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Page 28

BG44 Boiler Gun Operating Manual

6.2

HIPPING

The BG44 Boiler Gun can be shipped in its original ship-
ping container, as shown in Figure 6-1.

IGURE

6-1. BG44

SHIPPING

CONTAINER

6.3

ECOMMISSIONING

To decommission the BG44 Boiler Gun prior to disposal,
remove the drive motor and dispose of it separately
from the rest of the machine components. Refer to
Appendix A for component assembly information.

Summary of Contents for BOILER GUN BG44

Page 1: ...BOILER GUN BG44 BOILER GUN OPERATING MANUAL P N 100190 April 2017 Revision 1...

Page 2: ......

Page 3: ...NTS 9 2 2 CONTROLS 10 2 2 1 Pneumatic motor controls 10 2 2 2 Electric motor controls 10 2 3 11 2 4 SPECIFICATIONS 12 2 5 ITEMS REQUIRED BUT NOT SUPPLIED 12 13 SETUP 13 3 1 RECEIPT AND INSPECTION 13 3...

Page 4: ...Adjusting the oil flow rate of the in line oiler 24 5 3 4 Tool holders 25 5 3 5 Greasing the drive and pinion gears 25 5 4 TROUBLESHOOTING 25 5 4 1 The machine isn t turning 25 5 4 2 The machine isn...

Page 5: ...itioning on the pneumatic BG44 21 4 2 BG44 with electric motor 22 5 1 In line oiler sight glass 24 6 1 BG44 shipping container 28 A 1 BG44 Boiler Gun high velocity crank feed assembly P N BG44HVCR 30...

Page 6: ...Page iv BG44 Boiler Gun Operating Manual LIST OF FIGURES CONTINUED FIGURE PAGE A 20 Air hose assembly and parts list P N HS 50 509 49 A 21 Electric motor assembly and parts list P N EMB003610 50...

Page 7: ...ABLE PAGE 1 1 Sound levels 3 1 2 Risk assessment checklist before set up 5 1 3 Risk assessment checklist after set up 5 1 4 BG44 Boiler Gun labels 6 2 1 Sub component mass 12 5 1 Maintenance intervals...

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Page 9: ...g and Welding Systems we value your opinion For comments or questions about this manual or other Climax documentation please e mail documentation cpmt com For comments or questions about Climax produc...

Page 10: ...Page B CLIMAX GLOBAL LOCATIONS...

Page 11: ...P N 100190 Rev 1 Page C CE DOCUMENTATION CE Certification is pending...

Page 12: ...epresentative and return the part or repaired machine shipping prepaid to the factory Climax will at its option either repair or replace the defective part and or correct any defect in the labor perfo...

Page 13: ...lf with the BG44 Boiler Gun before attempting to set it up or oper ate it 1 2 SAFETY ALERTS Pay careful attention to the safety alerts printed throughout this manual Safety alerts will call your atten...

Page 14: ...ng sleeves and legs is recommended when operating the machine Hot chips from the workpiece may burn or cut bare skin Work area Keep the work area around the machine clear of clutter Restrain cords and...

Page 15: ...es potentially harmful sound levels Hearing protection is required when operating this machine or working around it During testing the machine produced the sound levels1 listed in Table 1 1 TABLE 1 1...

Page 16: ...he workpiece itself or to an adjacent struc ture and achieve their rigidity from the structure to which it is attached The design intent is that the Porta ble Machine Tool and the structure to which i...

Page 17: ...ine operates and identified the best placement for the controls cabling and the operator I evaluated and mitigated any other potential risks specific to my work area TABLE 1 3 RISK ASSESSMENT CHECKLIS...

Page 18: ...ts TABLE 1 4 BG44 BOILER GUN LABELS P N 100196 HV Boiler gun label P N 100197 LV Boiler gun label P N 100199 H S company label P N 100198 H S serial plate crank feed only P N 802112 Multi Prep label P...

Page 19: ...e location of the labels on each of the components of the BG44 Boiler Gun Label P N 100196 or 100197 100198 100199 802112 100200 87271 Label P N 87271 FIGURE 1 1 BG44 BOILER GUN CRANK FEED PNEUMATIC L...

Page 20: ...Page 8 BG44 Boiler Gun Operating Manual Label P N 87259 FIGURE 1 3 BG44 BOILER GUN WRENCH FEED ELECTRIC LABEL LOCATION...

Page 21: ...livers higher speeds to turn specialty car bide insert cutters while LV is geared for heavy wall and hard alloys Mounting systems Either a wedge or collet mount ing system secures the BG44 to the work...

