ROLLER 479092 Proven Robust Hand Die Stock Instruction Manual

ROLLER 479092 Proven Robust Hand Die Stock

Product Information

The product is a thread cutting tool with a quick-change die head, ratchet lever, bolt, two-part pipe arm, extension, ratchet bolt, countersunk screw, cover, die, die head body, guide bushing, and spindle (ROLLER’S Nipparo). It is designed for cutting threads on pipes with various thread types and sizes.

The product comes with Schneidbacken ROLLER’S Central, Gewindeschneidstoffe, and Nipparo. It weighs between 2.0 kg (4.4 lb) and 2.3 kg (5.1 lb) depending on the model.

Product Usage Instructions

1. Before using the product, read all safety notes, instructions, illustrations, and technical data that come with it to prevent severe injuries.
2. Set up your workplace by keeping it clean and well-lit. Ensure that children and bystanders are away while operating the tool to prevent distractions.
3. Select the appropriate Schneidbacken for the thread type and size you want to cut.
4. Apply enough Gewindeschneidstoffe to the pipe before cutting the thread. Avoid using unsuitable or insufficient Gewindeschneidstoffe as it can cause damage to the Schneidbacken and the pipe.
5. Place the pipe in the two-part pipe arm and secure it using the ratchet lever.
6. Use the ratchet bolt to adjust the position of the die head body according to the desired thread length.
7. Turn the spindle (ROLLER’S Nipparo) clockwise to cut the thread. Repeat until the desired thread length is achieved.
8. After use, dispose of the Gewindeschneidstoffe properly and clean the product before storing.
9. For maintenance, only have qualified personnel repair the tool with original Ersatzteilen to ensure its safety.

Translation of the Original Instruction Manual

Fig. 1 – 6

1. Quick-change die head
2. Ratchet lever
3. Bolt
4. Two-part pipe arm
5. Extension
6. Ratchet bolt
7. Countersunk screw
8. Cover
9. Die
10. Die head body
11. Guide bushing
12. Spindle (ROLLER’S Nipparo)

General safety instructions

WARNING

Read all the safety notes, instructions, illustrations and technical data which come with this tool. Failure to heed the following instructions can lead to severe injuries.
Keep all safety notes and instructions for the future. The term “tool” used in the safety notes refers to hand-held tools.

1. Workplace

   • Keep your workplace clean and well lit. Untidiness or poorly lit working areas can lead to accidents.
   • Keep children and bystanders away while operating the tool. Distractions can lead to you losing control of the tool.

2. Safety of persons

   • Be cautious, pay attention to what you are doing and use tools reasonably and responsibly. Do not use tools when you are tired or under the infl uence of drugs, alcohol or medicines. Just one careless moment when using the tool can lead to serious injury.
   • Wear personal safety equipment and always wear safety glasses. Wearing personal safety equipment such as a dust mask, non-slip safety shoes, a safety helmet or ear protectors depending on the type and use of the tool reduces the risk of injuries.
   • Avoid abnormal body posture Make sure that you have a fi rm footing and keep your balance at all times. You then have better control over the tool in unexpected situations.
   • Wear suitable clothing. Do not wear loose clothing or jewellery. Keep hair, clothing and gloves away from moving parts. Loose clothing, jewellery or long hair can get caught in moving parts.
   • Do not give yourself a false sense of security and do not ignore the safety rules for tools even when you are very familiar with the power tool after frequent use. Careless actions can lead to serious injuries within fractions of a second.

3. Use and handling of the tool

   • Do not overload the tool. Use the tool suitable for the work you are doing.
     You can work better and safer in the specifi ed power range with the suitable tool.

   • Keep tools out of reach of children when not in use. Do not allow persons to use the tool who are not familiar with it or have not read these instructions.
     Tools are dangerous when used by inexperienced persons.

   • Take good care of tools and accessories. Check that the moving parts are working perfectly and do not jam, that no parts are broken or damaged and
     that the function of the tool is not impaired. Have damaged parts repaired before using the tool. Many accidents are caused by poorly maintained tools.

