DS06 User Manual - Stanley Hydraulic Tools
Contents
1. 0506 HYDRAULIC DIAMOND SAW USER MANUAL Safety Operation and Maintenance 2014 Stanley Black amp Decker Inc New Britain CT 06053 U S A 34566 2 2015 Ver 10 DECLARATION OF CONFORMITY STA IN L EY UBEREINSTIMMUNGS ERKLARUNG DECLARATION DE CONFORMITE Hydraulic Tools DECLARACION DE CONFORMIDAD 4 DICHIARAZIONE DI CONFORMITA the undersigned 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 bestatige hiermit erklaren Produkt genannten Werk oder Gerat 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 Concrete Cutting Chainsaw Hydraulic Kategorie Cat gorie Categoria Categoria 2 Make Marke Marque Marca Marca Stanley 3 DS06200001 DS06300001 4 Serial number of equipment Seriennummer des Gerats 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 bereinstimmung mit Est fabriqu conform ment Ha sido fabricado de acuerdo con E stata costruita in conformit con2. orza 1 RETANINGRING s 7793 EXrENSIONSPRNGANCHOR pe memmmoneo 000 03786 GPM DECAL 8 GPM MODELS NOT SHOWN LO EC MET RR mw swWr STANLEY 0806 User Manual 4 25 STANLEY Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie Oregon 97267 5698 USA 503 659 5660 Fax 503 652 1780 www stanleyhydraulics com
3. 22 PARTS SES Ne 23 DOIG a He 24 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 L EY 0506 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 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 deat
4. 14 Ibs 6 kg Length WINOUT DSS 14 3 inches 36 cm MM EE EEE RENE EE PE 9 inches 23 cm Lubrication EE name Internal Water Channels in Bar EN OO 8 SAE O ring deepest EHTMA HTMA Flush Face B Yes Chain Speed 6 16 MOCE RE EE RE EE 4600 23 4 m s MT 5000 fom 25 4 m s SOUND POWER AND VIBRATION DECLARATION Measured A weighted sound power level Lwa ref 1pW in decibels 106 2 dBA Uncertainty Kwa in decibels 3 dBA Measured A weighted sound pressure level Lpa ref 20 uPa at operator s position in decibels 98 2 dBA Uncertainty Kpa in decibels 3 dBA Values determined according to noise test code given in ISO 15744 using the basic standard ISO 3744 NOTE The sum of a measured noise emission value and its associated uncertainty represents an upper boundary of the range of values which is likely to occur in measurements Declared vibration emission value in accordance win EN 1208 Values determined according to 15086621 180 534912 AGGESSORIES ee 111 Eee 20857 Diamond Chain Repair BEE deiee 20858 Diamond Chain Service EEE sub P N 20857 or 20858 Diamond Chain Butterfly Repair IL ee 20859 13 inch Bar Sprocket pp 35037 Ultra 25 Diamond Chain for 13 inch BAM ve resa ad 56799 Pinnacle 25 Diamond Chain for 13 inch Ba
5. Al Figure 2 Chain Direction STANLEY CONNECT HYDRAULIC HOSES 1 Wipe all hose couplers with a clean lint free cloth before making connections necessary use light weight penetrating oil in a spray can to clean the hose couplers before each connection 2 Connect the hoses from the hydraulic power source to the chain saw fittings or quick disconnects It is a good practice to connect return hose first and dis connect them last to minimize or avoid trapped pres sure within the chain saw 3 Observe the arrow on the couplers to ensure that the flow is in the proper direction The female cou pler on the chain saw is the inlet pressure coupler NOTE If uncoupled hoses are left in the sun pressure in crease inside the hoses might make them difficult to connect Whenever possible connect the free ends of the hoses together CONNECTING A WATER SUPPLY 1 Using a standard garden hose connect DS06 to a city or auxiliary water supply Make sure the flow is at least 4 gpm 15 lpm at 50 psi 3 5 bar IMPORTANT Chain and bar damage will occur if the tool operates without the proper water supply and water pressure 2 Make sure the water is running before starting the tool 3 water pump is being used refer to the manu facturers instructions for use of the pump Make sure the pump produces a minimum water flow of 4 gpm 15 Ipm at 50 psi 3 5 bar and the water pressure does not exceed 160
