ICS P95 User manual
F/N 521599 Oct 07 © 2007 ICS, Blount Inc.
OPERATOR’S MANUAL
P95
MultiFlow Hydraulic Powerpack
F/N 521599 Oct 07 © 2007 ICS, Blount Inc.
P95 OPERATOR’S MANUAL
3
TABLE OF CONTENTS
SYMBOLS & LABELS 4
SAFETY 5
TECHNICAL SPECIFICATIONS 6
LABELS 7
REQUIREMENTS 8
OPER ATION 10
MAINTENANCE 15
CONTROLLER / FAULT CODES 16
TESTING 18
TROUBLESHOOTING 19
© 2007 ICS, Blount Inc. F/N 521599 Oct 07
P95 OPERATOR’S MANUAL
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SYMBOLS & LABELS
THE FOLLOWING SYMBOLS & DEFINITIONS ARE FOUND THROUGHOUT THIS MANUAL AND
ARE DESIGNED TO MAKE YOU AWARE OF POTENTIAL HAZARDS OR UNSAFE PRACTICES.
A potentially hazardous situation exists which, if not avoided,
could result in death or serious injury.
A potentially hazardous situation exists which, if not avoided,
may result in minor or moderate injury or property damage.
A potential situation exists which, if not avoided, may result in
product or property damage.
THE FOLLOWING SYMBOLS & LABELS MAY BE FOUND IN THIS MANUAL OR ON THE SAW
Read the operator’s manual carefully and understand the
contents before you use this equipment.
Always use:
• Protective helmet
• Ear protection
• Protective glasses or full face protection
Wear hand protection
IMPORTANT
WARNING
CAUTION
F/N 521599 Oct 07 © 2007 ICS, Blount Inc.
P95 OPERATOR’S MANUAL
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SAFETY
GENERAL SAFETY PRECAUTIONS
• 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.
• 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.
• 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.
• Alwaysusehosesandfittingsratedat2500psi(172bar)witha4to1safetyfactor.Besureallhoseconnections
are tight.
• Besureallhosesareconnectedforcorrectflowdirectiontoandfromthetoolbeingused.
• Donotinspecthosesandfittingsforleaksbyusingbarehands.“Pin-hole”leakscanpenetratetheskin.
• NEVEROPERATETHEPOWERUNITINACLOSEDSPACE.Inhalationofengineexhaustcanbefatal.
• 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.
• Donotuseflammablesolventsaroundthepowerunitengine.
• Donotoperatethepowerunitwithin3.3ft(1m)ofbuildings,obstructionsorflammableobjects.
• Donotreversetoolrotationdirectionbychangingfluidflowdirection.
• Allow power unit engine to cool before storing in an enclosed space.
• Always keep critical tool markings, such as labels and warning stickers legible.
• To avoid personal injury or equipment damage, all tool repair, maintenance and service must only be performed by
authorized and properly trained personnel.
© 2007 ICS, Blount Inc. F/N 521599 Oct 07
P95 OPERATOR’S MANUAL
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TECHNICAL SPECIFICATIONS
Engine 18 hp Briggs
Capacity One5gpm(19l/min)Circuit
One8gpm(30l/min)Circuit
Length 36inches(91.4cm)
Width 23inches(58.4cm)
Height 29.5inches(74.9cm)
Weight(wet) 330lbs(149.6kg)
Fuel Tank Capacity 7gal(26.5ltr)
Esitmated Gas Consumption
perHour 1.3gal(4ltr)
HydraulicReservor
Capacity 3gal(11ltr)
Releif Valve "crack"
Setting 2,100psi(145bar)
Full Relief Setting 2,500psi(172bar)
HTMACategory "C"(20l/min@138bar)
"D"(30l/min@138bar)
SoundPowerLevel 104 dBA
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P95 OPERATOR’S MANUAL
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LABELS
TOOLS STICKERS AND TAGS
ICS®Dash Decal
Single Curcuit
Single Curcuit
© 2007 ICS, Blount Inc. F/N 521599 Oct 07
P95 OPERATOR’S MANUAL
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REQUIREMENTS
HYDRAULIC HOSE REQUIREMENTS
HydraulichosetypesauthorizedforusewiththeP95areasfollows:
• Certifiednon-conductive
• Wire-braided(conductive)
• Fabric-braided(notcertifiedorlabelednon-conductive)
Hoselistedaboveistheonlyhoseauthorizedforusenearelectricalconductors.
