Climax H&S BOILER GUN BG22 User manual

BOILER
GUN
BG22 BOILER GUN
OPERATING MANUAL
P/N 100241
August 2017
Revision 1

P/N 100241, Rev. 1 Page i
TABLE OF CONTENTS
CHAPTER/SECTION PAGE
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
1.7.2 Label location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OVERVIEW 9
2.1 FEATURES AND COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2.1 Pneumatic motor controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2.2 Electric motor controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2.3 Cordless electric motor controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3 DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.4 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.5 ITEMS REQUIRED BUT NOT SUPPLIED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SETUP 13
3.1 RECEIPT AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2 MACHINE SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2.1 Wedge locking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2.2 Collet locking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2.3 Tool holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2.4 Center shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.3 MACHINE MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.4 INSTALLING THE CUTTING TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.5 MOTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.5.1 Pneumatic motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.5.2 Electric motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.5.3 Cordless electric motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATION 19
4.1 PRE-OPERATION CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.2.1 Pneumatic motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Page ii
TABLE OF CONTENTS (CONTINUED)
CHAPTER/SECTION PAGE
4.2.2 Electric motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
MAINTENANCE 21
5.1 MAINTENANCE CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.2 APPROVED LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.3 MAINTENANCE TASKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.3.1 Checking and filling the in-line oiler reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.3.2 Servicing the filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.3.3 Adjusting the oil flow rate of the in-line oiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.3.4 Tool holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.3.5 Greasing the drive and pinion gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.4 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.4.1 The machine isn’t turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.4.2 The machine isn’t feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.4.3 The machine is performing poorly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
STORAGE AND SHIPPING 25
6.1 STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.1.1 Short-term storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.1.2 Long-term storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.2 SHIPPING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.3 DECOMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
ASSEMBLY DRAWINGS 27
SDS 39

LIST OF FIGURES
FIGURE PAGE
P/N 100241, Rev. 1 Page iii
1-1 BG22 Boiler Gun, pneumatic label location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1-2 BG22 Boiler Gun, electric label location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-1 BG22 and shipping container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2-2 Pneumatic motor throttle lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2-3 Direction and trigger controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2-4 Cordless motor controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2-5 BG22 Boiler Gun dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-1 BG22 Boiler Gun main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3-2 Installed wedge set with extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3-3 Small wedge set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3-4 Installed collet set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3-5 Changing the center shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3-6 BG22 Boiler Gun installed in workpiece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3-7 Locking rod wrench with speed wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3-8 Sliding tool holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3-9 Cutting bit installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3-10 Universal coupler (top) and quick disconnect (bottom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3-11 Motor direction control set to forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-1 Hand positioning during boiler gun operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-2 BG22 with electric motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5-1 In-line oiler sight glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6-1 BG22 shipping container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
A-1 BG22 boiler gun pneumatic assembly (P/N BG22). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
A-2 BG22 boiler gun electric assembly (P/N BG22E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
A-3 BG22 boiler gun cordless electric assembly (P/N BG22C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
A-4 Collet components and collets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
A-5 Wedge sets and wedge extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
A-6 Wedge set components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
A-7 Small wedge set components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
A-8 Tool holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
A-9 Air motor assembly and parts list (P/N CML3488) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
A-10 Air hose assembly and parts list (P/N HS 50-509) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
A-11 Electric motor assembly and parts list (P/N EB002615) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
A-12 Tool kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
A-13 Shipping container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Page iv
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LIST OF TABLES
TABLE PAGE
P/N 100241, Rev. 1 Page v
1-1 Sound levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-2 Risk assessment checklist before set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1-3 Risk assessment checklist after set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1-4 BG22 Boiler Gun labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2-1 Sub-component mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5-1 Maintenance intervals and tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5-2 Approved lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Page vi
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P/N 100241, Rev. 1 Page A
©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
[email protected].
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 factory representative with the following:
•Yourname
• Shipping address
• Telephone number
• Machine model
• Serial number (if applicable)
•Dateofpurchase
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: [email protected]
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: [email protected]
Climax European Headquarters
Climax GmbH
Am Langen Graben 8
52353 Düren, Germany
Telephone: [phone]
E-mail: [email protected]

Page B
CLIMAX GLOBAL LOCATIONS

P/N 100241, Rev. 1 Page C
CE DOCUMENTATION
CE Certification is pending

Page D
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.

P/N 100241, Rev. 1 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
1.7.2 LABEL LOCATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7
1.1 HOW TO USE THIS MANUAL
This manual describes information necessary for the
setup, operation, maintenance, storage, shipping, and
decommissioning of the BG22 Boiler Gun.
The first page of each chapter includes a summary of
the chapter contents to help you locate specific 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
BG22 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 BG22 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 100241, Rev. 1 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 BG22 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 100241, Rev. 1 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 BG22 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. BG22 BOILER GUN LABELS
P/N 100204
BG22 Boiler gun label
P/N 100199
H&S company label
P/N 100198
H&S serial plate
P/N 87271
Warning label: Use
eye and ear protec-
tion, and read the
manual.
P/N BG22 container
label
P/N 100240
Wedge and pad
chart

P/N 100241, Rev. 1 Page 7
1.7.2 Label location
The following figures display the location of the labels
on each of the components of the BG22 Boiler Gun.
Label P/N: 100204, 100198, 100199, 87271
FIGURE 1-1. BG22 BOILER GUN, PNEUMATIC LABEL LOCATION

Page 8 BG22 Boiler Gun Operating Manual
Label P/N: 100204, 100198, 100199, 87271
FIGURE 1-2. BG22 BOILER GUN, ELECTRIC LABEL LOCATION