FG10 - PG05 PARTS ILLUSTRATION .................................................................................................................16
FG10 PARTS LIST ................................................................................................................................................. 18
PG05 PARTS LIST ................................................................................................................................................. 20
To ll out a product warranty validation form, and for information on your warranty,
visit www.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 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 Infrastructure at (503) 659-5660 and ask for a Customer Service Representative.
FG10 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 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.
4 ► FG10-PG05 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 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 FG10 Hydraulic Frog Grinder and PG05 Prole
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 goggles, ear
and head protection and safety shoes at all times
when operating the tool. Use gloves and aprons
when necessary.
• The operator must be familiar with all prohibited work
areas such as excessive slopes and dangerous
terrain conditions.
• Maintain proper footing and balance at all times.
• Do not inspect, clean or replace the grinding wheel
while the hydraulic power source is connected. 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. High temperatures can cause 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 o 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 the OPERATION section of this manual.
• Do not reverse grinding wheel rotation direction by
changing uid ow direction.
• Do not move the tool until the wheel has stopped
rotating. Release the trigger if the power supply has
been interrupted.
• 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 lter 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 qualied person.
FG10-PG05 User Manual ◄ 5
Page 6
29715
PG05 Name Tag
28727
FG10 Name Tag
TOOL STICKERS & TAGS
03787
GPM Decal
05152
Stanley Sticker
25790
Caution Decal
25610
Railroad Help Desk Decal
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
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 CONNECTED 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 CLOSEDCENTER 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 PROTECTION.
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
USE ONLY PARTS AND REPAIR
PROCEDURES APPROVED BY
STANLEY AND DESCRIBED IN THE
TAG TO BE REMOVED ONLY BY
SAFETY TAG P/N 15875 (Shown smaller then actual size)
DANGERDANGER
TOOL BEFORE USING IT.
OPERATION MANUAL.
TOOL OPERATOR.
SEE OTHER SIDE
6 ► FG10-PG05 User Manual
Page 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:
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 certifi 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 certifi 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. 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
FG10-PG05 User Manual ◄ 7
Page 8
Min. Working Pressure
USE
Press/Return)
(
HOSE RECOMMENDATIONS
Certi ed Non-Conductive Hose - Fiber Braid - for Utility Bucket Trucks
Oil FlowHose LengthsInside Diameter
GPMLPMFEETMETERSINCHMMPSIBAR
4-915-34up to 10up to 33/810Both2250155
Conductive Hose - Wire Braid or Fiber Braid -DO NOT USE NEAR ELECTRICAL CONDUCTORS
4-615-23up to 25up to 7.53/810Both2500175
4-615-2326-1007.5-301/213Both2500175
5-10.519-40up to 50up to 151/213Both2500175
5-10.519-4051-10015-305/816Both2500175
5/816Pressure2500175
3/419Return2500175
5-10.519-40100-30030-90
10-1338-49up to 50up to 155/816Both2500175
5/816Pressure2500175
3/419Return2500175
10-1338-4951-10015-30
3/419Pressure2500175
125.4Return2500175
10-1338-49100-20030-60
5/816Pressure2500175
3/419Return2500175
13-1649-60up to 25up to 8
3/419Pressure2500175
125.4Return2500175
13-1649-6026-1008-30
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
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
8 ► FG10-PG05 User Manual
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
speci cations as set forth by SAE J517.
Page 9
HTMA / EHTMA REQUIREMENTS
HTMA / EHTMA REQUIREMENTS
TOOL TYPE
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 minimum operating temperature)
Temperature: Su cient heat rejection capacity to limit
maximum uid temperature to:
(At maximum expected ambient temperature)
Minimum cooling capacity at a temperature di erence 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
Sized for ow of at least:
(For cold temp startup and maximum dirt-holding capacity)
Hydraulic uid, petroleum based (premium grade, antiwear, non-conductive) Viscosity (at minimum and maximum
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.
