GT18B01_B02 User Manual 2-2015 V16
Contents
1. 5 TOOL STICKERS amp Wc 6 HYDRAULIC HOSE TYPES tiet etr ee ertt vet EE EA EE ER A Ea 7 HOSE RECOMMENDATION SS d dee Fecerat en gu 8 HTMAREGQUIREMEN es nte tete tere cir eed eere tret rex eere Dor ren E EE re dU a PERLE 9 OPERATION keen 10 FOR 5 GPM OPERATION eI 12 FOR 8 GPMOPERATI N TUE 12 COLD WEATHER teet re eere eee ater tad rd 13 SAUTDOW PLE 13 ROUTINE MAINTENANGE ES etri eee evtl eaa teer rr eee kc epe PvE EE eL RE EL a te 14 PROGRAMMABLE sinian tanui nesana ei t ki tu Fee Dn hard ee dE RE Ap eau uhr 15 CHECKING PERFORMANCE CONTROL ELECTRONIC GOVERNOR STATIC CHECK 15 KL 15 ra nd 17 GENERAL 17 TESTING THE HYDRAULIC rte tn err eet ti red 17 TROUBLESHOOTING EE 18 SPECIFICATION S 19 BRIGGS ENGINE ASSEMBLY orit nh eret gea Re kasd arna 20 BRIGGS ENGINE PARTS LIST erri there eed ce eere do rie e ep Eua er ii F2. SZL 0062 Winey 6L VIE ae ne rn jenbe eunsseJd m 0052 eunsseig gis pojeJ e 15291 oineJp u SLL 0052 9 8 9 GL 0 dn 090 dn e se 61 01 jeujo Aue 10 pesn eq jou SIL 0052 unes 6l pue joo sjoop Inep 06 06 00 001 07 6 FOLS H ejuejs uo peseq g l 0052 ainssald QL 8 6 JR oi neJp U 10 pesn SI yeyo siu g l 0052 ujog QL 8 6 06 6 001 18 07 6 GOL S 4 97 0052 ujog I e GL dn OG 0j dn 07 6 01 4 ee E e eunssaeJd oeq 97 0052 ujog e 0 6 001 92 9 ainssaid daay suon SLL 0052 ujog OL 9 92 0 dn 0 dn cSL 9 v 95941 Jed sJey SYOLONGNOD T1VOIN123 T3 YVAN ISN LON OQ 10 preJg M wid6 uo peseq syjBua SSL 0922 OL 8 dn 01 dn ve SL 6 SSOY SNOMEA JO 2504 syonJj 3exong Ain 104 plesg SMOUS 1uBu yeu 941 avg ISd uinjoy sseid WIN HONI SYILIN 1333 eunssaJg
3. 28322 CE Decal a GT18B01 Only dB 2900 1800 73306 Lift Point Decal 66653 Guaranteed GT18B01 Only Sound Power Level Decal GT18B01 Only DANGER 62302 Power Unit Dash Decal 62300 Single Circuit Decal STANLEY 6 GT18B01 B02 User Manual 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 T
4. aSN episu SyjBua esoH MO 5 0 00 STANLEY 8 gt GT18B01 B02 User Manual REQUIREMENTS TOOL TYPE HYDRAULIC SYSTEM REQUIREMENTS TYPE I TYPE TYPERR Flow Range 4 6 gpm 7 9 gpm 9 10 5 gpm 11 13 15 23 Ipm 26 34 Ipm 34 40 Ipm 42 49 Ipm Nominal Operating Pressure 1500 psi 1500 psi 1500 psi 1500 psi at the power supply outlet 103 bar 103 bar 103 bar 103 bar System relief valve setting 2100 2250 psi 2100 2250 psi 2200 2300 psi 2100 2250 psi at the power supply outlet 145 155 bar 145 155 bar 152 159 bar 145 155 bar Maximum back pressure 250 psi 250 psi 250 psi 250 psi at tool end of the return hose 17 bar 17 bar 17 bar 17 bar Measured at a max fluid viscosity of 400 ssu 400 ssu 400 ssu 400 ssu at min operating temperature 82 centistokes 82 centistokes 82 centistokes 82 centistokes Temperature Sufficient heat rejection 140 F 140 F 140 F 140 capacity to limit max fluid temperature to 60 C 60 C 60 C 60 C at max expected ambient temperature Min cooling capacity at a temperature 3 hp 5 hp 6 hp 7 hp difference of between ambient and fluid 2 24 kW 3 73 kW 5 22 kW 4 47 kW temps 40 40 F 40 F 40 22 22 22 22 Do not operate the tool at oil temperatures above 140 F 60 Ope
5. Cooler Capscrew 3 8 29 T2315 Engine Controller GT18B01 ONLY 72316 1 Engine Controller GT18B02 ONLY 30 40 53 8 Hex Flange Bolt 516 18 12 ew 1 ______ 35 71794 Fuel Cap Important see note on page 22 before ordering STANLEY 37 Fuel Tank Important see note on page 22 before ordering 39 40 41 42 43 T 45 46 48 49 50 51 52 53 55 56 57 58 59 62 63 69401 1 Wire Assembly 69 69262 1 Hex Socket Head Capscrew GT18B01 B02 User Manual lt 21 NOTE When ordering 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 power unit and it was pur chased prior to 2011 and need to re place 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 power unit prior to 2011 do not purchase new style fuel tank your engine will not be equipped with a fuel vapor fitting The old style fuel cap is vented cap while the new style fuel cap is not a vented cap and venting 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 22 gt GT18B01 B02 User Manual OLD STYLE FUEL TANK amp
