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GD50
HYDRAULIC
GROUND ROD DRIVER
USER MANUAL
Safety, Operation and Maintenance
© 2014 Stanley Black & Decker, Inc.
New Britain, CT 06053
U.S.A.
39234 8/2014 Ver. 7
TABLE OF CONTENTS
SAFETY SYMBOLS ..................................................................................................................................................4
SAFETY PRECAUTIONS ..........................................................................................................................................5
TOOL STICKERS & TAGS ........................................................................................................................................6
HOSE TYPES ............................................................................................................................................................7
HOSE RECOMMENDATIONS ..................................................................................................................................8
FIGURE 1. TYPICAL HOSE CONNECTIONS .......................................................................................................8
HTMA REQUIREMENTS ...........................................................................................................................................9
OPERATION ............................................................................................................................................................10
FIGURE 2. CONNECTING THE VALVE .............................................................................................................. 11
CHARGING THE ACCUMULATOR .........................................................................................................................12
FIGURE 3. CHARGING THE ACCUMULATOR ...................................................................................................12
TOOL PROTECTION & CARE ................................................................................................................................13
TROUBLESHOOTING ............................................................................................................................................14
SPECIFICATIONS ...................................................................................................................................................15
SERVICE TOOLS ....................................................................................................................................................15
GD50 PARTS ILLUSTRATION ................................................................................................................................16
GD50 PARTS LIST ..................................................................................................................................................17
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 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.
WARNING
SERIOUS INJURY OR DEATH COULD RESULT FROM THE IMPROPER 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.
GD50 User Manual ◄ 3
SAFETY SYMBOLS
Safety symbols and signal words, as shown below, are used to emphasize all operator, maintenance and repair actions which, if not strictly followed, could result in a life-threatening situation, bodily injury or damage to equipment.
DANGER
WARNING
CAUTION
CAUTION
NOTICE
IMPORTANT
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
This safety alert and signal word indicate an imminently hazardous situation which, if not avoided, will result in death or serious injury.
This safety alert and signal word indicate a potentially hazardous situation which, if not avoided, could result in death or serious injury.
This safety alert and signal word indicate a potentially hazardous situation which, if not avoided, could result in death or serious injury.
This signal word indicates a potentially hazardous situation which, if not avoided, may result in property damage.
This signal word indicates a situation which, if not avoided, will result in damage to the equipment.
This signal word indicates a situation which, if not avoided, may result in damage to the equipment.
Always observe safety symbols. They are included for your safety and for the protection of the tool.
LOCAL SAFETY REGULATIONS
Enter any local safety regulations here. Keep these instructions in an area accessible to the operator and maintenance personnel.
4 ► GD50 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 tool and hose.
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 in this manual.
The GD50 Hydraulic Rod Driver 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 tool and hoses before operation. Failure to do so could result in personal injury or equipment damage.
• To avoid personal injury or equipment damage, all tool repair, maintenance and service must only be performed by authorized and properly trained personnel.
• Always replace parts with replacement parts recommended by Stanley Hydraulic Tools.
• Check fastener tightness often and before each use daily.
• 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 tool unless thoroughly trained or under the supervision of an instructor.
• Always wear safety equipment such as goggles, ear and head protection, and safety shoes at all times when operating the tool.
• Do not inspect or clean the tool while the hydraulic power source is connected. Accidental engagement of the tool can cause serious injury.
• Always connect hoses to the tool hose couplers before energizing the hydraulic power source. Be sure all hose connections are tight.
• Do not operate the tool at oil temperatures above
140 °F/60 °C. Operation at higher temperatures can cause higher than normal temperatures at the tool which can result in operator discomfort.
• Do not operate a damaged, improperly adjusted, or incompletely assembled rod driver.
• Do not weld, cut with an acetylene torch, or hardface the rod driver anvil or guide housing.
