TRI tool 040921 Manual Download

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92-1

173 Orig. 040921

Model BOILERMASTER™

TABLE OF CONTENTS

CUSTOMER MESSAGE

Inside Front Cover

SAFETY PRECAUTIONS

GENERAL DESCRIPTION

SPECIFICATIONS

MAINTENANCE

OPERATION

CUTTING SPEEDS AND FEEDS

JAW BLOCKS, RAMPS AND

TOOL BITS

TROUBLE SHOOTING

ACCESSORIES

ILLUSTRATED PARTS BREAKDOWN

TOOL BIT RESHARPENING POLICY

Inside Back Cover

WARRANTY INFORMATION

Inside Back Cover

Summary of Contents for 040921

Page 1: ...Y PRECAUTIONS 3 GENERAL DESCRIPTION 6 SPECIFICATIONS 7 MAINTENANCE 10 OPERATION 13 CUTTING SPEEDS AND FEEDS 18 JAW BLOCKS RAMPS AND 20 TOOL BITS 24 TROUBLE SHOOTING 27 ACCESSORIES 29 ILLUSTRATED PARTS BREAKDOWN 30 TOOL BIT RESHARPENING POLICY Inside Back Cover WARRANTY INFORMATION Inside Back Cover ...

Page 2: ...Copyright 2004 Proprietary property of TRI TOOL Inc No reproduction use or duplication of the information shown hereon is permitted without the express written consent of TRI TOOL Inc ...

Page 3: ... not operate cutting tools without eye protection Dress properly Do not wear loose clothing or jewelry They can be caught in rotat ing and moving parts Avoid slippery floors or wear nonskid footwear If you have long hair wear protective hair covering to contain it WORK AREA Keep the work area clean Cluttered work areas and benches invite injuries Consider the work area environment Keep the area we...

Page 4: ...ut of all cutting fluids and water Hydraulic drives Observe proper procedures for electrically driven power sources Avoid damage to hydraulic lines Keep quick disconnects clean Grit contamination causes malfunctions Air tools Check the exhaust muffler Broken or damaged mufflers can restrict air flow or cause excessive noise Use air motors only with a filtered lubricated and regulated air supply Di...

Page 5: ...e designed Do not reach into rotating equipment Do not reach into the rotating head stock to clear chips to make adjustments or to check surface finish A machine designed to cut steel will not stop for a hand or an arm Handle chips with care Chips have very sharp edges and are hot Do not try to pull chips apart with are hands they are very tough Avoid unintentional starts Do not carry or handle to...

Page 6: ...ingent nuclear codes may be machined The various interchangeable Jaw Blocks and Ramps will secure the BOILERMASTER to pipe and tubing having an inside diameter ranging from 1 25 31 8 mm through 4 33 110 0 mm The expanding mandrel provides fast accurate self centering and alignment to the pipe or tubing to be machined There are two 2 different head kits available They are the 2 63 DIA head kit and ...

Page 7: ...y require optional equipment Basic Tube Sizes Up to 531 13 5 mm wall tubing with a maximum OD of 4 50 114 3 mm and minimum ID of 1 25 31 7 mm may be beveled with standard procedures Wall Thickness Capacity Wall thickness of all standard pipe schedules 531 13 5 mm maximum in the range listed Contact TRI TOOL INC for heavier wall procedures Counterboring Operations The machine will counterbore pipe ...

Page 8: ... stainless steel copper nickel and aluminum without limitations except size and wall thickness as specified under the Pipe Cutting Capacities paragraph Inconel and some other high temperature alloys may require special procedures as a function of wall thickness and type of end preparation Envelope Drawing ...

Page 9: ...per minute 762 surface centimeters per minute 4 50 114 3 mm 21 rpm 1 25 31 8 mm 76 rpm DRIVE SYSTEM Final Drive Gear driven Pneumatic Motor Free Speed 325 rpm Maximum H P Speed 162 rpm SPEED CONTROL Deadman type on off valve and twist type airflow control valve MOUNTING Manually actuated draw rod expands the mandrel ramps and the jaw blocks FEED Manual feed wrench is in line at the back of the mac...

Page 10: ... lubricator FRL to be used A maximum of 90 PSI 621 kPa line pressure is recommended NOTE NOTE The Motor warranty is void if damage occurs from contaminated air or lack of lubrication If the BOILERMASTER is operated in the vertical position cutting head up it should be turned upside down and the chips and or other debris removed after each bevel has been completed Tool life may be severely shortene...

