CO23
HYDRAULIC
CUTOFF SAW
USER MANUAL
Safety, Operation and Maintenance
© 2014 Stanley Black & Decker, Inc.
New Britain, CT 06053
U.S.A.
72409 7/2014 Ver. 7
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TABLE OF CONTENTS
DECLARATION OF CONFORMITY..........................................................................................................................2
SAFETY SYMBOLS ..................................................................................................................................................4
SAFETY PRECAUTIONS..........................................................................................................................................5
TOOL STICKERS & TAGS........................................................................................................................................6
HOSE TYPES............................................................................................................................................................7
HOSE RECOMMENDATIONS ..................................................................................................................................8
FIGURE 1. TYPICAL HOSE CONNECTIONS.......................................................................................................8
HTMA REQUIREMENTS...........................................................................................................................................9
OPERATION............................................................................................................................................................10
TROUBLESHOOTING ............................................................................................................................................13
SPECIFICATIONS...................................................................................................................................................14
ACCESSORIES.......................................................................................................................................................14
SERVICE TOOLS....................................................................................................................................................14
CO23 PARTS ILLUSTRATION................................................................................................................................15
CO23 PARTS LIST..................................................................................................................................................16
UNDERWATER TOOLS DEPTH GUIDELINE.........................................................................................................17
IMPORTANT
To fill out a Product Warranty Recording form, and for information on your warranty,
visit Stanleyhydraulics.com and select the Company tab, Warranty.
(NOTE: The warranty recording form must be submitted to validate the warranty).
SERVICING: This manual contains safety, operation, and routine maintenance instructions. 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 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.
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SAFETY SYMBOLS
Safety symbols and signal words, as shown below, are used to emphasize all operator, maintenance and repair ac-
tions which, if not strictly followed, could result in a life-threatening situation, bodily injury or damage to equipment.
This is the safety alert symbol. It is used to alert you to potential personal injury
hazards. Obey all safety messages that follow this symbol to avoid possible
injury or death.
This safety alert and signal word indicate an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
DANGER
WARNING
CAUTION
This safety alert and signal word indicate a potentially hazardous situation
which, if not avoided, could result in death or serious injury.
This safety alert and signal word indicate a potentially hazardous situation
which, if not avoided, could result in death or serious injury.
This signal word indicates a potentially hazardous situation which, if not avoid-
ed, may result in property damage.
CAUTION
NOTICE
This signal word indicates a situation which, if not avoided, will result in damage
to the equipment.
This signal word indicates a situation which, if not avoided, may result in dam-
age 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.
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SAFETY PRECAUTIONS
•
Never transport or store the tool with the wheel
mounted on the saw.
•
The cutoff saw is designed to provide safe and de-
pendable service if operated according to instruc-
tions. Read and understand this manual and any
decals attached to the saw before operating. Failure
to do so could result in personal injury or equipment
damage.
•
Do not operate the tool if it is damaged, improperly
adjusted or not completely and correctly assembled.
•
•
Never cock, jam or wedge the wheel during the cut.
Never cause sparks in the vicinity of flammable ma-
terials.
•
•
•
•
•
•
•
•
•
Do not operate the tool with the wheel guard re-
moved.
•
•
New operators must start in a work area without by-
standers. He/she must be familiar with all prohibited
work areas such as excessive slopes and danger-
ous terrain conditions.
Do not start cutting until you have a clear work area
and secure footing.
When using tools around energized transmission
lines, be sure to use only hoses labeled and certi-
fied non-conductive and follow all safety practices.
Do not allow other persons near the tool when start-
ing or cutting.
Never operate the tool when you are tired or fa-
tigued.
•
•
Know the location of buried or covered services be-
fore starting your work.
Do not use a wheel that is cracked or otherwise
damaged.
Do not inspect or clean the tool with the power
source operating or with operating pressure at the
tool. Accidental engagement of the tool can cause
serious injury.
Do not operate the tool if the wheel does not stop
when the throttle trigger is released.
Do not use the side of the wheel as the cutting sur-
face.
•
•
•
Never wear loose clothing that can get entangled in
the working end of the tool.
Never exceed the maximum operating speed
marked on the wheel.
Do not overreach. Maintain proper footing and bal-
ance at all times.
