hydraulic power unit

P110
HYDRAULIC
POWER UNIT
Safety, Operation and Maintenance
USER MANUAL
© Copyright 2012, ICS Blount, Inc.
ICS Blount, Inc.
4909 SE International Way
Portland, Oregon 97222
www.icsdiamondtools.com
NOTES
2 ► P110 User Manual
TABLE OF CONTENTS
SAFETY SYMBOLS...................................................................................................................................................4
SAFETY PRECAUTIONS...........................................................................................................................................5
TOOL STICKERS & TAGS.........................................................................................................................................6
HOSE REQUIREMENTS...........................................................................................................................................7
HTMA REQUIREMENTS............................................................................................................................................8
OPERATION...............................................................................................................................................................9
ROUTINE MAINTENANCE......................................................................................................................................13
PROGRAMMABLE CONTROLLER.........................................................................................................................14
FAULT CODES.........................................................................................................................................................15
TESTING & TROUBLESHOOTING.........................................................................................................................16
TROUBLESHOOTING.............................................................................................................................................17
SPECIFICATIONS....................................................................................................................................................18
BRIGGS ENGINE ASSEMBLY.................................................................................................................................19
BRIGGS ENGINE PARTS LIST...............................................................................................................................20
P110 FRAME PARTS LIST.......................................................................................................................................21
HOSE FITTINGS & CLAMPS LIST..........................................................................................................................22
P110 WIRING HARNESS.........................................................................................................................................23
LIMITED WARRANTY POLICY................................................................................................................................24
SERVICING THE ICS POWER UNIT: This manual contains safety, operation, and routine maintenance
instructions. ICS 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, visit our website,
www.icsdiamondtools.com or call 1-800-321-1240 and ask for a Customer Service
Representative.
P110 User Manual ◄ 3
SAFETY SYMBOLS
Safety 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
injury hazards. Obey all safety messages that follow this symbol to avoid
possible injury or death.
DANGER
This safety alert and signal word indicate an imminently hazardous situation
which, if not avoided, will 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
This safety alert and signal word indicate a potentially hazardous situation
which, if not avoided, may result in minor or moderate injury.
CAUTION
This signal word indicates a potentially hazardous situation which, if not
avoided, may result in property damage.
NOTICE
This signal word indicates a situation which, if not avoided, will result in
damage to the equipment.
IMPORTANT
This signal word indicates a situation which, if not avoided, may result in
damage 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
maintenance personnel.
4 ► P110 User Manual
SAFETY PRECAUTIONS
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
equipment.
•
Do not inspect hoses and fittings for leaks by using
bare hands. “Pin-hole” leaks can penetrate the
skin.
•
NEVER OPERATE THE POWER UNIT IN A
CLOSED SPACE. Inhalation of engine exhaust can
be fatal.
•
Do not operate a damaged, improperly adjusted
power unit.
•
Never wear loose clothing that can get entangled in
the working parts of the power unit.
•
Keep all parts of your body away from the working
parts of the power unit.
•
Keep clear of hot engine exhaust.
•
Do not add fuel to the power unit while the power
unit is running or is still hot.
•
Do not operate the power unit if gasoline odor is
present.
•
Do not use flammable solvents around the power
unit engine.
•
Do not operate the power unit within 3.3 ft/1 m of
buildings, obstructions or flammable objects.
•
Do not reverse tool rotation direction by changing
fluid flow direction.
Operator must start in a work area without
bystanders. The operator must be familiar with all
prohibited work areas such as excessive slopes
and dangerous terrain conditions.
•
Allow power unit engine to cool before storing in an
enclosed space.
•
Always keep critical tool markings, such as labels
and warning stickers legible.
•
Establish a training program for all operators to
ensure safe operation.
•
•
Do not operate the power unit unless thoroughly
trained or under the supervision of an instructor.
To avoid personal injury or equipment damage,
all tool repair, maintenance and service must only
be performed by authorized and properly trained
personnel.
•
Always wear safety equipment such as goggles,
ear, head protection, and safety shoes at all times
when operating the power unit and a hydraulic tool.
•
Do not inspect or clean the power unit while it is
running. Accidental engagement of the unit can
cause serious injury.
•
Always use hoses and fittings rated at 2500 psi/172
bar with a 4 to 1 safety factor. Be sure all hose
connections are tight.
•
Be sure all hoses are connected for correct flow
direction to and from the tool being used.
These safety precautions are given for your safety.
Review them carefully before operating the tool and
before performing general maintenance or repairs.
Supervising personnel should develop additional
precautions relating to the specific work area and local
safety regulations. If so, place the added precautions in
the space provided in this manual.
In addition to this manual, read and understand safety
and operating instructions in the Engine Operation
Manual furnished with the power unit.
The Hydraulic Power Unit 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
Power Unit. Failure to do so could result in personal
injury or equipment damage.
