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9

Maintenance operations

Important:

Only the operations described in this chapter are authorized. All other operations must

be carried out by personnel approved by Virax.

Cleaning the oil system

Remove turnings which have accumulated in the receiving bin and clean the scrap receiver.

Warning:

Wear gloves when handling turnings (risk of being badly cut).

Remove the scrap receiver and the oil filter grid and clean the strainer.

Note: The strainer can also be removed to facilitate cleaning.

Top up the oil if necessary by pouring it directly into the container. (Minimum oil level: half the

diameter of the strainer).

Important:

You must use oils supplied by Virax. (See page 9 for the part numbers of the various

oils which can be used).

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Summary of Contents for 162140

Page 1: ...Threading machine for tubes up to 4 Instruction Manual 162140 Machine 4 pouces couverture EN i3 3 22 08 2007 08 58 35 EN ...

Page 2: ...C relating to electrical equipment designed for use within certain voltage limits Low voltage 2004 108 EC ElectroMagnetic Compatibility relating to electromagnetic compatibility and repealing Directive 89 336 EEC 98 37 EC relating to machinery and to relevant national legislation transposing these directives Complies with harmonized European standards EN 55014 1 EN 55022 Epernay August 24th 2009 E...

Page 3: ...Machine 4 pouces EN indd 2 22 08 2007 08 59 01 EN ...

Page 4: ...vironmental engineering and Roofing trades supplies the tools you use in your everyday work Virax showing off your talent This documentation has been produced with care to enable you to use the machine to its best and in complete safety We strongly recommend you to read this instruction manual carefully before using the machine and to keep it within easy reach of the machine Machine 4 pouces EN in...

Page 5: ...Available thread types 12 Setting the length and outside diameter of the thread 12 Option of installing a groover 12 General characteristics 13 Moving and setting up the machine 14 Moving by lifting equipment 14 Moving manually 15 Moving using a trolley 16 Slope of the machine 16 Positioning a tube 17 Positioning short tubes 17 Cutting a tube 18 Reaming a tube 19 Threading a tube 20 Producing a th...

Page 6: ...lete 42 Replacing the front chuck jaws 42 Replacing the front chuck jaw holders 44 Diagnostics and fault fixes 47 Machine operating problems 47 Thread cutting problems 48 Tube cutting problems 50 Reaming problems 50 Exploded views 51 Exploded view of the lower frame 51 Exploded view of the upper frame chucks and pump 52 Exploded view of the motor 53 Exploded view of the motor transmission not incl...

Page 7: ... tool is in perfect working order All safety devices switches or other damaged or defective parts must be appropriately repaired or replaced by a qualified technician Warning Be sure to use the tool and its accessories in accordance with the safety instructions Consider the range of options for the tool taking into account the working conditions and the task to be carried out It can be dangerous t...

Page 8: ...oreover when loosening if the joint has not been released you will subject the motor to a force which may damage it The machine is not a winch You may be tempted to use the force of the motor to raise or lower loads This use is prohibited as the machine could topple over and jettison its load Moreover you may damage the motor The machine is not intended for coating the threads with sealing paste A...

Page 9: ...ected to a ground connection in the workshop Do not pull the machine by its power cable This is not a rope Likewise do not disconnect the machine by pulling on the cable Instructions relating to your protection and the protection of those around you It is essential to place the tube onto one or more pipe holders also called benches Virax part numbers pipe holder without feet 161100 pipe holder wit...

Page 10: ...eful not to cut yourself on contact with sharp items in particular cutter wheel thread dies reaming blade internal edges of the tube Wear gloves for handling metal turnings these can cause bad fine and deep cuts Wear gloves if you are allergic to lubrication oil Pay attention to crushing hazards in particular when lowering the tube cutter the die head or the reamer and when the saddle is moving Wa...

Page 11: ...ossible any cracks overlarge play etc and in general any anomaly Regularly change the four dies of the die head especially when the turnings become less whole and more broken up Regularly check the oil level You must not thread your tubes without a sufficient oil flow You must use one of the oils supplied by Virax as all mechanical tests have been carried out using these oils Oils which can be use...

