TABLE OF CONTENTS
DECLARATION OF CONFORMITY...................................................................................................................................2
OPERATION EP30200.........................................................................................................................................6 THRU 9
OPERATION EP30250.....................................................................................................................................10 THRU 13
ACCESSORIES.................................................................................................................................................16 THRU 21
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 the unit, 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
This safety alert and signal word indicate a potentially hazardous situation
which, if not avoided, could result in death or serious injury.
WARNING
This safety alert and signal word indicate a potentially hazardous situation
which, if not avoided, could result in death or serious injury.
CAUTION
CAUTION
NOTICE
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
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
• Do not operate a damaged, improperly adjusted, or in-
completely assembled tools.
comply with the safety precautions given in this manual
and on the stickers and tags attached to the tool and
hose.
• To avoid personal injury or equipment damage, all tool
repair, maintenance and service must only be performed
by authorized and properly trained personnel.
These safety precautions are given for your safety. Re-
view them carefully before operating the tool and before
performing general maintenance or repairs.
• Do not exceed the rated limits of the tool or use the tool
for applications beyond its design capacity.
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.
• Always keep critical tool markings, such as labels and
warning stickers legible.
• Always replace parts with replacement parts recom-
mended by Stanley Hydraulic Tools.
This tool 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 tool before operation.
Failure to do so could result in personal injury or equip-
ment damage.
• Operator must start in a work area without bystanders.
The operator must be familiar with all prohibited work
areas such as excessive slopes, dangerous terrain con-
ditions, and rail traffic.
• Establish a training program for all operators to ensure
safe operation.
• Do not operate the tool unless thoroughly trained or
under the supervision of an instructor.
• Always wear safety equipment such as goggles, ear,
head protection, and respiratory protection at all times
when operating the tool.
• Do not inspect or clean the tool while the battery power
source is connected. Accidental arcing can cause seri-
ous injury.
• Do not load brazing pins or ceramic rings while the bat-
tery power source is connected. Accidental arcing can
cause serious injury.
• Do not use the tool while it is connected to a battery
charger.
• Ensure battery charging is only done in a dry environ-
ment. Charging batteries in the rain or near standing
water presents an electrocution hazard. Read the safe-
ty and operation instructions provided with the battery
charger before using the battery charger.
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EP30200 OPERATION
GENERAL PROTECTION
WARNING
Store the Electronic Pin Brazing Unit in a place where it is
protected from the elements, abrasive dust, and damage.
Make sure battery charging is only accomplished in a
well ventilated room. DO NOT PLACE THE CONTROL
BOX ON TOP OF THE BATTERIES. REMOVE THE
BATTERY BOX COVER. Battery charging produces
explosive gases. A battery explosion can cause serious
injuries. Avoid battery explosions by keeping cigarettes,
sparks, and flames away from batteries being charged.
Always wear safety glasses when working with
batteries.
Use only recommended repair and replacement parts and
materials specified in the Parts List section of this manual.
Use only recommended accessories also specified in the
Parts List section of this manual.
Do not use the Electronic Pin Brazers for applications it was
not designed for.
Use the carrying handle to transport the unit from location
to location.
1. The three batteries furnished are sealed, maintenance
free batteries.
Sealed, maintenance free batteries do not contain cell caps
and are already filled with battery acid. They will require
charging before use.
CLEANING
Establish a routine to keep the unit as free from dirt as pos-
sible – daily, or at each shift change, for example.
NOTICE
Pin Brazers exposed to rain, sand, or grit-laden air should be
cleaned prior to each use.
Use only battery charger specially made for pin brazing
units (36V dc) approved by Stanley.
Keep tool labels and stickers legible.
2. Locate the four battery cables and connect them to the
terminals on the batteries and the battery box as shown in
figure 1. Do not replace the lid on the battery box at this time.
PREOPERATION PROCEDURES
Before putting a new Pin Brazer into initial service, or after an
extended period of being unused, perform a visual inspection
for bent, broken, cracked, missing or worn components.
INITIAL SETUP AND BATTERY CHARGING
+Pos.
-Neg.
