48382r Manual
48382r Manual
48382r Manual
OPERATOR’S
MANUAL
WARNING!
Read this Operator’s Manual
carefully before using this
tool. Failure to understand
and follow the contents of
this manual may result in
electrical shock, fire and/or
serious personal injury.
Table of Contents
General Safety Information
Work Area Safety ........................................................................................................................................................2
Electrical Safety ..........................................................................................................................................................2
Personal Safety...........................................................................................................................................................2
Tool Use and Care ......................................................................................................................................................3
Service ........................................................................................................................................................................3
Specific Safety Information
Roll Groover Safety.....................................................................................................................................................3
Description, Specifications, Standard Equipment
Description ..................................................................................................................................................................4
Specifications ..............................................................................................................................................................4
Standard Equipment....................................................................................................................................................4
918 Roll Groover Models ..........................................................................................................................................4
Roll Groover Assembly Instructions
Installing 918-1 Roll Groover on 300 Power Drive ......................................................................................................5
Installing 918-2 Roll Groover on 1822 Threading Machine.........................................................................................5
Installing 918-4 Roll Groover on 1224 Threading Machine.........................................................................................6
Installing 918-5 Heavy Duty Roll Groover on 535 Threading Machine .......................................................................7
Machine Inspection .......................................................................................................................................................8
Machine and Work Area Set-Up ...................................................................................................................................8
Operating the 918 Roll Groover
Pipe Preparation .........................................................................................................................................................9
Pipe/Tubing Length .....................................................................................................................................................9
Pipe Set-up .................................................................................................................................................................9
Adjusting Roll Groove Depth.....................................................................................................................................10
Forming the Roll Groove ...........................................................................................................................................11
Roll Grooving Tips with 918 ......................................................................................................................................11
Removing and Installing Groove Roll and Drive Shaft
Removing and Installing Groove Roll Sets with Solid Drive Shafts (2″ – 6″, 8″ – 12″) .............................................12
Removing and Installing Groove Roll Sets with Solid Drive Shafts (1,″, 11/4″ – 11/2″, 2″ – 6″ Copper) ......................13
Changing from Solid Drive Shaft Roll Set to Two-Piece Drive Shaft ........................................................................14
Installing & Operating Pipe Stabilizer/Nipple Bracket
Installation .................................................................................................................................................................14
Stabilizer Operation...................................................................................................................................................14
Accessories .................................................................................................................................................................15
Table I Standard Roll Groove Specifications............................................................................................................16
Table II Pipe Maximum and Minimum Wall Thickness.............................................................................................16
Table III Troubleshooting............................................................................................................................................17
Table IV Copper Roll Groove Specifications ............................................................................................................18
Maintenance Instructions
Hydraulic Fluid Level.................................................................................................................................................19
Lubrication.................................................................................................................................................................19
Machine Storage..........................................................................................................................................................19
Service and Repair ......................................................................................................................................................19
Lifetime Warranty .........................................................................................................................................Back Cover
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918
Roll Groover
Work Area Safety • Use only three-wire extension cords which have
three-prong grounding plugs and three-pole re-
• Keep your work area clean and well lit. Cluttered
ceptacles which accept the machine plug. Use of
benches and dark areas invite accidents.
other extension cords will not ground the tool and in-
• Do not operate electric tools in explosive atmo- crease the risk of electrical shock.
spheres, such as in the presence of flammable
• Use proper extension cords. (See chart.) Insufficient
liquids, gases, or dust. Electric motors create sparks
conductor size will cause excessive voltage drop, loss
which may ignite the dust or fumes.
of power.
