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. 6
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TABLE OF CONTENTS
DECLARATION OF CONFORMITY..........................................................................................................................2
SAFETY SYMBOLS ..................................................................................................................................................4
SAFETY PRECAUTIONS..........................................................................................................................................5
TOOL STICKERS & TAGS........................................................................................................................................6
HOSE TYPES............................................................................................................................................................7
HOSE RECOMMENDATIONS ..................................................................................................................................8
HTMA REQUIREMENTS...........................................................................................................................................9
OPERATION............................................................................................................................................................10
TOOL PROTECTION & CARE................................................................................................................................13
TROUBLESHOOTING ............................................................................................................................................14
ACCESSORIES.......................................................................................................................................................15
SPECIFICATIONS...................................................................................................................................................15
FG10 & PG05 PARTS ILLUSTRATION...................................................................................................................16
FG10 & PG05 PARTS ILLUSTRATION...................................................................................................................17
FG10 PARTS LIST ..................................................................................................................................................18
PG05 PARTS LIST..................................................................................................................................................20
SPARK GUARD & INNER GUARD.........................................................................................................................22
IMPORTANT
To fill out a Product Warranty Recording form, and for information on your warranty,
visit Stanleyhydraulic.com and select the Warranty tab.
(NOTE: The warranty recording form must be submitted to validate the warranty).
SERVICING THE STANLEY HYDRAULIC FROG GRINDER/PROFILE GRINDER. This manual contains safety,
operation, and routine maintenance instructions. Stanley Hydraulic Tools recommends that servicing of hydraulic
tools, other than routine maintenance, must be performed by an authorized and certified 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 certified dealer, call Stanley Hydraulic Tools at the number listed on the back of this
manual and ask for a Customer Service Representative.
FG10 Service Manual ◄ 3
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SAFETY SYMBOLS
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
which, if not avoided, will result in death or serious injury.
DANGER
WARNING
CAUTION
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.
CAUTION
NOTICE
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 dam-
age to the equipment.
IMPORTANT
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.
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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.
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.
These safety precautions are given for your safety. Re-
view them carefully before operating the tool and before
performing general maintenance or repairs.
Do not operate a damaged, improperly adjusted, or
incompletely assembled grinder.
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.
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.
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.
•
•
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.
•
•
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 op-
eration.
•
•
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.
•
•
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
FG10-PG05 Service Manual ◄ 5
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TOOL STICKERS & TAGS
29715
PG05 Name Tag
25790
03787
Caution Decal
GPM Decal
28727
FG10 Name Tag
05152
Stanley Sticker
28409
Composite
Decal (CE)
20647
Sound Power Level
Decal (CE)
25610
Railroad Help Desk Decal
28376
Stanley Logo Decal (CE)
28322
CE Decal
11207
Circuit Type D Decal (CE)
D A N G E R
D A N G E R
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.
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 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 SEVERE
PERSONAL INJURY.
BEFORE USING HOSE LABELEDAND CERTIFIEDAS NON-
CONDUCTIVE ON OR NEAR ELECTRIC LINES BE SURE THE
HOSE IS MAINTAINED AS NON-CONDUCTIVE. THE HOSE
SHOULD BE REGULARLY TESTED FOR ELECTRIC CUR-
RENT LEAKAGE IN ACCORDANCE WITH YOUR SAFETY
DEPARTMENT INSTRUCTIONS.
NOTE:
2. A HYDRAULIC LEAK OR BURST MAY CAUSE OIL INJEC-
TION INTO THE BODY OR CAUSE OTHER 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 SYSTEMAND/OR SEVERE PERSONAL INJURY.
THE INFORMATION LISTED
ON THE STICKERS SHOWN,
MUST BE LEGIBLE AT ALL
TIMES.
A. DO NOT EXCEED SPECIFIED FLOW AND PRESSURE
FOR THIS TOOL. EXCESS FLOW OR PRESSURE MAY
CAUSE A LEAK OR BURST.
5. BYSTANDERS MAY BE INJURED IN YOUR WORK AREA.
KEEP BYSTANDERS CLEAR OF YOUR WORK AREA.
