Small Diameter Split Frame User’s Manual

Small Diameter Split Frame User’s Manual
Small Diameter Split Frame
User’s Manual
E.H. Wachs
600 Knightsbridge Parkway
Lincolnshire, IL 60069
www.ehwachs.com
E.H. Wachs Part No. 80-MAN-01
Rev. C, September 2015
Revision History:
Original March 2009
Rev. 1
September 2009
Rev. 2
September 2010
Rev. 3
August 2011
Rev. A
December 2011
Rev. B
March 2013
Copyright © 2015 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.
Table of Contents
Table of Contents
Chapter 1: About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Purpose of This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
How to Use The Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Symbols and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Manual Updates and Revision Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Chapter 2: Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safe Operating Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safe Operating Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Operating and Maintenance Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydraulic Powered Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pneumatic Powered Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Loss or Shut-Off of Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety Alerts in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Protective Equipment Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Protective Clothing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Eye Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hearing Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Safe Operation of the SDSF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Intended Uses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Proper Use of the SDSF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Potential Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SDSF Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Enclosed Bearing and Drive Gear System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Stop-on-Release Power Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Paddle-Style Trip Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Remote Operation Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Guidelines for Safe Setup, Operation, and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pre-Operation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Operating Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Operator Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Service Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Disconnecting Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Safe Lifting and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Chapter 3: Introduction to the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Machine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Mounting Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Clamp Feet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Collets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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Tool Slide Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parting/Beveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Socket Weld Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Socket Weld Removal Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Counterboring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chipless Wheel Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tool Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bench Mounting Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Envelopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parting Slide (80-4101-XX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Beveling Slide (80-4102-XX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axial Slide (80-4104-XX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axial Slide Tooling Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FME Slide (80-4106-XX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radial Socket Weld Removal Slide (80-4100-10 Slide for 1” SDSF) . . . . . . . . . . . . . . . . .
Radial Socket Weld Removal Slide (80-4100-20 Slide for 1-1/2, 2”, and 2-1/2” SDSF) . . .
Radial Trip (80-4103-00) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axial Trip (80-4105-00) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Counterbore Slide (80-4107-00) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pneumatic Drive (80-4004-00) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electric Drive (80-4005-01/80-4006-01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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39
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43
44
45
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46
Chapter 4: Assembly, Disassembly, and Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Machine Disassembly and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Chapter 5: Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Pre-Operation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Configuring the SDSF for the Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Selecting Feet or Collet for Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Installing the Clamp Feet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Adding Clamp Foot Extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Removing the Clamp Feet for Collet Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Selecting the Slides, Tooling, and Trip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Installing the Radial Slides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Installing the Trip Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Installing the Axial Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Mounting the Machine on the Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Adjusting the Clamp Feet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Collet Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Mounting the Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Pneumatic Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
110 V Electric Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Parting and Beveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Counterboring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
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Socket Weld Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Radial Socket Weld Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Axial Socket Weld Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Foreign Material Exclusion Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Removing the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Clamp Feet Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Collet Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Remote Operation with the SF ACM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Control Panel Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Locating the ACM at the Worksite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Operating the ACM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Adjusting the Output Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Using the Venting Quick Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Configuring the Air Drive for the ACM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Air Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Air Trigger Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Chapter 6: Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Slides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Air Treatment Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Split Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Bearing Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Tool Slide Tension Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Air Motor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Gear Train Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Motor Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
DL Backhead Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
General Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Gear Case Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Motor Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
136DL Series Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Complete Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Electric Motor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Servicing the ACM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Chapter 7: Service and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Slide Feed Nut Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Slide Feed Screw Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
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Chapter 8: Parts Lists and Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SDSF Base Machine (80-4000-XX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SDSF Frame Assembly (80-3000-XX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Assembly (80-3002-XX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clamp Foot Assembly (80-4001-00) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Drive Pinion Assembly (80-4003-XX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parting Slide (80-4101-XX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Beveling Slide (80-4102-XX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axial Slide (80-4104-XX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FME Slide (80-4106-XX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radial Socket Weld Removal Slide (80-4100-XX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outside Bevel Tool Cover Plate Ass’y (80-4108-00) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Counterbore Slide (80-4107-00) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radial Trip (80-4103-00) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axial Trip (80-4105-00) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pneumatic Drive (80-4004-00) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
110 V Electric Drive (80-4005-01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
220 V Electric Drive (80-4006-01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
110 V Electric Drive (80-4005-00, OBSOLETE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Split Frame Air Control Module (60-420-00) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Control Module Subassembly (60-375-00) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Control Module Subassembly (60-375-00) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Control Module Schematic (60-420-00) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
127
128
129
130
131
132
Chapter 9: Accessories and Spare Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Chapter 10: Ordering Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return Goods Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iv
Part No. 80-MAN-01, Rev. C
139
139
139
140
140
E.H. Wachs
Chapter 1, About This Manual
Chapter 1
About This Manual
PURPOSE OF THIS MANUAL
This manual explains how to operate and maintain the
Small Diameter Split Frame (SDSF). It includes instructions for set-up, operation, and maintenance. It also contains parts lists, diagrams, and service information to help
you order replacement parts and perform user-serviceable
repairs.
In This Chapter
PURPOSE OF THIS MANUAL
HOW TO USE THE MANUAL
SYMBOLS AND WARNINGS
MANUAL UPDATES AND
REVISION TRACKING
Before operating the SDSF, you should read through this
manual and become familiar with all instructions. At a minimum, make sure you read and understand the following
chapters:
•
•
•
•
•
Chapter 1, About This Manual
Chapter 2, Safety
Chapter 3, Introduction to the Equipment
Chapter 5, Operating Instructions
Chapter 9, Accessories and Spare Parts
If you will be performing service or repairs, make sure you
read and understand these chapters:
•
•
•
•
Chapter 1, About This Manual
Chapter 4, Assembly, Disassembly, and Storage
Chapter 6, Routine Maintenance
Chapter 7, Service and Repair.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
1
Small Diameter Split Frame
You will also want to refer to Chapter 8, Parts Lists and
Drawings.
HOW TO USE THE MANUAL
Throughout this manual, refer
to this column for warnings,
cautions, and notices with
supplementary information.
This manual is organized to help you quickly find the information 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 illustrations. Use these instructions to operate and maintain the
equipment.
The narrower column on the outside contains additional
information such as warnings, special notes, and 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 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.
WARNING
A WARNING alert with the
safety alert symbol indicates
a potentially hazardous situation that could result in serious injury or death.
2
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. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 1, About This Manual: Symbols and Warnings
CAUTION
A CAUTION alert with the
safety alert symbol indicates
a potentially hazardous situation that could result in
minor or moderate injury.
This is 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.
CAUTION
A CAUTION alert with the
damage alert symbol indicates a situation that will
result in damage to the
equipment.
IMPORTANT
An IMPORTANT alert with
the damage alert symbol indicates a situation that may
result in damage to the
equipment.
NOTE
NOTE
This symbol indicates a user note. Notes
provide additional information to supplement the instructions, or tips for easier
operation.
A NOTE provides supplementary information or operating tips.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
3
Small Diameter Split Frame
MANUAL UPDATES AND REVISION TRACKING
Current versions of E.H.
Wachs manuals are also
available in PDF format. You
can request an electronic
copy of this manual by emailing customer service at
sales@ehwachs.com.
4
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.
You may have factory service or upgrades performed on the
equipment. If this service changes any technical data or
operation and maintenance procedures, we will include a
revised manual when we return the equipment to you.
Part No. 80-MAN-01, Rev. C
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.
In This Chapter
SAFE OPERATING GUIDELINES
SAFE OPERATION OF THE SDSF
Read this chapter carefully before operating your E.H.
Wachs equipment. It contains important safety instructions
and recommendations.
SAFE OPERATING GUIDELINES
Follow these guidelines for safe operation of all E.H.
Wachs equipment.
•
•
•
READ THE OPERATING MANUAL. Make sure you understand all setup and operating instructions before you
begin. Keep this manual with the machine.
INSPECT MACHINE AND ACCESSORIES BEFORE USE. Before
starting the machine, look for loose bolts or nuts, 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 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 Chapter 10 for ordering information.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
Look for this symbol throughout the
manual. It indicates
a personal injury
hazard.
5
Small Diameter Split Frame
•
•
•
KEEP CLEAR OF MOVING PARTS. Keep hands, arms, and
fingers clear of all rotating or moving parts. Always turn
the machine off and disconnect the power source before
doing any adjustments or service.
SECURE LOOSE CLOTHING AND JEWELRY. Secure or
remove loose-fitting clothing and jewelry, and securely
bind long hair, to prevent them from getting caught in
moving parts of the machine.
FOLLOW SAFE PROCEDURES FOR HANDLING LUBRICANTS.
Refer to the manufacturer’s instructions and the 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 regulations.
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
•
•
•
•
•
•
6
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 is supported adequately for
installation of the equipment. This includes supporting
any workpiece “fall-off” section when severing the
workpiece. Ensuring support of the workpiece is the
responsibility of the operator.
Tooling on any cutting equipment—including lathe
tools, saw blades, milling tools, etc.—may get very hot.
Do not touch tooling until you have made sure it is cool
enough to handle.
Wear gloves when removing or cleaning up chips and
cutting debris. Chips can be very sharp and cause cuts.
Before performing any service on the equipment, disconnect the power source. Follow all lock-out/tag-out
procedures required at the worksite.
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 2, Safety: Safe Operating Guidelines
Hydraulic Powered Equipment
•
•
Hydraulic components such as hoses, motors, and manifolds will get hot during operation and may cause burns.
Do not touch hydraulic components, except for operator
controls, during or after operating the machine.
Hydraulic injection injury—A pinhole in a hydraulic hose
or fitting can eject fluid with enough force to pierce
skin. Check hoses and fittings regularly for leaks. Do
not use bare hands to check for leaks while the system is pressurized. If you suspect a leak, move a piece
of paper or cardboard at least 6 inches (15 cm) over the
suspicious area and watch for fluid spraying on the surface.
Pneumatic Powered Equipment
•
•
WARNING
Injection of hydraulic fluid
through the skin is a serious
injury that can result in infection, tissue damage, and possible loss of limb. Seek
medical treatment immediately. First aid is not sufficient
treatment for injection injury.
Air motors may get hot during operation and may cause
burns. Do not touch the air motor, except for operator
controls, during or after operating the machine.
Before disconnecting the air line from the equipment,
always turn off air at the source and bleed all residual air
pressure at the air motor.
Loss or Shut-Off of Power Supply
•
•
•
If the power source to the equipment is lost, disconnect
power from the equipment and lock out the power supply immediately to prevent accidental restarting of the
machine.
ELECTRIC POWERED EQUIPMENT—If the electric drive
shuts off because of its built-in thermal protection, disconnect the motor from the power source immediately.
For all power sources, follow all lock-out/tag-out procedures required at the worksite when disconnecting or
servicing the equipment.
Safety Alerts in This Manual
The following alerts are used throughout this manual to
indicate operator safety hazards. In all cases, these alerts
include a notice describing the hazard and the means to
avoid or reduce risk. Carefully read all safety alerts.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
7
Small Diameter Split Frame
This icon is displayed with any safety alert that indicates a
personal injury hazard.
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.
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.
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.
Do not wear gloves while operating the machine. Gloves
can become entangled in moving parts, resulting in serious
injury. Gloves may be worn when setting up the machine or
cleaning up after the operation, but take them off when
operating the machine.
Eye Protection
Always wear impact-resistant eye protection while 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
8
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 2, Safety: Safe Operation of the SDSF
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 is required when operating 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.
SAFE OPERATION OF THE SDSF
Intended Uses
The small diameter split frame is designed to O.D. mount
on in-line or open-ended pipe, and perform cut-off and weld
prep (beveling, counterboring, and J-prep) operations. It
uses cold-cutting lathe techniques, with a variety of accessories and tooling for different cutting applications.
Make sure to follow all safety guidelines and procedures
required for machining operations at the work site,
including personal protective equipment (PPE). Do not
use the SDSF in a manner that violates these guidelines.
Proper Use of the SDSF
•
•
•
The SDSF should only be used by trained, qualified
operators.
The workpiece must be within the operating capacity of
the SDSF model you are using. See operating envelope
information and drawings in Chapter 3.
Make sure the operating environment allows you to
mount the machine securely and squarely on the workpiece.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
9
Small Diameter Split Frame
•
•
•
Make sure there is adequate clearance around the SDSF
and workpiece to operate the machine controls as
described in the operating instructions (Chapter 5).
Mount the SDSF with the pinion housing positioned for
convenient mounting and operation of the drive motor.
Use the SDSF only on empty, depressurized pipe or tubing.
Misuse
•
•
•
•
•
Do not attempt to mount or operate the SDSF on noncylindrical workpieces.
Do not attempt to mount or operate the SDSF on any
workpiece to which it cannot be securely mounted.
Do not attempt to mount or operate the SDSF on any
workpiece that is not stable enough to hold the SDSF.
Do not mount the SDSF on the “fall-off” side of the cut
line, unless you adequately rig and support the SDSF
and workpiece.
Do not disable any safety feature of the SDSF or remove
any safety labeling. Replace worn or damaged safety
labels immediately. (See “Safety Labels” later in this
chapter.)
Potential Hazards
The following figures illustrate potential hazards of operating the small diameter split frame. Refer to the description
of each hazard for guidelines on safe operation.
10
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 2, Safety: Safe Operation of the SDSF
6
3
4
7
5
1,2
Figure 2-1. Potential operating hazards of the SDSF.
See the descriptions in the side column.
SDSF Safety Features
The design of the small diameter split frame incorporates
the following features for safe operation.
Enclosed Bearing and Drive Gear System
The SDSF bearings and drive gears are enclosed inside the
machine to prevent operator contact with them while the
machine is running.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
1. Rotating ring—Keep clear
of the rotating ring and tool
slides when operating the
SDSF. Contact with moving
parts can cause serious
injury.
2. Entanglement hazard for
gloves or clothing—Do not
wear gloves or loose-fitting
clothing when operating the
SDSF. They can become
entangled with moving parts,
resulting in serious injury.
3. Starwheel/trip pinch point—
Operate the trip using the trip
lever only. Do not touch any
part of the trip assembly,
other than the lever, when
operating the SDSF or when
rotating it manually for any
reason.
4. Sharp cutting tools—Cutting tools used with the SDSF
can be very sharp. Be careful
when handling the tools, and
stay clear of them when the
machine is operating.
5. Chips—The metal debris
from the cutting process can
be very sharp and very hot.
Use care in cleaning debris
from the machine and cleaning up the work area. Stop
the machine before clearing
chips. Use appropriate gloves
when handling chips.
6. Hot surfaces—Air motors
and hydraulic components
such as hoses, manifolds,
and motors can become very
hot during operation. Make
sure these components are
not hot before touching them.
7. Air motor connection—A
pressurized air line can
cause serious injury if it
comes loose. Make sure the
air line is secured to the
equipment with a pin or other
appropriate fastener.
11
Small Diameter Split Frame
Stop-on-Release Power Control
WARNING
Do not disable or override
the stop-on-release feature.
Letting the machine run when
you are not holding the power
control could result in serious
injury.
All drives for the SDSF (pneumatic and electric) require the
operator to hold the power control on to operate the
machine. When the operator releases the power control, the
SDSF stops immediately.
Figure 2-2. Hold the air motor trigger to operate the
SDSF (left). When you release the trigger (right), the
air motor shuts off.
Paddle-Style Trip Lever
The SDSF trip design allows the operator to engage and disengage the trip from beside or behind the machine, without
reaching into the operating space of the rotating ring and
slides. The paddle trip lever moves the trip pin in and out to
control engagement of the trip.
Figure 2-3. The paddle-style trip lever allows you to
engage and disengage the trip from the back of the
SDSF, without putting your hands in the way of moving components.
12
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 2, Safety: Safe Operation of the SDSF
Remote Operation Option
Remotely controlled operation is available as an option for
all SDSF drives types.
•
•
For pneumatic drives, order the remote control panel
(part no. 80-4200-00). See the ACM operating instructions in Chapter 5.
For electric drives, contact E.H. Wachs customer service
to discuss your operating environment and requirements.
Guidelines for Safe Setup, Operation, and
Service
Pre-Operation Checklist
Every time you use the SDSF, perform the following checks
to make sure it is in good operating condition:
•
•
•
•
•
Check that all safety components are operating properly.
Inspect it for damage or wear that could affect operation
and safe use of the machine. Repair any defective component before using the machine.
Make sure the machine is clean and properly lubricated.
Make sure that tooling is sharp and in good condition.
Poor quality tooling can cause difficult cutting and the
possibility of machine malfunction and/or injury.
Check power connections (pneumatic or electric) to
make sure they are in good condition.
Operating Safety
•
•
•
Stop the SDSF drive motion to clear chips or make any
machine adjustments.
For parting (cut-off) operations, use a catch device to
prevent the cut-off piece of the pipe from falling.
Keep air hoses and electrical cords away from moving
parts while operating the machine.
Operator Position
The preferred position for operating the SDSF is to the side
of the machine (behind the stationary ring if possible).
Make sure you install the machine so that you can operate
the controls without coming in contact with moving parts.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
13
Small Diameter Split Frame
Service Checklist
•
•
Disconnect power from the SDSF during service. See
instructions in the following section.
