Subsea Rail Mill User Manual
Contents
1. 35 Drawings and Parts REY ARR Xe Co ees Rd ORE 35 Ordering Information ose T NOI MD eoe ee CMS 46 Ordering Replacement Parts 224222222 22250245455 ARR need NES LA RE hee ed 46 Repair Information RR DE eee SSE DE 46 Warranty nfonmmauons ED 46 Return Goods Address 22 deed take rte dive baie ead CORREA Java ee 46 E H Wachs Company Part No 03 012 MAN Rev 1 0607 1 Rail Mill User s Manual 2 Part No 03 012 MAN Rev 1 0607 E H Wachs Company Chapter 1 About this Manual Chapter 1 About this Manual PURPOSE OF THIS MANUAL This manual explains how to operate and maintain the rail mill It includes instructions for set up operation and maintenance It also contains parts lists and diagrams to help you order replacement parts and perform user service able repairs How USE THE MANUAL This manual is organized to help you quickly find the infor mation you need Each chapter describes a specific topic on using or maintaining the equipment Each page is designed with two columns This large col umn on the inside of the page contains instructions and illustrations Use these instructions to operate and maintain the equipment The narrower column on the outside contains additional information such as warnings special notes and defini tions Refer2. the feed direction valve handle in the forward direction The rail mill will begin cutting a longitudi nal slit through the casing 8 Adjust the cutting speed by changing the settings of the flow control valve Once the cut is complete turn off the feed direction valve and cutter spindle valve 10 Retract the cutter spindle up into the carriage 11 Turn feed control valve to the Reverse position to bring carriage back to start position 12 Turn off hydraulic fluid to the machine by opening the bypass valve Topside Control Unit Brief instructions for operating the TCU are on the instruc tion label on the top of the unit UNIVERSAL CONTROL PANEL UCP D START MPU REMOTE POWER UNET yep sere _ WAT FOR CLAMP PRESSURE CLAMP PRESSURE SYSTEM PRESSURE SET CLAMP CRECTON FORWARD REVERSE CLOSE CLAMP BALL VALVES BOTH LEVERS UP D SET CUTTER SPEED SEE REQUIREMENT S OPEN CUTTER BALL VALVES LEVER DOWN SET FEED ORECTON FORWARD REVERSE OPON FEED BALL VALVE LEVER 4 SET PEED SPEED SEE MAGNE REOLIAEMENT 7 MONTOR CUT FEED PRES ADJUST FEED SPOED F CLOSE ALL BALL VALVES ALL LEVERS UP MONTOR CLAMP PRESSURE MESET CLAMP F MIQUIMD CLOSE FEED BALL VALVE CLOSE CUTTER BALL VALVE REPEAT UCP OPERATION STEPS 2 BOU 8 CUT OPERATION ALWAYS CLOSE FEED BALL VALVE FIRST Figure 3 21 Ins
3. 3 Install the four shoes by positioning them inside the channels at each end of the frame and inserting the quick release pins 10 Part No 03 012 MAN Rev 1 0607 E H Wachs Company Chapter 3 Set Up and Operation Clamping the Mill to the Workpiece Figure 3 4 each mounting shoe in place and insert the quick release pin through the frame and shoe to secure it Lower the rail mill into position on the workpiece Securing the Chain Clamping Model 1 Wrap the chain at one end of the mill frame around the casing and loop the chain pins onto the clamp screws 2 Tighten the clamp nut with the supplied 2 1 2 combi nation wrench Figure 3 5 Tighten the chains to secure the rail mill to the workpiece E H Wachs Company Part No 03 012 MAN Rev 1 0607 11 Rail Mill User s Manual 3 Secure the chain at the other end of the mill frame in the same manner 4 Release the tension on the crane supporting the rail mill Leave the crane attached to the mill during cut ting Securing the Cable Clamping Model 1 Wrap the cable at one end of the mill around the cas ing and fasten the hook to the pin on the other side Figure 3 6 Run the cable around the pipe or casing and fasten the hook to the pin on the other side of the mill frame 2 Use the ratchet handle to tighten the cable 12 Part No 03 012 MAN Rev 1 0607 E H Wachs Company Chapter 3 Set Up and Operation
