TRI tool SEVERMASTER 576AC User manual

TABLE OF CONTENTS
CUSTOMER MESSAGE Inside Front Cover
SAFETY PRECAUTIONS 3
MACHINE SPECIFICATIONS 5
COLLETS 7
TOOL BITS 8
OPERATION 10
CUTTING SPEEDS AND FEEDS 12
MAINTENANCE 13
TROUBLESHOOTING 15
PARTS LIST 17
ACCESSORIES 24
TOOL BIT RESHARPENING POLICY Inside Back Cover
WARRANTY INFORMATION Inside Back Cover
92-1176 Orig. 041012
Model 576AC SEVERMASTERTM withAir Motor

Copyright 1996 proprietary property of TRI TOOL
Inc. No reproduction, use, or duplication of the infor-
mation shown hereon is permitted without the express
written consent of TRI TOOL Inc.

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576AC SEVERMASTERTM with Air Motor
IN GENERAL:
When using rotating head cutting equipment, basic safety precautions
should always be followed to reduce the risk of personal injury.
Operate this tool only in accordance with specific operating instructions.
Do not override the deadman switch on the power unit. Locking down,
obstructing, or in any way defeating the deadman switch on the power
drive unit may result in serious injury.
DRESS CONSIDERATIONS:
Use standard safety equipment. Hard hats, safety shoes, safety har-
nesses, protective clothes, and other safety devices should always be
used when appropriate.
Use safety glasses. Do not operate cutting tools without eye protection.
Dress properly. Do not wear loose clothing or jewelry. They can be
caught in rotating and moving parts. Avoid slippery floors or wear
nonskid footwear. If you have long hair, wear protective hair covering to
containit.
WORK AREA:
Keep the work area clean. Cluttered work areas and benches invite inju-
ries.
Consider the work area environment. Keep the area well lit. Keep electri-
cal cords, cables, rags, rigging straps, etc. clear of rotating equipment. Do
not use power cutting tools in the presence of flammable liquids and gasses.
Keep visitors away. Do not let visitors or untrained personnel near operat-
ing tools. Enforce eye protection requirements for all observers.
Do not over reach. Keep proper footing at all times.
Stay alert. Watch what you are doing. Use common sense. Do not oper-
ate tools when you are tired.
TOOL CARE:
Maintain tools with care. Keep tools in good operating condition. Sharp
tool bits perform better and safer than dull tool bits. Well maintained tools
function properly when needed.
Check for damaged parts. If a tool has malfunctioned, been dropped or
hit, it must be checked for damage. Run no-load tests and feed function
checks. Do a complete visual inspection.
SAFETYPRECAUTIONS
SAFETYPRECAUTIONS

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Electric motors. Use only with proper AC voltage power sources and
observe all normal electric shock hazard procedures.
Do not abuse power and control cords. Pulling or running over cords and
cables can result in electrical shock hazards and malfunctions. Keep
control and power cords out of all cutting fluids and water.
Hydraulic drives. Observe proper procedures for electrically driven
power sources. Avoid damage to hydraulic lines. Keep quick-discon-
nects clean. Grit contamination causes malfunctions.
Air tools. Check the exhaust muffler. Broken or damaged mufflers can
restrict air flow or cause excessive noise. Use air motors only with a
filtered, lubricated and regulated air supply. Dirty air, low pressure air or
over pressure air will cause malfunctions, including delayed starting.
AREA EQUIPMENT:
Secure work. Whenever possible use clamps, vises, chains and straps to
secure pipe.
Make sure the tool is secured, it is safer to have both hands free to
operate the tool.
TOOL USE:
Use the right tool and tool bit for the job. Do not use a tool which is
incorrect for the job you are doing.
Keep the tool bits fully engaged in the tool bit holders. Loose bits are a
safety hazard.
Disconnect power supply during setup and maintenance. Use all stop or
shut-offfeatures available when changing or adjusting tool bits, maintaining
the tool, or when the tool is not in use.
Remove adjusting keys and wrenches before applying power to the equip-
ment. Develop a habit of checking the tool before turning it on to make sure
that all keys and wrenches have been removed.
Do not force tools. Tools and tool bits function better and safer when used
at the feed and speed rate for which they were designed.
Do not reach into rotating equipment. Do not reach into the rotating head-
stock to clear chips, to make adjustments, or to check surface finish. A
machine designed to cut steel will not stop for a hand or an arm.
Handle chips with care. Chips have very sharp edges and are hot. Do
not try to pull chips apart with bare hands; they are very tough.
Avoid unintentional starts. Do not carry or handle tools with your hand on
the operating switches or levers. Do not lay the tool down in a manner
which will start the drive. Do not allow the tool to flip around or move
when adjusting or changing tool bits.
Store idle tools properly. Disconnect tools from the power source and
store in a safe place. Remove tool bits for safe handling of the tool.

