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Low Clearance Split Frame, Models 204-1420

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1. DIMENSIONS IN BRAC KETS ARE MILLIMETERS 1 29 PIPE DIAMETER A SHOWN WITHOUT CLEARANCE 165 1 WEIGHT 7 5lb 3 4kg 5 69 144 5 5 19 TABLE 1318 MODEL PosmoN OMe 124 os 76 4 47 3 15 19 2 113 5 2 76 5 46 i LCSF204 3 248 eh 55 2 HIGH 508 049 5 125 OW 140351 31 8 Ls 206 3 1580 ae Low ibe s csao 59 HGH 2244 Ded tow 0585 18801 1 LCS 610 3 MID 183 J HGH Low 23961 Lv I MD 248 7 um HGH 13309 pen pes f LA Low 0903 2402 1 wo 45 HIGH 1 3 12909 9 ow 4 ds mo dM dS OP O _L0 31 BEA 7 9 tow 18229 23 LCSF 1420 3 2885 1320 T 4 83 211 82 2 50 3 48 63 5 88 5 192 48 7 1 67 H 42 4 4 TRAVEL FEED RATE 0026 PER TRIP L0661 5 37 136 5 a Slide travel and diameter radius dimensions abov
2. DIMENSIONS IN BRAC KETS ARE MILLIMETERS TABLE PIPE DIAMETER DIM A SHOWN WITHOUT CLEARANCE WEIGHT 2 8lb 1 3kg MODEL RADIUS 76 50 LCSF204 3 45 1149 6 88 53 LCSF206 3 1748 14053 i 6 53 LCSF208 3 25561 1659 00 84 LCSF210 3 5799 1594 650 4 Lcsre12 3 1800 8 83 165 1 330 2 224 3 LCSF814 3 1225 5 81 6 2 0 147 6 LCSF10163 2720 LCSF14203 20 25 5270 348 88 5 67 TRAVEL 125 4 17 1 31 8 9 2 17 23 3 55 2 FEED RATE LL 0026 PER TRIP 066 A e Udo 99 25 1 1 4 E 96 Y A 225 259 x 5 37 a Vallee 136 5 ta ssa o 8 31 B AN I P 7 9 9 5 124 3 15 286 72 6 Slide travel and diameter radius dimensions above are same for 60 402 04 parting slide and 60 403 04 6 b ling slid xt 110 7 eveling slide next page 5 19 131 8 5 36 136 1 40 Chapter 3 Introduction to the Equipment Operating Envelopes Low Clearance Beveling Slide 60 403 04 The low clearance beveling slide is paired with the low clearance parting slide 60 402 04 It is used with LCSF models 204 1420
3. Part No Description Length 43 710 05 37 5 double bevel 3 1 8 53 703 00 37 5 inside bevel 5 43 708 06 37 5 outside bevel 5 w 43 710 06 37 5 double bevel 5 43 702 05 30 inside bevel 3 1 8 43 707 05 30 outside bevel 3 1 8 43 709 05 30 double bevel 3 1 8 53 703 01 30 inside bevel 5 43 707 06 30 outside bevel 5 43 709 06 30 double bevel 5 60 SPT 02 3 4 wide HSS single 3 1 8 angle bevel 60 SPT 03 1 1 wide HSS single 3 1 8 angle outside bevel 162 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 9 Accessories and Spare Parts Tooling Table 4 LCSF Single Angle Beveling Tools Part No Description Length 60 SPT 05 1 1 2 wide HSS double 3 1 8 bevel 60 SPT 02 3 4 wide HSS single angle bevel 60 5 04 1 2 wide HSS single angle outside bevel 60 SPT 06 1 1 2 wide HSS double 5 bevel Table 5 LCSF Compound Angle Beveling Tools Part No Description Length 43 712 01 10 x 37 5 inside bevel 4 43 712 02 10 x 37 5 outside bevel 4 53 705 00 10 x 37 5 inside bevel 5 53 704 00 10 x 30 inside bevel 5 60 SPT 07 Custom HSS compound bevel tool Custom single angle BOSE Te HSS J Prep bevel tool Custom compound 60 SPT 09 angle HSS J Prep bevel tool HSS High Speed Steel
4. R27 25 REF 692 2 DIMENSIONS IN BRACKETS ARE MILLIMETERS SPEED CONTROL AND OILER CAN BE RELOCATED FOR SPACE CONSTRAINTS 46 Chapter 3 Introduction to the Equipment Operating Envelopes 2 5 HP Right Angle Reversible Air Drive 60 4010 01 2 49 3 20 63 3 81 2 14 92 3790 6 OF HANDLE SPEED CONTROL R18 08 459 2 60 TYP _ 2 81 714 1 63 HON m 41 3 R26 57 675 0 DIMENSIONS IN BRACKETS ARE MILLIMETERS 47 Low Clearance Split Frame Models 204 1420 Hydraulic Drive 60 424 01 WEIGHT 25 4 Ibs 11 5 kg MUSTATIACH MOTOR MOUNTTO PINION HOUSING ent FLOW IN PRIOR TO MOUNTING HYDRAULIC MOTOR MAXIMUM FLOW 15 GPM 57 LPM PRESSURE UP TO 2000 PSI 138 BAR EE 1 2 NPT H i PERFORMANCE DATA FLOW GPM LPM RPM 2 7 6 47 4115 11 94 11 631 6122 71 141 295 4 8 30 3 188 10 37 9 235 12 45 4 282 14 53 0 330 8 231 15 56 8 353 209 1 3 934 4 022 99 9 102 2 3 125 79
5. y 33 Drive Motoi Goode ad eo aa aed nig ue e acri ut ene u rA cb 33 Hand Pool Kit eae th eade Kad uid oh 34 PNCCOSSOTIOS duce Du tes kus WA k Sig de 35 Noise Levels a a ee Bus 36 Operating Envelopes yQ al Pee se bp C eee 36 ESCF Models 204 and 200 s vti Shee PS DE pun iisas sa SS 37 LCSF Models 408 610 612 and 814 38 LCSE Models 1016 and 1420 Ga Federer e AUS hee FO e CR 39 Low Clearance Parting Slide 60 402 04 40 Low Clearance Beveling Slide 60 403 04 41 Extended Parting Slide 60 415 00 42 Extended Beveling Slide 60 416 00 43 Univeral Counterbore Slide 60 405 UC 44 Front Drive Pinion Assembly 60 425 03 45 1 5 HP Right Angle Air Drive 60 423 00 46 2 5 HP Right Angle Air Drive 60 423 01 46 2 5 HP Right Angle Reversible Air Drive 60 4010 01 47 Hydraulic Drive 00 424 01 d ve aem Ee etes tet b e e a 48 Chapter 4
6. drive Figure 3 6 The photo shows the drive options avail able with the LCSF Hand Tool Kit Each LCSF 15 delivered from the factory with all hand tools necessary for setup and operation Kit number 60 600 00 is provide with LCSF models 204 through 1420 The follow ing table lists the hand tools provided with the LCSF 34 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 3 Introduction to the Equipment LCSF Components Table 3 LCSF Hand Tool Kit Models 204 1420 Part No 60 000 00 Description Part Hex Wench Set 5 64 1 4 90 800 06 Deadblow Hammer 60 814 00 3 8 Hex Long Arm Wrench 90 800 10 1 4 Hex Driver Long Socket 1 2 Drive 90 800 18 7 16 Combination Wrench 90 800 38 Square 8 90 800 54 1 2 Drive Ratchet Wrench 90 800 63 Scale 6 90 800 70 3 8 Hex Driver Long Socket 1 2 Drive 90 800 76 Tool Box 60 227 00 Other tools may be required toperform certain maintenance operations These are specified in the instructions for those procedures Accessories The following accessory equipment 15 available for use with the LCSF These items are purchased separately see Chap ter 9 for descriptions and purchasing information Low clearance slides Extended stroke slides Hydraulic drive Electric drive Bridge slide O D tracking slides
7. e gt ITEM PARTNUMBER QTY DESCRIPTION 1 60 1178 00 2 WIPER 10 20 LC SF 6 Q 60 1179 00 SPACER 10 20 LC SF WIPER 60 1180 00 BRAC KET LC SF 10 20 WIPER 9 S Wiper Kit 60 552 02 d Used with these LCSF models 60 000 10 60 000 12 60 000 14 60 000 16 60 000 20 cD l Chapter 8 Introduction to the Equipment Pinion Housing 60 412 00 This is the standard pinion housing for LCSF models 204 1420 PART NUMBER DESCRIPTION 60 1235 00 BEARING DEEP GROOVE BALL 60 1237 00 GEAR 23TPINIO N 60 1238 00 HOUSING 23T PINION 60 1239 00 COVER 23T PINION 60 1240 00 BEARING DBL ROW ANGULAR CONTACT 60 1241 00 RING RETAINING 60 181 00 LABEL STARWHEEL 90 050 11 SHCS 1 4 20 x 1 1 8 Olo NIAJ AJ WIN Re 90 060 07 SHCS 5 16 18 X 3 4 90 060 22 SHC 5 5 16 18 x 2 1 4 90 076 05 3 8 X 1 2 DO WEL 145 Low Clearance Split Frame Models 204 1420 Front Drive Pinion Housing 60 425 03 The front drive pinion housing is optional on LCSF models 204 1420 PARTNUMBER DESCRIPTION 1 60 125 00 3 BEARING PINION REAR 2 60 341 00 1 HOUSING PINIO N FRO 4 20 LC SF 3 60 342 00 1 HOUSING PI
8. s q a dS ve 130 E H Wachs Part No 60 MAN 07 Rev 0 0311 ili Low Clearance Split Frame Models 204 1420 PLC a k BR Wa a asum q 130 REASSEMIDIY quei QE eM cS Q oe eile wa ee 130 holen UE DUC 131 zur Motor Valles ud ais deus quA DoD Ww al iita 131 Richt Angle Head d dos ae S Pt oe a hab ess 132 Chapter 8 Parts Lists and Drawings 133 Model 204 4 inch LCSF 60 000 04 134 Model 206 6 inch LCSF 60 000 06 135 Model 408 8 inch LCSF 60 000 08 136 Model 610 10 inch LCSF 60 000 10 137 Model 612 12 inch LCSF 60 000 12 138 Model 814 14 inch LCSF 60 000 14 139 Model 1016 16 inch LCSF 60 000 16 140 Model 1420 20 inch LCSF 60 000 20 141 Stationary Ring Assembly Models 204 through 814 142 Stationary Ring Assembly Models 1016 1420 143 Wiper Kit Assemblies 60 552 01 and 60 552 02
9. Puma YU N 64 Sete Dn ordine Pipe asuy E e WOW nia ais atas 66 Set Up Tor Open Ended Pipes e abuse So owt ted ab ee asnaq s patata 70 Installation on Vertical Pipe 71 Positioning the Machine for the Cut 71 Clamp Pad Centering Procedure 72 Install Tool Slides and Tooling 76 Standard ro Rena dates Eee voa d gS Be doas 76 Low Cl ara ce Slides os ceed M SRL daa etia rice paw dine 78 Installithe TPoolHng 3 tea ke Sas te Oe koe ed Boe wade hah BUREN 78 Dual Tooling Setup usus reia pan atta ere ale wus aT Ve WIR 82 Installthe Tap Assembly is 5 PRSE Hae Ra ESS 84 Install the Drive Motor See yasa su us PREYS 88 AMOO E od te eR up rep E te dal in 89 Hydraulic Motor Foods Ae pakpi ere e OUS 89 Cutis Operation od aie aoe a ba wien 93 steve pus fud 96 Planning the Operarions ager ewe use u d EN 96 CounDterbore SEUD eei sehe revive S S Wb du Ves
10. Wachs 600 Knightsbridge Parkway Lincolnshire IL 60069 www ehwachs com Low Clearance Split Frame Models 204 1420 User s Manual E H Wachs Part No 60 MAN 07 Rev 0 0311 March 2011 Revision History Original March 2011 Copyright 2011 E H Wachs All rights reserved This manual may not be reproduced in whole or in part without the written consent of E H Wachs Low Clearance Split Frame Models 204 1420 Part No 60 MAN 07 Rev 0 0311 E H Wachs Table Contents Table of Contents Chapter 1 About This Manual 1 P rpose of This Manual siiin asus REN CHR E PE 1 Howto Use Ehe Manual IST HAAS ERTE COM MS 1 Symbols and Warnings 5 e xu yas 2 Manual Updates and Revision Tracking 3 Technical File Responsible Party 3 Chapter 2 Safety erise eiia bh eX RES D Ge e n ic RR CR li 5 Safe Operating Guidelines eisi ser e ee ac d Re CU add dn 5 Safe Operating Environment 6 Operating and Maintenance Safety 6 Hydraulic Powered Equipment 7 Pneumatic Powered Equipment 7 Loss
11. 10 20 LC SF 7 60 122 00 2 SCREW CAPTIVATED 5 16 18 8 60 1242 00 2 SHAFT SMALL FIXED BEARING 9 60 1243 00 12 5 SMALL ADJ USTABLE BEARING 10 60 1260 06 1 6 STATIONARY FRAME ASSEMBLY 11 60 1261 00 2 55 10 20 LC SF WIPER BRACKET 12 60 1274 00 2 5 13 60 1275 00 1 LABEL PIN LOCATION 14 60 1279 06 1 LABEL WEIGHT LCSF 206 15 60 129 00 2 FRAMELOCKING 16 60 130 00 14 PLUG BEARING 17 60 166 04 4 GUARD CHIP LC 4 12 18 60 351 08 1 INSERTFOAM NOTSHOWN 19 60 363 00 1 MOVING PARTS 20 60 408 05 1 1 2 EXTENSION LEG SET NOTSHOWN 21 60 408 10 1 L0 EXTENSION LEG SET NOTSHOWN 22 60 408 15 1 1 1 2 EXTENSION LEG SET NOTSHOWN 23 60 408 20 1 72 0 EXTENSION LEG SET NOTSHOWN 24 60 412 00 1 HOUSING ASSEMBLY LC SF 4 20 25 60 447 02 4 CLAMP PAD ASSEMBLY 4 8 26 60 560 01 1 LCSF 4 20 FASTENERS NOTSHOWN 27 60 600 00 1 TOOLS 4 20 LC SF HAND NOTSHOWN 28 60 MAN 07 1 MANUAL SPLITFRAME NOTSHOWN 29 80 0080 00 1 NAMEPLATE 30 90 022 03 4 5 8 32 375 31 90 025 01 4 __ WASHER 8 FLAT 32 90 042 03 4 5 10 24 X 3 8 33 90 049 06 4 SCREW 2 3 16 U DRIVE 34 90 056 05 4 _ PIN 1 4 X 1 2 DOWEL 35 90 065 01 14 5 16 18 HEX 36 90 065 10 14 _ NUT 5 16 18 HEAVY J 37 90 165 53 14 WASHER 5 16 SECURING 38 90 900 00 1 READ MANUAL 1 50 DIA WIPERS ITEM NO 6 REQUIRE WAY OIL PART NO 60 1184 00 SOL
12. 98 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 5 Operating Instructions Counterboring In Figure 5 61 the planned counterbore depth is 0 375 of straight bore This 15 value that 15 specified in the weld prep detail general rule of thumb is the counterbore depth 15 Just deep enough to locate the transition of the straight bore taper Intersection out of the weld x ray zone or behind the end of the weld prep as shown in Figure 5 61 Depth 0 375 ee Figure 5 61 Counterbore depth From Step 1 0 15 needs to be removed from the wall thickness If the taper on the counterbore tool bit is 4 1 we can determine the depth of the first counterbore pass 0 60 4 0 15 Figure 5 62 The depth of the tapered part of the bore is a function of the tool taper and the counterbore thickness 0 15 x 4 taper ratio 0 60 length of the tapered portion 0 375 length of straight bore E H Wachs Part No 60 MAN 07 Rev 0 0311 99 Low Clearance Split Frame Models 204 1420 0 975 Total counterbore depth including the lead out angle COUNTERBORE PLANNING FORMULA The knowns Angle 14 1 2 or 4 to 1 taper ratio Material per pass 050 Total material removed of 150 Need to find how deep to bore c of our angle Formula to find Side Side b 150 Angle B 14 1 2 c bxcot B cot B 3 8667 c 150 x 3 8667 is 580 To ca
13. Improper tool installation Reinstall bit Wachs Part No 60 MAN 07 Rev 0 0311 109 Low Clearance Split Frame Models 204 1420 ADJUSTING THE BEARINGS Pre 2009 Machine The following procedure is for LCSFs with a serial number starting with 08 or less 08 manufactured before 2009 1 Remove any tool slides installed on the rotating ring 2 Using a 1 4 hex wrench split the LCSF Remove the rotating ring from the stationary frame m Figure 7 1 Separate the stationary and rotating rings 3 Clean out the area around the guide wheel bearings 37 005 00 in the stationary frame and the V groove area of the rotating ring 110 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 7 Service and Repair Adjusting the Bearings Figure 7 2 Clean debris from the stationary ring 4 Inspect the V groove area of the rotating ring for deformation cracking and or pitting If the ring 15 damaged you will need to replace it Figure 7 3 Inspect the V groove of the rotating ring for wear or damage Check to make sure eachbearing spins freely by hand E H Wachs Part No 60 MAN 07 Rev 0 0311 111 Low Clearance Split Frame Models 204 1420 6 Remove the plastic caps on the back of the stationary ring and inspect the bearing assemblies Replace worn or broken components Each bearing assembly con sists o
14. Su ad 101 Cutting the Counter bores vo eite She rcs MV PASE ape e dns 102 Operating DCSPACCESSOPIES saunas Soda denas pP dea ES 105 Chapter 6 Routine Maintenance 107 Daily Maintenance xao ead As ac Eg ed ee aba 107 PATTI CACO Da os rete ak es den RA SERENA 107 a vr xv 107 Bp BEA e o Goose SM SIUE uA 107 Aur MOLIOR Seok aquest ert ul qM oic z a ALT 108 Recommended Air Motor Lubricants 108 Chapter 7 Service and Repair 109 FRODDIESlOOUTIB t ann a anode Ras WORE DU VV PIS WV Pia 109 Adjusting the Bearings 605 suco rose eae Ain eom hs e oet Cee dard 110 Pre 2000 Machine n sa Re hr Hb adde CELA 110 2009 and Later Machines Raf o RA 117 Tool SHde Adjustmetit s o oet or bet PIRE eT E sma bis 123 Air Motor Maintenance 129 Disassembling Air Motor Subassemblies 130 Right Amele Head us ois to 9m odi ee Sg er epe E33 rte ed kusa la 130 Gear C ase taa bed els b me 130
15. Kit Universal Counterbore Slide 60 550 07 1 Fasteners E H Wachs Part No 60 MAN 07 Rev 0 0311 165 Low Clearance Split Frame Models 204 1420 166 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 10 Ordering Information Chapter 10 Ordering Information In This Chapter To place an order request service or get more detailed information on any E H Wachs products call us at one of ORDERING REPLACEMENT PARTS the following numbers REPAIR INFORMATION U S 800 323 8185 WARRANTY INFORMATION International 847 537 8800 Fen Goss You can also visit our Web site at www ehwachs com ORDERING REPLACEMENT PARTS When ordering parts refer to the drawings and parts lists in Chapter 8 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 Your name company name Your address Your phone number A description of the problem or the work to be done E H Wachs Part No 60 MAN 07 Rev 0 0311 167 Low Clearance Split Frame Models 204 1420 Before we perform any repair we will estimate the work and inform you of the cost and the time to complete it WARRANTY INFORMATION
16. 144 Pinion Housing 60 42 00 ees teed RC ERES Pr es 145 Front Drive Pinion Housing 60 425 03 146 Clamp Legs 60212 7 XX os u A Ale acr SER UA d AREE X 147 Trip Assembly 60401200 a sac aee dawns Paw wai ed pod 148 Low Clearance Parting Slide 60 402 04_ 149 Low Clearance Beveling Slide 60 A03 04 150 Extended Parting Slide 60 415 00 151 Extended Beveling Slide 60 416 00 152 Universal Counterbore Slide 60 405 UC 153 IS HP Air Drive 6042 3500 4 n ites asa pn sed 154 1 5 HP Air Drive Ported Exhaust 60 407 00 155 2 5 HP Air Drive 60 423 01 156 2 5 HP Reversible Air Drive 60 4010 00 157 Hydraulic Drive 60 424 01 e ku uides Sr WE dm ee 158 Chapter 9 Accessories and Spare Parts 159 d as Vus ae UAM OE PS eus VAS i 159 Mn 161 Hydraulic Power Units uu aa E RE hecha 164 Recommended Spates sowas ee ee eee NOR RR e 164
17. Tighten the pinion bearing retainer to 35 to 40 Ib ft 47 5 to 54 2 Nm ensure proper gear make up Torque the driven gear bearing cap to 100 110 Ib ft 135 149 Nm 132 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 8 Introduction to Equipment Chapter 8 Parts Lists and Drawings This chapter contains exploded view drawings with parts lists for LCSF models 204 1420 including sub assemblies To identify and order parts locate the assembly for your LCSF model Sub assemblies are called out by part number on top level assemblies E H Wachs Part No 60 MAN 07 Rev 0 0311 133 Low Clearance Split Frame Models 204 1420 134 Model 204 4 inch LCSF 60 000 04 PARTNUMBER DESCRIPTION 1 37 005 00 14 BEARING GUIDE WHEEL 2 56 150 00 SIDRAGECASE NOTSHOWN 3 60 028 00 LABEL NO GAPS 4 60 099 00 LABEL NOTSHOWN 5 60 1105 04 4 ROTATING RING ASSEMBLY 6 60 1176 00 WIPER 4 8 LC SF 7 60 1177 00 BRACKET 4 8 LC SF WIPER 8 60 122 00 SCREW CAPTIVATED 5 16 18 9 60 1242 00 10 60 1243 00 11 60 1260 04 12 60 1274 00 13 60 1275 00 14 60 129 00 15 60 130 00 16 60 166 04 17 60 351 04 18 60 363 00 19 60 408 05 20 60 408 07 21 60 408 10 22 60 412 00 23 60 447 02 24 60 560 0 25 60 600 00 26 60 MAN 07 27 80 0080 00 28 90 025 0 29 90 042 03 30 90 049 06 31 90 056 05 32 90 065 0 33 90 065 10 34 90 165 53 35 90 900 0 SHAFT SMALL FIXED
18. 1 5 HP standard pneumatic drive 60 423 00 9 Ib 4 kg E H Wachs Part No 60 MAN 07 Rev 0 0311 21 Low Clearance Split Frame Models 204 1420 Table 2 LCSF Accessory Weights Accessory Part Number Weight 12 HP right angle pneumatic 60 407 00 9 Ib 4 kg rive 2 5 HP pneumatic drive 60 423 01 13 Ib 6 kg n HP reversible pneumatic 60 4010 01 14 Ib 6 kg rive Hydraulic drive 60 424 00 25 Ib 11 kg Installation Procedures vertical workpieces Safety Labels See the detailed instructions in Chapter 5 for installing the LCSF on the workpiece Safe installation procedures are provided for mounting the machine on both horizontal and The following safety labels are provided on the LCSF If any of these labels is damaged or missing replace it imme diately See Chapter 10 for ordering information A CAUTION Loud noise hazard and risk of eye injury Ear and eye protection must be worn Figure 2 15 The ear and eye protection label is attached to the drive motor of the LCSF Always wear ear and eye protection when operating the equipment Part no 90 401 03 22 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 2 Safety Safe Operation of the LCSF 90 PSI ws 2 bar CAUTION Figure 2 16 The air pressure label is attached to the air drive of pneumatic LCSF models Do not operate the equipment with greater than
19. CUTTING OPERATION Set up the LCSE tool slides and drive motor as described the previous sections If you are doing a severing operation make sure the work piece 15 adequately supported boths sides of the cut line If necessary use a catch device for the fall off piece 1 Check that power connections air or hydraulic to the LCSF are securely attached 2 Make sure that tooling is installed correctly and securely 3 on the power air or hydraulic at the source 4 Set the speed control on the drive motor to the lowest setting Engage the drive motor on off lever to start the machine If the machine does not start increase the speed control slightly is IMPORTANT The standard hydraulic hose fittings are female for the pressure side and male for the return side Make sure the fittings and connections are correct Operating the LCSF in the reverse direction can damage the machine AN WARNING Failure to support the work piece and the fall off piece could result in serious injury and or damage to the machine AN WARNING Keep clear of moving parts while operating the LCSF E H Wachs Part No 60 MAN 07 Rev 0 0311 93 Low Clearance Split Frame Models 204 1420 y NOTE If the starwheel does not con tact the trip pin smoothly stop the machine immediately and follow starwheel timing proce dures mv Sl wer Faster Airmotor Hydraulic mot
20. DIM ENSIO NS IN BRAC KETS ARE MILLIMETERS WEIGHT 2 86 1 3kg See 60 402 04 parting slide dra wing 4 69 on previous page for slide travel and 119 diameter radius dimensons 452 114 7 369 93 6 125 31 8 219 55 5 6 56 166 7 e 80 31 20 2 O00 i h koto H i EDT 51 o N 13 press L ___ eI 155 150 39 3 38 1 348 77 4 88 5 5 81 ee 147 6 7 25 I 650 184 2 165 1 With double bevel tool cover With standard tool cover 41 Low Clearance Split Frame Models 204 1420 Extended Parting Slide 60 415 00 The extended parting slide is paired with the extended beveling slide 60 416 00 It is used with all LCSF models
