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TRI tool BEVELMASTER 204B Operation Manual

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  • 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

    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 RAMP SETS SUREFIRE 4 PAD KITS TOOL BITS TROUBLESHOOTING ACCESSORIES...

  • Page 4: Tri Tool Technologies Warranty

    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: Tool Bit Resharpening Policy

    Model 204B 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: About The Manual

    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: Safety Precautions

    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: Tool Care

    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: General Description

    Tri Tool Technologies 3. GENERAL DESCRIPTION The Model 204B BEVELMASTER™ is a Pipe Beveler designed for facing, beveling and/or counterboring the ends of pipe or tubing in preparation for welding. These machining operations may be performed either simultaneously or separately.

  • Page 11: Specifications

    Model 204B BEVELMASTER™ 4. SPECIFICATIONS MODEL 204B BEVELMASTER™ with AIR MOTOR Weight 18 lbs (8.1 kg) Power Requirements 55 cfm at 90 psi (26 L/s at 621 kPn) 16.42in 4.00in (417.1MM) (101.6MM) 8.97in (227.8MM) 7.18in (182.4MM) MANDREL CUTTING HEAD (TRAVEL 1.50in MAXIMUM) INLINE FEED ON/OFF SAFETY LEVER 19.88in...

  • Page 12: Clearance And Dimensions

    Inconel and 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: Power Supply

    Model 204B BEVELMASTER™ Power Supply Pneumatic motor requires 55 cfm (26 L/s) air supply at 90 psi (621 kPa) for maximum horsepower delivery. NOTE: Air Supply must have a Filter/Regulator/Lubricator (FRL) system to protect the warranty on the air motor. Cutting Head Speeds Maximum Cutting Head Speed 162 RPM...
  • Page 14 Tri Tool Technologies MODEL 204B BEVELMASTER™ with ELECTRIC MOTOR Weight 18 lbs (8.1 kg) Power Requirements 115 VAC, 28 to 60 Hz 9.6 amp 16.57in (420.88MM) 4.00in 8.79in (101.6MM) (223.27MM) 7.03in (178.56MM) MANDREL INLINE FEED 20.25in (514.35MM) CUTTING HEAD (TRAVEL 1.50in MAX)
  • Page 15 Inconel and some other high temperature alloys may require special procedures as a function of wall thickness and type of end preparations. Contact the Tri Tool Technologies Engineering Department for details.
  • Page 16 Tri Tool Technologies Clearance and Dimensions Rotating Head DIA. 4.00” (101.6mm) Length 8.97” (227.8mm) Length Over Motor 20.25” (514.35mm) Available Feed Travel 1.50” (38.1mm) Drive System Final Drive Gear Driven Electric Motor - 2 speed Ranges & 6:1 Gear Reduction...
  • Page 17 Model 204B BEVELMASTER™ MODEL 204DC with CORDLESS MOTOR Weight 25 lbs (11.3 kg) Power Requirements 204DC 110V 110 VAC, 50/60 Hz 204DC 220C 220 VAC, 50/60 Hz 4.00in [101.6MM] ROTATING DIA 16.39in [416.3MM] 8.83in [224.2MM] 7.03in [178.4MM] MANDREL 17.03in INLINE [432.5MM] FEED CUTTING HEAD...
  • Page 18 Inconel and some other high temperature alloys may require special procedures as a function of wall thickness and type of end preparations. Contact the Tri Tool Technologies Engineering Department for details.

  • Page 19: Maintenance

    Verify that there is adequate grease in the gear box. Gears and bearings are to be lubricated using a lithium-based grease. Disassembly of a power unit voids warranty, except when performed by a Tri Tool Technologies designated repair technician. A letter of designation is required.

  • Page 20: Air Motor Lubrication

    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 Technologies – Air Tool Lubricant (P/N 68-0022) • AMOCO – American Industrial Oil No. 32 •...

