Tri Tool 103 REP User Manual

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Page 1

TABLE OF CONTENTS

CUSTOMER MESSAGE Inside Front Cover

SAFETY PRECAUTIONS 3

92-0131 Rev. 960503

, Rapid End Prep Machine

Model 103 REP

GENERAL DESCRIPTION 6

SPECIFICATIONS 7

MAINTENANCE 8

OPERATION 10

OPERATION USING THE CROSS TRACK ASSY. 14

PILOT MANDREL & CUTTER HEAD KIT USAGE CHART 17

CUTTER HEAD KITS 24

TOOL INSERTS 27

TROUBLE SHOOTING 28

ACCESSORIES 30

ILLUSTRATED PARTS BREAKDOWN 31

TOOL BIT RESHARPENING POLICY Inside Back Cover

Page 2

Proprietary property of TRI TOOL Inc. No reproduction, use, or duplication of the information shown hereon is permitted without the express written

consent of TRI TOOL Inc.

Page 3

SAFETY PRECAUTIONS

IN GENERAL

When using rotating head cutting equipment, basic safety precautions should always be followed to reduce the risk of personal injury.

Operate this tool only in accordance with specific operating instructions.

Do not override the deadman switch on the power unit. Locking down, ob-

WARNING:

DRESS CONSIDERATIONS

structing, or in any way defeating the deadman switch on the power drive unit may result in serious injury.

Model 103 REP

, Rapid End Prep Machine

Use standard safety equipment. Hard hats, safety shoes, safety harnesses, protective clothes, and other safety devices should always be used when appropriate.

Use safety glasses. Do not operate cutting tools without eye protection.

Dress properly. Do not wear loose clothing or jewelry. They can be caught in rotating and moving parts. Avoid slippery floors or wear nonskid footwear. If you have long hair, wear protective hair covering to contain it.

WORK AREA

Keep the work area clean. Cluttered work areas and benches invite injuries.

Consider the work area environment. Keep the area well lit. Keep electrical cords, cables, rags, rigging straps, and etc. clear of rotating equipment. Do not use powercutting tools in the presence of flammable liquids and gasses.

Keep visitors away. Do not let visitors or untrained personnel at or near operating tools. Enforce eye protection requirements for all observers.

Do not over reach. Keep proper footing at all times.

Stay alert. Watch what you are doing. Use common sense. Do not operate tools when you are tired.

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TRI TOOL INC.

TOOL CARE

Maintain tools with care. Keep tools in good operating condition. Sharp tool bits perform better and safer than dull tool bits. Well maintained tools function properly when needed.

Check for damaged parts. If a tool has malfunctioned, been dropped or hit, it must be checked for damage. Run no-load tests and feed function checks. Do a complete visual inspection.

Electric motors. Use only with proper AC voltage power sources and observe all normal electric shock hazard procedures.

Do not abuse power and control cords. Pulling or running over cords and cables can result in electrical shock hazards and malfunctions. Keep control and power cords out of all cutting fluids and water.

Hydraulic drives. Observe proper procedures for electrically driven power sources. Avoid damage to hydraulic lines. Keep quick-disconnects clean. Grit contamination causes malfunctions.

Air tools. Check the exhaust muffler. Broken or damaged mufflers can restrict air flow or cause excessive noise. Use air motors only with a filtered, lubricated and regulated air supply. Dirty air, low-pressure air or over pressure air will cause malfunctions, including delayed starting.

AREA EQUIPMENT

Secure work. Whenever possible use clamps, vises, chains and straps to secure pipe.

Make sure the tool is secured; it is safer to have both hands free to operate the tool.

TOOL USE

Use the right tool and tool bit for the job. Do not use a tool, which is incorrect for the job you are doing.

Keep the tool bits fully engaged in the tool bit holders. Loose bits are a safety hazard.

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Model 103 REP

Disconnect power supply during setup and maintenance. Use all ‘Stop’ or Shut off’ features available when changing or adjusting tool bits, maintaining the tool, or when the tool is not in use.

Remove adjusting keys and wrenches before applying power to the equipment. Develop a habit of checking the tool before turning it on to make sure that all keys and wrenches have been removed.

Do not force tools. Tools and tool bits function better and safer when used at the feed and speed rate for which they were designed.

Do not reach into rotating equipment. Do not reach into the rotating head stock to clear chips, to make adjustments, or to check surface finish. A machine designed to cut steel will not stop for a hand or an arm.

Handle chips with care. Chips have very sharp edges and are hot. Do not try to pull chips apart with are hands; they are very tough.

, Rapid End Prep Machine

Avoid unintentional starts. Do not carry or handle tools with your hand on the operating switches or levers. Do not lay the tool down in a manner that will start the drive. Do not allow the tool to flip around or move when adjusting or changing tool bits.

Store idle tools properly. Disconnect tools from the power source and store in a safe place. Remove tool bits for safe handling of the tool.

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TRI TOOL INC.

GENERAL DESCRIPTION

The Model 103 REPTM Rapid End Prep Machine is a small, lightweight, beveling tool designed for beveling the ends of pipe or tubing in preparation for welding.

