Clemco PIPE-PRO XL User manual
PIPE-PRO XLTM
INTERNAL-PIPE BLAST TOOL
O. M. 27804
© 2017 CLEMCO INDUSTRIES CORP.
One Cable Car Dr.
Washington, MO 63090
Phone (636) 239-4300
Fax (800) 726-7559
www.clemcoindustries.com
DATE OF ISSUE: 2014
REVISION: A, 09/17
Do not use this
equipment until you
have READ this
MANUAL and YOU
UNDERSTAND its
contents. *
These WARNINGS are
included for the health
and safety of the
operator and those in
the immediate vicinity.
*If you are using a Clemco Distributor
Maintenance and Parts Guide, refer to
the orange warnings insert preceding
the Index before continuing with the
enclosed instructions.
Electronic files include a Preface
containing the same important
information as the orange cover.
WARNING
PIPE-PRO XL™ INTERNAL-PIPE BLAST TOOL Page 1
© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 27804 Rev A
1.0 INTRODUCTION
1.1 Scope of Manual
1.1.1 These instructions cover set-up, operation,
maintenance, troubleshooting, and replacement parts for
Clemco’s Pipe-Pro XLTM internal pipe blasting tool.
1.1.2 These instructions contain important safety
information. All operators and personnel involved with
the abrasive blast process must read and understand
the contents of these instructions, including the orange
cover. It is equally important that the operator is trained
and qualified to safely operate the blast machine, remote
controls, and all other equipment used with the blast
machine.
1.1.3 All personnel involved with the abrasive blasting
process must be made aware of the hazards associated
with abrasive blasting. The Clemco booklet Abrasive
Blasting Safety Practicesis included with every blast
machine, and contains important safety information
about abrasive blasting that may not be included in
equipment operation manuals. To order additional
copies, visit www.clemcoindustries.com or email
1.2 Safety Alerts
1.2.1 Clemco uses safety alert signal words, based on
ANSI Z535.4-2011, to alert the user of a potentially
hazardous situation that may be encountered while
operating this equipment. ANSI's definitions of the signal
words are as follows:
This is the safety alert symbol. It is
used to alert you to potential physical
injury hazards. Obey all safety
messages that follow this symbol to
avoid possible injury or death.
NOTICE
Notice indicates information that is considered
important, but not hazard-related, if not
avoided, could result in property damage.
CAUTION
Caution indicates a hazardous situation that, if
not avoided, could result in minor or moderate
injury.
WARNING
Warning indicates a hazardous situation that, if
not avoided, could result in death or serious
injury.
DANGER
Danger indicates a hazardous situation that, if
not avoided, will result in death or serious
injury.
1.3 Table of Contents
SUBJECT SECTION LOCATION
INTRODUCTION ........................................................1.0
Scope of Manual ........................................................1.1
Safety Alerts ...............................................................1.2
Table of Contents .......................................................1.3
COMPONENTS and OPERATING PRINCIPLES .....2.0
Components ................................................................2.1
Operating Principles ....................................................2.2
ANCILLARY EQUIPMENT REQUIREMENTS ...........3.0
Blast Machine and Accessories ..................................3.1
Nozzle Stand-Off Distance Tables ..............................3.2
For 16" to 31" Pipe ................................................3.2.1
For 32" to 60" Pipe ................................................3.2.2
Pipe Lance ..................................................................3.3
Air Motor Air-Requirements .........................................3.4
Compressed Air Requirements ...................................3.5
Ambient Temperature Range Limits ...........................3.6
ABRASIVES ...............................................................4.0
SET-UP .......................................................................5.0
Staging Platform ..........................................................5.1
Assemble Centering Carriage .....................................5.2
16" to 31" carriage ................................................5.2.1
32" to 60" carriage extensions ..............................5.2.2
Air Motor Connections .................................................5.3
Adjust Centering Carriage ...........................................5.4
Attach Nozzles and Nozzle Extensions ......................5.5
Connect Blast Hose and Lance ...................................5.6
OPERATION ...............................................................6.0
Set Motor Speed .........................................................6.3
PREVENTIVE MAINTENANCE ..................................7.0
Air Motor Air-Supply Line.............................................7.1
8-Hour Inspection ........................................................7.2
Nozzles and nozzle extensions .............................7.2.1
16-Hour Inspection ......................................................7.3
Blast head assembly..............................................7.3.1
Backplate coupling-flange .....................................7.3.2
30-Hour Inspection ......................................................7.4
Every Three Months and Before Long Term Storage .7.5
Air Motor Service .........................................................7.6
PIPE-PRO XL™ INTERNAL-PIPE BLAST TOOL Page 2
© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 27804 Rev A
SERVICE MAINTENANCE, DISASSEMBLY ............8.0
Carriage ......................................................................8.1
Blast Head Assembly, Removal and Inspection .........8.2
Backplate Coupling Flange, Removal and Inspection ..8.3
Front Housing and Bearing, Removal and Inspection ..8.4
Air Motor and Air Motor Gear, Remove and Inspect ..... 8.5
Axle, Axle Gear, and Rear Bearing
Removal and Inspection ..........................................8.6
Rear Seals Cartridge, Removal and Inspection .........8.7
SERVICE MAINTENANCE, REASSEMBLY .............9.0
Rear Seals Cartridge, Reassembly ............................9.1
Axle, Axle Gear, and Casing Reassembly...................9.2
Front Housing and Bearing Reassembly.....................9.3
Rear Bearing, U-Seal Cartridge, and Tube
Casing Reassembly..................................................9.4
Backplate Coupling-Flange Reassembly.....................9.5
Air Motor and Air Motor Gear Reassembly..................9.6
Blast Head Assembly Reassembly ............ Refer to 7.3.1
TROUBLESHOOTING
Blast head does not turn or turns too slowly .............10.1
ACCESSORIES and REPLACEMENT PARTS
Pipe-Pro XLTM Internal Pipe Blast Tools....................11.1
Conversion Kit, 16" to 31" Tool to 32" to 60" ............11.2
Nozzles and Nozzle Extensions ...............................11.3
Air-Motor Control Hose Kit.........................................11.4
Pipe-Pro XLTM Basic Tool..........................................11.5
Centering Carriage, 16" to 31" ..................................11.6
Centering Carriage, 16" to 60"...................................11.7
2.0 COMPONENTS and OPERATING PRINCIPLES
2.1 Components
2.1.1 The primary components of the Pipe-Pro XLTM
tool are shown in Figure 1 and Figure 2. Figure 1 shows
the basic tool, Figure 2 shows the items in the air motor
control hose kit. The control hose kit is packaged
separately and must be assembled and installed. Nozzle
and nozzle extension are options, which are shown for
reference and ordered separately.
For blasting 16-inch ID to 31-inch ID pipe the following
are included or required:
1. Basic tool: Includes the pipe tool with blast
hose/lance coupling, air motor green supply tube,
and red return tube.
2. Air motor control package includes:
Filter/pressure regulator assembly to filter air
and control compressed air pressure to the air
motor.
Inline air filter for the compressed air supply side
of the air motor.
Flow control assembly for the return side of the
air motor.
Two 50-ft. lengths of 3/8" ID air hose; one for the
air supply to air motor, the other for the air return
(exhaust) from the air motor.
