Stanley CO25, CO2554101, CO2514101 Service Manual
CO25
HYDRAULIC
CUT-OFF SAW
WARNING
Copyright© The Stanley Works 2005
OPS/SVCE USA
Printed in U.S.A.
34956 8/2005 ver 2
SAFETY, OPERATION AND MAINTENANCE
SERVICE MANUAL
Stanley Hydraulic Tools
3810 SE Naef Road
Milwaukie OR 97267-5698
503-659-5660
FAX 503-652-1780
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 performed by an authorized and certifi ed 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 certifi ed dealer, call Stanley Hydraulic Tools at the number listed on the
back of this manual and ask for a Customer Service Representative.
WARNING
TABLE OF CONTENTS
CERTIFICATE OF CONFORMITY ..................................................................................................................................................4
SAFETY SYMBOLS ........................................................................................................................................................................ 5
SAFETY PRECAUTIONS ...............................................................................................................................................................6
TOOL STICKERS & TAGS .............................................................................................................................................................8
HYDRAULIC HOSE REQUIREMENTS ..........................................................................................................................................9
HTMA REQUIREMENTS ..............................................................................................................................................................10
OPERATION ................................................................................................................................................................................. 11
PREOPERATION PROCEDURES ............................................................................................................................................11
CHECK THE POWER SOURCE ............................................................................................................................................... 11
CHECK THE TOOL ................................................................................................................................................................... 11
CHECK TRIGGER MECHANISM ............................................................................................................................................. 11
CONNECT HOSES ................................................................................................................................................................... 11
TOOL OPERATION ................................................................................................................................................................... 11
STARTUP ..................................................................................................................................................................................11
GENERAL OPERATION ...........................................................................................................................................................12
WET CUTTING .........................................................................................................................................................................12
BROKEN CUT-OFF WHEELS ..................................................................................................................................................12
SHUTDOWN .............................................................................................................................................................................12
PERIODIC MAINTENANCE ......................................................................................................................................................13
THRUST COLLAR AND INSIDE/OUTSIDE COLLAR INSPECTION ........................................................................................13
DRIVE-SHAFT SPEED CHECK ................................................................................................................................................ 13
BEARING CHECK ..................................................................................................................................................................... 13
CARE AND STORAGE ............................................................................................................................................................. 13
CUTOFF WHEELS .................................................................................................................................................................... 13
TOOL .........................................................................................................................................................................................13
CUTOFF WHEEL REPLACEMENT ..........................................................................................................................................14
COLD WEATHER OPERATION ................................................................................................................................................14
EQUIPMENT PROTECTION & CARE .......................................................................................................................................... 15
TROUBLESHOOTING ..................................................................................................................................................................16
SPECIFICATIONS ........................................................................................................................................................................17
ACCESSORIES ............................................................................................................................................................................ 17
SERVICE ...................................................................................................................................................................................... 18
CO25 PARTS ILLUSTRATION ..................................................................................................................................................... 25
CO25 PARTS LIST ....................................................................................................................................................................... 26
WARRANTY .................................................................................................................................................................................. 27
3
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:
hereby certify that the construction plant or equipment specified hereunder:
bestätige hiermit, daß das im folgenden genannten Werk oder Gerät:
certifies par ceci que l’ usine ou l’ équipement de construction indiqué cidessous:
por el presente certifico que la fabrica o el equipo especificado a continuacion:
certifico che l’impianto o l’attrezzatura sotto specificata:
1. Category: Cut-Off Saw
Kategorie:
Catégorie:
Categoria:
Categoria:
2. Make/Ausführung/Marque/Marca/Marca Stanley
3. Type/Typ/Type/Tipo/Tipo: CO2554101, CO2514101
4. Serial number of equipment:
Seriennummer des Geräts:
Numéro de série de l’équipement:
Numero de serie del equipo:
Matricola dell´attrezzatura:
5. Year of manufacture/Baujahr/année de fabrication/Año de fabricacion/Anno di fabbricazione 1998
Has been manufactured in conformity with - EEC Type examination as shown.
Wurde hergestellt in Übereinstimmung mit - EEC Typ-Prüfung nach.
Est fabriqué conformément - au(x) type(s) examiné(s) comme indiqué dans le tableau ci-après.
Ha sido fabricado de acuerdo con - tipo examen EEC como dice.