21. Parting slide 60 402 04 Beveling slide 60 403 04 Figure 3 4 The photo shows the low clearance tool slides available for applications with limited clear ance around the workpiece Cutting stroke slide travel is 0 67 17 mm Parting beveling slide 60 416 00 Parting slide r 60 415 00 Figure 3 5 The photo shows the extended tool slides which are standard for LCSF models 204 1420 Cut ting stroke slide travel is 1 67 41 8 mm 32 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 3 Introduction to the Equipment LCSF Components Clamp Pad Extensions Clamp pad extensions lengthen the LCSF clamp legs to allow the LCSF to cover its entire range of pipe diameters The operating instructions in Chapter 5 include a table of clamp pad requirements for each LCSF size for the pipe diameter range it can cut Trip Assembly The trip assembly is composed of a trip housing a trip pin a trip lever and two extension blocks The trip can be engaged or disengaged depending upon feed requirements by engaging or disengaging the trip lever Drive Motor The standard LCSF drive is an air motor Two air motor sizes are available 1 5 HP motor is standard with LCSF models 204 1420 available in conventional or right angle configu ration A2 5 HP motor is optional for LCSF models 204 1420 available in single direction or reversible configura tion Both air motors are interc
22. 3 3 1 CLE 848809 CYLINDER CASTING 1 3 3 2 1 812918 PIN CYLINDER 1 3 4 869927 ROTOR BLADE 5 3 5 C LE 869925 REAR BRG PLT 1 3 6 CLE 865352 ROTOR LOCK NUT 1 3 7 CLE 861914 SUBASSY GEAR TRAIN 75 3 1 3 7 1 CLE 869906 GEAR CASE 50T 1 PART NUMBER DESCRIPTION QTY 3 7 2 CLE 869905 SPIDER CAGE 1 3 7 3 CLE 869908 GEAR SHAFT 3 3 7 4 CLE 869907 NEEDLE ROLLER 39 3 7 5 CLE 869903 2ND RED IDGEAR 3 3 7 6 CLE 869898 OPEN SPIDER 1 3 7 6 1 CLE 869898 X OPEN SPIDER CAST 1 3 7 6 2 CLE 832125 IDLE GEAR PIN 6 3 7 7 CLE 869900 IDLER GEAR 1STRED IDL GR 3 3 7 7 1 CLE 866160 SEMI IDLER GEAR 1 3 7 72 CLE 844774 BEARING NEEDLE B 36 1 3 8 CLE 869923 FRONTBRG PLT 1 3 9 CLE 869929 SPACER MOTOR 3 10 1 861904 SUBASM HEAD V 1 2 SQ 1 3 10 1 CLE 869874 ANGLE HEAD 1 3 10 2 CLE 861903B GEAR SET T 3 10 3 CLE 861903A GEAR SET 1 3 10 4 CLE 869886 1 2 S D SPINDLE 1 3 10 5 1 869882 BEARING 1 3 10 6 CLE 867546 PLUG PIPE 3 10 7 CLE 869881 SPINDLE BEARING 1 3 10 8 CLE 869880 THRUST BRG T 3 10 9 CLE 869877 BEARING RETAIN 1 3 10 10 CLE 847659 BEARING 1 3 11 CLE 869878 CLAMP NUT 1 3 12 CLE 869879 CLAMP RING 2 3 13 CLE 847528 BALL BEARING 2 3 14 CLE 847960 SETSCREW 1 4 66 100 00 VALVE SPEED CONTROL 1 5 90 098 01 NIPPLE 1 2 CLOSE BLACK 2 3 6 C LE 203989 BEARING CAP 1 7 90 403 00 LABEL BURN HAZARD HOTSURFACE 1 8 90 401 02 LABEL PRESSURE AIR 1 9 90 401 03 LABEL EAR AND EYE PROTECTI
23. Recommended Air Motor Lubricants Air Motor Grease Standard duty NLGI Grade 2 grease such as Chevron Black Pearl CPS 24591 High temperature Amsoil Synthetic GVC or equivalent Air Motor Oil Wachs air motor oil Pint p n 02 407 00 Gallon p n 02 402 00 108 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 7 Service and Repair Chapter 7 Service and Repair In This Chapter ADJUSTING THE BEARINGS TooL SLIDE ADJUSTMENT AIR MOTOR MAINTENANCE AIR MOTOR MAINTENANCE TROUBLESHOOTING Trouble Possible Cause Remedy Detent pins not removed Remove pins Machine won t run Power supply not on Check power supply Improper bearing preload Refer to maintenance for adjustment Improper speed or gear box setting Turn throttle on the motor Machine runs slowly s p s i not correct Needs 80 100 p s i Trip pin not engaged Engage trip pin Tool slide does not feed Trip pin assembly in wrong position Add or remove spacers Stripped feed screw or nut Replace part or add dovetail Improper tool slide adjustment Readjust tool slide Tool penetration causes tool to bind Worn feed screw feed nut Replace feed screw feed nut Tool bit is dull Replace bit Machine moves during cut Loose clamp pads Tighten clamp pads Speed control too fast Reduce speed Machine chatters during cut Tool bit is dull Replace bit Improper ring adjustment Readjust ring Tool bit is dull Replace bit Poor cutting quality
24. which designates the generation of design The following numbers indicate the capacity 204 will mount on 2 through 4 pipe 206 will mount on 2 through 6 pipe 1016 will mount on 10 through 16 pipe 28 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 3 Introduction to the Equipment LCSF Components With me on 1 Red Line Stor Whee On Plate Ow IMPORTANT Figure 3 1 The I D tag mounted on the stationary ring next to the pinion housing identifies the LCSF model and includes the machine s serial number Table 1 LCSF Models Pipe Size Range Model Part Number Inches DN 204 3 60 000 04 2 4 50 100 206 3 60 000 06 27 6 50 150 408 3 60 000 08 47 8 100 200 610 3 60 000 10 6 10 150 250 612 3 60 000 12 6 12 150 300 814 3 60 000 14 87 14 200 350 1016 3 60 000 16 10 16 250 400 1420 3 60 000 20 14 20 350 500 See clamping leg charts Chapter 5 for measured pipe size capacities LCSF COMPONENTS The complete LCSF configuration includes the following components illustrated in Figure 3 2 E H Wachs Part No 60 MAN 07 Rev 0 0311 29 Low Clearance Split Frame Models 204 1420 Tool slides Air motor Split frame machine 2 Trip assembly lt SS t Tool kit Clamp pad extensions Figure 3 2 Standard equipment provided with the low clearance split frame St
25. 03 TABLE MODEL DIM A LCSF204 3 505 206 3 11050 1250 icsre1y 3 11281 ucsre12 3 11381 LCSF8143 164 LCSF10163 1569 Lcsri420 3 1169 5 00 127 0 1 12 28 5 H DRIVE INPUT mo DRIVE Q O L DIMENSIO NS IN 5 ARE MILLIMETERS WEIGHT 8lb 4kg 45 Low Clearance Split Frame Models 204 1420 1 5 HP Right Angle Air Drive 60 423 00 12 76 ye 3240 Q OF HANDLE SPEED CONTROL OILER R15 75 60 TYP 2 84 72 1 H D ne 1 65 U HLI 41 9 R23 75 REF 603 3 DIMENSIONS IN BRACKETS ARE MILLIMETERS SPEED CONTROL AND OILER CAN BE RELOCATED FOR SPACE CONSTRAINTS 2 5 HP Right Angle Air Drive 60 423 01 3 20 81 2 16 36 12 7 415 6 Q OF HANDLE a OILER SPEED R19 25 CONTROL 489 0 Bas 2 88 i Z 4 00 731 169 D 2 101 6 42 9 a
26. 204 1420 Use reasonable force to 5 arate the halves If you can t pull them apart check to make sure you have ade quately loosened the 6 capti vated screws For machines 12 inches and larger two people will be required to perform the set up 4 Pull the two halves of the machine apart at the split lines Use an equal amount of force on each side to prevent the halves from binding Figure 5 17 Pull the machine apart at the split lines Use equal force on each side to separate the halves without binding With the halves split place the upper half with the pinion housing on top of the workpiece Make sure you are attaching the stationary frame to a section of the pipe that will support its weight Do not clamp the machine onto a pipe section or end that will fall off after cutting 68 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 5 Operating Instructions Setting Up the LCSF lt igure 5 18 On horizontal pipe set the side of the machine with the pinion housing on top of the pipe the top half Align the dowel pin holes with the dowel 6 Lift the bottom half of the machine into place under y NOTE pins to ensure proper fit and press the halves together To install the machine on ver tical pipe you will need two people to support both halves or a stable support beneath the machine Figure 5 19 Fit the halves to
27. 4 ROTATION i 423 L 1 838 10 7 N 46 7 d H TE 500 12 7 6 688 169 9 bw INCREASE amp DECREASE FLOW KNOB m 7 956 202 1 8 48 Chapter 4 Assembly Disassembly and Storage Chapter 4 Assembly Disassembly and Storage MACHINE DISASSEMBLY FOR STORAGE These instructions assume the LCSF machine has been dis connected from the power source and removed from the workpiece as described in Chapter 5 1 Remove the drive assembly pneumatic or hydraulic from the LCSF 2 the tool slides It is not necessary to remove the standard tool slides to store the machine 3 Clean the machine of debris such as metal chips and excess coolant 4 Split the machine halves and examine the bearing raceway for metal chips In This Chapter MACHINE DISASSEMBLY FOR STORAGE STORAGE SHIPPING CASES STORAGE GUIDELINES E H Wachs Part No 60 MAN 07 Rev 0 0311 49 Low Clearance Split Frame Models 204 1420 Figure 4 1 Check the bearing raceway for chips and clean it if necessary 5 Applytwo drops of Wachs way oil 60 1184 00 to the felt wiper before storing the machine STORAGE SHIPPING CASES LCSF models 204 through 1420 are stored and shipped in custom cases made of heavy duty molded plastic The case contains a form
28. 8 88 225 4 7 05 179 0 8 26 209 8 60 408 10 5 49 139 5 6 74 1712 57 14 5 60 408 20 3 51 89 1 4 75 120 6 NONE 9 51 241 6 11 00 279 4 LCSF610 3 15 75 400 1 11 00 279 4 8 36 212 3 9 57 243 1 60 408 10 7 39 187 8 8 86 225 0 68 17 3 60 408 20 5 40 137 2 6 86 174 4 NONE 11 51 292 3 13 00 330 2 60 408 10 9 39 238 5 10 86 275 8 LCSF612 3 17 751450 9 13 00 330 2 9 36 237 7 10 57 268 5 68 17 3 26851 60 408 20 7 39 187 8 8 86 225 0 60 408 30 5 39 136 9 6 86 174 4 NONE 12 76 324 0 14 25 362 0 60 408 05 11 64 295 6 13 11 332 9 LCSF814 3 19 00 482 6 14 25 362 0 9 98 253 6 11 20 284 4 68 17 3 284 4 60 408 15 9 64 244 8 111112821 60 408 25 7 64 194 1 91112314 EXTENSION LEGS SHOWN ARE STANDARD WITH MACHINE REFER TO MANUAL FOR OPTIONAL EXTENSION LEG SETSAND CLAMPING RANGES DIMENSIONS IN BRACKETS ARE MILLIMETERS OUTER DIAMETER 2 59 65 9 B INNER DIAMETER 303 77 0 370 TRIP LOCATION 94 0 TRIP LOCATION i DRIVE gt INPUT 1 DRIVE G 1 F MAX FULLY RETRACTED TRIP LOCATION 35 TRIP LOCATION 337 85 7 m CLAMPING DIAMETER Chapter 3 Introduction to the Equipment Operating Envelopes LCSF Models 1016 and 1420 TABLE DIM A DIM B DIM C EXTENSION DIM E MIN DIM E MAX MODEL OUTER DIAMETER INNER DI
29. Annex 1 of the Conformity is Declared Machinery Directive We hereby certify that the machinery described above conforms to the provisions of Council Directive 2006 42 EC on the approximation of the laws of the Member States relating to the safety of 12 Signatory 2 Mullally Quality Manager E H Wachs E H WACHS Superior Equipment Complete Support 600 Knightsbridge Parkway Lincolnshire IL 60069 847 537 8800 www ehwachs com
30. Assembly Disassembly and Storage 49 Machine Disassembly for Storage 49 SIOFaee SINppiIBe Cases ct sues uf ned at ca a t 50 Storage G ideli esS us arse ky are Ste Lacie gabe wees 52 Chapter 5 Operating Instructions 53 Planning the Operation 1 acusa st juste Dor 53 Tool Selegati 55 Parting Only Operation siea 93 let Q ars 56 Parting O D Beveling Operation 56 O D Beveling Only Operation 58 Sinple Pornt Bevelmg eoo stunts 59 Operating Buvelopes uu z us es ee esr dep oe bus a ene do 59 Low Clearance Slides 60 402 04 60 403 04 60 Extended Standard Slides 60 415 00 60 416 00 60 ii Part No 60 MAN 07 Rev 0 0311 E H Wachs Table Contents Lif ng and Rigsine the LESE Qu a aw ee E GE ad 61 Models with Lift EyeBOlS cise RS ette qx p OUI y es 61 Setting Up Md i eR e ne 64 Clamp Leg eee a eid eg oi
31. Enclosed with the manual is a warranty card Please fill out the registration card and return to E H Wachs 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 600 Knightsbridge Parkway Lincolnshire Illinois 60069 USA 168 Part No 60 MAN 07 Rev 0 0311 E H Wachs EU DECLARATION OF CONFORMITY WITH COUNCIL DIRECTIVE 2006 42 EC Issue Details Date Place 1 1 2011 E H Wachs Lincolnshire IL USA Machinery Safety Directive 2006 42 EC Conforming Machinery Split Frame Machines Low Clearance Split Frame LCSF Small Diameter Split Frame SDSF Model Number 60 000 XX 60 AIR XX 60 HYD XX 80 0000 AX 80 0000 RA 80 4000 XX Serial Number Manufacturer E H Wachs 600 Knightsbridge Parkway Lincolnshire IL 60069 USA Responsible Representative Orbitalum Tools GmbH Josef Sch ttler Str 17 78224 Singen Germany Tel 49 0 7731 792 872 Fax 49 0 7731 792 566 Harmonised Standards amp EN ISO 12100 1 2003 A1 2009 Other Technical EN ISO 12100 2 2003 A1 2009 Standards Specifications EN 60204 1 2006 for electric machines Applied or Referenced EN ISO 13857 2008 EN 982 1996 A1 2008 E for hydraulic machines EN 983 1996 for pneumatic machines EN 13732 1 2006 EN ISO 14121 1 2007 EN ISO 13850 2008 for pneumatic machines Provisions with which Essential Health and Safety Requirements of
32. NUMBER 90 078 67 WOODRUFF KEY SUPPLIED WITH MOTOR E H WACHS PART MUMBER 90 059 48 ITEM PARTNUMBER DESCRIPTION 1 02 199 00 1 MOTOR COUPLING DRIVE PIN 2 02 203 00 1 ADAPTOR DRVEMOTOR 3 53 073 00 1 HYDRAULIC MOTOR 4 60 1186 00 1 LCSF FLOW DIRECTION LABEL 5 60 198 00 1 VALVE MRV DIRECTIONAL CONTROL 6 60 199 00 al MANIFOLD SDB HYDRAULIC 7 60 213 00 1 HYD MOTORMOUNT 8 76 072 00 T PLATE MRV ANTI ROTATION 9 76 073 00 1 CAP MRV OPERATOR 10 76 074 00 1 SPRING TORSION 11 76 075 00 1 PLATE SPRING COVER 12 76 175 00 1 RETAINING RING 43 64 13 76 176 00 1 VALVE PRESSURE RELIEF 14 76 177 00 1 VALVE PRESSURE COMPENSATED FLOW CONTROL 15 76 180 00 1 RING 26MM EXTRETAINING 16 76 181 00 1 DETENTSPRING 17 76 182 00 1 SPACER 18 76 183 00 1 HANDLE 5 16 18 19 76 185 00 1 FLOW CONTROL LABEL 20 90 026 56 1 PIN 1 8 x 5 8 ROLL 21 90 026 58 2 PIN 1 8 X 7 8 ROLL 22 90 026 61 2 PIN 1 8 X 1 125 ROLL 23 90 054 02 1 555 1 4 20 1 4 24 90 055 18 1 NUT 1 4 20 ACORN 25 90 059 48 0 1 4 1 WOODDRUFF KEY 26 90 060 12 2 5 5 5 16 18 X 1 1 4 27 90 061 34 4 HHCS 5 16 18 X 3 1 2 28 90 065 52 4 WASHER 5 16 29 90 078 67 0 O RING 112 30 90 088 84 2 PLUG 04 ZERO LEAK ORB 31 90 088 86 8 PLUG 06 ZERO LEAK ORB 32 90 090 15 2 SHCS 1 2 13 X 1 1 2 33 90 098 79 1 ADAPTER 1 2 NPTM X 1 2 ORBM STRAIGHT 34 90 098 89 1
33. SF WIPER BRACKET 12 60 1274 00 2 13 60 1275 00 1 PIN LOCATION 14 60 1279 20 1 WEIG HT LC SF 1420 15 60 129 00 2 FRAME LOCKING 16 60 130 00 30 PLUG BEARING CAP 17 60 207 00 2 SCREW CAPTIVE FRAME 18 60 363 00 1 MOVING PARTS 19 60 408 10 1 _ 1 0 EXTENSION LEG SET NOTSHOWN 20 60 408 20 1 _ 2 0 EXTENSION LEG SET NOTSHOWN 21 60 408 30 1 _ 3 0 EXTENSION LEG SET NOTSHOWN 22 60 412 00 1 HOUSING ASSEMBLY LC SF 4 20 23 60 447 03 4 CLAMP PAD ASSEMBLY 10 20 24 60 560 01 1 LCSF 4 20 FASTENERS NOTSHOWN 25 60 600 00 1 TOOLS 4 20 LCSF HAND NOTSHOWN 26 60 MAN 07 1 MANUAL SPLITFRAME NOTSHOWN 27 80 0080 00 1 NAMEPLATE 28 90 022 03 4 5 48 32 x 375 29 90 049 06 4 SCREW 2 3 16 U DRIVE 30 90 056 05 4 PIN 1 4 X 1 2 DOWEL 90 065 01 30 NUT 5 16 18 HEX 32 90 065 10 30 5 16 18 HEAVY JAM 33 90 099 92 2 1 34 90 165 53 30 WASHER 5 16 SECURING 35 90 900 00 1 LABEL READ MANUAL 1 50 DIA WIPERS ITEM NO 7 REQUIRE WAY OIL PARTNO 60 1184 00 SOLD SEPARATELY OPERATING WEIG HT 92 2 LB 41 9 kg 141 Low Clearance Split Frame Models 204 1420 Stationary Ring Assembly Models 204 through 814 ITEM PARTNUMBER DESCRIPTION TABLE 1 4303800 2 BUSHING OUTER RING 2 6012200 4 SCREW CAPTIVATED 5 16 18 2 LCSF M
34. The outer bearing race should be firmly seated and the rotor bumped forward when checking this clearance 4 Pack both rotor bearings with a good grade of No 2 Moly grease after assembly of the motor unit Air Motor Vanes Before installing new rotor vanes you may need to grind them to ensure precise sizing according to the following chart Air Motor js Rotor Blade Part No Description Part No Min Length Max Length 60 329 00 2 1 2 HP 899927 2 745 2 748 60 211 00 1 1 2 HP 869569 2 244 2 247 IMPORTANT During 5 sembly of the complete tool it is important that the motor be free After the tool is com pletely assembled the right angle square drive spindle should turn freely using a small hand wrench If the spindle does not turn freely the motor should be checked for proper spacing Do not run the tool until the spindle turns freely Failure to do this could result in damage to motor components E H Wachs Part No 60 MAN 07 Rev 0 0311 131 Low Clearance Split Frame Models 204 1420 Note When assembling the angle head to the complete tool the clamp nut left hand threads must be torqued to 100 110 Ib ft 135 149 Nm Right Angle Head When installing needle bearings press only on the bearing s stamped end The pinion needle bearing should be slipped on the pinion gear and pressed into the housing to the fol lowing depth e 3 3 16 81 mm
35. With the clamping screws snug you should be able to nudge the LCSF on the pipe If necessary SLIGHTLY loosen the clamp pads at the 6 and 12 o clock position or the 3 and 9 o clock positions You can tap on the LCSF with the provided rubber hammer to nudge it E H Wachs Part No 60 MAN 07 Rev 0 0311 73 Low Clearance Split Frame Models 204 1420 When the LCSF 15 square to the pipe check the dis tance from the slide mounting location on the machine to the cut line It should be 2 1 4 57 mm If neces sary nudge the machine to adjust the position When the LCSF 15 square and at the correct location tighten the clamping screws Start at the clamp leg nearest the 12 o clock position Using a scale measure the distance from the surface of the pipe to the inner surface of the LCSF at that location Write the measurement down Figure 5 24 Measure the gap at the clamp leg near est the 12 o clock position Move to the clamp leg 180 opposite the one in the previous step and measure the distance between the pipe surface and the inner surface of the LCSF Write this measurement down Add the two measurements together Divide the result by 2 This number is the distance the LCSF should be from the pipe at both clamp pad locations EXAMPLE The distance at the first location is 1 7 inches The distance at the second location is 2 1 inches Add 1 7 to 2 1 then divide by 2 The result is 1 9 inch
36. a 1 46 37 2 CLAMP PAD EXTENSION CHART LCSF 612 1420 12 20 LCSF 612 LCSF 814 LCSF 1016 LCSF 1420 CLAMPING RANGE INCH MM INCH MM INCH MM INCH MM WITH NO 13 00 330 2 14 25 362 0 16 25 412 8 20 25 514 4 EXTENSION MIN 11 51 2923 12 76 324 0 14 76 374 8 18 75 476 42 60 408 05 MAX 11 86 301 2 18 11 332 9 15 10 383 6 19 10 4852 1 2 EXT SET MIN 10 39 263 9 11 64 295 6 13 64 346 3 17 63 447 9 60 408 07 MAX 11 36 288 5 12 61 3202 14 60 371 0 18 60 472 5 3 4 EXT SET MIN 9 89 251 2 11 14 282 9 13 14 3336 17 13 435 2 60 408 10 10 86 275 8 12 11 307 5 14 11 358 3 18 10 459 8 1 EXT SET MIN 9 39 238 5 10 64 270 2 12 64 321 0 16 63 422 5 60 408 15 9 86 2504 11 11 282 1 13 11 332 9 17 10 434 4 1 1 2 EXT SET MIN 8 39 213 1 9 64 244 8 11 64 295 6 15 63 397 1 60 408 20 8 86 225 0 10 11 256 8 12 11 307 5 16 10 409 0 2 EXT SET MIN 7 39 187 8 8 64 219 4 10 64 270 2 14 64 371 7 60 408 25 7 86 199 7 9 11 231 4 11 11 282 1 15 10 383 6 2 1 2 EXT SET MIN 6 40 1625 7 64 194 1 9 64 244 8 13 64 346 3 60 408 28 7 36 187 0 8 61 218 7 10 61 269 4 14 60 371 0 2 8 EXT SET 5 90 1498 714 181 4 944 2322 13 14 3
37. be lifted by two people or a lif ng device See the machine weight tables in the following section It is the responsibility of the end user to determine whether a machine or assembly can be lifted by two or more people A lifting device is recommended for machines or assemblies that cannot be handled easily by two people LCSF models 610 and larger are equipped with eye bolts in the stationary ring for lifting Do not rig or lift the LCSF while power is attached Whenever possible remove all accessories slides trips drive assembly etc while lifting and handling the machine Lift the LCSF only at approved lift points as illustrated in the following figure E H Wachs Part No 60 MAN 07 Rev 0 0311 Low Clearance Split Frame Models 204 1420 Install lift eyes in adjacent holes and lift with chains You can wrap a lifting strap around the ring to lift the assembled machine Do not put the strap around or against an accessory component Figure 2 13 When lifting the assembled LCSF use the lift eyes provided You can also lift the machine using a lift strap around the ring 16 machine model 1016 shown Install lift eyes and lift with chains Make sure alignment pin is installed inserted through stationary ring on opposite side Figure 2 14 To lift a split machine always use two lift eyes Make sure the alignment pins are installed 20 Part No 60 MAN 07 Rev 0 03
