VCM-200 SERIES Portable Flame Cutting Machine SAFETY AND OPERATING INSTRUCTIONS Revision: A Issue Date: September 17, 2008 Manual No: 0056-1351
WE APPRECIATE YOUR BUSINESS! Congratulations on your new Victor® product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world-wide service network. To locate your nearest distributor or service agency, please contact a representative at the address and phone number in your area listed on the back cover of this guide, or visit us on the web at www.victorequip.com.
WARNINGS Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment. While the information contained in this Manual represents the Manufacturer’s judgment, the Manufacturer assumes no liability for its use. VCM-200 Series Portable Flame Cutting Machine Safety and Operating Instructions Instruction Guide Number: 0056-1351 Published by: Thermadyne® Industries, Inc. 2800 Airport Rd. Denton, TX 76208 (940) 566-2000 www.victorequip.com U.
Table of Contents Section 1: Introduction...............................................................................1-1 1.01 How to Use this Manual..............................................1-1 1.02 Receipt of Equipment..................................................1-1 1.03 Description..................................................................1-1 Section 2: Safety Precautions .................................................................2-3 section 3: features and specifications.........
Safety and Operating Instructions Section 1: Introduction 1.01 How to Use this Manual To ensure safe operation, read the entire manual, including the chapters on safety instructions and warnings. Throughout this manual, the words WARNING, CAUTION, and NOTE may appear. Pay particular attention to the information provided under these headings.
safety and operating instructions All Victor VCM-200 Series portable cutting machines are carefully assembled and thoroughly tested at the factory before shipment. The machine is designed to provide dependable, 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.
Safety and Operating Instructions Section 2: Safety Precautions Read and understand these operating instructions before attempting to operate or service this equipment. The information contained in this document is subject to change without notice. Warning This product contains chemicals, including lead, or otherwise produces chemicals known to the State of California to cause cancer, birth defects and other reproductive harm. Wash hands after handling. (California Health & Safety Code § 25249.5 et seq.
safety and operating instructions WARNING DO NOT kink, twist, or bend pigtails into a radius smaller than 5 inches. If you do this, the pigtail might burst. WARNING ALWAYS secure cylinders with racks, straps, or chains. Unrestrained cylinders may fall over and damage or break off the cylinder valve. WARNING Electrically ground oxygen and fuel gas manifolds and cylinders. Static discharges and lightning may ignite materials in an oxygen atmosphere, creating fire or explosions.
Safety and Operating Instructions section 3: features and specifications 3.01 Machine Features The VCM-200 Series cutting machine offers the following operation, performance and design features. 1. Operating Features • Makes straight-line cuts of any length. • Makes circle cuts up to 96" in diameter. • Makes bevel or chamfer cuts - has calibrated scale for easy torch angle selection. • Makes X, Y, V or K cuts with multiple torches for plate edge operation.
safety and operating instructions • Cone disk drive has an automatic wear adjusting mechanism which prolongs the life of the drive. Knobs and levers are recessed for added protection. Ball bearings or special bushings are used at all critical locations. • All rotating shafts run on permanently lubricated bearings. 3.02 Machine Specifications Outline Dimensions Outline dimensions are shown in Figure 1, below.
Safety and Operating Instructions SECTION 4: MACHINE OPERATION The information in this section is provided to familiarize the operator with operating controls and procedures. NOTE Other recommended operating instructions available at your distributor are: 0056-1625 - Safety & Operating Instructions for Compressed Gas Regulators; 0056-0136 - Safety & Operating Instructions for Cutting Torches. 4.01 Torch Setup A.
safety and operating instructions 5 4 2 4 3 1 Figure 3: Setup with Dual Torch Mount B. Optional Dual Torch Setup Set up the optional dual torch mount assembly, Part No. 0252-0136, as shown in Figure 3. Install the dual torch mount plate (1) on the machine housing in place of the single torch mount post supplied with the standard machine package. Attach the removed single torch mount post, along with the second one (supplied with the dual torch mount assembly), at the ends of the dual torch mount plate.
