HG60
HYDRAULIC BULL
NOSE GRINDER
USER MANUAL
Safety, Operation and Maintenance
© 2014 Stanley Black & Decker, Inc.
New Britain, CT 06053
U.S.A.
67373 9/2014 Ver. 6
Download from Www.Somanuals.com. All Manuals Search And Download.
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
HG60 PARTS ILLUSTRATION................................................................................................................................15
HG60 PARTS LIST..................................................................................................................................................16
IMPORTANT
To fill out a Product Warranty Validation form, and for information on your warranty,
visit Stanleyhydraulics.com and select the Company tab, Warranty.
(NOTE: The warranty Validation record must be submitted to validate the warranty).
SERVICING: This manual contains safety, operation, and routine maintenance instructions. Stanley Hydraulic
Tools recommends that servicing of hydraulic tools, other than routine maintenance, must be performed by an au-
thorized 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.
HG60 User Manual ◄ 3
Download from Www.Somanuals.com. All Manuals Search And Download.
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.
4 ► HG60 User Manual
Download from Www.Somanuals.com. All Manuals Search And Download.
SAFETY PRECAUTIONS
Tool operators and maintenance personnel must always
•
•
•
Do not operate a damaged, improperly adjusted, or
incompletely assembled grinder.
comply with the safety precautions given in this manual
and on the stickers and tags attached to the tool and
hose.
Never wear loose clothing that can get entangled in
the working parts of the tool.
These safety precautions are given for your safety. Re-
view them carefully before operating the tool and before
performing general maintenance or repairs.
Keep all parts of your body away from the rotating
grinding stone. Long hair or loose clothing can be-
come 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.
Do not use a grinding stone that is cracked, chipped
or otherwise damaged. Always inspect stones for
possible damage before installation or use.
The model HG60 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.
•
•
•
Always use stones that conform to the specifications
given in the OPERATION section of this manual.
Do not reverse grinding stone rotation direction by
changing fluid flow direction.
Do not move the tool until the stone has stopped
rotating. Release the trigger if the power supply has
been interrupted.
•
To avoid personal injury or equipment damage, all
tool repair, maintenance and service must only be
performed by authorized and properly trained per-
sonnel.
•
•
The operator must start in a work area without by-
standers. Flying debris can cause serious injury.
Do not operate the tool unless thoroughly trained
or under the supervision of an instructor. Establish
a training program for all operators to ensure safe
operation.
•
•
•
•
If the material being ground creates an emission of
dust and fumes, use personal protective devices.
Never cock, jam or wedge the grinding stone during
operation.
•
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 cause sparks in the vicinity of flammable ma-
terials.
Eye injury, and cutting or severing of body parts is
possible if proper procedures are not followed.
•
•
The operator must be familiar with all prohibited
work areas such as excessive slopes and danger-
ous terrain conditions.
•
Do not carry the tool by the hoses.
•
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 injury.
•
•
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.
HG60 User Manual ◄ 5
Download from Www.Somanuals.com. All Manuals Search And Download.
SAFETY PRECAUTIONS
•
•
Only use abrasive stone that comply with ANSI
B7.1/ISO 525, 603.
GRINDING WHEEL SAFETY
•
Ensure that the grinding stone is correctly mounted
and tightened before use.
Check that the maximum rpm operating speed of
the abrasive stone is equal to or greater than the
rated shaft speed of the grinder.
•
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 grinding stone dimensions are com-
patible with the grinder and that the grinding stone
fits the shaft.
Ensure that the thread type and size of the grinding
stone exactly matches the thread type and size of
the shaft.
•
If the grinder is dropped with an abrasive stone in-
stalled, the stone should be examined thoroughly
before use.
6 ► HG60 User Manual
Download from Www.Somanuals.com. All Manuals Search And Download.
TOOL STICKERS & TAGS
CAUTION
PROTECT YOUR EYES
WEAR SAFETY GOGGLES
HG60
1. Do not use damaged wheels.
2. Use only 5/8-11 cone and plug wheels per the
requirements of ANSI 87.1 or 525.603.
3. Inspect mounting flange for damage after wheel
breakage on the machine.
26212
Name Tag
4. Maximum wheel speed is 6000 RPM.
03787
GPM Sticker
ROTATION DIRECTION
26229
Wear Safety Goggles Sticker
05153
Stanley Sticker
25610
Railroad Help Desk Sticker
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
removal. We suggest you retain this tag and
attach it to the tool when not in use.
