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    Manual VCM 200 PDF

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    Gerardo Madrid

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    © All Rights Reserved
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    Fn OPERATING & INSTRUCTION MANUAL/PARTS LIST The VCM-200, VCM-200HT (Hi-Temp.) and VCM-200HS (High Speed) Portable Flame Cutting Machines have many outstanding de- sign and construction features to give dependable, trouble-free oper- ation. A constant speed AC induction motor is located on the side opposite the cutting torch for cooler operation. The cone disk drive has an automatic wear adjusting mechanism that prolongs the life of the disk drive. Design simplicity makes the VCM-200 extremely easy to service. Downtime and repair costs are reduced to a minimum. TABLE OF CONTENTS PAGE INTRODUCTION. SECTION 1: GENERAL INFORMATION so os I-I, MACHINE DESCRIPTION 00 os 1-2 MACHINE FEATURES..... 1-3. MACHINE SPECIFICATIONS. SECTION 2; MACHINE OPERATION .. SECTION 3: MACHINE MAINTE 3-1, GENERAL. 3.2. ROUTINE INSPECTION. ROUTINE LUBRICATION. 3.1, TROUBLESHOOTING. wv -5. DRIVE CLUTCH ADJUSTMENT. 3-6, CUTTING MACHINE REPAIR, SECTION 4: REPLACEMENT PARTS...... anna 4 SECTION 5: EXPORT MODEL INFORMATION LIST OF ILLUSTRATIONS. FIGURE NO. me PAGE Figure 1-1, VCM-200, VCM-200HT and VCM-200HS Outline Dimensions. i Figure 2-1. Pre-Operation Set-Up with Standard Torch Mount... Pre-Operation Set-Up with Dual Torch Mount.. VCM-200 Series Operating Contras, Figure 24. Circle Cutting Set-Up Figure 3-1, VCM-200 Series Internal Assemblies. Figure 3-2, Drive Clutch Adjustment. Figure 3-3, Pictorial Wiring Diagram, VCM-200. Figure 3-4. Schematic Wiring Diagram, VCM-200 Figure 3-5. Pictorial Wiring Diagram, VCM-200H1T Schematic Wiring Diagram, VCM-200H... VCM-200 Series Main Assembly. Figure 4-2, VCM-200HT Series Main Assembly. Figure 4-3, VCM-200 Series Rigging Assembly. Figure 4-4. Inner Case Assemblies - VCM- Figure 4-5. Inner Case Assemblies. : Common Hardware & Miscellaneous Assemblies Figure 4-6, Radius Rod Assembly 0252-0040, Figure 4-7, Heat Shield 0252-0103. Figure 4-8, VCM-200HT Outer Case Assembly Figure S-1,- VCM-200E/VCM-200HSE Assembly (Export Only), Figure 5-2, Pictorial Wiring Diagram, VCM-200E. Figure 5.3. Schematic Wiring Diagram, VCM-200E/VCM-20011 INTRODUCTION All Victor VCM-200 Series portable cutting machines are carefully assembled and thoroughly tested at the factory be- fore shipment. The machine is designed to provide depend able, trouble-free service with minimum maintenance, This manual contains information needed to operate and maintain the machine properly. If additional information is required, contact your Authorized Victor Distributor, Section 1, General Information, gives descriptive informa- tion on the VCM-200 Series. This information will help the fopenitar 1o become more familiar with the machine and its ‘capabilities. Installation instuetions are not included in this ‘manual since the VCM-200 is.a portable cutting machine and not usually used ina fixed location Section 2, Machine Operation, provides information on setting up the machine and making the necessary electrical and gas connections. It also contains operating instructions, including information such as the identification of all operat~ ing controls and an explanation of their functions, operational checks to be performed, and cautions to be observed. It is, assumed that the operator is thoroughly familiar with cutting practices and procedures: however, a set of Vietor tip charts is included with the machine, Use of these charts will allow even inexperienced operators to make successful cuts with the VEM-200. Section 3, Machine Maintenance, details inspe performed, troubleshooting and corrective maintenance pro- cedures, and a description of the machine components. ‘The exploded views of the VCM-200 shown in Seetion 4, Replace- ment Parts, may be used for reference in maintenance proce- «lures, as well as, pars identification. Section 4, Replacement Parts, illustrates all parts of the VCM-200 Series cutting machine for easy identification In presenting the information contained in this manual, a system of notes is used to call particular attention to specific information, The method used to idemtiy these notes, and