Remove accessories such as drive assemblies and tool
slides unless they are part of the service procedure.
Disconnecting Power
When disconnecting power for the SDSF, follow all lockout/tag-out procedures at your work site.
WARNING
•
PNEUMATIC POWER—To disconnect power from the
pneumatic SDSF, remove the air line from the air motor
coupling.
Before disconnecting the air
line, always turn off air at the
source and bleed all residual
air pressure at the air motor.
Disconnecting the air line
while under pressure could
result in serious injury.
Figure 2-4. Disconnect pneumatic power by removing
the air line from the pneumatic drive.
•
ELECTRIC POWER—To disconnect power from the elec-
tric SDSF, unplug the power cord from the power outlet.
Safe Lifting and Handling
•
•
14
Machines or assemblies over 40 lb (18 kg) must be
lifted by two people or a lifting device. See the machine
weight tables in the following section.
All SDSF models weigh less than 40 lb (18 kg). However, it is the responsibility of the end user to determine
whether a machine or assembly can be lifted by one person. For machines or assemblies that are difficult to handle, have two people lift the machine or use a lifting
device.
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 2, Safety: Safe Operation of the SDSF
•
Do not rig or lift the SDSF while power is attached.
Whenever possible, remove all accessories (slides, trips,
drive assembly, etc.) while lifting and handling the
machine.
Installation Procedures
See the detailed instructions in Chapter 5 for installing the
SDSF on the workpiece. Safe installation procedures are
provided for mounting the machine on both horizontal and
vertical workpieces.
Safety Labels
The following safety labels are on the SDSF.
Figure 2-5. This label is on the pinion housing. The
motor clamps must be secure to operate the SDSF
safely.
Figure 2-6. This label is on the pinion housing. Keep
hands and fingers clear of moving parts while the
SDSF is in operation.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
15
Small Diameter Split Frame
CAUTION
Personal hearing protection is recommended when operating or working near
this tool.
Figure 2-7. This label is on the air motor. Wear hearing protection to protect against high noise levels
when operating the air motor. Lack of hearing protection can cause loss of hearing.
Figure 2-8. This label is on the air motor. Do not use
air pressure greater than 90 psi (6.2 bar).
Figure 2-9. This label is on the air motor. Wear eye
protection while the SDSF is operating.
16
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 3, Introduction to the Equipment
Chapter 3
Introduction to the
Equipment
The Small Diameter Split Frame (SDSF) is designed to
part, end prep, and counterbore pipes and tubes with wall
thickness up to 0.44” (11 mm), and is capable of axial and
radial socket weld removal.
The SDSF is lightweight and flexible, making it ideal for
use in low-clearance environments. It offers simple setup
and operation, featuring a self-squaring clamping system
for precise cutting results typically available only with
fixed machine tools.
A range of machine sizes up to 6” is available, as shown in
Table 1. All machines are powered by an air or electric
motor.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
In This Chapter
MACHINE COMPONENTS
MOUNTING OPTIONS
TOOL SLIDE OPTIONS
TOOL KIT
DRIVE OPTIONS
DRIVE OPTIONS
BENCH MOUNTING OPTION
OPERATING ENVELOPES
17
Small Diameter Split Frame
Table 1: SDSF Machine Sizes
18
Machine Size
and Model No.
Standard Pipe Range
DIM A
Machine O.D.
DIM B
Machine I.D.
DIM C
Parting Line
DIM D
Machine
Thickness
1”
80-4000-10
NPS 1/2”–1”
DN 15–25
5.00”
(127.0 mm)
1.56”
(39.6 mm)
3.47”
(88.1 mm)
2.53”
(64.3 mm
1-1/2”
80-4000-15
NPS 1”–1-1/2”
DN 25–40
5.38”
(136.7 mm)
2.13”
(54.1 mm)
3.47”
(88.1 mm)
2.16”
(54.9 mm)
2”
80-4000-20
NPS 1-1/4”–2”
DN 32–50
5.69”
(144.5 mm)
2.63”
(66.8 mm)
3.47”
(88.1 mm)
2.16”
(54.9 mm)
2-1/2”
80-4000-25
NPS 1-1/2”–2-1/2”
DN 40–65
6.19”
(157.2 mm)
3.13”
(79.5 mm)
3.47”
(88.1 mm)
2.16”
(54.9 mm)
3”
80-4000-30
NPS 2”–3”
DN 50–80
6.81”
(173.0 mm)
3.75”
(95.3 mm)
3.47”
(88.1 mm)
2.16”
(54.9 mm)
3-1/2”
80-4000-35
NPS 2-1/2” –3-1/2”
DN 65–90
7.31”
(185.7 mm)
4.25”
(108.0 mm)
3.47”
(88.1 mm)
2.16”
(54.9 mm)
4”
80-4000-40
NPS 3”–4”
DN 80–100
7.81”
(198.4 mm)
4.75”
(120.7 mm)
3.47”
(88.1 mm)
2.16”
(54.9 mm)
5”
80-4000-50
NPS 4”–5”
DN 100–125
8.94”
(227.1 mm)
5.88”
(149.4 mm)
3.47”
(88.1 mm)
2.16”
(54.9 mm)
6”
80-4000-60
NPS 5”–6”
DN 125–150
9.94”
(252.5 mm)
6.88”
(174.8 mm)
3.47”
(88.1 mm)
2.16”
(54.9 mm)
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 3, Introduction to the Equipment:
MACHINE COMPONENTS
Major components of the SDSF are shown in Figure 3-1 and
Figure 3-2. Note that some machine components may have
different finishes.
Threaded starwheel mechanisms advance the cutting tools
into the pipe as the machine rotates. A mechanical trip turns
the starwheel, indexing the threaded tool block forward
along the feed screw as shown in Figure 3-3.
Tool slide
Stationary ring
Trip assembly
Trip engage lever
Air motor
Pinion housing
Rotating ring
Figure 3-1. This photo shows major components of
the SDSF.
Tool slides kits are available for the following applications:
•
•
•
•
•
parting (cut-off)
parting and O.D. beveling
counterboring
socket weld removal (radial or axial)
chipless severing (thin-wall).
The kits include the tool slide(s) and trip for the cutting
application.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
19
Small Diameter Split Frame
Tool cover plate
Motor gear clamp
Cutting tools
Split points
Starwheel
Figure 3-2. This photo shows the SDSF fitted with
standard parting and beveling slides.
Trip pin
Starwheel rotation
Feed direction
Direction of rotation
Figure 3-3. The trip pin advances the starwheel,
advancing the tool bits into the workpiece.
20
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 3, Introduction to the Equipment: Mounting Options
Figure 3-4. The SDSF ships disassembled in a waterproof carrying case.
MOUNTING OPTIONS
The SDSF mounts using either clamp feet or a collet. (The
1” and 1-1/2” SDSF models mount only using a collet.)
Standard clamp pads are provided with each SDSF machine
for mounting to the full O.D. range of the machine. Collets
for specific pipe sizes are available as an option, and custom
collets are available for any pipe O.D. up to 6”
NOTE
Collets are recommended for
wall thicknesses of 0.134”
(3.40 mm) or less. Clamp
legs may deform a thinwalled workpiece
Clamp Feet
Clamp feet are adjustable for the entire O.D. range of the
machine. Each clamp foot is mounted to a captivated adjustment screw in the SDSF stationary ring. When installing the
SDSF using the clamp feet, you need to manually center the
machine on the pipe; see instructions in Chapter 5.
For clamp foot mounting, order the standard clamp foot
extension kit (part no. 80-5001-00) with your SDSF
machine. The kit includes two sets of clamp foot extensions:
•
•
four 0.31” (7.9 mm) extensions
four 0.56” (14.2 mm) extensions.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
21
Small Diameter Split Frame
Optional clamp foot extensions are also available by special order. Two
sizes are available:
•
•
0.81” (20.6 mm) extensions (part no. 80-0078-08)
1.06” (26.9 mm) extensions (part no. 80-0078-11).
Table 2 describes the configurations for all SDSF models and clamp
foot extensions.
Table 2: SDSF Clamp Foot Configurations
Machine Size
(Model No.)
Clamping
O.D. Range
With No
Extension
With 0.31”
Extension
With 0.56”
Extension
With 0.81”
Extension
With 1.06”
Extension
Min
1.94”
(49.3 mm)
1.31”
(33.3 mm)
0.84”
(21.3 mm)
not applicable
not applicable
Max
2.56”
(65.0 mm)
1.94”
(49.3 mm)
1.44”
(36.6 mm)
not applicable
not applicable
Min
2.44”
(62.0 mm)
1.81”
(45.0 mm)
1.31”
(33.3 mm)
1.08”
(27.4 mm)
0.84”
(21.3 mm)
Max
3.06”
(77.7mm)
2.44”
(62.0 mm)
1.94”
(49.3 mm)
1.71”
(43.4 mm)
1.12”
(28.4 mm)
Min
3.06”
(77.7 mm)
2.44”
(62.0 mm)
1.94”
(49.3 mm)
1.59”
(40.4 mm)
1.12”
(28.4 mm)
Max
3.69”
(93.7 mm)
3.06”
(77.7 mm)
2.56”
(65.0 mm)
2.21”
(56.1 mm)
1.75”
(44.5 mm)
Min
3.56”
(90.4 mm)
2.94”
(74.7 mm)
2.44”
(62.0 mm)
2.08”
(52.8 mm)
1.59”
(40.4 mm)
Max
4.19”
(106.4 mm)
3.56”
(90.4 mm)
3.06”
(77.7 mm)
2.71”
(68.8 mm)
2.31”
(58.7 mm)
Min
4.06”
(103.1 mm)
3.44”
(87.4 mm)
2.94”
(74.7 mm)
2.57”
(65.3 mm)
2.08”
(52.8 mm)
Max
4.69”
(119.1 mm)
4.06”
103.1 mm)
3.56”
(90.4 mm)
3.19”
(81.0 mm)
2.71”
(68.8 mm)
Min
5.19”
(131.8 mm)
4.56”
(115.8 mm)
4.06”
(103.1 mm)
3.68”
(93.5 mm)
3.19”
(81.0 mm)
Max
5.81”
(147.6 mm)
5.19”
(131.8 mm)
4.69”
(119.1 mm)
4.31”
(109.5 mm)
3.81”
(96.8 mm)
Min
6.19”
(157.2 mm)
5.56”
(144.2 mm)
5.06”
(128.5 mm)
4.68”
(118.9 mm)
4.18”
(106.2 mm)
Max
6.81”
(173.0 mm)
6.19”
(157.2 mm)
5.69”
(144.5 mm)
5.31”
(134.9 mm)
4.81”
(122.3 mm)
2”
(81-000-20)
2-1/2”
(81-000-25)
3”
(81-000-30)
3-1/2”
(81-000-35)
4”
(81-000-40)
5”
(81-000-50)
6”
(81-000-60)
Shaded cells: These configurations may require extended tooling or
custom tool slides. Contact E.H. Wachs customer service to discuss
your requirements.
22
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 3, Introduction to the Equipment: Mounting Options
Figure 3-5 illustrates adjusting the clamp leg with the
adjustment screw.
IMPORTANT
Tighten the clamp leg screws
to a maximum of 50 lb-ft
(67 N-m).
Adjustment screw
Figure 3-5. Turn the adjustment screw to tighten or
loosen the clamp foot.
Collets
Collets are constructed for specific pipe O.D.s. The collet
fastens around the pipe using a spring mechanism, and is
secured inside the SDSF I.D. with a collet nut. The collet is
self-centering and is ideal for low clearance operations.
Table 3 describes the collet configurations for all SDSF
models.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
23
Small Diameter Split Frame
.
Table 3: Collet Configurations
Machine size
Pipe O.D. with collet
Standard collet
part numbers
Custom collet part no. and
available size range*
1”
0.84” (21.3 mm)
1.05” (26.7 mm)
1.315” (33.4 mm)
80-4010-05
80-4010-07
80-4010-10
80-4010-xx
0.375”–1.315”
(9.5–33.4 mm)
1-1/2”
1.315” (33.4 mm)
1.66” (42.2 mm)
1.9” (48.3 mm)
80-4015-10
80-4015-12
80-4015-15
80-4015-xx
0.375”–1.9”
(9.5–48.3 mm)
2”
1.66” (42.2 mm)
1.9” (48.3 mm)
2.375” (60.3 mm)
80-4020-12
80-4020-15
80-4020-20
80-4020-xx
0.5”–2.375”
(12.7–60.3 mm)
2-1/2”
1.9” (48.3 mm)
2.375” (60.3 mm)
2.875” (73.0 mm)
80-4025-15
80-4025-20
80-4025-25
80-4025-xx
0.75”–2.875”
(19.1–73.0 mm)
3”
2.375” (60.3mm)
2.875” (73.0 mm)
3.5” (88.9 mm)
80-4030-20
80-4030-25
80-4030-30
80-4030-xx
1.0”–3.5”
(25.4–88.9 mm)
3-1/2”
2.875” (73.0 mm)
3.5” (88.9 mm)
4.0” (101.6 mm)
80-4035-25
80-4035-30
80-4035-35
80-4035-xx
1.5”–4.0”
(38.1–101.6 mm)
4”
3.5” (88.9 mm)
4.0” (101.6 mm)
4.5” (114.3 mm)
80-4040-30
80-4040-35
80-4040-40
80-4040-xx
2.0”–4.5”
(50.8–114.3 mm)
5”
4.5” (114.3 mm)
5.56” (141.2 mm)
80-4050-40
80-4050-50
80-4050-xx
3.06”–5.56”
(77.7–141.2 mm)
6”
5.56” (141.2 mm)
6.625” (168.3 mm)
80-4060-50
80-4060-60
80-4060-xx
4.13”–6.625”
(104.9–168.3 mm)
* = Special order collets; specify your exact pipe O.D. Depending on
pipe O.D., may require extended tooling or custom tool slides. Contact
E.H. Wachs customer service to discuss your requirements.
Refer to the collet table in Chapter 9 for collet kit ordering information.
24
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 3, Introduction to the Equipment: Tool Slide Options
Collet
Collet Nut
Figure 3-6. The collet fits around the pipe, and is secured into the
bore of the SDSF machine with the collet nut.
TOOL SLIDE OPTIONS
The SDSF uses a modular tool slide system to accommodate tool slides
to fit varied applications.
Table 4: Tool Slide Part Numbers
Machine Size
Parting Slide
Beveling
Slide
Counterbore
Slide
Axial Slide
FME Slide
Radial
Socket Weld
Slide
1”
80-4101-10
80-4102-10
80-4107-00
80-4104-10
80-4106-10
80-4100-10
1-1/2”
80-4101-20
80-4102-20
80-4107-00
80-4104-20
80-4106-20
80-4100-20
2”
80-4101-20
80-4102-20
80-4107-00
80-4104-20
80-4106-20
80-4100-20
2-1/2”
80-4101-20
80-4102-20
80-4107-00
80-4104-20
80-4106-20
80-4100-20
3”
80-4101-40
80-4102-40
80-4107-00
80-4104-40
80-4106-40
—
3-1/2”
80-4101-40
80-4102-40
80-4107-00
80-4104-40
80-4106-40
—
4”
80-4101-40
80-4102-40
80-4107-00
80-4104-40
80-4106-40
—
5”
80-4101-60
80-4102-60
80-4107-00
80-4104-60
80-4106-60
—
6”
80-4101-60
80-4102-60
80-4107-00
80-4104-60
80-4106-60
—
E.H. Wachs
Part No. 80-MAN-01, Rev. C
25
Small Diameter Split Frame
Parting/Beveling
NOTE
Even if you are only doing a
straight parting cut-off, you
will need both the parting and
parting/beveling slides. The
slides have offset parting tool
holders to prevent the parting tool from binding in the
cut.
For parting or parting/beveling operations, order slide kit
80-5101-XX (where XX is the size of your SDSF machine).
The kit includes a radial parting slide (80-4101-XX), radial
parting/beveling slide (80-4102-XX), and radial trip assembly (80-4103-00, same for all SDSF models). You can also
order the slides or trips separately.
Radial trip assembly
80-4103-00)
Parting slide
80-4101-XX)
Parting/beveling slide
80-4102-XX)
Figure 3-7. The radial parting/beveling kit (80-5101XX) includes a parting slide, radial trip assembly, and
parting/beveling slide.
Socket Weld Removal
The SDSF can be configured for either radial or axial socket
weld removal. The radial socket weld slide (80-4100-XX)
uses the standard radial trip. The axial socket weld slide
(80-4104-XX) uses an axial trip assembly (80-4105-00,
same for all SDSF models).
Turn-key socket weld removal kits are available, including
1” and 2” SDSF machines with all accessories for socket
weld removal on standard sizes. Order 80-0000-AX for the
axial kit, or 80-0000-RA for the radial kit.
26
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 3, Introduction to the Equipment: Tool Slide Options
Radial trip assembly
80-4103-00)
Radial socket weld
removal slide
80-4100-XX)
Figure 3-8. The radial socket weld removal slide (804100-XX) uses the standard radial trip assembly.
