CD10,SERVICE 58858,9-02
Contents
1. a set of accessories which may be customized by each purchaser so as to facilitate performance of all work occurring within the scope of his specific application Tools included are for mounting and dismounting e single head wrench SW24 e single head wrench SW32 e single head wrench SW 41 e hex wrench SW 5 Basically you differentiate between freehand drilling and stand aided drilling The operating procedures to be adhered to for the two different operating modes are described below Drill Bit Installation A WARNING Before you start changing the drill bit make sure that the tool is disconnected from the power source in order to avoid unintentional operation of the tool and injury Disconnect only unpressurized hoses Use a single head wrench SW 24 small drill bit or SW 41 large drill bits and a single head wrench SW 32 to manually unscrew the drill bit to be removed and to screw on the new one There is no need to use any additional tools Dimension of the Drill Bit Drill head thread male 1 1 4 in UNC and female R 1 2 in Which drill bit at which speed speed jimi se drill bit diameter mm 100 162 40 100 20 40 Check the Power Source 1 Using a calibrated flowmeter and pressure gauge check that the hydraulic power source develops a flow of 5 8 13 2 gpm 22 50 Ipm at 950 2000 psi 66 140 bar 2 Make certain that the hydraulic power source is equipped with a relief valve set to ope2. other personnel damage to the tool or other threatening situation equipment This tool 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 A gt gt gt KEE E 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 operations Do not operate the tool unless thoroughly trained or under the supervision of an instructor Always wear safety equipment such as goggles 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 Do not operate this tool without first reading the Operating Instructions Do not install or remove this tool while the hydraulic power source is connected Accidental engagement of the tool can cause serious injury Never operate the tool if you cannot be sure that underground utilities are not present Underground electrical utilities present an electrocution hazard Underground gas utilities present an explosion hazard Other undergr
3. 2000 psi 138 bar 2100 2250 145 155 bar 250 psi 17 bar 400 SSU 82 centistokes 140 F 60 C 5 hp 3 73 kw 40 F 22 C Type Ill 11 13 GPM 42 49 Ipm 2000 psi 138 bar 2100 2250 145 155 bar 250 psi 17 bar 400 SSU 82 centistokes 140 F 60 C 7 hp 6 22 kw 40 F 22 C NOTE Do not operate the tool at oil temperatures above 140 F 60 C Operation at higher temperatures can cause operator discomfort at the tool Filter Min full flow filtration sized for flow of at least For cold temp startup and max dirt holding capacit Hydraulic fluid Petroleum based premium grade anti wear non conductive Viscosity at min and max operating temps 25 microns 30 GPM 114 Ipm 100 400 SSU 20 82 centistokes 25 microns 30 GPM 114 Ipm 100 400 SSU 20 82 centistokes 25 microns 30 GPM 114 Ipm 100 400 SSU 20 82 centistokes NOTE When choosing hydraulic fluid the expected oil temperature extremes that will be experienced in service determine the most suitable temperature viscosity characteristics Hydraulic fluids with a viscosity index over 140 will meet the requirements over a wide range of operating temperatures SSU Saybolt Seconds Universal NOTE These are general hydraulic system requirements See tool Specification page for tool specific requirements Operating Instructions General Operation The tool comes with
4. AL INJURY PRESSURE FOR THIS TOOL EXCESS FLOW DONOT CONNECT OPEN CENTERTOOLSTO _ CLO SE D CE NT ER PRESSURE MAY CAUSE A LEAK OR BURST HYDRAULIC SYSTEMS THIS MAY RESULT IN LOSS OF OTHER HYDRAULIC FUNCTIONS POWERED BY THE SAME SYSTEM AND OR B DO NOT EXCEED RATED WORKING PRESSU OF HYDRAULIC HOSE USED WITH THIS TOO SEVERE PERSONAL INJURY 30Lpm at 138bar BHTMA CATEGORY EXCESS PRESSURE MAY CAUSE A LEAK 5 BYSTANDERS MAY BE INJURED IN YOUR WORK ST WR KEEP BYSTANDERS CLEAR OF YOUR WORK A 6 WEAR HEARING EYE FOOT HAND AND HEAD PROTECTION 7 TO AVOID PERSONAL INJURY OR EQUIPMENT DAMAGE ALL TOOL REPAIR MAINTENANCE AND SERVICE MUST BE PERFORMED BY AUTHORIZED AND PROPER LY TRAINED PERSONNEL IMPORTANT IMPORTANT READ OPERATION MANUAL AND READ OPERATION MANUAL AND SAFETY INSTRUCTIONS FOR THIS SAFETY INSTRUCTIONS FOR THIS The SAFETY TAG P N 15875 shown at right smaller EES EES all Da wd Head ond w the E 1 e EE from the factory Read and understand the safety ERAND ORT GAL NETS DESCRIBED instructions listed on this tag before removal We S d A TAG TO BE REMOVED ONLY BY TOOL TAG TO BE REMOVED ONLY BY TOOL suggest you retain this tag and attach it to the tool OPERATOR OPERATOR SEE OTHER SIDE 15875 SEE OTHER SIDE 15875 when notin use Hydraulic Hose Requirements HOSE TYPES Hydraulic hose types authorized for use with Stanley Hydraulic Tools are as follows Certified non conductive Wire braided cond