B. DO NOT EXCEED RATED WORKING PRESSURE OF
HYDRAULIC HOSE USED WITH THIS TOOL. EXCESS
PRESSURE MAY CAUSE A LEAK OR BURST.
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.
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.
REPLACE DECALS IF
THEY BECOME WORN OR
DAMAGED. REPLACEMENTS
ARE AVAILABLE FROM
YOUR LOCAL STANLEY
DISTRIBUTOR.
I M P O R T A N T
I M P O R T A N T
READ OPERATION MANUAL AND
SAFETY INSTRUCTIONS FOR THIS
TOOL BEFORE USING IT.
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.
USE ONLY PARTS AND REPAIR
PROCEDURES APPROVED BY
STANLEY AND DESCRIBED IN THE
OPERATION MANUAL.
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.
TAG TO BE REMOVED ONLY BY
TOOL OPERATOR.
TAG TO BE REMOVED ONLY BY
TOOL OPERATOR.
SEE OTHER SIDE
SEE OTHER SIDE
SAFETY TAG P/N 15875 (Shown smaller then actual size)
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HOSE TYPES
The rated working pressure of the hydraulic hose must be 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 weather 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
D A N G E R
D A N G E R
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.
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.
FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROP-
ERLY TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND
ELECTRIC LINES.
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.
2. BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS NON-CONDUCTIVE
ON OR NEAR ELECTRIC LINES. WIPE THE ENTIRE LENGTH OF THE HOSE AND FIT-
TING 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.
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.
SEE OTHER SIDE
SEE OTHER SIDE
SIDE 1
SIDE 2
(Shown smaller than actual size)
THE TAG SHOWN BELOW IS ATTACHED TO “CONDUCTIVE” HOSE.
D A N G E R
D A N G E R
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.
5. CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKSABRASIONS, 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.
2. FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY
TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND ELEC-
TRIC LINES.
6. AFTER EACH USE STORE IN A CLEAN DRY AREA.
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.
SEE OTHER SIDE
SEE OTHER SIDE
SIDE 1
SIDE 2
(Shown smaller than actual size)
FG10-PG05 Service Manual ◄ 7
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HOSE RECOMMENDATIONS
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HTMA / EHTMA REQUIREMENTS
HTMA / EHTMA REQUIREMENTS
HTMA
TOOL TYPE
HYDRAULIC SYSTEM REQUIREMENTS
TYPE I
TYPE II
TYPE RR
9-10.5 gpm
(34-40 lpm)
1500 psi
TYPE III
11-13 gpm
(42-49 lpm)
1500 psi
4-6 gpm
7-9 gpm
Flow Range
(15-23 lpm)
1500 psi
(103 bar)
(26-34 lpm)
1500 psi
(103 bar)
Nominal Operating Pressure
(at the power supply outlet)
(103 bar)
(103 bar)
2100-2250 psi
(145-155 bar)
2100-2250 psi
(145-155 bar)
2200-2300 psi
(152-159 bar)
2100-2250 psi
(145-155 bar)
System relief valve setting
(at the power supply outlet)
250 psi
(17 bar)
250 psi
(17 bar)
250 psi
(17 bar)
250 psi
(17 bar)
Maximum back pressure
(at tool end of the return hose)
400 ssu*
400 ssu*
400 ssu*
400 ssu*
Measured at a max. fluid viscosity of:
(82 centistokes) (82 centistokes) (82 centistokes) (82 centistokes)
(at min. operating temperature)
Temperature: Sufficient heat rejection
capacity to limit max. fluid temperature to:
(at max. expected ambient temperature)
140° F
(60° C)
140° F
(60° C)
140° F
(60° C)
140° F
(60° C)
Min. cooling capacity at a temperature
3 hp
5 hp
6 hp
7 hp
difference of between ambient and fluid
temps
(2.24 kW)
40° F
(3.73 kW)
40° F
(5.22 kW)
40° F
(4.47 kW)
40° F
NOTE:
(22° C)
(22° C)
(22° C)
(22° C)
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
25 microns
30 gpm
(114 lpm)
25 microns
30 gpm
(114 lpm)
25 microns
30 gpm
(114 lpm)
25 microns
30 gpm
(114 lpm)
Min. full-flow filtration
Sized for flow of at least:
(For cold temp. startup and max.
