ICC Casing Cutting Manual
Contents
1. H M OF a y Lm ME 11 3 Cutting drive connectors Figure 5 16 The cutting drive hoses are on the right hose spool at the back of the control station They con nect to the smaller pair of connectors on the cutting machine 32 Part No 05 048 MAN Rev 0 0206 E H Wachs Company Internal Casing Cutter User s Manual Chapter 5 Operating Instructions 4 Poweron the HPU and set it to operate at the specific flow rate and pressure 8 15 gpm at 2000 psi 30 57 Ipm at 140 bar 5 Use the power pendant supplied with the HPU to con trol the hydraulic power Figure 5 17 HPU power pendant POSITIONING THE MACHINE FOR CUTTING When lifting the ICC cutting machine be sure not to set it upright so that its weight is resting on the slides This could damage the slides Attach the lift to the lift ring on top of the cutting machine 2 Liftthe machine carefully until it is suspended freely 3 Position the cutting machine over the casing Guide it carefully into the casing while slowly lowering it 4 Lowerthe machine to the desired position while care fully feeding the hydraulic hoses into the casing 5 When the machine is at the cutting position pull the clamping hydraulic lever toward you to engage the clamping feet 6 Watch the gauge on the Clamping lever When the pressure on the gauge jumps the feet will be clamped against the inside wall of the casing E H W2. Figure 5 9 Insert the tool into the slide with the engraved red line up 6 Looking down through the slot in the top of the slide align the red line on the tool with the mark for the size of casing you are cutting 28 Part No 05 048 MAN Rev 0 0206 E H Wachs Company Internal Casing Cutter User s Manual Chapter 5 Operating Instructions Figure 5 10 Align the tool so that the red line is on the mark for the casing size you are cutting 7 5 8 in this photo 7 Tighten the three screws on top of the slide to secure the tool 8 Repeat steps 2 7 for the other slide 9 Mount both slides on the cutting machine in the cor rect position inner or outer for the casing size you are cutting 10 Select the appropriate trips for the casing size you are cutting There are four different trip assemblies with different sized spacers 5 8 spacer No spacer 8 5 8 casing 7 casing 9 5 8 casing 7 5 8 casing Figure 5 11 Trips for the small cutting machine E H Wachs Company Part No 05 048 MAN Rev 0 0206 29 Chapter 5 Operating Instructions Internal Casing Cutter User s Manual 2 1 2 spacer 1 7 8 spacer 13 3 8 casing 10 3 4 casing 11 3 4 casing Figure 5 12 Trips for the large cutting machine 11 Attach the trip to the cutting machine flange so that the trip pin will contact the star wheel Tighten the two screws to secure the trip assembly Figure 5 13
3. Look for this symbol throughout the man ual It indicates a safety warning E H Wachs Company Part No 05 048 MAN Rev 0 0206 Chapter 2 Safety Internal Casing Cutter User s Manual Always turn machine off before doing any adjustments or service e SECURE LOOSE CLOTHING AND JEWELRY Secure or remove loose fitting clothing and jewelry and securely bind long hair to prevent them from getting caught in moving parts of the machine KEEP WORK AREA CLEAR Keep all clutter and nonessential materials out of the work area Only people directly involved with the work being performed should have access to the area Protective Equipment Requirements WARNING Always wear impact resistant eye pro tection while operating or working near this equipment For additional information on eye and face protection refer to Federal OSHA regulations 29 Code of Federal Regula tions Section 1910 133 Eye and Face Protection and American National Standards Institute ANSI Z87 1 Occu pational and Educational Eye and Face Protection Z87 1 is available from the American National Standards Institute Inc 1430 Broadway New York NY 10018 CAUTION Personal hearing protection is recom mended when operating or working near this tool Hearing protectors are required in high noise areas 85 dBA or greater The operation of other tools and equipment in the area reflective surfaces process noises and resonant stru
4. 1 05 048 023 MODIFICATION CLAMP CYLINDER 1 105048020 MODIFICATION DRIVEMOTOR_____ 6 102 078 0984 LEG CHUCK 1 SMALYWH325 RING RETAINING 3 25 INTERNAL 1 LAMINAA125F EI DRIVE 1 SHEFFER 2MHFX2 0625CCK CYLINDER CLAMP 1 TORRINGTON AW10AK_ BEARING SEALEDBALL O 1 TORRINGTON IRA 1012 BEARING SEALED NEEDLE 1 TORRINGTON JT 149 RACE NEEDLE 6 LEE LC 063L 1 S SPRING 1 0 DIA X 3 4 LG Compression 1 MCMASTER CARR 1446K1 0 GREASE TUBE BEL RAY Synthetic Molylube 65 SHCS 3 8 16 x 1 LG SHCS 5 16 18 x 2 3 4 LG 16 912744168 3 SHOS 1 4 20 x 7 8 LG SHOS 1 4 20 x 5 8 LG 6 92562A234 SCS 1U24x1 2 LG 6 922104581 FHCS 5 16 18 x 3 4 LG 8 902984535 14x3 8SHOULDERBO T 8 983804537 PINDDOWELT Ax1 2LG 18 92383A702 PIN ROLLi 8x1 1 A LG I ERE M gt 98370A019 E H Wachs Company Part No 05 048 MAN Rev 0 0206 49 Chapter 8 Parts Lists and Drawings Internal Casing Cutter User s Manual Large Machine ay Panno est S i i 2 2 2 2 i i i i 6 i i i i i i i i i i RACE NEEDLE i 2 i E i 2 SHCS 38 16 x 1 LG 4 L oje E AJo AJ aoe G 18 i 3 98570A019 _ 4 50 Part No 05 048 MAN Rev 0 0206 E H Wachs Company Internal Casing Cutter User s Manual Chapter 8 Parts Lists and Drawings