NOTE
Axial socket weld
removal slide
80-4104-XX)
Axial trip assembly
80-4105-00)
The axial socket weld slide
can be used on all 3000# and
6000# sockets. For heavier
sockets, check the clearances on the axial socket
weld slide envelope drawing
at the end of this chapter.
Figure 3-9. The axial socket weld removal slide (804104-XX) uses the axial trip assembly (80-4105-00).
Socket Weld Removal Kits
SDSF kits are available with all components for socket weld
removal. Two configurations are available:
•
•
Axial socket weld removal kit (80-0000-AX)
Radial socket weld removal kit (80-0000-RA).
The drawings on the following pages illustrate the components supplied with each kit.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
27
28
PART NUMBER
56-150-00
60-227-00
80-0007-10
80-0007-20
80-0078-00
80-0080-00
80-0081-00
80-0082-00
80-0104-00
80-0106-00
80-3000-10
80-3000-20
80-3002-10
80-3002-20
80-4001-00
80-4004-00
80-4010-05
80-4010-07
80-4010-10
80-4020-12
80-4020-15
80-4020-20
80-4104-10
80-4104-20
80-4105-00
80-5500-00
80-LIT-01
80-MAN-01
90-049-06
90-149-25
90-800-06
90-800-57
90-800-62
90-800-78
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
1
1
1
1
4
2
2
2
1
1
1
1
1
1
4
1
1
1
1
1
1
1
1
1
2
2
1
1
8
2
1
1
1
1
QTY
DESCRIPTION
CASE, STORAGE (NOT SHOWN)
TOOL BOX
NUT, 1" LP COLLET
NUT, 2" LP COLLET
EXTENSION, CLAMP FOOT ASSEMBLY .312
NAME PLATE
LABEL, MOVING PARTS
LABEL, AIR MOTOR CLAMP
SDSF, FOAM INSERT-KIT (NOT SHOWN)
LABEL, CASE-SDSF (NOT SHOWN)
1" LP FRAME ASSEMBLY
2" LP FRAME ASSEMBLY
1" PINION HOUSING ASSY.
2" PINION HOUSING ASSEMBLY
CLAMP FOOT ASSEMBLY
PNEUMATIC DRIVE ASSEMBLY
1" SD COLLET ASSEMBLY
1" SD COLLET ASSEMBLY
1" SD COLLET ASSEMBLY
2" SD COLLET ASSEMBLY
2" SD COLLET ASSEMBLY
2" SD COLLET ASSEMBLY
1" AXIAL SLIDE ASSY.
2" AXIAL SLIDE ASSEMBLY
AXIAL TRIP ASSEMBLY
SDSF SPARE FASTENER KIT (NOT SHOWN)
TOOLING CHART, SDSF (NOT SHOWN)
SDSF MANUAL (NOT SHOWN)
SCREW, #2-3/16 U-DRIVE
PIN, 3/16 x 2-1/2 SS QUICK
WRENCH, 5/64 - 1/4 HEX SET
WRENCH, 1/4 HEX X 6" T-HANDLE
WRENCH, 3/16 HEX X 9" T-HANDLE
WRENCH, SPANNER
16
11
7
13
6
29
Part No. 80-MAN-01, Rev. C
31
8
30
7
12
25
14
6
23
29
24
5
8
15
3
34
4
17
18
2
19
20
33
21
22
32
Small Diameter Split Frame
Figure 3-10. Axial Socket Weld Removal Kit, 80-0000-AX.
E.H. Wachs
E.H. Wachs
PART NUMBER
56-150-00
60-227-00
80-0007-10
80-0007-20
80-0078-01
80-0080-00
80-0081-00
80-0082-00
80-0104-00
80-0106-00
80-3000-10
80-3000-20
80-3002-10
80-3002-20
80-4001-00
80-4004-00
80-4010-05
80-4010-07
80-4010-10
80-4020-12
80-4020-15
80-4020-20
80-4100-10
80-4100-20
80-4103-00
80-5500-00
80-LIT-01
80-MAN-01
90-049-06
90-149-25
90-800-06
90-800-57
90-800-62
90-800-78
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
1
1
1
1
4
2
2
2
1
1
1
1
1
1
4
1
1
1
1
1
1
1
1
1
2
2
1
1
8
2
1
1
1
1
QTY
DESCRIPTION
CASE, STORAGE (NOT SHOWN)
TOOL BOX
NUT, 1" LP COLLET
NUT, 2" LP COLLET
EXTENSION, CLAMP FOOT ASSEMBLY .562
NAME PLATE
LABEL, MOVING PARTS
LABEL, AIR MOTOR CLAMP
SDSF, FOAM INSERT-KIT (NOT SHOWN)
LABEL, CASE-SDSF (NOT SHOWN)
1" LP FRAME ASSEMBLY
2" LP FRAME ASSEMBLY
1" PINION HOUSING ASSY.
2" PINION HOUSING ASSEMBLY
CLAMP FOOT ASSEMBLY
PNEUMATIC DRIVE ASSEMBLY
1" SD COLLET ASSEMBLY
1" SD COLLET ASSEMBLY
1" SD COLLET ASSEMBLY
2" SD COLLET ASSEMBLY
2" SD COLLET ASSEMBLY
2" SD COLLET ASSEMBLY
1" RADIAL SOCKET WELD
2" RADIAL SOCKET WELD
RADIAL TRIP ASSEMBLY
SDSF SPARE FASTENER KIT (NOT SHOWN)
TOOLING CHART, SDSF (NOT SHOWN)
SDSF MANUAL (NOT SHOWN)
SCREW, #2-3/16 U-DRIVE
PIN, 3/16 x 2-1/2 SS QUICK
WRENCH, 5/64 - 1/4 HEX SET
WRENCH, 1/4 HEX X 6" T-HANDLE
WRENCH, 3/16 HEX X 9" T-HANDLE
WRENCH, SPANNER
16
11
7
13
6
29
Part No. 80-MAN-01, Rev. C
31
8
30
25
7
14
12
6
23
24
29
5
8
15
3
34
4
17
18
2
19
20
33
21
22
32
Chapter 3, Introduction to the Equipment: Tool Slide Options
Figure 3-11. Radial Socket Weld Removal Kit, 80-0000-RA.
29
Small Diameter Split Frame
Counterboring
The SDSF counterbore slide (80-4107-00) can be used with
all SDSF models. The slide mounts to the tool holder of the
parting/beveling slide; remove the tool cover to install the
counterbore slide.
Figure 3-12. The counterbore slide is used with all
SDSF models.
Chipless Wheel Cutting
The SDSF foreign material exclusion (FME) slide (804106-XX) uses a cutting wheel for chipless severing of thinwall pipe or tube. Depending on material, the FME slide can
cut up to approximately 1/8” (3 mm) thickness. The FME
slide uses the standard radial trip assembly.
For FME applications on thicker wall pipe or tube, use the
parting/beveling slide kit to groove the workpiece down to
less than 1/8” (3 mm) thickness. Then install the FME slide
to complete the severing operation.
30
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 3, Introduction to the Equipment: Tool Kit
Figure 3-13. This photo shows the Foreign Material
Exclusion (FME) slide available with the SDSF. The
FME slide is used for chipless cutting in thin-wall and
high-purity applications.
TOOL KIT
The SDSF has a simplified fastener inventory, and requires
only three hex wrench sizes to operate (1/8”, 3/16”, 1/4”).
The hex-through torque wrench (90-800-84) is used to
adjust the bearings.
Table 5: Tool Kit
Description
Part Number
Hex Wrench Cluster
98-800-06
Spare Fastener Kit
80-5500-00
Collet Wrench
(Collet mounting only)
90-800-78 (for 1” to 2-1/2” SDSF)
90-800-79 (for 3” to 4” SDSF)
90-800-80 (for 5” to 6” SDSF)
DRIVE OPTIONS
Three drives are available for the SDSF. Any drive will fit
any size SDSF:
•
•
•
a 0.8 HP pneumatic drive (part no. 80-4004-00)
a 110 V electric drive (part no. 80-4005-01)
a 220 V electric drive (part no. 80-4006-01).
E.H. Wachs
Part No. 80-MAN-01, Rev. C
31
Small Diameter Split Frame
Figure 3-14. The pneumatic drive (80-4004-00) can
be used to power any size SDSF.
Figure 3-15. The electric drive (110 V: 80-4005-01;
220 V: 80-4006-01) can power any size SDSF.
BENCH MOUNTING OPTION
A bench mounting bracket is available to securely mount
the SDSF to a workbench. Two bracket sizes are available;
order the size appropriate for your SDSF model.
•
•
32
For 1” to 2-1/2” SDSF models, use bracket 80-4201-20.
For 3” to 6” SDSF models, use bracket 80-4201-60.
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 3, Introduction to the Equipment: Bench Mounting Option
Figure 3-16. The SDSF is shown attached to the
bench mounting bracket.
Mounting fasteners
Machine fasteners Bracket fasteners
Figure 3-17. The photo shows the bottom of the bench
mounting bracket, with fastener locations noted.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
33
Small Diameter Split Frame
OPERATING ENVELOPES
The following drawings and tables illustrate the dimensions and operating envelopes for all SDSF sizes and configurations.
D
C
A
B
SDSF Base Machine Dimensions
SDSF Model (Size)
DIM A
DIM B
DIM C
DIM D
Ø1.563”
(39.7 mm)
5.000”
(127.0 mm)
6.694”
(170.0 mm)
2.531”
(64.3 mm)
Ø2.125”
(54 mm)
5.375”
(136.5 mm)
7.132”
(181.2 mm)
2.155”
(54.8 mm)
80-4000-20 (2”)
Ø2.625”
(66.7 mm)
5.656”
(143.7 mm)
7.538”
(191.5 mm)
2.155”
(54.8 mm)
80-4000-25 (2-1/2”)
Ø3.125”
(79.4 mm)
6.188”
(157.2 mm)
8.038”
(204.2 mm)
2.155”
(54.8 mm)
80-4000-30 (3”)
Ø3.750”
(95.3 mm)
(6.813”
(173.1 mm)
8.664”
(222.1 mm)
2.155”
(54.8 mm)
80-4000-35 (3-1/2”)
Ø4.250”
(108.0 mm)
7.313”
(185.8 mm)
9.163”
(232.7 mm)
2.155”
(54.8 mm)
80-4000-40 (4”)
Ø4.750”
(120.7 mm)
7.813”
(198.5 mm)
9.585”
(243.5 mm)
2.155”
(54.8 mm)
80-4000-50 (5”)
Ø5.875”
(149.2 mm)
8.938”
(227.0 mm)
10.788”
(274.0 mm)
2.155”
(54.8 mm)
80-4000-60 (6”)
Ø6.875”
(174.6 mm)
9.938”
(252.4 mm)
11.710”
(297.4 mm)
2.155”
(54.8 mm)
80-4000-10 (1”)
80-4000-15 (1-1/2”)
34
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 3, Introduction to the Equipment: Operating Envelopes
2.635
66.9
3.401
86.4
C
A
B
Front Pinion Housing Dimensions
Pinion Housing
Part No.
DIM A
DIM B
DIM C
80-4000-10 (1”)
80-4003-10
Ø1.563”
(39.7 mm)
6.310”
(160.3 mm)
7.876”
(200.1 mm)
80-4000-15 (1-1/2”)
80-4003-15
Ø2.125”
(54 mm)
6.506”
(165.3 mm)
8.314”
(211.2 mm)
80-4000-20 (2”)
80-4003-20
Ø2.625”
(66.7 mm)
6.738”
(171.1 mm)
8.720”
(221.5 mm)
80-4000-25 (2-1/2”)
80-4003-25
Ø3.125”
(79.4 mm)
7.071”
(179.6 mm)
9.220”
(234.2 mm)
80-4000-30 (3”)
80-4003-30
Ø3.750”
(95.3 mm)
7.377”
(187.4 mm)
9.846”
(250.1 mm)
80-4000-35 (3-1/2”)
80-4003-35
Ø4.250”
(108 mm)
7.665”
(194.7 mm)
10.345”
(262.8 mm)
80-4000-40 (4”)
80-4003-40
Ø4.750”
(120.7 mm)
7.967”
(202.4 mm)
10.846”
(275.5 mm)
80-4000-50 (5”)
80-4003-50
Ø5.875”
(149.2 mm)
8.938”
(227 mm)
11.970”
(304 mm)
80-4000-60 (6”)
80-4003-60
Ø6.875”
(174.6 mm)
9.938”
(252.4 mm)
12.970”
(329.5 mm)
SDSF Model (Size)
E.H. Wachs
Part No. 80-MAN-01, Rev. C
35
Small Diameter Split Frame
Parting Slide (80-4101-XX)
4.34
110.3
4.09
104.0
3.47
88.1
DIMENSIONS IN BRACKETS ARE MILLIMETERS
2.66
67.5
DIM A
.56
14.3
1.50
38.1
.44
11.1
TRAVEL
80-7001-02
(2.13 [54.1] LONG)
DIM D
MIN RADIAL
CLEARANCE
.50
12.8
3.13
79.4
FEED RATE
.0031 PER TRIP
[.079]
.13
3.2
DIM C
DIM B
SHOWN WITH SDSF
SHOWN WITH COLLET NUT
SDSF Model (Size)
80-4000-10 (1”)
2.44
61.9
Slide Part No.
DIM A
DIM B
DIM C
DIM D RADIUS
80-4101-10
2.53”
(64.3 mm)
0.94”
(23.8 mm)
2.13”
(54.0 mm)
2.37”
(60.3 mm)
2.61”
(66.3 mm)
80-4000-15 (1-1/2”)
80-4000-20 (2”)
2.13”
(54.0 mm)
80-4101-20
3.09”
(78.6 mm)
80-4000-25 (2-1/2”)
80-4000-30 (3”)
80-4000-35 (3-1/2”)
80-4101-40
2.16”
(54.8 mm)
1.31”
(33.3 mm)
3.40”
(86.3 mm)
1.94”
(49.2 mm)
3.64”
(92.5 mm)
3.89”
(98.7 mm)
80-4000-40 (4”)
80-4000-50 (5”)
1.86”
(47.3 mm)
80-4101-60
80-4000-60 (6”)
36
2.85”
(72.4 mm)
Part No. 80-MAN-01, Rev. C
4.44”
(112.8 mm)
4.93”
(125.3 mm)
E.H. Wachs
Chapter 3, Introduction to the Equipment: Operating Envelopes
Beveling Slide (80-4102-XX)
4.30
109.1
4.05
102.8
DIMENSIONS IN BRACKETS ARE MILLIMETERS
3.05
77.4
2.66
67.5
DIM A
1.50
38.1
.56
14.3
.44
11.1
TRAVEL
52-710-02
(2.13 [54.1] LONG)
DIM D
MIN RADIAL
CLEARANCE
.50
12.8
3.13
79.4
.38
9.6
FEED RATE
.0031 PER TRIP
[.079]
.11
2.8
.50
12.7
DIM C
SHOWN WITH SDSF
SHOWN WITH COLLET NUT
SDSF Model (Size)
80-4000-10 (1”)
DIM B
2.39
60.7
Slide Part No.
DIM A
DIM B
DIM C
DIM D RADIUS
80-4102-10
2.53”
(64.3 mm)
0.52”
(13.1 mm)
2.13”
(54.0 mm)
2.37”
(60.3 mm)
2.61”
(66.3 mm)
80-4000-15 (1-1/2”)
80-4000-20 (2”)
2.13”
(54.0 mm)
80-4102-20
3.09”
(78.6 mm)
80-4000-25 (2-1/2”)
80-4000-30 (3”)
80-4000-35 (3-1/2”)
80-4102-40
2.16”
(54.8 mm)
0.89”
(22.6 mm)
3.40”
(86.3 mm)
1.94”
(49.2 mm)
3.64”
(92.5 mm)
3.89”
(98.7 mm)
80-4000-40 (4”)
80-4000-50 (5”)
1.86”
(47.3 mm)
80-4102-60
80-4000-60 (6”)
E.H. Wachs
2.85”
(72.4 mm)
Part No. 80-MAN-01, Rev. C
4.44”
(112.8 mm)
4.93”
(125.3 mm)
37
Small Diameter Split Frame
Axial Slide (80-4104-XX)
4.42
112.3
DIMENSIONS IN BRACKETS ARE MILLIMETERS
DIM A
.56
14.3
1.50
38.1
1.00
25.4
TRAVEL
DIM D
MIN RADIAL
CLEARANCE
80-7007-02
(2.00 [50.8] LONG)
.38
9.6
3.13
79.4
SHOWN AT
MAX TRAVEL
DIM E
MAX DIAMETER
FEED RATE
.0031 PER TRIP
[.079]
.38
9.6
SHOWN WITH SDSF
DIM B
DIM C
3.49
88.5
SHOWN WITH COLLET NUT
SDSF Model (Size) Slide Part No.
2.52
63.9
DIM A
DIM B
DIM C
DIM D RAD.
DIM E DIA.
