Parts Manual
Contents
1. 12 VOLT PLUG WIRING HARNESS RECEPTACLE ASSY 64942 TO STARTER SOLENOID 12 VOLT ACCESSORY NOT EQUIPPED ON ALL MODELS AVAILABLE AS AN ADD ON IF ADDING 12 VOLT ACCESSORY CUT AWAY LABEL AND PUNCH THROUGH DASH PANEL 7 370502 Capscrew 5 16 in 18 UNC NO A CQ N gt 03906 62270 58857 58856 60962 59130 62302 62317 59074 62300 62305 60963 60955 60954 60956 60946 62272 2 2 2 2 2 2 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 Dash Decal Dash Decal POWERLINK Hex Flange Bolt 1 4 in 20 Decal Single Circuit Decal Single Circuit POWERLINK Knob 2 Way Switch Rotary Switch 3 Way Switch Hour Meter Frame Weldment 2f Item No 17 23530 58916 62271 59079 59095 60955 350045 59131 59128 60959 2 Hex Flange Bolt 3 8 in 16 Handle Lock Lift Handle Cooler Guard Flange Nut 1 4 in 20 2 Way Switch on models with POWERLINK option only Hollow Hex Plug 6 SAE Relief Valve No Pressure Switch Assy Directional Valve FIGURE 3 HOSES FITTINGS amp CLAMPS2. 23 in 58 4 cm gie 29 5 in 74 9cm XK Weight Wet Single Circuit Briggs 330 Ibs 149 6 kg XK Weight Wet Single Circuit Honda e 348 Ibs 157 8 kg EET TE Um 7 gal 26 5 Itr Estimated Gas Consumption Per jm eas aka Omas hi RR admi la 1 3 gal 4 ltr Hydraulic Reservor Capacity 3 gal 11 Itr 2100 psi 145 bar s 2500 psi 172 bar C 20 Ipm 138 bar or D 30 lom 0 138 bar 18 SERVICE GENERAL Service instructions in this section are limited to parts and components other than the engine and hydraulic pump Other major components should be serviced by representa tives of the respective manufacturers as follows ENGINE Briggs and Stratton Vanguard OHV Model 356447 0115 E1 Model 35644A 0116 E1 PowerLink models Honda Engine 20 hp Model GX620K1QAB The Briggs engine should be serviced only by Briggs amp Stratton Industrial and Construction Equipment Dealers Lawn and Garden Dealers may not be able to offer warran ty work for this application It is recommended to contact a Central Sales amp Service Distributor for the nearest autho rized Briggs and Stratton representative or
3. 27 Hoses Fittings amp Clamps Fig 3 24 242 2 2 2 2 2 2 2 28 Wiring Diagram Additional Wiring for Honda Fig 4 29 Wiring Diagram POWERLINK Fig 4 30 Wiring Diagram Main Power 31 UN gc A E E m 32 SERVICING THE STANLEY POWER UNIT This manual contains safety operation and routine mainte nance instructions Stanley Hydraulic Tools 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 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 SAFETY SYMBOLS Safety symbols and signal words as shown below are used to emphasize all operator maintenance and repair actions which if not strictly followed could result in a life threatening situation bodily injury or damage to equip ment CAUTION NOTICE IMPORTANT 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 de
4. SERIOUS INJURY OR DEATH COULD RESULT FROM IM PROPER REPAIR OR SERVICE OF THIS TOOL REPAIRS AND OR SERVICE TO THIS TOOL MUST ONLY BE DONE BY AN AUTHORIZED AND CERTIFIED DEALER To avoid serious injury or death Copyright O 2005 The Stanley Works SVCE MAINT USA 65275 10 2005 Ver 2 GT18 HYDRAULIC POWER UNIT SAFETY OPERATION AND MAINTENANCE SERVICE MANUAL Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie OR 97267 5698 003 659 5660 FAX 503 652 1780 www stanley hydraulic tools com TABLE OF CONTENTS wies e c 4 Safety 9 2 5 Tool Stickers amp Tags eee ee 6 Hydraulic Hose 7 HTMA Requirements 8 Operation E 9 Routine MINN ors ovens bugs Foe 13 Programmable Controller 14 RRES s T8 Testing amp Troubleshooting 16 PECINA UONG Se 18 ETV Oasis A E 19 Parts Lists amp Illustrations AA a GR d 23 Briggs Engine Assembly Fig 1 23 OOS Engine SES a 24 Honda Engine Assembly Fig 25 Honda Engine Parts List TOT 26 PAS 2 E
5. ON FP CQ e 59130 59104 62199 350000 02773 58569 58943 350104 40364 59088 59089 59105 Manifold Assy Single Circuit Hose Barb 3 4 in Hose x 3 4 in Pipe Hose Clamp Elbow 45 Straight Thread Adapter Elbow 90 Hose Connector Straight Thread Elbow 45 Hose Hose Hose Barb 3 4 in Hose x 3 4 in Pipe 28 FIGURE 4 ADDITONAL WIRING DIAGRAM FOR HONDA POWER UNITS ONLY TO ACTUATOR PLUG ON MAIN POWER UNIT 7 WIRING HARNESS 7 62180 ACTUATOR i 5 ty i SS TO FUEL SHUT OFF ON MAIN POWER UNIT WIRING PARNE WIRE MAIN POWER UNIT WIRING HARNESS TO ENGINE KILL ON MAIN POWER UNIT WIRING HARNESS 62404 TO RECTIFIER WIRE ON MAIN a g POWER UNIT WIRING HARNESS HARNESS 37294 Receptacle with 1 4 inch Double Tab Location of Magnetgo Wire Connection Connected to Pick up Coil Fan Cover Removed From Honda Engine 29 FIGURE 4A POWERLINK WIRING DIAGRAM ONLY SPECIFIC MODELS WITH BRIGGS amp STRATTON ENGINES ARE EQUIPPED WITH THE POWER LINK FEATURE ADDITIONAL AC CONTROL SWITCH ON DASH PANEL GROUND TERMINAL PLUG TO MAIN POWER UNIT HARNESS HARNESS PART NUMBER 62335 TO INVERTER RELAY 62301 RED YELLOW BLU DASH PANEL GFCI OUTLET 62313 CAUTION MAKE SURE WIRE CONNECTIONS ARE ON THE LINE
