DS06
HYDRAULIC
DIAMOND SAW
WARNING
SAFETY, OPERATION AND MAINTENANCE
SERVICE MANUAL
Stanley Hydraulic Tools
3810 SE Naef Road
Milwaukie OR 97267-5698
503-659-5660
Copyright © 2005, The Stanley Works
OPS/MAINT USA
34567 8/2005 Ver 3
FAX 503-652-1780
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TABLE OF CONTENTS
CERTIFICATE OF CONFORMITY ............................................................................................................................................................................4
SAFETY SYMBOLS ..................................................................................................................................................................................................5
SAFETY PRECAUTIONS..........................................................................................................................................................................................6
TOOL STICKERS & TAGS ........................................................................................................................................................................................8
HYDRAULIC HOSE REQUIREMENTS.....................................................................................................................................................................9
HTMA REQUIREMENTS.........................................................................................................................................................................................10
OPERATION............................................................................................................................................................................................................11
PREOPERTION PROCEDURES ............................................................................................................................................................................11
CHECK THE POWER SOURCE.............................................................................................................................................................................11
CHECK TOOL..........................................................................................................................................................................................................11
CONNECT HYDRAULIC HOSES............................................................................................................................................................................11
CONNECTING TO A WATER SUPPLY ...................................................................................................................................................................11
CHECK CHAIN AND BAR ADJUSTMENT ..............................................................................................................................................................11
CHECK CHAIN SEGMENT WEAR .........................................................................................................................................................................12
OPERATING PROCEDURES .................................................................................................................................................................................12
PLAN THE CUT.......................................................................................................................................................................................................12
TYPES OF CUTS ....................................................................................................................................................................................................13
COLD WEATHER OPERATION..............................................................................................................................................................................13
USING THE WALL WALKER™...............................................................................................................................................................................13
MAINTENANCE & ADJUSTMENTS........................................................................................................................................................................14
GENERAL MAINTENANCE TIPS............................................................................................................................................................................14
SAW BAR RAIL .......................................................................................................................................................................................................14
ROTATING THE SAW BAR.....................................................................................................................................................................................14
CHAIN TENSION ADJUSTMENT............................................................................................................................................................................14
SERVICING THE CHAIN.........................................................................................................................................................................................15
MAINTENANCE & ADJUSTMENTS........................................................................................................................................................................15
MAINTENANCE & ADJUSTMENTS........................................................................................................................................................................16
REPLACING THE CHAIN BREAKER PUNCH........................................................................................................................................................16
SPINNING RIVETS .................................................................................................................................................................................................16
NOSE SPROCKET DISASSEMBLY AND ASSEMBLY ...........................................................................................................................................17
MAINTENANCE & ADJUSTMENTS........................................................................................................................................................................17
TOOL EQUIPMENT & CARE ..................................................................................................................................................................................19
TROUBLESHOOTING.............................................................................................................................................................................................20
SPECIFICATIONS...................................................................................................................................................................................................22
ACCESSORIES.......................................................................................................................................................................................................22
SERVICE.................................................................................................................................................................................................................23
MOTOR INSPECTION AND CLEANING.................................................................................................................................................................24
BAR & CHAIN AND CHAIN GUARD ASSEMBLY ...................................................................................................................................................26
DS06 PARTS ILLUSTRATION ................................................................................................................................................................................27
DS06 PARTS LIST ..................................................................................................................................................................................................28
DS06 PARTS ILLUSTRATION ................................................................................................................................................................................29
DS06 PARTS LIST ..................................................................................................................................................................................................30
DIAMOND CHAIN APPLICATIONS.........................................................................................................................................................................31
WARRANTY ............................................................................................................................................................................................................32
SERVICING THE STANLEY CONCRETE CHAINSAW: This manual contains safety, operation, and routine
maintenance instructions. Servicing of hydraulic tools, other than routine maintenance, must be per-
formed 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
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CERTIFICATE OF CONFORMITY
ÜBEREINSTIMMUNGS-ZERTIFIKAT
CERTIFICAT DE CONFORMITE CEE
CERTIFICADO DE CONFORMIDAD
CERTIFICATO DI CONFORMITA
Hydraulic Tools
______________________________________________________________________
I, the undersigned:
Ich, der Unterzeichnende:
Schultz, Theodore J.
Je soussigné:
Surname and First names/Familiennname und Vornamen/Nom et prénom/Nombre y apellido/Cognome e nome
El abajo firmante:
lo sottoscritto:
hereby certify that the construction plant or equipment specified hereunder:
bestätige hiermit, daß das im folgenden genannten Werk oder Gerät:
certifies par ceci que l’ usine ou l’ équipement de construction indiqué cidessous:
por el presente certifico que la fabrica o el equipo especificado a continuacion:
certifico che l’impianto o l’attrezzatura sotto specificata:
1. Category:
Kategorie:
Catégorie:
Categoria:
Categoria:
Concrete Cutting Chainsaw
2. Make/Ausführung/Marque/Marca/Marca
3. Type/Typ/Type/Tipo/Tipo:
Stanley
DS06200001, DS06300001
4. Serial number of equipment:
Seriennummer des Geräts:
Numéro de série de l’équipement:
Numero de serie del equipo:
Matricola dell´attrezzatura:
All
5. Year of manufacture/Baujahr/année de fabrication/Año de fabricacion/Anno di fabbricazione
1998
Has been manufactured in conformity with - EEC Type examination as shown.
Wurde hergestellt in Übereinstimmung mit - EEC Typ-Prüfung nach.
Est fabriqué conformément - au(x) type(s) examiné(s) comme indiqué dans le tableau ci-après.
Ha sido fabricado de acuerdo con - tipo examen EEC como dice.
E’ stata costruita in conformitá con - le norme CEE come illustrato.
Examen CEE de type
Directive
Richtlinie
Directives particulières
Directriz
Direttiva
No.
Nr
Date
Datum
Date
Fecha
Data
Approved body
Prüfung durch
Organisme agréé
Aprobado
Date of expiry
Ablaufdatum
Date d´expiration
Fecha de caducidad
Data di scadenza
Numéro
No
n.
Collaudato
Machinery Directive
98/37/EC
89/392/CEE
292
8662-1
3744
1998
Self
Self
Self
Self
Self
Self
NA
NA
NA
NA
NA
NA
EN
1991
1988
1994
1992
ISO
ISO
ISO
10726
6. Special Provisions:
None
Spezielle Bestimmungen:
Dispositions particulières:
Provisiones especiales:
Disposizioni speciali:
Done at/Ort/Fait à/Dado en/Fatto a Stanley Hydraulic Tools, Milwaukie, Oregon USA
Date/Datum/le/Fecha/Data
3/98
Signature/Unterschrift/Signature/Firma/Firma_______________________________________________________
Position/Position/Fonction/Puesto/Posizione Engineering Manager
P/N 62310 rev 03 3/05
4
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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 equip-
ment.
This is the safety alert symbol. It is used to alert you to potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid
possible injury or death.
This safety alert and signal word indicate an imminently hazardous situa-
DANGER
WARNING
CAUTION
tion which, if not avoided, will result in death or serious injury.
This safety alert and signal word indicate a potentially hazardous situation
which, if not avoided, could result in death or serious injury.
This safety alert and signal word indicate a potentially hazardous situation
which, if not avoided, may result in minor or moderate injury.
This signal word indicates a potentially hazardous situation which, if not
avoided, may result in property damage.
This signal word indicates a situation which, if not avoided, will result in
damage to the equipment.
NOTICE
This signal word indicates a situation which, if not avoided, may result in
damage to the equipment.
IMPORTANT
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 mainte-
nance personnel.
5
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SAFETY PRECAUTIONS
Tool operators and maintenance personnel must always comply with the safety
precautions given in this manual and on the stickers and tags attached to the tool
and hose.
These safety precautions are given for your safety. Review them carefully before
operating the tool and before performing general maintenance or repairs.
Supervising personnel should develop additional precautions relating to the specific
work area and local safety regulations. If so, place the added precautions in the
space provided on page 5.
The DS06 Diamond Chain Saw will provide safe and dependable service if operated
in accordance with the instructions given in this manual. Read and understand this
manual and any stickers and tags attached to the tool and hoses before operation.
Failure to do so could result in personal injury or equipment damage.
• Establish a training program for all operators to ensure safe operation.
• The operator must be familiar with all prohibited work areas such as excessive slopes and dangerous terrain condi-
tions.
• 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.
6
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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.
7
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TOOL STICKERS & TAGS
D
30 LPM @ 138 B AR
EHTMA CATEGORY
12412
Warning Decal
11207
11206
11206
33445
Name Tag Decal
Circuit “C” Decal
11207
Lwa
Circuit “D” Decal
28323
CE Decal
28409
28323
11212
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.
For proper and safe operation read owners manual
and mwke sure that you have been properly
trained in correct procedures required for work
on or around electric lines.
28409
Composite Decal
ELECTROCUTION
HAZARD
12412
11212
Sound Level Decal
33445
D A N G E R
D A N G E R
1. FAILURE TO USE HYDRAULIC HOSE LABELEDAND CERTIFIED
AS NON-CONDUCTIVE WHEN USING HYDRAULIC TOOLS
ON OR NEAR ELECTRICAL LINES MAY RESULT IN DEATH
OR SERIOUS INJURY.
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 HOSESARE 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 CONNEC-
TIONS MAY CAUSE REVERSE TOOL OPERATION WHICH CAN
RESULT IN SEVERE PERSONAL 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 DEPART-
MENT INSTRUCTIONS.
2. A HYDRAULIC LEAK OR BURST MAY CAUSE OIL INJECTION
INTO THE BODY OR CAUSE OTHER SEVERE PERSONAL
INJURY.
4. DO NOT CONNECT OPEN-CENTER TOOLS TO CLOSED-CEN-
TER HYDRAULIC SYSTEMS. THIS MAY RESULT IN LOSS OF
OTHER HYDRAULIC FUNCTIONS POWERED BY THE SAME
SYSTEM AND/OR SEVERE PERSONAL INJURY.
A
DO NOT EXCEED SPECIFIED FLOW AND PRESSURE FOR
THIS TOOL. EXCESS FLOW OR PRESSURE MAY CAUSE A
LEAK OR BURST.
5. BYSTANDERS MAY BE INJURED IN YOUR WORK AREA. KEEP
BYSTANDERS CLEAR OF YOUR WORK AREA.
B
DO NOT EXCEED RATED WORKING PRESSURE OF HY-
6. WEAR HEARING, EYE, FOOT, HAND AND HEAD PROTEC-
TION.
DRAU
LIC HOSE USED WITH THIS
TOOL. EXCESS PRESSURE MAY
CAUSE A LEAK OR BURST.
7. TO AVOID PERSONAL INJURY OR EQUIPMENT DAMAGE, ALL
TOOL REPAIR MAINTENANCE AND SERVICE MUST ONLY BE
PERFORMED BY AUTHORIZED AND PROPERLY TRAINED
PERSONNEL.
The safety tag (p/n
C
CHECK TOOL HOSE COUPLERS AND CONNECTORS DAILY
FOR LEAKS. DO NOT FEEL FOR LEAKS WITH YOUR
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.
I M P O R T A N T
I M P O R T A N T
READ OPERATION MANUAL AND
SAFETY INSTRUCTIONS FOR THIS
TOOL BEFORE USING IT.
READ OPERATION MANUAL AND
SAFETY INSTRUCTIONS FOR THIS
TOOL BEFORE USING IT.
USE ONLY PARTS AND REPAIR
PROCEDURES APPROVED BY
USE ONLY PARTS AND REPAIR
PROCEDURES APPROVED BY
STANLEY AND DESCRIBED IN THE OPERA-
TION MANUAL.
STANLEY AND DESCRIBED IN THE OPERA-
TION MANUAL.
TAG TO BE REMOVED ONLY BY
TOOL OPERATOR.
TAG TO BE REMOVED ONLY BY
TOOL OPERATOR.
SEE OTHER SIDE
SEE OTHER SIDE
SAFETY TAG P/N 15875
(shown smaller then actual size)
8
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HYDRAULIC HOSE REQUIREMENTS
HOSE TYPES
Hydraulic hose types authorized for use with Stanley Hydraulic Tools are as follows:
➊ Certified non-conductive
➋ Wire-braided (conductive)
➌ Fabric-braided (not certified or labeled non-conductive)
Hose ➊ listed above is the only hose authorized for use near electrical conductors.
Hoses ➋ and ➌ listed above are conductive and must never be used near electrical conductors.
HOSE SAFETY TAGS
To help ensure your safety, the following DANGER tags are attached to all hose purchased from Stanley Hydrau-
lic Tools. DO NOT REMOVE THESE TAGS.
If the information on a tag is illegible because of wear or damage, replace the tag immediately. A new tag may be
obtained from your Stanley Distributor.
THE TAG SHOWN BELOW IS ATTACHED TO “CERTIFIED NON-CONDUCTIVE” HOSE
D A N G E R
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.
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.
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.
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.
SIDE 1
SIDE 2
(shown smaller than actual size)
3
THE TAG SHOWN BELOW IS ATTACHED TO “CONDUCTIVE” HOSE.
D A N G E R
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.
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.
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.
6. AFTER EACH USE STORE IN A CLEAN DRY AREA.
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
SIDE 2
(shown smaller than actual size)
HOSE PRESSURE RATING
The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the
hydraulic system.