GD50 User Manual ◄ 5
GD50 ROD DRIVER
FLOW: 26-34 LPM/7-9 GPM
PRESS: 105-140 BAR
1500-2000 PSI
ACCUMULATOR CHG:
42 BAR/600 PSI NITROGEN
TOOL STICKERS & TAGS
37425
Name Tag
NOTE:
THE INFORMATION LISTED
ON THE STICKERS SHOWN,
MUST BE LEGIBLE AT ALL
TIMES.
REPLACE DECALS IF
THEY BECOME WORN OR
DAMAGED. REPLACEMENTS
ARE AVAILABLE FROM
YOUR LOCAL STANLEY
DISTRIBUTOR.
The safety tag (P/N 15875) at right is attached to the tool when shipped from the factory. Read and understand the safety instructions listed on this tag before removal. We suggest you retain this tag and attach it to the tool when not in use.
D A N G E R
1. FAILURE TO USE HYDRAULIC HOSE LABELED AND CER-
TIFIED AS NON-CONDUCTIVE WHEN USING HYDRAULIC
TOOLS ON OR NEAR ELECTRICAL LINES MAY RESULT IN
DEATH OR SERIOUS INJURY.
BEFORE USING HOSE
LABELED AND CERTIFIED AS NON-
CONDUCTIVE ON OR NEAR ELECTRIC LINES BE SURE THE
HOSE IS MAINTAINED AS NON-CONDUCTIVE. THE HOSE
SHOULD BE REGULARLY TESTED FOR ELECTRIC CUR-
RENT LEAKAGE IN ACCORDANCE WITH YOUR SAFETY
DEPARTMENT INSTRUCTIONS.
2. A HYDRAULIC LEAK OR BURST MAY CAUSE OIL INJEC-
TION INTO THE BODY OR CAUSE OTHER SEVERE
PERSONAL INJURY.
A. DO NOT EXCEED SPECIFIED FLOW AND PRESSURE
FOR THIS TOOL. EXCESS FLOW OR PRESSURE MAY
CAUSE A LEAK OR BURST.
B. DO NOT EXCEED RATED WORKING PRESSURE OF
HYDRAULIC HOSE USED WITH THIS TOOL. EXCESS
PRESSURE MAY CAUSE A LEAK OR BURST.
C. CHECK TOOL HOSE COUPLERS AND CONNECTORS
DAILY FOR LEAKS. DO NOT FEEL FOR LEAKS WITH
YOUR HANDS. CONTACT WITH A LEAK MAY RESULT
IN SEVERE PERSONAL INJURY.
D A N G E R
D. DO NOT LIFT OR CARRY TOOL BY THE HOSES. DO
NOT ABUSE HOSE. DO NOT USE KINKED, TORN OR
DAMAGED HOSE.
3. MAKE SURE HYDRAULIC HOSES ARE PROPERLY CON-
NECTED TO THE TOOL BEFORE PRESSURING SYSTEM.
SYSTEM PRESSURE HOSE MUST ALWAYS BE CON-
NECTED TO TOOL “IN” PORT. SYSTEM RETURN HOSE
MUST ALWAYS BE CONNECTED TO TOOL “OUT” PORT.
REVERSING CONNECTIONS MAY CAUSE REVERSE
TOOL OPERATION WHICH CAN RESULT IN SEVERE
PERSONAL INJURY.
4. DO NOT CONNECT OPEN-CENTER TOOLS TO CLOSED-
CENTER HYDRAULIC SYSTEMS. THIS MAY RESULT IN
LOSS OF OTHER HYDRAULIC FUNCTIONS POWERED BY
THE SAME SYSTEM AND/OR SEVERE PERSONAL INJURY.
5. BYSTANDERS MAY BE INJURED IN YOUR WORK AREA.
KEEP BYSTANDERS CLEAR OF YOUR WORK AREA.
6. WEAR HEARING, EYE, FOOT, HAND AND HEAD PRO-
TECTION.
7. TO AVOID PERSONAL INJURY OR EQUIPMENT DAMAGE,
ALL TOOL REPAIR MAINTENANCE AND SERVICE MUST
ONLY BE PERFORMED BY AUTHORIZED AND PROPERLY
TRAINED PERSONNEL.
