MHP Diesel User Manual - Stanley Hydraulic Tools
Contents
1. gt gt gt Er za JYNSSIYd HYDRAULIC CIRCUIT PRESSURE PRESSURE 6 1 0052 unay 794 08 8 001 95 09 67 9L EL 6 1 0052 eunsseJg 61 6 1 0092 61 8 dn 92 o dn 09 67 9L EL 9 1 0052 9 8 9 LISP IVS Aq 195 se 4 0052 vor i Jo 5 sou 09 06 002 001 67 85 EL OL SLL 0052 ainssald 6L Bunes SLL 0052 Winey 6L VIE WU ne rn jenbe eunsseJd m 0052 gis pojeJ e 15291 Je 4 oineJp u SLL 0052 9 8 9 GL 0 dn 090 dn e se 510 jeujo Aue 10 pesn eq jou pjnous 0052 unes 6l ve pue joo 1001 06 08 005 001 07 6 FOLS H ejuejs uo peseq joo 6 1 0052 ainssald QL 8 6 oi neJp U 10 pesn SI yeyo siu L 6 1 0052 ujog QL 8 6 06 6 001 15 07 6 GOL S d 6 1 0052 ujog I e GL dn OG 0 dn 07 6 01 4 ee PE ESS E e2. 03975 Coupler Body 1 2 Port 03976 Coupler Set 1 2 Port Bruning includes nose 03974 Hose Assy 50 ft with couplers 2 wire braid 58448 056 55 501 Wilh COUplefs tee mitt eterno radit es stati 31848 Hose Assy 25 ft with couplers U UU ULLA nen nn nenne rennes 31972 Hose Assy 25 ft with couplers 2 wire braid ind 58451 Lt SING u u has Z n 68358 22 gt MHP3 Diesel User Manual STAN LEY MHP3 DIESEL MAJOR ASSY PARTS ILLUSTRATION ADJUSTING TRACK TENSION The track tension is adjusted with the unit lifted off the ground Between the drive wheel and front idler wheel there are 3 smaller rollers Once the unit is lifted off the ground adjust the track tension to achieve 3 8 to 72 sag below the center small roller STAN LEY MHP3 Diesel User Manual lt 23 Tew PN Josscrenon es E Em mes ENS ma fo Ex pee gt 2 swa fa Favors 2 wes 2 f rer ES 6 18 EM 22 20 _ 23 24 25 26 _ 26 E 28 2 2 2 2 2 2 2 2 2 0 2 3 3 3 0 3 4 5 6 6 7 8 9 1 3 4 3 SPROCKET 69474 2 24 gt Diesel User Manual 5 36 37
3. 1 4 6 15 23 Ipm 1500 psi 103 2100 2250 psi 145 155 250 psi 17 bar 400 ssu 82 centistokes 140 60 C 3 hp 2 24 kW 40 F 22 C TOOL TYPE TYPE Il 7 9 26 34 Ipm 1500 psi 103 bar 2100 2250 psi 145 155 bar 250 psi 17 bar 400 ssu 82 centistokes 140 60 C 5 hp 3 73 kW 40 F 22 C TYPE RR 9 10 5 gom 34 40 Ipm 1500 psi 103 bar 2200 2300 psi 152 159 bar 250 psi 17 bar 400 ssu 82 centistokes 140 60 C 6 hp 5 22 kW 40 22 C TYPE Ill 11 13 42 49 Ipm 1500 psi 103 bar 2100 2250 psi 145 155 bar 250 psi 17 bar 400 ssu 82 centistokes 140 60 C 7 hp 4 47 kW 40 F 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 Min full flow filtration Sized for flow of at least For cold temp startup and max dirt holding capacity Hydraulic fluid Petroleum based premium grade anti wear non conductive Viscosity at min and max operating temps NOTE 25 microns 30 gpm 114 lpm 100 400 ssu 25 microns 30 gpm 114 lpm 100 400 ssu 20 82 centistokes 25 microns 30 gpm 114 lpm 100 400 ssu 25 microns 30 gpm 114 lpm 100 400 ssu When choosing hydraulic fluid the expected oil tem
4. STANLEY 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 maint
5. 24367 69473 69468 69469 2 SHOWN CAPSCREW CAPSCREW TENSIONER SPRING or TAIL GATE LATCH MAIN BODY MODEL STICKER LIFT POINT STICKER NO ITEM 2 SPEED LIGHT SWITCH PLUG EXHAUST CLAMP EXHAUST PIPE LIMIT ENGINE SPEED STICKER NUT VALVE TO DASH NOT SHOWN CAPSCREW o gt N gt 70151 N gt 2 O co DID 5 gt O O wlw o Q N o cO E E NIO O o O e STANLEY MHP3 DIESEL HOSE amp FITTINGS ILLUSTRATION SEE ITEM 13 ON MHP3 HOSE amp FITTINGS ILLUSTRATION B 25 SEE ITEM 5 ON MHP3 HOSE amp FITTINGS ILLUSTRATION B 15 ALSO SHOWN ON MHP3 HOSE amp FITTINGS ILLUSTRATION B STAN LEY MHP3 Diesel User Manual lt 25 MHP3 DIESEL HOSE amp FITTINGS PARTS LIST s ss s ss moseassemar s es 2 Hoseassemr some 15 69501 4 STRAIGHT THREAD ADAPTOR BSPP 37JIC 69502 2 STRAIGHT THREAD ADAPTOR BSPP 37JIC HOSE 1 2 5 5 IN LONG ame 1
6. item 54 major assy Use a socket and ratchet wrench to loosen the locknut on the re lief valve b Use an Allen wrench to adjust the relief valve Turn clockwise to raise the pressure and coun terclockwise to reduce the pressure Tighten the locknut and test for 2100 2200 51 148 155 bar as described above d Repeat the above test with the hoses and tester connected to the other circuit TESTING THE 10 GPM EHTMA TYPE D CIRCUIT The 10 gpm circuit is formed when the combiner knob is pulled out and both circuit control levers are set to the ON up position This allows the output of both pump sections to be combined at one set of fittings to provide 10 gpm 38 Ipm flow to a single tool To test the circuit proceed as follows 1 Perform Steps 1 through 5 under Testing The 5 gpm EHTMA Type C Circuits Make sure a tool and hoses ARE NOT CONNECTED to the other tool cir cuit 2 Pull the combiner knob OUT to combine the two cir cuits 3 Raise both control levers to the ON position With the engine at high speed the test flow gauge should read 9 10 gpm 34 38 lpm as the pressure gauge reaches 2100 2200 psi 148 155 bar 5 Perform Step 9 under Testing The 5 Type C Circuits ADJUSTING TRACK TENSION track tension is adjusted with the unit lifted off the ground Between the drive wheel and front idler wheel there are 3 smaller rollers Once the unit is lifted o
