STANLEY DS11 HYDRAULIC DIAMOND SAW User Manual

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STANLEY DS11 HYDRAULIC DIAMOND SAW

IMPORTANT
To fill out a product warranty validation form, and for information on your warranty, visit www.stanleyinfrastructure.com and select the Company tab > Warranty.
Note:
The warranty validation record must be submitted to validate the warranty.
SERVICING: This manual contains safety, operation and routine maintenance instructions. STANLEY 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 IMPROPER REPAIR OR SERVICE OF THIS TOOL. REPAIRS AND / OR SERVICE TO THIS TOOL MUST ONLY BE DONE BY AN AUTHORIZED AND CERTIFIED DEALER.
For the nearest certified dealer, call STANLEY Infrastructure at 503-659-5660 and ask for a Customer Service Representative.
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 indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
This safety alert and signal word indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
This safety alert and signal word indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
This signal word indicates a potentially hazardous situation which, if not avoided, may result in property damage.
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.

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 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. Place the added precautions in the space provided. 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.

• 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 protection, breathing protection, 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 balance 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 energizing 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. High temperatures can cause 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:

•  With a basic understanding of kickbacks you can reduce or eliminate the element of surprise. Sudden surprise contributes to accidents.

• 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.

•  Make sure the area in which you are cutting is free of obstructions.

• Cut at rated operating speeds (GPM).

•  Do not overreach or cut above shoulder height.

• Only use replacement bars and chains specified by STANLEY.

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

•  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.

• Do not operate a hydraulic power source or a hydraulic diamond saw in an explosive atmosphere.

• WARNING:
  Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are:

•  Lead from lead-based paints,

•  crystalline silica from bricks and cement and other masonry products, and

•  arsenic and chromium from chemically-treated lumber.
  Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemicals: work in a well ventilated area, and work with approved safety equipment, such as those dust masks that are specially designed to filter out microscopic particles. Protect yourself and those around you. Research and understand the materials you are cutting. Follow correct safety procedures and comply with all applicable national, state or provisional health and safety regulations relating to them, including, if appropriate arranging for the safe disposal of the materials by a qualified person.

•  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, including loose clothing and long hair.

• Carry the chain saw with the tool de-energized 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 utilities 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.

• Avoid contact with the saw bar rails as they can become very sharp during use.

•  Provide adequate lighting when operating the saw in a darkened area or at night.

• Always keep critical tool markings, such as labels and warning stickers, legible. Replace stickers and decals that have become worn or damaged.

•  Be observant of hydraulic and water hoses that lay about the work area, especially in trenches where they can be hidden from view due to liquids that have accumulated within the space.

•  Keep all parts of the body away from the cleats that are attached to the saw, as these are sharp and can be a puncture hazard.

•  Improper handling, use or maintenance can result in an oil leak or burst. Do not contact an oil leak as high pressure oil can cause injection into the body.

• Never stand in the path of the discharge, as ejection of material from the work piece can cause personal injury.

• Never use the saw in a potentially explosive atmosphere.

•   WARNING:
  Hydraulic fluid under pressure can cause skin injection injury. If injured by hydraulic fluid, get medical attention immediately.

TOOL STICKERS & TAGS

• 76544 CE Tool Plate
  
  

• DS113000 Only
  The safety tag (p/n 88346) 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.
  

• 88347 Composite Decal

• Warning Decal

• 12535

• Circuit “E” Decal – DS115000 Only 11207 Circuit “D” Decal – DS113000 Only

• NAME TAG

• Sound Level Decal

HOSE TYPES

The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the hydraulic system. There are three types of hydraulic hose that meet this requirement and are authorized for use with STANLEY hydraulic tools. They are:
Certified non-conductive — constructed of thermoplastic or synthetic rubber inner tube, synthetic fiber braid reinforcement, and weather resistant thermoplastic or synthetic rubber cover. Hose labeled certified non-conductive is the only hose authorized for use near electrical conductors.
Wire-braided (conductive) — constructed of synthetic rubber inner tube, single or double wire braid reinforcement, and weather resistant synthetic rubber cover. This hose is conductive and must never be used near electrical conductors.
Fabric-braided (not certified or labeled non-conductive) — constructed of thermoplastic or synthetic rubber inner tube, synthetic fiber braid reinforcement, and weather resistant thermoplastic or synthetic rubber cover. This hose is not certified non-conductive and must never be used near electrical conductors.
HOSE SAFETY TAGS
To help ensure your safety, the following DANGER tags are attached to all hose purchased from STANLEY. 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

• THE TAG SHOWN BELOW IS ATTACHED TO “CONDUCTIVE” HOSE.
  