Safety and Operating Instructions FWD-OFF-REV SWITCH REV CLUTCH CONTROL LEVER SPEED ADJUSTING KNOB LOW DRIVE HIGH FREE CASTER WHEEL LOCKING KNOBS Figure 4: VCM-200/VCM-200HT/VCM-200HS Operating Controls 4.02 Cutting Operations Operating procedures vary widely for the many different types of jobs on which the VCM-200 is used. For this reason, no typical operating procedure is given, but the following general suggestions may be helpful. A.
safety and operating instructions Place the clutch lever in the FREE position to permit easy manual positioning of the machine prior to or after the actual cutting operation. D. Torch Adjustment The VCM-200 racking assembly provides full adjustment for the torch. The rack handle assembly permits the torch holder assembly movement toward or away from the tractor unit. The torch holder allows the torch vertical positioning.
Safety and Operating Instructions DRIVE WHEEL PATH PATH OF CUT RA DI US Figure 5: Circle Cutting Setup F. Circle Cutting The radius rod and center point make it possible for the VCM-200/VCM-200HS to cut circles from 4" to 96" in diameter. Remove the two bolts located over the drive wheels in the outer case. Position the radius rod assembly on the cutting machine, re-insert the bolts and tighten securely. Adjust the radius rod assembly to the desired length.
safety and operating instructions simple method of determining the proper speed setting for circle cuts, regardless of whether the torch is positioned inside or outside the tractor path.
Safety and Operating Instructions SECTION 5: MACHINE MAINTENANCE The Victor VCM-200, VCM-200HT and VCM-200HS cutting machines are designed to operate over extended periods with minimum maintenance. However, continued satisfactory operation of the machine depends upon the careful performance of a few simple periodic inspections and the cleaning procedures outlined in this section. With proper care, problems can usually be detected and corrected before the result in loss of machine operating time.
safety and operating instructions selected torch position. Also, check the torch pivot knuckle to see that it's clamping screw is properly adjusted. Adjust tension of clamping screws, if required. 7. Check for free movement of the racking assembly in the rack handle 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.
Safety and Operating Instructions 5.03 Troubleshooting The Troubleshooting Chart serves as an aid in locating possible troubles that may occur in operating the machine. Problem Motor will not run Possible Cause 1. No power to machine. 2. 3. 4. 5. 6. 1. Motor runs, but wheels do not turn 2. Motor runs, but will not reverse Clutch does not disengage Clutch does not engage Machine travel speed not constant 1. Corrective Action 1. Check power source and cord; replace cord if required.
safety and operating instructions SPEED ADJUSTING SHAFT CLUTCH SHAFT CONE DISK ASSEMBLY OUTPUT DISK ASSEMBLY WORM SHAFT ASSEMBLY MOTOR TRANSFER SHAFT ASSEMBLY MOTOR DISK ASSEMBLY REAR AXLE DRIVE GEAR CLUTCH YOKE ASSEMBLY THROW-OUT LEVER CLUTCH DOG Figure 6: VCM-200/VCM-200HT/VCM-200HS Internal Assemblies 5.04 Drive Clutch Adjustment Turn the machine upside down; remove the two casters and the bottom cover to access the clutch.
Safety and Operating Instructions 4. Re-tighten the screw. 5. Freeplay will automatically be obtained; this allows approximately 1/4-inch movement at the extreme end of the throw-out lever. 1. LOOSEN SCEW 2. PRESS LEVER DOWN, HOLDING CLUTCH SHAFT ASSEMBLY CAM AGAINST ROLL PIN 3. TIGHTEN SCREW SCREW THROW-OUT LEVER CLUTCH YOKE SHAFT CLUTCH SHAFT ASSEMBLY ROLL PIN Figure 7: Drive Clutch Adjustment 5.
safety and operating instructions WARNING Unplug the power cord before performing any maintenance. Whenever the bottom 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 under the rubber boot. Hold the screwdriver by the insulated handle. 9. Lift the inner case assembly from the outer case.
