Bridge Slide Accessory for Low Clearance Split Frame
Contents
1. 09 482 l 09 EERKER 00 2Z l 09 1IN3WQT3M O vncH ALVIdWaAL I 5IO Vald 00 222 AVAL TVIXV 1491 JAVAL TIGVS 1391 NMOHS LON WVO4 LYSSNI 00 60 09 NMOHS LON 3OV3OIS ASVD 00 05 1 9S 13VHS Tl Val 007v S L S le OddhfS IYA SSH Q3 VONVIS TOOL NOLLdld2S3G 00 Zv S YIWAN Ld Vd cloicr ojonrjojoe 9 9l oz zzz 09 07 82 09 91 91 z2z 09 91 8t 09 vl i z2z 09 vL 87b 09 vl zizo Z1 87b 09 ALOE WAL 390148 TAGOW 30NS 391M9 qavl apis ebpug 4951 07 0 Z1 jqwu ssy pue sued T2 NMOHS LON 1d9 v X ANO Z 1 13312OS 89 008 06 NMOHS LON NOILVNISWOO 2 1 HON38M 60 008 06 1 Z 1 1109 343 6 660 06 0L18ci 09 Stro 8i 8ct 09 9pll S obpug 4S 1 807 91 72 CLOTS X3H OZ Z 1 LAN 01 860 06 04 487 1 09 Cv cLc 09 Cv 8cv 09 v E L X EL Z L SoOHS Z1 060 06 02 487 1 09 6 CLC 09 6 8Cv 09 A q LU assy D u e SJ ed KINO e Z1 50 06 S9 Z8Z1 09 ZE ZZZ 09 c 8cv 09 9 8 1 09 8c c4c 09 8C 8Cv 09 v X Oc v V SOHd LO0 50 06 NOSL eg 01 250 06 S9 8 L 09 vc cLc 09 vc 8cv 09 T38V1 LHOI3M2. E H Wachs 600 Knightsbridge Parkway Lincolnshire IL 60069 www ehwachs com Bridge Slide Accessory for Low Clearance Split Frame User s Manual E H Wachs Part No 60 MAN 03 Rev 3 0811 August 2011 Revision History Original February 2007 Rev 1 May 2009 Rev 2 July 2010 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 Bridge Slide Accessory for Low Clearance Split Frame Part No 60 MAN 03 Rev 3 0811 E H Wachs Table of Contents Table of Contents Chapter 1 About the Bridge SNCs i uvas ks 9s bees 2556 2056 RO ESSERE eee dees 1 Purpose of This Manual uus sac oo ea E ou Boob E co do E ra Oo as RR dc hoes l Howto Use The Mantal sasear gma puri e E seq a e E tog e eS E l SViNOOls ANd WOEBITISS usc oy eta neon EE EE ee eee ER 2 Manual Updates and Revision Tracking ae a5 ou qon dh oo os Qed AS Pu a ee Pg dnd Su vu dex ius 3 Ro on O I ve x EE EEN 9 Equipment Description 0 00 ee eee ee hrs 3 Bridge shide EEN 3a Ee beard Sa ee aot ee ee EE Ee dub oe e GEE 4 Bide de SIZ6 S ee EE e e 5 Bridge Slide LOOMING usos 39 ERE AY que eee S GO UR ed ASG eae PROMUS Aa eee oe 6 Operating EE E EE E 6 Chapter 2 DAILY sees bea 0655556 os hie oes 695658 EE 9 Safe Operating Nd EEN 9 Safe Operating Environment eg owe dea ow Papakea qae 473 drag one wad paar 10 Operating and Maintenance Safety a a 223 4 229 4 225272259 225 breed
3. Figure 3 50 With the end block loose turn the feed knob counter clockwise to remove the feed screw The knob end block and feed screw will come out of the slide Set the assembly aside in the machine storage case Using a 3 4 wrench or socket turn the castle nut to position the tip of the tool just past the O D of the pipe Figure 3 51 Turn the castle nut to position the bit just past the O D of the pipe Loosen the tool holder cover screws and move the tool holder forward to the desired cutting depth along the side of the pipe Typically about 1 4 per pass 1s appropriate multiple passes are usually required as shown in Figure 3 53 E H Wachs Part No 60 MAN 03 Rev 3 0811 51 Bridge Slide Accessory for Low Clearance Split Frame Figure 3 52 Position the tool to remove the appropriate width of cut 0 25 LI Figure 3 53 The diagram shows a compound bevel using multiple passes Set the tool holder depth about 1 4 further back along the pipe O D for each pass Note On the first pass the cut shown in Figure 3 54 will be performed 52 Part No 60 MAN 03 Rev 3 0811 E H Wachs Chapter 3 Operating Instructions Counterbore Operation 0 25 Final Land Figure 3 54 The illustration shows the profile of the first pass with the compound bevel template 13 Tighten the tool holder cover screws securely Cutting the Bevel 1 Pushthe trip pin in to engage the trip Figure 3
4. 2 4424441644 bend ROPA EE iers anig HL Ro HR HEAT 24 EE EE a2 dia poe ee bo ee ee ee ee E ee 24 Planning the ODEEAHOE ss aas nan bane niea 10 3 38 In RUP EORR e ROS and eae ane OR QR UR E d 28 Chine te C Once et EE EE AIRES 31 BV rD O ero enr E E RAE ERIS eee RENE eee SUN ENS 37 Machin Setup lor EE DEER 38 Straight Beveling SEMP EE 41 Compound Beveling Setup u uos eura ur uke E ORI RR KE AE Oe IRURE SOEUR AE SEN 46 Cuntin die Beve nc ee nee Sree ene ee ee SEA eee nee nee ERE d 99 JP EEDAODELIDIOR soo acces ee T Red ore oe we ee ee ESAE NEFRAES NAMENS n Chapter 4 MOIECHA CE sa da cos 2b E RUE EROR RE V RE A RE UR P Ad WR RE E UE Re dur dique 61 EE RE KEE RECETTE DREES 61 e E EE EE EE EE EE ee EEN 62 Male Slide Feed Tension 4 wm 64444555944 ure m dox pee asp FoR oR da prd ue dog HO 62 Chapter 5 Parts List and Ordering Information eere 69 Ordering Information 69 Ordering Replacement Parts esso suam eRAARETMURREGRSRUAS SABER ERREUR LAM ERES 69 Repair DOPOPBDGULOD saarena Ea CIERRIHEE dE ENTE ESPRIME mSATEmTETaS ben MES PS 69 Warranty Information EE 70 REWA GOS EE E RE E E oes 70 CCESSOTIES celer hh 70 Drawings and Parts isis 4 44024 need Ee pun db EHE A nS VE aus HUE PEU red der QUA PUE RP 71 li Part No 60 MAN 03 Rev 3 0811 E H Wachs Chapter 1 Introduction to the Equipment Chapter 1 About the Bridge Slide PURPOSE OF THIS MANUAL This manual explains how to operate and maintain the low clearance
5. 3 60 Position the bit so it touches the O D of the pipe 15 Using the scale position the tool holder exactly where it was when you measured it previous ly Tighten the tool holder cover screws securely 56 Part No 60 MAN 03 Rev 3 0811 E H Wachs Chapter 3 Operating Instructions Counterbore Operation Set AR TE T 7 98 ag gt i a f f gd K PROGE Ze 8 14 3 ei 5 ia 3 ENGINEFA Re ita tae e aa H LN hh e ad i P f 32 fitr as or E 12 UI Ou lo anpali biede Figure 3 61 Slide the tool holder in to position the end of it the same distance from the tool holder plate as you measured previously 16 Operate the machine to perform the final pass The tool will exit the face of the pipe at the land location J Prep Operation If you need to do a J prep profile follow the setup procedure for the straight bevel in the previous section but cut the bevel according to the following instructions You will use a radius tool to finish the J prep The figures in this section explain how to use the radius of the tool to calculate the operating dimensions for the straight bevel 1 Calculate the amount of material you will need to leave on the land side of the pipe face This is dimension B in Figure 3 62 2 Perform the straight bevel operation stopping on each pass as you reach the B dimension on the pipe face You can stop and measure as you cut or mark the location on the pipe face before you star
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7. 55 Push the trip pin in to engage the trip 2 Manually rotate the rotating ring to align the star wheel with the trip Time the star wheel by setting one point of it perpendicular to the ring E H Wachs Part No 60 MAN 03 Rev 3 0811 53 Bridge Slide Accessory for Low Clearance Split Frame 9 Figure 3 56 Set a point of the star wheel perpendicular to the LCSF ring and make sure the trip engages the point of the wheel as you rotate the ring Install the motor on the LCSF Start the motor Make sure the star wheel strikes the trip properly as the machine rotates The tool will follow the bevel profile until it comes out of the face surface of the pipe When the tool is clear turn off the motor Loosen the tool holder cover screws and slide the tool holder back Snug the screws Using a 3 4 wrench or socket turn the castle nut counter clockwise to position the tip of the tool just past the O D of the pipe Loosen the tool holder screws and slide the tool holder out to position the tool for the next pass Tighten the tool holder cover screws securely Operate the machine again and complete the second pass Retract the tool holder again and turn the castle nut to reset the slide for the next pass Note After each pass measure the distance from the end of the bevel you have machined to the land location on the pipe face You may want to mark the land location on the pipe When you are within one pass of reaching the
