Stanley DS11 Hydraulic Diamond Saw
Contents
1. 03786 12412 12535 11207 GPM Sticker D5113000 Warning Decal 03790 f Sticker DS115000 L WA 108 Tool Plate 29530 28409 tanl tuli Tool E Milwauki 29530 Sound Level Decal Failure to use hydraulic hose labeled and certified as non conductive when using hydraulic tools on or near electric lines may result In death or serious Injury For proper and safe operation read owners manual D A N G E R D A N G E R and mwke sure that you have been properly FLECTROCUTION tralned In correct procedures required for work HAZARD on or around electric lines 1 FAILURE TO 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 12412 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 OUT2. EN gt NE Mey 7 Top connecting link Clamping screw Drive link Breaker plate Breaker block Bottom connecting link Figure 12 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 13 Do not use excessive force 7 IN 2777 Figure 13 Removing a Rivet DS11 User Manual lt 15 REPLAGING THE CHAIN BREAKER PUNCH If the chain breaker punch P N 22801 becomes worn or damaged use the following procedures for replace ment 1 Remove the punch by loosening the set screw Fig ure 14 Figure 16 Rivet Spinner Mounting 2 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 17 Figure 14 Removing the Punch 2 Insert a new punch into the holder and push it up until it is fully seated Figure 15 Secure the punch m to the chain breaker holder by fully tightening the Nee OJO ay set screw om its Figure 17 Positioning the Chain 3 Turn the take up handle until the chain is tight against the spinner anvil Figure 18 Take up Rivet Spinner Handle 2 M Figure 15 Replacing the Punch ge DD DT SPINNING RIVETS e se The following procedures explain how to spin rivets us ing Stanley s bench m
3. DS11 HYDRAULIG DIAMOND SAW USER MANUAL Safety Operation and Maintenance O 2012 Stanley Black amp Decker Inc New Britain CT 06053 U S A 62211 5 2014 Ver 9 DECLARATION OF CONFORMITY STA N L EY BEREINSTIMMUNGS ERKLARUNG DECLARATION DE CONFORMITE CEE Hydraulic Tools DECLARACION DE CONFORMIDAD DICHIARAZIONE DI CONFORMITA the undersigned F 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 M Make Marke Marque Marca Marca Stanley 3 0 113000 DS115000 4 Serial number of equipment Seriennummer des Ger ts Num ro de s rie de l quipement All Numero de serie del equipo Matricola attrezzatura Has been manufactured in conformity with Wurde hergestellt in Ubereinstimmung mit Est fabriqu conform ment Ha sido fabricado de acuerdo con E stata costruita in conformit con Directive Standards Appro
4. Always store the tool in a clean dry space safe from damage or pilferage Make sure the circuit PRESSURE hose with male quick disconnect is connected to the IN port The circuit RETURN hose with female quick disconnect is connected to the opposite port Do not reverse cir cuit flow This can cause damage to internal seals Always replace hoses couplings and other parts with replacement parts recommended by Stanley Hydraulic Tools Supply hoses must have a mini mum working pressure rating of 2500 psi 172 bar 18 gt 0511 User Manual Do not exceed the rated flow and pressure See Specifications page in this manual for correct flow rate and rated pressure Rapid failure of the internal seals may result Always keep critical tool markings such as warning stickers and tags legible Tool repair should be performed by experienced personnel only Make certain that the recommended relief valves are installed in the pressure side of the system Do not use the tool for applications for which it was not intended STANLEY PROBLEM CAUSE REMEDY Excessive vibration and cuts rough Retension the chain Excessive feed force Reduce feed force Chain saw will not cut straight Operator feed force not applied Move left hand closer to centerline of saw directly over centerline of saw bar Accumulated saw bar wear and Turn the saw bar over and dress rails uneven chain segment profile wear square Replace the saw bar
