GTR20B01 - Pdfstream.manualsonline.com
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1. eb d Rx ka ded ed vane ed DLL 5 NES eleme 6 HYDRAULIC HOSE REQUIREMENTS tite a a t enhn td rade tnr a delet d en xe e tu dan 7 HOSE RECOMMENDATIONS saa 8 FIGURE 1 TYPICAL HOSE CONNECTIONS a a np tite ro betreten e Fe conden 8 EHTMA HTMA REQUIREMENTS nein ener TAE 9 OPERATION mm 10 ROUTINE MAINTENANCE 2 14 PROGRAMMABLE CONTROLLER tr dette tete enti t cna 15 FAULT CODES EET 16 TESTING amp TROUBLESHOOTING esses inttr eden cence ees nen tata dre or e ea rx en cd rada 17 TROUBLESHOOTING rtt a at dense tan een ia ca istis i 18 SPECIFICATIONS as 19 ACCESSORIES c 20 GTIRZOBOT IEEUSTEATIGOJIN acte 21 GTR20BOT PARTS LIST Assa ta 22 FUEL TANK dite est 23 sa izE dT 24 HOSES FITTINGS amp CLAMPS to dence trend teer cn ad Cade cde bee den lan et a 25 MAIN WIRING HARNESS eere enitn qp xu2. e 26 DUAL CIRCUIT WIRE HARNESS a hi ter ex ene tite ee nra se tee dere c anida d 27 IMPORTANT To fill out a Product Warranty Recording form and for information on your warranty visit Stanleyhydraulic com and select the Warranty tab NOTE The warranty recording form must be submitted to validate the warranty SERVICING This manual contains safety operation and routine maintenance instructions Stanley Hydraulic Tools recommends that servicing of hydraulic tools other than routine maintenance must be performed by an au thorized and certified dealer Please read the following 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 STANLEY GTR20B01 User Manual lt 3 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
3. 5 HYDRAULIC SYSTEM REQUIREMENTS Flow Range TOOL TYPE TYPE Il TYPE RR 7 9 gpm 9 10 5 gpm 26 34 Ipm 34 40 Ipm 1500 psi 1500 psi 103 bar 103 bar 4 6 15 23 1500 psi 103 bar TYPE Ill 11 13 gpm 42 49 Ipm 1500 psi Nominal Operating Pressure 103 bar at the power supply outlet 2100 2250 psi 145 155 bar 2100 2250 psi 145 155 bar 2200 2300 psi 152 159 bar 2100 2250 psi 145 155 bar System relief valve setting at the power supply outlet 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 400 ssu 400 ssu 82 centistokes 82 centistokes 400 ssu 82 centistokes 400 ssu 82 centistokes Measured at a max fluid viscosity of at min operating temperature 140 60 C 140 60 C 140 60 C 140 60 C Temperature Sufficient heat rejection capacity to limit max fluid temperature to at max expected ambient temperature Min cooling capacity at a temperature difference of between ambient and fluid temps 40 F 40 40 F 40 F NOTE 22 C 22 C 22 C 22 C Do not operate the tool at oil temperatures above 140 F 60 C Operation at higher temperatures can cause operator discomfort at the tool 3 hp 2 24 kW 5 hp 3 73 kW 6 hp 5 22 kW 7 hp 4 47 kW Filter Min f
4. e o Aue 10 pesn aq jou pjnous 2 SZ 0052 6L DIE pue sjueujeJimbeJ joo 5 06 0 00 001 076 901 9 H Agjue s uo paseq juo suoneoiydde 100 SLL 0052 eJnsseJg 9L 8 6 EN gt ojneJp u pesn SI yeyo 5141 SLL 0052 9L 8 9 06 6 001 165 O 6L S OL G SLL 0052 L el 91 dn 05 dn O 6L 901 9 Micra HEC ARR e yoeq 5 SLL 0052 L e 0 S 4 001 92 2 6 9 ainsseud d y suon E SLL 0052 OL 8 92 dn gz dn 62 81 9 eseu sed S11 SYOLONGNOD 1V9I3 123713 YVAN ASN LON OQ Jaqiy 10 preJg SIM eArjonpuo mu Jad uo peseq SS 0522 OL 8 dn OL dn ve GL 6 SISJOWEIP 29504 LLI syonjj 3exong An 10 plesg 4 eso 8Anonpuo2 uow panne SMOUS 1uBu y 0 Weyo 941 a e v avg ISd uinjoyysseid WIN HONI Sala 1334 Wd9 suonepueuiuooey sn apisu suy6ue esoH 9SOH NIA oijneJp H 001 um REQUIREMENTS
5. GLUA GTR20B01 Stanleyrailway HYDRAULIC POWER UNIT SAFETY OPERATION AND MAINTENANCE USER MANUAL 2011 Stanley Black amp Decker Inc New Britain CT 06053 U S A 72784 5 2013 Ver 6 DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY UBEREINSTIMMUNGS ERKLARUNG C DECLARATION DE CONFORMITE CEE DECLARACION DE CONFORMIDAD Hydraulic Tools DICHIARAZIONE DI CONFORMITA the undersigned Weisbeck Andy 3 Ich der Unterzeichnende Je soussign El abajo firmante lo sottoscritto Surname and First names Familiennname und Vornamen Nom et pr nom Nombre y apellido Cognome e nome hereby declare that the equipment specified hereunder best tige hiermit erklaren Produkt genannten Werk oder Ger t d clare que l quipement vis ci dessous Por la presente declaro que el equipo se especifica a continuaci n Dichiaro che le apparecchiature specificate di seguito 1 Category Hydraulic Power Unit Kategorie Cat gorie Categoria Categoria 2 Make Marke Marque Marca Marca Stanley 3 GTR20B01 4 Serial number of equipment Seriennummer des Ger ts Num ro de s rie de l quipement Numero de serie del equipo Matricola dell attrezzatura Has been manufactured in conformity with Wurde hergestellt in bereinstimmung mit Est fabriqu conform ment Ha sido fabricado de acuerdo con E stata costruita in co
