Stanley HG80 User manual

HG80HG80
HG80HG80
HG80
HYDRAULICGRINDER
SAFETY, OPERATION AND MAINTENANCE
SERVICE MANUAL
WARNING
Read the Manual Wear Eye
Protection
Wear Ear
Protection Wear Dust Mask
To avoid serious injury or death
47351
Stanley Hydraulic Tools
3810SENaefRoad
MilwaukieOR97267-5698
503-659-5660
FAX[phone]
www.stanley-hydraulic-tools.com
Copyright © 2003, The Stanley Works
OPS/SVCEUSA
29122 12/2003 Ver 2

TABLE OF CONTENTS
3
Safety Symbols and Precautions ..................................................................... 4-6
Tool Stickers and Tags ........................................................................................ 7
Hydraulic Hose Requirements ........................................................................... 8
HTMA Requirements ........................................................................................... 9
Operation ........................................................................................................... 10
Equipment Protection and Care........................................................................ 12
Troubleshooting ................................................................................................ 13
Specifications .................................................................................................... 14
Accessories....................................................................................................... 14
Service ............................................................................................................... 15
Parts Illustration................................................................................................. 19
Parts List............................................................................................................ 20
Warranty ............................................................................................................. 21
For the nearest authorized and certified dealer, call Stanley Hydraulic Tools at one of the numbers listed
on the back of this manual and ask for a Customer Service Representative.
SERVICING THE STANLEY GRINDER: 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.
SERIOUS INJURY OR DEATH COULD RESULT FROM THE IM-
PROPER REPAIR OR SERVICE OF THIS TOOL.
REPAIRS AND / OR SERVICE TO THIS TOOL MUST ONLY BE
DONE BY AN AUTHORIZED AND CERTIFIED DEALER.
WARNING

Safety symbols and signal words, as shown below, are used to emphasize all operator, maintenance and repair actions
which, if not strictly followed, could result in a life-threatening situation, bodily injury or damage to equipment.
This safety alert and signal word indicate an imminently hazardous situa-
tion which, if not avoided, will result in death or serious injury.
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-
nancepersonnel.
CAUTION
WARNING
DANGER
NOTICE
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 a potentially hazardous situation
which, if not avoided, could result in death or serious injury.
This safety alert and signal word indicate a potentially hazardous situation
which, if not avoided, may result in minor or moderate injury.
This signal word indicates a potentially hazardous situation which, if not
avoided, may result in property damage.
This signal word indicates a situation which, if not avoided, will result in
damage to the equipment.
This signal word indicates a situation which, if not avoided, may result in
damage to the equipment.
IMPORTANT
SAFETY SYMBOLS
4

SAFETY PRECAUTIONS
5
Read the Manual Wear Eye
Protection
Wear Ear
Protection Wear Dust Mask
To avoid serious injury or death
47351
Tooloperatorsandmaintenancepersonnel must always comply with the safety
precautions given in this manual and on the stickers and tags attached to the tool and
hose.
Thesesafetyprecautionsaregivenforyoursafety. Review them carefullybefore
operatingthetoolandbefore performing general maintenanceorrepairs.
Supervisingpersonnelshoulddevelopadditionalprecautionsrelating to the specific
work area and local safety regulations. If so, place the added precautions in the
spaceprovidedonpage4.
ThemodelHG80Hydraulic Grinder willprovidesafeanddependableservice if oper-
ated in accordance with the instructions given in this manual. Read and understand
this manual and any stickers and tags attached to the grinder and hose before
operation. Failure to do so could result in personal injury or equipment damage.
• The operator must start in a work area without bystanders. Flying debris can cause serious injury.
•Do not operate the tool unless thoroughly trained or under the supervision ofan instructor. Establishatraining program for
alloperatorstoensuresafeoperation.
•Always wear safety equipment such as goggles, ear and head protection, and safety shoes at all times when operating the
tool. Useglovesand aprons when necessary.
•The operator must be familiar with allprohibited work areas such as excessiveslopesand dangerous terrain conditions.
• Do not inspect, clean or replace the grinding wheel while the hydraulic power source is connected. Do not inspect or clean
the tool while the hydraulic power source is connected. Accidental engagement of the tool can cause serious injury.
•Always connect hoses to the tool hose couplers before energizing the hydraulic power source. Be sure all hose connec-
tions are tight and are in good condition.
•Donotoperate the tool at oil temperatures above 140°F/60°C. Operation athighertemperaturescan cause higher than
normaltemperatures at the tool whichcan result in operator discomfort.
•Donotoperate the tool with the wheel guard removed.
•Donotoperatea damaged, improperly adjusted, or incompletely assembled grinder.
• Never wear loose clothing that can get entangled in the working parts of the tool.
• Keep all parts of your body away from the rotating wheel. Long hair or loose clothing can become drawn intorotating
components.
•Keep the wheel offall surfaces when starting the grinder.
• Do not use a wheel that is cracked, chipped or otherwise damaged. Always inspect wheels for possible damage before
installation or use.
•Always use wheels that conform to the specifications given in the OPERATION section of this manual.
•Donotreversegrindingwheelrotationdirectionbychangingfluidflowdirection.
• Do not move the tool until the wheel has stopped rotating. Release the trigger if the power supply has been interrupted.

