HG60
HYDRAULIC BULL
NOSE GRINDER
USER MANUAL
Safety, Operation and Maintenance
© 2014 Stanley Black & Decker, Inc.
New Britain, CT 06053
U.S.A.
67373 9/2014 Ver. 6
TABLE OF CONTENTS
SAFETY SYMBOLS ..................................................................................................................................................4
SAFETY PRECAUTIONS .......................................................................................................................................... 5
TOOL STICKERS & TAGS ........................................................................................................................................7
HOSE TYPES ............................................................................................................................................................ 8
HOSE RECOMMENDATIONS ..................................................................................................................................9
FIGURE 1. TYPICAL HOSE CONNECTIONS .......................................................................................................9
HTMA REQUIREMENTS .........................................................................................................................................10
OPERATION ............................................................................................................................................................ 11
TOOL PROTECTION & CARE ................................................................................................................................12
TROUBLESHOOTING ............................................................................................................................................13
SPECIFICATIONS ................................................................................................................................................... 14
ACCESSORIES.......................................................................................................................................................14
HG60 PARTS ILLUSTRATION ................................................................................................................................ 15
HG60 PARTS LIST ..................................................................................................................................................16
IMPORTANT
To ll out a Product Warranty Validation form, and for information on your warranty,
visit Stanleyhydraulics.com and select the Company tab, Warranty.
(NOTE: The warranty Validation record must be submitted to validate the warranty).
SERVICING: This manual contains safety, operation, and routine maintenance instructions. Stanley Hydraulic
Tools recommends that servicing of hydraulic tools, other than routine maintenance, must be performed by an au-
thorized and certied 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 certied dealer, call Stanley Hydraulic Tools at the number listed on the back of this
manual and ask for a Customer Service Representative.
HG60 User Manual ◄ 3
DANGER
WARNING
CAUTION
CAUTION
NOTICE
IMPORTANT
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 ► HG60 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 pre-
cautions relating to the specic work area and local
safety regulations. If so, place the added precautions in
the space provided in this manual.
The model HG60 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 by-
standers. Flying debris can cause serious injury.
• Do not operate the tool unless thoroughly trained
or under the supervision of an instructor. Establish
a training program for all operators to ensure safe
operation.
• 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.
• 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 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.
• Do not operate a damaged, improperly adjusted, or
incompletely assembled grinder.
• 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
grinding stone. 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 grinding stone that is cracked, chipped
or otherwise damaged. Always inspect stones for
possible damage before installation or use.
• Always use stones that conform to the specications
given in the OPERATION section of this manual.
• Do not reverse grinding stone rotation direction by
changing uid ow direction.
• Do not move the tool until the stone has stopped
rotating. Release the trigger if the power supply has
been interrupted.
• To avoid personal injury or equipment damage, all
tool repair, maintenance and service must only be
performed by authorized and properly trained personnel.
• If the material being ground creates an emission of
dust and fumes, use personal protective devices.
• Never cock, jam or wedge the grinding stone during
operation.
• Never cause sparks in the vicinity of ammable materials.
• Eye injury, and cutting or severing of body parts is
possible if proper procedures are not followed.
• Do not carry the tool by the hoses.
• Warning: Use of this tool on certain materials during
demolition 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 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 qualied
person.
HG60 User Manual ◄ 5
SAFETY PRECAUTIONS
GRINDING WHEEL SAFETY
• Ensure that the grinding stone 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 stone in-
stalled, the stone should be examined thoroughly
before use.
• Only use abrasive stone that comply with ANSI
B7.1/ISO 525, 603.
• Check that the maximum rpm operating speed of
the abrasive stone is equal to or greater than the
rated shaft speed of the grinder.
• Ensure that the grinding stone dimensions are compatible with the grinder and that the grinding stone
ts the shaft.
• Ensure that the thread type and size of the grinding
stone exactly matches the thread type and size of
the shaft.
6 ► HG60 User Manual
CAUTION
PROTECT YOUR EYES
WEAR SAFETY GOGGLES
1. Do not use damaged wheels.
2. Use only 5/8-11 cone and plug wheels per the
requirements of ANSI 87.1 or 525.603.
3. Inspect mounting flange for damage after wheel
breakage on the machine.
4. Maximum wheel speed is 6000 RPM.
ROTATION DIRECTION
26229
Wear Safety Goggles Sticker
25610
Railroad Help Desk Sticker
TOOL STICKERS & TAGS
HG60
26212
Name Tag
03787
GPM Sticker
05153
Stanley Sticker
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.
1. FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON-CONDUCTIVE WHEN USING HYDRAULIC
TOOLS ON OR NEAR ELECTRICAL LINES MAY RESULT IN
DEATH OR SERIOUS INJURY.
