Stanley GT18 Service Manual

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Page 1

WARNING

GT18

HYDRAULIC

POWER UNIT

SAFETY, OPERATION AND MAINTENANCE

SERVICE MANUAL

Stanley Hydraulic Tools

3810 SE Naef Road

Milwaukie OR 97267-5698

503-659-5660

FAX 503-652-1780

www.stanley-hydraulic-tools.com

Page 2

Page 3

TABLE OF CONTENTS

Safety Symbols ......................................................................................... 4

Safety Precautions ...................................................................................5

Tool Stickers & Tags ................................................................................. 6

Hydraulic Hose Requirements .................................................................. 7

HTMA Requirements ................................................................................ 8

Operation .................................................................................................. 9

Routine Maintenance .............................................................................. 13

Programmable Controller .......................................................................14

Fault Codes ............................................................................................ 15

Testing & Troubleshooting ...................................................................... 16

Speciﬁ cations ......................................................................................... 18

Service .................................................................................................... 19

Parts Lists & Illustrations ........................................................................ 23

Briggs Engine Assembly (Fig. 1) ......................................................23

Briggs Engine Parts List ...................................................................24

Honda Engine Assembly (Fig. 1A) ................................................... 25

Honda Engine Parts List ..................................................................26

Frame Parts (Fig. 2) ......................................................................... 27

Hoses, Fittings & Clamps (Fig. 3) ....................................................28

Wiring Diagram - Additional Wiring for Honda (Fig. 4) ..................... 29

Wiring Diagram - POWERLINK™ (Fig. 4A) ..................................... 30

Wiring Diagram - Main Power Unit ................................................... 31

Warranty .................................................................................................32

SERVICING THE STANLEY POWER UNIT: 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 authorized and certiﬁ ed dealer. Please read the following warning.

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 certiﬁ ed dealer, call Stanley Hydraulic Tools at the number listed on the back of this manual and ask for a Customer Service Representative.

Page 4

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 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 situa-

DANGER

WARNING

CAUTION

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

CAUTION

NOTICE

IMPORTANT

Always observe safety symbols. They are included for your safety and for the protection of the tool.

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.

LOCAL SAFETY REGULATIONS

Enter any local safety regulations here. Keep these instructions in an area accessible to the operator and maintenance personnel.

Page 5

SAFETY PRECAUTIONS

Tool operators and maintenance personnel must always comply with the safety precautions given in this manual and on the stickers and tags attached to the equipment.

These safety precautions are given for your safety. Review them carefully before operating the tool and before performing general maintenance or repairs.

Supervising personnel should develop additional precautions relating to the speciﬁ c 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 ﬁ ttings 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 ﬂ ow direction to and from the tool being used.

• Do not inspect hoses and ﬁ ttings 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 ﬂ ammable solvents around the power unit engine.

• Do not operate the power unit within 3.3 ft/1 m of buildings, obstructions or ﬂ ammable objects.

• Do not reverse tool rotation direction by changing ﬂ uid ﬂ ow 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 authorized and properly trained personnel.

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TOOL STICKERS & TAGS

62302 Power Unit Dash Decal

62300 Single Circuit Decal

12v

62302

12v

62318 POWERLINK™ Only

DANGER

CHOKE

PULL TO START

PUSH TO RUN

DANGER

CHOKE

PULL TO START

PUSH TO RUN

AC 110V 1000W MAX CONTINUOUS

62300

62305 POWERLINK™ Only

Page 7

HYDRAULIC HOSE REQUIREMENTS

HOSE TYPES

Hydraulic hose types authorized for use with Stanley Hydraulic Tools are as follows:

➊ Certiﬁ ed non-conductive

➋ Wire-braided (conductive)

➌ Fabric-braided (not certiﬁ ed or labeled non-conductive)

Hose ➊ listed above is the only hose authorized for use near electrical conductors.

Hoses ➋ and ➌ 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 Hydraulic Tools. DO NOT REMOVE THESE TAGS.

If the information on a tag is illegible because of wear or damage, replace the tag immediately. A new tag may be obtained from your Stanley Distributor.

THE TAG SHOWN BELOW IS ATTACHED TO “CERTIFIED NON-CONDUCTIVE” HOSE

D A N G E R

1 FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON-CONDUCTIVE

WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRIC LINES MAYRESULT IN DEATH OR SERIOUS INJURY.

FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY

TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND ELECTRIC LINES.

2. BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS NON-CONDUCTIVE ON OR NEAR ELECTRIC LINES. WIPE THE ENTIRE LENGTH OF THE HOSE AND FITTING WITH A CLEAN DRY ABSORBENT CLOTH TO REMOVE DIRT AND MOSISTURE AND TEST HOSE FOR MAXIMUM ALLOWABLE CURRENT LEAKAGE IN ACCORDANCE WITH SAFETY DEPARTMENT INSTRUCTIONS.

DO NOT REMOVE THIS TAG

SIDE 1 SIDE 2

(shown smaller than actual size)

3. 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.

4. HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING, ABRASION, CUTTING, OR

CONTACT WITH HIGH TEMPERATURE SURFACES. DO NOT USE IF KINKED. DO NOT USE HOSE TO PULL OR LIFT TOOLS, POWER UNITS, ETC.

5. CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS, BULGES, OR DAMAGE TO COUPLINGS IF ANY OF THESE CONDITIONS EXIST, REPLACE THE HOSE IMMEDIATELY. NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE.

6. AFTER EACH USE STORE IN A CLEAN DRY AREA.

D A N G E R

THE TAG SHOWN BELOW IS ATTACHED TO “CONDUCTIVE” HOSE.

