TRI tool 202TS User manual

Operation
Manual
92-0771 Rev. 230306
Model 202TS Tube Sheet Cutter

ABOUT TRI TOOL TECHNOLOGIES
At Tri Tool, we are committed to your success through
relentless innovation and powerful partnership. We
insist on developing tools and equipment that exceed
your expectations of performance, precision, safety, and
durability. As a full-service engineering rm, we are here to
support you every step of the way.
For more information on engineered solutions, products,
and trainings, visit tritool.com or contact our engineers at
[phone].

92-0771 Rev. 230306
Model 202TS Tube Sheet Cutter
TABLE OF CONTENTS
Tri Tool Inc. Warranty 4
Tool Bit Resharpening Policy 5
About The Manual 6
Safety Precautions 8
General Description 10
 Specications         11
Maintenance 13
Operation 15
Cutting Speeds 19
Ramp Set 20
Tool Bits 21
Troubleshooting 22
Accessories 24
Illustrated Parts Breakdown 25
ABOUT TRI TOOL TECHNOLOGIES
At Tri Tool, we are committed to your success through
relentless innovation and powerful partnership. We
insist on developing tools and equipment that exceed
your expectations of performance, precision, safety, and
durability. As a full-service engineering rm, we are here to
support you every step of the way.
For more information on engineered solutions, products,
and trainings, visit tritool.com or contact our engineers at
[phone].

TRI TOOL INC.
92-0771 Rev. 230306
4
TRI TOOL INC. Warranty
LIMITED WARRANTY: All products manufactured by Seller are warranted to be free from
defects in materials and workmanship under normal use. The period of this warranty shall
be three years from the date of shipment for all products, except for welding and Non-Stan-
dard Products which shall be one year from the date of shipment. The Buyer shall bear all
shipping, packing and insurance costs and all other costs to and from a designated repair
service center. All return goods must be authorized in advance and communicated upon is-
suance of a Return Material Authorization (RMA) by Seller. The product will be returned to
the Seller accompanied by a RMA number and associated paperwork, freight prepaid and
billed to the Buyer. This warranty is not transferable and will not apply to tool bits or other
consumables, or to any Goods to have been (i) mishandled, misused, abused or damaged
by Buyer or any third party; (ii) altered without the express permission in writing by Seller,
(iii) repaired by a party other than Seller without Seller’s prior written approval; or (iv) im-
properly stored, installed, operated, or maintained in a manner inconsistent with Seller’s
instructions. This warranty does not apply to defects attributed to (i) normal wear and tear
or (ii) failure to comply with Seller’s safety warnings.
No warranty for any parts or other supplies provided to seller by buyer, whether or not
they are incorporated into goods. Goods supplied by seller which are designed or manu-
factured by a third party are subject strictly to the third party’s warranty for those goods.
Seller makes no warranty and disclaims all statutory or implied warranties for these goods,
including the implied warranties of merchantability, freedom from patent infringement and
tnessforaparticularpurpose.
Neither this warranty nor any other warranty, expressed or implied, including implied warran-
tiesofmechanicalability,tnessforaparticularuse,ormerchantability,shallextendbeyond
the warranty period. No responsibility is assumed for any incidental or consequential dam-
ages. Some states do not allow limitations on how long an implied warranty lasts and some
states do not allow the exclusion or limitations incidental or consequential damages, so the
above limitation of exclusion does not apply to all Buyers. This warranty gives the Buyer
speciclegalrights.Otherrightsvaryfromstatetostate.
Warranty Claims and Remedies
Buyer must promptly notify Seller in writing during the applicable warranty period, of
any defective Goods covered by Seller’s warranties under the Limited Warranty section
herein,andnolaterthanfteen(15)calendardaysafterdiscoveryofthedefect.Seller
has no obligation to honor any warranty claim made after the expiration of the warranty
period. However, despite the expiration of the warranty period, Seller, at its reasonable
discretion,mayacceptwarrantyclaimssubmitteduptofteen(15)calendardaysaf-
ter the expiration of the warranty period provided that Buyer provides Seller with cred-
ible and persuasive documentary evidence that the defect was discovered during the

