Manual - EH Wachs
Contents
1. bend 18 Environmental Requirements ose vele Rowe 22 Long Term Storage dated KAMEN 22 eae a edo nels A a 23 Chapter 5 Operating Instructions 25 Frame Set Upa ye DO ano qase Rud qus 25 Splitting and Closing the Frame 2 no a er R 25 Mounting The Frame on the Workpiece 28 Altemate Clamping Legs aes bre rU hg oh e EH aes 31 Installing and Connecting the Drive 33 Hydra lie Drive oai inae ets o tele dp 33 Dual Motor Drive Option 37 ub mec rm 37 Tracking slide esee thus LAU seta Saya te ci erase tete M LA 39 Slide Set Up for Cutting and Beveling 39 slide Set Up for Offset Cutting ya ves eS Pb eR PETENS Nee ded 43 Operation iie milicie na pex Pb VA b Pla Row A QI ETE PEDIS PES SA 43 Chapter 6 Routine Maintenance 45 ubricaliom AERE RR Zo V R HRAB REDIERE SRI TIG teenies 45 E H Wachs Part No 03 010 MAN Rev 4 0213 i Heavy Duty Split Frame Tool Inserts ces a E de C RR Ru C M I GU CR A NC dd 46 Cleaning volue ed vos tie eA Gale ee urne pr ee sa WP ES2. lo leo lo o FO AIN o 70 Part No 03 010 MAN Rev 4 0213 E H Wachs Chapter 8 Parts Lists and Drawings Parts Lists 2 00 07417 655 3 8 16 X 3 4 OVAL POINT 2 50 74 05 655 3 8 16 X 1 2 2 05 082 00 DILER AIRLINE 090 098 010 NIPPLE 1 2 NPT 2 100 00 KONTROL SPEED Slides and Trip Qty PartNo Description 4 60 1002 01 CLAMP SUDE 4 03010032 BARGUIDE 4 03010034 RETAINER SPRING SUDETOL O 03 010 035 SLIDE TOOL 60 1009 01 NUT FEED 2 60 1017 PIN TRACKINGWHEEL 60 1030 EARING 2 0 x 2 188 1 5 LG SLEEVE 03 010 209 EARING 753 x 878 x 1 5 LG SLEEVE 2 6 60 1036 WASHER 75x125x 063THRUST 4 02010214 4 601037 WASHER 1 0X1 75x 058THRUST 2 NN 22 H B B B E H Wachs Part No 03 010 Rev 4 0213 71 Heavy Duty Split Frame 03 010 216 03 010 217 03 010 218 60 1042 03 010 220 COLLAR 75 x1 5 x 50 SHAFT 2 PIECE 90 800 30 WRENCH 3 4 COM BINATION 90 800 29 90 80 40 90 170 15 SHCS 3 8 16 x 1 1 2 LG SS 90 173 10 FHCS 3 8 16 x 1 LG SS HHCS 1 2 13 x 1 1 4 LG GRADE 8 9 ULTRACOAT HHCS 1 2 13 x 1 1 2 LG GRADE 8 9 90 191 15 ULTRACOAT HHCS 1 2 13 x 4 LG FULLY THREADED GRADE 8 9 ULTRACOAT 90 164 05 90 066 07 2 9
3. Figure 5 14 Install the hydraulic motor on the frame at the mounting location 5 Back out the pinion clearance adjustment screw to allow the pinion the most travel into the machine Pinion clearance Pinion clearance set screw adjustment screw Mounting bolts Figure 5 15 The photo shows the screws used to mount and adjust the pinion housing 34 Part No 03 010 MAN Rev 4 0213 E H Wachs Chapter 5 Operating Instructions Installing and Connecting the Drive Motor 6 Press the pinion gear toward the large ring gear until full gear engagement is felt The housing rotates on the pin next to the mounting bolts 7 Hand tighten the pinion clearance adjustment screw until it bottoms out Tighten jam nut with wrench This prevents the motor from moving out of location 8 Fully tighten the two mounting bolts with a wrench 9 Connect the hoses from the hydraulic power unit HPU to the flow control valve assembly as shown in Figure 5 16 10 Connect the hoses from the hydraulic motor on the split frame to the flow control valve assembly as shown in Figure 5 16 Pressure hose from power unit Pressure hose to HDSF Flow bypass circuit Return hose to power unit Return hose from HDSF Figure 5 16 Connect the flow control valve as shown between the HPU and the split frame motor E H Wachs Part No 03 010 MAN Rev 4 0213 35 Heavy Duty Split Frame 11 Set the flow lever on the flow c
4. Wachs 600 Knightsbridge Parkway Lincolnshire IL 60069 www ehwachs com Heavy Duty Split Frame User s Manual E H Wachs Part No 03 010 MAN Rev 4 0213 February 2013 Revision History Original August 2006 Revision 1 April 2009 Revision 2 June 2009 Revision 3 October 2009 Copyright 2013 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 EU DECLARATION OF CONFORMITY WITH COUNCIL DIRECTIVE 2006 42 EC Issue Details Date Place 1 1 2011 Wachs Lincolnshire IL USA Directives Machinery Safety Directive 2006 42 EC Conforming Machinery Heavy Duty Split Frame Machine Model Number 010 4 Manufacturer E H Wachs Company 600 Knightsbridge Parkway Lincolnshire IL 60069 USA Responsible Representative Orbitalum Tools GmbH osef S ch ttler Str 17 78224 Singen Germany Tel 449 0 7731 792 872 Fax 49 0 7731 792 566 Harmonised Standards amp EN ISO 12100 1 2003 A1 2009 EN ISO 12100 2 2003 Other Technical A1 2009 EN ISO 13857 2008 EN 982 1996 A1 2008 Standards S pecifications E EN 983 1996 A1 2008 E EN 13732 1 2006 EN Applied or Referenced ISO 14121 1 2007 EN 60204 1 2006 for electrical machines EN ISO 13850 2008 for pneumatic machines Provisions with which Essential Health and Safety Requirements of Annex 1 of the Conformity is Declared Machinery Directive
5. 3 Reversethe ratchet on the frame jack Operate the jack to close the hinge 4 Push the swing latches back into their channels at all four locations and tighten the nuts to secure the split points 5 Screw the clamping pads all the way into the clamping legs using a socket wrench inserted through the back of each clamping leg 28 Part No 03 010 MAN Rev 4 0213 E H Wachs Chapter 5 Operating Instructions Frame Set Up Figure 5 6 Use a 1 1 8 socket inserted through the back of the clamping leg to screw the clamping pads all the way back 6 Set the clamping leg positions for the size of the pipe you are cutting With the leg clamping blocks loos ened move the leg to the desired position and rotate it to set the position pin into one of the notches on the leg Position notches Position pin Figure 5 7 The position notches in the leg fit onto the pin in the outside clamping block The notches are 1 25 mm apart By NOTE If you have the alternate design clamping legs see Alternate Clamping Legs later in this section IMPORTANT Set all four or eight clamping legs at the same position notch If all legs are not set the same the machine will not be centered on the work piece and will not operate properly E H Wachs Part No 03 010 MAN Rev 4 0213 29 Heavy Duty Split Frame 7 Tighten the screws on the clamping blocks to secure the leg
6. LONG TERM STORAGE SHIPPING E H Wachs Part No 03 010 MAN Rev 4 0213 Heavy Duty Split Frame By NOTE Keep the flow control valve assembly out of the crate until you have stored both halves of the HDSF ring Figure 4 2 An optional larger shipping case allows the HDSF to be shipped fully assembled See the Set Up section of Chapter 5 for instructions on opening the ring for mounting it on a workpiece STORING THE HDSF For the standard shipping case split the machine into halves before putting it into the storage case Reverse this proce dure to remove the machine from the case 1 Remove the slides trip assembly and hydraulic motor from the machine Store them in the case as shown in Figure 4 3 18 Part No 03 010 MAN Rev 4 0213 E H Wachs Chapter 4 Assembly Disassembly and Storage Storing the HDSF 0 Hydraulic motor Jack Trip assembly Figure 4 3 Store the smaller components of the machine in the bottom of the storage case 2 Rotate the rotating ring until the split points on both rings are aligned Figure 4 4 Turn the rotating ring so that the split lines on both rings are aligned E H Wachs Part No 03 010 MAN Rev 4 0213 19 Heavy Duty Split Frame AN WARNING Failure to engage the frame locking levers before splitting the machine could allow the rotating ring to rotate partially or fully out of the stationary ring Serious injur
7. 88 S3313WITIIW 33V 13159 34 NI SNOISNAWIG L021 SLY 955 loei toee 99 2018 86020 voz 3S0H 000 19 mia 00 18 98 06 0074 18 16211 188281 logit 990 DOCE 08061 z209 0017 1508 rset 109261 0052 985b 0009 Iegi 0551 866 Izigo 78 00 07 270091 0022 190b 2I 00 9 98 86 0088 0 86 26121 918 186481 78 86 9087 VS62U 0081 no Pra 00116 98 26 009 722 7716 189241 238 0095 9 06 ogyz 2S0H 0021 19 82 9609 00 6 9997 0047 377 9 609 Iep 9 918 2876 18 89 086 1977 75555 00 12 Tx a7 sniava 501098 40344 13 IHOHM WIG wid V WIG 318V1 Part No 03 010 Rev 4 0213 E H Wachs 16 Chapter 4 Assembly Disassembly and Storage Chapter 4 Assembly Disassembly and Storage The major components of the heavy duty split frame are factory assembled and ready for set up The machine can be supplied completed assembled or split apart with a custom case for shipping and storage Two case options are shown in Figure 4 1 and Figure 4 2 Figure 4 1 The heavy duty split frame is stored and shipped in a custom built case In This Chapter STORING THE HDSF ENVIRONMENTAL REQUIREMENTS
