Tri Tool 404, 424 User Manual
TM
Model KEYMASTER
92-0767 Rev. 990427
TABLE OF CONTENTS
CUSTOMER MESSAGE Inside Front Cover
SAFETY PRECAUTIONS 3
GENERAL DESCRIPTION 6
SPECIFICATIONS 7
MAINTENANCE 8
OPERATION 9
END MILLS 12
TROUBLE SHOOTING 13
ILLUSTRATED PARTS BREAKDOWN 15
TOOL BIT RESHARPENING POLICY Inside Back Cover
WARRANTY INFORMATION Inside Back Cover
Copyright 2006
Proprietary property of TRI TOOL Inc.
No reproduction, use, or duplication of the information
shown hereon is permitted without the express written
consent of TRI TOOL Inc.
SAFETY PRECAUTIONS
IN GENERAL
When using rotating head cutting equipment, basic safety precautions should always
be followed to reduce the risk of personal injury.
Operate this tool only in accordance with specific operating instructions.
Do not override the deadman switch on the power unit. Locking down, ob-
WARNING:
DRESS CONSIDERATIONS
structing, or in any way defeating the deadman switch on the power drive unit
may result in serious injury.
Model KEYMASTER
TM
Use standard safety equipment. Hard hats, safety shoes, safety harnesses, protective clothes, and other safety devices should always be used when appropriate.
Use safety glasses. Do not operate cutting tools without eye protection.
Dress properly. Do not wear loose clothing or jewelry. They can be caught in rotating and moving parts. Avoid slippery floors or wear nonskid footwear. If you have
long hair, wear protective hair covering to contain it.
WORK AREA
Keep the work area clean. Cluttered work areas and benches invite injuries.
Consider the work area environment. Keep the area well lit. Keep electrical cords,
cables, rags, rigging straps, etc. clear of rotating equipment. Do not use power-cutting
tools in the presence of flammable liquids and gasses.
Keep visitors away. Do not let visitors or untrained personnel at or near operating
tools. Enforce eye protection requirements for all observers.
Do not over reach. Keep proper footing at all times.
Stay alert. Watch what you are doing. Use common sense. Do not operate tools
when you are tired.
92-0767 : Rev. 990427
3
TRI TOOL INC.
TOOL CARE
Maintain tools with care. Keep tools in good operating condition. Sharp tool bits
perform better and safer than dull tool bits. Well maintained tools function properly
when needed.
Check for damaged parts. If a tool has malfunctioned, been dropped or hit, it must
be checked for damage. Run no-load tests and feed function checks. Do a complete visual inspection.
Electric motors. Use only with proper AC voltage power sources and observe all
normal electric shock hazard procedures.
Do not abuse power and control cords. Pulling or running over cords and cables
can result in electrical shock hazards and malfunctions. Keep control and power
cords out of all cutting fluids and water.
Hydraulic drives. Observe proper procedures for electrically driven power sources.
Avoid damage to hydraulic lines. Keep quick-disconnects clean. Grit contamination
causes malfunctions.
Air tools. Check the exhaust muffler. Broken or damaged mufflers can restrict air
flow or cause excessive noise. Use air motors only with a filtered, lubricated and
regulated air supply. Dirty air, low-pressure air or over pressure air will cause malfunctions, including delayed starting.
AREA EQUIPMENT
Secure work. Whenever possible use clamps, vises, chains and straps to secure
pipe.
Make sure the tool is secured; it is safer to have both hands free to operate the tool.
TOOL USE
Use the right tool and tool bit for the job. Do not use a tool, which is incorrect for the
job you are doing.
Keep the tool bits fully engaged in the tool bit holders. Loose bits are a safety hazard.
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92-0767 : Rev. 990427
Model KEYMASTER
Disconnect power supply during setup and maintenance. Use all ‘Stop’ or Shut off’
features available when changing or adjusting tool bits, maintaining the tool, or when
the tool is not in use.
Remove adjusting keys and wrenches before applying power to the equipment.
Develop a habit of checking the tool before turning it on to make sure that all keys
and wrenches have been removed.
Do not force tools. Tools and tool bits function better and safer when used at the
feed and speed rate for which they were designed.
