Stanley MHP3 Bedienungsanleitung

New Britain, CT 06053

U.S.A.

69887 11/2012 Ver. 4

Safety, OperatiOn and Maintenance

USer ManUaL

MHP3

DIESEL

tracHOrSe

MHP3 Diesel User Manual ◄ 3

TABLE OF CONTENTS

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 au-

thorized and certied dealer. Please read the following warning.

For the nearest authorized and certied dealer, call Stanley Hydraulic Tools at the number listed on the back of this

manual and ask for a Customer Service Representative.

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.

IMPORTANT

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

visit Stanleyhydraulic.com and select the Warranty tab.

(NOTE: The warranty recording form must be submitted to validate the warranty).

SAFETY SYMBOLS ..................................................................................................................................................4

SAFETY PRECAUTIONS..........................................................................................................................................5

TOOL STICKERS & TAGS ........................................................................................................................................7

HOSE TYPES............................................................................................................................................................8

HOSE RECOMMENDATIONS ..................................................................................................................................9

HTMA REQUIREMENTS.........................................................................................................................................10

HOSE & FITTING CONNECTIONS FOR SINGLE TOOL CIRCUIT ....................................................................... 11

HOSE & FITTING CONNECTIONS FOR DUAL TOOL CIRCUIT ...........................................................................12

OPERATION............................................................................................................................................................13

MAINTENANCE ......................................................................................................................................................19

TESTING & TROUBLESHOOTING ........................................................................................................................20

TROUBLESHOOTING ............................................................................................................................................21

SPECIFICATIONS...................................................................................................................................................22

ACCESSORIES.......................................................................................................................................................22

MHP3 DIESEL MAJOR ASSY PARTS ILLUSTRATION..........................................................................................23

MHP3 DIESEL MAJOR ASSY PARTS LIST............................................................................................................24

MHP3 DIESEL HOSE & FITTINGS ILLUSTRATION – A ........................................................................................25

MHP3 DIESEL HOSE & FITTINGS PARTS LIST – A..............................................................................................26

MHP3 DIESEL HOSE & FITTINGS ILLUSTRATION & PARTS – B........................................................................27

MHP3 DIESEL POWER UNIT FRAME ILLUSTRATION.........................................................................................28

MHP3 DIESEL POWER UNIT FRAME PARTS LIST ..............................................................................................29

MHP3 DIESEL POWER UNIT ENGINE ILLUSTRATION & PARTS .......................................................................30

MHP3 DIESEL POWER UNIT RESERVOIR ILLUSTRATION & PARTS ...............................................................31

MHP3 DIESEL POWER UNIT VALVE ILLUSTRATION & PARTS .......................................................................... 32

4 ► MHP3 Diesel User Manual

SAFETY SYMBOLS

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.

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.

DANGER

This safety alert and signal word indicate an imminently hazardous situation

which, if not avoided, will result in death or serious injury.

WARNING

This safety alert and signal word indicate a potentially hazardous situation

which, if not avoided, could result in death or serious injury.

CAUTION

This safety alert and signal word indicate a potentially hazardous situation

which, if not avoided, could result in death or serious injury.

CAUTION

This signal word indicates a potentially hazardous situation which, if not avoid-

ed, may result in property damage.

NOTICE

This signal word indicates a situation which, if not avoided, will result in damage

to the equipment.

IMPORTANT

This signal word indicates a situation which, if not avoided, may result in dam-

age to the equipment.

MHP3 Diesel User Manual ◄ 5

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 machine.

These safety precautions are given for your safety. Re-

view them carefully before operating the machine and

before performing general maintenance or routine ser-

vice.

Supervising personnel should develop additional pre-

cautions relating to the specic work area and local

safety regulations. If so, place the added precautions in

the space provided in this manual.

If you have not read this manual or the engine manu-

al, you are not ready to operate the MHP3. Read and

understand this manual and any stickers and tags

attached to the machine before operation. Failure to

do so can result in equipment damage, personal in-

jury, or death.

• Operate the machine in a work area WITHOUT BY-

STANDERS. The operator must be familiar with all

prohibited work areas such as excessive slopes and

dangerous terrain conditions.