Page 22: ...ctric motor controls The electric motor controls are similar to a drill or drill driver The trigger is squeezed to actuate the motor when released the motor will stop This is an on and off control onl...

Page 23: ...P N 100190 Rev 1 Page 11 2 3 DIMENSIONS Figures 2 4 and 2 5 show the machine and operating dimensions FIGURE 2 4 BG44 BOILER GUN PNEUMATIC DIMENSIONS FIGURE 2 5 BG44 BOILER GUN ELECTRIC DIMENSIONS...

Page 24: ...BUT NOT SUPPLIED The following items may be required but not supplied in your H S product kit Tape measure or steel ruler Rubber mallet Pliers TABLE 2 1 SUB COMPONENT MASS P N Component Mass in lbs k...

Page 25: ...he setup procedures for the BG44 Boiler Gun 3 1 RECEIPT AND INSPECTION Your H S product was inspected and tested prior to shipment then packaged for normal shipment condi tions H S does not guarantee...

Page 26: ...If installing wedge extensions secure three of the same size range onto the base wedges with the screws 3 2 1 1 Interchanging the M 01 and M 02 base wedge sets The M 01 and M 02 wedge sets can use the...

Page 27: ...f the center shaft are free of the feed nut On the wrench feed machine turn the wrench opposite of the feed direction until the threads of the center shaft are free of the feed nut 6 Slide the center...

Page 28: ...machine 7 Thread the required collet set on the end of the locking rod until the collets begin to engage the center shaft If flat are present on the center shaft align the collets with the flats 8 In...

Page 29: ...e it towards the front of the machine 3 The shaft key may come loose from the main gear during removal Retain it for reuse To install 1 Check that the set screw in the body of the tool holder is backe...

Page 30: ...ning the lock rod clock wise using either the rod wrench or the speed wheel Once snug verify that the mounting system position in the workpiece has been maintained Completely tighten the mounting syst...

Page 31: ...de locks b Slide the cutting bit into the channel with the beveled cutting edge facing the direc tion of rotation c Align the cutting edge of the tool to cut the full width of the workpiece wall 4 Tig...

Page 32: ...embly with the uni versal coupler Secure with the lock pin 2 Connect the air hose assembly to the pneumatic drive motor using the quick disconnect coupler 3 5 2 Electric motor Do the following to prep...

Page 33: ...ne and the work area 4 2 OPERATION The BG44 Boiler Gun can machine both O D and I D bevels and face or shorten pipes Aside from the use of different blades operation is the same for all the machining...

Page 34: ...plete Base the feed rate on the machine s feedback if the RPMs drop or the motor stalls slow the feed rate 4 Once complete allow the machine to make a few revolutions without feeding the cutting tool...

Page 35: ...CKLIST Table 5 1 lists maintenance intervals and tasks 5 2 APPROVED LUBRICANTS H S recommends using the following lubricants at the locations indicated Failure to use the appropriate lubricants can re...

Page 36: ...air 4 Reassemble the filter and replace the filter nut 5 3 3 Adjusting the oil flow rate of the in line oiler WARNING To adjust the oil flow rate the machine must be mounted as if being used ALL opera...

Page 37: ...G This section is intended to help you solve basic machine performance problems For serious maintenance or if you have questions on the following procedures contact H S 5 4 1 The machine isn t turning...

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Page 39: ...ths or less 1 Remove the tooling 2 Remove hoses 3 Clean the machine to remove dirt grease metal chips and moisture 4 Drain all liquids from the in line pneumatic oiler 5 Spray all unpainted surfaces w...

Page 40: ...al ship ping container as shown in Figure 6 1 FIGURE 6 1 BG44 SHIPPING CONTAINER 6 3 DECOMMISSIONING To decommission the BG44 Boiler Gun prior to disposal remove the drive motor and dispose of it sepa...

Page 41: ...G44LVWR 36 FIGURE A 8 BG44 BOILER GUN LOW VELOCITY WRENCH FEED PARTS LIST 37 FIGURE A 9 BG44 BOILER GUN ELECTRIC CRANK FEED ASSEMBLY P N BG44CR E 38 FIGURE A 10 BG44 BOILER GUN ELECTRIC CRANK FEED PAR...

Page 42: ...Page 30 FIGURE A 1 BG44 BOILER GUN HIGH VELOCITY CRANK FEED ASSEMBLY P N BG44HVCR...

Page 43: ...3 1 HELICAL GEAR 100137 12 1 KEY 3 16 X 5 8 100116 32 1 KEY 1 8 X 1 2 100136 11 2 NEEDLE BEARING 100115 31 2 THRUST BEARING 100135 10 1 TAPERED ROLLER BEARING 100114 30 2 NEEDLE BEARING 100134 9 1 BEA...