the purpose for each type of note is as follows; DETTE An operational procedure, or background information, which aids the operator in efficient use of the machine, the serviceman in performing maintenance, or information that re= uires additional emphasis, NATO 41, operational procedure hich, ifnot properly followed, may cause damage tothe TEIN an operational procedure which, if not properly followed, may cause injury to the operator or others in the operating ara, Figure 1-1. \VCM-200, VCM-200HT and VCM-200HS Outline Dimensions SECTION 1 GENERAL INFORMATION 1-1. MACHINE DESCRIPTION. The VCM-200 is a tough, ruggedly constructed cut chine, yet compact and light enough that it may be taken 10 the work site, wherever it may be. Ibis a versatile, economi basic guidance system that ean be used for oxy-fuel flame flame treating or hardening, MIG and TIG welding ing, or movement of special equip: table for field jobs and repair work, as well as, straight line and circle cutting operations required ‘metal fabrication, The complete VCM-200 cutting machine consists o duty tractor unit fitted with an adjustable toreh mount a three-hose gas manifold block, The torch holder has 32-piteh pinion to accommodate a variety of cutting torches available for use with the machine. Large knobs are provided for easy {otch position adjustments on both the cross rack holder and the cutting toreh holder, Accessories available for the VCM-200 cutting machine in- clude a six-foot track section for stright line cutting, a radius rod assembly for circle cutting operations, a dual torch mount assembly, a torch holder slide assembly anda heat shield. The ddual torch mount assembly provides an adjustable mount for up to four eutting torches. ‘The torch holder slide assembly is sed 0 install addtional torehes on the cross racks of either standard or dual torch mounts. Additional six-foot track se tionsare available forextending the VCM-200 ope: toany length desited:The VCM-200js listed with crs Laboratories, Inc 1-2, MACHINE FEATURES. ‘The VEM.200 Series cutting machine offers the followi ‘operation, performance and design features: Operating Features: + Makes straight-line cuts of any length + Makes circle cuts up 10 96 inches in diameter. Makes bevel or chamfer cuts - has calibrated seale for sy torch angle selection. Makes X, Y, V or K cuts with mu edge operation. + Cuts strips, with «wo or more torches, ina single pass. Jpeeds from | 1060 inches per le torches for plate ‘minute (VCM. per minute (VCM-200H8 + Speed indicator is calibrated at the factory to ini speed over the entire speed ran} + Dual speed and clutch controls make the {o operate from either end. + Routine maintenance is quickly ancl easily accomplished, ne easy Performance Features + Constant speed AC induction motor located on the side ‘opposite the cutting torch runs cooler; therefore, the drive speed is not adversely affected by temperature, as are electronically controlled motors. + Speed regulation is as good at low speeds asi is at high speeds die to the cone disk variable speed drive and the AC induction moto + Flat top mounting surface has standard bolt pattern to accommodate MIG, TIG, plasma or other welding or ‘cutting equipment + Location of the special rotating manifold ensures easy ther direction and aids in machine balance c, light weight and balanced design allow the machine to be carried with one hand. + A balanced design makes the machine stable when cutting, allowing a racking distance of up to 18" from th ‘machine witha standard torch, and no counter weight is required, + Cone disk drive has an automatic wear adjusting mechanism which prolongs the life ofthe drive + Knobs and levers are recessed for added protection, + Ball bearings or special bushings are used at all critical locations. + All rovating shafts run on permanently lubricated bearings. 1-3, MACHINE SPECIFICATIONS. OUTLINE DIMENSIONS: Outline dimensions are shown in Figure I-1, page 1 CAPACITIES: -Inerements of 72" (1829 mm) I" to 96" (102 to 2438 mm) Speed Range: VCM-200 and VOM-200HT 1 {0 60 ipm (25 to 1524 mmpm) Vem -20088 vo (0 120 ipny (127 to 3048 mmpm) POWER REQUIREMENTS: 11S V .42 A 60 Hy, single phase E Models; 220 V .23A 50 Hz/.21A 60 Hy, single phase WEIGHTS: Traetor Unit alone . 