8. Accessory for Low Clearance Split Frame 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 ma chine FOLLOW SAFE PROCEDURES FOR HANDLING LUBRICANTS Refer to the manufacturer s instruc tions and the Material 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 regula tions 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 Operating and Maintenance Safety This equipment is to be operated and maintained only by qualified trained personnel 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 1s 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 toolin
9. Chapter 1 Introduction to the Equipment Operating Envelope ST Operating Envelope 12 to 20 LCSF Bridge Slide SEE TABLE Le 5 5 9 9 0 0 CO S So IN C CS WW Ts CO O00 OO OOOO 16 LOW CLEARANCE SPLIT FRAM LCSF 10 38 SE 263 5 2 50 AXIAL TRAVEL 63 5 i 0417 PER REV rue BR 1 059 Ge d 8 315 7 1 98 Nace 50 3 i ES Y Oo di d g O i 225 x 57 2 oe 25 3 20 1 O O 6 4 81 4 lj re CUT LINE f oS spur FRAME I D SINGLE POINT TOOL EE RADIALTRAVEL DIM C SEE TABLE 0045 114 PER TRIP DIMENSIONS IN BRACKETS ARE MILLIMETERS Table 2 Dimensions for 12 20 Bridge Slides 10 14 18 52 8 75 257 5 mm 470 3 mm 222 3 mm 10 76 19 77 8 75 273 2 mm 502 1 mm 222 3 mm 11 99 22 27 8 50 304 7 mm 565 6 mm 215 9 mm 13 98 26 27 8 50 355 1 mm 667 2 mm 215 9 mm E H Wachs Part No 60 MAN 03 Rev 3 0811 Bridge Slide Accessory for Low Clearance Split Frame CUT LINE DIM B SEE TABLE o R S DIM A o SEE TABLE 2 34 59 5 2 50 AXIAL T
10. debris where the indicator tip touches it Move the adjustable components so that the tip of the indicator can touch the inner surface of the pipe Precisely Centering the LCSF Visually divide the LCSF into four 90 angle quadrants with a clamping pad at the center of each quadrant Refer to the quadrant numbers in Figure 3 1 yp NOTE 1824 and larger LCSF machines have 8 clamp legs Indicate and adjust one leg in each quadrant at 90 around the machine then tighten the remaining 4 legs against the pipe E H Wachs Part No 60 MAN 03 Rev 3 0811 19 Bridge Slide Accessory for Low Clearance Split Frame how No 20 Figure 3 1 Visually divide the LCSF into four quadrants as shown The white arrows indi cate the clamp pads in each quadrant Turn the rotating ring to position the dial indicator tip at the clamp pad location in quadrant 1 Put the indicator tip against the inner surface of the pipe under the clamp pad Set the indicator to 0 zero By hand turn the rotating ring 180 so that the indicator tip is under the clamp pad in quad rant 3 The indicator dial will move into the plus or minus zone unless the LSCF is perfectly cen tered across quadrant 1 and quadrant 3 If the dial moved into the plus zone in quadrant 3 then quadrant 3 has to move toward the pipe by one half the measurement indicated If the dial moved into the minus zone in quadrant 3 then quadrant 3 has to move away from the pipe
11. fit into the slide 5 Remove the tool holder plate and insert the tool holder into the male tool slide 1 NOTE If there is enough clearance to reach through the slide you can insert the tool holder from the inside without removing the tool holder plate Jay a E A DS ro j ie WA Figure 3 31 Remove the tool holder cover and insert the tool holder into the slide 6 Replace the tool holder plate Insert the screws and tighten them until they are just snug 40 Part No 60 MAN 03 Rev 3 0811 E H Wachs Chapter 3 Operating Instructions Counterbore Operation Straight Beveling Setup 1 Using a 3 4 wrench or socket turn the castle nut to position the tip of the tool just past the O D of the pipe Figure 3 32 Turn the castle nut to position the bit just past the O D of the pipe Gm IMPORTANT Do not turn the castle nut while you are installing and positioning the templates 2 Place the templates with their slots over the cam follower posts as shown in Figure 3 44 Position the templates so that the cam follower wheel is near the end of the template slot away from the center of the pipe Figure 3 33 Insert the template on the cam follower so that the wheel is near the end of the slot E H Wachs Part No 60 MAN 03 Rev 3 0811 4 Bridge Slide Accessory for Low Clearance Split Frame 3 Loosen the screws on the tool holder cover so that the holder can move if it contacts the pipe while
12. remove the feed screw 9 The knob end block and feed screw will come out of the slide Set the assembly aside in the machine storage case 10 Loosen the tool holder cover screws and move the tool holder forward to the desired cutting depth along the side of the pipe Typically about 1 4 per pass is appropriate multiple passes are usually required as shown in Figure 3 40 4400 ParNo 60 MAN 03Rev 3 081 EH Wachs Chapter 3 Operating Instructions Counterbore Operation Figure 3 39 Position the tool to remove the appropriate width of cut 0 25 Three passes LI Figure 3 40 The diagram shows a straight bevel using multiple passes Set the tool holder depth about 1 4 further back along the pipe O D for each pass Note On the first pass the cut shown in Figure 3 41 will be performed E H Wachs Part No 60 MAN 03 Rev 3 0811 45 Bridge Slide Accessory for Low Clearance Split Frame 0 25 Land Figure 3 41 The illustration shows the profile of the first pass with the straight bevel tem plate 11 Tighten the tool holder cover screws securely Compound Beveling Setup 1 Using a 3 4 wrench or socket turn the castle nut to position the tip of the tool over the location on the pipe face at the transition point where the two bevel angles meet of the proposed surface prep Figure 3 42 Turn the castle nut to move the tool bit into position over the pipe f
13. screws at the front of the slide and one screw at the back Front adjustment screws Lock nuts Figure 4 2 Front adjustment screws for male tool slide tension 62 Part No 60 MAN 03 Rev 3 0811 E H Wachs Chapter 4 Maintenance Machine Adjustments Lock nut Back adjustment screw Figure 4 3 Back adjustment screw for male tool slide tension You will first need to remove the feed knob Use the following procedure to remove the knob and adjust the tension 1 Turn the feed knob counter clockwise to feed the male slide forward in to the end of travel This will take most of the tension out of the spring i li E Pees pr i Figure 4 4 Feed the male slide all the way forward E H Wachs Part No 60 MAN 03 Rev 3 0811 63 Bridge Slide Accessory for Low Clearance Split Frame 1 NOTE The screws are captivated in the end block and will not fall out 2 Inserta hex wrench through the hole in the feed knob and remove the screws holding the end block to the slide Rotate the knob to access each screw in turn Figure 4 5 Use a hex wrench to remove the four screws in the end block Rotate the feed knob to access each screw 3 Turnthe feed knob counter clockwise to unscrew and remove it The knob end block and feed screw will come out ofthe slide Figure 4 6 With the end block loose turn the feed knob counter clockwise to remove the feed screw 64 Part No 60 MAN 03 Rev 3 0811
