CO23
HYDRAULIC
CUTOFF SAW
USER MANUAL
Safety, Operation and Maintenance
© 2014 Stanley Black & Decker, Inc.
New Britain, CT 06053
U.S.A.
72409 7/2014 Ver. 7
DECLARATION OF CONFORMITY
Weisbeck, Andy
DECLARATION OF CONFORMITY
ÜBEREINSTIMMUNGS-ERKLARUNG
DECLARATION DE CONFORMITE CEE
DECLARACION DE CONFORMIDAD
DICHIARAZIONE DI CONFORMITA
________________ ______________________________________________________
I, the undersigned:
Ich, der Unterzeichnende:
Je soussigné:
El abajo firmante:
lo sottoscritto:
hereby declare that the equipment specified hereunder:
bestätige hiermit, daß erklaren Produkt genannten Werk oder Gerät:
déclare que l’équipement visé ci-dessous:
Por la presente declaro que el equipo se especifica a continuación:
Dichiaro che le apparecchiature specificate di seguito:
Surname and First names/Familiennname und Vornamen/Nom et pr énom/Nombre y apellido/Cognome e nome
Hydraulic Tools
1. Category:
Kategorie:
Catégorie:
Categoria:
Categoria:
2. Make/Marke/Marque/Marca/Marca
3. Type/Typ/Type/Tipo/Tipo: CO23341
4. Serial number of equipment:
Seriennummer des Geräts:
Numéro de série de l’équipement:
Numero de serie del equipo:
Matricola dell´attrezzatura:
Has been manufactured in conformity with
Wurde hergestellt in Übereinstimmung mit
Est fabriqué conformément
Ha sido fabricado de acuerdo con
E’ stata costruita in conformitá con
Directive/Standards
Richtlinie/Standards
Directives/Normes
Directriz/Los Normas
Direttiva/Norme
EN ISO
ISO
ISO
Machinery Directive
ISO
5. Special Provisions: None
Spezielle Bestimmungen:
Dispositions particulières:
Provisiones especiales:
Disposizioni speciali:
No.
Nr
Numéro
No
n.
3744:2009
11148-7:2011
20643:2005
2006/42/EC:2006
19432:2006
Cut-Off-Saw, Hydraulic
Stanley
022212008 and above
Approved body
Prüfung durch
Organisme agréé
Aprobado
Collaudato
Self
Self
Self
Self
Self
6. Representative in the Union: Patrick Vervier, Stanley Dubuis 17-19, rue Jules Berthonneau-BP 3406 41034 Blois Cedex, France.
Vertreter in der Union/Représentant dans l’union/Representante en la Union/Rappresentante presso l’Unione
Done at/Ort/Fait à/Dado en/Fatto a Stanley Hydraulic Tools, Milwaukie, Oregon USA
Signature/Unterschrift/Signature/Firma/Firma
Position/Position/Fonction/Cargo/Posizione Engineering Manager
2 ► CO23 User Manual
Date/Datum/le/Fecha/Data 2-16-12
WARNING
IMPORTANT
TABLE OF CONTENTS
DECLARATION OF CONFORMITY .......................................................................................................................... 2
SAFETY SYMBOLS ..................................................................................................................................................4
SAFETY PRECAUTIONS .......................................................................................................................................... 5
TOOL STICKERS & TAGS ........................................................................................................................................6
HOSE TYPES ............................................................................................................................................................7
HOSE RECOMMENDATIONS ..................................................................................................................................8
FIGURE 1. TYPICAL HOSE CONNECTIONS .......................................................................................................8
HTMA REQUIREMENTS ...........................................................................................................................................9
OPERATION ............................................................................................................................................................10
TROUBLESHOOTING ............................................................................................................................................13
SPECIFICATIONS ................................................................................................................................................... 14
ACCESSORIES.......................................................................................................................................................14
SERVICE TOOLS ....................................................................................................................................................14
CO23 PARTS ILLUSTRATION ................................................................................................................................ 15
CO23 PARTS LIST ..................................................................................................................................................16
UNDERWATER TOOLS DEPTH GUIDELINE .........................................................................................................17
To ll out a Product Warranty Recording form, and for information on your warranty,
visit Stanleyhydraulics.com and select the Company tab, Warranty.
(NOTE: The warranty recording form must be submitted to validate the warranty).
SERVICING: This manual contains safety, operation, and routine maintenance instructions. Servicing of hydraulic
tools, other than routine maintenance, must be performed by an authorized and certied 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 certied dealer, call Stanley Hydraulic Tools at the number listed on the back of this
manual and ask for a Customer Service Representative.