5. 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 14 SERVICE INSTRUCTIONS Good maintenance practice keeps the core drill on the job and increases its service life The most important maintenance practice Is to keep the hydraulic fluid clean at all times Contaminated fluid causes rapid wear and or failure of internal parts Follow the procedure contained in the HYDRAULIC SYSTEM REQUIREMENTS section of this manual to ensure peak performance from the tool Do not disassemble the tool until you know whether the problem is in the hydraulic power supply the gearbox module or the power and control rear module Then only disassemble the tool as necessary to repair as required 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 reassemble Further wear and tool failure can result if the original cause is not corrected TOOL MODULE ASSEMBLIES The Core Drill consists of three modules 1st a gearbox module with three speed gearbox slip clutch side handle and water supply 2nd a motor module and 3rd a valve handle module with flow control valve trigger and trigger fixing key isolate the service problem to the circuit or one of the modules before separating the referring modules The TROUBLE SHOOTING sectio
6. ARRANTY 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 A WARRANTY 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 20 For additional Sales amp Service information contact STANLEY Stanley Hydraulic Tools Division of the Stanley Works 3810 SE Naef Road Milwaukie OR 97267 USA Tel 503 659 5660 Fax 503 652 1780
7. Finally connect the tool to the power source 6 Move the hydraulic circuit control valve to the ON posan 1 Insert the drill from above into the 7 Regulate the water valve to adjust the water corresponding seat and fasten the core drill by means of the hex head socket wrench SW 5 supply flow as desired 8 With the so prepared drill you may now 2 Mow manually screw the e s onding drill bit from below onto the drill bit adapter proceed to carry out your work ee f Manual tightening is sufficient because the drill bit will automatically fasten further A CAUTION during drilling operation Never switch into gear 1 in freehand drilling operation This delivers the highest torque 3 If necessary to attain an angled drill hole adjust the stand position by swiveling the arm 9 Put the drill in drilling position and squeeze of the stand the tri t tivate th ill eres 4 Connect the tool to water supply For this 10 Release the trigger to stop the drill purpose the device comes with a 10 liter pump Operating Instructions barrel which has to be pressurized first You may alternatively connect the device to a water tap using the Gardena hose couplings Maximum water pressure is 60 psi 4 bar 5 Finally connect the tool to the power source 6 Move the hydraulic circuit control valve to the ON position 7 To operate the drill regulate check valve to adjust the water supply flow as desired 8 With the s
8. H A CLEAN NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE DRY ABSORBENT CLOTH TO REMOVE DIRT AND MOISTURE AND TEST HOSE FOR MAXIMUM ALLOWABLE CURRENT LEAKAGE IN ACCORDANCE WITH SAFETY DEPARTMENT INSTRUCTIONS 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 POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT CONTACT DURING USE CONTACT va THE BURST CAN CAUSE BODILY INJECTION AND SEVERE PERSONAL INJURY SEE OTHER SIDE aO SEE OTHER SIDE oi DO NOT REMOVE THIS TAG SVL SIHL SAOWSY LON Od 7 Side 1 Side 2 This Tag attached to Conductive hose shown smaller than actual size p n 29144 1 DO NOT USE THIS HYDRAULIC HOSE ON OR NEAR ELECTRIC LINES THIS HOSE IS NOT CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAMAGE TO LABELED OR CERTIFIED AS NON CONDUCTIVE USING THIS HOSE ON OR NEAR ELECTRIC LINES COUPLINGS IF ANY OF THESE CONDITIONS EXIST REPLACE THE HOSE IMMEDIATELY MAY RESULT IN DEATH OR SERIOUS INJURY NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND ELECTRIC LINES ARTE EACH USE STOREINACLEAN DRY AREA DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE IMPROPER USE OR HANDLING OF HOSE COULD RESULT I
