Bostitch GT18B01 manual

1 GT18B01 HYDRAULIC POWER UNIT S AFETY , O PERA TION AND M AINTENANCE SER VICE MANUAL WARNING Stanley Hydraulic T ools 3810 SE Naef Road Milwaukie OR 97267-5698 503-659-5660 F AX 503-652-1780 www .stanley-hydraulic-tools.com Copyright © 2004, The Stanley W orks OPS/MAINT USA 65466 9/2004 V er 1[...]

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3 T ABLE OF CONTENTS For the nearest authorized and certifi ed dealer , call Stanley Hydraulic T ools at the number listed on the back of this manual and ask for a Customer Service Representative. SERVICING THE ST ANLEY POWER UNIT : This manual contains safety , operation, and routine mainte- nance instructions. Stanley Hydraulic T ools recommends[...]

4 CERTIFICATE OF CONFORMITY Hy draulic Tools ______________________________________________________________________ I, the undersigned: Burrows, James Surname and First names Hereby certify that the c onstruction plant or equipment specif ied hereunder: 1. Manufacturer: Stanley Hydraulic Tools, 3810 Naef Road, Milwauki e, Oregon USA 2. Representati[...]

5 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 resu[...]

6 T ool 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 s[...]

7 T OOL STICKERS & T AGS 65458 Sound Power Decal 62302 Power Unit Dash Decal 62300 CHOKE D ANGER PULL TO ST ART PUSH TO R UN 62300 Single Circuit 28322 CE Decal AUTO IDLE OFF AUTO IDLE ON R U 62302[...]

8 HOSE TYPES Hydraulic hose types authorized for use with Stanley Hydraulic T ools are as follows: ➊ Certifi ed non-conductive ➋ Wire-braided (conductive) ➌ Fabric-braided (not certifi ed or labeled non-conductive) Hose ➊ listed above is the only hose authorized for use near electrical conductors. Hoses ➋ and ➌ listed above are conduc[...]

9 HTMA REQUIREMENTS FLOW RA TE TOOL OPERA TING PRESSURE (at the power supply outlet) SYSTEM RELIEF V AL VE SETTING (at the power supply outlet) MAXIMUM BACK PRESSURE (at tool end of the return hose) Measured at a max. fl uid viscosity of: (at min. operating temperature) TEMPERA TURE Suffi cient heat rejection capacity to limit max. fl uid temper[...]

10 Chevron A W-MV -32 Exxon "Univis" J-26 Mobil D.T .E. 13 Gulf "Harmony" AW -HVI-150-32 Shell "T ellus" T -32 T exaco "Rando" HD-AZ Union "Unax" AW -WR-32 T erresolve EnviroLogic 132 4. HYDRA ULIC CONNECTIONS The recommended hose length is 25 ft/8 m with a 1/2 inch/12.7 mm inside diameter . The hos[...]

11 CONTROL P ANEL RETURN PRESSURE H.T .M.A. 1/2 INCH MALE QUICK DISCONNECT COUPLER H.T .M.A. 1/2 INCH FE- MALE QUICK DISCON- NECT COUPLER 1/2 INCH I.D. HOSE, 25 FT LONG WITH 2500 PSI/ 172 BAR RA TING AND 4 T O 1 SAFETY F ACTOR PRESSURE RETURN 1/2 INCH MALE PIPE HOSE END 1/2 INCH MALE PIPE HOSE END ADAPTER, 3/8 INCH MALE PIPE x -8 SAE O-RING H.T .M.[...]

12 CONTROLS This unit is equipped with an advanced proportional engine control system. It provides a means of controlling engine speed by adjusting the fuel control lever with an actuator . The Power Unit provides one circuit, with an oil fl ow of 5 gpm/19 lpm up to 2000 psi/140 bar or 8 gpm/30 lpm up to 2000 psi/140 bar with a factory-programmed [...]

13 OPERA TION COLD WEA THER ST ARTUP 1. Use the procedures described under "ST ARTUP" and then follow the procedure below . 2. Hydraulic fl uids are thicker in cold weather . Therefore, it is recommended that the engine be run at low idle long enough to bring the fl uid temperature up to a minimum of 50°F/10°C. 3. If the tools and too[...]

14 ST ORAGE • 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[...]

15 CHECKING PERFORMANCE CONTROL™ (ELECTRONIC GOVERNOR-ST A TIC CHECK) T o 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 mod[...]

16 F AUL T 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 [...]

17 GENERAL T ests and adjustments should be performed periodically to ensure the power unit is operating at maximum effi ciency . Stanley Circuit T ester (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[...]

18 Engine will not start. Flow selector switch not in the Make sure the fl ow selector switch is in OFF position. the OFF position when starting. Battery not connected. Attach battery cables, check wires. Weak battery . T est battery , charge or replace. No fuel. Add Fuel. Fuel fi lter plugged. Replace fuel fi lter . Defective spark plugs. Remov[...]

