Climax H&S BOILER GUN BG22 Operating Manual

BOILER

GUN

BG22 BOILER GUN

OPERATING MANUAL

P/N 100241
August 2017
Revision 1

TABLE OF CONTENTS

CHAPTER/SECTION PAGE

INTRODUCTION 1

1.1 HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2 S

1.3 G

1.4 M

1.5 R

1.6 R

1.7 L

AFETY ALERTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

ENERAL SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

ACHINE-SPECIFIC SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

ISK ASSESSMENT AND HAZARD MITIGATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

ISK ASSESSMENT CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

ABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.7.1 Label identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.7.2 Label location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

OVERVIEW 9

2.1 FEATURES AND COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.2 C

2.3 D

2.4 S

2.5 I

ONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.2.1 Pneumatic motor controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.2.2 Electric motor controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.2.3 Cordless electric motor controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

IMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

PECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

TEMS REQUIRED BUT NOT SUPPLIED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

SETUP 13

3.1 RECEIPT AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.2 M

ACHINE SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.2.1 Wedge locking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.2.2 Collet locking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.2.3 Tool holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.2.4 Center shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.3 M

3.4 I

3.5 M

ACHINE MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

NSTALLING THE CUTTING TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

OTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.5.1 Pneumatic motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.5.2 Electric motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.5.3 Cordless electric motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

OPERATION 19

4.1 PRE-OPERATION CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.2 O

PERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.2.1 Pneumatic motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

P/N 100241, Rev. 1 Page i

TABLE OF CONTENTS (CONTINUED)

CHAPTER/SECTION PAGE

4.2.2 Electric motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

MAINTENANCE 21

5.1 MAINTENANCE CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

5.2 A

5.3 M

5.4 T

STORAGE AND SHIPPING 25

6.1 STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

6.2 S

6.3 D

PPROVED LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

AINTENANCE TASKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

5.3.1 Checking and filling the in-line oiler reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

5.3.2 Servicing the filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

5.3.3 Adjusting the oil flow rate of the in-line oiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

5.3.4 Tool holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5.3.5 Greasing the drive and pinion gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

ROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5.4.1 The machine isn’t turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5.4.2 The machine isn’t feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5.4.3 The machine is performing poorly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

6.1.1 Short-term storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

6.1.2 Long-term storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

HIPPING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

ECOMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

ASSEMBLY DRAWINGS 27

SDS 39

Page ii

LIST OF FIGURES

FIGURE PAGE

1-1 BG22 Boiler Gun, pneumatic label location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1-2 BG22 Boiler Gun, electric label location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2-1 BG22 and shipping container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2-2 Pneumatic motor throttle lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2-3 Direction and trigger controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2-4 Cordless motor controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2-5 BG22 Boiler Gun dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3-1 BG22 Boiler Gun main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3-2 Installed wedge set with extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3-3 Small wedge set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3-4 Installed collet set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3-5 Changing the center shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3-6 BG22 Boiler Gun installed in workpiece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3-7 Locking rod wrench with speed wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3-8 Sliding tool holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3-9 Cutting bit installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3-10 Universal coupler (top) and quick disconnect (bottom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3-11 Motor direction control set to forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4-1 Hand positioning during boiler gun operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4-2 BG22 with electric motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

5-1 In-line oiler sight glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

6-1 BG22 shipping container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

A-1 BG22 boiler gun pneumatic assembly (P/N BG22). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

A-2 BG22 boiler gun electric assembly (P/N BG22E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

A-3 BG22 boiler gun cordless electric assembly (P/N BG22C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

A-4 Collet components and collets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

A-5 Wedge sets and wedge extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

A-6 Wedge set components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

A-7 Small wedge set components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

A-8 Tool holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

A-9 Air motor assembly and parts list (P/N CML3488) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

A-10 Air hose assembly and parts list (P/N HS 50-509) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

A-11 Electric motor assembly and parts list (P/N EB002615) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

A-12 Tool kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

A-13 Shipping container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

P/N 100241, Rev. 1 Page iii

This page intentionally left blank

Page iv

LIST OF TABLES

TABLE PAGE

1-1 Sound levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1-2 Risk assessment checklist before set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1-3 Risk assessment checklist after set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1-4 BG22 Boiler Gun labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2-1 Sub-component mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5-1 Maintenance intervals and tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

5-2 Approved lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

P/N 100241, Rev. 1 Page v

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Page vi

©2017 Climax Portable Machining and Welding Systems or its subsidiaries.