2.53”
(64.3 mm)
0.95”
(24.2 mm)
2.13”
(54.0 mm)
2.33”
(59.3 mm)
2.75”
(69.8 mm)
2.58”
(65.6 mm)
3.25”
(82.6 mm)
2.83”
(71.9 mm)
3.75”
(95.3 mm)
80-4000-10 (1”)
80-4104-10
80-4000-15 (1-1/2”)
80-4104-20
80-4000-20 (2”)
80-4104-20
80-4000-25 (2-1/2”)
80-4104-20
3.08”
(78.2 mm)
4.25”
(108.0 mm)
80-4000-30 (3”)
80-4104-40
3.39”
(86.1 mm)
4.87”
(123.8 mm)
80-4000-35 (3-1/2”)
80-4104-40
3.64”
(92.4 mm)
5.38”
(136.5 mm)
80-4000-40 (4”)
80-4104-40
3.89”
(98.7 mm)
5.88”
(149.2 mm)
80-4000-50 (5”)
80-4104-60
80-4000-60 (6”)
80-4104-60
38
2.00”
(50.8 mm)
2.16”
(54.8 mm)
1.33”
(33.7 mm)
1.94”
(49.2 mm)
1.63”
(41/3 mm)
4.45”
7.00”
(113.0 mm) (177.8 mm)
4.95”
8.00”
(125.7 mm) (203.2 mm)
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 3, Introduction to the Equipment: Operating Envelopes
Axial Slide Tooling Clearances
Tool Part No:
52-701-01
80-7007-02
80-7007-03
52-702-01
Min. 0.565”
(14.35 mm)
Tool Part No:
52-701-02
52-702-02
Max. 0.061”
(1.55 mm)
Tool Part No:
52-701-03
Max. 0.309”
(7.85 mm)
E.H. Wachs
Part No. 80-MAN-01, Rev. C
39
Small Diameter Split Frame
FME Slide (80-4106-XX)
4.46
113.2
4.09
104.0
3.53
89.6
DIMENSIONS IN [BRACKETS] ARE MILLIMETERS
CUTTING WHEEL SHOULD ONLY BE USED TO PENETRATE FINAL .03 [.8] - .09 [2.3] WALL
MAX WALL THICKNESS .37 [9.4]
2.66
67.5
DIM A
.37
9.4
MAX WALL
1.50
38.1
.56
14.3
.56
14.2
TRAVEL
DIM E
MAX RADIAL
CLEARANCE
2.19
55.6
3.13
79.4
DIM F DIAMETER
MIN WHEEL
CUTTER
PENETRATION
FEED RATE
.0031 PER TRIP
[.079]
DIM G DIAMETER
MAX OD
80-0053-00
(1.53 [38.9] DIA)
DIM D
DIM B
SHOWN ON SDSF
SHOWN WITH COLLET NUT
SDSF Model (Size)
DIM C
Slide Part No.
DIM A
DIM B
DIM C
80-4000-10 (1”)
80-4106-10
2.53”
(64.3 mm)
1.00”
(25.3 mm)
2.30”
(58.5 mm)
80-4000-15 (1-1/2”)
80-4106-20
80-4000-20 (2”)
80-4106-20
80-4000-25 (2-1/2”)
80-4106-20
80-4000-30 (3”)
80-4106-40
80-4000-35 (3-1/2”)
80-4106-40
80-4000-40 (4”)
80-4106-40
80-4000-50 (5”)
80-4106-60
80-4000-60 (6”)
80-4106-60
40
DIM D
2.13”
(54.0 mm)
2.16”
(54.8 mm)
1.37”
(34.9 mm)
2.55”
(64.8 mm)
1.94”
(49.2 mm)
1.86”
(47.3 mm)
Part No. 80-MAN-01, Rev. C
DIM E RAD.
DIM F DIA.
DIM G DIA.
2.39”
(60.7 mm)
0.35”
(8.8 mm)
1.315”
(33.40 mm)
2.61”
(66.3 mm)
0.85”
(21.5 mm)
1.900”
(48.26 mm)
2.85”
(72.4 mm)
1.35”
(34.3 mm)
2.375”
(60.33 mm)
3.09”
(78.6 mm)
1.85”
(46.9 mm)
2.875”
(75.03 mm)
3.40”
(86.3 mm)
2.47”
(62.8 mm)
3.500”
(88.90 mm)
3.64”
(92.5 mm)
2.97”
(75.5 mm)
4.000”
(101.60 mm)
3.89”
(98.7 mm)
3.47”
(88.2 mm)
4.500”
(114.30 mm)
4.44”
(112.8 mm)
4.60”
(116.8 mm)
5.560”
(141.22 mm)
4.93”
(125.3 mm)
5.60”
(142.2 mm)
6.625”
(168.28 mm)
E.H. Wachs
Chapter 3, Introduction to the Equipment: Operating Envelopes
Radial Socket Weld Removal Slide (80-4100-10 Slide
for 1” SDSF)
DIMENSIONS IN BRACKETS ARE MILLIMETERS
4.00
101.6
3.06
77.8
2.66
67.5
2.53
64.3
.56
14.3
1.50
38.1
.44
11.1
(TRAVEL)
R2.37 MIN
60.3
(RADIAL CLEARANCE)
80-7006-02
(1.50 [38.1] LONG)
.38
9.5
3.13
79.4
2.31 MAX
58.7
FEED RATE
.0031 PER TRIP
[.079]
.50
12.7
SHOWN WITH SDSF
80-4000-10
SHOWN WITH COLLET NUT
80-0007-10
2.13
54.0
.53
13.5
2.09
53.2
E.H. Wachs
Part No. 80-MAN-01, Rev. C
41
Small Diameter Split Frame
Radial Socket Weld Removal Slide (80-4100-20 Slide
for 1-1/2, 2”, and 2-1/2” SDSF)
4.56
115.9
-TABLE-
2.66
67.5
MODEL
2.16
54.8
DIM. "A" MIN.
RADIAL CLEARANCE
DIM. "B"
DIA. MAX.
SDSF 1-1/2"
2.61 [66.3]
2.81 [71.4]
SDSF 2"
2.85 [72.4]
3.26 [82.7]
SDSF 2-1/2"
3.09 [78.6]
3.70 [94.0]
1.50
38.1
.56
14.3
R "A" MIN
RADIAL CLEARANCE
(SEE TABLE)
.44
11.1
TRAVEL
80-7006-02
(1.50 [38.1] LONG)
.38
9.5
3.13
79.4
.50
12.7
SHOWN WITH SDSF
80-4000-XX
SHOWN WITH COLLET NUT
80-0007-XX
42
FEED RATE
.0031 PER TRIP
[.079]
"B" MAX
(SEE TABLE)
.91
23.0
2.09
53.2
2.13
54.0
DIMENSIONS IN BRACKETS ARE MILLIMETERS
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 3, Introduction to the Equipment: Operating Envelopes
Radial Trip (80-4103-00)
.781
19.8
RADIAL TRIP 80-4103-00
2.500
63.5
"A"
E.H. Wachs
Part No. 80-MAN-01, Rev. C
RING SIZE
DIM "A"
1"
(80-4000-10)
6.564
[166.7]
1-1/2"
(80-4000-15)
6.784
[172.3]
2"
(80-4000-20)
7.064
[179.4]
2-1/2"
(80-4000-25)
7.284
[185]
3"
(80-4000-30)
7.597
[192.9]
3-1/2"
(80-4000-35)
7.846
[199.2]
4"
(80-4000-40)
8.097
[205.6]
5"
(80-4000-50)
8.659
[219.9]
6"
(80-4000-60)
9.159
[232.6]
43
Small Diameter Split Frame
Axial Trip (80-4105-00)
AXIAL TRIP 80-4105-00
.620
15.7
R1.938
49.2
"A"
1.063
27
44
Part No. 80-MAN-01, Rev. C
RING SIZE
DIM
"A"
1"
(80-4000-10)
6.657
[169.1]
1-1/2"
(80-4000-15)
6.908
[175.4]
2"
(80-4000-20)
7.158
[181.8]
2-1/2"
(80-4000-25)
7.408
[188.1]
3"
(80-4000-30)
7.722
[196.1]
3-1/2"
(80-4000-35)
7.972
[202.4]
4"
(80-4000-40)
8.222
[208.8]
5"
(80-4000-50)
8.784
[223.1]
6"
(80-4000-60)
9.284
[235.8]
E.H. Wachs
Chapter 3, Introduction to the Equipment: Operating Envelopes
Counterbore Slide (80-4107-00)
COUNTERBORE SLIDE 80-4107-00
3.566
90.6
2.297
58.4
3.409
86.6
PARTING
LINE
.750 MAX DEPTH
19.1
SHOWN WITH
80-7003-01
.469 MAX THICKNESS
11.9
E.H. Wachs
Part No. 80-MAN-01, Rev. C
45
Small Diameter Split Frame
Pneumatic Drive (80-4004-00)
DIMENSIONS IN BRACKETS ARE MILLIMETERS
Electric Drive (80-4005-01/80-4006-01)
11.62 REF
295.1
2.80 REF
71.1
2.98 REF
75.7
9.54 REF
242.4
7.47 REF
189.7
DIMENSIONS IN BRACKETS ARE MILLIMETERS
46
.50 REF
12.7
Part No. 80-MAN-01, Rev. C
8.96 REF
227.5
2.92 REF
74.0
E.H. Wachs
Chapter 4, Assembly, Disassembly, and Storage
Chapter 4
Assembly,
Disassembly, and
Storage
MACHINE DISASSEMBLY AND STORAGE
1. Disconnect the power source (air or electric) from the
drive.
In This Chapter
MACHINE DISASSEMBLY AND
STORAGE
2. Remove the drive assembly from SDSF. Leave the
motor clamps in place.
3. Retract the tool slides.
4. Loosen the four clamp feet, or loosen and remove the
collet nut and collet.
5. Unscrew the frame locking screws.
6. Remove SDSF from pipe.
7. Clean the machine of debris such as metal chips and
excess coolant.
8. Split the machine halves and examine the bearing
raceway for metal chips.
9. Apply two drops of Wachs way oil (60-1184-00) to
the felt wiper before storing the machine.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
47
Small Diameter Split Frame
Felt wiper
Figure 4-1. Oil the felt wiper after every use of the
machine.
Figure 4-2. Store the SDSF in its carrying case when
not in use.
48
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions
Chapter 5
Operating
Instructions
In This Chapter
PRE-OPERATION CHECKLIST
PRE-OPERATION CHECKLIST
To avoid damaging the equipment, follow these usage
guidelines.
CONFIGURING THE
THE APPLICATION
MOUNTING THE
THE PIPE
SDSF FOR
MACHINE ON
1. Lubricate the machinery according to the recommen-
MOUNTING THE DRIVE MOTOR
2. Before starting the machine, make sure the tooling is
COUNTERBORING
3. Make sure that the air connection is secure (pneu-
FOREIGN MATERIAL
EXCLUSION CUTTING
dations in Chapter 6.
inserted and fastened securely.
matic drive only).
4.
If using clamp feet, make sure the machine is centered
and squared on the pipe or tube.
PARTING AND BEVELING
SOCKET WELD REMOVAL
REMOVING THE MACHINE
REMOTE OPERATION WITH THE
SF ACM
5. If using clamp feet, the clamp feet must be securely
tightened.
6. If using a collet, make sure the collet nut is securely
tightened.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
49
Small Diameter Split Frame
CONFIGURING THE SDSF FOR THE
APPLICATION
Selecting Feet or Collet for Mounting
Determine whether a collet or clamping feet will work best
for your application. Generally, a collet will provide easier
and more accurate clamping, but the collet must be exactly
the right size for the pipe O.D. Use the clamp feet if you do
not have a correctly sized collet to fit the pipe you are cutting.
Installing the Clamp Feet
You do not need to remove the clamp feet each time you use
the machine. If you need to install the clamp feet, follow
this procedure.
NOTE
The 1” and 1-1/2”
SDSF models do not have
clamp feet. They install with
collets only.
1. Insert the clamp feet into the clamp foot holes on the
I.D. of the SDSF.
2. Insert a 1/4” hex wrench through the clamp foot screw
hole in the frame. Turn the clamp foot screw counterclockwise to snug the clamp foot screws.
3. Turn the set screws clockwise until they snug against
the clamp feet.
4. Turn the set screws 1/4 turn counter-clockwise.
50
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Configuring the SDSF for the Application
Clamp Foot Screw
Set Screw
Figure 5-1. Install the clamp feet as shown.
5. Ensure the clamp feet can move freely by turning the
clamp foot screws.
Adding Clamp Foot Extensions
Measure the O.D of the pipe to be machined and determine
whether clamp foot extensions will be necessary. Refer to
the table on page 22. Attach the clamp foot extensions to the
clamp feet.
Removing the Clamp Feet for Collet Mounting
1. Loosen the set screws. Refer to Figure 5-1.
2. Unscrew and remove the clamp feet.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
51
Small Diameter Split Frame
Selecting the Slides, Tooling, and Trip
Use this table to determine which slide(s) are needed for the
cutting application you are performing.
Table 1: Slide and Tooling Application
Application
Slide(s)
Tooling
Trip
Cut-off
Radial Parting
Slide
AND
Radial Parting/
Beveling Slide
Parting
AND
Parting
Radial
Parting and
Beveling
Radial Parting
Slide
AND
Radial Parting/
Beveling Slide
Parting
AND
Beveling
Radial
Counterboring
Counterbore
Slide
Counterbore
Not used
FME Cutting
Radial Parting
Slide
AND
FME Slide
Parting
AND
Wheel
Radial
Socket Weld
Removal
Axial
Slide
Standard
OR
Extended
Axial
Socket Weld
Removal
Radial Slide
Standard
OR
Extended
Radial
Installing the Radial Slides
1. Align and tighten the three tool slide mounting
screws. Use a 3/16” hex wrench to attach each tool
slide (parting and parting/beveling) to the SDSF.
52
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Configuring the SDSF for the Application
Figure 5-2. Secure the mounting screws as shown.
2. Use a 3/16” hex wrench to turn the starwheel clockwise to fully retract the tool slides.
3. Loosen the three screws on the tool cover plate with a
3/16” hex wrench.
Tool Cover Plate Screws
Tool Slide Mounting Screws
Figure 5-3. Use the screws noted to mount the radial
tool slides.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
53
Small Diameter Split Frame
4. Select the tool bits appropriate for the desired cut, and
slide the tool bits into the tooling slots. The cutting
edge of each tool bit must face clockwise when viewing the SDSF from the front.
Cutting Edge
Direction of Rotation
Figure 5-4. The cutting edges on both the parting and
beveling tools must face clockwise.
5. Tighten the three screws on the tool cover plate.
Installing the Trip Assembly
1. Align the mounting screws on the trip assembly with
the holes on the pinion housing.
2. Tighten the trip assembly mounting screws with a 3/
16” hex wrench.
54
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Configuring the SDSF for the Application
Figure 5-5. Install the radial or axial trip assembly as
shown.
3. Always use the radial trip assembly with radial tool
slides and the axial trip assembly with the axial tool
slides. Refer to Table 1 on page 52.
NOTE
The axial trip pin
should be flush with the edge
of the assembly when disengaged.
CAUTION
Using the wrong trip
for the installed
slides will cause damage.
Refer to Table 1 on page 52.
Figure 5-6. Use the radial trip (left) with the radial
tool slides, and use the axial trip (right) with the axial
tool slides.
Installing the Axial Slide
1. Use a 3/16” hex wrench to turn the starwheel clockwise to fully retract the tool slide.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
55
Small Diameter Split Frame
NOTE
Axial tool slides
must be detached from the
SDSF before tooling is
inserted or removed.
2. Loosen the tool set screw with a 3/16” hex wrench.
3. Select the tool bit appropriate for the desired cut, and
slide the tool bit into the tooling slot.
4. Tighten the tool set screw.
5. Align and tighten the two mounting screws to attach
the tool slide to the SDSF.
Figure 5-7. Attach the axial slide to the SDSF after
mounting the desired tooling.
MOUNTING THE MACHINE ON THE PIPE
NOTE
The SDSF does not
need to be split if mounting
the machine on open-ended
pipe. Simply install it over the
end of the pipe with the tool
slides out (towards the cut-off
end).
56
The SDSF is designed to mount on inline pipe. All components split open so they can be assembled around the workpiece.
1. Turn the rotating ring so that the split points of the
rotating and stationary rings are aligned.
2. Loosen the frame locking screws with a 1/4” hex
wrench to separate the two halves of the SDSF. Pull
the halves of the SDSF apart.
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Mounting the Machine on the Pipe
Split points
Figure 5-8. The split points on the rotating ring and
stationary ring must be aligned to separate the halves
of the SDSF.
3. Place the two halves of the SDSF around the pipe to
be cut. If necessary, insert frame locking detent pins
into the pinholes to prevent the rotating ring from
moving while the SDSF is split.
4. Partially tighten one frame locking screw on the stationary ring and one screw on the rotating ring.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
57
Small Diameter Split Frame
CAUTION
The SDSF will
rotate freely on the pipe
until the clamp legs or
collet are tightened. Support the machine so it
does not spin or shift on
the pipe. Failure to do so
could result in injury.
Figure 5-9. Tighten the frame locking screws to attach
the SDSF around inline pipe.
5. Remove all frame locking detent pins (if used).
6. Securely tighten all four frame locking screws.
Figure 5-10. The photo shows the two halves of the
SDSF split apart.