I M P O R T A N T
I M P O R T A N T
READ OPERATION MANUAL AND
SAFETY INSTRUCTIONS FOR THIS
TOOL BEFORE USING IT.
READ OPERATION MANUAL AND
SAFETY INSTRUCTIONS FOR THIS
TOOL BEFORE USING IT.
USE ONLY PARTS AND REPAIR
PROCEDURES APPROVED BY
STANLEY AND DESCRIBED IN THE
OPERATION MANUAL.
USE ONLY PARTS AND REPAIR
PROCEDURES APPROVED BY
STANLEY AND DESCRIBED IN THE
OPERATION MANUAL.
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)
HG60 User Manual ◄ 7
Download from Www.Somanuals.com. All Manuals Search And Download.
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)
8 ► HG60 User Manual
Download from Www.Somanuals.com. All Manuals Search And Download.
HOSE RECOMMENDATIONS
HG60 User Manual ◄ 9
Download from Www.Somanuals.com. All Manuals Search And Download.
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
10 ► HG60 User Manual
Download from Www.Somanuals.com. All Manuals Search And Download.
OPERATION
CONNECT HOSES
PRE-OPERATION PROCEDURES
1. Wipe all hose couplers with a clean lint-free cloth
before making connections.
PREPARATION FOR INITIAL USE
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 instal-
lation of a grinding stone a unit may be put to use.
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.
CHECK HYDRAULIC POWER SOURCE
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.
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.
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 together.
2. Make certain the hydraulic power source is equipped
with a relief valve set to open at 2200–2300 psi/152–
159 bar.
3. Check that the hydraulic circuit matches the tool for
open-center (OC) operation.
OPERATING PROCEDURES
1. Observe all safety precautions.
CHECK TOOL
2. Always start the grinder with the grinding stone
away from the work surface.
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.
3. Move the hydraulic circuit control valve to the ON
position.
2. There should be no signs of leaks.
4. Squeeze the trigger momentarily. If the grinder does
not operate, the hoses might be reversed. Verify
correct connection of the hoses before continuing.
3. The tool should be clean, with all fittings and fasten-
ers tight.
CHECK TRIGGER MECHANISM
5. Start the grinder and move the grinding stone to the
work surface.
1. Check that the trigger operates smoothly and is free
to travel between the ON and OFF positions.
6. Grind a small amount of material at a time.
INSTALLING AND REMOVING GRINDING
STONES
COLD WEATHER OPERATION
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.
READAND BECOME FAMILIAR WITH THE SECTIONS
IN THIS MANUAL ON SAFETY PRECAUTIONS, TOOL
STICKERS AND TAGS, HYDRAULIC HOSE REQUIRE-
MENTS, HYDRAULIC REQUIREMENTS, AND PRE-
OPERATION PROCEDURES BEFORE USING THIS
PRODUCT.
NOTE:
Use 3 inch diameter up to 5 inch long (Type 16, 17, 18
or 19) grinding cones or plugs with a 5/8-11 threaded
arbor hole. Only use grinding cones or plugs which
comply with ANSI B7.1/ISO 525, 603.
1. Install the abrasive cone or plug onto the spindle
(33). Using an open-end wrench on the flats of the
drive flange (51) and while griping the cone or plug,
tighten sufficiently to prevent disengagement of the
cone or plug from the spindle.
HG60 User Manual ◄ 11
Download from Www.Somanuals.com. All Manuals Search And Download.
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.
•
Always keep critical tool markings, such as warning
stickers and tags legible.
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.
•
•
Do not force a small tool to do the job of a large tool.
Tool repair should be performed by experienced
personnel only.
•
•
Make certain that the recommended relief valves
are installed in the pressure side of the system.
•
•
Always store the tool in a clean dry space, safe from
damage or pilferage.
Do not use the tool for applications for which it was
not intended.
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.
•
•
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.
Do not exceed the rated flow. Refer to Specifications
in this manual for correct flow rate. Rapid failure of
the internal seals may result.
12 ► HG60 User Manual
Download from Www.Somanuals.com. All Manuals Search And Download.
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 2200–2300
psi/152–159 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.
Spindle rotates in the wrong
direction.
Hydraulic flow is in the wrong
direction.
Connect the pressure line to the
grinder port marked IN. Connect the
return line to the grinder port marked
OUT.
