RS25
HYDRAULIC
RAIL SAW
USER MANUAL
Safety, Operation and Maintenance
© 2014 Stanley Black & Decker, Inc.
New Britain, CT 06053
U.S.A.
31846 8/2014 Ver. 11
Weisbeck, Andy
Directive/Standards
No.
Approved body
Machinery Directive
2006/42/EC:2006
Self
DECLARATION OF CONFORMITY
DECLARATION OF CONFORMITY
ÜBEREINSTIMMUNGS-ERKLARUNG
DECLARATION DE CONFORMITE CEE
DECLARACION DE CONFORMIDAD
DICHIARAZIONE DI CONFORMITA
___________________________________ ___________________________________
I, the undersigned:
Ich, der Unterzeichnende:
Je soussigné:
El abajo firmante:
lo sottoscritto:
hereby declare that the equipment specified hereunder:
bestätige hiermit, daß erklaren Produkt genannten Werk oder Gerät:
déclare que l’équipement visé ci-dessous:
Por la presente declaro que el equipo se especifica a continuación:
Dichiaro che le apparecchiature specificate di seguito:
Surname and First names/Familiennname und Vornamen/Nom et prénom /Nombre y apellido/Cognome e nome
Hydraulic Tools
1. Category:
Kategorie:
Catégorie:
Categoria:
Categoria:
2. Make/Marke/Marque/Marca/Marca
3. Type/Typ/Type/Tipo/Tipo: RS25103
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
Richtlinie/Standards
Directives/Normes
Directriz/Los Normas
Direttiva/Norme
EN ISO
ISO
ISO
5. Special Provisions: None
Spezielle Bestimmungen:
Dispositions particulières:
Provisiones especiales:
Disposizioni speciali:
Nr
Numéro
No
n.
3744:2009
20643:2005
19432:2006
Rail Saw, Hydraulic
Stanley
All
Prüfung durch
Organisme agréé
Aprobado
Collaudato
Self
Self
Self
6. Representative in the Union: Patrick Vervier, Stanley Dubuis 17-19, rue Jules Berthonneau-BP 3406 41034 Blois Cedex, France.
Vertreter in der Union/Représentant dans l’union/Representante en la Union/Rappresentante presso l’Unione
Done at/Ort/Fait à/Dado en/Fatto a Stanley Hydraulic Tools, Milwaukie, Oregon USA
Signature/Unterschrift/Signature/Firma/Firma
Position/Position/Fonction/Cargo/Posizione Engineering Manager
2 ► RS25 User Manual
Date/Datum/le/Fecha/Data 1-4-11
WARNING
TABLE OF CONTENTS
DECLARATION OF CONFORMITY .......................................................................................................................... 2
SAFETY SYMBOLS ..................................................................................................................................................4
SAFETY PRECAUTIONS .......................................................................................................................................... 5
TOOL STICKERS & TAGS ........................................................................................................................................7
HOSE TYPES ............................................................................................................................................................8
HOSE RECOMMENDATIONS ..................................................................................................................................9
FIGURE 1. TYPICAL HOSE CONNECTIONS .......................................................................................................9
HTMA REQUIREMENTS .........................................................................................................................................10
OPERATION ............................................................................................................................................................ 11
FIGURE 2. ............................................................................................................................................................ 12
FIGURE 3. ............................................................................................................................................................ 12
TOOL PROTECTION & CARE ................................................................................................................................14
TROUBLESHOOTING ............................................................................................................................................15
SPECIFICATIONS ................................................................................................................................................... 16
ACCESSORIES.......................................................................................................................................................16
RS25 PARTS ILLUSTRATION ................................................................................................................................17
RS25 PARTS LIST ..................................................................................................................................................18
IMPORTANT
To ll out a Product Warranty Validation form, and for information on your warranty,
visit Stanleyhydraulics.com and select the Company tab, Warranty.
(NOTE: The warranty Validation record 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.
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.
RS25 User Manual ◄ 3
DANGER
WARNING
CAUTION
CAUTION
NOTICE
IMPORTANT
SAFETY SYMBOLS
Safety symbols and signal words, as shown below, are used to emphasize all operator, maintenance and repair actions which, if not strictly followed, could result in a life-threatening situation, bodily injury or damage to equipment.
This is the safety alert symbol. It is used to alert you to potential personal injury
hazards. Obey all safety messages that follow this symbol to avoid possible
injury or death.
This safety alert and signal word indicate an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
This safety alert and signal word indicate a potentially hazardous situation
which, if not avoided, could result in death or serious injury.
This safety alert and signal word indicate a potentially hazardous situation
which, if not avoided, could result in death or serious injury.
This signal word indicates a potentially hazardous situation which, if not avoided, may result in property damage.
This signal word indicates a situation which, if not avoided, will result in damage
to the equipment.
This signal word indicates a situation which, if not avoided, may result in damage to the equipment.
Always observe safety symbols. They are included for your safety and for the protection of the tool.
