Manual - EH Wachs
Low Clearance Split Frame,
Models 1824-4248
User’s Manual
E.H. Wachs
600 Knightsbridge Parkway
Lincolnshire, IL 60069
www.ehwachs.com
E.H. Wachs Part No. 60-MAN-08
Rev. C, August 2014
Revision History:
Original March 2011
Rev. 1
August 2011
Rev. A
December 2011
Rev. B
March 2014
Copyright © 2014 E.H. Wachs. All rights reserved.
This manual may not be reproduced in whole or in part
without the written consent of E.H. Wachs.
EU Declaration OF CONFORMITY
WITH
COUNCIL DIRECTIVE 2006/42/EC
Issue Details:
Directives:
DATE:
Place:
1/1/2011
E.H.Wachs, Lincolnshire, IL USA
Machinery Safety Directive 2006/42/EC
Conforming Machinery:
Split Frame Macchines:
Low-Clearance Split Frame (LCSF)
Small-Diameter Split Frame (SDSF)
Model Number:
60-000-XX, 60-AIR-XX, 60-HYD-XX
80-0000-AX, 80-0000-RA, 80-4000-XX
Serial Number:
Manufacturer:
E.H. Wachs
600 Knightsbridge Parkway
Lincolnshire
IL 60069
USA
Responsible Representative:
Orbitalum Tools GmbH
Josef-Schüttler-Str. 17, 78224 Singen
Germany
Tel. +49 (0) 7731 - 792 872
Fax +49 (0) 7731 - 792 566
Harmonised Standards &
EN ISO 12100-1:2003 + A1:2009
Other Technical
EN ISO 12100-2:2003 + A1:2009
Standards/Specifications
EN 60201-1:2006 (for electric machines)
Applied or Referenced:
EN ISO 13857:2008
EN 982:1996 + A1:2008 (E) (for hydrailic machines)
EN 983:1996 (for pneumatic machines)
EN 13732-1:2006
EN ISO 14121-1:2007
EN ISO 13850:2008 (for pneumatic machines)
Provisions with which
Essential Health and Safety Requirements of Annex 1 of the
Conformity is Declared:
Machinery Directive
We hereby certify that the machinery descrived above conforms to the provisions of
Council Directive 2006/42/EC on the approximation of the laws of the Member States
relating to the safety of machinery.
Signed:
Signatory:
Pete Mullally
Quality Manager
E.H. Wachs
Table of Contents
Table of Contents
Chapter 1: About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Purpose of This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Symbols and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Manual Updates and Revision Tracking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Technical File Responsible Party . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Chapter 2: Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safe Operating Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safe Operating Environment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Operating and Maintenance Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydraulic Powered Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Safe Operation of the LCSF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Intended Uses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Proper Use of the LCSF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Misuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Potential Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
LCSF Safety Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Enclosed Bearing and Drive Gear System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Stop-on-Release Power Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Paddle-Style Trip Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Remote Operation Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Guidelines for Safe Setup, Operation, and Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pre-Operation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Operating Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Operator Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Service Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Disconnecting Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Safe Lifting and Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Machine Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Safety Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
E.H. Wachs Part No. 60-MAN-07, Rev. Ciii
Low Clearance Split Frame, Models 204-1420
Chapter 3: Introduction to the Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Overview of the LCSF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Models and Model Designation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
LCSF Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Split Frame Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Tool Slides. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Clamp Pad Extensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Trip Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Drive Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Hand Tool Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Noise Levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Operating Envelope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
LCSF Models 1824-4248 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Extended Parting Slide, 60-415-00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Extended Beveling Slide, 60-416-00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Super Extended Parting Slide, 60-437-00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Super Extended Beveling Slide, 60-438-00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Univeral Counterbore Slide, 60-405-UC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Worm Gear Slides, 60-430-01/60-430-02. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Front Drive Pinion Assembly, 60-425-04. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.5 HP Right-Angle Air Drive, 60-423-00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.5 HP Right-Angle Air Drive, 60-423-01. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.5 HP Right-Angle Reversible Air Drive, 60-4010-01. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Hydraulic Drive, 60-424-02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Chapter 4: Assembly, Disassembly, and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Machine Disassembly for Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Storage/Shipping Cases. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Storage Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Chapter 5: Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Planning the Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Tool Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Parting-Only Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Parting/O.D. Beveling Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
O.D. Beveling-Only Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Single-Point Beveling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Operating Envelopes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Extended Slides (60-415-00/60-416-00). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Super Extended Slides (60-437-00/60-438-00). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Lifting and Rigging the LCSF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Setting Up the LCSF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
iv
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Table of Contents
Clamp Leg Set-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Set-Up for In-line Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Set-Up for Open-Ended Pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Installation on Vertical Pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Positioning the Machine for the Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Clamp Pad Centering Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Install Tool Slides and Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Standard Slides. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Extended Slides. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Install the Tooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Dual Tooling Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Install the Trip Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Install the Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Air Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Hydraulic Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Cutting Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Counterboring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Planning the Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Counterbore Set-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Cutting the Counterbore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
LCSF Cutting Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Remote Operation with the SF ACM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Control Panel Reference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Locating the ACM at the Worksite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Operating the ACM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Adjusting the Output Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Using the Venting Quick Disconnect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Configuring the Air Drive for the ACM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Air Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Air Trigger Modification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Chapter 6: Routine Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Tool Slides. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Split Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Air Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Recommended Air Motor Lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Servicing the SF ACM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Chapter 7: Service and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Adjusting the Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Extended Slide Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
E.H. Wachs Part No. 60-MAN-07, Rev. Cv
Low Clearance Split Frame, Models 204-1420
Super Extended Slide Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Air Motor Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Disassembling Air Motor Subassemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Right Angle Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Handle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Air Motor Vanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Right Angle Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Chapter 8: Parts Lists and Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Model 1824-4248 (24”-48” inch LCSF). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Stationary Ring Assembly (Models 1824 through 4248). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Wiper Kit Assembly, 60-552-03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Pinion Housing, 60-409-00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Front Drive Pinion Housing, 60-425-04. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Clamp Legs, 60-127-XX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Trip Assembly, 60-434-00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Extended Parting Slide, 60-415-00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Extended Beveling Slide, 60-416-00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Super Extended Parting Slide, 60-437-00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Super Extended Beveling Slide, 60-438-00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Universal Counterbore Slide, 60-405-UC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Worm Gear Parting Slide, 60-430-01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Worm Gear Beveling Slide, 60-430-02. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Worm Gear Slide Trip Assembly, 60-431-00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Heavy Wall Parting Tool Holders, 60-433-00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Heavy Wall Carbide Tool Kit, 60-712-00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
1.5 HP Air Drive, 60-423-00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
1.5 HP Air Drive, Ported Exhaust, 60-407-00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
2.5 HP Air Drive, 60-423-01. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
2.5 HP Reversible Air Drive, 60-4010-00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Hydraulic Drive, 60-424-02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Hydraulic Drive, 60-424-01 (OBSOLETE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Split Frame Air Control Module (60-420-00). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Air Control Module Subassembly (60-375-00). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Air Control Module Subassembly (60-375-00). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Air Control Module Schematic (60-420-00). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
vi
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Table of Contents
Chapter 9: Accessories and Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Hydraulic Power Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Recommended Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Chapter 10: Ordering Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Ordering Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Warranty Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Return Goods Address. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
E.H. Wachs Part No. 60-MAN-07, Rev. Cvii
Low Clearance Split Frame, Models 204-1420
viii
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 1, About This Manual
Chapter 1
About This Manual
Purpose of This Manual
This manual explains how to operate and maintain the Low Clearance Split Frame (LCSF). It
includes instructions for set-up, operation, and maintenance. It also contains parts lists, diagrams,
and service information to help you order replacement parts and perform user-serviceable repairs.
LCSF models are available in a wide range of sizes. This manual covers models from 24-inch
capacity (model 1824) through 48-inch capacity (model 4248).
Carefully read Chapter 2, Safety, and follow all guidelines for safe operation of the LCSF.
E.H. Wachs
Part No. 60-MAN-07, Rev. C1
Low Clearance Split Frame, Models 204-1420
Symbols and Warnings
The following symbols are used throughout this manual to indicate special notes and warnings.
They appear in the out­side column of the page, next to the section they refer to. Make sure you
understand what each symbol means, and follow all instructions for cautions and warnings.
This is the safety alert symbol. It is used to alert you to potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid
possible injury or death.
WARNING
A WARNING alert with the safety alert symbol indicates a potentially hazardous situa­tion that could
result in seri­ous injury or death.
CAUTION
A CAUTION alert with the safety alert symbol indicates a potentially hazardous situa­tion that could result
in minor or moderate injury.
A CAUTION alert with the damage alert symbol indicates a situation that will result in
damage to the equipment.
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.
IMPORTANT
An IMPORTANT alert with the damage alert symbol indi­cates a situation that may result in
damage to the equipment.
This symbol indicates a user note. Notes provide additional information to
supple­ment the instructions, or tips for easier operation.
2
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 1, About This Manual: Manual Updates and Revision Tracking
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.
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.
Technical File Responsible Party
The low clearance split frame is manufactured by E.H. Wachs at the following address:
E.H. Wachs
600 Knightsbridge Parkway
Lincolnshire, IL 60069
U.S.A.
