Stanley ZGG81, ZGG81-N User Manual

Download

Page 1

ZGG81

ZGG81-N

ZERO GRAVITY

WEB GRINDER

USER MANUAL

Safety, Operation and Maintenance

New Britain, CT 06053

U.S.A.

76531 8/2017 Ver. 1

Page 2

Page 3

TABLE OF CONTENTS

SAFETY SYMBOLS ...............................................................................................................................................4

SAFETY PRECAUTIONS .......................................................................................................................................5

TOOL STICKERS & TAGS .....................................................................................................................................6

WARNINGS / PINCH POINTS ...............................................................................................................................7

HOSE TYPES .........................................................................................................................................................8

HOSE RECOMMENDATIONS ...............................................................................................................................9

HTMA / EHTMA REQUIREMENTS ........................................................................................................................10

OPERATION ...........................................................................................................................................................11

TOOL PROTECTION & CARE ...............................................................................................................................13

TROUBLESHOOTING ...........................................................................................................................................14

SPECIFICATIONS ..................................................................................................................................................15

ZGG81/81-N MOTOR PARTS ILLUSTRATION .....................................................................................................16

ZGG81/81-N MOTOR/BEARING HOUSING PARTS LIST ....................................................................................17

ZGG81/81-N QUAD ARM ASSEMBLY ILLUSTRATION ........................................................................................18

ZGG81/81-N QUAD ARM ASSEMBLY PARTS LIST ..............................................................................................19

ZGG81/81-N CLAMP PARTS ILLUSTRATION ......................................................................................................20

ZGG81/81-N CLAMP PARTS LIST ........................................................................................................................21

ZGG81/81-N HANDLE PARTS ILLUSTRATION ....................................................................................................22

ZGG81/81-N MOTOR MOUNT ILLUSTRATION .................................................................................................... 23

ZGG81/81-N GUARD ILLUSTRATION & PARTS LIST ..........................................................................................24

ZGG81/81-N HOSE/COUPLERS ILLUSTRATION & PARTS LIST ........................................................................25

To ll out a product warranty validation form, and for information on your warranty,

visit www.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 certied dealer. Please read the following 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 certied dealer, call Stanley Hydraulic Tools at (503) 659-5660 and ask for a Customer Service Representative.

ZGG81 User Manual ◄ 3

Page 4

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 indicate an imminently hazardous situation which, if not avoided, will 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 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.

4 ► ZGG81 User Manual

Page 5

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.

These safety 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 specic work area and local safety regulations. Place the added precautions in the

space provided in this manual.

The model ZGG81 Zero Gravity 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 safety equipment such as eye protection, ear protection, head protection, respiratory protection and safety shoes at all times

when operating the tool. Use gloves if necessary.

• The operator must be familiar with all prohibited work areas such as excessive slopes and dangerous

terrain conditions. Railway workers must follow all FRA Federal/State Railroad Administration safety

regulations at all times.

• 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 and pinch points. 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 specications

given in “Grinding Wheel Safety” on page 6.

• Do not reverse grinding wheel rotation direction by changing uid ow direction.

• Do not move the tool until the grinding 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 ammable materials or gases.

• Eye injury, cutting or severing of body parts is

possible if proper procedures are not followed.

• Warning: Use of this tool on certain materials during

grinding could generate dust potentially containing a variety of hazardous substances such as asbestos,

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 grinding or cutting. Follow correct safety procedures and comply with all applicable national,

state or provisional health and safety regulations relating to them, including arranging for the safe

disposal of the materials by a qualied person.

ZGG81 User Manual ◄ 5

Page 6

SAFETY PRECAUTIONS

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

B7.1:2010/ISO 525, 603.

TOOL STICKERS & TAGS

• Ensure 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 ts the shaft.

• Ensure that the thread type and size of the grinding

wheel exactly matches the thread type and size of

the shaft.

