GT23
HYDRAULIC
POWER UNIT
SAFETY, OPERATION AND MAINTENANCE
USER’S MANUAL
© 2011 Stanley Black & Decker, Inc.
New Britain, CT 06053
U.S.A.
69405 5/2013 Ver. 5
1
NOTES
2
WARNING
IMPORTANT
TABLE OF CONTENTS
SAFETY SYMBOLS ........................................................................................................................................................................ 4
SAFETY PRECAUTIONS ............................................................................................................................................................... 5
TOOL STICKERS & TAGS ............................................................................................................................................................. 6
HYDRAULIC HOSE REQUIREMENTS .......................................................................................................................................... 7
HOSE SAFETY TAGS .................................................................................................................................................................... 7
HOSE RECOMMENDATIONS ........................................................................................................................................................ 8
HTMA REQUIREMENTS ................................................................................................................................................................ 9
OPERATION ................................................................................................................................................................................. 10
PREPARATION FOR USE ............................................................................................................................................................ 10
CONTROLS .................................................................................................................................................................................. 12
STARTUP ...................................................................................................................................................................................... 12
FOR 8 GPM OPERATION ............................................................................................................................................................ 12
FOR 12 GPM OPERATION .......................................................................................................................................................... 12
COLD WEATHER STARTUP ........................................................................................................................................................ 13
SHUTDOWN ................................................................................................................................................................................. 13
ROUTINE MAINTENANCE ........................................................................................................................................................... 14
STORAGE .................................................................................................................................................................................... 14
PROGRAMMABLE CONTROLLER .............................................................................................................................................. 15
TROUBLESHOOTING GUIDELINES ........................................................................................................................................... 15
FAULT CODES ............................................................................................................................................................................. 16
TESTING & TROUBLESHOOTING .............................................................................................................................................. 17
TESTING THE HYDRAULIC CIRCUIT ......................................................................................................................................... 17
TESTING THE 8 GPM HTMA TYPE II CIRCUIT .......................................................................................................................... 17
OR THE 12 GPM TYPE III CIRCUIT ............................................................................................................................................ 17
TROUBLESHOOTING .................................................................................................................................................................. 18
SPECIFICATIONS ........................................................................................................................................................................ 19
BRIGGS ENGINE ASSEMBLY ..................................................................................................................................................... 20
BRIGGS ENGINE PARTS LIST .................................................................................................................................................... 21
FUEL TANK & CAP ....................................................................................................................................................................... 22
FRAME PARTS ............................................................................................................................................................................. 23
HOSES, FITTINGS & CLAMPS .................................................................................................................................................... 24
MAIN POWER UNIT WIRING HARNESS .................................................................................................................................... 25
SERVICING: This manual contains safety, operation, and routine maintenance instructions. Stanley
recommends that servicing of hydraulic tools, other than routine maintenance, must be performed by an
authorized and certied dealer. Please read the following warning.
For the nearest authorized and certied dealer, call Stanley Hydraulic Tools at the number listed on the
back of this manual and ask for a Customer Service Representative.
To ll out a Product Warranty Recording form, and for information on your warranty,
visit Stanleyhydraulic.com and select the Warranty tab.
(NOTE: The warranty recording form must be submitted to validate the warranty).
SERIOUS INJURY OR DEATH COULD RESULT FROM THE IM-
PROPER REPAIR OR SERVICE OF THIS TOOL.
REPAIRS AND / OR SERVICE TO THIS TOOL MUST ONLY BE
DONE BY AN AUTHORIZED AND CERTIFIED DEALER.
3
SAFETY SYMBOLS
DANGER
WARNING
CAUTION
CAUTION
NOTICE
IMPORTANT
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 situation
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, could result in death or serious injury.
This signal word indicates a potentially hazardous situation which, if not avoided, may result in property damage.
This signal word indicates a situation which, if not avoided, will result in damage
to the equipment.
This signal word indicates a situation which, if not avoided, may result in damage to the equipment.
Always observe safety symbols. They are included for your safety and for the protection of the tool.
