Page 1
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
Page 2
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
Page 3
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
Page 4
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
Page 5
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
Page 6
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.
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Page 7
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.
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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)
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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
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Page 10
HTMA REQUIREMENTS
TOOL CATEGORY
HYDRAULIC SYSTEM
REQUIREMENTS TYPE 1 TYPEII TYPEIII TYPE RR
FLOW RATE
TOOL 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. fl uid viscosity of:
(at min. operating temperature)
TEMPERATURE
Suffi cient heat rejection capacity
to limit max. fl uid temperature to:
(at max. expected ambient temperature)
Min. cooling capacity
at a temperature difference of
between ambient and fl uid temps
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.
4-6 gpm 7-9 gpm 11-13 gpm 9-10.5 gpm
(15-23 lpm) (26-34 lpm) (42-49 lpm) (34-40 lpm)
2000 psi 2000 psi 2000 psi 2000 psi
(138 bar) (138 bar) (138 bar) (138 bar)
2100-2250 psi 2100-2250 psi 2100-2250 psi 2200-2300 psi
(145-155 bar) (145-155 bar) (145-155 bar) (152-159 bar)
250 psi 250 psi 250 psi 250 psi
(17 bar) (17 bar) (17 bar) (17 bar)
400 ssu* 400 ssu* 400 ssu* 400 ssu*
(82 centistokes) (82 centistokes) (82 centistokes) (82 centistokes)
140° F 140° F 140° F 140° F
(60° C) (60° C) (60° C) (60° C)
3 hp 5 hp 7 hp 6 hp
(2.24 kW) (3.73 kW) (4.47 kW) (5.22 kW)
40° F 40° F 40° F 40° F
(22° C) (22° C) (22° C) (22° C)
FILTER
Min. full-fl ow fi ltration
Sized for fl ow 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:
When choosing hydraulic fl uid, the expected oil temperature extremes that will be experienced in service determine the
most suitable temperature viscosity characteristics. Hydraulic fl uids with a viscosity index over 140 will meet the requirements over a wide range of operating temperatures.
*SSU = Saybolt Seconds Universal
NOTE:
These are general hydraulic system requirements. See tool Specifi cation page for tool specifi c requirements.
25 microns 25 microns 25 microns 25 microns
30 gpm 30 gpm 30 gpm 30 gpm
(114 lpm) (114 lpm) (114 lpm) (114 lpm)
100-400 ssu* 100-400 ssu* 100-400 ssu* 100-400 ssu*
(20-82 centistokes)
10
Page 11
OPERATION
PREOPERATION PROCEDURES
CHECK THE POWER SOURCE
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.
Careful inspection of the tool and hydraulic system before
startup is important for safe, reliable operation of the tool.
1. Using a calibrated fl owmeter and pressure gauge, check
that the hydraulic power source develops a fl ow of 7–9 gpm
(26–34 lpm) 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 is 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 correct 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.
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 fi ttings or quick disconnects. It is good practice to connect the return hose fi rst and disconnect it last to minimize
or eliminate trapped pressure within the wrench.
3. Observe the fl ow indicators stamped on the valve handle
assembly and the hose couplers to ensure that the fl ow 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 diffi cult 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.
5. Inspect the handlebar. Make sure the handlebar is securely fastened to the cutoff saw and is clean of any oil to
ensure a fi rm grip.
IMPORTANT
Check the speed of the motor output shaft after every
100 hours of operation.
CHECK TRIGGER MECHANISM
1. Inspect the trigger and safety catch. Make sure the trigger operates smoothly and is free to travel between the
“ON: and “OFF” positions.
2. Make sure the trigger is set to disengage the cut-off saw
when released.
HANDHELD CONFIGURATION:
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.
11
Page 12
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 expansion 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 control valve is in
neutral. Alternatively, use a direct line from the tool outlet to
the tank.
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 allow 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 diffi cult
to break during normal use.