6. Hydraulic Tools Supply hoses must have a mini mum working pressure rating of 2500 psi 172 bar Do not exceed the rated flow see Specifications page in this manual for correct flow rate and model number Rapid failure of the internal seals may re sult STANLEY 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 DS06 User Manual lt 19 20 gt 0506 User Manual If symptoms 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 cor rect 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 CAUSE SOLUTION Tool does not run Hydraulic power source not Check power source for proper flow and functioning correctly pressure 7 9 gpm 26 34 at 2000 psi 140 bar Coupler or hoses blocked Remove obstruction Mechanical failure Have tool serviced by authorized dealer Tool runs backwards Pressure and return lines incorrectly Correct hose connections Motor shaft connected rotates
7. CAUSE OIL INJEC TION INTO THE BODY OR CAUSE OTHER SEVERE DO NOT CONNECT OPEN CENTER TOOLS TO CLOSED CENTER HYDRAULIC SYSTEMS THIS MAY RESULT IN PERSONAL INJURY LOSS OF OTHER HYDRAULIC FUNCTIONS POWERED BY DO NOT EXCEED SPECIFIED FLOW AND PRESSURE THE SAME SYSTEM AND OR SEVERE PERSONAL INJURY FOR THIS TOOL EXCESS FLOW OR PRESSURE MAY CAUSE A LEAK OR BURST BYSTANDERS MAY BE INJURED IN YOUR WORK AREA KEEP BYSTANDERS CLEAR OF YOUR WORK AREA DO NOT EXCEED RATED WORKING PRESSURE OF WEAR HEARING EYE FOOT HAND AND HEAD PRO HYDRAULIC HOSE USED WITH THIS TOOL EXCESS PRESSURE MAY CAUSE A LEAK OR BURST er EE TO AVOID PERSONAL INJURY OR EQUIPMENT DAMAGE ALL TOOL REPAIR MAINTENANCE AND SERVICE MUST DAILY FOR LEAKS DO NOT FEEL FOR LEAKS WITH ONLY BE PERFORMED BY AUTHORIZED AND PROPERLY YOUR HANDS CONTACT WITH A LEAK MAY RESULT IN SEVERE PERSONAL INJURY TRAINED PERSONNEL IMPORTANT IMPORTANT READ OPERATION MANUAL AND READ OPERATION MANUAL AND SAFETY INSTRUCTIONS FOR THIS SAFETY INSTRUCTIONS FOR THIS TOOL BEFORE USING IT TOOL BEFORE USING IT USE ONLY PARTS AND REPAIR USE ONLY PARTS AND REPAIR PROCEDURES APPROVED BY PROCEDURES APPROVED BY STANLEY AND DESCRIBED IN THE STANLEY AND DESCRIBED IN THE OPERATION MANUAL OPERATION MANUAL TAG TO BE REMOVED ONLY BY TAG TO BE REMOVED ONLY BY TOOL OPERATOR TOOL OPERATOR SEE OTHER SIDE SEE OTHER SIDE SAFETY TAG P N 15875 Shown smaller then actual size DS06 User Ma
8. DS06 User Manual 6 With the bar and rivets solidly supported on a strong flat steel surface carefully peen the rivet heads down with the flat end of a hammer Be careful to only hit the rivet head Do not hit the bar body this will pinch the nose sprocket Rivet heads must com pletely fill the countersinks in the bar body and be snug and secure while still allowing the sprocket to freely turn See Figure 29 Figure 29 Replacing Rivets 7 Using flat file shave the rivet heads to uniform height that is as close to the bar body as possible See Figure 30 Figure 30 Filing Rivets STANLEY 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 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 couplers 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
9. Directive Standards Approved body Richtlinie Standards Pr fung durch Directives Normes Organisme agr Directriz Los Normas Aprobado Direttiva Norme Collaudato 12100 2010 3744 2010 20643 2005 10726 1992 Machinery Directive 2006 42 EC 2006 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 1 4 11 Signature Unterschrift Signature Firma Firma FAR Position Position Fonction Cargo Posizione Director of Product Development 2 gt 0506 User Manual STAN LEY DECLARATION OF CONFORMITY tsa cg e 2 PETN PULS 4 TETTE INN 9 TOOLS TOKER pc 7 8 HOSE RKECUOUNMENDAT mien imas tantom lian aa Da a E Disi 9 MARE EET phpbb 10 FER TN 11 MAINTENANCE SDI 440 ______ 14 TOOLPROTEGHON 5 E 5 1 5 Bada et se 19 TROUBLE OTNES 20 DIAMOND CHAIN APPEICA MONS eee 21 PEPE TN 22
10. 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 Ipm 100 400 ssu 25 microns 30 gpm 114 Ipm 100 400 ssu 20 82 centistokes 25 microns 30 gpm 114 Ipm 100 400 ssu 25 microns 30 gpm 114 Ipm 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 EHTMA HYDRAULIC SYSTEM REQUIREMENTS Flow Range Nominal Operating Pressure at the power supply outlet System relief valve setting at the power supply outlet CLASSIFICATION AAAA 3 5 4 3 gpm 13 5 16 5 Ipm 1870 psi 129 bar 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 NOT