• Keep bystanders, children, and visitors away while
Minimum Wire Gauge for Extension Cord
operating a tool. Distractions can cause you to lose
control. Nameplate
Amps Total Length (in feet)
• Keep floors dry and free of slippery materials such 0-25 26-50 51-100
as oil. Slippery floors invite accidents. 0-6 18 AWG 16 AWG 16 AWG
6-10 18 AWG 16 AWG 14 AWG
Electrical Safety
10-12 16 AWG 16 AWG 14 AWG
• Grounded tools must be plugged into an outlet, 12-16 14 AWG 12 AWG NOT RECOMMENDED
properly installed and grounded in accordance
with all codes and ordinances. Never remove the Personal Safety
grounding prong or modify the plug in any way. Do
• Stay alert, watch what you are doing and use com-
not use any adapter plugs. Check with a qualified
mon sense when operating a tool. Do not use tools
electrician if you are in doubt as to whether the out-
while tired or under the influence of drugs, alcohol,
let is properly grounded. If the tools should electrically
or medications. A moment of inattention while oper-
malfunction or break down, grounding provides a low
ating tools may result in serious personal injury.
resistance path to carry electricity away from the user.
• Dress properly. Do not wear loose clothing or jew-
Cover of
grounded
elry. Contain long hair. Keep your hair and clothing
outlet box away from moving parts. Loose clothes, jewelry, or
long hair can be caught in moving parts.
• Avoid accidental starting. Be sure switch is OFF be-
fore plugging in. Plugging tools in that have the
Grounding prong Grounding prong switch ON invites accidents.
• Remove wrenches or adjusting keys before turning
• Avoid body contact with grounded surfaces. There
the tool ON. A wrench or a key that is left attached to
is an increased risk of electrical shock if your body is
a rotating part of the tool may result in personal injury.
grounded.
• Do not over-reach. Keep proper footing and bal-
• Don’t expose electrical tools to rain or wet condi-
ance at all times. Proper footing and balance enables
tions. Water entering an electrical tool will increase the
better control of the tool in unexpected situations.
risk of electrical shock.
• Use safety equipment. Always wear eye protec-
• Do not abuse cord. Never use the cord to pull the
tion. Dust mask, non-skid safety shoes, hard hat,
plug from an outlet. Keep cord away from heat, oil,
or hearing protection must be used for appropriate
sharp edges or moving parts. Replace damaged
conditions.
cords immediately. Damaged cords increase the risk
of electrical shock.
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918 Roll Groover
Tool Use and Care around your arm or other body parts with enough force to
crush or break bones.
• Do not use tool if switch does not turn it ON or
OFF. Any tool that cannot be controlled with the switch Roll Groover Safety
is dangerous and must be repaired. • Roll Groover is made to groove pipe and tubing.
• Disconnect plug from the power source before Follow instructions in Operator’s Manual on ma-
making any adjustments, changing accessories, or chine uses. Other uses may increase the risk of injury.
storing the tool. Such preventive safety measures re- • Keep hands away from grooving rolls. Do not wear
duce risk of starting the tool accidentally. loose fitting gloves when operating unit. Fingers
• Store idle tools out of the reach of children and could get caught between grooving and drive rolls.
other untrained persons. Tools are dangerous in • Keep guards in place. Do not operate the groover
the hands of untrained users. with guard removed. Exposure to grooving rolls may
• Check for misalignment or binding of moving parts, result in entanglement and serious injury.
breakage of parts, and any other condition that • Set-up Groover on a flat, level surface. Be sure
may affect the tool’s operation. If damaged, have the machine, stand, and groover are stable. Will pre-
the tool serviced before using. Many accidents are vent tipping of the unit.
caused by poorly maintained tools.
• Do not wear loose clothing. Keep sleeves and
• Use only accessories that are recommended by the jackets buttoned. Do not reach across the ma-
manufacturer for your model. Accessories that may chine or pipe. Clothing can be caught by the pipe
be suitable for one tool may become hazardous when resulting in entanglement and serious injury.
used on another tool.
• Do not use this Roll Groover with a Power Drive or
• Keep handles dry and clean; free from oil and Threading Machine that does not have a foot
grease. This allows for better control of the tool. switch. Foot switch is a safety device to prevent seri-
Service ous injury.
