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- Page 1 OPERATOR’S MANUAL CORDLESS FROG GRINDER FG60 Original Instructions Manual Number: 88885 Date: May 2025 Rev. 4 503-659-5600 I www.stanleyinfrastructure.com | 6430 SE Lake Road, Portland, OR. 97222, United States of America | Copyright ©2021...
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Page 3: Table Of Contents
Table of Contents Preface ................................5 Safety Statements ............................6 General Safety Precautions ........................6 Decals ................................16 Nomenclature ............................... 18 Installation ..............................19 General Information ..................................19 Charge Batteries ..................................19 Operation ............................... 21 General Information ..................................21 Intended Use ....................................21 Noise Emission Data ................................22 Vibrations Emission Data Preparation Procedure ......................22 Shaft Lock Operation ................................ - Page 4 THIS PAGE IS INTENTIONALLY BLANK...
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Page 5: Preface
Preface General Comments Congratulations on the purchase of your new product! This product was carefully designed and manufactured to give you many years of dependable service. Only minor maintenance (such as cleaning and lubricating) is required to keep it in top working condition. -
Page 6: Safety Statements
Safety Statements THIS SYMBOL BY ITSELF OR WITH A WARNING WORD THROUGHOUT THIS MANUAL IS USED TO CALL YOUR ATTENTION TO INSTRUCTIONS INVOLVING YOUR PERSONAL SAFETY OR THE SAFETY OF OTHERS. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN INJURY OR DEATH. -
Page 7: Personal Protective Equipment (Ppe)
PERSONAL PROTECTIVE EQUIPMENT (PPE) ⊲ Always wear personal protective equipment (PPE) appropriate for the job, such as eye protection, ear protection, gloves, head protection, breathing protection and safety shoes. PPE should be worn at all times when operating, maintaining or observing the tool. -
Page 8: California Proposition 65 Warning
General Safety Precautions ⊲ Do not alter or remove any safety feature from the prime mover or tool. ⊲ Stay alert, watch what you are doing and use common sense when operating the tool. Do not operate the tool if you are tired or under the influence of drugs, alcohol or medication. -
Page 9: End Of Life Disposal
⊲ Wear protective equipment specified by the tool manufacturer. ⊲ Do not perform any work on the tool unless you are authorized and qualified to do so. Always read the operator service manuals before any repair is made. After completing maintenance or repair, check for correct functioning of the tool. -
Page 10: Equipment Safety Precautions
⊲ Slips, trips and falls are major causes of workplace injury. Be observant of hoses and other objects or oily surfaces lying about the work area, as they can be a tripping hazard. ⊲ Only use clean fluids and lubricants that have been recommended by STANLEY. - Page 11 ⊲ Keep all body parts away from rotating components of the tool. ⊲ Do not start the tool if the grinding wheel is touching a surface. ⊲ Repair and service of this tool must only be performed by an authorized STANLEY service center.
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Page 12: Battery And Charger
⊲ Use and maintain tool as recommended in the manual to prevent an unnecessary increase in vibration. ⊲ Check the vibration level after each service. If higher than normal, contact your STANLEY dealer. BATTERY AND CHARGER ⊲... - Page 13 The charger and battery pack are specifically designed to work together. ⊲ These chargers are not intended for any users other than charging STANLEY rechargeable batteries. Any other uses may result in risk of fire, electric shock or electrocution.
- Page 14 If the plastic housing of the battery pack breaks or cracks, return to a service center for recycling. ⊲ CAUTION: Burn hazard. To reduce the risk of injury, charge only STANLEY rechargeable battery packs. Other types of batteries may overheat and burst resulting in personal injury and property damage.
- Page 15 such as, but not limited to, grinding dust, metal chips, steel wool, aluminum foil or any buildup of metallic particles should be kept away from the charger cavities. Always unplug the charger from the power supply when there is no battery pack in the cavity. Unplug the charger before attempting to clean.