I M P O R T A N T
READ OPERATION MANUAL AND
SAFETY INSTRUCTIONS FOR THIS
TOOL BEFORE USING IT.
USE ONLY PARTS AND REPAIR
PROCEDURES APPROVED BY
STANLEY AND DESCRIBED IN THE
OPERATION MANUAL.
TAG TO BE REMOVED ONLY BY
TOOL OPERATOR.
SEE OTHER SIDE
SAFETY TAG P/N 15875 (Shown smaller then actual size)
I M P O R T A N T
READ OPERATION MANUAL AND
SAFETY INSTRUCTIONS FOR THIS
TOOL BEFORE USING IT.
USE ONLY PARTS AND REPAIR
PROCEDURES APPROVED BY
STANLEY AND DESCRIBED IN THE
OPERATION MANUAL.
TAG TO BE REMOVED ONLY BY
TOOL OPERATOR.
SEE OTHER SIDE
6 ► GD50 User Manual
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 reinforcement, 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) — constructed 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 Hydraulic
Tools. DO NOT REMOVE THESE TAGS.
If the information on a tag is illegible because of wear or damage, replace the tag immediately. A new tag may be obtained from your Stanley Distributor.
THE TAG SHOWN BELOW IS ATTACHED TO “CERTIFIED NON-CONDUCTIVE” HOSE
D A N G E R
1. FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON-CONDUCTIVE
WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRIC LINES MAY RESULT IN
DEATH OR SERIOUS INJURY.
FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROP-
ERLY TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND
ELECTRIC LINES.
2. BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS NON-CONDUCTIVE
ON OR NEAR ELECTRIC LINES. WIPE THE ENTIRE LENGTH OF THE HOSE AND FIT-
TING WITH A CLEAN DRY ABSORBENT CLOTH TO REMOVE DIRT AND MOISTURE AND
TEST HOSE FOR MAXIMUM ALLOWABLE CURRENT LEAKAGE IN ACCORDANCE WITH
SAFETY DEPARTMENT INSTRUCTIONS.
SEE OTHER SIDE
3. DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE. IMPROPER USE
OR HANDLING OF HOSE COULD RESULT IN BURST OR OTHER HOSE FAILURE.
KEEP HOSE AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT
CONTACT DURING USE. CONTACT AT THE BURST CAN CAUSE BODILY INJECTION
AND SEVERE PERSONAL INJURY.
4. HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING, ABRASION, CUTTING, OR
CONTACT WITH HIGH TEMPERATURE SURFACES. DO NOT USE IF KINKED. DO NOT
USE HOSE TO PULL OR LIFT TOOLS, POWER UNITS, ETC.
5. CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS, BULGES, OR DAM-
AGE TO COUPLINGS IF ANY OF THESE CONDITIONS EXIST, REPLACE THE HOSE
IMMEDIATELY. NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE.
6. AFTER EACH USE STORE IN A CLEAN DRY AREA.
SEE OTHER SIDE
SIDE 1 SIDE 2
(Shown smaller than actual size)
THE TAG SHOWN BELOW IS ATTACHED TO “CONDUCTIVE” HOSE.
D A N G E R
1. DO NOT USE THIS HYDRAULIC HOSE ON OR NEAR ELECTRIC LINES. THIS HOSE IS
NOT LABELED OR CERTIFIED AS NON-CONDUCTIVE. USING THIS HOSE ON OR NEAR
ELECTRICAL LINES MAY RESULT IN DEATH OR SERIOUS INJURY.
2. FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY
TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND ELEC-
TRIC 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
5. CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS, BULGES, OR DAMAGE TO
COUPLINGS IF ANY OF THESE CONDITIONS EXIST, REPLACE THE HOSE IMMEDIATELY.
NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE.