38. depth 15 reached stop the machine VERY sharp DO NOT touch them with bare hands Serious injury could result 7 Use the depth gauge on the support block monitor to CAUTION Figure 5 71 Depth gauge on the support block 8 Measure the I D of the pipe If the desired I D has been attained remove the counterbore assembly If the I D measurement required has not been achieved repeat steps 3 9 OPERATING LCSF ACCESSORIES The following LCSF accessories are provided with their own user s manuals for setup and operation Bridge Slide Accessory for Low Clearance Split Frame manual part no 60 MAN 03 Small LCSF O D Tracking Slide for LCSF models 610 to 1420 manual part no 60 MAN 06 External Internal Casing Cutter EICC manual part no 60 MAN 05 E H Wachs Part No 60 MAN 07 Rev 0 0311 105 Low Clearance Split Frame Models 204 1420 106 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 6 Routine Maintenance Chapter 6 Routine Maintenance DAILY MAINTENANCE After each use clean debris from all moving parts includ ing the rotating ring and slide components This will pro long the life of the machine and prevent contamination of the storage shipping case 1 Use a brush or compressed air to remove loose debris from all sliding and rotating surfaces 2 Neutralize any corrosive fluids that the machine may have come into contact with during operation by wip in
39. maintenance instructions before using the machine Part no 90 900 00 E H Wachs Part No 60 MAN 07 Rev 0 0311 25 Low Clearance Split Frame Models 204 1420 26 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 3 Introduction to Equipment Chapter 3 Introduction to the Equipment OVERVIEW OF THE LCSF The E H Wachs Low Clearance Split Frame Machine LCSF 15 portable pipe cutting and beveling system developed for on site operation The LCSF uses lathe type machining principles with capabilities for cutting sever process beveling form tool or single point and counter boring Set up and operation is quick and simple and the machine requires little maintenance other than lubrication Split frame prepping is a safe cleanoperation that neither affects the metallurgical qualities of the metal nor places airborne contaminants in the environment The LCSF assembly consists of two halves that can be dis assembled for installation on the pipe The stationary frame contains the clamping feet which secure the machine to the pipe and the pinion housing which contains the drive gear that turns the rotating frame The stationary frame is made from lightweight aluminum material The rotating frame is of steel construction with hardened bearing raceways and has locations for mounting the tool slides and machining accessories In This Chapter OVERVIEW OF THE LCSF LCSF COMPONENTS OPERATING ENV
40. on the vise jaws and use soft faced mallet to drive the rotor out of the rear rotor bearing Handle 1 Unscrew the inlet bushing forinspection of the throttle components Wash the air inlet screen in a solvent and blow it out in the reverse direction of normal airflow Replace if damaged or clogged Reassembly The tool is reassembled in the reverse order of disassembly 130 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 7 Service and Repair Air Motor Maintenance 1 Cleanall parts thoroughly in solvent and inspect for damage or wear 2 Check all bearings for wear which can be detected by excessive end play and or roughness that would indi cate a brinelled condition 3 The rotor blades should be replaced if they measure less than 3 8 9 5 mm at either end 4 All gear teeth bearings and pins should receive a close inspection and be replaced if necessary All gears and open bearings should receive a generous amount of No 2 Moly grease during reassembly r Install the rear rotor bearing into the rear bearing plate Make sure the outer bearing race 15 firmly seated in the bearing plate I 2 Clamp the rotor body lightly in the vise with the threaded end up and slip the rear bearing plate assem bly onto the rotor shaft far enough for the bearing lock nut to start 3 Tighten the lock nut until there is approximately 0015 clearance between the rotor and bearing plate
41. potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death This is the equipment damage alert symbol It is used to alert you to poten tial equipment damage situations Obey all messages that follow this 5 bol to avoid damaging the equipment or workpiece on which it is operating N Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 1 About This Manual Manual Updates and Revision Tracking NOTE This symbol indicates a user note Notes a provide additional information to supple 5 SAs 5 ment the instructions tips for easter y p operation ating tips MANUAL UPDATES AND REVISION TRACKING Occasionally we will update manuals with improved opera Current versions of E H tion or maintenance procedures or with corrections if nec Wachs manuals are also essary When a manual is revised we will update the available in PDF format You can request an electronic copy of this manual by email ing customer service at sales ehwachs com revision history on the title page 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 TECHNICAL FILE RESPONSIBLE PARTY The low clearance split frame is manufactured by E H Wachs at the following address E H Wachs 600 Knig
42. the cutting direction as shown 2 Snugall4 tool cover screws then tighten them 3 Tighten the 2 tool set screws To install a beveling tool loosen the 2 tool set screws in the tool cover plate and the set screw in the side of the tool holder E H Wachs Part No 60 MAN 07 Rev 0 0311 79 Low Clearance Split Frame Models 204 1420 i Figure 5 31 Insert the bevel tool in the holder with Figure 5 30 There are three set screws for beveling tools Insert the beveling tool with the cutting edge in the direction of rotation as shown in Figure 5 31 Se the cutting edge in the direction of rotation Snug the set screw on the side of the tool holder then tighten the 2 set screws on the tool cover Tighten the side set screw Turn the rotating ring by hand to check the tooling clearances Make sure the tools do not touch the pipe and that there is enough slide travel for the tooling to reach the I D Refer to the slide envelope drawings in Chapter 3 80 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 5 Operating Instructions Install Tool Slides and Tooling 8 Set the tooling Bring the parting tool 1 8 inch away from the pipe and the bevel tool 1 8 inch away from the pipe Check tool extension and slide travel again as in the previous step F igure 5 32 The tip of the parting tool should be about 1 8 3 mm from the pipe surface 2 Figure 5 33 The tip of the be
43. the maximum wall thickness that can be form tool beveled with a 10 x 37 5 form tool is 1 1 4 inch e it machines a larger surface area thus requiring a slower r p m and maximun horsepower See the tooling tables in Chapter 9 for available beveling tools Figure 5 5 Standard form Tools 10 x 37 5 pound Angle top and 37 5 Single Angle bottom E H Wachs Part No 60 MAN 07 Rev 0 0311 57 Low Clearance Split Frame Models 204 1420 PARTING TOOL OFFSET 078 WITH 43 711 XX HSS 062 WITH 43 705 00 CARBIDE MAX WALL Figure 5 6 The drawing illustrates the parting bevel ing operation O D Beveling Only Operation If you are only beveling a pipe end that has already been cut off use a beveling tool in the parting beveling slide Leave the parting tool slide empty 58 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 5 Operating Instructions Planning Operation Land if required Beveling tool Figure 5 7 The drawing illustrates the O D bevel operation Single Point Beveling Single point beveling is performed on thick walled pipes where the cutting surface is too wide for a form tool to work effectively Only the tip of the tool cuts the tool feed 15 in two dimensions to follow the profile of the desired bevel Single point beveling with the LCSF is performed using the bridge slide accessory with a standard single point tool holder and
44. treatment for injection injury E H Wachs Part No 60 MAN 07 Rev 0 0311 Low Clearance Split Frame Models 204 1420 Gloves should be worn when cleaning up chips and other cutting debris Chips can be very sharp and can cause serious cuts Do not wear gloves when the machine is operating This icon is displayed with any safety alert that indicates a personal injury hazard N WARNING This safety alert with the personal injury hazard symbol 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 Protective Equipment Requirements Protective Clothing Wear safety shoes when operating or servicing the equip ment Serious injury could result from dropping the machine or its components Do not wear gloves while operating the machine Gloves can become entangled in moving parts resulting in serious injury Gloves may be worn when setting up the machine or cleaning up after the operation but take them off when operating the machine Eye Protection Always wear impact resistant eye protection while operat ing or working near this equipment For additional information on eye and face protection refer to Federal OSHA regulations 29 Code of Federal Regula tions Sec
45. turn with the machine The marks you made earlier will help you see if the 122 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 7 Service and Repair Tool Slide Adjustment are turning Repeat the adjustment proce dure if any bearings are not turning Figure 7 21 Use the marks on the bearing to see if the bearings are turning as you rotate the machine TooL SLIDE ADJUSTMENT To check the tension on the tool slide attempt to turn the starwheel at the front of the slide It should be very difficult to turn with your bare hand butyou should be able to turn it by hand with a rag or some form of cushion The slide tension 15 adjusted usng four 4 set screws on the dovetail on one side of the slide The dovetail clamps the male tool slide and the screws adjust how tightly the dove tail holds the male slide Use the following procedure to completely reset the slide tension 1 Loosen the four 4 1 4 20 jam nuts and set screws on the side of the slide The star wheel should require approximately 15 17 in Ibs of torque to turn E H Wachs Part No 60 MAN 07 Rev 0 0311 123 Low Clearance Split Frame Models 204 1420 Figure 7 22 Loosen the jam nuts top then loosen the set screws bottom 2 Remove the four 4 1 4 20 x 7 8 socket head cap screws from the adjustable dovetail 3 Remove the four 4 1 4 20 cap screws from the star wheel
46. 0 1 DOVETAIL ADJ USTABLE H D 5 60 191 00 1 DOVETAIL FIXED H D 6 60 193 00 1 SUDE MALE FORM TOOL H D 7 60 194 00 1 COVER TOOL SLIDE H D e 8 60319500 1 SCREW FEED U e 12 9 60 196 00 2 ALIGNMENT g AU 10 60 214 00 1 COVER H D DBL BEVEL e 55 11 60229 00 1 FEED H D STAR FEED D AL 12 90 050 05 2 SHCS 1 4 20 X 1 2 13 90 050 08 8 5 5 1 4 20 7 8 14 90 054 08 4 555 1 420 7 8 y 15 90 055 04 4 NUT 1 4 20 16 90 056 12 2 1 4 X 1 1 4 DOWEL 17 90 059 05 2 HSHCS 1 420X 1 2 18 90 060 12 5 SHCS 5 16 18 X 1 1 4 19 90 060 17 4 SHCS 5 16 18 X 1 3 4 20 90 065 09 8 5 16 PUSH 21 90 060 08 8 SHCS 5 16 18 X 7 8 o px 152 Chapter 8 Introduction to the Equipment Universal Counterbore Slide 60 405 UC ITEM PARTNUMBER DESCRIPTION 1 60 134 04 BAR BORING C BO RE 2 60 140 10 KEY BORING BAR 3 60 145 00 INSERT KEYLOC KING 4 60 146 00 LABEL C BO RE DEPTH 6 60 146 01 LABEL RADIAL FEED 7 60 147 01 SC REW FEED 8 60 148 00 BLOCK SUPPORTLC 1 12 9 60 149 00 PLATE THRUSTLC 1 12 10 60 150 00 11 60 151 00 12 60 152 02 13 60 157 00 14 60 236 10 15 90 036 52 16 90 046 51 17 90 050 30 18 90 060 06 19 90 060 12 20 90 065 09 21 90 065 53 22 90 074 06 23 90 075 00 24 60 135 00 BUSHING LC 1 12 WASHER SPRING KNOB FEED B
47. 03203 NUT METERING 3 1 19 CLE 201638 SUBASSY LO CKOFF LEVER 3 1 19 1 CLE 204178 LEVER LOCKOFF 3 1 19 2 CLE 202105 TOGGLE 3 1 19 3 CLE 845409 PIN SPRING 3 1 19 4 CLE 869855 SPRING TOGGLE 32 CLE 201311 SUBASSY G EAR TRAIN 3 2 1 CLE 201308 GEAR SPIDER 3 2 1 1 CLE 203105 2ND RED GEAR SPIDER 3242 CLE 204809 2ND GEAR PIN 3 16 DOWEL 3 3 2 1 3 CLE 203107 IDLER G EAR 2ND RED 3 3 2 1 3 1 CLE 203062 BUSHING 2 3 2 1 3 2 CLE 846659 GEAR 20T IDLER GEAR 3 2 2 CLE 861485 SPIDER OPEN ITEM NO PART NUMBER DESCRIPTION QTY 3 2 2 1 CLE 832125 IDLE GEAR PIN 3 3 2 2 2 CLE 867532 GEAR SPIDER 1 3 2 3 CLE 867526 GEAR IDLER 3 3 231 CLE 844774 BEARING NEEDLE B 36 1 3 2 4 CLE 867544 GEAR CASE 501 1 3 3 CLE 203101 CYLINDER 1 3 3 1 CLE 863887 PIN SLOTTED SPRING 1 3 4 CLE 203102 ROTOR 1 3 5 CLE 843444 BEARING BALL 1 3 6 CLE 861496 HEAD ANGLE T 4 1 3 6 1 CLE 867507 ANGLE HEAD LONG HEAVY DUTY 1 3 6 2 CLE 842517 BALL BEARING 1 3 6 3 CLE 867511 PINION 1 3 6 4 CLE 867512 GEAR 1 3 6 5 CLE 867546 PLUG PIPE 1 3 6 6 CLE 867547 BALL BEARING 1 3 6 7 CLE 867548 BEARING 1 3 6 8 CLE 882661 NEEDLE BEARING 1 3 6 9 CLE 207288 SPINDLE 1 2 SQ DRIVE 1 3 7 CLE 865352 ROTOR LOCK NUT 1 3 8 CLE 867520 PLATE MAKE UP 1 3 9 CLE 867521 LOCK NUT 1 3 10 CLE 867522 SNAP RING 2 3 11 CLE 867528 MOTOR MAKE UP PLATE 1 3 12 CLE 867536 PLATE FRONT BEARING 1 3 13 CLE 869569 ROTOR BLADE 5 3 14 CLE 869572 PLATE REAR BEARING 1 3 15 CLE 203989 BEARIN
48. 09 PIN SPRING 1 1 1 17 4 CLE 869855 SPRING TOGGLE 1 1 1 18 1 832079 SPRING 1 1 1 19 CLE 203203 NUT METERING 1 12 CLE 201311 SUBASSY GEAR TRAIN 1 1 2 1 CLE 201308 GEAR SPIDER 1 1211 CLE 203105 2ND RED GEAR SPIDER 1 12 12 CLE 204809 2ND GEAR PIN 3 16 DOWEL 3 1 2 1 3 CLE 203107 IDLER GEAR 2ND RED 3 1 2 1 3 1 CLE 203062 BUSHING 2 1 2 1 3 2 CLE 846659 GEAR 20T IDLER GEAR 1 1 2 2 CLE 861485 SPIDER OPEN 1 1 2 2 1 1 832125 IDLE GEAR PIN 1 2 2 2 CLE 867532 GEAR SPIDER 1 2 3 CLE 867526 GEAR IDLER 3 1 2 3 1 1 844774 BEARING NEEDLE B 36 1 1 2 4 CLE 867544 GEAR CASE 507 1 13 CLE 203101 CYLINDER 1 1 3 1 1 863887 PIN SLOTIED SPRING 1 1 4 CLE 203102 ROTOR 1 1 5 CLE 843444 BEARING BALL 1 1 6 1 861496 HEAD ANGLE 4 1 1 6 1 CLE 867507 ANGLE HEAD LONG HEAVY DUTY 1 1 6 2 1 842517 BALL BEARING 1 1 6 3 CLE 867511 PINION 1 1 6 4 1 867512 GEAR 1 1 6 5 CLE 867546 PLUG PIPE 1 1 6 6 1 867547 BALL BEARING 1 1 6 7 CLE 867548 BEARING 1 16 8 CLE 882661 NEEDLE BEARING 1 1 6 9 CLE 207288 SPINDLE 1 2 SQ DRIVE 1 17 CLE 865352 ROTOR LOCK NUT 1 18 CLE 867520 PLATE MAKE UP 1 19 CLE 867521 LOCK NUT 1 1 10 CLE 867522 SNAP RING 2 111 CLE 867528 MOTOR MAKE UP PLATE 1 1 12 CLE 867536 PLATE FRONT BEARING 1 1 13 CLE 869569 ROTOR BLADE 5 1 14 CLE 869572 PLATE REAR BEARING 1 1 15 CLE 203989 BEARING 1 1 16 CLE 619377 BEARING 1 1 17 1 382633 SPLINE 1 2 60 210 00 FLANGE 1 5 HP C
49. 1 NUT 1 4 20JAM 15 9005612 2 1 4 1 1 4 DOWEL 16 90 05905 2 LHSHCS 1 4 20x1 2 17 90 059 22 10 NSERT 1 4 20 x 1 1 2D 38 LG HELICAL 18 90 060 2 4 SHCS 5 16 18X 1 1 4 19 90 065 09 2 5 16 PUSH 20 9007607 2 PIN 3 8X3 4DOWEL 90 060 08 3 5 5 5 16 18 X 7 8 149 Low Clearance Split Frame Models 204 1420 Low Clearance Beveling Slide 60 403 04 ITEM PARTNUMBER QTY DESCRIPTION 1 6011004 1 SUPPORT TOOLSUDE4 68 60 111 04 1 WEAR 4 6 8 3 6011204 1 DOVETAIL ADJ USTABLE 4 6 8 4 6011304 1 DOVETAIL FIXED 4 6 8 5 6011500 1 SUDE MALEFORM TOOL 6 60 116 00 1 NUT FEED STARWHEEL 7 6011700 1 COVER TOOL SUDE 8 6011804 1 SCREW FEED STARWHEEL 9 6011900 1 PLATE ASSEMBLY FEED SCREW 10 60 18400 1 COVER DBL BEVEL Z 11 9005005 2 5 5 1 4 20 1 2 umm 12 9005008 4 SHCS 1 4 20 X7 8 13 9005405 1 SSS 1 4 20X 1 2 AN NN 14 9005408 1 555 1 420 7 8 7S8 gt 15 90 055 04 2 1 4 20 557755 16 9005612 2 1 4 1 1 4 DOWEL S CO 17 9005905 2 1 HCS 1 4 20 1 2 N 222 INSERT 174 20 x 10 25 LG VOR 18 9005919 i 2516 SN INSERT 1 4 20 x 1 1 2D 38 LG 19 9005923 9 1204 20 9006008 4 5 5 5 1618 7 8 21
50. 1 0 16 55 Planned 1 0 16 85 H Counterbore 0 15 Pipe thickness 1 25 Figure 5 59 The width of the counterbore is 1 2 of the difference between the existing I D and planned I D E H Wachs Part No 60 MAN 07 Rev 0 0311 97 Low Clearance Split Frame Models 204 1420 Planned I D dimension 16 85 Existing I D dimension 16 55 Difference 0 30 Divide by 2 0 15 Per side Thus the existing diameter needs to be counterbored to increase the existing I D by 0 30 or 0 15 per side 2 Determine the thickness that can be removed with each pass As a rule of thumb you can cut about 0 060 on most pipe materials without causing excess machine vibration damag ing the tooling or stalling the machine Depending on the material you are cutting you may need to decrease this thickness On some materials you may be able to cut a thicker pass but in general you should not exceed more than about half the width of the tool taper 3 Determine the depth for the first counterbore pass Because the counterbore tool is tapered you must start out making longer passes than the desired counterbore depth Each pass is shorter than the previous one until the final pass completes the I D of the required straight bore to the desired depth Three passes Figure 5 60 In this example three passes with the counterbore tool are required to achieve the desired straight counterbore depth
51. 11 119 Low Clearance Split Frame Models 204 1420 AN CAUTION Use a crane or other lifting device to lift the LCSF There is a risk of injury from lifting the machine or from setting or dropping it on hands or feet Figure 7 16 Assemble the ring halves and tighten the captivated screws Position the machine with the rotating ring face down on the workbench and check for free play between the rotating and stationary rings The stationary ring should wobble on the rotating ring Disassemble the machine and repeat Step 2 if play is not felt Figure 7 17 Check for play between the rotating and stationary rings Insert alignment pins 60 098 00 in opposite posi tions to secure the rotating and stationary rings Make sure pins penetrate both rings The fit between the pins and rings could be snug 120 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 7 Service and Repair Adjusting the Bearings Figure 7 18 Insert alignment pins to keep rotating ring from turning 7 Identify the bearing at position 1 Figure 7 19 Using a 3 16 hex wrench turn the eccentric shaft clockwise until the guide wheel bearing feels fully seated in the groove e POSITION 3 PINS J V NC gt P e POSITION 4 N d POSITION 1 Figure 7 19 Adjust the bearings in order at the posi tions shown 8 Holding the shaft securely with
52. 11 E H Wachs Chapter 2 Safety Safe Operation the 8 Machine Weights Table 1 lists the weights for each LCSF model Weights are included for the entire machine as well as each separable assembly Table 2 lists the weights for slides drives and other assemblies To determine lifting weight add weights of installed components to the machine assembly Table 1 LCSF Machine and Assembly Weights Model Full Machine Split Ring Weight Split Ring Weight FAC Weight Pinion Side Non Pinion Side T 212 14 Ib 6 kg 10 Ib 4 kg Mi HE x k 17 Ib 8 kg 13 Ib 6 kg Tee T i i 20 Ib 9 kg 16 Ib 7 kg s 26 Ib 12 kg 22 Ib 10 kg 29 Ib 13 kg 25 11 SEU a 32 Ib 15 kg 28 Ib 13 kg m Wi 40 Ib 18 kg 36 Ib 16 kg 5 48 Ib 22 kg 44 lb 20 kg With standard pinion housing installed no slides or drive installed Add 5 4 Ib 2 5 kg for front drive pinion Rounded to nearest lb kg Sum may not add exactly to Full Machine Weight Table 2 LCSF Accessory Weights Accessory Part Number Weight Low clearance parting slide 60 402 04 3 Ib 1 4 kg Low clearance beveling slide 60 403 04 3 Ib 1 4 kg Extended parting slide 60 415 00 8 Ib 4 kg Extended beveling slide 60 416 00 8 Ib 4 kg Trip assembly 60 401 00 1 4 Ib 0 6 kg Front drive pinion for 204 1420 60 425 03 8 Ib 4 kg
53. 13 0 Cu EI 31 2 7 9 See 60 415 00 parting slide drawi e 00 parting slide dra wing 060 o on previous page for slide travel and HL 125 dia dius dimensions 3 18 2 50 63 5 gt 223 56 6 17 L 4 3 r 150 38 1 83 21 1 125 DIMENSIONSIN BRACKETS ARE MILLIMETERS 31 8 PIPE DIAMETER DIM A SHOWN WITHOUT CLEARANCE WEIGHT 7 5lb 3 4 kg 3 54 4 90 0 43 Low Clearance Split Frame Models 204 1420 44 3 86 98 0 3 56 90 5 Univeral Counterbore Slide 60 405 UC The universal counterbore slide 15 used with all LCSF models 7 61 193 3 f 1 I T e 60 416 00 9 O C gt 60 438 00 loo zo1 09 D 0 0 up 60 000 04 2 19 55 THRU s 55 5 60 000 48 1 7 69 195 4 1 PARTING LINE 7 di RP 1 13 MAX DEPTH 28 7 Chapter 3 Introduction to the Equipment Operating Envelopes Front Drive Pinion Assembly 60 425