The following organization is the responsible party for maintaining the LCSF technical file in the
EU:
Orbitalum Tools GmbH
Josef-Schüttler-Str. 17
78224 Singen
Deutschland
E.H. Wachs
Part No. 60-MAN-07, Rev. C3
Low Clearance Split Frame, Models 204-1420
4
Part No. 60-MAN-07, 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.
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.
• 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.
Look for this sym­bol throughout the manual. It indicates a personal injury
hazard.
E.H. Wachs
Part No. 60-MAN-07, Rev. C5
Low Clearance Split Frame, Models 204-1420
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
• 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.
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.
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.
• 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.
6
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 2, Safety: Safe Operating Guidelines
Pneumatic Powered Equipment
• Air motors may get hot during operation and may cause burns. Do not touch the air motor,
except for operator controls, during or after operating the machine.
• Before disconnecting the air line from the equipment, always turn off air at the source and
bleed all residual air pressure at the air motor.
Loss or Shut-Off of Power Supply
• If the power source to the equipment is lost, disconnect power from the equipment and lock out
the power 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.
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.
E.H. Wachs
Part No. 60-MAN-07, Rev. C7
Low Clearance Split Frame, Models 204-1420
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 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 LCSF
Intended Uses
The low clearance split frame is designed to O.D. mount on in-line or open-ended pipe, and perform cut-off and weld prep (beveling, counterboring, and J-prep) operations. It uses cold-cutting
lathe techniques, with a variety of acces­sories and tooling for different cutting applications.
8
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 2, Safety: Safe Operation of the LCSF
Make sure to follow all safety guidelines and procedures required for machining operations
at the work site, including personal protective equipment (PPE). Do not use the LCSF in a
manner that violates these guidelines.
Proper Use of the LCSF
• The LCSF should only be used by trained, qualified operators.
• The workpiece must be within the operating capacity of the LCSF 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.
• Make sure there is adequate clearance around the LCSF and workpiece to operate the machine
controls as described in the operating instructions (Chapter 5).
• Mount the LCSF with the pinion housing positioned for convenient mounting and operation of
the drive motor.
• Use the LCSF only on empty, depressurized pipe.
Misuse
• Do not attempt to mount or operate the LCSF on non-cylindrical workpieces.
• Do not attempt to mount or operate the LCSF on any workpiece to which it cannot be securely
mounted.
• Do not attempt to mount or operate the LCSF on any workpiece that is not stable enough to
hold the LCSF.
• Do not mount the LCSF on the “fall-off” side of the cut line, unless you adequately rig and
support the LCSF and workpiece.
• Do not disable any safety feature of the LCSF or remove any safety labeling. Replace worn or
damaged safety labels immediately. (See “Safety Labels” later in this chapter.)
E.H. Wachs
Part No. 60-MAN-07, Rev. C9
Low Clearance Split Frame, Models 204-1420
Potential Hazards
The following figures illustrate potential hazards of operat­ing the low clearance split frame. Refer
to the description of each hazard for guidelines on safe operation.
3
6
1,2
4
5
Figure 2-1. Potential operating hazards of the LCSF. See the descriptions below.
1. Rotating ring—Keep clear of the rotating ring and tool slides when operating the LCSF. Contact
with moving parts can cause serious injury.
2. Entanglement hazard for gloves or clothing—Do not wear gloves or loose-fitting clothing when
operating the LCSF. They can become entangled with moving parts, resulting in serious injury.
3. Starwheel/trip pinch point—Operate the trip using the trip lever only. Do not touch any part of the trip
assembly, other than the lever, when operating the LCSF or when rotating it manually for any reason.
4. Sharp cutting tools—Cut­ting tools used with the LCSF can be very sharp. Be careful when
handling the tools, and stay clear of them when the machine is operating.
5. Chips—The metal debris from the cutting process can be very sharp and very hot. Use care in
cleaning debris from the machine and 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.
10
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 2, Safety: Safe Operation of the LCSF
8
7
Figure 2-2. Potential operating hazards of the LCSF. See the descriptions below.
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.
8. Fall-off workpiece—When you are severing the work­piece, make sure the fall-off section is
supported or that a catch device is in place. A support chain and scaffold­ing are shown in the
picture.
9
10
Figure 2-3. Potential operating hazards of the LCSF. See the descriptions below.
E.H. Wachs
Part No. 60-MAN-07, Rev. C11
Low Clearance Split Frame, Models 204-1420
9. Lifting the machine—Use care when lifting the LCSF and its components to avoid injury. Machines and compo­nents heaver than 40 lb (18 kg) should be lifted by two people or with a lifting
device. Larger LCSF models are pro­vided with lifting eyes for rig­ging and lifting. See “Machine
Weights” later in this chapter for weights of all LCSF mod­els and accessories.
10. Splitting the ring—Align­ment pins are provided to keep the rotating and station­ary rings together when split­ting the ring. Make sure you insert the pins before sepa­rating the ring halves. If the
pins are not inserted, the rotating ring could fall out of the stationary ring, causing personal injury
and/or dam­age to the machine.
LCSF Safety Features
The design of the low clearance split frame incorporates the following features for safe operation.
Enclosed Bearing and Drive Gear System
The LCSF bearings and drive gears are enclosed inside the machine to prevent operator contact
with them while the machine is running.
Bearings
Drive gear
Figure 2-4. The bearings and drive gear are enclosed in the LCSF frame. The pinion housing covers the drive gear when installed.
Stop-on-Release Power Control
All drives for the LCSF (pneumatic and hydraulic) require the operator to hold the power control
on to operate the machine. When the operator releases the power control, the LCSF stops immediately.
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.
12
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 2, Safety: Safe Operation of the LCSF
Figure 2-5. Hold the air motor trigger to operate the LCSF (left). When you release the
trigger (right), the air motor shuts off.
Figure 2-6. Hold the hydraulic lever to operate the LCSF (left). When you release the lever
(right), the hydraulic motor shuts off.
Paddle-Style Trip Lever
The LCSF trip design allows the operator to engage and dis­engage the trip from behind the machine, without reaching into the operating space of the rotating ring and slides. The paddle trip
lever moves the trip pin in and out to control engagement of the trip.
Figure 2-7. The paddle-style trip lever allows you to engage and disengage the trip from the
back of the LCSF, without putting your hands in the way of mov­ing components.
E.H. Wachs
Part No. 60-MAN-07, Rev. C13
Low Clearance Split Frame, Models 204-1420
Remote Operation Option
Remotely controlled operation is available as an option for all LCSF drives types.
• For pneumatic drives, order the remote control panel (part no. 60-420-00). The control panel is
provided with its own operating instructions.
• For hydraulic 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 LCSF, 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, hydraulic, or electric) to make sure they are in good
condition.
Operating Safety
• Stop the LCSF 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 and hydraulic hoses and electrical cords away from moving parts while operating the
machine.
Operator Position
The preferred position for operating the LCSF is behind the stationary ring, on the mounting side
of the cut line.
14
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 2, Safety: Safe Operation of the LCSF
Figure 2-8. If possible, stand behind the LCSF to stay clear of moving parts while operating
the controls.
If the operating environment does not allow you to stand behind the LCSF, make sure you install
the machine so that you can operate the controls without coming in contact with moving parts.
Figure 2-9. When operating the LCSF from the front, stand to the side of the machine to
operate the controls without reaching across the rotating ring.
Some accessories, such as the universal counterbore slide, require that you operate them from in
front of the machine. Stand in a position that allows you to operate the machine controls without
contacting moving parts.
E.H. Wachs
Part No. 60-MAN-07, Rev. C15
Low Clearance Split Frame, Models 204-1420
Figure 2-10. When using accessories that require you to operate their controls (shown with
universal coun­terbore slide), stand in a position where you can oper­ate the machine without
contacting moving parts.
Service Checklist
• Disconnect power from the LCSF during service. See instructions in the following section.
• Remove accessories such as drive assemblies and tool slides unless they are part of the service
procedure.
Disconnecting Power
The following photos show the means of disconnecting power for the LCSF. Follow all lock-out/
tag-out procedures at your work site.
WARNING
Before disconnecting the air line, always turn off air at the source and bleed all residual air
pressure at the air motor. Disconnecting the air line while under pressure could result in
serious injury.
• PNEUMATIC POWER—To disconnect power from the pneumatic LCSF, remove the air line from
the air motor coupling.
16
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 2, Safety: Safe Operation of the LCSF
Figure 2-11. Disconnect pneumatic power by remov­ing the air line from the pneumatic drive.
WARNING
Hydraulic components such as hoses, motors, and mani­folds will get hot during oper­ation and
may cause burns. Use appropriate gloves or wait until the components cool before touching
them.
• HYDRAULIC POWER—To disconnect power from the hydraulic LCSF, remove the hydraulic
hoses from the fittings on the manifold.
Figure 2-12. Disconnect hydraulic power by remov­ing the hydraulic hoses from the fittings
on the mani­fold.
E.H. Wachs
Part No. 60-MAN-07, Rev. C17
Low Clearance Split Frame, Models 204-1420
Safe Lifting and Handling
• 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.
• It is the responsibility of the end user to determine whether a machine or assembly can be lifted
by two or more people. A lifting device is recommended for machines or assemblies that
cannot be handled easily by two people.
