PG10
HYDRAULIC
PROFILE GRINDER
USER MANUAL
Safety, Operation and Maintenance
© 2014 Stanley Black & Decker, Inc.
New Britain, CT 06053
U.S.A.
65846 2/2015 Ver. 6
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TABLE OF CONTENTS
DECLARATION OF CONFORMITY..........................................................................................................................2
SAFETY SYMBOLS ..................................................................................................................................................4
SAFETY PRECAUTIONS..........................................................................................................................................5
TOOL STICKERS & TAGS........................................................................................................................................6
HOSE TYPES............................................................................................................................................................7
HOSE RECOMMENDATIONS ..................................................................................................................................8
FIGURE 1. TYPICAL HOSE CONNECTIONS.......................................................................................................8
HTMA REQUIREMENTS...........................................................................................................................................9
OPERATION............................................................................................................................................................10
PREVENTATIVE MAINTENANCE ..........................................................................................................................12
TOOL PROTECTION & CARE................................................................................................................................13
TROUBLESHOOTING ............................................................................................................................................14
SPECIFICATIONS...................................................................................................................................................15
ACCESSORIES.......................................................................................................................................................15
PG10 PARTS ILLUSTRATION................................................................................................................................16
PG10 PARTS LIST..................................................................................................................................................18
SPARK GUARD KIT................................................................................................................................................20
IMPORTANT
To fill out a Product Warranty Validation form, and for information on your warranty,
visit Stanleyhydraulics.com and select the Company tab, Warranty.
(NOTE: The warranty Validation record must be submitted to validate the warranty).
SERVICING: This manual contains safety, operation, and routine maintenance instructions. Stanley Hydraulic Tools
recommends that servicing of hydraulic tools, other than routine maintenance, must be performed by an authorized
and certified dealer. Please read the following warning.
WARNING
SERIOUS INJURY OR DEATH COULD RESULT FROM THE IMPROPER REPAIR OR SERVICE OF THIS
TOOL.
REPAIRS AND / OR SERVICE TO THIS TOOL MUST ONLY BE DONE BY AN AUTHORIZED AND
CERTIFIED DEALER.
For the nearest authorized and certified dealer, call Stanley Hydraulic Tools at the number listed on the back of this
manual and ask for a Customer Service Representative.
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SAFETY SYMBOLS
Safety symbols and signal words, as shown below, are used to emphasize all operator, maintenance and repair ac-
tions which, if not strictly followed, could result in a life-threatening situation, bodily injury or damage to equipment.
This is the safety alert symbol. It is used to alert you to potential personal injury
hazards. Obey all safety messages that follow this symbol to avoid possible
injury or death.
This safety alert and signal word indicate an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
DANGER
WARNING
CAUTION
This safety alert and signal word indicate a potentially hazardous situation
which, if not avoided, could result in death or serious injury.
This safety alert and signal word indicate a potentially hazardous situation
which, if not avoided, could result in death or serious injury.
This signal word indicates a potentially hazardous situation which, if not avoid-
ed, may result in property damage.
CAUTION
NOTICE
This signal word indicates a situation which, if not avoided, will result in damage
to the equipment.
This signal word indicates a situation which, if not avoided, may result in dam-
age to the equipment.
IMPORTANT
Always observe safety symbols. They are included for your safety and for the protection of the tool.
LOCAL SAFETY REGULATIONS
Enter any local safety regulations here. Keep these instructions in an area accessible to the operator and mainte-
nance personnel.
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SAFETY PRECAUTIONS
Tool operators and maintenance personnel must always
comply with the safety precautions given in this manual
and on the stickers and tags attached to the tool and hose.
•
•
Do not operate the tool with the wheel guard removed.
Do not operate a damaged, improperly adjusted, or in-
completely assembled grinder.
These safety precautions are given for your safety. Review
them carefully before operating the tool and before per-
forming 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 rotating
wheel. Long hair or loose clothing can become drawn
into rotating components.
Supervising personnel should develop additional precau-
tions 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 grind-
er.
The model PG10 Hydraulic Profile Grinder will provide safe
and dependable service if operated 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.
Do not use a wheel that is cracked, chipped or oth-
erwise 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.
Do not reverse grinding wheel rotation direction by
changing fluid flow direction.
Do not move the tool until the wheel has stopped rotat-
ing. Release the trigger if the power supply has been
interrupted.
•
•
The operator must start in a work area without bystand-
ers. Flying debris can cause serious injury.
