H&S BOILER GUN BG44 Operating Manual

BOILER

GUN

BG44 BOILER GUN

OPERATING MANUAL

P/N 100190
April 2017
Revision 1

TABLE OF CONTENTS

CHAPTER/SECTION PAGE

1 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

9 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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

2.2 C

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

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

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

2.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.4 S

2.5 I

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

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

13 SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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

3.2 M

3.3 M

3.4 I

3.5 M

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

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

3.2.2 Collet locking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.2.3 Tool holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

ACHINE MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

NSTALLING THE CUTTING TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

OTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.5.1 Pneumatic motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.5.2 Electric motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

21 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4.1 PRE-OPERATION CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4.2 O

PERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4.2.1 Pneumatic motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4.2.2 Electric motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

23 MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5.1 MAINTENANCE CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

P/N 100190, Rev. 1 Page i

TABLE OF CONTENTS (CONTINUED)

CHAPTER/SECTION PAGE

5.2 APPROVED LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5.3 M

5.4 T

27 STORAGE AND SHIPPING

6.1 STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

6.2 S

6.3 D

AINTENANCE TASKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

5.3.1 Checking and filling the in-line oiler reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

5.3.2 Servicing the filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

5.3.3 Adjusting the oil flow rate of the in-line oiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

5.3.4 Tool holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

5.3.5 Greasing the drive and pinion gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

ROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

5.4.1 The machine isn’t turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

5.4.2 The machine isn’t feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

5.4.3 The machine is performing poorly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

6.1.1 Short-term storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

6.1.2 Long-term storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

HIPPING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

ECOMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

29 APPENDIX A ASSEMBLY DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

51 APPENDIX B SDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Page ii BG44 Boiler Gun Operating Manual

LIST OF FIGURES

FIGURE PAGE

1-1 BG44 Boiler Gun- crank feed, pneumatic label location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1-2 BG44 Boiler Gun- wrench feed, pneumatic label location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1-3 BG44 Boiler Gun- wrench feed, electric label location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2-1 BG44 and shipping container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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

2-3 Speed selector and Trigger controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2-4 BG44 Boiler gun pneumatic dimensions (P/N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2-5 BG44 Boiler Gun electric dimensions (P/N PB06EL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3-1 BG44 Boiler Gun main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3-2 Wedge extensions installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3-3 Installed wedge set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3-4 The .875 wedge set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3-5 The 1.25” collet set installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3-6 The .875” collet set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3-7 Tool holder set screw and key slot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3-8 BG44 installed in workpiece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3-9 Locking rod wrench with speed wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3-10 Fixed (L) and sliding (R) tool holders with cutting bits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3-11 Cutting bit installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3-12 Universal coupler (top) and quick disconnect (bottom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3-13 Speed control set to low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4-1 Hand positioning on the pneumatic BG44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4-2 BG44 with electric motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

5-1 In-line oiler sight glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

6-1 BG44 shipping container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

A-1 BG44 Boiler Gun - high velocity, crank feed assembly (P/N BG44HVCR) . . . . . . . . . . . . . . . . . . . . . . 30

A-2 BG44 Boiler Gun - high velocity, crank feed parts list (P/N BG44HVCR) . . . . . . . . . . . . . . . . . . . . . . . 31

A-3 BG44 Boiler Gun - high velocity, wrench feed assembly (P/N BG44HVWR) . . . . . . . . . . . . . . . . . . . . 32

A-4 BG44 Boiler Gun - high velocity, wrench feed parts list (P/N BG44HVWR) . . . . . . . . . . . . . . . . . . . . . 33

A-5 BG44 Boiler Gun - low velocity, crank feed assembly (P/N BG44LVCR) . . . . . . . . . . . . . . . . . . . . . . . 34

A-6 BG44 Boiler Gun - low velocity, crank feed parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

A-7 BG44 Boiler Gun - low velocity, wrench feed assembly (P/N BG44LVWR) . . . . . . . . . . . . . . . . . . . . . 36

A-8 BG44 Boiler Gun - low velocity, wrench feed parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

A-9 BG44 Boiler Gun - electric, crank feed assembly (P/N BG44CR-E) . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

A-10 BG44 Boiler Gun - electric, crank feed parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

A-11 BG44 Boiler Gun - wrench feed, electric assembly (P/N BG44WR-E) . . . . . . . . . . . . . . . . . . . . . . . . 40

A-12 BG44 Boiler Gun - wrench feed, electric parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

A-13 Collet Sets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

A-14 Wedge sets and wedge extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

A-15 Center shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

A-16 Locking rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

A-17 Tool holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

A-18 HV air motor assembly and parts list (P/N 100105) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

A-19 LV air motor assembly and parts list (P/N CML3488) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

P/N 100190, Rev. 1 Page iii

LIST OF FIGURES (CONTINUED)

FIGURE PAGE

A-20 Air hose assembly and parts list (P/N HS 50-509) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

A-21 Electric motor assembly and parts list (P/N EMB003610) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Page iv BG44 Boiler Gun Operating Manual

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 BG44 Boiler Gun labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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