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Page 16: Decals
Keep all safety decals clean and legible. Replace all missing, illegible, or damaged safety decals. When replacing parts with safety decals attached, the safety decals must also be replaced. Safety decals are available from your local dealer or STANLEY. REPLACING SAFETY DECALS: Clean the area of application with nonflammable solvent, then wash the same area with soap and water. - Page 17 # 89635 # 89620 STA�LEY 3!110 SE Nae! Rd. Milwaukie, Oregon 97267 U.S.A. 1333-723-1843 www .industrialtoolsandattachments.com/ 1Mlool<91 No. WARNING! Too! �psedl: 6000 RIPM IMIAA IEiaititel)': 60/ 1! lVJA)( # 89635 - REMOVE BATTERY FOR AWARNING TO REDUCE THE RISK OF !�JURY, USER STORAGE OR TRANSPORTATION DECAL MUST READ INSTRUCTION MANUAL.
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Page 18: Nomenclature
Nomenclature TRIGGER BAR GRINDING WHEEL HEIGHT TRIGGER ADJUSTMENT INTERLOCK ELECTRIC MOTOR BATTERY COMPARTMENT BATTERY COMPARTMENT CARRY HANDLE TILT ADJUSTMENT FROG ARM ADJUSTMENT FROG ARM ATTACHMENT SOCKET GEARBOX AND TOWER GRINDING WHEEL SPARK GUARD GUARD ROLLER GUIDE EXTENSION ARM ASSEMBLY ASSEMBLY... - Page 19 OPTIONAL LARGER 6IN STONE GUARD 88885 | May 2025 | 19...
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Page 20: Installation
OR ELECTROCUTION. Plug the charger into a standard 120V household electrical outlet. Insert the battery pack into the charger. Ensure the battery pack is fully seated in the charger. Only use battery packs and chargers that have been recommended by STANLEY. - Page 21 NOTE The red light on the charger will blink, indicating that the charging process has started. When the red light remains on continuously, the battery pack is full. Push the battery release button on the battery pack to remove the battery from the charger. NOTE The charger and battery pack may become warm to the touch during charging.
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Page 22: Operation
Operation NOISE EMISSION DATA STANLEY - CORDLESS FROG GRINDER FG60 DECLARED DAUL-NUMBER NOISE EMISSION VALUES IN ACCORDANCE WITH ISO 4871 No-load Load A-weighted sound power level, L (reference 1pW), in decibels Uncertainty, K , in decibels A-weighted emission sound pressure level, L (reference 20 μPa), in decibels... -
Page 23: Intended Use
INTENDED USE This tool has been designed and built to grind railroad rail. Use in any other way is considered contrary to the intended use. Compliance with and strict adherence to operation, service, and repair conditions as specified by the manufacturer, are also essential elements of the intended use. WARNING! DISCONNECT BATTERIES Do not install, change tool accessories, clean, or perform maintenance on the tool while the... -
Page 24: Shaft Lock Operation
Operation SHAFT LOCK OPERATION When installing or removing the grinding wheel, it will be necessary to lock the shaft from turning. Lock the shaft with the shaft lock button as shown below. It may be necessary to rotate the shaft until the shaft lock is able to engage. -
Page 25: Removing The Grinding Wheel
REMOVING THE GRINDING WHEEL Remove batteries from tool. Push in the shaft lock button to keep shaft from turning. Remove the grinding wheel. IMPORTANT Never loosen the grinding wheel by impacting the wrench or the stone with a mallet or hammer. - Page 26 Operation Grinding The Point For grinding the point of a frog, place the grinder on top of the point with the rollers resting on the top of the point. Adjust each roller guide to the position shown below. Grinding is accomplished by moving the grinder back and forth in line with the rail.
- Page 27 Profile Grinding For profile grinding of rail, place the grinder on top of the rail with the rollers resting on top of the rail to be ground. Adjust each roller guide to the position shown below. Grinding is accomplished by moving the grinder back and forth in line with the rail.