SAFETY PRECAUTIONS
•To avoid personal injury or equipment damage, all toolrepair,maintenanceandservicemustonly be performed by autho-
rizedandproperlytrainedpersonnel.
•Ifthe material being ground creates an emissionofdust and fumes, use personal protective devices.
•Nevercock,jamorwedgethegrindingwheelduringoperation.
• Never cause sparks in the vicinity of flamable materials.
• Eye injury, and cutting or severing of body parts is possible if proper procedures are not followed.
GRINDING WHEEL SAFETY
• Ensure that the grinding wheel is correctly mounted and tightened before use.
• Operate the grinder at “no load” for 30 seconds in a safe position and ensure there is no vibration or other defects detected.
Ifconsiderablevibrationor other defects are detected, stop operation of thetoolimmediatelyand determine the cause. Do
not use the tool until the defect is corrected.
•Ifthegrinderisdroppedwithanabrasivewheelinstalled,theabrasivewheelswhouldbeexaminedthoroughlybeforeuse.
• Only use abrasive wheels that comply withANSI B7.1/ISO 525, 603.
• Check that the maximum rpm operating speed of the abrasive wheel is equal to or greater than the rated shaft speed of the
grinder.
• Ensure that the grinding wheel dimensions are compatible with the grinder and that the grinding wheel fits the shaft.
• Ensure that the thread type and size of the grinding wheel exactly matches the thread type and size of the shaft.
6

Thesafetytag(p/n15875)
at right is attached to the
toolwhenshippedfromthe
factory. Readand under-
stand the safety instruc-
tions listed on this tag
beforeremoval. We
suggest you retain this tag
and attach it to the tool
when not in use.
TOOL STICKERS & TAGS
7
DANGER
IMPORTANT
READOPERATIONMANUALAND
SAFETY INSTRUCTIONS FOR THIS
TOOLBEFORE USING IT.
USE ONLY PARTSANDREPAIR
PROCEDURES APPROVED BY
STANLEYAND DESCRIBED IN THE OPERATION
MANUAL.
TAGTO BE REMOVED ONLYBY
TOOLOPERATOR.
SEEOTHER SIDE
1. FAILURETO USEHYDRAULIC HOSELABELED ANDCERTIFIED
AS NON-CONDUCTIVE WHENUSINGHYDRAULICTOOLSON
ORNEAR ELECTRICALLINES MAY RESULTIN DEATHOR SERI-
OUSINJURY.
BEFOREUSING HOSELABELED ANDCERTIFIED AS NON-CON-
DUCTIVEONORNEAR ELECTRICLINES BESURE THEHOSE IS
MAINTAINED AS NON-CONDUCTIVE. THEHOSE SHOULD BE
REGULARLYTESTED FOR ELECTRIC CURRENT LEAKAGE IN
ACCORDANCEWITH YOUR SAFETY DEPARTMENT INSTRUC-
TIONS.
2. AHYDRAULICLEAK ORBURSTMAY CAUSEOIL INJECTION
INTOTHEBODYORCAUSEOTHERSEVEREPERSONALINJURY.
ADONOT EXCEED SPECIFIEDFLOWAND PRESSUREFOR
THISTOOL. EXCESSFLOWORPRESSUREMAY CAUSEA
LEAKORBURST.
BDONOT EXCEEDRATEDWORKING PRESSUREOF HYDRAU
LICHOSEUSEDWITHTHIS TOOL. EXCESSPRESSUREMAY
CAUSEALEAKORBURST.
C CHECKTOOLHOSECOUPLERSANDCONNECTORSDAILY
FORLEAKS. DONOT FEELFORLEAKS WITHYOURHANDS.
CONTACTWITHALEAKMAY RESULTINSEVEREPERSONAL
INJURY.
IMPORTANT
READOPERATION MANUALAND
SAFETY INSTRUCTIONS FOR THIS
TOOLBEFORE USING IT.
USE ONLY PARTSANDREPAIR
PROCEDURES APPROVED BY
STANLEY AND DESCRIBED IN THE OPERATION
MANUAL.
TAGTO BE REMOVED ONLY BY
TOOLOPERATOR.
SEEOTHER SIDE
D DO NOT LIFT OR CARRY TOOL BY THE HOSES. DO NOT
ABUSE HOSE. DO NOT USE KINKED, TORN OR DAMAGED
HOSE.
3. MAKESURE HYDRAULIC HOSESARE PROPERLY CONNECTED
TOTHE TOOLBEFORE PRESSURINGSYSTEM. SYSTEM PRES-
SUREHOSEMUSTALWAYS BECONNECTEDTOTOOL "IN"PORT.
SYSTEMRETURNHOSEMUSTALWAYSBECONNECTEDTOTOOL
"OUT"PORT. REVERSINGCONNECTIONSMAY CAUSEREVERSE
TOOLOPERATION WHICHCAN RESULTIN SEVEREPERSONAL
INJURY.
4. DONOT CONNECTOPEN-CENTER TOOLSTO CLOSED-CENTER
HYDRAULICSYSTEMS. THIS MAY RESULTIN LOSS OFOTHER
HYDRAULICFUNCTIONSPOWEREDBY THESAMESYSTEMAND/
ORSEVEREPERSONALINJURY.
5. BYSTANDERSMAYBE INJUREDIN YOURWORK AREA. KEEPBY-
STANDERSCLEAROF YOURWORKAREA.
6. WEARHEARING,EYE, FOOT,HANDAND HEADPROTECTION.
7. TOAVOIDPERSONALINJURYOR EQUIPMENTDAMAGE,ALLTOOL
REPAIR MAINTENANCE AND SERVICE MUST ONLY BE PER-
FORMEDBY AUTHORIZEDAND PROPERLYTRAINED PERSON-
NEL.
(shown smaller then actual size)
SAFETY TAG P/N 15875
DANGER
25413
NAMETAG
NOTE
THEINFORMATIONLISTEDONTHE
STICKERSSHOWN,MUSTBE
LEGIBLEATALLTIMES.
REPLACEDECALS IF THEY BECOME
WORNOR DAMAGED.
REPLACEMENTSAREAVAILABLE
FROMYOUR LOCALSTANLEY
DISTRIBUTOR.
SERIALNUMBER &
MODELNUMBER
STAMPING
25413
25610
RAILROADHELPDESKDECAL
25610
03787
GPMDECAL
03787
25414
HG80110CAUTIONDECAL
25556
HG80120CAUTIONDECAL
05153
STANLEY NAME DECAL
05153