CO23 User Manual ◄ 3
DANGER
WARNING
CAUTION
CAUTION
NOTICE
IMPORTANT
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 situation
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, could result in death or serious injury.
This signal word indicates a potentially hazardous situation which, if not avoided, may result in property damage.
This signal word indicates a situation which, if not avoided, will result in damage
to the equipment.
This signal word indicates a situation which, if not avoided, may result in damage to the equipment.
Always observe safety symbols. They are included for your safety and for the protection of the tool.
LOCAL SAFETY REGULATIONS
Enter any local safety regulations here. Keep these instructions in an area accessible to the operator and maintenance personnel.
4 ► CO23 User Manual
SAFETY PRECAUTIONS
• The cutoff saw is designed to provide safe and de-
pendable service if operated according to instructions. Read and understand this manual and any
decals attached to the saw before operating. Failure
to do so could result in personal injury or equipment
damage.
• New operators must start in a work area without by-
standers. He/she must be familiar with all prohibited
work areas such as excessive slopes and dangerous terrain conditions.
• When using tools around energized transmission
lines, be sure to use only hoses labeled and certi-
ed non-conductive and follow all safety practices.
• Know the location of buried or covered services be-
fore starting your work.
• Do not inspect or clean the tool with the power
source operating or with operating pressure at the
tool. Accidental engagement of the tool can cause
serious injury.
• Never wear loose clothing that can get entangled in
the working end of the tool.
• Do not overreach. Maintain proper footing and bal-
ance at all times.
• Always connect hoses to the tool hose couplers be-
fore energizing the power source. Be sure that all
hose connections are tight.
• 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.
• Always hold the tool with both hands when the unit
is running. Use a rm grip.
• Keep all parts of your body away from a rotating cut-
off wheel.
• Keep the wheel off all surfaces when starting the
saw.
• Always carry the tool with the wheel stopped.
• Make sure the wheel has stopped before setting
down the tool.
• Keep the handles clean and free of oil at all times.
• All service must be performed by experienced ser-
vice personnel only.
• Always inspect wheels for possible damage before
installation.
• Establish a training program for all operators to en-
sure safe operation.
• Do not operate the tool unless thoroughly trained.
• Never transport or store the tool with the wheel
mounted on the saw.
• Do not operate the tool if it is damaged, improperly
adjusted or not completely and correctly assembled.
• Never cock, jam or wedge the wheel during the cut.
• Never cause sparks in the vicinity of ammable ma-
terials.
• Do not operate the tool with the wheel guard removed.
• Do not start cutting until you have a clear work area
and secure footing.
• Do not allow other persons near the tool when starting or cutting.
• Never operate the tool when you are tired or fatigued.
• Do not use a wheel that is cracked or otherwise
damaged.
• Do not operate the tool if the wheel does not stop
when the throttle trigger is released.
• Do not use the side of the wheel as the cutting surface.
• Never exceed the maximum operating speed
marked on the wheel.
• Always use cutoff wheels that conform to the speci-
cations given in the OPERATION section of this
manual.
• Always wear safety equipment such as goggles, ear
protection, safety shoes, and head protec tion at all
times when operating the tool.
• Do not reverse wheel rotation direction by chang-
ing oil ow direction. Obtain a saw designed for the
wheel direction that you desire.
• Whenever working near electrical conductors, always assume that all conductors are energized and
that insulating devices and clothing and hydraulic
hoses may conduct electricity. Always use nonmetallic braided hoses and ensure that the hydraulic oil
is free of moisture.
• Warning: Use of this tool on certain materials during
demolition could generate dust potentially containing a variety of hazardous substances such as asbestos, silica or lead. Inhalation of dust containing
these or other hazardous substances could result
in serious injury, cancer or death. Protect yourself
and those around you. Research and understand
the materials you are cutting. Follow correct safety
procedures and comply with all applicable national,
state or provisional health and safety regulations
relating to them, including, if appropriate arranging
for the safe disposal of the materials by a qualied
person.
CO23 User Manual ◄ 5
72880
CO23 Information Sticker
14090
Stanley Logo Sticker
TOOL STICKERS & TAGS
02751
Name Tag Sticker
28788
Manual Sticker
72893
Rotation Direction Sticker
72881
Abrasive Wheel Warning Sticker
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.
12535
EHTMA “E” Sticker
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
HYDRAULIC 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 HANDS. CONTACT WITH A LEAK MAY RESULT
IN SEVERE PERSONAL INJURY.
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
OPERATION MANUAL.
TAG TO BE REMOVED ONLY BY
TOOL OPERATOR.