8. 46 Chapter 7 Service and Repair sey ese EE 47 Adj sti g the Bearings Suor ness uad cepe ERI ERSTER MEE i Sua fed 47 Adj stng the Pinion Gear ous esce eMe MUNI GM A 52 Adjustneg the s yau saus EE eet R A V kia kau Se 53 Slide HSpECHON fossa ee ad Q su ly kee es Hos ae ede 53 Tracking Wheel Disassembly 54 Peed Screw Adjustment Procedure 56 Bushing Inspection and Replacement 60 Chapter 8 Parts Lists and Drawings cece cece cece rece nnn 63 Parts Lasts ssa ea Gy Rekorde ae A RS eG ERE IEA QU ARG eS Hae eee ees 63 Dive Options q SQ eo T a Ee ee Oa 68 BAW Soa een Le Mo 75 Chapter 9 Accessories and Spare Parts 83 85011857 Or SD ELLA eia a ELLA RN 83 Recommended Spares xu PRAK TA OA OBA se 84 Chapter 10 Ordering Information 85 Ordering Replacement Parts Be TRA 85 Information ua us d tado ed 85 Warranty Information banana 86 Return Goods Addresses is ud PO ER ONS s de es DuC eae 86 ii Part No 03 010 MAN Rev 4 0213 E H Wachs Chapter 1 About This Manual Chapter 1 About Th
9. Figure 5 8 After positioning the leg tighten the clamping block bolts to secure it 8 Inserta 1 1 8 socket through the back of each clamp ing leg and adjust them so that the pads are just touch ing the pipe 9 Working on two opposite legs at a time adjust the legs so that each one is extended to the same length cen tering the HDSF on the pipe Figure 5 9 Tighten the clamping pads using a 1 1 8 socket inserted through the back of the clamping leg 10 Securely tighten all clamping legs to firmly affix the frame to the pipe 30 Part No 03 010 MAN Rev 4 0213 E H Wachs Chapter 5 Operating Instructions Frame Set Up 1 1 Remove tension on the lift slowly making sure the ring does not shift Remove the lift chains or straps Alternate Clamping Legs If your HDSF has the alternate design clamping legs install and adjust them using the following procedure Figure 5 10 Use the procedure in this section if you have the alternate clamping legs shown in the photo 1 Align one of the holes in the leg with the dowel pin in the HDSF rotating ring Choose the hole that will mount the leg as close to the workpiece as possible with enough travel in the clamp screw to tighten and loosen the leg E H Wachs Part No 03 010 MAN Rev 4 0213 31 Heavy Duty Split Frame Mounting e Dowel pin Figure 5 11 Align one of the mounting holes in the leg with the dowel pin on the HDSF
10. Install the air motor on the motor mount as shown in Figure 5 19 2 Adjust the clearance between the pinion gear and the rotating frame gear using the pinion clearance adjust ment screw see Figure 5 15 The pinion gear should be as close as possible to the frame gear without bind ing Ay NOTE The air supply should provide 95 cfm 2690 Maximum pressure should be no more than 90 psi 1300 bar E H Wachs Part No 03 010 MAN Rev 4 0213 37 Heavy Duty Split Frame Use the following tools to attach and By adjust the air motor 3 4 socket to tighten the motor mounting bolts and the pinion clearance set screw 1 2 socket to turn the pinion clearance adjustment screw Figure 5 19 Install the air motor on the frame and tighten the two bolts underneath that secure it Pinion clearance Pinion clearance set screw adjustment screw Mounting bolts Figure 5 20 Two bolts fasten the air motor mount to the frame To set the pinion clearance loosen the set screw and turn the adjustment screw Re tighten the set screw 38 Part No 03 010 MAN Rev 4 0213 E H Wachs Chapter 5 Operating Instructions Tracking Slide Set Up 3 Attach the air supply line to the connector on the drive motor TRACKING SLIDE SET UP The tracking slides provide uniform cutting and beveling on pipes that are out of round or in situations where the split frame is not centered on the pipe The spring
11. We hereby certify that the machinery described above conforms to the provisions of Council Directive 2006 42 EC on the approximation of the laws of the Member States relating to the safety of machinery Signatory Pete Mullally Quality Manager E H Wachs Table of Contents Table of Contents Chapter 1 About This Manual 1 Purpose Manual 3 s eee Ves eee R 1 How te Use The Manual Cond es ame o NR 2 Symbols and acea dd Seales She ees 2 Manual Updates and Revision Tracking sa doda eis ee ee s ee ea ai 3 Chapter 2 Sdlely oss iua eREEOXPSCEERPIRA COSE GA QE EUER N 5 Operator SAC sous ROL OB 5 Safety Symbols 255 cde dos sepe LE dU UNE cL Lp ere utei 6 Protective Equipment Requirements 7 Safety Eabels ERE RUNE E PARAR b la 7 Chapter 3 Introduction to the Equipment 9 Usage and Applications iiis ok oA REI AR la ran riadni d ky 1A TT IR s 9 Mechanical OVerview UT 10 ACCPSSOHES ANG QptI BS ed b Eq eo od piae s D EN M A S ata us 14 Operating Envelope ss 2s 21143414414 so a doh TA GA ERA REDIERE NAAR 15 Chapter 4 Assembly Disassembly and Storage 17 Storing the HDSE
12. access hole in the rotating ring NOTE depending on the size of the split frame you may need to use the motor drive to turn the frame 50 Part No 03 010 MAN Rev 4 0213 E H Wachs Chapter 7 Service and Repair Adjusting the Bearings 17 18 19 20 21 22 Figure 7 5 The diagram shows the tightening order of bearings in the heavy duty split frame View is look ing down onto rotating ring Different sized machines will have different numbers of bearings Insert a 1 4 hex wrench through the bearing access hole and turn the eccentric shaft of the bearing clock wise until the bearing feels fully seated in the groove Hold the eccentric shaft at this position with the wrench On the back of the stationary ring tighten the Nylock hex nut for bearing 1 Repeat steps 16 18 for bearing 2 then 3 and 4 in order See Figure 7 5 After you tighten these four bearings turn the rotating ring to re align the split points Swivel the frame locking levers to the locked posi tions If the levers cannot be fully seated in the locked position loosen bearings 1 4 and repeat steps 16 18 Do not proceed until the bearings are adjusted so that the locking levers will seat properly Swivel the frame locking levers back to the unlocked position before proceeding to the next pair of opposite bearings By NOTE Depending on the size of the split frame there may be a different number of be
13. 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 Safety Symbols A This icon 18 displayed with any safety alert that indicates a personal injury hazard Z WARNING This safety alert indicates a potentially hazardous situation that if not avoided could result in death or serious injury Z CAUTION This safety alert with the personal injury hazard symbol indicates a potentially hazardous situation that if not avoided could result in minor or moderate injury Part No 03 010 MAN Rev 4 0213 E H Wachs Chapter 2 Safety Safety Labels 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 Eve and Face Protection Z87 1 18 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 operat
14. tensioned tracking mechanism allows radial motion perpendicular to the side of the pipe of up to 1 2 inch keeping the cutting tool on the pipe at all times and compensating for a maxi mum 1 inch out of roundness for a parting tool the other can hold either a parting tool or a beveling tool You can use these slides to perform a cut ting and beveling operation or an offset severing operation with two parting tools Two tracking slides are provided One includes a tool holder By NOTE The beveling tool holder is designed for 1 2 wide x 3 4 tall cutting tools You can order a special tool cover for Slide Set Up for Cutting and Beveling 1 Position the slide mounting blocks for the parting tool slide on the split frame rotating ring and insert the Ay NOTE mounting bolts as shown in Figure 5 21 Do fob lightentne mounting bolts yet You will tighten them when you finish posi tioning the slide Figure 5 21 Install the slide mounting blocks on the rotating ring Leave the mounting bolts loose 2 Turn the star wheel on the parting tool slide to fully E H Wachs Part No 03 010 MAN Rev 4 0213 39 Heavy Duty Split Frame NOTE The parting tool slide can be mounted at either slide posi tion on the frame By NOTE Use a 1 1 8 inch open end wrench to turn the jacking nut NOTE Use a 3 4 inch socket wrench to tighten the mounting bolts retract the tool mount away from th