14. split frame bridge slide It includes instructions for set up operation and maintenance It also contains parts lists and dia grams and troubleshooting instructions to help you order replacement parts and perform user serviceable repairs How To Use THE MANUAL This manual is organized to help you quickly find the information you need Each chapter de scribes a specific topic on using or maintaining your equipment Use these instructions to operate and maintain the equipment E H Wachs Part No 60 MAN 03 Rev 3 0811 i Bridge Slide Accessory for Low Clearance Split Frame SYMBOLS AND WARNINGS The following symbols are used throughout this manual to indicate special notes and warnings They appear in the outside 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 potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death AWARNING alert with the safety alert symbol indicates a potentially hazardous situation that could result in serious injury or death A CAUTION alert with the safety alert symbol indicates a potentially hazardous situation that could result in minor or moderate injury A CAUTION alert with the damage alert symbol indicates a situation that will result in damage to the equipment
15. spring plate and turn the feed knob clockwise to reinstall the assembly When the knob becomes snug position the end block so that the screws line up with the holes in the spring plate Figure 4 10 Insert the feed screw back through the end block and screw it into the slide by turning the knob clockwise Part No 60 MAN 03 Rev 3 0811 E H Wachs Chapter 4 Maintenance Machine Adjustments 13 Tighten the screws in the end block by inserting a hex wrench through the hole in the feed knob Turn the knob clockwise from one screw to the next so that you do not loosen the feed screw 14 Check the tension on the feed knob Make sure you can turn it both directions to move the male slide E H Wachs Part No 60 MAN 03 Rev 3 0811 67 Bridge Slide Accessory for Low Clearance Split Frame 68 Part No 60 MAN 03 Rev 3 0811 E H Wachs Chapter 5 Parts List and Ordering Information Chapter 5 Parts List and Ordering Information To order spare or replacement parts see the ordering instructions below Refer to the exploded view drawings and the parts lists that accompany them for assembly and parts identification ORDERING INFORMATION To place an order request service or get more detailed information on any E H Wachs products call us at one of the following numbers U S 800 323 8185 International 847 537 8800 Ordering Replacement Parts When ordering parts refer to the parts lists earlier in this chapter Please prov
16. the procedure in this section to install and center the LCSF E H Wachs Part No 60 MAN 03 Rev 3 0811 17 Bridge Slide Accessory for Low Clearance Split Frame Rough Centering the LCSF 1 Ifnecessary install the LCSF onto the open end of the pipe as described in the LCSF user s manual Select the proper extensions for the size of pipe using the clamp pad extension chart in the manual 1 NOTE When installing the LCSF on an open pipe end the top surface of the rotating ring should be about 1 3 4 inches below the end face of the pipe enough to allow for about 1 4 1 2 inch of clearance between the bridge slide and the pipe face See the operating envelope drawings in Chapter 1 2 Startatthe location of one of the clamp pads near the top of the machine 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 3 Moveto the clamp pad 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 4 Addthe 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 e The distance at the second location is 2 1 inches e Add 1 7 to 2 1 then divide by 2 The result is 1 9 inches which is the desired di
17. E H Wachs Chapter 4 Maintenance Machine Adjustments 1 NOTE Unscrew each spring plate screw a few turns at a time until they are all removed 4 Remove the spring plate on the end of the slide Hold the plate down as you remove the screws Figure 4 7 Remove the screws holding the spring plate Turn each screw out a few turns ata time so that the spring pushes the plate up evenly 5 Remove the spring Replace the spring plate 6 Loosen the lock nuts on both front adjustment screws and the back adjustment screw 7 To tighten the male slide tension retract the back adjustment screw and screw in the front adjustment screws Figure 4 8 To tighten the slide tension retract the back adjustment screw left then screw in the front adjustment screws E H Wachs Part No 60 MAN 03 Rev 3 0811 65 Bridge Slide Accessory for Low Clearance Split Frame 10 11 12 66 To loosen the male slide tension retract the front adjustment screws and screw in the back adjustment screw Figure 4 9 To loosen the slide tension retract the front adjustment screws left then screw in the back adjustment screw Adjust the tension by about 1 2 turn of the screws You will need to re install the feed knob to check the tension Tighten down the two front adjustment screws Remove the spring plate and replace the spring Put the spring plate back on and tighten the four screws Insert the feed screw back through the
18. RAVEL 63 5 0417 RER REV 1 059 ik LOW CLEARANCE SPLIT FRAME LCSF DIM C SEE TABLE 250 63 5 OLI i o O o o 3 50 89 0 SINGLE POINT TOOL 52 701 01 32 02 813 2 mm 7 75 196 9 RADIAL TRAVEL 0045 114 PER TRIP Ps FRAME I D Operating Envelope 24 to 48 LCSF Bridge Slide Q Ze dO cess O DIMENSIONS IN BRACKETS ARE MILLIMETERS Table 3 Dimensions for 24 48 Bridge Slides 16 84 427 6 mm 18 83 478 3 mm 20 83 529 0 mm 22 82 579 6 mm 24 32 617 7 mm 25 81 655 5 mm 28 81 731 8 mm 36 02 914 8 mm 40 02 1016 4 mm 44 02 1118 0 mm 47 02 1194 2 mm 50 02 1270 4 mm 56 02 1422 8 mm Part No 60 MAN 03 Rev 3 0811 1 98 50 3 mm 1 98 mm 2 17 55 1 mm 2 17 55 1 mm 2 17 55 1 mm 2 17 55 1 mm 2 17 55 1 mm E H Wachs Chapter 2 Safety Chapter 2 Safety E H Wachs takes great pride in designing and manufacturing safe high quality products We make user safety a top priority in the design of all our products Read this chapter carefu
19. This 1s the equipment damage alert symbol It is used to alert you to potential equipment damage situations Obey all messages that follow this symbol to avoid damaging the equipment or workpiece on which it is operating e IMPORTANT An IMPORTANT alert with the damage alert symbol indicates a situation that may result in damage to the equipment NOTE Gm This symbol indicates a user note Notes provide additional information to supplement the instructions or tips for easier operation 2 Part No 60 MAN 03 Rev 3 0811 E H Wachs Chapter 1 Introduction to the Equipment Manual Updates and Revision Tracking MANUAL UPDATES AND REvisioN TRACKING Occasionally we will update manuals with improved operation or maintenance procedures or with corrections if necessary When a manual is revised we will update the revision history on the title page Current versions of E H Wachs Company manuals are also available in PDF format You can request an electronic copy of this manual by emailing customer service at sales ehwachs com 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 Revision History e February 2007 Original version R0 0207 printed e May 2009 Revision 1 R1 0509 e July 2010 Revision 2 R2 0710 EQUIPMENT DESCRIPTION The bridge slide acces
20. XSLl 91 g SSS cOv9006 ze VIEX BL 9L S SOHH v 4019006 IZ v L X8L 9L G SOHS S L090 06 OZ ld ANA 8 E XOC V L SSS 9 vO SO O6 6l YOON ld DOG v 1 XZE OL SSS C vvO O6 Zl po BOND 02SL09 vl po TST 009601L09 EL AOD ANM OOS ll09 cl Jans SIWW INJWdQTM OO 610l 09 II po NS OO ll 09 OI HE l0 O0C ll09 6 daivAlldvO 8 2 X 81 91 S SOHS c OO 1611 09 8 DOTS OO 680l09 9 J4HVHS WVTIOO 0001009 JOVal HiTON C ODES IEG C NOILdld 5S4d wo d38WhN LdVd WALI 74 Chapter 5 Parts List and Ordering Information Drawings and Parts Lists C c o d u Gei Gei 90 064 05 BS SW TOOL ASSEMBLY DESCRIPTION STANDARD HSS a TOOL HOLDER LK LLJ eo ed E I De si a ITEM NO Single point tool assembly E H Wachs Part No 60 MAN 03 Rev 3 0811 75 Bridge Slide Accessory for Low Clearance Split Frame S0 S0 06 V X OZ F 1 SSS A18W3SSVv CNI1OOL 3308 2 33d 10H OZv LJS FOCJS 4OJ TOOL JaOgaa3iNmDIO add l Ip HCOULAIa 20 l 00 80 09 g oo AID maan lawa ON Wall Counterbore tool assembly E H Wachs Part No 60 MAN 03 Rev 3 0811 76 E H WACHS Superior Equipment Complete Support 600 Knightsbridge Parkway Lincolnshire IL 60069 847 537 8800 www wachsco com