6. SOCIATION quick disconnect fittings NPT type threads See Figure 2 Figure 1 Control Panel Facing the control panel the bottom male quick disconnect fitting is the PRESSURE FLUID OUT fitting The top female quick disconnect fitting is the RETURN FLUID IN fitting STANLEY QUICK DISCONNECT COUPLERS H T M A approved quick disconnect couplings are installed to hydraulic hoses so that the direction of oil flow is always from the male to the female quick disconnect as shown in figure 2 Quick disconnect couplings and hose fittings are selected so that additional fittings such as reducer or adapt er fittings are not required If adapter fittings are used they must be approved steel hydraulic fittings meeting minimum operating pressure rating of 2500 psi 172 bar Do not use galvanized pipe fit tings or black pipe fittings Use thread tape or pipe joint compound when installing quick disconnect couplings to hose or tool fittings Follow the instructions furnished with the selected thread sealant DO NOT OVERTIGHTEN THE FITTINGS 6 BATTERY Do not charge the battery with a standard automotive battery charger This type of charger produces 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 operation and the ignition switch is left in the ON or RUN position this could drain the battery Make sure the ignitio
7. W 62293 HARNESS POSITIVE BATTERY CABLE TO STARTER SOLENOID Y STARTER SOLENOID GROUND WIRES mi GREEN Ji ENGINE KILL TO ACTUATOR RED GREEN LE d KE r 2 4 E RECTIFIER WIRE 2 I WHITE D TO MAGNETO WIRE ON ENGINE GRAY WIRE OIL PRESSURE SWITCH RED WIRE EXHI SN RED WIRE P TERMINAL CONTROLLER ORANGE WIRE 5 TERMINAL EF YELLOW WIRE I TERMINAL ENGINE OIL PRESS SWITCH WIRING DETAIL STAN LEY GT18B01 B02 User Manual lt 25 STANLEY Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie Oregon 97267 5698 USA 503 659 5660 Fax 503 652 1780 www stanleyhydraulics com
8. until you have read the engine operating and maintenance instructions manual furnished with the unit 1 ENGINE CRANKCASE OIL LEVEL Always check the oil level before starting the engine Make sure the oil level is at the FULL MARK on the dipstick Do not overfill Use detergent oil classified For Service SE SF SG as specified in the engine operating and mainte nance 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 war ranty 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 10 GT18B01 B02 User Manual 4 HYDRAULIC FLUID RECOMMENDED HYDRAULIC OILS Below is a list of recommended oils by brand Brand Biodegradable Description mo ExxonMobil No 10 Excel chevron No Rando HOZ 32 Recommended for extreme cold temperatures 5 HYDRAULIC CONNECTIONS The recommended hose length is 25 ft 8 m with a 1 2 inch 12 7 mm inside diameter The hoses must have a working pressure rating of at least 2500 psi 175 bar Each hose end must have male thread ends compatible with H T M A HYDRAULIC TOOL MANUFACTURERS AS
9. AGS 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 Stanley Distributor THE TAG SHOWN BELOW IS ATTACHED TO CERTIFIED NON CONDUCTIVE HOSE DANGER DANGER 1 FAILURE 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 ANT OF THESE CONDITIONS ENST REPLACE THE HO
