HG80
HYDRAULIC GRINDER
USER MANUAL
Safety, Operation and Maintenance
© 2014 Stanley Black & Decker, Inc.
New Britain, CT 06053
U.S.A.
28075 8/2014 Ver. 8
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TABLE OF CONTENTS
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
TOOL PROTECTION & CARE................................................................................................................................12
TROUBLESHOOTING ............................................................................................................................................13
SPECIFICATIONS...................................................................................................................................................14
ACCESSORIES.......................................................................................................................................................14
HG80 PARTS ILLUSTRATION................................................................................................................................15
HG80 PARTS LIST..................................................................................................................................................16
IMPORTANT
To fill out a Product Warranty Recording form, and for information on your warranty,
visit Stanleyhydraulics.com and select the Company tab, Warranty.
(NOTE: The warranty recording form must be submitted to validate the warranty).
SERVICING: This manual contains safety, operation, and routine maintenance instructions. 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 with the wheel guard re-
moved.
comply with the safety precautions given in this manual
and on the stickers and tags attached to the tool and
hose.
Do not operate a damaged, improperly adjusted, or
incompletely assembled grinder.
These safety precautions are given for your safety. Re-
view them carefully before operating the tool and before
performing general maintenance or repairs.
Never wear loose clothing that can get entangled in
the working parts of the tool.
Keep all parts of your body away from the rotat-
ing wheel. Long hair or loose clothing can become
drawn into rotating components.
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 the wheel off all surfaces when starting the
grinder.
The model HG80 Hydraulic Grinder 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 grinder and hose before operation. Failure to do
so could result in personal injury or equipment damage.
Do not use a wheel that is cracked, chipped or oth-
erwise damaged. Always inspect wheels for pos-
sible damage before installation or use.
•
•
•
Always use wheels that conform to the specifications
given in the OPERATION section of this manual.
Do not reverse grinding wheel rotation direction by
changing fluid flow direction.
Do not move the tool until the wheel has stopped
rotating. Release the trigger if the power supply has
been interrupted.
•
•
The operator must start in a work area without by-
standers. Flying debris can cause serious injury.
•
To avoid personal injury or equipment damage, all
tool repair, maintenance and service must only be
performed by authorized and properly trained per-
sonnel.
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.
•
•
•
•
•
If the material being ground creates an emission of
dust and fumes, use personal protective devices.
•
Always wear safety equipment such as goggles, ear
and head protection, and safety shoes at all times
when operating the tool. Use gloves and aprons
when necessary.
Never cock, jam or wedge the grinding wheel during
operation.
Never cause sparks in the vicinity of flammable ma-
terials.
•
•
The operator must be familiar with all prohibited
work areas such as excessive slopes and danger-
ous terrain conditions.
Eye injury, and cutting or severing of body parts is
possible if proper procedures are not followed.
Warning: Use of this tool on certain materials during
demolition could generate dust potentially contain-
ing a variety of hazardous substances such as as-
bestos, silica or lead. Inhalation of dust containing
these or other hazardous substances could result
in serious injury, cancer or death. Protect yourself
and those around you. Research and understand
the materials you are cutting. Follow correct safety
procedures and comply with all applicable national,
state or provisional health and safety regulations
relating to them, including, if appropriate arranging
for the safe disposal of the materials by a qualified
person.
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 pow-
er source is connected. Accidental engagement of
the tool can cause serious in jury.
•
•
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.
Do not operate the tool at oil temperatures above
140 °F/60 °C. Operation at higher temperatures can
cause higher than normal temperatures at the tool
which can result in operator discomfort.
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SAFETY PRECAUTIONS
•
•
•
Check that the maximum rpm operating speed of
the abrasive wheel is equal to or greater than the
rated shaft speed of the grinder.
GRINDING WHEEL SAFETY
•
Ensure that the grinding wheel is correctly mounted
and tightened before use.
Ensure that the grinding wheel dimensions are com-
patible with the grinder and that the grinding wheel
fits the shaft.
•
Operate the grinder 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.
Ensure that the thread type and size of the grinding
wheel exactly matches the thread type and size of
the shaft.