•
P110 User Manual ◄ 5
TOOL STICKERS & TAGS
ICS Dash Sticker
Single Circuit Sticker
ICS Dash Sticker
Single Circuit Sticker
6 ► P110 User Manual
HOSE REQUIREMENTS
Hydraulic hose types authorized for use with ICS are as follows:
Certified non-conductive — Hose labeled certified non-conductive is the only hose authorized for use
near electrical conductors.
Wire-braided (conductive) — This hose is conductive and must never be used near electrical conductors.
Fabric-braided (not certified or labeled non-conductive) — This hose is not certified non-conductive and
must never be used near electrical conductors.
HOSE PRESSURE RATING
The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the
hydraulic system.
P110 User Manual ◄ 7
HTMA REQUIREMENTS
TOOL CATEGORY
HYDRAULIC SYSTEM
REQUIREMENTS
TYPE I
TYPE II
TYPE III
TYPE RR
FLOW RATE
4–6 gpm
(15–23 lpm)
7–9 gpm
(26–34 lpm)
11–13 gpm
(42–49 lpm)
9–10.5 gpm
(34–40 lpm)
TOOL OPERATING PRESSURE
(At the power supply outlet)
2000 psi
(138 bar)
2000 psi
(138 bar)
2000 psi
(138 bar)
2000 psi
(138 bar)
SYSTEM RELIEF VALVE SETTING
(At the power supply outlet)
2100–2250 psi
(145–155 bar)
2100–2250 psi
(145–155 bar)
2100–2250 psi
(145–155 bar)
2200–2300 psi
(152–159 bar)
MAXIMUM BACK PRESSURE
(At tool end of the return hose)
250 psi
(17 bar)
250 psi
(17 bar)
250 psi
(17 bar)
250 psi
(17 bar)
Measured at a max. fluid viscosity of:
(At min. operating temperature)
400 ssu*
(82 centistokes)
400 ssu*
400 ssu*
400 ssu*
(82 centistokes) (82 centistokes) (82 centistokes)
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 difference of
between ambient and fluid temps
3 hp
(2.24 kW)
40 °F
(22 °C)
5 hp
(3.73 kW)
40 °F
(22 °C)
7 hp
(4.47 kW)
40 °F
(22 °C)
6 hp
(5.22 kW)
40 °F
(22 °C)
NOTE:
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
Min. full-flow filtration
Sized for flow of at least:
(For cold temp. start-up and max. dirt-holding
capacity)
25 microns
30 gpm
(114 lpm)
25 microns
30 gpm
(114 lpm)
25 microns
30 gpm
(114 lpm)
25 microns
30 gpm
(114 lpm)
HYDRAULIC FLUID
100–400 ssu*
100–400 ssu*
100–400 ssu*
100–400 ssu*
Petroleum based
(Premium grade, anti-wear, non-conductive)
VISCOSITY
(At min. and max. operating temps)
(20–82 centistokes)
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
NOTE:
These are general hydraulic system requirements. See tool Specification page for tool specific requirements.
8 ► P110 User Manual
OPERATION
PREPARATION FOR USE
Do not operate the power unit until you have read the
engine operating and maintenance instructions manual
furnished with the unit.
1. ENGINE CRANKCASE OIL LEVEL
Always check the oil level before starting the engine.
Make sure the oil level is at the FULL MARK on the
dipstick. Do not overfill. Use detergent oil classified
“For Service SE, SF, SG” as specified in the engine
operating and maintenance manual. See engine
manual for oil viscosity grade.
2. SPARK PLUG
On power units equipped with Briggs & Stratton
Engines, ONLY Champion RC12YC or equivalent can
be used.
Incorrect type spark plugs can produce radio frequency
interference that will corrupt and damage the controller.
Failure to use the correct spark plug could result in a
warranty that will not be considered.
3. ENGINE FUEL LEVEL
The following fluids work well over a wide temperature
range, allow moisture to settle out and resist biological
growth that may occur in cool operating hydraulic
circuits. These fluids are recommended by ICS. Other
fluids that meet or exceed the specifications of these
fluids may also be used.
•
•
•
•
•
•
•
•
Chevron AW-MV-32
Exxon “Univis” J-26
Mobil D.T.E. 13
Gulf “Harmony” AW-HVI-150-32
Shell “Tellus” T-32
Texaco “Rando” HD-AZ
Union “Unax” AW-WR-32
Terresolve EnviroLogic 132
5. HYDRAULIC CONNECTIONS
The recommended hose length is 25 ft/8 m with a
1/2 inch/12.7 mm inside diameter. The hoses must
have a working pressure rating of at least 2500
psi/175 bar. Each hose end must have male thread
ends compatible with HTMA (HYDRAULIC TOOL
MANUFACTURERS ASSOCIATION) quick disconnect
fittings (NPT type threads). (See Figure 2.)