dirt-holding capacity)
Hydraulic fluid Petroleum based
(premium grade, anti-wear, non-conductive)
Viscosity (at min. and max. operating temps)
100-400 ssu*
100-400 ssu*
(20-82 centistokes)
100-400 ssu*
100-400 ssu*
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
CLASSIFICATION
EHTMA
HYDRAULIC SYSTEM
REQUIREMENTS
C
B
D
Flow Range
3.5-4.3 gpm
(13.5-16.5 lpm) (18-22 lpm)
1870 psi
(129 bar)
4.7-5.8 gpm
7.1-8.7 gpm
(27-33 lpm)
1500 psi
9.5-11.6 gpm
(36-44 lpm)
1500 psi
11.8-14.5 gpm
(45-55 lpm)
1500 psi
Nominal Operating Pressure
(at the power supply outlet)
1500 psi
(103 bar)
(103 bar)
(103 bar)
(103 bar)
System relief valve setting
(at the power supply outlet)
2495 psi
(172 bar)
2000 psi
(138 bar)
2000 psi
(138 bar)
2000 psi
(138 bar)
2000 psi
(138 bar)
NOTE: These are general hydraulic system requirements. See tool specification page for tool specific requirements
FG10-PG05 Service Manual ◄ 9
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OPERATION
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.
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/105-
140 bar.
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.
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
GRINDING WINGS
1. Make sure all tool accessories are correctly in-
stalled. Failure to install tool accessories properly
can result in damage to the tool or personal injury.
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.
2. There should be no signs of leaks.
3. 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 “ON” and “OFF” positions.
IMPORTANT
CHECK GUARD WELDMENT
Never over-tighten the grinding wheel by impacting
the wrench with a mallet or hammer. Sufficient
torque is attained by hand-tightening the wheel with
a strap wrench while securing the drive flange with
the wrench provided.
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 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.
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OPERATION
Cross Section of Typical Rail
Cross Section of Typical Frog at 1/2” Point
Figure 3. Profile Grinding
Figure 1. Grinding the Wings of a Frog
USING THE EXTENSION ASSEMBLY
GRINDING THE POINT
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).
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.
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.
Cross Section of Typical Frog at 1/2” Point
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.
Figure 2. Grinding the Point of a Frog
PROFILE GRINDING
3. Move the hydraulic circuit control valve to the “ON”
position.
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.
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 ◄ 11
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OPERATION
6. Grind a small amount of material at a time adjust-
ing the grinding wheel as necessary by turning the
handwheel.
PREVENTATIVE MAINTENANCE
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.
Note: If the grinder is not loaded 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.
2. After each servicing, measure the spindle speed
(rpm - revolutions per minute) at 12 gpm/45 lpm in-
put. The nominal speed is 4000, not to exceed 6000
rpm. This procedure must be accomplished by a
trained technician.
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.
3. 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.
4. 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.
Damage to the hydraulic system or grinder can result
from use with fluid that is to viscous or too thick.
5. To grease between main housing bore (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).
Figure 4
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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 con-
nection.
•
Do not exceed the rated flow (see Specifications) in
this manual for correct flow rate and model number.
Rapid failure of the internal seals may result.
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 keep critical tool markings, such as warning
stickers and tags legible.
Tool repair should be performed by experienced
personnel only.
•
•
Always store the tool in a clean dry space, safe from
damage or pilferage.
Make certain that the recommended relief valves
are installed in the pressure side of the system.
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.
Do not use the tool for applications for which it was
not intended.
•
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.
FG10/PG05 Service Manual ◄ 13
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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
CAUSE
SOLUTION
Hydraulic power source not
functioning.
Check power source for proper flow
and pressure (7-10 gpm/ 26-38 lpm
@ 1500-2000 psi/ 105-140 bar.
Couplers or hoses blocked.
Hydraulic motor failure.
Locate and remove restriction.
Inspect and repair.
Hydraulic lines not connected.
Hydraulic motor speed to slow.