E’ stata costruita in conformitá con - le norme CEE come illustrato.
Examen CEE de type
Directive
Richtlinie
Directives particulières
Directriz
Direttiva
Machinery Directive
EN
EN
ISO
ISO
6. Special Provisions: None
Spezielle Bestimmungen:
Dispositions particulières:
Provisiones especiales:
Disposizioni speciali:
Done at/Ort/Fait à/Dado en/Fatto a
Signature/Unterschrift/Signature/Firma/Firma____________________________________________________________________________
Position/Position/Fonction/Puesto/Posizione
P/N 62311 rev 02 3/05
No.
Nr
Numéro
No
n.
98/37/EC
1454
792-7
3744
8662-1
Schultz, Theodore J.
Surname and First names/Familiennname und Vornamen/Nom et prénom/Nombre y apellido/Cognome e nome
All
Date
Datum
Date
Fecha
Data
1998
1997
2001
1994
1988
Stanley Hydraulic Tools, Milwaukie, Oregon USA Date/Datum/le/Fecha/Data 3/98
Engineering Manager
Approved body
Prüfung durch
Organisme agréé
Aprobado
Collaudato
Self
Self
Self
Self
Self
Date of expiry
Ablaufdatum
Date d´expiration
Fecha de caducidad
Data di scadenza
NA
NA
NA
NA
NA
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.
This safety alert and signal word indicate an imminently hazardous situa-
DANGER
WARNING
CAUTION
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
NOTICE
IMPORTANT
Always observe safety symbols. They are included for your safety and for the protection of the tool.
damage to the equipment.
This signal word indicates a situation which, if not avoided, may result in
damage to the equipment.
LOCAL SAFETY REGULATIONS
Enter any local safety regulations here. Keep these instructions in an area accessible to the operator and maintenance personnel.
5
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 specifi c work area and local safety regulations. 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 when
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 fi rm
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 connections are tight and are in good condition.
• Do not operate the tool at oil temperatures above 140°F/60°C. Operation at higher temperatures can cause higher than
normal temperatures at the tool which can result in operator discomfort.
• 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 specifi cations 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 certifi ed as non-conductive.
• To avoid personal injury or equipment damage, all tool repair, maintenance and service must only be performed by authorized and properly trained personnel.
6
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 rotation by changing the direction of the oil fl ow.
• Always operate the tool within its rated capacity. Never exceed the maximum operating speed marked on the wheel.
• Do not operate the tool near fl ammable 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 fl ow control on the valve handle.
• Know the location of burried or covered services before starting work.
• Adjust the 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.
7
TOOL STICKERS & TAGS
28886
COMPOSITE DECAL
(CE MODELS ONLY)
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
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 & collars for damage after any wheel breakage on the machine.
5. Maximum spindle speed is 4700 rpm.
05868
SAFETY LABEL
Stanley Hydraulic tools
Division of the Stanley Works
3810 SE Naef Road
Milwaukie, OR 97267
05152
ADDRESS DECAL
Stanley Hydraulic Tools
3810 SE Naef Road
Milwaukie, OR 97062
Model
33206
CO25 NAME TAG
CAUTION
7-9 GPM / 26-34 LPM
DO NOT EXCEED 2000 PSI / 140 BAR
DO NOT EXCEED SPECIFIED FLOW OR PRESSURE
USE CLOSED-CENTER TOOLON CLOSED-CENTER
SYSTEM. USE OPEN-CENTER TOOLON OPEN-CENTER
SYSTEM. CORRECTLYCONNECT HOSES TO TOOL “IN”
AND “OUT” PORTS. IMPROPER HANDLING,USE OR OTHER
MAINTENANCE OF TOOLCOULD RESULT IN A LEAK, BURST
OR OTHER TOOLFAILURE. CONTACT AT A LEAK OR BURST
CAN CAUSE OIL INJECTION INTOTHE BODY. FAILURE TO
OBSERVE THESE PRECAUTIONS CAN RESULTIN SERIOUS
PERSONAL INJURY.
03786
GPM DECAL
Lwa
113
52539
SOUND POWER DECAL
(CE MODELS ONLY)
28811
INFORMATION PLAQUE
(CE MODELS ONLY)
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.