5. CONTROL STATION Manufactured Parts Qty Part No Description 4 4 2 2 i i i 2 2 2 i i 2 i i i i i i i i i i E H Wachs Company Part No 05 048 MAN Rev 0 0206 51 Chapter 8 Parts Lists and Drawings Internal Casing Cutter User s Manual Purchased Parts Qty PartNo Description 2 2 2 3 8 Hyd Hose Assembly 2 1 1 2 1 1 4 12 2 3 1 i 1 i PRESSURE GAUGE 200 PSI 52 Part No 05 048 MAN Rev 0 0206 E H Wachs Company Internal Casing Cutter User s Manual Chapter 9 Accessories Chapter 9 Accessories and Spare Parts There are no standard accessories for the internal casing cutter All required components are included with the machine Table 1 lists recommended spare parts Part No no assembly number Description Clamping legs for small cutting machine no assembly number Clamping legs for large cutting machine no assembly number Trip assemblies for small cutting machine no assembly number 05 048 700 05 048 011 Trip assemblies for large cutting machine Cutting tool Trip housing Aa no photo available Table 1 Spare Parts for the Internal Casing Cutter E H Wachs Company Part No 05 048 MAN Rev 0 0206 53 Chapter 9 Accessories Internal Casing Cutter User s Manual Part No Description 05 048 026 Trip pin no photo available 05 048 017A Tri
6. Slide alignment dowel pins Figure 3 3 The face of the cutting machine is shown E H Wachs Company Part No 05 048 MAN Rev 0 0206 11 Chapter 3 Introduction to the Internal Casing Cutter Internal Casing Cutter User s Manual TooLiNG SETUP COMPONENTS The slides tooling and accessories are stored in a toolbox that is kept in the control station Figure 3 4 Slides and tooling are stored in the tool box Keep the box strapped securely in the control sta tion when you are not using the machine Slides There are two sets of slides provided with the ICC The standard set of slides shown in Figure 3 5 is used with the smaller cutting machine for the following casing diame ters 7 e 7 5 8 e 8 5 8 e 9 5 8 The extended slides shown in Figure 3 6 are used for the following casing diameters e 10 3 4 e 1 3 4 e 13 3 8 12 Part No 05 048 MAN Rev 0 0206 E H Wachs Company Internal Casing Cutter User s Manual Chapter 3 Introduction to the Internal Casing Cutter Figure 3 5 The standard slides are used for cutting smaller sized casings Figure 3 6 The extended slides have longer mounting plates to position the slides for cutting larger sized casings Clamping Legs The clamping legs hold and center the ICC cutting machine inside the casing There are seven different sized legs one for each casing size Six legs of each size are provided three legs are mo
7. 020 e esse eee eee ees 53 Chapter 10 Ordering Information 00 00sec eee eee eee 55 Ordering Replacement Parts 20 cece eee eee eee eee nennen 55 Repair Information TTL 55 Warranty Information auda xt ex e RE d Xe o CREE HR UR e REA Bes 56 Return Goods Address 2 295r xi n 2 ARR AA RAS 56 Part No 05 048 MAN Rev 0 0206 E H Wachs Company Internal Casing Cutter User s Manual Chapter 1 About This Manual Chapter 1 About This Manual PURPOSE OF THIS MANUAL This manual explains how to operate and maintain the inter nal casing cutter system It includes instructions for assem bly set up operation and maintenance It also contains parts lists assembly diagrams and troubleshooting instruc tions to help you order replacement parts and perform user serviceable repairs Before operating your internal casing cutter you should read through this manual and become familiar with all instructions At a minimum make sure you read and under stand the following chapters Chapter 1 About This Manual e Chapter 2 Safety e Chapter 3 Introduction to the Internal Casing Cutter e Chapter 5 Operating Instructions If you will be performing service or repairs make sure you read and understand these chapters e Chapter 1 About This Manual e Chapter 4 Assembly and Disassembly e Chapter 6 Routine Maintenance e Chapter 7 Service and Repair You will also want to refer to Chapter 8 Parts Lis
8. 55 Chapter 10 Ordering Information Internal Casing Cutter User s Manual WARRANTY INFORMATION Enclosed with the manual is a warranty card Please fill out the registration card and return to E H Wachs Company Retain the owner s registration record and warranty card for your information RETURN GOODS ADDRESS Return equipment for repair to the following address E H Wachs Company 100 Shepard Street Wheeling Illinois 60090 USA 56 Part No 05 048 MAN Rev 0 0206 E H Wachs Company
9. The trip assembly fastens to the front flange of the cutting machine with two screws 12 Rotate the star wheel so that one point of it is perpen dicular to the trip pin 30 Part No 05 048 MAN Rev 0 0206 E H Wachs Company Internal Casing Cutter User s Manual Chapter 5 Operating Instructions ATTACHING THE HYDRAULIC HosES Attach the hoses from the hydraulic power unit HPU to the connectors on the front of the control station beneath the hydraulic controls Figure 5 14 The hydraulic connectors to the HPU are under the hydraulic controls on the front of the control station 2 The hoses for the clamping drive are on the left reel in the back of the control station Pull out the hoses and attach them to the clamping drive connectors on the cutting machine Make sure both hydraulic control levers are in the center disen gaged position before attaching the hoses E H Wachs Company Part No 05 048 MAN Rev 0 0206 3l Chapter 5 Operating Instructions Internal Casing Cutter User s Manual Clamping drive connectors Figure 5 15 The clamping drive hoses are on the left hose spool at the back of the control station They con nect to the larger pair of connectors on the cutting machine 3 The hoses for the cutting drive are on the right reel in the back of the control station Pull out the hoses and attach them to the cutting drive connectors on the cut ting machine
