WS10 User Manual 2-2015 V13
Contents
1. kun cdi 0156 14 PARTS IEDUSTRATION WS10921 2 22xxi2 412 55 7122016xk 10304646X56 0286331434E260a5sy82488pa83ugbcs2axedasfaotssa y6e25 a3A905 58 da 15 PARIS LIST WS TOZZI e rette aan 16 PARTS ILLUSTRATIONMWS10220 rre ea ec er tenete tree end eret a dinne 17 PARTS LIST WS10220 citt tote there oe atus drenere 18 IMPORTANT To fill out a Product Warranty Validation form and for information on your warranty visit Stanleyhydraulics com and select the Company tab Warranty NOTE The warranty Validation record must be submitted to validate the warranty SERVICING This manual contains safety operation and routine maintenance instructions Stanley Hydraulic Tools recommends that servicing of hydraulic tools other than routine maintenance must be performed by an authorized and certified dealer Please read the following warning SERIOUS INJURY OR DEATH COULD RESULT FROM THE IMPROPER REPAIR OR SERVICE OF THIS TOOL REPAIRS AND OR SERVICE TO THIS TOOL MUST ONLY BE DONE BY AN AUTHORIZED AND CERTIFIED DEALER For the nearest authorized and certified dealer call Stanley Hydraulic Tools at the number listed on the back of this manual and ask for a Customer Service Representative STAN LEY WS10 User Manual 4 3 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 a2. SEE OTHER SIDE SAFETY TAG P N 15875 Shown smaller then actual size STANLEY 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 Fabric braided not certified or labeled non conductive constructed of thermoplastic or synthetic rubber in ner tube synthetic fiber braid reinforcement and weather resistant thermoplastic or synthetic rubber cover This hose is not certified non conductive and must never be used near electrical conductors HOSE SAFETY TAGS To help ensure your safety the following DANGER tags are attached to all hose purchased from Stanley Hydraulic Tools DO NOT REMOVE THESE TAGS If the information on a tag is illegible because of wear or damage replace the tag immediately A new
3. Approved body Richtlinie Standards Nr Prufung durch Directives Normes Num ro Organisme agr Directriz Los Normas No Aprobado Direttiva Norme n Collaudato Machinery Directive 2006 42 EC 2006 Self EN ISO 12100 2010 Self 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 a Dado en Fatto a Stanley Hydraulic Tools Milwaukie Oregon USA Date Datum le Fecha Data 1 10 11 Signature Unterschrift Signature Firma Firma R R Position Position Fonction Cargo Posizione Director of Product Development 2 gt WS10 User Manual STAN LEY DECLARATION OF CONFORMI TY 2 SAFETY SYMBOLS uns 4 SAFETY PRECAUTIONS itte dinside 5 TOOL STICKERS cc 6 TOOLHOSE INFORMATION LLL 7 RECOMMENDATIONS si x c tte ttr naar 8 HATMA REQUIREMENTS EUM 9 eiue 10 EQUIPMENT PROTECTION amp CARE ettet beati a a sages e EE 12 TROUBLESHOOTING dnte re ete t h 13 SPECIFICATIONS Hu 32 ee reagieren 14 ACCESSORIES canori oinaan
4. Manual lt 7 Ovl SIHL dAOW3H LON OG lt 2 T H w gt o o a Suonoeuuo ssoH leold AL 4 lt lt lt MO 13 NYNLIY RETURN gt gt gt STANLEY HYDRAULIC CIRCUIT PRESSURE JYNSSAYd H8 PRESSURE SLL 0092 y 08 8 00 92 09 67 9I L SLL 0092 eJnsseJg 6L vie SLL 0092 unay 6L vie 8 ol dn gz ol dn 09 67 9I EL GLI 0092 ensseJd 9L 8 9 119 IVS Aq 195 se suoneoyroeds E 0062 mn i p x Jo JSNUI 2Ijne1p u 09 08 002 001 I 0L SLL 0052 sjJnssejd 6L vIe Bunes ollneJpAU 0062 uno 6L VIE mm mp jenbe eunsseJd Burgo E 0082 B gie p e 15291 Je JSNUI SSOY oineJp u SLL 0092 9L 8 9 GL ol dn 09 0 dn e o suoneoidde Jedlo Aue 1o pesn ag jou plnous SZ 0052 umey 6L vic pue s ueweuinbes 6