D A N G E R

1 DO NOT USE THIS HYDRAULIC HOSE ON OR NEAR ELECTRIC LINES. THIS HOSE IS

NOT LABELED OR CERTIFIED AS NON-CONDUCTIVE. USING THIS HOSE ON OR NEAR ELECTRICAL LINES MAY RESULT IN DEATH OR SERIOUS INJURY.

2. FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND ELECTRIC LINES.

3. 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.

4. 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 THIS TAG

SIDE 1 SIDE 2

(shown smaller than actual size)

6. AFTER EACH USE STORE IN A CLEAN DRY AREA.

D A N G E R

SEE OTHER SIDE

DO NOT REMOVE THIS TAG

The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the hydraulic system.

HOSE PRESSURE RATING

Page 8

HTMA REQUIREMENTS

TOOL CATEGORY

HYDRAULIC SYSTEM REQUIREMENTS TYPE I TYPEII TYPEIII TYPE RR

FLOW RATE

TOOL OPERATING PRESSURE (at the power supply outlet)

SYSTEM RELIEF VALVE SETTING (at the power supply outlet)

MAXIMUM BACK PRESSURE (at tool end of the return hose)

Measured at a max. ﬂ uid viscosity of: (at min. operating temperature)

TEMPERATURE Sufﬁ cient heat rejection capacity to limit max. ﬂ uid temperature to: (at max. expected ambient temperature)

Min. cooling capacity at a temperature difference of between ambient and ﬂ uid temps

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.

4-6 gpm 7-9 gpm 11-13 gpm 9-10.5 gpm (15-23 lpm) (26-34 lpm) (42-49 lpm) (34-40 lpm) 2000 psi 2000 psi 2000 psi 2000 psi (138 bar) (138 bar) (138 bar) (138 bar)

2100-2250 psi 2100-2250 psi 2100-2250 psi 2200-2300 psi (145-155 bar) (145-155 bar) (145-155 bar) (152-159 bar)

250 psi 250 psi 250 psi 250 psi (17 bar) (17 bar) (17 bar) (17 bar)

400 ssu* 400 ssu* 400 ssu* 400 ssu* (82 centistokes) (82 centistokes) (82 centistokes) (82 centistokes)

140° F 140° F 140° F 140° F (60° C) (60° C) (60° C) (60° C)

3 hp 5 hp 7 hp 6 hp (2.24 kW) (3.73 kW) (4.47 kW) (5.22 kW) 40° F 40° F 40° F 40° F (22° C) (22° C) (22° C) (22° C)

FILTER Min. full-ﬂ ow ﬁ ltration Sized for ﬂ ow of at least: (For cold temp. startup and max. dirt-holding capacity)

HYDRAULIC FLUID Petroleum based (premium grade, anti-wear, non-conductive) VISCOSITY (at min. and max. operating temps)

NOTE: When choosing hydraulic ﬂ uid, the expected oil temperature extremes that will be experienced in service determine the most suitable temperature viscosity characteristics. Hydraulic ﬂ uids with a viscosity index over 140 will meet the requirements over a wide range of operating temperatures.

*SSU = Saybolt Seconds Universal

NOTE:

These are general hydraulic system requirements. See tool Speciﬁ cation page for tool speciﬁ c requirements.

25 microns 25 microns 25 microns 25 microns 30 gpm 30 gpm 30 gpm 30 gpm (114 lpm) (114 lpm) (114 lpm) (114 lpm)

100-400 ssu* 100-400 ssu* 100-400 ssu* 100-400 ssu* (20-82 centistokes)

Page 9

OPERATION

PREPARATION FOR USE

Do not operate the power unit until you have read the engine operating and maintenance instructions manual furnished with the unit.

1. ENGINE CRANKCASE OIL LEVEL

Always check the oil level before starting the engine. Make sure the oil level is at the FULL MARK on the dipstick. Do not overﬁ ll. Use detergent oil classiﬁ ed "For Service SE, SF, SG" as speciﬁ ed in the engine operating and maintenance manual. See engine manual for oil viscosity grade.

2. SPARK PLUG

On power units equipped with Briggs & 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, ﬁ ll with un-leaded gasoline with a minimum of 85 octane.

4. HYDRAULIC FLUID

Rust Inhibition (ASTM D-665 A & B) Pass

Oxidation (ASTM D-943) 1000 Hours Minimum

Pump Wear Test (ASTM D-2882) 60 mg Maximum

The following ﬂ uids 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 ﬂ uids are recommended by Stanley. Other ﬂ uids that meet or exceed the speciﬁ cations of these ﬂ uids 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 TOOL MANUFACTURERS ASSOCIATION) quick disconnect ﬁ ttings (NPT type threads). (See Figure 2.)

Check the dip stick in the hydraulic ﬂ uid reservoir for the proper ﬁ uid level. Use ﬂ uids meeting the following speciﬁ cations.

Viscosity (Fluid Thickness)

U.S. METRIC

50°F 450 SSU Maximum 10°C 95 C.S. 100°F 130-200 SSU 38°C 27-42 C.S. 140°F 85 SSU Minimum 60°C 16.5 C.S. Min

Pour Point -10°F/-23°C Minimum (for cold startup)

Viscosity Index (ASTM D-2220) 140 Minimum

Demulsibility (ASTM D-1401) 30 Minutes Maximum

Flash Point (ASTM D-92) 340°F/171°C Minimum

Figure 1. Panel Control Valve

Facing the panel control valve, the bottom male quick disconnect ﬁ tting is the PRESSURE FLUID OUT ﬁ tting. The top female quick disconnect ﬁ tting is the RETURN FLUID IN ﬁ tting.

QUICK DISCONNECT COUPLERS

H.T.M.A. approved quick disconnect couplings are installed to hydraulic hoses so that the direction of oil ﬂ ow is always from the male to the female quick disconnect as shown in ﬁ gure 2. Quick disconnect couplings and hose ﬁ ttings are

Page 10

OPERATION

selected so that additional ﬁ ttings such as reducer or adapter ﬁ ttings are not required.

