WARNING
GT18B01
HYDRAULIC
POWER UNIT
Copyright © 2004, The Stanley Works
OPS/MAINT USA
65466 9/2004 Ver 1
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
1
2
TABLE OF CONTENTS
SAFETY SYMBOLS ............................................................................................................................................................. 5
SAFETY PRECAUTIONS ..................................................................................................................................................... 6
TOOL STICKERS & TAGS ................................................................................................................................................... 7
HYDRAULIC HOSE REQUIREMENTS ................................................................................................................................8
HTMA REQUIREMENTS ......................................................................................................................................................9
OPERATION ....................................................................................................................................................................... 10
PREPARATION FOR USE ............................................................................................................................................... 10
CONTROLS ........................................................................................................................................................................ 12
STARTUP ........................................................................................................................................................................... 12
FOR 5 GPM OPERATION ................................................................................................................................................ 12
FOR 8 GPM OPERATION ................................................................................................................................................ 12
COLD WEATHER STARTUP ........................................................................................................................................... 13
SHUTDOWN .................................................................................................................................................................... 13
ROUTINE MAINTENANCE ................................................................................................................................................ 14
STORAGE ........................................................................................................................................................................ 14
PROGRAMMABLE CONTROLLER ................................................................................................................................... 15
CALIBRATION .................................................................................................................................................................... 15
CHECKING PERFORMANCE CONTROL™ (ELECTRONIC GOVERNOR-STATIC CHECK) .......................................... 15
FAULT CODES ................................................................................................................................................................... 15
TESTING & TROUBLESHOOTING ................................................................................................................................... 17
GENERAL ..........................................................................................................................................................................17
TESTING THE HYDRAULIC CIRCUIT ..............................................................................................................................17
TESTING THE 5 GPM HTMA TYPE 1 CIRCUIT ................................................................................................................ 17
TROUBLESHOOTING ....................................................................................................................................................... 18
SPECIFICATIONS .............................................................................................................................................................. 19
SERVICE ............................................................................................................................................................................20
FIGURE 1. BRIGGS ENGINE ASSEMBLY ....................................................................................................................... 24
FIGURE 1. BRIGGS ENGINE PARTS LIST ...................................................................................................................... 25
FIGURE 2. FRAME PARTS .............................................................................................................................................. 26
FIGURE 3. HOSES, FITTINGS & CLAMPS ...................................................................................................................... 27
FIGURE 4B. MAIN POWER UNIT WIRING HARNESS .................................................................................................... 28
WARRANTY ....................................................................................................................................................................... 29
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
CERTIFICATE OF CONFORMITY
Hydraulic Tools
______________________________________________________________________
I, the undersigned:
Hereby certify that the construction plant or equipment specified hereunder:
1. Manufacturer: Stanley Hydraulic Tools, 3810 Naef Road, Milwaukie, Oregon USA
2. Representative in the Union: Stanley Svenska AB, Box 9054, 400 92 Göteborg, SWEDEN
3. Category: Hydraulic Power Unit
4. Make: Stanley Hydraulic Tools
5. Type: GT18B01
6. Type serial number of equipment: ALL
7. Year of manufacture: Beginning 2004
Has been manufactured in conformity with the provisions of the Machinery Directive 98/37/EC
Burrows, James
Surname and First names
Harmonized standard applied: EN 3744
We also declare that it meets the specification of Noise Directive 2000/14/EC, measured in accordance to
the Conformity Evaluation Method set out in Annex VI para. 5 and evaluated during production as in Annex
VI para. 6, 2
nd
procedure.
8. Noise related value: 13.25 Kw/18 hp
9. Measured sound power on equipment representative of this type: 100 LwA
10. Guaranteed sound power level for this equipment: 104 LwA
11. Notified body for EC directive 2000/14/EC: 0404 SMP Svensk Maskinprovning AB
Fyrisborgsgatan 3
754 50 Uppsala, SWEDEN
12. Special Provisions: None
Issued at Stanley Hydraulic Tools, Milwaukie, Oregon USA
Date: 8/24/04
Signature
Position: Engineering Manager
P/N 65472 Rev.1, 8/24/04
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
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
avoided, may result in property damage.
