HYDRAULIC CHIPPING HAMMER
Contents
1. 2000 psi 140 bar for 8 gom model Couplers or hose blocked Remove restriction Fluid too hot Provide cooler to maintain proper above 140 F 60 C fluid temperature Incorrect tool bit Ensure tool bit meets specifica tions Tool operates slow Low oil flow from power unit Check power source for proper flow High backpressure Check hydraulic system for excessive backpressure and correct as required 12 SPECIFICATIONS Oil Flow Range CEA ennta 4 6 gpm 1 5 23 Ipm CH15121 8 gpm Model oroia aeai a i a 7 9 gpm 26 34 Ipm Pressure Rango usaras 1000 2000 psi 69 140 Bar Length ga a a A E E E E ante han 17 in 43 cm Wed cda A E A E TE a cee E 16 lb 7 25 kg Tool lluita 580 in Hex Shank or 680 in Round Shank PO odds 8 SAE O ring Couplers innn at ei een HTMA EHTMA Flush Face Type Male amp Female Connect Size and Type cecccececeeeeeeeeeecesaeeeeeeeeeseaaeeseaeeseeaaeeeceaeeeeenaeeeseaeeeeeneees 3 8 in Male Pipe Adapter ROSE WIPS iii Be je en ee ee ee Yes Maximum Back Pressure 250 psi 17 bar Maximum Fluid Temperature eeeeeennn err 140 F 60 C N ise Level Lane Lee 106 LWA Vibrati n Level aaa ee ee 5 8 m s Description Part No Bushing Tool Bit 580 Hex 404400snsanennnnnnnnnnannnnnnnnnnnnnnnnnnnnnnnnnannnnnnnnnnnnnnnnnnnnnnnnnnnn sans 02277 Flat Chisel Bit 1 in xT 8 1n 580 Hex ara EI 02278 Bull Point Bit 1 in x 18 in2. 580 Hex ueasseseseeneennunnnnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nennen ennnnnn 02279 G isel Bits 119 ins 580 Hex mn See A IR 03690 Chisel Bit 2 in x 5 in 580 HeX irna aerei T eea aa anaa ia na aeaa iaaa eea a anA ioar aieeaa 03963 Chisel Bit AS ROUNG a a anna nenn an E e ana a nad Rau 02339 Moil Point 1 8 1n 680 Round 2 2 2 EA a a 04401 Moil Point 14 in 680 Round ccccccnnnnneniconicononoononononononnnnnnnnnnnnnnnnnnnnnnnnnonnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnns 04901 Chisel Bit 3 in x 14 in 680 ROUNA minai aan a a a iaae a a ia 02330 Chisel Bit 3 in x 18 in 680 Round a e aea aa aar Aa aa a a er AE raeed diraka keiid odiana 04402 Bruning Flush Face Coupler Set 3 8 NPT 240422400444n0nnnnnnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennnnnnnnnnnnnnnn nen 03971 Bruning Flush Face Coupler Set 1 2 NPT 4002244004snnsnnnnnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennnnnnnnnnnnnnna nen 03974 Aeroquip Flush Face Coupler Set 3 8 NPT uuursuuussnseenssnnnnnnnnnnnnnnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnsnnnnnn ann 24069 Aeroquip Flush Face Coupler Set 1 2 NPT ociccinnnnccnncccnnnccccconrnnnnnnn coronan rca 24070 Hose 50 ft x 1 2 in ID wire braid dual with couplers 00 00 0000 31848 Hose 25 ft x 1 2 in ID wire braid dual with couplers 2240440000ssnnnnnnnnnnnnnnennnnnnenn nennen 31972 A O Sand nn 35979 13 SERVICE INSTRUCTIONS
3. 1 Apply grease and install a new cup seal 28 into the cylinder with the lips of the seal facing toward the handle end of the cylinder See figure 1 2 Apply grease and install a new scraper 27 into the cylinder with the lips of the seal facing toward the handle end of the cylinder See figure 1 CYLINDER CUP SEAL SCRAPER PISTON Figure 1 3 Apply grease and install a new o ring 30 onto the cylinder 4 Place the cylinder 29 into a vice with soft jaws Coat the cylinder bore and piston 31 with clean hydraulic fluid Insert the piston into the cylinder 5 Install the dowel pin 33 into the tube 32 See figure 2 DOWEL PIN LOCATION TUBE VIEWED FROM BOTTOM Figure 2 6 Install the tube with dowel pin installed onto the cylinder See figure 3 SERVICE INSTRUCTIONS Figure 3 7 Lubricate with clean hydraulic fluid and install the shuttle valve 34 into the tube 8 Install the body 9 over the tube and shuttle valve onto the cylinder Ensure the suttle valve and roll pin are correctly aligned with holes in the body See figure 4 Use a soft faced mallet to tap the body onto the cylinder BODY VIEWED FROM BOTTOM Figure 4 9 Install the 4 capscrews 16 and tighten to 25 ft Ibs 10 Apply grease and install a new o ring 15 onto the valve sleeve 14 11 Apply grease and install a new o ring 13 onto the valve spool 12 12 Lubricate t
