Tri Tool 602-5SBM User Manual
TABLE OF CONTENTS
CUSTOMER MESSAGE Inside Front Cover
SAFETY PRECAUTIONS 3
GENERAL DESCRIPTION 6
SPECIFICATIONS 8
92-0093 Rev. 131230
Model 602.5SBM, Low Prole Clamshell
MAINTENANCE 10
OPERATION 20
CUTTING SPEEDS 29
CLAMPING PAD SETS 30
TOOL BITS 31
TOOL BLOCKS 37
TROUBLESHOOTING 38
ACCESSORIES 41
ILLUSTRATED PARTS BREAKDOWN 42
SPARE PARTS 53
TOOL BIT RESHARPENING POLICY Inside Back Cover
WARRANTY INFORMATION Inside Back Cover
Copyright 2013
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 specic 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 602.5SBM, Low Prole Clamshell
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 rotat-
ing and moving parts. Avoid slippery oors or wear nonskid footwear. If you have
long hair, wear protective hair covering to contain it.
WORK AREA
Keep the work area clean. Consider the work area environment. Keep the area
well lit. Keep electrical cords, cables, rags, rigging straps, and etc. clear of rotating
equipment. Do not use power-cutting tools in the presence of ammable 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.
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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 uids 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 mufer. Broken or damaged mufers can restrict
air ow or cause excessive noise. Use air motors only with a ltered, 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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92-0093 Rev. 131230
Model 602.5SBM, Low Prole Clamshell
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 nish. 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 are hands; they are very tough.
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 ip 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.
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TRI TOOL INC.
GENERAL DESCRIPTION
The Model 602.5SBM Low-Prole Clamshell is a split-frame pipe lathe designed for
severing and beveling in-line pipe with a minimum range of 1” pipe through 3” tube
with minimal radial and axial clearance.
Using standard Tool Blocks the Model 602.5SBM may be congured to perform the
following operations:
Sever in-line pipe.
Sever and bevel in-line pipe.
Sever and double bevel in-line pipe.
Do socket weld removal.
DESIGN AND OPERATION FEATURES
The easily adjustable precision bearing surfaces pre-load and stabilize the rotating
head to provide long life, low maintenance, stability, and precision.
The Clamshell splits into two halves for mounting on closed loop systems.
All parts are secured to the two halves, thus avoiding the loss of parts and at the
same time providing maximum ease of handling.
The Clamshell may be equipped with self-centering Clamping Pads for quick, easy
mounting or may be equipped with Adjustable Clamping Pads for out-of-round pipe
conditions.
Dual Tool Blocks with Auto-feed Sprockets and Adjustable Slides provide maximum
maintainability, life, and operator safety, with a minimum of operator training.
The Auto-feed Sprockets provide .003” (.08mm) of radial feed per revolution of the
Headstock for a controlled depth of cut.
The drive gears and bearing surfaces are covered for operator safety and are
shielded to provide protection from dust and chips.
The operator’s controls are located away from the rotating Headstock for the
operator’s safety.
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92-0093 Rev. 131230
Model 602.5SBM, Low Prole Clamshell
A modular design concept provides quick, easy maintenance and maximum
versatility in the drive and tooling options.
A detachable right angle Air Motor provides maximum handling ease and low axial
clearance.
92-0093 Rev. 131230
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TRI TOOL INC.
HEIGHT
106
MACHINE
SPECIFICATIONS
Model 602.5SBM with the standard Air Motor.
Weight: 29 lbs. (13 kg)
Power Requirements: 55 cfm at 90 psi (26 lt/sec at 6.3 kg/cm3) with the standard
Air Motor.
Envelope, Model 602.5SBM Clamshell
548.3
21.59
4.17 773.03
88.9
3.50
253.3
9.97
MAX
ROTATION
NOMINAL
SEVER
LINE
174.6
6.88
79.6
3.14
50.8
2.00
BASIC
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92-0093 Rev. 131230
Model 602.5SBM, Low Prole Clamshell
Capacity exceeds the maximum wall thickness for small pipe sizes.