10. Feed Nut and Screw 000 c eee 41 Chapter 8 Parts Lists and Drawings llle 43 Base Cutting Machine Parts leeeeeeeeeee enne 44 Manutacturgd Paris nk mnt iei tec ice E ad ORDRE CN RUD EORR 44 Purchased URANUS sad ti beter mast MA cie nire DRM M pa rade ted ut Lini a 44 FaSteners sr aro hada ee A A edu A Ad CA ed edu ee dod ah arce ad ec e ded 45 Small Cutting Machln 12 12 ea a S E 45 Manutactured Pans 2 222 2 ewe A Yates ei sau 45 Purchased Paris o ofr Ma Md pea LA Ded LM E 46 Fasteners zu E eR rant e OUR UR et e d a C ea wee ew aod eae i ers 46 Large Cutting Machine Lco ER ERR et es EE ERR ER ERRAT ERES 46 Manufactured Pans ns eR eek e SEE EUREN ER RIP ERE a 46 P rchased Pas ar nee en ARE ee ser mt AA d Ted 47 Fasteners sita ER an Ra ae ae non Had acr Biken EOS en 47 TooliNg ans 47 Emergency Repair Parts 5 55 sers E xxx ana 48 SmallMachina oeste Sore soie drei esc Een Iba e Eo dq IA cas 48 Large Machine traci n de Die eM i roa cbe EO ca I Bde Bt a SAN ca Bak D S 48 Overnaul Hebulld KIEL ome nd Uum Heu re had ta end 49 Shall CIR eg cain e E Ran A NR Ae modos t t qe aca o x ar ac Foe a ae E 49 Large Machine eii nete d o eee I Y ERE REE eee e wei a uh 50 Control Station gt np y ES em t is A ee 51 Manulactured Pals esie LEE DER EU Xa ERES EAE Kad m ede td ud 51 F rghased Paris epa su yana eve e the toe rd a R dio e bh ta e 52 Chapter 9 Accessories and Spare Parts 0
11. MAN Rev 0 0206 Chapter 2 Safety Internal Casing Cutter User s Manual 8 Part No 05 048 MAN Rev 0 0206 E H Wachs Company Internal Casing Cutter User s Manual Chapter 3 Introduction to the Internal Casing Cutter Chapter 3 Introduction to the Internal Casing Cutter Read this chapter carefully to become familiar with the components of your Internal Casing Cutter ICC system The ICC system includes two cutting heads and two slide assemblies for easy setup and optimized cutting perfor mance on a variety of casing diameters An integrated con trol station allows remote setup and operation of the cutting units USAGE AND APPLICATIONS The Internal Casing Cutter system performs fast clean spark less cold cutting of well casings from 7 inches to 13 3 8 inches in diameter A hydraulic powered self centering clamping mechanism provides easy setup at any location within the casing Remote machine control and a self advancing trip mechanism mean that cutting is fast and nearly automatic The ICC is designed to be operated in a vertical casing A lift hook on the cutting head allows you to lower the head with a cable or chain to the desired cutting location within the casing CUTTER COMPONENTS There are two cutting machines supplied with the ICC sys tem One is for cutting casings from 7 to 9 5 8 in diame In This Chapter USAGE AND APPLICATIONS CUTTER COMPONENTS TOOLING SETUP COMPONENTS CONTROL
12. STATION E H Wachs Company Part No 05 048 MAN Rev 0 0206 Chapter 3 Introduction to the Internal Casing Cutter Internal Casing Cutter User s Manual The cutting and clamping drive By hoses have differ ent sized connectors so it is not possible to hook them up incorrectly ter the other is for casings 10 3 4 to 13 3 8 in diameter The cutting machines are identical except for an external gearbox on the larger one This gearbox reduces the rotation speed so that the linear speed of the cutting tool is approxi mately the same for large as well as small casings Figure 3 1 The cutting machine for smaller casings is on the left and the machine for larger casings with the external gearbox is on the right Hoses and lift assemblies have been removed Each machine has two sets of hydraulic hoses one for rotat ing the cutting drive and one for engaging the clamping legs These hoses and other components are illustrated in Figure 3 2 10 Part No 05 048 MAN Rev 0 0206 E H Wachs Company Internal Casing Cutter User s Manual Chapter 3 Introduction to the Internal Casing Cutter Hydraulic connectors for motor drive Hydraulic connectors for leg clamping drive Lift hook Drive motor Clamping leg mounting holes 8 on each flange six total Slide mounting plate Figure 3 2 The photo illustrates the components of the ICC cutting machine 7 Holes for slide mounting screws
13. customer service at sales wachsco com E H Wachs Company Part No 05 048 MAN Rev 0 0206 Chapter 1 About This Manual Internal Casing Cutter User s Manual 4 Part No 05 048 MAN Rev 0 0206 E H Wachs Company Internal Casing Cutter User s Manual Chapter 2 Safety Chapter 2 Safety The E H Wachs Company takes great pride in designing and manufacturing safe high quality products We make user safety a high priority in the design of all our products Read this chapter carefully before operating your internal casing cutter It contains important safety instructions and recommendations OPERATOR SAFETY Follow these guidelines for safe operation of your internal casing cutter READ THE OPERATING MANUAL Make sure you understand all setup and operating instructions before you begin INSPECTMACHINE AND ACCESSORIES Before starting the machine look for loose bolts or nuts leak ing lubricant rusted components and any other physical conditions that may affect operation Properly maintain ing the machine can greatly decrease the chances for injury ALWAYS READ PLACARDS AND LABELS Make sure all placards labels and stickers are clearly legible and in good condition You can purchase replacement labels from E H Wachs Company KEEP CLEAR OF MOVING PARTS Keep hands arms and fingers clear of all rotating or moving parts In This Chapter OPERATOR SAFETY SAFETY LABELS MACHINE SAFETY
