FG10-PG05 User Manual - Stanley Hydraulic Tools
Contents
1. dee ebd 13 TROUBLESHOOTING neret te Ei rere te eere cert ec er b reete e ee rb d EE eed eina 14 ACGGESSORIE S mE 15 SPECIFICATIONS e EA A T E 15 FG10 amp PG05 PARTS ILLUSTRATION 000 000 ec eect aiae i rsen 16 amp PG05 PARTS ILLUSTRATION 17 PARTS LIST aa E sua tang 18 PG05 PARTS aen 20 SPARK GUARD amp INNER GUARD inns 22 fill 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 certified dealer Please read the following warning SERIOUS INJURY OR DEATH COULD RESULT FROM THE IMPROPER REPAIR OR SERVICE OF THIS TOOL2. I 101 102 3 6 o6 cm 90 97 cm 55 joo 4 10 1 ojo ON OFF VALVE WIPER WASHER 2 O RING 7 8 X 1 1 16 X 3 32 118 BALL JOINT STUD O RING 644 X 818 X 087 908 INCL WITH ITEMS 114 z NJN ajo N njoj gt gt gt 3 a gt I e EJ ES NIEI IS gt z als o m nm m 70 N N STANLEY N EXTENSION BRACKET WELDMENT EXTENSION ASSY INCL 52 66 89 90 amp 129 NO ITEM NO ITEM NO ITEM NO ITEM NO ITEM NO ITEM NO ITEM 1 INNER GUARD SEE SPARK GUARD 4 INNER GUARD ILLUSTRATION PAGE FOLLOWING NO ITEM NO ITEM SERVICE RAM ASSY NOT SHOWN SPARK GUARD SEE SPARK GUARD amp INNER GUARD ILLUSTRATION PAGE FOLLOWING HANDLE GRIP SEAL KIT N 136 29052 E ES BEEN gt aJ ES w I 29264 69772 40 N O N gt z E FG10 PG05 Service Manual lt 21 E SPARK GUARD ASSY 69712 Inner Guard Items in this view be found on the main parts list 22 gt FG10 PG05 Service Manual STAN LEY STANLEY Stanley Hydraulic Tools
3. mem PIN ary DESCRIPTION N A N e N N 25 x O oio 4 4 4 4 4 4 zx EM EE 3 gt 52 wo 09 m N I 17 0148 0166 12 gt gt o o o o o O ojoj N o ojo o o o o oO 25610 7330 29715 00171 25166 06881 00708 25158 02688 2509 25291 25289 2529 25281 25279 27941 0077 2527 2528 2541 0160 3 4 5 6 7 8 9 0 1 3 4 5 6 7 8 9 3 4 5 1 3 4 5 7 8 9 3 E CD 21 2 23 24 25 26 27 28 29 30 5 5 5 5 6 6 6 67 0 B 2 7 N 76 36 y 37 38 39 2680 0 25287 5 5 5 5 5 7 7 7 7 7 B 2 20 gt FG10 PG05 Service Manual STAN LEY ER wm WIPER GUARD WELDMENT CAPSCREW LOCK WASHER COUPLING NUT PIVOT SHAFT WHEEL HANDLE BAR ASSY TRIGGER WELDMENT ROLL PIN SPACER TORSION SPRING LEVER WELDMENT ROLL PIN 5 7 I N 1217 2620 2604 2624 0160 2527 26211 0252 2624 2624 2602 2609 2736 25292 2737 27599 27366 18601 2503 2530 2525 0801 1803 0160 o
4. 4000 MOTOT ect ten RTT 25251 Maximum Fluid Temperature 140 60 Sound Power Level ttt eer REA 104 dBA Sound Pressure Level 94dBA Vibration Less than 2 5m sec SOUND AND VIBRATION DECLARATION Test conducted on FG10110 S N 527 operated at standard 10 gpm input PF Measured A weighted sound power level Lwa ref 1pW in decibels 103 86 dBA Uncertainty Kwa in decibels 3 dBA Measured A weighted sound pressure level Lpa ref 20 at operator s position in decibels 94 dBA Uncertainty Kpa in decibels 3 dBA Values determined according to noise test code given in ISO 15744 using the basic standard 1503744 NOTE The sum of a measured noise emission value and its associated uncertainty rep resents an upper boundary of the range of values which is likely to occur in measurements Declared vibration emission value in accordance with EN 1206 Values determined according to 150 86624 150 534912 ACCESSORIES 0X 33x 5 8 11 Thread Cup SONE iu eerie rrt Iudae re Fe ko euh ERR a ee RE AS PRESE 28597 STAN LEY FG10 PG05 Service Manual 4 15 FG10 FROG GRINDER and PG05 PROFILE GRINDER L lt o STANLEY 16 gt FG10 PG05 Serv