9. N 15 CD10 Parts List NOTE Use Part Number and Description when ordering 16 Part Item No Description Composite Safety Decal Not Shown Hose Set With Quick Couplers Not Shown Manual Oper amp Safety Connecting Nipple Not Shown Sticker CD10 Name Tag Part Item No Description a 41249 Motor Assy Motor Housing Output Shaft Spur Gear Shaft Sealing Snap Ring Washer Thrust Bearing Thrust Spacer Shaft Spool Drive Drive O ring Plate Spacer Geroler Assy Spool Bearing Bearing Ring Snap Ring Needle Bearing Snap Ring Part Item No Description WS 41252 Centering Aid Handle Assy 41608 Centering Aid 259 41609 Spring Gas Pressure w Buffer 260 41611 Rod Extension 261 Buffer QTY ch ch ch ch ch ch an EA ch ch ch ch ch nnn ii QTY 1 1 1 1 1 ch 41612 Clamp Clip Assy Le Clamp Clip Screw Locking Nut Square Washer Distance Ring Handle CD10 Parts List NOTE Part Use Part Number and Item No Description Bearing Housing Output Shaft Spur Gear Notched Wheel Spur Gear Needle Bearing Ball Compression Spring Grooved Ball Bearing Snap Ring Washer Snap Ring Snap Ring Snap Ring Feather Key Snap Ring Gearshift Lever O ring Snap Ring Dowel Pin Radial Shaft Sealing Radial Shaft Sealing Connecting Nipple Gear Shaft Spur Gear Washer Spring Belleville Nut Washer Ball Bearing Grooved Snap Ring Shim Shim D
10. N BURST OR OTHER HOSE FAILURE KEEP HOSE AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT CONTACT DURING USE CONTACT AT THE BURST CAN CAUSE BODILY INJECTION AND SEVERE PERSONAL INJURY 7 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 EN SEL OTHER SOE a EN SEE OTHER SIDE C DO NOT REMOVE THIS TAG SVL SIHL SAOWSY LON Od Oo Side 1 Side 2 HOSE PRESSURE RATING The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the hydraulic system 6 Tool Hydraulic System Requirements Flow rate Tool Operating Pressure at the power supply outlet System relief valve setting at the power supply outlet Maximum back pressure at tool end of the return hose Measured at a max fluid viscosity of at min operating temperature Temperature Sufficient heat rejection capacity to limit max fluid temperature to at max expected ambient temperature Min cooling capacity at a temperature difference of between ambient and fluid temps HTMA Requirements Type 4 6 GPM 15 23 Ipm 2000 psi 138 bar 2100 2250 145 155 bar 250 psi 17 bar 400 SSU 82 centistokes 140 F 60 C 3 hp 2 24 kw 40 F 22 C 30Lpm at 138bar BHTMA CATEGORY Type Il 7 9 GPM 26 34 Ipm
11. STANLEY HYDRAULIC CORE DRILL CD10 A DANGER SERIOUS INJURY OR DEATH COULD RESULT FROM THE IMPROPER REPAIR OR SERVICE OF THIS TOOL REPAIRS AND OR SERVICE TO THIS TOOL Copyright 2001 The Stanley Works MUST ONLY BE DONE BY AN AUTHORIZED AND OPS USA amp CE Version CERTIFIED DEALER 58858 9 2002 Ver 1 Stanley Table of Contents CD10 CORE DRILL SERVICING THE CD10 CORE DRILL This manual contains Safety Operation and Troubleshooting information Stanley Hydraulic Tools recommends that servicing of hydraulic tools other than routine maintenance must be performed by an authorized and certified dealer Please read the DANGER warning on the cover and the Copyright 2001 The Stanley Works All rights reserved Under copyright law this document may not be copied in whole or in part without the prior written consent of The Stanley Works This exception does not permit copies to be made for others whether or not sold Under the law copying includes translating into another language format or medium This copyright notice must appear on any permitted copies 2 Specifications General Safety Instructions Tools Decals and Tags Hydraulic Hose Requirements HTMA Requirements Operating Instructions Troubleshooting Maintenance Parts Illustration Parts List Accessories Warranty 11 14 15 16 19 20 SAFETY FIRST It is the responsibility of the operator and service technician