11. a potentially explosive atmo sphere WARNING Hydraulic fluid under pressure could cause skin injection injury If you are injured by hydraulic fluid get medical attention immedi ately STANLEY 2OLom at 138bar CATEGORY 30Lpm at 138bar BHTMA CATEGORY STANLEY Stanley Hydraulic Tools 3810 SE Naef Rd Milwaukie Oregon 97267 U S A Model No 0506 Lwa 10948 E CE Decal 11206 11212 73659 Circuit C Decal 5 GPM Models Sound Level Decal Name Tag Decal 11207 Circuit D Decal 8 GPM models DANGER CAUTION 7 9 GPM 26 34 LPM Failure to use hydraulic hose labeled and certified DO NOT EXCEED 2000 PSI 140 BAR as non conductive when using hydraulic tools on or near electric lines may result In death or DO NOT EXCEED SPECIFIED FLOW OR PRESSURE serlous Injury USE CLOSED CENTER TOOL ON CLOSED CENTER SYSTEM USE OPEN CENTER TOOL ON OPEN CENTER Fo popa andras oncon edd SYSTEM CORRECTLY CONNECT HOSES TO TOOL IN es AND OUT PORTS IMPROPER HANDLING USE OR OTHER de MAINTENANCE TOOL COULD RESULT IN A LEAK BURST ELECTROCUTION or around electe Ines OR OTHER TOOL FAILURE CONTACT AT A LEAK OR BURST HAARD CAN CAUSE OIL INJECTION INTO THE BODY FAILURE TO OBSERVE THESE PRECAUTIONS CAN RESULT IN SERIOUS PERSONAL INJURY 12412 Warning Sticker E
12. by occasionally turning the bar over so the top and bottom bar surfaces wear evenly Refer to the saw bar disassembly proce dures in the Service Manual for further details 14 0506 User Manual CHAIN TENSION ADJUSTMENT Correct chain tension is very important throughout the life of the chain Check the chain tension often during use when the chain saw is stopped and the saw bar and chain have cooled off The chain should move easily around the saw bar when pulled by hand To adjust the chain tension 1 Turn off the water and power supplies 2 Loosen the two saw bar attachment nuts Figure 9 Bar Attachment Nuts 2 Bar Adjusting Screw Figure 9 Attachment Screw Locations 3 Using the saw bar adjustment screw Item 68 Parts Illustration tighten the chain until you are still able to rotate it one full revolution by hand Figure 10 Figure 10 Pulling the Chain 4 Pull the chain around the saw bar to make sure it properly fits the sprocket and saw bar The chain should be easily pulled 5 Fully tighten the two saw bar attachment nuts Figure 9 NOTE Adjust the chain tension each time the drive link tang hangs fully exposed from the groove at the bot tom of the saw bar Figure 11 STANLEY Bottom of Bar et Figure 11 Exposed Drive Link Tang SERVICING THE CHAIN The following procedures explain how to break chain u
13. counterclockwise as viewed from the end of the motor shaft Diamond saw cuts slow Insufficient fluid flow or too high Check hydraulic supply If hydraulic back pressure or relief valve too supply is correct have unit serviced by low authorized dealer Back pressure too high Should not exceed 250 psi 17 bar at 9 gpm 34 Ipm measured at the end of the Loss of diamond segment side clearance tools operating hoses Chain segment dulled because of Replace chain Redress segmented by cutting in continuous use in hard material or abrasive material i e concrete building rebar block etc NOTE This indicates that the wrong chain is being used Wrong chain for application Scale down to a lower numbered chain Wired edged bar rails Hydraulic fluid mixed in water Have tool serviced supply rough Will not cut straight Accumulated saw bar wear and Turn the saw bar over and dress rails uneven chain segment profile wear Square Replace the saw bar and chain Loss of power Drive sprocket slipping on Adjust and tighten Trantorque adapter Trantorque adapter to 17 ft Ib 23 Nm Trigger hard to press Pressure and return hose reversed Connect for proper flow direction Motor shaft must rotate clockwise Back pressure too high Should not exceed 250 psi 17 bar 9 gpm 34 Ipm measured at the end of the tool s operating hoses STANLEY SYMPTOM CAUSE SOLUTION No water discharge at bar Blocked
