CO25 Svce Manual 8-05 V2.indb
Contents
1. REN LE RR nsn sed nen 62358 17 SERVICE GENERAL SERVICE REQUIREMENTS Do not disassemble the tool unless an internal problem has been identified The tool may not be the cause of the malfunction Refer to the Troubleshooting Section of this manual Disassemble the tool only to the extent necessary to re place a defective part Do not put the tool back in service until the source of the problem has been identified and repaired If not corrected the original problem may cause excessive wear or tool failure NOTE When servicing the tool keep your work surface clean Do not allow dirt or grit to contaminate internal parts of the tool TOOLS PARTS AND MATERIALS basic tools such as screwdrivers and hammer combination and hex wrenches punches for driving out roll pins seal kit clean grease or O ring lubricant degreasing solvent clean dry lint free cloths HYDRAULIC SYSTEM CONNECTIONS If the hydraulic hoses are connected to the tool Turn the hydraulic system control valve OFF Disconnect first the hydraulic input supply hose then the output return hose Insert plugs in each hose to prevent contamination of the hydraulic circuit and interior of the valve handle assembly CLEANING Clean any dirt debris or grease from the tool before removing any parts Keep the work surface clean to avoid contaminating the interior of the tool Before reassembly remove and di2. 3 8 inch Male Pipe Adapter Rotation RPM nee a O O ATO E 4500 SOUND POWER AND VIBRATION DECLARATION Measured A weighted sound power level Lwa ref 1pW in decibels 109 4 dBA Uncertainty Kwa in decibels 3 dBA Measured A weighted sound pressure level Lpa ref 20 uPa at operator s position in decibels 101 5dBA Uncertainty Kpa in decibels 3dBA Values determined according to noise test code given in ISO 15744 using the basic standard ISO3744 NOTE The sum of a measured noise emision value and its associated uncertainty represents an upper boundry of the range of values which is likely to occur in measurements Declared vibration emission value in accordance with EN 12096 Measured vibration emmission value a 5 9 m sec Uncertainty K 1 0 m sec Values determined according to ISO 8662 1 ISO 5349 1 2 ACCESSORIES DESCRIPTION PART NUMBER 14 inch Abrasive Wheel for Metal 1 inch Arbor 000a rr 02691 14 inch Abrasive Wheel for Masonry 1 inch Arbor 4444444444440snnonnnnnnnnnnnnnnnnnannnnonnnnnennnnnnnnnsnnnnnnnnnnnenn nn 02692 Water ttan sista Lo Ren EV EB Cn aa a Regen 33228 Slab Saw Cats JR INIMICI INI MI 33281 Water Tank Kit for P N 33281 niaidne n nnne n 33474 Handie EXtenstomsib aida 34175 Diamond Blade 14 inch Dry C t siitin a reisan
3. CHECK TRIGGER MECHANISM 1 Inspect the trigger and safety catch Make sure the trig ger operates smoothly and 15 free to travel between the ON and OFF positions 2 Make sure the trigger is set to disengage the cut off saw when released 11 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 that 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 CONFIGURATIO
4. 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 FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRICAL LINES MAY RESULT IN DEATH OR SERIOUS INJURY BEFORE USING HOSE 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 CURRENT LEAKAGE IN ACCORDANCE WITH YOUR SAFETY DEPART MENT INSTRUCTIONS A HYDRAULIC LEAK OR BURST MAY CAUSE OIL INJECTION INTO THE BODY OR CAUSE OTHER SEVERE PERSONAL INJURY A DO NOT EXCEED SPECIFIED FLOW AND PRESSURE FOR THIS TOOL EXCESS FLOW OR PRESSURE MAY CAUSE A LEAK OR BURST DO NOT EXCEED RATED WORKING PRESSURE OF HY DRAU LIC HOSE USED WITH THIS TOOL EXCESS PRESSURE MAY CAUSE A LEAK OR BURST CHECK TOOL COUPLERS AND CONNECTORS DAILY FOR LEAKS DO NOT FEEL FOR LEAKS WITH YOUR SAFETY TAG P N 15875 IMPORTANT READ OPERATION MANUAL AND SAFETY INSTRUCTIONS FOR THIS TOOL BEFORE USING IT US
5. To avoid personal injury or equipment damage all tool repair maintenance and service must only be performed by au thorized and properly trained personnel 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 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 wheen as a cutting surface Make sure the tool is designed for the wheel direction suitable for the job Do not reverse the direction of the wheel rota tion 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 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 burried or covered services before starting work Adjust t
6. 25 HYDRAULIC CUT OFF SAW SERIOUS INJURY OR DEATH COULD RESULT FROM IM PROPER REPAIR OR SERVICE OF THIS TOOL REPAIRS AND OR SERVICE TO THIS TOOL MUST ONLY BE DONE BY AN AUTHORIZED AND CERTIFIED DEALER DE JD QUAM Q SAFETY OPERATION AND MAINTENANCE N Y iJ SERVICE MANUAL Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie OR 97267 5698 Copyright The Stanley Works 2005 OPS SVCE USA 503 659 5660 Printed in U S A FAX 503 652 1780 34956 8 2005 ver 2 www stanley hydraulic tools com SERVICING THE STANLEY HYDRAULIC Cutoff Saw This manual contains safety operation and routine maintenance instructions Servicing of hydraulic tools other than routine maintenance must be per formed by an authorized and certified dealer Please read the following warning SERIOUS INJURY OR DEATH COULD RESULT FROM THE IM PROPER REPAIR OR SERVICE OF THIS TOOL REPAIRS AND OR SERVICE TO THIS TOOL MUST ONLY BE DONE BY AN AUTHORIZED AND CERTIFIED DEALER For the nearest authorized and certified dealer call Stanley Hydraulic Tools at the number listed on the back of this manual and ask for a Customer Service Representative TABLE OF CONTENTS CERTIFICATE OF CONFORMIT Y illa 4 SAFETY SYMBOLS Da a anne SVD ideada deco eine 5 SAFETY PRECAUTIONS s as an as ia a a A a A na 6 TOOL STICKERS amp TAGS 22 128022 anga mE 8 HYDRAULIC HOSE REQU