Connect lines.
Grinder operates too slow.
Check power unit for proper flow
(7-10 gpm/26-38 lpm).
High back-pressure.
Check hydraulic system for
excessive back-pressure (over 250
psi/17 bar).
Couplers or hoses blocked.
Locate and remove restriction.
Oil too hot (above 140°F/60°C) or
too cold (below 60°F/16°C).
Check hydraulic power source for
proper oil temperature. Bypass
cooler to warm oil or provide cooler
to maintain proper temperature.
Relief valve set too low.
Adjust relief valve to 2100-2250
psi/145-155 bar.
Hydraulic motor worn.
Inspect, repair or replace.
Flow control malfunctioning.
Have flow control serviced at an
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 ► FG10/PG05 Service Manual
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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
Porting...................................................................................................................................................-8 SAE O-ring
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
RPM.....................................................................................................................................................................4000
HyrevzTM Motor..................................................................................................................................................25251
Maximum Fluid Temperature.................................................................................................................. 140° F/60° C
Sound Power Level ....................................................................................................................................... 104 dBA
Sound Pressure Level (1m).............................................................................................................................. 94dBA
Vibration Level.............................................................................................................................Less than 2.5m/sec2
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 decibels
Uncertainty, Kwa, in decibels
103.86 dBA
3 dBA
Measured A-weighted sound pressure level, Lpa (ref. 20 µPa) at operator's position, in decibels
Uncertainty, Kpa, in decibels
94 dBA
3 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 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 12096
Measured vibration emission value: a
2.0 m/sec²
0.5 m/sec²
Uncertainty: K
Values determined according to ISO 8662-4, ISO 5349-1,2
ACCESSORIES
6 x 3 x 5/8-11 Thread Cup Stone.......................................................................................................................28597
FG10/PG05 Service Manual ◄ 15
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FG10-PG05 PARTS ILLUSTRATION
A
B
FG10 FROG GRINDER and
PG05 PROFILE GRINDER
14
15
16
1
2
3
28
29
7
131
38
39
17
28
30
4
5
24
22
5
25
6
8
7
31
40
41
19
132
20
9
25
32
33
33
49
42
26
10
11
12
13
21
22
43
44
52
27
23
53
34
54
**
45
50
51
35
36
58
55
75
76
46
57
88
47
44
56
62
37
48
61
68
135
59
77
60
136
70
78
67
36
81
82
66
83
69
64
85
65
71
80
84
72
86
53
52
3
44
73
99
74
54
55
75
79
65
64
92
93
60
59
66
56
**
57
89
76
88
58
90
79
62
61
91
63
90
89
62
98
78
52
94
77
*
97
96
93
58
92
57
56
83
26087 Assy (FG10 Only)
95
87
*
26088 Assy (FG10 Only)
86
85
**
89
56
81
90
57
84
82
80
91
58
83
63
52
90
62
89
*
16 ► FG10-PG05 Service Manual
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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
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FG10 PARTS LIST
ITEM P/N
QTY DESCRIPTION
ITEM P/N
QTY DESCRIPTION