Hoseandlistedaboveareconductiveandmustneverbeusednearelectricalconductors.
HOSE SAFETY TAGS
To help ensure your safety, the following DANGER tags are attached to all hoses purchased from ICS.
DONOTREMOVETHESETAGS
If the information on the tag is illegible because of wear or damage, replace the tag immediately. A new tag maybe
obtained from your ICS Distributor.
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
THE TAG SHOWN BELOW IS ATTACHED TO "CERTIFIED NON-CONDUCTIVE" HOSE
THE TAG SHOWN BELOW IS ATTACHED TO "CONDUCTIVE" HOSE
DO NOT REMOVE THIS TAG
DANGER
SIDE 2
3. DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE. IMPROPER
USE OR HANDLING OF HOSE COULD RESULT OR OTHER HOSE FAILURE. KEEP
HOSE AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT
CONTACT DURING HOSE. CONTACT AT THE BURST CAN CAUSE BODILY
INJECTION AND SEVERE PERSONAL INJURY.
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.
5. CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS, 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.
6. AFTER EACH USE, STORE IN A CLEAN DRY AREA.
DANGER
SIDE 1
DO NOT REMOVE THIS TAG
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.
2. FOR PROPER AND SAFE OPERATION, MAKE SURE THAT YOU HAVE BEEN
PROPERLY TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK IN OR
AROUND ELECTRICAL LINES.
3. BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS
NON-CONDUCTIVE ON OR NEAR ELECTRICAL LINES, WIPE THE ENTIRE LENGTH
OF THE HOSE AND FITTING WITH A CLEAN DRYABSORBENT CLOTH TO REMOVE
DIRT AND MOISTURE AND TEST HOSE FOR MAXIMUM ALLOWABLE CURRENT
LEAKAGE IN ACCORDANCE WITH SAFETY DEPARTMENT INSTRUCTIONS.
DO NOT REMOVE THIS TAG
DANGER
SIDE 2
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.
5. CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS, 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.
6. AFTER EACH USE, STORE IN A CLEAN DRY AREA.
DANGER
SIDE 1
DO NOT REMOVE THIS TAG
1. THIS HOSE NOT LABELED OR CERTIFIED AS NON-CONDUCTIVE WHEN USING
HYDRAULIC TOOLS ON OR NEAR ELECTRIC LINES MAY RESULT IN DEATH OR
SERIOUS INJURY.
2. FOR PROPER AND SAFE OPERATION, MAKE SURE THAT YOU HAVE BEEN
PROPERLY TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK IN OR
AROUND ELECTRICAL LINES.
3. DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE. IMPROPER
USE OR HANDLING OF HOSE COULD RESULT OR OTHER HOSE FAILURE. KEEP
HOSE AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT
CONTACT DURING HOSE. CONTACT AT THE BURST CAN CAUSE BODILY
INJECTION AND SEVERE PERSONAL INJURY.
DO NOT REMOVE THIS TAG
DANGER
SIDE 2
3. DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE. IMPROPER
USE OR HANDLING OF HOSE COULD RESULT OR OTHER HOSE FAILURE. KEEP
HOSE AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT
CONTACT DURING HOSE. CONTACT AT THE BURST CAN CAUSE BODILY
INJECTION AND SEVERE PERSONAL INJURY.
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.
5. CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS, 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.
6. AFTER EACH USE, STORE IN A CLEAN DRY AREA.
DANGER
SIDE 1
DO NOT REMOVE THIS TAG
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.