54. 33 6 60 408 30 6 86 174 4 8 11 206 0 10 11 256 8 14 11 358 3 3 EXT SET MIN 5 39 136 9 6 64 168 8 8 64 219 5 12 64 321 0 60 408 31 6 60 167 8 7 85 199 4 9 85 2502 13 85 351 7 3 1 8 EXT SET MIN 5 14 1306 6 38 1622 838 212 9 1238 314 4 60 408 35 5 87 149 0 7 11 180 7 9 11 231 4 13 11 332 9 3 1 2 EXT SET MIN 4 40 111 9 5 65 143 4 7 64 1944 11 64 295 6 60 408 40 487 123 7 6 12 155 4 8 11 206 0 12 11 307 5 4 EXT SET MIN 3 41 86 7 465 1182 6 65 168 8 10 64 2702 Set Up for In line Pipe To mount the LCSF on in line pipe you will have to split the machine into halves by removing the frame locking screws at the split points 66 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 5 Operating Instructions Setting Up the LCSF Make sure the two frame locking pins are installed to keep the rotating and stationary rings together Figure 5 15 Insert the frame locking pins through the machine 2 Lay machine on a secure surface 3 Using a 1 4 hex wrench loosen the 6 captivated screws four in the stationary frame and two in the rotating frame Figure 5 16 Loosen the captivated screws to separate the halves E H Wachs Part No 60 MAN 07 Rev 0 0311 67 Low Clearance Split Frame Models
55. 35 60 127 35 60 408 35 60 127 40 See clamp leg charts Chapter 5 for pipe size configurations 60 127 40 60 408 40 147 Low Clearance Split Frame Models 204 1420 Trip Assembly 60 401 00 ITEM PARTNUMBER QTY DESCRIPTION 1 6030700 1 BLOCK HOUSING TRIP PIN 2 6033800 1 3 60104800 1 4 60 1049 00 1 LEVER 5 60 1050 00 1 QUICKPIN 6 9002655 1 18 X 1 2 PIN 7 9005504 1 NUT 1 4 20 AM 8 9005908 1 SPRING PLUNGER 9006007 3 SHCS 5 1618X 3 4 SHCS 5 16 18 X 1 3 4 10 9006037 3 NOT SONA WEIGHT 1 Ib 5kg 148 Chapter 8 Introduction to the Equipment Low Clearance Parting Slide 60 402 04 ITEM PART NUMBER DESCRIPTION 6011004 1 SUPPORT TOOLSUDE4 68 2 6011104 1 PLATE WEAR 46 8 3 6011204 1 DOVETAIL ADJ USTABLE 4 6 8 4 6011304 1 FIXED 4 6 8 5 6011400 1 ISIDE MALE PARTING 6 6011600 1 FEED STARWHEEL 7 6011700 1 COVER TOOLSUDE 8 6011804 1 SCREW FEED STARWHEEL 9 60119 00 1 PLATE ASSEMBLY FEED SCREW 10 9005005 2 SHCS 1 4 20x1 2 11 9005008 4 SHCS 1 4 20x 7 8 12 9005405 1 SSS 1 4 20 1 2 13 9005408 1 555 1 420 7 8 14 90 05504
56. 42 03 4 5 10 24 X 3 8 30 90 049 06 4__ 5 2 3 16 U DRIVE 31 90 056 05 4 PIN 1 4X 1 2 DOWEL 32 90 065 01 18 5 16 18 HEX 33 90 065 10 18 5 16 18 HEAVY JAM 34 90 165 53 18 WASHER 5 16 SEC URING 35 90 900 00 1 READ MANUAL 1 50 DIA 136 ANS SS SHIPPING WEIGHT 36 8 LB 16 7 kg WIPERS ITEM NO 8 REQUIRE WAY OIL PART NO 60 1184 00 SOLD SEPARATELY Chapter 8 Introduction to the Equipment Model 610 10 inch LCSF 60 000 10 ITEM PART NUMBER o 3 lt DESCRIPTION 1 37 005 00 BEARING GUIDE WHEEL 2 60 028 00 LABEL GAPS 3 60 094 00 INSERT FOAM NOTSHOWN 4 60 096 00 CASE NOTSHOWN 5 60 099 00 LABEL NOTSHOWN 6 60 1105 10 10 ROTATING RING ASSEMBLY 7 60 1178 00 WIPER 10 20 LC SF 8 60 122 00 SCREW CAPTIVATED 5 16 18 9 60 1242 00 10 60 1243 00 11 60 1260 10 12 60 1261 00 13 60 1274 00 14 60 1275 00 15 60 129 00 16 60 130 00 17 60 166 04 18 60 363 00 19 60 408 10 20 60 408 20 21 60 412 00 22 60 447 03 23 60 560 01 24 60 600 00 25 60 MAN 07 26 80 0080 00 27 90 022 03 28 90 025 01 29 90 042 03 30 90 049 06 31 90 056 05 32 90 065 01 33 90 065 10 34 90 099 92 35 90 165 53 36 90 900 00 SHAFT SMALL FIXED BEARING SHAFT SMALL ADJ USTABLE BEARING 10 STATIONARY FRAME ASSEMBLY ASSEMBLY 10 20 LC SF WIPER BRAC KET TAG LCSF LABEL PIN LOCATION PIN FRAME LOCKING PLUG B
57. 5 9 86 250 4 1 2 EXT SET MIN 2 40 60 9 4 50 1143 6 49 1648 839 213 1 60 408 07 3 14 79 7 5 25 133 2 7 2 183 9 9 36 237 7 3 4 EXT SET 1 91 48 6 4 00 101 6 5 99 152 2 7 89 200 5 60 408 10 2 64 67 2 4 75 120 6 6 74 1712 8 86 225 0 1 5 MIN 1 44 36 5 3 51 89 1 5 49 139 5 7 39 187 8 60 408 15 1 67 42 5 3 76 95 4 5 74 145 9 7 86 199 7 1 1 2 EXT SET 0 61 15 4 2 52 64 0 4 50 114 3 6 40 162 5 60 408 20 0 78 19 8 2 77 70 3 4 75 1206 6 86 174 4 2 EXT SET MIN E 1 55 39 4 3 51 89 1 5 40 1372 60 408 25 MAX 1 79 45 5 3 76 95 4 5 87 149 0 2 1 2 EXT SET MIN 0 69 17 4 2 52 64 0 4 40 111 9 60 408 28 MAX 1 32 33 5 3 26 82 8 5 37 136 4 2 8 EXT SET MIN 0 15 3 8 2 03 51 6 3 91 99 3 60 408 30 MAX 0 88 22 3 2 77 70 3 4 87 123 7 3 EXT SET MIN 1 55 39 4 3 41 86 7 E H Wachs Part No 60 MAN 07 Rev 0 0311 65 Low Clearance Split Frame Models 204 1420 CLAMP PAD EXTENSION CHART LCSF 204 610 4 10 LCSF 204 LCSF 206 LCSF 408 LCSF 610 CLAMPING RANGE INCH MM INCH MM INCH MM INCH MM 60 408 31 MAX 0 64 16 3 2 51 63 8 4 61 117 2 3 1 8 EXT SET MIN Een 1 31 33 3 3 16 80 2 60 408 35 1 79 45 5 3 88 98 5 3 1 2 EXT SET 0 65 16 5 2 43 61 7 60 408 40 0 88 22 3 2 89 73 4 4 x
58. 60 SPT XX are made to customer specifications call for quotation E H Wachs Part No 60 MAN 07 Rev 0 0311 163 Low Clearance Split Frame Models 204 1420 HYDRAULIC PowER UNITS The following Wachs hydraulic power units HPUs designed to operate low clearance split frames and similar tools Table 6 Hydraulic Power Units for LCSF Power Unit Part No HCM 1G gas powered 8 gpm 1500 psi 30 I min ES 103 bar 14 000 01 2 2 electric powered 8 1500 psi 30 l min 103 bar 14000 06 HCM 2E4 electric powered 8 1500 psi PUES 80 l min 103 bar 14100007 HCM 2G gas powered 10 1500 psi PU 38 l min 103 bar 1000 08 HCM 3D diesel powered 10 1500 psi 38 l min 103 bar 000 09 HCM 3G gas powered 14 1500 psi 53 l min 103 bar HCM 4D diesel powered 14 gom 1500 psi Aani 53 l min 103 bar 54 900 28 HPU 15 electric powered 0 15 1500 psi 0 57 l min 103 bar 5 90920 HSM 5D diesel powered skid mount 14 14 000 31 1500 psi 53 l min 103 bar HTM 5D diesel powered trailer mount 14 gpm 2 14 000 32 1500 psi 53 l min 103 bar Tandem Pump Offshore diesel powered 15 gpm 14 000 12 2000 psi 57 l min 140 bar RECOMMENDED SPARES Spare parts and fastener kits are available for the LCSF Select the kit s appropriate for your LCSF model Separat
59. 90 psi 6 2 bar air pressure Part no 90 401 02 N CAUTION 2000 PSI 138 bar Figure 2 17 The hydraulic pressure label is attached to the LCSF hydraulic drive Do not operate the equipment with greater than 2000 psi 138 bar hydraulic pressure Part no 90 402 01 Figure 2 18 The hot surface label is attached to the LCSF drive motor pneumatic or hydraulic Drive components may become hot enough to cause burns Make sure they are not hot before touching them Part no 90 403 00 E H Wachs Part No 60 MAN 07 Rev 0 0311 23 Low Clearance Split Frame Models 204 1420 Y Keep Hands Clear When Equipment Is Running L Figure 2 19 The Keep Hands Clear label is attached to the stationary ring of the LCSF Stay clear of moving parts when the LCSF is operating Part no 60 363 00 24 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 2 Safety Safe Operation of the LCSF Figure 2 20 The alignment pin tag is attached to the ring on the alignment pin Make sure to insert the pins before splitting the machine Part 60 1274 00 Figure 2 21 The alignment pin location label is attached to indicate the alignment pin holes Two labels are on the LCSF one for each pin location Part no 60 1275 00 Figure 2 22 The Read Manual label is attached to the stationary ring of the LCSF Make sure you under stand all operating and
60. 9006012 5 58 5 5 16 18 1 4 22 9006017 2 555 23 9006509 4 5 16 PUSH 24 9007607 2 3 8X3 4DOWEL 150 Chapter 8 Introduction to the Equipment Extended Parting Slide 60 415 00 ITEM PARTNUMBER QTY DESCRIPTION 1 60 119 00 1 PLATE ASSEMBLY FEED SC REW 2 60 188 01 1 ISUPPORT TOOL SLIDE 3 60 189 00 1 WEAR H D 4 60 190 00 1 DOVETAIL ADJ USTABLE H D 5 60 191 00 1 DOVETAIL FIXED H D 6 60 192 00 1 SLDE MALE PARTING H D 7 60 194 00 1 COVER TOOL SLIDE H D 8 60 195 00 1 SCREW FEED H D 9 60 196 00 2 ALIGNMENT 0 60 229 00 1 FEED H D STAR FEED 1 90 050 05 2 SHCS 1 4 20 X 1 2 2 90 050 08 8 SHCS 1 4 20X 7 8 3 90 054 08 4 555 1 4 20 7 8 4 90 055 04 4 JNUT 1 4 20 5 90 056 12 2 1 4 1 1 4 DOWEL 6 90 059 05 2 LHSHCS 1 4 20 X 1 2 7 90 060 12 4 5 5 5 1618 X 1 1 4 8 90 065 09 4 NUT 5 16 PUSH 9 90 060 08 6 SHCS 5 16 18 X 7 8 151 Low Clearance Split Frame Models 204 1420 Extended Beveling Slide 60 416 00 ITEM PARTNUMBER QTY DESCRIPTION 1 60 119 00 1 PLATE ASSEMBLY FEED SCREW 2 60 188 01 1 SUPPORT TOOL SLIDE 3 60 189 00 1 PLATE WEAR H D 4 60 190 0
61. ADAPTER 1 2 ORBM 1 2 NPTM 90 35 90 401 01 1 LABEL EYE PROTECTION 36 90 402 01 Al LABEL PRESSURE HYD 37 90 403 02 1 LABEL HAZARD HOTSURFACE Chapter 9 Accessories and Spare Parts Chapter 9 Accessories and Spare Parts ACCESSORIES The following equipment accessories expand the operating capabilities of the low clearance split frame Table 1 Tool Slide Assemblies I D counterboring Accessory Description Part No Parting slide 60 402 04 Standard Low Clear ance Tool Slides One Beveling slide 60 403 04 setting onl i i i i g only Slide kit parting slide bev 60 421 04 eling slide trip Parting slide 60 415 00 Beveling slide 60 416 00 Extended Tool Slides TI Slide parting slide bev eling slide trip extension 60 422 01 blocks O D Tracking Slides Parting slide 60 451 01 spring loaded slides to track the surface of out Beveling slide 60 451 02 of round pipe for 610 through 1420 models Trip 60 451 03 Counterbore slide MOUNIS tO Devel Side Tof 60 405 In This Chapter ACCESSORIES TOOLING HYDRAULIC POWER UNITS RECOMMENDED SPARES E H Wachs Part No 60 MAN 07 Rev 0 0311 Low Clearance Split Frame Models 204 1420 Table 1 Tool Slide Assemblies Accessory Description Part No Single point beveling and counterboring applications with LCSF models 612 through 1420
62. AMETER DRIVE 4 DIM D LEG SET CLAMPING DIA CLAMPING DIA NONE 14 76 374 8 16 25 412 8 60 408 10 12 64 321 0 14 11 358 3 LCSF1016 3 21 50 546 1 16 25 412 8 11 23 285 3 12 45 316 1 12 Ios 60 408 25 9 64 244 8 11 11 282 1 NONE 18 75 476 4 20 25 514 4 60 408 10 16 63 422 5 18 10 459 8 LCSF1420 3 25 50 647 7 20 25 514 4 13 23 336 1 14 45 366 9 S a 16101409 60 408 30 12 64 321 0 14 11 358 3 EXTENSION LEGS SHOWN ARE STANDARD WITH MACHINE REFER TO MANUAL FOR OPTIONAL EXTENSION LEG SETS AND CLAMPING RANGES DIMENSIONS IN BRACKETS ARE MILLIMETERS OUTER DIAMEIER igi 303 INNER DIAMETER 77 0 DRIVE INPUT L 259 TRIP LOCATION 370 TRIP LOCATION 65 9 94 0 ETT L I T D DRIVE Q Y 43 MAX 10 9 FULLY RETRAC TED TRIP LOCATION 30 TYP TRIP LOCATION 5 362 92 0 e CLAMPING DIAMETER 39 Low Clearance Split Frame Models 204 1420 Low Clearance Parting Slide 60 402 04 The low clearance parting slide is paired with the low clearance beveling slide 60 403 04 It is used with LCSF models 204 1420
63. BEARING SHAFT SMALL ADJ USTABLE BEARING ASSEMBLY 4 STATIONARY FRAME TAG LCSF LABEL PIN LOCATION PIN FRAME LOCKING PLUG BEARING CAP GUARD CHIP LC 4 12 INSERTFOAM NOTSHOWN LABEL MOVING PARTS 1 2 EXTENSION LEG SET NOTSHOWN 3 4 EXTENSION LEG SET NOTSHO WN 1 0 EXTENSIO N LEG SET NOT SHOWN PINION HOUSING ASSEM BLY LCSF 4 20 CLAMP PAD ASSEMBLY 4 8 KIT LC SF 4 20 FASTENERS SHOWN TOOLS 4 20 LC SF HAND NOTSHO WN MANUAL 4 20 LC SF NOTSHOWN NAME PLATE WASHER 8 FLAT BHCS 10 24 3 8 SC REW 2 3 16 U DRIVE PIN 1 4 X 1 2 DOWEL NUT 5 16 18 HEX NUT 5 16 18 HEAVY J AM WASHER 5 16 SEC URING LABEL READ MANUAL 75 DIA iN N Ns s s m WIPERS ITEM NO 6 REQUIRE WAY OIL PART NO 60 1184 00 SOLD SEPARATELY OPERATING WEIGHT 23 LB 10 5 kg Chapter 8 Introduction to the Equipment Model 206 6 inch LCSF 60 000 06 ITEM PARTNUMBER QTY DESCRIPTION 1 37 005 00 14 BEARING GUIDE WHEEL 2 56 150 00 1 CASESIORAGE NOTSHOWN 3 60 028 00 2 NO GAPS 4 60 099 00 1 LABEL NOTSHOWN 5 60 1105 06 1 6 ROTATING RING ASSEMBLY 6 60 1178 00 2
64. Bridge slide 60 428 20 Table 2 Drive Motors and Components Description Part No 1 5 HP right angle air drive 60 423 00 right angle air drive with ported exhaust col 60 407 00 Heavy duty 2 5 HP right angle air motor 60 423 01 Hydraulic drive 60 424 00 Front drive pinion housing for 4 20 LCSF 60 425 03 Air treatment module for all air motors 26 407 00 160 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 9 Accessories and Spare Parts Tooling TOOLING Table 3 LCSF Parting Tools Part No Description Length 43 711 00 3 16 wide HSS 3 76 ui T un i 43 704 00 3 16 wide carbide insert holder 43 705 00 3 16 wide carbide insert 43 701 00 1 4 wide carbide insert holder 43 702 00 1 4 wide carbide insert 60 SPT 11 3 16 wide special order 5 stock 60 SPT 12 1 4 wide special order 5 stock 60 SPT 13 1 2 wide special order HSS High Speed Steel 60 SPT XX are made to customer specifications call for quotation Table 4 LCSF Single Angle Beveling Tools Part No Description Length 43 703 05 37 5 inside bevel 3 1 8 43 708 05 37 52 outside bevel 3 1 8 E H Wachs Part No 60 MAN 07 Rev 0 0311 161 Low Clearance Split Frame Models 204 1420 Table 4 LCSF Single Angle Beveling Tools
65. CSF model you are using See operating envelope information and drawings in Chapter 3 Make sure the operating environment allows you to mount the machine securely and squarely on the work piece Make sure there is adequate clearance around the LCSF and workpiece to operate the machine controls as described in the operating instructions Chapter 5 Mount the LCSF with the pinion housing positioned for convenient mounting and operation of the drive motor E H Wachs Part No 60 MAN 07 Rev 0 0311 9 Low Clearance Split Frame Models 204 1420 Use the LCSF only on empty depressurized pipe Misuse Do not attempt to mount or operate the LCSF on non cylindrical workpieces Do not attempt to mount or operate the LCSF on any workpiece to which it cannot be securely mounted Do not attempt to mount or operate the LCSF on any workpiece that is not stable enough to hold the LCSF Do not mount the LCSF on the fall off side of the cut line unless you adequately rig and support the LCSF and workpiece Do not disable any safety feature of the LCSF or remove any safety labeling Replace worn or damaged safety labels immediately See Safety Labels later in this chapter 10 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 2 Safety Safe Operation of the LCSF Potential Hazards The following figures illustrate potential hazards of operat ing the low clearance split frame Refer to the desc
66. Chapter 10 Ordering Information 167 Ordering Replacement Parts Ls t Re exu IDE AURI e 167 Repair Information uo ee repe SL Der GR EPIS db t Ee haud deas 167 Warranty Information 168 Return Goods Address 168 iv Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 1 About This Manual Chapter 1 About This Manual PURPOSE OF THIS MANUAL This manual explains how to operate and maintain the Low Clearance Split Frame LCSF It Includes instructions for set up operation and maintenance It also contains parts lists diagrams and service information to help you order replacement parts and perform user serviceable repairs LCSF models are available in a wide range of sizes This manual covers models from 4 inch capacity model 204 through 20 inch capacity model 1420 Carefully read Chapter 2 Safety and follow all guidelines for safe operation of the LCSF How TO 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 your equipment Each page is designed with two columns This large column on the inside of the page contains instructions and illustra tions Use these instructions to operate and maintain the equipment The narrower column on the outside contains a
67. Clearance Split Frame Models 204 1420 Figure 5 28 Tighten the SHCS on each side of the tool slide 3 Using a 3 16 hex wrench turn the starwheels on both slides clockwise to fully retract the slides Low Clearance Slides The low clearance slides have fixed mounting pins and only one mounting position The parting slide number is 60 402 04 and the beveling slide number is 60 403 04 1 Mount the tool slides to the rotating frame by inserting the pins in the mounting holes at each slide position Tighten the four 5 16 18 SHCS in each slide with the supplied hex key set 2 Using a 3 16 hex wrench turn the starwheels on both slides clockwise to fully retract the slides Install the Tooling For a straight cut off operation install a parting tool in both the parting and beveling slide It is important that you use two parting tools The tools are offset to prevent binding and stalling of the machine 78 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 5 Operating Instructions Install Tool Slides and Tooling For a parting and bevel operation install a parting tool and beveling tool See the information in Tool Selection ear lier in this chapter 1 To install parting tools loosen the 2 tool set screws and the 4 tool cover screws Insert the tool as shown in Figure 5 29 Tool set screws vA Cutting edge Figure 5 29 Installing the parting tool with the cut ting edge in
68. Counterbore slide Front drive pinion External internal casing cutter Extension legs Dial Indicator E H Wachs Part No 60 MAN 07 Rev 0 0311 35 Low Clearance Split Frame Models 204 1420 2 operating envelope is the space required around the workpiece to install and operate the machine Noise Levels The noise levels in Table 4 were measured at 1 meter high and 1 6 meters away from the machine equipped with the air motor drive Hydraulic and electric drives have lower noise levels Table 4 LCSF Noise Levels Continuous A weighted sound pressure 62 dBA level at workstation Peak C weighted maximum sound 95 dBA pressure Sound power level emitted by machine 89 dBA OPERATING ENVELOPES The drawings on the following pages illustrate the operating envelope for LCSF models 204 1420 and for all slides and accessories Use the drawings in this section to plan the operation for your workpiece See Planning the Operation at the begin ning of Chapter 5 36 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 3 Introduction to the Equipment Operating Envelopes LSCF Models 204 and 206 TABLE DIM A DIM B DIM C EXTENSION DIM E MIN DIM E MAX MODEL OUTER DIAMETER INNER DIAMETER DRI
69. D SEPARATELY OPERATING WEIGHT 30 6 LB 13 9 kg 135 Low Clearance Split Frame Models 204 1420 Model 408 8 inch LCSF 60 000 08 ITEM PARTNUMBER QTY DESCRIPTION 1 37 005 00 18 GUIDE WHEEL 2 56 150 00 1 CASE STORAGE NOTSHOWN 2 60 028 00 2 LABEL NO GAPS 4 60 099 00 1 5 5 60 1105 08 1 8 ROTATING RING ASSEMBLY 6 60 1178 00 2 10 20 LC SF 7 60 122 00 2 SCREW CAPTIVATED 5 16 18 8 60 1242 00 2 SHAFT SMALL FIXED BEARING 9 60 1243 00 16 SHAFT SMALL ADJ USTABLE BEARING 0 60 1260 08 1 8 FRAME ASSEMBLY 1 60 1261 00 2 ASSEMBLY 10 20 LC SF WIPER BRACKET 2 60 1274 00 2 TAG LCSF 3 60 1275 00 1 PIN LOCATON 4 60 129 00 2 PIN FRAME LOCKING 5 60 130 00 18 PLUG BEARING 6 60 166 04 4 _ GUARD CHIP LC4 12 7 60 351 08 INSERT FOAM 5 8 60 363 00 LABEL MOVING PARTS 9 60 408 10 1 0 EXTENSION LEG SET NOTSHOWN 20 60 408 20 2 0 EXTENSION LEG SET NOTSHOWN 21 60 412 00 PINION HOUSING ASSEMBLY LC SF 4 20 22 60 447 02 4 PAD ASSEMBLY 4 8 23 60 560 01 KIT LC SF 4 20 FASTENERS NOT SHO WN 24 60 600 00 TOOLS 4 20 LCSF HAND NOTSHOWN 25 60 MAN 07 MANUAL SPLITFRAME NOTSHOWN 26 80 0080 00 NAMEPLATE 27 90 022 03 4 5 8 32 x 375 28 90 025 01 4 WASHER 8 29 90 0
70. E 5 1 1 13 CLE 202481 PIN VALVE 1 1 11 C LE 861904 SUBASM RA HEAD V 1 2 SQ 1 1 1 14 CLE 864195 PIN LEVER 1 1 11 1 CLE 869874 ANGLE HEAD 1 1 1 15 CLE 865063 LEVER THRO TILE 1 1 11 2 CLE 861903B GEAR SET 1 1 1 16 CLE 869942 REVERSE RING 1 1 11 3 C LE 861903A GEAR SET 1 1 1 17 CLE 847234 O RING 1 1 11 4 C LE 869886 1 2 S D SPINDLE 1 1 1 18 CLE 867554 SCREW REVERSING VALVE 1 1 11 5 CLE 869882 BEARING 1 1 1 19 CLE 869939 SPACER 1 1 11 6 CLE 867546 PLUG PIPE 1 1 1 20 CLE 869940 VALVE REVERSING 1 1 11 7 CLE 869881 SPINDLE BEARING 1 1 1 21 CLE 617510 O RING 1 111 8 C LE 869880 THRUST BRG 1 1 1 22 CLE 622881 O RING 1 1 11 9 CLE 869877 BEARING RETAIN 1 1 2 CLE 203148 CYLINDER 1 1 11 10 CLE 847659 BEARING 1 1 2 1 CLE 848810 CYLINDER CASTING 1 1 12 CLE 869879 CLAMP RING 2 1 2 2 CLE 812918 PIN CYLINDER 1 1 13 CLE 869878 CLAMP NUT 1 1 3 CLE 203147 ROTOR 1 1 14 CLE 847528 BALL BEARING 2 1 4 CLE 861913 SUBASM GEAR TRAIN 1 2 05 082 00 OILER LINE 1 1 4 1 C LE 869906 GEAR CASE 50 1 3 60 328 00 FLANGE CLECO MOTOR 1 1 4 2 CLE 869904 2ND RED SPIDER 1 4 66 100 00 VALVE SPEED CONTROL 1 1 4 3 CLE 869902 IDLER GEAR 2ND RED IDLGR 3 5 90 098 01 NIPPLE 1 2 CLOSE LP BLACK 2 6 90 403 00 LABEL BURN HAZARD HOTSURFACE 1 157 Low Clearance Split Frame Models 204 1420 158 NOTE Hydraulic Drive 60 424 01 1 112 BUNA N O RING COMES WITH HYDRAULIC MOTOR FOR 2 REPLAC EMENTS CONTACTE H WACHS PART