  

HOSE RECOMMENDATIONS

Tool to Hydraulic Circuit Hose Recommendations
The chart to the right shows recommended minimum hose diameters for various hose lengths based on gallons per minute (GPM)/liters per minute (LPM). These recommendations are intended to keep return line pressure (back pressure) to a minimum acceptable level to ensure maximum tool performance. This chart is intended to be used for hydraulic tool applications only based on STANLEY tool operating requirements and should not be used for any other applications. All hydraulic hose must have at least a rated minimum working pressure equal to the maximum hydraulic system relief valve setting. All hydraulic hose must meet or exceed specifications as set forth by SAE J517.

Oil Flow| Hose Lengths| Inside Diameter| USE

( Press/Return)

| Min. Working Pressure
---|---|---|---|---
GPM| LPM| FEET| METERS| INCH| MM| PSI| BAR
Certified Non-Conductive Hose – Fiber Braid – for Utility Bucket Trucks
4-9| 15-34| up to 10| up to 3| 3/8| 10| Both| 2250| 155
Conductive Hose – Wire Braid or Fiber Braid -DO NOT USE NEAR ELECTRICAL CONDUCTORS
4-6| 15-23| up to 25| up to 7.5| 3/8| 10| Both| 2500| 175
4-6| 15-23| 26-100| 7.5-30| 1/2| 13| Both| 2500| 175
5-10.5| 19-40| up to 50| up to 15| 1/2| 13| Both| 2500| 175
5-10.5| 19-40| 51-100| 15-30| 5/8| 16| Both| 2500| 175

5-10.5

|

19-40

|

100-300

|

30-90

| 5/8| 16| Pressure| 2500| 175
3/4| 19| Return| 2500| 175
10-13| 38-49| up to 50| up to 15| 5/8| 16| Both| 2500| 175

10-13

|

38-49

|

51-100

|

15-30

| 5/8| 16| Pressure| 2500| 175
3/4| 19| Return| 2500| 175

10-13

|

38-49

|

100-200

|

30-60

| 3/4| 19| Pressure| 2500| 175
1| 25.4| Return| 2500| 175

13-16

|

49-60

|

up to 25

|

up to 8

| 5/8| 16| Pressure| 2500| 175
3/4| 19| Return| 2500| 175

13-16

|

49-60

|

26-100

|

8-30

| 3/4| 19| Pressure| 2500| 175
1| 25.4| Return| 2500| 175

•  Typical Hose Connections

HTMA / EHTMA REQUIREMENTS

HTMA / EHTMA REQUIREMENTS
TOOL TYPE

HTMA HYDRAULIC SYSTEM REQUIREMENTS

| TYPE I| TYPE II| TYPE RR| TYPE III
---|---|---|---|---
Flow range| 4-6 GPM

(15-23 LPM)

| 7-9 GPM

(26-34 LPM)

| 9-10.5 GPM

(34-40 LPM)

| 11-13 GPM

(42-49 LPM)

Nominal operating pressure (At the power supply outlet)| 1500 psi

(103 bar)

| 1500 psi

(103 bar)

| 1500 psi

(103 bar)

| 1500 psi

(103 bar)

System relief valve setting (At the power supply outlet)| 2100-2250 psi

(145-155 bar)

| 2100-2250 psi

(145-155 bar)

| 2200-2300 psi

(152-159 bar)

| 2100-2250 psi

(145-155 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 minimum operating temperature)

| 400 ssu*

(82 centistokes)

| 400 ssu*

(82 centistokes)

| 400 ssu*

(82 centistokes)

| 400 ssu*

(82 centistokes)