5. bar 103 bar 103 bar System relief valve setting 2100 2250 psi 2100 2250 psi 2200 2300 psi 2100 2250 psi at the power supply outlet 145 155 bar 145 155 bar 152 159 bar 145 155 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 Sufficient heat rejection 140 F 140 F 140 F 140 F capacity to limit max fluid temperature to 60 C 60 C 60 C 60 C at max expected ambient temperature Min cooling capacity at a temperature 3 hp 5 hp 6 hp 7 hp difference of between ambient and fluid 2 24 kW 3 73 kW 5 22 kW 4 47 kW temps 40 F 40 F 40 F 40 F NOTE 22 C 22 C 22 C 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 25 microns 25 microns 25 microns 25 microns Min full flow filtration 30 gpm 30 gpm 30 gpm 30 gpm ___ m dirt holding capacity Hydraulic fluid Petroleum based 100 400 ssu 100 400 ssu 100 400 ssu 100 400 ssu premium grade anti wear non conductive 20 82 centistokes Viscosity at min and max operating temps NOTE When choosing hydraulic fluid the expected oil temperature extrem
6. exceed the rated flow see Specifications 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 person nel only Make certain that the recommended relief valves are in stalled in the pressure side of the system Do not use the tool for applications for which it was not intended STANLEY If symptoms of poor performance develop the following chart can be used as a guide to correct the problem When diagnosing problems with operation of the weld shear always check that the hydraulic power source is sup plying the correct hydraulic flow and pressure to the tool as listed in the specifications Use a flow meter known to be accurate Check the flow with the hydraulic oil temperature at least 80 F 27 C SYMPTOM CAUSE SOLUTION HYDRAULIC POWER SOURCE NOT POWER UNIT MODELS CHECK POWER FUNCTIONING SOURCE FOR PROPER FLOW AND PRESSURE 3 10 GPM 11 38 LPM AT 2000 PSI 140 BAR POWER UNIT MODELS COUPLERS OR HOSES LOCATE AND REMOVE RESTRICTION BLOCKED WELD SHEAR DOES NOT OPERATE POWER UNIT MODELS HYDRAULIC LINES CONNECT LINES NOT CONNECTED HAND PUMP MODELS HYDRAULIC PUMP LOCATE AND REMOVE RESTRICTION FAILURE CYLINDER SEAL FAILURE HAVE INSPECTED AND REPAIRED AT AN AUTHORIZED STANLEY SERVICE CENTER STAN LEY WS10 User Manual lt 1
7. tag may be obtained from your Stanley Distributor THE TAG SHOWN BELOW IS ATTACHED TO CERTIFIED NON CONDUCTIVE HOSE DANGER DANGER 1 FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE IMPROPER USE WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRIC LINES MAY RESULT IN OR HANDLING OF HOSE COULD RESULT IN BURST OR OTHER HOSE FAILURE 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 ELECTRIC LINES WIPE THE ENTIRE LENGTH OF THE HOSE AND FIT CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAM TING WITH A CLEAN DRY ABSORBENT CLOTH TO REMOVE DIRT AND MOISTURE AND TEST HOSE FOR MAXIMUM ALLOWABLE CURRENT LEAKAGE IN ACCORDANCE WITH AGE TO COUPLINGS IF ANY OF THESE CONDIHONSJENIST REPLACE THE HOSE IMMEDIATELY NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE SAFETY DEPARTMENT INSTRUCTIONS AFTER EACH USE STORE IN A CLEAN DRY AREA FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROP ERLY TRAINED IN CORRECT PR
8. tags attached to the tool and hose These safety precautions are given for your safety Re view them carefully before operating the tool and before performing general maintenance or repairs Supervising personnel should develop additional pre cautions relating to the specific work area and local safety regulations If so place the added precautions in the space provided in this manual The model WS10 Hydraulic Weld Shear will provide safe and dependable service if operated in accordance with the instructions given in this manual Read and un derstand this manual and any stickers and tags attached