The Model 103 REP the pipe or tube by means of a rigid, self-centering Pilot Mandrel.

There are various Pilot Mandrels which are available that will position the Model 103

REP from .42” through 3.16” (10.7 mm through 80.3 mm).

The Model 103 REPTM generates low torque during the machining operations.

The Model 103 REPTM features a Cutting Head Spindle offset from the motor to allow installation and cutting of boiler tubes in a water wall panel.

Rapid End Prep Machine to pipe and/or tubing having an inside diameter range

Rapid End Prep Machine is mounted to the inside diameter of

The Model 103 REPTM features eight different diameter Cutting Heads which allow the operator to select the optimum size head for the operation.

The smallest is the 1.85” (47.0 mm) dia Cutting Head which provides for a minimum radial clearance.

The largest is the 3.60” (91.4 mm) dia Cutting Head which requires the most radial clearance, but increases the Tool Bit capabilities and size of pipe or tubing which may be effectively end prepped.

The end prep geometry is built into the Cutting Heads.

A Chip Deflection Shield is supplied with each Cutting Head.

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Model 103 REP

SPECIFICATIONS

Model 103 REP with an Air Motor

Weight: 9 to 15 pounds (4 to 7 kg), depending on Cutting Head and Pilot size

Power Requirements: 75 cfm at 90 psi (35 L/s at 621 kPa)

Envelope, Model 103REP, Rapid End Prep Machine

, Rapid End Prep Machine

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TRI TOOL INC.

MAINTENANCE

All components should be cleaned and coated with a light film of oil prior to use.

Use a clean, non-detergent oil, preferably SAE 10 (90 SSU) or lighter, or oil which is specified for the Air Motor.

AIR SUPPLY FOR THE MODEL 103 REPTM WITH AIR MOTOR

An adequate filter, regulator, and lubricator must be used in the air supply line.

NOTE:

If the Model 103 REPTM is operated in the vertical position (Cutting Head up), it should be turned upside down and the chips and/or other debris removed after each bevel has been completed.

The motor warranty is void if damage occurs from contaminated air or lack of lubrication.

Clean Up

Tool life may be severely shortened, unless chips and/or other debris that have

NOTE:

After every 10 hours of operation the Drive Gears should be re-lubricated. See the picture ‘Grease’.

NOTE:

been deposited on the Cutting Head during the machining operation are removed.

Use TRI TOOL Inc. Lubricant (P/N 68-0019), this is a Lithium base white grease.

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Model 103 REP

, Rapid End Prep Machine

Grease

In order to lubricate the Gears, a grease fitting has been provided.

After every 50 hours of operation, the Model 103 REPTM should be disassembled and inspected for worn parts.

All Gears and Bearings should be cleaned and re-lubricated with a Lithium base white grease, such as TRI TOOL Inc. lubricant (P/N 68-0019).

92-0131 : Rev. 960503

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TRI TOOL INC.

Read the operation instructions carefully before attempting to operate the Model 103 REPTM.

Use eye protection at all times when operating the Model 103 REP

Select the recommended Cutter Head Kit for the outside diameter to be machined. Refer to the section on Cutter Head Kits.

Select the recommended Pilot Mandrel for the pipe size to be machined. Refer to the section on Pilot Mandrels.

OPERATION

NOTE:

For special applications, i.e., very thin wall, extra heavy wall or tough materials, please contact TRI TOOL Inc. for assistance in the selection.

Attach the cover (part of the Cutter Head Kit) by using the two Button Head Screws which fit into the slots.

Pilot Mandrels are recommended based on the inside diameters of the pipe or tubing to be machined.

Tool Insert Positioning

Screw the Cutter Head onto the threaded output shaft of the Model 103 REP End Prep Machine.

Use the 11/16” Wrenches (supplied) to tighten.

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Rapid

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Model 103 REP

Screw the Pilot Mandrel into the Cutter Head and tighten with the 11/16” wrench and 1/4” Wrench (supplied).

Insert the 1/4-20 UNC left-hand thread Screw (supplied with Cutter Head Kit) through the Pilot Mandrel and the Cutter Head into the Cutter Shaft.

This Screw prevents the Pilot Mandrel from spinning off during deceleration of the Cutter Head.

, Rapid End Prep Machine

CAUTION:

The Cutter Head may spin off. Select the Tool Inserts required to machine the pipe. Refer to the Tool Insert list in the section ‘Cutter Head Kits’.

WARNING:

Insert the Tool Inserts into the slots in the Cutting Head.

CAUTION:

Tighten the Cap Screws to secure the Tool Inserts to the Cutting Head. Refer to the picture ‘Tool Insert positioning’.

Never attempt to run the Model 103 REPTM without the Pilot Mandrel and Lock Screw installed.

Use of dull or improperly designed Tool Inserts may result in poor performance and may constitute abuse of this machine and therefore voids the TRI TOOL Inc. factory warranty.

The cutting edge of the Tool Insets must be located on the radial centerline. Refer to the picture ‘Tool Insert positioning’.