5. 10 HYDRAULIC FROG GRINDER PG05 HYDRAULIC PROFILE GRINDER USER MANUAL Safety Operation and Maintenance New Britain CT 06053 STANLEY Hydraulic Tools DECLARATION OF CONFORMITY UBEREINSTIMMUNGS ERKLARUNG DECLARATION DE CONFORMITE CEE DECLARACION DE CONFORMIDAD DICHIARAZIONE DI CONFORMITA the undersigned Ich der Unterzeichnende Je soussign abajo firmante lo sottoscritto Weisbeck Andy Surname and First names Familiennname und Vornamen Nom et pr nom Nombre y apellido Cognome e nome hereby declare that the equipment specified hereunder bestatige hiermit erklaren Produkt genannten Werk oder Gerat d clare que l quipement vis ci dessous Por la presente declaro que el equipo se especifica a continuaci n Dichiaro che le apparecchiature specificate di seguito 1 Category Grinder Hydraulic Kategorie Cat gorie Categoria Categoria 2 Make Marke Marque Marca Marca Stanley 3 FG1011001 4 Serial number of equipment Seriennummer des Ger ts Num ro de s rie de l quipement Numero de serie del equipo Matricola dell attrezzatura Has been manufactured in conformity with Wurde hergestellt in Ubereinstimmung mit Est fabriqu conform ment Ha sido fabricado de acuerdo con E stata costruita in conformita con Directive Standards No Approved body Ric
6. Keep the wheel off all surfaces when starting the grinder Do not use a wheel that is cracked chipped or oth erwise damaged Always inspect wheels for pos sible damage before installation or use Always use wheels that conform to the specifications given in the OPERATION section of this manual Do not reverse grinding wheel rotation direction by changing fluid flow direction Do not move the tool until the wheel has stopped rotating Release the trigger if the power supply has been interrupted FG10 PG05 Service Manual 4 5 Stanley Hydraulic Tools 5810 SE Naef Rd Milwoukie Oregon 97267 U S A 26 38 Ipm 7 10 gpm 140 bar 2000 psi Y STA JANI NLEY FEE NOT EXCEED 2000 51 140 BAR SPECIFIED FLOW OR 29715 1 2 3 WHEELS SHOULD LARGER THAN 6 x LEAST 6000 RPM OPERATING SPEED 4 INSPECT GUARD AND MOUNTING FLANGE FOR DAMAGE AFTER ANY WHEEL 5 6 CAUTION PROTECT YOUR EYES WEAR SAFETY GOGGLES DO NOT USE DAMAGED WHEELS USE ONLY WHEELS THAT MEET REQUIREMENTS OF ANSI B7 1 87 5 ISO 525 603 3 x 5 8 11 THREAD RATED FOR AT BREAKAGE ON THE MACHINE SPINDLE SPEED 4000 RPM READ OPERATION MANUAL ROTATION DIRECTION PG05 Name Tag 03787 Stanley Hydraulic Tools 3810 SE Naef Rd Milwaukie Oregon 97267 U S A 26 38 Ipm 7 10 gpm 140 bar 2000 psi NLEV STAD 23 Model No FC10 28727 FG10 Name Tag 25790
7. 103 bar 103 bar System relief valve setting 2495 psi 2000 psi 2000 psi 2000 psi 2000 psi at the power supply outlet 172 bar 138 bar 138 bar 138 bar 138 bar NOTE These are general hydraulic system requirements See tool specification page for tool specific requirements STAN LEY FG10 PG05 Service Manual lt 9 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 Ipm 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 sure all tool accessories are correctly stalled Failure to install tool accessories properly can result in damage to the tool or personal injury There should be no signs of leaks The tool should be clean with all fittings and fasten ers tight CHECK TRIGGER MECHANISM 1 Check that the trigger operates smoothly and is free to travel between the and OFF positions CHECK GUARD WELDMENT 1 Inspect the wheel guard weldment for cracks and other structural damage 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
8. 3810 SE Naef Road Milwaukie Oregon 97267 5698 USA 503 659 5660 Fax 503 652 1780 www stanleyhydraulics com