Temperature: Sufficient heat rejection capacity to limit maximum fluid temperature to:

(At maximum expected ambient temperature)

| 140° F

(60° C)

| 140° F

(60° C)

| 140° F

(60° C)

| 140° F

(60° C)

Minimum cooling capacity at a temperature difference of between ambient and fluid temps| 3 hp

(2.24 kW)

40° F

(22° C)

| 5 hp

(3.73 kW)

40° F

(22° C)

| 6 hp

(5.22 kW)

40° F

(22° C)

| 7 hp

(4.47 kW)

40° F

(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 minimum full-flow filtration| 25 microns

30 GPM

)   (114 LPM)

100-400 ssu

m      (20-82

centistokes)

| 25 microns| 25 microns| 25 microns
Sized for flow of at least:

(For cold temp startup and maximum dirt-holding capacity)

| 30 GPM

(114 LPM)

| 30 GPM

(114 LPM)

| 30 GPM

(114 LPM)

Hydraulic fluid, petroleum based (premium grade, anti-

wear, non-conductive) Viscosity (at minimum and maximum operating temps)

| 100-400 ssu

(20-82

centistokes)

| 100-400 ssu

(20-82

centistokes)

| 100-400 ssu

(20-82

centistokes)

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

• **** SSU = Say bolt Seconds Universal

CLASSIFICATION

EHTMA HYDRAULIC SYSTEM REQUIREMENTS| | | | |
---|---|---|---|---|---
Flow range| 3.5-4.3 GPM

(13.5-16.5

LPM)

| 4.7-5.8 GPM

(18-22 LPM)

| 7.1-8.7 GPM

(27-33 LPM)

| 9.5-11.6 GPM

(36-44 LPM)

| 11.8-14.5 GPM

(45-55 LPM)

Nominal operating pressure (At the power supply outlet)| 1870 psi

(129 bar)

| 1500 psi

(103 bar)

| 1500 psi

(103 bar)

| 1500 psi

(103 bar)

| 1500 psi

(103 bar)

System relief valve setting (At the power supply outlet)| 2495 psi

(172 bar)

| 2000 psi

(138 bar)

| 2000 psi

(138 bar)

| 2000 psi

(138 bar)

| 2000 psi

(138 bar)

Note:
These are general hydraulic system requirements. See tool specification page for tool specific requirements.

OPERATION

PREPARATION 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.
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 hoses first and disconnect them last to minimize or avoid trapped pressure within the chain saw.
3. Observe the arrow on the couplers to ensure that the 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.
   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.

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.
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 P/N 29361).

CHECK CHAIN AND BAR ADJUSTMENT

1.  Check the chain tension often during operation, especially 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 Maintenance and Adjustments 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.
   

   • Maximum Chain Clearance

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

CHECK CHAIN SEGMENT WEAR

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

   • 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.

CHECK THE WATER SUPPLYCHECK 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.
   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 Maintenance 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).
   

   •  Chain Direction

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 STANLEY Representative. They can often provide information that will make your work safer and more productive.
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.
   

   • 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 DS11 can be operated using the types of cuts shown in Figure 6. When making cuts:

• 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.

MAINTENANCE & ADJUSTMENTS

GENERAL MAINTENANCE TIPS
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.
UNDERWATER MODEL MAINTENANCE
After each use, the movable portions of the tool that were exposed to water should be flushed with a water displacing oil, such as WD40™. Remove water and de-bris as follows:

1. Spray oil through the tool and displace any remaining water.

2. Spray oil into the On/Off trigger slot area

3.  Dip or spray the entire tool.

4. Cycle the tool hydraulically several times before storing away.
   SAW BAR RAIL
   A quick check can be made to determine if saw bar rail or chain segment wear exists. Figure 6 shows a worn saw bar rail.
   