10. 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 8 CAP 71794 2011 amp FORWARD FUEL VAPOR HOSE FROM FUEL TANK TO STANLEY See 12 Volt Harness at Right 2 03906 7 _ Nut 5 16 in 18UNC 4 58857 1 Coupler Male 3 8 85 _ s 50962 2 Capscrew in 20 Manifold Assy Single Circuit in cludes items 23 thru 29 s 692 DeshDeca fo 50074 6 Hex Flange Bot tam 20 10 62300 1 Single Circuit 14 60956 1 3 WaySwitch STANLEY 12 VOLT PLUG WIRING HARNESS RECEPTACLE ASSY 64942 TO STARTER SOLENOID y 2 2 RED ZN GROUND y BLACK m Nem O 25 wem 2s n Cep ncudedwihtem27 GT18B01 B02 User Manual 4 23 Description Connector Straight Thread Elbow 45 Hose Barb 3 4 in Hose x 3 4 in Pipe Elbow 90 24 gt GT18B01 B02 User Manual STAN LEY HARNESS PART NUMBER 65147 THROTTLE CONTROL SWITCH NOTE PLUG BEHIND SWITCH WITH BLUE amp YELLOW WIRES GOES TO SWITCH ON TOP FLOW CONTROL SWITCH HOUR METER DIRECTIONAL VALVE START A SWITCH MANIFOLD ASSY BLACK AC PRESSURE SWITCH TO STARTER SOLENOID RELAY 62301 N SUPPLIED
11. GT18B01 GT18B02 HYDRAULIC POWER UNIT USER MANUAL Safety Operation and Maintenance 2014 Stanley Black amp Decker New Britai 4 5 65465 2 2015 Ver 16 DECLARATION OF CONFORMITY UBEREINSTIMMUNGS ERKLARUNG DECLARATION DE CONFORMITE CEE DECLARACION DE CONFORMIDAD DICHIARAZIONE DI CONFORMITA STANLEY Hydraulic Tools I the undersigned Weisbeck Andy 3 Ich der Unterzeichnende Je soussign 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 Kategorie Cat gorie Categoria Categoria 2 Make Marke Marque Marca Marca 3 Type Typ Type Tipo Tipo 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 conformit con Hydraulic Power Unit Stanley GT18B01 GT18B07 All Di
12. H CURVE SOLENOID NOT WORKING CHECK SOLENOID OPERATION AND ELECTRICAL CONNECTIONS TOOL IS DEFECTIVE REFER TO TOOL MANUAL 18 GT18B01 B02 User Manual STAN LEY EE 18 hp Briggs CAPACI e T One 5 gpm 19 Ipm Circuit or One 8 gpm 30 lpm Circuit E e 36 in 91 4 cm To 23 in 58 4 gie 29 5 in 74 9cm Weight Wet Single Circuit Briggs e aa ceres cce be eve aca 330 Ibs 149 6 kg Fuel Tank Pt 5 5 gal 20 8 Itr Estimated Gas Consumption Per 1 3 gal 4 Itr Hydraulic Reservor gal 11 Itr Relief Valve crack 2100 145 Max fellet SUING T 2500 172 Category tret e de Type 1 and 2 30Lpm at 138bar BHTMA CATEGORY Nominal ETERNA 1500 psi 103 bar Max Pressure 2000 psi 138 bar Guaranteed Sound Power Level cte etas cete te kniven idet mist 101 dBA Measured Sound Power Level mmvvrvruvrvanvvvrrnvvvvnvnerrrnnnevrrsnnvvvnnenrrunnenvanenvvvnne
13. ING 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 hydraulic reservoir is empty turn the engine off immediately Allow the fluid to sit long enough for the water to settle to the bottom of the container Slowly pour the fluid back into the hydraulic tank avoiding the water at the bottom of the container Each day check hydraulic lines and fittings for leaks kinks etc Do not use your hand to perform this check 14 GT18B01 B02 User Manual Change the hydraulic filter element every 200 hours of operation Change more often if cold moist or dusty condi tions exist Check oil cooler for debris Remove debris with air pres sure 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 STANLEY 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 f
14. OID 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 NEMO OTHER SIDE LLL Lu d SEE OTHER SIDE SIDE 1 SIDE 2 Shown smaller than actual size STAN LEY GT18B01 B02 User Manual lt 7 Ovl SIHL SAONAIY LON OG lt 9 X H w gt o z ul suonoeuuo esoH 210 17 4 lt lt lt ____ lt lt Tm gt gt gt Er El JYNSSIYd HYDRAULIC CIRCUIT PRESSURE PRESSURE g l 0052 unay 794 0 8 001 92 9L EL g l 0052 eunsseJg 97 0052 8 dn 92 dn 09 67 9L EL 821 0052 9 8 9 LISP IVS Aq 195 se suoneoyioeds 0052 une voz i Jo 21 09 0 002 001 6r9 L 0L SLL 0052 ainssald 6L vIe Bunes W JS S
15. SE 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 AROUND 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 DO NOT USE THIS HYDRAULIC HOSE ON OR NEAR ELECTRIC LINES THIS HOSE IS 5 CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAMAGE 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 AV
