Stanley Black & Decker GT23 user guide

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GT23

HYDRAULIC

POWER UNIT

USER’S MANUAL

SAFETY, OPERATION AND MAINTENANCE

New Britain, CT 06053

U.S.A.

69405 10/2014 Ver. 7

NOTES

2 GT23 User Manual

WARNING

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

IMPORTANT

To ll out a Product Warranty Validation form, and for information on your warranty,

visit Stanleyhydraulics.com and select the Company tab, Warranty.

(NOTE: The warranty Validation record must be submitted to validate the warranty).

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 certied dealer. Please read the following warning.

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.

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

GT23 User Manual 3

DANGER

WARNING

CAUTION

NOTICE

IMPORTANT

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 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 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 GT23 User Manual

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 specic work area and local safety regulations. If

so, place the added precautions in the space provided on page 4.

In addition to this manual, read and understand safety and operating instructions in the Engine Operation Manual furnished with the power unit.

The 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 autho-

rized and properly trained personnel.

GT23 User Manual 5

Stanley Dash Sticker 62302

Single Circuit Sticker 68595

DASH DECALS

6 GT23 User Manual

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:

Certied non-conductive - constructed of thermoplastic or synthetic rubber inner tube, synthetic ber braid reinforcement, and weather resistant thermoplastic or synthetic rubber cover. Hose labeled certied 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 certied 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 certied 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

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.

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

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

GT23 User Manual 7

Min. Working Pressure

USE

Press/Return)

(

HOSE RECOMMENDATIONS

Certied 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

8 GT23 User Manual

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-

cations as set forth by SAE J517.

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: Sufcient 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 specication page for tool specic requirements

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)

GT23 User Manual 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 overll. Use detergent oil classied "For Service SE, SF, SG" as specied in the engine operating and maintenance

manual. See engine manual for oil viscosity grade.

2. SPARK PLUG

On power units equipped with Briggs & Stratton Engines, ONLY Champion RC12YC or equivalent can be used.

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.

5. HYDRAULIC CONNECTIONS

The recommended hose length is 25 ft/8 m with a 1/2 inch/12.7 mm inside diameter. The hoses must have a working pressure rating of at least 2500 psi/175 bar. Each hose end must have male thread ends compatible with H.T.M.A. (HYDRAULIC TOOL MANUFACTURERS AS-

SOCIATION) quick disconnect ttings (NPT type threads).

(See Page 8.)

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.

3. ENGINE FUEL LEVEL

Check the fuel level. If low, ll with un-leaded gasoline with a minimum of 85 octane.

4. HYDRAULIC FLUID

RECOMMENDED HYDRAULIC OILS

Below is a list of recommended oils by brand.

Brand Biodegradable Description

CITGO No Hydurance AW32

AMS Oil No HVH 32

Exxon Mobil No Univis HVI26*

Exxon Mobil No DTE 10 Excel

Shell No S2 V 32

Chevron No Rando HDZ 32

Conoco Phillips No Unax AW-WR-32

Clarion (CITGO) Yes Green Bio 32

Exxon Mobil Yes EAL 224H

Chevron Yes Clarity AW32

Terresolve Yes Envirologic 132

Shell Yes Naturelle HF-E-32

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 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.

* Recommended for extreme cold temperatures

10 GT23 User Manual

OPERATION

6. BATTERY

The supplied 12 Volt DC battery is a non-spillable, maintenance-free battery and is fully charged.

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

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.

GT23 User Manual 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-idle-

off 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-idle-

off position. Move the ow selector switch to the 12 gpm

position.

12 GT23 User Manual

When nished operating the tool, move the ow selector

switch to the OFF position.

OPERATION

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.

3. Allow the engine to idle for approximately one minute and move the Ignition Switch to the OFF position.

GT23 User Manual 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 specications 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 con-

tainer 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 conditions 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.

14 GT23 User Manual

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 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). 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 Stanley 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.

GT23 User Manual 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 con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 GT23 User Manual

TESTING THE HYDRAULIC CIRCUIT

GENERAL

Tests and adjustments should be performed periodically to

ensure the power unit is operating at maximum efciency.

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 op-

erating smoothly. If test results are not as specied, 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 watch-

ing 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

GT23 User Manual 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 overlled. 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 GT23 User Manual

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 purchase

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 evaporative 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.

GT23 User Manual 19

BRIGGS ENGINE ASSEMBLY

PART OF

ENGINE ASSY

SIDE OF ENGINE

TO OIL FILTER ON

TO ENGINE

THROTTLE LINKAGE

PART OF

ENGINE ASSY

VAPOR HOSE ON

CONNECT TO FUEL

FUEL LINE

ENGINE

COMES WITH ENGINE

FUEL VAPOR HOSE

FROM FUEL TANK TO

ENGINE

GROMMET ONLY

ITEM 36 IS RUBBER

Cable P/N-35395

Positive Battery

Cable P/N-62332

Ground Battery

20 GT23 User Manual

BRIGGS ENGINE PARTS LIST

ITEM P/N QTY DESCRIPTION

1 N/A 1 Mufer (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 Rectier 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)

GT23 User Manual 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 GT23 User Manual

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

GT23 User Manual 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 GT23 User Manual

THROTTLE CONTROL SWITCH

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

MAIN WIRING HARNESS

Wire Harness P/N-65147

DIRECTIONAL VALVE

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

GT23 User Manual 25

Stanley Hydraulic Tools

3810 SE Naef Road

Milwaukie, OR 97267-5698

503-659-5660

FAX 503-652-1780

www.stanleyhydraulics.com

Stanley Black & Decker GT23 user guide

Specifications and Main Features

Frequently Asked Questions

User Manual