HYDRAULIC CUT-OFF SAW - Stanley Hydraulic Tools
Contents
1. ee 11 GENER OPEN EEEE EE AE REEE EEEE AES 12 VET TN 12 BROKEN CUTOFF W EEEE NR I t m cR 12 PUTO ONIN m 12 PER GIN NANG 13 THRUST COLLAR AND INSIDE OUTSIDE COLLAR INSPECTIONS 13 RNET PENNEN 15 NEC A E a 13 GRE ND TRE 13 GE Eg NE 13 Tolv 13 CUTOFF NELL REP e ME NT u cee xu ey ee eee ee ee 14 HJERNE NER OPEN EEEE E EE EE EEE ETE 14 ze Pm FROTEC NNN 15 TROUBE E IOO eee meer rere E re a ee na ee re ere EI ELI MI ME CIIM ME d I MEME 16 PEF NS erani ee uU u MM eu ML eer eee ee Ed 17 Pr 17 E LEOU TRIO P 18 COP DIST uyu usu am III MU IE M 19 IMPORTANT To fill out a Product Warranty Recording form and for information on your warranty visit Stanleyhydraulic com and select the Warranty tab NOTE The warranty recording form must be submitted to validate the warranty SERVICING This manual contains safety operation and routine maintenance instructions Stanley Hydraulic Tools recommends that servicing of hydraulic tools other than routine maintenance must be performed by an authorized and certified dealer Please read the following warning SERIOU2. suoneorjdde saujo Aue JO pesn q jou p nous pue SJUSUWSJINbaJ DuneJjedo 100 s oo Inep H ue S uo peseq Ajuo suoneoijdde 00 ol neJP Y 104 pesn 9q o pepueoiul SI yeyo siu eoueuloJied 00 LUINWIXEW eJnsue o 9 A ejqe1doooe uunuuluiuJ e o nss id yoeq oJnssaJd Sul UINJSJ d y o p pu u 9Je suoi esau wdi ejnuiu Jed 51 udb aynuiw 184 suojjeb uo peseq syjbue SSOY 5 sJejeuleip esou WNWIUIW pepueuuulooaJ s ous yf ou yey SUL Suoinepueuluio29M 5 N92119 03 loo L CO25 User Manual 4 9 HTMA EHTMA REQUIREMENTS HTMA EHTMA REQUIREMENTS HTMA HYDRAULIC SYSTEM REQUIREMENTS Flow Range Nominal Operating Pressure at the power supply outlet System relief valve setting at the power supply outlet Maximum back pressure at tool end of the return hose Measured at a max fluid viscosity of at min operating temperature Temperature Sufficient heat rejection capacity to limit max fluid temperature to at max expected ambient temperature Min cooling capacity at a temperature difference of between ambient and fluid temps NOTE TYPE 4 6 gpm 15 23 Ipm 1500 psi 103 bar 2100 2250 psi 145 155 bar 250 psi 17 bar 400 ssu 82 centistokes 140 F 60 C 3 hp 2 24 kW 40 F 22 C TOOL TYPE TYPE Il 7 9 gpm 26 34 Ipm 1500 psi 103 bar 2100 2250
3. 16 CO25 User Manual STANLEY SPECIFICATIONS Mel 14 inch 15 6 cm MOT EEE EEE 20 Ibs 9 kg SEE Lengi EEE EEE 21 inch 53 cm ear RET MY 11 inch 28 cm Pressu RAR me cn mec kestrel Om 1500 2000 psi 105 140 bar 0 EE 7 9 gpm 26 34 Ipm Bondi FION ERE tied 8 gpm 30 Ipm y lH NS uma UTER Open Center HTMA Type ll PORIN 8 SAE O Ring GONE Size and 3 8 inch Male Pipe Adapter WA S s io REE RER EE nee ee 0 4700 rpm AGGESSORIES DESCRIPTION PART NUMBER 14 inch Abrasive Wheel for Metal 1 inch Arbor 02691 14 inch Abrasive Wheel for Masonry 1 inch Arbor r arrrnrnnnrnnnnnrnvrnnnrnrnnnennnnnrrnnanrennnnnennnnnrnnnnesennnsnennnnnsnnnnssennnsnennnssen 02692 Diamond Blade 14 inch Dry CU t 62358 Water Attachment Kit for CO25 Includes 1 Water Hose Assy P N 33220 1 9 125 inch Long Tube P N 33226 1 7 812 inch Long Tube P N 33227 1 Brass Adaptor P N 35196 3 Male 90Deg Elbow 1 4 hose barb P N 33223 1 Male Elbow BESSP NS se Eia 33228 OE VM 69290 Water Tank Kit for Slab Saw Cart Includes 1 Tank Top Bracket P N 69296 1 Tank Bracket P N 69542 1 Water tank P N 41240 1 Needle Valve Clamp P N 69914
4. CO25 HYDRAULIC CUT OFF SAW SAFETY OPERATION AND MAINTENANCE USER MANUAL 2012 Stanley Black amp Decker Inc New Britain CT 06053 U S A 34962 11 2013 Ver 12 DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY UBEREINSTIMMUNGS ERKLARUNG C DECLARATION DE CONFORMITE CEE DECLARACION DE CONFORMIDAD Hydraulic Tools DICHIARAZIONE DI CONFORMITA the undersigned i Ich der Unterzeichnende Weisbeck Andy Je soussign El abajo firmante lo sottoscritto Surname and First names Familiennname und Vornamen Nom et pr nom Nombre y apellido Cognome e nome hereby declare that the equipment specified hereunder best tige hiermit da erklaren Produkt genannten Werk oder Ger t d clare que l quipement vis ci dessous Por la presente declaro que el equipo se especifica a continuaci n Dichiaro che le apparecchiature specificate di seguito 1 Category Cut Off Saw Hydraulic Kategorie Cat gorie Categoria Categoria 2 Make Marke Marque Marca Marca Stanley 3 Type Typ Type Tipo Tipo CO2554101 CO2514101 4 Serial number of equipment Seriennummer des Ger ts Num ro de s rie de l quipement All Numero de serie del equipo Matricola dell attrezzatura Has been manufactured in conformity with Wurde hergestellt in Ubereinstimmung mit Est fabriqu conform ment Ha sido fabricado de acuerdo con E stata costruita in conformita con Directive Standards No Approved body R
