TRI tool 550 Series User manual

92-0116 Rev. 110203
Model 550 Tube Severing Tool
TABLE OF CONTENTS
CUSTOMER MESSAGE Inside Front Cover
SAFETY PRECAUTIONS 3
GENERAL DESCRIPTION 6
SPECIFICATIONS 7
MAINTENANCE 9
OPERATION 10
REPAIRS AND REPLACEMENT 13
AIR DRIVE ASSEMBLY 15
TROUBLE SHOOTING 16
ACCESSORIES 18
ILLUSTRATED PARTS BREAKDOWN 19
DEWALT SAFETY INSTRUCTIONS 43
TOOL BIT RESHARPENING POLICY Inside Back Cover
WARRANTY INFORMATION Inside Back Cover

Copyright 2011
Proprietary property of TRI TOOL Inc.
No reproduction, use, or duplication of the information
shown hereon is permitted without the express written
consent of TRI TOOL Inc.

3
Model 550 Tube Severing Tool
92-0116 : Rev. 110203
SAFETY PRECAUTIONS
WARNING:
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, ob-
structing, 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 harnesses, protec-
tive 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 rotat-
ing and moving parts. Avoid slippery floors or wear nonskid footwear. If you have
long hair, wear protective hair covering to contain it.
WORK AREA
Keep the work area clean. Cluttered work areas and benches invite injuries.
Consider the work area environment. Keep the area well lit. Keep electrical cords,
cables, rags, rigging straps, and 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 at or near operating
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 operate tools
when you are tired.

4
TRI TOOL INC.
92-0116 : Rev. 110203
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 com-
plete visual inspection.
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-disconnects 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 mal-
functions, 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 haz-
ard.

5
Model 550 Tube Severing Tool
92-0116 : Rev. 110203
Disconnect power supply during setup and maintenance. Use all ‘Stop’ or Shut off’
features 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 equipment.
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 are hands; they are very tough.
Avoid unintentional starts. Do not carry or handle tools with your hand on the oper-
ating switches or levers. Do not lay the tool down in a manner that 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.

6
TRI TOOL INC.
92-0116 : Rev. 110203
GENERAL DESCRIPTION
The Model 550 Tube Severing Tool series of tube cutters is designed to cut tubing in
areas where access to and around the tube is limited.
The Model 550 uses a cutter wheel to sever the tube. Normal operation will not
produce chips.
The Model 550 is powered by Tri Tool Inc. pneumatic, electrical or manual Drive
Units.
The Model 550 features an automatic feed, which permits an even pressure on the
cutting wheel during operation.