Page 44: ...Page 32 FIGURE A 3 BG44 BOILER GUN HIGH VELOCITY WRENCH FEED ASSEMBLY P N BG44HVWR...

Page 45: ...P N 100190 Rev 1 Page 33 FIGURE A 4 BG44 BOILER GUN HIGH VELOCITY WRENCH FEED PARTS LIST P N BG44HVWR...

Page 46: ...Page 34 FIGURE A 5 BG44 BOILER GUN LOW VELOCITY CRANK FEED ASSEMBLY P N BG44LVCR...

Page 47: ...4 100138 12 1 MAIN GEAR 100117 32 1 HELICAL GEAR 100137 11 1 KEY 3 16 X 5 8 100116 31 1 KEY 1 8 X 1 2 100136 10 2 NEEDLE BEARING 100115 30 2 THRUST BEARING 100135 9 1 TAPERED ROLLER BEARING 100114 29...

Page 48: ...Page 36 FIGURE A 7 BG44 BOILER GUN LOW VELOCITY WRENCH FEED ASSEMBLY P N BG44LVWR...

Page 49: ...TAPERED ROLLER BEARING 100114 23 FEED NUT SNAP RING 100152 8 BEARING CUP 100113 22 FEED WRENCH 1 1 4 100151 7 NEEDLE BEARING 100112 21 BUTTON HEAD CAP SCREW 10 24 X 3 8 100150 6 HOUSING 100144 20 RET...

Page 50: ...Page 38 FIGURE A 9 BG44 BOILER GUN ELECTRIC CRANK FEED ASSEMBLY P N BG44CR E...

Page 51: ...R BEARING 100114 34 2 THRUST BEARING 100135 12 1 BEARING CUP 100113 33 2 NEEDLE BEARING 100134 11 2 NEEDLE BEARING 100112 32 1 SHOULDER BOLT 100133 10 1 HOUSING 100111 31 1 FEED HANDLE KNOB 100132 9 1...

Page 52: ...Page 40 FIGURE A 11 BG44 BOILER GUN WRENCH FEED ELECTRIC ASSEMBLY P N BG44WR E...

Page 53: ...P N 100190 Rev 1 Page 41 FIGURE A 12 BG44 BOILER GUN WRENCH FEED ELECTRIC PARTS LIST 7 0 12 3 57 1 0 3 57 180 5 7 0 12 3 57 1 0 3 57 180 5...

Page 54: ...4 14 2 2 COLLET SET MC2 2 4 125 COLLET SET MC4 18 2 1 875 COLLET SET MC1 78 2 4 COLLET SET MC4 2 1 75 COLLET SET MC1 34 2 3 875 COLLET SET MC3 78 2 1 625 COLLET SET MC1 58 2 3 75 COLLET SET MC3 34 2 1...

Page 55: ...P N 100190 Rev 1 Page 43 FIGURE A 14 WEDGE SETS AND WEDGE EXTENSIONS 7 0 12 47 3 57 1 0 3 57 180 5 7 0 12 47 3 57 1 0 3 57 180 5...

Page 56: ...160 7 1 25 CRANK FEED WEDGE 100159 6 1 25 CRANK FEED COLLET MB003549 5 1 25 WRENCH FEED COLLET MB003550 4 875 CRANK FEED COLLET MB003545 3 875 WRENCH FEED COLLET MB003546 2 875 WRENCH FEED WEDGE 10015...

Page 57: ...P N 100190 Rev 1 Page 45 FIGURE A 16 LOCKING RODS...

Page 58: ...5A 4 FIXED TOOL HOLDER MB003581 5 3 FIXED TOOL HOLDER MB003570 4 O RING MB003572 3 DIFFERENTIAL SCREW 917 0001 2 BLADE LOCK 000875 1C 5 5 SLIDING TOOL HOLDER MB003583 1B 4 SLIDING TOOL HOLDER MB00358...

Page 59: ...P N 100190 Rev 1 Page 47 FIGURE A 18 HV AIR MOTOR ASSEMBLY AND PARTS LIST P N 100105...

Page 60: ...Page 48 FIGURE A 19 LV AIR MOTOR ASSEMBLY AND PARTS LIST P N CML3488...

Page 61: ...UNIVERSAL COUPLER HS50 524 5 1 VALVE O RING HS50 514 14 1 NUT O RING HS50 523 4 1 OILER VALVE HS50 513 13 1 FILTER NUT HS50 522 3 1 LUBRICATOR BODY HS50 512 12 1 ELEMENT O RING HS50 521 LUBRICATOR ASS...

