Stanley ZGG81, ZGG81-N User Manual
ZGG81
ZGG81-N
ZERO GRAVITY
WEB GRINDER
USER MANUAL
Safety, Operation and Maintenance
© 2017 Stanley Black & Decker, Inc.
New Britain, CT 06053
U.S.A.
76531 8/2017 Ver. 1
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 certied 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 certied dealer, call Stanley Hydraulic Tools at (503) 659-5660 and ask for a Customer Service Representative.
ZGG81 User Manual ◄ 3
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 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
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 specic 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 specications
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 qualied person.
ZGG81 User Manual ◄ 5
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
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
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:
Certied non-conductive — constructed of thermoplastic or synthetic rubber inner tube, synthetic ber braid
reinforcement, and weather resistant thermoplastic or synthetic rubber cover. Hose labeled certied 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 certied 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 certied 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
DANGER
SEE OTHER SIDE
SIDE 2
THE TAG SHOWN BELOW IS ATTACHED TO “CONDUCTIVE” HOSE.
DANGER
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.
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.
DO NOT REMOVE THIS TAG
SEE OTHER SIDE
SIDE 1
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
DO NOT REMOVE THIS TAG
DO NOT REMOVE THIS TAG
8 ► ZGG81 User Manual
Min. Working Pressure
USE
Press/Return)
(
HOSE RECOMMENDATIONS
Certied 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
specications as set forth by SAE J517.
ZGG81 User Manual ◄ 9
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