Stanley GTR20 User manual

1
GTR20
HYDRAULIC
POWER UNIT
SAFETY, OPERATION AND MAINTENANCE
USER’S MANUAL
WARNING
To avoid serious injury or death
WARNING
Stanley Hydraulic Tools
3810 SE Naef Road
Milwaukie OR 97267-5698
503-659-5660
FAX [phone]
www.stanley-hydraulic-tools.com
Copyright©2006, The Stanley Works
USER USA
65114 9/2006Ver 3
Stanleyrailwayproducts

2

3
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.
WARNING
TABLE OF CONTENTS
For the nearest authorized and certified dealer, call Stanley Hydraulic Tools at the number listed on the
back of this manual and ask for a Customer Service Representative.
SERVICING THE STANLEY POWER UNIT: This manual contains safety, operation, and routine mainte-
nance instructions. Stanley Hydraulic Tools recommends that servicing of hydraulic tools, other than
routine maintenance, must be performed by an authorized and certified dealer. Please read the following
warning.
SAFETY SYMBOLS............................................................................................................................................................. 4
SAFETY PRECAUTIONS.................................................................................................................................................... 5
TOOL STICKERS & TAGS .................................................................................................................................................. 6
HYDRAULIC HOSE REQUIREMENTS............................................................................................................................... 7
HTMA REQUIREMENTS..................................................................................................................................................... 8
OPERATION........................................................................................................................................................................ 9
PREPARATION FOR USE................................................................................................................................................ 9
CONTROLS.....................................................................................................................................................................11
USING THE 12 VOLT DC OUTLET.................................................................................................................................11
STARTUP.........................................................................................................................................................................11
COLD WEATHER STARTUP.......................................................................................................................................... 12
SHUTDOWN................................................................................................................................................................... 12
ROUTINE MAINTENANCE................................................................................................................................................ 13
STORAGE ......................................................................................................................................................................... 13
PROGRAMMABLE CONTROLLER................................................................................................................................... 14
TROUBLESHOOTING GUIDELINES................................................................................................................................ 14
FAULT CODES.................................................................................................................................................................. 14
TESTING THE HYDRAULIC CIRCUIT.............................................................................................................................. 16
TROUBLESHOOTING....................................................................................................................................................... 17
SPECIFICATIONS............................................................................................................................................................. 18
FIGURE 1. BRIGGS ENGINE ASSEMBLY....................................................................................................................... 19
FIGURE 1. BRIGGS ENGINE PARTS LIST..................................................................................................................... 20
FIGURE 1A. HONDA ENGINE ASSEMBLY ...................................................................................................................... 21
FIGURE 1A. HONDA ENGINE PARTS LIST..................................................................................................................... 22
FIGURE 2. FRAME PARTS............................................................................................................................................. 23
FIGURE 3. HOSES, FITTINGS & CLAMPS..................................................................................................................... 24
FIGURE 4. ADDITONAL WIRING DIAGRAMFOR HONDA POWER UNITS ONLY......................................................... 25
FIGURE 4B. MAIN POWER UNIT WIRING HARNESS................................................................................................... 26
FIGURE 4C. DUAL CIRCUIT WIRE HARNESS................................................................................................................ 27
WARRANTY....................................................................................................................................................................... 28

4
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 equip-
ment.
This safety alert and signal word indicate an imminently hazardous situa-
tion which, if not avoided, will result in death or serious injury.
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 mainte-
nance personnel.
CAUTION
WARNING
DANGER
NOTICE
CAUTION
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 a potentially hazardous situation
which, if not avoided, could result in death or serious injury.
This safety alert and signal word indicate a potentially hazardous situation
which, if not avoided, may result in minor or moderate injury.
This signal word indicates a potentially hazardous situation which, if not
avoided, may result in property damage.
This signal word indicates a situation which, if not avoided, will result in
damage to the equipment.
This signal word indicates a situation which, if not avoided, may result in
damage to the equipment.
SAFETY SYMBOLS
IMPORTANT

5
Tool operators and maintenance personnel must always comply with the safety precau-
tions 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 operat-
ing the tool and before performing general maintenance or repairs.
Supervising personnel should develop additional precautions relating to the specific
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 GTR20 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 fittings 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 flow direction to and from the tool being used.
• Do not inspect hoses and fittings 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 flammable solvents around the power unit engine.
• Do not operate the power unit within 3.3 ft/1 m of buildings, obstructions or flammable objects.
• Do not reverse tool rotation direction by changing fluid flow 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.
SAFETY PRECAUTIONS
To avoid serious injury or death
WARNING