Always use cutoff wheels that conform to the speci-
fications given in the OPERATION section of this
manual.
Always connect hoses to the tool hose couplers be-
fore energizing the power source. Be sure that all
hose connections are tight.
•
•
•
Always wear safety equipment such as goggles, ear
protection, safety shoes, and head protection at all
times when operating the tool.
•
Do not operate the tool at oil temperatures above
140 °F/60 °C. Operation at higher temperatures can
cause higher than normal temperatures at the tool,
which can result in operator discomfort.
Do not reverse wheel rotation direction by chang-
ing oil flow direction. Obtain a saw designed for the
wheel direction that you desire.
•
•
•
Always hold the tool with both hands when the unit
is running. Use a firm grip.
Whenever working near electrical conductors, al-
ways assume that all conductors are energized and
that insulating devices and clothing and hydraulic
hoses may conduct electricity. Always use nonme-
tallic braided hoses and ensure that the hydraulic oil
is free of moisture.
Keep all parts of your body away from a rotating cut-
off wheel.
Keep the wheel off all surfaces when starting the
saw.
•
•
Always carry the tool with the wheel stopped.
•
Warning: Use of this tool on certain materials during
demolition could generate dust potentially contain-
ing a variety of hazardous substances such as as-
bestos, silica or lead. Inhalation of dust containing
these or other hazardous substances could result
in serious injury, cancer or death. 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
Make sure the wheel has stopped before setting
down the tool.
•
•
Keep the handles clean and free of oil at all times.
All service must be performed by experienced ser-
vice personnel only.
•
•
•
Always inspect wheels for possible damage before
installation.
Establish a training program for all operators to en-
sure safe operation.
Do not operate the tool unless thoroughly trained.
person.
CO23 User Manual ◄ 5
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TOOL STICKERS & TAGS
72880
CO23 Information Sticker
02751
Name Tag Sticker
28788
Manual Sticker
14090
Stanley Logo Sticker
12535
EHTMA “E” Sticker
12536
EHTMA “F” Sticker
72893
Rotation Direction Sticker
D A N G E R
D A N G E R
1. FAILURE TO USE HYDRAULIC HOSE LABELED AND CER-
TIFIED 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 HOSES ARE PROPERLY CON-
NECTED TO THE TOOL BEFORE PRESSURING SYSTEM.
SYSTEM PRESSURE HOSE MUST ALWAYS BE CON-
NECTED TO TOOL “IN” PORT. SYSTEM RETURN HOSE
MUST ALWAYS BE CONNECTED TO TOOL “OUT” PORT.
REVERSING CONNECTIONS MAY CAUSE REVERSE
TOOL OPERATION WHICH CAN RESULT IN SEVERE
PERSONAL INJURY.
BEFORE USING HOSE LABELEDAND CERTIFIEDAS NON-
CONDUCTIVE ON OR NEAR ELECTRIC LINES BE SURE THE
HOSE IS MAINTAINED AS NON-CONDUCTIVE. THE HOSE
SHOULD BE REGULARLY TESTED FOR ELECTRIC CUR-
RENT LEAKAGE IN ACCORDANCE WITH YOUR SAFETY
DEPARTMENT INSTRUCTIONS.
2. A HYDRAULIC LEAK OR BURST MAY CAUSE OIL INJEC-
TION INTO THE BODY OR CAUSE OTHER SEVERE
PERSONAL INJURY.
4. DO NOT CONNECT OPEN-CENTER TOOLS TO CLOSED-
CENTER HYDRAULIC SYSTEMS. THIS MAY RESULT IN
LOSS OF OTHER HYDRAULIC FUNCTIONS POWERED BY
THE SAME SYSTEMAND/OR SEVERE PERSONAL INJURY.
72881
A. DO NOT EXCEED SPECIFIED FLOW AND PRESSURE
FOR THIS TOOL. EXCESS FLOW OR PRESSURE MAY
CAUSE A LEAK OR BURST.
Abrasive Wheel Warning Sticker
5. BYSTANDERS MAY BE INJURED IN YOUR WORK AREA.
KEEP BYSTANDERS CLEAR OF YOUR WORK AREA.
B. DO NOT EXCEED RATED WORKING PRESSURE OF
HYDRAULIC HOSE USED WITH THIS TOOL. EXCESS
PRESSURE MAY CAUSE A LEAK OR BURST.
6. WEAR HEARING, EYE, FOOT, HAND AND HEAD PRO-
TECTION.
7. TO AVOID PERSONAL INJURY OR EQUIPMENT DAMAGE,
ALL TOOL REPAIR MAINTENANCE AND SERVICE MUST
ONLY BE PERFORMED BY AUTHORIZED AND PROPERLY
TRAINED PERSONNEL.
C. CHECK TOOL HOSE COUPLERS AND CONNECTORS
DAILY FOR LEAKS. DO NOT FEEL FOR LEAKS WITH
YOUR HANDS. CONTACT WITH A LEAK MAY RESULT
IN SEVERE PERSONAL INJURY.
The safety tag (P/N 15875) at right is attached to
the tool when shipped from the factory. Read and
understand the safety instructions listed on this tag
before removal. We suggest you retain this tag and
attach it to the tool when not in use.
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
STANLEY AND DESCRIBED IN THE
OPERATION MANUAL.
USE ONLY PARTS AND REPAIR
PROCEDURES APPROVED BY
STANLEY AND DESCRIBED IN THE
OPERATION 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)
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HOSE TYPES
The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the hy-
draulic 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 reinforce-
ment, 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 in-
ner 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 Hydraulic
Tools. DO NOT REMOVE THESE TAGS.
If the information on a tag is illegible because of wear or damage, replace the tag immediately. A new tag may be
obtained from your Stanley Distributor.
THE TAG SHOWN BELOW IS ATTACHED TO “CERTIFIED NON-CONDUCTIVE” HOSE
D A N G E R
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 MAY RESULT IN
DEATH OR SERIOUS INJURY.
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.
FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROP-
ERLY TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND
ELECTRIC LINES.
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 FIT-
TING WITH A CLEAN DRY ABSORBENT CLOTH TO REMOVE DIRT AND MOISTURE AND
TEST HOSE FOR MAXIMUM ALLOWABLE CURRENT LEAKAGE IN ACCORDANCE WITH
SAFETY DEPARTMENT INSTRUCTIONS.
5. CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS, BULGES, OR DAM-
AGE TO COUPLINGS IF ANY OF THESE CONDITIONS EXIST, REPLACE THE HOSE
IMMEDIATELY. NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE.
6. AFTER EACH USE STORE IN A CLEAN DRY AREA.
SEE OTHER SIDE
SEE OTHER SIDE
SIDE 1
SIDE 2
(Shown smaller than actual size)
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 LEAKSABRASIONS, 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 ELEC-
TRIC 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
SEE OTHER SIDE
SIDE 1
SIDE 2
(Shown smaller than actual size)
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HOSE RECOMMENDATIONS
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HTMA / EHTMA REQUIREMENTS
HTMA / EHTMA REQUIREMENTS
HTMA
TOOL TYPE
HYDRAULIC SYSTEM REQUIREMENTS
TYPE I
TYPE II
TYPE RR
9-10.5 gpm
(34-40 lpm)
1500 psi
TYPE III
11-13 gpm
(42-49 lpm)
1500 psi
4-6 gpm
7-9 gpm
Flow Range
(15-23 lpm)
1500 psi
(103 bar)
(26-34 lpm)
1500 psi
(103 bar)
Nominal Operating Pressure
(at the power supply outlet)
(103 bar)
(103 bar)
2100-2250 psi
(145-155 bar)
2100-2250 psi
(145-155 bar)
2200-2300 psi
(152-159 bar)
2100-2250 psi
(145-155 bar)
System relief valve setting
(at the power supply outlet)
250 psi
(17 bar)
250 psi
(17 bar)
250 psi
(17 bar)
250 psi
(17 bar)
Maximum back pressure
(at tool end of the return hose)
400 ssu*
400 ssu*
400 ssu*
400 ssu*
Measured at a max. fluid viscosity of:
(82 centistokes) (82 centistokes) (82 centistokes) (82 centistokes)
(at min. operating temperature)
Temperature: Sufficient heat rejection
capacity to limit max. fluid temperature to:
(at max. expected ambient temperature)
140° F
(60° C)
140° F
(60° C)
140° F
(60° C)
140° F
(60° C)
Min. cooling capacity at a temperature
3 hp
5 hp
6 hp
7 hp
difference of between ambient and fluid
temps
(2.24 kW)
40° F
(3.73 kW)
40° F
(5.22 kW)
40° F
(4.47 kW)
40° F
NOTE:
(22° C)
(22° C)
(22° C)
(22° C)
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 Petroleum based
(premium grade, anti-wear, non-conductive)
Viscosity (at min. and max. operating temps)
100-400 ssu*
100-400 ssu*
(20-82 centistokes)
100-400 ssu*
100-400 ssu*
NOTE:
When choosing hydraulic fluid, the expected oil temperature extremes that will be experienced in service determine the
most suitable temperature viscosity characteristics. Hydraulic fluids with a viscosity index over 140 will meet the requirements
over a wide range of operating temperatures.