TYPE ITYPE IITYPE RRTYPE III
4-6 GPM
(15-23 LPM)
1500 psi
(103 bar)
2100-2250 psi
(145-155 bar)
250 psi
(17 bar)
400 ssu*
(82 centistokes)
140° F
(60° C)
3 hp
(2.24 kW)
40° F
(22° C)
30 GPM
(114 LPM)
100-400 ssu
(20-82
centistokes)
7-9 GPM
(26-34 LPM)
1500 psi
(103 bar)
2100-2250 psi
(145-155 bar)
250 psi
(17 bar)
400 ssu*
(82 centistokes)
140° F
(60° C)
5 hp
(3.73 kW)
40° F
(22° C)
30 GPM
(114 LPM)
100-400 ssu
(20-82
centistokes)
9-10.5 GPM
(34-40 LPM)
1500 psi
(103 bar)
2200-2300 psi
(152-159 bar)
250 psi
(17 bar)
400 ssu*
(82 centistokes)
140° F
(60° C)
6 hp
(5.22 kW)
40° F
(22° C)
30 GPM
(114 LPM)
100-400 ssu
(20-82
centistokes)
11-13 GPM
(42-49 LPM)
2100-2250 psi
(145-155 bar)
(82 centistokes)
100-400 ssu
centistokes)
1500 psi
(103 bar)
250 psi
(17 bar)
400 ssu*
140° F
(60° C)
7 hp
(4.47 kW)
40° F
(22° C)
30 GPM
(114 LPM)
(20-82
*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: These are general hydraulic system requirements. See tool speci cation page for tool speci c requirements.
B
3.5-4.3 GPM
(13.5-16.5
LPM)
1870 psi
(129 bar)
2495 psi
(172 bar)
C
4.7-5.8 GPM
(18-22 LPM)
1500 psi
(103 bar)
2000 psi
(138 bar)
CLASSIFICATION
D
7.1-8.7 GPM
(27-33 LPM)
1500 psi
(103 bar)
2000 psi
(138 bar)
9.5-11.6 GPM
(36-44 LPM)
1500 psi
(103 bar)
2000 psi
(138 bar)
FG10-PG05 User Manual ◄ 9
11.8-14.5 GPM
(45-55 LPM)
1500 psi
(103 bar)
2000 psi
(138 bar)
Page 10
OPERATION
PREPARATION PROCEDURES
CHECK HYDRAULIC POWER SOURCE
1. Using a calibrated ow meter 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) 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 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 WELDMENT
1. Inspect the wheel guard weldment for cracks and
other structural damage.
4. Replace the guard weldment.
WHEEL PIVOT ADJUSTMENTS
FOR PROFILE OR FROG GRINDING
OPERATIONS
Note: The PG05 does not contain the pivot wheels or
the extension assembly.
GRINDING WINGS
For grinding a wing of the frog, place the grinder on top
of the wing with the rollers (91) resting on top of the
wing to be ground. Adjust each wheel pivot (86) to the
position shown in gure 1. Grinding is accomplished by
moving the grinder back and forth in line with the rail.
When nished with one wing, rotate the entire grinder
180 degrees and place it on the other wing.
Never over-tighten the grinding wheel by impacting
the wrench with a mallet or hammer. Sucient
torque is attained by hand-tightening the wheel with
a strap wrench while securing the drive ange with
the wrench provided.
INSTALLING AND REMOVING
GRINDING WHEEL
Note: Use 6 inch diameter up to 3 inch thick (Type
6 for USA) grinding wheels with a 5/8-11 threaded
arbor hole. Only use grinding wheels which comply
with ANSI B7.1, B7.5/ISO 525, 603.
Read and become familiar with the sections in this
manual on safety precautions, tool stickers and tags,
hydraulic hose requirements, hydraulic requirements,
and preparation procedures before using this product.
USA CONFIGURATION
1. Unscrew the two nuts (98) which secure the guard
weldment (95) to the frame and remove the guard
weldment.
2. Install the grinding wheel until it comes in contact
with the drive ange.
