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Scotchman AL100U-01 Manual

Pipe notcher grinder
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MODELS
AL100U-01
AL100U-02
PIPE NOTCHER
GRINDER
VERSION 1 - JULY 2019
SCOTCHMAN INDS. - 180 E. HWY 14 - PO BOX 850 - PHILIP, SD 57567 PHONE: 1-605-859-2542

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  • Page 1 MODELS AL100U-01 AL100U-02 PIPE NOTCHER GRINDER VERSION 1 - JULY 2019 SCOTCHMAN INDS. - 180 E. HWY 14 - PO BOX 850 - PHILIP, SD 57567 PHONE: 1-605-859-2542...
  • Page 2 MODEL - AL100U-01 AL100U-01 (2) Hand Lever Feed Handles PAGE 2...
  • Page 3 MODEL - AL100U-02 AL100U-02 (2) Handwheels & Feed Handle NOTE: The larger hand wheel and it's spindle must be removed to use the handle. PAGE 3...
  • Page 4 Thank You for your purchase of Scotchman products - We appreciate your business!! PAGE 4 SCOTCHMAN INDS. - 180 E US HWY 14 - PO BOX 850 - PHILIP, SD 57567 Call: 1-605-859-2542...

  • Page 5: Table Of Contents

    Drive for the Grinding Belt Securing a Tubing Section Angle Adjustment Depth Stop Length Stop Notching the Tubing Deburring NOTCHING CAPACITIES Angled Notching Capacity PAGE 5 SCOTCHMAN INDS. - 180 E US HWY 14 - PO BOX 850 - PHILIP, SD 57567 Call: 1-605-859-2542...
  • Page 6 AVAILABLE ROLLERS 11.0 AVAILABLE GRINDING BELTS 12.0 AL100U-01 & COMMON PARTS LIST 13.0 AL100U-02 PARTS LIST OPTION OPTIONAL BACK GAUGE PAGE 6 SCOTCHMAN INDS. - 180 E US HWY 14 - PO BOX 850 - PHILIP, SD 57567 Call: 1-605-859-2542...

  • Page 7: Introduction

    1.0 INTRODUCTION Tube & Pipe Notch Grinders Scotchman Tube & Pipe Grinder/Notchers are strong, accurate machines that operate at high speeds. Stainless-steel sections and pipes can be machined problem free, at high speed without grinding burrs or heat discoloration. The grinding rollers can be changed without tools in just seconds, saving time and money! The grinding belt can also be changed easily from one side of the machine.

  • Page 8: Warranty

    2.1 WARRANTY Scotchman Industries, Inc. will, within three (3) years of the date of purchase, replace F.O.B. the factory or refund the purchase price for any goods which are defective in materials or workmanship, provided the buyer returns the warranty registration card within thirty (30) days of the purchase date and, at the seller’s option, returns the defective goods freight and delivery prepaid to the seller, which shall be the...

  • Page 9: Machine Decals

    3.0 MACHINE DECALS Qty Part # Description Item A050.00024 Safety Sticker 8.5 x 8cm A050.00025 Sticker Door 13 x 5cm Belt Size Decal CE Sticker MODEL - AL100U-02 Shown FAILURE TO COMPLY COULD RESULT IN SERIOUS KEEP LID CLAP CLOSED BODILY INJURY WHILE BELT IS IN MOTION...

  • Page 10: Warning Symbols

    3.1 WARNING SYMBOLS BEFORE OPERATING THIS MACHINE PICTOGRAM 1: READ OWNERS MANUAL FIRST!! PICTOGRAM 2: USE OF EYE PROTECTION REQUIRED!! PICTOGRAM 3: USE OF HEARING PROTECTION REQUIRED!! PICTOGRAM 4: KEEP LID CLAP CLOSED WHILE BELT IS IN MOTION!! Strictly comply with all warning labels and decals on the machine. Never remove any of the labels and replace worn or damaged labels promptly!! PAGE 10...

  • Page 11: Installation And Set Up

    4.0 INSTALLATION AND SET UP ► CAUTION: THIS SECTION (4.0 to 5.0) DISCUSSES INSTALLATION AND SET-UP PROCEDURES. PLEASE READ THOROUGHLY BEFORE OPERATING THIS MACHINE. 4.1 PHYSICAL DIMENSIONS ► SEE FIGURE 2 ◄ DESCRIPTION INCHES ITEM Machine Height 45-1/4 114.9 Length 50-3/4 128.9 26-1/8...
  • Page 12 FAILURE TO COMPLY COULD RESULT IN SERIOUS BODILY KEEP LID CLAP CLOSED INJURY WHILE BELT IS IN MOTION Ø30mm R929 < Ø30mm < RX66 GREEN ALMI Motor Type AL 100U-02 Volt Sr.No. l/min 3420 2011 Weight FIGURE 2 PAGE 12...