Check each Tool Insert for proper installation. Refer to the picture ‘Tool Insert positioning’.

Insure that there is rotational clearance between the Pilot Mandrel and Tool Inserts.

Attach the proper air supply line to the Model 103 REPTM Rapid End Prep Machine.

NOTE:

Slide the Model 103 REPTM with the Pilot Mandrel installed, Pilot Mandrel end first into the pipe or tube to receive the end preparation. Refer to the picture ‘Mounting the Model 103 REPTM on a water wall’.

Make sure that the Tool Inserts are not contacting the end of the pipe or tube before the Model 103 REPTM Rapid End Prep Machine begins the end prep.

Use an Adequate in-line filter, regulator, and lubricator.

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TRI TOOL INC.

Depress the Air Motor Hand Lever.

Lower the Model 103 REP

into the pipe or tube.

CAUTION:

The actual machining operation will begin when the Tool Inserts contact the pipe.

If the pipe end is not square to the pipe axis, the Tool Inserts will contact only a small segment of the pipe during each revolution.

Mounting the Model 103 REP on a water wall

To avoid Tool Insert damage, the feed rate should be very slow until the Tool Inserts are contacting the pipe continually during at least one full revolution.

Continue feeding the Model 103 REP

into the pipe or tube until the end is completely

machined.

Stop feeding and allow the Cutting Head to rotate to improve the finish of the prep surface.

Stop the tool rotation.

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Model 103 REP

, Rapid End Prep Machine

Release the Air Motor Hand Lever.

Remove the Model 103 REP

completely from the pipe or tube.

If the next bevel is to be identical to the previous bevel, follow the sequence starting at the beginning of this section, beginning at ‘Attach the proper air supply line’.

If the next bevel is to be different than the previous bevel, follow the sequence starting at the beginning of this section, beginning ‘Select the recommended Cutter Head Kit’.

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TRI TOOL INC.

OPERATION USING THE CROSS TRACK ASSY.

If the Model 512A1 Panel Saw has been used to cut a window in the water wall and the 64” (1.6 mm) Track is still in place than go ahead to ‘Slide the Cross Track Assy’.

INSTALLING THE TRACK ONTO THE WORK.

Bolt a Locator Tab onto the Track at each end perpendicular to the Track.

Track Positioning with the Locator Tabs

Bolt a Weld Tab onto both ends of the Track in the next position toward the center from the Locator tab.

Place the Track on the work.

Line up the Locator Tabs perpendicular to and touching the cut line.

Weld both of the Weld Tabs down. Refer to the picture ‘Weld Tab locations on the Track’.

Weld Tabs may be rotated as required to make contact with the tops of the tubes.

NOTE:

The Weld Tabs do not have to be 90O to the Track.

Remove the Locator Tabs from the Track.

When welding Weld Tabs to tubes is not permissible, small stacks (not supplied) may be welded to the membrane and then to the Weld Tabs.

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Model 103 REP

, Rapid End Prep Machine

Weld Tab Locations on the Track

Bolt Weld tabs to the Track at the remaining positions, as required.

Weld the Weld Tabs to the work where possible.

Slide the Cross-Track Assy onto the 64” (1.6 m) Track.

Track Set-up on a Warped Water Wall

It may be required to remove the 23” (.6 m) Track from the top of the Cross-Track Assy in order to put the Cross-Track Assy onto the 64” (1.6 m) Track.

Remove the two Cap Screws which retain the 23” (.6 m) Track to the top of the CrossTrack Assy.

LOADING THE MODEL 103 REPTM ONTO THE REP ADAPTOR ASSY.

If the Model 103 REPTM is already loaded into the REP Adapter Assy then go to ‘Slide the Track Adapter Assy onto the Cross Track Assy’.

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TRI TOOL INC.

Rapid End Prep Machine Mounted on the Adaptor Assembly

First prepare the Model 103 REPTM in the configuration required for the job at hand. Refer to the Operating Instructions; ‘Select the recommended Pilot Mandrel’.

Loosen the two Cap Screws, which hold the Clamping Plate together.

Remove the part of the Clamping Plate in which the Cap Screws are held.

Install the Model 103 REPTM into the Clamping Plate and reinstall the other part of the Clamping Plate and tighten the Cap Screws to hold the Model 103 REPTM in place.

SLIDE THE TRACK ADAPTER ASSY ONTO THE CROSS-TRACK ASSY

Slide the Cross-Track Assy along the 64” (1.6 m) Track to the desired location.

Slide the Track Adapter Assy along the 23” (.6 m) Track until the Model 103 REPTM is located directly over the tube to be worked on.

Rotating the Handle on the REP Adapter Assy will cause the Model 103 REPTM to be lowered into the end of the tube.

See the Previous Section for the machining operation.

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Model 103 REP

, Rapid End Prep Machine

PILOT MANDREL & CUTTER HEAD KIT USAGE CHART

Recommended clearance of Pilot Mandrel to actual I.D. of pipe or tube is .015” (.38 mm) minimum to .050” (1.27 mm) maximum.