If adapter ﬁ ttings are used, they must be approved steel hydraulic ﬁ ttings meeting a minimum operating pressure rating of 2500 psi/172 bar. Do not use galvanized pipe ﬁ ttings or black pipe ﬁ ttings.

Use thread tape or pipe joint compound when installing quick disconnect couplings to hose or tool ﬁ ttings. 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, maintenance-free battery and is fully charged.

Make sure the battery cables are tight and charging circuit functions are operating properly.

CONTROL PANEL

PRESSURE

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

RETURN

NOTICE

Do not charge the battery with a standard automotive battery charger. This type of charger produces a charging amperage higher than 2 amps. Charging the battery at higher than 2 amps will damage the battery.

NOTICE

If the engine runs out of gas or dies during operation and the ignition switch is left in the ON or RUN position, this could drain the battery. Make sure the ignition switch is returned to the OFF position.

PRESSURE

1/2 INCH MALE PIPE HOSE END

ADAPTER, 3/8 INCH MALE PIPE x

PRESSURE

H.T.M.A. 1/2 INCH FE-

MALE QUICK DISCON-

NECT COUPLER

H.T.M.A. 1/2 INCH MALE

QUICK DISCONNECT

-8 SAE O-RING

TOOL

COUPLER

RETURN

Figure 1. Hydraulic Connections

Page 11

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 ﬂ ow of 5 gpm/19 lpm up to 2000 psi/140 bar or 8 gpm/30 lpm up to 2000 psi/140 bar with a factory-programmed electronic governed engine throttle.

THROTTLE CONTROL SWITCH

AC CONTROL SWITCH

FLOW SELECTOR SWITCH

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 110 VOLT AC OUTLET

The 110 volt AC outlet is only found on speciﬁ c models with the Briggs & Stratton engine.

The POWELINK™ system output remains 110 volts throughout the entire engine speed range. Output wattage increases with engine speed.

IGNITION SWITCH

Figure 3. Panel Control Valve

One hydraulic tool can be connected to the tool circuit. The circuit is activated by turning the ﬂ ow control switch to either the 5 gpm/19 lpm or 8 gpm/30 lpm 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 ﬂ ow 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" position, the oil ﬂ ow 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 lpm or 8 gpm/30 lpm depending on which postion the operator has selected with the ﬂ ow selector switch.

AUTO-OFF

When the throttle control switch is in the "AUTO-OFF" position, the engine speed is held to maintain 5 gpm/19 lpm or 8 gpm/30 lpm depending on which position the operator has selected with the ﬂ ow selector switch. When a tool is not being used the engine will not return to idle until either the ﬂ ow 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.

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 ﬂ ow 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 speciﬁ c 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 ﬂ ow selector switch is in the OFF position.

Note: The power unit will not start if the ﬂ ow 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 ﬂ ow selector switch is in the OFF position.

On power units equipped with the POWERLINK™ feature,

Page 12

OPERATION

it is good practice to start the power unit with the AC Control 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.

COLD WEATHER STARTUP

1. Use the procedures described under "STARTUP" and then follow the procedure below.

2. Hydraulic ﬂ uids are thicker in cold weather. Therefore, it is recommended that the engine be run at low idle long enough to bring the ﬂ uid temperature up to a minimum of 50°F/10°C.

3. If the tools and tool hoses are cold, it is recommended to allow hydraulic ﬂ uid to circulate through the tool hoses until warm before using the tool.

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-idleoff position. Move the ﬂ ow selector switch to the 5 gpm position.

When ﬁ nished operating the tool, move the ﬂ ow 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-idleoff position. Move the ﬂ ow selector switch to the 8 gpm position.

When ﬁ nished operating the tool, move the ﬂ ow selector switch to the OFF position.

SHUTDOWN

1. Ensure the ﬂ ow 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.

Page 13

ROUTINE MAINTENANCE

ENGINE MAINTENANCE

Follow the maintenance schedule and general maintenance instructions in the engine maintenance and operation manual furnished with the power unit.

the bottom of the container. Slowly pour the ﬂ uid back into the hydraulic tank, avoiding the water at the bottom of the container.

• Each day, check hydraulic lines and ﬁ ttings for leaks, kinks, etc. Do not use your hand to perform this check.

SPARK PLUG

On power units equipped with Briggs & 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.

HYDRAULIC SYSTEM MAINTENANCE

• Check hydraulic ﬂ uid level daily. Add ﬂ uid per speciﬁ cations in this manual. (See "HYDRAULIC FLUID" under the section titled "OPERATING INSTRUCTIONS".

• Remove condensed moisture from the hydraulic ﬂ uid by pumping the hydraulic ﬂ uid into a 5 gal/20 l container through the pressure hose. Make sure the engine is at idle when performing this procedure. When the hydraulic reservoir is empty turn the engine off immediately.

• Change the hydraulic ﬁ lter element every 200 hours of operation. Change more often if cold, moist or dusty conditions exist.

• Check oil cooler for debris. Remove debris with air pressure.

STORAGE

• Clean the unit thoroughly before storage. Do not use water pressure.

• Always store the unit in a clean and dry facility.

• If the unit will be stored for a prolonged period (over 30 days), add a fuel additive to the fuel tank to prevent the fuel from gumming. Run engine for a short period to circulate

• Allow the ﬂ uid to sit long enough for the water to settle to

Page 14

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 ﬂ ashing LED indicates the fault condition

CALIBRATION

ACT is a PC (personal computer) based software calibration and monitoring tool. ACT is designed speciﬁ cally for use with engines equipped with the Stanley controller. Stanley Hydraulic Tools recommends that an authorized and certiﬁ ed 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.

