Stanley Black Decker Saw RS25 User Manual

RS25  
HYDRAULIC  
RAIL SAW  
USER MANUAL  
Safety, Operation and Maintenance  
© 2014 Stanley Black & Decker, Inc.  
New Britain, CT 06053  
U.S.A.  
31846 8/2014 Ver. 11  
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TABLE OF CONTENTS  
DECLARATION OF CONFORMITY..........................................................................................................................2  
SAFETY SYMBOLS ..................................................................................................................................................4  
SAFETY PRECAUTIONS..........................................................................................................................................5  
TOOL STICKERS & TAGS........................................................................................................................................7  
HOSE TYPES............................................................................................................................................................8  
HOSE RECOMMENDATIONS ..................................................................................................................................9  
FIGURE 1. TYPICAL HOSE CONNECTIONS.......................................................................................................9  
HTMA REQUIREMENTS.........................................................................................................................................10  
OPERATION............................................................................................................................................................ 11  
FIGURE 2.............................................................................................................................................................12  
FIGURE 3.............................................................................................................................................................12  
TOOL PROTECTION & CARE................................................................................................................................14  
TROUBLESHOOTING ............................................................................................................................................15  
SPECIFICATIONS...................................................................................................................................................16  
ACCESSORIES.......................................................................................................................................................16  
RS25 PARTS ILLUSTRATION ................................................................................................................................17  
RS25 PARTS LIST ..................................................................................................................................................18  
IMPORTANT  
To fill out a Product Warranty Validation form, and for information on your warranty,  
visit Stanleyhydraulics.com and select the Company tab, Warranty.  
(NOTE: The warranty Validation record must be submitted to validate the warranty).  
SERVICING: This manual contains safety, operation, and routine maintenance instructions. Stanley Hydraulic Tools  
recommends that servicing of hydraulic tools, other than routine maintenance, must be performed by an authorized  
and 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  
Tool operators and maintenance personnel must always  
Do not operate the tool at oil temperatures above  
comply with the safety precautions given in this manual  
and on the stickers and tags attached to the tool and  
hose.  
140 °F/60 °C. Operation at higher temperatures can  
cause higher the normal temperatures at the tool  
which can result in operator discomfort.  
These safety precautions are given for your safety. Re-  
view them carefully before operating the tool and before  
performing general maintenance or repairs.  
Do not operate a damaged, improperly adjusted, or  
incompletely assembled tool.  
Never wear loose clothing that can get entangled in  
the working parts of the tool.  
Supervising personnel should develop additional pre-  
cautions relating to the specific work area and local  
safety regulations. If so, place the added precautions in  
the space provided in this manual.  
Keep all parts of your body away from the rotating  
parts. Long hair or loose clothing can become drawn  
into rotating components.  
The model RS25 Hydraulic Rail Saw will provide safe  
and dependable service if operated in accordance with  
the instructions given in this manual. Read and under-  
stand this manual and any stickers and tags attached  
to the tool and hose before operation. Failure to do so  
could result in personal injury or equipment damage.  
Always use accessories that conform to the speci-  
fications given in the OPERATION section of this  
manual.  
Do not operate the tool with the wheel guard re-  
moved.  
Release the trigger if the power supply has been in-  
terrupted.  
Keep the wheel off all surfaces when starting the  
rail saw.  
To avoid personal injury or equipment damage, all  
tool repair, maintenance and service must only be  
performed by authorized and properly trained per-  
sonnel.  
The operator must start in a work area without by-  
standers. Flying debris can cause serious injury.  
Do not operate the tool unless thoroughly trained  
or under the supervision of an instructor. Establish  
a training program for all operators to ensure safe  
operation.  
Always hold the tool with both hands when the unit  
is running. Use a firm grip.  
Make sure the wheel has stopped before setting  
the tool down. Always carry the tool with the wheel  
stopped.  
Always wear safety equipment such as goggles,  
gloves, ear and head protection, and safety shoes  
at all times when operating the tool.  
Inspect the wheel guard and collars for damage af-  
ter any wheel breakage.  