Do not operate the tool unless thoroughly trained or
under the supervision of an instructor. Establish a train-
ing program for all operators to ensure safe 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.
The operator must be familiar with all prohibited work
areas such as excessive slopes and dangerous terrain
conditions.
•
•
Maintain proper footing and balance at all times.
Do not inspect, clean or replace the grinding wheel
while the hydraulic power source is connected. Acci-
dental 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 condition.
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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TOOL STICKERS & TAGS
28811
03787
25357
INFORMATION PLAQUE (CE)
GPM DECAL (US)
CAUTION DECAL
D
30 LPM @ 138 B AR
EHTMA CATEGORY
25610
RAILROAD HELP DESK DECAL
51296
SOUND POWER LEVEL
DECAL
28409
11207
CIRCUIT TYPE D
STICKER
COMPOSITE DECAL (CE)
28322
CE DECAL
29714
PG10 NAME TAG (US & CE)
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)
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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
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
3. Using the wrench (89) provided, place it on the
PRE-OPERATION PROCEDURES
CHECK HYDRAULIC POWER SOURCE
flats of the drive flange. Place a strap wrench on
the grinding wheel and then tighten by gripping and
turning the strap wrench while holding the wrench
provided.
1. Using a calibrated flow meter and pressure gauge,
check that the hydraulic power source develops a
flow of 7–10 gpm/26–38 lpm at 2200–2300 psi/152–
159 bar.
4. Replace the guard weldment.
2. Make certain the hydraulic power source is equipped
with a relief valve set to open at 2100–2250 psi/145–
155 bar minimum.
IMPORTANT
3. Check that the hydraulic circuit matches the tool for
open-center (OC) or closed-center (CC) operation.
Never over-tighten the grinding wheel by impacting
the wrench with a mallet or hammer. Sufficient
torque is attained by hand-tightening the wheel with
a strap wrench while securing the drive flange with
the wrench provided.
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.
ADJUST WHEEL FLANGES TO FIT RAIL
2. There should be no signs of leaks.
The wheel flanges may be adjusted to fit the width of the
rail by removing one or more of the washers.
3. The tool should be clean, with all fittings and fasten-
ers tight.
CONNECTING THE HOSES
CHECK TRIGGER MECHANISM
1. Wipe all hose couplers with a clean lint-free cloth
before making connections.
1. Check that the trigger operates smoothly and is free
to travel between the ON and OFF positions.
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 GUARD WELDMENT
1. Inspect the wheel guard weldment for cracks and
other structural damage.
INSTALLING AND REMOVING
GRINDING WHEEL
NOTE:
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.
Use 6 inch diameter up to 3 inch thick (Type 6 for
USA) grinding wheels with a 5/8-11 threaded arbor
hole. Only use grinding wheels which comply with
ANSI B7.1, B7.5/ISO 525, 603.
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.
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.
1. Unscrew the two nuts (98) which secure the guard
weldment (95) to the frame and remove the guard
weldment.
2. Install the grinding wheel until it comes in contact
with the drive flange.
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OPERATION
OPERATING PROCEDURES
COLD WEATHER OPERATION
1. Observe all safety precautions.
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.
2. Always start the grinder with the grinding wheel
away from the work surface by turning the hand
wheel counter clockwise to raise the wheel.
3. Move the hydraulic circuit control valve to the ON
Damage to the hydraulic system or grinder can result
from use with fluid that is to viscous or too thick.
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.
5. Start the grinder and move the grinding wheel to the
work surface by turning the hand wheel clockwise.
6. Grind a small amount of material at a time adjusting
the grinding wheel as necessary by turning the hand
wheel.
NOTE:
If the grinder is not loaded against a work surface
when the trigger is released, the wheel will take 5-10
seconds to come to a complete stop. Avoid uninten-
tional contact of the grinding wheel during the coast
down period.
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PREVENTATIVE MAINTENANCE
1. The gears and bearings in the ram, spindle, and
housing assemblies should be regreased every 6
months or 500 hours. This procedure must be ac-
complished by a trained technician.
2. After each servicing, measure the spindle speed
(rpm – revolutions per minute) at 12 gpm/45 lpm in-
put. The nominal speed is 4000, not to exceed 6000
rpm. This procedure must be accomplished by a
trained technician.
3. Inspect the spindle and drive flange for signs of
wear or damage. Run out should not exceed .004
in./.1 mm TIR on threads or .002 in./.05 mm TIR on
arbor diameters and faces.