6. itis good practice to start the power unit with the AC Con trol Switch in the OFF position The unit will however start with this switch in either the ON or OFF position Note If the power unit is started in the ON position the 110 volt AC outlet will not funtion unless the switch is turned off and back on again Turn the Ignition Switch to the START position After the engine starts release the switch Gradually push in the choke knob as the engine begins to idle smoothly Allow the engine to warm up Connect hoses and the tool as desrcribed on pages 9 and 10 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 gpm 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 gpm position When finished operating the tool move the flow selector switch to the OFF position 12 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 m
7. SCREW 62304 INVERTER 62321 BRACKET 30 FIGURE 4B MAIN POWER UNIT WIRING HARNESS HARNESS P N 62293 THROTTLE CONTROL SWITCH NOTE PLUG BEHIND SWITCH WITH BLUE amp YELLOW WIRES GOES TO SWITCH ON TOP FLOW SELECTOR SWITCH HOUR METER DIRECTIONAL VALVE START SWITCH MANIFOLD ASSY pde Cr un RED o 1 A SS atO LEE Y 2 TO STARTER PRESSURE SWITCH SOLENOID J wh PLUG TO PRESSURE RELAY 62301 SUPPLIED ee SWITCH WITH 62293 HARNESS 5 X POSITIVE BATTERY CABLE TO STARTER SOLENOID PLUG TO POWER LINK IF SO EQUIPPED r gt STARTER SOLENOID GROUND WIRES S GREEN TO ITEM 53 ON BRIGGS amp HONDA ENGINE ASSY ENGINE KILL BLACK TO ACTUATOR RECTIFIER TO MAGNETO WIRE ON ENGINE OIL PRESSURE SWITCH FUEL SHUTOFF ENGINE OIL PRESS SWITCH WIRING DETAIL RED WIRE P TERMINAL CONTROLLER bn X ORANGE WIRE S TERMINAL Ped m YELLOW WIRE I TERMINAL rO Sat 31 WARRANTY Stanley Hydraulic Tools hereinafter called Stan
8. SIDE OF 110 AC OUTLET mini HOT 62315 E kl D o 8 EISE GROUND WIRE GREEN WHITE WIRE WIRING VIEW INSIDE OUTLET WIRE NUT BOTH GREEN WIRES BOX WIRE BOTH WHITE WIRES 2 TOGETHER 62316 O 62316 III I STRAIN RELIEF FROM INVERTER IN TO 62321 OUTLET BOX L Wl WIRE HARNESS 62331 FROM OUTLET BOX TO GFCI 110 VOLT AC OUTLET ON DASH PANEL INLET PLUG TO INVERTER C FROM J a RED TUA BLUE YELLOW 62315 SCREW t POWER LINK CABLE FROM BRIGGS ENGINE IN TO INVERTER
9. Flange Nut 5 16 Clamp Bushing Key Blower Hub Capscrew 10 24 Filter Assy Capscrew M8 x 16 Grip Plate Std Thread Union Button Head HS 1 4 x 20 Washer 1 4 in ID Capscrew 1 2 20 UNC Front Grille Cooler Capscrew 3 8 16 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 Washer 1 4 Hex Flange Bolt 5 16 Hex Flange Bolt 5 16 Lockwasher 3 8 Foot 26 18893 58976 31240 21318 59083 56655 60919 62385 371503 60972 49174 62185 62179 60945 60962 62181 62184 62183 62180 64990 65072 Flang Nut 3 8 16 Hex Flange Bolt 3 8 16 Retaining Ring Washer 3 4 Blower Housing Pump Mount Fuel Elbow Stud Nut Hex Flange Bolt M6 x 15 Screw M8 x 30 Spring Choke Pivot Weldment Washer 1 4 inch ID HSHCS 1 4 20 x 1 2 inch Link Retainer Choke Link Spring Rotary Actuator Spring Torsion Link Retainer Throttle Link No Item Screw M8 x 12 Cable Clamp Actuator Weldment Hex Flange Bolt M5 x 10 Flange Nut 8 32 Stub Shaft Washer HSHCS M8 x 55 Hex Flange Bolt 1 4 20 x 1 inch Rectifier Bracket Rectifier Part of Engine Assy Flange Nut 1 4 20 Wire Harness No Item Mag Kill Wire Fuel Shutoff Wire No Item No Item Heat Shield Handle Bumper FIGURE 2 FRAME PARTS
10. 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 USING THE 110 VOLT AC OUTLET The 110 volt AC outlet is only found on specific models with the Briggs amp Stratton engine The POWELINK system output remains 110 volts throughout the entire engine speed range Output wattage increases with engine speed To use the 110 volt AC feature turn the AC control switch to the ON position The 110 volt outlet can also be used while in the 8 gpm mode but is disabled when the flow control switch is set to the 5 gpm mode See included POWERLINK On Board Generator System Manual for details 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 bat tery 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 On power units equipped with the POWERLINK feature OPERATION
11. Hydraulic tank overfilled Pump suction leak Check suction connections Tighten if necessary Check that the flow selector switch is set to 5 or 8 gpm Correct the fluid level Hydraulic tool won t operate Flow selector switch not switched ON 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 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 a smooth curve Solenoid not working Check solenoid operation and electrical connections Tool is defective Refer to tool manual SPECIFICATIONS 18 hp Briggs 20 hp Honda PO One 5 gpm 19 Ipm Circuit or One 8 gpm 30 Ipm Circuit LO au a A M 36 in 91 4 cm lp Fc P
12. IMPROPER USE OR WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRIC LINES MAYRESULT IN DEATH HANDLING OF HOSE COULD RESULT IN BURST OR OTHER HOSE FAILURE KEEP OR SERIOUS INJURY HOSE AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT CONTACT FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY DURING USE CONTACT AT THE BURST CAN CAUSE BODILY INJECTION AND SEVERE TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND 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 USE 2 BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE ON HOSE TO PULL OR LIFT TOOLS POWER UNITS ETC OR NEAR ELECTRIC LINES WIPE THE ENTIRE LENGTH OF THE HOSE AND FITTING OR AND Test 5 CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAMAGE TO HOSE FOR MAXIMUMALLOWABLE CURRENT LEAKAGE INACCORDANCE WITR SAFE TY COUPLINGS IF ANY OF THESE CONDITIONS EXIST REPLACE THE HOSE IMMEDIATELY DEPARTMENT INSTRUCTIONS NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE 6 AFTER EACH USE STORE IN A CLEAN DRY AREA DO NOT REMOVE THIS TAG OVL SIHL 34AONW3 H LON OG 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 NOT LABELED OR CERTIFIED AS NON CONDUCTIVE USING TH