• DO NOT operate the machine ACROSS excessive

slopes or unstable terrain where “tip over” is a hazard.

• DO NOT operate the machine in conned areas

where there may be a risk of crushing the operator

between the machine and another object.

• DO NOT OPERATE THE TRACHORSE IN EN-

CLOSED SPACES. Inhalation of engine exhaust

can be fatal.

• DO NOT WEAR LOOSE CLOTHING that can get

entangled in the working parts of the machine or hy-

draulic tools.

• DO NOT add fuel to the machine while it is running

or still hot.

• DO NOT operate the machine if a fuel odor is pres-

ent.

• DO NOT operate the machine within 3.3 ft./1 m of

buildings, obstructions, or ammable objects.

• Allow the engine to cool before storing the machine

in an enclosure.

• DO NOT RIDE ON, OR ALLOW ANYONE ELSE TO

RIDE ON, THE MACHINE AT ANY TIME.

• Establish a training program for all operators to en-

sure safe operation.

• DO NOT operate the machine unless thoroughly

trained or under the supervision of an instructor.

• Always wear safety equipment such as goggles,

ear, head protection, respiratory and safety shoes

at all times when operating the TracHorse and hy-

draulic tools.

• DO NOT inspect or clean the machine while the en-

gine is running. Accidental engagement of the ma-

chine can cause serious injury or death.

• Wear a homologated respirator when cutting or

breaking masonry, concrete, asbestos and other

materials that produce dust.

• The hydraulic circuit control levers must be in the

“OFF”position when coupling or uncoupling hydrau-

lic tools. Wipe all couplers clean before connecting.

Use only lint-free cloths. Failure to do so may result

in damage to the quick couplers and cause over-

heating of the hydraulic system.

• Before operating hydraulic tools, read and under-

stand the operation manual furnished with the tool.

• DO NOT operate a damaged, or improperly adjusted,

machine. DO NOT operate with guards removed.

• DO NOT weld or cut with an acetylene torch any

surface or component of the equipment. Consult

with the Stanley factory before performing any weld-

ing or acetylene cutting of the equipment.

• Prevent possible personal injury or equipment dam-

age by having all repair, maintenance and service

performed only by authorized and properly trained

personnel.

• DO NOT exceed the rated limits of the equipment

or use the equipment for applications beyond its de-

sign capacity.

• Always keep critical markings, such as labels and

warning stickers legible.

• Always replace parts with replacement parts recom-

mended by Stanley Hydraulic Tools.

• Keep all body parts away from working parts of the

TracHorse.

• Be aware of surrounding hazards. Noise created by

the TracHorse and the tools it operates may mask

early indications of approaching hazards.

6 ► MHP3 Diesel User Manual

SAFETY PRECAUTIONS

• Only use the TracHorse in well-ventilated areas. DO

NOT operate in explosive atmospheres, in closed

environments or near ammable substances.

• Always be well-rested and mentally alert when op-

erating the TracHorse and tools. DO NOT operate if

affected by medications, drugs or alcohol.

• Keep clear of hot (engine) parts and exhaust.

• DO NOT use ammable solvents around the engine.

• DO NOT reverse tool rotation by changing uid ow

direction.

• Always use hose and ttings rated for 2500 psi/172

bar with a 4 to 1 safety factor. Be sure all hose con-

nections are tight.

• Be sure all hoses are correct for current ow direc-

tion to and from the tool being used.

• DO NOT inspect hoses and ttings for leaks by us-

ing bare hands. “Pin-hole” leaks can penetrate the

skin.

• DO NOT operate tools if oil temperature exceeds

140 °F/60 °C. Operation at high temperatures can

cause higher than normal temperatures at the tools

which can result in operator discomfort.

• Disconnect battery before servicing electrical com-

ponents. Electrocution or burns could result from

improper contact.

MHP3 Diesel User Manual ◄ 7

TOOL STICKERS & TAGS

68335

Throttle Sticker

68334

Limit Engine Speed Sticker

47352

Lift Point Sticker

Usein well ventilatedareas only. Exhaust contains chemicals known to the

state of California to cause cancer,birth defects, and other reproductive

harm.

Contact with high pressure fluid at leak or burst resulting from

improper handling, operation, or maintenance will causeoil injection

to body.