6. AFTER EACH USE STORE IN A CLEAN DRY AREA.
(Shown smaller than actual size)
SEE OTHER SIDE
SIDE 2
GD50 User Manual ◄ 7
HOSE RECOMMENDATIONS
Tool to Hydraulic Circuit Hose Recommendations
The chart to the right shows recommended minimum hose diameters for various hose lengths based on gallons
8 ► GD50 User Manual
All hydraulic hose must meet or exceed specifications as set forth by SAE J517.
HTMA / EHTMA REQUIREMENTS
HTMA / EHTMA REQUIREMENTS
HTMA
HYDRAULIC SYSTEM REQUIREMENTS
Flow Range
Nominal Operating Pressure
(at the power supply outlet)
TYPE I
4-6 gpm
(15-23 lpm)
1500 psi
(103 bar)
System relief valve setting
(at the power supply outlet)
TOOL TYPE
TYPE II
7-9 gpm
(26-34 lpm)
1500 psi
(103 bar)
TYPE RR
9-10.5 gpm
(34-40 lpm)
1500 psi
(103 bar)
TYPE III
11-13 gpm
(42-49 lpm)
1500 psi
(103 bar)
2100-2250 psi 2100-2250 psi 2200-2300 psi 2100-2250 psi
(145-155 bar) (145-155 bar) (152-159 bar) (145-155 bar)
Maximum back pressure
(at tool end of the return hose)
250 psi
(17 bar)
250 psi
(17 bar)
250 psi
(17 bar)
250 psi
(17 bar)
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)
400 ssu* 400 ssu* 400 ssu* 400 ssu*
(82 centistokes) (82 centistokes) (82 centistokes) (82 centistokes)
140° F
(60° C)
140° F
(60° C)
140° F
(60° C)
140° F
(60° C)
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)
3 hp
(2.24 kW)
40° F
(22° C)
25 microns
30 gpm
(114 lpm)
5 hp
(3.73 kW)
40° F
(22° C)
25 microns
30 gpm
(114 lpm)
6 hp
(5.22 kW)
40° F
(22° C)
25 microns
30 gpm
(114 lpm)
7 hp
(4.47 kW)
40° F
(22° C)
25 microns
30 gpm
(114 lpm)
Hydraulic fluid Petroleum based
(premium grade, anti-wear, non-conductive)
100-400 ssu* 100-400 ssu* 100-400 ssu* 100-400 ssu*
Viscosity (at min. and max. operating temps)
(20-82 centistokes)
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
HYDRAULIC SYSTEM
REQUIREMENTS
B
C
CLASSIFICATION
D
Flow Range
Nominal Operating Pressure
(at the power supply outlet)
System relief valve setting
(at the power supply outlet)
3.5-4.3 gpm 4.7-5.8 gpm
(13.5-16.5 lpm) (18-22 lpm)
1870 psi
(129 bar)
1500 psi
(103 bar)
2495 psi
(172 bar)
2000 psi
(138 bar)
7.1-8.7 gpm
(27-33 lpm)
1500 psi
(103 bar)
2000 psi
(138 bar)
9.5-11.6 gpm
(36-44 lpm)
1500 psi
(103 bar)
2000 psi
(138 bar)
11.8-14.5 gpm
(45-55 lpm)
1500 psi
(103 bar)
2000 psi
(138 bar)
NOTE: These are general hydraulic system requirements. See tool specification page for tool specific requirements
GD50 User Manual ◄ 9
OPERATION
PRE-OPERATION PROCEDURES
PREPARATION FOR INITIAL USE
Each unit as shipped has no special unpacking or assembly requirements prior to usage. Inspection to assure the unit was not damaged in shipping and does not contain packing debris is all that is required.
CHECK HYDRAULIC POWER SOURCE
1. Using a calibrated flowmeter and pressure gauge, check that the hydraulic power source develops a flow of 7–9 gpm/26–34 lpm for HTMA Type II tools/
EHTMA category D at 2000 psi/105–140 bar.
