610II

ID MOUNTED
FLANGE FACING
使 用 MACHINE
说 明 书

INSTRUCTION

◎ Read the instruction thoroughly before operation

◎ Keep it well for future referring

 CONTENTS

SECTION 1 SAFETY INSTRUCTIONS ................................................................................1

SECTION 2 INSTRUCTION ...............................................................................................5
2.1 APPLICATION ..........................................................................................................5
2.2 FEATURE ..................................................................................................................5
SECTION 3 MAIN COMPONENT .....................................................................................6
SECTION 4 DETAIL PARAMETER .................................................................................7
4.1TECHNICAL PARAMETER .....................................................................................7
4.2 TOOLING BIT CHART ............................................................................................8
SECTION 5 INSTALL INSTRUCTION .................................................................................9
5.1 CONSTRUCTION .....................................................................................................9
5.2 CLAMPING SYSTEM ............................................................................................10
5.2.1 CONSTRUCTION ........................................................................................10
5.2.2 INSTALL/CHANGE PROCEDURE ............................................................12
5.3 HOISTING AND INSTALL THE MACHINE’S MAIN BODY ............................13
5.3.1 HOISTING ....................................................................................................13
5.3.2 INSTALL AND ADJUSTMENT ..................................................................14
5.4 CHOOSING TOOLING BIT ...................................................................................14
5.5 INSTALL/DISASSEMBLY TOOLING BIT ...........................................................15
5.5.1 INSTALL TOOLING BIT.............................................................................15
5.5.2 DISASSEMBLY TOOLING BIT..................................................................16
5.6 TOOLING POST CONSTRUCTION......................................................................17
5.6.1 INSTRUCTION ............................................................................................17
5.6.2 AXIAL FEEDING WHEEL ..........................................................................18
5.6.3 RADIAL FEEDING WHEEL .......................................................................18
5.6.4 WORKING RANGE AND ADJUST ANGLE ..........................................19
5.6.5 ADJUST FEEDING ...................................................................................20
5.6.6 WEIGHT BANLANCE ................................................................................21
5.7 TRANSMISSION SYSTEM....................................................................................22
SECTION 6 WORKING PROCEDURE ...............................................................................23
6.1CONFIRMATION AND INDICATION BEFORE WORKING ..............................23

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 6.2 CLAMPING .............................................................................................................23
6.3 COOLING OIL ........................................................................................................23
6.4 FEEDING .................................................................................................................24
6.5 COMPLETION ........................................................................................................24
SECTION 7 TROUBLE SHOOTING ...................................................................................25
SECTION 8 MAINTAINT AND REPAIR ............................................................................26
SECTION 9 ORDERING INFORMATION AND FEEDBACK ......... 错误！未定义书签。

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 SECTION 1 SAFETY INSTRUCTIONS

We take great pride in manufacturing safe, quality products with user safety
apriority. We recommend that all users comply with the following safety rules and
instructions when operating our equipment. For your safety and the safety of
others, read and understand these safety recommendations and operating
instructions before operating.

Warn! To avoid unforeseeable environment or man causes, before operating the

machines, the users should read the instruction carefully, understand the operating
procedures and use range. Keep the manual clean and well for reference at any
time.
Regarding the safety instructions, sorted into two grades: Danger and Caution.

Danger：Danger causes if the machine is operated wrongly, probably, death

or serious injury will cause.

Caution：Danger causes if the machine is operated wrongly, probably,

medium or gentle injury and damage to equipment will cause.

Different cases probably cause serious result. The caution and danger notes
should be obeyed strictly.

The equipment must be operated by qualified technician, who has received

training about how to operate the machine.

The equipment can just be applied for corresponding design purpose.

Keep working place clean, messy working site will increase the risk of
accidents.

Considering the working environment of operating, don’t get the equipment

wet and don’t use the equipment in humid circumstance. Make the machine work
in good conditon.

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 Don’t operate the electric switch, button with wet hands for fear of electric
shock .

Protect the body from injury of electric shock, and avoid touch electric
parts.

Put the euqipment in dry and safe circumstance if the machine has not been
used for a long time.