LOCAL SAFETY REGULATIONS
Enter any local safety regulations here. Keep these instructions in an area accessible to the operator and 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 specic 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 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 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 ow direction to and from the tool being used.
• Do not inspect hoses and 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 ammable solvents around the power unit engine.
• Do not operate the power unit within 3.3 ft/1 m of buildings, obstructions or ammable objects.
• Do not reverse tool rotation direction by changing uid 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 DECALS
Stanley Dash Sticker 62302
Single Circuit Sticker 68595
6
HYDRAULIC HOSE REQUIREMENTS
HOSE TYPES
The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the
hydraulic system.There are three types of hydraulic hose that meet this requirement and are authorized for use
with Stanley Hydraulic Tools. They are:
Certied non-conductive - constructed of thermoplastic or synthetic rubber inner tube, synthetic ber
braid reinforcement, and weather resistant thermoplastic or synthetic rubber cover. Hose labeled certied non-
conductive is the only hose authorized for use near electrical conductors.
Wire-braided (conductive) - constructed of synthetic rubber inner tube, single or double wire braid reinforcement, and weather resistant synthetic rubber cover. This hose is conductive and must never be used near
electrical conductors.
Fabric-braided (not certied or labeled non-conductive) - constucted of thermoplastic or synthetic rubber
inner tube, synthetic ber braid reinforcement, and weather resistant thermoplastic or synthetic rubber cover. This
hose is not certied non-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
SEE OTHER SIDE
(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
SEE OTHER SIDE
DO NOT REMOVE THIS TAG
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
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
(shown smaller than actual size)
DO NOT REMOVE THIS TAG
7
HOSE RECOMMENDATIONS
Min. Working Pressure
USE
Press/Return)
(
Certied Non-Conductive Hose - Fiber Braid - for Utility Bucket Trucks
Oil Flow Hose Lengths Inside Diameter
GPM LPM FEET METERS INCH MM PSI BAR
4-9 15-34 up to 10 up to 3 3/8 10 Both 2250 155
Conductive Hose - Wire Braid or Fiber Braid -DO NOT USE NEAR ELECTRICAL CONDUCTORS
4-6 15-23 up to 25 up to 7.5 3/8 10 Both 2500 175
4-6 15-23 26-100 7.5-30 1/2 13 Both 2500 175
5-10.5 19-40 up to 50 up to 15 1/2 13 Both 2500 175
5-10.5 19-40 51-100 15-30 5/8 16 Both 2500 175
5/8 16 Pressure 2500 175
3/4 19 Return 2500 175
5-10.5 19-40 100-300 30-90
10-13 38-49 up to 50 up to 15 5/8 16 Both 2500 175
5/8 16 Pressure 2500 175
3/4 19 Return 2500 175
10-13 38-49 51-100 15-30
3/4 19 Pressure 2500 175
1 25.4 Return 2500 175
10-13 38-49 100-200 30-60
5/8 16 Pressure 2500 175
3/4 19 Return 2500 175
13-16 49-60 up to 25 up to 8
3/4 19 Pressure 2500 175
1 25.4 Return 2500 175
13-16 49-60 26-100 8-30
PRESSURE
<<< FLOW
RETURN
FLOW >>>
Typical Hose Connections
Tool to Hydraulic Circuit Hose Recom-
mendations
The chart to the right shows recommended mini-
mum hose diameters for various hose lengths
based on gallons per minute (gpm)/liters per min-
ute (lpm). These recommendations are intended
to keep return line pressure (back pressure) to a
minimum acceptable level to ensure maximum tool
performance.
This chart is intended to be used for hydraulic tool
applications only based on Stanley Hydraulic Tools
tool operating requirements and should not be used
for any other applications.
All hydraulic hose must have at least a rated
minimum working pressure equal to the maximum
hydraulic system relief valve setting.
All hydraulic hose must meet or exceed speci-
8
cations as set forth by SAE J517.