   • 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 .
     Also make sure the saw bar is perfectly straight. If bows or bends are present in the saw bar, it must be replaced before dressing any rail.
     ROTATING THE SAW BAR
     Maximum saw bar life can be achieved by occasionally turning the bar over so the top and bottom bar surfaces wear evenly. Refer to the saw bar disassembly
     procedures in the Service Manual for further details.
     CHAIN TENSION ADJUSTMENT
     Correct chain tension is very important throughout the life of the chain. Check the chain tension often during use (when the chain saw is stopped and the saw bar and chain have cooled off). The chain should move easily around the saw bar when pulled by hand. To adjust the chain tension:

5.  Turn off the water and power supplies.

6.  Loosen the two saw bar attachment nuts (Item 62, Parts Illustration).

7. 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 .
   

   • Pulling the Chain

8. Using hand and finger protection pull the chain around the saw bar to make sure it properly fits the sprocket and saw bar. The chain should be easily pulled.

9. 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.

• Exposed Drive Link Tang

SERVICING THE CHAIN
The following procedures explain how to break a chain using the STANLEY bench mounted chain breaker (P/N 20858) to remove a worn or damaged segment.

•  Exposed Drive Link Tang

SERVICING THE CHAIN
The following procedures explain how to break a chain using the STANLEY bench mounted chain breaker (P/N 20858) to remove a worn or damaged segment.

•  Mount the chain breaker flush with the side or front of a flat, clean work surface .
  

• 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 11 are the only ones that can be removed.

• Removable Rivet Heads
• 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.

•  Inserting the Chain

• Position the rivet head you want removed directly under the chain breaker punch and then pull the handle down far enough to remove the rivet (Figure 13). Do not use excessive force.
  

• Removing a Rivet

REPLACING THE CHAIN BREAKER PUNCH
If the chain breaker punch (P/N 22801) becomes worn or damaged, use the following procedures for replacement.

• Remove the punch by loosening the set screw.
  

• Removing the Punch

• Insert a new punch into the holder and push it up until it is fully seated (Figure 15). Secure the punch to the chain breaker holder by fully tightening the set screw.
  

• Replacing the Punch

SPINNING RIVETS
The following procedures explain how to spin rivets using the STANLEY bench- mounted rivet spinner (P/N 20857) to assembly the chain.

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

   • 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  .
   

   • Positioning the Chain

3.  Turn the take-up handle until the chain is tight against the spinner anvil .
   

   • Securing the Chain

4. Turn the rivet spinner crank a few times to center the rivet hub in the spinner anvil .
   

   • Centering the Rivet Hub

5.  Apply a few drops of oil to the rivet hub.
   

   • 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 .

Note:
The take-up handle provides pressure while the spinner anvil forms the rivet head.

•  Forming a Rivet Head

Note:
The rivet spinner is equipped with oiling chambers and should be maintained periodically with a light-weight oil .

• Spinner Oiling Chambers

• TOOL PROTECTION & CARE

NOTICE
In addition to the safety precautions found in this manual, observe the following for equipment protection and care.

• Make sure all couplers are wiped clean before connection.
•  The hydraulic circuit control valve must be in the “OFF” position when coupling or uncoupling hydraulic tools. Failure to do so may result in damage to the quick couplers and cause overheating of the hydraulic system.
•  Always store the tool in a clean dry space, safe from damage or pilferage.
• Make sure the circuit PRESSURE hose (with male quick disconnect) is connected to the “IN” port. The circuit RETURN hose (with female quick disconnect) is connected to the opposite port. Do not reverse circuit flow. This can cause damage to internal seals.
•  Always replace hoses, couplings and other parts with replacement parts recommended by STANLEY. Supply hoses must have a minimum working pres-sure rating of 2500 psi/172 bar.
• Do not exceed the rated flow and pressure. Rapid failure of the internal seals may result. “SPECIFI-CATIONS” on page 20 for correct flow rate and pressure.
•  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.

TROUBLESHOOTING

If symptoms of poor performance develop, the following chart can be used as a guide to correct the problem. When diagnosing faults in operation of the tool, always check that the hydraulic power source is supplying the correct hydraulic flow and pressure to the tool as listed in the following table. Use a flow meter known to be accurate. Check the flow with the hydraulic fluid temperature at least 80 °F/27 °C.

chain.
Excessive feed force.| Reduce feed force.
Chain saw will not cut straight.| Operator feed force not applied directly over center line of saw.

