WARNING
DS06
HYDRAULIC
DIAMOND SAW
Copyright © 2005, The Stanley Works
OPS/MAINT USA
34567 8/2005 Ver 3
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
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
PREOPERTION PROCEDURES ............................................................................................................................................................................ 11
CHECK THE POWER SOURCE ............................................................................................................................................................................. 11
CHECK TOOL .......................................................................................................................................................................................................... 11
CONNECT HYDRAULIC HOSES ............................................................................................................................................................................11
CONNECTING TO A WATER SUPPLY ................................................................................................................................................................... 11
CHECK CHAIN AND BAR ADJUSTMENT .............................................................................................................................................................. 11
CHECK CHAIN SEGMENT WEAR .........................................................................................................................................................................12
OPERATING PROCEDURES .................................................................................................................................................................................12
PLAN THE CUT .......................................................................................................................................................................................................12
TYPES OF CUTS ....................................................................................................................................................................................................13
COLD WEATHER OPERATION ..............................................................................................................................................................................13
USING THE WALL WALKER™ ...............................................................................................................................................................................13
MAINTENANCE & ADJUSTMENTS ........................................................................................................................................................................14
GENERAL MAINTENANCE TIPS ............................................................................................................................................................................14
SAW BAR RAIL .......................................................................................................................................................................................................14
ROTATING THE SAW BAR .....................................................................................................................................................................................14
CHAIN TENSION ADJUSTMENT ............................................................................................................................................................................14
SERVICING THE CHAIN .........................................................................................................................................................................................15
MAINTENANCE & ADJUSTMENTS ........................................................................................................................................................................15
MAINTENANCE & ADJUSTMENTS ........................................................................................................................................................................16
REPLACING THE CHAIN BREAKER PUNCH ........................................................................................................................................................16
SPINNING RIVETS .................................................................................................................................................................................................16
NOSE SPROCKET DISASSEMBLY AND ASSEMBLY ...........................................................................................................................................17
MAINTENANCE & ADJUSTMENTS ........................................................................................................................................................................17
TOOL EQUIPMENT & CARE ..................................................................................................................................................................................19
TROUBLESHOOTING .............................................................................................................................................................................................20
SPECIFICATIONS ...................................................................................................................................................................................................22
ACCESSORIES .......................................................................................................................................................................................................22
SERVICE .................................................................................................................................................................................................................23
MOTOR INSPECTION AND CLEANING .................................................................................................................................................................24
BAR & CHAIN AND CHAIN GUARD ASSEMBLY ...................................................................................................................................................26
DS06 PARTS ILLUSTRATION ................................................................................................................................................................................27
DS06 PARTS LIST ..................................................................................................................................................................................................28
DS06 PARTS ILLUSTRATION ................................................................................................................................................................................29
DS06 PARTS LIST ..................................................................................................................................................................................................30
DIAMOND CHAIN APPLICATIONS .........................................................................................................................................................................31
WARRANTY ............................................................................................................................................................................................................32
SERVICING THE STANLEY CONCRETE CHAINSAW: 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.
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.
3
CERTIFICATE OF CONFORMITY
ÜBEREINSTIMMUNGS-ZERTIFIKAT
CERTIFICAT DE CONFORMITE CEE
CERTIFICADO DE CONFORMIDAD
CERTIFICATO DI CONFORMITA
Hydraulic Tools
______________________________________________________________________
I, the undersigned:
Ich, der Unterzeichnende:
Je soussigné:
El abajo firmante:
lo sottoscritto:
hereby certify that the construction plant or equipment specified hereunder:
bestätige hiermit, daß das im folgenden genannten Werk oder Gerät:
certifies par ceci que l’ usine ou l’ équipement de construction indiqué cidessous:
por el presente certifico que la fabrica o el equipo especificado a continuacion:
certifico che l’impianto o l’attrezzatura sotto specificata:
1. Category: Concrete Cutting Chainsaw
Kategorie:
Catégorie:
Categoria:
Categoria:
2. Make/Ausführung/Marque/Marca/Marca
3. Type/Typ/Type/Tipo/Tipo: DS06200001, DS06300001
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.
Schultz, Theodore J.
Surname and First names/Familiennn ame und Vornamen/Nom et prénom/Nombr e y apellido/Cognome e nome
Stanley
All
Examen CEE de type
Directive
Richtlinie
Directives particulières
Directriz
Direttiva
Machinery Directive
EN
ISO
ISO
ISO
6. Special Provisions: None
Spezielle Bestimmungen:
Dispositions particulières:
Provisiones especiales:
Disposizioni speciali:
Done at/Ort/Fait à/Dado en/Fatto a Stanley Hydraulic Tools, Milwaukie, Oregon USA
Signature/Unterschrift/Signature/Firma/Firma____________________________________________________________________________
Position/Position/Fonction/Puesto/Posizione Engineering Manager
P/N 62310 rev 03 3/05
No.
Nr
Numéro
No
n.
98/37/EC
89/392/CEE
292
8662-1
3744
10726
Date
Datum
Date
Fecha
Data
1998
1991
1988
1994
1992
Approved body
Prüfung durch
Organisme agréé
Aprobado
Collaudato
Self
Self
Self
Self
Self
Self
Date/Datum/le/Fecha/Data 3/98
Date of expiry
Ablaufdatum
Date d´expiration
Fecha de caducidad
Data di scadenza
NA
NA
NA
NA
NA
NA
4
SAFETY SYMBOLS
Safety symbols and signal words, as shown below, are used to emphasize all operator, maintenance and repair
actions which, if not strictly followed, could result in a life-threatening situation, bodily injury or damage to equipment.
This is the safety alert symbol. It is used to alert you to potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid
possible injury or death.
This safety alert and signal word indicate an imminently hazardous situa-
DANGER
WARNING
CAUTION
tion which, if not avoided, will result in death or serious injury.
This safety alert and signal word indicate a potentially hazardous situation
which, if not avoided, could result in death or serious injury.
This safety alert and signal word indicate a potentially hazardous situation
which, if not avoided, may result in minor or moderate injury.
This signal word indicates a potentially hazardous situation which, if not
avoided, may result in property damage.
This signal word indicates a situation which, if not avoided, will result in
NOTICE
IMPORTANT
Always observe safety symbols. They are included for your safety and for the protection of the tool.
damage to the equipment.
This signal word indicates a situation which, if not avoided, may result in
damage to the equipment.
LOCAL SAFETY REGULATIONS
Enter any local safety regulations here. Keep these instructions in an area accessible to the operator and maintenance personnel.
5
SAFETY PRECAUTIONS
Tool operators and maintenance personnel must always comply with the safety
precautions given in this manual and on the stickers and tags attached to the tool
and hose.
These safety precautions are given for your safety. Review them carefully before
operating the tool and before performing general maintenance or repairs.
Supervising personnel should develop additional precautions relating to the specifi c
work area and local safety regulations. If so, place the added precautions in the
space provided on page 5.