30.5 Ibs (13.8 Kg) ‘Tractor Unit with rigging wnnnmd7S Ibs (17.0 Kg) BSI sinc Vc-200 is nt designed io detect the end of its track or work piece. Take care that an unattended machine does not fall from an elevated work piece, SRE 3. vew-200117 is moditied wo ‘withstand 30°F continuous operating temper tures such as found in mill and foundry applica SECTION 2 MACHINE OPERATION 21. GE ERAL. ‘The information inthis seetion is provided to familiarize the ‘operator or serviceman with operating controls and proce dures, nea Other recommended opera ns available at your distributor are 56-0135 ~ Safety & Operating Instiuctions for Compressed Gas Regulators; (0056-0136 - Safety & Operating Instructions for Cutting Torches. Figure 2-1. Pre-Operation Set-Up with Standard Torch Mount 2.2, PRE-OPERATION SE’ UP. 2-2-1, Standard Single Torch Set-Up, Set-up of the VCM-200 with standard ‘or andl ifold block is shown in Figure 2-1. Secure the single torch ‘mount post (1) the outer case mounting surface with four allen-head cap serews, Slip the rack handle assembly (2) over the torch mount post and secure it with its set-screw. ‘The rack handle assembly is free to rotate until the clamping bolt is tightened. Insert racking bar assembly (3) so that its rack properly engages the pinion gear in the rack handle assembly. Connect the torch holder assembly (4) to the torch pivol knuckle (5) which, in turn, fits over the round end of th racking bar assembly. Leave clamping. serews provided at each of these points slightly loose for adjustment, Tighten securely after positioning adjustments are made. Insert the cutting torch (6) into the torch holder so that the torch rack properly engages the adjusting gear of the torch holder. Tighten the torch holder wing nuts enough to hold the toteh securely, yet permit vertical adjustment of the torch in the torch holder with the adjusting knob. Use either wo-hose ‘or three-hose torches. Figure 2-2. Pre-Operation Set-Up with Dual Torch Mount Insert the manifold block (7) in the end of the rack handle assembly, Serew the proper hose adapter ‘outlets of the manifold block. Use fuel gas hose the center pair of holes and oxygen hose adapters inthe outer ‘wo pairs of holes. Connect the required hoses rom the anifold block to the cutting torch, [rusing atwo-hose cutting {oreh, omit the right-hand hose, 2.2.2. Optional Dual-Torch Set-Up. up the optional dual torch mount assembly as shown in jgure 2-2, Install the dual torch mount plate (1) on the invichine housing in place of the single torch mount post supplied with the standard machine package. Attach the re= moved single torch mount post, along with the second one supplied with the dual toreh mount assembly, at the ends of the dual torch mount plate Install the rack handle assembly (2) supplied with the dual torch mount assembly on one of the torch mount posts. and install the rack handle assembly from the single torch mount ‘assembly on the other torch mount post (3). Then install the 'wvo torch holders (4) on their respective racking bar assem- blies and torches as explained in 21. Use the ‘Y-fiuings (5) furnished with the dual torch m to make the necessary dual connections at the gas m accommodate the additional eutting torch. SPEED CLUTCH ADJUSTING CONTROL KNOB. LEVER FWD-OFF-REV ‘SWITCH HIGH FREE U CASTER WHEEL LOCKING KNOBS Figure 2-3. VCM-200/VCMI-200HT/VCM-200HS Operating Controls a TTING OPERATIONS. 2-3-1.General Information. op c spes of jobs of no typical operat general suggestion 2: widely for the many different VCM-200 is used. For this reason, 12 procedure is given, but the following y be helpful. 2,Direetional Control. A unique feature of the VCM-200 is its ease of operation in either direction, forward or reverse, Dual speed adjustment and clutch engagement controls are conveniently located on teach end of the machine. Machine direction is set by the FWD. OFF-REV toggle switch located next tothe power cord. 2 Speed Control. ‘Set cutting speeds for straight line cuts direct indicator located on top of the VCM-200 and the VCM- 200HS. The speed range i infinitely variable from | ipm (inch per minute) (© 60 ipm (VCM-200/VCM-200HT) or 5 ipm to, 120 ipm (VCM-200HS). Turn the large knob on either end of the machine (© position the speed indicator to the desired ‘cutting speed. Determine the speed setings forcirclecuts with the formula given in Section 2-3-7. FTES eine export (£) modes ot the ‘YCM-200 Sores with her 90 Hz or 6D He, 220 VAC power, When used with 50 Hz power, the speed is approximately 12% less than the ‘on the speed 2:34, Clute Operation, Engage the clutch by rota located on either end of th ng one of the two clutch levers, ne, 10 the DRIVE position. Place the clutch lever in the FREE position to permit easy ‘manual positioning of the machine prior o orafter the actual cutting operation. 