DS06 HYDRAULIC DIAMOND SAW WARNING SAFETY, OPERATION AND MAINTENANCE SERVICE MANUAL Copyright © 2005, The Stanley Works OPS/MAINT USA 34567 8/2005 Ver 3 Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie OR 97267-5698 503-659-5660 FAX 503-652-1780 www.stanley-hydraulic-tools.
TABLE OF CONTENTS CERTIFICATE OF CONFORMITY ............................................................................................................................................................................4 SAFETY SYMBOLS ..................................................................................................................................................................................................5 SAFETY PRECAUTIONS ................................................................
CERTIFICATE OF CONFORMITY ÜBEREINSTIMMUNGS-ZERTIFIKAT CERTIFICAT DE CONFORMITE CEE CERTIFICADO DE CONFORMIDAD CERTIFICATO DI CONFORMITA Hydraulic Tools ______________________________________________________________________ I, the undersigned: Ich, der Unterzeichnende: Je soussigné: El abajo firmante: lo sottoscritto: Schultz, Theodore J.
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 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.
SAFETY PRECAUTIONS Tool operators and maintenance personnel must always comply with the safety precautions given in this manual and on the stickers and tags attached to the tool and hose. These safety precautions are given for your safety. Review them carefully before operating the tool and before performing general maintenance or repairs. Supervising personnel should develop additional precautions relating to the specific work area and local safety regulations.
SAFETY PRECAUTIONS • Remove or control the water slurry to prevent yourself or others from slipping while cutting. • Provide adequate ventilation in closed areas when operating a gas or diesel hydraulic power source. • Always be well rested and mentally alert before operating 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.
TOOL STICKERS & TAGS D 30 LPM @ 138 B AR EHTMA CATEGORY 12412 Warning Decal 11207 11206 Lwa 11206 Circuit “C” Decal 11207 Circuit “D” Decal 33445 Name Tag Decal 28323 CE Decal 28409 11212 DANGER 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.
HYDRAULIC HOSE REQUIREMENTS HOSE TYPES Hydraulic hose types authorized for use with Stanley Hydraulic Tools are as follows: ➊ Certified non-conductive ➋ Wire-braided (conductive) ➌ Fabric-braided (not certified or labeled non-conductive) Hose ➊ listed above is the only hose authorized for use near electrical conductors. Hoses ➋ and ➌ listed above are conductive and must never be used near electrical conductors.
HTMA REQUIREMENTS TOOL CATEGORY HYDRAULIC SYSTEM REQUIREMENTS FLOW RATE TYPE 1 TYPEII 7-9 gpm (26-34 lpm) 2000 psi (138 bar) TYPEIII TOOL OPERATING PRESSURE (at the power supply outlet) 4-6 gpm (15-23 lpm) 2000 psi (138 bar) SYSTEM RELIEF VALVE SETTING (at the power supply outlet) 2100-2250 psi 2100-2250 psi 2100-2250 psi 2200-2300 psi (145-155 bar) (145-155 bar) (145-155 bar) (152-159 bar) MAXIMUM BACK PRESSURE (at tool end of the return hose) 250 psi (17 bar) Measured at a max.
OPERATION CONNECT HYDRAULIC HOSES PREOPERTION PROCEDURES 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. 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 for the 8 gpm model and 4-6 gpm/15-23 lpm for the 5 gpm model at 2000 psi/140 bar. 2.
OPERATION 2. Make your cuts in the order shown in Figure 4, starting with cut 1 (base horizontal cut) and proceeding with the remaining three cuts. 2. Make sure the bar attaching nuts are fully tightened and the chain guard is in place. Bottom of Bar Max 5/16” Figure 2. Maximum Chain Clearance CHECK CHAIN SEGMENT WEAR Figure 4. Planning Cuts 1. Using adjustable calipers, measure several chain segments as illustrated in Figure 3. 3. Outline the concrete area with a permanent marker for a visual guide.
OPERATION TYPES OF CUTS COLD WEATHER OPERATION The DS06 can be operated using the types of cuts shown in Figure 5. When making cuts: 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.
MAINTENANCE & ADJUSTMENTS GENERAL MAINTENANCE TIPS CHAIN TENSION ADJUSTMENT Several simple maintenance tasks which, if performed, can keep a chain saw operating at a high level of efficiency. Routine maintenance also keeps replacement costs down on the parts of the chain saw, which occasionally wear out. 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).
MAINTENANCE & ADJUSTMENTS Max 5/16” Bottom of Bar Figure 10. Exposed Drive Link Tang SERVICING THE CHAIN The following procedures explain how to break a chain using Stanley’s bench mounted chain breaker (part number 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 11). Figure 13. Inserting the Chain 3.
MAINTENANCE & ADJUSTMENTS REPLACING THE CHAIN BREAKER PUNCH If the chain breaker punch (part number 22801) becomes worn or damaged, use the following prcedures for replacement. 1. Remove the punch by loosening the set screw (Figure 15). Figure 17. Rivet Spinner Mounting 2. Lay the chain across the plastic chain supports and then rotate the supports so the rivet head is centered between the take-up handle pocket and the spinner anvil (Figure 18). Figure 15. Removing the Punch 2.