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 secure and there is a steady fl ow 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 counterclockwise (CCW).
If a wheel breaks while operating the cut-off saw, investigate 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 (fi rst 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.
12
Page 13
OPERATION
PERIODIC MAINTENANCE
For maximum performance and reliability of the tool, periodically 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 Replacement).
1. Remove the key and thrust collar from the motor shaft.
2. Check the thrust collar for burrs. Remove burrs as required.
3. Check the threads on the clamping setscrew.
4. Inspect the collar bores and fl anges.
5. Check for burrs. Remove burrs as required.
6. Check that the bearing surfaces are fl at and run true
when mounted on the motor shaft and thrust collar.
DRIVE-SHAFT SPEED CHECK
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 fl at surface of steel or similar
rigid material.
4. If wheels are supplied with blotters attached, insert suitable separators between each wheel and the supporting
surface to preserve fl atness.
5. Do not store wheels where they will be exposed to high
humidity, water or other liquids, excessive heat, or freezing
temperatures.
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
fl uid fl ow to the tool.
BEARING CHECK
Periodically inspect the bearings and associated parts for
proper operation. A worn or damaged bearing can cause
motor damage.
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 removed 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 improperly used by someone who is not familiar with the safety
requirements.
3. Store the tool in a clean, dry place.
13
Page 14
OPERATION
CUTOFF WHEEL REPLACEMENT
1. Move the hydraulic system control valve to the Off position.
2. Disconnect the hydraulic hoses from the tool (fi rst 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 integrity of the wheel at the maximum tool speed.
5. Prior to installing the wheel, inspect it for chips, cracks or
other damage and replace if damaged.
6. Install the outside blotter and collar, rotate the collar so
that the fl at on the motor shaft aligns with the fl at 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
fl uid 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
Page 15
EQUIPMENT PROTECTION & 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.
• 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 fl ow. 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 working pressure rating of 2500 psi/172 bar.
• Do not exceed the rated fl ow (see Specifi cations) in this manual for correct fl ow 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
Page 16
TROUBLESHOOTING
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 wrench, always check that the hydraulic power source is supplying the correct hydraulic
fl ow and pressure to the tool as listed in the following table. Use a fl ow meter known to be accurate. Check the fl ow with
the hydraulic fl uid temperature at least 80o F/27o C.
PROBLEM CAUSE SOLUTION
Hydraulic ontrol valve OFF. Turn the hydraulic system control
valve ON.
Tool does not operate.
Tool operates in reverse.
Oil leakage between motor housing
and ON/OFF vlave block or motor.
Trigger diffi cult to operate.
Saw cuts too slowly.
Hydraulic hoses not connected properly.
Hydraulic system not functioning. Check power unit for correct fl ow and
Couplers or hoses blocked. Remove obstruction.
Mechanical failure. Disassemble tool and inspect for dam-
Hoses connected to wrong ports on
tool.
Oil tube o-ring failure. Replace o-ring.
Motor face seal failure. Replace seal.
Hoses connected to wrong ports on
tool.
Excessive back-pressure. If back pressure is greater than 250
Wrong cut-off wheel for work material. Use correct wheel.
Insuffi cient oil fl ow. Adjust oil fl ow to 7-9 gpm/26-34 lpm.
Relief valve setting too low. Adjust relief valve to 2100-2250
Make sure the hoses are connected
and the couplers are tight.
presssure.
age.
Connect input (supply) line to IN port
and connect output (return) line to
OUT port.
Connect input (supply) line to IN port
and connect output (return) line to
OUT port.
psi/17 bar, correct the return line obstruction or restriction.
psi/145-155 bar.