*SSU = Saybolt Seconds Universal
CLASSIFICATION
EHTMA
HYDRAULIC SYSTEM
REQUIREMENTS
C
B
D
Flow Range
3.5-4.3 gpm
(13.5-16.5 lpm) (18-22 lpm)
1870 psi
(129 bar)
4.7-5.8 gpm
7.1-8.7 gpm
(27-33 lpm)
1500 psi
9.5-11.6 gpm
(36-44 lpm)
1500 psi
11.8-14.5 gpm
(45-55 lpm)
1500 psi
Nominal Operating Pressure
(at the power supply outlet)
1500 psi
(103 bar)
(103 bar)
(103 bar)
(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
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OPERATION
•
•
Always store an idle cutoff saw in a clean dry space
safe from damage or pilferage.
•
The hydraulic system should have a minimum of 25
micron filtration. It is recommended that filter ele-
ments be sized for a flow of at least 30 gpm/1131
pm for cold temperature startup and maximum dirt
holding capacity.
Replace the cutoff wheel if worn for maximum
tool performance. Make sure that the wheel is not
chipped or damaged.
•
The hydraulic fluid used should have a viscosity
between 100 and 400 ssu/20 and 82 centistokes
at the maximum and minimum expected operating
temperatures. Hydraulic fluids of petroleum base
with anti wear properties and viscosity indexes over
140 will meet the recommended requirements over
a wide range of operating temperatures.
•
•
Always keep critical tool markings, such as labels
and warning stickers legible.
Always replace hoses, couplings and other parts
with replacement parts recommended by Stanley
Hydraulic Tools. Supply hoses must have a mini-
mum working pressure rating of 2000 psi/140 bar.
•
•
All hoses must have an oil resistant inner surface
and an abrasive resistant outer surface. Hoses that
conform to SAE100R1A are recommended for most
tool applications.
•
The recommended hose size is .625 in/ 16 mm 1.0.
up to 50 ft/15 m long and .750 in/20 mm 1.0. mini-
mum up to 100 ft/30 m long.
PREOPERATION CHECKOUT
PROCEDURES
POWER SOURCE
Use only cutoff wheels that meet requirements of
ANSI 87.5. Wheels should be no larger than 10-inch-
es/25.4 em in diameter, 5/32-inch/4 mm thick with a
1-inch/25.4 or 22 mm arbor hole. Rated speed must
be 5000 rpm minimum.
1. Using a calibrated flowmeter and pressure gauge,
check that the hydraulic power source develops a
flow of 10-15 gpm/38-57 lpm at 1500-2000 psi/105-
140 bar.
•
•
•
Tool repair should be performed by experienced
personnel only.
Make sure all couplers are wiped clean before con-
nection.
2. Make certain that the power source is equipped with
a relief valve set to open at 2250 psi/155 bar maxi-
mum.
The hydraulic circuit control valve must be in the
“OFF” position when coupling or uncoupling hydrau-
lic tools. Failure to do so may result in damage to
the quick couplers and cause overheating of the hy-
draulic system.
3. Check that all operating controls and indicators are
easily accessible.
CUTOFF SAW TRIGGER AND SAFETY
CATCH
HYDRAULIC SYSTEM
REQUIREMENTS
1. Check that the trigger operates smoothly and is free
to travel between the “ON” and “OFF” positions.