Accumulated saw bar wear and

uneven chain segment profile wear.

| Move left hand closer to center line of saw bar. Turn the saw bar over and dress rails square. Replace the saw bar and chain.
Loss of power.| Drive sprocket slipping on Trantorque® adapter.| Adjust and tighten Trantorque® adapter, (35 ft lbs/47 Nm).
Tool does not run.| Power source not functioning.| Check power source for proper flow and pressure (7–9 GPM/26–34 LPM @ 2000 psi/140 bar).
Coupler or hoses are blocked.| Remove obstruction.
Mechanical failure.| Disassemble the chain saw and inspect fo damage.
Tool runs backwards.| Pressure and return hoses reversed.| Connect for proper flow direction. Motor

shaft must rotate clockwise.

Trigger is hard to press.| Pressure and return hoses reversed.| Connect to proper flow direction. Motor

shaft must rotate clockwise.

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.

Fluid leakage around drive sprocket.| Motor shaft seal failure.| Replace as required.
Fluid leakage between the rear gear housing and the chain saw adaptor.| Motor face seal failure.| Replace as required.
Fluid leakage between the valve

handle and the extension housing.

| Oil tube seal failure.| Replace as required.
Fluid leakage between the extension housing assembly and the chain saw adaptor.| Oil tube seal failure.| Replace as required.
Chain saw cuts slowly.| Insufficient hydraulic fluid flow or low

relief valve setting.

| Adjust proper hydraulic fluid flow to proper

GPM. For optimum performance, adjust

relief valve to 2100–2250 psi/145–155 bar

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 clearance.| Replace the chain.
Hydraulic fluid mixed in water supply| Check motor for leaks.
Chain segment dulled because of continuous use in hard material or rebar.| Redress segment by cutting in abrasive material (i.e., concrete, build-block, etc.).

Note: This indicates that the wrong chain is being used.

Wrong chain for application.| Scale down to a lower numbered chain.
Wire edged bar rails.| Dress rails square.
Excessive vibration and cuts rough.| Segment(s) broken or missing from chain.| Remove and repair broken segment or replace chain.

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 / 12 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
• Sound Power Level………………………………………………………………………………………………………………………..103 dBa
• Sound Pressure Levels………………………………………………………………………………………………………………….95.1 dBa
• Vibration Level, 3 axis (Trigger Handle)………………………………………………………………………………………… 2.3 m/sec²
• Vibration Level, 3 axis (Non-Trigger Handle)…………………………………………………………………………………. 2.5 m/sec²
• Uncertainty, K……………………………………………………………………………………………………………………………. 1.1 m/sec²

ACCESSORIES

• Chain Repair Spinner………………………………………………………………………………………………………………………..20857
• Diamond Chain Repair Breaker………………………………………………………………………………………………………….20858
• Diamond Chain Repair Kit (includes P/N 20857 & 20858)………………………………………………………………………20856
• Wall Walker (Standard Equipment on Newer Models)……………………………………………………………………………23176
• Drive Sprocket………………………………………………………………………………………………………………………………….20470
• Replacement Nose Sprocket………………………………………………………………………………………………………………22800
• Sprocket Wrench………………………………………………………………………………………………………………………………23517
• 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
• Diamond Ultra-32, Sealed Chain for 15 inch Bar…………………………………………………………………………………..56801
• Diamond Pinnacle-32, Sealed Chain for 15 inch Bar……………………………………………………………………………..56803
• Diamond Ultra-37, Sealed Chain for 18 inch Bar…………………………………………………………………………………..56802
• Diamond Pinnacle-37, Sealed Chain for 18 inch Bar……………………………………………………………………………..58632
• Water Pump, 12 VDC, DC Plug…………………………………………………………………………………………………… DCP30100
• Water Pump, 12 VDC, Battery Clips…………………………………………………………………………………………….. DCP30101

DS11 PARTS ILLUSTRATION

DS11 PARTS LIST

ITEM

| PART

NO.