4. CUTTER 476 t 2 j 10 94 7 4 GPM SPEED UNIVERSAL CONTROL PANEL Figure 3 30 Move the feed drive lever down to stop the feed motion 13 Set the clamping drive auto plunge direction lever to the RETRACT position Figure 3 31 Set the clamping auto plunge direction lever to the RETRACT position 14 Engage both clamping drive levers down to retract the cutter out of the workpiece E H Wachs Company Part No 03 012 MAN Rev 1 0607 27 Rail Mill User s Manual Figure 3 32 Push the clamping drive levers down to reverse the auto plunge drive 15 When the cutter is above the workpiece pull both clamping drive levers back up Figure 3 33 Return both clamping auto plunge levers back to the up position when the cutter is fully retracted 16 To reverse the feed and move the cutting head back to the start position set the feed direction lever to the REVERSE position and use the feed drive lever to operate the drive 17 Set the cutting speed lever back to 0 to stop the cutter Close the cutting drive lever by moving it to the up position 28 Part No 03 012 MAN Rev 1 0607 E H Wachs Company Chapter 3 Set Up and Operation Removing the Mill _ m eee CAMP a Se m E meme T Ji UNIVERSAL CONTROL PANEL Figure 3 34 When the cut is complete set
5. E H Wachs Company 600 Knightsbridge Parkway Lincolnshire IL 60069 www wachsco com Rail Mill User s Manual E H Wachs Company Part No 03 012 MAN Rev 0 0307 March 2007 Revision History Original March 2007 Revision 1 June 2007 Copyright 2007 E H Wachs Company All rights reserved This manual may not be reproduced in whole or in part without the written consent of E H Wachs Company Rail Mill User s Manual Part No 03 012 MAN Rev 1 0607 E H Wachs Company Table of Contents Table of Contents Chapter 1 About this Manual 1 Purpose This Manual S RPM EISE ULIS d N 1 Howto Use The Manual ede as LOS 1 Symbols and Warnings ed Boe we eate Abed eu be ane we eke ee 1 Manual Updates and Revision Tracking ok eae et 2 Chapter 2 Safety sii oes SSS 3 Operator Safety 22665522 eM d 3 Safety Symbols vay aes age 4 Protective Equipment Requirements 5 safety Labels LAG e idea EN 5 Machine Safety acetic OE Ge ee 6 Chapter 3 Set Up and
6. Clamping the Mill to the Workpiece Figure 3 7 Push the ratchet handle forward to tighten the cable Figure 3 8 If the ratchet is set to turn in the wrong direction switch the setting knob to reverse it E H Wachs Company Part No 03 012 MAN Rev 1 0607 13 Rail Mill User s Manual 3 Secure the cable at the other end of the mill frame the same manner 4 Release the tension on the crane supporting the rail mill Leave the crane attached to the mill during cut ting HYDRAULIC CONNECTIONS Machine Mounted Controls One hydraulic hose pair supplies power to the control mani fold Connect the hoses as shown in Figure 3 9 CUTTER FEED SPEED CONTROL VALVE Rae Gu e T 4 gt F BYPASS CETT GT Figure 3 9 Connect the pressure hose to the fitting labeled P and the return tank hose to the fitting labeled T Topside Control Unit If you are operating the rail mill with the optional topside control unit TCU set up the hydraulic connections using the following procedure Connect Hoses to TCU 1 Wipe all hose couplers with a clean lint free cloth before making connections 14 Part No 03 012 MAN Rev 1 0607 E H Wachs Company Chapter 3 Set Up and Operation Hydraulic Connections Connect the hoses from the hydraulic power unit HPU to the HPU fittings on the back of the topside control unit TCU HPU FITTINGS Return Pres
