tool hose is the inlet cou-
pler.
FLASHING THE FIELD
This procedure establishes residual magnetism in the
field windings, to provide start‑up excitation and proper
output voltage levels.
4. Move the hydraulic circuit control valve to the ON
position to operate the tool.
1. Stop the alternator.
NOTE:
2. Remove the receptacle panel.
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
the hoses together.
3. Using a 12 volt automotive battery, touch the posi-
tive lead to the positive (+) diode set with the white
or silver band, located on the rotor assembly. At the
same time touch the negative lead to the negative
(-) diode. Hold the leads against the diodes for 2-4
seconds.
NOTE:
Do not reverse the polarity of the leads. This may
cause damage to the diodes or the rotor or both.
4. Replace the receptacle panel and start the alterna-
tor.
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OPERATION
PREVENTATIVE MAINTENANCE
SCHEDULE
IN DIRTY OR MOIST ENVIRONMENTS
90 DAY INTERVALS
If the unit is operated or stored in a dirty, moist, or salt
moisture environment, the electrical contacts, rotor and
stator should be inspected and cleaned every 90 days or
more frequently as deemed necessary.
Positive and
Negative
Diodes
IN CLEAN, DRY ENVIRONMENTS
12 MONTH INTERVALS
If the unit is operated or stored in a clean and dry envi-
ronment, the electrical contacts, rotor, and stator should
be inspected and cleaned every 12 months or more fre-
quently as deemed necessary.
Figure 2. Diode Location
No other preventative maintenance is required.
COLD WEATHER OPERATION
If the breaker is to be used during cold weather, preheat
the hydraulic fluid at low engine speed. When using the
normally recommended fluid, fluid temperature should
be at or above 50 °F/10 °C (400 ssu/82 centistokes) be-
fore use.
Damage to the hydraulic system or breaker can result
from use with fluid that is too viscous or thick.
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TOOL PROTECTION & CARE
NOTICE
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.
•
•
Keep tool bit sharp for maximum breaker perfor-
mance. Make sure that tool bits are not chipped or
rounded on the striking end.
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.
Never operate a breaker without a tool bit or without
holding it against the work surface. This puts exces-
sive strain on the breaker foot.
•
•
•
Tool repair should be performed by experienced
personnel only.
•
•
Always store the tool in a clean dry space, safe from
damage or pilferage.
Make certain that the recommended relief valves
are installed in the pressure side of the system.
Make sure the circuit PRESSURE hose (with male
quick disconnect) is connected to the “IN” port. The
circuit RETURN hose (with female quick disconnect)
is connected to the opposite port. Do not reverse cir-
cuit flow. This can cause damage to internal seals.
Do not use the tool for applications for which it was
not intended.
•
•
Always replace hoses, couplings and other parts
with replacement parts recommended by Stanley
Hydraulic Tools. Supply hoses must have a mini-
mum working pressure rating of 2500 psi/172 bar.
Do not exceed the rated flow (see Specifications) in
this manual for correct flow rate and model number.
Rapid failure of the internal seals may result.
•
•
Always keep critical tool markings, such as warning
stickers and tags legible.
Do not force a small breaker to do the job of a large
breaker.
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TROUBLESHOOTING
PROBLEM
CAUSE
REMEDY
Tool does not run.
Power unit not functioning.
Check power unit for power flow and
pressure (7-9 gpm/26-34 lpm, 2000
psi/140 bar.
Couplers or hoses blocked.
Hyrevz motor failure.
Remove restriction.
Inspect and repair.
Connect lines.
Hydraulic lines not connected.
Open circuit breaker.
No electrical output.
Reset circuit breaker.
Replace receptacle.
Locate and repair.
Faulty receptacle.
Loose/broken wires.
Loss of residual magnetism.
Flash and Field. Refer to section in this
manual.
Short circuit in rotor filed or diodes. Return to an authorized service center.
Shorted AC or exciter stator
windings.
Check with Ohmmeter. Continuity should
exist between black/white and red/red
wires. No continuity from black/white to
red wire or any wire to ground. If a short is
found, replace the stator.
Low output.
Hyrevz motor speed too slow.
Unbalanced or excessive load.
High backpressure.
Check for proper flow of 7‑9 gpm/26‑34
lpm.
Balance load between circuits, load should
not exceed rated capacity.
Check for excessive backpressure, over
250 psi/17 bar.
Couplers/hoses blocked.
Locate and remove blockage.
Oil too hot/cold. Above 150°F/66°C Check power source for proper oil
or below 50°F/10°C.
temperature. Bypass cooler to warm
oil; or provide cooler to maintain proper
temperature.
Relief valve set too low.
Motor worn.
Adjust relief valve to 2000 psi/145 bar.
Inspect; repair/replace.
Output too high.
Motor over-speeding.
Check power unit for proper flow. 7‑9
gpm/26-34 lpm.
Alternator overheats.
Overloaded.
Reduce electrical load; load should not
exceed rated capacity.
Air intake plugged or covered.
Clear air intake.
Clean windings.
Windings covered with dirt.