Safety and Operating Instructions 3. Loosen the cone block backlash adjusting cap screw using a 7/64" hex key. Gain access to the cap screw through the inner case speed indicator slot. 4. Temporarily, reinstall a SPEED knob on the speed adjusting shaft end that is farthest from the drive cone. This aids in turning the shaft to free both the shaft and the cone block assembly. 5. Lift the cone and cone block from the inner case. 6. Pull the output disk assembly from the worm shaft.
safety and operating instructions F. Switch Replacement 1. Unplug the power cord. 2. Remove the bottom cover from the machine. 3. Short out the capacitor by touching an insulated screwdriver to the capacitor terminals. 4. Disconnect the five switch leads. Four of these are the red, blue, yellow and black motor leads. The fifth switch lead is the black line from the power cord. (See Figure 8) 5. Remove the jam nut on the threaded portion of the switch protruding outside of the case.
Safety and Operating Instructions BLACK CAPACITOR YELLOW MOTOR BLUE WHITE RED RED 1 WHITE 115 VAC POWER SUPPLY BLACK BLACK SWITCH BLACK YELLOW BLUE BOOT RED GREEN WHITE RED 4 2 5 3 6 BLUE 7 8 9 BLUE Figure 8: Pictorial Wiring Diagram, VCM-200 WHITE 115 VAC POWER LINE RED RED 4µF CAPACITOR WHITE RED BLACK GREEN 4 5 FUSE LINK YELLOW 6 1 BLACK 2 8 7 START 3 MAIN BLUE 9 BLACK FWD-OFF-REV SWITCH AC MOTER Figure 9: Schematic Wiring Diagram, VCM-200 0056-1351 5
safety and operating instructions BOOT CAPACITOR RED RED BLACK YELLOW TERMINAL STRIP BLUE RED 1 WHITE 115 VAC POWER SUPPLY BLACK YELLOW RED BLUE WHITE GREEN MOTOR 4 7 WHITE 2 BLACK IN-LINE FUSE (AGC 1A. FAST ACTING) 3 SWITCH BLUE 5 8 9 6 BLUE Figure 10: Pictorial Wiring Diagram, VCM-200HT (Hi-Temp) WHITE 115 VAC POWER LINE RED RED 4µF CAPACITOR 440V WHITE WHITE RED BLACK GREEN 4 5 FUSE LINK YELLOW 6 1 BLACK FUSE AGC 1A.
Safety and Operating Instructions section 6: replacement parts 2 1 4 3 28 14 27 15 16 5 7 24 18 6 26 25 17 23 8 9 19 20 21 10 22 11 12 13 Figure 12: VCM-200 Series Rigging Assembly. Part No. 0252-0134 Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Part No.
safety and operating instructions 8 2 9 3 1 5 6 4 13 7 16 25 12 14 15 17 19 10 11 26 27 18 28 29 20 21 30 22 23 24 31 32 35 33 34 Figure 13: VCM-200 / VCM-200HT* Series Main Assembly (*For continuous use at up to 300˚F) Replacement Parts 6-24 0056-1351
Safety and Operating Instructions Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 Part No.
51 50 49 48 43 42 24 45 44 38 35 31 4 32 4 6 1 5 34 33 19 36 20 8 7 2 3 9 37 11 12 10 39 13 14 40 23 22 21 15 41 46 17 47 25 16 26 18 30 27 28 53 29 52 54 safety and operating instructions Figure 14: Inner Case Assembly VCM-200, Part No. 0252-0130 VCM-200HS, Part No. 0252-0131 VCM-200HT, Part No.
Safety and Operating Instructions Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 0056-1351 Part No.
safety and operating instructions 3 4 2 6 1 8 5 10 7 11 12 9 15 13 14 16 17 Detail A: Cone Disk Assembly, Part No. 0252-0129 1 2 3 5 4 Detail B: Inner Case, Part No.
