Stanley Black & Decker DS06 User's Manual
Contents
1. nur TYPES OF CUTS etes COLD WEATHER OPERATION USING THEWAUEL WALKER IW zer ere certe eerie tee erre ree atienden E E EAEE A MAINTENANCE amp ADJUSTMENTS correntina reci ten A 14 GENERAL MAINTENANCE TIPS SAWIBAR Allin ia OI A AT aires ROTATING THE SAW BAR ae dios CHAIN TENSION ADJUSTMENT cc ei een nee A A DP 14 SERVICING TIE CHAINS cartas EE 15 MAINTENANCE S ADJUSTMENT Skitrein ae en een A End 15 MAINTENANCE S ADJUSTMEN TS st icri kst atri a ita Ia rper atten 16 REPLACING ua AA pce ente nitet 16 SPINNING RIVE TS EE 16 NOSE SPROCKET DISASSEMBLY AND ASSEMBL tiraa nn n i 17 MAINTENANCE S ADJUSTMENT See tror aa aa aa A a tes A A 17 TOOLEQUIRMENT CARE E 19 TROUBLESHOOTING ES 20 SPECIFICATIONS A EE 22 ACCESSORIES ini a TI 22 SERVICE a o 23 MOTOR INSPRECTON AND CUEANIN cen Dr 24 BAR CHAIN AND CHAIN GUARD ASSEMB int a iii 26 DS05PARTS ILLUSTRATION conca A A O DA IA 27 IDDS06 PARTS LIST anar AA A TE 28 DS06 PARTS ALLUSTRAMON o A AD 29 DS06 PARTS ST A 30 BIAMONDIGHIAINAPREICATIONS EP 31 WARRANTY een aeons 32 SERVICING THE STANLEY CONCRETE CHAINSAW This manual contains safety operation and2. 53 43690 1 Motor Shaft See Item 60 for Serial No Break 54 04044 2 Needle Roller 55 02688 1 HSHCS 5 16 18 UNC x 3 4 28 DS06 PARTS ILLUSTRATION For Serial Numbers 356 and Below o 2 gt S 2 2 Ce K SI Ar a CRO 2 4 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 2 1 1 3 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 0506 PARTS LIST HSHCS 10 24UNCx1 1 4 NAME TAG CIRCUIT D STICKER 8 gpm model CIRCUIT C STICKER 5 gpm model REAR GEAR HOUSING ASSY INCLD ITEM 5 8 6 8 gpm model only REAR GEAR HOUSING ASSY INCLD ITEM 5 amp 6 5 model only DOWEL PIN BUSHING O RING 5 329 R17 IDLER SHAFT IDLER GEAR 8 gpm model only IDLER GEAR 5 gpm model only PIVOT PIN ST ELBOW 1 8NPT WATER GAUGE DRIVE GEAR 8 gpm model only DRIVE GEAR 5 gpm model only ON OFF VALVE O RING 2 014 R18 SPRING WASHER SPRING RETAINING RING 1 2 EX PLUG BUTTON ROLL PIN ROLL PIN 3 16 X 1 VALVE HANDLE ASSY INCLD ITEMS 31 amp 66 O RING PIGTAIL HOSE ASSEMBLY MALE COUPLER FEMALE COUPLER WATER HOSE ASSY TRIGGER SPRING SAFETY CATCH STUD FLOW CONTROL VALVE 8 gpm model only FLOW CONTROL VALVE 5 gpm model only ROLL PIN O RING 2 016 R24 O RING 2 021 R16 SELF LOCKING RETAINING RING O RING 2 005 R16 WATER VALVE SLEEVE O RING 2 020 R16 PIN STEEL BALL 3 8 DIA
3. Diamond saws with a serial number of 357 and above no longer require a flow control The flow control 32 is factory preset and is not field ser viceable Use the following as guides to check for proper regulated flow For 5 model If the regulated flow is over 6 6 gpm or under 5 4 gpm at 8 gpm input the flow control valve should be replaced For 8 gpm model If the regulated flow is over 10 gpm or under 8 gpm at 12 gpm input the flow control valve should be replaced 23 SERVICE INSTRUCTIONS MOTOR SERVICING 1 Remove the 2 nuts 51 and then lift off the chain guard 50 2 Lift off the bar 61 and chain 73 If it is necessary to take tension off the bar and chain turn the screw 68 counter clockwise For Diamond Saws with Serial Number 357 and above follow the steps a thru c then proceed to Step 7 a Remove the e clip 60 and slide off items 48 49 and 58 b Remove the retaining ring 100 and then spacer 47 c Remove the retaining ring 98 and then items 93 thru 96 For Diamond Saws with Serial Number 356 and below follow the steps below 3 Slide the sprocket wrench 84 over the sprocket 48 While gripping the sprocket wrench and using an open end wrench turn the hex head on the Trantorque adapter cap 49 counter clockwise until the Trantorque adapter can be removed from the motor shaft 53 4 Remove the spacer 47 support washer 100 and o ring 97 5 Remove
4. 23 01605 O Ring Supplied with Item 24 78 33261 1 Fender Washer 24 01652 2 Pigtail Hose Assy 79 33258 1 Hand Guard 25 24059 1 Male Coupler 80 12412 1 Electrical Warning Decal 26 24058 1 Female Coupler 81 12175 2 Washer 27 33443 1 Water Hose Assy 82 33454 2 HHCS 5 16 18 x 5 8 Zinc 28 58879 1 Trigger 83 33263 1 Handle Grip 29 07602 1 Spring 84 No Item 30 34105 1 Safety Catch 85 17134 1 Nut 1 4 20 HHD LT SST 31 32197 1 Stud Supplied with Item 22 86 31614 1 Spirol Pin 32 No Item 87 30635 1 Spirol Pin 5 16 x 7 8 33 00072 1 Roll Pin 88 28409 1 Composite Decal CE 34 07627 1 O Ring 89 11212 1 Sound Power Level Decal 35 00074 1 O Ring 90 00173 1 Quad Ring 36 33488 1 Self Locking Retaining Ring 91 04856 1 Retaining Ring 37 05632 1 O Ring 92 35965 1 Bearing 38 58970 1 Water Valve Sleeve 93 00621 1 O Ring 39 01403 1 O Ring 94 38897 1 Seal Washer 40 33380 1 Pin 95 39070 1 V Ring 41 36259 1 Steel Ball 3 8 Dia 96 38700 1 Seal Ring 42 32188 1 Spring 97 No Item 43 04052 1 O Ring 98 07324 1 Retaining Ring 44 32189 1 Seal Cap 99 37793 1 Extension Spring Anchor 45 28323 1 CE Decal 100 41764 1 Retaining Ring 46 No Item 03786 1 GPM Decal 8 gpm Models Not Shown 47 38898 1 Seal Spacer 48 09098 1 Sprocket 49 41765 1 Washer 33360 1 SEAL KIT 50 32255 1 Chain Guard 51 32203 2 Nut 52 20721 1 Cord Stock 3 16 Dia
5. HOSE AFTER EACH USE STORE IN A CLEAN DRY AREA DO NOT REMOVE THIS TAG SIHL JAOWSY LON OG 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 IS NOT LABELED OR CERTIFIED AS NON CONDUCTIVE USING THIS HOSE ON OR NEAR 5 CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAMAGE TO ELECTRICAL LINES MAY RESULT IN DEATH OR SERIOUS INJURY COUPLINGS IF ANY OF THESE CONDITIONS EXIST REPLACE THE HOSE IMMEDIATELY NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY AE IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND 6 AFTER EACH USE STORE IN A CLEAN DRY AREA 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 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 o SEE OTHER SIDE KK SIDE 1 SIDE 2 shown smaller than actual size HOSE PRESSURE RATING SIHL JAOWSY LON OG 9 lt E 2 I E
6. Model 58 43689 1 Sprocket Adapter 11206 Circtuit Decal 5 Model 59 58969 1 Wiper Seal Rear Gear Housing Assy Incl Items 5 6 Ch 4 07652 1 8 gpm Model Only 60 41763 1 For bsosaooo s n 434 and below and for 07834 4 Rear Gear Housing Assy Incl Items 5 6 DS06200001 s n 110 and below 5 gpm Model Only Spiral Retainer Ring 5 00289 2 Dowel Pin 66299 1 For 05063000 s n 435 and above and for 6 04041 4 Bushing DS06200001 s n 111 and above 7 00020 1 O Ring 61 Saw Bar See Accessories 8 07612 1 Idler Shaft 62 9 m No ltem 63 32196 1 Mount 10 32190 1 Pivot Pin 33219 11 00961 1 Pipe Plug 65 32192 1 Chain Guide Plate 12 4 No ltem 66 32245 1 Stud Supplied with Item 22 18 04106 2 Drive Gear 8 Model Only 67 58968 2 bona 1 4 20 UNC x 5 8 07832 Drive Gear 5 gpm Model Only 68 02687 1 Machine Screw 14 32207 1 On Off Valve 69 32191 1 Stat O Seal 15 07626 1 O Ring 70 32198 1 Bar Adjustment Nut 16 07609 2 Spring Washer 71 33481 1 Wall Walker Clevis Pin 17 34119 1 Spring 72 Spring Incl with Item 74 18 04512 1 Retaining Ring 1 2 EX 73 Chain See Accessories 19 07625 1 Plug Button 74 32206 1 Wall Walker 20 03009 2 Roll Pin 75 02649 1 Handle Bar Retainer 21 07624 1 Roll Pin 3 16 x 1 76 33229 1 Handle Weldment 22 33267 1 Valve Handle Assy Incl Items 6 31 66 77 33260 1 BHCS 1 4 20 x 625 Zinc
