STANLEY HGL61 Hydraulic Grinders User Manual

STANLEY HGL61 Hydraulic Grinders

To fill out a product warranty validation form, and for information on your warranty, visitwww.stanleyinfrastructure.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 Infrastructure recommends that servicing of hydraulic tools, other than routine maintenance, must be performed by an authorized and certified dealer. Please read the following warning.

SE RIOUS 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 certified dealer, call STANLEY Infrastructure at 503-659-5660 and ask for a Customer Service Representative.

SAFETY SYMBOLS

Safety symbols and signal words, as shown below, are used to emphasize all operator, maintenance and repair actions which, if not strictly followed, could result in a life-threatening situation, bodily injury or damage to equipment.

| This 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 indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
| This safety alert and signal word indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
| This safety alert and signal word indicates 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 avoided, may result in property damage.
| This signal word indicates a situation which, if not avoided, will result in damage to the equipment.
| This signal word indicates a situation which, if not avoided, may result in damage to the equipment.

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 maintenance personnel.

SAFETY PRECAUTIONS

Tool operators and maintenance personnel must comply with the safety precautions given in this manual and on the stickers and tags attached to the tool and hose.

These precautions are given for your safety. Review them carefully before operating the tool and before performing general maintenance or repairs.

Supervising personnel should develop additional precautions relating to the specific work area and local safety regulations. Place the added precautions in the space provided.

The HGL Hydraulic 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.

• The operator must start in a work area without bystanders. Flying debris can cause serious injury.
• Do not operate the tool unless thoroughly trained or under the supervision of an instructor. Establish a training program for all operators to ensure safe operation.
• Always wear the appropriate safety equipment for the job such as goggles, ear protection, breathing mask, safety shoes and head protection 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.
• Do not inspect, clean or replace the grinding wheel while the hydraulic power source is connected. Do not inspect or clean the tool while the hydraulic power source is connected. Accidental engagement of the tool can cause serious injury.
• Always connect hoses to the tool hose couplers before energizing the hydraulic power source. Be sure all hose 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.
• Do not operate the tool with the wheel guard removed.
• Do not operate a damaged, improperly adjusted or incompletely assembled grinder.
• Never wear loose clothing that can become 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.
• Keep the wheel off all surfaces when starting the grinder.
• Do not use a wheel that is cracked, chipped or otherwise damaged. Always inspect wheels for possible damage before installation or use.
• Always use wheels that conform to the specifications given in the OPERATION section of this manual.
• 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.
• To avoid personal injury or equipment damage, all tool repair, maintenance and service must only be performed by authorized and properly trained personnel.
• If the material being ground creates an emission of dust and fumes, use personal protective devices.
• Never cock, jam or wedge the grinding wheel during operation.
• Never cause sparks in the vicinity of flammable materials.
• Eye injury, and cutting or severing of body parts is possible if proper procedures are not followed.
• WARNING: Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are:
  • Lead from lead-based paints,
  • crystalline silica from bricks and cement and other masonry products, and
  • arsenic and chromium from chemicallytreated lumber.

Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemicals: work in a well ventilated area, and work with approved safety equipment, such as those dust masks that are specially designed to filter out microscopic particles.
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.

GRINDING WHEEL SAFETY

• Ensure that the grinding wheel is correctly mounted and tightened before use.
• Operate the grinder at “no load” for 30 seconds in a safe position and ensure there is no vibration or other defects detected. 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.
• 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.
• Check that the maximum rpm operating speed of the abrasive wheel is equal to or greater than the rated shaft speed of the grinder.
• Ensure that the grinding wheel dimensions are compatible with the grinder and that the grinding wheel fits the shaft.
• Ensure that the thread type and size of the grinding wheel exactly matches the thread type and size of the shaft.
• Do not operate this tool in a potentially explosive environment. Do not grind on vessels containing combustible substances.

TOOL STICKERS & TAGS

NOTE:
THE INFORMATION LISTED ON THE STICKERS SHOWN, MUST BE LEGIBLE AT ALL TIMES.
REPLACE DECALS IF THEY BECOME WORN OR DAMAGED. REPLACEMENTS ARE AVAILABLE FROM YOUR LOCAL STANLEY DISTRIBUTOR.

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.

HOSE TYPES

The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the hydraulic 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 reinforcement, and weather resistant synthetic rubber cover. This hose is conductive and must never be used near electrical conductors.