• LCSF models 610 and larger are equipped with eye bolts in the stationary ring for lifting.
• Do not rig or lift the LCSF while power is attached. Whenever possible, remove all accessories
(slides, trips, drive assembly, etc.) while lifting and handling the machine.
• Lift the LCSF only at approved lift points, as illustrated in the following figure.
Install lift eyes in adjacent
holes and lift with chains
You can wrap a lifting strap
around the ring to lift the
assembled machine. Do not
put the strap around or against
an accessory component.
Figure 2-13. When lifting the assembled LCSF, use the lift eyes provided. You can also lift the
machine using a lift strap around the ring. (16” machine, model 1016 shown.)
18
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 2, Safety: Safe Operation of the LCSF
Install lift eyes and
lift with chains
Make sure alignment pin is
installed (inserted through
stationary ring on opposite
side)
Figure 2-14. To lift a split machine, always use two lift eyes. Make sure the alignment pins
are installed.
Machine Weights
Table 1 lists the weights for each LCSF model. Weights are included for the entire machine as well
as each separable assembly. The following tables list the weights for slides, drives, and other
accessories. To determine lifting weight, add weights of installed components to the machine
assem­bly.
Table 1: LCSF Machine and Assembly Weights
Model
Part No.
Full Machine Weight*
Split Ring Weight
(Pinion Side)**
Split Ring Weight (Non-Pinion
Side)**
1824
60-000-24
189 lb
(86 kg)
97 lb (44 kg)
92 lb (42 kg)
2228
60-000-28
213 lb
(97 kg)
109 lb (50 kg)
104 lb (47 kg)
2632
60-000-32
235 lb
(107 kg)
120 lb (55 kg)
115 lb (52 kg)
3036
60-000-36
259 lb
(118 kg)
132 lb (60 kg)
127 lb (58 kg)
3339
60-000-39
277 lb
(126 kg)
141 lb (64 kg)
136 lb (62 kg)
3642
60-000-42
297 lb
(135 kg)
151 lb (69 kg)
146 lb (66 kg)
4248
60-000-48
329 lb
(150 kg)
167 lb (76 kg)
162 lb (74 kg)
* With standard pinion housing installed; no slides or drive installed. Add 5.4 lb (2.5 kg) for front drive pinion.
** Rounded to nearest lb/kg. Sum may not add exactly to Full Machine Weight.
E.H. Wachs
Part No. 60-MAN-07, Rev. C19
Low Clearance Split Frame, Models 204-1420
Table 2: LCSF Slide Kit Weights
Accessory
Extended Slide Kit
(standard on LCSF
1824-4248)
Super Extended Slide
Kit
O.D. Tracking Slide Kit
Worm Slide Kit
Kit Part No.
60-422-01
60-440-00
60-446-00
60-430-00
Part
Number
Component
Weight
Extended parting slide
60-415-00
8 lb (4 kg)
Extended beveling slide
60-416-00
8 lb (4 kg)
Trip assembly and extension blocks
60-401-00
1.4 lb (0.6 kg)
Super extended parting slide
60-437-00
10 lb (4.5 kg)
Super extended beveling slide
60-438-00
10 lb (4.5 kg)
Trip assembly and extension blocks
60-401-00
1.4 lb (0.6 kg)
O.D. Tracking Parting Slide
60-446-01
42 lb (19.1 kg)
O.D. Tracking Beveling Slide
60-446-02
42 lb (19.1 kg)
O.D. Tracking Slide Trip Assembly
60-446-03
11 lb (5 kg)
Worm Gear Parting Slide
60-430-01
23 lb (10.5 kg)
Worm Gear Beveling Slide
60-430-02
24 lb (10.9 kg)
Worm Slide Trip Assembly
60-431-00
1.2 lb (0.5 kg)
Table 3: Accessory Slide Weights
Component
20
Part Number
Weight
Universal Counterbore Slide
60-405-UC
10 lb (4.5 kg)
Bridge slide for model 1824 LCSF
60-428-24
61 lb (27.7 kg)
Bridge slide for model 2228 LCSF
60-428-28
62 lb (28.2 kg)
Bridge slide for model 2632 LCSF
60-428-32
64 lb (29.1 kg)
Bridge slide for model 3036 LCSF
60-428-36
65 lb (29.6 kg)
Bridge slide for model 3339 LCSF
60-428-39
67 lb (30.5 kg)
Bridge slide for model 3642 LCSF
60-428-42
68 lb (30.9 kg)
Bridge slide for model 4248 LCSF
60-428-48
70 lb (31.8 kg)
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 2, Safety: Safe Operation of the LCSF
Table 4: Drive Component Weights
Component
Part Number
Weight
Front drive pinion for 1824-4248
60-425-04
8 lb (4 kg)
1.5 HP standard pneumatic drive
60-423-00
9 lb (4 kg)
1.5 HP ported pneumatic drive
60-407-00
9 lb (4 kg)
2.5 HP pneumatic drive
60-423-01
13 lb (6 kg)
2.5 HP reversible pneumatic drive
60-4010-01
14 lb (6 kg)
Hydraulic drive
60-424-00
25 lb (11 kg)
Installation Procedures
See the detailed instructions in Chapter 5 for installing the LCSF on the workpiece. Safe installation procedures are provided for mounting the machine on both horizontal and vertical workpieces.
Safety Labels
The following safety labels are provided on the LCSF. If any of these labels is damaged or missing,
replace it imme­diately. See Chapter 10 for ordering information.
Figure 2-15. The ear and eye protection label is attached to the drive motor of the LCSF.
Always wear ear and eye protection when operating the equipment. (Part no. 90-401-03.)
Figure 2-16. The air pressure label is attached to the air drive of pneumatic LCSF models.
Do not operate the equipment with greater than 90 psi (6.2 bar) air pressure. (Part no.
90-401-02.)
E.H. Wachs
Part No. 60-MAN-07, Rev. C21
Low Clearance Split Frame, Models 204-1420
Figure 2-17. The hydraulic pressure label is attached to the LCSF hydraulic drive. Do not
operate the equipment with greater than 2000 psi (138 bar) hydraulic pressure. (Part no.
90-402-01.)
Figure 2-18. The hot surface label is attached to the LCSF drive motor (pneumatic or
hydraulic). Drive components may become hot enough to cause burns. Make sure they are
not hot before touching them. (Part no. 90-403-00.)
Figure 2-19. Weight labels for the LCSF are attached to the pinion housing. Weights and
part no. vary according to LCSF model. (Part no. 60-1279-XX.)
22
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 2, Safety: Safe Operation of the LCSF
Figure 2-20. The “Keep Hands Clear” label is attached to the stationary ring of the LCSF.
Stay clear of moving parts when the LCSF is operating. (Part no. 60-363-00.)
Figure 2-21. The alignment pin tag is attached to the ring on the alignment pin. Make sure to
insert the pins before splitting the machine. (Part no. 60-1274-00.)
E.H. Wachs
Part No. 60-MAN-07, Rev. C23
Low Clearance Split Frame, Models 204-1420
Figure 2-22. The alignment pin location label is attached to indicate the alignment pin
holes. Two labels are on the LCSF, one for each pin location. (Part no. 60-1275-00.)
Figure 2-23. The Read Manual label is attached to the stationary ring of the LCSF. Make
sure you under­stand all operating and maintenance instructions before using the machine.
(Part no. 90-900-00.)
24
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 3, Introduction to the Equipment
Chapter 3
Introduction to the Equipment
Overview of the LCSF
The E.H. Wachs Low Clearance Split Frame Machine (LCSF) is a portable pipe cutting and
beveling system developed for on-site operation. The LCSF uses lathe type machining principles,
with capabilities for cutting (sever process), beveling (form tool or single point), and counter­
boring.
Set up and operation is quick and simple, and the machine requires little maintenance other than
lubrication. Split frame prepping is a safe, clean operation that neither affects the metallurgical
qualities of the metal nor places airborne contaminants in the environment.
The LCSF assembly consists of two halves that can be dis­assembled for installation on the pipe.
The stationary frame contains the clamping feet, which secure the machine to the pipe, and the
pinion housing, which contains the drive gear that turns the rotating frame. The stationary frame is
made from lightweight aluminum material. The rotating frame is of steel construction with hardened bearing raceways and has locations for mounting the tool slides and machining accessories.
Features
• Simple, lightweight, rugged design for cutting and prep­ping in tight places.
• Works on all sizes, wall thicknesses, and material across the entire range of pipe diameter
capacities.
• Self-squaring clamping system for easy set-up.
• Safe cold-cutting for use in any environment.
• Standard air motor drive with options for hydraulic or electric power.
• Adjustable bearings and hardened bearing raceways for maximum dependability and performance.
• Modular accessories for counterboring, compound bev­eling, J-prepping, heavy-wall cutting,
and internal cut­ting.
• Remote operation capability for safe use in hazardous environments.
E.H. Wachs
Part No. 60-MAN-07, Rev. C25
Low Clearance Split Frame, Models 204-1420
Models and Model Designation
The low clearance split frame (LCSF) consists of 15 models for cutting and beveling pipes from 2”
(51 mm) to 48” (1219 mm) outside diameter (O.D.). Models from 1824 (24” capacity) to 4248
(48” capacity) are described in this manual. Each model covers a range of pipe sizes, as described
in Table 1.