HTMA / EHTMA REQUIREMENTS
HTMA / EHTMA REQUIREMENTS
HTMA
HYDRAULIC SYSTEM REQUIREMENTS
Flow Range
Nominal 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. uid viscosity of:
(at min. operating temperature)
Temperature: Sufcient heat rejection
capacity to limit max. uid temperature to:
(at max. expected ambient temperature)
Min. cooling capacity at a temperature
difference of between ambient and 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.
Filter
Min. full-ow ltration
Sized for ow of at least:
(For cold temp. startup and max.
dirt-holding capacity)
4-6 gpm 7-9 gpm 9-10.5 gpm 11-13 gpm
(15-23 lpm) (26-34 lpm) (34-40 lpm) (42-49 lpm)
1500 psi 1500 psi 1500 psi 1500 psi
(103 bar) (103 bar) (103 bar) (103 bar)
2100-2250 psi 2100-2250 psi 2200-2300 psi 2100-2250 psi
(145-155 bar) (145-155 bar) (152-159 bar) (145-155 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 6 hp 7 hp
(2.24 kW) (3.73 kW) (5.22 kW) (4.47 kW)
40° F 40° F 40° F 40° F
(22° C) (22° C) (22° C) (22° C)
25 microns 25 microns 25 microns 25 microns
30 gpm 30 gpm 30 gpm 30 gpm
(114 lpm) (114 lpm) (114 lpm) (114 lpm)
TYPE I TYPE II
TOOL TYPE
TYPE RR
TYPE III
Hydraulic uid Petroleum based
(premium grade, anti-wear, non-conductive)
Viscosity (at min. and max. operating temps)
NOTE:
When choosing hydraulic uid, the expected oil temperature extremes that will be experienced in service determine the
most suitable temperature viscosity characteristics. Hydraulic uids with a viscosity index over 140 will meet the requirements
over a wide range of operating temperatures.
*SSU = Saybolt Seconds Universal
EHTMA
100-400 ssu* 100-400 ssu* 100-400 ssu* 100-400 ssu*
(20-82 centistokes)
CLASSIFICATION
HYDRAULIC SYSTEM
REQUIREMENTS
Flow Range
Nominal Operating Pressure
(at the power supply outlet)
System relief valve setting
(at the power supply outlet)
NOTE: These are general hydraulic system requirements. See tool specication page for tool specic requirements
B
3.5-4.3 gpm 4.7-5.8 gpm 7.1-8.7 gpm 9.5-11.6 gpm 11.8-14.5 gpm
(13.5-16.5 lpm) (18-22 lpm) (27-33 lpm) (36-44 lpm) (45-55 lpm)
1870 psi 1500 psi 1500 psi 1500 psi 1500 psi
(129 bar) (103 bar) (103 bar) (103 bar) (103 bar)
2495 psi 2000 psi 2000 psi 2000 psi 2000 psi
(172 bar) (138 bar) (138 bar) (138 bar) (138 bar)
C
D
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 overll. Use detergent oil classied "For Service SE, SF,
SG" as specied 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.
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, ll with un-leaded gasoline with
a minimum of 85 octane.
4. HYDRAULIC FLUID
Oxidation (ASTM D-943) 1000 Hours Minimum
Pump Wear Test (ASTM D-2882) 60 mg Maximum
The following 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 uids are recommended by Stanley. Other uids
that meet or exceed the specications of these 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
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 AS-
SOCIATION) quick disconnect ttings (NPT type threads).
(See Page 8.)
Check the dip stick in the hydraulic uid reservoir for the
proper uid level. Use uids meeting the following speci-
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
Rust Inhibition (ASTM D-665 A & B) Pass
Figure 1. Panel Control Valve
Facing the panel control valve, the bottom male quick
disconnect tting is the PRESSURE FLUID OUT tting. The
top female quick disconnect tting is the RETURN FLUID
IN tting.
QUICK DISCONNECT COUPLERS
H.T.M.A. approved quick disconnect couplings are installed
to hydraulic hoses so that the direction of oil ow is always
from the male to the female quick disconnect as shown on
page 8. Quick disconnect couplings and hose ttings are
10
selected so that additional ttings such as reducer or adapter
ttings are not required.
