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Climax BG38LV Operating Manual

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BOILER
GUN
BG38 BOILER GUN
OPERATING MANUAL
ORIGINAL INSTRUCTIONS
BG38LV model shown
P/N 100242
September 2023
Revision 3

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Summary of Contents for Climax BG38LV

  • Page 1 BOILER BG38 BOILER GUN OPERATING MANUAL ORIGINAL INSTRUCTIONS BG38LV model shown P/N 100242 September 2023 Revision 3...
  • Page 3 CLIMAX. CLIMAX hereby grants permission to download a single copy of this manual and of any revision hereto onto an electronic storage medium to be viewed and to print one copy of this manual or any revision hereto, pro-...
  • Page 4 CLIMAX GLOBAL LOCATIONS Page B BG38 Boiler Gun Operating Manual...
  • Page 5 Climax will, at its option, either repair or replace the defective machine at no charge and will return the machine with shipping prepaid.
  • Page 6 This page intentionally left blank Page D BG38 Boiler Gun Operating Manual...

  • Page 7: Table Of Contents

    TABLE OF CONTENTS HAPTER ECTION 1 INTRODUCTION ............1 .
  • Page 8 TABLE OF CONTENTS (CONTINUED) HAPTER ECTION ............19 PPROVED LUBRICANTS .
  • Page 9 A-4 BG38 boiler gun high-velocity pneumatic assembly (P/N BG38HV-R) ......29 A-5 BG38 boiler gun low-velocity pneumatic assembly (P/N BG38LV-R) ......30 A-6 BG38E110-R boiler gun electric assembly (P/N 102987) .
  • Page 10 This page intentionally left blank Page iv BG38 Boiler Gun Operating Manual...
  • Page 11 LIST OF TABLES ABLE 1-1 Sound levels ..............3 1-2 Risk assessment checklist before set-up .
  • Page 12 This page intentionally left blank Page vi BG38 Boiler Gun Operating Manual...

  • Page 13: Introduction

    INTRODUCTION IN THIS CHAPTER: 1.1 H - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 OW TO USE THIS MANUAL 1.2 S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1...

  • Page 14: General Safety Precautions

    ENERAL SAFETY PRECAUTIONS H&S leads the way in promoting the safe use of portable cause severe impact, pinching, cutting, and machine tools. Safety is a joint effort. You, the end other injuries. Except for stationary operating user, must do your part by being aware of your work controls, avoid contact with moving parts by environment and closely following the operating proce- hands or tools during machine operation.

  • Page 15: Achine Specific Safety Precautions

    ACHINE SPECIFIC SAFETY PRECAUTIONS Eye hazard – This machine produces metal chips Sound level – This machine produces potentially during operation. Always wear eye protection harmful sound levels. Hearing protection is required when operating the machine. when operating this machine or working around it. During testing, the machine produced the sound Hazardous environments –...

  • Page 16: Risk Assessment And Hazard Mitigation

    ISK ASSESSMENT AND HAZARD MITIGATION Machine Tools are specifically designed to perform pre- To achieve the intended results and to promote safety, cise material-removal operations. the operator must understand and follow the design intent, set-up, and operation practices that are unique Stationary Machine Tools include lathes and milling to Portable Machine Tools valve testers.

  • Page 17: Risk Assessment Checklist

    ISK ASSESSMENT CHECKLIST The following checklist is not intended to be an all However, these checklists are typical of the types of inclusive list of things to watch out for when setting up risks the assembler and operator should consider. Use and operating this Portable Machine Tool.

  • Page 18: Labels

    ABELS 1.7.1 Label identification The following warning labels should be on your machine. If any are defaced or missing, contact H&S Tool immediately for replacements. 1-4. BG38 B ABLE OILER UN LABELS P/N 100206 BG38-HV label P/N 100199 P/N 100207 H&S company label BG38-LV label P/N 100251...

  • Page 19: Overview

    OVERVIEW IN THIS CHAPTER: 2.1 F - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 EATURES AND COMPONENTS 2.2 C - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8...