25414

CAUTION STICKER

74832

STANLEY LOGO STICKER

73038

PINCH POINT STICKER

6 ► ZGG81 User Manual

Page 7

WARNINGS / PINCH POINTS

Keep all body parts clear of

potential pinch points or moving

parts indicated by the arrows

shown here.

CAUTION:

PINCH POINT

KEEP CLEAR OF

MOVING PARTS

Do not open or damage gas

spring, under high pressure.

CAUTION: PINCH POINT,

ARM FRAME COLLAPSES

WHEN MOVED

OPERATING POSITION

CARRY AND STORAGE

POSITION

ZGG81 User Manual ◄ 7

Page 8

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:

Certied non-conductive — constructed of thermoplastic or synthetic rubber inner tube, synthetic ber braid reinforcement, and weather resistant thermoplastic or synthetic rubber cover. Hose labeled certied 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 certied or labeled non-conductive) — constructed of thermoplastic or synthetic rubber inner tube, synthetic ber braid reinforcement, and weather resistant thermoplastic or synthetic rubber cover. This

hose is not certied 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

DANGER

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.

FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND ELECTRIC LINES.

2. BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS NON-CONDUCTIVE ON OR NEAR ELECTRIC LINES. WIPE THE ENTIRE LENGTH OF THE HOSE AND FITTING 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.

DO NOT REMOVE THIS TAG

SEE OTHER SIDE

SIDE 1

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, 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.

5. CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS, 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.

6. AFTER EACH USE STORE IN A CLEAN DRY AREA.

(Shown smaller than actual size)

DANGER

SEE OTHER SIDE

SIDE 2

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

DANGER

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.

2. FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND ELECTRIC LINES.

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.

DO NOT REMOVE THIS TAG

SEE OTHER SIDE

SIDE 1

6. AFTER EACH USE STORE IN A CLEAN DRY AREA.

(Shown smaller than actual size)

DANGER

SEE OTHER SIDE

SIDE 2

DO NOT REMOVE THIS TAG

8 ► ZGG81 User Manual

Page 9

Min. Working Pressure

USE

Press/Return)

(

HOSE RECOMMENDATIONS

Certied Non-Conductive Hose - Fiber Braid - for Utility Bucket Trucks

Oil Flow Hose Lengths Inside Diameter

GPM LPM FEET METERS INCH MM PSI BAR

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

5/8 16 Pressure 2500 175

3/4 19 Return 2500 175

5-10.5 19-40 100-300 30-90

10-13 38-49 up to 50 up to 15 5/8 16 Both 2500 175

5/8 16 Pressure 2500 175

3/4 19 Return 2500 175

10-13 38-49 51-100 15-30

3/4 19 Pressure 2500 175

1 25.4 Return 2500 175

10-13 38-49 100-200 30-60

5/8 16 Pressure 2500 175

3/4 19 Return 2500 175

13-16 49-60 up to 25 up to 8

3/4 19 Pressure 2500 175

1 25.4 Return 2500 175

13-16 49-60 26-100 8-30

PRESSURE

<<< FLOW

RETURN

FLOW >>>

Figure 1. Typical Hose Connections

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 recommenda-

tions are intended to keep return line pressure

(back pressure) to a minimum acceptable lev-

el to ensure maximum tool performance.

This chart is intended to be used for hydraulic

tool applications only based on Stanley Hy-

draulic Tools 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 maxi-

mum hydraulic system relief valve setting.

All hydraulic hose must meet or exceed

specications as set forth by SAE J517.

ZGG81 User Manual ◄ 9

Page 10

HTMA / EHTMA REQUIREMENTS

HTMA HYDRAULIC SYSTEM REQUIREMENTS

Flow Range

Nominal Operating Pressure (at the power supply outlet)

System relief valve setting (at the power supply outlet)

Maximum back pressure (at tool end of the return hose)

(at min. operating temperature)

(at max. expected ambient temperature)

Min. cooling capacity at a temperature

temps 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

(For cold temp. startup and max. dirt-holding capacity)

