TRI tool BOILERMASTER Manual
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TRI tool BOILERMASTER Manual

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CUSTOMER MESSAGE
JAW BLOCKS, RAMPS AND
TOOL BIT RESHARPENING POLICY
WARRANTY INFORMATION

TABLE OF CONTENTS

Inside Front Cover
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Inside Back Cover
Inside Back Cover

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Summary of Contents for TRI tool BOILERMASTER

  • Page 1: Table Of Contents

    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...
  • 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: Safety Precautions

    Model BOILERMASTER™ SAFETY PRECAUTIONS IN GENERAL When using rotating head cutting equipment, basic safety precautions should always be followed to reduce the risk of personal injury. Operate this tool only in accordance with specific operating instructions. Do not override the deadman switch on the power unit. Locking down, ob-...
  • Page 4 TRI TOOL INC. TOOL CARE Maintain tools with care. Keep tools in good operating condition. Sharp tool bits perform better and safer than dull tool bits. Well maintained tools function properly when needed. Check for damaged parts. If a tool has malfunctioned, been dropped or hit, it must be checked for damage.
  • Page 5 Model BOILERMASTER™ Disconnect power supply during setup and maintenance. Use all ‘Stop’ or Shut off’ features available when changing or adjusting tool bits, maintaining the tool, or when the tool is not in use. Remove adjusting keys and wrenches before applying power to the equipment.

  • Page 6: General Description

    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.

  • Page 7: Specifications

    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 and tubing with an ID range of 1.50” (38.1 mm) to 4.33”...
  • Page 8 TRI TOOL INC. Envelope Drawing MATERIAL CUTTING CAPABILITIES Mild steels, chrome steels (Rc 35 maximum), 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.
  • Page 9 Model BOILERMASTER™ Contact the TRI TOOL INC. engineering department for details. CUTTING HEAD SPEEDS Maximum Cutting Head Speed 162 rpm Cutting Head Speed at Maximum H.P. 82 rpm Functional Speed Range 20 to 100 rpm Rpm at 300 surface inches per minute (762 surface centimeters per minute) 4.50”...

  • Page 10: Maintenance

    Use a clean, non-detergent oil, preferably SAE 10 (90 SSU) or lighter or oil as specified for the air motor. Air Supply for the BOILERMASTER™ with an air motor requires an adequate filter/ regulator/lubricator (FRL) to be used. A maximum of 90 PSI (621 kPa) line pressure is recommended.
  • Page 11 2 to 5 seconds is flowing. If the BOILERMASTER™ is to be left idle for 24 hours or more after being run on ‘wet’ air, it is advisable to squirt oil directly into the air motor inlet and run the motor for 2 to 3 seconds.
  • Page 12 The air motor requires a Class 2 lubricant, viscosity of 100 to 200 SSU at 100° 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 –...

  • Page 13: Operation

    PREPARING THE BOILERMASTER™ Select the recommended jaw blocks for the pipe size to be machined. Gently slide the mandrel assembly into the BOILERMASTER™ 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™...
  • Page 14 TRI TOOL INC. The BOILERMASTER™ with the mandrel assembly installed may be mounted into the pipe or tube as one unit. In order to avoid cutting the ramps and/or jaw blocks during the machining NOTE: operation, the mandrel must be installed beyond the final end preparation location.
  • Page 15 Use of dull or improperly designed tool bits or tool bits not manufactured by WARNING: TRI TOOL INC. may result in poor performance and may constitute abuse of this machine and therefore voids the TRI TOOL INC. factory warranty. When performing any multiple machining operation such as facing and beveling, the facing tool bit should be installed as shown above.
  • Page 16 TRI TOOL INC. Depress the air motor trigger. Adjust the cutting speed by rotating the flow valve at the air connection. Reference the 'Cutting Speeds and Feeds' later in this manual. Rotate the feed handle clockwise to bring the tool bit(s) and pipe closer together.
  • Page 17 Rotate the feed handle counterclockwise until the tool bit to pipe clearance is 1/8” (3 mm). Loosen the draw nut on the mandrel to release the mandrel from the pipe. The mandrel assembly may be left in the BOILERMASTER™ and installed as a complete assembly. 92-1173 : Orig. 040921...