LOCAL SAFETY REGULATIONS
Enter any local safety regulations here. Keep these instructions in an area accessible to the operator and maintenance personnel.
4 ► RS25 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 pre-
cautions relating to the specic work area and local
safety regulations. If so, place the added precautions in
the space provided in this manual.
The model RS25 Hydraulic Rail 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 by-
standers. 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,
gloves, ear and head protection, and safety shoes
at all times when operating the tool.
• 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.
• 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 be-
fore 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 the normal temperatures at the tool
which can result in operator discomfort.
• Do not operate a damaged, improperly adjusted, or
incompletely assembled tool.
• 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 speci-
cations given in the OPERATION section of this
manual.
• Do not operate the tool with the wheel guard removed.
• Release the trigger if the power supply has been interrupted.
• Keep the wheel off all surfaces when starting the
rail saw.
• To avoid personal injury or equipment damage, all
tool repair, maintenance and service must only be
performed by authorized and properly trained personnel.
• Always hold the tool with both hands when the unit
is running. Use a rm grip.
• Make sure the wheel has stopped before setting
the tool down. Always carry the tool with the wheel
stopped.
• Inspect the wheel guard and collars for damage after any wheel breakage.
• Do not operate the tool in the vicinity of ammable
materials.
• Never exceed the maximum operating speed
marked on the wheel.
• Do not attempt to adjust the ow control in the valve
handle.
• Eye injury and cutting or severing of body parts is
possible if proper procedures are not followed.
RS25 User Manual ◄ 5
SAFETY PRECAUTIONS
CUTTING WHEEL SAFETY
• Do not store or transport the saw with the wheel installed.
• Ensure that the cutting wheel is correctly mounted
and tightened before use.
• Operate the Rail Saw at “no load” for 30 seconds in
a safe position and ensure there is no vibration or
other defects detected. 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.
• If the Rail Saw is dropped with a cutting wheel installed, the cutting wheel should be examined thoroughly before use.
• Only use cutting wheels that comply with ANSI B7.5/
ISO 525, 603.
• Check that the maximum operating speed (rpm –
revolutions per minute) of the cutting wheel is equal
to or greater than the rated shaft speed of the grind-
er. Stanley recommends wheels rated at 4700 RPM
for 16 inch models and 5300 RPM for 14 inch models.
6 ► RS25 User Manual
WHEEL SIZE
RPM: SPINDLE:
PRESS: BAR PSI
FLOW: LPM GPM
PROTECT YOUR EYES...
WEAR SAFETY GOGGLES
28728
RS25 Name Tag
03787
GPM Sticker 7–9 2000 PSI
TOOL STICKERS & TAGS
PROTECT YOUR EYES - WEAR SAFETY GOGGLES
1. Do not use damaged wheels.
2. Use full throttle only while cutting.
3. Use only wheels marked high speed reinforced that meet requirements
of ANSI B7.5. Wheels should be no larger than 16” diameter x 5/31” thick with a 1” arbor hole
28811
Information Plaque
(CE models only)
28409
Composite Sticker
(CE models only)
and rated for 4700 rpm minimum speed.
4. Inspect wheel guard & collars for damage after any wheel breakage on the machine.
5. Maximum spindle speed is 4700 rpm.
05868
Abrasive Cut-Off Safety Label
(14 inch models only – except CE)
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
16" DIA X 5/32" THICK WITH A 1" ARBOR HOLE & RATED FOR 4700 RPM
MINIMUM SPEED.
4. INSPECT WHEEL GUARD & COLLARS FOR DAMAGE AFTER ANY WHEEL
BREAKAGE ON THE MACHINE.
5. MAXIMUM SPINDLE SPEED IS 4700 RPM.
6. READ OPERATION MANUAL.
17641
Abrasive Cut-Off Safety Label
(16 inch models only)
CAUTION
CAUTION
25610
Railroad Help Desk Sticker
05152
Logo-Address Decal
(UP models only)
THE INFORMATION LISTED
ON THE STICKERS SHOWN,
MUST BE LEGIBLE AT ALL
REPLACE DECALS IF
THEY BECOME WORN OR
DAMAGED. REPLACEMENTS
ARE AVAILABLE FROM
YOUR LOCAL STANLEY
DISTRIBUTOR.
The safety tag (P/N 15875) at right is
attached to the tool when shipped from
the factory. Read and understand the
safety instructions listed on this tag before
removal. We suggest you retain this tag and
attach it to the tool when not in use.
NOTE:
TIMES.
11207
Sound Power Level Sticker
1. FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON-CONDUCTIVE WHEN USING HYDRAULIC
TOOLS ON OR NEAR ELECTRICAL LINES MAY RESULT IN
DEATH OR SERIOUS INJURY.
BEFORE USING HOSE LABELED AND CERTIFIED AS NON-
CONDUCTIVE ON OR NEAR ELECTRIC LINES BE SURE THE
HOSE IS MAINTAINED AS NON-CONDUCTIVE. THE HOSE
SHOULD BE REGULARLY TESTED FOR ELECTRIC CURRENT LEAKAGE IN ACCORDANCE WITH YOUR SAFETY
DEPARTMENT INSTRUCTIONS.