4-6 gpm 7-9 gpm 9-10.5 gpm 11-13 gpm (15-23 lpm) (26-34 lpm) (34-40 lpm) (42-49 lpm) 1500 psi 1500 psi 1500 psi 1500 psi (103 bar) (103 bar) (103 bar) (103 bar)

2100-2250 psi 2100-2250 psi 2200-2300 psi 2100-2250 psi (145-155 bar) (145-155 bar) (152-159 bar) (145-155 bar)

250 psi 250 psi 250 psi 250 psi (17 bar) (17 bar) (17 bar) (17 bar)

400 ssu* 400 ssu* 400 ssu* 400 ssu* (82 centistokes) (82 centistokes) (82 centistokes) (82 centistokes)

140° F 140° F 140° F 140° F (60° C) (60° C) (60° C) (60° C)

3 hp 5 hp 6 hp 7 hp (2.24 kW) (3.73 kW) (5.22 kW) (4.47 kW) 40° F 40° F 40° F 40° F (22° C) (22° C) (22° C) (22° C)

25 microns 25 microns 25 microns 25 microns 30 gpm 30 gpm 30 gpm 30 gpm (114 lpm) (114 lpm) (114 lpm) (114 lpm)

TYPE I TYPE II

TOOL TYPE

TYPE RR

TYPE III

(premium grade, anti-wear, non-conductive) Viscosity (at min. and max. operating temps)

NOTE:

over a wide range of operating temperatures.

*SSU = Saybolt Seconds Universal

EHTMA HYDRAULIC SYSTEM REQUIREMENTS

Flow Range

Nominal Operating Pressure (at the power supply outlet)

System relief valve setting (at the power supply outlet)

NOTE:

100-400 ssu* 100-400 ssu* 100-400 ssu* 100-400 ssu* (20-82 centistokes)

CLASSIFICATION

3.5-4.3 gpm 4.7-5.8 gpm 7.1-8.7 gpm 9.5-11.6 gpm 11.8-14.5 gpm (13.5-16.5 lpm) (18-22 lpm) (27-33 lpm) (36-44 lpm) (45-55 lpm) 1870 psi 1500 psi 1500 psi 1500 psi 1500 psi (129 bar) (103 bar) (103 bar) (103 bar) (103 bar)

2495 psi 2000 psi 2000 psi 2000 psi 2000 psi (172 bar) (138 bar) (138 bar) (138 bar) (138 bar)

10 ► ZGG81 User Manual

Page 11

OPERATION

PREPARATION FOR INITIAL USE

Each unit, as shipped, has no special unpacking or assembly requirements prior to usage. Inspection to assure the unit was not damaged in shipping and does not contain packing debris is all that is required. After installation of a grinding wheel a unit may be put to use.

CHECK HYDRAULIC POWER SOURCE

1. Using a calibrated owmeter and pressure gauge, check that the hydraulic power source develops a ow 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) 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 ttings 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 for cracks and other structural damage. Do not use a damaged guard assembly. Do not use this tool if the guard

has been removed.

INSTALLING AND REMOVING GRINDING

WHEELS

Read and understand the sections titled Safety

Precautions, Tool Stickers And Tags, Hydraulic

Hose Requirements, Hydraulic Requirements, And

Preparation Procedures, before using this product.

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

1. Remove the 3 capscrews and remove the guard

front plate and set aside.

2. Depress the push lock to lock the spindle. Unscrew

the jam nut. Remove the outside ange.

3. Make sure blotters or labels remain on the grinding wheel. Install the grinding wheel onto the spindle and reinstall the outside ange and jam nut.

4. Depress the push lock and tighten the jam nut. Only tighten sufciently to prevent slippage of the wheel between the anges.

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. Connect the return hose rst and disconnect it last to minimize trapped pressure within the grinder motor.

3. Observe ow indicators stamped on hose couplers to be sure that oil will ow 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 difcult to connect. When possible, connect the free ends of the operating hoses together, when not in use.

OPERATING PROCEDURES

1. Observe all safety precautions.

2. Always start the grinder with the grinding wheel

away from the work surface.