7. mermmewssr 26 MHP3 Diesel User Manual HOSE 1 2 25 5 IN LONG EMES or nom em steeve wor snowy STANLEY MHP3 DIESEL HOSE amp FITTINGS ILLUSTRATION 4 PARTS B PARTS SHOWN BELOW ARE ALSO SHOWN ON MHP3 HOSE amp FITTINGS ILLUSTRATION FOR CLARITY THIS FUEL HOSE IS FURNISHED WITH ENGINE ITEM DESCRIPTION 07821 90 ELBOW 07822 1 HOSE BARB 1 2 x 1 2 NPT 69740 HOSE 1 2 4 1 4 LONG 27767 ADJUSTABLE ELBOW 69738 HOSE ASSY 11179 HOSE CLAMP 07747 SLEEVE SUCTION TUBE SUCTION 56696 1 HOSE FUEL RETURN 2 11 2 HOSE CLAMP __ 13 HOSE ASSY gt STANLEY SEE ITEM 25 ON MHP3 HOSE amp FITTINGS ILLUSTRATION A 200 5 SEE ITEM 33 ON MHP3 HOSE 4 FITTINGS ILLUSTRATION A DESCRIPTION 16 69742 1 HOSE 1 2 10 5 IN LONG m wos Hose awe 122 arme 1 a z mostcuwm tur a mes 12 WPT MHP3 Diesel User Manual lt 27 MHP3 DIESEL POWER UNIT FRAME ILLUSTRATION 2970 DIT SEE MHP3 HY ULI 2 4 Va 3 HYDRAULIC RESERVOIR ILLUSTRATIO 28 gt MHP3 Diesel User Manual STAN LEY mw Em we n owscnew us 5 WASHER EN 20135 1 w
8. 58451 2 wire braid HYDRAULIC HOSE FOR 50 FEET STANLEY P N 31848 HYDRAULIC HOSE or STANLEY P N 58634 TWINNED HYDRAULIC HOSES or 58448 2 wire braid HYDRAULIC HOSE 1 2 INCH MALE PIPE HOSE END 1 2 INCH MALE QUICK DISCONNECT COUPLER BN _ STANLEY P N 03975 COUPLER NOSE or STANLEY P N A Xy 03974 COUPLER SET nose amp body Ra HTMA 1 2 INCH FEMALE QUICK DISCONNECT a COUPLER STANLEY P N 03976 COUPLER BODY or STANLEY P N 03974 COUPLER SET nose amp body Before disconnecting hydraulic tools ensure the tool circuit control levers are in the down position and the throttle is in the SLOW position STAN LEY MHP3 Diesel User Manual lt 11 HOSE amp FITTING CONNECTIONS FOR DUAL TOOL CIRCUIT 3 8 INCH MALE QUICK DISCONNECT COUPLER STANLEY P N 03973 COUPLER NOSE or STANLEY P N 03971 COUPLER SET nose amp body HTMA 3 8 INCH FEMALE QUICK DISCONNECT COUPLER STANLEY P N 03972 COUPLER BODY or STANLEY P N 03971 COUPLER SET nose amp body b 3 1 2 INCH 1 0 HOSE 25 FT TO 50 FT LONG a FOR 25 FEET STANLEY P N 31972 HYDRAULIC HOSE STANLEY P N 58633 TWINNED HYDRAULIC HOSES or 58451 2 wire braid HYDRAULIC HOSE M a lt 2 FOR 50 FEET STANLEY P N 31848 HYDRAULIC n LX HOSE or STANLEY P N 58634 TWINNED HYDRAULIC HOSES 58448 2 wire braid HYDRAULIC HOSE NG hr 1 2 INCH MALE PIPE HOSE END M SN gt 0
9. degree incline 27 percent 2 Ensure the wheels of the trailer and the tow vehicle have been chocked front and rear 3 Use the SLOW throttle setting when loading or unloading Always switch the two speed control to LOW speed operation when moving in reverse 18 MHP3 Diesel User Manual Loading and unloading of any type of machine is dangerous Never attempt to load or unload the machine without loading ramps or a loading dock Loading ramps must be strong enough have a low angle and correct height Load and unload the machine on a level surface Never attempt to load or unload the machine if the ramp incline exceeds 15 degrees Failure to follow these instructions may result in serious injury or death 4 Drive the machine onto the trailer backwards en gine first This will help prevent instability and keeps the operator up hill from the machine during load ing and unloading 5 After loading place chocks at the front and rear of the tracks LIFTING The unloaded TracHorse can be lifted using the single central lift point Some safety rules may require 3 point lifting Center lift point plus 2 points on forward side of rails If lifting with any items in the bed a 3 point lift is re quired A 3 point lifting sling is available refer to Acces Sories page TRANSPORTING 1 Read the instructions for loading and unloading in this section 2 Use chains and binders to secure the load to the trai
10. eunssaeJd oeq 6 1 0092 ujog e 08 92 001 95 85 91 9 ainssaid daay suon 9 1 0052 ujog OL 8 5 92 o dn 0 dn 85 91 9 95941 Jed sJey SYOLONGNOD T1VOIN123 T3 ISN LON OQ 10 preJg M aynuiw uo SSL 0922 OL 8 dn 01 04 dn ve SL 6 SSOY SNOMEA JO 2504 3exong 20 p pu uuuu0991 SMOUS 1 y yeu 941 uva ISd uinjoy sseid WIN HONI SYILIN 1333 eunssaJg episu sy45u97 esoH MO 0 1001 MHP3 Diesel User Manual 4 9 STANLEY 5 HYDRAULIC SYSTEM 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 fluid viscosity of at min operating temperature Temperature Sufficient heat rejection capacity to limit max fluid temperature to at max expected ambient temperature Min cooling capacity at a temperature difference of between ambient and fluid temps NOTE