  • Page 13: Assembling Machine & Moving

    4.2 ASSEMBLING MACHINE & MOVING ASSEMBLING OVERVIEW This grinder/notcher machine is shipped unassembled in a wooden crate. There are basically four parts. See FIGURE 3 on the next page. FOOT PLATE: This is a 1 inch thick by 19-1/2 inch square metal plate that sits on the floor. SUPPORT PILLAR: This is the rectangular "box"...
  • Page 14 FRONT OF AL100U-01 MACHINE MACHINE IS TOP HEAVY!! Use Only LIFTING EYE to move machine Use Extreme Caution when moving BALL HANDLE LIFTING EYE NOTE: (Motor-Side of Machine) Longer Spacer is for Slots LOWER HANDLE AL100U-02 NOTE: The larger hand...

  • Page 15: Machine Identification

    ALL ELECTRICAL CONNECTIONS MUST BE MADE BY A LICENSED ELECTRICIAN. The AL100U-01 and AL100U-02 are available 240V and 440V Three Phase and 240V Single Phase. To insure satisfactory machine performance, the supply voltage should be +/- 10% of the motor voltage rating.

  • Page 16: Wiring Diagrams

    4.5 WIRING DIAGRAMS (Contactors, Overloads & Motors) LINE POWER LINE POWER AL-100U AL-100U 230V Single Phase 230V Single Phase PART # DESCRIPTION 011436 CONTACTOR WITH COIL 230V 1PH. 011435 OVERLOAD 230V E030.00001 MOTOR 230V 1PHASE 60HZ 3KW LC1D18 LC1D18 SCHNEIDER SCHNEIDER START START...
  • Page 17 AL-100U Three Phase NOTE: Swap (2) Incoming Power Wires to change Rotation 230V THREE PHASE PART # DESCRIPTION LINE POWER 011432 CONTACTOR WITH COIL 230V 011433 OVERLOAD 230V E030.00002 MOTOR 230/460V 3PHASE 60HZ 3KW 460V THREE PHASE PART # DESCRIPTION 011420 CONTACTOR WITH COIL 460V 011421...

  • Page 18: Machine Start-Up

    5.0 MACHINE START-UP This machine is equipped with (3) switches located on the right side of the Support Pillar. The Green is the START Button and next to it is the Red STOP Button. Below them is the larger EMERGENCY STOP Button. REFER TO FIGURE 6 BELOW To start the machine the EMERGENCY STOP Button must be pulled out.

  • Page 19: Machine Controls & Adjustments

    5.1 MACHINE CONTROLS & ADJUSTMENTS MODEL - AL100U-01 REFER TO FIGURE 7 1. Allen key, 8mm, with handle; for securing rotatable tubing clamp, for securing standard stopper, and for adjustment of grinding belt. 2. Allen bolt (may be a knob) for opening and closing side cover. Use key with handle (1).
  • Page 20 MODEL - AL100U-01 FIGURE 7 PAGE 20...
  • Page 21 MODEL - AL100U-02 REFER TO FIGURE 8 1. Allen key, 8mm, with handle; for securing rotatable tubing clamp, for securing standard stopper, and for adjustment of grinding belt. 2. Allen bolt (may be a knob) for opening and closing side cover. Use key with handle (1). 3.
  • Page 22 MODEL - AL100U-02 FIGURE 8 PAGE 22...

  • Page 23: Machine Operations

    6.0 MACHINE OPERATION CAUTION: MAKE SURE ALL COVERS ARE CLOSED 6.1 STARTING AND STOPPING BELT The switches are located on the right side of the Support Pillar. To START the machine, push the GREEN button. To STOP the machine, push the RED button. REFER TO SECT.

  • Page 24: Depth Stop

    6.5 DEPTH STOP Pipe Notcher is provided with a Depth Stop. There is a slot under the front of the machine and the Depth Stop is located there. The Depth Stop works to stop the movement of the support toward the grinding roller. This Stop is secured with an Allen bolt and the 8mm Allen key can be used for adjustment.