ZGG81 User Manual ◄ 11

Page 12

OPERATION

Operating Position

Trigger

Rear Adjuster

Roller

Clamp Lever Wheels

FIGURE 1

OPERATION

1. Before placing the unit on the rail, loosen Rear

Adjuster (see gure 1), raising the Roller.

2. Open the Wheels by lifting the Clamp Lever and

rotate wheels so they are sideways.

Leg Brace

Cradle

Hose Coupler

Handle Lock Release

FIGURE 2

continuing.

10. Start the grinder and move the grinding wheel to the work surface.

NOTE: Rest your leg against the leg brace to increase your leverage on the grinding wheel.

3. Place on rail, lift and rotate Clamp Lever/wheels and lock the pin in place.

4. Tighten Rear Adjustor until the roller touches rail, do not over tighten, the clamp will roll freely.

5. Pull Handle Lock Release (see gure 2) and lift handle to the operating position. Verify the lock is

engaged in the side plate.

6. Connect hose whips.

7. Rotate the motor to the side of rail to be ground.

8. Move the hydraulic circuit control valve to the ON position

9. Squeeze the trigger momentarily. If the grinder

does not operate, the hoses might be reversed. Verify correct connection of the hoses before

12 ► ZGG81 User Manual

11. Grind a small amount of material at a time.

12. Grind the web, then move grinder over the rail

head and grind the second web.

13. When nished, turn off the power supply and disconnect the hose whips.

14. Release handle lock (see gure 2) and rest the handle back in the cradle and lock in place.

15. Lift up and rotate clamp lever (see gure 1) and

remove grinder from rail.

COLD WEATHER OPERATION

If the grinder is to be used during cold weather, preheat the hydraulic uid at low engine speed. When using the normally recommended uids, uid temperature should be at or above 50 °F/10 °C (400 ssu/82 centistokes)

before use.

Page 13

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 ow. This can cause damage to internal seals.

• Replace all parts, including hoses and couplings, with replacement parts recommended by Stanley

Hydraulic Tools. Supply hoses must have a minimum

working pressure rating of 2500 psi/172 bar.

• Do not exceed the rated ow and pressure. See “Specications” on page 15 for correct ow rate and pressure rating. Rapid failure of the internal

seals may result.

• 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.

ZGG81 User Manual ◄ 13

Page 14

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 ow and pressure to the grinder as listed in the table. Use a owmeter known to be accurate. Check the ow with the hydraulic oil temperature at least 80 °F/27 °C.

Problem Cause Solution

Grinder does not run. Hydraulic power source not

functioning.

Couplers or hoses blocked. Locate and remove restriction.

Hydraulic motor failure. Inspect and repair.

Hydraulic lines not connected. Connect lines.

Grinder operates too slow. Hydraulic motor speed to slow. Check power unit for proper ow (7–10

High back-pressure. Check hydraulic system for excessive

Couplers or hoses blocked. Locate and remove restriction.

Oil too hot (above 140 °F/60 °C) or too cold (below 60 °F/16 °C).

Relief valve set too low. Adjust relief valve to 2100–2250 psi /

Hydraulic motor worn. Inspect, repair or replace.

Flow control malfunctioning. Have ow control serviced at an

Grinder operates too fast. Flow control malfunctioning. Have ow control and valve body

Check power source for proper ow and pressure (7–10 GPM/26–38 LPM @ 1500–2000 psi/105–140 bar.

GPM/26–38 LPM).

back-pressure (over 250 psi/17 bar).

Check hydraulic power source for

proper oil temperature. Bypass

cooler to warm oil or provide cooler to

maintain proper temperature.

145–155 bar.

authorized Stanley service center.

serviced at an authorized Stanley service center.

14 ► ZGG81 User Manual

Page 15

SPECIFICATIONS

Wheel Capacity ...........................................................................................8 in. dia. × 1 in. thick × 5/8 arbor (type 1)

Pressure Range.............................................................................................................. 2000–2500 psi/138–172 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) ................................................................................................... 48.1 lb/21.8 kg

Overall Length .............................................................................................................................32.5 inches/82.5 cm

Overall Width ..................................................................................................................................... 11 inches/28 cm

Overall Height ..............................................................................................................................................................