13. TOOL MANUFACTURERS 5 SOCIATION quick disconnect fittings NPT type threads See Figure 2 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 in figure 2 Quick disconnect couplings and hose fittings are OPERATION selected so that additional fittings such as reducer or adapter fittings are not required If adapter fittings are used they must be approved steel hy draulic 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 Follow 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 mainte nance free battery and is fully charged Make sure the battery cables are tight and charging circuit functions are operating properly NOTICE Do not charge the battery with a standard auto motive battery charger This type of charger pro duces a charging amperage higher than 2 am
14. damaged BLOWER HOUSING BLOWER HUB AND BUSHING REMOVAL SEE FIGURE 1 amp 1A 1 Follow steps 1 through 6 of the Hydraulic Tank Cooler and Filter Assembly removal procedure 2 Follow steps 1 through 4 of the Blower Wheel removal procedure 3 Remove one hex flange bolt 30 fig 1 Briggs or 42 fig 1A Honda from the bottom of the blower housing 4 The blower housing can now be removed 5 To remove the blower hub and bushing remove the 3 capscrews 14 fig 1 amp 1A NOTE This hub as well as the bushing each have 6 holes 3 drilled and three tapped Reinstall the 3 capscrews back into the 3 tapped holes in the blower hub Screw all 3 down until they touch the bushing Screw in one at a time in rotation until the ta pered bushing releases from the blower hub If installed loosen the set screw in the bushing flange then slide both from the shaft 6 Reverse the above procedure to reinstall the blower housing blower hub and bushing 20 SERVICE Be sure the tapered cone surfaces of the bushing and blower hub are clean and free of anti seize lubricants Assemble the bushing and blower hub with the bolts inserted but not tightened through the drilled holes in the blower hub and into the tapped holes in the bushing With the key in the shaft slide assembly into position on the shaft and tighten the setscrew over the key if equipped Tighten the 3 capscrews 14 fig 1 amp 1A alter nately a
15. fuel level If low fill with un leaded gasoline with a minimum of 85 octane 4 HYDRAULIC FLUID Check the dip stick in the hydraulic fluid reservoir for the proper fiuid level Use fluids meeting the following specifi cations Viscosity Fluid Thickness U S METRIC 10 95 C S 38 27 42 C S 60 C 16 5 C S Min 50 F 450 SSU Maximum 100 F 130 200 550 140 F 85 SSU Minimum Pour Point 10 F 23 C Minimum for cold startup Viscosity Index ASTM D 2220 140 Minimum Demulsibility ASTM D 1401 30 Minutes Maximum Flash Point ASTM D 92 340 F 171 C Minimum Rust Inhibition ASTM D 665 A amp B Pass Oxidation ASTM D 943 1000 Hours Minimum Pump Wear Test ASTM D 2882 60 mg Maximum The following fluids work well over a wide temperature range allow moisture to settle out and resist biological growth that may occur in cool operating hydraulic circuits These fluids are recommended by Stanley Other fluids that meet or exceed the specifications of these fluids may also be used Chevron AW MV 32 Exxon Univis J 26 Mobil D T E 13 Gulf Harmony AW HVI 150 32 Shell Tellus T 32 Texaco Rando HD AZ Union Unax AW WR 32 Terresolve EnviroLogic 132 5 HYDRAULIC CONNECTIONS The recommended hose length is 25 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
16. ground 5 Follow steps 1 through 3 under Choke Cable Assembly Removal 6 Follow steps 1 through 6 under Hydraulic Tank Cooler and Filter Removal 7 Follow steps 1 through 5 under Blower Housing Blower Hub amp Bushing Removal From this point there are two options to remove the engine with the pump and pump mount attached A Lift straight up after removing the frame weldment or B Remove the wheel from one side of the unit and slide the engine out the side of the unit Make sure the frame base is on blocks or supported before removing the wheel OPTION A Remove the frame weldment by removing the two hex flange bolts 17 fig 2 and two hex flange bolts 47 fig 1 amp 1A Make sure the frame base is on blocks or supported before removing the wheel Remove the two capscrews 21 fig 1 amp 1A that hold the cooler guard 20 fig 2 Lift off the frame weldment OPTION B Block up the unit to keep it from tipping over Remove the handle bumper 42 fig 1 Briggs or 88 fig 1A Honda from one end of the axle Remove the retaining ring and washer 48 49 fig 1 amp 1A and remove the wheel The engine and hydraulic tank can now be removed from the side of the unit ELECTRICAL Refer to the wiring diagram in this manual for the correct connections wire sizes and colors IMPORTANT Never change any wiring connections If wires are not connected correctly compo nenets could be
