ESCO Tool MILLHOG Series, COMMANDER MILLHOG Operating Instructions Manual

Operating Instructions Revision: COM-001

Factory: Agent:
ESCO Tool Company, a Unit of ESCO Technologies, Inc.
75 October Hill Road Ste A, Holliston, MA 01746 USA
Tel [phone] | Fax [phone]
Email: [e-mail] | Website: www.escotool.com

Millhog Series 314 “Commander”

MILLHOG SERIES: COMMANDER MILLHOG

- (Includes 48 series, 30 series & P CD-1 1 0 /2 0 series motors)

- 90 PSI (6.2 BAR) INLET PRESSURE

- 120/230V AC FOR ELECTRIC MOTO R S

DISCONNECT AIR SUPPLY BEFORE SERVICING

UNDERSTAND ALL INSTRUCTIONS BEFORE USING

ESCO Tool Company, a Unit of ESCO Technologies, Inc. 1
Holliston, MA - USA | Tel [phone]

Operating Instructions Revision: COM-001
Millhog Series 314 “Commander”

ESCO Tool Guarantee

Guarantee: The manufacturer guarantees its products to be free from defects in material or workmanship for a
period of one year from date of shipment from its factory. Said guarantee will not apply if equipment is used in
conditions of service for which it is not recommended. The manufacturer is not responsible for damage to its
products through improper use, physical damage, poor operating practice, or normal wear.

If any device is found unsatisfactory under the guarantee, the buyer must notify ESCO Tool in writing and after
receipt of shipping instructions, buyer must return it directly to ESCO Tool, 75 October Hill Road, Holliston,
Massachusetts 01746, USA, shipping charges prepaid. Such equipment will be replaced or put in satisfactory
operating condition, free of all charges except transportation. The correction of any factory defect by repair or
replacement by the manufacturer shall constitute fulfillment of all obligations to the purchaser.
Manufacturer's guarantee is void if unauthorized repairs are made to its products.

Manufacturer shall not be liable for consequential damage in case of failure to meet the conditions of any
Guarantee or Shipping Schedule, nor will claims for labor, loss of profit, repairs, or other expenses incidental to
replacement be allowed.

No other representations, guarantees or warranties, expressed or implied, are made by the manufacturer in
connection with the manufacture and sale of its equipment.

Hold Harmless Agreement

Customer agrees to defend, indemnify and hold ESCO Tool, its owners, agents, officers, and/or employees free

and harmless from and against any and all claims, liabilities, losses, costs and out of pocket expenses (including
attorneys fees) arising out of, or in connection with the ESCO Tool equipment, its use or transportation, or out
of operations conducted by customer, its agents, employees, contractors, representatives, guests or invitees,
including, but not limited to, active and/or passive negligence.

ESCO Tool Company, a Unit of ESCO Technologies, Inc. 2
Holliston, MA - USA | Tel [phone]

Operating Instructions Revision: COM-001
Millhog Series 314 “Commander”

Contents

INSTRUCTION FOR PUTTING INTO USE ................................................................................................................................... 4

UNPACKING ................................................................................................................................................................................ 4

POWER SUPPLY............................................................................................................................................................................ 4

ILLUSTRATED DESCRIPTION OF FUNCTION .......................................................................................................................................... 4

LIMITATION ON AMBIENT CONDITIONS ............................................................................................................................................. 5

LIST OF CONTENTS ........................................................................................................................................................................ 5

SAFETY PRECAUTIONS ............................................................................................................................................................ 5

PRECAUTIONS AND USE OF PERSONAL PROTECTIVE EQUIPMENT, EYE PROTECTION ..................................................................................... 5

SPECIAL SAFETY PRECAUTIONS, PINCH POINTS .................................................................................................................................... 5

EXPLANATION OF SYMBOLS ............................................................................................................................................................ 6

DISCLAIMER ................................................................................................................................................................................ 6

OPERATING ERGONOMICS ............................................................................................................................................................. 6

OPERATING INSTRUCTIONS ................................................................................................................................................... 7

IDENTIFICATION OF OPERATING CONTROLS AND THEIR USE ................................................................................................................... 7

SELECTION OF PROPER TOOLING ...................................................................................................................................................... 7

Clamp rib selection ................................................................................................................................................................ 7

Cutting blade selection .......................................................................................................................................................... 7

INSTALLATION OF PROPER TOOLING ................................................................................................................................................. 8

Clamp rib installation ............................................................................................................................................................ 8

Cutting blade removal and installation ................................................................................................................................. 8

MOUNTING THE TOOL TO THE WORK ............................................................................................................................................... 8

POWER CONNECTION.................................................................................................................................................................... 8

OPERATION OF TOOL .................................................................................................................................................................... 8

TOOL LIMITS ............................................................................................................................................................................... 9

Size limits ............................................................................................................................................................................... 9

Material limits ....................................................................................................................................................................... 9

MAINTENANCE AND SERVICING ............................................................................................................................................. 9

REGULAR CLEANING AND LUBRICATION ............................................................................................................................................. 9

USER SERVICE .............................................................................................................................................................................. 9