Check the fuel level. If low, fill with unleaded gasoline
with a minimum of 85 octane.
4. HYDRAULIC FLUID
Check the dip stick in the hydraulic fluid reservoir for
the proper fluid level. Use fluids meeting the following
specifications.
VISCOSITY (FLUID THICKNESS)
U.S.
METRIC
50 °F 450 SSU Maximum
10 °C 95 C.S.
100 °F 130-200 SSU
38°C 27–42 C.S.
140 °F 85 SSU Minimum
60 °C 16.5 C.S. Min
Pour Point
-10 °F/-23 °C Minimum (for cold startup)
Viscosity Index (ASTM D-2220) 140 Minimum
Demulsibility (ASTM D-1401) 30 Minutes Maximum
Flash Point
(ASTM D-92) 340 °F/171 °C Minimum
Rust Inhibition (ASTM D-665 A & B) Pass
Oxidation (ASTM D-943) 1000 Hours Minimum
Pump Wear Test
(ASTM D-2882) 60 mg
Maximum
Figure 1. Control Panel
Facing the control panel, the bottom male quick
disconnect fitting is the PRESSURE FLUID OUT fitting.
The top female quick disconnect fitting is the RETURN
FLUID IN fitting (see Figure 1).
QUICK DISCONNECT COUPLERS
HTMA-approved quick disconnect couplings are
installed to hydraulic hoses so that the direction of
oil flow is always from the male to the female quick
disconnect as shown in Figure 2. Quick disconnect
couplings and hose fittings are selected so that
additional fittings such as reducer or adapter fittings are
not required.
P110 User Manual ◄ 9
OPERATION
If adapter fittings are used, they must be approved
steel hydraulic fittings meeting a minimum operating
pressure rating of 2500 psi/172 bar. Do not use
galvanized pipe fittings or black pipe fittings.
Use thread tape or pipe joint compound when installing
quick disconnect couplings to hose or tool fittings.
Follow the instructions furnished with the selected
thread sealant. DO NOT OVERTIGHTEN THE
FITTINGS.
CONTROL PANEL
PRESSURE
RETURN
HTMA 1/2 INCH FEMALE
QUICK DISCONNECT
COUPLER
6. BATTERY
The supplied 12-Volt DC battery is a non-spillable,
maintenance-free battery and is fully charged.
Make sure the battery cables are tight and charging
circuit functions are operating properly.
HTMA 1/2 INCH MALE
QUICK DISCONNECT
COUPLER
1/2 INCH MALE PIPE HOSE END
NOTICE
1/2 INCH I.D. HOSE, 25 FT
LONG WITH 2500 PSI/
172 BAR RATING AND
4 TO 1 SAFETY FACTOR
Do not charge the battery with a standard automotive
battery charger. This type of charger produces a
charging amperage higher than 2 amps. Charging
the battery at higher than 2 amps will damage the
battery.
RETURN
PRESSURE
NOTICE
If the engine runs out of gas or dies during operation
and the ignition switch is left in the ON or RUN
position, this could drain the battery. Make sure the
ignition switch is returned to the OFF position.
1/2 INCH MALE PIPE HOSE END
HTMA 1/2 INCH FEMALE
QUICK DISCONNECT
COUPLER
HTMA 1/2 INCH MALE
QUICK DISCONNECT
COUPLER
ADAPTER, 3/8 INCH MALE PIPE
× -8 SAE O-RING
RETURN
PRESSURE
TOOL
Figure 2. Hydraulic Connections
10 ► P110 User Manual
OPERATION
Controls
This unit is equipped with an advanced proportional engine control system. It provides a means
of controlling engine speed by adjusting the fuel
control lever with an actuator. The Power Unit
provides one circuit, with an oil flow of 8 gpm/30
lpm up to 2000 psi/140 bar or 12 gpm/45 lpm up
to 2000 psi/140 bar with a factory-programmed
electronic governed engine throttle.
THROTTLE CONTROL
SWITCH
NOTE:
It may be necessary to reset the Controller.
At times it may be necessary to reset the controller.
This could happen if a fault occurs in the controller. For
example, excessive engine speed. If a fault does occur
the power unit will return to an idle and the operator
will have no control of the unit. To reset the controller,
simply turn off the power unit and restart it.
STARTUP
Before starting the engine make sure the flow selector
switch is in the OFF position.
NOTE:
The power unit will not start if the flow control
switch is not in the “OFF” position.
IGNITION
SWITCH
FLOW SELECTOR SWITCH
Figure 3. Control Panel
One hydraulic tool can be connected to the tool circuit.
The circuit is activated by turning the flow control switch
to either the 8 gpm/30 lpm or 12 gpm/45 lpm setting.
Pull choke knob out and move the Throttle Control
Switch to the auto-idle-off or the auto-idle-on position,
whichever mode of operation the operator prefers.
