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Transmate TapMate XL-424, Operating Manual

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Transmate TapMate XL-424 Operating Manual Download Page 42

42

TAPMATE

™

 XL-424  TRAVEL CHARTS

14

16

18

20

24

30

36

15.30

17.40

19.50

21.60

25.80

32.00

38.30

DR 51

 18.74 ~ 18.63

20.75 ~ 20.63

24.79 ~ 24.65

30.75 ~ 30.57

36.80 ~ 36.59

DR 41

14.55 ~ 14.45

16.55 ~ 16.43

18.55 ~ 18.41

20.55 ~ 20.40

24.54 ~ 24.37

30.44 ~ 30.22

36.43 ~ 36.17

DR 32.5

14.36 ~ 14.25

16.33 ~ 16.20

18.30 ~ 18.16

20.27 ~ 20.11

24.21 ~ 24.02

30.03 ~ 29.79

35.94 ~ 35.66

DR 25

14.08 ~ 13.93

16.01 ~ 15.84

17.94 ~ 17.75

19.87 ~ 19.66

23.74 ~ 23.49

29.44 ~ 29.13

35.24 ~ 34.87

DR 21

13.84 ~ 13.67

15.74 ~ 15.54

17.64 ~ 17.42

19.54 ~ 19.30

23.34 ~ 23.05

28.95 ~ 28.59

34.65 ~ 34.21

DR 18

13.60 ~ 13.40

15.47 ~ 15.13

17.33 ~ 17.07

19.20 ~ 18.91

22.93 ~ 22.59

28.44 ~ 28.02

DR 14

13.11 ~ 12.85

14.91 ~ 14.62

17.10 ~ 16.77

DR 51

5/8"

3/4"

3/4"

7/8"

1"

DR 41

3/4"

3/4"

3/4"

7/8"

7/8"

1"

1-1/4"

DR 32.5

3/4"

7/8"

7/8"

1"

1-1/8"

1-1/4'

1-1/2"

DR 25

1"

1"

1-1/8"

1-1/4"

1-3/8"

1-5/8"

1-7/8"

DR 21

1-1/8"

1-1/4"

1-1/4"

1-3/8"

1-5/8"

1-7/8"

2-1/4"

DR 18

1-1/4"

1-3/8"

1-1/2"

1-5/8"

1-7/8"

2-1/8"

DR 14

1-1/2"

1-5/8"

1-5/8"

DR 51

7/8"

7/8"

1"

1"

1-1/8"

DR 41

1"

1"

1"

1"

1-1/8"

1-1/4"

1-3/8"

DR 32.5

1-1/8"

1-1/8"

1-1/8"

1-1/8"

1-1/4"

1-3/8"

1-5/8"

DR 25

1/1/4"

1-3/8"

1-3/8"

1-3/8"

1-1/2"

1-3/4"

2"

DR 21

1-1/2"

1-1/2"

1-1/2"

1-5/8"

1-3/4"

2"

2-3/8"

DR 18

1-5/8"

1-3/4"

1-3/4"

1-7/8"

2"

2-3/8"

DR 14

1-7/8"

2"

1-7/8"

DR 51

1-1/4"

1-1/4"

1-1/8"

1-1/4"

1-1/4"

DR 41

1-1/2"

1-1/2"

1-3/8"

1-3/8"

1-3/8"

1-3/8"

1-1/2"

DR 32.5

1-5/8"

1-5/8"

1-1/2"

1-1/2"

1-1/2"

1-5/8"

1-3/4"

DR 25

1-7/8"

1-3/4"

1-3/4"

1-3/4"

1-7/8"

2"

2-1/8"

DR 21

2"

2"

2"

2"

2-1/8"

2-1/4"

2-1/2"

DR 18

2-1/8"

2-1/8"

2-1/8"

2-1/4"

2-3/8"

2-1/2"

DR 14

2-1/2"

2-1/2"

2-3/8"

DR 51

1-3/4"

1-3/4"

1-5/8"

1-1/2"

1-1/2"

DR 41

2-1/4"

2"

1-7/8"

1-7/8"

1-3/4"

1-3/4"

1-3/4"

DR 32.5

2-3/8"