If adapter ttings are used, they must be approved steel hydraulic ttings meeting a minimum operating pressure rating
of 2500 psi/172 bar. Do not use galvanized pipe ttings or
black pipe ttings.
Use thread tape or pipe joint compound when installing quick
disconnect couplings to hose or tool ttings. Follow the
instructions furnished with the selected thread sealant. 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.
OPERATION
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.
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.
11
OPERATION
CONTROLS
This unit is equipped with an advanced proportional engine
control system. It provides a means of controlling engine
speed by adjusting the fuel control lever with an actuator.
The Power Unit provides one circuit, with an oil ow of 8
gpm/30 lpm up to 2000 psi/140 bar or 12 gpm/45 lpm up
to 2000 psi/140 bar with a factory-programmed electronic
governed engine throttle.
THROTTLE CONTROL
SWITCH
throttle control
switch
Note:
It may be necessary to reset the Controller.
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 ow selector
switch is in the OFF position.
flow selector
switch
IGNITION SWITCH
ignition switch
FLOW SELECTOR SWITCH
Figure 3. Panel Control Valve
One hydraulic tool can be connected to the tool circuit.
The circuit is activated by turning the ow control switch to
either the 8 gpm/30 lpm or 12 gpm/45 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 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 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 8 gpm/30 lpm or 12 gpm/45 lpm
depending on which postion the operator has selected with
the ow selector switch.
AUTO-OFF
When the throttle control switch is in the "AUTO-OFF" position, the engine speed is held to maintain 8 gpm/30 lpm or
12 gpm/45 lpm depending on which position the operator
has selected with the ow selector switch. When a tool is
not being used the engine will not return to idle until either
the 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 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 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 page 8 and
10.
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 ow selector switch to the 8 gpm
position.
When nished operating the tool, move the ow selector
switch to the OFF position.
FOR 12 GPM OPERATION
For 12 gpm operation, select mode of operation with the
Throttle Control Switch, either auto-idle-on or the auto-idleoff position. Move the ow selector switch to the 12 gpm
position.
When nished operating the tool, move the ow selector
switch to the OFF position.
12
COLD WEATHER STARTUP
1. Use the procedures described under "STARTUP" and
then follow the procedure below.
2. Hydraulic uids are thicker in cold weather. Therefore,
it is recommended that the engine be run at low idle long
enough to bring the 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 uid to circulate through the tool hoses
until warm before using the tool.
SHUTDOWN
1. Ensure the 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.
OPERATION
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 uid level daily. Add uid per specications in this manual. (See "HYDRAULIC FLUID" under the
section titled "OPERATION".
• Remove condensed moisture from the hydraulic
uid by pumping the hydraulic 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 uid to sit long enough for the water to settle to
the bottom of the container. Slowly pour the uid back into
the hydraulic tank, avoiding the water at the bottom of the
container.
• Each day, check hydraulic lines and 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.
• Disconnect tool hoses.
• Change the hydraulic lter element every 200 hours of
operation. Change more often if cold, moist or dusty condi-
tions exist.
• Check oil cooler for debris. Remove debris with air pressure.
SPARK PLUGS
On power units equipped with Briggs & Stratton Engines,
ONLY Champion RC12YC 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.
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 factory programmable and has no manual
adjustments.
A ashing LED indicates
the fault condition
CALIBRATION
Calibration and programming can only be done by the factory.
TROUBLESHOOTING GUIDELINES
1. Disconnect red wires from the control module to actuator.
2. Attach jumper wires from battery to the RED wires to
actuator.
3. Actuator should move throttle lever to wide open posi-
tion.
a. If actuator does not move it is defective. (Replace).
b. If actuator moves throttle to wide-open position, the
module is defective. (Replace). Note: Before replacing
the actuator verify signal inputs to module (see Stanley
Electrical Trouble shooting guide "TechHELP # 032807. A
copy of the TechHELP can be obtained from the Stanley
Hydraulic Tools web site at www.stanley-hydraulic-tools.
com/support%20page.htm or contact a Customer Service
Representative at (503) 659-5660.
