ESCO Tool MILLHOG Series, MONGOOSE MILLHOG Operating Instructions Manual

Operating Instructions Revision: MON-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 - “Mongoose” Millhog

MILLHOG SERIES: MONGOOSE MILLHOG

- (includes pneumatic & elect r i c m o tors)

- 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: MON-001
Millhog Series - “Mongoose” Millhog

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, MA
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 attorney’s 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: MON-001
Millhog Series - “Mongoose” Millhog

Contents

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

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

AIR SUPPLY .................................................................................................................................................................................... 4

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

Mongoose with standard motor ............................................................................................................................................ 4

Mongoose air clamp ............................................................................................................................................................. 5

Mongoose SS (slow speed) .................................................................................................................................................... 5

LIMITATION ON AMBIENT CONDITIONS ................................................................................................................................................ 6

LIST OF CONTENTS ........................................................................................................................................................................... 6

Kit contains: ........................................................................................................................................................................... 6

SAFETY PRECAUTIONS ............................................................................................................................................................ 7

PRECAUTIONS AND USE OF PERSONAL PROTECTIVE EQUIPMENT, EYE PROTECTION ........................................................................................ 7

SPECIAL SAFETY PRECAUTIONS, PINCH POINTS ....................................................................................................................................... 7

EXPLANATION OF SYMBOLS ............................................................................................................................................................... 8

DISCLAIMER ................................................................................................................................................................................... 8

OPERATING ERGONOMICS ................................................................................................................................................................ 8

OPERATING INSTRUCTIONS ................................................................................................................................................... 9

IDENTIFICATION OF OPERATING CONTROLS AND THEIR USE ...................................................................................................................... 9

SELECTION OF PROPER TOOLING ......................................................................................................................................................... 9

Clamp rib selection ................................................................................................................................................................ 9

Cutterhead selection .............................................................................................................................................................. 9

Cutting blade selection ........................................................................................................................................................ 10

INSTALLATION OF PROPER TOOLING .................................................................................................................................................. 10

Clamp rib installation .......................................................................................................................................................... 10

Cutterhead removal and installation ................................................................................................................................... 10

Cutting blade removal and installation ............................................................................................................................... 11

MOUNTING THE TOOL TO THE WORK ................................................................................................................................................ 11

POWER CONNECTION..................................................................................................................................................................... 11

OPERATION OF TOOL ..................................................................................................................................................................... 12

TOOL LIMITS ................................................................................................................................................................................ 12

Size limits ............................................................................................................................................................................. 12

Material limits ..................................................................................................................................................................... 12

MAINTENANCE AND SERVICING ........................................................................................................................................... 13

REGULAR CLEANING AND LUBRICATION .............................................................................................................................................. 13

USER SERVICE ............................................................................................................................................................................... 13

SERVICING BY MANUFACTURER OR AGENT .......................................................................................................................................... 13

CLAMP RIB & PAD SELECTOR CHART .................................................................................................................................... 14

PARTS LIST AND DRAWINGS ................................................................................................................................................ 15

GEARHEAD ASSEMBLY ................................................................................................................................................................... 16

AIR MOTOR ASSEMBLY .................................................................................................................................................................. 18

ELECTRIC MOTOR ASSEMBLY ............................................................................................................................................................ 20

DRAW ROD ASSEMBLY ................................................................................................................................................................... 22

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

AIR CLAMP ASSEMBLY .................................................................................................................................................................... 24

CUTTING BLADES .......................................................................................................................................................................... 26

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

Operating Instructions Revision: MON-001
Millhog Series - “Mongoose” Millhog

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 injury.

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

Air supply

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

2. Recommended air volume, 25 cfm (708 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 950 w
c. Frequency 40-60 Hz

Illustrated description of function

Mongoose with standard motor

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

Operating Instructions Revision: MON-001
Millhog Series - “Mongoose” Millhog

Mongoose air clamp

Mongoose SS (slow speed)

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

Operating Instructions Revision: MON-001
Millhog Series - “Mongoose” Millhog

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:

Mongoose

 Motor gear drive assembly
 Draw rod assembly
 Mandrel, ¾” or 5/8”
 Hose, 1/2” w/ filter
 Carrying case
 Allen wrench
 Operating instructions
 One or more clamp rib sets
 One or more cutterheads

