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TRI tool BEVELMASTER 208B Operation Manual

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Summary of Contents for TRI tool BEVELMASTER 208B

  • Page 1 Operation Manual...
  • Page 2 ABOUT TRI TOOL TECHNOLOGIES At Tri Tool Technologies, 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 TRI TOOL TECHNOLOGIES WARRANTY TOOL BIT RESHARPENING POLICY ABOUT THE MANUAL SAFETY PRECAUTIONS GENERAL DESCRIPTION SPECIFICATIONS MAINTENANCE OPERATION MACHINING OPERATION CUTTING SPEEDS AND FEEDS JAW BLOCKS AND RAMPS SUREFIRE 8 PAD KITS TOOL BITS TROUBLESHOOTING ACCESSORIES ILLUSTRATED PARTS BREAKDOWN...
  • Page 4 Tri Tool Technologies Tri Tool Technologies 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- Standard Products which shall be one year from the date of shipment.
  • Page 5 Model 208B BEVELMASTER™ 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 instructions issued by Seller.
  • Page 6 The instructions and descriptions in this manual were accurate when the manual was written. However, the information in the manual is subject to change without notice. Check for updated information before you start any job. The Tri Tool Technologies web site has the most current information.
  • Page 7 Appropriate PPE and tools required when working on this equipment. SHOCK HAZARD READ MANUAL: Read manual before use, refer to manual for Tri Tool Technologies machine being used. READ MANUAL DISCONNECT FROM POWER: Disconnect main plug from electrical outlet before performing all maintenance.
  • Page 8 Tri Tool Technologies 2. SAFETY PRECAUTIONS In General Use standard safety equipment such as: hard hats, safety shoes, safety harnesses, protective clothes, and other safety devices when appropriate. Operate this tool only in accordance with specific operating instructions. WARNING: Do not override the deadman switch on the power unit.
  • 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 Technologies 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 Tri Tool Technologies 3. GENERAL DESCRIPTION The Model 208B BEVELMASTER™ is a Pipe Beveler designed for facing, beveling and/or counterboring the ends of pipe and/or tubing in preparation for welding. These machining operations may be performed either simultaneously or separately.
  • Page 11 Model 208B BEVELMASTER™ 4. SPECIFICATIONS BEVELMASTER™ with Air Motor Attached 17.95” (456.0mm) 8.77” (222.8mm) 10.13” (257.3mm) (3 ea) Bolt-On Tool Bit Holder 28.13” 9.16” (232.7mm) (714.5mm) Rotating DIA Feed Control 23.07” (586.0mm) ON/OFF Control w/ Safety Lever Air Flow (Speed) Control Valve Weight (Approx.) 57 lbs.
  • Page 12 Inconel and some other high-temperature alloys may require special procedures as a function of wall thickness and type of end preparation. Contact the Tri Tool Technologies Engineering Department for details.
  • Page 13 Model 208B BEVELMASTER™ Speed Control On/Off safety lever valve and twist-type air flow control valve. Feeds Manual Feed handle is in line at the back of the machine. Feed Rate .083” (2.1 mm) per revolution of the Feed Handle. Maximum Feed Travel 2.00”...
  • Page 14 Tri Tool Technologies BEVELMASTER™ with Electric HD (Heavy Duty) Motor Attached 9.25” (235.0mm) 17.95” 10.13” (456.0mm) (257.3mm) 9.46” (240.3mm) 24.64” (625.9mm) 9.16” DIA (232.7mm) Weight (Approx.) 63 lbs (28.6 kg) Clearance and Dimensions Maximum Rotating Head DIA 9.16” (232.7 mm) Length (parallel to axis of pipe) 17.95”...
  • Page 15 Inconel and some other high-temperature alloys may require special procedures as a function of wall thickness and type of end preparation. Contact the Tri Tool Technologies Engineering Department for details.
  • Page 16 Tri Tool Technologies Cutting Speeds Maximum Head Speed 28 RPM Functional Head Range 12-28 RPM RPM @ 300 in/min (7620 mm/min) • 8.63” (219.2mm)/11 RPM • 1.69” (42.9mm)/56 RPM Speed Control On/Off trigger and variable speed dial. Feeds Manual feed handle is in line at the back of the machine.