9
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HTMA REQUIREMENTS
TOOL CATEGORY
HYDRAULIC SYSTEM
REQUIREMENTS
TYPE 1
TYPEII
TYPEIII
TYPE RR
FLOW RATE
4-6 gpm
7-9 gpm
11-13 gpm
9-10.5 gpm
(34-40 lpm)
2000 psi
(15-23 lpm)
2000 psi
(138 bar)
(26-34 lpm)
2000 psi
(42-49 lpm)
2000 psi
TOOL OPERATING PRESSURE
(at the power supply outlet)
(138 bar)
(138 bar)
(138 bar)
SYSTEM RELIEF VALVE SETTING
(at the power supply outlet)
2100-2250 psi 2100-2250 psi 2100-2250 psi 2200-2300 psi
(145-155 bar) (145-155 bar) (145-155 bar) (152-159 bar)
MAXIMUM BACK PRESSURE
(at tool end of the return hose)
250 psi
(17 bar)
250 psi
(17 bar)
250 psi
(17 bar)
250 psi
(17 bar)
Measured at a max. fluid viscosity of:
(at min. operating temperature)
400 ssu*
400 ssu*
400 ssu*
400 ssu*
(82 centistokes)(82 centistokes)(82 centistokes)(82 centistokes)
TEMPERATURE
140° F
(60° C)
140° F
(60° C)
140° F
(60° C)
140° F
(60° C)
Sufficient heat rejection capacity
to limit max. fluid temperature to:
(at max. expected ambient temperature)
Min. cooling capacity
3 hp
5 hp
7 hp
6 hp
at a temperature difference of
between ambient and fluid temps
(2.24 kW)
40° F
(3.73 kW)
40° F
(4.47 kW)
40° F
(5.22 kW)
40° F
(22° C)
(22° C)
(22° C)
(22° C)
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
25 microns
30 gpm
(114 lpm)
25 microns
30 gpm
(114 lpm)
25 microns
30 gpm
(114 lpm)
25 microns
30 gpm
(114 lpm)
Min. full-flow filtration
Sized for flow of at least:
(For cold temp. startup and max. dirt-holding capacity)
HYDRAULIC FLUID
100-400 ssu* 100-400 ssu* 100-400 ssu* 100-400 ssu*
(20-82 centistokes)
Petroleum based
(premium grade, anti-wear, non-conductive)
VISCOSITY
(at min. and max. operating temps)
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 require-
ments over a wide range of operating temperatures.
*SSU = Saybolt Seconds Universal
NOTE:
These are general hydraulic system requirements. See tool Specification page for tool specific requirements.
10
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OPERATION
CONNECT HYDRAULIC HOSES
PREOPERTION PROCEDURES
1. Wipe all hose couplers with a clean lint-free cloth before
making connections. If necessary, use a light-weight pen-
etrating oil in a spray can to clean the hose couplers before
each connection.
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 for the 8 gpm model and 4-6 gpm/15-23
lpm for the 5 gpm model at 2000 psi/140 bar.
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 hose first and disconnect them
last to minimize or avoid trapped pressure within the chain
saw.
2. Make certain that the power source is equipped with a
relief valve set to open at 2100-2250 psi/145-155 bar.
3. Check that the hydraulic circuit matches the tool for
open-center (OC) or closed-center (CC) operation. The
DS06 is designed for open-center operation only.
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.
NOTE:
CHECK TOOL
If uncoupled hoses are left in the sun, pressure in-
crease inside the hoses might make them difficult to
connect. Whenever possible, connect the free ends of
the hoses together.
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.
CONNECTING TO A WATER SUPPLY
3. The tool should be clean, with all fittings and fasteners
tight.
1. Using a standard garden hose, connect the DS06 to a
city or auxiliary water supply. Make sure the flow is at least
4 gpm/15 lpm at 50 psi/3.5 bar.
4. Observe the arrow on the couplers to ensure that the
hydraulic oil flow is in the proper direction. The female cou-
pler is the inlet (pressure) coupler.
IMPORTANT
5. Check that the trigger operates smoothly and is free to
travel between the "ON" and "OFF" positions.
Chain and bar damage will occur if the tool operates
without the proper water supply and water pressure.
6. Check that the chain is properly installed. The chain is
designed to only operate in one direction. Make sure the
chain is installed so the bumper guard precedes each dia-
mond segment. See figure 1.
2. Make sure the water is running before starting the tool.
3. If a water pump is being used, refer to the manufacturers
instructions for use of the pump. Make sure the pump pro-
duces a minimum watger flow of 4 gpm/15 lpm at 50 psi/3.5
bar and the water pressure does not exceed 160 psi/11 bar.
Segment
Bumper
CHECK CHAIN AND BAR ADJUSTMENT
CORRECT
Guard
Note:
Check the chain tension often during operation, expe-
cially during the first 1/2 hour when using a new chain.
Adjust the chain accordingly when it becomes loose.
Follow the procedures contained in the Mainenance
and Adjustements section of this manual.
INCORRECT
1. Make sure the chain does not exceed a clearance of
5/16 in./8 mm from the bar (see figure 2). Exceeding the
maximum clearance increases the chance of the chain be-
ing dislodged from the bar groove.
Figure 1. Chain Direction
11
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OPERATION
2. Make your cuts in the order shown in Figure 4, starting
with cut 1 (base horizontal cut) and proceeding with the
remaining three cuts.
2. Make sure the bar attaching nuts are fully tightened and
the chain guard is in place.
Bottom of Bar
Max
5/16”
Figure 2. Maximum Chain Clearance
CHECK CHAIN SEGMENT WEAR
Figure 4. Planning Cuts
1. Using adjustable calipers, measure several chain seg-
ments as illustrated in Figure 3.
3. Outline the concrete area with a permanent marker for a
visual guide.
Bottom of Bar
4. Know what kind of material and how much reinforcing
you are going to cut.
Min.
1/16”
NOTICE
Figure 3. Chain Segment Wear
2. If the average measurement is less than 1/16-inch/1.6
mm, then the chain must be replaced. Refer to your Service
Manual for chain replacement procedures.
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
Stanley Representative. He/she can often provide
information that will make your work safter and more
productive.
OPERATING PROCEDURES
1. Observe all safety precautions.
2. Turn on the water supply. Water at the tool will be di-
rected to the bar and chain when the trigger on the tool is
squeezed “ON”.
3. Operate the tool for two minutes away from the intended
cut and then check the chain tension. New chain will nor-
mallhy stretch during its first usage. It is very important to
keep the chain tension adjusted so that it does not exceed
5/16 in./8 mm clearance from the bottom of the bar. See
Check Chain & Bar Adjustment in this manual.
4. If the chain requires adjustment, see Maintenance &
Adjustments in this manual.
PLAN THE CUT
1. Plan your cuts to prevent injury to yourself and to keep
from pinching the saw bar and chain as a result of falling
pieces of concrete, brick, etc.
12
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OPERATION
COLD WEATHER OPERATION
TYPES OF CUTS
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.
The DS06 can be operated using the types of cuts shown
in Figure 5. When making cuts:
Damage to the hydraulic system or chain saw can result
from use with fluid that is too viscous or thick.
DOWN CUT
USING THE WALL WALKER™
The Wall Walker™ lessens operator fatigue and effort dur-
ing cutting by automatic insertion of the wedge into the cut,
thus allowing the operator to apply leverage to the saw.
1. Position the Wall Walker™ in the "autofeed" position by
pinning the lever arm at the lowest hole as shown in the
illustration.
PLUNGE CUT
Start cutting with the DS06 until the cut is large enough to
allow the tip of the wedge to insert into the cut. With the tip
of the wedge in the cut, the operator can easily apply lever-
age to the saw which will aid the cutting process and lessen
operator fatigue and effort.