3. Using the wrench (127) provided, place it on the
ats of the drive ange. Place a strap wrench on
the grinding wheel and then tighten by gripping and
turning the strap wrench while holding the wrench
provided.
Cross Section of Typical Frog at 1/2” Point
Figure 1. Grinding the Wings of a Frog
GRINDING THE POINT
For grinding the point of a frog, place the grinder on top
of the point with the rollers (91) resting on the top of
the point. Adjust each wheel pivot (86) to the position
shown in gure 2. Grinding is accomplished by moving
the grinder back and forth in line with the rail. It may
be necessary to rotate the entire grinder 180 degrees
and place it on the other side of the point in order to
10 ► FG10/PG05 User Manual
Page 11
OPERATION
completely grind the width of the point. The extension
assembly (128) is normally used during point grinding
operations.
Cross Section of Typical Frog at 1/2” Point
Figure 2. Grinding the Point of a Frog
PROFILE GRINDING
For prole grinding of rail, place the grinder on top of
the rail with the rollers (91) resting on top of the rail to
be ground. Adjust each wheel pivot (86) to the position
shown in Figure 3. Grinding is accomplished by moving
the grinder back and forth in line with the rail.
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 dicult 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 away
from the work surface by turning the handwheel
counter clockwise to raise the grinding wheel.
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 to the
work surface by turning the handwheel clockwise.
6. Grind a small amount of material at a time adjusting
the grinding wheel as necessary by turning the
handwheel.
Note: If the grinder is not loaded against a work
surface when the trigger is released, the wheel will
take 5-10 seconds to come to a complete stop. Avoid
unintentional contact of the grinding wheel during
the coast down period.
Cross Section of Typical Rail
Figure 3. Prole Grinding
USING THE EXTENSION ASSEMBLY
The extension assembly (128) can be used at anytime
by simply connecting it to one end of the grinder at the
barrel nut (61) and clamping it in place by turning the
adjustable handle (44).
CONNECTING THE HOSES
1. Wipe all hose couplers with a clean lint-free cloth
before making connections.
2. Connect the hoses from the hydraulic power source
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. Damage to the hydraulic system or grinder
can result from use with uid that is to viscous or too
thick.
FG10/PG05 User Manual ◄ 11
Page 12
OPERATION
PREVENTATIVE MAINTENANCE
1. The gears and bearings in the ram, spindle and housing assemblies should be re-greased every 6 months or
500 hours, This procedure must be accomplished by a trained technician.
2. After each servicing, measure the spindle speed (rpm - revolutions per minute) at 12 gpm/45 lpm input. The
nominal speed is 4000, not to exceed 6000 rpm. This procedure must be accomplished by a trained technician.
3. Inspect the spindle and drive ange for signs of wear or damage. Run-out should not exceed .004 in./.1 mm TIR
on threads or .002 in./.05 mm TIR on arbor diameters and faces.
4. Check hoses and ttings weekly for any evidence of leakage, cover wear, cracking or cuts. If any of these
defects are found, discontinue use of the tool immediately and have the defects repaired or replaced by a
trained technician.
5. To grease between main housing bore (item 73) and the ram outer diameter (item 26), 1 - 2 pumps of grease
are required at these locations. Too much grease will lockup the feed assembly (See gure 4 below).
12 ► FG10/PG05 User Manual
Figure 4
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.
• 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 ow. Rapid failure of the
internal seals may result. See “SPECIFICATIONS”
on page 15 for correct ow rate and model
number.
• Always keep critical tool markings, such as warning
stickers and tags, legible.
• Tool repair must be performed by experienced
personnel only.
• Ensure 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.
FG10/PG05 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 ow meter known to be accurate.
Check the ow with the hydraulic oil temperature at least 80°F/27°C.
PROBLEMCAUSESOLUTION
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
High back-pressure.Check hydraulic system for
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
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.
(7-10 gpm/26-38 lpm).
excessive 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/145-155 bar.
authorized STANLEY service
center.
serviced at an authorized STANLEY
service center.