14. psi 11 bar CHECK CHAIN AND BAR ADJUSTMENT NOTE Check the chain tension often during operation es pecially during the first 1 2 hour when using a new chain Adjust the chain accordingly when it becomes loose Follow the procedures contained in the Main tenance and Adjustments section of this manual 1 Make sure the chain does not exceed a clearance of 5 16 in 8 mm from the bar see Figure 3 Exceed DS06 User Manual 4 11 ing the maximum clearance increases the chance of the chain being dislodged from the bar groove 2 Make sure the bar attaching nuts are fully tightened and the chain guard is in place Figure 3 Maximum Chain Clearance CHECK CHAIN SEGMENT WEAR 1 Using adjustable calipers measure several chain segments as illustrated in Figure 4 Bottom of Bar pp Figure 4 Chain Segment Wear 2 f the average measurement is less than 1 16 inch 1 6 mm then the chain must be replaced Refer to your Service Manual for chain replacement pro cedures OPERATING PROCEDURES 1 Observe all safety precautions 2 Turn on the water supply Water at the tool will be directed to the bar and chain when the trigger on the tool is squeezed ON 3 Operate the tool for two minutes away from the in tended cut and then check the chain tension New chain will normally stretch during its first usage It is very important to keep the chain tension adjusted so that it does not exceed 5 16 in 8 mm clear
15. too viscous or thick USING THE WALL WALKER The Wall Walker lessens operator fatigue and effort during cutting by automatic insertion of the wedge into the cut thus allowing the operator to apply leverage to the saw 1 Position the Wall Walker in the autofeed position by pinning the lever arm at the lowest hole as shown PLUNGE CUT ve in the illustration Start cutting with the 0506 until the cut is large enough to allow the tip of the wedge to insert into the cut With the tip of the wedge in the cut the opera tor can easily apply leverage to the saw which will aid the cutting process and lessen operator fatigue and effort After the saw cuts approximately 1 to 2 5 in 25 to 65 mm withdraw the saw only enough to allow the lever arm and wedge to reposition After reposition ing continue cutting Figure 6 Types of Cuts chain guard removed for 2 The Wall Walker can be positioned to the parked clarity position by pinning the lever arm at the upper most kg Excessive force causes the chain to slow down bucking cleat or stall and causes premature wear of the saw bar and chain 2 Always maintain a high chain speed High chain speeds produce the best results 3 Always check that plenty of water is being expelled from the bar and chain When the tool is running water is directed to the interior of the bar and then out of several holes located along the top and bot tom channels on the bar I
16. E These are general hydraulic system requirements See tool specification page for tool specific requirements 10 gt DS06 User Manual STANLEY PRE OPERTION PROCEDURES CHECK THE POWER SOURCE 1 Using a calibrated flow meter and pressure gauge make sure the hydraulic power source develops flow of 7 9 gpm 26 34 Ipm for the 8 model and 4 6 gpm 15 23 lpm for the 5 gom model at 2000 psi 140 bar 2 Make certain that the power source Is equipped with a relief valve set to open at 2100 2250 psi 145 155 bar 3 Check that the hydraulic circuit matches the tool for open center OC or closed center CC operation The DS06 is designed for open center operation only 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 4 Observe the arrow on the couplers to ensure that the hydraulic oil flow is in the proper direction The female coupler is the inlet pressure coupler 5 Check that the trigger operates smoothly and is free to travel between the ON and OFF positions 6 Check that the chain is properly installed The chain is designed to only operate in one direction Make sure the chain is installed so the bumper guard pre cedes each diamond segment See Figure 2 CORRECT INCORRECT
17. N eold AL eunDi RETURN HYDRAULIC CIRCUIT PRESSURE lt lt lt NYNLIH gt gt gt JYUNSSIYUd 0 8 dn 09 06 OE GL 06 06 006 001 Ov 6l GOL G G 2 dn dn SYOLONGNOD 1VOIW12313 YVAN ASN LON OQ 19q 4 10 pIEJg 9JIM SOH syonJL jeyong AU9n 404 Jeq 4 SOH aAonpuoO uoN Jelauueld eplsul RETURN PRESSURE LLSF AWS Aq UMOJ 195 se suoeoyloads 5 rv Bunes Jalal 5 ollneJpAU xew y e Seal je 15 esou oi neJp U y 1 Aue pesn aq zou 5 pue joo 5100 Inep H uo peseq AIuo joo 95lIneJpAU 104 pesn ol SI yeyo siu S0UBUIIOJSd 00 eJnsue ejqe1doooe e eJnssejJd oJnssaJd UINJSJ ol epueuuuloo8J 2594 Jed Jed Suolle6 uo peseq SUl6uael sJejeuleip 2504 SMOUS 1 SU yey 941 a