•
•
If the grinder is dropped with an abrasive wheel
installed, the abrasive wheel should be examined
thoroughly before use.
Only use abrasive wheels that comply with ANSI
B7.1/ISO 525, 603.
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TOOL STICKERS & TAGS
25413
HG80 Name Tag
25414
HG80110B CAUTION DECAL
25556
HG80120B CAUTION DECAL
25610
Railroad Help Desk Sticker
05153
Stanley Sticker
03787
GPM Sticker 7–10 2000 PSI
NOTE:
D A N G E R
D A N G E R
THE INFORMATION LISTED
ON THE STICKERS SHOWN,
MUST BE LEGIBLE AT ALL
TIMES.
1. FAILURE TO USE HYDRAULIC HOSE LABELED AND CER-
TIFIED AS NON-CONDUCTIVE WHEN USING HYDRAULIC
TOOLS ON OR NEAR ELECTRICAL LINES MAY RESULT IN
DEATH OR SERIOUS INJURY.
D. DO NOT LIFT OR CARRY TOOL BY THE HOSES. DO
NOT ABUSE HOSE. DO NOT USE KINKED, TORN OR
DAMAGED HOSE.
3. MAKE SURE HYDRAULIC HOSES ARE PROPERLY CON-
NECTED TO THE TOOL BEFORE PRESSURING SYSTEM.
SYSTEM PRESSURE HOSE MUST ALWAYS BE CON-
NECTED TO TOOL “IN” PORT. SYSTEM RETURN HOSE
MUST ALWAYS BE CONNECTED TO TOOL “OUT” PORT.
REVERSING CONNECTIONS MAY CAUSE REVERSE
TOOL OPERATION WHICH CAN RESULT IN SEVERE
PERSONAL INJURY.
BEFORE USING HOSE LABELEDAND CERTIFIEDAS NON-
CONDUCTIVE ON OR NEAR ELECTRIC LINES BE SURE THE
HOSE IS MAINTAINED AS NON-CONDUCTIVE. THE HOSE
SHOULD BE REGULARLY TESTED FOR ELECTRIC CUR-
RENT LEAKAGE IN ACCORDANCE WITH YOUR SAFETY
DEPARTMENT INSTRUCTIONS.
REPLACE DECALS IF
THEY BECOME WORN OR
DAMAGED. REPLACEMENTS
ARE AVAILABLE FROM
YOUR LOCAL STANLEY
DISTRIBUTOR.
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.
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.
B. DO NOT EXCEED RATED WORKING PRESSURE OF
HYDRAULIC HOSE USED WITH THIS TOOL. EXCESS
PRESSURE MAY CAUSE A LEAK OR BURST.
6. WEAR HEARING, EYE, FOOT, HAND AND HEAD PRO-
TECTION.
7. TO AVOID PERSONAL INJURY OR EQUIPMENT DAMAGE,
ALL TOOL REPAIR MAINTENANCE AND SERVICE MUST
ONLY BE PERFORMED BY AUTHORIZED AND PROPERLY
TRAINED PERSONNEL.
C. CHECK TOOL HOSE COUPLERS AND CONNECTORS
DAILY FOR LEAKS. DO NOT FEEL FOR LEAKS WITH
YOUR HANDS. CONTACT WITH A LEAK MAY RESULT
IN SEVERE PERSONAL INJURY.
The safety tag (P/N 15875) at right is
attached to the tool when shipped from
the factory. Read and understand the
safety instructions listed on this tag before
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
READ OPERATION MANUAL AND
SAFETY INSTRUCTIONS FOR THIS
TOOL BEFORE USING IT.
removal. We suggest you retain this tag and
TOOL BEFORE USING IT.
attach it to the tool when not in use.
USE ONLY PARTS AND REPAIR
PROCEDURES APPROVED BY
STANLEY AND DESCRIBED IN THE
OPERATION MANUAL.
USE ONLY PARTS AND REPAIR
PROCEDURES APPROVED BY
STANLEY AND DESCRIBED IN THE
OPERATION MANUAL.
TAG TO BE REMOVED ONLY BY
TOOL OPERATOR.