All operators mustread, understand, and followALL safteyprecautions

and operatinginstructions found in owners manual before operatingtool.

Engine,exhaust, and other surfaces of tool may be hot.Avoid accidental

contact with hot surfaces.Allowtool to cool before maintenance or

storage.

59126

Dash Decal

28045

Combiner Knob Sticker

35677

Start Sticker

28046

Carbon Monoxide Sticker

Hot Parts Sticker

P/N-28047

29133

California Proposition Sticker

Refer to the parts illustrations for correct location of stickers.

51297

Fluid Level Sticker

HYDRAU-

LIC FLUID

35686

Hydraulic Fluid Sticker

8 ► MHP3 Diesel 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 hy-

draulic system. There are three types of hydraulic hose that meet this requirement and are authorized for use with

Stanley Hydraulic Tools. They are:

Certied non-conductive — constructed of thermoplastic or synthetic rubber inner tube, synthetic ber braid

reinforcement, and weather resistant thermoplastic or synthetic rubber cover. Hose labeled certied non-

conductive is the only hose authorized for use near electrical conductors.

Wire-braided (conductive) — constructed of synthetic rubber inner tube, single or double wire braid reinforce-

ment, and weather resistant synthetic rubber cover. This hose is conductive and must never be used near

electrical conductors.

Fabric-braided (not certied or labeled non-conductive) — constructed of thermoplastic or synthetic rubber in-

ner tube, synthetic ber braid reinforcement, and weather resistant thermoplastic or synthetic rubber cover. This

hose is not certied non-conductive and must never be used near electrical conductors.

HOSE SAFETY TAGS

To help ensure your safety, the following DANGER tags are attached to all hose purchased from Stanley Hydraulic

Tools. DO NOT REMOVE THESE TAGS.

If the information on a tag is illegible because of wear or damage, replace the tag immediately. A new tag may be

obtained from your Stanley Distributor.

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

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

(Shown smaller than actual size)

SIDE 1

DANGER

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

SIDE 2

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 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

DANGER

DO NOT REMOVE THIS TAG

DANGER

(Shown smaller than actual size)

SIDE 2

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.

DANGER

DO NOT REMOVE THIS TAG

DANGER

SIDE 1

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.

DO NOT REMOVE THIS TAG

DANGER

SEE OTHER SIDE SEE OTHER SIDE

MHP3 Diesel User Manual ◄ 9

HOSE RECOMMENDATIONS

Oil Flow Hose Lengths Inside Diameter USE

(Press/Return)

Min. Working Pressure

GPM LPM FEET METERS INCH MM PSI BAR

Certied Non-Conductive Hose - Fiber Braid - for Utility Bucket Trucks

4-9 15-34 up to 10 up to 3 3/8 10 Both 2250 155

Conductive Hose - Wire Braid or Fiber Braid -DO NOT USE NEAR ELECTRICAL CONDUCTORS

4-6 15-23 up to 25 up to 7.5 3/8 10 Both 2500 175

4-6 15-23 26-100 7.5-30 1/2 13 Both 2500 175

5-10.5 19-40 up to 50 up to 15 1/2 13 Both 2500 175

5-10.5 19-40 51-100 15-30 5/8 16 Both 2500 175

5-10.5 19-40 100-300 30-90 5/8 16 Pressure 2500 175

3/4 19 Return 2500 175

10-13 38-49 up to 50 up to 15 5/8 16 Both 2500 175

10-13 38-49 51-100 15-30 5/8 16 Pressure 2500 175

3/4 19 Return 2500 175

10-13 38-49 100-200 30-60 3/4 19 Pressure 2500 175

1 25.4 Return 2500 175

13-16 49-60 up to 25 up to 8

5/8 16 Pressure 2500 175

3/4 19 Return 2500 175

13-16 49-60 26-100 8-30

3/4 19 Pressure 2500 175

1 25.4 Return 2500 175

Figure 1. Typical Hose Connections

Tool to Hydraulic Circuit Hose

Recommendations

The chart to the right shows recommended

minimum hose diameters for various hose

lengths based on gallons per minute (gpm)/

liters per minute (lpm). These recommenda-

tions are intended to keep return line pressure

(back pressure) to a minimum acceptable lev-

el to ensure maximum tool performance.