7. 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 26 01594 03047 05071 32445 03025 32436 33084 33083 32047 32872 00170 30333 350771 00214 00120 31849 06316 06881 00772 00148 00166 30591 00713 00178 06854 06853 06855 33206 28322 28886 28811 05153 02004 52539 24058 24059 24069 31845 2 2 23 2 2 2 2 c 2 BR CO lo Ad I 2 c 2 c M 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 Idler Gear Name Tag CE Sticker CE Models Only Composite Sticker CE Models Only Information Plaque CE Models Only Stanley Sticker C
8. 2 Install and tighten the cutting head collar bolt and nut through the clamp on the cart 3 Install the hairpin cotter on the saw and the middle bracket on the cart to secure the saw s valve handle as sembly to the cart 4 Adjust the cable jacket travel Adjust the cable stop set screw on the bottom of the cable until the slack is taken out of the cable 5 Connect the water supply hose to the wheel guard REMOVE CUTOFF SAW FROM SAW CART The tool can easily be converted back to its original hand held configuration 1 Remove the water hose assembly as required 2 Release the saw from the cart by removing the hairpin cotter and cutting head collar nut and bolt DISASSEMBLY FLOW CONTROL REPLACEMENT The tamper proof flow control valve in the handle is preset at the factory and is not field serviceable If the drive shaft 20 speed exceeds the 4500 rpm maximum limit replace the flow control Refer to the Periodic Maintenance procedure earlier in this section for the drive shaft speed test CUTOFF WHEEL REMOVAL 1 Loosen and remove the wheel nut using a wrench while gripping the cutoff wheel 2 Remove the outside collar and blotter 3 Remove the wheel 4 Remove the inside blotter and collar Note Periodically inspect the thrust collar before replacing the wheel WHEEL GUARD REMOVAL The cutoff wheel and collars must first be removed by fol lowing the steps above 1 Remove the beveled retaining
9. Be careful not to damage the groove or surrounding surface 7 Remove the motor shaft from the bearing housing 8 Be careful to protect the surfaces on the bearing housing from damage while doing the rest of this step 9 Remove the large retaining ring securing the bearing on the wheel guard side of the motor housing 10 Tap lightly on the small end of the motor shaft gear side with a soft faced hammer to remove the shaft and bearing from the bearing housing Be careful not to strike the shaft from an angle or otherwise bend it IMPORTANT Do not remove the bearing from the motor shaft un less it must be replaced It may be damaged during removal 11 To remove a damaged bearing from the motor shaft support the bearing s outer race with an appropriate tube or pipe Press the threaded end of the motor shaft out of the bear ing Be careful not to bend the shaft Discard the bearing SERVICE 12 Remove the seals from the motor shaft bore in the bearing housing using Method A or B METHOD A Remove the retaining ring at the bottom of the bore Use the appropriate O ring service tool to carefully pry the seal gland out of the bore Note Do not damage the seal surfaces Note the seal orienta tion Remove the O ring from the outside of the seal gland and then remove the quad ring from inside the seal gland METHOD Insert a rubber tipped air nozzle in the gear side of the bore Partially ins
10. opposite holes in the face of the bearing housing Care fully align the dowel and bolt holes in the bearing and gear housings The hole pattern is designed so the housings can be joined only one way SERVICE 19 Slowly slide the gear housing over the gears until it con tacts the bearing housing 20 Turn the motor shaft manually to check for free rotation If it does not turn easily separate the housings and find the cause of the binding 21 Install eight capscrews Tighten finger tight 22 Recheck the shaft rotation When the shaft rotates eas ily tighten the capscrews 23 Install the motor in the motor housing by making sure the oil tubes are removed from the motor housing 24 Insert the motor into the motor housing and secure with two flat head machine screws 25 When new parts are installed it may be necessary to break in the motor After the saw has been reassembled without the guard the motor may be broken in as follows Connect the cutoff saw to a hydraulic power supply Start the saw and check for smooth operation If break in is required rotate the shaft with a wrench with and against pressure until the motor starts and runs freely The ON OFF valve must be held in the ON position THRUST COLLAR INSTALLATION 1 Insert the key into the groove on the motor shaft Use a small amount of grease to hold it in place 2 Push the thrust collar onto the motor shaft aligning the keyway with the key i
11. Date Datum le Fecha Data 3 98 N Signature Unterschrift Signature Firma Firma 4 4 bl Position Position Fonction Puesto Posizione Engineering Manager P N 62311 rev02 3 05 SAFETY SYMBOLS Safety symbols and signal words as shown below are used to emphasize all operator maintenance and repair actions which if not strictly followed could result in a life threatening situation bodily injury or damage to equip ment NOTICE IMPORTANT This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death This safety alert and signal word indicate an imminently hazardous situa tion which if not avoided will result in death or serious injury This safety alert and signal word indicate a potentially hazardous situation which if not avoided could result in death or serious injury This safety alert and signal word indicate a potentially hazardous situation which if not avoided may result in minor or moderate injury This signal word indicates a potentially hazardous situation which if not avoided may result in property damage This signal word indicates a situation which if not avoided will result in damage to the equipment This signal word indicates a situation which if not avoided may result in damage to the equipment Always observe safety symbols They are included for you