2. A HYDRAULIC LEAK OR BURST MAY CAUSE OIL INJECTION INTO THE BODY OR CAUSE OTHER SEVERE
PERSONAL INJURY.
A. DO NOT EXCEED SPECIFIED FLOW AND PRESSURE
FOR THIS TOOL. EXCESS FLOW OR PRESSURE MAY
CAUSE A LEAK OR BURST.
B. DO NOT EXCEED RATED WORKING PRESSURE OF
HYDRAULIC HOSE USED WITH THIS TOOL. EXCESS
PRESSURE MAY CAUSE A LEAK OR BURST.
C. CHECK TOOL HOSE COUPLERS AND CONNECTORS
DAILY FOR LEAKS. DO NOT FEEL FOR LEAKS WITH
YOUR HANDS. CONTACT WITH A LEAK MAY RESULT
IN SEVERE PERSONAL INJURY.
IMPORTANT
READ OPERATION MANUAL AND
SAFETY INSTRUCTIONS FOR THIS
TOOL BEFORE USING IT.
USE ONLY PARTS AND REPAIR
PROCEDURES APPROVED BY
STANLEY AND DESCRIBED IN THE
OPERATION MANUAL.
TAG TO BE REMOVED ONLY BY
TOOL OPERATOR.
SEE OTHER SIDE
SAFETY TAG P/N 15875 (Shown smaller then actual size)
DANGERDANGER
D. DO NOT LIFT OR CARRY TOOL BY THE HOSES. DO
NOT ABUSE HOSE. DO NOT USE KINKED, TORN OR
DAMAGED HOSE.
3. MAKE SURE HYDRAULIC HOSES ARE PROPERLY CONNECTED TO THE TOOL BEFORE PRESSURING SYSTEM.
SYSTEM PRESSURE HOSE MUST ALWAYS BE CONNECTED TO TOOL “IN” PORT. SYSTEM RETURN HOSE
MUST ALWAYS BE CONNECTED TO TOOL “OUT” PORT.
REVERSING CONNECTIONS MAY CAUSE REVERSE
TOOL OPERATION WHICH CAN RESULT IN SEVERE
PERSONAL INJURY.
4. DO NOT CONNECT OPEN-CENTER TOOLS TO CLOSEDCENTER HYDRAULIC SYSTEMS. THIS MAY RESULT IN
LOSS OF OTHER HYDRAULIC FUNCTIONS POWERED BY
THE SAME SYSTEM AND/OR SEVERE PERSONAL INJURY.
5. BYSTANDERS MAY BE INJURED IN YOUR WORK AREA.
KEEP BYSTANDERS CLEAR OF YOUR WORK AREA.
6. WEAR HEARING, EYE, FOOT, HAND AND HEAD PROTECTION.
7. TO AVOID PERSONAL INJURY OR EQUIPMENT DAMAGE,
ALL TOOL REPAIR MAINTENANCE AND SERVICE MUST
ONLY BE PERFORMED BY AUTHORIZED AND PROPERLY
TRAINED PERSONNEL.
IMPORTANT
READ OPERATION MANUAL AND
SAFETY INSTRUCTIONS FOR THIS
TOOL BEFORE USING IT.
USE ONLY PARTS AND REPAIR
PROCEDURES APPROVED BY
STANLEY AND DESCRIBED IN THE
OPERATION MANUAL.
TAG TO BE REMOVED ONLY BY
TOOL OPERATOR.
SEE OTHER SIDE
RS25 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 PROPERLY TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND
ELECTRIC LINES.
2. BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS NON-CONDUCTIVE
ON OR NEAR ELECTRIC LINES. WIPE THE ENTIRE LENGTH OF THE HOSE AND FITTING WITH A CLEAN DRY ABSORBENT CLOTH TO REMOVE DIRT AND MOISTURE AND
TEST HOSE FOR MAXIMUM ALLOWABLE CURRENT LEAKAGE IN ACCORDANCE WITH
SAFETY DEPARTMENT INSTRUCTIONS.
DO NOT REMOVE THIS TAG
SEE OTHER SIDE
SIDE 1
3. DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE. IMPROPER USE
OR HANDLING OF HOSE COULD RESULT IN BURST OR OTHER HOSE FAILURE.
KEEP HOSE AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT
CONTACT DURING USE. CONTACT AT THE BURST CAN CAUSE BODILY INJECTION
AND SEVERE PERSONAL INJURY.
4. HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING, ABRASION, CUTTING, OR
CONTACT WITH HIGH TEMPERATURE SURFACES. DO NOT USE IF KINKED. DO NOT
USE HOSE TO PULL OR LIFT TOOLS, POWER UNITS, ETC.
5. CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS, BULGES, OR DAMAGE TO COUPLINGS IF ANY OF THESE CONDITIONS EXIST, REPLACE THE HOSE
IMMEDIATELY. NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE.
