Matweld 09200 User manual

632South3rdStreet
P.O.Box2816•Paducah,KY42002
270-444-0085
Fax:[phone]
Website:www.matweld.com
Email:[email protected]
MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
TheMatweld“PRECISIONFROGGRINDER”isahydraulicpowered,trackmountedmachinethat
providesaprecisionguideframewithmultipleaxisadjustment enabling the operatortomake
consistentrefinishinggrinds.
Rev.06/09
Accessories 00499- 8 x 1x5/8 GRINDING STONE
09299 - 4 x 3 x 5/8-11 CUP STONE
09295- 2’RAILKIT
Weight Base: 38 lbs (17.25 kg)
Grinder: 84 lbs (38 kg)
Overall:122 lbs (55.5 kg) PATENT PENDING
09200/09200A PRECISION FROG GRINDER

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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
Rev. 02/10

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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
Rev. 02/10
GENERAL SAFETY PRECAUTIONS:
TOOLOPERATORSAND MAINTENANCE PERSONNELMUSTALWAYS COMPLY WITH THE SAFETY
PRECAUTIONS GIVEN INTHIS MANUAL,AND WITHALL STICKERSAND TAGSATTACHEDTO THE
TOOLANDHOSE. ALLSAFETYPRECAUTIONSAREGIVEN FOR YOUR SAFETY. READTOUNDER-
STANDAND FOLLOWALLSAFETY,MAINTENANCEANDOPERATIONINSTRUCTIONS BEFOREYOU
USE OR MAINTAIN THE TOOL. REVIEW THE MANUAL DAILY BEFORE USING THE TOOL. IN ADDI-
TION, FOLLOWALLSAFETY GUIDELINES GIVEN YOU BYYOUR SUPERVISOR. DO NOTUSE THE
TOOL IF YOU HAVE ANY QUESTIONS ABOUT THE OPERATION, SAFETY OR MAINTENANCE OF
THIS TOOL. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY
OREQUIPMENTDAMAGE.
MATWELD HAS NO CONTROLOVER TOOLUSE OR OPERATION ONCE ITLEAVES THE MATWELD
PLANT. MATWELDHAS NO CONTROLOVEROPERATOR ORMAINTAINER SELECTION. THE CUS-
TOMERMUSTASSUMERESPONSIBILITYFORTHETOOL’SSUITABILITYFORAPARTICULARFUNC-
TION. DURING USE OF TOOL, GOOD JUDGEMENT MUST BE USED TO WORK SAFELYAND EFFI-
CIENTLY WITHOUT ENDANGERING THEMSELVES OR BYSTANDERS. UNDERSTANDING OF THE
OPERATIONANDMAINTENANCEMANUALISESSENTIALFORANYONEUSINGORMAINTAININGTHE
TOOL.
• DONOTOPERATETHETOOLUNTILYOU HAVEBEENTHOROUGHLYANDPROPERLYTRAINED
OR UNDER THE SUPERVISION OFAN INSTRUCTOR.
• CHECK POWER SOURCE DAILY TO DETERMINE IF CORRECT FLOW AND PRESSURE ARE
AVAILABLE. NEVER EXCEED FLOWS OR PRESSURES FOR THE TOOL BEING USED. PER-
SONALINJURY OR DAMAGE TO THE TOOLCAN RESULT.
• OPERATORS MUST CLEAR THE WORKAREA OF NONESSENTIAL PERSONNEL. FLYING DE-
BRISCAN CAUSE SERIOUS INJURY.
• THE OPERATOR MUST BE FAMILIAR WITHALLPROHIBITED WORKAREAS SUCHAS UNSAFE
GRADES, POOR FOOTINGAREASAND OVERHEAD HAZARDS.
• MAINTAIN BALANCEAND PROPER FOOTINGATALLTIMES. NEVER OVERREACHTOTHE EX-
TENT THAT A BROKEN PART OR SUDDEN MOVEMENT OF THE TOOL CAN CAUSE YOU TO
LOSE YOUR BALANCE AND FALL, OR CAUSE INJURY TO YOUR SELF OR SOMEONE ELSE.
• WHEN WORKING NEAR ELECTRICAL CONDUCTORS, ALWAYSASSUME THAT THE CONDUC-
TORS ARE ENERGIZED AND THAT HOSES AND CLOTHING CAN CONDUCT HARMFUL ELEC-
TRICITY. USE HOSES LABELEDAND CERTIFIED AS NONCONDUCTIVE.
• DO NOT OPERATE THE TOOL AT EXCESSIVE FLUID TEMPERATURES OPERATOR DISCOM-
FORTAND POTENTIALBURNS CAN RESULTAT HIGH OILTEMPERATURES.
• NEVER WEAR LOOSE CLOTHING THAT CAN GET ENTANGLED IN THE WORKING PARTS OF
THE TOOLS OR BE CARELESS WITH HANDS, FEET OR OTHER BODY PARTS AROUND THE
WORKING PARTS OF THE TOOLS. HYDRAULIC TOOLS EXERT HIGH TORQUE AND FORCE
AND CAN CAUSE SERIOUS INJURY OR DEATH IF IMPROPERLYUSED.