12. attaching or removing the saw from the cart requires only a few steps INSTALLATION Steps 1 through 4 are required only for the initial installation on a cart 1 Install the handlebar assembly by inserting the handlebar assembly in the tube at the top of the cart Insert with the control lever on the left side as you stand behind the cart 2 Center the assembly and secure with the 3 8 inch handlebar set bolt and locking nut 3 Install the foam grip on the left end of the handlebar us ing soapy water The right grip is installed at the factory 4 Connect the control cable to the control lever by insert ing the cable head into the lever housing and turn to lock in place and align the cable in the slotted conduit retainer on the control lever assembly and tighten the thumb nut SERVICE REMOVING HANDLEBAR FROM THE CUT OFF SAW 1 Loosen and remove the hex socket capscrews from the top and bottom of the handlebar next to the wheel guard 2 Slide the handle horizontally off the end of the motor as sembly Note Included with the saw cart is a tubular handle This handle replaces the existing tubular handle on the saw so that the operator may easily switch from cart use to hand use INSTALL CUTOFF SAW ON THE SAW CART 1 Position the saw on the cart with the round motor body inserted into the cart housing The cutting blade must be perpendicular to the floor and the guard positioned parallel to the cart frame
13. 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 Periodically look at the depth gauge and pointer 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 all
14. 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 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 If wheels are supplied with blotters attached inse
15. E Models Only Drive Screw Sound Power Level Decal Coupler Female Not Shown Coupler Male Not Shown Coupler Set SEAL KIT WARRANTY Stanley Hydraulic Tools hereinafter called Stanley subject to the exceptions contained below warrants new hydraulic tools for a period of one year from the date of sale to the first retail purchaser or for a period of 2 years from the shipping date from Stanley whichever period expires first to be free of defects in material and or workmanship at the time of delivery and will at its option repair or replace any tool or part of a tool or new part which is found upon examination by a Stanley authorized service outlet or by Stanley s factory in Milwaukie Oregon to be DEFECTIVE IN MATERIAL AND OR WORKMANSHIP EXCEPTIONS FROM WARRANTY FREIGHT COSTS Freight costs to return parts to Stanley if requested by Stanley for the purpose of evaluating a warranty claim for warranty credit are covered under this policy if the claimed part or parts are approved for warranty credit Freight costs for any part or parts which are not approved for warranty credit will be the responsibility of the individual SEALS 8 DIAPHRAGMS Seals and diaphragms installed in new tools are warranted to be free of defects in material and or workmanship for a period of 6 months after the date of first usage or for a period of 2 years from the shipping date from Stanley whichever period expires first CUTTING ACCESSORI
16. E ONLY PARTS AND REPAIR PROCEDURES APPROVED BY STANLEY AND DESCRIBED IN THE OPERA TION MANUAL TAG TO BE REMOVED ONLY BY TOOL OPERATOR SEE OTHER SIDE 8 D DO NOT LIFT OR CARRY TOOL BY THE HOSES DO NOT ABUSE HOSE DO NOT USE KINKED TORN OR DAMAGED HOSE 3 MAKE SURE HYDRAULIC HOSES ARE PROPERLY CONNECTED TO THE TOOL BEFORE PRESSURING SYSTEM SYSTEM PRESSURE HOSE MUST ALWAYS BE CONNECTED TO TOOL IN PORT SYSTEM RETURN HOSE MUST ALWAYS CONNECTED TO TOOL OUT PORT REVERSING CONNEC TIONS MAY CAUSE REVERSE TOOL OPERATION WHICH CAN RESULT IN SEVERE PERSONAL INJURY CONNECT OPEN CENTER TOOLS TO CLOSED CEN TER HYDRAULIC SYSTEMS THIS MAY RESULT IN LOSS OF OTHER HYDRAULIC FUNCTIONS POWERED BY THE SAME SYSTEM AND OR SEVERE PERSONAL INJURY BYSTANDERS MAY BE INJURED IN YOUR WORKAREA KEEP BYSTANDERS CLEAR OF YOUR WORK AREA WEAR HEARING EYE FOOT HAND AND HEAD PROTEC TION 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 OPERA TION MANUAL TAG TO BE REMOVED ONLY BY TOOL OPERATOR SEE OTHER SIDE shown smaller then actual size HYDRAULIC HOSE REQUIREMENTS HOSE TYPES Hydraulic hose type
17. ES Cutting accessories such as breaker tool bits are warranted to be free of defects in material and or workmanship at the time of delivery only ITEMS PRODUCED BY OTHER MANUFACTURERS Components which are not manufactured by Stanley and are warranted by their respective manufacturers a Costs incurred to remove a Stanley manufactured component in order to service an item manufactured by other manufacturers ALTERATIONS amp MODIFICATIONS Alterations or modifications to any tool or part All obligations under this warranty shall be terminated if the new tool or part is altered or modified in any way NORMAL WEAR any failure or performance deficiency attributable to normal wear and tear such as tool bushings retaining pins wear plates bumpers retaining rings and plugs rubber bushings recoil springs etc INCIDENTAL CONSEQUENTIAL DAMAGES To the fullest extent permitted by applicable law in no event will STANLEY be liable for any incidental consequential or special damages and or expenses FREIGHT DAMAGE Damage caused by improper storage or freight handling LOSS TIME Loss of operating time to the user while the tool s is out of service IMPROPER OPERATION Any failure or performance deficiency attributable to a failure to follow the guidelines and or procedures as outlined in the tool s operation and maintenance manual MAINTENANCE Any failure or performance deficiency attributable to not maintaining the tool s in good operatin
