GT23 User Manual 10-2014 V-7
Contents
1. 1 Check battery voltage for stability and correct value The LED will turn on for one second when the controller 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 STANLEY 1 Disconnect red wires from the control module to actuator 2 Attach jumper wires from battery to the RED wires to actuator 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 Replace Note Before replacing the actuator verify signal inputs to module see Stanley Electrical Trouble shooting guide TechHELP 032807 A copy ofthe TechHELP can be obtained from the Stanley Hydraulic Tools web site at www stanley hydraulic tools com support 20page htm or contact a Customer Service Representative at 503 659 5660 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 applie2. 0 LE 8c 9c m 9 e EL cE lt jr 6 2EEZ9 N d age Aeteg punoip le d E ot S6ESE N d 81489 N Aeneg eAnisod 2 4 ATNO LINNOU o N 7 Yagany SI 9 WILI 3NION3 La OL HNVL 13N4 WOU 3SOH HOdVA 1 m 3NION3 HLIM S3NO2 81 9 n se bb 4L es re 3NION3 vz NO ISOH dOdVA pi vr IS 13N4 OL 19 NNOO IN 1304 08 3 e 8 i S S 9v 19 L 9v In NS M lt 9 gt e 14 8z L ASSY 3NIS9N3 30 1i Vd 3 eL 89 39VMNI131LLOSHL NISN OL SL STANLEY 20 GT23 User Manual ONO STANLEY o lt sch NI sch sch AO NM P PM P B NM GAN sch sch AQ sch CO EI NI NI MM B P sch sch sch A P sch sch sch A DESCRIPTION Muffler Part of Item 4 Heat Shield Screw Hex Washer Briggs Engine Coupling Square Key Capscrew 3 8 16 x 1 1 4 Pressure Switch Flange Nut Bushing Key Blower Hub Capscrew Filter Assy Capscrew Grip Plate Std Thread Union Button Head HS Washer 1 4 in ID Capscrew 1 4 20 UNC Front Grille Cooler Capscrew 3 8 Hydraulic Tank Weather Strip Blower Wheel Hex Flange Bolt 1 4 20 Engine Controller Hex Flange Bolt Frame Base Weldment Wheel amp Tire Axle Pump Single Fuel Cap Grommet Fuel Tank Battery Battery Cover Capscrew 1 4 20 x 3 4 Washer Handle Bumper
3. 30 Ipm 138 bar or E 45 Ipm 138 bar Nominal Press re iet tex RA RA AR ii 1500 psi 103 bar Max PressSufe ae eret ete ficta aa te bebat aetatis a iai A laun ea ea ei a 2000 psi 138 bar 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 evaporative 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 GT23 User Manual 19 99 S9 ASSY 3NI9N3 40 lHVd 02 43 NISN 40 IS NO Y31714 10 OL ES Sc 44 cL 8c Lv Z 0 0 ee
4. 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 Hydrau lic 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 lt E a SE E w gt o z D m o z o a DANGER FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRIC LINES MAYRESULT IN DEATH OR SERIOUS INJURY FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND ELECTRIC LINES BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE ON OR NEAR ELECTRIC LINES WIPE THE ENTIRE LENGTH OF THE HOSE AND FITTING WITH A CLEAN DRY ABSORBENT CLOTH TO REMOVE DIRT AND MOSISTURE AND TEST HOSE FOR MAXIMUM ALLOWABLE CURRENT LEAKAGE IN ACCORDANCE WITH SAFETY DEPARTMENT INSTRUCTIONS SEE OTHER SIDE DANGER DO NOT 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
5. CAUSE BODILY INJECTION AND SEVERE PERSONAL INJURY HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING ABRASION CUTTING OR CONTACT WITH HIGH TEMPERATURE SURFACES DO NOT USE IF KINKED DO NOT USE HOSE TO PULL OR LIFT TOOLS POWER UNITS ETC CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAMAGE TO COUPLINGS IF ANY OF THESE CONDITIONS EXIST REPLACE THE HOSE IMMEDIATELY NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE 6 AFTER EACH USE STORE IN A CLEAN DRY AREA SEE OTHER SIDE Ovl SIHL 3AON3U LON OG shown smaller than actual size THE TAG SHOWN BELOW IS ATTACHED TO CONDUCTIVE HOSE DO NOT REMOVE THIS TAG DANGER ps NoT e THIS HYDRAULIC HOSE ON OR NEAR ELECTRIC LINES THIS HOSE IS ELED OR CERTIFIED AS NON CONDUCTIVE USING THIS HOSE ON OR NEAR ELECTRICAL LINES MAY RESULT IN DEATH OR SERIOUS INJURY FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND ELECTRIC LINES DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE IMPROPER USE OR HANDLING OF HOSE COULD RESULT IN BURST OR Va 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