The DS06 Diamond Chain 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 hoses before operation.
Failure to do so could result in personal injury or equipment damage.
• Establish a training program for all operators to ensure safe operation.
• The operator must be familiar with all prohibited work areas such as excessive slopes and dangerous terrain conditions.
• Do not operate the chain saw unless thoroughly trained or under the supervision of an instructor.
• Always wear safety equipment such as goggles, ear, head protection, leg protection, gloves, snug fi tting clothing and
safety shoes at all times when operating the chain saw.
• Do not overreach. Maintain proper footing and balnace at all times.
• Do not inspect or clean the chain saw while the hydraulic power source is connected. Accidental engagement of the
chain saw can cause serious injury.
• Always connect hoses to the chain saw hose couplers before engergizing the hydraulic power source. Make sure all
hose connections are tight.
• Do not operate the chain saw at fl uid temperatures above 140°F/60°C. Operation at higher temperatures can cause
higher than normal temperatures at the chain saw which can result in operator discomfort.
• Do not rely exclusively upon the safety devices built into the chain saw. As a chain saw user, several steps must be
taken to keep your cutting jobs free from accident or injury:
1. With a basic understanding of kickbacks, you can reduce or eliminate the element of surprise. Sudden surprise
contributes to accidents.
2. Keep a good fi rm grip on the chain saw with both hands, the right hand on the rear handle and the left hand on
the front handle when operating the chain saw. Use a fi rm grip with thumbs and fi ngers encircling the chain saw
handles. A fi rm grip helps reduce kickbacks and maintains control of the chain saw. Do not let go.
3. Make sure the area in which you are cutting is free of obstructions.
4. Cut at rated operating speeds (gpm).
5. Do not overreach or cut above shoulder height.
6. Only use replacement bars and chains specifi ed by Stanley or the equivalent.
• Make sure the chain guard is in place before operating the chain saw.
6
SAFETY PRECAUTIONS
• Remove or control the water slurry to prevent yourself or others from slipping while cutting.
• Provide adequate ventilation in closed areas when operating a gas or diesel hydraulic power source.
• Always be well rested and mentally alert before operating the chain saw.
• Do not allow bystanders near the chain saw when starting or cutting.
• Do not start cutting until you have a clear work area and secure footing.
• Keep all parts of the body away from the chain saw during operation.
• Carry the chain saw with the tool deenergized and the bar and chain to the rear of your body.
• Do not operate a chain saw that is damaged, improperly adjusted, or not completely and securely assembled. Make
sure the chain stops moving when the control trigger is released.
• Keep the handle dry, clean and free of hydraulic fl uid.
• Do not use the chain saw near energized transmission lines.
• Turn off the power source or move the hydraulic control valve to neutral before setting the chain saw down.
• Use a guide bar scabbard when transporting the chain saw.
• Know the location of buried or covered electrical services before starting work.
• To avoid personal injury or equipment damage, all chain saw repair, maintenance and service must only be performed
by authorized and properly trained personnel.
• Make sure the chain breaker and rivet spinner are securely mounted on fl at, clean work surfaces. Check the mounting
screws/bolts often.
• Check all chain breaker and rivet spinner components regularly for wear and general condition.
7
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
For proper and safe operation read owners manual
and mwke sure that you have been properly
trained in correct procedures required for work
serious injury.
on or around electric lines.
11206
28409
28323
TOOL STICKERS & TAGS
D
30 LPM @ 138 B AR
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 read owners manual
and mwke sure that you have been properly
trained in correct procedures required for work
ELECTROCUTION
on or around electric lines.
HAZARD
33445
EHTMA CATEGORY
11207
Lwa
11212
DANGER
12412
11206
Circuit “C” Decal
11207
Circuit “D” Decal
28323
CE Decal
12412
Warning Decal
11212
Sound Level Decal
33445
Name Tag Decal
28409
Composite Decal
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.
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)
8
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
HYDRAULIC HOSE REQUIREMENTS
HOSE TYPES
Hydraulic hose types authorized for use with Stanley Hydraulic Tools are as follows:
➊ Certifi ed non-conductive
➋ Wire-braided (conductive)
➌ Fabric-braided (not certifi ed or labeled non-conductive)
Hose ➊ listed above is the only hose authorized for use near electrical conductors.
Hoses ➋ and ➌ listed above are conductive and must never be used near electrical conductors.
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
HOSE PRESSURE RATING
The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the
hydraulic system.
9
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
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)
NOTE:
These are general hydraulic system requirements. See tool Specifi cation page for tool specifi c requirements.
10
OPERATION
PREOPERTION PROCEDURES
CHECK THE POWER SOURCE
1. Using a calibrated fl ow meter and pressure gauge, make
sure the hydraulic power source develops a fl ow of 7-9
gpm/26-34 lpm for the 8 gpm model and 4-6 gpm/15-23
lpm for the 5 gpm model at 2000 psi/140 bar.
2. Make certain that the power source is equipped with a
relief valve set to open at 2100-2250 psi/145-155 bar.
3. Check that the hydraulic circuit matches the tool for
open-center (OC) or closed-center (CC) operation. The
DS06 is designed for open-center operation only.
CHECK TOOL
1. Make sure all tool accessories are correctly installed.
Failure to install tool accessories properly can result in
damage to the tool or personal injury.
2. There should be no signs of leaks.
CONNECT HYDRAULIC HOSES
1. Wipe all hose couplers with a clean lint-free cloth before
making connections. If necessary, use a light-weight penetrating oil in a spray can to clean the hose couplers before
each connection.
2. Connect the hoses from the hydraulic power source to
the chain saw fi ttings or quick disconnects. It is a good
practice to connect return hose fi rst and disconnect them
last to minimize or avoid trapped pressure within the chain
saw.
3. Observe the arrow on the couplers to ensure that the
fl ow is in the proper direction. The female coupler on the
chain saw is the inlet (pressure) coupler.
NOTE:
If uncoupled hoses are left in the sun, pressure increase inside the hoses might make them diffi cult to
connect. Whenever possible, connect the free ends of
the hoses together.
CONNECTING TO A WATER SUPPLY
3. The tool should be clean, with all fi ttings and fasteners
tight.
4. Observe the arrow on the couplers to ensure that the
hydraulic oil fl ow is in the proper direction. The female coupler is the inlet (pressure) coupler.
5. Check that the trigger operates smoothly and is free to
travel between the "ON" and "OFF" positions.
6. Check that the chain is properly installed. The chain is
designed to only operate in one direction. Make sure the
chain is installed so the bumper guard precedes each diamond segment. See fi gure 1.
Segment
CORRECT
INCORRECT
Bumper
Guard
1. Using a standard garden hose, connect the DS06 to a
city or auxiliary water supply. Make sure the fl ow is at least
4 gpm/15 lpm at 50 psi/3.5 bar.
IMPORTANT
Chain and bar damage will occur if the tool operates
without the proper water supply and water pressure.
