TRI tool 301A User manual

92-0630 Rev. 060811
Model 301 Tube Squaring Machine
TABLE OF CONTENTS
CUSTOMER MESSAGE Inside Front Cover
SAFETY PRECAUTIONS 3
GENERAL DESCRIPTION 6
SPECIFICATIONS 8
MAINTENANCE 10
OPERATION 11
INSTALLING THE QL 21
CUTTING SPEEDS AND FEEDS 22
COLLETS 24
TOOL BITS 28
TROUBLE SHOOTING 30
ACCESSORIES 32
ILLUSTRATED PARTS BREAKDOWN 33
DEWALT SAFETY INSTRUCTIONS 40
TOOL BIT RESHARPENING POLICY Inside Back Cover
WARRANTY INFORMATION Inside Back Cover

Copyright 2006
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.

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Model 301 Tube Squaring Machine
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SAFETY PRECAUTIONS
WARNING:
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-
structing, or in any way defeating the deadman switch on the power drive unit
may result in serious injury.
DRESS CONSIDERATIONS
Use standard safety equipment. Hard hats, safety shoes, safety harnesses, protec-
tive 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 rotat-
ing 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 power-
cutting 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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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 com-
plete 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 mal-
functions, 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 haz-
ard.

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Model 301 Tube Squaring Machine
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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 your hands; they are very tough.
Avoid unintentional starts. Do not carry or handle tools with your hand on the oper-
ating 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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GENERAL DESCRIPTION
The Model 301*, Tube Squaring Machine is a lightweight portable machine designed
for facing and squaring .125” to 1.102” (3.2 mm to 28.0 mm) outside diameter tubing
with an ability to handle up to .125” (3.2 mm) thick wall.
The Model 301 Tube Squaring Machine has several Motor options.
There is an integral, variable speed Air Motor.
There is an integral, variable speed 110 VAC, 500 watt Electric Motor.
There is an integral, variable speed 220 VAC, 500 watt Electric Motor.
There is a Battery supported DC Electric Motor.
Precision inside diameter Collets hold the tubing round to accurately square and
face the tubing with a minimum burr.
The portable version uses a Nut to retain the Collet.
There is a Quick Lock Clamp System to retain the Collet available.
This Machine accepts its own torque through the Collet clamping system.
The Cutting Head accepts Squaring Tool Bits or combinations of Squaring, Beveling
or ID deburring Tool Bits.
All required tools for operation of the Model 301 are supplied with the Machine or
with the accessory Collet Adapters.

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Model 301 Tube Squaring Machine
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Model No. Part No. Description
301A 01-1203 Tube Squaring Machine
powered by an Air Motor
301AQL 01-1322 Tube Squaring Machine
with a Quick Lock attachment
powered by an Air Motor
301BDC 01-1325 Tube Squaring Machine
with 14.4 V Battery
powered Motor
301E110 01-1205 Tube Squaring Machine
with a 110 VAC Electric Motor
301E110QL 01-1323 Tube Squaring Machine
with a Quick Lock attachment
with a 110 VAC Electric Motor
301E220 01-1207 Tube Squaring Machine
with a 220 VAC Electric Motor
301E220QL 01-1324 Tube Squaring Machine
with a Quick Lock attachment
with a 220 VAC Electric Motor
*DESIGNATIONS FOR THE MODEL 301

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SPECIFICATIONS
Model 301 with an Air Motor:
Weight: 6.75 lbs. (3.1 kg) (varies slightly with Collet size)
Power requirements: 22 cfm at 90 psi (10 L/s at kPa)
Envelope, Model 301A Tube Squaring Machine

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Model 301 Tube Squaring Machine
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Model 301 with an Electric Motor:
Weight: 6.8 lbs. (3/1 kg) (varies slightly with Collet size)
Power Requirements:
Model 301E110 115 VAC +10%, 25 to 60 Hz
Model 301E220 220 VAC +10%, 25 to 50 Hz
Envelope, Model 301E Tube Squaring Machine

