Stanley GT 18B01 User Manual

WARNING

GT18B01

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

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.

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

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

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 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.

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.

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

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

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.

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.

+ 21 hidden pages

Stanley GT 18B01 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual