Tri Tool 648RBL User Manual
TABLE OF CONTENTS
CUSTOMER MESSAGE Inside Front Cover
SAFETY PRECAUTIONS 3
92-1238 Rev. 070126
Model 648RBL Low Profile Clamshell
GENERAL DESCRIPTION 6
SPECIFICATIONS 7
MAINTENANCE 9
OPERATION 16
CUTTING SPEEDS AND FEEDS 25
TOOL BITS 26
TROUBLE SHOOTING 33
ACCESSORIES 35
ILLUSTRATED PARTS BREAKDOWN 36
TOOL BIT RESHARPENING POLICY Inside Back Cover
WARRANTY INFORMATION Inside Back Cover
Copyright 2007
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 648RBL Low Profile 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 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, and etc. clear of rotating equipment. Do not use powercutting 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.
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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 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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92-1238 : Rev. 070126
Model 648RBL Low Profile 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 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.
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.
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TRI TOOL INC.
GENERAL DESCRIPTION
The Model 648RBL Low-Profile Clamshell is a four piece split-frame pipe lathe
designed for severing and beveling in-line pipe with a minimum range of 42” through
48” pipe with minimal radial and axial clearance.
Using extended Tool Blocks the Model 648RBL may be configured to perform the
following operations.
• Sever in-line pipe.
• Sever and bevel in-line pipe.
• Sever and double bevel in-line pipe.
DESIGN AND OPERATING FEATURES
The easily adjustable precision 90° Vee Bearing pre-load and stabilize the rotating
head to provide long life, low maintenance, stability and precision.
The Clamshell splits into four (4) quarters for mounting on closed loop systems.
All parts are secured to the four (4) quarters, thus avoiding the loss of parts and at
the same time providing maximum ease of handling.
The Clamshell is equipped with Jackscrews and Adjustable Mounting Pads for outof-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 .004” (.10 mm) 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 sealed
to provide protection from dust and chips.
The operator’s controls are located away from the rotating Headstock for the
operator’s safety.
A Modular design concept provides quick, easy maintenance and maximum
versatility in the drive and tooling options.
Two (2) detachable Motors provide maximum handling ease and low axial clearance.
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92-1238 : Rev. 070126
WEIGHT
900 lbs (Less Motor)
Envelope Drawing
SPECIFICATIONS
Model 648RBL Low Profile Clamshell
"
9.39
(238.5 mm)
"
7.82
(198.6 mm)
"
36.18
(919.0 mm)
" Dia
60.00
(1524.0 mm)
Rotation
Nominal
Sever Line
50.00" Dia.
(1270.0 mm)
"
5.14
(130.6 mm)
Basic Machine Width
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TRI TOOL INC.
CUTTING CAPACITIES ON 42” THROUGH 48” PIPE
NOTE: Capacity may exceed the maximum wall thickness for small pipe
sizes.
Severing with Standard Procedures
2.50” (63.5 mm) wall
Severing and Single Beveling
1.25” (31.8 mm) wall
Severing and Double Beveling
1.25” (31.8 mm) wall
Severing and Beveling with Special Procedures
2.00” (50.8 mm) wall
CLEARANCES
Main Frame Diameter
60.00” (1524.0 mm)
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92-1238 : Rev. 070126
Model 648RBL Low Profile Clamshell
MAINTENANCE
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.
NOTE:
Clean-Up
The motor warranty is void if damage occurs from contaminated hydraulic
fluid or air supply.
If the Clamshell is operated in such a manner that the tool blocks collect
debris while cutting, the tool blocks and the feed screws should be cleaned
after each cutting operation.
RECOMMENDED MAINTENANCE SCHEDULE
Daily
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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TRI TOOL INC.
Every 20 Hours
Lubricate the male and female tool block slides and the feed screw.
Every 40 Hours
Thoroughly clean and lubricate main gear, drive gear, male and female tool
slides, feed screws, and tripper block assembly.
NON-SCHEDULED
Thoroughly clean and check the tool blocks in the event of feed problems.
Readjust the 90° Vee bearings if the Headstock becomes loose on the Clamshell.
STORAGE
When the Clamshell is to be stored or if it will remain out of service for a significant
period of time, 30 days or more, it should be thoroughly cleaned, lubricated and
sprayed with a rust preventative prior to storage.
ADJUSTMENT OF THE 90° VEE BEARINGS PRE-LOAD
Adjustment is done without the drive housing(s) attached.
Loosen all of the bearing lock screws and adjustment eccentric nuts about 1/4 turn.
Turn the four (4) bearing adjustment eccentric nuts in so that they are snugged
tightly.
The OD of the gear is centered with the OD of the housing.