14 ► FG10/PG05 User Manual
Page 15
SPECIFICATIONS
Wheel Capacity .............................................................6 in. dia. x 3 in. thk x 5/8-11 threaded arbor (Type 6) U.S.A.
Pressure Range..................................................................................................................1000-2000 psi/70-140 bar
Maximum Back Pressure...................................................................................................................... 250 psi/17 bar
Flow Range ......................................................................................................HTMA Type RR, 7-10 gpm/26-38 lpm
Couplers ..........................................................................................HTMA/EHTMA Flush Face Type Male & Female
Connect Size and Type ...................................................................................................... 3/8 in. Male Pipe Adapter
Hose Whips ............................................................................................................................................................ No
Weight (with couplers) ............................................................................................................................... 90 lb/41 kg
Overall Length ........................................................................................................................... 44 inches/111.76 cm
Overall Width ............................................................................................................................. 10.5 inches/26.7 cm
Overall Height ............................................................................................................................ 32.5 inches/82.5 cm
HyrevzTM Motor ..................................................................................................................................................25251
Maximum Fluid Temperature .................................................................................................................. 140° F/60° C
Sound Power Level ....................................................................................................................................... 104 dBA
Vibration Level .............................................................................................................................Less than 2.5m/sec
SOUND AND VIBRATION DECLARATION
Test conducted on FG10110 S/N 527 operated at standard 10 gpm input
Measured A-weighted sound power level, Lwa (ref. 1pW) in decibels103.86 dBA
Uncertainty, Kwa, in decibels3 dBA
Measured A-weighted sound pressure level, Lpa (ref. 20 µPa) at operator's position, in decibels94 dBA
Uncertainty, Kpa, in decibels3 dBA
Values determined according to noise test code given in ISO 15744, using the basic standard
ISO3744 NOTE- The sum of a measured noise emission value and its associated uncertainty
represents an upper boundary of the range of values which is likely to occur in measurements.
Declared vibration emission value in accordance with EN 12096
Measured vibration emission value: a2.0 m/sec²
Uncertainty: K0.5 m/sec²
Values determined according to ISO 8662-4, ISO 5349-1,2
2
ACCESSORIES
6 x 3 x 5/8-11 Thread Cup Stone ....................................................................................................................... 28597
FG10/PG05 User Manual ◄ 15
Page 16
**
*
**
*
55B
146
131
143
*
**
52
81
82
83
80
84
Wheel Pivot Assy P/N-
26085 Shown Here
Includes the following:
26087 Assy, 26088 Assy,
26089 Assy and Items
84, 86, 77 & 78.
FG10 - PG05 PARTS ILLUSTRATION
1A
A
B
1
2
3
4
5
6
7
8
9
10
11
12
13
53
54
55
75
76
78
86
63
55B
**
58
57
56
77
85
83
99
79
58
62
*
55A
59
92
56
57
52
Assemblies below are shown with
dotted lines around them in the
above exploded view.
*
**
14
15
16
7
17
22
5
19
132
20
21
22
23
88
62
61
60
64
93
90
91
90
89
26087 Assy (FG10 Only)
26088 Assy (FG10 Only)
26089 Assy (FG10 & PG05)
98
97
96
28
29
24
25
26
27
44
68
67
66
65
89
95
52
28
30
31
25
32
33
34
35
69
94
36
37
93
92
90
91
90
89
FG10 FROG GRINDER and
PG05 PROFILE GRINDER
72
73
89
63
62
38
39
40
41
42
43
44
45
46
47
48
70
71
52
74
65
64
44
60
59
79
61
78
83
87
86
56
57
58
55A
84
80
33
49
50
51
143
*
**
53
54
55
75
66
76
88
62
77
58
57
56
85
81
82
83
16 ► FG10-PG05 User Manual
Page 17
FG10 - PG05 PARTS ILLUSTRATION
126
125
130
105
104
103
101
100
102
124
129
123
122
25
2
106
111
112
110
116
117
112
108
107
109
110
A
1
B
113
144
114
115
145
Connect to 99
NO. 128 IS SHIPPED LOOSE FOR
GRINDING WHEEL INSTALLATION/REMOVAL
127
Extension Assembly
Insert Between 61
and Frame.
