GTR20 User Manual - Stanley Hydraulic Tools
Contents
1. oineJp u SLL 0052 9L 8 9 GL 0 0509147 61 0 suoneoi dde Aue 10 pesn eq jou 5 SZ 0052 6L DIE pue 00 1001 06 0 005 001 0v 6L S OL G H Agjue s uo juo 100 9 1 0042 oinsseld 9L 8 6 pesn SI yey 5141 SLL 0052 ujog 9L 8 9 08 61 001 18 S OL G SLL 0052 L el 91 dn 09 dn O 6L 901 9 eee ee A e eunsseJd SLL 0052 L e 08 5 001 92 62 91 9 ainssaid suon SLL 0052 OL 8 dn dn ET GL 9 95941 sed SYOLONGNOD 1V9I3 123713 YVAN ASN LON OQ 49914 JO preJg SIM 9 synuiw Jed uo peseq SSL 0522 ujog OL 8 dn OL 04 dn ve GL 6 SSOY SISJOWEIP esou syonjj 3949n9 10 preg 4 eso 2 panne SMOUS 1uBu 94 O eyo avg ISd WIN HONI SYILIN 1334 Wd9 sn apisu syjBua esoH 9SOH 3112195 001 STANLEY 82. 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 suction leak Check suction connections Tighten if necessary Hydraulic tool won t operate 18 GTR20 User Manual Flow selector switch not switched ON Check that the flow selector switch is set to 5 or 10 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 STANLEY en gd derme ms eee ae 18 hp Briggs 20 hp Honda Capacity
3. 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 STANLEY VALVE BLOCK PRESSURE PRESSURE Adapter 1 2 inch Male Pipe x 10 SAE O Ring P N 07882 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 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 PRESSURE RETURN RETURN Figure 2 Hydraulic Connections GTR20 User Manual 4 11 CONTROLS Th
4. GTR20 User Manual 4 29 STANLEY Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie Oregon 97267 5698 USA 503 659 5660 Fax 503 652 1780 www stanleyhydraulics com
5. gt GTR20 User Manual HTMA EHTMA REQUIREMENTS HTMA 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 TYPE I 4 6 gpm 15 23 Ipm 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 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 3 hp 2 24 kW 5 hp 3 73 kW 6 hp 5 22 kW
6. 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 ASSOCIATION quick disconnect fittings NPT type Figure 1 Control Panel Facing the control panel the 2 left male quick discon nect 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 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
7. 7 hp 4 47 kW Filter Min full 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 a amp L EHTMA HYDRAULIC SYSTEM REQUIREMENTS 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 gpm 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 gpm 45 55 Ipm 1500 psi 103 bar 2000 psi 138 bar NOTE These are general hydraulic system requirements See tool specification page
8. 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 evapora tive emissions Your emissionrelated 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 GTR20 User Manual 4 19 ACCESSORIES Coupler Male 3 8 8 SAE 58857 Coupler Female 3 8 8 SAE Parker 58856 Coupler Male 3 8 8 SAE 66785 Coupler Female 3 8 8 5 er Sa I ERE Een te la Ye Rua Rx ERR ELM eases cu du ane 66784 Hose Assy 50 ft with couplers 2 wire braid RR iii 58448 Hose Assy 50 1 with COUplers ha A Ha nine
9. THIS TAG 9OVIL SIHL LON OG EMEND OTHER SIDE h s e SE Lx SEE OTHER SIDE SIDE 1 SIDE 2 Shown smaller than actual size STAN LEY GTR20 User Manual lt 7 Suonoeuuo lt lt lt NYNLIY RETURN gt gt gt __ JYNSSAYd HYDRAULIC CIRCUIT PRESSURE PRESSURE 9 1 0042 792 L 05 8 001 92 09 67 9L EL 9 1 0052 ensseJgd 6L SLL 0062 6L 8 dn gz o dn 09 67 9L EL 9 1 0052 ensseJd 9 8 9 LISP IVS Aq ulio 195 se 4 m 0062 mem ans 10 jsnui 09 08 005 001 51 0 SLL 0092 eJnsseJg 6L vie Bunes 0052 6l m ne m jenbe eJnssaud Buom ET 0062 IR gl 9 6 e 1529
10. Unit Dash Decal 59125 Dual Circuit Decal ADANGER PUSH TO RUN 59126 DASH RR DECAL 59125 DUAL CIRCUIT CECAL 6 gt GTR20 User Manual STANLEY 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