12. e fittings Low drilling torque Incorrect hydraulic flow Check that the hydraulic power source is producing 5 8 13 2 gpm 22 50 Ipm at 950 2000 psi 66 140 bar Defective quick disconnect Check each disconnect separately Hydraulic circuit relief set too low Set relief valve at 2100 psi 145 bar hoses too restrictive or the hydraulic fluid is too thick Fluid Restriction in hose or valve Locate and remove restrictions Excess back pressure Use correct fluid continued 11 Troubleshooting Symptom Low drilling torque continued Tool runs too fast Trigger operation erratic Control difficult Fluid leak at air gap between moto and valve housing 12 Possible Cause Fluid Restriction in hose or valve Excess back pressure continued Priority flow control valve is malfunctioning Flow reversed through hoses Too low slip clutch torque Incorrect hydraulic flow Hydraulic flow reversed Priority valve faulty Trigger mechanism blocked Motor capscrews loose Solution Fluid not warmed up Preheat system Hoses too long for hose D Use shorter hose See your authorized service dealer for replacement Correct the power source control valve position Prevent reverse flow by using only one port from the valve for pressure the return tool hose to the cooler and the filter line Correct the quick disconnect male female routing per instructions and the arr
13. f 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 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
14. gpm 50 lpm maximum Circuit is generating high heat with Use pump size and rpm for flow controls producing needed flow only Eliminate circuit heating causes Circuit has contaminants that have Replace worn pump and valves caused wear and high heat Install a large clean filter and keep generation the fluid clean Gearshift knob Oil leak at motor shaft seal into See your authorized dealer for turns hard gearbox causes high pressure in repair gearbox No gearshift Shifter pin worn or broken See your authorized dealer for function repair Water leaking out Output shaft seals worn See your authorized dealer for of shaft seal or repair side hole Water pressure too high Seal Maximum water pressure 60 psi damaged 4 bar 13 Maintenance Good maintenance practice keeps the core drill on the job and increases its service life The most important maintenance practice is to keep the hydraulic fluid clean at all times Contaminated fluid causes rapid wear and or failure of internal parts Follow the procedure contained in the HYDRAULIC SYSTEM REQUIREMENTS section of this manual to ensure peak performance from the tool Do not disassemble the tool until you know whether the problem is in the hydraulic power supply the gearbox module or the power and control rear module Then only disassemble the tool as necessary to repair as required KEEP CONTAMINANTS SUCHAS DIRT AND GRIT AWAY FROM INTERNAL PARTS AT
15. ion Handle Assy 19 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 NEW PARTS New parts which are obtained individually are warranted subject to the exceptions herein to be free of defects in material and or workmanship at the time of delivery and for a period of 6 months after the date of first usage Seals and diaphragms are warranted to be free of defects in material and or workmanship at the time of delivery and for a period of 6 months after the date of first usage or 2 years after the date of delivery whichever period expires first Warranty for new parts is limited to replacement of defective parts only Labor is not covered 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 i
16. ling 11 The handle and the spot drilling aid enable controlled manual operation of the drill A CAUTION Monitor continuously the water supply to ensure that 1 Observe all safety precautions 2 Mount the spot drilling aid onto the centering collar to ensure precise positioning sufficient water is supplied to the cut surface to avoid unnecessary wear of drilling equipment 3 Screw on the desired drill bit up to max 80 mm approx 3 inches Refer to the DRILL BIT INSTALLATION for details Manual tightening is sufficient because the drill bit will automatically fasten further during drilling 12 To change drill bits proceed as described above Adhere to safety instructions 13 For dismounting the drill upon completion of drilling work follow the mounting f instructions in reverse order 4 Connect the tool to water supply For this purpose the device comes with a 10 liter pump barrel which has to be pressurized first You may alternatively connect the device to a water tap using the Gardena hose couplings Maximum water pressure is 60 psi 4 bar Stand aided Drilling First fix the stand at the point where you wish to drill the opening or hole To do so drill a hole matching the size of the corresponding screw anchor screw the stand onto the surface Align the stand such that the drill bit will make contact with the surface precisely at the point where you want to drill the opening or hole 5