7. 5 311131138 1 09150904 6 O1 X 26 88 SOHS 1 8 5 80 9 1 SOHS 200 8Sv0 6C 14 NO1V3 NOLOW pt 5 65094 8 L 6004 27 L 98160904 ST V V NOILO3S on DOOQOOY 43 Part No 03 012 MAN Rev 1 0607 E H Wachs Company Rail Mill User s Manual Rail Mill Cutter Spindle Gear Housing RE amp partno oEscmemON 02 057 00 02 058 00 02 059 00 02 060 00 02 061 00 02 062 00 02 063 00 02 064 00 02 065 00 02 073 01 02 074 00 02 075 00 02 076 00 02 077 00 02 078 00 02 079 00 02 186 00 ELEVATING NUT AND BEARING CAP BEARING LOCK NUT BEARING LOCK WASHER BALL BEARING CUTTER SPINDLE GEAR HOUSING SEAL STEEL WORM SHAFT NEEDLE BEARING SEAL CUTTER SPINDLE BALL BEARING BRONZE WORM GEAR BALL BEARING BEARING LOCK WASHER BEARING LOCK NUT CUTTER SPINDLE BEARING CAP BRONZE BUSHING SHCS 1 4 20 17 65 SHPP 1 8 FLUSH MOUNT KEY 1 4 SQ x 7 8 LG KEY 5 16 SQ x 2 1 4 LG SHCS 1 4 20 x 3 4 SS PLUG OIL Reference numbers refer to drawing on the next page Part No 03 012 MAN Rev 1 0607 E H Wachs Company Chapter 5 Parts Lists and Ordering Information Drawings and Parts Lists E H Wachs Company Part No 03 012 MAN Rev 1 0607 45 Rail Mill User s Manual ORDERING INFORMATION To place an order request service or get more detailed information on any E H Wachs Company products cal
8. Operation 7 Clamping Mill to the Workpiece Oy be nde 7 Securing the Chain Clamiping Model 11 Securing the Cable Clamping Model 12 Hydraulic Connections 55555 Yaswx Y es 14 Machine Mounted Controls 14 Topside Control 14 Connect 10 20 acres oe a eh le ae SN ll 14 Connect Hoses to the Rail Mill usus Hk 16 the Blade aout Ind pug a doe Uo oe e eee Pe 18 Operating the Mill chide debit REDE 20 Machine Mounted Controls 2555 os Mese eV os ees eA let ees 20 Topside Control Unit 22234304 dae ud dd QE E Rude 22 Removing the osos cep eeu Ree Ded E baies 29 Removing the Chain Clamping Model 29 Removing the Cable Clamping Model 30 Chapter 4 Routine Maintenance 55 esr RR hmm oie bo EE EVER 33 L bEiCatlol eS s rief wu EE etre 33 Chapter 5 Parts Lists and Ordering Information
9. assembly for autoplunge machine e 06 150 Feed end view for autoplunge machine e 06 150 Feed detail for autoplunge machine e 06 150 Autofeed assembly e 02 020 00 Cutter spindle gear housing In This Chapter DRAWINGS AND PARTS LISTS ORDERING INFORMATION E H Wachs Company Part No 03 012 MAN Rev 1 0607 35 Rail Mill User s Manual 9 0 210 0 8 8 1 520 210 lt 0 8 6 6 01 0 210 0 8g 1 0 210 0 91 2 0 210 lt 0 02 1 lt 0 210 lt 0 7 3NON 08 VN os wie 610 0 4S00 0S 1 390 3S00 0S1 90 S 0 210 0 0500 051 90 2500 051 90 0 210 0 8600 061 90 c 0 210 0 500 051 90 3NON L7 8 8 1 8 6 6 4 01 8 91 102 bZ OE 061 90 EI E H Wachs Company Part No 03 012 MAN Rev 1 0607 36 Chapter 5 Parts Lists and Ordering Information Drawings and Parts Lists JYIHSNIOONN 02 SHOVWH 3 SOHH 1 X 8 91 6 00 102 20 30v18 ONLLLS 00 500 20 532 14 8 290 210 60 88 411 06 16 6 lt 1 06 A18W3SSV 10 111 06 00 020 20 s3ovia v 532 14 2 20 610 20 800 Z10 0 A18W3SSV 033301nv 910 210 0 s30v1d SOHS 1 6 2 0 x gi c z x Z ONIHSNE MANIS 00 200 20 1 981 06 532 14 MHL 680 2 ONIHSNG LSNYHL 532 14 9 L00 210 0 s3ov1d z 600 210 lt 0 532
10. cable is loose around the pipe Remove the cable hook from the pin on the back of the mill frame E H Wachs Company Part No 03 012 MAN Rev 1 0607 31 Rail Mill User s Manual bons Figure 3 38 After loosening the cable remove the hook from the pin on the back of the mill frame Repeat the procedure to remove the cable on the other end of the mill frame 7 Use the crane to remove the mill from the workpiece 32 Part No 03 012 MAN Rev 1 0607 E H Wachs Company Chapter 4 Routine Maintenance Chapter 4 Routine Maintenance LUBRICATION Before each cut apply grease to all grease fittings on the machine In This Chapter LUBRICATION E H Wachs Company Part No 03 012 MAN Rev 1 0607 33 Rail Mill User s Manual 34 Part No 03 012 MAN Rev 1 0607 E H Wachs Company Chapter 5 Parts Lists and Ordering Information Chapter 5 Parts Lists and Ordering Information Refer to the part assembly drawings and parts lists that accompany them for parts identification To order spare or replacement parts see the ordering instructions at the end of this chapter DRAWINGS AND PARTS LISTS The following drawings with parts lists are provided Shoe selection chart e 03 012 Axial carriage assembly for manual plunge machine 03 012 Feed end view for manual plunge machine e 03 012 Feed detail for manual plunge machine e 06 150 Axial carriage