Page 11: ...er the air supply must flow through a filter regulator lubricator FRL unit or separate units before arriving at the air motor The FRL unit must be maintained as required frequency dependent on the basic air supply to keep the water trap drained filter cleaned and the lubricator oil reservoir filled so that a drop of oil every 2 to 5 seconds is flowing If the BOILERMASTER is to be left idle for 24 ...

Page 12: ...F 38 C minimum aniline point of 200 F 93 C TRI TOOL Inc Air Tool Lubricant P N 68 0022 AMOCO American Industrial Oil No 32 Atlantic Richfield Duro Oil S 150 Chevron A W Machine Oil 32 Exxon Nuto H32 Shell Tellus Oil 32 The bearings in the air motor are sealed and do not require any lubrication The drive gears require a lithium based grease ...

Page 13: ...OILERMASTER until it comes to a stop against the torque acceptance key Rotate the mandrel assembly as required to engage the torque acceptance key of the BOILERMASTER with the slot in the mandrel shaft Since the mandrel shaft will contact the torque acceptance key before the feed nut engages the mandrel shaft threads caution should be taken not to force or allow the machine to impact the lead thre...

Page 14: ...ed into the pipe or tube as one unit In order to avoid cutting the ramps and or jaw blocks during the machining operation the mandrel must be installed beyond the final end preparation location Tighten the draw nut to force the jaw blocks out to the inside diameter of the pipe or tube TOOL BIT INSTALLATION ...

Page 15: ...forming any multiple machining operation such as facing and beveling the facing tool bit should be installed as shown above Insert the tool bit s into the slot s in the cutting head The cutting edge of the tool bit s must be located on the radial centerline Insure that no tool bit is installed backwards Make sure that there is a clearance between the tool bit s and the mandrel Tighten the wedge sc...

Page 16: ... Cutting Speeds and Feeds later in this manual Rotate the feed handle clockwise to bring the tool bit s and pipe closer together The actual machining operation will begin when the first tool bit contacts the pipe DO NOT OVERRIDE THE DEADMAN SWITCH ON THIS UNIT Locking down obstructing or in any way defeating the deadman switch on this unit may result in serious injury ...

Page 17: ...handle clockwise until the end of the pipe is completely machined Discontinue feed and allow the head to rotate 1 to 3 revolutions to improve finish of the prep surface Release the air motor trigger to stop the head rotation Rotate the feed handle counterclockwise to separate the tool bit s from the pipe Rotate the feed handle counterclockwise until the tool bit to pipe clearance is 1 8 3 mm Loose...

Page 18: ...ute 6350 surface millimeters per minute for Mild steels and some thin wall stainless steels when coolants are permitted and applied Use 300 surface inches per minute 7620 surface millimeters per minute for Aluminum and some thin wall mild steel and tube with coolants CUTTING FEEDS Use very light feed for initial beveling or until a continuous cut is established This is very important for longer to...

Page 19: ...ess steel which work hardens must be worked with a haevy enough feed to stay under the work hardened surface 003 08 mm to 006 15 mm feed Never allow the Tool Bit to burnish the surface Reduced feeds and speeds will normally minimize chatter problems ...

Page 20: ...80 3 mm 16 4 mm 3 090 to 3 550 841 78 5 mm to 90 2 mm 21 4 mm 3 480 to 3 940 1 041 88 4 mm to 100 1 mm 26 4 mm 3 870 to 4 330 1 239 98 3 mm to 110 0 mm 31 5 mm 48 0965A 48 0965A NOTE Blocks can only be mounted on the 2 Ramp P N 48 0965A Steel Jaw Blocks and Ramps for Mandrel Assembly P N 06 0415A 48 0965A 48 0965A 48 0965A Block Height Standard Ramp 3 Req d 48 0966A Jaw Block Assembly 3 Req d 48 0...

Page 21: ...mp and Block Combination 1 560 to 2 000 39 6 mm to 50 8 mm 1 930 to 2 390 49 0 mm to 60 7 mm 2 320 to 2 780 58 9 mm to 70 6 mm 2 710 to 3 160 68 8 mm to 80 3 mm 1 250 to 1 630 31 8 mm to 41 4 mm 08 0377A 48 0965A 48 0965A 48 0965A 08 0376A 48 0966A 48 0964A ...