TAG TO BE REMOVED ONLY BY
TOOL OPERATOR.
SEE OTHER SIDE
SEE OTHER SIDE
SAFETY TAG P/N 15875 (Shown smaller then actual size)
HG80 User Manual ◄ 7
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HOSE TYPES
The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the hy-
draulic system. There are three types of hydraulic hose that meet this requirement and are authorized for use with
Stanley Hydraulic Tools. They are:
Certified non-conductive — constructed of thermoplastic or synthetic rubber inner tube, synthetic fiber braid
reinforcement, and weather resistant thermoplastic or synthetic rubber cover. Hose labeled certified non-
conductive is the only hose authorized for use near electrical conductors.
Wire-braided (conductive) — constructed of synthetic rubber inner tube, single or double wire braid reinforce-
ment, and weather resistant synthetic rubber cover. This hose is conductive and must never be used near
electrical conductors.
Fabric-braided (not certified or labeled non-conductive) — constructed of thermoplastic or synthetic rubber in-
ner tube, synthetic fiber braid reinforcement, and weather resistant thermoplastic or synthetic rubber cover. This
hose is not certified non-conductive and must never be used near electrical conductors.
HOSE SAFETY TAGS
To help ensure your safety, the following DANGER tags are attached to all hose purchased from Stanley Hydraulic
Tools. DO NOT REMOVE THESE TAGS.
If the information on a tag is illegible because of wear or damage, replace the tag immediately. A new tag may be
obtained from your Stanley Distributor.
THE TAG SHOWN BELOW IS ATTACHED TO “CERTIFIED NON-CONDUCTIVE” HOSE
D A N G E R
D A N G E R
1. FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON-CONDUCTIVE
WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRIC LINES MAY RESULT IN
DEATH OR SERIOUS INJURY.
3. DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE. IMPROPER USE
OR HANDLING OF HOSE COULD RESULT IN BURST OR OTHER HOSE FAILURE.
KEEP HOSE AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT
CONTACT DURING USE. CONTACT AT THE BURST CAN CAUSE BODILY INJECTION
AND SEVERE PERSONAL INJURY.
FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROP-
ERLY TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND
ELECTRIC LINES.
4. HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING, ABRASION, CUTTING, OR
CONTACT WITH HIGH TEMPERATURE SURFACES. DO NOT USE IF KINKED. DO NOT
USE HOSE TO PULL OR LIFT TOOLS, POWER UNITS, ETC.
2. BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS NON-CONDUCTIVE
ON OR NEAR ELECTRIC LINES. WIPE THE ENTIRE LENGTH OF THE HOSE AND FIT-
TING WITH A CLEAN DRY ABSORBENT CLOTH TO REMOVE DIRT AND MOISTURE AND
TEST HOSE FOR MAXIMUM ALLOWABLE CURRENT LEAKAGE IN ACCORDANCE WITH
SAFETY DEPARTMENT INSTRUCTIONS.
5. CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS, BULGES, OR DAM-
AGE TO COUPLINGS IF ANY OF THESE CONDITIONS EXIST, REPLACE THE HOSE
IMMEDIATELY. NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE.
6. AFTER EACH USE STORE IN A CLEAN DRY AREA.
SEE OTHER SIDE
SEE OTHER SIDE
SIDE 1
SIDE 2
(Shown smaller than actual size)
THE TAG SHOWN BELOW IS ATTACHED TO “CONDUCTIVE” HOSE.
D A N G E R
D A N G E R
1. DO NOT USE THIS HYDRAULIC HOSE ON OR NEAR ELECTRIC LINES. THIS HOSE IS
NOT LABELED OR CERTIFIED AS NON-CONDUCTIVE. USING THIS HOSE ON OR NEAR
ELECTRICAL LINES MAY RESULT IN DEATH OR SERIOUS INJURY.
5. CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKSABRASIONS, BULGES, OR DAMAGE TO
COUPLINGS IF ANY OF THESE CONDITIONS EXIST, REPLACE THE HOSE IMMEDIATELY.
NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE.
2. FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY
TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND ELEC-
TRIC LINES.