7
Model 550 Tube Severing Tool
92-0116 : Rev. 110203
SPECIFICATIONS
Envelope, Model 550-00, Tube Severing Tool

8
TRI TOOL INC.
92-0116 : Rev. 110203
Envelope, Model 550-00, Tube Severing Tool
Model
No. P/N Tube Size "A" "B" "C" Weight
550-03 01-1062 3/16"
(
4.8 mm
)
3.67"
(
93.2 mm
)
1.50"
(
38.8 mm
)
1.25"
(
31.8 mm
)
.75 lb
(
.34 k
g)
550-04 01-1063 1/4"
(
6.4 mm
)
3.67"
(
93.2 mm
)
1.50"
(
38.8 mm
)
1.25"
(
31.8 mm
)
.75 lb
(
.34 k
g)
550-05 01-1064 5/16"
(
7.9 mm
)
3.67"
(
93.2 mm
)
1.50"
(
38.8 mm
)
1.25"
(
31.8 mm
)
.75 lb
(
.34 k
g)
550-06 01-1009 3/8"
(9.5 mm)
3.67"
(93.2 mm)
1.50"
(38.8 mm)
1.25"
(31.8 mm)
.75 lb
(.34 kg)
550-08 01-1065 1/2"
(12.7 mm)
4.36"
(110.7 mm)
2.25"
(57.2 mm)
1.53"
(38.9 mm)
2.25 lb
(1.02 kg)
550-10 01-1066 5/8"
(15.9 mm)
4.53"
(115.1 mm)
2.38"
(60.5 mm)
1.53"
(38.9 mm)
2.47 lb
(1.12 kg)
550-12 01-1067 3/4"
(
19.1 mm
)
4.63"
(
117.6 mm
)
2.50"
(
63.5 mm
)
1.53"
(
38.9 mm
)
2.65 lb
(
1.20 k
g)
550-14 01-1075 7/8"
(
22.2 mm
)
4.88"
(
124.0 mm
)
2.63"
(
66.8 mm
)
1.53"
(
38.9 mm
)
2.94 lb
(
1.33 k
g)
550-16 01-1068 1"
(
25.4 mm
)
5.02"
(
127.5 mm
)
2.75"
(
69.9 mm
)
1.53"
(
38.9 mm
)
3.16 lb
(
1.43 k
g)
550-18 01-1069 1 1/8"
(
28.6 mm
)
5.88"
(
149.4 mm
)
3.13"
(
79.5 mm
)
1.53"
(
38.9 mm
)
4.22 lb
(
1.91 k
g)
550-20 01-1070 1 1/4"
(31.8 mm)
6.13"
(155.6 mm)
3.38"
(85.9 mm)
1.56"
(39.6 mm)
4.85 lb
(2.20 kg)
550-24 01-1071 1 1/2"
(38.1 mm)
7.10"
(180.3 mm)
4.00"
(101.6 mm)
1.56"
(39.6 mm)
6.64 lb
(3.01 kg)
550-28 01-1072 1 3/4"
(44.5 mm)
7.70"
(195.6 mm)
4.38"
(111.3 mm)
1.56"
(39.6 mm)
7.87 lb
(3.57 kg)
550-32 01-1073 2"
(
50.8 mm
)
8.19"
(
208.0 mm
)
4.75"
(
120.7 mm
)
1.56"
(
39.6 mm
)
9.10 lb
(
4.13 k
g)

9
Model 550 Tube Severing Tool
92-0116 : Rev. 110203
MAINTENANCE
All components should be periodically cleaned and coated with a light film of oil.
Use a clean, non-detergent oil, preferably SAE 10 (90 SSU or lighter.)
The Cutting Wheel should be replaced if worn or damaged.
The Cutting Wheel life depends upon the tube material, wall thickness, and
operator’s experience.
Short and long bearing plugs should be replaced when worn, damaged or scratches
occur on the tube being cut.

10
TRI TOOL INC.
92-0116 : Rev. 110203
OPERATION
Read the operating instructions carefully before attempting to operate the Model 550
Tube Severing Tool.
Be sure to use eye protection at all times when operating the Model 550.
Select the proper Model 550 for the size of tubing to be severed.
Maximum Tube Wall Thickness
Model
No.
Tube
Size Aluminum Stainless Steel Titanium
550-03 3/16" (4.8 mm) .065" (1.6 mm) .065" (1.6 mm) .065" (1.6 mm)
550-04 1/4" (6.4 mm)
550-05 5/16" (7.9 mm)
550-06 3/8" (9.5 mm)
550-08 1/2" (12.7 mm) .095" (2.4 mm) .100" (2.5 mm) .100" (2.5 mm)
550-10 5/8" (15.9 mm) .125" (3.2 mm)
550-12 3/4" (19.1 mm) .095" (2.4 mm)
550-14 7/8" (22.2 mm) .125" (3.2 mm)
550-16 1" (25.4 mm) .095" (2.4 mm)
550-18 1 1/8" (28.6 mm) .125" (3.2 mm)
550-20 1 1/4" (31.8 mm) .100" (2.5 mm)
550-24 1 1/2" (38.1 mm) .110" (2.8 mm)
550-28 1 3/4" (44.5 mm) .125" (3.2 mm)
550-32 2" (50.8 mm)
Be sure the Cutter Wheel of the Tube Severing Tool you have selected is sharp,
rotates freely and is not damaged in any way.
A damaged or non-rotating Cutter Wheel can affect the performance of the tool.
Be sure Bearing Plugs are clean and not damaged.
Damaged Bearing Plugs affect the performance of the tool and should be changed.