6. 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 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 autho rized and properly trained personnel STANLEY GTR20B01 User Manual 4 5 TOOL STICKERS 59126 Power Unit Dash Decal 72783 Dual Circuit CE Decal 73306 Lift Point Decal 59126 DASH RR DECAL 27 33 BOTH SWITCHES REQUIRED 0 M 72783 DUAL CIRCUIT CE CECAL 6 gt G
7. Circuit Briggs tiri ete b mens AB A exe ERR ees 334 Ibs 151 5 kg Fuel Tank Capacity tese derum a ame utt d eR Tut ne 5 5 gal 20 8 Itr Estimated Gas Consumption Per Hour 1 3 gal A Itr Hydraulic Reservor Capacity sec return AA A a h na BARN AOE 3 gal 11 Itr Nominal Operating 1500 psi 103 bar Relief Valve crack 2100 psi 145 bar Foll relief Setting ie eto eiit D O E nid 2500 psi 172 bar AX EHTMA HTMA B 15 lpm 138 bar D 30 lpm 138 bar OR GTR20B01 Sound Declaration Guaranteed sound power level 101 Lwa Measured sound power level 100 Lwa Stdev 0 7 dB Values determined according to noise test code given in ISO 15744 using the basic standard 1503744 Test conducted by independent notified body to comply with 2000 14 EC 2005 requirements E H T M A Category The European Hydraulic Tool Manufacturers Association E H T M A has categorised hydraulic power units and tools in terms of flow rate and working pressure Our GTR20B01 power unit is categorised by the E H T M A as follows Flow Rate 2x15 1x30 Ipm 2x4 1x8 US gal min Nominal Pressure 103 bar 1500 psi Max Pressure 172 bar 2500 psi E H T M A Category B
8. Disconnect Coupler P N 24061 Coupler Body or P N 03974 Coupler Set HTMA 1 2 inch Female Quick Disconnect Coupler P N 24060 Coupler Body or P N 03974 Coupler Set 1 2 inch ID Hose 25 ft to 50 ft long 25 ft P N 04972 or P N 05009 Dual Hydraulic Hose 50 ft P N 04978 or P N 05008 Dual Hydraulic Hose 1 2 inch Male Pipe Hose End HTMA 1 2 inch Male Quick Disconnect Coupler P N 24061 Coupler Body or P N 03974 Coupler Set HTMA 1 2 inch Female Quick Disconnect Coupler P N 24060 Coupler Body or P N 03974 Coupler Set Adapter 3 8 inch Male Pipe x 8 SAE O Ring P N 00936 le PRESSURE RETURN PRESSURE Figure 2 Hydraulic Connections GTR20B01 User Manual 4 11 OPERATION CONTROLS This unit is equipped with an advanced proportional en gine control system It provides a means of controlling engine speed by adjusting the fuel control lever with an actuator The Power Unit provides two 4 gpm 15 up to 2000 psi 140 bar circuits or one 8 gpm 30 Ipm up to 2000 psi 140 bar circuit
9. STANLEY 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 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 Fol low the instructions furnished with the selected thread sealant DO NOT OVERTIGHTEN THE FITTINGS 6 BATTERY The supplied 12 Volt DC battery is a non spillable main tenance free battery and is fully charged Make sure the battery cables are tight and charging cir cuit functions are operating properly Do not charge the battery with a standard auto motive battery charger This type of charger pro duces a charging amperage higher than 2 amps Charging the battery at higher than 2 amps will damage the battery If the engine runs out of gas or dies during op eration 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 OPERATION VALVE BLOCK PRESSURE PRESSURE Adapter 1 2 inch Male Pipe x 10 SAE O Ring P N 07882 HTMA 1 2 inch Male Quick
10. User Manual lt 7 DO NOT REMOVE THIS TAG 9OVIL SIHL SAOWSY LON OG Ssuonoeuuo j eoid lt lt lt 1 gt gt gt __ 834715544 2 O 5 a gt T PRESSURE PRESSURE 92 0052 792 0 lt 8 001 92 09 67 91 SLL 0052 eJnsseJg 6L SLL 0052 6L 8 0 dn gz 0 dn 09 67 91 1 GLL 0052 9L 8 9 119 AVS Aq Jas se suoneoyoods 2 m 0062 mem JO 09 06 002 001 686 L 0L SLL 0052 eunssoJgd 6l vIe Bumjas GL 0052 6l m ne m ou jenbe eunsseJd 0062 IE gl BIG e 15291 JSNW oineJp u SLL 0052 9 8 9 GL dn ogoidn