7. and rivet spinner are securely mounted on flat clean work surfaces Check the mounting screws bolts often Check all chain breaker and rivet spinner components regularly for wear and general condition TOOL STICKERS 8 TAGS 30 LPM 138 BAR EHTMA CATEGORY 20 Ipm 138 bar EHTMA CATEGORY 11207 10948 11212 DANGER Fallure to use hydraulic hose labeled and certified as non conductive when using hydraulic tools on near electric Ines may result In death or serious injury For proper and safe operation read owners manual and mwke sure that you have been properly trained In correct procedures required for work or around electric Ines 12412 Stanley Hydraulic Tools 3810 SE Neef fioad Milwaukie OR 97062 Maciel Ds06 The safety tag p n 15875 at right is attached to the tool when shipped from the factory Read and understand the safety instructions listed on this tag before removal We suggest you retain this tag and attach it to the tool when not in use 12412 Warning Decal 11206 Circuit C Decal 11207 Circuit D Decal 28323 CE Decal 11212 Sound Level Decal FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRICAL LINES MAY RESULT IN DEATH OR SERIOUS INJURY BEFORE USING HOSE LABELE
8. direction The female coupler on the chain saw is the inlet pressure coupler NOTE If uncoupled hoses are left in the sun pressure in crease inside the hoses might make them difficult to connect Whenever possible connect the free ends of the hoses together CONNECTING TO A WATER SUPPLY 1 Using a standard garden hose connect the 0506 to a city or auxiliary water supply Make sure the flow is at least 4 gpm 15 at 50 psi 3 5 bar IMPORTANT Chain and bar damage will occur if the tool operates without the proper water supply and water pressure 11 2 Make sure the water is running before starting the tool 3 If a water pump is being used refer to the manufacturers instructions for use of the pump Make sure the pump pro duces a minimum watger flow of 4 gpm 15 Ipm at 50 psi 3 5 bar and the water pressure does not exceed 160 psi 11 bar CHECK CHAIN AND BAR ADJUSTMENT Note Check the chain tension often during operation expe cially during the first 1 2 hour when using a new chain Adjust the chain accordingly when it becomes loose Follow the procedures contained in the Mainenance and Adjustements section of this manual 1 Make sure the chain does not exceed a clearance of 5 16 in 8 mm from the bar see figure 2 Exceeding the maximum clearance increases the chance of the chain be ing dislodged from the bar groove OPERATION 2 Make sure the bar attaching nuts are fully tightened and the chain
9. routine maintenance instructions Servicing of hydraulic tools other than routine maintenance must be per formed 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 the number listed on the back of this manual and ask for a Customer Service Representative 3 CERTIFICATE OF CONFORMITY UBEREINSTIMMUNGS ZERTIFIKAT CERTIFICAT DE CONFORMITE CEE CERTIFICADO DE CONFORMIDAD CERTIFICATO DI CONFORMITA Hydraulic Tools 1 the undersigned Ich der Unterzeichnende Schultz Theodore J Je soussign El abajo firmante lo sottoscritto hereby certify that the construction plant or equipment specified hereunder best tige hiermit daf das im folgenden genannten Werk oder Ger t certifies par ceci que usine ou quipement de construction indiqu cidessous por el presente certifico que la fabrica o el equipo especificado a continuacion certifico che l impianto o l attrezzatura sotto specificata 1 Category Kategorie Cat gorie Categoria Categoria Concrete Cutting Chainsaw 2 Make Ausf hrung Marque Marca Marca Stanley 3 Type Typ Type Tipo Tipo DS06200001 DS06300001 4 Serial number of equipment Surnam
10. 0506 HYDRAULIC DIAMOND SAW SERIOUS INJURY OR DEATH COULD RESULT FROM IM PROPER REPAIR OR SERVICE OF THIS TOOL WoR ao 7005 REPAIRS AND OR SERVICE TO THIS TOOL MUST ONLY BE DONE BY AN AUTHORIZED AND CERTIFIED DEALER To avoid serious injury or death 777 SAFETY OPERATION AND MAINTENANCE SERVICE MANUAL Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie OR 97267 5698 Copyright 2005 The Stanley Works z E OPS MAINT USA E 503 us x 34567 8 2005 Ver 3 503 652 1780 www stanley hydraulic tools com TABLE OF CONTENTS CERTIFICATE QF CONFORMITY A A a a ds 4 SAFETY SYMBOLS m SAFETY PRECAUTIONS 2 6 TOOL STICKERS amp TAGS 8 HXDRAUEIGHHOSEIREQUIREMENTS isss ts rice li als E outers A A AS 9 REQUIREMENTS 10 OPERATION e 11 PREOPERTION PROCEDURES A O in 11 CHECK THEPOWER SOURCE cura ta AO a nae Aaa 11 EC 11 CONNECT HYDERAUEIG BIOSES cor o tert eerte ether E E 11 CONNECTING TO A WATER SUPPLY iom etes creen t errem aden ene ta Ee cec t ese pnt tn 11 CHECK CHAIN AND BARADJUSTMENT A Fen e es 11 CHECK CHAIN SEGMENT WEAR OPERANNG PROCEDURES
11. ATIONS 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 tool and hose To avoid serious injury or death These safety precautions are given for your safety Review them carefully before operating the tool and before performing general maintenance or repairs Supervising personnel should develop additional precautions relating to the specific work area and local safety regulations If so place the added precautions in the space provided on page 5 The 0506 Diamond Chain Saw will provide safe and dependable service if operated in accordance with the instructions given in this manual Read and understand this manual and any stickers and tags attached to the tool and hoses before operation Failure to do so could result in personal injury or equipment damage Establish a training program for all operators to ensure safe operation The operator must be familiar with all prohibited work areas such as excessive slopes and dangerous terrain condi tions Do not operate the chain saw unless thoroughly trained or under the supervision of an instructor Always wear safety equipment such as goggles ear head protection leg protection gloves snug fi
12. D AND CERTIFIED AS NON CONDUCTIVE ON OR NEAR ELECTRIC LINES BE SURE THE HOSE IS MAINTAINED AS NON CONDUCTIVE THE HOSE SHOULD BE REGULARLY TESTED FOR ELECTRIC CURRENT LEAKAGE IN ACCORDANCE WITH YOUR SAFETY DEPART MENT INSTRUCTIONS A HYDRAULIC LEAK OR BURST MAY CAUSE OIL INJECTION INTO THE BODY OR CAUSE OTHER SEVERE PERSONAL INJURY A DO NOT EXCEED SPECIFIED FLOW AND PRESSURE FOR THIS TOOL EXCESS FLOW OR PRESSURE MAY CAUSE A LEAK OR BURST B DO NOT EXCEED RATED WORKING PRESSURE OF HY DRAU LIC HOSE USED WITH THIS TOOL EXCESS PRESSURE MAY CAUSE ALEAK OR BURST C CHECK TOOL HOSE COUPLERS AND CONNECTORS DAILY FOR LEAKS DO NOT FEEL FOR LEAKS WITH YOUR 33445 Name Tag Decal 28409 Composite Decal MAKE SURE HYDRAULIC HOSES ARE PROPERLY CONNECTED DO NOT CONNECT OPEN CENTER TOOLS TO CLOSED CEN BYSTANDERS MAY BE INJURED IN YOUR WORK AREA KEEP WEAR HEARING EYE FOOT HAND AND HEAD PROTEC TO AVOID PERSONAL INJURY OR EQUIPMENT DAMAGE ALL IMPORTANT READ OPERATION MANUAL AND SAFETY INSTRUCTIONS FOR THIS TOOL BEFORE USING IT USE ONLY PARTS AND REPAIR PROCEDURES APPROVED BY STANLEY AND DESCRIBED IN THE OPERA TION MANUAL TAG TO BE REMOVED ONLY BY TOOL OPERATOR SEE OTHER SIDE D DO NOT LIFT OR CARRY TOOL BY THE HOSES DO NOT ABUSE HOSE DO NOT USE KINKED TORN OR DAMAGED HOSE TO THE TOOL BEFORE PRESSURING SYSTEM SYSTEM PRESSURE HOSE MUST ALWAYS BE CONNECTED TO TOOL IN