5. 2 Capscrews P N 32412 9 Capscrews P N 15476 and 11 Nuts P N Handle Extension Kit Includes 2 Oil Tubes P N 31945 1 Handle Weldment P N 34116 1 Extension P N 34172 4 O Rings P N 00175 Hardware 2 Lockwashers P N 01459 2 3 8 Capscrews P N 02116 4 5 16 Capscrews P N EEE EE ES 34175 SOUND POWER AND VIBRATION DECLARATION Test conducted on CO25541 S N 673 operated at standard 12 gpm input Measured A weighted sound power level Lwa ref 1pW in decibels a r 109 4 dBA Uncertainty KWA EEE REE EE 3 dBA Measured A weighted sound pressure level Lpa ref 20 uPa at operator s position in decibels 101 5 dBA Uncertal ty Kpa NE renn 3 dBA Values determined according to noise test code given in ISO 15744 using the basic standard IS03744 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 ses Measured vibration emimisslon value a Lauen ane a Sur danene esi massa S axes
6. 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 Ee OTHER SIDE rr Kma rmY SEE OTHER SIDE OVL SIHL AAOWSY LON OG O 2 I LU gt O LU O lt O a Shown smaller than actual size 8 CO25 User Manual STANLEY v lt O lt lt LLI O Q LLI x LLI v O SUONDSUUON 85 eunDi RETURN HYDRAULIC CIRCUIT PRESSURE lt lt lt MO14 3 gt gt gt JYUNSSIYUd 0 8 g o dn 09 0 O GL 06 0 00 00L O 6L GOL G o dn Gz o dn Z G Ob SYOLONGNOD 1VOIW12313 YVAN ASN LON OQ 19q 4 10 pIEJg 9JIM 9850H 9AHonpuo 1919 8 404 plesg Jeq 4 2S0H 9Aljonpuo2 uoN 9 ounssaJgd BUIHIOM Jojouireiq 9PISUI RETURN PRESSURE LES IVS Aq ulio Jes se 5 945 p x 10 19901 snuu esoy oi neJp u rv Bunes AJLA 1 118155 91neJpAU uunuu IXeuJ eu 0 jenb inss id Bur40 uunuuiuruu 09 8 e 1588 18 BABY JSNW esou oi neJp U y
7. INJURY BYSTANDERS MAY BE INJURED IN YOUR WORK AREA KEEP BYSTANDERS CLEAR OF YOUR WORK AREA WEAR HEARING EYE FOOT HAND AND HEAD PRO TECTION TO AVOID PERSONAL INJURY OR EQUIPMENT DAMAGE ALL 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 OPERATION MANUAL TAG TO BE REMOVED ONLY BY TOOL OPERATOR SEE OTHER SIDE SAFETY TAG P N 15875 Shown smaller then actual size CO25 User Manual 4 7 HOSE TYPES The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the hy draulic system There are three types of hydraulic hose that meet this requirement and are authorized for use with Stanley Hydraulic Tools They are Certified non conductive constructed of thermoplastic or synthetic rubber inner tube synthetic fiber braid reinforcement and weather resistant thermoplastic or synthetic rubber cover Hose labeled certified non conductive is the only hose authorized for use near electrical conductors Wire braided conductive constructed of synthetic rubber inner tube single or double wire braid reinforce ment and weather resistant synthetic rubber cover This hose is conductive and must never be used near electrical conductors Fabr
8. equipment This signal word indicates a situation which if not avoided may result in dam IMPORTANT age to the equipment Always observe safety symbols They are included for your safety and for the protection of the tool LOCAL SAFETY REGULATIONS Enter any local safety regulations here Keep these instructions in an area accessible to the operator and mainte nance personnel 4 CO25 User Manual STANLEY 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 These safety precautions are given for your safety Review them carefully before operating the tool and before per forming general maintenance or repairs Supervising personnel should develop additional precau tions relating to the specific work area and local safety regulations If so place the added precautions in the space provided on the previous page The CO25 Hydraulic Cut Off 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 hose before operation Failure to do so could result in personal injury or equipment damage The operator must start in a work area without bystand ers Flying debris can cause serious injury Do not operate the tool unless thoroughly traine
9. wheel does not stop when the trigger is released Inspect the wheel guard and collars for damage after any wheel breakage on the tool Always use full throttle when cutting Never cock jam or wedge the wheel during the cut Do not use the side of the wheel as a cutting surface and be aware of kick back from the saw Make sure the tool is designed for the wheel direction suitable for the job Do not reverse the direction of the wheel rotation by changing the direction of the oil flow Always operate the tool within its rated capacity Never exceed the maximum operating speed marked on the wheel Do not operate the tool near flammable materials sparks can ignite flammable or combustible materials e Do not over reach Do not use the tool for applications for which it was not designed Keep the wheel off all surfaces when starting the saw Do not attempt to adjust the flow control on the valve handle Know the location of buried or covered services before starting work Adjust the wheel guard so it is between you and the cut ting wheel Never operate the tool when you are tired CUT OFF WHEEL SAFETY Always inspect the cut off wheels for possible damage be fore operating the tool Do not use a wheel that is cracked or otherwise damaged Never transport or store the tool with the cut off wheel 6 CO25 User Manual mounted on the saw e f the cut off saw is dropped with a cutt