18. H HIGH TEMPERATURE SURFACES DO NOT USE IF KINKED DO NOT USE BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE ON HOSE TO PULL OR LIFT TOOLS POWER UNITS ETC OR NEAR ELECTRIC LINES WIPE THE ENTIRE LENGTH OF THE HOSE AND FITTING WITHA CLEAN DRY ABSORBENT CLOTH TO REMOVE DIRT AND MOSISTURE AND TEST CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAMAGE TO HOSE FOR MAXIMUM ALLOWABLE CURRENT LEAKAGE IN ACCORDANCE WITH SAFETY COUPLINGS IF ANY OF THESE CONDITIONS EXIST REPLACE THE HOSE IMMEDIATELY DEPARTMENT INSTRUCTIONS NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE AFTER EACH USE STORE IN A CLEAN DRY AREA DO NOT REMOVE THIS TAG OVL SIHL JAOWSY LON OG shown smaller than actual size THE TAG SHOWN BELOW IS ATTACHED TO CONDUCTIVE HOSE DANGER DANGER DO NOT USE THIS HYDRAULIC HOSE ON OR NEAR ELECTRIC LINES THIS HOSE IS NOT LABELED OR CERTIFIED AS NON CONDUCTIVE USING THIS HOSE ON OR NEAR 5 CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAMAGE TO ELECTRICAL LINES MAY RESULT IN DEATH OR SERIOUS INJURY COUPLINGS IF ANY OF THESE CONDITIONS EXIST REPLACE THE HOSE IMMEDIATELY NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY AED INCORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND 6 AFTER EACH USE STORE IN A CLEAN DRY AREA DO NOT EXCEED HOSE WORK
19. ING 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 KK SIDE 1 SIDE 2 shown smaller than actual size HOSE PRESSURE RATING Ovl SIHL dAOWdH LON OG lt E 2 I E gt gt x m o z a The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the hydraulic system HTMA REQUIREMENTS TOOL CATEGORY at 1 careco HYDRAULIC SYSTEM des REQUIREMENTS TYPE 1 TYPEII TYPE RR FLOW RATE 4 6 gpm 11 13 9 10 5 15 23 Ipm 26 34 Ipm 42 49 34 40 Ipm TOOL OPERATING PRESSURE 2000 psi 2000 psi 2000 psi 2000 psi at the power supply outlet 138 bar 138 bar 138 bar 138 bar SYSTEM RELIEF VALVE SETTING 2100 2250 psi 2100 2250 psi 2100 2250 psi 2200 2300 psi at the power supply outlet 145 155 bar 145 155 bar 145 155 bar 152 159 bar MAXIMUM BACK PRESSURE 250 psi 250 psi 250 psi 250 psi at tool end of the return hose 17 b
20. IREMENTS 03 455 a assa a Ek SA a EG BA An dL Ud 9 REQUIREMEN gcc a ir a a 10 OPERATION isss EEE E a a aii raion 11 PREOPERATION PROCEDURES ataca i on cree te BE Po ko EE idad 11 CHECK THE POWER SOURCE ts ei sin aa ta ga rin e 11 CHECK THE TOOL has a a E A a a EES la A fa R 11 CHECK TRIGGER MECHANISM itc etit mette et a ni ia a ad 11 GONNECTHIHOSES zu EEUU 11 TOOLOPERATON 222 11 STARTU eek sua BN a a S 11 GENERAL OPERATION asna sn er A SI S A cR RD NS 12 WET CUTTING conato Ea EN a a lito as 12 BROKEN CUT OFF WHEELS ii sl ka ask a ana Eg SA eed Ha Paesi e a LE N eb sa bi aan 12 A la a a B a a 12 PERIODIC MAINTENANCE u a a ai a a nf saa en Pe cenae 13 THRUST COLLAR AND INSIDE OUTSIDE COLLAR INSPECTION eee eeen 13 DRIVE SHAFT SPEED CHECK ica 13 BEARING CHECK cutis asian illa a lf dales A ia 13 CAREAND STORAGE comica 13 CUTOFF WHEEL S eei tido ocean cali ie 13 TOOL cinc A E T 13 CUTOFF WHEEL REPLACEMENT ai re tir cate sitae lada ae E MR de 14 COLD WEATHER OPERALDION rnt di ii id
21. LOSED 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 ALEAK BURST OR OTHER TOOL FAILURE CONTACT AT ALEAK OR BURST CAUSE OIL INJECTION INTO THE BODY FAILURE TO OBSERVE THESE PRECAUTIONS CAN RESULT IN SERIOUS PERSONAL INJURY Model 025 CAUTION PROTECT YOUR EYES WEAR SAFETY GOGGLES 1 Do not use damaged wheels 2 Use full throttle only while cutting 3 Use only wheels marked high speed reinforced that meet requirements Lwa 113 Za A of ANSI B7 5 Wheels should be no larger than 16 diameter x 5 31 thick with a 1 arbor hole and rated for 4700 rpm minimum speed 4 Inspect wheel guard amp collars for damage after any wheel breakage on the machine 5 Maximum spindle speed is 4700 rpm 05868 SAFETY LABEL 52539 SOUND POWER DECAL CE MODELS ONLY WHEEL SIZE MEL BRE TREO STANLEY B o e Stanley Hydraulic tools FLOW LPM GPM 30 LPM 138 B AR Stanley Works EHTMA CATEGORY 3810 SE Naef Road ee er Milwaukie OR 97267 28811 11207 05153 28322 INFORMATION PLAQUE CE MODELS ONLY CIRCUIT TYPE D DECAL STANLEY ADDRESS DECAL DECAL CE MODELS ONLY CE MODELS ONLY CE MODELS ONLY
22. N 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 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 work 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
23. amaged bushings Abrasive particles can become imbedded in the bushings and grind into the hardened shaft If this abnormal shaft wear occurs in excess of normal polishing both the shaft and associated bushings must be replaced Check the hydraulic system filter and hydraulic fluid for contamination Operating conditions may required changing from a 25 micron filter to an oversize 10 micron filter ASSEMBLY Always replace any seals or O rings that are disturbed dur ing disassembly of a part When installing the new seals lubricate them and make sure they seat all the way around the groove in the part All the required seals are in the seal kit Refer to the parts illustration in this manual for the location of parts MOTOR ASSEMBLY 1 Install the seal gland in the motor shaft bore in the bear ing housing 2 Lubricate and install the quad ring in the inside groove in the seal gland 3 Lubricate and install a new O ring on the outside of the seal gland 4 Carefully insert the narrow end of the seal gland in the bearing housing in the wheel guard end of the motor shaft bore 5 Install the retaining ring to hold the seal gland in place 6 Install a new bearing on the motor shaft if the old bearing was removed during disassembly 7 Support the new bearing s inner race and press the threaded end of the motor shaft through the center of the bearing until it bottoms out on the shaft s flange 8 Install the m