1
25294
2
1
HOSE ASSEBLY
44
45
46
47
48
49
50
51
52
53
54
55
25285
3
1
1
1
1
1
1
1
2
2
2
2
1
ADJUSTABLE HANDLE
25251
HYREVZ MOTOR ASSY (INCL ITEMS
4-15, 17, 18, & 20-23)
25104
25286
25293
25103
26810
25083
25283
03906
02634
00048
26019
26087
BACKUP WASHER
WIPER TYPE H •
SQUARE RING •
THRUST WASHER
SHAFT
2
3
4
5
6
7
8
01604
25790
00713
25718
00178
06316
19905
3
1
2
2
1
4
1
O-RING •
CAUTION STICKER (US MODELS)
DOWEL PIN
DRIVE GEARS
PINION GEAR
ROLL PIN
O-RING, 2-1/8 X 2-1/4 X 1/16 70D •
BUSHING
HEX NUT
FRONT BEARING HOUSING ASSY
(INCL ITEM 7)
WASHER
BEARING
9
00669
19884
00170
00148
00166
00120
06846
1
1
1
1
1
8
1
QUAD RING •
SEAL GLAND
RETAINING RING
BEARING
ROLLER
10
11
12
13
14
15
WHEEL ASSY 2.5 INCH (INCL ITEMS
56-58 & 62,63)
26088
1
WHEEL ASSY 3.0 INCH (INCL ITEMS
56-58 & 62, 88)
RETAINING RING
CAPSCREW
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
03226
26042
26091
26250
26216
26155
00664
26025
26249
00719
26202
00272
25082
25284
10888
25167
05152
26103
26215
00007
26045
26051
03011
00635
26059
00899
26831
06989
26090
17668
4
4
4
2
2
2
4
2
2
2
2
2
1
1
2
1
1
1
1
2
2
2
4
2
2
2
2
4
2
2
RETAINING RING
WHEEL SHAFT
BEARING
GEAR HOUSING ASSEMBLY (INCL
ITEMS 5 & 8)
16
25610
1
RAILROAD HELP DESK DECAL (US
MODELS ONLY)
JAM NUT
ADJUSTMENT SCREW
BARREL NUT
RETAINING RING
WHEEL, 2.5 INCH
SPHERICAL WASHER (2 PCS)
LOCKNUT
17
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
73309
28727
00171
25166
06881
00708
25158
02688
25099
25291
25289
25290
25281
25279
27941
00772
25278
25280
25419
01607
02179
26809
25287
27748
27749
02900
1
1
1
1
2
1
1
10
1
1
2
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
IDLER SHAFT KEYED
NAME TAG (US & CE MODELS)
O-RING, 11/16 X 13/16 X 1/16 70D •
MOTOR SHAFT
NEEDLE ROLLER
RETAINING RING
SPLINED COUPLING
CAPSCREW
CAPSCREW
DOWEL PIN
FEED GEAR
RAM
DU BEARING
CAPSCREW
NEEDLE ROLLER BEARING
RETAINING RING
INNER RING
KEY
STANLEY DECAL (US MODELS ONLY)
MAIN HOUSING
CHASSIS WELDMENT
BEARING
RETAINING RING
BEARING
SPINDLE
WOODRUFF KEY
RETAINING RING
OIL SEAL, 1.250 X 2.047 X .299 •
DRIVE FLANGE (US MODELS ONLY)
SET SCREW
ROLLER SHAFT
HANGER
CAPSCREW
KEY
PIVOT PIN ASSY
CAPSCREW
NUT
HAND WHEEL
WASHER
WIPER •
O-RING, -018 •
BUSHING
BUSHING
HOUSING
ROLL PIN
ROLL PIN
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FG10 PARTS LIST
ITEM P/N
QTY DESCRIPTION
ITEM P/N
QTY DESCRIPTION
86
87
88
89
90
91
92
93
94
95
26056
2
1
2
4
4
2
4
2
1
1
WHEEL PIVOT
PIVOT SHAFT WHEEL
WHEEL, 3.3 INCH
WASHER
126
127
128
00144
2
1
1
1
CAPSCREW
26022
26024
12175
26203
26046
26247
01606
25277
26211
25842
26142
26200
WRENCH (TAPED TO FRAME)
EXTENSION BRACKET WELDMENT
EXTENSION ASSY (INCL 52, 66, 89-90,
& 129)
BALL BEARING
ROLLER
129
11207
1
CIRCUIT "D" STICKER (CE MODELS
ONLY)
FLANGED BUSHING
O-RING, -120 •
WIPER •
130
131
372155
28409
2
1
DRIVE SCREW
COMPOSITE STICKER (CE MODELS
ONLY)
132
133
134
135
136
28322
---
1
-
CE STICKER (CE MODELS ONLY)
GUARD WELDMENT (US MODELS
ONLY)
NO ITEM
NO ITEM
NO ITEM
96
02525
26248
26246
26021
26098
27369
25292
27370
27599
27366
18601
25036
25305
25256
08017
18037
01605
3
3
2
1
1
1
1
1
1
1
1
1
1
1
2
1
4
CAPSCREW
---
-
97
LOCK WASHER
COUPLING NUT
PIVOT SHAFT WHEEL
HANDLE BAR ASSY
TRIGGER WELDMENT
ROLL PIN
---
-
98
29052
1
INNER GUARD (SEE SPARK GUARD &
INNER
99
GUARD ILLUSTRATION PAGE
FOLLOWING)
100
101
102
103
104
105
106
107
108
109
110
111
112
137
138
139
140
---
-
NO ITEM
---
-
NO ITEM
SPACER
29264
69772
1
1
SERVICE RAM ASSY (NOT SHOWN)
TORSION SPRING
LEVER WELDMENT
ROLL PIN
SPARK GUARD (SEE SPARK GUARD
& INNER GUARD ILLUSTRATION
FOLLOWING)
141
142
08080
20647
25942
2
1
1
HANDLE GRIP
ON-OFF VALVE, O.C.