2-1/4"

2-1/8"

2"

1-7/8"

2"

2"

DR 25

2-5/8"

2-3/8"

2-1/4"

2-1/4"

2-1/4"

2-1/4"

2-3/8"

DR 21

2-3/4"

2-5/8"

2-1/2"

2-1/2"

2-1/2"

2-5/8"

2-3/4'

DR 18

3"

2-7/8"

2-3/4"

2-3/4"

2-3/4"

2-7/8"

DR 14

3-3/8"

3-1/4"

2-7/8"

DR 51

2-1/2"

2-3/8"

2"

1-7/8"

1-7/8"

DR 41

3-3/8"

2-7/8"

2-5/8"

2-1/2"

2-1/4"

2-1/8"

2"

DR 32.5

3-1/2"

3"

2-3/4"

2-5/8"

2-38"

2-1/4"

2-3/8"

DR 25

3-3/4"

3-1/4"

3"

2-7/8"

2-3/4"

2-5/8"

2-3/4"

DR 21

4"

3-1/2"

3-1/4"

3-1/8'

3"

3"

3-1/8"

DR 18

4-1/4"

3-7/8"

3-1/2"

3-3/8"

3-1/4"

3-1/4"

DR 14

4-7/8"

4-1/4"

3-3/4"

DR 51

3-3/8"

3"

2-5/8"

2-3/8"

2-1/4"

DR 41

5-1/8"

4-1/8"

3-1/2"

3-1/4"

2-7/8"

2-1/2"

2-3/8"

DR 32.5

5-1/2"

4-1/4"

3-3/4"

3-3/8"

3"

2-3/4"

2-3/4"

DR 25

6"

4-5/8"

4"

3-3/4"

3-3/8"

3-1/8"

3.1/8"

DR 21

6-5/8"

4-7/8"

4-1/4"

4"

3-5/8"

3-1/2"

3-1/2"

DR 18

see note

5-3/8"

4-5/8"

4-1/4"

3-7/8"

3-3/4"

DR 14

see note

6"

4-7/8"

DR 51

4-5/8"

4"

3-3/8"

2-7/8"

2-5/8"

DR 41

6"

4-7/8"

4-1/4"

3-1/2"

3-1/8"

2-7/8"

DR 32.5

6-3/8"

5-1/8"

4-1/2"

3-3/4"

3-3/8"

3-1/8"

DR 25

7-1/8"

5-1/2"

4-3/4"

4-1/8"

3-3/4"

3-5/8"

DR 21

8-1/4"

5-7/8'

5-1/4"

4-3/8"

4"

4"

DR 18

see note

6-1/4"

5.1/2"

4-3/4"

4-3/8"

DR 14

see note

6-5/8"

DR 51

6-5/8"

5-3/8'

4-1/4"

3-1/2"

3-1/8"

DR 41

7"

5-5/8'

4-1/2"

3-3/4"

3-3/8"

DR 32.5

7-3/8"

5-7/8"

4-3/4"

4"

3-5/8"

DR 25

8-3/8"

6-3/8"

5-1/8"

4-3/8"

4-1/8"

DR 21

see note

6-3/4"

5-1/2"

4-3/4"

4-1/2"

DR 18

see note

7-1/4"

5-7/8"

5-1/8"

DR 14

see note

DR 51

7-1/2"

5-3/8"

4-1/4"

3-3/4"

DR 41

7-7/8"

5-5/8"

4-1/2'

4"

DR 32.5

8-3/8"

6"

4-3/4"

4-1/4"

DR 25

9-5/8"

6-3/8"

5-1/4"

4-3/4"

DR 21

see note

6-7/8"

5-5/8"

5-1/8"

DR 18

see note

7-1/4"

6"

DR 14

DR 51

7-7/8"

5-3/4"

4-3/4"

DR 41

8-1/4"

6"

5"

DR 32.5

8-3/4"

6-1/4"

5-3/8"

DR 25

9-5/8"

6-3/4"

5-7/8"

DR 21

10.1/2"

7-1/4'

6-3/8'

DR 18

12"

7-3/4"

DR 14

Nominal Size

C905  

PVC pipe with CI outside diameter

PIPE OD

TAP SIZE      6                            

(actual size 5-1/2")