10. 06316 06881 00772 00148 00166 30591 00713 00178 73309 06853 33206 28322 28886 28811 05153 02004 52539 24058 24059 24069 31845 gt gt Na gt gt NN gt NN gt M HR mm gt gt gt gt PO NNN PARTS LIST fe a Lever Washer Roll Pin Capscrew Guard Clamp Bolt Wheel Guard Motor Assy CCW Incl Items 49 57 59 66 Motor Assy CW Incl Items 49 57 59 66 Motor Shaft CCW Models Only Motor Shaft CW Models Only Retaining Ring Seal Gland O ring Quad Ring Capscrew Gear Hsg Assy Bushing Needle Roller Key Bearing Retaining Ring Bearing Hsg Assy Dowel Pin O ring Idler Shaft Driver Gear Name Tag CE Sticker CE Models Only Composite Sticker CE Models Only Information Plaque CE Models Only Stanley Sticker CE Models Only Drive Screw Sound Power Level Decal Coupler Female Not Shown Coupler Male Not Shown Coupler Set SEAL KIT e Denotes Part in Seal Kit 33084 Motor Assy CCW Rotation Incl Items 49 57 59 66 33083 Motor Assy CW Rotation Incl Items 49 57 59 66 CO25 User Manual 4 19 Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie Oregon 97267 5698 USA 503 659 5660 Fax 503 652 1780 www stanleyhydraulic com
11. A HYDRAULIC SYSTEM REQUIREMENTS CLASSIFICATION AAAA Flow Range 3 5 4 3 gpm 13 5 16 5 Ipm 1870 psi 129 bar Nominal Operating Pressure at the power supply outlet System relief valve setting at the power supply outlet 2495 psi 172 bar 4 7 5 8 gpm 18 22 Ipm 1500 psi 103 bar 2000 psi 138 bar 7 1 8 7 gpm 27 33 Ipm 1500 psi 103 bar 2000 psi 138 bar 9 5 11 6 gpm 36 44 Ipm 1500 psi 103 bar 2000 psi 138 bar 11 8 14 5 gpm 45 55 Ipm 1500 psi 103 bar 2000 psi 138 bar NOTE These are general hydraulic system requirements See tool specification page for tool specific requirements 10 gt CO25 User Manual STANLEY OPERATION PREOPERATION PROCEDURES CHECK THE POWER SOURCE Careful inspection of the tool and hydraulic system before Startup is important for safe reliable operation of the tool 1 Using a calibrated flowmeter and pressure gauge check that the hydraulic power source develops a flow of 7 9 gpm 26 34 lpm at 2000 psi 140 bar 2 Make certain the hydraulic power source is equipped with a relief valve set to open at 2100 2250 psi 145 155 bar CHECK THE TOOL The following items should be checked daily Make sure the hydraulic system control valve is in the OFF position and the hoses are disconnected before inspecting the cutoff saw 1 Inspect the cut off wheel and guard Make sure the cor rect cut off wheel is ins
12. ECTRIC LINES WIPE THE ENTIRE LENGTH OF THE HOSE AND FIT CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAM TING WITH A CLEAN DRY ABSORBENT CLOTH TO REMOVE DIRT AND MOISTURE AND TEST HOSE FOR MAXIMUM ALLOWABLE CURRENT LEAKAGE INACCORDANCE WITH AGE TO COUFLINGS IF ANY OF THESE CONDITIONS EXIST REPLACE THE HOSE SAFETY DEPARTMENT INSTRUCTIONS IMMEDIATELY NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROP ERLY TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND AFTER EACH USE STORE IN A CLEAN DRY AREA DO NOT REMOVE THIS TAG OVL SIHL 34AONW3 H LON OG SEE OTHER SIDE SEE OTHER SIDE Shown smaller than actual size THE TAG SHOWN BELOW IS ATTACHED TO CONDUCTIVE HOSE DO NOT USE THIS HYDRAULIC HOSE ON OR NEAR ELECTRIC LINES THIS HOSE IS CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAMAGE TO NOT LABELED OR CERTIFIED AS NON CONDUCTIVE USING THIS HOSE ON OR NEAR COUPLINGS IF ANY OF THESE CONDITIONS EXIST REPLACE THE HOSE IMMEDIATELY ELECTRICAL LINES MAY RESULT IN DEATH OR SERIOUS INJURY NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY AFTER EACH USE STORE IN A CLEAN DRY AREA TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND ELEC TRIC LINES DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE IMPROPER USE OR HANDLING OF HOSE
13. NLEY CARE AND STORAGE Remove the cutoff wheel from the tool after use Do not store or transport the saw with the wheel installed Clean and inspect the wheel and tool before storing CUTOFF WHEELS All abrasive cutoff wheels are breakable Exercise care in handling and storage to prevent damage 1 Clean used wheels to remove any dirt debris or grease Dry thoroughly 2 Inspect the wheel for chips cracks or other damage For maximum tool performance replace the wheel if it is worn or defective 3 Store cutoff wheels on a flat surface of steel or similar rigid material 4 f wheels are supplied with blotters attached insert suit able separators between each wheel and the supporting surface to preserve flatness 5 Do not store wheels where they will be exposed to high humidity water or other liquids excessive heat or freezing temperatures 6 Avoid temperatures low enough to cause condensation on the wheels if they are moved from storage to an area of higher temperature 7 Wheels carried on emergency vehicles should be re moved after use and discarded or stored carefully steps 1 and 2 TOOL 1 Clean the tool to remove any dirt debris or grease Dry with compressed air or clean dry cloths 2 Replace any damaged or missing safety labels and tags before storing the tool Otherwise the tool might be improp erly used by someone who is not familiar with the safety requirements 3 Store the to