11. follow this symbol to avoid possible injury or death This safety alert and signal word indicate an imminently hazardous situation A DANGER 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 avoid 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 gt MHP3 Diesel User Manual STAN LEY 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 maintena
12. lpm up to 2000 psi 140 bar Male Quick Disconnect Couplers Combiner Knob Hour Meter 7 Y REVERSE TRAVEL Control Lever shown in OFF position Female Quick Disconnect Couplers DO NOT attempt to travel in reverse with the throttle ADJUSTING THROTTLE FOR positioned above SLOW This may result in loss of control and result in injury or death to the operator Always position the throttle to a slow position for re verse travel to permit increased control and safety STAN LEY MHP3 Diesel User Manual lt 15 Always switch the two speed control to LOW speed operation when moving in reverse SLOPE OPERATION DO NOT operate the machine on slopes exceed ing 60 percent 30 in the travel direction or across slopes exceeding 45 percent 24 Depending on the load carried in the bed it may be preferable to back up steep slopes If traversing over large obstructions such as railroad rail or curbs travel at an angle 45 degrees to the obstruction In some cases it may be easier to back over them Avoid turning on slopes If you must turn turn slowly downhill if possible DO NOT operate the machine near drop offs ditch es or embankments The machine could suddenly turn over if a track goes over the edge or if an edge collapses DO NOT try to stabilize the machine if it is tipping over Let go of t
13. 046 DECAL CARBON MONOXIDE 28047 DECAL HOT PARTS 2 3 SPIROL PIN e 00016 O RING 1 8 10 aa 13 2 3 4 rm 1 1 1 04216 WASHER DECAL TO START EE NO ITEM DECAL CHECK HYDRAULICS 1 2 13 4 5 32 gt MHP3 Diesel User Manual STAN LEY STANLEY Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie Oregon 97267 5698 USA 503 659 5660 Fax 503 652 1780 www stanleyhydraulics com
14. 19 of each pump section is directed to the panel control valve assembly It is the position of the hydraulic circuit combiner knob on the panel control When first learning to operate the Track Horse valve assembly which keeps the output of each pump position the throttle to the SLOW position More section separated or combined experienced operators may use higher throttle settings When the hydraulic circuit combiner knob is pulled out the two circuits are combined into one 10 gpm 38 circuit One hydraulic tool may be connected to one ci FORWARD TRAVEL cuit The other circuit must not have a tool connected to it or have the hoses connected The circuit is activated by pushing both control levers up The throttle can be positioned anywhere between slow and fast for traveling forward depending on the weight of the load being carried Heavy loads will When the hydraulic circuit combiner knob is pushed in require higher throttle settings and low range in or the two circuits are not combined and each circuit pro der for the engine to provide enough power to move vides 5 gpm 19 Ipm One hydraulic tool may be connect the load ed to each circuit Each circuit is activated by pushing Ap Aswitch mounted on the control provides two speed the circuit lever up FAST amp SLOW operation Oil flow is regulated by pulling the throttle control to the full throttle position This setting will produce 10 gpm 38
15. EATH OR SERIOUS INJURY 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 ELECTRIC LINES HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING ABRASION CUTTING OR CONTACT WITH HIGH TEMPERATURE SURFACES DO NOT USE IF KINKED DO NOT BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE USE HOSE TO PULL OR LIFT TOOLS POWER UNITS ETC ON OR NEAR ELECTRIC LINES WIPE THE ENTIRE LENGTH OF THE HOSE AND FIT CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAM TING WITH A CLEAN DRY ABSORBENT CLOTH TO REMOVE DIRT AND MOISTURE AND TEST HOSE FOR MAXIMUM ALLOWABLE CURRENT LEAKAGE IN ACCORDANCE WITH AGE TO COUPLINGS IF ANY OF THESE CONDITIONS EXIST REPLACE THE HOSE SAFETY DEPARTMENT INSTRUCTIONS IMMEDIATELY NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROP ERLY TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND AFTER EACH USE STORE IN A CLEAN DRY AREA DO NOT REMOVE THIS TAG Ovl SIHL LON OG SEE OTHER SIDE SEE OTHER SIDE SIDE 1 SIDE 2 Shown smaller than actual size THE TAG SHOWN BELOW IS ATTACHED TO CONDUCTIVE HOSE DANGER DANGER DO NOT USE THIS HYDRAULIC HOSE ON OR NEAR ELECTRIC LINES THIS HOSE 15 CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DA
