The Matweld "PRECISION FROG GRINDER" (model 09200/09200A) is a hydraulic-powered, track-mounted machine designed for consistent refinishing grinds on railway frogs. It features a precision guide frame with multiple axis adjustment, enabling operators to achieve accurate and consistent results.

Function Description:

The primary function of the Precision Frog Grinder is to perform refinishing grinds on railway frogs. It utilizes a hydraulic power source to drive grinding stones, allowing for precise material removal and shaping. The machine's track-mounted design ensures stability and accurate positioning on the rail. The multiple axis adjustment of the guide frame allows the operator to control the grinding angle and depth, facilitating consistent refinishing grinds.

The grinder is designed to operate with two types of grinding stones:

1" X 8" grinding stone (Part No. 00499): Used for the majority of operations, including grinding out defects and grinding back the profile of the frog after rebuilding.
4" X 3" cup stone (Part No. 09299): Ideal for finish grinding, radius profiling, and grinding in the point slope.

Usage Features:

Setup and Operation:
- The base of the grinder is placed on the frog, centered on the work area.
- The grinder head is then set onto the base and locked with roller clamps.
- For rough grinding after welding, the 1" X 8" stone is used with the grinder base centered.
- For flange way alignment, the frog casting is marked with a straight edge and soapstone to reference the original profile. A guide cable is stretched from eye hooks on the base to align the grinder over the straight edge mark.
- The base is tightened to the frog, ensuring the soapstone reference line and cable are aligned.
- Flange way grinding proceeds from bottom up, with angle adjustment typically around the 4th notch from vertical (though this may vary with stone wear).
- A hand wheel is used to move the stone up or down, and crank handles adjust the stone side-to-side while rolling the grinder across the base.
- For finish grinding the top of the rail, the cup stone is installed (position 1). The stone is set to just touch the rail on either side of the weld repair and then run into the weld.
- Radius grinding involves adjusting the cup stone angle to approximately position 6, then to position 8, and finally to position 3 to complete the radius.
- The manual includes instructions for checking the grinding results.
Additional Uses: The Precision Frog Grinder can also be used to grind switch points and stock rails, and for grinding defects for head wash rail weld repair (with the optional 09295 - 2' Rail Kit).
Stone Changing: Detailed instructions are provided for changing both the 8" grinding stone and the 4" cup stone. This involves disconnecting the power source, loosening hex fasteners and removing the stone guard, rotating the stone while depressing the shaft locking pin mechanism, removing the nut and flanges, installing the new stone with a blotter, tightening the nut (without overtightening), releasing the locking mechanism, and reinstalling the stone guard. Torque settings for stone attachment should refer to manufacturer's specifications.

Important Technical Specifications:

Flow: 10 GPM (38 LPM)
Pressure: 2000 PSI (140 BAR)
Max Back Pressure: 250 PSI (17 BAR)
RPM: 4000
Weight:
- Base: 38 lbs (17.25 kg)
- Grinder: 84 lbs (38 kg)
- Overall: 122 lbs (55.5 kg)
Accessories:
- 00499 - 8 x 1 x 5/8 GRINDING STONE
- 09299 - 4 x 3 x 5/8-11 CUP STONE
- 09295 - 2' RAIL KIT

Maintenance Features:

Daily Checks: The tool should be checked daily for proper operation, leaks, or damage. Hoses should be inspected daily for cuts, burns, or other damage and replaced if necessary. Quick disconnect couplers must be kept clean and lubricated.
Hydraulic Fluid: Use hydraulic fluids that comply with HTMA Specification 5.7, with a viscosity between 100 and 400 SSU (20-82 Centistoke) at operating temperatures. Petroleum-based hydraulic fluids with anti-wear properties and a viscosity index over 140 are recommended for a wide range of conditions. A list of suitable oils (AMOCO RYKON MV, SUNVIS 706, CHEVRON EP-MV, CITGO A/W ALL TEMP, MOBIL D.T.E. 13, TEXACO "RANDO" HDAZ) is provided.
Annual Inspection: The tool should be inspected at least annually by Matweld or a qualified service representative to determine if safety changes or worn part replacements are needed.
Service Bulletins: Matweld should be contacted periodically, at least annually, for service bulletins, safety notices, or other important information.
Cold Weather Operation: Hydraulic system performance is affected below 50°F. Measures should be taken to pre-warm tools and fluids before operating in cold weather.

Safety Precautions:

The manual emphasizes several safety precautions:

Operators and maintenance personnel must always comply with safety precautions in the manual and on tool stickers/tags.
Thorough training and supervision are required before operating the tool.
Power source flow and pressure must be checked daily, and never exceeded.
The work area must be clear of nonessential personnel and potential ignition sources (sparks, smoldering ties/trash).
Operators must be familiar with prohibited work areas (unsafe grades, poor footing, overhead hazards).
Maintain balance and proper footing at all times; avoid overreaching.
Assume electrical conductors are energized; use nonconductive hoses.
Avoid operating at excessive fluid temperatures to prevent burns.
Never wear loose clothing that can get entangled in moving parts.
Hydraulic tools exert high torque and force, requiring careful use to prevent serious injury or death.
All repair, maintenance, or service must be performed by authorized and properly trained personnel.
Always wear appropriate safety equipment: oil injection resistant work gloves, safety glasses, safety boots, ear protection.
Do not clean, inspect, or repair the tool while connected to the power source.
Be aware of oil injection hazards; wear gloves and repair leaks immediately. Never carry the tool by the hoses.
Immediately replace damaged equipment (hoses, fittings, components showing wire braid, nicks, cuts, abrasions).
Clean up oil or fluid spills immediately.
Supervisors should add additional precautions for specific work areas and local regulations.
Never change stones or carry the grinder with the power source in the "ON" position.
Never touch or try to stop a moving stone.
When changing stones, follow grinding stone manufacturers' instructions and use stones complying with ANSI standards. Run new stones for one minute at full speed to check for defects or vibration.
Be aware of hydraulic oil flash point (approx. 450°F); keep hoses clear of sparks and hot debris. Have another person near hydraulic power source controls for emergency shutdown.

Matweld 09200 - Page 2

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