•
The hydraulic system should provide a flow of 10-15
gpm/38-57 lpm at an operating pressure of 1500-
2000 psi/105-140 bar. Recommended relief valve
settings are 2100-2250 psi/145-155 bar.
2. Check that the trigger is set to disengage the cutoff
saw when released.
3. Check that the safety catch on the handle assembly
is operating properly. It should prevent engagement
of the trigger unless the catch is fully pressed down
into the handle slot.
•
The system should have no more than 250 psi/17
bar backpressure measured at the tool end of the
operating hoses. The system conditions for mea-
surement are at maximum fluid viscosity or 400
ssu/82 centistokes (minimum operating tempera-
tures).
HANDLE
Check that the handle bar is securely fastened to the
motor housing and handle bar strut. Remove any oil
from the handle bar.
•
The hydraulic system should have sufficient heat re-
jection capacity to limit the maximum oil temperature
to 140 °F/60 °C at the maximum expected ambient
temperature. The recommended minimum cooling
capacity is 7 hp/5.22 kW at a 40 °F/22 °C difference
between ambient temperature and oil temperature.
WHEEL GUARD
1. Inspect the wheel guard for cracks and other struc-
tural damage.
2. Rotate the guard to ensure that it moves freely on
the wheel-arbor centerline.
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OPERATION
3. Check that the locking mechanism operates prop- cutoff saw is 3600 rpm. This speed must be equal to or
erly to hold the guard in a set position.
less than the rated speed of the cutting wheel.
Tests should be conducted while operating the normal
hydraulic power supply used with the cutoff saw.
WHEEL CONDITION
1. Before installing abrasive wheels, “sound” the wheel
for possible damage by hanging the wheel vertically
by the arbor hole and rapping lightly with a screw-
driver handle or similar instrument. Thin, organic
bond wheels will produce a low drumming tone if it
is physically sound. If the wheel produces a “dead”
or “flat” sound, it may be cracked. Cracked or dam-
aged wheels must never be used.
NOTE:
Excessive speed may be caused by excessive oil
flow to the tool.
OPERATING INSTRUCTIONS
CUTOFF WHEEL INSTALLATION
2. Check that the surfaces of the wheel that come in
contact with blotters and flanges are free of dirt and
other foreign particles.
IMPORTANT
3. Check that the correct wheel is used for the job.
Make sure the wheel has been thoroughly inspected
prior to installation.
4. Check that the wheel conforms to the physical re-
quirements listed in the Specification section of this
manual. The cutoff wheel shall fit freely on the drive
flange and remain free under all cutting conditions.
A controlled clearance between the arbor hole and
the cutoff saw drive flange is essential to avoid ex-
cessive pressure from installation and/or arbor ex-
pansion.
NOTE:
When mounting the wheel, use blotters at the col-
lars. The blotters should be made from highly com-
pressible material and should not be more than
0.025-inch/.6 mm thick.
1. Install the wheel on the drive flange. Refer to the
Specification and Parts List sections of this manual
for wheel requirements and parts orientation, re-
spectively.
5. Check diamond wheels to ensure all segments are
intact.
ARBOR AND COLLARS
1. Inspect the drive flange and outer flange prior to in-
stallation. Check for burrs. Check that the bearing
surfaces are flat and run true when mounted on the
drive shaft.
2. Install the outer flange. (Use the Spirol drive pin on
diamond wheels only.)
3. Install and tighten the wheel nut. Tighten the nut
only tight enough to prevent slippage of the wheel.
2. Inspect the drive shaft threads.
4. Adjust the sole plate assembly for proper depth of
cut.
REDUCING BUSHINGS
1. When a reducing bushing is used in the cutoff wheel
mounting hole, check that it does not exceed the
thickness of the wheel.
CONNECTING HOSES
1. Wipe all hose couplers with a clean lint-free cloth
before making connections.
2. Make sure that the reducing bushing does not pro-
trude beyond the surface of the wheel on both sides.
Bushings that are too thick will not allow the collars
to fit properly against the wheel.
2. Connect the hoses from the power supply to the
tool hoses. It is a good practice to connect return
hoses first and disconnect last to minimize or avoid
trapped pressure within the tool.