16. MAGE TO NOT LABELED OR CERTIFIED AS NON CONDUCTIVE USING THIS HOSE ON OR NEAR COUPLINGS IF ANY OF THESE CONDITIONS EXIST REPLACE THE HOSE IMMEDIATELY ELECTRICAL LINES MAY RESULT IN DEATH OR SERIOUS INJURY NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY AFTER EACH USE STORE IN A CLEAN DRY AREA TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND ELEC TRIC LINES 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 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 SIHL 3AON3U LON OG NEMO OTHER SIDE w OTHER SIDE Shown smaller than actual size 8 MHP3 Diesel User Manual STAN LEY suonoeuuo JESIdAL 4 lt lt lt NENNEN lt Tm
17. MD191 19 h p Fuel een 4 2 gal 16 Itr Fuel Type aars Diesel Pressure suge ee ermene sidan a bn cxi 2000 psi 140 bar Flow Range n 2 5 gpm 20 Ipm 10 gpm 38 Ipm Coupleis HTMA EHTMA Flush Face Type amp Female Gonneet Size and uuu u u Mee 8 SAE 1316 16 597 Kg Miren 1000 16 523 Kg Overall 2 5 rtp ee ee e ed ies 93 in 109 Overall Widih 2 2 ri Sasam ora oci Sean 2200 36 in 92 cm Overall Tie innere rca He 43 5 in 110 5 cm Hydraulic Oil Capacity der uu e ebenen 2 7 gpm 11 Itr ACCESSORIES DESCRIPTION PART NUMBER ode 40457 ele 40455 PUgdig kata 40456 Hydraulic OilFilter Element ree rere eks 40408 Hydrauli Oil Fur ASS uu uu nee ai 40080 Coupler Nose 3 8 Port 03972 Coupler 3 Port pa 03973 Coupler Set 3 8 Port Bruning includes nose 03971 Coupler Nose 1 2 Port Bruna aus umu erre
18. MHP3 DIESEL TRACHORSE USER MANUAL Safety Operation and Maintenance 2014 Stanley Black amp Decker Inc New Britain CT 06053 U S A 69887 10 2014 Ver 5 Lun um anu 4 SAFETY PREGCAUTIOINS 1 tert t tr a serbe t d EN Va de 5 TOOL STICKERS amp TAGS T 7 HOSE TYPES uuu E 8 HOSE RECOMMENDATIONS O 9 ATMA REQUIREMENT S hugse un ae ne a en 10 HOSE amp FITTING CONNECTIONS FOR SINGLE 11 HOSE amp FITTING CONNECTIONS FOR DUAL TOOL CIRCUIT 12 OPERATION vred 13 MAINTENANCE ana ea ea en 19 TESTING amp TROUBLESHOOTING tte ee ee ea 20 TROUBLESHOOTING ee a a added 21 SPECIFICATIONS c EU MUT 22 ACCESSORIES e 22 MHP3 DIESEL MAJOR ASSY PARTS 05 23 MHP3 DIESEL MAJOR ASSY PARTS ennt ent ta ne arr ar dan 24 MHP3 DIESEL HOSE amp FITTINGS ILLUSTRATION A 25 MHP3 DIESEL HOSE FITTINGS PARTS 26 MHP3 DIESEL HOSE amp FITTINGS ILLUSTRATION amp PARTS 27 MHP3 DIESEL POWER UNIT FRAME 28 MHP3 DIESEL POWER UNIT FRAME PARTS LIS T teta titt nn kenn 29 MHP3 DIESEL POWER UNIT ENGINE ILLUSTRATIO
19. N amp PARTS eter tees nennen rennen 30 MHP3 DIESEL POWER UNIT RESERVOIR ILLUSTRATION amp PARTS 31 MHP3 DIESEL POWER UNIT VALVE ILLUSTRATION 32 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 au thorized and certified dealer Please read the following 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 STAN LEY MHP3 Diesel User Manual 4 3 Safety symbols and signal words as shown below are used to emphasize all operator maintenance and repair 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
20. ance free NOTE Before starting the engine make sure the tool circuit switch is in the OFF position DUAL CIRCUIT OPERATION Facing the panel the male quick disconnect fittings are the PRESSURE FLUID OUT fitting The female quick disconnect fittings are the RETURN FLUID IN RE 2 Engine Fuel Level Check the fuel level If low fill with DF 1 or DF 2 diesel fuel A S T M D975 66T No 1 or no 2 dark Shut the engine off before attempting to add fuel to the fuel tank Do not remove the fuel cap while the engine is running Do not add fuel to the tank while the engine is hot Do not fill the fuel tank to a point of overflowing HYDRAULIC FLUID Check the sight gauge in the hydraulic fluid reservoir for the proper fluid level STANLEY TURN fitting The Dual Circuit control panel contains connections for two 5 GPM tool circuits In addition the two circuits may be combined into one 10 GPM tool circuit 1 If using one 5 GPM tool circuit select either circuit and connect the PRESSURE FLUID OUT hose to the male coupler and connect the RETURN FLUID IN RETURN to the female coupler near to it Con nect the other ends of the hoses to the tool If using both 5 GPM tool circuits connect PRES SURE FLUID OUT hoses to the male couplers and connect the RETURN FLUID IN RETURN hoses to the female couplers Connect the other ends of the hoses to the tools 2 Ensure the throttle control is depressed fully t