All rights reserved.

Except as expressly provided herein, no part of this manual may be reproduced, copied, transmitted, disseminated,
downloaded, or stored in any storage medium, without the express prior written consent of 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, provided that such electronic or
printed copy of this manual or revision must contain the complete text of this copyright notice and provided further
that any unauthorized commercial distribution of this manual or any revision hereto is prohibited.

At Climax Portable Machining and Welding Systems, we value your opinion.

For comments or questions about this manual or other Climax documentation, please e-mail

[e-mail].

For comments or questions about Climax products or services, please call Climax or e-mail
quick and accurate service, please provide your factory representative with the following:

•Your name

• Shipping address

• Telephone number

• Machine model

• Serial number (if applicable)

•Date of purchase

[e-mail]. For

Climax World Headquarters

Climax Portable Machining and Welding Systems
2712 South Second Street Newberg, Oregon 97132 USA
Telephone (worldwide): [phone]
Toll-free (North America):1-800-333-8311
Fax: [phone]
E-mail:

[e-mail]

Climax UK Headquarters

Climax Portable Machine Tools Ltd
Unit 10 Heather Close
Lyme Green Business Park
Macclesfield, Cheshire SK11 0LR, UK
Telephone: [phone]
E-mail:

[e-mail]

Climax European Headquarters

Climax GmbH
Am Langen Graben 8
52353 Düren, Germany
Telephone: [phone]
E-mail:

[e-mail]

P/N 100241, Rev. 1 Page A

CLIMAX GLOBAL LOCATIONS

Page B

CE DOCUMENTATION

CE Certification is pending

P/N 100241, Rev. 1 Page C

LIMITED WARRANTY

Climax Portable Machine Tools, Inc. (hereafter referred to as “Climax”) warrants that all new machines are free
from defects in materials and workmanship. This warranty is available to the original purchaser for a period of one
year after delivery. If the original purchaser finds any defect in materials or workmanship within the warranty
period, the original purchaser should contact its factory representative and return the entire machine, shipping pre­paid, to the factory. Climax will, at its option, either repair or replace the defective machine at no charge and will
return the machine with shipping prepaid.

Climax warrants that all parts are free from defects in materials and workmanship, and that all labor has been per­formed properly. This warranty is available to the customer purchasing parts or labor for a period of 90 days after
delivery of the part or repaired machine or 180 days on used machines and components. If the customer purchasing
parts or labor finds any defect in materials or workmanship within the warranty period, the purchaser should con­tact its factory representative and return the part or repaired machine, shipping prepaid, to the factory. Climax
will, at its option, either repair or replace the defective part and/ or correct any defect in the labor performed,
both at no charge, and return the part or repaired machine shipping prepaid.

These warranties do not apply to the following:

• Damage after the date of shipment not caused by defects in materials or workmanship

• Damage caused by improper or inadequate machine maintenance

• Damage caused by unauthorized machine modification or repair

• Damage caused by machine abuse

• Damage caused by using the machine beyond its rated capacity

All other warranties, express or implied, including without limitation the warranties of merchantability and fitness
for a particular purpose are disclaimed and excluded.

Terms of sale

Be sure to review the terms of sale which appear on the reverse side of your invoice. These terms control and limit
your rights with respect to the goods purchased from Climax.

About this manual

Climax provides the contents of this manual in good faith as a guideline to the operator. Climax cannot guarantee
that the information contained in this manual is correct for applications other than the application described in this
manual. Product specifications are subject to change without notice.

