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TRI tool 202TS Operation Manual

Tube sheet cutter
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Summary of Contents for TRI tool 202TS

  • Page 1 Operation Manual...
  • Page 2 ABOUT TRI TOOL TECHNOLOGIES At Tri Tool, we are committed to your success through relentless innovation and powerful partnership. We insist on developing tools and equipment that exceed your expectations of performance, precision, safety, and durability. As a full-service engineering firm, we are here to support you every step of the way.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Tri Tool Inc. Warranty Tool Bit Resharpening Policy About The Manual Safety Precautions General Description Specifications 11 Maintenance Operation Cutting Speeds Ramp Set Tool Bits Troubleshooting Accessories Illustrated Parts Breakdown...

  • Page 4: Tri Tool Inc. Warranty

    TRI TOOL INC. TRI TOOL INC. Warranty LIMITED WARRANTY: All products manufactured by Seller are warranted to be free from defects in materials and workmanship under normal use. The period of this warranty shall be three years from the date of shipment for all products, except for welding and Non-Stan- dard Products which shall be one year from the date of shipment.

  • Page 5: Tool Bit Resharpening Policy

    Model 202TS Tube Sheet Cutter warranty period. No warranty claims submitted after this fifteen (15) day calendar period will be considered by Seller. Buyer’s notice of a defective Goods must identify the specific Goods affected, and the nature of the defect. It is required when returning the defective Goods, that it is suitably packed, fully insured, and transportation and insurance prepaid in accordance with in- structions issued by Seller.

  • Page 6: About The Manual

    The instructions and descriptions in this manual were accurate when the manual was writ- ten. However, the information in the manual is subject to change without notice. Check for updated information before you start any job. The Tri Tool Inc. web site has the most cur- rent information.
  • Page 7 Model 202TS Tube Sheet Cutter SAFETY GLASSES: Indicates a hazardous situation that requires the use of safety glasses. GLASSES HOT SURFACE: Indicates a hazardous situation that hot surfaces may be present. HOT SURFACE GLOVES: Indicates a hazardous situation that requires glasses.

  • Page 8: Safety Precautions

    TRI TOOL INC. 2. SAFETY PRECAUTIONS In General Use standard safety equipment such as: hard hats, safety shoes, safety harnesses, protec- tive clothes, and other safety devices when appropriate. Operate this tool only in accordance with specific operating instructions. WARNING: Do not override the dead-man switch on the power unit. Locking down, obstructing, or in any way defeating the dead-man switch on the power drive unit may result in serious injury.
  • Page 9 Before you start operating the equipment, do no-load tests and feed function checks. Tool Use Use the right tool and tool bit for the job. Contact Tri Tool to help with your application. Keep the tool bits fully engaged in the tool bit holders. Loose bits are sharp and can cause cuts or punctures.

  • Page 10: General Description

    TRI TOOL INC. 3. GENERAL DESCRIPTION The Model 202TS™ Tube Sheet Cutter is an ID Mount Machine tool for facing and chamfering the ends of tubing and tube sheet bores in preparation for welding and finish squaring. Design and Operation Features: 1. The lathe accepts it’s own torque through the mandrel.

  • Page 11: Specifications

    Model 202TS Tube Sheet Cutter 4. SPECIFICATIONS Clearance and Dimensions 4.00” (101.6mm) 10.81” (274.6mm) 11.20” (284.5mm) 16.53” Figure 1: Envelope Drawing (419.9mm) IN GENERAL: The Tube Sheet Cutter has been designed for quick and easy repetition cutting of a tube sheet.
  • Page 12 TRI TOOL INC. Pipe range: Maximum O.D. of 2.00” (50.8mm) and Minimum I.D. of .77” (19.6mm) Optional Small Mandrel: Minimum ID of .50” (12.7mm) Maximum ID of .78” (19.8mm) 92-0771 Rev. 230306...

  • Page 13: Maintenance

    Bearings and gears are to be lubricated using “Chevron Ultra-Duty NLGI 2 Grease” or equivalent. Air Motor Lubrication: NOTE: Disassembly of a power unit voids warranty, except when performed by TRI TOOL Inc. designated repair technician. (Letter of designation is required). •...
  • Page 14 The air motor requires 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) • AMACO - American Industrial Oil No. 32 •...