Safety and Operating Instructions 5 6 1 7 2 3 4 8 10 9 Detail C: Motor Disk Assembly, Part No. 0252-0132 / 0252-0142 VCM-200HT Detail a Item No. 1 2 3 4 5 6 7 8 9 Part No. 0251-0162 1406-0121 1406-0141 1416-0031 0251-0163 1406-0141 0253-0102 1416-0031 0251-0102 Description Cone Disk Spring Washer Retaining Ring Ball Bearning Spacer Retaining Ring Cone Shaft Ball Bearing Spacer Item No. 10 11 12 13 14 15 16 17 Part No.
safety and operating instructions common hardware specifications Part No. Description 1400-0151 Screw, Slotted Head, #8-32 UNC-2A x 6/16 Long 1400-0160 Bolt, Hex Head Tap, 5/16-18 UNC-2A x 2.0 Long 1400-0161 Bolt, Hex Head Tap, 5/16-18 UNC-2A x 1-1/2 Long 1400-0163 Screw, Hex Socket Flat Head Cap, #8-32 UNC-2A x 1/2 Long 1400-0165 Screw, Hex Head Cap, 1/4-20 UNC-2A x 1.
Safety and Operating Instructions 4 3 5 1 6 2 8 7 9 10 11 12 Figure 15: Radius Rod Assembly (top), Part No. 0252-0040 Heat Shield (bottom), Part No. 0252-0103 Item No. 1 2 3 4 5 6 0056-1351 Part No. 0253-0039 0251-0021 1409-0001 1409-0100 0251-0022 0251-0103 Description Radius Rod Mounting Plate Nut (2) Wing Nut (2) Link (2) Spacer (2) Item No. 7 8 9 10 11 12 6-31 Part No.
safety and operating instructions 1 TIGHTEN NUT UNTIL IT BOTTOMS OUT. SLEEVING IS TO BE FLUSH TO 1/8" EXTRUDED OUT. 2 3 4 5 7 6 8 BEND LEG TO FIT 10 WHITE RED BLACK BLUE BLACK YELLOW 9 GREEN 11 Figure 16: VCM-200HT Outer Case Assembly, Part No. 0252-0116 Item No. Part No.
Safety and Operating Instructions SECTION 7: EXPORT MODEL INFORMATION 3 1 4 2 5 6 7 8 Figure 17: VCM-200E / VCM-200HSE Assembly (Export Only) Item No. 1 2 3 4 Part No. Description 1417-0051 0252-0066 0254-0043 0254-0044 1400-0151 Dust Boot and Nut Switch Speed Label, VCM-200E Speed Label, VCM-200HSE Screw Item No. 5 6 7 8 Part No. Description 0208-0254 0204-0156 1406-0088 1409-0072 Spacer Transformer Lockwasher Nut note VCM-200 and VCM-200E Conversion Kit, Part No.
safety and operating instructions STEP-DOWN TRANSFORMER BLACK EXPORT MODELS ONLY RED WHITE WHITE CAPACITOR BLACK YELLOW BLUE MOTOR BLACK YELLOW BLUE RED RED BLACK WHITE BOOT GREEN RED BLUE 220 VAC POWER SUPPLY YELLOW RED BLACK SWITCH Figure 18: Pictorial Wiring Diagram, VCM-200E WHITE RED WHITE RED RED FUSE LINK RED 4 220 VAC POWER LINE WHITE RED 4µF CAPACITOR 220V/110V STEP-DOWN TRANSFORMER 220VAC PRIMARY 110 VAC 5 6 SECONDARY BLACK BLACK BLACK 2 BLACK GREEN 8 YELLOW
Safety and Operating Instructions Section 8: Statement of Warranty LIMITED WARRANTY: THERMADYNE® warrants that its products will be free of defects in workmanship or material.
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