9. REPAIRS AND OR SERVICE TO THIS TOOL MUST ONLY BE DONE BY AN AUTHORIZED AND CERTIFIED DEALER For the nearest authorized and certified dealer call Stanley Hydraulic Tools at the number listed on the back of this manual and ask for a Customer Service Representative STAN LEY FG10 Service Manual lt 3 Safety symbols and signal words as shown below are used to emphasize all operator maintenance and repair ac tions 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 A DANGER 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 avoid ed may result in property damage This signal word indicates a situation which if not avoided will result in damage NOTICE to the equipment This signal word indicates situation which if not avoided may res
10. torque is attained by hand tightening the wheel with a strap wrench while securing the drive flange with the wrench provided STANLEY 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 It may be necessary to rotate the entire grinder 180 degrees and place it on the other side of the point in order to completely grind the width of the point The extension assembly 128 is normally used during point grinding operations 7 Cross Section of Typical Frog at 1 2 Point Figure 2 Grinding the Point of a Frog PROFILE GRINDING For profile 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 STANLEY Cross Section of Typical Rail Figure 3 Profile 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 ad
11. SEVERE PERSONAL INJURY 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 BYSTANDERS MAY BE INJURED IN YOUR WORK AREA KEEP BYSTANDERS CLEAR OF YOUR WORK AREA TECTION 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 6 FG10 PG05 Service Manual STANLEY The rated working pressure of hydraulic hose must equal to or higher than the relief valve setting on the hy draulic 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 Hose labeled certified 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 reinforce ment and w
12. hole Only use grinding wheels which comply with ANSI B7 1 B7 5 ISO 525 603 READ AND BECOME FAMILIAR WITH THE SEC TIONS IN THIS MANUAL ON SAFETY PRECAU TIONS TOOL STICKERS AND TAGS HYDRAULIC HOSE REQUIREMENTS HYDRAULIC REQUIRE MENTS AND PREOPERATION PROCEDURES BE FORE 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 flange 10 gt FG10 PG05 Service Manual 3 Using the wrench 127 provided place it on the flats of the drive flange Place a strap wrench on the grinding wheel and then tighten by gripping and turning the strap wrench while holding the wrench provided 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 posi tion shown in figure 1 Grinding is accomplished by mov ing the grinder back and forth in line with the rail When finished with one wing rotate the entire grinder 180 de grees and place it on the other wing IMPORTANT Never over tighten the grinding wheel by impacting the wrench with a mallet or hammer Sufficient
13. o o o a BAJO N a E x EX me gt 0093 0397 4743 115 0397 4743 1800 2481 1790 0095 2428 28914 01411 20145 2500 0378 28811 a AIO 116 117 118 o E NIN o 122 EX AJ EN I I gt r m lt 127 25002 WRENCHUMPEDTOFRAWE 26200 EXTENSION ASSY INCL 52 66 89 90 amp 129 129 11207 1 CIRCUIT STICKER CE MODELS ONLY 130 372155 DRIVE SCREW 131 28409 1 COMPOSITE STICKER CE MODELS ONLY mz ms v STOKER TCE MODELS ON 136 29052 INNER GUARD SEE SPARK GUARD amp INNER GUARD ILLUSTRATION FOLLOWING SERVICE RAM ASSY NOT SHOWN 140 69772 1 SPARK GUARD SEE SPARK GUARD amp INNER GUARD ILLUSTRATION FOLLOWING 141 08080 HANDLE GRIP 142 20647 104 SOUND POWER LEVEL DECAL 25942 1 SEALKIT Denotes part in seal kit NOTE Use Part Number and Part Name when order ing FG10 PG05 Service Manual lt 19 RU z TY DESCRIPTION 41 27748 HOSE ASSEBLY 4 27749 HYREVZ MOTOR ASSY INCL ITEMS 02900 4 15 17 18 amp 20 23 25285 282 25104 ORG GEAR HOUSING ASSY INCL ITEMS 4 amp 7 IDLER SHAFT KEYED 2 2 INNER RING 10888 2 caPscREW 00007 2 BEARING 4 GIY DESCRIPHION La 4 O RING 26090 jeuse