Figure 1
* Nozzle extensions are included with
28046 - 16" to 60" Pipe-Pro XL Tool
28047 - Large Pipe Conversion Kit
* Optional Nozzle Extension
Nozzle
Nozzle Washer
Nozzle Washer
Blast Head
Air Motor
Carriage Collar
Blast Head Lock Nut Red Outlet (exhaust)Tube
Green Inlet Tube
Carriage Rail and Casters (3 sets)
Carriage Leg (6 [3-Sets])
Blast Hose (Lance) Coupling
Carriage Assembly Outlet (exhaust) hose Connector
Connects to red outlet tube
Inlet Tube Connector with Filter
Connects to green inlet tube
PIPE-PRO XL™ INTERNAL-PIPE BLAST TOOL Page 3
© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 27804 Rev A
Figure 2
3. Centering carriage: Includes the carriage collar, a
set of three rail and castor assemblies, and six
each 6-inch and 12-inch legs.
4. Nozzles: Order two separately, refer to cfm
requirements in Figure 3.
For blasting 32-inch ID to 60-inch ID pipe: In addition to
the 16" to 31" tool noted above the large-pipe conversion
kit, Stock No. 28047, is required. Refer to Section 11.7
for items included with the kit.
2.2 Operating Principles
2.2.1 The Pipe-Pro XLTM blast tool attaches to the end
of a pipe lance (refer to Section 3.3 for description and
additional information on the lance) and blast hose in
place of a standard nozzle.
2.2.2 The tool is designed to blast clean the inside of
16" to 60" ID pipe, to a maximum distance of 100 feet;
Distances beyond 100 feet may require blast machines
with electric remote controls and large unrestricted air
line, piping and blast hose.
2.2.3 The tool includes a pneumatic-driven blast head
that rotates independently from the force of the blast
nozzles. Rotation speed is controlled with the flow-
control valve on the air motor return (exhaust) line.
2.2.4 The tool utilizes two venturi blast nozzles with
orifice size ranging from 1/4" to 3/8", as shown in the
table in Figure 3 and Section 11.3.
2.2.5 The adjustable centering carriage centers the
tool within the pipe. Soft carriage wheels provide smooth
movement through the length of the pipe.
3.0 ANCILLARY EQUIPMENT REQUIREMENTS
3.1 Blast Machine and Accessories
3.1.1 The blast machine should be of at least 6 cu. ft.
capacity and have a minimum of 1-1/4" piping.
3.1.2 Minimum recommended size for blast hose and
pipe lance are as follows:
1/4" orifice or 5/16" orifice nozzles
Use a 1 1/4" ID blast hose and lance.
3/8" orifice nozzles
Use a 1 1/2" ID blast hose and lance.
Smaller diameter hose and lance may result in lower
nozzle pressure and could cause premature wear on the
blast hose and tool.
NOTE: The maximum recommended nozzle orifice size
is 3/8" diameter. Larger orifice nozzles may result in
lower nozzle pressure and will accelerate wear on the
blast hose and tube.
Nozzles (2)
Orifice Size
Air Consumption
CFM at 100 PSI
New Worn
Minimum ID
Air Line
1/4" 165 to 275 1-1/2"
5/16" 275 to 395 2"
3/8" 395 to 510 2-1/2"
The table shows the minimum recommended ID for the
air supply line to the blast machine. CFM shown is the
approximate cfm consumed by two nozzles when the
nozzles are new and when worn. A nozzle is considered
worn when the orifice is 1/16" larger than its original size.
Figure 3
3/8-NPT Filter/Regulator
Adaptor, 3/8-NPT x 3/8 Hose (2)
Air Supply 3/8 Hose Union, use to attach additional
3/8 hose length when needed.
From red outlet tube
To green inlet tube
Adaptor, 1/4-NPT x 3/8 Hose (2)
Quick-Release Tube Fitting (2)
3/8-NPT Muffler
3/8-NPT Flow-Control Valve
Adaptor, 3/8-NPT x 3/8 Hose (2) Adaptor, 1/4-NPT x 3/8 Hose (2)
In-Line Filter, 1/4-NPT M/F
Quick-Release Tube Fitting (2)
3/8 x 50-Ft, Air Hose (2)
PIPE-PRO XL™ INTERNAL-PIPE BLAST TOOL Page 4
© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 27804 Rev A
3.2 Nozzle Stand-Off-Distance Tables
The stand-off distance is the distance from the exit end
of the nozzle to the inside surface (diameter) of the pipe.
3.2.1 For 16" to 31" Pipe
3.2.1.1 The table in Figure 4 shows the approximate
stand-off distances of short and long venturi nozzles
when blasting pipe diameters between 16" and 31".
3.2.2 For 32" to 60" Pipe
3.2.2.1 The table in Figure 5 is a quick view of
approximate stand-off distance for nozzles and nozzle
extensions when blasting 32" to 60" pipe. When more
precision is needed refer to Figure 6 to calculate nozzle
stand-off distances.
3.2.3 The nozzles and stand-off distances shown are
only guidelines to assist the user in choosing nozzle type
and orifice diameter; it does not show the nozzle to use
with a given pipe diameter. Usually the minimum stand-
off distance is about four inches; maximum distance is
generally between 8" and 16" but depends on nozzle
orifice size (usually determined by the volume of
compressed air available), nozzle pressure, surface
condition, and degree of cleaning required.
NOZZLE STAND-OFF-DISTANCE
FOR 16" to 31" ID PIPE
PIPE SHORT LONG VENTURI NOZZLE
INSIDE VENTURI 1/4" 5/16" 3/8"
DIAMETER NOZZLE Orifice Orifice Orifice
16" 3-3/4" 1-3/4" 1-1/4" N/A
17" 4-1/4" 2-1/4" 1-3/"4 3/4"
18" 4-3/4" 2-3/4" 2-1/4" 1-1/4"
19" 5-1/2" 3-1/4" 3" 2"
20" 6" 4" 3-1/2" 2-1/2"
21" 6-1/2" 4-1/5" 4" 3"
22" 7" 5" 4-3/4" 3-3/4"
23" 7-3/4" 5-1/2" 5-1/4" 4-1/4"
24" 8-1/4" 6-1/2" 5-3/4" 4-3/4"
25" 9" 6-3/4" 6-1/2" 5-1/2"
26" 9-1/2" 7-1/2" 7" 6"
27" 10" 8" 7-1/2" 6-1/2"
28" 10-1/2" 8-1/2" 8" 7"
29" 11-1//4" 9" 8-3/4" 7-3/4"
30" 11-3/4" 9-3/4" 9-1/4" 8-1/4"
31" 12-3/4" 10-1/4" 9-3/4" 8-3/4"
Figure 4
NOZZLE STAND-OFF DISTANCE for 32" TO 60" ID pipe
LONG VENTURI NOZZLE
PIPE INSIDE SHORT 1/4" 5/16" 3/8"
DIAMETER VENTURI NOZZLE Orifice Orifice Orifice
32" to 36" W/O Extensions 13" to 15-1/4" 10-3/4" to 13" 10-1/2" to 12-3/4" 9-1/2" to 11-3/4"
32" to 36" W/6" Extensions 7" to 9-1/2" 4-3/4" to 7" 4-1/2" to 6-3/4 N/A
37" to 47" W/6" Extensions 9-3/4" to 15-1/2" 7-3/4" to 13-1/5" 7-1/4" to 13" 6-1/4" to 12"
48" to 60" W/12" Extensions 10" to 17" 8" to 15" 7-3/4" to 14-3/4" 6-3/4" to 13-3/4"
53" to 60" W/18" Extensions 7" to 11" 5" to 9" 4-1/2" to 8-3/4 3-1/2" to 7-3/4"
Figure 5
FORMULA TO CALCULATE NOZZLE STAND-OFF
FOR 32" to 60" PIPE
NOZZLE TYPE BASE DIMENSION
@ 32” DIA. PIPE
Short Venturi 13 Inches
1/4" Orifice Long Venturi 11 Inches
5/16" Orifice Long Venturi 10-1/2 Inches
3/8" Orifice Long Venturi 9-1/2 Inches
To obtain stand-off distance for pipe larger than 32", add
0.58" for every inch over 32 and subtract length of nozzle
extension.