Model 202TS Tube Sheet Cutter
92-0771 Rev. 230306 5
warrantyperiod.Nowarrantyclaimssubmittedafterthisfteen(15)daycalendarperiod
will be considered by Seller.
Buyer’snoticeofadefectiveGoodsmustidentifythespecicGoodsa󰀨ected,andthe
nature of the defect. It is required when returning the defective Goods, that it is suitably
packed, fully insured, and transportation and insurance prepaid in accordance with in-
structions issued by Seller. Seller, at its sole option, will either repair or replace any Goods
authorized for return to Seller. Such repair, replacement, or credit shall be Buyer’s sole
remedy for defective Goods. Buyer must promptly provide Seller with all information re-
questedregardingtheidentieddefect.
IfthedefectclaimedbyBuyercannotbereproducedorotherwiseveriedbySeller,the
GoodswillbereturnedtoBuyerunmodiedatBuyer’sexpense.
The warranty period for repaired or replaced Goods shall be (i) ninety (90) days or (ii) the
unexpired portion of the original warranty period. Under no circumstances is Seller liable for
recall, retrieval, removal, dismantling, re-installation, redeployment, or re-commissioning of
any defective Goods or any costs associated therewith.
Tool Bit Resharpening Policy
Buyer is required to check all tool bits prior to returning and ensure they are packaged well
for shipment. The price structure is available from the Seller’s sales coordinator. Seller can-
not resharpen badly gouged, chipped, or broken tool bits. Seller will return tool bits that are
not suitable for resharpening with the tool bits that were resharpened upon Buyer’s request.
Buyer is responsible for all shipping charges to and from Seller.

TRI TOOL INC.
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1. ABOUT THE MANUAL
Copyright
©Copyright Tri Tool Inc. Proprietary property of Tri Tool Inc. No reproduction, use, or dupli-
cation of the information shown hereon is permitted without the express written consent of
Tri Tool Inc.
Disclaimer
The instructions and descriptions in this manual were accurate when the manual was writ-
ten. However, the information in the manual is subject to change without notice. Check for
updated information before you start any job. The Tri Tool Inc. web site has the most cur-
rent information.
Do not operate or work on this equipment unless you have read and understood the in-
structions in this Manual. Failure to follow the instructions or follow the safety instructions
could result in serious injury or death. This manual describes conditions and hazards that
are common and anticipated during equipment operation. No manual can address all con-
ditions which may occur.
Safety Symbols
The manual may contain one or more safety symbols. These symbols and the associated
text warn you of potentially hazardous conditions. Examples of the safety symbols and the
associated text follow:
DANGER
DANGER: Indicates a hazardous situation that, if not avoided, will result in serious
injury or death.
WARNING
WARNING: Indicates a hazardous situation that, if not avoided, could result in serious
injury or death.
CAUTION
CAUTION: Indicates a hazardous situation that, if not avoided, could result in minor or
moderate injury, or cause property damage.

Model 202TS Tube Sheet Cutter
92-0771 Rev. 230306 7
GLASSES
SAFETY GLASSES: Indicates a hazardous situation that requires the use
of safety glasses.
HOT SURFACE
HOT SURFACE: Indicates a hazardous situation that hot
surfaces may be present.
SHOCK HAZARD
ARC FLASH & SHOCK HAZARD: High voltage. Entry by authorized
personnel only. Appropriate PPE and tools required when working on this
equipment.
GLOVES
GLOVES: Indicates a hazardous situation that requires glasses.