HOSE TYPES
Hydraulic hose types authorized for use with Stanley Hydraulic Tools are as follows:
!!
!!
!
Certifiednon-conductive
""
""
"
Wire-braided(conductive)
##
##
#
Fabric-braided(notcertifiedorlabelednon-conductive)
Hose !!
!!
! listed above is the only hose authorized for use near electrical conductors.
Hoses ""
""
"and ##
##
#listed above are conductive and must never be used near electrical conductors.
HOSE SAFETY TAGS
To help ensure your safety, the following DANGER tags are attached to all hose purchased from Stanley Hydraulic
Tools. DO NOTREMOVETHESE TAGS.
If the information on a tag is illegible because of wear or damage, replace the tag immediately. Anew tag may be
obtainedfromyourStanleyDistributor.
HOSE PRESSURE RATING
The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the
hydraulic system.
THETAG SHOWN BELOW ISATTACHED TO"CERTIFIED NON-CONDUCTIVE" HOSE
THE TAG SHOWN BELOW IS ATTACHED TO "CONDUCTIVE" HOSE.
HYDRAULIC HOSE REQUIREMENTS
SIDE1 SIDE2
D A N G E R
DO NOT REMOVE THIS TAG
D A N G E R
1 FAILURETOUSE HYDRAULICHOSE LABELEDAND CERTIFIEDAS NON-CONDUCTIVEWHEN
USINGHYDRAULICTOOLS ONOR NEARELECTRICLINESMAYRESULTIN DEATHOR SERIOUS
INJURY.
FOR PROPERANDSAFEOPERATION MAKESURETHATYOUHAVEBEENPROPERLY TRAINEDIN
CORRECTPROCEDURES REQUIREDFOR WORKON OR AROUNDELECTRIC LINES.
2. BEFOREUSINGHYDRAULIC HOSELABELED ANDCERTIFIED ASNON-CONDUCTIVE ONOR
NEARELECTRICLINES. WIPETHEENTIRE LENGTHOFTHE HOSEANDFITTING WITHACLEAN
DRYABSORBENTCLOTHTO REMOVEDIRTAND MOSISTUREANDTESTHOSE FORMAXIMUM
ALLOWABLECURRENTLEAKAGEIN ACCORDANCEWITHSAFETY DEPARTMENT
INSTRUCTIONS.
SEEOTHERSIDE
DO NOT REMOVE THIS TAG
3. DONOTEXCEEDHOSEWORKING PRESSUREORABUSEHOSE. IMPROPERUSE ORHANDLING
OFHOSECOULDRESULT INBURSTOR OTHERHOSEFAILURE. KEEP HOSEASFARAWAY AS
POSSIBLEFROMBODY ANDDO NOTPERMIT DIRECTCONTACTDURING USE. CONTACTAT THE
BURSTCANCAUSE BODILYINJECTIONAND SEVEREPERSONALINJURY.
4. HANDLEANDROUTE HOSECAREFULLY TOAVOIDKINKING, ABRASION, CUTTING,OR CONTACT
WITHHIGHTEMPERATURE SURFACES. DONOT USEIFKINKED. DONOTUSE HOSETOPULL OR
LIFTTOOLS,POWERUNITS,ETC.
5. CHECKENTIREHOSEFOR CUTSCRACKSLEAKSABRASIONS, BULGES,ORDAMAGETO
COUPLINGSIFANYOFTHESECONDITIONS EXIST,REPLACETHEHOSEIMMEDIATELY. NEVER
USETAPEORANYDEVICETOATTEMPTTOMENDTHEHOSE.
6. AFTEREACHUSESTORE INACLEANDRY AREA.
SEEOTHERSIDE
3(shown smaller than actual size)
(shown smaller than actual size)
D A N G E R
DO NOT REMOVE THIS TAG
D A N G E R
1 DONOT USETHIS HYDRAULICHOSEON ORNEAR ELECTRICLINES. THIS HOSEISNOT
LABELEDORCERTIFIED ASNON-CONDUCTIVE. USING THISHOSE ONORNEAR ELECTRICAL
LINESMAYRESULT INDEATHOR SERIOUSINJURY.
2. FORPROPERANDSAFEOPERATIONMAKESURETHAT YOUHAVEBEENPROPERLY TRAINEDIN
CORRECTPROCEDURES REQUIREDFOR WORKON OR AROUNDELECTRIC LINES.
3. DONOTEXCEED HOSEWORKINGPRESSURE ORABUSEHOSE. IMPROPER USEORHANDLING
OFHOSECOULDRESULT INBURSTOR OTHERHOSEFAILURE. KEEP HOSEASFARAWAY AS
POSSIBLEFROMBODY ANDDO NOTPERMITDIRECTCONTACTDURINGUSE. CONTACT AT
THEBURSTCAN CAUSEBODILYINJECTION ANDSEVEREPERSONALINJURY.
4. HANDLEANDROUTE HOSECAREFULLY TOAVOID KINKING, CUTTING,OR CONTACTWITH
HIGHTEMPERATURESURFACES. DO NOTUSEIF KINKED. DONOT USEHOSETO PULLOR LIFT
TOOLS,POWERUNITS,ETC.
SEEOTHERSIDE
DO NOT REMOVE THIS TAG
5. CHECKENTIREHOSEFOR CUTSCRACKSLEAKSABRASIONS, BULGES,ORDAMAGETO
COUPLINGSIFANYOFTHESECONDITIONS EXIST,REPLACETHEHOSEIMMEDIATELY. NEVER
USETAPEORANYDEVICETOATTEMPTTOMENDTHEHOSE.
6. AFTEREACHUSESTORE INACLEANDRY AREA.
SEEOTHERSIDE
SIDE1 SIDE 2
8