For example, to calculate the stand-off distance of a 48
inch diameter pipe when using a No. 5 long venturi nozzle
Subtract 32" from 48" = 16"
Multiply 0.58" x 16 = 9.28 (9-1/4")
Add 9-1/4" to No. 5 base dim. (9.1/4 + 10-1/2" = 19-3/4")
The stand-off distance is approximately 19-3/4".
When using a nozzle extension subtract the length of the
extension. In the case of the example:
Subtract 6" for a 6" extension (19-3/4" - 6" = 13-3/4"
stand-off).
Subtract 12" for a 12" extension (19-3/4" - 12" = 7-3/4"
stand-off).
Figure 6
PIPE-PRO XL™ INTERNAL-PIPE BLAST TOOL Page 5
© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 27804 Rev A
3.3 Pipe Lance, Figure 7
Figure 7
3.3.1 The Pipe-Pro XLTM includes a Clemco CFT
Coupling, Stock No. 24232, which provides a quick
connection for a blast hose or lance using standard
Clemco quick couplings.
3.3.2 A lance is one or more length of standard
schedule-40 pipe connected end-to-end to equal the
length of pipe being blasted. Sections of pipe may be
coupled or uncoupled as needed as the tool is moved
through the pipe.
3.3.3 Standard pipe couplings may be used to
connect pipe sections together if there is no need to
attach or remove sections while blasting. When sections
do need to be added or removed, the following quick
couplings on each end of the lance sections are
recommended:
1-1/4" NPT lance: use two Clemco CF Couplings,
Stock No. 00551.
1-1/2" NPT lance: use two Clemco CF-2 Couplings,
Stock No. 00553.
3.4 Air Motor Air-Requirements
NOTICE
The air motor does not require lubrication.
Trace amounts of oil in the air supply will not
damage the motor. However, oil-contaminated
compressed air will accelerate wear on the
motor and cause sluggish rotation. Moisture
will damage the motor.
3.4.1 Clean dry air is essential for trouble-free operation
of the air motor; moisture in the air motor air line could will
accelerate wear on the motor.
3.4.2 Dust or abrasive ingress will cause extensive
damage to the air motor. The filter/pressure regulator
removes particulates from the air supply. An inline filter
is installed on the air inlet side of the air motor for
additional protection.
3.4.3 Maximum air pressure to the air motor is 100
psi. Higher pressure will damage the motor. A
combination filter/pressure regulator is provided and
must be installed at a convenient location in the air
supply line. The regulator is used to adjust pressure
between the recommended pressures of 80 to 90 psi.
3.5 Compressed Air Requirements
3.5.1 The compressor and air supply line to the blast
machine must be sized to maintain a minimum of 100 psi
at the cfm shown in the table in Figure 8.
3.5.2 The table shows the volume of air used at 100
psi (minimum pressure) when nozzles are new and
when they are considered worn (the nozzle is
considered worn when the orifice, which is the smallest
diameter inside the nozzle, is 1/16" larger than original
size). The pneumatic drive motor (air motor) requires
approximately 50 scfm of clean dry air for proper
operation. Consult with an air compressor supplier for
compressor recommendations.
Pipe Pro Tool
Carriage Rail
CFT Blast Hose (Lance) Coupling
Lance Coupling, Refer to Paragraph 3.3.3.
Lance, Refer to Paragraph 3.3.3.
Additional lance when needed
Blast Hose
Safety Lock-Pin
PIPE-PRO XL™ INTERNAL-PIPE BLAST TOOL Page 6
© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 27804 Rev A
\
Pipe-Pro Air Consumption
Nozzle Orifice New Nozzles Worn Nozzles
1/4" 220 cfm 330 cfm
5/16" 330 cfm 450 cfm
3/8" 450 cfm 560 cfm
Figures include an additional 50 cfm
required to operate the air motor
Figure 8
3.6 Ambient Temperature Range Limits
3.6.1 25oto 120oFahrenheit. These are the upper and
lower temperature limits for the air motor.
4.0 ABRASIVES
4.1 The tool is best suited for use with slag products
that are specifically manufactured for blasting.
Nozzle Orifice Nominal Abrasive Size
1/4" 20 to 40 mesh
5/16" 20 to 40 mesh
3/8" 16 to 40 mesh
4.2 Aggressive abrasives, such as garnet may be
used, but consideration must be given to the accelerated
wear on all parts in contact with the abrasive and the
additional maintenance required to keep the tool in good
working order.
5.0 SET-UP
WARNING
Hose disconnection while under pressure could
cause serious injury or death. Use safety lock-
pins and safety cables on all coupling
connections to help prevent hose couplings
from accidental disconnection.
5.1 Staging Platform
5.1.1 Provide a level platform or structural support for
the carriage wheels to ride on at the entrance/exit end of
the pipe. Do not manually lift the tool in or out of the pipe
while blasting. A shroud may be built at the ends of the
pipe to contain blasting, or any voids at the ends of the
pipe can be blasted using a standard blast nozzle.
5.2 Assemble Centering Carriage
5.2.1 16" to 31" carriage, Refer to Figure 9
5.2.1.1 Refer to the table in Paragraph 5.4.3, Figure 14,
to determine which size leg should be used and how far
the leg should be inserted into the collar couplings to
center the tool in the pipe.
5.2.1.2 Thread the six legs into the three carriage rails
as shown in Figure 9.
Figure 9
5.2.1.3 One rail end is covered with a plate. When
inserting the legs into the collar couplings, make sure the
covered ends face the front of the collar, and inserted
into the same side of the couplings, as shown.
5.2.1.4 Insert the legs to the initial length noted in the
table in Paragraph 5.4.3, Figure 14, and tighten the bolts
to secure.
5.2.2 Optional 32" to 60" Carriage Extensions
Refer to Figure 10.
5.2.2.1 Screw the 26" legs into the rails.
5.2.2.2 Refer to the table in Paragraph, 5.4.3, Figure 14
to determine how far the leg should be inserted into the
collar coupling to center the tool in the pipe. Make sure
the legs are inserted into the same side of the coupling.
Tighten coupling bolts to secure the legs.
5.2.2.3 Insert the rail extensions into the carriage rails
and align bolt holes. Use 8 mm fasteners provided to
secure.