Page 22: ...ID Ramp and Block Combination 3 480 to 3 940 88 4 mm to 100 1 mm 3 870 to 4 330 98 3 mm to 110 0 mm 3 090 to 3 550 78 5 mm to 90 2 mm Steel Jaw Blocks and Ramp profiles for the Standard Mandrel 08 0378A 48 0965A 48 0965A 08 0379A 08 0380A 48 0965A ...

Page 23: ...4 mm Butt Plate Spring and Ramp for Mandrel Assembly P N 06 0413 24 1464 40 0136 48 0597 Ramp P N Butt Plate P N Spring P N 48 0596 24 1463 40 0130 ID Mounting Range 1 000 to 1 250 25 4 mm to 31 8 mm Butt Plate Spring and Ramp for Mandrel Assembly P N 06 0414 Ramp P N Butt Plate P N Spring P N 48 0976 24 1462 40 0108 ...

Page 24: ...ess Tool Bit P N 1 25 ID thru 2 63 OD 31 8 mm ID thru 66 8 mm OD CS SS BOILERMASTER1 531 13 5 mm 2 63 DIA Head Kit 4 00 DIA Head Kit ID Pipe Max Beveling Mounting or Tube Wall 37 5 Degree Range Material Thickness Tool Bit P N 1 25 ID thru 4 50 OD 31 8 mm ID thru 114 3 mm OD CS SS BOILERMASTER1 531 13 5 mm Tool Bit Beveling ...

Page 25: ...r Tube Wall Tool Bit Range Material Thickness P N 1 25 ID thru 2 63 OD 31 8 mm ID thru 66 8 mm OD CS SS 99 5243 531 13 5 mm ID Pipe Max Facing Mounting or Tube Wall Tool Bit Range Material Thickness P N 1 25 ID thru 4 50 OD 31 8 mm ID thru 114 3 mm OD CS SS 99 5243 531 13 5 mm Tool Bit Facing Land Heavy Duty ...

Page 26: ...3 ID thru3 92 ID 46 5 mm ID thru 99 6 mm ID 99 0257 99 2095 CS SS BOILERMASTER1 CS SS BOILERMASTER1 531 13 5 mm 531 13 5 mm ID Pipe Max Beveling Facing Mounting or Tube Wall 37 5 Degree Tool Bit Range Material Thickness Tool Bit P N P N 1 25 ID thru1 90 ID 31 8 mm ID thru48 3 mm ID 1 83 ID thru2 57 ID 46 5 mm ID thru65 3 mm ID 99 0257 99 2095 CS SS BOILERMASTER1 CS SS BOILERMASTER1 531 13 5 mm 531...

Page 27: ...is required A dull Tool Bit is causing surface hardening conditions Stainless pipe or tubing There is scale or other foreign matter on the pipe or tube which is dulling the tool bit at the start of the cut The tool bit is incorrect for the material being cut Problem The surface finish is rough The tool bit is dull chipped etc Metal buildup on the cutting edge of the tool bit is creating a false cu...

Page 28: ...he hydraulic supply pressure is too low The hydraulic filter is plugged The hydraulic line size is insufficient The hydraulic line is too long Problem The tool bit will not reach the work Incorrect tool blocks are installed for the size of the pipe or tube being worked on Incorrect tool bit is installed Problem The hydraulic motor will not start The hydraulic power supply is shut off The hydraulic...

Page 29: ...SSORIES The following accessories are recommended for use with the BOILERMASTER and are available from TRI TOOL INC 1 Portable Air Filter P N 75 0115 A portable Air Caddy FRL is required to protect the warranty on all TRI TOOL INC air driven tools ...

Page 30: ... PARTS BREAKDOWN 1 19 0728A HOUSING MAIN 1 2 19 0729A HOUSING FEED 1 3 20 1025A SHAFT MAIN 1 4 27 0513A ADAPTER FEED 1 5 28 0248 O RING 1 6 29 0005 BEARING BALL 1 Parts List BOILERMASTER Sub Assembly P N 02 2215A Item Part No No Description Qty 1 10 3 5 7 8 9 11 14 18 16 27 28 31 10 9 A ...

Page 31: ... N 02 2215A 7 29 0326 BEARING BALL 1 8 29 0327 BEARING BALL 1 9 29 0328 BEARING TAPER CONE 2 10 29 0329 BEARING TAPER CUP 2 11 29 0345 BEARING BALL 1 12 30 0309 RING RETAINING EXTERNAL 1 13 30 0411 RING RETAINING EXTERNAL 1 14 30 2358 RING RETAINING INTERNAL 1 15 30 2359 SHIM 1 16 31 0103 KEY SQUARE ROUND ENDS 1 2 4 6 12 13 15 19 17 21 22 23 24 25 26 29 A 20 30 ...