2-3-5. Torch Adjustment, ‘The VCM-200 racking assembly provides Full adjustment for the torch. The rack handle assembly permits the torch holder ‘assembly movement toward oraway fromthe tractor unit. The torch holder allows the torch vertial positioning. The torch pivot knuckle allows the torch positioning at any angle from 490" 10-90" ina plane perpendicular to the rack. Ifadditiona torch clearance is needed, rotate the torch holder assembly 180° for an aclditional clearance of 2 inches. After adjusting the torch to the desired position, tighten all clamping screws. toprevent the torch from making any unexpected movements. 2-3-6, Straight Line Cutting, SINS sic ve34-200is nor desi detect the end of its track or work piece. Ta that an unattended machine does not elevated work piece: ‘Cut straight Fines using the following procedure: |. Place the machine track on the work and Tine it up before placing the machine on the track. fully. When properly connected, the machine should travel smoothly from one track section to the next. 3. Place the machine on the track. Place the elutch lever to the FREE position, Be sure that the gas hoses and the power line are long enough and free to move with the ‘machine so that it can complete the eut properly. 4, Move the machine to the approximate point where the cut ‘ill start Set the drive speed control tothe desired cutting speed. Set the FWD-OFF-REV switch to the OFF posi- tion. Plug the power cord into a 115 AC, 60 Hz power outlet. ‘The export (E) model of the YM-200 Series is equipped with a step-down transformer which permit. operation with 220 VAC, 50 Hz (or 60 Ha) power 5, Ensure that all clamping serews are properly tightened. Light and properly adjust the torch. Set the FWD-OFF- REV switch to the desired direction of travel. Set the clutch lever to the DRIVI 6, When the eut is completed, stop the machine and shut off the torch, 2.3-7.Circle Cutting. ‘The radius rod and center point make it possible for the VCM-200/VCM-200HS to cut circles from 4 inches to 96 inches in diameter. Remove the two bolis located over the ‘drive wheels in the outer case. Position the radius rod assem- Figure 2-4. Circle Cutting Set-Up bly on the cutting machine, reinsert the bolts and tighten securely. Adjust the radius rod assembly tothe desired length, Drill a small pilot hole or puneh the center of the cele to be Cut. Place the point ofthe center point in the center ofthe circle and adjust the radius rod so that the cutting torch ean be properly positioned. Position the torch between the machine nd the center point for small diameter circles. Position the ‘machine between the torch and the center point for large diameter circles. Adjust the center point so that the inside driving wheel lifts slightly off the work. Loosen the caster whee! lock knobs so that the caster wheels pivot freely. The machine is now fee to follow the desired radivs. OTS eacjust the cutting torch to its prop {ng the adjustment to lilt the inside driving wheel Cuiting speeds for circle cuts are not set directly on the VCM-200 speed indicator. The indicator shows the speed of the drive wheel, The driving wheel moves along the circum: ference of a larger or smaller circle than the one being cut by the cutting torch. The following formula provides a simple ‘method of determining the proper speed setting for circle cuts, regandless of whether the torch is positioned inside or outside the tractor path, Caleulate the VM-200 speed setting forany radius ore speed using the following formu ing Speed = CS (A/B) where: ‘Speed = speed indicated on the VCM-200 CS = desired cutting speed A = distance from the outside driving wheel tothe center of the circle B= distance from the cutting torch to the center of the circle Example 1. The cutting torch positioned inside the path of the cutting machine iF 25 inches, Speed = 20 ipm (25/15) 3 