2. Make sure the water is running before starting the tool.
3. If a water pump is being used, refer to the manufacturers
instructions for use of the pump. Make sure the pump produces a minimum watger fl ow of 4 gpm/15 lpm at 50 psi/3.5
bar and the water pressure does not exceed 160 psi/11 bar.
CHECK CHAIN AND BAR ADJUSTMENT
Note:
Check the chain tension often during operation, expecially during the fi rst 1/2 hour when using a new chain.
Adjust the chain accordingly when it becomes loose.
Follow the procedures contained in the Mainenance
and Adjustements section of this manual.
Figure 1. Chain Direction
1. Make sure the chain does not exceed a clearance of
5/16 in./8 mm from the bar (see fi gure 2). Exceeding the
maximum clearance increases the chance of the chain being dislodged from the bar groove.
11
OPERATION
2. Make sure the bar attaching nuts are fully tightened and
the chain guard is in place.
Bottom of Bar
Max
5/16”
Figure 2. Maximum Chain Clearance
CHECK CHAIN SEGMENT WEAR
1. Using adjustable calipers, measure several chain segments as illustrated in Figure 3.
Bottom of Bar
Min.
1/16”
Figure 3. Chain Segment Wear
2. If the average measurement is less than 1/16-inch/1.6
mm, then the chain must be replaced. Refer to your Service
Manual for chain replacement procedures.
OPERATING PROCEDURES
1. Observe all safety precautions.
2. Make your cuts in the order shown in Figure 4, starting
with cut 1 (base horizontal cut) and proceeding with the
remaining three cuts.
Figure 4. Planning Cuts
3. Outline the concrete area with a permanent marker for a
visual guide.
4. Know what kind of material and how much reinforcing
you are going to cut.
NOTICE
The following are general cutting procedures and
techniques. Differences in the terrain and the type of
material being cut will make this information more or
less valid for particular areas. For advice on specifi c
cutting problems or techniques, consult your local
Stanley Representative. He/she can often provide
information that will make your work safter and more
productive.
2. Turn on the water supply. Water at the tool will be directed to the bar and chain when the trigger on the tool is
squeezed “ON”.
3. Operate the tool for two minutes away from the intended
cut and then check the chain tension. New chain will normallhy stretch during its fi rst usage. It is very important to
keep the chain tension adjusted so that it does not exceed
5/16 in./8 mm clearance from the bottom of the bar. See
Check Chain & Bar Adjustment in this manual.
4. If the chain requires adjustment, see Maintenance &
Adjustments in this manual.
PLAN THE CUT
1. Plan your cuts to prevent injury to yourself and to keep
from pinching the saw bar and chain as a result of falling
pieces of concrete, brick, etc.
12
OPERATION
TYPES OF CUTS
The DS06 can be operated using the types of cuts shown
in Figure 5. When making cuts:
DOWN CUT
PLUNGE CUT
COLD WEATHER OPERATION
If the saw is to be used during cold weather, preheat the
hydraulic fl uid at low power source speed. When using the
normally recommended fl uids, fl uid should be at or above
50°F/10°C (400 ssu/82 centistokes) before use.
Damage to the hydraulic system or chain saw can result
from use with fl uid that is too viscous or thick.
USING THE WALL WALKER™
The Wall Walker™ lessens operator fatigue and effort during cutting by automatic insertion of the wedge into the cut,
thus allowing the operator to apply leverage to the saw.
1. Position the Wall Walker™ in the "autofeed" position by
pinning the lever arm at the lowest hole as shown in the
illustration.
Start cutting with the DS06 until the cut is large enough to
allow the tip of the wedge to insert into the cut. With the tip
of the wedge in the cut, the operator can easily apply leverage to the saw which will aid the cutting process and lessen
operator fatigue and effort.
UP CUT
Figure 5. Types of Cuts (chain guard removed for clarity)
1. Do not use a cutting force in excess of 45 lbs/20 kg.
Excessive force causes the chain to slow down or stall and
causes premature wear of the saw bar and chain.
2. Always maintain a high chain speed. High chain speeds
produce the best results.
3. Always check that plenty of water is being expelled
from the bar and chain. When the tool is running, water is
directed to the interior of the bar and then out of several
holes located along the top and bottom channels on the
bar. If these holes become plugged, cutting debris will not
be adequately washed away and will result in premature
wear of the bar and chain.
3. Avoid aggressive/heavy plunge forces. Aggressive
plunge force creates fragmenting of the concrete when the
saw bar and chain exits and causes premature bar and
chain wear.
After the saw cuts approximately 1 to 2.5 in. / 25 to 65 mm,
withdraw the saw only enough to allow the lever arm and
wedge to reposition. After repositioning, continue cutting.
2. The Wall Walker™ can be positioned to the "parked"
position by pinning the lever arm at the upper most hole. In
this position, the Wall Walker™ is used as a bucking cleat.
Wall Walker™ Lever Arm
(shown in “autofeed position)
13
Figure 6. Wall Walker™
MAINTENANCE & ADJUSTMENTS
GENERAL MAINTENANCE TIPS
Several simple maintenance tasks which, if performed, can
keep a chain saw operating at a high level of effi ciency.
Routine maintenance also keeps replacement costs down
on the parts of the chain saw, which occasionally wear out.
If any chain saw disassembly is required, refer to the Service Manual.
SAW BAR RAIL
A quick check can be made to determine if saw bar rail or
chain segment wear exists. Figure 7 shows a worn saw bar
rail.
CHAIN TENSION ADJUSTMENT
Correct chain tension is very important throughout the life
of the chain. Check the chain tension often during use
(when the chain saw is stopped and the saw bar and chain
have cooled off). The chain should move easily around the
saw bar when pulled by hand. To adjust the chain tension:
1. Turn off the water and power supplies.
2. Loosen the two saw bar attachment nuts (Figure 8).
Bar Attachment
Nuts (2)
Bar Adjusting Screw
Figure 7. Rail Wear
If the saw bar rails are worn, use a fl at fi le and dress each
one until it is fl at and square with the side of the saw bar
(Figure 7).
Also make sure the saw bar is perfectly straight. If bows
or bends are present in the saw bar, it must be replaced
before dressing any rail.
ROTATING THE SAW BAR
Maximum saw bar life can be achieved by occasionally
turning the bar over so the top and bottom bar surfaces
wear evenly. Refer to the saw bar disassembly procedures
in the Service Manual for further details.
Figure 8. Attachment Screw Locations
3. Using the saw bar adjustment screw (Item 68, Parts Illustration), tighten the chain until you are still able to rotate
it one full revolution by hand (Figure 9).
Figure 9. Pulling the Chain
4. Pull the chain around the saw bar to make sure it properly fi ts the sprocket and saw bar. The chain should be easily
pulled.
5. Fully tighten the two saw bar attachment nuts (Figure 8).
Note:
Adjust the chain tension each time the drive link tang
hangs fully exposed from the groove at the bottom of
the saw bar (Figure 10).