  • Page 17 Model 208B BEVELMASTER™ Model 208B BEVELMASTER™ with Hydraulic Motor Attached 17.95” (456.0mm) 9.16” (232.7mm) Rotating DIA 9.46” (240.3mm) 18.14” (460.8mm) 13.58” (344.9mm) Weight (Approx.) 75 lbs. (34.0 kg) Clearance and Dimensions Maximum Rotating Head DIA 9.16” (232.7 mm) Length (parallel to axis of pipe) 17.95”...
  • Page 18 Inconel and some other high-temperature alloys may require special procedures as a function of wall thickness and type of end preparation. Contact the Tri Tool Technologies Engineering Department for details.
  • Page 19 • Free Speed 550 RPM Power Requirements Requires separate hydraulic power supply. Refer to the Tri Tool Technologies Model 765RVC. Flow 3 gpm (.19 L/s) - 15 gpm (.94 L/s) @ 1500 PSI (10.342 kPa) 15 gpm (.94 L/s) - 20 gpm (1.265 L/s) @ 1000 PSI (6895 kPa)
  • Page 20 Verify that there is adequate grease in the gear box. Lubricate bearing and gears with a high string utility grease (P/N 68-0024). Disassembly of a power unit voids the warranty, except when performed by a Tri Tool Technologies designated repair technician (a letter of designation is required).
  • Page 21 Model 208B BEVELMASTER™ Check Lubrication Figure 2: Locations That Need Grease Air Motor Lubrication No maintenance is usually required on the air motor. However, 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.
  • Page 22 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 •...
  • Page 23 Always read the operating instructions before you operate the Model 208B BEVELMASTER™. A FRL (Filter/Regulator/Lubricator) is required to protect the warranty on all Tri Tool Technologies air or hydraulic driven tools. The motor warranty is void if damage occurs from contaminated air or lack of lubrication.
  • Page 24 4. Select the tool bit(s) required to machine the pipe to the configuration desired. Use of dull or improperly designed tool bits or tool bits not manufactured by Tri Tool Technologies may result in poor performance and may constitute abuse of this machine and therefore voids the Tri Tool Technologies factory warranty.
  • Page 25 Model 208B BEVELMASTER™ Tool Bit Installation 1. Adjust the counterbore tool bit radially to control counterbore diameter. 2. Adjust the bevel tool bit radially to control the counterbore depth to the bevel relationship. 3. Slide the Model 208B gently onto the Mandrel Assembly until it comes to a solid stop against the torque acceptance keys.
  • Page 26 Tri Tool Technologies Cutting Edge, Tool Bit, Beveling Headstock Cutting Edge, Tool Bit, Counterbore (Deburring) Rotation Cutting Edge, Tool Bit, Facing (Land) Figure 5: Engaging the Torque Acceptance Keys Adjustment of the Torque Acceptance Keys 1. Adjusting the torque acceptance keys is required if the Model 208B BEVELMASTER™...
  • Page 27 Model 208B BEVELMASTER™ Feed Housing Mandrel Shaft Set Screw Cap Screw Torque Acceptance Key Figure 6: Adjusting the Torque Acceptance Keys 8. Verify that there is a clearance of 1/8” (3mm) minimum between the tool bit and the pipe face. 92-1482 Rev.
  • Page 28 Tri Tool Technologies 1/8” (3mm) Clearance Tool Bit Draw Nut Pipe Mandrel Clearance Feed Handle Figure 7: Clearance Between the Tool Bit and Pipe Face 9. Make sure that there is a clearance between the tool bit(s) and the mandrel.
  • Page 29 Model 208B BEVELMASTER™ 7. MACHINING OPERATION WARNING: Do not override the deadman switch on the power unit. Locking down, obstructing, or in any way defeating the deadman switch on the power drive unit may result in serious injury. WARNING Deadman Switch Flow Control Valve Figure 8: Deadman Switch...
  • Page 30 Tri Tool Technologies Timing Mark Feed Handle Graduation Marks Figure 9: Feed Handle 9. Discontinue feed and allow the head to rotate one to three revolutions to improve the finish of the prep surface. 10. Release the trigger to stop the head rotation.
