TRI tool BEVELMASTER 204B User manual

92-0699 Rev. 060412
Model 204B BEVELMASTER™
TABLE OF CONTENTS
CUSTOMER MESSAGE Inside Front Cover
SAFETY PRECAUTIONS 3
GENERAL DESCRIPTION 6
SPECIFICATIONS 7
MAINTENANCE 14
OPERATION 17
CUTTING SPEEDS AND FEEDS 22
JAW BLOCKS AND RAMP SETS 24
TOOL BITS 28
TROUBLE SHOOTING 32
ACCESSORIES 34
ILLUSTRATED PARTS BREAKDOWN 35
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.

3
Model 204B BEVELMASTER™
92-0699 : Rev. 060412
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.

4
TRI TOOL INC.
92-0699 : Rev. 060412
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.

5
Model 204B BEVELMASTER™
92-0699 : Rev. 060412
Disconnect power supply during setup and maintenance. Use all ‘Stop’ or Shut off’
features available when changing or adjusting tool bits, maintaining the tool, or when
the tool is not in use.
Remove adjusting keys and wrenches before applying power to the equipment.
Develop a habit of checking the tool before turning it on to make sure that all keys
and wrenches have been removed.
Do not force tools. Tools and tool bits function better and safer when used at the
feed and speed rate for which they were designed.
Do not reach into rotating equipment. Do not reach into the rotating head stock to
clear chips, to make adjustments, or to check surface finish. A machine designed to
cut steel will not stop for a hand or an arm.
Handle chips with care. Chips have very sharp edges and are hot. Do not try to pull
chips apart with are hands; they are very tough.
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.

6
TRI TOOL INC.
92-0699 : Rev. 060412
GENERAL DESCRIPTION
The Model 204B BEVELMASTER™ is a Pipe Beveler designed for facing, beveling
and/or counterboring the ends of pipe or tubing in preparation for welding.
These machining operations may be performed either simultaneously or separately.
Pipe weld end preparations that meet all existing conventional codes including the
more stringent nuclear codes may be machined.
The various interchangeable jaw blocks and ramps will secure the Model 204B
BEVELMASTER™ to pipe and tubing having an inside diameter ranging from 1.25”
(31.8 mm) through 4.33” (110.0 mm).
The expanding mandrel provides fast, accurate self-centering and alignment to the
pipe or tubing to be machined.
The Model 204B BEVELMASTER™ accepts the reaction torque generated by the
machining operations through the mandrel.
No additional restraining devices are required.

7
Model 204B BEVELMASTER™
92-0699 : Rev. 060412
SPECIFICATIONS
MODEL 204B BEVELMASTER™ with an AIR MOTOR
Weight 18 lbs (8.1 kg)
Power Requirements 55 cfm at 90 psi (26 L/s at 621 kPn)
Envelope Drawing
Air Flow
(Speed)
Control Valve
On/Off
Safety Lever
16.42"
(417.1 mm)
7.18"
(182.4 mm)
Inline Feed
19.88"
(505.0 mm)
Cutting Head
(Travel 1.5"
maximum)
Mandrel
8.97"
(227.8 mm)
4.00"
(101.6 mm)

8
TRI TOOL INC.
92-0699 : Rev. 060412
PIPE CUTTING CAPACITIES
Basic Pipe Sizes
All schedules of 1 1/4” through 4” pipe.
Some schedules may require optional equipment.
Basic Tube Size
Up to .531” ( 13.5mm ) wall tubing with a maximum O.D. of 4.50” ( 114.3mm )
and a minimum I.D. of 1.25” ( 31.7mm ) may be beveled with standard
mandrel.
Wall Thickness Capacity
Wall thickness of all standard pipe schedules [.531” (13.5mm) maximum] in
the range listed. Contact Tri Tool for heavier wall procedures.
Counterboring Operations
The tool will counterbore pipe and tubing with an I.D. range of 1.50” (38.1mm)
to 4.33” ( 110.2mm ).
Material Cutting Capabilities
Mild steels, Chrome steels ( Rc 35 max ), stainless steel, copper-nickel alloys
and aluminum without limitations except size and wall thickness as specified
in paragraph #2.
Inconel and some other high temperature alloys may require special proce-
dures as a function of wall thickness and type of end preparation. Contact
Tri Tool’s Engineering Department for details.
CLEARANCE AND DIMENSIONS
Rotating Head DIA. 4.00” ( 101.6mm )
Length Over Motor 19.88” ( 505.0mm )
Length (of machine ) 8.97” ( 227.8mm )
Available Feed Travel 1.50” ( 38.1mm )