FAULT CODES
The Stanley controller is capable of identifying certain fault
conditions and alerting the user to them. A 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 rst applied to the controller, the LED will
ash just once for one second to indicate that the LED is
working.
Please follow the checklist below to troubleshoot your Stan-
ley controller.
1. Check battery voltage for stability and correct value. The
LED will turn on for one second when the controller is rst
powered up.
2. Check the actuator linkage for binding and backlash.
CHECKING PERFORMANCE CONTROL
(ELECTRONIC GOVERNOR-STATIC CHECK)
To determine whether a governor problem is being caused
by the actuator or the control module, perform the following
static check exactly in order shown.
A pair of jumper wires and a known good 12-volt battery is
required.
2. If there are multiple faults, the LED will ash them all
in sequence. Count the 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 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 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 conict
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 efciency.
Stanley Circuit Tester 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 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 specied, refer to
the troubleshooting table in this section for possible causes.
TESTING THE 8 GPM HTMA TYPE II CIRCUIT
OR THE 12 GPM TYPE III CIRCUIT
pressure". At the "cracking pressure," the ow rate should
start to drop because the relief valve is allowing 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.
c. Tighten the nut and retest.
To test the circuit, proceed as follows:
1. Set the 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 ow selector switch to 8 or 12 gpm depending
on which ow you are testing.
7. With the engine at the programed speed, the test
ow gauge should read 7-9 gpm/26.5-34 lpm or 11-13
gpm/41.6-49 lpm.
8. Slowly turn the restrictor valve clockwise while watching the pressure gauge. The ow rate should stay at 7-9
gpm/26.5-34 lpm or 11-13 gpm/41.6-49 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
begins to open is commonly referred to as the "cracking
17
TROUBLESHOOTING
PROBLEM CAUSE REMEDY
Engine will not start. Flow selector switch not in the Make sure the 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 lter plugged. Replace fuel lter.
Defective spark plugs. Remove plugs, check gap, clean or
replace.
Fluid blowing out of uid
reservoir vent. Hydraulic tank overlled. Correct the uid level.
Pump suction leak. Check suction connections. Tighten if
necessary.
Hydraulic tool won't operate. Flow selector switch not switched Check that the ow selector switch
ON. is set to 8 or 12 gpm.
Incorrect hose connection to Make sure the tool hose circuit goes
tool. from left (pressure) tting to tool
and back to the right tting
(return). Fluid always ows from the
male to female ttings.
Quick disconnect ttings Detach from hose, connect set
defective. together and check for free ow.
Hydraulic uid level low. Check for correct uid level. Fill
using the recommended 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 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: ............................................................................................................................................................... 23 hp Briggs
Capacity......................................................................................... One 8 gpm/30 lpm Circuit or One 12 gpm/45 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: ...................................................................................................................................... 5.5 gal. / 20.8 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 ..................................................."D" (30 lpm @ 138 bar) or "E" (45 lpm @ 138 bar)
Nominal Pressure........................................................................................................................................ 1500 psi/103 bar
Max Pressure.............................................................................................................................................. 2000 psi/138 bar
POWER UNITS,TRACHORSE & GAS/FUEL DRIVEN EQUIPMENT: A1. Federal Emission Component Compliance
40CFR part 1060.120 Stanley warrants all fuel system emission components for 2 years from the date of original pur-
chase
provided there has been no abuse, neglect, modi cations, or improper maintenance.
Components covered. The emission-related warranty covers all components whose failure would increase the evapora-
tive
emissions. Your emission-related warranty does not cover components whose failure would not increase evaporative
emissions. Coverage under this warranty extends only to the following parts; fuel tank, fuel cap, fuel hose and vapor
hose from the fuel tank to the engine and any connectors that are apart of the fuel system.
The equipment is designed, built, and equipped so it conforms at the time of sale to the ultimate purchaser and each
subsequent purchaser and is in compliance with 40 C.F.R. 1060.120 standards. The equipment is free from defects in
materials and workmanship that may keep it from meeting these requirements.