14
MAINTENANCE & ADJUSTMENTS
Max
5/16”
Figure 10. Exposed Drive Link Tang
Bottom of Bar
SERVICING THE CHAIN
The following procedures explain how to break a chain using Stanley’s bench mounted chain breaker (part number
20858) to remove a worn or damaged segment.
1. Mount the chain breaker fl ush with the side or front of a
fl at, clean work surface (Figure 11).
Figure 13. Inserting the Chain
3. Position the rivet head you want removed directly under
the chainbreaker punch and then pull the handle down far
enough to remove the rivet (Figure 14). Do not use excessive force.
Figure 11. Chain Breaker Mounting
Note:
The Stanley chain breaker is only designed to remove
rivet heads from the connecting links, not from a chain
segment. The rivet heads shown in the shaded areas of
Figure 12 are the only ones that can be removed.
Figure 12. Removable Rivet Heads
2. Place the chain (the portion that you want broken) into
the slot of the anvil pushing it forward until the bottom connecting link is fl ush with the far side of the slot (Figure 13).
Figure 14. Removing a Rivet
15
MAINTENANCE & ADJUSTMENTS
REPLACING THE CHAIN BREAKER
PUNCH
If the chain breaker punch (part number 22801) becomes
worn or damaged, use the following prcedures for replacement.
1. Remove the punch by loosening the set screw (Figure
15).
Figure 17. Rivet Spinner Mounting
2. Lay the chain across the plastic chain supports and then
rotate the supports so the rivet head is centered between
the take-up handle pocket and the spinner anvil (Figure
18).
Figure 15. Removing the Punch
2. Insert a new punch into the holder and push it up until it
is fully seated (Figure 16). Secure the punch to the chain
breaker holder by fully tightening the set screw.
Figure 16. Replacing the Punch
SPINNING RIVETS
The following procedures explain how to spin rivets using
Stanley’s bench-mounted rivet spinner (part number 20857)
to assembly the chain.
Figure 18. Positioning the Chain
3. Turn the take-up handle until the chain is tight against
the spinner anvil (Figure 19).
Rivet Spinner
Crank
Figure 19. Securing the Chain
Take-up
Handle
1. Mount the rivet spinner fl ush with the side or front of a
fl at, clean work surface (Figure 17).
16
MAINTENANCE & ADJUSTMENTS
4. turn the rivet spinner crank a few times to center the rivet
hub in the spinner anvil (Figure 20).
Take-up
Rivet Spinner
Crank
Figure 20. Centering the Rivet Hub
Handle
Figure 23. Spinner Oiling Chambers
5. Apply a few drops of oil to the rivet hub (Figure 21).
Figure 21. Applying the Oil
6. Turn the spinner crank while slowly running the take-up
handle inward (approximately one full revolution) until the
rivet head is formed (Figure 22).
Note:
The take-up handle provides pressure while the spinner anvil forms the rivet head.
NOTE:
the rivet spinner is equipped with oiling chambers and
should be maintained periodically with a light-weight
oil (Figure 23).
NOSE SPROCKET DISASSEMBLY
AND ASSEMBLY
1. Using the bench mounted chain breaker (see accessories), line up the 1/4 inch hole in the side of the chain
breaker anvil with the chain breaker punch. Punch out the
six nose sprocket rivets. See Figure 24.
Figure 22. Forming a Rivet Head
Figure 24. Punching Out Nose Sprocket
Rivets
2. Insert a straight blade screw driver to spread the bar
nose rails just enough to remove the old nose sprocket.
Use a rag or paper towel to clean the nose sprocket area.
See Figure 25.
17
MAINTENANCE & ADJUSTMENTS
Figure 25. Removing Old Nose Sprocket
3. Remove the new nose sprocket package's clips and fold
back the top portion of the insertion card being careful not
to remove or disturb the components. See Figure 26.
5. Insert 6 nose rivets into the holes and then hold them
with your thumb. Remove the screwdriver and slide out the
insertion card.
Note: On used bars the nose rails might tend to spread
apart. Use a small clamp if necessary to hold the rails
together.
6. With the bar and rivets solidly supported on a strong fl at
steel surface, carefully peen the rivet heads down with the
fl at end of a hammer. Be careful to only hit the rivet head.
Do not hit the bar body; this will pinch the nose sprocket.
Rivet heads must completely fi ll the countersinks in the
bar body and be snug and secure while still allowing the
sprocket to freely turn. See Figure 28.
Figure 26. Preparing New Nose Sprocket
4. With a fl at blade screw driver in the bar nose rails, slide
the nose sprocket assembly into position aligning the 6
holes in the bar nose with the 6 holes in the nose sprocket
assembly without removing the components from the card.
See Figure 27.
Figure 27. Installing a New Nose Sprocket
Figure 28. Replacing Rivets
7. Using a fl at fi le, shave the rivet heads to a uniform height
that is as close to the bar body as possible. See Figure 29.
Figure 29. Filing Rivets
18
TOOL EQUIPMENT & CARE
NOTICE
In addition to the Safety
Precautions in this manual,
observe the following for
equipment protection and
care.
• Make sure all couplers are wiped clean before connection.
• The hydraulic circuit control valve must be in the “OFF” position when coupling or uncoupling
hydraulic tools. Failure to do so may result in damage to the quick couplers and cause overheating
of the hydraulic system.
• Always store the tool in a clean dry space, safe from damage or pilferage.
• 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) page 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.
19
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 tool, always
check that the hydraulic power source is supplying the
SYMPTOM CAUSE REMEDY
Tool does not run. Hydraulic power source not function-
ing correctly.
Coupler or hoses blocked. Remove obstruction.
Mechanical failure. Have tool serviced by authorized
Tool runs backwards. Pressure and return lines incorrectly
connected.
Diamond saw cuts slow. Insuffi cient fl uid fl ow or too high back
pressure or relief valve set too low.
Back pressure too high. Should not exceed 250 psi/17 bar at
Loss of diamond segment side clearance.
Chain segment dulled because of continuous use in hard material or rebar.
Wrong chain for application. Scale down to a lower numbered
Wired edged bar rails. Dress rails square.
Hydraulic fl uid mixed in water supply. Have tool serviced.
Excessive vibration and cuts rough. Segment(s) broken or missing. Repair broken segment or replace
Chain installed backwards. Correct chain direction.
Loose chain tension. Retension the chain.
Excessive feed force. Reduce feed force.
Wil not cut straight. Accumulated saw bar wear and un-
even chain segment profi le wear.
Loss of power. Drive sprocket slipping on Tran-
torque® adapter.
Trigger hard to press. Pressure & return hose reversed. Connect for proper fl ow direction. Mo-
Back-pressure too high. Should not exceed 250 psi/17 bar @
correct hydraulic fl ow and pressure to the tool as listed
in the table. Use a fl owmeter known to be accurate.
Check the fl ow with the hydraulic oil temperature at least
80°F/27°C.