5-1 Maintenance intervals and tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5-2 Approved lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

P/N 100190, Rev. 1 Page v

This page intentionally left blank

Page vi BG44 Boiler Gun Operating Manual

©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 100190, Rev. 1 Page A

CLIMAX GLOBAL LOCATIONS

Page B

CE DOCUMENTATION

CE Certification is pending

P/N 100190, 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 BG44 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
BG44 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 100190, 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 BG44 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 100190, 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 BG44 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 100190, 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. BG44 BOILER GUN LABELS

P/N 100196

HV Boiler gun label

P/N 100197

LV Boiler gun label

P/N 100199

H&S company label

P/N 100198

H&S serial plate

crank feed only

P/N 87259

H&S serial plate

wrench feed only

P/N 87271

Warning label: use
eye and ear protec­tion, and read the
operating manual

P/N 802112

Multi-Prep label

P/N 100200

H&S serial plate

crank feed only

P/N 100248

Wedge and pad
chart label

Page 6 BG44 Boiler Gun Operating Manual

1.7.2 Label location

FIGURE 1-1. BG44 BOILER GUN- CRANK FEED, PNEUMATIC LABEL LOCATION

FIGURE 1-2. BG44 BOILER GUN- WRENCH FEED, PNEUMATIC LABEL LOCATION

The following figures display the location of the labels on each of the components of the BG44 Boiler Gun.

Label P/N: 100196 or 100197, 100198, 100199, 802112, 100200, 87271

Label P/N: 87271

P/N 100190, Rev. 1 Page 7

Label P/N: 87259

FIGURE 1-3. BG44 BOILER GUN- WRENCH FEED, ELECTRIC LABEL LOCATION

Page 8 BG44 Boiler Gun Operating Manual

2 OVERVIEW

FIGURE 2-1. BG44 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

2.3 D

IMENSIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -11
PECIFICATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -12

2.4 S

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

2.5 I

2.1 FEATURES AND COMPONENTS

The BG44 is a portable, gear-driven, inside-diameter
(ID)-mounted, single or dual-point beveling and facing
machine for use on workpieces with a range of .875”
(22.2mm) I.D. to 5.00” (127mm) O.D.

Principle components include the following:

Drive options: Available with either a 1.625 HP

pneumatic motor or a 1.5 HP electric motor.

High Velocity (HV) or Low Velocity (LV) gearing—

HV delivers higher speeds to turn specialty car­bide insert cutters while LV is geared for heavy
wall and hard alloys.

Mounting systems—Either a wedge or collet mount­ing system secures the BG44 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

BG44 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.

Crank feed—Advances the cutting tools with a fast

and convenient side-mounted crank.

Speed wheel—Provides a quicker way advance the

locking rod nut before fully tightening with the
wrench.

P/N 100190, Rev. 1 Page 9

2.2 CONTROLS

WARNING

WARNING

FIGURE 2-2. PNEUMATIC MOTOR THROTTLE LEVER

FIGURE 2-3. SPEED SELECTOR AND TRIGGER CONTROLS

Depending on the users requirements, the BG44 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 BG44 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 is an on and off control only.

A two speed gearing selector is located at the front of
the motor. The BG44 is designed to be used with the
electric motor in the low setting ONLY.The low setting is
indicated with a single arrow while the high setting is
indicated with two arrows.

To adjust, if the motor is not in the low setting, push in
and slide the selector. The spindle may need turned by
hand to fully engage, when fully engaged the selector
will spring back up. If not fully engaged the drive motor
will not function properly.

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.

Page 10 BG44 Boiler Gun Operating Manual

2.3 DIMENSIONS

Figures 2-4 and 2-5 show the machine and operating
dimensions.

FIGURE 2-4. BG44 BOILER GUN PNEUMATIC DIMENSIONS

FIGURE 2-5. BG44 BOILER GUN ELECTRIC DIMENSIONS

P/N 100190, Rev. 1 Page 11

2.4 SPECIFICATIONS

TABLE 2-1. SUB-COMPONENT MASS

P/N Component Mass in lbs (kg)

BG44 BG44 Boiler Gun Pneumatic 21 (9.5)

BG44 BG44 Boiler Gun Electric 25 (11.3)

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 BG44 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

WEDGE SETS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -14

WEDGE MOUNTING SYSTEMS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -15

3.2.2 C

3.2.3 T

3.3 M

3.4 I

NSTALLING THE CUTTING TOOLS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -19

3.5 M

3.5.1 P

3.5.2 E

This section describes the setup procedures for the
BG44 Boiler Gun.

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

3.2.1.1 I

3.2.1.2 I

3.2.2.1 I

ACHINE MOUNTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -18

OTORS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -20

NTERCHANGING THE M-01 AND M-02 BASE

NTERCHANGING THE .875” AND 1.200”

OLLET LOCKING SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -16

NTERCHANGING THE COLLET SETS - - - - - - - - - - - - - - - - - - - - - - - - - - - -16

OOL HOLDERS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -17

NEUMATIC MOTOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -20
LECTRIC MOTOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -20

3.1 RECEIPT AND INSPECTION

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 100190, Rev. 1 Page 13

3.2 MACHINE SETUP

FIGURE 3-1. BG44 BOILER GUN MAIN COMPONENTS

FIGURE 3-2. WEDGE EXTENSIONS INSTALLATION

Do the following to setup the BG44 Boiler Gun:

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

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 I.D. of the pipe to be machined and
determine the size of the wedge extension set
to be used, if required. The wedge bases can
also be used without extensions.