6. AFTER EACH USE STORE IN A CLEAN DRY AREA.
(Shown smaller than actual size)
DANGER
DANGER
SEE OTHER SIDE
SIDE 2
THE TAG SHOWN BELOW IS ATTACHED TO “CONDUCTIVE” HOSE.
DANGER
DANGER
1. DO NOT USE THIS HYDRAULIC HOSE ON OR NEAR ELECTRIC LINES. THIS HOSE IS
NOT LABELED OR CERTIFIED AS NON-CONDUCTIVE. USING THIS HOSE ON OR NEAR
ELECTRICAL LINES MAY RESULT IN DEATH OR SERIOUS INJURY.
2. FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY
TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND ELECTRIC LINES.
3. DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE. IMPROPER USE OR
HANDLING OF HOSE COULD RESULT IN BURST OR OTHER HOSE FAILURE. KEEP HOSE
AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT CONTACT
DURING USE. CONTACT AT THE BURST CAN CAUSE BODILY INJECTION AND SEVERE
PERSONAL INJURY.
4. HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING, CUTTING, OR CONTACT
WITH HIGH TEMPERATURE SURFACES. DO NOT USE IF KINKED. DO NOT USE HOSE TO
PULL OR LIFT TOOLS, POWER UNITS, ETC.
DO NOT REMOVE THIS TAG
SEE OTHER SIDE
SIDE 1
5. CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS, BULGES, OR DAMAGE TO
COUPLINGS IF ANY OF THESE CONDITIONS EXIST, REPLACE THE HOSE IMMEDIATELY.
NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE.
6. AFTER EACH USE STORE IN A CLEAN DRY AREA.
(Shown smaller than actual size)
DANGER
SEE OTHER SIDE
SIDE 2
DO NOT REMOVE THIS TAG
DO NOT REMOVE THIS TAG
8 ► RS25 User Manual
Min. Working Pressure
USE
(Press/Return)
HOSE RECOMMENDATIONS
Certied Non-Conductive Hose - Fiber Braid - for Utility Bucket Trucks
Oil Flow Hose Lengths Inside Diameter
GPM LPM FEET METERS INCH MM PSI BAR
4-9 15-34 up to 10 up to 3 3/8 10 Both 2250 155
Conductive Hose - Wire Braid or Fiber Braid -DO NOT USE NEAR ELECTRICAL CONDUCTORS
4-6 15-23 up to 25 up to 7.5 3/8 10 Both 2500 175
4-6 15-23 26-100 7.5-30 1/2 13 Both 2500 175
5-10.5 19-40 up to 50 up to 15 1/2 13 Both 2500 175
5-10.5 19-40 51-100 15-30 5/8 16 Both 2500 175
5/8 16 Pressure 2500 175
3/4 19 Return 2500 175
5-10.5 19-40 100-300 30-90
10-13 38-49 up to 50 up to 15 5/8 16 Both 2500 175
5/8 16 Pressure 2500 175
3/4 19 Return 2500 175
10-13 38-49 51-100 15-30
3/4 19 Pressure 2500 175
1 25.4 Return 2500 175
10-13 38-49 100-200 30-60
5/8 16 Pressure 2500 175
13-16 49-60 up to 25 up to 8
3/4 19 Return 2500 175
3/4 19 Pressure 2500 175
1 25.4 Return 2500 175
13-16 49-60 26-100 8-30
PRESSURE
<<< FLOW
RETURN
FLOW >>>
Figure 1. Typical Hose Connections
Tool to Hydraulic Circuit Hose
Recommendations
The chart to the right shows recommended
minimum hose diameters for various hose
lengths based on gallons per minute (gpm)/
liters per minute (lpm). These recommenda-
tions are intended to keep return line pressure
(back pressure) to a minimum acceptable lev-
el to ensure maximum tool performance.
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.
RS25 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)
4-6 gpm 7-9 gpm 9-10.5 gpm 11-13 gpm
(15-23 lpm) (26-34 lpm) (34-40 lpm) (42-49 lpm)
1500 psi 1500 psi 1500 psi 1500 psi
(103 bar) (103 bar) (103 bar) (103 bar)
2100-2250 psi 2100-2250 psi 2200-2300 psi 2100-2250 psi
(145-155 bar) (145-155 bar) (152-159 bar) (145-155 bar)
250 psi 250 psi 250 psi 250 psi
(17 bar) (17 bar) (17 bar) (17 bar)
400 ssu* 400 ssu* 400 ssu* 400 ssu*
(82 centistokes) (82 centistokes) (82 centistokes) (82 centistokes)
140° F 140° F 140° F 140° F
(60° C) (60° C) (60° C) (60° C)
3 hp 5 hp 6 hp 7 hp
(2.24 kW) (3.73 kW) (5.22 kW) (4.47 kW)
40° F 40° F 40° F 40° F
(22° C) (22° C) (22° C) (22° C)
25 microns 25 microns 25 microns 25 microns
30 gpm 30 gpm 30 gpm 30 gpm
(114 lpm) (114 lpm) (114 lpm) (114 lpm)
TYPE I TYPE II
TOOL TYPE
TYPE RR
TYPE III
Hydraulic uid Petroleum based
(premium grade, anti-wear, non-conductive)
Viscosity (at min. and max. operating temps)
NOTE:
When choosing hydraulic uid, the expected oil temperature extremes that will be experienced in service determine the
most suitable temperature viscosity characteristics. Hydraulic uids with a viscosity index over 140 will meet the requirements
over a wide range of operating temperatures.