WALL THICKNESS CAPACITY

.35” (8.9 mm) with #1 and #2 Cutter Heads .45” (11.4 mm) with #3 through #8 Cutter Heads

If radial clearance is a problem, use smallest Cutter Head available for Pilot Mandrel selected.

Pilot Mandrel

Pilot Mandrel Per Cutting Head Function

Pilot

P/N

13-0080 .420" 10.7 mm 1

13-0081 .435" 11.0 mm 1

13-0082 .450" 11.4 mm 1

13-0083 .465" 11.8 mm 1

13-0084 .480" 12.2 mm 1

13-0085 .495" 12.6 mm 1

13-0086 .510" 13.0 mm 1

13-0087 .525" 13.3 mm 1

13-0088 .540" 13.7 mm 1

13-0089 .555" 14.1 mm 1

Pilot

Size

Chart Continued on next page

92-0131 : Rev. 960503

Cuttin

Functions with

Head Kit Numbers

Page 18

TRI TOOL INC.

Pilot Mandrel Per Cutting Head Function

Pilot

P/N

13-0090 .570" 14.5 mm 1

13-0091 .585" 14.9 mm 1

13-0092 .600" 15.2 mm 1

13-0093 .615" 15.6 mm 1

13-0094 .630" 16.0 mm 1

13-0095 .645" 16.4 mm 1

13-0096 .660" 16.8 mm 1

13-0097 .675" 17.1 mm 1

13-0098 .690" 17.5 mm 1

13-0099 .705" 17.9 mm 1

13-0100 .720" 18.3 mm 1

13-0101 .735" 18.7 mm 1

13-0102 .745" 18.9 mm 1

13-0103 .750" 19.1 mm 1

Pilot

Size

Cuttin

Functions with

Head Kit Numbers

13-0104 .760" 19.3 mm 1

13-0105 .775" 19.7 mm 1

13-0106 .790" 20.1 mm 1

13-0107 .805" 20.4 mm 1

13-0108 .820" 20.8 mm 1

13-0109 .835" 21.2 mm 1

13-0110 .850" 21.6 mm 1

13-0111 .865" 22.0 mm 1

13-0112 .880" 22.4 mm 1

13-0113 .895" 22.7 mm 1

13-0114 .910" 23.1 mm 1

13-0115 .925" 23.5 mm 1

13-0116 .940" 23.9 mm 1

13-0117 .955" 24.3 mm 1

13-0118 .970" 24.6 mm 1

13-0119 .985" 25.0 mm 1

13-0120 .995" 25.3 mm 1 2 3

Chart Continued on next page

92-0131 : Rev. 960503

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Model 103 REP

Pilot Mandrel Per Cutting Head Function

, Rapid End Prep Machine

Pilot

P/N

13-0121 1.000" 25.4 mm 1 2 3

13-0122 1.010" 25.7 mm 1 2 3

13-0123 1.025" 26.0 mm 1 2 3

13-0124 1.040" 26.4 mm 1 2 3

13-0125 1.055" 26.8 mm 1 2 3

13-0126 1.070" 27.2 mm 1 2 3

13-0127 1.085" 27.6 mm 1 2 3

13-0128 1.100" 27.9 mm 1 2 3

13-0129 1.115" 28.3 mm 1 2 3

13-0130 1.130" 28.7 mm 1 2 3

13-0131 1.145" 29.1 mm 1 2 3

13-0132 1.160" 29.5 mm 1 2 3

13-0133 1.175" 29.8 mm 1 2 3

13-0134 1.190" 30.2 mm 1 2 3

Pilot

Size

Cuttin

Functions with

Head Kit Numbers

13-0135 1.205" 30.6 mm 1 2 3

13-0136 1.220" 31.0 mm 1 2 3

13-0137 1.235" 31.4 mm 1 2 3

13-0138 1.245" 31.6 mm 1234

13-0139 1.250" 31.8 mm 1234

13-0140 1.260" 32.0 mm 1234

13-0141 1.275" 32.4 mm 1234

13-0142 1.290" 32.8 mm 1234

13-0143 1.305" 33.1 mm 1234

13-0144 1.320" 33.5 mm 1234

13-0145 1.335" 33.9 mm 1234

13-0146 1.350" 34.3 mm 1234

13-0147 1.365" 34.7 mm 1234

13-0148 1.380" 35.1 mm 1234

13-0149 1.395" 35.4 mm 1234

13-0150 1.410" 35.8 mm 2 3 4

13-0151 1.425" 36.2 mm 2 3 4

Chart Continued on next page

92-0131 : Rev. 960503

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TRI TOOL INC.