Mongoose Air Clamp

 Motor gear drive assembly
 Air clamp and draw rod assembly
 Mandrel, ¾” or 5/8”
 Hose, 1/2” w/ filter
 Carrying case
 Allen wrench
 Operating instructions
 One or more clamp rib sets
 One or more cutterheads

Mongoose SS (slow speed)

 Motor gear drive assembly
 Draw rod assembly
 Mandrel, ¾”
 Hose, 1/2” w/ filter
 Carrying case
 Allen wrench
 Operating instructions
 One or more clamp rib sets
 One or more cutterheads

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

Operating Instructions Revision: MON-001
Millhog Series - “Mongoose” Millhog

Safety precautions

Precautions and use of personal protective equipment, eye protection

1. Power tools are not insulated for coming into contact with electric power sources.

2. Tool must not be used in an explosive atmosphere.

3. Do not use tool in a manner other than stated. Use other than stated in the instructions is forbidden.

4. For air powered tools, use valved, quick connect couplers to avoid an unrestrained compressed air hose

after disconnecting.

5. Use care regarding the drawing in or trapping long hair, loose clothing, etc.

6. Cover all exposed skin before operating. Cutting blades are sharp and produce hot chips. Both can cause

injury.

7. Do not connect power source until tool is securely fastened to the pipe or tube.

8. Use caution when handling, disconnect power source before removing from work, changing blades,

performing maintenance or breaking down.

9. Personal protective garments should include but not be limited to.
a. Safety glasses
b. Work gloves
c. Work boots, or shoes
d. Protective clothing
e. Hearing protection when operator is exposed to long periods of use.

10. Have all nearby persons wear safety glasses with side shields.

Special safety precautions, pinch points

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

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

blades as they cannot be adequately guarded.

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

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

Operating Instructions Revision: MON-001
Millhog Series - “Mongoose” Millhog

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

Hearing 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. 8
Holliston, MA - USA | Tel [phone]

Operating Instructions Revision: MON-001
Millhog Series - “Mongoose” Millhog

Operating instructions

Identification of operating controls and their use

(All tools have similar m a n n e r controls except a s no ted.)

Feed wrench

 Used to advance and retract the cutting blade

from the work.

Draw rod wrench

 Actuates the clamping mechanism.

Actuator

 Holds and aligns the clamp ribs and pads with

mandrel.

Cutterhead

 Rotates and holds the cutting blades.
 Three sizes available (2-1/4”, 2-1/2” and 3”)

Throttle lever

 Locking throttle lever requires deliberate

action by the operator to activate the tool.

 Actuating lever starts tool.
 Release of lever stops tool.

Nipple air inlet

 Accepts valved quick connect coupler for

connecting air supply.

 Always disconnect air supply before installing,

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

Cutting blade

 Consumable item, available in many sizes and

configurations.

 Purpose: to machine end preparations on tube

or pipe.

Blade lock

 Hold cutting blade to cutterhead.

Clamp ribs

 Secures tool to tube or pipe inside diameter
 Available in many sizes, see accompanying

clamp rib chart.

Actuator

 Connects the clamp ribs to the draw rod.

Mandrel

 Two sizes available 5/8” & ¾”
 Provides torque acceptance for entire tool.
 Allows axial movement of tool.
 Provides point of rotation for cutterhead.

Air clamp

 Actuates the clamping mechanism

Toggle switch

 Actuates the air clamp

Wedge

 for use with H series clamp ribs and pads on ¾”

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 set.

3. Please note G-4 - G-13 uses clamp rib springs while G-02A, G-03A use bands.

Cutterhead selection

1. Measure the outside diameter of the tube or pipe.

2. Select a cutterhead that either matches the outside diameter or is at least one size larger than the outside

diameter.

3. Sizes are: 2-1/4”, 2-1/2”, or 3”
a. ¾” Mandrel uses cutterheads MG-28 2-1/4”, MG-28A 2-1/2”, MG-28B 3”.
b. 5/8” Mandrel uses cutterheads MG-28C 2-1/4”.

4. Larger cutterheads may be used, subject to mechanical restrictions.

ESCO Tool Company, a Unit of ESCO Technologies, Inc. 9
Holliston, MA - USA | Tel [phone]