21. d in a straight line DO NOT attempt to travel in reverse with the throttle positioned above SLOW This may result in loss of TURNING FROM A STOP control and result in injury or death to the operator TO TURN LEFT FROM A STOP Moving the right track control forward and moving the left track con TO MOVE BACKWARDS IN A STRAIGHT LINE trol backward at the same time will increase the Move both the left and right track controls backward at the same time TO TURN LEFT WHILE MOVING BACKWARD Release the left track control while pulling backward on the right track control Resume pulling back ward on the left track control to move backward in a straight line TO TURN RIGHT WHILE MOVING BACKWARD Release right control while holding left control backward turning rate TO TRAVEL BACKWARD Move Both Controls Backward STAN LEY MHP3 Diesel User Manual lt 17 TURN LEFT FROM A STOP Move the right control forward and the left control backward TO TURN RIGHT FROM A STOP Moving the left track control forward and moving the right track control backward at the same time will increase the turning rate TO TURN RIGHT FROM A STOP Move the left control forward and the right control backward LOADING AND UNLOADING 1 Useloading ramps or a loading dock to load and un load the machine Ensure loading ramps are strong enough to support the load When using ramps do not exceed a 15
22. eds 140 F 60 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 STANLEY Refer to the parts illustrations for correct location of stickers TO START BOTH HYDRAULIC VALVES OFF TURN KEY TO START HOLD TO CRANK ENGINE RELEASE KEY TO RUN NOTE FOR COLD STARTS TURN KEY TO ON PRESS AND HOLD GLOW PLUG BUTTON FOR 10 15 SEC BEFORE CRANKING TO STOP BOTH HYDRAULIC VALVES OFF ENGINE THROTTLE TO SLOW TURN SWITCH KEY OFF TO OPERATE TOOLS CONNECT TOOL S TURN VALVE S ON N 35677 Start Sticker ON is _ CERTAIN PARTS OF THE POWER UNIT WILL BE HOT AVOID CONTACT WITH THOSE PARTS TO PREVENT INJURY FLUID LEVEL AND ADD FLUID WHEN ENGINE IS OFF OFF Hot Parts Sticker P N 28047 51297 Fluid Level Sticker LIMIT ENGINE SPEED DURING REVERSE TRAVEL DO NOT USE HIGH RANGE DURING REVERSE TRAVEL 68334 Limit Engine Speed Sticker HYDRAU LIC FLUID 35686 Hydraulic Fluid Sticker 47352 Lift Point Sticker STANLEY Use in well ventilated areas 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 resu
23. enance 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 MHP3 Diesel User Manual 4 5 Only use the TracHorse in well ventilated areas DO NOT operate in explosive atmospheres in closed environments or near flammable 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 flammable solvents around the engine DO NOT reverse tool rotation by changing fluid flow direction Always use hose and fittings rated for 2500 psi 172 bar with a 4 to 1 safety factor Be sure all hose con nections are tight 6 MHP3 Diesel User Manual Be sure all hoses are correct for current flow direc tion to and from the tool being used DO NOT inspect hoses and fittings for leaks by us ing bare hands Pin hole leaks can penetrate the skin DO NOT operate tools if oil temperature exce
24. ewmGSTOKER E mas i 2 E p sen 2 xo 16 SQ e e 7 _ 9 EMI 24 2 _ E STANLEY HP3 DIESEL POWER UNIT FRAME PARTS LIST m ___________ fs fon O O Es wes s emnene wwm Ls MHP3 Diesel User Manual 4 29 MHP3 DIESEL POWER UNIT ENGINE ILLUSTRATION 4 PARTS DESCRIPTION FILTER ASSY INCL W ITEM 19 CAPSCREW CAPSCREW INCL W ITEM 19 CAPSCREW LOCK WASHER COOLER MOUNT Em w I a 241 3031 FUEL FILTER BRACKET COOLER NO ITEM gt 1 COOLER MOUNT orem war e wase ES EE gt 30 gt MHP3 Diesel User Manual ENGINE RUGGERINI MD191 SPACER BLOWER WHEEL BLOWER HUB QD BUSHING CAPSCREW INCL W ITEM 26 COUPLING ASSY GASKET 90 ELBOW 1 2 HOSE 1 2 NPT STANLEY A N MHP3 DIESEL POWER UNIT RESERVOIR ILLUSTRATION 4 PARTS T ITEM QTY DESCRIPTION QTY DESCRIPTION DIPSTICK BOLT IPSTICK SERVICE KIT MHP3 Diesel User Manual lt 31 MHP3 DIESEL POWER UNIT VALVE ILLUSTRATION PARTS ITEM QTY 1 69595 DASH PANEL 20606 HOUR METER 28
25. ff the ground adjust the track tension to achieve 3 8 to 72 sag below the center small roller STANLEY If symptoms of poor performance develop the following chart can be used as a guide to correct problem When diagnosing faults in operation of the machine or tool always check that the hydraulic power source is supply ing the correct hydraulic flow and pressure 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 Gue Seo connections Fluid blowing out of fiui controls are pushed Incorrect hose connection to tool Make sure the tool hose circuit goes 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 together and check for free flow 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 Suction hose kinked Make sure suction hose from fluid reservoir to pump inlet has a smooth curve Tool is defective Refer to tool manual using hydraulic controls One or more defective hydraulic Have machine serviced component Hydraulic fluid level low Check for correct level Pump coupling defective STAN LEY MHP3 Diesel User Manual lt 21 Ruggerini