6
TOOL STICKERS & TAGS
59125
Dual Circuit Decal
59126
Power Unit Dash Decal
59126
59125

7
HOSE TYPES
Hydraulic hose types authorized for use with Stanley Hydraulic Tools are as follows:
➊ Certified non-conductive
➋Wire-braided (conductive)
➌Fabric-braided (not certified or labeled non-conductive)
Hose ➊listed above is the only hose authorized for use near electrical conductors.
Hoses ➋and ➌listed above are conductive and must never be used near electrical conductors.
HOSE SAFETY TAGS
To help ensure your safety, the following DANGER tags are attached to all hose purchased from Stanley Hydrau-
lic 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.
HOSE PRESSURE RATING
The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the
hydraulic system.
THE TAG SHOWN BELOW IS ATTACHED TO “CERTIFIED NON-CONDUCTIVE” HOSE
THE TAG SHOWN BELOW IS ATTACHED TO “CONDUCTIVE” HOSE.
HYDRAULIC HOSE REQUIREMENTS
SIDE 1 SIDE 2
D A N G E R
DO NOT REMOVE THIS TAG
D A N G E R
1 FAILURE TO USE HYDRAULIC HOSE LABELEDAND 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 ORAROUND
ELECTRIC LINES.
2. BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIEDAS NON-CONDUCTIVE ON
OR NEAR ELECTRIC LINES. WIPE THE ENTIRE LENGTH OF THE HOSEAND FITTING
WITH ACLEAN DRY ABSORBENT CLOTH TO REMOVE DIRT AND MOSISTURE AND TEST
HOSE FOR MAXIMUM ALLOWABLE CURRENT LEAKAGE INACCORDANCE WITH SAFETY
DEPARTMENT INSTRUCTIONS.
DO NOT REMOVE THIS TAG
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 FARAWAYAS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT CONTACT
DURING USE. CONTACTAT THE BURST CAN CAUSE BODILY INJECTION AND SEVERE
PERSONAL INJURY.
4. HANDLE AND ROUTE HOSE CAREFULLY TOAVOID KINKING,ABRASION, CUTTING, OR
CONTACT WITH HIGH TEMPERATURE SURFACES. DO NOT USE IF KINKED. DO NOT USE
HOSE TO PULLOR LIFT TOOLS, POWER UNITS, ETC.
5. CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS, BULGES, OR DAMAGE TO
COUPLINGS IF ANYOF THESE CONDITIONS EXIST, REPLACE THE HOSE IMMEDIATELY.
NEVER USE TAPE ORANY DEVICE TO ATTEMPT TO MEND THE HOSE.
6. AFTER EACH USE STORE INA CLEAN DRYAREA.
3(shown smaller than actual size)
(shown smaller than actual size)
D A N G E R
DO NOT REMOVE THIS TAG
D A N G E R
1 DO NOT USE THIS HYDRAULIC HOSE ON OR NEAR ELECTRIC LINES. THIS HOSE IS
NOT LABELED OR CERTIFIEDAS 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 THATYOU HAVE BEEN PROPERLY
TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON ORAROUND
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 FARAWAYAS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT CONTACT
DURING USE. CONTACTAT THE BURST CAN CAUSE BODILY INJECTION AND SEVERE
PERSONAL INJURY.
4. HANDLE AND ROUTE HOSE CAREFULLY TOAVOID KINKING, CUTTING, OR CONTACT
WITH HIGH TEMPERATURE SURFACES. DO NOT USE IF KINKED. DO NOT USE HOSE TO
PULL OR LIFTTOOLS, POWER UNITS, ETC.
DO NOT REMOVE THIS TAG
5. CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS, BULGES, OR DAMAGE TO
COUPLINGS IF ANYOF THESE CONDITIONS EXIST, REPLACE THE HOSE IMMEDIATELY.
NEVER USE TAPE ORANY DEVICE TO ATTEMPT TO MEND THE HOSE.
6. AFTER EACH USE STORE INA CLEAN DRYAREA.
SEE OTHER SIDE
SIDE 1 SIDE 2

