FG10 HYDRAULIC FROG GRINDER PG05 HYDRAULIC PROFILE GRINDER Safety, Operation and Maintenance USER MANUAL © 2011 Stanley Black & Decker, Inc. New Britain, CT 06053 U.S.A. 28072 11/2013 Ver.
DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY ÜBEREINSTIMMUNGS-ERKLARUNG DECLARATION DE CONFORMITE CEE DECLARACION DE CONFORMIDAD DICHIARAZIONE DI CONFORMITA Hydraulic Tools ______________________________________________________________________ I, the undersigned: Ich, der Unterzeichnende: Je soussigné: El abajo firmante: lo sottoscritto: Weisbeck, Andy Surname and First names/Familiennname und Vornamen/Nom et prénom/Nombre y apellido/Cognome e nome hereby declare that the equipment specified here
TABLE OF CONTENTS DECLARATION OF CONFORMITY...........................................................................................................................2 SAFETY SYMBOLS...................................................................................................................................................4 SAFETY PRECAUTIONS...........................................................................................................................................5 TOOL STICKERS & TAGS..
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.
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 specific work area and local safety regulations.
TOOL STICKERS & TAGS 29715 PG05 Name Tag 25790 Caution Decal 03787 GPM Decal 28727 FG10 Name Tag 20647 Sound Power Level Decal (CE) 05152 Stanley Sticker 28409 Composite Decal (CE) 25610 Railroad Help Desk Decal 28322 CE Decal 28811 Information Plaque (CE) 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.
HOSE TYPES The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the hydraulic system. There are three types of hydraulic hose that meet this requirement and are authorized for use with Stanley Hydraulic Tools. They are: Certified non-conductive — constructed of thermoplastic or synthetic rubber inner tube, synthetic fiber braid reinforcement, and weather resistant thermoplastic or synthetic rubber cover.
► FG10-PG05 Service Manual All hydraulic hose must meet or exceed specifications as set forth by SAE J517. All hydraulic hose must have at least a rated minimum working pressure equal to the maximum hydraulic system relief valve setting. This chart is intended to be used for hydraulic tool applications only based on Stanley Hydraulic Tools tool operating requirements and should not be used for any other applications.
HTMA / EHTMA REQUIREMENTS HTMA / EHTMA REQUIREMENTS HTMA HYDRAULIC SYSTEM REQUIREMENTS TYPE I Nominal Operating Pressure (at the power supply outlet) 4-6 gpm (15-23 lpm) 1500 psi (103 bar) TOOL TYPE TYPE II TYPE RR 7-9 gpm (26-34 lpm) 1500 psi (103 bar) 9-10.
OPERATION PREOPERATION PROCEDURES CHECK HYDRAULIC POWER SOURCE 1. Using a calibrated flowmeter and pressure gauge, check that the hydraulic power source develops a flow of 7-10 gpm/26-38 lpm at 1500-2000 psi/105140 bar. 2. Make certain the hydraulic power source is equipped with a relief valve set to open at 2100-2250 psi/145155 bar minimum. 3. Check that the hydraulic circuit matches the tool for open-center (OC) or closed-center (CC) operation. CHECK TOOL 1.
OPERATION Cross Section of Typical Rail 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 figure 2. Grinding is accomplished by moving the grinder back and forth in line with the rail.
OPERATION 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. COLD WEATHER OPERATION If the grinder is to be used during cold weather, preheat the hydraulic fluid at low engine speed.
TOOL PROTECTION & CARE NOTICE 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.
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 flow and pressure to the grinder as listed in the table. Use a flowmeter known to be accurate. Check the flow with the hydraulic oil temperature at least 80°F/27°C. PROBLEM Grinder does not run Grinder operates too slow. Grinder operates too fast.
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.......................................