Do not reach into rotating equipment. Do not reach into the rotating head stock to
clear chips, to make adjustments, or to check surface finish. A machine designed to
cut steel will not stop for a hand or an arm.
Handle chips with care. Chips have very sharp edges and are hot. Do not try to pull
chips apart with your hands; they are very tough.
TM
Avoid unintentional starts. Do not carry or handle tools with your hand on the operating switches or levers. Do not lay the tool down in a manner that will start the
drive. Do not allow the tool to flip around or move when adjusting or changing tool
bits.
Store idle tools properly. Disconnect tools from the power source and store in a safe
place. Remove tool bits for safe handling of the tool.
92-0767 : Rev. 990427
5
TRI TOOL INC.
GENERAL DESCRIPTION
The Model 424 Keyway Cutter is designed to mill 1/4” (6.35 mm) to 1 1/4” (31.75 mm)
wide by up to 6” (152.4 mm) long keyway slots in 1 1/2” (38.1 mm) to 24” (609.6 mm)
diameter shafts.
The cutter may be used to install new keyways, re-cut keyways after being weld
repaired, or install second keyways to byp ass a damaged keyway.
The tool uses a Vee block system to auto align and center the tool to the shaft, for shaf t
sizes up to 4 1/2” (1 14.3 mm).
The tool mounts with a fixed bottom clamp bar .
For larger shaft sizes a system of spacers and chain clamps are included.
The tool incorporates a graduated depth of cut system and a mechanism to shift the
cutter off center to allow milling the sides of the keyway with a light finish cut for optimum
width precision and surface finishes.
With this system the keyway width is not dependent on the mill cutter dimensions. For
example, a 3/8” (9.5 mm) mill cutter can be used to cut up to a 5/8” (15.88 mm) wide
key slot.
Provisions are incorporated to allow use of a dial indicator for adjustments and to verify
the setting accuracy .
Axial feed is provided for by a manual ratchet system.
The Model 424 uses standard 1/2” (12.70 mm) shank mill cutters and is provided with a
collet reducer bushing to allow use of 3/8” shank mill cutters.
The KEYMASTERTM comes in a custom fitted carrying/storage case, a selection of end
mills [1/4” (6.35 mm) to 1” (25.40 mm) in 1/4” (6.35 mm) increments] and clamping
systems for 1 1/2” (38.1 mm) to 24” (609.6 mm) diameter shafts.
The standard drive motor is a variable speed 1 HP 1 15 V olt AC motor .
6
NOTE:
1/8” increments for End Mills are available.
92-0767 : Rev. 990427
Model KEYMASTER
SPECIFICATIONS
Minimum Axial Shaft Clamp Length: 1” (25.4 mm)
Shaft Diameter Range: 1 1/2” to 24” diameters (38.1 mm to 609.6 mm)
Motor Power Requirements: Variable speed, 1 HP, 115 VAC, 10.2 Amps
Speed Control: Variable speed control in motor
Weight: 61 lbs. (27.67 kg)
Axial Feed Travel: 5 1/2” (139.7 mm)
Vertical Feed Travel: 2" (50.8 mm)
TM
POWER DRIVE OPTIONS
The Model 424 can be supplied with a pneumatic motor or a 230 VAC, 50/60 Hz
electric motor.
Envelope, Model KEYMASTER
TM
92-0767 : Rev. 990427
7
TRI TOOL INC.
All components should be cleaned and coated with a light film of oil prior to use.
Use a clean, non-detergent oil, preferably SAE 10 (90 SSU) or lighter.
The air supply for the KEYMASTERTM with an Air Motor should include an adequate
filter, regulator and lubricator (FRL).
MAINTENANCE
NOTE:
If the KEYMASTERTM is operated in the vertical position (End Mill up), it should be
turned upside down and the chips and/or other debris removed after each keyway has
been completed.
NOTE:
NOTE:
The Air motor warranty is void if damage occurs from contaminated air or lack of
lubrication.
Tool life may be severely shortened, unless chips and/or other debris that have
been deposited on the Base Clamp/Rails during the machining operation are
removed.
Disassembly of the KEYMASTERTM will void the warranty, except when
performed by a TRI TOOL Inc. designated repair technician.
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92-0767 : Rev. 990427
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