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NOTE:
NOTE:
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.
If the Model 301 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.
Tool life may be severely shortened, unless chips and/or other debris that
have been deposited on the Cutting Head during the machining operation are
removed.
Disassembly of a power unit voids warranty, except when performed by a
TRI TOOL Inc. designated repair technician.
Clean-Up

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Model 301 Tube Squaring Machine
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WARNING:
OPERATION
Select the tool bit(s) required to machine the end configuration desired.
Use of dull or improperly designed 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.
GENERAL GUIDE LINES FOR SELECTING A TOOL BIT
Selection of the Tool Bit should be based on tubing material, the tubing size, and
how critical is it to have a near burr free end.
A standard entrance angle Tool Bit is recommended for carbon steel.
These Tool Bits also function well with some stainless steel applications where a
near burr free end is not a critical requirement.
A high entrance angel Tool Bit is recommended for most stainless steels.
Generally this is the most suitable edge geometry for about 90 % of all of the
stainless steel tubing applications.
An extra hook angle Tool Bit is recommended for stainless steels which are very
soft.
These stainless steels include materials like 316L, which have been bright hydrogen
annealed, vacuum annealed or annealed and electro-polished.
Electro-polished stainless steel has a micro-thin surface, which is high in Cr and Ni
which makes it very soft, but tough and difficult to cut without a burr.
Use a .969” (24.6 mm) tall Tool Bit for 3/16” (4.7 mm) diameter or less tubing.
The tall Tool Bit may provide some advantages for wall thicknesses less than
.020” (.5 mm).
The tall Tool Bit will cut very close to the Collet face, which minimizes flexing of the
tubing from the cutting pressure.
The tall Tool Bit will require more time to adjust the tubing position for cutting and
there is some risk of crashing the Tool Bit into the Collet on larger OD tubing.

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CAUTION:
NOTE:
CAUTION:
The M-42 Tool Bits are for use with the exotic alloys where the high heat resistance
is required to avoid burning the cutting edge of the Tool Bit.
M-42 can improve the life expectancy of the Tool Bit under some conditions on
stainless steel.
It should be noted that M-42 Tool Bits are more brittle than the M-2 Tool Bits,
therefore there is a much greater risk of damaging the M-42 Tool Bit when installing
the tubing in the Tube Squaring Machine.
Loss of Tool Bits from damaged edges may not off-set the improved cutting life that
those Tool Bits promise.
Some of the exotic alloys may require Tool Bits with both the extra hook angle as
well as the M-42 tool steel for heat resistance.
Insert the Tool Bit into the slot in the Cutting Head.
Ensure that the Model 301 is disconnected from the power source before
installing a Tool Bit.
The normal position for the Tool Bit (P/N 99-1445) is shown in following picture.
This position is used for .50” (12.7 mm) and smaller diameter tubing.
This is the designed working position of the Tool Bit and will leave virtually no burr
with standard tubing.
When working with electro-polished stainless steel tubing, slow cutting speeds must
be used to minimize the ID burr.
The Tool Bit (P/N 99-1445) may be reversed as shown in the following pictures.
This reversed position may be used for tubing with an ID greater than .50"
(12.7mm).
With the extreme shear cutting action, the burr on the ID will be virtually eliminated.
Minimum burr may be obtained with a slow RPM and a slow feed, which will
cut a continuous chip.
Terminate the cut with one or two revolutions without feed to square the end of the
tubing.
The cutting edge of the Tool Bit must be located on the radial centerline.