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

Grinding Wheel

Part number 28598

ZGG81 User Manual ◄ 15

Page 16

ZGG81/81-N MOTOR PARTS ILLUSTRATION

NOTE: MOTOR IS A CCW ROTATION

ITEM # 16 TORQUE TO 120 IN. LBS. X 8.

ITEM # 14 (QTY-6) TORQUE TO 225 IN. LBS.

FLOW RATE, PSI & RPM LOCATION

ITEM # 20 and 28 TORQUE TO 225 IN. LBS.

ITEM # 41 TORQUE TO 37 IN. LBS.

NOTE: GREASE O-RINGS, SEALS, WIPERS, AND QUAD RINGS BEFORE ASSEMBLY

COMPLETE MOTOR ASSY P/N-211142

16 ► ZGG81 User Manual

Page 17

ZGG81/81-N MOTOR/BEARING HOUSING PARTS LIST

ITEM # PART # QTY DESCRIPTION

1 00026 1 O-Ring *

2 00106 1 O-Ring *

3 00171 1 O-Ring *

4 00214 1 Quad Ring *

5 00289 2 Dowel Pin

6 00708 1 Retaining Ring External

7 01205 1 O-Ring *

8 01608 1 Steel Ball

10 03227 2 Dowel Pin

11 04856 1 Retaining Ring

12 06316 4 Bushing, Garlock

13 06891 1 O-Ring *

14 08104 6 Hollow Hex Plug

15 16638 1 Retaining Ring

16 21962 8 Capscrew

17 22064 1 Rod Wiper *

18 25635 1 Flow Regltr.crtrdg.

19 25666 2 Drive Gear

20 73021 1 Sae Orb Plug Modied

21 73308 1 Idler Shaft Keyed

22 74890 1 Roll Pin 3/32 X .75 Lg

23 206095 1 Retaining Ring

24 74866 1 Motor Valve, Grinder (Includes 2

Bushings Item # 12 And Orice Plug Not Pictured)

25 207823 2 Bearing

26 207828 1 Shaft Lock

28 207839 1 Trigger Cap

29 207841 1 Spool Oc

31 207843 1 Compression Coil Spring

32 76692 1 Bearing Housing, Grinder (In-

cludes 2 Du Bushings Item # 12).

33 210880 1 Motor Shaft, Ccw

34 213702 1 Seal Carrier

37 211510 1 Compression Coil Spring

38 211511 1 Compression Coil Spring

39 211519 1 Spring Seat

40 211581 1 Retaining Ring External

41 350016 1 Hollow Hex Plug

SEAL KIT P/N-74868 * Denotes Part in Seal Kit

ZGG81 User Manual ◄ 17

Page 18

ZGG81/81-N QUAD ARM ASSEMBLY ILLUSTRATION

CONNECTS TO ITEM # 32 PAGE 16.

CAUTION: DO NOT DISASSEMBLE ITEM # 8 GAS SPRING, UNDER HIGH PRESSURE

CONNECTION (AA).

18 ► ZGG81 User Manual

Page 19

ZGG81/81-N QUAD ARM ASSEMBLY PARTS LIST

ITEM # PART # QTY DESCRIPTION

1 08253 2 Capscrew (Apply 263 Loctite & torque to 6 ft/

lbs.)

2 28409 1 Composite Sticker

3 73037 1 Pinch Point Sticker

4 74832 2 Decal-Stanley Logo

5 76685 1 Lower Arm Assembly Right (Includes 2 Ser-

rated Bushings & 2 Du Bushings).

6 208041 1 Upper Arm Assembly (Includes Decals, 4 Ser-

rated Bushings & 4 Du Bushings).

7 76684 1 Lower Arm Assembly Left (Includes 2 Serrated

Bushings & 2 Du Bushings).