4. Follow the procedures contained in the HYDRAULIC SYSTEM REQUIREMENTS section of this manual to ensure peak performance from the tool Never disas semble the tool unless proper troubleshooting proce dures have isolated the problem to an internal part Then only disassemble it to the extent necessary to replace the defective part KEEP CONTAMINANTS SUCH AS DIRT AND GRIT AWAY FROM INTERNAL PARTS AT ALL TIMES Always determine and correct the cause of the problem prior to reassembly Further wear and tool failure can result if the original cause is not corrected PRIOR TO DISASSEMBLY Clean the exterior of the tool e Obtain a seal kit to replace all seals exposed during disassembly Note the orientation of seals before removing them Install new seals in the same position as original seals DISASSEMBLY 1 Slide the outer chuck sleeve 43 toward the handle and remove the retaining ring 42 Slide off the outer chuck sleeve being careful to catch the 3 steel balls 37 Remove the spring 44 and retaining ring 46 2 Slide the chuck adjuster off of the shank 36 being careful to not let the hex blocks 38 and springs 35 fall out of the shank Slide the hex blocks and springs out of the shank 3 Slide the foam grip 39 off of the shank 4 Unscrew and remove the capscrews 45 5 Pull the shank away from the cylinder 29 A soft faced mallet may be required to assist in the shank removal by tapping on the sha
5. Supply hoses must have a minimum working pressure rating of 2500 psi 172 bar Do not exceed the rated flow see Specifications page 13 in the 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 Do not force a small breaker to do the job of a large breaker Keep tool bit sharp for maximum breaker performance Make sure that tool bits are not chipped or rounded on the striking end Never operate a breaker without a tool bit or without holding it against the work surface This puts excessive strain on the breaker foot 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 11 TROUBLESHOOTING Tool does not run Power unit not functioning Check power unit for proper flow and pressure 7 9gpm 26 34 lpm 2000 psi 140 bar for 8 gom model Couplers or hoses blocked Remove restriction Presssure and return line hoses reversed at ports Be sure hoses are connected to their proper ports Mechanical failure of piston or shuttle valve Have inspected and repaired by authorized dealer Tool does not hit effectively Power unit not functioning Check power unit for proper flow and pressure 7 9gpm 26 34 lpm
6. only be performed by authorized and properly trained personnel Do not exceed the rated limits of the tool or use the tool for applications beyond its design capacity Always keep critical tool markings such as lables and warning stickers legible Always replace parts with replacement parts recommended by Stanley Hydraulic Tools Check fastener tightness often and before each use daily TOOL STICKERS amp TAGS 107 58601 Sound Power Level Sticker Underwater Model Only 28323 CE Sticker Underwater Model Only Serial Number Stamping C 20Lpir at 13822 BHTMA CATEGORY 11206 Circuit 11207 Circuit C Sticker D Sticker 11206 CIRCUIT C STICKER 5gpm 11207 CIRCUIT D STICKER 8gpm 30Lpm at 138bar BHTMA CATEGORY O 28409 Composite Sticker Underwater Model Only Stanley Hydraulic Tools STANLEY 3810 SE Naef Rd Milwaukie Oregon 97267 U S A Model No 26 34 Ipm 7 9 gpm CH15 140 bar 2000 psi 33513 Name Tag Sticker CH15521 36112 Name Tag Sticker CH15121 amp CH1532101 D DO NOT LIFT OR CARRY TOOL BY THE HOSES DO NOT 1 FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED ABUSE HOSE DO NOT USE KINKED TORN OR DAMAGED AS NON CONDUCTIVE WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRICAL LINES MAY RESULT IN DEATH OR SERI OUS INJURY BEFORE USING HOSE LABELED AND CERTIFIED AS NON CON DUCTIVE ON OR NEAR ELECTRIC LINES BE S