inches 0 ipm Speed = 33.3 ipm (68-20 imp RADIUS ROD \ Assy. CIRCLE TO Be CUT vom 200' CUTTING A~— pati oF OUTSIDE TORCH DRIVING WHEEL Example 2, ‘The cutting torch position outside the path of | the cutting machine. Speed =20 ipm(2: Speed = 14. RADIUS ROD ASSY. GIRCLE TO BE CUT PATH OF OUTSIDE DRIVING WHEEL SECTION3 MACHINE MAINTENANCE 34. Gi ENERAL. ‘The Victor VCM-200, VCM-200HT and VCM-200HS cut ng machines are designed to operate over extended periods ‘with minimum maintenance, However, continued satisfactory ‘operation of the machine depends upon the careful perfor- mance oF a few simple periodie inspections and the cle procedures outlined in this section, With proper care, prob- Jems can usually be detected and corrected before the result in loss of machine operating time. Troubleshooting proce- dures are included to help di correct problems as they occur and before serious trouble occurs. Following the inspection and troubleshooting procedures are the maintenance procedures necessary for maintaining the machine. These sections are designed to provide an under standing of the components involved and to supply additional ntenance information which eannot be noted in detail in the Troubleshooting Chart, 3-2, ROUTINE INSPECTION. Inspect the machine carefully each day before placing it in ‘operation. Visually inspect the machine and perform the fol- lowing steps, which include operating checks of all machine ‘components. If faults or malfunctions are noted while per- forming these procedures, refer to the Troubleshooting Chart ‘Section 3-4, and the following maintenance procedures forthe ‘components involved, 1. Wipe off all parts of the machine, rack, surfaces, orch and all track 2. Tum the clutch control lever to the FREE position, Check to see that the machine can be easily pushed along the track. REY toggle switch to the OFF posi nob to | ipm, Plug the power cord oa 115 ¥, 60 Hz power outlet INGER the export (H) model of the VCM-200 Series is equipped with a step-down transformer which permits operation with 220 VAC, 50 Hz (or 60 Hz) power 4, Set the FWD-OFF-REV toggle switch to the FWD posi- tion. With the clutch lever still in the FREE position, slowly advanee the SPEED knob to 60 ipm (VCM-200) or 120 ipm (VCM-200H5). The sound level should in- ‘crease as the knob is advanced. Return the FWD-OFF- REV toggle switch to the OFF position 5. Set the clutch lever to the DRIVE position and set the FWD-OFF-REV switch to FWD. If the clutch en mechanism is properly adjusted, the machine should move the track at the selected speed. Move the FWD- OFF-REV togele switch (o the REV position and verily that the machine reverses direction 6, Check fo see that the torch (or torches) can be moved up ant down with the adjusting knob(s) and that the torch holder clamping screws are tight enough (o maintain the selected torch position. Also, check the torch pivot knuckle to see that itsclamping screw is properly adjusted. Adjust tension of clamping serews, itrequired. 7. Check for free movement of the racking assembly in the rack handlle by rotating the rack adjustment knob, 8. Inspect all hoses and the power cord carefully for signs of deterioration or damage. See that all hose connections to the manifold block and the torch (or torches) are secure 9. Inspect power cord for frayed insulation or signs of dam- age. 10, Inspect all gas connections for le 3:3, ROUTINE LUBRICATION. ‘The only periodic inspection or maintenance required for the VCM-200, other than the inspection and maintenance covered in the daily procedures, isthe following periodie lubrication procedure. 1. Redistribute the grease on the gear train and the groove in the cluteh dog every 100 hours. Itis not necessary to add grease, Remove the outer case cover and the inier case over to gain access to the gear train (Refer to Section 3-6-1). Use the blade of a small screwdriver or similar “object to redistribute the grease. FREI vipise tne power cond before forming any maintenance on the machine. Whenever the bottom cover of the machine is re moved, short out the capacitor. Capacitors hol electrical charge even afer the power has. bes disconnected. Touch an insulated serewdriver (plastic or rubber handle) seross the capacitor ter- minals. DO NOT touch the metal blade of the screwdriver with your fingers. 