26. he fluid to sit long enough for the wa ter to settle to the bottom of the container Slowly pour the fluid back into the hydraulic tank avoiding the water at the bottom of the container Checking Suction Hose Make sure the suction hose from the hydraulic tank to the pump inlet is not kinked and is clamped se curely This reduces the risk of pump cavitation and sucking air into the system All pump fittings should be tight Checking Hydraulic Lines and Fittings Check for loose fittings leaks etc throughout the hydraulic circuit Check hydraulic lines and fittings for leaks kinks etc daily Do not use your hand to per form this check MHP3 Diesel User Manual lt 19 GENERAL Tests and adjustments should be performed periodically to ensure the TracHorse is operating at maximum ef ficiency Stanley Circuit Tester P N 04182 is recom mended This tester can be used to isolate problems in both the engine and hydraulic system prior to any Tra cHorse disassembly TESTING THE HYDRAULIC CIRCUIT The following tests can be performed to ensure that the hydraulic pump is supplying the correct flow and pres sure and that the system relief valve is operating prop erly During these tests make sure the engine is warm and operating smoothly If test results are not as specified refer to the troubleshooting table given in this section for possible causes TESTING THE 5 GPM EHTMA TYPE C CIRCUITS To test either of
27. he machine and get out of its way TRAVELING FORWARD OR REVERSE em 8 LIMIT ENGINE SPEED DURING REVERSE TRAVEL DO NOT USE HIGH RANGE DURING REVERSE TRAVEL Track Steering Controls To travel forward reverse turn left or turn right do the following FORWARD TRAVEL TO MOVE FORWARD INA STRAIGHT LINE Move both the left and right track controls forward at the same time TO TURN LEFT WHILE MOVING FORWARD Re lease the left track control while pushing forward on 16 MHP3 Diesel User Manual the right track control Resume pushing forward on the left track control to move forward in a straight line TO TURN RIGHT WHILE MOVING FORWARD Release the right track control while pushing for ward on the left track control Resume pushing for ward on the right track control to move forward in a straight line 4 TRAVEL FORWARD Move Both Controls Forward TO TURN LEFT WHILE MOVING FORWARD Release left control while holding right control forward STANLEY TURN LEFT WHILE MOVING BACKWARD Release left control while holding right control backward TO TURN RIGHT WHILE MOVING FORWARD Release right control while holding left control forward REVERSE TRAVEL TO TURN RIGHT WHILE MOVING BACKWARD Release the right track control while pulling back ward on the left track control Resume pulling back ward on the right track control to move backwar
28. ic 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 reinforce ment 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 in ner 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 DANGER DANGER 1 FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE IMPROPER USE WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRIC LINES MAY RESULT IN OR HANDLING OF HOSE COULD RESULT IN BURST OR OTHER HOSE FAILURE D
29. ler ROUTINE MAINTENANCE Good maintenance practices will keep the machine on the job and increase its service life A very important maintenance practice is to keep the hy draulic fluid clean at all times Contaminated hydraulic STANLEY fluid causes rapid wear and or failure of internal parts Follow the maintenance instructions contained in the en gine manual ENGINE MAINTENANCE Follow the maintenance schedule and general mainte nance instructions in the engine maintenance and op eration manual furnished with the unit Normal mainte nance includes Check the air filter daily Clean if necessary Replace dry air filter every 200 hours of operation Replace fuel filter every 100 hours of operation Change engine oil after first 50 hours of operation then after every 200 hours of operation Change more often if cold moist or dusty conditions exist Check oil level daily Change oil filter when engine oil is changed Remove dirt and debris from engine with a cloth or brush daily Do not use water spray HYDRAULIC SYSTEM MAINTENANCE Observe the following for maximum performance and service life from the hydraulic system Always keep hydraulic system and fluids clean Keep water out of fluid See 1 below Keep air out of hydraulic lines Hydraulic system overheating and foam at the hydraulic tank breather indicate air is present in the lines Keep all suction line fittings and clamps tight Hydraulic sy