17. operating time to the user while the tool s is out of service IMPROPER OPERATION Any failure or performance deficiency attributable to a failure to follow the guidelines and or procedures as outlined in the tool s operation and maintenance manual MAINTENANCE Any failure or performance deficiency attributable to not maintaining the tool s in good operating condition as outlined in the Operation and Maintenance Manual HYDRAULIC PRESSURE amp FLOW HEAT TYPE OF FLUID Any failure or performance deficiency attributable to excess hydraulic pressure excess hydraulic back pres sure excess hydraulic flow excessive heat or incorrect hydraulic fluid REPAIRS OR ALTERATIONS Any failure or performance deficiency attributable to repairs by anyone which in Stanley s sole judgement caused or contributed to the failure or deficiency MIS APPLICATION Any failure or performance deficiency attributable to mis application Mis application is defined as usage of products for which they were not originally intended or usage of products in such a matter which exposes them to abuse or accident without first obtaining the written consent of Stanley PERMISSION TO APPLY ANY PRODUCT FOR WHICH IT WAS NOT ORIGINALLY INTENDED CAN ONLY BE OBTAINED FROM STANLEY ENGINEERING WARRANTY REGISTRATION STANLEY ASSUMES NO LIABILITY FOR WARRANTY CLAIMS SUBMITTED FOR WHICH NO TOOL REGISTRATION IS ON RECORD In the event a warranty claim is submitted and no tool registrati
18. procedure to reinstall the fuel tank HYDRAULIC TANK COOLER amp FILTER ASSEMBLY see figure 1 1A 2 amp 3 1 First remove the hydraulic fluid from the tank by either pumping it out with a portable drill pump or draining it into a container 2 Remove the cooler guard 20 fig 2 by removing the 2 hex flange bolts 9 fig 2 and 2 capscrews 21 fig 1 1A Remove the remaining 2 capscrews on the back side of the cooler 3 Remove the hose clamps 3 fig 3 from the cooler and the button of the hydraulic tank Note It is not necessary to remove the hose at the bottom of the hydraulic tank if you are only removing the cooler or filter Pull the hoses 10 11 fig 3 off the elbow 9 12 fig 3 Oil will drain from cooler and hoses when removed 4 Remove the dip stick from the filter assembly and re move the 2 hex nuts that hold on the filter assembly Do not remove the filter assembly at this time 5 The cooler and filter assembly can now be removed together as a unit 6 To remove the hydraulic tank remove the 4 hex flange bolts 30 fig 1 Briggs and 42 fig 1A Honda The hydrau lic tank can now be removed 7 With the cooler and filter assembly removed the cooler and filter assembly can be separated by removing the threaded union 18 fig 1 or 1A 8 The cooler or filter assembly can now be replaced if necessary Note Check the under side of the cooler for debris and clean if necessa
19. 2000 psi 2000 psi 2000 psi 2000 psi at the power supply outlet 138 bar 138 bar 138 bar 138 bar SYSTEM RELIEF VALVE SETTING 2100 2250 psi 2100 2250 psi 2100 2250 psi 2200 2300 psi at the power supply outlet 145 155 bar 145 155 bar 145 155 bar 152 159 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 140 F 140 F Sufficient heat rejection capacity 60 C 60 C to limit max fluid temperature to at max expected ambient temperature Min cooling capacity hp o hp 7 hp 6 hp at a temperature difference of 2 24 kW 3 73 kW 4 47 kW 5 22 kW between ambient and fluid temps 40 40 F 40 F 40 22 C 22 C 22 C 22 C NOTE 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 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 least 114 lpm 114 lpm 114 lpm 114 lpm For cold temp startup and max dirt holding capacity HYDRAULIC FLUID 100 400 ssu 100 400 ssu 100 400 ssu 100 400 ssu Petroleum based 20 82 centistokes premium grade anti wear non conduc
20. IS HOSE ON OR NEAR 5 CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAMAGE TO ELECTRICAL LINES MAY RESULT IN DEATH OR SERIOUS INJURY COUPLINGS IF ANY OF THESE CONDITIONS EXIST REPLACE THE HOSE IMMEDIATELY NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY eee PROCEDURES REQUIRED FOR WORK ON OR AROUND 6 AFTER EACH USE STORE IN A CLEAN DRY AREA 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 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 SEE OTHER SIDE 1 OVL SIHL AAOWSY LON OG lt kK 2 L He gt gt c 2 a shown smaller than actual size HOSE PRESSURE RATING The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the hydraulic system REQUIREMENTS TOOL CATEGORY HYDRAULIC SYSTEM REQUIREMENTS TYPE TYPEIII TYPE RR FLOW RATE 4 6 11 13 9 10 5 15 23 Ipm 26 34 Ipm 42 49 Ipm 34 40 Ipm TOOL OPERATING PRESSURE