  • Page 21: Operation

    Model 204B BEVELMASTER™ 6. OPERATION Read the operating instructions carefully before attempting to operate the Model 204B BEVELMASTER™. Use eye protection at all times when operating the Model 204B BEVELMASTER™. Installation 1. Select the recommended Jaw Blocks for the pipe size to be machined. 2.
  • Page 22 Tri Tool Technologies Figure 4: Tool Installation NOTE: In order to avoid cutting the Ramps and/or Jaw Blocks during the machining operation, the Mandrel must be installed beyond the final preparation location. 6. Tighten the Draw Nut to force the Jaw Blocks out to the inside diameter of the pipe or tube.
  • Page 23 Model 204B BEVELMASTER™ WARNING: 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 the machine and therefore voids the Tri Tool Technologies factory warranty.

  • Page 24: Machining Operation

    Tri Tool Technologies 7. MACHINING OPERATION 1. Depress the Air Motor trigger. Adjust the cutting speed by rotating the flow valve at the air connection. 2. Rotate the Feed Handle clockwise to bring the Tool Bit(s) and pipe closer together.
  • Page 25 Model 204B BEVELMASTER™ WARNING: 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. WARNING 4. Discontinue feed and allow the head to rotate one (1) to three (3) revolutions to improve finish of the prep surface.

  • Page 26: Cutting Speeds And Feeds

    Tri Tool Technologies 8. CUTTING SPEEDS AND FEEDS RPM for RPM for RPM for Pipe True DIA 200 in/min 250 in/min 300 in/min Size (5080 mm/min) (6350 mm/min) (7620 mm/min) 1” 1.315” 33.4mm 2” 2.375” 60.3mm 3” 3.500” 88.9mm 3 1/2”...

  • Page 27: Jaw Blocks And Ramp Sets

    Model 204B BEVELMASTER™ 9. JAW BLOCKS AND RAMP SETS Steel Jaw Blocks and Ramps Used with Mandrel Assembly (P/N 06-0419) Standard Jaw Block ID Mounting Range Ramp Assembly Block Height (3 Req’d) (3 Req’d) 1.250” to 1.630” 48-0964 (31.8mm to 41.4mm) 1.560”...
  • Page 28 Tri Tool Technologies Steel Jaw Block and Ramp Profiles (Standard Mandrel) Mounting ID Ramp and Block Combination 1.250” to 1.630” (31.8 mm to 41.4mm) 1.560” to 2.000” (39.6 mm to 50.8mm) 1.930” to 2.390” (49.0 mm to 60.7mm) 2.320” to 2.780”...
  • Page 29 Model 204B BEVELMASTER™ Steel Jaw Block and Ramp Profiles (Standard Mandrel) Mounting ID Ramp and Block Combination 3.480” to 3.940” (88.4 mm to 100.1mm) 3.870” to 4.330” (98.3 mm to 110.0mm) 92-0699 Rev. 250204...
  • Page 30 Tri Tool Technologies Butt Plate, Spring and Ramp Used with Mandrel Assembly (P/N 06-0413) Butt Spring Ramp ID Mounting Range Plate .610” to .800” 24-1463 40-0130 48-0596 (15.5mm to 20.3mm) .800” to 1.000” 24-1464 40-0136 48-0597 (20.3mm to 25.4mm) Butt Plate, Spring and Ramp...

  • Page 31: Surefire 4 Pad Kits

    Model 204B BEVELMASTER™ 10. SUREFIRE 4 PAD KITS 2"-2 1/2" PIPE 3"- 4" PIPE Pipe ID SUREFIRE Kit P/N 2" SCH 5S 05-1610 2" SCH 10S 05-1611 2 1/2" SCH 5S 05-1612 2 1/2" SCH 10S 05-1613 3" SCH 5S 05-1614 3"...
  • Page 32 Tri Tool Technologies MANDREL PAD KIT ASSEMBLY RAMP BLOCK Pad Assembly 05-1610 through 05-1613 PAD KIT MANDREL ASSEMBLY RAMP BLOCK Pad Assembly 05-1614 through 05-1617 92-0699 Rev. 250204...

