GT18B01 HYDRAULIC POWER UNIT WARNING SAFETY, OPERATION AND MAINTENANCE SERVICE MANUAL Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie OR 97267-5698 503-659-5660 FAX 503-652-1780 www.stanley-hydraulic-tools.
TABLE OF CONTENTS SAFETY SYMBOLS ............................................................................................................................................................. 5 SAFETY PRECAUTIONS..................................................................................................................................................... 6 TOOL STICKERS & TAGS ................................................................................................................................
CERTIFICATE OF CONFORMITY Hydraulic Tools ______________________________________________________________________ I, the undersigned: Burrows, James Surname and First names Hereby certify that the construction plant or equipment specified hereunder: 1. Manufacturer: Stanley Hydraulic Tools, 3810 Naef Road, Milwaukie, Oregon USA 2. Representative in the Union: Stanley Svenska AB, Box 9054, 400 92 Göteborg, SWEDEN 3. Category: Hydraulic Power Unit 4. Make: Stanley Hydraulic Tools 5. Type: GT18B01 6.
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.
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. 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.
TOOL STICKERS & TAGS 62302 Power Unit Dash Decal 62300 Single Circuit 65458 Sound Power Decal 28322 CE Decal DANGER CHOKE PULL TO START PUSH TO RUN 62302 AUTO IDLE OFF AUTO IDLE ON RU 62300 7
HYDRAULIC HOSE REQUIREMENTS HOSE TYPES Hydraulic hose types authorized for use with Stanley Hydraulic Tools are as follows: ➊ Certified non-conductive ➋ Wire-braided (conductive) ➌ Fabric-braided (not certified or labeled non-conductive) Hose ➊ listed above is the only hose authorized for use near electrical conductors. Hoses ➋ and ➌ listed above are conductive and must never be used near electrical conductors.
HTMA REQUIREMENTS TOOL CATEGORY HYDRAULIC SYSTEM REQUIREMENTS TYPE I TYPEII TYPEIII TOOL OPERATING PRESSURE (at the power supply outlet) 4-6 gpm (15-23 lpm) 2000 psi (138 bar) 7-9 gpm (26-34 lpm) 2000 psi (138 bar) 11-13 gpm (42-49 lpm) 2000 psi (138 bar) SYSTEM RELIEF VALVE SETTING (at the power supply outlet) 2100-2250 psi 2100-2250 psi 2100-2250 psi 2200-2300 psi (145-155 bar) (145-155 bar) (145-155 bar) (152-159 bar) MAXIMUM BACK PRESSURE (at tool end of the return hose) 250 psi (17 bar) Me
OPERATION PREPARATION FOR USE 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 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.
OPERATION DO NOT OVERTIGHTEN THE FITTINGS. CONTROL PANEL 5. BATTERY The supplied 12 Volt DC battery is a non-spillable, maintenance-free battery and is fully charged. RETURN PRESSURE H.T.M.A. 1/2 INCH FEMALE QUICK DISCONNECT COUPLER Make sure the battery cables are tight and charging circuit functions are operating properly. H.T.M.A. 1/2 INCH MALE QUICK DISCONNECT COUPLER NOTICE 1/2 INCH MALE PIPE HOSE END Do not charge the battery with a standard automotive battery charger.
OPERATION At times it may be neccessary 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. CONTROLS This unit is equipped with an advanced proportional engine control system.
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.
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. • Check hydraulic fluid level daily. Add fluid per specifications in this manual. (See "HYDRAULIC FLUID" under the section titled "OPERATING INSTRUCTIONS".
PROGRAMMABLE CONTROLLER CHECKING PERFORMANCE CONTROL™ (ELECTRONIC GOVERNOR-STATIC CHECK) The Stanley 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. 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.
FAULT CODES FLASH CODE FAULT ENGINE SHUTDOWN CORRECTIVE ACTION 1 APECS unit not calibrated yes Have engine serviced by an Authorized Stanley Dealer. 2 Engine speed excessive yes Have engine serviced by an Authorized Stanley Dealer. 3 Engine speed unusually low yes Have engine serviced by an Authorized Stanley Dealer. 4 Engine shutdown due to engine protection input yes Have engine serviced by an Authorized Stanley Dealer.
TESTING & TROUBLESHOOTING 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 re-set as follows: GENERAL Tests and adjustments should be performed periodically to ensure the power unit is operating at maximum efficiency.
TROUBLESHOOTING PROBLEM Engine will not start. Fluid blowing out of fluid reservoir vent. Hydraulic tool won't operate. CAUSE REMEDY 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.