SERVICING BY MANUFACTURER OR AGENT ......................................................................................................................................... 9

CLAMP RIB AND PAD SELECTOR CHART ............................................................................................................................... 10

PARTS LIST AND DRAWINGS ................................................................................................................................................ 11

GEAR HEAD ASSEMBLY ................................................................................................................................................................ 12

48 SERIES AIR MOTOR ................................................................................................................................................................. 14

30 SERIES AIR MOTOR ................................................................................................................................................................. 16

PCD-110/220 ELECTRIC MOTOR ................................................................................................................................................. 18

DRAW ROD ASSEMBLY, CLAMP RIB AND PAD ASSEMBLY...................................................................................................................... 20

RIGHT ANGLE DRIVE ASSEMBLY FOR COMMANDER AND DICTATOR ....................................................................................................... 21

OFF-SET GEAR DRIVE .................................................................................................................................................................. 22

AIR HOSE.................................................................................................................................................................................. 23

STANDARD CUTTING BLADES ........................................................................................................................................................ 24

ESCO Tool Company, a Unit of ESCO Technologies, Inc. 3
Holliston, MA - USA | Tel [phone]

Operating Instructions Revision: COM-001
Millhog Series 314 “Commander”

Instruction for putting into use

Unpacking

1. Use caution when handling the tool, cutting blades are sharp.

TYPICALLY THEY ARE PROTECTED, HOWEVER, EXPOSED BLADES CAN CAUSE INJUR Y.

2. Clean any excess oil, grease or rust preventive from the surface of the tool.

Power supply

1. Recommended air pressure, 90 psi (6.2 bar)

2. Recommended air volume, 95 cfm (2690 lt/min.)

3. Clean, moisture free air is essential for trouble free operation.

4. Oil laden operating air should be used. Use a light weight air tool motor oil (s.a.e.10).

5. A hose whip with filter and lubricator is provided with each tool. Be sure air filter is clean and lubricator is

full before use. For lubricator adjustment instructions see 4a.

6. For electric motors
a. Rated Voltage 230/120v ac
b. Power input 1800 w

c. Frequency 40-60 Hz

Illustrated description of function

(optional right angle dr i v e not shown)

ESCO Tool Company, a Unit of ESCO Technologies, Inc. 4
Holliston, MA - USA | Tel [phone]

Operating Instructions Revision: COM-001
Millhog Series 314 “Commander”

Limitation on ambient conditions

1. In damp, moist or humid air, extra precaution must be taken in order to provide the tool with moisture

free, oil laden air.

2. In temperatures below 32 degrees Fahrenheit (0 Celsius) a lubricant with antifreeze, such as Marvel Air-

Tool Oil , must be used.

3. Do not use the electric motor in wet or excessively humid ambient conditions

List of contents

Kit contains:

 Motor and gear head
 Feed mechanism
 Draw rod and wrench assembly
 One or more clamp rib sets
 One or more clamp pad set
 Hose, ¾” with filter, oiler (lubricator) and quick connect couplers, or electric cord attached to motor
 Allen wrench set
 Carrying case

Safety precautions

Precautions and use of personal protective equipment, eye protection

1. Do not connect the power supply until tool is securely fastened to the inside diameter of a pipe or tube.

2. Use caution when handling the tool, cutting blades are sharp. Typically they are protected, however,

exposed blades can cause injury.

3. Personal protective equipment should include, but not be limited to:
a. Safety glasses
b. Work gloves
c. Work boots, or shoes
d. Long sleeve shirts
e. Long pants
f. Ear protection should be used when operator is exposed to long periods of use.

Special safety precautions, pinch points

1. Always disconnect power supply before installing or changing cutting blades, securing to pipe or tube,

adjusting, moving, or breaking machine down.

2. Do not modify or defeat safety devices

3. Cutting blades are sharp and can cause serious injury, use caution when handling tool when blades are

installed

4. Chips can be hot and sharp. Be careful when clearing from tool.

5. Moving and stationary parts can pinch or cause serious injury. Pay extra attention to rotating cutting

blades as they can not be adequately guarded.

6. During use, machinery may separate, lurch or fall.

ESCO Tool Company, a Unit of ESCO Technologies, Inc. 5
Holliston, MA - USA | Tel [phone]

Operating Instructions Revision: COM-001
Millhog Series 314 “Commander”

Explanation of symbols

Caution (refer to accompanying documents).

Safety glasses must be worn.

Protective gloves, cutting blades and chips can be hot and sharp.

Work boots, or shoes

Protective clothing

Ear protection

Pinch points

Disclaimer

1. If the equipment is used in a manner not specified by ESCO Tool, the protection provided by the

equipment may be impaired.

Operating ergonomics

1. Tool must be mounted at a reasonable working height.

2. Tool may be used in any orientation.

3. Operator must be in a position not to be injured as the machinery may separate, lurch or fall. Operator

must have both feet on a stable platform. Reaching or leaning is not acceptable operating ergonomics.

ESCO Tool Company, a Unit of ESCO Technologies, Inc. 6
Holliston, MA - USA | Tel [phone]

Operating Instructions Revision: COM-001
Millhog Series 314 “Commander”

Operating instructions

Identification of operating controls and their use

Feed wrench

 Used to advance and retract the cutting blade

from the work.