15. the two mounting bolts and let the pinion housing move back against the pinion clearance adjustment screw 11 Fully tighten the two mounting bolts with a wrench 12 Continue this method until the gears sound and feel smooth as the machine rotates 13 If using two drive motors repeat the procedure for the second motor Do not remove or change the first drive motor ADJUSTING THE SLIDES Slide Inspection 1 After each use wipe slides down and remove all cut ting chips 2 Inspectthe tracking wheel and bearing Make sure that it turns smoothly If it binds or turns rough further inspection of the bearing is required See Tracking Wheel Disassembly later in this section 3 The starwheel should turn by hand but not be free spinning If it spins freely you may need to adjust the E H Wachs Part No 03 010 MAN Rev 4 0213 53 Heavy Duty Split Frame feed screw split ring lock See Feed Screw Adjust ment Procedure later in this section 4 Inspect the starwheel trip for damage or wear Replace the trip if it is worn or broken 5 Inspect the tool post to ensure it is in good working order Using the feed nut on top of the starwheel move the slide through the full travel range top to bot tom If it binds or has play further inspection is required See Bushing Inspection and Replacement later in this section 6 The tool post and rods use bushings that need no fur ther lubricatio
16. 0 211 22 3 4 10 x 2 1 4 HHCS Gr 8 2 90 121 32 118 9 x 3 1 4 Gr 8 4 90 125 51 7 8 SAE WASHER 66 Part No 03 010 MAN Rev 4 0213 E H Wachs Chapter 8 Parts Lists and Drawings Parts Lists 24 90 062 05 5 16 18 1 2 BHCS 2 90 225 04 NUT NYLOCK 7 8 9 1 90 317 30 3 4 X 3 SHOULDER SCREW 1 90 205 04 NUT NYLOCK 1 90 215 51 3 4 SAE WASHER 1 90 205 59 5 8 SAE WASHER 1 90 175 54 WASHER X TRA THICK STAINLESS 1 90 072 07 BHCS 3 8 16 X 3 4 2 90 214 30 3 4 10 X3 555 12 90 093 10 FHCS 1 2 13 x 1 24 HDSF Frame 1 03 010 001 24 ROTATING RING 03 010 002 24 STATIONARY RING 03 010 005 GUARD STRIP 18 51 017 00 SHAFT ECCENTRIC 18 51 018 00 SPACER BEARING 2 03 010 014 ARM HINGE RATCHET 03 010 016 HINGE MAIN 03 010 015 PLATE LIFTING 03 010 017 STUD HINGE 18 51 024 00 BEARING GUIDE 43 in feet SEAL FELT WIPER 1 03 010 200 RATCHET HINGE 2 03 010 201 LOCK FRAM E 18 90 095 52 WASHER 1 2 SAE 18 90 045 08 NUT NYLOCK 1 2 13 2 90 121 32 7 8 9 x 3 1 4 HHCS Gr 8 4 90 125 51 7 8 SAE WASHER 24 90 062 05 5 16 18 x 1 2 BHCS 2 90 225 04 NUT NYLOCK 7 8 9 1 90 317 30 3 4 X 3 SHOULDER SCREW 1 90 215 51 3 4 SAE WASHER 1 90 205 59 5 8 SAE WASHER 1 90 175 54 WASHER X TRA THICK STAINLESS 1 90 072 07 BHCS 3 8 16 X 3 4 2 90 214 30 3 4 10 X3 SSS 12 90 093 10 E H Wachs Part No 03 010 MAN Rev
17. 016610 6 90 195 52 N 2 NA m m e HANDLE KNOB HHCS 1 2 13 x 2 LG SSS 3 8 16 X 1 LNG 4 90086210 PIN 7 16x1 D0OWEL Bearings 72 Part No 03 010 MAN Rev 4 0213 E H Wachs Chapter 8 Parts Lists and Drawings Parts Lists ty PartNo Description 90 500 05 14 28 GREASE ZERK 91831 137 NYLOCK 93919 pm SKF BEARING DOUBLE ROW 5203 ATN9 SKF 9815 SEAL BEARING 1 03 010 024 CLAMP BLOCK WHEEL 03 010 025 DRIVER BEARING NUT Clamping Legs Eu 1 1 Qty PartNo Description 03 010 098 1 COLAR 1 1 8 TWO PIECE CLAMP ZINC 4 HHGS 1 2 13 X4 GRADE 8 ZINC PLATED 1 1 SOCKET 1 1 8 SIX POINT x 1 2 DRIVE 1 RING 0 987 INCH INTERNAL RETAINING Hydraulic Speed Control E H Wachs Part No 03 010 MAN Rev 4 0213 73 Heavy Duty Split Frame Qty PartNo Description 03 010 136 03 010 138 03 010 137 03 010 225 03 010 226 03 010 227 Optional Milling Attachment Qty PartNo Description 1 03010083 Adapter FeedMotor 1 03010087 Shaft GearboxOutput 1 03010088 Adapter Pinion Housing 1 03 010 089 Flange Adapter 1 03 010 184 Adapter Coupling e e Planetary Gear Set 3 1 1 PlanetaryGearSet 4 1 Poa Spacer 0 0 0 0 01 HydradicMotr H Sere Radial Ball Bearing Reta
18. 0213 E H Wachs Chapter 5 Operating Instructions Operation Trip lock lever Trip adjustment knob Figure 5 25 Loosen the trip lock lever and slide the trip adjustment knob to position the trip beneath the star wheel on the slide Slide Set Up for Offset Cutting Follow the same procedure as the previous section for installing both slides When you install the beveling tool slide insert a parting tool instead of a beveling tool The beveling tool slide is designed to hold a parting tool with a 1 16 offset from the tool in the parting tool slide This will result in a cut 1 16 wider than the cut made by a single parting tool OPERATION 1 Power on the hydraulic power unit or turn on the compressed air supply 2 For hydraulic machines open the flow valve on the hydraulic motor 3 Slowly increase the hydraulic or air flow to provide power to the motor For hydraulic machines a flow of about 15 gpm will rotate the split frame at approxi mately 8 7 RPM IMPORTANT Do not operate the split frame with a single parting tool only A beveling tool or second parting tool is required to keep the parting tool from binding in the cutting groove AN WARNING Keep hands and clothing clear of the machine while operating it E H Wachs Part No 03 010 MAN Rev 4 0213 43 Heavy Duty Split Frame Ay NOTE If the beveling blade contacts the pipe before the parting blade stop the machin
19. 1 3 1 1 FR 1 1 1 00 098 01 NIPPLE 1 2 NPT 3 010 408 Double Pneumatic Drive Motor 2 2 2 2 90 060 07 SHCS 5 16 18 x 3 4 LNG 90 050 07 1 4 20 x 3 4 LNG 90 091 18 90 095 52 010 PIN LOCATING ADJUSTABLE LX EN 1 EM E 2 aw EN ES 21 EE E 21 EN cS co 95 CO vo N O CO UJ O H N 92 gt o e C u o H 00 O o N NA E H Wachs Part No 03 010 MAN Rev 4 0213 69 Heavy Duty Split Frame 90 059 48 074 074 66 100 00 082 90 098 01 3 010 409 Single Pneumatic Drive Motor 1 1 1 1 00 050 07 1 4 20 x 3 4 LNG 2 1 1 3 90 086 10 DOWELPIN 7 16 DIA x 1 LNG 1 1 1 1 3 010 410 Double Pneumatic Drive Motor 2 p3 010 2 p3 010 2 p3 010 2 p3 010 90 060 07 90 050 07 90 091 18 095 075 90 095 52 086 010 PIN LOCATING USTABLE 90 059 48 DRF KEY 1 4x1 EAR 2 2 2 2 2 c5 O O NN N o o e 1 4 0 e ad Ez ET a EX EX 21 EH L3 1 EX EN EN N u o lo Ww w o o o la lo lo N
20. 4 0213 67 Heavy Duty Split Frame Drive Options Qty PartNo Description 03 010 405 Single Hydraulic Drive Motor 1 1 1 00 070 07 3 8 16 x 3 4 LNG 10 NA 0 095 03 NUT 1 2 20 JAM 010 0 075 00 NUT 3 8 16 JAM 095 52 ASHER 1 2 SAE 90 086 10 DOWELPIN 7 16 DIA x1 LNG 90 091 18 HHCS 1 2 13 x 1 3 4 LNG GRADE 8 9 03 010 202 PIN LOCATING ADJUSTABLE 03 90 1 1 1 1 3 1 PEAR 1 3 010 406 Double Hydraulic Drive Motor 2 2 2 00 070 07 EHCS 3 8 16 x 3 4 LNG Co UJ lt gt co N 2 2 6 009552 WASHERI 2SAE DRF KEY 1 4 x 1 2 103 010 203 MOTOR 1 9 025 00 FEMALE o o co 68 Part No 03 010 MAN Rev 4 0213 E H Wachs Chapter 8 Parts Lists and Drawings Parts Lists C o e N a mn C wo e N N 21500 00000000 074 17 BSS 3 8 16X3 4OVALPONT 2 007405 655 3 816 02 Drive HDSF 1224 HDSF 3648 275 CO wo e N 99 25 N N Hn O c 00 OD MALE OTS NN 4 1 103 010 080 HOUSING PINION 1 103 010 081 OVER PINION HOUSING e e A e u e Tu 3 et a lt et o 00 050 07 1 4 20 x 3 4 LNG 2 1
21. 40 2 39Vd N 1n0AYl 300 9 00 sao omens 09 H3 820 OL Ba O EDI9 DT Hi um 05 23 LU ULL OvO E H Wachs Part No 03 010 MAN Rev 4 0213 78 Chapter 8 Parts Lists and Drawings Drawings 931319345 SSTINN 09 SHOVM CH J JHL WOM4 IN3SNOO 1 SNOUOVAJ SIOF X 1NOHLIM 35048014 ANY 404 G3SN 38 OL 219 010 60 O SONIMVEC SLYVd V SdNYTO 00 IL XX NIN SLF 5310 S00F XXX S39NVH3TIOL IWNOISN3AIQ 10N SI 9NIONVISN3OND AHL 09 SHOVM CH 3 3HL AB OZLIINANS ONY 30 AlM3dONd JHL SI NOISIG 40 FIdIONIYd IHL ONIONIONI 9NIMYMO SIHL 30 LON ON 193 084 79395 SHOVM 41020 SLIT Odd 2226 ws 103 084 60 5 01 OINM3d 9NFT33HM ow INA co c oi 39 09 SHOVMH I SOLO EE EL 920 010 0 IN IND SHOWM 13MOG 91 2 91 980 06 TAMOG ub X 91 2 Nid 01 980 06 Q3N3QMNVH Z L H3HSVM vS S60 06 6 8 91 L Z L SOHH Ly L60 06 ONINIVLAY GO M Z O ODL DNIA EZZ 0L0 0 690 X 2991 X O L H3HSVM 222 010 60 NMOHS LON 51 LSU OO U O AJ 79 Part No 03 010 MAN Rev 4 0213 E H Wachs Heavy Duty Split Frame 1 S4