  • Page 15: Operation

    Model 202TS Tube Sheet Cutter 7. OPERATION Standard Mandrel Installation and Removal Procedure (P/N 12-0127) INSTALLATION: Select the ramp block set for the size of the tube to be machined. Slide the mandrel into the tool until it bottoms out.
  • Page 16 TRI TOOL INC. 4. After the draw rod is loose and no longer threaded into the tool, pull the mandrel out of the tool. Optional Small Mandrel Installation and Removal Procedure (P/N 06- 0450) INSTALLATION: Slide the mandrel into the tool unit until it bottoms out.
  • Page 17 Select the tool bit(s) to do the required machining. Note: The use of dull tool bits or tool bits not manufactured by TRI TOOL Inc. may result in poor performance and may constitute abuse of this machine and therefore voids the TRI TOOL Inc.
  • Page 18 TRI TOOL INC. • Actuate the air valve to expand the mandrel ramp blocks out to contact the inside di- ameter of the tube. CAUTION: Make sure the lever on the air valve is thrown all of the way when the mandrel is expanded to prevent the air valve from releasing during the machining se- quence.

  • Page 19: Cutting Speeds

    Model 202TS Tube Sheet Cutter 8. CUTTING SPEEDS Outside 200 in/min 250 in/min 300 in/min (508 cm/min) (635 cm/min) (762 cm/min) 1.00” 25.4 mm 1.25” 31.8 mm 1.50” 38.1 mm 2.00” 50.8 mm Cutting Speed (Approximately) Use 200 surface inches per minute (508 surface centimeters per minute) for: Stainless steels in general when no coolant is allowed, all heavy-wall tube and some of the chrome/molybdenum steels.

  • Page 20: Ramp Set

    TRI TOOL INC. 8. RAMP SETS Mandrel Assembly Ramp Set P/N ID Range .77” to 1.00” 12-0127 08-0439 (19.6mm to 25.4mm) 1.00” to 1.23” 12-0127 08-0440 (25.4mm to 31.2mm) 1.22” to 1.48” 12-0127 08-0441 (31.0mm to 37.6mm) 1.45” to 1.72”...

  • Page 21: Tool Bits

    Model 202TS Tube Sheet Cutter 9. TOOL BITS Part No. Description Figure TOOL BIT, FACING, OUTSIDE 99-5533 1.50” ID (38.1MM) UP TO 2.00” OD (50.8MM) TOOL BIT, FACING, INSIDE 99-5534 .50” ID (12.7MM) UP TO 1.50” OD (38.1MM) 92-0771 Rev. 230306...

  • Page 22: Troubleshooting

    TRI TOOL INC. 11. TROUBLESHOOTING Problem: Tool Bit Chatters The tool bit is loose or overextended. 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 23 Model 202TS Tube Sheet Cutter Problem: Air Motor Will Not Start The air power supply is shut off. The air motor is damaged and will not run free.The air motor needs lubrication. Add lubrication and do not run the air motor for a few minutes, then try running the motor.

  • Page 24: Accessories

    • Mandrel Assembly, Small (P/N 06-0450) .500” ID to .780” ID (12.7mm to 19.8mm) • Portable Air Filter Caddy (P/N 75-0100) NOTE: A FRL is required to protect the warranty on all TRI TOOL Inc. Air Driven Tools. 92-0771 Rev. 230306...