  • Page 20: Controls

    ONTROLS 2.2.2 Electric motor controls Depending on the users requirements, the BG38 Boiler Gun can be powered by either a pneumatic or electric The electric motor controls are similar to a drill or drill motor. The controls for each type of motor follow. driver.

  • Page 21: Dimensions

    IMENSIONS Figure 2-4 shows the machine and operating dimen- sions. 2-4. BG38 B IGURE OILER UN DIMENSIONS PECIFICATIONS 2-1. S ABLE COMPONENT MASS Component Mass in lbs (kg) BG38 BG38 Boiler Gun Pneumatic 17 (7.7) BG38E BG38 Boiler Gun Electric 14 (6.3) TEMS REQUIRED BUT NOT SUPPLIED The following items may be required but not supplied in...
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  • Page 23: Setup

    SETUP IN THIS CHAPTER: 3.1 R - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -11 ECEIPT AND INSPECTION 3.2 M - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -12...

  • Page 24: Machine Setup

    ACHINE ETUP 3-1. BG38 B IGURE OILER UN MAIN COMPONENTS Do the following to setup the BG38 Boiler Gun: 8. If installing wedge extensions, secure three of the same size range onto the base wedges with 3.2.1 Wedge locking system the screws.

  • Page 25: Tool Holders

    4. Slide a locking rod into the center shaft from 4. Tap into place until seated against the shoulder the rear of the machine. on the main gear. 5. Thread the required collet set on the end of the 5. Reinstall or tighten the set screw in the tool locking rod until the collets begin to engage the holder body until secure.

  • Page 26: Machine Mounting

    ACHINE MOUNTING Do the following to mount the BG38 Boiler Gun on the 2. Tighten the mounting system by turning the lock workpiece: rod clock-wise using either the rod wrench or the speed wheel. Once snug, verify that the 1. Insert the mounting system end of the BG38 mounting system position in the workpiece has Boiler Gun into the workpiece until there is been maintained.

  • Page 27: Installing The Cutting Tools

    NSTALLING THE CUTTING TOOLS While the BG38 Boiler Gun can be operated with one blade, smoother operation on harder materials or thicker pipe walls will result with the use of two blades. 3-7. S IGURE LIDING TOOL HOLDER AND FIXED TOOL HOLDER Do the following to install the cutting bit(s): 1.

  • Page 28: Motors

    OTORS 3.5.2 Electric motor The BG38 Boiler Gun is powered by either a pneumatic motor or an electric motor. The following subsections Do the following to prepare the electric motor for use explain how to set up each for operation. (See Section 2.2 for controls): 3.5.1 Pneumatic motor...

  • Page 29: Operation

    OPERATION IN THIS CHAPTER: 4.1 P - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -17 OPERATION CHECKS 4.2 O - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -17...

  • Page 30: Electric Motor

    a) Turn off the air supply at the source. Dis- Release the trigger to stop the machine. connect the air hose assembly from the machine. b) Turn the locking wrench to loosen the locking system from the workpiece. c) Slide the BG38 Boiler Gun straight out from the workpiece using the body of the machine to support it’s weight.

  • Page 31: Maintenance

    MAINTENANCE IN THIS CHAPTER: 5.1 M - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -19 AINTENANCE CHECKLIST 5.2 A - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -19...

  • Page 32: Maintenance Tasks

    CAUTION Avoid damage, premature machine wear, and protect your warranty by using only approved lubricants. 5-2. A ABLE PPROVED LUBRICANTS Biodegradable Lubri- Application Area Lubricant Viscosity (cSt) Quantity Frequency cant Light coating Threads of the cen- WD-40 or light- Daily during machine applied by ter shaft weight spray lube...

  • Page 33: Tool Holders

    5.3.4 Tool holders 2. Set the oiler valve to ‘3’ as a baseline for the flow rate. Do the following to service the tool holders: 3. Replace the cap. 1. Monitor and replace as necessary, the o-rings on 4. Mount and setup the machine (see Section 3.2- the ID of the tool holder.
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  • Page 35: Storage And Shipping

    STORAGE AND SHIPPING IN THIS CHAPTER: 6.1 S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -23 TORAGE 6.1.1 S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -23...

