GT23

HYDRAULIC
POWER UNIT

USER’S MANUAL
SAFETY, OPERATION AND MAINTENANCE

© 2014 Stanley Black & Decker, Inc.

New Britain, CT 06053
U.S.A.
69405 10/2014 Ver. 7
 NOTES

2 GT23 User Manual

 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 fill 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 certified dealer. Please read the following warning.

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 certified 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
 SAFETY SYMBOLS

Safety symbols and signal words, as shown below, are used to emphasize all operator, maintenance and repair ac-
tions 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
DANGER which, if not avoided, will result in death or serious injury.

This safety alert and signal word indicate a potentially hazardous situation
WARNING which, if not avoided, could result in death or serious injury.

This safety alert and signal word indicate a potentially hazardous situation
CAUTION which, if not avoided, could result in death or serious injury.

This signal word indicates a potentially hazardous situation which, if not avoid-
CAUTION ed, may result in property damage.

This signal word indicates a situation which, if not avoided, will result in damage
NOTICE to the equipment.

This signal word indicates a situation which, if not avoided, may result in dam-
IMPORTANT age 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 mainte-
nance 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 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 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.

GT23 User Manual 5

 DASH DECALS

Stanley Dash Sticker 62302

Single Circuit Sticker 68595

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:

Certified non-conductive - constructed of thermoplastic or synthetic rubber inner tube, synthetic fiber
braid reinforcement, and weather resistant thermoplastic or synthetic rubber cover. Hose labeled certified 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 rein-
forcement, and weather resistant synthetic rubber cover. This hose is conductive and must never be used near
electrical conductors.

Fabric-braided (not certified or labeled non-conductive) - constucted of thermoplastic or synthetic rubber

inner tube, synthetic fiber braid reinforcement, and weather resistant thermoplastic or synthetic rubber cover. This
hose is not certified 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 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.

THE TAG SHOWN BELOW IS ATTACHED TO “CERTIFIED NON-CONDUCTIVE” HOSE

D A N G E R D A N G E R
DO NOT REMOVE THIS TAG

DO NOT REMOVE THIS TAG

1 FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON-CONDUCTIVE 3. DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE. IMPROPER USE OR
WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRIC LINES MAYRESULT IN DEATH HANDLING OF HOSE COULD RESULT IN BURST OR OTHER HOSE FAILURE. KEEP
OR SERIOUS INJURY. HOSE AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT CONTACT
FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY DURING USE. CONTACT AT THE BURST CAN CAUSE BODILY INJECTION AND SEVERE
TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND PERSONAL INJURY.
ELECTRIC LINES.
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
2. BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS NON-CONDUCTIVE ON
HOSE TO PULL OR LIFT TOOLS, POWER UNITS, ETC.
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 5. CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS, BULGES, OR DAMAGE TO
HOSE FOR MAXIMUM ALLOWABLE CURRENT LEAKAGE IN ACCORDANCE WITH SAFETY COUPLINGS IF ANY OF THESE CONDITIONS EXIST, REPLACE THE HOSE IMMEDIATELY.
DEPARTMENT INSTRUCTIONS. NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE.

6. AFTER EACH USE STORE IN A CLEAN DRY AREA.

SEE OTHER SIDE SEE OTHER SIDE

SIDE 1 SIDE 2
3 (shown smaller than actual size)

THE TAG SHOWN BELOW IS ATTACHED TO “CONDUCTIVE” HOSE.

D A N G E R D A N G E R
DO NOT REMOVE THIS TAG
DO NOT REMOVE THIS TAG

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 5. CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS, BULGES, OR DAMAGE TO
ELECTRICAL LINES MAY RESULT IN DEATH OR SERIOUS INJURY. COUPLINGS IF ANY OF THESE CONDITIONS EXIST, REPLACE THE HOSE IMMEDIATELY.
NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE.
2. FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY
TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND 6. AFTER EACH USE STORE IN A CLEAN DRY AREA.
ELECTRIC LINES.

3. DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE. IMPROPER USE OR

HANDLING OF HOSE COULD RESULT IN BURST OR OTHER HOSE FAILURE. KEEP
HOSE AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT CONTACT
DURING USE. CONTACT AT THE BURST CAN CAUSE BODILY INJECTION AND SEVERE
PERSONAL INJURY.

4. HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING, CUTTING, OR CONTACT

WITH HIGH TEMPERATURE SURFACES. DO NOT USE IF KINKED. DO NOT USE HOSE TO
PULL OR LIFT TOOLS, POWER UNITS, ETC.
SEE OTHER SIDE

SIDE 1 SIDE 2
(shown smaller than actual size)

GT23 User Manual 7

 Oil Flow Hose Lengths Inside Diameter USE Min. Working Pressure
Tool to Hydraulic Circuit Hose Recom-
GPM LPM FEET METERS INCH MM (Press/Return) PSI BAR
mendations
Certified Non-Conductive Hose - Fiber Braid - for Utility Bucket Trucks

8 GT23 User Manual

The chart to the right shows recommended mini- 4-9 15-34 up to 10 up to 3 3/8 10 Both 2250 155
mum hose diameters for various hose lengths Conductive Hose - Wire Braid or Fiber Braid -DO NOT USE NEAR ELECTRICAL CONDUCTORS
based on gallons per minute (gpm)/liters per min- 4-6 15-23 up to 25 up to 7.5 3/8 10 Both 2500 175
ute (lpm). These recommendations are intended 4-6 15-23 26-100 7.5-30 1/2 13 Both 2500 175
to keep return line pressure (back pressure) to a
5-10.5 19-40 up to 50 up to 15 1/2 13 Both 2500 175
minimum acceptable level to ensure maximum tool
5-10.5 19-40 51-100 15-30 5/8 16 Both 2500 175
performance.
5/8 16 Pressure 2500 175
5-10.5 19-40 100-300 30-90
This chart is intended to be used for hydraulic tool 3/4 19 Return 2500 175
applications only based on Stanley Hydraulic Tools 10-13 38-49 up to 50 up to 15 5/8 16 Both 2500 175
tool operating requirements and should not be used 5/8 16 Pressure 2500 175
for any other applications. 10-13 38-49 51-100 15-30
3/4 19 Return 2500 175
3/4 19 Pressure 2500 175
All hydraulic hose must have at least a rated 10-13 38-49 100-200 30-60
minimum working pressure equal to the maximum 1 25.4 Return 2500 175
hydraulic system relief valve setting. 5/8 16 Pressure 2500 175
13-16 49-60 up to 25 up to 8
3/4 19 Return 2500 175
All hydraulic hose must meet or exceed specifi- 3/4 19 Pressure 2500 175
cations as set forth by SAE J517. 13-16 49-60 26-100 8-30
1 25.4 Return 2500 175

PRESSURE
HOSE RECOMMENDATIONS

<<< FLOW

RETURN

FLOW >>>

Typical Hose Connections

 HTMA / EHTMA REQUIREMENTS
HTMA / EHTMA REQUIREMENTS

HTMA TOOL TYPE

HYDRAULIC SYSTEM REQUIREMENTS TYPE I TYPE II TYPE RR TYPE III
Flow Range 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)
Nominal Operating Pressure 1500 psi 1500 psi 1500 psi 1500 psi
(at the power supply outlet) (103 bar) (103 bar) (103 bar) (103 bar)

System relief valve setting 2100-2250 psi 2100-2250 psi 2200-2300 psi 2100-2250 psi
(at the power supply outlet) (145-155 bar) (145-155 bar) (152-159 bar) (145-155 bar)

Maximum back pressure 250 psi 250 psi 250 psi 250 psi
(at tool end of the return hose) (17 bar) (17 bar) (17 bar) (17 bar)

Measured at a max. fluid viscosity of: 400 ssu* 400 ssu* 400 ssu* 400 ssu*
(at min. operating temperature) (82 centistokes) (82 centistokes) (82 centistokes) (82 centistokes)

Temperature: Sufficient heat rejection 140° F 140° F 140° F 140° F

capacity to limit max. fluid temperature to: (60° C) (60° C) (60° C) (60° C)
(at max. expected ambient temperature)

Min. cooling capacity at a temperature 3 hp 5 hp 6 hp 7 hp

difference of between ambient and fluid (2.24 kW) (3.73 kW) (5.22 kW) (4.47 kW)
temps 40° F 40° F 40° F 40° F
NOTE: (22° C) (22° C) (22° C) (22° C)
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 25 microns 25 microns 25 microns 25 microns

Min. full-flow filtration 30 gpm 30 gpm 30 gpm 30 gpm
Sized for flow of at least: (114 lpm) (114 lpm) (114 lpm) (114 lpm)
(For cold temp. startup and max.
dirt-holding capacity)

Hydraulic fluid Petroleum based 100-400 ssu* 100-400 ssu* 100-400 ssu* 100-400 ssu*
(premium grade, anti-wear, non-conductive) (20-82 centistokes)
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 requirements
over a wide range of operating temperatures.

