DS11

HYDRAULIC

DIAMOND SAW

WARNING

To avoid serious injury or death

Read the Manual

Wear Eye

Protection

Wear Ear

Protection

Wear Dust Mask

47351

Copyright © 2003, The Stanley Works

SVCE/MAINT USA

22799 11/2003 Ver 1

S

AFETY

, O

PERATION AND

M

AINTENANCE

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

Safety Symbols and Precautions ........................................................................ 4

Tool Stickers and Tags ........................................................................................ 7

Hydraulic Hose Requirements ........................................................................... 8

HTMA Requirements ........................................................................................... 9

Operation ........................................................................................................... 10

Equipment Protection and Care ........................................................................ 17

Troubleshooting ................................................................................................ 18

Specifications .................................................................................................... 20

Accessories ....................................................................................................... 20

Service ............................................................................................................... 21

Parts Illustration ................................................................................................. 27

Parts List ............................................................................................................ 28

Chain Applications ............................................................................................ 29

Warranty ............................................................................................................. 30

SERVICING THE STANLEY DIAMOND SAW: 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 certified dealer. Please read the following warning.

WARNING

SERIOUS INJURY OR DEATH COULD RESULT FROM THE IM-

PROPER 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 certified dealer, call Stanley Hydraulic Tools at the number listed on the back of this manual and ask for a Customer Service Representative.

3

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.

DANGER

This safety alert and signal word indicate an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

This safety alert and signal word indicate a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

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.

NOTICE

This signal word indicates a situation which, if not avoided, will result in damage to the equipment.

IMPORTANT

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

SAFETY PRECAUTIONS

To avoid serious injury or death

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 specific work area and local safety regulations. If so, place the added precautions in the space provided on page 4.

Read the Manual

Wear Eye

Protection

The DS11 Concrete 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.

Wear Ear

Protection

Wear Dust Mask

47351

• 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 fitting 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 fluid 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 firm 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 firm grip with thumbs and fingers encircling the chain saw handles.

A firm 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 specified by Stanley or the equivalent.

• Make sure the chain guard is in place before operating the chain saw.

5

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 fluid.

• 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 flat, clean work surfaces. Check the mounting screws/bolts often.

• Check all chain breaker and rivet spinner components regularly for wear and general condition.

6

TOOL STICKERS & TAGS

E

40 LPM @ 138 BAR

EHTMA CATEGORY

12535

D

30 LPM @ 138 B AR

EHTMA CATEGORY

11207

12535

Circuit “E” Decal - DS115000 Only

11207

Circuit “D” Decal - DS113000 Only

20588

Name Tag Decal

12412

Warning Decal

28409

28323

Stanley Hydraulic Tools

3810 SE Naef Road

Milwaukie, OR 97062

Model

DS11

L

WA

108

29530

DANGER

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.

ELECTROCUTION

HAZARD

HAZARD

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.

on or around electric lines.

For proper and safe operation read owners manual and mwke sure that you have been properly

12412 on or around electric lines.

20588

28409

Composit Decal

28323

CE Decal

29530

Sound Level 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.

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 ELECTRICAL LINES MAY RESULT IN DEATH OR SERI-

OUS INJURY.

BEFORE USING HOSE LABELED AND CERTIFIED AS NON-CON-

DUCTIVE 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 INSTRUC-

TIONS.

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 HYDRAU

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 HANDS.

CONTACT WITH A LEAK MAY RESULT IN SEVERE PERSONAL

INJURY.

I M P O R T A N T

READ OPERATION MANUAL AND

SAFETY INSTRUCTIONS FOR THIS

TOOL BEFORE USING IT.

USE ONLY PARTS AND REPAIR

PROCEDURES APPROVED BY

STANLEY AND DESCRIBED IN THE OPERATION

MANUAL.

TAG TO BE REMOVED ONLY BY

TOOL OPERATOR.

SEE OTHER SIDE

D A N G E R

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 PRES-

SURE 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 BY-

STANDERS 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 PER-

FORMED BY AUTHORIZED AND PROPERLY TRAINED PERSON-

NEL.

I M P O R T A N T

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

7

HYDRAULIC HOSE REQUIREMENTS

HOSE TYPES

Hydraulic hose types authorized for use with Stanley Hydraulic Tools are as follows:

–

Certified non-conductive

—

Wire-braided (conductive)

˜

Fabric-braided (not certified or labeled non-conductive)

Hose

–

listed above is the only hose authorized for use near electrical conductors.

Hoses

—

and

˜

listed above are conductive and must never be used near electrical conductors.

HOSE SAFETY TAGS

To help ensure your safety, the following DANGER tags are attached to all hose purchased from Stanley Hydraulic

Tools. DO NOT REMOVE THESE TAGS.

If the information on a tag is illegible because of wear or damage, replace the tag immediately. A new tag may be obtained from your Stanley Distributor.

THE TAG SHOWN BELOW IS ATTACHED TO "CERTIFIED NON-CONDUCTIVE" HOSE

3

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.

SEE OTHER SIDE

SIDE 1

D A N G E R

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.

SEE OTHER SIDE

SIDE 2

(shown smaller than actual size)

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.

SEE OTHER SIDE

SIDE 1

(shown smaller than actual size)

HOSE PRESSURE RATING

D A N G E R

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.