71. EARING CAP GUARD CHIP LC 4 12 LABEL MOVING PARTS 1 0 EXTENSION LEG SET NOTSHOWN 2 0 EXTENSION LEG SET NOTSHOWN PINION HOUSING ASSEMBLY LCSF 4 20 CLAMP PAD ASSEMBLY 10 20 KIT LC SF 4 20 FASTENERS NOTSHO WN TOOLS 4 20 LC SF HAND NOTSHOWN MANUAL SPLITFRAME NOTSHOWN NAME PLATE BHC S 48 32 x 375 WASHER 8 FLAT BHCS 10 24 X 3 8 SCREW 3 2 3 16 U DRIVE PIN 1 4 X 1 2 DOWEL NUT 5 16 18 HEX NUT 5 16 18 HEAVY JAM EYE BOLT WASHER 5 16 SEC URING LABEL READ MANUAL 1 50 DIA B s siss el s s 5SN s b WIPERS ITEM NO 9 REQUIRE WAY O IL PARTNO 60 1184 00 SOLD SEPARATELY OPERATING WEIG HT 48 6 LB 22 1 kg 137 Low Clearance Split Frame Models 204 1420 Model 612 12 inch LCSF 60 000 12 ITEM PART NUMBER DESCRIPTION 1 37 005 00 BEARING GUIDE WHEEL 2 60 028 00 LABEL NO GAPS 60 094 00 INSERT FOAM NOTSHOWN 4 60 096 00 CASE NOTSHOWN 5 60 099 00 LABEL 5 WN 6 60 1105 12 12 ROTATING RING ASSEMBLY 7 60 1178 00 WIPER 10 20 LC SF 8 60 122 00 SCREW CAPTIVATED 5 16 18 9 60 1242 00 SHAFT SMALL FIXED BEARING 10 60 1243 00 SHAFT SMALL ADJ USTABLE BEARING 11 60 1260 12 12 STATIONARY FRAME ASSEMB
72. ELOPES E H Wachs Part No 60 MAN 07 Rev 0 0311 27 Low Clearance Split Frame Models 204 1420 Features Simple lightweight rugged design for cutting and prep ping in tight places Works on all sizes wall thicknesses and material across the entire range of pipe diameter capacities Self squaring clamping system for easy set up Safe cold cutting for use in any environment Standard air motor drive with options for hydraulic or electric power Adjustable bearings and hardened bearing raceways for maximum dependability and performance Modular accessories for counterboring compound bev eling J prepping heavy wall cutting and internal cut ting Remote operation capability for safe use in hazardous environments Models and Model Designation The low clearance split frame LCSF consists of 15 models for cutting and beveling pipes from 2 51 mm to 48 1219 mm outside diameter O D Models up to 1420 20 capacity are described in this manual Each model covers a range of pipe sizes as described in Table 1 E H Wachs uses a model numbering system that designates the capacity of the machine All model numbers include the following This information is required when ordering parts or tooling Type 60 000 08 Model SF 408 3 Serial 06 1234 Example SF Designates Wachs Low Clearance Split Frame Machine followed by the capacity of the machine and 3
73. G CAP 1 3 16 CLE 619377 BEARING 1 3 17 CLE 382633 PROTECTOR SPLINE 1 4 66 100 00 VALVE SPEED CONTROL 1 5 90 098 01 NIPPLE 1 2 CLOSE LP BLACK 2 6 90 403 00 LABEL BURN HAZARD HOTSURFACE 1 7 90 401 02 LABEL PRESSURE AIR 1 8 90 401 03 LABEL EAR AND EYE PROTECTION 1 WEIGHT 8 6 LB 3 9 kg GEARS CAN BE PURCHASED AS SET PARTNO CLE 861478 Chapter 8 Introduction to the Equipment 1 5 HP Air Drive Ported Exhaust 60 407 00 ITEM PART NUMBER DESCRIPTION QTY 1 60 211 00 CLECO AIR MOTOR 55NL 3T 960 1 11 CLE 201812 SUBASSY HANDLE 111 CLE 202632 PAD MUFFLER 1 1 1 2 CLE 203109 PAD MUFFLER 1 1 1 3 CLE 202481 PIN VALVE 1 1 1 4 CLE 202011 SEAL RING I 1 1 5 CLE 617754 O RING 2 1 1 7 CLE 202055 THROTILE VALVE 1 118 CLE 202508 INLET SPACER 1 1 1 9 CLE 864195 PIN LEVER 1 1 1 10 1 869933 BUSHING INLET 1 1111 CLE 843656 SCREEN 1 1 1 12 1 864973 SPRING VALVE 1 1 1 13 CLE 622062 O RING 1 1 1 14 CLE 869931 SEAT THROTILE VALVE 1 1 1 15 1 622881 O RING I 11 16 CLE 203111 HANDLE REVERSIBLE 1 1 1 17 1 201638 SUBASSY LOC KOFF LEVER 1 11171 CLE 204178 LEVER LOCKOFF 1 1117 2 CLE 202105 TOGGLE 1 1 1 17 3 CLE 8454
74. LECO AIR 1 3 66 100 00 VALVE SPEED CONTROL 1 4 90 098 01 NIPPLE 1 2 CLOSE LP BLACK 2 5 60 215 00 COLLECTOR EXHAUST 1 6 05 082 00 OILER AIR LINE 1 WEIGHT 9 LB 4 1 kg 155 Low Clearance Split Frame Models 204 1420 156 2 5 HP Air Drive 60 423 01 ITEM NO PARTNUMBER DESCRIPTION QTY 1 05 082 00 OILER AIR LINE 1 2 60 328 00 FLANGE H D CLECO MOTOR 1 3 60 329 00 CLECO AIR MOTOR 75 3 959 1 3 1 CLE 201811 SUB ASSY HANDLE 230959 i 3 11 CLE H203150 HANDLE 1 3 1 2 CLE 864195 PIN LEVER 1 3 1 3 1 202481 PIN VALVE 1 3 1 4 CLE 869943 MUFFLER 1 3 1 5 CLE 615018 O RING 4 3 1 6 CLE 202050 SPACER EXHAUST DEFLECTOR 1 3 1 7 202051 DEFLEC TER EXHAUST 1 3 1 8 CLE 869933 BUSHING INLET 1 3 1 9 CLE 622881 O RING 1 3 1 10 CLE 202508 INLETSPACER 1 3 1 11 CLE 843656 SCREEN 1 3 1 12 864973 SPRING VALVE 1 3 1 13 202055 THROTILE VALVE I 3 114 CLE 622062 O RING 1 3 1 15 CLE 869931 SEAT THROTILE VALVE 1 3 1 16 CLE 201638 SUBASSY LOC LEVER I 3 1 16 1 CLE 204178 LEVER LOCKOFF 3 1 16 2 CLE 202105 TOGGLE 1 3 1 16 3 845409 PIN SPRING 1 3 1 16 4 CLE 869855 SPRING TOGGLE 3 2 CLE 203147 ROTOR 1 3 3 1 203149 CYLINDER 1
75. LY 38 90 900 00 22 2 1 1 1 2 2 2 20 1 12 60 1261 00 2 ASSEMBLY 10 20 LC SF WIPER BRACKET 13 60 1274 00 2 14 60 1275 00 1 PIN LOCATION 15 60 1279 12 1 WEIG HT LC SF 612 16 60 129 00 2 PIN FRAME LOCKING 17 60 130 00 22 PLUG BEARING CAP 18 60 166 04 4 GUARD CHIP LC4 12 19 60 363 00 1 MOVING PARTS 20 60 408 10 1 _ 1 0 EXTENSION LEG SET NOTSHOWN 21 60 408 20 1 2 0 EXTENSION LEG SET NOTSHOWN 22 60 408 30 1 3 0 EXTENSION LEG SET NOTSHOWN 23 60 412 00 1 HOUSING ASSEMBLY LC SF 4 20 24 60 447 03 4 CLAMP PAD ASSEMBLY 10 20 25 60 560 01 1 KIT LC SF 4 20 FASTENERS NOTSHOWN 26 60 600 00 1 TOOLS 4 20 LC SF HAND NOTSHOWN 21 60 MAN 07 1 MANUAL SPLITFRAME NOTSHOWN 28 80 0080 00 1 29 90 022 03 4 5 48 32 x 375 30 90 025 01 4 __ WASHER 8 FLAT 31 90 042 03 4 5 10 24 X 3 8 32 90 049 06 4 SCREW 2 3 16 U DRIVE 33 90 056 05 4 _ PIN 1 4 X 1 2 DOWEL 34 90 065 01 22 NUT 5 16 18 HEX 35 90 065 10 22 NUT 5 16 18 HEAVY JAM 36 90 099 92 2 EYEBOLT 37 90 165 53 22 WASHER 5 16 SECURING 1 LABEL READ MANUAL 1 50 DIA 138 WIPERS ITEM NO 7 REQUIRE WAY OIL 60 1184 00 SOLD SEPARATELY OPERATING WEIG HT 54 8 LB 24 9 kg Chapter 8 Introducti
76. NIO N REAR 4 20 LC SF 4 60 343 00 1 GEAR PINION FRONT DRIVE 4 20 LC SF 5 60 344 00 1 GEAR IDLER FRONT DRIVE LC SF 4 20 6 60 345 00 1 BEARING PINION GEAR 7 90 060 07 2 SHCS 5 16 18X 3 4 8 90 060 10 4 SHCS 5 16 18X1 9 90 060 20 4 SHCS 5 16 18 X 2 10 90 069 12 2 INSERT 5 16 18 X 1 5 D 47 LG HELICAL 11 90 076 07 2 PIN 3 8 X 3 4 DOWEL 12 90 076 10 2 PIN 3 8 X 1 0 DOWEL 146 Chapter 8 Introduction to the Equipment Clamp Legs 60 127 XX PART NUMBER DESCRIPTION WHERE USED 90 060 05 EXTENSIONS CLAMP PAD SHCS 5 16 18 X 1 2 90 065 09 NUT 5 16 PUSH WHERE USED ORDERING NUMBERS ITEM NOTE LC SF models 204 through 1420 have 4 clamp legs PART NUMBER 60 027 05 60 027 07 60 027 10 60 027 15 60 027 20 60 027 25 60 027 28 60 027 30 60 027 31 60 027 35 60 027 40 DESCRIPTION EXTENSIONS CLAMP LEG ASSEMBLY NUMBER 60 127 05 INDIVIDUAL CLAMP PADS 60 127 05 SIZE CLAMP PAD SETS QTY 4 60 408 05 60 127 07 60 127 07 60 408 07 60 127 10 60 127 15 60 127 10 60 127 15 60 408 10 60 408 15 60 127 20 60 127 20 60 408 20 60 127 25 60 127 25 60 408 25 60 127 28 60 127 28 60 408 28 60 127 30 60 127 30 60 408 30 60 127 31 60 127 31 60 408 31 60 127
77. NSION LEG SET NOTSHOWN 20 60 408 25 1 2 1 2 EXTENSION LEG SET NOTSHOWN 21 60 412 00 1 HOUSING ASSEMBLY LC SF 4 20 22 60 447 03 4 CLAMP PAD ASSEMBLY 10 20 23 60 560 01 1 KIT LC SF 4 20 FASTENERS WN 24 60 600 00 1 TOOLS 4 20 LC SF HAND NOTSHOWN 25 60 MAN 07 1 MANUAL SPLITFRAME NOTSHOWN 26 80 0080 00 1 NAMEPLATE 27 90 022 03 4 5 8 32 375 28 90 049 06 4 SCREW 2 3 16 U DRIVE 29 90 056 05 4 PIN 1 4 X 1 2 DOWEL 30 90 065 01 30 5 16 18 HEX 31 90 065 10 30 5 16 18 HEAVY JAM 32 90 099 92 2 EYEBOLT 30 1 90 900 00 LABEL READ MANUAL 1 50 DIA WIPERS ITEM NO 7 REQUIRE WAY OIL PARTNO 60 1184 00 SOLD SEPARATELY SHIPPING WEIG HT 76 8 LB 34 9 kg Chapter 8 Introduction to the Equipment Model 1420 20 inch LCSF 60 000 20 ITEM PARTNUMBER QTY DESCRIPTION 1 37 005 00 30 BEARING GUIDE WHEEL 2 60 028 00 2 NO GAPS 3 60 095 00 1 INSERT FOAM NOTSHOWN 4 60 096 00 1 CASE NOTSHOWN 5 60 099 00 1 LABEL NOTSHOWN 6 60 1105 20 1 20 ROTATING RING ASSEMBLY 7 60 1178 00 2 10 20 LC SF 8 60 1242 00 2 SHAFT SMALL FIXED BEARING 9 60 1243 00 28 SHAFT SMALL ADJ USTABLE BEARING 10 60 1260 20 1 20 STATIONARY FRAME ASSEMBLY 11 60 1261 00 2 ASSEMBLY 10 20 LC
78. ODEL RING UPPER RING LOWER SEE TABLE ISIATIONAPYTING 60 000 04 60 100 04 60 101 04 4 SEETABLE 1 SIATIONARY RING 5 9005605 2 PIN 1 4 X 1 2 DOWEL 50 000 06 6019006 0101205 6 90 069 12 14 INSERT 5 16 18 X 1 5 D 47 LG HELICAL 60 000 08 60 100 08 60 101 08 7 9021975 4 INSERT 3 4 10 X 1D 75 LG HELICAL 60 000 10 60 100 10 60 101 10 60 000 12 60 100 12 60 101 12 60 000 14 60 100 14 60 101 14 142 Chapter 8 Introduction to the Equipment Stationary Ring Assembly Models 1016 and 1420 ITEM PARTNUMBER QTY DESCRIPTION TABLE 1 60 207 00 2 SCREW CAPTIVE FRAME STATIONARY STATIONARY 2 60 208 00 2 BUSHING J IG LCSF MODEL RING UPPER RING LOWER 3 SEE TABLE 1 STATONARY RING 60 000 16 60 365 16 60 366 16 4 SEE TABLE 1 STATONARY RING 6000020 6036520 6036620 5 90 069 12 10 INSERT 5 16 18 X 1 5 D 47 LG HELICAL 6 90 076 07 2 3 8 X 3 4 DOWEL 7 90 099 13 2 INSERT 1 2 13 X 1 50 75 LG HELICAL 8 90 219 75 4 INSERT 3 4 10 X 1D 75 LG HELICAL 143 Low Clearance Split Frame Models 204 1420 Wiper Kit Assemblies 60 552 01 and 60 552 02 ITEM PARTNUMBER DESCRIPTION 1 60 1176 00 2 4 8 LCSF 2 60 1177 00 2 BRACKET 4 8 LC SF WIPER Wiper Kit 60 552 01 Used with these LCSF models 60 000 04 60 000 06 60 000 08 ON E
79. ON 1 WEIG HT 13 4 Ib 6 1 kg Chapter 8 Introduction to the Equipment 2 5 HP Reversible Air Drive 60 4010 00 9 Q ic n WAZ i Y lt WEIGHT 14 6 4 kg NO PARTNUMBER DESC RIPTION MEM NO PARTNUMBER DESC RIPTION QTY 1 60 329 01 CLECO AIR MOTOR 75RNL 4V 4 1 1 4 4 C LE 869907 NEEDLE ROLLER 39 1 1 CLE 201330 SUBASSY HANDLE 1 1 4 5 CLE 869908 GEAR SHAFT 3 1 1 1 CLE 203151 HANDLE 1 1 4 6 CLE 869897 1STRED SPIDER 1 1 1 2 CLE 202050 SPACER EXHAUST DEFLEC TOR 1 1 4 6 1 CLE 832125 IDLE GEAR PIN 6 1 1 3 CLE 202051 DEFLEC TER EXHAUST 1 1 4 62 C LE 869897 X OPEN SPIDER CAST 1 1 1 4 CLE 615018 O RING 4 1 4 7 C LE 869899 1ST RED IDLER GEAR A amp B 3 1 1 5 CLE 869943 MUFFLER 1 1 4 7 1 CLE 844774 BEARING NEEDLE B 36 1 1 1 6 CLE 202055 THROTILE VALVE 1 1 4 7 2 C LE 869899 X SEMI IDLER GEAR 1 1 1 7 CLE 202508 INLETSPACER 1 1 5 CLE 865352 ROTOR LOCK NUT 1 1 1 8 CLE 622062 O RING 1 1 6 C LE 869901 1STRED PINION A amp B 1 1 1 9 CLE 843656 SCREEN 1 17 C LE 869923 FRONTBRG PLT 1 1 1 10 CLE 864973 SPRING THRO TLE VALVE 1 1 8 CLE 869928 REAR BRG PLATE 1 1 1 11 CLE 869931 SEAT THRO TILE VALVE 1 1 9 CLE 869929 SPACER MOTOR 1 1 1 12 CLE 869933 BUSHING INLET 1 1 10 CLE 869927 ROTOR BLAD
80. R 8 31 90 042 03 4 5 10 24 X 3 8 32 90 049 06 4 SCREW 2 3 16 U DRIVE 33 90 056 05 4 PIN 1 4 X 1 2 DOWEL 34 90 065 01 22 NUT 5 16 18 HEX 35 90 065 10 22 5 16 18 HEAVY JAM 36 90 099 92 2 37 90 165 53 22 WASHER 5 16 SECURING 38 90 900 00 1 READ MANUAL 1 50 DIA WIPERS ITEM NO 7 REQUIRE WAY OIL PART NO 60 1184 00 SOLD SEPARATELY OPERATING WEIG HT 59 LB 26 8 kg 139 Low Clearance Split Frame Models 204 1420 140 Model 1016 16 inch LCSF 60 000 16 33 90 165 53 WASHER 5 16 SECURING ITEM PART NUMBER DESCRIPTION 1 37 005 00 30 BEARING GUIDE WHEEL 2 60 028 00 2 NO GAPS 3 60 095 00 1 INSERT FOAM NOTSHOWN 4 60 096 00 1 CASE NOTSHOWN 5 60 099 00 1 LABEL NOTSHOWN 6 60 1105 16 1 _ 16 ROTATING RING ASSEMBLY 7 60 1178 00 2 10 20 LC SF 8 60 1242 00 2 SHAFT SMALL FIXED BEARING 9 60 1243 00 28 5 SMALL ADJ USTABLE BEARING 10 60 1260 16 1 16 STATIONARY FRAME ASSEMBLY 11 60 1261 00 2 ASSEMBLY 10 20 LC SF WIPER BRACKET 12 60 1274 00 2 TAG ICSF 13 60 1275 00 1 PIN LOCATON 14 60 129 00 2 PIN FRAME LOCKING 15 60 130 00 30 PLUG BEARING CAP 16 60 207 00 2 SCREW CAPTIVE FRAME 17 60 363 00 1 MOVING PARTS 18 60 408 10 1 _ 1 0 EXTENSION LEG SET NOTSHOWN 19 60 408 15 1 _ 1 1 2 EXTE
81. Rev 0 0311 117 Low Clearance Split Frame Models 204 1420 If you are installing new guide wheel bearings assemble the bearings eccentric shafts and bearing spacers to the stationary ring Tighten the 3 8 16 nylock hex nut enough to allow eccentric shafts to rotate smoothly Required tools 3 16 hex wrench 9 16 socket wrench Alignment pins 60 098 00 Bearing adjustment wrench 60 089 00 1 To prepare existing guide wheel bearings for adjustment procedure loosen the 3 8 16 Nylock hex nut only enough to allow eccentric shafts to rotate smoothly Make a mark on the edge of each bearing with a permanent marker These marks will help you check that the bearings are turning later in this proce dure Figure 7 1 3 Mark the edge of each bearing 2 Rotate all eccentric shafts to position the guide wheel bearings toward the inside of the stationary ring 118 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 7 Service and Repair Adjusting the Bearings Figure 7 14 Rotate the eccentric shafts so that the high point of each bearing faces the inside of the ring 3 Slide the rotating ring into the stationary ring then repeat with the other half of the machine Figure 7 15 Slide rotating ring into stationary ring 4 Assemble the ring halves tightening the captivated screws of the stationary ring first E H Wachs Part No 60 MAN 07 Rev 0 03
82. Tighten set screws while turning the star wheel 12 Move the tool slide to the top and adjust the 1 4 20 set screw until you feel the same amountof tension as in the middle 13 Repeat the process for the bottom of the slide 14 Fully tighten the four 4 1 4 20 x 7 8 socket head cap screws on the adjustable dovetail E H Wachs Part No 60 MAN 07 Rev 0 0311 127 Low Clearance Split Frame Models 204 1420 Figure 7 28 Tighten SHCS on dovetail 15 Tighten the four 4 1 4 20 socket cap screws on the starwheel plate 16 Check the tension on the full range of the slide It should be the same Figure 7 29 Check the tension on the slide by driving it to both ends of the feed screw 17 Ifyou can still turn the starwheel with your bare hand you need to slightly tighten the four 4 set screws once again so that the tension is the same throughout the travel of the tool slide 128 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 7 Service and Repair Air Motor Maintenance 18 Ifa torque wrench is available attach to the feed screw while turning the star wheel Turning the star wheel should require 15 17 in lb of torque Figure 7 30 Adjust the feed screw with the torque wrench AIR MOTOR MAINTENANCE See the exploded view drawings for air motors in the Parts Lists and Drawing section of this manual 1 Clamp the flats of the handle in a vise with the tool in a vertica
83. USHING LC 1 3 WELDMENT C BORE FRAME PIN 5 32 X 1 4 ROLL PIN 3 16 ROLL SHCS 1 420X 3 SHCS 5 16 18 X 5 8 SHCS 5 16 18 X 1 1 4 NUT 5 16 PUSH WASHER 5 16 AN SSS 3 8 16 X 5 8 NUT 3 8 16 AM INDICATOR LC 1 12 WEIGHT 10lb 4 5kg 153 Low Clearance Split Frame Models 204 1420 154 1 5 HP Air Drive 60 423 00 PART NUMBER DESCRIPTION QTY 05 082 00 OILER AIR LINE 1 2 60 210 00 FLANGE 1 5 HP CLECO AIR 1 3 60 211 00 CLECO AIR MOTOR 55NL 3T 960 1 3 1 CLE 201812 SUBASSY HANDLE 1 3 1 1 CLE 202632 PAD MUFFLER 1 3 1 2 CLE 203109 PAD MUFFLER 1 3 1 3 CLE 202481 PIN VALVE 3 1 4 CLE 202011 SEAL RING 1 3 1 5 CLE 617754 O RING 2 3 1 6 CLE 202626 DEFLECTOR EXHAUST 3 1 7 CLE 202055 VALVE 3 18 CLE 202508 INLETSPACER 3 1 9 CLE 864195 PIN LEVER 3 1 10 CLE 869933 BUSHING INLET 3 1 11 CLE 843656 SC REEN 3 1 12 CLE 864973 SPRING VALVE 3 1 13 CLE 622062 O RING 3 1 14 CLE 869931 SEAT THROTILE VALVE 3 1 15 CLE 622881 O RING 3 1 16 CLE 203111 HANDLE REVERSIBLE 3 1 17 CLE 832079 SPRING 3 1 18 CLE 2
84. VE Q DIM D LEG SET CLAMPINGDIA CLAMPING DIA NONE 3 51 89 1 4 75 120 7 60 408 05 2 40 60 9 3 63 92 2 LCSF204 3 9 00 228 6 4 75 120 7 4 99 126 6 6 20 157 4 0408 07 1911488 60 408 10 144 36 5 2 64 67 2 NONE 5 62 142 7 6 88 174 6 60 408 05 4 50 114 3 5 74 145 9 LCSF206 3 11 13 282 6 6 88 174 6 6 05 153 6 7 26 184 4 60 408 10 3 51 89 1 4 75 120 6 60 408 15 2 52 64 0 3 76 95 4 60 408 20 1 55 39 4 2 77 70 3 EXTENSION LEGS SHOWN ARE STANDARD WITH MACHINE REFER TO MANUAL FOR OPTIONAL EXTENSION LEG SETS AND CLAMPING RANGES DIMENSIONS IN BRACKETS ARE MILLIMETERS L 337 85 7 OUTER DIAMEIER 322 81 8 B ra INNER DIAMETER lt 3 03 77 0 LL 370 259 94 0 65 9 N DRIVE 1 INPUT i pi ica DRIVE Q i i TRIP LOCATION TRIP LOCATION 57 MAX re 14 5 FULLY RETRAC TED LL En zu CLAMPING DIAMETER 37 Low Clearance Split Frame Models 204 1420 38 LCSF Models 408 610 612 and 814 TABLE MODEL DIM A DIM C DIM D EXTENSION DIM E MIN DIM E MAX DIM F MAX OUTER DIAMETER INNER DIAMETER DRIVE Q x LEG SET CLAMPING DIA CLAMPING DIA FULLY RETRACTED NONE 736 1933 8 88 225 4 LCSF408 3 131313334
85. WARNING Before disconnecting the air line always turn off air at the source and bleed all residual air pressure at the air motor Disconnecting the air line while under pressure could result in serious injury N WARNING Hydraulic components such as hoses motors and mani folds will get hot during oper ation and may cause burns Use appropriate gloves or wait until the components cool before touching them Service Checklist Disconnect power from the LCSF during service See instructions in the following section Remove accessories such as drive assemblies and tool slides unless they are part of the service procedure Disconnecting Power The following photos show the means of disconnecting power for the LCSF Follow all lock out tag out procedures at your work site PNEUMATIC POWER To disconnect power from the pneumatic LCSF remove the air line from the air motor coupling DE gt Z Fi igure 2 11 Disconnect pneumatic power by remov ing the air line from the pneumatic drive HYDRAULIC POWER To disconnect power from the hydraulic LCSF remove the hydraulic hoses from the fittings on the manifold 18 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 2 Safety Safe Operation of the LCSF Figure 2 12 Disconnect hydraulic power by remov ing the hydraulic hoses from the fittings on the mani fold Safe Lifting and Handling Machines or assemblies over 40 Ib 18 kg must
86. a piece of paper or cardboard at least 6 inches 15 cm over the suspicious area and watch for fluid spraying on the sur face Pneumatic Powered Equipment Air motors may get hot during operation and may cause burns Do not touch the air motor except for operator controls during or after operating the machine Before disconnecting the air line from the equipment always turn off air at the source and bleed all residual air pressure at the air motor Loss or Shut Off of Power Supply If the power source to the equipment is lost disconnect power from the equipment and lock out the power sup ply immediately to prevent accidental restarting of the machine ELECTRIC POWERED EQUIPMENT If the electric drive shuts off because of its built in thermal protection dis connect the motor from the power source immediately For all power sources follow all lock out tag out proce dures required at the worksite when disconnecting or servicing the equipment Safety Alerts in This Manual The following alerts are used throughout this manual to indicate operator safety hazards In all cases these alerts include a notice describing the hazard and the means to avoid or reduce risk Carefully read all safety alerts A N WARNING Injection of hydraulic fluid through the skin is a serious injury that can result in infec tion tissue damage and pos sible loss of limb Seek medical treatment immedi ately First aid is not sufficient
87. afety Features The design of the low clearance split frame incorporates the following features for safe operation Enclosed Bearing and Drive Gear System The LCSF bearings and drive gears are enclosed inside the machine to prevent operator contact with them while the machine 15 running Figure 2 4 The bearings and drive gear are enclosed in the LCSF frame The pinion housing covers the drive gear when installed Stop on Release Power Control All drives for the LCSF pneumatic and hydraulic require the operator to hold the power control on to operate the N WARNING machine When the operator releases the power control the LCSF stops immediately Do not disable or override the stop on release feature Letting the machine run when you are not holding the power control could result in serious injury E H Wachs Part No 60 MAN 07 Rev 0 0311 13 Low Clearance Split Frame Models 204 1420 AS Figure 2 5 Hold the air motor trigger to operate the LCSF left When you release the trigger right the air motor shuts off Figure 2 6 Hold the hydraulic lever to operate the LCSF left When you release the lever right the hydraulic motor shuts off Paddle Style Trip Lever The LCSF trip design allows the operator to engage and dis engage the trip from behind the machine without reaching into the operating space of the rotating ring and slides The paddle trip lever moves the trip pin in