2. Keep the drive disks and cone free of grease. Clean them by wiping with a rag dampened with a solvent that does not [eave a residue. Alcohol is not an effective cleaner, MVASISINE Use solvents only in well vemti- lated areas. Avoid contact with skin or prolonged exposure to fumes. Read and follow the manufacturer's warning label for the solvent used. bearings or special bushings are used at all Tocations and require no 1 3-4, TROUBLESHOOTING. ‘The Troubleshooting Cha bile troubles that may ce id in locating possi- the machine. TROUBLESHOOTING CHART TROUBLE A. Motor will notrun, 1. 2 B. Motor runs, but 1. wheels do not turn. POSSIBLE CAUSE No power to machine. Wire connection is loose. Motor thermal protector is burned out. Switch is bad. Motor has open winding. Faulty capacitor. Disk Drive slipping because output disk shaft is not sliding freely in worm shaft REMEDY * Check power source and cord; replace cord if required. * Check all wire connections. * Replace motor. * Replace switch. * Replace motor. * Replace capacitor. Remove output disk assembly. Clean and re-grease the shaft with a grease containing molybdenum disulfide, such as EM Lubricants ME-62 or equivalent. 2. Gears worn. ‘Check gear train and replace worn parts. ©. Motor runs, but will 1. Faulty capacitor. * Replace capacitor. not reverse. D. Clutch does not 41. Clutch out of adjustment. Adjust Clutch, See Section 3-5 disengage. 2. Throw-out assembly broken. Replace part. 3. Grooved pin in clutch yoke Replace pin. broken or missing. 4, Tabs on yoke not positione Reassemble properly. groove on clutch dog. 5. Control knobs not in proper Readjust after checking all of the above. position on shaft. E. Clutch does not 4. Broken clutch spring. Replace spring. engage. 2, Worn clutch gears. Replace gears. F Machine travel 1. Disks Slipping. Clean Disks. ‘speed not constant. “See Wiring Dingrams, Figure 33, End play of speed knobs too loose. Loosen set screws securing speed knobs. Then snub-up knobs against ‘spring washer and retighten set screws. SPEED ADJUSTING __ SHAFT CLUTCH “a Le SHAFT CONE DISK aj wl ASSEMBLY ourPuT E Disk ASSEMBLY Gl WORM SHAFT MOTOR ASSEMBLY (| | TRANSFER MOTOR SHAFT DISK U ASSEMBLY ASSEMBLY ° 0, REAR AXLE olde ana = weer 2 oy DRIVE © GEAR CLUTCH Dog cuuTcH” = [J ‘THROW-OUT YOKE LEVER ASSEMBLY Figure 3-1. VCM-200, VCM-200HT and VCM-200HS Internal Assemblies remove the two ch. Operate the chute ‘Tum the machine upside dow the bottom cover toaccess th times by moving the clutch le observe how thy ter’ action disengages the clutch. With the clutch lever in the DRIVE position. the end of the lever should have about 1/4-inch movement for ideal free- play. This is necessary to assure that the clutch will fully sige and have enough travel for disengagement Adjust the eluich free-play by the following steps: 1. Place the elutch in DRIVE position, 2. Rotate the drive wheels by hand to assure that the clutch teeth are fully engaged, 3. Loosen the serew in the throw-out lever and rotate the throw-out lever unl it presses against the cam on the clutch shat 4, Re-tighten the screw. 5. Free-play will automatically be obtained; this allows ap- proximaicly 1/4 Uhrow-out lever. ch movement atthe extreme end of the 1, LOOSEN SCREW 2. PRESS LEVER DOWN, HOLDING. CLUTCH SHAFT ASSEMBLY CAM, AGAINST ROLL PIN <3. TIGHTEN SCREW SCREW THROW-OUT LEVER cLUuTcH YOKE ¢ s SHAFT . cet / CLUTCH SHAFT-— ASSEMBLY oi pI Figure 3-2. Drive Clutch Adjustment 3-6, CUTTING MACHINE REPAIR. Remove the inner case from the outer case when making ‘major repairs to the cutting machine. This is not necessary for minor work such as lubrication or clutch adjustment. 3-6-1. Inner Case Removal. Perform the following steps: |. Unplug the power cord. 2. Remove the rack handle assembly. 3, Remove the clutch control levers from each end of the machine, 4, Remove the SPEED knobs from each end of the machine. A flat washer and two (2) spring washers are provided ‘under each SPEED knob. Remove one end plate, which is held by two butte socket screws cad {6. Remove the four socket head cap screws that have their heads counter bored into the top of the outer ease. These serews secure the inner case. 7. Turn the machine upside down, Loosen the easter locking knobs a few tums to clear groove in caster, then remove ‘casters, 8, Remove the bottom cover, which is held by six slotted hhead screws. SUTEININED Unplug the power cord before performing any maintenance. Whenever the bot- fom cover of the machine is removed, short out the capacitor. Capacitors hold an electrical charge even after the power cord has been disconnected. Touch an insulated screwdriver (plastic or rubber handle) across the capacitor terminals und boot. Hold the screwdriver by the ins 9. Lift the wse assembly from the outer case. Place it beside the outer case with the wires still connected. 