  • Page 36: Shipping

    HIPPING The BG38 Boiler Gun can be reshipped in its original shipping container, as shown in Figure 6-1. 6-1. BG22 IGURE SHIPPING CONTAINER ECOMMISSIONING To decommission the BG38 Boiler Gun prior to disposal, remove the drive motor and dispose of it separately from the rest of the machine components.

  • Page 37: Appendix Aassembly Drawings

    (P/N BG38HV-R) - - - - - - - - - -29 IGURE BOILER GUN HIGH VELOCITY PNEUMATIC ASSEMBLY A-5. BG38 (P/N BG38LV-R) - - - - - - - - - - -30 IGURE BOILER GUN LOW VELOCITY PNEUMATIC ASSEMBLY A-6. BG38E110-R...

  • Page 38: Igure A-1. Bg38 Boiler Gun Assembly (P/N 102985)

    PARTS LIST ITEM P/N: DESCRIPTION SEE CHART (NOT SHOWN) CHART TOOLKIT SEE CHART CHART MOUNTING SYSTEM SEE CHART CHART BG38 BOILER GUN SEE CHART CHART KIT TOOL HOLDER BG38 SEE CHART CHART KIT TOOL BITS BG38 A-1. BG38 (P/N 102985) IGURE BOILER GUN ASSEMBLY Page 26...

  • Page 39: Igure A-2. Bg38 Boiler Gun Chart (P/N 102985)

    A-2. BG38 (P/N 102985) IGURE BOILER GUN CHART P/N 100242, Rev. 2 Page 27...

  • Page 40: Igure A-3. Boiler Gun Base Unit Feed Wrench Assembly (P/N 99969)

    AS NEEDED PARTS LIST ITEM P/N: DESCRIPTION 911-0005 KEY 3/16 RADIUS ONE SIDE X 5/8 SQ BOTH ENDS 10534 RING SNAP 1 OD 10588 SCREW DRIVE #2 x 1/4 HOLE SIZE .089 23361 SCREW 10-24 X 3/8 BHSCS 26395 SCREW 10-24 X 5/8 FHSCS 35828 PLATE SERIAL YEAR MODEL CE 1.5 X 2.0 87271...

  • Page 41: Igure A-4. Bg38 Boiler Gun High - Velocity Pneumatic Assembly

    PARTS LIST ITEM P/N: DESCRIPTION 911-0011 KEY 3/16 RADIUS ONE SIDE X 3/4 SQ BOTH ENDS 11731 SCREW 5/16-18 X 1 SSSHDP 98855 SWIVEL DOUBLE AIR 1/2 NPTM X 1/2 NPTF 99969 NFIS BASE UNIT BG38 BOILER GUN TUBE BEVELER WRENCH FEED 100206 (NOT SHOWN) LABEL BG38HV METALLIC 100242...

  • Page 42: Igure A-5. Bg38 Boiler Gun Low - Velocity Pneumatic Assembly

    SWIVEL DOUBLE AIR 1/2 NPTM X 1/2 NPTF 99969 NFIS BASE UNIT BG38 BOILER GUN TUBE BEVELER WRENCH FEED 98723 (NOT SHOWN) ASSY TOOLKIT BG 100207 (NOT SHOWN) LABEL BG38LV METALLIC 100242 (NOT SHOWN) OPERATING MANUAL BG-38 100847 (NOT SHOWN) TAG H&S TOOL LOCKING B002531...

  • Page 43: Igure A-6. Bg38E110-Rboiler Gun Electric Assembly (P/N 102987)

    AVAILABLE CONFIGURATIONS PART NO. DESCRIPTION ITEM 12 MODEL BG38 BOILER GUN ELEC 110V BG38E110-R EB002615 0.75KW WRENCH FEED MODEL BG38 BOILER GUN ELEC 220V BG38E220-R EOD005504 0.75KW WRENCH FEED MODEL BG38 BOILER GUN CORDLESS BG38C110-R 103054 ELEC 120V 1HP WRENCH FEED MODEL BG38 BOILER GUN CORDLESS BG38C220-R 103055...