HTMA REQUIREMENTS
9
FLOWRATE
TOOLOPERATINGPRESSURE
(atthepower supply outlet)
SYSTEMRELIEFVALVESETTING
(atthepower supply outlet)
MAXIMUMBACKPRESSURE
(attool end of the return hose)
Measured at a max. fluid viscosity of:
(atmin.operatingtemperature)
TEMPERATURE
Sufficientheatrejection capacity
to limit max. fluid temperature to:
(atmax.expectedambienttemperature)
Min. cooling capacity
atatemperaturedifferenceof
betweenambientandfluidtemps
NOTE:
Donotoperatethetool at oil temperatures above 140° F (60° C). Operation at highertemperaturescancauseoperator
discomfort at the tool.
FILTER
Min.full-flowfiltration
Sized for flow of at least:
(For cold temp. startup and max. dirt-holding capacity)
HYDRAULICFLUID
Petroleumbased
(premiumgrade,anti-wear,non-conductive)
VISCOSITY
(at min. and max. operating temps)
NOTE:
Whenchoosinghydraulic fluid, the expected oil temperature extremesthatwill be experienced in service determine the
most suitable temperature viscosity characteristics. Hydraulic fluids with a viscosity index over 140 will meet the require-
mentsoverawiderangeof operating temperatures.
*SSU=Saybolt Seconds Universal
4-6gpm 7-9gpm 11-13gpm 9-10.5 gpm
(15-23lpm) (26-34lpm) (42-49lpm) (34-40lpm)
2000psi 2000psi 2000 psi 2000 psi
(138bar) (138bar) (138bar) (138bar)
2100-2250psi 2100-2250psi 2100-2250psi 2200-2300psi
(145-155bar) (145-155bar) (145-155bar) (152-159bar)
250psi 250psi 250psi 250psi
(17bar) (17bar) (17bar) (17bar)
400 ssu* 400 ssu* 400 ssu* 400 ssu*
(82 centistokes)(82centistokes) (82centistokes) (82centistokes)
140°F 140°F 140° F 140°F
(60°C) (60°C) (60°C) (60° C)
3hp 5hp 7hp 6hp
(2.24 kW) (3.73 kW) (4.47 kW) (5.22 kW)
40°F 40°F 40°F 40°F
(22°C) (22°C) (22°C) (22° C)
25microns 25microns 25microns 25microns
30gpm 30gpm 30 gpm 30 gpm
(114 lpm) (114lpm) (114lpm) (114 lpm)
100-400ssu* 100-400ssu* 100-400ssu* 100-400ssu*
(20-82 centistokes)
TOOL CATEGORY
HYDRAULIC SYSTEM
REQUIREMENTS TYPE 1 TYPEII TYPEIII TYPE RR
NOTE:
These are general hydraulic system requirements. See tool Specification page for tool specific requirements.

PREOPERATION
PROCEDURES
PREPARATION FOR INITIAL USE
Each unit as shipped has no special unpacking or assembly
requirements prior to usage. Inspection to assure the unit
was not damaged in shipping and does not contain packing
debris is all that is required. After installation of a grinding
wheel a unit may be put to use.
CHECK HYDRAULIC POWER SOURCE
1. Usinga calibrated flowmeter and pressure gauge,check
thatthehydraulicpowersourcedevelopsaflowof 7-10 gpm/
26-38lpmat1500-2000psi/105-140bar.
2. Make certain the hydraulic power source is equipped with
areliefvalvesettoopen at 2100-2250 psi/145-155 bar
minimum.
3. Check that the hydraulic circuit matches the tool for
open-center(OC)orclosed-center (CC) operation.
CHECK TOOL
1. Make sure all tool accessories are correctly installed.
Failure to install tool accessories properly can result in
damage to the tool or personal injury.
2. There should be no signs of leaks.
3. The tool should be clean, with all fittings and fasteners
tight.
CHECK TRIGGER MECHANISM
1. Check that the trigger operates smoothly and is free to
travelbetweenthe "ON" and "OFF" positions.
CHECK GUARD ASSEMBLY
1. Inspect the wheel guard assembly for cracks and other
structuraldamage.
INSTALLINGANDREMOVINGGRINDINGWHEELS
READANDBECOMEFAMILIARWITHTHE SECTIONSIN
THISMANUALON SAFETYPRECAUTIONS,TOOLSTICK-
ERSANDTAGS, HYDRAULICHOSEREQUIREMENTS,
HYDRAULICREQUIREMENTS,ANDPREOPERATION
PROCEDURESBEFOREUSINGTHISPRODUCT.
OPERATION
NOTE:
Use 8 inch by 1 inch thick (Type 1) grinding wheels with a
5/8 arbor hole. Only use grinding wheels which comply
with ANSI B7.1/ISO 525, 603.
1. Loosen 3 capscrews and lockwashers (64 & 63) and
removetheguardfrontplate(62)andsetaside.
2. Depress the push lock (45) to lock the spindle. Unscrew
thejamnut(61). Remove the outside flange (60).
3. Make sure blotters or labels remain on the grinding
wheel. Installthegrinding wheel onto the spindle (33) and
reinstall the outside flange and jam nut.
4. Depress the push lock and tighten the jam nut. Only
tightensufficientlytopreventslippageofthewheelbetween
theflanges.
5. Reinstall the guard front plate, capscrews and
lockwashers.
CONNECT HOSES
1. Wipe all hose couplers with a clean lint-free cloth before
makingconnections.
2. Connect the hoses from the hydraulic power source to
the hose couplers on the grinder. It is a good practice to
connect the return hose first and disconnect it last to
minimizeoravoidtrappedpressurewithinthegrindermotor.
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:
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 to-
gether.
OPERATING PROCEDURES
1. Observeallsafety precautions.
2. Always start the grinder with the grinding wheel or cone
awayfromtheworksurface.
3. Move the hydraulic circuit control valve to the "ON"
position.
10