3. Check that reducing bushings are tight in the cutoff
wheel mounting hole. Never use bushings that do
not fit tightly in the mounting hole. Never use shim
stock.
3. If hose couplers are used, observe the arrow on the
coupler to ensure that the flow is in the proper direc-
tion. The female coupler on the tool hose is the inlet
coupler.
DRIVESHAFT SPEED CHECK
4. Move the hydraulic circuit control valve to the “ON”
position to operate the tool.
The speed of the motor output shaft should be checked
at least every 100 hours of operation by trained and
experienced personnel. A record of the speed checks
should be maintained. The maximum rated speed of the
CO23 User Manual ◄ 11
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OPERATION
NOTE:
When used on cutoff saws carried on emergency vehi-
cles, wheels should be removed after use and discarded
or carefully stored as described in this section.
If uncoupled hoses are left in the sun, pressure in-
crease within the hose may make them difficult to
connect. When possible, connect the free ends of If wheels are supplied with blotters attached, suitable
operating hoses together.
separators should be used to preserve flatness.
TOOL OPERATION
INVESTIGATION OF WHEEL BREAKAGE
NOTE:
Wheels designed for use with hand-held portable saws
are specifically manufactured for this application. They
are manufactured to be extremely tough and are difficult
to break under normal use.
At the beginning of each shift or when a new cutoff
wheel has been installed, run the saw at operating
speed for at least one minute before starting work.
Keep personnel from in front of or in line with the If a wheel breaks during use, a careful investigation
wheel.
should be conducted by the user to determine the cause
of the breakage. The cause must then be corrected as
soon as possible.
GENERAL PROCEDURES
1. Whenever possible, the work should be held down
and securely supported on both sides of the cut.
If the user is unable to determine the cause of breakage,
the wheel manufacturer should be consulted.
2. Press down the safety catch; then slowly squeeze
the trigger. Start the cut with the wheel rotating. Start
the work gently, do not “bump” the work.
COLD WEATHER OPERATION
If the saw is to be used during cold weather, preheat
the hydraulic oil at low engine speed. When using the
normally recommended oils, oil should be at or above
50 °F/10 °C (400 ssu/82 centistokes) before use.
3. Feed the wheel through the material as fast as pos-
sible without allowing the wheel to reduce its speed.
Cutting through the material too slowly allows heat
expansion and can cause wheel “pinching” in the
material. “Pinching” the wheel from heat expansion
is one of the most common causes of wheel break-
age.
Damage to the hydraulic system or saw can result from
use with oil that is too viscous or thick.
CARE OF ABRASIVE CUTOFF WHEELS
All abrasive cutting-off wheels are breakable and, there-
fore, care must be exercised during handling and stor-
age to prevent damage.
STORAGE
Thin, organic bonded wheels such as cutting off wheels
should be laid horizontally on a flat surface of steel or
similar rigid material away from excessive heat or mois-
ture. Wheels should not be stored where they will be
exposed to high humidity, water, other liquids, or freez-
ing temperatures. Temperatures low enough to cause
condensation on the wheels when moving them from
storage to an area of higher temperatures should be
avoided.
12 ► CO23 User Manual
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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 cutoff saw, always check that the hydraulic power source is supplying the
correct hydraulic flow and pressure to the cutoff saw as listed in the table. Use a flowmeter known to be accurate.
Check the flow with the hydraulic oil temperature at least 80 °F/27 °C.
PROBLEM
Tool does not run.
CAUSE
REMEDY
Power not functioning.
Check power unit for proper flow and
pressure (15 gpm at 2000 psi/56 lpm
at 140 bar).
Coupler or hoses blocked.
Mechanical failure.
Remove obstruction.
Disassemble tool and inspect for
damage.
Tool runs backwards.
Pressure and return reversed.
Correct hose connection or flow di-
rection. Motor shafts with right-hand
threads rotate counterclockwise,
motor shafts with left-hand threads
rotate clockwise.
Oil leakage between motor housing Oil tube O-ring failure.
Replace as required.
Replace as required.
and on-off block or motor.
Motor face seal failure.
On-off trigger is hard to press.
Backpressure too high.
Should not exceed 250 psi at 15
gpm/17 bar at 571 pm measured at
the end of the tool operating hoses.