Ensure the flow selector switch is in the OFF position.
Turn the Ignition Switch to the START position. After
the engine starts, release the switch.
Gradually push in the choke knob as the engine begins
to idle smoothly.
THROTTLE CONTROL
Allow the engine to warm up.
The throttle control permits the operator to select one
of 2 operating modes after the engine has warmed up.
When starting the engine, make sure the flow selector
switch is in the OFF position. The throttle control switch
can be set in either the AUTO-IDLE-ON or AUTO-IDLEOFF positions.
FOR 8 GPM OPERATION
AUTO-ON
When the throttle control switch is in the “AUTO-ON”
position, the oil flow is regulated automatically when
the trigger on the tool is activated. When the tool is not
being used the engine will return to idle automatically,
after a 10 second delay.
This setting will produce 8 gpm/30 lpm or 12 gpm/45
lpm depending on which position the operator has
selected with the flow selector switch.
AUTO-OFF
When the throttle control switch is in the “AUTO-OFF”
position, the engine speed is held to maintain 8 gpm/30
lpm or 12 gpm/45 lpm depending on which position
the operator has selected with the flow selector switch.
When a tool is not being used the engine will not return
to idle until either the flow selector switch is turned to
the OFF position or the throttle control switch is turned
to AUTO-ON.
Connect hoses and the tool as described on pages 9
and 10.
For 8 gpm operation, select mode of operation with the
Throttle Control switch, either auto-idle-on or the autoidle-off position. Move the flow selector switch to the 8
gpm position.
When finished operating the tool, move the flow
selector switch to the OFF position.
FOR 12 GPM OPERATION
For 12 gpm operation, select mode of operation with
the Throttle Control Switch, either auto-idle-on or the
auto-idle-off position. Move the flow selector switch to
the 12 gpm position.
When finished operating the tool, move the flow
selector switch to the OFF position.
P110 User Manual ◄ 11
OPERATION
COLD WEATHER STARTUP
1. Use the procedures described under “STARTUP”
and then follow the procedure below.
2. Hydraulic fluids are thicker in cold weather.
Therefore, it is recommended that the engine
be run at low idle long enough to bring the fluid
temperature up to a minimum of 50 °F/10 °C.
3. If the tools and tool hoses are cold, it is
recommended to allow hydraulic fluid to circulate
through the tool hoses until warm before using the
tool.
SHUTDOWN
1. Ensure the flow selector switch in the OFF position
(center position).
2. Unless already at idle the power unit should return
to idle. This may take a few seconds for the unit to
react due to a built-in program delay.
3. Allow the engine to idle for approximately one
minute and move the Ignition Switch to the OFF
position.
12 ► P110 User Manual
ROUTINE MAINTENANCE
ENGINE MAINTENANCE
STORAGE
Follow the maintenance schedule and general
maintenance instructions in the engine maintenance
and operation manual furnished with the power unit.
•
Clean the unit thoroughly before storage. Do not
use water pressure.
HYDRAULIC SYSTEM MAINTENANCE
•
Always store the unit in a clean and dry facility.
•
If the unit will be stored for a prolonged period
(over 30 days), add a fuel additive to the fuel tank
to prevent the fuel from gumming. Run engine for a
short period to circulate the additive.
•
Replace crankcase oil with new oil.
•
Remove spark plugs and pour approximately 1
ounce (30 ml) of engine oil into each cylinder.
Replace spark plugs and crank the engine slowly to
distribute the oil.
•
Check hydraulic reservoir for water. If water is
found, change the oil and circulate it through the
tool hose and tool. (See “HYDRAULIC SYSTEM
MAINTENANCE” earlier in this section).
•
Disconnect tool hoses.
•
•
•
Check hydraulic fluid level daily. Add fluid per
specifications in this manual. (See “HYDRAULIC
FLUID” under the section titled “OPERATING
INSTRUCTIONS”.
Remove condensed moisture from the hydraulic
fluid by pumping the hydraulic fluid into a 5 gal/20 l
container through the pressure hose. Make
sure the engine is at idle when performing this
procedure. When the hydraulic reservoir is empty
turn the engine off immediately.
Allow the fluid to sit long enough for the water to
settle to the bottom of the container. Slowly pour
the fluid back into the hydraulic tank, avoiding the
water at the bottom of the container.
•
Each day, check hydraulic lines and fittings for
leaks, kinks, etc. Do not use your hand to perform
this check.
•
Change the hydraulic filter element every 200
hours of operation. Change more often if cold,
moist or dusty conditions exist.
•
Check oil cooler for debris. Remove debris with air
pressure.
SPARK PLUG
On power units equipped with Briggs & Stratton
Engines, ONLY Champion RC12YC or equivalent can
be used.
Incorrect type spark plugs can produce radio frequency
interference that will corrupt and damage the controller.