  • Page 18: Cutting Speeds And Feeds

    TRI TOOL INC. CUTTING SPEEDS AND FEEDS RPM for RPM for RPM for Nominal Pipe True DIA 200 in / min 250 in / min 300 in/ min Diameter (5080 mm / min) (6350 mm / min) (7620 mm / min) 1"...
  • Page 19 Model BOILERMASTER™ Stainless 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 TRI TOOL INC. JAW BLOCKS AND RAMP SETS Standard Jaw Block Block Mounting Ramp Assembly Height (3 Req'd) (3 Req'd) Range 1.250" to 1.630" 48-0964A (31.8 mm to 41.4 mm) 1.560" to 2.000" 48-0965A (39.6 mm to 50.8 mm) 1.930" to 2.390"...
  • Page 21 Model BOILERMASTER™ Mounting ID Ramp and Block Combination 1.250" to 1.630" (31.8 mm to 41.4 mm) 48-0964A 1.560" to 2.000" (39.6 mm to 50.8 mm) 48-0965A 1.930" to 2.390" (49.0 mm to 60.7 mm) 48-0966A 08-0376A 2.320" to 2.780" (58.9 mm to 70.6 mm)
  • Page 22 TRI TOOL INC. Mounting ID Ramp and Block Combination 08-0378A 3.090" to 3.550" (78.5 mm to 90.2 mm) 48-0965A 08-0379A 3.480" to 3.940" (88.4 mm to 100.1 mm) 48-0965A 08-0380A 3.870" to 4.330" (98.3 mm to 110.0 mm) 48-0965A Steel Jaw Blocks and Ramp profiles for the Standard Mandrel.
  • Page 23 Model BOILERMASTER™ Butt Spring Ramp Plate Mounting Range 1.000" to 1.250" 24-1462 40-0108 48-0976 (25.4 mm to 31.8 mm) Butt Plate, Spring and Ramp for Mandrel Assembly (P/N 06-0414) Butt Spring Ramp Plate Mounting Range .610" to .800" 24-1463 40-0130 48-0596 (15.5 mm to 20.3 mm)

  • Page 24: Tool Bits

    TRI TOOL INC. TOOL BITS Tool Bit, Beveling 2.63" DIA Head Kit Pipe Beveling Mounting or Tube Wall 37.5 Degree Range Material Thickness Tool Bit P/N 1.25" ID thru 2.63" OD .531" CS/SS BOILERMASTER1™ (13.5 mm) (31.8 mm ID thru 66.8 mm OD) 4.00"...
  • Page 25 Model BOILERMASTER™ Tool Bit, Facing (Land), Heavy Duty 2.63" DIA Head Kit Pipe Facing Mounting or Tube Wall Tool Bit Range Material Thickness 1.25" ID thru 2.63" OD .531" CS/SS 99-5243 (13.5 mm) (31.8 mm ID thru 66.8 mm OD) 4.00"...
  • Page 26 TRI TOOL INC. Tool Bit, Beveling and Facing 2.63" DIA Head Kit Pipe Beveling Facing Mounting or Tube Wall 37.5 Degree Tool Bit Range Material Thickness Tool Bit P/N 1.25" ID thru 1.90" ID .531" CS/SS BOILERMASTER1™ 99-0257 (13.5 mm) (31.8 mm ID thru 48.3 mm ID)

  • Page 27: Trouble Shooting

    Model BOILERMASTER™ TROUBLE SHOOTING Problem: The Tool Bit Chatters The tool bit is loose or over extended. The tool bit is damaged. The tool holder is too loose in the slides. The cutting speed is too fast. The clamping pads are loose on the pipe or tube.
  • Page 28 TRI TOOL INC. Problem: There is a loss of air power The air supply pressure is too low. The air filter is plugged. The air line size is insufficient. The air line is too long. Problem: There is a loss of hydraulic power The hydraulic supply pressure is too low.

  • Page 29: Accessories

    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. 92-1173 : Orig. 040921...