21. Nut Clamp Bushing Key Blower Hub Capscrew Filter Assy Capscrew Grip Plate Std Thread Union Button Head HS Washer 1 4 in ID Capscrew 1 2 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 5 16 18 x 1 2 Frame Base Weldment Wheel amp Tire Axle 24 04134 07810 60920 59078 04303 60921 15476 65058 21714 58942 01459 58975 18893 58976 31240 21318 59083 56655 60919 62385 371503 62324 62292 64991 56709 65042 Na M NNA B PO BR WO gt Pump Single Fuel Cap Grommet Fuel Tank Battery Battery Cover Capscrew 1 4 20 x 3 4 Hex Flange Bolt Handle Bumper Hex Flange Bolt 5 16 x 1 3 4 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 Nut Heat Shield Hex Washer Head Screws Screw Cable Clamp Rectifier Wire FIGURE 1A HONDA ENGINE ASSEMBLY 25 o ON Oo fF CQ B A A A A 0 CQ CQ m nmn m ND m m nm m NN Be a a BS n on ono on SH 2 A N O O WAN O Ci A OO N lt Ii O A FIGURE 1A HONDA ENGINE PARTS LIST Muffler Kit Hex Washer Head Screw No Item Honda Engine Coupling Square Key Capscrew 3 8 16 x 1 1 4 Pressure Switch
22. ands 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 TOOL STICKERS amp TAGS 62302 Power Unit Dash Decal 62300 Single Circuit Decal DANGER in wel ventilated areas only Exhaust contains chemicals known to the of Califomia to cause cancer birih defects and other reproductive CHOKE Contact with pressure m handhg operation or melnionence wil careo ol injection PULL TO START of tool be h
23. ath This safety alert and signal word indicate an imminently hazardous situa tion 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 may result in minor or moderate injury This signal word indicates a potentially hazardous situation which if not avoided 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 damage 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 SAFETY PRECAUTIONS M Tool operators and maintenance personnel must always comply with the safety precau To avoid serious injury or death tions given in this manual and on the stickers and tags attached to the equipment These safety precautions are given for your safety Review them carefully before operat ing the tool and before performing general maintenance or repairs Supervising personnel should develop additional precautions r
24. auge 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 16 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 side of the unit just behind the dash panel It putrudes 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 TROUBLESHOOTING PROBLEM CAUSE REMEDY Engine will not start Flow selector switch not in the OFF sure the flow selector switch is in position the OFF position when starting Battery not connected Attach battery cables check wires Weak battery Test battery charge or replace No fuel Add Fuel Fuel filter plugged Replace fuel filter Defective spark plugs Remove plugs check gap clean or replace Fluid blowing out of fluid reservoir vent
25. circuit 15 TESTING amp TROUBLESHOOTING 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 the troubleshooting table in this section for possible causes TESTING THE 5 GPM HTMA TYPE 1 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 gpm 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 lpm or 7 9 gpm 26 5 34 lpm 8 Slowly turn the restrictor valve clockwise while watch ing the pressure g
26. 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 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 14 FAULT CODES ENGINE SHUT CORRECTIVE ACTION DOWN FLASH CODE 1 APECS unit not calibrated FAULT Calibrate APECS unit 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 excessive Check parameter settings Check linkage and the actuator travel Ensure that load is not greater than engine capacity Check parameter settings Check what may have trigg
27. contact Briggs and Stratton at 1 800 233 3723 www briggsandstratton com For a list of Honda dealers see web site www honda engines com DASH PANEL amp MANIFOLD ASSEMBLY See Figure 2 and 3 If itis necessary to remove the manifold assembly the manifold 7 fig 2 has no internal parts and it would be a rare case that the manifold would need replacing The parts attached to the manifold are as follows Directional valve 27 fig 2 Pressure switch 26 fig 2 Relief valve 24 fig 2 Coil 29 fig 2 and attached hoses couplers and plugs NOTE Disconnect the battery terminals before servicing the manifold assembly or any dash panel components MANIFOLD ASSEMBLY REMOVAL 1 Remove hose clamp 3 fig 3 from the hose near the manifold assembly then remove the hose 10 fig 3 Hydraulic oil will drain from this hose take steps to clamp off hose or drain the hydraulic tank 19 2 Remove hose 7 fig 3 from the manifold assembly again hydraulic oil will drain from this hose 3 Disconnect the wiring harness plugs from the pressure switch 26 fig 2 and from the directional valve 27 fig 2 4 While holding the manifold assembly in one hand re move the 2 capscrews 6 fig 2 and remove the manifold out through the back of the dash panel 5 Reinstall in the reverse order RELIEF VALVE See Figure 2 Item 24 DESCRIPTION The relief valve allows oil to by pass to the reservoir when the sy
28. elating 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 GT18 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 training program for all operators to ensure safe operation Do not operate the power unit unless thoroughly trained or under the supervision of an instructor Always wear safety equipment such as goggles ear head protection and safety shoes at all times when operating the power unit and a hydraulic tool Do not inspect or clean the power unit while it is running Accidental engagement of the unit can cause serious injury Always use hoses and fittings rated at 2500 psi 172 bar with a 4 to 1 safety factor Be sure all hose connections are tight 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 h