11. and D The power unit is clearly marked with these categories It is important that any work tool used with the power unit is of a compatible category If in any doubt consult your Stanley Hydraulic Tool dealer STANLEY GTR20B01 User Manual lt 19 ACCESSORIES EMISSIONS POWER UNITS TRACHORSE amp GAS FUEL DRIVEN EQUIPMENT 1 Federal Emission Component Compliance 40CFR part 1060 120 Stanley warrants all fuel system emission com ponents for 2 years from the date of original purchase provided there has been no abuse neglect modifi cations or improper maintenance Components covered The emission related warranty covers all components whose failure would increase the evapo rative emissions Your emissionrelated warranty does not cover components whose failure would not increase evapo rative 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 ACCESSORIES Coupler Male 3 8 8 SAE PatkKGr nie ree rente ten set e d Ree bp Tc ste eoe a R
12. and adjustments should be performed periodically to ensure the power unit is operating at maximum ef Tighten the nut and retest ficiency Stanley Circuit Tester part number 04182 is recommended This tester can be used to isolate prob lems 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 pres sure and that the system relief valve is operating prop erly 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 pos sible causes TESTING THE 4 GPM OR 8 GPM CIRCUIT To test the circuit proceed as follows 1 Set the flow selector switches to the OFF center po sition 2 Set the throttle control switch to AUTO OFF position 3 Connect the Stanley Circuit Tester across two hose ends where the tool would normally be connected 4 Fully open the tester restrictor valve counterclock wise 5 Start the engine and allow it to run until warm 6 Switch the flow selector switch to 4 or 8 gpm depend ing on which flow you are testing 7 With the engine at the programed speed the test flow gauge should read 4 gpm 15 or 8 gpm 30 8 Slowly turn the restrictor valve clockwise while watch ing the pressure gauge The flow rate shou
13. manual ad justments Aflashing LED indicates the fault condition TROUBLESHOOTING GUIDELINES Please follow the checklist below to troubleshoot your Stanley controller 1 Check battery voltage for stability and correct value The LED will turn on for one second when the controller 4500 is first powered up 2 Check the actuator linkage for binding and backlash 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 1 Disconnect red and green wires from the control mod ule 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 STANLEY 3 Actuator should move throttle lever to wide open posi tion a If actuator does not move it is defective Replace b If actuator moves throttle to wide open position the module is defective or there is a wiring problem Re place FAULT CODES The Stanley controller is capable of identifying certain fault conditions and alerting the user to them A flash ing LED indicates the fault conditions The current fault code list is shown on the following page Please note the following 1 When power is first a
14. power again If controller still does not work or if no calibration file is A External pot out of range 7 Accelerator position idle switch conflict available consult factory Controller unit failed Electrical noise may be entering the controller Verify that pot is wired correctly Recalibrate external pot Verify that signals are working and synchronized Check wiring shielding and connections to controller Cycle power to engine If controller still does not work consult factory Limiting excessive actuator current 2 o Check actuator for short to ground or low resistance Check parameter settings Check linkage and actuator travel Ensure that load is not greater than engine capacity Engine speed input signal missing 2 o gt Active only in Auto crank mode Check speed sensor wiring Check starter motor Auto crank unable to Check fuel start engine Auxiliary output is shorted Check the lamp or relay hooked to the output If fault is still present consult factory Auxiliary output 2 is shorted Check the lamp or relay hooked to the output If fault is still present consult factory Actuator disconnected or Check actuator wiring and actuator resistance open circuit Resistance should be less than 10 ohms 2 o 16 gt GTR20B01 User Manual STANLEY TESTING TROUBLESHOOTING GENERAL clockwise to raise the pressure and counterclockwise to re duce the pressure Tests
15. suction leak Check suction connections Tighten if necessary Hydraulic tool won t operate 18 gt GTR20B01 User Manual Flow selector switch not switched ON Check that the flow selector switch is set to 4 or 8 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 SPECIFICATIONS eee EET 18 hp Briggs Capacity FIOW rtr nn nt nimes EHE EP Two 4 gpm 15 Circuits or One 8 gpm 30 Ipm Circuit Ee 36 in 91 4 cm WVU Saisie 23 in 58 4 wise t 29 5 in 74 9cm Weight Wet Dual