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HTMA REQUIREMENTS
FLOW RATE
TOOL OPERATING PRESSURE
(at the power supply outlet)
SYSTEM RELIEF VALVE SETTING
(at the power supply outlet)
MAXIMUM BACK PRESSURE
(at tool end of the return hose)
Measured at a max. fluid viscosity of:
(at min. operating temperature)
TEMPERATURE
Sufficient heat rejection capacity
to limit max. fluid temperature to:
(at max. expected ambient temperature)
Min. cooling capacity
at a temperature difference of
between ambient and fluid 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-flow filtration
Sized for flow of at least:
(For cold temp. startup and max. dirt-holding capacity)
HYDRAULIC FLUID
Petroleum based
(premium grade, anti-wear, non-conductive)
VISCOSITY
(at min. and max. operating temps)
NOTE:
When choosing hydraulic fluid, the expected oil temperature extremes that will be experienced in service determine the
most suitable temperature viscosity characteristics. Hydraulic fluids with a viscosity index over 140 will meet the require-
ments over a wide range of operating temperatures.
*SSU = Saybolt Seconds Universal
4-6 gpm 7-9 gpm 11-13 gpm 9-10.5 gpm
(15-23 lpm) (26-34 lpm) (42-49 lpm) (34-40 lpm)
2000 psi 2000 psi 2000 psi 2000 psi
(138 bar) (138 bar) (138 bar) (138 bar)
2100-2250 psi 2100-2250 psi 2100-2250 psi 2200-2300 psi
(145-155 bar) (145-155 bar) (145-155 bar) (152-159 bar)
250 psi 250 psi 250 psi 250 psi
(17 bar) (17 bar) (17 bar) (17 bar)
400 ssu* 400 ssu* 400 ssu* 400 ssu*
(82 centistokes)(82 centistokes)(82 centistokes)(82 centistokes)
140° F 140° F 140° F 140° F
(60° C) (60° C) (60° C) (60° C)
3 hp 5 hp 7 hp 6 hp
(2.24 kW) (3.73 kW) (4.47 kW) (5.22 kW)
40° F 40° F 40° F 40° F
(22° C) (22° C) (22° C) (22° C)
25 microns 25 microns 25 microns 25 microns
30 gpm 30 gpm 30 gpm 30 gpm
(114 lpm) (114 lpm) (114 lpm) (114 lpm)
100-400 ssu* 100-400 ssu* 100-400 ssu* 100-400 ssu*
(20-82 centistokes)
TOOL CATEGORY
HYDRAULIC SYSTEM
REQUIREMENTS TYPE I TYPEII TYPEIII TYPE RR
NOTE:
These are general hydraulic system requirements. See tool Specification page for tool specific requirements.

9
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 overfill. Use detergent oil classified "For Service SE, SF,
SG" as specified in the engine operating and maintenance
manual. See engine manual for oil viscosity grade.
2. SPARK PLUG
On power units equipped with Briggs & Stratton Engines,
ONLY Champion RC12YC or equivalent can be used.
For power units equipped with Honda Engines, ONLY
Denso J16CR-U or equivalent can be used.
Incorrect type spark plugs can produce radio frequency
interference that will corrupt and damage the controller.
Failure to use the correct spark plug could result in a war-
ranty that will not be considered.
3. ENGINE FUEL LEVEL
Check the fuel level. If low, fill with un-leaded gasoline with
a minimum of 85 octane.
4. HYDRAULIC FLUID
Check the dip stick in the hydraulic fluid reservoir for the
proper fiuid level. Use fluids meeting the following specifi-
cations.
Viscosity (Fluid Thickness)
U.S. METRIC
50°F 450 SSU Maximum 10°C 95 C.S.
100°F 130-200 SSU 38°C 27-42 C.S.
140°F 85 SSU Minimum 60°C 16.5 C.S. Min
Pour Point -10°F/-23°C Minimum (for cold startup)
Viscosity Index (ASTM D-2220) 140 Minimum
Demulsibility (ASTM D-1401) 30 Minutes Maximum
Flash Point (ASTM D-92) 340°F/171°C Minimum
Rust Inhibition (ASTM D-665 A & B) Pass
Oxidation (ASTM D-943) 1000 Hours Minimum
Pump Wear Test (ASTM D-2882) 60 mg Maximum
The following fluids 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 fluids are recommended by Stanley. Other fluids
that meet or exceed the specifications of these fluids may
also be used.
Chevron AW-MV-32
Exxon "Univis" J-26
Mobil D.T.E. 13
Gulf "Harmony" AW-HVI-150-32
Shell "Tellus" T-32
Texaco "Rando" HD-AZ
Union "Unax" AW-WR-32
Terresolve EnviroLogic 132
5. HYDRAULIC CONNECTIONS
The recommended hose length is 25 ft/8 m with a 1/2
inch/12.7 mm inside diameter. The hoses must have a
working pressure rating of at least 2500 psi/175 bar. Each
hose end must have male thread ends compatible with
H.T.M.A. (HYDRAULIC TOOL MANUFACTURERS AS-
SOCIATION) quick disconnect fittings (NPT type threads).
(See Figure 2.)
Figure 1. Panel Control Valve
Facing the panel control valve, the 2 left male quick discon-
nect fittings are the PRESSURE FLUID OUT fittings. The
2 right female quick disconnect fittings are the RETURN
FLUID IN fittings.
QUICK DISCONNECT COUPLERS
H.T.M.A. approved quick disconnect couplings are installed
to hydraulic hoses so that the direction of oil flow is always
OPERATION

