Transmate TapMate XL-424 User manual

08/30/2018
Before you operate this equipment,
read carefully and understand this operating manual.
If you need assistance or find parts missing or damaged,
call: 1.800.426.9341
ROMAC INDUSTRIES, INC. • 1.800.426.9341 • www.romac.com
TapMate™XL-424
Pipe Drilling Machine
OPERATING MANUAL
Waterworks Tools By Romac
Transmate

2
TAPMATE™ XL-424 Operating Manual
TABLE OF CONTENTS
Specication.................................................................................................................................................... page 3
Machine Overview........................................................................................................................................ page 4
ASSEMBLY
Open the Shipping Crate............................................................................................................................ page 5
Cutter and Pilot Identication .................................................................................................................. page 6
About Adapter Hub Sizes ........................................................................................................................... page 7
Adapter Hub Installation and Removal................................................................................................. page 8
TapMate XL-424 Set-Up for 4"-12" Taps...............................................................................................page 10
TapMate XL-424 Set-Up for 14"-24" Taps .............................................................................................page 14
Attaching the TapMate XL-424 to the Valve........................................................................................page 19
OPERATION
Performing the Tap .....................................................................................................................................page 22
Disassembly and Removal of the Coupon .........................................................................................page 27
Care and Maintenance ..............................................................................................................................page 28
PARTS IDENTIFICATION DRAWINGS
TapMate XL-424 (included items)...........................................................................................................page 29
TapMate XL-424 (base machine).............................................................................................................page 30
Adapter Bells (4" - 12")................................................................................................................................page 31
Adapter Bell (14" - 24") ...............................................................................................................................page 32
Small Shaft Head Assembly......................................................................................................................page 33
Large Shaft Head Assembly......................................................................................................................page 33
Jam Nut............................................................................................................................................................page 33
TM-XL, PVC Pilot............................................................................................................................................page 34
TM, PVC Pilot..................................................................................................................................................page 34
TM-XL, Shaft Nose ........................................................................................................................................page 35
TM, Shaft Nose...............................................................................................................................................page 35
Hydraulic Motor Assembly........................................................................................................................page 36
Shipping Crate / Workstation...................................................................................................................page 36
TRAVEL CHARTS..........................................................................................................................................page 37
Cast Iron Pipe...............................................................................................................................................pages 38
Ductile Iron Pipe ................................................................................................................................ pages 39 - 40
C900 PVC Pipe ...............................................................................................................................................page 41
C905 Pipe ............................................................................................................................................. pages 42 - 43
ASTM D2241 - IPS PVC Pipe ........................................................................................................... pages 44 - 45
Asbestos Cement (A/C) Pipe.....................................................................................................................page 46
ASTM D1785 PVC (Sch. 40, 80 &120) Pipe ...........................................................................................page 47
HDPE Pipe ............................................................................................................................................pages 48 - 50

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TAPMATE™ XL-424 Operating Manual
• Heavydutysteelconstruction.
• Hydraulicmotorintegratedtoshaftandmachine.
• Weightofthedrillingmachineis285lbs.(lesstheadapterbell,pilotdrillandcutters).
• Lengthofthedrillingmachineonlyis87”(lesstheadapterbell,pilotdrillandcutters).
• Cuttertraveldistanceis39".
• Forusewith4"-24"cutters.
• SuitableforuseonCastIron,DuctileIron,Asbestos/Cement,Steel,PVCandHDPEpipe.
• 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.
• rustTubeisa#2StubAcmereadforrapidandcontrolledtravelthrough
thevalveandtappingsleeveneck.
• rustTubefeaturesascaletoindicatetheamountoftravel.
• IndicatorscaleontheLeadTubeshowstheexactcutterdepthandprogressofthecut.
• Inputtorquelimit:Continuous=3,604in-lbs.,Intermittent=4,283in-lbs.
• InputRPM:33.
TAPMATE™ XL-424 MACHINE SPECIFICATION