TRI TOOL INC.
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2. SAFETY PRECAUTIONS
In General
Use standard safety equipment such as: hard hats, safety shoes, safety harnesses, protec-
tive clothes, and other safety devices when appropriate.
Operatethistoolonlyinaccordancewithspecicoperatinginstructions.
Personal Protective Equipment
Use standard safety equipment such as: hard hats, safety shoes, safety harnesses, protec-
tive clothes, and other safety devices when appropriate.
Wear safety glasses.
Do not wear loose clothing or jewelry.
Wear nonskid footwear.
Put long hair in a cap or a net to make sure hair does not get tangled in equipment.
Personnel
Only personnel who are trained or are being trained may operate the equipment.
Keep the operation manual available where the equipment is used.
The operator must read the operation manual before using the equipment.
The equipment must be operated in accordance with the manual information.
The operator must follow the safety precautions in this manual and good engineering prac-
tices to reduce the risk of injury.
Before using the equipment, the operator must ensure that all safety messages on the
equipment are legible.
Work Area
Keep the work area clean.
Keep the area well lit.
Keep items such as electrical cords, cables, rags, rigging straps, away from rotating equip-
ment.
Donotusepower-cuttingtoolsinthepresenceofammableliquidsandgases.
WARNING
WARNING: Do not override the dead-man switch on the power unit. Locking down,
obstructing, or in any way defeating the dead-man switch on the power drive unit may
result in serious injury.

Model 202TS Tube Sheet Cutter
92-0771 Rev. 230306 9
Do not let visitors or untrained personnel near tools that are in use.
Ensure all observers wear eye protection.
Keep proper footing at all times.
Area Equipment
Secure the pipe with clamps, vises, chains or straps.
Ensure that both sides of the pipe at the cut site is fully supported so that the pipe will not
move after the cut is completed. Long lengths of pipe may be under load and the separa-
tion of the pipe can release pressure. This pressure can cause both sides of the pipe to
move.
Tool Care
Keep tools in good operating condition. Sharp tool bits perform better and are safer than
dull tool bits.
Do not use damaged tools. Always check your tools for damage especially if a tool has mal-
functioned, been dropped or hit, check it for damage.
Before you start operating the equipment, do no-load tests and feed function checks.
Tool Use
Use the right tool and tool bit for the job. Contact Tri Tool to help with your application.
Keep the tool bits fully engaged in the tool bit holders. Loose bits are sharp and can cause
cuts or punctures.
Disconnectpowersupplyduringsetupandmaintenance.Useall‘Stop’orShuto󰀨’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. Check 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 recom-
mended speeds.
Do not reach into rotating equipment.
Do not reach into the rotating head stock to remove chips, to make adjustments, or to
checkthesurfacenish.
Handle chips with care. Chips have very sharp edges and are hot. Do not try to pull chips
apart with bare hands.
Store tools properly. Disconnect tools from the power source, remove the tool bits, and
store in a safe place.

TRI TOOL INC.
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3. GENERAL DESCRIPTION
The Model 202TS™ Tube Sheet Cutter is an ID Mount Machine tool for facing
and chamfering the ends of tubing and tube sheet bores in preparation for welding
andnishsquaring.
Design and Operation Features:
1. The lathe accepts it’s own torque through the mandrel.
2. The expanding mandrel provides fast, accurate self-centering and alignment.
3. All wrenches needed for operation are provided with the system.
4. The lathe, at less then 17 lbs. (7.7 Kg), is light weight and is easily handled by
one operator.
5. Pneumatic Clamping System.
6. Mandrel shaft seal to keep coolants out of the gears.
7. Heat treated mandrel mounting blocks for maximum life and secure mounting.
8. Stops, adjustable, to set mounting and/or cut depth.
9. Hoist ring for attachment to an overhead balancer.

Model 202TS Tube Sheet Cutter
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4. SPECIFICATIONS
Clearance and Dimensions
IN GENERAL:
The Tube Sheet Cutter has been designed for quick and easy repetition cutting of a tube
sheet.
IN SPECIFIC:
Feed Travel: .56” (14.2 mm)
Weight: 16.5 lbs (7.5 kg)
Power requirement: 55 cfm at 90 psi 26 L/s at 621 kPa)
4.00”
(101.6mm)
10.81”
(274.6mm)
16.53”
(419.9mm)
11.20”
(284.5mm)
Figure 1: Envelope Drawing

TRI TOOL INC.
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Pipe range: Maximum O.D. of 2.00” (50.8mm) and
Minimum I.D. of .77” (19.6mm)
Optional Small Mandrel: Minimum ID of .50” (12.7mm)
Maximum ID of .78” (19.8mm)

