Romac Transmate TapMate, Operating Manual

Page 1: ...se of the TapMate XL 424 Pipe Drilling Machine Please read and understand this operation manual Our goal is to serve you our customer If you have any questions complaints or improvement suggestions please call us at 1 800 426 9341 06 19 2019 TAPMATE XL 424 Pipe Drilling Machine ...

Page 2: ...14 Attaching the TapMate XL 424 to the Valve 18 OPERATION Performing the Tap 21 Disassembly and Removal of the Coupon 26 Care and Maintenance 27 PARTS IDENTIFICATION DRAWINGS TapMate XL 424 included items 28 TapMate XL 424 base machine 29 Adapter Bells 4 12 30 Adapter Bells 14 24 31 Adapter Hubs 31 Small Shaft Head Assembly 32 Large Shaft Head Assembly 32 Jam Nut 32 TM XL PVC Pilot 33 TM PVC Pilot...

Page 3: ...300 psi pressure 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 corrosion Manual feed provides control and feedback during the cut Thrust Tube Thread is a 2 Stub Acme Thread for rapid and controlled travel through the Valve and Tapping Sleeve Neck Thrust Tube...

Page 4: ...nd Pilot Drill are extended through the valve and tapping sleeve neck to the pipe wall using the Brake Tube Han dles After the cut is complete the Shell Cutter and Pilot Drill retract through the valve to allow the valve to be operated After the tap is completed and you are drawing the Cutter away from the Pipe the Brake Tube thread prevents water pressure from turning the Brake Tube The Lead Tube...

Page 5: ...ATE XL 424 OPERATING MANUAL 5 v 1 3 OPEN THE SHIPPING CRATE WORKSTATION 3 Lift and remove Cover see fig 3 1 Open all six of the latches around bottom of the Crate 2 Swing open the End see fig 2 fig 2 fig 3 ...

Page 6: ... DQG 3LORWV VKRZQ EHORZ DUH IRU XVH RQ XFWLOH URQ DVW URQ DQG VEHVWRV HPHQW SLSH 70 6 7 126 7 36 TM XL PVC PILOT 14 16 TAPS TM XL PVC PILOT 18 24 TAPS 4 12 TYPICAL PVC CUTTER DESIGN TM SHAFT NOSE 4 12 TAPS fig 4 fig 5 Cutter and Pilots shown below are for use on Ductile Iron Cast Iron and Asbestos Cement pipe Cutter and Pilots shown here are for use on PVC pipe NOTE USE CARBIDE CUTTER PER FIG 4 FO...

Page 7: ...rely attached to the Lead Tube To determine which Adapter Hub you ll need see fig 6 below Small Adapter Hub for use with 4 12 TapMate Adapter Bells Large Adapter Hub for use with 14 24 TapMate XL 424 Adapter Bells NOTE The TapMate XL 424 is shipped from the factory without an Adapter Hub installed fig 6 ...

Page 8: ...propriate Adapter Hub for the size of Adapter Bell to be used Small Adapter Hub for 4 12 and Large Adapter Hub for 14 24 2 Align the Keyway in the Adapter Hub with the Key in the top of the Lead Tube see fig 7 3 Slide Adapter Hub over the end of the Lead Tube and engage the threads of the Lead Tube Locking Hub Collar see fig 8 Large Adapter Hub Small Adapter Hub fig 7 fig 8 ...

Page 9: ...en 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 Station Large Adapter Hub Small Adapter Hub Large Adapter Hub Small Adapter Hub fig 9 fig 10 ...

Page 10: ...rew Holes around the Neck of the Adapter Bell Continue to thread the Adapter on until the 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 fig 12 NOTE The Set Screw must bear ENTIRELY on the Flat of the Small Adapter Hub Otherwise damage to the threads of the Hub under the Set ...

Page 11: ...Nut facilitates easy removal the Shell Cut ters Thread the Jam Nut onto the Shaft Run it to the end of the Threads and then back off one complete revolution With a 3 16 Allen Wrench tighten Jam Nut Halves so that the gap between them is even see fig 16 Secure the Jam Nut halves by torquing the Jam Nut Bolts to approximately 50 in lbs 9 Take the TM Shaft Nose or TM PVC Pilot and exam ine the retent...

Page 12: ...er over the TM Shaft Nose or TM PVC Pilot and thread it onto the Shaft until it is snug against the Jam Nut 12 Retract the Shell Cutter into the Adapter Bell by rotating the Brake Tube in a count er clockwise direction The Brake Tube will stop rotating when it shows zero or a little beyond on the Thrust Tube Locate the Set Screw hole in the Brake Tube back over the scale in the Thrust Tube and re ...