13. Nose Sprocket Rivets 2 Insert a straight blade screw driver to spread the bar nose rails just enough to remove the old nose sprocket Use a rag or paper towel to clean the nose sprocket area See Figure 25 MAINTENANCE 8 ADJUSTMENTS Figure 25 Removing Old Nose Sprocket 3 Remove the new nose sprocket package s clips and fold back the top portion of the insertion card being careful not to remove or disturb the components See Figure 26 Figure 26 Preparing New Nose Sprocket 4 With a flat blade screw driver in the bar nose rails slide the nose sprocket assembly into position aligning the 6 holes in the bar nose with the 6 holes in the nose sprocket assembly without removing the components from the card See Figure 27 Figure 27 Installing a New Nose Sprocket 5 Insert 6 nose rivets into the holes and then hold them with your thumb Remove the screwdriver and slide out the insertion card Note On used bars the nose rails might tend to spread apart Use a small clamp if necessary to hold the rails together 6 With the bar and rivets solidly supported on a strong flat steel surface carefully peen the rivet heads down with the flat end of a hammer Be careful to only hit the rivet head Do nat hit the bar body this will pinch the nose sprocket Rivet heads must completely fill the countersinks in the bar body and be snug and secure while still allowing the sprocket to freely turn See Figure 28 Figure 28 R
14. PORT SYSTEM RETURN HOSE MUST ALWAYS CONNECTED TO TOOL OUT PORT REVERSING CONNEC TIONS MAY CAUSE REVERSE TOOL OPERATION WHICH CAN RESULT IN SEVERE PERSONAL INJURY TER HYDRAULIC SYSTEMS THIS MAY RESULT IN LOSS OF OTHER HYDRAULIC FUNCTIONS POWERED BY THE SAME SYSTEM AND OR SEVERE PERSONAL INJURY BYSTANDERS CLEAR OF YOUR WORK AREA TION TOOL REPAIR MAINTENANCE AND SERVICE MUST ONLY BE PERFORMED BY AUTHORIZED AND PROPERLY TRAINED PERSONNEL IMPORTANT READ OPERATION MANUAL AND SAFETY INSTRUCTIONS FOR THIS TOOL BEFORE USING IT USE ONLY PARTS AND REPAIR PROCEDURES APPROVED BY STANLEY AND DESCRIBED IN THE OPERA TION MANUAL TAG TO BE REMOVED ONLY BY TOOL OPERATOR SEE OTHER SIDE SAFETY TAG P N 15875 shown smaller then actual size 8 HYDRAULIC HOSE REQUIREMENTS HOSE TYPES Hydraulic hose types authorized for use with Stanley Hydraulic Tools are as follows O Certified non conductive Wire braided conductive O Fabric braided not certified or labeled non conductive Hose O listed above is the only hose authorized for use near electrical conductors Hoses and 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 Hydrau lic Tools DO NOT REMOVE THESE TAGS If the information on a tag is illegible because of wear or damage replace the tag imme
15. SPRING O RING 3 914 R17 SEAL CAP CE STICKER RET RING 1 3 8 INT SEAL SPACER SPROCKET TRANTORQUE ADAPTOR CHAIN GUARD NUT CORD STOCK 3 16DIA R1 MOTOR SHAFT NEEDLE ROLLER HSHCS 5 16 18UNCx3 4 For Serial Numbers 356 and Below RD ER cs 1 1 1 1 1 1 1 2 2 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 O RING SEAL LINER NO ITEM NO ITEM NO ITEM SAW BAR SEE ACCESSORIES NO ITEM FLAP MOUNT SPACER CHAIN GUIDE PLATE STUD HSHCS 1 4 20UNCx5 8 MACHINE SCREW STAT O SEAL BAR ADJUSTMENT NUT WALLWALKER CLEVIS PIN SPRING INCLD WITH ITEM 74 CHAIN SEE ACCESSORIES WALL WALKER HANDLE BAR RETAINER HANDLE WELDMENT BHCS 1 4 20x 625 ZINC FENDER WASHER HAND GUARD WARNING STICKER ELECT WASHER HHCS 5 16 18x5 8 ZINC HANDLE GRIP SPROCKET WRENCH NUT 1 4 20 HHD LT SST SPIROL PIN SPIROL PIN 5 16 x 7 8 COMPOSITE STICKER CE SOUND POWER LEVEL STICKER CE QUAD RING RETAINING RING BEARING O RING SEAL WASHER V RING SEAL RING O RING RETAINING RING NO ITEM SUPPORT WASHER SEAL KIT Denotes Part in Seal Kit 30 DIAMOND CHAIN APPLICATIONS Model Bar Length Correct Applications Pinnacle 13 inch Very hard aggregate concretes flint chert granite etc Heavy steel Pinnacle reinforcing 5 8 inch 16 mm diameter and larger Medium hard aggre gate concretes granite quartz river rock etc Moderate steel rein forcing wi
16. anning Cuts 3 Outline the concrete area with a permanent marker for a visual guide 4 Know what kind of material and how much reinforcing you are going to cut The following are general cutting procedures and techniques Differences in the terrain and the type of material being cut will make this information more or less valid for particular areas For advice on specific cutting problems or techniques consult your local Stanley Representative He she can often provide information that will make your work safter and more productive OPERATION TYPES OF CUTS The DS06 can be operated using the types of cuts shown in Figure 5 When making cuts 29230 en so nora Gey 2 0 ex 6 c Den PLUNGE CUT Figure 5 Types of Cuts chain guard removed for clarity 1 Do not use a cutting force in excess of 45 Ibs 20 kg Excessive force causes the chain to slow down or stall and causes premature wear of the saw bar and chain 2 Always maintain a high chain speed High chain speeds produce the best results 3 Always check that plenty of water is being expelled from the bar and chain When the tool is running water is directed to the interior of the bar and then out of several holes located along the top and bottom channels on the bar If these holes become plugged cutting debris will not be adequately washed away and will result in premature wear of the bar and chain 3 Avoid aggressive heavy plunge force
17. balls do not rattle then they are probably plugged with contaminants and the gear housing will require replacement SHAFTS The shaft diameter at the bearing and seal locations must be smooth Grooves roughness or a reduced diameter indicate fluid contamination or damaged bushings Grit particles may have been imbedded in the bushings grind ing into the hardened shaft If abnormal shaft wear as above occurs more than normal polishing replace both the shaft and associated bushings Also check the hydraulic system for excess contamination in the fluid and for filter condition Operating conditions may require changing from a 25 micron filter to an over sized 10 micron filter MOTOR REASSEMBLY Refer to the illustration below for correct placement of parts 1 If the bushings 6 were removed from the valve handle 22 and the gear housing 4 install new bushings using a p n 11918 bearing pusher NOTE The bushing split line must face the center of the gear housing Serial Number 356 and Below Serial Number 357 and Above qe 53 8 90 57 4 91 5 gt 92 lt 98 47 A a Ss 4 gt 100 25 EN 48 RN a N 58 TEL 9 49 60 7 96 95 94 93 56 2 Grease and carefully install a new quad ring 90 into the seal liner 57 Grease and install a new o ring 56 onto the seal liner Install the seal liner into the valve handle assy 22 Replace the retaining ring 91 3 To replace the beari