14. Release the trigger if the power supply has been inter rupted e When working near electrical conductors always as sume that all conductors are energized and that insula tion clothing and hoses can conduct electricity Use hose labeled and certified as non conductive To avoid personal injury or equipment damage all tool repair maintenance and service must only be performed by authorized and properly trained personnel Warning Use of this tool on certain materials during demolition could generate dust potentially containing a variety of hazardous substances such as asbestos silica or lead Inhalation of dust containing these or other hazardous substances could result in serious injury cancer or death Protect yourself and those around you Research and understand the materials you are cut ting Follow correct safety procedures and comply with all applicable national state or provisional health and safety regulations relating to them including if appropri ate arranging for the safe disposal of the materials by a qualified person CO25 User Manual 4 5 SAFETY PRECAUTIONS Never carry the tool or put it down while the wheel is rotating Make sure it is completely stopped before moving your position or set the tool down Do not operate the tool with the wheel guard removed Keep the handles dry clean and free of oil at all times Operate the tool in well ventilated areas only Do not operate the tool if the
15. S 1 DO NOT USE DAMAGED WHEELS 2 USE FULL TROTTLE ONLY WHILE CUTTING 3 USE ONLY WHEELS MARKED HIGH SPEED REINFORCED THAT MEET REQUIREMENTS OF ANSI B7 1 B7 5 WHEELS SHOULD BE NO LARGER THAN 14 DIA X 5 32 THICK WITH A 1 ARBOR HOLE amp RATED FOR 5300 RPM MINIMUM SPEED 4 INSPECT WHEEL GUARD amp COLLARS FOR DAMAGE AFTER ANY WHEEL BREAKAGE ON THE MACHINE 5 MAXIMUM SPINDLE SPEED IS 5300 RPM 6 READ OPERATION MANUAL 05868 SAFETY LABEL NOTE THE INFORMATION LISTED ON THE STICKERS SHOWN MUST BE LEGIBLE AT ALL TIMES REPLACE DECALS IF THEY BECOME WORN OR DAMAGED REPLACEMENTS ARE AVAILABLE FROM YOUR LOCAL STANLEY DISTRIBUTOR 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 INFORMATION PLAQUE 3810 SE Naef Road Milwaukie OR 97267 05153 ADDRESS DECAL CE MODELS ONLY 92539 SOUND POWER DECAL CE MODELS ONLY 28886 COMPOSITE DECAL CE MODELS ONLY DANGER DANGER IMPORTANT 1 2 FAILURE TO USE HYDRAULIC HOSE LABELED AND CER TIFIED AS NON CONDUCTIVE WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRICAL LINES MAY RESULT IN DEATH OR SERIOUS INJURY BEFORE USING HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE ON OR NEAR ELECTRIC LINES BE SURE THE HOSE IS MAINTAINED AS NON CONDUCTI
16. S INJURY OR DEATH COULD RESULT FROM THE IMPROPER REPAIR OR SERVICE OF THIS TOOL REPAIRS AND OR SERVICE TO THIS TOOL MUST ONLY BE DONE BY AN AUTHORIZED AND CERTIFIED DEALER For the nearest authorized and certified dealer call Stanley Hydraulic Tools at the number listed on the back of this manual and ask for a Customer Service Representative STANLEY CO25 User Manual 4 3 SAFETY SYMBOLS Safety symbols and signal words as shown below are used to emphasize all operator maintenance and repair ac tions which if not strictly followed could result in a life threatening situation bodily injury or damage to equipment This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death This safety alert and signal word indicate an imminently hazardous situation A DANGER which if not avoided will result in death or serious injury This safety alert and signal word indicate a potentially hazardous situation which if not avoided could result in death or serious injury This safety alert and signal word indicate a potentially hazardous situation which if not avoided could result in death or serious injury This signal word indicates a potentially hazardous situation which if not avoid ed may result in property damage This signal word indicates a situation which if not avoided will result in damage to the