128
142
125
126
Connect to 87
66
116
121
120
119
118
NOTE
Some pf the following item numbers are not
included in the light weight model of
the PG05 Profile Grinder.
44 52 56 57 58 59 60
61 62 63 64 65 66 88
89 90 91 129
52
89
90
91
90
89
FG10-PG05 User Manual ◄ 17
Page 18
FG10 PARTS LIST
ITEM P/NQTY DESCRIPTION
1252942HOSE ASSEBLY
1A252511HYREVZ MOTOR ASSY (INCL ITEMS
4-15, 17, 18, & 20-23)
2016043O-RING •
3257901CAUTION STICKER (US MODELS)
4007132DOWEL PIN
5257182DRIVE GEARS
6001781O-RING, 2-1/8 X 2-1/4 X 1/16 70D •
7063164BUSHING
8199051FRONT BEARING HOUSING ASSY
(INCL ITEM 7)
9006691QUAD RING •
10198841SEAL GLAND
11001701RETAINING RING
12001481BEARING
13001661RETAINING RING
14001208CAPSCREW
15068461GEAR HOUSING ASSEMBLY (INCL
ITEMS 5 & 8)
16256101RAILROAD HELP DESK DECAL (US
MODELS ONLY)
17733091IDLER SHAFT KEYED
19287271NAME TAG
20001711O-RING, 11/16 X 13/16 X 1/16 70D •
21251661MOTOR SHAFT
22068812NEEDLE ROLLER
23007081RETAINING RING
24251581SPLINED COUPLING
250268810CAPSCREW
26250991RAM
27252911NEEDLE ROLLER BEARING
28252892RETAINING RING
29252901INNER RING
30252811RETAINING RING
31252791BEARING
32279411SPINDLE
33007722WOODRUFF KEY
34252781RETAINING RING
35252801OIL SEAL, 1.250 X 2.047 X .299 •
36254191DRIVE FLANGE (US MODELS ONLY)
37016071SET SCREW
38021791NUT
39268091HAND WHEEL
40252871WIPER •
41277481BUSHING
42277491HOUSING
43029001ROLL PIN
ITEM P/NQTY DESCRIPTION
44252853ADJUSTABLE HANDLE
45251041BACKUP WASHER
46252861WIPER TYPE H •
47252931SQUARE RING •
48251031THRUST WASHER
49268101SHAFT
50250831PINION GEAR
51252831ROLL PIN
52039062HEX NUT
53026342WASHER
54000482BEARING
55260192ROLLER
55A260871WHEEL ASSY 2.5 INCH (INCL ITEMS
56-58 & 62,63)
55B260881WHEEL ASSY 3.0 INCH (INCL ITEMS
56-58 & 62, 88)
56032264RETAINING RING
57260424WHEEL SHAFT
58260914BEARING
59262502JAM NUT
60262162ADJUSTMENT SCREW
61261552BARREL NUT
62006644RETAINING RING
63260252WHEEL, 2.5 INCH
64262492SPHERICAL WASHER (2 PCS)
65007192LOCKNUT
66262022CAPSCREW
67002722DOWEL PIN
68250821FEED GEAR
69252841DU BEARING
70108882CAPSCREW
71251671KEY
72051521STANLEY DECAL (US MODELS ONLY)
73261031MAIN HOUSING
74262151CHASSIS WELDMENT
75000072BEARING
76260452ROLLER SHAFT
77260512HANGER
78030114CAPSCREW
79006352KEY
80260592PIVOT PIN ASSY
81008992CAPSCREW
82268312WASHER
83069894O-RING, -018 •
84260902BUSHING
85176682ROLL PIN
18 ► FG10-PG05 User Manual
Page 19
FG10 PARTS LIST
ITEM P/NQTY DESCRIPTION
86260562WHEEL PIVOT
87260211PIVOT SHAFT WHEEL
88260242WHEEL, 3.3 INCH
89121754WASHER
90262034BALL BEARING
91260462ROLLER
92262474FLANGED BUSHING
93016062O-RING, -120 •
94252771WIPER •
95262111GUARD WELDMENT (US MODELS
ONLY)
96025253CAPSCREW
97262483LOCK WASHER
98262462COUPLING NUT
99260221PIVOT SHAFT WHEEL
100260981HANDLE BAR ASSY
101273691TRIGGER WELDMENT
102252921ROLL PIN
103273701SPACER
104275991TORSION SPRING
105273661LEVER WELDMENT
106186011ROLL PIN
107250361ON-OFF VALVE, O.C.