8 208043 1 Gas Spring

9 208046 2 Spacer Sleeve

10 208048 1 Gimbal Lug Assembly (Includes Bearings,

Bushing & Retainer Ring).

11 208049 1 Frame Lug Assembly (Includes Bushing And

Bearing).

12 208050 2 SHSS 3/8 X 3 1/2 X 1/2Thd Lgth

13 213701 1 Motor Gimbal Assembly (Includes Bearing

Item 18, Gimbal Pin, Retainer Ring Item 17 & Gimbal Stop Item 21).

14 213707 2 Zgg Nail 3/8 X 3.850

15 213967 1 Handle / Hose Guide

16 211583 1 Bearing

17 213703 2 Retaining Ring

18 210858 1 Ball Bearing

19 213692 2 Bearing

20 213705 1 Retaining Ring

21 213706 1 Gimbal Stop

22 26812 1 Retaining Ring

23 08014 1 Bushing

ZGG81 User Manual ◄ 19

Page 20

ZGG81/81-N CLAMP PARTS ILLUSTRATION

SEE NOTE PAGE 21

ITEM # 43 APPLY 263 LOCTITE.

ITEM # 9 TORQUE TO 13 FT LBS.

CONNECTS TO (AA) PAGE 18.

ITEM # 3 APPLY 263 LOCTITE.

ITEMS # 49 & 6 APPLY 263 LOCTITE & TORQUE TO 13 FT

LBS.

ITEM # 4 TORQUE TO 6 FT LBS.

ITEM # 10 APPLY 263 LOCTITE & TORQUE TO 23

FT LBS.

ITEM # 15 APPLY

263 LOCTITE.

Roller, bearings & washers attach to item # 40.

20 ► ZGG81 User Manual

Page 21

ZGG81/81-N CLAMP PARTS LIST

ITEM # PART # QTY DESCRIPTION

1 00077 3 Retaining Ring

External

2 00233 2 Retaining Ring

3 00289 1 Dowel Pin

4 01397 2 Setscrew

5 04585 4 Washer

6 09892 2 Setscrew

7 17668 3 Roll Pin

8 211165 1 Roll Pin

9 20334 1 Hex Jam Nut

10 21052 1 Capscrew

11 26812 3 Retaining Ring

External

12 79217 2 Lock Nut

13 67803 1 Washer

15 204332 1 Knob, Tapered, Red

17 206116 2 Flanged Bushing

19 208077 1 Cross Dowel Nut

23 208654 8 Ball Bearing, Radial

24 208664 1 Spacer Tube Rear Bearing

27 208853 1 Wheel Pivot, Main

28 208854 1 Cross Link, Wheel Pivot

29 208856 4 Pivot Tab

30 210844 1 Roller, Upper

31 210845 2 Wheel, Lower

32 210846 2 Spacer, Lower Wheel

33 210847 1 Spindle, Quad Arm

34 210849 1 Clamp Assembly

(Includes Dowel Pins & 4 Du

Bushings

36 210851 1 Lever Rod, Wheel Pivot

37 210852 1 Wheel Pivot, Follower

38 210853 2 Thrust Washer

39 79269 2 Capscrew

40 210883 1 Roller, Rear

ITEM # PART # QTY DESCRIPTION

41 211060 2 Roller, Side

42 211062 1 Lead Screw, Rear Clamp

43 211137 1 Knob, Alum

45 211145 1 Zgg Nail 3/8 X 4.69

46 211151 2 Grooved Clevis Pin

47 211514 2 Dowel Pin

48 211574 1 Capscrew

49 211575 1 Hex Nut

50 213690 1 Rear Adjuster Asm

51 213696 2 Square Key

52 213708 1 Zgg Nail 3/8 X 4.45

NOTE: The wheel assemblies pictured below are identical in components with the exception of two parts.

1). Items 27 and 37 shown below and also on page # 20

are not the same.

2). Also the upper roll pin item # 8 is not the same on each wheel assembly.