17. TION PERIODIC MAINTENANCE For maximum performance and reliability of the tool peri odically check the following components THRUST COLLAR AND INSIDE OUTSIDE COLLAR INSPECTION Periodically inspect the thrust collar for damage when you remove the cut off wheel refer to Cutoff Wheel Replace ment 1 Remove the key and thrust collar from the motor shaft 2 Check the thrust collar for burrs Remove burrs as re quired 3 Check the threads on the clamping setscrew 4 Inspect the collar bores and flanges 5 Check for burrs Remove burrs as required 6 Check that the bearing surfaces are flat and run true when mounted on the motor shaft and thrust collar DRIVE SHAFT SPEED CHECK Check the speed of the motor output shaft at least every 100 hours of operation The test should be performed only by a trained experienced technician Maintain a record of the speed checks The maximum rated speed of the CO25 Hydraulic Cutoff Saw is 4500 rpm The rated speed of the cutting wheel must be equal to or greater than that of the tool to ensure the integrity of the wheel at maximum tool speed Use the hydraulic power supply normally used with the cutoff saw when conducting this test Excessive speed may be caused by excessive hydraulic fluid flow to the tool BEARING CHECK Periodically inspect the bearings and associated parts for proper operation A worn or damaged bearing can cause motor damage STA
18. VE THE HOSE SHOULD BE REGULARLY TESTED FOR ELECTRIC CUR RENT LEAKAGE IN ACCORDANCE WITH YOUR SAFETY DEPARTMENT INSTRUCTIONS A HYDRAULIC LEAK OR BURST MAY CAUSE OIL INJEC TION INTO THE BODY OR CAUSE OTHER SEVERE PERSONAL INJURY DO NOT EXCEED SPECIFIED FLOW AND PRESSURE FOR THIS TOOL EXCESS FLOW OR PRESSURE MAY CAUSE A LEAK OR BURST DO NOT EXCEED RATED WORKING PRESSURE OF HYDRAULIC HOSE USED WITH THIS TOOL EXCESS PRESSURE MAY CAUSE ALEAK OR BURST CHECK TOOL HOSE COUPLERS AND CONNECTORS DAILY FOR LEAKS DO NOT FEEL FOR LEAKS WITH YOUR HANDS CONTACT WITH A LEAK MAY RESULT IN SEVERE PERSONAL INJURY 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 OPERATION 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 MAKE SURE HYDRAULIC HOSES ARE PROPERLY CON NECTED TO THE TOOL BEFORE PRESSURING SYSTEM SYSTEM PRESSURE HOSE MUST ALWAYS BE CON NECTED TO TOOL IN PORT SYSTEM RETURN HOSE MUST ALWAYS BE CONNECTED TO TOOL OUT PORT REVERSING CONNECTIONS MAY CAUSE REVERSE TOOL OPERATION WHICH CAN RESULT IN SEVERE PERSONAL INJURY DO NOT CONNECT OPEN CENTER TOOLS TO CLOSED CENTER HYDRAULIC SYSTEMS THIS MAY RESULT IN LOSS OF OTHER HYDRAULIC FUNCTIONS POWERED BY THE SAME SYSTEM AND OR SEVERE PERSONAL
19. d or under the supervision of an instructor Establish a training pro gram for all operators to ensure safe operation Always wear safety equipment such as goggles ear breathing and head protection and safety shoes at all times when operating the tool Use gloves and aprons when necessary The operator must be familiar with all prohibited work areas such as excessive slopes and dangerous terrain conditions Maintain proper footing and balance at all times Alway hold the tool with both hands when the unit is running Use a firm grip Do not inspect or clean the tool while the hydraulic power source is connected Accidental engagement of the tool can cause serious injury Always connect hoses to the tool hose couplers before energizing the hydraulic power source Be sure all hose connections are tight and are in good condition Do not operate the tool at oil temperatures above 140 F 60 C Operation at higher temperatures can cause higher than normal temperatures at the tool which can result in operator discomfort STANLEY Do not operate a damaged improperly adjusted or incompletely assembled tools Never wear loose clothing that can get entangled in the working parts of the tool Keep all parts of your body away from the rotating parts Long hair or loose clothing can become drawn into rotating components Always use accessories that conform to the specifica tions given in this manual
20. essa sen dabee SR TAS VR C ARA CaKE 4 9 m sec 6 47072 iq L AR i tenn EE EE 0 14 m sec Values determined according to ISO 19432 2012 ISO 5349 1 2 rrrnnnnnrnnnnnvnnnnnnnnnnnvnnnnnrnnnnsrnnnnnnnnnnnrnnnsnrnnnenrnnnnnrnnsnsnnnnnennnnennnre STANLEY CO25 User Manual lt 17 lt O lt x v gt op lt an L 9084 uo s lioss 55vV 996 JIM uoisu9 x3 S PUEH SEG 104 18 CO25 User Manual Pass O QO CO NN aa N a NM c NN BJ BR PO OO BN A Aa Jam Nut CCW Jame Nut CW Outer Collar Inside Collar Set Screw Thrust Collar Retaining Ring Roll Pin Stanley Sticker USA Models Only Caution Sticker USA Models Only Helicoil Handle Strut Capscrew Capscrew Handle Bar Retainer O ring Oil Tube Spring Pin Valve Spool CCW Models Only Valve Spool CW Models Only O ring Valve Cap Quad Ring Pipe Plug Flow Control Capscrew Spacer Trigger Safety Catch Torsion Spring Valve Handle Assy Incld Item 22 Hose Assy Incld Item 34 Roll Pin Hose Clip Caution Sticker USA Models Only Circuit D Sticker CE Models Only O ring Incld with Item 30 Poppet Compression Spring NO ITEM Plug Handle Bar Motor Housing Swing Over Nut 03048 01594 03047 05071 32445 03025 32436 33084 33083 32047 32872 00170 30333 350771 00214 00120 31849