16
Page 17
SPECIFICATIONS
Wheel Capacity .............................................................................................................................................14-inch/15.6 cm
Weight ...................................................................................................................................................................20 lbs/9 kg
Overall Length ..................................................................................................................................................21-inch/53 cm
Width ................................................................................................................................................................ 11-inch/28 cm
Pressure Range .......................................................................................................................... 1500-2000 psi/105-140 bar
Flow Range .............................................................................................................................................. 7-9 gpm/26-34 lpm
Optimum Flow ...................................................................................................................................................8 gpm/30 lpm
System Type ............................................................................................................................... Open Center, HTMA Type II
Porting ..............................................................................................................................................................8 SAE O-Ring
Connect Size and Type ............................................................................................................... 3/8-inch Male Pipe Adapter
Rotation RPM ................................................................................................................................................................. 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 µPa) at operator’s position, in decibels 101.5 dBA
Uncertainty, Kpa, in decibels 3 dBA
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/sec²
Uncertainty: K 1.0 m/sec²
Values determined according to ISO 8662-1, ISO 5349-1,2
ACCESSORIES
DESCRIPTION PART NUMBER
14-inch Abrasive Wheel for Metal, 1-inch Arbor ...........................................................................................................02691
14-inch Abrasive Wheel for Masonry, 1-inch Arbor ....................................................................................................... 02692
Water Attachment ......................................................................................................................................................... 33228
Slab Saw Cart .............................................................................................................................................................. 33281
Water Tank Kit for P/N 33281 .......................................................................................................................................33474
Handle Extension Kit .................................................................................................................................................... 34175
Diamond Blade, 14-inch Dry Cut .................................................................................................................................. 62358
17
Page 18
SERVICE
GENERAL SERVICE
REQUIREMENTS
Do not disassemble the tool unless an internal problem
has been identifi ed. 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 replace a defective part.
Do not put the tool back in service until the source of the
problem has been identifi ed 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
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, periodically 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 Replacement).
1. Remove the key and thrust collar from the motor shaft.
2. Check the thrust collar for burrs. Remove burrs as required.
• 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 fi rst 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 discard any exposed
O-rings. Do not install any parts in the tool until they have
been cleaned.
3. Check the threads on the clamping setscrew.
4. Inspect the collar bores and fl anges.
5. Check for burrs. Remove burrs as required.
6. Check that the bearing surfaces are fl at 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 when conducting this test.
• Excessive speed may be caused by excessive hydraulic
fl uid fl ow to the tool.
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Page 19
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 assembly 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.
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
4. Carefully remove the two short oil tubes from the motor
housing or valve handle. If you plan to remove the extension at a later date and restore the cutoff saw to its original
confi guration:
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 lubricating 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 extension 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.
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, 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 new 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 using soapy water. The right grip is installed at the factory.
4. Connect the control cable to the control lever by inserting 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.
19
Page 20
SERVICE
REMOVING HANDLEBAR FROM THE CUTOFF 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 assembly.
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 fl oor and the guard positioned parallel
to the cart frame.
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 assembly to the cart.
4. Adjust the cable jacket travel. Adjust the cable stop setscrew 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
speed exceeds the 4500 rpm maximum limit, replace the
fl ow 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 fi rst be removed by following the steps above.
1. Remove the beveled retaining 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.
The tool can easily be converted back to its original handheld confi guration.
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 fl ow control valve in the handle is preset
at the factory and is not fi eld serviceable. If the drive-shaft
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.
20
Page 21
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 motor 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 motor 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 pulling 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 housing. 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
tubes.
IMPORTANT
Do not remove the bearing housing from the motor
housing unless the oil tubes are removed.
1. Remove two fl at-head machine screws securing the
bearing housing to the motor housing.
2. Remove the motor from the motor housing.
2. Slide the handle horizontally off the end of the motor assembly.
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 fl at-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. 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 unless it must be replaced. It may be damaged during
removal.
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.
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 bearing. Be careful not to bend the shaft.
Discard the bearing.
21
Page 22
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 orientation.
Remove the O-ring from the outside of the seal gland and
then remove the quad ring from inside the seal gland.
METHOD B:
Insert a rubber-tipped air nozzle in the gear side of the
bore.