   • Keep cutting tools sharp and clean. Carefully maintained cutting tools with sharp cutting edges jam less and are easier to control.

   • Use tools, accessories and insert tools etc. according to these instructions.
     Take the working conditions and activity being performed into consideration.
     The use of tools for purposes for which they are not intended can lead to dangerous situations.

   • Keep handles and gripping surfaces dry, clean and free from oil and grease.
     Slippery handles and gripping surfaces prevent safe handling and control of the tool in unforeseeable situations.

4. Service

   • Have your tool repaired only by qualifi ed technical personnel and only with genuine spare parts. This ensures that the safety of the tool is maintained.

Safety instructions for hand die stocks

CAUTION
Read all the safety notes, instructions, illustrations and technical data which come with this tool. Failure to heed the following instructions can lead to severe injuries.

Keep all safety notes and instructions for the future.

• Do not use the hand die stock if it is damaged. There is a danger of accident.

• Only use original ROLLER’S Central quick-change die heads / ROLLER’S quick-change die heads S. Other die heads do not guarantee a secure fi t or damage the die head holder of the hand die stock.

• Never extend the ratchet lever of the ROLLER’S Central. Extending the ratchet lever is prohibited and will increase the risk of property damage and injuries.

• Always work with the bolt (3) closed. Otherwise the die head may be pushed out of the die head holder, e.g. during start-cutting.

• Clamp short pipe sections only with ROLLER’S Nipparo. Hand dis stock and/ or tools can be damaged.

• Thread cutting materials in spray cans (ROLLER’S Smaragdol, ROLLER’S
  Rubinol 2000) contains environmentally friendly but highly infl ammable propellant gas (butane). Aerosol cans are pressurised; do not open by force. Protect them against direct sunlight and temperatures above 50 °C.
  The aerosol cans can burst, risk of injury.

• Avoid intensive skin contact with thread-cutting materials because of the degreasing effect. Use skin protectors with a greasing effect or a suitable hand protection.

• Children and persons who, due to their physical, sensory or mental abilities or lack of experience and knowledge are unable to operate the hand die stock safely may not use this electric die stock without supervision or instruction by a responsible person. Otherwise there is a risk of operating errors and injuries.

• Only allow trained persons to use the hand die stock. Apprentices may only use the hand die stock when they are over 16, when this is necessary for their training and when they are supervised by a trained operative.

NOTICE

• Do not dispose of thread-cutting material undiluted in the drain system,ground water or ground. Unused thread-cutting material should be handed in to responsible disposal companies. Waste code for thread-cutting materials containing mineral oil (ROLLER’S Smaragdol) 120106, for synthetic materials (ROLLER’S Rubinol 2000) 120110. Waste code for thread cutting materials containing mineral oils (ROLLER’S Smaragdol) and synthetic thread cutting materials (ROLLER’S Rubinol 2000) in spray cans 150104. Observe the national regulations.

Explanation of symbols

Danger with a low degree of risk which could result in minor injury (reversible) if not heeded.

Material damage, no safety note! No danger of injury.

Read the operating manual before starting

Technical Data

Use for the intended purpose

CAUTION

• ROLLER’S Central is designed for cutting pipe and bolt threads with original
• ROLLER’S Central quick-change die heads / ROLLER’S quick-change die heads S.
• All other uses are not for the intended purpose and are therefore prohibited.

Scope of Supply
Ratchet lever (up to 2″ additionally with ratchet lever 1½ – 2″), ROLLER‘S Central quick-change die heads according to ordered set, operating instructions, steel case.