21. hat the flow is in the proper directions The female couple on the tools IN port is the inlet pressure coupler Note If the uncoupled hoses are left in the sun pressure increase within the hoses can make them difficult to connect Whenever possible connect the free ends of hoses together TOOL OPERATION STARTUP 1 Move the hydraulic system control valve to the ON position 2 At the beginning of each shift or after a new wheel is installed run the cut off saw at operating speed for at least one minute before starting work HANDHELD CONFIGURATION 1 Press the safety catch into the handle then slowly squeeze the trigger 2 Run the saw at least one minute 3 Release the trigger and safety catch MOUNTED CONFIGURATION SAW CART 1 Make sure the lower edge of the cutoff wheel is at least 1 inch above the work surface 2 Slowly squeeze the hand control lever 3 Run the saw at least one minute then release the control lever CO25 User Manual lt 11 OPERATION If excessive vibration or any other defect is detected stop the tool immediately and determine the cause Do not use the tool until the problem is corrected GENERAL OPERATION HANDHELD CONFIGURATION 1 Whenever possible clamp or hold down the work and support it securely on both sides of the cut 2 Press the safety catch into the handle then slowly squeeze the trigger 3 Start the cut with the wheel rotating Start the wo
22. ially explosive envi ronment Do not grind on vessels containing combustible substances Any use of this tool outside those stated in this manual are forbidden TOOL STICKERS amp TAGS 30 LPM 138 BAR EHTMA CATEGORY 11207 CIRCUIT TYPE D DECAL CE MODELS ONLY CAUTION STANLEY Stanley Hydraulic tools Division of the Stanley Works 3810 SE Naef Road Milwaukie OR 97267 05152 ADDRESS DECAL CUTS Stanley Hydraulic Tools 3810 SE Naef Rd Milwaukie Oregon 97267 U S A Model No 9s C 28322 CE DECAL CE MODELS ONLY 33206 CO25 NAME TAG T4 GPM 26 34 LPM DO NOT EXCEED 2000 PSI 140 BAR H DO NOT EXCEED SPECIFIED FLOW OR PRESSURE Ix FINDLE USE CLOSED CENTER TOOL ON CLOSED CENTER SYSTEM USE OPEN CENTER TOOL ON OPEN CENTER BP SYSTEM CORRECTLY CONNECT HOSES TO TOOL IN AND OUT PORTS IMPROPER HANDLING USE OR OTHER FL MAINTENANCE OF TOOL COULD RESULT IN A LEAK BURST OR OTHER TOOL FAILURE CONTACT AT A LEAK OR BURST CAN CAUSE OIL INJECTION INTO THE BODY FAILURE TO OBSERVE THESE PRECAUTIONS CAN RESULT IN SERSOUS BAI PSI LPM IGPM Stanley Hydraulic tools Division of the Stanley Works PERSONAL INJURY 03786 GPM DECAL 28811 CAUTION PROTECT YOUR EYES TH WEAR SAFETY GOGGLE
23. ic braided not certified or labeled non conductive constructed of thermoplastic or synthetic rubber in ner tube synthetic fiber braid reinforcement and weather resistant thermoplastic or synthetic rubber cover This hose is not certified non conductive and must never be used near electrical conductors HOSE SAFETY TAGS To help ensure your safety the following DANGER tags are attached to all hose purchased from Stanley Hydraulic Tools DO NOT REMOVE THESE TAGS If the information on a tag is illegible because of wear or damage replace the tag immediately A new tag may be obtained from your Stanley Distributor THE TAG SHOWN BELOW IS ATTACHED TO CERTIFIED NON CONDUCTIVE HOSE DANGER DANGER FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE IMPROPER USE WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRIC LINES MAY RESULT IN OR HANDLING OF HOSE COULD RESULT IN BURST OR OTHER HOSE FAILURE DEATH OR SERIOUS INJURY KEEP HOSE AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT CONTACT DURING USE CONTACT AT THE BURST CAN CAUSE BODILY INJECTION AND SEVERE PERSONAL INJURY ELECTRIC LINES HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING ABRASION CUTTING OR CONTACT WITH HIGH TEMPERATURE SURFACES DO NOT USE IF KINKED DO NOT BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE USE HOSE TO PULL OR LIFT TOOLS POWER UNITS ETC ON OR NEAR EL
24. ichtlinie Standards Nr Prufung durch Directives Normes Numero Organisme agr Directriz Los Normas No Aprobado Direttiva Norme n Collaudato ISO 3744 2010 ISO 20643 A1 2012 Machinery Directive 2006 42 EC 2006 ISO 19432 2012 ISO 11148 7 2012 5 Special Provisions None Spezielle Bestimmungen Dispositions particuli res Provisiones especiales Disposizioni speciali 6 Representative in the Union Patrick Vervier Stanley Dubuis 17 19 rue Jules Berthonneau BP 3406 41034 Blois Cedex France Vertreter in der Union Repr sentant dans l union Representante en la Union Rappresentante presso l Unione Done at Ort Fait Dado en Fatto a Stanley Hydraulic Tools Milwaukie Oregon USA Date Datum le Fecha Data 8 10 2013 Signature Unterschrift Signature Firma Firma n Position Position Fonction Cargo Posizione Engineering Manager 2 CO25 User Manual STANLEY TABLE OF CONTENTS GERE TE OF CONE ORBIT eS EEES 2 ES MI ee ee 4 EN RENN 5 OO RER EN UE e T HDR ULIC ROSE 8 gie PE I E ee ee eee eee ener ee ere 9 STL TEI FR Nero 10 RERO E E 11 TION PROCEDURE ee 11 eer E 11 TOOL OPBISSTE ane eee 11 ARTUR