D
30 LPM @ 138 B AR
EHTMA CATEGORY
11207
CIRCUIT TYPE D DECAL
(CE MODELS ONLY)
DANGER
1. 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 DEPARTMENT INSTRUCTIONS.
2. 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.
B DO NOT EXCEED RATED WORKING PRESSURE OF HY-
DRAU LIC HOSE USED WITH THIS
TOOL. EXCESS PRESSURE MAY
CAUSE A LEAK OR BURST.
C CHECK TOOL HOSE COUPLERS AND CONNECTORS DAILY
FOR LEAKS. DO NOT FEEL FOR LEAKS WITH YOUR
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-
SAFETY TAG P/N 15875
TION MANUAL.
TAG TO BE REMOVED ONLY BY
TOOL OPERATOR.
SEE OTHER SIDE
(shown smaller then actual size)
05153
STANLEY ADDRESS DECAL
(CE MODELS ONLY)
DANGER
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 BE
CONNECTED TO TOOL “OUT” PORT. REVERSING CONNECTIONS MAY CAUSE REVERSE TOOL OPERATION WHICH CAN
RESULT IN SEVERE PERSONAL INJURY.
4. DO NOT CONNECT OPEN-CENTER TOOLS TO CLOSED-CENTER HYDRAULIC SYSTEMS. THIS MAY RESULT IN LOSS OF
OTHER HYDRAULIC FUNCTIONS POWERED BY THE SAME
SYSTEM AND/OR SEVERE PERSONAL INJURY.
5. BYSTANDERS MAY BE INJURED IN YOUR WORK AREA. KEEP
BYSTANDERS CLEAR OF YOUR WORK AREA.
6. WEAR HEARING, EYE, FOOT, HAND AND HEAD PROTECTION.
7. 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
28322
CE DECAL
(CE MODELS ONLY)
8
HYDRAULIC HOSE REQUIREMENTS
HOSE TYPES
Hydraulic hose types authorized for use with Stanley Hydraulic Tools are as follows:
Certifi ed non-conductive
Wire-braided (conductive)
Fabric-braided (not certifi ed 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 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
D A N G E R
1 FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON-CONDUCTIVE
WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRIC LINES MAYRESULT IN DEATH
OR SERIOUS INJURY.
FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY
TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND
ELECTRIC LINES.
2. BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS NON-CONDUCTIVE ON
OR NEAR ELECTRIC LINES. WIPE THE ENTIRE LENGTH OF THE HOSE AND FITTING
WITH A CLEAN DRY ABSORBENT CLOTH TO REMOVE DIRT AND MOSISTURE AND TEST
HOSE FOR MAXIMUM ALLOWABLE CURRENT LEAKAGE IN ACCORDANCE WITH SAFETY
DEPARTMENT INSTRUCTIONS.
DO NOT REMOVE THIS TAG
SIDE 1 SIDE 2
3
(shown smaller than actual size)
3. 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.
4. HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING, ABRASION, CUTTING, OR
CONTACT WITH HIGH TEMPERATURE SURFACES. DO NOT USE IF KINKED. DO NOT USE
HOSE TO PULL OR LIFT TOOLS, POWER UNITS, ETC.
5. CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS, BULGES, OR DAMAGE TO
COUPLINGS IF ANY OF THESE CONDITIONS EXIST, REPLACE THE HOSE IMMEDIATELY.
NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE.
6. AFTER EACH USE STORE IN A CLEAN DRY AREA.
D A N G E R
THE TAG SHOWN BELOW IS ATTACHED TO “CONDUCTIVE” HOSE.
D A N G E R
1 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
ELECTRICAL LINES MAY RESULT IN DEATH OR SERIOUS INJURY.
2. FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY
TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND
ELECTRIC LINES.
3. 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.
4. 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.
DO NOT REMOVE THIS TAG
SIDE 1 SIDE 2
(shown smaller than actual size)
5. CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS, BULGES, OR DAMAGE TO
COUPLINGS IF ANY OF THESE CONDITIONS EXIST, REPLACE THE HOSE IMMEDIATELY.
NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE.
6. AFTER EACH USE STORE IN A CLEAN DRY AREA.
D A N G E R
SEE OTHER SIDE
DO NOT REMOVE THIS TAG
DO NOT REMOVE THIS TAG
The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the
hydraulic system.
HOSE PRESSURE RATING
9
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