Check power source for proper fl ow
and pressure (7-9 gpm26-34 lpm at
2000 psi/140 bar.
dealer.
Correct hose connections. Motor shaft
rotates counterclockwise as viewed
from the end of the motor shaft.
Check hydraulic supply. If hydraulic
supply is correct, have unit serviced
by authorized dealer.
9 gpm/34 lpm measured at the end of
the tools operating hoses.
Replace chain.
Redress segmented by cutting in
abrasive material (i.e. concrete, building block, etc.).
Note: This indicates that the wrong
chain is being used.
chain.
chain.
Turn the saw bar over and dress rails
square. Replace the saw bar and
chain.
Adjust and tighten Trantorque®
adapter to 17 ft lb/23 Nm.
tor shaft must rotate clockwise.
9gpm/34 lpm measured at the end of
the tool’s operating hoses.
20
TROUBLESHOOTING
SYMPTOM CAUSE REMEDY
Leakage around drive sprocket. Motor shaft seal failure. Have unit serviced.
No water discharge at bar. Blocked port(s) in bar. Turn off hydraulic supply. Remove bar
and chain and clean bar thoroughly.
Blow ports with compressed air.
Blocked inlet or outlet. Turn off hydraulic supply. Remove bar
and chain. Make sure water supply
is on. Press trigger to see if water
exits near bar adjustment nut area (a
small port). If no water exits, have unit
serviced.
21
SPECIFICATIONS
Cutting Depths ............................................................................................................................................13 inches / 33 cm
Bar Lengths ....................................................................................................................................................13 inch / 33 cm
Chain Type ............................................................................................................ 3/8 inch pitch with 21 diamond segments
Maximum Back Pressure ................................................................................................................................ 250 psi/17 bar
Input Flow Range
5 gpm model ..........................................................................................................................4-6 gpm / 15-23 lpm
8 gpm model ............................................................................................................................7-9 gpm/26-34 lpm
Input Pressure ........................................................................................................................................... 2000 psi / 140 bar
Weight (without bar) ............................................................................................................................................ 14 lbs / 6 kg
Length (without bar) ................................................................................................................................ 14.3 inches / 36 cm
Width ............................................................................................................................................................ 9 inches / 23 cm
Lubrication / Cooling .............................................................................................................. Internal Water Channels in Bar
Porting ............................................................................................................................................................ -8 SAE O-Ring
Connection ...................................................................................................................................EHTMA/HTMA Flush Face
Hose Whips ...................................................................................................................................................................... Yes
Chain Speed
5 gpm model ........................................................................................................................... 4600 fpm/23.4 m/s
8 gpm model ........................................................................................................................... 5000 fpm/25.4 m/s
SOUND POWER AND VIBRATION DECLARATION
Measured A-weighted sound power level, Lwa (ref. 1pW) in decibels 106.2 dBA
Uncertainty, Kwa, in decibels 3 dBA
Measured A-weighted sound pressure level, Lpa (ref. 20 µPa) at operator’s position, in decibels 98.2 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 6.0 m/sec²
Uncertainty: K 2.0 m/sec²
Values determined according to ISO 8662-1, ISO 5349-1,2
ACCESSORIES
Chain Repair Spinner ................................................................................................................................................... 20857
Diamond Chain Repair Breaker ................................................................................................................................... 20858
Diamond Chain Service Kit ...........................................................................................................(sub p/n 20857 or 20858)
Diamond Chain Butterfl y Repair Kit .............................................................................................................................. 20859
Water Pump Kit (115/230 Volt / 60 Hz) ......................................................................................................................... 26020
Water Pump Kit (220/380/440 Volt /50 Hz) ................................................................................................................... 26237
HP1 Power Unit Water Pump Kit .................................................................................................................................. 29361
13 inch Bar, Sprocket Nose .......................................................................................................................................... 35037
Ultra-25, Diamond Chain for 13 inch Bar ..................................................................................................................... 56799
Pinnacle-25, Diamond Chain for 13 inch Bar ............................................................................................................... 56800
Water Pump Attachment for GT18 & HP1, with Couplers ..........................................................................................HWP10
Water Flow Meter, 0-7 gpm .......................................................................................................................................... 60859
22
SERVICE INSTRUCTIONS
PRIOR TO DISASSEMBLY
Clean exterior of the tool.
Obtain a seal kit so that all seals exposed during disassembly can be replaced.
ON-OFF VALVE SERVICING
a reduced diameter indicate fl uid contamination. If
abnormal wear is present (more than normal polishing),
replace both the spool and the handle.
2. Apply grease and install a new o-ring (15) onto the ON/
OFF valve (14).
3. Apply grease and install new o-rings (34 & 35) into the
spool bore of the handle.
TRIGGER (28) AND SAFETY CATCH (30)
REMOVAL & INSTALLATION
1. Drive the roll pins (20) out of the handle assembly using
a 3/16 in./4 mm diameter punch. Press the safety latch and
remove the trigger (28).
NOTE: The safety catch can be removed at this time by
driving out the 3/16 inch roll pin (21), but this is not necessary for servicing the on-off valve.
2. To install the trigger and safety catch reverse the above
procedures.
VALVE SPOOL (14) REMOVAL &
INSTALLATION
1. Remove the plug button (19) from the top of the handle
by prying under the edge and then pulling it from the
handle.
2. Drive the roll pins (20) out of the handle assembly using
a 3/16 in./4 mm diameter punch. Press the safety latch and
remove the trigger (28).
3. Drive the roll pin (20) (holding the valve spool (14) in
place) out of the handle using a 3/16 in./4 mm diameter
punch.
4. Unscrew the seal cap (44) and remove it, the spring
(42), and the steel ball (41).
4. Apply grease and install new o-rings (37 & 39) onto the
water valve sleeve (38).
5. If the spring retainers (16) and spring (17) were removed
from the ON/OFF valve, reinstall them. Lubricate the ON/
OFF valve with hydraulic fl uid and install it into the valve
handle. Secure it in place with the roll pin (20).
6. Install the water valve sleeve into the valve handle.
7. Install the push pin (40), steel ball (41), spring (42), and
seal cap (44). Make sure a new o-ring (43) is installed onto
the seal cap.
8. Install the safety catch (30) making sure the spring (29)
is positioned properly. Make sure the pin (33) is in place.
Secure the safety catch with the roll pin (21).
9. Install the trigger (28) and secure with the roll pin (20).
10. Replace the plug button (19) and test the action of the
safety catch and trigger.
FLOW CONTROL
Note:
Diamond saws with a serial number of 357 and above,
no longer require a fl ow control.
The fl ow control (32) is factory preset and is not fi eld serviceable. Use the following as guides to check for proper
regulated fl ow.
5. Lift out the valve spool assy (14 thru 18).
6. Using a 1/2 in./12.7 mm diameter wood dowel, place the
dowel into the valve spool bore from the plug button (19)
end of the handle. Push the dowel against the water valve
sleeve (38) to push the water sleeve out.