14. 87 WHEEL ASSY 2 5 INCH INCL ITEMS 56 58 amp 62 63 8 1 WHEEL ASSY 3 0 INCH INCL ITEMS 56 58 amp 62 88 mma 1 DUBEARNG Froese z carscrew zerliler MANHOUSNG gt men ws m mmo s mess Rouen 4 4 4 4 4 4 52 5 5 N 5 6 7 8 9 0 1 54 6 7 8 9 3 5 1 3 5 7 8 9 5 5 5 5 5 5 5 1 2 6 6 6 67 7 2 B 4 4 4 4 7 7 6 7 if 7 7 7 gt STANLEY ITEM 2605 26021 2602 12175 2620 2604 2624 0160 25277 26211 aTy oescrprion gt i PwvoTsHaFT WHEEL GUARD WELDMENT US MODELS ONLY i PvoTSHAFT WHEEL RANDLE Baas v TRIGGER WELOMENT ______ v spacer i i oworrwavE OG weer CS v wen _ 7 ORIG 1 i A aid WITH ITEMS 114 gt ewm 1 FEMALE COUPENG PARKER i FEMALE COUPLING AEROGUIP 1 COUPLING PARKER 1 maECOuPUNG AROQUP gt spRNewasER i see _ r RETAWNGRNG i mere _ EN GEN i FLOW CONTROL PRE SET 1 O RING 466X 07606 i ste _ i wave nto INFORMATION PLAQUE CE MODELS ONLY 2 feo EN EM Ea Em EA Em EN 400 93 94 95 0252 2624 2624 2602 2609 2736 2529 2737 2759 2736 18601 2503 2530 2525 0801 1803 0160 I Ea ES o
15. 92 09 67 9L L 6 1 0092 eJnsseJg 61 vIe 6 1 0092 unes 61 vIe 8 dn 92 ol dn 09 67 9L EL 9 1 0082 9 8 9 LISP IVS Aq YHOJ yas se 8 0082 TE voz JO 09 08 002 001 67 88 10 SLL 0052 eJnssejd 6l vIe Bulles 5 SZL 0052 ume 6L m WU ne rw SU jenbe eJnsseJd Buom m 0052 15551 9i 979 e 15291 JSNUI Iv SLL 0092 9 8 9 dn 09odn 61 0 Jedlo Aue 40 pesn eq jou pjnous 0097 umey 6l ve pue sjueujeJinbeJ lool 5 00 06 0 00 001 Ov 6L FOLS H ejuejs uo peseq juo SLL 0092 slnssejd ov 8 9 put Joj pesn SI yeyo siu SLL 0092 ov 8 9 05 61 001 19 Ov 6l FOLS d 6 1 0092 l e GL ol dn 09 ol dn 07 6 FOLS GE 5 E ejqejdaooe uunuuluiu e oj eunsseJd 6 1 0092 EL e 08 5 001 92 62 91 9 7 ainssaid unlel daay suon 6 1 0092 OL 8 8 92 ol dn 92 ol dn 62 91 9 7 95941 SYOLONGNOD 1V9IN1L9414 YVAN ASN LON OQ pleJ9 JO 311M SOH elnulw sed suolle6 uo peseq sul6uel SSL 0922 OL 8 8 0
16. Caution Decal 28409 Composite Decal CE M 20647 Sound Power Level Decal CE CE 25610 Railroad Help Desk Decal 30Lpm at 138bar BHTMA CATEGORY STANLEY Stanley Hydraulic Tools Division of The Stanley Works S E Naef Road Milwaukie Oregon 97267 U S A 05152 Stanley Sticker STANLEY Stanley Hydraulic tools Division of the Stanley Works 3810 SE Naef Road Milwaukie OR 97267 28376 Stanley Logo Decal CE WHEEL SIZE RPM SPINDLE 28322 11207 PRESS BAR Circuit Decal FLOW LPM GPM DANGER 28811 Information Plaque CE 1 FAILURE TO USE HYDRAULIC HOSE LABELED AND CER TIFIED 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 15 MAINTAINED AS NON CONDUCTIVE THE HOSE SHOULD BE REGULARLY TESTED FOR ELECTRIC CUR RENT LEAKAGE IN ACCORDANCE WITH YOUR SAFETY DEPARTMENT INSTRUCTIONS NOTE THE INFORMATION LISTED ON THE STICKERS SHOWN MUST BE LEGIBLE AT ALL TIMES 2 AHYDRAULIC LEAK OR BURST MAY CAUSE OIL INJEC TION INTO THE BODY OR CAUSE OTHER SEVERE PERSONAL INJURY DO NOT EXCEED SPECIFIED FLOW AND PRESSURE FOR THIS TOOL EXCESS FLO