5. 05 91 06 08 00 00L 07 61 GOL G G 2 0 dn dn SYOLONGNOD 1VOIW12313 YVAN ASN LON OQ J80 4 pIEJg 9JIM SOH sy n L 3113 404 Jeq 4 9Aljonpuo2 uoN 4 PRESSURE 219 IVS Aq yoy 195 se 4 5 rv Bunes AJLA 5 y p9 8J e 52 15 esou oi neJp U Aue pesn aq zou 5 pue joo 5100 Inep H uo peseq joo 104 pesn SI yeyo siu 00 eJnsue 2 e oJnssaJd Sul UINJSJ daay epueuuuloo8J 2594 Jed sed uo peseq 9504 sJejeuleip 2504 SMOUS 1 SU yey 941 9SOH JOO DS11 User Manual lt 9 STANLEY HTMA
6. 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 CLASSIFICATION AAAA Flow Range 3 5 4 3 gpm 13 5 16 5 Ipm 1870 psi 129 bar Nominal Operating Pressure at the power supply outlet System relief valve setting 2495 psi at the power supply outlet 172 bar 4 1 5 8 18 22 Ipm 1500 psi 103 bar 2000 psi 138 bar 7 1 8 7 gpm 27 33 Ipm 1500 psi 103 bar 2000 psi 138 bar 9 5 11 6 gpm 36 44 Ipm 1500 psi 103 bar 2000 psi 138 bar 11 8 14 5 gpm 45 55 Ipm 1500 psi 103 bar 2000 psi 138 bar NOTE These are general hydraulic system requirements See tool specification page for t
7. 95 dBa PANNEN ve 3 7m sec ACCESSORIES AGR ETNE T t 20857 Diamond Chaini BE SN 20858 Diamond Chain Repair Kit includes 20857 amp 20858 eene nnn nnne nnn nnns 20856 Wall Walker Standard Equipment on Newer Models 23176 BIER e evi o NS SE NE t 20470 Replacement Nose SIK ede 22800 e See VV ENC EE EE 23517 3rodnch Flushi Face Coupler SE Lua rosenes 03971 172 me Flush Face Coupler _ _ 03974 25 feet 1 2 inch Dual Hose with Flush Face Couplers 31972 50 feet 1 2 inch Dual Hose with Flush Face Couplers rrrrrrrnnrenarernrrnnnnnranenanennnvnraneranennernranennnennnsenasennnennesene 31848 BT ENE 30305 TET NE 30306 Diamond Ultra 32 Sealed Chain for 15 inch 56801 Diamond Pinnacle 32 Sealed Chain for 15 inch 56803 Diamond Ultra 37 Sealed Chain for 18 inch 56802 Diamond Pinnacle 32 Sealed Chain for 18 inch 58632 wie GE eee RO ____6 6__ _____________ 39496 Water Pump 12 VDO DO PIU EE DCP30100 Water Pump 12 VDC Battery D aneneacadsdagteataneutoneacecuasdineancatemnneceds DCP30101 20 gt 0511 User Manual STANLEY w ox Item 3
8. EHTMA REQUIREMENTS HTMA HYDRAULIC SYSTEM REQUIREMENTS Flow Range Nominal Operating Pressure at the power supply outlet System relief valve setting at the power supply outlet Maximum back pressure at tool end of the return hose Measured at a max fluid viscosity of at min operating temperature Temperature Sufficient heat rejection capacity to limit max fluid temperature to at max expected ambient temperature Min cooling capacity at a temperature difference of between ambient and fluid temps NOTE TYPE 4 6 gpm 15 23 lpm 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 TOOL TYPE 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 C TYPE RR 9 10 5 gpm 34 40 lpm 1500 psi 103 bar 2200 2300 psi 152 159 bar 250 psi 17 bar 400 ssu 82 centistokes 140 F 60 C 6 hp 5 22 kW 40 F 22 C TYPE Ill 11 13 gpm 42 49 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 F 60 C Operation at higher temperatures can cause operator discomfort at the tool
9. This signal word indicates a potentially hazardous situation which if not avoid ed may result in property damage This signal word indicates a situation which if not avoided will result in damage to the 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 gt 0511 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 additional pre cautions relating to the specific work area and local safety regulations If so place the added precautions in the space provided in this manual The DS11 Concrete Chain 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 hoses before operation Failure to do so could result i