22. 90 317 30 3 4 X3 SHOULDER SCREW 1 90 205 04 NUT NYLOCK 1 90 215 51 3 4 SAE WASHER 1 90 205 59 5 8 SAE WASHER 1 90 175 54 WASHER X TRA THICK STAINLESS 1 90 072 07 BHCS 3 8 16 X 3 4 2 90 214 30 3 4 10 X3 SSS 12 90 093 10 FHCS 1 2 13 x 1 72 HDSF Frame 1 03 010 002 72 STATIONARY RING 38 51 017 00 SHAFT ECCENTRIC 2 03 010 014 ARM HINGE RATCHET 4 03 010 015 PLATE LIFTING 38 51 024 00 BEARING GUIDE 1 03 010 200 RATCHET HINGE 2 03 010 201 LOCK FRAME 38 90 095 52 WASHER 1 2 SAE 2 90 211 22 3 4 10 x 2 1 4 HHCS Gr 8 4 90 125 51 7 8 SAE WASHER 24 90 062 05 5 16 18 x 1 2 BHCS 2 90 225 04 NUT NYLOCK 7 8 9 1 90 317 30 3 4 X 3 SHOULDER SCREW 1 90 205 04 NUT NYLOCK 1 90 215 51 3 4 SAE WASHER 1 90 205 59 5 8 SAE WASHER 64 Part No 03 010 MAN Rev 4 0213 E H Wachs Chapter 8 Parts Lists and Drawings Parts Lists 1 90 175 54 WASHER X TRA THICK STAINLESS 1 90 072 07 BHCS 3 8 16 X 3 4 2 90 214 30 3 4 10 X3 SSS 12 90 093 10 FHCS 1 2 13 x 1 60 HDSF Frame 1 03 010 001 60 ROTATING RING 03 010 005 GUARD STRIP 38 51 018 00 SPACER BEARING 1 03 010 016 HINGE MAIN 1 03 010 017 STUD HINGE 43 in feet SEAL FELT WIPER 2 03 010 201 LOCK FRAM E 38 90 095 52 WASHER 1 2 SAE 38 90 045 08 NUT NYLOCK 1 2 13 2 90 121 32 7 8 9 x 3 1 4 5 Gr 8 4 90 125 51 7 8 SAE WASHER 24 90 062 05 5 16 18 x 1 2 BHCS 2 90 225 04 NUT NYLOCK 7 8 9 1 90 317 30 3 4 X 3 SHOU
23. AIYG O1 010 0 0 ON 9NIMYHO SONIMVYG SLYVd 53 140 Juu 03419345 SSTINN ze tF SNOILOVA4 90 X 00 NTL OLOF XX NIN SLF 5310 S00F XXX SJINYM3101 TWNOISN3WIG 09 SHOVM CH 3 3HL 1N3SNOO NALLIYM 1NOHLIM 3SOduNd ANY 404 0350 38 OL LON SI LVHL ONIGNVISY3ONN JHL HLM 09 SHOVM CH 3 3HL AB OJLUNENS ONY JO AlN3dONd 3Hl SI N9IS3Q JO JIdIONIYd JHL ONIONIONI ONIMVYC SIHL 32 ON 103 0844 14912345 SHOVM 193fOdd S0 G 0 NOS10 ON 034 1N3110 60 6 01 OlNN3d Nawa 1 SHOVM 40020 SIIT Odd WiDZdS 1 DNIT33HM 03 SHOVMH 3 CeO kl TU o E H Wachs Part No 03 010 MAN Rev 4 0213 80 Chapter 8 Parts Lists and Drawings Drawings i 0010 0 O SLYVd 1081 03 9134 031312395 SSTINN SNOILOVY4 SIOF X 00 IL 010 XX NIN SLF S3IONV 00 A8 349389 S39NVH310L IWNOISN3AIQ Q310N SV wam 3NON ON LO3POYd 799345 SHOVM TI 1 ex Nano 90 18 80 w 07 SHOVMH I 3WVN 1N3ITO awo 41027 SLIT Odd 2226 00 SHOVM CH JHL WOM4 IN3SNOO 1NOHLIM 36504804 ANY 404 0351 38 OL 10N SI IVHL ONIONVISM3ONN JHL 09 SHOVM CH 3 JHL AB GALIINBNS ON
24. H Wachs Chapter 7 Service and Repair Adjusting the Slides Figure 7 15 Turn the spring tension nut to move the end plate all the way forward 7 Turn the feed nut on the starwheel clockwise to retract the slide to the center of its travel lt Center of travel Figure 7 16 Turn the starwheel nut clockwise until the slide is approximately at the center of travel E H Wachs Part No 03 010 MAN Rev 4 0213 59 Heavy Duty Split Frame Bushing Inspection and Replacement Remove roll pin from the starwheel and slide the star wheel off of feed shaft Figure 7 17 Use a punch to remove the roll pin hold ing the starwheel in place then pull the starwheel off the feed shaft 2 Loosen the screws on the split ring lock and remove it 7 pm Ve 1 vM e b 1 Figure 7 18 Remove the split ring lock from the feed shaft 3 Remove the set screw in the end of the tool post and remove tracking wheel shaft and wheel 60 Part No 03 010 MAN Rev 4 0213 E H Wachs Chapter 7 Service and Repair Adjusting the Slides Figure 7 19 Remove the tracking wheel shaft and the tracking wheel 4 Loosen and remove the screws in the bottom shaft supports Figure 7 20 Remove the screws holding the shaft supports 5 Remove the bottom two shaft supports E H Wachs Part No 03 010 MAN Rev 4 0213 61 Heavy Duty Split F
25. LDER SCREW 1 90 215 51 3 4 SAE WASHER 1 90 175 54 WASHER X TRA THICK STAINLESS 1 90 072 07 BHCS 3 8 16 X 3 4 2 90 214 30 3 4 10 X3 SSS 12 90 093 10 FHCS 1 2 13 x 1 48 HDSF Frame 1 03 010 001 48 ROTATING RING 03 010 002 48 STATIONARY RING 4 03 010 005 GUARD STRIP 32 51 017 00 SHAFT ECCENTRIC 32 51 018 00 SPACER BEARING 2 03 010 014 ARM HINGE RATCHET E H Wachs Part No 03 010 MAN Rev 4 0213 65 Heavy Duty Split Frame 1 03 010 016 HINGE MAIN 1 03 010 017 STUD HINGE 43 in feet SEAL FELT WIPER 1 03 010 200 RATCHET HINGE 2 03 010 201 LOCK FRAME 32 90 095 52 WASHER 1 2 SAE 32 90 045 08 NUT NYLOCK 1 2 13 2 90 211 22 3 4 10 x 2 1 4 HHCS Gr 8 2 90 121 32 7 8 9 x 3 1 4 HHCS Gr 8 4 90 125 51 7 8 SAE WASHER 24 90 062 05 5 16 18 x 1 2 BHCS 2 90 225 04 NUT NYLOCK 7 8 9 1 90 317 30 3 4 X 3 SHOULDER SCREW sst 1 90 215 51 3 4 SAE WASHER 1 90 205 59 5 8 SAE WASHER 1 90 175 54 WASHER X TRA THICK STAINLESS 1 90 072 07 BHCS 3 8 16 X 3 4 2 90 214 30 3 4 10 X3 SSS 12 90 093 10 FHCS 1 2 13 x 1 36 HDSF Frame 1 03 010 001 36 ROTATING RING 4 03 010 005 GUARD STRIP 26 51 018 00 SPACER BEARING 1 03 010 016 HINGE MAIN 1 03 010 017 STUD HINGE 43 in feet SEAL FELT WIPER 1 03 010 200 RATCHET HINGE 2 03 010 201 LOCK FRAME 26 90 095 52 WASHER 1 2 SAE 26 90 045 08 NUT NYLOCK 1 2 13 2 9
26. NSTALLING AND CONNECTING THE DRIVE MOTOR TRACKING SLIDE SET UP OPERATION By NOTE Required tools for this proce dure 3 8 hex wrench 1 2 socket wrench 3 4 socket wrench 7 8 socket wrench 1 1 8 socket wrench 1 1 8 open end wrench E H Wachs Part No 03 010 MAN Rev 4 0213 25 Heavy Duty Split Frame AN WARNING Failure to insert the frame locking pins before splitting the machine could allow the rotating ring to rotate partially or fully out of the stationary ring Serious injury and equipment damage could result 2 Insert the frame locking pins at both locations next to the split points to keep the rotating and stationary rings together 1 2 v i crt Figure 5 2 Insert both frame locking pins through the stationary ring and rotating ring Press the button on the handle of the pin to insert or remove it 3 Attach the hinge and the jack to the hinge side of the frame The hinge side has two threaded holes as shown in Figure 5 4 Swing latches Frame jacking screw 8 Hinge Ratchet arm vA Figure 5 3 Attach the hinge and the jack to the split point 26 Part No 03 010 MAN Rev 4 0213 E H Wachs Chapter 5 Operating Instructions Frame Set Up Ss Figure 5 4 The hinge side of the frame has two threaded holes for attaching the hinge 4 There are four swing latches at each split point as shown in Figure 5 3 two on the top ro
27. S CLEANING E H Wachs Part No 03 010 MAN Rev 4 0213 45 Heavy Duty Split Frame TOOL INSERTS Check the sharpness of the tool inserts frequently Replace dull inserts as necessary CLEANING Clean the slides of all chips and debris after each use Make sure that all chips are cleared from around the tracking wheel See instructions for disassembly in Chapter 7 Every 8 hours of operation remove and clean the tracking wheel and bearings on both slides 46 Part No 03 010 MAN Rev 4 0213 E H Wachs Chapter 7 Service and Repair Chapter 7 Service and Repair The heavy duty split frame is a durable system with little required maintenance This chapter contains information on performing machine adjustments and service ADJUSTING THE BEARINGS You should adjust the bearings in the split frame if you can feel play between the rotating and stationary rings To check for play lay the assembled split frame on a work sur face with the rotating ring down Push back and forth on the stationary ring if it moves the bearings need to be adjusted according to the following procedure 1 Lay the split frame on the work surface with the rotat ing ring up 2 If the tool slides are installed remove them 3 Align the rotating ring with the stationary ring so that the split points are aligned In This Chapter ADJUSTING THE BEARINGS ADJUSTING THE PINION GEAR ADJUSTING THE SLIDES By NOTE Requi
28. Wall Alternate Clamp Leg Design E H Wachs Part No 03 010 MAN Rev 4 0213 82 Chapter 9 Accessories and Spare Parts Chapter 9 Accessories and Spare Parts In This Chapter 2 ACCESSORIES This chapter lists accessories and recommended spares for the heavy duty split frame See Chapter 8 for information on ordering replacement parts and accessories RECOMMENDED SPARES ACCESSORIES Speed control valve for use with hydraulic power units without built in flow control See Figure 9 1 Figure 9 1 The flow control valve is used to set the cutting speed of the HDSF when there is no flow con trol on the hydraulic power unit E H Wachs Part No 03 010 MAN Rev 4 0213 83 Heavy Duty Split Frame RECOMMENDED SPARES Table 1 lists the recommended spare parts for stocking Table 1 Spare Tooling Part Description Part Number 6 x 1 4 Parting Tool HSS 60 711 00 37 5 Beveling Tool 53 703 00 84 Part No 03 010 MAN Rev 4 0213 E H Wachs Chapter 10 Ordering Information Chapter 10 Ordering Information To place an order request service or get more detailed In This Chapter information on any E H Wachs products call us at one of ORDERING REPLACENIENT the following numbers PARTS US 800 323 8185 REPAIR INFORMATION International 847 537 8800 WARRANTY INFORMATION RETURN GOODS ADDRESS You can also visit our Web site at www ehwachs