Page D

1 INTRODUCTION

DANGER

WARNING

CAUTION

NOTICE

IN THIS CHAPTER:

1.1 HOW TO USE THIS MANUAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1

1.2 S

AFETY ALERTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1

ENERAL SAFETY PRECAUTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2

1.3 G

ACHINE-SPECIFIC SAFETY PRECAUTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3

1.4 M

1.5 R

ISK ASSESSMENT AND HAZARD MITIGATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4
ISK ASSESSMENT CHECKLIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5

1.6 R

ABELS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6

1.7 L

1.7.1 L

ABEL IDENTIFICATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
ABEL LOCATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7

1.7.2 L

1.1 HOW TO USE THIS MANUAL

This manual describes information necessary for the
setup, operation, maintenance, storage, shipping, and
decommissioning of the BG22 Boiler Gun.

The first page of each chapter includes a summary of
the chapter contents to help you locate specific infor­mation. The appendices contain supplemental product
information to aid in setup, operation, and maintenance
tasks.

1.2 SAFETY ALERTS

Pay careful attention to the safety alerts printed
throughout this manual. Safety alerts will call your
attention to specific hazardous situations that may be
encountered when operating this machine.

Examples of safety alerts used in this manual are
defined here

1

:

indicates a hazardous situation which, if not
avoided, WILL result in death or severe
injury.

Read this entire manual to familiarize yourself with the
BG22 Boiler Gun before attempting to set it up or oper­ate it.

indicates a hazardous situation which, if not
avoided, COULD result in death or severe
injury.

indicates a hazardous situation which, if not
avoided, could result in minor or moderate
injury.

1. For more information on safety alerts, refer to ANSI/NEMA

Z535.6-2011, Product safety Information in Product
Manuals, Instructions, and Other Collateral Materials

P/N 100241, Rev. 1 Page 1

indicates a hazardous situation which, if not
avoided, could result in property damage,
equipment failure, or undesired work
results

.

1.3 GENERAL SAFETY PRECAUTIONS

H&S leads the way in promoting the safe use of portable
machine tools. Safety is a joint effort. You, the end
user, must do your part by being aware of your work
environment and closely following the operating proce­dures and safety precautions contained in this manual,
as well as your employer’s safety guidelines.

Observe the following safety precautions when operat­ing or working around the machine.

Training – Before operating this or any machine

tool, you should receive instruction from a qual­ified trainer. Contact H&S for machine-specific
training information.

Risk assessment – Working with and around this

machine poses risks to your safety. You, the end
user, are responsible for conducting a risk
assessment of each job site before setting up
and operating this machine.

Intended use – Use this machine in accordance with

the instructions and precautions in this manual.
Do not use this machine for any purpose other
than its intended use as described in this man­ual.

Personal protective equipment – Always wear

appropriate personal protective gear when
operating this or any other machine tool.
Flame-resistant clothing with long sleeves and
legs is recommended when operating the
machine. Hot chips from the workpiece may
burn or cut bare skin.

Work area – Keep the work area around the

machine clear of clutter. Restrain cords and
hoses connected to the machine. Keep other
cords and hoses away from the work area.

Lifting – Many H&S machine components are very

heavy. Whenever possible, lift the machine or
its components using proper hoisting equipment
and rigging. Always use designated lifting points
on the machine. Follow lifting instructions in
the setup procedures of this manual.

Lock-out/tag-out – Lock-out and tag-out the

machine before performing maintenance.

Moving parts – H&S machines have numerous

exposed moving parts and interfaces that can

cause severe impact, pinching, cutting, and
other injuries. Except for stationary operating
controls, avoid contact with moving parts by
hands or tools during machine operation.
Remove gloves and secure hair, clothing, jew­elry, and pocket items to prevent them from
becoming entangled in moving parts.

Sharp edges – Cutting tools and workpieces have

sharp edges that can easily cut skin. Wear pro­tective gloves and exercise caution when han­dling a cutting tool or workpiece.

Hot surfaces – During operation, motors, pumps,

HPUs, and cutting tools can generate enough
heat to cause severe burns. Pay attention to hot
surface labels, and avoid contact with bare skin
until the machine has cooled.

Page 2 BG22 Boiler Gun Operating Manual

1.4 MACHINE-SPECIFIC SAFETY PRECAUTIONS

Eye hazard – This machine produces metal chips

during operation. Always wear eye protection
when operating the machine.