Pilot Mandrel Per Cutting Head Function

Pilot

P/N

13-0152 1.440" 36.6 mm 2 3 4

13-0153 1.455" 37.0 mm 2 3 4

13-0154 1.470" 37.3 mm 2 3 4

13-0155 1.485" 37.7 mm 2 3 4

13-0156 1.495" 38.0 mm 2 3 4

13-0157 1.500" 38.1 mm 2345

13-0158 1.510" 38.4 mm 2345

13-0159 1.525" 38.7 mm 2345

13-0160 1.540" 39.1 mm 2345

13-0161 1.555" 39.5 mm 2345

13-0162 1.570" 39.9 mm 2345

13-0163 1.585" 40.3 mm 2345

13-0164 1.600" 40.6 mm 2345

13-0165 1.615" 41.0 mm 2345

Pilot

Size

Cuttin

Functions with

Head Kit Numbers

13-0166 1.630" 41.4 mm 2345

13-0167 1.645" 41.8 mm 2345

13-0168 1.660" 42.2 mm 2345

13-0169 1.675" 42.5 mm 3 4 5

13-0170 1.690" 42.9 mm 3 4 5

13-0171 1.705" 43.3 mm 3 4 5

13-0172 1.720" 43.7 mm 3 4 5

13-0173 1.735" 44.1 mm 3 4 5

13-0174 1.745" 44.3 mm 3456

13-0175 1.750" 44.5 mm 3456

13-0176 1.760" 44.7 mm 3456

13-0177 1.775" 45.1 mm 3456

13-0178 1.790" 45.5 mm 3456

13-0179 1.805" 45.8 mm 3456

13-0180 1.820" 46.2 mm 3456

13-0181 1.835" 46.6 mm 3456

13-0182 1.850" 47.0 mm 3456

Chart Continued on next page

92-0131 : Rev. 960503

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Model 103 REP

Pilot Mandrel Per Cutting Head Function

, Rapid End Prep Machine

Pilot

P/N

13-0183 1.865" 47.4 mm 4 5 6

13-0184 1.880" 47.8 mm 4 5 6

13-0185 1.895" 48.1 mm 4 5 6

13-0186 1.910" 48.5 mm 4 5 6

13-0187 1.925" 48.9 mm 4 5 6

13-0188 1.940" 49.3 mm 4 5 6

13-0189 1.955" 49.7 mm 4 5 6

13-0190 1.970" 50.0 mm 4 5 6

13-0191 1.985" 50.4 mm 4 5 6

13-0192 1.995" 50.7 mm 4567

13-0193 2.000" 50.8 mm 4567

13-0194 2.010" 51.1 mm 4567

13-0195 2.025" 51.4 mm 4567

13-0196 2.040" 51.8 mm 4567

Pilot

Size

Cuttin

Functions with

Head Kit Numbers

13-0197 2.055" 52.2 mm 4567

13-0198 2.070" 52.6 mm 4567

13-0199 2.085" 53.0 mm 4567

13-0200 2.100" 53.3 mm 5 6 7

13-0201 2.115" 53.7 mm 5 6 7

13-0202 2.130" 54.1 mm 5 6 7

13-0203 2.145" 54.5 mm 5 6 7

13-0204 2.160" 54.9 mm 5 6 7

13-0205 2.175" 55.2 mm 5 6 7

13-0206 2.190" 55.6 mm 5 6 7

13-0207 2.205" 56.0 mm 5 6 7

13-0208 2.220" 56.4 mm 5 6 7

13-0209 2.235" 56.8 mm 5 6 7

13-0210 2.245" 57.0 mm 5678

13-0211 2.250" 57.2 mm 5678

13-0212 2.260" 57.4 mm 5678

13-0213 2.275" 57.8 mm 5678

Chart Continued on next page

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TRI TOOL INC.

