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Model 302 Tube Squaring Machine

92-0547 Rev. 210906

23

8. SADDLE SETS

Figure 8: Saddle Sets

SADDLE SET PART NUMBERS

Fraction

Decimal

Metric

Saddle P/N

1/4"

.250"

6.4 mm

67-3523

3/8"

.375"

9.5 mm

67-3532

1/2"

.500"

12.7 mm

67-3545

3/4"

.750"

19.1 mm

67-3567

1"

1.000"

25.4 mm

67-3582

1 1/4"

1.250"

31.8 mm

67-3589

1 1/2"

1.500"

38.1 mm

67-3598

2"

2.000"

50.8 mm

67-3612

2 3/8"

2.375"

60.3 mm

67-3619

The Saddles are made of Stainless Steel

If you need a size that is not listed, please contact Tri Tool, Inc.

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Summary of Contents for 302

Page 1: ...Operation Manual 92 0547 Rev 210906 Model 302 Tube Squaring Machine ...

Page 2: ... insist on developing tools and equipment that exceed your expectations of performance precision safety and durability As a full service engineering firm we are here to support you every step of the way For more information on engineered solutions products and trainings visit tritool com or contact our engineers at 1 916 288 6100 ...

Page 3: ...l 6 Safety Precautions 8 General Description 10 Specifications 11 Maintenance 13 Operation 15 Cutting Speeds and Feeds 22 Saddle Sets 23 Tool Bits 24 Troubleshooting 26 Illustrated Parts Breakdown 28 92 0547 210906 Model 302 Tube Squaring Machine ...

Page 4: ...a third party are subject strictly to the third party s warranty for those goods Seller makes no warranty and disclaims all statutory or implied warranties for these goods including the implied warranties of merchantability freedom from patent infringement and fitness for a particular purpose Neither this warranty nor any other warranty expressed or implied including implied warranties of mechanic...

Page 5: ...when returning the defective Goods that it is suitably packed fully insured and transportation and insurance prepaid in accordance with instructions issued by Seller Seller at its sole option will either repair or replace any Goods authorized for return to Seller Such repair replacement or credit shall be Buyer s sole remedy for defective Goods Buyer must promptly provide Seller with all informati...

Page 6: ...s in this Manual Failure to follow the instructions or follow the safety instructions could result in serious injury or death This manual describes conditions and hazards that are common and anticipated during equipment operation No manual can address all conditions which may occur Safety Symbols The manual may contain one or more safety symbols These symbols and the associated text warn you of po...

Page 7: ...use of safety glasses HOT SURFACE HOT SURFACE Indicates a hazardous situation that hot surfaces may be present SHOCK HAZARD ARC FLASH SHOCK HAZARD High voltage Entry by authorized personnel only Appropriate PPE and tools required when working on this equipment GLOVES GLOVES Indicates a hazardous situation that requires glasses ...

Page 8: ...e Wear safety glasses Do not wear loose clothing or jewelry Wear nonskid footwear Put long hair in a cap or a net to make sure hair does not get tangled in equipment Personnel Only personnel who are trained or are being trained may operate the equipment Keep the operation manual available where the equipment is used The operator must read the operation manual before using the equipment The equipme...

Page 9: ...rating the equipment do no load tests and feed function checks Tool Use Use the right tool and tool bit for the job Contact Tri Tool to help with your application Keep the tool bits fully engaged in the tool bit holders Loose bits are sharp and can cause cuts or punctures Disconnect power supply during setup and maintenance Use all Stop or Shut off features available when changing or adjusting too...

Page 10: ... uses an OD Saddle Clamping System to holding and to round the tube The 302 accepts its torque through the Saddle Clamping System The standard Saddle Clamping System requires a straight length of tube 875 22 2 mm long An optional pneumatic clamping system can provide automatic clamping Speed control is provided with a variable speed electric drive or a pneumatic drive motor Lever action provides f...

Page 11: ...P N 01 1271 9 57 243 1mm 8 57 217 7mm Clamp Handle Cutter Head Feed Handle Base Plate 12 00 304 8mm 5 20 132 1mm Tool Bit Slots 12 80 325 1mm 12 00 304 8mm Air Motor Figure 1 Envelope Drawing with Air Motor Weight 18 5 lbs 8 4 kg without saddles Power Requirements 26 cfm at 90 PSI 12 L s at 621 kPa ...