11. 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 ITEM QTY DESCRIPTION 1 370502 Capscrew EN cmm HEN 25 05104 E ar BE gt EN EN a Coupler Female 3 8 in 8 SAE Aeroquip Capscrew 1 4 in 20 Manifold Dual Circuit eoose 15 sos STANLEY 3 Way Switch METT Ca 62020 Ear 10 11 12 13 4 5 T 7 7 1 2 2 D 2 2 1 1 1 1 1 1 1 2 1 1 LI ES 2 2 2 2 E 59085 Manifold Assy Dual Circuit 22 29 31 EMEN ER 2 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 12 VOLT PLUG WIRING HARNESS Receptacle Assy 64942 TO STARTER SOLENOID DESCRIPTION GTR20 User Manual 4 25 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
12. 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 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 ANT 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
13. 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 26 gt GTR20 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 P N DESCRIPTION Manifold Assy Dual Circuit sem 2 e f sss 1 OOO 79 1 O OO STANLEY GTR20 User Manual 4 27 DUAL CIRCUIT POWER UNIT HARNESS P N 62294 RED WIRE TO POSITIVE SIDE HOUR METER 1 5 BLACK WIRE TO v NEGATIVE SIDE TOOL CIRCUIT HOUR METER TOOL CIRCUIT 1 SWITCH 1 SOLENOID Hb AUTO IDLE RING SWITCH LL WHITE WIRE ON SIDE pe OF STARTER SWITCH PRESSURE SWITCH STARTER SOLENOID GREEN WMHITE STRIPE WIRE STARTER POST TOOL CIRCUIT 2 SWITCH PEER TOOL CIRCUIT 2 SOLENOID 3 GROUND WIRES MAG KILL ALLELES 9 BLACK WIRE STARTER 57 2 ACTUATOR INTERLOCK Z LG gs RED GREEN 2 RELAY LG 2 MAG PICKUP gt COBINER YELLOW WIRE SN SOL
14. be used for the 10 gpm circuit but DO NOT use two separate tools when in the 10 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 cold 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 STAN LEY GTR20 User Manual 4 13 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 For power units equipped with Honda Engines ONLY Denso J16CR U 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 hydrau
15. ees eec eng aeos 24 FRAME PARTS 25 PUBL TANK amp cT TT 26 HOSES FITTINGS amp CLAMPS eere t ertet xe kaserne a nine ie npe studi aed 27 MAIN WIRING HARNES 28 DUAL CIRCUIT WIRE HARNES S crece Ren aa 29 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 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 STAN LEY GTR20 User Manual 4 3 Safety symbols and signal words as shown below are used to emphasize all operator maintenance and repair ac
16. for tool specific requirements STANLEY GTR20 User Manual lt 9 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 the 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 For power units equipped with Honda Engines ONLY Denso J16CR U 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 10 GTR20 User Manual 4 HYDRAULIC FLUID RECOMMENDED HYDRAULIC OILS Below is a list of recommended oils by brand Brand Biodegradable Description amsoi mo we Exxon Mobi No Dreioexe chevron no RandoHDZ32 Recommended for extreme cold temperatures 5 HYDRAULIC CONNECTIONS The recommended hose length is 25 8 m with a 1 2 inch
17. 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 power again External pot out of range If controller still does not work or if no calibration file is available consult factory Verify that pot is wired correctly Recalibrate external pot Verify that signals are working and synchronized Controller unit failed Electrical noise may be entering the controller 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 Resis
18. 2 ette tree Two 5 gpm 19 Ipm Circuits or One 10 gpm 37 8 Circuit BC E dutee 36 in 91 4 cm Te Per E E M 23 in 58 4 cm plo I ee 29 5 in 74 9cm Weight Wet Dual Circuit Briggs eren Eee E 334 16 151 5 kg Weight Wet Dual Circuit Honda sisi reris ener a Ree sebo e 352 16 159 6 kg Fuel Tank Capacity M 5 5 gal 20 8 Itr Estimated Gas Consumption Per HOUT I Lese iiie eia icit RELAY mens 1 3 gal A Itr Hydraulic Reservor Capacity s eei seb LT aac 3 gal 11 Itr Nominal Operating Pressure u 1 retient Pa papa ka AR PUR bena nad 1500 psi 103 bar Relef valve 2100 psi 145 bar Full relief setting uu 2500 psi 172 bar C t gory ii uester merenti mt epe etta etae en den C 19 103 bar or E 37 8 103 bar HTMA Type 1 4 6 gpm 15 23 Ipm 103 bar or Type RR 9 10 5 gpm 34 40 Ipm 103 bar EMISSIONS POWER UNITS TRACHORSE amp GAS FUEL DRIVEN EQUIPMENT A1 Federal Emission Component Compliance 40CFR part 1060 120