16. actory preset and has no manual adjust ments A flashing LED indicates the fault condition TROUBLESHOOTING GUIDELINES Please follow the checklist below to troubleshoot your Stan ley 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 module to actuator 2 Attach jumper wires from battery to RED and GREEN wires to actuator a Attach 12 volt positive to RED wire b Attach 12 volt negative to GREEN wire 3 Actuator should move throttle lever to wide open position STANLEY a If actuator does not move it is defective Replace b If actuator moves throttle to wide open position the module is defective Replace FAULT CODES The Stanley controller is capable of identifying certain fault conditions and alerting the user to them A flashing LED indicates the fault conditions The current fault code list is shown on the following page Please note the following 1 When power is first applied to the con
17. e of the unit just behind the dash panel It protrudes out from the manifold assembly Use open end or box end wrench to loosen the nut on the relief valve b Use an Allen wrench to adjust the relief valve Turn clockwise to raise the pressure and counterclockwise to reduce the pressure Tighten the nut and retest GT18B01 B02 User Manual 4 17 PROBLEM CAUSE REMEDY IN THE OFF POSITION THE OFF POSITION WHEN STARTING FLUID BLOWING OUT OF FLUID RESERVOIR VENT HYDRAULIC TANK OVERFILLED CORRECT THE FLUID LEVEL PUMP SUCTION LEAK CHECK SUCTION CONNECTIONS TIGHTEN IF NECESSARY HYDRAULIC TOOL WON T OPERATE FLOW SELECTOR SWITCH NOT CHECK THAT THE FLOW SELECTOR SWITCH SWITCHED IS SET TO 5 OR 8 GPM INCORRECT HOSE CONNECTION MAKE SURE THE TOOL HOSE CIRCUIT GOES TO TOOL 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 DETACH FROM HOSE CONNECT SET DEFECTIVE 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 ASMOOT
18. ed 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 situation A 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 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 A A DANGER a WARNING CAUTION _NOTICE IMPORTANT 4 gt GT18B01 B02 User Manual STAN LEY 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 equ
19. er STARTUP and then follow the procedure below 2 Hydraulic fluids are thicker in cold weather Therefore it is recommended that the engine be run at low idle long enough to bring the fluid temperature up to a minimum of 50 F 10 C 3 If the tools and tool hoses are cold it is recommended to allow hydraulic fluid to circulate through the tool hoses until warm before using the tool SHUTDOWN 1 Ensure the flow selector switch in the OFF position center position 2 Unless already at idle the power unit should return to idle This may take few seconds for the unit to react due to a built in program delay 3 Allow the engine to idle for approximately one minute and move the Ignition Switch to the OFF position STANLEY GT18B01 B02 User Manual 4 13 ENGINE MAINTENANCE Follow the maintenance schedule and general mainte nance instructions in the engine maintenance and opera tion 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 war ranty that will not be considered HYDRAULIC SYSTEM MAINTENANCE Check hydraulic fluid level daily Add fluid per specifica tions in this manual See HYDRAULIC FLUID under the section titled OPERAT
20. ere ariii 21 xen 22 FRAME PARTS tci ttti ete deerit Ta ped Pers 23 HOSES FITTINGS amp CLAMP S oc terret pecie er nb based re ma A pute adve hart 24 MAIN POWER UNIT WIRING HARNESS IMPORTANT To fill out a Product Warranty Validation form and for information on your warranty visit Stanleyhydraulics com and select the Company tab Warranty NOTE The warranty Validation record must be submitted to validate the warranty SERVICING This manual contains safety operation and routine maintenance instructions Servicing of hydraulic tools other than routine maintenance must be performed by an authorized 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 STAN LEY GT18B01 B02 User Manual lt 3 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 us