11. lock NOTE Left hand thread in the spacer and cutter tightly to the spindle with the nut turns counter clockwise lock nut to tighten E H Wachs Company Part No 03 012 MAN Rev 1 0607 19 Rail Mill User s Manual Figure 3 18 Turn the blade nut counter clockwise as shown to tighten the blade OPERATING THE MILL Machine Mounted Controls 1 Visually inspect the machine for any loose bolts or fit tings Ensure the controls on the manifold are set to off or neutral 2 Tum on the hydraulic power supply and start flow to the rail mill 3 controls for the rail mill are described in Figure 3 19 Close the bypass valve to direct hydraulic flow into the manifold 20 Part No 03 012 MAN Rev 1 0607 E H Wachs Company Chapter 3 Set Up and Operation Operating the Mill Figure 3 19 The photo illustrates the operation of the machine mounted control unit Ifnecessary turn the feed direction handle to traverse the carriage to the desired starting position 5 Turn on the cutter spindle valve 6 Slowly feed the rotating cutter spindle down until it extends through the wall of the casing This is done by turning the feed screw in a clockwise direction One complete turn of the feed screw lowers the cutter 1 10 Figure 3 20 Turn the plunge drive nut clockwise to feed the spindle E H Wachs Company Part No 03 012 MAN Rev 1 0607 21 Rail Mill User s Manual 7
12. plunge drive The cutter will move down into the surface of the work piece 24 Part No 03 012 MAN Rev 1 0607 E H Wachs Company Chapter 3 Set Up and Operation Operating the Mill Figure 3 26 Put both clamping levers down at the same time to engage the auto plunge drive 7 When the cutter has reached the desired depth close both clamping drive levers up position at the same time Figure 3 27 When the cutter has reached the desired depth return both clamping levers to the up position 8 Set the feed direction lever to the FORWARD posi tion as shown in Figure 3 28 Open the feed drive lever by pushing it down 10 Adjust the feed speed lever until the feed motion starts Set the lever to the desired speed E H Wachs Company Part No 03 012 MAN Rev 1 0607 25 Rail Mill User s Manual 171 UNIVERSAL CONTROL PANEL Figure 3 28 With the feed direction lever in the FOR WARD position move the feed drive lever up to start the drive Then move the feed adjustment lever to start flow to the feed drive 11 When the cut is complete move the feed speed lever back to 0 to stop the feed motion Figure 3 29 Stop the feed motion by setting the feed speed lever back to 0 12 Move the feed drive lever back to the down position 26 Part No 03 012 MAN Rev 1 0607 E H Wachs Company Chapter 3 Set Up and Operation Operating the Mill
13. the cutting speed lever back to 0 Then return the cutting drive lever to the off up position REMOVING THE MILL 1 Tum off power to the HPU 2 Slowly raise the lift holding the mill until there is just enough tension to hold the mill in place Removing the Chain Clamping Model 1 Loosen the chain tensioning nuts at both ends of the mill frame using the supplied 2 1 2 wrench E H Wachs Company Part No 03 012 MAN Rev 1 0607 29 Rail Mill User s Manual Figure 3 35 Loosen the clamping nuts to release the tension on the chains 2 Remove the clamping chains from the slots on the back of the mill frame 3 Use the crane to remove the mill from the workpiece Removing the Cable Clamping Model Use the following procedure to safely loosen the cable clamp one notch at a time 1 Set the ratchet on the handle to the forward direction Figure 3 36 Push the right side ratchet knob to set the ratchet direction forward 4 P 30 Part No 03 012 MAN Rev 1 0607 E H Wachs Company Chapter 3 Set Up and Operation Removing the Mill 2 Push the handle forward just far enough to release the catch on the cable winch Push the catch down to dis engage it Figure 3 37 Turn the handle just enough to release the catch 3 Back the handle off one notch of the gear and reset the catch 4 Continue to loosen the winch one gear notch at a time until the