  • Page 44: Igure A-7. Bg38Cp Collet Kit Assembly (P/N 103077)

    PARTS LIST ITEM P/N: DESCRIPTION 921-1001 SNAP RING 11/16 ID X .042 TH 923-1001 COTTER PIN 3/32" X 1/2" B002520L LG COLLET CENTERSHAFT B002550L LONG B COLLET ROD BC58 ASSY B COLLET 5/8" 5 DEGREE BC34 ASSY B COLLET 3/4" 5 DEGREE BC78 ASSY B COLLET 7/8"...
  • Page 45 Item # Part name Part number Item # Part name Part number Wedge set B-01 (.625-.810”) 100216 Wedge extension B-14 (2.250-2.435”) 100229 Wedge set B-02 (.750-.935”) 100217 Wedge extension B-15 (2.375-2.560”) 100230 Wedge set B-03 (.875-1.060”) 100218 Wedge extension B-16 (2.500-2.685”) 100231 Wedge set B-04 (1.000-1.185”) 100219...

  • Page 46: Igure A-8. Bg38 Tool Holder Assembly (P/N 103081)

    P/N 98231 SCALE 1 : 1 P/N 103083 SCALE 1 : 1 A-8. BG38 (P/N 103081) IGURE TOOL HOLDER ASSEMBLY Page 34...

  • Page 47: Igure A-9. Bg38 Tool Holder Assembly Parts List (P/N 103081)

    P/N 103084 SCALE 1:1 PARTS LIST ITEM P/N: DESCRIPTION 103083 103084 98231 BG38THS 000875 BLADE LOCK 917-0001 SCREW DIFFERENTIAL XNS-48 20812 RING O 3/32 X 5/8 ID X 13/16 OD 77253 SCREW 5/16-18 X 1/2 SSSFP B002534 TOOLHOLDER SLIDING 2-5/8" 2-FLUTE B002536 TOOLHOLDER SLIDING 2-5/8"...

  • Page 48: Igure A-10. Wedge Mount System Kit (P/N 103081)

    PARTS LIST ITEM P/N: DESCRIPTION 11019 RING SNAP 5/8 OD X .035 THICK 100211 SPEED WHEEL, BG22-BG38 100215 WEDGE CENTER SHAFT 0.625 BG22-BG38 100216 SET WEDGE B-01 BG22 BG38 5/8" - 3/4" 100217 (NOT SHOWN) WEDGE SET B-02 BG22-BG38 3/4" - 7/8" 100218 (NOT SHOWN) WEDGE SET B-03 BG22-BG38 7/8"...
  • Page 49 P/N 100242, Rev. 2 Page 37...

  • Page 50: Igure A-11. Air Hose Assembly (P/N Hs50509)

    PARTS LIST ITEM P/N: DESCRIPTION 19297 FTG QUICK COUPLER 3/8B 1/2 NPTF FEMALE AIR 95056 LABEL ROUND 3/4" OIL FLUID 95087 LABEL ROUND 3/4" FILTER 2152030 ASSY HOSE 7094 1/2 ID X 1/2 NPTM X 1/2 NPTM X 72" HS50512 LUBRICATOR INLINE 1/2 NPTF X 1/2 NPTF HS50517 FTG NIPPLE CLOSE 1/2 NPTM SCH 40...

  • Page 51: Igure A-12. Tool Kit (P/N 100603)

    INSIDE OF CASE PARTS LIST ITEM P/N: DESCRIPTION 911-0005 KEY 3/16 RADIUS ONE SIDE X 5/8 SQ BOTH ENDS 921-1001 SNAP RING 11/16 ID X .042 TH 923-1001 COTTER PIN 3/32" X 1/2" 10534 RING SNAP 1 OD 11206 SCREW 5/16-18 X 5/16 SSSCP 19729 NUT 5/16-18 NYLON INSERT LOCKNUT 29377...
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  • Page 53: Appendix Bsds

    APPENDIX B Contact CLIMAX for the latest Safety Data Sheets. P/N 100242, Rev. 2 Page 41...
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