to the pressure washer and hose before operation Fail ure 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 trained or under the supervision of an instructor Establish a train ing program for all operators to ensure safe operation Always wear safety equipment such as goggles ear and head protection and safety shoes at all times when operating the tool The operator must be familiar with all prohibited work areas Such as excessive slopes and dangerous terrain conditions Do not inspect clean or replace the sher baldes while the hydraulic power source is connected Do not inspect or clean the tool while the hydraulic power source is con nected Accidental
9. 3 WS10 LIGHTWEIGHT MODELS CI 20 000 Ib 89 000 N Pressure RANGE de 2000 psi 140 bar Maximum Back Pressure esr e ng agere aa ne Eo aT URN RR RA a e T A a 250 psi 17 bar detis 3 10 gpm 11 38 Ipm Porting power unit mOC c3 1121211111111 110 111 TH kg KH HT KT KT kh 8 SAE O ring Couplers power unit model only HTMA Flush Face Type Male amp Female Hose WIPS EPA No Hand Pump Model Yes Weight hand OO 102 Ib 46 2 power Unit model 90 Ib 41 kg Overall Length hand pump Modelers 34 5 inches 87 6 cm power unit model na 28 inches 71 cm Overall Width hand pump amp power unit models pp 19 5 inches 49 5 cm Overall Height hand pump model without pump handle sse 12 inches 30 4 cm power unit model nocti eter ta eir ecce n seed 14 inches 35 5 cm Maximum Fluid Temperature pp 140 F 60 C Sound Pressure Level e M Less Than 70 dBA 1 meter Vibration Level c Less Than 2 5m sec2 m R 6 in 15 2 cm ACCESSORIES Part Shear Blade Set 105 155 Ib yd 47 70 kg m Rail 27948 Shear Blade Set B 60 130 Ib yd 41 60 kg m 27989 Rail Ty
10. K MAY RESULT IN SEVERE PERSONAL INJURY 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 INJURY 5 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 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
11. OCEDURES REQUIRED FOR WORK ON OR AROUND DO NOT REMOVE THIS TAG OVL SIHL JAOW3H LON OG SEE OTHER SIDE SEE OTHER SIDE SIDE 1 SIDE 2 Shown smaller than actual size THE TAG SHOWN BELOW IS ATTACHED TO CONDUCTIVE HOSE DANGER DANGER DO NOT USE THIS HYDRAULIC HOSE ON OR NEAR ELECTRIC LINES THIS HOSE IS 5 CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAMAGE 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 6 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 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 SEE OTHER SIDE SEE OTHER SIDE o SIDE 1 SIDE 2 Shown smaller than actual size STAN LEY WS10 User
12. Sheet Metal Screw 45 Degree Elbow Cylinder 67996 68291 68296 68297 68306 68307 68309 68311 68316 69809 69810 69904 372037 02504 Frame Weldment Slide Weldment Bottom Cover N OOA Top Cover Tube Assembly Long 45 Tube Assembly Shoulder Screw Roller Valve Block Valve Cap Serial Number Plate Cap Screw 1 2 13 x 1 1 2 Pinch Point Warning Sticker O Ring Steel Ball Bearing Race Bearing SEAL KIT P N 73166 Washer 3 4 ID Cap Screw 1 2 13 UNC x 1 1 4 Grommet Shaft Rod Torsion Spring A a a NNa NN SHEAR BLADES Shear Blade Set A 105 155 Ib yd 47 70 kg m Rail P N 27948 Shear Blade Set B S 60 130 Ib yd 41 60 kg m Rail P N 27989 Spring Washer Rail Type amp Size Determins The Correct Blade Size Housing Rotor Assy Railroad Help Desk Sticker Plug Hex Jam Nut 3 4 16UNF Hex Nut 3 4 10UNC Bearing 10FDU12 Not Pictured part of valve block assy GPM Sticker NO Hammer Sticker Roller Adjustment Sticker Roller Pivot Handle Assembly Elbow 1 1 2 3 4 2 1 1 1 8 1 4 1 2 2 1 1 2 1 6 4 3 1 1 1 1 9 1 1 1 1 8 4 4 2 1 2 2 4 4 4 1 1 gt WS1022001A WS102200A x Li m BA 48 33 STAN LEY WS10 User Manual lt 17 PART NO QTY DESCRIPTION PART NO Q