29. ered the protection input Engine speed unusually low Engine shutdown due to engine pro tection input If calibration file is available download the file and cycle power again Factory settings lost yes If controller still does not work or if no calibration file is available consult factory External pot out of range S Verify that pot is wired correctly Recalibrate external pot T RO Verify that signals working synchronized conflict 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 Controller unit failed 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 Limiting excessive actuator current Active only in Auto crank mode Check speed sensor wiring Check starter motor Check fuel Check the lamp or relay hooked to the output If fault is still present consult factory Check the lamp or relay hooked to the output If fault is still present consult factory Check actuator wiring and actuator resistance Resistance should be less than 10 ohms Engine speed input signal missing 11 Auto crank unable to start engine 12 Auxiliary output is shorted 13 Auxiliary output 2 is shorted 14 Actuator disconnected or open
30. inimum 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 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 ROUTINE MAINTENANCE ENGINE MAINTENANCE Follow the maintenance schedule and general maintenance instructions in the engine maintenance and operation 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 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 OPERATING INSTRUCTIONS e Remove condensed moisture from the hydraulic fluid by pumping the hydraulic fluid into a 5 gal 20 con tainer through the pres
31. ld be damaged 1 Unplug the 2 12 pin Deutsch connectors attached to the controller 2 Remove the 2 hex washer head screws 56 fig 1 Briggs and 2 fig 1A Honda Note The controller is software programmable and has no manual adjustments The controller must be loaded with the proper program Briggs Honda to operate the unit correctly Without the controller programmed the power unit will not start Refer to the Programmable Controller section in this manual FRAME ASSY amp RELATED COMPONENTS FUEL TANK see figure 1 or 1A If the fuel tank contains fuel take extreme precautions to remove the fuel into approved containers Do not attempt to service the fuel tank in unventilated areas or in areas containing electric or natural gas appliances which may start up unexpectantly or in shop areas where grinding or welding is present all of which can ignite the fuel vapors 1 Remove both battery connections and remove the bat tery 2 Remove the fuel line from the tank by pulling it off the fuel pump end on Briggs engines and pull it it off the fuel filter end on Honda engines SERVICE 3 Remove the 4 hex flange bolts 30 fig 1 42 fig 1A under the fuel tank that hold it to the frame base weldment 4 The tank can now be removed Note The positive and negative battery cables must be fed through the fuel tank as it is removed 5 horoughly clean the tank and replace the fuel filter 6 Use the reverse
32. ley subject to the exceptions contained below warrants new hydraulic tools for a period of one year from the date of sale to the first retail purchaser or for a period of 2 years from the shipping date from Stanley whichever period expires first to be free of defects in material and or workmanship at the time of delivery and will at its option repair or replace any tool or part of a tool or new part which is found upon examination by a Stanley authorized service outlet or by Stanley s factory in Milwaukie Oregon to be DEFECTIVE IN MATERIAL AND OR WORKMANSHIP EXCEPTIONS FROM WARRANTY NEW PARTS New parts which are obtained individually are warranted subject to the exceptions herein to be free of defects in material and or workmanship at the time of delivery and for a period of 6 months after the date of first usage Seals and diaphragms are warranted to be free of defects in material and or workmanship at the time of delivery and for a period of 6 months after the date of first usage or 2 years after the date of delivery whichever period expires first Warranty for new parts is limited to replacement of defective parts only Labor is not covered FREIGHT COSTS Freight costs to return parts to Stanley if requested by Stanley for the purpose of evaluating a warranty claim for warranty credit are covered under this policy if the claimed part or parts are approved for warranty credit Freight costs for any part or parts which are not approved f
