Matweld 09200 Manual Download Page 19

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MATWELD, INC. PHONE:(270) 444-0085 FAX:(270) 443-6180

Matweld reserves the right to change parts, features, or specifications without notice.

Rev. 02/10

09200 PRECISION FROG GRINDER

ITEM NO.

PART NO.

DESCRIPTION

QTY.

1
2
3
4
5
6
7
8
9

10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
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35
36
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38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58

00403
00404
00405
00406

00410B

00412
00413
00415
00502
00705

00706HD

00710
00713

00806-01

03930A

05919
05940
09218
09220
09221
09222
09223
09224
09225
09226
09228
09229
09230
09231
09232

09232-01

09237
09238

315-08-10
515-08-10

6500-08-08

A1005
A1021
A1041

A1043 - CARRIAGE

A1452
A1481
A2046
A2190

A2192-N

A2192-T

A2200
03858
A3860
A5434
A5620
A5624
A5751
A6311
A6358
A6960
00402
A1436

INTERNAL RETAINING RING

SEAL

EXTERNAL RET. RING

DRIVE SHAFT BEARING

TOP PORT MOTOR

LOCKING PIN

SPRING

PLUG

DRIVE SHAFT CCW

1 5/8 INT. RET. RING

3/4 EXT. RET. RING HD

HEIGHT ADJ. TUBE SEAL

HEIGHT ADJ. BEARING

MOTOR SHAFT KEY

CRANK HANDLE KNOB

HAND WHEEL

1/2 WAVE WASHER

SLIDE BEARING

HEIGHT ADJUSTMENT ASSEMBLY

HEIGHT ADJUSTMENT SHAFT

HEIGHT ADJUSTMENT SCREW

BEARING HOUSING

SUPPORT SHAFT

ANGLE ADJUSTMENT ASSEMBLY

ANGLE LOCK PLATE

8” STONE GUARD ASSEMBLY

SUPPORT BLOCK

GUARD MOUNT

4” CUPSTONE GUARD
ADJUSTABLE HANDLE

LOCK KNOB SHAFT

SUPPORT SHAFT BLOCK

PRESSURE/RETURN HOSE

1/2 T x #10 MALE CONN.

1/2 T x 10 STR. THRD. 90

#8 MJIC x #8 FJIC SWIVEL

1/4-20 x 1 3/4 HEX HEAD BOLT

5/16-18 x 3/4 HEX HEAD BOLT

3/8-16 x 3/4 HEX HEAD BOLT

3/8-16 x 1 1/4 CARRIAGE BOLT

5/16-18 JAM NUT ZP

DIA. 1/2 x 1 SHOULDER BOLT

1/4-20 NYLOCK NUT

1/4 SAE FLAT WASHER

3/8 NYLON WASHER

3/8 TOOLING WASHER

3/4 x 1 1/4 WASHER

5/16 x 1 1/4 FENDER WASHER

3/8 x 1 1/4 FENDER WASHER

1/4-20 x 3/4 SHCS

5/16-18 x 1/2 SET SCREW

5/16-18 x 1/2 SET SCREW - N

5/16-18 x 1 3/4 COUPLING NUT

5/16 x 3/4 FLAT HEAD BOLT

5/16-18 x 3/4 BHCS

DIA. 3/4 x 1 SHOULDER BOLT

STONE FLANGE

5/8-11 HVY HEX NUT

1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
3
1
1
1
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1
1
1
1
1
1
1
1
1
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1
1
1
4
1
1
1
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1
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8
1
1
1
1
1

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1
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1

Summary of Contents for 09200

Page 1: ...s without notice The Matweld PRECISION FROG GRINDER is a hydraulic powered track mounted machine that provides a precision guide frame with multiple axis adjustment enabling the operator to make consistent refinishing grinds Rev 06 09 Accessories 00499 8 x 1 x 5 8 GRINDING STONE 09299 4 x 3 x 5 8 11 CUP STONE 09295 2 RAIL KIT Weight Base 38 lbs 17 25 kg Grinder 84 lbs 38 kg Overall 122 lbs 55 5 kg...

Page 2: ...2 MATWELD INC PHONE 270 444 0085 FAX 270 443 6180 Matweld reserves the right to change parts features or specifications without notice Rev 02 10 ...

Page 3: ...CE MANUALIS ESSENTIALFORANYONE USING OR MAINTAININGTHE TOOL DO NOT OPERATE THE TOOL UNTIL YOU HAVE BEEN THOROUGHLYAND PROPERLY TRAINED OR UNDER THE SUPERVISION OF AN 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 SONAL INJURY OR DAMAGE TO THE TOOL CAN RESULT OPERATORS MUST CLEAR THE WORK AREA O...