*SSU = Saybolt Seconds Universal
EHTMA
100-400 ssu* 100-400 ssu* 100-400 ssu* 100-400 ssu*
(20-82 centistokes)
CLASSIFICATION
HYDRAULIC SYSTEM
REQUIREMENTS
Flow Range
Nominal Operating Pressure
(at the power supply outlet)
System relief valve setting
(at the power supply outlet)
NOTE: These are general hydraulic system requirements. See tool specication page for tool specic requirements
B
3.5-4.3 gpm 4.7-5.8 gpm 7.1-8.7 gpm 9.5-11.6 gpm 11.8-14.5 gpm
(13.5-16.5 lpm) (18-22 lpm) (27-33 lpm) (36-44 lpm) (45-55 lpm)
1870 psi 1500 psi 1500 psi 1500 psi 1500 psi
(129 bar) (103 bar) (103 bar) (103 bar) (103 bar)
2495 psi 2000 psi 2000 psi 2000 psi 2000 psi
(172 bar) (138 bar) (138 bar) (138 bar) (138 bar)
C
D
10 ► RS25 User Manual
OPERATION
PRE-OPERATION PROCEDURES
CHECK HYDRAULIC POWER SOURCE
1. Using a calibrated owmeter and pressure gauge,
check that the hydraulic power source develops a
ow of 9–10.5 gpm/34–40 lpm at 2000 psi/140 bar.
2. Make certain the hydraulic power source is equipped
with a relief valve set to open at 2200–2300 psi/152–
159 bar minimum.
3. Check that the hydraulic circuit matches the tool for
open-center (OC) operation.
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.
3. The tool should be clean, with all ttings and fasten-
ers tight.
CHECK TRIGGER MECHANISM
1. Check that the trigger operates smoothly and is free
to travel between the ON and OFF positions.
CHECK GUARD ASSEMBLY
1. Inspect the wheel guard assembly for cracks and
other structural damage.
INSTALLING AND REMOVING
ABRASIVE CUTTING WHEELS
NOTE:
Use 14 in./350 mm diameter (for 14 in. model) or 16
in./400 mm diameter (for 16 in. model) abrasive cutting wheels with a 1 in. arbor hole. Only use cutting
wheels which comply with ANSI B7.5/ISO 525, 603.
Make sure the paper labels or blotters are installed
between the wheel and collars.
1. Before installing abrasive wheels, “sound” the wheel
for possible damage by hanging the wheel vertically
be the arbor hole and rapping lightly with a screwdriver handle or similar instrument. Thin, organic
bond wheels will produce a low drumming tone if it
is physically sound. If the wheel produces a “dead”
or “at” sound, it may be cracked. Cracked or damaged wheels must never be used.
2. Check that the surfaces of the wheel that come in
contact with blotters and anges are free of dirt and
other foreign particles.
3. Remove the jam nut (77) and outside collar (78) by
using a box type wrench while gripping the cutting
wheel.
4. Install the cutting wheel. Make sure blotters or labels
remain on the cutting wheel.
5. Reinstall the outside collar and jam nut. Tighten the
jam nut with a box type wrench while gripping the
cutting wheel. Only tighten sufciently to prevent
slippage of the wheel between the collars (78 & 79).
DRIVE SHAFT SPEED CHECK
The speed of the motor output shaft should be checked
at least every 100 hours of operation by trained and
experienced personnel. A record of the speed checks
should be maintained. The rated speed of the RS25 Rail
Saw is 3600 rpm at 10 gpm/38 lpm for the 16 inch/400
mm model and 4500 rpm at 10 gpm/38 lpm for the 14
inch/350 mm model. The cutting wheel must be rated for
a minimum of 4700 rpm for the 16 inch/400 mm model and 5300 rpm for the 14 inch/350 mm model. Tests
should be conducted while operating the normal power
supply used with the saw.
CONNECT HOSES
1. Wipe all hose couplers with a clean lint-free cloth
before making connections.
2. Connect the hoses from the hydraulic power source
to the hose couplers on the rail saw. It is a good
practice to connect the return hose rst and disconnect it last to minimize or avoid trapped pressure
within the rail saw motor.
3. Observe ow indicators stamped on hose couplers
to be sure that oil will ow in the proper direction.
The female coupler is the inlet coupler.
NOTE:
The pressure increase in uncoupled hoses left in the
sun may result in making them difcult to connect.