9
Model 204B BEVELMASTER™
92-0699 : Rev. 060412
DRIVE SYSTEM
Final Drive Gear Driven
Pneumatic Motor
Free speed 325 rpm
Max. H.P. speed 162 rpm
POWER SUPPLY
Pneumatic motor requires 55 cfm ( 26 L/s ) air supply at 90 psi ( 621 kPa ) for
maximum horsepower delivery.
Note: Air Supply must have a filter/regulator/lubricator ( FRL ) system to protect the
warranty on the air motor.
CUTTING HEAD SPEEDS
Maximum Cutting Head Speed 162 rpm
Cutting Head Speed @ Maximum H.P. 82 rpm
Functional Speed Range 20-100 rpm
RPM at 300 Surface Inches Per Minute
4.50” ( 114.3mm ) 21 rpm
1.25” ( 31.8mm ) 76 rpm
SPEED CONTROL
On/off safety lever valve and twist-type air flow control valve.
MOUNTING
Manually actuated draw rod expands mandrel ramps and jaw blocks.
FEED
Manual-Feed Handle is in line at the back of the machine. Feed rate is
.100” (2.5mm ) per revolution of the feed handle.

10
TRI TOOL INC.
92-0699 : Rev. 060412
MODEL 204B BEVELMASTER™ with an ELECTRIC MOTOR
Weight 18 lbs (8.1 kg)
Power Requirements 115 VAC, 28 to 60 Hz 5.25 amp
Envelope Drawing
16.57"
(420.88 mm)
7.03"
(178.56 mm)
In-line Feed 20.25"
(514.35 mm)
Cutting Head
(Travel 1.5"
maximum)
Mandrel
8.79"
(223.27 mm)
4.00"
(101.60 mm)

11
Model 204B BEVELMASTER™
92-0699 : Rev. 060412
PIPE CUTTING CAPACITIES
Basic Pipe Sizes
1” Pipe
Schedule 40 (Small Mandrel required to mount in 1” schedule 80 and
above.)
1 1/4” through 2 1/2” Pipe
Up to Schedule 80
3” through 4” Pipe
Up to Schedule 40
* Some Schedules may require optional equipment.
Basic Tube Sizes
Up to .250” (6.4 mm) wall tubing with a maximum OD of 4.50” (114.3 mm)
and a minimum ID of 1.25” (31.7 mm) may be beveled with standard mandrel.
Wall Thickness Capacity (Limitations)
Wall thickness of schedules listed, .276” (7 mm) maximum, in the range listed
can be machined without limitations.
Wall thicknesses greater than .276” (7 mm) require special procedures and
are subject to Duty Cycle limitations to prevent motor damage. Contact Tri
Tool Inc. for heavier wall procedures.
Counterboring Operations
The tool will counterbore pipe and tubing with an ID of 1.50” (38.1 mm) to
4.33” (110.2 mm).
DUTY CYCLE
The 204BE with an electric motor (P/N 58-0147 or equivalent) duty cycle on high
cutting load applications (see above), is limited to 50% ‘On’ time with a maximum of
five (5) minutes continuos ‘On’ time.

12
TRI TOOL INC.
92-0699 : Rev. 060412
MATERIAL CUTTING CAPABILITIES
Mild steels, chrome steels, (Rc 35 max), stainless steel, copper-nickel alloys and
aluminum without limitations except size and wall thickness as specified in the
above paragraphs.
Inconel and some other high temperature alloys may require special procedures as
a function of wall thickness and type of end preparations. Contact Tri Tool’s
Engineering Department for details.
CLEARANCE AND DIMENSIONS
Rotating Head DIA. 4.00” (101.6 mm)
Length 8.97” (227.8 mm)
Length Over Motor 20.25” (514.35 mm)
Available Feed Travel 1.50” (38.1 mm)
DRIVE SYSTEM
Final Drive Gear Driven
Electric Motor - 2 speed Ranges & 6:1 Gear Reduction
Free speed
Low Range 168 rpm
High Range 316 rpm
Max. HP Speed
Low Range 112 rpm
High range 210 rpm
POWER SUPPLY
115 VAC, 5.25 Amps, 28 to 60 Hz.

13
Model 204B BEVELMASTER™
92-0699 : Rev. 060412
CUTTING HEAD SPEEDS
Max. Cutting Head Speed
Low Range 84 rpm
High Range 156 rpm
Cutting Head Speed @ Max. H.P.
Low Range 56 rpm
High Range 105 rpm
Functional Speed Range 20 to 100 rpm
Speed Control
On/Off Trigger control with Variable Speed.
MOUNTING
Manually actuated draw rod expands mandrel ramps and jaw blocks.
FEED
Manual-Feed Handle is in line at the back of the machine. Feed rate is .100”
(2.5mm) per revolution of the feed handle.