The operator must be familiar with all prohibited  
work areas such as excessive slopes and danger-  
ous terrain conditions.  
Do not operate the tool in the vicinity of flammable  
materials.  
Maintain proper footing and balance at all times.  
Never exceed the maximum operating speed  
marked on the wheel.  
Do not inspect or clean the tool while the hydraulic  
power source is connected. Accidental engagement  
of the tool can cause serious injury.  
Do not attempt to adjust the flow control in the valve  
handle.  
Always connect hoses to the tool hose couplers be-  
fore energizing the hydraulic power source. Be sure  
all hose connections are tight and are in good condi-  
tion.  
Eye injury and cutting or severing of body parts is  
possible if proper procedures are not followed.  
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SAFETY PRECAUTIONS  
CUTTING WHEEL SAFETY  
Do not store or transport the saw with the wheel in-  
stalled.  
Ensure that the cutting wheel is correctly mounted  
and tightened before use.  
Operate the Rail Saw at “no load” for 30 seconds in  
a safe position and ensure there is no vibration or  
other defects detected. If considerable vibration or  
other defects are detected, stop operation of the tool  
immediately and determine the cause. Do not use  
the tool until the defect is corrected.  
If the Rail Saw is dropped with a cutting wheel in-  
stalled, the cutting wheel should be examined thor-  
oughly before use.  
Only use cutting wheels that comply with ANSI B7.5/  
ISO 525, 603.  
Check that the maximum operating speed (rpm –  
revolutions per minute) of the cutting wheel is equal  
to or greater than the rated shaft speed of the grind-  
er. Stanley recommends wheels rated at 4700 RPM  
for 16 inch models and 5300 RPM for 14 inch mod-  
els.  
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TOOL STICKERS & TAGS  
WHEEL SIZE  
RPM:  
SPINDLE:  
BAR  
CAUTION  
PRESS:  
PSI  
GPM  
FLOW:  
LPM  
PROTECT YOUR EYES - WEAR SAFETY GOGGLES  
1. Do not use damaged wheels.  
2. Use full throttle only while cutting.  
3. Use only wheels marked high speed reinforced that meet requirements  
of ANSI B7.5. Wheels should be no larger than 16” diameter x 5/31” thick with a 1” arbor hole  
and rated for 4700 rpm minimum speed.  
4. Inspect wheel guard & collars for damage after any wheel breakage on the machine.  
5. Maximum spindle speed is 4700 rpm.  
28728  
RS25 Name Tag  
28811  
Information Plaque  
(CE models only)  
05868  
Abrasive Cut-Off Safety Label  
(14 inch models only – except CE)  
CAUTION  
PROTECT YOUR EYES...  
WEAR SAFETY GOGGLES  
1. DO NOT USE DAMAGED WHEELS.  
2. USE FULL TROTTLE ONLY WHILE CUTTING.  
3. USE ONLY WHEELS MARKED HIGH SPEED REINFORCED THAT MEET  
REQUIREMENTS OF ANSI B7.1,B7.5 WHEELS SHOULD BE NO LARGER THAN  
16" DIA X 5/32" THICK WITH A 1" ARBOR HOLE & RATED FOR 4700 RPM  
MINIMUM SPEED.  
03787  
GPM Sticker 7–9 2000 PSI  
4. INSPECT WHEEL GUARD & COLLARS FOR DAMAGE AFTER ANY WHEEL  
BREAKAGE ON THE MACHINE.  
5. MAXIMUM SPINDLE SPEED IS 4700 RPM.  
28409  
Composite Sticker  
(CE models only)  
6. READ OPERATION MANUAL.  
17641  
Abrasive Cut-Off Safety Label  
(16 inch models only)  
25610  
Railroad Help Desk Sticker  
11207  
Sound Power Level 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.  
05152  
Logo-Address Decal  
(UP models only)  
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.  
NOTE:  
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.  
THE INFORMATION LISTED  
ON THE STICKERS SHOWN,  
MUST BE LEGIBLE AT ALL  
TIMES.  
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.  