18. diately A new tag may be obtained from your Stanley Distributor THE TAG SHOWN BELOW IS ATTACHED TO CERTIFIED NON CONDUCTIVE HOSE DANGER DANGER FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE 3 DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE IMPROPER USE OR WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRIC LINES MAYRESULT IN DEATH HANDLING OF HOSE COULD RESULT IN BURST OR OTHER HOSE FAILURE KEEP OR SERIOUS INJURY HOSE AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT CONTACT FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY DURING USE CONTACT AT THE BURST CAN CAUSE BODILY INJECTION AND SEVERE TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND PERSONAL INJURY ELECTRIC LINES HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING ABRASION CUTTING OR CONTACT WITH HIGH TEMPERATURE SURFACES DO NOT USE IF KINKED DO NOT USE BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE ON HOSE TO PULL OR LIFT TOOLS POWER UNITS ETC OR NEAR ELECTRIC LINES WIPE THE ENTIRE LENGTH OF THE HOSE AND FITTING WITHA CLEAN DRY ABSORBENT CLOTH TO REMOVE DIRT AND MOSISTURE AND TEST CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAMAGE TO HOSE FOR MAXIMUM ALLOWABLE CURRENT LEAKAGE IN ACCORDANCE WITH SAFETY COUPLINGS IF ANY OF THESE CONDITIONS EXIST REPLACE THE HOSE IMMEDIATELY DEPARTMENT INSTRUCTIONS NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE
19. e and First names Familiennname und Vornamen Nom et pr nom Nombre y apellido Cognome e nome Seriennummer des Ger ts Num ro de s rie de l quipement All Numero de serie del equipo Matricola dell attrezzatura 5 Year of manufacture Baujahr ann e de fabrication A o de fabricacion Anno di fabbricazione Has been manufactured in conformity with EEC Type examination as shown Wurde hergestellt in bereinstimmung mit EEC Typ Pr fung nach Est fabriqu conform ment au x type s examin s comme indiqu dans le tableau ci apres Ha sido fabricado de acuerdo con tipo examen EEC como dice E stata costruita in conformit con le norme CEE come illustrato 1998 Examen CEE de type Directive No Date Approved body Date of expiry Richtlinie Nr Datum Pr fung durch Ablaufdatum Directives particuli res Num ro Date Organisme agr Date d expiration Directriz No Fecha Aprobado Fecha de caducidad Direttiva n Data Collaudato Data di scadenza Machinery Directive 98 37 EC 1998 Self NA 89 392 CEE Self NA EN 292 1991 Self NA ISO 8662 1 1988 Self NA ISO 3744 1994 Self NA ISO 10726 1992 Self NA 6 Special Provisions None Spezielle Bestimmungen Dispositions particuli res Provisiones especiales Disposizioni speciali Done at Ort Fait a Dado en Fatto a Stanley Hydraulic Tools Milwaukie Oregon USA Date Datum le Fecha Data 3 98 Signature Unterschrift Signature Firma Fi
20. e 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 merchantability 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 32 Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie OR 97267 5698 503 659 5660 FAX 503 652 1780 www stanley hydraulic tools com
21. e rivet head you want removed directly under the chainbreaker punch and then pull the handle down far enough to remove the rivet Figure 14 Do not use exces sive force Figure 11 Chain Breaker Mounting Note The Stanley chain breaker is only designed to remove rivet heads from the connecting links not from a chain segment The rivet heads shown in the shaded areas of Figure 12 are the only ones that can be removed 99505 Figure 14 Removing a Rivet Figure 12 Removable Rivet Heads 2 Place the chain the portion that you want broken into the slot of the anvil pushing it forward until the bottom con necting link is flush with the far side of the slot Figure 13 15 MAINTENANCE amp ADJUSTMENTS REPLACING THE CHAIN BREAKER PUNCH If the chain breaker punch part number 22801 becomes worn or damaged use the following prcedures for replace ment 1 Remove the punch by loosening the set screw Figure 15 Figure 17 Rivet Spinner Mounting 2 Lay the chain across the plastic chain supports and then rotate the supports so the rivet head is centered between the take up handle pocket and the spinner anvil Figure 18 Figure 15 Removing the Punch 2 Insert a new punch into the holder and push it up until it is fully seated Figure 16 Secure the punch to the chain breaker holder by fully tightening the set screw Figure 18 Positioning the Chain 3 Turn the take up
22. e water supply is on Press trigger to see if water exits near bar adjustment nut area a small port If no water exits have unit serviced 21 SPECIFICATIONS Cutting DG Pts EET 13 inches 33 cm Lengths 13 33 Chain DPE EET 3 8 inch pitch with 21 diamond segments Maximum Back Pressute 2 2 2 rn tdm ib teta tbe het e ra aaan 250 psi 17 bar Input Flow Range BO MOJE 4 6 15 23 Ipm 9 gpm model t E RIDERS a A 7 9 gpm 26 34 lpm T 2000 psi 140 bar Weight Withiout Dar ciet nieto ct A des iba 14 lbs 6 kg Length withOUtbar an FA pdf 14 3 inches 36 WI 9 inches 23 Lubrication CoO Internal Water Channels in Bar Poesia A 8 SAE O Ring CAN CMA EHTMA HTMA Flush Face Hose Yes Chain Speed PIM MONO EE 4600 fpm 23 4 m s s 5000 fpm 25 4 m s SOUND POWER AND VIBRATION DECLARATION Measured A weighted sound power level Lwa ref 1pW in decibels 106 2 dBA Uncertainty Kwa in decibels 3dBA Measur
23. ed A weighted sound pressure level Lpa ref 20 uPa at operator s position in decibels 98 2 dBA Uncertainty Kpa in decibels 3dBA Values determined according to noise test code given in ISO 15744 using the basic standard 1503744 NOTE The sum of a measured noise emision value and its associated uncertainty represents an upper boundry of the range of values which is likely to occur in measurements Declared vibration emission value in accordance with EN 12096 Measured vibration emmission value a 6 0 m sec Uncertainty K 2 0 m sec Values determined according to ISO 8662 1 ISO 5349 1 2 ACCESSORIES Chain Repair Spinner a AAA Ai 20857 Diamond Chain Repaint Breaker Nn Ai 20858 Diamond Chain Service Kit urn es ii sub p n 20857 or 20858 Diamond Chain Butterfly Repat ga na 20859 Water Pump Kit 115 230 Volt 60 errang a ERKRRXRS NER AR NR De a ran AR KG Sa 26020 Water Pump Kit 220 380 440 Volt 150 Hz ee a A auda 26237 HP1 Power Unit Water Pump NS a ba ARI ade 29361 13 inch Bar Sprocket NOSE na kein 35037 Ultra 25 Diamond Chain for 13 inch Bar 0 00 000001 sane nsn aen 56799 Pinnacle 25 Diamond Chain for T3 ineh Bar u a ana a aa a aaa nal 56800 Water Pump Attachment f