16. 1 SOLENOID AUTO IDLE BLUE BLACK N SWITCH BLUE YELLOW iN uN WHITE WIRE ON SIDE OF Ns SS STARTER SWITCH Swan PRESSURE SWITCH 52 STARTER SOLENOID STARTER POST RED WIRE GREEN WIRE 2 SOLENOID GREEN BLACK e MAG KILL 3 GROUND WIRES D BLACK WIRE STARTER ALL BLACK INTERLOCK RELAY lt X y gt ACTUATOR RED GREEN 47 0 til 25 COBINER SOLENOID BROWN BLACK MAG PICKUP GRAY WIRE RECTIFIER WHITE WIRE FUEL SHUTOFF RED WIRE TO CONTROLLER ORANGE WIRES RED WIRE P TERMINAL ORANGE WIRE S TERMINAL SEE ENGINE OIL PRESSURE SWITCH DETAIL YELLOW WIRE I TERMINAL ENGINE OIL PRESS SWITCH WIRING DETAIL 26 gt GTR20BO01 User Manual STANLEY DUAL CIRCUIT WIRE HARNESS CONTROLLER PLUGS ENGINE OIL PRESSURE SWITCH RED WIRE MAGNETO WIRE GRAY ACTUATOR PLUG RED amp GREEN WIRES ENGINE OIL PRESSURE SWITCH ORANGE WIRE ENGINE OIL PRESSURE SWITCH YELLOW WIRE PRESSURE SWITCH ES m YELLOW BLUE L GREEN BLACK COMBINER BROWN BLACK CIRCUIT 1 L BLUE BLACK GROUND WIRES BLACK HOUR METER BLACK WIRE L HOUR METER RED WIRE STARTER POST RED W
17. Flash Point ASTM D 92 340 F 171 C Minimum 10 gt GTR20B01 User Manual Rust Inhibition ASTM D 665 amp Pass Oxidation ASTM D 943 1000 Hours Minimum Pump Wear Test ASTM D 2882 60 mg Maxi mum 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 cir cuits These fluids are recommended by Stanley Other fluids that meet or exceed the specifications of these flu ids 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 8 m with 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 HYDRAULIC TOOL MANUFACTURERS ASSOCIATION quick disconnect fittings NPT type threads See Figure 2 E Figure 1 Panel Control Valve Facing the panel control valve the 2 left male quick dis connect fittings are the PRESSURE FLUID OUT fittings The 2 right female quick disconnect fittings are the RE TURN FLUID IN fittings QUICK DISCONNECT COUPLERS H T M A approved quick disconnect couplings are in stalled to hydraulic hoses so that the direction of oil flow is always
18. IRE STARTER SOLENOID LIGHT GREEN WIRE STARTER SWITCH RED WHITE AUTO IDLE SWITCH 3 YELLOW BLUE DIODE DU DE 10 AMP FUSE Kt DIODE DIODE CIRCUIT 2 SWITCH YELLOW WHITE BLUE GREEN STARTER SWITCH CIRCUIT 1 SWITCH ENGINE KILL BLACK WIRE RECTIFIER WHITE WIRE FUEL SHUTOFF RED WIRE GTR20B01 User Manual lt 27 Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie Oregon 97267 5698 USA 503 659 5660 Fax 503 652 1780 www stanleyhydraulic com IMPORTANT To fill out a Product Warranty Recording form and for information on your warranty visit Stanleyhydraulic com and select the Warranty tab NOTE The warranty recording form must be submitted to validate the warranty
19. Stanley Distributor THE TAG SHOWN BELOW IS ATTACHED TO CERTIFIED NON CONDUCTIVE HOSE DANGER DANGER 1 FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE IMPROPER USE WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRIC LINES MAY RESULT IN OR HANDLING OF HOSE COULD RESULT IN BURST OR OTHER HOSE FAILURE DEATH OR SERIOUS INJURY KEEP HOSE AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT CONTACT DURING USE CONTACT AT THE BURST CAN CAUSE BODILY INJECTION AND SEVERE PERSONAL INJURY ELECTRIC LINES HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING ABRASION CUTTING OR CONTACT WITH HIGH TEMPERATURE SURFACES DO NOT USE IF KINKED DO NOT BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE USE HOSE TO PULL OR LIFT TOOLS POWER UNITS ETC ON OR NEAR ELECTRIC LINES WIPE THE ENTIRE LENGTH OF THE HOSE AND FIT CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAM TING WITH A CLEAN DRY ABSORBENT CLOTH TO REMOVE DIRT AND MOISTURE AND TEST HOSE FOR MAXIMUM ALLOWABLE CURRENT LEAKAGE IN ACCORDANCE WITH AGE TO GOUELINGS IP ANY OF THESE CONDITIONS ENST REPLACE THE HOSE IMMEDIATELY NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE SAFETY DEPARTMENT INSTRUCTIONS AFTER EACH USE STORE IN A CLEAN DRY AREA FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROP ERLY TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR ARO