Page 12: ...arried out by personnel approved by Virax Important Virax may not be held liable for accidents which occur as a result of an unauthorized maintenance operation Strorage instructions Keep the machine powered off in a dry place where there is no risk of water or dust spatter and cover it with a tarpaulin Machine 4 pouces EN indd 10 22 08 2007 08 59 13 EN ...

Page 13: ...tional linear densities EN 10216 5 March 2005 Seamless steel tubes operating under pressure Technical delivery conditions Part 5 Stainless steel tubes EN 10217 7 August 2005 Welded steel tubes operating under pressure Technical delivery conditions Part 7 Stainless steel tubes 2 Carbon steel tubes EN 10208 2 October 1996 Steel tubes for carrying combustible fluids Technical delivery conditions Part...

Page 14: ...PT NPT scale as standard 2 From 2 to 4 each head is specific NPT or BSPT Setting the length and outside diameter of the thread The heads allow the length and outside diameter of the thread to be set Option of installing a groover In addition to the three basic functions cutting reaming threading the machine can be used with a Virax groover part no 162400 optionally available for hollow carbon stee...

Page 15: ...thout die head 132 0 kg Weight of feet 5 8 kg Weight of 4 die head without dies 10 2 kg Weight of 2 die head without dies 6 6 kg Overall dimensions of the machine on its feet length x width x height in mm 940 x 825 x 1215 Acoustic power level LwA 86 dB A Acoustic pressure at the user s ears LwA 76 dB A LpMaxPeak 130 db C Machine supplied with 4 feet 2 x 5L drums of cutting oil for steel tubes 1 x ...

Page 16: ...ing by lifting equipment Raise the die head see pages 24 28 and 31 for the procedure for installing the various heads Warning Do not forget to do this as the die head is simply fixed to its shaft and can therefore fall off during transport Use a 4 tube of sufficient length to overlap the two sides of the machine by about 30 cm Carefully ream each end of the tube to avoid the tube edges cutting the...

Page 17: ...nded you can if necessary unscrew the feet to facilitate transport ATTENTION VIRAX Moving manually The machine has four transporting handles on the sides of the frame ATTENTION VIRAX Warning Four people are needed to raise the machine Raise and move the machine only by using its handles The other parts of the machine do not give a secure grip Machine 4 pouces EN indd 15 22 08 2007 08 59 15 EN ...

Page 18: ... is being transported or used 2 The trolley must not be used as a platform Slope of the machine The machine placed on the level on its feet or on its trolley slopes 2 to the front ATTENTION VIRAX 2 This slope prevents oil flowing towards the back in the tube Check therefore that this slope is maintained where work is to be carried out Be careful to secure the feet firmly to avoid the machine falli...

Page 19: ...mer chuck strike several blows towards you when you are on the operator s side to tighten the jaws onto the tube To loosen the chuck give successive blows in the opposite direction Positioning short tubes Place the tube in the front chuck and tighten the chuck just so it holds the tube Lower the die head and move the saddle so that the dies come into contact with the tube end Use the dies in the d...

Page 20: ...tive to the tube diameter Position the tube and tighten both chucks Select fast speed position 1 2 3 4 regardless of the tube diameter 2 4 1 2 Start the machine Lower the tube cutter and tighten it by turning its wheel to the right until the cutter wheel enters the tube Turn the tube cutter wheel evenly to the right until the end of the cutting operation The wheel must be turned about a quarter of...

Page 21: ...saddle wheel to the right move the saddle forward so that the reaming blade comes into contact with the tube end Note A plate on the frame gives a reminder that the saddle moves in the opposite direction to the direction of rotation of the wheel the saddle moves to the left i e towards the front chuck when you turn the wheel to the right and vice versa By applying a light force to the wheel contin...

Page 22: ...s well to the right of the groove on the front rail of the saddle ATTENTION VIRAX The saddle must not go past this limit doing this will tear the thread and could even cause the tube to crack Start the motor Switch the oil system selector to the position corresponding to the tube diameter 1 2 2 2 4 This selector is located behind the machine on the head spindle reception block Note The intermediat...

Page 23: ...die has cut 3 or 4 threads release the wheel and let the saddle move by itself You should not accompany the movement of the saddle as this risks making the thread inaccurate When the preset length of the thread is reached the dies will retract automatically The operator has to manually open the 1 4 3 8 die head Stop the motor Check that the length of the thread and the outside diameter are suffici...