13. TY DESCRIPTION gt gt A A NNa ao Oa WFD NN A Na A Hose Assy O Ring Cap Screw 5 16 18 4 x 3 8 Drive Screw O Ring Ball Knob O Ring LockWasher 1 2 ID CE Sticker Roll Pin 1 4 OD Roll Pin 3 16 OD Stanley Logo Crushing Hazard Sticker CE O Ring Steel Ball Bearing Race Bearing Washer 3 4 ID Cap Screw 1 2 13 UNC x 1 1 4 Grommet Shaft Rod Setscrew Spring Washer Housing Rotor Assy Railroad Help Desk Sticker Plug Hex Jam Nut 3 4 16UNF Hex Nut 3 4 10UNC Bearing 10FDU12 Not Pictured part of valve block assy Spring NO Hammer Sticker Roller Adjustment Sticker Roller Pivot Handle Assembly Elbow Tee Port Plug Shear Blade Set A or B See Accesso ries page or this page Sheet Metal Screw 45 Degree Elbow Cylinder For Weld Shear Hold Down Kit See Page 14 18 gt WS10 User Manual 70792 68297 68306 68307 68309 68311 68316 69809 69810 69904 372037 31049 00283 28788 12100 26073 08104 01212 26074 23002 05043 25915 70745 04858 26069 25916 01411 25901 24289 01411 26071 370508 56521 52832 52831 25292 26005 1 1 1 2 2 4 4 1 1 1 1 2 1 3 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 4 1 1 1 1 02504 SEAL KIT P N 73166 SHEAR BLADES Shear Blade Set A Frame Weldment Slide Weldment Bottom Cover Top Cover Tube Assembly Long 45 Tube Assembly S
14. WS10 HYDRAULIC WELD SHEAR USER MANUAL Safety Operation and Maintenance O 2014 Stanley Black amp Decker Inc New Britain CT 06053 U S A 28860 2 2015 Ver 13 DECLARATION OF CONFORMITY STA IN L EY UBEREINSTIMMUNGS ERKLARUNG DECLARATION DE CONFORMITE CEE Hydraulic Tools DECLARACION DE CONFORMIDAD DICHIARAZIONE DI CONFORMITA 1 the undersigned H 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 Weld Shear Hydraulic Kategorie Cat gorie Categoria Categoria 2 Make Marke Marque Marca Marca Stanley 3 Type Typ Type Tipo Tipo WS1032101A WS1022001A 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
15. ailroad Help Desk Sticker ST 17572 Pinch Point Warning Sticker 28322 CE Sticker 31049 Eye Protection Sticker 31064 Crushing Hazard Warning Sticker anley Hydraulic Tools Milwaukie Oregon U S A Naef Rd 372037 PUM Bode nan DANGER Serial Number Plate 28788 Manual Sticker TO MAINTAIN FREE MOVEMENT ADJUST THE STOP NUTS FOR 1 8 CLEARANCE BETWEEN THE ROLLERS AND THE UNDERSIDE OF THE RAIL 35295 Roller Adjustment Sticker DANGER 1 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 CONDUCTIVE THE HOSE SHOULD BE REGULARLY TESTED FOR ELECTRIC CUR RENT LEAKAGE IN ACCORDANCE WITH YOUR SAFETY DEPARTMENT INSTRUCTIONS 2 AHYDRAULIC 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 ALEAK OR BURST DO NOT EXCEED RATED WORKING PRESSURE OF HYDRAULIC HOSE USED WITH THIS TOOL EXCESS PRESSURE MAY CAUSE A LEAK OR BURST CHECK TOOL HOSE COUPLERS AND CONNECTORS DAILY FOR LEAKS DO NOT FEEL FOR LEAKS WITH YOUR HANDS CONTACT WITH A LEA
16. engagement of the tool can cause serious injury STANLEY 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 Never wear loose clothing that can get entangled in the working parts of the tool To avoid personal injury or equipment damage all tool repair maintenance and service must only be performed by authorized and properly trained personnel 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 over heating Use only lint free cloths Never transport or carry the tool with the unit ener gized Keep all parts of your body away from the cylinders and shear blades Long hair or loose clothing can be come drawn into moving components Do not use a shear blade that is cracked chipped or otherwise damaged Always inspect shear blades for possible damage before installation or use Do not operate a damaged improperly adjusted or in completely assembled tool Do not exceed the rated limits of the tool or use the tool for applications be