CHECKING PERFORMANCE CONTROL™ (ELECTRONIC GOVERNOR-STATIC CHECK)

To determine whether a governor problem is being caused by the actuator or the control module, perform the following static check exactly in order shown.

A pair of jumper wires and a known good 12-volt battery is required.

1. Disconnect red and green wires from the control module to actuator.

2. Attach jumper wires from battery to RED and GREEN wires to actuator.

a. Attach 12 volt + (positive) to RED wire. b. Attach 12 volt – (negative) to GREEN wire.

3. Actuator should move throttle lever to wide open position.

a. If actuator does not move it is defective. (Replace). b. If actuator moves throttle to wide-open position, the module is defective. (Replace).

FAULT CODES

The Stanley controller is capable of identifying certain fault conditions and alerting the user to them. A ﬂ ashing LED indicates the fault conditions. The current fault code list is shown on the following page. Please note the following:

1. When power is ﬁ rst applied to the controller, the LED will ﬂ ash just once for one second to indicate that the LED is working.

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 ﬁ rst powered up.

2. Check the actuator linkage for binding and backlash.

2. If there are multiple faults, the LED will ﬂ ash them all in sequence. Count the ﬂ ash 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 ﬂ ash 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.

Page 15

FAULT CODES

FLASH

CODE

1 APECS unit not calibrated yes Calibrate APECS unit.

2 Engine speed excessive yes

3 Engine speed unusually low yes

5 Factory settings lost yes

6 External pot out-of-range no

8 Controller unit failed yes

9 Limiting excessive actuator current no

10 Engine speed input signal missing no

11 Auto crank unable to start engine no Check fuel.

12 Auxiliary output is shorted no

13 Auxiliary output #2 is shorted no

14 Actuator disconnected or open circuit no

Engine shutdown due to engine protection input

Accelerator position / idle switch conﬂ ict

FAULT

ENGINE

SHUT-

DOWN

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.

Check parameter settings. Check linkage and the actuator travel. Ensure that load is not greater than engine capacity.

yes

no Verify that signals are working and synchronized.

Check parameter settings. Check what may have triggered the protection input.

If calibration ﬁ le is available, download the ﬁ le and cycle power again.

If controller still does not work or if no calibration ﬁ le is available, consult factory.

Verify that pot is wired correctly. Recalibrate external pot.

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.

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.

(Active only in Auto crank mode). Check speed sensor wiring. Check starter motor.

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.

CORRECTIVE ACTION

Page 16

TESTING & TROUBLESHOOTING

GENERAL

Tests and adjustments should be performed periodically to ensure the power unit is operating at maximum efﬁ ciency. Stanley Circuit Tester (part number 04182) is recommended. This tester can be used to isolate problems in both the engine and hydraulic system prior to any power unit disassembly.

TESTING THE HYDRAULIC CIRCUIT

The following tests can be performed to ensure that the hydraulic pump is supplying the correct ﬂ ow and pressure and that the system relief valve is operating properly.

During these tests, make sure the engine is warm and operating smoothly. If test results are not as speciﬁ ed, refer to the troubleshooting table in this section for possible causes.

TESTING THE 5 GPM HTMA TYPE 1 CIRCUIT

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 ﬂ ow rate should start to drop because the relief valve is allowing ﬂ uid 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 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.

To test the circuit, proceed as follows:

1. Set the ﬂ ow 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 ﬂ ow selector switch to 5 or 8 gpm depending on which ﬂ ow you are testing.

7. With the engine at the programed speed, the test ﬂ ow 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 watching the pressure gauge. The ﬂ ow rate should stay at 4-6 gpm/15-23 lpm or 7-9 gpm/26.5-34 lpm as the pressure gauge reaches 2100-2200 psi/148-155 bar.

Page 17

TROUBLESHOOTING

PROBLEM CAUSE REMEDY

Engine will not start. Flow selector switch not in the OFF Make sure the ﬂ ow 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 ﬁ lter plugged. Replace fuel ﬁ lter.

Defective spark plugs. Remove plugs, check gap, clean or replace.

Fluid blowing out of ﬂ uid reservoir vent. Hydraulic tank overﬁ lled. Correct the ﬂ uid level.

Pump suction leak. Check suction connections. Tighten if necessary.

Hydraulic tool won't operate. Flow selector switch not switched Check that the ﬂ ow selector switch ON. is set to 5 or 8 gpm.

Incorrect hose connection to Make sure the tool hose circuit goes tool. from left (pressure) ﬁ tting to tool and back to the right ﬁ tting (return). Fluid always ﬂ ows from the male to female ﬁ ttings.

Quick disconnect ﬁ ttings Detach from hose, connect set defective. together and check for free ﬂ ow.

Hydraulic ﬂ uid level low. Check for correct ﬂ uid level. Fill using the recommended ﬂ uid.

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 ﬂ uid reservoir to pump inlet has a smooth curve.

Solenoid not working. Check solenoid operation and electrical connections.

Tool is defective. Refer to tool manual.