10. 1 to a city or auxiliary water supply 2 Holding the saw away from your body turn the saw on and read the water pressure at the water gauge Water pressure must be at least 35 psi 2 4 bar to avoid damage to the saw bar and chain 3 If you plan on operating the chain saw in freezing weather make sure you purge all the water from the system after each use 4 If the water pressure is below 35 psi 2 4 bar make the required adjustments to the water supply If the required pressure cannot be achieved you must use the Stanley Electric Water Pump Kit Part Number 26020 or the Power Unit Water Pump Kit P N 29361 STANLEY CHECK CHAIN AND BAR ADJUSTMENT 1 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 2 Make sure the chain does not exceed a clearance of 1 4 in 6 mm from the bar see Figure 2 Exceeding the maximum clearance increases the chance of the chain being dislodged from the bar groove Figure 2 Maximum Chain Clearance 3 Make sure the bar attaching nuts are fully tightened and the chain guard is in place CHECK CHAIN SEGMENT WEAR 1 Using adjustable calipers measure several chain segments as illustrated in Figure 3 Figure 3 Chain Segment Wear 2 f the average measurement is less than 1 16 i
11. 9 torque to 23 30 ft Ibs 2 6 360 inch 05 STANLEY DS11 User Manual lt 21 PART ITEM NO QTY DESCRIPTION a fors s e ona 1 HELICON sr6 18 uc x 21216 ___ 2 CIRCUIT TYPE D STICKER WASHER 5 16 1 0 22 DS11 User Manual PART ITEM NO UY DESCRIPTION 56 25688 1 MOTOR ASSY SEE PAGE 23 FOR ene STANDARD amp UNDER WATER MOTOR PARTS 28552 VALVE HANDLE ASSY INCLUDES ITEM 49 seo 1 ROLLPINTEOD X200016 f r meo DRIVE SPROCKET ea fam CHANGUARD es from 1 nemos nos 1 room sr 357 1 homommexmuG esa e mue 1 wawar 29530 SOUND POWER LEVEL STICKER NOT PICTURED 107386 GPM STICKER NOT PICTURED gt gt gt gt gt Part of Seal Kit SEAL KIT PIN 22798 00173 LEN 00175 _____ 0069 0 0 on gt 0164 02008 0990 26260 350771 STANLEY U W DENOTES USED ON UNDER WATER MODELONLY DESCRIPTION RETAINING RING 4 100208 HSHCS 1 4 20 X 1 3 4 p wer caPscREW wosto _____ 5 wee ws 1 s ow WEEPERSERLRBENNNG p fosset 2 DOWEL PIN UW BSTT5000 2 orive cear Uw DENS STANLEY ITEM PART NO DESCRIPTION 15 06861 1 GEAR HOUSING ASSY INCLUDES ITEMS 13 a
12. GENERAL MAINTENANCE TIPS Several simple maintenance tasks which if performed can keep a chain saw operating at a 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 6 shows a worn saw bar rail REMOVE WIRE EDGE WITH FLAT FILE Figure 7 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 7 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 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 gt 0511 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 ba
13. ING 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 LON OG SEE OTHER SIDE SEE OTHER SIDE Shown smaller than actual size THE TAG SHOWN BELOW IS ATTACHED TO CONDUCTIVE HOSE DO NOT USE THIS HYDRAULIC H
14. OIL INJECTION INTO THE BODY FAILURE TO CAUSE OIL INJECTION INTO THE BODY FAILURE TO OBSERVE THESE PRECAUTIONS CAN RESULT IN SERIOUS OBSERVE THESE PRECAUTIONS CAN RESULT IN SERIOUS PERSONAL INJURY PERSONAL INJURY TO AVOID PERSONAL INJURY OR EQUIPMENT DAMAGE CHECK TOOL HOSE COUPLERS AND CONNECTORS ALL TOOL REPAIR MAINTENANCE AND SERVICE MUST LEAKS DO NOT Ree Oe TEARS WITH ONLY BE PERFORMED BY AUTHORIZED AND PROPERLY 03786 DS113000 03790 DS115000 te se ge 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 The safety tag p n 15875 at right is attached to PROCEDURES APPROVED