14. Clamping Leds Ln 13 THp ASSOMDIIGS 12 5 ias mentem ee RR ea ete eed bende be ek 14 BURN TOOS m ri r a E ee eii ane qol IR n iaa 15 Control Station 595 22 id uL else ed ie sated mide es ae id 15 Chapter 4 Assembly Disassembly and Storage 19 Storing Components in the Control Station 00 ce eee ee 19 Long Tetm Storage 22 coacciones Hate ee sn eens cease dene eee 22 SHIPPING 244324 2 ee WE ean es RIA Re id EEA 22 Chapter 5 Operating Instructions 00 cece eee eee ee 23 Selecting and Configuring the Cutting Machine sse 23 Installing the Slides and Tooling llle 25 Attaching the Hydraulic Hoses 2000s 31 Positioning the Machine for Cutting lessen 33 Performing the Gut o2 ox sa es CRI PI Sume He ipe ets Ecl des MEAM 34 Removing the Machine oooooccccnnnc ee eee eee eee 35 Removing the Machine from the Casing 0 00 eee tee 36 Removing the Casing with the Machine 000 tee 36 Setup Chart ansehen 37 Chapter 6 Routine Maintenance 0 00 c cee eee eee eee 39 Machine Lubrication uia ea ues ROC rarae RC a Een 39 Hydraulic System uoo bur per eR RIED ERG Mh EPA er RI ci eee wee 39 Internal Casing Cutter User s Manual Chapter 7 Service and Repair sllleeesseees 41 Adjusting the Starwheel Tension 00 eee eee eee eee eee 41 Inspect Tool Slide
15. Cut lever Make sure the casing is cut through and that you can lift it free If you cannot lift it engage the Retract Cut lever again to fully penetrate the casing REMOVING THE MACHINE You can either leave the casing in place while you remove the machine or lift the casing out with the machine still clamped in place Either way first retract the slides to avoid damaging the machine when you remove it 1 Once the cut is complete push the Retract Cut lever away from you to retract the slides Run the machine about 30 seconds longer than the cutting time to make sure the slides are fully retracted E H Wachs Company Part No 05 048 MAN Rev 0 0206 35 Chapter 5 Operating Instructions Internal Casing Cutter User s Manual Figure 5 20 Retract the slides by pushing the Retract Cut lever away from you and running the machine 30 seconds longer than the cutting time Removing the Machine from the Casing If you are lifting the casing out with the machine in place lift it carefully without moving the Clamping hydraulic lever Removing the Casing with the Machine If you are lifting the ICC machine out of the casing first make sure the chain or cable supporting the ICC machine is not slack 36 Part No 05 048 MAN Rev 0 0206 E H Wachs Company Internal Casing Cutter User s Manual Chapter 5 Operating Instructions SETUP CHART The following chart describes all machine configuration option
16. FEED NUT AND SCREW E H Wachs Company Part No 05 048 MAN Rev 0 0206 41 Chapter 7 Service and Repair Internal Casing Cutter User s Manual will occasionally need to be replaced Check for any wear that allows backlash on the screw To access the feed nut and screw loosen the gib as shown in Figure 7 2 and retract the slide Push the slide Sd 3 E Loosen the two screws on this gib to free the slide access the feed nut and screw Figure 7 2 Loosen the gib screws and push the slide forward to check the feed nut and screw If there is significant wear on the nut or screw you should replace the worn component See Chapter 8 for parts infor mation and Chapter 10 for ordering instructions 42 Part No 05 048 MAN Rev 0 0206 E H Wachs Company Internal Casing Cutter User s Manual Chapter 8 Parts Lists and Drawings Chapter 8 Parts Lists and Drawings The drawing below is a reference for major parts of the ICC In This Chapter cutting machines Refer to the parts lists in this chapter for BASE CUTTING MACHINE ordering and maintenance PARTS SMALL CUTTING MACHINE LARGE CUTTING MACHINE 2 4 al TOOLING e e OIM S 11 8 H3 aat e oes EMERGENCY RE
17. Internal Casing Cutter User s Manual E H Wachs Company 100 Shepard Street Wheeling IL 60090 www wachsco com E H Wachs Company Part No 05 048 MAN Rev 0 0206 February 2006 Revision History February 2006 Copyright 2006 E H Wachs Company All rights reserved This manual may not be reproduced in whole or in part without the written consent of E H Wachs Company Internal Casing Cutter User s Manual Part No 05 048 MAN Rev 0 0206 E H Wachs Company Table of Contents Chapter 1 About This Manual 0000 cece eee eee 1 Purpose of This Manual 4 en aire to Rx cae x el n RR RU a Cn Lg cmn EUR wa ee D ON 1 How to Use The Manual 2 42 m er hh eee a RC Un 2 Symbols and W rnings 2 siii f Steed D Bor RR RIEN a pe eee Rods 2 Manual Updates and Revision Tracking esee 3 Chapter 2 Safely s u0uuu u 00 aa audax ke xa ra Ree RR X n n 5 Operator Safety v o 2 ecu sees ea ea 5 Protective Equipment Requirements 020 nennen eee 6 Operating Recommendations 2222er seen een en tees 7 Safety L belS sica ao ae a a SR era 7 Machine Saf ly 15 920 0x0 os Rege ee EI Es 7 Chapter 3 Introduction to the Internal Casing Cutter 9 Usage and Applications u dusk ke eX AAA A 9 Cutler Components 2c e eine 9 Tooling Setup Components seeseeeeeee nn I nnn 12 SILES ues pss aati a y UE sd E Maced hone BU ED Mati dico UTR 12