REPLACE DECALS IF  
THEY BECOME WORN OR  
DAMAGED. REPLACEMENTS  
ARE AVAILABLE FROM  
YOUR LOCAL STANLEY  
DISTRIBUTOR.  
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.  
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.  
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)  
RS25 User Manual ◄ 7  
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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  
RS25 User Manual ◄ 9  
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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  
2. Check that the surfaces of the wheel that come in  
PRE-OPERATION PROCEDURES  
CHECK HYDRAULIC POWER SOURCE  
contact with blotters and flanges are free of dirt and  
other foreign particles.  
1. Using a calibrated flowmeter and pressure gauge,  
check that the hydraulic power source develops a  
flow of 9–10.5 gpm/34–40 lpm at 2000 psi/140 bar.  
3. Remove the jam nut (77) and outside collar (78) by  
using a box type wrench while gripping the cutting  
wheel.  
2. Make certain the hydraulic power source is equipped  
with a relief valve set to open at 2200–2300 psi/152–  
159 bar minimum.  
4. Install the cutting wheel. Make sure blotters or labels  
remain on the cutting wheel.  
5. Reinstall the outside collar and jam nut. Tighten the  
jam nut with a box type wrench while gripping the  
cutting wheel. Only tighten sufficiently to prevent  
slippage of the wheel between the collars (78 & 79).  
3. Check that the hydraulic circuit matches the tool for  
open-center (OC) operation.  
CHECK TOOL  
DRIVE SHAFT SPEED CHECK  
1. Make sure all tool accessories are correctly in-  
stalled. Failure to install tool accessories properly  
can result in damage to the tool or personal injury.  
The speed of the motor output shaft should be checked  
at least every 100 hours of operation by trained and  
experienced personnel. A record of the speed checks  
should be maintained. The rated speed of the RS25 Rail  
Saw is 3600 rpm at 10 gpm/38 lpm for the 16 inch/400  
mm model and 4500 rpm at 10 gpm/38 lpm for the 14  
inch/350 mm model. The cutting wheel must be rated for  
a minimum of 4700 rpm for the 16 inch/400 mm mod-  
el and 5300 rpm for the 14 inch/350 mm model. Tests  
should be conducted while operating the normal power  
supply used with the saw.  
2. There should be no signs of leaks.  
3. The tool should be clean, with all fittings and fasten-  
ers tight.  
CHECK TRIGGER MECHANISM  
1. Check that the trigger operates smoothly and is free  
to travel between the ON and OFF positions.  
CHECK GUARD ASSEMBLY  
1. Inspect the wheel guard assembly for cracks and  
other structural damage.  
CONNECT HOSES  
1. Wipe all hose couplers with a clean lint-free cloth  
before making connections.  
INSTALLING AND REMOVING  
ABRASIVE CUTTING WHEELS  
NOTE:  
2. Connect the hoses from the hydraulic power source  
to the hose couplers on the rail saw. It is a good  
practice to connect the return hose first and discon-  
nect it last to minimize or avoid trapped pressure  
within the rail saw motor.  
Use 14 in./350 mm diameter (for 14 in. model) or 16  
in./400 mm diameter (for 16 in. model) abrasive cut-  
ting wheels with a 1 in. arbor hole. Only use cutting  
wheels which comply with ANSI B7.5/ISO 525, 603.  
Make sure the paper labels or blotters are installed  
between the wheel and collars.  
3. Observe flow indicators stamped on hose couplers  
to be sure that oil will flow in the proper direction.  
The female coupler is the inlet coupler.  
NOTE:  
1. Before installing abrasive wheels, “sound” the wheel  
for possible damage by hanging the wheel vertically  
be the arbor hole and rapping lightly with a 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.  
The pressure increase in uncoupled hoses left in the  
sun may result in making them difficult to connect.  
When possible, connect the free ends of operating  
hoses together.  