*SSU = Saybolt Seconds Universal

EHTMA CLASSIFICATION
HYDRAULIC SYSTEM
REQUIREMENTS
B C D
Flow Range 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)
Nominal Operating Pressure 1870 psi 1500 psi 1500 psi 1500 psi 1500 psi
(at the power supply outlet) (129 bar) (103 bar) (103 bar) (103 bar) (103 bar)

System relief valve setting 2495 psi 2000 psi 2000 psi 2000 psi 2000 psi
(at the power supply outlet) (172 bar) (138 bar) (138 bar) (138 bar) (138 bar)

NOTE: These are general hydraulic system requirements. See tool specification page for tool specific requirements

GT23 User Manual 9

 OPERATION

PREPARATION FOR USE 5. HYDRAULIC CONNECTIONS

The recommended hose length is 25 ft/8 m with a 1/2

Do not operate the power unit until you have read the inch/12.7 mm inside diameter. The hoses must have a
engine operating and maintenance instructions manual working pressure rating of at least 2500 psi/175 bar. Each
furnished with the unit. hose end must have male thread ends compatible with
H.T.M.A. (HYDRAULIC TOOL MANUFACTURERS AS-
1. ENGINE CRANKCASE OIL LEVEL SOCIATION) quick disconnect fittings (NPT type threads).
(See Page 8.)
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.
Figure 1. Panel Control Valve

Incorrect type spark plugs can produce radio frequency Facing the panel control valve, the bottom male quick
interference that will corrupt and damage the controller. disconnect fitting is the PRESSURE FLUID OUT fitting. The
Failure to use the correct spark plug could result in a war- top female quick disconnect fitting is the RETURN FLUID
ranty that will not be considered. IN fitting.

3. ENGINE FUEL LEVEL

Check the fuel level. If low, fill with un-leaded gasoline with
a minimum of 85 octane. QUICK DISCONNECT COUPLERS

4. HYDRAULIC FLUID H.T.M.A. approved quick disconnect couplings are installed

to hydraulic hoses so that the direction of oil flow is always
RECOMMENDED HYDRAULIC OILS from the male to the female quick disconnect as shown
on page 8. Quick disconnect couplings and hose fittings
Below is a list of recommended oils by brand. are selected so that additional fittings such as reducer or
adapter fittings are not required.
Brand Biodegradable Description
CITGO No Hydurance AW32 If adapter fittings are used, they must be approved steel
AMS Oil No HVH 32 hydraulic fittings meeting a minimum operating pressure
rating of 2500 psi/172 bar. Do not use galvanized pipe fit-
Exxon Mobil No Univis HVI26*
tings or black pipe fittings.
Exxon Mobil No DTE 10 Excel
Shell No S2 V 32 Use thread tape or pipe joint compound when installing
Chevron No Rando HDZ 32 quick disconnect couplings to hose or tool fittings. Follow
the instructions furnished with the selected thread sealant.
Conoco Phillips No Unax AW-WR-32 DO NOT OVERTIGHTEN THE FITTINGS.
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

* Recommended for extreme cold temperatures

10 GT23 User Manual
 OPERATION

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
functions are operating properly.

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.

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.

GT23 User Manual 11

 OPERATION

Note:
It may be necessary to reset the Controller.
CONTROLS
At times it may be neccessary to reset the controller. This
This unit is equipped with an advanced proportional engine could happen if a fault occurs in the controller. For ex-
control system. It provides a means of controlling engine ample, excessive engine speed. If a fault does occur the
speed by adjusting the fuel control lever with an actuator. power unit will return to an idle and the operator will have
The Power Unit provides one circuit, with an oil flow of 8 no control of the unit. To reset the controller, simply turn off
gpm/30 lpm up to 2000 psi/140 bar or 12 gpm/45 lpm up the power unit and restart it.
to 2000 psi/140 bar with a factory-programmed electronic
governed engine throttle.
STARTUP
THROTTLE CONTROL
SWITCH
throttle control Before starting the engine make sure the flow selector
switch switch is in the OFF position.

flow selector Note:

switch
The power unit will not start if the flow control switch is
IGNITION SWITCH FLOW SELECTOR SWITCH not in the "OFF" position.
ignition switch