REASSEMBLY
1. Inspect the spool bore of the handle and the outer
surfaces of the spool for damage. Some light surface
scratches will be noticeable. Grooves, roughness or
For 5 gpm model:
If the regulated fl ow is over 6.6 gpm or under 5.4 gpm at 8
gpm input, the fl ow control valve should be replaced.
For 8 gpm model:
If the regulated fl ow is over 10 gpm or under 8 gpm at 12
gpm input, the fl ow control valve should be replaced.
23
SERVICE INSTRUCTIONS
MOTOR SERVICING
1. Remove the 2 nuts (51) and then lift off the chain guard
(50).
2. Lift off the bar (61) and chain (73). If it is necessary to
take tension off the bar and chain, turn the screw (68)
counter clockwise.
For Diamond Saws with Serial Number 357 and above,
follow the steps a thru c, then proceed to Step 7.
a. Remove the e-clip (60) and slide off items 48, 49 and 58.
b. Remove the retaining ring (100) and then spacer (47).
c. Remove the retaining ring (98) and then items 93 thru
96.
For Diamond Saws with Serial Number 356 and below,
follow the steps below.
3. Slide the sprocket wrench (84) over the sprocket (48).
While gripping the sprocket wrench and using an open end
wrench, turn the hex head on the Trantorque™ adapter cap
(49) counter clockwise until the Trantorque™ adapter can
be removed from the motor shaft (53).
4. Remove the spacer (47), support washer (100), and
o-ring (97).
11. To remove the bearing from the shaft, press on the outside end (sprocket end) of the motor shaft while supporting
the outer race of the bearing. Discard the old bearing.
12. Remove the retaining ring (91) at the bottom of the
bearing bore. Remove the seal backup washer (57). Remove the quad ring (90) and o-ring (56) using the appropriate o-ring service tools. Discard the quad ring and o-ring
13. The bushings (6) can be removed using p/n 11930 collet from p/n 05064 bearing puller kit.
MOTOR INSPECTION AND
CLEANING
Inspect and clean all parts as follows:
CLEANING
Clean all parts with a degreasing solvent. Blow dry with
compressed air and wipe clean. Use only lint-free cloths.
GEAR HOUSING
The chamber bores and bottoms around the shaft bushings
should be polished and not rough or grooved. If the bushing bores are yellow-bronze, replace them and investigate
the cause of wear.
5. Remove the retaining ring (98).
6. Remove the capscrews (1).
7. Using a fl at-blade screwdriver or similar tool, gently pry
the gear housing (4) away from the valve handle (22). Lift
the gear housing straight up. Do Not tilt the housing or pry
on the fl at surface inside of the surrounding groove. For
prying, only use the groove provided at the split between
the parts to prevent scratches on the inner mating surfaces.
8. Remove the two gears (9 & 13), needle roller (54), and
the idler shaft (8).
9. Remove the large face seal o-ring (7) while being careful not to damage the o-ring groove or surrounding surface.
10. While protecting the motor surface of the valve handle
from damage, tap lightly on the small diameter end (gear
side) of the motor shaft to remove it and the seal washer
(94), seal ring (96), v-ring seal (95), o-ring (93), and bearing (92) from the front of the valve handle. Remove the seal
keeper, seal spacer, seal, and o-ring from the motor shaft.
The fl at surfaces around the chamber and bolt holes should
be fl at and free of nicks or burrs that could cause misalignment or leaks.
BUSHINGS
The inside of the bushings should be gray with
some bronze showing through. If signifi cant yellow-bronze
shows, replace the bushings. Inspect motor shaft for corresponding wear and replace as required.
GEARS
The drive and idler gears should have straight tips without
nicks, square tooth ends and a smooth even polish on the
teeth and end faces. Check for cracks between the drive
gear keyway and gear tooth root. Replace the gear if
cracks are present.
VALVE HANDLE MOTOR SURFACE
The surface near the gears should show two interconnecting polished circles without a step. The bottom of the o-ring
24
SERVICE INSTRUCTIONS
groove should be smooth as should the rest of the fl at
surface.
The bore for the shaft seal should be smooth or oil leakage
may occur.
GEAR HOUSING
Shake the gear housing and the two seal check balls (not
shown) should rattle. If the seal balls do not rattle then
they are probably plugged with contaminants and the gear
housing will require replacement.
SHAFTS
The shaft diameter at the bearing and seal locations must
be smooth. Grooves, roughness or a reduced diameter
indicate fl uid contamination or damaged bushings. Grit
particles may have been imbedded in the bushings grinding into the hardened shaft. If abnormal shaft wear as
above occurs (more than normal polishing), replace both
the shaft and associated bushings.
Also check the hydraulic system for excess contamination
in the fl uid and for fi lter condition. Operating conditions
may require changing from a 25-micron fi lter to an oversized 10-micron fi lter.
MOTOR REASSEMBLY
Serial Number 357 and Above.
54
13
90
57
91
92
98
47
100
48
58
49
60
96
94
95
53
8
4
9
7
56
93
2. Grease and carefully install a new quad ring (90) into the
seal liner (57). Grease and install a new o-ring (56) onto the
seal liner. Install the seal liner into the valve handle assy
(22). Replace the retaining ring (91).
3. To replace the bearing (92) onto the motor shaft (53),
support the bearing inner race and press the motor shaft
through the bearing inner race.
4. Place the valve handle assy on a smooth clean arbor
press surface (protected from damage) with the large bearing bore facing up. Position the valve handle so a clearance
hole exists for the insertion of the motor shaft.
Refer to the illustration below for correct placement of
parts.
1. If the bushings (6) were removed from the valve handle
(22) and the gear housing (4), install new bushings using
a p/n 11918 bearing pusher. (NOTE: The bushing split line
must face the center of the gear housing).
Serial Number 356 and Below.
54
90
57
91
92
98
96
47
48
49
100
13
97
94
95
53
8
4
9
7
56
93
5. Apply grease to the motor shaft, keyway and bushing and then insert the motor shaft through the shaft seal.
Using a socket with a diameter equal to the bearing O.D.,
press the bearing and motor shaft into place. Press only on
the outer race.
6. Install the needle roller (54) in the keyway of the motor
shaft. Use grease to keep the needle roller in place. Slide
the drive gear (13) over the needle roller and shaft. Install
the idler shaft (8) and gear (9).
7. Apply grease to the face seal o-ring groove; then install
the o-ring (7).
8. Note the screw hole pattern on the rear gear housing
and the valve handle. They will only assemble one way.
With all parts aligned, carefully slide the gear housing assembly over the gears until it contacts the valve handle. Do
not force parts together.
9. Turn the motor shaft manually to check for free rotation.
Install the eight capscrews (1) and then recheck rotation.
25
SERVICE INSTRUCTIONS
For Diamond Saws with Serial Number 357 and above
follow steps a thru e.