19. 2 31848 Hose Assy 25 ft with couplers sise 31972 Hose Assy 25 ft with couplers 2 wire braid 58451 Wheel Kit Converts a Skid Mount unit into a wheeled unit 73393 FILTERS EE ________ MODEL OIL FILTER AIR FILTER FUEL FILTER jode FILTER 18384 18382 19947 18383 40408 40458 40459 40460 40462 40408 20 GTR20 User Manual STAN LEY CONNECT TO FUEL VAPOR HOSE ON FUEL VAPOR HOSE FROM FUEL TANK TO ENGINE ITEM 36 RUBBER gt GROMMET ONLY ENGINE FUEL LINE STANLEY GTR20 User Manual 4 21 Biggs Engine Includes 5 7 2 1 4 10 1 I 12 1 13 1 14 15 1 7 lt E 4 2 60 60574 1 2 2 x 23 z 5 25 es 2 7 69 69282 Hex Skt Head Capserew 532 2 m I 75 Suppe By Eng Manufacturer 33 34 35 37 22 gt GTR20 User Manual STANLEY RE SS 22 wheel kit is available to convert Skid Mount unit to a wheeled unit P N 73393 CONNECT TO FUEL VAPOR HOSE ON ENGINE UEL VAPOR HOSE FROM UEL TANK TO ENGINE ITEM 36 IS RUBBER GROMMET ONLY Q 2 STANLEY GTR20 User Manual 4 23 P 5 s 5 5 m 20 22 23 7 5 S 3s 2 cs o 24 gt GTR20 User Manual STAN LEY 12
20. 34 41 6 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 or 9 11 gpm 34 41 6 Ipm as the pressure gauge reaches 2100 2200 psi 148 155 bar STANLEY 9 At 2100 2200 psi 148 155 bar the relief valve should be gin to open The pressure at which the relief valve just be gins to open is commonly referred to as the cracking pres sure 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 manifold as sembly 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 clock wise to raise the pressure and counterclockwise to reduce the pressure c Tighten the nut and retest GTR20 User Manual 4 17 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
21. ENOID RECTIFIER YELLOW WIRE ENGINE OIL UF PRESSURE FUEL SWITCH TO CONTROLLER SHUTOFF RED WIRE RED URE TERMNAL ORANGE WJ 5 TERMINAL LLOW C CI TER MNAL ENG NE L F FE 55 SJ NG DE TAL 28 gt GTR20 User Manual STANLEY DUAL CIRCUIT WIRE HARNESS PIN 62294 CONTROLLER PLUGS El RED BLACK GREEN YELLOW amp GRAY CONTROLLER PLUGS BLUE amp WHITE MAGNETO WIRE H GRAY ACTUATOR PLUG RED amp GREEN WRES ENGINE OIL PRESSURE SWITCH RED WIRE GROUND WIRES En 6 BLACK ENGINE OIL PRESSURE SWITCH ENGINE OIL 6 ORANGE WIRE A PRESSURE SWITCH YELLOW WIRE RELAY ORANGE WHITE PRESSURE SWITCH GREEN WWHITE STRIPE amp BLACK YELLOW BLUE CIRCUIT 2 TORELAY GREEN WIWHITE STRIPE AND BLACK Y ii Tr STARTER SWITCH WHITE COMBINER BROWN BLACK HOUR METER BLACK WIRE STARTER POST RED WIRE STARTER SOLENOID GREEN WMAITE STRIPE WIRE RECTIFIER WHITE WIRE STANLEY AUTO IDLE SWTCH YELLOW BLUE CIRCUIT 1 LBLUE BLACK fl DIODE HOUR METER RED WIRE 10 AMP FUSE P CIRCUIT 2 SWTCH YELLOW BROWN BLACK PURPLE AND GREEN WHITE STRIPE DIODE STARTER SWITCH RED ORANGE amp BLACK CIRCUIT 1 SWITCH YELLOW WHITE LIGHT BLUE amp PURPLE ENGINE KILL BLACK FUEL SHUTOFF 2 NS RED WIRE
22. GTR20 HYDRAULIC POWER UNIT USER MANUAL Safety Operation and Maintenance 2014 Stanley Black amp Decker Inc New Britain CT 06053 U S A 65114 6 2015 Ver 13 2 gt GTR20 User Manual STAN LEY SAFETY SYMBOL ur 4 SAFETY PRECAUTIONS nt 5 TOQESTICKERS EE 6 HYDRAULIC HOSE REQUIREMENTS tenant n ant ea tra been ea Gives a dn dde can aqa 7 HOSE RECOMMENDATIONS naiss 8 FIGURE 1 TYPICAL HOSE CONNECTIONS uu uu cit ttt rtt dete tite 8 EHTMA HTMA REQUIREMENTS netu ec ste 9 OPERATION 10 ROUTINE MAINTENANCE 2 taste tette 14 PROGRAMMABLE CONTROLLER tet tete n ti t e 15 FAULT CODES EET 16 TESTING amp TROUBLESHOOTING inttr th eden nn cress nr tan dra tan ln ana te dinar da 17 TROUBLESHOOTING Luske 18 SPECIFICATIONS e 19 ACCESSORIES m 20 GTR20 BRIGGS IEEUSTRATION ette teat en ra enr fide a 21 GIR20 BRIGGS PARTS TEM 22 GTR20 HONDA IBEUSTERATIQN hen et et e etae ett tree tet t rp etl tease ann e ge sardines 23 GTR20 HONDA PARTS LIS ctae euo cure tore cette eee exte titane eere d x