Wear suitable work clothes. Don’t wear loose clothing and jewelry.

Keep clear of rotating parts during opeating.

Wear impact resistant eye and ear protection while operating. If much dust,
wear the dustproof respirator or mask.

Don’t overuse the cable. Don’t pull the equipment with the cable or
sintak the cable to cut off the power. The cable should be kept away from heat
power, oil dirt and sharp-pointed tools. Check the cable regularly, change it if
damaged and repair it if loose.

Maintain the equipment regularly。To make the machine work in good

performance, keep it clean. Add oil lubricant and change parts as per operating
rules.

Before maintenance or change accessories, such as Tool Bits, make sure the
power plug has been pulled out.

Avoid start up the euqipment unconsciously. When plug in, don’t put hands
on the switch and ensure it is cut off.

Use suitable extending power board. If the equipment is used in outdoor, the
power board must be restricted to the outdoor use.

Focus on operating equipment. The operator should careful about the

process. If sick or tire, stop operating.

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 Check whether the equipment is damaged. Before using equipment, check all
the parts to ensure the function of the equipment. Check the parallelism or the
working parts, lockpin of the rotating parts, damage of parts and the possible
influence conditions caused. The damaged parts should be repaired or replaced.
Caution: If the equipment is damaged, please stop using.

Use our original parts or accessories.

The euqipment must be repaired by professional according to safety

standards.

If use the electric motor, make sure input voltage is the same as that of
nameplate.

If use the pneumatic motor, check the pressure of compressed air.

Check the handle and safety pedal regularly ( just for pneumatic machines).

Make sue the right way of operating euqipment.

Don’t change key parts of the equpment for fear of danger or low
performance. Machine Partial warning sign for machine use.

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4
SECTION 2 INSTRUCTION

The machine is driven by pneumatic motor, through gear box then output large
torque to the tooling post, which can do both Automatic and manual feeding. The
tooling bit can do axial and radial feeding to producing the flange face

2.1 APPLICATION

The machine is used in the processing of flange reconstruction and the industrial
on-line pipeline and the pre welding work. For aerospace, petroleum, chemical,
electric power construction, boiler, gas and other industrial pipeline installation
works. It also can work in narrow space since small volume. Meanwhile, It can
save a lot of production time and cost since high speed working, clamping easily,
etc.

2.2 FEATURE

（1） Simple and easy to change the tooling bit；

（2） Finish cutting one time, simple and quickly；
（3） Cold cutting, do not change the flange and pipe’s material；
（4） Feeding automatically, can do serrated spiral, facing or grooving on the
flange or end pipeline
（5） High precision cutting
（6） Feeding by serrated spirally, 6 shifts control
（7） Working range ID: 400-1140mm; Application for welded convex flange
and plane flange.
（8） The machine can be driven by server motor or pneumatic motor, separate
reducing gear system, running more steady, low noise.
（9） Clamping system adopts 4-8 symmetrical calmping claws, separate tension,
overcome the misalignment problem.

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 SECTION 3 MAIN COMPONENT

The machine is packed by wooden case with following：

● 1 set of main body;
● 1 pc of accessory box
● 1 pc of operation instruction (with warranty certification)
Accessory box with following ：

● 1 set of swelling block for different size flange

● 1 set of tooling bit
● 1 set of different size hex wrench for installing
● 1 set of different size hex wrench for clamping

After getting the machine, pls check the package and accessory carefully, pls
contact us if any problems. We will solve your problem as soon as possible.

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 SECTION 4 DETAIL PARAMETER

4.1TECHNICAL PARAMETER

CHART 1 SERRATED SPIRAL PITCH DISTANCE

CLAMPING OUTPUT BASICS HIGH-LOW BASICS HIGH-LOW
FEEDS FEEDS
MODEL RANGE SPEED SHIFT SHIFT SHIFT SHIFT
（I.Dmm） （r/min） （N/1/2/3） （A/B） （mm/r） （N/1/2/3） （A/B） （mm/r）
1 0.06 1 0.12
2 0.15 2 0.30
SYI-610 200-500 10-24 3 A 0.24 3 B 0.48
2 0.15 2 0.30
3 0.24 3 0.48

REMARK：
1. The above chart clamping range is the machine clamping range. Total 6 size clamping
system.
2. The output speed is a theoretical data based on no-load running. The rotating speed of the
pneumatic products is greatly influenced by the pressure of the gas source. Customer should
prepare air power in advance. Air pressure: 0.7~1.0MPa, air consuming flux: 3000-3500
L/min. No spark during working, it is safe and reliable, especially in the field of flammable,
explosive and dangerous operation.
3. The machine only have standard tooling bit. Non-standard bit are available according to
the customer requirement.