UP CUT
After the saw cuts approximately 1 to 2.5 in. / 25 to 65 mm,
withdraw the saw only enough to allow the lever arm and
wedge to reposition. After repositioning, continue cutting.
Figure 5. Types of Cuts (chain guard removed for clarity)
1. Do not use a cutting force in excess of 45 lbs/20 kg.
Excessive force causes the chain to slow down or stall and
causes premature wear of the saw bar and chain.
2. The Wall Walker™ can be positioned to the "parked"
position by pinning the lever arm at the upper most hole. In
this position, the Wall Walker™ is used as a bucking cleat.
2. Always maintain a high chain speed. High chain speeds
produce the best results.
3. Always check that plenty of water is being expelled
from the bar and chain. When the tool is running, water is
directed to the interior of the bar and then out of several
holes located along the top and bottom channels on the
bar. If these holes become plugged, cutting debris will not
be adequately washed away and will result in premature
wear of the bar and chain.
3. Avoid aggressive/heavy plunge forces. Aggressive
plunge force creates fragmenting of the concrete when the
saw bar and chain exits and causes premature bar and
chain wear.
Wall Walker™ Lever Arm
(shown in “autofeed position)
Figure 6. Wall Walker™
13
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MAINTENANCE & ADJUSTMENTS
CHAIN TENSION ADJUSTMENT
GENERAL MAINTENANCE TIPS
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:
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 Ser-
vice Manual.
1. Turn off the water and power supplies.
2. Loosen the two saw bar attachment nuts (Figure 8).
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.
Bar Attachment
Nuts (2)
Bar Adjusting Screw
Figure 8. Attachment Screw Locations
3. Using the saw bar adjustment screw (Item 68, Parts Il-
lustration), 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).
Figure 9. Pulling the Chain
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.
4. Pull the chain around the saw bar to make sure it proper-
ly fits the sprocket and saw bar. The chain should be easily
pulled.
ROTATING THE SAW BAR
5. Fully tighten the two saw bar attachment nuts (Figure 8).
Maximum saw bar life can be achieved by occasionally
turning the bar over so the top and bottom bar surfaces
wear evenly. Refer to the saw bar disassembly procedures
in the Service Manual for further details.
Note:
Adjust the chain tension each time the drive link tang
hangs fully exposed from the groove at the bottom of
the saw bar (Figure 10).
14
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MAINTENANCE & ADJUSTMENTS
Bottom of Bar
Max
5/16”
Figure 10. Exposed Drive Link Tang
SERVICING THE CHAIN
The following procedures explain how to break a chain us-
ing 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 13. Inserting the Chain
3. Position the rivet head you want removed directly under
the chainbreaker punch and then pull the handle down far
enough to remove the rivet (Figure 14). Do not use exces-
sive force.
Figure 11. Chain Breaker Mounting
Note:
The Stanley chain breaker is only designed to remove
rivet heads from the connecting links, not from a chain
segment. The rivet heads shown in the shaded areas of
Figure 12 are the only ones that can be removed.
Figure 14. Removing a Rivet
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 con-
necting link is flush with the far side of the slot (Figure 13).
15
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MAINTENANCE & ADJUSTMENTS
REPLACING THE CHAIN BREAKER
PUNCH
If the chain breaker punch (part number 22801) becomes
worn or damaged, use the following prcedures for replace-
ment.
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 18. Positioning the Chain
3. Turn the take-up handle until the chain is tight against
the spinner anvil (Figure 19).
Take-up
Rivet Spinner
Handle
Crank
Figure 16. Replacing the Punch
SPINNING RIVETS
Figure 19. Securing the Chain
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).
16
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MAINTENANCE & ADJUSTMENTS
4. turn the rivet spinner crank a few times to center the rivet
hub in the spinner anvil (Figure 20).
Take-up
Handle
Rivet Spinner
Crank
Figure 23. Spinner Oiling Chambers
Figure 20. Centering the Rivet Hub
5. Apply a few drops of oil to the rivet hub (Figure 21).
NOTE:
the rivet spinner is equipped with oiling chambers and
should be maintained periodically with a light-weight
oil (Figure 23).
NOSE SPROCKET DISASSEMBLY
AND ASSEMBLY
1. Using the bench mounted chain breaker (see acces-
sories), line up the 1/4 inch hole in the side of the chain
breaker anvil with the chain breaker punch. Punch out the
six nose sprocket rivets. See Figure 24.
Figure 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 spin-
ner anvil forms the rivet head.
Figure 24. Punching Out Nose Sprocket
Rivets
2. Insert a straight blade screw driver to spread the bar
nose rails just enough to remove the old nose sprocket.
Use a rag or paper towel to clean the nose sprocket area.
See Figure 25.
Figure 22. Forming a Rivet Head
17
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MAINTENANCE & ADJUSTMENTS
5. Insert 6 nose rivets into the holes and then hold them
with your thumb. Remove the screwdriver and slide out the
insertion card.
Note: On used bars the nose rails might tend to spread
apart. Use a small clamp if necessary to hold the rails
together.
6. With the bar and rivets solidly supported on a strong 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. See Figure 28.
Figure 25. Removing Old Nose Sprocket
3. Remove the new nose sprocket package's clips and fold
back the top portion of the insertion card being careful not
to remove or disturb the components. See Figure 26.
Figure 28. Replacing Rivets
Figure 26. Preparing New Nose Sprocket
7. Using a flat file, shave the rivet heads to a uniform height
that is as close to the bar body as possible. See Figure 29.
4. With a flat blade screw driver in the bar nose rails, slide
the nose sprocket assembly into position aligning the 6
holes in the bar nose with the 6 holes in the nose sprocket
assembly without removing the components from the card.
See Figure 27.
Figure 29. Filing Rivets
Figure 27. Installing a New Nose Sprocket
18
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TOOL EQUIPMENT & CARE
NOTICE
In addition to the Safety
Precautions in this manual,
observe the following for
equipment protection and
care.
• Make sure all couplers are wiped clean before connection.
• The hydraulic circuit control valve must be in the “OFF” position when coupling or uncoupling
hydraulic tools. Failure to do so may result in damage to the quick couplers and cause overheating
of the hydraulic system.
• Always store the tool in a clean dry space, safe from damage or pilferage.
• Make sure the circuit PRESSURE hose (with male quick disconnect) is connected to the “IN” port.
The circuit RETURN hose (with female quick disconnect) is connected to the opposite port. Do not
reverse circuit 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.
19
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TROUBLESHOOTING
correct hydraulic flow and pressure to the tool as listed
If symptoms of poor performance develop, the following
chart can be used as a guide to correct the problem.
in the table. Use a flowmeter known to be accurate.
Check the flow with the hydraulic oil temperature at least
80°F/27°C.
When diagnosing faults in operation of the tool, always
check that the hydraulic power source is supplying the
SYMPTOM
CAUSE
REMEDY
Tool does not run.
Hydraulic power source not function-
ing correctly.
