Stanley GT18 Service Manual

WARNING

GT18

HYDRAULIC

POWER UNIT

Copyright © 2005, The Stanley Works
SVCE/MAINT USA
65275 10/2005 Ver 2

SAFETY, OPERATION AND MAINTENANCE

SERVICE MANUAL

Stanley Hydraulic Tools

3810 SE Naef Road

Milwaukie OR 97267-5698

503-659-5660

FAX [phone]

www.stanley-hydraulic-tools.com

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.

3

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.

4

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.

5

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

6

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

3

(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)

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

SEE OTHER SIDE

DO NOT REMOVE THIS TAG

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

7

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)

8

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

9

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

RETURN

Figure 1. Hydraulic Connections

10