  • Page 33: Tool Bits

    Model 204B BEVELMASTER™ 11. TOOL BITS Tool Bit, 37.5° Beveling Pipe or Max. Wall 37.5° Beveling Range Tube Thickness Tool Bit P/N Material 1 1/4” ID thru 3” pipe .531” (13.5mm) Durabit 7 (31.8mm ID thru 88.9mm OD) 1 1/4” ID thru 3” pipe .531”...
  • Page 34 Tri Tool Technologies Tool Bit, Beveling and Facing 37.5° Pipe or Facing Max. Wall Beveling Range Tube Tool Bit Thickness Tool Bit Material 1 1/4” pipe – sch 10 thru 40 up to .531” (13.5mm) 99-0333 99-0257 2 1/2” pipe – all schs 1 1/4”...
  • Page 35 Model 204B BEVELMASTER™ Tool Bit, Facing (Land) Pipe or Max. Wall Facing Range Tube Thickness Tool Bit P/N Material 1 1/4” ID thru 4” pipe .531” (13.5mm) 99-0485 (31.8mm ID thru 114.3mm OD) 1 1/4” ID thru 4” pipe .531” (13.5mm) 99-0277 (31.8mm ID thru 114.3mm OD) 92-0699 Rev.
  • Page 36 Tri Tool Technologies Tool Bit, ID Chamfer Pipe or ID Chamfer Range Tube Tool Bit P/N Material 1.60” ID thru 2.66” ID 99-0168 (40.6mm thru 67.6mm) 1.60” ID thru 2.66” ID 99-3713 (40.6mm thru 67.6mm) 2.14” ID thru 3.32” ID 99-0833 (54.4mm thru 84.3mm)

  • Page 37: Troubleshooting

    Model 204B BEVELMASTER™ 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. Cutting fluid is required.
  • Page 38 Tri Tool Technologies 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.

  • Page 39: Accessories

    Kit, SUREFIRE 4 Pads (P/N 05-1610 - 05-1617) • Pipe Wrench, 12 In, Smooth Jaw, 2-5/8 (P/N 36-0755)** *Wrench is recommended for removal of pneumatic motor **A portable Air Caddy (FRL) is required to protect the warranty on all Tri Tool Technologies air-driven tools. 92-0699 Rev. 250204...