Partially install 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.
To determine the extent of wear or damage to any part,
compare the surface to the examples in the Stanley Refurbishing Guide (P/N 28431). The kit includes a surface-fi nish
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 interconnecting polished circles without a step and should not be rough
or grooved. Replace the housing if it is damaged or the motor 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.
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.
The fl at surface around the chamber and bolt holes should
be fl at and free of nicks or burrs that could cause misalignment 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 signifi cant 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 damaged.
22
Page 23
SERVICE
Check for cracks between the drive gear keyway and gear
tooth root. Replace the gear if one or more cracks are present.
SHAFTS
The surface of the motor shaft where the bearing and seal
are mounted must be smooth.
Grooves, roughness or a reduced diameter indicate fl uid
contamination or damaged 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 fi lter and hydraulic fl uid for
contamination. Operating conditions may required changing
from a 25-micron fi lter to an oversize 10-micron fi lter.
ASSEMBLY
Always replace any seals or O-rings that are disturbed during 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 bearing housing.
2. Lubricate and install the quad ring in the inside groove in
the seal gland.
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 fl ange.
8. Install the motor shaft and bearing in the bearing housing. Place the bearing housing on a smooth clean arbor
press surface (protected from damage), with the large bearing 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
fi ll the keyway on the shaft.
10. Insert the motor shaft through the seal gland in the motor 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 bearing 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.
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.
IMPORTANT
Do not force the housings together.
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
opposite holes in the face of the bearing housing. Carefully 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.
23
Page 24
SERVICE
19. Slowly slide the gear housing over the gears until it contacts the bearing housing.
20. Turn the motor shaft manually to check for free rotation.
If it does not turn easily, separate the housings and fi nd the
cause of the binding.
21. Install eight capscrews. Tighten fi nger tight.
22. Recheck the shaft rotation. When the shaft rotates easily, 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 fl at-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
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
If the safety catch was removed from the valve handle,
place the torsion spring on the boss of the safety catch with
the spring tab on top of, and facing, the back of the catch.
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 in 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 removed, 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.
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 using 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 corresponding 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 outward.
2. Place the remaining washer and the swingover nut on
the carriage bolt and tighten only until secure.
24
Page 25
CO25 PARTS ILLUSTRATION
25
Page 26
CO25 PARTS LIST
Item
Part No. Qty Description
No.
1 01714 1 Jam Nut, CCW
03012 1 Jame Nut, CW
2 31028 1 Outer Collar
3 04876 1 Inside Collar
4 00720 1 Set Screw
5 04673 1 Thrust Collar
6 03013 1 Retaining Ring
7 00563 1 Roll Pin
8 05152 1 Stanley Sticker (USA Models Only)
9 05868 1 Caution Sticker (USA Models Only)
10 01420 1 Helicoil
11 20460 1 Handle Strut
12 03006 2 Capscrew
13 02688 8 Capscrew
14 02649 2 Handle Bar Retainer
15 00175 4 O-ring •
16 02912 2 Oil Tube
17 17681 1 Spring Pin
18 32026 1 Valve Spool (CCW Models Only)
31138 1 Valve Spool (CW Models Only)
19 01604 2 O-ring •
20 02931 1 Valve Cap
21 00112 1 Quad Ring •
22 01219 1 Pipe Plug
23 25635 1 Flow Control
24 35963 1 Capscrew
25 02920 1 Spacer
26 22707 1 Trigger
27 22704 1 Safety Catch
28 22701 1 Torsion Spring
29 28552 1 Valve Handle Assy (Incld Item 22)
30 07226 2 Hose Assy (Incld Item 34)
31 03009 1 Roll Pin
32 02911 1 Hose Clip
33 03786 1 Caution Sticker (USA Models Only)
11207 1 Circuit D Sticker (CE Models Only)
34 01605 2 O-ring • (Incld with Item 30)
35 31186 1 Poppet
36 02916 1 Compression Spring
37 ——- - NO ITEM
38 31137 1 Plug
39 02654 1 Handle Bar
40 02950 1 Motor Housing
41 03049 1 Swing Over Nut
Item
Part No. Qty Description
No.