18. PAIR PARTS E en Gly se com R m ae T us Be OVERHAUL REBUILD KIT 0 GES e gt N amp E gy co o T m Zl wes CONTROL STATION e 2 oc ak I Ole 38 LO wed Z S 58 Hung Q MBE CAN lt N 9 u Glo T o 0D UV am Lent A E H Wachs Company Part No 05 048 MAN Rev 0 0206 43 Chapter 8 Parts Lists and Drawings Internal Casing Cutter User s Manual BASE CUTTING MACHINE PARTS The following parts are used in both cutting machine assemblies Manufactured Parts Qty Part No Description 6 05048024 GUIDE CLAMPLEG________________ 6 02078 0504 LEG CHUCK Purchased Parts Qty Part No Description XxX MAT MEGAFLEX 2 GATES G251 70 0406 FEMALE JIC HOSE END 1 4 ID HOSE PARKER 6 WTX BULKHEAD UNION 44 Part No 05 048 MAN Rev 0 0206 E H Wachs Company Internal Casing Cutter User s Manual Chapter 8 Parts Lists and Drawings Fasteners Qty Part No Description 2 91274A308 SHCS 3 8 16 x 1 LG 2 6 912744172 SHCS 1 4 20 x 1 LG 8 912744168 SHCS 1 4 20 x 7 8 LG 6 922104581 FHCS 5 16 18 x 3 4 LG PIN DOWEL 1 4 x 1 LG 8 983804537 PIN DOWEL 1 4 x 1 2 LG PIN ROLL 1 8 x 1 1 4 LG NUT 3 8 16 HEAVY HEX 98370A019 WASHER 3 8 HEAVY SMALL CuUTTING MACHINE The parts listed in this section are specific to the small cutting machine Manufactured Parts Q
19. TTING MACHINE 1 Select the appropriate cutting machine for the size of the casing you are cutting Large T cutter has external gearbox Small Cutter Large Cutter 7 casing 10 3 4 casing 7 5 8 casing 11 3 4 casing 8 5 8 casing 13 3 8 casing 9 5 8 casing Figure 5 1 Cutting machines and associated casing sizes In This Chapter SELECTING AND CONFIGUR ING THE CUTTING MACHINE INSTALLING THE SLIDES AND TOOLS ATTACHING THE HYDRAULIC HOSES POSITIONING THE MACHINE FOR CUTTING PERFORMING THE CUT REMOVING THE MACHINE SETUP CHART E H Wachs Company Part No 05 048 MAN Rev 0 0206 23 Chapter 5 Operating Instructions Internal Casing Cutter User s Manual CAUTION Make sure you use six legs of the same size Having an incorrect leg will cause the machine to mount off center and damage the slides or other components 2 Selectthe clamping legs for the size of the casing You will use six legs three in each of the flanges T 7 5 8 8 5 8 9 5 8 casing casing casing casing Figure 5 2 Clamping legs for the small cutting machine 10 3 4 11 3 4 13 3 8 casing casing casing Figure 5 3 Clamping legs for the large cutting machine 3 Screw one of the legs into each clamping leg mount ing hole on the cutting machine Insert a 9 64 hex wrench into the end of each leg and tighten it securely 24 Part No 05 048 MAN Rev 0 0206 E H Wach
20. achs Company Part No 05 048 MAN Rev 0 0206 33 Chapter 5 Operating Instructions Internal Casing Cutter User s Manual Be careful NOT to push the Clamp ing lever forward and loosen the clamping legs It is recommended that you time the Ay cut so that you will know how long to retract the slides once the cut is com plete Figure 5 18 Pull the Clamping lever toward you to clamp the machine in place inside the casing Return the lever to the center position 7 Return the Clamping lever to the center position PERFORMING THE CUT Make sure you have the casing above the cut position sup ported with a crane or lift so that it is pulled free when the cut is complete The Clamping hydraulic lever must be in the center position labeled CUT before you start cutting Pull the Retract Cut hydraulic lever toward you to engage the machine in the forward cutting direction 34 Part No 05 048 MAN Rev 0 0206 E H Wachs Company Internal Casing Cutter User s Manual Chapter 5 Operating Instructions Figure 5 19 Pull the Retract Cut lever toward you to start the machine Make sure the Clamping lever on the right is in the center position Watch the pressure gauge on the Retract Cut lever as the machine advances The pressure will increase as the tool contacts the casing and begins to cut When the cut is complete the pressure on the Retract Cut gauge will drop Release the Retract
21. c 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 S12 6 Hearing Protectors Part No 05 048 MAN Rev 0 0206 E H Wachs Company Internal Casing Cutter User s Manual Chapter 2 Safety Operating Recommendations CAUTION Some people experience chronic pain in their hands and arms when performing repetitive tasks or operating vibrating equipment Repetitious forceful exertion of the hands and arms can cause or aggra vate disorders such as carpal tunnel syn drome and tendonitis Use minimum hand grip force e Keep your wrists straight e Avoid prolonged continuous exposure to vibration e Avoid repeated bending of your wrists and hands e Keep your hands and arms warm and dry SAFETY LABELS There is no safety labeling on the internal casing cutter machine MACHINE SAFETY To avoid damaging your internal casing cutter follow these usage guidelines Make sure the hydraulic supply is within the specifica tion 8 15 gpm 30 57 lpm at 2000 psi 140 bar e Operating the drive motor and clamping leg drives while greasing them e Keep the caps on the hydraulic connectors at all times when the hoses are not attached e Always store all components in the control station when they are not in use E H Wachs Company Part No 05 048