Model 202TS Tube Sheet Cutter
92-0771 Rev. 230306 13
5. MAINTENANCE
IN GENERAL
• Allcomponentsshouldbecleanedandcoatedwithalightlmofoilpriortouse.
Use a clean, non detergent oil, preferably SAE 10 (90 SSU) or lighter.
• TheairsupplyfortheTubeSheetCuttershouldincludealladequatelter,regulator
and lubricator (FRL).
Note: The motor warranty is void if damage occurs from contaminated air or lack of
lubrication.
• If the Tube Sheet Cutter 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.
Note: Tool life may be severely shortened, unless chips and/or debris, that have been de-
posited on the cutting head during the machining operation, are removed.
• Bearings and gears are to be lubricated using “Chevron Ultra-Duty NLGI 2 Grease”
or equivalent.
Air Motor Lubrication:
NOTE: Disassembly of a power unit voids warranty, except when performed by TRI TOOL
Inc. designated repair technician. (Letter of designation is required).
• No direct maintenance is normally required on the air motor.
• However,theairsupplymustowthroughalter/regulator/lubricator(FRL)unitor
separate
• units before arriving at the air motor.
• The FRL unit must be maintained as required (frequency dependent upon the basic
airsupply)tokeepthewatertrapdrained,ltercleanedandthelubricatoroilreser-
voirlledsothatadropofoilisowingevery2to5seconds..
• If the Tube Sheet Cutter is to be left idle for 24 hours or more after being run on
‘wet’air, it is
• advisable to squirt oil directly into the air motor inlet and run the motor for 2 to 3
seconds.
• This will prevent rusting and ‘freezing’ of the rotor vanes.

TRI TOOL INC.
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• Lubricant recommendations:
• The air motor requires Class 2 lubricant, viscosity of 100 to 200 SSU at 100° F
(38°C) minimum aniline point of 200° F (93°C).
TRI TOOL Inc. - Air Tool Lubricant (P/N 68-0022)
• AMACO - American Industrial Oil No. 32
• AtlanticRicheld-DuroOilS-150
• Exxon - Nuto H32
• Shell - Tellus Oil 32
The bearings in the air motor are sealed and do not require any lubrication.

Model 202TS Tube Sheet Cutter
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7. O P E R AT I O N
Standard Mandrel Installation and Removal Procedure (P/N 12-0127)
INSTALLATION:
1. Select the ramp block set for the size of the tube to be machined.
2. Slide the mandrel into the tool until it bottoms out.
3. Attach the butt plate on the draw rod. Tighten the set screw on the
 drawrodattheat.
4. With the draw rod in the extended position, install (1) ramp block in to each of
the (3) slots on the mandrel shaft and into the matching slots in the butt plate
on the draw rod.
5. Install the spring to retain the ramp blocks.
Note: Depending on the ramp block set, the spring can be fed through the ramp blocks or
wrapped around the ramp blocks.
6. Thread the draw rod and the mandrel together into the tool.
7. Align the holes in the mandrel with the set screw holes in the feed
housing.
8. Install the cone point set screws on both sides.
9. Install the cup point set screws after the cone point set screws.
10. Install the cup point set screws after the cone point set screws.
REMOVAL:
1. Remove the cup point set screws.
2. Remove the cone point set screws.
3. Unthread the draw rod from the tool.
Note: The feed handle will rotate when the draw rod is being removed. The feed handle
can be rotated back and forth to help in threading of the mandrel from the tool. If the ramp
blocks are attached to the mandrel, unthread the mandrel and the draw rod at the same
time.

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4. After the draw rod is loose and no longer threaded into the tool, pull the mandrel
out of the tool.
Optional Small Mandrel Installation and Removal Procedure (P/N 06-
0450)
INSTALLATION:
1. Slide the mandrel into the tool unit until it bottoms out.
2. Thread the draw rod into the tool.
3. The draw rod will thread up to the mandrel.
4. Rotate the feed handel to its full range and back. This will pull the mandrel
into the tool.
5. Repeat steps 3 and 4 until the mandrel and draw rod are fully installed.
6. Back the draw rod away to a maximum of .03” between the butt plate on the
draw rod and the mandrel.
7. Align the holes in the mandrel with the set screws holes in the feed housing.
8. Install the cone point set screws on both sides.
9. Install the cup point set screws after the cone point set screws.
10. Slide the seal block up to the head.
11. Install (2) 10-24 x 1/4” button head screws into head, to secure the seal lock.
12. Actuate the air cylinder for the draw rod to be in extended position.
13. Select the ramp block set for the size of the tube to be machined.
14. Install (1) ramp block into each of the (3) slots on the mandrel shaft and into
the matching slots in the butt plate on the draw rod.
15. Install the spring to retain the ramp blocks.
REMOVAL:
1. Remove the cup point set screws.

