ESCO Tool PREPZILLA MILLHOG Operating Instructions Manual

Operating Instructions Revision: PRE-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 - “Prepzilla” Millhog

MILLHOG SERIES: PREPZILLA MILLHOG

- 90 PSI (6.2 BAR) INLET PRESSURE

- 120/230V AC FOR ELECTRIC MOTORS

DISCONNECT POWER 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: PRE-001
Millhog Series - “Prepzilla” 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: PRE-001
Millhog Series - “Prepzilla” Millhog

Contents

SPECIFICATIONS ...................................................... 4

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

LIST OF CONTENTS ......................................................... 4

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

Pneumatic motor .................................................. 4

Electric motor ....................................................... 4

LIMITATION ON AMBIENT CONDITIONS ............................. 4

Pneumatic motor .................................................. 4

Electric motor ....................................................... 4

ILLUSTRATED DESCRIPTION OF FUNCTION .......................... 5

IDENTIFICATION OF OPERATING CONTROLS AND THEIR USE ... 6

SAFETY INSTRUCTIONS ............................................ 7

PRECAUTIONS AND USE OF PERSONAL PROTECTIVE

EQUIPMENT, EYE PROTECTION ......................................... 7

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

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

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

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

POWER CONNECTION .................................................... 9

Pneumatic ............................................................. 9

Electric .................................................................. 9

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

Clamp rib clamp pad selection .............................. 9

Cutting blade selection ......................................... 9

INSTALLATION OF PROPER TOOLING ................................. 9

Clamp rib installation ............................................ 9

Cutting blade removal and installation ............... 10

MOUNTING THE TOOL TO THE WORK .............................. 10

AIR CONNECTION ........................................................ 10

OPERATION OF TOOL ................................................... 10

TOOL LIMITS ............................................................... 10

Size limits ............................................................. 10

Material limits ..................................................... 11

MAINTENANCE AND SERVICING ............................. 11

REGULAR CLEANING AND LUBRICATION ........................... 11

USER SERVICE ............................................................. 11

SERVICING BY MANUFACTURER OR AGENT ....................... 11

CLAMP RIB AND PAD SELECTOR CHART .................. 12

PARTS LIST AND DRAWINGS .................................. 13

GEAR HEAD ASSEMBLY ................................................. 14

PNEUMATIC MOTOR .................................................... 16

Handle assembly ................................................. 16

Spider gear assembly .......................................... 18

Cylinder assembly ................................................ 18

ELECTRIC MOTOR – PCD-110/220 ............................... 20

Electric motor adapter ........................................ 22

DRAW ROD ASSEMBLY .................................................. 23

AIR HOSE ASSEMBLY .................................................... 24

CUTTING BLADES ......................................................... 25

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

Operating Instructions Revision: PRE-001
Millhog Series - “Prepzilla” Millhog

Specifications

Unpacking

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

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 (pneumatic motor only)

 Allen wrench set
 Carrying case

Power supply

Pneumatic motor

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

2. Recommended air volume, 80 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 (SAE 10).

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

(lubricator) is full before use.

TO ADJUST LUBRICATOR, REMOVE FILLER PLUG FROM LUBRICATOR AND BE SURE THE

ADJUSTING SCREW (AHG-310) IS SET HALF WAY BETWEEN OPEN AND CLOSED.

Electric motor

1. Rated Voltage 230/120v ac

2. Power input 1800 w

3. Frequency 40-60 Hz

4. Prior to putting into operation, check the mains voltage for conformity with the requirements on the tools

nameplate

5. The motor is made in protection class II

Limitation on ambient conditions

Pneumatic motor

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.

Electric motor

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

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

Operating Instructions Revision: PRE-001

Electric

motor

Motor

adapter

Gear

selector

Millhog Series - “Prepzilla” Millhog

Illustrated description of function

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

Operating Instructions Revision: PRE-001
Millhog Series - “Prepzilla” Millhog

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.

DRAW ROD STOP COLLAR

 Prevents draw rod, actuator and clamp rib and

pads from becoming separated from mandrel.

CUTTERHEAD

 Rotates and holds the tool post.

TOOL POST

 Locates cutting blade.

CUTTING BLADE

 Purpose: to machine end preparations on tube

or pipe.

 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.

THROTTLE LEVER

 Activates the cutterhead.
 Requires deliberate action by the operator to

activate the cutterhead.

 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 cutting blades, adjusting,
moving, or breaking down.

MOTOR

 Provides power to gear head.

GEAR HEAD

 Rotates cutterhead.
 Axially moves on mandrel.

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

Operating Instructions Revision: PRE-001
Millhog Series - “Prepzilla” Millhog

Safety Instructions

DISCLAIMER

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

provided by the equipment may be impaired.

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. Use valved, quick connect couplers to avoid whipping compressed air hose.

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 supply until tool is securely fastened to the inside diameter of a pipe or tube.

8. Use caution when handling, disconnect power supply 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. Ear 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 can not 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: PRE-001
Millhog Series - “Prepzilla” 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

Ear protection

Pinch points

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]