• Tool service must be performed only by qualified • When grooving pipe, keep hands away from the
repair personnel. Service or maintenance performed end of the pipe. Do not reach inside pipe end. Will
by unqualified repair personnel could result in injury. prevent being cut on sharp edges and burrs.
• When servicing a tool, use only identical replace- • Be sure groover is properly secured to the power
ment parts. Follow instructions in the Maintenance drive or threading machine. Carefully follow the set-
Section of this manual. Use of unauthorized parts or up procedures. Will prevent tipping of the pipe or
failure to follow maintenance instructions may create a grooving unit.
risk of electrical shock or injury. • Properly support pipe with pipe stands. Use two
pipe stands to groove pipe over 36″ long. Prevents
tipping of the unit.
Specific Safety Information
• Use only power drives and threading machines
WARNING that operate under 58 RPM. Higher speed machines
Read this operator’s manual carefully before using increase the risk of injury.
the Roll Groover. Failure to understand and follow
the contents of this manual may result in electrical • Lock foot switch when not in use. (See Figure 1.)
shock, fire and/or serious personal injury. Avoids accidental starting.
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918 Roll Groover
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918 Roll Groover
Drive Bar
Mounting
Base
Hydraulic
Pump /2″ x 11/4″
1
Bolts (2)
1
/4″ x 3/4″
Bolts (4)
Figure 2 – Installing on 300 Power Drive
Figure 3 – 918 Heavy Duty Roll Groover on 1822 Mounting
1. Remove carriage or other attachments from the 300 Base
Power Drive.
2. Fully open front chuck of power drive. Installing on 1822 Threading Machine with 1406
Stand
3. Slide the base assembly onto the support arms of the
1. Position carriage towards front chuck and swing tools
300 Power Drive. (Figure 2)
to the rear position. Remove carriage stop pin at the
4. Align the notched flats of the drive shaft with the end of rail.
jaws on the 300 Power Drive chuck.
CAUTION Position reamer inside the die head to
5. Close and tighten the front chuck. prevent accidental contact.
2. Front chuck must be open. Position 918-2 so that the
Installing the 918-2 Roll Groover on the base slides onto the support rails and drive bar feeds
1822 Threading Machine into open chuck.
Sub-Assembly
3. Place carriage stop pin in support rail hole.
1. Position 918 Roll Groover on the mounting base as
shown in Figure 3. 4. Install support legs into socket holes on the base.
(Figure 4) and tighten locking bolts.
2. Install and tighten the (2) 1/2″ x 11/4″ hex bolts which
connect 918 to mounting base. WARNING Drive bar must be centered in front chuck
jaws. All bolts must be tight and the drive bar must be
3. Position hydraulic pump and securely bolt in place securely held in chuck when closed.
with (4) 1/4″ x 3/4″ hex bolts.
Installing on 1822 Threading Machine with 100,
4. Attach drive bar adapter to roll groover by tightening 150, or 200 Stands
two (2) set screws.
1. Position carriage towards front chuck and swing tools
to the rear position. Remove carriage stop pin at the
end of the rail.
CAUTION Position reamer inside the die head to
prevent accidental contact.
2. Front chuck must be open. Position 918-2 so that the
base slides onto the support rails and drive bar feeds
into open chuck.
3. Replace carriage stop pin in support rail hole.
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918 Roll Groover
918-2
Drive Bar Sub-assembly
Front Chuck
Carriage
Housing
Plate
/4″ x 3/4″ bolts (4)
1
for mounting 1
/2″ x 11/4″ bolts (2)
hydraulic pump for mounting base
Support
Leg Installing on 1224 Threading Machine
1. Position carriage towards front chuck and swing car-
riage tools to rear position.
1406
Stand CAUTION Position reamer inside the die head to
prevent accidental contact.
2. Place 918-4 on the far side carriage rail and lower
onto near side rail. (Figure 6)
3. Position base so that the drive bar feeds into the
Support open chuck.