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TAPMATE™ XL-424 Operating Manual
MACHINE OVERVIEW
  WhileyoumaybefamiliarwiththeTapmatedrillingmachine,thismachineislargerandhasdierent
 operatingrequirements.eseinclude:
  • eTapMateXL-424hasnoslidingtubesorbrakes.
  • Fewerturnsarerequiredtocompletethetap(inmostcases).
  • TwojamnutsinsteadofonehavebeenusedtolockthecutterinplaceontheTapMateXL-424 (14"-24").
  • TapMateXL-424feedratesareslowerbecauseofthenewthreads. 
  eTapMateXL424drillingmachineconsistsoffourdistinctsections.esesectionsaretheShaft,Lead
  Tube,rustTubeandtheBrakeTube.
  ethreadedrustTubeislocatedinthecenterofthemachineandtheBrakeTubeispositionedtoward
 thebackofthemachine.Together,theycontroltraveloftheHolesawandpilotdrill.Priortothecut,the
 HolesawandPilotDrillareextendedthroughthevalveandtappingsleevenecktothepipewallusingthe 
 BrakeTubeHandles.Afterthecutiscomplete,theHolesawandPilotDrillretractbackoutofthewaytoallow
 thevalvetobeoperated.
  AfterthetapiscompletedandyouaredrawingtheCutterawayfromthepipe,thethreadpitchprevents
 waterpressurefromturningthebraketube.
  eLeadTubeandLeadNut,arelocatedinsidethefrontendoftherustTube.Together,theyprovide
 theforwardpressurenecessaryforthePilotDrillandShellCutterduringthecutting
operation.
  eShaftisasinglepiecerunningthroughthecenterofthemachine.Itisthreadedonthefrontendto
 acceptthePilotDrillandShellCutter.eotherendoftheShaftmateswiththehydraulicdriveunit.
Lead Tube
Thrust Tube
Brake Tube
Shaft
Lead Nut
w/Handles
Brake Locking
Bolt
Rear Lifting Ring
Locking
Collar
Integrated
Hydraulic
Drive

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TAPMATE™ XL-424 Operating Manual
OPEN THE SHIPPING CRATE/WORKSTATION
       1. Openall(six)ofthelatchesaroundbottomofthe
crate.
       2. Swingopentheend(seedrawingatleft).
       3. Liftandremovecover(seedrawingatleft).

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TAPMATE™ XL-424 Operating Manual
CUTTER AND PILOT IDENTIFICATION
 1.Selectthepropercutterandpilotforthepipeyou'llbetapping.Seethedrawingsbelow. 
TM, Shaft Nose
(4" - 12" taps)
Cutter and Pilots shown below are for use on Ductile Iron, Cast Iron and
Asbestos / Cement pipe.
TM, Shaft Nose
(4" - 12" taps)
Cutter and Pilots shown here are for use on PVC pipe.
TM, Shaft Nose
(14" - 24" taps)
Carbide Cutters
TM, Shaft Nose
(14" - 24" taps)
Carbide Cutters

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TAPMATE™ XL-424 Operating Manual
ABOUT ADAPTER HUB SIZES
 1.EnsurethatthecorrectAdapterHubissecurelyattachedtotheLeadTube.
  TodeterminewhichAdapterHubyou'llneed,seethedrawingsbelow.
Note: The TapMate XL-424 is shipped from the factory without an Adapter Hub installed.
Small Adapter Hub
for use with
4" - 12" TapMate Adapter Bells.
Large Adapter Hub
for use with
14" - 24" TapMate XL-424 Adapter Bells.

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TAPMATE™ XL-424 Operating Manual
ADAPTER HUB INSTALLATION AND REMOVAL
Large Adapter
Hub
Lead Tube
Locking Collar
Small Adapter
Hub
Installation:
1. Selecttheappropriate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keywayintheAdapterHubwiththekeyinthe
 topoftheLeadTube(seedrawingatleft).
3. SlideAdapterHubovertheendoftheLeadTubeand
 engagethethreadsoftheLeadTubeLockingHubCollar
 (seedrawingatleft).
Large Adapter
Hub
Small Adapter
Hub

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TAPMATE™ XL-424 Operating Manual
ADAPTER HUB INSTALLATION AND REMOVAL (cont.)
4. Tighten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otheLeadTubeand
 storeinShippingCrate/WorkStation.
Large Adapter HubSmall Adapter Hub
Large Adapter HubSmall Adapter Hub