Lightly turn in the remaining bearing adjustment eccentric nuts until all of the
bearings make contact with the Headstock.
The safe torque range on the bearing adjustment eccentric nuts is 1 in-lbs (.1
N m) to 3 in-lbs (.3 N m).
Relax the four (4) bearing adjustment eccentric nuts and resnug them so that all of
the bearings are evenly loaded against the gear race.
NOTE:
10
Overtightening the bearing adjustment eccentric nuts will result in accelerated
bearing wear and lower available power.
92-1238 : Rev. 070126
Bearing Adjustment Screw Locations
Model 648RBL Low Profile Clamshell
INSPECTION OF THE MAIN GEAR
When the Headstock does not run smoothly, even after adjustment, inspect the Main
Gear to ensure that no chips, dirt or dust have damaged the gear.
DRIVE GEAR AND MAIN GEAR LUBRICATION
Remove the Drive Housings.
Inspect both Drive and Main Gears for chips or burrs and clean as required.
Coat the teeth of the Drive and Main Gears with a grease that is approved by TRI
TOOL INC.
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TRI TOOL INC.
For further information see 'Lubricant Recommendations'.
TOOL BLOCK MAINTENANCE
Clean the Slide Rails, the Feed Nut, the Sprocket Assembly and the Feed Screw.
Inspect these parts for damage and replace as required.
LUBRICATE AND REASSEMBLE THE TOOL BLOCK
Use lubricant on the Feed Screw sparingly or wipe to a film condition.
Excess lubricant will collect grit and/or chips and tend to cause thread
jamming and/or damage.
Tool Block Assembly
NOTE:
12
Adjust the adjustable slide rail to provide a firm, but not excessive rotational
pressure on the sprocket.
The Slide Rails must be over-tightened to squeeze the oil into a thin film
against the male and female surfaces of the Slide Rails.
Reset for proper operation.
When the mounting bracket has been overstressed, the Slide Rails may
appear to loosen when mounted if they were adjusted off of the Clamshell.
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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.
Tool Holder Adjustment
Model 648RBL Low Profile Clamshell
Adjust only those screws that bear directly in-line with the Tool Holder.
Tighten the Hold Down Screws to about 12 in-lbs (1.4 N m) to 24 in-lbs (2.7 N m).
Finger tight using a Hex Key.
Using the Hex 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.
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TRI TOOL INC.
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 with some resistance.
In, general when the Slide Rail is set correctly, teh 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 2 ft-lbs (2.7 N m) to 5 ftlbs (6.8 N m).
TRIPPER BLOCK ASSEMBLY LUBRICATION AND TRIPPER SHAFT ADJUSTMENT
Back off the half dog set screw until it disengages from the tripper shaft.
Remove the tripper shaft assembly from the block and clean off all of the old
lubrication.
Apply a fresh lubrication to the tripper shaft assembly. and reinstall it in the block.
Tripper Shaft Installation
Screw in the half dog set screw until it locates itself in the slot on the tripper shaft.
LUBRICANT RECOMMENDATIONS
The drive gears require a high string lubrication grease such as 'Chevron Utility
Grease, light
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92-1238 : Rev. 070126
Model 648RBL Low Profile Clamshell
The slide rails and tool blocks require a light oil such as SAE 10 light machine oil.
The feed screw for the tool block and the tripper block assembly require a SAE 10
light machine oil for normal conditions, and under dusty conditions a silicone,
graphite or molybdenum disulfide ‘dry’ lubricant.
A light film of all-purpose grease may be used, but it must be checked for grit
contamination frequently.
LUBRICANT RECOMMENDATIONS FOR HYDRAULIC MOTORS
The bearings in the hydraulic motors are sealed and do not require any lubrication.
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TRI TOOL INC.
OPERATION
Read the ‘Operation’ section carefully before attempting to operate the Model
648RBL Low Profile Clamshell.
CONFIGURE THE CLAMSHELL FOR THE SPECIFIC TASK REQUIRED
Mount the Tool Blocks and Tripper Bracket onto the Clamshell.
Select and install the proper Clamping Pad Set into the Clamshell.
Do not install the Tool Bits until the Clamshell has been installed on the pipe.
INSTALLATION OF THE CLAMSHELL ON AN IN-LINE PIPE
Separate the Clamshell into two (2) halves or four (4) quarters.
Locking Screw Locations
Rotate the Headstock until the split-lines of the Headstock match the split-lines of
the Housing.
Unbolt the Red Lock Blocks attached to the Headstock, flip them over and re-attach
them with the Dowel Pin going through the Headstock and into the Housing.
16
This is to prevent the Headstock from rotating out of the Housing while the
Clamshell is split in half.
Unbolt the Clamshell.
92-1238 : Rev. 070126
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