21. ace 46 Part No 60 MAN 03 Rev 3 0811 E H Wachs Chapter 3 Operating Instructions Counterbore Operation Figure 3 43 Adjust the radial position until the bit is located at the proposed bevel transi tion point shown on a beveled pipe for illustration Place the templates with their slots over the cam follower posts as shown in Figure 3 44 Position the templates so that the cam follower wheel is at the transition point of the tem plate Gm IMPORTANT Do not turn the castle nut while you are installing and positioning the templates Figure 3 44 Insert the template on the cam follower so that the wheel is at the transition point of the bevel Loosen the screws on the tool holder cover slightly so that the tool holder can slide back if the tool contacts the pipe face as you position the templates Advance the male tool slide by turning the feed knob counter clockwise Guide the bases of the templates into the mounting slots as you advance the slide Keep the cam follower wheels at the transition points E H Wachs Part No 60 MAN 03 Rev 3 0811 47 Bridge Slide Accessory for Low Clearance Split Frame Figure 3 45 Turn the feed knob counter clockwise to advance the slide and push the tem plates into their slots 5 Advance the slide until the bases of the template plates are fully seated in their slots while the transition points are still located on the cam follower wheels Figure 3 46 The template is
22. bored I D Subtract this measurement from the planned I D Divide the result by 2 to determine the thickness of the final pass See the example in Figure 3 25 Planned I D 16 79 16 55 16 85 pipe thickness not to scale Measured I D 16 79 Planned D 16 85 Material to remove 16 85 16 79 0 06 Thickness of pass 0 06 2 0 03 Figure 3 25 In this example the thickness of the final pass will be 0 05 36 Part No 60 MAN 03 Rev 3 0811 E H Wachs Chapter 3 Operating Instructions Counterbore Operation 18 Measuring carefully turn the castle nut to move the tool the final pass thickness over the pipe I D Perform the final pass blending the taper when you reach the end of the previous pass 19 Stop the machine and retract the male slide using the feed knob Remove the counterbore tool from the tool holder If you are finished preparing the end of the pipe remove the bridge slide BEvEL OPERATION The bridge slide uses templates to perform O D beveling of the pipe face Various templates are available to do different beveling profiles A straight bevel is generated by the tool slide following a template with a tracking slot at the angle of the desired bevel profile Figure 3 26 shows a set of straight beveling templates Figure 3 26 Two identical straight bevel templates are used for the specified bevel angle E H Wachs Part No 60 MAN 03 Rev 3 0811 37 Bridge Slide Accessory for Low Clearan
23. bridge slide is designed to attach to a low clearance split frame mounted on open ended pipe The bridge slide performs weld prep operations beveling counterboring and J prep It uses cold cutting lathe techniques with a variety of 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 Bridge Slide with LCSF e The LCSF and bridge slide should only be used by trained qualified operators e The workpiece must be within the operating capacity of the LCSF and bridge slide models you are using See operating envelope information and drawings in Chapter 1 Make sure the operating environment allows you to mount the machine securely and squarely on the workpiece Make sure there is adequate clearance around workpiece and the LCSF bridge slide combina tion to operate the machine controls as described in the operating instructions Misuse Donotattempt to mount or operate the LCSF and bridge slide on non cylindrical workpieces e Donotattempt to mount or operate the LCSF and bridge slide on any workpiece to which the equipment cannot be securely mounted e Donotattempt to mount or operate the LCSF and bridge slide on any workpiece that is not stable enough to hold the equipment e Do not disable any safety feature
24. by one half the measurement indicated Ifthe indicator has moved into the plus zone loosen the clamp pad in quadrant 1 and tighten the clamp pad in quadrant 3 Watch the dial as you adjust the screws it should move about half way back to 0 Part No 60 MAN 03 Rev 3 0811 E H Wachs Chapter 3 Operating Instructions Setting up the LCSF 1 NOTE If the difference between quadrant 1 and quadrant 3 is small a few thousandths of an inch you may be able to center the machine by just tightening the clamp pad where the LCSF is too close to the pipe 7 Ifthe indicator has moved into the minus zone loosen the clamp pad in quadrant 3 and tighten the clamp pad in quadrant 1 Watch the dial as you adjust the screws it should move about half way back to 0 8 Resetthe indicator to 0 and re check quadrants 1 and 3 Adjust if necessary 9 Perform the same procedure for quadrants 2 and 4 10 After adjusting quadrants 2 and 4 re check quadrants 1 and 3 Installing the Trip 1 Remove the standard tool slides from the LCSF if they are attached Place the slides in their location in the LCSF case 2 Mount the trip assembly onto the LCSF stationary frame with one spacer low range configu ration Refer to the LCSF manual if necessary Trip spacer Trip assembly Figure 3 2 Tighten the three screws holding the trip assembly and spacer to the LCSF stationary ring E H Wachs Part No 60 MAN 03 Rev 3 0811 21 Bridge Slide A
25. ccessory for Low Clearance Split Frame 3 Pull out the plunger on the trip to disengage it while you are setting up the bridge slide Figure 3 3 Pull the trip pin plunger out to disengage the trip INSTALLING THE BRIDGE SLIDE The tool slides must be removed from the LCSF before you install the bridge slide 1 NOTE The bridge slide mounting holes are not the same as the standard slide mounting holes 1 Position the bridge slide across the rotating ring of the LCSF so that the bridge slide mount ing screws are aligned with the slide mounting holes in the ring N CAUTION Use a lifting device to hold the bridge slide in place while you install it Attach the lifting device to the lifting eye and lifting slots on the ends of the bridge slide 22 Part No 60 MAN 03 Rev 3 0811 E H Wachs Chapter 3 Operating Instructions Installing the Bridge Slide Bridge slide mounting holes Direction of rotation Bridge slide mounting holes Figure 3 4 Position the bridge slide across the LCSF rotating ring at the location shown 2 Screw in the 4 captivated bridge slide mounting screws to attach the slide to the LCSF E H Wachs Part No 60 MAN 03 Rev 3 0811 23 Bridge Slide Accessory for Low Clearance Split Frame Figure 3 5 Fasten the bridge slide to the LCSF by tightening the 4 captivated screws in the 2 bottom supports COUNTERBORE OPERATION To counterbore with the bridge slide you will keep th