WIPER •
104 SOUND POWER LEVEL DECAL
SEAL KIT
WASHER
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) •
113
114
00936
03972
47436
03973
47437
18008
24819
17904
00955
24289
28914
01411
20145
25005
03787
28811
2
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
ADAPTER
FEMALE COUPLING, PARKER
FEMALE COUPLING, AEROQUIP
MALE COUPLING, PARKER
MALE COUPLING, AEROQUIP
SPRING WASHER
115
•Denotes part in seal kit
116
117
118
119
120
121
122
123
124
125
SPRING
RETAINING RING
NOTE: Use Part Number and Part Name when order-
ing.
PIPE PLUG
PLUG
FLOW CONTROL (PRE-SET)
O-RING, .488 X .624 X .078 -906 •
STEEL BALL
VALVE BLOCK
GPM DECAL (US MODELS ONLY)
INFORMATION PLAQUE (CE MODELS
ONLY)
FG10-PG05 Service Manual ◄ 19
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PG05 PARTS LIST
ITEM P/N
QTY DESCRIPTION
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
27748
27749
02900
25285
25104
25286
25293
25103
26810
25083
25283
03906
02634
00048
26019
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
BUSHING
1
25294
2
1
HOSE ASSEBLY
HOUSING
25251
HYREVZ MOTOR ASSY (INCL ITEMS
4-15, 17, 18, & 20-23)
ROLL PIN
ADJUSTABLE HANDLE
BACKUP WASHER
WIPER TYPE H •
SQUARE RING •
THRUST WASHER
SHAFT
2
01604
25790
00713
25718
00178
06316
19905
00669
19884
00170
00148
00166
00120
06846
3
1
2
2
1
4
1
1
1
1
1
1
8
1
O-RING •
3
CAUTION STICKER
DOWEL PIN
4
5
DRIVE GEARS
6
O-RING, 2-1/8 X 2-1/4 X 1/16 70D •
BUSHING
7
PINION GEAR
ROLL PIN
8
FRONT BRG HSG ASSY (INCL ITEM 7)
QUAD RING •
9
HEX NUT
10
11
12
13
14
15
SEAL GLAND
WASHER
RETAINING RING
BEARING
BEARING
ROLLER
RETAINING RING
CAPSCREW
NO ITEM
NO ITEM
GEAR HOUSING ASSY (INCL ITEMS 5
& 8)
NO ITEM
NO ITEM
16
17
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
25610
73309
29715
00171
25166
06881
00708
25158
02688
25099
25291
25289
25290
25281
25279
27941
00772
25278
25280
25419
01607
02179
26809
25287
1
1
1
1
1
2
1
1
10
1
1
2
1
1
1
1
2
1
1
1
1
1
1
1
RAILROAD HELP DESK DECAL
IDLER SHAFT KEYED
NAME TAG
NO ITEM
NO ITEM
NO ITEM
O-RING, 11/16 X 13/16 X 1/16 70D •
MOTOR SHAFT
NEEDLE ROLLER
RETAINING RING
SPLINED COUPLING
CAPSCREW
NO ITEM
NO ITEM
NO ITEM
26202
00272
25082
25284
10888
25167
05152
26103
26215
00007
26045
26051
03011
00635
26059
00899
26831
06989
26090
2
2
1
1
2
1
1
1
1
2
2
2
4
2
2
2
2
4
2
CAPSCREW
DOWEL PIN
FEED GEAR
DU BEARING
CAPSCREW
KEY
RAM
NEEDLE ROLLER BEARING
RETAINING RING
INNER RING
STANLEY DECAL
MAIN HOUSING
CHASSIS WELDMENT
BEARING
RETAINING RING