OR
19
BRIGGS ENGINE ASSEMBLY
PART OF
ENGINE ASSY
70
67
19
69
70
60
23
40
28
18
15
14
13
41
17
16
12
65
22
28
26
66
66
25
56
SIDE OF ENGINE
TO OIL FILTER ON
29
32
27
31
33
30
30
42
49
48
47
46
58
57
4
75
68
TO ENGINE
THROTTLE LINKAGE
74
62
71
55
63
72
PART OF
ENGINE ASSY
3
11
9
76
61
73
64
28
1
53
6
53
5
46
50
20
21
VAPOR HOSE ON
CONNECT TO FUEL
8
79
FUEL LINE
80
46
54
ENGINE
79
52
51
44
24
34
COMES WITH ENGINE
FUEL VAPOR HOSE
FROM FUEL TANK TO
ENGINE
GROMMET ONLY
ITEM 36 IS RUBBER
77
78
77
36
35
44
7
36
37
38
Cable P/N-35395
Positive Battery
41
40
43
45
43
30
Cable P/N-62332
Ground Battery
39
2
20
BRIGGS ENGINE PARTS LIST
ITEM P/N QTY DESCRIPTION
1 N/A 1 Mufer (Part of Item 4)
2 66214 1 Heat Shield
3 36152 2 Screw, Hex Washer
4 68674 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
11 59076 1 Bushing
12 20990 1 Key
13 65108 1 Blower Hub
14 00753 3 Capscrew
15 40080 1 Filter Assy
16 43687 2 Capscrew
17 64937 1 Grip Plate
18 51292 1 Std Thread Union
19 17821 4 Button Head HS
20 26831 2 Washer, 1/4 in. ID
21 01213 2 Capscrew, 1/4 -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 65107 1 Blower Wheel
28 59074 8 Hex Flange Bolt, 1/4 -20
29 69407 1 Engine Controller
30 40433 9 Hex Flange Bolt
31 58897 1 Frame Base Weldment
32 58918 2 Wheel & Tire
33 58917 1 Axle
34 68561 1 Pump, Single
35 71794 1 Fuel Cap
36 60920 1 Grommet
37 73050 1 Fuel Tank
38 04303 1 Battery
39 60921 1 Battery Cover
40 15476 3 Capscrew, 1/4-20 x 3/4
41 60945 3 Washer
42 21714 2 Handle Bumper
43 58942 4 Hex Flange Bolt
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 69374 1 Throttle Lever
56 62292 2 Hex Washer Head Screws
57 64991 1 Screw
58 56709 1 Cable Clamp
ITEM P/N QTY DESCRIPTION
59 ------ -- No Item
60 66215 1 Cooler Mount
61 69387 1 90° 1/8 NPT Street EL.
62 68675 1 Angle Bracket Weldment
63 68560 1 Rotary Actuator
64 68676 1 Actuator Bracket
65 69384 4 Hose Clamp
66 69383 2 Hose
67 59075 1 Hex Flange Screw
68 69288 1 Throttle Link
69 60774 1 Clamp
70 59095 3 Hex Flange Nut
71 62181 1 Link Retainer
72 69282 1 Hex Socket Head Capscrew 8-32
73 69281 4 Hex Socket Head Capscrew 6-32
74 69401 1 Wire Assemble
75 65042 1 Rectier Wire
76 01212 1 Pipe Plug
77 72451 3 Spring Hose Clamp
78 72571 1 Fuel Vapor Hose
79 72317 2 Spring Hose Clamp
80 62289 1 Fuel Hose
40408 1 Filter Element (Part of item # 15)
43592 1 Filter, Service Kit
(Includes Filter and Seals)
21
FUEL TANK & CAP
NOTE: When ordering a fuel tank (item
37) or fuel tank cap (item 35) DO NOT
MIX OLD STYLE TANK AND CAP
WITH NEW STYLE TANK AND CAP.
If you have a power unit and it was purchased
prior to 2011 and need to replace
the fuel tank or fuel tank cap, you
must purchase the same tank and cap
that came with your unit.