7. ITEM NOITEM NOITEM NOITEM SPIROLPIN CESTICKER SOUND PWR LEVEL STICKER COMPOSITE STICKER BODY O RING 2 015 R16 INSERT VALVE SPOOL O RING 176x 040 5 193 VALVE SLEEVE O RING 2 016 R16 CAPSCREW 5 16 18UNC x 3 HANDLE TRIGGER ROD NOITEM TRIGGER DOWEL PIN 3 16 X 1 2 SS SPIROL PIN 5 32 x 1 2 CAPSCREW 5 16 18UNC x 1 TRIGGER PIN NAME TAG CH15521 MODEL NAME TAG CH15121 MODEL CIRCUIT C STICKER CH15521MODEL CIRCUIT D STICKER CH15121MODEL SCRAPER CUP SEAL CYLINDER CH15121 MODEL CYLINDER CH15521 MODEL O RING 2 135 R16 PISTON CH15121 MODEL PISTON CH15521 MODEL TUBE CH15121 MODEL TUBE CH15521 MODEL DOWEL PIN 5 32 X 1 500 SHUTTLE VALVE SPRING SHANK SHANK UNDERWATER MODEL ONLY STEEL BALL 3 8 DIA G HEX BLOCK FOAM GRIP CHUCK ADJUSTOR NOITEM RETAINING RING CHUCK OUTER SLEEVE SPRING CAPSCREW 1 4X1 500 RETAINING RING UW MODEL ONLY PIGTAIL HOSE ASSY 12 FLUSH FACE COUPLER SET 19 MODEL DESIGNATIONS CH15521 5 gpm Model CH15121 8 gpm Model SEAL KIT 35979 WARRANTY Stanley Hydraulic Tools hereinafter called Stanley subject to the exceptions contained below warrants new hydraulic tools for a period of one year from the date of sale to the first retail purchaser or for a period of 2 years from the shipping date from Stanley whichever period expires first to be free of defects in material and or workmanship at the time of delivery and will at its option rep
8. LON OG The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the shown smaller than actual size HOSE PRESSURE RATING hydraulic system HTMA REQUIREMENTS Tool Category Hyd raulic System HTA CATEGORY ETMA CATEGORY Requirements Type Type ll Type Ill 20Lpm at 138bar BHTMA CATEGORY Flow rate 4 6gpm 7 9gpm 10 5 11 69pm 11 13gpm Tool Operating Pressure 15 23 Ipm 26 34 Ipm 36 44 Ipm 42 49 Ipm at the power supply outlet 2000 psi 2000 psi 2000 psi 2000 psi 138 bar 138 bar 138 bar 138 bar System relief valve setting 2100 2250 psi 2100 2250 psi 2100 2250 psi 2100 2250 psi at the power supply outlet 145 155 bar 145 155 bar 145 155 bar 145 155 bar Maximum back pressure 200 psi 200 psi 200 psi 200 psi at tool end of the return hose 14 bar 14 bar 14 bar 14 bar Measured at a max fluid viscosity of 400 ssu at min operating temperature Temperature Sulfjeient Neal rejection capacity 140 F 60 C 140 F 60 C 140 F 60 C 140 F 60 C to limit max fluid temperature to at max expected ambient temperature Min cooling capacity 3 hp 2 24 kw 5 hp 3 73 kw 6 hp 4 47 kw 7 hp 5 22 kw ata temperature difference of 40 F 22 C 40 F 22 C 40 F 22 C 40 F 22 C between ambient and fluid temps NOTE Do not operate the tool at oil temperatures above 140 F 60 C Operation at higher temperatu
9. NT READ OPERATION MANUAL AND SAFETY INSTRUCTIONS FOR THIS TOOL BEFORE USING IT CHECK TOOL HOSE COUPLERS AND CONNECTORS DAILY FOR LEAKS DO NOT FEEL FOR LEAKS WITH YOUR HANDS CONTACT WITHALEAK MAY RESULT IN SEVERE PERSONAL INJURY IMPORTANT READ OPERATION MANUAL AND SAFETY INSTRUCTIONS FOR THIS TOOL BEFORE USING IT USE ONLY PARTS AND REPAIR USE ONLY PARTS AND REPAIR PROCEDURES APPROVED BY PROCEDURES APPROVED BY STANLEY AND DESCRIBED IN THE OPERATION STANLEY AND DESCRIBED IN THE OPERATION MANUAL MANUAL TAG TO BE REMOVED ONLY BY TOOL OPERATOR TAG TO BE REMOVED ONLY BY TOOL OPERATOR SEE OTHER SIDE SEE OTHER SIDE SAFETY TAG P N 15875 shown smaller then actual size 6 HYDRAULIC HOSE REQUIREMENTS HOSE TYPES Hydraulic hose types authorized for use with Stanley Hydraulic Tools are as follows Certified non conductive Wire braided conductive Fabric braided not certified or labeled non conductive Hose listed above is the only hose authorized for use near electrical conductors Hoses and 6 listed above are 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 Anew tag may be obtained from your Stanley Distribut
10. OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE 6 AFTER EACH USE STORE IN A CLEAN DRY AREA SEE OTHER SIDE SIDE 2 VIL SIHL 3AOWN34 LON OG shown smaller than actual size THE TAG SHOWN BELOW IS ATTACHED TO CONDUCTIVE HOSE DO NOT REMOVE THIS TAG 1 DONOT 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 FORPROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND ELECTRIC LINES 3 DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE IMPROPER USE OR HANDLING OF HOSE COULD RESULT IN BURST OR OTHER HOSE FAILURE KEEP HOSE AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT CONTACT DURING USE CONTACT AT THE BURST CAN CAUSE BODILY INJECTION AND SEVERE PERSONAL INJURY 4 HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING CUTTING OR CONTACT WITH HIGH TEMPERATURE SURFACES DO NOT USE IF KINKED DO NOT USE HOSE TO PULL OR LIFT TOOLS POWER UNITS ETC A SEEOTHERSIDE 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 SEE OTHER SIDE SIDE 2 Ovl SIHL JAOWSY
11. STANLEY CH15 SERIOUS INJURY OR DEATH COULD RESULT FROM IM PROPER REPAIR OR SERVICE OF THIS TOOL REPAIRS AND OR SERVICE TO THIS TOOL MUST ONLY BE DONE BY AN AUTHORIZED AND CERTIFIED DEALER To avoid serious injury or death Copyright 2003 The Stanley Works SVCE MAINT USA 35980 11 2003 Ver 1 HYDRAULIC CHIPPING HAMMER SAFETY OPERATION AND MAINTENANCE SERVICE MANUAL Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie OR 97267 5698 503 659 5660 FAX 503 652 1780 www stanley hydraulic tools com TABLE OF CONTENTS Safety Symbols and Precautions ceccececeeeseeeeeeeeeeeeeeeeeaeeeeeeeeeeseneeseaeeeeete 4 5 Tool Stickers and Tags ecccecceeeeeeeeeeeneeeeeeeeeeeeaeeeeeeeseeeeaeeeaeeseaeeseeeseaeesieeenaeeeaees 6 Hydraulic Hose Requirements 2uuurssasnennnennennnnen nennen nnnnnnnnnnnennnnnnnnnnnennennnr nen 7 HTMA Requirements aaa ii nennen andre 8 Operation een a BE aaa ner nad a 9 Equipment Protection and Care ooo ceceeeceseceeeeeeeeeeeneeeeeeeeeeseaeeseesseeeteeeeeeenaaes 11 Troubleshooting 4 u un arnim 0 nl a 12 SPECI CAL Si asnar aga Al did 13 ACCOSSOPIOS massinn ekra an AR E a a n 13 SIC ER I SR sae tate set gett io 14 Parts Illustration een ai ie 18 Parts Mistica ii 19 cc 20 SERVICING THE STANLEY CHIPPING HAMMER This manual contains safety operation service and routine maintenance instructions Stanley Hydraulic T
12. URE THE HOSE IS MAINTAINED AS NON CONDUCTIVE THE HOSE SHOULD BE REGULARLY TESTED FOR ELECTRIC CURRENT LEAKAGE IN ACCORDANCE WITH YOUR SAFETY DEPARTMENT INSTRUC TIONS 3 MAKE SURE HYDRAULIC HOSES ARE PROPERLY CONNECTED TO THE TOOL BEFORE PRESSURING SYSTEM SYSTEM PRES SURE HOSE MUST ALWAYS BE CONNECTED 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 DONOT CONNECT OPEN CENTER TOOLS TO CLOSED CENTER HYDRAULIC SYSTEMS THIS MAY RESULT INLOSS OF OTHER HYDRAULIC FUNCTIONS POWERED BY THE SAME SYSTEM AND OR SEVERE PERSONAL INJURY 2 AHYDRAULIC LEAK OR BURST MAY CAUSE OIL INJECTION INTO THE BODY OR CAUSE OTHER SEVERE PERSONAL INJURY A DONOTEXCEED SPECIFIED FLOW AND PRESSURE FOR THIS TOOL EXCESS FLOW OR PRESSURE MAY CAUSE A The safety tag p n 15875 EAKONBURST at right is attached to the en tool when shipped from the en factory Read and under stand the safety instruc tions listed on this tag before removal We suggest you retain this tag and attach it to the tool when not in use 5 BYSTANDERS MAY BE INJURED IN YOUR WORK AREA KEEP BY STANDERS CLEAR OF YOUR WORK AREA 6 WEAR HEARING EYE FOOT HAND AND HEAD PROTECTION 7 TOAVOID PERSONAL INJURY OR EQUIPMENT DAMAGE ALL TOOL REPAIR MAINTENANCE AND SERVICE MUST ONLY BE PER FORMED BY AUTHORIZED AND PROPERLY TRAINED PERSON IMPORTA