10
Figure 2. Hydraulic Connections
from the male to the female quick disconnect as shown in
figure 2. Quick disconnect couplings and hose fittings are
selected so that additional fittings such as reducer or adapter
fittings are not required.
If adapter fittings are used, they must be approved steel hy-
draulic fittings meeting a minimum operating pressure rating
of 2500 psi/172 bar. Do not use galvanized pipe fittings or
black pipe fittings.
Use thread tape or pipe joint compound when installing quick
disconnect couplings to hose or tool fittings. Follow the
instructions furnished with the selected thread sealant. DO
NOT OVERTIGHTEN THE FITTINGS.
6. BATTERY
The supplied 12 Volt DC battery is a non-spillable, mainte-
nance-free battery and is fully charged.
Make sure the battery cables are tight and charging circuit
OPERATION
Do not charge the battery with a standard auto-
motive battery charger. This type of charger pro-
duces a charging amperage higher than 2 amps.
Charging the battery at higher than 2 amps will
damage the battery.
NOTICE
NOTICE
If the engine runs out of gas or dies during op-
eration 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.
VALVE BLOCK
PRESSURE PRESSURE
PRESSURE
RETURN
PRESSURE
RETURN
Adapter, 1/2 inch Male Pipe x
-10 SAE O-Ring (P/N 07882)
HTMA, 1/2 inch Male Quick
Disconnect Coupler (P/N
24061, Coupler Body or
P/N 03974, Coupler Set)
HTMA, 1/2 inch Female Quick
Disconnect Coupler (P/N
24060, Coupler Body or
P/N 03974, Coupler Set)
1/2 inch. ID Hose, 25 ft to 50
ft long.
(25 ft: P/N 04972 or P/N
05009, Dual Hydraulic Hose)
(50 ft: P/N 04978 or P/N
05008, Dual Hydraulic Hose)
1/2 inch Male Pipe Hose End
HTMA, 1/2 inch Male Quick
Disconnect Coupler (P/N
24061, Coupler Body or
P/N 03974, Coupler Set)
HTMA, 1/2 inch Female Quick
Disconnect Coupler (P/N
24060, Coupler Body or
P/N 03974, Coupler Set)
Adapter, 3/8 inch Male Pipe x
-8 SAE O-Ring (P/N 00936)