20. TR20B01 User Manual HYDRAULIC HOSE REQUIREMENTS The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the hy draulic system There are three types of hydraulic hose that meet this requirement and are authorized for use with Stanley Hydraulic Tools They are Certified non conductive constructed of thermoplastic or synthetic rubber inner tube synthetic fiber braid reinforcement and weather resistant thermoplastic or synthetic rubber cover Hose labeled certified non conductive is the only hose authorized for use near electrical conductors Wire braided conductive constructed of synthetic rubber inner tube single or double wire braid reinforce ment and weather resistant synthetic rubber cover This hose is conductive and must never be used near electrical conductors Fabric braided not certified or labeled non conductive constructed of thermoplastic or synthetic rubber in ner tube synthetic fiber braid reinforcement and weather resistant thermoplastic or synthetic rubber cover This hose is not certified non conductive and must never be used near electrical conductors HOSE SAFETY TAGS To help ensure your safety the following DANGER tags are attached to all hose purchased from Stanley Hydraulic Tools DO NOT REMOVE THESE TAGS If the information on a tag is illegible because of wear or damage replace the tag immediately A new tag may be obtained from your
21. Throttle Control Switch Flow Selector tool Circuit 1 Switch 27 33 BOTH SWITCHES m Xf Flow Selector tool Circuit 2 Switch Ignition Switch Figure 3 Panel Control Valve Two 4 gpm hydraulic tools can be connected to the tool circuit or one 8 gpm tool The circuit is activated by turning one or both flow selector switches to 4 or both Switches to 8 gpm If both are at 8 gpm 8 gpm can be had by connecting to either coupler set THROTTLE CONTROL 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 IDLE OFF positions AUTO ON When the throttle control switch is in the position the oil flow is regulated automatically when the trigger on the tool activated When the tool is not being used the engine will return to idle automatically after a 10 second delay This setting will produce one or two 4 gpm 15 cir cuits or one 8 gpm 30 circuit depending on which postion 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 4 gpm 15 or 8 gpm 30 Ipm depending on which position the 12 gt GTR20B01 User Manual operator has selected with the flow select
22. UND DO NOT REMOVE THIS TAG SIHL JAOWSY LON OG SEE OTHER SIDE SEE OTHER SIDE SIDE 1 SIDE 2 Shown smaller than actual size THE TAG SHOWN BELOW IS ATTACHED TO CONDUCTIVE HOSE DANGER DANGER NOT USE THIS HYDRAULIC HOSE ON OR NEAR ELECTRIC LINES THIS HOSE IS 5 CHECKENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAMAGE TO NOT LABELED OR CERTIFIED AS NON CONDUCTIVE USING THIS HOSE ON OR NEAR COUPLINGS IF ANY OF THESE CONDITIONS EXIST REPLACE THE HOSE IMMEDIATELY ELECTRICAL LINES MAY RESULT IN DEATH OR SERIOUS INJURY NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY 6 AFTER EACH USE STORE IN A CLEAN DRY AREA TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND ELEC TRIC LINES EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE IMPROPER USE OR HANDLING OF HOSE COULD RESULT IN BURST OR OTHER HOSE FAILURE KEEP HOSE AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT CONTACT DURING USE CONTACT AT THE BURST CAN CAUSE BODILY INJECTION AND SEVERE PERSONAL INJURY HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING CUTTING OR CONTACT WITH HIGH TEMPERATURE SURFACES DO NOT USE IF KINKED DO NOT USE HOSE TO PULL OR LIFT TOOLS POWER UNITS ETC EMEND OTHER SIDE SEE OTHER SIDE SIDE 1 SIDE 2 Shown smaller than actual size STANLEY GTR20B01
23. a ERE 58857 Coupler Female 3 8 8 SAE Parker 56856 Coupler Male 3 8 8 SAE 66785 Coupler Female 3 8 8 SAE 4 lt 66784 Hose Assy 50 ft with 7007 31848 Hose Assy 25 ft with 31972 Hose Assy 25 ft with couplers 2 wire braid RR 58451 FILTERS tic OIL MODEL OIL FILTER AIR FILTER FUEL FILTER FILTER 18384 18382 19947 18383 40408 20 gt GTR20B01 User Manual STANLEY GTR20B01 ILLUSTRATION FIG 1 CONNECT TO FUEL VAPOR HOSE ON FUEL VAPOR HOSE FROM FUEL TANK TO ENGINE ITEM 36 RUBBER SS GROMMET ONLY ENGINE FUEL LINE STANLEY GTR20B01 User Manual lt 21 AUN Nm gt A GTR20B01 PARTS LIST FIG 1 DESCRIPTION Muffler Heat Shield Screw Hex Washer Briggs ua Includes Items 60 thru 70 Con Square Key Capscrew Pressure Switch Flange Nut Clamp Bushing Key Blower Hub Capscrew Filter Assy Capscrew Grip Plate Std Thread Union Button Head HS Washer Capscrew Front Grille Cooler Capscrew 3 8 Hydraul