29. Y 30 AlM3dOMd JHL SI N9IS3Q jO 3142 4 IHL 9NIQTIONI ONIMVYG SIHL 39LLON NANLIY OL HLONJ1 3SOH 9391553 BE die 2 bu NdH E 55444 31VW4 4 dvd LSNA GO 3TvN LSNA F1VW dd T1VW4 dd LV14 MOOTAN 02 9 LAN X 02 v 1 SOHS A 18IN3SSV ISOH 331 Moga dH 2 1 1 AQQVO 00 820 60 00 220 60 00 920 60 00 80 60 0 SS0 06 90 SS0 06 0 0G0 06 161 010 60 146 010 60 9 6 010 60 8S 860 06 Scc 010 0 861 010 60 961 010 60 N lt QN QN CN CN CN CN 540 N d 81 Part No 03 010 MAN Rev 4 0213 E H Wachs Heavy Duty Split Frame l ONIX ONINIVI33 86 HM ASIIOLUS LL YOWAY 61 0 1 SOHH 98016 01 L dWY10 JOJld OM1 8 1 1 6 I3IOV3g 660 010 0 8 1N3I3Q Nid 860 010 0 Z ISNYHL W4HSYM 160 010 60 9 L 931 dWV1O 432V4S 960 010 0 S l 231 dWV19 M332 60 010 0 y l 231 dWV1TO 1NAWNGIJM 760 010 0 l 231 dWV1O A33 160 010 0 l 231 dWV19 ONISNOH 060 010 0 l AID NOIIdI32 3Q 13 vd ON
30. arings than shown in the diagram Follow the general pattern of tightening opposite pairs then moving to another pair approximately 90 around the frame Ay NOTE Use a 7 8 socket to tighten the Nylock nuts E H Wachs Part No 03 010 MAN Rev 4 0213 51 Heavy Duty Split Frame NOTE Do NOT force the bearing tight against the groove 23 24 23 26 27 28 Starting with bearing 5 use the 1 4 hex wrench to turn the eccentric shaft counter clockwise until you can feel the bearing just touch the groove While hold ing the bearing in this position tighten the Nylock nut on the back of the stationary ring Repeat steps 22 23 for the remaining bearings in order After adjusting each pair of opposite bearings set the frame locking levers to make sure they fully seat If the levers do not seat re do the adjustment of the pair of bearings just completed Go back to bearing 1 and turn the eccentric shaft back counter clockwise until it just touches the groove While holding the bearing in this position tighten the Nylock nut on the back of the stationary ring Repeat step 25 for bearings 2 through 4 Check that locking levers seat after each pair of bearings After adjusting all bearings check that the rotating ring turns freely on the stationary ring If it doesn t repeat steps 23 26 Looking through the alignment pin hole turn the rotating ring through one full revolution a
31. com 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 Your name company name Your address e Your phone number A description of the problem or the work to be done E H Wachs Part No 03 010 MAN Rev 4 0213 85 Heavy Duty Split Frame Before we perform any repair we will estimate the work and inform you of the cost and the time to complete it 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 86 Part No 03 010 MAN Rev 4 0213 E H Wachs E H WACHS Superior Equipment Complete Support 600 Knightsbridge Parkway Lincolnshire IL 60069 847 537 8800 www ehwachs com
32. crate using the provided straps ENVIRONMENTAL REQUIREMENTS The heavy duty split frame can be used in any industrial environment The machine can be used for dry cutting or with coolant applied to the workpiece If you use the HDSF in a salt water environment spray it thoroughly with clean water after use LONG TERM STORAGE If you will be storing the heavy duty split frame take the following steps to prepare it e Make sure the machine is thoroughly cleaned and cleared of chips and debris e Spray the machine with a rust preventative Add a desiccant to the storage case 22 Part No 03 010 MAN Rev 4 0213 E H Wachs Chapter 4 Assembly Disassembly and Storage Shipping Always store the machine and its accessories in the stor age case provided SHIPPING The heavy duty split frame should be shipped in its storage case Make sure all components are correctly positioned and fastened in the case and securely fasten the case lid E H Wachs Part No 03 010 MAN Rev 4 0213 23 Heavy Duty Split Frame 24 Part No 03 010 MAN Rev 4 0213 E H Wachs Chapter 5 Operating Instructions Chapter 5 Operating Instructions FRAME SET UP Splitting and Closing the Frame 1 Align the rotating and stationary rings so that the split points are aligned Figure 5 1 Turn the rotating ring so that the split lines on both rings are aligned In This Chapter FRAME SET UP I
33. e and adjust the slides by turning the star wheel IMPORTANT s Watch the tracking wheels to make sure that they stay clear of chips Use coolant on the cutting surface to improve cutting and extend tool life As the tools penetrate the pipe surface watch to make sure both slides are advancing at the same rate Depending on the type of material being cut the difference in resistance on the two tools may cause one to advance more slowly If one slide is advancing too rapidly slow the machine to the slow est speed possible and retract the slide slightly using a socket on the star wheel If you are operating with the split frame horizontal cutting a vertical pipe you may have to clear chips from the track ing wheels Use compressed air to blow the chips out as the slides pass or stop the machine and brush the chips out of the wheel assembly Part No 03 010 MAN Rev 4 0213 E H Wachs Chapter 6 Routine Maintenance Chapter 6 Routine Maintenance The heavy duty split frame requires minimal maintenance Follow the lubrication guidelines in this chapter LUBRICATION Before each machining operation lubricate the slide rods on both slides Lubricate the slide rods using conventional grease Figure 6 1 Lubricate the slides before each machin ing operation Apply standard grease to all grease fittings on the split frame every time you use the machine In This Chapter LUBRICATION TOOL INSERT
34. e pipe Mount the parting tool slide onto the rotating ring by sliding the base plate into the channels on the under sides of the slide mounting blocks Leave the mount ing bolts loose Turn the jacking screw on the parting tool slide so that the end plate is all the way forward toward the bar guides Turn the nut back one turn Jacking nut End plate Figure 5 22 Turn the slide jacking nut to retract the end plate all the way back fully compressing the springs After fully retracting turn the nut back one turn Push the slide all the way toward the pipe until the tracking wheel contacts the pipe surface Tighten down the bolts on the mounting blocks until they are just snug enough to keep the slide from mov ing freely Do not tighten them completely the slide will need to move when you run the machine to set the high point Repeat Steps 1 6 for the beveling tool slide 40 Part No 03 010 MAN Rev 4 0213 E H Wachs Chapter 5 Operating Instructions Tracking Slide Set Up 8 Remove the frame locking pins and put them in the storage holes provided Figure 5 23 Remove the frame locking pins and put them in the holes provided for storing them as shown 9 Engage the power and slowly drive the frame around the pipe one complete rotation As the tracking wheel AN WARNING on each slide travels over the surface of the pipe it will push the slide back so that it is in position to con Keep hands and cloth
35. gning and manufactur ing safe high quality products We make user safety a top priority in the design of all our products Read this chapter carefully before operating the heavy duty split frame It contains important safety instructions and recommendations OPERATOR SAFETY Follow these guidelines for safe operation of the equip ment READ THE OPERATING MANUAL Make sure you understand all setup and operating instructions before you begin INSPECT MACHINE AND ACCESSORIES Before starting the machine look for loose bolts or nuts leaking lubricant rusted components and any other physical conditions that may affect operation Properly maintaining the machine can greatly decrease the chances for injury 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 Look for this sym AN bol throughout the manual It indicates a personal injury hazard E H Wachs Part No 03 010 MAN Rev 4 0213 Heavy Duty Split Frame Always turn machine off before doing any adjustments or service SECURE LOOSE CLOTHING AND JEWELRY Secure or remove loose fitting clothing and jewelry and securely bind long hair to prevent them from getting