SEE OTHER SIDE

SIDE 2

The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the hydraulic system.

8

HTMA REQUIREMENTS

Tool Category

Hydraulic System

Requirements

Flow rate

Tool Operating Pressure

(at the power supply outlet)

20Lpm at 138bar

BHTMA CATEGORY

Type I

4-6 gpm

(15-23 lpm)

2000 psi

(138 bar)

System relief valve setting

(at the power supply outlet)

2100-2250 psi

(145-155 bar)

Maximum back pressure

(at tool end of the return hose)

200 psi

(14 bar)

Measured at a max. fluid viscosity of:

(at min. operating temperature)

400 ssu*

(82 centistokes)

Temperature

Sufficient heat rejection capacity to limit max. fluid temperature to:

(at max. expected ambient temperature)

140 ° F

(60° C)

Min. cooling capacity at a temperature difference of between ambient and fluid temps

NOTE:

Do not operate the tool at oil temperatures above 140 discomfort at the tool.

° F (60° C). Operation at higher temperatures can cause operator

3 hp

40 ° F

(2.24 kW)

(22° C)

30Lpm at 138bar

BHTMA CATEGORY

Type II

7-9gpm

(26-34 lpm)

2000 psi

(138 bar)

40Lpm at 138bar

EHTMA CATEGORY

Type III

10.5-11.6 gpm 11-13 gpm

(36-44 lpm)

2000 psi

(138 bar)

(42-49 lpm)

2000 psi

(138 bar)

2100-2250 psi 2100-2250 psi 2100-2250 psi

(145-155 bar) (145-155 bar) (145-155 bar)

200 psi

(14 bar)

400 ssu*

(82 centistokes)

200 psi

(14 bar)

400 ssu*

(82 centistokes)

200 psi

(14 bar)

400 ssu*

(82 centistokes)

140 ° F

(60° C)

5 hp

40 ° F

(3.73 kW)

(22° C)

140 ° F

(60° C)

6 hp

40 ° F

(4.47 kW)

(22° C)

140 ° F

(60° C)

7 hp

40 ° F

(5.22 kW)

(22° C)

Filter

Min. full-flow filtration

Sized for flow of at least:

(For cold temp. startup and max. dirt-holding capacity)

25 microns

18 gpm

(68 lpm)

25 microns

30 gpm

(114 lpm)

25 microns

35 gpm

(132 lpm)

25 microns

40 gpm

(151 lpm)

Hydraulic fluid

Petroleum based

(premium grade, anti-wear, non-conductive)

Viscosity

(at min. and max. operating temps)

100-400 ssu* 100-400 ssu* 100-400 ssu* 100-400 ssu*

NOTE:

When choosing hydraulic fluid, the expected oil temperature extremes that will be experienced in service determine the most suitable temperature viscosity characteristics. Hydraulic fluids with a viscosity index over 140 will meet the requirements over a wide range of operating temperatures.

(20-82 centistokes) (20-82 centistokes) (20-82 centistokes) (20-82 centistokes)

NOTE: These are general hydraulic system requirements. See tool Specification page for tool specific requirements.

9

OPERATION

PREOPERTION PROCEDURES

CHECK THE POWER SOURCE

1. Using a calibrated flow meter and pressure gauge, make sure the hydraulic power source develops a flow of 7-9 gpm/

26-34 lpm at 2000 psi/140 bar.

4. If the water pressure is below 35 psi/2.4 bar, make the required adjustments to the water supply. If the required pressure cannot be achieved, you must use the Stanley

Electric Water Pump Kit (Part Number 26020 or the Power

Unit Water Pump Kit Part Number 29361).

2. Make certain that the power source is equipped with a relief valve set to open at 2100-2250 psi/145-155 bar.

3. Make certain that the power source return pressure does not exceed 250 psi/17 bar.

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 fittings or quick disconnects. It is a good practice to connect return hoes first and disconnect them last to minimize or avoid trapped pressure within the chain saw.

CHECK CHAIN AND BAR ADJUSTMENT

1. Check the chain tension often during operation, expecially during the first 1/2 hour when using a new chan. Adjust the chain accordingly when it becomes loose. Follow the prcedures contained in the Mainenance and Adjustements section of this manual.

2. Make sure the chain does not exceed a clearance of 1/4 in./6 mm from the bar (see figure 2). Exceeding the maximum clearance increases the chance of the chain being dislodged from the bar groove.

Max

1/4”

3. Observe the arrow on the couplers to ensure that the flow is in the proper direction. the female coupler on the chain saw is the inlet (pressure) coupler.

4. Move the hydraulic circuit control valve to the “ON” position to operate the chain saw.

Figure 2. Maximum Chain Clearance

3. Make sure the bar attaching nuts are fully tightened and the chain guard is in place.

NOTE:

If uncoupled hoses are left in the sun, pressure increase inside the hoses might make them difficult to connect. Whenever possible, connect the free ends of the hoses together.

CHECK CHAIN SEGMENT WEAR

1. Using adjustable calipers, measure several chain segments as illustrated in Figure 3.

CONNECTING TO A WATER SUPPLY

1. Using a standard garden hose, connect the DS11 to a city or auxiliary water supply.

2. Holding the saw away from your body, turn the saw on and read the water pressure at the water gauge. Water pressure must be at least 35 psi/2.4 bar to avoid damage to the saw bar and chain.