17. lt the gearbox housing and motor housing Subsequently the assembly of the main components can be done Use only ORIGINAL SPARE PARTS for repairs Use sodium saponified semi fluid grease GP 000 M 30 DIN 51502 approx 100 g e g REMOLIT SO D 8024 from Fuchs page 11 14 CD10 Parts Illustration REND ZZ PASSE di ELE OZE ZE OZE ZIE 80E OLE LOE KLH OZ 70E 6ZE DLE SZE IZE 8LE 60E 8ZE 9OET ZZE L WN len anbig dis yLy SWB YM jas aid 33UD S P l d zae SC CT DI zE Her nz IL 807 ziy or Ley z v K E Re Bg nae D Se a oly 60 Loy ery oz vey EE 9Z7 Siy on SEY IN A cze elef WE N S SSASSN SE A Oy fail oor Si DX 2 Orn DX CH lee ES SE C aS Fea Es Boa N ees Vv CT bose d ES LE Lt ees KH og DOT OSS si E BE ee E ei ae te GE i Reeg ENT O SSS we e EAE 4 i SE SIRA ZA a Bad N 4 d Z PAIS CEE ts L7 LOE SOE Z7 07 LCE 7LL LL f RS op Go VAY OAT AK Fa He Fafe st Hoi ie fe a DE ESCH Lo NAA SSR peeked cb SCH AN OA ELL OLL Si GH d lt i AL AN E sS E TNNT ZOLI 90 SO SOL Li 827 907 SLY S27 727 227 O27 ZO LOL EOL o DU 27 b 6b7 707 WO7 EZY L E ee ZU 60L 801 LOL OE7 627 uaus o GU apis pa 1300 D
18. me tag sticker must be legible at all times Replace this sticker if it becomes worn or damaged A replacement is available from your local Stanley distributor Ise IS 28409 Composite Sticker Location Model SN 11206 Circuit Type C Decal 20Lpm at 138bar BHTMA CATEGORY 11207 e A Die UI yircuit T e D Decal 1 FAILURE TO USE HYDRAULIC HOSE LABELED AND D DO NOT LIFT OR CARRY TOOL BY THE HOSES DO NOT ABUSE CERTI FIED_AS NON CONDUCTIVE WHEN USING HOSE DO NOT USE KINKED TORN OR DAMAGED HOSES HYDRAULIC TOOLS ON OR NEAR ELECTRICAL LINES MAKE SURE HYDRAULIC HOSES ARE PROPERLY MAY RESULT IN DEATH ORSERIOUSINIURY CONN ECTED TO THE TOOL BEFORE PRESSURIZING BEFORE USING HOSE LABELED AND CERTIFIED AS SYSTEM SYSTEM PRESSURE HOSE MUST ALWAYS NON CONDUCTIVE ON OR NEAR ELECTRIC LINES BE CONNECTED TO TOOL IN PORT SYSTEM BE SURE THEHOSE IS MAINTAINED AS NON CONDUC TIVE THE RETURN HOSE MUST ALWAYS BE CONNECTED AT HOSE SHOULD BE REGULARLY TESTED FOR ELECTRIC CURRENT TOOL OUT PORT REVERSING CONNECTIONS MAY LEAKAGE IN ACCORDANCE WITH YOUR SAFETY DEPARTMENT CAUSE REVERSE TOOL OPERATION WHICH CAN INSTRUCTIONS CAUSE SEVERE PERSONAL INJURY 2 A HYDRAULIC LEAK OR BURST MAY CAUSE OIL DO NOT CONNECT CLOSED CENTER TOOLS TO INJECTION INTO THE BODY OR CAUSE OTHER SEVERE PERSONAL OPEN CENTER HYDRAULIC SYSTEMS THIS MAY INJURY CAUSE EXTREME SYSTEM HEAT AND OR SEVERE A DO NOT EXCEED SPECIFIED FLOW A PERSON
19. move the second snapring item 120 Take out motor parts items 108 114 Than push off snapring item 105 Now you can push out the motor shaft item 102 with thrust washer item 106 and thrust bearing item 107 Press out shaft seal item 104 and remove spur gear item 103 4 Gearbox Unscrew complete water connection items 211 217 After removing snapring item 433 draw off gearshift lever item 431 Take off snaprings item 427 and pull out spur gear item 406 notched wheel item 405 feather key item 426 ball item 418 and compression spring item 419 After removing snaprings item 425 and 421 the output shaft item 402 with bearing item 420 can be pressed out of page 10 14 E Se F 8 a EE T H e ih rm cg e s kF e housing item 401 Take out washer item 422 and press out radial shaft seals items 435 and 436 after removing snapring item 424 To disassemble countershaft assembly items 403 433 unscrew hexagonal nut item 410 After that remove shims item 414 belleville springs item 409 washers item 408 and 411 and spur gear item 407 After removing snapring item 413 press off roller bearing item 412 Reassembly Before starting reassembly check all parts for wear and replace them if necessary Wear parts are in particular O rings radial shaft seals bearings and the slip clutch washers 1 Handle Reassembly is performed essentially the same as disassembly but in reverse order Adj