WARNING
Failure to follow the instructions in the battery charger
operation manual can result in battery explosion and
serious bodily injury. To reduce the risk of battery ex-
plosion, read and understand the safety and operation
instructions in the battery charger operation manual,
the instructions published by the battery manufacturer,
and the instructions in this manual before attempting to
charge the batteries.
Figure 1. Battery cable and terminals
3. Insert the enclosed foam-rubber spacers between each
battery and at both ends between the battery and the unit.
4. Connect the battery charger to the grinder outlet on the
unit, then to the mains. When removing the charger remove
the main first, the remove the plug from the unit.
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EP30200 OPERATION
5. Charging is ready in approximately 3-5 hours. Follow the
instructions in the battery charger manual to complete the
charging process.
OPERATION
PREPARE THE RAIL SURFACE
Select the type and length of bonding cable to use for the
bond and use it as a guide to determine where brazing points
on the rail will be required.
6. Plug the two cable leads from the adapter box into the
battery box.
7. Insert the plug from the battery charger into the grinder
outlet on the adapter box.
Before brazing, the rail must be cleaned of rust, corrosion,
paint, pits, or other contamination at the points where the braz-
ing is going to be done and on an area close to the brazing for
placement of the grounding cable. Cleaning is accomplished
with a grinder to ensure clean, bare metal.
8. Plug the battery charger into a standard 110 volt AC
outlet.
9. Follow the instructions in the battery charger manual to
complete the charging process.
NOTE:
Use only grinding wheels furnished by Stanley. Other
wheels have shown to leave residues which cause faulty
brazing.
CONNECTIONS
CAUTION
Grinder Receptacle
Pin Size Switch
Control Cable
Female Socket
Gun Power Supply
Receptacle
Always use eye protection when grinding and brazing.
1. Grind the surface of the rail where brazing is going to be
done, until the surface shows shiny metal, free of rust, cor-
rosion, pits, or other contamination. When grinding, use the
edge of the grinding wheel - not the face of the wheel.
1 A Fuse
Ground Receptacle
2. Grind the surface of the rail where the grounding cable
will be placed to ensure a good ground. The grounding cable
should be placed in close proximity to the brazing area.
15 A Fuse
Figure 2. EP30 Connections
1. Connect the brazing gun, power and trigger cables to the
unit.
PLACING THE GROUNDING CABLE
2. Connect the ground cable .
3. Connect the grinder.
3. When finished grinding the rail for placement of the ground-
ing cable, place the grounding cable on the cleaned surface
and then insert the other end into the twist lock receptacle
in the control box marked "GROUND" or "EARTHING" and
twist to lock.
SELECT PINS AND RINGS
4. Select brazing pins and ceramic rings to match the speci-
fications of the bonding cable you selected.
CHANGING PIN AND RING HOLDER
5. Check that the pin holder and ring holder on the gun are
the correct sizes for the brazing pins and ceramic rings you
selected. If the sizes are incorrect, the pin holder and ring
holder can be changed as follows:
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EP30200 OPERATION
a. The ring holder is a "push fit" to the gun. To remove it from
the gun, simply pull it away from the gun.
The BG10100 automatically adjusts the correct distance of
the brazing pin to the surface to be brazed.
b. The pin holder is threaded onto a threaded shaft in the gun
and locked in place with a nut. Place an open end wrench
over the nut and an open end wrench over the flats on the
pin holder. While holding the nut in place, unscrew the pin
holder counter clockwise.
NOTE:
The BG10100 may be adjusted manually if necessary
using the dial located on the back of the gun. The set-
tings are as follows:
Pin Holder
Ring Holder
+ = 2.5 mm distance
0 = 2.0 mm distance (normal position)
- ꢀꢀꢀ= 1.5 mm distance
Figure 3. Pin and Ring Holder
c. Install the correct pin holder and tighten it securely against
the nut.
Dial
Figure 2. Gun Adjustment Dial
IMPORTANT
8. Plug the two gun cable into the appropriate outlets on the
control box.
Make sure, never twist the axle when mounting the
pin holder.
SET CONTROL FOR PIN SIZE
d. Install the correct ring holder by placing it over the pin holder
and into the circular groove in the gun, and finally, pushing
on it to seat it in place.
9. Set the PIN TYPE switch on the control box for the
appropriate pin type being used. See Figure 3 below.