24. ar 17 bar 17 bar 17 bar Measured at a max fluid viscosity of 400 ssu 400 ssu 400 ssu 400 ssu at min operating temperature 82 centistokes 82 centistokes 82 centistokes 82 centistokes TEMPERATURE 140 F Sufficient heat rejection capacity 60 to limit max fluid temperature to at max expected ambient temperature Min cooling capacity hp 5 hp 7hp 6 hp at a temperature difference of 2 24 kW 3 73 kW 4 47 kW 5 22 kW between ambient and fluid temps 40 F 40 F 40 F 40 F 22 C 22 C 22 C 22 C NOTE Do not operate the tool at oil temperatures above 140 F 60 C Operation at higher temperatures can cause operator discomfort at the tool FILTER 25 microns 25 microns 25 microns 25 microns Min full flow filtration 30 gpm 30 gpm 30 gpm 30 gpm Sized for flow of at least 114 lpm 114 lpm 114 Ipm 114 Ipm For cold temp startup and max dirt holding capacity HYDRAULIC FLUID 100 400 ssu 100 400 ssu 100 400 ssu 100 400 ssu Petroleum based 20 82 centistokes premium grade anti wear non conductive VISCOSITY at min and max operating temps NOTE When choosing hydraulic fluid the expected oil temperature extremes that will be experienced in service determine the most suitable temperature viscosity characteristics Hydraulic fluids with a viscosity index over 140 will meet the require ments over a wide range of operating temperatures SSU Saybolt Secon
25. 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 EQUIPMENT PROTECTION amp CARE In addition to the Safety Precautions in this manual observe the following for equipment protection and care Make sure all couplers are wiped clean before connection The hydraulic circuit control valve must be in the OFF position when coupling or uncoupling hydraulic tools Failure to do so may result in damage to the quick couplers and cause overheating of the hydraulic system Always store the tool in a clean dry space safe from damage or pilferage Make sure the circuit PRESSURE hose with male quick disconnect is connected to the IN port The circuit RETURN hose with female quick disconnect is connected to the opposite port Do not reverse circuit flow This can cause damage to internal seals Always replace hoses couplings and other parts with replacement parts recommended by Stanley Hydraulic Tools Supply hoses must have a minimum wor
26. ds Universal NOTE These are general hydraulic system requirements See tool Specification page for tool specific requirements 10 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 Ipm 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 15 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 installed 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
27. e dd oet cda 14 EQUIPMENT PROTECTION SGARE 2 aa ds En sta a ln petere tent tt exea cil io cade iia cad eta ibn a aei ee etie 15 TROUBLESHOOTING 16 2 UE 17 ACCESSORIES e 17 SERVICE nation use Sita coL IV AUCI LAELIUS Id 18 25 PARTS ILLUSTRATION E 25 25 PARTS LIST ai ba a a E 26 WARRANTY saa sat aa al a a 27 CERTIFICATE OF CONFORMITY UBEREINSTIMMUNGS ZERTIFIKAT CERTIFICAT DE CONFORMITE CEE CERTIFICADO DE CONFORMIDAD Hvdraulic Tool CERTIFICATO DI CONFORMITA yaraulic 100IS 1 the undersigned Ich der Unterzeichnende Schultz Theodore J 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 certify that the construction plant or equipment specified hereunder best tige hiermit da das im folgenden genannten Werk oder Ger t certifies par ceci que l usine ou l quipement de construction indiqu cidessous por el presente certifico que la fabrica o el equipo especificado a continuacion certifico che l impianto o l attrezzatura sotto specificata 1 Cate
28. g condition as outlined in the Operation and Maintenance Manual HYDRAULIC PRESSURE amp FLOW Any failure or performance deficiency attributable to excess hydraulic pressure excess hydraulic back pressure or excess hydraulic flow REPAIRS OR ALTERATIONS Any failure or performance deficiency attributable to repairs by anyone which in Stanley s sole judgement caused or contributed to the failure or deficiency MIS APPLICATION Any failure or performance deficiency attributable to mis application Mis application is defined as usage of products for which they were not originally intended or usage of products in such a matter which exposes them to abuse or accident without first obtain ing the written consent of Stanley WARRANTY REGISTRATION STANLEY ASSUMES NO LIABILITY FOR WARRANTY CLAIMS SUBMITTED FOR WHICH NO TOOL REG ISTRATION IS ON RECORD In the event a warranty claim is submitted and no tool registration is on record no warranty credit will be issued without first receiving documentation which proves the sale of the tool or the tools first date of usage The term DOCUMENTATION as used in this paragraph is defined as a bill of sale or letter of intent from the first retail customer A WARRANTY REGISTRATION FORM THAT IS NOT ALSO ON RECORD WITH STANLEY WILL NOT BE ACCEPTED AS DOCUMENTATION NO ADDITIONAL WARRANTIES OR REPRESENTATIONS This limited warranty and the obligation of Stanley thereunder is in lieu of all othe
29. gory Cut Off Saw Kategorie Cat gorie Categoria Categoria 2 Make Ausf hrung 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 5 Year of manufacture Baujahr ann e de fabrication A o de fabricacion Anno di fabbricazione 1998 Has been manufactured in conformity with EEC Type examination as shown Wurde hergestellt in bereinstimmung mit EEC Typ Pr fung nach Est fabriqu conformement au x type s examin s comme indiqu dans le tableau ci apres Ha sido fabricado de acuerdo con tipo examen EEC como dice E stata costruita in conformit con le norme CEE come illustrato Examen CEE de type Directive No Date Approved body Date of expiry Richtlinie Nr Datum Pr fung durch Ablaufdatum Directives particulieres Num ro Date Organisme agr Date d expiration Directriz No Fecha Aprobado Fecha de caducidad Direttiva n Data Collaudato Data di scadenza Machinery Directive 98 37 EC 1998 Self NA EN 1454 1997 Self NA EN 792 7 2001 Self NA ISO 3744 1994 Self NA ISO 8662 1 1988 Self NA 6 Special Provisions None Spezielle Bestimmungen Dispositions particulieres Provisiones especiales Disposizioni speciali Done at Ort Fait Dado en Fatto a Stanley Hydraulic Tools Milwaukie Oregon USA