58
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Mounting the Machine on the Pipe
Adjusting the Clamp Feet
Most Small Diameter Split Frame machines mount using
clamp feet. If using a collet, go to the next section.
1. Starting with the clamp foot closest to the 12 o’clock
position, tighten the clamp foot screw with a 1/4” hex
wrench until the gap at the top and the bottom of the
machine are approximately equal.
2. Snug the clamp foot at the 6 o’clock position.
Figure 5-11. Use a hex driver to square the SDSF
with the clamp pads.
3. Measure the gap between the pipe and the SDSF at the
6 o’clock and 12 o’clock positions. Loosen the clamp
foot on the side with the larger gap, and snug the
opposite foot. Continue until both gaps are within
0.03” (0.78 mm).
4. Repeat the centering procedure for the clamp feet at
the 3 and 9 o’clock positions. At this point the
machine should be fairly square.
5. When the machine is squared and centered, tighten
down all 4 clamp feet to a maximum of 50 lb-ft
(67 N-m).
E.H. Wachs
Part No. 80-MAN-01, Rev. C
59
Small Diameter Split Frame
IMPORTANT
Tighten the clamp leg screws
to a maximum of 50 lb-ft
(67 N-m).
Figure 5-12. Tighten the clamp feet as indicated.
Collet Mounting
The SDSF is best mounted using a collet if you have a collet
precisely sized for the pipe you are cutting. The 1”and
1-1/2” SDSF only use collet mounting.
NOTE
The SDSF does not
need to be split if mounting
the machine on open-ended
pipe. Simply install it over the
end of the pipe with the tool
slides out (towards the cut-off
end).
60
1. Remove the collet nut from the machine. Use the collet wrench to loosen it if necessary.
2. Loosen the captivated screws in the collet nut.
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Mounting the Machine on the Pipe
Figure 5-13. Remove the collet from the SDSF before
mounting the machine on the pipe.
3. Turn the rotating ring so that the split points of the
rotating and stationary rings are aligned.
Rotating Ring Screw
Split points
Stationary Ring Screw
Figure 5-14. The SDSF split points can be wedged
apart if necessary.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
61
Small Diameter Split Frame
4. Loosen the two captivated screws in the stationary
ring with a 1/4” hex wrench.
5. Loosen the two captivated screws in the rotating ring
using a 1/4” hex wrench.
Figure 5-15. Loosen the frame locking screws in both
the rotating and stationary rings.
6. Pull the two halves of the machine apart.
7. Assemble the collet nut around the work piece.
Tighten the captivated screws.
8. Assemble the collet around the work piece. The wider
edge of the collet plates should face toward the collet
nut threading.
62
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Mounting the Machine on the Pipe
Figure 5-16. Arrange the collet and collet nut as
shown.
9. Attach the SDSF around the work piece. The narrow
edge of the collet plates should face toward the SDSF.
Figure 5-17. The collet mounting is self-centering
when assembled properly.
10. Slide the collet into the I.D. of the SDSF with finger
pressure.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
63
Small Diameter Split Frame
Figure 5-18. Slide the collet into the SDSF near the
cut line.
11. Screw the collet nut into the SDSF. The collet nut has
left handed threading.
12. Tighten the collet nut using the collet wrench.
Figure 5-19. Turn the collet nut counter-clockwise to
tighten it.
64
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Mounting the Drive Motor
MOUNTING THE DRIVE MOTOR
Pneumatic Drive
1. Loosen the motor clamp screws farthest from the
SDSF stationary ring using a 3/16” hex wrench.
2. Swing the clamps down, clearing space for the drive
flange.
WARNING
Ensure the motor
clamps are secure
before operating the SDSF.
Keep hands clear while the
machine is operating.
.
NOTE
Use of an air treatment module (80-4202-00) is
recommended when using
the air motor. Lubricate the
air motor with air motor oil
daily.
Figure 5-20. Pivot the clamps downward to attach the
drive.
3. Attach the drive to the pinion housing. Turn the motor
as required to engage the square shaft in the pinion.
4. Swing the clamps back into place, and tighten all
screws.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
NOTE
The clamps hold
the gear in place. Do not
remove the clamps completely unless you are replacing the gear.
65
Small Diameter Split Frame
NOTE
If the motor
covers one screw, snug it
using finger pressure,
and tighten the other
three. Do not overtighten
the clamp screws.
Figure 5-21. Tighten the motor clamp screws to
secure the motor in place.
110 V Electric Drive
The electric drive mounts using motor clamps with hex
head screws. This is so that you can tighten the screws with
a combination wrench (provided).
NOTE
When the electric
drive is purchased as an
accessory, it includes clamps
with hex head screws and a
7/16” combination wrench to
tighten them.
If your SDSF came in electric drive configuration, it is prefitted with the hex head screws. If you are installing the
electric drive on an air configuration SDSF, you will need to
remove the clamps with socket head cap screws and install
the clamps with the hex head screws.
Figure 5-22. To convert an air drive SDSF to use the
electric drive, remove the socket head cap screws in
the motor clamps and install the hex head screws.
66
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Mounting the Drive Motor
1. Loosen the hex head motor clamp screws farthest
from the SDSF stationary ring, using the 7/16” combination wrench if necessary.
2. Swing the clamps down, clearing space for the drive
flange.
NOTE
The clamps hold
the gear in place. Do not
remove the clamps completely unless you are replacing the gear.
Figure 5-23. Loosen the clamp screws and swing the
clamps downward to provide clearance for attaching
the electric drive.
3. Attach the drive to the pinion housing. Turn the motor
as required to engage the square shaft in the pinion.
Figure 5-24. Install the electric drive, pressing the
drive flange flush against the pinion housing.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
67
Small Diameter Split Frame
WARNING
Ensure the motor
clamps are secure
before operating the SDSF.
Keep hands clear while the
machine is operating.
4. Swing the clamps back into place, and tighten all
screws.
Figure 5-25. Put the clamps back in place over the
flange and tighten the clamp screws with the supplied
7/16” combination wrench.
PARTING AND BEVELING
1. Attach a compressed air hose to the pneumatic drive,
or supply power to the electric drive.
2. Turn the starwheels on the tool slides counterclockwise to remove backlash.
NOTE
Make sure the
pipe is supported on both
sides of the cut line.
68
3. Engage the trip by pushing the trip lever so the starwheel strikes the trip pin.
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Parting and Beveling
Figure 5-26. The radial trip is shown in the engaged
position.
4. Engage the drive motor at low speed through one revolution to check the tool clearance around the pipe
O.D.
5. Disengage the drive motor, and stop the machine
where you can access the starwheel on the parting
slide.
6. Turn the starwheel counterclockwise until the tip of
CAUTION
Keep hands
and clothing clear of moving parts when the
machine is operating.
Failure to do so could
result in injury.
the tool is about 1/16” from the pipe surface at its closest point to the pipe.
7. Repeat step 6 for the parting/beveling slide.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
69
Small Diameter Split Frame
Figure 5-27. The tool bit should only contact the pipe
after the machine begins to run.
NOTE
After the cut,
loosen the parting tool
cover plate before retracting the slide to avoid chipping the parting tool.
8. Start the drive motor to run the machine. When the
tool starts cutting the pipe, apply water soluble coolant
(02-406-00) frequently to keep the cutting surface
lubricated.
9. The beveling tool should closely follow the parting
tool. To adjust this, stop the machine and turn the starwheel on the parting/beveling slide.
10. Operate the machine until the pipe is cut through. Turn
off the drive motor, and disconnect power or air supply.
11. Leave the machine mounted on the pipe if you will be
performing a counterbore.
COUNTERBORING
The universal counterbore assembly is used to counterbore
tube and pipe. The counterbore assembly mounts on the
radial parting/beveling slide. The starwheel is used to set the
I.D. of the counterbore, and the hand wheel is used to feed
the tool into the pipe axially.
1. Retract the parting slide completely by rotating the
starwheel clockwise using a 3/16” hex wrench.
2. Retract the beveling slide roughly halfway.
70
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Counterboring
3. Remove the parting and beveling tooling.
4. Remove the parting/beveling tool cover plate.
5. Remove the trip assembly.
6. Mount the universal counterbore assembly to the parting/beveling slide. Snug the side screws first, and then
tighten the top screws.
Figure 5-28. Tighten the top screws after securing the
counterbore slide with the side screws.
7. Rotate the starwheel counterclockwise until the counterbore tool lightly touches the I.D. of the pipe.
8. Measure the radial depth of the counterbore.
9. Turn the hand wheel to move the tool axially away
from the pipe face.
E.H. Wachs
NOTE
Each point on
the starwheel adds
0.006" to the diameter of
the counterbore.
Part No. 80-MAN-01, Rev. C
71
Small Diameter Split Frame
Figure 5-29. Do not start the drive motor with the
counterbore tool touching the I.D. of the pipe.
10. Engage the air motor.
11. Grab and hold the feed wheel to engage the tool.
Figure 5-30. Run the machine until the desired counterbore depth is reached.
12. Once the tool begins to cut, release the feed wheel.
72
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Socket Weld Removal
13. Hold the feed wheel for approximately 1/8 turn per
revolution to gradually feed the tool into the pipe axially to the required depth of the counterbore.
14. Withdraw the tool when the counterbore depth is
reached.
15. Turn the starwheel clockwise to adjust the diameter of
the counterbore.
16. Repeat the above steps until the desired diameter of
the counterbore is reached.
17. Once the counterbore is complete, turn off the motor
and disconnect the air or power supply.
SOCKET WELD REMOVAL
As a general rule, use the radial slide if you wish to reuse
the socket, and use the axial slide if you want to save the
pipe. However, both operations can be performed with
either slide.
Radial Socket Weld Removal
1. Mount the radial socket weld slide and the radial trip
to the SDSF.
2. Fully retract the tool slide using a 3/16” hex wrench.
3. Mount the SDSF close to the socket weld so the tool
slide can be as far back as possible when beginning
the cut.
NOTE
Remove all other slides and
trip assemblies before configuring the SDSF for socket
weld removal.
4. Turn the starwheel counter-clockwise until the tip of
the tooling is about 1/16” from the weld material at its
closest point to the pipe.
5. Start the drive motor to run the machine. When the
tool starts cutting the pipe, apply water-soluble coolant (02-406-00) frequently to keep the cutting surface
lubricated.
6. When all welding material is removed, the socket and
pipe will easily separate.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
73
Small Diameter Split Frame
Axial Socket Weld Removal
NOTE
1. Mount the axial socket weld slide and the axial trip to
the SDSF.
Remove all other slides and
trip assemblies before configuring the SDSF for socket
weld removal.
Figure 5-31. The photo shows the axial socket weld
slide in position for socket weld removal.
NOTE
The axial socket weld slide
can be used on all 3000# and
6000# sockets. For heavier
sockets, check the clearance
on the axial socket weld slide
envelope drawing at the end
of Chapter 3.
74
2. Fully retract the tool slide using a 3/16” hex wrench.
3. Mount the SDSF close to the socket weld so the tool
slide can be as far back as possible when beginning
the cut.
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Socket Weld Removal
Figure 5-32. Adjust the tooling so it is close to the
weld material before beginning the cut.
4. Turn the starwheel counter-clockwise until the tip of
the tooling is about 1/16” from the weld material at its
closest point to the pipe.
5. Start the drive motor to run the machine. When the
tool starts cutting the pipe, apply water-soluble coolant (02-406-00) frequently to keep the cutting surface
lubricated.
6. When all welding material is removed, the socket and
pipe will easily separate.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
75
Small Diameter Split Frame
Figure 5-33. The socket can be reused after it is
removed from the pipe.
FOREIGN MATERIAL EXCLUSION CUTTING
Foreign material exclusion cutting (FME), also known as
blue-line cutting, is used for high-purity applications.
Mount the machine normally, and then follow these steps.
1. Mount the radial slides on the SDSF.
2. Insert parting tools into both of the radial slides. Using
parting tools in both slides prevents burrs from entering the I.D.
3. Run the machine until the cut is within 0.03” - 0.09”
(0.8 - 2.3 mm) of the pipe I.D.
4. Stop the machine and remove the radial slides.
5. Install the FME slide by aligning and tightening the
three slide mounting screws. Adjust the slide using the
starwheel so that the wheel cutter is almost touching
the pipe surface in the groove.
76
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Removing the Machine
Figure 5-34. The cutting wheel should be just above
the O.D. of the cut before the machine is turned on.
6. Operate the machine until the pipe is cut through. Turn
off the drive motor, and disconnect the power or air
supply.
REMOVING THE MACHINE
Clamp Feet Mounting
1. Remove the drive (pneumatic or electric) from the
SDSF.
2. Retract the tool slides and loosen the tool bits. If using
a parting tool, loosen the parting tool cover plate
slightly to avoid chipping the tool bit.
3. Loosen the clamp foot screws with a 1/4” hex wrench
4. Align the split points on the rotating ring and the stationary ring.
CAUTION
The SDSF will
rotate freely on the pipe
when the clamp legs or
collet are loosened. Support the machine so it
does not spin or shift on
the pipe. Failure to do so
could result in injury.
5. Loosen the frame locking screws, and pull the SDSF
apart. Use equal pressure on both halves of the rings.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
77
Small Diameter Split Frame
Collet Mounting
CAUTION
The SDSF will
rotate freely on the pipe
when the clamp legs or
collet are loosened. Support the machine so it
does not spin or shift on
the pipe. Failure to do so
could result in injury.
1. Remove the drive (pneumatic or electric) from the
SDSF.
2. Retract the tool slides and loosen the tool bits. If using
a parting tool, loosen the parting tool cover plate
slightly to avoid chipping the tool bit.
3. Remove the collet nut using the collet wrench.
Figure 5-35. Turn the collet nut clockwise to loosen it.
4. Loosen the collet nut screws with a 3/16” hex wrench,
and pull the collet nut apart.
5. Align the split points on the rotating ring and stationary ring of the SDSF.
6. Loosen the frame locking screws, and pull the SDSF
apart. Use equal pressure on both halves of the rings.
7. Remove the collet from the pipe.
78
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Remote Operation with the SF ACM
REMOTE OPERATION WITH THE SF ACM
The split frame air control module (SF ACM) provides
remote operation for E.H. Wachs split frame machines. The
ACM is fully self-contained, requiring no power source
other than compressed air. It is enclosed in a durable case
that includes a handle and wheels for easy portability.
The SF ACM works with all LCSF and SDSF pneumatic
drives:
• adapter 90-302-02 is required to operate the LCSF
• adapter 90-302-01 is required to operate the SDSF.
Air input
connector
Control
panel
Handheld
pendant
Output hose
to split frame
Figure 5-36. The photo shows the major components
of the SF ACM. The case includes wheels and a
retractable handle for easy transport.
Connectors
Input
1/2” female NPT (1/2-18 NPT per ANSI
B1.20.1). Install appropriate fitting for
your air supply.
Output
Quick disconnect to air motor fitting, provided (part no. 90-302-01 for SDSF; part
no. 90-302-02 for LCSF).
E.H. Wachs
Part No. 80-MAN-01, Rev. C
79
Small Diameter Split Frame
Control Panel Reference
Figure 5-37 illustrates and describes the features of the
ACM control panel.
Reset button (required
at startup, after emergency stop, or after loss
of input pressure)
ON/OFF lockout
(shown in unlocked
position)
ON/OFF valve
(shown in OFF
position)
Pendant enable switch
(shown in ON position)
Output pressure gauge
Emergency off switch
Pressure regulator
Figure 5-37. The photo illustrates the ACM controls.
80
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Remote Operation with the SF ACM
Locating the ACM at the Worksite
Before you connect the ACM, decide where you will locate
it for operating the split frame machine.
•
•
The ACM has a 15 ft (4.6 m) output hose, allowing you
to locate it up to 15 ft from the split frame.
The ACM remote pendant has a 6 ft (1.8 m) hose. You
must stand within this distance of the ACM while operating the split frame, so that you have ready access to
the controls and emergency stop.
Figure 5-38. Position the ACM at a convenient distance from the split frame machine.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
81
Small Diameter Split Frame
Operating the ACM
NOTE
An instruction sticker for setting up and operating the
ACM is attached to the inside
of the case lid.
Before connecting the ACM, mount the split frame machine
on the workpiece as described in the machine’s user manual.
Set up the machine so that it is ready to operate, and install
the air drive on the machine.
The air drive must be configured to be “always on” for use
with the ACM. See “Configuring the Air Drive for the
ACM” on page 90.
Before connecting the ACM, the control panel should be in
the pre-operation state, as shown in Figure 5-39.
ACM Operation Sticker (part
no. 60-1296-00).
Figure 5-39. The ACM controls should be in the preoperation state, as shown, before connecting the air
lines.
NOTE
The ACM is supplied with a
female 1/2” NPT fitting on the
input connector. Install an
appropriate coupling for your
air supply line.
82
1. Make sure the air supply is turned off at the source.
2. Attach the air supply line to the input connector of the
ACM.
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Remote Operation with the SF ACM
Figure 5-40. Connect the line from the air source to
the input connector on the ACM.
3. Remove the output hose and control pendant from the
case. Connect the output hose to the air drive connector on the split frame machine.
4. Align the air motor and route all hoses so that the
hoses do not come in contact with any moving parts.