E.H. Wachs uses a model numbering system that designates the capacity of the machine. All model
numbers include the following. (This information is required when ordering parts or tooling.)
Type: 60-000-08
Model: SF 408/3
Serial: 06-1234 (Example)
“SF” Designates Wachs Low Clearance Split Frame Machine, followed by the capacity of the
machine, and “/3” which designates the generation of design.
The following numbers indicate the capacity:
• 1824 will mount on 18” through 24” pipe
• 4248 will mount on 42” through 48” pipe.
Figure 3-1. The I.D. tag (mounted on the stationary ring next to the pinion housing) identifies the LCSF model, and includes the machine’s serial number.
26
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 3, Introduction to the Equipment: LCSF Components
Table 1: LCSF Models
Model
Part Number
1824/3
Pipe Size Range
Inches
DN
60-000-24
18”–24”
450-600
2228/3
60-000-28
22”–28”
550-700
2632/3
60-000-32
26”–32”
650-800
3036/3
60-000-36
30”–36”
750-900
3339/3
60-000-39
33”-39”
825-975
3642/3
60-000-42
36”–42”
900-1050
4248/3
60-000-48
42”–48”
1050-1200
See clamping leg charts in Chapter 5 for measured pipe size capacities.
LCSF Components
The complete LCSF configuration includes the following components, illustrated in Figure 3-2.
Air motor
Tool slides
Split frame machine
Trip assembly
Clamp pad extensions
Tool kit
Figure 3-2. Standard equipment provided with the low clearance split frame.
E.H. Wachs
Part No. 60-MAN-07, Rev. C27
Low Clearance Split Frame, Models 204-1420
Standard Equipment
Split Frame Machine
The LCSF ring consists of one rotating ring and one station­ary ring. Each ring splits into two
pieces. When assembled, the rotating ring and stationary rings are integrated and split apart simultaneously for mounting on in-line piping appli­cations. These rings are preassembled and adjusted
prior to leaving the factory.
Figure 3-3 shows the assembled LCSF.
Rotating ring
Stationary ring
Rotating ring
Slide mounting
location
Pinion housing (with
motor attachment
Trip
Clamp legs
Slide mounting
location
Split point (opened
for illustration)
Clamp leg adjust­
ment screw
Figure 3-3. The photo shows the components of the LCSF.
Tool Slides
Two sizes of tool slides are available for LCSF models 1824-4248: Extended and Super Extended slides. Super extended slides are standard on LCSF 1824 through LCSF 4248. Check the
packing list to see which slides you should have received with your LCSF.
Other types of slides are available for special applications such as counterboring, heavy-wall
cutting, and out-of-round pipe. See the “Accessories” section below and the ordering information
in Chapter 9 for information on these slides.
28
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 3, Introduction to the Equipment: LCSF Components
Parting/beveling slide
60-416-00
Parting slide
60-415-00
Figure 3-4. The photo shows the extended tool slides. Cutting stroke (slide travel) is 1.67”
(41.8 mm).
Parting slide
60-437-00
Parting/beveling slide
60-438-00
Figure 3-5. The photo shows the super extended tool slides, which are standard for LCSF
models 1824 through 4248. Cutting stroke (slide travel) is 2.28” (57.9 mm).
Clamp Pad Extensions
NOTE
Clamp pad requirements are included on the envelope drawings at the end of this
chapter.
Clamp pad extensions lengthen the LCSF clamp legs to allow the LCSF to cover its entire range of
pipe diameters. The operating instructions in Chapter 5 include a table of clamp pad requirements
for each LCSF size for the pipe diameter range it can cut.
E.H. Wachs
Part No. 60-MAN-07, Rev. C29
Low Clearance Split Frame, Models 204-1420
Trip Assembly
The trip assembly is composed of a trip housing, a trip pin, a trip lever, and two extension blocks.
The trip can be engaged or disengaged, depending upon feed requirements, by engaging or disengaging the trip lever. Refer to Tool Slide Mounting Location and Trip Assembly Configuration.
Drive Motor
The standard LCSF drive is an air motor. Two air motor sizes are available:
• A 1.5 HP motor is available for all LCSF models (avail­able in conventional or right-angle
configuration).
• A 2.5 HP motor is standard with LCSF models 1824 through 4248 (available in single-direction or reversible configuration).
Both air motors are interchangeable by design and can be used on any size LCSF as needed. For
instance, the 2.5 HP motor can be used on a smaller LCSF for a heavy cutting application. The
1.5 HP air drive requires 55 cfm air flow at 90 psi (1,557 1/m @ 6.3 bar). The 2.5 HP air drive
requires 65 cfm at 90 psi (1,841 1/m @ 6.3 bar).
A hydraulic drive is available as an option. The hydraulic drive requires 8-15 gpm hydraulic flow
rate at 1500-2000 psi (30-57 l/m @ 103-138 bar).
Electric drives are available as special-order items. Contact E.H. Wachs customer service to
discuss requirements.
30
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 3, Introduction to the Equipment: LCSF Components
Table 2: LCSF Drive Options
Drive Option
Part No.
Description
Input Requirements
60-423-00
Right angle 1.5 HP
55 cfm at 90 psi
(1,557 1/m @ 6.3 bar)
60-407-00
Right angle 1.5 HP with ported exhaust
55 cfm at 90 psi
(1,557 1/m @ 6.3 bar)
60-423-01
Right angle 2.5 HP
65 cfm at 90 psi
(1,841 1/m @ 6.3 bar)
60-4010-01
Right angle reversible 2.5 HP
65 cfm at 90 psi
(1,841 1/m @ 6.3 bar)
Hydraulic Drive
60-424-01
Hydraulic motor with adapter
8-15 gpm, 1500-2000 psi
(30-57 l/min, 103-138 bar)
Electric Drive
(Special)
Electric motor with adapter; special order item
Varies depending on
requirements
Air Drive
Hydraulic
drive
Pneumatic
drive
Electric
drive
Figure 3-6. The photo shows the drive options avail­able with the LCSF.
Hand Tool Kit
Each LCSF is delivered from the factory with all hand tools necessary for setup and operation. Kit
number 60-600-36 is provided with LCSF models 1824 through 4248). The fol­lowing tables list
the hand tools provided with the LCSF.
E.H. Wachs
Part No. 60-MAN-07, Rev. C31
Low Clearance Split Frame, Models 204-1420
Table 3: LCSF Hand Tool Kit, Models 1824-4248
(Part No. 60-000-36)
Description
Part #
Hex Wench Set, 5/64” - 1/4”
90-800-06
Deadblow Hammer
60-814-00
3/8” Hex Long Arm Wrench
90-800-10
1/2” 6-Point Socket, 1/2” Drive
90-800-15
1/4” Hex Driver Long Socket, 1/2” Drive
90-800-18
3/4” Combination Wrench
90-800-30
7/16” Combination Wrench
90-800-38
Square, 8”
90-800-54
1/2” Drive Ratchet Wrench
90-800-63
5/8” Hex Driver Long Socket, 1/2” Drive
90-800-65
7/8” Socket, 1/2” Drive
90-800-67
Scale, 6”
90-800-70
3/8” Hex Driver Long Socket, 1/2” Drive
90-800-76
Tool Box
60-227-00
Other tools may be required to perform certain maintenance operations. These are specified in the
instructions for those procedures.
Accessories
The following accessory equipment is available for use with the LCSF. These items are purchased
separately; see Chap­ter 9 for descriptions and purchasing information.
•
•
•
•
•
•
•
•
•
•
32
Hydraulic drive
Electric drive
Bridge slide
O.D. tracking slides
Counterbore slide
Worm slides with heavy-wall tool holder and tool bit
Front drive pinion
External-internal casing cutter
Extension legs
Dial Indicator.
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 3, Introduction to the Equipment: Operating Envelope
Noise Levels
The noise levels in Table 4 were measured at 1 meter high and 1.6 meters away from the machine,
equipped with the air motor drive. (Hydraulic and electric drives have lower noise levels.)
Table 4: LCSF Noise Levels
Continuous “A”-weighted sound pressure level at workstation
62 dBA
Peak “C”-weighted maximum sound pressure
95 dBA
Sound power level emitted by machine
89 dBA
Operating Envelope
The drawings on the following pages illustrate the operating envelope for each of the LCSF models.
E.H. Wachs
Part No. 60-MAN-07, Rev. C33
Low Clearance Split Frame, Models 204-1420
LCSF Models 1824-4248
-TABLEMODEL
DIM. "A"
OUTER DIAMETER
DIM. "B"
INNER DIAMETER
DIM. "C"
DRIVE CL
DIM. "D"
LCSF1824
32.50 [825.5]
24.50 [622.3]
16.90 [429.3]
18.32 [465.4]
LCSF2228
36.50 [927.1]
28.50 [723.9]
18.90 [480.1]
20.32 [516.2]
LCSF2632
40.50 [1028.7]
32.50 [825.5]
20.90 [530.9]
22.32 [567.0]
LCSF3036
44.50 [1130.3]
36.50 [927.1]
22.90 [581.7]
24.32 [617.8]
EXTENSION
LEG SET
DIM. "E" MIN.
CLAMPING DIA.