|

QTY

|

DESCRIPTION

---|---|---|---
1.| 02764| 3| CAP SCREW – 5/16-18 X 3/4
2.| 02643| 3| WASHER
3.| 20461| 1| HANDLE STRUT
4.| 22713| 1| CHAIN SAW ADAPTOR
5.| 88347| 1| COMPOSITE SAFETY STICKER
6.| 12412| 1| ELECTRICAL DANGER STICKER
7.| 81779| 1| HANDLE RETAINER
8.| 73583| 1| HANDLE SPACER
9.| 73582| 1| HAND GUARD
10.| 33261| 1| WASHER
11.| 33260| 1| CAP SCREW – 1/4-20 X 5/8
12.| 22752| 1| NYLOCK NUT – 5/16-18 UNC
13.| 22702| 1| BAR ADJUSTMENT NUT
14.| 22714| 1| SCREW – 5/16-18 X 2.750
15.| 20465| 2| STUD
16.| 23176| 1| WALL WALKER
17.| 22711| 1| CHAIN GUARD
18.| 02766| 2| WASHER
19.| 03276| 2| HEX NUT – 3/8-16 UNC
20.| 22945| 1| CHAIN COVER
21.| 23196| 2| CAP SCREW – 5/16 UNC X 3/8 HSBH
22.| 20471| 1| TRANTORQUE ADAPTER – TORQUE TO 23-30 FT. LBS.
23.| 20470| 1| DRIVE SPROCKET
24.| 02649| 2| HANDLE RETAINER
25.| 02764| 3| CAP SCREW – 5/16-18 X 3/4
26.| 03006| 4| CAP SCREW – 5/16-18 X 3/4 HSFT
27.| 01758| 4| CAP SCREW – 5/16-18 X 3-1/2
28.| 00112| 1| QUAD RING – 1/4 X 3/8 X 1/16-010
29.| 01604| 2| O-RING – .755 X .949 X .097-910
30.| 02931| 1| ON-OFF VALVE CAP
31.| 02925| 1| VALVE SPOOL
32.| 02920| 1| ON-OFF VALVE SPACER
33.| 08104| 1| PLUG
34.| 31804| 1| ROLL PIN
35.| 74841| 1| ROLL PIN
36.| 02004| 2| DRIVE SCREW
37.| 76544| 1| CE TOOL PLATE
38.| 00018| 1| O-RING – 7/16 X 9/16 X 1/16-013
39.| 25260| 1| QUAD RING – 3/8 X 1/2 X 1/16-012
40.| 20463| 1| WATER VALVE
41.| 01211| 1| O-RING – 5/8 X 3/4 X 1/16-016
42.| 20458| 1| SPRING
43.| 350237| 1| PLUG
44.| 00175| 8| O-RING – 1/2 X 5/8 X 1/16-014
45.| 02912| 2| OIL TUBE
46.| 20453| 1| EXTENSION HOUSING

I TEM

| PART

NO.

|

QTY

|

DESCRIPTION

---|---|---|---
47.| 00174| 2| OIL TUBE
48.| 350023| 1| PLUG
49.| 28552| 1| HANDLE ASSEMBLY – INCLUDES

PART 08104 – MUST PURCHASE WITH PART 74841.

50.| 02916| 1| SPRING
51.| 01604| 2| O-RING – .755 X .949 X .097-910*
52.| 09437| 1| PLUG
53.| 00787| 1| CAP SCREW – 1/4-20 X 1-1/4 HSFT SST
54.| 88356| 1| SOUND POWER STICKER
55.| 20459| 1| HOSE CLIP
56.| 22707| 1| TRIGGER
57.| 22704| 1| SAFETY CATCH
58.| 22701| 1| SPRING
59.| 71799| 1| FLOW REGULATOR CARTRIDGE (DS113000)
| 71835| 1| FLOW REGULATOR CARTRIDGE (DS115000)
60.| 00208| 8| CAP SCREW – 1/4-20 X 1-3/4
61.| 74804| 1| TOOL NAME TAG (DS113000)
| 74807| 1| TOOL NAME TAG (DS115000)
62.| 09612| 1| GENERAL CAUTION STICKER
63.| 02936| 1| HANDLE (DS113000)
| 23754| 1| HANDLE (DS115000)
64.| 03006| 4| CAP SCREW – 5/16-18 X 3/4 HSFT
65.| 22715| 1| CAP SCREW – 5/16-18 X 5/8
66.| 11207| 1| CIRCUIT TYPE “D” STICKER (DS113000) – NOT SHOWN
| 12535| 1| CIRCUIT TYPE “E” STICKER (DS115000) – NOT SHOWN
*SEAL KIT P/N 22798