3. If you plan on operating the chain saw in freezing weather, make sure you purge all the water from the system after each use.

Figure 3. Chain Segment Wear

10

OPERATION

2. If the average measurement is less than 1/16-inch/1.6

mm, then the chainmust be replaced. Refer to your Service

Manual for chain replacement procedures.

CHECK THE WATER SUPPLY

IMPORTANT

Chain and bar damage will occur if the chain saw operates without the proper water supply.

1. Always have water running before starting the chain saw.

2. Water flow must be 4 gpm/15 lpm at 50 psi/3.5 bar minimum.

CUTTING TIPS

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 specific cutting problems or techniques, consult your local Lynx Representative.

He/she can often provide information that will make your work safter and more productive.

OPERATING PROCEDURES

NEW SAW CHAIN BREAK-IN

1. Always make sure the bar and sprocket are in good condition.

2. Turn on the water supply.

3. Operate the chain saw for two minutes (away from the intended cut) and then check the chain tension.

4. Adjust accordingly using the procedures contained in the

Maintanence and Adjustments section of this manual.

NOTE:

The chain is designed to only operate in one direction.

Make sure the chain is installed so the bumper guard proceeds each diamond segment. (See figure 4).

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.

2. Make your cuts in the order shown in Figure 5, starting with cut 1 (base horizontal cut) and proceeding with the remaining three cuts.

Figure 5. Making 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.

TYPES OF CUTS

The LCC31 can be operated using the types of cuts shown in

Figure 6. When making cuts:

Figure 4. Chain Direction

11

OPERATION

DOWN CUT

PLUNGE CUT

UP CUT

Figure 6. 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. Avoid aggressive/heavy plunge forces. Aggressive plunge force creates spalling of the concrete when the saw bar and chain exits and causes premature bar and chain wear.

COLD WEATHER OPERATION

If the saw is to be used during cold weather, preheat the hydraulic fluid at low power source speed. When using the normally recommended fluids, fluid 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 fluid that is too viscous or thick.

12

MAINTENANCE & ADJUSTMENTS

evenly. Refer to the saw bar disassembly procedures in the

Service Manual for further details.

GENERAL MAINTENANCE TIPS

CHAIN TENSION ADJUSTMENT

Several simple maintenance tasks which, if performed, can keep a chain saw operating at a high level of efficiency.

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.

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.

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.

2. Loosen the two saw bar attachment nuts (Item 62, Parts

Illustration).

3. Using the saw bar adjustment screw (Item 65, Parts

Illustration), tighten the chain until you are still able to rotate it one full revolution by hand (Figure 9).

Figure 7. Rail Wear

If the saw bar rails are worn, use a flat file and dress each one until it is flat 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

Figure 9. Pulling the Chain

4. Pull the chain around the saw bar to make sure it properly fits the sprocket and saw bar. The chain should be easily pulled.

5. Fully tighten the two saw bar attachment nuts.

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).

Max

1/4”

Figure 10. Exposed Drive Link Tang

13

MAINTENANCE & ADJUSTMENTS

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 flush with the side or front of a flat, clean work surface (Figure 11).

Figure 11. Chain Breaker Mounting

Figure 13. Inserting the Chain

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.

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 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 flush with the far side of the slot (Figure 13).

Figure 14. Removing a Rivet

14

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.

1. Mount the rivet spinner flush with the side or front of a flat, clean work surface (Figure 17).

15

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

Take-up

Handle

Figure 19. Securing the Chain

MAINTENANCE & ADJUSTMENTS

4. turn the rivet spinner crank a few times to center the rivet hub in the spinner anvil (Figure 20).

Rivet Spinner

Crank

Take-up

Handle

NOTE: the rivet spinner is equipped with oiling chambers and should be maintained periodically with a light-weight oil (Figure 23).

Figure 20. Centering the Rivet Hub

5. Apply a few drops of oil to the rivet hub (Figure 21).

Figure 23. Spinner Oiling Chambers

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.

Figure 22. Forming a Rivet Head

16

TOOL EQUIPMENT & CARE

NOTICE

In addition to the Safety

Precautions on page 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 couples 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 flow. 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 flow (see Specifications) page in this manual for correct flow 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.

17

TROUBLESHOOTING

CHAIN SAW TROUBLESHOOTING

Excessive vibration and cuts rough.

Chain saw will not cut straight.

Loose chain tension.

Excessive feed force.

Operator feed force not applied directly over centerline of saw.

Accumulated saw bar wear and uneven chain segment profile wear.

Loss of power.

Chain saw does not run.

Chain saw runs backwards.

Trigger is hard to press.

Drive sprocket slipping on

Trantorque® adapter.

Power source not functioning.

Coupler or hoses are blocked.

Mechanical failure.

Pressure and return hoses reversed.

Pressure and return hoses reversed.

Back pressure too high.

Motor shaft seal failure.

Retension the chainl.

Reduce feed force.

move left hand closer to centerline of saw bar.

Turn the saw bar over and dress rails square. Replace the saw bar and chain.

Adjust and tighten Trantorque® adapter, (35 ft lbs/47 Nm).