Check power source for proper flow
and pressure (7-9 gpm26-34 lpm at
2000 psi/140 bar.
Coupler or hoses blocked.
Mechanical failure.
Remove obstruction.
Have tool serviced by authorized
dealer.
Tool runs backwards.
Pressure and return lines incorrectly
connected.
Correct hose connections. Motor shaft
rotates counterclockwise as viewed
from the end of the motor shaft.
Diamond saw cuts slow.
Insufficient fluid flow or too high back
pressure or relief valve set too low.
Check hydraulic supply. If hydraulic
supply is correct, have unit serviced
by authorized dealer.
Back pressure too high.
Should not exceed 250 psi/17 bar at
9 gpm/34 lpm measured at the end of
the tools operating hoses.
Loss of diamond segment side clear-
ance.
Replace chain.
Chain segment dulled because of con- Redress segmented by cutting in
tinuous use in hard material or rebar.
abrasive material (i.e. concrete, build-
ing block, etc.).
Note: This indicates that the wrong
chain is being used.
Wrong chain for application.
Scale down to a lower numbered
chain.
Wired edged bar rails.
Hydraulic fluid mixed in water supply.
Segment(s) broken or missing.
Dress rails square.
Have tool serviced.
Repair broken segment or replace
chain.
Excessive vibration and cuts rough.
Wil not cut straight.
Chain installed backwards.
Loose chain tension.
Excessive feed force.
Accumulated saw bar wear and un-
even chain segment profile wear.
Correct chain direction.
Retension the chain.
Reduce feed force.
Turn the saw bar over and dress rails
square. Replace the saw bar and
chain.
Loss of power.
Drive sprocket slipping on Tran-
torque® adapter.
Adjust and tighten Trantorque®
adapter to 17 ft lb/23 Nm.
Trigger hard to press.
Pressure & return hose reversed.
Connect for proper flow direction. Mo-
tor shaft must rotate clockwise.
Back-pressure too high.
Should not exceed 250 psi/17 bar @
9gpm/34 lpm measured at the end of
the tool’s operating hoses.
20
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TROUBLESHOOTING
SYMPTOM
CAUSE
REMEDY
Leakage around drive sprocket.
No water discharge at bar.
Motor shaft seal failure.
Blocked port(s) in bar.
Have unit serviced.
Turn off hydraulic supply. Remove bar
and chain and clean bar thoroughly.
Blow ports with compressed air.
Blocked inlet or outlet.
Turn off hydraulic supply. Remove bar
and chain. Make sure water supply
is on. Press trigger to see if water
exits near bar adjustment nut area (a
small port). If no water exits, have unit
serviced.
21
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SPECIFICATIONS
Cutting Depths............................................................................................................................................13 inches / 33 cm
Bar Lengths....................................................................................................................................................13 inch / 33 cm
Chain Type ............................................................................................................ 3/8 inch pitch with 21 diamond segments
Maximum Back Pressure ................................................................................................................................ 250 psi/17 bar
Input Flow Range
5 gpm model..........................................................................................................................4-6 gpm / 15-23 lpm
8 gpm model............................................................................................................................7-9 gpm/26-34 lpm
Input Pressure........................................................................................................................................... 2000 psi / 140 bar
Weight (without bar) ............................................................................................................................................14 lbs / 6 kg
Length (without bar) ................................................................................................................................14.3 inches / 36 cm
Width ............................................................................................................................................................9 inches / 23 cm
Lubrication / Cooling.............................................................................................................. Internal Water Channels in Bar
Porting............................................................................................................................................................ -8 SAE O-Ring
Connection ...................................................................................................................................EHTMA/HTMA Flush Face
Hose Whips...................................................................................................................................................................... Yes
Chain Speed
5 gpm model ........................................................................................................................... 4600 fpm/23.4 m/s
8 gpm model ........................................................................................................................... 5000 fpm/25.4 m/s
SOUND POWER AND VIBRATION DECLARATION
Measured A-weighted sound power level, Lwa (ref. 1pW) in decibels
Uncertainty, Kwa, in decibels
106.2 dBA
3 dBA
Measured A-weighted sound pressure level, Lpa (ref. 20 µPa) at operator’s position, in decibels
Uncertainty, Kpa, in decibels
98.2 dBA
3 dBA
Values determined according to noise test code given in ISO 15744, using the basic standard ISO3744
NOTE- The sum of a measured noise emision value and its associated uncertainty represents an upper
boundry of the range of values which is likely to occur in measurements.
Declared vibration emission value in accordance with EN 12096
Measured vibration emmission value: a
Uncertainty: K
6.0 m/sec²
2.0 m/sec²
Values determined according to ISO 8662-1, ISO 5349-1,2
ACCESSORIES
Chain Repair Spinner................................................................................................................................................... 20857
Diamond Chain Repair Breaker ................................................................................................................................... 20858
Diamond Chain Service Kit ...........................................................................................................(sub p/n 20857 or 20858)
Diamond Chain Butterfly Repair Kit.............................................................................................................................. 20859
Water Pump Kit (115/230 Volt / 60 Hz)......................................................................................................................... 26020
Water Pump Kit (220/380/440 Volt /50 Hz)................................................................................................................... 26237
HP1 Power Unit Water Pump Kit.................................................................................................................................. 29361
13 inch Bar, Sprocket Nose.......................................................................................................................................... 35037
Ultra-25, Diamond Chain for 13 inch Bar ..................................................................................................................... 56799
Pinnacle-25, Diamond Chain for 13 inch Bar ............................................................................................................... 56800
Water Pump Attachment for GT18 & HP1, with Couplers ..........................................................................................HWP10
Water Flow Meter, 0-7 gpm .......................................................................................................................................... 60859
22
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SERVICE INSTRUCTIONS
a reduced diameter indicate fluid contamination. If
abnormal wear is present (more than normal polishing),
replace both the spool and the handle.
PRIOR TO DISASSEMBLY
Clean exterior of the tool.
2. Apply grease and install a new o-ring (15) onto the ON/
OFF valve (14).
Obtain a seal kit so that all seals exposed during disas-
sembly can be replaced.
3. Apply grease and install new o-rings (34 & 35) into the
spool bore of the handle.
ON-OFF VALVE SERVICING
4. Apply grease and install new o-rings (37 & 39) onto the
water valve sleeve (38).
TRIGGER (28) AND SAFETY CATCH (30)
REMOVAL & INSTALLATION
5. If the spring retainers (16) and spring (17) were removed
from the ON/OFF valve, reinstall them. Lubricate the ON/
OFF valve with hydraulic fluid and install it into the valve
handle. Secure it in place with the roll pin (20).
1. Drive the roll pins (20) out of the handle assembly using
a 3/16 in./4 mm diameter punch. Press the safety latch and
remove the trigger (28).
NOTE: The safety catch can be removed at this time by
driving out the 3/16 inch roll pin (21), but this is not neces-
sary for servicing the on-off valve.
6. Install the water valve sleeve into the valve handle.
7. Install the push pin (40), steel ball (41), spring (42), and
seal cap (44). Make sure a new o-ring (43) is installed onto
the seal cap.