RS25 User Manual ◄ 11  
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OPERATION  
6. While holding onto the upper link of the rail clamp  
OPERATING PROCEDURES  
CLAMPING THE RAIL SAW TO THE RAIL  
assembly (near the red knob of the handle), release  
the detent (129) by turning the knob and then posi-  
tion the lower link forward (away from the operator)  
until the detent can be re-engaged in one or the oth-  
er of the two holes away from the “top dead center  
hole”. This positions the saw so that the operator  
may stand erect while cutting the rail and also allows  
the saw to cut down to the flange of the rail.  
1. Observe all safety precautions.  
2. Make sure the rail clamp assembly is tight to the  
disconnect pivot (60) by turning the handle (20) to  
tighten the disconnect pivot bolt.  
3. Fully extend the indicator rod located on the clamp  
and position the rail clamp on the rail so the clamp  
arms bear on the top and sides of the rail and the  
bell crank bears under the rail as shown in Figure 2.  
An optional method is to disengage the detent and  
adjust the capscrews (see Figure 2) as required.  
7. Adjust the wheel guard (87) so that it does not in-  
terfere with the cutting process and cuttings are di-  
rected away from the operator.  
CLAMP  
LOWER  
SAWING THE RAIL  
1. Always start the rail saw with the cutting wheel away  
from the work surface.  
2. Start the cut with the wheel rotating.  
CAPSCREW  
INDICATOR  
ROD  
NOTE:  
Do not “bump” the rail. Feed the wheel through  
the material as fast as possible without allowing  
the wheel to reduce its speed. Cutting through the  
material too slowly allows heat expansion and can  
cause wheel “pinching” in the material. “Pinching”  
the wheel from heat expansion is one of the most  
common causes of wheel breakage.  
CLAMP  
BELL  
CRANK  
Figure 2.  
4. Move the rail saw along the rail until the indicator is  
next to the cut as shown in Figure 3.  
3. Starting at the top of the rail, cut straight down while  
rocking the handle back and forth. Cut down until  
near the flange.  
RAIL  
4. When near the flange, stop the saw, release the de-  
tent and move the lower link toward the operator un-  
til the detent can be re-engaged in one of the holes  
away from the “top dead center hole”. This positions  
the saw lower so that the flange of the rail may be  
easily cut.  
INDICATOR  
If the detent has been removed in favor of using the  
capscrews as stops for the lower link, simply move  
the lower link toward the capscrew closest to the op-  
erator.  
EDGE OF  
CUT LINE  
If the wheel is worn such that it will not completely  
cut through the rail, loosen the clamp lever on the  
saw, and rotate the saw to allow cutting from the op-  
posite side. Readjust the lower link as required and  
finish the cut.  
Figure 3.  
5. Tighten the bell crank to the rail by turning the clamp  
screw (75) clockwise.  
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OPERATION  
DETACHING THE UPPER AND LOWER  
LINKS  
COLD WEATHER OPERATION  
If the saw is to be used during cold weather, preheat  
the hydraulic fluid at low engine speed. When using the  
normally recommended fluids, fluid temperature should  
be at or above 50 °F/10 °C (400 ssu/82 centistokes) be-  
fore use.  
The upper and lower links of the rail clamp assembly  
can be detached from the motor mount (50) by unscrew-  
ing the handle (20).  
SAW STORAGE  
INVESTIGATION OF WHEEL  
BREAKAGE  
If a wheel breaks during use, a careful investigation  
should be conducted by to determine the cause of the  
breakage. The cause must then be corrected before us-  
ing the saw again.  
By disengaging the double cam (52), the rail clamp as-  
sembly can be rotated so that the entire saw has a flatter  
profile for storage.  
Do not store the saw with the abrasive wheel attached.  
CARE OF ABRASIVE CUT-OFF WHEELS  
If unable to determine the cause of breakage, the wheel  
manufacturer should be consulted.  
CAUTION  
All abrasive cut-off wheels are breakable and,  
therefore, care must be exercised during handling  
and storage to prevent damage.  
Wheels should be laid on a flat, rigid, surface away from  
excessive heat or moisture. Wheels should not be stored  
where they will be exposed to high humidity, water, other  
liquids or freezing temperature. If wheels are supplied  
with blotters attached, suitable separators should be  
used to preserve flatness.  