18. N 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 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 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 cn SEE OTHER SIDE n Pn SEE OTHER SIDE OVL SIHL LON OG lt 2 I gt Shown smaller than actual size 8 gt 0506 User Manual STAN LEY SUONDSUUO
19. W 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 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 INACCORDANCE WITH AGE rec otc 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 LO
20. ance from the bottom of the bar See Check Chain amp Bar Adjustment in this manual 4 Ifthe chain requires adjustment see Maintenance amp Adjustments in this manual PLAN THE CUT keep from pinching the saw bar and chain as a re sult of falling pieces of concrete brick etc 2 Make your cuts in the order shown in Figure 5 start ing with cut 1 base horizontal cut and proceeding with the remaining three cuts Figure 5 Planning Cuts 3 Outline the concrete area with a permanent marker for a visual guide 4 Know what kind of material and how much reinforc ing you are going to cut TYPES OF CUTS The 0506 can be operated using the types of cuts shown in Figure 6 When making cuts NOTICE The following are general cutting procedures and techniques Differences in the terrain and the type of material being cut will make this information more or less valid for particular areas For advice on specific cutting problems or techniques consult your local Stanley Representative He she can often provide information that will make your work safer and more productive 1 Plan your cuts to prevent injury to yourself and to 12 0506 User Manual STANLEY hydraulic fluid at low power source speed When using the normally recommended fluids fluid should be at or above 50 F 10 C 400 ssu 82 centistokes before use Damage to the hydraulic system or chain saw can result from use with fluid that is
21. e inward approximately one full revolution until the rivet head is formed Figure 23 NOTE The take up handle provides pressure while the spinner anvil forms the rivet head Figure 25 Punching Out Nose Sprocket Rivets 2 Insert straight blade screw driver to spread the bar nose rails just enough to remove the old nose sprocket Use a rag or paper towel to clean the nose sprocket area See Figure 26 Figure 26 Removing Old Nose Sprocket Figure 24 Spinner Oiling Chambers NOTE The rivet spinner is equipped with oiling chambers and should be maintained periodically with a light weight oil Figure 24 STAN L EY DS06 User Manual lt 17 3 Remove the new nose sprocket package s clips and fold back the top portion of the insertion card be ing careful not to remove or disturb the components See Figure 27 Figure 27 Preparing New Nose Sprocket 4 With a flat blade screw driver in the bar nose rails slide the nose sprocket assembly into position align ing the 6 holes in the bar nose with the 6 holes in the nose sprocket assembly without removing the components from the card See Figure 28 Figure 28 Installing a New Nose Sprocket 5 Insert 6 nose rivets into the holes and then hold them with your thumb Remove the screwdriver and slide out the insertion card NOTE On used bars the nose rails might tend to spread apart Use a small clamp if necessary to hold the rails together 18
22. f these holes become plugged cutting debris will not be adequately washed away and will result in premature wear of the bar and chain 4 Avoid aggressive heavy plunge forces Aggressive Wall Walker Lever Arm plunge force creates fragmenting of the concrete Shown in autofeed position when the saw bar and chain exits and causes pre mature bar and chain wear COLD WEATHER OPERATION If the saw is to be used during cold weather preheat the Figure 7 Wall Walker STAN L EY DS06 User Manual 4 13 GENERAL TIPS Several simple maintenance tasks which if performed can keep chain saw operating at high level of ef ficiency Routine maintenance also keeps replacement costs down on the parts of the chain saw which occa sionally wear out If any chain saw disassembly is required refer to the Service Manual SAW BAR RAIL A quick check can be made to determine if saw bar rail or chain segment wear exists Figure 8 shows a worn saw bar rail REMOVE WIRE EDGE WITH FLAT FILE SQUARE Figure 8 Rail Wear If the saw bar rails are worn use a flat file and dress each one until it is flat and square with the side of the saw bar Figure 8 Also make sure the saw bar is perfectly straight If bows or bends are present in the saw bar it must be replaced before dressing any rail ROTATING THE SAW BAR Maximum saw bar life can be achieved