21. es and fittings rated at 2500 psi 172 bar with a 4 to 1 safety factor Be sure all hose connec tions are tight STANLEY Be sure all hoses are connected for correct flow direction to and from the tool being used 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 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 per formed by authorized and properly trained personnel GT18B01 B02 User Manual 4 5 bus O a
22. idle and the operator will have no control of the unit To reset the controller simply turn off the power unit and restart it STARTUP Before starting the engine make sure the flow selector switch is in the OFF position Note The power unit will not start if the flow control switch is not in the OFF position Pull choke knob out and move the Throttle Control Switch to the auto idle off or the auto idle on position whichever mode of operation the operator prefers Ensure the flow selector switch is in the OFF position Turn the Ignition Switch to the START position After the engine starts release the switch Gradually push in the choke knob as the engine begins to idle smoothly Allow the engine to warm up Connect hoses and the tool as desrcribed in this manual FOR 5 GPM OPERATION For 5 gpm operation select mode of operation with the Throttle Control switch either auto idle on or the auto idle off position Move the flow selector switch to the 5 position When finished operating the tool move the flow selector switch 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 the flow selector switch to the 8 position When finished operating the tool move the flow selector switch to the OFF position STANLEY COLD WEATHER STARTUP 1 Use the procedures described und
23. ipment These safety precautions are given for your safety Re view them carefully before operating the tool and before performing general maintenance or repairs Supervising personnel should develop additional precautions relating to the specific work area and local safety regulations If so place the added precautions in the space provided on page 5 In addition to this manual read and understand safety and operating instructions in the Engine Operation Manual furnished with the power unit The Hydraulic Power Unit will provide safe and de pendable service if operated in accordance with the instructions given in this manual Read and understand this manual and any stickers and tags attached to the Power Unit Failure to do so could result in personal injury or equipment damage Operator must start in a work area without bystand ers 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 en sure 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 hos
24. n switch is returned to the OFF position STANLEY CONTROL PANEL Figure 2 PRESSURE RETURN H T M A 1 2 INCH FE MALE QUICK DISCON NECT COUPLER H T M A 1 2 INCH MALE QUICK DISCONNECT COUPLER 1 2 INCH MALE PIPE HOSE END 1 2 INCH I D HOSE 25 FT LONG WITH 2500 PSI 172 BAR RATING AND 4TO 1 SAFETY FACTOR PRESSURE RETURN 1 2 INCH MALE PIPE HOSE END 1 1 2 MALE QUICK DISCON NECT COUPLER ess 1 2 INCH MALE QUICK DISCONNECT COUPLER ADAPTER 3 8 INCH MALE PIPE x 8 SAE O RING TOOL PRESSURE RETURN EN GT18B01 B02 User Manual 4 11 CONTROLS This unit is equipped with an advanced proportional engine control system It provides means of controlling engine speed by adjusting the fuel control lever with an actuator The Power Unit provides one circuit with an oil flow of 5 gpm 19 Ipm up to 2000 psi 140 bar or 8 gpm 30 lpm up to 2000 psi 140 bar with factory programmed electronic governed engine throttle THROTTLE CONTROL SWITCH FLOW SELECTOR 8 GPM OFF 5 GPM SWITCH A ITION SWITCH VO Figure 3 Control Panel One hydraulic tool can be connected to the tool circuit The circuit is activated by turning the flow control switch to either