42 03048 1 Lever
43 01594 2 Washer
44 03047 1 Roll Pin
45 05071 2 Capscrew
46 32445 1 Guard Clamp
47 03025 1 Bolt
48 32436 1 Wheel Guard
33084 1 Motor Assy, CCW (Incl Items 49-57, 59-66)
33083 1 Motor Assy, CW (Incl Items 49-57, 59-66)
49 32047 1 Motor Shaft (CCW Models Only)
32872 1 Motor Shaft (CW Models Only)
50 00170 1 Retaining Ring
51 30333 1 Seal Gland
52 350771 1 O-ring •
53 00214 1 Quad Ring •
54 00120 8 Capscrew
55 31849 1 Gear Hsg Assy
56 06316 4 Bushing
57 06881 1 Needle Roller
58 00772 1 Key
59 00148 1 Bearing
60 00166 1 Retaining Ring
61 30591 1 Bearing Hsg Assy
62 00713 2 Dowel Pin
63 00178 1 O-ring
64 06854 1 Idler Shaft
65 06853 1 Driver Gear
66 06855 1 Idler Gear
67 33206 1 Name Tag
68 28322 1 CE Sticker (CE Models Only)
69 28886 1 Composite Sticker (CE Models Only)
70 28811 1 Information Plaque (CE Models Only)
71 05153 1 Stanley Sticker (CE Models Only)
72 02004 2 Drive Screw
73 52539 1 Sound Power Level Decal
24058 1 Coupler, Female (Not Shown)
24059 1 Coupler, Male (Not Shown)
24069 1 Coupler Set
31845 1 SEAL KIT
26
Page 27
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 fi rst retail purchaser, or for a period of 2 years from the shipping date from Stanley, whichever period
expires fi rst, 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 & 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 fi rst usage, or for a period of 2 years from the shipping date from Stanley, whichever period expires fi rst.
CUTTING ACCESSORIES: 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 & MODIFICATIONS: Alterations or modifi cations to any tool or part. All obligations under this warranty shall be terminated if
the new tool or part is altered or modifi ed in any way.
NORMAL WEAR: any failure or performance defi ciency 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 defi ciency 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 defi ciency attributable to not maintaining the tool(s) in good operating condition as outlined in the
Operation and Maintenance Manual.
HYDRAULIC PRESSURE & FLOW: Any failure or performance defi ciency attributable to excess hydraulic pressure, excess hydraulic backpressure, or excess hydraulic fl ow.
REPAIRS OR ALTERATIONS: Any failure or performance defi ciency attributable to repairs by anyone which in Stanley’s sole judgement
caused or contributed to the failure or defi ciency.
MIS-APPLICATION: Any failure or performance defi ciency attributable to mis-application. “Mis-application” is defi ned 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 fi rst obtaining the written consent of Stanley.
WARRANTY REGISTRATION: STANLEY ASSUMES NO LIABILITY FOR WARRANTY CLAIMS SUBMITTED FOR WHICH NO TOOL REGISTRATION 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 fi rst receiving documentation which proves the sale of the tool or the tools’ fi rst date of usage. The term “DOCUMENTATION” as used
in this paragraph is defi ned as a bill of sale, or letter of intent from the fi rst 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 other warranties, expressed or implied including merchantability
or fi tness for a particular purpose except for that provided herein. There is no other warranty. This warranty gives the purchaser specifi c legal
rights and other rights may be available which might vary depending upon applicable law.
27
Page 28
Stanley Hydraulic Tools
3810 SE Naef Road
Milwaukie OR 97267-5698
503-659-5660
FAX 503-652-1780
www.stanley-hydraulic-tools.com
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