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576AC SEVERMASTERTM with Air Motor
MACHINE
SPECIFICATIONS
IN GENERAL:
The Model 576AC SEVERMASTER™ severs 2.00" to 6.63" (50.8mm
to 168.3mm) diameter tubes and thin wall pipe within the size range. This
machine enhances productivity by incorporation of anAuto-Cycle Tool
Module and Quick Lock Collet Closure. TheAuto-Cycle Tool Module
incorporates a cam cycle tool bit feed mechanism which automatically
returns the tool bit to the home position ready to start the next cut. The
tool module also allows setting the start and finish cut position to minimize
the cycle time. The feed increment per revolution is adjustable to match
the cutting relative to the material. Avariable speed motor provides
cutting speed control for tool bit life and ID burr condition. The Quick
Lock Collet Closure mechanism actuates the collet with a single lever
stroke and provides for simple collet changes.
Tool bit options are available to minimize the burr on either the mounting
side or the drop-off side of the sever line and in different edge widths to
matchthetubewall thicknesses. The Model576ACalsoincorporates mount-
ing features to allow use of an SQM-2AC Tube Squaring Module for opti-
mum burr free ends.
The Model 576AC SEVERMASTER™ System, consists of the mainframe
with the Quick Lock Collet Closure,Auto-Cycle Tool Module with adjust-
able depth of feed from .001" to .005" (.02mm to .13mm) per revolution,
drive motor, wrench kit and operator’s manual.
DESIGN AND OPERATING FEATURES:
° The Model 576AC accepts its own torque through the collet clamp-
ing system.
° The collet provides accurate centering and full diameter support for
minimumdistortionofthinwall tubing.
° Gear driven powerhead rotates on a precision ball bearing system.
° Single lever actuation of collet.
° Gears are enclosed for operator safety.
° The wrenches that are required for operation of the machine are
supplied.
CUTTING CAPACITIES:
° 2" pipe schedule 5 thru 40
° 2 1/2" pipe through 6" pipe schedules 5 and 10.
° 2.00" through 6.63" (50.8 mm through 168.3 mm) diameter tubing up
to .156" (4.0 mm) wall.
MATERIAL CUTTING CAPABILITIES:
° Mild steels, chrome steels (Rc 35 max.), stainless steel, copper-nickel
and aluminum without limitations other than size and wall thickness
as specified.
SPECIFICATIONS

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° Inconel and some other high-temperature alloys may require special
procedures as a function of wall thickness.
Contact TRI TOOL INC’s Engineering Department for details.
MACHINE FEATURES:
° Pneumatic drive system: 55 cfm at 90 psi
(26 it/sec at 6.3 Kg/cm2)
° Max. cutting head speed: 40 rpm
° Mounting: Manually actuated collet
clamping system.
° Feed: Autofeed system adjust-
able from .001" to .005"
(.02 mm to .13 mm)
° Weight: 93 lbs (42.2 kg)
Envelope Model 576AC SEVERMASTER™
12.00”
(304.8 mm)
17.31”
(439.7 mm)
17.46”
(443.6 mm)
8.75”
(222.3 mm)
Tripper Pin
Air Motor 15.70” (398.8 mm)
Rotating DIA
Feed Arm
Collet
Latch
Handle
21.38”
(542.9 mm)