17. es 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 EHTMA CLASSIFICATION HYDRAULIC SYSTEM Flow Range 3 5 4 3 gpm 4 7 5 8 gpm 7 1 8 7 gpm 9 5 11 6 gpm 11 8 14 5 gpm 13 5 16 5 Ipm 18 22 Ipm 27 33 Ipm 36 44 lpm 45 55 Ipm Nominal Operating Pressure 1870 psi 1500 psi 1500 psi 1500 psi 1500 psi at the power supply outlet 129 bar 103 bar 103 bar 103 bar 103 bar System relief valve setting 2495 psi 2000 psi 2000 psi 2000 psi 2000 psi at the power supply outlet 172 bar 138 bar 138 bar 138 bar 138 bar NOTE These are general hydraulic system requirements See tool specification page for tool specific requirements STAN LEY WS10 User Manual lt 9 PREPARATION FOR INITIAL USE On hand pump units replace the plastic shipping plug on top of the pump assembly with the breather vent No other special unpacking or assembly requirements are required on either unit prior to usage Each unit should be inspected to assure the unit was not damaged in shipping and does not contain packing debris CHECK HYDRAULIC POWER SOURCE POWER UNIT MODEL ONLY 1 Using a calibrated flowmeter and pressure gauge check that the hydraulic power source develops a flow of 4 10 gpm 15 38 lpm Do Not exceed 140 bar 2000 ps
18. houlder Screw Roller Valve Block Valve Cap Serial Number Plate Eye Protection Sticker CE Washer Manual Sticker CE Steel Ball Spring Hollow Hex Plug Pipe Plug Back up Ring O Ring Relief Valve Plunger Pump Block Hollow Hex Plug Piston Seal Plug O Ring Lever Plug O Ring Spring Capscrew Capscrew Reservoir Bladder Roll Pin Master Link Cap Screw 1 2 13 UNC x 1 1 2 105 155 Ib yd 47 70 kg m Rail P N 27948 Shear Blade Set B 60 130 Ib yd 41 60 kg m Rail P N 27989 Rail Type amp Size Determins The Correct Blade Size STANLEY STANLEY Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie Oregon 97267 5698 USA 503 659 5660 Fax 503 652 1780 www stanleyhydraulics com 28860 1 2014 Ver 10
19. i 2 Make certain the hydraulic power source is equipped with a relief valve set to open at 2200 2300 psi 151 158 bar 3 Make certain that the power source return pressure does not exceed 250 psi 17 bar 4 Check that the hydraulic circuit matches the tool for open center OC operation CHECK TOOL 1 Make sure all tool accessories are correctly in stalled Failure to install tool accessories properly can result in damage to the tool or personal injury There should be no signs of leaks The tool should be clean with all fittings and fasten ers tight CHECK CONTROL MECHANISM Hand Pump Models On hand pump models check that the directional control valve operates freely from the neutral position to the for ward position and then back to the neutral position and then to the rearward position In each position work the lever to assure movement of the cylinders is free of bind ing and that the hydraulics are performing as intended Power Unit Models On power unit models check that the directional control valve operates freely from the neutral position to the for ward position and then through the neutral and rearward positions CONNECT HOSES Power Unit Model Only 1 Wipe all hose couplers with a clean lint free cloth before making connections 2 Connect the hoses from the hydraulic power source 10 WS10 User Manual to the hose couplers on the weld shear It is a good practice to connect the return h