4. Check hoses and fittings weekly for any evidence of
leakage, cover wear, cracking or cuts. If any of these
defects are found, discontinue use of the tool imme-
diately and have the defects repaired or replaced by
a trained technician.
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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.
•
•
•
•
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.
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.
Do not use the tool for applications for which it was
not intended.
•
•
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 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 (see Specifications) in
this manual for correct flow rate and model number.
Rapid failure of the internal seals may result.
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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) or Check hydraulic power source for
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 2100–2250
psi/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.
14 ► PG10 User Manual
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SPECIFICATIONS
Wheel Capacity .............................................................6 in. dia. × 3 in. thk × 5/8-11 threaded arbor (Type 6) U.S.A.
Pressure Range................................................................................................................1000–2000 psi/70–140 bar
Maximum Back Pressure......................................................................................................................250 psi/17 bar
Flow Range .................................................................................................... HTMA Type RR, 7–10 gpm/26–38 lpm
Porting...................................................................................................................................................-8 SAE O-ring
Couplers ....................................................................................................... HTMA Flush Face Type Male & Female
Connect Size and Type ...................................................................................................... 3/8 in. Male Pipe Adapter
Hose Whips............................................................................................................................................................ No
Weight (with couplers)...........................................................................................................................118 lb/53.5 kg
Overall Length........................................................................................................................... 44 inches/111.76 cm
Overall Width ................................................................................................................................ 20 inches/50.8 cm
Overall Height ............................................................................................................................ 30.5 inches/77.4 cm
RPM.....................................................................................................................................................................4000
Hyrevz™ Motor..................................................................................................................................................24251
Maximum Fluid Temperature.................................................................................................................. 140 °F/60 °C
Sound Power Level ....................................................................................................................................... 102 dBA
Sound Pressure Level (1m).............................................................................................................................. 93dBA
Vibration Level.............................................................................................................................................3.4m/sec2
SOUND AND VIBRATION DECLARATION
Test conducted on PG10110 S/N 206 operated at standard 10 gpm input
Measured A-weighted sound power level, Lwa (ref. 1pW) in decibels
Uncertainty, Kwa, in decibels
102.00 dBA
3 dBA
Measured A-weighted sound pressure level, Lpa (ref. 20 µPa) at operator’s position, in decibels
Uncertainty, Kpa, in decibels
93 dBA
3 dBA
Values determined according to noise test code given in ISO 15744, using the basic standard
ISO 3744
NOTE: The sum of a measured noise emission value and its associated uncertainty represents
an upper boundary of the range of values which is likely to occur in measurements.
Declared vibration emission value in accordance with EN 12096
Measured vibration emission value: a
3.4 m/sec²
1.0 m/sec²
Uncertainty: K
Values determined according to ISO 8662-4, ISO 5349-1,2
ACCESSORIES
6 × 3 × 5/8-11 Thread Cup Stone ......................................................................................................................28597
PG10 User Manual ◄ 15
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PG10 PARTS ILLUSTRATION
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PG10 PARTS ILLUSTRATION
PG10 User Manual ◄ 17
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PG10 PARTS LIST
ITEM P/N
QTY DESCRIPTION
ITEM P/N
25293
QTY DESCRIPTION
1
25294
2
2
1
1
1
1
1
1
1
1
8
3
1
1
4
1
1
1
1
1
1
1
1
HOSE ASSY
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
1
1
1
1
1
2
SQUARE RING •
THRUST WASHER
SHAFT
2
00713
06854
25717
00178
00669
19884
25166
00148
00166
00120
01604
06880
06846
06316
25718
19898
19905
00171
00170
06881
00708
25158
DOWEL PIN
25103
26810
25083
25283
25304
3
IDLER SHAFT
4
IDLER GEAR
PINION GEAR
ROLL PIN
5
O-RING, 2-1/8 × 2-1/4 × 1/16 70D •
QUAD RING •
6
CAPSCREW
7
SEAL GLAND
20876 30
WASHER
8
MOTOR SHAFT
25045
25303
25302
25111
25610
25357
25284
00272
25082
29714
25076
25297
25296
25295
25046
25126
10888
25167
04353
25277
25060
04984
25300
25299
25298
25047
25048
25036
25161
28453
18037
25305
25256
08017
01605
2
4
4
1
1
1
1
2
1
1
1
2
2
4
2
1
2
1
3
1
1
2
2
4
4
2
2
1
1
1
1
1
1
2
4
FLANGE
9
BEARING
BEARING
10
11
12
13
RETAINING RING
CAPSCREW
RETAINING RING
ARM L.H.