11
has selected with the flow selector switch. When a tool is
not being used the engine will not return to idle until either
the flow selector switch is turned to the OFF position or the
throttle control switch is turned to AUTO-ON.
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 ex-
ample, 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.
USING THE 12 VOLT DC OUTLET
A 12 VDC outlet is on specific models. The DC outlet is ON
at all times.
STARTUP
Before starting the engine make sure the flow selector
switches are in the OFF position.
Note:
The power unit will not start if the flow selector switch-
es are 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 flow
selector switch is in the OFF position.
Turn the Ignition Switch to the START position. After the
engine starts, release the switch.
Gradually push in the choke knob as the engine begins to
idle smoothly.
Allow the engine to warm up.
Connect hoses and the tool as desrcribed on pages 9 and
10.
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 actua-
tor. The Power Unit provides two 5 gpm/9 lpm up to 2000
psi/140 bar circuits or one 10 gpm/37.8 lpm up to 2000
psi/140 bar circuit.
Figure 3. Panel Control Valve
Two 5 gpm hydraulic tools can be connected to the tool
circuit or one 10 gpm tool. The circuit is activated by turning
one or both flow selector switches to 5 or both switches to
10 gpm. If both are at 10 gpm, 10 gpm can be had by con-
necting to either coupler set.
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 flow 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" posi-
tion, the oil flow 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 one or two 5 gpm/19 lpm circuits
or one 10 gpm/37.8 lpm circuit depending on which postion
the operator has selected with the flow selector switch.
AUTO-OFF
When the throttle control switch is in the "AUTO-OFF" posi-
tion, the engine speed is held to maintain 5 gpm/19 lpm or
10 gpm/37.8 lpm depending on which position the operator
OPERATION
The accessories (if left on) that are
plugged into this outlet could drain the bat-
tery.
IMPORTANT
Throttle Control Switch
Flow Selector tool
Circuit 2 Switch
Ignition Switch
Flow Selector tool
Circuit 1 Switch

12
FOR 5 GPM OPERATION
For 5 gpm operation, select mode of operation with the
Throttle Control switch, either auto-idle-on or the auto-idle-
off position. Move the flow selector switch to the 5 gpm
position.
Note:
If operating both 5 gpm circuits move both flow selector
switches to the 5 gpm position. Both 5 gpm circuits are
independent from each other and can be operated on
its own.
When finished operating the tool, move one or both flow
selector switches to the OFF position.
FOR 10 GPM OPERATION
For 10 gpm operation, select mode of operation with the
Throttle Control Switch, either auto-idle-on or the auto-idle-
off position. Move both flow selector switches to the 10 gpm
position.
When finished operating the tool, move both flow selector
switches to the OFF position.
Note:
Either set of couplers can be used for the 10 gpm circuit,
but DO NOT use two separate tools when in the 10 gpm
operation mode.
COLD WEATHER STARTUP
1. Use the procedures described under "STARTUP" and
then follow the procedure below.
2. Hydraulic fluids are thicker in cold weather. Therefore,
it is recommended that the engine be run at low idle long
enough to bring the fluid 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 fluid to circulate through the tool hoses
until warm before using the tool.
SHUTDOWN
1. Ensure the flow selector switches are in the OFF posi-
tion (center position).
OPERATION
2. Unless already at idle the power unit should return to
idle. This may take a few seconds for the unit to react due
to a built-in program delay.
3. Allow the engine to idle for approximately one minute
and move the Ignition Switch to the OFF position.

13
the hydraulic tank, avoiding the water at the bottom of the
container.
• Each day, check hydraulic lines and fittings for leaks,
kinks, etc. Do not use your hand to perform this check.
• Change the hydraulic filter 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 pres-
sure.
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.
ENGINE MAINTENANCE
Follow the maintenance schedule and general maintenance
instructions in the engine maintenance and operation
manual furnished with the power unit.
SPARK PLUG
On power units equipped with Briggs & Stratton Engines,
ONLY Champion RC12YC or equivalent can be used.
For power units equipped with Honda Engines, ONLY
Denso J16CR-U or equivalent can be used.
Incorrect type spark plugs can produce radio frequency
interference that will corrupt and damage the controller.
Failure to use the correct spark plug could result in a war-
ranty that will not be considered.
HYDRAULIC SYSTEM MAINTENANCE
• Check hydraulic fluid level daily. Add fluid per specifica-
tions in this manual. (See "HYDRAULIC FLUID" under the
section titled "OPERATING INSTRUCTIONS".
• Remove condensed moisture from the hydraulic
fluid by pumping the hydraulic fluid 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 fluid to sit long enough for the water to settle to
the bottom of the container. Slowly pour the fluid back into
ROUTINE MAINTENANCE