3.2.1.1 Interchanging the M-01 and M-02 base
wedge sets

The M-01 and M-02 wedge sets can use the same center
shaft. Do the following to change between the wedge
set sizes:

1. Return the machine to a solid support for
removal and installation of the wedge sets.

2. To remove: Pull out on the wedge set enough to
slide them up and over the wedge guide.

3. To install: Expand the wedge bases enough to
slide the wedge set over the wedge guide and
onto the center shaft.

Page 14 BG44 Boiler Gun Operating Manual

4. Align the wedges sets with the slots in the cen-

FIGURE 3-3. INSTALLED WEDGE SET

FIGURE 3-4. THE .875 WEDGE SET

ter shaft and seat the other ends on the wedge
guide.

3.2.1.2 Interchanging the .875” and 1.200”
wedge mounting systems

The .875” wedge mounting system uses a dedicated
center shaft.

Do the following to change between a 1.200” wedge set
and the .875” wedge set:

1. Return the machine to a solid support for
removal and installation of the wedge sets.

2. Remove the jam nut from the end of the locking
rod.

3. Remove the locking rod wrench from the locking
rod. The direction of the ratchet mechanism
may need to be switched to feed off instead of
on.

4. Slide the wedge set with locking rod out of the
center shaft from the wedge end of the
machine.

5. On the crank feed machine, turn the crank
opposite of the feed direction until the threads
of the center shaft are free of the feed nut.

On the wrench feed machine, turn the wrench
opposite of the feed direction until the threads
of the center shaft are free of the feed nut.

6. Slide the center shaft out from the front of the
machine.

7. Insert the center shaft of the .875” wedge set,
threaded end first, through the tool holder and
into center shaft lock, aligning the slots in the
threaded shaft with splines in the center shaft
lock. Continue to insert the center shaft until it
stops against the feed nut.

8. On the crank feed machine, turn the crank to
advance the center shaft.

On the wrench feed machine, turn the wrench
to advance the center shaft. The direction of
the ratchet mechanism may need switched to
feed in instead of off.

9. Advance the center shaft until approximately
.50” (12.7mm) of threads protrude past the rear
of the machine or the feed wrench.

10. Reinstall the locking rod wrench until .50”
(12.7mm) of the locking rod protrudes.

P/N 100190, Rev. 1 Page 15

11. Reinstall the jam nut on the end of the locking

FIGURE 3-5. THE 1.25” COLLET SET INSTALLED

FIGURE 3-6. THE .875” COLLET SET

rod.

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. Based on size, locate the center shaft that
matches the collet set required.

5. To install the center shaft:

a) Insert the center shaft through the tool

holder and into the center shaft lock,
aligning the slots in the threaded shaft
with the splines on the center shaft lock.
Continue to insert the center shaft until it
stops against the feed nut.

b) On the crank feed machine, turn the

crank to advance the center shaft.

On the wrench feed machine, turn the
wrench to advance the center shaft. The
direction of the ratchet mechanism may
need switched to feed in instead of off.

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

7. Thread the required collet set on the end of the
locking rod until the collets begin to engage the
center shaft. If flat are present on the center
shaft, align the collets with the flats.

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

9. If not installed, slide the locking rod wrench
onto the locking rod nut and secure with a
retaining clip.

10. To remove the center shaft, reverse steps 5-8.

3.2.2.1 Interchanging the collet sets

The .875” collet system has a range of .875 to 1.25”. It
uses three collet sets, in .125” increments and the
.875” center shaft.

The 1.25” collet system has a range of 1.25 to 4.75”.
The collet sets are in .125” increments and use the

1.25” center shaft.

Do the following to change between the collet sets:

1. Return the machine to a solid support.

2. Remove the cotter pin from the end of the lock­ing rod.

3. Remove the collet set from the locking rod.

4. Install the collet set on the locking rod. If flats
are present on the center shaft, align the collet
segments with the flats.

5. Reinstall the cotter pin.

6. See Section 3.2.2, Steps 5-8 to interchange the
center shafts.

Page 16 BG44 Boiler Gun Operating Manual

3.2.3 Tool holders

FIGURE 3-7. TOOL HOLDER SET SCREW AND KEY SLOT

The BG44 Boiler Gun can be used with two styles of 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 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.

P/N 100190, Rev. 1 Page 17

3.3 MACHINE MOUNTING

WARNING

FIGURE 3-8. BG44 INSTALLED IN WORKPIECE

.50”

FIGURE 3-9. LOCKING ROD WRENCH WITH SPEED WHEEL

Do the following to mount the BG44 on the workpiece:

1. Insert the mounting system end of the BG44 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.

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

Page 18 BG44 Boiler Gun Operating Manual