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TAPMATE™ XL-424 Operating Manual
TAPMATE XL424 SETUP FOR 4"  12" taps:
For instructions on attaching the Large Adapter Bell (for 14" - 24" taps), turn to page 14.
 1. AftertheSmallAdapterHubhasbeensecurelyattachedtothe 
  LeadTube,checktheTapMateAdapterBelltobesurethatthe 
  o-ringisinneckoftheadapter.
 2. ScrewtheappropriatesizeandstyleAdapterBellontotheendof
  theAdapterHub.Youshouldfeeltheo-ringcompressasyou
  nishthreadingitontotheAdapterHub(seedrawingatleft).
 3. erearefoursetscrewholesaroundtheneckoftheadapterbell.
  Continuetothreadtheadapteronuntilthenextholeisoverthe
  atslotonthetopofthehub.
 4. Insertonesetscrewintotheholelocatedabovetheatandusea
3/16”allenwrenchtotightenthesetscrew(seedrawingatleft).
Note: The set screw must bear ENTIRELY on the at of the Small
Adapter Hub. Otherwise, damage to the threads of the Hub under
the set screw may occur, which in turn will make the Adapter very
dicult to remove. Further damage to the threads of the Adapter Bell
may also occur as you unscrew it from the Hub.
 5. RemovetheBrakeTubeLockingBoltfromtheBrakeTube
  (seedrawingatleft).iswillallowtheBrakeTube
  torotateseperatefromtheentiremachine.Removetheback
  workstationbrace.Leavethefrontworkstationbraceinplace.
Small
Adapter
Hub
Adapter Bell
(4" - 12")
Set
Screw
Brake Tube
Locking Bolt
Workstation
Rear Brace

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TAPMATE™ XL-424 Operating Manual
TAPMATE XL424 SETUP FOR 4"  12" taps:
(cont.)
 6. readtheBrakeTubedowntherustTubeby
  rotatingitinaclockwisedirection,asviewedfromthe 
  backofthemachine(seedrawingatleft).Dothisuntil 
  theShaftextendsoutoftheAdapterBell.edistance 
  willvarydependingonthetypeandsizeofAdapter 
  Bellbeingused.
 7. Applytheanti-gallinglubricanttotheSmallShaft  
  HeadBoltandstarttothreaditintotheendofthe 
  Shaftwiththe3/8"Allenwrench.Alighthekeyup
  withthekeywayandnishscrewingtheSmallShaft 
  Headintoplace.Applytheanti-gallinglubricanttoboth 
  setscrewsandthreadthemintotheShaftusingthe1/8"
  Allenwrench.eylocktheSmallShaftHeadBoltinplace,
  preventingitfromlooseningduringthecuttingoperations.
 8. eJamNutfacilitateseasyremovaltheShellCutters. 
  readtheJamNutontotheShaft.Runittothe  
  endofthethreads,andthenbackoonecomplete 
  revolution.Witha3/16"allenwrench,tightenJamNut 
  halvessothatthegapbetweenthemiseven
  (seedrawingatleft).SecuretheJamNuthalvesby  
  torquingscrewstoapproximately50in-lbs.
9. TaketheTMShaftNose(orTMPVCPilot)and
  examinetheretentionballsystem.Itshouldrequire 
  rm-to-hardpressuretodepresstheball.eball  
  shouldsnapbackintoplacesmoothly.Iftheballis 
  sticking,disassemble,andcleanthehole,balland  
  spring.Reassemble,andre-examinetoensuretheballis
functioning properly.
  ChecktoseethattheSpadeBitintheTMShaftNose 
is sharp and that it is held securely in the slot. If the
  SpadeBitischippedordamaged,itshouldbereplaced.
TM Shaft Nose

