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 nom e
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
CERTIFICATE OF CONFORMITY ...................................................................................................................................................2
GENERAL OPERATION ................................................................................................................................................................12
CARE AND STORAGE ..................................................................................................................................................................13
EQUIPMENT PROTECTION & CARE ...........................................................................................................................................15
CO25 PARTS ILLUSTRATION ......................................................................................................................................................18
CO25 PARTS LIST ........................................................................................................................................................................19
To ll out a Product Warranty Recording form, and for information on your warranty,
visit Stanleyhydraulic.com and select the Warranty tab.
(NOTE: The warranty recording form must be submitted to validate the warranty).
SERVICING: This manual contains safety, operation, and routine maintenance instructions. Stanley Hydraulic Tools
recommends that servicing of hydraulic tools, other than routine maintenance, must be performed by an authorized
and certied dealer. Please read the following warning.
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.
CO25 User Manual ◄ 3
SAFETY SYMBOLS
DANGER
WARNING
CAUTION
NOTICE
IMPORTANT
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.
CAUTION
Always observe safety symbols. They are included for your safety and for the protection of the tool.
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.
LOCAL SAFETY REGULATIONS
Enter any local safety regulations here. Keep these instructions in an area accessible to the operator and maintenance personnel.
4 ► CO25 User Manual
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 precau-
tions relating to the specic work area and local safety
regulations. If so, place the added precautions in the
space provided on the previous page.
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.
• 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 specications 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 certied 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.
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.
• 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 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.
CO25 User Manual ◄ 5
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 wheel as a cutting surface and be
aware of kick-back from the saw.
• 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 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 ammable materials, sparks
can ignite ammable or combustible 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 ow control on the valve
handle.
• Know the location of buried 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
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 4700 rpm
minimum.
• Warning: Hydraulic uid under pressure could cause
skin injection injury. If you are injured by hydraulic
uid, get medical attention immediately
• Always support and secure items being worked on.
• Caution when handling the work piece after cutting,
object can be hot and have sharp edges, use your personal protection equipment.
• Keep your work area clean and clear of tripping hazards, oily surfaces and hoses laying about can be hazardous.
• Make sure adequate lighting is always available.
• Never operate the tool if you cannot be sure that
underground utilities are not present. Underground
electrical utilities present an electrocution hazard.
Underground gas utilities present an explosion hazard.
Other underground utilities may present other hazards.
• Do not operate this tool in a potentially explosive environment. Do not grind on vessels containing combustible
substances.
• Any use of this tool outside those stated in this manual
are forbidden.
• 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
6 ► CO25 User Manual
Stanley Hydraulic tools
Division of the Stanley Works
3810 SE Naef Road
Milwaukie, OR 97267
D
PROTECT YOUR EYES...
WEAR SAFETY GOGGLES
30 LPM @ 138 BAR
EHTMA CATEGORY
TOOL STICKERS & TAGS
11207
CIRCUIT TYPE D DECAL
05152
ADDRESS DECAL
(CE MODELS ONLY)
03786
GPM DECAL
28811
INFORMATION PLAQUE
CAUTION
1. DO NOT USE DAMAGED WHEELS.
2. USE FULL TROTTLE ONLY WHILE CUTTING.
3. USE ONLY WHEELS MARKED HIGH SPEED REINFORCED THAT MEET
REQUIREMENTS OF ANSI B7.1,B7.5 WHEELS SHOULD BE NO LARGER THAN
14" DIA X 5/32" THICK WITH A 1" ARBOR HOLE & RATED FOR 5300 RPM
MINIMUM SPEED.
4. INSPECT WHEEL GUARD & COLLARS FOR DAMAGE AFTER ANY WHEEL
BREAKAGE ON THE MACHINE.
5. MAXIMUM SPINDLE SPEED IS 5300 RPM.
6. READ OPERATION MANUAL.
05868 SAFETY LABEL
NOTE
33206
CO25 NAME TAG
05153
ADDRESS DECAL
(CE MODELS ONLY)
28322
CE DECAL
(CE MODELS ONLY)
Lwa
113
52539
SOUND POWER DECAL
(CE MODELS ONLY)
28886
COMPOSITE DECAL
(CE MODELS ONLY)
DANGERDANGER
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.