30. he spring tab on top of and facing the back of the catch 1 Place the safety catch in the valve handle and align the holes using a 3 16 inch 4 mm punch 2 Drive a 3 16 inch 4 8 mm roll pin through the holes us ing a punch and hammer 3 Push down on the spring tab until it snaps in place under the safety catch WHEEL GUARD If the wheel guard was removed install a washer on the guard clamp carriage bolt and align the bolt with the cor responding hole in the motor housing 1 Slide the center hole in the guard onto the motor pilot diameter and secure with the beveled retaining ring Make sure the beveled edge of the retaining ring is facing out ward 2 Place the remaining washer and the swingover nut on the carriage bolt and tighten only until secure CO25 PARTS ILLUSTRATION De Y gt d 7 7 N es MY 2 Ca NS 7 99 X ENG t N A L 8 s AM y S o P CEA amp VES el gt EOS N Se 25 1 1 1 1 1 1 1 1 1 1 1 1 2 8 2 4 2 1 1 1 2 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 2 1 1 25 PARTS LIST 42 mom _ 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
31. he wheel guard so it is between you and the cutting wheel Never operate the tool when you are tired CUT OFF WHEEL SAFETY Always inspect the cut off wheels for possible damage before 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 mounted on the saw If the cut off saw is dropped with a cutting wheel installed 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 4500 rpm minimum TOOL STICKERS TAGS STANLEY mum Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie OR 97062 Stanley Hydraulic tools Division of the Stanley Works 28886 3810 SE Naef Road COMPOSITE DECAL Milwaukie OR 97267 CE MODELS ONLY 05152 33206 03786 ADDRESS DECAL CO25 NAME TAG GPM DECAL CAUTION 7 9 GPM 26 34 LPM DO NOT EXCEED 2000 PSI 140 BAR DO NOT EXCEED SPECIFIED FLOW OR PRESSURE USE CLOSED CENTER TOOL ON C
32. hen 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 connec tions 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 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 specifications given in this manual Release the trigger if the power supply has been interrupted When working near electrical conductors always assume that all conductors are energized and that insulation clothing and hoses can conduct electricity Use hose labeled and certified as non conductive
33. hen conducting this test Excessive speed may be caused by excessive hydraulic fluid flow to the tool SERVICE BEARING CHECK Periodically inspect the bearings and associated parts for proper operation A worn or damaged bearing can cause motor damage ACCESSORY INSTALLATION HANDLE EXTENSION INSTALLATION An optional handle extension can be installed on the CO25 cutoff saw between the motor mount and the valve handle assembly 1 Remove the wheel guard by loosening and removing the wheel nut using a box end wrench while gripping the cutoff wheel 2 Remove the outside collar wheel and inside collar by removing the beveled retaining ring and swingover nut as sembly securing the wheel guard Remove the guard 3 Remove the four hex socket capscrews securing the valve handle assembly to the motor housing Separate the two assemblies 4 Carefully remove the two short oil tubes from the motor housing or valve handle If you plan to remove the exten sion at a later date and restore the cutoff saw to its original configuration Note Take care not to damage the sealing surfaces of the tubes 5 Clean wrap mark and store the oil tubes in a safe place 6 Install the extension on the motor housing by aligning the holes in the extension with those in the motor housing 7 Install and tighten the four hex socket capscrews from the motor housing side of the joint 8 Install the two long oil tubes in the extension by l
34. king 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 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 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 power 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 Tool does not operate Hydraulic ontrol valve OFF Turn the hydraulic system control valve ON Hydraulic hoses not connected prop erly Make sure the hoses are connected and the couplers are tight 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 Tool operates in reverse Hoses connected to
35. n the shaft 3 Tighten the setscrew using a hex wrench OIL TUBE AND VALVE HANDLE ASSEMBLY If the oil tubes and or valve handle assembly were re moved lubricate and install a new O ring on each end of the two oil tubes 2 Carefully insert the oil tubes in the motor housing until they bottom out in the motor Do not damage the sealing surfaces on the tubes or motor housing 3 Install the valve handle assembly on the motor housing by aligning the holes in the valve handle assembly with those in the motor housing 24 4 Carefully slide the valve handle assembly over the oil tubes until it meets the motor housing and secure in place with four hex socket capscrews ON OFF VALVE INSTALLATION If the valve in the valve handle assembly was removed lubricate and install new O rings on the plug and valve cap 1 Thread the valve cap assembly into the top of the valve handle assembly 2 Insert the poppet and spring in the bottom of the valve spool Insert the valve spool through the bottom of the valve handle Secure in place with the threaded plug TRIGGER INSTALLATION If the trigger was removed from the valve handle place the trigger and spacer between the upper set of holes in the valve handle 1 Drive a 1 4 inch 6 mm roll pin through the holes using a punch and hammer SAFETY CATCH INSTALLATION Ifthe safety catch was removed from the valve handle place the torsion spring on the boss of the safety catch with t
