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