88. and out to control engagement of the trip 14 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 2 Safety Safe Operation of the LCSF Figure 2 7 The paddle style trip lever allows you to engage and disengage the trip from the back of the LCSF without putting your hands the way of mov ing components Remote Operation Option Remotely controlled operation is available as an option for all LCSF drives types Contact E H Wachs customer ser vice to discuss your operating environment and require ments Guidelines for Safe Setup Operation and Service Pre Operation Checklist Every time you use the LCSE perform the following checks to make sure it is in good operating condition Check that all safety components are operating properly Inspect it for damage or wear that could affect operation and safe use of the machine Repair any defective com ponent before using the machine Make sure the machine is clean and properly lubricated Make sure that tooling is sharp and in good condition Poor quality tooling can cause difficult cutting and the possibility of machine malfunction and or injury Check power connections pneumatic hydraulic or electric to make sure they are in good condition E H Wachs Part No 60 MAN 07 Rev 0 0311 Low Clearance Split Frame Models 204 1420 Operating Safety Stop the LCSF drive motion to clear chips or make any machine adjustments Fo
89. andard Equipment Split Frame Machine The LCSF ring consists of one rotating ring and one station ary ring Each ring splits into two pieces When assembled the rotating ring and stationary rings are Integrated and split apart simultaneously for mounting on in line piping appli cations These rings are preassembled and adjusted prior to leaving the factory Figure 3 3 shows the assembled LCSF 30 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 3 Introduction to the Equipment LCSF Components Rotating ring Slide mounting Pinion housing with Stationary ring location motor attachment Clamp legs Slide mounting Split point opened Clamp leg adjust location for illustration ment screw Figure 3 3 The photo shows the components of the LCSF Tool Slides Two sizes of tool slides are available for model 204 1420 LCSFs Extended and Low Clearance slides Extended slides are standard on the models 204 1420 The low clear ance slides are special order slides used when minimal radial clearance is required Check the packing list to see which slides you should have received with your LCSF Other types of slides are available for special applications such as counterboring and out of round pipe See the Accessories section below and the ordering information in Chapter 9 for information on these slides E H Wachs Part No 60 MAN 07 Rev 0 0311 3l Low Clearance Split Frame Models 204 1420
90. ator Position ees ces exe E ROPA ee eei d XR A 16 Service Checklist 44 4 ura et pube AG 4 eT ES Me EY du S UN 18 Disconnectine POWER datae date dut do ALI da oe ated 18 Sate Lifting and Handling oca dm 19 WAC HCW BISA oues vis muta OR Rete dota uadit 2 Installation Procedures ia e ADU ete Statale pita Suse 22 Safety Labels sedeo vous EE a Ales och dua d a adire 22 E H Wachs Part No 60 MAN 07 Rev 0 0311 1 Low Clearance Split Frame Models 204 1420 Chapter 3 Introduction to the Equipment 27 Overview the T Lua e es ats UU STE RO ass ead Oe qiu 27 M E dition E eds 28 Models and Model Designation 28 LCSE Componente veas wes aere n ditat vae S Y ap e Mrd 29 Standard autre uio nllo usd teles ade FLU fS ON 30 Split Frame Machine u Sa Cy e Che eta a T SA uu Ia d dor iced 30 idee Roscoe aucun cda Rates UR A FLU S CRAT a 31 Clamp Pad Extensions 2 2 ee boat S e e 33 DIPS XSSERIBIY A
91. ch from each other Adjust the position of the parting tool in the beveling slide for the desired land thickness To increase the land set the parting tool beyond the tip of the beveling tool The land thickness willbe 3 32 plus the distance the parting tool extends past the beveling tool Start the tooling with a 1 16 to 1 8 inch gap from the pipe surface and proceed to the installation of the trip assembly Y NOTE Example For a 1 4 land extend the parting tool 5 32 beyond the beveling tool 3 32 5 32 1 4 E H Wachs Part No 60 MAN 07 Rev 0 0311 83 Low Clearance Split Frame Models 204 1420 Figure 5 37 Set the tip of parting tool 1 8 3 mm from the pipe surface LONN Figure 5 38 The photo shows the parting tool 1 8 3 mm above the punch mark Install the Trip Assembly Configure the trip assembly for the slide position on the LCSF low middle or high position e Attach the trip directly with no extension blocks to the LCSF for slides in the low position 84 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 5 Operating Instructions Install Tool Slides and Tooling Attach the trip with one extension block for slides in the middle position Attach the trip with two extension blocks for slides in the high position Different length screws are provided for each configuration il M T a fils Figure 5 39 The trip is papanin
92. collide with the pipe surface This minimizes the extended length of the tool increasing rigidity of the cutting system Setting the position is described in the section Install Tool Slides and Tooling later in this chapter 60 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 5 Operating Instructions Planning the Operation LIFTING AND RIGGING THE LCSF Smaller LCSF models can be handled safely by one person Depending on configuration some components are heavy enough to require 2 operators or a lifting device See the weight charts in Chapter 2 Models with Lift Eyebolts LCSF models 610 and larger have 4 threaded holes 2 on each half of the stationary ring for lifting eyebolts Two lift eyebolts are provided with the machine To lift the entire machine assembled ring install the lift eyes in two adjacent threaded holes To lift one half of the machine separated ring install the lift eyebolts in both holes of the half you are lifting Do not lift the ring half using only one lift eye Make sure the alignment pin is installed through the rotating and stationary ring Figure 5 8 Lift the assembled machine as shown 1 Lift one half of the machine out of the case N WARNING See weight charts in Chapter 2 for weights of the LCSF models One person should not lift a machine or compo nent over 40 Ib 18 kg Two people should not lift a machine or component over 80 Ib 36 kg Us
93. dditional information such as warnings special notes and defini tions Refer to it for safety notes and other information In This Chapter PURPOSE OF THIS MANUAL How TO USE THE MANUAL SYMBOLS AND WARNINGS MANUAL UPDATES AND REVISION TRACKING TECHNICAL FILE RESPONSIBLE PARTY Throughout this manual refer to this column for warnings cautions and notices with supplementary information E H Wachs Part No 60 MAN 07 Rev 0 0311 Low Clearance Split Frame Models 204 1420 WARNING P A WARNING alert with the safety alert symbol indicates a potentially hazardous situa tion that could result in seri ous injury or death CAUTION P A CAUTION alert with the safety alert symbol indicates a potentially hazardous situa tion that could result in minor or moderate injury CAUTION A CAUTION alert with the damage alert symbol indi cates a situation that will result in damage to the equipment IMPORTANT IMPORTANT alert with the damage alert symbol indi cates a situation that may result in damage to the equipment 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 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
94. e Pd are same for 60 415 00 parting slide and 60 416 00 m a beveling slide next page 42 Chapter 3 Introduction to the Equipment Operating Envelopes Extended Beveling Slide 60 416 00 The extended beveling slide is paired with the extended parting slide 60 415 00 It is used with all LCSF models 7 31 185 6 TABLE With double bevel B tool C SUE MODEL POSITION D 76 4 47 Low 19 2 113 5 276 5 46 LCSF2043 MID ud HGH 2508 2 88 5 53 LOW 73 2 1405 LCS 206 3 MID Ton 6 88 752 HIGH 1748 1911 4 96 6 53 LOW 126 0 165 8 D LCSF408 3 E did 7 9 Mal iea Low 2589 2880 LCSF610 3 HGH aa 12485 943 Low 239 6 Baa LCSF612 3 MID 6 56 13 00 10 83 HIGH 166 6 With standard 330 2 275 1 L Haeo zi tool cover Low 1064 2402 LCSF814 3 MID 133 2 14 25 11 45 i 1 HIGH 362 0 290 9 4 52 114 7 tow 095 mo LCSF 1016 3 MID E 21270 cH 1625 12 70 412 8 322 7 99 25 1 tow 18529 LCSF 1420 3 MID 1896 137 a 20 25 i HIGH 514 4 3734 51
95. e around the pipe SETTING UP THE LCSF Clamp Leg Set Up 1 Measure the O D of the pipe to be machined If nec essary measure the circumference and divide by 3 14 to get the diameter 2 Inthe Clamp Pad Extension Charts on the following pages find the column for your LCSF model 3 Findthe MAX MIN range that includes the diameter you measured in Step 1 Select the corresponding leg set in the table row legs have their part numbers and size range stamped on them Example You have a model 206 LCSF and the pipe O D is 5 5 inches You need to use the 1 2 leg exten sion set 60 408 05 4 Install the 4 legs in the set onto the clamp pads of the LCSF The legs have captivated screws Tighten the screws securely 64 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 5 Operating Instructions Setting Up the LCSF 5 Make sure the legs are fully retracted by turning the clamping screws counter clockwise until they stop The clamp screws require a 3 8 hex wrench PART NUMBER AND RANGE Figure 5 14 Install the legs onto the clamp pads CLAMP PAD EXTENSION CHART LCSF 204 610 4 10 LCSF 204 LCSF 206 LCSF 408 LCSF 610 CLAMPING RANGE INCH MM INCH MM INCH MM INCH MM WITH NO 4 75 120 7 6 88 1746 888 225 4 11 00 279 4 EXTENSION MIN 3 51 89 1 5 62 142 7 7 16 193 3 9 51 241 6 60 408 05 MAX 3 63 92 2 5 74 145 9 7 7 196
96. e kits are provided for the base LCSF machine and for the tool slides Note that the spare parts kits include fastener kits Fastener kits can also be purchased separately 164 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 9 Accessories and Spare Parts Recommended Spares Table 7 LCSF Spare Parts Kits Kit No Description Part Description Part No Qty Bearing Guide Wheel 37 005 00 5 Lock Pin Chain 46 067 00 2 Eccentric Bearing Shaft 60 105 02 3 5 16 18 1 5 8 60 122 00 2 Spare Parts Kit for LCSF 4 Rear Pinion Bearing 60 125 00 1 905991294 through 1420 Front Pinion Bearing 60 126 00 1 Frame Bearing Spacer 60 128 01 5 Pin Frame Locking 60 129 00 2 Plug Bearing Cap 60 130 00 5 SHCS 1 2 13 x 2 1 2 Captivated 60 207 00 2 Kit LCSF 4 20 Fasteners 60 550 01 1 Feed Nut 60 116 00 2 Feed Screw 60 118 04 1 551 08 rere ao Trip Pin 60 338 00 2 Kit LC Slide Fasteners 60 550 03 1 Spring Plunger 1 4 20 x 1 2 90 059 08 1 Feed Screw 60 195 00 1 Alignment Pin 60 196 00 2 Feed Nut 60 229 00 2 60 551 04 Shim 60 232 00 1 60 338 00 2 LC Slide Fasteners 60 550 03 1 Spring Plunger 1 4 20 x 1 2 90 059 08 1 Feed Screw 60 147 00 1 Bushing LC1 12 60 150 00 1 60 551 07 Universal Bushing LC1 3 60 157 00 1 Rev 1 to Rev 2 Upgrade Kit 60 370 00 1
97. e a crane or other lifting device to lift heavy components The photos in this section use a 24 LCSF model 1824 as an example The instructions are identical for all LCSFs that have lift eyebolts E H Wachs Part No 60 MAN 07 Rev 0 0311 61 Low Clearance Split Frame Models 204 1420 Figure 5 9 Use a lifting device to lift each half of the machine out of the storage case 2 Lay the ring half on the floor or a suitable work sur face Figure 5 10 Lay the ring half on the work surface 3 Assemble the halves of the ring 62 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 5 Operating Instructions Planning the Operation Figure 5 11 Assemble machine the floor for use on an open ended pipe To install the machine on an inline pipe use lift bar to pick up the machine as shown 15 Figure 5 12 Assemble the ring halves around the pipe as shown 5 Push the machine halves together and tighten the screws E H Wachs Part No 60 MAN 07 Rev 0 0311 63 Low Clearance Split Frame Models 204 1420 If your pipe O D is within the range 2 leg sets it is generally better to select the longer legs However shorter legs may be an advantage if the pipe is out of round or if the work environ ment has limited clearance for mounting the LCSF Figure 5 13 Assemble the halves of the machin
98. ed foam insert that securely holds the LCSF machine slides tools drive motor and accessories Models 204 206 and 408 are stored with the machine assembled as a ring as shown in Figure 4 2 50 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 4 Assembly Disassembly and Storage Storage Shipping Cases Figure 4 2 The photo shows the model 206 LCSF stored in it case The larger models are split into halves for storage Figure 4 3 shows the case layout for models 610 612 and 814 Figure 4 4 shows the case layout for models 1016 and 1420 The machines are stored with the slides and trip assembly attached Figure 4 3 The photo shows a model 814 LCSF stored in its case E H Wachs Part No 60 MAN 07 Rev 0 0311 51 Low Clearance Split Frame Models 204 1420 21 Figure 4 4 photo shows the model 1016 LCSF in its case STORAGE GUIDELINES Clean the machine by wiping off dirt debris and accu mulated oil or grease Put oil in the air motor oiler and operate the motor for few seconds to lubricate its internal components Lubricate the machine according to the instructions in Chapter 6 Spray or wipe a light coating of anti corrosion lubricant on non finished non painted surfaces Put the machine in its storage case with all components stored in their compartments Jfpossible keep the storage case indoors and away from moisture 52 Par
99. es which 15 the desired distanced between the pipe and LCSF at each location 74 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 5 Operating Instructions Setting Up the LCSF 10 Using the scale as you make the adjustments turn the clamp pad screws alternately until you have the same pipe to LCSF distance at both locations 11 Repeat this procedure at the two clamp leg locations 90 from the first two 12 Measure at all four locations again Re adjust if neces sary 13 Remove the frame locking pins and manually rotate the machine a full 360 Figure 5 23 Remove the frame locking pins 14 Ifyou can t turn the rotating frame by hand the clamp legs may be too tight binding the machine One at a time loosen and then re snug the clamping screws Try to rotate the machine again y NOTE You should make a final check for squareness after the clamp pads are tightened E H Wachs Part No 60 MAN 07 Rev 0 0311 75 Low Clearance Split Frame Models 204 1420 d 7 o 1 O F igure 5 26 Rotate the machine by hand 15 Ifyou still can t turn the machine see the section Bearing Adjustment in Chapter 7 INSTALL TOOL SLIDES AND TOOLING Standard Slides The standard slides for LCSF models 204 1420 are the extended parting and beveling slides part nos 60 415 00 and 60 416 00 On the back of each of the tool slides are pairs of
100. f a bearing a spacer an eccentric shaft a washer and a lock nut See assem bly drawings in Chapter 8 for specific part numbers for your LCSF model Figure 7 4 Remove the plastic caps to inspect the bearing assemblies 7 Using a 1 2 socket wrench break loose the 5 16 18 lock nuts 90 065 03 Figure 7 5 Loosen the lock nuts 8 Turn the eccentric shafts so that the lines on top of them point toward the frame center 112 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 7 Service and Repair Adjusting the Bearings Figure 7 6 Set the marks on the eccentric shafts toward the center of the ring 9 Insert the rotating ring halves back into the stationary ring halves 10 Reassemble the machine halves using a 1 4 hex wrench An optional bearing fixture plate 60 205 00 is 11 p g plate Z NOTE available to make adjusting the bearings easier Install the plate on the rotating ring at one of the slide mount ing positions using two 2 5 16 18 x 7 8 SHCS and a 1 4 hex wrench The bearing fixture plate keeps the eccentric shafts from turning as you tighten the bearing lock nuts This keeps the guide wheel bear ings within the V groove preload of 10 15 in Ib Figure 7 7 Install the bearing fixture plate on the rotating ring at the slide mounting position E H Wachs Part No 60 MAN 07 Rev 0 0311 113 Low Clearance Split Frame Models 204 1420 Figu
101. f the pipe wall A longer tool is required for heavy wall pipe to reach the I D Cutting heavy wall pipe makes using the correct LCSF size and slide position even more important It is possible to reduce the effective tool length of a longer tool by mounting it farther back in the tool holder so that it extends behind the slide However this is not recommended for safety reasons Having tools extend beyond the diameter of the machine is hazardous to the operator E H Wachs Part No 60 MAN 07 Rev 0 0311 55 Low Clearance Split Frame Models 204 1420 2 Standard LCSF beveling slides are also referred to as parting beveling slides since the beveling tool holder is designed so that it can hold a parting tool instead Part ing slide tool holders can only hold parting tools Refer to the tooling tables in Chapter 9 and operating enve lope drawings in Chapter 3 Parting Only Operation For a parting straight cut off operation you will use 2 identical parting tools in in the parting slide and one in the beveling slide The tool holders are designed with a part ing offset so the tools cut a wider groove than the thickness of each tool This prevents the tools from jamming in the groove and breaking off or stalling the machine Standard parting blades are 3 16 thick and are available in a variety of lengths You can use solid high speed steel blades or insert holders with carbide
102. g surfaces with a clean cloth sprayed with a house hold cleaning solvent LUBRICATION Tool Slides Lubricate all moving parts every 10 hours of operation Use Mobil lith AW 2 or equivalent Split Frame Apply two drops of way oil to the felt wiper before storing the LCSF Separate the ring halves and remove the rotating ring to access the felt wipers In This Chapter DAILY MAINTENANCE LUBRICATION E H Wachs Part No 60 MAN 07 Rev 0 0311 107 Low Clearance Split Frame Models 204 1420 2 The numbers on the dial do not indicate the number of drips per minute Air Motor An in line oiler lubricates the air motor You can adjust the drip rate of the oiler by turning the needle valve in the oiler using a flat screwdriver Turn the screw counter clockwise to increase the drip rate Figure 6 1 Use the needle valve screw to adjust the drip rate of the air motor oiler To check the drip rate of the oiler run the air motor for one minute while holding a sheet of paper in front of the air out let port The paper should become stained with oil If the paper is not oily increase the drip rate on the oiler If the paper becomes saturated or gets oily within a few seconds decrease the drip rate As a general guideline the standard LCSF air motor 1 5 HP should use about 6 10 drops of oil per minute The heavy duty and reversible air motors 2 5 HP should use about 8 12 drips per minute
103. gether on the pipe E H Wachs Part No 60 MAN 07 Rev 0 0311 69 Low Clearance Split Frame Models 204 1420 is IMPORTANT Be sure that all frame locking SHCS are equally tightened before continuing with mount ing procedure Failure to do so may cause damage to drive gears 7 Partially tighten one of the frame locking SHCS in the rotating frame This will secure the machine while the other bolts are tightened 8 Using a 1 4 hex wrench snug down all of the frame locking screws to bring the split lines together then securely tighten the screws Figure 5 20 Tighten the frame locking screws Set Up for Open Ended Pipe For open ended workpieces slide the machine over the pipe end It is not necessary to split the machine Make sure you are attaching the stationary frame to a section of the pipe that will support its weight Do not clamp the machine onto a pipe section or end that will fall off after cutting Make sure all locking frame screws are tight and detent pins are installed in the machine Use the same clamping and positioning procedures as for in line pipe 70 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 5 Operating Instructions Setting Up the LCSF Installation on Vertical Pipe LCSF be installed on inline or open ended vertical pipe with the machine in a horizontal position Set up and operating procedures are the same as for horizontal pipe However