108253051WIPER •
109252561WASHER
110080172O-RING, 7/8 X 1-1/16 X 3/32 -118 •
111180371BALL JOINT STUD
112016054O-RING, .644 X.818 X .087 -908 (INCL
WITH ITEMS 114) •
113009362ADAPTER
114039721FEMALE COUPLING, PARKER
115039731MALE COUPLING, PARKER
116180082SPRING WASHER
117248191SPRING
118179041RETAINING RING
119009551PIPE PLUG
120242891PLUG
121289141FLOW CONTROL (PRE-SET)
122014111O-RING, .488 X .624 X .078 -906 •
123201451STEEL BALL
124250051VALVE BLOCK
125037871GPM DECAL (US MODELS ONLY)
126001442CAPSCREW
127258421WRENCH (TAPED TO FRAME)
128261421EXTENSION BRACKET WELDMENT
129
ITEM P/NQTY DESCRIPTION
130372155 2DRIVE SCREW
136290521INNER GUARD (SEE SPARK GUARD &
INNER
139292641SERVICE RAM ASSY (NOT SHOWN)
141080802HANDLE GRIP
142262001EXTENSION ASSY (INCL 52, 66, 89-91,
& 128)
143260891ROLLER ASSY
144811581FEMALE COUPLING
145811591MALE COUPLING
146260851WHEEL PIVOT ASSY
259421SEAL KIT
• Denotes part in seal kit
Note: Use Part Number and Part Name when
ordering.
FG10-PG05 User Manual ◄ 19
Page 20
PG05 PARTS LIST
ITEM P/NQTY DESCRIPTION
1252942HOSE ASSEBLY
1A252511HYREVZ MOTOR ASSY (INCL ITEMS
4-15, 17, 18, & 20-23)
2016043O-RING •
3257901CAUTION STICKER
4007132DOWEL PIN
5257182DRIVE GEARS
6001781O-RING, 2-1/8 X 2-1/4 X 1/16 70D •
7063164BUSHING
8199051FRONT BRG HSG ASSY (INCL ITEM 7)
9006691QUAD RING •
10198841SEAL GLAND
11001701RETAINING RING
12001481BEARING
13001661RETAINING RING
14001208CAPSCREW
15068461GEAR HOUSING ASSY (INCL ITEMS 4
& 7)
16256101RAILROAD HELP DESK DECAL
17733091IDLER SHAFT KEYED
19297151NAME TAG
20001711O-RING, 11/16 X 13/16 X 1/16 70D •
21251661MOTOR SHAFT
22068812NEEDLE ROLLER
23007081RETAINING RING
24251581SPLINED COUPLING
250268810CAPSCREW
26250991RAM
27252911NEEDLE ROLLER BEARING
28252892RETAINING RING
29252901INNER RING
30252811RETAINING RING
31252791BEARING
32279411SPINDLE
33007722WOODRUFF KEY
34252781RETAINING RING
35252801OIL SEAL, 1.250 X 2.047 X .299 •
36254191DRIVE FLANGE
37016071SET SCREW
38021791NUT
39268091HAND WHEEL
40252871WIPER •
ITEM P/NQTY DESCRIPTION
41277481BUSHING
42277491HOUSING
43029001ROLL PIN
44252851ADJUSTABLE HANDLE
45251041BACKUP WASHER
46252861WIPER TYPE H •
47252931SQUARE RING •
48251031THRUST WASHER
49268101SHAFT
50250831PINION GEAR
51252831ROLL PIN
52039062HEX NUT
53026342WASHER
54000482BEARING
55260192ROLLER
66262022CAPSCREW
67002722DOWEL PIN