13. air or replace any tool or part of a tool or new part which is found upon examination by a Stanley authorized service outlet or by Stanley s factory in Milwaukie Oregon to be DEFECTIVE IN MATERIALAND OR WORKMANSHIP EXCEPTIONS FROM WARRANTY FREIGHT COSTS Freight costs to return parts to Stanley if requested by Stanley for the purpose of evaluating a warranty claim for warranty credit are covered under this policy if the claimed part or parts are approved for warranty credit Freight costs for any part or parts which are not approved for warranty credit will be the responsibility of the individual SEALS amp DIAPHRAGMS Seals and diaphragms installed in new tools are warranted to be free of defects in material and or workmanship for a period of 6 months after the date of first usage or for a period of 2 years from the shipping date from Stanley whichever period expires first CUTTING ACCESSORIES Cutting accessories such as breaker tool bits are warranted to be free of defects in material and or workman ship at the time of delivery only ITEMS PRODUCED BY OTHER MANUFACTURERS Components which are not manufactured by Stanley and are warranted by their respective manufacturers a Costs incurred to remove a Stanley manufactured component in order to service an item manufactured by other manufacturers ALTERATIONS amp MODIFICATIONS Alterations or modifications to any tool or part All obligations under this warranty shall be terminate
14. al 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 mainte nance personnel 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 To avoid serious injury or death 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 precau tions in the space provided on page 4 The CH15 Hydraulic Chipping Hammer 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 resul
15. 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 all tool accessories are correctly installed Failure to install tool accessories properly 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 Install Tool Bit The CH16 Chipping Hammer accepts standard 580 inch hex shank or 680 round shank tool bits TO INSTALL A HEX SHANK TOOL BIT 1 Slide the chuck outer sleeve toward the handle end of the tool and then insert the tool bit Release the chuck outer sleeve 2 Try turning the tool bit If the tool bit does not turn no further adjustment is necessary If the tool bit turns slide the chuck adjustor toward the tool bit end of the tool and then turn it clockwise to close the hex blocks against the tool bit shank When the chuck adjustor is properly set it should click into place and the tool bit should not turn Chuck Adjustor Chuck Outer Sleeve Installing The Tool Bit TO INSTALL A ROUND SHANK TOOL BIT 1 Slide the chuck outer sleeve toward the handle end of the tool and then insert the tool bit Re
16. d if the new tool or part is altered or modified in any way NORMAL WEAR any failure or performance deficiency attributable to normal wear and tear such as tool bushings retaining pins wear plates bumpers retaining rings and plugs rubber bushings recoil springs etc INCIDENTAL CONSEQUENTIAL DAMAGES To the fullest extent permitted by applicable law in no event will STANLEY be liable for any incidental consequential or special damages and or expenses FREIGHT DAMAGE Damage caused by improper storage or freight handling LOSS TIME Loss of operating time to the user while the tool s is out of service IMPROPER OPERATION Any failure or performance deficiency attributable to a failure to follow the guidelines and or procedures as outlined in the tool s operation and maintenance manual MAINTENANCE Any failure or performance deficiency attributable to not maintaining the tool s in good operating condition as outlined in the Operation and Maintenance Manual HYDRAULIC PRESSURE amp FLOW Any failure or performance deficiency attributable to excess hydraulic pressure excess hydraulic back pressure or excess hydraulic flow REPAIRS OR ALTERATIONS Any failure or performance deficiency attributable to repairs by anyone which in Stanley s sole judgement caused or contributed to the failure or deficiency MIS APPLICATION Any failure or performance deficiency attributable to mis application Mis application is defined as usage