2. FOR PROPER AND SAFE OPERATION, MAKE SURE THAT YOU HAVE BEEN
PROPERLY TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK IN OR
AROUND ELECTRICAL LINES.
3. BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS
NON-CONDUCTIVE ON OR NEAR ELECTRICAL LINES, WIPE THE ENTIRE LENGTH
OF THE HOSE AND FITTING WITH A CLEAN DRYABSORBENT CLOTH TO REMOVE
DIRT AND MOISTURE AND TEST HOSE FOR MAXIMUM ALLOWABLE CURRENT
LEAKAGE IN ACCORDANCE WITH SAFETY DEPARTMENT INSTRUCTIONS.
DO NOT REMOVE THIS TAG
DANGER
SIDE 2
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.
5. CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS, 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.
6. AFTER EACH USE, STORE IN A CLEAN DRY AREA.
DANGER
SIDE 1
DO NOT REMOVE THIS TAG
1. THIS HOSE NOT LABELED OR CERTIFIED AS NON-CONDUCTIVE WHEN USING
HYDRAULIC TOOLS ON OR NEAR ELECTRIC LINES MAY RESULT IN DEATH OR
SERIOUS INJURY.
2. FOR PROPER AND SAFE OPERATION, MAKE SURE THAT YOU HAVE BEEN
PROPERLY TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK IN OR
AROUND ELECTRICAL LINES.
3. DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE. IMPROPER
USE OR HANDLING OF HOSE COULD RESULT OR OTHER HOSE FAILURE. KEEP
HOSE AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT
CONTACT DURING HOSE. CONTACT AT THE BURST CAN CAUSE BODILY
INJECTION AND SEVERE PERSONAL INJURY.
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REQUIREMENTS
HTMA REQUIREMENTS
TOOL CATEGORY
Hydrualic System Requirements
TYPE I TYPE II TYPE III TYPE RR
Flow Rate 4-6gpm
(15-23l/min)
7-9gpm
(26-34l/min)
11-13gpm
(42-49l/min)
9-10.5gpm
(34-40l/min)
Tool Operating Pressure
(atthepowersupplyoutlet)
2000 psi
(138bar)
2000 psi
(138bar)
2000 psi
(138bar)
2000 psi
(138bar)
System Relief Valve Setting
(atthepowersupplyoutlet)
2100-2250psi
(145-155bar)
2100-2250ps
(145-155bar)i
2100-2250psi
(145-155bar)
2200-2300psi
(152-159bar)
Maximum Back Pressure
(atthetoolendofthereturnhose)
250 psi
(17bar)
250 psi
(17bar)
250 psi
(17bar)
250 psi
(17bar)
Measured at max. fluid viscosity of:
(atmin.operatingtemperature)
400SSU*
(82CST)**
400SSU*
(82CST)**
400SSU*
(82CST)**
400SSU*
(82CST)**
Temperature
Sufficient heat rejection capacity to limit
max.fluidtemperatureto:(atmax.expected
ambienttemp.)
140˚F
(60˚C)
140˚F
(60˚C)
140˚F
(60˚C)
140˚F
(60˚C)
Minimum Cooling Capacity
(atatemperaturedifferenceofbetween
ambientandfluidtemps)
3hp(2.24kW)
40˚F(22˚C)
5hp(3.73kW)
40˚F(22˚C)
7hp(4.47kW)
40˚F(22˚C)
6hp(5.22kW)
40˚F(22˚C)
NOTE: DO NOT operate the tool at oil temperature above 140˚F (60˚C).
Operation at higher temperatures can cuase operator discomfort at the tool.