6. MANUFACTURERS AS SOCIATION quick disconnect fittings NPT type threads See Page 8 Figure 1 Panel Control Valve Facing the panel control valve the bottom male quick disconnect fitting is the PRESSURE FLUID OUT fitting The top female quick disconnect fitting is the RETURN FLUID IN fitting 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 on page 8 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 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 STANLEY 6 BATTERY The supplied 12 Volt DC battery is a non spillable mainte nance free battery and is fully charged Make sure the battery cables are tight and charging circuit 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 batte
7. 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 STAN LEY GT23 User Manual 5 Stanley Dash Sticker 62302 6 GT23 User Manual STAN L EY HOSE TYPES The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the hydraulic 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 rein forcement 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 constucted of thermoplastic or synthetic rubber inner tube synthetic fiber braid reinforcement and weather resistant thermoplastic or synthetic rubber cover This
8. GT23 HYDRAULIC POWER UNIT USER S MANUAL SAFETY OPERATION AND MAINTENANCE 2014 Stanley Black amp Decker Inc New Britain CT 06053 U S A 69405 10 2014 Ver 7 2 GT23 User Manual STAN L EY SAFETY SYMBOLES ind Nasi na ann ibaa an a Br a a a ra ld FERN 4 SAFETY PRECAUTIONS ss ei ban a a id a a aka 5 TOOL STICKERS TAGS EUR ETE 6 HYDRAULIC HOSE REQUIREMENTS OO ei 7 FIOSE SAFETY TAGS nain EE 7 HOSE RECOMMENDATIONS ente tert cete rr mages BE AA SNL xo eL Kee e Pe i Lo e feet XA REDE XR CHR an EA mania hs 8 HTMAREQUIREMENT S traiter test eet eie er deutet ire et ee deret iie Pes Fo Qi cioe Trece EES 9 OPERATION M 10 PREPARATION FOR US X 10 CONTROLS HR 12 SUI dU HELM TETUR 12 FOR S GPM OPERATION 2 ois do 12 FOR A2 GPM OPERATION ts a uu lg a aaa nennen 12 COLD WEATHER STARTUP a aaa M nenn 13 TOW de NR a 13 ROUTINE MAINTENANCE EE 14 SO 14 PROGRAMMABLE CONTROLLER erret imei eter iden iret eise Ep C daira aeu Ld Fee E eb uda il ad bak 15 EL UR e eleng lege IR 15 FAULT CODES U 16 TESTING ee ee e El EE 17 TESTING THE HYDRAULIC CIRCUS SA GR NA GER E sid wii RS cates 17 TESTING THE 8 GP
9. HOSE TO PULL OR LIFT TOOLS POWER UNITS ETC SIDE 1 DANGER 5 CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAMAGE TO COUPLINGS IF ANY OF THESE CONDITIONS EXIST REPLACE THE HOSE IMMEDIATELY NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE 6 AFTER EACH USE STORE IN A CLEAN DRY AREA SEE OTHER SIDE E SIDE 2 Ovl SIHL JAOWSY LON OG shown smaller than actual size STANLEY GT23 User Manual 7 HYDRAULIC CIRCUIT RETURN PRESSURE Suonoouuo 9SOH edIdAL lt lt lt MO H N33 MO 14 gt gt gt 3unssaaud zZ mm mm RETURN g l 0057 ume 792 L 0 8 001 92 09 67 9L L g l 00GZ einsseJg SL vIe g l 0052 unes 6L VIE 8 o dn Sz 0 dn 09 67 9L 6L g l 00GZ einsseJg EI 879 GLL 0052 unes 792 L 09 0 002 001 65 9 LOL g l 00GZ einsselg 6L DIS GLL 0052 unes 6L vIe 08 91 OOL LS 6r 8e L OL g l 00GZ einsselg EI 8 9 GLL 0052 yog QL 8 9 GL o dn 0g 0 dn 6r 8e L OL g l 0092 L