24. ed relief valves are installed in the pressure side of the system Do not use the tool for applications for which it was not intended 19 TROUBLESHOOTING If symptoms of poor performance develop the following correct hydraulic flow and pressure to the tool as listed chart can be used as a guide to correct the problem in the table Use a flowmeter known to be accurate Check the flow with the hydraulic oil temperature at least When diagnosing faults in operation of the tool always 80 F 27 C check that the hydraulic power source is supplying the SYMPTOM CAUSE REMEDY Tool does not run Hydraulic power source not function Check power source for proper flow ing correctly and pressure 7 9 gpm26 34 Ipm at 2000 psi 140 bar Coupler or hoses blocked Remove obstruction Mechanical failure Have tool serviced by authorized dealer Tool runs backwards Pressure and return lines incorrectly Correct hose connections Motor shaft connected rotates counterclockwise as viewed from the end of the motor shaft Diamond saw cuts slow Insufficient fluid flow or too high back Check hydraulic supply If hydraulic pressure or relief valve set too low supply is correct have unit serviced by authorized dealer Back pressure too high Should not exceed 250 psi 17 bar at 9 gpm 34 lpm measured at the end of the tools operating hoses Loss of diamond segment side clear Replace chain ance Chain segment dulled because of con Red
25. eplacing Rivets 7 Using a flat file shave the rivet heads to a uniform height that is as close to the bar body as possible See Figure 29 18 Figure 29 Filing Rivets TOOL EQUIPMENT 8 CARE In addition to the Safety Precautions in this manual observe the following for equipment protection and care Make sure all couplers are wiped clean before connection The hydraulic circuit control valve must be in the OFF position when coupling or uncoupling hydraulic tools Failure to do so may result in damage to the quick couplers and cause overheating of the hydraulic system Always store the tool in a clean dry space safe from damage or pilferage Make sure the circuit PRESSURE hose with male quick disconnect is connected to the IN port The circuit RETURN hose with female quick disconnect is connected to the opposite port Do not reverse circuit flow This can cause damage to internal seals Always replace hoses couplings and other parts with replacement parts recommended by Stanley Hydraulic Tools Supply hoses must have a minimum working pressure rating of 2500 psi 172 bar Do not exceed the rated flow see Specifications page in this manual for correct flow rate and model number Rapid failure of the internal seals may result Always keep critical tool markings such as warning stickers and tags legible Tool repair should be performed by experienced personnel only Make certain that the recommend
26. gned for open center operation only 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 4 Observe the arrow on the couplers to ensure that the hydraulic oil flow is in the proper direction The female cou pler is the inlet pressure coupler 5 Check that the trigger operates smoothly and is free to travel between the ON and OFF positions 6 Check that the chain is properly installed The chain is designed to only operate in one direction Make sure the chain is installed so the bumper guard precedes each dia mond segment See figure 1 _ Segment iD Bumper CORRECT ole Guard gt INCORRECT ole Je A Figure 1 Chain Direction CONNECT HYDRAULIC HOSES 1 Wipe all hose couplers with a clean lint free cloth before making connections If necessary use a light weight pen etrating oil in a spray can to clean the hose couplers before each connection 2 Connect the hoses from the hydraulic power source to the chain saw fittings or quick disconnects It is a good practice to connect return hose first and disconnect them last to minimize or avoid trapped pressure within the chain saw 3 Observe the arrow on the couplers to ensure that the flow is in the proper
27. gt x z a The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the hydraulic system HTMA REQUIREMENTS TOOL CATEGORY ff 20Lpm at 1 MA CATEGO REQUIREMENTS TYPE 1 TYPEII TYPEIII TYPE RR FLOW RATE 4 6 gpm 11 13 gpm 9 10 5 gpm 15 23 Ipm 26 34 42 49 Ipm 34 40 TOOL OPERATING PRESSURE 2000 psi 2000 psi 2000 psi 2000 psi at the power supply outlet 138 bar 138 bar 138 bar 138 bar SYSTEM RELIEF VALVE SETTING 2100 2250 psi 2100 2250 psi 2100 2250 psi 2200 2300 psi at the power supply outlet 145 155 bar 145 155 bar 145 155 bar 152 159 bar MAXIMUM BACK PRESSURE 250 psi 250 psi 250 psi 250 psi at tool end of the return hose 17 bar 17 bar 17 bar 17 bar Measured at a max fluid viscosity of 400 ssu 400 ssu 400 ssu 400 ssu at min operating temperature 82 centistokes 82 centistokes 82 centistokes 82 centistokes TEMPERATURE 140 Sufficient heat rejection capacity 60 C to limit max fluid temperature to at max expected ambient temperature Min cooling capacity 3 hp 5 hp 7 hp 6 hp at a temperature difference of 2 24 kW 3 73 kW 4 47 kW 5 22 kW between ambient and fluid temps 40 40 40 F 40 F 22 C 22 C 22 C 22 C NOTE Do not operate the tool at oil temperatures above 140 F 60 C Operation at higher
28. guard is in place Bottom of Bar A As AR f H 5 16 Figure 2 Maximum Chain Clearance CHECK CHAIN SEGMENT WEAR 1 Using adjustable calipers measure several chain seg ments as illustrated in Figure 3 Bottom of Bar Figure 3 Chain Segment Wear 2 If the average measurement is less than 1 16 inch 1 6 mm then the chain must be replaced Refer to your Service Manual for chain replacement procedures OPERATING PROCEDURES 1 Observe all safety precautions 2 Turn on the water supply Water at the tool will be di rected to the bar and chain when the trigger on the tool is squeezed ON 3 Operate the tool for two minutes away from the intended cut and then check the chain tension New chain will nor mallhy stretch during its first usage It is very important to keep the chain tension adjusted so that it does not exceed 5 16 in 8 mm clearance from the bottom of the bar See Check Chain amp Bar Adjustment in this manual 4 If the chain requires adjustment see Maintenance amp Adjustments in this manual PLAN THE CUT 1 Plan your cuts to prevent injury to yourself and to keep from pinching the saw bar and chain as a result of falling pieces of concrete brick etc 12 2 Make your cuts in the order shown in Figure 4 starting with cut 1 base horizontal cut and proceeding with the remaining three cuts Figure 4 Pl
29. handle until the chain is tight against the spinner anvil Figure 19 Figure 16 Replacing the Punch SPINNING RIVETS Figure 19 Securing the Chain The following procedures explain how to spin rivets using Stanley s bench mounted rivet spinner part number 20857 to assembly the chain 1 Mount the rivet spinner flush with the side or front of a flat clean work surface Figure 17 16 MAINTENANCE amp ADJUSTMENTS 4 turn the rivet spinner crank a few times to center the rivet hub in the spinner anvil Figure 20 Take up Rivet Spinner _ fh Handle Figure 20 Centering the Rivet Hub 5 Apply a few drops of oil to the rivet hub Figure 21 Figure 21 Applying the Oil 6 Turn the spinner crank while slowly running the take up handle inward approximately one full revolution until the rivet head is formed Figure 22 Note The take up handle provides pressure while the spin ner anvil forms the rivet head Figure 22 Forming a Rivet Head Figure 23 Spinner Oiling Chambers NOTE the rivet spinner is equipped with oiling chambers and should be maintained periodically with a light weight oil Figure 23 NOSE SPROCKET DISASSEMBLY AND ASSEMBLY 1 Using the bench mounted chain breaker see acces sories line up the 1 4 inch hole in the side of the chain breaker anvil with the chain breaker punch Punch out the six nose sprocket rivets See Figure 24 17 Figure 24 Punching Out