68250821FEED GEAR
69252841DU BEARING
70108882CAPSCREW
71251671KEY
72051521STANLEY DECAL
73261031MAIN HOUSING
74262151CHASSIS WELDMENT
75000072BEARING
76260452ROLLER SHAFT
77260512HANGER
78030114CAPSCREW
79006352KEY
80260592PIVOT PIN ASSY
81008992CAPSCREW
82268312WASHER
83069894O-RING, -018 •
84260902BUSHING
20 ► FG10-PG05 User Manual
Page 21
PG05 PARTS LIST
ITEM P/NQTY DESCRIPTION
85176682ROLL PIN
86260562WHEEL PIVOT
87260211PIVOT SHAFT WHEEL
89121754WASHER
90262034BALL BEARING
91260462ROLLER
92262474FLANGED BUSHING
93016062O-RING, -120 •
94252771WIPER •
95262111GUARD WELDMENT
96025253CAPSCREW
97262483LOCK WASHER
98262462COUPLING NUT
99260221PIVOT SHAFT WHEEL
100260981HANDLE BAR ASSY
101273691TRIGGER WELDMENT
102252921ROLL PIN
103273701SPACER
104275991TORSION SPRING
105273661LEVER WELDMENT
106186011ROLL PIN
107250361ON-OFF VALVE, O.C.
108253051WIPER •
109252561WASHER
110080172O-RING, 7/8 X 1-1/16 X 3/32 -118 •
111180371BALL JOINT STUD
112016054O-RING, .644 X.818 X .087 -908 (INCL
WITH ITEMS 114) •
113009362ADAPTER
114039721FEMALE COUPLING, PARKER
115039731MALE COUPLING, PARKER
116180082SPRING WASHER
117248191SPRING
118179041RETAINING RING
119009551PIPE PLUG
120242891PLUG
121289141FLOW CONTROL (PRE-SET)
122014111O-RING, .488 X .624 X .078 -906 •
123201451STEEL BALL
124250051VALVE BLOCK
125037871GPM DECAL
ITEM P/NQTY DESCRIPTION
126001442CAPSCREW
127258421WRENCH (TAPED TO FRAME)
128261421EXTENSION BRACKET WELDMENT
136290521INNER GUARD (SEE SPARK GUARD &
INNER GUARD ILLUSTRATION PAGE
FOLLOWING)
139292641SERVICE RAM ASSY (NOT SHOWN)
141080802HANDLE GRIP
142262001EXTENSION ASSY (INCL 52, 66, 89-91,
& 128)
143260891ROLLER ASSY
144474361FEMALE COUPLING, AEROQUIP
145474371MALE COUPLING, AEROQUIP
259421SEAL KIT
• Denotes part in seal kit
Note: Use Part Number and Part Name when
ordering.
FG10-PG05 User Manual ◄ 21
Page 22
SPARK GUARD & INNER GUARD
ITEM #P/NQTYDESCRIPTION
1007192NYLOCK NUT
2299202CAPSCREW
3022592WASHER
4697551SPARK GUARD
5697671SPARK SCREEN
6697721SPARK GUARD ASSY (INCLUDES ITEMS 1
THRU 5)
6
22 ► FG10-PG05 User Manual
Inner Guard
Note: Items in this view can be
found on the main parts list.
Page 23
Page 24
STANLEY Infrastructure
6430 SE Lake Road
Portland, Oregon 97222 USA
(503) 659-5660 / Fax (503) 652-1780
www.stanleyinfrastructure.com
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