33. nd evenly to 60 inch pounds There should be a gap between the face of the bushing and hub BLOWER WHEEL REMOVAL see figure 1 amp 1A 1 To remove the blower wheel first follow steps 2 through 5 of the Hydraulic Tank Removal Note Do not remove the hose at the bottom of the hydraulic tank 11 fig 3 It is not necessary to drain the hydraulic tank when only removing the blower wheel 2 Remove the front grille 22 fig 1 amp 1A by removing the 4 button head screws 19 fig 1 amp 1A 3 Remove the 4 hex flange bolts 28 fig 1 amp 1A that hold the blower wheel on 4 The blower wheel can now be removed by lifting it out through the top opening of the blower housing 5 Replace the blower wheel by reversing the above proce dures CHOKE CABLE ASSEMBLY REMOVAL see figure 1 1A amp 2 1 The choke cable assembly can be removed by removing 1 screw 57 fig 1 Briggs or 69 fig 1A Honda 2 Disconnect cable from carburetor linkage 3 Remove hex nut from back of dash panel and pull choke cable assembly out through the hole in dash panel 21 4 Reinstall in reverse order 5 Honda Only Adjust screw 56 fig 1A to prevent the choke cable from over centering the choke linkage CONTROLLER REMOVAL see figure 1 or 1A Refer to the wiring diagram in this manual for the correct connections IMPORTANT Never change any wiring connections If wires are not connected correctly compo nenets cou
34. on is on record no warranty credit will be issued without first receiving documentation which proves the sale of the tool or the tools first date of usage The term DOCUMENTATION as used in this paragraph is defined as a bill of sale or letter of intent from the first retail customer A WARRANTY REGISTRATION FORM THAT IS NOT ALSO ON RECORD WITH STANLEY WILL NOT BE ACCEPTED AS DOCUMENTATION NO ADDITIONAL WARRANTIES OR REPRESENTATIONS This limited warranty and the obligation of Stanley thereunder is in lieu of all other warranties expressed or implied including merchantability or fitness for a particular purpose except for that provided herein There is no other warranty This warranty gives the purchaser specific legal rights and other rights may be available which might vary depending upon applicable law 32 Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie Oregon 503 659 5660 Fax 503 652 1780 www stanley hydraulic tools com
35. or warranty credit will be the responsibility of the individual SEALS amp DIAPHRAGMS Seals and diaphragms installed in new tools are warranted to be free of defects in material and or workmanship for a period of 6 months after the date of first usage or for a period of 2 years from the shipping date from Stanley whichever period expires first CUTTING ACCESSORIES Cutting accessories such as breaker tool bits are warranted to be free of defects in material and or workmanship at the time of delivery only ITEMS PRODUCED BY OTHER MANUFACTURERS Components which are not manufactured by Stanley and are warranted by their respective manufacturers a Costs incurred to remove a Stanley manufactured component in order to service an item manufactured by other manufacturers ALTERATIONS amp MODIFICATIONS Alterations or modifications to any tool or part All obligations under this warranty shall be terminated if the new tool or part is altered or modified in any way NORMAL WEAR any failure or performance deficiency attributable to normal wear and tear such as tool bushings retaining pins wear plates bumpers retaining rings and plugs rubber bushings recoil springs etc INCIDENTAL CONSEQUENTIAL DAMAGES To the fullest extent permitted by applicable law in no event will STANLEY be liable for any incidental consequential or special damages and or expenses FREIGHT DAMAGE Damage caused by improper storage or freight handling LOSS TIME Loss of
36. ot to cool All operators must understand and follow ALL saftey precautions and operating Pr owners rudi before operalrg fool PUSH TO RUN 62302 DANGER areas only Exhaust contains chemicals known fo the cause cancer birth defects and other reproductive Fn CHOKE PULL TO START PUSH TO RUN AC 110 1000W MAX CONTINUOUS 62318 POWERLINK Only 62300 62305 POWERLINK Only HYDRAULIC HOSE REQUIREMENTS HOSE TYPES Hydraulic hose types authorized for use with Stanley Hydraulic Tools are as follows Q Certified non conductive O wire braided conductive Fabric braided not certified or labeled non conductive Hose listed above is the only hose authorized for use near electrical conductors Hoses and listed above are 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 DANGER DANGER 1 FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE
37. ps Charging the battery at higher than 2 amps will damage the battery NOTICE 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 10 CONTROL PANEL 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 4 TO 1 SAFETY FACTOR PRESSURE RETURN 1 2 INCH MALE PIPE HOSE END 1 2 INCH FE MALE QUICK DISCON n COUPLER L H T M A 1 2 INCH MALE m QUICK DISCONNECT COUPLER we SK 2 25 524 3 8 8 SAE TOOL PRESSURE RETURN Figure 1 Hydraulic Connections OPERATION 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 5 gpm 19 lpm up to 2000 psi 140 bar or 8 gpm 30 Ipm up to 2000 psi 140 bar with a factory programmed electronic governed engine throttle THROTTLE CONTROL FJ SWITCH FLOW SELECTOR SWITCH 8 GPM OFF 5 GPM IGNITION SWITCH Figure 3 Panel Control Val