Hazardous environments – Do not operate the

machine in environments where potentially
explosive materials, toxic chemicals, or radia­tion may be present.

Sound level – This machine produces potentially
harmful sound levels. Hearing protection is required
when operating this machine or working around it.
During testing, the machine produced the sound

1

levels

listed in Table 1-1.

TABLE 1-1. SOUND LEVELS

S

Pneumatic Motor

Average sound pressure 90.6 dBA

Operator sound pressure 91.5 dBA

Bystander sound pressure 89.4 dBA

Electric Motor

Average sound pressure 85 dBA

Operator sound pressure 85 dBA

Bystander sound pressure 85 dBA

1. Machine sound testing was conducted in accordance with Euro­pean Harmonized Standards EN ISO 3744:2010 and EN 11201:2010.

P/N 100241, Rev. 1 Page 3

1.5 RISK ASSESSMENT AND HAZARD MITIGATION

Machine Tools are specifically designed to perform pre­cise material-removal operations.

Stationary Machine Tools include lathes and milling
machines and are typically found in a machine shop.
They are mounted in a fixed location during operation
and are considered to be a complete, self-contained
machine. Stationary Machine Tools achieve the rigidity
needed to accomplish material-removal operations from
the structure that is an integral part of the machine
tool.

In contrast, Portable Machine Tools are designed for on­site machining applications. They typically attach
directly to the workpiece itself, or to an adjacent struc­ture, and achieve their rigidity from the structure to
which it is attached. The design intent is that the Porta­ble Machine Tool and the structure to which it is
attached become one complete machine during the
material-removal process.

To achieve the intended results and to promote safety,
the operator must understand and follow the design
intent, set-up, and operation practices that are unique
to Portable Machine Tools valve testers.

The operator must perform an overall review and on­site risk assessment of the intended application. Due to
the unique nature of portable machining applications
hydrostatic testing, identifying one or more hazards
that must be addressed is typical.

When performing the on-site risk assessment, it is
important to consider the Portable Machine Tool valve
tester and the workpiece as a whole.

Page 4 BG22 Boiler Gun Operating Manual

1.6 RISK ASSESSMENT CHECKLIST

The following checklist is not intended to be an all
inclusive list of things to watch out for when setting up
and operating this Portable Machine Tool.

TABLE 1-2. RISK ASSESSMENT CHECKLIST BEFORE SET-UP

Before set-up

I took note of all the warning labels on the machine.



I removed or mitigated all identified risks (such as tripping, cutting, crushing, entanglement, shearing, or falling objects).



I considered the need for personnel safety guarding and installed any necessary guards.



I read the machine setup instructions (Section 3.2) and took inventory of all the items required but not supplied (Section 2.5).



I considered how this machine operates and identified the best placement for the controls, cabling, and the operator.



I evaluated and mitigated any other potential risks specific to my work area.



ABLE 1-3. RISK ASSESSMENT CHECKLIST AFTER SET-UP

T

After set-up

I checked that the machine is safely installed (according to Section 3) and the potential fall path is clear. If the machine is installed at



an elevated position, I checked that the machine is safeguarded against falling.

I identified all possible pinch points, such as those caused by rotating parts, and informed the affected personnel.



However, these checklists are typical of the types of
risks the assembler and operator should consider. Use
these checklists as part of your risk assessment:

I planned for containment of any chips or swarf produced by the machine.



I followed the required Maintenance Intervals (Section 5.1) with the recommended lubricants (Section 5.2).



I checked that all affected personnel have the recommended personal protective equipment, as well as any site-required or regulatory



equipment.

I checked that all affected personnel understand and are clear of the danger zone.



I evaluated and mitigated any other potential risks specific to my work area.



P/N 100241, Rev. 1 Page 5

1.7 LABELS

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.

TABLE 1-4. BG22 BOILER GUN LABELS

P/N 100204

BG22 Boiler gun label

P/N 100198

H&S serial plate

P/N BG22 container
label

P/N 100199

H&S company label

P/N 87271

Warning label: Use
eye and ear protec­tion, and read the
manual.