BEARING
SPINDLE
WOODRUFF KEY
RETAINING RING
OIL SEAL, 1.250 X 2.047 X .299 •
DRIVE FLANGE
SET SCREW
ROLLER SHAFT
HANGER
CAPSCREW
KEY
PIVOT PIN ASSY
CAPSCREW
WASHER
NUT
HAND WHEEL
WIPER •
O-RING, -018 •
BUSHING
ITEM P/N
QTY DESCRIPTION
ITEM P/N
QTY DESCRIPTION
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PG05 PARTS LIST
85
17668
26056
26022
2
2
1
ROLL PIN
128
26142
26200
1
1
EXTENSION BRACKET WELDMENT
86
WHEEL PIVOT
PIVOT SHAFT WHEEL
NO ITEM
EXTENSION ASSY (INCL 52, 66, 89-90,
& 129)
87
129
130
131
132
133
134
135
136
---
-
-
-
-
-
-
-
1
NO ITEM
NO ITEM
NO ITEM
NO ITEM
NO ITEM
NO ITEM
NO ITEM
88
---
89
12175
26203
26046
26247
01606
25277
26211
02525
26248
26246
26021
26098
27369
25292
27370
27599
27366
18601
25036
25305
25256
08017
18037
01605
4
4
2
4
2
1
1
3
3
2
1
1
1
1
1
1
1
1
1
1
1
2
1
4
WASHER
---
90
BALL BEARING
ROLLER
---
91
---
92
FLANGED BUSHING
O-RING, -120 •
WIPER •
---
93
---
94
29052
INNER GUARD (SEE SPARK GUARD &
INNER GUARD ILLUSTRATION PAGE
FOLLOWING)
95
GUARD WELDMENT
CAPSCREW
96
137
138
139
140
---
-
NO ITEM
97
LOCK WASHER
COUPLING NUT
PIVOT SHAFT WHEEL
HANDLE BAR ASSY
TRIGGER WELDMENT
ROLL PIN
---
-
NO ITEM
98
29264
69772
1
1
SERVICE RAM ASSY (NOT SHOWN)
99
SPARK GUARD (SEE SPARK GUARD &
INNER GUARD ILLUSTRATION PAGE
FOLLOWING)
00
101
102
103
104
105
106
107
108
109
110
111
112
141
08080
25942
2
1
HANDLE GRIP
SEAL KIT
SPACER
TORSION SPRING
LEVER WELDMENT
ROLL PIN
ON-OFF VALVE, O.C.
WIPER •
WASHER
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) •
113
114
115
116
117
118
119
120
121
122
123
124
125
00936
03972
03973
18008
24819
17904
00955
24289
28914
01411
20145
25005
03787
2
1
1
2
1
1
1
1
1
1
1
1
1
ADAPTER
FEMALE COUPLING, PARKER
MALE COUPLING, PARKER
SPRING WASHER
SPRING
RETAINING RING
PIPE PLUG
PLUG
FLOW CONTROL (PRE-SET)
O-RING, .488 X .624 X .078 -906 •
STEEL BALL
VALVE BLOCK
GPM DECAL
ITEM P/N
QTY DESCRIPTION
126
127
00144
25842
2
1
CAPSCREW
WRENCH (TAPED TO FRAME)
FG10-PG05 Service Manual ◄ 21
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SPARK GUARD & INNER GUARD
ITEM #
P/N
QTY
DESCRIPTION
NYLOCK NUT
CAPSCREW
1
2
3
4
5
00719
29920
02259
69755
69767
2
2
2
1
1
WASHER
SPARK GUARD
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.
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Stanley Hydraulic Tools
3810 SE Naef Road
Milwaukie, Oregon 97267-5698 USA
(503) 659-5660 / Fax (503) 652-1780
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