Model 202TS Tube Sheet Cutter
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2. Remove the cone point set screws.
3. Remove the spring and the (3) three ramp blocks.
4. Remove (2) 10-24 x 1/4” button head screws that secure the seal block to the
head.
5. Unthread the draw rod from the tool.
Note: The feed handle will rotate when the draw rod is being removed. For ease of removal,
the feed handle can rotate back and forth to help the unthreading of the draw rod.
6. After the draw rod is loose and no longer threaded into the tool, pull the mandrel
out of the tool.
INSTALL THE TOOL BITS:
• Select the tool bit(s) to do the required machining.
Note: The use of dull tool bits or tool bits not manufactured by TRI TOOL Inc. may result in
poor performance and may constitute abuse of this machine and therefore voids the TRI
TOOL Inc. factory warranty
• Insert the tool bit(s) into the slot with the cutting edge located on the radial centerline.
• Tighten the (2) two wedges to secure each tool bit in it’s slot.
SETUP:
• Adjust the stop pins so that the tool bit will rest about .05” (1.3mm) back from the maxi-
mum height tube to be machined.
• If a pre-determined stop point is desired, loosen the locking screw and rotate the outer
sleeve to the desired position.
• Tighten the locking screw.
• Position the three set screws so they rest at the same height and location betweenthe
tubes on the tube sheet.
INSTALLATION:
• Reduce the diameter of the mandrel ramp blocks by actuating the 4-way air valve.
Note: Check that all (3) three stop pins are resting on the tube sheet and that the tool bit(s)
is not in contact with the tube.

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• Actuate the air valve to expand the mandrel ramp blocks out to contact the inside di-
ameter of the tube.
MACHINING SEQUENCE:
• Turn the air motor on by pulling the trigger on the air motor.
• Feed the tool bit in by rotating the feed knob.
• When the tube has been machined, retract the feed knob.
• Turntheairmotoro󰀨byreleasingthetrigger.
CAUTION
CAUTION: Make sure the lever on the air valve is thrown all of the way when the
mandrel is expanded to prevent the air valve from releasing during the machining se-
quence.

Model 202TS Tube Sheet Cutter
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8. CUTTING SPEEDS
Outside Dia
RPM
for
200 in/min
(508 cm/min)
RPM
for
250 in/min
(635 cm/min)
RPM
for
300 in/min
(762 cm/min)
1.00” 25.4 mm 64 80 95
1.25” 31.8 mm 51 64 76
1.50” 38.1 mm 42 53 64
2.00” 50.8 mm 32 40 48
Cutting Speed (Approximately)
Use 200 surface inches per minute (508 surface centimeters per minute) for:
Stainless steels in general when no coolant is allowed, all heavy-wall tube and
some of the chrome/molybdenum steels.
Use 250 surface inches per minute (635 surface centimeters per minute) for:
Mild steels and some thin wall stainless steels when coolants are permitted and
applied.
Use 300 surface inches per minute (762 surface centimeters per minute) for:
Aluminumand thin-wall mild steel and tube with coolants.

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8. RAMP SETS
Mandrel Assembly Ramp Set P/N ID Range
12-0127 08-0439 .77” to 1.00”
(19.6mm to 25.4mm)
12-0127 08-0440 1.00” to 1.23”
(25.4mm to 31.2mm)
12-0127 08-0441 1.22” to 1.48”
(31.0mm to 37.6mm)
12-0127 08-0442 1.45” to 1.72”
(36.8mm to 43.7mm)
12-0127 08-0443 1.70” to 1.95”
(43.2mm to 49.5mm)