NOTE:
CUTTING CAPACITIES ON 1" PIPE THROUGH 3" TUBE
Low Prole Tool Blocks StandardTool Locks
Severing with standard procedures .40" wall (10.2 mm) .63" wall (16.0 mm)
Severing with special procedures .80" wall (20.3 mm) 1.25" wall (31.8 mm)
Severing and single beveling .40" wall (10.2 mm) .63" wall (16.0 mm)
Severing and double beveling .26" wall (6.6 mm) .40" wall (10.2 mm)
CLEARANCES
Rotating parts diameter 6.95" (176.5 mm) 6.87" (174.5 mm)
Main Frame diameter 6.87" (174.5 mm) 6.87" (174.5 mm)
Axial clearance required relative to
Center-line of the cut mounting side
Side opposite of the frame .63" (16.0 mm) .63" (16.0 mm)
2.51" (63.8 mm) 3.50" (88.9 mm)
RADIAL CLEARANCE OVER THE TUBE OR PIPE
Pipe Size True Diameter Clearance Low
Prole Tool Blocks
3.000" 76.2 mm 1.97" 50.0 mm 1.94" 49.3 mm
2 1/2" 2.875" 73.0 mm 2.04" 51.8 mm 2.00" 50.8 mm
2" 2.375" 60.3 mm 2.29" 58.2 mm 2.25" 57.2 mm
1 1/2" 1.900" 48.3 mm 2.52" 64.0 mm 2.49" 63.2 mm
1 1/4" 1.660" 42.2 mm 2.65" 67.3 mm 2.61" 66.3 mm
1" 1.315" 33.4 mm N/A N/A 2.78" 70.6 mm
Clearance Standard
Tool Blocks
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TRI TOOL INC.
MAINTENANCE
All components should be cleaned and coated with a light lm of oil prior to use. Use
a clean, non-detergent oil, preferable SAE 10 (90 SSU) or lighter.
Air supply for the Model 602.5SBM Clamshell with an Air Motor requires an
adequate lter/regulator/lubricator (FRL) to be used.
The Motor warranty is void if damage occurs from contaminated air or lack of
NOTE:
lubrication.
Clean Up
If the Clamshell is operated in such a manner that the Tool Blocks collect debris
while cutting, the Tool Blocks and the Feed Screw should be cleaned after each
cutting operation.
RECOMMENDED MAINTENANCE SCHEDULE
Daily maintenance when the unit is in operation
Wipe the unit down and spray with rust preventative under severe humidity
conditions.
Visually inspect for loose screws, missing screws, damage, etc.
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92-0093 Rev. 131230
Model 602.5SBM, Low Prole Clamshell
After every 20 hours of actual operation
Check adjustment of the Main Bearing pre-load.
Drive torque as measured at the Drive Socket should be 5 to 10 ft-lbs. (7 to
14 N-m).
Lubricate the male and female Tool Block Slides and the Feed Screw. Refer
to the Tool Block Maintenance located later in this section.
After every 40 hours of actual operation
Thoroughly clean and lubricate Main Gear, Drive Gear, male and female Tool
Slides, Feed Screws, and Tripper Block Assy.
Non-scheduled maintenance
Readjust the Main Bearing pre-load if the Clamshell generates excessive
heat or if the Main Bearing becomes loose. Refer to the Adjustment of the
Main Bearing pre-load.
Thoroughly clean and check the Tool Blocks in the event of feed problems.
STORAGE
If the Clamshell is to be stored or if it will remain out of service for a signicant
period of time (30 days or more), it should be thoroughly cleaned lubricated and
sprayed with a rust preventative prior to storage.
Remove the airline Quick Disconnect and spray it with a lightweight oil.
Squirt oil into the male Quick Disconnect.
Reconnect the airline and turn on the Air Motor for 1 or 2 seconds to disperse oil
throughout the vanes and rotor.
ADJUSTMENT OF THE MAIN BEARING PRE-LOAD
Loosen all Bearing Adjustment Lock Screws (A through F).
Loosen all Bearing Adjustment Set Screws about ½ turn. (1 through 12).
Turn in Bearing Adjustment Set Screws (1, 4, 7, and 10) so that they are snugged
tightly. This insures that the Bearing is fully pushed forward. Refer to the Bearing
Adjustment Screw locations.
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TRI TOOL INC.
Lightly turn in the remaining Bearing Adjustment Set Screws in the order shown until
they all touch the Bearing.
Relax Bearing Adjustment Set Screws (1,4,7, and 10) and resnug them so that all of
the Bearing Adjustment Set Screws are evenly loaded against the Bearing.
Connect the air supply and apply power to the Clamshell so that it is running at full
speed.
Adjust the SetScrews (1 through 12) so that the Clamshell rotation slows slightly.
Listen for a change in the sound of the Air Motor. Refer to the Bearing Adjustment
Screw locations for the recommended sequence.
Adjust the SetScrews in small increments so that the bearing is loaded evenly.
All of the SetScrews should be snugged to ensure that the bearing is uniformly
loaded.
Drive torque as measured at the drive socket should be 5 to 10 ft-lbs. (7 to 14 N-m).
The safe torque range on the Bearing Adjustment Set Screws is 1 to 3 in-lbs. (.1 to
.3 N-m).