Page 62: ...Page 50 FIGURE A 21 ELECTRIC MOTOR ASSEMBLY AND PARTS LIST P N EMB003610...

Page 63: ...RE A 22 TOOL KIT 3 RETAINING CLIP PLIERS SNAP 2 FOLD UP KEY SET 5 64 1 4 100093 1 1 8 HEX KEY LONG ARM SLIDING TOOL HOLDER ONLY ODWR 1 5 32 HEX KEY LONG ARM 05471107 1 FIXED TOOL HOLDER ONLY 05471107...

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Page 65: ...P N 100190 Rev 1 Page 53 APPENDIX B SDS SDS list LPS 1 55 LPS 2 64 ExxonMobil Mobil Almo 525 73 Nook PAG 1 Grease 82 WD 40 90...

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Page 67: ...gas under pressure may explode if heated Causes skin irritation May cause an allergic skin reaction May cause drowsiness or dizziness Precautionary statement Prevention Keep away from heat sparks ope...

Page 68: ...t as an extinguisher as this will spread the fire Specific hazards arising from the chemical Contents under pressure Pressurized container may explode when exposed to heat or flame During fire gases h...

Page 69: ...any incompatibilities Level 1 Aerosol Store locked up Pressurized container Protect from sunlight and do not expose to temperatures exceeding 50 C 122 F Do not puncture incinerate or crush Do not han...

Page 70: ...t 58 F 50 C Initial boiling point and boiling range 415 4 F 213 C Flash point 174 2 F 79 0 C Tag Closed Cup dispensed liquid Evaporation rate 0 1 BuAc 1 Flammability solid gas Flammable gas Upper lowe...

Page 71: ...scomfort Defatting of the skin Rash Vapors have a narcotic effect and may cause headache fatigue dizziness and nausea Decrease in motor functions Behavioral changes Information on toxicological effect...

Page 72: ...S 1 Aerosol 1 Mobility in soil No data available Other adverse effects None known 13 Disposal considerations Disposal instructions Consult authorities before disposal Contents under pressure Do not pu...

Page 73: ...2 1 Label s Not applicable Packing group No Marine pollutant Environmental hazards F D S U EmS Read safety instructions SDS and emergency procedures before handling Special precautions for user This s...

Page 74: ...y Right to Know Act Carbon Dioxide CAS 124 38 9 US Pennsylvania Worker and Community Right to Know Law Carbon Dioxide CAS 124 38 9 US Rhode Island RTK Not regulated US California Proposition 65 Califo...

Page 75: ...combination with its product may be used It is the user s responsibility to ensure safe conditions for handling storage and disposal of the product and to assume liability for loss injury damage or ex...

Page 76: ...Causes serious eye irritation May cause drowsiness or dizziness Precautionary statement Prevention Keep away from heat sparks open flames hot surfaces No smoking Do not spray on an open flame or other...

Page 77: ...ld gloves rubber boots and in enclosed spaces SCBA Fire fighting equipment instructions In case of fire Stop leak if safe to do so Move containers from fire area if you can do so without risk Cool con...

Page 78: ...controls personal protection Occupational exposure limits U S OSHA Value Components Form Type PEL 5 mg m3 Oil mist Distillates Petroleum Hydroteated Light CAS 64742 47 8 PEL 5 mg m3 Oil mist Petroleu...

Page 79: ...e gas Upper lower flammability or explosive limits Flammability limit lower 0 6 Flammability limit upper 7 Explosive limit lower Not available Explosive limit upper Not available Vapor pressure 0 05 m...

Page 80: ...Hours LC50 Cat Inhalation 6 4 mg l 6 Hours Rat 7 5 mg l 6 Hours 4 3 mg l 4 Hours 0 1 mg l 8 Hours LD50 Rat Oral 5000 mg kg Petroleum Oil CAS 64742 52 5 LD50 Rabbit Dermal Acute 2000 mg kg 2000 mg kg 2...

Page 81: ...ordance with all applicable regulations Hazardous waste code D003 Waste Reactive material Waste from residues unused products Dispose of in accordance with local regulations Empty containers or liners...

Page 82: ...ndling Read safety instructions SDS and emergency procedures before handling Special precautions for user Not applicable Transport in bulk according to Annex II of MARPOL 73 78 and the IBC Code DOT IA...

Page 83: ...ny chemicals currently listed as carcinogens or reproductive toxins International Inventories Country s or region Inventory name On inventory yes no Yes Australia Australian Inventory of Chemical Subs...

Page 84: ...ignated and may not be valid for such material used in combination with any other materials or in any process unless specified in the text Revision Information Product and Company Identification Produ...