17. LEAN DRY AREA TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND ELEC TRIC LINES DO 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 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 9vL SIHL 3AOWN3zd LON OG Ce SEE OTHER SIDE OTHER SIDE M SIDE 1 SIDE 2 Shown smaller than actual size STAN LEY FG10 PG05 Service Manual 47 suonoeuuo leold AL 4 lt lt lt d lt 1 RETURN RETURN gt gt gt M m _ JYNSSIYd HYDRAULIC CIRCUIT PRESSURE PRESSURE 6 1 0092 unes 06 8 001
18. W OR PRESSURE MAY CAUSE ALEAK OR BURST DO NOT EXCEED RATED WORKING PRESSURE OF HYDRAULIC HOSE USED WITH THIS TOOL EXCESS PRESSURE MAY CAUSE A LEAK OR BURST 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 REPLACE DECALS IF THEY BECOME WORN OR DAMAGED REPLACEMENTS ARE AVAILABLE FROM YOUR LOCAL STANLEY DISTRIBUTOR 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 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 DANGER WEAR HEARING EYE FOOT HAND AND HEAD PRO TO AVOID PERSONAL INJURY OR EQUIPMENT DAMAGE D DO NOT LIFT OR CARRY TOOL BY THE HOSES DO NOT ABUSE HOSE DO NOT USE KINKED TORN OR DAMAGED HOSE MAKE SURE HYDRAULIC HOSES ARE PROPERLY CON NECTED TO THE TOOL BEFORE PRESSURING SYSTEM SYSTEM PRESSURE HOSE MUST ALWAYS BE CON NECTED 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
19. YDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE USE HOSE TO PULL OR LIFT TOOLS POWER UNITS ETC ON OR NEAR ELECTRIC LINES WIPE THE ENTIRE LENGTH OF THE HOSE AND FIT CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAM TING WITH A CLEAN DRY ABSORBENT CLOTH TO REMOVE DIRT AND MOISTURE AND TEST HOSE FOR MAXIMUM ALLOWABLE CURRENT LEAKAGE IN ACCORDANCE WITH AGE TO GOUELINGS IP ANT OF THESE CONDITIONS ENST REPLACE THE HOSE IMMEDIATELY NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE SAFETY DEPARTMENT INSTRUCTIONS AFTER EACH USE STORE IN A CLEAN DRY AREA FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROP ERLY TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND DO NOT REMOVE THIS TAG Ovl SIHL JAOWSY LON OG SEE OTHER SIDE SEE OTHER SIDE SIDE 1 SIDE 2 Shown smaller than actual size THE TAG SHOWN BELOW IS ATTACHED TO CONDUCTIVE HOSE DANGER DANGER DO NOT USE THIS HYDRAULIC HOSE ON OR NEAR ELECTRIC LINES THIS HOSE IS 5 CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAMAGE TO NOT LABELED OR CERTIFIED AS NON CONDUCTIVE USING THIS HOSE ON OR NEAR COUPLINGS IF ANY OF THESE CONDITIONS EXIST REPLACE THE HOSE IMMEDIATELY ELECTRICAL LINES MAY RESULT IN DEATH OR SERIOUS INJURY NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY 6 AFTER EACH USE STORE IN A C
20. eather resistant synthetic rubber cover This hose is conductive and must never be used near electrical conductors Fabric braided not certified or labeled non conductive constructed of thermoplastic or synthetic rubber in ner tube synthetic fiber braid reinforcement and weather resistant thermoplastic or synthetic rubber cover This hose is not certified 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 DANGER 1 FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE IMPROPER USE WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRIC LINES MAY RESULT IN OR HANDLING OF HOSE COULD RESULT IN BURST OR OTHER HOSE FAILURE DEATH OR SERIOUS INJURY 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 ELECTRIC LINES HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING ABRASION CUTTING OR CONTACT WITH HIGH TEMPERATURE SURFACES DO NOT USE IF KINKED DO NOT BEFORE USING H