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Model 301 Tube Squaring Machine
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Tool Bit Installed With The
Cutting Edge Out
Tool Bit Installed With The
Cutting Edge In
Tool Bit Tightening

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CAUTION:
NOTE:
WARNING:
CAUTION:
NOTE:
Do NOT install the Tool bit backwards.
Tighten the Set Screws to secure the Tool bit to the Cutting Head.
Select the proper size Collet for the outside diameter of the tube or pipe to be
squared.
The size of the Collet is determined by the outside diameter of the tube or
pipe to be squared.
Do not drop the Collet.
Always place a hand under the Collet when installing or removing it from the
Model 301.
INSTALLING A COLLET IN THE MODEL 301
Remove the Knurled Nut from the end of the Model 301.
Insert the Collet into the tapered end of the Model 301.
Screw the Knurled Nut back onto the Model 301.
Be sure that there is a light film of grease on Knurled Nut threads at all times
to prevent them from galling or freezing during use.
Back the Knurled Nut off just enough to allow insertion of the tube or pipe into the
Collet.
Partially tighten the Knurled Nut until the tube or pipe may still be moved into
position.
Move the tube or pipe approximately 1/16” (1.6 mm) from the Tool Bit.
As the Collet closes, the tube is drawn toward the Tool Bit.
Do not let the Tool Bit touch the tube or pipe.
To do so will cause damage to the Tool Bit or the Tube Squaring Machine when
power is applied.
Tighten the Knurled Nut to prevent the rotation of the tube or pipe during machining.

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Model 301 Tube Squaring Machine
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NOTE:
CAUTION:
NOTE:
NOTE:
NOTE:
INSTALLING A COLLET IN THE MODEL 301QL
Remove the Ball Lock Pin from the Collet Clamping Assy of the Model 301QL by
pulling straight out.
Be sure that the Toggle Clamp Lever is in the up position to allow the pin to
be pulled out.
Swing the Clamping Head Assy upward to allow the Collet to be slid into place.
Insert the Collet into the tapered Collet Clamping Model 301QL.
Swing the Collet Clamping Assy down into position.
Insert the Ball Lock Pin completely into the hole provided for it in the Collet clamping
Assy.
Be sure that the Toggle Clamp Lever is in the up position in order to permit
the pin to be pushed into the Collet Clamping Assy.
Insert the pipe or tube to be machined into the Collet.
Verify a clearance of 1/16” (1.6 mm) between the Tool Bits(s) and the pipe or tube
face as held by the Collet.
As the Collet closes, the tube is drawn toward the Tool bit.
Do not let the Tool Bit touch the pipe or tube at this time.
To do so will cause damage to the Tool Bit or the Tube Squaring Machine when
power is applied.
Lock the tube or pipe in position by pushing the Toggle Clamp Lever all of the way
down.
Attach the power supply to the Model 301 and pull the Trigger to start rotation of the
Cutting Head
POWER REQUIREMENTS
Power requirements for a Model 301 equipped with an Air Motor.
The air supply should be 22 cfm at 90 psi (10 L/s at 621 kPa).

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NOTE:
NOTE:
NOTE:
Connect the Model 301 to the air supply and pull the trigger to start rotation of the
Cutting Head.
Ensure that the air supply has an adequate FRL (filter/regulator/lubricator)
installed and adjusted properly.
Power requirement for a Model 301 equipped with an Electric Motor.
The 110 VAC version will require a 110 VAC outlet.
The 220 VAC version will require a 220 VAC outlet.
Connect the Model 301 to the required power supply and pull the trigger to start
rotation of the Cutting Head.
Location of the Various Controls
Location of the Various Controls

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Model 301 Tube Squaring Machine
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CAUTION:
NOTE:
ADJUSTMENT OF THE CUTTING SPEED
Use the Speed Control to adjust the cutting speed.
Refer to the section ‘Cutting Speeds and Feeds’ for the recommended cutting
speeds.
In order to obtain a minimum burr tube end, it is essential that heat build up be
avoided.
When either the tube or the Tool Bit gets hot then the tube material starts to flow or
push away from the Tool Bit edge in the form of a burr, instead of being cut cleanly
with a minimum burr.
Avoid the conditions, which generate excessive heat by:
Keep the RPM’s low; excessive cutting speed will generate unwanted heat.
Keep the chip curling loose; avoid excessive depth of cut.
Use a sharp Tool Bit; a dull Tool Bit just isn’t going to do the job right.
Rotate the Feed Handle clockwise to bring the Cutting Head and tube closer
together.
The actual machining operation will begin when the Tool Bit contacts the tube
or pipe.
Location of the Various Controls
If the tube end is not square to the tube axis, the Tool Bit will contact only a small
segment of the pipe during each revolution.
To avoid Tool Bit damage, the feed rate should be very slow until the Tool Bit is
contacting the pipe continually during at least one revolution.