14. 14 110 210 60 010 210 lt 0 37 Part No 03 012 MAN Rev 1 0607 E H Wachs Company Rail Mill User s Manual 03112345 SSTINN 20 20 5 am 10 2200 am WW veo QN3 0334 200 lt 0 86 100 210 lt 0 wf 2 66 3400 6 2 2 19 200 80 86 900 10 90 ONIY 34 00 60 86 ONIY 639 14 9 00 0 86 850 00 2 1 2 ONIHSNG LSNYHL SOHS x 81 91 S 900 061 90 YJHSYM 1 13 SOHS 8 91 8 2015 3 9 1 1 X 91 v0 210 0 0333 0z0 Z10 0 5 5 81 91 6 020 081 90 539 14 9 91 2 1 1 2 1 1 5 8 3 331S 10 210 0 E H Wachs Company Part No 03 012 MAN Rev 1 0607 38 Chapter 5 Parts Lists and Ordering Information Drawings and Parts Lists 15 SNOU artis i f 3 5 1 0102 XX 0 SHOVMH 3 QSION SV 20 82 20 SOHS YOLOW 0334 8 2 81 91 G 610 210 lt 0 MOOLSASM 71 1 X 8 1 X 1 SESS 1 1 I 22222 810 210 lt 0 gt SOHS v OZ v l 39 Part No 03 012 MAN Rev 1 0607 E H Wachs Company Rail Mill User s Manual JYIHSNIOO
15. AFETY Look for this sym AN bol throughout the manual It indicates a personal injury hazard E H Wachs Company Part No 03 012 MAN Rev 1 0607 Rail Mill User s Manual Always turn machine off before doing any adjustments or service e SECURE LOOSE CLOTHING AND JEWELRY Secure or remove loose fitting clothing and jewelry and securely bind long hair to prevent them from getting caught in moving parts of the machine e KEEP WORK AREA CLEAR Keep all clutter and nonessential materials out of the work area Only people directly involved with the work being performed should have access to the area Safety Symbols A This icon is displayed with any safety alert that indicates a personal injury hazard N WARNING This safety alert indicates a potentially hazardous situation that if not avoided could result in death or serious injury Z CAUTION This safety alert with the personal injury hazard symbol indicates a potentially hazardous situation that if not avoided could result in minor or moderate injury NOTICE This alert indicates a situation that 1f not avoided will result in damage to the equipment Part No 03 012 MAN Rev 1 0607 E H Wachs Company Chapter 2 Safety Safety Labels IMPORTANT This alert indicates a situation that if not avoided may result in damage to the equipment Protective Equipment Requirements WARNING Always wear impact resistant eye pro tecti
16. NN 02 SHOVWH 3 00 102 20 30v18 532 14 8 H2v3 211 88 411 06 16 6 lt 1 06 18 355 10 111 06 00 020 20 532 14 9 10 8 1 20 532 14 20 610 20 55 SOHH 1 X 81 91 S 00 500 20 2 0 210 lt 0 532 14 2 800 210 lt 0 532 14 SOHS 1 X 1 7 1 sa z 1 1 x gi c z x Z 508 MANS 00 200 20 s39v1d 8 MHL 680 X X ONIHSNG LSNYHL 532 14 9 L00 210 0 532 14 2 600 210 lt 0 532 14 110 210 60 010 210 lt 0 Wachs Company Part No 03 012 MAN Rev 1 0607 40 Chapter 5 Parts Lists and Ordering Information Drawings and Parts Lists JYIHSNIOONN 02 SHOVWH 3 a 20 81 80 a AT 39 0334 5214 91 Z i 1 2 1 1 SNIHSnS 3 3 X201SA39 1 1 91 5914 v MHL B 0 210 0 510 051 90 SOHS 81 91 6 410 210 lt 0 41 Part No 03 012 MAN Rev 1 0607 E H Wachs Company Rail Mill User s Manual JYIHSNIOONN 09 SHOVWH 3 8 1 X 81 91 8 N 000 4 5 NS h 2 1 24 1 1 610 210 lt 0 7 1334 E H Wachs Company Part No 03 012 MAN Rev 1 0607 42 Chapter 5 Parts Lists and Ordering Information Drawings and Parts Lists pot 0004950 9 21 60006190 1