Brazing Pin
8 mm Std
8 mm Extra
9.5 mm
Setting
P1
LOADING PIN AND RING
6. Insert the brazing pin into the pin holder. The rounded tip
should be facing away from the gun.
P2
P3
7. Insert the ceramic ring into the ring holder. The serrated
edge should be facing away from the gun. See figure 4.
SWITCH
Figure 3. Pin Type Control Switch
10. Turn the POWER switch to 1.
Figure 4. Loading pin and ring
ADJUSTING BRAZING PIN DISTANCE TO
BRAZE SURFACE
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EP30200 OPERATION
NOTE:
The EP30 does not have a power switch.
11. Position the terminal lug of the bonding cable against the
cleaned surface of the rail. Position the gun against the cable
lug so that the brazing pin is at the top edge of the cable lug
hole. See Figure 4 below.
Figure 4. Gun position
IMPORTANT
Make sure the correct ferrule and brazing pin are used.
The pin braze must be made in the top of the hole when
brazing to a vertical surface.
12. Hold the gun firmly with both hands and pull the trigger
once. The electronics will finish the braze automatically.
13. Hold the gun in place for 3-4 seconds after the brazing is
complete to allow for cooling. Then remove the gun straight
backwards without pulling trigger.
14. After the braze has cooled, knock the shank off the braz-
ing pin using a hammer.
15. Use a new ceramic ring for each new pin braze.
NOTE:
A red light indicates low batteries on the unit. Charge
as soon as possible.
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EP30250 OPERATION
CAUTION
The S300 requires a welding machine capable to deliver
250-300 Amp, open circuit voltage of max. 80V.
(Not supplied by Stanley)
1. Check that all parts were received.
EP300 Unit Delivered with:
Gun S15, incl 2,7 m SAFE 91015
Ground device 2,7 m SAFE 8089
1 - Power cord
2 - Power cable 3 m
2. Connect
Connect power cords to mains and power
cables to an welding machine.
(Welding machine not supplied by Stanley).
Make sure positive and negative is correct.
Set welding current on welding
machine to 250 Amp.
(Max 280 Amp)
Open circuit voltage of max. 80V.
Connect brazing gun, power cable and
control cable, to units gun outlets.
Connect ground magnet to ground outlet.
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EP30250 OPERATION
3. Brazing instruction.
WARNING
Warning! Always use eye protectors when grinding and brazing!
Note, use only STANLEY´s grinding wheel specially made for brazing, other type of wheels will leave a surface
not suitable for brazings. Keep the grinding wheel clean and free from oil etc.
IMPORTANT
- Grind the brazing and grounding area until you have an even and clean surface
Move the grinder up and down until you have an
even surface for both the pinbraze and ground
magnet.
- Attach the earth magnet on the same rail/work piece where the pinbrazing should be done. Try to attach the
magnet within 0,5m from brazing area.
- Set pintype:
Pin
Setting
8 mm std
8 mm Extra
9,5 mm
1
2
3
- Load the gun with brazing pin and ferrule.
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EP30250 OPERATION
- Press carefully the gun with the cable shoe, the ferrule and the
brazing pin to the work piece.
- Note that you always must use a railbond together with the brazing pin and the ferrule to do a pin brazing, except
when brazing a special threaded brazing pin then only a ferrule and M8, M10 or M12 brazing pin is to be used.
- Make sure to braze in the top of the hole
when brazing to a vertical surface.
Brazing.
- Hold the gun firmly with both hands as shown and
pull the trigger just once.
The electronic will by it self finish the brazing process.
- Hold the gun in place for 3-4 sec after the brazing
while the braze freezes.
- Remove the gun straight backwards without
pulling the trigger!
Knock off the shank of the brazing pin.
The brazing is completed.
ACCESSORIES EP300
SEE PAGE 17
Pin holder 8-9,5 mm (A)
Pin holder M8 (B)
Pin holder M10 (C)
Pin holder M12 (D)
Ring holder 8-9,5 mm
Ring holder M8/M10/M12
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EP30250 MAINTENANCE
PIN HOLDERS
Squeeze the fingers on the pin holder together each time you feel that the brazing pin goes in too easy when
mounting them into the pin holder. This is important since all the current goes thru the pin holder to the
brazing pin. If the fingers are too loose the pin holder will be damaged and must be replaced.