Figure 3. Panel Control Valve Pull choke knob out and move the Throttle Control Switch
to the auto-idle-off or the auto-idle-on position, whichever
One hydraulic tool can be connected to the tool circuit. mode of operation the operator prefers. Ensure the flow
The circuit is activated by turning the flow control switch to selector switch is in the OFF position.
either the 8 gpm/30 lpm or 12 gpm/45 lpm setting.
Turn the Ignition Switch to the START position. After the
THROTTLE CONTROL engine starts, release the switch.
The throttle control permits the operator to select one of 2
operating modes after the engine has warmed up. When Gradually push in the choke knob as the engine begins to
starting the engine, make sure the flow selector switch is in idle smoothly.
the OFF position. The throttle control switch can be set in
either the AUTO-IDLE-ON or AUTO-IDLE-OFF positions. Allow the engine to warm up.

AUTO-ON Connect hoses and the tool as desrcribed on page 8 and

When the throttle control switch is in the "AUTO-ON" posi- 10.
tion, the oil flow is regulated automatically when the trigger
on the tool activated. When the tool is not being used the FOR 8 GPM OPERATION
engine will return to idle automatically, after a 10 second
delay. For 8 gpm operation, select mode of operation with the
Throttle Control switch, either auto-idle-on or the auto-idle-
This setting will produce 8 gpm/30 lpm or 12 gpm/45 lpm off position. Move the flow selector switch to the 8 gpm
depending on which postion the operator has selected with position.
the flow selector switch.
When finished operating the tool, move the flow selector
AUTO-OFF switch to the OFF position.
When the throttle control switch is in the "AUTO-OFF" posi-
tion, the engine speed is held to maintain 8 gpm/30 lpm or FOR 12 GPM OPERATION
12 gpm/45 lpm depending on which position the operator
has selected with the flow selector switch. When a tool is For 12 gpm operation, select mode of operation with the
not being used the engine will not return to idle until either Throttle Control Switch, either auto-idle-on or the auto-idle-
the flow selector switch is turned to the OFF position or the off position. Move the flow selector switch to the 12 gpm
throttle control switch is turned to AUTO-ON. position.

When finished operating the tool, move the flow selector

switch to the OFF position.
12 GT23 User Manual
 OPERATION

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 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
STORAGE
Follow the maintenance schedule and general maintenance
instructions in the engine maintenance and operation • Clean the unit thoroughly before storage. Do not use
manual furnished with the power unit. water pressure.

HYDRAULIC SYSTEM MAINTENANCE • Always store the unit in a clean and dry facility.

• Check hydraulic fluid level daily. Add fluid per specifica- • If the unit will be stored for a prolonged period (over 30
tions in this manual. (See "HYDRAULIC FLUID" under the days), add a fuel additive to the fuel tank to prevent the fuel
section titled "OPERATION". from gumming. Run engine for a short period to circulate
the additive.
• Remove condensed moisture from the hydraulic
fluid by pumping the hydraulic fluid into a 5 gal/20 l con- • Replace crankcase oil with new oil.
tainer through the pressure hose. Make sure the engine is
at idle when performing this procedure. When the hydraulic • Remove spark plugs and pour approximately 1 ounce (30
reservoir is empty turn the engine off immediately. ml) of engine oil into each cylinder. Replace spark plugs
and crank the engine slowly to distribute the oil.
• Allow the fluid to sit long enough for the water to settle to
the bottom of the container. Slowly pour the fluid back into • Check hydraulic reservoir for water. If water is found,
the hydraulic tank, avoiding the water at the bottom of the change the oil and circulate it through the tool hose and
container. tool.

• Each day, check hydraulic lines and fittings for leaks, • Disconnect tool hoses.
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.

SPARK PLUGS

On power units equipped with Briggs & Stratton Engines,

ONLY Champion RC12YC or equivalent can be used.

Incorrect type spark plugs can produce radio frequency

interference that will corrupt and damage the controller.
Failure to use the correct spark plug could result in a war-
ranty that will not be considered.

14 GT23 User Manual

 PROGRAMMABLE CONTROLLER

The Stanley programmable controller is an electronic

1. Disconnect red wires from the control module to actuator.
engine governor that provides a means of controlling and
limiting engine speed by adjusting the fuel control lever with
2. Attach jumper wires from battery to the RED wires to
a proportional actuator.
actuator.
The controller is factory programmable and has no manual
3. Actuator should move throttle lever to wide open posi-
adjustments.
tion.

a. If actuator does not move it is defective. (Replace).

b. If actuator moves throttle to wide-open position, the
module is defective. (Replace). Note: Before replacing
the actuator verify signal inputs to module (see Stanley
A flashing LED indicates Electrical Trouble shooting guide "TechHELP # 032807. A
the fault condition 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
CALIBRATION 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:
Calibration and programming can only be done by the fac-
tory.
1. When power is first applied to the controller, the LED will
flash just once for one second to indicate that the LED is
TROUBLESHOOTING GUIDELINES working.