23. h This safety alert and signal word indicate an imminently hazardous situation 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 0506 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 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 addi
24. lectrical 03786 28409 Composite Decal 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 STANLEY GPM sticker 7 9 2000 psi DS063000 only DANGER DANGER 1 FAILURE USE HYDRAULIC HOSE LABELED AND CER D DO NOT LIFT OR CARRY TOOL BY THE HOSES DO TIFIED AS NON CONDUCTIVE WHEN USING HYDRAULIC NOT ABUSE HOSE DO NOT USE KINKED TORN OR TOOLS ON OR NEAR ELECTRICAL LINES MAY RESULT IN DAMAGED HOSE DEATH OR SERIOUS INJURY MAKE SURE HYDRAULIC HOSES ARE PROPERLY CON BEFORE USING HOSE LABELED AND CERTIFIED AS NON NECTED TO THE TOOL BEFORE PRESSURING SYSTEM CONDUCTIVE ON OR NEAR ELECTRIC LINES BE SURE THE SYSTEM PRESSURE HOSE MUST ALWAYS BE CON HOSE IS MAINTAINED AS NON CONDUCTIVE THE HOSE NECTED TO TOOL IN PORT SYSTEM RETURN HOSE SHOULD BE REGULARLY TESTED FOR ELECTRIC CUR MUST ALWAYS BE CONNECTED TO TOOL OUT PORT RENT LEAKAGE IN ACCORDANCE WITH YOUR SAFETY REVERSING CONNECTIONS MAY CAUSE REVERSE DEPARTMENT INSTRUCTIONS TOOL OPERATION WHICH CAN RESULT IN SEVERE PERSONAL INJURY 2 A HYDRAULIC LEAK OR BURST MAY
25. nerate dust potentially contain ing a variety of hazardous substances such as as bestos 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 cutting Follow correct safety procedures and comply with all applicable national state or provisional health and safety regulations relating to them including if appropriate arranging for the safe disposal of the materials by a qualified person DS06 User Manual lt 5 Always be well rested and mentally alert before op erating the chain saw Do not allow bystanders near the chain saw when starting or cutting Do not start cutting until you have a clear work area and secure footing Keep all parts of the body away from the chain saw during operation including loose clothing and long hair Carry the chain saw with the tool de energized and the bar and chain to the rear of your body Do not operate chain saw that is damaged im properly adjusted or not completely and securely assembled Make sure the chain stops moving when the control trigger 15 released Keep the handle dry clean and free of hydraulic fluid Do not use the chain saw near energized transmis sion lines Turn off the power source or move the hydraulic control valve to neutral before setting the chain saw down Use a guide bar scabbard when tra
26. nsporting the chain saw Know the location of buried or covered utilities be fore starting work To avoid personal injury or equipment damage all chain saw repair maintenance and service must only be performed by authorized and properly trained personnel Make sure the chain breaker and rivet spinner are securely mounted on flat clean work surfaces Check the mounting screws bolts often 6 gt 0506 User Manual Check all chain breaker and rivet spinner nents regularly for wear and general condition Avoid contact with the saw bar rails as they can be come very sharp during use Provide adequate lighting when operating the saw in a darkened area or at night Always keep critical tool markings such as labels and warning stickers legible Always replace stick ers and decals that have become worn or damaged Be observant of hydraulic and water hoses that lay about the work area especially in trenches where they can be hidden from view due to liquids that have accumulated within the space Keep all parts of the body away from the cleats that are attached to the saw as these are sharp and can be a puncture hazard Improper handling use or maintenance can result in an oil leak or burst Do not contact an oil leak as high pressure oil can cause injection into the body Never stand in the path of the discharge as ejection of material from the work piece can cause personal injury Never use the saw in