CHANGE PIN HOLDER
-Separate the ring holder from the gun with your hands.
-Hold the nut closest to the pin holder with a 10mm key.
-Screw the pin holder off.
-When replacing the new pinholder, hold the nut, closest to the pinholder even now.
WARNING
WARNING! Never rotate the shaft! The internal cables may be damaged!
EQUIPMENT
-Check the cables from time to time, to make sure they are not damaged.
-Check the contact surface on the ground magnet from time to time and use a file to even or clean the surface.
BRAZING PINS AND FERRULES
-Keep them dry.
RAILBONDS AND CABLE LUGS
-Keep them free from oxidation.
-Keep them free from contamination like: Grease, oil, dirt, paint, glue etc.
-Make sure that they are not damaged.
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TROUBLESHOOTING
EP30250
In order to perform this trouble shooting you will need: voltmeter, 8 mm and 10 mm spanners, hexagon spanner
3 mm, 4mm and 5 mm, control instrument to check lift height for S15 pistol.
Working material
Are the bonds in good condition - no breaks, clean ?
Are the pins of the correct type ?
Grinding wheeel
Is the grinding wheel the approved type ?
The Tyrolit is a silicon free wheel.
You can use a steel carbide wheel.
No other wheels are allowed.
Brazing gun
S 15
Check cables, plugs.
Does axle move easily with pin and ring installed ?
Are the pin and ring holders bent ?
Unscrew the front of the gun and open carefully. Smell if there is burning, otherwise
clean and replace.
Check the lifting height with the control instrument.
Ground magnet
Electronic units
Is the magnet broken ( between the plates) ?
Is the plug well screwed in ?
Make sure the contact surfaces are even.
Check cables and connections for play.
Are the contact on the cables damaged ?
Are the knobs loose ?
Are the fuses whole ?
Open the panel, check for a burnt smell, ( the breaker can have burnt out )
Check that cables are attached correctly.
Make a full optical control.
EP30200
PROBLEM
CAUSE
Batteries not charged or are defective.
Blown fuse.
SOLUTION
Brazing pin does not ignite
or does not ignite long
enough.
Test batteries for proper charge. Replace and/or
charge as necessary.
Check fuses.
Check that surface magnetic ground is applied to
is ground clean. Check magnetic ground cable
and plug for damage.
Magnetic ground faulty.
Faulty cables.
Check gun cables and plugs for damage.
Bonding surface contaminated.
Check that the brazing surface is ground clean.
Test batteries for proper charge. Replace and/or
charge as necessary.
Braze is faulty.
Batteries not charged or are defective.
Incorrect PIN TYPE setting.
Check PIN TYPE setting on the control box.
Check that surface magnetic ground is applied to
is ground clean. Check magnetic ground cable
and plug for damage.
Magnetic ground faulty.
Bonding surface contaminated.
Incorrect grinding wheel is used.
Check that the brazing surface is ground clean.
Use only Tyrolit grinding wheels or carbide burr.
Ceramic ring was not positioned
square to the lug.
Ensure ring is positioned correctly.
Ensure pin is positioned correctly.
Brazing pin not positioned correctly in
lug hole.
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EQUIPMENT MAINTENANCE & CARE
NOTICE
In addition to the Safety
Precautions in this manual,
observe the following for
equipment protection and
care.
• Check that the pin holder is not burnt or not holding the pin tightly. If not, remove the ring holder, clean all the
parts and squeeze the fingers of the pin holder together.
• Check the cables on the gun from time to time for damage. Replace as required.
• Check that the lift level is correct with lift level tool.
• Always store the tool in a clean dry space, safe from damage or pilferage.
• Always keep critical equipment markings, such as warning stickers and tags legible.
• Equipment repair should be performed by experienced personnel only.
• Do not use the equipment for applications for which it was not intended.