2. Make certain the hydraulic power source is equipped with a relief valve set to open at 2100–2250 psi/145–
155 bar minimum.
3. Check that the hydraulic circuit matches the tool for open-center (OC) operation.
CHECK TOOL
1. Make sure the tool contains the correct anvil for the rod size to be driven. Use the 5/8 inch anvil (standard in the model GD50132RF Rod Driver) for 5/8 inch diameter rod. Use the 1 inch anvil (standard in the model GD50133RF Rod Driver) for 3/4 inch to
1 inch diameter rod. Failure to use the correct anvil with the appropriate rod size can result in damage to the tool or personal injury.
2. There should be no signs of leaks.
3. The tool should be clean, with all fittings and fasteners tight.
CHECK TRIGGER MECHANISM
1. Check that the trigger operates smoothly and is free to travel between the ON and OFF positions.
CONNECT HOSES
1. Wipe all hose couplers with a clean lint-free cloth before making connections.
2. Connect the hoses from the hydraulic power source to the hose couplers on the rod driver. It is a good practice to connect the return hose first and disconnect it last to minimize or avoid trapped pressure within the rod driver.
3. Observe flow indicators stamped on hose couplers to be sure that oil will flow in the proper direction.
The female coupler is the inlet coupler.
NOTE:
The pressure increase in uncoupled hoses left in the sun may result in making them difficult to connect.
When possible, connect the free ends of operating hoses together.
OPERATING PROCEDURES
1. Observe all safety precautions.
2. Move the hydraulic circuit control valve to the ON position.
3. Place the anvil of the rod driver over the rod to be driven.
4. Ensure adequate down pressure is applied to the rod driver before starting the rod driver. To start the rod driver, press the button on the control valve to the ON position. Adequate down pressure is very important. When you wish to stop the tool, press the button on the control valve to the OFF position.
INLINE CONTROL VALVE OPERATION
The 38632 Inline Control Valve is designed to provide the ON/OFF functions for a hydraulic tool connected to either an OPEN CENTER (OC) hydraulic system or an
CLOSED CENTER (CC) hydraulic system. The valve is to be used with tools which do not have an ON/OFF trigger control. The 38632 Control Valve can be used on hydraulic systems producing up to 10 gpm/38 lpm with a maximum relief valve setting of 2500 psi/172 bar. The valve ports are -8 SAE (3/4-16 thread) O-ring ports.
SETTING FOR OPEN CENTER (OC) OR
CLOSED CENTER (CC)
Set the valve to OC or CC before connecting it to the hydraulic system. To set the valve for open center operation, use a straight blade screw driver to turn the selector screw counter clockwise until it stops. To set the valve for closed center operation, turn the selector screw clockwise until it stops.
WARNING
Be sure you know if you have an OPEN CENTER
(OC) OR CLOSED CENTER (CC) hydraulic system,
DO NOT attempt to install or operate the 38632
Valve until you do. Incorrect installation or operation of the valve can result in seal failures in the tool, cause excessive heat in the hydraulic system, and may damage the tool and hydraulic system.
Understand which type of hydraulic system you are using before installing or operating this valve.
10 ► GD50 User Manual
OPERATION
INSTALLING THE VALVE
Connect the valve to the hydraulic system as shown in
Figure 2.
OPERATING THE VALVE
Connect the valve to the tool using the illustration below as a guide. Make sure the valve spool on the valve is pushed OFF before connecting the valve to the hydraulic system. Make sure the hydraulic system is OFF before connecting the valve to the hydraulic system. Connect the valve to the hydraulic system. Turn ON the hydraulic system. Place the tool to be operated in its operating position. Push the valve spool ON to begin operating the tool. Push the valve spool OFF to stop operating the tool. Turn the hydraulic system OFF before disconnecting the valve.
COLD WEATHER OPERATION
If the rod driver is to be used during cold weather, preheat the hydraulic fluid at low engine speed. When using the normally recommended fluids, fluid temperature should be at or above 50 °F/10 °C (400 ssu/82 centistokes) before use.