10, Remove inner case cover and gasket which are secured by seven slotted head serews. 11. Reverse procedures for reassembly. When reassembling the SPEED knobs, apply enough pressure 10 the SPEED knob to flaten the spring washers and hold while tighten- ing the set serews, 3-6-2.Rear Axle Removal. | Remove the inner ease from the outer case (Refer to Section 3-6-1.) Remove the drive wheel and the key from each end of the axle, 3. Remove the retaining ring at the end of the spring. Re- move the ring by inserting a screwdriver under the ting and twist the screwdriver to pry the ring off the axle. 4, Remove the bushing on the end of the axle toward the motor. 5. Slide the axle and spring partway through the bushing hhole. Remove the spring and the two (2) remaining retan- ing rings. 6. Slide the axle through the bushing hol clutch dog and drive gear 7. Reverse this procedure for reassembly. Kc! out of the 6-3.Transfer Shaft Removal. 2, Remove the capacitor which is held by two serews and a clamp. 3. Remove the ret 10 4, Remove the transfer shaft by sliding the entire assembly ‘out of the inner ease through the bearing mounting hole. 5. Note that the center bearing is shaft and is not avaiable separately. ured on the transfer 3-64, Cone Disk, Output Disk and Worm Shaft Removal. 1. Remove the inner ease from the outer case. (Refer to Section 3-6-1.) Remove the retaining rings and v ‘of the speed adjusting . Loosen the cone block backlash adjusting eap serew using 2 7/63 inch hex key. Gain access tothe eap screw through the inner ease speed indicator slo Temporarily, reinstall 1 SPEED knob on the speed adjust ing shaft end that is farthest from the drive cone. This will aid in turning the shaft o free both the shaft and the cone block assembly. 5. Lift the cone and cone block from the 6. Pull the output disk assembly from the worm shaft. Key the disk assembly to the worm shaft with a woodrufl key 7. If required, remove worm shaft retaining ring, then re- ‘move the worm shaft and outer bearing as one piece. A. spring is located inside the worm shat. This spring ssauliomatic pressure adjustment for the entire disk ishers from box ends 8, Before reassembly, do the following ‘a, Clean the drive disks. bb, Wipe a very thin coating ofa moly grease on the shaft and Key of the output disk assembly, rings on the speed adjust ing shaft. Assemble the end of the shaft that requires the spring washer first. This will allow compression of the spring washerand ease the assembly of the larger retaining, ring. 10. Tighten the cone block backlash adjusting eap serew until play between the cone block and speed adjusting shalt is ‘minimized. Loosen cap serew slightly if speed knob re- uires excessive turning force or cone block rotates with adjusting shat 1. Tighten all knob set serews securely (15 in-Ib). 3-6-5. Power Cord Replacement. 1. Unplug the power cord, 2. Remove the bottom cor 3, Short out the capacitor by touching an insulated serew- river to the capacitor terminals. 4. Disconnect the black and white power line leads and the green groundwire (See Figure 3-3 or 3-4 for VCM-200) (see Figure 3-5 or 3-6 for VCM-200HT).. 5. Remove the power cord by loosening the power cond holder. We recommend that the replacement cord be Vie tor Part No, 0252-0058 (Use Hi-Temp cord assembly (0252-0068 for VCM-200HT). This is a cord and holder ‘hich includes the wire connectors. er from the machine, 6, Reconnect the power cord wires as disc 4 nected in Step 7. Tighten the strain relief bushing securely (12in-1h). 3-6-6.80i ch Repkicement, 1. Unplug the power cont. 2. Remove the bottom cover from the 3. Short out the capacitor by touching an insulated serew ‘river to the capacitor terminals, 4. Disconnect the five switch leads, Four ofthese are the red, blue, yellow and black motor leads, The fifth switch lead is the black line from the power cord (See Figure 3-3), ‘5. Remove the jam nut on the threaded portion of the switel protruding oulside of the ease, Pull the switch cease and remove. 