17. he valve spool and valve sleeve with clean hydraulic fluid Insert the valve spool into the valve sleeve Install the insert 11 onto the valve sleeve Install anew o ring 10 around the outer diameter of the insert Insert this assembly into the body See figure 5 VALVE SLEEVE 14 O RING 10 NN SS HANDLE 17 O RING 15 O RING 13 VALVE SPOOL 12 Figure 5 13 Apply grease and install 4 o rings 15 into the grooves surrounding the capscrew 16 holes 1n the body 14 Apply a light coat of grease to the trigger pin 24 and install it into the handle Install the handle onto the body using 4 capscrews 23 Tighten to 25 ft lbs NOTE If the trigger was disassembled from the handle reinstall it before installing the handle to the body 15 Apply grease and install a new o ring 6 into the groove on the control shaft 16 Install the shank 36 to the cylinder Apply Loctite TM and install 4 capscrews 45 Tighten to 15 ft lb There is no special alignment of the shank to the cylinder Use the parts drawing as a guide for alignment 17 Install the foam grip 39 over the shank and cylinder 18 Apply Kopr Kote to the springs 35 and insert each of them into a hole in one of the hex block 38 halves Install the other hex block halve over the springs and then install
18. it easy to start the tool bit into the surface to be broken NOT FOR UNDERWATER USE COLD WEATHER OPERATION f the tool 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 STORAGE 1 Disconnect the tool from the hydraulic power source 2 Remove the tool bit and spray the chuck area with WD 40 inside and out 3 Wipe clean and store in a clean dry place 10 EQUIPMENT PROTECTION amp CARE NOTICE In addition to the Safety Precautions on page 4 8 5 ofthis 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
19. lease the chuck outer sleeve 2 If the tool bit can be inserted fully no other adjust ments are necessary If the tool bit cannot be inserted fully slide the chuck adjustor toward the tool bit end of the tool and then turn it counter clockwise to open the hex blocks and allow room for the tool bit shank When the chuck adjustor is properly set it should click into place and the tool bit should be fully inserted 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 tool It is a good practice to connect the return hose first and disconnect it last to minimize or avoid trapped pressure within the tool 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 OPERATION 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 tool bit firmly on the surface to be broken 4 Squeeze the trigger to start the chipping hammer Adequate down pressure is very important NOTE Partially depressing the trigger allows the tool to operate at a slow speed making
20. nk 6 Secure the tool in a bench vise with the IN and OUT ports up clamping on the cylinder Soft vise jaws are necessary 7 Remove the pigtail hose assemblies Note The tool is full of fluid and will drip from the ports when the hoses are removed 8 Unscrew and remove the 4 capscrews 23 and set the handle 17 aside being careful to prevent the trigger pin 24 valve sleeve 14 and valve spool 12 from falling out Remove these items from the handle or body 9 and set them aside 9 Unscrew and remove the 4 capscrews 16 Remove the body from the cylinder Tapping on the body with a soft faced mallet may be required to assist in the removal Be careful to prevent the tube 32 from falling out as it may stay in the body as the body is removed 10 Remove the tube and the shuttle valve 34 and set them aside 11 Slide the piston 31 out of the cylinder and set it aside 12 The trigger 20 may be removed from the handle by driving out the 2 spirol pins 22 13 Remove all seals and discard them INSPECTION OF PARTS Piston and Cylinder Inspect the surface of the bore of the cylinder and the surface of the piston for wear galling and cracks A light scuffing or burnishing of surfaces is normal Check especially for freedom of movement of the parts and that the piston does not stick or bind as it is moved in the cylinder Coat the parts with hydraulic oil for this test If small burrs a