24. and 10 STANLEY OPERATION SHUTDOWN FOR 4 GPM OPERATION 1 Ensure the flow selector switches are in the OFF po For 4 gpm operation select mode of operation with the sition center position Throttle Control switch either auto idle on or the auto idle off position Move the flow selector switch to the 4 gpm 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 Note If operating both 4 gpm circuits move both flow se 5 Allow the engine to idle for approximately one minute lector switches to the 4 gpm position Both 4 gpm ang move the Ignition Switch to the OFF position circuits are independent from each other and can be operated on its own When finished operating the tool move one or both flow selector switches to the OFF position FOR 8 GPM OPERATION For 8 gpm operation select mode of operation with the Throttle Control Switch either auto idle on or the auto idle off position Move both flow selector switches to the 8 gpm position When finished operating the tool move both flow selec tor switches to the OFF position Note Either set of couplers can be used for the 8 gpm circuit but DO NOT use two separate tools when in the 8 gpm operation mode COLD WEATHER STARTUP 1 Use the procedures described under STARTUP and then follow the procedure below 2 Hydraulic fluids are thicker in c
25. cific requirements GTR20B01 User Manual 4 9 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 FULL MARK on the dip Stick Do not overfill Use detergent oil classified For Service SE SF SG as specified in the engine operat ing and maintenance manual See engine manual for oil viscosity grade 2 SPARK PLUG On power units equipped with Briggs amp 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 Check the fuel level If low fill with un leaded gasoline with a minimum of 85 octane 4 HYDRAULIC FLUID Check the dip stick in the hydraulic fluid reservoir for the proper fiuid level Use fluids meeting the following specifications VISCOSITY FLUID THICKNESS U S METRIC 50 F 450 SSU Maximum 100 F 130 200 SSU 140 F 85 SSU Minimum 10 C 95 C S 38 C 27 42 C S 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
26. ic Tank eather Strip Blower Wheel Brazed Hex Flange Bolt Engine Controller Hex Flange Bolt Frame Base Weldment Wheel amp Tire Axle Pump Dual Fuel Cap Grommet Fuel Tank Battery Battery Cover Capscrew Hex Flange Bolt Handle Bumper Hex Flange Bolt Lockwasher Foot P NN N DESCRIPTION Washer 3 4 Blower Housing Pump Mount Fuel Elbow Stud Heat Shield Hex Washer Head Screws Screw Cable Clamp Rectifier Wire Throttle Lever Hex Flange Bolt Angle Bracket Weldment Rottary Actuator Actuator Bracket Wire Assembly Hex Skt Head Capscrew 6 32 Hex Skt Head Capscrew 8 32 Link Retainer Spring Hose Clamp Fuel Vapor Hose Supplied BE Eng Manufacturer Emissions Sticker Spring Hose Clamp Hose Fuel ES Hex Flange Bolt Retaining Ring NA D A SB SB N NN BP 22 gt GTR20B01 User Manual STANLEY 370502 03906 62267 58857 66785 58856 66784 60962 59084 59085 59126 59074 72783 67899 60955 67899 60956 60946 62269 23530 58916 62268 59079 59095 59127 350041 ANNNNN ANN XON SNS NS SNS 234 gt FRAME PARTS FIG 2 12 VOLT PLUG WIRING HARNESS 12 VOLT ACCESSORY NOT EQUIPPED ON ALL MODELS AVAILABLE AS AN ADD ON IF ADDING 12 VOLT ACCESSORY CUT AWAY LABEL AND PUNCH THROUGH DASH PANEL DESCRIPTION Capsc
27. injury or death This safety alert and signal word indicate an imminently hazardous situation DANGER which if not avoided will result in death or serious injury This safety alert and signal word indicate a potentially hazardous situation which if not avoided could result in death or serious injury This safety alert and signal word indicate a potentially hazardous situation which if not avoided could result in death or serious injury 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 NOTICE to the equipment This signal word indicates a situation which if not avoided may result in dam IMPORTANT age 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 mainte nance personnel 4 gt GTR20B01 User Manual STANLEY 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 Superv
28. ising 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 on page 4 In addition to this manual read and understand safety and operating instructions in the Engine Operation Manual furnished with the power unit This 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 per sonal injury or equipment damage Operator must start 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 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 Besure all hoses are connected for correct flow direction to and from the tool being used