Class 305

Class 165

PIPE ID. SIZE 

RANGE

Class 80

Class 125

TAP SIZE      18

       

(actual 

size 17-1/2")

TAP SIZE     16                            

(actual size 15-1/2")

TAP SIZE     14                            

(actual size 13-1/2")

TAP SIZE     12                            

(actual size 11-1/2")

TAP SIZE     10                            

(actual size 9-1/2")

TAP SIZE      8                            

(actual size 7-1/2")

********************** TRAVEL DISTANCE ***************************

TAP SIZE      4                            

(actual size 3-1/2")

Class 235

TAP SIZE      20

       

(actual 

size 19-1/2")

TAP SIZE      24

       

(actual 

size 22-1/2")

Class 100

Class 200

Summary of Contents for TapMate XL-424

Page 1: ...understand this operating manual If you need assistance or find parts missing or damaged call 1 800 426 9341 ROMAC INDUSTRIES INC 1 8 0 0 4 2 6 9 3 4 1 w w w r o m a c c o m TapMate XL 424 Pipe Drilli...

Page 2: ...and Maintenance page 28 PARTS IDENTIFICATION DRAWINGS TapMate XL 424 included items page 29 TapMate XL 424 base machine page 30 Adapter Bells 4 12 page 31 Adapter Bell 14 24 page 32 Small Shaft Head A...

Page 3: ...ssure rating Compatible with TapMate and or QuikValve Adapters Cutters and Shaft Noses and PVC Pilots External components of the TapMate XL 424 are QPQ heat treated for protection from wear and corros...

Page 4: ...saw and pilot drill Prior to the cut the Holesaw and Pilot Drill are extended through the valve and tapping sleeve neck to the pipe wall using the Brake Tube Handles After the cut is complete the Hole...

Page 5: ...ATE XL 424 Operating Manual OPEN THE SHIPPING CRATE WORKSTATION 1 Open all six of the latches around bottom of the crate 2 Swing open the end see drawing at left 3 Lift and remove cover see drawing at...

Page 6: ...you ll be tapping See the drawings below TM Shaft Nose 4 12 taps Cutter and Pilots shown below are for use on Ductile Iron Cast Iron and Asbestos Cement pipe TM Shaft Nose 4 12 taps Cutter and Pilots...

Page 7: ...ely attached to the Lead Tube To determine which Adapter Hub you ll need see the drawings below Note The TapMate XL 424 is shipped from the factory without an Adapter Hub installed Small Adapter Hub f...

Page 8: ...Adapter Hub for the size of Adapter Belltobeused SmallAdapterHubfor4 12 andLarge Adapter Hub for 14 24 2 Align the key way in the Adapter Hub with the key in the top of the Lead Tube see drawing at l...

Page 9: ...Tighten with a spanner wrench Removal 1 Unscrew the Adapter Hub from the Lead Tube Locking Collar with the Spanner Wrench 2 Slide the Adapter Hub off the Lead Tube and store in Shipping Crate Work St...

Page 10: ...next hole is over the flat slot on the top of the hub 4 Insert one set screw into the hole located above the flat and use a 3 16 allen wrench to tighten the set screw see drawing at left Note The set...

Page 11: ...d Bolt in place preventing it from loosening during the cutting operations 8 The Jam Nut facilitates easy removal the Shell Cutters Thread the Jam Nut onto the Shaft Run it to the end of the threads a...

Page 12: ...tter over the TM Shaft Nose or TM PVC Pilot and thread it onto the Shaft until it is snug against the Jam Nut 12 RetracttheShellcutterintotheAdapterBellbyrotatingtheBrakeTubeinacounter clockwisedirect...

Page 13: ...tie down brace from the crate 14 The TapMate XL 424 is now ready to be lifted and attached to the gate valve When lifting the machine use the Lifting Rings at the rear of the machine and at the Small...

Page 14: ...XL 424 Adapter bell into place see drawing at left 3 Remove the six nuts and washers from the outside of the adapter Also make sure that the gasket is in place 4 Lift the Adapter Bell by the lifting e...