BEFORE USING HOSE LABELED AND CERTIFIED AS NON-
CONDUCTIVE ON OR NEAR ELECTRIC LINES BE SURE THE
HOSE IS MAINTAINED AS NON-CONDUCTIVE. THE HOSE
SHOULD BE REGULARLY TESTED FOR ELECTRIC CURRENT LEAKAGE IN ACCORDANCE WITH YOUR SAFETY
DEPARTMENT INSTRUCTIONS.
2. A HYDRAULIC LEAK OR BURST MAY CAUSE OIL INJECTION INTO THE BODY OR CAUSE OTHER SEVERE
PERSONAL INJURY.
A. DO NOT EXCEED SPECIFIED FLOW AND PRESSURE
FOR THIS TOOL. EXCESS FLOW OR PRESSURE MAY
CAUSE A LEAK OR BURST.
B. DO NOT EXCEED RATED WORKING PRESSURE OF
HYDRAULIC HOSE USED WITH THIS TOOL. EXCESS
PRESSURE MAY CAUSE A LEAK OR BURST.
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.
IMPORTANT
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.
TAG TO BE REMOVED ONLY BY
TOOL OPERATOR.
SEE OTHER SIDE
DANGERDANGER
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 CONNECTED 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.
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 SYSTEM AND/OR SEVERE PERSONAL INJURY.
5. BYSTANDERS MAY BE INJURED IN YOUR WORK AREA.
KEEP BYSTANDERS CLEAR OF YOUR WORK AREA.
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.
IMPORTANT
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.
TAG TO BE REMOVED ONLY BY
TOOL OPERATOR.
SEE OTHER SIDE
SAFETY TAG P/N 15875 (Shown smaller then actual size)
HG60 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 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.
(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 ► HG60 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
13-16 49-60 up to 25 up to 8
3/4 19 Return 2500 175
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.
HG60 User Manual ◄ 9
HTMA / EHTMA REQUIREMENTS
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)
Measured at a max. uid viscosity of:
(at min. operating temperature)
Temperature: Sufcient heat rejection
capacity to limit max. uid temperature to:
(at max. expected ambient temperature)
Min. cooling capacity at a temperature
difference of between ambient and uid
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
Min. full-ow ltration
Sized for ow of at least:
(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
Hydraulic uid Petroleum based
(premium grade, anti-wear, non-conductive)
Viscosity (at min. and max. operating temps)
NOTE:
When choosing hydraulic uid, the expected oil temperature extremes that will be experienced in service determine the
most suitable temperature viscosity characteristics. Hydraulic uids with a viscosity index over 140 will meet the requirements
over a wide range of operating temperatures.
*SSU = Saybolt Seconds Universal
EHTMA
100-400 ssu* 100-400 ssu* 100-400 ssu* 100-400 ssu*
(20-82 centistokes)
CLASSIFICATION
HYDRAULIC SYSTEM
REQUIREMENTS
Flow Range
Nominal Operating Pressure
(at the power supply outlet)
System relief valve setting
(at the power supply outlet)
NOTE: These are general hydraulic system requirements. See tool specication page for tool specic requirements
B
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)
C
D
10 ► HG60 User Manual
OPERATION
PRE-OPERATION PROCEDURES
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 stone 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 2200–2300 psi/152–
159 bar.
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 fasten-
ers tight.
CHECK TRIGGER MECHANISM
1. Check that the trigger operates smoothly and is free
to travel between the ON and OFF positions.
INSTALLING AND REMOVING GRINDING
STONES
READ AND BECOME FAMILIAR WITH THE SECTIONS
IN THIS MANUAL ON SAFETY PRECAUTIONS, TOOL
STICKERS AND TAGS, HYDRAULIC HOSE REQUIRE-
MENTS, HYDRAULIC REQUIREMENTS, AND PREOPERATION PROCEDURES BEFORE USING THIS
PRODUCT.
NOTE:
Use 3 inch diameter up to 5 inch long (Type 16, 17, 18
or 19) grinding cones or plugs with a 5/8-11 threaded
arbor hole. Only use grinding cones or plugs which
comply with ANSI B7.1/ISO 525, 603.
1. Install the abrasive cone or plug onto the spindle
(33). Using an open-end wrench on the ats of the
drive ange (51) and while griping the cone or plug,
tighten sufciently to prevent disengagement of the
cone or plug from the spindle.
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 prac-
tice to connect the return hose rst and disconnect
it last to minimize or avoid 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 difcult 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 stone
away from the work surface.
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 stone 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 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.
HG60 User Manual ◄ 11
NOTICE
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 con-
nection.
• 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 cir-
cuit ow. 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 minimum working pressure rating of 2500 psi/172 bar.
• Do not exceed the rated ow. Refer to Specications
in this manual for correct ow rate. Rapid failure of
the internal seals may result.
• Always keep critical tool markings, such as warning
stickers and tags legible.
• Do not force a small tool to do the job of a large tool.
• Tool repair should be performed by experienced
personnel only.
• Make certain that the recommended relief valves
are installed in the pressure side of the system.
• Do not use the tool for applications for which it was
not intended.