Filter 25 microns 25 microns 25 microns 25 microns
Minimum Full-Flow Filtration
SizedforFlowatLeast:
(forcoldtemp.start-upandmax.dirtholding
capacity)
30 gpm
(114l/min)
30 gpm
(114l/min)
30 gpm
(114l/min)
30 gpm
(114l/min)
Hydraulic Fluid
(Petroleumbased;premiumgrade,anti-wear,
nonconductive)
100-400SSU*
(20-82CST)**
100-400SSU*
(20-82CST)**
100-400SSU*
(20-82CST)**
100-400SSU*
(20-82CST)**
NOTE: When choosing hydraulic fluid, the expected oil temperature extremes that will be experienced
win 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=SayboltSecondsUniversal
**CST=Centistokesl
NOTE: These are general hydraulic sysem requirements.
See tool Specification page (page 6) for tool specific requirements.
C
20l/min@138bar
BHTMACATEGORY
D
30l/min@138bar
BHTMACATEGORY
© 2007 ICS, Blount Inc. F/N 521599 Oct 07
P95 OPERATOR’S MANUAL
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OPER ATION
OPERATION
Do not operate the power until you have read the operating manual.
1. CrankcaseOilLevel:Alwayschecktheoillevelbeforestartingtheengine.MakesuretheoillevelisattheFULL
MARKonthedipstick.Donotoverfill.Usedetergentoilclassified“ForServiceSE,SF,SG”asspecifiedinthe
engine operating and maintenance manual. See engine manual for oil viscosity grade.
2. EngineFuelLevel:Checkthefuellevel.Iflow,fillwithun-leadedgasolinewithaminimumof85octane.
3. HydraulicFluid:Checkthedipstickinthehydraulicfluidreservoirfortheproperfiuidlevel.Usefluidsmeetingthe
followingspecifications.
U.S.A. Metric
50˚F-450SSUMaximum 10˚C-95CSTMaximum
100˚F-130-200SSU 38˚C-27-42CST
140˚F-85SSUMinimum) 60˚C-16.5CSTMinimum
PourPoint -10˚F(-23˚C)Min.(coldstartup)
Viscosity Index (ASTMD-2220)140Min.
Demulsibility (ASTMD-1401)30MinutesMax.
FlashPoint (ASTMD-92)340˚F(171˚C)Min.
Rust Inhibition (ASTMD-665A&B)Pass
Oxidation (ASTMD-943)1,000Hrs.Min.
PumpWearTest (ASTMD-2882)60mgMax.
Thefollowingfluidsworkwelloverawidetemperaturerange, allow moisture to settle out and resist biological
growththatmayoccurincooloperatinghydrauliccircuits.ThesefluidsarerecommendedbyICS.Otherfluidsthat
meetorexceedthespecificationsofthesefluidsmayalsobeused.
Chevron AW-MV-32
Exxon "Univis"J-26
Mobile D.T.E. 13
Gulf "Harmony"AW-HVI-150-32
Shell "Tellus"T-32
Texaco "Rando"HD-HZ
Union "Unax"AW-WR-32
Terresolve EnviroLogic132
3. Therecommendedhoselengthis25ft(8m)witha1/2inch(12.7mm)insidediameter.Thehosesmusthavea
working pressure rating of at least 2500 psi/175 bar. Each hose end must have male thread ends compatible with
H.T.M.A.(HYDRAULICTOOLMANUFACTURERSASSOCIATION)quickdisconnectfittings(NPTtypethreads).
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OPER ATION
OPERATION
Facingthepanelcontrolvalve,thebottommalequickdisconnectfittingisthePRESSUREFLUIDOUTfitting.The
topfemalequickdisconnectfittingistheRETURNFLUIDINfitting.
QUICK DISCONNECT COUPLERS
H.T.M.A.approvedquickdisconnectcouplingsareinstalledtohydraulichosessothatthedirectionofoilflowis
alwaysfromthemaletothefemalequickdisconnectasshowninfigure2.Quickdisconnectcouplingsandhose
fittingsareselectedsothatadditionalfittingssuchasreduceroradapterfittingsarenotrequired.