10. Hex Flange Bolt Lockwasher 3 8 Foot Flang Nut 3 8 16 Hex Flange Bolt 3 8 16 Retaining Ring Washer 3 4 Blower Housing Pump Mount Fuel Elbow Stud Nut Throttle Lever Hex Washer Head Screws Screw Cable Clamp ch Ni sch 0 sch sch sch A p A sch sch DESCRIPTION No Item Cooler Mount 90 1 8 NPT Street EL Angle Bracket Weldment Rotary Actuator Actuator Bracket Hose Clamp Hose Hex Flange Screw Throttle Link Clamp Hex Flange Nut Link Retainer Hex Socket Head Capscrew 8 32 Hex Socket Head Capscrew 6 32 Wire Assemble Rectifier Wire Pipe Plug Spring Hose Clamp Fuel Vapor Hose Spring Hose Clamp Fuel Hose Filter Element Part of item 15 Filter Service Kit Includes Filter and Seals GT23 User Manual 21 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 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 venting is achieved thru the vapor line The old style fuel tank has only one fuel line coming fr
11. M HTMA TYPE GIRO ULT aede preteen ener fnac ch jas EE eene cet ser eb ARA a A i ja e Roda 17 OR THE412 GPM TYPE LL CIRCUIT a ek ska rt teni bf na Re ND ded need ronda erecta ga nhac st en aL esed aA 17 TROUBEESHOO TING SN a 18 SPECIFICATIONS 2 22 42 E 19 BRIGGS ENGINE ASSEMBEY sessa ad Bassa fag titer ie P iat eco ror te ti edere pi au e o Fea EES 20 BRIGGS ENGINE EB EEN e 21 FUEL TANK amp CAP LE E 22 FRAME PARTS te 23 HOSES FITTINGS amp CLAMPS 0 EET 24 MAIN POWER UNIT WIRING HARNESS eniti tee tete ttn eti eet etn atta ctae vad Eiki nn keel eda a rds daba aerea aia ane tend eR Fa 25 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 Stanley recommends that 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 IM PROPER REPAIR OR SERVICE OF THIS TOOL REPAIRS AND OR
12. 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 GT23 User Manual 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 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 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 NOTICE to the equipment This signal word indicates a situation which if not avoided may result in dam IMPORTANT a
13. ULIC SYSTEM REQUIREMENTS TYPE TYPE Il TYPERR TYPE III Flow Range 4 6 gpm 7 9 gpm 9 10 5 gpm 11 13 gpm 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 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 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 F 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 F 40 F 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 Filter d NM 25 microns 25 microns 25 microns 25 microns Min full flow filtration 30 gpm 30 gpm 30 gpm 30 gpm Sized for flow of at leas
14. aining 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 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 notreverse tool rotation direction by
15. being used the engine will return to idle automatically after a 10 second delay This setting will produce 8 gpm 30 Ipm or 12 gpm 45 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 8 gpm 30 Ipm or 12 gpm 45 Ipm 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 12 GT23 User Manual 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 ex ample excessive engine speed If a fault does occur the power unit will return to an idle and the operator will have no control of the unit To reset the controller simply turn off the power unit and restart it 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 th
16. c fluid level low Detach from hose connect set together and check for free flow 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 STANLEY pec M M 23 hp Briggs CAD ACILY RA SR a One 8 gpm 30 Ipm Circuit or One 12 gpm 45 Ipm Circuit Hiep EE ET 36 in 91 4 cm lao EUIS 23 in 58 4 cm misse 29 5 in 74 9cm Weight Wet Single Circuit Briggs sta na eter Siena en ee 330 Ibs 149 6 kg Foel Tank Capacity u M 5 5 gal 20 8 Itr Estimated Gas Consumption Per Hour nia icti irit tie en tad dar SSES ABEE RN s dE SER SG 1 3 gal A Itr Hydraulic Reservor elei AMETE I A A A DD 3 gal 11 Itr Relief Valve crack setting iti itte EES roten ED lat ie 2100 psi 145 bar F ll reliet setting iius aaa nd uito en eren bd ne esc n beoe nabe 2500 psi 172 bar HTMA Category D