FG10-PG05 PARTS ILLUSTRATION A B FG10 FROG GRINDER and PG05 PROFILE GRINDER 14 1 15 28 2 16 29 3 7 131 17 4 22 5 38 28 24 30 39 5 6 25 7 31 19 40 8 41 132 9 20 26 10 25 42 32 43 33 21 11 49 22 12 44 52 33 27 13 23 53 34 ** 54 45 55 46 57 36 88 75 50 35 58 56 47 44 62 51 37 48 61 76 59 77 68 60 135 81 67 82 70 136 78 83 66 64 85 36 69 65 71 80 84 72 86 3 73 99 53 52 44 74 54 79 55 65 64 92 60 75 59 66 93 56 57 89 58 76
FG10-PG05 PARTS ILLUSTRATION NOTE Some of the following item numbers are not included in the light weight model of the PG05 Profile Grinder 44 59 64 90 52 60 65 91 56 61 66 129 57 62 88 58 63 89 FG10-PG05 Service Manual ◄ 17
FG10 PARTS LIST ITEM P/N QTY DESCRIPTION ITEM P/N QTY DESCRIPTION 1 25294 2 HOSE ASSEBLY 44 25285 3 ADJUSTABLE HANDLE 25251 1 HYREVZ MOTOR ASSY (INCL ITEMS 4-15, 17, 18, & 20-23) 45 25104 1 BACKUP WASHER 2 01604 3 O-RING • 46 25286 1 WIPER TYPE H • 3 25790 1 CAUTION STICKER (US MODELS) 47 25293 1 SQUARE RING • 4 00713 2 DOWEL PIN 48 25103 1 THRUST WASHER 5 25718 2 DRIVE GEARS 49 26810 1 SHAFT 6 00178 1 O-RING, 2-1/8 X 2-1/4 X 1/16 70D • 50 25083 1
FG10 PARTS LIST ITEM P/N QTY DESCRIPTION ITEM P/N QTY DESCRIPTION 86 26056 2 WHEEL PIVOT 126 00144 2 CAPSCREW 87 26022 1 PIVOT SHAFT WHEEL 127 25842 1 WRENCH (TAPED TO FRAME) 88 26024 2 WHEEL, 3.
PG05 PARTS LIST ITEM P/N QTY DESCRIPTION 41 27748 1 BUSHING 1 25294 2 HOSE ASSEBLY 42 27749 1 HOUSING 25251 1 HYREVZ MOTOR ASSY (INCL ITEMS 4-15, 17, 18, & 20-23) 43 02900 1 ROLL PIN 2 01604 3 O-RING • 44 25285 1 ADJUSTABLE HANDLE 3 25790 1 CAUTION STICKER 45 25104 1 BACKUP WASHER 4 00713 2 DOWEL PIN 46 25286 1 WIPER TYPE H • 5 25718 2 DRIVE GEARS 47 25293 1 SQUARE RING • 6 00178 1 O-RING, 2-1/8 X 2-1/4 X 1/16 70D • 48 25103 1 THRUST WASHER 7 0
PG05 PARTS LIST 85 17668 2 ROLL PIN 86 26056 2 WHEEL PIVOT 87 26022 1 PIVOT SHAFT WHEEL 88 NO ITEM 128 26142 1 EXTENSION BRACKET WELDMENT 26200 1 EXTENSION ASSY (INCL 52, 66, 89-90, & 129) 129 --- - NO ITEM 130 --- - NO ITEM 131 --- - NO ITEM 132 --- - NO ITEM 133 --- - NO ITEM 134 --- - NO ITEM 135 --- - NO ITEM 136 29052 1 INNER GUARD (SEE SPARK GUARD & INNER GUARD ILLUSTRATION PAGE FOLLOWING) 89 12175 4 WASHER 90 26203 4 BALL BEARING 91 26046
SPARK GUARD & INNER GUARD ITEM # P/N QTY DESCRIPTION 1 00719 2 NYLOCK NUT 2 29920 2 CAPSCREW 3 02259 2 WASHER 4 69755 1 SPARK GUARD 5 69767 1 SPARK SCREEN 69772 1 SPARK GUARD ASSY (INCLUDES ITEMS 1 THRU 5) Inner Guard NOTE: Items in this view can be found on the main parts list.
Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie, Oregon 97267-5698 USA (503) 659-5660 / Fax (503) 652-1780 www.stanleyhydraulic.