Page 12: ...g with Electric Motor Model 302E with a 110 VAC 60 Hz Electric Motor P N 01 1242 Weight 20 6 lbs 9 3 kg without saddles Power Requirements 110 VAC 50 60hz 7 0 amp Model 302E with a 220 VAC 50 Hz Electric Motor P N 01 1770 Weight 20 6 lbs 9 3 kg without saddles Power Requirements 220 VAC 50 60hz 4 0 amp For Japan Model 302E with a 100 VAC 50 Hz Electric Motor P N 58 0217 Weight 20 6 lbs 9 3 kg with...

Page 13: ...aminated air or lack of lubrication Air Motor Lubrication Disassembly of a power unit voids warranty except when performed by a TRI TOOL designated repair technician Letter of designation is required No direct maintenance is normally required on the Air Motor The air supply must flow through a filter regulator lubricator FRL unit or separate units before arriving at the air motor The FRL unit must...

Page 14: ...sity of 100 to 200 SSU at 100 F 38 C Tri Tool Inc Air Tool Lubricant P N 68 0022 AMOCO American Industrial Oil No 32 Atlantic Richfield Duro Oil S 150 Chevron A W Machine Oil 32 Exxon Nuto H32 Shell Tellus Oil 32 The bearings in the air motor and in the electric motor are sealed and do not require lubrication ...

Page 15: ...tro polished stainless steels have a micro thin surface on the ID which is high in Cr and Ni This surface is soft but tough and difficult to cut without a burr The Part Number for a DURABIT 1 is DURBIT1 DURABIT 2 is DURBIT2 and DURABIT 3 is DURBIT3 Contact your Tri Tool representative for Tool Bit recommendations for carbon steel tubes with a wall thickness greater than 0 083 2 24mm M 42 Tool Bits...

Page 16: ...slot Installing a Tool Bit 1 Make sure that the Model 302 Tube Squaring Machine is disconnected from the power source before installing a Tool Bit 2 Insert the Tool Bit into the slot in the Cutting Head The cutting edge of the Tool Bit must be located on the radial centerline Make sure the cutting edge is positioned correctly 3 Position the tip of the tool bit just inside the inner side of the tub...

Page 17: ...mal return position A tube end that is cut at an angle not square can be set so the tool bit clears the end but when the tool bit is rotated it engages the tube will a very heavy cut CAUTION CAUTION Do not do an excess cut to reduce the risk of damage to the tool bit from an excessive cut Use the maximum speed to turn the machine on and advance the tool bit into the end On interrupted or out of sq...

Page 18: ...e sure that the tube bit clears the end of the tube with the feed fully retracted normal return position A tube end that is cut at an angle not square can be set such that the tool bit clears the end but when the tool bit is rotated it engages the tube with a very heavy cut Turn the machine on and set the RPM between 30 and 50 Advance the tool bit into the end Use the low end of the speed range 30...

Page 19: ...he bevel relationship Saddle Installation 1 Select the saddle size for the pipe or tube to be worked on 2 Insert the lower saddle half into the lower front of the main housing Refer to Fig 5 Clamping Screw Assembly Upper Saddle Half Cap Screws Adjust Knob Lower Saddle Half Figure 5 Mount the Indicator Kit on the Mandrel 3 Thread the adjust knob in through the bottom of the main housing and into th...

Page 20: ...be once the proper clearance has been verified Operation Sequence 1 Connect the proper power supply 2 Depress the motor trigger Refer to Fig 6 Trigger Figure 6 Trigger Location 3 Control and maintain constant cutting speed Refer to section 7 Cutting Speeds and Feeds 4 Rotate the feed knob clockwise to bring the cutting head and end of the tube or pipe closer together Refer to Fig 7 Each line on th...

Page 21: ...on 5 Continue rotating the feed knob clockwise until the end of the tube or pipe is completely machined Do not let the tool bit s cut into the saddle 6 Discontinue the feed and allow the cutting head to rotate one to three more revolutions to improve the finish of the prep surface 7 Rotate the feed knob counterclockwise to separate the cutting head and the tube or pipe 8 Stop the tool rotation 9 R...