Check power source for proper flow and pressure (7-9 gpm/26-34 lpm @

2000 psi/140 bar).

Remove obstruction.

Disassemble the chain saw and inspect for damage.

Connect for proper flow direction.

Motor shaft must rotate clockwise.

Connect to proper flow direction.

Motor shaft must rotate clockwise.

Should not exceed 250 psi/17 bar @

9 gpm/34 lpm measured at the end of the chain saw’s operating hoses.

Replace as required.

Fluid leakage around drive sprocket.

Fluid leakage between the rear gear housing and the chain saw adaptor.

Fluid leakage between the valve handle and the extension housing.

Fluid leakage between the extension housing assembly and the chain saw adaptor.

Chain saw cuts slow.

Motor face seal failure.

Oil tube seal failure.

Oil tube seal failure.

Insufficient hydraulic fluid flow or low relief valve setting.

Replace as required.

Replace as required.

Replace as required.

Adjust proper hydraulic fluid flow to proper gpm. For optimum performance, adjust relief valve to 2100-

2250 psi/145-155 bar.

18

TROUBLESHOOTING

CHAIN SAW TROUBLESHOOTING CONTINUED

Chain saw cuts slow.

Excessive vibration and cuts rough.

Back pressure too high.

Should not exceed 250 psi/17 bar @

9 gpm/34 lpm measured at the end of the chain saw’s operating hoses.

Loss of diamond segment side Replace the chain.

clearance.

Hydraulic fluid mixed in water supply.

Check motor for leaks.

Chain segment dulled because of continuous use in hard material or rebar.

Wrong chain for application.

Wire edged bar rails.

Redress segment by cutting in abrasive material (i.e., concrete, buildblock, etc.). NOTE: This indicates that the wrong chain is being used.

Scale down to a lower numbered chain.

Dress rails square.

Segment(s) broken or missing from chain.

Remove and repair broken segment or replace chain.

19

SPECIFICATIONS

Cutting Depths ............................................................................................................................. 15 or 18 inch / 38 or 46 cm

Bar Lengths ................................................................................................................................. 15 or 18 inch / 38 or 46 cm

Input Flow Range

DS113000 ............................................................................................................................ 7-9 gpm / 26-34 lpm

DS115000 .................................................................................................................................... 12 gpm/45 lpm

Input Pressure ............................................................................................................................................ 2000 psi / 140 bar

Chain Type ....................................................................................................................................................... 3/8 inch Pitch

Weight (with bar) ............................................................................................................................................ 26 lbs / 11.8 kg

Length ...................................................................................................................................... 35 or 38 inches / 89 or 97 cm

Width .......................................................................................................................................................... 9 inches / 23 cm

Lubrication / Cooling ............................................................................................................... Internal Water Channels in Bar

Porting ........................................................................................................................................................... -8 SAE O-Ring

Connection .................................................................................................... 3/8 inch Flush-Face Quick Disconnect Coupler

Hose Whips ..................................................................................................................................................................... Yes

ACCESSORIES

Chain Repair Spinner ................................................................................................................................................... 20857

Diamond Chain Repair Breaker .................................................................................................................................... 20858

Diamond Chain Repair Kit (inludes p/n 20857 & 20858) ................................................................................................ 20856

Diamond Chain Service Kit .............................................................................................................. (sub p/n 20857 or 20858)

Wall Walker (Standard Equipment on Newer Models) ................................................................................................... 23176

Drive Sprocket .............................................................................................................................................................. 20470

Replacement Nose Sprocket ........................................................................................................................................ 22800

Carrying Case .............................................................................................................................................................. 28232

Sprocket Wrench ......................................................................................................................................................... 23517

Replacement Punch ..................................................................................................................................................... 22801

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

3/8 inch Flush-Face Coupler Set .................................................................................................................................. 03971

1/2 inch Flush-Face Coupler Set .................................................................................................................................. 03974

25 feet, 1/2 inch Dual Hose with Flush-Face Couplers .................................................................................................. 31972

50 feet, 1/2 inch Dual Hose with Flush-Face Couplers .................................................................................................. 31848

15 inch Bar, Sprocket Nose .......................................................................................................................................... 30305

18 inch Bar, Sprocket Nose .......................................................................................................................................... 30306

Ultra-32, Sealed Chain for 15 inch Bar .......................................................................................................................... 56801

Pinnacle-32, Sealed Chain for 15 inch Bar .................................................................................................................... 56803

Ultra-37, Sealed Chain for 18 inch Bar .......................................................................................................................... 56802

Pinnacle-32, Sealed Chain for 18 inch Bar .................................................................................................................... 58632

Speed Hook Kit ............................................................................................................................................................ 39496

20

SERVICE

INTRODUCTION

Good maintenance practice keeps the chain saw on the job and increases its service life.

the most important maintenance practice is to keep the hydraulic fluid clean at all times. Contaminated hydraulic fluid causes rapid wear and/or failure of internal parts.

Follow the procedure contained in the Hydraulic System

Requirements section of this manual to ensure peak performance from the chain saw.

Never disassemble the chain saw unless proper troubleshooting procedures have isolated the problem to an internal part. Then, disassemble the chain saw only to the extent necessary to replace the defective part.

NOTE:

Keep contaminants such as dirt and grit away from internal parts at all times.