2. To install the trigger and safety catch reverse the above
procedures.
8. Install the safety catch (30) making sure the spring (29)
is positioned properly. Make sure the pin (33) is in place.
Secure the safety catch with the roll pin (21).
VALVE SPOOL (14) REMOVAL &
INSTALLATION
9. Install the trigger (28) and secure with the roll pin (20).
1. Remove the plug button (19) from the top of the handle
by prying under the edge and then pulling it from the
handle.
10. Replace the plug button (19) and test the action of the
safety catch and trigger.
2. Drive the roll pins (20) out of the handle assembly using
a 3/16 in./4 mm diameter punch. Press the safety latch and
remove the trigger (28).
FLOW CONTROL
Note:
3. Drive the roll pin (20) (holding the valve spool (14) in
place) out of the handle using a 3/16 in./4 mm diameter
punch.
Diamond saws with a serial number of 357 and above,
no longer require a flow control.
The flow control (32) is factory preset and is not field ser-
viceable. Use the following as guides to check for proper
regulated flow.
4. Unscrew the seal cap (44) and remove it, the spring
(42), and the steel ball (41).
5. Lift out the valve spool assy (14 thru 18).
For 5 gpm model:
If the regulated flow is over 6.6 gpm or under 5.4 gpm at 8
gpm input, the flow control valve should be replaced.
6. Using a 1/2 in./12.7 mm diameter wood dowel, place the
dowel into the valve spool bore from the plug button (19)
end of the handle. Push the dowel against the water valve
sleeve (38) to push the water sleeve out.
For 8 gpm model:
If the regulated flow is over 10 gpm or under 8 gpm at 12
gpm input, the flow control valve should be replaced.
REASSEMBLY
1. Inspect the spool bore of the handle and the outer
surfaces of the spool for damage. Some light surface
scratches will be noticeable. Grooves, roughness or
23
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SERVICE INSTRUCTIONS
MOTOR SERVICING
11. To remove the bearing from the shaft, press on the out-
side end (sprocket end) of the motor shaft while supporting
the outer race of the bearing. Discard the old bearing.
1. Remove the 2 nuts (51) and then lift off the chain guard
(50).
12. Remove the retaining ring (91) at the bottom of the
bearing bore. Remove the seal backup washer (57). Re-
move the quad ring (90) and o-ring (56) using the appropri-
ate o-ring service tools. Discard the quad ring and o-ring
2. Lift off the bar (61) and chain (73). If it is necessary to
take tension off the bar and chain, turn the screw (68)
counter clockwise.
For Diamond Saws with Serial Number 357 and above,
follow the steps a thru c, then proceed to Step 7.
13. The bushings (6) can be removed using p/n 11930 col-
let from p/n 05064 bearing puller kit.
a. Remove the e-clip (60) and slide off items 48, 49 and 58.
b. Remove the retaining ring (100) and then spacer (47).
MOTOR INSPECTION AND
CLEANING
c. Remove the retaining ring (98) and then items 93 thru
96.
Inspect and clean all parts as follows:
For Diamond Saws with Serial Number 356 and below,
follow the steps below.
CLEANING
Clean all parts with a degreasing solvent. Blow dry with
compressed air and wipe clean. Use only lint-free cloths.
3. Slide the sprocket wrench (84) over the sprocket (48).
While gripping the sprocket wrench and using an open end
wrench, turn the hex head on the Trantorque™ adapter cap
(49) counter clockwise until the Trantorque™ adapter can
be removed from the motor shaft (53).
GEAR HOUSING
The chamber bores and bottoms around the shaft bushings
should be polished and not rough or grooved. If the bush-
ing bores are yellow-bronze, replace them and investigate
the cause of wear.
4. Remove the spacer (47), support washer (100), and
o-ring (97).
5. Remove the retaining ring (98).
6. Remove the capscrews (1).
The flat surfaces around the chamber and bolt holes should
be flat and free of nicks or burrs that could cause misalign-
ment or leaks.
7. Using a flat-blade screwdriver or similar tool, gently pry
the gear housing (4) away from the valve handle (22). Lift
the gear housing straight up. Do Not tilt the housing or pry
on the flat surface inside of the surrounding groove. For
prying, only use the groove provided at the split between
the parts to prevent scratches on the inner mating surfaces.
BUSHINGS
The inside of the bushings should be gray with
some bronze showing through. If significant yellow-bronze
shows, replace the bushings. Inspect motor shaft for cor-
responding wear and replace as required.
8. Remove the two gears (9 & 13), needle roller (54), and
the idler shaft (8).
GEARS
The drive and idler gears should have straight tips without
nicks, square tooth ends and a smooth even polish on the
teeth and end faces. Check for cracks between the drive
gear keyway and gear tooth root. Replace the gear if
cracks are present.
9. Remove the large face seal o-ring (7) while being care-
ful not to damage the o-ring groove or surrounding surface.
10. While protecting the motor surface of the valve handle
from damage, tap lightly on the small diameter end (gear
side) of the motor shaft to remove it and the seal washer
(94), seal ring (96), v-ring seal (95), o-ring (93), and bear-
ing (92) from the front of the valve handle. Remove the seal
keeper, seal spacer, seal, and o-ring from the motor shaft.
VALVE HANDLE MOTOR SURFACE
The surface near the gears should show two interconnect-
ing polished circles without a step. The bottom of the o-ring
24
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SERVICE INSTRUCTIONS
54
13
groove should be smooth as should the rest of the flat
Serial Number 357 and Above.
surface.
53
8
The bore for the shaft seal should be smooth or oil leakage
may occur.
90
57
4
91
92
GEAR HOUSING
98
47
Shake the gear housing and the two seal check balls (not
shown) should rattle. If the seal balls do not rattle then
they are probably plugged with contaminants and the gear
housing will require replacement.
100
48
58
49
60
9
7
SHAFTS
56
93
96
94
95
The shaft diameter at the bearing and seal locations must
be smooth. Grooves, roughness or a reduced diameter
indicate fluid contamination or damaged bushings. Grit
particles may have been imbedded in the bushings grind-
ing into the hardened shaft. If abnormal shaft wear as
above occurs (more than normal polishing), replace both
the shaft and associated bushings.
2. Grease and carefully install a new quad ring (90) into the
seal liner (57). Grease and install a new o-ring (56) onto the
seal liner. Install the seal liner into the valve handle assy
(22). Replace the retaining ring (91).
3. To replace the bearing (92) onto the motor shaft (53),
support the bearing inner race and press the motor shaft
through the bearing inner race.
Also check the hydraulic system for excess contamination
in the fluid and for filter condition. Operating conditions
may require changing from a 25-micron filter to an over-
sized 10-micron filter.
4. Place the valve handle assy on a smooth clean arbor
press surface (protected from damage) with the large bear-
ing bore facing up. Position the valve handle so a clearance
hole exists for the insertion of the motor shaft.
MOTOR REASSEMBLY
5. Apply grease to the motor shaft, keyway and bush-
ing and then insert the motor shaft through the shaft seal.