14
To determine whether a governor problem is being caused
by the actuator or the control module, perform the following
static check exactly in order shown.
A pair of jumper wires and a known good 12-volt battery is
required.
1. Disconnect red and green wires from the control module
to actuator.
2. Attach jumper wires from battery to RED and GREEN
wires to actuator.
a. Attach 12 volt + (positive) to RED wire.
b. Attach 12 volt – (negative) to GREEN wire.
3. Actuator should move throttle lever to wide open 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 or there is a wiring problem. (Replace).
FAULT CODES
The Stanley controller is capable of identifying certain fault
conditions and alerting the user to them. A flashing LED
indicates the fault conditions. The current fault code list is
shown on the following page. Please note the following:
1. When power is first applied to the controller, the LED will
flash just once for one second to indicate that the LED is
working.
2. If there are multiple faults, the LED will flash them all
in sequence. Count the flash 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 flash 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.
The Stanley programmable controller is an electronic
engine governor that provides a means of controlling and
limiting engine speed by adjusting the fuel control lever with
a proportional actuator.
The controller is software programmable and has no
manual adjustments.
CALIBRATION
ACT is a PC (personal computer) based software
calibration and monitoring tool. ACT is designed
specifically for use with engines equipped with
the Stanley controller. Stanley Hydraulic Tools
recommends that an authorized and certified
dealer perform calibration of this unit.
Once the controller has been programmed, ACT
may be disconnected. The Stanley controller
will continue to operate normally with ACT either
connected or disconnected.
TROUBLESHOOTING GUIDELINES
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 4500 is
first powered up.
2. Check the actuator linkage for binding and backlash.
CHECKING PERFORMANCE CONTROL™
(ELECTRONIC GOVERNOR-STATIC CHECK)
PROGRAMMABLE CONTROLLER
A flashing LED indicates
the fault condition

15
FAULT CODES
1 APECS unit not calibrated yes Have engine serviced by an Authorized Stanley Dealer.
2 Engine speed excessive yes Have engine serviced by an Authorized Stanley Dealer.
3 Engine speed unusually low yes Have engine serviced by an Authorized Stanley Dealer.
4 Engine shutdown due to engine yes Have engine serviced by an Authorized Stanley Dealer.
protection input
5 Factory settings lost yes Have engine serviced by an Authorized Stanley Dealer.
6 External pot out-of-range no Have engine serviced by an Authorized Stanley Dealer.
7 Accelerator position / idle no Have engine serviced by an Authorized Stanley Dealer.
switch conflict
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.
FLASH ENGINE
CODE FAULT SHUTDOWN CORRECTIVE ACTION

16
GENERAL
Tests and adjustments should be performed periodically to
ensure the power unit is operating at maximum efficiency.
Stanley Circuit Tester (part number 04182) is recommend-
ed. This tester can be used to isolate problems in both the
engine and hydraulic system prior to any power unit disas-
sembly.
TESTING THE HYDRAULIC CIRCUIT
The following tests can be performed to ensure that the
hydraulic pump is supplying the correct flow 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 specified, refer to
the troubleshooting table in this section for possible causes.
TESTING THE 5 GPM HTMA TYPE 1 CIRCUIT
OR 10 GPM TYPE RR CIRCUIT
To test the circuit, proceed as follows:
1. Set the flow selector switches to the OFF (center) posi-
tion.
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 flow selector switch to 5 or 10 gpm depending
on which flow you are testing.
7. With the engine at the programed speed, the test flow
gauge should read 4-6 gpm/15-23 lpm or 9-11 gpm/34-41.6
lpm.
8. Slowly turn the restrictor valve clockwise while watch-
ing the pressure gauge. The flow rate should stay at 4-6
gpm/15-23 lpm or 9-11 gpm/34-41.6 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
TESTING & TROUBLESHOOTING
begins to open is commonly referred to as the "cracking
pressure". At the "cracking pressure," the flow rate should
start to drop because the relief valve is allowing fluid to by-
pass 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 putrudes 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.

17
Engine will not start. Flow selector switch not in the Make sure both flow selector switches
OFF position. are in 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 filter plugged. Replace fuel filter.
Defective spark plugs. Remove plugs, check gap, clean or
replace.
Fluid blowing out of fluid
reservoir vent. Hydraulic tank overfilled. Correct the fluid level.
Pump suction leak. Check suction connections. Tighten if
necessary.
Hydraulic tool won't operate. Flow selector switch not switched Check that the flow selector switch
ON. is set to 5 or 10 gpm.
Incorrect hose connection to Make sure the tool hose circuit goes
tool. from left (pressure) fitting to tool
and back to the right fitting (return).
Fluid always flows from the male to
female fittings.
Quick disconnect fittings Detach from hose, connect set
defective. together and check for free flow.
Hydraulic fluid level low. Check for correct fluid level. Fill
using the recommended fluid.
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 fluid
reservoir to pump inlet has a smooth
curve.
Solenoid not working. Check solenoid operation and electrical
connections.
Tool is defective. Refer to tool manual.
TROUBLESHOOTING
PROBLEM CAUSE REMEDY