17. he bottom of the pages You may have factory service or upgrades performed on the equipment If this service changes any technical data or operation and maintenance procedures we will include a revised manual when we return the equipment to you Part No 03 012 MAN Rev 1 0607 E H Wachs Company Chapter 2 Safety Chapter 2 Safety The E H Wachs Company takes great pride in designing and manufacturing safe high quality products We make user safety a top priority in the design of all our products Read this chapter carefully before operating the rail mill It contains important safety instructions and recommenda tions OPERATOR SAFETY Follow these guidelines for safe operation of the equip ment READ THE OPERATING MANUAL Make sure you understand all setup and operating instructions before you begin INSPECT MACHINE AND ACCESSORIES Before starting the machine look for loose bolts or nuts leaking lubricant rusted components and any other physical conditions that may affect operation Properly maintaining the machine can greatly decrease the chances for injury e ALWAYS READ PLACARDS AND LABELS Make sure all placards labels and stickers are clearly legible and in good condition You can purchase replacement labels from E H Wachs Company KEEP CLEAR OF MOVING PARTS Keep hands arms and fingers clear of all rotating or moving parts In This Chapter OPERATOR SAFETY SAFETY LABELS MACHINE S
18. l mill bulkhead as shown in Figure 3 15 Cutting drive pressure Cutting drive return Figure 3 15 Connect the cutting drive hoses to the mill as shown E H Wachs Company Part No 03 012 MAN Rev 1 0607 17 Rail Mill User s Manual Connect the feed drive hoses from the TCU or hose reel to the hoses on the end of the mill as shown in Figure 3 15 Feed drive hose fittings Figure 3 16 Connect the feed drive hoses to the hose fittings on the end of the rail mill NOTE The feed drive hose fittings are physically inter changeable If the feed drive is operating in the wrong direc tion reverse the hose connections INSTALLING THE BLADE 1 Make sure the cutter spindle is in its uppermost posi tion Use the plunge drive on the TCU to raise the spindle or turn the spindle wrench counterclockwise on the plunge drive nut 18 Part No 03 012 MAN Rev 1 0607 E H Wachs Company Chapter 3 Set Up and Operation Installing the Blade Figure 3 17 On mills with machine mounted con trols turn the plunge drive nut counter clockwise to retract the spindle 2 Make sure the cutter drive collar spacer and lock nut are clean and free of chips and dirt so that the assem bly can be tightened securely 3 Install the cutter onto the spindle shaft The cutter should be placed on the spindle so the flat sharp cut ting edges lead into the pipe 4 Place the driving collar spacer on the spindle and
19. l us at one of the following numbers US 800 323 8185 International 847 537 8800 Ordering Replacement Parts When ordering parts refer to the parts lists earlier in this chapter Please provide the part description and part number for all parts you are ordering Repair Information Please call us for an authorization number before returning any equipment for repair or factory service We will advise you of shipping and handling When you send the equip ment please include the following information e Your name company name e Your address e Your phone number A brief description of the problem or work to be done Before we perform any repair we will estimate the work and inform you of the cost and the time required to com plete it Warranty Information Enclosed with the manual is a warranty card Please fill out the registration card and return to E H Wachs Company Retain the owner s registration record and warranty card for your information Return Goods Address Return equipment for repair to the following address E H Wachs Company 600 Knightsbridge Parkway Lincolnshire Illinois 60069 USA 46 Part No 03 012 MAN Rev 1 0607 E H Wachs Company