P/N 100240

Wedge and pad
chart

Page 6 BG22 Boiler Gun Operating Manual

1.7.2 Label location

FIGURE 1-1. BG22 BOILER GUN, PNEUMATIC LABEL LOCATION

The following figures display the location of the labels
on each of the components of the BG22 Boiler Gun.

Label P/N: 100204, 100198, 100199, 87271

P/N 100241, Rev. 1 Page 7

Label P/N: 100204, 100198, 100199, 87271

FIGURE 1-2. BG22 BOILER GUN, ELECTRIC LABEL LOCATION

Page 8 BG22 Boiler Gun Operating Manual

2 OVERVIEW

FIGURE 2-1. BG22 AND SHIPPING CONTAINER

IN THIS CHAPTER:

2.1 FEATURES AND COMPONENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9

2.2 C

ONTROLS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10

NEUMATIC MOTOR CONTROLS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10

2.2.1 P

LECTRIC MOTOR CONTROLS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10

2.2.2 E

2.2.3 C

ORDLESS ELECTRIC MOTOR CONTROLS - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10

IMENSIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -11

2.3 D

PECIFICATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -12

2.4 S

2.5 I

TEMS REQUIRED BUT NOT SUPPLIED - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -12

2.1 FEATURES AND COMPONENTS

The BG22 Boiler Gun is a portable, gear-driven, inside­diameter (ID)-mounted, single or dual-point beveling
and facing machine for use on workpieces with a range
of .50” (12.7mm) I.D. to 2.50” (63.5mm) O.D.

Principle components include the following:

Drive options: Available with either a 1.3 HP pneu-

matic motor or a 1 HP electric motor.

High Velocity (HV), Low Velocity (LV) and Plus
(PL) gearing-HV delivers higher cutting speeds to

turn specialty carbide inserts, PL offers even higher
speeds for smaller walls in a compact, lighter
machine. LV is geared for heavy walls and hard
alloys.

Mounting systems—Either a wedge or collet mount­ing system secures the BG22 Boiler Gun to the work­piece. They are both self-centering and adapt to a
wide range of pipe sizes.

Tool holders—Available with either fixed or sliding

tools holders, in multiple sizes.

Torque free operation—Once securely mounted the

BG22 Boiler Gun requires no additional effort to
operate aside from feeding the cutting tool.

Wrench feed—Advances the cutting tools in con-

fined areas with a ratcheting system. This sys­tem has a smaller footprint.

Speed wheel—Provides a quicker way to advance

the locking rod nut before fully tightening with
the wrench in confined spaces.

P/N 100241, Rev. 1 Page 9

2.2 CONTROLS

WARNING

FIGURE 2-2. PNEUMATIC MOTOR THROTTLE LEVER

FIGURE 2-3. DIRECTION AND TRIGGER CONTROLS

Depending on the user’s requirements, the BG22 Boiler
Gun can be powered by either a pneumatic or electric
motor. The controls for each type of motor follow.

Always stop the machine and disconnect
any power supply before making
adjustments to controls or machine
components. Failure to follow this safety
precaution may result in severe injury.

2.2.1 Pneumatic motor controls

The pneumatic motor used on the BG22 features a
throttle lever. The safety lock must be disengaged by
pressing and holding up while depressing the throttle
lever. The throttle lever actuates the motor; when
released, the motor will stop and the safety lock will re­engage.

This is an on or off control only.

2.2.2 Electric motor controls

The electric motor controls are similar to a drill or drill
driver. The trigger is squeezed to actuate the motor,
when released the motor will stop.

This speed is controlled by how far the trigger is pulled
in or let out.

The electric motor also has a direction control, which in
this application is not used. The direction control should
always be set to forward.

2.2.3 Cordless electric motor controls

To actuate the motor on the cordless electric motor
slide the red button up. The motor will run until the
button is slid down into the off position.

There is no speed or direction controls on the cordless
electric motor.

Page 10 BG22 Boiler Gun Operating Manual

WARNING

2.3 DIMENSIONS

FIGURE 2-4. CORDLESS MOTOR CONTROLS

Figure 2-5 shows the machine and operating dimen­sions.