21. htlinie Standards Nr Pr fung durch Directives Normes Num ro Organisme agr Directriz Los Normas No Aprobado Direttiva Norme n Collaudato EN ISO 3744 2010 Self ISO 11148 7 2012 Self ISO 28927 1 2009 Self Machinery Directive 2006 42 EC 2006 Self 5 Special Provisions None Spezielle Bestimmungen Dispositions particuli res Provisiones especiales Disposizioni speciali 6 Representative in the Union Patrick Vervier Stanley Dubuis 17 19 rue Jules Berthonneau BP 3406 41034 Blois Cedex France Vertreter in der Union Repr sentant dans l union Representante en la Union Rappresentante presso l Unione Done at Ort Fait Dado en Fatto a Stanley Hydraulic Tools Milwaukie Oregon USA Signature Unterschrift Signature Firma Firma AAR 0 Position Position Fonction Cargo Posizione Date Datum le Fecha Data 1 10 13 2 gt FG10 Service Manual STANLEY DECLARATION OF CONFORMITY 2 SAFETY 4 i um i2e aao cL 5 TOOL STICKERS amp TAGS E IUE 6 HOSE TYPES mE 7 HOSE RECOMMENDATIONS eese ceo rire faen 8 HATMA REQUIREMENTS reet a AAD 9 OPERATION O 10 amp GARE
22. ice Manual to 99 128 is shipped loose for grinding wheel installation removal URP 8 Connect to 87 Some of 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 Extension Assembly e 64 65 66 88 89 Insert between d 90 91 129 and frame STAN LEY FG10 PG05 Service Manual lt 17 ITEM P N 2529 25251 QTY DESCRIPTION 2 HOSE ASSEBLY 4 15 17 18 amp 20 23 INCL ITEM 7 ITEMS 5 amp 8 MODELS ONLY 1 IDLER SHAFT KEYED 2 1 INNER RING 01604 25790 00713 25718 00178 06316 1990 gt 0066 19884 00170 00148 00166 00120 0684 rm E 25610 1 gt 28727 00171 25166 06881 00708 25158 02688 25099 25291 2528 2529 25281 2527 27941 0077 2527 2528 2541 0160 1 2 23 24 25 26 27 28 29 30 31 32 33 34 35 6 37 8 39 CD A CD N 2680 2528 2774 2774 0290 N gii o EOI oO N 18 gt FG10 PG05 Service Manual em Jan DESCRIPTION mos ADIUSTAGLEHANDIE 25108 1 BACKUP WASHER Esos 1 souwERNG O 25102 mmusrwasuR mmo sar mm km 260
23. item 73 and the ram outer diameter item 26 use CAUTION only one to two pumps of grease are required at these locations excess grease will lockup feed assembly See figure 4 below Ow NOTE PLACE SPINDLE IN FULLY RETRACTED POSITION TEMPORARILY INSTALL ZIRK FITTING IN PORTS TO GREASE SPINDLE BEFORE INSTALLING 00961 PIPE PLUGS ONLY ONE TO TWO PUMPS OF THE GREASE GUN ARE REQUIRED EXCESS MAY EXIT THROUGH LOWER LIP SEAL TOO MUCH GREASE WILL LOCKUP FEED ASSEMBLY Figure 4 STANLEY 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 hydrau lic tools Failure to do so may result in damage to the quick couplers and cause overheating of the hy draulic 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 flow 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 mini mum working pressure rating of 2500 psi 172 bar STANLEY Do no
24. j dn 0 dn ve SL 6 9504 SNOMEA 2504 syonJL 3exong ANN 20 plesg 4 eso SMOUS 1uBu 94 0 Weyo 941 avg ISd uinjoysseid WI HONI SYUILIN 1334 Ido 5 Buom 3Sn eplsul sudl6ue asoH MO asoH 5 0 00 STANLEY 8 gt FG10 PG05 Service Manual 5 TOOL TYPE HYDRAULIC SYSTEM REQUIREMENTS TYPE I TYPE Il TYPERR TYPE III Flow Range 4 6 gpm 7 9 gpm 9 10 5 gpm 11 13 gpm 15 23 Ipm 26 34 Ipm 34 40 Ipm 42 49 Ipm Nominal Operating Pressure 1500 psi 1500 psi 1500 psi 1500 psi at the power supply outlet 103 bar 103 bar 103 bar 103 bar System relief valve setting 2100 2250 psi 2100 2250 psi 2200 2300 psi 2100 2250 psi at the power supply outlet 145 155 bar 145 155 bar 152 159 bar 145 155 bar Maximum back pressure 250 psi 250 psi 250 psi 250 psi at tool end of the return hose 17 bar 17 bar 17 bar 17 bar Measured at a max fluid viscosity of 400 ssu 400 ssu 400 ssu 400 ssu at min operating temperature 82 centistokes 82 centistokes 82 centistokes 82 centistokes Temperature Sufficient heat rejection 140 140 140 140 capacity to limit max fluid temperature to 60 C 60 C 60 C 60 C at max expected ambient temperature Min c