20. on while operating or working near this equipment For additional information on eye and face protection refer to Federal OSHA regulations 29 Code of Federal Regula tions Section 1910 133 Eye and Face Protection and American National Standards Institute ANSI Z87 1 Occu pational and Educational Eye and Face Protection Z87 1 is available from the American National Standards Institute Inc 1430 Broadway New York NY 10018 CAUTION Personal hearing protection is recom mended when operating or working near this tool Hearing protectors are required in high noise areas 85 dBA or greater The operation of other tools and equipment in the area reflective surfaces process noises and resonant struc tures can increase the noise level in the area For additional information on hearing protection refer to Federal OSHA regulations 29 Code of Federal Regulations Section 1910 95 Occupational Noise Exposure and ANSI 512 6 Hearing Protectors SAFETY LABELS There is no safety labeling on the rail mill E H Wachs Company Part No 03 012 MAN Rev 1 0607 Rail Mill User s Manual MACHINE SAFETY To avoid damaging the equipment follow these usage guidelines e Lubricate the machinery according to the recommenda tions in Chapter 4 e Before starting the machine make sure the blade is inserted and fastened securely Make sure that the chain or cable clamping system is securely tightened Make su
21. re that all hydraulic connections are secure 6 Part No 03 012 MAN Rev 1 0607 E H Wachs Company Chapter 3 Set Up and Operation Chapter 3 Set Up and Operation This manual explains how to install and operate the rail mill using either machine mounted controls or the topside con trol unit TCU Follow the instructions in the appropriate section for your machine s configuration There are two rail mill models Model number 03 012 has a manual plunge drive and uses a 6 milling blade Model number 06 150 has a hydraulic plunge drive and uses a 7 milling blade CLAMPING THE MILL TO THE WORKPIECE The rail mill cuts from the end with the feed motor and gear box toward the opposite end The maximum length of travel depends on the size of the rail mill frame Position the machine to take into account the direction of cut The machine only performs conventional milling not climb milling Figure 3 1 and Figure 3 2 illustrate the machine s cutting motions In This Chapter CLAMPING THE MILL TO THE WORKPIECE HYDRAULIC CONNECTIONS INSTALLING THE BLADE OPERATING THE MILL REMOVING THE MILL E H Wachs Company Part No 03 012 MAN Rev 1 0607 Rail Mill User s Manual Figure 3 1 The rail mill is designed to cut only in one direction as shown in the photo Blade rotation utting airection Figure 3 2 The blade rotates in the direction shown as the mill moves If you are cut
22. sure Figure 3 10 HPU hose fittings on the back of the control unit Connect the cutting drive hose set from the machine or from the hose reel to the cutting drive fittings on the back of the TCU The hoses and fittings are color coded Return Pressure CUTTER DRIVE Figure 3 11 Connect the cutting drive hoses to the TCU 4 Connect the auto plunge hose set to the fittings labeled clamp on the back of the TCU The hoses and fittings are color coded E H Wachs Company Part No 03 012 MAN Rev 1 0607 15 Rail Mill User s Manual Return Pressure AUTO PLUNGE DRIVE Figure 3 12 Connect the hoses for the auto plunge drive to the clamping drive fittings on the TCU 5 Connect the feed drive hose set to the feed drive fit tings on the back of the TCU The hoses and fittings are color coded Return Pressure FEED DRIVE Figure 3 13 Feed drive connectors for machines with hydraulic feed drives Connect Hoses to the Rail Mill Connect the auto plunge drive hoses from the TCU or hose reel to the fittings on the rail mill bulkhead as shown in Figure 3 14 16 Part No 03 012 MAN Rev 1 0607 E H Wachs Company Chapter 3 Set Up and Operation Hydraulic Connections Auto plunge drive pressure Auto plunge drive return Figure 3 14 Connect the auto plunge drive hoses to the mill as shown 2 Connectthe cutting drive hoses from the TCU or hose reel to the fittings on the rai