Failure to use the correct spark plug could result in a
warranty that will not be considered.
P110 User Manual ◄ 13
PROGRAMMABLE CONTROLLER
The ICS programmable controller is an electronic
engine governor that provides a means of controlling
and limiting engine speed by adjusting the fuel control
lever with a proportional actuator.
The controller is factory programmable and has no
manual adjustments.
1. Disconnect red and green wires from the control
module to actuator.
2. Attach jumper wires from battery to RED and
GREEN wires to actuator.
a. Attach 12 volt + (positive) to RED wire.
b. Attach 12 volt – (negative) to GREEN wire.
3. Actuator should move throttle lever to wide open
position.
a. If actuator does not move it is defective.
(Replace).
A flashing LED indicates
the fault condition
b. If actuator moves throttle to wide-open position,
the module is defective. (Replace). Note:
Before replacing the actuator, verify signal
inputs to module (see ICS Electrical Trouble
shooting guide “TechHELP # 032807). Contact
a customer service representative.
FAULT CODES
CALIBRATION
Calibration and programming can only be done by the
factory.
TROUBLESHOOTING GUIDELINES
The ICS controller is capable of identifying certain fault
conditions and alerting the user to them. A flashing LED
indicates the fault conditions. The current fault code
list is shown on the following page. Please note the
following:
Please follow the checklist below to troubleshoot your
ICS controller.
1. When power is first applied to the controller, the
LED will flash just once for one second to indicate
that the LED is working.
1. Check battery voltage for stability and correct
value. The LED will turn on for one second when
the controller is first powered up.
2. If there are multiple faults, the LED will flash them
all in sequence. Count the flash codes to determine
the fault conditions.
2. Check the actuator linkage for binding and
backlash.
3. If there are no faults, the LED will flash once at
reset and from then on indicate the detection of
engine speed. A continuous ON LED indicates that
a valid engine speed is being sensed.
CHECKING PERFORMANCE CONTROL
(ELECTRONIC GOVERNOR-STATIC
CHECK)
To determine whether a governor problem is being
caused by the actuator or the control module, perform
the following static check exactly in order shown.
A pair of jumper wires and a known good 12-volt
battery is required.
14 ► P110 User Manual
4. The controller will attempt to shut down for some
faults and will not permit starting after reset with
faults 1, 5 and 8.
FAULT CODES
Flash
Code
Fault
Engine
Shutdown
Corrective Action
1
Unit not calibrated
Yes
Have engine serviced by an Authorized Service Center.
2
Engine speed excessive
Yes
Have engine serviced by an Authorized Service Center.
3
Engine speed unusually low
Yes
Have engine serviced by an Authorized Service Center.
4
Engine shutdown due to
engine protection input
Yes
Have engine serviced by an Authorized Service Center.
5
Factory settings lost
Yes
Have engine serviced by an Authorized Service Center.
6
External pot out-of-range
No
Have engine serviced by an Authorized Service Center.
7
Accelerator position/idle
switch conflict
No
Have engine serviced by an Authorized Service Center.
8
Controller unit failed
Yes
Have engine serviced by an Authorized Service Center.
9
Limiting excessive actuator
current
No
Have engine serviced by an Authorized Service Center.
10
Engine speed input signal
missing
No
(Active only in Auto crank mode). Check speed sensor
wiring. Check starter motor.
11
Auto crank unable to start
engine
No
Check fuel.
12
Auxiliary output is shorted
No
Check the lamp or relay hooked to the output. If fault
is still present, have engine serviced by an authorized
Service Center.
13
Auxiliary output #2 is shorted
No
Check the lamp or relay hooked to the output. If fault
is still present, have engine serviced by an authorized
Service Center.
14
Actuator disconnected or
open circuit
No
Check actuator wiring and actuator resistance.
Resistance should be less than 10 ohms.
P110 User Manual ◄ 15
TESTING & TROUBLESHOOTING
GENERAL
Tests and adjustments should be performed
periodically to ensure the power unit is operating
at maximum efficiency. Use a calibrated flow and
pressure tester. This tester can be used to isolate
problems in both the engine and hydraulic system prior
to any power unit disassembly.
TESTING THE HYDRAULIC CIRCUIT
The following tests can be performed to ensure that
the hydraulic pump is supplying the correct flow and
pressure and that the system relief valve is operating
properly.
During these tests, make sure the engine is warm and
operating smoothly. If test results are not as specified,
refer to the troubleshooting table in this section for
possible causes.
TESTING THE 8 GPM HTMA TYPE II
CIRCUIT OR THE 12 GPM TYPE III CIRCUIT
To test the circuit, proceed as follows:
1. Set the flow selector switch to the OFF (center)
position.
2. Set the throttle control switch to AUTO-OFF
position.