Always determine and correct the cause of the problem prior to assembly. Further wear and chain saw failure can result if the original cause is not corrected.

PRIOR TO DISASSEMBLY

1. Clean the exterior of the chain saw.

2. Obtain Seal Kit (part number 22798) to replace all seals exposed during disassembly. Note the orientation of the seals before removing them. Install new seals the same way they were removed.

PRIOR TO ASSEMBLY

1. Clean all parts with a degreasing solvent.

2. Make sure all seals that were exposed have been replaced with new parts.

3. Apply clean grease or o-ring lubricant to all parts during assembly.

MOTOR REMOVAL,

DISASSEMBLY, INSPECTION,

CLEANING, REPLACEMENT &

REMOVAL

ASSEMBLY

1. Remove the two 3/8-inch nuts and plain washers securing the chain guard to the chain saw adaptor. Remove the guard.

2. Remove the chain and saw bar.

3. Clamp the drive sprocket (a chain type locking wrench works best) and then loosen the Trantorque® adaptor securing the drive sprocket to the motor shaft.

4. Remove the drive sprocket and the Trantorque® adaptor.

5. Remove the four capscrews securing the chain saw adaptor, valve handle and extension housing together.

Seperate these assemblies.

6. Insert a hooked instrument through the oil tubes in the chain saw adaptor and valve handle (if necessary) and then pull them out. Take care to avoid damaging the oil tube bores in the chain saw adaptor and valve handle.

7. Remove the two oval head machine screws to allow the motor to be withdrawn from the chain saw adaptor.

MOTOR DISASSEMBLY

1. Place the motor in a vise (with soft jaws or v-blocks) around the bearing end. Make sure the output shaft faces down.

2. Remove the eight 1/4-20 x 1-3/4-inch / 44 mm capscrews securing the rear gear housing to the chain saw adaptor.

3. Using a flat-bladed screwdriver or similar tool, gently and evenly pry all around the groove between the front bearing housing and the rear gear housing. DO NOT tilt the rear gear housing or pry on the flat surface inside the surrounding groove. Damage to the sealing surfaces can result.

NOTE:

The gears and idler shaft might remain in the rear gear housing. Do not drop or damage them.

21

4. Carefully lift the rear gear housing from the front bearing housing.

SERVICE

5. Remove the two gears, idler shaft and needle roller.

Gear Chamber

6. Remove the large face seal o-ring being careful not to damage the o-ring grooves or surrounding surfaces.

The chamber bores and bottoms around the shaft bushings should be polished and smooth. The flat surface surrounding the gear chambers and bolt holes should be flat and free of nicks which could cause misalignment or leaks.

7. To remove the motor shaft from the front bearing housing, remove the large retaining ring securing the ball bearing/ keeper. Place the housing on a flat surface with clearance for bearing removal. Push on the small end of the motor shaft until the shaft and bearing slides free. Be careful not to bend the motor shaft.

8. The ball bearing should be removed from the motor shaft only if it must be replaced because damage can occur during removal. To remove the bearing from the motor shaft, remove the small retaining ring securing the seal race spacer the large retaining ring covering the bearing and then press on the end of the motor shaft while supporting the outer race of the bearing. Discard the bearing.

9. Remove the retaining ring at the bottom of the ball bearing bore to service the motor shaft seal.

Gears

The gears should have straight tips without nicks, square tooth ends and smooth even polish on the teeth and end surfaces. Check for cracks at the groove in the drive gear bore.

Front Bearing Housing

The surface near the gears hould show two overlapping polished circles without a step and should not be rough or grooved. The bore for the seal and bearing keeper should be smooth and free from nicks and scratches or leakage might occur.

Motor Shaft

10. To remove the seal liner and associated parts, insert the small end of the motor shaft through the seal liner. Place a rag across the gear face of the front bearing retainer and blow air though the small diameter motor shaft bearing. Use a shop air nozzle to force the seal liner onto the motor shaft for removal.

The shaft diameter at the bearing and seal locations must be smooth. Grooves, roughness or a reduced diameter indicate fluid contamination. Grit particles may have been imbedded in the bushings grinding into the hardened shaft. If abnormal shaft wear as a bove occurs (in excess of normal polishing), both the seal and associated bearings/bushings must be replaced.

11. Remove the bushings using Collet (part number 11930) and Actuator Pin (part number 05067) along with Slide

Hammer (part number 11931).

CLEANING & INSPECTION

Check the hydraulic system for excess contamination in the fluid and for filter condition. Operating conditions might require changing from a 25 micron filter to an oversized 10 micron filter.

Inspect and clean all parts as follows:

1. Clean all parts with a degreasing solvent.

2. Blow dry all parts with compressed air and wipe clean.

Use only lint-free cloths.

Bushings

1. Assemble the seal gland assembly by installing the outside diameter o-ring and quad ring as shown on the parts illustration. Place idler shaft through the seal gland, then loosely position the assembly in the seal bore of the front bearing housing (quad ring side down). Then carefully push the seal gland into place. Install the retaining ring. Remove the idler shaft.

The inside of the bushings should be gray with some bronze showing through. If a significant amount of yellow-bronze shows, bushing replacement is required. Inspect the motor shaft corresponding wear and replace as required.