When possible, connect the free ends of operating
hoses together.
RS25 User Manual ◄ 11
OPERATION
OPERATING PROCEDURES
CLAMPING THE RAIL SAW TO THE RAIL
1. Observe all safety precautions.
2. Make sure the rail clamp assembly is tight to the
disconnect pivot (60) by turning the handle (20) to
tighten the disconnect pivot bolt.
3. Fully extend the indicator rod located on the clamp
and position the rail clamp on the rail so the clamp
arms bear on the top and sides of the rail and the
bell crank bears under the rail as shown in Figure 2.
LOWER
CAPSCREW
BELL
CRANK
Figure 2.
4. Move the rail saw along the rail until the indicator is
next to the cut as shown in Figure 3.
EDGE OF
CUT LINE
Figure 3.
5. Tighten the bell crank to the rail by turning the clamp
screw (75) clockwise.
CLAMP
INDICATOR
ROD
CLAMP
RAIL
INDICATOR
6. While holding onto the upper link of the rail clamp
assembly (near the red knob of the handle), release
the detent (129) by turning the knob and then position the lower link forward (away from the operator)
until the detent can be re-engaged in one or the other of the two holes away from the “top dead center
hole”. This positions the saw so that the operator
may stand erect while cutting the rail and also allows
the saw to cut down to the ange of the rail.
An optional method is to disengage the detent and
adjust the capscrews (see Figure 2) as required.
7. Adjust the wheel guard (87) so that it does not interfere with the cutting process and cuttings are directed away from the operator.
SAWING THE RAIL
1. Always start the rail saw with the cutting wheel away
from the work surface.
2. Start the cut with the wheel rotating.
NOTE:
Do not “bump” the rail. Feed the wheel through
the material as fast as possible without allowing
the wheel to reduce its speed. Cutting through the
material too slowly allows heat expansion and can
cause wheel “pinching” in the material. “Pinching”
the wheel from heat expansion is one of the most
common causes of wheel breakage.
3. Starting at the top of the rail, cut straight down while
rocking the handle back and forth. Cut down until
near the ange.
4. When near the ange, stop the saw, release the de-
tent and move the lower link toward the operator until the detent can be re-engaged in one of the holes
away from the “top dead center hole”. This positions
the saw lower so that the ange of the rail may be
easily cut.
If the detent has been removed in favor of using the
capscrews as stops for the lower link, simply move
the lower link toward the capscrew closest to the operator.
If the wheel is worn such that it will not completely
cut through the rail, loosen the clamp lever on the
saw, and rotate the saw to allow cutting from the opposite side. Readjust the lower link as required and
nish the cut.
12 ► RS25 User Manual
CAUTION
OPERATION
DETACHING THE UPPER AND LOWER
LINKS
The upper and lower links of the rail clamp assembly
can be detached from the motor mount (50) by unscrewing the handle (20).
SAW STORAGE
By disengaging the double cam (52), the rail clamp as-
sembly can be rotated so that the entire saw has a atter
prole for storage.
Do not store the saw with the abrasive wheel attached.
CARE OF ABRASIVE CUT-OFF WHEELS
All abrasive cut-off wheels are breakable and,
therefore, care must be exercised during handling
and storage to prevent damage.
Wheels should be laid on a at, rigid, surface away from
excessive heat or moisture. Wheels should not be stored
where they will be exposed to high humidity, water, other
liquids or freezing temperature. If wheels are supplied
with blotters attached, suitable separators should be
used to preserve atness.
COLD WEATHER OPERATION
If the saw is to be used during cold weather, preheat
the hydraulic uid at low engine speed. When using the
normally recommended uids, uid temperature should
be at or above 50 °F/10 °C (400 ssu/82 centistokes) before use.
INVESTIGATION OF WHEEL
BREAKAGE
If a wheel breaks during use, a careful investigation
should be conducted by to determine the cause of the
breakage. The cause must then be corrected before using the saw again.
If unable to determine the cause of breakage, the wheel
manufacturer should be consulted.
RS25 User Manual ◄ 13
NOTICE
TOOL PROTECTION & CARE
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 cir-
cuit 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.
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.
14 ► RS25 User Manual
TROUBLESHOOTING
If symptoms of poor performance develop, the following chart can be used as a guide to correct the problem.
When diagnosing faults in operation of the grinder, always check that the hydraulic power source is supplying the
correct hydraulic ow and pressure to the grinder as listed in the table. Use a owmeter known to be accurate.
Check the ow with the hydraulic oil temperature at least 80 °F/27 °C.
SYMPTOM POSSIBLE CAUSE SOLUTION
Saw does not run. Hydraulic power source not
functioning correctly.
Coupler or hoses blocked. Remove obstruction.
Mechanical failure. Have tool serviced by authorized
Saw runs backwards. Pressure and return lines incorrectly
connected.
Saw cuts too slow. Insufcient uid ow or too high back-
pressure or relief valve set too low.
Wrong wheel for material being cut. Use correct wheel.