Page 4: ...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 HYDRAULIC OIL IS INJECTED UNDER THE SKIN FROM PRESSURE IN THE LINE ALWAYS WEAR GLOVES AND REPAIR ANY LEAKS IMMEDIATELY NEVER CARRY ATOOL BY THE HOSES DO NOT USE DAMAGED EQUIPMENT IMMEDIATELY...

Page 5: ... 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 WORK AREA FOR ANY TRASH WHICH MAY IGNITE FROM SPARKS 9 ALWAYS CHECK THE AREA FOR SMOLDERING TIES OR TRASH BEFORE LEAVING THE SITE 10 WHEN CHANGING STONES FOLLOWALLGRINDING STONE MANUFACTURERS INST...

Page 6: ...orityofoperationssuchasgrindingoutdefectsaswellasgrinding back the profile of the Frog after rebuilding The4 X3 cupstoneisidealforthefinishgrinding radiusprofilingandtogrindinthepointslope Set the base of the Precision Frog Grinder on the Frog centering it on the work area Set the grinder onto the base and lock with the roller clamps With the 1 X 8 stone installed the defect can be ground out or i...

Page 7: ...NDER After welding up the Frog begin to rough grind the surface with the 1 X 8 stone The base of the grinder is stillcenteredforthispurpose For flange way alignment Mark the casting of the Frog with a straight edge and soap stone for reference of original profile Stretch the guide cable from each eye hook on the base to align the base grinder over the straight edge mark ...

Page 8: ...ap stone reference line and cable arealigned Grindtheflangewayfromthebottomup Theangleadjustmentwillbeonapproximatelythe4thnotchfrom vertical 8 notch in this example This may vary depending on the grinding stone wear Startingatthebottomoftheflangewaybegingrindingupward Use the hand wheel to move the stone up or down The crank handles are for adjusting the stone from side to side while rolling the ...

Page 9: ...GRINDER Finish Grinding the Top of Rail With the cup stone installed as position 1 start on either side of the weld repair and set the stone to where it just touches the rail and then run the stone into the weld Grinding the Radius Adjust angle of cup to approximately position 6 to grind radius Grinding the Radius Change angle of cup stone to approximately position 8 ...

Page 10: ... 444 0085 FAX 270 443 6180 Matweld reserves the right to change parts features or specifications without notice Rev 02 10 09200A PRECISION FROG GRINDER CheckGrinding Set angle of cup stone to approximately 3 to complete radius ...

Page 11: ...ht to change parts features or specifications without notice Rev 02 10 Grinding Defect for Head Wash Rail Weld Repair Picture below shows 09295 2 Rail Kit installed Grind Switch Points and Stock Rails 09200A PRECISION FROG GRINDER ADDITIONAL USES OF THE PRECISION FROG GRINDER ...

Page 12: ...FT LOCKING PIN MECHA NISM LOCATED ON THE SIDE OF BEARING HOUSING 4 WHEN THE PIN ENGAGES LOCKING THE SHAFT REMOVE THE NUT HOLDING THE STONE AND FLANGES TO THE SHAFT 5 INSTALL THE NEW STONE BE SURE THAT THE FLANGES HAVE BEEN REPLACED AND THAT THE GRINDING STONE IS EQUIPPED WITH A BLOTTER 6 TIGHTEN THE NUT ON THE SHAFT DO NOT OVER TIGHTEN AS THIS MAY CAUSE THE STONE TO FAIL WHILE IN USE 7 RELEASE THE...

Page 13: ...TONE GUARD 3 ROTATE THE STONE SLOWLY BY HAND WHILE DEPRESSING THE SHAFT LOCKING PIN MECHA NISM LOCATED ON THE SIDE OF BEARING HOUSING 4 WHEN THE PIN ENGAGES LOCKING THE SHAFT CONTINUE DEPRESSING THE LOCKING PIN WHILE TURNING THE 4 CUP STONE BY HAND TO LOOSEN AND REMOVE 5 LEAVE THE BACKING FLANGE IN PLACE AND INSTALL THE NEW CUP STONE MAKE SURE THE NEW CUP STONE HAS A PAPER BLOTTER INSTALLED 6 RELE...

Page 14: ... WITH ANTI WEAR PROPERTIESANDAVISCOSITY INDEX OF OVER 140 WORK FOR A WIDE RANGE OF OPERATING CONDITIONS THE FOLLOWING OILS MEET HTMA SPECIFICATION 5 7 AMOCO RYKON MV CITGOA W ALL TEMP SUNVIS 706 MOBIL D T E 13 CHEVRON EP MV TEXACO RANDO HDAZ OTHER FLUIDS THAT MEET OR EXCEED THIS SPECIFICATION CAN BE USED 5 HAVE TOOL INSPECTED AT LEASTANNUALLY BY MATWELD OR A MATWELD QUALIFIED SER VICE REPRESENTATI...