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576AC SEVERMASTERTM with Air Motor
Spare parts for the collets are:
Part No. Description
40-0238 Spring, Extension (.25” dia x 12.00”)
40-0248 Spring, Compression (.25” dia x 1.38”)
40-0249 Spring, Extension (.25” dia x 1.88”)
40-0250 Spring, Extension (.25” dia x 6.00”)
Decimal mm Part
Inches Equiv. Number
2.000 50.8 30-2558
2.008 51.0 30-2559
2.063 52.4 30-2560
2.125 54.0 30-2561
2.188 55.6 30-2562
2.240 56.9 30-2563
2.244 57.0 30-2564
2.250 57.2 30-2565
2.313 58.8 30-2566
2.375 60.3 30-2567
2.382 60.5 30-2568
2.438 61.9 30-2569
2.480 63.0 30-2570
2.492 63.3 30-2572
2.500 63.5 30-2573
2.563 65.1 30-2574
2.625 66.7 30-2575
2.688 68.3 30-2576
2.750 69.9 30-2577
2.795 71.0 30-2578
2.813 71.5 30-2579
2.875 73.0 30-2580
2.938 74.6 30-2581
2.992 76.0 30-2582
2.996 76.1 30-2583
3.000 76.2 30-2584
3.004 76.3 30-2585
3.125 79.4 30-2586
3.250 82.6 30-2587
3.375 85.7 30-2588
3.500 88.9 30-2589
3.508 89.1 30-2590
3.625 92.1 30-2591
The size of the collet is determined by the outside diameter of
the tube or pipe to be severed or squared.
SELECTION:
Decimal mm Part
Inches Equiv. Number
3.750 95.3 30-2592
3.875 98.4 30-2593
3.988 101.3 30-2594
4.000 101.6 30-2595
4.125 104.8 30-2596
4.250 108.0 30-2597
4.375 111.1 30-2598
4.500 114.3 30-2599
4.750 120.7 30-2600
5.000 127.0 30-2601
5.250 133.4 30-2602
5.500 139.7 30-2603
5.563 141.3 30-2604
5.750 146.1 30-2605
6.000 152.4 30-2606
6.250 158.8 30-2607
6.500 165.1 30-2608
6.625 168.3 30-2609
NOTE
COLLETS

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CAUTION
SELECTION:
INSTALLATION:
Make sure that the Model 576AC is disconnected from its power source
before installing a tool bit.
Install a collet into the Model 576AC.
Insert a tube into the collet and bring it flush to the front of the collet and
clamp the tube in place.
Rotate the cam feed knob counter-clockwise with a 3/8” wrench, so that
the scribe mark points to the bottom (this will place the tool holder to the
end of the feed).
The cam can only rotate in the direction noted on the knob with an
arrow.
Slide a tool bit into the tool slot until the end of the cutting edge of the tool
bit passes the ID of the tube by approximately .020".
DO NOT install the tool bit backwards; it will not cut and may destroy
the tool bit.
Secure the tool bit in place by tightening the (6) six set screws in the tool
holder.
Rotate the cam feed knob until the tool holder returns to top of its travel.
Pipe
Max or
Wall Tube
Range Thk Mat’l Notes:
The following tool bits leave the burr on the piece on which the machine is mounted on:
.016” thru .040” 99-5482 Tool Bit, Sever, Right Hand, .040” wide
.040” thru .065” 99-5477 Tool Bit, Sever, Right Hand, .060” wide
.065” thru .156” 92-5472 Tool Bit, Sever, Right Hand, .100” wide
The following tool bits leave the burr on the piece opposite to which the machine is mounted on:
.016” thru .040” 99-5481 Tool Bit, Sever, Right Hand, .040” wide
.040” thru .065” 99-5480 Tool Bit, Sever, Right Hand, .060” wide
.065” thru .156” 99-5473 Tool Bit, Sever, Right Hand, .100” wide
WARNING
NOTE
TOOL BITS

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576AC SEVERMASTERTM with Air Motor
Setscrews
Feed Rate Lock Screw
FeedRateAdjustmentScrew
FeedArm Cam Feed Knob
TripperShaft
IndicatorMark
FeedLimitAdjustScrew
(Hidden)
Screw in the feed limit adjustment screw until the end of the cutting edge
of the tool bit just clears the OD of the tube.
Rotate the cam feed knob counter-clockwise to pick up the feed slack.
Loosen the collet and re-position the tube to sever.
To adjust the feed rate, loosen feed lock screw, rotate the feed adjustment
screw and read the feed rate graduations to find the desired feed rate.
Some experimentation should be made to maximize the efficiency and tool
bitlife.
A feed rate of .002” to .003” (.05 mm to .08 mm) will accommodate most
tube materials.
When the desired feed rate is set, tighten the feed lock screw.
(DO NOT over tighten.)
NOTE