30. lt gt X bn es Q e gt 5 gt SET 7 lt HTMA 1 2 INCH MALE QUICK DISCONNECT COU PLER STANLEY P N 03975 COUPLER NOSE gt STANLEY P N 03974 COUPLER SET 8 body HTMA 1 2 INCH FEMALE QUICK DISCONNECT COU PLER STANLEY P N 03976 COUPLER BODY or STANLEY P N 03974 COUPLER SET nose amp body Before disconnecting hydraulic tools ensure the tool circuit control levers are in the down position and the throttle is in the SLOW position 12 MHP3 Diesel User Manual STAN LEY RECOMMENDED HYDRAULIC OILS PREPARATION FOR USE ENGINE Below is a list of recommended oils by brand Biodegradable Description mo mme Exxon Mobi mo DTE 10 Excel chevron Rando HDZ 32 Do not operate the TracHorse until you have read the engine operating and maintenance instructions manual furnished in addition to this manual 1 Engine Crankcase Oil Level Conoco Phillips Unax AW WR 32 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 oil as specified in the engine operating and maintenance manual The engine oil sump must never be overfilled Overfilling can cause the engine to overheat and cause crankshaft seal damage Yes Clarion CITGO Exxon Mobil Recommended for extreme cold temperatures Yes Yes Yes Yes BATTERY The supplied battery is mainten
31. lting from improper handling operation or maintenance will cause oil injection to body Engine exhaust and other surfaces of tool may be hot Avoid accidental contact with hot surfaces Allow tool to cool before maintenance or storage All operators must read understand and follow ALL saftey precautions and operating instructions found in owners manual before operating tool 59126 Dash Decal CHECK HYDRAULIC OPERATE UNIT ONLY INA WELL VENTILATED AREA ENGINES PRODUCE CARBON MONOXIDE WHICH IS AN ODORLESS DEADLY POISON 28046 Carbon Monoxide Sticker CALIFORNIA PROPOSITION 65 WARNING ENGINE EXHAUST CONTAINS CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER BIRTH DEFECTS AND OTHER REPRODUCTIVE HARM 29133 California Proposition Sticker FOR ONE OR TWO 5 GPM TOOLS PUSH THE COMBINER KNOB IN FOR ONE 10 GPM TOOL PULL THE COMBINER KNOB OUT AND TURN BOTH TOOL VALVES ON 28045 Combiner Knob Sticker I LOW 68335 Throttle Sticker MHP3 Diesel User Manual lt 7 The rated working pressure of 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 Certified non conductive constructed of thermoplast
32. nce or routine ser vice Supervising personnel should develop additional pre cautions relating to the specific 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 NOT operate the machine in confined 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 flammable objects Allow the engine to cool before storing the machine in an enclosure
33. o the idle position MHP3 Diesel User Manual lt 13 3 Ensure tool circuit levers are in the OFF position If starting the engine in cold weather conditions turn the start switch until the battery charge light comes on Then press and hold the glow plug button for 10 15 seconds Release the glow plug button and turn the start switch to the third start position to crank the engine 5 Turn the start switch clockwise to begin cranking the engine Use short starting cycles 15 seconds per minute to prolong starter life Extended cranking can damage the starter motor 6 After the engine starts allow it to warm up NOTE Hydraulic fluids are thicker in cold weather It is rec ommended that the engine be operated at low idle long enough to allow the fluid temperature to warm to a minimum of 50 F 7 When the engine is warmed up the throttle may be advanced and the hydraulic tool circuits may be used INSTRUMENTS BATTERY CHARGE LIGHT A problem with the charging circuit exists if the battery charge light remains on after the engine has started OIL PRESSURE LIGHT A problem with the engine oil lubricating system exists if the oil pressure light remains on after the engine has started Shutdown the engine and then have the lubri cating system serviced by a qualified technician 14 MHP3 Diesel User Manual OIL PRESSURE CHARGE Dash Panel Warning Lights If the engine runs out of fuel or dies during operati