Foot Switch
Leg
4. Tighten chuck jaws securely into drive bar.
Figure 4 – 918 Roll Groover Mounted on 1822 with 1406
Stand WARNING Drive bar must be centered in front chuck
jaws. All bolts must be tight and the drive bar must be se-
Installing the 918-4 Roll Groover on the curely held in chuck.
1224 Threading Machine
Sub-Assembly
1. Align housing plate in recessed area of 1224.
2. Align 918 on the 1224 mounting base. (Figure 5)
3. Install and tighten the (2) 1/2″ x 11/4″ hex bolts which
connect the 918 to mounting base.
4. Attach pump bracket with the two (2) 3/8″ x 1/2″ hex
bolts.
5. Position hydraulic pump and securely bolt in place
with (4) 1/4″ x 3/4″ hex bolts.
6. Attach drive bar adapter to roll groover by tightening
(2) set screws.
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918 Roll Groover
Drive Bar
Carriage
918-5
Front Chuck Sub-assembly
Drive Bar
Foot Switch
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918 Roll Groover
Machine Inspection 11. Inspect the groove rolls to insure they are not dam-
aged or worn. Worn groover rolls can lead to pipe
WARNING slippage and poor quality grooves.
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918 Roll Groover
WARNING To avoid electrical shock and electrical fires, Operating the 918 Roll Groover
never use an extension cord that is damaged or does not
meet the following requirements. WARNING
• The cord has a three-prong plug similar to shown in
Electrical Safety section.
• The cord is rated as “W” or “W-A” if being used out-
doors.
• The cord has sufficient wire thickness (14 AWG
below 25′/12AWG 25′ - 50′). If the wire thickness is
too small, the cord may overheat, melting the cord’s Do not wear loose clothing when operating a Roll
insulation or causing nearby objects to ignite. Groover. Keep sleeves and jackets buttoned. Do
WARNING To reduce risk of electrical shock, keep all
not reach across the machine or pipe.
electrical connections dry and off he ground. Do not touch Do not use this Roll Groover with a Power Drive or
plug with wet hands. Threading Machine that has a broken or missing foot
switch. Always wear eye protection to protect eyes
8. Check the unit to insure it is operating properly. from dirt and other foreign objects.
• Flip the directional switch to FOR (Forward). Press Keep hands away from grooving rolls. Do not wear
and release the foot switch. Check that the groove loose fitting gloves when operating groover. Use
roll rotates in a counterclockwise direction as you pipe stands to support pipe.
are facing the groover. Have the power drive or
threading machine serviced if it rotates in the wrong Pipe Preparation
direction or if the foot switch does not control its
1. Pipe ends must be cut square. Do not use cutting
stopping or starting.
torch.
• Depress and hold the foot switch. Inspect the mov-
ing parts for misalignment, binding, odd noises or any 2. Pipe out-of-roundness must not exceed the
other unusual conditions that may affect the safe and total O.D. tolerance listed in groove specifications,
normal operation of the machine. If such conditions Table 1.
are present, have the roll groover drive serviced. NOTE! Determine out-of-roundness by measuring max-
• Check the speed of the machine to insure it rotates imum and minimum O.D. at 90 degrees apart.
under 58 RPM. Higher speed machine increases 3. All internal or external weld beads, flash or seams
the risk of injury. must be ground flush at least 2″ back from pipe end.
• Flip the directional switch to REV (Reverse) (Except NOTE! Do not cut flats on gasket seat area.