Page 32: ...25 4 22 34 0236 WASHER THRUST 1 23 34 0310 WASHER LOCK 1 24 35 0443 NUT LOCK 1 25 35 0444A NUT FEED 1 26 36 0213A WRENCH RATCHET 1 27 39 0754A GEAR BEVEL PINION 1 28 39 0755A GEAR BEVEL 1 29 40 0227 SPRING WAVE 1 30 45 0248A BUSHING FEED ADAPTER 1 31 54 0375 FITTING GREASE 1 NOT SHOWN 36 0004 WRENCH L 7 64 HEX 1 36 0006 WRENCH L 9 64 HEX 1 36 0007 WRENCH L 5 32 HEX 1 36 0010 WRENCH L 1 4 HEX 1 36 ...

Page 33: ...ig 040921 MOTOR ASSEMBLY AIR P N 57 0224 1 53 0046 VALVE FLOW CONTROL 1 2 54 0126 COUPLING MALE QD 1 3 54 0201 CAP YELLOW 1 4 57 0223 MOTOR INLINE AIR 1 Parts List Motor Assembly Air P N 57 0224 Item Part No No Description Qty 1 2 3 4 ...

Page 34: ...A HEAD 2 63 DIA 1 2 28 0249 SEAL OIL 1 3 33 0056 SCREW CAP 5 16 18 X 1 3 4 33 0500 SCREW SET 1 4 20 X 31 1 5 33 0504 SCREW SET 1 4 20 X 63 1 6 33 1958 SCREW WEDGE 2 7 48 0947A BLOCK WEDGE 2 Parts List Cutting Head Kit 2 63 DIA P N 03 0047A Item Part No No Description Qty 1 2 3 4 5 7 6 ...

Page 35: ...455A HEAD 4 0 DIA 1 2 28 0249 SEAL OIL 1 3 33 0056 SCREW CAP 5 16 18 X 1 3 4 33 0517 SCREW SET 5 16 18 X 63 2 5 33 0518 SCREW SET 5 16 18 X 75 1 6 33 1958 SCREW WEDGE 4 7 48 0947A BLOCK WEDGE 4 Parts List Cutting Head Kit 4 DIA P N 03 0048A Item Part No No Description Qty 1 2 3 4 5 7 6 ...

Page 36: ...REL 1 3 23 0295A ROD DRAW 1 4 24 1384A PLATE BUTT 1 5 30 2365 COLLAR SHAFT 1 6 30 2366 COLLAR SHAFT 1 7 30 2367 RING RETAINING EXTERNAL 1 8 33 0490 SCREW SET 10 24 X 38 CUP POINT 1 9 35 0445A NUT DRAW ROD 1 Parts List Mandrel Assembly P N 06 0415A Item Part No No Description Qty 1 10 2 3 4 5 7 6 8 9 11 12 ...

Page 37: ...2 1173 Orig 040921 Parts List Mandrel Assembly P N 06 0415A Item Part No No Description Qty 10 36 0214A WRENCH RATCHET 1 11 40 0001 SPRING EXTENSION 5 12 48 0964A BLOCK RAMP 1 3 48 0965A BLOCK RAMP 2 3 48 0966A BLOCK RAMP 3 3 ...

Page 38: ...3 0426 MANDREL 1 2 23 0297 ROD DRAW 1 3 24 1462 PLATE BUTT 1 4 33 0489 SCREW SET 10 24 X 31 1 5 40 0108 SPRING EXTENSION 1 6 48 0976 BLOCK RAMP 3 NOT SHOWN 35 0523 NUT DRAW ROD 3 8 16 1 Parts List Mandrel Assembly P N 06 0414 Item Part No No Description Qty 1 2 3 4 5 6 ...

Page 39: ...1 1 24 1464 PLATE BUTT 2 1 4 33 0477 SCREW SET 8 32 X 19 1 33 0478 SCREW SET 8 32 X 25 1 5 40 0130 SPRING FLAT 1 40 0136 SPRING FLAT 1 6 46 0437 SLEEVE MANDREL 1 7 48 0596 BLOCK RAMP 1 3 48 0597 BLOCK RAMP 2 3 NOT SHOWN 35 0523 NUT DRAW ROD 3 8 16 1 Parts List Mandrel Assembly P N 06 0413 Item Part No No Description Qty 1 2 3 4 5 7 6 ...

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