Page 24: ...om 1 2 to 4 Available diameters Nipple holder diameter Minimum reel length mm Virax part numbers 1 2 46 162450 3 4 53 162451 1 56 162452 1 66 162453 1 66 162454 2 73 162455 2 77 162456 3 82 162457 4 95 162459 Produce the first thread as indicated in the previous paragraph Screw the threaded section fully onto the nipple holder Machine 4 pouces EN indd 22 22 08 2007 08 59 24 EN ...

Page 25: ...key loosen the screws holding the upper shell and remove the nipple Important Release the nipple by loosening the holding shell and not by unscrewing the nipple The central section is too narrow to accept pliers When unscrewing the nipple you would risk damaging the two threads Machine 4 pouces EN indd 23 22 08 2007 08 59 24 EN ...

Page 26: ...ne is delivered the head is fitted with its dies Tilt the die head support block for the 2 head to the right This block is behind the locking handle for the 4 head the lever with Open plate on its body Position the head tilting spindle in the large diameter cylinder on the frame The small diameter cylinder is for the spindles for 1 4 3 8 and 1 2 2 heads Pull the head housing unlocking handle marke...

Page 27: ...o the diameter Loosen the setting thumbwheel for the cam associated with the required diameter 5mm Allen key Turn the thumbwheel clockwise to increase the thread depth i e to reduce the thread outside diameter and anticlockwise to reduce the thread depth i e to increase the thread outside diameter Note The setting thumbwheels have marks allowing the thread outside diameter to be set finely Tighten...

Page 28: ...ter Replace the locking lever spindle Lock the locking lever again Adjusting the thread length There is a thread length corresponding to each tube diameter Position the length selector on the indication corresponding to the tube diameter Important If an NPT head is to be used put the turret in place part no 753171 Position of the plate s to increase the thread outside diameter Position of the plat...

Page 29: ...tion or the other Use a 5mm Allen key for this The setting screws are pre positioned in the workshop The red line on each screw corresponds to the standard thread length for this diameter Note The dies open when the cam roller reaches the end of the cam and drops Machine 4 pouces EN indd 27 22 08 2007 08 59 32 EN ...

Page 30: ...ilt the die head support block to the left This block is located behind the locking lever for the 4 head the lever with Open plate on its body Position the head tilting spindle in the small diameter cylinder on the frame The large diameter cylinder receives the spindle for the 4 head Tilt the head to lock it in the die head support block see above Machine 4 pouces EN indd 28 22 08 2007 08 59 34 EN...

Page 31: ...rrow indicates the tightening direction Holding the setting lever position the scale such that the indication of the tube diameter is opposite the setting marker Note The head is delivered with a scale for BSPT and NPT threads The BSPT settings are shown by single red lines the NPT settings are shown by red lines each accompanied by a blue dot Machine 4 pouces EN indd 29 22 08 2007 08 59 35 EN ...

Page 32: ...y decreasing or increasing the angle of the finger which controls the retraction of the dies Note While cutting the thread you can open the head by operating the lever Loosen the screw located below and behind the die retraction lever 6mm Allen key Position the required line opposite the marker the leftmost line gives the greatest thread length and the rightmost line gives the shortest thread leng...

Page 33: ...stalling dies for the 1 4 3 8 head Tilt the die head support block to the left This block is behind the locking lever for the 4 head the lever with Open plate on its body Position the head tilting spindle in the small diameter cylinder on the frame The large diameter cylinder receives the spindle for the 4 head Tilt the head to mount it in the die head support block see above Machine 4 pouces EN i...

Page 34: ...to the BSPT thread standard G for Gas The other markers refer to the BSW standard Adjusting the thread outside diameter You can set the thread outside diameter by moving the thread scale a short distance in one direction or the other relative to the marker Manually opening the dies When the tube end reaches the tips of the dies open the dies by moving the die bearer plate lever anticlockwise 3 1 2...

Page 35: ...BSPT dies NPT dies etc The thread standard is engraved on the face opposite the die Make sure you insert the correct dies for the thread standard you are going to use 2 The four dies must be replaced with four new dies supplied exclusively by Virax 3 The dies are numbered as each die works separately Ensure that each die is placed in the corresponding socket die no 1 in socket no 1 die no 2 in soc...