Pressure and return reversed.
Correct for proper flow direction.
Saw cuts too slow.
Insufficient oil flow or low relief valve Adjust oil flow to proper gpm. For
setting.
optimum performance adjust relief
valve to 2250 psi/155 bar.
Wrong wheel for material being cut. Use correct wheel.
Hot oil or excessive oil flow. Check power unit for adequate cool-
Saw gets hot.
ing; should maintain fluid at or below
140 °F/60 °C. Power unit may be
producing more flow than the saw
will accept under the existing cutting
conditions. Reduce flow until saw
performance starts to drop off.
CO23 User Manual ◄ 13
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SPECIFICATIONS
Weight ....................................................................................................................................................25 lb./11.3 kg
Length..............................................................................................................................................20 1/2 inch/52 cm
Width .....................................................................................................................................................11 inch/28 cm
Pressure Range..............................................................................................................1500–2000 psi/105–140 bar
Flow Range .............................................................................................................................10–15 gpm/38–57 lpm
Optimum Flow .....................................................................................................................................15 gpm/57 lpm
System Type...................................................................................................................O.C. or C.C. HTMA TYPE III
Porting....................................................................................................................................................SAE 8 O-ring
Connect Size..................................................................................................................1/2 inch male pipe hose end
Cutting Wheel..................................................................................................ANSI B7.5., 10 inch/25.4 cm diameter
5/32-inch/4 mm thick, 1-inch/25.4 or 22 mm arbor hole
5000 RPM minimum rated speed
CO23 Vibration Declaration:
Test conducted on CO23341, operateed at optimum flow 15 gpm / 56.7 lpm input
Declared vibration emission value in accordance with EN 12096
Measured vibration emission value: 3-Axis (Main Handle).........................................................................3.8 m/sec²
Uncertainty: K............................................................................................................................................0.34 m/sec²
Measured vibration emission value: 3-Axis (Assist Handle)........................................................................4.2 m/sec²
Uncertainty: K............................................................................................................................................0.70 m/sec²
Values determined according to ISO 19432:2006
ACCESSORIES
Description
Part Number
10-inch diameter Diamond Wheel for Masonry 1-inch Arbor.............................................................................03694
10-inch diameter Abrasive Wheel for Metal 1-inch Arbor Fast Cutting.............................................................. 04116
10-inch diameter Abrasive Wheel for Metal 1-inch Arbor-Long Wear................................................................ 04117
SERVICE TOOLS
Description
Part Number
Bearing Installation Tool ....................................................................................................................................05044
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CO23 PARTS ILLUSTRATION
CO23 User Manual ◄ 15
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CO23 PARTS LIST