Page 15: ...nding on the type and size of Adapter Bell being used 8 Apply the anti galling lubricant to the Large Shaft Head Bolt and start to thread it into the end of the Shaft with the 3 8 Allen wrench Align t...

Page 16: ...firm pressure to depress the pin and the pin should snap back into place smoothly If the pin is sticking disassemble and clean the hole pin and spring Reassemble and re examine to ensure the pin is fu...

Page 17: ...Pilot into place 11 Move the appropriate size Shell Cutter over the Shaft Nose or PVC Pilot and onto the front boss of the Large Shaft Head Align the through holes of the Large Shaft Head with the ta...

Page 18: ...ont 13 The TapMate TM XL 424 is now ready to be lifted and attached to the gate valve When lifting the machine using the lifting loop at the end of the machine and the loop on the adapter bell Note Ad...

Page 19: ...the distance from the valve flange face to the gate see drawing at left 3 With the Shell Cutter fully retracted take the following measurements see drawings at left Measure the distance the Shaft Nos...

Page 20: ...uent steps Pipe Distance to Distance of Cut Travel Chart s 39 Inches Total Machine Bar Travel Distance C L Cutter s Extension out of Adapter and into Valve Body or BORING BAR TRAVEL DISTANCE OF CUT 7...

Page 21: ...4 machine to the valve NOTE Incorrect alignment can result in damage to the valve tapping sleeve and or pipe Adequately support the TapMate XL 424 so as not to put stress on the pipe valve or tapping...

Page 22: ...rust Tube see drawing at left Rotate the Brake Tube back counter clockwise until the next hole in the front collar of the Brake Tube lines up with the scale in the Thrust Tube Thread the Brake Tube Lo...

Page 23: ...its travel distance in calculating cutter travel If this distance differs from your earlier measurement several things could be causing the discrepancy Check for the most common problems Is the Cutte...

Page 24: ...essure to the drive unit by following the instructions 8 Slowly move the lever on the Hydraulic drive towards the RUN position to start the rotation of the Shaft and the Cutter see drawing at left NOT...

Page 25: ...t paragraph for information on size on size taps TheMaximumRequiredTraveldistanceis theoutsidediameterofthepipe evenifyoustillfeelresistance while feeding the cutting tools At the completion of the cu...

Page 26: ...cont 21 Reattach the lifting chains see drawings below Lifting Eye Rear Lifting Ring Adjust for Level Lift Small Adapter Hub Lifting Ring Rear Lifting Ring LIFTING CHAIN POSITIONS FOR 4 12 TAPS LIFTIN...

Page 27: ...bell by unscrewing the set screw and then unthreading the adapter from the Small hub 12 Clean the machine as outlined in the section Care and Maintenance of the Machine For 14 24 Taps 1 With the machi...

Page 28: ...ht Keeping them tight will hold the Cutters securely in place and will also simplify their removal Use only sharp hex wrenches to tighten set screws when securing Jam Nuts ANNUAL MAINTENANCE The follo...

Page 29: ...8FW 410 WASHER 304SS 5 8 IN 4 350 05 80 96 52 TM HUB ADAPTER NUTS 4 350 23 512 TM LEAD TUBE PRESSURE PLUG 3 350 05 571 TM ADAPTER BELL O RING 355 60 3 35 ALLEN WRENCH 1 8 IN 353 60 31 B1 ALLEN WRENCH...

Page 30: ...PA 15 366 28 TM XL NEEDLE ROLLER BEARINGS TIMKEN HJ648032 16 366 32 TM XL THRUST TUBE COMPLETE 17 366 37 TM XL THRUST TUBE STOP BLOCK BOLT SHCS 5 16 18 X 3 4 18 366 36 TM XL THRUST TUBE STOP PIN 19 36...

Page 31: ...ADAPTER BOLTS 10 12 IN HHCS 5 8 11 X 1 3 4 IN TM HUB ADAPTER SEALS 10 12 IN 5 8 TM HUB ADAPTER GASKET 10 12 TM HUB ADAPTER 10 12 WASHER 304SS 5 8 IN MS820 095 THK X 1 5 16 OD TM HUB ADAPTER NUTS 10 12...