Page 36: ...late down to its stop Remove the dies Insert the dies with the notch towards the front of the machine Insert each die until you can feel that the die is blocked by the ball inside the socket Holding the notch pointer support tilt the die bearer plate up so that the notch pointer is opposite the cam corresponding to the tube diameter Lock the pointer on the cam Machine 4 pouces EN indd 34 22 08 200...

Page 37: ...to its working position Replacing dies on the self opening 2 head Firstly retract the dies by operating the opening lever Loosen the cam bearer plate locking lever by turning it in the reverse direction to that indicated by the arrow Machine 4 pouces EN indd 35 22 08 2007 08 59 43 EN ...

Page 38: ...e no 1 in socket no 1 die no 2 in socket no 2 etc Insert each die until you can feel that the die is blocked by the ball inside the socket Note The line engraved on the die is used to position the die when it is placed in a manually opened head It must not therefore be used as positioning marker with the 2 head Position the setting cam according to the tube diameter and the desired outside thread ...

Page 39: ...the stop which frees the dies The anti stop finger of the washer prevents the die bearer plate from moving into the die freeing position Remove the dies in any order To remove die no 3 lift the die bearer plate lever Put the new dies in place in compliance with the numbering die no 1 in socket no 1 die no 2 in socket no 2 etc the notch turned anticlockwise Insert each die up to its stop Note The d...

Page 40: ...r to the right which places the cams in the dies Position the die bearer plate according to the tube diameter and the desired external thread diameter see page 32 tighten up the lever Machine 4 pouces EN indd 38 22 08 2007 08 59 45 EN ...

Page 41: ...ning Wear gloves when handling turnings risk of being badly cut Remove the scrap receiver and the oil filter grid and clean the strainer Note The strainer can also be removed to facilitate cleaning Top up the oil if necessary by pouring it directly into the container Minimum oil level half the diameter of the strainer Important You must use oils supplied by Virax See page 9 for the part numbers of...

Page 42: ...if it shows signs of wear or if you need to cut tubes in a different material Two wheels are available depending on the material used for the tube wheel for tubes in carbon steel part no 162470 wheel for tubes in stainless steel part no 162471 Remove the gudgeon wires holding the wheel replace the wheel and tighten the gudgeon wires again Warning Do not forget to tighten the gudgeon after replacin...

Page 43: ...ube cutter and replace it with a new one Replace the tube cutter and insert it using the gudgeon punch by striking towards the front of the machine Replacing the reaming cone Replace the reaming cone when it shows signs of wear Reaming cone for the 162140 part no 753077 Remove the gudgeon holding the cone in place using a 5 mm gudgeon punch Remove the cone replace it with a new one and replace the...

Page 44: ...mer in place and reposition the gudgeon Replacing the front chuck jaws The front chuck jaws must be replaced when they show signs of wear Set of jaws for the 162140 part no 753071 Note The jaw holders do not have to be removed to replace the jaws Important All three jaws must be replaced at the same time Turn the motor over so as to bring the jaw holder whose jaw is to be removed into vertical pos...

Page 45: ...the jaw Replace the jaw and reassemble it transfer set screw towards the front of the chuck Replace the spring retainer spring and screw and tighten the jaw fastening screw Jaw retaining screw Jaw retaining screw Spring Spring Spring retainer Spring retainer Jaw and jaw transfer set screw shown here on the right of the jaw not visible in the figure Jaw and jaw transfer set screw shown here on the ...

Page 46: ...eplace the jaw holders 2 The jaw holders of the centring chuck rear chuck are only subject to slight wear Using a 5mm Allen key unscrew the 6 jaw holding plate screws Dismantle the jaw holding plate crown assembly or ask a colleague to hold the crown by the spindle nose while you remove the jaw holder Spindle nose Spindle nose Crown Crown Machine 4 pouces EN indd 44 22 08 2007 08 59 57 EN ...

Page 47: ...er Position the start of the drive ring spiral opposite jaw holder no 1 and insert the jaw holder into the spiral Turn the ring 120 such that the start of the spiral is opposite jaw holder no 2 and insert the jaw holder Do the same for jaw holder no 3 Continue to turn the ring until the jaw holders are completely blocked If necessary replace the chuck crown around the spindle nose and place the ja...