1822-I and 535 Automatic machines). Press and
release the foot switch. Check that the drive roll ro- Pipe/Tubing Length
tates in a clockwise direction as you are facing the Chart A lists the minimum length of pipe or tubing to be
roll groover. grooved and the maximum length to be grooved with (1)
• Release the foot switch and flip the directional pipe stand.
switch to OFF. Groovable Pipe Lengths – Inches
9. Check the groove and drive rolls to insure they are the Nom. Min. Max. Nom. Min. Max.
correct size. Size Length Length Size Length Length
CAUTION Use of roll sets on both carbon and stainless 1 8 36 4 8 36
steel pipe can lead to contamination of the stainless steel 11/4 8 36 41/2 8 32
material. This contamination could cause corrosion and pre- 11/2 8 36 5 8 32
mature pipe failure. To prevent ferrous contamination, use 2 8 36 6 O.D. 10 30
roll sets dedicated for stainless steel grooving. 21/2 8 36 6 10 28
3 8 36 8 10 24
31/2 8 36 10 10 24
12 10 24
Chart A – Minimum/Maximum Pipe Length
Pipe Set-Up
1. Pipe or tubing longer than the specified maximum
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918 Roll Groover
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918 Roll Groover
NOTE! Upper roll should only touch the pipe surface. placing the pump release lever in the RETURN posi-
Care must be taken not to penetrate pipe surface tion (toward operator).
with upper roll by applying excessive pressure.
5. Check groove diameter before proceeding with addi-
2. Turn down the indexed depth adjustment knob (clock- tional grooves.
wise) until it stops against the top of the machine.
3. Back the depth adjustment knob off one turn. (Figure
14)
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918 Roll Groover
• Tighten groove roll set screw into detent on upper 4. Installing groove roll:
roll shaft. • With upper housing fully raised and drive shaft in
6. Using a grease gun, grease the drive shaft through place, insert groove roll into upper roll assembly
the fitting on the side of the Groover. and fully insert upper roll shaft through bearings
and groove roll.
Changing from Solid Drive Shaft Roll
• Tighten groove roll set screw into detent on upper
Set to Two-Piece Drive Shaft
roll shaft.
1. Recommended removing 918 Roll Groover from
5. Using a grease gun, grease the drive shaft through
power drive or machine, and placing it on workbench
the fitting on the side of the Groover.
in an upright position. If a suitable workplace is not
available, roll sets can be changed with the Roll
Groover mounted on the machine. Installing and Operating Pipe
WARNING Use care that the Groover does not slide Stabilizer/Nipple Bracket
off the support arms on the 300 Power Drive.
NOTE! The pipe stabilizer/nipple bracket works on 300
2. Removing groove roll: Power Drive Mounting only. Use for grooving
• Fully raise the upper roll housing by moving the nipples and pipe 21/2″ through 12″ nominal pipe
sizes.
pump release lever to the return position, away
from the operator. WARNING Make sure machine is unplugged from
power source before installing pipe stabilizer/nipple.
• Loosen groove roll set screw (Figure 17). Grasp
groove roll and remove upper roll shaft and groove Installation
roll from Groover (Figure 18).
1. Align mounting bracket onto base of roll groover so
3. Changing solid drive shaft rollset to two-piece drive that the bolt holes in the mounting bracket line up with
shaft: bolt holes in the base. (Figure 22)
• Manually rotate the drive shaft while applying 2. Install and tighten two bolts through the bottom of the
pressure to the spindle lock pin until the lock pin roll groover base.
engages the spindle lock hole in the drive shaft.
• With the spindle lock engaged, use the box wrench
to remove the drive shaft bearing retaining nut (Fi-
gure 19).
• Release pressure on the spindle lock pin, allowing
to retract.
• Remove the drive shaft (Figure 20).
• Remove the three 1/4″ bolts that hold the retaining
plate in place, remove retaining plate, remove bear-
ing (Figure 21).
• Insert drive shaft/bearing assembly (for two-piece
driveshaft) into Groover. Replace retaining plate
and bolt, tighten bolts.
• Install new drive roll, insert and hand tighten draw
bolt.
• Manually rotate the drive shaft/drive roll assembly
Figure 22 – Line Up Bolt Holes in the Mounting Bracket
while applying pressure to the spindle lock pin until with Bolt Holes in the Base
the lock pin engages the spindle lock hole in the
drive shaft.