BY PROCEDURES APPROVED BY STANLEY AND DESCRIBED IN THE STANLEY AND DESCRIBED IN THE the tool when shipped from the factory Read and OPERATION MANUAL OPERATION MANUAL understand the safety instructions listed on this tag TAG TO BE REMOVED ONLY BY TAG TO BE REMOVED ONLY BY before removal We suggest you retain this tag and TOOL OPERATOR TOOL OPERATOR attach it to the tool when not in use SEE OTHER SIDE SEE OTHER SIDE SAFETY TAG PIN 15875 Shown smaller then actual size STANLEY DS11 User Manual 4 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
15. OSE 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 PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY AFTER EACH USE STORE IN A CLEAN DRY AREA TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND ELEC TRIC LINES DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE IMPROPER USE OR HANDLING OF HOSE COULD RESULT IN BURST OR OTHER HOSE FAILURE KEEP HOSE AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT CONTACT DURING USE CONTACT AT THE BURST CAN CAUSE BODILY INJECTION AND SEVERE PERSONAL INJURY HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING CUTTING OR CONTACT WITH HIGH TEMPERATURE SURFACES DO NOT USE IF KINKED DO NOT USE HOSE TO PULL OR LIFT TOOLS POWER UNITS ETC ee SEE OTHER SIDE SEE OTHER SIDE OVL SIHL LON OG lt I gt Shown smaller than actual size 8 DS11 User Manual STANLEY SUONDSUUON eoid eunDi RETURN HYDRAULIC CIRCUIT PRESSURE lt lt lt NYNLIH gt gt gt JYUNSSIYUd 0 8 g dn 09 08
16. PORT RENT LEAKAGE IN ACCORDANCE WITH YOUR SAFETY REVERSING CONNECTIONS MAY CAUSE REVERSE DEPARTMENT INSTRUCTIONS TOOL OPERATION WHICH CAN RESULT IN SEVERE PERSONAL INJURY GR Ne DO NOT CONNECT OPEN CENTER TOOLS TO CLOSED EN CENTER HYDRAULIC SYSTEMS THIS MAY RESULT IN LOSS OF OTHER HYDRAULIC FUNCTIONS POWERED DO NOT EXCEED SPECIFIED FLOW AND PRESSURE THE SAME SYSTEM AND OR SEVERE PERSONAL INJURY OR PRESSURE BYSTANDERS MAY BE INJURED IN YOUR WORK AREA KEEP BYSTANDERS CLEAR OF YOUR WORK AREA DO NOT EXCEED RATED WORKING PRESSURE OF HYDRAULIC HOSE USED WITH THIS TOOL EXCESS oa HERE ENG PRESSURE MAY CAUSE A LEAK OR BURST 7 9 GPM 26 34 LPM 10 14 GPM 38 53 LPM DO NOT EXCEED 2000 PSI 140 BAR DO NOT EXCEED 2000 PSI 140 BAR DO NOT EXCEED SPECIFIED FLOW OR PRESSURE USE DO NOT EXCEED SPECIFIED FLOW OR PRESSURE USE CLOSED CENTER TOOL ON CLOSED CENTER SYSTEM CLOSED CENTER TOOL ON CLOSED CENTER SYSTEM USE OPEN CENTER TOOL ON OPEN CENTER SYSTEM USE OPEN CENTER TOOL ON OPEN CENTER SYSTEM CORRECTLY CONNECT HOSES TO TOOL IN AND OUT CORRECTLY CONNECT HOSES TO TOOL IN AND OUT PORTS IMPROPER HANDLING USE OR MAINTENANCE PORTS IMPROPER HANDLING USE OR MAINTENANCE OF TOOL COULD RESULT IN A LEAK BURST OR OTHER OF TOOL COULD RESULT IN A LEAK BURST OR OTHER TOOL FAILURE CONTACT AT A LEAK OR BURST CAN TOOL FAILURE CONTACT AT A LEAK OR BURST CAN CAUSE
17. RE 6 TYPES OF CUTS CHAIN GUARD REMOVED FOR CLARITY Lunner p E pou dU mase 12 MAINTENANCE TMEN T cease 14 FIGURE RLE T H 14 FIGURE LI M H Pr 14 FIGUREN EXPOSED DRIVE TAN eee 14 FIGURE NERE ERNA 15 FIGURE Ti REMOVABLE RNET EADS Le ee 15 FIGURE INSERTING TET Ne 15 Pe ee ARIVE cem 15 FIGURE 14 REMOVING ENN 16 FIGURE 19 REPLACING THE PIN ve 16 FIGURE 16 RIVE MOUNTING oE oE EEEE ee ee ee eee ee 16 FIGURE THES ANN 16 HEN SECUIRING THE C ANIN n a Easa ek 16 Pe CENTERING THE RIVE T AUB eee 17 FIGURE ZOG FTSE EE NS 17 FIGURE Z FORMING EE 17 FIGURE 22 SANNER OLING CHAMBERS c 17 TOOLE PROTE G NE 18 19 FE TNS 20 NE ME 20 DST PART pects 21 BE EE 22 BS PES Eu 24 IMPORTANT To fill out a Product Warranty Recording form and for information on your warranty visit Stanleyhydraulics com and select the Company tab Warranty NOTE The warranty recording form must be submitted to validate the warranty SERVICING THE STANLEY DIAMOND CHAIN SAW This manual contains safety operation and routine mainte nance in