29. ld stay at 4 gpm 15 or 8 gpm 30 as the pressure gauge reaches 2100 2200 psi 148 155 bar 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 crack ing 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 a The relief valve is located on the right side of the unit just behind the dash panel It putrudes out from the man ifold 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 STANLEY GTR20B01 User Manual lt 17 TROUBLESHOOTING PROBLEM Engine will not start CAUSE Flow selector switch not in the OFF position REMEDY Make sure both flow selector switches are 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
30. nformit con Directive Standards No Approved body Richtlinie Standards Nr Pr fung durch Directives Normes Num ro Organisme agr Directriz Los Normas No Aprobado Direttiva Norme n Collaudato EN ISO 12100 1 2009 Self EN ISO 12100 2 2009 Self Noise Directive 2000 14 EC 2005 AkustikNet Notified body ID 1585 Bagsvard Hovedgade 141 2880 Bagsvard Denmark Certificate 863 2011 007 Machinery Directive 2006 42 EC 2006 Self 6 Special Provisions None 7 Measurements Measured Sound Power Level 100 LwA Spezielle Bestimmungen Messungen Guaranteed Sound Power Level 101 LwA Dispositions particuli res Mesures Measured in accordance to Directive 2000 14 EC Provisiones especiales Mediciones Noise related value Installed Power 13 4 kW Disposizioni speciali Misurazioni 8 Representative in the Union Patrick Vervier Stanley Dubuis 17 19 rue Jules Berthonneau BP 3406 41034 Blois Cedex France Vertreter in der Union Repr sentant dans l union Representante en la Union Rappresentante presso l Unione Done at Ort Fait a Dado en Fatto Stanley Hydraulic Tools Milwaukie Oregon USA Date Datum le Fecha Data 11 21 2011 Signature Unterschrift Signature Firma Firma Position Position Fonction Cargo Posizione Engineering Manager 2 gt GTR20B01 User Manual STANLEY TABLE OF CONTENTS SAFETY SYMBOL aa etant een esed aen ect 4 SAFETY PRECAUTIONS
31. old weather There fore 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 recom mended to allow hydraulic fluid to circulate through the tool hoses until warm before using the tool STANLEY GTR20B01 User Manual lt 13 ROUTINE MAINTENANCE ENGINE MAINTENANCE Follow the maintenance schedule and general mainte nance instructions in the engine maintenance and op eration manual furnished with the power unit SPARK PLUG On power units equipped with Briggs amp 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 HYDRAULIC SYSTEM MAINTENANCE Check hydraulic fluid level daily Add fluid per specifi cations in this manual See HYDRAULIC FLUID un der the section titled OPERATING INSTRUCTIONS Remove condensed moisture from the hydraulic fluid by pumping the hydraulic fluid into a 5 gal 20 con tainer through the pressure hose Make sure the engine is at idle when performing this procedure When the hy draulic reservoir is empty turn the engine off immedi ately Allow the fluid to sit long enough for the water to settle to the bottom of the container Slowly po
32. or switch When 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 Note It may be necessary to reset the Controller 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 USING THE 12 VOLT DC OUTLET A 12 VDC outlet is on specific models The DC outlet is ON at all times IMPORTANT The accessories if left on that are plugged into this outlet could drain the battery STARTUP Before starting the engine make sure the flow selector Switches are in the OFF position Note The power unit will not start if the flow selec tor switches are not in the OFF position 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 En sure 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 Allow the engine to warm up Connect hoses and the tool as desrcribed on pages 9
33. pplied to the controller the LED will flash just once for one second to indicate that the LED is working 2 If there are multiple faults the LED will flash them all in sequence Count the flash codes to determine the fault conditions or connect the Calibration Tool to observe the fault conditions Use the Display Faults option under the Monitor Menu 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 4 The controller will attempt to shut down for some faults and will not permit starting after reset with faults 1 5 and 8 GTR20B01 User Manual 4 15 FAULT CODES FLASH ENGINE CODE FAULT SHUTDOWN CORRECTIVE ACTION APECS unit not calibrated Calibrate APECS unit Engine speed excessive Check parameter settings Over speed criteria may be too sensitive Check for electrical noise entering controller Check wiring and connections Check case ground Make sure linkage moves freely without backlash Check tip of speed sensor Engine speed unusually low Check parameter settings Check linkage and the actuator travel Ensure that load is not greater than engine capacity Engine shutdown due to engine yes Check parameter settings protection input Check what may have triggered the protection input Factory settings lost If calibration file is available download the file and cycle