22. en tighten the correct pair of screws on each slide 26 Part No 05 048 MAN Rev 0 0206 E H Wachs Company Internal Casing Cutter User s Manual Chapter 5 Operating Instructions When the slides are mounted in the inner position they will CAUTION Make be about 1 8 inch apart in the center In the outer position sure both slides they will be about 1 1 2 inch apart are mounted in the same posi tion inner or Take out the set of slides for the cutting machine you outer Mounting are using Set them on a level work surface slides in different positions can cause severe damage to 2 Turn the star wheel until the base of the slide is flush with the mounting dovetail the machine Base of slide Dovetail Faces are flush Figure 5 7 Pre position the slide and dovetail to be flush for the starting position 3 Tum the star wheel 1 2 turn in the forward counter clockwise direction to take any slop out of the gear 4 Ifnecessary loosen the three tool mounting screws on the top of the slide E H Wachs Company Part No 05 048 MAN Rev 0 0206 27 Chapter 5 Operating Instructions Internal Casing Cutter User s Manual The tool will only fit into the slide in one orientation f Three screws hold the tool in the slide Figure 5 8 Loosen the screws before inserting the tool into the slide 5 Insert the tool into the slide above the star wheel with the engraved red line up
23. ling are stored in the toolbox on the control station Make sure the toolbox is securely latched and is strapped into its com partment before moving or transporting the system Figure 4 1 Store all tooling and accessories in the toolbox on the control station In This Chapter STORING COMPONENTS LONG TERM STORAGE SHIPPING E H Wachs Company Part No 05 048 MAN Rev 0 0206 Chapter 4 Assembly and Disassembly Internal Casing Cutter User s Manual The cutting machines are stored vertically in their compart ments with the cutting face down Use the following proce dure to store the cutting machines Remove the storage rod from the cutting machine compartment Figure 4 2 Remove the storage rod for the compart ment you will be putting the cutting machine into 2 Using a strap or chain attach a lift to the lift hook on the top end of the cutting machine You can put either 3 Lift the cutting machine over the control station and cutting machine lower it carefully into one of the storage compart into either storage ments compartment 4 The bottom end of the machine will rest on the bottom of the compartment Rotate the machine so that you will be able to insert the storage rod through the lift hook 5 Put the storage rod through the side of the compart ment and through the lift hook 20 Part No 05 048 MAN Rev 0 0206 E H Wachs Company Internal Casing Cutter User s Manual Chapter 4 As
24. m age to the equipment or to the component being serviced NOTE This symbol indicates a user notice Notices provide additional information to supplement the instructions or tips for easier operation Part No 05 048 MAN Rev 0 0206 E H Wachs Company Internal Casing Cutter User s Manual Chapter 1 About This Manual MANUAL UPDATES AND REVISION TRACKING Occasionally we will update manuals with improved opera tion or maintenance procedures or with corrections if nec essary Revised chapters will be available for customers If you receive revised chapters for your manual remove the old chapters from your binder and replace them with the new chapters When a manual is revised we will update the revision his tory on the title page and at the bottom of the pages in the revised chapters It is important to put the current title page with the revision history in your manual This will help you make sure you have all current information You may have factory service or upgrades performed on your internal casing cutter If this service changes any tech nical data or operation and maintenance procedures we will include revised sections of the manual when we return the equipment to you Remove the old chapters from your man ual and replace them with the revised chapters Current versions of E H Wachs Company manuals are also available in PDF for mat You can request an electronic copy of this manual by emailing
25. o Deseripti n SHCS 5 16 18 x 2 1 2 LG SHCS 1 4 20 x 3 1 2 LG 8 912744172 SHCS 1 420x1 lG 8 912744168 SHCS 1 420x7 8 lG 6 92562223 SHCS 10 24 x 1 2 LG LHCS 1 4 20 x 5 8 LG 8 90298A535 1 4x3 8SHOULDERBOLT 1 4 x 1 SHOULDER BOLT PIN DOWEL 1 4 x 1 2 LG TOOLING Qty Part No Description TOOL PARTING CARBIDE HOLDER PARTING TOOL WRENCH SANDVIK N151 2 250 5E GRADE 2145 INSERT PARTING TOOL _____ SANDVIK N151 2 250 02 9E GRADE 4125 INSERT PARTING TOOL INSERT PARTING TOOL E H Wachs Company Part No 05 048 MAN Rev 0 0206 47 Chapter 8 Parts Lists and Drawings Internal Casing Cutter User s Manual EMERGENCY REPAIR PARTS Small Machine PartNo 1 Description 1 1 1 05 048 017A MCMASTER CARR 94800A700 SHCS 1 4 20 x 7 8 LG PIN DOWEL 1 8 x 3 4 LG Large Machine Qty PartNo Description 6 02 078 295 7 FOOT 10 3 4 13 3 8 CHUCK SHCS 1 4 20 x 2 3 4 LG 48 Part No 05 048 MAN Rev 0 0206 E H Wachs Company Internal Casing Cutter User s Manual Chapter 8 Parts Lists and Drawings OVERHAUL REBUILD KIT Small Machine Qty Part No Description O 1 05048008 CE GEAR RING 1 105048000 GEAR PINION 1 105048021 ROD DRAWBAR
26. p spacers no photo available 05 048 017B 05 048 017C 02 078 035 8 02 078 035 7 Clamping foot 7 through 9 5 8 Clamping foot 10 3 4 through 13 3 8 no photo available Table 1 Spare Parts for the Internal Casing Cutter 54 Part No 05 048 MAN Rev 0 0206 E H Wachs Company Internal Casing Cutter User s Manual Chapter 10 Ordering Information Chapter 10 Ordering Information To place an order request service or get more detailed information on any E H Wachs Company products call us at one of the following numbers US 800 323 8185 International 847 537 8800 ORDERING REPLACEMENT PARTS When ordering parts refer to the parts lists 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 e Your name company name e Your address e Your phone number e A brief description of the problem or the work to be done Before we perform any repair we will estimate the work and inform you of the cost and the time required to com plete it In This Chapter REPLACEMENT PARTS REPAIR INFORMATION WARRANTY INFORMATION RETURN GOODS ADDRESS E H Wachs Company Part No 05 048 MAN Rev 0 0206