Selector Screw
Tool Hoses
72264 Valve
00936 Adapter Fittings
Quick Disconnect Couplers
IN
(PRESSURE)
OUT
(RETURN)
Figure 2. Connecting the Valve
GD50 User Manual ◄ 11
CHARGING THE ACCUMULATOR
To check or charge the accumulator the following equipment is required:
• Charge kit (Part Number 31254) Includes the following:
NOTE:
It may be necessary to set the regulator at 650–
700 psi/41–48 bar to overcome any pressure drop through the charging system.
– Accumulator tester (P/N 02835).
– Charge assembly (P/N 15304). Includes a liquid-filled gauge with snub valve, hose and fittings.
6. Open the valve on the charging assembly hose.
When the tester gauge reads 600–700 psi/41–48 bar, close the valve on the charging assembly hose and remove the charging assembly.
• NITROGEN bottle with a 800 psi/56 bar minimum charge (not a part of 31254 kit).
1. Holding the chuck end of the Stanley tester
(P/N 02835), turn the gauge fully counterclockwise
7. Turn the gauge end of the tester fully counterclockwise to retract the plunger in the chuck. Remove the tester from the charge valve.
8. Replace the valve cap.
Charging the Accumulator (BR72125S & BR72135S)
2. Thread the tester onto the charging valve of the tool accumulator (do not advance the gauge-end into the chuck end. Turn as a unit). Seat the chuck on the accumulator charging valve by hand tightening only.
CW
TESTER CHARGING
VALVE
1. Follow Steps 1 through 3 under CHARGING THE
ACCUMULATOR.
2. Read the pressure on the gauge. It should be between 500–700 psi/35–48 bar.
3. Advance the valve stem by turning the gauge-end clockwise.
CHUCK
3. If the pressure is low, recharge the tool.
4. Connect the charging assembly to the valve on the tester.
5. Adjust the regulator on the nitrogen bottle to 600 psi/42 bar.
ACCUMULATOR TESTER ( P/ N 02835 ) LOCATION OF CHARGING VALVE
Figure 2
(
Nitrogen Tank
)
31254 ACCUMULATOR CHARGE KIT
Includes: Liquid Filled Gauge w/Snub Valve,
Hose, Charge Fitting, 02835 Tester, and Box
(not pictured)
12 ► GD50 User Manual
CW
TESTER CHARGING
VALVE
CHUCK
GAUGE
ACCUMULATOR TESTER ( P/ N 02835 )
Figure 2
LOCATION OF CHARGING VALVE
TOOL PROTECTION & CARE
NOTICE
In addition to the Safety Precautions found in this manual, observe the following for equipment protection and care.
• Make sure all couplers are wiped clean before connection.
• The hydraulic circuit control valve must be in the
OFF position when coupling or uncoupling hydraulic tools. Failure to do so may result in damage to the quick couples and cause overheating of the hydraulic system.
• Always store the tool in a clean dry space, safe from damage or pilferage.
• Make sure the circuit PRESSURE hose (with male quick disconnect) is connected to the IN port. The circuit RETURN hose (with female quick disconnect) is connected to the opposite port. Do not reverse circuit flow. This can cause damage to internal seals.
• Always replace hoses, couplings and other parts with replacement parts recommended by Stanley
Hydraulic Tools. Supply hoses must have a minimum working pressure rating of 2500 psi/172 bar.
• Do not exceed the rated flow (see Specifications) in this manual for correct flow rate and model number.
Rapid failure of the internal seals may result.
• Always keep critical tool markings, such as warning stickers and tags legible.
• Tool repair should be performed by experienced personnel only.
• Make certain that the recommended relief valves are installed in the pressure side of the system.
• Do not use the tool for applications for which it was not intended.
GD50 User Manual ◄ 13
TROUBLESHOOTING
If symptoms of poor performance develop, the following chart can be used as a guide to correct the problem.