4. Squeeze the trigger momentarily. If the grinder does not
operate,thehoses might be reversed. Verify correct connec-
tionofthehosesbefore continuing.
5. Start the grinder and move the grinding wheel or cone to
theworksurface.
6. Grind a small amount of material at a time.
COLD WEATHER OPERATION
Ifthegrinder is to be used during coldweather,preheatthe
hydraulic fluid at low engine speed. When using the nor-
mallyrecommendedfluids,fluidtemperatureshould be at or
above50°F/10°C(400ssu/82centistokes) before use.
OPERATION
11

EQUIPMENT PROTECTION & CARE
•Make sure all couplers are wiped clean before connection.
•The hydraulic circuit control valve must be in the “OFF”position when coupling or uncoupling
hydraulic tools. Failure to do so may result in damage to the quick couples and cause overheating
of the hydraulic system.
•Always store the tool in a clean dry space, safe from damage or pilferage.
•Make sure the circuit PRESSURE hose (with male quick disconnect) is connected to the “IN”port.
The circuit RETURN hose (with female quick disconnect) is connected to the opposite port. Do not
reverse circuit flow. This can cause damage to internal seals.
•Always replace hoses, couplings and other parts with replacement parts recommended by Stanley
Hydraulic Tools. Supply hoses must have a minimum working pressure rating of 2500 psi/172 bar.
•Do not exceed the rated flow (see Specifications) in this manual for correct flow rate and
model number. Rapid failure of the internal seals may result.
•Always keep critical tool markings, such as warning stickers and tags legible.
•Tool repair should be performed by experienced personnelonly.
•Make certain that the recommended relief valves are installed in the pressure side of the system.
•Do not use the tool for applications for which it was not intended.
In addition to the Safety
Precautions in this manual,
observethefollowingfor
equipmentprotectionand
care.
NOTICE
12

TROUBLESHOOTING
Grinerdoesnotrun Hydraulicpowersourcenot Checkpowersource for proper
functioning. flowandpressure(7-10gpm/
26-38lpm@1500-2000psi/
105-140bar.
Couplersorhosesblocked. Locateandremoverestriction.
Hydraulicmotorfailure. Inspectandrepair.
Hydrauliclines not connected. Connect lines.
Grinderoperatestooslow. Hydraulicmotor speed to slow. Checkpowerunitforproper
flow(7-10gpm/26-38 lpm).
Highback-pressure. Check hydraulic system for
excessiveback-pressure(over
250psi/17bar).
Couplersorhosesblocked. Locateandremoverestriction.
Oiltoohot(above 140°F/60°C) Checkhydraulicpowersource
ortoocold(below60°F/16°C). forproper oiltemperature.
Bypass cooler to warm oil or
providecoolertomaintain proper
temperature.
Reliefvalvesettoo low. Adjust reliefvalveto2100-2250
psi/145-155bar.
Hydraulicmotorworn. Inspect,repairorreplace.
Flowcontrolmalfunctioning. Haveflow control serviced at
anauthorizedStanleyservice
center.
Grinderoperatestoofast. Flowcontrolmalfunctioning. Haveflowcontrol andvalvebody
servicedatanauthorized
Stanleyservicecenter.
Ifsymptomsofpoorperformance develop, the
following chart can be used as a guide to correct
theproblem.
Whendiagnosingfaultsin operation of the grinder,
always check that the hydraulic power source is
supplyingthecorrect hydraulic flow and pressure to
the grinder as listed in the table. Use a flowmeter
known to be accurate. Check the flow with the
hydraulicoiltemperatureatleast 80°F/27°C.
13

SPECIFICATIONS
WheelCapacity ........................................................................................................ 8 in. dia. x 1 in. thk x 5/8 arbor (type 1)
PressureRange ............................................................................................................................. 1000-2000psi/70-140bar
Maximum Back Pressure................................................................................................................................ 250psi/17bar
FlowRange .............................................................................................................................................7-10gpm/26-38lpm
OptimumFlow.............................................................................................................................................. 10 gpm / 38 lpm
Porting .............................................................................................................................................................-8 SAE O-ring
Couplers ..................................................................................................... HTMA/EHTMAFlush Face Type Male & Female
Hose Whips .....................................................................................................................................................................Yes
Weight (with whip hoses & couplers)............................................................................................................ 14.1 lb / 6.40 kg
OverallLength .........................................................................................................................................23 inches / 58.4 cm
OverallWidth...........................................................................................................................................10 inches / 25.4 cm
OverallHeight.......................................................................................................................................10.5 inches / 26.7 cm
RPM ...................................................................................................................................................................... 4500Max
MaximumFluidTemperature ..............................................................................................................................140°F/60°C
ACCESSORIES
28598 Grinding Wheel - Norton Norzon IV (8 inch dia. x 1 inch wide x 5/8 arbor)
26847 AssistHandle(Straight)
14