20. n at 2100 2250 psi 145 155 bar 3 Check that the hydraulic circuit matches the tool for open center OC operation Check the Tool 1 Make certain 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 and dry with all fittings and fasteners tight 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 tool fittings or quick disconnects Connect the return hose first and disconnect it last to eliminate or reduce trapped pressure for easier quick connect fitting attachment NOTE If uncoupled hoses are left in the sun pressure increase within the hoses can make them difficult to connect When ever possible connect the free ends of hoses together 3 Observe the flow indicators stamped on the hose couplers to ensure that the flow is in the proper direction The female coupler on the tool s IN port is the inlet coupler Operating Instructions 4 Squeeze the drill trigger momentarily If the drill does not operate the hoses might be reversed Verify correct connection of the hoses before continuing To avoid injury do not use the valve trigger lock in freehand drilling operation Use valve trigger lock in stand aided drilling operation only Freehand Dril
21. n contains information to help isolate the problem PRIOR TO DISASSEMBLY Clean the exterior of the tool Make sure to have all new seals so they can be replaced during reassembly Note the orientation of seals before removal Install new seals in the same position as the original Seals Note For orientation of the parts identified in the following procedures refer to the Erstellt 03 04 00 Dokument 21317001 Eoc sectional drawing and parts list located at the end of this manual Disassembly Disassemble into main components Handle with valve Motor and gearbox Remove complete handle valve housing after loosening screws item 327 Remove screws item 429 and separate gearbox from motor Continue to disassemble 1 Handle Remove screws item 432 and item 325 and separate handle item 601 from valve housing item 301 Knock out the double notched pin item 603 and take out valve lever item 602 Unscrew complete valve lever locking assembly items 40 43 2 Valve Remove ring item 324 and unscrew guide item 315 Pull out valve assembly Remove snapring item 307 to get gland item 306 After loosening screw item 308 control piston item 310 compression spring item 317 and spring seat item 311 can be removed Load the compression spring item 316 to remove snapring item 313 Now you can push out the pin item 312 with all the seals 3 Motor First remove snapring item 120 and pull out countershaft assembly then re
22. o prepared drill you may now proceed to carry out your work 9 Squeeze the trigger to activate the drill and press valve trigger fixing key to ensure comfortable working A CAUTION Monitor continuously the water supply to ensure that sufficient water is supplied to the cut surface to avoid unnecessary wear of drilling equipment 10 You may continuously control the advance motion of the drill by adjusting the star knob at the side of the drilling stand 11 To switch off the machine unlock the valve trigger fixing key Then shut off the water supply 12 To change drill bits proceed as described above Adhere to safety instructions 13 For dismounting the drill upon completion of drilling work follow the mounting instructions in reverse order 10 A CAUTION When drilling into a structure that might contain electrical wiring be sure to know the location of the wiring and avoid drilling into it The housing can carry electrical current from live electrical wires into which the drill is accidentally drilled resulting in injury or death Cold Weather Operation If the drill 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 Damage to the hydraulic system or drill can result from use with fluid that is too viscous or too thick Trouble
23. 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 HEAT TYPE OF FLUID Any failure or performance deficiency attributable to excess hydraulic pressure excess hydraulic back pressure excess hydraulic flow excessive heat or incorrect hydraulic fluid 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 obtaining the written consent of Stanley PERMISSION TO APPLY ANY PRODUCT FOR WHICH IT WAS NOT ORIGINALLY INTENDED CAN ONLY BE OBTAINED FROM STANLEY ENGINEERING WARRANTY REGISTRATION STANLEY ASSUMES NO LIABILITY FOR W