Page 22: ...00 50 8 mm 32 40 48 Cutting Speeds are approximate Use 200 surface inches per minute 5080 surface millimeters per minute for Stainless steels in general when no coolant is allowed all heavy wall tube and some chrome molybdenum steels Use 250 surface inches per minute 6350 surface millimeters per minute for Mild steels and some thin wall stainless steels when coolants are permitted and applied Use ...

Page 23: ...ddle P N 1 4 250 6 4 mm 67 3523 3 8 375 9 5 mm 67 3532 1 2 500 12 7 mm 67 3545 3 4 750 19 1 mm 67 3567 1 1 000 25 4 mm 67 3582 1 1 4 1 250 31 8 mm 67 3589 1 1 2 1 500 38 1 mm 67 3598 2 2 000 50 8 mm 67 3612 2 3 8 2 375 60 3 mm 67 3619 The Saddles are made of Stainless Steel If you need a size that is not listed please contact Tri Tool Inc ...

Page 24: ... Material Tool Bit Height Squaring Tool Bit P N 187 OD thru 2 00 OD 4 8 mm OD thru 50 8 mm OD 200 5 1 mm CS 750 19 1 mm 99 1480 187 OD thru 2 00 OD 4 8 mm OD thru 50 8 mm OD 200 5 1 mm SS 750 19 1 mm DURABIT 1 187 OD thru 2 00 OD 4 8 mm OD thru 50 8 mm OD 200 5 1 mm SS 750 19 1 mm DURABIT 1 187 OD thru 2 00 OD 4 8 mm OD thru 50 8 mm OD 200 5 1 mm Inconel 750 19 1 mm 99 3650 M42 ...

Page 25: ... OD thru 60 5 mm OD 200 5 1 mm SS 37 50 99 0276 187 OD thru 1 00 OD 4 8 mm OD thru 25 4 mm OD 200 5 1 mm CS 45 99 5085 100 OD thru 2 38 OD 25 4 mm OD thru 60 5 mm OD 200 5 1 mm SS 45 99 5994 Centerline of Pipe or Tube Tool Bit Pipe or Tube Figure 11 Facing Tool Bit Facing Range Max Wall Thickness Pipe or Tube Material Tool Bit Height Facing Tool Bit P N 187 OD thru 2 00 OD 4 8 mm OD thru 50 8 mm O...

Page 26: ...required A dull Tool Bit is causing surface hardening conditions Stainless pipe or tubing There is scale or other foreign matter on the pipe or tube which is dulling the tool bit at the start of the cut The tool bit is incorrect for the material being cut Problem Rough Surface Finish The tool bit is dull chipped etc Metal build up on the cutting edge of the tool bit is creating a false cutting edg...

Page 27: ... Problem Air Motor does not Start The air power supply is shut off The air motor is damaged and will not run free The air motor needs lubrication Add lubrication and do not run the air motor for a few minutes then try running the motor Tap on the side of the air motor casing lightly with a piece of wood or with a soft rubber mallet just in case the vanes may be sticking Sand or other foreign mater...

Page 28: ...Rev 210906 28 11 ILLUSTRATED PARTS BREAKDOWN MODEL 302 TUBE SQUARING MACHINE SUB ASSY REF P N 02 2174 1 OF 2 1 2 3 4 5 5 6 7 7 8 9 10 11 12 13 29 14 15 18 19 20 21 22 23 23 26 27 28 30 31 32 33 35 36 38 38 39 40 44 45 46 47 ...

Page 29: ...Model 302 Tube Squaring Machine 92 0547 Rev 210906 29 MODEL 302 TUBE SQUARING MACHINE SUB ASSY REF P N 02 2174 2 OF 2 16 17 24 24 25 34 42 49 17 24 24 24 24 24 25 34 37 41 43 49 48 ...

Page 30: ...83 LABEL LOGO SMALL 1 12 30 0508 LABEL WARNING DISCONNECT 1 13 30 0924 PLATE DATA 1 14 30 0961 LABEL WARNING SAFETY SWITCH 1 15 30 2061 LABEL TRI TOOL 1 16 30 6120 MAGNET 5 MM DIA X 5 MM 2 17 30 6530 LATCH DRAW RUBBER PULL HANDLE 1 18 31 0142 KEY 3 16 SQ X 1 1 2 1 19 33 0037 SCREW CAP 1 4 20 X 3 8 1 20 33 0038 SCREW CAP 1 4 20 X 1 2 4 21 33 0040 SCREW CAP 1 4 20 X 3 4 4 22 33 0041 SCREW CAP 1 4 20...