This signal word indicates a situation which, if not avoided, will result in
NOTICE
IMPORTANT
Always observe safety symbols. They are included for your safety and for the protection of the tool.
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.
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 5.
In addition to this manual, read and understand safety and operating instructions in the
Engine Operation Manual furnished with the power unit.
The GT18B01 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.
6
TOOL STICKERS & TAGS
62302
Power Unit Dash Decal
62300
Single Circuit
65458
Sound Power Decal
62302
28322
CE Decal
62300
DANGER
CHOKE
PULL TO START
PUSH TO RUN
AUTO
IDLE
OFF
AUTO
IDLE
ON
R
U
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
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
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.
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
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)
NOTE:
These are general hydraulic system requirements. See tool Specifi cation page for tool specifi c requirements.
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. ENGINE FUEL LEVEL
Check the fuel level. If low, fi ll with un-leaded gasoline with
a minimum of 85 octane.
3. HYDRAULIC FLUID
Check the dip stick in the hydraulic fl uid reservoir for the
proper fi uid level. Use fl uids meeting the following specifi cations.
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
4. 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.)
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
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.
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
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.
10
OPERATION
DO NOT OVERTIGHTEN THE FITTINGS.
5. 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.
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.
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
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
11
Figure 2. 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 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.
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.
STARTUP
Before starting the engine make sure the fl ow selector
switch is in the OFF position.
THROTTLE
CONTROL
SWITCH
FLOW SELECTOR
SWITCH
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:
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.
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-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.
Note:
It may be necessary to reset the Controller.
12
OPERATION
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.
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.
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.
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.
• Allow the fl uid to sit long enough for the water to settle to
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.
STORAGE
• Clean the unit thoroughly before storage. Do not use
water pressure.
• Always store the unit in a clean and dry facility.
• If the unit will be stored for a prolonged period (over 30
days), add a fuel additive to the fuel tank to prevent the fuel
from gumming. Run engine for a short period to circulate
the additive.
• Replace crankcase oil with new oil.
• Remove spark plugs and pour approximately 1 ounce (30
ml) of engine oil into each cylinder. Replace spark plugs
and crank the engine slowly to distribute the oil.
• Check hydraulic reservoir for water. If water is found,
change the oil and circulate it through the tool hose and
tool. (See "HYDRAULIC SYSTEM MAINTENANCE" earlier
in this section).
• Disconnect tool hoses.
• 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.
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.
15
FAULT CODES
FLASH ENGINE
CODE FAULT SHUTDOWN CORRECTIVE ACTION
1 APECS unit not calibrated yes Have engine serviced by an Authorized Stanley Dealer.
2 Engine speed excessive yes Have engine serviced by an Authorized Stanley Dealer.
3 Engine speed unusually low yes Have engine serviced by an Authorized Stanley Dealer.
4 Engine shutdown due to engine yes Have engine serviced by an Authorized Stanley Dealer.
protection input
5 Factory settings lost yes Have engine serviced by an Authorized Stanley Dealer.
6 External pot out-of-range no Have engine serviced by an Authorized Stanley Dealer.
7 Accelerator position / idle no Have engine serviced by an Authorized Stanley Dealer.
switch confl ict
8 Controller unit failed yes Have engine serviced by an Authorized Stanley Dealer.
9 Limiting excessive no Have engine serviced by an Authorized Stanley Dealer.
actuator current
10 Engine speed input no (Active only in Auto crank mode).
signal missing Check speed sensor wiring.
Check starter motor.
11 Auto crank unable to no Check fuel.
start engine
12 Auxiliary output is shorted no Check the lamp or relay hooked to the output. If fault is
still present, have engine serviced by an authorized
Stanley Dealer.
13 Auxiliary output #2 is shorted no Check the lamp or relay hooked to the output. If fault is
still present, have engine serviced by an authorized
Stanley dealer.
14 Actuator disconnected or no Check actuator wiring and actuator resistance.
open circuit Resistance should be less than 10 ohms.