25. ing wheel in stalled thoroughly examine the cutting wheel before use Make sure the cutting wheel is correctly mounted and tightened before use Operate the cut off saw at no load for 30 seconds in a safe position If considerable vibration or other defects are detected stop operation of the tool immediately and determine the cause Do not use the tool until the defect is corrected Only use cutting wheels that comply with ANSI B7 5 ISO 525 603 Check that the maximum operating speed of the cutting wheel is equal to or greater than the rated shaft speed of the cut off saw Wheels must be rated at 4700 rpm minimum Warning Hydraulic fluid under pressure could cause skin injection injury If you are injured by hydraulic fluid get medical attention immediately Always support and secure items being worked on e Caution when handling the work piece after cutting object can be hot and have sharp edges use your per sonal protection equipment Keep your work area clean and clear of tripping haz ards oily surfaces and hoses laying about can be haz ardous Make sure adequate lighting is always available 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 underground utilities may present other hazards Do not operate this tool in a potent
26. inter to check the actual depth of the cutting blade 6 Move slowly and safely forward along the cutting line until the desired cut is complete The safe forward rate depends on your blade type 7 Release the hand control lever 8 To raise the blade from of the cutting surface wait until the blade comes to a complete stop in the work material Turn the depth control crank clockwise CW until the blade clears the surface WET CUTTING 1 Make sure the cutting wheel is suitable for wet cutting 2 When shutting down a wet cutting operation a Stop the tool b Shut off the water Restart the tool and allow the wheel to spin off the excess water BROKEN CUT OFF WHEELS Cut off wheels designed for use with portable saws are extremely tough When used as directed they are difficult to break during normal use If a wheel breaks while operating the cut off saw investi gate the cause of the failure and correct the problem as soon as possible If you cannot determine the cause of failure contact the wheel manufacturer SHUTDOWN 1 Move the hydraulic system control valve to the OFF position 2 Disconnect the hydraulic hoses from the tool first the input supply hose then the output return hose 3 Place dust plugs in the hose ends couplers or tool ports as applicable 4 Wipe the tool thoroughly with a clean dry cloth 5 Clean any foreign matter from the cut off wheel surfaces STANLEY OPERA
27. ol in a clean dry place CO25 User Manual 4 13 OPERATION CUTOFF WHEEL REPLACEMENT 1 Move the hydraulic system control valve to the Off posi tion 2 Disconnect the hydraulic hoses from the tool first the input Supply hose then the output return hose 3 Install the inside collar and blotter rotate the collar to align the slot in the collar with the pin on the thrust collar 4 The maximum rated speed of the hydraulic cutoff saw is 4500 rpm Never install a cutoff wheel that is not rated equal to or greater than that of the tool to ensure the integ rity of the wheel at the maximum tool speed 5 Prior to installing the wheel inspect it for chips cracks or other damage and replace if damaged 6 Install the outside blotter and collar rotate the collar so that the flat on the motor shaft aligns with the flat on the outside collar 7 Install the wheel nut using a wrench while gripping the cutoff wheel Tighten securely COLD WEATHER OPERATION Before using the tool in cold weather preheat the hydraulic fluid with the power unit operating at a low speed The oil should be at or above 50 F 10 C with a viscosity of 400 SSU 82 cs before operating the tool 14 CO25 User Manual TOOL PROTECTION amp CARE NOTICE In addition to the Safety Precautions found in this manual observe the following for equipment protection and care Make sure all couplers are wiped clean before connection The hyd
28. ower source is supplying the correct hydraulic flow and pressure to the tool as listed in the following table Use a flow meter known to be accurate Check the flow with the hydraulic fluid temperature at least 80 F 27 C PROBLEM CAUSE SOLUTION Hydraulic ontrol valve OFF Turn the hydraulic system control valve ON Hydraulic hoses not connected prop Make sure the hoses are connected erly and the couplers are tight Tool does not operate Hydraulic system not functioning Check power unit for correct flow and presssure Couplers or hoses blocked Remove obstruction Mechanical failure Disassemble tool and inspect for dam age Hoses connected to wrong ports on Connect input supply line to IN port Tool operates in reverse tool and connect output return line to OUT port Oil leakage between motor housing Oil tube o ring failure Replace o ring and ON OFF vlave block or motor Motor face seal failure Replace seal Hoses connected to wrong ports on Connect input supply line to IN port tool and connect output return line to OUT port Excessive back pressure If back pressure is greater than 250 psi 17 bar correct the return line ob struction or restriction Wrong cut off wheel for work material Use correct wheel Saw cuts too slowly Insufficient oil flow a TON to 7 9 gpm 26 34 Ipm Relief valve setting too low Adjust relief valve to 2100 2250 psi 145 155 bar Trigger difficult to operate