2. If there are multiple faults, the LED will flash them all
Please follow the checklist below to troubleshoot your Stan-
in sequence. Count the flash codes to determine the fault
ley controller.
conditions or connect the Calibration Tool to observe the
fault conditions. (Use the “Display Faults” option under the
1. Check battery voltage for stability and correct value. The
Monitor Menu.)
LED will turn on for one second when the controller is first
powered up.
3. If there are no faults, the LED will flash once at reset
and from then on indicate the detection of engine speed. A
2. Check the actuator linkage for binding and backlash.
continuous ON LED indicates that a valid engine speed is
being sensed.
CHECKING PERFORMANCE CONTROL
(ELECTRONIC GOVERNOR-STATIC CHECK) 4. The controller will attempt to shut down for some faults
and will not permit starting after reset with faults 1, 5 and 8.
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.

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 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.

16 GT23 User Manual

 TESTING THE HYDRAULIC CIRCUIT

pressure". At the "cracking pressure," the flow rate should

GENERAL start to drop because the relief valve is allowing fluid to by-
pass to the hydraulic reservoir. The "cracking pressure" is
Tests and adjustments should be performed periodically to preset at the factory and if it is not within the above range,
ensure the power unit is operating at maximum efficiency. the relief valve must be re-set as follows:
Stanley Circuit Tester is recommended. This tester can be
used to isolate problems in both the engine and hydraulic a. The relief valve is located on the right side of the unit just
system prior to any power unit disassembly. 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.
TESTING THE HYDRAULIC CIRCUIT
b. Use an Allen wrench to adjust the relief valve. Turn
The following tests can be performed to ensure that the clockwise to raise the pressure and counterclockwise to
hydraulic pump is supplying the correct flow and pressure reduce the pressure.
and that the system relief valve is operating properly.
c. Tighten the nut and retest.
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 8 GPM HTMA TYPE II CIRCUIT

OR THE 12 GPM TYPE III CIRCUIT

To test the circuit, proceed as follows:

1. Set the flow 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 flow selector switch to 8 or 12 gpm depending

on which flow you are testing.

7. With the engine at the programed speed, the test

flow 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 flow 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 flow 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 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 8 or 12 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.

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

OR HTMA Category...................................................."D" (30 lpm @ 138 bar) or "E" (45 lpm @ 138 bar)

Nominal Pressure........................................................................................................................................ 1500 psi/103 bar

Max Pressure.............................................................................................................................................. 2000 psi/138 bar

POWER UNITS,TRACHORSE & GAS/FUEL DRIVEN EQUIPMENT: A1. Federal Emission Component Compliance
40CFR part 1060.120 Stanley warrants all fuel system emission components for 2 years from the date of original pur-
chase
provided there has been no abuse, neglect, modifi cations, or improper maintenance.
Components covered. The emission-related warranty covers all components whose failure would increase the evapora-
tive
emissions. Your emission-related warranty does not cover components whose failure would not increase evaporative
emissions. Coverage under this warranty extends only to the following parts; fuel tank, fuel cap, fuel hose and vapor
hose from the fuel tank to the engine and any connectors that are apart of the fuel system.
The equipment is designed, built, and equipped so it conforms at the time of sale to the ultimate purchaser and each
subsequent purchaser and is in compliance with 40 C.F.R. 1060.120 standards. The equipment is free from defects in
materials and workmanship that may keep it from meeting these requirements.

GT23 User Manual 19

 74 75
70
TO ENGINE 4
THROTTLE LINKAGE
28
63 PART OF
ENGINE ASSY
55 68
71 57
15
58
72 62 18
3 PART OF
ENGINE ASSY 73 23
1 14 60