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IN GENERAL:
Read the operating instructions carefully before attempting to operate the
Model 576AC SEVERMASTER™.
Inserting the collet:
Select the desired size collet for the pipe or tube to be worked on.
Raise the handle to release pressure on the adjust nut.
Rotate the adjust nut until the eyebolt can be raised out of the slot and
then the hinge bracket may be rotated back and down.
Remove the pusher sleeve from the main housing.
Remove the collet, if there is one, from the inside of the main housing.
Insert the correct collet into the main housing and then slide the pusher
sleeve back into the main housing and into contact with the collet.
Rotate the hinge bracket back up and let the eyebolt drop back into the
slot.
Rotate the adjust nut on the eyebolt to secure in the slot.
Mounting the tool holder:
Select the tool holder which will allow the tool bit to reach the work
surface.
Place the tool holder in the tool holder slot.
Insert the (4) four cap screws that hold the tool holder in place.
GraduationMarks
Feed rate Lock Screw
FeedrateAdjustmentScrew
FeedArm
OPERATION

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576AC SEVERMASTERTM with Air Motor
TripperShaft
Handle
Mount tool holder #1 for tube ranging from 4.50” to 6.625” (114.3 mm to
168.3 mm).
Mount tool holder #2 for tube ranging from 2.00” to 4.50” (50.8 mm to
114.3 mm).
MACHINING INSTRUCTIONS:
Turn the motor on to full speed by depressing the lever.
Engage the feed by pushing the tripper shaft in.
Monitor the cutting operation and apply cutting fluid as necessary.
The machine operation is finished when the tool holder returns home,
release the lever in order to turn off the motor.
Loosen the collet by rotating the handle up.
Remove the pipe or tubing from the Model 576AC.
The tool holder will retract automatically in 5 to 10 revolutions.
There is an audible ‘snap’ when the tool holder returns to the home
position.
Observe the relationship between the pipe or tube and the tool bit.
The tool holder may be reset quickly by hand by rotating the cam feed
knob to pick up the feed slack.
It is not necessary to disengage the tripper shaft after each cutting
operation.
NOTE
NOTE
Cam feed knob

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12
CUTTING SPEEDS:
The table below shows RPM required to obtain a specified Tool Bit
cutting speed on the surface of a pipe or tube.
Use 200 surface inches per minute (5080 surface millimeters per minute)
for stainless steels in general when no coolant is allowed, all heavy wall
tube, and some chrome/molybdenum alloys.
Use 250 surface inches per minute (6350 surface millimeters per minute)
for mild steel and some thin wall stainless steel when coolant are permit-
ted and used.
Use 300 surface inches per minute (7620 surface millimeters per minute)
for aluminum and thin-wall mild steel tube with coolant.
CUTTING FEEDS:
Use very light feed for initial severing or until a continuous cut is estab-
lished.
Use a feed rate .002" to .003" (.05mm to .08mm) per revolution once a
continuous cut is established.
If the feed is too light, only light stringer chips will be removed.
If the feed is too heavy, the drive will start to overload and the chip will
take on a rough or torn appearance.
Stainless steel, which work hardens, must be worked with a heavy
enough feed to stay under the work hardened surface.
Feed at rate of at least .003" to .005" (.08mm to .13mm) per revolution.
Never allow the bit to burnish the surface.
Reducing cutting feed and speed will normally minimize any chatter
problems.
Cutting Speeds approximately
RPM for RPM for RPM for
tube 200in/min 250 in/min 300in/min
size (5080mm/min) (6350mm/min) (7620mm/min)
2” 50.8 mm 32 40 48
3” 76.2 mm 21 26 32
4” 101.6 mm 16 20 24
5” 127.0 mm 13 16 19
6” 152.4 mm 11 13 16
CUTTING SPEEDS & FEEDS