Page 32: ...1 02 2 8FW 410 3 350 05 80 96 57 4 350 05 80 96 52 AD AIR DRIVE VALVE 1 2 IN BALL VALVE BT EXHAUST ELBOW BT SLIDE GATE PIPE NIPPLE 1 2 IN NPT DBL ENDED 1 1 2 IN LONG STANDARD TM XL ADAPTER EXHAUST VAL...

Page 33: ...SHAFT HEAD TM XL SHAFT HEAD BOLT TM XL SHAFT HEAD KEY TM XL SHAFT HEAD KEY SCREW SHCS 1 4 20 X 1 1 4 1 366 11 01 2 366 09 01 3 366 09 02 4 366 09 03 HD HYDRAULIC COUPLNG SET SCREW SHSS 1 4 20 X 1 2 IN...

Page 34: ...60 22 04 1 360 22 03 QVIM SHAFT NOSE RETAINING PIN SPRING QVIM SHAFT NOSE RETAINING PIN QVIM SHAFT NOSE RETAINING PIN SET SCREW QTY 2 QTY 2 QTY 2 350 04 TM PVC PILOT 350 21 561 TM COUPON RETAINER BALL...

Page 35: ...3 360 22 02 QVIM SHAFT NOSE RETAINING PIN SET SCREW 1 360 22 03 QVIM SHAFT NOSE RETAINING PIN SPRING QTY 3 QTY 3 QTY 3 QTY 1 QTY 1 350 21 512 TM COUPON RETAINER SET SCREW 3 8 24 X 3 8 SHSS CUP POINT...

Page 36: ...XL HYD PRESSURE GAUGE 0 3 000 PSI 6 366 72 04 TM XL HYD MOTOR MANIFOLD 7 366 72 09 TM XL HYD MOTOR MANIFOLD BOLTS 5 16 18 X 4 1 2 8 372 13 11 HD 3 8 IN X 3 8 IN NPT HYD NIPPLE WEATHERHEAD 9 372 13 10...

Page 37: ...424 Pipe Drilling Machine TR AVEL CHARTS Waterworks Tools By Romac Cast Iron Pipe page 38 Ductile Iron Pipe pages 39 40 C900 PVC Pipe page 41 C905 Pipe pages 42 43 ASTM D2241 IPS PVC Pipe pages 44 45...

Page 38: ...5 8 1 3 8 1 1 4 1 1 4 1 1 4 1 1 4 1 1 4 1 1 4 2 1 4 1 5 8 1 1 2 1 3 8 1 1 4 1 3 8 1 3 8 1 3 8 1 3 8 TAP SIZE 8 actual size 7 1 2 Class 3 2 1 4 1 5 8 1 1 2 1 3 8 1 3 8 1 1 4 2 7 8 2 1 8 1 7 8 1 5 8 1...

Page 39: ...8 2 1 4 2 1 3 4 1 5 8 1 3 8 thru To To To To To To To Class 56 4 2 7 8 2 1 2 2 1 4 2 1 7 8 1 5 8 Class 50 4 1 8 3 1 4 2 3 4 2 1 2 2 1 4 1 7 8 thru To To To To To To Class 56 4 3 4 3 5 8 3 2 3 4 2 1 2...

Page 40: ...4 2 1 8 2 2 thru To To To To To To To Class 56 3 1 2 3 1 8 2 7 8 2 3 4 2 5 8 2 3 8 2 1 4 Class 50 4 3 1 4 2 7 8 2 5 8 2 3 8 2 3 8 2 1 4 thru To To To To To To To Class 56 4 3 8 3 3 4 3 3 8 3 1 8 3 2...

Page 41: ...3 8 24 10 21 10 11 6 13 6 04 8 04 7 92 9 87 9 72 7 76 7 60 9 51 9 32 7 8 3 4 7 8 3 4 7 8 1 1 1 1 8 1 1 8 1 1 4 1 1 8 1 1 4 1 1 8 1 1 4 1 7 8 2 1 1 2 1 1 4 1 3 8 2 1 8 2 1 4 1 5 8 1 3 4 1 1 2 1 5 8 2 3...

