POWERMASTER Tube End Facing Machine FMP-8000

Operation and Maintenance

Guide

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TUBE END FACING MACHINE

Operation and Maintenance Guide

PNEUMATIC DRIVE

Powermaster Engineers Pvt. Ltd.229 • Pragati Industrial Estate

N.M. Joshi Marg • MumbaiPhone 91-22-23006122 • Fax 91-22-23073761

mailbox@tubeexpander.com www.tubeexpanders.com

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OPERATION INSTRUCTIONS

FACING MACHINE WITH PNEUMATIC DRIVE

TECHNICAL SPECIFICATIONS

P N E U M A T I C D R I V E F M D - P STALL TORQUE –220NM FEED COMPRESSED AIR, DEHUMIDIFIED AND

LUBRICATED MAXIMUM PRESSURE 8 BAR AIR CONSUMPTION 39 CFM SPEED 110 RPM WEIGHT 3.5 KG

PART NOMENCLATURE

F A C I N G A T T A C H M E N T F M P - 8 0 0 0 RANGE 50-203 mm TUBE ID WEIGHT 27 kg.

Hand

BevellingTool

Extension Jaws

Jaws Expansion Nut

feed

facing

Tool

ASSEMBLY INSTRUCTIONS

MOUNTING OF JAWS ON CENTRAL MANDREL ( Fig 1 & 2 )

1. Select the proper jaws set/sets from the selection charts (page 15) as per the I.D. of the tube which is to be faced/beveled.

2. Remove the csk. screws from the top of extension jaw (2), then remove the allen cap screws from the top of the extension jaw (1).

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PneumaticDrive

Hos

Ball

Fig.1 : FACING MACHINE FMP-8000

2

1

3. Fix the selected extension jaws (1) to the locking jaws, which are already engaged with the central mandrel. Now fix the selected extension jaws (2) to the extension jaws (1) with csk screws.

4. Slide facing or bevelling tool bit through one of the slots provided in the tool holder. Fix the tool bit as per the tube O.D. and marking provided on the tool holder. So that it can cover the thickness of the tube.

MOUNT FACING MACHINE ON TUBE (Fig. 1 & 3)

1. Turn the Hand wheel anti-clockwise for maximum required distance (do not touch to max. limit). Insert the jaws in the tube and tighten the Jaws -expansion nut at the rear end until jaws expand to hold firmly at the inner diameter of tube.

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Fig. 2

The Facing assembly self aligns and clamps with tube. The operator is now free to suspend the assembly on tube, allowing operator’s hands free.

CONNECTING AIR SUPPLY

1. Keep ball valve closed. Connect hose to ball valve on air motor and connect the other end of hose to source of filtered, dehumidified and lubricated air supply.

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Fig. 3

Hand

Jaws Expansion Nut

NOTICE

Supply air 6 –7 bar pressure @ 39 CFV

Install Filter Regulator Lubricator (FRL) close to Air motor

8

Expl

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Vie

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Ball Valve Closed Ball Valve Open

STARTING THE FACING MACHINE

NOTE: Ensure the tool bit is away from tube. Reach air pressure 6-7 bars by turning the handgrip of the pressure regulator on FRL, verifying the air pressure reading on the manometer.

Open the ball valve of air motor. The tool holder rotates in clockwise direction and is ready for operation.

Slowly turn the hand wheel clockwise to bring tool bit in contact with tube face, while the tool holder is rotating and start operation as required

To bevel the tube end, replace facing tool bit with bevelling bit and cut a bevel as explained above

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STAGE 6 :- PNEUMATIC MOTOR ATTACHMENT

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EXTENSION JAWS SELECTION CHART

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The selection chart of extension jaw set/sets as per the tube I.D. is given below. Each jaw is marked with the alphabet for easy selection. Extension jaw set (1) :- H , J , K , L , M , NExtension jaw set (2) :- A , B ,C , D , E , F , G

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OPERATION AND MAINTENANCE MANUAL

AIR MOTOR

{NON-REVERSIBLE, FLANGE MOUNTED}

IMPORTANT INSTRUCTION

Always operate, inspect and maintain this tool in accordance with American national standard institute safety code for portable air tool (ANSI B186.1) and any other applicable safety codes and regulation

For safety, top performance and maximum durability of parts, operate this tool at 6.3 kg/ cm2 (90psig) max air pressure

Use 12mm bore hosepipe.

.

WARNING

Always turn off the air supply and disconnect the air supply hose before installing, removing and adjusting any accessory of this tool.

Use of other parts than the recommend parts may result in safety hazards, decreased tool performance and increased maintenance cost

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PLACING TOOL IN SERVICE

LUBRICATION

OIL Hydraulic oil No. 32 &64.

GREASE High temp grease

We recommend the use of airline lubrication in the air supply line. Attach the unit as close to the tool as practical. After each forty hours of operation, or as experienced, introduce 1.5cc of recommended grease. Do not grease excessive. Too much grease in the gear case will cause heating.

Grease leakage from the spindle end is also an indication that an excessive amount of grease has accumulated within the gearbox

Whenever the Gear end of the motor is disassembled, lubricate the gear train.

For 3 M Series air motors work approximately 25cc of the recommended grease into the gear train and around the bearing and the spindle.

WARNING

GENERAL INSTRUCTIONS

Always disconnect the air supply before doing maintenance.

Always use protective eye wear when performing on a tool or when operating a tool

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Do not disassemble the tool any further than necessary to replace or repair damage parts.

Do not disassemble the motor unless it is necessary to replace or repair damaged parts.

Do not disassemble the motor unless you have a complete set of new gaskets and O-rings for replacement

Do not remove any part, which is a press fit in or on a subassembly unless the removal of that part is necessary for repair or replacement.

Whenever grasping a tool or part in a vice, always use leather covered or copper cover vice jaws to protect the surface of the parts and help prevent distortion. THIS IS PARTICULARLTY TRUE OF THREADED MEMBER AND HOUSING.

The modular construction of 3 series motor permits selective disassembly whereby gearing can be separated from the power unit and disassembled without removing the motor from the rotor housing or in the motor can be removed and disassembled without removing the gear train from the gear chamber. Because of the modular construction the steps in the following disassembly procedures can be sequentially change to meet the particular situation.

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TROUBLE SHOOTING GUIDE

TROUBLE

PROBABLE CAUSE

SOLUTION

MOTOR WILL NOT

OPERATE

Rotor shaft and idler gears binding due to improper installation

First remove the adaptor. Then using an Allen key turn the output shaft. If the force to be applied is very great considering the gear ratio, the Gearing is

Spline in shaft of drive shaft and idler gears binding due to improper

Solution same as above

Rotor blades do not move out of their slots

The center punch mark on rotor housing A/F should be upper most while clamping the tool in horizontal position.

LOSS OF POWER Low air pressure at motor

Check air supply for top performance. The air pressure must be 90 psig

Worn vanes Install a new set of vanesInadequate motor

lubricationCheck air line lubricator refer the Diag for

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Worn or damaged parts

Replace parts

MOTOR HEATS UP Inadequate lubrication

Select the lubrication as specified

GEAR BOX HEATS UP BEYOND NORMAL

Improper lubrication

Select the lubrication as specified

GREASE LEAKAGE Too much grease in the gear box

Select the lubrication as specified

IN CASE OF ANY PROBLEM OTHER THAN THE SPECIFIED ABOVE PLEASE CONTACT POWERMASTER ENGG FOR HELP.

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