14
TRI TOOL INC.
92-0699 : Rev. 060412
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 or oil as
specified for the air motor.
Air supply for the Model 204B BEVELMASTER™ with an Air Motor requires an
adequate filter/regulator/lubricator (FRL) to be used.
A maximum of 90 psi (621 kPa) line pressure is recommended.
The motor warranty is void if damage occurs from contaminated air or lack of
lubrication.
When the Model 204B BEVELMASTER™ 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 operations are
removed.
Clean Up
Clean Up
Clean Up

15
Model 204B BEVELMASTER™
92-0699 : Rev. 060412
NOTE:
Disassembly of a power unit voids warranty, except when performed by a
TRI TOOL INC. designated repair technician. A letter of designation is
required.
AIR MOTOR LUBRICATION
No direct maintenance is normally required on the air motor.
However, the air supply must flow through a filter/regulator/lubricator (FRL)
unit or separate units before arriving at the air motor.
The FRL unit must be maintained as required, frequency dependent on the basic air
supply, to keep the water trap drained, filter cleaned and the lubricator oil reservoir
filled so that a drop of oil every two (2) to five (5) seconds is flowing.
If the Model 204B BEVELMASTER™ 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 two (2) to three (3) seconds.
This will prevent rusting and ‘freezing‘ of the rotor vanes.
Grease Port
Verify that there is adequate grease in the gear box. Gears and bearings are to be
lubricated using a lithium based grease.

16
TRI TOOL INC.
92-0699 : Rev. 060412
Lubricant Recommendations
The air motor requires a 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)
•AMOCO – American Industrial Oil No. 32
•Atlantic Richfield – Duro Oil S 150
•Chevron – A. W. Machine Oil 32
•Exxon – Nuto H32
•Shell – Tellus Oil 32
The bearings in the Air and Electric Motor are sealed and do not require any
lubrication.
The drive gears require a lithium based grease.

17
Model 204B BEVELMASTER™
92-0699 : Rev. 060412
NOTE:
OPERATION
Read the operating instructions carefully before attempting to operate the Model
204B BEVELMASTER™
Use eye protection at all times when operating the Model 204B BEVELMASTER™
INSTALLATION
Select the recommended jaw blocks for the pipe size to be machined.
Gently slide the mandrel assembly into the Model 204B BEVELMASTER™ until it
comes to a stop against the torque acceptance key.
Rotate the mandrel assembly as required to engage the torque acceptance key of
the Model 204B BEVELMASTER™ with the slot in the mandrel shaft.
Since the mandrel shaft will contact the torque acceptance key before the
feed nut engages the mandrel shaft threads, caution should be taken not to
force, or allow, the machine to impact the lead threads of the feed nut with the
lead threads of the mandrel.
Rotate the feed handle clockwise to engage the feed nut with the thread on the
mandrel shaft.
The Model 204B BEVELMASTER™ with the mandrel assembly installed maybe
mounted into the pipe or tube as one unit.
Tool Bit
Mandrel
Assembly
Feed
Handle
Draw Nut

18
TRI TOOL INC.
92-0699 : Rev. 060412
NOTE:
In order to avoid cutting the ramps and/or jaw blocks during the machining
operation, the mandrel must be installed beyond the final preparation
location.
Tighten the draw nut to force the jaw blocks out to the inside diameter of the pipe or
tube.
Draw Nut
Pipe
Jaw Block
and/or
Ramp
Final Prep
Location
Mandrel Assembly
Feed Handle
Draw Nut
Tool Bit
1/8" (3 mm)
Clearance
Pipe
Mandrel
Clearance

19
Model 204B BEVELMASTER™
92-0699 : Rev. 060412
CAUTION:
CAUTION:
WARNING:
Verify a clearance of 1/8” (3 mm) minimum between the tool bit and the pipe face.
Select the tool bit(s) required to machine the pipe to the 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
the machine and therefore voids the TRI TOOL INC. factory warranty.
When performing any multiple machining operation such as facing and beveling, the
facing tool bit should be installed as shown.
Insert the tool bit(s) into the slot(s) in the cutting head.
The cutting edge of the tool bit(s) must be located on the radial centerline.
Insure that no tool bit is installed backwards.
Make sure that there is a clearance between the tool bit(s) and the mandrel.
Tighten the setscrews to secure the tool bit in the tool bit slot.
Adjust the bevel tool bit radially to control the land width.
Adjust the cam to alter the width of the land with the facing tool bit.
Attach the proper air supply line to the Model 204B BEVELMASTER™
Cam Adjustment
Lock (On the Side)
Cutting Edge, Tool Bit,
Facing (Land)
Cutting Edge,
Tool Bit, Beveling
Cam Adjustment
Cutting Head
Rotation

20
TRI TOOL INC.
92-0699 : Rev. 060412
WARNING:
CAUTION:
NOTE: Check that the filter/regulator/lubricator (FRL) is installed and set properly.
MACHINING SEQUENCE
Depress the air motor trigger. Adjust the cutting speed by rotating the flow valve at
the air connection.
Rotate the feed handle clockwise to bring the tool bit(s) and pipe closer together.
DO NOT OVERRIDE THE DEADMAN SWITCH ON THIS UNIT. Locking
down, obstructing, or in any way defeating the deadman switch on this unit
may result in serious injury.
The actual machining operation will begin when the first tool bit contacts the
pipe.
When the pipe end is not square to the pipe axis, the Tool Bit will contact only a
small segment of the pipe during each revolution.
Flow Control Valve
Deadman Switch
Set Screws
Tool Bit Cutting Edge
Rotation