  • Page 25: Illustrated Parts Breakdown

    Model 202TS Tube Sheet Cutter 15. ILLUSTRATED PARTS BREAKDOWN 202TS SUB ASSEMBLY (P/N 02-2298) 92-0771 Rev. 230306...
  • Page 26 TRI TOOL INC. Parts List, 202TS Sub Assembly (P/N 02-2298) Item Part No. Description 04-0112 DRIVE ASSY 16-0038 FEED ASSY 29-0311 BRG,,ROLLER, 5/16",X,1/2",X,7/16",LONG 30-2632 CYLINDER,AIR (SPECIAL) 33-0016 SCREW,CAP, #6 - 32 X 7/8 33-0028 SCREW,CAP,10-24 X 1/2 33-0225 SCREW,CAP,5/16-24 X 1-1/4...
  • Page 27 Model 202TS Tube Sheet Cutter DRIVE ASSEMBLY (P/N 04-0112) Drive Assembly ( P/N 04-0112) Parts List, Item Part Description 19-0848 HOUSING,MAIN 20-0725 SHAFT,MAIN 21-0529 HEAD,2 3/8"D 28-0265 SEAL,1.25"ID X 1.985"OD X .25" 28-0287 SEAL,OIL,3/4"IDX 1-1/8"OD X 3/16" 29-0005 BRG,BALL,1-9/16 X 2-5/16X 7/16...
  • Page 28 TRI TOOL INC. Drive Assembly ( P/N 04-0112) Parts List, Item Part Description 30-0578 WEDGE,TOOL BIT 31-0186 KEY,3/16 SQ X .500 SQ ENDS 31-0172 KEY,1/8"SQ X 1.500,RND ENDS 32-0272 PIN,DOWEL,3/16 DIA X 1-1/4 33-0013 SCREW,CAP,#6-32 X 1/2 33-0028 SCREW,CAP,10-24 X 1/2...
  • Page 29 Model 202TS Tube Sheet Cutter STANDARD MANDREL ASSEMBLY (P/N 12-0127) & RAMP SETS (P/N 08-0439 THROUGH 08-0443) Parts List, Drive Assembly ( P/N 04-0112) & Ramp Sets (P/N 08-0439 through 08-0443) Item Part Description 13-0447 MANDREL,STD 23-0325 DRAWROD,STD 92-0771 Rev. 230306...
  • Page 30 TRI TOOL INC. Item Part Description 08-0439 RAMP BLOCK SET , #1 48-1123 BLOCK,RAMP,#1 24-1544 PLATE,BUTT,#1 40-0130 SPRING,FLAT,1/4W,.500 X .004 33-0488 SCREW,SET,10-24 X 1/4 CUP PT Item Part Description 08-0440 RAMP BLOCK SET , #2 48-1124 BLOCK,RAMP,#2 24-1545 PLATE,BUTT,#2 40-0108...
  • Page 31 Model 202TS Tube Sheet Cutter SMALL MANDREL ASSEMBLY (P/N 06-0450) Small Mandrel Assembly (P/N 06-0450) Parts List, Item Part Description 13-0457 MANDREL,SMALL,202TS 23-0351 DRAWROD,SMALL 24-1741 BUTTPLATE,202TS SMALL MDRL 48-1269 BLOCK,RAMP,#1 .50” TO .65” (12.7MM TO 16.5MM) 48-1270 BLOCK,RAMP,#2 .65” TO .78” (16.5MM TO 19.8MM) 28-0269 "O-RING,.489""ID X .070""...
  • Page 32 TRI TOOL INC. FEED ASSEMBLY (P/N 16-0038) Parts List, Feed Assembly (P/N 16-0038) Item Part No. Description 19-0852 HOUSING,FEED 27-0592 ADAPTER,CYLINDER 30-2708 EYEBOLT,SHLDR,1/4-20 33-0033 SCREW,CAP,10-24 X 1-1/4 33-2045 SCREW,LOCKING,5/16-18UNC 33-2136 SETSCREW,LOCK,CONE PT,1/2-20 33-2137 SET SCREW,SS,1/2-20 X3/8,CUP PT 34-0353 WASHER,NYLON,.740"OD X .340"ID X 1/16"...
  • Page 33 Model 202TS Tube Sheet Cutter PNEUMATIC MOTOR ASSEMBLY (P/N 57-0239) 92-0771 Rev. 230306...
  • Page 34 TRI TOOL INC. Parts List, Motor Assembly, Pneumatic (P/N 57-0239) Item Part No. Description 20-0726 SHAFT,DRIVE 28-0274 O-RING,.862"ID X .103"W 31-0115 KEY,1/8"SQ X 15/16, BOTH ENDS ROUND 53-0045 VALVE,FLOW CONTROL,1/4"NPT 54-0149 COUPLING,MALE,QD,HOSE TO PIPE 57-0227 MOTOR,AIR,PISTOL GRIP 54-0394 FITTING,STREET TEE,1/4" P,BRASS 54-0353 FITTING,ELBOW,1/4"P - 1/4"TUBE...
  • Page 36 • Disconnect power sources before servicing or moving the equipment. • Remove all loose articles of clothing and jewelry before operating the equipment. Be Safety Conscious! 3041 Sunrise Blvd. Rancho Cordova, CA 95742 +1(916) 288-6100 • +1(800) 345-5015 www.tritool.com ©Copyright Tri Tool Inc. PN 81-0542 (04-21)

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