SEE OTHER SIDE
12536
EHTMA “F” Sticker
DANGERDANGER
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 CLOSEDCENTER 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
OPERATION MANUAL.
TAG TO BE REMOVED ONLY BY
TOOL OPERATOR.
SEE OTHER SIDE
6 ► CO23 User Manual
SAFETY TAG P/N 15875 (Shown smaller then actual size)
HOSE TYPES
The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the hydraulic system. There are three types of hydraulic hose that meet this requirement and are authorized for use with
Stanley Hydraulic Tools. They are:
Certied non-conductive — constructed of thermoplastic or synthetic rubber inner tube, synthetic ber braid
reinforcement, and weather resistant thermoplastic or synthetic rubber cover. Hose labeled certied non-
conductive is the only hose authorized for use near electrical conductors.
Wire-braided (conductive) — constructed of synthetic rubber inner tube, single or double wire braid reinforcement, and weather resistant synthetic rubber cover. This hose is conductive and must never be used near
electrical conductors.
Fabric-braided (not certied or labeled non-conductive) — constructed of thermoplastic or synthetic rubber inner tube, synthetic ber braid reinforcement, and weather resistant thermoplastic or synthetic rubber cover. This
hose is not certied non-conductive and must never be used near electrical conductors.
HOSE SAFETY TAGS
To help ensure your safety, the following DANGER tags are attached to all hose purchased from Stanley Hydraulic
Tools. DO NOT REMOVE THESE TAGS.
If the information on a tag is illegible because of wear or damage, replace the tag immediately. A new tag may be
obtained from your Stanley Distributor.
THE TAG SHOWN BELOW IS ATTACHED TO “CERTIFIED NON-CONDUCTIVE” HOSE
DANGER
1. FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON-CONDUCTIVE
WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRIC LINES MAY RESULT IN
DEATH OR SERIOUS INJURY.
FOR PROPER AND SAFE OPERATION 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 MOISTURE AND
TEST HOSE FOR MAXIMUM ALLOWABLE CURRENT LEAKAGE IN ACCORDANCE WITH
SAFETY DEPARTMENT INSTRUCTIONS.
DO NOT REMOVE THIS TAG
SEE OTHER SIDE
SIDE 1
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.
(Shown smaller than actual size)
DANGER
DANGER
SEE OTHER SIDE
SIDE 2
THE TAG SHOWN BELOW IS ATTACHED TO “CONDUCTIVE” HOSE.
DANGER
DANGER
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
SEE OTHER SIDE
SIDE 1
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.
(Shown smaller than actual size)
DANGER
SEE OTHER SIDE
SIDE 2
DO NOT REMOVE THIS TAG
DO NOT REMOVE THIS TAG
CO23 User Manual ◄ 7
Min. Working Pressure
USE
(Press/Return)
HOSE RECOMMENDATIONS
Certied Non-Conductive Hose - Fiber Braid - for Utility Bucket Trucks
Oil Flow Hose Lengths Inside Diameter
GPM LPM FEET METERS INCH MM PSI BAR
4-9 15-34 up to 10 up to 3 3/8 10 Both 2250 155
Conductive Hose - Wire Braid or Fiber Braid -DO NOT USE NEAR ELECTRICAL CONDUCTORS
4-6 15-23 up to 25 up to 7.5 3/8 10 Both 2500 175
4-6 15-23 26-100 7.5-30 1/2 13 Both 2500 175
5-10.5 19-40 up to 50 up to 15 1/2 13 Both 2500 175
5-10.5 19-40 51-100 15-30 5/8 16 Both 2500 175
5/8 16 Pressure 2500 175
3/4 19 Return 2500 175
5-10.5 19-40 100-300 30-90
10-13 38-49 up to 50 up to 15 5/8 16 Both 2500 175
5/8 16 Pressure 2500 175
3/4 19 Return 2500 175
10-13 38-49 51-100 15-30
3/4 19 Pressure 2500 175
1 25.4 Return 2500 175
10-13 38-49 100-200 30-60
5/8 16 Pressure 2500 175
13-16 49-60 up to 25 up to 8
3/4 19 Return 2500 175
3/4 19 Pressure 2500 175
1 25.4 Return 2500 175
13-16 49-60 26-100 8-30
PRESSURE
<<< FLOW
RETURN
FLOW >>>
Figure 1. Typical Hose Connections
Tool to Hydraulic Circuit Hose
Recommendations
The chart to the right shows recommended
minimum hose diameters for various hose
lengths based on gallons per minute (gpm)/
liters per minute (lpm). These recommenda-
tions are intended to keep return line pressure
(back pressure) to a minimum acceptable lev-
el to ensure maximum tool performance.