12 ► HG60 User Manual
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 2200–2300
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
Spindle rotates in the wrong
direction.
Hydraulic ow is in the wrong
direction.
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.
psi/152–159 bar.
authorized Stanley service center.
serviced at an authorized Stanley
service center.
Connect the pressure line to the
grinder port marked IN. Connect the
return line to the grinder port marked
OUT.
HG60 User Manual ◄ 13
SPECIFICATIONS
Wheel Capacity ............................................................................... 3 in. dia. × 5 in. long × 5/8-11 arbor (type 16-19)
Pressure Range................................................................................................................ 1000–2000 psi/70–140 bar
Maximum Back Pressure...................................................................................................................... 250 psi/17 bar
Flow Range ............................................................................................................................... 7–10 gpm/26–38 lpm
Optimum Flow ..................................................................................................................................... 10 gpm/38 lpm
Porting ...................................................................................................................................................-8 SAE O-ring
Couplers .........................................................................................HTMA/EHTMA Flush Face Type Male & Female
Hose Whips ........................................................................................................................................................... Yes
Weight (with whip hoses & couplers) ................................................................................................... 10.8 lb/4.89 kg
Overall Length ................................................................................................................................23 inches/58.4 cm
Overall Width ...................................................................................................................................3.3 inches/8.4 cm
Overall Height ...................................................................................................................................4 inches/10.2 cm
RPM ............................................................................................................................................................. 6000 Max
Maximum Fluid Temperature .................................................................................................................. 140 °F/60 °C
ACCESSORIES
Grinding Stone (Cone).......................................................................................................................................30872
14 ► HG60 User Manual
HG60 PARTS ILLUSTRATION
OIL FLOW IN
HG60 User Manual ◄ 15
HG60 PARTS LIST
PART
ITEM
NO. QTY DESCRIPTION
1 26229 1 CAUTION STICKER
2 06316 4 BUSHING
3 00178 1 O-RING*
4 73308 1 IDLER SHAFT KEYED
6 04031 2 DOWEL PIN
7 26212 1 NAME TAG
8 03249 8 CAPSCREW
9 27602 2 OIL TUBE
10 30381 1 DIPPED HANDLE
11 30366 2 CAPSCREW
12 00018 4 O-RING*
13 21437 1 FRONT BEARING HOUSING ASSY
14 03227 2 NEEDLE ROLLER
15 25666 2 DRIVE GEAR
16 29775 1 REAR BEARING HOUSING
17 27441 1 THUMB LATCH
18 27445 1 TORSION SPRING
19 01851 2 ROLL PIN
20 00114 1 ROLL PIN
21 27442 1 THUMB TRIGGER
22 04097 1 COIL SPRING
23 01211 2 O-RING*
24 27608 1 DIPPED VALVE
25 01605 2 O-RING*
26 66728 2 HOSE ASSY (AEROQUIP)
58630 2 HOSE ASSY (PARKER)
27 47436 1 FEMALE COUPLER BODY
03972 1 FEMALE COUPLER BODY (PARKER)
28 47437 1 MALE COUPLER BODY (AEROQUIP)
03973 1 MALE COUPLER BODY (PARKER)
29 350041 1 -4 SAE PLUG
30 28915 1 FLOW REGULATOR CARTRIDGE
31 04098 1 VALVE SPOOL
32 02447 1 KEY
34 06314 1 BALL BEARING
35 00708 1 RETAINING RING
36 06300 1 BEARING SPACER
37 25360 1 COUPLING
38 00148 1 BALL BEARING
39 06303 1 MOTOR SHAFT
40 00170 1 RETAINING RING
(INCL ITEM 2,)
(AEROQUIP)
(PRE-SET)
ITEM
41 30333 1 SEAL GLAND
42 00214 1 QUAD RING*
43 350771 1 O-RING*
44 00769 3 CAPSCREW
45 06301 1 SPINDLE HOUSING
46 — — NO ITEM
47 06299 1 BEARING RACE
48 06313 1 NEEDLE ROLLER BEARING
49 06312 1 SEAL*
50 06311 1 V-RING SEAL*
54 25610 1 RAILROAD HELP DESK STICKER
55 03787 1 GPM STICKER 7–10 2000 PSI
56 — — NO ITEM
57 26206 1 SPINDLE
58 05153 1 STANLEY STICKER
59 26207 1 DRIVE FLANGE
63 00032 2 LOCKWASHER
64 24289 1 PLUG
65 01411 1 O-RING
66 20145 1 STEEL BALL
67 01521 1 CAPSCREW
68 20939 1 ROLL PIN
PART
NO. QTY DESCRIPTION
29137 1 SEAL KIT
* Denotes part in seal kit.
16 ► HG60 User Manual
Stanley Hydraulic Tools
3810 SE Naef Road
Milwaukie, Oregon 97267-5698 USA
(503) 659-5660 / Fax (503) 652-1780
www.stanleyhydraulics.com
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