11
Model 550 Tube Severing Tool
92-0116 : Rev. 110203
NOTE:
Select the proper Tri Tool Inc. Drive Unit that best suits the operation needed to be
performed.
Drive Input Location
A non Tri Tool Inc. Drive Unit will void the warranty.
If input is counterclockwise, sever damage will occur during cutting.
CONNECTING AND DISCONNECTING THE DRIVE SYSTEM TO THE MODEL 550
The entire series of Model 550 Tube Cutters are equipped with a quick disconnect
drive-mounting system.
The drive units, which are equipped with a mating quick disconnect, are universal,
they will operate with any Model 550 size that is selected.
! WARNING !
Disconnect the Drive Unit from its power source
when installing or removing it from the Model 550
Tub Cutter otherwise serious injury may occur.
To connect an air or electric drive unit, simply align the slots of the drive system to
the pin located inside the Model 550 coupling, push the drive system inward and
rotate counterclockwise and release.
The drive unit is equipped with a spring to allow it to lock securely.
The drive unit should now be locked in place.
Align the slot.
The rotation direction of the input must be clockwise.

12
TRI TOOL INC.
92-0116 : Rev. 110203
Rotate drive shaft in a clockwise direction to align the slot.
If you miss alignment, simply realign the slot.
Load the Model 550 around the tube to be cut.
Apply a light force to insure that the Model 550 is over the tube.
The Model 550 must be held perpendicular to the surface of the tube to be cut.
Turn on the power for the Model 550 and begin the tube sever.
After the tube has severed, continue rotation, observing the cutting wheels until they
have returned to the home position.
Turn the power off.
Remove the Model 550 from the tube.

13
Model 550 Tube Severing Tool
92-0116 : Rev. 110203
WARNING:
REPAIRS AND REPLACEMENT
Cutter Wheel Replacement
Disconnect the Drive Unit from the Model 550 Tube Cutter prior to any repairs
or replacements.
Rotate the drive shaft manually clockwise to rotate the cutter carriage to the desired
position.
REPLACEMENT OF THE CUTTER WHEEL
Rotate the Cutter Carriage Assy until you see the Cutting Wheel and the cutter
Wheel Securing Pin access hole.
Take a small screwdriver and a pair of needle nose pliers to remove the Wheel
Securing Pin.
Insert a pair of needle nose pliers and take hold of the edge of the Cutter Wheel and
remove it from the Model 550 Tube Cutter.
Take the new Cutter Wheel and install it by reversing the removal procedure.
REPLACEMENT OF THE BEARING PLUGS
Rotate the Cutter Carriage Assy until the Bearing Plug that is to be replaced can be
seen.
Press out the worn Bearing Plug.

14
TRI TOOL INC.
92-0116 : Rev. 110203
Press in the new Bearing Plug.
Refer to the Illustrated Parts Breakdown for the correct Bearing Plug.
Bearing Plug Replacement

15
Model 550 Tube Severing Tool
92-0116 : Rev. 110203
AIR DRIVE ASSEMBLY
REMOVAL OF A SHEARED ROLL PIN FROM THE DRIVE ASSY.
Push the Air Drive Assy into the Model 550 Tube Cutter and rotate it clockwise and
pull it out.
Unscrew the Bayonet Mounting Tube from the Motor Housing by rotating the
Bayonet Mounting Tube counterclockwise.
Take a punch and gently remove the remaining parts of the Roll Pin from the Drive
Shaft and the Motor Shaft.
ASSEMBLY OF THE DRIVE ASSY.
Press Roll Pin partly into one side of hole in Drive Shaft being careful not to protrude
into inside diameter.
Position Drive Shaft onto the Motor Shaft and press Roll Pin into the Shafts.
Recess the Roll Pin slightly below the surface of the outside diameter of the Drive
Shaft using a punch.
Pin Placement
Slide the Bayonet Mounting Tube over the Drive Shaft and screw the Bayonet
Mounting Tube onto the Motor Housing by rotating clockwise.

16
TRI TOOL INC.
92-0116 : Rev. 110203
TROUBLE SHOOTING
Problem: The Tool Bit Chatters
Probable causes:
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 clamping pads are loose on the pipe or tube.
Cutting fluid is required.
The main bearing pre-load is loose.
Problem: There is excessive Tool Bit wear
Probable causes:
The pipe or tube material is too hard or abrasive.
The cutting speed is too fast.
Cutting fluid is required.
A dull Tool Bit is causing surface hardening conditions (Stainless pipe or
tubing).
There is scale or other foreign matter on the pipe or tube, which is dulling the
tool bit at the start of the cut.
The tool bit is incorrect for the material being cut.
Problem: The surface finish is rough
Probable causes:
The tool bit is dull, chipped, etc.
Metal build-up on the cutting edge of the tool bit is creating a false cutting
edge.
Cutting fluid is required.