Do not take any measures to lock the
throttle or the trigger in the on position.
Failure to follow this safety precaution may
result in severe injury.

FIGURE 2-5. BG22 BOILER GUN DIMENSIONS

P/N 100241, Rev. 1 Page 11

2.4 SPECIFICATIONS

TABLE 2-1. SUB-COMPONENT MASS

P/N Component Mass in lbs (kg)

BG22 BG22 Boiler Gun Pneumatic 14 (6.4)

BG22E BG22 Boiler Gun Electric 11 (5)

BG22C BG22 Boiler Gun Cordless Electric 16 (7.3)

2.5 ITEMS REQUIRED BUT NOT SUPPLIED

The following items may be required but not supplied in
your H&S product kit:

• Tape measure or steel ruler

• Rubber mallet

•Pliers

Page 12 BG22 Boiler Gun Operating Manual

3SETUP

NOTICE

IN THIS CHAPTER:

3.1 RECEIPT AND INSPECTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -13

ACHINE SETUP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -14

3.2 M

3.2.1 W

3.2.2 C

3.2.3 T

3.2.4 C

3.3 M

3.4 I

NSTALLING THE CUTTING TOOLS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -17

3.5 M

3.5.1 P

3.5.2 E

3.5.3 C

This section describes the setup procedures for the
BG22 Boiler Gun.

3.1 RECEIPT AND INSPECTION

EDGE LOCKING SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -14

3.2.1.1 S

ACHINE MOUNTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -16

OTORS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -18

MALL I.D. WEDGE LOCKING SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - -14

OLLET LOCKING SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -15

OOL HOLDERS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -15

ENTER SHAFTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -15

NEUMATIC MOTOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -18
LECTRIC MOTOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -18
ORDLESS ELECTRIC MOTOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -18

Your H&S product was inspected and tested prior to
shipment then packaged for normal shipment condi­tions. H&S does not guarantee the condition of your
machine upon delivery.

When you receive your H&S product, perform the fol­lowing receipt checks:

1. Inspect the shipping containers for damage.

2. Check the contents of the shipping containers
against the included invoice to make sure that
all components have been shipped.

3. Inspect all components for damage.

Contact H&S immediately to report damaged or missing
components.

Keep the shipping container and all packing
materials for future storage and shipping of
the machine.

P/N 100241, Rev. 1 Page 13

3.2 MACHINE SETUP

FIGURE 3-1. BG22 BOILER GUN MAIN COMPONENTS

FIGURE 3-2. INSTALLED WEDGE SET WITH EXTENSIONS

Do the following to setup the BG22 Boiler Gun:

3.2.1 Wedge locking system

1. Complete the risk assessment checklist in Table
1-2 on page 5.

2. Position the machine on a solid support for
installation of the wedge set.

3. Measure the ID of the pipe to be machined. Use
the chart on the inside lid of the shipping con­tainer to determine the size of the base wedge,
extension set and locking rod.

4. Install the locking rod from the front of the
machine, sliding it through the center shaft.

5. Install the speed wheel/rod wrench on the end
of the locking rod and install the lock nut.

6. Slide the base wedge set over the end plate by
expanding the springs or band spring.

7. Seat the base wedges in the end plate and align
the base wedges with the slots in the center
shaft.

3.2.1.1 Small I.D. wedge locking system

8. If installing wedge extensions, secure three of
the same size range onto the base wedges with
the screws.

The small ID wedge locking system allows the BG22
Boiler Gun to mount on IDs of .500-.625”.

Do the following to setup the small ID wedge locking
system.

1. Position the machine on a solid support for
installation of the wedge system.

2. Follow the instructions for changing the center
shafts, if necessary, in Section 3.2.4.

Page 14 BG22 Boiler Gun Operating Manual

3. Install three of the same size wedges in the

FIGURE 3-3. SMALL WEDGE SET

FIGURE 3-4. INSTALLED COLLET SET

slots of the center shaft with the thinner end
facing the threaded portion of the center shaft
and the recess for the band spring facing out.