27. s Company Internal Casing Cutter User s Manual Chapter 5 Operating Instructions Figure 5 4 There are three holes for clamping legs on each flange of the cutting machine INSTALLING THE SLIDES AND TOOLING Use the standard slides with the small cutting machine and the extended slides with the large cutting machine Figure 5 5 The standard slides are used with the small cutting machine left and the extended slides are used with the large cutting machine right There are two mounting positions on the cutting head inner with the slides mounted closer to the center and outer with the slides mounted further from the center E H Wachs Company Part No 05 048 MAN Rev 0 0206 25 Chapter 5 Operating Instructions Internal Casing Cutter User s Manual If the screws for the mounting posi By tion you want will not go into the holes you have the wrong alignment hole in the back of the slide on the dowel pin Re position the slide and insert the screws Each slide has a pair of inner position mounting screws and outer position mounting screws There are two sets of align ment holes on the back of each slide that fit onto the dowel pins in the cutting machine at the appropriate location Threaded mounting holes 77 Alignment _ dowel pins Outer position mounting screws Inner position mounting screws Figure 5 6 Put the slides onto the dowel pins for the required position th
28. s for each casing size Use it as a reference for setting up the machine Cutting Clamping Slides Slide Mount Trip Machine Legs Position Assembly Small 0 15 Standard Inner No spacer Small 0 50 Standard Inner No spacer Small 0 94 Standard Outer 5 8 spacer Small 1 45 Standard Outer 5 8 spacer Large 2 05 Extended Inner 1 7 8 spacer Extended 1 7 8 spacer Extended 2 1 2 spacer Table 1 Machine configurations for all casing sizes NOTE The clamping leg lengths refer to the lengths of the feet as shown in Figure 5 21 TO m piis The feet are the large diameter shafts that extend beyond the flanges of the cutting machine ae qe Figure 5 21 The legs lengths refer to the length of the larger diameter feet E H Wachs Company Part No 05 048 MAN Rev 0 0206 37 Chapter 5 Operating Instructions Internal Casing Cutter User s Manual 38 Part No 05 048 MAN Rev 0 0206 E H Wachs Company Internal Casing Cutter User s Manual Chapter 6 Routine Maintenance Chapter 6 Routine Maintenance The internal casing cutter is a durable system with little required maintenance Lubricate mechanical components regularly MACHINE LUBRICATION e Every time you use one of the cutting machines apply grease to all 4 grease fittings on the machine NOTE Connect the machine to hydraulic power and oper ate the appropriate drive while putting in the grease Grea
29. se the fittings on the hydraulic hose reel shafts and the hose reel tension knob fittings Every time you assemble the slides apply oil to the machine ways e You can dip the entire cutting machine in light oil or die sel fuel to prevent corrosion HYDRAULIC SYSTEM e Check all hoses and connections for leaks or damage each time you use the machine e Check that the hydraulic flow and pressure are correct each time you run the machine In This Chapter MACHINE LUBRICATION HYDRAULIC SYSTEM E H Wachs Company Part No 05 048 MAN Rev 0 0206 39 Chapter 6 Routine Maintenance Internal Casing Cutter User s Manual 40 Part No 05 048 MAN Rev 0 0206 E H Wachs Company Internal Casing Cutter User s Manual Chapter 7 Service and Repair Chapter 7 Service and Repair ADJUSTING THE STARWHEEL TENSION The starwheel tension is adjusted by adding or removing shims under the gib plate as shown in Figure 7 1 The star wheel should be set to about 30 Ib in tension e Ifthe starwheel is too loose take out a shim e Ifthe starwheel is too tight add a shim Loosen this gib to add or remove shims Figure 7 1 Add or remove shims under the gib to adjust the starwheel tension INSPECT TOOL SLIDE FEED NUT AND SCREW You should periodically disassemble the slide to access the feed nut and screw These components are wear items and In This Chapter MECHANICAL PROBLEMS INSPECT TOOL SLIDE
30. sembly and Disassembly Figure 4 3 Insert the storage rod through the top of the cutting machine to secure it in the compartment 6 Secure the locking pin in the end of the rod on the other side of the compartment Figure 4 4 Secure the pin to hold the storage rod in place 7 Wrap the storage strap around the cutting machine and feed the end of the strap through the slot in the storage compartment E H Wachs Company Part No 05 048 MAN Rev 0 0206 21 Chapter 4 Assembly and Disassembly Internal Casing Cutter User s Manual Figure 4 5 After putting the strap around the cutting machine in the compartment feed it through the clamp and tighten it to hold the machine securely LoNG TERM STORAGE Ifthe system has been used in a salt water environment spray it thoroughly with fresh water to remove any salt residue e Lubricate all system components according to the instructions in Chapter 6 Make sure the covers are secured fastened onto all hydraulic hose connectors e Apply a coating of machine oil to all bare metal compo nents to prevent corrosion SHIPPING The ICC system can be shipped as stored in the control sta tion Make sure all components are secured in their com partments 22 Part No 05 048 MAN Rev 0 0206 E H Wachs Company Internal Casing Cutter User s Manual Chapter 5 Operating Instructions Chapter 5 Operating Instructions SELECTING AND CONFIGURING THE CU