  • Page 25: Length Stop

    Again, a Length Stop is NOT included with the machine and must be fabricated by the user. NOTE: SCOTCHMAN INDS. HAS A OPTIONAL BACK GAUGE AVAILABLE FOR THIS MACHINE SEE PAGE 49 - P/N 04.00931...

  • Page 26: Notching The Tubing

    6.7 NOTCHING THE TUBING MODEL AL100U-01 SEE FIGURE 7 After adjusting to the correct angle (7) and the Stops (if desired) have been set up, clamp a piece of tubing into the tubing clamp using the handle (6). The slide with ball handle (4) moves tubing clamp side to side. It must be positioned so the piece of tubing that is to be notched is moved toward the center of the grinding roller.
  • Page 27 DEBURRING OPEN TABLE COVER FIGURE 11 PAGE 27...

  • Page 28: Notching Capacities

    7.0 NOTCHING CAPACITIES SEE FIGURE 12 The capacities of the AL100U machines are 1/2" to 3" O.D. (12.7mm to 76mm). Machine is supplied with (2) belts and (2) pipe mandrels (1-1/4" & 1-1/2"). There are 13 mandrels available to ensure correct gap-free fits. The grinding rollers (mandrels) and belt can be changed tool-free in seconds.

  • Page 29: Angled Notching Capacity

    7.1 ANGLED NOTCHING CAPACITY SEE FIGURE 13 Below shows the capacities for the AL100U Grinder/Notchers when grinding tubes at an angle. The tube size must be reduced as the angle is increased. ANGLE RANGE IS 90° TO 30° 90° 45° 30°...

  • Page 30: Changing Rollers And Belt

    8.0 CHANGING ROLLERS AND BELT SEE FIGURE 14 CAUTION: DISCONNECT POWER FROM MACHINE BEFORE PROCEEDING To gain access to the grinding belt, the side cover and the top cover must be opened. The top cover is shown in Figure 11 and below along with the side cover. Use the Allen Key to turn the bolt indicated below to release the side cover.

  • Page 31: Belt Tension

    8.1 BELT TENSION SEE FIGURE 15 After the power has been disconnected and the covers are opened, grinding belt tension is adjusted by using the handle located on the motor side of the machine. It's location is shown below. Spring tension is used to keep the belt tight.

  • Page 32: Changing The Roller

    8.2 CHANGING THE ROLLER SEE FIGURE 16 After the grinding belt is removed, the roller can be changed. CAUTION: WEAR SAFETY GLOVES!! WITH INTENSIVE USE THE ROLLER CAN BECOME EXTREMELY HOT. Below are a couple of images that show how the roller mounts to the machine. Each roller has (2) bearings - One on each end.
  • Page 33 SEE FIGURE 17 Below is an exploded view of the roller and related parts. To remove roller, grasp roller and pull it out of the holder. Before the new grinding roller is installed, the recesses of the support for the grinding roller must be cleaned thoroughly!! To install roller, align the roller with the holder and push it in.

  • Page 34: Setting Belt Tension

    8.3 SETTING BELT TENSION SEE FIGURE 18 After changing the roller the belt can be installed. Slide the grinding belt over the motor pulley and the grinding roller. Make sure it is installed so it rotates in the right direction. NOTE: If a roller smaller than 30mm (1-3/16") diameter is being used, use a grinding belt that has been "broken in"...

  • Page 35: Setting The Belt Tracking

    8.4 SETTING BELT TRACKING After changing the roller and belt and tensioning it properly, The next thing is to check the tracking of the belt. You want the belt to run so it's as centered on the rollers as it can be. To begin, make sure the machine is still Disconnected From Power.

  • Page 36: Adjustment Of Grinding Roller

    8.5 ADJUSTMENT OF GRINDING ROLLER SEE FIGURE 20 The center of the grinding roller must be at the same height as the center of the tubing. This is set at the factory and generally doesn't need to be adjusted. If the center of the tubing isn't centered on the grinding roller it can be adjusted with the (2) bolts that are aligned vertically on the motor side of the machine - See Below.

  • Page 37: Available Options

    9.0 AVAILABLE OPTIONS This section will show some optional equipment that is available for the AL100U grinders. 9.1 ROLLER SUPPORT KIT SEE FIGURE 21 Below is an image of P/N 04.00318 Roller Support Kit. When grinding diameters are almost always smaller than 60mm (2.36") and machine will be subject to heavy use, it is recommended that this kit is used.

  • Page 38: Roller Support Kit Location

    9.2 ROLLER SUPPORT KIT LOCATION SEE FIGURE 22 Below are (2) views that show where the "Support Axis" is located via the circles. It is held on by (1) bolt on the other side of the machine. The side cover must opened to gain access to it. FIGURE 22 PAGE 38...