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4.2 TOOLING BIT CHART

TOOLING POST:

CHART 1

The standard tool material of this series of products is high speed tool steel, which
is suitable for processing all kinds of carbon steel and stainless steel.If the user
needs to process the pipe of alloy steel, cast steel and other materials, please
contact of the cutting tools are all common angles. If you need other angles tools,
please contact us too.

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 SECTION 5 INSTALL INSTRUCTION
5.1 CONSTRUCTION

CHART 2

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5.2 CLAMPING SYSTEM

5.2.1 CONSTRUCTION

CHART 3

CLAMPING HEAD 1 ( only suit for big than 1400 model)

No. ITEM NO DESCRIPTION No. ITEM NO DESCRIPTION
1 -00-009-01 Swelling Block 4 -00-011 Swelling Nut
2 -00-099 Swellinng Bolt 5
3 GB/T 893.1-1986 Elastic retainer

CHART 4

CLAMPING HEAD 2
NO ITEM NO DESCRIPTION NO ITEM NO DESCRIPTION
1 -30-06 Swellinng Bolt 2 -30-10 Adjust bolt
3 -30-07 Swelling Block 4

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SWELLING BLOCK SIZE
CHART 5

Chart 4 Clamping size (mm)

Clamping Clamping Clamping -30-11 -30-12 -30-13 -30-14
size head 1 head 2
195-253 ●
252-313 ● ●
312-373 ● ●
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 372-433 ● ● ●
432-493 ● ● ●
492-550 ● ● ●
●—Means superposition.

5.2.2 INSTALL/CHANGE PROCEDURE

Before install or change clamping system, use brush to clean the connect part between
clamping block and main body.
1）CHOOSE SWELLING BLOCK
SYI610Ⅱ clamping range Φ200-Φ500，as chart 4.
2）CHANGE CLAMPING SYSTEM
1ST Step: Dispatch swelling block;
2nd Step: Choose the swelling block as chart 4
3rd step: Install the swelling block on the site of clamping system
3）INSTALL CLAMPING SYSTEM
CHART 6

Clamping system adopts 4 symmetrical calmping claws, separate tension, overcome

the misalignment problem.Step：
1. Put the clamping system on the flange with balance block “1”
2. Using wrench to tight the clamping hole “3” clockwise, it is tighten; Anti-clockwise
is loosen.

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 3. Use wrench to adjust the swelling pole “2” clockwise or anti-clockwise, to verniering
the height.
4. Use wrench to tighten clamping jaws ”3” to fixed the system clockwisely.
P.S: The Cleanliness of connector part between flange and clamping jaws will directly
affect the cutting surface and the pipe flange coaxial

5.3 HOISTING AND INSTALL THE MACHINE’S MAIN BODY

5.3.1 HOISTING

CHART 7

Chart 7
Install the hang screw into the main shaft, then use lifting machine to hoisting the machine’s
main body into the clamping system carefully.
P.S: lifting machine carefully, cannot make the tooling post and machine knocked on
the ground or other objects. Operator should be careful own safety since the tooling post
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can rotating one the main body. Take off the hang screw after install the machine’s main
body.

5.3.2 INSTALL AND ADJUSTMENT

CHART 8

Insert 4 screws “1” into the hole “L”, tighten them with wrench, To make the two sides
fit tightly as chart 8

5.4 CHOOSING TOOLING BIT

Tooling bit have to be taken off during no working. Select correct tooling bit according
to the flange size, process requirement, etc. as Chart 1

Warning: Make sure the power is off before operating motor or tooling bit.