34. rew 5 16 in 18 UNC Nylock Nut 5 16 in 18 UNC Handle Rear Lift Coupler Male 3 8 in 8 SAE Parker Coupler Male 3 8 in 8 SAE Aeroquip Coupler Female 3 8 in 8 SAE Parker Coupler Female 3 8 in 8 SAE Aeroquip Capscrew 1 4 in 20 Manifold Dual Circuit Manifold Assy Dual Circuit Incl 22 29 31 33 34 Dash Decal Hex Flange Bolt 1 4 in 20 Decal Dual Circuit Knob part of item 13 2 Way Switch Rotary Switch 3 Way Switch Hour Meter Frame Weldment Hex Flange Bolt 3 8 in 16 Handle Lock Lift Handle Cooler Guard Flange Nut 1 4 in 20 Shuttle Check Valve Hollow Hex Plug 4 SAE Receptacle Assy 64942 TO STARTER SOLENOID cS DESCRIPTION Relief Valve Hollow Hex Plug 6 SAE Pressure Switch Assy Directional Valve Cap Included with Item 27 Coil 12 volt Receptacle Assy Combiner Valve Choke Cable Assy Solenoid Coil Nut Incl with Item 31 Lift Point Decal GTR20B01 User Manual 4 23 FUEL TANK 4 CAP NOTE When ordering a fuel tank item 37 or fuel tank cap item 35 DO NOT MIX OLD STYLE TANK AND CAP WITH NEW STYLE TANK AND CAP If you have a power unit and it was purchased prior to 2011 and need to replace the fuel tank or fuel tank cap you must purchase the same tank and cap that came with your unit For example if you have a power unit prior to 2011 do not purchase a new style fuel tank your engine will not be equipped
35. ull flow filtration Sized for flow of at least For cold temp startup and max dirt holding capacity 25 microns 30 gpm 114 Ipm 25 microns 30 gpm 114 Ipm 25 microns 30 gpm 114 Ipm 25 microns 30 gpm 114 Ipm Hydraulic fluid Petroleum based premium grade anti wear non conductive Viscosity at min and max operating temps 100 400 ssu 100 400 ssu 20 82 centistokes 100 400 ssu 100 400 ssu 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 CLASSIFICATION amp amp L EHTMA HYDRAULIC SYSTEM REQUIREMENTS STANLEY Flow Range Nominal Operating Pressure at the power supply outlet System relief valve setting at the power supply outlet 3 5 4 3 gpm 13 5 16 5 Ipm 1870 psi 129 bar 2495 psi 172 bar 4 7 5 8 gom 18 22 Ipm 1500 psi 103 bar 2000 psi 138 bar 7 1 8 7 gpm 27 33 lpm 1500 psi 103 bar 2000 psi 138 bar 9 5 11 6 gpm 36 44 Ipm 1500 psi 103 bar 2000 psi 138 bar 11 8 14 5 45 55 Ipm 1500 psi 103 bar 2000 psi 138 bar NOTE These are general hydraulic system requirements See tool specification page for tool spe
36. ur 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 STORAGE Clean the unit thoroughly before storage Do not use water pressure 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 14 gt GTR20B01 User Manual PROGRAMMABLE CONTROLLER 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 The controller is factory preset and has no
37. with a fuel vapor fitting The old style fuel cap is a vented cap while the new style fuel cap is not a vented cap and vent ing is achieved thru the vapor line The old style fuel tank has only one fuel line coming from the tank to the engine The new style fuel tank has two lines coming from the fuel tank to the engine one is the fuel line and the other is a fuel vapor line 24 gt GTR20B01 User Manual OLD STYLE FUEL TANK amp CAP PRIOR TO 2011 FUEL TANK P N 59078 amp CAP P N 68645 PRIOR TO 2011 NEW STYLE FUEL TANK amp CAP 2011 amp FORWARD FUEL TANK P N 73050 amp CAP P N 71794 2011 amp FORWARD FUEL VAPOR HOSE FROM FUEL TANK TO 59085 59104 62199 350000 02773 58569 58943 350104 40364 59089 59089 59105 NN Pb A HOSES FITTINGS amp CLAMPS DESCRIPTION Manifold Assy Dual 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 Return Briggs Engine Hose Suction Hose Barb 3 4 in Hose x 3 4 in Pipe GTR20B01 User Manual lt 25 MAIN WIRING HARNESS HARNESS PART NUMBER 62294 RED WIRE TO POSITIVE TOOL CIRCUIT 1 SIDE HOUR METER SWITCH 2 WHITES MULTI COLORS 9 BLACK WIRE TO NEGATIVE PLUG TO ROTARY START SWITCH ul SIDE HOUR METER TOOL CIRCUIT
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