Fluid leakage. Seal failure. Do not use. Have serviced by an
Off-center cut and binding. Bearings worn on link arms. Have unit serviced by an authorized
Incorrect cutting technique. Review operating procedures.
Check power source for proper ow
and pressure (7–10 gpm/26–34 lpm,
2000 psi/140 bar.
dealer.
Correct hose connections. Motor
shaft rotates counter-clockwise as
viewed from the end of the motor
shaft.
Check hydraulic supply. If hydraulic
supply is correct, have unit serviced
by authorized dealer.
authorized dealer.
dealer.
RS25 User Manual ◄ 15
SPECIFICATIONS
Wheel Capacity
14 inch Model ....................................................14 in./35.5 cm Dia. × 25.4 mm Arbor (ANSI B7.5/ISO 525, 603)
16 inch Model .............................................................. 16 in./41 cm Dia. × 1 in. Arbor (ANSI B7.5/ISO 525, 603)
Pressure Range.............................................................................................................. 1800–2000 psi/124–140 bar
Maximum Back Pressure...................................................................................................................... 250 psi/17 bar
Flow Range ................................................................................................HTMA Class RR, 9–10.5 gpm/34–40 lpm
EHTMA (D) .......................................................................................................................................30 lpm – 138 bar
EHTMA (E) .......................................................................................................................................40 lpm – 138 bar
Porting ...................................................................................................................................................-8 SAE O-ring
Couplers ..................................................................................................................HTMA/EHTMA Flush Face Type
Hose Whips ........................................................................................................................................................... Yes
Weight (with hose whips & couplers) ................................................................................................... 14.1 lb/6.40 kg
Overall Length ...................................................................................................................................36 inches/92 cm
Overall Width ..................................................................................................................................... 11 inches/28 cm
Overall Height (w/wheel, guard rotated to any position) ....................................................................13 inches/33 cm
Weight (less wheel)
14 inch Model ..................................................................................................................................55 lbs/24.4 kg
16 inch Model .....................................................................................................................................56 lbs/25 kg
RPM
14 inch Model ................................................................................................................................................ 4500
16 inch Model ................................................................................................................................................ 4000
Maximum Fluid Temperature .................................................................................................................. 140 °F/60 °C
Rail Size .......................................................................................................................... 75–165 lb/yard/37–82 kg/M
Sound and Vibration Declaration
Test conducted on RS25103, operated at standard 10 gpm input
Measured A-weighted sound power level, Lwa (ref. 1pW) in decibels 108 dBA
Uncertainty, Kwa, in decibels 3 dBA
Measured A-weighted sound pressure level, Lpa (ref. 20 µPa) at operator’s position, in decibels 97 dBA
Uncertainty, Kpa, in decibels 3 dBA
Values determined according to noise test code given in ISO 15744, using the basic standard ISO
3744
NOTE: The sum of a measured noise emission value and its associated uncertainty represents an
upper boundary of the range of values which is likely to occur in measurements.
Declared vibration emission value in accordance with EN 12096
Measured vibration emission value: a 9.1 m/sec²
Uncertainty: K 2.4 m/sec²
Values determined according to ISO 8662-1, ISO 5349-1,2
ACCESSORIES
Railsaw Blade 14 inch Custom-Labeled ............................................................................................................ 73647