Ifadapterfittingsareused,theymustbeapprovedsteelhydraulicfittingsmeetingaminimumoperatingpressure
ratingof2500psi(172bar).Donotusegalvanizedpipefittingsorblackpipefittings.
Usethreadtapeorpipejointcompoundwheninstallingquickdisconnectcouplingstohoseortoolfittings.Follow
the instructions furnished with the selected thread sealant.
DONOTOVERTIGHTENTHEFITTINGS.
Thesupplied12VoltDCbatteryisanon-spillable,maintenance-freebatteryandisfullycharged.
Makesurethebatterycablesaretightandchargingcircuitfunctionsareoperatingproperly.
Donotchargethebatterywithastandardauto-
motive 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
NOTICE
If the engine runs out of gas or dies during
operation and the ignition switch is left in the
ONorRUNposition,thiscoulddrainthebattery.
Makesuretheignitionswitchisreturnedtothe
OFF position.
NOTICE
© 2007 ICS, Blount Inc. F/N 521599 Oct 07
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OPER ATION
CONTROL PANEL
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OPER ATION
CONTROLS
This unit is equipped with an advanced proportional engine control system. It provides a means of controlling engine
speedbyadjustingthefuelcontrolleverwithanactuator.ThePowerUnitprovidesonecircuit,withanoilflowof
5gpm(19l/min)upto2000psI(140bar)or8gpm(30l/min)upto2000psi(140bar)withafactory-programmed
electronic governed engine throttle.
Onehydraulictoolcanbeconnectedtothetoolcircuit.Thecircuitisactivatedbyturningtheflowcontrolswitchto
eitherthe5gpm(19l/min)or8gpm(30l/min)setting.
THROTTLECONTROL
Thethrottlecontrolpermitstheoperatortoselectoneof2operatingmodesaftertheenginehaswarmedup.When
startingtheengine,makesuretheflowselectorswitchisintheOFFposition.Thethrottlecontrolswitchcanbeset
ineithertheAUTO-IDLE-ONorAUTO-IDLE-OFFpositions.
AUTO-ON
Whenthethrottlecontrolswitchisinthe“AUTO-ON”position,theoilflowisregulatedautomaticallywhenthetrigger
onthetoolactivated.Whenthetoolisnotbeingusedtheenginewillreturntoidleautomatically,aftera10second
delay. Thissettingwillproduce5gpm(19l/min)or8gpm(30l/min)dependingonwhichpositiontheoperatorhas
selectedwiththeflowselectorswitch.
AUTO-OFF
Whenthethrottlecontrolswitchisinthe“AUTO-OFF”position,theenginespeedisheldtomaintain5gpm/19l/min
or8gpm/30l/mindependingonwhichpositiontheoperatorhasselectedwiththeflowselectorswitch.Whenatool
isnotbeingusedtheenginewillnotreturntoidleuntileithertheflowselectorswitchisturnedtotheOFFpositionor
thethrottlecontrolswitchisturnedtoAUTO-ON.Note:ItmaybenecessarytoresettheController.
Attimesitmaybenecessarytoresetthecontroller.Thiscouldhappenifafaultoccursinthecontroller.Forex-
ample, 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.
THROTTLECONTROLSWITCH
IGNITIONSWITCH FLOWSELECTORSWITCH
© 2007 ICS, Blount Inc. F/N 521599 Oct 07
P95 OPERATOR’S MANUAL
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OPER ATION
START UP
Before starting the engine make sure the flow selector switch is in the OFF position.
NOTE:Thepowerunitwillnotstartiftheflowcontrolswitchisnotinthe“OFF”position.
• PullchokeknoboutandmovetheThrottleControlSwitchtotheauto-idle-offortheauto-idle-onposition,whichever
modeofoperationtheoperatorprefers.EnsuretheflowselectorswitchisintheOFFposition.
• 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.
• Allow the engine to warm up.
• Connecthosesandthetool
FOR 5 gpm (19 l/min) OPERATION
• For5gpm(19l/min)operation,selectmodeofoperationwiththeThrottleControlswitch,eitherauto-idle-onorthe
auto-idle-offposition.Movetheflowselectorswitchtothe5gpmposition.