18
Engine: ....................................................................................................................................... 18 hp Briggs / 20 hp Honda
Capacity.....................................................................................Two 5 gpm/19 lpm Circuits or One 10 gpm/37.8 lpm Circuit
Length:............................................................................................................................................................36 in. / 91.4 cm
Width: .............................................................................................................................................................23 in: / 58.4 cm
Height:..........................................................................................................................................................29.5 in. / 74.9cm
Weight (Wet): Dual Circuit Briggs .................................................................................................334 lbs / 151.5 kg
Weight (Wet): Dual Circuit Honda.................................................................................................352 lbs / 159.6 kg
Fuel Tank Capacity:......................................................................................................................................... 7 gal. / 26.5 ltr
Estimated Gas Consumption Per Hour .............................................................................................................. 1.3 gal / 4 ltr
Hydraulic Reservor Capacity:..............................................................................................................................3 gal. / 11 ltr
Relief Valve "crack" setting........................................................................................................................ 2100 psi / 145 bar
Full relief setting ........................................................................................................................................ 2500 psi / 172 bar
HTMA Category................................................"C" (20 lpm @ 138 bar) or "RR" (38 lpm @ 138 bar)
SPECIFICATIONS
OR

19
FIGURE 1. BRIGGS ENGINE ASSEMBLY
56
35
37
34
36
52
44
27
50
51
8
26
28
45
30
43
30
47
33
31
30 32
29
49
48
17
16
14
13
12
11
9
10
4
15
20
21
23
18
25
22
19
41
40
39
38
7
2
1
3
46
54
53
44
24
55
57
58
56
42
54 48
59
41

20
ITEM P/N QTY DESCRIPTION
1 36150 1 Muffler
2 36151 1 Heat Shield
3 36152 2 Screw, Hex Washer
4 59007 1 Briggs Engine
5 56656 1 Coupling
6 07819 1 Square Key
7 07860 2 Capscrew, 3/8-16 x 1-1/4
8 31765 1 Pressure Switch
9 12787 4 Flange Nut
10 24287 1 Clamp
11 59076 1 Bushing
12 20990 1 Key
13 65108 1 Blower Hub
14 00111 3 Capscrew
15 40080 1 Filter Assy
16 43687 1 Capscrew
17 64937 1 Grip Plate
18 51292 1 Std Thread Union
19 17821 4 Button Head HS
20 60945 2 Washer, 1/4 in. ID
21 15476 2 Capscrew, 1/2 -20 UNC
22 59080 1 Front Grille
23 59091 1 Cooler
24 07860 2 Capscrew, 3/8
25 59077 1 Hydraulic Tank
26 62296 2 Weather Strip
27 65107 1 Blower Wheel-Brazed
28 59074 4 Hex Flange Bolt, 1/4 -20
`
FIGURE 1. BRIGGS ENGINE PARTS LIST
29 65616 1 Engine Controller
30 40433 9 Hex Flange Bolt 5/16-18 x 1/2
31 58897 1 Frame Base Weldment
32 58918 2 Wheel & Tire
33 58917 1 Axle
34 27695 1 Pump, Dual
35 07810 1 Fuel Cap
36 60920 1 Grommet
37 59078 1 Fuel Tank
38 04303 1 Battery
39 60921 1 Battery Cover
40 15476 1 Capscrew, 1/4-20 x 3/4
41 65058 1 Hex Flange Bolt
42 21714 2 Handle Bumper
43 58942 3 Hex Flange Bolt, 5/16 x 1-3/4
44 01459 4 Lockwasher, 3/8
45 58975 2 Foot
46 18893 4 Flang Nut, 3/8-16
47 58976 4 Hex Flange Bolt, 3/8-16
48 31240 2 Retaining Ring
49 21318 2 Washer, 3/4
50 59083 1 Blower Housing
51 56655 1 Pump Mount
52 60919 1 Fuel Elbow
53 62385 2 Stud
54 371503 1 Nut
55 62324 1 Heat Shield
56 62292 2 Hex Washer Head Screws
57 64991 1 Screw
58 56709 1 Cable Clamp
59 65042 1 Rectifier Wire
ITEM P/N QTY DESCRIPTION