17. d Stanley Dealer switch conflict Controller unit failed os Have engine serviced by an Authorized Stanley Dealer engine serviced by an Authorized Stanley Dealer E excessive Have engine serviced by an Authorized Stanley Dealer actuator current Engine speed input Active only in Auto crank mode signal missing Check speed sensor wiring Check starter motor 11 Auto crank unable to no Check fuel start engine 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 still present have engine serviced by an authorized Stanley dealer 14 Actuator disconnected or Check actuator wiring and actuator resistance open circuit Resistance should be less than 10 ohms 16 GT23 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 is recommended This tester can be used to isolate problems 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 pressure and that the system relief valve is operating properly During these tests make sure the engine is warm and op erating
18. d 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 GT23 User Manual 15 FLASH ENGINE CODE FAULT SHUTDOWN CORRECTIVE ACTION Unit not calibrated Have engine serviced by an Authorized Stanley Dealer ES Engine speed excessive Have engine serviced by an Authorized Stanley Dealer p Engine speed unusually low Have engine serviced by an Authorized Stanley Dealer Engine shutdown due to engine Have engine serviced by an Authorized Stanley Dealer protection input 5 Factory settingslost settings Factory settings lost yes raue engine serviced by an Authorized Stanley Dealer engine serviced Have engine serviced by an Authorized Stanley Dealer an Authorized Stanley Dealer External pot out of range Have engine serviced by an Authorized Stanley Dealer Accelerator position idle Have engine serviced by an Authorize
19. e This may take a 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 STAN LEY GT23 User Manual 13 ENGINE MAINTENANCE Follow the maintenance schedule and general maintenance instructions in the engine maintenance and operation manual furnished with the power unit HYDRAULIC SYSTEM MAINTENANCE Check hydraulic fluid level daily Add fluid per specifica tions in this manual See HYDRAULIC FLUID under the section titled OPERATION 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 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 SPARK PLUGS On power units equipped with Briggs amp Stratton Engines ONLY Champion RC12YC o
20. e 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 page 8 and 10 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 gpm position When finished operating the tool move the flow selector Switch to the OFF position FOR 12 GPM OPERATION For 12 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 12 gpm position When finished operating the tool move the flow selector Switch to the OFF position STANLEY COLD WEATHER STARTUP 1 Use the procedures described under STARTUP and then follow the procedure below 2 Hydraulic fluids are thicker in cold weather Therefore itis 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 idl
21. ge 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 DEM 4 GT23 User Manual STAN L EY Tool operators and maintenance personnel must always comply with the safety precautions given in this manual and on the stickers and tags attached to the equipment These safety precautions are given for your safety Review them carefully before operating the tool and before performing general maintenance or repairs Supervising personnel should develop additional precautions relating to the specific work area and local safety regulations 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 The Hydraulic 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 personal injury or equipment damage Operator must start in a work area without bystanders The operator must be familiar with all prohibited work areas such as excessive slopes and dangerous terrain conditions Establish a tr