8 ► CO23 User Manual
This chart is intended to be used for hydraulic
tool applications only based on Stanley Hy-
draulic Tools tool operating requirements and
should not be used for any other applications.
All hydraulic hose must have at least a rated
minimum working pressure equal to the maxi-
mum hydraulic system relief valve setting.
All hydraulic hose must meet or exceed
specications as set forth by SAE J517.
HTMA / EHTMA REQUIREMENTS
HTMA / EHTMA REQUIREMENTS
HTMA
HYDRAULIC SYSTEM REQUIREMENTS
Flow Range
Nominal Operating Pressure
(at the power supply outlet)
System relief valve setting
(at the power supply outlet)
Maximum back pressure
(at tool end of the return hose)
Measured at a max. uid viscosity of:
(at min. operating temperature)
Temperature: Sufcient heat rejection
capacity to limit max. uid temperature to:
(at max. expected ambient temperature)
Min. cooling capacity at a temperature
difference of between ambient and 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.
Filter
Min. full-ow ltration
Sized for ow of at least:
(For cold temp. startup and max.
dirt-holding capacity)
4-6 gpm 7-9 gpm 9-10.5 gpm 11-13 gpm
(15-23 lpm) (26-34 lpm) (34-40 lpm) (42-49 lpm)
1500 psi 1500 psi 1500 psi 1500 psi
(103 bar) (103 bar) (103 bar) (103 bar)
2100-2250 psi 2100-2250 psi 2200-2300 psi 2100-2250 psi
(145-155 bar) (145-155 bar) (152-159 bar) (145-155 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 6 hp 7 hp
(2.24 kW) (3.73 kW) (5.22 kW) (4.47 kW)
40° F 40° F 40° F 40° F
(22° C) (22° C) (22° C) (22° C)
25 microns 25 microns 25 microns 25 microns
30 gpm 30 gpm 30 gpm 30 gpm
(114 lpm) (114 lpm) (114 lpm) (114 lpm)
TYPE I TYPE II
TOOL TYPE
TYPE RR
TYPE III
Hydraulic uid Petroleum based
(premium grade, anti-wear, non-conductive)
Viscosity (at min. and max. operating temps)
NOTE:
When choosing hydraulic uid, the expected oil temperature extremes that will be experienced in service determine the
most suitable temperature viscosity characteristics. Hydraulic uids with a viscosity index over 140 will meet the requirements
over a wide range of operating temperatures.
*SSU = Saybolt Seconds Universal
EHTMA
100-400 ssu* 100-400 ssu* 100-400 ssu* 100-400 ssu*
(20-82 centistokes)
CLASSIFICATION
HYDRAULIC SYSTEM
REQUIREMENTS
Flow Range
Nominal Operating Pressure
(at the power supply outlet)
System relief valve setting
(at the power supply outlet)
NOTE: These are general hydraulic system requirements. See tool specication page for tool specic requirements
B
3.5-4.3 gpm 4.7-5.8 gpm 7.1-8.7 gpm 9.5-11.6 gpm 11.8-14.5 gpm
(13.5-16.5 lpm) (18-22 lpm) (27-33 lpm) (36-44 lpm) (45-55 lpm)
1870 psi 1500 psi 1500 psi 1500 psi 1500 psi
(129 bar) (103 bar) (103 bar) (103 bar) (103 bar)
2495 psi 2000 psi 2000 psi 2000 psi 2000 psi
(172 bar) (138 bar) (138 bar) (138 bar) (138 bar)
C
D
CO23 User Manual ◄ 9
OPERATION
• Always store an idle cutoff saw in a clean dry space
safe from damage or pilferage.
• Replace the cutoff wheel if worn for maximum
tool performance. Make sure that the wheel is not
chipped or damaged.
• Always keep critical tool markings, such as labels
and warning stickers legible.
• 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 2000 psi/140 bar.
• All hoses must have an oil resistant inner surface
and an abrasive resistant outer surface. Hoses that
conform to SAE100R1A are recommended for most
tool applications.
• Use only cutoff wheels that meet requirements of
ANSI 87.5. Wheels should be no larger than 10-inches/25.4 em in diameter, 5/32-inch/4 mm thick with a
1-inch/25.4 or 22 mm arbor hole. Rated speed must
be 5000 rpm minimum.
• Tool repair should be performed by experienced
personnel only.
• 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.
HYDRAULIC SYSTEM
REQUIREMENTS
• The hydraulic system should provide a ow of 10-15
gpm/38-57 lpm at an operating pressure of 15002000 psi/105-140 bar. Recommended relief valve
settings are 2100-2250 psi/145-155 bar.