  • Page 31 Model 208B BEVELMASTER™ 8. CUTTING SPEEDS AND FEEDS RPM for RPM for RPM for Tube Size 200 in/min 250 in/min 300 in/min (5080 mm/min) (6350 mm/min) (7620 mm/min) 1.50” (38.1mm) 2.00” (50.8mm) 2.50” (63.5mm) 3.00” (76.2mm) 3.50” (88.9mm) 4.00” (101.6mm) 4.50”...
  • Page 32 Tri Tool Technologies Feed Recommendations Use very light feed for initial beveling or until a continuous cut is established. NOTE: This is very important for longer tool bit life when cutting through flame cut or out of square pipe ends.
  • Page 33 Model 208B BEVELMASTER™ 9. JAW BLOCKS AND RAMPS Jaw Block Assembly Standard ID Ramp Sets Block Assembly ID Ramp Set Block P/N Mounting Range Adapter P/N Standard* 1.50” to 1.65” ID (48-1202) (38.1mm to 41.9mm) Standard 1.63” to 2.18” ID (48-0474) (41.4mm to 55.4mm) Standard...
  • Page 34 Tri Tool Technologies Extended ID Ramp Sets Block Assembly ID Ramp Set Block P/N Mounting Range Adapter P/N Extended 3.98" to 4.55" ID (48-0475) (101.1mm to 115.6mm ID) Extended 4.47" to 5.05" ID 08-0162 (48-0475) (113.5mm to 128.3mm ID) Extended 4.95"...
  • Page 35 Model 208B BEVELMASTER™ 10. SUREFIRE 8 PAD KITS 3" PIPE 4"- 8" PIPE SUREFIRE Pad Assembly Pipe ID SUREFIRE Kit P/N 3” SCH 5S 05-1618 3” SCH 10S 05-1619 4” SCH 5S 05-1620 4” SCH 10S 05-1621 5” SCH 5S 05-1622 5”...
  • Page 36 Tri Tool Technologies Full Support Pad Kit Mandrel Assembly Ramp Pad Assembly 05-1618 and 05-1619 Mounting Instructions for SUREFIRE Pad Kits 05-1618 and 05-1619 For Pad Assembly sets 05-1618 and 05-1619, mount the pad directly to the Ramp and secure with its designated screw.
  • Page 37 Model 208B BEVELMASTER™ Full Support Pad Kit Mandrel Assembly Ramp Pad Assembly 05-1620 through 05-1627 Mounting Instructions for SUREFIRE Pad Kits 05-1620 through 05-1627 Expand the SUREFIRE Pad Kit by stretching the springs until it can fit around the Mandrel and each Support Pad is sitting on top of a Ramp. Secure the Pad Assembly to the Ramp block with its designated screw that is retained inside the assembly.
  • Page 38 Tri Tool Technologies 11. TOOL BITS Tool Bit, Beveling Model 208 Tool Bit, Beveling BEVELMASTER™ Pipe Cutting Edge 92-1482 Rev. 241023...
  • Page 39 Model 208B BEVELMASTER™ 37.5° Beveling Tool Bit Pipe or Tube 37.5° Beveling Facing Tool Bit ID Range Material Tool Bit P/N 2.223” thru 7.160” DURABIT® 5 DURABIT® 4 (56.5mm thru 181.9mm) 2.203” thru 7.160” 99-2918 99-2917 (56.0mm thru 181.9mm) 2.750” thru 8.060” DURABIT®...
  • Page 40 Tri Tool Technologies Tool Bit, Facing (Land) Tool Bit, Facing (Land) Model 208 BEVELMASTER™ Pipe Cutting Edge Facing (Land) Tool Bit Pipe or Tube Facing (Land) OD Range Material Tool Bit P/N 1.625" thru 8.630" (41.3mm thru 219.2mm) 99-0135 1.625" thru 8.630" (41.3mm thru 219.2mm) DURABIT®...
  • Page 41 Model 208B BEVELMASTER™ Tool Bit, Counterbore Tool Bit, Counterbore Model 208 BEVELMASTER™ Cutting Edge Pipe Counterbore Tool Bit Pipe or 14.5° (4:1) Counterbore ID Range Tube 1/2" (12.7mm) Facing Tool Bit P/N Material Deep Tool Bit P/N 2.141” thru 7.220” 99-2907 DURABIT®...