SPECIFICATIONS Engine: ............................................................................................................................................................... 18 hp Briggs Capacity .......................................................................................... One 5 gpm/19 lpm Circuit or One 8 gpm/30 lpm Circuit Length: ..........................................................................................................................................................
SERVICE 3. Disconnect the wiring harness plugs from the pressure switch (26, fig. 2) and from the directional valve (27, fig. 2). GENERAL Service instructions in this section are limited to parts and components other than the engine and hydraulic pump. Other major components should be serviced by representatives of the respective manufacturers as follows: 4. While holding the manifold assembly in one hand, remove the 2 capscrews (6, fig. 2) and remove the manifold out through the back of the dash panel. 5.
SERVICE 2. Disconnect the wiring harness (See Figure 4, Wiring Diagrams for the correct connections). Remove the retaining ring and washer (48, 49, fig. 1) and remove the wheel. The engine and hydraulic tank can now be removed from the side of the unit. 3.Follow steps 1 through 4 under "Manifold Assembly Removal". ELECTRICAL 4. Remove the RED wire attached to the starter solenoid and the BLACK wire to ground. Refer to the wiring diagram in this manual for the correct connections, wire sizes and colors.
SERVICE Assemble the bushing and blower hub with the bolts inserted (but not tightened) through the drilled holes in the blower hub and into the tapped holes in the bushing. IMPORTANT Never change any wiring connections. If wires are not connected correctly, componenets could be damaged. With the key in the shaft, slide assembly into position on the shaft and tighten the setscrew over the key (if equipped). Tighten the 3 capscrews (14, fig.1) alternately and evenly to 60-inch pounds.
SERVICE HYDRAULIC TANK, COOLER & FILTER ASSEMBLY (see figure 1, 2 & 3) HYDRAULIC PUMP, COUPLING AND PUMP MOUNT (see figure 1) 1. First remove the hydraulic fluid from the tank by either pumping it out with a portable drill pump or draining it into a container. 1. Drain the hydraulic tank. 2. Remove the cooler guard (20, fig. 2) by removing the 2 hex flange bolts (9, fig. 2) and 2 capscrews (21, fig. 1). Remove the remaining 2 capscrews on the back side of the cooler. 2.
40 41 54 39 55 7 48 44 54 46 1 1 35 3 34 24 2 24 36 38 44 5 51 37 6 52 59 53 8 4 30 50 43 58 45 9 57 10 41 11 12 47 30 26 13 31 14 30 27 33 28 16 15 17 32 48 29 49 20 56 18 42 21 23 25 19 22 FIGURE 1.
FIGURE 1.
FIGURE 2. FRAME PARTS 9 21 20 18 2 1 10 28 16 31 13 29 27 11 8 1 30 23 15 * 7 17 26 2 19 24 1 23 2 12 14 2 6 2 1 5 4 32 1 3 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 P/N 370502 03906 62270 58857 58856 60962 59130 QTY 60963 60955 60954 60956 60946 62272 23530 58916 62271 59079 59095 7 7 1 1 1 2 1 1 6 1 1 1 1 1 1 1 2 1 2 1 2 350045 59131 -59128 60959 2 1 1 1 59074 DESCRIPTION ITEM P/N QTY Capscrew, 5/16 in. -18 UNC Nylock Nut, 5/16 in.
FIGURE 3. HOSES, FITTINGS & CLAMPS 1 7 2 8 9 4 3 5 3 6 10 3 11 3 12 ITEM P/N 1 2 3 4 5 6 7 8 9 10 11 12 59130 59104 62199 350000 02773 58569 58943 350104 40364 59088 59089 59105 QTY 1 1 4 1 1 1 1 1 1 1 1 1 DESCRIPTION Manifold Assy, Single Circuit Hose Barb, 3/4 in. Hose x 3/4 in. Pipe Hose Clamp Elbow, 45° Straight Thread Adapter Elbow, 90° Hose Connector, Straight Thread Elbow, 45° Hose Hose Hose Barb, 3/4 in. Hose x 3/4 in.
FIGURE 4B.
WARRANTY Stanley Hydraulic Tools (hereinafter called “Stanley”), subject to the exceptions contained below, warrants new hydraulic tools for a period of one year from the date of sale to the first retail purchaser, or for a period of 2 years from the shipping date from Stanley, whichever period expires first, to be free of defects in material and/or workmanship at the time of delivery, and will, at its option, repair or replace any tool or part of a tool, or new part, which is found upon examination by a Stan
Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie OR 97267-5698 503-659-5660 FAX 503-652-1780 www.stanley-hydraulic-tools.