CAUTION
Do not allow the hoses to
contact moving parts. This
could damage the hoses or
components of the split
frame.
Figure 5-41. Route the hoses so they do not touch
moving parts of the split frame.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
83
Small Diameter Split Frame
NOTE
The quick disconnect on the
ACM output hose requires a
specific fitting on the air
motor. This fitting is provided
with the ACM (90-302-01 for
SDSF; 90-302-02 for LCSF).
Figure 5-42. Connect the ACM output hose to the air
motor fitting.
5. Turn on the air supply at the source.
6. Make sure the emergency stop button on the control
panel is pulled out.
7. Push in the lock-out tab on the ON/OFF valve.
Figure 5-43. Press in the lock-out tab to enable the
ON/OFF valve.
8. Turn the ON/OFF valve counter-clockwise to the ON
position.
84
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Remote Operation with the SF ACM
Figure 5-44. Turn the ON/OFF valve counter-clockwise to the ON position (shown in OFF position).
9. Press the Reset button on the control panel.
NOTE
You do not need to press
Reset every time you restart
the machine. Reset is
required only after loss of
supply pressure or an emergency stop.
Figure 5-45. The Reset button resets the ACM after a
loss of pressure or an emergency stop.
10. Turn the Remote Enable switch to the ON position.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
85
Small Diameter Split Frame
Figure 5-46. Turn the Remote Enable switch on to
allow operation using the handheld pendant.
CAUTION
11. The handheld pendant will now operate the split frame
machine.
Keep the pendant and its
hoses away from moving
parts. Allowing hoses to contact the equipment could
damage them.
Figure 5-47. Squeeze the trigger on the handheld pendant to operate the machine.
Adjusting the Output Pressure
NOTE
Use the pressure regulator on the control panel to adjust the
output pressure to 90 psi (6.2 bar).
The maximum output pressure is 116 psi (8.0 bar).
1. Pull the knob up and turn it to adjust the pressure.
86
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Remote Operation with the SF ACM
• To increase pressure, turn it clockwise.
• To decrease pressure, turn it counter-clockwise.
DECREASE
PRESSURE
INCREASE
PRESSURE
Figure 5-48. Pull up on the pressure knob and turn it
to adjust the pressure.
2. To lock the pressure regulator so that it can’t be
adjusted, turn the knob (without pulling it) to expose
the lock tabs. You can install a lock on the tabs.
Figure 5-49. Without pulling the pressure knob, you
can turn it to expose the lock tabs. Put a lock through
the tab to prevent the pressure from being adjusted.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
87
Small Diameter Split Frame
Using the Venting Quick Disconnect
A venting quick disconnect is provided on the air line that
connects to the air drive of the split frame machine. This
disconnect offers two convenient features:
•
•
A “release position” vents line pressure before you disconnect the air line from the drive.
The connector closes when it is disconnected, preventing air flow from a loose air line.
Operate the venting quick disconnect as shown in the following figures.
1. To connect the air line, push the disconnect onto the
fitting until it clicks and locks in place.
Figure 5-50. Push the air line disconnect onto the air
drive fitting until it locks in place.
88
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Remote Operation with the SF ACM
2. To release the air line, first pull the collar back to the
release position. The disconnect will come partly off
the fitting and the line pressure is released.
NOTE
A symbol on the disconnect
shows the steps to remove it
from the fitting.
Figure 5-51. To release the disconnect, pull the collar
back. The disconnect will snap back to the release
position. (This will vent air in the air line.)
3. To fully remove the air line, press the collar forward
and pull the disconnect off the fitting.
Figure 5-52. Push the collar forward and pull the disconnect to remove it from the fitting.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
89
Small Diameter Split Frame
Configuring the Air Drive for the ACM
Air Fitting
The quick disconnect on the ACM output hose requires a
specific air nipple fitting on the air motor. This nipple is
provided with the ACM (part no. 90-302-01 for the SDSF;
part no. 90-302-02 for the LCSF). Remove the existing fitting on the air motor and install the replacement nipple.
Figure 5-53. Install the supplied nipple onto the air
motor for use with the ACM.
Air Trigger Modification
For remote operation, the air drive on the split frame must
be modified for an “always on” configuration. Two alternatives for this configuration are provided with the ACM:
•
•
A trigger strap for temporary use.
An “open throttle plate” for long-term or permanent use.
Both devices fully open the on/off valve on the air drive.
Use the air drive with these devices installed only when you
are operating the split frame with the ACM.
To use the trigger strap, wrap it around the air drive trigger,
pull it tight through the buckle, and attach the Velcro.
Use the following procedure to install the open throttle
plate.
90
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Remote Operation with the SF ACM
1. Disconnect the air supply from the air drive, and
remove it from the split frame machine. Set it on a
workbench or stable work surface.
2. With a hammer or mallet and a punch, drive out the
mounting pin holding the trigger to the air drive.
Remove the trigger.
Figure 5-54. Use a punch to drive out the pin holding
the air trigger.
3. Put the open throttle plate in place at the trigger location, and insert the pin.
Figure 5-55. Attach the open throttle plate with the
trigger pin.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
91
Small Diameter Split Frame
4. With the hammer and punch, drive in the pin until it is
flush
Figure 5-56. Drive in the pin to secure the open throttle plate.
CAUTION
5. The open throttle plate holds the air valve open on the
motor.
When the open throttle plate
is installed, do not connect
the air drive directly to an air
source. Use it only with the
ACM. Turning on the air supply with the throttle open
could cause damage or
injury.
Figure 5-57. The photo shows the correct installation
of the open throttle plate.
92
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 6, Routine Maintenance
Chapter 6
Routine Maintenance
In This Chapter
LUBRICATION
LUBRICATION
BEARING ADJUSTMENT
Slides
Clean and oil the threads on the tool block and slide block
each time you use the machine. Lubricate using way oil.
TOOL SLIDE TENSION
ADJUSTMENTS
AIR MOTOR MAINTENANCE
Lubrication point
Figure 6-1. Lubricate the tool slides in the locations
shown.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
93
Small Diameter Split Frame
Air Treatment Module
Air Filter Housing
Air Motor
Air Motor Oiler
Speed control valve
Figure 6-2. The air treatment module (80-4202-00) is
shown with the air motor above. The speed control
valve should be oriented so the speed dial is adjacent
to the air motor.
Use of an Air Treatment Module (ATM) is recommended
when operating the SDSF. If you have an ATM from an
E.H. Wachs Low Clearance Split Frame machine, you can
use it with the SDSF.
Use a suitable air motor oil when running the air motor.
94
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 6, Routine Maintenance: Lubrication
Figure 6-3. Fill the ATM with air motor oil daily.
Figure 6-4. Inspect the air filter weekly. Replace as
needed.
If you disassemble the air motor components for service,
make sure you replace the speed control valve in the correct
direction.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
95
Small Diameter Split Frame
Split Frame
Apply two drops of way oil to the felt wiper every time
before storing the SDSF. If the SDSF does not have a felt
wiper, apply two drops of oil to the bearing raceway before
storing the SDSF.
Felt oil wiper
Figure 6-5. Apply oil to the felt wiper before storing
the SDSF.
BEARING ADJUSTMENT
If there is wobble between the rotating and stationary rings,
or if the rotating ring binds or is hard to turn, the bearings
need to be adjusted. The SDSF can be returned to the factory for this, or you can perform the adjustment.
Adjust the bearings in numerical order as indicated in
Figure 6-9 (for 1” to 2-1/2” models), or in Figure 6-10 (for
3” to 6” models).
1. Remove the motor clamps and pinion gear.
2. Tighten the frame locking screws on the rotating ring
and the stationary ring.
3. Lock the SDSF pinion housing in a soft-jaw vice to
make adjustment easier.
96
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 6, Routine Maintenance: Bearing Adjustment
Figure 6-6. Use of a soft-jaw vice prevents damage to
the SDSF pinion housing.
4. Use a 7/16” socket wrench to loosen all bearing nuts
except those on the fixed bearing shafts at 5 and 7 o’
clock.
5. Using a 1/8” hex wrench, turn all bearing shafts clockwise to loosen them.
6. Turn the topmost bearing shaft counterclockwise with
a 1/8” hex wrench to firmly seat the bearing in the
raceway.
Bearing nut rotation to
tighten nut
Bearing shaft rotation to
tighten bearing
Figure 6-7. Loosen the bearing nuts and bearing
shafts as indicated.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
97
Small Diameter Split Frame
7. Securely tighten (75-95 lb-in) the topmost bearing nut
with the 7/16” hex-through torque wrench (90-80084).
Figure 6-8. Tightening the topmost bearing centers
all of the bearings.
8. Refer to the bearing adjustment order in Figure 6-9 for
1” to 2-1/2” machines, or Figure 6-10 for 3” to 6”
machines. Using the 1/8” hex wrench, turn the bearing
shaft lightly counter-clockwise until the bearing just
touches. Hold the shaft and tighten the bearing nut
using the 7/16” torque wrench.
9. Adjust the bottom-most bearings last. There is one
bottom bearing on 1” to 2-1/2” machines, and two bottom bearings on 3” to 6” machines. (The bottom bearings are between the fixed bearings.)
10. Look through the slide mounting holes while turning
the rotating ring to confirm all bearings turn. If more
than one bearing isn’t turning, loosen all bearings and
start over. If all bearings are properly turning, the
rotating ring will turn with a slight drag and will not
spin freely.
98
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 6, Routine Maintenance: Bearing Adjustment
Pinholes
Fixed bearing shafts
Figure 6-9. Adjust the bearings in numerical order as
indicated.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
99
Small Diameter Split Frame
Fixed bearing shafts
Pinion housing
14
13
7
8
12
11
10
9
5
6
3
4
2
1
Figure 6-10. Adjust the bearings in numerical order
as indicated.
TOOL SLIDE TENSION ADJUSTMENTS
The tool slide starwheel tension can be increased or
decreased by adding or removing dovetail shims.
1. Remove the tool slide from the SDSF by loosening the
tool slide mounting screws.
2. Loosen the three dovetail screws.
100
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 6, Routine Maintenance: Air Motor Maintenance
Dovetail screws
Figure 6-11. Loosen the dovetail screws shown to
adjust the slide tension.
3. Carefully remove the dovetail from the tool slide.
4.
Add one shim to decrease the tool slide tension, or
remove one shim to increase the tool slide tension.
NOTE
Each shim is
0.002” thick.
5. Store all unused shims for reuse later.
6. Replace the dovetail, making sure the holes in the
shims are aligned with the dovetail screws.
7. Test the tool slide tension. The tool slide starwheel
should turn with 5-15 inch pounds of force.
8. Repeat steps 2-6 if necessary.
AIR MOTOR MAINTENANCE
Gear Train Disassembly
1. Unscrew and remove the gear case.
2. Remove the motor unit from the front of the handle.
3. Unscrew (left hand threads) the spindle bearing
retainer.
4. Press the spindle out of the spindle bearings.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
101
Small Diameter Split Frame
Motor Disassembly
1. Secure the cylinder in a vise with the rear bearing
plate facing upward.
CAUTION
Take care not to
damage the rotor during
motor disassembly.
2. Using a 1/8” diameter punch, tap the rotor out of the
rear bearing plate.
3. Remove cylinder and rotor blades.
4. Rest the front bearing plate on the jaws of the vise
with the rotor hanging loosely between the jaws, and
tap the rotor out of the front bearing.
DL Backhead Disassembly
1. Unscrew and remove the air inlet bushing.
2. Remove the throttle valve and related components for
inspection.
General Reassembly
1. Wash all parts in solvent and inspect them for damage
and wear. Particular attention should be paid to all
bearings, gears, gear pins, and rotor blades. Damage to
these parts can cause damage to more expensive parts.
2. Particular inspection should also be given to the governor assembly. Replace any parts of the governor
assembly that show wear or damage.
3. Rotor blades must measure a minimum 3/16” at both
ends. If not, replace the rotor blades.
4. Inspect and replace any O rings or seals that show
signs of wear or deterioration.
5. Apply No. 2 Moly grease to all gears, gear pins, and
open bearings.
6. Reassemble all of the various sub-assemblies in the
reverse order of disassembly.
Gear Case Assembly
The front spindle bearing must be installed on the spindle
with its shielded side out.
102
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 6, Routine Maintenance: Electric Motor Maintenance
Motor Reassembly
1. As the motor unit is assembled, the rear face of the
rotor should be set to within 0.0015” of the face of the
rear bearing plate.
2. After final assembly, the cylinder should be held
firmly, but not tightly, between the two bearing plates.
3. The rotor should turn freely and not rub either of the
bearing plates.
136DL Series Motor Installation
When installing the motor unit into the backhead, the rear
bearing plate pin must engage the 1/8” hole in the rear
motor bore. The front of the backhead is marked to aid this
operation.
Complete Reassembly
1. The rotor pinion (if required) should be installed on
the rotor shaft with the undercut side toward the rotor.
2. Install (left hand threads) the spindle bearing retainer
on the front of the gear case. Put a few drops of 10W
machine oil into the tool’s air inlet to ensure immediate lubrication of all motor parts when the tool is
tested.
ELECTRIC MOTOR MAINTENANCE
The electric motor (80-4004-00) comes with a circuit
breaker (80-0091-00) to prevent overload damage. If the
electric motor stops working during operation, reset the circuit breaker. Refer to the drawing in Chapter 8 for details.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
103
Small Diameter Split Frame
SERVICING THE ACM
CAUTION
Remove the control panel
from the case before tipping
it. The panel is not fastened
in the case and can fall out if
you turn the case over.
After each use, check for water in the bottom of the ACM
case. The ACM includes a draining filter that can release a
small amount of water during operation. Lift the control
panel out of the case and pour out any water that has accumulated. Wipe the case dry and replace the control panel.
NOTE
Remove the output hose and
control pendant before lifting
the control panel out of the
case.
Figure 6-12. Lift the control panel out of the case for
service or to drain out accumulated water.
NOTE
The 5 micron filter element is
available from E.H. Wachs or
from the manufacturer (Rexroth, part no. 1829207068).
104
The filter should be checked periodically. The filter is
accessible when you have the control panel out of the case.
To remove the filter, pull the locking tab down and turn the
filter to the left.
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 6, Routine Maintenance: Servicing the ACM
Figure 6-13. To remove the filter, pull the locking tab
down with your thumb and turn the filter to the left.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
105
Small Diameter Split Frame
106
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 7, Service and Repair
Chapter 7
Service and Repair
SLIDE FEED NUT REPLACEMENT
The slide feed nut may need to be replaced if the tool slide
crashes. Always replace the slide feed nut if it breaks or its
threads are stripped.
In This Chapter
SLIDE FEED NUT
REPLACEMENT
SLIDE FEED SCREW
REPLACEMENT
1. Remove the slide from the SDSF.
2. Loosen the dovetail screws. Do not remove the dovetail.
3. Remove the male tool slide by unscrewing the starwheel completely. If the slide does not come off,
loosen the dovetail screws further.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
107
Small Diameter Split Frame
Figure 7-1. Use a hex wrench to turn the starwheel
clockwise to remove the male tool slide.
4. Remove the feed nut (80-0030-00).
Figure 7-2. Replace the old feed nut in the slide.
5. Insert the new feed nut so it is centered.
6. Hold the feed nut in the slide and turn the starwheel
counterclockwise to engage the feed screw and
remove any play.
7. Tighten the dovetail screws.
108
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 7, Service and Repair: Slide Feed Screw Replacement
SLIDE FEED SCREW REPLACEMENT
If the slide stops feeding correctly when the star wheel
trips, the slide feed screw may need to be replaced. If the
threads are stripped, replace the slide feed screw.
1. Remove the slide from the SDSF.
2. Loosen the dovetail screws. Do not remove the dovetail.
3. Remove the male tool slide.
4. Remove the bushing screws on the bottom of the slide.
Figure 7-3. The bushing screws hold the feed bushing
in place.
5. Separate the two halves of the feed bushing by tapping
on the bushing pins with a mallet.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
109
Small Diameter Split Frame
Figure 7-4. Use a mallet to separate the feed bushing
as shown.
6. Replace the starwheel feed screw.
7. If necessary, use a mallet to affix the feed bushing
around the new feed screw.
Figure 7-5. Align the bushing pins by hand, and then
tap the bushing halves flush with a mallet.
8. Align and tighten the bushing screws.
9. Replace the male tool slide, and engage the feed nut
by turning the starwheel counterclockwise.
10. Tighten the dovetail screws.
110
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 8, Parts Lists and Drawings
Chapter 8
Parts Lists and
Drawings
The following pages illustrate the components for the Small
Diameter Split Frame. Use the parts list on each drawing to
order replacement parts.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
111
Small Diameter Split Frame
SDSF Base Machine (80-4000-XX)
ITEM
PART NUMBER
QTY.