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5.5 INSTALL/DISASSEMBLY TOOLING BIT

5.5.1 INSTALL TOOLING BIT

Clean the connecting area between tooling bit and tooling post with brush.
P.S: The connector area’s cleanliness will directly affect the machining quality of the
tube groove
CHART 9

As chart 9, observe equipment front, tooling post rotate clockwise or anti-clockwise

(overlooking). Make sure the tooling bit is one the correct way.

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CHART 10

As chart 10, Insert the tooling bit “2” on the tooling pole “3”, tighten the express screw
“1” with wrench, knock the wrench lightly to tighten the screw “2”, to make sure the
express screw “1” contact well with tooling bit “2”. Rotating hand wheel “6” to adjust
to tooling pole up and down, then tighten the fix screw “4” after tooling pole be in the
correct length, tighten hex screw “5” after confirm the angle.
Suggest to observing the rotating way before running.

5.5.2 DISASSEMBLY TOOLING BIT

Loosen the express screw “1” anti-clockwise with wrench, take off the tooling bit on
the tooling post. It’s easy to losing screw if knock the wrench.
P.S: Make sure power off or turn off the air motor before changing the tooling bit

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5.6 TOOLING POST CONSTRUCTION

5.6.1 INSTRUCTION

CHART 11

As chart 11, tooling post is composed with hand wheel, support pallet, tooling post,
tooling bit, wire rod. Tooling bit is for do facing or grooving; support pallet drive the
tooling bit; wire rod can do feeding automatically; tooling post can adjust angle from
-27.5°to 27.5. After finish processing, insert hex wrench into the quit hex hole,
rotating anti-clockwise, can return the tooling post quickly. ( Make sure pull the gear
box on the “N” shift)
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5.6.2 AXIAL FEEDING WHEEL

As chart 10, Loosen the 2 pcs of screw anti-clockwise with wrench before using axial
feeding wheel. Then rotate the wheel clockwise or anti-clockwise to make the tooling
pole up or down, finally tighten the 2 pcs of screws. The max height trip is 40 mm

5.6.3 RADIAL FEEDING WHEEL

The machine is feeding automatically. Need to return tooling bit manually after finish
working. As chart 12
Chart 12

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5.6.4 WORKING RANGE AND ADJUST ANGLE

CHART 13

Tooling post angle is from -27.5º~27.5º . Loosen the 2 pcs ofscrews beside, then rotate
the tooling post to correct angle. Then tighten the 2 pcs of screws.
P.S: Knock the screws with wrench lightly can make loosing easily.

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5.6.5 ADJUST FEEDING

CHART 14

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 BASICS HIGH-LOW BASICS HIGH-LOW
FEEDS FEEDS
SHIFT SHIFT SHIFT SHIFT
（N/1/2/3） （A/B） （mm/r） （N/1/2/3） （A/B） （mm/r）
N 0 N 0
1 0.06 1 0.12
A B
2 0.15 2 0.30
3 0.24 3 0.48

Tooling bit feeds is 0.06-0.48mm/r, as above chart.

Change shift with hand wheel, rotate the cutter head so that the variable stop pin falls
into the slot. Forbidden to change basics shift（N/1/2/3）and high-low（A/B） shift as the
same time.

5.6.6 WEIGHT BANLANCE

CHART 15

Weight banlance part is composed of balance rod and balance block.The total length
of balance rod is 850mm, and the adjustable length of banlance rod is 520mm for
rough balance adjustment.Then run the machine to check if the vibration is too
large.The balance rod and balance block are connected by screw and can be balanced
and adjusted slightly.After adjustment, tighten it and lock the bolt on the balance
block.

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5.7 TRANSMISSION SYSTEM

The machine has transmission system separately. Firstly, insert the power output shaft
into the main body, fixed the power output shaft with screws. (It has 6 screw holes,
fixed 2 holes is enough, Adjusted the shaft to no interference with the outside space)

2nd, insert the air power pipe into the input vavle, open the vavle to run machine.
Chart 16

NO DESCRIPTION NO DESCRIPTION
1 Input valve 2 muffler
3 Pneumatic motor 4 Reducing
5 Power output shaft

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 SECTION 6 WORKING PROCEDURE

6.1CONFIRMATION AND INDICATION BEFORE WORKING

Read section 1 “safe instruction” carefully.