• Whenfinishedoperatingthetool,movetheflowselectorswitchtotheOFFposition.
FOR 8 gpm (30 l/min) OPERATION
• For8gpm(30l/min)operation,selectmodeofoperationwiththeThrottleControlSwitch,eitherauto-idle-onorthe
auto-idle-offposition.Movetheflowselectorswitchtothe8gpm(30l/min)position.
• Whenfinishedoperatingthetool,movetheflowselectorswitchtotheOFFposition.
COLD WEATHER START UP
1. Usetheproceduresdescribedunder“STARTUP”andthenfollowtheprocedurebelow.
2. Hydraulicfluidsarethickerincoldweather.Therefore,itisrecommendedthattheengineberunatlowidlelong
enoughtobringthefluidtemperatureuptoaminimumof50˚F(10˚C).
3. Ifthetoolsandtoolhosesarecold,itisrecommendedtoallowhydraulicfluidtocirculatethroughthetoolhoses
until warm before using the tool.
SHUTDOWN
1. EnsuretheflowselectorswitchintheOFFposition(centerposition).
2. Unlessalreadyatidlethepowerunitshouldreturntoidle.Thismaytakeafewsecondsfortheunittoreactduetoa
built-inprogramdelay.
3. Allow the engine to idle for approximately one minute and move the Ignition Switch to the OFF position.
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P95 OPERATOR’S MANUAL
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MAINTENANCE
ROUTINE MAINTENANCE
ENGINE MAINTENANCE
Follow the maintenance schedule and general maintenance instructions in the engine maintenance and operation
manual furnished with the power unit
HYDRAULIC SYSTEM MAINTENANCE
• Checkhydraulicfluidleveldaily.Addfluidperspecificationsinthismanual.
• Removecondensedmoisturefromthehydraulicfluidbypumpingthehydraulicfluidintoa5gal/20lcontainer
throughthepressurehose.Makesuretheengineisatidlewhenperformingthisprocedure.Whenthehydraulic
reservoir is empty turn the engine off immediately.
• Allowthefluidtositlongenoughforthewatertosettletothebottomofthecontainer.Slowlypourthefluidbackinto
the hydraulic tank, avoiding the water at the bottom of the container.
• Eachday,checkhydrauliclinesandfittingsforleaks,kinks,etc.Donotuseyourhandtoperformthischeck.
• Changethehydraulicfilterelementevery200hoursofoperation.Changemoreoftenifcold,moistordusty
conditions exist.
• Checkoilcoolerfordebris.Removedebriswithairpressure.
STORAGE
• Cleantheunitthoroughlybeforestorage.Donotusewaterpressure.
• Alwaysstoretheunitinacleananddryfacility.
• Iftheunitwillbestoredforaprolongedperiod(over30days),addafueladditivetothefueltanktopreventthefuel
from gumming. Run engine for a short period to circulate the additive.
• Replacecrankcaseoilwithnewoil.
• Removesparkplugsandpourapproximately1ounce(30ml)ofengineoilintoeachcylinder.Replacesparkplugs
and crank the engine slowly to distribute the oil.
• Checkhydraulicreservoirforwater.Ifwaterisfound,changetheoilandcirculateitthroughthetoolhoseandtool.
• Disconnecttoolhoses.
© 2007 ICS, Blount Inc. F/N 521599 Oct 07
P95 OPERATOR’S MANUAL
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CONTROLLER / FAULT CODES
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.
CALIBRATION
Calibration and programming can only be done by the factory.
TROUBLESHOOTING GUIDELINES
PleasefollowthechecklistbelowtotroubleshootyourICScontroller.
1. Checkbatteryvoltageforstabilityandcorrectvalue.TheLEDwillturnonforonesecondwhenthecontrollerisfirst
powered up.