21. of products for which they were not originally intended or usage of products in such a matter which exposes them to abuse or accident without first obtaining the written consent of Stanley WARRANTY REGISTRATION STANLEY ASSUMES NO LIABILITY FOR WARRANTY CLAIMS SUBMITTED FOR WHICH NO TOOL REGISTRA TION IS ON RECORD In the event a warranty claim is submitted and no tool registration is on record no warranty credit will be issued without first receiving documentation which proves the sale of the tool or the tools first date of usage The term DOCUMENTATION as used in this paragraph is defined as a bill of sale or letter of intent from the first retail customer AWARRANTY REGISTRATION FORM THAT IS NOT ALSO ON RECORD WITH STANLEY WILL NOT BE ACCEPTED AS DOCUMENTATION NO ADDITIONAL WARRANTIES OR REPRESENTATIONS This limited warranty and the obligation of Stanley thereunder is in lieu of all other warranties expressed or implied including merchantabil ity or fitness for a particular purpose except for that provided herein There is no other warranty This warranty gives the purchaser specific legal rights and other rights may be available which might vary depending upon applicable law 20 Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie OR 97267 5698 ST AN LEY 503 659 5660 FAX 503 652 1780 www stanley hydraulic tools com
22. ools recommends that servicing of hydraulic tools other than routine maintenance must be performed by an authorized and certified dealer Please read the following warning SERIOUS INJURY OR DEATH COULD RESULT FROM THE IM PROPER REPAIR OR SERVICE OF THIS TOOL REPAIRS AND OR SERVICE TO THIS TOOL MUST ONLY BE DONE BY AN AUTHORIZED AND CERTIFIED DEALER For the nearest authorized and certified dealer call Stanley Hydraulic Tools at one of the numbers listed on the back of this manual and ask for a Customer Service Representative 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 equip ment NOTICE IMPORTANT THIIG 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 situa tion 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 may result in minor or moderate injury This sign
23. or THE TAG SHOWN BELOW IS ATTACHED TO CERTIFIED NON CONDUCTIVE HOSE lt E 2 pal E w gt o w ec E o Zz o a 1 FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRIC LINES MAYRESULT IN DEATH OR SERIOUS INJURY FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY 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 FITTING WITH A CLEAN DRY ABSORBENT CLOTH TO REMOVE DIRT AND MOSISTURE AND TEST HOSE FOR MAXIMUM ALLOWABLE CURRENT LEAKAGE IN ACCORDANCE WITH SAFETY DEPARTMENT INSTRUCTIONS SEE OTHER SIDE SIDE 1 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 DAMAGE TO COUPLINGS IF ANY OF THESE CONDITIONS EXIST REPLACE THE HOSE IMMEDIATELY NEVER USE TAPE
24. re found remove them with 220 grit emery cloth If galling or cracks are present the part s must be replaced Valve Sleeve and Valve Spool 14 SERVICE INSTRUCTIONS Inspect the surface of the bore of the valve spool and valve sleeve for galling and cracks A light scuffing or burnishing of surfaces is normal Check espescially for freedom of movement of the valve spool in the valve sleeve If small burrs are found remove them with 220 grit emery cloth Do not break or buff the sharp edges of the valve sleeve or valve spool as this will cause the valve to malfunction If galling or cracks are present the part s must be replaced Hex Block and Chuck Parts Inspect the hex blocks and chuck parts for damage or excessive wear Replace any parts that are damaged or worn Fasteners Inspect all fasteners for wear and cracks When clean and coated with anti sieze the fasteners should thread into their related parts without any effort If some resistance is encountered check the threads for dirt particles or damage ASSEMBLY Prior to Assembly e Clean all parts with a degreasing solvent Ensure that all seals exposed during disassembly are replaced with new parts e Apply clean grease or o ring lubricant to all seals during assembly e Obtain a seal kit so that all seals exposed during disassembly can be replaced Note For orientation of parts identified in the following procedures see the parts illustration