SERVICE
GRINDERDISASSEMBLY
SPINDLE & SPINDLE HOUSING DISASSEMBLY
1. Loosen 3 capscrews and lockwashers (64 & 63) and
removetheguardfrontplate(62)andsetaside.
2. Depress the push lock (45) to lock the spindle. Remove
thejamnut (61), outside flange (60), grindingwheelif one is
present,thedriveflange(59)andthekey(32).
3. Unscrew the capscrew (56) and slide the inner guard assy
(58)offofthespindlehousing(49).
4.Remove3capscrews (51) and lift the spindle housing (49)
offof the motor front bearing housing (13).Pick out the
coupling (37) and set it aside.
5.Pressthespindle (33), bearing (34) and bearing spacer
(36) out of the spindle housing by using an arbor press and
pressingonthespindlefromthe threaded end. This proce-
durewillalsoremovethev-ringseal(54)fromthespindle.
Discardthev-ringseal.
6.Removetheretainingring(35)fromthespindle.
7.Removethebearing(34) from the spindle by placing the
spindle in an arbor press and pressing on the coupling end.
8.Removethebearingrace(48)from the spindle by placing
thespindlein an arbor press and pressingonthe threaded
endofthe spindle.
6. Pry the seal (53) out of the spindle housing and discard it.
7.Removetheneedlerollerbearing(52) from the spindle
housingby using a bearing puller tool.
8.Thepush lock (45) may be removed from thespindle
housingbyfirstremoving the retaining ring (44). Pull the
push lock out of the spindle housing. Pick out the spring
(47). Pry the o-ring (46) off of the push lock and discard it.
MOTOR DISASSEMBLY
1. Complete steps 1 through 4 of the Spindle and Spindle
HousingDisassembly.
3. Remove8capscrews(8) and using a flat-blade screw-
driverorsimilartool, gently pry the front (13) and rear (16)
bearinghousingsapart.Liftthefrontbearinghousingstraight
up. Do Not tilt the housing or pry on the flat surface inside of
thesurroundinggroove.Forprying,only use the groove
providedatthe split between the parts to prevent scratches
ontheinner mating surfaces.
4.Remove the two gears(5 & 15), needle roller key (14), and
theidlershaft (4).
5.Removethelargefacesealo-ring(3)whilebeingcareful
nottodamagetheo-ring groove or surrounding surface.
6. While protecting the motor surface of the shaft housing
fromdamage,hold the front bearing housing on its side and
tap lightly on the small diameter end (gear side) of the motor
shaft(39)toremoveitandthebearing(38) from the front of
thehousing.
7.To remove the bearing (38)fromthe shaft(39), presson
thespindleend of the motor shaft whilesupportingthe outer
raceofthebearing. Discard the old bearing.
8.Remove the retaining ring (40) atthe bottom of the ball
bearingboretoservicetheshaftseal. Remove the seal gland
(41)using the appropriate o-ring service tools to pry it out of
its bore.Take care to avoid damaging the seal surfaces.
Notesealorientation.Removetheo-ring(43)fromthe
outsideofthesealgland.Remove the quad ring (42) from the
inside of the seal gland.
9.Removethefourbushings(2)fromtheshafthousingand
gearchamberusingp/n11930 collet from p/n 05064 bearing
puller kit.
INSPECTION AND CLEANING
Inspect and clean all parts as follows:
Cleaning
Cleanall parts with a degreasingsolvent. Blow dry with
compressed air and wipe clean. Use only lint-free cloths.
Gear Chamber
Thechamberboresandbottomsaroundtheshaftbushings
shouldbepolishedandnotroughorgrooved.Ifthebushing
boresareyellow-bronze,replacethemandinvestigatethe
causeofwear.
Theflatsurfacesaroundthechamberand bolt holes should
15

inthefluid and for filter condition. Operating conditionsmay
requirechangingfroma25-micronfiltertoan oversized 10-
micronfilter.
REASSEMBLY
1.Greaseand carefully install the quad ring into the groove
on the inside of the seal gland. Care-fully install the o-ring
intothegroove on the outside diameter of the sealglandand
install the seal gland into the bore of the shaft housing.
Replacetheretainingring.
2. To replace the bearing on the motor shaft, support the
bearinginnerraceand press the motor shaft through the
bearinginnerrace.
3.Ifthebushingswereremoved, install new bushings using
ap/n11918 bearing pusher.
4.Apply grease to the motor shaft, keyway and bushing then
insert it through the shaft seal. Using a sleeve/socket with a
diameterequalto the bearing O.D., press the bearing
assembly into place. Press only on the outer race.
5. Install the needle roller in the keyway of the motor shaft.
Use grease to keep the roller in place. Slide the drive gear
overtheroller and shaft.Installtheidlershaftandgear.
6.Apply grease to the face seal o-ring groove; then install
theo-ring.
7. Note the screw hole pattern on both housings. They will
only assemble one way. With all parts aligned, carefully slide
the gear housing assembly over the gears until it contacts
the bearing housing assembly. Do not force parts together.
8. Turn the motor shaft manually to check for free rotation.
Install the eight capscrews and then recheck rotation.
VALVE HANDLE DISASSEMBLY
1.Removethe2capscrews(11)whichfastenthevalvebody
(24)tothedipped tube (10).
2.Removethevalvebodyand related parts from the dipped
tube by wiggling the valve body and pulling at the same time.
3.Removetheoiltubes(9) from the valve body.Ifoneorboth
oiltubesremainedin the dipped tube, remove the eight
capscrews (8) which fasten the dipped tube to the motor
assemblyand then remove thedipped tube and theoil tubes.
4. Knock out the roll pin (20) which holds the valve spool (31)
be flat and free of nicks or burrs that could cause misalign-
ment or leaks.
Bushings
Theinside of the bushingsshould be gray with some bronze
showingthrough.Ifsignificantyellow-bronzeshows,replace
thebushings.Inspectmotorshaftforcorrespondingwearand
replaceasrequired.
Thedriveandidlergearsshouldhavestraighttipswithout
nicks; square tooth ends and a smooth even polish on the
teethandend faces. Check for cracks between the drive
gear keyway and gear tooth root. Replace the gear if cracks
arepresent.
ShaftHousingAssembly
Thesurfacenearthegearsshouldshowtwointerconnecting
polished circles without a step. The bottom of the o-ring
groove should be smooth as should the rest of the flat
surface.
Theborefor the shaft seal (inside of thesealgland) should
be smooth or oil leakage may occur. The bore in which the
seal liner fits should also be smooth.
Shake the shaft housing and the two seal check balls (not
shown) should rattle. Unless there are leaks at theAllen type
plugs which retain the check balls (not shown), or the check
balls have jammed because of fluid contaminants, it is not
necessary to remove the plugs or check balls. If these are
removed, be sure the check seats (the bottom of the holes
into which the balls are placed around the small oil holes)
are smooth. If not, the seat can usually be fixed by cleaning
and then placing the ball in the hole and tapping on the ball
withanaluminumorbronze rod.
Reassemble ball and plug with the inner end of the plug just
starting to show in the hole as viewed through the oil slot on
the gear face of the housing. You can also use a wire
through this hole to feel when the plug is deep enough. Note:
Use sealant/adhesive such as Loctitetm PST on plug to seal
threads.
Shafts
The shaft diameter at the bearing and seal loca-tions must
besmooth.Grooves,roughnessorareduceddiameter
indicatefluidcontaminationordamagedbushings.Grit
particlesmayhavebeenimbeddedinthebushings,grinding
intothehard-enedshaft.Ifabnormalshaft wear as above
occurs(morethannormal polishing), replace both the shaft
andassociatedbushings.
Also check the hydraulic system for excess con-tamination
SERVICE
16