Page 15: ...UM BACK PRES SURE FOR THEIR HYDRAULIC TOOLS AT 250 PSI BACK PRESSURE MEASURED ON THE RE TURN SIDE OF THE TOOL IS THE FORCE REQUIRED TO GET THE OIL BACK TO THE TANK IN ALMOSTALL CASES THE LOWER THE BACK PRESSURE THE BETTER THE TOOL PERFORMANCE FIRST THE BACK PRESSURE IS SUBTRACTED FROM THE MAXIMUM TOOL PRESSURE TO AR RIVE ATA MAXIMUM TOOL OPERATING PRESSURE FOR EXAMPLE TOOLS WITH 2000 PSI OPER ATIN...

Page 16: ... INC PHONE 270 444 0085 FAX 270 443 6180 Matweld reserves the right to change parts features or specifications without notice Rev 02 10 BASE FRAME ASSEMBLY 09200 PRECISION FROG GRINDER PRODUCED PRIOR TO 08 29 07 ...

Page 17: ...90 00804 01 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 BASE FRAMEASSEMBLY STRUT BEARING CAP BEARING BLOCK FEED ROD FLANGE BEARING 3 4 x 5 8 RAIL CLAMP LH RAIL CLAMP RH CLAMP FEED HANDLE FEED ROD LH FEED ROD DUAL BASEADJUSTMENT KNOB SWIVEL BASE FLAP GUARD 1 4 20 x 3 4 HEX HEAD BOLT 5 16 18 x 3 4 HEX HEAD BOLT 5 16 18 x 2 1 2 HEX HEAD BOLT 5 16 18 JAM NUT ZP 1 2 13 JAM NUT ZP 1 4 20 NU...

Page 18: ...serves the right to change parts features or specifications without notice Rev 02 10 GRINDER HEAD ASSEMBLY 09200 PRECISION FROG GRINDER PRODUCED PRIOR TO 08 29 07 PART 09275 CHAIN REEL THAT IS USED AS THE CABLE GUIDE IS SUPPLIED WITH GRINDER BUT ISN T SHOWN HERE ...

Page 19: ...4 EXT RET RING HD HEIGHTADJ TUBE SEAL HEIGHTADJ BEARING MOTOR SHAFT KEY CRANK HANDLE KNOB HAND WHEEL 1 2 WAVE WASHER SLIDE BEARING HEIGHTADJUSTMENTASSEMBLY HEIGHTADJUSTMENT SHAFT HEIGHTADJUSTMENT SCREW BEARING HOUSING SUPPORT SHAFT ANGLEADJUSTMENTASSEMBLY ANGLE LOCK PLATE 8 STONE GUARDASSEMBLY SUPPORT BLOCK GUARD MOUNT 4 CUPSTONE GUARD ADJUSTABLE HANDLE LOCK KNOB SHAFT SUPPORT SHAFT BLOCK PRESSURE...

Page 20: ...tweld reserves the right to change parts features or specifications without notice Rev 02 10 BASE FRAME ASSEMBLY 09200A PRECISION FROG GRINDER PRODUCED AFTER 08 29 07 13 19 21 7 25 3 5 8 6 5 4 5 20 22 18 17 11 18 12 10 16 9 1 19 14 15 19 2 23 22 18 24 26 ...

Page 21: ...1084 BASE STRUTASSEMBLY BASE FRAME RAIL STRUT BEARING CAP BEARING BLOCK FEED ROD FLANGE BEARING 3 4 x 5 8 RAIL CLAMP RH CLAMP FEED HANDLE FEED ROD RH BASEADJUSTMENT KNOB BASE SUPPORT PAD FLAP GUARD 1 4 20 x 3 4 HEX HEAD BOLT 5 16 18 x 3 4 HEX HEAD BOLT 5 16 18 x 3 HEX HEAD BOLT 5 16 18 x 1 1 4 HEX HEAD BOLT 1 2 13 JAM NUT ZP 1 4 20 NUT INSERT 1 4 SAE FLAT WASHER 5 16 SAE FLAT WASHER 10 24 x 1 4 SE...