• The system should have no more than 250 psi/17
bar backpressure measured at the tool end of the
operating hoses. The system conditions for mea-
surement are at maximum uid viscosity or 400
ssu/82 centistokes (minimum operating temperatures).
• The hydraulic system should have sufcient heat rejection capacity to limit the maximum oil temperature
to 140 °F/60 °C at the maximum expected ambient
temperature. The recommended minimum cooling
capacity is 7 hp/5.22 kW at a 40 °F/22 °C difference
between ambient temperature and oil temperature.
• The hydraulic system should have a minimum of 25
micron ltration. It is recommended that lter elements be sized for a ow of at least 30 gpm/1131
pm for cold temperature startup and maximum dirt
holding capacity.
• The hydraulic uid used should have a viscosity
between 100 and 400 ssu/20 and 82 centistokes
at the maximum and minimum expected operating
temperatures. Hydraulic uids of petroleum base
with anti wear properties and viscosity indexes over
140 will meet the recommended requirements over
a wide range of operating temperatures.
• The recommended hose size is .625 in/ 16 mm 1.0.
up to 50 ft/15 m long and .750 in/20 mm 1.0. minimum up to 100 ft/30 m long.
PREOPERATION CHECKOUT
PROCEDURES
POWER SOURCE
1. Using a calibrated owmeter and pressure gauge,
check that the hydraulic power source develops a
ow of 10-15 gpm/38-57 lpm at 1500-2000 psi/105-
140 bar.
2. Make certain that the power source is equipped with
a relief valve set to open at 2250 psi/155 bar maximum.
3. Check that all operating controls and indicators are
easily accessible.
CUTOFF SAW TRIGGER AND SAFETY
CATCH
1. Check that the trigger operates smoothly and is free
to travel between the “ON” and “OFF” positions.
2. Check that the trigger is set to disengage the cutoff
saw when released.
3. Check that the safety catch on the handle assembly
is operating properly. It should prevent engagement
of the trigger unless the catch is fully pressed down
into the handle slot.
HANDLE
Check that the handle bar is securely fastened to the
motor housing and handle bar strut. Remove any oil
from the handle bar.
WHEEL GUARD
1. Inspect the wheel guard for cracks and other structural damage.
2. Rotate the guard to ensure that it moves freely on
the wheel-arbor centerline.
10 ► CO23 User Manual
IMPORTANT
OPERATION
3. Check that the locking mechanism operates properly to hold the guard in a set position.
WHEEL CONDITION
1. Before installing abrasive wheels, “sound” the wheel
for possible damage by hanging the wheel vertically
by the arbor hole and rapping lightly with a screwdriver handle or similar instrument. Thin, organic
bond wheels will produce a low drumming tone if it
is physically sound. If the wheel produces a “dead”
or “at” sound, it may be cracked. Cracked or damaged wheels must never be used.
2. Check that the surfaces of the wheel that come in
contact with blotters and anges are free of dirt and
other foreign particles.
3. Check that the correct wheel is used for the job.
4. Check that the wheel conforms to the physical re-
quirements listed in the Specication section of this
manual. The cutoff wheel shall t freely on the drive
ange and remain free under all cutting conditions.
A controlled clearance between the arbor hole and
the cutoff saw drive ange is essential to avoid excessive pressure from installation and/or arbor expansion.
5. Check diamond wheels to ensure all seg ments are
intact.
ARBOR AND COLLARS
1. Inspect the drive ange and outer ange prior to installation. Check for burrs. Check that the bearing
surfaces are at and run true when mounted on the
drive shaft.
2. Inspect the drive shaft threads.
REDUCING BUSHINGS
1. When a reducing bushing is used in the cutoff wheel
mounting hole, check that it does not exceed the
thickness of the wheel.
2. Make sure that the reducing bushing does not protrude beyond the surface of the wheel on both sides.
Bushings that are too thick will not allow the collars
to t properly against the wheel.
3. Check that reducing bushings are tight in the cutoff
wheel mounting hole. Never use bushings that do
not t tightly in the mounting hole. Never use shim
stock.
DRIVESHAFT SPEED CHECK
The speed of the motor output shaft should be checked
at least every 100 hours of operation by trained and
experienced personnel. A record of the speed checks
should be maintained. The maximum rated speed of the
cutoff saw is 3600 rpm. This speed must be equal to or
less than the rated speed of the cutting wheel.
Tests should be conducted while operating the normal
hydraulic power supply used with the cutoff saw.