1
See Table
1
CASE (NOT SHOWN)
2
See Table
1
SDSF, FOAM INSERT (NOT SHOWN)
3
80-0080-00
1
PLATE, IDENTIFICATION
4
5
80-0081-00
80-0082-00
1
1
LABEL, MOVING PARTS
LABEL, AIR MOTOR CLAMP
6
7
See Table
See Table
1
1
LP FRAME ASSEMBLY
PINION HOUSING ASSEMBLY
8
80-5500-00
1
SDSF SPARE FASTENER KIT (NOT SHOWN)
9
80-LIT-01
1
TOOLING CHART, SDSF (NOT SHOWN)
10
80-MAN-01
1
SDSF, MANUAL (NOT SHOWN)
11
90-049-06
90-149-25
4
2
SCREW, #2-13/16" U-DRIVE
PIN, 3/16 x 2-1/2 SS QUICK (SEE NOTE)
11
3
4
12
13
DESCRIPTION
90-800-06
1
WRENCH, 5/64 - 1/4 HEX SET (NOT SHOWN)
14
90-800-57
1
WRENCH, 1/4 HEX X 6" T-HANDLE (NOT SHOWN)
15
90-800-62
1
WRENCH, 3/16 HEX X 9" T-HANDLE (NOT SHOWN)
16
80-0106-00
1
LABEL, CASE SDSF (NOT SHOWN)
5
NOTE: Pins (Item12) not included
with 80-4000-10 or 80-4000-15.
7
12 SEE NOTE
6
112
SDSF Model (Size)
LP Frame
Assembly
Pinion Housing
Assembly
80-4000-10 (1”)
80-3000-10
80-3002-10
80-4000-15 (1-1/2”)
80-3000-15
80-3002-15
80-4000-20 (2”)
80-3000-20
80-3002-20
80-4000-25 (2-1/2”)
80-3000-25
80-3002-25
80-4000-30 (3”)
80-3000-30
80-3002-30
80-4000-35 (3-1/2”)
80-3000-35
80-3002-35
80-4000-40 (4”)
80-3000-40
80-3002-40
80-4000-50 (5”)
80-3000-50
80-3002-50
80-4000-60 (6”)
80-3000-60
80-3002-60
Case
Case Foam
16-082-00
80-0071-00
56-150-00
80-0105-00
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 8, Parts Lists and Drawings:
SDSF Frame Assembly (80-3000-XX)
ITEM
PART NUMBER
QTY.
DESCRIPTION
1
2
3
4
5
6
7
8
9
10
11
12
13
43-006-00
See Table
See Table
80-0003-00
80-0004-00
80-0076-00
80-0077-00
80-0102-00
90-001-02
90-044-92
90-045-01
90-055-02
90-055-54
A
1
1
B
2
2
2
1
2
4
A
A
A
BEARING, GUIDE WHEEL
STATIONARY FRAME
ROTATING FRAME ASSY.
SHAFT, ADJUSTABLE BEARING
SHAFT, FIXED BEARING
WIPER BRACKET
WIPER, FELT
LABEL, CLAMP FOOT SCREWS
SHCS, 6-32 X 1/4
SSS, 10-32 x 1/4 DOG PT NYLOCK
NUT, 10-32 JAM
NUT, 1/4-28 HEX
WASHER, 1/4 AN
7
SEE NOTE 1
6
2
12
13
9
SEE NOTES 1 & 2
8
A,B: See table for quantities.
5
NOTES:
1. Components not used in 80-3000-10.
2. Components not used in 80-3000-15.
4
1
3
11
10
SEE NOTES 1 & 2
5
E.H. Wachs
SDSF Model (Size)
Stationary Frame
Assembly
Rotating Frame
Assembly
Bearing
Component
Quantity (A)
Adjustable Bearing
Shaft Quantity (B)
80-4000-10 (1”)
80-0001-10
80-0002-10
10
8
80-4000-15 (1-1/2”)
80-0001-15
80-0002-15
10
8
80-4000-20 (2”)
80-0001-20
80-0002-20
10
8
80-4000-25 (2-1/2”)
80-0001-25
80-0002-25
10
8
80-4000-30 (3”)
80-0001-30
80-0002-30
16
14
80-4000-35 (3-1/2”)
80-0001-35
80-0002-35
16
14
80-4000-40 (4”)
80-0001-40
80-0002-40
16
14
80-4000-50 (5”)
80-0001-50
80-0002-50
16
14
80-4000-60 (6”)
80-0001-60
80-0002-60
16
14
Part No. 80-MAN-01, Rev. C
113
Small Diameter Split Frame
Pinion Assembly (80-3002-XX)
ITEM
PART NUMBER
QTY.
DESCRIPTION
1
2
52-145-00
60-125-00
1
2
RING RETAINING
BEARING, PINION-REAR
3
4
80-0008-00
See Table
4
1
SHCS, 1/4-20 x 7/8 CAPTIVATED
PINION HOUSING
5
80-0022-00
1
GEAR, PINION
6
7
80-0023-00
80-0099-00
2
2
8
90-044-93
1
9
90-046-03
2
CLAMP, MOTOR
SHCS, 5/16-18 x 2-1/4 CAPTIVATED
SSS, 10-32 x 3/8 NYLON SOFT POINT
PIN, 3/16 x 3/8 DOWEL
6
3
2
7
1
5
4
9
114
8
SDSF Model (Size)
Pinion Assembly
Part No.
Pinion Housing
80-4000-10 (1”)
80-3002-10
80-0021-10
80-4000-15 (1-1/2”)
80-3002-15
80-0021-20
80-4000-20 (2”)
80-3002-20
80-0021-20
80-4000-25 (2-1/2”)
80-3002-25
80-0021-30
80-4000-30 (3”)
80-3002-30
80-0021-30
80-4000-35 (3-1/2”)
80-3002-35
80-0021-40
80-4000-40 (4”)
80-3002-40
80-0021-40
80-4000-50 (5”)
80-3002-50
80-0021-60
80-4000-60 (6”)
80-3002-60
80-0021-60
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 8, Parts Lists and Drawings:
Clamp Foot Assembly (80-4001-00)
ITEM
PART NUMBER
QTY.
DESCRIPTION
1
2
3
4
80-0006-00
80-0068-00
90-024-02
90-023-12
1
1
1
1
SCREW, CLAMP FOOT
CLAMP FOOT
SSS, 8-32 x 1/4 CUP PT
FHCS, 8-32 x 1-1/4
3
1
2
4
E.H. Wachs
Part No. 80-MAN-01, Rev. C
115
Small Diameter Split Frame
Front Drive Pinion Assembly (80-4003-XX)
ITEM
PART NUMBER
QTY.
DESCRIPTION
1
2
3
4
5
6
7
8
9
10
11
12
13
14
52-145-00
60-125-00
80-0008-00
80-0022-00
80-0023-00
80-0050-00
See Table
See Table
80-0081-00
80-0082-00
80-0100-00
90-044-93
90-046-03
90-050-05
2
4
6
2
2
1
1
1
1
1
2
2
2
4
RING RETAINING
BEARING, PINION-REAR
SHCS, 1/4-20 x 7/8 CAPTIVATED
GEAR, PINION
CLAMP, MOTOR
CAP, BEARING
BRACKET, FRONT DRIVE TRIP
HOUSING, FRONT DRIVE PINION
LABEL, MOVING PARTS
LABEL, AIR MOTOR CLAMP
SHCS, 5/16-18 x 3-1/2 CAPTIVATED
SSS, 10-32 x 3/8 NYLON SOFT POINT
PIN, 3/16 x 3/8 DOWEL
SHCS, 1/4-20 X 1/2
14
6
11
2
10
8
4
9
1
4
2
1
7
5
12
13
3
3
116
SDSF Model (Size)
Front Drive Pinion
Assembly Part No.
Front Drive Trip
Bracket
Front Drive Pinion
Housing
80-4000-10 (1”)
80-4003-10
80-0051-10
80-0067-10
80-4000-15 (1-1/2”)
80-4003-15
80-0051-15
80-0067-20
80-4000-20 (2”)
80-4003-20
80-0051-20
80-0067-20
80-4000-25 (2-1/2”)
80-4003-25
80-0051-25
80-0067-30
80-4000-30 (3”)
80-4003-30
80-0051-30
80-0067-30
80-4000-35 (3-1/2”)
80-4003-35
80-0051-35
80-0067-40
80-4000-40 (4”)
80-4003-40
80-0051-40
80-0067-40
80-4000-50 (5”)
80-4003-50
80-0051-50
80-0067-60
80-4000-60 (6”)
80-4003-60
80-0051-60
80-0067-60
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 8, Parts Lists and Drawings:
Parting Slide (80-4101-XX)
SDSF Model (Size) Slide Part No.
80-4000-10 (1”)
Female Radial
Slide
Male Parting
Slide
Gib
80-4101-10
80-0025-10 80-0032-20 80-0026-10
80-4101-20
80-0025-20 80-0032-20 80-0026-20
80-4101-40
80-0025-40 80-0032-40 80-0026-40
80-4101-60
80-0025-60 80-0032-60 80-0026-60
80-4000-15 (1-1/2”)
80-4000-20 (2”)
80-4000-25 (2-1/2”)
80-4000-30 (3”)
80-4000-35 (3-1/2”)
80-4000-40 (4”)
80-4000-50 (5”)
80-4000-60 (6”)
1
6
8
5
11
9
7
3
1
4
2
12
E.H. Wachs
ITEM
PART NUMBER
QTY.
1
2
3
4
5
6
7
8
9
10
11
12
80-0008-00
See Table
See Table
80-0027-00
80-0028-00
80-0029-00
80-0030-00
80-0031-00
See Table
90-039-06
90-040-05
90-046-03
6
1
1
3
1
1
1
1
1
2
3
2
DESCRIPTION
SHCS, 1/4-20 x 7/8 CAPTIVATED
SLIDE, FEMALE RADIAL
GIB
SHIM
FEED BUSHING
STAR WHEEL
NUT, FEED
PLATE, TOOL COVER
SLIDE, MALE PARTING
LHCS, 10-24 x 5/8
SHCS, 10-24 X 1/2
PIN, 3/16 x 3/8 DOWEL
Part No. 80-MAN-01, Rev. C
10
117
Small Diameter Split Frame
Beveling Slide (80-4102-XX)
SDSF Model (Size) Slide Part No.
80-4000-10 (1”)
Female Radial Male Beveling
Slide
Slide
Gib
80-4102-10
80-0025-10 80-0033-20 80-0026-10
80-4102-20
80-0025-20 80-0033-20 80-0026-20
80-4102-40
80-0025-40 80-0033-40 80-0026-40
80-4102-60
80-0025-60 80-0033-60 80-0026-60
80-4000-15 (1-1/2”)
80-4000-20 (2”)
80-4000-25 (2-1/2”)
80-4000-30 (3”)
80-4000-35 (3-1/2”)
80-4000-40 (4”)
80-4000-50 (5”)
80-4000-60 (6”)
1
6
8
5
13
9
11
1
3
4
7
2
118
ITEM
PART NUMBER
QTY.
1
2
3
4
5
6
7
8
9
10
11
12
13
80-0008-00
See Table
See Table
80-0027-00
80-0028-00
80-0029-00
80-0030-00
80-0031-00
See Table
90-039-06
90-040-05
90-046-03
90-050-07
6
1
1
3
1
1
1
1
1
2
3
2
1
12
DESCRIPTION
SHCS, 1/4-20 x 7/8 CAPTIVATED
SLIDE, FEMALE RADIAL
GIB
SHIM
FEED BUSHING
STAR WHEEL
NUT, FEED
PLATE, TOOL COVER
SLIDE, MALE BEVELING
LHCS, 10-24 x 5/8
SHCS, 10-24 X 1/2
PIN, 3/16 x 3/8 DOWEL
SHCS, 1/4-20 X 3/4
Part No. 80-MAN-01, Rev. C
10
E.H. Wachs
Chapter 8, Parts Lists and Drawings:
Axial Slide (80-4104-XX)
5
4
1
11
10
6
3
7
9
8
2
ITEM
PART NUMBER
QTY.
DESCRIPTION
1
2
3
4
5
6
7
8
18-048-00
80-0008-00
SEE TABLE
80-0039-00
80-0040-00
80-0041-00
80-0042-00
90-044-00
1
2
1
1
1
1
1
1
BEARING, FLANGE
SHCS, 1/4-20 x 7/8 CAPTIVATED
SLIDE, FEMALE AXIAL
SLIDE, MALE AXIAL
SCREW, FEED
SHAFT, AXIAL
BUSHING, ADJUSTABLE
SSS, 10-24 x 3/16
9
90-044-03
1
SSS, 10-24 X 3/8
10
11
90-046-03
90-074-52
2
1
PIN, 3/16 x 3/8 DOWEL
SSS, 3/8-24 x 1/4
SDSF Model (Size)
Slide Part No.
Female Axial Slide
80-4000-10 (1”)
80-4104-10
80-0038-10
80-4104-20
80-0038-20
80-4104-40
80-0038-40
80-4104-60
80-0038-60
80-4000-15 (1-1/2”)
80-4000-20 (2”)
80-4000-25 (2-1/2”)
80-4000-30 (3”)
80-4000-35 (3-1/2”)
80-4000-40 (4”)
80-4000-50 (5”)
80-4000-60 (6”)
E.H. Wachs
Part No. 80-MAN-01, Rev. C
119
Small Diameter Split Frame
FME Slide (80-4106-XX)
ITEM PART NUMBER QTY.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
15
10
9
80-0008-00
See Table
See Table
80-0027-00
80-0028-00
80-0029-00
80-0030-00
See Table
80-0053-00
80-0054-00
90-039-06
90-040-05
90-044-92
90-046-03
90-500-05
3
1
1
3
1
1
1
1
1
1
2
3
1
2
1
DESCRIPTION
SHCS, 1/4-20 x 7/8 CAPTIVATED
SLIDE, FEMALE RADIAL
GIB
SHIM
FEED BUSHING
STAR WHEEL
NUT, FEED
SLIDE, MALE FME
WHEEL, CUTTING
PIN, CUTTING WHEEL
LHCS, 10-24 x 5/8
SHCS, 10-24 X 1/2
SSS, 10-32 x 1/4 DOG PT NYLOCK
PIN, 3/16 x 3/8 DOWEL
1/4-28 GREASE ZERK
6
5
8
13
12
1
7
3
4
2
14
SDSF Model (Size) Slide Part No.
11
80-4000-10 (1”)
Female Radial
Slide
Gib
80-4106-10
80-0025-10
80-4106-20
80-0025-20
80-4106-40
80-0025-40 80-0052-40 80-0026-40
80-4106-60
80-0025-60 80-0052-60 80-0026-60
80-4000-15 (1-1/2”)
80-4000-20 (2”)
Male FME
Slide
80-0026-10
80-0052-20
80-0026-20
80-4000-25 (2-1/2”)
80-4000-30 (3”)
80-4000-35 (3-1/2”)
80-4000-40 (4”)
80-4000-50 (5”)
80-4000-60 (6”)
120
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 8, Parts Lists and Drawings:
Radial Socket Weld Removal Slide (80-4100-XX)
ITEM
1
PART NUMBER
QTY.
DESCRIPTION
1
66-086-00
2
SHCS, 1/4-20 X 5/8 CAPTIVATED
2
80-0008-00
3
SHCS, 1/4-20 x 7/8 CAPTIVATED
3
See Table
1
SLIDE, FEMALE RADIAL
4
See Table
1
GIB
5
80-0027-00
3
SHIM
6
80-0028-00
1
FEED BUSHING
7
80-0029-00
1
STAR WHEEL
8
80-0030-00
1
NUT, FEED
9
80-0072-20
1
SLIDE, MALE SOCKET WELD
10
80-0073-00
1
PLATE, SOCKET WELD COVER
11
90-039-06
2
LHCS, 10-24 x 5/8
12
90-040-05
3
SHCS, 10-24 X 1/2
13
90-046-03
2
PIN, 3/16 x 3/8 DOWEL
7
10
6
9
12
8
4
2
3
5
13
11
SDSF Model (Size)
Slide Part No.
Female Radial
Slide
Gib
80-4000-10 (1”)
80-4100-10
80-0025-10
80-0026-10
80-4100-20
80-0025-20
80-0026-20
80-4000-15 (1-1/2”)
80-4000-20 (2”)
80-4000-25 (2-1/2”)
E.H. Wachs
Part No. 80-MAN-01, Rev. C
121
Small Diameter Split Frame
Outside Bevel Tool Cover Plate Ass’y (80-4108-00)
80-4108-00
ITEM
PART NUMBER
QTY.
DESCRIPTION
1
2
80-0098-00
80-0008-00
1
3
PLATE, TOOL COVER
SHCS, 1/4-20 x 7/8 CAPTIVATED
2
1
122
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 8, Parts Lists and Drawings:
Counterbore Slide (80-4107-00)
ITEM
PART NUMBER
QTY.
DESCRIPTION
1
2
3
4
5
6
7
8
9
10
11
12
13
80-0008-00
80-0055-00
80-0060-00
80-0061-00
80-0062-00
80-0063-00
80-0064-00
80-0065-00
90-001-02
90-020-05
90-020-07
90-029-06
90-044-51
3
1
1
1
1
1
1
1
4
2
3
3
1
SHCS, 1/4-20 x 7/8 CAPTIVATED
WLDMNT, COUNTERBORE SLIDE
SLIDE, MALE COUNTERBORE
PLATE, THRUST
PLATE, BACKING
SCREW, FEED
GIB, COUNTERBORE
KNOB
SHCS, 6-32 X 1/4
SHCS, 8-32 x 1/2
SHCS, 8-32 x 3/4
NUT, 8/32 HEX
SSS, 10-32 x 3/16
80-4107-00
10
4
5
7
3
8
12
9
11
13
6
2
1
E.H. Wachs
Part No. 80-MAN-01, Rev. C
123
Small Diameter Split Frame
Radial Trip (80-4103-00)
ITEM
PART NUMBER
QTY.