3. Use a calibrated flow and pressure tester across
two hose ends (where the tool would normally be
connected).
4. Fully open the tester restrictor valve
(counterclockwise).
5. Start the engine and allow it to run until warm.
6. Switch the flow selector switch to 8 or 12 gpm
depending on which flow you are testing.
7. With the engine at the programed speed, the test
flow gauge should read 7-9 gpm/26.5-34 lpm or 1113 gpm/41.6-49 lpm.
8. Slowly turn the restrictor valve clockwise while
watching the pressure gauge. The flow rate should
stay at 7-9 gpm/26.5-34 lpm or 11-13 gpm/41.6-49
lpm as the pressure gauge reaches 2100-2200
psi/148-155 bar.
16 ► P110 User Manual
9. At 2100–2200 psi/148–155 bar, the relief valve
should begin to open. The pressure at which
the relief valve just begins to open is commonly
referred to as the “cracking pressure”. At the
“cracking pressure,” the flow rate should start to
drop because the relief valve is allowing fluid to
bypass to the hydraulic reservoir. The “cracking
pressure” is preset at the factory and if it is not
within the above range, the relief valve must be reset as follows:
a. The relief valve is located on the right side of
the unit just behind the dash panel. It protrudes
out from the manifold assembly. Use a open
end or box end wrench to loosen the nut on the
relief valve.
b. Use an Allen wrench to adjust the relief valve.
Turn clockwise to raise the pressure and
counterclockwise to reduce the pressure.
c. Tighten the nut and retest.
TROUBLESHOOTING
Problem
Cause
Solution
Flow selector switch not in the OFF
position.
Make sure the flow selector switch
is in the OFF position when starting.
Battery not connected.
Attach battery cables, check wires.
Weak battery.
Test battery, charge or replace.
No fuel.
Add fuel.
Fuel filter plugged.
Replace fuel filter.
Defective spark plugs.
Remove plugs, check gap, clean or
replace.
Fluid blowing out of fluid reservoir
vent.
Hydraulic tank overfilled.
Correct the fluid level.
Pump suction leak.
Check suction connections. Tighten
if necessary.
Hydraulic tool won’t operate.
Flow selector switch not switched
ON.
Check that the flow selector switch
is set to 8 or 12 gpm.
Incorrect hose connection to tool.
Make sure the tool hose circuit
goes from left (pressure) fitting to
tool and back to the right fitting
(return). Fluid always flows from the
male to female fittings.
Quick disconnect fittings defective.
Detach from hose, connect set
together and check for free flow.
Hydraulic fluid level low.
Check for correct fluid level. Fill
using the recommended fluid.
Pump coupling defective.
With the engine not running: Check
the coupling between the pump and
engine that it is engaged and is not
damaged. Caution: Keep hands
clear of rotating objects.
Relief valve stuck open.
Adjust or replace valve.
Suction hose kinked.
Make sure suction hose from
fluid reservoir to pump inlet has a
smooth curve.
Solenoid not working.
Check solenoid operation and
electrical connections.
Tool is defective.
Refer to tool manual.
Engine will not start.
P110 User Manual ◄ 17
SPECIFICATIONS
Engine:.....................................................................................................................................................23 hp Briggs
Capacity.............................................................................. One 8 gpm/30 lpm Circuit or One 12 gpm/45 lpm Circuit
Length:.................................................................................................................................................. 36 in./91.4 cm
Width:.................................................................................................................................................... 23 in./58.4 cm
Height:................................................................................................................................................. 29.5 in./74.9cm