22. ime 6L DIS 06 0 008 001 0r 6L SOL S g l 00GZ einsselg EI 8 9 g l 0052 yog QL 8 9 0 SL 00L G 0r 6L SOL S g l 0052 yog CL ZIL GL 9 dn 0 0 dn 0r 6L OL G GLL 0052 yog CL ZIL 08 92 001 92 2 SL or GLL 0052 yjog OL 9 87 0 dn gz 0 dn 2 SL ENZ SMOLONANOO TVOIMLOTTA YVAN ISN LON OQ plejg 13q 4 10 plesg 9JIM SOH BAHDNPUOD GGL 0GZZ yog OL 9 0 dn OL o dn be SL 6 Son 3exong API 10 pleig 19q14 SSOH BAHONPUOD UON PS9 uva ISd unjea Ssed WIN HONI Sd 1 1333 Wd INdS INSS ld BuyJoM UIN 3sn J9jeugei episu su fus7 9SOH MOI4 UO PRESSURE LLSr AVS Aq yo jas se suoneo 1199ds P999X9 10 199UU SNUW 9SOU OIInBJD AU IV Bunjes AJLA 9II9 WEIS S OIInBJDAU UJnUJIXBUJ y oj jenbe einsseid BUIyJOM LUNUUIUILU Deg e jsee Je 9ABU JSNW esou oineJp u Iv suoneoidde sayjo Aue 104 pesn eq jou DInOUS pue syusweuinbal Bunejedo 100 sjoo OIInBJDAH ASIUB1S uo peseq Ajuo SUOIBQIIddg JOO QIInBJDAU JO pasn aq oj DSDUS1UI SI yeyo siu eoueuuojed JOO WNWIXEW eJnsue oj aal ejqeydeooe WiNWIUIW e 0 eunsseJud xoeq eunsseJd eui UJn19 dee oi pepuejur aie suonepueuiuJlo29J eseu wd ein uiuJ Jed Sa ll uud5 omuuu 1ed suojje uo peseq Su15ug 9SOU snoueA JO SI JALUBIP esou WNW UILU DSDUSUUUJOOS SMOUS 1uBu eui 0 yeyo eu suoinepuouil W099y 9SOH 3In2JI2 21jneJp H 03 IOOL STANLEY 8 GT23 User Manual HTMA EHTMA REQUIREMENTS HTMA TOOL TYPE HYDRA
23. l ch ch ch A x A DESCRIPTION Manifold Assy Single Circuit Hose Clamp Elbow 45 Straight Thread Adapter Elbow 90 Hose Connector Straight Thread Elbow 45 Hose Hose Hose Barb 3 4 in Hose x 3 4 in Pipe STANLEY Wire Harness P N 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 SWITCH MANIFOLD ASSY BLACK TO STARTER SOLENOID RELAY 62301 SUPPLIED W 62293 HARNESS POSITIVE BATTERY CABLE TO STARTER SOLENOID GROUND WIRES ENGINE KILL BLACK TO ACTUATOR RED GREEN A WHITE TO MAGNETO WIRE ON ENGINE GRAY WIRE A OIL PRESSURE FUEL SHUTOFF SWITCH RED WIRE L RED WIRE P TERMINAL A LS 3 ORANGE WIRE S TERMINAL CON 3 CONTROLLER YELLOW WIRE I TERMINAL ENGINE OIL PRESS SWITCH WIRING DETAIL STAN LEY GT23 User Manual 25 ANLE Y Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie OR 97267 5698 503 659 5660 FAX 503 652 1780 www stanleyhydraulics com
24. ntenance 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 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 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 4 HYDRAULIC FLUID RECOMMENDED HYDRAULIC OILS Below is a list of recommended oils by brand Brand Biodegradable Description son No we Exon Mobil Ne DTE10Exs chewon No Rando HDZ 32 Conoco Phillips Unax AW WR 32 Yes Yes Clarion CITGO Exxon Mobil Recommended for extreme cold temperatures 10 GT23 User Manual Yes Yes Yes 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
25. om 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 GT23 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 STANLEY 370502 03906 62268 58857 58856 60962 59130 62302 59075 68595 67899 60955 67899 60956 60946 62269 23530 58916 62267 59079 59095 08104 NND a aa cX c cx NO x DESCRIPTION Capscrew 5 16 in 18 UNC Nylock Nut 5 16 in 18 UNC Handle Rear Lift Coupler Male 3 8 in 8 SAE Coupler Female 3 8 in 8 SAE Capscrew 1 4 in 20 Manifold Assy Single Circuit Includes Items 23 thru 29 Dash Decal Hex Flange Bolt 1 4 20 x 5 8 Decal Single 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 Hollow Hex Plug 6 SAE DESCRIPTION Relief Valve Pressure Switch Assy Directional Valve Cap Included with Item 27 Coil Choke Cable Assy GT23 User Manual 23 59130 62199 350000 02773 58569 58943 350104 40364 59088 59089 59105 24 GT23 User Manua