tothetrigger(21)andremovethevalvespoolassemblyand
spring(22).
5. Knock out the roll pin (20) which holds the trigger to the
valvebodyand removethetrigger.
6.Theflowregulatorcartridge(30)maybe removed by
placing a wrench on the hex flats and unscrewing the
cartridgeassembly. The flow regulator cartridge is preset and
isnotfieldser-viceable.
7. Pry out the 2 o-rings (23), the 2 o-rings (12) and discard
them.
GRINDERREASSEMBLY
VALVE HANDLE REASSEMBLY
1.Apply grease and install 2 o-rings (23). Grease and install
2o-rings(12).
2.Installtheflowregulatorcartridge(30).
3.Apply grease to the outer surface of thevalvespool
assembly and install it into the valve body as shown in the
partsdrawing.
4.Placethespring(22)andtrigger(21)overthevalvespool.
Align the roll pin hole in the valve spool with the roll pin hole
in the trigger and install the roll pin (20).
5.Align the roll pin hole in the trigger with the roll pin hole in
thevalvebodyand install the roll pin (20).
OIL TUBESAND DIPPED TUBE
REASSEMBLY
1.Apply grease to 2 o-rings (12) and install them into the oil
portsoftherearbearingretainer(16) of the motor.
2.Apply grease to the end of each oil tube (9) and insert one
endof each tube into an oil port in the rear bearingretainer of
themotor.
3. Slide the dipped tube (10) over the two oil tubes and align
the fastener holes with those in the motor.Apply 242
Loctitetm and install the 8 capscrews (8). Tighten to 68-75
in. Ibs.
4.Placethevalvehandle(24)overtheotherendof the oil
tubes making sure the tubes are not twisted and are aligned
with the correct ports (directly in line with ports in the valve
handleandmotor).Pushthevalve handle onto the oil tubes
andintothe dipped tube until the valve handleisup against
the end of the dipped tube. Some wiggling of the handle may
berequiredtosuccess-fullyperform this procedure.Apply
242 Loctitetm and install the 2 capscrews (11). Tighten to
68-75in.Ibs.
5.Ifremoved,reinstallthehosesandcouplers(female
couplertothe “IN”port, male coupler to the “OUT”port).
SPINDLE & SPINDLE HOUSING
REASSEMBLY
1.Lubricatetheneedlerollerbearing(52)thor-oughlywith
lithiumbasedgreaseforextremepressureapplicationsand
containingan NLGI rating of 2. Installthebearing into the
spindlehousing(49)usinganarborpress.
2.Apply grease and install the seal (53) into the spindle
housing,ontop of the needle roller bear-ing, with lips facing
down.
3.Lubricatethebearing(34)thoroughly with lithium based
greaseforextremepressureapplica-tionsandcontainingan
NLGIrating of 2. Installthe bearing onto the motor end of the
spindle (33) using an arbor press. Secure the bearing in
placewiththeretaining ring (35).
4. Install the bearing race (48) onto the spindle using an
arborpress. Lubricate the outer surface of the race withthe
lithiumgreaseusedfortheneedlerollerbearing.
5. Install the spindle (threaded end first) into the motor end of
the spindle housing. Using an arbor press, press the spindle
into the spindle housing until the bearing butts against the
bottomofthebearingbore.
6. Install the bearing spacer (36) into the spindle housing.
7.Apply grease and install the v-ring seal (50) onto the
spindlewiththebeveledsidefacing toward the threads of the
spindle.
8.Lubricatethe coupling (37) and coupling ends ofthe
spindle and motor shaft with the extreme pressure lithium
grease. Install the coupling onto the spindle and then install
the completed spindle and spindle housing assembly to the
motor being careful to assure the coupling is aligned with the
motor shaft and spindle. Secure the assembly in place with
the 3 capscrews (51).
SERVICE
17

