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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
Copyright © 2004, The Stanley Works
FAX 503-652-1780
OPS/MAINT USA
www.stanley-hydraulic-tools.com
65466 9/2004 Ver 1
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TABLE OF CONTENTS SAFETY SYMBOLS ............................................................................................................................................................. 5 SAFETY PRECAUTIONS ..................................................................................................................................................... 6 TOOL STICKERS & TAGS ...................................................................................................................
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CERTIFICATE OF CONFORMITY Hydraulic Tools ______________________________________________________________________ Burrows, James I, the undersigned: 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:
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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 equip- ment. 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 s
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SAFETY PRECAUTIONS Tool operators and maintenance personnel must always comply with the safety precau- tions 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 operat- ing the tool and before performing general maintenance or repairs. Supervising personnel should develop additional precautions relating to the specifi c work area and local safety regulations. If so, place the added precaut
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U R TOOL STICKERS & TAGS 62302 Power Unit Dash Decal 62300 Single Circuit 65458 28322 CE Decal Sound Power Decal DANGER CHOKE PULL TO START PUSH TO RUN 62302 AUTO IDLE OFF AUTO IDLE ON 62300 7
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DO NOT REMOVE THIS TAG DO NOT REMOVE THIS TAG HYDRAULIC HOSE REQUIREMENTS HOSE TYPES Hydraulic hose types authorized for use with Stanley Hydraulic Tools are as follows: ➊ Certifi ed non-conductive ➋ Wire-braided (conductive) ➌ Fabric-braided (not certifi ed 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. HOSE SAFETY TAGS To help ensu
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HTMA REQUIREMENTS TOOL CATEGORY HYDRAULIC SYSTEM REQUIREMENTS TYPE I TYPEII TYPEIII TYPE RR FLOW RATE 4-6 gpm 7-9 gpm 11-13 gpm 9-10.5 gpm (15-23 lpm) (26-34 lpm) (42-49 lpm) (34-40 lpm) TOOL OPERATING PRESSURE 2000 psi 2000 psi 2000 psi 2000 psi (at the power supply outlet) (138 bar) (138 bar) (138 bar) (138 bar) SYSTEM RELIEF VALVE SETTING 2100-2250 psi 2100-2250 psi 2100-2250 psi 2200-2300 psi (at the
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OPERATION PREPARATION FOR USE Chevron AW-MV-32 Exxon "Univis" J-26 Do not operate the power unit until you have read the Mobil D.T.E. 13 engine operating and maintenance instructions manual Gulf "Harmony" AW-HVI-150-32 furnished with the unit. Shell "Tellus" T-32 Texaco "Rando" HD-AZ 1. ENGINE CRANKCASE OIL LEVEL Union "Unax" AW-WR-32 Terresolve EnviroLogic 132 Always check the oil level before starting the engine. Make sure the oil level is at the FULL MARK on the dipstick. Do 4. HYD
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OPERATION DO NOT OVERTIGHTEN THE FITTINGS. CONTROL PANEL 5. BATTERY The supplied 12 Volt DC battery is a non-spillable, mainte- PRESSURE RETURN nance-free battery and is fully charged. H.T.M.A. 1/2 INCH FE- Make sure the battery cables are tight and charging circuit MALE QUICK DISCON- NECT COUPLER 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 auto- motive battery charger.
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OPERATION At times it may be neccessary to reset the controller. This could happen if a fault occurs in the controller. For ex- CONTROLS ample, excessive engine speed. If a fault does occur the power unit will return to an idle and the operator will have This unit is equipped with an advanced proportional engine no control of the unit. To reset the controller, simply turn off control system. It provides a means of controlling engine the power unit and restart it. speed by adjusting the fue
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OPERATION COLD WEATHER STARTUP 1. Use the procedures described under "STARTUP" and then follow the procedure below. 2. Hydraulic fl uids are thicker in cold weather. Therefore, it is recommended that the engine be run at low idle long enough to bring the fl uid 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 fl uid to circulate through the tool hoses until warm before using the tool. SHUTDOWN 1. Ensure the fl ow sel
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ROUTINE MAINTENANCE ENGINE MAINTENANCE STORAGE Follow the maintenance schedule and general maintenance • Clean the unit thoroughly before storage. Do not use instructions in the engine maintenance and operation water pressure. manual furnished with the power unit. • Always store the unit in a clean and dry facility. HYDRAULIC SYSTEM MAINTENANCE • If the unit will be stored for a prolonged period (over 30 • Check hydraulic fl uid level daily. Add fl uid per specifi ca- days), add a fue
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PROGRAMMABLE CONTROLLER CHECKING PERFORMANCE CONTROL™ The Stanley programmable controller is an electronic (ELECTRONIC GOVERNOR-STATIC CHECK) engine governor that provides a means of controlling and limiting engine speed by adjusting the fuel control lever with To determine whether a governor problem is being caused a proportional actuator. by the actuator or the control module, perform the following static check exactly in order shown. The controller is software programmable and has no
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FAULT CODES FLASH ENGINE CODE FAULT 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 yes Have engine serviced by an Authorized Stanley Dealer. protection input 5 Factory settings lost yes Have engine serviced by an Author
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TESTING & TROUBLESHOOTING begins to open is commonly referred to as the "cracking pressure". At the "cracking pressure," the fl ow rate should GENERAL start to drop because the relief valve is allowing fl uid to by- pass to the hydraulic reservoir. The "cracking pressure" is Tests and adjustments should be performed periodically to preset at the factory and if it is not within the above range, ensure the power unit is operating at maximum effi ciency. the relief valve must be re-set as follow
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TROUBLESHOOTING PROBLEM CAUSE REMEDY Engine will not start. Flow selector switch not in the Make sure the fl ow selector switch is in OFF position. 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 fi lter plugged. Replace fuel fi lter. Defective spark plugs. Remove plugs, check gap, clean or replace. Fluid blowing out of fl uid reservoir vent. Hydraulic tank over
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SPECIFICATIONS Engine: ............................................................................................................................................................... 18 hp Briggs Capacity .......................................................................................... One 5 gpm/19 lpm Circuit or One 8 gpm/30 lpm Circuit Length: ...............................................................................................................................................
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SERVICE 3. Disconnect the wiring harness plugs from the pressure GENERAL switch (26, fi g. 2) and from the directional valve (27, fi g. 2). Service instructions in this section are limited to parts and 4. While holding the manifold assembly in one hand, re- components other than the engine and hydraulic pump. move the 2 capscrews (6, fi g. 2) and remove the manifold Other major components should be serviced by representa- out through the back of the dash panel. tives of the respective manufactur