20 GT23 User Manual

28
13 70

2 69
11 67
64
12
17
16 19
53
53 9 41
40
6
76
5

46
65
26 22
61
46 79
28
8
54 80 FUEL LINE 50
51 25

CONNECT TO FUEL
44
24 79 VAPOR HOSE ON 66
ENGINE 20 66
34 21
52
77 27
44 35

7 36 78 COMES WITH ENGINE

77
FUEL VAPOR HOSE
FROM FUEL TANK TO
ENGINE

ITEM 36 IS RUBBER
36 GROMMET ONLY
56
29

Positive Battery 31
TO OIL FILTER ON
BRIGGS ENGINE ASSEMBLY

Cable P/N-35395
SIDE OF ENGINE

30
41
38 32
40 37 33

Ground Battery 30
Cable P/N-62332

39 43
46
43
30
45 49
42

48
47
 BRIGGS ENGINE PARTS LIST

ITEM P/N QTY DESCRIPTION ITEM P/N QTY DESCRIPTION

59 ------ -- No Item
1 N/A 1 Muffler (Part of Item 4)
60 66215 1 Cooler Mount
2 66214 1 Heat Shield 61 69387 1 90° 1/8 NPT Street EL.
3 36152 2 Screw, Hex Washer 62 68675 1 Angle Bracket Weldment
4 68674 1 Briggs Engine 63 68560 1 Rotary Actuator
5 56656 1 Coupling 64 68676 1 Actuator Bracket
6 07819 1 Square Key 65 69384 4 Hose Clamp
7 07860 2 Capscrew, 3/8-16 x 1-1/4
66 69383 2 Hose
8 31765 1 Pressure Switch 67 59075 1 Hex Flange Screw
9 12787 4 Flange Nut 68 69288 1 Throttle Link
11 59076 1 Bushing 69 60774 1 Clamp
12 20990 1 Key 70 59095 3 Hex Flange Nut
13 65108 1 Blower Hub 71 62181 1 Link Retainer
14 00753 3 Capscrew 72 69282 1 Hex Socket Head Capscrew 8-32
15 40080 1 Filter Assy 73 69281 4 Hex Socket Head Capscrew 6-32
16 43687 2 Capscrew 74 69401 1 Wire Assemble
17 64937 1 Grip Plate 75 65042 1 Rectifier Wire
18 51292 1 Std Thread Union 76 01212 1 Pipe Plug
19 17821 4 Button Head HS 77 72451 3 Spring Hose Clamp
20 26831 2 Washer, 1/4 in. ID 78 72571 1 Fuel Vapor Hose
21 01213 2 Capscrew, 1/4 -20 UNC
79 72317 2 Spring Hose Clamp
22 59080 1 Front Grille 80 62289 1 Fuel Hose
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 40408 1 Filter Element (Part of item # 15)
28 59074 8 Hex Flange Bolt, 1/4 -20 43592 1 Filter, Service Kit
29 69407 1 Engine Controller (Includes Filter and Seals)
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

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 fitting.

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 ITEM P/N QTY DESCRIPTION

1 370502 7 Capscrew, 5/16 in. -18 UNC 24 59131 1 Relief Valve

2 03906 7 Nylock Nut, 5/16 in. -18 UNC 26 59128 1 Pressure Switch Assy
3 62268 1 Handle, Rear Lift 27 60959 1 Directional Valve
4 58857 1 Coupler, Male 3/8 in., -8 SAE 28 ------ 1 Cap (Included with Item 27)
5 58856 1 Coupler, Female 3/8 in., -8 SAE 29 60958 1 Coil
6 60962 2 Capscrew, 1/4 in. -20 32 62298 1 Choke Cable Assy
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

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

 MAIN WIRING HARNESS

Wire Harness P/N-65147

THROTTLE CONTROL SWITCH

(NOTE: PLUG BEHIND SWITCH WITH
BLUE & YELLOW WIRES GOES TO SWITCH ON TOP)
FLOW CONTROL
SWITCH HOUR METER

DIRECTIONAL VALVE START

SWITCH
MANIFOLD ASSY BLACK

RED

PRESSURE SWITCH
TO STARTER SOLENOID

PLUG TOP RESSURE SWITCH

RELAY-62301
SUPPLIED W/62293 HARNESS
+ POSITIVE BATTERY CABLE TO
STARTER SOLENOID
--

STARTER SOLENOID
ERY GREEN
GROUND WIRES BATT

ENGINE KILL
BLACK
TO ACTUATOR
RED/GREEN

RECTIFIER WIRE
WHITE

TO MAGNETO WIRE ON ENGINE

GRAY WIRE

OIL PRESSURE FUEL SHUTOFF

SWITCH RED WIRE

RED WIRE (P TERMINAL)

CONTROLLER
ORANGE WIRE (S TERMINAL)

YELLOW WIRE (I TERMINAL)

ENGINE OIL PRESS SWITCH

WIRING DETAIL

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