25. ration at higher temperatures can cause operator discomfort at the tool Filter P 25 microns 25 microns 25 microns 25 microns Min full flow filtration 30 gpm 30 gpm 30 gpm 30 gpm M dem dem dirt holding capacity Hydraulic fluid Petroleum based 100 400 ssu 100 400 ssu 100 400 ssu 100 400 ssu premium grade anti wear non conductive 20 82 centistokes Viscosity at min and max operating temps 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 HYDRAULIC SYSTEM Flow Range 3 5 4 3 gpm 4 7 5 8 gpm 7 1 8 7 gpm 9 5 11 6 gpm 11 8 14 5 gpm 13 5 16 5 Ipm 18 22 Ipm 27 33 Ipm 36 44 Ipm 45 55 Ipm Nominal Operating Pressure 1870 psi 1500 psi 1500 psi 1500 psi 1500 psi at the power supply outlet 129 bar 103 bar 103 bar 103 bar 103 bar System relief valve setting 2495 psi 2000 psi 2000 psi 2000 psi 2000 psi at the power supply outlet 172 bar 138 bar 138 bar 138 bar 138 bar NOTE These are general hydraulic system requirements See tool specification page for tool specific requirements STAN LEY GT18B01 B02 User Manual 4 9 PREPARATION FOR USE Do not operate the power unit
26. rective 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 2010 Self Self Noise Directive 2000 14 EC 2005 AkustikNet Notified body ID 1585 ISO 3744 2010 Bagsvard Hovedgade 141 2880 Bagsvard Denmark Certificate 863 201 1 001 Machinery Directive 2006 42 EC 2006 Self 6 Special Provisions None 7 Measurements Measured Sound Power Level 99 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 25 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 Dado en Fatto Stanley Hydraulic Tools Milwaukie Oregon USA Date Datum le Fecha Data 7 21 11 Signature Unterschrift Signature Firma Firma ua RE Dir ctor of Product Development Position Position Fonction Cargo Posizione 2 gt GT18B01 B02 User Manual STANLEY DECLARATION OF CONFORMITY te ab Etui a rer ee E dade ane 2 SAFETY SYMBOLS ne 4 SAFETY PRECAUTIONS ettet iet asira eia EHE
27. rrannnenvanenvvnnneeransnevensennvvnnerrunnsevvnnsen 99 dBA Vibration Level POWER UNITS TRACHORSE amp GAS FUEL DRIVEN EQUIPMENT A1 Federal Emission Component Compliance 40CFR part 1060 120 Stanley warrants all fuel system emission components for 2 years from the date of original pur chase 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 evapora tive emissions Your emission related warranty does not cover components whose failure would not increase evapora tive 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 STAN LEY GT18B01 B02 User Manual lt 19 CONNECT FUEL HOSE ON COMES WITH ENGINE V ENGINE R FROM FUEL TANK TO FUEL VAPOR HOSE ENGINE ITEM 36 IS RUBBER GROMMET ONLY 20 GT18B01 B02 User Manual STAN LEY
28. sive Have engine serviced by an Authorized Stanley Dealer 10 Engine speed input Active only in Auto crank mode signal missing Check speed sensor wiring Check starter motor 11 Auto crank unable to Check fuel 12 Auxiliary output is shorted Check the lamp or relay hooked to the output If fault is still present have engine serviced by an authorized Stanley Dealer 13 Auxiliary output 2 is shorted Check the lamp or relay hooked to the output If fault is Stanley dealer 4 1 Actuator disconnected or n Check actuator wiring and actuator resistance open circuit Resistance should be less than 10 ohms still present have engine serviced by an authorized es es es es es 5 16 GT18B01 B02 User Manual STAN LEY GENERAL Tests and adjustments should be