30. ing puller kit MOTOR INSPECTION AND CLEANING Inspect and clean all parts as follows CLEANING Clean all parts with a degreasing solvent Blow dry with compressed air and wipe clean Use only lint free cloths GEAR HOUSING The chamber bores and bottoms around the shaft bushings should be polished and not rough or grooved If the bush ing bores are yellow bronze replace them and investigate the cause of wear The flat surfaces around the chamber and bolt holes should be flat and free of nicks or burrs that could cause misalign ment or leaks BUSHINGS The inside of the bushings should be gray with some bronze showing through If significant yellow bronze shows replace the bushings Inspect motor shaft for cor responding wear and replace as required GEARS The drive and idler gears should have straight tips without nicks square tooth ends and a smooth even polish on the teeth and end faces Check for cracks between the drive gear keyway and gear tooth root Replace the gear if cracks are present VALVE HANDLE MOTOR SURFACE The surface near the gears should show two interconnect ing polished circles without a step The bottom of the o ring 24 SERVICE INSTRUCTIONS groove should be smooth as should the rest of the flat surface The bore for the shaft seal should be smooth or oil leakage may occur GEAR HOUSING Shake the gear housing and the two seal check balls not shown should rattle If the seal
31. ng 92 onto the motor shaft 53 support the bearing inner race and press the motor shaft through the bearing inner race 4 Place the valve handle assy on a smooth clean arbor press surface protected from damage with the large bear ing bore facing up Position the valve handle so a clearance hole exists for the insertion of the motor shaft 5 Apply grease to the motor shaft keyway and bush ing and then insert the motor shaft through the shaft seal Using a socket with a diameter equal to the bearing O D press the bearing and motor shaft into place Press only on the outer race 6 Install the needle roller 54 in the keyway of the motor shaft Use grease to keep the needle roller in place Slide the drive gear 13 over the needle roller and shaft Install the idler shaft 8 and gear 9 7 Apply grease to the face seal o ring groove then install the o ring 7 8 Note the screw hole pattern on the rear gear housing and the valve handle They will only assemble one way With all parts aligned carefully slide the gear housing as sembly over the gears until it contacts the valve handle Do not force parts together 9 Turn the motor shaft manually to check for free rotation Install the eight capscrews 1 and then recheck rotation 25 SERVICE INSTRUCTIONS For Diamond Saws with Serial Number 357 and above follow steps a thru e For Diamond Saws with Serial Number 356 and below follow steps 10 thru 13 a I
32. nstall the o ring 43 Push in until it contacts the bearing face b Install seal washer 94 and the retainer ring 98 c Install v ring 95 onto seal ring 96 then with both in hand apply a small amount of 242 Loctite to the bore of the seal ring 96 Make sure it is applied around the entire bore of the seal ring then slide both parts onto the motor shaft d Install the seal spacer 47 and then the retainer ring 100 e Install items 58 48 49 and e clip 60 10 Apply grease and install a new v ring seal 95 into the seal washer 94 Apply grease and install a new o ring onto the seal keeper Insert the seal ring 96 into the seal washer and then install the seal spacer and seal keeper onto the motor shaft as an assembly Press the assembly against the bearing and then install the retaining ring 98 11 Apply grease and install a new o ring 97 onto the motor shaft Slide the o ring against the seal spacer Install the spacer 47 and support washer 100 12 Install the sprocket 48 over the Trantorque adapter cap 49 and then install this assembly onto the motor shaft While gripping the sprocket hand tighten the hex head of the Trantorque adapter cap by turning it clockwise 13 Slide the sprocket wrench 84 over the sprocket 48 While gripping the sprocket wrench and using an open end wrench tighten the hex head on the Trantorque adapter 49 clockwise to 17 Ib ft 23 Nm BAR am
33. or GT18 amp HP1 with HWP10 WatenFlow Meter 74 AAA 60859 22 SERVICE INSTRUCTIONS PRIOR TO DISASSEMBLY Clean exterior of the tool Obtain a seal kit so that all seals exposed during disas sembly can be replaced ON OFF VALVE SERVICING TRIGGER 28 AND SAFETY CATCH 30 REMOVAL amp INSTALLATION 1 Drive the roll pins 20 out of the handle assembly using a 3 16 in 4 mm diameter punch Press the safety latch and remove the trigger 28 NOTE The safety catch can be removed at this time by driving out the 3 16 inch roll pin 21 but this is not neces sary for servicing the on off valve 2 To install the trigger and safety catch reverse the above procedures VALVE SPOOL 14 REMOVAL 8 INSTALLATION 1 Remove the plug button 19 from the top of the handle by prying under the edge and then pulling it from the handle 2 Drive the roll pins 20 out of the handle assembly using a 3 16 in 4 mm diameter punch Press the safety latch and remove the trigger 28 3 Drive the roll pin 20 holding the valve spool 14 in place out of the handle using a 3 16 in 4 mm diameter punch 4 Unscrew the seal cap 44 and remove it the spring 42 and the steel ball 41 5 Lift out the valve spool assy 14 thru 18 6 Using a 1 2 in 12 7 mm diameter wood dowel place the dowel into the valve spool bore from the plug b
34. p CHAIN AND CHAIN GUARD ASSEMBLY 1 Back the bar adjustment nut 70 off by turning the ad justment screw 68 counter clockwise 2 Install the chain 73 onto the bar 61 Make sure the chain is installed so that the bumper guards precede the segments See the section titled OPERATION 3 Install the chain guide plate 65 over the stud 66 as shown in the parts illustration 4 Place the bar with chain over the studs making sure the chain is looped around the sprocket and the bar adjust ment nut is seated in the hole on the bar While holding the bar and chain in place turn the adjustment screw 68 clockwise to take the slack out of the chain Install the chain guard 50 and the 2 nuts 51 Hand tighten the 2 nuts and then back them off 1 4 turn 5 Adjust the chain tension by turning the adjustment screw 68 in accordance with the instructions contained in the section titled MAINTENANCE amp ADJUSTMENTS 6 When adjustments are completed be sure to tighten the nuts 51 26 DS06 PARTS ILLUSTRATION For Serial Numbers 357 and Above ES LO O o JAS 0 2 1 NEN DS06 PARTS LIST For Serial Numbers 357 and Above Part Qty Description a Part No Qty Description 1 00753 8 HSHCS 10 24 UNC x 1 1 4 56 60804 1 O Ring 2 33445 1 Name Tag 57 19215 1 Seal Back Up Washer 3 11207 4 Circuit D Decal 8