36. ng straight apart The oil tubes may be damaged if you twist or pull at an angle 2 Carefully remove the two oil tubes from the motor hous ing Make sure you do not damage the sealing surfaces on the tubes or motor housing MOTOR REMOVAL Remove the wheel thrust collar valve handle and oil IMPORTANT tubes Do not remove the bearing housing from the motor housing unless the oil tubes are removed 1 Remove two flat head machine screws securing the bearing housing to the motor housing 2 Remove the motor from the motor housing MOTOR DISASSEMBLY Remove the motor from the motor housing 1 Remove the tubular handlebar from the cutoff saw by loosening and removing the hex socket capscrews from the top and bottom of the handlebar next to the wheel guard 21 2 Slide the handle horizontally off the end of the motor as sembly 3 Remove the handlebar retainers from the ends of the handle 4 Remove eight capscrews securing the gear housing to the bearing housing 3 Carefully separate the gear and bearing housings using a flat blade screwdriver in the groove in the split between the housings to pry the parts apart IMPORTANT Pry only in the groove not on the mating surfaces Be sure not to scratch the mating surfaces 4 Separate the parts in a straight line to prevent damaging any internal components 5 Remove the two gears needle roller and idler shaft 6 Remove the large face seal O ring
37. otor shaft and bearing in the bearing hous ing Place the bearing housing on a smooth clean arbor press surface protected from damage with the large bear ing bore facing up Position the piece so that a clearance hole exists for the insertion of the motor shaft 9 Apply heavy grease to the motor shaft and bushing and fill the keyway on the shaft 10 Insert the motor shaft through the seal gland in the mo tor shaft bore 11 Use a sleeve or socket with a diameter equal to the bearing OD or shaft pusher P N 00850 to press the bear ing assembly into place Note Press only on the bearing outer race 12 Install the bearing retaining ring to secure the motor shaft assembly in place and then install the drive gear on the motor shaft 13 Install the needle roller in the keyway in the motor shaft Use a small amount of grease to keep it in place 14 Slide the drive gear onto the shaft over the needle roller 15 Install the idler shaft and gear by inserting the idler shaft in the second bore in the bearing housing Slide the idler onto the idler shaft 16 Apply grease to the face seal O ring groove Install the O ring in the groove 17 Install the gear housing on the bearing housing IMPORTANT Do not force the housings together 23 Note If they do not go together easily they are not properly aligned or one or more parts are not correctly installed 18 Make sure the two alignment dowel pins are in the
38. ow 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 OPERATION 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
39. r 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 hance personnel SAFETY PRECAUTIONS Tool operators and maintenance personnel must always comply with the safety precautions given in this manual and on the stickers and tags at tached to the tool and hose These safety precautions are given for your safety Review them carefully before operating the tool and before performing general maintenance or repairs Supervising personnel should develop additional precautions relating to the specific work area and local safety regula tions If so place the added precautions in the space provided on page 5 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 bystanders Flying debris can cause serious injury Do not operate the tool unless thoroughly trained or under the supervision of an instructor Establish a training program 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 w
40. r warranties expressed or implied including merchantability or fitness for a particular purpose except for that provided herein There is no other warranty This warranty gives the purchaser specific legal rights and other rights may be available which might vary depending upon applicable law 27 Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie OR 97267 5698 503 659 5660 FAX 503 652 1780 www stanley hydraulic tools com
41. ring from the motor pilot diameter inside the wheel guard using snap ring pliers 2 Unscrew and remove the swingover nut and washer securing the wheel guard 3 Remove the guard SAFETY CATCH REMOVAL 1 Drive the roll pin out of the valve handle assembly using a 3 16 inch 4 mm punch 2 Remove the safety catch and spring TRIGGER REMOVAL The cut off wheel wheel guard and safety catch must be removed to provide access to the roll pin in the valve handle 1 Drive the roll pin out of the valve handle assembly using a 1 4 inch 6 mm punch 2 Remove the trigger and spacer ON OFF VALVE REMOVAL The cutoff wheel wheel guard safety catch and trigger must be removed before valve removal SERVICE 1 Unscrew and remove the valve cap from the top of the valve handle assembly 2 Lift out the valve spool 3 Unscrew and remove the plug from the bottom of the valve handle assembly Carefully remove the spring and poppet blade brake from the spool bore if they do not come out with the plug THRUST COLLAR REMOVAL 1 Loosen the setscrew securing the thrust collar to the mo tor shaft using a hex wrench 2 Remove the key and thrust collar from the motor shaft OIL TUBE REMOVAL The valve handle assembly must be removed from the mo tor housing to access the oil tubes 1 Remove four hex socket capscrews securing the valve handle assembly to the motor housing Carefully separate the two assemblies by pulli
42. rt 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 tool in a clean dry place 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
43. s authorized for use with Stanley Hydraulic Tools are as follows O Certified non conductive Wire braided conductive Fabric braided not certified or labeled non conductive Hose listed above is the only hose authorized for use near electrical conductors Hoses and listed above are conductive and must never be used near electrical conductors HOSE SAFETY TAGS To help ensure your safety the following DANGER tags are attached to all hose purchased from Stanley Hydrau lic Tools DO NOT REMOVE THESE TAGS If the information on a tag is illegible because of wear or damage replace the tag 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 3 DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE IMPROPER USE OR WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRIC LINES MAYRESULT IN DEATH HANDLING OF HOSE COULD RESULT IN BURST OR OTHER HOSE FAILURE KEEP OR SERIOUS INJURY HOSE AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT CONTACT FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY DURING USE CONTACT AT THE BURST CAN CAUSE BODILY INJECTION AND SEVERE TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND PERSONAL INJURY ELECTRIC LINES HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING ABRASION CUTTING OR CONTACT WIT