12
TAPMATE™ XL-424 Operating Manual
TAPMATE XL424 SETUP FOR 4"  12" taps:
(cont.)
10. readtheTMShaftNoseorTMPVCPilot(dependingonthematerialofpipeyouaretapping)into
 theendoftheShaftandtightenuntiltheshankoftheTMShaftNoseortheTMPVCPilotisushagainsttheface
 oftheShaft.Duetothelongerbodylengthofthe10and12inchshellcutters,aPilotDrillExtensionmust 
 beattachedbetweentheShaftandtheShaftNose(orPVCPilot)andtightenedintoplaceforthesesizetaps. 
 Seedrawings(below)forShaftNosecongurations.
11. Nowsliptheshellcutter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counter-clockwisedirection.eBrake
 Tubewillstoprotatingwhenitshows“zero”(oralittlebeyond)ontherustTube.Locatethesetscrewholein
 theBrakeTubebackoverthescaleintherustTubeandre-attachtheBrakeTubeLockingHandle.eBrake
 TubeLockingHandlemaydamagetherustTubethreadsifitisn'tlocatedoverthescale.
13. CheckthattheLeadNutissittingat"zero"ontheLeadTube.
SHAFT NOSE CONFIGURATION FOR 10"  12" CUTS
TM Shaft Nose
XL Shaft TM Jam Nut
TM Pilot Drill
Extension
SHAFT NOSE CONFIGURATION FOR 4"  8" CUTS
TM Shaft Nose
XL Shaft TM Jam Nut

13
TAPMATE™ XL-424 Operating Manual
TAPMATE XL424 SETUP FOR 4"  12" taps:
(cont.)
 13. Removethefronttie-downbracefromthecrate.
 14. eTapMateXL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aslevelas 
  possible.

14
TAPMATE™ XL-424 Operating Manual
TAPMATE XL424 SETUP FOR 14"  24" taps:
For instructions on attaching the Small Adapter Bell (for 4" - 12" taps), go to page 8.
 1. Removefrontandrearbracesfromworkstation.
 2. WiththeLargeAdapterHubproperlyinstalledonthe
  LeadTube(seestepsonpage6),liftandmovethe
  appropriatesizeandstyleTapMateXL-424Adapterbell
  intoplace(seedrawingatleft).
 3. Removethesixnutsandwashersfromtheoutsideof
  theadapter.Alsomakesurethatthegasketisinplace.
 4. LifttheAdapterBellbytheliftingeye,andmove 
  itintoplace.e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.
6. RemovetheBrakeTubeLockingBoltfromtheBrake
  Tube(seedrawingatleft).iswillallowtheBrakeTube
to rotate.

15
TAPMATE™ XL-424 Operating Manual
TAPMATE XL424 SETUP FOR 14"  24" taps:
(cont.)
 7. readtheBrakeTubedowntherustTubebyrotating
  itinaclockwisedirection,asviewedfromthebackof
  themachine(seedrawingatleft).DothisuntiltheShaft
  extendsoutoftheAdapterBell.edistancewillvary
  dependingonthetypeandsizeofAdapterBellbeing
used.
 8. Applytheanti-gallinglubricanttotheLarge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nishscrewingtheLargeShaftHeadintoplace.
  Appytheanti-gallinglubricanttobothsetscrewsand
  threadthemintotheShaftusingthe1/8"Allenwrench.
  eylocktheLargeShaftHeadBoltinplacepreventing
it from loosening during the cutting operation.

16
TAPMATE™ XL-424 Operating Manual
TAPMATE XL424 SETUP FOR 14"  24" taps:
(cont.)
 9. TaketheTMXL-ShaftNose(orTMXL-PVCPilot)and
  examinetheretentionpinsystem.Itshouldrequire
firm pressure to depress the pin, and the pin should
  snapbackintoplacesmoothly.Ifthepinissticking,
  disassemble,andcleanthehole,pinandspring.
  Reassemble,andre-examinetoensurethepinis
functioning properly.
  ChecktoseethattheSpadeBitissharpandthatitis
  heldsecurelyintheslot.IftheSpadeBitischippedor
  damaged,itshouldbereplaced.
TM XL Shaft Nose