Legs (6)
Collar Couplings
Cover
Plate
Front of
Collar
Like This Not Like This
Carriage Rails (3)
Make sure all legs are
inserted as shown.
PIPE-PRO XL™ INTERNAL-PIPE BLAST TOOL Page 7
© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 27804 Rev A
Figure 10
5.3 Air Motor Connections
5.3.1 Assemble and attach the inlet and outlet tube
connectors as shown in Figures 1 and 2. The inlet tube
connector with filter must be connected to the green inlet
tube. To attach the connectors to the tubing, simply insert
the tubing through the collar and push until it bottoms out
in the fitting. Tug on the tube to make sure it is secured.
To release the connectors, refer to Figure 11. An arrow on
the inlet tube shows the direction of air flow; the green
tube, with the arrow pointing toward the tool is the inlet,
the red tube is the outlet. NOTE: If the arrow or tubing
are removed or damaged, use a flashlight to look into
the carriage collar; the green inlet tube goes to the
"R" port on the air motor, the red outlet tube goes to
the "EXH" port on the motor.
Figure 11
5.3.2 Refer to Figure 12 and set up an air supply to
the 3/8" x 50' air hose provided with the tool.
NOTICE
To reduce the risk of abrasive ingress into the
air motor, cover air motor fittings and hose ends
when disconnecting air hoses from the tool. Any
dust or abrasive from the air supply, which
enters the air motor, will cause the air motor to
fail. Motor failure from ingress of dust, abrasive,
or any foreign matter voids the warranty.
5.3.3 The air supply line to the filter/regulator inlet and
the smallest inside diameter of any connections must be
at least 3/8" ID. Increase the inside diameter to 1/2"
when using more than one section of supply hose;
multiple connections of 3/8" hose could restrict air
volume needed to operate the air motor.
NOTICE
A combination filter/pressure regulator is
provided and must be installed in the air motor
air supply line. The filter removes particles that
could damage the motor. The pressure regulator
reduces pressure to below 100 psi. Maximum
operating pressure for the air motor is 100 psi.
5.3.4 Attach one 3/8" air hose from the air supply
(filter/regulator) to the air motor inlet-tube connector, as
shown in Figure 12. The inlet tube is identifiable by its
green color and inline filter. The hose must be long
enough to reach between both ends of the pipe being
blasted; attach additional lengths of hose as needed.
5.3.5 Attach the flow-control assembly to one end of
the second 3/8" hose and attach the other end to the
tube connector on the red outlet tube from the air motor;
this hose must also be long enough to reach between
both ends of the pipe being blasted.
5.3.6 The flow-control valve should be placed at
approximately the same location as the blasting control
handle. Air flow through the motor begins when the flow-
control valve is opened, the more the flow-valve is
opened, the faster the head rotates. The head stops
rotating when the flow-control valve or shutoff valve is
closed. The flow-control valve is opened or closed, as
required to rotate the blast head at 40-60 rpm.
Push collar in to release tubing
Pull tubing straight out
Retaining Collar
Collar Couplings
8 mm Cap Screw
Rail Extension
Rail
8 mm Lock Nut
Make sure all legs are
inserted from the same side
PIPE-PRO XL™ INTERNAL-PIPE BLAST TOOL Page 8
© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 27804 Rev A
Figure 12
5.4 Adjust Centering Carriage
5.4.1 Refer to the drawing in Figure 13, which show
from which points on the carriage the measurements for
the legs are taken.
5.4.2 Refer to the PIPE ID column in the table at
Figure 14 to find the ID of the pipe to be blasted.
Figure 13
5.4.3 Refer to the LEG column in the table to find the
length of the carriage leg to use, then thread the
appropriate length legs (two into each rail) into the rail
assemblies as shown in Figures 9 and 10.
INITIAL CARRIAGE LEG SETTINGS
PIPE ID LEG DIST. PIPE ID LEG DIST.
16" 6" 5/8" 39" 26" 12-3/4"
17" 6" 1-1/4" 40" 26" 13-1/4"
18" 6" 1-3/4" 41" 26" 13-3/4"
19" 12" 2-3/8" 42" 26" 14-3/8"
20" 12" 2-7/8" 43" 26" 14-7/8"
21" 12" 3-3/8" 44" 26" 15-3/8"
22" 12" 4" 45" 26" 15-7/8"
23" 12" 4-1/2" 46" 26" 16-3/8"
24" 12" 5" 47" 26" 16-7/8"
25" 12" 5-1/2" 48" 26" 17-3/8"
26" 12" 6-1/8" 49" 26" 17-7/8"
27" 12" 6-5/8" 50" 26" 18-3/8"
28" 12" 7-1/8" 51" 26" 18-7/8"
29" 12" 7-5/8" 52" 26" 19-3/8"
30" 12" 8-1/8" 53" 26" 19-7/8"
31" 12" 8-5/8" 54" 26" 20-3/8"
32" 26" 9-1/4" 55" 26" 20-7/8"
33" 26" 9-3/4" 56" 26" 21-3/8"
34" 26" 10-1/4" 57" 26" 21-7/8"
35" 26" 10-3/4" 58" 26" 22-3/8"
36" 26" 11-1/4" 59" 26" 22-7/8"
37" 26" 11-3/4" 60" 26" 23-3/8"
38" 26" 12-1/4"
Figure 14
3/8-NPT or larger shutoff valve (supplied by user)
3/8-inch filter/pressure regulator combo (provided with basic tool)
3/8-inch ID or larger air supply hose (supplied by user)
3/8-inch ID x 50-foot air hose, same length
a pipe being blasted (Two 50 feet lengths
p
rovided with basic tool
)
Return line, from (red tube)
air motor outlet tube
Muffler
Hose adaptor, 3/8 NPT x 3/8 hose
Flow Control Assembly
2nd length of 3/8-inch ID air hose
provided with basic tool
Connect supply line to inline filter
on (green) air motor inlet tube
Base of Rail
Measure from end of
coupling to base of rail.
End of Coupling
PIPE-PRO XL™ INTERNAL-PIPE BLAST TOOL Page 9
© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 27804 Rev A
5.4.4 Insert the legs into the couplings on the collar
and adjust the depth to the distances noted in the DIST.
column.
Note that the distance shown is for an initial adjustment
so the tool is approximately centered in the pipe. Minor
readjustment may be needed.
5.4.5 Place the tool inside the pipe and if needed,
make minor final adjustments to center the tool.
5.5 Attach Nozzles and Nozzle Extensions
Refer to Figure 15
5.5.1 Refer to Section 3.2 for guidelines to determine
nozzle stand-off distance.
5.5.2 Insert nozzle washers into both ports in the blast
head. If the nozzle is farther than 18 inches from the inner
surface of the pipe, use a nozzle extension and insert a
nozzle washer in the female end of the extension.
Figure 15
5.5.3 Screw the nozzles (and extensions when
needed) into the blast head. Make sure the nozzles and
extensions are fully seated and compress the nozzle
washers.
5.6 Connect Blast Hose and Lance
5.6.1 Refer to Section 3.3 and connect a lance and
appropriately sized blast hose between the blast
machine and Pipe-Pro XLTM.
Use:
1-1/4" ID x 2-brd hose coupled with 00570 aluminum, or
00565 brass couplings.