20. kly remove any excess weld material from the cutters to prevent overheating COLD WEATHER OPERATION If a power unit model weld shear is to be used during cold weather preheat the system hydraulic fluid at low engine speed Power unit models should use normally recommended fluids with fluid temperature at or above 50 F 10 C 400 ssu 82 centistokes before use Hand pump models may be warmed by placing them in a heated compartment STANLEY WS10 User Manual lt 11 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 con nection The hydraulic circuit control valve must be in the OFF position when coupling or uncoupling hydrau lic tools Failure to do so may result in damage to the quick couples and cause overheating of the hy draulic 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 cir cuit 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 mini mum working pressure rating of 2500 psi 172 bar 12 gt WS10 User Manual Do not
21. 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 NOTICE to the equipment This signal word indicates a situation which if not avoided may result in dam IMPORTANT age to the equipment Always observe safety symbols They are included for your safety and for the protection of the tool LOCAL SAFETY REGULATIONS Enter any local safety regulations here Keep these instructions in an area accessible to the operator and mainte nance personnel 4 WS10 User Manual STAN LEY Tool operators and maintenance personnel must always comply with the safety precautions given in this manual and on the stickers and
22. not correct do not use the weld shear and have it serviced by an authorized and certified dealer If the gap is correct retract the shear blade to its most rearward position by moving the control lever to the rearward position The shear blades should now be as far apart as the tool will permit 7 Remove the weld shear from the rail STANLEY CUTTING PROCEDURE 1 Proceed with the preparations for welding and put the molds and accessories in their place Pour the weld 3 As soon as permitted by the mold manufacturer s instructions remove the two side iron sheets of the mold The bottom plate does not need to be re moved 4 Remove any excess sand from the railhead to pre vent damage to the cutters 5 Place the weld shear on the rail so that it straddles the mold 6 Pivot the four roller pivots under the rail head by turning the handle assemblies 7 Start cutting at the correct time based on the mold manufacturer s instructions by moving the direction al control valve lever forward hand pump models require pumping of the lever 8 Cut to the end of the stroke and hold for approxi mately 1 to 2 seconds 9 Move the valve handle to the rearward position for opening the cutters hand pump models require pumping of the lever and retract the shear blade to its most rearward position 10 Pivot the four roller pivots away from the rail and remove the weld shear from the rail as soon as pos sible 11 Quic
23. ose first and discon nect it last to minimize or avoid trapped pressure within the cylinders 3 Observe flow indicators stamped on hose couplers to be sure that oil will flow in the proper direction The female coupler is the inlet coupler NOTE The pressure increase in uncoupled hoses left in the sun may result in making them difficult to connect When possible connect the free ends of operating hoses together OPERATING PROCEDURES POWER UNIT AND HAND PUMP MODELS CHECKING OPERATION AND PERFORMANCE 1 Observe all safety precautions 2 Remove any debris and burrs from the rail joint that will interfere with the weld shear cutters 3 Place the weld shear on the rail over the location to be welded 4 Adjust the height of the four roller pivots The pivots must once pivoted be placed under the rail head with a minimum of clearance to avoid any forcing during the forward movement of the cutters This adjustment is done with the 4 hex nuts 5 On the power unit model move the hydraulic circuit control valve to the ON position 6 On the Weld Shear move the directional con trol valve lever to the forward position so that the shear blade advances On hand pump versions the shear blade will not advance or retract without pumping the lever Check that the shear blade ad vances without binding With the cylinders fully ex tended there should be a gap of 1 32 1 16 inch be tween the two shear blades If this gap is