Page 85: ...ubstance s SECTION 3 HAZARDS IDENTIFICATION This material may be considered to be hazardous according to regulatory guidelines see M SDS Section 15 POTENTIAL HEALTH EFFECTS This product may be used in...

Page 86: ...ter fog foam dry chemical or carbon dioxide CO2 to extinguish flames Inappropriate Extinguishing Media Straight Streams of Water FIRE FIGHTING Fire Fighting Instructions Evacuate area Prevent runoff f...

Page 87: ...IONS Large Spills Dike far ahead of liquid spill for later recovery and disposal Prevent entry into waterways sewers basements or confined areas SECTION 7 HANDLING AND STORAGE HANDLING Avoid breathing...

Page 88: ...rdinarily required under normal conditions of use Eye Protection If contact is likely safety glasses with side shields are recommended Chemical type goggles should be worn during misting operations Sk...

Page 89: ...e at ambient temperatures HAZARDOUS POLYMERIZATION Will not occur SECTION 11 TOXICOLOGICAL INFORMATION ACUTE TOXICITY Route of Exposure Conclusion Remarks Inhalation Toxicity Rat LC50 5000 mg m3 Minim...

Page 90: ...RCHED 1 NTP CARC 3 IARC 1 5 IARC 2B 2 NTP SUS 4 IARC 2A 6 OSHA CARC SECTION 12 ECOLOGICAL INFORMATION The information given is based on data available for the material the components of the material a...

Page 91: ...suitably qualified or licensed contractor and in accordance with governmental regulations DO NOT PRESSURISE CUT WELD BRAZE SOLDER DRILL GRIND OR EXPOSE SUCH CONTAINERS TO HEAT FLAME SPARKS STATIC ELE...

Page 92: ...as added Section 15 SARA 313 TOXIC RELEASE INVENTORY Table was deleted Section 15 SARA 313 Chemical Name Header was deleted Section 15 SARA 313 CAS Number Header was deleted Section 15 SARA313 Typical...

Page 93: ...____________________________________________________________________________________ affiliates in which they directly or indirectly hold any interest Internal Use Only MHC 0 0 0 0 0 1 PPEC A DGN 2008...

Page 94: ...re may cause skin dryness or cracking No information available on skin absorption Inhalation Breathing No information available on acute toxicity Inhalation is not an expected route of exposure Ingest...

Page 95: ...of injury SECTION 5 FIRE FIGHTING MEASURES NFPA 704 Hazard Class Health 1 Flammability 1 Instability 0 0 Minimal 1 Slight 2 Moderate 3 Serious 4 Severe Unusual Fire Explosion Hazards This material ma...

Page 96: ...h appropriate methods e g skimming booms or absorbents In case of soil contamination remove contaminated soil for remediation or disposal in accordance with local regulations SECTION 7 HANDLING AND ST...

Page 97: ...onditions of use Emergencies or conditions that could result in significant airborne exposures may require the use of NIOSH approved respiratory protection An industrial hygienist or other appropriate...

Page 98: ...ll of the oils meet the IP 346 criteria of less than 3 percent PAH s and are not considered carcinogens by NTP IARC or OSHA ACUTETOXICITY COMPONENT ORAL LD50 DERMAL LD50 INHALATION LC50 Lubricant Base...

Page 99: ...d contains constituents which are not required to be listed in the MSDS but could affect the hazardous waste determination Additionally use which results in chemical or physical change of this materia...

Page 100: ...llowing chemicals known to the State of California to cause cancer birth defects or other reproductive harm and which may be subject to the requirements of California Proposition 65 CA Health Safety C...

Page 101: ...e Environmental Response Compensation and Liability Act EPA Environmental Protection Agency IARC International Agency for Research on Cancer LEL Lower Explosive Limit NE Not Established NFPA National...

Page 102: ...ting with possible dermatitis Eye Contact Contact may be irritating to eyes May cause redness and tearing Ingestion This product has low oral toxicity Swallowing may cause gastrointestinal irritation...

Page 103: ...spraying or bringing the can near any source of electricity Electricity can burn a hole in the can and cause contents to burst into flames To avoid serious burn injury do not let the can touch battery...

Page 104: ...rbon monoxide and carbon dioxide 11 Toxicological Information The oral toxicity of this product is estimated to be greater than 5 000 mg kg based on an assessment of the ingredients This product is no...

Page 105: ...re listed on the TSCA inventory California Safe Drinking Water and Toxic Enforcement Act Proposition 65 This product does not contain chemicals regulated under California Proposition 65 VOC Regulation...

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