RS25 User Manual ◄ 13  
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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 con-  
nection.  
Do not exceed the rated flow (see Specifications) in  
this manual for correct flow rate and model number.  
Rapid failure of the internal seals may result.  
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.  
Always keep critical tool markings, such as warning  
stickers and tags legible.  
Tool repair should be performed by experienced  
personnel only.  
Always store the tool in a clean dry space, safe from  
damage or pilferage.  
Make certain that the recommended relief valves  
are installed in the pressure side of the system.  
Make sure the circuit PRESSURE hose (with male  
quick disconnect) is connected to the IN port. The  
circuit RETURN hose (with female quick disconnect)  
is connected to the opposite port. Do not reverse cir-  
cuit flow. This can cause damage to internal seals.  
Do not use the tool for applications for which it was  
not intended.  
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 2500 psi/172 bar.  
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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 grinder, always check that the hydraulic power source is supplying the  
correct hydraulic flow and pressure to the grinder 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.  
SYMPTOM  
Saw does not run.  
POSSIBLE CAUSE  
SOLUTION  
Hydraulic power source not  
functioning correctly.  
Check power source for proper flow  
and pressure (7–10 gpm/26–34 lpm,  
2000 psi/140 bar.  
Coupler or hoses blocked.  
Mechanical failure.  
Remove obstruction.  
Have tool serviced by authorized  
dealer.  
Saw runs backwards.  
Saw cuts too slow.  
Pressure and return lines incorrectly  
connected.  
Correct hose connections. Motor  
shaft rotates counter-clockwise as  
viewed from the end of the motor  
shaft.  
Insufficient fluid flow or too high back- Check hydraulic supply. If hydraulic  
pressure or relief valve set too low.  
supply is correct, have unit serviced  
by authorized dealer.  
Wrong wheel for material being cut.  
Seal failure.  
Use correct wheel.  
Fluid leakage.  
Do not use. Have serviced by an  
authorized dealer.  
Off-center cut and binding.  
Bearings worn on link arms.  
Incorrect cutting technique.  
Have unit serviced by an authorized  
dealer.  
Review operating procedures.  
RS25 User Manual ◄ 15  
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SPECIFICATIONS  
Wheel Capacity  
14 inch Model....................................................14 in./35.5 cm Dia. × 25.4 mm Arbor (ANSI B7.5/ISO 525, 603)  
16 inch Model.............................................................. 16 in./41 cm Dia. × 1 in. Arbor (ANSI B7.5/ISO 525, 603)  
Pressure Range..............................................................................................................1800–2000 psi/124–140 bar  
Maximum Back Pressure......................................................................................................................250 psi/17 bar  
Flow Range ................................................................................................HTMA Class RR, 9–10.5 gpm/34–40 lpm  
EHTMA (D) .......................................................................................................................................30 lpm – 138 bar  
EHTMA (E) .......................................................................................................................................40 lpm – 138 bar  
Porting...................................................................................................................................................-8 SAE O-ring  
Couplers ..................................................................................................................HTMA/EHTMA Flush Face Type  
Hose Whips...........................................................................................................................................................Yes  
Weight (with hose whips & couplers)................................................................................................... 14.1 lb/6.40 kg  
Overall Length...................................................................................................................................36 inches/92 cm  
Overall Width.....................................................................................................................................11 inches/28 cm  
Overall Height (w/wheel, guard rotated to any position)....................................................................13 inches/33 cm  
Weight (less wheel)  
14 inch Model..................................................................................................................................55 lbs/24.4 kg  
16 inch Model.....................................................................................................................................56 lbs/25 kg  
RPM  
14 inch Model................................................................................................................................................4500  
16 inch Model................................................................................................................................................4000  
Maximum Fluid Temperature.................................................................................................................. 140 °F/60 °C  
Rail Size .......................................................................................................................... 75–165 lb/yard/37–82 kg/M  
Sound and Vibration Declaration  
Test conducted on RS25103, operated at standard 10 gpm input  
Measured A-weighted sound power level, Lwa (ref. 1pW) in decibels  
Uncertainty, Kwa, in decibels  
108 dBA  
3 dBA  
Measured A-weighted sound pressure level, Lpa (ref. 20 µPa) at operator’s position, in decibels  
Uncertainty, Kpa, in decibels  
97 dBA  
3 dBA  
Values determined according to noise test code given in ISO 15744, using the basic standard ISO  
3744  
NOTE: The sum of a measured noise emission value and its associated uncertainty represents an  
upper boundary of the range of values which is likely to occur in measurements.  