18. and chain Loss of power Drive sprocket slipping on Adjust and tighten Trantorque adapter Trantorque adapter 35 ft 165 47 Nm Chain saw does not run Power source not functioning Check power source for proper flow and pressure 7 9 gpm 26 34 2000 psi 140 bar Coupler or hoses are blocked Remove obstruction Mechanical failure Disassemble the chain saw and inspect for damage Chain saw runs backwards Pressure and return hoses reversed Connect for proper flow direction Motor shaft must rotate clockwise Trigger is hard to press Pressure and return hoses reversed Connect to proper flow direction Motor shaft must rotate clockwise Back pressure too high Should not exceed 250 psi 17 bar Q 9 gpm 34 Ipm measured at the end of the chain saw s operating hoses Fluid leakage around drive sprocket Motor shaft seal failure Replace as required Fluid leakage between the rear gear Motor face seal failure Replace as required housing and the chain saw adaptor Fluid leakage between the valve Oil tube seal failure Replace as required handle and the extension housing Fluid leakage between the extension Oil tube seal failure Replace as required housing assembly and the chain saw adaptor Chain saw cuts slow Insufficient hydraulic fluid flow or low Adjust proper hydraulic fluid flow to proper relief valve setting gpm For optimum performance adjust relief valve to 2100 2250 psi 145 155 ba
19. ations relating to them including if appropriate arranging for the safe disposal of the materials by a qualified person 0511 User Manual 4 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 a chain saw that is damaged im properly adjusted or not completely and securely assembled Make sure the chain stops moving when the control trigger is 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 transporting 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 0511 User Manual Che
20. ccidents 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 e 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 generate 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 regul
21. ck all chain breaker and rivet spinner compo 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 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 12535 Circuit E Decal DS115000 Only 11207 Circuit D Decal DS113000 Only 28409 Composite Decal 40 LPM 138 BAR EHTMA CATEGORY 30 LPM 138 BAR EHTMA CATEGORY
22. mp 20 31849 1 GEAR HOUSING ASSY U W DS115000 Incds Items 13 amp 20 19884 SEAL GLAND 20466 MOTOR SHAFT 23752 MOTOR SHAFT U W 20472 RETAINING RING EXTERNAL 19 21436 1 FRONT BEARING HOUSING ASSY INCLUDES ITEM 13 amp EXPANDER PLUGS ten SHAFT KEYED UW DS 16000 Part of Seal Kit 22798 DS11 User Manual lt 23 ITEM QTY DESCRIPTION 03972 1 COUPLER 3 8 FEM 3 8 NPT COUPLER SET P N 03971 03973 1 COUPLER 3 8 MALE 3 8 NPT COUPLER SET P N 03971 40 _ 20497 WATER HOSE ASSY 5 6 0 58 62 63 2 2 4 2550 SPROCKET WRENCH 56725 HOSE ASSY 18 INCH BAR SEE ACCESSORIES ON PAGE 20 AT CHAINS SEE BELOW OR AC ACE CESSORIES ON PAGE 20 E DIAMOND CHAIN APPLICATIONS PINNACLE 32 15 INCH 56803 VERY HARD AGGREGATE CONCRETES FLINT CHERT GRANITE ETC HEAVY PINNACLE 37 18 INCH 58632 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 32 15 INCH 56801 MEDIUM HARD AGGREGATE CONCRETES GRANITE QUARTZ RIVER ROCK ULTRA 37 18 INCH 56802 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 24 gt DS11 U
23. n personal injury or equipment damage e Establish a training program for all operators to en sure safe operation e 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 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 a