Railsaw Blade 16 inch Custom-Labeled ............................................................................................................ 73648
Railsaw Blade 16 inch Norton AT-36 .................................................................................................................22439
Railsaw Blade 16 inch Norton Norzone III Fastcut ............................................................................................ 29745
Railsaw Blade 14 inch Norton Norzone III Fastcut ............................................................................................ 30974
Seal Kit (Includes 66399 JIHOSTROJ Seal Kit) ................................................................................................ 31845
Motor Seal Kit Assy (Serial No. 3585 (included in 31845) .................................................................................66399
Universal Bellcrank Kit (Grooved Rail) ..............................................................................................................34733
Motor Upgrade Kit 14 inch Model (After Serial No. 2598) ................................................................................. 66191
Includes 65625 Disconnect Pivot Bolt, 65626 Pivot Tube, 65627 Indicator Rod, 66133 Motor Assy)
Motor Upgrade Kit 16 inch Model (After Serial No. 2598) ................................................................................. 66192
Includes 65625 Disconnect Pivot Bolt, 65626 Pivot Tube, 65627 Indicator Rod, 66134 Motor Assy)
16 ► RS25 User Manual
RS25 PARTS ILLUSTRATION
RS25 User Manual ◄ 17
RS25 PARTS LIST
PART
ITEM
NO. QTY DESCRIPTION
6 28181 1 BELL CRANK
15 30958 1 “D” WASHER
20 66136 1 HANDLE WELDMENT
26 — 1
27 30671 1 ASSIST HANDLE
28 31030 1 HANDLE GRIP
29 31181 5 BELLEVILLE WASHER
30 30667 1 SHOULDER BOLT
31 31138 1 VALVE SPOOL
32 01604 2 O-RING*
33 02931 1 VALVE CAP
34 00112 1 QUAD RING*
35 31853 1 FLOW CONTROL (16 IN MODEL ONLY)
31854 1 FLOW CONTROL (14 IN MODEL ONLY)
36 08104 1 SAE PLUG
38 02920 1 SPACER
39 22707 1 TRIGGER
40 22704 1 SAFETY CATCH
41 22701 1 TORSION SPRING
42 03009 1 ROLL PIN
43 00165 1 SCREW
44 02911 1 HOSE CLIP
45 31186 1 POPPET
46 28552 1 VALVE HANDLE ASSY (INCL ITEM 36)
47 17641 1 WHEEL SAFETY LABEL (16 IN MODEL)
05868 WHEEL SAFETY LABEL (14 IN MODEL)
48 17681 1 ROLL PIN
49 24869 1 HANDLE
50 35289 1 MOTOR MOUNT ASSY
51 02688 4 CAPSCREW
52 30632 1 DOUBLE CAM
53 30635 1 SPIROL PIN
54 29510 1 EYE BOLT
55 04856 1 RETAINING RING
56 30841 2 WASHER
58 28673 1 SPRING
59 30412 1 MOTOR MOUNT PIVOT
60 30530 1 DISCONNECT PIVOT
61 28711 1 TOLERANCE RING
62 30543 1 STUD
63 04353 1 LOCKNUT
75 56708 1 CLAMP SCREW ASSY
77 03012 1 JAM NUT
78 62291 1 OUTER COLLAR
REFER TO ITEM 131
*
PART
ITEM
NO. QTY DESCRIPTION
79 62290 1 INSIDE COLLAR
80 00720 1 SET SCREW
81 23246 1 DOWEL PIN
82 59050 1 THRUST COLLAR
83 30219 1 RETAINING RING
84 31034 A/R SHIM, .005
85 31032 A/R SHIM, .020
86 31033 A/R SHIM, .010
87 30957 1 WHEEL GUARD (16 IN MODEL)
28709 1 WHEEL GUARD (14 IN MODEL)
73168 WHEEL GUARD (16 IN MODEL) LOW
88 17652 1 SECTOR
89 28729 1 CARRIAGE BOLT
90 01594 2 WASHER
91 03906 1 LOCKNUT
92 17676 2 CAPSCREW
93 03006 2 MACHINE SCREW
94 66134 1 MOTOR ASSY (16 IN, CAN ONLY BE
66133 1 MOTOR ASSY (14 IN, CAN ONLY BE
103 00283 3 LOCK WASHER
104 16260 3 CAPSCREW
105 00772 1 KEY
110 00698 2 HELICOIL
111 03973 1 MALE COUPLER BODY (PARKER)
47437 1 MALE COUPLER BODY (AEROQUIP)
112 03972 1 FEMALE COUPLER BODY (PARKER)
47436 1 FEMALE COUPLER BODY
113 31137 1 PLUG
114 02916 1 SPRING
115 56725 2 HOSE ASSY (PARKER)
66727 1 HOSE ASSY (AEROQUIP)
116 00175 4 O-RING*
117 29604 2 OIL TUBE
118 30922 1 O-RING (16 IN MODEL)*
350771 1 O-RING (14 IN MODEL)*
119 30921 1 QUAD RING (16 IN MODEL)*
00214 1 QUAD RING (14 IN MODEL)*
122 28728 1 NAME TAG (16 IN MODEL
28409 1 COMPOSITE STICKER (14 IN MODEL)
123 25610 1 RAILROAD HELP DESK (16 IN MODEL)
28728 1 NAME TAG (14 IN MODEL)
124 03787 1 GPM STICKER (16 IN MODEL)
SPARK (SEE PHOTO PAGE 19)
PURCHASED AS AN ASSEMBLY)
PURCHASED AS AN ASSEMBLY)
(AEROQUIP)
18 ► RS25 User Manual
RS25 PARTS LIST
PART
ITEM
NO. QTY DESCRIPTION
28322 1 CE STICKER (14 IN MODEL)
127 11207 1 CIRCUIT “D” STICKER (14 IN MODEL)
128 28811 1 INFORMATION PLAQUE (14 IN
129 56706 1 DETENT ASSY
130 — 1 REFER TO ITEM 129
131 66138 1 RAIL CLAMP ASSY
132 11210 1 SOUND POWER STICKER
133 05152 1 LOGO-ADDRESS DECAL
66134 1 MOTOR ASSY
31845 1 SEAL KIT
MODEL)
* DENOTES PART IN SEAL KIT
Item 133 (P/N-05152)
Logo/Address Decal (UP Model Only)
Verify the correct model number before ordering.
WHEEL GUARD 16 INCH
“LOW SPARK” P/N-73168
RS25 User Manual ◄ 19
Stanley Hydraulic Tools
3810 SE Naef Road
Milwaukie, Oregon 97267-5698 USA
(503) 659-5660 / Fax (503) 652-1780
www.stanleyhydraulics.com
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