No other impurities are identified in the work area.
During running, suggest to wear protection glass all the time.
Check the tooling bit can meet the process requirement or not, such as “U” shape, need
to change bit.
Check the tooling bit rotating direction.
Check the tooling bit feeding rate

6.2 CLAMPING

Warning: Don’t allow the flange face to hit tooling bit

6.3 COOLING OIL

Cooling oil enables cutting chips to be more easily discharged from tool bit and
facilitates heat dissipation.This will effectively improve the service life of the tool and
the finish of the cutting surface.
Warning!Not allow motor and liquid contact during operation!In fact, the motors used
in this series are not waterproof, and the contact with the liquid will cause the risk of
motor damage, and may put the user's personal safety at risk.

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6.4 FEEDING

Warning! please make sure there are no other sundries in the processing area before
starting. Press the rotary inlet valve switch to start the motor.
Note: in the process of feed cutting, tool feed is very important.In order not to damage
the tool bit, it is recommended not to use the maximum feed, impact load will seriously
affect the life of the tool bit.

6.5 COMPLETION

Press the rotary inlet valve switch to close the motor.

Lift the tool bar up to the original position, rotate the feed handwheel, manually rotate
to return the tool rest to the original position.
According to the way of use, use the lifting mechanism to support the machine, and
then loosen the tightening claw one by one.
Remove the equipment, be careful not to let the tool bit hit the finished flange face.

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AOTAI MACHINE MANUFACTURING CO.LTD

SECTION 7 TROUBLE SHOOTING

Trouble Possible Cause Solution

Check if tool is good condition, if tool is installed
Tool bit correctly, if the mounting surface is clean, and if
the fastening screw is tightened.
Poor machining Ensure clamped is good and select the appropriate
quality of processed expansion pad.Check that the screws on the expansion
Clamping system
surface pad are installed correctly.Check the surface of the
clamping claw for excessive deformation or wear.
Different materia lpipe,diierent feeding，
Feeding
adjustsuitable feeding
Make sure the blade is installed correctly.If the
blade is installed in the wrong direction or not
Tooling install
locked, remove the blade to clean the whole part
and reinstall it in the correct direction.

Tool bit wears too Tool bit choice Choose suitable tool bit according to the guide
fast
Feeding Please adjust the suitable feeding

Using lubricants and cooling, tool life can be

Cooling oil
doubled.
Switch Whether the start switch is pressed
Pneumatic supply Check whether the air source pressure is sufficient
Motor can’t work
Connector If damage, Changed it by a professional
Inlet pipe If damage, Changed it by a professional
Gear damage Change to new
Abnormal noise
Bearingdamage Change to new
If the fault still exists or the table does not explain, please stop the operation, and
contact us company for advice, we will solve your problem as soon as possible.

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AOTAI MACHINE MANUFACTURING CO.LTD

SECTION 8 MAINTAINT AND REPAIR

Maintenance and repair operations must be performed by skilled professionals.
In order to ensure good operation of the equipment, it is recommended to use original
spare parts.
Note: make sure the power is cut off before maintenance.
Keep the original package to facilitate timely shipment of equipment and accessories.
It is important to keep the equipment clean in order to keep the equipment in the best
working condition.
After each use, the equipment must be cleaned with a brush and applied with anti-rust
oil in key parts (such as guide surface, joint joints).Drive mechanism lubricant
selection grease.Grease replacement cycle: the grease should be replaced after 30 days
of operation and the grease inside should be washed clean.After the normal
circumstances, every 2 months to replace.The bearing part of the main engine passes
through the nozzle, and lithium base grease is added regularly.
Do not place equipment in a damp, dirty environment.
Note: do not place any debris on the rotating shaft.
Note: brush is recommended for cleaning equipment.

Warning!Do not use compressed air to clean equipment!

Before each use, it is recommended to clean the equipment properly to ensure that
there are no residual cutting chips.
It is recommended that the moving parts be removed and lubricated by a professional
once a year.

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