Weight (Wet): Single Circuit Briggs....................................................................................................330 lbs/149.6 kg
Fuel Tank Capacity:................................................................................................................................. 6 gal./22.7 ltr
Estimated Gas Consumption Per Hour...................................................................................................... 1.3 gal/4 ltr
Hydraulic Reservor Capacity:..................................................................................................................... 3 gal./11 ltr
Relief Valve “Crack” Ssetting............................................................................................................. 2100 psi/145 bar
Full Relief Setting.............................................................................................................................. 2500 psi/172 bar
HTMA Category
18 ► P110 User Manual
...........................................“D” (30 lpm @ 138 bar) or “E” (45 lpm @ 138 bar)
2
40
46
41
54
3
44
39
Positive Battery
Cable P/N-35395
7
46
1
35
PART OF
ENGINE ASSY
36
44
Ground Battery
Cable P/N-62332
34
24
28
5
51
38
72
64
37
37
79
52
77
63
80
78
68
78
53
73
62
8
61
75
20
FUEL VAPOR HOSE
FROM FUEL TANK TO
ENGINE
21
CONNECT TO FUEL
VAPOR HOSE ON
ENGINE
FUEL LINE
71
79
6
53
55
81
TO ENGINE
THROTTLE LINKAGE
74
4
30
50
76
9
57
45
11
58
43
46
12
13
30
26
47
14
30
33
31
28
16
15
27
17
32
56
41
48
49
42
TO OIL FILTER ON
SIDE OF ENGINE
29
18
28
40
23
22
69
25
70
60
66
19
67
65
66
PART OF
ENGINE ASSY
70
BRIGGS ENGINE ASSEMBLY
P110 User Manual ◄ 19
BRIGGS ENGINE PARTS LIST
ITEM
QTY
DESCRIPTION
ITEM
QTY
DESCRIPTION
1
P/N
1
MUFFLER
45
2
FOOT
1A
1
SPARK ARRESTER
46
4
FLANG NUT, 3/8-16
2
1
HEAT SHIELD
47
4
HEX FLANGE BOLT, 3/8-16
3
2
SCREW, HEX WASHER
48
2
RETAINING RING
4
1
BRIGGS ENGINE
49
2
WASHER, 3/4
5
1
COUPLING
50
1
BLOWER HOUSING
6
1
SQUARE KEY
51
1
PUMP MOUNT
7
2
CAPSCREW, 3/8-16 × 1-1/4
52
1
FUEL ELBOW
8
1
PRESSURE SWITCH
53
2
STUD
9
4
FLANGE NUT
54
1
NUT
10
1
CLAMP
55
1
HEAT SHIELD
11
1
BUSHING
56
2
HEX WASHER HEAD SCREWS
12
1
KEY
57
1
SCREW
13
1
BLOWER HUB
58
1
CABLE CLAMP
14
3
CAPSCREW
59
1
RECTIFIER WIRE
15
1
FILTER ASSY
60
1
THROTTLE LEVER
16
2
CAPSCREW
61
2
HEX FLANGE BOLT
17
1
GRIP PLATE
62
1
ANGLE BRACKET WELDMENT
18
1
STD THREAD UNION
63
1
ROTARY ACTUATOR
19
4
BUTTON HEAD HS
64
1
ACTUATOR BRACKET
20
2
WASHER, 1/4 IN. ID
66
1
WIRE ASSEMBLY
21
2
CAPSCREW, 1/2 -20 UNC
67
4
HEX HD CAPSCREW 6-32
22
1
FRONT GRILLE
69
1
HEX HD CAPSCREW 8-32
23
1
COOLER
70
1
LINK RETAINER
24
2
CAPSCREW, 3/8
71
3
SPRING HOSE CLAMP
25
1
HYDRAULIC TANK
72
1
FUEL VAPOR HOSE
26
2
WEATHER STRIP
73
1
BARB
27
1
BLOWER WHEEL
74
1
EMISSIONS STICKER
28
4
HEX FLANGE BOLT, 1/4 -20
75
2
SPRING HOSE CLAMP
29
1
ENGINE CONTROLLER
76
1
HOSE (FUEL)
30
9
HEX FLANGE BOLT 5/16-18 × 1/2
77
1
FUEL LINE
31
1
FRAME BASE WELDMENT
78
2
SPRING HOSE CLAMP
32
2
WHEEL & TIRE
79
2
SPRING HOSE CLAMP
33
1
AXLE
80
1
FUEL VAPOR HOSE
34
1
PUMP, SINGLE
81
1
EMISSIONS STICKER
35
1
FUEL CAP
36
1
GROMMET
37
1
FUEL TANK
38
1
BATTERY
39
1
BATTERY COVER
40
1
CAPSCREW, 1/4-20 × 3/4
41
1
HEX FLANGE BOLT
42
2
HANDLE BUMPER
43
3
HEX FLANGE BOLT, 5/16 × 1-3/4
44
4
LOCKWASHER, 3/8
20 ► P110 User Manual
P/N
P110 FRAME PARTS LIST
9
21
20
18
2
1
10
28
11
8
16
31
13
29
27
1
30
23
15
7
17
26
2
19
24
1
23
2
12
14
2
6
2
1
5
4
1
32
3
ITEM
P/N
QTY
DESCRIPTION
ITEM
1
7
CAPSCREW, 5/16 IN. -18 UNC
2
7
NYLOCK NUT, 5/16 IN. -18 UNC
3
1
4
1
5
6
P/N
QTY
DESCRIPTION
17
2
HEX FLANGE BOLT, 3/8 IN. -16
18
1
HANDLE LOCK
HANDLE, REAR LIFT
19
2
LIFT HANDLE
COUPLER, MALE 3/8 IN., -8 SAE
20
1
COOLER GUARD
1
COUPLER, FEMALE 3/8 IN., -8 SAE
21
2
FLANGE NUT, 1/4 IN. -20
2
CAPSCREW, 1/4 IN. -20
22
7
1
MANIFOLD ASSY, SINGLE CIRCUIT
23
2