Using a socket with a diameter equal to the bearing O.D.,
press the bearing and motor shaft into place. Press only on
the outer race.
Refer to the illustration below for correct placement of
parts.
1. If the bushings (6) were removed from the valve handle
(22) and the gear housing (4), install new bushings using
a p/n 11918 bearing pusher. (NOTE: The bushing split line
must face the center of the gear housing).
6. Install the needle roller (54) in the keyway of the motor
shaft. Use grease to keep the needle roller in place. Slide
the drive gear (13) over the needle roller and shaft. Install
the idler shaft (8) and gear (9).
Serial Number 356 and Below.
53
54
13
8
7. Apply grease to the face seal o-ring groove; then install
the o-ring (7).
90
4
57
91
92
8. Note the screw hole pattern on the rear gear housing
and the valve handle. They will only assemble one way.
With all parts aligned, carefully slide the gear housing as-
sembly over the gears until it contacts the valve handle. Do
not force parts together.
98
96
47
48
9
7
9. Turn the motor shaft manually to check for free rotation.
Install the eight capscrews (1) and then recheck rotation.
49
100
56
93
97
94
95
25
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SERVICE INSTRUCTIONS
4. Place the bar (with chain) over the studs making sure
the chain is looped around the sprocket and the bar adjust-
ment nut is seated in the hole on the bar. While holding
the bar and chain in place, turn the adjustment screw (68)
clockwise to take the slack out of the chain. Install the chain
guard (50) and the 2 nuts (51). Hand tighten the 2 nuts and
then back them off 1/4 turn.
For Diamond Saws with Serial Number 357 and above
follow steps a thru e.
For Diamond Saws with Serial Number 356 and below,
follow steps 10 thru 13.
a. Install the o-ring (43). Push in until it contacts the bearing
face.
5. Adjust the chain tension by turning the adjustment screw
(68) in accordance with the instructions contained in the
section titled "MAINTENANCE & ADJUSTMENTS".
b. Install seal washer (94) and the retainer ring (98).
c. Install v-ring (95) onto seal ring (96) then with both in
hand, apply a small amount of 242 LoctiteTM to the bore of
the seal ring (96). Make sure it is applied around the entire
bore of the seal ring, then slide both parts onto the motor
shaft.
6. When adjustments are completed, be sure to tighten the
nuts (51).
d. Install the seal spacer (47) and then the retainer ring
(100).
e. Install items 58, 48, 49 and e-clip (60).
10. Apply grease and install a new v-ring seal (95) into
the seal washer (94). Apply grease and install a new o-ring
onto the seal keeper. Insert the seal ring (96) into the seal
washer and then install the seal spacer and seal keeper
onto the motor shaft as an assembly. Press the assembly
against the bearing and then install the retaining ring (98).
11. Apply grease and install a new o-ring (97) onto the
motor shaft. Slide the o-ring against the seal spacer. Install
the spacer (47) and support washer (100).
12. Install the sprocket (48) over the Trantorque™ adapter
cap (49) and then install this assembly onto the motor
shaft. While gripping the sprocket, hand tighten the
hex head of the Trantorque™ adapter cap by turning it
clockwise.
13. Slide the sprocket wrench (84) over the sprocket (48).
While gripping the sprocket wrench and using an open end
wrench, tighten the hex head on the Trantorque™ adapter
(49) clockwise to 17 lb. ft./23 Nm.
BAR & CHAIN AND CHAIN GUARD ASSEMBLY
1. Back the bar adjustment nut (70) off by turning the ad-
justment screw (68) counter clockwise.
2. Install the chain (73) onto the bar (61). Make sure the
chain is installed so that the bumper guards precede the
segments. See the section titled 'OPERATION".
3. Install the chain guide plate (65) over the stud (66) as
shown in the parts illustration.
26
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DS06 PARTS ILLUSTRATION
For Serial Numbers
357 and Above.
54
99
27
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For Serial Numbers
357 and Above.
DS06 PARTS LIST
Item
No.
Item
Part No. Qty
Description
Part No. Qty
Description
No.
1
2
00753
33445
8
1
HSHCS 10-24 UNC x 1-1/4
Name Tag
Circuit “D” Decal (8 gpm Model)
Circtuit “C” Decal (5 gpm Model)
56
57
58
59
60804
19215
43689
58969
1
1
1
1
O-Ring
Seal Back-Up Washer
Sprocket Adapter
Wiper Seal
11207
3
4
1
1
1
11206
Rear Gear Housing Assy. (Incl. Items 5-6),
E-Clip
07652
07834
8 gpm Model Only
60
41763
66299
1
1
(For DS063000 s/n 434 and below and for
DS06200001 s/n 110 and below)
Rear Gear Housing Assy. (Incl. Items 5-6),
5 gpm Model Only
Dowel Pin
Bushing
O-Ring
Idler Shaft
No Item
Pivot Pin
Pipe Plug
No Item
Spiral Retainer Ring
5
6
7
8
9
10
11
12
00289
04041
00020
07612
---
32190
00961
---
2
4
1
1
-
1
1
-
(For DS063000 s/n 435 and above and for
DS06200001 s/n 111 and above)
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
---
---
-
-
Saw Bar (See Accessories)
No Item
Flap Mount
32196
33219
32192
32245
58968
02687
32191
32198
33481
---
1
1
1
1
2
1
1
1
1
-
Spacer
Chain Guide Plate
Stud (Supplied with Item 22)
HSHCS 1/4 -20 UNC x 5/8
Machine Screw
04106
Drive Gear, 8 gpm Model Only
13
2
07832
Drive Gear, 5 gpm Model Only
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
32207
07626
07609
34119
04512
07625
03009
07624
33267
01605
01652
24059
24058
33443
58879
07602
34105
32197
---
00072
07627
00074
33488
05632
58970
01403
33380
36259
32188
04052
32189
28323
---
1
1
2
1
1
1
2
1
1
-
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
2
1
1
2
1
On/Off Valve
O-Ring
Spring Washer
Spring
Retaining Ring, 1/2 EX
Plug Button
Roll Pin
Roll Pin, 3/16 x 1
Valve Handle Assy. (Incl. Items 6, 31, 66)
O-Ring, (Supplied with Item 24)
Pigtail Hose Assy.
Male Coupler
Female Coupler
Water Hose Assy.
Trigger
Spring
Safety Catch
Stud (Supplied with Item 22)
No Item
Roll Pin
O-Ring
O-Ring
Self Locking Retaining Ring
O-Ring
Water Valve Sleeve
O-Ring
Pin
Steel Ball, 3/8” Dia.