26. ce Split Frame A compound bevel is generated by the tool slide following a template with a tracking slot at differ ent angles representing the angles of the desired bevel profile Figure 3 27 shows a set of com pound beveling templates Figure 3 27 Two identical compound bevel templates are used for the specified bevel pro file Follow the appropriate procedure in this section to set up and cut a bevel on the O D of the pipe These procedures assumes you have installed the LCSF and bridge slide as described earlier in the chapter Machine Setup for Beveling 1 Ifnecessary remove the drive motor from the LCSF and pull the trip pin out to the retracted position 2 Insert the single point tool in the tool holder as shown in Figure 3 28 Tighten the set screw on the tool holder 38 Part No 60 MAN 03 Rev 3 0811 E H Wachs Chapter 3 Operating Instructions Counterbore Operation Figure 3 28 Insert the single point tool in the holder as shown Tighten the set screw on the back on the holder 3 Retractthe male tool slide to its farthest back position by turning the feed knob clockwise Figure 3 29 Retract the male tool slide using the feed knob 4 Loosen the screws holding the tool holder plate on the male tool slide E H Wachs Part No 60 MAN 03 Rev 3 0811 39 Bridge Slide Accessory for Low Clearance Split Frame Figure 3 30 Loosen the screws on the tool holder plate to allow the tool holder to
27. device turn the castle nut clockwise to move the radius tool out along the pipe face by the thickness of the desired land measurement 9 Start the LCSF 10 Turn the feed knob counter clockwise to advance the radius tool into the pipe Continue feeding until the radius blends into the bottom of the bevel Step 2 in Figure 3 64 E H Wachs Part No 60 MAN 03 Rev 3 0811 59 Bridge Slide Accessory for Low Clearance Split Frame 60 Part No 60 MAN 03 Rev 3 0811 E H Wachs Chapter 4 Maintenance Chapter 4 Maintenance LUBRICATION Lubricate the following components each time you use the bridge slide Male slide guides Feed screw Guide rods Figure 4 1 Lubricate the bridge slide at the indicated locations E H Wachs Part No 60 MAN 03 Rev 3 0811 61 Bridge Slide Accessory for Low Clearance Split Frame MACHINE ADJUSTMENTS On a regular basis check all fasteners to make sure they are tight In particular check the tightness of the castle nut on the end of the feed screw and the castle nut on the inside end of the starwheel shaft Male Slide Feed Tension You can adjust the tension on the male tool slide It should be tight enough so that the feed knob does not turn freely You should be able to turn the knob with one hand but it should feel fairly snug An adjustable wedge shim lets you set the male slide tension Figure 4 2 and Figure 4 3 show the adjustment screws for adjusting the wedge there are two
28. dling Machines or assemblies over 40 Ib 18 kg must be lifted by two people or a lifting device All bridge slide models are greater than this weight See the weight table 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 All bridge slide models are equipped with a lifting eye and a lifting slot shown in Figure 2 1 for attaching the slide to a lift device When using a lift device always attach it at these points Do not rig or lift the LCSF with the bridge slide attached The assembled combination may not be balanced to enable safe lifting Do not lift the assembled LCSF and bridge slide using the bridge slide lift points The bridge slide lift points are not designed for the full weight of the assembled combination Machine Weights Table 1 lists the weights for each bridge slide model 14 Table 1 Bridge Slide Weights Bridge slide for model 1824 LCSF 60 428 24 60 8 Ib 27 6 kg Bridge slide for model 3642 LCSF 60 428 42 67 6 Ib 30 7 kg Bridge slide for model 4248 LCSF 60 428 48 69 7 Ib 31 6 kg Part No 60 MAN 03 Rev 3 0811 E H Wachs SAFETY LABELS The following safety labels are on the bridge slide 0769 in 417 in 1 055 mm 60 1174 00 60 1187 60 Chapter 2 Safety Safety Labels Figure 2 2 Sa
29. e This is a value that is specified in the weld prep detail A general rule of thumb is the counterbore depth is 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 3 14 Depth 0 375 Figure 3 14 Counterbore depth E H Wachs Part No 60 MAN 03 Rev 3 0811 29 Bridge Slide Accessory for Low Clearance Split Frame 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 x bore nor 0 15 Ca A Figure 3 15 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 0 975 Depth of first counterbore pass 0 975 Figure 3 16 The depth of the first counterbore pass is the sum of the desired counterbore depth 0 375 plus the depth required for the tool taper on each pass 30 Part No 60 MAN 03 Rev 3 0811 E H Wachs Chapter 3 Operating Instructions Counterbore Operation Cutting the Counterbore Counterboring the I D of a pipe requires moving the bridge slide in opposite direction than when it is trip driven Therefore you will operate the radial drive manually using a wrench with a 3 4 socket Note the maximum ax
30. e following pages to identify and order spare or replacement parts E H Wachs Part No 60 MAN 03 Rev 3 0811 71 Chapter 5 Parts List and Ordering Information Drawings and Parts Lists NMOHS LON 1d9 X ANC 2 1 13332OS 89 008 06 NMOHS LON NOILWNISWOD 2 1 HON3NM 60 008 06 l Z 1 1109 3A3 L6 660 06 CLOTS X3H OZ Z 1 LAN 01 860 06 c A L X L c 1 SOHS G1 060 06 8 S X BL 9L S SOHS 90 090 06 v L X O L SCH C1 S0 06 v X Oc v 1 SOHJ 0 S0 06 X OZ 7 1 SOH8 OL S0 06 X Oc v 1 SOHS 01 080 06 PIC X Oc v l SOHS 0 0S0 06 TION r X ZE S Nid LS 9 0 06 NMOHS LON IVANVW asn aans 3Dalag O NYW 09 ATaWASSV ONMOOL 3404 9 8i3Q OH 00 807 09 A18W3SSYV 1OOL MS 3drisoa3drig SaqTOH 00 Z0Z 09 Ocv LJS VOCA4S HOF TOOL ANOPSSLNNOD Ad V1 Lk v0 002 09 ONIHSNE 00 92 09 ONIHSNd 00 SZE 09 gans JOA 34921 ATAWASSVENS 0 00 09 YACGINOHS ONIYI 00 88 09 MAACHE Q334 Nv31oO 00 47 09 T33HM VIS AVIO 00 9 72 09 TH3HM3l VIS 00 87 09 DCL WOLLOS8 14Oddns LO 6 09 DCL dOL 14Oddfls LO Z2 09 doadlad dldvl 33S MAOS A334 0014 00 1 22 09 a334 MINOS 00 0472 09 Q3l3IQOW AA 00 SEZ 09 C eco 5st t0 o r 0 oa g1 09 IHOI3M 38 VT
31. e star feed trip disengaged and will manually feed the tool slide radially Depending on how much material you are removing for the counter bore you will probably need to perform multiple passes moving the tool slide radially into the pipe I D between each axial pass Counterbore Setup Use the tool holder specifically designed to hold the counterbore tool part no 60 708 00 1 NOTE Use the allen wrench set provided with the LCSF to assemble and disassemble the bridge slide components 1 Pullthe trip pin plunger to retract and disengage the trip When counterboring with the bridge slide the radial feed is performed manually 24 Part No 60 MAN 03 Rev 3 0811 E H Wachs Chapter 3 Operating Instructions Counterbore Operation RK D Figure 3 6 Pull the trip pin plunger out to disengage the trip for counterboring 2 Insert the counterbore tool in the tool holder as shown in Figure 3 7 Tighten the three set screws on the tool holder Figure 3 7 Insert the counterbore tool in the holder as shown Tighten the three set screws on the holder 3 Loosen the screws holding the tool holder plate on the male tool slide E H Wachs Part No 60 MAN 03 Rev 3 0811 25 Bridge Slide Accessory for Low Clearance Split Frame Figure 3 8 Loosen the screws on the tool holder plate to allow the tool holder to fit into the slide 1 NOTE If there is not enough clearance to reach through the slide you can re