NOTE:
Excessive speed may be caused by excessive oil
ow to the tool.
OPERATING INSTRUCTIONS
CUTOFF WHEEL INSTALLATION
Make sure the wheel has been thoroughly inspected
prior to installation.
NOTE:
When mounting the wheel, use blotters at the col-
lars. The blotters should be made from highly compressible material and should not be more than
0.025-inch/.6 mm thick.
1. Install the wheel on the drive ange. Refer to the
Specication and Parts List sections of this manual
for wheel requirements and parts orientation, respectively.
2. Install the outer ange. (Use the Spirol drive pin on
diamond wheels only.)
3. Install and tighten the wheel nut. Tighten the nut
only tight enough to prevent slippage of the wheel.
4. Adjust the sole plate assembly for proper depth of
cut.
CONNECTING HOSES
1. Wipe all hose couplers with a clean lint-free cloth
before making connections.
2. Connect the hoses from the power supply to the
tool hoses. It is a good practice to connect return
hoses rst and disconnect last to minimize or avoid
trapped pressure within the tool.
3. If hose couplers are used, observe the arrow on the
coupler to ensure that the ow is in the proper direction. The female coupler on the tool hose is the inlet
coupler.
4. Move the hydraulic circuit control valve to the “ON”
position to operate the tool.
CO23 User Manual ◄ 11
OPERATION
NOTE:
If uncoupled hoses are left in the sun, pressure in-
crease within the hose may make them difcult to
connect. When possible, connect the free ends of
operating hoses together.
TOOL OPERATION
NOTE:
At the beginning of each shift or when a new cutoff
wheel has been installed, run the saw at operating
speed for at least one minute before starting work.
Keep personnel from in front of or in line with the
wheel.
GENERAL PROCEDURES
1. Whenever possible, the work should be held down
and securely supported on both sides of the cut.
2. Press down the safety catch; then slowly squeeze
the trigger. Start the cut with the wheel rotating. Start
the work gently, do not “bump” the work.
3. Feed the wheel through the material as fast as possible without allowing the wheel to reduce its speed.
Cutting through the material too slowly allows heat
expansion and can cause wheel “pinching” in the
material. “Pinching” the wheel from heat expansion
is one of the most common causes of wheel breakage.
When used on cutoff saws carried on emergency vehicles, wheels should be removed after use and discarded
or carefully stored as described in this section.
If wheels are supplied with blotters attached, suitable
separators should be used to preserve atness.
INVESTIGATION OF WHEEL BREAKAGE
Wheels designed for use with hand-held portable saws
are specically manufactured for this application. They
are manufactured to be extremely tough and are difcult
to break under normal use.
If a wheel breaks during use, a careful investigation
should be conducted by the user to determine the cause
of the breakage. The cause must then be corrected as
soon as possible.
If the user is unable to determine the cause of breakage,
the wheel manufacturer should be consulted.
COLD WEATHER OPERATION
If the saw is to be used during cold weather, preheat
the hydraulic oil at low engine speed. When using the
normally recommended oils, oil should be at or above
50 °F/10 °C (400 ssu/82 centistokes) before use.
Damage to the hydraulic system or saw can result from
use with oil that is too viscous or thick.
CARE OF ABRASIVE CUTOFF WHEELS
All abrasive cutting-off wheels are breakable and, therefore, care must be exercised during handling and storage to prevent damage.
STORAGE
Thin, organic bonded wheels such as cutting off wheels
should be laid horizontally on a at surface of steel or
similar rigid material away from excessive heat or moisture. Wheels should not be stored where they will be
exposed to high humidity, water, other liquids, or freezing temperatures. Temperatures low enough to cause
condensation on the wheels when moving them from
storage to an area of higher temperatures should be
avoided.
12 ► CO23 User Manual
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 cutoff saw, always check that the hydraulic power source is supplying the
correct hy draulic ow and pressure to the cutoff saw as listed in the table. Use a owmeter known to be accurate.
Check the ow with the hydraulic oil temperature at least 80 °F/27 °C.
PROBLEM CAUSE REMEDY
Tool does not run. Power not functioning. Check power unit for proper ow and
pressure (15 gpm at 2000 psi/56 lpm
at 140 bar).
Coupler or hoses blocked. Remove obstruction.
Mechanical failure. Disassemble tool and inspect for
damage.
Tool runs backwards. Pressure and return reversed. Correct hose connection or ow di-
rection. Motor shafts with right-hand
threads rotate counterclockwise,
motor shafts with left-hand threads
rotate clockwise.
Oil leakage between motor housing
and on-off block or motor.