2. To install the ball bearing on the motor shaft, support the ball bearing inner race and press the motor shaft through the bearing inner race. Place a new o-ring on the motor shaft, adjacent to the bearing inner race, slide the seal race over

22

SERVICE

the shaft, chamfered end first and secure with the retaining ring. It may be necessary to slide a deep socket or tube over the motor shaft to depress the o-ring and retaining ring so that the retaining ring end engages its groove.

10. When the new parts are installed, it might be necessary to “break-in” the motor. After the chain saw has been assembled without the guard, bar and chain, the motor can be broken-in as follows:

NOTE:

Some motor shafts may have two retaining ring grooves. The inner most groove is to be used.

WARNING

3. Install the bushings using Bearing Pusher (part number

11918).

The following procedures can be hazardous. Failure to heed the instructions could result in serious injury.

4. Place the front bearing housing assembly on a smooth clean arbor press surface (protected from damage) with the large bearing bore facing up. Position the part so a clearance hole exists for inserting the motor shaft.

a. Make sure the hydraulic power source is running at the lowest gpm/lpm rate it can while still producing full pressure.

5. Apply grease to the motor shaft and keyway, then insert it through the shaft seal. Using Bearing Pusher (part number

00850), or a sleeve/socket with a diameter slightly smaller than the outside diameter of the ball bearing, press the bearing assembly into place. Press only on the outer race.

Place the o-ring in the housing bore adjacent to the bearing outer race. Fill the bearing cavity with lubricating oil. Install the keeper using the bearing pusher as above and secure the assembly with the retaining ring.

b. Grasp the chain saw firmly in a bench vise and place the correct size wrench on the Trantorque® adaptor.

c. Connect the hydraulic power source to the chain saw and then turn the power source valve to the “ON” position.

d. With a firm grip on the chain saw and wrench, SLOWLY squeeze the trigger to activate the chain saw.

6. Install the needle roller in the keyway of the motor shaft.

Use a small amount of grease to keep the needle roller in place. Slide the drive gear over the needle roller and motor shaft. Install the idler shaft and gear.

e. Turn the motor shaft both against and with the direction of rotation.

f. Release the trigger and remove the wrench.

7. Apply grease to the face seal o-ring groove and then install the o-ring.

g. Activate the chain saw to determine that the motor starts and runs freely.

NOTE:

Make sure the dowel pins and shafts are aligned during installation.

h. If the motor is not starting or running freely, carefully repeat the break-in procedures until the motor performs satisfactorily.

REPLACEMENT

IMPORTANT

Do not force parts together.

1. Push the motor into the chain saw adaptor assembly.

2. Align the motor mounting holes and then secure it using two 5/16-18 x 3/4 inch / 18 mm screws and 242 Loctite.

8. Note the screw hole pattern on the front and rear housings. They will only assembly one way. With all parts aligned, carefully slide the rear gear housing over the gears until it contacts the front bearing housing assembly.

3. Install new o-rings on the oil tubes and then install them in the chain saw adaptor and valve handle. Align with the extension housing and press together. Secure all parts using the four capscrews.

9. Turn the motor shaft manually to check for free rotation.

Install the eight 1/4-20 x 1-3/4 inch / 44 mm capscrews. then recheck rotation.

NOTE:

DO NOT lubricate or clean the drive sprocket or

Trantorque® adaptor.

23

SERVICE

4. Place the drive sprocket on the Trantorque® adaptor and install the assembly on the shaft so the shaft extends completely through the bore.

5. Properly position the drive sprocket and then hand tighten the Trantorque® adaptor until the drive sprocket begins to snug up.

6. Make any fine adjustments and then fully tighten the

Trantorque® adaptor to a torque value of 200 inch lbs / 22.6

Nm. Use chain-type vise grip pliers to keep the sprocket from rotating as you tighten the Trantorque® nut.

7. Replace the chain guard and then secure it to the chain saw adaptor using two 3/8 inch nuts and plain washers.

8. Perform the Chain Tension Adjustment procedure.

VALVE SPOOL DISASSEMBLY &

ASSEMBLY

DISASSEMBLY

1. Drive out the 1/4-inch roll pin securing the trigger to the valve handle assembly. Depress the safety catach and remove the triggers through the top of the valve handle.

NOTE:

It is not always necessary to drive the roll pins completely out of the valve handle to allow removal of parts.

The safety catch can be removed at this time by driving out the 3/16-inch roll pin with a 3/16-inch / 5 mm diameter punch. It is not necessary to remove the safety catch to service the On/Off valve.

2. Remove the valve cap from the top of the handle. Remove the quad ring from the valve cap bore.

3. Pull the On/Off valve out through the top of the valve handle.

4. Remove the port plug from the bottom of the valve handle.

The coil spring will drop out in your hand.

5. Carefully clean and inspect the valve spool and its bore in the valve handle. The valve spool and bore should have a polished appearance without scoring or deep scratches.

Excessive wear indicates contaminated fluid in the hydraulic system.

ASSEMBLY

1. Lubricate and install the quad ring in the valve cap bore.

2. Push the valve cap onto the valve stem, then thread the assembly into the top of the valve handle assembly.

3. Install the coil spring and the port plug into the bottom of the valve handle.

4. Line up the trigger and spacer with the pivot by inserting a

1/4-inch / 6 mm diameter punch into the valve handle (to maintain alignment while driving the roll pin into the handle.).