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.
1. FAILURE TO USE HYDRAULIC HOSE LABELED AND CER-
TIFIED 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 CUR-
RENT 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
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 PRO-
TECTION.
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
USE ONLY PARTS AND REPAIR
PROCEDURES APPROVED BY
STANLEY AND DESCRIBED IN THE
TAG TO BE REMOVED ONLY BY
SAFETY TAG P/N 15875 (Shown smaller then actual size)
TOOL BEFORE USING IT.
OPERATION MANUAL.
TOOL OPERATOR.
SEE OTHER SIDE
CO25 User Manual ◄ 7
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 PROP-
ERLY 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.
Conductive Hose - Wire Braid or Fiber Braid -DO NOT USE NEAR ELECTRICAL CONDUCTORS
4-615-23up to 25up to 7.53/810Both2500175
4-615-2326-1007.5-301/213Both2500175
5-10.519-40up to 50up to 151/213Both2500175
5-10.519-4051-10015-305/816Both2500175
5/816Pressure2500175
3/419Return2500175
5-10.519-40100-30030-90
10-1338-49up to 50up to 155/816Both2500175
5/816Pressure2500175
3/419Return2500175
10-1338-4951-10015-30
3/419Pressure2500175
125.4Return2500175
10-1338-49100-20030-60
5/816Pressure2500175
13-1649-60up to 25up to 8
3/419Return2500175
3/419Pressure2500175
125.4Return2500175
13-1649-6026-1008-30
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.
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.
CO25 User Manual ◄ 9
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)
(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
Careful inspection of the tool and hydraulic system before
startup is important for safe, reliable operation of the tool.
1. Using a calibrated owmeter and pressure gauge, check
that the hydraulic power source develops a 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.
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.
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 ttings or quick disconnects. It is good practice to connect the return hose rst and disconnect it last to minimize
or eliminate trapped pressure within the wrench.
3. Observe the ow indicators stamped on the valve handle
assembly and the hose couplers to ensure that the 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 difcult to
connect. Whenever possible, connect the free ends of
hoses together.
TOOL OPERATION
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.
5. Inspect the handlebar. Make sure the handlebar is securely fastened to the cutoff saw and is clean of any oil to
ensure a 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.
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.
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.
2. Make sure the trigger is set to disengage the cut-off saw
when released.
3. Run the saw at least one minute, then release the control
lever.
CO25 User Manual ◄ 11
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 difcult
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 se-
cure and there is a steady 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 coun-
terclockwise (CCW).
12 ► CO25 User Manual
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 (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.
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 anges.
5. Check for burrs. Remove burrs as required.
6. Check that the bearing surfaces are 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 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 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
uid 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.
CO25 User Manual ◄ 13
OPERATION
CUTOFF WHEEL REPLACEMENT
1. Move the hydraulic system control valve to the Off position.
2. Disconnect the hydraulic hoses from the tool (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 at on the motor shaft aligns with the 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
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 ► CO25 User Manual
TOOL PROTECTION & CARE
NOTICE
In addition to the Safety Precautions found in
this manual, observe the following for equipment
protection and care.
• Make sure all couplers are wiped clean before 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 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 ow (see Specications) in this manual for correct ow rate and
model number. Personal Injury and 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.
CO25 User Manual ◄ 15
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
ow and pressure to the tool as listed in the following table. Use a ow meter known to be accurate. Check the ow with
the hydraulic uid temperature at least 80o F/27o C.
PROBLEMCAUSESOLUTION
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 difcult to operate.
Saw cuts too slowly.
Hydraulic hoses not connected properly.
Hydraulic system not functioning.Check power unit for correct 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.