  • Page 42 Tri Tool Technologies Tool Bit, ID Chamfer Tool Bit, ID Chamfer Model 208 BEVELMASTER™ Cutting Edge Pipe Chamfer Tool Bit Pipe or 10° ID Chamfer Facing ID Range Tube Tool Bit P/N Tool Bit P/N Material 2.000” thru 7.035” 99-2910 DURABIT®...
  • Page 43 Model 208B BEVELMASTER™ Tool Bit, J-Bevel Tool Bit, J-Bevel Model 208 BEVELMASTER™ Cutting Edge Pipe J-Bevel Tool Bit Pipe or 25° J-Bevel Facing ID Range Tube Tool Bit P/N Tool Bit P/N Material 1.625” thru 6.410” 99-2915 DURABIT® 4 (41.3mm thru 162.8mm) 1.625"...
  • Page 44 Tri Tool Technologies 12. 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 45 Model 208B BEVELMASTER™ Problem: 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: Loss Of Hydraulic Power The hydraulic supply pressure is too low. The hydraulic filter is plugged.
  • Page 46 Lathe Stand (P/N 60-0111) • Kit, SUREFIRE 8 Pads (P/N 05-1618 - 05-1627) Spare parts and standard tool bits are available from stock. CAUTION: A (FRL) is required to protect the warranty on all Tri Tool Technologies air-driven tools. CAUTION 92-1482 Rev. 241023...
  • Page 47 Model 208B BEVELMASTER™ 14. ILLUSTRATED PARTS BREAKDOWN MODEL 208B BEVELMASTER® (P/N 01-1133) Parts List, Model 208B BEVELMASTER® (P/N 01-1133) Item Part Description 02-2487 208B BEVELMASTER SUB-ASSEMBLY 06-0499 MANDREL ASSEMBLY 49-0872 HOLDER ASSEMBLY, TOOL 57-0168 MOTOR ASSEMBLY, AIR, INLINE, 310 RPM NOT SHOWN 05-1256 SHIPPING KIT...
  • Page 48 Tri Tool Technologies MODEL 208B SUB-ASSEMBLY (P/N 02-2487) 92-1482 Rev. 241023...
  • Page 49 Model 208B BEVELMASTER™ Parts List, Model 208B Sub-Assembly (P/N 02-2487) Item Part Description 19-0411 HOUSING, FEED 19-1228 HOUSING, MAIN 20-1216 SHAFT, MAIN 24-0726 PLATE, FEED 24-3495 PLATE, HANDLE 24-0831 PLATE, SEAL 28-0172 SEAL, SHAFT, 2 1/4" X 1 1/2" X 1/8" 28-0176 SEAL, EXTRUDED, 3/16"...
  • Page 50 Tri Tool Technologies Parts List, Model 208B Sub-Assembly (P/N 02-2487) continued Item Part Description 34-0567 WASHER, LOCK, 2 3/4" 34-0568 SHIM, BEARING, .007" 35-0269 NUT, FEED, 206B 35-0849 NUT, LOCK, MOD. 39-1070 GEAR, SET, MOD. 41-0076 HANDLE, FEED 41-0211 HANDLE 42-0017 KNOB, SPHERICAL, 1-3/8"...
  • Page 51 Model 208B BEVELMASTER™ MANDREL ASSEMBLY (P/N 06-0499) Parts List, Mandrel Assembly (P/N 06-0499) Item Part Description 08-0162 BLOCK ASSEMBLY, JAW, AL, .340" (8.6MM) 08-0163 BLOCK ASSEMBLY, JAW, AL, .580" (14.7MM) 08-0164 BLOCK ASSEMBLY, JAW, AL, .820" (20.8MM) 08-0165 BLOCK ASSEMBLY, JAW, AL, 1.060" (26.9MM) 08-1029 BLOCK ASSEMBLY, ADAPTER 11-0139...
  • Page 52 Tri Tool Technologies MANDREL ASSEMBLY, 2” SCH XX (P/N 06-0580) Parts List, Mandrel Assembly, 2” Sch XX (P/N 06-0580) Item Part Description 11-0167 ROD ASSEMBLY, DRAW, MOD. 13-0616 MANDREL, MODIFIED, 2" - XX PIPE 24-1673 PLATE, BUTT, 2"XX 33-1527 SCREW, SET, 1/4-20 X 1/4”, HDOG...