Install the 1/4-inch roll pin in the trigger pivot hole.

5. Replace the safety catch (if previously removed). Place the torsion spring on the boss of the safety catch with the spring tab on the top of and facing the back of the catch as shown in the parts list illustration.

6. Place the safety catch in the valve handle and align the holes using a 3/16-inch / 5 mm diameter punch.

7. Install the 3/16 x 1-3/8-inch roll pin.

8. Push down on the spring tab until it snaps in place under the safety catch.

9. Check the safety catch and trigger mechanism for proper operation. The trigger must not activate the chain saw without the operator first depressing the safety catch.

EXTENSION HOUSING

DISASSEMBLY & ASSEMBLY

DISASSEMBLY

1. Remove the four hex socket head capscrews the chain saw adaptor and valve handle to the extension housing.

2. Carefully remove the o-ring plug to release the spring and water valve.

3. Remove the spring and water valve.

4. Remove the two seals from inside the extension housing valve bore.

5. Carefully clean and inspect the water valve and its bore in the extension housing. The water valve and bore should have a polished appearance without scoring or deep scratches.

24

SERVICE

Excessive wear indicates contaminated water.

ASSEMBLY

1. Lubricate and insert two new seals into the extension housing.

NOTE:

Make sure the innermost seal (quad ring) is not twisted within its groove.

2. Insert the water valve into the extension housing.

3. Insert the spring into the valve counterbore.

4. Complete the assembly by installing the o-ring plug.

5. Secure the extension housing to the valve handle and chain saw adaptor using the four hex socket head capscrews.

NOTE:

Before proceeding to the Nose Sprocket Disassembly, order a new Stanley Nose Sprocket, part number

22800.

Figure 25. Removing the Old Nose Sprocket

3. Remove the new nose sprocket clips and fold back the top portion of the insertion card being careful not to remove or disturb the components (Figure 26).

NOSE SPROCKET

DISASSEMBLY & ASSEMBLY

DISASSEMBLY

1. Using Stanley’s bench mounted chain breaker, line up the

1/4-inch hole in the side of the chainbreaker anvil with the chain breaker punch. Punch out the six nose sprocket rivets

(Figure 24).

Figure 26. Preparing the New Nose Sprocket

4. With a flat blade screwdriver in the bar nose rails, slide the nose sprocket assembly into position aligning the six holes in the bar nose with the six holes in the nose sprocket assembly without removing the components from the card

(Figure 27).

Figure 24. Punching out Nose Sprocket Rivets

2. Insert a straight blade screwdriver 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 (Figure 25).

Figure 27. Installing the New Nose Sprocket

5. Insert six nose rivets into theholes and then hold them with your thumb. Remove the screwdriver and slide out the insertion card.

25

SERVICE

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 flat steel surface, carefully peen the rivet heads down with the flat 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 fill the countersinks in the bar body and be snug and secure while still allowing the sprocket to freely turn (Figure 28).

Figure 28. Replacing the Rivets

7. using a flat file, shave the rivet heads to a uniform height that is as close to the bar body as possible (Figure 29).

Figure 29. Filing the Rivets

26

N

LI

OI

83

30

29

28

DS11 PARTS ILLUSTRATION

1

2

24

3

85

26

37

32

39

33

34

35

36

3

79

27

44

45

47

44

49

46

50

48

72

78

77

44

9

7

40

25

43

38

31

O

M

D

EL

/S

N

IN

FO

42

35

41

52

53

54

55

56

17

15

13

12

10

11

47

14

23

22

21

19

20

18

74

16

66

67

76

75

51

71

69

58

57

59

63

86

84

65

73

64

60

82

8

5

4

6

68

72

67

66

70

81

80

62

61

27

DS11 PARTS LIST

11

12

13

14

15

8

9

10

6

7

4

5

1

2

3

27

28

29

30

23

24

25

26

31

32

16

17

18

19

20

21

22

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

ITEM P/N QTY

02920

22704

01605

01219

340045

00112

02931

01604

02925

28552

20459

00787

35963

07226

06830

09437

03010

02916

20497

23755

00175

00174

20453

00961

01211

03280

20472

20588

03278

22701

31804

22707

06881

20466

23752

12119

02905

03104

03110

00633

00178

21417

350771

00171

00669

19884

00170

03227

25688

23756

00208

06835

06316

06838

06840

06839

00713

2

1

1

2

1

1

1

1

1

2

1

1

2

1

1

1

1

2

8

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

1

1

1

4

1

1

8

DESCRIPTION

Motor Assy - Land Model DS113000

Motor Assy - U/W Model DS115000

Capscrew, 1/4-20 x 1-3/4

Rear Gear Housing

Bushing

Drive Gear

Idler Shaft

Idler Gear

Dowel Pin

O-Ring*

Front Bearing Housing

O-Ring* (DS113000)

O-Ring* (DS115000)

Quad Ring*

Seal Gland

Retaining Ring

Needle Roller (DS113000)

Needle Roller (DS115000)

Motor Shaft (DS113000)

Motor Shaft (DS115000)