For example if you have a power unit
prior to 2011 do not purchase a new
style fuel tank, your engine will not be
equipped with a fuel vapor tting.
The old style fuel cap is a vented cap,
while the new style fuel cap is not a
vented cap and venting is achieved thru
the vapor line.
The old style fuel tank has only one fuel
line coming from the tank to the engine.
The new style fuel tank has two lines
coming from the fuel tank to the engine,
one is the fuel line and the other is a fuel
vapor line.
P/N-73050
22
FRAME PARTS
ITEM P/N QTY DESCRIPTION
1 370502 7 Capscrew, 5/16 in. -18 UNC
2 03906 7 Nylock Nut, 5/16 in. -18 UNC
3 62268 1 Handle, Rear Lift
4 58857 1 Coupler, Male 3/8 in., -8 SAE
5 58856 1 Coupler, Female 3/8 in., -8 SAE
6 60962 2 Capscrew, 1/4 in. -20
7 59130 1 Manifold Assy, Single Circuit
(Includes Items 23 thru 29)
8 62302 1 Dash Decal
9 59075 2 Hex Flange Bolt, 1/4-20 x 5/8
10 68595 1 Decal, Single Circuit
11 67899 1 Knob (Part of item 13)
12 60955 1 2-Way Switch
13 67899 1 Rotary Switch
14 60956 1 3-Way Switch
15 60946 1 Hour Meter
16 62269 1 Frame Weldment
17 23530 2 Hex Flange Bolt, 3/8 in. -16
18 58916 1 Handle Lock
19 62267 2 Lift Handle
20 59079 1 Cooler Guard
21 59095 2 Flange Nut, 1/4 in. -20
23 08104 2 Hollow Hex Plug 6 SAE
ITEM P/N QTY DESCRIPTION
24 59131 1 Relief Valve
26 59128 1 Pressure Switch Assy
27 60959 1 Directional Valve
28 ------ 1 Cap (Included with Item 27)
29 60958 1 Coil
32 62298 1 Choke Cable Assy
23
HOSES, FITTINGS & CLAMPS
ITEM P/N QTY DESCRIPTION
1 59130 1 Manifold Assy, Single Circuit
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 2 Elbow, 45°
10 59088 1 Hose
11 59089 1 Hose
12 59105 1 Hose Barb, 3/4 in. Hose x 3/4 in. Pipe
24
THROTTLE CONTROL SWITCH
B
A
T
T
E
R
Y
-
+
PLUG TOP RESSURE SWITCH
POSITIVE BATTERY CABLE TO
STARTER SOLENOID
ENGINE KILL
BLACK
STARTER SOLENOID
GREEN
FLOW CONTROL
SWITCH
STA RT
SWITCH
HOUR METER
BLACK
ENGINE OIL PRESS SWITCH
WIRING DETAIL
ORANGE WIRE (S TERMINAL)
YELLOW WIRE (I TERMINAL)
RED WIRE (P TERMINAL)
(NOTE: PLUG BEHIND SWITCH WITH
BLUE & YELLOW WIRES GOES TO SWITCH ON TOP)
MANIFOLD ASSY
DIRECTIONAL VALVE
Wire Harness P/N-65147
MAIN WIRING HARNESS
RED
PRESSURE SWITCH
RELAY-62301
SUPPLIED W/62293 HARNESS
GROUND WIRES
TO ACTUATOR
RED/GREEN
TO MAGNETO WIRE ON ENGINE
GRAY WIRE
OIL PRESSURE
SWITCH
-
CONTROLLER
TO STARTER SOLENOID
FUEL SHUTOFF
RED WIRE
RECTIFIER WIRE
WHITE
25
Stanley Hydraulic Tools
IMPORTANT
3810 SE Naef Road
Milwaukie, OR 97267-5698
503-659-5660
FAX 503-652-1780
www.stanleyhydraulic.com
To ll out a Product Warranty Recording form, and for information on your warranty,
visit Stanleyhydraulic.com and select the Warranty tab.
(NOTE: The warranty recording form must be submitted to validate the warranty).
25
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