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CAUTION:
Adjust the cutting RPM with the Speed Control to just above the required cutting
speed as the Tool Bit enters the cut.
The Tool will slow down slightly as the cutting load increases, apply additional power
to hold the cutting speed.
Observe the chip as the machine is cutting.
The ideal chip will come off in a loose pig tail spiral.
A chip that is coming off in a tight straight spiral normally indicates that the feed is
too heavy.
A straight or slightly curled chip normally indicates that the feed is too light.
Back off the feed as required to break the chips and let them fall away.
If a significant amount of stock must be removed, occasionally back out of the cut
and let the Tool Bit spin free in the air to cool.
Continue rotating the Feed Handle clockwise until the end of the pipe is completely
machined.
Be careful not to let the Tool Bit cut into the Collet or the Collet Adapter.
Discontinue feed and allow the Cutting Head to rotate one time for stainless steel
and up to three times for other materials to improve the finish of the prep surface.
Never let a Tool Bit ‘rub’ the surface of a stainless steel tube without cutting.
This will work harden the material and it will be difficult for the Tool Bit to get under
the material in order to finish the cut.
This will also cause excessive Tool Bit wear.
Rotate the Feed Handle counter-clockwise to separate the Cutting Head and the
pipe.
Stop the Cutting Head rotation.
Release the Trigger.
Rotate the Feed Knob counter-clockwise until the Cutting Head clears the tube or
pipe by at least 1/8” (3.2 mm) or more.

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Model 301 Tube Squaring Machine
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On the Model 301 loosen the Collet Nut to release the tube or pipe.
On the Model 301QL pull the Toggle Clamp Lever back to release the tube or pipe.
If the next cut is to be identical to the previous cut, then follow the sequence starting
with ‘Installing a Collet in the Model 301’ earlier in this section.
If the next cut is to be different than the previous cut, disconnect the power cord and
then follow the sequence starting at the beginning of this section ‘Operation’.
End squaring of 1/8” (3.2 mm) diameter or smaller tubing with the Model 301.
End squaring small tubing with the Model 301 can be difficult due to the fact that the
cutting force causes the tube to flex.
Another problem is that it is difficult to get the tip of the Tool Bit into the bore of the
tube.
Resharpened Tool Bits will not work as the cutting edge has been moved away from
the center and therefore the cutting edge cannot be positioned in the bore of the
tube.
A taller Tool Bit can be used to minimize the length of the tubing, which is not
supported by the Collet.
This will reduce the flexing of the tubing and in turn provide a cleaner cut with less
smearing or burr.
Tool Bit (P/N 99-2448) is a taller Tool Bit, which has extra hook to provide a very low
force cutting action.
Tool Bit is too far from the tubing Longer Tool Bit in use

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This Tool Bit allows the tubing to be positioned in the Collet so that only 1/16”
(1.6 mm) to 1/8” (3.2 mm) is unsupported by the Collet at the cut line.
Another method is to use a consumable aluminum “pot chuck” which has been
made from approximately 6” (152 mm) lengths of 3/16” (4.8 mm), or 1/4” (6.4 mm)
aluminum rod or tubing.
The rod or tubing is then bored and or reamed to match the OD of the tubing to be
squared.
A very fine longitudinal slit is then cut in the consumable pot chuck, which will allow
the Collet to clamp on the product tubing.
The product tubing along with the pot chuck are loaded into the Model 301 and both
are squared.
In this manner the tube is supported and a clean burr free end is obtained.
Support added to the tubing