00018| O-RING| 1
00112| QUAD RING| 1
00173| QUAD RING| 1
00175| O-RING| 8
00178| O-RING| 1
00669| QUAD RING| 1
01211| O-RING| 2
01604| O-RING| 2
01605| O-RING| 3
02905| O-RING| 1
03110| TEFLON SEAL| 1
03847| HOSE WASHER| 1
25260| QUAD RING| 1
350771| O-RING| 1

DS11 MOTOR PARTS LIST

U/W – DENOTES USED ON UNDER WATER MODEL ONLY

GEAR HOUSING ASSY (U/W
DS115000) Incds Items 13 & 20

16| 19884| 1| SEAL GLAND
17| 20466| 1| MOTOR SHAFT
| 23752| 1| MOTOR SHAFT (U/W)
18| 20472| 1| RETAINING RING EXTERNAL
19| 21436| 1| FRONT BEARING HOUSING ASSY (INCLUDES ITEM 13 & EXPANDER PLUGS)
20| 25444| 2| DOWEL PIN 1/4 X 1
22| 73308| 1| IDLER SHAFT KEYED
| 73309| 1| IDLER SHAFT KEYED (U/W DS115000)
23| 350771| 1| O-RING*

DS11 PARTS LIST

DIAMOND CHAIN APPLICATIONS

18 INCH

| 56803

58632

| 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.
ULTRA-32 ULTRA-37| 15 INCH

18 INCH

| 56801

56802

| 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.

UNDERWATER TOOLS DEPTH GUIDELINE

UNDERWATER MODELS ONLY
CAUTION
Do not use hydraulic tools underwater that are not designated as an “underwater” model, or this will result in damage to the tool. For underwater hydraulic tools the applications are broken down into four quadrants depending on type of tool and method of operation. The types of tools are percussive and rotational, each with different characteristics allowing for different depth operation. With percussive tools, the nitrogen accumulator PSI must counter the increase in ambient pressure found at lower depths. Since there is a maximum PSI for percussive tools they are limited to certain depths. Rotational tools do not have accumulators and thus are capable of deeper depths.
The methods are broken into diver operated or remote operated vehicle (ROV). ROV’s can reach lower depths and with an onboard hydraulic power source that is depth compensated, can operate hydraulic tools at depths of thousands of feet. ROV operation is still limited to the tool, for example a percussive tool has the same depth limitation whether ROV or diver operated.
OPERATION OVERVIEW

| PERCUSSIVE| ROTATIONAL
---|---|---
DIVER| Tools: Breakers, Hammer Drills and Chipping Hammers| Tools: Grinders, Saws, Chain Saws
Max Depth: 500’ – limitations due to accumulator PSI max (increase 40 PSI for every 100’)| Max Depth: 1000’ – Reference hose sizing guide below
ROV| Tools: Breakers, Hammer Drills and Chipping Hammers| Tools: Grinders, Saws, Chain Saws
Max Depth: 500’ – limitations due to accumulator PSI max (increase 40 PSI for every 100’)| Max Depth: 1000’ – Reference hose sizing guide below
RECOMMENDED HOSE DIAMETERS

DEPTH (FT)| 8 GPM| 12 GPM
100| 5/8”| 5/8”
300| 3/4”| 1”
600| 1”| 1”
1000| 1”| 1-1/4”

Documents / Resources

| STANLEY DS11 HYDRAULIC DIAMOND SAW [pdf] User Manual
DS11 HYDRAULIC DIAMOND SAW, HYDRAULIC DIAMOND SAW, DIAMOND SAW
---|---

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