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SPECIFICATIONS
EP30200
Voltage...............................................................................................................................................................................................36V dc
Approximate Number of Brazings per Battery Charge........................................................................................................................40-60
Weight .....................................................................................................................................................................................44 lbs / 20 kg
Overall Length.................................................................................................................................................................. 12.5 in. / 315 mm
Overall Width.................................................................................................................................................................... 8.75 in. / 220 mm
Overall Height...................................................................................................................................................................... 16 in. / 400 mm
EP30250............................................................................................................................................................................... - This unit
does not have on-board batteries but is powered by an external welding machine (not included) capable of 250-300 amps at 80
volts. Otherwise this has the same functionality and uses the same accessories as our other EP30 units.
ACCESSORIES
35812...............................................................................................................................................................Carrying Case
58867.................................................................................................................................Transport Wagon, EPX 31, EP30
EP30010 (Includes Items Below)..................................................................................................... Pin Brazing Kit 110VAC
35866..............................................................................................................................................Battery Charger
40409.....................................................................................................................Battery, Genesis 16amp 12V (3)
72776..............................................................................................................................Nonspillable Battery Label
73358..........................................................................................................................................Carbide Burr SF-5
EP30200..........................................................................................................Medium Duty Elec. Pin Brazing Unit
BG10100.........................................................................................................................................Pin Brazing Gun
HGE12151......................Grinder, Elec. Cordless Kit (Includes: Grinder, Charger 120V & Battery Lithium-Ion 18V
EP30020 (Includes Items Blelow)..............................................................................................Pin Brazing Kit 110V/12VDC
73358...........................................................................................................................Carbide Burr (1/4 in. Shank)
35812.................................................................................................................................................Carrying Case
35818.........................................................................................................................Extension Cable for S4 Pistol
35819........................................................................................................................Extension Cable for Earth 5m
35866..............................................................................................................................................Battery Charger
40409................................................................................................................... Battery, Genesis 16amp 12V (3)
47320.............................................................................................................................Inverter 12VDC to 110VAC
72776............................................................................................................................. Nonspillable Battery Label
EP30200..........................................................................................................Medium Duty Elec. Pin Brazing Unit
BG10100.........................................................................................................................................Pin Brazing Gun
HGE12151......................Grinder, Elec. Cordless Kit (Includes: Grinder, Charger 120V & Battery Lithium-Ion 18V
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ACCESSORIES
BRAZING PINS & CERAMIC RINGS
STANDARD BRAZING PINS
Part No.
Description
Ceramic Ring Reqd
Brazing Pins are for
use on Rail Only
35835
35836
35837
35840
35841
35839
8 mm
8 mm w/ extra silver
9.5 mm
M8/12 Threaded
M10 Threaded
M12 Threaded
35832
35832
35833
35834
35834
35834
CERAMIC RINGS
Part No.
Description
35832
35833
35834
8 mm
9.5 mm
12 mm
PIN & RING HOLDERS
Part No.
Description
35826
35827
35828
35829
Pin Holder for Pinbrazing, 8-9,5 mm brazing pins.
Pin Holder for Pinbrazing, M8 Threaded pins.
Pin Holder for Pinbrazing, M10 Threaded pins.
Pin Holder for Pinbrazing, M12 Threaded pins.
35827 Pictured
35825
Extended pin and ring holder set for 8-9,5 mm brazing pins.
37945
35830
35831
Ring Holder, 8 mm pin & ringholder Set
Ring Holder, 8-9,5 mm ceramic rings.
Ring Holder, M8/M10/M12 mm ceramic rings.
35831 Pictured
CABLE LUGS (for Pin Brazing to rail)
Part No.
Description
Brazing Pin Reqd
47523
47524
47525
Braze Lug for 25 mm Cable
Braze Lug for 35 mm Cable
Braze Lug for 50 mm Cable
35836
35836
35836
47523 Pictured
39241 Pictured
39241
35847
35855
Cable Shoe #6
Cable Shoe 10 mm
Cable Shoe D=8 mm
2 x 35836
35835
35836
47526
47527
47528
47529
47522
Cable Lug for 16 mm Cable
Cable Lug for 25 mm Cable
Cable Lug for 35 mm Cable
Cable Lug for 50 mm Cable
Cable Lug 5/8" ground rod to #2 cable
35835
35836
35836
35836
47527 Pictured
2 x 35836
47521 Pictured
41625 Pictured
47521
41625
Braze Sleeve #6 to #6
35836
Multi-Wire Track Connection
2 x 35836
35865
67122
Clip for 18x5mm
Brazing Clip
(Secures Wire to Rail)
35835
35835
67122 Pictured
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ACCESSORIES
BONDING CABLE WITH LUGS (for Pin Brazing)
Part No.