Stabilizer Operation
• With the spindle lock engaged, use a wrench to
NOTE! Once the stabilizer is adjusted for a selected
tighten the draw bolt.
pipe diameter, it does not have to be readjusted.
• Release pressure on the spindle lock pin, allowing
1. Place pipe on to drive roll on Model 918 Roll Groover.
to retract.
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918 Roll Groover
Rolled groove not per- Pipe length not straight. Use straight pipe.
pendicular to pipe axis. Pipe end not square with pipe axis. Cut pipe end square.
Pipe does not track Pipe not level. Adjust stand to level pipe.
while grooving. Groover not level. Level groover.
Pipe axis not offset 1/2 degree from drive roll axis. Offset pipe 1/2 degree (See Figs. 12 &13).
/2 degree offset not sufficient.
1
Offset pipe slightly more.
Not applying pressure to pipe. Apply pressure to pipe (See Figs. 15 &16).
Not using stabilizer. Use stabilizer.
Excessive weld seam. Grind flush 2″ from end of pipe.
Pipe end not square. Cut pipe end square.
Pipe flared at groove Pipe not level. Adjust stand to level pipe.
end. Operator is advancing groove roll too fast. Slow down pumping action. (Refer to proper oper-
ating instructions.)
Pipe is too hard. Replace pipe.
Stabilizer too tight. Adjust stabilizer.
Pipe drifts back and Pipe length not straight. Use straight pipe.
forth on driving roll axis Pipe end not square with pipe axis. Cut pipe end square.
while grooving.
Pipe rocks from side to Pipe stand too close to end of pipe. Move pipe stand in 1/4 distance from end of pipe.
side.
Pipe end flattened or damaged. Cut off damaged pipe end.
Hard spots in pipe material or weld seams harder Use high quality pipe of uniform hardness.
than pipe.
Grooving roll feed rate too slow. Feed grooving roll into pipe faster.
Power drive speed exceeds 57 rpm. Reduce speed to 57 rpm.
Pipe support stand rollers not in correct location for Position pipe stand rollers for pipe size being used.
pipe size.
Groover does not roll Pipe wall maximum thickness exceeded. Check pipe capacity chart.
groove in pipe. Wrong rolls. Install correct rolls.
Pipe material too hard. Replace pipe.
Adjustment nut not set. Set depth.
Groove does not meet Maximum pipe diameter tolerance exceeded. Use correct diameter pipe.
specification.
Mismatched grooving and driving rolls. Use correct set of rolls.
Grooving 8″ Sch. 40 steel pipe harder than 150 Do not groove hard pipe.
BHN.
Pipe slips on driving roll. Driving roll knurling plugged with metal or worn flat. Clean or replace driving roll.
Grooving roll feed rate too slow. Feed grooving roll into pipe faster.
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918 Roll Groover
Pump not delivering oil, Pump release valve open. Close release valve.
cylinder does not Low oil in reservoir. Check oil level per instructions.
advance.
Dirt in pump body. Have serviced by qualified technician.
Seats worn or not seating. Have serviced by qualified technician.
Too much oil in reservoir. Check oil level per instructions.
Pump handle operates Air trapped in system. Position ram lower than pump by tipping the
with “spongy” action. machine on its side opposite the operator. Extend
and return the cylinder piston several times to
permit air to return to the pump reservoir.
Too much oil in reservoir. Check oil level per instructions.
Cylinder extends only Pump reservoir is low on oil. Fill and bleed system.
partially. Depth adjustment set incorrectly. Follow depth adjustment instructions.
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918 Roll Groover
Lubrication
Drive shaft and Groove roll shaft bearings.
Lubricate with multi-purpose grease through fittings lo-
cated on groove roll shaft and lower roll housing once a
month, and after every roll change.
Machine Storage
WARNING Motor-driven equipment must be kept in-
doors or well covered in rainy weather. Store the machine
in a locked area that is out of reach of children and people
unfamiliar with roll groover equipment. This machine can
cause serious injury in the hands of untrained users.
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