6. AFTER EACH USE STORE IN A CLEAN DRY AREA.
3. DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE. IMPROPER USE OR
HANDLING OF HOSE COULD RESULT IN BURST OR OTHER HOSE FAILURE. KEEP HOSE
AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT CONTACT
DURING USE. CONTACT AT THE BURST CAN CAUSE BODILY INJECTION AND SEVERE
PERSONAL INJURY.
4. HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING, CUTTING, OR CONTACT
WITH HIGH TEMPERATURE SURFACES. DO NOT USE IF KINKED. DO NOT USE HOSE TO
PULL OR LIFT TOOLS, POWER UNITS, ETC.
SEE OTHER SIDE
SEE OTHER SIDE
SIDE 1
SIDE 2
(Shown smaller than actual size)
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HOSE RECOMMENDATIONS
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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. Depress the push lock (45) to lock the spindle. Un-
PRE-OPERATION PROCEDURES
PREPARATION FOR INITIAL USE
screw the jam nut (61). Remove the outside flange
(60).
Each unit as shipped has no special unpacking or as-
sembly requirements prior to usage. Inspection to as-
sure 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.
3. Make sure blotters or labels remain on the grind-
ing wheel. Install the grinding wheel onto the spindle
(33) and reinstall the outside flange and jam nut.
4. Depress the push lock and tighten the jam nut. Only
tighten sufficiently to prevent slippage of the wheel
between the flanges.
CHECK HYDRAULIC POWER SOURCE
1. Using a calibrated flowmeter and pressure gauge,
check that the hydraulic power source develops a
flow of 7–10 gpm/26–38 lpm at 1500–2000 psi/105–
140 bar.
5. Reinstall the guard front plate, capscrews and
lockwashers.
CONNECT HOSES
1. Wipe all hose couplers with a clean lint-free cloth
2. Make certain the hydraulic power source is equipped
with a relief valve set to open at 2100–2250 psi/145–
155 bar minimum.
before making connections.
2. Connect the hoses from the hydraulic power source
to the hose couplers on the grinder. It is a good prac-
tice to connect the return hose first and disconnect
it last to minimize or avoid trapped pressure within
the grinder motor.
3. Check that the hydraulic circuit matches the tool for
open-center (OC) or closed-center (CC) operation.
CHECK TOOL
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.
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.
2. There should be no signs of leaks.
NOTE:
3. The tool should be clean, with all fittings and fasten-
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.
ers tight.
CHECK TRIGGER MECHANISM
1. Check that the trigger operates smoothly and is free
OPERATING PROCEDURES
to travel between the ON and OFF positions.
1. Observe all safety precautions.
CHECK GUARD ASSEMBLY
2. Always start the grinder with the grinding wheel or
cone away from the work surface.
1. Inspect the wheel guard assembly for cracks and
other structural damage.
3. Move the hydraulic circuit control valve to the ON
INSTALLING AND REMOVING GRINDING
WHEELS
position.
4. Squeeze the trigger momentarily. If the grinder does
not operate, the hoses might be reversed. Verify
correct connection of the hoses before continuing.
READ AND BECOME FAMILIAR WITH THE SEC-
TIONS IN THIS MANUAL ON SAFETY PRECAU-
TIONS, TOOL STICKERS AND TAGS, HYDRAULIC
HOSE REQUIREMENTS, HYDRAULIC REQUIRE-
MENTS, AND PRE-OPERATION PROCEDURES BE-
FORE USING THIS PRODUCT.
5. Start the grinder and move the grinding wheel or
cone to the work surface.
6. Grind a small amount of material at a time.
NOTE:
COLD WEATHER OPERATION
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.
If the grinder 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.
1. Loosen 3 capscrews and lockwashers (64 & 63) and
remove the guard front plate (62) and set aside.
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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 and pressure. See
Specifications in this manual for correct flow rate
and pressure rating. 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.
Problem
Cause
Solution
Grinder does not run.
Hydraulic power source not
functioning.
Check power source for proper flow
and pressure (7–10 gpm/26–38 lpm @
1500–2000 psi/105–140 bar.
Couplers or hoses blocked.
Hydraulic motor failure.
Locate and remove restriction.