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576AC SEVERMASTERTM with Air Motor
IN GENERAL:
All components should be cleaned and coated with a light film of
oil prior to use. Use a clean, non-detergent oil, preferably
SAE 10 (90 SSU) or lighter.
The air supply for the Model 576AC (pneumatic drive) should
include an adequate filter, regulator and lubricator (FRL).
If the Model 576AC is operated in such a manner that the tool
holder collect debris while cutting, the tool holder and the slides
should be cleaned after each cutting operation.
Tool life may be severely shortened, unless chips and/or other
debris that have been deposited on the cutting head during the
machining operation are removed.
RECOMMENDED MAINTENANCE SCHEDULE:
Daily maintenance when the unit is in operation includes wiping
the unit down and spraying with rust preventative under severe
humidity conditions. Visually inspect for loose screws, missing
screws, damage, etc.
After every 20 hours of actual operation, lubricate the male and
female tool holder slides.
After every 40 hours of actual operation, thoroughly clean and
lubricate main gear, drive gear, male and female tool slides, and
tripper bracket assembly.
If the Model 576AC is to be stored or if it will remain out of
service for a significant period of time (30 days or more), it
should be thoroughly cleaned, lubricated and sprayed with a rust
preventative prior to storage.
Tool holder maintenance:
Clean the slide rails, the tool holder, and the feed components.
Inspect these parts for damage and replace as required.
Lubricate and reassemble.
Adjust the adjustable slide rail to provide a firm, but not excessive
pressure on the tool holder.
The slide rails must be overtightened to squeeze the oil into a thin
film against the male and female surfaces of the slide rails.
Reset for proper operation.
Tripper bracket assembly lubrication and adjustment:
Back off the half-dog setscrew until it disengages from the
tripper shaft.
Remove the tripper shaft assembly from the bracket and clean
off all of the old lubrication.
MAINTENANCE

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14
Apply fresh lubrication to the tripper shaft assembly and
reinstall it in the bracket.
Screw in the half-dog setscrew until it locates itself in the
slot on the tripper shaft.
Try turning the tripper shaft assembly to insure that the
setscrew is in the slot of the tripper shaft assembly and is
preventing it from rotating.
LUBRICANT RECOMMENDATIONS:
The drive gears require a heavy duty grease such as
“Chevron Ultra Duty Grease, EP, NLGI2”.
The slide rails and tool holder require a light oil such as
SAE 10 light machine oil.
The tripper bracket assembly also require a SAE 10 light
machine oil for normal conditions and under dusty
conditionsasilicone,graphiteormolybdenumdisulfide
‘dry’ lubricant.
A light film of all purpose grease may be used, but it
must be checked for grit contamination frequently.

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576AC SEVERMASTERTM with Air Motor
PROBLEM: The tool bit chatters.
The tool bit is loose or overextended.
The tool bit is damaged.
The tool holder is too loose in the slides.
The cutting speed is too fast.
The collet is loose on the pipe or tube.
Cuttingfluidis required.
PROBLEM: There is excessive tool bit wear.
The pipe or tube material is too hard or abrasive.*
The cutting speed is too fast.
Cuttingfluidis required.
A dull tool bit is causing surface hardening conditions (Stainless pipe or
tubing)
There is scale or other foreign material on the pipe or tubing, which is
dulling the tool bit at the start of the cut.
The tool bit is incorrect for the material being cut.*
PROBLEM: Thetool bit is diving and the SEVERMASTERTM isstalling:
The tool bit is dull, chipped, etc.
The tool holder adjustment slide is too loose.
The tool bit is over-extended.
PROBLEM: Thesurface finish is rough.
The tool bit is dull, chipped, etc.
Metal build-up on the cutting edge of the tool bit is creating a false cutting
edge.
Cuttingfluidis required.
The cutting speed is incorrect.
The feed per revolution is too great.
PROBLEM: The tool holder is not feeding.
The cam feed knob roller clutch is broken.
The slide rails are too tight.
PROBLEM: There is a loss of airpower.
The air supply pressure is too low.
The air filter is plugged.
The air supply line size is insufficient.
The air supply line is too long.
The water trap is full.
* Consult the factory for tool bit material recommendations for specialty pipe or tube
materials.
TROUBLESHOOTING

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PROBLEM: Thepipeor tube is slipping in the collet.
The clamping pressure is not tight enough.
Scale and/or other foreign material is present on the pipe or tube.
Weld seams, swelling, or bumps are preventing full contact of the collet.
Dull tool bits are causing extra force in the axial and/or radial direction.
PROBLEM: Thetool bit will notreachthework.
An incorrect tool bit is installed.
PROBLEM: Theair motor willnot start.
The air supply is shut off.
The air motor will not run free. The air motor may need lubrication. Add
lubrication to the air motor and wait a few minutes before attempting to run
it again. Try running the motor again. If it still will not run, the vanes may
be sticking; tap on the air motor casing lightly with a piece of wood or with
a soft rubber mallet.
Sand or other foreign material is in the vanes of the air motor.