Page 18

SPECIFICATIONS

Engine: ....................................................................................................................................... 18 hp Briggs / 20 hp Honda

Capacity .......................................................................................... One 5 gpm/19 lpm Circuit or One 8 gpm/30 lpm Circuit

Length: ...........................................................................................................................................................36 in. / 91.4 cm

Width: .............................................................................................................................................................23 in: / 58.4 cm

Height: ..........................................................................................................................................................29.5 in. / 74.9cm

Weight (Wet): Single Circuit Briggs ...............................................................................................330 lbs / 149.6 kg

Weight (Wet): Single Circuit Honda ..............................................................................................348 lbs / 157.8 kg

Fuel Tank Capacity: ......................................................................................................................................... 7 gal. / 26.5 ltr

Estimated Gas Consumption Per Hour .............................................................................................................. 1.3 gal / 4 ltr

Hydraulic Reservor Capacity: ..............................................................................................................................3 gal. / 11 ltr

Relief Valve "crack" setting ........................................................................................................................ 2100 psi / 145 bar

Full relief setting ........................................................................................................................................ 2500 psi / 172 bar

HTMA Category ..................................................."C" (20 lpm @ 138 bar) or "D" (30 lpm @ 138 bar)

Sound Power Level ..................................................................................................................................................100 dBA

Vibration Level .................................................................................................................................................................. N/A

Page 19

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 representatives 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 &

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 & Service Distributor for the nearest authorized Briggs and Stratton representative or 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

2. Remove hose (7, ﬁ g. 3) from the manifold assembly, again hydraulic oil will drain from this hose.

3. Disconnect the wiring harness plugs from the pressure switch (26, ﬁ g. 2) and from the directional valve (27, ﬁ g. 2).

4. While holding the manifold assembly in one hand, remove the 2 capscrews (6, ﬁ g. 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 system 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 TROUBLE SHOOTING section of this manual.

DASH PANEL & MANIFOLD

ASSEMBLY

(See Figure 2 and 3)

If it is necessary to remove the manifold assembly, the manifold (7, ﬁ g. 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, ﬁ g. 2), Pressure switch (26, ﬁ g. 2) , Relief valve (24, ﬁ g.

2), Coil (29, ﬁ g. 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, ﬁ g. 3) from the hose near the manifold assembly, then remove the hose (10, ﬁ g. 3).

CAUTION

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 ﬁ nd 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 & 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.

Hydraulic oil will drain from this hose, take steps to clamp off hose or drain the hydraulic tank.

Page 20

SERVICE

1. To remove the engine, follow steps 1 through 4 under "Fuel Tank Removal".

2. Disconnect the wiring harness (See Figure 4 & 4A, Wiring Diagrams for the correct connections).

3.Follow steps 1 through 4 under "Manifold Assembly Removal".

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 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 & 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.

OPTION B

Block up the unit to keep it from tipping over.

Remove the handle bumper (42, ﬁ g. 1 Briggs) or (88 ﬁ g. 1A Honda) from one end of the axle.

Remove the retaining ring and washer (48, 49, ﬁ g. 1 & 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, componenets could be damaged.

BLOWER HOUSING, BLOWER HUB AND BUSHING REMOVAL (SEE FIGURE 1 & 1A)

B) Remove the wheel from one side of the unit and slide the engine out the side of the unit.

CAUTION

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 ﬂ ange bolts (17, ﬁ g. 2) and two hex ﬂ ange bolts (47, ﬁ g. 1 & 1A).

CAUTION

Make sure the frame base is on blocks or supported before removing the wheel.

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 ﬂ ange bolt (30, ﬁ g. 1 Briggs or 42, ﬁ g. 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, ﬁ g. 1 & 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 tapered bushing releases from the blower hub. If installed, loosen the set-screw in the bushing ﬂ ange, then slide both from the shaft.

Remove the two capscrews (21, ﬁ g. 1 & 1A) that hold the cooler guard (20, ﬁ g. 2). Lift off the frame weldment.

6. Reverse the above procedure to reinstall the blower housing, blower hub and bushing.

Page 21

SERVICE

4. Reinstall in reverse order.

CAUTION

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, ﬁ g.1 & 1A) alternately and evenly to 60-inch pounds. There should be a gap between the face of the bushing and hub.

BLOWER WHEEL REMOVAL

(see ﬁ gure 1 & 1A)

1. To remove the blower wheel, ﬁ rst follow steps 2 through 5 of the Hydraulic Tank Removal.

Note: Do not remove the hose at the bottom of the hydraulic tank (11, ﬁ g. 3).

It is not necessary to drain the hydraulic tank when only removing the blower wheel.

2. Remove the front grille (22, ﬁ g. 1 & 1A) by removing the 4 button-head screws (19, ﬁ g. 1 & 1A).

5. Honda Only. Adjust screw (56, ﬁ g. 1A) to prevent the choke cable from over-centering the choke linkage.

CONTROLLER REMOVAL (see ﬁ gure 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, componenets could be damaged.

1. Unplug the 2 12-pin Deutsch connectors attached to the controller.

2. Remove the 2 hex washer head screws (56, ﬁ g.1 Briggs and 2, ﬁ g. 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 & RELATED

3. Remove the 4 hex ﬂ ange bolts (28, ﬁ g. 1 & 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 procedures.

CHOKE CABLE ASSEMBLY REMOVAL

(see ﬁ gure 1, 1A & 2)

1. The choke cable assembly can be removed by removing 1 screw (57, ﬁ g.1 Briggs or 69, ﬁ g. 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

COMPONENTS

FUEL TANK (see ﬁ gure 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 battery.

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 ﬁ lter end on Honda engines.

Page 22

SERVICE

3. Remove the 4 hex ﬂ ange bolts (30, ﬁ g. 1, 42, ﬁ g. 1A) under the fuel tank that hold it to the frame base weldment.

7. With the cooler and ﬁ lter assembly removed, the cooler and ﬁ lter assembly can be separated by removing the threaded union (18, ﬁ g. 1 or 1A).

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. Thoroughly clean the tank and replace the fuel ﬁ lter.

6. Use the reverse procedure to reinstall the fuel tank.

HYDRAULIC TANK, COOLER & FILTER ASSEMBLY (see ﬁ gure 1, 1A, 2 & 3)

1. First remove the hydraulic ﬂ uid 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, ﬁ g. 2) by removing the 2 hex ﬂ ange bolts (9, ﬁ g. 2) and 2 capscrews (21, ﬁ g. 1, 1A). Remove the remaining 2 capscrews on the back side of the cooler.