Pilot Mandrel Per Cutting Head Function

Pilot

P/N

13-0214 2.290" 58.2 mm 5678

13-0215 2.305" 58.5 mm 5678

13-0216 2.320" 58.9 mm 5678

13-0217 2.335" 59.3 mm 6 7 8

13-0218 2.350" 59.7 mm 6 7 8

13-0219 2.365" 60.1 mm 6 7 8

13-0220 2.380" 60.5 mm 6 7 8

13-0221 2.395" 60.8 mm 6 7 8

13-0222 2.410" 61.2 mm 6 7 8

13-0223 2.425" 61.6 mm 6 7 8

13-0224 2.440" 62.0 mm 6 7 8

13-0225 2.455" 62.4 mm 6 7 8

13-0226 2.470" 62.7 mm 6 7 8

13-0227 2.485" 63.1 mm 6 7 8

Pilot

Size

Cuttin

Functions with

Head Kit Numbers

13-0228 2.495" 63.4 mm 6 7 8

13-0229 2.500" 63.5 mm 6 7 8

13-0230 2.510" 63.8 mm 6 7 8

13-0231 2.525" 64.1 mm 6 7 8

13-0232 2.540" 64.5 mm 6 7 8

13-0233 2.555" 64.9 mm 6 7 8

13-0234 2.570" 65.3 mm 6 7 8

13-0235 2.585" 65.7 mm 6 7 8

13-0236 2.600" 66.0 mm 6 7 8

13-0237 2.615" 66.4 mm 7 8

13-0238 2.630" 66.8 mm 7 8

13-0239 2.645" 67.2 mm 7 8

13-0240 2.660" 67.6 mm 7 8

13-0241 2.675" 67.9 mm 7 8

13-0242 2.690" 68.3 mm 7 8

13-0243 2.705" 68.7 mm 7 8

13-0244 2.720" 69.1 mm 7 8

Chart Continued on next page

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Model 103 REP

Pilot Mandrel Per Cutting Head Function

, Rapid End Prep Machine

Pilot

P/N

13-0245 2.735" 69.5 mm 7 8

13-0246 2.750" 69.9 mm 7 8

13-0247 2.760" 70.1 mm 7 8

13-0248 2.775" 70.5 mm 7 8

13-0249 2.790" 70.9 mm 7 8

13-0250 2.805" 71.2 mm 7 8

13-0251 2.820" 71.6 mm 7 8

13-0252 2.835" 72.00 mm 7 8

13-0253 2.850" 72.4 mm 8

13-0254 2.865" 72.8 mm 8

13-0255 2.880" 73.2 mm 8

13-0256 2.895" 73.5 mm 8

13-0257 2.910" 73.9 mm 8

13-0258 2.925" 74.3 mm 8

Pilot

Size

Cuttin

Functions with

Head Kit Numbers

13-0259 2.940" 74.7 mm 8

13-0260 2.955" 75.1 mm 8

13-0261 2.970" 75.4 mm 8

13-0262 2.985" 75.8 mm 8

13-0263 3.000" 76.2 mm 8

13-0264 3.010" 76.5 mm 8

13-0265 3.025" 76.8 mm 8

13-0266 3.040" 77.2 mm 8

13-0267 3.055" 77.6 mm 8

13-0268 3.070" 78.0 mm 8

13-0269 3.085" 78.4 mm 8

13-0270 3.100" 78.7 mm 8

13-0271 3.115" 79.1 mm 8

13-0272 3.130" 79.5 mm 8

13-0273 3.145" 79.9 mm 8

13-0274 3.160" 80.3 mm 8

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TRI TOOL INC.

CUTTER HEAD KITS

Cutter head kit

#1 Cutter Head Kit, (P/N 05-0107) Cutting Range .70" to 1.50" (17.8 mm to 38.1 mm) dia

Item Part No. No. Description Qty

1. 21-0162 HEAD, CUTTER 1

2. 30-0784 INSERT CARBIDE 1/2” 3

3. 33-0200 SCREW, CAP, 10-32 X 1/2” 3

4. 43-0281 COVER, WELDMENT 1

5. 33-1468 SCREW, CAP, 1/4-20 X 2 3/4, LEFT HD 3

5. 33-1469 SCREW, CAP, 1/4-20 X 1 1/4, LEFT HD 3

#2 Cutter Head Kit, (P/N 05-0108) Cutting Range 1.00" to 1.75" (25.4 mm to 44.5 mm) dia

Item Part No. No. Description Qty

1. 21-0168 HEAD, CUTTER 1

2. 30-0784 INSERT CARBIDE 1/2” 3

3. 33-0200 SCREW, CAP, 10-32 X 1/2” 3

4. 43-0281 COVER, WELDMENT 1

5. 33-1469 SCREW, CAP, 1/4-20 X 1 1/4, LEFT HD 3

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Model 103 REP

, Rapid End Prep Machine

#3 Cutter Head Kit, (P/N 05-0109) Cutting Range 1.00" to 1.95" (25.4 mm to 49.5 mm) dia

Item Part No. No. Description Qty

1. 21-0167 HEAD, CUTTER 1

2. 30-0785 INSERT CARBIDE 5/8” 3

3. 33-0041 SCREW, CAP, 1/4-20 X 7/8” 3

4. 43-0282 COVER, WELDMENT 1

5. 33-1469 SCREW, CAP, 1/4-20 X 1 1/4, LEFT HD 3

#4 Cutter Head Kit, (P/N 05-0110) Cutting Range 1.25" to 2.20" (31.8 mm to 55.9 mm) dia

Item Part No. No. Description Qty

1. 21-0166 HEAD, CUTTER 1

2. 30-0785 INSERT CARBIDE 5/8” 3

3. 33-0041 SCREW, CAP, 1/4-20 X 7/8” 3

4. 43-0282 COVER, WELDMENT 1

5. 33-1469 SCREW, CAP, 1/4-20 X 1 1/4, LEFT HD 3

#5 Cutter Head Kit, (P/N 05-0111) Cutting Range 1.50" to 2.44" (38.1 mm to 62.0 mm) dia

Item Part No. No. Description Qty

1. 21-0165 HEAD, CUTTER 1

2. 30-0785 INSERT CARBIDE 5/8” 3

3. 33-0041 SCREW, CAP, 1/4-20 X 7/8” 3

4. 43-0283 COVER, WELDMENT 1

5. 33-1469 SCREW, CAP, 1/4-20 X 1 1/4, LEFT HD 3

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TRI TOOL INC.