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576AC SEVERMASTERTM with Air Motor
PARTSLIST
Model 576AC Sub-assembly, Group B (P/N 02-2438)
1
2
3
4
8
9
10
5
6
11
12
13
14
15
16
17
18
19
20
21
22
5
8
7
23

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Model 576AC Sub-assembly, Group B (P/N 02-2438)
Item Part
No. No. Description Qty
1. 19-0777 Housing, Main 1
2. 20-0651 Shaft, Drive 1
3. 20-0652 Shaft, Main 1
4. 27-0633 Adaptor, Motor 1
5. 28-0264 O-Ring 2
6. 28-0245 Seal, Grease 1
7. 28-0263 O-Ring 1
8. 29-0020 Bearing, Ball 2
9. 29-0096 Bearing, Ball 1
10. 30-2612 Ball, Bearing, Steel (3/8 dia) 72
11. 31-0142 Key 1
12. 33-0030 Screw, Cap (#10-24 x .75) 8
13. 33-0041 Screw, Cap (1/4-20 x .88) 8
14. 54-0398 Plug, Pressure 4
15. 33-2033 Screw, Cap (1/4-20 x .75, Zinc Plt) 4
16. 35-0534 Nut,Adjustment, Bearing Race 1
17. 39-0815 Gear, Main, Worm 1
18. 39-0819 Gear, Worm 1
19. 44-0473 Spacer 1
20. 44-0474 Spacer, Collet 1
21. 46-0446 Sleeve, End 1
22. 46-0448 Sleeve, Main Inner 1
23. 40-0271 Spring,Wave Disc 1
29-0362 Bearing, Inner Race ref
46-0467 Sleeve, Main Inner Race ref

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576AC SEVERMASTERTM with Air Motor
Model 576AC Sub-assembly, Group C (P/N 02-2438)
1
2
3
4
7
8
9
10
5
6
11
12
13
14
15
16
17
18
19
20
23
21
22

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Model 576AC Sub-assembly, Group C (P/N 02-2438)
Item Part
No. No. Description Qty
1. 19-0777 Housing, Main ref
2. 20-0633 Shaft, Clamp 1
3. 20-0637 Shaft,Tripper 1
4. 24-1511 Plate, Clamp 1
5. 24-1525 Plate, Stand 1
6. 29-0031 Cam Follower 1
7. 30-0125 Plunger, Ball (1/4-20 x .53) 1
8. 30-2611 Button, Spherical 2
9. 32-0118 Pin, Dowel (3/8 dia x .75) 1
10. 32-0509 Pin, Clevis,1/4 2
11. 33-0032 Screw, Cap (#10-24 x 1.00) 2
12. 33-0300 Screw, Button Head (3/8-16 x 1.00) 2
13. 33-1950 Screw, Shoulder (.50 dia x 2.50) 1
14. 33-2001 Screw, Cap, SS (#10-24 x .75) 1
15. 33-2005 Screw, Flat Head (5/16-18 x .75, SS) 4
16. 33-2006 Screw, Button Head (3/8-16 x 1.00, SS) 1
17. 33-2030 Eyebolt 1
18. 34-0134 Washer Set, Self Align (3/8) 1
19. 35-0139 Nut, Check (3/8-16) 1
20. 41-0125 Handle 1
21. 42-0023 Knob 1
22. 47-1163 Bracket, Hinge 1
23. 62-0110 Cam, Clamp 1
NotShown:
05-1319 Wrench Kit
36-0007 Wrench, L, 5/32” hex 1
36-0008 Wrench, L, 3/16” hex 1
36-0020 Wrench, T, 5/32” hex 1
36-0052 Wrench,Combination,3/8” 1
49-0321 Holder, Tool, #2 1