17
Model 550 Tube Severing Tool
92-0116 : Rev. 110203
Problem: The tool holder is not feeding
Probable causes:
The feed pin is broken or out of position.
The feed sprocket shear pin is broken.
The feed screw is stripped.
The feed nut is stripped.
The slide rails are too tight.
Problem: There is a loss of air power
Probable causes:
The air supply pressure is too low.
The air filter is plugged.
The air line size is insufficient.
The air line is too long.
Problem: There is a loss of hydraulic power
Probable causes:
The hydraulic supply pressure is too low.
The hydraulic filter is plugged.
The hydraulic line size is insufficient.
The hydraulic line is too long.
Problem: The tool bit will not reach the work
Probable causes:
Incorrect tool blocks are installed for the size of the pipe or tube being worked
on.
Incorrect tool bit is installed.
Problem: The hydraulic motor will not start
Probable causes:
The hydraulic power supply is shut off.
The hydraulic motor is damaged and will not run free.

18
TRI TOOL INC.
92-0116 : Rev. 110203
ACCESSORIES
The following accessories are recommended for use with the Model 550 Tube Cut-
ters and are available from TRI TOOL INC.
1. Portable Air Filter (P/N 75-0115)
2. Drive Assembly, Air (P/N 04-0084)
3. Shaft Assembly, 18” Flexible (P/N 14-0036)
4. Motor Assembly, Cordless, 14.4V (P/N 58-0213)
A Filter/Regulator/Lubricator (FRL) is required to protect the warranty on all TRI
TOOL INC air driven tools.

19
Model 550 Tube Severing Tool
92-0116 : Rev. 110203
MODEL 550-03, 04, 05, AND 06
TUBE SEVERING TOOL ASSEMBLY (P/N 01-XXXX)
ILLUSTRATED PARTS BREAKDOWN
1
10
2
3
4
5
7
6
8
9
11
12
13
15
14
17
16
25
10
22
18
24
26
23
21
20
4
9
19

20
TRI TOOL INC.
92-0116 : Rev. 110203
02-2057 CARRIAGE ASSEMBLY, CUTTER 1
1. 19-0353 HOUSING, CARRIAGE, TUBE CUTTER 1
2. 32-0003 PIN, ROLL, 1/16" DIA X 1/2" 1
3. 32-0179 PIN, DOWEL, 3/16" DIA X 5/8" 1
4. 32-0226 PIN, DOWEL, 3/16" DIA X 1" LONG 2
5. 32-0251 PIN, CUTTER 1
6. 38-0065 SPROCKET ASSEMBLY, FEED 1
7. 39-0382 GEAR, CARRIAGE, 12DP, 29T, 1.21PD 1
8. 40-0139 SPRING, TORSION 1
9. 54-0270 PLUG, SHORT, BEARING 2
10. 54-0271 PLUG, LONG, BEARING 2
11. 61-0017 WHEEL, CUTTER, 1/2" 1
12. 62-0066 CAM ASSEMBLY, AUTOFEED 1
13. 63-0081 ARM, CUTTER 1
14. 19-0355 HOUSING, MAIN 1
15. 24-0518 PLATE, RETAINING 1
16. 32-0172 PIN, TRIPPER, 3/32" 2
17. 32-0179 PIN, DOWEL, 3/16" DIA X 5/8" 2
18. 32-0272 PIN, DOWEL, 3/16" X 1 1/4" 1
19. 33-0017 SCREW, CAP, #6-32 X 1" 3
20. 33-0024 SCREW, CAP, #8-32 X 1" 3
21. 33-0927 SCREW, SET, 1/4-20 X 1/2", HDOG 1
22. 39-0289 GEAR, PINION 2
23. 39-0295 GEAR ASSEMBLY, WORM 1
24. 39-0335 GEAR, DRIVE, 24DP, 30T, .96PD 1
25. 43-0274 COVER, MAIN HOUSING 1
26. 45-0112 BUSHING,BRONZE, FL, 3/16" X 5/16" X 1/4" 1
Parts List, Model 550-03, Tube Cutter (P/N 01-1062)
Item Part
No. No. Description Qty