24. ound utilities may present other hazards Do not wear loose fitting clothing when operating the tool Loose fitting clothing can get entangled with the tool and 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 Failure to do so may result in damage to the quick couplers and cause overheating Use only lint free cloths Do not operate the tool at oil temperatures above 140 F 60 C Operation at higher oil temperatures can cause operator discomfort and may cause damage to the tool Do not operate a damaged improperly adjusted or incompletely assembled tool To avoid personal injury or equipment damage all tool repair maintenance and service must 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 labels 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 Decals amp Tags AName Tag Sticker is attached to the tool Never exceed the flow and pressure levels specified on this sticker The information listed on the na
25. owel Pin Seal Screw Fillister Head Dowel Pin Connecting Piece Gasket Elbow Hose Connector Clamp Hose Gasket Stopcoxk Connecting Piece Water Stop Gardena 1 2 in Mi Se ce ee Cer eer Cs Cer OC gry ees CC 17 CD10 Parts List NOTE Use Part Number and Description when ordering semien J Filter Element Gasket Muffler Element Stand Gasket Seal Kit Instruction Seal Kit 18 Part Hem No Description Valve Housing Assy Bar Gland Snap Ring Compression Spring Ring Segment Swivel Screw Fillister Head Screw Fillister Head Plug Thread Joint Screw Handle Valve Lever Double Notched Pin Screw Lock Bolt Bushing Bushing Compression Spring Snap Ring Screw Fillister Head Washer Control Piston Spring Seat Pin Bushing Guide Spring Compression Spring Snap O ring O ring O ring Screw O ring O ring Washer aso Valve Lever Locking Assy Housing Latch Pin Spring Compression Push Button QTY k mi i i k ch i i P O CO OI a ch mi mk mk ch ch NOTE Use Part Number and Description when ordering Part Accessories Description Anchor Stand Motor Mount 7 8 in Core Bit w Crown 1 in Core Bit w Crown 1 1 4 in Core Bit w Crown 2 in Core Bit Segmented 3 in Core Bit Segmented 4 in Core Bit Segmented 6 in Core Bit Segmented Carrying Case Pipe Clamp Water Tank Vacuum Pump Accessory Vacuum Pump Instruct
26. ows on the fittings Inspect and replace slip clutch washers if necessary Set torque to 20 1 5 Nm 151 Ibf ft See your authorized service dealer for repair Do not overload drill to avoid wear of slip clutch Check that hydraulic power source is not producing over 13 2 50 Ipm at 950 2000 psi 66 149 bar Correct the tool hoses IN and OUT per instructions and if the power supply valve is reversible reconnect the tool return hose to the oil cooler or to the filter directly Do not separate modules Remove inspect and replace priority valve if necessary See your authorized service dealer for replacement Do not separate modules Clean trigger area Adjust trigger Tighten to recommended torque 10 Nm 7 5 Ibf ft continued Troubleshooting Symptom Possible Cause Solution Fluid leak at air Motor O rings worn See your authorized dealer for gap between repair n l motar And valve Motor a main housing eee your authorized dealer for housin centile damaged eee Fluid leaks at flow Damaged O rings See your authorized dealer for control valve repair Wrong hydraulic fluid See OPERATING INSTRUCTIONS Circuit to hot for correct fluid circuit specifications Hydraulic pressure and return Correct hose connections hoses reversed Power unit center circuit or vice versa working hard Adjust relief valve to 2100 22500 psi 145 155 bar Too much fluid going through tool Adjust flow for 13 2
27. shooting This section describes how to find and resolve problems users may experience Ifa situation occurs that is not covered call your Stanley Customer Service representative for assistance A WARNING Inspecting the tool or installing parts with the hydraulic hoses connected can result in severe personal injury or equipment damage To prevent accidental startup disconnect the hydraulic power before beginning any inspection or installation task Ifsymptoms of poor performance develop the following chart can be used as a guide to correct the problem When diagnosing faults in operation of the tool always check that the hydraulic power source is supplying the correct hydraulic flow and pressure to the tool as listed in the table Use a flowmeter known to be accurate Check the flow with the hydraulic oil temperature at least 80 F 27 C Symptom Possible Cause Solution Tool will not start Power not being supplied Check to make certain that both hoses are connected a SEH Circuit control valve Defective quick disconnect Check each disconnect separately Replace as necessary Jammed motor See your authorized dealer for service Flow reversed through hoses Correct the power source control valve position Prevent reverse flow by using only one port from the valve for pressure the return tool hose to the cooler and the filter line Correct the quick disconnect male female routing per instructions and the arrows on th