Inspect and repair.
Hydraulic lines not connected.
Hydraulic motor speed to slow.
Connect lines.
Grinder operates too slow.
Check power unit for proper flow (7–10
gpm/26–38 lpm).
High back-pressure.
Check hydraulic system for excessive
back-pressure (over 250 psi/17 bar).
Couplers or hoses blocked.
Locate and remove restriction.
Oil too hot (above 140 °F/60 °C) Check hydraulic power source for
or too cold (below 60 °F/16 °C).
proper oil temperature. Bypass
cooler to warm oil or provide cooler to
maintain proper temperature.
Relief valve set too low.
Adjust relief valve to 2100–
2250psi/145–155 bar.
Hydraulic motor worn.
Inspect, repair or replace.
Flow control malfunctioning.
Have flow control serviced at an
authorized Stanley service center.
Grinder operates too fast.
Flow control malfunctioning.
Have flow control and valve body
serviced at an authorized Stanley
service center.
HG80 User Manual ◄ 13
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SPECIFICATIONS
Wheel Capacity ............................................................................................. 8 in. dia. × 1 in. thk × 5/8 arbor (type 1)
Pressure Range................................................................................................................1000–2000 psi/70–140 bar
Maximum Back Pressure......................................................................................................................250 psi/17 bar
Flow Range ...............................................................................................................................7–10 gpm/26–38 lpm
Optimum Flow .....................................................................................................................................10 gpm/38 lpm
Porting..................................................................................................................................................–8 SAE O-ring
Couplers .........................................................................................HTMA/EHTMA Flush Face Type Male & Female
Hose Whips...........................................................................................................................................................Yes
Weight (with whip hoses & couplers)................................................................................................... 14.1 lb/6.40 kg
Overall Length................................................................................................................................23 inches/58.4 cm
Overall Width..................................................................................................................................10 inches/25.4 cm
Overall Height..............................................................................................................................10.5 inches/26.7 cm
RPM.............................................................................................................................................................6000 Max
Maximum Fluid Temperature.................................................................................................................. 140 °F/60 °C
ACCESSORIES
Grinding Wheel – Norton Norzon IV (8 inch dia. × 1 inch wide × 5/8 arbor)......................................................28598
14 ► HG80 User Manual
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HG80 PARTS ILLUSTRATION
HG80 User Manual ◄ 15
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HG80 PARTS LIST
PART
ITEM NO.
PART
ITEM NO.