O-RING (INCL WITH ITEM 1) •
GEAR HOUSING
GEAR HSG ASSY (INCL ITEMS 2 & 14)
BUSHING
HELP DESK STICKER
CAUTION STICKER
BUSHING
14
15
16
-
DOWEL PIN
DRIVE GEAR
FEED GEAR
NAME TAG
FRONT BEARING HOUSING
FRONT BRG HSG ASSY (INCL ITEMS 14)
O-RING 11/16 × 13/16 × 1/16 70D •
RETAINING RING
NEEDLE ROLLER
RETAINING RING
SPLINED COUPLING
CAPSCREW
FRAME
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
RETAINING RING
THRUST WASHER
FLANGED BUSHING
FLANGE
ARM R.H
02688 10
CAPSCREW
25099
25291
25289
25290
25281
25279
27941
00772
25278
25280
25419
01607
04374
26809
25287
27748
02900
27749
25285
25104
25286
1
1
2
1
1
1
1
2
1
1
1
1
4
1
1
1
1
1
1
1
1
RAM
KEY
NEEDLE ROLLER BEARING
RETAINING RING
INNER RING
STOP NUT
WIPER •
GUARD WELDMENT
STOP NUT
RETAINING RING
BEARING
WASHER
SPINDLE
BEARING
WOODRUF KEY
RETAINING RING
OIL SEAL, 1.250 × 2.047 × .299 •
DRIVE FLANGE
SET SCREW
RETAINING RING
ROLLER
SHAFT BOLT
ON-OFF SPOOL (O.C.)
HANDLE WELDMENT
TRIGGER ASSY
BALL JOINT STUD
WIPER •
NUT
HAND WHEEL
WIPER •
BUSHING
WASHER •
ROLL PIN
O-RING 7/8 × 1-1/16 × 3/32 -118 •
HOUSING
O-RING .644 × .818 × .087 -908 (INCL W/
ITEMS 1 & 86) •
ADJUSTABLE HANDLE
BACKUP WASHER
WIPER TYPE H •
86
87
00936
03972
47436
2
1
1
ADAPTER
FEMALE COUPLING, PARKER
FEMALE COUPLING, AEROQUIP
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PG10 PARTS LIST
• Denotes part in seal kit
ITEM P/N
QTY DESCRIPTION
MALE COUPLING, PARKER
NOTE:
88
03973
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
2
47437
25842
17904
18008
24819
28914
00955
24289
01411
20145
25292
25005
03787
28811
21336
MALE COUPLING, AEROQUIP
WRENCH (SHIPPED LOOSE)
RETAINING RING
SPRING WASHER
SPRING
Use Part Number and Part Name when ordering.
89
90
91
92
93
94
95
96
97
98
99
100
FLOW CONTROL (PRE-SET)
PIPE PLUG
PLUG
O-RING, .488 × .624 × .078 -906 •
STEEL BALL
ROLL PIN
VALVE BLOCK
GPM STICKER
INFORMATION PLAQUE (CE ONLY)
POP RIVET FOR INFORMATION
PLAQUE (CE ONLY)
101
25251
1
MOTOR ASSY (INCL 2 THRU 11, & 13
THRU 20)
102
103
104
105
106
107
108
109
110
111
25052
02179
18601
27366
27599
27370
28409
28322
11207
51296
25942
2
1
1
1
1
1
1
1
1
1
1
WASHER
NUT
ROLL PIN
LEVER WELDMENT
SPRING (MODIFIED)
SPACER
DECAL, COMPOSITE SAFETY
DECAL, CE
DECAL, CIRCUIT TYPE D
DECAL, SOUND POWER LEVEL
SEAL KIT
PG10 User Manual ◄ 19
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SPARK GUARD KIT
ITEM P/N
QTY DESCRIPTION
1
2
3
4
5
6
7
69915
1
1
1
1
8
9
9
SPARK BARRIER SECONDARY
69899
65202
62402
2072
GUARD WELDMENT
SPARK BARRIER
SPARK GUARD FRAME WELDMENT
CAPSCREW
70743
2395
FABRIC SNAP
CABLE TIE (NOT PICTURED)
69814
69820
1
1
SPARK GUARD ASSY (INCL ITEMS 3 & 4)
SPARK GUARD KIT (INCL ITEMS 1 THRU 7
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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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