36. ilable in different sizes that will cut pipes ranging from 12 to 60 inches in diameter Model 1224 12 to 24 305 610 mm Model 2436 24 to 36 610 914 mm Model 3648 36 to 48 914 1219 mm Model 4860 48 to 60 1219 1524 mm Model 6072 60 to 72 1524 1829 mm Model 7284 72 to 84 1829 2134 mm In This Chapter USAGE AND APPLICATIONS MECHANICAL OVERVIEW ACCESSORIES AND OPTIONS E H Wachs Part No 03 010 MAN Rev 4 0213 Heavy Duty Split Frame mounting on inline pipe The machine is supplied with a custom storage case to hold all components and accessories Keep the split frame stored in its case when it is not in use MECHANICAL OVERVIEW The heavy duty split frame HDSF consists of two inter locking steel rings onto which the machine s components are mounted The stationary ring is fitted with adjustable clamping legs that are tightened to hold the machine on the outside surface of the pipe It has an inner track or raceway equipped with bearings The rotating ring travels on the bearing system moving the tool slides around the pipe to perform the cutting action A trip mounted on the stationary ring turns a starwheel on the slide with each rotation the starwheel turns a feed screw that advances the tool into the pipe as the machine operates The O D outside diameter tracking slides use a spring mechanism and a surface tracking whee
37. ing tact the pipe at the high point the location where the clear of the machine while clearance is least operating it 10 Without moving the slides securely tighten the bolts on the slide mounts Turn the jacking nuts on both slides back until the end 11 i plate almost touches the bar guide E H Wachs Part No 03 010 Rev 4 0213 41 Heavy Duty Split Frame 2 Use a 1 1 8 inch socket wrench to turn the star wheel AN WARNING Keep hands and clothing clear of the machine while operating it 2 height of the trip is not adjustable It is fixed in rela tion to the slide 12 13 14 15 16 17 Jacking nut End plate Close this gap to about 1 16 Figure 5 24 Turn the jacking nut back until the end plate is almost fully retracted There should be about 1 16 clearance between the endplate collar and the Jacking nut post Insert the tool into the tool mount Turn the star wheel to drive the tool toward the pipe until the blade is 1 16 from the pipe surface Repeat Steps 2 13 for the beveling tool slide Install the trip assembly on the stationary frame Using the drive motor rotate the frame to position one of the star wheels over the trip assembly Loosen the trip locking lever Using the trip adjust ment knob slide the trip toward or away from the frame to position it beneath the star wheel 42 Part No 03 010 MAN Rev 4
38. ining Ring External 781 1 Retaining Ring Internal 2 047 0 Bushing Flange 1 1 8 pa dempOolr 410 e m H Gearbox Worm Reduction 20 1 1 90 500 05 GREASE ZERK 1 4 28 STR 74 Part No 03 010 MAN Rev 4 0213 E H Wachs Chapter 8 Parts Lists and Drawings Drawings 4 HRCS 1 4 20 x 5 8 18 8 SS 8 HHGS 3 8 16 x 1 18 8 SS 33 KEY 1 4 SO x 13 2 undersized 1 KEY 3 16 SQ x 1 undersized SHCS 8 32 x2 18 8 SS 1 Sues 1 4 20x 3 4 18 8 SS 8 SHCS 3 8 16 x 1 18 8 SS SHCS 3 8 16 x 1 1 4 18 8 SS La T sayeye dess La La La Power sexes DRAWINGS Use the drawings on the following pages for parts identifi cation E H Wachs Part No 03 010 MAN Rev 4 0213 75 Heavy Duty Split Frame mma 53 1 0 10 500 SONIMVHO SLUVd S3NWV33 PLU ULUTEU S3LO OLO O0 00 4010 450 E H Wachs Part No 03 010 MAN Rev 4 0213 76 Chapter 8 Parts Lists and Drawings Drawings 01 00 010 0 irs wes sow 3l z 40 39Vd jeesemes on a 100 1 30 ONDIOVUL QO 77 Part No 03 010 MAN Rev 4 0213 E H Wachs Heavy Duty Split Frame 41227 121 OM WNE Z
39. ion of other tools and equipment in the area reflective surfaces process noises and resonant struc tures can increase the noise level in the area For additional information on hearing protection refer to Federal OSHA regulations 29 Code of Federal Regulations Section 1910 95 Occupational Noise Exposure and ANSI 12 6 Hearing Protectors SAFETY LABELS There is no safety labeling on the heavy duty split frame E H Wachs Part No 03 010 MAN Rev 4 0213 Heavy Duty Split Frame 8 Part No 03 010 MAN Rev 4 0213 E H Wachs Chapter 3 Parts Lists and Drawings Chapter 3 Introduction to the Equipment Read this chapter carefully to become familiar with the components of the heavy duty split frame USAGE AND APPLICATIONS The heavy duty split frame is a pipe cutting and beveling machine using outside diameter O D tracking slides for even efficient cutting of pipes that are out of round or that are not centered within the frame of the machine A cantile ver slide is also available for single point turning and flange facing The HDSF is designed to be mounted on in line pipe The machine splits open at two points using a hinge and frame jacking system and will open far enough to fit around pipes up to its maximum machining capacity The hinge can also be removed to separate the machine into two halves for shipping or storage Figure 3 1 shows the machine opened for mounting The split frame is ava
40. is Manual PURPOSE OF THIS MANUAL This manual explains how to operate and maintain the heavy duty split frame HDSF with O D tracking slides It includes instructions for set up operation and maintenance It also contains parts lists and diagrams to help you order replacement parts and perform user serviceable repairs Before operating the HDSF you should read through this manual and become familiar with all instructions At a min imum make sure you read and understand the following chapters Chapter 1 About This Manual e Chapter 2 Safety Chapter 3 Introduction to the Equipment Chapter 5 Operating Instructions e Chapter 9 Accessories 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 Disassembly and Storage e Chapter 6 Routine Maintenance e Chapter 7 Troubleshooting and Repair You will also want to refer to Chapter 8 Parts Lists and Drawings In This Chapter PURPOSE OF THIS MANUAL How USE THE MANUAL SYMBOLS AND WARNINGS MANUAL UPDATES AND REVISION TRACKING E H Wachs Part No 03 010 MAN Rev 4 0213 Heavy Duty Split Frame Throughout this manual refer to this column for warnings cautions and notices with supplementary information AN WARNING A WARNING alert with the safety alert symbol indicates a potentially hazardous situa tion that could result in seri ous in
41. jury or death AN CAUTION A CAUTION alert with the safety alert symbol indicates a potentially hazardous situa tion that could result in minor or moderate injury How USE THE MANUAL This manual is organized to help you quickly find the infor mation you need Each chapter describes a specific topic on using or maintaining your equipment Each page is designed with two columns This large column on the inside of the page contains instructions and illustra tions Use these instructions to operate and maintain the equipment The narrower column on the outside contains 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 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 Part No 03 010 MAN Rev 4 0213 E H Wachs Chapter 1 About This Manual Manual Updates and Revision Tracking This is the equipment damage alert symbol It is used to alert you to poten tial equipment damage situations Obey all messages that fo
42. l to keep the cutting tools in constant contact with the pipe The tracking wheel on the end of the slide travels along the pipe surface and the springs allow the slide to adjust itself to any irregularities in 10 Part No 03 010 MAN Rev 4 0213 E H Wachs Chapter 3 Parts Lists and Drawings Mechanical Overview the pipe For corrosive environments a stainless steel tracking wheel is available The O D tracking slides feed into the pipe 0 0026 0 066 mm per trip The spring tensioned tracking mechanism allows radial motion perpendicular to the side of the pipe of up to 1 2 inch keeping the cutting tool on the pipe at all times and compensating for a maximum 1 inch out of roundness Figure 3 2 and Figure 3 3 illustrate the major components of the HDSF Figure 3 5 shows one of the tracking slides Figure 3 6 and Figure 3 7 show two different designs of the machine s clamping legs Refer to these figures during set up instructions for identifying the parts of the machine Trip Frame opening jack O D tracking slide p O D tracking slide Clamp 4 or 8 Figure 3 2 The photo shows the rotating ring side of the heavy duty split frame E H Wachs Part No 03 010 MAN Rev 4 0213 11 Heavy Duty Split Frame 2 Some older HDSFs may have frame locking levers rather than pins Lift rings with straps attached Hydraulic motor mi machine shown with 8 in