1-1/2" ID x 4-ply hose coupled with 00573 aluminum, or
00566 brass couplings.
6.0 OPERATION
6.1 Set up and load abrasive into the blast machine
and connect air lines, blast lines, and blast equipment as
described in the applicable operation manuals.
6.2 Push the tool through pipe until blast head exits
the opposite end.
6.3 Set Motor Speed
6.3.1 Adjust the pressure regulator to 80 to 90 psi.
NOTICE
Before providing air to the air motor make sure
the pressure regulator is set to reduce pressure
to below 100 psi. Maximum operating pressure
for the air motor is 100 psi.
6.3.2 Open air supply to air motor. The flow control
valve, when used in conjunction with the pressure
regulator, enables the operator to control the rotation
and speed of the air motor at the same location as the
blasting controls. Smoothest head rotation is usually
achieved when the air motor pressure is set high, around
80 to 90 psi, and rotation is controlled by opening or
closing the flow valve.
6.4 Pressurize the blast machine and adjust
abrasive flow.
6.5 Pull the tool through pipe at a constant speed to
achieve the desired degree of blast cleanliness.
6.6 As the tool exits the pipe, turn off air/abrasive
supply from the blast machine. NOTE: Provide an exit
ramp, platform, or structural support at the exit end of
the pipe.
6.7 When finished blasting, empty abrasive from the
blast hose and lance, and shut down all equipment as
described in the applicable operation manuals.
Blast Head
Nozzle
Nozzle Washer
Nozzle Extension, when needed,
refer to Section 3.2
Nozzle Washer
PIPE-PRO XL™ INTERNAL-PIPE BLAST TOOL Page 10
© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 27804 Rev A
7.0 PREVENTIVE MAINTENANCE
7.1 Air Motor Air-Supply Line
7.1.1 Make sure the air supply hose fittings are clean
before connecting the hose to the tool’s air connections.
NOTICE
The filter/regulator in the air supply line protects
the air motor from contamination in the air line.
Take special care to prevent contaminants from
the blasting environment from entering the air
motor or air motor supply hose. Any dust or
abrasive in the air supply that enters the air
motor will cause the air motor to fail. To prevent
contamination, cover the air hose connections
and air motor tubing whenever the air supply or
return hoses are removed. Motor failure from
ingress of dust, abrasive, or any foreign matter
voids the warranty.
7.2 8-Hour Inspection, Refer to Figure 16
7.2.1 Nozzles and nozzle extensions
7.2.1.1 Remove the nozzles, extensions, and nozzle
washers and inspect for wear.
7.2.1.2 Replace the nozzle when the orifice diameter
has worn 1/16" larger than the original size.
Figure 16
7.2.1.3 Inspect the inside of the nozzle extensions for
wear. If extensions are worn to an oblong shape, turn
the extension a quarter of a turn several times a day
while maintaining pressure on the nozzle washer.
7.2.1.4 Make sure the nozzle washers in the head and
in the extensions are in good condition before screwing
in the extension and nozzles.
7.3 16-Hour Inspection
7.3.1 Blast head assembly, Refer to Figure 17
NOTICE
Disassemble and reassemble the blast head on
a bench in a clean dust-free and abrasive-free
environment.
7.3.1.1 Remove nozzles and nozzle extensions and
inspect for wear.
7.3.1.2 To remove the head, loosen the blast head lock
nut and turn the head counterclockwise (when viewed
from the head end of the tool). Note: If the axle turns
with the head, insert the spanner’s pin into the recess
(between the lock nut and front housing) as shown in
Figure 18 and use the spanner to hold the axle while
turning the head counterclockwise to remove.
7.3.1.3 Remove the blast head gasket from the head.
7.3.1.4 Place the blast head in a vise. Remove the
retaining plug and swivel eye assembly from the head.
NOTE: If the wrench is too wide to fit onto the plug flats,
remove the swivel eye by removing the bolt and then
remove the plug.
Figure 17
Blast Head
Nozzle
Nozzle Washer
Nozzle Extension
Nozzle Washer
Swivel Eye
Lock Nut
Blast Head Gasket
Blast Head
Deflector Gasket
Deflector
Retaining Plug
Deflector Alignment Pin
PIPE-PRO XL™ INTERNAL-PIPE BLAST TOOL Page 11
© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 27804 Rev A
Figure 18
7.3.1.5 Remove the deflector gasket and carbide
deflector from the head. The deflector slides out from the
plug end of the head; use fingers through the nozzle ports
to push the deflector out. It does fit snugly; do not pound
on it with a hammer or other hard surfaced tool, as doing
so will break the brittle carbide deflector. If the deflector
cannot be removed by hand, use a soft piece of wood or
similar material placed against the deflector, and gently
tap on the wood or use a press to remove the deflector.
7.3.1.6 Inspect all items for wear, and clean and replace
as needed. The tolerance between the deflector and the
head is very tight; make sure all surfaces are totally free
of abrasive before inserting the deflector.
7.3.1.7 Notice the notch in the deflector’s flange and the
alignment roll-pin in the mating flange in the blast head.
The notch fits over the alignment pin and orientates the
deflector to the correct position.
7.3.1.8 Refer to Figure 19. Slide the deflector into the
head and position it so the notch in the deflector's flange
fits over the alignment pin; the flange must seat firmly
onto the shoulder. Note that the tolerance is very tight
between the deflector and head; some realigning may be
needed to keep the deflector straight within the head.
The deflector must be inserted straight into the head with
no cocking or binding. Make sure the deflector is
correctly seated; the top of the alignment pin should be
at the top of the deflector.
NOTICE
The deflector must be correctly aligned and
seated in the head. If not correctly installed,
rapid and irregular wear will occur on the head
and related parts.
Figure 19
7.3.1.9 Place the deflector gasket atop the deflector’s
flange.
7.3.1.10 Wrap the plug thread with thread-seal tape and
install the retaining plug. Tighten the plug to secure.
NOTICE
Do not substitute the retaining plug with a
common 1-1/4-NPT pipe plug. The taper on a
pipe plug could prevent full compression of the
deflector, deflector gasket, and plug, causing
rapid and irregular wear.
7.3.1.11 If the swivel eye was removed from the plug as
noted in Section 7.3.1.4, inspect the O-ring, and if
needed, place a new O-ring on the swivel eye’s bolt and
attach the swivel to the blast head retaining plug.
7.3.1.12 Refer to Figure 20 and install a new blast head
gasket into the head’s axle port. Male sure the gasket is
fully seated within the thread-relief and against the
shoulder in the head.
Figure 20
Spanner
Spanner Pin
S
p
anne
r
-Pin Recess
Spanner
Blast Head Gasket
Lock Nut
Gasket Thread Relief
The notch in the deflector’s
flange must fit over the
alignment pin on the flange
shoulder in the blast head.
Alignment Roll-Pin
Shoulder
Deflector
Gasket
Deflector
PIPE-PRO XL™ INTERNAL-PIPE BLAST TOOL Page 12
© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 27804 Rev A
7.3.1.13 Insert the spanner into the recess on the axle
as shown in Figure 20 and hand-tighten the lock nut
against the spanner. Use the spanner to hold the axle
while turning the blast head clockwise to install. Tighten
the head enough to compress the gasket and create an
airtight seal.