24. pe amp Size Determines The Correct Blade Size Seal kit For Models WS1022001A WS102200A WS10321A 51032101 73166 Seal Kit Older Models WS10100 WS10200 WS10301 WS1030101 WS1020001 28586 Weld Shear Hold Down c areas ee kk EXER Re Eee 73394 Kit consists of the following items found on page 17 Item 13 34 35 40 41 55 and 56 14 WS10 User Manual STAN LEY WS10321A WS1032101A WS10321AB amp WS10321AS O M gt b 4 33 CH STAN LEY WS10 User Manual 4 15 WS10321A WS1032101A WS10321AB amp WS10321AS PART NO DESCRIPTION 00285 Roll Pin 1 8 OD 00757 Roll Pin 1 8 OD 00936 Adapter 01362 O Ring 01758 Cap Screw 5 16 18 02004 4 x 3 8 Drive Screw 02177 O Ring 02633 Ball Knob 02901 O Ring 03061 LockWasher 1 2 ID 03972 Coupler Female Set 03971 03973 Coupler Male Set 03971 07492 Roll Pin 1 4 OD 07890 Roll Pin 3 16 OD 14090 Stanley Logo 17572 17924 20145 20761 20762 21318 22374 24231 24233 24291 24297 24300 24305 24313 24877 25610 25912 25995 26196 26247 28911 29188 35294 35295 67094 67107 67116 67117 67124 Flow Control Valve 1 Flow Gono vive WET0521AS ONLY 16 gt WS10 User Manual STAN LEY PART NO DESCRIPTION Shear Blade Set A or See Accesso ries page or this page
25. ulleJedo slool 06 0 00 001 0ty 6L S OL G H AaluelS uo peseq SLL 0092 eJnsseJg 9L 9 G MK oineJp u 1oJ eq pepuelul SI yeyo siu GZL 0092 9L 9 G 08 91 00L 19 0 6L 901 9 a SLL 0092 L el 91 ol dn 09 ol dn 0 6L 901 9 EEE a db 9 e qejdeooe e eunsseJd yoeq SLL 0092 L el 08 92 001 92 60 81 9y ainssaid aul daay papuayu SUON SLL 0092 OL 9 5 ol dn gz ol dn Z GL 9y epueuuooel 95941 Jed S1 SHOLOnQNOO 1V9I3 123713 YVAN ASN LON OQ pleJg Jeqi JO preJg 8JIM SAINPUOJ Jed suolle6 uo peseq sdl6uael SSL 0922 OL 9 ol dn OL ol dn y SL 6y SSOY SNOMEA 29504 syonJL jeyong AII9n 104 plesg esoH 9Anonpuo2 uow panne pepueuJulo29J SMOUS 1uBH y 0 uva ISd uinjoyysseud WIN HONI SYILIN 1334 Wd9 3Sn Jeleueld eplsul su1Bue asoH 9SOH 1In21I2 2Iine1p H JOOL 8 WS10 User Manual HTMA EHTMA REQUIREMENTS HTMA TOOL TYPE HYDRAULIC SYSTEM REQUIREMENTS TYPE I TYPE II TYPERR TYPE III Flow Range 4 6 gpm 7 9 gpm 9 10 5 gpm 11 13 gpm 15 23 Ipm 26 34 Ipm 34 40 Ipm 42 49 Ipm Nominal Operating Pressure 1500 psi 1500 psi 1500 psi 1500 psi at the power supply outlet 103 bar 103
26. yond its design capacity Always keep critical tool markings such as labels and warning stickers legible Eye injury and cutting or severing of body parts is pos sible if proper procedures are not followed WS10 User Manual lt 5 30Lpm at 138bar BHTMA CATEGORY 11206 Circuit Type C Sticker 11207 Circuit Type D Sticker 35294 No Hammer Sticker 25610 CAUTION 4 10 GPM 15 38 LPM DO NOT EXCEED 2000 PSI 140 BAR DO NOT EXCEED SPECIFIED FLOW OR PRESSURE USE CLOSED CENTER TOOL ON CLOSED CENTER SYSTEM USE OPEN CENTER TOOL ON OPEN CENTER SYSTEM CORRECTLY CONNECT HOSES TO TOOL IN AND OUT PORTS IMPROPER HANDLING USE OR OTHER MAINTENANCE OF TOOL COULD RESULT IN A LEAK BURST OR OTHER TOOL FAILURE CONTACT AT ALEAK OR BURST ___ CAN CAUSE OIL INJECTION INTO THE BODY FAILURE TO __ OBSERVE THESE PRECAUTIONS CAN RESULT IN SERIOUS PERSONAL INJURY 29188 GPM Pressure Caution Sticker 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 6 gt WS10 User Manual 20Lpm at 138bar BHTMA CATEGORY R
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