1
2
80-0008-00
80-0034-00
2
1
SHCS, 1/4-20 x 7/8 CAPTIVATED
HOUSING, RADIAL TRIP
3
80-0035-00
1
4
5
80-0036-00
80-0037-00
1
TRIP, RADIAL
SPOOL
6
7
8
90-026-56
90-040-07
1
1
90-055-55
9
90-057-52
1
1
10
90-059-07
1
PLUNGER, 1/4-20 x 1/2 LT-SPRNG SS BALL
11
90-401-05
1
LABEL, 3/4" DIA EYE PROTECTION
DESCRIPTION
LEVER, RADIAL TRIP
PIN, 1/8 x 5/8 ROLL
SHCS, 10-24 X 3/4
WASHER, 1/4 WAVE
1
SHSB, 1/4 X 1/4
80-4103-00
7
4
3
6
10
2
5
1
11
1
8
9
124
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 8, Parts Lists and Drawings:
Axial Trip (80-4105-00)
ITEM
PART NUMBER
QTY.
DESCRIPTION
1
2
3
80-0008-00
80-0044-00
80-0045-00
2
1
1
SHCS, 1/4-20 x 7/8 CAPTIVATED
4
80-0046-00
1
5
6
7
80-0047-00
80-0048-00
80-0049-00
1
1
1
TRIP, AXIAL
PLATE, CAM
8
9
80-0079-00
90-043-05
6
10
90-046-06
1
DOWEL PIN 3/16 X 5/8
11
90-401-05
1
LABEL, 3/4" DIA EYE PROTECTION
HOUSING, AXIAL TRIP
LEVER, AXIAL TRIP
ROD, CAM
SPRING, .325 OD x .058 DIA x 1.5 Lg
1
COVER, AXIAL TRIP
FHCS, 10-24 X 1/2
80-4105-00
6
3
9
10
5
1
2
8
11
4
9
E.H. Wachs
Part No. 80-MAN-01, Rev. C
7
125
Small Diameter Split Frame
Pneumatic Drive (80-4004-00)
ITEM
PART NUMBER
QTY.
DESCRIPTION
1
16-060-00
1
VALVE, SPEED CONTROL
2
3
80-0024-00
80-0069-00
1
1
FLANGE, AIR MOTOR
AIR MOTOR
4
5
6
7
8
80-0075-00
80-0101-00
90-058-58
90-401-00
90-401-02
1
1
1
1
1
DRIVE, SQUARE
LUBRICATOR, IN-LINE 1/4"
NIPPLE, 1/4 HEX H.P.
LABEL, EAR PROTECTION
LABEL, PRESSURE-AIR
8
7
3
1
5
6
2
4
126
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 8, Parts Lists and Drawings:
110 V Electric Drive (80-4005-01)
SPECIFICATIONS:
1.
VOLTS: 120
2.
AMPS: 12
3.
POWER: 1530W
4.
HERTZ: 50-60
SPEED RPM
5.
1
80
2
115
3
150
4
190
5
225
6
240
6.
WEIGHT: 10.2 LB. [4.6 kg]
INCLUDES 3/16" STUBBY
ALLEN KEY (NOT SHOWN)
220 V Electric Drive (80-4006-01)
SPECIFICATIONS:
1.
VOLTS: 230
2.
AMPS: 6
3.
POWER: 1530W
4.
HERTZ: 50-60
SPEED RPM
5.
1
80
2
115
3
150
4
190
5
225
6
240
6.
WEIGHT: 10.2 LB. [4.6 kg]
CEE 7/17 PLUG
E.H. Wachs
INCLUDES 3/16" STUBBY
ALLEN KEY (NOT SHOWN)
Part No. 80-MAN-01, Rev. C
127
Small Diameter Split Frame
110 V Electric Drive (80-4005-00, OBSOLETE)
110 V ELECTRIC DRIVE
80-4005-00
4.7
4.2
4.6
4.4
4.8
ITEM
PART NUMBER
QTY.
DESCRIPTION
1
11-103-00
1
GEARBOX, PLANETARY OUTPUT
2
76-175-00
1
RETAINING RING, 43/64
3
80-0023-00
2
CLAMP, MOTOR
4
80-0084-01
1
MOTOR, 110V CIRCUIT BREAKER ASSY.
4.1
80-0084-00
1
MOTOR, 110V
4.2
11-004-00
2
GRIP, CORD
4.3
80-0091-00
1
CIRCUIT BREAKER, 10A
4.4
80-0093-00
1
ENCLOSURE, BREAKER
4.5
90-002-04
4
PHMS, 4-40 x 7/16
4.6
90-002-02
2
BHCS, 6-32 x 1/4
4.7
90-501-49
2
TERMINAL, 16-14 AWG 1/4 FLAG INSULATED
4.8
90-501-50
1
TERMINAL, 16-14 AWG 1/4 SPADE MALE INSULATED
4.9
90-501-51
1
TERMINAL, 16-14 AWG 1/4 SPADE FEMALE INSULATED
5
80-0085-00
1
HOUSING, PLANETARY DRIVE
6
80-0086-00
1
COLLAR, CLAMP
7
80-0087-00
1
ADAPTER, INPUT
8
80-0088-00
1
SHAFT, OUTPUT
9
80-0089-00
1
BEARING
10
80-0090-00
1
RING, SNAP
11
80-0094-00
4
HHCS, 1/4 x 7/8 CAPTIVATED
12
90-020-20
2
SHCS #8-32 x 2
13
90-060-10
1
SHCS, 5/16-18 X 1.0
14
90-401-00
1
LABEL, EAR PROTECTION
15
90-800-38
1
WRENCH, 7/16” COMBINATION
14
4.3
4.1
4.9
4.5
1
10
12
8
7
9
6
2
11
3
5
128
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 8, Parts Lists and Drawings:
Split Frame Air Control Module (60-420-00)
ITEM
PART NUMBER
QTY
1
2
60-373-00
60-375-00
1
1
DESCRIPTION
HAND PENDANT ASSEMBLY, SF REMOTE CONTROL
AIR CONTROL MODULE
1
2
E.H. Wachs
Part No. 80-MAN-01, Rev. C
129
Small Diameter Split Frame
Air Control Module Subassembly (60-375-00)
Page 1 of 2
ITEM
PART NUMBER
QTY
DESCRIPTION
ITEM
PART NUMBER
QTY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
60-1283-00
60-1284-00
60-1285-00
60-1286-00
60-1289-00
60-1290-00
60-1291-00
60-1292-00
60-1293-00
60-1294-00
60-1295-00
60-1296-00
60-1297-00
60-1298-00
60-1299-00
60-1300-01
60-1300-10
60-1301-01
60-1301-02
60-1301-03
60-1301-11
60-1301-12
60-1301-13
60-1302-00
60-1303-00
60-1304-00
60-1307-00
1
1
1
2
1
1
2
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
2
1
1
FILTER, PRESSURE REGULATOR
VALVE, 3/2-SHUT OFF
3/2 DIR DUMP VALVE - PNEUM OPERATED
AS3 BLOCK ASSEMBLY
CASE PANEL
CASE SEPERATOR PLATE
AS3 BRACKET
CASE, 1440
LABEL, E-STOP BACKGROUND
LABEL, RESET-ON/OFF
LABEL, PRESSURE-AIR
LABEL, ACM OPERATION
NO AIR SPOOL VALVE
NC AIR SPOOL VALVE
MANIFOLD, AIR
MODULAR 3 WAY AIR VALVE
MODULAR 3 WAY MEMORY AIR VALVE
22 mm MUSROOM BUTTON, PUSH/TURN
SWITCH, TWIST 90-DEG.
BUTTON, PUSH
ADAPTER, PB-22-K
ADAPTER, PB-22-T
ADAPTER, PB-22-P
GAUGE, BACK MOUNT W/U-CLAMP
3/8 BANTAM MUFFLER
GROMMET, 1.5" PANEL
NUT, AS3 PANEL
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
60-1308-00
60-1309-00
60-1310-01
60-1310-02
60-1311-00
90-002-10
90-010-01
90-038-02
90-038-03
90-038-04
90-042-12
90-045-03
90-045-51
90-045-52
90-052-08
90-055-01
90-055-52
90-055-53
90-058-10
90-098-15
90-098-56
90-200-05
90-220-01
90-302-04
90-501-62
90-902-01
1
1
1
1
1
4
1
4
3
1
2
2
2
2
7
7
7
7
2
1
1
1
2
1
4
5-FT.
DESCRIPTION
LABEL, ACM CASE (NOT SHOWN)
QUICK EXHAUST VALVE
1/2" HOSE ASSEMBLY
1/2" HOSE ASSEMBLY
STRAP, 9" VELCRO CINCH (NOT SHOWN)
PHTF, M3 X 10 MM
BAG, 3 x 5 COTTON DRAWSTRING
ADAPTER, 1/8 NPTM X 1/4 PTC BRASS
ELBOW, 1/8 NPTF x 1/4 PTC 90 BRASS
ADAPTER, 1/8" FPT x 1/4" PTC
BHCS, 10-24 X 1-1/8
NUT, 10-24 HEX
WASHER, #10 FLAT
WASHER, #10 SPLIT RING
BHCS 1/4-20 X .875 LG
NUT, 1/4-20 HEX
WASHER, 1/4 SPLIT RING
WASHER, 1/4 FLAT
ADAPTER, 1/4" MPT X 1/4" PTC 90 ELBOW
ADAPTER, 08MP - 08FP STRAIGHT
STREET ELBOW, 1/2 X 1/2
SWIVEL, 1/2"
BULKHEAD, 1/4" PTC
QD AIR COUPLING, 1/2" X 1/2" MPT
SPACER
HOSE, 1/4" OD X 1/8" ID POLYURETHANE
12
31
9
51
30
26
10
11
5
8
130
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 8, Parts Lists and Drawings:
Air Control Module Subassembly (60-375-00)
Page 2 of 2
VIEWS SHOWN WITHOUT ITEMS CALLED OUT ON SHEET-1
36
36
35
35
35
14
36
13
33
21
23
2
18
14
38
41
40
29
27
22
15
1
17
39
50
16
43
44
45
52
36
36
7
19
20
18
50
50
6
36
42
?
49
48
2
1
53
24
29
4
34
3
4
2
3
37
25
46
37
24
25
53
2
46
7
43
44
45
52
42
36
E.H. Wachs
Part No. 80-MAN-01, Rev. C
131
Small Diameter Split Frame
Air Control Module Schematic (60-420-00)
132
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 9, Accessories and Spare Parts
Chapter 9
Accessories and
Spare Parts
In This Chapter
ACCESSORIES
ACCESSORIES
TOOLING
OIL
Table 1: Accessories
Name
Part Number
Pneumatic drive
80-4004-00
Electric drive
80-4005-00
Front drive pinion housing
80-4003-xx
Axial feed tool slide set
80-5102-xx
Radial feed tool slide set
80-5101-xx
Radial socket weld slide
80-4100-xx
Counterbore attachment
80-4107-00
FME tool slide
80-4106-xx
Outside bevel tool cover ass’y
80-4108-00
Aluminum collet sets
80-5201-xx
Clamp feet set
80-5001-00
Bench mount
80-4201-xx
7/16” Hex-through torque wrench
90-800-84
LCSF air treatment module
05-082-00
Air treatment module hose
80-4202-00
PIPE COLLET SETS
SPARE PARTS
The part numbers listed are common to all SDSF machines.
Refer to the drawings in Chapter 8 to determine which
accessories are used with your SDSF model.
E.H. Wachs
Part No. 80-MAN-01, Rev. C
133
Small Diameter Split Frame
Table 2: Tooling
Photo
134
Description
Part Number
Parting tool,
low clearance
80-7001-01
Parting tool,
standard
80-7001-02
Parting tool,
extended
Reach
80-7001-03
Outside bevel,
37.5°, low
clearance
80-7008-01
Outside bevel,
37.5°, standard
80-7008-02
Outside bevel,
37.5°,
extended
reach
80-7008-03
Beveling tool,
37.5°, low
clearance
52-710-01
Beveling tool,
37.5°, standard
52-710-02
Beveling tool,
37.5°,
extended
reach
52-710-03
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 9, Accessories and Spare Parts: Accessories
Table 2: Tooling
Photo
E.H. Wachs
Part No. 80-MAN-01, Rev. C
Description
Part Number
Beveling tool,
30°, extended
reach
52-705-01
Beveling tool,
45°, extended
reach
52-705-03
Counterbore
tool
80-7003-01
Radial socket
weld removal
tool, low clearance
80-7006-01
Radial socket
weld removal
tool, standard
80-7006-02
Radial socket
weld removal
tool, extended
reach
80-7006-03
135
Small Diameter Split Frame
Table 2: Tooling
Photo
Min. 0.565”
(14.35 mm)
Description
Part Number
Axial socket
weld removal,
low clearance
52-701-01
Axial socket
weld removal,
standard
80-7007-02
Axial socket
weld removal,
extended
reach
80-7007-03
Standard axial
carbide tool
52-702-01
Offset axial
HSS tool
52-701-02
Offset axial
carbide tool
52-702-02
Extended Offset axial HSS
tool
52-701-03
Max. 0.061”
(1.55 mm)
Max. 0.309”
(7.85 mm)
136
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 9, Accessories and Spare Parts: Accessories
Table 3: Oil
Description
Part Number
Way oil —Half Pint
60-1184-00
Table 4: Pipe Collet Sets
Machine
Size
1”
1-1/2”
2”
2-1/2”
3”
3-1/2”
4”
E.H. Wachs
Collet Set
Includes
80-5201-10
1” SD x 1/2” pipe collet
1” SD x 3/4” pipe collet
1” SD x 1” pipe collet
1” collet nut
Adjustable spanner wrench (90800-78)
80-5201-15
1-1/2” SD x 1” pipe collet
1-1/2” SD x 1-1/4” pipe collet
1-1/2” SD x 1-1/2” pipe collet
1-1/2” collet nut
Adjustable spanner wrench (90800-78)
80-5201-20
2” SD x 1-1/4” pipe collet
2” SD x 1-1/2” pipe collet
2” SD x 2” pipe collet
2” collet nut
Adjustable spanner wrench (90800-78)
80-5201-25
2-1/2” SD x 1-1/2” pipe collet
2-1/2” SD x 2” pipe collet
2-1/2” SD x 2-1/2” pipe collet
2-1/2” collet nut
Adjustable spanner wrench (90800-78)
80-5201-30
3” SD x 2” pipe collet
3” SD x 2-1/2” pipe collet
3” SD x 3” pipe collet
3” collet nut
Adjustable spanner wrench (90800-79)
80-5201-35
3-1/2” SD x 2-1/2” pipe collet
3-1/2” SD x 3” pipe collet
3-1/2” SD x 3-1/2” pipe collet
3-1/2” collet nut
Adjustable spanner wrench (90800-79)
80-5201-40
4” SD x 3” pipe collet
4” SD x 3-1/2” pipe collet
4” SD x 4” pipe collet
4” collet nut
Adjustable spanner wrench (90800-79)
Part No. 80-MAN-01, Rev. C
137
Small Diameter Split Frame
Table 4: Pipe Collet Sets
Machine
Size
5”
6”
Collet Set
Includes
80-5201-50
5” SD x 4” pipe collet
5” SD x 5” pipe collet
5” collet nut
Adjustable spanner wrench (90800-80)
80-5201-60
6” SD x 5” pipe collet
6” SD x 6” pipe collet
6” collet nut
Adjustable spanner wrench (90800-80)
SPARE PARTS
No spare parts are recommended with initial purchase of the
SDSF. Order replacement parts as needed.
When ordering spare parts, refer to the parts lists in Chapter
8. Please provide the part description and part number for
all parts you are ordering. Refer to Chapter 10 for ordering
information.
138
Part No. 80-MAN-01, Rev. C
E.H. Wachs
Chapter 10, Ordering Information
Chapter 10
Ordering Information
In This Chapter
To place an order, request service, or get more detailed
information on any E.H. Wachs products, call us at one of
the following numbers:
ORDERING REPLACEMENT
PARTS
U.S.
800-323-8185
International: 847-537-8800
WARRANTY INFORMATION
REPAIR INFORMATION
RETURN GOODS ADDRESS
You can also visit our Web site at:
www.ehwachs.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 equipment, please include the following information:
• Your name/company name
• Your address
• Your phone number
• A description of the problem or the work to be done
E.H. Wachs
Part No. 80-MAN-01, Rev. C
139
Small Diameter 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, Illinois 60069 USA
140
Part No. 80-MAN-01, Rev. C
E.H. Wachs
600 Knightsbridge Parkway • Lincolnshire, IL 60069
847-537-8800 • www.ehwachs.com
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