28. to read rules and instructions for safe and proper operation and maintenance A cautious worker using common sense is the greatest safety device Pressure 2000 psi 140 bar Water Pressure max 60 psi 4 bar Maximum Back Pressure 250 psi 17 bar Weight 18 7 lbs 8 5 kg Overall Length 19 3 in 490 mm Max Fluid Temp 140 F 60 C Capacity 3 6 hp 2 8 kW Flow Range 5 13 gpm 20 50 Ipm Maximum Flow 13 gpm 49 Ipm Porting 8 SAE O ring Water Connection Gardena System Free Speed 1st Gear 380 rpm 2nd Gear 900 rpm 3rd Gear 1800 rom Drill Bit Connection 1 1 4 in UNC male R 1 2 in Female Specifications Hydraulic Connection Quick Couplers 1 2 in FF Hose Diameter 500 in 12 mm HTMA Class 4 6 gom 2000 psi EHTMA Category 20 Ipm 138 bar HTMA Class II 7 9 gom 2000 psi D fz EHTMA Category 30 lpm 138 bar Sound Pressure 80 dBA 1m Vibration Level 0 82 m s General Safety Instructions Always observe safety symbols They are included for your safety and the protection of the tool AWARNING A CAUTION This safety symbol may appear on This safety symbol appears in these This safety symbol appears in these the tool It is used to alert the instructions to identify an action instructions to identify an action or operator of an action that could that could cause bodily injury to the condition that could result in place him her or others in a life operator or
29. uctive Fabric braided not certified or labeled non conductive Hose listed above is the only hose authorized for use near electrical conductors Hoses and listed above are conductive and must never be near electrical conductors HOSE SAFETY TAGS To help ensure your safety the following DANGER tags are attached to all hoses purchased from Stanley Hydraulic Tools DO NOT REMOVE THESE TAGS If the information in a tag is illegible because of wear or damage replace the tag immediately A new tag may be obtained at no charge from your Stanley Distributor This Tag attached to Certified Non Conductive hose shown smaller than actual size p n 27987 1 FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE WHEN USING 4 HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING ABRASION CUTTING OR CONTACT HYDRAULIC TOOLS ON OR NEAR ELECTRIC ee MAY RESULT IN DEATH OR SERIOUS INJURY WITH HIGH TEMPERATURE SURFACES DO NOT USE IF KINKED DO NOT USE HOSE TO PULL OR FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY TRAINED IN LIFT TOOLS POWER UNITS ETC CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND ELECTRIC LINES CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAMAGE TO BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE ON OR NEAR COUPLINGS IF ANY OF THESE CONDITIONS EXIST REPLACE THE HOSE IMMEDIATELY ELECTRIC LINES WIPE THE ENTIRE LENGTH OF THE HOSE AND FITTINGS WIT
30. ust the trigger position by turning screw item 604 2 Valve Reassembly is done essentially in reverse order Grease all O rings before assembly Make sure that the O rings do not get damaged when the valve parts are inserted To assemble snap ring item 312 load the compression spring item 316 3 Motor Reassembly is done essentially in reverse order Grease all seals before assembly Observe the position of Geroler rotor item 112 and the square head of spool drive item 109 as shown at the drawing to get the right direction of rotation Erstellt 03 04 00 Dokument 21317001 Eoc CAUTION Never use the tool with the slip clutch At installing the gearshift lever item 431 take 4 Gearbdox After installing new radial shaft seals into housing item 401 washer item 422 and output shaft item 402 pre assembled with bearing have to be pushed in and made complete If countershaft assembly items 403 433 was disassembled use shims item 414 to get a slip torque of 20 1 5 Nm After tightening hexagonal nut item 410 fix the countershaft assembly in a vice at the spur gear item 407 and check the slip torque with a torque wrench by turning at the hexagonal nut item 410 If the torque is not 20 1 5 Nm add ore remove shims item 414 torque set higher than 22 Nm care that positioning is correct After inserting the countershaft assembly in the motor housing item 104 pour in approx 0 2 liter grease lubricating oil and bo
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