43. llow this sym bol to avoid damaging the equipment or workpiece on which it is operating NOTE This symbol indicates a user note Notes provide additional information to supple ment the instructions or tips for easier operation f MANUAL UPDATES AND REVISION TRACKING Occasionally we will update manuals with improved opera tion or maintenance procedures or with corrections if nec essary When a manual is revised we will update the revision history on the title page 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 30 CAUTION A CAUTION alert with the damage alert symbol indi cates a situation that will result in damage to the equipment s IMPORTANT An IMPORTANT alert with the damage alert symbol indi cates a situation that may result in damage to the equipment NOTE A NOTE provides supple mentary information or oper ating tips Current versions of E H Wachs manuals are also available in PDF format You can reguest an electronic copy of this manual by email ing customer service at sales ehwachs com E H Wachs Part No 03 010 MAN Rev 4 0213 Heavy Duty Split Frame 4 Part No 03 010 MAN Rev 4 0213 E H Wachs Chapter 2 Safety Chapter 2 Safety E H Wachs takes great pride in desi
44. n If play exists at any of these locations bushing replacement is recommended See Bushing Inspection and Replacement later in this section Tracking Wheel Disassembly 1 Remove the set screw that retains the tracking wheel shaft Figure 7 6 Remove the set screw holding the tracking wheel shaft 2 Remove the shaft from the tool post 54 Part No 03 010 MAN Rev 4 0213 E H Wachs Chapter 7 Service and Repair Adjusting the Slides Figure 7 7 Pull out the tracking wheel shaft Inspect the shaft and bearing If the shaft is pitted or damaged replace it before reassembling the tracking wheel If the bearing shows wear replace it Other wise clean re lubricate and reassemble the bearing Bearing Figure 7 8 Remove the tracking wheel to inspect the bearing for wear 4 Replace the wheel and insert the shaft into the tool post through the bearing with the flat on the shaft aligned with the front of the tool post Replace and tighten the set screw E H Wachs Part No 03 010 MAN Rev 4 0213 55 Heavy Duty Split Frame Figure 7 9 Insert the shaft through the wheel with the flat toward the end of the slide left photo Then re insert and tighten the set screw right photo Feed Screw Adjustment Procedure If the tool is diving into the workpiece advancing too far when the starwheel trips you may need to adjust the feed screw tension Check for a gap betwee
45. n the split ring lock and end plate as shown in Figure 7 10 The split ring lock should be tight against the end plate Figure 7 10 If there is a gap between the split ring lock and the end plate you will need to adjust the slide to close the gap 56 Part No 03 010 MAN Rev 4 0213 E H Wachs Chapter 7 Service and Repair Adjusting the Slides 1 Set the slide on a workbench or stable work surface 2 Turn the feed nut on the starwheel counter clockwise to advance the slide to the end of travel travel Figure 7 11 Turn the feed nut counter clockwise to advance the slide to the end of travel 3 the feed nut so that you can access the screws on the split ring lock Loosen the screws Um mL E k A o 2 e Figure 7 12 Loosen the two screws in the split ring lock E H Wachs Part No 03 010 MAN Rev 4 0213 57 Heavy Duty Split Frame 4 the spring tension nut clockwise until the split ring lock is pressed tight against the end plate Figure 7 13 Tighten the spring tension nut left photo until the split ring lock is tight against the end plate with no gap right photo 5 Securely tighten the screws in the split ring lock Figure 7 14 With the split ring lock pressed in place tighten the screws securely 6 Turn the spring tension nut counter clockwise all the way 58 Part No 03 010 MAN Rev 4 0213 E
46. nd make sure each bearing turns with the machine If they don t repeat steps 23 26 ADJUSTING THE PINION GEAR 1 2 Be sure there is no load on the HDSF Back off any cutting tools and disengage the trip Remove any cutting debris or chips from the gear mounting area on the machine and wipe clean with a rag Make sure the threaded holes and pivot hole are clean of debris Check the pinion housing for any debris and wipe clean with a rag Mount the pinion housing loosely in the desired loca tion If using more than one drive motor connect only one at this time 52 Part No 03 010 MAN Rev 4 0213 E H Wachs Chapter 7 Service and Repair Adjusting the Slides 5 pinion clearance adjustment screw it is perpen dicular 90 degrees from the mounting bolts and has a jam nut on it should be backed out to allow the pinion the most travel into the machine 6 Press the pinion gear towards the large ring gear until full gear engagement is felt The housing is rotating on the pin that is next to the mounting bolts 7 Hand tighten the pinion clearance adjustment screw until it bottoms out Tighten jam nut with wrench This prevents the motor from moving out of location 8 Fully tighten the two mounting bolts with a wrench 9 Run the machine slowly If any gear binding is felt or heard stop the machine Back out the pinion clearance adjustment screw 1 8 turn and lock in place with jam nut 10 Loosen
47. nuts Ay NOTE Use a 3 8 hex wrench to turn the frame jacking screws E H Wachs Part No 03 010 MAN Rev 4 0213 49 Heavy Duty Split Frame By NOTE Perform steps 9 12 for both halves of the ring By NOTE Check the condition of all bearings and replace any components that are worn or damaged NOTE Position the split frame so that the section you are working on hangs over the edge of the work surface You will need to access the bearing you are adjusting from both sides of the frame 10 11 12 13 14 15 16 On each half of the frame turn the rotating ring out of the stationary ring and remove it Turn the stationary ring over to access the bearing nuts on the back Using a 7 8 socket loosen the Nylock hex nut on each bearing just enough to allow the eccentric shafts to rotate smoothly Turn the ring back over Rotate all eccentric shafts so that the notch in the bear ing surface points toward the inside of the ring Slide the rotating ring back into the stationary ring and reset the frame locking lever Reassemble the two halves of the frame aligning the dowel pins into the corresponding alignment holes Set all eight swing latches back in their channels and tighten them to secure the frame Release the frame locking lever to allow the rotating ring to turn Turn the rotating ring so that you can access bearing 1 shown in Figure 7 5 through the bearing
48. ontrol valve to 0 and set the flow lever on the motor to the closed position 12 To operate the split frame open the flow valve on the hydraulic motor then move the flow control lever on the control valve to increase the flow Flow control lever in 0 position Figure 5 17 Move the flow control lever down to open flow to the hydraulic motor 13 Run the machine slowly If any gear binding is felt or heard stop the machine Back out the pinion clearance adjustment screw 1 8 turn and lock it in place with the jam nut 14 Loosen the two mounting bolts and let the pinion housing move back against the pinion clearance adjustment screw 15 Fully tighten the two mounting bolts with a wrench 16 Continue this method until the gears sound and feel good 17 If using two drive motors install and adjust it follow ing the same procedure used for the first motor Do not remove or change the first drive motor 36 Part No 03 010 MAN Rev 4 0213 E H Wachs Chapter 5 Operating Instructions Installing and Connecting the Drive Motor Dual Motor Drive Option For HDSF machines equipped with the dual motor drive connect the hydraulic hoses as illustrated in Figure 5 18 Note that the dual motor option has its own on off flow lever Return tank connection Flow on off lever Pressure connection Figure 5 18 Connect the hydraulic hoses to the dual motor drive as illustrated Air Drive 1