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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
Rev. 02/10
• TOAVOID PERSONALINJURYOR EQUIPMENTDAMAGE,ALLTOOLREPAIR, MAINTENANCE OR
SERVICE MUST ONLY BE PERFORMED BYAUTHORIZEDAND PROPERLYTRAINED PERSON-
NEL.
• ALWAYS WEAR SAFETY EQUIPMENT SUCH AS OIL INJECTION RESISTANT WORK GLOVES,
SAFETY GLASSES, SAFETY BOOTS, EAR PROTECTION AND OTHER SAFETY APPAREL DIC-
TATED BY YOUR SUPERVISOR APPLICABLE FOR THE JOB YOU ARE DOING AND THE TOOL
YOUARE USING.
• DO NOT CLEAN INSPECT OR REPAIR THE TOOL WHILE CONNECTED TO THE POWER
SOURCE. ACCIDENTAL ENGAGEMENT OF THE TOOL CAN CAUSE SERIOUS PERSONAL IN-
JURY.
• OIL INJECTION HAZARD EXISTS WITH THIS TOOL. OIL INJECTION IS A CONDITION WHERE
HYDRAULICOILISINJECTED UNDERTHESKINFROMPRESSUREINTHELINE. ALWAYSWEAR
GLOVESAND REPAIRANYLEAKS IMMEDIATELY. NEVER CARRYATOOL BYTHE HOSES.
• DO NOT USE DAMAGED EQUIPMENT. IMMEDIATELY REPLACE ANY DAMAGED HOSES, FIT-
TINGS, OR OTHER COMPONENTS SHOWING WIRE BRAID, NICKS, CUTS, DAMAGE ORABRA-
SIONS. FAILURE TO DO SO MAY RESULT IN EQUIPMENT DAMAGE AND / OR PERSONAL IN-
JURY OR DEATH.
• CLEANUPANYOILORFLUIDSPILLS IMMEDIATELY.
• HAVE SUPERVISORADDADDITIONAL PRECAUTIONS RELATING TOTHE SPECIFIC WORK
AREAAND LOCALSAFETY REGULATIONS BELOW:
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*
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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
Rev. 02/10
09200A PRECISION FROG GRINDER
SAFETY PRECAUTIONS:
1. ALWAYS WEAR PROTECTIVE EQUIPMENT SUCHAS GLOVES, SAFETY GLASSES, EAR PRO-
TECTIONAND SAFETY SHOES.
2. DO NOT WEAR CLOTHING WHICH MAY BECOME ENTANGLED IN THE TOOL.
3. ALWAYS KEEP WORK AREA FREE OF TOOLS OR ANY OTHER OBJECTS
WHICHMAYIMPAIR SOUND FOOTING.
4. CAUTION OIL INJECTION HAZARD EXISTS WITH THIS TOOL. OIL INJECTION ISACONDITION
WHERE THE HYDRAULIC OIL IS FORCED UNDER THE SKIN THROUGH PRESSURE IN THE
LINE. ALWAYS WEAR GLOVES, DO NOT CARRY THE TOOL BY HYDRAULIC HOSES, AND RE-
PAIRLEAKSIMMEDIATELY..
5. NEVER CHANGE STONES WITH THE POWER SOURCE VALVE(S) IN THE “ON” POSITION,
TURN THE POWER SOURCE “OFF”.
6. NEVER ATTEMPT TO CARRY THE GRINDER WITH THE POWER SOURCE IN THE “ON” POSI-
TION, TURN THE POWER SOURCE “OFF”.
7. NEVER TOUCH OR TRY TO STOP A MOVING STONE.
8. ALWAYS CHECK THE WORKAREAFORANYTRASH WHICH MAYIGNITE FROM SPARKS.
9. ALWAYS CHECK THEAREAFOR SMOLDERING TIES OR TRASH BEFORE LEAVING THE SITE.
10. WHENCHANGINGSTONES,FOLLOWALLGRINDINGSTONEMANUFACTURERSINSTRUCTIONS
FOR SAFETYAND OPERATION. USE ONLY STONES THAT COMPLY WITHANSI STANDARDS.
BEFORE USING, RUN NEW GRINDING STONE FOR ONE MINUTE AT FULL SPEED TO CHECK
FOR DEFECTS OR VIBRATION.
11 MOSTHYDRAULIC OILS HAVEAFLASH POINT OFAPPROXIMATELY450 DEGREES (F). MAKE
SURE HOSES ARE COMPLETELY CLEAR OF SPARKS AND HOT DEBRIS. HAVE ANOTHER
PERSON STAND CLOSE TO HYDRAULIC POWER SOURCE CONTROLS TO OBSERVE OP-
ERATION AND FOR EMERGENCYSHUTDOWN IF NECESSARY.
HYDRAULICSPECIFICATIONS
FLOW:
PRESSURE:
MAXBACK PRESSURE:
RPM:
10 GPM (38 LPM)
2000 PSI (140 BAR)
250 PSI (17 BAR)
4000