27. nual lt 7 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 tag may be obtained from your Stanley Distributor THE TAG SHOWN BELO
28. port s in bar Turn off hydraulic supply Remove bar and chain and clean bar thoroughly Blow ports with compressed air Blocked inlet or outlet Turn off hydraulic supply Remove bar and chain Make sure water supply Is on Press trigger to see if water exits near bar adjustment nut area a small port If no water exits have unit serviced DIAMOND CHAIN APPLICATIONS Pinnacle 13 inch Very hard aggregate concretes flint chert granite etc Heavy steel reinforcing 5 8 inch 16 mm diameter and larger Medium hard aggregate concretes granite quartz river rock etc Moderate steel reinforcing wire mesh 3 8 1 2 inch 10 12 mm diameter Soft aggregate concrete concrete block masonry green concrete highly abrasive conditions Ultra 13 inch Medium hard aggregate concretes granite quartz river rock etc Moderate steel reinforcing wire mesh 3 8 1 2 inch 10 12 mm diameter Soft aggregate concrete concrete block masonry green concrete highly abrasive conditions STAN L EY DS06 User Manual 4 21 22 DS06 User Manual UNDE 13 inches 33 cm PENE 13 inch 33 cm NTN 3 8 inch pitch with 21 diamond segments METERNE 250 psi 17 bar Input Flow Range OSI 4 6 gpm 15 23 Ipm 250 6 0018 TUO ENE EE sakin 7 9 gpm 26 34 Ipm MP 2000 psi 140 bar Weight without bar
29. r 1 56800 ve 60859 Water Pump DER DCP30100 Water Pump 72 VDC Battery Ne DCP30101 STANLEY L na 20 PG d 25 lt NI Ih STAN L EY 0506 User Manual 4 23 PART ITEM NO QTY DESCRIPTION oss msmcstozeunc 1m 1206 SIGUG neca spumo INCL ITEMS 5 6 8 GPM MODEL ONLY BH cm INCL ITEMS 5 6 5 GPM MODEL ONLY e won s wee messer s wm o wes 2 DRIVE GEAR MODEL ONLY INCL ITEMS 6 31 66 m O RING SUPPLIED w menan m rm o 24 0506 User Manual PART ITEM NO QTY DESCRIPTION STEEL BALL 3 8 DIA as norm CORD STOCK 3 16 DIA SERIAL NO BREAK s 1215 1 SEALBACKURWASHER ases t SPROCKETADAPTER ss ses wes esse t SPRALRETANERRNG s SEEAGCESSORES m _ o es seas 1 STUD SUPPLIED WiTTEM22 ____ 00687 1 MACHINE SCREW ___________ s fame 1 smrosem 72 sernemmawnmmm CRAIN SEEACCESSORIES feo 12412 1 ELECTRICAL WARNING DECAL m norm STANLEY PART ITEM NO QTY DESCRIPTION Jomo ferron _ ma SOUND POWER LEVEL DECAL CE so fors omore _ ser fer _ _
30. sing Stanley s bench mounted chain breaker P N 20858 to remove a worn or damaged segment 1 Mount the chain breaker flush with the side or front of a flat clean work surface Figure 12 Figure 12 Chain Breaker Mounting NOTE The Stanley chain breaker is only designed to re move rivet heads from the connecting links not from a chain segment The rivet heads shown in the shaded areas of Figure 13 are the only ones that can be removed Figure 13 Removable Rivet Heads 2 Place the chain the portion that you want broken into the slot of the anvil pushing it forward until the bottom connecting link is flush with the far side of the slot Figure 14 STANLEY Top connecting link Clamping screw Drive link Breaker block Bottom connecting link Figure 14 Inserting the Chain Position the rivet head you want removed directly under the chain breaker punch and then pull the handle down far enough to remove the rivet Figure 15 Do not use excessive force 28 i Figure 15 Removing a Rivet DS06 User Manual lt 15 REPLAGING THE CHAIN BREAKER PUNCH If the chain breaker punch 22801 becomes worn or damaged use the following procedures for replace ment 1 Remove the punch by loosening the set screw Figure 16 Figure 16 Removing the Punch 2 Insert a new punch into the holder and push it up until it is fully seated Figure 17 Secure the punch to the chain breaker holder by f
31. soH dI NEIP H 03 00 DS06 User Manual lt 9 STANLEY HTMA EHTMA REQUIREMENTS HTMA HYDRAULIC SYSTEM REQUIREMENTS TOOL TYPE 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 I 4 6 gpm 15 23 1500 psi 103 bar 2100 2250 psi 145 155 bar 250 psi 17 bar 400 ssu 82 centistokes 140 F 60 C hp 2 24 kW 40 F 22 C TYPE Il 7 9 gpm 26 34 Ipm 1500 psi 103 bar 2100 2250 psi 145 155 bar 250 psi 17 bar 400 ssu 82 centistokes 140 F 60 C 5 hp 3 73 kW 40 F 22 TYPE RR 9 10 5 gpm 34 40 Ipm 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 Ipm 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