17
TAPMATE™ XL-424 Operating Manual
TAPMATE XL424 SETUP FOR 14"  24" taps:
(cont.)
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threadedallthewayontotheLargeShaftHead,this
  smoothareawilllineupwiththetwosetscrewholes
  locatedintheLargeShaftHead.readSetScrewinto
  placeandtightenwithan1/8"allenwrench(seedrawing
  atleft)lockingtheShaftNoseorPVCPilotintoplace.
' 11.
  MovetheappropriatesizeShellCutterovertheShaft
  Nose(orPVCPilot)andontothefrontbossofthe 
  LargeShaftHead.AlignthethroughholesoftheLarge
  ShaftHeadwiththetappedholesintheCutter.Secure
  withthesixCutterboltsprovided.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counter-clockwisedirection.
  eBrakeTubewillstoprotatingwhenitshows"zero"
  ontherustTube.
CheckthattheLeadNutissittingat"zero"onthe
  LeadTube.
Note: Due to the weight of some Shell Cutters,
use a suitable strap and lifting mechanism
when lifting and installing the Shell Cutter.

18
TAPMATE™ XL-424 Operating Manual
TAPMATE XL424 SETUP FOR 14"  24" taps:
(cont.)
 13. eTapMateTM-XL424isnowreadytobeliftedand
  attachedtothegatevalve.Whenliftingthemachine,
using the lifting loop at the end of the machine and the
  loopontheadapterbell.
Note: Adjust the Chain Choker so that the machine is
lifted as level as possible.

19
TAPMATE™ XL-424 Operating Manual
ATTACHING THE TAPMATE XL424 TO THE VALVE:
eillustrationsinthissectiondepicta6”size-on-sizetapusingaRomacFTS420FabricatedSteelTappingSleeve,anMJ
byFlangegatevalveandtheTapMateXL-424machinewithanMJadapterbell.Regardlessofthesizetapyou're
performing, the steps are the same.
 1. Installandassembletappingsleeveandgatevalveperthe
  manufacturer'sinstructions.Pressuretestthetapping
  sleeveandgatevalveassemblybeforebeginningthetap.
NOTE: At this point, you'll take some measurments to
determine the necessary depth of your tap. Record
these measurements, as you'll use these values in
subsequent steps.
 2. Withthevalvegatestillclosedfromthepressuretest,
  measurethedistancefromthevalveangefacetothe
  gate(seedrawingatleft).
3. WiththeShellCutterfullyretracted,takethefollowing
  measurements(seedrawingsatleft) 
  • MeasurethedistancetheShaftNose/PVCPilot
   extendsbeyondtheAdapterBellange.
  • MeasurethedistancethattheShellCutterextends
   beyondtheAdapterBellange.
  • esedistanceareoftendierentdepending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 Clearance
Valve
Flange
Face
Tapping Sleeve Neck
Pipe
Extension Distance
Shaft Nose/PVC Pilot
Extension Distance
Shaft Nose/PVC Pilot
MJ Adapter
(without Gasket)
Distance
Cutter's Extension
Flange Adapter
Distance
Cutter's Extension

20
TAPMATE™ XL-424 Operating Manual
Distance to Pipe
Centerline of
the Waterway
Valve Gate
C
L
Pipe OD
Valve
Flange
 5. Carefullyreleasethepressureinthesleeveandvalve.
  OPENthevalvegatecompletely.
 6. Measure,andnotethedistancefromthevalveangeto
  thepipe(throughthevalve,sleeveneckandany
  extensions).Recordthismeasurment,asthisvalueis
  necessaryinsubsequentsteps.
Pipe
Distance to Distance of Cut
Travel Chart's
<
=
39 Inches Total Machine
Bar Travel Distance
C
L
-
+Cutter's Extension
out of Adapter
and into Valve Body
or
BORING BAR TRAVEL & DISTANCE OF CUT
7.eTapMateXL-424boringbarcantravel39inches,whichismorethanadequateformosttaps.
 Beforeyoubeginyourtap,makesurethetotaldistancetocutisnotmorethan39inches.
 Todeterminethedistancenecessaryforyourtap,seethedrawingbelow.
ATTACHING THE TAPMATE XL-424 TO THE VALVE:
(cont.)
Note: Conrm that the ID of the pipe is greater than the Cutter's OD.