Fabric-braided (not certifi ed or labeled non-conductive) — constructed of thermoplastic or synthetic rubber inner tube, synthetic fi ber 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. 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

THE TAG SHOWN BELOW IS ATTACHED TO “CONDUCTIVE” HOSE.

HOSE RECOMMENDATIONS

Tool to Hydraulic Circuit Hose Recommendations

The chart to the right shows recommended minimum hose diameters for various hose lengths based on gallons per minute (GPM)/liters per minute (LPM). These recommendations are intended to keep return line pressure (back pressure) to a minimum acceptable level to ensure maximum tool performance.

This chart is intended to be used for hydraulic tool applications only based on STANLEY tool operating requirements and should not be used for any other applications.

All hydraulic hose must have at least a rated minimum working pressure equal to the maximum hydraulic system relief valve setting.

All hydraulic hose must meet or exceed specifi cations as set forth by SAE J517.

Oil Flow| Hose Lengths| Inside Diameter| USE ( Press/Return)| Min. Working Pressure
---|---|---|---|---
GPM| LPM| FEET| METERS| INCH| MM| PSI| BAR
Certified Non-Conductive Hose – Fiber Braid – for Utility Bucket Trucks
4-9| 15-34| up to 10| up to 3| 3/8| 10| Both| 2250| 155
Conductive Hose – Wire Braid or Fiber Braid -DO NOT USE NEAR ELECTRICAL CONDUCTORS
4-6| 15-23| up to 25| up to 7.5| 3/8| 10| Both| 2500| 175
4-6| 15-23| 26-100| 7.5-30| 1/2| 13| Both| 2500| 175
5-10.5| 19-40| up to 50| up to 15| 1/2| 13| Both| 2500| 175
5-10.5| 19-40| 51-100| 15-30| 5/8| 16| Both| 2500| 175
c 5-10.5| 19-40| 100-300| 30-90| 5/8| 16| Pressure| 2500| 175
3/4| 19| Return| 2500| 175
10-13| 38-49| up to 50| up to 15| 5/8| 16| Both| 2500| 175
10-13| 38-49| 51-100| 15-30| 5/8| 16| Pressure| 2500| 175
3/4| 19| Return| 2500| 175
10-13| 38-49| 100-200| 30-60| 3/4| 19| Pressure| 2500| 175
1| 25.4| Return| 2500| 175
13-16| 49-60| up to 25| up to 8| 5/8| 16| Pressure| 2500| 175
3/4| 19| Return| 2500| 175
13-16| 49-60| 26-100| 8-30| 3/4| 19| Pressure| 2500| 175
1| 25.4| Return| 2500| 175

HTMA / EHTMA REQUIREMENTS

TOOL TYPE

HTMA HYDRAULIC SYSTEM REQUIREMENTS| TYPE I| TYPE II| TYPE RR| TYPE III
---|---|---|---|---
Flow range| 4-6 GPM (15-23 LPM)| 7-9 GPM (26-34 LPM)| 9-10.5 GPM (34-40 LPM)| 11-13 GPM (42-49 LPM)
Nominal operating pressure (At the power supply outlet)| 1500 psi (103 bar)| 1500 psi (103 bar)| 1500 psi (103 bar)| 1500 psi (103 bar)
System relief valve setting (At the power supply outlet)| 2100-2250 psi (145-155 bar)| 2100-2250 psi (145-155 bar)| 2200-2300 psi (152-159 bar)| 2100-2250 psi (145-155 bar)
Maximum back pressure (At tool end of the return hose)| 250 psi (17 bar)| 250 psi (17 bar)| 250 psi (17 bar)| 250 psi (17 bar)
Measured at a max fluid viscosity of: (At minimum operating temperature)| 400 ssu(82 centistokes)| 400 ssu(82 centistokes)| 400 ssu(82 centistokes)| 400 ssu(82 centistokes)
Temperature: Sufficient heat rejection capacity to limit maximum fluid temperature to: (At maximum expected ambient temperature)| 140° F(60° C)| 140° F(60° C)| 140° F(60° C)| 140° F(60° C)
Minimum cooling capacity at a temperature difference of between ambient and fluid temps| 3 hp (2.24 kW) 40° F (22° C)| 5 hp (3.73 kW) 40° F (22° C)| 6 hp (5.22 kW) 40° F (22° C)| 7 hp (4.47 kW) 40° F (22° C)
Note: 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 minimum full-flow filtration| 25 microns| 25 microns| 25 microns| 25 microns
Sized for flow of at least: (For cold temp startup and maximum dirt-holding capacity)| 30 GPM (114 LPM)| 30 GPM (114 LPM)| 30 GPM (114 LPM)| 30 GPM (114 LPM)
Hydraulic fluid, petroleum based (premium grade, anti- wear, non-conductive) Viscosity (at minimum and maximum operating temps)| 100-400 ssu (20-82 centistokes)| 100-400 ssu (20-82 centistokes)| 100-400 ssu (20-82 centistokes)| 100-400 ssu (20-82 centistokes)
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| | | | |
---|---|---|---|---|---
Flow range| 3.5-4.3 GPM (13.5-16.5 LPM)| 4.7-5.8 GPM (18-22 LPM)| 7.1-8.7 GPM (27-33 LPM)| 9.5-11.6 GPM (36-44 LPM)| 11.8-14.5 GPM (45-55 LPM)
Nominal operating pressure (At the power supply outlet)| 1870 psi (129 bar)| 1500 psi (103 bar)| 1500 psi (103 bar)| 1500 psi (103 bar)| 1500 psi (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 specifi cation page for tool specifi c requirements.