#6 Cutter Head Kit, (P/N 05-0112) Cutting Range 1.75" to 2.70" (44.5 mm to 68.6 mm) dia

Item Part No. No. Description Qty

1. 21-0164 HEAD, CUTTER 1

2. 30-0785 INSERT CARBIDE 5/8” 3

3. 33-0041 SCREW, CAP, 1/4-20 X 7/8” 3

4. 43-0283 COVER, WELDMENT 1

5. 33-1469 SCREW, CAP, 1/4-20 X 1 1/4, LEFT HD 3

#7 Cutter Head Kit, (P/N 05-0113) Cutting Range 2.00" to 2.94" (50.8 mm to 74.7 mm) dia

Item Part No. No. Description Qty

1. 21-0170 HEAD, CUTTER 1

2. 30-0785 INSERT CARBIDE 5/8” 3

3. 33-0041 SCREW, CAP, 1/4-20 X 7/8” 3

4. 43-0284 COVER, WELDMENT 1

5. 33-1469 SCREW, CAP, 1/4-20 X 1 1/4, LEFT HD 3

#8 Cutter Head Kit, (P/N 05-0114) Cutting Range 2.25" to 3.25" (57.2 mm to 82.6 mm) dia

Item Part No. No. Description Qty

1. 21-0163 HEAD, CUTTER 1

2. 30-0785 INSERT CARBIDE 5/8” 3

3. 33-0041 SCREW, CAP, 1/4-20 X 7/8” 3

4. 43-0284 COVER, WELDMENT 1

5. 33-1469 SCREW, CAP, 1/4-20 X 1 1/4, LEFT HD 3

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Page 27

Model 103 REP

, Rapid End Prep Machine

TOOL INSERTS

TOOL INSETS

Item Part No. No. Description Qty

1. 30-0784 INSERT, TOOL 3 (FOR CUTTER HEAD KITS #1 AND #2)

2. 30-0785 INSERT, TOOL 3 (FOR CUTTER HEAD KITS #3 THROUGH #8)

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Page 28

TRI TOOL INC.

TROUBLE SHOOTING

Problem: The 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. The main bearing pre-load is loose.

Problem: There is excessive Tool Bit wear

The pipe or tube material is too hard or abrasive. The cutting speed is too fast. Cutting fluid is required. A dull Tool Bit is causing surface hardening conditions (Stainless pipe or tubing). There is scale or other foreign matter on the pipe or tube, which is dulling the tool bit at the start of the cut. The tool bit is incorrect for the material being cut.

Problem: The surface finish is rough

The tool bit is dull, chipped, etc. Metal build-up on the cutting edge of the tool bit is creating a false cutting edge. Cutting fluid is required.

Problem: The tool holder is not feeding

The feed pin is broken or out of position. The feed sprocket shear pin is broken. The feed screw is stripped. The feed nut is stripped. The slide rails are too tight.

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Model 103 REP

Problem: There is a 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: There is a loss of hydraulic power

The hydraulic supply pressure is too low. The hydraulic filter is plugged. The hydraulic line size is insufficient. The hydraulic line is too long.

Problem: The tool bit will not reach the work

, Rapid End Prep Machine

Incorrect tool blocks are installed for the size of the pipe or tube being worked on. Incorrect tool bit is installed.

Problem: The hydraulic motor will not start

The hydraulic power supply is shut off. The hydraulic motor is damaged and will not run free.

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Page 30

TRI TOOL INC.

The following accessories are recommended for use with the Model 103 REP Rapid End Prep Machine and are available from TRI TOOL INC.

1. Portable Air Caddy (P/N 75-0115)

2. Over two hundred different Pilot Mandrels. Refer to the section ‘Pilot Mandrels’.

3. Eight Cutter Head Kits. Refer to the section ‘Cutter Head Kits’.

4. Two Tool Inserts. Refer to the section ‘Cutter Head Kits’.

5. Cross Track Assy (P/N 66-0070)

ACCESSORIES

64” (1.6 m) Track Assy (P/N 66-0077) Locator Tab (P/N 47-0360) Weld Tab (P/N 47-0359)

6. Case, Custom Carrying (P/N 86-0075)

A Filter/Regulator/Lubricator (FRL) is required to protect the warranty on all TRI TOOL INC air driven tools.

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Page 31

Model 103 REP

, Rapid End Prep Machine

ILLUSTRATED PARTS BREAKDOWN

MODEL 103 REP RAPID END PREP MACHINE (P/N 01-1117)

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Page 32

TRI TOOL INC.