6, Werecommend that the replacement sw No. 0252-0057 (Use HicTemp switeh a 0140 for VCM-200117). This Is a pre-w includes the wire connectors. 7. Install the new switch by reversing th Step 5 procedure in 8, Reconnect the switch as disconnected Step 4. 3-6-7. Motor Replacement Victor necommends that the motor be replaced as an entire assembly. Iineludes the motor, mounting plate, spacer sleeve and drive disk, Purchase the assembly directly from Victor, “down-time” and asstires that the drive disk |. Remove the inner case from the outer case(Refer to Sec- tion 3-6-1), 2. Short out the capacitor by touching driver to the eapacitor terminals, insulated serew= 3. Remove the rubber boot from the capacitor and disconnect the two red leads. 4, Disconnect the red, blue, black, yellow and white motor ‘wires leading to the switch, Note that red is connected 10 red, blue is connected to blue, ete. 5. Remove the four socket head cap serews that mount the ‘motor plate to the inner case, Note that the green ground ‘wire from the power cord is secured to the ease by one of the four screws, 6. Loosen the motor disk set serew, if so equipped (optional ‘on keyed motors). Slide the disk away from the motor to allow motor plate dowels to clear the inner case. PETER tric movor disk isto be re-used, DO NOT pry on hack side of the disk. Remove a tight disk by bending a pry bar to reach behind the disk bos, 7. Remove the motor xl drive disk assembly from the inner 8, Reverse this procedure for n cembly) " 115 VAC WIRING DIAGRAMS BLACK CAPACITOR POWER SUPPLY SWITCH Figure 3-3. Pictorial Wiring Diagram, VCM-200 WHITE 115 VAC. POWER {¢ BLACK _ LINE GREEN FWO-OFF-REV | L L_SwitcH Figure 3-4, ‘Schematic Wiring Diagram, VCM-200 Boor 115 VAC WIRING DIAGRAMS ‘CAPACITOR: wena ‘TERMINAL, 115 VAC POWER SUPPLY BEARN: 115 VAC. POWER: UNE FUSE AGC 1A. FAST ACTING STRIP a IN-LINE FUSE (AGC 1A, FAST ACTING) we ave Figure 3-5. Pictorial Wiring Diagram, VCM-200HT (Hi-Temp) SD aif CAPACITOR. '440V | Fwo-OFF-REV L_ Sane "| La Figure 3-6. ‘Schematic Wiring Diagram, VCM-200HT (Hi-Temp) 13 SECTION 4 REPLACEMENT PARTS RIGGING ASSEMBLY __ # 0252-0134 SEE FIG. 4-3 for breakdown HOSE-oxy Tibia mee sab NTRS MANIFOLD ASSEMBLY } 0252-0081 OXYGENADAPTOR hee 206) FUELADAPTOR @) ‘000.0029, a seit Eien Saeale sas | WASHER 2) abouts waaeors MANIFOLD SHAFT SGREW (4) ‘253-0081 iaouorss SMEQHAEGEND gy DUST PROTECTION ASSY. — a oT ane =e CuavED WASHER 0) na owen coro 8, un __ eye aa SPRING. ~ ra ‘Sen (4) *sbDorS? sonew a) sams? \ OER gage cea > 1a INNER CASE ASSEMBLY _ 0252-0130 (VCM 200), 0252-0131 (VCM 200HS) SEE FIG. 4-4 for breakdown CLUTCH LEVER 2) ‘a251-0088, Foto” agg CASTER RNG ' SWITCH 0252-0057, SWITCH Hee SIRE tm eT eocteT may be purchased as OUTER: 4 CASE ASSEMBLY 0252-0115. _— CASTER (3 rapa the VICTOR a VCM.200 Series Main Assembly. HosE-oxy Hoserue, —=| WaIz0108 0252-0134 SEE FIG. 4-3 for breakdown sonew (4) TaovOrse v 0252-0081 ‘OXYGEN ADAPTOR (4) 1980 0068, FUELADAPTOR @) S WasHen.2) Haoeotss SORE (4) Ta00018 ase oasis MANIFOLD SHAFT ——goneW a) per Tonos SWITCH LEGEND DUST PROTECTION Assy. 254-0020 Verr-cos swircn, cae 0180 TEND PLATE (oar) "ser ‘0254-0018 oer iee "sopew 1a aster Ta00.01 Sone) 3 eats! \ \ Ons Saerean” p eB 2 INNER CASE ASSEMBLY _ 0252-0141 SEE FIG. 4-5 for breakdown cup Fon sea.) PEED AB JUSTIN KNOB.2) Er CaER ‘The OUTER CASE 0251-0170, POWER CORD 0252-0058, oASTeBoie ' SWITCH 0252-0057, SWITCH LEGEND 0254-0020, and ouenosseraven, | CASTER BUSHING 0251-0138 may be purchased as OUTER. | CASE ASSEMBLY 0252-0116 EE FIG. 4-8 ORDERING INFORMATION “aee2 00ee VCM-200HT Series Main Assembly. (For continuous use at up to 30°F). SSO BOLO Ass eon 2810-cort SrneeDS, "2L10-1820 POL0-¥0>1, cern 000 zeLo-oorL gLo0-0b1 wooo SLOSS 90-bort 0908 RETaSMECOOM Bees aOLON sa00-2520. 300-2620 ‘BOLOW waite 807 9 Xy2-ONN 26" ‘ve-ONN ‘JEL BEOH ¥9H "08 Bu u01 91/9 x Ve-ONN 2e-8# PEOH pOwaS 'Maios ts10-00m Noldiwosaa "ON Lud HOLOIA SNOILVOI4IDAdS JHVMGHVH NOWNOD grooste1 ‘ONSITE 2000-1091 gr00-92 91 2210-2620 3SVO YANNI @IVL3G zso-Lor sos 135 ‘9s00-s0r1 OOTESINOD WING NUT (2) 1409-0100

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