DIM. "E" MAX.
CLAMPING DIA.
NONE
60-408-10
60-408-20
60-408-30
NONE
60-408-10
60-408-20
60-408-30
NONE
60-408-10
23.01 [584.4]
20.89 [530.5]
18.89 [479.7]
16.89 [428.9]
27.01 [685.9]
24.89 [632.1]
22.89 [581.3]
20.89 [530.5]
31.01 [787.5]
28.88 [733.7]
24.50 [622.3]
22.35 [567.7]
20.35 [516.9]
18.35 [466.2]
28.50 [723.9]
26.35 [669.3]
24.35 [618.5]
22.35 [567.7]
32.50 [825.5]
30.35 [770.9]
60-408-20
60-408-30
26.88 [682.9]
24.89 [632.1]
NONE
60-408-10
60-408-20
60-408-30
35.00 [889.1]
32.88 [835.3]
NONE
LCSF3339
LCSF3642
LCSF4248
47.50 [1206.5]
50.50 [1282.7]
56.50 [1435.1]
39.50 [1003.3]
42.50 [1079.5]
48.50 [1231.9]
24.40 [619.8]
25.90 [657.9]
28.90 [734.1]
25.81 [655.7]
27.32 [694.0]
30.32 [770.2]
DRIVE
INPUT
60-408-10
60-408-20
38.00 [965.2]
35.88 [911.4]
33.88 [860.6]
31.88 [809.8]
41.00 [1041.5]
38.88 [987.6]
36.88 [936.8]
34.88 [886.0]
47.00 [1193.9]
44.88 [1140.0]
34.35 [872.5]
32.35 [821.7]
30.35 [770.9]
39.50 [1003.3]
37.35 [948.7]
35.35 [897.9]
33.35 [847.1]
42.50 [1079.5]
40.35 [1024.9]
38.35 [974.1]
60-408-30
NONE
60-408-10
60-408-20
42.88 [1089.2]
46.35 [1177.3]
44.35 [1126.5]
60-408-30
40.88 [1038.4]
42.35 [1075.7]
36.35 [923.3]
48.50 [1231.9]
"A"
OUTER DIAMETER
2.63
66.7
3.56
90.5
60-408-10
60-408-20
60-408-30
NONE
30.88 [784.5]
28.88 [733.7]
28.35 [720.1]
26.35 [669.3]
36.50 [927.1]
4.81
122.2
TRIP
LOCATION
"B"
INNER DIAMETER
3.70
94.0
TRIP
LOCATION
"C"
DRIVE CL
TRIP
LOCATION
DIMENSIONS IN BRACKETS ARE MILLIMETERS
34
18°
45° TYP
"E"
CLAMPING
DIAMETER
TRIP
LOCATION
"D"
Chapter 3, Introduction to the Equipment: Operating Envelope
Extended Parting Slide, 60-415-00
-TABLEDIMENSIONS IN BRACKETS ARE MILLIMETERS.
PIPE DIAMETER (DIM. "A") SHOWN WITHOUT CLEARANCE.
WEIGHT = 7.5lb. [3.4kg]
6.99
[177.5]
6.18
[157.0]
5.68
[144.2]
.124
3.15
POSITION
DIM. "A"
DIAMETER
DIM. "B"
RADIUS
LCSF 1824
N/A
24.50
[622.3]
16.64
[422.6]
LCSF 2228
N/A
28.50
[723.9]
18.64
[473.7]
LCSF 2632
N/A
32.50
[825.5]
20.64
[524.3]
LCSF 3036
N/A
36.50
[927.1]
22.64
[575.1]
LCSF 3642
N/A
42.50
[1079.5]
25.64
[651.3]
LCSF 4248
N/A
48.50
[1231.9]
28.64
[727.5]
Slide travel and diameter/radius dimensions below
are same for 60-415-00 parting slide and 60-416-00
beveling slide (next page).
2.17
55.2
1.92
48.7
1.25
31.8
1.67
42.4
TRAVEL
.99
25.1
.31
7.9
.17
4.3
MODEL
FEED RATE
.0026 PER TRIP
[.066]
"A"
5.37
136.5
"B"
.83
21.1
2.50
63.5
3.48
88.5
35
Low Clearance Split Frame, Models 204-1420
Extended Beveling Slide, 60-416-00
7.80
[198.0]
-TABLE-
7.11
[180.6]
1.61
40.8
.31
7.9
3.11
78.9
4.29
109.0
MODEL
POSITION
DIM. "A"
DIAMETER
DIM. "B"
RADIUS
LCSF 1824
N/A
24.50
[622.3]
16.64
[422.6]
LCSF 2228
N/A
28.50
[723.9]
18.64
[473.7]
LCSF 2632
N/A
32.50
[825.5]
20.64
[524.3]
LCSF 3036
N/A
36.50
[927.1]
22.64
[575.1]
LCSF 3642
N/A
42.50
[1079.5]
25.64
[651.3]
LCSF 4248
N/A
48.50
[1231.9]
28.64
[727.5]
DIMENSIONS IN BRACKETS ARE MILLIMETERS.
PIPE DIAMETER (DIM. "A") SHOWN WITHOUT CLEARANCE.
WEIGHT = 7.5lb. [3.4 kg]
7.05
[179.0]
6.36
[161.4]
5.73
[145.6]
5.00
[127.1]
.99
25.1
.51
13.0
.31
7.9
.125
3.18
2.50
63.5
2.23
56.6
.17
4.3
1.50
38.1
.83
21.1
1.25
31.8
3.54
90.0
36
See 60-415-00 parting slide drawing
on previous page for slide travel and
diameter/radius dimensions.
Chapter 3, Introduction to the Equipment: Operating Envelope
Super Extended Parting Slide, 60-437-00
6.99
177.5
2.28 TRAVEL
57.9
3.48
88.5
2.17
55.2
1.00 TYP.
25.4
"A"
1.16
29.5
FEED RATE
.0026 PER TRIP
[.066]
.31
7.9
.99
25.1
"B"
Slide travel and diameter/radius dimensions above
are same for 60-415-00 parting slide and 60-416-00
beveling slide (next page).
LSCF 1824
LSCF 2228
LSCF 2632
LSCF 3036
LSCF 3642
LSCF 4248
4.68
118.8
.12
3.1
-TABLEMODEL
3.18
80.7
5.68
144.2
DIM. "B"
RADIAL
CLEARANCE
POSITION
DIM. "A"
PIPE
DIAMETER
LOW
20.35
[516.9]
17.00
[431.8]
MID
22.35
[567.7]
18.00
[457.2]
HIGH
24.35
[618.5]
19.00
[482.6]
LOW
24.34
[618.2]
19.00
[482.6]
MID
26.34
[669.0]
20.00
[508.0]
HIGH
28.34
[719.8]
21.00
[533.4]
LOW
28.33
[719.6]
21.00
[533.4]
MID
30.33
[770.4]
22.00
[558.8]
HIGH
32.33
[821.2]
23.00
[584.2]
LOW
32.32
[820.9]
23.00
[584.2]
MID
34.32
[871.7]
24.00
[609.6]
HIGH
36.32
[922.5]
25.00
[635.0]
LOW
38.31
[973.1]
26.00
[660.4]
MID
40.31
[1023.9]
27.00
[685.8]
HIGH
42.31
[1125.2]
28.00
[711.2]
LOW
44.30
[1074.7]
29.00
[736.6]
MID
46.30
[1176.0]
30.00
[762.0]
HIGH
48.30
[1226.8]
31.00
[787.4]
6.30
160
DIMENSIONS IN BRACKETS ARE MILLIMETERS.
PIPE DIAMETER (DIM. "A") SHOWN WITHOUT CLEARANCE.
WEIGHT = 10lb. [4.5kg]
37
Low Clearance Split Frame, Models 204-1420
Super Extended Beveling Slide, 60-438-00
See 60-437-00 parting slide drawing
on previous page for slide travel and
diameter/radius dimensions.
-TABLEMODEL
LSCF 1824
LSCF 2228
LSCF 2632
LSCF 3036
LSCF 3642
LSCF 4248
DIM. "B"
RADIAL
CLEARANCE
POSITION
DIM. "A"
PIPE
DIAMETER
LOW
20.35
[516.9]
17.00
[431.8]
MID
22.35
[567.7]
18.00
[457.2]
HIGH
24.35
[618.5]
19.00
[482.6]
LOW
24.34
[618.2]
19.00
[482.6]
MID
26.34
[669.0]
20.00
[508.0]
HIGH
28.34
[719.8]
21.00
[533.4]
LOW
28.33
[719.6]
21.00
[533.4]
MID
30.33
[770.4]
22.00
[558.8]
HIGH
32.33
[821.2]
23.00
[584.2]
LOW
32.32
[820.9]
23.00
[584.2]
MID
34.32
[871.7]
24.00
[609.6]
HIGH
36.32
[922.5]
25.00
[635.0]
LOW
38.31
[973.1]
26.00
[660.4]
MID
40.31
[1023.9]
27.00
[685.8]
HIGH
42.31
[1125.2]
28.00
[711.2]
LOW
44.30
[1074.7]
29.00
[736.6]
MID
46.30
[1176.0]
30.00
[762.0]
HIGH
48.30
[1226.8]
31.00
[787.4]
DIMENSIONS IN BRACKETS ARE MILLIMETERS.