7.3.1.14 Tighten the lock nut against the head to secure.
7.3.2 Backplate coupling-flange, Figure 21
7.3.2.1 Remove the carriage per Section 8.1.1
7.3.2.2 Use a 4 mm hex key to remove the six socket
head screws securing backplate flange to tube casing,
and remove the flange.
7.3.2.3 Remove the plastic seal-disc. Note the groove
on the axle side of the disc; replace the disc if it is worn
more than half way through.
Figure 21
7.3.2.4 Thoroughly clean the spacer and u-seal that
remain in the tube casing and all parts that are to be
reused.
7.3.2.5 Insert the grooved side of the plastic seal-disc
into the tube casing. NOTE: New discs are not grooved;
the groove will be formed from the ridge on the end of
the axle as the axle turns.
NOTICE
If a new plastic seal-disc is installed, operate
the tool for a short period of time with air only
(no abrasive) so the ridge on the axle can form
the groove in the seal.
7.3.2.6 Attach the backplate coupling-flange to the
casing using the six socket head screws to secure.
7.3.2.7 Attach the carriage per Section 8.1.2.
7.4 30-Hour Inspection
7.4.1 Inspect element in filter/regulator and clean or
replace as needed.
7.4.2 Remove the front housing per Section 8.4 and
inspect the bearing. Replace the bearing if it does not
turn smoothly.
7.4.3 Remove the backplate coupling-flange per
Section 7.3.2. Turn the axle; replace the bearing if it
does not turn smoothly.
7.5 Every Three Months and Before Long Term
Storage
7.5.1 Completely disassemble the base tool, clean all
parts, replace worn parts, lubricate, and reassemble.
7.6. Air Motor Service
Recommended service to the air motor should be done
every 12 months or 500 hours of operation, whichever
comes first. The air motor must be serviced by qualified
technicians. Contact:
www.pneumatictechnology.com
Pneumatic Technology, Inc
30447 Edison
Roseville, MI 48066
Tel: (586) 776-1480
8.0 SERVICE MAINTENANCE, DISASSEMBLY
Service instructions are shown in order of total
disassembly, and Section 9.0 is in order of reassembly
after the tool is completely disassembled. If total
disassembly is not required, skip the service that is not
needed. For example, if bearings need service but the
air motor is in good working order, the air motor need not
be removed to service bearings (or the other way
around).
NOTICE
Disassemble and reassemble the tool on a
bench in a clean dust-free and abrasive-free
environment. The bench should be covered
with soft material to prevent damage to the
tool’s machined surfaces. If no other protective
cover is available, use cardboard.
The most frequent service is to the blast head and at the
backplate coupling-flange. Instructions for removal,
service, and reassembly of the head and backplate
Tube Casing Plastic Seal-Disc
Backplate Flange
Clean spacer and u-seal
Screw
PIPE-PRO XL™ INTERNAL-PIPE BLAST TOOL Page 13
© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 27804 Rev A
coupling-flange are shown in the preventive
maintenance section. Refer to Section 7.3.1 to service
the blast head assembly and Section 7.3.2 to service the
backplate coupling-flange assembly.
NOTICE
Removed the tool from the blast hose or lance
and service it in a clean, abrasive-free and dust-
free environment.
Remove the tool from the carriage collar before
performing any service other than the blast
head and nozzles.
8.1 Carriage
8.1.1 Removing the carriage
8.1.1.1 Completely remove the three cap screws
holding the carriage collar to the drive cap and then slide
the carriage from the base tool. Note: If lodged abrasive
prevents removal from the carriage, pry the pieces apart
at the seam between the drive cap and carriage collar
flange, or place a wooden block or similar object against
the quick coupling and rap the block with a hammer to
remove the tool.
8.1.2 Attaching the carriage
8.1.2.1 Insert the base tool, quick coupling first into the
flanged end of the carriage.
8.1.2.2 Align the bolt holes in the drive cap with those in
the carriage collar and insert the plate into the flange.
Align the holes as needed and install the three flat
washers, lock washers, and cap screws to secure.
8.2 Blast Head Assembly, Removal and Inspection
8.2.1 Remove the blast head per Section 7.3.1 and
service the head assembly as needed. Do not yet
reassemble the blast head unless no further service is
required.
8.3 Backplate Coupling Flange Assembly
Removal and Inspection
8.3.1 Remove the backplate coupling flange per
Section 7.3.2 and service the head assembly as needed.
8.3.2 The rear-seals cartridge (sleeve with u-seals and
spacer) may slide out without pressing it. If it slides out,
remove it now; if it does not slide, it will be pressed out
later in Section 8.6. Do not yet reassemble the backplate
and coupling flange unless no further service is required.
8.4 Front Housing and Bearing Removal and
Inspection
8.4.1 Refer to Figure 22 and unscrew the lock nut
from the axle.
8.4.2 Refer to the following caution and use a 4 mm
hex key to remove the six socket head screws to
separate the front housing from the drive cap and slide
the housing off the axle.
CAUTION
The housing is under moderate spring
pressure. When the retaining screws are
removed, the spring will force the housing
about 1-1/2 inches from the drive cap.
Figure 22
8.4.3 Remove spring bushing and spring from the axle.
8.4.4 Inspect the rim on the head (bearing) side of
spring bushing. When new, the rim extends about 1/16"
from the flange. If the rim is worn beyond 1/32", replace
the bushing.
8.4.5 Refer to Figure 23 and remove the felt seal from
the front housing.
Figure 23
8.4.6 Refer to Figure 24 and remove the bearing from
the front housing; the bearing fits snugly in the housing, if
Axle Spring Bushing
Spring
Felt Seal
Front Housing
Drive Cap
Socket Head Screw
Front Housing
Lock Nut
Axle
PIPE-PRO XL™ INTERNAL-PIPE BLAST TOOL Page 14
© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 27804 Rev A
required, use a puller to remove the bearing. Note: if the
bearing stays on the axle, it will be removed later as
noted in Paragraph 8.6.5.
Figure 24
8.4.7 Wipe the bearing clean and turn the races; the
races should turn smoothly. Replace the bearing if it
feels gritty when turning it.
8.4.8 Inspect the inside of the housing:
If no dust is present, replace only the felt seal.
If dust is present on only the head side of the bearing,
replace the felt seal and the u-seal.
If dust is present on the inward side of the bearing,
axle and axle-gear, service the axle per Section 8.6
8.4.9 If the gears are totally dust free, apply a liberal
amount of Mobilgrease XHP 462 Moly, Chevron Delo
Heavy Duty Moly 3% EP 2, or equivalent gear grease to
the gear teeth, and reassemble the bearing and housing
per Section 9.3.
8.4.10 If no additional service is required, reassemble
the tool per Section 9.0.
8.5 Air Motor and Air Motor Gear Removal and
Inspection. Refer to Figure 25
NOTE: Removing the air motor requires a narrow 33
millimeter wrench or an adjustable wrench narrow enough
to fit within the confines of the air motor’s flats. If a wrench
is not available, one should be purchased, or machine (or
grind) one until it is narrow enough to fit within the flats.
Remove the air motor for protection and inspection before
removing the axle or drive cap.
NOTICE
Do not use a pipe wrench or similar tool to
remove the air motor; doing so will damage the
motor.