  • Page 40: Illustrated Parts Breakdown

    Tri Tool Technologies 14. ILLUSTRATED PARTS BREAKDOWN MODEL 204B BEVELMASTER™ SUB-ASSEMBLY (P/N 02-3173) 1 of 2 92-0699 Rev. 250204...
  • Page 41 Model 204B BEVELMASTER™ MODEL 204B BEVELMASTER™ SUB-ASSEMBLY (P/N 02-3173) 2 of 2 92-0699 Rev. 250204...
  • Page 42 Tri Tool Technologies Parts List, Model 204B BEVELMASTER™ Sub-Assembly (P/N 02-3173) Item Part Description 19-0729 HOUSING, FEED 19-1962 HOUSING, MAIN BLACK 20-1025 SHAFT, MAIN 27-1686 ADAPTER, FEED BLACK 28-0248 O-RING, 2-1/4” ID X 3/32” 29-0005 BRG, BALL, 1-9/16” X 2-5/16” X 7/16”...
  • Page 43 Model 204B BEVELMASTER™ Parts List, Model 204B BEVELMASTER™ Sub-Assembly (P/N 02-3173) continued Item Part Description NOT SHOWN 05-1327 WRENCH KIT, 204B 36-0004 WRENCH, L, 7/64" HEX 36-0006 WRENCH, L, 9/64" HEX 36-0007 WRENCH, L, 5/32" HEX 36-0010 WRENCH, L, 1/4" HEX 36-0018 WRENCH, T, 1/8"...
  • Page 44 Tri Tool Technologies 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 92-0699 Rev. 250204...
  • Page 45 Model 204B BEVELMASTER™ MOTOR ASSEMBLY, ELECTRIC, 110V, 220V (P/N 58-0133, 58-0147) Parts List, Motor Assembly, Electric, 110V, 220V (P/N 58-0133, 58-0147) Item Part Description 27-0357 ADAPTER, MOTOR 29-0182 BRG, BALL, 1/2” X 1-1/8” X 3/8” 30-0508 LABEL, “WARNING, DISCONNECT” 30-0961 LABEL, WARNING, SAFETY SWITCH 33-0039 SCREW, CAP, 1/4-20 X 5/8”...
  • Page 46 Tri Tool Technologies MOTOR ASSEMBLY, CORDLESS, 18V, METABO, 110V, 220V (P/N 58-0422, 58-0436) Parts List, Motor Assembly, Cordless, 18V, Metabo, 110V, 220V (P/N 58-0422, 58-0436) Item Part Description 27-1707 ADAPTER, MOTOR 29-0182 BRG, BALL, 1/2” X 1-1/8” X 3/8” 30-6136 LABEL, POWER DISCONNECT & SAFETY SWITCH 33-0055 SCREW, CAP, 5/16-18 X .88”...
  • Page 47 Model 204B BEVELMASTER™ CUTTING HEAD KIT, 4” DIA (P/N 03-0049) Parts List, Cutting Head Kit, 4” DIA (P/N 03-0049) Item Part Description 21-0475 HEAD, 4.0" DIA 28-0249 SEAL, OIL 33-0057 SCREW, CAP, 5/16-18 X 1 1/4" 33-0514 SCREW, SET, 5/16-18 X 3/8", CUP PT 33-0517 SCREW, SET, 5/16-18 X 5/8", CUP PT 33-0518...
  • Page 48 Tri Tool Technologies 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 3/16", CUP PT 33-0478 SCREW, SET, #8-32 X 1/4", CUP PT...
  • Page 49 Model 204B BEVELMASTER™ 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 5/16", CUP PT 35-0523 NUT, DRAW ROD, 3/8-16 40-0108 SPRING, EXTENSION 48-0976 BLOCK, RAMP 92-0699 Rev.
  • Page 50 Tri Tool Technologies MANDREL ASSEMBLY (P/N 06-0419) Parts List, Mandrel Assembly (P/N 06-0419) Item Part Description 08-XXXX BLOCK, JAW (SEE “JAW BLOCKS” SECTION) 13-0424 MANDREL 23-0295 ROD, DRAW 24-1384 PLATE, BUTT 33-0490 SCREW, SET, #10-24 X 3/8", CUP PT 35-0523...
  • Page 51 Model 204B BEVELMASTER™ KIT, SUREFIRE 4 PADS (P/N 05-1610 - 05-1613) Parts List, Kit, SUREFIRE 4 Pads (P/N 05-1610 & 05-1611) Item Part Description 33-5056 SCREW, ULTRA LOW, 10-24 X 1/2” 67-5757 PAD, FULL SUPPORT, SUREFIRE 4, 2” SCH 5S (05-1610) 67-5758 PAD, FULL SUPPORT, SUREFIRE 4, 2”...
  • Page 52 Tri Tool Technologies KIT, SUREFIRE 4 PADS (P/N 05-1614 & 05-1615) Parts List, Kit, SUREFIRE 4 Pads (P/N 05-1614 & 05-1615) Item Part Description 33-0027 SCREW, CAP, 10-24 X 3/8” 33-0029 SCREW, CAP, 10-24 X 5/8” 48-4686 BLOCK, EXTENSION, SUREFIRE 4 67-5761 PAD, FULL SUPPORT, SUREFIRE 4, 3”...
  • Page 53 Model 204B BEVELMASTER™ KIT, SUREFIRE 4 PADS (P/N 05-1616 & 05-1617) Parts List, Kit, SUREFIRE 4 Pads (P/N 05-1616 & 05-1617) Item Part Description 33-0027 SCREW, CAP, 10-24 X 3/8” 33-0029 SCREW, CAP, 10-24 X 5/8” 34-0252 WASHER, NYLON, .370” OD X .192” ID 48-4686 BLOCK, EXTENSION, SUREFIRE 4 67-5763...
  • Page 54 • 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) ©...

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250204

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