HOLLOW HEX PLUG 6 SAE
8
1
DASH DECAL
24
1
RELIEF VALVE
9
6
HEX FLANGE BOLT, 1/4 IN. -20
25
-
NO ITEM
10
1
DECAL, SINGLE CIRCUIT
26
1
PRESSURE SWITCH ASSY
11
1
KNOB (PART OF ITEM 13)
27
1
DIRECTIONAL VALVE
12
1
2-WAY SWITCH
28
1
CAP (INCLUDED WITH ITEM 27)
13
1
ROTARY SWITCH
29
1
COIL
14
1
3-WAY SWITCH
30
1
STICKER, CE
15
1
HOUR METER
31
1
STICKER, SOUND POWER LEVEL
16
1
FRAME WELDMENT
32
1
CHOKE CABLE ASSY
NO ITEM
P110 User Manual ◄ 21
HOSE FITTINGS & CLAMPS LIST
1
7
2
8
9
4
3
5
3
6
10
3
11
3
12
ITEM
P/N
QTY
DESCRIPTION
1
1
MANIFOLD ASSY, SINGLE CIRCUIT
2
1
HOSE BARB, 3/4 IN. HOSE × 3/4 IN. PIPE
3
4
HOSE CLAMP
4
1
ELBOW, 45° STRAIGHT THREAD
5
1
ADAPTER
6
1
ELBOW, 90°
7
1
HOSE
8
1
CONNECTOR, STRAIGHT THREAD
9
1
ELBOW, 45°
10
1
HOSE
11
1
HOSE
12
1
HOSE BARB, 3/4 IN. HOSE × 3/4 IN. PIPE
22 ► P110 User Manual
P110 WIRING HARNESS
THROTTLE CONTROL SWITCH
(NOTE: PLUG BEHIND SWITCH WITH
BLUE & YELLOW WIRES GOES TO SWITCH ON TOP)
FLOW CONTROL
SWITCH
DIRECTIONAL VALVE
HOUR METER
START
SWITCH
MANIFOLD ASSY
BLACK
RED
PRESSURE SWITCH
TO STARTER SOLENOID
PLUG TOP RESSURE SWITCH
RELAY-62301
SUPPLIED W/62293 HARNESS
+
POSITIVE BATTERY CABLE TO
STARTER SOLENOID
-STARTER SOLENOID
GREEN
ERY
BATT
GROUND WIRES
ENGINE KILL
BLACK
TO ACTUATOR
RED/GREEN
RECTIFIER WIRE
WHITE
TO MAGNETO WIRE ON ENGINE
GRAY WIRE
OIL PRESSURE
SWITCH
FUEL SHUTOFF
RED WIRE
RED WIRE (P TERMINAL)
CONTROLLER
ORANGE WIRE (S TERMINAL)
YELLOW WIRE (I TERMINAL)
ENGINE OIL PRESS SWITCH
WIRING DETAIL
P110 User Manual ◄ 23
LIMITED WARRANTY POLICY
This limited warranty is offered for 90 days (30 days if product is used in rental) from date of original purchase on
ICS® manufactured parts. Components not manufactured by ICS® will be covered for the period and according
to the provisions of each manufacturer’s warranty. During the warranty period, ICS® will replace or, at its option,
repair for the original purchaser only, free of charge, any product or part manufactured by ICS® which is found upon
examination by ICS® to be defective in material and/or workmanship. The purchaser shall be responsible for all
transportation charges and any cost of removing any part submitted for replacement under this warranty. This warranty does not cover any failure caused by accident, abuse, misuse, improper maintenance, normal wear, neglect,
damage caused by stale or improper fuel mix or operation under conditions not specified by ICS®. There are no
other warranties expressed or implied. There is no implied warranty of merchantability and no implied warranty of
fitness for a particular purpose. Replacement or repair is the exclusive remedy, and ICS® disclaims all liability for
incidental and consequential damages of any kind.
POWER UNITS & GAS/FUEL DRIVEN EQUIPMENT: A1. Federal Emission Component Compliance 40CFR part
1060.120 ICS warrants all fuel system emission components for 2 years from the date of original purchase provided
there has been no abuse, neglect, modifications, or improper maintenance.
Components covered. The emission-related warranty covers all components whose failure would increase the
evaporative emissions. Your emission related warranty does not cover components whose failure would not increase evaporative emissions. Coverage under this warranty extends only to the following parts; fuel tank, fuel cap,
fuel hose and vapor hose from the fuel tank to the engine and any connectors that are apart of the fuel system.
The equipment is designed, built, and equipped so it conforms at the time of sale to the ultimate purchaser and each
subsequent purchaser and is in compliance with 40 C.F.R. 1060.120 standards. The equipment is free from defects
in materials and workmanship that may keep it from meeting these requirements.
24 ► P110 User Manual
ICS, Blount Inc.
4909 SE International Way
Portland, Oregon 97222
www.icsdiamondtools.com
Part Number 69403