35845
35844
39243
39244
37944
Description
Brazing Pin Reqd
35837
1 AWG / 50 mm², 185 mm long, copper
4 AWG / 25 mm², 145 mm long, copper
3/16 Bond, 300 mm long
25 mm², 200 mm long
35835
35835
35835
35836
35844 Pictured
50 mm², 185 mm long
39705
39706
39707
Bond Wire 16" OAL x 25 mm
Bond Wire 24" OAL x 25 mm
Bond Wire 36" OAL x 25 mm
35835
35835
35835
39242 Pictured
39242
3/16 Bond Crimpable Sleev
35835
40366
40091
40090
Signal Extension Bond 3/16" (170 mm)
Signal Extension Bond 150 mm L=430
Signal Extension Bond 2 x 35 mm - 2 x L=170
35835
35837
35836
40366 Pictured
41635 Pictured
41635
3/16 Signal Bond Wire W/Eye & Crimpable sleeve
24 inch long
3/16 x 7”/180 mm Long with Electrode & Ferrule
3/16 Bond 12’ Long Eyelet one end, AL block for
Tig Weld Other End
35835
35835
58563
41815
43686
43519
41225
Extension Bond CU, 25 mm², x 330 mm Long
3/16 Extension Bond 12"
Bond Wire 34" Long C/L-C/L W/9 mm eyelets on
both ends
35835
35835
35835
41226
Bond Wire 46" Long C/L-C/L W/9 mm eyelets on
both ends.
35835
66579
66580
66269
25mm2 x 500mm Extension Bond
25mm2 x 900mm Extension Bond
Signal Bond 3/16" x 6' Braze Lug Both Ends
35835
35835
35835
67634
Railbond 300 mcm L=330 mm Uninsulated
(4) 9.5 Pins Required
67634 Pictured
35837
73652
73016
Railbond 300 mcm L=430 mm Use with 4X Pins
Railbond 300 MCM
72988
72989
73016
67635
Railbond 3/16, 4 in. Reversed (50 pack)
Railbond 3/16, 6 in. Reversed (50 pack)
300MCM Rail Bond
Extension Bond 300 mcm x 200 mm crimp sleeve
(2) 9.5 Pins Required
35837
35836
67635 Pictured
47530
Bungalow Grounding Bond 3/16"
"T" CONNECTORS
(for Pin Brazing)
TYPE C
Part No.
Description
Brazing Pin Reqd
35857
Copper Plate with M8 x 18 Brass Threaded Stud
35835 x 2
35857 Pictured
TYPE D
Part No.
35860
35861
Description
Brazing Pin Reqd
Copper Plate with M16 x 26 Staniless Steel Threaded Stud
Copper Plate with M16 x 32 Stainless Steel Threaded Stud
35837 x 4
35837 x 4
35860 Pictured
18 ► EP30200 / EP30250 User Manual
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ACCESSORIES
Grinder Abrasives
Part No.
Description
73358
Carbide Burr (1/4 in. Shank)
35810
73052
Grinding Wheel “Note, Not for SAFEBONDING!”
Bull Nose Stone 2 inch (1/4 inch Shank)
Fuses, Chargers, & Batteries
Part No.
Description
56557 Pictured
56561 Pictured
56557
56558
56559
Fuse, PCB EP30/60
Fuse, Grinder Outlet EP30
Fuse, Control Cable EP30
56560
56561
56562
Auto Fuse, 5A EP60
Auto Fuse, 15A EP60
Auto Fuse, 30A EP60
35866
Charger 36 VDC 7 AMP EP30/60 W/ Special DC plug.
47320
41769
Inverter 12V DC-110VAC
Battery Charger for EP60 20A 36V DC PLG Continuous Use
40409
39434
Battery 16 AH 12 Volt EP30
Battery 30 AH EP60
40409 Pictured
EP30200 / EP30250 User Manual ◄ 19
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ACCESSORIES
CABLES
Part No.