performed periodically to ensure the power unit is operating at maximum efficiency Stanley Circuit Tester part number 04182 is recommend ed This tester can be used to isolate problems in both the engine and hydraulic system prior to any power unit disas sembly TESTING THE HYDRAULIC CIRCUIT The following tests can be performed to ensure that the hydraulic pump is supplying the correct flow and pressure and that the system relief valve is operating properly During these tests make sure the engine is warm and op erating smoothly If test results are not as specified refer to
29. the 5 gom 19 Ipm or 8 gpm 30 Ipm setting 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 AUTO ON posi tion the oil flow is regulated automatically when the trigger on the tool is activated When the tool is not being used the engine will return to idle automatically after a 10 second delay This setting will produce 5 19 Ipm or 8 gpm 30 Ipm 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 posi tion the engine speed is held to maintain 5 gpm 19 Ipm 8 30 lpm depending on which position the operator has selected with the flow selector switch When a tool is not being used the engine will not return to idle until either the flow selector switch is turned to the off position or the throttle control switch is turned to auto on Note It may be necessary to reset the Controller 12 GT18B01 B02 User Manual At times it may be neccessary to reset the controller This could happen if a fault occurs in the controller For ex ample excessive engine speed If a fault does occur the power unit will return to an
30. the troubleshooting table in this section for possible causes Testing The 5 gpm htma type circuit or the 8 gpm type II circuit To test the circuit proceed as follows 1 Set the flow selector switch to the OFF center position 2 Set the throttle control switch to AUTO OFF position 3 Connect the Stanley Circuit Tester across two hose ends where the tool would normally be connected 4 Fully open the tester restrictor valve counterclockwise 5 Start the engine and allow it to run until warm 6 Switch the flow selector switch to 5 or 8 depending on which flow you are testing 7 With the engine at the programed speed the test flow gauge should read 4 6 gpm 15 23 or 7 9 gpm 26 5 34 Ipm 8 Slowly turn the restrictor valve clockwise while watch ing the pressure gauge The flow rate should stay at 4 6 gpm 15 23 Ipm or 7 9 gpm 26 5 34 lpm as the pressure gauge reaches 2100 2200 psi 148 155 bar STANLEY 9 At 2100 2200 psi 148 155 bar the relief valve should begin to open The pressure at which the relief valve just begins to open is commonly referred to as the cracking pressure At the cracking pressure the flow rate should start to drop because the relief valve is allowing fluid to by pass 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 sid
31. troller 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 GT18B01 B02 User Manual 4 15 FLASH ENGINE CODE FAULT SHUTDOWN CORRECTIVE ACTION 1 APECS unit not calibrated Have engine serviced by an Authorized Stanley Dealer 2 Engine speed excessive Have engine serviced by an Authorized Stanley Dealer 3 Engine speed unusually low Have engine serviced by an Authorized Stanley Dealer 4 Engine shutdown due to engine y Have engine serviced by an Authorized Stanley Dealer MR i RM no Factory settings lost Have engine serviced by an Authorized Stanley Dealer 6 External pot out of range Have engine serviced by an Authorized Stanley Dealer 7 Accelerator position idle Have engine serviced by an Authorized Stanley Dealer switch conflict Controller unit failed Have engine serviced by an Authorized Stanley Dealer Limiting exces
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