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
OR THE 8 GPM TYPE II CIRCUIT
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 protrudes out from the manifold
assembly. Use a open end or box end wrench to loosen the
nut on the relief valve.
b. Use an Allen wrench to adjust the relief valve. Turn
clockwise to raise the pressure and counterclockwise to
reduce the pressure.
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.
9. At 2100-2200 psi/148-155 bar, the relief valve should
begin to open. The pressure at which the relief valve just
17
TROUBLESHOOTING
PROBLEM CAUSE REMEDY
Engine will not start. Flow selector switch not in the Make sure the fl ow selector switch is in
OFF 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.
18
SPECIFICATIONS
Engine: ............................................................................................................................................................... 18 hp Briggs
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
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 ..................................................................................................................................................104 dBA
Vibration Level .................................................................................................................................................................. N/A
OR
D
19
GENERAL
SERVICE
3. Disconnect the wiring harness plugs from the pressure
switch (26, fi g. 2) and from the directional valve (27, fi g. 2).
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
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
DASH PANEL & MANIFOLD
ASSEMBLY
(See Figure 2 and 3)
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 SWITCH REMOVAL
1. Disconnect the battery.
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).
2. Remove hose (7, fi g. 3) from the manifold assembly,
again hydraulic oil will drain from this hose.
CAUTION
Hydraulic oil will drain from this hose, take
steps to clamp off hose or drain the hydraulic
tank.
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 Dealer
regarding engine repairs.
1. To remove the engine, follow steps 1 through 4 under
"Fuel Tank Removal".
20
SERVICE
2. Disconnect the wiring harness (See Figure 4, Wiring
Diagrams for the correct connections).
3.Follow steps 1 through 4 under "Manifold Assembly Removal".
4. 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.
or
B) Remove the wheel from one side of the unit and slide
the engine out the side of the unit.
Remove the retaining ring and washer (48, 49, fi g. 1) 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, componets could be damaged.
BLOWER HOUSING, BLOWER HUB AND
BUSHING REMOVAL (SEE FIGURE 1)
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), from the
bottom of the blower housing.
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).
CAUTION
Make sure the frame base is on blocks or
supported before removing the wheel.
Remove the two capscrews (21, fi g. 1) that hold the cooler
guard (20, fi g. 2). Lift off the frame weldment.
OPTION B
Block up the unit to keep it from tipping over.
Remove the handle bumper (42, fi g. 1 Briggs) from one end
of the axle.
4. The blower housing can now be removed.
5. To remove the blower hub and bushing, remove the 3
capscrews (14, fi g. 1).
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.
6. Reverse the above procedure to reinstall the blower
housing, blower hub and bushing.
CAUTION
Be sure the tapered cone surfaces of the
bushing and blower hub are clean and
free of anti-seize lubricants.
21
SERVICE
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) 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)
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).
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) by removing the 4 button-head screws (19, fi g. 1).
3. Remove the 4 hex fl ange bolts (28, fi g. 1) 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 & 2)
1. The choke cable assembly can be removed by removing
1 screw (57, fi g.1 Briggs).
2. Disconnect cable from carburetor linkage.
Note:
The controller is software programmable and has no
manual adjustments. The controller must be loaded with
the proper program (Briggs) 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
COMPONENTS
FUEL TANK (see fi gure 1)
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.
3. Remove the 4 hex fl ange bolts (30, fi g. 1) under the fuel
tank that hold it to the frame base weldment.
3. Remove hex nut from back of dash panel and pull choke
cable assembly out through the hole in dash panel
4. Reinstall in reverse order.
CONTROLLER REMOVAL (see fi gure 1)
Refer to the wiring diagram in this manual for the correct
connections.
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.
22
SERVICE
HYDRAULIC TANK, COOLER & FILTER
ASSEMBLY
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).
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.
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).
(see fi gure 1, 2 & 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). The hydraulic tank can now be removed.
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).
HYDRAULIC PUMP, COUPLING AND PUMP
MOUNT
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.
(see fi gure 1)
CAUTION
Hydraulic oil will drain out from both the
pump and hoses when removed.