35. placement bars and chains specified by Stanley or the equivalent Make sure the chain guard is in place before operating the chain saw SAFETY PRECAUTIONS Remove or control the water slurry to prevent yourself or others from slipping while cutting Provide adequate ventilation in closed areas when operating a gas or diesel hydraulic power source Always be well rested and mentally alert before operating the chain saw Do not allow bystanders near the chain saw when starting or cutting Do not start cutting until you have a clear work area and secure footing Keep all parts of the body away from the chain saw during operation Carry the chain saw with the tool deenergized and the bar and chain to the rear of your body Do not operate a chain saw that is damaged improperly adjusted or not completely and securely assembled Make sure the chain stops moving when the control trigger is released Keep the handle dry clean and free of hydraulic fluid Do not use the chain saw near energized transmission lines Turn off the power source or move the hydraulic control valve to neutral before setting the chain saw down Use a guide bar scabbard when transporting the chain saw Know the location of buried or covered electrical services before starting work To avoid personal injury or equipment damage all chain saw repair maintenance and service must only be performed by authorized and properly trained personnel Make sure the chain breaker
36. r 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 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 obtain ing the written consent of Stanley WARRANTY REGISTRATION STANLEY ASSUMES NO LIABILITY FOR WARRANTY CLAIMS SUBMITTED FOR WHICH NO TOOL REG ISTRATION 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 th
37. ragms 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 workmanship 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 terminated 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 o
38. re mesh 3 8 1 2 inch 10 12 mm diameter Soft aggregate concrete concrete block masonry green concrete highly abrasive Ultra 13 inch Medium hard aggregate concretes granite quartz river rock etc Ultra Moderate steel reinforcing wire mesh 3 8 1 2 inch 10 12 mm di ameter Soft aggregate concrete concrete block masonry green concrete highly abrasive conditions 31 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 repair 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 MATERIAL AND 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 8 DIAPHRAGMS Seals and diaph
39. ress segmented by cutting in tinuous use in hard material or rebar abrasive material i e concrete build ing block etc Note This indicates that the wrong chain is being used Wrong chain for application Scale down to a lower numbered chain Wired edged bar rails Hydraulic fluid mixed in water supply Have tool serviced Excessive vibration and cuts rough Segment s broken or missing Repair broken segment or replace chain Chain installed backwards Correct chain direction Retension the chain Excessive feed force Reduce feed force Wil not cut straight Accumulated saw bar wear and un Turn the saw bar over and dress rails even chain segment profile wear square Replace the saw bar and chain Loss of power Drive sprocket slipping on Tran Adjust and tighten Trantorque torque adapter adapter to 17 ft lb 23 Nm Trigger hard to press Pressure amp return hose reversed Connect for proper flow direction Mo tor shaft must rotate clockwise Back pressure too high Should not exceed 250 psi 17 bar 9gpm 34 lpm measured at the end of the tool s operating hoses 20 TROUBLESHOOTING SYMPTOM CAUSE REMEDY Leakage around drive sprocket Motor shaft seal failure No water discharge at bar Blocked port s in bar Blocked inlet or outlet Turn off hydraulic supply Remove bar and chain and clean bar thoroughly Blow ports with compressed air Turn off hydraulic supply Remove bar and chain Make sur
40. rma 2 N y DINA Position Position Fonction Puesto Posizione Engineering Manager P N 62310 rev 03 3 05 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 signal word indicates a potentially hazardous situation which if not avoided may result in property damage This signal word indicates a situation which if not avoided will result in damage to the equipment This signal word indicates a situation which if not avoided may result in damage to the equipment Always observe safety symbols They are included for your safety and for the protection of the tool LOCAL SAFETY REGUL
41. s Aggressive plunge force creates fragmenting of the concrete when the saw bar and chain exits and causes premature bar and chain wear COLD WEATHER OPERATION If the saw is to be used during cold weather preheat the hydraulic fluid at low power source speed When using the normally recommended fluids fluid should be at or above 50 F 10 C 400 ssu 82 centistokes before use Damage to the hydraulic system or chain saw can result from use with fluid that is too viscous or thick USING THE WALL WALKER The Wall Walker lessens operator fatigue and effort dur ing cutting by automatic insertion of the wedge into the cut thus allowing the operator to apply leverage to the saw 1 Position the Wall Walker in the autofeed position by pinning the lever arm at the lowest hole as shown in the illustration Start cutting with the 0506 until the cut is large enough to allow the tip of the wedge to insert into the cut With the tip of the wedge in the cut the operator can easily apply lever age to the saw which will aid the cutting process and lessen operator fatigue and effort After the saw cuts approximately 1 to 2 5 in 25 to 65 mm withdraw the saw only enough to allow the lever arm and wedge to reposition After repositioning continue cutting 2 The Wall Walker can be positioned to the parked position by pinning the lever arm at the upper most hole In this position the Wall Walker is used as a bucking clea
42. t Wall Walker Lever Arm shown in autofeed position Figure 6 Wall Walker MAINTENANCE amp ADJUSTMENTS GENERAL MAINTENANCE TIPS Several simple maintenance tasks which if performed can keep a chain saw operating at a high level of efficiency Routine maintenance also keeps replacement costs down on the parts of the chain saw which occasionally wear out If any chain saw disassembly is required refer to the Ser vice Manual SAW BAR RAIL A quick check can be made to determine if saw bar rail or chain segment wear exists Figure 7 shows a worn saw bar rail REMOVE WIRE EDGE WITH FLAT FILE Figure 7 Rail Wear If the saw bar rails are worn use a flat file and dress each one until it is flat and square with the side of the saw bar Figure 7 Also make sure the saw bar is perfectly straight If bows or bends are present in the saw bar it must be replaced before dressing any rail ROTATING THE SAW BAR Maximum saw bar life can be achieved by occasionally turning the bar over so the top and bottom bar surfaces wear evenly Refer to the saw bar disassembly procedures in the Service Manual for further details CHAIN TENSION ADJUSTMENT Correct chain tension is very important throughout the life of the chain Check the chain tension often during use when the chain saw is stopped and the saw bar and chain have cooled off The chain should move easily around the saw bar when p
