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)
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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
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.
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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.
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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)
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RS25 PARTS ILLUSTRATION
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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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