HG60 User Manual ◄ 13
Download from Www.Somanuals.com. All Manuals Search And Download.
SPECIFICATIONS
Wheel Capacity ...............................................................................3 in. dia. × 5 in. long × 5/8-11 arbor (type 16-19)
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)................................................................................................... 10.8 lb/4.89 kg
Overall Length................................................................................................................................23 inches/58.4 cm
Overall Width...................................................................................................................................3.3 inches/8.4 cm
Overall Height...................................................................................................................................4 inches/10.2 cm
RPM.............................................................................................................................................................6000 Max
Maximum Fluid Temperature.................................................................................................................. 140 °F/60 °C
ACCESSORIES
Grinding Stone (Cone).......................................................................................................................................30872
14 ► HG60 User Manual
Download from Www.Somanuals.com. All Manuals Search And Download.
HG60 PARTS ILLUSTRATION
HG60 User Manual ◄ 15
Download from Www.Somanuals.com. All Manuals Search And Download.
HG60 PARTS LIST
PART
ITEM NO.
PART
ITEM NO.
QTY DESCRIPTION
QTY DESCRIPTION
1
26229
06316
00178
73308
04031
26212
03249
27602
30381
30366
00018
21437
1
4
1
1
2
1
8
2
1
2
4
1
CAUTION STICKER
BUSHING
41
42
43
44
45
46
47
48
49
50
54
55
56
57
58
59
63
64
65
66
67
68
30333
00214
350771
00769
06301
—
1
1
1
3
1
—
1
1
1
1
1
1
—
1
1
1
2
1
1
1
1
1
SEAL GLAND
QUAD RING*
2
3
O-RING*
O-RING*
4
IDLER SHAFT KEYED
DOWEL PIN
NAME TAG
CAPSCREW
6
SPINDLE HOUSING
NO ITEM
7
8
CAPSCREW
OIL TUBE
06299
06313
06312
06311
25610
03787
—
BEARING RACE
NEEDLE ROLLER BEARING
SEAL*
9
10
11
12
13
DIPPED HANDLE
CAPSCREW
O-RING*
V-RING SEAL*
RAILROAD HELP DESK STICKER
GPM STICKER 7–10 2000 PSI
NO ITEM
FRONT BEARING HOUSING ASSY
(INCL ITEM 2,)
14
15
16
17
18
19
20
21
22
23
24
25
26
03227
25666
29775
27441
27445
01851
00114
27442
04097
01211
27608
01605
66728
58630
47436
2
2
1
1
1
2
1
1
1
2
1
2
2
2
1
NEEDLE ROLLER
DRIVE GEAR
26206
05153
26207
00032
24289
01411
20145
01521
20939
SPINDLE
STANLEY STICKER
DRIVE FLANGE
LOCKWASHER
PLUG
REAR BEARING HOUSING
THUMB LATCH
TORSION SPRING
ROLL PIN
O-RING
ROLL PIN
STEEL BALL
THUMB TRIGGER
COIL SPRING
CAPSCREW
ROLL PIN
O-RING*
DIPPED VALVE
O-RING*
29137
1
SEAL KIT
HOSE ASSY (AEROQUIP)
HOSE ASSY (PARKER)
* Denotes part in seal kit.
27
28
FEMALE COUPLER BODY
(AEROQUIP)
03972
47437
03973
350041
28915
1
1
1
1
1
FEMALE COUPLER BODY (PARKER)
MALE COUPLER BODY (AEROQUIP)
MALE COUPLER BODY (PARKER)
-4 SAE PLUG
29
30
FLOW REGULATOR CARTRIDGE
(PRE-SET)
31
32
34
35
36
37
38
39
40
04098
02447
06314
00708
06300
25360
00148
06303
00170
1
1
1
1
1
1
1
1
1
VALVE SPOOL
KEY
BALL BEARING
RETAINING RING
BEARING SPACER
COUPLING
BALL BEARING
MOTOR SHAFT
RETAINING RING
16 ► HG60 User Manual
Download from Www.Somanuals.com. All Manuals Search And Download.
Download from Www.Somanuals.com. All Manuals Search And Download.
Stanley Hydraulic Tools
3810 SE Naef Road
Milwaukie, Oregon 97267-5698 USA
(503) 659-5660 / Fax (503) 652-1780
Download from Www.Somanuals.com. All Manuals Search And Download.
|