3. Remove the hose clamps (3, ﬁ g. 3) from the cooler and the button of the hydraulic tank.

8. The cooler or ﬁ lter assembly can now be replaced if necessary.

Note: Check the under-side of the cooler for debris and clean if necessary.

HYDRAULIC PUMP, COUPLING AND PUMP MOUNT (see ﬁ gure 1 & 1A)

1. Drain the hydraulic tank.

2. Follow steps 1 through 4 of the fuel tank removal procedures.

3. Remove the inlet and outlet hoses from the hydraulic pump.

CAUTION

Hydraulic oil will drain out from both the pump and hoses when removed.

Note: It is not necessary to remove the hose at the bottom of the hydraulic tank if you are only removing the cooler or ﬁ lter.

Pull the hoses (10, 11, ﬁ g. 3) off the elbow (9, 12, ﬁ g. 3).

CAUTION

Oil will drain from cooler and hoses when removed.

4. Remove the dip stick from the ﬁ lter assembly and remove the 2 hex nuts that hold on the ﬁ lter assembly. Do not remove the ﬁ lter assembly at this time.

5. The cooler and ﬁ lter assembly can now be removed together as a unit.

6. To remove the hydraulic tank, remove the 4 hex ﬂ ange bolts (30, ﬁ g. 1 Briggs and 42, ﬁ g. 1A Honda). The hydraulic tank can now be removed.

4. Remove the 2 capscrews (7, ﬁ g. 1 & 1A). Pull the hydraulic pump out from pump mount.

Note: Part of the coupling (5, ﬁ g. 1 & 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 mufﬂ er that hold on the heat shield.

7. To remove the pump mount (51, ﬁ g 1 & 1A), remove the 2 capscrews (24, ﬁ g. 1 & 1A) and remove the nuts (54, ﬁ g. 1 & 1A).

8. Reverse the above procedure to reinstall the pump mount, coupling and hydraulic pump.

Page 23

FIGURE 1. BRIGGS ENGINE ASSEMBLY

Page 24

FIGURE 1. BRIGGS ENGINE PARTS LIST

Item

Part No. Qty Description

No.

1 36150 1 Mufﬂ er

2 36151 1 Heat Shield

3 36152 2 Screw, Hex Washer

4 59007 1 Briggs Engine

5 56656 1 Coupling

6 07819 1 Square Key

7 07860 2 Capscrew, 3/8-16 x 1-1/4

8 31765 1 Pressure Switch

9 12787 4 Flange Nut

10 24287 1 Clamp

11 59076 1 Bushing

12 20990 1 Key

13 59103 1 Blower Hub

14 00753 3 Capscrew

15 40080 1 Filter Assy

16 43687 1 Capscrew

17 64937 1 Grip Plate

18 51292 1 Std Thread Union

19 17821 4 Button Head HS

20 60945 2 Washer, 1/4 in. ID

21 15476 2 Capscrew, 1/2 -20 UNC

22 59080 1 Front Grille

23 59091 1 Cooler

24 07860 2 Capscrew, 3/8

25 59077 1 Hydraulic Tank

26 62296 2 Weather Strip

27 62303 1 Blower Wheel

28 59074 4 Hex Flange Bolt, 1/4 -20

29 65310 1 Engine Controller

30 40433 9 Hex Flange Bolt 5/16-18 x 1/2

31 58897 1 Frame Base Weldment

32 58918 2 Wheel & Tire

33 58917 1 Axle

Item

Part No. Qty Description

No.

34 04134 1 Pump, Single

35 07810 1 Fuel Cap

36 60920 1 Grommet

37 59078 1 Fuel Tank

38 04303 1 Battery

39 60921 1 Battery Cover

40 15476 1 Capscrew, 1/4-20 x 3/4

41 65058 1 Hex Flange Bolt

42 21714 2 Handle Bumper

43 58942 3 Hex Flange Bolt, 5/16 x 1-3/4

44 01459 4 Lockwasher, 3/8

45 58975 2 Foot

46 18893 4 Flang Nut, 3/8-16

47 58976 4 Hex Flange Bolt, 3/8-16

48 31240 2 Retaining Ring

49 21318 2 Washer, 3/4

50 59083 1 Blower Housing

51 56655 1 Pump Mount

52 60919 1 Fuel Elbow

53 62385 2 Stud

54 371503 1 Nut

55 62324 1 Heat Shield

56 62292 2 Hex Washer Head Screws

57 64991 1 Screw

58 56709 1 Cable Clamp

59 65042 1 Rectiﬁ er Wire

Page 25

FIGURE 1A. HONDA ENGINE ASSEMBLY

MAGNETO WIRE

Page 26

FIGURE 1A. HONDA ENGINE PARTS LIST

Item

Part No. Qty Description

No.