Page 22: ...ev 02 10 GRINDER ASSEMBLY 09200A PRECISION FROG GRINDER PRODUCED AFTER 08 29 07 26 19 9 8 12 24 13 14 11 1 10 28 22 34 33 37 32 30 17 29 15 27 16 36 41 18 25 35 2 3 21 4 5 6 7 20 14 31 23 38 PART 09231 06910 ARE SECURED HERE WIT H W ING NUT S NOT E 1 SIDE OF GRINDER IS SHO WN IN EXPLO DED VIEW OPPOSIT E SIDE IS SYMMET RICAL L Y OPPOSIT E ...

Page 23: ...ONTROLVALVE KNOB QUICK DISCONNECT COUPLER QUICK DISCONNECT NIPPLE FLOW CONTROL MANIFOLD FLOW REGULATOR VALVE FLANGE BEARING 3 4 x 5 8 CLAMP FEED HANDLE FLANGED ROLLER WHEEL GRINDER FRAMEASSEMBLY FEED ROD SUPPORT BRACKET CROSS FEED ROD SLIDE ROD GUIDE WHEEL 1 4 20 WING NUT TOGGLE CLAMP SPACER BLOCK DRIVE SHAFT KEY 4 O RING PLUG 1 2 NPT HEX NIPPLE 1 4 20 x 1 1 2 HEX HEAD BOLT 5 16 18 x 2 3 4 HEX HEA...

Page 24: ...Y 57 27 1 2 3 4 22 9 25 41 42 31 49 14 28 6 8 7 5 51 55 50 35 34 26 49 61 33 48 23 47 39 40 10 13 45 58 20 21 16 12 11 10 32 61 49 17 15 43 56 36 29 USED WITH 4 STONE 44 18 60 59 30 52 19 59 46 59 60 24 54 38 54 53 50 37 PART 09275 CHAIN REEL THAT IS USED AS THE CABLE GUIDE IS SUPPLIED WITH GRINDER BUT ISN T SHOWN HERE 09200A PRECISION FROG GRINDER PRODUCED AFTER 08 29 07 ...

Page 25: ... BEARING HEIGHTADJ SEAL HEIGHTADJUSTMENT 5 16 SAE LOCK WASHER CRANK HANDLE KNOB 3 16 SHAFT KEY 1 2 WAVE WASHER SLIDE BEARING HEIGHTADJUSTMENTASSEMBLY HEIGHTADJUSTMENT SHAFT HEIGHTADJUSTMENT SCREW BEARING HOUSING SUPPORT SHAFT SUPPORT SHAFT BLOCK TOP PORT MOTOR BOLT 8 STONE GUARDASSEMBLY 5 16 SAE FLAT WASHER 4 CUPSTONE GUARD FEED RODADJUSTMENT PLATE STONE FLANGE HAND WHEEL SUPPORT BLOCK ANGLEADJUST...

Page 26: ...26 MATWELD INC PHONE 270 444 0085 FAX 270 443 6180 Matweld reserves the right to change parts features or specifications without notice Rev 02 10 09295 2 RAIL KIT ...

Page 27: ...27 MATWELD INC PHONE 270 444 0085 FAX 270 443 6180 Matweld reserves the right to change parts features or specifications without notice Rev 02 10 09200A PRECISION FROG GRINDER DECAL LEGEND ...

Page 28: ...N SUBJECTED TO DELIBERATE DAMAGE SHIPPING DAMAGE NEGLECT TAMPERING BY UNAUTHORIZED PERSONNEL OR DAMAGE BY IM PROPER USE STORAGE OR MAINTENANCE SERIAL NUMBERS MUST NOT HAVE BEEN ALTERED DEFACED OR REMOVED SUCHACTION VOIDS LIMITED WARRANTY EXCLUSIONS TO LIMITED WARRANTY THIS LIMITED WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTY WRIT TEN OR ORAL EXPRESSED OR IMPLIED INCLUDING WITHOUT LIM...

Page 29: ...29 MATWELD INC PHONE 270 444 0085 FAX 270 443 6180 Matweld reserves the right to change parts features or specifications without notice Rev 02 10 09200A PRECISION FROG GRINDER GENERALNOTES ...

Page 30: ...INDERS 09200A PRECISION FROG GRINDER 06000 PROFILE GRINDER 06900 06900A MULTI PURPOSE GRINDER TRIGGER VERSION AVAILABLE 05900 FROG PROFILE GRINDER TRIGGER VERSION AVAILABLE 00700 RAIL SURFACING GUIDE 04600 STRAIGHT STONE CW ROTATION TRIGGER VERSION AVAILABLE 04700 STRAIGHT STONE CCW ROTATION TRIGGER VERSION AVAILABLE 07500 CHAMFER TOOL 04800 CUP STONE GRINDER TRIGGER VERSION AVAILABLE 00600C CUP S...

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