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Page 28: Tilt Feature
Operation TILT FEATURE The grinder can be tilted for grinding more vertical surfaces. Unlock by pulling the over center lever out. Rotate grinder to desired position. Lock into place by pushing over center lever in. Rotating the lever will not change the clamping force. UNLOCK LOCK... -
Page 29: Extension Assembly
EXTENSION ASSEMBLY The extension assembly can be used at anytime by simply connecting it to one end of the grinder and inserting the lock pin. The angle adjustment for the extension arm should be done at the factory, but if it needs to be adjusted later it can be. -
Page 30: Grinding Wheel Height Adjustment
Operation GRINDING WHEEL HEIGHT ADJUSTMENT Adjust the height of the grinding wheel by turning the hand wheel on the grinder. While standing in the proper operating position, either turn the hand wheel clockwise to lower the grinding wheel or counter- clockwise to raise the grinding wheel. -
Page 31: Operating Procedure
OPERATING PROCEDURE WARNING! ENTANGLEMENT HAZARD Keep all body parts, hair, and loose clothing away from rotating drives. Entanglement, choking, scalping and laceration can occur if loose clothing, personal jewelry, neck wear, hair, or gloves are not kept away from the rotating tool and it’s accessories. KEEP AWAY FROM ROTATING DRIVES Observe all safety precautions. -
Page 32: Operating Tips
Operation OPERATING TIPS ⊲ Keep the batteries charged so that all the fuel gauge lights are on. Keeping the batteries charged will help prolong grinding wheel life and will extend the service life of the batteries. ⊲ If the grinder fails to grind material, check the battery fuel gauges and ensure they are fully charged. -
Page 33: Removal From Storage
⊲ Fully charge the tool batteries. ⊲ Inspect all the tool safety labels. Replace if they are damaged or not legible. Contact your STANLEY dealer for replacements. TRANSPORTING WARNING! DISCONNECT BATTERIES Do not store or transport the tool while the batteries are connected to the tool. Remove the batteries from the tool. - Page 34 Operation Shipping the D WALT FLEXVOLT™ Battery The D WALT FLEXVOLT™ battery has two modes: Use and Shipping. Use Mode: When the FLEXVOLT™ battery stands alone or is in a D WALT 20V max product, it will operate as a 20V Max battery. When the FLEXVOLT™ battery is in a 60V Max or a 120V Max (two 60V Max batteries) product, it will operate as a 60V Max battery.
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Page 35: Maintenance
Inspect all the tool safety labels. Replace if they are damaged or not legible. Contact your STANLEY dealer for replacements. Inspect the spindle and drive flange 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... -
Page 36: Troubleshooting
Troubleshooting Problem Possible Cause Possible Solution BATTERY PACK IS NOT No power to charger Check operation of the power receptacle by CHARGING PROPERLY plugging in a lamp or other appliance. Check to see if the receptacle is connected to a light switch which turns power off when you turn out the lights. -
Page 37: Tool Disposal
Tool Disposal Electrical Components Contact your local municipal recycling authorities for an approved electronics recycling center. Tool Body Disassemble the tool and dispose of all non-metal parts. Recycle the metal components. Contact your local municipal recycling authorities for recycling instructions. Batteries The RBRC®... -
Page 38: Specifications
Specifications SPECIFICATIONS AND DESIGN ARE SUBJECT TO CHANGE WITHOUT NOTICE AND WITHOUT LIABILITY THEREFOR. FG60 Cordless Grinder Description Value A. Overall Length (without Extension Arm) 44 inches (111.76 cm) B. Overall Width 10.5 inches (26.7 cm) C. Overall Height 32.5 inches (82.5 cm) -
Page 39: Accessories
Stone Wrench for 6” Grinding Stone 28597 6 x 3 x 5/8-11 Thread Cup Stone Warranty In order to provide you with the most UP-TO-DATE Warranty information, STANLEY Warranty information can be found at https://industrialtoolsandattachments.com/company/warranty. Sales, Service, & Support Resources For service, support resources, or to contact a sales representative please visit https://industrialtoolsandattachments.com/handheld-tools-sales-and-support. -
Page 40: Declaration Of Conformity
Provisiones especiales: Disposizioni speciali: Representative in the Union: Patrick Vervier, STANLEY Dubuis 17-19, rue Jules Berthonneau- CS 73406 41034 Blois CEDEX, France. Vertreter in der Union/Représentant dans l’union/Representante en la Union/Rappresentante presso l’Unione Done at/Ort/Fait à/Dado en/Fatto a Blois France... - Page 41 THIS PAGE IS INTENTIONALLY BLANK 62211 | May 2025 | 41...
- Page 42 © 2021 Stanley Milwaukie, OR 97267 USA...
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