44. s damaged or the mo tor appears to slow down excessively or be low on power Shake the bearing housing The two seal check balls should rattle If they do not the check valves are probably plugged with contaminants and the bearing housing should be replaced GEAR HOUSING Inspect the inner surface and bores The chamber bores and bottoms around the shaft bushings should appear smooth and polished If they are rough or grooved replace the gear housing The flat surface around the chamber and bolt holes should be flat and free of nicks or burrs that could cause misalign ment or leaks If they are not smooth replace the gear housing BUSHINGS Inspect the bushings for wear or discoloration The inside of the bushing should be gray with some bronze showing through If a significant amount of yellow bronze shows replace the bushing Inspect the motor shaft for corresponding wear Replace as required GEARS Check the gears for wear or damage Both gears should have square tooth ends straight tips without nicks and a smooth even polish on the teeth and end faces Replace both gears if either one is worn or dam aged SERVICE Check for cracks between the drive gear keyway and gear tooth root Replace the gear if one or more cracks are pres ent SHAFTS The surface of the motor shaft where the bearing and seal are mounted must be smooth Grooves roughness or a reduced diameter indicate fluid contamination or d
45. scard any exposed O rings Do not install any parts in the tool until they have been cleaned 18 1 Clean all parts with cleaning solvent making sure the area is well ventilated 2 Blow the parts dry with compressed air or wipe with clean lint free cloths 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 w
46. tall the small end of the motor shaft through the shaft seal Plug the seal vent holes on the face of the bearing housing and apply air pressure to force the seal gland out and onto the shaft PREPARE PARTS FOR ASSEMBLY Before the tool can be reassembled all parts must be cleaned inspected and repaired or replaced as needed Remove and discard all seals and O rings CLEANING 1 Clean all parts with degreasing solvent making sure the area is well ventilated 2 Blow the parts dry with compressed air to thoroughly clean oil passage ways or wipe with clean lint free cloths INSPECTION Inspect all parts for wear or damage replace as needed Parts with special inspection requirements are listed below IMPORTANT The tool parts are carefully machined at the factory to critical tolerances Do not attempt to refurbish the parts 22 To determine the extent of wear or damage to any part compare the surface to the examples in the Stanley Refur bishing Guide P N 28431 The kit includes a surface finish comparator and instructions for refurbishing parts BEARING HOUSING Inspect the inner surface and bores of the front bearing housing The bore for the seal gland should be smooth to prevent oil leakage If it is nicked or scratched replace the bearing housing The surface near the gears should show two interconnect ing polished circles without a step and should not be rough or grooved Replace the housing if it i
47. ubricat ing and installing an O ring on each end of the two long oil tubes included in the extension kit 9 Carefully insert the tubes in the large holes in the exten sion until they bottom out inside the motor 10 Install the valve handle assembly on the extension by aligning the oil tubes protruding from the extension with the holes in the valve handle assembly 19 11 Carefully slide the valve handle assembly onto the oil tubes until the handle mates with the extension 12 Install and tighten four hex socket capscrews from the extension side of the joint 13 Remove the tubular handlebar from the cutoff saw by loosening and removing the hex socket capscrews from the top and bottom of the handlebar next to the wheel guard 14 Slide the handlebar horizontally off the end of the motor assembly 15 Install the new assist handle by using two capscrews and the handlebar retainers removed from the original handle 16 Fasten the vertical strut of the assist handle to the extension using the hardware included in the extension kit On models using a 1 4 inch fastener install the spacer between the strut and the extension 17 Remove the handle strut assembly from the cut off saw as desired SAW CART INSTALLATION AND REMOVAL The CO25 cut off saw can be installed on a Stanley saw cart to provide a stable platform for slab cutting The saw can be easily removed again for handheld operation After the original installation
48. wrong ports on tool Connect input supply line to IN port and connect output return line to OUT port Oil leakage between motor housing and ON OFF vlave block or motor Oil tube o ring failure Replace o ring Motor face seal failure Replace seal Trigger difficult to operate Hoses connected to wrong ports on tool Connect input supply line to IN port 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 Saw cuts too slowly Wrong cut off wheel for work material Use correct wheel Insufficient oil flow Adjust oil flow to 7 9 gpm 26 34 Ipm Relief valve setting too low Adjust relief valve to 2100 2250 psi 145 155 bar 16 SPECIFICATIONS Wheel NS 14 inch 15 6 cm ANA 2110 0 mc 20 165 9 kg Overall Length ea en ee anne 21 inch 53 cm 11 inch 28 cm Pressure Range viii ais 1500 2000 psi 105 140 bar aedem 7 9 gpm 26 34 Ipm edunt 8 gpm 30 Ipm System Open Center Type II eemP 8 SAE O Ring Connect Size and Type
Download Pdf Manuals
Related Search