Declared vibration emission value in accordance with EN 12096  
Measured vibration emission value: a  
9.1 m/sec²  
2.4 m/sec²  
Uncertainty: K  
Values determined according to ISO 8662-1, ISO 5349-1,2  
ACCESSORIES  
Railsaw Blade 14 inch Custom-Labeled............................................................................................................73647  
Railsaw Blade 16 inch Custom-Labeled............................................................................................................73648  
Railsaw Blade 16 inch Norton AT-36 .................................................................................................................22439  
Railsaw Blade 16 inch Norton Norzone III Fastcut............................................................................................29745  
Railsaw Blade 14 inch Norton Norzone III Fastcut............................................................................................30974  
Seal Kit (Includes 66399 JIHOSTROJ Seal Kit)................................................................................................31845  
Motor Seal Kit Assy (Serial No. 3585 (included in 31845).................................................................................66399  
Universal Bellcrank Kit (Grooved Rail) ..............................................................................................................34733  
Motor Upgrade Kit 14 inch Model (After Serial No. 2598).................................................................................66191  
Includes 65625 Disconnect Pivot Bolt, 65626 Pivot Tube, 65627 Indicator Rod, 66133 Motor Assy)  
Motor Upgrade Kit 16 inch Model (After Serial No. 2598).................................................................................66192  
Includes 65625 Disconnect Pivot Bolt, 65626 Pivot Tube, 65627 Indicator Rod, 66134 Motor Assy)  
16 ► RS25 User Manual  
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RS25 PARTS ILLUSTRATION  
RS25 User Manual ◄ 17  
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RS25 PARTS LIST  
PART  
ITEM NO.  
PART  
ITEM NO.  
QTY DESCRIPTION  
QTY DESCRIPTION  
6
28181  
30958  
66136  
1
1
1
1
BELL CRANK  
79  
80  
81  
82  
83  
84  
85  
86  
87  
62290  
00720  
23246  
59050  
30219  
31034  
31032  
31033  
30957  
28709  
73168  
1
INSIDE COLLAR  
SET SCREW  
15  
20  
26  
“D” WASHER  
1
HANDLE WELDMENT  
1
DOWEL PIN  
1
THRUST COLLAR  
RETAINING RING  
SHIM, .005  
REFER TO ITEM 131  
*
1
27  
28  
29  
30  
31  
32  
33  
34  
35  
30671  
31030  
31181  
30667  
31138  
01604  
02931  
00112  
31853  
31854  
08104  
02920  
22707  
22704  
22701  
03009  
00165  
02911  
31186  
28552  
17641  
05868  
17681  
24869  
35289  
02688  
30632  
30635  
29510  
04856  
30841  
28673  
30412  
30530  
28711  
30543  
04353  
56708  
03012  
62291  
1
1
5
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