32. fety and operation labels on the bridge slide are shown Left radial travel label top right axial travel label bottom right weight label varies depending on bridge slide model E H Wachs Part No 60 MAN 03 Rev 3 0811 Bridge Slide Accessory for Low Clearance Split Frame 16 Part No 60 MAN 03 Rev 3 0811 E H Wachs Chapter 3 Operating Instructions Chapter 3 Operating Instructions Follow the procedures in this chapter to set up the LCSF and bridge slide and to perform counter boring and beveling operations You should be familiar with the procedures described in the LCSF manual refer to it for detailed instructions on operating the LCSF When doing a weld prep on a pipe you will generally perform the separate operations in the following order Each operation is optional depending on your specific application e pipe cut off using LCSF e pipe squaring facing using LCSF e counterboring using LCSF and bridge slide e beveling using LCSF and bridge slide SETTING UP THE LCSF The bridge slide is used across the open face of a pipe end Thus you do not need to split the LCSF to install it merely mount it over the open end of the pipe If you are performing an operation using the bridge slide after parting the pipe with the LCSF you do not need to reposition the machine However it is critical that the LCSF be centered exactly on the workpiece This requires the use of a dial indicator that mounts to the LCSF Use
33. fully seated in its slot 48 Part No 60 MAN 03 Rev 3 0811 E H Wachs Chapter 3 Operating Instructions Counterbore Operation 6 Tighten the locking screws on the templates securely Use at least three screws on each template Gm IMPORTANT The screws holding the template must be tight or the template may pull out of the slot as the slide advances Figure 3 47 Tighten the screws holding the template 7 Retractthe tool holder so the tool is not touching the pipe face Move it far enough back so the tool will clear the pipe face when you move the slide out to the pipe O D Snug the tool holder plate screws yp NOTE The screws in the end block are captivated and will not fall out E H Wachs Part No 60 MAN 03 Rev 3 0811 49 50 Bridge Slide Accessory for Low Clearance Split Frame E mem E eg SS sch Figure 3 48 Pull the tool holder back so that the tool stays clear of the pipe face while adjusting the slide Insert a hex wrench through the hole in the feed knob and remove the screws holding the end block to the slide Rotate the knob to access each screw in turn Figure 3 49 Use a hex wrench to remove the four screws in the end block Rotate the feed knob to access each screw 9 Turn the feed knob counter clockwise to unscrew and remove it Part No 60 MAN 03 Rev 3 0811 E H Wachs 10 11 12 Chapter 3 Operating Instructions Counterbore Operation
34. g major components Female slide 3 T Male slide Cam follower post Tool holder cover plate Template a i locking screws T e Castle nut 3 Starwheel Figure 1 2 End view of the bridge slide showing major components 4 Part No 60 MAN 03 Rev 3 0811 E H Wachs Chapter 1 Introduction to the Equipment Equipment Description iin d Standard slide P mounting location Split line Bridge slide mounting locations Split line Standard slide 7 mounting location Figure 1 3 The photo shows the LCSF mounting holes for the bridge slide Different LCSF ring sizes will have slightly different hole patterns Bridge Slide Sizes Bridge slides are available for 12 through 48 LCSF models as described in Table 1 Table 1 Bridge Slide Sizes E H Wachs Part No 60 MAN 03 Rev 3 0811 5 Bridge Slide Accessory for Low Clearance Split Frame Bridge Slide Tooling Two tool holders are provided with the bridge slide a single point tool holder and a counterbore tool holder These are shown in Figure 1 4 and Figure 1 5 Figure 1 4 Single point tool holder part no 60 707 00 and tool Figure 1 5 Counterbore tool holder part no 60 708 00 and tool OPERATING ENVELOPE The operating envelope for all bridge slide LCSF combinations is illustrated in the figures and tables on the following pages 6 Part No 60 MAN 03 Rev 3 0811 E H Wachs
35. g 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 disconnect the power source Follow all lock out tag out procedures required at the worksite 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 10 This icon 1s 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 Part No 60 MAN 03 Rev 3 0811 E H Wachs Chapter 2 Safety Safe Operating Guidelines N 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 equipment 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
36. hickness 1 25 Figure 3 12 The width of the counterbore is of the difference between the existing I D and the planned I D 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 28 Part No 60 MAN 03 Rev 3 0811 E H Wachs Chapter 3 Operating Instructions Counterbore Operation 2 Determine the thickness that can be removed with each pass As arule of thumb you can cut about 0 060 on most pipe materials without causing excess machine vibration damaging 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 1s 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 ofthe required straight bore to the desired depth 0 60 0 375 Three passes Figure 3 13 In this example three passes with the counterbore tool are required to achieve the desired straight counterbore depth In Figure 3 14 the planned counterbore depth is 0 375 of straight bor
37. ial travel for the bridge slide is 1 62 If you need to cut a bore deeper than that including the length of the required taper you will need to reposition the tool holder First cut to the maximum travel then reposition the slide Loosen the tool holder cover plate and set the holder down into the pipe by the distance that still needs to be cut 1 Make sure the slide is positioned radially so that the tool holder is inside the I D of the pipe We fae n IL EFI ti i PPP Li j TP i jj a TP j ja n j liaa FEF nT Ai Ze 2 m P j LG e y hd T FM e Ka Figure 3 17 Make sure the tool is within the pipe s I D before advancing the male slide into the pipe E H Wachs Part No 60 MAN 03 Rev 3 0811 3l Bridge Slide Accessory for Low Clearance Split Frame 2 Turnthe feed knob counter clockwise to advance the male slide so that the tool 1s inside the end of the pipe Figure 3 18 Advance the tool into the pipe by turning the feed knob counter clockwise 3 Manually rotate the split frame observing the clearance between the tool and the I D ofthe pipe Position the machine where the tool is closest to the pipe surface Figure 3 19 Rotate the split frame to find the point where the tool is closest to the pipe I D 32 Part No 60 MAN 03 Rev 3 0811 E H Wachs Chapter 3 Operating Instructions Counterbore Operation 4 Using a 3 4 wrench or socket turn the castle nut counter clock
38. ide 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 equipment please include the following information e Your name company name e Your address e Your phone number e Adescription 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 complete it E H Wachs Part No 60 MAN 03 Rev 3 0811 69 Bridge Slide Accessory for Low Clearance Split Frame Warranty Information 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 IL 60069 USA ACCESSORIES Use the part numbers in the following table to order accessories Table 1 Bridge Slide Accessories 53 409 11 10 x 37 5 compound bevel template 52 711 01 R 3 32 HSS single point tool other radii available on request 60 414 00 Dial indicator 70 Part No 60 MAN 03 Rev 3 0811 E H Wachs Chapter 5 Parts List and Ordering Information Drawings and Parts Lists DRAWINGS AND Parts LIsTs Use the drawings on th