Spring
O-Ring
Seal Cap
Stat-O-Seal
Bar Adjustment Nut
Wall Walker Clevis Pin
Spring (Incl. with Item 74)
Chain (See Accessories)
Wall Walker
Handle Bar Retainer
Handle Weldment
BHCS 1/4 -20 x .625 Zinc
Fender Washer
Hand Guard
Electrical Warning Decal
Washer
HHCS 5/16 -18 x 5/8 Zinc
Handle Grip
No Item
Nut, 1/4 -20 HHD LT SST
Spirol Pin
Spirol Pin, 5/16 x 7/8
Composite Decal (CE)
Sound Power Level Decal (CE)
Quad Ring
Retaining Ring
Bearing
O-Ring
Seal Washer
---
-
32206
02649
33229
33260
33261
33258
12412
12175
33454
33263
---
17134
31614
30635
28409
11212
00173
04856
35965
00621
38897
39070
38700
---
1
1
1
1
1
1
1
2
2
1
-
1
1
1
1
1
1
1
1
1
1
1
1
-
V-Ring
Seal Ring
No Item
Retaining Ring
Extension Spring Anchor
Retaining Ring
GPM Decal (8 gpm Models) (Not Shown)
07324
37793
41764
03786
1
1
1
1
CE Decal
No Item
Seal Spacer
Sprocket
Washer
Chain Guard
Nut
Cord Stock, 3/16” Dia.
Motor Shaft (See Item #60 for Serial No. Break)
Needle Roller
38898
09098
41765
32255
32203
20721
43690
04044
02688
33360
1
SEAL KIT
HSHCS 5/16 -18 UNC x 3/4
28
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DS06 PARTS ILLUSTRATION
For Serial Numbers
356 and Below.
29
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For Serial Numbers
356 and Below.
DS06 PARTS LIST
Item Qty
No
Part
No.
Description
Item Qty
No
Part
No.
Description
1
2
3
8
1
1
1
1
00753 HSHCS 10-24UNCx1-1/4
33445 NAME TAG
11207 CIRCUIT "D" STICKER (8 gpm model)
11206 CIRCUIT "C" STICKER (5 gpm model)
07652 REAR GEAR HOUSING ASSY (INCLD ITEM 5 &
6), 8 gpm model only
07834 REAR GEAR HOUSING ASSY (INCLD ITEM 5 &
6), 5 gpm model only
00289 DOWEL PIN
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
1
1
-
-
-
60804 O-RING
•
19215 SEAL LINER
----- NO ITEM
----- NO ITEM
----- NO ITEM
----- SAW BAR (SEE ACCESSORIES)
----- NO ITEM
32196 FLAP MOUNT
33219 SPACER
32192 CHAIN GUIDE PLATE
32245 STUD
02446 HSHCS 1/4-20UNCx5/8
02687 MACHINE SCREW
•
4
1
-
1
1
1
1
2
1
1
1
1
5
6
7
8
9
2
4
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
2
1
1
3
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
2
1
1
1
1
04041 BUSHING
00020 O-RING 5-329 R17
07612 IDLER SHAFT
•
04105 IDLER GEAR, 8 gpm model only
07831 IDLER GEAR, 5 gpm model only
32190 PIVOT PIN
22716 ST ELBOW 1/8NPT
21550 WATER GAUGE
04106 DRIVE GEAR, 8 gpm model only
07832 DRIVE GEAR, 5 gpm model only
32207 ON/OFF VALVE
32191 STAT-O-SEAL
•
10
11
12
13
32198 BAR ADJUSTMENT NUT
33481 WALLWALKER CLEVIS PIN
SPRING (INCLD WITH ITEM 74)
----- CHAIN (SEE ACCESSORIES)
32206 WALL WALKER
02649 HANDLE BAR RETAINER
33229 HANDLE WELDMENT
33260 BHCS 1/4-20x.625 ZINC
33261 FENDER WASHER
33258 HAND GUARD
12412 WARNING STICKER-ELECT
12175 WASHER
33454 HHCS 5/16-18x5/8 ZINC
33263 HANDLE GRIP
33429 SPROCKET WRENCH
17134 NUT 1/4-20 HHD LT SST
31614 SPIROL PIN
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
07626 O-RING 2-014 R18
07609 SPRING WASHER
34119 SPRING
•
04512 RETAINING RING 1/2 EX
07625 PLUG BUTTON
03009 ROLL PIN
07624 ROLL PIN-3/16 X 1
32201 VALVE HANDLE ASSY (INCLD ITEMS 31 & 66)
01605 O-RING
01652 PIGTAIL HOSE ASSEMBLY
24059 MALE COUPLER
24058 FEMALE COUPLER
33443 WATER HOSE ASSY
34093 TRIGGER
07602 SPRING
34105 SAFETY CATCH
30635 SPIROL PIN 5/16 x 7/8
28409 COMPOSITE STICKER (CE)
11212 SOUND POWER LEVEL STICKER (CE)
00173 QUAD RING
04856 RETAINING RING
35965 BEARING
•
32197 STUD
33444 FLOW CONTROL VALVE, 8 gpm model only
34006 FLOW CONTROL VALVE, 5 gpm model only
00072 ROLL PIN
00621 O-RING
38897 SEAL WASHER
•
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
39070 V-RING
38700 SEAL RING
•
07627 O-RING 2-016 R24
00074 O-RING 2-021 R16
33488 SELF LOCKING RETAINING RING
•
•
1 350810 O-RING
1
-
07324 RETAINING RING
----- NO ITEM
05632 O-RING 2-005 R16
33377 WATER VALVE SLEEVE
•
100
1
34118 SUPPORT WASHER
01403 O-RING 2-020 R16
33380 PIN
•
33360
SEAL KIT
36259 STEEL BALL 3/8 DIA.
32188 SPRING
04052 O-RING 3-914 R17
32189 SEAL CAP
•
• Denotes Part in Seal Kit
28323 CE STICKER
06635 RET RING 1 3/8 INT
38898 SEAL SPACER
32210 SPROCKET
39071 TRANTORQUE™ ADAPTOR
32255 CHAIN GUARD
32203 NUT
20721 CORD STOCK 3/16DIA R1
35897 MOTOR SHAFT
04044 NEEDLE ROLLER
02688 HSHCS 5/16-18UNCx3/4
30
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DIAMOND CHAIN APPLICATIONS
Model
Bar Length
P/N
Correct Applications
Very hard aggregate concretes (flint, chert, granite, etc). Heavy steel
reinforcing, 5/8 inch/16 mm diameter and larger. Medium/hard aggre-
gate concretes (granite, quartz, river rock, etc). Moderate steel rein-
forcing (wire mesh 3/8-1/2 inch/10-12 mm diameter). Soft aggregate
concrete, concrete block, masonry, “green” concrete, highly abrasive
13 inch
Pinnacle-
Pinnacle-
Medium/hard aggregate concretes (granite, quartz, river rock, etc).
Moderate steel reinforcing (wire mesh 3/8-1/2 inch/10-12 mm di-
ameter). Soft aggregate concrete, concrete block, masonry, “green”
concrete, highly abrasive conditions.
Ultra-
Ultra-
13 inch
31
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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 obtain-
ing the written consent of Stanley.
WARRANTY REGISTRATION: STANLEY ASSUMES NO LIABILITY FOR WARRANTY CLAIMS SUBMITTED FOR WHICH NO TOOL REG-
ISTRATION 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.
32
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Stanley Hydraulic Tools
3810 SE Naef Road
Milwaukie OR 97267-5698
503-659-5660
FAX 503-652-1780
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