Article numbers

• Ratchet lever ⅛ –1¼”,16 – 40 mm 479092
• Ratchet lever 1½ – 2″, 50 mm 479093
• Dies ROLLER’S Central see ROLLER catalogue
• Quick-change die heads ROLLER’S Central see ROLLER catalogue
• Extension 300 mm 476035
• Thread cutting materials see ROLLER catalogue
• Nipparo see ROLLER catalogue
• Steel case with inlay for
• ROLLER’S quick-change die heads ⅛ –1¼” 479800
• Steel case with inlay for
• ROLLER’S quick-change die heads 1½ – 2″ 479803
• Steel case with inlay for
• ROLLER’S quick-change die heads S 526052
• ROLLER’S Anaconda 3B 120270
• ROLLER’S Anaconda WB 120250
• ROLLER’S Werkmeister E 120240
• ROLLER’S Werkmeister 120200
• ROLLER’S Assistent 3B 120120
• ROLLER’S Assistent WB 120130

Applications

Thread diameter

• Pipe thread with ratchet lever ⅛ –1¼”,16 – 40 mm
• Pipe thread with ratchet lever 1½ – 2″, 50 mm

Thread types

• Tapered pipe thread right and left-handed R ISO 7-1, EN 10226 (DIN 2999, BSPT)
• Pipe thread, tapered, right-handed Taper Pipe Thread ASME B1.20.1
• Threads for electric conduit M ×1.5 (DIN EN 60423)

Thread lengths

• Pipe threads, tapered standard length
• Pipe threads, parallel 50 mm, unlimited with reclamping
• Nipples and double nipples with manual inside clamping
  ROLLER’S Nipparo nipple holders ⅜”– 2″

Dimensions

• Ratchet lever ⅛ –1¼” 750 × 80 × 40 mm (29,5″ × 3,1″ × 1,6″)
• Ratchet lever 1½ – 2″ 780 × 105 × 50 mm (30,7″ × 4,1″ × 2,0″)

Weights

• Ratchet lever ⅛ –1¼” 2,0 kg (4,4 lb)
• Ratchet lever 1½ – 2″ 2,3 kg (5,1 lb)
• Die heads ½ … 2” 0.8 … 1.8 kg (1.8 … 4.0 lb)

Start-up

Tools
Screw the two-part pipe arm (4) of the ratchet lever (2) together hand- tight.
Only use original ROLLER’S Central quick-change die heads, ROLLER’S quick- change die heads S. Insert quick-change die head (1) in the ratchet lever (2) as follows: Open the bolt (3), pull back the ratchet bolt (6), insert the quickchange die head into the die head holder, close the bolt, release the ratchet bolt. Insert quick-change die heads ⅛ –1¼”, 16 – 40 mm into ratchet lever 1⅛ –1¼” and quick-change die heads 1½ – 2″, 50 mm, into ratchet lever 1½ – 2″.
If a thread is to be cut on a section of pipe protruding from the wall, the ROLLER’S quick-change die heads S are used with an additional guide bushing on the cover side (Fig. 3). These can be inserted directly into the ratchet lever (2). To drive the S quick-change die heads in places with diffi cult access, e.g. in wall cavities (Fig. 4), the extension (5) is fi tted to the ratchet drive. Insert the extension (5) into the ratchet lever (2) as described above and fi x the selected S quick-change die head (Fig 3) in the extension (5) by threaded pins.

Thread-cutting Materials
Safety data sheets see www.albert-roller.de → Downloads → Safety data sheets.
Use only ROLLER’S thread-cutting oils. You will have perfect threading results,long durability of dies as well as high protection of the drive unit. ROLLER recommends the practical and economical spray can/spray bottle.
NOTICE
ROLLER’S Smaragdol: High-alloyed, mineral based hread-cutting oil. For all materials: steel, stainless steel, non-ferrous metals, plastics. Can be washed
out with water, tested by experts. Mineral oil-based thread cutting materials are not approved for drinking water pipes in different countries, e.g. Germany,
Austria and Switzerland. Mineral oil-free ROLLER’S Rubinol 2000 must be used in this case. Observe the national regulations.
ROLLER’S Rubinol 2000 Mineral oil-free, synthetic thread-cutting oil for drinking water supplies. Completely water-soluable. Complies with regulations: in Germany DVGW Approval No. DW-0201AS2031, in Austria ÖVGW
Approval No. W 1.303, in Switzerland SVGW Approval No. 9009-2496. Viscosity at –10°C: ≤ 250 mPa s (cP). Pumpable to –28°C. Easy to use. Dyed red for rinse- out inspection. Observe the national regulations.
Both thread cutting materials are available in aerosol cans, canisters and barrels,ROLLER’S Rubinol 2000 also in spray bottles.