For Diamond Saws with Serial Number 356 and below,
follow steps 10 thru 13.
a. Install the o-ring (43). Push in until it contacts the bearing
face.
b. Install seal washer (94) and the retainer ring (98).
c. Install v-ring (95) onto seal ring (96) then with both in
hand, apply a small amount of 242 Loctite
the seal ring (96). Make sure it is applied around the entire
bore of the seal ring, then slide both parts onto the motor
shaft.
d. Install the seal spacer (47) and then the retainer ring
(100).
e. Install items 58, 48, 49 and e-clip (60).
10. Apply grease and install a new v-ring seal (95) into
the seal washer (94). Apply grease and install a new o-ring
onto the seal keeper. Insert the seal ring (96) into the seal
washer and then install the seal spacer and seal keeper
onto the motor shaft as an assembly. Press the assembly
against the bearing and then install the retaining ring (98).
TM
to the bore of
4. Place the bar (with chain) over the studs making sure
the chain is looped around the sprocket and the bar adjustment nut is seated in the hole on the bar. While holding
the bar and chain in place, turn the adjustment screw (68)
clockwise to take the slack out of the chain. Install the chain
guard (50) and the 2 nuts (51). Hand tighten the 2 nuts and
then back them off 1/4 turn.
5. Adjust the chain tension by turning the adjustment screw
(68) in accordance with the instructions contained in the
section titled "MAINTENANCE & ADJUSTMENTS".
6. When adjustments are completed, be sure to tighten the
nuts (51).
11. Apply grease and install a new o-ring (97) onto the
motor shaft. Slide the o-ring against the seal spacer. Install
the spacer (47) and support washer (100).
12. Install the sprocket (48) over the Trantorque™ adapter
cap (49) and then install this assembly onto the motor
shaft. While gripping the sprocket, hand tighten the
hex head of the Trantorque™ adapter cap by turning it
clockwise.
13. Slide the sprocket wrench (84) over the sprocket (48).
While gripping the sprocket wrench and using an open end
wrench, tighten the hex head on the Trantorque™ adapter
(49) clockwise to 17 lb. ft./23 Nm.
BAR & CHAIN AND CHAIN GUARD ASSEMBLY
1. Back the bar adjustment nut (70) off by turning the adjustment screw (68) counter clockwise.
2. Install the chain (73) onto the bar (61). Make sure the
chain is installed so that the bumper guards precede the
segments. See the section titled 'OPERATION".
3. Install the chain guide plate (65) over the stud (66) as
shown in the parts illustration.
26
DS06 PARTS ILLUSTRATION
For Serial Numbers
357 and Above.
54
99
27
DS06 PARTS LIST
For Serial Numbers
357 and Above.
Item
Part No. Qty Description
No.
1 00753 8 HSHCS 10-24 UNC x 1-1/4
2 33445 1 Name Tag
112 07
3
112 06
4 07652 1
07834 1
5 00289 2 Dowel Pin
6 04041 4 Bushing
7 00020 1 O-Ring
8 07612 1 Idler Shaft
9 --- - No Item
10 32190 1 Pivot Pin
11 00961 1 Pipe Plug
12 --- - No Item
04106
13
07832
14 32207 1 On/Off Valve
15 07626 1 O-Ring
16 07609 2 Spring Washer
17 34119 1 Spring
18 04512 1 Retaining Ring, 1/2 EX
19 07625 1 Plug Button
20 03009 2 Roll Pin
21 07624 1 Roll Pin, 3/16 x 1
22 33267 1 Valve Handle Assy. (Incl. Items 6, 31, 66)
23 01605 - O-Ring, (Supplied with Item 24)
24 01652 2 Pigtail Hose Assy.
25 24059 1 Male Coupler
26 24058 1 Female Coupler
27 33443 1 Water Hose Assy.
28 58879 1 Trigger
29 07602 1 Spring
30 34105 1 Safety Catch
31 32197 1 Stud (Supplied with Item 22)
32 --- - No Item
33 00072 1 Roll Pin
34 07627 1 O-Ring
35 00074 1 O-Ring
36 33488 1 Self Locking Retaining Ring
37 05632 1 O-Ring
38 58970 1 Water Valve Sleeve
39 01403 1 O-Ring
40 33380 1 Pin
41 36259 1 Steel Ball, 3/8” Dia.
42 32188 1 Spring
43 04052 1 O-Ring
44 32189 1 Seal Cap
45 28323 1 CE Decal
46 --- - No Item
47 38898 1 Seal Spacer
48 09098 1 Sprocket
49 41765 1 Washer
50 32255 1 Chain Guard
51 32203 2 Nut
52 20721 1 Cord Stock, 3/16” Dia.
53 43690 1 Motor Shaft (See Item #60 for Serial No. Break)
54 04044 2 Needle Roller
55 02688 1 HSHCS 5/16 -18 UNC x 3/4
Circuit “D” Decal (8 gpm Model)
1
Circtuit “C” Decal (5 gpm Model)
Rear Gear Housing Assy. (Incl. Items 5-6),
8 gpm Model Only
Rear Gear Housing Assy. (Incl. Items 5-6),
5 gpm Model Only
Drive Gear, 8 gpm Model Only
2
Drive Gear, 5 gpm Model Only
Item
Part No. Qty Description
No.
56 60804 1 O-Ring
57 19215 1 Seal Back-Up Washer
58 43689 1 Sprocket Adapter
59 58969 1 Wiper Seal
60 41763 1
66299 1
61 --- - Saw Bar (See Accessories)
62 --- - No Item
63 32196 1 Flap Mount
64 33219 1 Spacer
65 32192 1 Chain Guide Plate
66 32245 1 Stud (Supplied with Item 22)
67 58968 2 HSHCS 1/4 -20 UNC x 5/8
68 02687 1 Machine Screw
69 32191 1 Stat-O-Seal
70 32198 1 Bar Adjustment Nut
71 33481 1 Wall Walker Clevis Pin
72 --- - Spring (Incl. with Item 74)
73 --- - Chain (See Accessories)
74 32206 1 Wall Walker
75 02649 1 Handle Bar Retainer
76 33229 1 Handle Weldment
77 33260 1 BHCS 1/4 -20 x .625 Zinc
78 33261 1 Fender Washer
79 33258 1 Hand Guard
80 12412 1 Electrical Warning Decal
81 12175 2 Washer
82 33454 2 HHCS 5/16 -18 x 5/8 Zinc
83 33263 1 Handle Grip
84 --- - No Item
85 17134 1 Nut, 1/4 -20 HHD LT SST
86 31614 1 Spirol Pin
87 30635 1 Spirol Pin, 5/16 x 7/8
88 28409 1 Composite Decal (CE)
89 11212 1 Sound Power Level Decal (CE)
90 00173 1 Quad Ring
91 04856 1 Retaining Ring
92 35965 1 Bearing
93 00621 1 O-Ring
94 38897 1 Seal Washer
95 39070 1 V-Ring
96 38700 1 Seal Ring
97 --- - No Item
98 07324 1 Retaining Ring
99 37793 1 Extension Spring Anchor
100 41764 1 Retaining Ring
03786 1 GPM Decal (8 gpm Models) (Not Shown)
33360 1 SEAL KIT
E-Clip
(For DS063000 s/n 434 and below and for
DS06200001 s/n 110 and below)
Spiral Retainer Ring
(For DS063000 s/n 435 and above and for
DS06200001 s/n 111 and above)
28
DS06 PARTS ILLUSTRATION
For Serial Numbers
356 and Below.