38. ry HYDRAULIC PUMP COUPLING AND PUMP MOUNT see figure 1 amp 1A 1 Drain the hydraulic tank 2 Follow steps 1 through 4 of the fuel tank removal proce dures 3 Remove the inlet and outlet hoses from the hydraulic pump Hydraulic oil will drain out from both the pump and hoses when removed 4 Remove the 2 capscrews 7 fig 1 amp 1A Pull the hy draulic pump out from pump mount Note Part of the coupling 5 fig 1 amp 1A is attached to the shaft of the hydraulic pump and will come off with the pump Loosen the setscrew on the coupling to remove it from the pump shaft 5 To remove remaining half of the coupling from the engine shaft loosen the setscrew on the coupling and slide off the shaft 6 Remove 2 screws from the top of the muffler that hold on the heat shield 7 To remove the pump mount 51 fig 1 amp 1A remove the 2 capscrews 24 fig 1 amp 1A and remove the nuts 54 fig 1 amp 1A 8 Reverse the above procedure to reinstall the pump mount coupling and hydraulic pump 22 FIGURE 1 BRIGGS ENGINE ASSEMBLY 23 me fpern fossem NN ON ON BPW gt FIGURE 1 BRIGGS ENGINE PARTS LIST 1 2 1 1 1 2 1 4 1 1 1 1 3 1 1 1 1 4 2 2 1 1 2 1 2 1 4 1 9 1 2 1 Muffler Heat Shield Screw Hex Washer Briggs Engine Coupling Square Key Capscrew 3 8 16 x 1 1 4 Pressure Switch Flange
39. stem pressure reaches a pre set setting The relief valve is set to by pass at a cracking pressure of 2100 2300 psi 145 158 bar While adjustments can be made to the relief setting see TESTING and TROUBLESHOOTING the parts of the relief valve are not serviceable To adjust or remove the relief valve follow the steps under Testing the Hydraulic Circuit in the TESTING and TROU BLE SHOOTING section of this manual DASH PANEL SWITCH REMOVAL 1 Disconnect the battery 2 Disconnect the wire harness plugs from the back of the switches before removing them 3 To remove the switches from the dash panel push in on the sides of the switch from the inside or back of the dash panel You will find four plastic narrow strips that must be pushed in while the switch is being pulled out from the front of the dash panel 4 Reinstall in reverse order ENGINE amp RELATED COMPONENTS ENGINE Most engine servicing can be performed without removing the engine Consult with your Briggs and Stratton or Honda Dealer regarding engine repairs SERVICE 1 To remove the engine follow steps 1 through 4 under Fuel Tank Removal 2 Disconnect the wiring harness See Figure 4 amp 4A Wir ing Diagrams for the correct connections 3 Follow steps 1 through 4 under Manifold Assembly Re moval 4 Disconnect the 12 Volt plug wiring harness if so equipped Remove the RED wire attached to the starter solenoid and the BLACK wire to
40. sure 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 STORAGE Clean the unit thoroughly before storage Do not use water pressure Always store the unit in a clean and dry facility e f 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 PROGRAMMABLE CONTROLLER The Stanley programmable controller is an electronic engine governor that provides a means of controlling and limiting engine speed by adjusting the fuel control lever with a proportional actuator The controller is software programmable and has no manual adjustments A flashing LED indicates the fault condition CALIBRATION ACT is a PC personal computer based software calibration and monitoring tool ACT is designed specifically for use wi
41. th engines equipped with the Stanley controller Stanley Hydraulic Tools recommends that an authorized and certified dealer perform calibration of this unit Once the controller has been programmed ACT may be disconnected The Stanley controller will continue to operate normally with ACT either connected or disconnected 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 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 FAULT CODES The Stanley controller is capable of identifying certain fault
42. tive 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 require ments over a wide range of operating temperatures SSU Saybolt Seconds Universal NOTE These are general hydraulic system requirements See tool Specification page for tool specific requirements OPERATION PREPARATION FOR USE Do not operate the power unit until you have read the engine operating and maintenance instructions manual furnished with the unit 1 ENGINE CRANKCASE OIL LEVEL Always check the oil level before starting the engine Make sure the oil level is at 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 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 war ranty that will not be considered 3 ENGINE FUEL LEVEL Check the
43. ve One hydraulic tool can be connected to the tool circuit The circuit is activated by turning the flow control switch to either the 5 gpm 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 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 gpm 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 lpm or 8 gpm 30 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 Note It may be necessary to reset the Controller 11 At times it may be neccessary to reset the controller This could happen if a fault occurs in the controller
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