43. temperatures can cause operator discomfort at the tool FILTER 25 microns 25 microns 25 microns 25 microns Min full flow filtration 30 gpm 30 gpm 30 gpm 30 gpm Sized for flow of at least 114 lpm 114 lpm 114 Ipm 114 Ipm For cold temp startup and max dirt holding capacity HYDRAULIC FLUID 100 400 ssu 100 400 ssu 100 400 ssu 100 400 ssu Petroleum based 20 82 centistokes premium grade anti wear non conductive VISCOSITY at min and max operating temps NOTE When choosing hydraulic fluid the expected oil temperature extremes that will be experienced in service determine the most suitable temperature viscosity characteristics Hydraulic fluids with a viscosity index over 140 will meet the require ments over a wide range of operating temperatures SSU Saybolt Seconds Universal NOTE These are general hydraulic system requirements See tool Specification page for tool specific requirements 10 OPERATION PREOPERTION PROCEDURES CHECK THE POWER SOURCE 1 Using a calibrated flow meter and pressure gauge make sure the hydraulic power source develops a flow of 7 9 gpm 26 34 Ipm for the 8 model and 4 6 15 23 lpm for the 5 model at 2000 psi 140 bar 2 Make certain that the power source is equipped with a relief valve set to open at 2100 2250 psi 145 155 bar 3 Check that the hydraulic circuit matches the tool for open center OC or closed center CC operation The DS06 is desi
44. the retaining ring 98 6 Remove the capscrews 1 7 Using a flat blade screwdriver or similar tool gently pry the gear housing 4 away from the valve handle 22 Lift the gear housing straight up Do Not tilt the housing or pry on the flat surface inside of the surrounding groove For prying only use the groove provided at the split between the parts to prevent scratches on the inner mating surfaces 8 Remove the two gears 9 amp 13 needle roller 54 and the idler shaft 8 9 Remove the large face seal o ring 7 while being care ful not to damage the o ring groove or surrounding surface 10 While protecting the motor surface of the valve handle from damage tap lightly on the small diameter end gear side of the motor shaft to remove it and the seal washer 94 seal ring 96 v ring seal 95 o ring 93 and bear ing 92 from the front of the valve handle Remove the seal keeper seal spacer seal and o ring from the motor shaft 11 To remove the bearing from the shaft press on the out side end sprocket end of the motor shaft while supporting the outer race of the bearing Discard the old bearing 12 Remove the retaining ring 91 at the bottom of the bearing bore Remove the seal backup washer 57 Re move the quad ring 90 and o ring 56 using the appropri ate o ring service tools Discard the quad ring and o ring 13 The bushings 6 can be removed using p n 11930 col let from p n 05064 bear
45. tting clothing and safety shoes at all times when operating the chain saw Donotoverreach Maintain proper footing and balnace at all times Do not inspect or clean the chain saw while the hydraulic power source is connected Accidental engagement of the chain saw can cause serious injury Always connect hoses to the chain saw hose couplers before engergizing the hydraulic power source Make sure all hose connections are tight Do not operate the chain saw at fluid temperatures above 140 F 60 C Operation at higher temperatures can cause higher than normal temperatures at the chain saw which can result in operator discomfort Donotrely exclusively upon the safety devices built into the chain saw As a chain saw user several steps must be taken to keep your cutting jobs free from accident or injury 1 With a basic understanding of kickbacks you can reduce or eliminate the element of surprise Sudden surprise contributes to accidents 2 Keep a good firm grip on the chain saw with both hands the right hand on the rear handle and the left hand on the front handle when operating the chain saw Use a firm grip with thumbs and fingers encircling the chain saw handles A firm grip helps reduce kickbacks and maintains control of the chain saw Do not let go 3 Make sure the area in which you are cutting is free of obstructions 4 Cut at rated operating speeds gpm 5 Do not overreach or cut above shoulder height 6 Only use re
46. ulled by hand To adjust the chain tension 1 Turn off the water and power supplies 2 Loosen the two saw bar attachment nuts Figure 8 Bar Attachment Nuts 2 Bar Adjusting Screw Figure 8 Attachment Screw Locations 3 Using the saw bar adjustment screw Item 68 Parts ll lustration tighten the chain until you are still able to rotate it one full revolution by hand Figure 9 14 Figure 9 Pulling the Chain 4 Pull the chain around the saw bar to make sure it proper ly fits the sprocket and saw bar The chain should be easily pulled 5 Fully tighten the two saw bar attachment nuts Figure 8 Note Adjust the chain tension each time the drive link tang hangs fully exposed from the groove at the bottom of the saw bar Figure 10 MAINTENANCE amp ADJUSTMENTS Sta Bottom of Bar gt A Figure 10 Exposed Drive Link Tang ay UT SERVICING THE CHAIN The following procedures explain how to break a chain us Drive link ing Stanley s bench mounted chain breaker part number 20858 to remove a worn or damaged segment Top connecting link Clamping screw Breaker plate 1 Mount the chain breaker flush with the side or front of a flat clean work surface Figure 11 Bottom connecting link Figure 13 Inserting the Chain 3 Position th
47. utton 19 end of the handle Push the dowel against the water valve sleeve 38 to push the water sleeve out REASSEMBLY 1 Inspect the spool bore of the handle and the outer surfaces of the spool for damage Some light surface scratches will be noticeable Grooves roughness or a reduced diameter indicate fluid contamination If abnormal wear is present more than normal polishing replace both the spool and the handle 2 Apply grease and install a new o ring 15 onto the ON OFF valve 14 3 Apply grease and install new o rings 34 amp 35 into the spool bore of the handle 4 Apply grease and install new o rings 37 amp 39 onto the water valve sleeve 38 5 If the spring retainers 16 and spring 17 were removed from the ON OFF valve reinstall them Lubricate the ON OFF valve with hydraulic fluid and install it into the valve handle Secure it in place with the roll pin 20 6 Install the water valve sleeve into the valve handle 7 Install the push pin 40 steel ball 41 spring 42 and seal cap 44 Make sure a new o ring 43 is installed onto the seal cap 8 Install the safety catch 30 making sure the spring 29 is positioned properly Make sure the pin 33 is in place Secure the safety catch with the roll pin 21 9 Install the trigger 28 and secure with the roll pin 20 10 Replace the plug button 19 and test the action of the safety catch and trigger FLOW CONTROL Note
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