QTY DESCRIPTION
QTY DESCRIPTION
1
2
3
4
25610
06316
00178
06305
1
4
1
1
RAILROAD HELP DESK STICKER
26
27
28
58630
66728
03972
47436
03973
47437
350041
28915
2
2
1
1
1
1
1
1
HOSE ASSY, PARKER
BUSHING
HOSE ASSY, AEROQUIP
FEMALE COUPLING, PARKER
FEMALE COUPLING, AEROQUIP
MALE COUPLING, PARKER
MALE COUPLING, AEROQUIP
-4 SAE PLUG
O-RING, 2-1/8 × 2-1/4 × 1/16 -034 70D
IDLER SHAFT (HG80110, HG80120,
HG80122 MODELS ONLY)
73308
25667
1
1
IDLER SHAFT KEYED (HG80113,
HG80123 MODELS ONLY)
29
30
5
IDLER GEAR (ALL HG80110, HG80120,
HG80122 MODELS ONLY)
FLOW REGULATOR CARTRIDGE
(PRE-SET)
6
04031
25413
03249
27667
30008
30243
70726
30366
00018
21437
2
1
8
2
1
1
DOWEL PIN
31
32
33
04098
02447
30230
1
1
1
VALVE SPOOL
7
NAME TAG (US & CE MODELS)
CAPSCREW
KEY
8
SPINDLE (HG80110B, HG80110BN,
HG80113, HG80110BUP)
9
OIL TUBE
10
HANDLE (ALL HG80110 MODELS)
HANDLE (ALL HG80120 MODELS)
HANDLE (HG80122BN MODEL ONLY)
CAPSCREW, 10-24 × 3/8
O-RING, 7/16 × 9/16 × 1/16 -013 90D
30271
1
SPINDLE (HG80120B, HG80120BN,
HG80122BN, HG80123, HG80120BUP),
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
00148
00708
30231
25360
00148
06303
00170
30333
00214
350771
25918
25689
00106
25788
06299
30229
03787
00120
06313
06312
06311
05153
01458
01459
25908
25355
25354
01714
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
1
BALL BEARING
11
12
13
2
4
1
RETAINING RING
BEARING SPACER
COUPLING
FRONT BEARING HSG (HG80110B,
HG80110BN, HG80113, HG80110BUP)
WITH BUSHINGS INSTALLED ITEM 2
BALL BEARING
MOTOR SHAFT
25554
1
2
FRONT BEARING HSG (HG80120B,
HG80120BN, HG80122BN, HG80123,
HG80120BUP) WITH BUSHINGS
INSTALLED ITEM 2
RETAINING RING
SEAL GLAND
QUAD RING, 1/2 × 5/8 × 1/16 Q-4014
O-RING 2-017 R17 90D BUNA
RETAINING RING
PUSH LOCK
14
15
16
03227
25666
29775
29776
71579
71580
NEEDLE ROLLER (MODELS HG80113,
HG80123 REQUIRE A QTY OF 2,
OTHER MODELS ONLY QTY OF 1)
2
OR
1
DRIVE GEAR (MODELS HG80113,
HG80123 REQUIRE A QTY OF 2, ALL
OTHER MODELS ONLY QTY OF 1)
O-RING, 3/8 × 1/2 × 1/16 -012
COIL SPRING
1
1
REAR BEARING RETAINER CCW (ALL
HG80110 MODELS) NO BUSHINGS
INSTALLED
BEARING RACE
SPINDLE HOUSING
GPM STICKER
REAR BEARING RETAINER CW
(ALL HG80120 & 122 MODELS) NO
BUSHINGS INSTALLED
CAPSCREW, 1/4-20 × 2-1/4
NEEDLE ROLLER BEARING
SEAL
16A
GEAR HSG ASSY (HG80113 ONLY)
WITH BUSHINGS & DOWEL PIN
INSTALLED
GEAR HSG ASSY (HG80123 ONLY)
WITH BUSHINGS & DOWEL PIN
INSTALLED
V-RING SEAL
STANLEY STICKER
CAPSCREW, 3/8-16 × 3/4
LOCKWASHER
17
18
19
20
21
22
23
24
25
27441
27445
01851
00114
27442
04097
01211
28595
01605
1
1
1
2
1
1
2
1
2
THUMB LATCH
TORSION SPRING
ROLL PIN
INNER GUARD ASSY
DRIVE FLANGE
ROLL PIN
OUTSIDE FLANGE
THUMB TRIGGER
COIL SPRING
NUT (HG80110B, HG80110BN,
HG80113, HG80110BUP
O-RING, 5/8 × 3/4 × 1/16 -013 90D
DIPPED VALVE BODY
O-RING (INCL W/ 26)
03012
25906
1
1
NUT (HG80120B, HG80120BN,
HG80122BN, HG80123, HG80120BUP
62
GUARD FRONT PLATE
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HG80 PARTS LIST
PART
ITEM NO.
QTY DESCRIPTION
LOCKWASHER
63
64
65
01298
25907
25414
25556
01459
01525
25914
20939
00032
01411
24289
20145
01647
01521
3
3
1
1
2
2
1
1
2
1
1
1
1
1
MODIFIED CAPSCREW
CAUTION STICKER (HG80110B)
CAUTION STICKER (HG80120B)
LOCKWASHER
66
67
68
69
70
71
72
73
74
75
CAPSCREW, 3/8-16 × 3/4
ASSIST HANDLE ASSY
ROLL PIN
LOCKWASHER
O-RING
PLUG
STEEL BALL
O-RING
CAPSCREW, 1/4-20 × 1
29139
1
SEAL KIT
HG80 User Manual ◄ 17
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Stanley Hydraulic Tools
3810 SE Naef Road
Milwaukie, Oregon 97267-5698 USA
(503) 659-5660 / Fax (503) 652-1780
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