1 65294 1 Muffler Kit

2 62292 2 Hex Washer Head Screw

3 --- - No Item

4 36918 1 Honda Engine

5 56656 1 Coupling

6 07819 1 Square Key

7 07860 2 Capscrew, 3/8-16 x 1-1/4

8 31765 1 Pressure Switch

9 12787 4 Flange Nut, 5/16

10 24287 1 Clamp

11 59076 1 Bushing

12 20990 1 Key

13 59103 1 Blower Hub

14 00753 3 Capscrew, 10-24

15 40080 1 Filter Assy

16 43687 1 Capscrew, M8 x 16

17 64937 1 Grip Plate

18 51292 1 Std Thread Union

19 17821 4 Button Head HS, 1/4 x 20

20 60945 2 Washer, 1/4 in. ID

21 15476 2 Capscrew, 1/2 -20 UNC

22 59080 1 Front Grille

23 59091 1 Cooler

24 07860 2 Capscrew, 3/8-16

25 59077 1 Hydraulic Tank

26 62296 2 Weather Strip

27 62303 1 Blower Wheel

28 59074 4 Hex Flange Bolt, 1/4 -20

29 65082 1 Engine Controller

30 65058 1 Hex Flange Bolt

31 58897 1 Frame Base Weldment

32 58918 2 Wheel & Tire

33 58917 1 Axle

34 04134 1 Pump, Single

35 07810 1 Fuel Cap

36 60920 1 Grommet

37 59078 1 Fuel Tank

38 04303 1 Battery

39 60921 1 Battery Cover

40 15476 1 Capscrew, 1/4-20

41 60945 1 Washer, 1/4

42 40433 9 Hex Flange Bolt, 5/16

43 58942 4 Hex Flange Bolt, 5/16

44 01459 4 Lockwasher, 3/8

45 58975 2 Foot

Item

Part No. Qty Description

No.

46 18893 4 Flang Nut, 3/8-16

47 58976 4 Hex Flange Bolt, 3/8-16

48 31240 2 Retaining Ring

49 21318 2 Washer, 3/4

50 59083 1 Blower Housing

51 56655 1 Pump Mount

52 60919 1 Fuel Elbow

53 62385 2 Stud

54 371503 1 Nut

55 60972 2 Hex Flange Bolt, M6 x 15

56 49174 1 Screw, M8 x 30

57 62185 1 Spring

58 62179 1 Choke Pivot Weldment

59 60945 1 Washer, 1/4 inch ID

60 60962 1 HSHCS 1/4-20 x 1/2 inch

61 62181 2 Link Retainer

62 62184 1 Choke Link

63 62183 1 Spring

64 62180 1 Rotary Actuator

65 64990 1 Spring, Torsion

66 65072 1 Link Retainer

67 62182 1 Throttle Link

68 ----- -- No Item

69 64991 1 Screw, M8 x 12

70 56709 1 Cable Clamp

71 62177 1 Actuator Weldment

72 60970 2 Hex Flange Bolt, M5 x 10

73 60971 2 Flange Nut, 8-32

74 60948 1 Stub Shaft

75 60949 3 Washer

76 60950 3 HSHCS, M8 x 55

77 60953 2 Hex Flange Bolt, 1/4-20 x 1 inch

78 60957 1 Rectifier Bracket

79 --- 1 Rectifier (Part of Engine Assy)

80 59095 2 Flange Nut, 1/4-20

81 37294 1 Wire Harness

82 --- - No Item

83 62404 1 Mag Kill Wire

84 62405 1 Fuel Shutoff Wire

85 --- - No Item

86 --- - No Item

87 62325 1 Heat Shield

88 21714 2 Handle Bumper

Page 27

FIGURE 2. FRAME PARTS

Item

Part No. Qty Description

No.

1 370502 7 Capscrew, 5/16 in. -18 UNC

2 03906 7 Nylock Nut, 5/16 in. -18 UNC

3 62270 1 Handle, Rear Lift

4 58857 1 Coupler, Male 3/8 in., -8 SAE

5 58856 1 Coupler, Female 3/8 in., -8 SAE

6 60962 2 Capscrew, 1/4 in. -20

7 59130 1 Manifold Assy, Single Circuit

8 62302 1 Dash Decal

62317 1 Dash Decal,

POWERLINK™

9 59074 6 Hex Flange Bolt, 1/4 in. -20

10 62300 1 Decal, Single Circuit

62305 1 Decal, Single Circuit

11 60963 1 Knob

12 60955 1 2-Way Switch

13 60954 1 Rotary Switch

14 60956 1 3-Way Switch

15 60946 1 Hour Meter

16 62272 1 Frame Weldment

POWERLINK™

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

Item

Part No. Qty Description

No.

17 23530 2 Hex Flange Bolt, 3/8 in. -16

18 58916 1 Handle Lock

19 62271 2 Lift Handle

20 59079 1 Cooler Guard

21 59095 2 Flange Nut, 1/4 in. -20

22 60955 1 2-Way Switch (on models with

POWERLINK™ option only)

23 350045 2 Hollow Hex Plug 6 SAE

24 59131 1 Relief Valve

25 -- - No Item

26 59128 1 Pressure Switch Assy

27 60959 1 Directional Valve

RECEPTACLE ASSY-64942

25 Amp FUSE

12-VOLT RECEPTACLE

RED

TO STARTER

SOLENOID

GROUND

BLACK

Page 28

FIGURE 3. HOSES, FITTINGS & CLAMPS

Item

Part No. Qty Description

No.

1 59130 1 Manifold Assy, Single Circuit

2 59104 1 Hose Barb, 3/4 in. Hose x 3/4 in. Pipe

3 62199 4 Hose Clamp

4 350000 1 Elbow, 45° Straight Thread

5 02773 1 Adapter

6 58569 1 Elbow, 90°

7 58943 1 Hose

8 350104 1 Connector, Straight Thread

9 40364 1 Elbow, 45°

10 59088 1 Hose

11 59089 1 Hose

12 59105 1 Hose Barb, 3/4 in. Hose x 3/4 in. Pipe

Page 29

FIGURE 4. ADDITONAL WIRING DIAGRAM

)

FOR HONDA POWER UNITS ONLY

TO ACTUATOR PLUG ON MAIN POWER UNIT

62180 ACTUATOR

TO FUEL SHUT-OFF ON MAIN POWER UNIT WIRING HARNESS-62405

TO ENGINE KILL ON MAIN POWER UNIT WIRING HARNESS-62404

TO RECTIFIER WIRE ON MAIN

POWER UNIT WIRING HARNESS

HARNESS 37294

WIRING HARNESS

GROUND

2 GRAY WIRES

TO RECTIFIER

62407 MAGNETO WIRE (SEE PHOTOS

TO PICK-UP COIL (SEE PHOTOS)