9.Apply grease and install a new o-ring (46) onto the push
lock (45).
10.Apply grease and install the spring (47) into the bore in
the spindle housing. Apply grease to the push lock and
install it on top of the spring being careful to assure the push
lock slides inside of the spring. Push down on the push lock
andinstalltheretaining ring (44).
9. Do not install the wheel guard, flanges (59 & 60) or the
grindingwheeluntilaftertestingthegrinderforoperationand
performance.
TESTING FOR OPERATION &
PERFORMANCE
1.Connectthe grinder to a hydraulic power sourceand
checkforsmooth running. Observe for leaks.
Note: Make sure the hydraulic power source is running at the
lowest gpm/lpm rate it can while still producing full pressure.
2.Motors will sometimes betight and require “break-in”.
break-inis accomplished by turning the shaft while applying
hydraulicpressure.OntheHG80Grindersthisprocedure
canbeaccomplished by obtain-inga5/8-11nutandenough
thick washers to permit the nut to be tightened against the
washerson the spindle shaft.
Usingawrench, turn the shaft while applying hydraulic
power.Turntheshaftboth withand against the hydraulic
pressure until the motor starts and runs freely.
3. Install the inner guard assy (49) onto the spindle housing.
Position it so that the handle on top of the housing is in line
withthetriggeronthevalvehandleandthen tighten the
capscrew(56).
4. Install the key (32) and drive flange (59). Install the
grindingwheel,theouterflange(60)and the jam nut (61).
Depress the push lock and tighten the jam nut sufficiently to
preventthegrindingwheelfrom slipping between the flanges.
DONOTOVERTIGHTEN! SEEINSTALLATIONOFGRIND-
INGWHEELSUNDERTHE SECTION MARKED “OPERA-
TION”.
5. Install the guard front plate (62) with the 3 capscrews (64)
andlockwashers(63).
SERVICE
18
During this break-in procedure, maintain grip on
wrench while hydraulic power is applied to motor.
Loosing grip may result in injury.
WARNING

HG80 PARTS ILLUSTRATION
19

HG80 PARTS LIST
Item Part Number
No. HG80110B HG80120B Qty Description
1 25610 25610 1 Railroad Help Desk Sticker
2 06316 06316 4 Bushing
3 00178 00178 1 O-ring, 2-1/8 x 2-1/4 x 1/16 -034 70D*
4 06305 06305 1 Idler Shaft
5 25667 25667 1 Idler Gear
6 04031 04031 2 Dowel Pin
7 25413 25413 1 NameTag (US & CE models)
8 03249 03249 8 Capscrew
9 27667 27667 2 Oil Tube
10 30008 30243 1 Dipped Tube
11 30366 30366 2 Capscrew, 10-24 x 3/8
12 00018 00018 4 O-ring, 7/16 x 9/16 x 1/16 -013 90D*
13 21430 25553 1 Front Bearing Hsg
21437 25554 1 Front Brg Hsg Assy (incl item 2)
14 03227 03227 1 Needle Roller
15 25666 25666 1 Drive Gear
16 29775 29776 1 Rear Bearing Housing
28566 28565 1 Rear Bearing HousingAssy (incl items 2 & 14)
17 27441 27441 1 Thumb Latch
18 27445 27445 1 Torsion Spring
19 01851 01851 1 RollPin
20 00114 00114 2 RollPin
21 27442 27442 1 Thumb Trigger
22 04097 04097 1 CoilSpring
23 01211 01211 2 O-ring, 5/8 x 3/4 x 1/16 -013 90D*
24 27608 27608 1 Dipped Valve Body
25 01605 01605 2 O-ring, .644 x .818 x .087 -908* (incl. w/ 26)
26 58630 58630 2 Hose Assy
27 24058 24058 1 Female Coupler Body
28 24059 24059 1 Male Coupler Body
29 350041 350041 1 -4 SAE Plug
30 25635 25635 1 Flow Regulator Cartridge (pre-set)
31 04480 04480 1 Valve Spool
32 02447 02447 1 Key
33 30230 30271 1 Spindle
34 00148 00148 1 Ball Bearing
35 00708 00708 2 RetainingRing
36 30231 30231 1 Bearing Spacer
37 25360 25360 1 Coupling
38 00148 00148 1 Ball Bearing
39 06303 06303 1 Motor Shaft
40 00170 00170 1 RetainingRing
41 30333 30333 1 SealGland
42 00214 00214 1 Quad Ring, 1/2 x 5/8 x 1/16 Q-4014*
43 350771 350771 1 O-ring, 11/16 x 13/16 xz 1/16 -017 90D*
44 25918 25918 1 RetainingRing
45 25689 25689 1 Push Lock
46 00106 00106 1 O-ring, 3/8 x 1/2 x 1/16 -012*
47 25788 25788 1 CoilSpring
48 06299 06299 1 Bearing Race
49 30229 30229 1 Spindle Housing
50 03787 03787 1 GPMSticker
51 00120 00120 3 Capscrew, 1/4-20 x 2-1/4
52 06313 06313 1 Needle Roller Bearing
53 06312 06312 1 Seal*
54 06311 06311 1 V-ring Seal*
55 05153 05153 1 Stanley Sticker
56 01458 01458 1 Capscrew, 3/8-16 x 3/4
57 01459 01459 2 Lockwasher
58 25908 25908 1 Inner Guard Assy
59 25355 25355 1 Drive Flange
60 25354 25354 1 Outside Flange
61 01714 03012 1 Nut
62 25906 25906 1 Guard Front Plate
Item Part Number
No. HG80110 HG80120 Qty Description
63 01298 01298 3 Lockwasher
64 25907 25907 3 Modified Capscrew
65 25414 25556 1 Caution Sticker
66 01459 01459 3 Lockwasher
67 01525 01525 2 Capscrew, 3/8-16 x 3/4
68 25914 25914 1 Assist Handle Assy
69 20939 20939 1 RollPin
70 00032 00032 2 Lockwasher
71 01411 01411 1 O-ring
72 24289 24289 1 Plug
73 20145 20145 1 SteelBall
74 01647 01647 1 O-ring
75 01521 01521 1 Capscrew, 1/4-20 x 1
Seal Kit Part No. 29139
Item Part
No. No. Qty Description
3 00178 1 O-ring
12 00018 4 O-ring
23 01211 2 O-ring
25 01605 2 O-ring
42 00214 1 QuadRing
43 350771 1 O-ring
46 00106 1 O-ring
53 06312 1 Seal
54 06311 1 V-ring Seal
20