Climax BG38LV User manual

BOILER
GUN
BG38 BOILER GUN
OPERATING MANUAL
ORIGINAL INSTRUCTIONS
P/N 100242
September 2023
Revision 3
BG38LV model shown

P/N 100242, Rev. 3 Page A
©2023 CLIMAX or its subsidiaries.
All rights reserved.
Except as expressly provided herein, no part of this manual may be reproduced, copied, transmitted, dissem-
inated, 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, pro-
vided 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, 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
[email protected]. For quick and accurate service, please provide your representative with the following:
• Your name
• Shipping address
• Telephone number
• Machine model
• Serial number (if applicable)
• Date of purchase
CLIMAX World Headquarters
2712 East 2nd Street
Newberg, Oregon 97132 USA
Telephone (worldwide): [phone]
Toll-free (North America): 1-800-333-8311
Fax: [phone]
CLIMAX | H&S Tool World Headquarters
715 Weber Dr.
Wadsworth, OH 44281 USA
Telephone: [phone]
Fax: [phone]
hstool.com
CLIMAX | H&S Tool (UK Headquarters)
Unit 3 Martel Court
S. Park Business Park
Stockport SK1 2AF, UK
Telephone: [phone]
CLIMAX | H&S Tool (European Headquarters)
Am Langen Graben 8
52353 Düren, Germany
Telephone: [phone]
E-mail: [e-mail]
CLIMAX | H&S Tool (Asia Pacific Head-
quarters)
316 Tanglin Road #02-01
Singapore 247978
Telephone: [phone]
Fax: [phone]
CLIMAX | H&S Tool (Middle East Headquarters)
Warehouse #5, Plot: 369 272
Um Sequim Road
Al Quoz 4
PO Box 414 084
Dubai, UAE
Telephone: [phone]

Page B BG38 Boiler Gun Operating Manual
CLIMAX GLOBAL LOCATIONS

P/N 100242, Rev. 3 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 pre-
paid, 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 per-
formed 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 con-
tact 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 BG38 Boiler Gun Operating Manual
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P/N 100242, Rev. 2 Page i
TABLE OF CONTENTS
CHAPTER/SECTION PAGE
1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 SAFETY ALERTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 GENERAL SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 MACHINE-SPECIFIC SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 RISK ASSESSMENT AND HAZARD MITIGATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.6 RISK ASSESSMENT CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.7 LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.7.1 Label identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 FEATURES AND COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2.1 Pneumatic motor controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2.2 Electric motor controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.5 ITEMS REQUIRED BUT NOT SUPPLIED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 RECEIPT AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 MACHINE SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2.1 Wedge locking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2.2 Collet locking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2.3 Tool holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2.4 Center shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.3 MACHINE MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.4 INSTALLING THE CUTTING TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.5 MOTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.5.1 Pneumatic motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.5.2 Electric motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.1 PRE-OPERATION CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.2.1 Pneumatic motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.2.2 Electric motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.1 MAINTENANCE CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Page ii BG38 Boiler Gun Operating Manual
TABLE OF CONTENTS (CONTINUED)
CHAPTER/SECTION PAGE
5.2 APPROVED LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.3 MAINTENANCE TASKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.3.1 Checking and filling the in-line oiler reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.3.2 Servicing the filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.3.3 Adjusting the oil flow rate of the in-line oiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.3.4 Tool holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.3.5 Greasing the drive and pinion gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.4 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.4.1 The machine isn’t turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.4.2 The machine isn’t feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.4.3 The machine is performing poorly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6 STORAGE AND SHIPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
6.1 STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.1.1 Short-term storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.1.2 Long-term storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.2 SHIPPING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.3 DECOMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
APPENDIX A ASSEMBLY DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
APPENDIX B SDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

P/N 100242, Rev. 2 Page iii
LIST OF FIGURES
FIGURE PAGE
2-1 BG38 and shipping container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-2 Pneumatic motor throttle lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-3 Direction and trigger controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-4 BG38 Boiler Gun dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-1 BG38 Boiler Gun main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3-2 Installed wedge set with extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3-3 Installed collet set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3-4 Changing the center shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3-5 BG38 Boiler Gun installed in workpiece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3-6 Locking rod wrench with speed wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3-7 Sliding tool holder (l) and fixed tool holder (r) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3-8 Cutting bit installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3-9 Universal coupler (top) and quick disconnect (bottom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3-10 Motor direction control set to forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-1 Hand positioning during boiler gun operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4-2 BG38 with electric motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-1 In-line oiler sight glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6-1 BG22 shipping container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
A-1 BG38 boiler gun assembly (P/N 102985) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
A-2 BG38 boiler gun chart (P/N 102985). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
A-3 Boiler gun base unit feed wrench assembly (P/N 99969) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
A-4 BG38 boiler gun high-velocity pneumatic assembly (P/N BG38HV-R) . . . . . . . . . . . . . . . . . . . . . . . . . 29
A-5 BG38 boiler gun low-velocity pneumatic assembly (P/N BG38LV-R) . . . . . . . . . . . . . . . . . . . . . . . . . . 30
A-6 BG38E110-R boiler gun electric assembly (P/N 102987) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
A-7 BG38CP collet kit assembly (P/N 103077) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
A-8 BG38 tool holder assembly (P/N 103081). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
A-9 BG38 tool holder assembly parts list (P/N 103081) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
A-10 Wedge mount system kit (P/N 103081) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
A-11 Air hose assembly (P/N HS50509) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
A-12 Tool kit (P/N 100603) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