This chart is intended to be used for hydraulic

tool applications only based on Stanley Hy-

draulic Tools tool operating requirements and

should not be used for any other applications.

All hydraulic hose must have at least a rated

minimum working pressure equal to the maxi-

mum hydraulic system relief valve setting.

All hydraulic hose must meet or exceed

specications as set forth by SAE J517.

PRESSURE

RETURN

<<< FLOW

FLOW >>>

10 ► MHP3 Diesel User Manual

HTMA / EHTMA REQUIREMENTS

Flow Range

Nominal Operating Pressure

(at the power supply outlet)

System relief valve setting

(at the power supply outlet)

Maximum back pressure

(at tool end of the return hose)

Measured at a max. uid viscosity of:

(at min. operating temperature)

Temperature: Sufcient heat rejection

capacity to limit max. uid temperature to:

(at max. expected ambient temperature)

Min. cooling capacity at a temperature

difference of between ambient and uid

temps

NOTE:

Do not operate the tool at oil temperatures above 140° F (60° C). Operation at higher temperatures can cause operator

discomfort at the tool.

Filter

Min. full-ow ltration

Sized for ow of at least:

(For cold temp. startup and max.

dirt-holding capacity)

Hydraulic uid Petroleum based

(premium grade, anti-wear, non-conductive)

Viscosity (at min. and max. operating temps)

NOTE:

When choosing hydraulic uid, the expected oil temperature extremes that will be experienced in service determine the

most suitable temperature viscosity characteristics. Hydraulic uids with a viscosity index over 140 will meet the requirements

over a wide range of operating temperatures.

*SSU = Saybolt Seconds Universal

4-6 gpm 7-9 gpm 9-10.5 gpm 11-13 gpm

(15-23 lpm) (26-34 lpm) (34-40 lpm) (42-49 lpm)

1500 psi 1500 psi 1500 psi 1500 psi

(103 bar) (103 bar) (103 bar) (103 bar)

2100-2250 psi 2100-2250 psi 2200-2300 psi 2100-2250 psi

(145-155 bar) (145-155 bar) (152-159 bar) (145-155 bar)

250 psi 250 psi 250 psi 250 psi

(17 bar) (17 bar) (17 bar) (17 bar)

400 ssu* 400 ssu* 400 ssu* 400 ssu*

(82 centistokes) (82 centistokes) (82 centistokes) (82 centistokes)

140° F 140° F 140° F 140° F

(60° C) (60° C) (60° C) (60° C)

3 hp 5 hp 6 hp 7 hp

(2.24 kW) (3.73 kW) (5.22 kW) (4.47 kW)

40° F 40° F 40° F 40° F

(22° C) (22° C) (22° C) (22° C)

25 microns 25 microns 25 microns 25 microns

30 gpm 30 gpm 30 gpm 30 gpm

(114 lpm) (114 lpm) (114 lpm) (114 lpm)

100-400 ssu* 100-400 ssu* 100-400 ssu* 100-400 ssu*

(20-82 centistokes)

HTMA

HYDRAULIC SYSTEM REQUIREMENTS

NOTE: These are general hydraulic system requirements. See tool specication page for tool specic requirements

TOOL TYPE

HTMA / EHTMA REQUIREMENTS

TYPE I TYPE II TYPE III

TYPE RR

BCD

3.5-4.3 gpm 4.7-5.8 gpm 7.1-8.7 gpm 9.5-11.6 gpm 11.8-14.5 gpm

(13.5-16.5 lpm) (18-22 lpm) (27-33 lpm) (36-44 lpm) (45-55 lpm)

1870 psi 1500 psi 1500 psi 1500 psi 1500 psi

(129 bar) (103 bar) (103 bar) (103 bar) (103 bar)

EHTMA

HYDRAULIC SYSTEM

REQUIREMENTS

CLASSIFICATION

Flow Range

Nominal Operating Pressure

(at the power supply outlet)

System relief valve setting

(at the power supply outlet) 2495 psi 2000 psi 2000 psi 2000 psi 2000 psi

(172 bar) (138 bar) (138 bar) (138 bar) (138 bar)

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