25. justable 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 to the hose couplers on the grinder It is a good prac tice to connect the return hose first and disconnect it last to minimize or avoid trapped pressure within the grinder motor 3 Observe flow indicators stamped on hose couplers to be sure that oil will flow 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 difficult 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 hand wheel counter clockwise to raise the 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 FG10 PG05 Service Manual lt 11 6 Grind a small amount of material at a time adjust ing the grinding wheel as necessary by turning the handwheel Note If the grinder is not l
26. oaded against a work sur face when the trigger is released the wheel will take 5 10 seconds to come to a complete stop Avoid un intentional 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 When using the normally recommended fluids fluid temperature should be at or above 50 F 10 C 400 ssu 82 centistokes be fore use Damage to the hydraulic system or grinder can result from use with fluid that is to viscous or too thick 12 gt FG10 PG05 Service Manual 1 The gears and bearings in the ram spindle and housing assemblies should be regreased every 6 months or 500 hours This procedure must be ac complished by a trained technician After each servicing measure the spindle speed rpm revolutions per minute at 12 gpm 45 Ipm in put The nominal speed is 4000 not to exceed 6000 rpm This procedure must be accomplished by a trained technician Inspect the spindle and drive flange for signs of wear or damage Runout should not exceed 004 in 1 mm TIR on threads or 002 in 05 mm TIR on arbor diameters and faces Check hoses and fittings weekly for any evidence of leakage cover wear cracking or cuts If any of these defects are found discontinue use of the tool imme diately and have the defects repaired or replaced by a trained technician To grease between main housing bore
27. ocked Locate and remove restriction Oil too hot above 140 F 60 C or Check hydraulic power source for too cold below 60 F 16 C proper oil temperature Bypass cooler to warm oil or provide cooler to maintain proper temperature psi 145 155 bar authorized Stanley service center Grinder operates too fast Flow control malfunctioning Have flow control and valve body serviced at an authorized Stanley Service center 14 gt FG10 PG05 Service Manual STAN LEY Wheel Capacity 6 in dia x 3 in thk x 5 8 11 threaded arbor Type 6 U S A Pressur Ranga E O 1000 2000 psi 70 140 bar Maximum Back 250 17 Fow Type RR 7 10 gpm 26 38 Ipm OO 8 SAE O ring GOuplers sieves HTMA EHTMA Flush Face Type 4 Female Connect Size and Type a aa E 3 8 Male Pipe Adapter Iam occ Weight Ovit COUDIETS a suce 90 16 41 kg og 44 inches 111 76 cm Overall Widt TERUEL 10 5 inches 26 7 cm Overall 2 po eaa tod o ve d D ea Pee 32 5 inches 82 5 cm