MAINTENANCE & ADJUSTMENTS 4. turn the rivet spinner crank a few times to center the rivet hub in the spinner anvil (Figure 20). Take-up Handle Rivet Spinner Crank Figure 23. Spinner Oiling Chambers Figure 20. Centering the Rivet Hub 5. Apply a few drops of oil to the rivet hub (Figure 21). NOTE: the rivet spinner is equipped with oiling chambers and should be maintained periodically with a light-weight oil (Figure 23). NOSE SPROCKET DISASSEMBLY AND ASSEMBLY 1.
MAINTENANCE & ADJUSTMENTS 5. Insert 6 nose rivets into the holes and then hold them with your thumb. Remove the screwdriver and slide out the insertion card. Note: On used bars the nose rails might tend to spread apart. Use a small clamp if necessary to hold the rails together. 6. With the bar and rivets solidly supported on a strong flat steel surface, carefully peen the rivet heads down with the flat end of a hammer. Be careful to only hit the rivet head.
TOOL EQUIPMENT & CARE NOTICE 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.
TROUBLESHOOTING correct hydraulic flow and pressure to the tool as listed in the table. Use a flowmeter known to be accurate. Check the flow with the hydraulic oil temperature at least 80°F/27°C. If symptoms of poor performance develop, the following chart can be used as a guide to correct the problem. When diagnosing faults in operation of the tool, always check that the hydraulic power source is supplying the SYMPTOM Tool does not run. CAUSE REMEDY Hydraulic power source not functioning correctly.
TROUBLESHOOTING SYMPTOM CAUSE REMEDY Leakage around drive sprocket. Motor shaft seal failure. Have unit serviced. No water discharge at bar. Blocked port(s) in bar. Turn off hydraulic supply. Remove bar and chain and clean bar thoroughly. Blow ports with compressed air. Blocked inlet or outlet. Turn off hydraulic supply. Remove bar and chain. Make sure water supply is on. Press trigger to see if water exits near bar adjustment nut area (a small port). If no water exits, have unit serviced.
SPECIFICATIONS Cutting Depths ............................................................................................................................................ 13 inches / 33 cm Bar Lengths ....................................................................................................................................................13 inch / 33 cm Chain Type ............................................................................................................
SERVICE INSTRUCTIONS PRIOR TO DISASSEMBLY a reduced diameter indicate fluid contamination. If abnormal wear is present (more than normal polishing), replace both the spool and the handle. Clean exterior of the tool. Obtain a seal kit so that all seals exposed during disassembly can be replaced. ON-OFF VALVE SERVICING TRIGGER (28) AND SAFETY CATCH (30) REMOVAL & INSTALLATION 1. Drive the roll pins (20) out of the handle assembly using a 3/16 in./4 mm diameter punch.
SERVICE INSTRUCTIONS MOTOR SERVICING 1. Remove the 2 nuts (51) and then lift off the chain guard (50). 2. Lift off the bar (61) and chain (73). If it is necessary to take tension off the bar and chain, turn the screw (68) counter clockwise. For Diamond Saws with Serial Number 357 and above, follow the steps a thru c, then proceed to Step 7. 11. To remove the bearing from the shaft, press on the outside end (sprocket end) of the motor shaft while supporting the outer race of the bearing.
SERVICE INSTRUCTIONS groove should be smooth as should the rest of the flat surface. Serial Number 357 and Above. 13 The bore for the shaft seal should be smooth or oil leakage may occur. 91 57 54 53 8 90 4 92 GEAR HOUSING 47 Shake the gear housing and the two seal check balls (not shown) should rattle. If the seal balls do not rattle then they are probably plugged with contaminants and the gear housing will require replacement.
SERVICE INSTRUCTIONS For Diamond Saws with Serial Number 357 and above follow steps a thru e. For Diamond Saws with Serial Number 356 and below, follow steps 10 thru 13. a. Install the o-ring (43). Push in until it contacts the bearing face. b. Install seal washer (94) and the retainer ring (98). c. Install v-ring (95) onto seal ring (96) then with both in hand, apply a small amount of 242 LoctiteTM to the bore of the seal ring (96).
DS06 PARTS ILLUSTRATION For Serial Numbers 357 and Above.
DS06 PARTS LIST For Serial Numbers 357 and Above. Item No. Part No. Qty Description Item No. Part No.
DS06 PARTS ILLUSTRATION For Serial Numbers 356 and Below.
DS06 PARTS LIST Item Qty No 1 2 3 Part No.
DIAMOND CHAIN APPLICATIONS Model Bar Length P/N Correct Applications PinnaclePinnacle- 13 inch Very hard aggregate concretes (flint, chert, granite, etc). Heavy steel reinforcing, 5/8 inch/16 mm diameter and larger. Medium/hard aggregate concretes (granite, quartz, river rock, etc). Moderate steel reinforcing (wire mesh 3/8-1/2 inch/10-12 mm diameter).
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 Stan
Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie OR 97267-5698 503-659-5660 FAX 503-652-1780 www.stanley-hydraulic-tools.