25. res can cause operator discomfort at the tool Filter Min full flow filtration 25 microns 25 microns 25 microns 25 microns Sized for flow of at least For cold temp startup and max dirt holding 18 gpm 68lpm 30 gpm 114lpm 35 gpm 132 lpm 40 gpm 151 lpm capacit Hydraulic fluid Petroleum based premium grade anti wear non conductive Viscosity at min and max operating temps 100 400 ssu 100 400 ssu 100 400 ssu 100 400 ssu 20 82 centistokes 20 82 centistokes 20 82 centistokes 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 NOTE These are general hydraulic system requirements See tool Specification page for tool specific requirements OPERATION _PREOPERATION PROCEDURES _ Preparation For Initial Use The tool as shipped has no special unpacking or assembly requirements prior to usage Inspection to assure the tool 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 at 1500 2000 psi 105 140 bar for the CH15100 8 gpm model 2 Make
26. t in personal injury or equipment damage Operator must start in a work area without bystanders The operator must be familiar with all prohibited work areas such as excessive slopes and dangerous terrain conditions Establish a training program for all operators to ensure safe operation Do not operate the tool unless thoroughly trained or under the supervision of an instructor Always wear safety equipment such as goggles ear head protection and safety shoes at all times when operating the tool Do not inspect or clean the tool while the hydraulic power source is connected Accidental engagement of the tool can cause serious injury Supply hoses must have a minimum working pressure rating of 2500 psi 175 bar Be sure all hose connections are tight The hydraulic circuit control valve must be in the OFF position when coupling or uncoupling the tool 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 overheating of the hydraulic system Do not operate the tool at oil temperatures above 140 F 60 C Operation at higher oil temperatures can cause operator discomfort and may damage the tool Do not operate a damaged improperly adjusted or incompletely assembled tool Do not weld cut with an acetylene torch or hardface the tool bit To avoid personal injury or equipment damage all tool repair maintenance and service must
27. the assembly into the slot in the shank 16 SERVICE INSTRUCTIONS and hold it in place with one hand Obtain the chuck adjustor 40 and turn it so that the end containing 4 channels is facing toward the handle Slide the chuck adjustor onto the shank and over the slot containing the hex blocks and springs 19 Apply grease and install the 3 steel balls 37 Install the retaining ring 46 the spring 44 outer chuck 43 and retaining ring 42 20 Install the hose assemblies 47 making sure the female coupler is installed to the IN port and the male coupler is installed to the OUT port TESTING FOR OPERATION AND PERFORMANCE 1 Install a tool bit 2 Connect the tool to a hydraulic power source 3 Operate the tool with the bit pressed against a hard surface The tool should not stall 4 Turn the tool ON and OFF several times to ensure the valve is operating correctly 5 Test the speed control by moving the speed adjuster lever back and forth STORAGE 1 Disconnect the tool from the hydraulic power source 2 Remove the tool bit and spray the chuck area with WD 40 inside and out 3 Wipe clean and store in a clean dry place 17 CH15 PARTS ILLUSTRATION CH15121 8 GPM Model CH15521 5 GPM Model CH1532101 8 GPM Model 18 ANOaAKRWDND E ee ee a 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 3 2 4 4 CH15 PARTS LIST DESCRIPTION NO
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