NOTICE
All ROLLER’S thread cutting materials may only be used in undiluted form!

Operation

Work procedure
Cut the pipe at a right angle without burr and clamp in the ROLLER’S Anaconda 3B/ROLLER’S Anaconda WB (accessory art. no. 120270/120250) so that the end of the pipe is protruding approx. 10 cm from the dies. Support longer pipes with the ROLLER’S Assistent 3B/ROLLER’S Assistent WB (accessory art. no.
120120/120130) material rest. Insert the selected quick-change die head (1) into the ratchet lever (2) (see 2.1). Set the thread direction by pulling back the ratchet bolt (6) and set to R = right-hand thread or L = left-hand thread, lubricate the cutting point with ROLLER’S thread cutting material (see 2.2.). Place the quick-change die head on the pipe, press, turn the ratchet, lubricate several times. The standard thread length is reached when the dies are fl ush with the end of the pipe. Switch over the ratchet bolt. Turn back the die stock or die head with the ratchet or by hand.
To improve the thread quality, press the ratchet lever as evenly as possible by at least 90° in cutting direction and only then turn back the ratchet.

Production of nipples and double nipples
Manual inside clamping ROLLER’S Nipparo nipple holders (accessory) are used for clamping short pipe sections to produce nipples and double nipples.
These are available in the sizes ⅜”– 2″. To clamp the pipe section (with or without thread) with the ROLLER’S Nipparo, the head of the nipple holder is splayed by turning the spindle (12) with a tool (e.g. screwdriver). This may only be done with the pipe inserted (Fig. 5).
When using the ROLLER’S Nipparo it must be observed that no shorter nipples are threaded than specifi ed in the standards.

Maintenance

Maintenance
Keep the ratchet lever (2), quick-change die heads (1) and their receptacle in the ratchet lever clean. Clean heavily soiled die heads and remove loose chips.

Inspection/Repair
This work may only be performed by qualified personnel.
Check perfect functioning of the bolt (3) and replace if necessary. The dies of the quick-change die heads are subject to wear and need to be replaced from time to time. Blunt dies are recognized when cutting pressure increases and/ or threads are ripping off despite good lubrication.

Changing the dies on the ROLLER’S Central quick-change die head (Fig. 6)

1. Clamp the quick-change die head vertically in the vice.
2. Remove countersunk screws (7) and cover (8).
3. Knock out the dies (9) carefully to the centre of the die head body.
4. Knock the die heads (9) with the start-cutting edge (A) towards the bottom into the corresponding slots to the extent that they do not protrude beyond the outer diameter of the body (10). The dies (9) and bodies (10) are numbered.

Die 1 in slot 1, die 2 in slot 2, die 3 in slot 3 and die 4 in slot 4.

1. Fit the cover (8) and tighten the screws (7) lightly.
2. Carefully knock the dies (9) outwards with a soft pin (copper, brass or hard wood) until they are in contact with the edge of the cover.
3. Tighten the countersunk screws (7) firmly.

Changing dies in the ROLLER’S quick-change die head S (Fig. 6)

1. Clamp the quick-change die head vertically in the vice.
2. Remove countersunk screws (7) and cover (8) with guide bushing(11) (do not remove the guide bushing).
3. Knock out the dies (9) carefully to the centre of the die head body.
4. Knock the die heads (9) with the start-cutting edge (A) towards the top into the corresponding slots to the extent that they do not protrude beyond the outer diameter of the body (10). The dies (9) and bodies (10) are numbered. Die 1 in slot 3, die 2 in slot 2, die 3 in slot 1 and die 4 in slot 4.
5. Fit the cover (8) with guide bushing (11) and tighten the countersunk screws (7) lightly.
6. Carefully knock the dies (9) outwards with a soft pin (copper, brass or hard wood) until they are in contact with the edge of the cover.
7. Tighten the countersunk screws (7).