4. Install the band spring across the recess of the
three wedges to secure.

5. Slide the wedge rod into the center shaft and
turn to advance until the wedges begin to
expand.

6. Install the rod wrench and secure with the two
retaining clips.

3.2.2 Collet locking system

1. Complete the risk assessment checklist in Table
1-2 on page 5.

2. Position the machine on a solid support for
installation of the collet set.

3. Measure the I.D. of the pipe to be machined and
determine the size of the collet set to be used.

4. Slide a locking rod into the center shaft from
the rear of the machine.

5. Thread the required collet set on the end of the
locking rod until the collets begin to engage the
center shaft.

6. Insert a cotter pin through the hole in the lock­ing rod and open the splines to secure.

7. If not present, install the locking rod wrench
and secure with the retaining clips.

3.2.3 Tool holders

The BG22 Boiler Gun can be used with tool holders in
several different sizes.

Do the following to switch between tool holders:

To remove:

1. Loosen the set screw in the body of the tool
holder.

2. The tool holder has an interference fit with the
main gear. Strike the back face of the tool
holder to remove it towards the front of the
machine.

3. The shaft key may come loose from the main
gear during removal. Retain it for reuse.

To install:

1. Check that the set screw in the body of the tool
holder is backed out or remove it completely.

2. Install the shaft key in the key slot on the main
gear.

3. Slide the tool holder onto the main gear, align­ing the key way with the shaft key.

4. Tap into place until seated against the shoulder
on the main gear.

5. Reinstall or tighten the set screw in the tool
holder body until secure.

3.2.4 Center shafts

Depending on the application, the center shaft may
need switched out to offer a different size range or
locking system.

Do the following to switch out center shafts:

P/N 100241, Rev. 1 Page 15

1. Position the machine on a solid support to

FIGURE 3-5. CHANGING THE CENTER SHAFT

FIGURE 3-6. BG22 BOILER GUN INSTALLED IN WORKPIECE

.50”

FIGURE 3-7. LOCKING ROD WRENCH WITH SPEED WHEEL

change the center shafts.

2. Remove the locking rod, rod wrench and wedge
or collet locking sets.

3. Remove the two screws in the retaining plate
and the lift the retaining plate from the
machine body. Be aware of the thrust bearing
parts during disassembly

4. Remove the feed nut from the center shaft.

5. The center shaft can now be removed through
the front of the machine.

6. Install the other center shaft from the front of
the machine threads first.

7. Replace the thrust bearing parts being mindful
of the order and orientation.

8. Thread the feed nut onto the center shaft until
the center shaft is flush with the back of the
feed nut.

3.3 MACHINE MOUNTING

9. Reinstall the retaining plate and secure with the
two screws.

Do the following to mount the BG22 Boiler Gun on the
workpiece:

1. Insert the mounting system end of the BG22
Boiler Gun into the workpiece until there is
approximately .50” (12.7mm) between the end
of the mounting system and the face of the
workpiece. This will provide enough material
for most procedures.

2. Tighten the mounting system by turning the lock
rod clock-wise using either the rod wrench or
the speed wheel. Once snug, verify that the
mounting system position in the workpiece has
been maintained. Completely tighten the
mounting system using the locking rod wrench.

Page 16 BG22 Boiler Gun Operating Manual

WARNING

Check that the mounting system has been

TIP:

FIGURE 3-8. SLIDING TOOL HOLDER

FIGURE 3-9. CUTTING BIT INSTALLED

fully tightened. After the machine has made
2-3 revolutions during operation, recheck
the mounting system for tightness in the
workpiece. If loose, the machine itself
could rotate causing severe injury to the
operator.

3.4 INSTALLING THE CUTTING TOOLS

While the BG22 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.

Do the following to install the cutting bit(s):

1. Advance the tool holder towards the workpiece
to help with alignment of the cutting bit(s).

2. Loosen the set screws in the blade locks.

3. Slide the cutting bit into the channel with the
beveled cutting edge facing the direction of
rotation.

4. Align the cutting edge of the tool to cut the full
width of the workpiece wall.

5. Tighten the set screw(s) to secure the cutting
bit(s) to the tool holder.

P/N 100241, Rev. 1 Page 17