ITEM
NO.
ITEM
P/N
QTY. DESCRIPTION
NO.
43
44
45
46
47
48
49
50
51
P/N
QTY. DESCRIPTION
1
2
70980
02764
1
HANDLE BAR
-----
--
--
1
1
1
1
1
1
4
NO ITEM
11
CAPSCREW, 5/16-18 × 3/4
HEX SOC HD
-----
NO ITEM
03812
03824
00600
03813
00253
35285
01217
SPACER WASHER
SEAL *
3
02649
02643
20460
00112
01604
32026
02931
31804
22707
03278
22701
22704
28552
00787
06830
02911
03806
31137
00174
02920
02916
00175
35286
-----
3
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
2
1
1
4
1
1
1
1
1
HANDLE BAR RETAINER
NEOPRENE WASHER
HANDLE STRUT
4
KEY
5
MOTOR SHAFT CCW
O-RING, 2 1/2 × 2 5/8 × 1/16 *
MOTOR HOUSING CAP
6
QUAD-RING *
7
O-RING, .097 × .755 (90 DURO) *
VALVE SPOOL
8
CAPSCREW, 3/8-16 × 2 1/2 HEX
SOC HD
9
ON-OFF VALVE CAP
ROLL PIN, 1/4 × 2 1/2
TRIGGER
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
52
03826
4
BEARING
(INCL WITH ITEM # 50 & 25)
53
54
55
56
57
58
59
60
61
62
03818
04033
00713
01211
72880
14090
72879
12535
12536
03971
1
1
2
1
1
1
1
1
1
1
GEAR
ROLL PIN, 3/16 × 1 3/8
TORSION SPRING
SAFETY CATCH
IDLER GEAR
DOWEL PIN, 1/4 × 1
O-RING, 5/8 × 3/4 × 1/16 *
CO23 STICKER
VALVE HANDLE ASSEMBLY
CAPSCREW, 1/4-20 × 1-1/4 FL HD
HOSE ASSEMBLY
HOSE CLIP
STANLEY LOGO DECAL
FLOW CONTROL
EHTMA “E” DECAL
EHTMA “F” DECAL
SOLE PLATE ASSEMBLY
PORT PLUG
COUPLER SET (MALE & FEMALE)
FOR INDIVIDUAL COUPLERS (P/N-
03972 FEMALE / 03973 MALE)
OIL TUBE
SPACER
63
64
65
66
67
28788
31186
72881
01420
72893
1
1
1
1
1
WARNING MANUAL STICKER
POPPET
SPRING
O-RING, 1/2 × 5/8 × 1/6 *
MOTOR HOUSING CCW
NO ITEM
WHEEL WARNING STICKER
HELICOIL
ROTATION DIRECTION STICKER
-----
NO ITEM
08104
04046
PLUG SAE O-RING
NOTE:
GRINDING WHEEL GUARD
ASSEMBLY
Use Part Name and Part Number when ordering.
30
31
32
33
34
35
36
37
38
39
40
41
42
03821
03827
03819
01714
03802
03969
03803
03810
03811
03823
01262
03822
03109
1
1
1
1
1
1
1
1
1
1
2
1
1
STUD
* Denotes Part in Seal Kit.
WASHER, 1/2
SEAL KIT DATA
KNOB
HEX NUT, 5/8-11 CCW
OUTER FLANGE
SPIROL PIN
P/N
QTY.
DESCRIPTION
SEAL KIT PART NO. 04120
00175
00253
00112
01211
01262
01362
01604
03823
03824
01605
4
1
1
1
2
1
2
1
1
2
O-RING
O-RING
QUAD-RING
O-RING
O-RING
O-RING
O-RING
SEAL
DRIVE FLANGE 1 IN.
SEAL RACE
SEAL CARRIER
SEAL *
O-RING, 1 3/4 × 1 7/8 × 1/16 *
SEAL CARRIER WASHER
BEARING
SEAL
O-RING
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UNDERWATER TOOLS DEPTH GUIDELINE
UNDERWATER MODELS ONLY
Operation Overview
CAUTION
Percussive
Tools: Breakers,
Hammer Drills and
Chipping Hammers
Rotational
Tools: Grinders,
Saws, Chain Saws
DO NOT USE HYDRAULIC TOOLS UNDER-
WATER THAT ARE NOT DESIGNATED AS
AN “UNDERWATER” MODEL, OR THIS
WILL RESULT IN DAMAGE TO THE TOOL.
Max Depth: 1000' -
Reference hose
sizing guide below
Max Depth: 500' -
limitations due to
accumulator PSI
max (increase 40
PSI for every 100')
For underwater hydraulic tools the applications are
broken down into four quadrants depending on
type of tool and method of operation.
Tools: Breakers,
Hammer Drills and
Chipping Hammers
Tools: Grinders,
Saws, Chain Saws
The types of tools are percussive and rotational,
each with different characteristics allowing for dif-
ferent depth operation. With percussive tools, the
nitrogen accumulator PSI must counter the in-
crease 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 capable of
deeper depths.
Max Depth: 1000' -
Reference hose
sizing guide below
Max Depth: 500' -
limitations due to
accumulator PSI
max (increase 40
PSI for every 100')
The methods are broken into diver operated or
remote operated vehicle (ROV). ROV's can reach
lower depths and with an on-board 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.
Recommended Hose Diameters
Depth (ft)
100
8 GPM
5/8”
3/4”
1”
12 GPM
5/8”
300
1”
600
1”
1000
1”
1-1/4”
CO23 User Manual ◄ 17
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Stanley Hydraulic Tools
3810 SE Naef Road
Milwaukie, Oregon 97267-5698 USA
(503) 659-5660 / Fax (503) 652-1780
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