  • Page 39: Roller Support Installation

    ENLARGED ISOMETRIC VIEW GREEN GREEN ROLLER HOLDER ALMI ALMI Motor Motor Type Type AL 100U-02 AL 100U-02 Volt Volt Sr.No. Sr.No. l/min l/min 3420 3420 2011 2011 Weight Weight ATTACHES WITH THE (2) TABS GREEN GREEN EXTRA ROLLERS ARE ALMI ALMI Motor Motor...
  • Page 40 Drill Holes and Countersink Them - as Shown Below. All dimensions are in inches. DETAIL Countersink Holes .394 4.530 Drill .590 Ø.219 .125 .590 (7/32) 2.265 The bolt heads should be at least flush 4 Plcs or slightly below the surface of the metal deburring table.

  • Page 41: Roller Support Kit Start Up

    9.4 ROLLER SUPPORT KIT START UP Once the Roller Support Kit is bolted on securely, reinstall the grinding belt. See Section 8.0 for belt installation. Once belt is tensioned and tracking properly, let the machine run for a minute to make sure everything stays and is working properly.
  • Page 42 ROLLER HOLDER INSTALLATION ENLARGED ISOMETRIC VIEW FAILURE TO COMPLY COULD RESULT IN SERIOUS KEEP LID CLAP CLOSED BODILY WHILE BELT IS IN MOTION INJURY Ø30mm GREEN ALMI Motor Type AL 100U-02 Volt Sr.No. l/min 3420 2011 Weight ROLLER HOLDER COLUMN FAILURE TO COMPLY COULD RESULT IN SERIOUS...

  • Page 43: Available Rollers

    10.0 AVAILABLE ROLLERS Below is a list of sizes and part numbers of the standard rollers we have for PIPE and TUBE. Intermediate sizes are also available. PIPE PART NUMBER TUBE PART NUMBER 1/2" A042.21.3 1.00" A042.26 3/4" A042.26.9 1.25" A042.32 1"...

  • Page 44: Al100U-01 & Common Parts List

    Spindle Assy. 38210.M12 Plain Washer M-12 01210.M12x30 Hex Stud Bolt M-12 x 30 8.8 M090.00006 Spring d=3, 2 DM=20 LO=105 PAGE 44 SCOTCHMAN INDS. - 180 E US HWY 14 - PO BOX 850 - PHILIP, SD 57567 Call: 1-605-859-2542...
  • Page 45 Hex Nut M-10 38130.M16 Plain Washer M-16 07160.M6x10 Hex Socket Head M-6 x 10 8.8 M050.00001 Ball Plunger 210012 M10 Jam Nut PAGE 45 SCOTCHMAN INDS. - 180 E US HWY 14 - PO BOX 850 - PHILIP, SD 57567 Call: 1-605-859-2542...
  • Page 46 201212 214012 201212 M10x35 M4x12 - May or May Not have this part. 221002 201212 M10x35 68 69 FIGURE 25 PAGE 46 SCOTCHMAN INDS. - 180 E US HWY 14 - PO BOX 850 - PHILIP, SD 57567 Call: 1-605-859-2542...

  • Page 47: Al100U-02 Parts List

    Spacer 04.00239 Lever Assy. G140.00002 Guide Bush DIN 179A-8x16 38210.M8 Plain Washer M-8 d2=3xd1 G140.00001 Guide Bush DIN 179A-8x10 ALMI PAGE 47 SCOTCHMAN INDS. - 180 E US HWY 14 - PO BOX 850 - PHILIP, SD 57567 Call: 1-605-859-2542...
  • Page 48 KEEP LID CLAP CLOSED BODILY WHILE BELT IS IN MOTION INJURY ALMI 208012 221002 M4x12 221002 M4x12 221002M4x12 FIGURE 26 PAGE 48 SCOTCHMAN INDS. - 180 E US HWY 14 - PO BOX 850 - PHILIP, SD 57567 Call: 1-605-859-2542...

  • Page 49: Optional Back Gauge

    Contact your Dealer or call us at 1-605-859-2542. TUBE COMPLETE BACK GAUGE HOLD TUBE STOP AGAINST STOP MOUNTS TO TUBE CLAMP PAGE 49 SCOTCHMAN INDS. - 180 E US HWY 14 - PO BOX 850 - PHILIP, SD 57567 Call: 1-605-859-2542...

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Al100u-02

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