Page 13: ... 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 Adapter Hub as your lift points Adjust the Chain Choker so that the Machine is as level as possible fig 20 fig 21 TAPMATE XL 424 SET UP FOR 4 12 TAPS CONT ...

Page 14: ...er Bell Gasket is in place 4 Lift the Adapter Bell by the Lifting Eye and move it into place The Shaft goes through the Center Hole in the Adapter Carefully slide the Adapter Bolts through the Mating Holes in the Large Adapter Hub 5 Replace the Nuts and Washer back onto the Adapter and tighten Nuts in a star pattern 6 Remove the Brake Tube Locking Bolt from the Brake Tube see fig 23 This will allo...

Page 15: ...Lubricant to the Shaft Head Bolt and start to thread it into the end of the Shaft with the 3 8 Allen Wrench Align the Key with the Keyway and finish bolting the Large Shaft Head into place using a torque wrench to install the Shaft Head Bolt to 95 ft lbs Apply Anti Galling Lubricant to both Set Screws and thread them into the Shaft using the 1 8 Allen Wrench The Set Screws lock the Shaft Head Bolt...

Page 16: ...s held securely in the slot If the Spade Bit is chipped or damaged it should be replaced For PVC Pilots check that the teeth are sharp If the teeth are chipped or damaged it should be replaced 10 Notice that the threaded ends on the TM XL Shaft Nose and the TM XL PVC Pilot are interrupted by a smooth area When the TM Shaft Nose or TM XL PVC Pilot is thread ed all the way onto the Large Shaft Head ...

Page 17: ...ided Tighten to a minimum of 30 40 ft lbs 12 Retract the Shell Cutter into the Adapter Bell by rotating the Brake Tube in a count er clockwise direction The Brake Tube will stop rotating when it shows zero on the Thrust Tube Check that the Lead Nut is sitting at zero on the Lead Tube TAPMATE XL 424 SET UP FOR 14 24 TAPS cont fig 28 fig 29 fig 30 13 The TapMate XL 424 is now ready to be lift ed and...

Page 18: ...lange NOTE These distances are often different de pending on the tap size and the Adapter Bell 4 Carefully compare the measurements taken in Steps 2 and 3 to ensure that there will be no interference between the Shaft Nose PVC Pilot or Shell Cutter and the Gate Valve when the tap is completed Clearance Distance Pilot Drill C L Valve Body Centerline of the Waterway Valve Gate Distance Cutter Cleara...

Page 19: ...ecord this measurement for later use Pipe Distance to Distance of Cut Travel Chart s 39 Inches Total Machine Shaft Travel Distance C L Cutter s Extension out of Adapter and into Valve Body or BORING SHAFT TRAVEL DISTANCE OF CUT 7 The TapMate XL 424 Boring Shaft can travel up to 39 inches which is more than adequate for most taps Before you begin your tap make sure the total distance to cut is not ...

Page 20: ... Valve Tapping Sleeve and or Pipe Adequately support the TapMate XL 424 so as not to put stress on the Pipe Valve or Tapping Sleeve Ensure that this support will accommo date the travel distance of the Thrust Tube and Brake Tube during the tap NOTE Do not support the machine by the threads 9 With the TapMate XL 424 secured to the Valve and supported disconnect and remove the Lifting Chains ATTACHI...

Page 21: ... Thrust Tube see fig 37 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 Locking Bolt into the collar of the Brake Tube and securely tighten It needs to bear down directly onto the Scale and NOT the threads of the Thrust Tube see fig 38 NOTE The Locking Bolt can ratchet if necessa...

Page 22: ...e sure to include 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 Cutter hitting the Valve s Seat Ring Is the Valve completely open Is there misalignment between the Valve and the Tapping Sleeve Neck Is the TapMate XL 424 in alignment with the Valve NOTE...

Page 23: ...art your Hydraulic Power Unit per the HPU manufac turer s 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 fig 41 NOTE The Shaft MUST BE TURNING IN THE CLOCKWISE DIRECTION as viewed from the back of the machine facing the pipe Damage will occur to the cutting equipment if the rotation is incorrect 9 Move the ...

Page 24: ...o determine completion of the tap On All Taps Except Size on Size Taps see next paragraph for information on size on size taps The Maximum Required Travel distance is the outside diameter of the pipe even if you still feel resistance while feeding the cutting tools At the comple tion of the cut you will feel the feed resistance and Cutter noise diminish When this happens turn the lever on the Driv...