8.5.1 The air motor has left-handed or reverse
threads; to remove the motor from the drive cap, turn the
motor clockwise as shown in Figure 25.
Figure 25
8.5.2 Inspect the gear; there is no need to separate
the gear from the motor if neither is being replaced. If
service or replacement is needed, use a 2-mm hex key
to remove the gear.
8.5.3 It is not necessary to remove the 1/8 x 8 mm
inlet tube adaptor, 1/4 x 8 mm outlet tube adaptor, or
tubing from the air motor unless either requires
replacement or the air motor needs service. When
required, remove the adaptors by unscrewing them.
NOTICE
To reduce the risk of abrasive or foreign
material contamination into the air motor, cover
air motor fittings, ports, or tubing. Any foreign
material entering the air motor will cause the air
motor to fail. Motor failure from ingress of dust,
abrasive, or foreign matter voids the warranty.
8.6 Axle, Axle Gear, and Rear Bearing Removal
and Inspection
8.6.1 Occasionally the axle can be removed from the
tube casing by sliding the axle back and forth as you
would a slide puller. If the axle cannot be removed as
noted, it can be pressed out, as follows.
8.6.2 Support the drive cap and tube casing in the
press as shown in Figure 26. Make sure the supports do
not block the axle.
Air motor and gear removed
from the drive cap.
Wrench Flats
Turn air motor
clockwise to remove.
Drive Cap
Bearing
Back side of Front Housing
U-Seal, open side
toward bearing
PIPE-PRO XL™ INTERNAL-PIPE BLAST TOOL Page 15
© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 27804 Rev A
8.6.3 Place a wooden dowel or similar soft object of
approximately 1-7/8" diameter on the end of the axle,
shown shaded in Figure 26. Make sure it is no larger in
diameter than the axle. Take precautions not to damage
the ridge on the entry end of the axle.
Figure 26
8.6.4 Make sure there is means of catching the axle
and gear if they suddenly slide from the casing. The axle
needs to be pressed only about 2 inches to be free of
the rear bearing. If in doubt about catching it, place
sufficient padding below the axle to prevent it from being
damaged if it should fall. Apply a small amount of
pressure to press the axle free of the drive cap and
casing.
8.6.5 The rear-seals cartridge and bearing may easily
be removed from the opposite end of the casing.
Note: if the bearing stayed on the axle as noted in
Paragraph 8.4.6, turn the axle around and press off the
bearing and axle gear.
8.7 Rear-Seals Cartridge Removal and Inspection
8.7.1 Since the rear-seals cartridge has been
removed, replacing the u-seals recommended.
8.7.2 To remove the u-seals, press or pry the old
seals from the sleeve. Note: If the seals are to be
replaced, it does not matter if the old seals are destroyed
while removing them However, take precautions not to
damage the sleeve and spacer.
8.7.3 Cleans all parts to be reused.
If no other service is required, reassemble per Section 9.0.
9.0 SERVICE MAINTENANCE, REASSEMBLY
The order of reassembly is shown for a tool that was
totally disassembled. If the tool was not totally
disassembled, skip the sections that do not apply.
9.1 Rear-Seals Cartridge Reassembly
Refer to Figure 27
9.1.1 To ease insertion of the seals, apply a thin layer
of grease to the outside of the seals and inside of the
sleeve.
9.1.2 Lay the sleeve on a clean table, with the flanged
end facing down.
9.1.3 Press the first u-seal (open end up) into the
sleeve until it is fully seated on the sleeve’s flange. Note:
U-seals are identical; it does not matter which seal is
installed first.
Figure 27
9.1.4 Insert the spacer above the first seal and then
press the second seal into place against the spacer.
Temporarily set the cartridge assembly aside.
9.2 Axle, Axle Gear, and Casing Reassembly,
Refer to Figure 28
9.2.1 It should not be necessary to press the axle gear
onto the axle. Slide the gear onto the axle, align the
keyway and key and apply even pressure to seat the
gear against the retaining ring. If pressing is needed
make sure not to use excessive pressure that would
damage the retaining ring.
9.2.2 Place a liberal amount of Mobilgrease XHP 462
Moly, Chevron Delo Heavy Duty Moly 3% EP 2, or
equivalent gear grease to the gear teeth.
9.2.3 Insert the axle with gear attached, into the
casing. When fully inserted, the gear will move up by
about 3/16". Make sure the key is correctly placed in the
gear keyway; when the front bearing housing is
attached, the spring will push the gear into position.
Entry End of Axle
Tube Casing
Drive Cap
Support
Spacers
Axle Removed
Protect axle ridge
U-Seal
Spacer
Sleeve
Shown open end up
The bottom end is flanged
U-Seal
Axle Gear
PIPE-PRO XL™ INTERNAL-PIPE BLAST TOOL Page 16
© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 27804 Rev A
Figure 28
9.3 Front Housing and Bearing Reassembly
9.3.1 Place a liberal amount of 10 weight oil or
machine oil on the felt strip and insert the strip fully into
the groove in the front bearing housing, as shown in the
upper illustration in Figure 29. Make sure the strip is fully
inserted into its groove and that the ends are
compressed together for a full seal.
9.3.2 Turn the housing around and press the bearing
u-seal (open end facing out) into the housing, making
sure it is fully seated. To ease insertion of the seal, apply
a thin layer of grease to the outside of the seal and
inside of the housing.
Figure 29
9.3.3 Turn the front housing on its end as shown in
Figure 30 and insert the bearing into the housing until it
is fully seated against the u-seal. Note that the fit
between the outer race on the bearing and housing are
very tight; the bearing can be inserted without pressing
it, if it inserted straight into the housing without any side-
cocking.
9.3.4 Place the spring bushing and spring in the
housing as shown in the illustration.
Figure 30
9.3.5 Place the tube casing (drive cap up, as shown in
Figure 31) securely in a vice.
9.3.6 While holding the spring in place to prevent the
spring bushing and bearing from moving, turn the
housing assembly over and slide it onto the axle as
shown in Figure 31. NOTE: Make sure the felt is not
damaged or pushed from the housing as the axle passes
through. If necessary, use a small screwdriver to make
sure the felt remains in place.
Figure 31
9.3.7 Refer to Figure 32 and align the screw holes in
the bearing housing with those in the drive cap. Apply
downward pressure to lower the housing enough to
engage the screw threads into the drive cap. Start at
least two screws on opposite sides of the housing before
releasing downward pressure.
Insert felt seal into
groove in housing
U-Seal
Felt Seal
Open end facing out
Front view of front bearing housing
Rear view of front housing
Spring
Spring Bushing
Bearing
Housing Assembled
Front Bearing Housing
Drive Cap and
Casing Assembly
Axle and Gear
Assembly
Axle
Axle Gear
Retaining Ring Key
Key Way
While holding spring, slide
housing assembly onto axle
Front bearing housing
in place on axle
Axle
PIPE-PRO XL™ INTERNAL-PIPE BLAST TOOL Page 17
© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 27804 Rev A
NOTICE
If the housing makes hard contact before it is
close enough for the screws to engage, do not
force it; internal parts are not aligned. Release
and reapply pressure until the housing slides
into position so it can be secured with screws.