14 ► AL35 User Manual
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SPECIFICATIONS
The AL35 is a hydraulic motor powered electrical alternator, designed to provide power for lights, small power
tools, and small appliances. It produces 3500 watts of power at a nominal 120/240 volts AC single phase at 60 Hz
frequency. The unit requires hydraulic power delivered at 7–9 gallons per minute (gpm) with pressure up to 2000
pounds per square inch (psi).
Capacity..........................................................................................3500 W 120/240 V, 60 Hz at 8 gpm/30 Ipm Input
Outlets ...................................................................................................240 V/15 A, 120 V/20 A, 120 V/15 A Duplex
Pressure Range ...............................................................................................................................2000 psi/140 bar
Flow Range .................................................................................................................................7–9 gpm/26–34 Ipm
Optimum Flow ......................................................................................................................................8 gpm/30 Ipm
Porting..................................................................................................................................................10 SAE O-ring
Connect Size and Type ..............................................................................................................1/2 NPT Pipe Fitting
Weight ...................................................................................................................................................70 Ib/31.8 kg
Overall Length ...............................................................................................................................19 inches/47.9 cm
Width ...............................................................................................................................................9 inches/22.7 cm
Height ............................................................................................................................................10 inches/25.4 cm
Motor ................................................................................................................................Stanley Hyrevz P/N 21446
AL35 User Manual ◄ 15
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AL35 PARTS ILLUSTRATION
16 ► AL35 User Manual
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AL35 PARTS LIST
PART
ITEM NO.
PART
ITEM NO.
QTY DESCRIPTION
QTY DESCRIPTION
38
39
40
41
42
12622
04353
21446
03786
00936
1
4
1
1
2
MOUNTING BRACKET—TALL
1
15100
COM*
COM*
1
4
4
1
1
1
—
1
1
4
—
1
1
4
1
1
1
1
1
VOLTMETER
ESNA NUT
2
PHILLIPS HEAD MACHINE SCREW
WASHER
HYREVZ MOTOR ASSEMBLY
STICKER, GPM
ADAPTOR
3
4
RECEPTACLE PANEL
RECEPTACLE, 30 A, 120 V
RECEPTACLE, 15 A, 240 V
INCLUDED WITH ITEM 1
CIRCUIT BREAKER, 30 A
CAPACITOR
5
15101
15103
—
6
COM* indicates common parts available through local
sources
7
8
15106
35235
05734
—
9
10
11
12
13
14
15
16
17
18
19
CAPSCREW, 3/8‑16 × 2 HEX HEAD
NO ITEM
15102
15105
12692
12735
26604
COM*
COM*
26607
RECEPTACLE, 15 A, 120 V
CIRCUIT BREAKER, 15 A
STATOR BOLT 11" LONG
NAME TAG
RECEPTACLE BOX
CAPSCREW
LOCKWASHER
OUTBOARD BEARING BRACKET
ASSY
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
05351
00429
03031
12628
21315
00171
35237
12690
12691
—
4
FOOT
6
HEX NUT 5/16-18
WASHER 5/16
6
1
MOUNTING BRACKET—SHORT
CAPSCREW, 5/16‑18 × 1-1/4
O-RING
2
1
1
STATOR ASSY
1
CAPSCREW
1
"C" WASHER
—
1
NO ITEM
35236
26606
12694
—
ROTOR ASSEMBLY
ADAPTER, INBOARD ENGINE END
GROUNDING LUG
NO ITEM
1
1
—
—
4
—
NO ITEM
20051
02688
05325
NUT, LOCKWASHER 1/4‑20
CAPSCREW 5/16‑18 × 3/4
MOTOR ADAPTOR
2
1
AL35 User Manual ◄ 17
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AL35 MOTOR PARTS ILLUSTRATION
AL35 MOTOR ASSEMBLY P/N 21446
PART
NO.
ITEM
QTY
DESCRIPTION
1
2
00120
07386
8
1
CAPSCREW, 1/4‑20 × 2-1/4 HSH
GEAR HOUSING ASSEMBLY
(INCLUDES ITEMS 3 & 4)
3
4
5
6
7
9
00713
06316
00178
73309
06853
21432
2
4
1
1
2
DOWEL PIN
BUSHING
O-RING *
IDLER SHAFT
DRIVE GEAR
BEARING HOUSING ASSEMBLY
(INCLUDES ITEM 4)
10
11
12
13
14
15
16
17
18
00669
00171
19884
00170
00708
00148
06881
06876
00166
1
1
1
1
1
1
2
1
1
QUAD RING *
O-RING *
SEAL GLAND
RETAINING RING
RETAINING RING
BEARING
NEEDLE ROLLER
DRIVE SHAFT
RETAINING RING
* Indicates part of Seal Kit 07388
18 ► AL35 User Manual
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AL35 WIRING DIAGRAM
Use clean solvent In well ventilated areas. Avoid prolonged Inhalation of vapors and prolonged or repeated contact
with skin. Keep away from heat or open flame.
C A P A C I T O R
1 4 A W G G R N
1 4 A W G B L K
AL35 User Manual ◄ 19
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Stanley Hydraulic Tools
3810 SE Naef Road
Milwaukie, Oregon 97267-5698 USA
(503) 659-5660 / Fax (503) 652-1780
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