Faults

Fault: Manual die stock has difficulty cutting.

Cause:

• Not an original ROLLER’S Central quick-change die head.
• Dies are blunt.
• Unsuitable or insufficient thread cutting material

Fault: No workable thread, thread rips off.

Cause:

• Dies are blunt.
• Dies inserted incorrectly.
• Unsuitable or insufficient thread cutting material
• Pipe material is unsuitable for thread cutting.

Fault: Thread is cut skew to the pipe axis.

Cause:

• Pipe not cut at right angle

Fault: Pipe slips in the vice.

Cause:

• Pipe not clamped tight enough.
• Vice/die unsuitable or defective.

Remedy:

• Only use original ROLLER’S Central quick-change die heads, ROLLER’S quick-change die heads S.
• Change ROLLER’S dies, see 4.2.
• Use suffi cient, undiluted quantity of ROLLER’S Smaragdol or ROLLER’S Rubinol 2000 thread cutting material.
• Change dies, see 4.2.
• Note the numbering of the dies to the slot number of the die head body (10), see 4.2, change dies if necessary
• Use suffi cient, undiluted quantity of ROLLER’S Smaragdol or ROLLER’S Rubinol 2000 thread cutting material.
• Only use approved pipes.
• Cut pipe at right angle with ROLLER’S Fox with guide holder and ROLLER’S special saw blade or with ROLLER’S Corso St, ROLLER’S Filou, ROLLER’S Disc 100
• Increase clamping pressure.
• Change vice/die. ROLLER’S Anaconda 3B/ROLLER’S Anaconda WB is recommended for secure clamping.

Disposal
The tool may not be thrown into the domestic waste at the end of use but must be disposed of properly by law.

Manufacturer’s Warranty

The warranty period shall be 12 months from delivery of the new product to the fi rst user. The date of delivery shall be documented by the submission of the original purchase documents, which must include the date of purchase and the designation of the product. All functional defects occurring within the warranty period, which are clearly the consequence of defects in production or materials, will be remedied free of charge. The remedy of defects shall not extend or renew the warranty period for the product. Damage attributable to natural wear and tear, incorrect treatment or misuse, failure to observe the operational instructions, unsuitable operating materials, excessive demand, use for unau-thorized purposes, interventions by the customer or a third party or other reasons, for which ROLLER is not responsible, shall be excluded from the warranty

Services under the warranty may only be provided by customer service stations authorized for this purpose by ROLLER. Complaints will only be accepted if the product is returned to a customer service station authorized by ROLLER without prior interference and in a fully assembled condition. Replaced products and parts shall become the property of ROLLER.

The user shall be responsible for the cost of shipping and returning the product.
A list of the ROLLER-authorized customer service stations is available on the Internet under www.albert-roller.de. For countries which are not listed, the product must be sent to the SERVICE- CENTER, Neue Rommelshauser Strasse 4, 71332 Waiblingen, Deutschland. The legal rights of the user, in particular the right to make claims against the seller in case of defects as well as claims due to wilful violation of obligations and claims under the product liability law are not restricted by this warranty.
This warranty is subject to German law with the exclusion of the confl ict of laws rules of German International Private Law as well as with the exclusion of the United Nations Convention on Contracts for the International Sales of Goods (CISG). Warrantor of this world-wide valid manufacturer’s warranty is Albert Roller GmbH & Co KG, Neue Rommelshauser Straße 4, 71332 Waiblingen, Deutschland.

Spare parts lists

For spare parts lists, see www.albert-roller.de → Downloads → Parts lists.

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References

• Albert Roller
• Albert Roller

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