Insufcient oil ow.Adjust oil 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 ► CO25 User Manual
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
System Type ............................................................................................................................... Open Center, HTMA Type II
Connect Size and Type ............................................................................................................... 3/8-inch Male Pipe Adapter
Max Spindle Speed ................................................................................................................................................. 4700 rpm
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 Kit for CO25 (Includes (1) Water Hose Assy P/N-33220, (1) 9.125-inch Long Tube P/N-33226, (1)-
7.812-inch Long Tube P/N-33227, (1) Brass Adaptor P/N-35196, (3) Male 90Deg Elbow 1/4” hose barb P/N-33223, (1)
Male Elbow Brass P/N-35197....................................................................................................................................... 33228
10888 and Inst Sheet .................................................................................................................................................. 34175
SOUND POWER AND VIBRATION DECLARATION
Test conducted on CO25541, S/N 673 operated at standard 12 gpm input ....................................................................................
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 NOTEThe 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 ......................................................................................................................... 4.9 m/sec²
Uncertainty: K ............................................................................................................................................................... 0.14 m/sec²
Values determined according to ISO 19432:2012, ISO 5349-1,2 ....................................................................................................
CO25 User Manual ◄ 17
PARTS ILLUSTRATION
For Parts to Handle Extension
Kit, See Accessories on Page 17
18 ► CO25 User Manual
PARTS LIST
Item
Part No. Qty Description
No.
1017141Jam Nut, CCW
030121Jame Nut, CW
2310281Outer Collar
3048761Inside Collar
4007201Set Screw
5046731Thrust Collar
6030131Retaining Ring
7005631Roll Pin
8051521Stanley Sticker (USA Models Only)
9058681Caution Sticker (USA Models Only)
10014201Helicoil
11204601Handle Strut
12030062Capscrew
13026888Capscrew
14026492Handle Bar Retainer
15001754O-ring •
16029122Oil Tube
17176811Spring Pin
18320261Valve Spool (CCW Models Only)
311381Valve Spool (CW Models Only)
19016042O-ring •
20029311Valve Cap
21001121Quad Ring •
22012191Pipe Plug
23318541Flow Control
24359631Capscrew
25029201Spacer
26227071Trigger
27227041Safety Catch
28227011Torsion Spring
29285521Valve Handle Assy (Incld Item 22)
30072262Hose Assy (Incld Item 34)
31030091Roll Pin
32029111Hose Clip
33037861Caution Sticker (USA Models Only)
112071Circuit D Sticker (CE Models Only)
34016052O-ring • (Incld with Item 30)
35311861Poppet
36029161Compression Spring
37 ——- -NO ITEM
38311371Plug
39026541Handle Bar
40029501Motor Housing
41030491Swing Over Nut
Item
Part No. Qty Description
No.
42030481Lever
43015942Washer
44030471Roll Pin
45050712Capscrew
46324451Guard Clamp
47030251Bolt
48324361Wheel Guard
330841Motor Assy, CCW (Incl Items 49-57, 59-66)
330831Motor Assy, CW (Incl Items 49-57, 59-66)
49320471Motor Shaft (CCW Models Only)
328721Motor Shaft (CW Models Only)
50001701Retaining Ring
51303331Seal Gland
523507711O-ring •
53002141Quad Ring •
54001208Capscrew
55318491Gear Hsg Assy
56063164Bushing
57068812Needle Roller
58007721Key
59001481Bearing
60001661Retaining Ring
61305911Bearing Hsg Assy
62007132Dowel Pin
63001781O-ring •
64733091Idler Shaft
65068532Driver Gear
67332061Name Tag
68283221CE Sticker (CE Models Only)
69288861Composite Sticker (CE Models Only)
70288111Information Plaque (CE Models Only)
71051531Stanley Sticker (CE Models Only)
72020042Drive Screw
73525391Sound Power Level Decal
240581Coupler, Female (Not Shown)
240591Coupler, Male (Not Shown)
240691Coupler Set
318451SEAL KIT
• Denotes Part in Seal Kit
33084 - Motor Assy, CCW Rotation (Incl Items 49-57, 59-66)
33083 - Motor Assy, CW Rotation (Incl Items 49-57, 59-66)
CO25 User Manual ◄ 19
Stanley Hydraulic Tools
3810 SE Naef Road
Milwaukie, Oregon 97267-5698 USA
(503) 659-5660 / Fax (503) 652-1780
www.stanleyhydraulic.com
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