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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
Rev. 02/10
09200APRECISION FROG GRINDER
Setup and operation
ThePrecision FrogGrinder isdesigned to operateboth 1”X 8”and 4” X3” grindingstones.
The1”X 8”grindingstone isusedfor themajorityofoperationssuchasgrinding outdefectsas wellasgrinding
backtheprofile oftheFrog afterrebuilding.
The4”X3” cupstoneisideal forthefinishgrinding, radiusprofilingandto grindinthepointslope.
Setthe base ofthe Precision FrogGrinder on theFrog, centering iton the workarea. Set thegrinder onto the
baseand lockwiththe rollerclamps.
Withthe 1” X8” stone installedthe defectcan be groundout or ifdefect iscarbonarc cutwith air (CAC-A)
thenthe grindercan beused toclean outthe slagbefore welding.
ROLLERCLAMP

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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
Rev. 02/10
09200APRECISION FROG GRINDER
Afterwelding upthe Frog,beginto roughgrind thesurface withthe 1”X 8”stone. Thebase ofthe grinderis
stillcenteredfor thispurpose.
Forflangewayalignment
Markthe castingofthe Frogwith astraight edgeand soapstone forreferenceof originalprofile.
Stretchthe guidecable from eacheye hookon the baseto alignthe basegrinder over thestraight edgemark.

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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
Rev. 02/10
09200APRECISION FROG GRINDER
Tightenthe baseto the Frog,centered overthis work area.Ensure that thesoap stonereference line andcable
arealigned
Grindtheflangeway fromthebottomup. Theangleadjustmentwill beonapproximatelythe 4thnotchfrom
vertical.
(#8 notch in this example. This may vary depending on the grinding stone wear.)
Startingatthebottomof theflangewaybegin grindingupward.
Usethe hand wheelto move the stoneup or down.
Thecrankhandles arefor adjustingthestone fromside-to-side whilerolling thegrinderback andforth across
thelengthof thebase.

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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
Rev. 02/10
09200APRECISION FROG GRINDER
FinishGrinding theTopofRail
Withthe cup stoneinstalled asposition 1, starton eitherside of theweld repairand setthestone towhere itjust
touchesthe railandthen runthe stoneinto theweld.
GrindingtheRadius
Adjustangleof cuptoapproximately position6to grindradius.
GrindingtheRadius
Changeangleof cupstoneto approximatelyposition8.

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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
Rev. 02/10
09200APRECISION FROG GRINDER
CheckGrinding
Setangleof cup stone to approximately 3 to complete radius.