26. r 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 war ranty that will not be considered 14 GT23 User Manual 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 Disconnect tool hoses 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 factory programmable and has no manual adjustments A flashing LED indicates he fault condition CALIBRATION Calibration and programming can only be done by the fac tory TROUBLESHOOTING GUIDELINES Please follow the checklist below to troubleshoot your Stan ley controller
27. re set as follows a The relief valve is located on the right side of the unit just behind the dash panel It protrudes out from the manifold 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 clockwise to raise the pressure and counterclockwise to reduce the pressure c Tighten the nut and retest GT23 User Manual 17 PROBLEM Engine will not start Fluid blowing out of fluid reservoir vent CAUSE Flow selector switch not in the OFF position Battery not connected REMEDY Make sure the flow selector switch is in the OFF position when starting 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 Hydraulic tank overfilled Pump suction leak Remove plugs check gap clean or replace Correct the fluid level Check suction connections Tighten if necessary Hydraulic tool won t operate 18 GT23 User Manual Flow selector switch not switched ON Check that the flow selector switch is set to 8 or 12 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 Hydrauli
28. ry 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 STA N L EY GT23 User Manual 11 CONTROLS This unit is equipped with an advanced proportional engine control system It provides a 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 8 gpm 30 Ipm up to 2000 psi 140 bar or 12 gpm 45 Ipm up to 2000 psi 140 bar with a factory programmed electronic governed engine throttle THROTTIEE GGOPNin rime SWITCH NOS A t ep IGNITION SWITCH FLOW SELECTOR SWITCH Figure 3 Panel Control Valve One hydraulic tool can be connected to the tool circuit The circuit is activated by turning the flow control switch to either the 8 gpm 30 Ipm or 12 gpm 45 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 activated When the tool is not
29. smoothly If test results are not as specified refer to the troubleshooting table in this section for possible causes TESTING THE 8 GPM HTMA TYPE II CIRCUIT OR THE 12 GPM TYPE Ill 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 8 or 12 gpm depending on which flow you are testing 7 With the engine at the programed speed the test flow gauge should read 7 9 gpm 26 5 34 Ipm or 11 13 gpm 41 6 49 Ipm 8 Slowly turn the restrictor valve clockwise while watch ing the pressure gauge The flow rate should stay at 7 9 gpm 26 5 34 Ipm or 11 13 gpm 41 6 49 Ipm 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 cracking STANLEY 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
30. t 114 Ipm 114 Ipm 114 Ipm 114 Ipm For cold temp startup and max dirt holding capacity Hydraulic fluid Petroleum based premium grade anti wear non conductive Viscosity at min and max operating temps NOTE 100 400 ssu 100 400 ssu 20 82 centistokes 100 400 ssu 100 400 ssu 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 EHTMA CLASSIFICATION HYDRAULIC SYSTEM REQUIREMENTS Flow Range Nominal Operating Pressure at the power supply outlet System relief valve setting at the power supply outlet A 3 5 4 3 gpm 13 5 16 5 Ipm 1870 psi 129 bar 2495 psi 172 bar 4 7 5 8 gpm 18 22 Ipm 1500 psi 103 bar 2000 psi 138 bar 7 1 8 7 gpm 27 33 Ipm 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 gpm 45 55 Ipm 1500 psi 103 bar 2000 psi 138 bar NOTE These are general hydraulic system requirements See tool specification page for tool specific requirements STANLEY GT23 User Manual 9 PREPARATION FOR USE Do not operate the power unit until you have read the engine operating and mai
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