24. nch 1 6 mm then the chain must be replaced Refer to your Service Manual for chain replacement pro cedures CHECK THE WATER SUPPLY IMPORTANT Chain and bar damage will occur if the chain saw operates without the proper water supply 1 Always have water running before starting the chain saw 2 Water flow must 4 gpm 15 at 50 psi 3 5 bar minimum DS11 User Manual lt 11 OPERATING PROCEDURES NEW SAW CHAIN BREAK IN 1 Always make sure the bar and sprocket are in good condition Turn on the water supply 3 Operate the chain saw for two minutes away from the intended cut and then check the chain tension 4 Adjust accordingly using the procedures contained in the Maintenance and Adjustments section of this manual NOTE The chain is designed to only operate in one direc tion Make sure the chain is installed so the bumper guard proceeds each diamond segment See Figure 4 Incorrect Figure 4 Chain Direction CUTTING TIPS 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 PLAN THE CUT 1 Plan your cuts to prevent injury to yourself and to keep f
25. ool specific requirements STANLEY 10 gt DS11 User Manual PREOPERATION PROCEDURES CHECK THE POWER SOURCE 1 Using a calibrated flow meter and pressure gauge make sure the hydraulic power source develops a flow of 7 9 gpm 26 34 lpm 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 Make certain that the power source return pressure does not exceed 250 psi 17 bar CONNECT HYDRAULIC HOSES 1 Wipe all hose couplers with a clean lint free cloth before making connections If necessary use a 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 hoses 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 4 Move the hydraulic circuit control valve to the ON position to operate the chain saw 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 TO A WATER SUPPLY 1 Using a standard garden hose connect the DS1
26. ounted rivet spinner P N 20857 to assembly the chain Figure 18 Securing the Chain Turn the rivet spinner crank a few times to center the 1 Mount the rivet spinner flush with the side or front of rivet hub in the spinner anvil Figure 19 a flat clean work surface Figure 16 16 gt DS11 User Manual STANLEY Rivet Spinner Take up Handle Figure 19 Centering the Rivet Hub 5 Apply a few drops of oil to the rivet hub Figure 20 Te 2 207 gu NY je n jJ Figure 20 Applying the Oil 6 Turn the spinner crank while slowly running the take up handle inward approximately one full revolution until the rivet head is formed Figure 21 NOTE The take up handle provides pressure while the spinner anvil forms the rivet head Figure 21 Forming a Rivet Head STANLEY NOTE The rivet spinner is equipped with oiling chambers and should be maintained periodically with a light weight oil Figure 22 Figure 22 Spinner Oiling Chambers DS11 User Manual 4 17 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
27. r Back pressure too high Should not exceed 250 psi 17 bar Q 9 gpm 34 Ipm measured at the end of the chain saw s operating hoses Loss of diamond segment side Replace the chain clearance Hydraulic fluid mixed in water supply Check motor for leaks Chain segment dulled because of Redress segment by cutting in abrasive continuous use in hard material or material i e concrete build block etc rebar NOTE This indicates that the wrong chain is being used Wrong chain for application Scale down to a lower numbered chain Excessive vibration and cuts rough Segment s broken or missing from Remove and repair broken segment or chain replace chain STANLEY DS11 User Manual lt 19 C uting Depths c gt gt 15 or 18 inch 38 or 46 cm PTE NM 15 or 18 inch 38 or 46 cm Input Flow Range BEE TE EE EE 7 9 gpm 26 34 Ipm BREE EE EE 12 gpm 45 Ipm MIP 2000 psi 140 bar ATT NN 3 8 inch Pitch ve 26 Ibs 11 8 kg Zope penc M ee re rere 35 or 38 inches 89 or 97 cm MN 9 inches 23 cm HU oa fee Lie Sc Internal Water Channels in Bar ein e 8 SAE O ring CONDECION EE 3 8 inch Flush Face Quick Disconnect Coupler SN Yes Sound Power Level aen 108 dBa Sound Pressure Levels Operator 1 meter ISO 3744