OPERATION

PREPARATION PROCEDURES

CHECK HYDRAULIC POWER SOURCE

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 1500–2000 psi/105–140 bar.
2. Make certain the hydraulic power source is equipped with a relief valve set to open at 2100–2250 psi/145–155 bar minimum.
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 installed.
   Failure to install tool accessories properly can result in damage to the tool or personal injury.

2. There should be no signs of leaks.

3. The tool should be clean, with all fittings and fasteners tight.

CHECK TRIGGER MECHANISM

1. Check that the trigger operates smoothly and is free to travel between the ON and OFF positions.

CHECK GUARD ASSEMBLY

1. Inspect the wheel guard assembly (if equipped) for cracks and other structural damage. Do not operate if damaged.

INSTALLING AND REMOVING GRINDING WHEELS

READ AND BECOME FAMILIAR WITH THE SECTIONS IN THIS MANUAL ON SAFETY PRECAUTIONS, TOOL STICKERS AND TAGS, HYDRAULIC HOSE REQUIREMENTS, HYDRAULIC REQUIREMENTS, AND PRE-OPERATION PROCEDURES BEFORE USING THIS PRODUCT.

Note: On HGL80/81 use 8 inch by 1 inch thick (Type
1) grinding wheels with a 5/8 arbor hole. Only use grinding wheels which comply with ANSI B7.1/ISO 525, 603.

1. Loosen 3 capscrews (item 1, page 18) and remove the guard front plate (item 20, page 18) and set aside.

2. Depress the push lock (item 12, page 21) to lock the spindle. Unscrew the jam nut (item 4, page 18).
   Remove the outside flange (item 8, page 18).

3. Make sure blotters or labels remain on the grinding wheel. Install the grinding wheel onto the spindle (item 15, page 21) 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.

5. Reinstall the guard front plate and capscrews.

CONNECT HOSES

1. Wipe all hose couplers with a clean lint-free cloth before making connections.
2. Connect the hoses from the hydraulic power source to the hose couplers on the grinder. It is a good practice to connect the return hose first and disconnect it last to minimize or avoid trapped pressure within the grinder motor.
3. Observe flow indicators stamped on hose couplers to be sure that oil will flow in the proper direction.
   The female coupler is the inlet coupler.

Note: The pressure increase in uncoupled hoses left in the sun may result in making them difficult to connect. When possible, connect the free ends of operating hoses together.

OPERATING PROCEDURES

1. Observe all safety precautions.
2. Always start the grinder with the grinding wheel or cone away from the work surface and have both hands on the grinder at all times.
3. Move the hydraulic circuit control valve to the ON 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 or cone to the work surface.
6. Grind a small amount of material at a time.

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) before use.

TOOL PROTECTION & CARE

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 connection.

• The hydraulic circuit control valve must be in the OFF position when coupling or uncoupling hydraulic tools. Failure to do so may result in damage to the quick couplers and cause overheating of the hydraulic system.

• Always store the tool in a clean dry space, safe from damage or pilferage.

• Make sure the circuit PRESSURE hose (with male quick disconnect) is connected to the IN port. The circuit RETURN hose (with female quick disconnect) is connected to the opposite port. Do not reverse circuit flow. This can cause damage to internal seals.

• Always replace hoses, couplings and other parts with replacement parts recommended by STANLEY. Supply hoses must have a minimum working pressure rating of 2500 psi/172 bar.