4. Remove the 2 capscrews (7, fi g. 1). 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), remove the 2 capscrews (24, fi g. 1) and remove the nuts (54, fi g. 1).
8. Reverse the above procedure to reinstall the pump
mount, coupling and hydraulic pump.
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.
23
FIGURE 1. BRIGGS ENGINE ASSEMBLY
2
2
9
1
3
2
1
2
0
8
1
5
1
4
1
3
1
2
7
1
6
1
6
2
1
2
5
2
6
5
9
2
2
3
8
2
7
2
3
3
0
3
1
3
2
4
9
4
8
4
7
0
3
4
1
8
5
7
5
4
9
5
2
3
1
1
0
1
9
6
5
1
6
4
4
5
8
5
5
4
4
5
0
5
8
3
5
2
5
1
5
4
4
4
2
4
3
6
3
5
3
4
4
7
1
4
0
4
1
4
3
4
5
4
0
3
7
3
8
3
9
3
24
FIGURE 1. BRIGGS ENGINE PARTS LIST
ITEM P/N QTY DESCRIPTION
1 36150 1 Muffl er
1A 65456 1 Spark Arrester
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 00111 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
ITEM P/N QTY DESCRIPTION
`
29 65467 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
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
25
FIGURE 2. FRAME PARTS
9
21
20
18
1
10
13
8
15
11
*
1
12
2
2
1
3
14
32
2
28
16
31
30
6
5
4
29
27
1
23
17
26
2
1
7
24
23
2
19
ITEM P/N QTY DESCRIPTION
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
1 370502 7 Capscrew, 5/16 in. -18 UNC
ITEM P/N QTY DESCRIPTION
28 --- 1 Cap (Included with Item 27)
29 60958 1 Coil
30 28322 1 CE Decal
31 65458 1 Sound Power Decal
32 62298 1 Choke Cable Assy
6 60962 2 Capscrew, 1/4 in. -20
7 59130 1 Manifold Assy, Single Circuit
8 1 Dash Decal
9 59074 6 Hex Flange Bolt, 1/4 in. -20
10 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
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 No Item
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
26
FIGURE 3. HOSES, FITTINGS & CLAMPS
1
2
4
3
5
6
3
11
7
8
9
3
10
3
12
ITEM P/N QTY DESCRIPTION
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
27
FIGURE 4B. MAIN POWER UNIT WIRING HARNESS
HARNESS PART NUMBER 65147
THROTTLE CONTROL SWITCH
(NOTE: PLUG BEHIND SWITCH WITH
BLUE & YELLOW WIRES GOES TO SWITCH ON TOP)
FLOW CONTROL
SWITCH
HOUR METER
MANIFOLD ASSY
PRESSURE SWITCH
RELAY-62301
SUPPLIED W/62293 HARNESS
GROUND WIRES
TO ACTUATOR
RED/GREEN
TO MAGNETO WIRE ON ENGINE
GRAY WIRE
DIRECTIONAL VALVE
OIL PRESSURE
SWITCH
PLUG TOP RESSURE SWITCH
-
-
Y
R
E
T
T
A
B
START
SWITCH
+
FUEL SHUTOFF
RED WIRE
BLACK
RED
TO STARTER SOLENOID
POSITIVE BATTERY CABLE TO
STARTER SOLENOID
STARTER SOLENOID
GREEN
ENGINE KILL
BLACK
RECTIFIER WIRE
WHITE
CONTROLLER
RED WIRE (P TERMINAL)
ORANGE WIRE (S TERMINAL)
YELLOW WIRE (I TERMINAL)
ENGINE OIL PRESS SWITCH
WIRING DETAIL
28
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
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: Any failure or performance defi ciency attributable to excess hydraulic pressure, excess hydraulic backpressure, or excess hydraulic fl ow.
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.
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 the purchaser specifi c legal
rights and other rights may be available which might vary depending upon applicable law.
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Stanley Hydraulic Tools
3810 SE Naef Road
Milwaukie OR 97267-5698
503-659-5660
FAX 503-652-1780
www.stanley-hydraulic-tools.com
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