ASSIST HANDLE  
A/R  
A/R  
A/R  
1
HANDLE GRIP  
SHIM, .020  
BELLEVILLE WASHER  
SHOULDER BOLT  
VALVE SPOOL  
SHIM, .010  
WHEEL GUARD (16 IN MODEL)  
WHEEL GUARD (14 IN MODEL)  
1
O-RING*  
WHEEL GUARD (16 IN MODEL) LOW  
SPARK (SEE PHOTO PAGE 19)  
VALVE CAP  
QUAD RING*  
88  
89  
90  
91  
92  
93  
94  
17652  
28729  
01594  
03906  
17676  
03006  
66134  
1
1
2
1
2
2
1
SECTOR  
FLOW CONTROL (16 IN MODEL ONLY)  
FLOW CONTROL (14 IN MODEL ONLY)  
SAE PLUG  
CARRIAGE BOLT  
WASHER  
36  
38  
39  
40  
41  
42  
43  
44  
45  
46  
47  
LOCKNUT  
SPACER  
CAPSCREW  
MACHINE SCREW  
TRIGGER  
SAFETY CATCH  
TORSION SPRING  
ROLL PIN  
MOTOR ASSY (16 IN, CAN ONLY BE  
PURCHASED AS AN ASSEMBLY)  
66133  
1
MOTOR ASSY (14 IN, CAN ONLY BE  
PURCHASED AS AN ASSEMBLY)  
SCREW  
103  
104  
105  
110  
111  
00283  
16260  
00772  
00698  
03973  
47437  
03972  
47436  
3
3
1
2
1
1
1
1
LOCK WASHER  
HOSE CLIP  
CAPSCREW  
POPPET  
KEY  
VALVE HANDLE ASSY (INCL ITEM 36)  
WHEEL SAFETY LABEL (16 IN MODEL)  
WHEEL SAFETY LABEL (14 IN MODEL)  
ROLL PIN  
HELICOIL  
MALE COUPLER BODY (PARKER)  
MALE COUPLER BODY (AEROQUIP)  
FEMALE COUPLER BODY (PARKER)  
48  
49  
50  
51  
52  
53  
54  
55  
56  
58  
59  
60  
61  
62  
63  
75  
77  
78  
1
1
1
4
1
1
1
1
2
1
1
1
1
1
1
1
1
1
112  
HANDLE  
FEMALE COUPLER BODY  
(AEROQUIP)  
MOTOR MOUNT ASSY  
CAPSCREW  
113  
114  
115  
31137  
02916  
56725  
66727  
00175  
29604  
30922  
350771  
30921  
00214  
28728  
28409  
25610  
28728  
03787  
1
1
2
1
4
2
1
1
1
1
1
1
1
1
1
PLUG  
DOUBLE CAM  
SPRING  
SPIROL PIN  
HOSE ASSY (PARKER)  
HOSE ASSY (AEROQUIP)  
O-RING*  
EYE BOLT  
RETAINING RING  
WASHER  
116  
117  
118  
OIL TUBE  
SPRING  
O-RING (16 IN MODEL)*  
O-RING (14 IN MODEL)*  
QUAD RING (16 IN MODEL)*  
QUAD RING (14 IN MODEL)*  
NAME TAG (16 IN MODEL  
COMPOSITE STICKER (14 IN MODEL)  
RAILROAD HELP DESK (16 IN MODEL)  
NAME TAG (14 IN MODEL)  
GPM STICKER (16 IN MODEL)  
MOTOR MOUNT PIVOT  
DISCONNECT PIVOT  
TOLERANCE RING  
STUD  
119  
122  
123  
124  
LOCKNUT  
CLAMP SCREW ASSY  
JAM NUT  
OUTER COLLAR  
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RS25 PARTS LIST  
Verify the correct model number before ordering.  
PART  
ITEM NO.  
QTY DESCRIPTION  
28322  
11207  
28811  
1
1
1
CE STICKER (14 IN MODEL)  
CIRCUIT “D” STICKER (14 IN MODEL)  
127  
128  
INFORMATION PLAQUE (14 IN  
MODEL)  
129  
130  
131  
132  
133  
56706  
1
1
1
1
1
1
1
DETENT ASSY  
REFER TO ITEM 129  
RAIL CLAMP ASSY  
SOUND POWER STICKER  
LOGO-ADDRESS DECAL  
MOTOR ASSY  
66138  
11210  
05152  
66134  
31845  
SEAL KIT  
* DENOTES PART IN SEAL KIT  
Item 133 (P/N-05152)  
Logo/Address Decal (UP Model Only)  
WHEEL GUARD 16 INCH  
“LOW SPARK” P/N-73168  
RS25 User Manual ◄ 19  
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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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