28. r attachment nuts Item 62 Parts Illustration 3 Using the saw bar adjustment screw Item 65 Parts Illustration tighten the chain until you are still able to rotate it one full revolution by hand Figure 8 Figure 8 Pulling the Chain 4 Using hand and finger protection 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 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 9 7 3 pz Figure 9 Exposed Drive Link Tang STANLEY SERVICING THE CHAIN The following procedures explain how to break a chain using 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 10 Figure 10 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 11 are the only ones that can be removed IRN Figure 11 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 12 STANLEY
29. rom pinching the saw bar and chain as a re sult of falling pieces of concrete brick etc 12 gt 0511 User Manual 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 Making 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 DS11 can be operated using the types of cuts shown in Figure 6 When making cuts PLUNGE CUT Figure 6 Types of Cuts Chain guard removed for clarity 1 Do not use a cutting force in excess of 45 Ibs 20 kg Excessive force causes the chain to slow down or stall and causes premature wear of the saw bar and chain STANLEY 2 Always maintain a high chain speed High chain speeds produce the best results 3 Avoid aggressive heavy plunge forces Aggressive plunge force creates spalling of the concrete when the saw bar and chain exits and causes premature bar and chain wear COLD WEATHER OPERATION If the saw is to be used during cold weather preheat the 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 too viscous or thick STANLEY DS11 User Manual 4 13
30. ser Manual STAN LEY NOTES STANLEY Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie Oregon 97267 5698 USA 503 659 5660 Fax 503 652 1780 www stanleyhydraulics com
31. structions Stanley Hydraulic Tools recommends that servicing of hydraulic tools other than routine main tenance 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 STANLEY DS11 User Manual lt 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 death This safety alert and signal word indicate an imminently hazardous situation which if not avoided will result in death or serious injury A DANGER 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
32. 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 BELOW IS ATTACHED TO CERTIFIED NON CONDUCTIVE HOSE DANGER DANGER FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE DO NOT EXCEED HOSE WORK
33. ved body Richtlinie Standards Prufung durch Directives Normes 5 Organisme agr Directriz Los Normas Aprobado Direttiva Norme Collaudato 12100 1 2009 12100 2 2009 3744 2009 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 Were he Position Position Fonction Cargo Posizione Engineering Manager 1 4 2011 2 gt DS11 User Manual STANLEY DECLARATION OF NN 2 FEN SMP se 4 SPE RE UNN 5 Dies STICKER NNN 7 HO ETNE sa gh sn ttc 8 POSE RECOMMENDATION meen ee EEE EE eee M I ICM eee 9 LANSEN MENN 9 EU sls Es QUIREMENT crm 10 FIGURE 2 MAXIMUM CLEARANCE vr ___________ ____ _ 11 FIGURE 3 CPIRIN SEGMENT WEAR ___________ _______ _ __________ SERES 11 UN 11 FIGURE ae Sd U IN 12 mtb p c 12 FIGU
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