39. land set the machine for the final pass 54 Part No 60 MAN 03 Rev 3 0811 E H Wachs Chapter 3 Operating Instructions Counterbore Operation Figure 3 57 You can mark the final land location on the pipe to see when you are getting close to the final pass 10 To set the final pass loosen the tool holder cover screws and retract the tool holder slightly 11 Using a 3 4 wrench or socket turn the castle nut to position the tip of the tool at the land position on the face of the pipe Push the tool holder forward so the tool is touching the pipe at the land location adjust it slightly by turning the castle nut Figure 3 58 Set the tip of the bit against the pipe face at the specified land position 12 Using a scale measure the distance from the end of the tool holder to the tool holder plate Write this measurement down E H Wachs Part No 60 MAN 03 Rev 3 0811 55 Bridge Slide Accessory for Low Clearance Split Frame RELA a ed j 4 HU i pe d lt i 1 38 an 4 di f ovy 7C LIRODUCTS we P um 34 332 i itil ct Loe i Im IT il filii PE first K Figure 3 59 With the bit at the land position measure the distance from the tool holder plate to the end of the tool holder 13 Retract the tool holder and turn the castle nut to position the tool past the O D of the pipe 14 Push the tool holder forward and slowly turn the castle nut until the tool tip just touches the O D ofthe pipe Figure
40. lly before operating the bridge slide It contains important safety instruc tions and recommendations FULL SAFETY INSTRUCTIONS AND GUIDELINES ARE IN THE MANUAL FOR YOUR LOW CLEARANCE SPLIT FRAME MACHINE Make sure you read and understand all safety information in the LCSF manua SAFE OPERATING GUIDELINES Follow these guidelines for safe operation of all E H Wachs equipment N Look for this symbol throughout the manual It indicates a personal injury hazard e READ THE OPERATING MANUAL Make sure you understand all setup and operating instructions before you begin Keep this manual with the machine e INSPECT MACHINE AND ACCESSORIES BEFORE USE Before starting the machine look for loose bolts or nuts leaking lubricant rusted components and any other physical conditions that may affect operation Properly maintaining the machine can greatly decrease the chances for injury e ALWAYS READ 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 the machine Replace any damaged or missing safety labels see the ordering information at the end of this manual e 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 adjust ments or service E H Wachs Part No 60 MAN 03 Rev 3 0811 9 Bridge Slide
41. move the tool holder plate and insert the tool holder from the outside 4 Insertthe tool holder into the tool block on the bridge slide so that the tool faces the inner surface of the pipe Reach through the opening in the slide with the tool holder to access the front of the tool block Figure 3 9 To install the tool holder you can reach through the slide and insert the holder into the front of the tool block 26 Part No 60 MAN 03 Rev 3 0811 E H Wachs Chapter 3 Operating Instructions Counterbore Operation i T E i E H i A E 1 r es iy TA b ez BW e 2 m INS red _ Ah Den Figure 3 10 From the inside slide the counterbore holder into the tool block with the cutting edge of the tool facing the I D of the pipe 5 Tighten the screws in the tool holder plate to secure the counterbore tool holder Figure 3 11 Tighten the screws in the cover to secure the counterbore tool holder in the slide E H Wachs Part No 60 MAN 03 Rev 3 0811 27 Bridge Slide Accessory for Low Clearance Split Frame Planning the Operation 1 Determine the amount of material that needs to be machined from the I D of the pipe 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 Example Existing I D 16 55 Planned I D 16 85 Counterbore 0 15 Pipe t
42. of the bridge slide or LCSF or remove any safety labeling Replace worn or damaged safety labels immediately See Safety Labels later in this chap ter 12 Part No 60 MAN 03 Rev 3 0811 E H Wachs Chapter 2 Safety Safe Operation of the Bridge Slide Potential Hazards See the Potential Hazards section in Chapter 2 of the user s manual for your low clearance split frame machine Follow all guidelines for avoiding hazards associated with operating the machine Bridge Slide Safety Features The bridge slide incorporates the features illustrated in Figure 2 1 to reduce operating hazards p S Raised axial Ef 7 M feed knob E Gear guard 1M Lifting eye Figure 2 1 The photo illustrates the bridge slide safety features Lifting slot Gear Guard A metal cover guards the starwheel gear and feed screw gear to prevent contact with moving parts Raised Axial Feed Knob The axial feed knob is positioned at the top of the axial slide allowing the operator to turn it without reaching across moving parts The knob is an easy grip design for convenient operation Lifting Attachments The bridge slide is equipped with two lift points for attaching a lifting device There 1s a slot for a lift hook at one end of the bridge channel and a lifting eye installed at the other end E H Wachs Part No 60 MAN 03 Rev 3 0811 13 Bridge Slide Accessory for Low Clearance Split Frame Safe Lifting and Han
43. s 2127239 d ee 10 Safety Er This Minal osu 264044054 cues eiin 4a ees sees eee gn genoa eats 10 Protective Equipment Requirements 2g ace ego ko HUE GUY eo gt RUE RO ELE E C 11 Protective Clothing M Cr 11 EVO PROICOUOD S serunt auc oat ERREUR PEORES S RENATA RO PEG Sq ERA URGE ERR 11 Hearne e ee we oa eee de eae AR ha Ae ee eee Red eee eee ees 11 Safe Operation of the Bridge Slide e 9909 9 ERADESSEESTOEIS SENA ESOS ESSE IS SM 12 Intended OSES a6 ca ht 9942909231983 Re a ee oe OS POE eb a SUPERO RS FPES 12 Proper Use or tie Bridge Slidewitt LG SE 4 us ee ee te ben Ee 12 lui c P 12 Potenti hazards sues ete eet eee eee ee ae SUPR eee caesar nen NA 13 Bridge Slide Safety Features io adora dena deiode diei don cd den edad diode addi dete ica 13 edi EE 13 Raised Axial Feed Knob eme ie k ie RdoeeR e urban Ae Eb y oe ey d 13 Liftin Attachments ae NEE ke De EE ENER 13 sae Linne and Eer 14 Machine Weights 0 0 0 0 anann 14 Dalcly E le 5 esau dechene edo sGenee done SeaGdusaeeee dons EE 15 E H Wachs Part No 60 MAN 03 Rev 3 0811 1 Bridge Slide Accessory for Low Clearance Split Frame Chapter 3 Operating Instructions e See dE ee ee dee A ee dE 17 Setting up the LCSF 2 er 17 Rousan Centering He WC EE 18 Setting Up the Indicator System 24 4 c 105424604 e604 sone deacetetdideeaiweeeaceds 19 Precisely Centers De LOST 19 re red CR TH EE 2l Installing the Bridge Side 22 EE EIER 24
44. sory is used for facing counterboring and beveling a pipe end surface The slide attaches to a low clearance split frame LCSF machine and bridges the end ofthe pipe A two axis tool mount has a trip driven radial drive that uses the LCSF s standard trip and a manual axial drive for setting the tool depth into the face of the pipe The bridge slide uses a single point tool and 1s available with beveling templates for various form contours The star wheel feed mechanism on the bridge slide feeds the tool slide radially in toward the center of the pipe If you need to perform an operation feeding the slide out away from the center of the pipe such as counterboring you will need to disengage the trip pin and operate the slide manually using a wrench on the castle nut Before setting up and operating the bridge slide you should be familiar with all of the operating and safety instructions for the low clearance split frame machine you are using Refer to the LCSF user s manual for instructions Bridge Slide Components Figure 1 1 and Figure 1 2 illustrate the components of the bridge slide Figure 1 3 illustrates the bridge slide mounting holes on the LCSF E H Wachs Part No 60 MAN 03 Rev 3 0811 3 Bridge Slide Accessory for Low Clearance Split Frame Axial Feed knob Bridge Lifting eye Radial feed hail shafts screw 22 EY Se os Top support Bottom support Figure I 1 Top view of the bridge slide showin