Page 42: ...8 2 3 4 2 3 4 2 3 4 2 7 8 DR 14 3 3 8 3 1 4 2 7 8 DR 51 2 1 2 2 3 8 2 1 7 8 1 7 8 DR 41 3 3 8 2 7 8 2 5 8 2 1 2 2 1 4 2 1 8 2 DR 32 5 3 1 2 3 2 3 4 2 5 8 2 38 2 1 4 2 3 8 DR 25 3 3 4 3 1 4 3 2 7 8 2 3...

Page 43: ...3 8 2 1 2 DR 32 5 2 7 8 2 3 4 DR 25 3 1 4 3 3 8 DR 21 DR 18 DR 14 DR 51 2 1 2 2 1 2 DR 41 2 3 4 2 3 4 DR 32 5 3 1 8 3 1 8 DR 25 3 5 8 3 5 8 DR 21 DR 18 DR 14 DR 51 2 7 8 2 7 8 DR 41 3 1 4 3 1 8 DR 32...

Page 44: ...8 1 1 4 1 1 4 1 1 8 SDR 26 2 1 8 1 1 2 1 3 8 1 1 4 1 1 4 SDR 21 2 1 4 1 5 8 1 1 2 1 1 2 1 1 2 SDR 17 2 1 2 1 7 8 1 5 8 1 5 8 1 5 8 SDR 13 5 3 1 8 SDR 64 2 5 8 1 7 8 1 1 2 SDR 41 2 3 4 2 1 3 4 1 5 8 S...

Page 45: ...2 1 4 2 1 8 2 SDR 32 5 3 1 4 3 2 3 4 2 1 2 2 3 8 2 3 8 SDR 26 3 1 2 3 1 4 3 2 3 4 2 5 8 2 5 8 SDR 21 3 3 4 3 3 8 3 1 4 3 2 3 4 3 SDR 17 4 1 8 3 3 4 3 1 2 3 3 8 3 3 8 3 1 2 SDR 41 4 5 8 3 7 8 3 1 2 3...

Page 46: ...2 19 2 20 2 39 2 51 2 84 3 05 3 49 4 22 Min 3 22 2 32 2 00 1 77 1 68 2 04 1 98 2 19 2 38 Max 4 28 3 15 2 90 2 95 2 99 3 24 3 40 3 78 4 45 Min 4 06 3 02 2 54 2 31 2 58 2 45 2 57 2 67 Max 6 06 4 04 3 7...

Page 47: ...2 1 8 2 1 7 8 5 3 8 3 1 2 3 1 8 2 7 8 2 5 8 2 5 8 2 1 2 see note 4 1 8 5 4 3 3 8 3 2 5 8 2 3 8 see note 4 7 8 4 3 1 2 3 3 8 3 1 8 see note see note 4 7 8 4 1 8 3 5 8 3 1 8 see note 6 4 7 8 4 3 8 3 7...

Page 48: ...e see note see note see note see note NOTE Special Undersized Cutters can be made upon request TAP SIZE 18 actual size 17 1 2 Class PIPE ID SIZE RANGE SDR 17 SDR 13 5 SDR 11 SDR 9 SDR 21 1 1 4 1 3 8 N...

Page 49: ...3 1 4 see note 5 3 4 4 3 4 4 3 5 8 see note see note 5 1 2 4 3 8 4 see note see note see note 4 7 8 4 1 2 see note see note see note 5 5 8 5 1 8 see note see note see note see note 5 1 2 4 1 2 see not...

Page 50: ...8 4 1 2 4 3 8 SDR 11 5 3 8 5 1 8 4 7 8 SDR 9 6 1 4 5 3 4 5 5 8 SDR 7 SDR 21 5 3 8 4 7 8 4 1 2 SDR 17 5 7 8 5 1 4 4 7 8 SDR 13 5 6 1 2 5 3 4 5 3 8 SDR 11 7 3 8 6 1 5 6 SDR 9 9 3 8 7 1 2 6 7 8 SDR 7 SDR...

Page 51: ...51 TAPMATE XL 424 TRAVEL CHARTS Notes...

Page 52: ...ROMAC INDUSTRIES INC 1 8 0 0 4 2 6 9 3 4 1 w w w r o m a c c o m...

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