TO MAGNETO WIRE ON MAIN

POWER UNIT WIRING HARNESS

RECTIFIER

Location of Magnetgo Wire Connection

Fan Cover Removed From Honda

Engine

Receptacle with 1/4-inch Double Tab

Connected to Pick-up Coil

Page 30

FIGURE 4A. POWERLINK™ WIRING DIAGRAM

ONLY SPECIFIC MODELS WITH BRIGGS & STRATTON ENGINES

ARE EQUIPPED WITH THE POWER LINK FEATURE

ADDITIONAL AC CONTROL SWITCH ON DASH PANEL

GROUND TERMIN AL

PLUG TO MAIN POWER UN IT HARNESS

HARNESS PART NUMBER 62335

TO INVERTER

RELAY-62301

RED

YELLOW

DASH PANEL GFCI OUTLET

62313

CAUTION: MAKE SURE WIRE CONNECTIONS ARE ON THE “LINE" SIDE OF 110 AC OU TLET

BLUE

62314

62315 SCREW

62306 BOX

62306

62321 BRACKET

59075 SCREW

BLACK W IRE (HOT)

GROUND WIR E

(GREEN)

FROM INVERTER IN TO OUTLET BOX

I NLE T PLU G TO INVERTER

FROM E NGIN E

62304 INVERTER

WHITE WIRE

WIRE NUT BOTH GREEN WIRES TOGET HER

62316

62315

62315 SCREW

RED

WIRING VIEW I NSIDE O UTLET

BOX

WIRE NUT BOTH WHITE WIRES

WIRE NUT BOTH BLACK WI RES

TOGET HER

BLUE

YELLOW

TOGET HER

RED

62316 STRAIN RELIEF

WIRE HARNESS 62331 FROM OUTLET BOX TO GFCI

110 VO LT AC OUTLET ON D ASH PA NEL

POWER LINK CABLE FROM BRIGGS ENGINE IN TO INVERTER

62321 BRACKET

Page 31

FIGURE 4B. MAIN POWER UNIT WIRING HARNESS

HARNESS P/N-62293

THROTTLE CONTROL SWITCH (NOTE: PLUG BEHIND SWITCH

WITH BLUE & YELLOW WIRES GOES TO SWITCH ON TOP)

MANIFOLD ASSY

DIRECTIONAL

VALVE

FLOW SELECTOR SWITCH

START

SWITCH

RED

HOUR METER

BLACK

PRESSURE SWITCH

RELAY-62301 SUPPLIED

WITH 62293 HARNESS

(IF SO EQUIPPED)

GROUND WIRES TO ITEM 53 ON BRIGGS & HONDA ENGINE ASSY

TO ACTUATOR

TO MAGNETO WIRE ON ENGINE

OIL PRESSURE SWITCH

CONTROLLER

PLUG TO PRESSURE SWITCH

FUEL SHUTOFF

TO STARTER

SOLENOID

POSITIVE BATTERY CABLE TO STARTER

SOLENOID

STARTER SOLENOID

GREEN

ENGINE KILL BLACK

RECTIFIER

RED WIRE (P TERMINAL)

ORANGE WIRE (S TERMINAL)

YELLOW WIRE (I TERMINAL)

Page 32

WARRANTY

Stanley Hydraulic Tools (hereinafter called “Stanley”), subject to the exceptions contained below, warrants new hydraulic tools for a period of one year from the date of sale to the ﬁ rst retail purchaser, or for a period of 2 years from the shipping date from Stanley, whichever period expires ﬁ rst, 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 ﬁ rst 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 ﬁ rst usage or 2 years after the date of delivery, whichever period expires ﬁ rst. 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 for warranty credit will be the responsibility of the individual.

SEALS & 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 ﬁ rst usage, or for a period of 2 years from the shipping date from Stanley, whichever period expires ﬁ rst.

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 & MODIFICATIONS: Alterations or modiﬁ cations to any tool or part. All obligations under this warranty shall be terminated if the new tool or part is altered or modiﬁ ed in any way.

NORMAL WEAR: any failure or performance deﬁ ciency 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 operating time to the user while the tool(s) is out of service.

IMPROPER OPERATION: Any failure or performance deﬁ ciency 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 deﬁ ciency attributable to not maintaining the tool(s) in good operating condition as outlined in the Operation and Maintenance Manual.

HYDRAULIC PRESSURE & FLOW, HEAT, TYPE OF FLUID: Any failure or performance deﬁ ciency attributable to excess hydraulic pressure, excess hydraulic back-pressure, excess hydraulic ﬂ ow, excessive heat, or incorrect hydraulic ﬂ uid.

REPAIRS OR ALTERATIONS: Any failure or performance deﬁ ciency attributable to repairs by anyone which in Stanley’s sole judgement caused or contributed to the failure or deﬁ ciency.

MIS-APPLICATION: Any failure or performance deﬁ ciency attributable to mis-application. “Mis-application” is deﬁ ned 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 ﬁ rst 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 registration is on record, no warranty credit will be issued without ﬁ rst receiving documentation which proves the sale of the tool or the tools’ ﬁ rst date of usage. The term “DOCUMENTATION” as used in this paragraph is deﬁ ned as a bill of sale, or letter of intent from the ﬁ rst 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 ﬁ tness for a particular purpose except for that provided herein. There is no other warranty. This warranty gives

vary depending upon applicable law.

the purchaser speciﬁ c legal rights and other rights may be available which might

Page 33

Stanley Hydraulic Tools

3810 SE Naef Road

Milwaukie, Oregon

503-659-5660 / Fax 503-652-1780

www.stanley-hydraulic-tools.com