Page 48: ...w the jaw holding plate back onto the spindle nose Spindle nose Spindle nose Nose pin Nose pin Crown Crown Slot for spindle nose pin Slot for spindle nose pin Machine 4 pouces EN indd 46 22 08 2007 08 59 59 EN ...

Page 49: ...the start button see page 8 Attention concerning the machine being restarted after an unexpected stop The motor is burnt out Contact Virax or their representative to change the motor The machine shaft is not driven by the motor The transmission is broken Contact Virax or their representative to change the transmission The rotation of the shaft is slow or irregular The power supply voltage is too l...

Page 50: ...selector to the position corresponding to the tube diameter See page 20 The oil system is fouled Remove turnings from the scrap receiver and the oil filter grid and clean the strainer See page 39 The oil level is insufficient Add oil supplied by Virax see page 9 by pouring it directly into the container Minimum oil level half the diameter of the strainer The oil is no longer clear The oil has been...

Page 51: ...uality of the thread obtained is not satisfactory Same reasons as above dies fouled or worn or die numbering not complied with See above Oil worn out Drain the oil see page 40 and refill with a sufficient quantity of oil supplied by Virax see page 9 The thread is not deep enough or is too deep The outside diameter of the thread has not been set correctly Adjust the thread outside diameter so as to...

Page 52: ...e cutter by a new one See page 41 Use the tube cutter on carbon steel or stainless steel tubes Reaming problems Reaming is not satisfactory The reaming cone is worn Replace the cone by a new one See page 41 The reamer is damaged The reamer is worn or has been used for tubes which are too hard Replace the reamer by a new one See page 42 Use the reamer on carbon steel or stainless steel tubes Machin...

Page 53: ...views If you need a particular part please indicate the title of the exploded view as well as the number of the part on this view Exploded view of the lower frame Machine 4 pouces EN indd 51 22 08 2007 09 00 00 EN ...

Page 54: ...52 Exploded view of the upper frame chucks and pump Pump Pump Machine 4 pouces EN indd 52 22 08 2007 09 00 01 EN ...

Page 55: ...53 Exploded view of the motor Machine 4 pouces EN indd 53 22 08 2007 09 00 02 EN ...

Page 56: ...54 Exploded view of the motor transmission not including chucks and the speed selector Machine 4 pouces EN indd 54 22 08 2007 09 00 03 EN ...

Page 57: ...55 Exploded view of the saddle Machine 4 pouces EN indd 55 22 08 2007 09 00 04 EN ...

Page 58: ...56 Exploded view of the automatic opening mechanism for the 4 chuck Machine 4 pouces EN indd 56 22 08 2007 09 00 04 EN ...

Page 59: ...57 Exploded view of the 4 die head Machine 4 pouces EN indd 57 22 08 2007 09 00 05 EN ...

Page 60: ...58 Exploded view of the automatic opening 2 die head Machine 4 pouces EN indd 58 22 08 2007 09 00 05 EN ...

Page 61: ...59 Exploded view of the 1 4 3 8 die head Machine 4 pouces EN indd 59 22 08 2007 09 00 07 EN ...

Page 62: ...60 Exploded view of the tube cutter Machine 4 pouces EN indd 60 22 08 2007 09 00 07 EN ...

Page 63: ...61 Exploded view of the reamer Machine 4 pouces EN indd 61 22 08 2007 09 00 07 EN ...

Page 64: ...62 Components of a nipple holder Machine 4 pouces EN indd 62 22 08 2007 09 00 08 EN ...

Page 65: ...EN ...

Page 66: ...EN ...

Page 67: ...EN ...

Page 68: ...t van onze resellers www virax com EL Συμβουλευτείτε τη λίστα των διανομέων μας στο www virax com PL Listę naszych dystrybutorów znajdziecie na www virax com DE Eine aktuelle Liste unserer Handelspartner finden Sie unter www virax com CS Seznam našich prodejců najdete na www virax com RU Список дилеров вы можете найти на сайте www virax com TR Distribütör lerimizin listesini www virax com web site...

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