Bearing Adjustment Screw locations
E
10
11
F
12
1
9
8
D
7
6
12
A
C
2
3
B
4
5
92-0093 Rev. 131230
Model 602.5SBM, Low Prole Clamshell
Over-tightening the Bearing Adjustment Set Screws will result in accelerated bearing
wear and lower available power.
Lock the Bearing pre-load by tightening the Bearing Adjustment Lock Screws (A
through F).
The safe torque should be 6 to 10 ft-lbs. (11 to 14 N-m).
Too much torque may crack the Bearing while too little torque may allow the
WARNING:
Bearing pre-load to relax.
INSPECTION OF THE MAIN GEAR
If the Headstock does not run smoothly, even after adjustment, inspect the main
gear to insure that no chips, dirt or dust has damaged the gear.
Remove both of the front Thrust Plates by removing the eight (8) Hold Down
Screws.
Lift the Headstock from the Housing. Refer to the Clamshell cross section.
The Main Gear and the Main Bearing may now be inspected.
Check the Bearing, Housing, and the race on the Gear.
All surfaces should be smooth, without scratches, and they should feature even
wear patterns over the entire surface.
Check the Housing cavity for chips, dirt and/or corrosion.
To reassemble, wipe clean all of the Bearing surfaces and clean the Housing cavity.
Re-grease the Gear using a lubricant approved by Tri Tool. Refer to the Lubricant
Recommendations located later in this section.
Place the Headstock carefully back into the Housing.
Bolt the Front Thrust Plates back into place.
If the bearing pre-load was properly adjusted before disassembly, then it will still be
adjusted when reassembled.
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13
TRI TOOL INC.
GEAR
BEARING
HOUSING
Clamshell Cross Section
HEADSTOCK
SEVER
LINE
THRUST
PLATE
RACE
THRUST
PLATE
HOLD-DOWN
SCREWS
HOUSING
CAVITY
MAIN
MAIN
DRIVE GEAR AND MAIN GEAR LUBRICATION
Remove the Drive Housing.
Inspect both Drive and Main Gears for chips or burrs and clean as required.
Coat the teeth of the Drive Gear and the Main Gear with a grease which is approved
by Tri Tool. Refer to the lubricant recommendations located later in this section.
TOOL BLOCK MAINTENANCE
Clean the Slide Rails, the Feed Nut, the Sprocket Assy. and the Feed Screw.
Inspect these parts for damage and replace as required.
Lubricate and reassemble the Tool Block. Refer to the picture Tool Block Assembly.
NOTE:
Use lubricant on the Feed Screw sparingly or wipe to a lm condition.
Excess lubricant will collect grit and/or chips and tend to cause thread jamming
and/or damage.
Adjust the adjustable Slide Rail to provide a rm, but not excessive rotational
pressure on the sprocket.
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92-0093 Rev. 131230
Tool Block Assembly
Model 602.5SBM, Low Prole Clamshell
The Slide Rails must be over-tightened to squeeze the oil into a thin lm against the
male and female surfaces of the Slide Rails.
Reset for proper operation.
If the Mounting Bracket has been overstressed, the Slide Rails may appear
NOTE:
to loosen when mounted if they were adjusted off of the Clamshell.
Adjustment when mounted provides the most satisfactory results.
TOOL HOLDER ADJUSTMENT
Loosen the Hold-down Screws on the Adjustable Slide Rail.
Run the Tool Holder to the most outward position.
Using the Adjustment Set Screws, apply a light force to the side of the Adjustable
Slide Rail so that it is in positive contact with the Tool Holder.
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TRI TOOL INC.
Tool Holder Adjustment
Adjust only those screws, which bear directly inline with the Tool Holder.
Tighten the Hold down Screws to about 12 to 24 in-lbs. (1.4 to 2.7 N-m). (Finger tight
using a hex key)
Using the Spanner Wrench, run the Tool Holder to the inward most position.
Note any changes in the feed pressure.
Adjust the remaining Adjustment Set Screws so that the Tool Holder has a smooth,
even feel.
Run the Tool Holder the full length of the Slide Rail.
Tightly lock the Adjustable Slide Rail in place with the Hold-down Screws and fully
snug the Adjustment Set Screws.
Check that the Tool Holder runs smoothly and evenly for the full length of travel.
Readjust as necessary.
The Tool Holder should move snugly.
In general, when the Slide Rail is set correctly, the Feed Sprocket cannot be turned
by hand but may be turned easily with the spanner wrench.
The torque on the Spanner Wrench should be about 1 to 3 ft-lbs. (1 to 4 N-m).
16
92-0093 Rev. 131230
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