29
DS06 PARTS LIST
For Serial Numbers
356 and Below.
Item Qty Part Description
No No.
1 8 00753 HSHCS 10-24UNCx1-1/4
2 1 33445 NAME TAG
3 1 11207 CIRCUIT "D" STICKER (8 gpm model)
1 11206 CIRCUIT "C" STICKER (5 gpm model)
4 1 07652 REAR GEAR HOUSING ASSY (INCLD ITEM 5 &
6), 8 gpm model only
1 07834 REAR GEAR HOUSING ASSY (INCLD ITEM 5 &
6), 5 gpm model only
5 2 00289 DOWEL PIN
6 4 04041 BUSHING
7 1 00020 O-RING 5-329 R17 •
8 1 07612 IDLER SHAFT
9 1 04105 IDLER GEAR, 8 gpm model only
1 07831 IDLER GEAR, 5 gpm model only
10 1 32190 PIVOT PIN
11 1 22716 ST ELBOW 1/8NPT
12 1 21550 WATER GAUGE
13 1 04106 DRIVE GEAR, 8 gpm model only
1 07832 DRIVE GEAR, 5 gpm model only
14 1 32207 ON/OFF VALVE
15 1 07626 O-RING 2-014 R18 •
16 2 07609 SPRING WASHER
17 1 34119 SPRING
18 1 04512 RETAINING RING 1/2 EX
19 1 07625 PLUG BUTTON
20 2 03009 ROLL PIN
21 1 07624 ROLL PIN-3/16 X 1
22 1 32201 VALVE HANDLE ASSY (INCLD ITEMS 31 & 66)
23 3 01605 O-RING
24 2 01652 PIGTAIL HOSE ASSEMBLY
25 1 24059 MALE COUPLER
26 1 24058 FEMALE COUPLER
27 1 33443 WATER HOSE ASSY
28 1 34093 TRIGGER
29 1 07602 SPRING
30 1 34105 SAFETY CATCH
31 1 32197 STUD
32 1 33444 FLOW CONTROL VALVE, 8 gpm model only
1 34006 FLOW CONTROL VALVE, 5 gpm model only
33 1 00072 ROLL PIN
34 1 07627 O-RING 2-016 R24
35 1 00074 O-RING 2-021 R16 •
36 1 33488 SELF LOCKING RETAINING RING
37 1 05632 O-RING 2-005 R16
38 1 33377 WATER VALVE SLEEVE
39 1 01403 O-RING 2-020 R16 •
40 1 33380 PIN
41 1 36259 STEEL BALL 3/8 DIA.
42 1 32188 SPRING
43 1 04052 O-RING 3-914 R17 •
44 1 32189 SEAL CAP
45 1 28323 CE STICKER
46 1 06635 RET RING 1 3/8 INT
47 1 38898 SEAL SPACER
48 1 32210 SPROCKET
49 1 39071 TRANTORQUE™ ADAPTOR
50 1 32255 CHAIN GUARD
51 2 32203 NUT
52 1 20721 CORD STOCK 3/16DIA R1
53 1 35897 MOTOR SHAFT
54 1 04044 NEEDLE ROLLER
55 1 02688 HSHCS 5/16-18UNCx3/4
•
•
Item Qty Part Description
No No.
56 1 60804 O-RING
57 1 19215 SEAL LINER
58 - ----- NO ITEM
59 - ----- NO ITEM
60 - ----- NO ITEM
61 ----- SAW BAR (SEE ACCESSORIES)
62 - ----- NO ITEM
63 1 32196 FLAP MOUNT
64 1 33219 SPACER
65 1 32192 CHAIN GUIDE PLATE
66 1 32245 STUD
67 2 02446 HSHCS 1/4-20UNCx5/8
68 1 02687 MACHINE SCREW
69 1 32191 STAT-O-SEAL
70 1 32198 BAR ADJUSTMENT NUT
71 1 33481 WALLWALKER CLEVIS PIN
72 SPRING (INCLD WITH ITEM 74)
73 ----- CHAIN (SEE ACCESSORIES)
74 1 32206 WALL WALKER
75 1 02649 HANDLE BAR RETAINER
76 1 33229 HANDLE WELDMENT
77 1 33260 BHCS 1/4-20x.625 ZINC
78 1 33261 FENDER WASHER
79 1 33258 HAND GUARD
80 1 12412 WARNING STICKER-ELECT
81 2 12175 WASHER
82 2 33454 HHCS 5/16-18x5/8 ZINC
83 1 33263 HANDLE GRIP
84 1 33429 SPROCKET WRENCH
85 1 17134 NUT 1/4-20 HHD LT SST
86 1 31614 SPIROL PIN
87 1 30635 SPIROL PIN 5/16 x 7/8
88 1 28409 COMPOSITE STICKER (CE)
89 1 11212 SOUND POWER LEVEL STICKER (CE)
90 1 00173 QUAD RING
91 1 04856 RETAINING RING
92 1 35965 BEARING
93 1 00621 O-RING
94 1 38897 SEAL WASHER
95 1 39070 V-RING
96 1 38700 SEAL RING
97 1 350810 O-RING
98 1 07324 RETAINING RING
99 - ----- NO ITEM
100 1 34118 SUPPORT WASHER
33360 SEAL KIT
•
•
•
•
•
•
• Denotes Part in Seal Kit
30
DIAMOND CHAIN APPLICATIONS
Model Bar Length P/N Correct Applications
PinnaclePinnacle-
UltraUltra-
13 inch
13 inch
Very hard aggregate concretes (fl int, chert, granite, etc). Heavy steel
reinforcing, 5/8 inch/16 mm diameter and larger. Medium/hard aggregate concretes (granite, quartz, river rock, etc). Moderate steel reinforcing (wire mesh 3/8-1/2 inch/10-12 mm diameter). Soft aggregate
concrete, concrete block, masonry, “green” concrete, highly abrasive
Medium/hard aggregate concretes (granite, quartz, river rock, etc).
Moderate steel reinforcing (wire mesh 3/8-1/2 inch/10-12 mm diameter). Soft aggregate concrete, concrete block, masonry, “green”
concrete, highly abrasive conditions.
31
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.
32
Stanley Hydraulic Tools
3810 SE Naef Road
Milwaukie OR 97267-5698
503-659-5660
FAX 503-652-1780
www.stanley-hydraulic-tools.com
Loading...