  • Page 30: Illustrated Parts Breakdown

    TRI TOOL INC. ILLUSTRATED PARTS BREAKDOWN BOILERMASTER™ SUB-ASSEMBLY (P/N 02-2215A) Parts List, BOILERMASTER™ Sub-Assembly (P/N 02-2215A) Item Part Description 19-0728A HOUSING, MAIN 19-0729A HOUSING, FEED 20-1025A SHAFT, MAIN 27-0513A ADAPTER, FEED 28-0248 O-RING 29-0005 BEARING, BALL 92-1173 : Orig. 040921...
  • Page 31 Model BOILERMASTER™ BOILERMASTER™ SUB-ASSEMBLY (P/N 02-2215A) Parts List, BOILERMASTER™ Sub-Assembly (P/N 02-2215A) Continued Item Part Description 29-0326 BEARING, BALL 29-0327 BEARING, BALL 29-0328 BEARING, TAPER, CONE 29-0329 BEARING, TAPER, CUP 29-0345 BEARING, BALL 30-0309 RING, RETAINING, EXTERNAL 30-0411 RING, RETAINING, EXTERNAL...
  • Page 32 TRI TOOL INC. Parts List, BOILERMASTER™ Sub-Assembly (P/N 02-2215A) Continued Item Part Description 31-0155 KEY, SQUARE, ROUND ENDS 32-0493 PIN, DOWEL, 1/8" DIA X .88" 32-0081 PIN, DOWEL, 3/16" DIA X .75" 33-0030 SCREW, CAP, #10-24 X .75" 33-0047 SCREW, CAP, 1/4-20 X 2.25"...
  • Page 33 Model BOILERMASTER™ MOTOR ASSEMBLY, AIR (P/N 57-0224) Parts List, Motor Assembly, Air (P/N 57-0224) Item Part Description 53-0046 VALVE, FLOW CONTROL 54-0126 COUPLING, MALE QD 54-0201 CAP, YELLOW 57-0223 MOTOR, INLINE AIR 92-1173 : Orig. 040921...
  • Page 34 TRI TOOL INC. CUTTING HEAD KIT, 2.63" DIA (P/N 03-0047A) Parts List, Cutting Head Kit, 2.63" DIA (P/N 03-0047A) Item Part Description 21-0454A HEAD, 2.63" DIA 28-0249 SEAL, OIL 33-0056 SCREW, CAP, 5/16-18 X 1" 33-0500 SCREW, SET, 1/4-20 X .31"...
  • Page 35 Model BOILERMASTER™ CUTTING HEAD KIT, 4" DIA (P/N 03-0048A) Parts List, Cutting Head Kit, 4" DIA (P/N 03-0048A) Item Part Description 21-0455A HEAD, 4.0" DIA 28-0249 SEAL,OIL 33-0056 SCREW, CAP, 5/16-18 X 1" 33-0517 SCREW, SET, 5/16-18 X .63" 33-0518 SCREW, SET, 5/16-18 X .75"...
  • Page 36 TRI TOOL INC. MANDREL ASSEMBLY (P/N 06-0415A) Parts List, Mandrel Assembly (P/N 06-0415A) Item Part Description 08-xxxx BLOCK, JAW 13-0424A MANDREL 23-0295A ROD, DRAW 24-1384A PLATE, BUTT 30-2365 COLLAR, SHAFT 30-2366 COLLAR, SHAFT 30-2367 RING, RETAINING, EXTERNAL 33-0490 SCREW, SET, #10-24 X .38", CUP POINT...
  • Page 37 Model BOILERMASTER™ Parts List, Mandrel Assembly (P/N 06-0415A) Item Part Description 36-0214A WRENCH, RATCHET 40-0001 SPRING, EXTENSION 48-0964A BLOCK, RAMP, #1 48-0965A BLOCK, RAMP, #2 48-0966A BLOCK, RAMP, #3 92-1173 : Orig. 040921...
  • Page 38 TRI TOOL INC. MANDREL ASSEMBLY (P/N 06-0414) Parts List, Mandrel Assembly (P/N 06-0414) Item Part Description 13-0426 MANDREL 23-0297 ROD, DRAW 24-1462 PLATE, BUTT 33-0489 SCREW, SET, #10-24 X .31" 40-0108 SPRING, EXTENSION 48-0976 BLOCK, RAMP NOT SHOWN 35-0523 NUT, DRAW ROD, 3/8-16...
  • Page 39 Model BOILERMASTER™ MANDREL ASSEMBLY (P/N 06-0413) Parts List, Mandrel Assembly (P/N 06-0413) Item Part Description 13-0429 MANDREL 23-0298 ROD, DRAW 24-1463 PLATE, BUTT #1 24-1464 PLATE, BUTT #2 33-0477 SCREW, SET, #8-32 X .19 33-0478 SCREW, SET, #8-32 X .25...

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