Parts List, Model 103 REP Rapid End Prep Machine (P/N 01-1117)

Item Part No. No. Description Qty

1. HEAD KIT, CUTTER (REFER TO THE SECTION ON CUTTER HEAD KITS)

2. MANDREL, PILOT (REFER TO THE SECTION ON PILOT MANDRELS)

3. 19-0364 HOUSING, UPPER 1

4. 19-0365 HOUSING, LOWER 1

5. 20-0318 SHAFT, DRIVE 1

6. 20-0319 SHAFT, CUTTER 1

7. 29-0107 BEARING, THRUST 3

8. 29-0188 BEARING, ROLLER, NEEDLE 1

9. 29-0189 BEARING, ROLLER, NEEDLE 1

10. 29-0190 BEARING, THRUST 2

11. 29-0191 BEARING, ROLLER, NEEDLE 1

12. 29-0193 BEARING 1

13. 29-0194 BEARING 1

14. 30-0771 RING, RETAINGIN, EXTERNAL 1

15. 30-0786 GRIP, RUBBER, BLACK 1

16. 31-0004 KEY, WOODRUFF 4

17. 32-0104 PIN, DOWEL, 5/16 DIA X 2” 1

18. 33-0044 SCREW, CAP, 1/4-20 X 1 1/2” 3

19. 33-0072 SCREW, CAP, 3/8-16 X 1 1/4” 1

20. 33-0278 SCREW, BUTTON HEAD, #10-24 X 3/8” 2

21. 34-0162 WASHER, THRUST 6

22. 34-0163 WASHER, THRUST 1

23. 34-0185 WASHER, THRUST 1

24. 34-0202 WASHER, THRUST 4

25. 39-0401 GEAR, SPUR, DRIVE 1

26. 39-0402 GEAR, SPUR, IDLER 1

27. 39-0403 GEAR, SPUR, CUTTER 1

28. 40-0156 SPRING, WAVE 1

29. 41-0062 HANDLE 1

30. 54-0375 FITTING, GREASE 1

31. 54-0126 FITTING, QUICK DISCONNECT 1

32. 54-0201 CAP, PLASTIC 1

33. 57-0121 MOTOR, AIR, INLINE 1

92-xxxx : Orig. or Rev. YRMTHDY

Page 33

Model No. and Name

REP ADAPTOR ASSY (P/N 27-0254)

92-XX : Orig. or Rev. YRMTHDY

Page 34

TRI TOOL INC.

Parts List, REP Adaptor Assy (P/N 27-0254)

Item Part No. No. Description Qty

1. 19-0379 HOUSING ASSY, GEAR 1

2. 20-0326 SHAFT, CYLINDER 1

3. 20-0327 SHAFT, GEAR 1

4. 20-0328 SHAFT ASSY, REP ADAPTOR 1

5. 24-0617 PLATE, MOUNTING 1

6. 24-0618 PLATE, CLAMPING 1

7. 24-0621 PLATE, TOP 1

8. 30-0411 RING, RETAINING, EXTERNAL 1

9. 31-0072 KEY, SQUARE 1

10. 32-0015 PIN, ROLL, 3/32 DIA X 5/16 2

11. 32-0043 PIN, ROLL, 3/16 DIA X 1 1/4” 1

12. 32-0283 PIN, GROOVED 1

13. 33-0028 SCREW, CAP, #10-24 X 1/2” 3

14. 33-0043 SCREW, CAP, 1/4-20 X 1 1/4” 8

15. 33-0057 SCREW, CAP, 5/16-18 X 1 1/4” 2

16. 33-0287 SCREW, FLAT HEAD, 1/4-20 X 3/4” 4

17. 33-1144 SCREW SET, 3/8-16 X 1”, HDOG 1

18. 33-1445 SCREW, HEX HEAD, 3/8-16 X 1 3/4” 4

19. 33-1467 SCREW, THUMB, 1/2-13 1

20. 34-0018 WASHER, FLAT 4

21. 35-0248 NUT, CHECK 1

22. 39-0153 GEAR, SPUR 1

23. 39-0428 RACK 1

24. 39-0429 GEAR, CHANGE 1

25. 40-0155 SPRING, RETURN 1

26. 41-0070 HANDLE 1

27. 42-0017 KNOB, SPHERICAL 1

28. 45-0110 BUSHING, ADJUSTABLE 2

29. 45-0111 BUSHING, STATIONARY 2

30. 45-0120 KNOB 1

31. 45-0121 BUSHING 1

32. 61-0019 JOURNAL 4

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Page 35

Model 103 REP

, Rapid End Prep Machine

CROSS TRACK ASSY (P/N 66-0070)

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Page 36

TRI TOOL INC.

Parts List, Cross Track Assy (P/N 66-0070)

Item Part No. No. Description Qty

1. 24-0615 PLATE, BASE 1

2. 24-0616 PLATE, GUSSET 1

3. 30-0031 KEENSERT 1

4. 30-0356 PIN, LOCK 1

5. 30-0817 NUT, SWIVEL 1

6. 32-0057 PIN, ROLL, 1/4” DIA X 2” 2

7. 33-0072 SCREW, CAP, 3/8-16 X 1 1/4” 2

8. 33-0074 SCREW, CAP, 3/8-16 X 1 3/4” 2

9. 33-1445 SCREW, HEX HEAD, 3/8-16 X 1 3/4” 4

10. 34-0018 WASHER, FLAT 4

11. 42-0090 KNOB ASSY, HAND 1

12. 45-0110 BUSHING, ADJUSTABLE 2

13. 45-0111 BUSHING, STATIONARY 2

14. 61-0019 JOURNAL, DUAL VEE 4

15. 66-0068 TRACK, 23” (.6m) 1

92-0131 : Rev. 960503