29. psi 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 RR 9 10 5 gpm 34 40 lpm 1500 psi 103 bar 2200 2300 psi 152 159 bar 250 psi 17 bar 400 ssu 82 centistokes 140 F 60 C 6 hp 5 22 kW 40 F 22 C TYPE Ill 11 13 gpm 42 49 lpm 1500 psi 103 bar 2100 2250 psi 145 155 bar 250 psi 17 bar 400 ssu 82 centistokes 140 F 60 C 7 hp 4 47 kW 40 F 22 C Do not operate the tool at oil temperatures above 140 F 60 C Operation at higher temperatures can cause operator discomfort at the tool Filter Min full flow filtration Sized for flow of at least For cold temp startup and max dirt holding capacity Hydraulic fluid Petroleum based premium grade anti wear non conductive Viscosity at min and max operating temps NOTE 25 microns 30 gpm 114 lpm 100 400 ssu 25 microns 30 gpm 114 lpm 100 400 ssu 20 82 centistokes 25 microns 30 gpm 114 lpm 100 400 ssu 25 microns 30 gpm 114 lpm 100 400 ssu When choosing hydraulic fluid the expected oil 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 EHTM
30. raulic 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 in this manual for correct flow rate and model number Personal Injury and 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 recommended relief valves are installed in the pressure side of the system Do not use the tool for applications for which it was not intended STANLEY CO25 User Manual 4 15 TROUBLESHOOTING If symptoms of poor performance develop the following chart can be used as a guide to correct the problem When diag nosing faults in operation of the wrench always check that the hydraulic p
31. rk gently with consistent pressure Do not bump the saw into the workpiece 4 Feed the wheel through the material as fast as possible without slowing the wheel rotation speed Cutting through the material too slowly causes heat expan sion and can result in wheel pinching in the material This is one of the most common causes or wheel breakage MOUNTED CONFIGURATION SAW CART When the cutoff saw is mounted on a saw cart always use a motor type hydraulic system control valve to turn the saw ON and OFF All ports must be connected to the tank hydraulic system reservoir when the control valve is in neutral Alternatively use a direct line from the tool outlet to the tank IMPORTANT Keep all four wheels of the cart on the cutting surface at all times Do not tip the front of the cart up during operation or while the blade is in motion 1 Align the cut line indicator on the line to be cut 2 Lower the blade to approximately 1 2 to 1 inch above the cutting surface Set the depth gauge to ensure accurate cutting depth 3 Make sure the water hose and its connections are se cure and there is a steady flow of coolant water 4 Slowly squeeze the hand control lever 5 Slowly and safely lower the rotating blade into the cutting surface to the desired depth Increase the depth by turning the depth control crank coun terclockwise CCW 12 CO25 User Manual Periodically look at the depth gauge and po
32. talled for the job If not follow the instructions for Cut off Wheel Replacement section of this manual 2 Inspect the wheel for chips cracks or other damage For maximum tool performance replace the wheel if it is worn or defective 3 Inspect the wheel guard for cracks or other structural damage 4 There should be no signs of leaks 5 Inspect the handlebar Make sure the handlebar is se curely fastened to the cutoff saw and is clean of any oil to ensure a firm grip IMPORTANT Check the speed of the motor output shaft after every 100 hours of operation CHECK TRIGGER MECHANISM 1 Inspect the trigger and safety catch Make sure the trig ger operates smoothly and is free to travel between the ON and OFF positions 2 Make sure the trigger is set to disengage the cut off saw when released STANLEY 3 Check that the safety catch on the handle assembly is operating properly It should prevent engagement of the trigger unless the catch is pressed down fully in the handle slot CONNECT HOSES 1 Wipe all hose couplers with a clean lint free cloth before making connections 2 Connect hoses from the hydraulic power source to the tool fittings or quick disconnects It is good practice to con nect the return hose first and disconnect it last to minimize or eliminate trapped pressure within the wrench 3 Observe the flow indicators stamped on the valve handle assembly and the hose couplers to ensure t
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