When diagnosing faults in operation of the spike driver, always check that the hydraulic power source is supplying the correct hydraulic flow and pressure to the spike driver as listed in the table. Use a flowmeter known to be accurate. Check the flow with the hydraulic oil temperature at least 80 °F/27 °C.
PROBLEM
Rod driver does not run.
CAUSE
Power unit not functioning.
SOLUTION
Check power unit for proper flow and pressure (7–9 gpm /26–34 lpm at
2000 psi /140 bar).
Remove restriction.
Couplers or hoses blocked.
Pressure and return line hoses reversed at ports.
Mechanical failure of piston or automatic valve.
Rod driver does not hit effectively. Power unit not functioning.
Be sure hoses are connected to their proper ports.
Have inspected and repaired by an authorized dealer.
Check power unit for proper flow and pressure (7–9 gpm /26–34 lpm at
2000 psi /140 bar).
Remove restriction.
Couplers or hoses blocked.
Low accumulator charge (pressure hose will pulse more than normal).
Have recharged by an authorized dealer.
Fluid too hot (above 140 °F /60 °C).
Provide cooler to maintain proper fluid temperature.
Rod driver operates slow.
Rod anvil is not sliding freely in the anvil guide.
Low oil flow from power unit.
High back-pressure.
Remove, clean and replace as necessary.
Check power source for proper flow.
Check hydraulic system for excessive back-pressure and correct as required.
14 ► GD50 User Manual
SPECIFICATIONS
Capacity (Rod Anvil)
1/2 to 5/8 inch/12 to 16 mm diameter rod (model GD50132RF)
3/4 to 1 inch/19 to 25 mm diameter rod (model GD50133RF)
Pressure Range.............................................................................................................. 1500–2000 psi/105–140 bar
Maximum Back Pressure...................................................................................................................... 250 psi/17 bar
Flow Range ................................................................................................................................ 7–9 gpm/26–34 lpm
Couplers .........................................................................................HTMA/EHTMA Flush Face Type Male & Female
Hose Whips ...........................................................................................................................................................Yes
Weight .................................................................................................................................................57.3 lbs./26 kg
Overall Length .............................................................................................................................25.5 inches/64.8 cm
Overall Width ..................................................................................................................................10 inches/25.4 cm
Maximum Fluid Temperature .................................................................................................................. 140 °F/60 °C
SERVICE TOOLS
DESCRIPTION PART NUMBER
O-ring Tool Kit: General Service of Seals ..........................................................................................................04337
Split Rings: Used with 04910.............................................................................................................................04908
Flow Sleeve Removal Tool ................................................................................................................................04919
Flow Sleeve Removal Tube: Used with 04908 & 05508....................................................................................04910
Bearing Puller Kit: General Bearing Pulling .......................................................................................................05064
Accumulator Disassembly Tool: Used with 04910 .............................................................................................05508
Tamper Sleeve Tool: Used to Pull Porting Block from Valve Block .................................................................... 01120
Accumulator Cylinder Puller: An Aluminum Disk (handy for protecting parts when using an arbor press .........05640
GD50 User Manual ◄ 15
16 ► GD50 User Manual
GD50 PARTS ILLUSTRATION
GD50 PARTS LIST
27
28
29
33
34
35
36
37
38
30
31
32
39
40
41
42
12
13
16
17
18
8
9
10
11
19
20
21
22
23
4
5
6
7
2
3
ITEM
1
24
25
26 67008 1
38631 1
00936 2
03973 1
03972 1
03971 1
04382 1
04571 2
02900 2
37425 1
04383 1
04384 1
04605 4
04954 1
02022 1
04387 1
04780 1
04386 1
12139 4
PART
NO.