34. on or if the stop knob is pulled and the ignition switch is left in the ON position the battery may become discharged Make sure the start switch is returned to the OFF position COLD WEATHER STARTUP 1 Use the procedures described under Starting The Engine and then follow the procedures below 2 Hydraulic fluids are thicker in cold weather there fore 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 or until the top of the hydraulic filter feels warm 3 Ifthe tools and tool hoses are cold it is recommend ed to allow hydraulic fluid to circulate through the tool hoses until warm before using the tools ENGINE SHUTDOWN Place both control levers in the OFF position Push the throttle control completely in Allow the engine to idle for approximately one minute turn the switch to OFF and then pull the stop knob to shutdown the unit Make sure the start switch is in the off position HYDRAULIC TOOL CIRCUIT CONTROLS The MHP3 TracHorse provides two circuits each with an oil flow of 5 gpm 19 Ipm up to 2000 psi 140 bar Or the two circuits may be combined into one circuit provid STANLEY ing 10 gpm 38 Ipm up to 2000 psi 140 bar VARIOUS TYPES OF WORK MHP3 TracHorse contains a hydraulic pump with two sections Each pump section will provide 5 gpm 19 at the maximum governed engine throttle The out A WARNING put 5 gpm
35. perature 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 CLASSIFICATION AAA EHTMA HYDRAULIC SYSTEM REQUIREMENTS Flow Range 3 5 4 3 gpm 13 5 16 5 lpm Nominal Operating Pressure 1870 psi at the power supply outlet 129 bar System relief valve setting 2495 psi at the power supply outlet 172 bar 4 7 5 8 18 22 Ipm 1500 psi 103 bar 2000 psi 138 bar 7 1 8 7 gpm 27 33 Ipm 1500 psi 103 bar 2000 psi 138 bar 9 5 11 6 gom 36 44 Ipm 1500 psi 103 bar 2000 psi 138 bar 11 8 14 5 gpm 45 55 Ipm 1500 psi 103 bar 2000 psi 138 bar NOTE These are general hydraulic system requirements See tool specification page for tool specific requirements 10 gt MHP3 Diesel User Manual STANLEY HOSE amp FITTING CONNECTIONS FOR SINGLE TOOL CIRCUIT HTMA 3 8 INCH MALE QUICK DISCONNECT COUPLER STANLEY P N 03973 COUPLER NOSE or STANLEY P N 03971 COUPLER SET nose amp body HTMA 3 8 INCH FEMALE QUICK DISCONNECT COUPLER STANLEY P N 03972 COUPLER BODY or STANLEY P N 03971 COUPLER SET nose amp body 1 2 INCH 1 0 HOSE 25 FT TO 50 FT LONG FOR 25 FEET STANLEY P N 31972 HYDRAULIC HOSE or STANLEY P N 58633 TWINNED HYDRAULIC HOSES or
36. stem wear is noted by increased heat during tool operation reduced tool performance and eventual system breakdown Operate with the fluid temperature at 50 140 F 10 60 C for improved seal and hose life and maximum efficiency Filling The Reservoir Make sure the engine is stopped before opening the filler cap Add fluid as needed Fill slowly with the recommended fluid Stop filling when the sight gauge shows full Fluid STANLEY must be visible in the sight gauge at all times Secure the filler cap before restarting the engine Change the hydraulic filter element every 200 hours of operation Change more often if cold moist or dusty conditions exist Check oil cooler for debris Remove debris with air pressure Removing Condensed Moisture From Hydraulic Fluid Condensation is a frequent problem with cool mo bile hydraulic circuits This condition occurs in moist or cold climates When warm air in the hydraulic tank draws moisture from the cooler air outside wa ter accumulates in the tank Check hydraulic fluid level daily Add fluid per specifications in this manual Refer to Hydraulic Fluid in this section Remove condensed moisture from the hydrau lic fluid by pumping the hydraulic fluid into a 5 gal 20 container through the pressure hose Make sure the engine is at idle when performing this procedure When the hydraulic reservoir is empty turn the engine OFF immediately Allow t
37. the two circuits proceed as follows 1 Set both Circuit Control Levers to the OFF down position Push the Combiner Knob IN to separate the two circuits 2 Connect the Stanley Circuit Tester across two hose ends where the tool would normally be connected of one circuit 3 Fully open the tester restrictor valve counter clock wise Start the engine and allow it to run until warm Pull the engine throttle control completely OUT so that the engine is running at full RPM 6 Move the Circuit Control Lever for the circuit to be tested to the ON up position 7 With the engine at high speed the test flow gauge should read 4 5 gpm 15 19 lpm 8 Slowly turn the restrictor valve clockwise while watching the pressure gauge The flow rate should stay at 4 5 gpm 15 19 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 re lief valve just begins to open is commonly referred to as the cracking pressure At the cracking pres sure the flow rate should start to drop because the relief valve is allowing fluid to bypass to the hydrau lic reservoir The cracking pressure is preset at the factory and if it is not within the above range the relief valve must be reset as follows 20 MHP3 Diesel User Manual a Access to the relief valves can be gained through the front of the dash behind the two plugs
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