45. stanced between the pipe and LCSF at each location 5 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 1 NOTE LCSF machines 1824 and larger have 8 clamp pads Rough center at 4 locations 90 apart then tighten the remaining 4 clamp pads against the pipe 6 Repeatthis procedure at the two clamp pads locations 90 from the first two 7 Measure at all four locations again Re adjust if necessary 18 Part No 60 MAN 03 Rev 3 0811 E H Wachs Chapter 3 Operating Instructions Setting up the LCSF Setting Up the Indicator System The instructions 1n this section are for the Wachs indicator system part number 60 414 00 If you have a different indicator use the manufacturer s specific instructions for assembly and operation 1 Remove the motor assembly from the LCSF This is necessary to turn the rotating ring by hand Remove the frame locking pins if necessary Screw the threaded end of the indicator support shaft into the LCSF rotating ring For LCSFs from 612 through 1420 the indicator support shaft goes into the counterbore attachment hole on the rotating ring For LCSFs from 1824 through 4248 the indicator support shaft goes into the tool slide mounting hole on the rotating ring Assemble the dial indicator onto the support shaft 1 NOTE Make sure the inner surface of the pipe is clean and free of
46. t See Step 1 in Figure 3 64 E H Wachs Part No 60 MAN 03 Rev 3 0811 57 Bridge Slide Accessory for Low Clearance Split Frame x A o R fk n a V BY TANGENT 22 5X i i 7 gt i Gea E COSO C R SINO i SSSI A L EXTENSION We KH av m A LAND EXTENSION 6X B LAND R Y C A TAN WALL Y LAND R FOR REFERENCE ONLY Figure 3 62 Formulas for calculating bevel dimensions for a J prep Table 1 Example J Prep Dimensions om 0 250 0 125 0 125 0 3599 0 2895 0 8005 E 0 188 0 125 0 063 0 2258 0 2190 0 9654 Figure 3 63 Example dimensions for common bevel angles and J prep radii Part No 60 MAN 03 Rev 3 0811 E H Wachs Chapter 3 Operating Instructions Counterbore Operation SIEF T SIEP 2 SINGLE POINT BEVEL BLEND RADIUS MATERIAL REMOVED Figure 3 64 Cutting the J prep 3 Remove the straight bevel templates from the bridge slide 4 Remove the single point tool and insert the radius tool The radius tool fits in the single point tool holder 5 Replace the feed knob on the bridge slide 6 Turn the feed knob until the radius tool is close to the pipe face 7 Align a straightedge along the inner surface of the pipe out to the radius tool Using a 3 4 wrench or socket turn the castle nut until the edge of the radius tool is precisely aligned with the I D of the pipe 8 Using an indicator or other measuring
47. the machine or cleaning up after the operation but take them off when operating the machine 1 NOTE 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 Eye Protection Always wear impact resistant eye protection while operating or working near this equipment For additional information on eye and face protection refer to Federal OSHA regulations 29 Code of Federal Regulations Section 1910 133 Eye and Face Protection and American National Standards Institute ANSI Z87 1 Occupational and Educational Eye and Face Protection Hearing Protection This equipment can produce noise levels above 80 dB Hearing protection 1s required when operat ing the equipment The operation of other tools and equipment in the area reflective surfaces process noises and resonant structures 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 E H Wachs Part No 60 MAN 03 Rev 3 0811 11 Bridge Slide Accessory for Low Clearance Split Frame SAFE OPERATION OF THE BRIDGE SLIDE Refer to Safe Operation of the LCSF in Chapter 2 of the Low Clearance Split Frame User s Manual for full safety guidelines and instructions Intended Uses The
48. ure 3 23 Turn the feed knob counter clockwise as the machine rotates to advance the tool into the pipe 10 Stop the machine periodically and measure the depth of cut Figure 3 24 Measure the depth of the bore to the end of the taper as you cut the first pass 11 When you have reached the depth of cut you calculated in the previous section including the length of the tapered section stop turning the feed knob 12 Letthe LCSF make at least one complete rotation to finish the cut then stop the machine 13 Turn the feed knob clockwise to retract the male slide until the tool 1s past the I D ofthe pipe E H Wachs Part No 60 MAN 03 Rev 3 0811 35 Bridge Slide Accessory for Low Clearance Split Frame yp NOTE Each turn of the castle nut moves the tool radially about 0 077 For a 0 060 thick pass turn the nut about 3 4 turn 14 Turn the castle nut counter clockwise to move the tool the thickness of the next cutting pass over the I D of the pipe Remove the wrench before starting the LCSF 15 Start the machine and complete the second pass in the same way as the first Blend the taper of the second pass into the taper of the first and stop the machine 16 Perform an accurate measurement of the I D after each pass so that you know how much material still needs to be removed When the material remaining 1s less than the thickness of each cut you are ready to make the final pass 17 Forthe final pass measure the
49. wise until the tool just touch es the inside of the pipe Figure 3 20 Turn the castle nut counter clockwise to feed the tool toward the pipe I D 5 Manually rotate the split frame again slowly to verify that the tool clears the pipe surface all the way around Adjust by turning the castle nut if necessary 6 Turn the feed knob clockwise to retract the male tool slide until the tool is beyond the end of the pipe Figure 3 21 Retract the tool out of the pipe by turning the feed knob clockwise 1 NOTE If the cutting thickness is critical measure the movement of the slide as you turn the castle nut E H Wachs Part No 60 MAN 03 Rev 3 0811 33 Bridge Slide Accessory for Low Clearance Split Frame 7 Turn the castle nut counter clockwise to advance the tool over the I D of the pipe One turn of the castle nut moves the slide 0 077 If you are going to cut 0 060 turn the castle nut just over 3 4 of a turn Figure 3 22 Turn the castle nut counter clockwise to move the tool the required cutting width over the I D of the pipe 8 Attach the motor to the LCSF Refer to the LCSF user manual if necessary 9 Startthe machine To feed the counterbore tool turn the feed knob counter clockwise about 1 8 turn each revolution of the LCSF Each full rotation of the feed knob advances the tool 0 042 34 Part No 60 MAN 03 Rev 3 0811 E H Wachs Chapter 3 Operating Instructions Counterbore Operation Fig
50. you turn the feed knob 4 Advance the male tool slide by turning the feed knob counter clockwise Guide the bases of the templates into the mounting slots as you advance the slide Figure 3 34 Turn the feed knob counter clockwise to advance the slide and push the tem plates into their slots 5 Advance the slide until the bases of the template plates are fully seated in their slots Figure 3 35 The template is fully seated in its slot 42 Part No 60 MAN 03 Rev 3 0811 E H Wachs Chapter 3 Operating Instructions Counterbore Operation 6 Tighten the locking screws on the templates securely Use at least three screws on each template Gm IMPORTANT The screws holding the template must be tight or the template may pull out of the slot as the slide advances Figure 3 36 Tighten the screws holding the template 7 Inserta hex wrench through the hole in the feed knob and remove the screws holding the end block to the slide Rotate the knob to access each screw in turn 1 NOTE The screws in the end block are captivated and will not fall out E H Wachs Part No 60 MAN 03 Rev 3 0811 43 Bridge Slide Accessory for Low Clearance Split Frame Figure 3 37 Use a hex wrench to remove the four screws in the end block Rotate the feed knob to access each screw 8 Turn the feed knob counter clockwise to unscrew and remove it Figure 3 38 With the end block loose turn the feed knob counter clockwise to
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