Draw rod nut

 Activates draw rod and actuator.

Actuator

 Holds and aligns the clamp ribs and pads with

mandrel.

Draw rod

 Connects the actuator and draw rod nut.
 Turning draw rod nut clockwise pulls actuator

towards mandrel and expands clamp ribs and
pads.

 Turning draw rod nut counter-clockwise

pushes actuator away from mandrel and
relaxes clamp ribs and pads.

Cutterhead

 Rotates and holds the tool post.

Tool post

 Locates cutting blade.

Cutting blade

 Purpose: to machine end preparations on tube

or pipe. b. Consumable item, available in many
sizes and configurations.

Blade lock

 Secures the cutting blade to tool post.

Clamp ribs / pads

 Secures tool to tube or pipe inside diameter.
 Come in sets of three
 Available in many sizes, see accompanying

clamp rib chart.

Mandrel

 Provides torque acceptance for entire tool.
 Allows axial movement of tool.
 Provides point of rotation for cutterhead.

Horizontal lifting ring

 For lifting tool horizontally.

Vertical lifting rings

 For lifting tool vertically.

Nipple air inlet

 Accepts valved quick connect coupler for

connecting air supply.

 Always disconnect air supply before installing,

changing or securing cutting blades, adjusting,
moving, or breaking down.

Air motor

 Provides power to gear head.

Gear head

 Rotates cutterhead.
 Axially moves on mandrel.

Selection of proper tooling

Clamp rib selection

1. Measure inside diameter of tube or pipe. Or using the outside diameter and minimum wall thickness,

calculate the inside diameter.

2. Using the inside diameter and the accompanying clamp rib chart select the proper clamp rib / pad set(s).

3. Please note clamp pads attach to clamp ribs. Clamp ribs can be used without clamp pads.

Cutting blade selection

1. Measure the wall thickness of the tube or pipe.

2. Select a blade that is wider than the wall thickness.

3. Standard sizes are: 1/2”, 3/4” and 1”. Consult factory for other widths.

4. Cutting blade configuration should be matched to your welding specification.

5. Consult factory for special applications such as: counter boring, compound bevels , “J” preps, etc.

ESCO Tool Company, a Unit of ESCO Technologies, Inc. 7
Holliston, MA - USA | Tel [phone]

Operating Instructions Revision: COM-001
Millhog Series 314 “Commander”

Installation of proper tooling

Clamp rib installation

1. Remove draw rod nut (C-15), and pull draw rod assembly from mandrel (C-37).

2. Slide clamp ribs over the draw rod (C-14) with the slotted end of the clamp rib towards the actuator (C-

11).

3. Insert the clamp rib slots into the slots on the actuator (C-11).

4. Inspect springs, replace if stretched or damaged.

5. There are two sets of clamp springs per set of clamp ribs.

6. Reassemble, insert draw rod assembly into mandrel and install the draw rod nut.

Cutting blade removal and installation

1. Loosen blade lock screw(s) (C-53), do not remove. If more than one blade lock screw has to loosened they

should be loosened evenly.

2. Cutting blade must be slid to the outside of the cutterhead for removal.

3. Insert new cutting blade from the outside of the cutterhead and align so that the blade fully covers the

tube or pipe wall.

4. Be sure to tighten all blade lock screws

Mounting the tool to the work

1. Using the feed wrench extend the mandrel all the way forward (this moves clamp ribs away from

cutterhead.

2. Retract the the mandrel two turns of the feed wrench.

3. Insert the clamp rib portion of the tool into the end of tube or pipe.

4. While positioning the cutting blade away, at least 1/4” from the work, tighten the draw rod wrench.

5. Be sure cutterhead can rotate freely, without coming into contact with the tube or pipe, when first

starting tool.

Power connection

1. Use the hose supplied with the tool.

2. This hose has a valved quick connect coupler which will hold back all air that is in the supply hose.
a. This feature allows the air supply to be safely removed from the tool at any time.

3. Connect the air supply.

4. For electric tools, be sure to connect the tool to a properly grounded outlet and if using an extension cord,

be sure that the extension cord is properly sized for the application. Failure to properly size an extension
cord can result in personal injury and/or harm to the electric motor

Operation of tool

1. Engage the ball valve (or switch) this will activate the tool.

2. Using the feed wrench advance the cutting blade towards the work.

3. Use a steady constant feed creating a continuous chip.
a. Using a constant feed allows the heat generated by the cutting action to be removed by the chip.

Heat build up is a primary failure mode for cutting tools.

b. Engaging a rotating cutting blade with the work surface without feed (rubbing), creates excessive

heat build up.

4. When the desired end prep is accomplished, quickly reverse the feed wrench by reversing the directional

pawl, and retract the cutting blade from the work.

5. Turn power supply off, so the motor no longer rotates the cutterhead, this will stop the tool.

6. Disconnect the power supply.

7. Release the draw rod nut and remove the tool from the work.

ESCO Tool Company, a Unit of ESCO Technologies, Inc. 8
Holliston, MA - USA | Tel [phone]