Description
35809
35806
35820
35819
41768
62214
Ground Cable_____________________________________
Carrying Harness__________________________________
Extension Cable for Grinding_________________________
Extension Cable for Ground__________________________
Adapter, Charging__________________________________
Pigtail Charge Adapter_______________________________
66266
72999
35818
35816
35817
Ground Clamp Assembly (Vise Grip Style)________________________
Econect Ground Magnet (Magnetic ground for econect kit) (Not Pictured)
Extension Cable for S4 Brazing Gun (Not Pictured)
Standard Cable for S4 Pistol 2.7m/8.8ft (Not Pictured)
Long Cable for S4, 4.5m/14.75ft (Not Pictured)
GRINDER
Part No.
Qty
Description
HGE12141
HGE12151
HGE12161
Grinder Only (NO Battaery or Charger)
Includes: Grinder, Battery and Charger.
Includes: Grinder, Battery, Charger and Bull Nose Stone
Includes: Grinder, Battery, Charger and Bull Nose Stone & BNSF Stone.
HGE12161B
73399
73400
Battery 18V and Charger 120V
Battery Lithium 18V LI-ION
20 ► EP30200 / EP30250 User Manual
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ACCESSORIES
GUNS
Part No.
Description
BG10100
Pin Brazing Gun____________________________________
Angle Head Gun____________________________________
BG10101
Plugs
Part No.
Description
35823
65831
66696
66697
56556
Plug Male Grinder 4-Pin______________
Plug Male Controller Gun 3-Pin______________
Plug Male Power Supply Gun Cable__________________
Plug Male Ground Cable_________________________________
Carger/Generator Plug___________________________________________
Tools
Part No.
Description
37946
35824
62394
Hole Punch Tool 9.5mm
Hole Punch Tool 8.0mm
Lift Height Tool BG10100 Pin Braze Gun
EP30200 / EP30250 User Manual ◄ 21
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EP30 PARTS ILLUSTRATION
INTERNAL ELECTRONIC CONTROL BOX
34. Resistor & Circuit Board Unit
Assembled and precalibrated
25
26
25
26
A
07
20
26
25
04
21
26
25
31
06
26
25
05
25
22
16
25
31
15
28
27
33
25
28
29
30
03
24
29
23
23
30
19
14
30
A
29
30
29
11
24
16
13
01
15
11
32
10
08
02
12
18
09
32
14
17
22 ► EP30200 / EP30250 User Manual
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EP30 PARTS LIST
Item
01
02
03
04
Part No.
66838
66846
66839
66018
Qty
1
Description
FRAME EP30
LABEL EP30
CIRCUIT BOARD
RELAY
1
1
1
CIRCUIT BOARD MOUNTING
PLATE
05
66840
1
06
07
08
09
10
11
12
13
14
66841
66698
66843
66844
66694
66695
66691
65830
66847
1
1
1
1
1
1
1
1
2
RESISTOR MOUNTING PLATE
RESISTOR ASSY W/CABLE
YELLOW LED LENS
RED LED LENS
KNOB FOR ROTARY SWITCH
ROTARY SWITCH
GRINDER RECEPTACLE
GUN CONTROL RECEPTACLE
FUSE BRACKET 5x20
GUN POWER SUPPLY
RECEPTACLE
15
66692
1
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
66693
56558
56559
1
1
GROUND RECEPTACLE
FUSE FOR GRINDER 15A
FUSE 1A
1
2
STRAIN RELIEF BUSHINGS
SPACER
1
2
NUT M6
2
SHAKEPROOF WASHER M6
SCREW M6x10
SCREW M4x8
2
3
10
12
4
NUT M4
WASHER M4
SCREW M4x30
SPACER
4
8
WASHER M3
8
NUT M3
4
SCREW M3x6
4
SCREW M3x10
GLASS FUSE FOR PCB
56557
66845
1
RESISTOR & CIRCUIT BOARD
UNIT (As shown on previous page
outlined by black line).
34
1
1
1
EP30 ELECTRONIC BOX
Complete unit as shown on previ-
ous page.
66131
35801
Battery Box
EP30200 / EP30250 User Manual ◄ 23
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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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