PIPE DIAMETER (DIM. "A") SHOWN WITHOUT CLEARANCE.
WEIGHT = 10lb. [4.5kg]
7.05
179.0
3.54
90.0
2.23
56.6
1.16
29.5
7.80
198.0
1.50
38.1
.31
7.9
.31
7.9
COVER TOOL SLIDE (H.D.)
60-194-00
COVER H.D. DBL. BEVEL
60-214-00
.99
25.1
.51
13.0
.125
3.18
1.61
40.8
.86
21.7
3.11
78.9
2.50
63.6
4.00
101.7
5.00
127.1
5.73
145.6
6.67
169.5
38
7.42
188.5
7.80
198.0
Chapter 3, Introduction to the Equipment: Operating Envelope
Univeral Counterbore Slide, 60-405-UC
3.86
98.0
3.56
90.5
7.61
193.3
7.56
192.0
7.57
192.3
60-416-00
OR
60-438-00
60-000-04
THRU
60-000-48
2.19 MAX. THICKNESS
55.5
7.69
195.4
PARTING
LINE
1.13 MAX. DEPTH
28.7
39
Low Clearance Split Frame, Models 204-1420
Worm Gear Slides, 60-430-01/60-430-02
2.35 TRAVEL
59.7
-TABLEMODEL
POSITION
DIM. "A"
PIPE
DIAMETER
LOW
20.38
[517.6]
18.48
[469.3]
MID
24.38
[619.2]
20.48
[520.1]
LOW
24.38
[619.2]
20.48
[520.1]
MID
28.38
[720.8]
22.48
[570.9]
LOW
28.38
[720.8]
22.48
[570.9]
MID
32.38
[822.4]
24.48
[621.7]
LOW
32.38
[822.4]
24.48
[621.7]
MID
36.38
[924.0]
26.48
[672.5]
LOW
38.37
[974.5]
27.48
[697.9]
MID
42.31
[1074.7]
29.48
[748.7]
LOW
44.29
[1125.0]
30.48
[774.1]
MID
48.25
[1225.5]
32.48
[824.9]
LSCF 1824
LSCF 2228
LSCF 2632
LSCF 3036
LSCF 3642
LSCF 4248
DIM. "B"
RADIAL
CLEARANCE
"A"
"B"
DIMENSIONS IN BRACKETS ARE MILLIMETERS.
PIPE DIAMETER (DIM. "A") SHOWN WITHOUT CLEARANCE.
6.98
177.4
7.10
180.3
5.23
132.8
5.82
147.9
BEVEL TOOL HOLDER
(60-312-00)
PARTING TOOL HOLDER-HIGH
(60-313-01)
.99
25.1
.51
13.0
.28
7.0
.76
19.2
2.32
58.9
3.59
91.3
40
1.72
43.8
3.48
88.4
Chapter 3, Introduction to the Equipment: Operating Envelope
Front Drive Pinion Assembly, 60-425-04
-TABLEMODEL
DIM. "A"
LCSF1824
21.20
[538.5]
LCSF2228
23.20
[589.3]
LCSF2632
25.20
[640.1]
LCSF3036
27.20
[690.9]
LCSF3642
30.20
[767.1]
LCSF4248
33.20
[843.3]
DIMENSIONS IN BRACKETS ARE MILLIMETERS.
WEIGHT = 8lb. [4kg]
3.22
81.8
1.11
28.2
5.00
127.0
DRIVE
INPUT
"A"
DRIVE CL
41
Low Clearance Split Frame, Models 204-1420
1.5 HP Right-Angle Air Drive, 60-423-00
2.49
63.3
2.64
67.1
.50 SQ
12.7
A
12.76
324.0
CL OF HANDLE
SPEED
CONTROL
A
A
60° TYP
R15.75
400.0
OILER
2.84
72.1
4.00
101.6
1.65
41.9
2.47
62.7
A
R23.75 REF
603.3
DIMENSIONS IN BRACKETS ARE MILLIMETERS
SPEED CONTROL AND OILER CAN BE RELOCATED FOR SPACE CONSTRAINTS
2.5 HP Right-Angle Air Drive, 60-423-01
2.49
63.3
3.20
81.2
16.36 A
415.6
CL OF HANDLE
A
A
OILER
R19.25
489.0
SPEED
CONTROL
2.88
73.1
.50 SQ
12.7
60° TYP
4.00
101.6
1.69
42.9
3.00
76.2
A
R27.25 REF
692.2
DIMENSIONS IN BRACKETS ARE MILLIMETERS
SPEED CONTROL AND OILER CAN BE RELOCATED FOR SPACE CONSTRAINTS
42
Chapter 3, Introduction to the Equipment: Operating Envelope
2.5 HP Right-Angle Reversible Air Drive, 60-4010-01
2.49
63.3
3.20
81.2
14.92
379.0
CL OF HANDLE
OILER
SPEED CONTROL
2.81
71.4
R18.08
459.2
60° TYP.
4.00
101.6
1.63
41.3
3.00
76.2
R26.57
675.0
DIMENSIONS IN BRACKETS ARE MILLIMETERS
43
Low Clearance Split Frame, Models 204-1420
Hydraulic Drive, 60-424-02
FLOW OUT
WEIGHT: 25.4 lbs [11.5 kg]
MUST ATTACH MOTOR MOUNT TO PINION HOUSING
PRIOR TO MOUNTING HYDRAULIC MOTOR.
MAXIMUM FLOW: 15 GPM [57 LPM]
PRESSURE: UP TO 2000 PSI [138 BAR]
FLOW IN
1/2 NPT
1/2 NPT
PERFORMANCE DATA
11.631
295.4
8.231
209.1
3.934
99.9
FLOW
GPM [LPM]
2 [7.6]
4 [15.1]
6 [22.7]
8 [30.3]
10 [37.9]
12 [45.4]
14 [ 53.0]
15 [56.8]
RPM
47
94
141
188
235
282
330
353
4.022
102.2
3.125
79.4
ROTATION
1.838
46.7
.423
10.7
.500
12.7
6.688
169.9
INCREASE &
DECREASE FLOW KNOB
7.956
202.1
44
R3.705
94.1
SPRING RETURN OPERATOR
Chapter 4, Assembly, Disassembly, and Storage
Chapter 4
Assembly, Disassembly, and
Storage
Machine Disassembly for Storage
These instructions assume the LCSF machine has been dis­connected from the power source and
removed from the workpiece, as described in Chapter 5.
1.
Remove the drive assembly (pneumatic or hydraulic) from the LCSF.
2.
Retract the tool slides. It is not necessary to remove the standard tool slides to store the
machine.
3.
Clean the machine of debris such as metal chips and excess coolant.
4.
Split the machine halves and examine the bearing raceway for metal chips.
Figure 4-1. Check the bearing raceway for chips and clean it if necessary.
5.
Apply two drops of Wachs way oil (60-1184-00) to the felt wiper before storing the machine.
E.H. Wachs
Part No. 60-MAN-07, Rev. C45
Low Clearance Split Frame, Models 204-1420
Storage/Shipping Cases
LCSF models 1824 through 4248 are stored and shipped in steel cases. The LCSF is separated into
halves and mounted to brackets inside the case for secure storage. The cases have sheet-metal
compartments for all components and accessories.
Mounting
brackets
Figure 4-2. The LCSF is secured in its case with 2 mounting brackets.
Figure 4-3. To take the LCSF out of the case, remove the screws holding the brackets to the
machine (left), then remove the brackets by taking out the screws attaching them to the case
(right).
IMPORTANT
Remove the brackets before lifting the LCSF out of the case, to avoid damaging them.
46
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 4, Assembly, Disassembly, and Storage: Storage Guidelines
Storage Guidelines
• Clean the machine by wiping off dirt, debris, and accu­mulated oil or grease.
• Put oil in the air motor oiler, and operate the motor for a few seconds to lubricate its internal
components.
• Lubricate the machine according to the instructions in Chapter 6.
• Spray or wipe a light coating of anti-corrosion lubricant on non-finished, non-painted surfaces.
• Put the machine in its storage case, with all components stored in their compartments.
• Secure large-range LCSFs in their cases using both mounting brackets.
• If possible, keep the storage case indoors and away from moisture.
E.H. Wachs
Part No. 60-MAN-07, Rev. C47
Low Clearance Split Frame, Models 204-1420
48
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions
Chapter 5
Operating Instructions
Planning the Operation
It is important to begin each project by visually inspecting the worksite. Important information can
be gathered at this time to aid in the setup of the machine tool. The following items should be
considered when doing this review:
•
•
•
•
•
Work space constraints
Proper scaffolding to support equipment and workers
Machine operating clearances
Power requirements to run equipment
Containment of cutting debris /coolant during the oper­ation
In order to perform machine set-up, be sure to take the fol­lowing measurements:
• Radial clearance around the pipe.
• Axial clearances end to end.
• Verify the pipe schedule / size.
This information will help to determine if clamp pads will be required, what tool slides will be
needed to perform the operation, and what tooling is necessary to complete the cut.
See the drawings at the end of Chapter 3 for machine dimensions of all LCSF models. The dimensions in the drawings will allow you to plan how to install the machine for the operating environment.