104. hangeable by design and can be used on any size LCSF as needed The 1 5 HP air drive requires 55 cfm air flow at 90 psi 1 557 1 m 6 3 bar The 2 5 HP air drive requires 65 cfm at 90 psi 1 841 1 6 3 bar A hydraulic drive is available as an option The hydraulic drive requires 8 15 gpm hydraulic flow rate at 1500 2000 psi 30 57 l m 103 138 bar Electric drives are available as special order items Contact E H Wachs customer service to discuss requirements Y NOTE Clamp pad requirements are included on the envelope drawings at the end of this chapter E H Wachs Part No 60 MAN 07 Rev 0 0311 33 Low Clearance Split Frame Models 204 1420 Table 2 LCSF Drive Options Drive Option Part No Description Input Requirements 55 cfm at 90 psi 60 423 00 Right angle 1 5 HP 1 557 1 m 6 3 bar HAD Right angle 1 5 HP with 55 cfm at 90 psi 90740700 ported exhaust 1 557 1 m 6 3 bar Air Drive 65 cfm at 90 psi 60 423 01 Right angle 2 5 HP 1 841 1 m 6 3 bar Right angle reversible 2 5 65 cfm at 90 psi 60 4010 01 HP 1 841 1 m 6 3 bar Hydraulic DIS i 8 15 1500 2000 psi Drive 60 424 01 Hydraulic motor with adapter 30 57 l min 103 138 bar Electric Electric motor with adapter Varies depending on Special i Drive special order item requirements Hydraulic drive 3 4 Pneumatic 4 drive hy 7 x gt
105. holes for three mounting positions as shown in Figure 5 27 Two mounting pins are provided to use in the appropriate hole pair The hole pairs represent the three possible mounting positions high farthest from machine I D middle and low closest to machine I D Choose the lowest slide position that will not collide with the pipe surface Refer to the operating envelope drawings in Chapter 3 This minimizes the extended length of the tool increasing rigidity of the cutting system 76 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 5 Operating Instructions Install Tool Slides and Tooling 1 Insert mounting pins in the required holes for the pipe size Use the high position if the pipe diameter is less than 2 51 mm smaller than the machine size for instance 12 5 pipe with 14 inch LCSF Use the middle position if the pipe diameter 15 2 4 51 102 mm smaller than the machine size for instance 11 pipe with 14 inch LCSF Use the low position if the pipe diameter is more than 4 102 mm smaller than the machine size for instance 9 pipe with 14 inch LCSF Figure 5 27 Insert the mounting pins in the slide 2 Mount the tool slide to the rotating frame by inserting the pins in the mounting holes at each slide position Tighten the four 5 16 18 SHCS in each slide with the supplied hex key set E H Wachs Part No 60 MAN 07 Rev 0 0311 TI Low
106. htsbridge Parkway Lincolnshire IL 60069 U S A The following organization is the responsible party for maintaining the LCSF technical file in the EU Orbitalum Tools GmbH Josef Sch ttler Str 17 78224 Singen Deutschland E H Wachs Part No 60 MAN 07 Rev 0 0311 3 Low Clearance Split Frame Models 204 1420 4 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 2 Safety Chapter 2 Safety E H Wachs takes great pride in designing and manufactur ing safe high quality products We make user safety a top priority in the design of all our products Read this chapter carefully before operating your E H Wachs equipment It contains important safety instructions and recommendations SAFE OPERATING GUIDELINES Follow these guidelines for safe operation of all E H Wachs equipment READ THE OPERATING MANUAL Make sure you under stand all setup and operating instructions before you begin Keep this manual with the machine INSPECT MACHINE AND ACCESSORIES BEFORE USE Before starting the machine look for loose bolts or nuts leak ing lubricant rusted components and any other physi cal conditions that may affect operation Properly maintaining the machine can greatly decrease the chances for ALWAYS READ STICKERS AND LABELS Make sure all labels and stickers are in place clearly legible and in good condition Refer to Safety Labels later In this chapter for label locations on
107. insert See the Bridge Slide Accessory for Low Clearance Split Frame User s Manual for instructions on beveling with the bridge slide Operating Envelopes The drawings at the end of Chapter 3 illustrate the operating envelope for the available combinations of LCSF machines and tool slides In the table on each drawing find the row for your LCSF model The DIM A DIAMETER column indicates the maxi mum pipe diameter for the given LCSF machine and slide combination Note that the maximum pipe diameter is sometimes a little more than the nominal LCSF size Where multiple slide mounting postions are available there is a separate row with dimensions for each position E H Wachs Part No 60 MAN 07 Rev 0 0311 59 Low Clearance Split Frame Models 204 1420 Low Clearance Slides 60 402 04 60 403 04 Parting slide 60 402 04 and beveling slide 60 403 04 can be used with all LCSF models from LCSF 204 4 Inch to LCSF 1420 20 inch These slides have a single installation position on the LCSF Extended Standard Slides 60 415 00 60 416 00 Parting slide 60 415 00 and beveling slide 60 416 00 are the standard slides for LCSF models 204 4 inch through 1420 20 inch The drawings and tables in Chapter 3 illus trate the operating envelopes for all slides These slides have three installation positions on the LCSF indicated in the tables as LOW MEDIUM and HIGH Choose the lowest slide position that will not
108. inserts For heavier wall applications 1 4 tools are available See the tooling tables in Chapter 9 for available parting tools Parting offset Figure 5 4 The drawing illustrates the parting opera tion with two offset parting tools The parting offset distance is built into the parting and parting beveling tool holders Parting O D Beveling Operation For a parting beveling operation you will use a parting tool in the parting slide and a beveling tool with the desired bevel angle in the beveling slide 56 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 5 Operating Instructions Planning the Operation Beveling tools are made with the desired form angle built into the cutting edge of the tool The tool feeds radially into the end of the pipe This methodis used mainly for thin wall pipe up to 1 inch For heavier wall pipe single point bevel ing is typically required see Single Point Beveling below Standard beveling tools are available with single angles or compound angles 30 single angle 37 59 single angle 10 x 37 5 compound angle 10 x 30 compound angle Form tool beveling is fast on thinner wall pipe and is easier to set up than single point However it can have the follow ing disadvantages there are a limited number of designs unless tools are specially made it requires cutting fluid to extend tool life e it has limitations on heavy wall pipe
109. l Make sure the equipment is stable when attached to the workpiece for the operation Ensuring stability of the installed tool is the responsibility of the operator Make sure the workpiece is supported adequately for installation of the equipment This includes supporting any workpiece fall off section when severing the workpiece Ensuring support of the workpiece is the responsibility of the operator Tooling on any cutting equipment including lathe tools saw blades milling tools etc may get very hot Do not touch tooling until you have made sure it is cool enough to handle Wear gloves when removing or cleaning up chips and cutting debris Chips can be very sharp and cause cuts Before performing any service on the equipment dis connect the power source Follow all lock out tag out procedures required at the worksite 6 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 2 Safety Safe Operating Guidelines Hydraulic Powered Equipment Hydraulic components such as hoses motors and mani folds will get hot during operation and may cause burns Do not touch hydraulic components except for operator controls during or after operating the machine Hydraulic injection injury A pinhole in a hydraulic hose or fitting can eject fluid with enough force to pierce skin Check hoses and fittings regularly for leaks Do not use bare hands to check for leaks while the sys tem is pressurized If you suspect a leak move
110. l position 2 Using a suitable wrench loosen left hand threads the clamp nut and remove the angle head assembly Unscrew and remove the clutch housing and gear case assemblies Clamp the gear case in the vise and unscrew the clutch housing 3 Slip the motor unit out the front of the handle It may be necessary to bump the handle on the work bench to loosen the motor E H Wachs Part No 60 MAN 07 Rev 0 0311 129 Low Clearance Split Frame Models 204 1420 Disassembling Air Motor Subassemblies Right Angle Head 1 Remove the bearing cap lock screw 1 16 hex and unscrew left hand threads the bearing cap Clamp the square drive in the vise and use a soft mallet to drive the angle head off Press the spindle out of the driven gear and then press the spindle out of the ball bearing 2 Unscrew and remove the bearing retainer and grease plug Use a suitable driver to drive the pinion gear out of the housing Gear Case 1 Slip the entire gear train out the rear of the gear case The 2nd reduction idler gears may be removed for inspection by driving the idler gear pins out the rear of the spider r Use a soft faced mallet to drive the rotor out of the front rotor bearing This will allow the removal of the front bearing plate cylinder and five 5 rotor blades from the rotor 2 Clamp the rotor lightly in the vise and unscrew the rotor lock nut 3 Rest the rear bearing plate
111. lculate desired amount to be removed First Pass Depth Second Pass Depth Third Pass Depth c 050 x 3 8667 193 580 193 387 375 762 762 193 569 569 193 376 100 Part No 60 MAN 07 Rev 0 03 11 E H Wachs Chapter 5 Operating Instructions Counterboring Counterbore Set up 1 Remove the tooling from the slides Clean then place the tooling in secure location 2 Remove the front cap from the bevel slide only 3 Attach the counterbore slide using the four 5 16 SHCS to the bevel slide Figure 5 63 Attach the counterbore slide 4 Secure the final 5 16 SHCS on the side of the bevel slide to complete installation Figure 5 64 Secure the SCHS on the side of the bevel slide E H Wachs Part No 60 MAN 07 Rev 0 0311 101 Low Clearance Split Frame Models 204 1420 5 Install the counterbore bit into the tool slot and secure with screws Figure 5 65 Install the counterbore tool into the slot Cutting the Counterbore 1 Feed the cutting tool into the pipe by turning the axial feed handle counter clockwise until the flat of the tool Is Inside the pipe face Figure 5 66 Turn the feed handle counter clockwise 102 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 5 Operating Instructions Counterboring 2 Turn the radial feed handle counterclockwise until the cutting tool lightly touches the pipe wall Fig
112. ntact E H Wachs customer support to discuss requirements E H Wachs Part No 60 MAN 07 Rev 0 0311 71 Low Clearance Split Frame Models 204 1420 amp NOTE For easy visualization we often refer to positions on the LCSF by numbers on a clock Figure 5 21 Measure 2 1 4 back from the punch mark Clamp Pad Centering Procedure Starting with the clamp pad nearest the 12 o clock position tighten the clamping screw until the gap at the top and the bottom of the machine are approxi mately equal E H Wachs 72 Part No 60 MAN 07 Rev 0 0311 Chapter 5 Operating Instructions Setting Up the LCSF 2 Snug the clamp pad nearest the 6 o clock position Figure 5 22 Tighten the clamping screw until the leg is just snug on the pipe Snug the clamping screws nearest the 3 and 9 o clock positions At this point the machine is rough centered and you may begin making the final adjustments Place the short end of the provided square on the pipe with the ruler side against the stationary ring at the 12 o clock position Check the LCSF s squareness to the O D of the pipe If there is a gap adjust the machine until the gap is closed Figure 5 23 Use the square to make sure the machine is perpendicular to the pipe Clamp legs are secured with Integrated Captivated Socket Head Cap Screws SHCS to secure themselves to the sta tionary ring Y NOTE
113. observe the following guidelines for machining vertical or other non horizontal angle workpieces Make sure the machine is adequately supported until you tighten the clamp feet securely on the workpiece Refer to the weight chart in Chapter 2 to determine if multiple operators or a lifting device are needed to help support the machine The LCSF is easier to handle in a horizontal position when the ring halves are assembled If possible install it as an assembled ring If you need to split the machine to install on in line pipe make sure each half is supported until installation is complete Two lifting devices may be required one for each half of the machine Use a scaffolding or other support structure s if avail able Make sure the LCSF rests stably on the support When performing a parting operation make sure the workpiece is securely supported both above and below the LCSF Positioning the Machine for the Cut 1 2 With the frame halves securely tightened move the machine to the cut line position marked on the pipe Using the scale set your machine 2 1 4 57 mm back from the line or punchmark at the position where you mount the tool slides See the cut line identified in the envelope drawings in Chapter 3 For difficult installation envi ronments a custom mounting adapter can be provided The adapter can be bolted or welded to the workpiece to hold the LCSF in place for installation Co
114. on to the Equipment Model 814 14 inch LCSF 60 000 14 ITEM PARTNUMBER QTY DESCRIPTION 1 37 005 00 22 GUIDE WHEEL 2 60 028 00 2 LABEL NO GAPS 3 60 094 00 1 INSERTFOAM NOTSHOWN 4 60 096 00 1 CASE NOTSHOWN 5 60 099 00 1 LABEL NOTSHOWN 6 60 1105 14 1 14 ROTATING RING ASSEMBLY 7 60 1178 00 2 _ WIPER 10 20 LC SF 8 60 122 00 2 SCREW CAPTIVATED 5 16 18 9 60 1242 00 2 SMALL FIXED BEARING 10 60 1243 00 20 5 SMALL ADJ USTABLE BEARING 11 60 1260 14 1 14 STATIONARY FRAME ASSEMBLY 12 60 1261 00 2 ASSEMBLY 10 20 LC SF WIPER BRAC KET 13 60 1274 00 2 IAG LCSF 14 60 1275 00 1 PIN LOCATON 15 60 1279 14 1 LABEL WEIG HT LC SF 814 16 60 129 00 2 FRAME LOCKING 17 60 130 00 22 PLUG BEARING CAP 18 60 166 04 4 _ GUARD CHIP LC 4 12 19 60 363 00 1 LABEL MOVING PARTS 20 60 408 05 1 _ 1 2 EXTENSION LEG SET NOTSHOWN 21 60 408 15 1 _ 1 1 2 EXTENSION LEG SET NOTSHOWN 22 60 408 25 1 2 1 2 EXTENSION LEG SET NOTSHOWN 23 60 412 00 1 HOUSING ASSEMBLY LC SF 4 20 24 60 447 03 4 CLAMP PAD ASSEMBLY 10 20 25 60 560 01 1 KIT LCSF 4 20 FASTENERS NOTSHOWN 26 60 600 00 1 4 20 LCSF HAND NOTSHOWN 27 60 MAN 07 1 MANUAL SPLITFRAME NOTSHO WN 28 80 0080 00 1 29 90 022 03 4 548 32 375 30 90 025 01 4 WASHE
115. or Figure 5 54 The photos show the speed adjustment controls on the drive motors Set the speed control to the minimum before starting the LCSF on a new setup 5 Engage the trip and operate the machine slowly 3 4 RPM to verify that the trip 15 turning the starwheel Ss Figure 5 55 Pull the trip lever up to engage the trip 6 Set the speed control to increase the speed to the desired RPM Continue machine operation The tool slides will advance until the tools begin to cut the workpiece 94 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 5 Operating Instructions Cutting Operation Faster Figure 5 56 Turn the air motor throttle to increase the speed 7 Once the tool bits begin to remove material from the workpiece be sure to apply liberal amounts of coolant for the duration of the machining process 8 You may need to disengage the trip occasionally to adjust the feed rate or to let chips clear out of the cut Push the trip lever down as the machine is rotating and operate the machine for 2 3 rotations Pull the trip lever up to re engage the trip and continue cutting y NOTE Using coolant is strongly rec ommended to enhance cut ting and increase tool life If worksite requirements pre vent you from using coolant you may need to adjust oper ating speed feed rate using the trip or tooling E H Wachs Part No 60 MAN 07 Rev 0 0311 95 Low Clearance Spli
116. or Shut Off of Power Supply 7 Safety Alerts in This Manial aa en a a are wom T Protective Equipment Requirements 8 Protective 8 EVOPIOISC UD m eR pd aaa RO w 8 Hearing Protection e ente outa ier OU the ante ale tud 9 Safe Operation or the LESE ders ced ded s word heb Uae 9 Intended ayude ate o vA Raed PR Ua ee Se E e c 9 Proper Wse oF the ECS oa Pues Rated ea vu 9 MISUSE v Lace ve he Ra eww ua a add ee RANE ee OU ORS 10 Potential H3a2ards ss ee eu RE RACE ODE b e reds S chew anu S 11 CSE Safety Beanies ong ance deus qe adus CORBIS 13 Enclosed Bearing and Drive Gear System 13 Stop on Rel as Power 1 13 P ddle Style Trip ever a eese een o d ais Wa saka a AR d 14 Remote Operation Option 15 Guidelines for Safe Setup Operation and Service 15 Pre Operation Check Hist c os eS sea ares kaq See era Le ree PRUSSIAE sees 15 ture Ae rae uei eate rei A qe A 16 Oper
117. plate 4 Clean the slide as best you can and apply a thin layer of grease on the face of the adjustable dovetail 124 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 7 Service and Repair Tool Slide Adjustment Figure 7 23 Remove the dovetail and clean the slide 5 Turn the starwheel until the tool slide is in the central position 6 Replace the adjustable dovetailand the four 4 1 4 20 x 7 8 socket head cap screws Figure 7 24 Replace the dovetail and SHCS 7 Position the adjustable dovetail so that there is no gap between it and the slide base E H Wachs Part No 60 MAN 07 Rev 0 0311 125 Low Clearance Split Frame Models 204 1420 8 Tighten the 1 4 20 x 7 8 socket head cap screws so they snug You do not want them to be fully tightened or the tension will not be set correctly Figure 7 25 Tighten the SHCS until snug 9 Replace the center two 2 1 4 20 set screws and tighten them until the adjustable dovetail is touching the tool slide Figure 7 26 Replace the set screws and tighten 10 Make sure the dovetail stays as straight as possible 126 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 7 Service and Repair Tool Slide Adjustment 11 Tighten the 1 4 20 set screws and turn the star wheel at the same time until you feel tension in the star wheel Try to keep the tension on the set screws as even as possible Figure 7 27
118. re 7 8 The fixture plate will hold the eccentric shaft as you set the bearing wheel against the V groove 12 If you do not have the bearing fixture plate you will need to use a 3 16 hex wrench to hold the eccen tric shaft Since this is done while tightening the 5 16 18 lock nut you must be careful to keep adequate V groove preload 10 15 1 16 on the eccentric shaft 13 Refer to the Figure 7 9 for your LCSF model and locate the 1 position eccentric shaft 114 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 7 Service and Repair Adjusting the Bearings e 2 9 Z CX qe 24 97 SON p S lt y O NN Q X ue 2 SF 051 3 H m A s N C T e qo 2 50 6 2 2 4 4 3 12 2 Ges 00 wc O S E 2 eO 2 O O 1 lt 2 e AN s 4 ar Wwe Z OM gt NO N ia se2 2 TS 208 3 et CA Den A ENT Ecce ced os U Figure 7 9 Bearing Adjustment Sequence Chart 14 Turn the eccentric shaft counter clockwise until the guide wheel bearing touches the rotating ring V groove Torque 10 15 in Ib 15 Secure the eccentric shaft using the bearing fixture plate and tighten the lock nut to 150 in lb E H Wachs Part No 60 MAN 07 Rev 0 0311 115 Low Clearance Split Frame Models 204 1420 Figure 7 10 Secu
119. re the eccentric shaft 16 Repeat Steps 14 and 15 for the 2 3 and 4 posi tions 17 Check that the rotating ring is centered to the station ary frame using the supplied square If not centered repeat Steps 14 and 15 Figure 7 11 Center the rotating ring to the stationary frame 18 Turn the rotating ring by hand around the stationary frame The machine should turn smoothly and consis tently Check the backlash between the rotating ring and the pinion gear 116 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 7 Service and Repair Adjusting the Bearings 19 20 Repeat Steps 14 and 15 for the remaining bearings Check that all guide wheel bearings rotate while the machine turns Look through the holes in the rotating ring while turning the machine 7 IX 94 21 Figure 7 12 Check for bearing rotation as you turn the rotating ring Turn the rotating ring by hand around the stationary ring The machine should turn smoothly and consis tently and should stop immediately when you stop turning it If it doesn t operate this way repeat the bearing adjustment procedure 2009 and Later Machines The following instructions are for 6 through 20 machines with serial numbers 09 X XX orlater Approximate time to complete 30 90 minutes Remove the pinion housing assembly and tool slides before beginning bearing adjustment E H Wachs Part No 60 MAN 07