QTY DESCRIPTION
35770 2 HANDLE BAR
370351 4
07493 1
CAPSCREW
O-RING PLUG-MALE
05243 1
20499 1
04374 4
15190 1
ORIFICE PLUG (INCL W/ ITEM 13)
CHARGE VALVE
LOCK NUT
TOP PLATE
00720 4
07479 1
00293 1
15188 1
04058 1
11588 1
10536 1
04381 2
04379 2
04378 1
35784 2
07480 1
16070 1
56749 2
01003 2
07224 2
13568 2
07626 2
13567 2
SET SCREW
DIAPHRAGM
O-RING
VALVE SPOOL
SPRING
ACCUMULATOR VALVE BLOCK
SELECTOR SCREW
BACK-UP RING
O-RING
PORTING BLOCK
HOSE ASSY
AUTOMATIC VALVE BODY
RETAINING RING
SEAL CAP (NEW INLINE VALVE)
VALVE BUTTON (OLD INLINE VALVE)
BACK-UP RING (NEW INLINE VALVE)
BACK-UP RING (OLD INLINE VALVE)
O-RING (NEW INLINE VALVE)
O-RING (OLD INLINE VALVE)
VALVE SPOOL (NEW INLINE VALVE)
VALVE SPOOL (OLD INLINE VALVE)
ADAPTOR
MALE COUPLER BODY
FEMALE COUPLER BODY
COUPLER SET
AUTOMATIC VALVE
PUSH PIN
ROLL PIN
NAME TAG
FLOW SLEEVE TUBE
FLOW SLEEVE
PUSH PIN
PISTON
O-RING
WIPER RING
BACK-UP WASHER
CUP SEAL
SIDE ROD
47
48
49
50
51
52
53
54
ITEM
43
44
45
46
PART
NO.
QTY DESCRIPTION
43527 1 ADAPTOR BLOCK
12143 1
12146 1
36106 1
UPPER ANVIL STOP
SPRING
35751 1
ROD ANVIL, 5/8 INCH RODS
(MODEL GD50132RF)
ROD ANVIL, 3/4 TO 1 IN. RODS
(MODEL GD50133RF)
65812 1
35753 1
67007 1
38629
00026
65813
1
1
1
371071 2
01604 2
56747 2
ANVIL GUIDE
GUIDE HOUSING
VALVE BODY ASSY. (NEW INLINE
VALVE)
VALVE BODY ASSY. (OLD INLINE
VALVE)
O-RING
BUMPER
WASHER
O-RING (NEW INLINE VALVE)
SEAL WIPER (NEW INLINE VALVE)
Model GD50132RF—1/2 and 5/8 inch rods.
Model GD50133RF—3/4 and 1 inch rods.
Verify the correct model number before ordering.
Seal Kit
GD50 Rapid Fire Model—04595
All Other GD50 Models—13552
Read Before Ordering Inline Valve Parts:
Inline Valve Assembly (OC-CC) - 72264
Includes Items (16, 22 thur 26, 49, 50, 53, and 54)
The inline valve changed around June 2011. To determine if you have the old or new inline valve, see parts illustration.
NOTE: Individual parts are still available for the older inline valve but if replacing the entire inline valve assy, you must order the new inline valve assy P/N-
72264.
GD50 User Manual ◄ 17
Stanley Hydraulic Tools
3810 SE Naef Road
Milwaukie, Oregon 97267-5698 USA
(503) 659-5660 / Fax (503) 652-1780 www.stanleyhydraulics.com
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Table of contents
- 4 SAFETY SYMBOLS
- 5 SAFETY PRECAUTIONS
- 6 TOOL STICKERS & TAGS
- 7 HOSE TYPES
- 8 HOSE RECOMMENDATIONS
- 8 FIGURE 1. TYPICAL HOSE CONNECTIONS
- 9 HTMA REQUIREMENTS
- 10 OPERATION
- 11 FIGURE 2. CONNECTING THE VALVE
- 12 CHARGING THE ACCUMULATOR
- 12 FIGURE 3. CHARGING THE ACCUMULATOR
- 13 TOOL PROTECTION & CARE
- 14 TROUBLESHOOTING
- 15 SPECIFICATIONS
- 15 SERVICE TOOLS
- 16 GD50 PARTS ILLUSTRATION
- 17 GD50 PARTS LIST