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P/N 100242, Rev. 2 Page v
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 BG38 Boiler Gun labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2-1 Sub-component mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5-1 Maintenance intervals and tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5-2 Approved lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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P/N 100242, Rev. 2 Page 1
1 INTRODUCTION
IN THIS CHAPTER:
1.1 HOW TO USE THIS MANUAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
1.2 SAFETY ALERTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
1.3 GENERAL SAFETY PRECAUTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2
1.4 MACHINE-SPECIFIC SAFETY PRECAUTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3
1.5 RISK ASSESSMENT AND HAZARD MITIGATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4
1.6 RISK ASSESSMENT CHECKLIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5
1.7 LABELS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
1.7.1 LABEL IDENTIFICATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
1.1 HOW TO USE THIS MANUAL
This manual describes information necessary for the
setup, operation, maintenance, storage, shipping, and
decommissioning of the BG38 Boiler Gun.
The first page of each chapter includes a summary of
the chapter contents to help you locate specific infor-
mation. The appendices contain supplemental product
information to aid in setup, operation, and maintenance
tasks.
Read this entire manual to familiarize yourself with the
BG38 Boiler Gun before attempting to set it up or oper-
ate it.
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 here1:
DANGER
indicates a hazardous situation which, if not
avoided, WILL result in death or severe
injury.
WARNING
indicates a hazardous situation which, if not
avoided, COULD result in death or severe
injury.
CAUTION
indicates a hazardous situation which, if not
avoided, could result in minor or moderate
injury.
NOTICE
indicates a hazardous situation which, if not
avoided, could result in property damage,
equipment failure, or undesired work
results
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.

Page 2 BG38 Boiler Gun Operating Manual
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 proce-
dures and safety precautions contained in this manual,
as well as your employer’s safety guidelines.
Observe the following safety precautions when operat-
ing or working around the machine.
Training – Before operating this or any machine
tool, you should receive instruction from a qual-
ified 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 man-
ual.
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, jew-
elry, 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 pro-
tective gloves and exercise caution when han-
dling 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.

P/N 100242, Rev. 2 Page 3
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 radia-
tion 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
levels1listed in Table 1-1.
TABLE 1-1. SOUND LEVELS
SPneumatic 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 Euro-
pean Harmonized Standards EN ISO 3744:2010 and EN 11201:2010.

Page 4 BG38 Boiler Gun Operating Manual
1.5 RISK ASSESSMENT AND HAZARD MITIGATION
Machine Tools are specifically designed to perform pre-
cise 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 on-
site machining applications. They typically attach
directly to the workpiece itself, or to an adjacent struc-
ture, and achieve their rigidity from the structure to
which it is attached. The design intent is that the Porta-
ble 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 on-
site 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.

P/N 100242, Rev. 2 Page 5
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.
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:
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.
TABLE 1-3. RISK ASSESSMENT CHECKLIST AFTER SET-UP
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.
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.

Page 6 BG38 Boiler Gun Operating Manual
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. BG38 BOILER GUN LABELS
P/N 100206
BG38-HV label
P/N 100207
BG38-LV label
P/N 100251
BG38-E label
P/N 100199
H&S company label
P/N 35828
CE serial number
plate
P/N 100239
BG38 container
label
PN 87271
Warning label: use
eye and ear protec-
tion, and read the
operating manual
P/N 100240
Wedge and pad
chart

P/N 100242, Rev. 2 Page 7
2 OVERVIEW
IN THIS CHAPTER:
2.1 FEATURES AND COMPONENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7
2.2 CONTROLS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8
2.2.1 PNEUMATIC MOTOR CONTROLS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8
2.2.2 ELECTRIC MOTOR CONTROLS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8
2.3 DIMENSIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9
2.4 SPECIFICATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9
2.5 ITEMS REQUIRED BUT NOT SUPPLIED - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9
2.1 FEATURES AND COMPONENTS
The BG38 Boiler Gun 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 .625” (12.7mm) ID to 3.00” (63.5mm) OD.
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) and Low Velocity (LV) -HV
delivers higher cutting speeds to turn specialty car-
bide inserts. LV is geared for heavy walls and hard
alloys.
Mounting systems—Either a wedge or collet mount-
ing system secures the BG38 Boiler Gun to the work-
piece. They are both self-centering and adapt to a
wide range of pipe sizes.
Tool holders—Available with sliding tools holders, in
multiple sizes.
Torque free operation—Once securely mounted the
BG38 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 sys-
tem 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.
FIGURE 2-1. BG38 AND SHIPPING CONTAINER

Page 8 BG38 Boiler Gun Operating Manual
2.2 CONTROLS
Depending on the users requirements, the BG38 Boiler
Gun can be powered by either a pneumatic or electric
motor. The controls for each type of motor follow.
WARNING
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 BG38 Boiler Gun fea-
tures a throttle lever. The safety lock must be disen-
gaged 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 re-engage.
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.
FIGURE 2-2. PNEUMATIC MOTOR THROTTLE LEVER
FIGURE 2-3. DIRECTION AND TRIGGER CONTROLS