9.3.8 Observe the gap between the bearing housing
and tighten the screws in unison until the flange on the
housing just begins to enter the drive cap. At that time
tighten each screw about half a turn at a time, the
screws should easily turn. If a screw becomes tight,
move to another until the housing is fully seated into the
drive cap.
Figure 32
9.3.9 After the housing is seated in the drive cap,
tighten all screws to secure.
9.4 Rear Bearing, U-Seal Cartridge, and Tube
Casing Reassembly
9.4.1 Place the assembled tool on a bench with the
rear of the tube casing facing up as shown in Figure 33.
9.4.2 Fully insert the rear bearing into the end of the
tube casing. Pressing the bearing is usually not needed
if the bearing is inserted straight with no side-cocking.
Figure 33
9.4.3 Insert the u-seal cartridge into the tube casing.
The side of the cartridge with the open u-seal faces up.
9.5 Backplate Coupling-Flange Reassembly,
Figure 34
9.5.1 Place the plastic seal-disc into the tube casing.
Note: If the disc is to be reused, make sure the grooved
side faces toward the axle. If the disc is new the sides
are identical; it does not matter how it is installed. The
groove will be formed by the rotating axle.
9.5.2 Place the backplate atop the disc and uniformly
tighten the screws to secure. Note: If the end of the axle
extends too far out to prevent installation of the screws,
remove the disc, place a folded paper towel or similar
protective cover over the ridge on the axle, and tighten
the backplate enough to press the axle into the tube
casing. Remove the backplate and protective cover and
reassemble with the seal-disc in place.
Figure 34
9.6 Air Motor and Air Motor Gear Reassembly,
Refer to Figure 35
NOTE: Installation of the air motor requires a narrow 33-
millimeter wrench. If a wrench is not available, one
should be purchased, or machine (or grind) one until it is
narrow enough to fit within the flats.
9.6.1 If the gear was removed or replaced, install it
onto the motor shaft with the set screw end facing
toward the motor as shown in Figure 35. Slide it fully
onto the shaft leaving only enough room to insert a 2-mm
hex key into the set screw. Tighten the screw to secure.
9.6.2 Apply a generous amount of Mobilgrease XHP
462 Moly, Chevron Delo Heavy Duty Moly 3% EP 2, or
equivalent gear grease to the gear teeth, and gear
socket in the drive cap.
Front Bearing Housing
Apply downward pressure on the
bearing housing to start at least
two screws into the drive cap.
Drive Cap
Bearing and Cartridge
Installed in Tube
Assembled U-Seal Cartridge
The open side of u-seal faces up
Bearing
Tube
Backplate with Coupling
Plastic Seal-Disc
Tube Casing
PIPE-PRO XL™ INTERNAL-PIPE BLAST TOOL Page 18
© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 27804 Rev A
Figure 35
9.6.3 If the tube adaptors were removed from the air
motor, make sure they are clean and that the O-rings
are on both adaptors before reinstalling them. Refer to
Figure 36.
Figure 36
9.6.4 Insert the gear end into the drive cap and mesh
the teeth on the motor gear with those on the axle gear.
If the teeth are not correctly meshed, the motor cannot
be inserted into the opening in the drive cap.
9.6.5 The air motor has left-handed (reverse) threads;
to install the motor, turn it counterclockwise as shown in
Figure 36. Use a narrow 33-millimeter wrench to tighten
the motor.
9.7 Blast Head Assembly Reassembly
9.7.1 Reassemble the blast head per Section 7.3.1.
10.0 TROUBLESHOOTING
10.1 Blast head does not turn or turns too slowly
10.1.1 Volume or pressure of air at motor is too low.
Adjust pressure to between 80 and 90 psi.
10.1.2 Flow control valve is closed too far. Open flow
valve.
10.1.3 Leak or blockage in supply line to the air motor.
Check for leaks or blockage.
10.1.4 Inlet and outlet tubes reversed on air motor.
Make sure green supply tube connects to air motor "R"
Port and red outlet tube connect to the "Exh" Port. If lines
are reversed, the head will rotate slowly
counterclockwise when vied from the head end of the
tool.
10.1.5 Dust or abrasive ingress in bearing area. After
checking the steps above, inspect felt seal, u-seals, and
bearings for wear.
Use a narrow 33 millimeter wrench
on these flats to secure the motor
to the drive cap.
Turn motor counterclockwise
to tighten onto drive cap.
Tube Adaptors
Set Screw Key
Keyway
Air Motor
Set Screw, as close as possible
to air motor
PIPE-PRO XL™ INTERNAL-PIPE BLAST TOOL Page 19
© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 27804 Rev A
11.0 ACCESSORIES and REPLACEMENT PARTS
11.1 Pipe-Pro XLTM Internal Pipe Blast Tools
Item Description Stock No.
(-) Pipe-Pro XL tool only, without carriage
or air-motor control hose kit, includes
items1 through 37 in Figure 38.................28050
(-) Pipe-Pro XL tool 16" to 31" .......................27792
Includes:
Pipe-Pro XL tool with 16" to 31" centering
carriage
Air-motor control hose kit (all items shown in
Section 11.4, Figure 37).
(-) Pipe-Pro XL tool 16" to 60" .......................28046
Includes:
27792 Pipe-Pro XL tool with 16" to 31"
centering carriage and control hose package
32" to 60" carriage leg and rail extensions, as
shown in Section 11.7, Figure 40
2 each 6-inch and 12-inch nozzle extensions,
as shown in Section 11.7, Figure 40
10 nozzle washers (for nozzle extensions)
11.2 Conversion kit
Item Description Stock No.
Large pipe, converts 16" to 31" tool to 16" to 60",
includes items 1 thru 6 as shown in Section
11.7, Figure 40 ..........................................28047
11.3 Nozzles and Nozzle Extensions
Item Description Stock No.
(-) Nozzle, each, 2- required
Long venturi
TSP-4, 1/4" orifice ..............................23514
TSP-5, 5/16" orifice ............................23515
TSP-6, 3/8" orifice ..............................23516
Short venturi
TJP-4, 1/4" orifice ...............................23508
TJP-5, 5/16" orifice .............................23509
TJP-6, 3/8" orifice ...............................23510
(-) Nozzle extensions
6" long, set of 2 ......................................25118
12" long, set of 2 ....................................24647
(-) Nozzle washers, NW-4, pack of 10
for nozzles and extensions ....................00869
11.4 Air-Motor Control Hose Kit, Figure 37
Item Description Stock No.
(-) Kit, air-motor control hose
includes all item shown in Figure 37 ..... 28859
1. Filter/Regulator, 3/8-NPT w/gauge .......... 11690
2. Muffler, 3/8-NPT ....................................... 28041
3. Valve, 3/8-NPT flow control ...................... 28040
4. Hose, 3/8" x 50 ft., coupled ...................... 27799
5. Union, 3/8 hose to 3/8 hose ..................... 01020
6. Adaptor, 1/4-NPT x 3/8 hose .................... 01019
7. Adaptor, 1/4-NPTF x 8 mm tube .............. 28038
8. Adaptor, 3/8-NPT x 3/8 hose .................... 00022
9. Filter, 1/4-NPT m/f inline .......................... 28039
Figure 37
1
6
8 4 5
9 7
7
6
8
3
2
4
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