28. ooling capacity at a temperature 3 hp 5 hp 6 hp 7 hp difference of between ambient and fluid 2 24 kW 3 73 kW 5 22 kW 4 47 kW temps 40 F 40 F 40 F 40 F NOTE 22 22 22 22 Do not operate the tool at oil temperatures above 140 F 60 Operation at higher temperatures can cause operator discomfort at the tool Filter 25 microns 25 microns 25 microns 25 microns Min full flow filtration 30 30 30 30 Sized for flow of at least 114 Ipm 114 114 Ipm 114 Ipm For cold temp startup and max dirt holding capacity Hydraulic fluid Petroleum based 100 400 ssu 100 400 ssu 100 400 ssu 100 400 ssu premium grade anti wear non conductive 20 82 centistokes Viscosity at min and max operating temps NOTE When choosing hydraulic fluid the expected oil temperature extremes that will be experienced in service determine the most suitable temperature viscosity characteristics Hydraulic fluids with a viscosity index over 140 will meet the requirements over a wide range of operating temperatures SSU Saybolt Seconds Universal EHTMA CLASSIFICATION HYDRAULIC SYSTEM A A A A Flow Range 3 5 4 3 gpm 4 7 5 8 gpm 7 1 8 7 9 5 11 6 gpm 11 8 14 5 gpm 13 5 16 5 Ipm 18 22 Ipm 27 33 Ipm 36 44 Ipm 45 55 Ipm Nominal Operating Pressure 1870 psi 1500 psi 1500 psi 1500 psi 1500 psi at the power supply outlet 129 bar 103 bar 103 bar
29. ss thoroughly trained or under the supervision of an instructor Establish a training program for all operators to ensure safe op eration e 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 danger ous terrain conditions e M 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 pow er 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 STANLEY 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 re moved 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 rotat ing wheel Long hair or loose clothing can become drawn into rotating components
30. t exceed the rated flow see Specifications in this manual for correct flow rate and model number Rapid failure of the internal seals may result Always keep critical tool markings such as warning stickers and tags legible Tool repair should be performed by experienced personnel only Make certain that the recommended relief valves are installed in the pressure side of the system Do not use the tool for applications for which it was not intended FG10 PG05 Service Manual lt 13 If symptoms of poor performance develop the following chart be used as a guide to correct 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 CAUSE SOLUTION Grinder does not run Hydraulic power source not Check power source for proper flow functioning and pressure 7 10 gpm 26 38 1500 2000 psi 105 140 bar Couplers or hoses blocked Locate and remove restriction Hydraulic motor failure Inspect and repair Hydraulic lines not connected Grinder operates too slow Hydraulic motor speed to slow Check power unit for proper flow 7 10 gpm 26 38 High back pressure Check hydraulic system for excessive back pressure over 250 psi 17 bar Couplers or hoses bl
31. ult in IMPORTANT age 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 mainte nance personnel A DANGER a WARNING CAUTION NOTICE IMPORTANT 4 gt FG10 PG05 Service Manual STAN LEY 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 Re view them carefully before operating the tool and before performing general maintenance or repairs Supervising personnel should develop additional pre cautions relating to the specific work area and local safety regulations If so place the added precautions in the space provided in this manual The model FG10 Hydraulic Frog Grinder or the model PG05 Profile 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 operator must start in a work area without by standers Flying debris can cause serious injury Do not operate the tool unle
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