31. ts and Drawings In This Chapter PURPOSE OF THIS MANUAL HOW TO USE THE MANUAL SYMBOLS AND WARNINGS MANUAL UPDATES E H Wachs Company Part No 05 048 MAN Rev 0 0206 Chapter 1 About This Manual Internal Casing Cutter User s Manual Throughout this manual refer to this column for warnings cautions and notices with supplementary information 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 internal casing cutter system 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 your internal casing cutter The narrower column on the outside contains additional information such as warnings special notes and definitions Refer to it for safety notes and other information SYMBOLS AND WARNINGS The following symbols are used throughout this manual to indicate special notes and warnings They appear in the out side column of the page next to the section they refer to Make sure you understand what each symbol means and follow all instructions for cautions and warnings WARNING This symbol indicates a safety warning A warning means that there is a risk of operator injury CAUTION This symbol indicates a caution alert A caution means that there is a risk of da
32. tting heads and storage compartments for all the ICC machine components E H Wachs Company Part No 05 048 MAN Rev 0 0206 15 Chapter 3 Introduction to the Internal Casing Cutter Internal Casing Cutter User s Manual Figure 3 11 The photo shows the hose side of the control station Figure 3 12 The hydraulic controls are on the front side of the control station The lever on the left con trols the cutting rotation drive and the lever on the right controls the clamping leg mechanism 16 Part No 05 048 MAN Rev 0 0206 E H Wachs Company Internal Casing Cutter User s Manual Chapter 3 Introduction to the Internal Casing Cutter Figure 3 13 The hydraulic power system is con nected to the control station for supplying power to the cutting machine Figure 3 14 The hose reels have hand knobs to adjust the tension on the reel E H Wachs Company Part No 05 048 MAN Rev 0 0206 Chapter 3 Introduction to the Internal Casing Cutter Internal Casing Cutter User s Manual 18 Part No 05 048 MAN Rev 0 0206 E H Wachs Company Internal Casing Cutter User s Manual Chapter 4 Assembly and Disassembly Chapter 4 Assembly Disassembly and Storage The ICC system is stored and shipped in the control station which is designed with compartments for all system compo nents STORING COMPONENTS IN THE CONTROL STATION The slides clamping legs trip assemblies and all too
33. ty PartNo Description Z O 8 05 048 020 MODIFICATION SHIM 60 322 00 6 02 078 035 8 FOOT 7 THROUGH 9 5 8 CHUCK E H Wachs Company Part No 05 048 MAN Rev 0 0206 45 Chapter 8 Parts Lists and Drawings Internal Casing Cutter User s Manual Purchased Parts PartNo Description MCMASTER CARR 94800A700 NUT PUSH 8 SCREW MCMASTER CARR 94800A720 NUT PUSH 1 4 SCREW LEE LC 051D 12 M SPRING 300 DIA X 1 1 8 LG Fasteners Qty PartNo Description SHCS 1 4 20 x 1 1 2 LG 8 912744172 SHCS 1420x1i LG SHCS 1 4 20 x 5 8 LG 6 92562A234 SHCS 10 24 x 1 2 LG SHCS 8 32 x 1 LG LHCS 1 4 20 x 5 8 LG 8 90298A535 1 4x3 8SHOULDER BOLT LARGE CUTTING MACHINE The parts listed in this section are specific to the large cutting machine Manufactured Parts Qty PartNo Description O 8 05 048 020 MODIFICATION SHIM 60 322 00 6 02 078 235 7 FOOT 10 3 4 13 3 8 CHUCK 46 Part No 05 048 MAN Rev 0 0206 E H Wachs Company Internal Casing Cutter User s Manual Chapter 8 Parts Lists and Drawings Purchased Parts Description Qty Parto i SKF 6001 2RSH BEARING SEALED BALL SKF 61805 2RS1 BEARING SEALED BALL SPIROLOX RR 145 RING RETAINING 1 46 INTERNAL Fasteners Gy Parti
34. unted in each of the two flanges on the cut ting machine E H Wachs Company Part No 05 048 MAN Rev 0 0206 13 Chapter 3 Introduction to the Internal Casing Cutter Internal Casing Cutter User s Manual Figure 3 7 The four shorter clamping legs are used with the smaller cutting machine for the four smaller casing diameters Figure 3 8 The three larger legs are used with the large cutting machine for the three larger casing diameters Trip Assemblies There are four trip assemblies included with the ICC machine Each assembly has a different sized spacer to operate the trip on different casing sizes No spacer 7 and 7 5 8 casings 5 8 spacer 8 5 8 and 9 5 8 casings 14 Part No 05 048 MAN Rev 0 0206 E H Wachs Company Internal Casing Cutter User s Manual Chapter 3 Introduction to the Internal Casing Cutter 1 7 8 spacer 10 3 4 and 11 3 4 casings 2 1 2 spacer 13 3 8 casing Figure 3 9 There are four trip assemblies with differ ent spacer sizes to operate the trip on different sized casings Cutting Tools A supply of cutting tools is provided with the ICC The indi cator line is used to align the tool in the slide for the size of casing you are cutting Figure 3 10 The indicator line on the tool is used to align it in the tool block on the slides CONTROL STATION The control station includes the hydraulic machine controls hose reels for the hydraulic hoses to the cu
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