Page 25: ...he Exhaust Valve on the back of the Adapter Bell 14 24 adapters 19 Reattach the Lifting Chains see figs 42 43 Small Adapter Hub Lifting Ring Rear Lifting Ring LIFTING CHAIN POSITIONS FOR 4 12 TAPS Adjust for Level Lift fig 42 Lifting Eye Rear Lifting Ring Adjust for Level Lift LIFTING CHAIN POSITIONS FOR 14 24 TAPS fig 43 ...

Page 26: ...Adapter Bell by unscrewing the Set Screw and then unthreading the Adapter Bell 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 Machine resting on the Work Station remove the Lifting Chains 2 Extend the Shaft until you have access to the back of the Shell Cutter and the Set Screws in the Large Shaft Head This is done b...

Page 27: ... keep the Jam Nuts tight Keeping them tight will hold the Cutter 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 following steps should be performed yearly Lubricate the Shaft as it moves through the inside of the Lead Tube To do this remove both 1 8 27 NPTF Set Screws located in the scale of the...

Page 28: ...LUBRICANT TECH LUBE TAPPING COMPOUND 16 366 66 10 TM XL TOOL KIT SPARE PARTS items listed below not pictured 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 3 16 IN 355 60 4 35 12 IN SPUD WRENCH 356 01 03 BT SLIDE GATE PIPE NIPPLE 1 2 IN x 1 1 2 IN...

Page 29: ...ETAINING RING ROTOR CLIP SH 400ST 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 19 366 35 TM XL THRUST TUBE STOP BLOCK 20 372 08 COUPLING SET SCREW SHSS 1 4 20 X 1 2 IN 21 366 20 TM XL SHAFT 22 366 20 10 TM XL SHAFT END INTERNAL SNAP RING SH225 23 366...

Page 30: ...PTER 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 IN 5 8 11 GR 8 HEX NUT TM ADAPTER BELL SET SCREW TM ADAPTER BELL O RING 3 1 2 3 4 5 6 7 8 TM ADAPTER BELL 4 8 INCH 350 05 XXXX 350 05 1032 TM MJ ADAPTER 4 350 05 1048 TM MJ ADAPTER 6 350 05 1064 TM MJ A...

Page 31: ...71 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 VALVE GASKET 511 3 00 SBR 366 05 1112 TM XL 14 INCH MJ ADAPTER 366 05 1128 TM XL 16 INCH MJ ADAPTER 366 05 1144 TM XL 18 INCH MJ ADAPTER 366 05 1160 TM XL 20 INCH MJ ADAPTER 366 05 1192 TM XL 24 INCH MJ...

Page 32: ... 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 TM XL SHAFT HEAD KEY TM XL SHAFT HEAD BOLT TM XL LARGE SHAFT HEAD 4 5 372 08 5 1 2 3 TM XL SHAFT HEAD KEY SCREW SHCS 1 4 20 X 1 1 4 5 1 366 10 01 2 366 09 01 3 366 09 02 4 366 09 03 366 10 TM XL LAR...

Page 33: ...366 39 2 1 360 22 03 2 360 22 04 3 360 22 02 QVIM SHAFT NOSE RETAINING PIN SET SCREW QVIM SHAFT NOSE RETAINING PIN SPRING QVIM SHAFT NOSE RETAINING PIN QTY 2 QTY 2 QTY 2 350 04 TM PVC PILOT 350 21 561 TM COUPON RETAINER BALL 5 16 350 21 55 TM COUPON RETAINER SPRING 350 21 512 TM COUPON RETAINER SET SCREW 3 8 24 X 3 8 ...

Page 34: ...FOR SHAFT NOSE QVR 6 REAMER CLAMP SCREW QTY 3 QTY 3 QTY 3 QTY 1 QTY 1 4 1 2 3 3 2 1 3 2 1 5 QTY 2 QTY 2 QTY 2 QTY 1 QTY 1 366 38 TM XL SHAFT NOSE COMPLETE 14 16 366 38 2 366 38 2 350 21 512 TM COUPON RETAINER SET SCREW 3 8 24 x 3 8 SHSS CUP POINT 350 21 55 TM COUPON RETAINER SPRING 350 21 561 TM COUPON RETAINER BALL 5 16 350 03 531 TM SPADE BIT LOCK SCREW 10 24 x 3 4 IN LONG S H C S 350 03 08 TM P...

Page 35: ...XL HYD MOTOR FLOW CONTROL 5 366 72 06 TM 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 HD 1 2 IN X 3 8 IN NPT BUSHING WEATHERHEAD 10 372 13 7 HD QUICK DISCONNECT FEMALE 1 2 IN FLUSH FACE 11 372 13 6 HD QUICK DISCONNECT MALE 1 2 IN FLUSH FACE 12 3...