120. ressurized air line can cause serious injury if it comes loose Make sure the air line is secured to the equipment with a pin or other appropriate fastener 8 Fall off workpiece When you are severing the work piece make sure the fall off section is supported or that a catch device is in place A support chain and scaffold ing are shown in the picture 9 Lifting the machine Use care when lifting the LCSF and its components to avoid injury Machines and compo nents heaver than 40 Ib 18 kg should be lifted by two people or with a lifting device LCSF models 610 and larger are provided with lifting eyes for rigging and lifting See Machine Weights later in this chapter for weights of LCSF models 204 1420 and accessories 10 Splitting the ring Align ment pins are provided to keep the rotating and station ary rings together when split ting the ring Make sure you insert the pins before sepa rating the ring halves If the pins are not inserted the rotating ring could fall out of the stationary ring causing personal injury and or dam age to the machine Figure 2 2 Potential operating hazards of the LCSF See the descriptions in the side column 1 E 2 Figure 2 3 Potential operating hazards the LCSF See the descriptions in the side column 12 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 2 Safety Safe Operation of the LCSF LCSF S
121. ription of each hazard for guidelines on safe operation Figure 2 1 Potential operating hazards of the LCSF See the descriptions in the side column 1 Rotating ring Keep clear of the rotating ring and tool slides when operating the LCSF Contact with moving parts can cause serious injury 2 Entanglement hazard for gloves or clothing Do not wear gloves or loose fitting clothing when operating the LCSF They can become entangled with moving parts resulting in serious injury 3 Starwheel trip pinch point Operate the trip using the trip lever only Do not touch any part of the trip assembly other than the lever when operating the LCSF or when rotating it manually for any reason 4 Sharp cutting tools Cut ting tools used with the LCSF can be very sharp Be careful when handling the tools and stay clear of them when the machine is operating 5 Chips The metal debris from the cutting process can be very sharp and very hot Use care in cleaning debris from the machine and clean ing up the work area Stop the machine before clearing chips Use appropriate gloves when handling chips 6 Hot surfaces Air motors and hydraulic components such as hoses manifolds and motors can become very hot during operation Make sure these components are not hot before touching them E H Wachs Part No 60 MAN 07 Rev 0 0311 Low Clearance Split Frame Models 204 1420 7 Air motor connection A p
122. rparting cut off operations use a catch device to prevent the cut off piece of the pipe from falling Keep air and hydraulic hoses and electrical cords away from moving parts while operating the machine Operator Position The preferred position for operating the LCSF is behind the stationary ring on the mounting side of the cut line ww Figure 2 8 If possible stand behind the LCSF to stay clear of moving parts while operating the controls If the operating environment does not allow you to stand behind the LCSF make sure you install the machine so that you can operate the controls without coming in contact with moving parts 16 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 2 Safety Safe Operation of the LCSF Figure 2 9 When operating the LCSF from the front stand to the side of the machine to operate the controls without reaching across the rotating ring Some accessories such as the universal counterbore slide require that you operate them from in front of the machine Stand in a position that allows you to operate the machine controls without contacting moving parts Figure 2 10 When using accessories that require you to operate their controls shown with universal coun terbore slide stand in a position where you can oper ate the machine without contacting moving parts E H Wachs Part No 60 MAN 07 Rev 0 0311 17 Low Clearance Split Frame Models 204 1420 N
123. sure the radial clearance around the pipe surface za 4 ar X Ll Figure 5 2 Measure the axial clearance along the planned work area on the pipe Verify the actual diameter of the pipe If you cannot mea sure the diameter directly for instance an in line pipe with no open end measure the ciraumference and divide by 3 14 pi Example 40 0 circumference 3 14 12 74 diameter 54 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 5 Operating Instructions Planning the Operation ink I Figure 5 3 Verify the pipe circumference by measur ing Tool Selection This section describes the features of each type of tooling and explains the factors to consider when selecting specific tools for a given application When selecting tooling you will typically want to use the shortest tool that will accomplish the operation you re per forming A shorter effective tool length the distance between the tool holder and the cutting surface increases rigidity reducing vibration orchatter during cutting Factors that affect the required tool length are the following difference in size between the LCSF machine and the pipe Cutting performance 15 usually best with the smallest LCSF that will fit on the pipe The mounting position of the slide on the LCSF for slides with multiple positions The slide should be as close as possible to the pipe O D thickness o
124. t Frame Models 204 1420 AN WARNING Use wire brush or a pliers to avoid touching the chips which can be hot and very sharp Wear appropriate gloves for cleaning up chips CAUTION When cutting never extend the male tool holder of the tool beyond the red line scribed on the tool slide body Figure 5 57 Push the trip lever down to disengage the trip 9 Ifyou need to manually clear chips from the cut or the machine disengage the trip as described above Then stop the machine before clearing chips 10 When you have finished clearing chips start the machine without the trip engaged Operate it for at least one rotation before engaging the trip 11 Continue operating the LCSF until the machining operation is complete 12 Release the on off lever to stop the LCSF COUNTERBORING If a counterbore is to be performed be sure to leave an over sized land This will allow for material removal without vio lating the land thickness Planning the Operation Determine the amount of material that needs to be machined from the I D of the pipe 96 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 5 Operating Instructions Counterboring Measure the existing pipe I D and subtract this value from the planned I D The difference is the amount of material that needs to be machined from the existing pipe I D to 11 Figure 5 58 Measure the I D of the pipe Example Existing
125. t No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 5 Operating Instructions Chapter 5 Operating Instructions PLANNING THE OPERATION It is important to begin each project by visually inspecting the worksite Important information can be gathered at this time to aid in the setup of the machine tool The following items should be considered when doing this review Work space constraints Proper scaffolding to support equipment and workers Machine operating clearances Power requirements to run equipment Containment of cutting debris coolant during the oper ation In order to perform machine set up be sure to take the fol lowing measurements Radial clearance around the pipe Axial clearances end to end Verify the pipe schedule size This information will help to determine if clamp pads will be required what tool slides will be needed to perform the operation and what tooling is necessary to complete the cut See the drawings at the end of Chapter 3 for machine dimensions of all LCSF models The dimensions in the In This Chapter PLANNING THE OPERATION SETTING UP THE LCSF INSTALL TOOL SLIDES AND TOOLING CUTTING OPERATION COUNTERBORING OPERATING LCSF ACCESSORIES E H Wachs Part No 60 MAN 07 Rev 0 0311 53 Low Clearance Split Frame Models 204 1420 drawings will allow you to plan how to install the machine for the operating environment Figure 5 1 Mea
126. the 3 16 hex key tighten the 9 16 nylock hex nut E H Wachs Part No 60 MAN 07 Rev 0 0311 121 Low Clearance Split Frame Models 204 1420 10 11 12 13 14 Figure 7 20 Turn the bearing shaft clockwise with the hex key then tighten the nylock nut Repeat this procedure for positions 2 through 4 in order When guide wheel bearings are properly adjusted the alignment pins should be free to rotate in their bores with hand pressure only Adjust the remaining guide wheel bearings in oppo site pairs by turning the eccentric shafts counter clockwise until you can feel the bearing just touch the groove Tighten 9 16 nylock hex nut After each pair check that alignment pins are free to rotate in their bores with hand pressure only If this is not the case repeat Step 10 until alignment pins can be rotated by hand When remaining bearings have been properly adjusted return to the clockwise adjusted bearings at positions 1 through 4 and readjust them by turning the eccentric shaft counter clockwise as in step 10 Tighten the nylock hex nuts and check alignment pins for rotation Remove alignment pins and turn the machine over so that the stationary ring is sitting flat on a workbench Check that the rotating ring turns freely on the sta tionary ring While rotating machine through at least one full revo lution look through an alignment pin hole and check that all guide wheel bearings
127. the feed mechansim To take the backlash out turn the starwheel counter clockwise direction of feed until all backlash is gone and you can feel a slight resistance To time the starwheel make sure a point of the star is aligned with the machined line usually marked in red on the top of the tool block The feed rate for all tool slides is 0 0312 0 79 mm per revolution of the star wheel This equals 0 0026 0 066 mm per revolution of machine E H Wachs Part No 60 MAN 07 Rev 0 0311 87 Low Clearance Split Frame Models 204 1420 Figure 5 44 Time the starwheel You can align any point of the wheel with the red line on the tool block 8 Repeat step 5 for the other slide 9 Engage the trip pin by pulling up on the trip lever Figure 5 45 Engage the trip pin by pulling up on the paddle lever Install the Drive Motor The air and hydraulic drive motors are provided with adapt ers to attach to the LCSF pinion housing See the appropri ate section below for the drive motor you are using 88 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 5 Operating Instructions Install Tool Slides and Tooling Air Motor 1 2 Loosen two 5 16 18 SHCS located on the back of the pinion housing Align two of the bolt holes in the drive motor mount ing flange with the two SHCSs in the pinion housing and slip the flange over the SHCS All air motors use
128. the machine Replace any dam aged or missing safety labels see Chapter 10 for order ing information In This Chapter SAFE OPERATING GUIDELINES SAFE OPERATION OF THE LCSF Look for this sym throughout the manual It indicates a personal injury hazard E H Wachs Part No 60 MAN 07 Rev 0 0311 Low Clearance Split Frame Models 204 1420 KEEP CLEAR OF MOVING PARTS Keep hands arms and fingers clear of all rotating or moving parts Always turn the machine off and disconnect the power source before doing any adjustments or service 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 FOLLOW SAFE PROCEDURES FOR HANDLING LUBRICANTS Refer to the manufacturer s instructions and the Mate rial Safety Data Sheets Safe Operating Environment Do not use this equipment in a potentially explosive atmosphere Fire or explosion could result with the risk of serious injury or death Provide adequate lighting to use the equipment in accordance with worksite or local regulations KEEP WORK AREA CLEAR Keep all clutter and nonessen tial materials out of the work area Only people directly involved with the work being performed should have access to the area Operating and Maintenance Safety This equipment is to be operated and maintained only by qualified trained personne
129. the same style flange 4 5 Figure 5 46 Align the bolt holes in the motor flange with the two SHCS in the pinion housing Tighten the 2 motor mounting screws to secure the drive motor Re time the starwheel Attach the power supply to the drive motor Hydraulic Motor The hydraulic motor is supplied with an adapter to attach to the LCSF pinion housing First attach the adapter to the LCSF then mount the motor on the adapter 1 The hydraulic motor is supplied with the adapter attached Remove the two screws holding the motor to the adapter Y NOTE The drive motor may be placed in several different positions The motor should be mounted in a position that allows the operator the easi est and safest access possi ble y NOTE The square drive shaft on the motor must insert fully into the socket in the pinion hous ing If necessary turn the rotating frame slightly back and forth by hand until the drive hex seats itself properly E H Wachs Part No 60 MAN 07 Rev 0 0311 89 Low Clearance Split Frame Models 204 1420 Figure 5 47 Remove the hydraulic drive screws to detach the drive motor from the adapter 2 Remove the 2 motor mounting screws from the pinion housing and set them aside The hydraulic motor adapter Includes screws for mounting to the pinion housing Figure 5 48 Remove the pinion housing motor mounting screws and store them secure place 3 A
130. tion 1910 133 Eye and Face Protection and American National Standards Institute ANSI Z87 1 Occu pational and Educational Eye and Face Protection Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 2 Safety Safe Operation the 8 Hearing Protection This equipment can produce noise levels above 80 dB Hearing protection 15 required when operating the equip ment 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 SAFE OPERATION OF THE LCSF Intended Uses The low clearance split frame is designed to O D mount on in line or open ended pipe and perform cut off and weld prep beveling counterboring and J prep operations It uses cold cutting lathe techniques with a variety of acces sories and tooling for different cutting applications Make sure to follow all safety guidelines and procedures required for machining operations at the work site including personal protective equipment PPE Do not use the LCSF in a manner that violates these guidelines Proper Use of the LCSF The LCSF should only be used by trained qualified operators The workpiece must be within the operating capacity of the L
131. ttach the hydraulic motor adapter to the pinion hous ing and securely tighten the 2 screws 90 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 5 Operating Instructions Install Tool Slides and Tooling Figure 5 49 Attach the hydraulic drive adapter to the pinion housing E Figure 5 50 Tighten the 2 screws holding the hydrau lic drive adapter to the pinion housing 4 Insert the hydraulic motor shaft through the adapter so that the square shaft fits into the pinion Turn the y NOTE motor as required to align the shaft and fully seat the motor flange on the adapter The drive shaft fits snugly into the socket in the pinion You may have to wiggle the drive to insert the shaft into the socket E H Wachs Part No 60 MAN 07 Rev 0 0311 91 Low Clearance Split Frame Models 204 1420 Figure 5 51 Insert the hydraulic drive shaft through the adapter so that the square drive fits into the pinion socket 5 Attach the motor to the adapter using the 2 screws pro vided Tighten the screws securely Figure 5 52 Tighten the 2 screws holding the drive to the adapter 92 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 5 Operating Instructions Cutting Operation Connect the hydraulic hoses to the motor as shown Make sure the pressure and return tank lines are con nected to the correct fittings Figure 5 53 Connect the hydraulic hoses to the drive as shown
132. ure 5 67 Turn the radial feed handle until the tool lightly touches the pipe 3 Adjust the counterbore slide for the first cut by turning NOTE the radial toolslide feed screw clockwise each revolu Turn axial feed tion is 0312 knob clockwise to move the tool away from the pipe face F igure 5 68 Adjust the counterbore slide by turning the radial feed screw clockwise E H Wachs Part No 60 MAN 07 Rev 0 0311 103 Low Clearance Split Frame Models 204 1420 NOTE The incremental y decal on the radial feed handle is not the radial feed depth indica tor Each line on the decal irepresents a 020 cut on the overall D Figure 5 69 Axial 0312 and radial 0784 adjust ment per revolution 0 375 0 60 Doo dei Three passes Figure 5 70 First pass of the counterbore tool 4 Engage air motor and set the speed at approximately 6 8 rpm 5 Hold the axial feed handle as the machine rotates This feeds the tool into the pipe 6 Once the tool begins to cut release the axial feed han dle Holding the feed handle for approximately 1 4 104 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 5 Operating Instructions Operating LCSF Accessories turn per revolution will feed the tool into the pipe gradually The longer the handle is held the greater the feed rate observe the depth of the counterboring operation As Cutting chips are soon as the desired
133. veling tool should be about 1 8 3 mm from the pipe surface 9 Rotate the machine manually to make sure the tool clears all the way around the pipe E H Wachs Part No 60 MAN 07 Rev 0 0311 81 Low Clearance Split Frame Models 204 1420 Figure 5 34 Rotate the machine to check tool clear ances Dual Tooling Setup You can stack parting and beveling tools in the beveling slide to prevent tool binding on heavy wall pipe This setup helps clear chips as the cutting groove deepens F 5 35 You use combination of parting and beveling tools in the beveling slide 82 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 5 Operating Instructions Install Tool Slides and Tooling Install the required parting toolin the parting slide tool holder Set the cutting tip of the tool 1 16 from the surface of the pipe and tighten the screws in the tool Cover Install the required beveling tool the beveling slide tool holder Set the cutting edge of the beveling tool 1 16 from the surface of the pipe Snug the screws on the beveling tool cover then securely tighten the screw s on the tool block holding the side of the tool Number of screws depends on the slide model Loosen the screws in the beveling tool cover and insert the parting tool on top of the beveling tool Figure 5 36 Insert the tooling as shown with the off set between the parting blades at 1 16 in
134. with 2 extension blocks and 3 sizes of screws for the 3 con figurations no block 1 block or 2 blocks 1 Pull out the trip lever swivel and remove the lever from the trip assembly Figure 5 40 Pull out the pin and remove the trip lever E H Wachs Part No 60 MAN 07 Rev 0 0311 85 Low Clearance Split Frame Models 204 1420 2 Ifextension blocks are required align the block s with the bottom of the trip mount Stack the blocks so that the raised tabs on the top interlock with the slot on the bottom of the adjacent piece EI Figure 5 41 Use the required number extension blocks for the slide position 3 Insert the required screws through the base of the trip mount and the holes the extension block s as shown above 4 trip assembly in place on the stationary ring and tighten the three screws Figure 5 42 The trip assembly is shown with 2 exten sion blocks corresponding to the slides in the high position 86 Part No 60 MAN 07 Rev 0 0311 E H Wachs Chapter 5 Operating Instructions Install Tool Slides and Tooling Put the trip lever in place with the fork in the lever engaged on the trip plunger Insert the swivel pin Push the trip lever down to disengage the trip Figure 5 43 Push the trip lever down to lift the trip pin into the disengaged position Time the starwheel feed system and take all the backlash out of

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