2. Check the actuator linkage for binding and backlash.
CHECKING PERFORMANCE CONTROL (ELECTRICAL 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.
Apairofjumperwiresandaknowngood12-voltbatteryisrequired.
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.Attach12volt+(positive)toREDwire.
B.Attach12volt–(negative)toGREENwire.
3. Actuator should move throttle lever to wide open position.
A.Ifactuatordoesnotmoveitisdefective.(Replace).
B.Ifactuatormovesthrottletowide-openposition,themoduleisdefective.(Replace).
FAULT CODES
TheICScontrolleriscapableofidentifyingcertainfaultconditionsandalertingtheusertothem.AflashingLED
indicatesthefaultconditions.Thecurrentfaultcodelistisshownonthefollowingpage.Pleasenotethefollowing:
1. Whenpowerisfirstappliedtothecontroller,theLEDwillflashjustonceforonesecondtoindicatethattheLEDis
working.
2. Iftherearemultiplefaults,theLEDwillflashthemallinsequence.Counttheflashcodestodeterminethefault
conditionsorconnecttheCalibrationTooltoobservethefaultconditions.(Usethe“DisplayFaults”optionunderthe
MonitorMenu).
3. Iftherearenofaults,theLEDwillflashonceatresetandfromthenonindicatethedetectionofenginespeed.A
continuousONLEDindicatesthatavalidenginespeedisbeingsensed.
4. The controller will attempt to shut down for some faults and will not permit starting after reset with faults 1, 5 and 8.
F/N 521599 Oct 07 © 2007 ICS, Blount Inc.
P95 OPERATOR’S MANUAL
17
CONTROLLER / FAULT CODES
FLASH
CODE
FAULT ENGINE
SHUTDOWN
CORRECTIVE ACTION
1Unitnotcalibrated YES HaveengineservicedbyanAuthorizedICSDealer.
2 Engine speed
excessive
YES HaveengineservicedbyanAuthorizedICSDealer.
3 Engine speed unusually
low
YES HaveengineservicedbyanAuthorizedICSDealer.
4 Engine shutdown due
to engine protection
input
YES HaveengineservicedbyanAuthorizedICSDealer.
5 Factory settings lost YES HaveengineservicedbyanAuthorizedICSDealer.
6Externalpotout-of-
range
NO HaveengineservicedbyanAuthorizedICSDealer.
7 Accelerator position/
idle switch conflict
NO HaveengineservicedbyanAuthorizedICSDealer.
8 Controller unit failed YES HaveengineservicedbyanAuthorizedICSDealer.
9Limitingexcessive
actuator current
NO HaveengineservicedbyanAuthorizedICSDealer.
10 Engine speed input
signal missing
NO Check speed sensor wiring.
Check starter motor.
11 Auto crank unable to
start engine
NO Check fuel.
12 Auxillary output is
shorted
NO Check the lamp or relay hooked to the output. If fault is
still present, have engine serviced by and ICS Authorized
Deale.r
13 Auxillary output #2 is
shorted
NO Check the lamp or relay hooked to the output. If fault is
still present, have engine serviced by and ICS Authorized
Dealer.
14 Actuator disconnected
or open circuit
NO Check actuator wiring and actuatro resistance.
Resistance should be less than 10 ohms.
© 2007 ICS, Blount Inc. F/N 521599 Oct 07
P95 OPERATOR’S MANUAL
18
TESTING
TESTING
GENERAL
Tests and adjustments should be performed periodically to ensure the power unit is operating at maximum
efficiency.ICSCircuitTesterisrecommended.Thistestercanbeusedtoisolateproblemsinboththeengineand
hydraulic system prior to any power unit disassembly.
TESTING THE HYDRAULIC CIRCUIT
Thefollowingtestscanbeperformedtoensurethatthehydraulicpumpissupplyingthecorrectflowandpressure
and that the system relief valve is operating properly.