Page 31: ... 39 0725 GEAR WORM 1 36 41 0106 HANDLE FEED 1 37 41 1133 HANDLE ASSY LATCH 1 38 42 0076 KNOB BALL 1 39 42 0143 KNOB ADJUST 1 40 43 0426 COVER 1 41 43 1248 COVER GUARD WINDOW 1 42 43 1249 COVER 1 GUARD 1 43 43 1250 COVER 2 GUARD 1 44 44 0417 SPACER FEED 1 45 46 0384 SLEEVE DRIVE 1 46 46 0385 SLEEVE FEED 1 47 54 0374 PLUG PRESSURE 1 4 NPT 1 48 71 0626 WELDMENT HINGE GUARD WINDOW 1 49 71 0627 WELDMEN...

Page 32: ...TRI TOOL INC 92 0547 Rev 210906 32 MOTOR ASSEMBLY AIR 302A P N 57 0213 16 7 4 5 8 4 12 10 9 1 2 10 3 11 7 6 13 15 14 17 ...

Page 33: ...233 O RING 2 5 31 0115 KEY ROUND ENDS 1 6 33 0041 SCREW CAP 1 4 20 X 7 8 1 7 33 0292 SCREW BUTTON 5 16 18 X 5 8 2 8 33 0619 SCREW SET 10 32 X 1 4 CUP PT 1 9 39 0005 WORM 1 10 45 0221 BUSHING FLANGE 5 8 ID 2 11 46 0390 SLEEVE MOTOR AIR 1 12 47 0919 BRACKET CLAMP 1 13 53 0045 VALVE FLOW CONTROL 1 4 NPT 1 14 54 0149 COUPLING MALE QD HOSE TO PIPE 1 15 54 0201 CAP YELLOW 1 16 54 0347 PLUG 1 17 57 0212 ...

Page 34: ...TRI TOOL INC 92 0547 Rev 210906 34 MOTOR ASSEMBLY ELECTRIC 110V P N 58 0184 AND 220V P N 58 0080 9 13 12 4 8 1 2 9 3 10 6 5 7 4 11 ...

Page 35: ...7 1111 BRACKET CLAMP 1 12 54 0347 PLUG 1 13 58 0183 MOTOR ELECTRIC MOD 110 VAC Milwaukee 1 NOT SHOWN 33 0292 SCREW BUTTON 5 16 18 X 5 8 REF Parts List Motor Assembly Metabo 110 VAC P N 58 0301 Item No Part No Description Qty 1 20 0617 SHAFT DRIVE 1 2 20 0619 SHAFT DRIVE 1 3 28 0245 SEAL GREASE 1 4 28 0233 O RING 2 5 31 0115 KEY ROUND ENDS 1 6 33 0041 SCREW CAP 1 4 20 X 7 8 1 7 33 0619 SCREW SET 10...

Page 36: ...LAMP 1 12 54 0347 PLUG 1 13 58 0324 MOTOR MOD ELECTRIC 220 VAC BOSCH 1 NOT SHOWN 33 0292 SCREW BUTTON 5 16 18 X 5 8 REF Parts List Motor Assembly Electric 100 V Japan only P N 58 0217 Item No Part No Description Qty 1 20 0617 SHAFT DRIVE 1 2 20 0619 SHAFT DRIVE 1 3 28 0245 SEAL GREASE 1 4 28 0233 O RING 2 5 31 0115 KEY ROUND ENDS 1 6 33 0041 SCREW CAP 1 4 20 X 7 8 1 7 33 0619 SCREW SET 10 32 X 1 4...

Page 37: ......

Page 38: ...ous injury Never lock or tie down any safety triggers SHOCK HAZARD Ensure that the equipment is properly installed and grounded Ensure that the equipment is not damaged and that the power cord is intact Tool bits are sharp and can cause serious injury Do not defeat or modify safety features Disconnect power sources before servicing or moving the equipment Remove all loose articles of clothing and ...

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