32. tional 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 0506 Diamond Saw will provide safe and depend able service if operated in accordance with the instruc tions 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 e Establish a training program for all operators to en sure safe operation e The operator must be familiar with all prohibited work areas such as excessive slopes and danger ous terrain conditions Do not operate the chain saw unless thoroughly trained or under the supervision of an instructor Always wear safety equipment such as goggles ear breathing head protection leg protection gloves snug fitting clothing and safety shoes at all times when operating the chain saw Do not overreach Maintain proper footing and bal ance at all times Do not inspect or clean the chain saw while the hy draulic power source is connected Accidental en gagement of the chain saw can cause serious injury Always connect hoses to the chain saw hose cou plers before energizing the hydraulic power source Make sure all hose connections are tight Do not operate the chain saw at fluid temperatures above 140 F 60 C Operation at higher tempera
33. tures can cause higher than normal temperatures at the chain saw which can result in operator dis comfort STANLEY Do not rely exclusively upon the safety devices built into the chain saw As a chain saw user several steps must be taken to keep your cutting jobs free from accident or injury a With a basic understanding of kickbacks you can reduce or eliminate the element of surprise Sudden surprise contributes to accidents b Keep a good firm grip on the chain saw with both hands the right hand on the rear handle and the left hand on the front handle when oper ating the chain saw Use a firm grip with thumbs and fingers encircling the chain saw handles A firm grip helps reduce kickbacks and maintains control of the chain saw Do not let go c Make sure the area in which you are cutting is free of obstructions d Cut at rated operating speeds gpm Do not overreach or cut above shoulder height f Only use replacement bars and chains specified by Stanley or the equivalent Make sure the chain guard is in place before operat ing the chain saw Remove or control the water slurry to prevent your self or others from slipping while cutting Provide adequate ventilation in closed areas when operating a gas or diesel hydraulic power source Do not operate a hydraulic power source or a hy draulic diamond saw in an explosive atmosphere Warning Use of this tool on certain materials during demolition could ge
34. ully tightening the set screw Figure 17 Replacing the Punch SPINNING RIVETS The following procedures explain how to spin rivets us ing Stanley s bench mounted rivet spinner P N 20857 to assembly the chain 1 Mount the rivet spinner flush with the side or front of a flat clean work surface Figure 18 16 DS06 User Manual Rivet Spinner Rivet Spinner Figure 18 Rivet Spinner Mounting Lay the chain across the plastic chain supports and then rotate the supports so the rivet head is cen tered between the take up handle pocket and the spinner anvil Figure 19 Figure 19 Positioning the Chain 3 Turn the take up handle until the chain is tight against the spinner anvil Figure 20 7 EEE A elle Ly ULL Figure 20 Securing the Chain 4 Turn the rivet spinner crank a few times to center the rivet hub in the spinner anvil Figure 21 T m NNI I Enen 0 T m VI gt Figure 21 Centering the Rivet Hub STANLEY 5 Apply a few drops of oil to the rivet hub Figure 22 NOSE SPROCKET DISASSEMBLY AND ASSEMBLY 1 Using the bench mounted chain breaker see acces sories line up the 1 4 inch hole in the side of the chain breaker anvil with the chain breaker punch Punch out the six nose sprocket rivets See Figure 25 d mm 22 Figure 22 Applying the Oil 6 Turn the spinner crank while slowly running the take up handl
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