Bearing

O-Ring*

Keeper Seal & Bearing

Teflon Seal*

Retaining Ring

O-Ring, 2-016 R16*

Spacer, Seal Race

Retaining Ring

Name Tag

Roll Pin

Torsion Spring

Roll Pin, 1/4 x 2 Stainless

Trigger

On/Off Valve Spacer

Safety Catch

O-Ring

Pipe Plug (Before 2003)

SAE Plug (2003 and Later)

Quad Ring*

Valve Cap

O-Ring, 3-910 R17*

Valve Spool

Valve Handle Assy (incl. 32 & 41)

Hose Clip

Capscrew, 1/4-20 x 1-1/4 (DS113000)

Capscrew, 1/4-20 x 1-1/4 (DS115000)

Hose Assy, 18 inch (DS113000)

Hose Assy, 18 inch (DS115000)

Plug (DS113000)

Plug (DS115000)

Comp. Coil Spring

Water Hose Assy (DS113000)

Water Hose Assy (DS15000)

O-Ring, 2-014 R17*

Oil Tube

Extension Housing

Pipe Plug

28

ITEM

60

61

62

63

56

57

58

59

52

53

54

55

48

49

50

51

64

65

66

67

68

69

70

83

84

85

86

79

80

81

82

75

76

77

78

71

72

73

74

QTY

2

3

1

1

1

1

4

1

4

1

1

3

1

3

3

2

1

2

1

1

2

1

1

1

1

1

1

1

1

2

1

1

3

P/N

07473

03006

23176

01758

22716

21550

12175

22715

12412

20465

22714

02649

02764

02643

20461

02936

23754

350237

22752

20470

20471

22711

02766

03276

22702

00018

22717

02912

22713

25260

01211

20463

20458

20721

24069

22945

25635

23196

23517

1

1

1

1

2

1

DESCRIPTION

O-Ring, 2-013 R17*

Pipe Plug, 1/16-27

Oil Tube

Chain Saw Adaptor

Quad Ring*

O-Ring, 2-016 R16*

Water Valve

Spring

Hollow Hex Plug

Hex Nut, 5/16-18 ESNA

Drive Sprocket

Trantorque® Adaptor

Chain Guard

Plain Washer

Nut

Bar Adjustment Nut

Stud

Screw, 5/16-18 x 2-3/4

Handle Bar Retainer

Screw, 5/16 x 3/4

Neoprene Washer

Handle Strut Assy

Handle Bar (DS113000)

Handle Bar (DS115000)

Hand Guard

Capscrew, 5/16-18 x 3/4

Wall Waker™

Screw

Street Elbow

Gauge (DS113000 Only)

Washer, 5/16

Capscrew, 5/16-18 x .625

Warning Sticker

Bar (See Accessories)

Chain (See Chain Applications)

Cord Stock

Coupler Set

Chain Cover

Flow Regulator

Capscrew, 5/16-18 UNC x 3

Sprocket Wrench (Not Shown)

SEAL KIT PART NUMBER 22798

00178

350771

00669

02905

03110

01211

00112

01604

03847

00175

00018

25260

01605

O-Ring

O-Ring

Quad Ring

O-Ring

Teflon Seal

O-Ring

Quad Ring

O-Ring

Hose Washer

O-Ring

O-Ring

Quad Ring

O-Ring

2

2

1

2

1

1

1

1

1

1

1

8

3

* Part of Seal Kit

DIAMOND CHAIN APPLICATIONS

Model Bar Length

Pinnacle-32

Pinnacle-37

15 inch

18 inch

P/N

56803

58632

Ultra-32

Ultra-37

15 inch

18 inch

56801

56802

Correct Applications

Very hard aggregate concretes (flint, 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 conditions.

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.

29

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 first retail purchaser, or for a period of 2 years from the shipping date from Stanley, whichever period expires first, 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 first usage, or for a period of 2 years from the shipping date from Stanley, whichever period expires first.

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 modifications to any tool or part. All obligations under this warranty shall be terminated if the new tool or part is altered or modified in any way.

NORMAL WEAR: any failure or performance deficiency 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 deficiency 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 deficiency 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 deficiency attributable to excess hydraulic pressure, excess hydraulic back-pressure, or excess hydraulic flow.

REPAIRS OR ALTERATIONS: Any failure or performance deficiency attributable to repairs by anyone which in Stanley’s sole judgement caused or contributed to the failure or deficiency.

MIS-APPLICATION: Any failure or performance deficiency attributable to mis-application. “Mis-application” is defined 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 first obtaining the written consent of Stanley.

WARRANTY REGISTRATION: STANLEY ASSUMES NO LIABILITY FOR WARRANTY CLAIMS SUBMITTED FOR WHICH NO TOOL REGISTRA-

TION 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 first receiving documentation which proves the sale of the tool or the tools’ first date of usage. The term “DOCUMENTATION” as used in this paragraph is defined as a bill of sale, or letter of intent from the first 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 fitness for a particular purpose except for that provided herein. There is no other warranty. This warranty gives the purchaser specific legal rights and other rights may be available which might vary depending upon applicable law.

30

Stanley Hydraulic Tools

3810 SE Naef Road

Milwaukie OR 97267-5698

503-659-5660

FAX 503-652-1780 www.stanley-hydraulic-tools.com