On-off trigger is hard to press. Backpressure too high. Should not exceed 250 psi at 15
Saw cuts too slow. Insufcient oil ow or low relief valve
Saw gets hot. Hot oil or excessive oil ow. Check power unit for adequate cool-
Oil tube O-ring failure. Replace as required.
Motor face seal failure. Replace as required.
gpm/17 bar at 571 pm measured at
the end of the tool operating hoses.
Pressure and return reversed. Correct for proper ow direction.
Adjust oil ow to proper gpm. For
setting.
Wrong wheel for material being cut. Use correct wheel.
optimum performance adjust relief
valve to 2250 psi/155 bar.
ing; should maintain uid at or below
140 °F/60 °C. Power unit may be
producing more ow than the saw
will accept under the existing cutting
conditions. Reduce ow until saw
performance starts to drop off.
CO23 User Manual ◄ 13
SPECIFICATIONS
Weight ....................................................................................................................................................25 lb./11.3 kg
Length..............................................................................................................................................20 1/2 inch/52 cm
Width .....................................................................................................................................................11 inch/28 cm
Pressure Range.............................................................................................................. 1500–2000 psi/105–140 bar
Flow Range ............................................................................................................................. 10–15 gpm/38–57 lpm
Optimum Flow ..................................................................................................................................... 15 gpm/57 lpm
System Type ...................................................................................................................O.C. or C.C. HTMA TYPE III
Porting ....................................................................................................................................................SAE 8 O-ring
Connect Size ..................................................................................................................1/2 inch male pipe hose end
Cutting Wheel ..................................................................................................ANSI B7.5., 10 inch/25.4 cm diameter
5/32-inch/4 mm thick, 1-inch/25.4 or 22 mm arbor hole
5000 RPM minimum rated speed
CO23 Vibration Declaration:
Test conducted on CO23341, operateed at optimum ow 15 gpm / 56.7 lpm input
Declared vibration emission value in accordance with EN 12096
Measured vibration emission value: 3-Axis (Main Handle).........................................................................3.8 m/sec²
Uncertainty: K............................................................................................................................................0.34 m/sec²
Measured vibration emission value: 3-Axis (Assist Handle)........................................................................4.2 m/sec²
Uncertainty: K............................................................................................................................................0.70 m/sec²
Values determined according to ISO 19432:2006
ACCESSORIES
Description Part Number
10-inch diameter Diamond Wheel for Masonry 1-inch Arbor .............................................................................03694
10-inch diameter Abrasive Wheel for Metal 1-inch Arbor Fast Cutting .............................................................. 04116
10-inch diameter Abrasive Wheel for Metal 1-inch Arbor-Long Wear ................................................................ 04117
SERVICE TOOLS
Description Part Number
Bearing Installation Tool .................................................................................................................................... 05044
14 ► CO23 User Manual
CO23 PARTS ILLUSTRATION
CO23 User Manual ◄ 15
CO23 PARTS LIST
ITEM
NO. P/N QTY. DESCRIPTION
1 70980 1 HANDLE BAR
2 02764 11 CAPSCREW, 5/16-18 × 3/4
HEX SOC HD
3 02649 3 HANDLE BAR RETAINER
4 02643 1 NEOPRENE WASHER
5 20460 1 HANDLE STRUT
6 00112 1 QUAD-RING *
7 01604 1 O-RING, .097 × .755 (90 DURO) *
8 32026 1 VALVE SPOOL
9 02931 1 ON-OFF VALVE CAP
10 31804 1 ROLL PIN, 1/4 × 2 1/2
11 22707 1 TRIGGER
12 03278 1 ROLL PIN, 3/16 × 1 3/8
13 22701 1 TORSION SPRING
14 22704 1 SAFETY CATCH
15 28552 1 VALVE HANDLE ASSEMBLY
16 00787 1 CAPSCREW, 1/4-20 × 1-1/4 FL HD
17 06830 2 HOSE ASSEMBLY
18 02911 1 HOSE CLIP
19 03806 1 SOLE PLATE ASSEMBLY
20 31137 1 PORT PLUG
21 00174 2 OIL TUBE
22 02920 1 SPACER
23 02916 1 SPRING
24 00175 4 O-RING, 1/2 × 5/8 × 1/6 *
25 35286 1 MOTOR HOUSING CCW
26 ----- 1 NO ITEM
27 ----- 1 NO ITEM
28 08104 1 PLUG SAE O-RING
29 04046 1 GRINDING WHEEL GUARD
ASSEMBLY
30 03821 1 STUD
31 03827 1 WASHER, 1/2
32 03819 1 KNOB
33 01714 1 HEX NUT, 5/8-11 CCW
34 03802 1 OUTER FLANGE
35 03969 1 SPIROL PIN
36 03803 1 DRIVE FLANGE 1 IN.