• Do not exceed the rated flow and pressure.
  Rapid failure of the internal seals may result. See Specifications in this manual for correct flow rate and pressure rating.

• Always keep critical tool markings, such as warning stickers and tags, legible.

• 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.

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 tool, always check that the hydraulic power source is supplying the correct hydraulic flow and pressure to the tool, as listed in the table. Use a flow meter known to be accurate. Check the flow with the hydraulic oil temperature at least 80 °F/27 °C.

source for proper flow and pressure (7–10 GPM/26–38 LPM @ 1500–2000 psi/105–140 bar.).
Couplers or hoses blocked.| Locate and remove restriction.
Hydraulic motor failure.| Inspect and repair.
Hydraulic lines not connected.| Connect lines.
Shaft lock is engaged| Check that the shaft lock is not engaged.
Grinder operates too slow.| Hydraulic motor speed to 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 too cold (below 60 °F/16 °C).| Check hydraulic power source for 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.
Excessive vibration| Grinding wheel or cone missing wheel segments.| Check grinding wheel or cone for any large missing segments of the wheel that could cause an out of balance condition.
Bent motor shaft.| Check motor shaft for any bent condition, replace if necessary.

SPECIFICATIONS

Wheel Capacity
HGL61 CCW Rotation (5500 rpm)
HGL80 CCW or CW Rotation, 8” Wheel (5500 rpm)| Bullnose
8 in. dia. × 1 in. thk × 5/8 arbor (type 1)
---|---
Pressure Range| 2000–2500 psi/138–172 bar
Maximum Back Pressure| 500 psi/34 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 HGL61 / 61-N (with hose whips & couplers and without bullnose stone)| 9.6 lbs / 4.3 kg
Overall Length HGL61 / 61-N| 19 in. / 48.2 cm
Overall Width HGL61 / 61-N| 10 in. / 25.4 cm
Weight HGL80 / 81 (with hose whips & couplers and without grinding wheel)| 13.6 lbs / 6.1 kg
Overall Length HGL80 / 80-N / 80-L / 80-LN| 23.35 in. / 59.3 cm
Overall Length HGL81 / 81-N / 81-L / 81-LN| 19 in. / 48.2 cm
Overall Width HGL80 / 80-N / 80-L / 80-LN| 12 in. / 30.4 cm
Overall Width HGL81 / 81-N / 81-L / 81-LN| 12 in. / 30.4 cm
RPM| 5500 Max
Maximum Fluid Temperature| 140 °F/60 °C

ACCESSORIES

Grinding Wheel – Norton Norzon IV (8 inch dia. × 1 inch wide × 5/8 arbor) (HGL80/81)…………………………….28598

Grinding Wheel Cone – Bullnose (HGL61)…………………………………………………………………………………………..30872

HGL61 PARTS ILLUSTRATION

Note: both the HGL61 and HGL61N are CCW rotation tools. The only difference between the two models are the type of couplers.

HGL61 PARTS LIST

SEAL KIT P/N – 74868

• COUPLER SET P/N-88685 (ONE EACH OF ITEM # 2 & 3) USED ON MODEL HGL61
  COUPLER SET P/N-81160 (ONE EACH OF ITEM # 2 & 3) USED ON MODEL HGL61N

HGL80 / 81 PARTS ILLUSTRATION

HGL80 / 81 PARTS LIST

MOTOR PARTS LIST & ILLUSTRATION

ALL HGL MODELS USE THE SAME MOTOR PARTS

SEAL KIT P/N-74868
* Denotes Part in Seal Kit
Note: All seals are purchased thru seal kit.

BEARING NOSE PARTS LIST & ILLUSTRATION

ALSO INCLUDES ITEM 7.
 | 74869| 1| BEARING HOUSING, CCW ROTATION, USE WITH P/N- 210880 SEE ITEM 16, ALSO INCLUDES ITEM 7.
16| 211071| 1| MOTOR SHAFT, GRINDER CW ROTATION
 | 210880| 1| MOTOR SHAFT, GRINDER CCW ROTATION
17| 213702| 1| SEAL CARRIER

SEAL KIT P/N-74868
* Denotes Part in Seal Kit
Note: All seals are purchased thru seal kit.

STANLEY Infrastructure
6430 SE Lake Road
Portland, Oregon 97222 USA
503-659-5660 / Fax 503-652-1780
www.stanleyinfrastructure.com

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