ZGG81 User Manual ◄ 21

Page 22

ZGG81/81-N HANDLE PARTS ILLUSTRATION

13 14

ITEM # PART # QTY DESCRIPTION

1 79204 1 Handle

2 79205 1 Handle Clamp

3 79203 2 Clamp Receiver

4 21962 4 Socket Head Cap Screw

5 79213 1 Pad

6 79197 1 Leg Brace Weldment

7 203222 4 Capscrew

8 79270 1 Leg Brace Clamp

9 79206 1 Trigger Cable Assembly

10 27441 1 Thumb Latch

11 27445 1 Latch Spring

12 01851 1 Roll Pin (1/8 Ø X 1)

13 07718 1 Roll Pin (3/16 Ø X 1)

14 372035 1 Roll Pin (3/16 Ø X 1/2)

15 208084 1 Trigger

22 ► ZGG81 User Manual

Page 23

ZGG81/81-N MOTOR MOUNT ILLUSTRATION

91011

ITEM # PART # QTY DESCRIPTION

1 79198 1 Handle Assembly

2 79193 1 Right Mounting Bracket

3 00147 1 Nut

4 207845 4 Motor Mounting Screws

5 79219 1 Grooved Clevis Pin

6 04855 1 Retaining Ring

7 01228 1 Roll Pin (1/8 Ø x 7/8)

8 79196 1 Left Mounting Bracket

9 206083 1 Retaining Ring

10 206084 1 Spring

ITEM # PART # QTY DESCRIPTION

11 206085 1 Plunger Cap

12 79201 1 Plunger

13 208849 1 Button Head Cap Screw

14 04040 2 Bushing

15 79202 1 Handle Pivot

16 79218 1 Grooved Clevis Pin

17 206114 1 Sleeve Bearing

18 208062 1 Motor Trigger

19 208891 1 Washer

20 00077 1 Retaining Ring

ZGG81 User Manual ◄ 23

Page 24

ZGG81/81-N GUARD ILLUSTRATION & PARTS LIST

ATTACH TO BEARING HOUSING ITEM # 31 PAGE 16.

ITEM # 7 TORQUE TO 23 FT LBS.

24 ► ZGG81 User Manual

ITEM # PART # QTY DESCRIPTION

1 00787 3 Capscrew

2 01714 1 Heavy Hex Jam Nut

3 02447 1 Key Woodruff

4 02689 3 O-Ring

7 10793 1 Capscrew

8 25354 1 Outside Flange

9 25355 1 Drive Flange

10 25414 1 Caution Sticker Ccw

17 206088 1 Inner Guard Assembly

27 211154 1 Guard Front Plate

Page 25

ZGG81/81-N HOSE/COUPLERS ILLUSTRATION & PARTS LIST

152 162 151 161

153 163

152 162

150 160

ITEM REV DESCRIPTION HOSE GROUP

ZGG81 1 Zero Gravity Grinder A

ZGG81-N 1 Zero Gravity Grinder BN B

ITEM PART NO QTY. HOSE GROUP "A" PARKER

150 03972 1 Coupler,3/8Fem. 3/8Npt Fl.face Set 03971

151 03973 1 Coupler,3/8Male 3/8Npt Fl.face Set 03971

152 76678 2 Spiral Hose Wrap 24"

153 207824 2 Hose Assy Railroad 32"

ITEM PART NO QTY. HOSE GROUP "B" AEROQUIP

160 47436 1 Coupler,3/8Fem. 3/8Npt Fl.face Set 47438

161 47437 1 Coupler,3/8Male 3/8Npt Fl.face Set 47438

162 76678 2 Spiral Hose Wrap 24"

163 208848 2 Hose Assy Railroad 32"

ZGG81 User Manual ◄ 25

Page 26

Page 27

Page 28

Stanley Hydraulic Tools

3810 SE Naef Road

Milwaukie, Oregon 97267-5698 USA

(503) 659-5660 / Fax (503) 652-1780

www.stanleyhydraulics.com