49. rame Figure 7 21 Remove the shaft supports to allow the feed block and feed screw assembly to be removed 6 Slide the feed block and feed screw out of the tool slide housing 7 Inspect and replace bushings if required 8 Re assemble the slide using these instructions in reverse order 62 Part No 03 010 MAN Rev 4 0213 E H Wachs Chapter 8 Parts Lists and Drawings Chapter 8 Parts Lists and Drawings Refer to the parts lists and drawings in this chapter for ordering and maintenance You can call E H Wachs service at 800 323 8185 for assistance in ordering PARTS LISTS The parts list tables below are broken out by machine sub assembly Main Frame Qty Part No Description 84 HDSF Frame 1 03 010 002 84 STATIONARY RING 48 51 017 00 SHAFT ECCENTRIC 2 03 010 014 ARM HINGE RATCHET 4 03 010 015 PLATE LIFTING 48 51 024 00 BEARING GUIDE 43 in feet SEAL FELT WIPER In This Chapter PARTS LISTS DRAWINGS E H Wachs Part No 03 010 MAN Rev 4 0213 63 Heavy Duty Split Frame 1 03 010 200 RATCHET HINGE 2 03 010 201 LOCK FRAME 48 90 095 52 WASHER 1 2 SAE 48 90 045 08 NUT NYLOCK 1 2 13 2 90 211 22 3 4 10 x 2 1 4 HHCS Gr 8 2 90 121 32 7 8 9 x 3 1 4 HHCS Gr 8 4 90 125 51 7 8 SAE WASHER 24 90 062 05 5 16 18 x 1 2 BHCS 2 90 225 04 NUT NYLOCK 7 8 9 1
50. red tools 1 4 hex wrench 3 8 hex wrench 7 8 socket wrench 1 1 8 socket wrench E H Wachs Part No 03 010 MAN Rev 4 0213 47 Heavy Duty Split Frame Figure 7 1 Turn the rotating ring so that the split lines on both rings are aligned 4 Insert the frame locking pins on both sides of the frame 7 i pa e L A F igure 7 2 Insert the frame locking pins to lock the stationary and rotating rings together A 48 Part No 03 010 MAN Rev 4 0213 E H Wachs Chapter 7 Service and Repair Adjusting the Bearings There are four swing latches at each split point two on the top rotating side of the frame and two on the bottom stationary side of the frame Loosen all eight swing latch nuts and swing the latches out of their channels F igure 7 3 The photo shows the swing latches on the stationary ring side of the frame Loosen the nuts and lift the latches out of their channels 6 Turn in the frame jacking screws on both split points to separate the two halves of the frame Once the frame is separated turn the jacking screws back out all the way F igure 7 4 Turn the frame jacking screw into the block to separate the frame at the split point 7 Pull the two halves of the frame apart 8 Swing the frame locking lever toward the inside of the frame to allow the rotating ring to turn By NOTE Use a 1 1 8 inch socket wrench to loosen the swing latch
51. rotating ring Make sure all legs are mounted in the same hole o Install the mounting brackets over the leg and tighten the screws down firmly Figure 5 12 Install the leg mounting brackets and tighten the screws 3 When you have the HDSF in place on the workpiece turn the adjustment screws on the legs to clamp the machine in place Center the HDSF as described in the previous section 32 Part No 03 010 MAN Rev 4 0213 E H Wachs Chapter 5 Operating Instructions Installing and Connecting the Drive Motor Figure 5 13 Turn the leg adjustment screw to clamp the legs on the workpiece INSTALLING AND CONNECTING THE DRIVE MOTOR Hydraulic Drive 1 Be sure there is no load on the HDSF Back off any cutting tools and disengage the trip 2 Remove any cutting debris or chips from the are mounting area on the machine and wipe clean with a rag Make sure the threaded holes and pivot hole are clean of debris 3 Check the pinion housing for any debris and wipe clean with a rag 4 Mount the pinion housing loosely as shown in Figure 5 14 If using more than one drive motor con nect only one at this time NOTE Use the following tools to attach and adjust the hydraulic motor 3 4 socket to tighten the motor mounting bolts and the pinion clearance set screw 1 2 socket to turn the pinion clearance adjustment screw E H Wachs Part No 03 010 MAN Rev 4 0213 33 Heavy Duty Split Frame
52. stalled k Y Trip rame opening jac Figure 3 3 The photo shows the stationary ring side of the heavy duty split frame Figure 3 4 Two frame locking pins one next to each split point keep the rotating ring from turning when you split the machine for mounting it on a pipe Remove the pins before operating the HDSF 12 Part No 03 010 MAN Rev 4 0213 E H Wachs Chapter 3 Parts Lists and Drawings Mechanical Overview Tool holder End plate Jacking screw Star wheel Tracking wheel Bar guides Jacking nut Figure 3 5 The photo shows the components of the O D tracking slide Clamping leg position notches Clamping pad Clamping pad alignment rod Figure 3 6 The photo illustrates the parts of the clamping leg Either 4 or 8 legs are used on the HDSF machines E H Wachs Part No 03 010 MAN Rev 4 0213 13 Heavy Duty Split Frame Figure 3 7 The photo shows an alternate design for the HDSF clamping leg ACCESSORIES AND OPTIONS Optional dual motor drive for increased torque in low speed operation See Figure 3 8 Figure 3 8 The photo shows the HDSF with dual motor drive configuration Speed control valve for use with hydraulic power units without built in flow control See Figure 3 9 14 Part No 03 010 MAN Rev 4 0213 E H Wachs Chapter 3 Parts Lists and Drawings Operating Envelope Pressure hose from power unit Pressure hose to HDSF Flow speed con
53. tating side of the frame and two on the bottom stationary side of the frame Loosen all eight swing latch nuts and swing the latches out of their channels 5 Turn the frame jacking screws see Figure 5 3 on the split point opposite the hinge to separate the two halves of the frame Make sure the dowel pins are fully retracted from the other side of the frame 6 Turn the frame jacking screws on the split point with the hinge to separate the frame Make sure the dowel pins are fully retracted Ay NOTE Use a 1 1 8 inch socket wrench to loosen the swing latch nuts Ay NOTE Use a 3 8 inch hex wrench to turn the frame jacking screws E H Wachs Part No 03 010 MAN Rev 4 0213 27 Heavy Duty Split Frame IMPORTANT s Make sure the halves of the ring do not close again while operating the jack The dowel pins could bind and break if they are in the alignment holes while you are opening the ring AN WARNING Make sure that no one is near the split frame while operating the lift AA ZM i Figure 5 5 Turn the frame jacking screw into the block to separate the frame at the split point 7 Operate the frame jack to pull the sides of the hinge together Open the frame as far as necessary to install it on the workpiece Mounting The Frame on the Workpiece 1 Lift the split frame into position over the workpiece 2 Tum the frame jacking screws back out to allow the split points to close
54. trol lever Flow bypass circuit Return hose to power unit Return hose from HDSF Figure 3 9 The flow control valve is used to set the cutting speed of the HDSF when there is no flow con trol on the hydraulic power unit OPERATING ENVELOPE The drawing and table on the following page describe the dimensions and operating envelope for all HDSF models E H Wachs Part No 03 010 MAN Rev 4 0213 15 Heavy Duty Split Frame 119901 dl31 334 09200 sniava Du O ojo O o oto 5 ERE lt rele 333 vei 2145 434 1601 688 03 8706 986 EY sniava q gt 8 Ne Ha 5 i 5 KD 5 TO 344 ys E 4 15 Z 220 E X lt 23 222 5 s 1 Q oa 25 59 0751 825 8 26 686 47L 982 931 335 4071 fy TlIV13G 531 dWV1D 1681 086 ose
55. y and equipment damage could result By NOTE Store the rings in the case with the rotating ring side down Swivel the frame locking levers in toward the center of the machine to lock the rotating and stationary rings together Turn the frame jacking screw on each split point in to separate the halves of the ring Turn the screws until the dowel pins that align the halves are fully out of their holes Figure 4 5 Turn the frame jacking screw into the block to separate the frame at the split point Attach a crane to one half of the ring using lifting straps Lower the ring half into the crate in the posi tion shown in Figure 4 6 20 Part No 03 010 MAN Rev 4 0213 E H Wachs Chapter 4 Assembly Disassembly and Storage Storing the HDSF 3 Figure 4 6 Put the first half of the ring into the crate as shown The ends of the ring should rest on the sup port blocks in the corners 6 Attach the crane to the other half of the ring using lift ing straps and lower it into the crate as shown in Figure 4 7 Figure 4 7 Put the second half of the ring into the crate and position it on the taller mounting blocks 7 Put the flow control assembly in the case alongside the split frame E H Wachs Part No 03 010 MAN Rev 4 0213 21 Heavy Duty Split Frame Figure 4 8 Put the flow control assembly along the side of the case 8 Strap the split frame to the eye bolts on the bottom of the
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