23. LT 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 applied 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 GTR20 User Manual 4 15 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
24. 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 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 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 DO NOT REMOVE
25. ector Switch AUTO OFF When the throttle control switch is in the AUTO OFF position the engine speed is held to maintain 5 gpm 19 or 10 gpm 37 8 Ipm depending on which position 12 GTR20 User Manual 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 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 po
26. is unit is equipped with an advanced proportional en gine control system It provides means of controlling engine speed by adjusting the fuel control lever with an actuator The Power Unit provides two 5 gpm 19 lpm up to 2000 psi 140 bar circuits or one 10 gpm 37 8 Ipm up to 2000 psi 140 bar circuit Flow Selector tool Circuit 1 Switch Throttle Control Switch Flow Selector tool Circuit 2 Switch Ignition Switch Figure 3 Panel Control Valve Two 5 gpm hydraulic tools can be connected to the tool circuit or one 10 gpm tool The circuit is activated by turning one or both flow selector switches to 5 or both Switches to 10 gpm If both are at 10 gpm 10 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 5 gpm 19 Ipm cir cuits or one 10 gpm 37 8 Ipm circuit depending on which postion the operator has selected with the flow sel
27. lic 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 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 conditions exist Check oil cooler for debris Remove debris with air pressure 14 GTR20 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 See HYDRAULIC SYSTEM MAINTENANCE earlier in this sectio
28. n 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 preset and has no 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 3 Actuator should move throttle lever to wide open posi STANLEY 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 FAU
29. 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 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 STAN LEY GTR20 User Manual 4 5 59126 Power
30. sition 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 7 and 8 STANLEY SHUTDOWN FOR 5 GPM OPERATION 1 Ensure the flow selector switches are in the OFF po For 5 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 5 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 5 gpm circuits move both flow se 3 Allow the engine to idle for approximately one minute lector switches to the 5 gpm position Both 5 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 10 GPM OPERATION For 10 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 10 gpm position When finished operating the tool move both flow selec tor switches to the OFF position Note Either set of couplers can
31. tance should be less than 10 ohms 5 o 7 Accelerator position idle Switch conflict 16 GTR20 User Manual STAN LEY GENERAL Tests and adjustments should be performed periodically to ensure the power unit is operating at maximum ef 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 5 GPM OR 10 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 5 or 10 gpm de pending 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 Ipm or 9 11 gpm
32. 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 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 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 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
33. 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 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 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 GTR20 User Manual STAN LEY Tool operators and maintenance personnel must always comply with
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