E.H. Wachs Part No. 60-MAN-07, Rev. C49
Low Clearance Split Frame, Models 204-1420
Figure 5-1. Measure the radial clearance around the pipe surface.
Figure 5-2. Measure the axial clearance along the planned work area on the pipe.
Verify the actual diameter of the pipe. If you cannot mea­sure the diameter directly (for instance, an
in-line pipe with no open end), measure the circumference and divide by 3.14 (pi).
Example:
40.0” circumference / 3.14 = 12.74” diameter
50
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Planning the Operation
Figure 5-3. Verify the pipe circumference by measur­ing.
Tool Selection
This section describes the features of each type of tooling, and explains the factors to consider
when selecting specific tools for a given application.
When selecting tooling, you will typically want to use the shortest tool that will accomplish the
operation you’re per­forming. A shorter effective tool length (the distance between the tool holder
and the cutting surface) increases rigidity, reducing vibration or chatter during cutting. Factors that
affect the required tool length are the following:
• The difference in size between the LCSF machine and the pipe. Cutting performance is usually
best with the smallest LCSF that will fit on the pipe.
• The mounting position of the slide on the LCSF (for slides with multiple positions). The slide
should be as close as possible to the pipe O.D.
• The thickness of the pipe wall. A longer tool is required for heavy-wall pipe, to reach the I.D.
(Cutting heavy-wall pipe makes using the correct LCSF size and slide position even more
important.)
It is possible to reduce the effective tool length of a longer tool by mounting it farther back in the
tool holder, so that it extends behind the slide. However, this is not recommended for safety reasons. Having tools extend beyond the diameter of the machine is hazardous to the operator.
Refer to the tooling tables in Chapter 9 and operating enve­lope drawings in Chapter 3.
Parting-Only Operation
NOTE
Standard LCSF beveling slides are also referred to as “parting/beveling slides”,
since the beveling tool holder is designed so that it can hold a parting tool instead.
(Part­ing slide tool holders can only hold parting tools.)
E.H. Wachs
Part No. 60-MAN-07, Rev. C51
Low Clearance Split Frame, Models 204-1420
For a parting (straight cut-off) operation, you will use 2 identical parting tools, one in in the parting
slide and one in the beveling slide. The tool holders are designed with a part­ing offset, so the tools
cut a wider groove than the thickness of each tool. This prevents the tools from jamming in the
groove and breaking off, or stalling the machine.
Standard parting blades are 3/16” thick, and are available in a variety of lengths. You can use solid
high speed steel blades, or insert holders with carbide inserts. For heavier wall applications, 1/4”
tools are available. See the tooling tables in Chapter 9 for available parting tools.
Pipe
O.D.
Pipe
I.D.
Cut-off
line
Parting
tools
Parting offset
Figure 5-4. The drawing illustrates the parting opera­tion, with two offset parting tools. The
parting offset distance is built into the parting and parting/beveling tool holders.
Parting/O.D. Beveling Operation
For a parting/beveling operation, you will use a parting tool in the parting slide, and a beveling tool
with the desired bevel angle in the beveling slide.
Beveling tools are made with the desired form (angle) built into the cutting edge of the tool. The
tool feeds radially into the end of the pipe. This method is used mainly for thin wall pipe up to 1
inch. For heavier-wall pipe, single-point bevel­ing is typically required; see “Single-Point Beveling” below.
Standard beveling tools are available with single angles or compound angles.
•
•
•
•
52
30° single angle
37.5° single angle
10° x 37.5° compound angle
10° x 30° compound angle
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Planning the Operation
Form tool beveling is fast on thinner wall pipe, and is easier to set up than single-point. However, it
can have the follow­ing disadvantages:
• there are a limited number of designs unless tools are specially made
• it requires cutting fluid to extend tool life
• it has limitations on heavy wall pipe; the maximum wall thickness that can be form tool beveled with a 10° x 37.5° form tool is 1-1/4 inch
• it machines a larger surface area, thus requiring a slower r.p.m. and maximun horsepower.
See the tooling tables in Chapter 9 for available beveling tools.
Figure 5-5. Standard form Tools: 10° x 37.5° Com­pound Angle (top), and 37.5° Single Angle
(bottom)
E.H. Wachs
Part No. 60-MAN-07, Rev. C53
Low Clearance Split Frame, Models 204-1420
Parting
tool
Land (if
required)
Pipe
O.D.
Pipe
I.D.
Cut-off
line
Beveling
tool
Figure 5-6. The drawing illustrates the parting/bevel­ing operation.
O.D. Beveling-Only Operation
If you are only beveling a pipe end that has already been cut off, use a beveling tool in the parting/
beveling slide. Leave the parting tool slide empty.
Land (if
required)
Pipe
O.D.
Pipe
I.D.
Beveling
tool
Figure 5-7. The drawing illustrates the O.D. bevel operation.
54
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Planning the Operation
Single-Point Beveling
Single-point beveling is performed on thick-walled pipes, where the cutting surface is too wide for
a form tool to work effectively. Only the tip of the tool cuts; the tool feed is in two dimensions to
follow the profile of the desired bevel.
Single-point beveling with the LCSF is performed using the bridge slide accessory, with a standard
single-point tool holder and insert. See the Bridge Slide Accessory for Low-Clearance Split Frame
User’s Manual for instructions on beveling with the bridge slide.
Operating Envelopes
The drawings at the end of Chapter 3 illustrate the operating envelope for the available combinations of LCSF machines and tool slides.
In the table on each drawing, find the row for your LCSF model. The DIM “A” DIAMETER column
indicates the maxi­mum pipe diameter for the given LCSF machine and slide combination. (Note
that the maximum pipe diameter is sometimes a little more than the nominal LCSF size.) Where
multiple slide mounting positions are available, there is a separate row with dimensions for each
position.
Extended Slides (60-415-00/60-416-00)
Parting slide 60-415-00 and beveling slide 60-416-00 are optional for LCSF models 1824 (24 inch)
through 4248 (48 inch). The drawings and tables in Chapter 3 illustrate the operating envelopes for
all slides.
Super Extended Slides (60-437-00/60-438-00)
Parting slide 60-437-00 and beveling slide 60-438-00 are the standard slides for LCSF models
1824 through 4248. The drawings and tables in Chapter 3 illustrate the operating envelopes for all
slides.
These slides have three installation positions on the LCSF, indicated in the tables as LOW, MEDIUM,
and HIGH. Choose the lowest slide position that will not collide with the pipe surface. This minimizes the extended length of the tool, increasing rigidity of the cutting system.
Setting the position is described in the section “Install Tool Slides and Tooling”, later in this
chapter.
E.H. Wachs
Part No. 60-MAN-07, Rev. C55
Low Clearance Split Frame, Models 204-1420
Lifting and Rigging the LCSF
WARNING
All LCSF models 1824 and larger are too heavy to be lifted safely by one person. (See weight
charts in Chapter 2.) Always use a lifting device to lift the large-range LCSF.
Model 1824 through 4248 LCSFs have 4 threaded holes (2 on each half of the stationary ring) for
lifting eyes. Two lift eyes are provided with the machine.
To lift the entire machine (assembled ring), install the lift eyes in two adjacent threaded holes.
To lift one half of the machine (separated ring), install the lift eyes in both holes of the half you are
lifting.
• Do not lift the ring half using only one lift eye.
• Make sure the alignment pin is installed through the rotating and stationary ring.
Figure 5-8. Lift the assembled machine as shown.
1.
56
Lift one half of the machine out of the case.
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Lifting and Rigging the LCSF
Figure 5-9. Use a lifting device to lift each half of the machine out of the storage case.
2.
Lay the ring half on the floor or a suitable work sur­face.
Figure 5-10. Lay the ring half on the work surface.
E.H. Wachs
Part No. 60-MAN-07, Rev. C57
Low Clearance Split Frame, Models 204-1420
3.
Assemble the halves of the ring.
Figure 5-11. Assemble the machine on the floor for use on an open-ended pipe.
4.
To install the machine on an inline pipe, use a lift bar to pick up the machine as shown.
Figure 5-12. Assemble the ring halves around the pipe as shown.
58
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Setting Up the LCSF
5.
Push the machine halves together and tighten the screws.
Figure 5-13. Assemble the halves of the machine around the pipe.
Setting Up the LCSF
Clamp Leg Set-Up
1.
Measure the O.D. of the pipe to be machined. (If nec­essary, measure the circumference and
divide by 3.14 to get the diameter.)
2.
In the Clamp Pad Extension Charts on the following pages, find the column for your LCSF
model.
NOTE
If your pipe O.D. is within the MAX/MIN range of 2 leg sets, it is generally better to
select the longer legs. However, shorter legs may be an advantage if the pipe is out
of round or if the work environ­ment has limited clearance for mounting the LCSF.
3.
Find the MAX/MIN range that includes the diameter you measured in Step 1. Select the
corresponding leg set in the table row. All legs have their part numbers and size range
stamped on them.
Example: You have a model 1824 LCSF, and the pipe O.D. is 20.5”. You need to use the 1-1/2”
leg extension set, 60-408-15.
E.H. Wachs
Part No. 60-MAN-07, Rev. C59
Low Clearance Split Frame, Models 204-1420
4.