19 Engine: ....................................................................................................................... ........................................ 18 hp Briggs Capacity .......................................................................................... One 5 gpm/19 lpm Circuit or One 8 gpm/30 lpm Circuit Length: ....[...]

20 SER VICE GENERAL Service instructions in this section are limited to parts and components other than the engine and hydraulic pump. Other major components should be serviced by representa- tives of the respective manufacturers as follows: ENGINE - Briggs and Stratton V anguard OHV Model-356447-01 15-E1 The Briggs engine should be serviced only b[...]

21 Be sure the tapered cone surfaces of the bushing and blower hub are clean and free of anti-seize lubricants. CA UTION 2. Disconnect the wiring harness (See Figure 4, Wiring Diagrams for the correct connections). 3.Follow steps 1 through 4 under "Manifold Assembly Re- moval". 4. Remove the RED wire attached to the starter solenoid and t[...]

22 Assemble the bushing and blower hub with the bolts inserted (but not tightened) through the drilled holes in the blower hub and into the tapped holes in the bushing. With the key in the shaft, slide assembly into position on the shaft and tighten the setscrew over the key (if equipped). T ighten the 3 capscrews (14, fi g.1) alternately and even[...]

23 SER VICE HYDRAULIC T ANK, COOLER & FIL TER ASSEMBL Y (see fi gure 1, 2 & 3) 1. First remove the hydraulic fl uid from the tank by either pumping it out with a portable drill pump or draining it into a container . 2. Remove the cooler guard (20, fi g. 2) by removing the 2 hex fl ange bolts (9, fi g. 2) and 2 capscrews (21, fi g. 1).[...]

24 FIGURE 1. BRIGGS ENGINE ASSEMBL Y 5 6 3 5 3 7 3 4 3 6 5 2 4 4 2 7 5 0 5 1 8 2 6 2 8 4 5 3 0 4 3 3 0 4 7 3 3 3 1 3 0 3 2 2 9 4 9 4 8 1 7 1 6 1 4 1 3 1 2 1 1 9 1 0 4 1 5 2 0 2 1 2 3 1 8 2 5 2 2 1 9 4 1 4 0 3 9 3 8 7 2 1 3 4 6 5 4 5 3 4 4 2 4 5 5 5 7 5 8 5 6 4 2 5 4 4 8 5 9 4 1 1[...]

25 ITEM P/N Q T Y DESCRIPTION 1 36150 1 Muffl er 1A 65456 1 Spark Arrester 2 36151 1 Heat Shield 3 36152 2 Screw , Hex W asher 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 1 1 59076 1 Bushing 12 20990 1 Key 13 59103 1 Blower Hub 1[...]

26 FIGURE 2. FRAME P ARTS ITEM P/N Q T Y DESCRIPTION 1 370502 7 Capscrew , 5/16 in. -18 UNC 2 03906 7 Nylock Nut, 5/16 in. -18 UNC 3 62270 1 Handle, Rear Lift 4 58857 1 Coupler , Male 3/8 in., -8 SAE 5 58856 1 Coupler , Female 3/8 in., -8 SAE 6 60962 2 Capscrew , 1/4 in. -20 7 59130 1 Manifold Assy , Single Circuit 8 1 Dash Decal 9 59074 6 Hex Flan[...]

27 ITEM P/N QTY DESCRIPTION 1 59130 1 Manifold Assy , Single Circuit 2 59104 1 Hose Barb, 3/4 in. Hose x 3/4 in. Pipe 3 62199 4 Hose Clamp 4 350000 1 Elbow , 45° Straight Thread 5 02773 1 Adapter 6 58569 1 Elbow , 90° 7 58943 1 Hose 8 350104 1 Connector , Straight Thread 9 40364 1 Elbow , 45° 10 59088 1 Hose 1 1 59089 1 Hose 12 59105 1 Hose Barb[...]

28 RECTIFIER WIRE WHITE CONTROLLER TO MAGNETO WIRE ON ENGINE GRA Y WIRE OIL PRESSURE SWITCH FUEL SHUTOFF RED WIRE - THROTTLE CONTROL SWITCH (NOTE: PLUG BEHIND SWITCH WITH BLUE & YELLOW WIRES GOES T O SWITCH ON TOP) RELA Y -62301 SUPPLIED W/62293 HARNESS PRESSURE SWITCH TO AC TUATOR RED/GREEN GROUND WIRES MANIFOLD ASSY DIRECTIONAL V AL VE RED TO[...]

29 Stanley Hydraulic T ools (hereinafter called “Stanley”), subject to the exceptions contained below , warrants new hydraulic tools for a period of one year from the date of sale to the fi rst retail purchaser , or for a period of 2 years from the shipping date from Stanley , whichever period expires fi rst, to be free of defects in material[...]

30 Stanley Hydraulic T ools 3810 SE Naef Road Milwaukie OR 97267-5698 503-659-5660 F AX 503-652-1780 www .stanley-hydraulic-tools.com[...]