37 03810 1 SEAL RACE
38 03811 1 SEAL CARRIER
39 03823 1 SEAL *
40 01262 2 O-RING, 1 3/4 × 1 7/8 × 1/16 *
41 03822 1 SEAL CARRIER WASHER
42 03109 1 BEARING
ITEM
NO. P/N QTY. DESCRIPTION
43 ----- -- NO ITEM
44 ----- -- NO ITEM
45 03812 1 SPACER WASHER
46 03824 1 SEAL *
47 00600 1 KEY
48 03813 1 MOTOR SHAFT CCW
49 00253 1 O-RING, 2 1/2 × 2 5/8 × 1/16 *
50 35285 1 MOTOR HOUSING CAP
51 01217 4 CAPSCREW, 3/8-16 × 2 1/2 HEX
SOC HD
52 03826 4 BEARING
(INCL WITH ITEM # 50 & 25)
53 03818 1 GEAR
54 04033 1 IDLER GEAR
55 00713 2 DOWEL PIN, 1/4 × 1
56 01211 1 O-RING, 5/8 × 3/4 × 1/16 *
57 72880 1 CO23 STICKER
58 14090 1 STANLEY LOGO DECAL
59 72879 1 FLOW CONTROL
60 12535 1 EHTMA “E” DECAL
61 12536 1 EHTMA “F” DECAL
62 03971 1 COUPLER SET (MALE & FEMALE)
FOR INDIVIDUAL COUPLERS (P/N03972 FEMALE / 03973 MALE)
63 28788 1 WARNING MANUAL STICKER
64 31186 1 POPPET
65 72881 1 WHEEL WARNING STICKER
66 01420 1 HELICOIL
67 72893 1 ROTATION DIRECTION STICKER
NOTE:
Use Part Name and Part Number when ordering.
* Denotes Part in Seal Kit.
SEAL KIT DATA
P/N QTY. DESCRIPTION
SEAL KIT PART NO. 04120
00175 4 O-RING
00253 1 O-RING
00112 1 QUAD-RING
01211 1 O-RING
01262 2 O-RING
01362 1 O-RING
01604 2 O-RING
03823 1 SEAL
03824 1 SEAL
01605 2 O-RING
16 ► CO23 User Manual
UNDERWATER TOOLS DEPTH GUIDELINE
UNDERWATER MODELS ONLY
CAUTION
DO NOT USE HYDRAULIC TOOLS UNDER-
WATER THAT ARE NOT DESIGNATED AS
AN “UNDERWATER” MODEL, OR THIS
WILL RESULT IN DAMAGE TO THE TOOL.
For underwater hydraulic tools the applications are
broken down into four quadrants depending on
type of tool and method of operation.
The types of tools are percussive and rotational,
each with different characteristics allowing for different depth operation. With percussive tools, the
nitrogen accumulator PSI must counter the increase in ambient pressure found at lower depths.
Since there is a maximum PSI for percussive tools
they are limited to certain depths. Rotational tools
do not have accumulators and thus capable of
deeper depths.
Operation Overview
Percussive Rotational
Tools: Breakers,
Hammer Drills and
Chipping Hammers
Max Depth: 500' -
DiverROV
limitations due to
accumulator PSI
max (increase 40
PSI for every 100')
Tools: Breakers,
Hammer Drills and
Chipping Hammers
Max Depth: 500' limitations due to
accumulator PSI
max (increase 40
PSI for every 100')
Tools: Grinders,
Saws, Chain Saws
Max Depth: 1000' Reference hose
sizing guide below
Tools: Grinders,
Saws, Chain Saws
Max Depth: 1000' Reference hose
sizing guide below
The methods are broken into diver operated or
remote operated vehicle (ROV). ROV's can reach
lower depths and with an on-board hydraulic
power source that is depth compensated, can
operate hydraulic tools at depths of thousands of
feet. ROV operation is still limited to the tool, for
example a percussive tool has the same depth
limitation whether ROV or diver operated.
Recommended Hose Diameters
Depth (ft) 8 GPM 12 GPM
100 5/8” 5/8”
300 3/4” 1”
600 1” 1”
1000 1” 1-1/4”
CO23 User Manual ◄ 17
Stanley Hydraulic Tools
3810 SE Naef Road
Milwaukie, Oregon 97267-5698 USA
(503) 659-5660 / Fax (503) 652-1780
www.stanleyhydraulics.com
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