23. ting longer lengths than the rail mill s maxi mum travel you will have to reposition the machine to con tinue the cut Be sure to align the cut lines 1 Attach a crane or hoist to the rail mill at its lifting locations Part No 03 012 MAN Rev 1 0607 E H Wachs Company Chapter 3 Set Up and Operation Clamping the Mill to the Workpiece Figure 3 3 Connect a strap or chain to the lifting points Use the center point at both ends for horizontal lifting use all three points at one end for vertical lift ing 2 Select the appropriate mounting shoes for the size of the pipe you are cutting The shoes are different sizes for the two rail mill models refer to Table 1 for model 03 012 and Table 2 for model 06 150 E H Wachs Company Part No 03 012 MAN Rev 1 0607 9 Rail Mill User s Manual Table 1 Mounting shoes for 03 012 Rail Mill Pipe Diameter Shoe Part No Shoe Height 24 03 012 31 1 1 4 20 03 012 32 1 3 4 16 03 012 33 2 1 2 13 3 8 03 012 34 2 3 4 2 03 012 35 3 3 8 7 5 8 03 012 36 3 5 8 Table 2 Mounting shoes for 06 150 Rail Mill Pipe Diameter Shoe Part No Shoe Height 30 None 24 06 150 005A or 03 012 32 1 3 4 20 06 150 005B or 03 012 33 2 1 2 16 06 150 005C 3 13 3 8 06 150 005D or 03 012 35 3 3 8 10 3 4 5 9 5 8 06 150 005 4 23 06 150 005F 4 3 8
24. to it for safety notes and other information SYMBOLS AND WARNINGS The following symbols are used throughout this manual to indicate special notes and warnings They appear in the out side column of the page next to the section they refer to In This Chapter PURPOSE OF THIS MANUAL How TO USE THE MANUAL SYMBOLS AND WARNINGS MANUAL UPDATES AND REVISION TRACKING Throughout this manual refer to this column for warnings cautions and notices with supplementary information E H Wachs Company Part No 03 012 MAN Rev 1 0607 Rail Mill User s Manual Current versions of E H Wachs Company manuals are also available in PDF for mat You can request an electronic copy of this manual by emailing customer service at sales wachsco com Make sure you understand what each symbol means and follow all instructions for cautions and warnings This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death NOTE This symbol indicates a user notice Notices provide additional information to supplement the instructions or tips for easier operation MANUAL UPDATES AND REVISION TRACKING Occasionally we will update manuals with improved opera tion or maintenance procedures or with corrections if nec essary When a manual is revised we will update the revision history on the title page and at t
25. truction label on the topside control unit NOTE The TCU has fittings and controls for a clamping drive which are identified on the unit as clamp or clamping With the rail mill these controls are used for the auto plunge drive 1 Setall drive power levers to the up closed position and make sure the clamping auto plunge direction lever is set to the ENGAGE position 22 Part No 03 012 MAN Rev 1 0607 E H Wachs Company Chapter 3 Set Up and Operation Operating the Mill Figure 3 22 Before starting the HPU make sure that all drive levers are in the up position and that the clamping direction lever is in the ENGAGE position 2 Start the hydraulic power unit 3 Make sure the cutting drive speed control lever is set to 0 gt e Figure 3 23 Set the cutting drive speed lever to 0 before starting the mill 4 Open the cutting drive lever down position E H Wachs Company Part No 03 012 MAN Rev 1 0607 23 Rail Mill User s Manual Figure 3 24 Push the cutting drive lever down to open it 5 Move the cutting drive speed lever up gradually to the desired cutting speed ae HEN CLAMP RETRACT Figure 3 25 Push the cutting speed lever up slowly to the desired cutter speed 6 Open both clamping drive levers down position at the same time to engage the auto
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