  • Page 53 Model 208B BEVELMASTER™ TOOL HOLDER ASSEMBLY (P/N 49-0872) Parts List, Tool Holder Assembly (P/N 49-0872) Item Part Description 33-0039 SCREW, CAP, 1/4-20 X 5/8" 33-0042 SCREW, CAP, 1/4-20 X 1" 33-0518 SCREW, SET, 5/16-18 X 3/4", CUP PT 49-0871 HOLDER, TOOL 92-1482 Rev.
  • Page 54 Tri Tool Technologies MOTOR ASSEMBLY, AIR, INLINE, 310 RPM (P/N 57-0168) Parts List, Motor Assembly, Air, Inline, 310 RPM (P/N 57-0168) Item Part Description 57-0161 AIR MOTOR, INLINE, 1/2" SQ, 310 RPM 53-0046 VALVE, FLOW CONTROL, 1/2" NPT 54-0126 COUPLING, MALE QD TO 1/2" EPIPE...
  • Page 55 Model 208B BEVELMASTER™ MOTOR ASSEMBLY, 110V, 220V, LOW RPM (P/N 58-0408, 58-0409) Parts List, Motor Assembly, 110V, 220V, Low RPM (P/N 58-0408, 58-0409) Item Part Description 27-0826 ADAPTER, DRIVE 30-3143 1/2" SQUARE DRIVE 33-0055 SCREW, CAP, 5/16-18 X 7/8" LG. 33-0057 SCREW, CAP, 5/16-18 X 1 1/4"...
  • Page 56 Tri Tool Technologies MOTOR ASSEMBLY, HYDRAULIC (P/N 56-0101) 92-1482 Rev. 241023...
  • Page 57 Model 208B BEVELMASTER™ Parts List, Motor Assembly, Hydraulic (P/N 56-0101) Item Part Description 27-0618 ADAPTER, DRIVE 27-0619 ADAPTER, HYDRAULIC MOTOR 32-0090 PIN, SHEAR 33-0061 SCREW, CAP, 5/16-18 X 2 1/4" 33-0107 SCREW, CAP, 1/2-13 X 1 1/2" 54-0002 ADAPTER 54-0333 COUPLER, QD, HYD, DRIPLESS, FEMALE 54-0334 COUPLER, QD, HYD, DRIPLESS, MALE...
  • Page 58 Tri Tool Technologies LATHE STAND ASSEMBLY, 208B (P/N 60-0111) Parts List, Lathe Stand Assembly, 208B (P/N 60-0111) Item Part Description 24-4260 PLATE, STAND, 208B 33-0039 SCREW, CAP, 1/4-20 X 5/8 33-0370 SCREW, FLAT, 5/16-18 X 1 34-0003 WASHER, FLAT, USS, 5/16" NOMINAL...
  • Page 59 Model 208B BEVELMASTER™ KIT, SUREFIRE 8 PAD (P/N 05-1618, 05-1619) Parts List, Kit, SUREFIRE 8 Pad (P/N 05-1618, 05-1619) Item Part Description 33-0027 SCREW, CAP, 10-24 X 3/8 34-0252 WASHER, NYLON, .370" OD X .192" ID 67-5765 PAD, FULL SUPPORT, SUREFIRE 8, 3" SCH 5S (05-1618) 67-5766 PAD, FULL SUPPORT, SUREFIRE 8, 3"...
  • Page 60 Tri Tool Technologies KIT, SUREFIRE 8 PAD (P/N 05-1620 - 05-1627) Parts List, Kit, SUREFIRE Pad, SUREFIRE 8 (P/N 05-1620 - 05-1623) Item Part Description 32-0293 PIN, DOWEL, 3/16 DIA X 7/8” 33-0030 SCREW, CAP, 10-24 X 3/4” 33-0031 SCREW, CAP, 10-24 X 7/8”...
  • Page 61 Model 208B BEVELMASTER™ Parts List, Kit, SUREFIRE Pad, SUREFIRE 8 (P/N 05-1624 & 05-1625) Item Part Description 32-0293 PIN, DOWEL, 3/16 DIA X 7/8” 33-0030 SCREW, CAP, 10-24 X 3/4” 33-0032 SCREW, CAP, 10-24 X 1 34-0252 WASHER, NYLON, .370" OD X .192" ID 40-0250 SPRING, EXT, 1/4"...
  • Page 62 • 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 Technologies. PN 81-0542 (04-21) ©...