Duringthesetests,makesuretheengineiswarmandoperatingsmoothly.Iftestresultsarenotasspecified,refer
to the troubleshooting table in this section for possible causes.
TESTING THE 5 GPM HTMA TYPE 1 CIRCUIT OR THE 8 GPM TYPE 11 CIRCUIT
Totestthecircuit,proceedasfollows:
1. SettheflowselectorswitchtotheOFF(center)position.
2. SetthethrottlecontrolswitchtoAUTO-OFFposition.
3. ConnecttheICSCircuitTesteracrosstwohoseends(wherethetoolwouldnormallybeconnected).
4. Fullyopenthetesterrestrictorvalve(counterclockwise).
5. Start the engine and allow it to run until warm.
6. Switchtheflowselectorswitchto5or8gpmdependingonwhichflowyouaretesting.
7. Withtheengineattheprogramedspeed,thetestflowgaugeshouldread4-6gpm(15-23l/min)or7-9gpm(26.5-34
l/min).
8. Slowlyturntherestrictorvalveclockwisewhilewatchingthepressuregauge.Theflowrateshouldstayat4-6gpm
(15-23l/min)or7-9gpm(26.5-34l/min)asthepressuregaugereaches2100-2200psi(148-155bar).
9. At2100-2200psi(148-155bar),thereliefvalveshouldbegintoopen.Thepressureatwhichthereliefvalvejust
beginstoopeniscommonlyreferredtoasthe“crackingpressure”.Atthe“crackingpressure,”theflowrateshould
starttodropbecausethereliefvalveisallowingfluidtoby-passtothehydraulicreservoir.The“crackingpressure”is
presetatthefactoryandifitisnotwithintheaboverange,thereliefvalvemustbere-setasfollows:
A. The relief valve is located on the right side of the unit just behind the dash panel. It protrudes out from the
manifoldassembly.Useaopenendorboxendwrenchtoloosenthenutonthereliefvalve.
B.UseanAllenwrenchtoadjustthereliefvalve.Turnclockwisetoraisethepressureandcounterclockwiseto
reducethepressure.UseanAllenwrenchtoadjustthereliefvalve.Turnclockwisetoraisethepressureand
counterclockwise to reduce the pressure.
C. Tighten the nut and retest.
F/N 521599 Oct 07 © 2007 ICS, Blount Inc.
P95 OPERATOR’S MANUAL
19
TROUBLESHOOTING
TROUBLESHOOTING
PROBLEM CAUSE REMEDY
Engine will not
start
Flow selector switch not in the
OFF position
MakesuretheflowselectorswitchintheOFF
position when starting
Battery not connected Attch battery cables, check wires
Weakbattery 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 reservior
vent
Hydraulictankoverfilled Correct the fluid level
Pumpsuctionleak Check suction connections, Tighten
Hydraulic tool
won't operate
Flow selector switch not switched
ON
Check that the flow selector switch is set to 5 or 8
gpm
Incorrect hose connection tool Makesurethetoolhosecircuitgoesfromleft
(pressure)fittingtotoolandbacktotherightfitting
(return),fluidalwaysflowsformthemaletothe
female fittings
Quickdisconnectfittings
defective
Detach from hose, connect set together and
check for free flow
Hydraulicfluidlevellow Check for correct fluid level, fill using the
recommended fluid
Pumpcouplingdefective Withtheenginenotrunning,checkthecoupling
between the pump and engine that is engaged
and is not damaged
CAUTION:keephandsclearofrotatingobjects
Relief valve stuck open Adjust or replace valve
Suction hose kinked Makesuresuctionhosefromfluidreservoirto
pump inlet has a smooth curve
Solenoid not working Check solenoid operation and electrical
connections
Tool is defective Refer to tool manul
© 2007 ICS, Blount Inc. F/N 521599 Oct 07
ICS, Blount Inc.
4909 SE International Way
Portland, OR 97222
Tel 800-321-1240 Fax 503-653-4393
icsbestway.com
P95OPERATOR'SMANUAL
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