Install the 4 legs in the set onto the clamp pads of the LCSF. The legs have captivated screws.
Tighten the screws securely.
5.
Make sure the legs are fully retracted by turning the clamping screws counter-clockwise until
they stop. The clamp screws require a 3/8” hex wrench.
PART NUMBER AND RANGE
Figure 5-14. Install the legs onto the clamp pads.
60
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Setting Up the LCSF
Table 1: CLAMP PAD EXTENSION CHART: LCSF 1824-3036 (18”-36”)
LCSF 1824
CLAMPING RANGE
LCSF 2228
LCSF 2632
LCSF 3036
INCH
MM
INCH
MM
INCH
MM
INCH
MM
WITH NO
EXTENSION
MAX
MIN
24.50
23.01
622.3
584.4
28.50
27.01
669.3
632.1
32.50
31.01
825.5
787.5
36.50
35.00
927.1
889.1
60-408-05
1/2” EXT. SET
MAX
MIN
23.47
22.01
596.2
558.9
27.47
26.01
697.8
660.5
31.47
30.00
799.3
762.1
35.47
34.00
900.9
863.7
60-408-07
3/4” EXT. SET
MAX
MIN
22.97
21.51
583.5
546.3
26.97
25.51
685.1
647.8
30.97
29.50
786.6
749.4
34.97
33.50
888.2
851.0
60-408-10
1” EXT. SET
MAX
MIN
22.47
21.01
570.8
533.6
26.47
25.01
672.4
635.1
30.47
29.00
773.9
736.7
34.47
33.00
875.5
838.3
60-408-15
1-1/2” EXT. SET
MAX
MIN
21.47
20.01
545.4
508.2
25.47
24.01
647.0
609.7
29.47
28.00
748.5
711.3
33.47
32.00
850.1
812.9
60-408-20
2” EXT. SET
MAX
MIN
20.47
19.01
520.0
482.8
24.47
23.01
621.6
584.3
28.47
27.00
723.1
685.9
32.47
31.00
824.7
787.5
60-408-25
2-1/2” EXT. SET
MAX
MIN
19.47
18.01
494.6
457.4
23.47
22.01
596.2
558.9
27.47
26.01
697.8
660.5
31.47
30.00
799.3
762.1
60-408-28
2.8” EXT. SET
MAX
MIN
18.97
17.51
481.9
444.7
22.97
21.51
583.5
546.3
26.97
25.51
685.1
647.8
30.97
29.50
786.6
749.4
60-408-30
3” EXT. SET
MAX
MIN
18.47
17.01
469.2
432.0
22.47
21.01
570.8
533.6
26.47
25.01
672.4
635.1
30.47
29.00
773.9
736.7
60-408-31
3-1/8” EXT. SET
MAX
MIN
18.21
16.75
462.6
425.4
22.21
20.75
564.2
527.0
26.21
24.75
665.8
628.5
30.21
28.74
767.3
730.1
60-408-35
3-1/2” EXT. SET
MAX
MIN
17.47
16.01
443.8
406.6
21.47
20.01
545.4
508.2
25.47
24.01
647.0
609.7
29.47
28.00
748.5
711.3
60-408-40
4” EXT. SET
MAX
MIN
16.47
15.01
418.4
381.2
20.47
19.01
520.0
482.8
24.47
23.01
621.6
584.3
28.47
27.00
723.1
685.9
E.H. Wachs Part No. 60-MAN-07, Rev. C61
Low Clearance Split Frame, Models 204-1420
Table 2: CLAMP PAD EXTENSION CHART:
LCSF 3339-4248 (39”-48”)
LCSF 3339
CLAMPING RANGE
LCSF 3642
LCSF 4248
INCH
MM
INCH
MM
INCH
MM
WITH NO
EXTENSION
MAX
MIN
39.50
37.00
1003.1
939.8
42.50
41.00
1079.5
1041.5
48.50
47.00
1231.9
1193.9
60-408-05
1/2” EXT. SET
MAX
MIN
38.47
37.00
977.1
939.9
41.47
40.00
1053.3
1016.1
47.47
46.00
1205.7
1168.5
60-408-07
3/4” EXT. SET
MAX
MIN
37.97
36.50
964.4
927.2
40.97
39.50
1040.6
1003.4
46.97
45.50
1193.0
1155.8
60-408-10
1” EXT. SET
MAX
MIN
37.47
36.00
951.7
914.5
40.47
39.00
1027.9
990.7
46.47
45.00
1180.3
1143.1
60-408-15
MAX
1-1/2” EXT. SET MIN
36.47
35.00
926.3
889.1
39.47
38.00
1002.5
965.3
45.47
44.00
1154.9
1117.7
MAX
MIN
35.47
34.00
900.9
863.7
38.47
37.00
977.1
939.9
44.47
43.00
1129.5
1092.3
60-408-25
MAX
2-1/2” EXT. SET MIN
34.47
33.00
875.5
838.3
37.47
36.00
951.7
914.5
43.47
42.00
1104.1
1066.9
60-408-20
2” EXT. SET
60-408-28
2.8” EXT. SET
MAX
MIN
33.97
32.50
862.8
825.6
36.97
35.50
939.0
901.8
42.97
41.50
1091.4
1054.2
60-408-30
3” EXT. SET
MAX
MIN
33.47
32.00
850.1
812.9
36.47
35.00
926.3
889.1
42.47
41.00
1078.7
1041.5
60-408-31
MAX
3-1/8” EXT. SET MIN
33.21
31.74
843.5
806.3
36.21
34.74
919.7
882.5
42.21
40.74
1072.1
1034.9
60-408-35
MAX
3-1/2” EXT. SET MIN
32.47
31.00
824.7
787.5
35.47
34.00
900.9
863.7
41.47
40.00
1053.3
1016.1
31.47
30.00
799.3
762.1
34.47
33.00
875.5
838.3
40.47
39.00
1027.9
990.7
60-408-40
4” EXT. SET
MAX
MIN
Set-Up for In-line Pipe
To mount the LCSF on in-line pipe, you will have to split the machine into halves by removing the
frame locking screws at the split points.
1.
Make sure the two frame locking pins are installed to keep the rotating and stationary rings
together.
62
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Setting Up the LCSF
Figure 5-15. Insert the frame locking pins through the machine.
2.
Lay machine on a secure surface.
3.
Using a 1/4” hex wrench, loosen the 6 captivated screws, four in the stationary frame and two
in the rotating frame.
Figure 5-16. Loosen the captivated screws to separate the halves.
E.H. Wachs
Part No. 60-MAN-07, Rev. C63
Low Clearance Split Frame, Models 204-1420
4.
Pull the two halves of the machine apart at the split lines. Use an equal amount of force on
each side to prevent the halves from binding.
NOTE
Use reasonable force to sep­arate the halves. If you can’t pull them apart, check to
make sure you have ade­quately loosened the 6 capti­vated screws.
Figure 5-17. Pull the machine apart at the split lines. Use equal force on each side to separate the halves without binding.
NOTE
Two people will be required to perform the set-up.
5.
64
With the halves split, place the upper half (with the pinion housing) on top of the workpiece.
Make sure you are attaching the stationary frame to a section of the pipe that will
support its weight. Do not clamp the machine onto a pipe section or end that will “fall
off” after cutting.
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Setting Up the LCSF
Figure 5-18. On horizontal pipe, set the side of the machine with the pinion housing on top of
the pipe.
6.
Lift the bottom half of the machine into place under the top half. Align the dowel pin holes
with the dowel pins to ensure proper fit, and press the halves together.
NOTE
To install the machine on ver­tical pipe, you will need two people to support both
halves, or a stable support beneath the machine.
Figure 5-19. Fit the halves together on the pipe.
E.H. Wachs
Part No. 60-MAN-07, Rev. C65
Low Clearance Split Frame, Models 204-1420
IMPORTANT
Be sure that all frame locking SHCS are equally tightened before continuing with mount­ing
procedure. Failure to do so may cause damage to drive gears.
7.
Partially tighten one of the frame locking SHCS in the rotating frame. This will secure the
machine while the other bolts are tightened.
8.
Using a 1/4” hex wrench, snug down all of the frame locking screws to bring the split lines
together, then securely tighten the screws.
Figure 5-20. Tighten the frame locking screws.
Set-Up for Open-Ended Pipe
For open-ended workpieces, slide the machine over the pipe end. It is not necessary to split the
machine. Make sure you are attaching the stationary frame to a section of the pipe that will
support its weight. Do not clamp the machine onto a pipe section or end that will “fall off”
after cutting.
Make sure all locking frame screws are tight and detent pins are installed in the machine. Use the
same clamping and positioning procedures as for in-line pipe.
66
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Setting Up the LCSF
Installation on Vertical Pipe
The LCSF can be installed on in-line or open-ended vertical pipe, with the machine in a horizontal
position. Set-up and operating procedures are the same as for horizontal pipe. However, observe
the following guidelines for machining vertical (or other non-horizontal angle) workpieces.
NOTE
For difficult installation envi­ronments, a custom mounting adapter can be provided.
The adapter can be bolted or welded to the workpiece to hold the LCSF in place for
installation. Contact E.H. Wachs customer support to discuss requirements.
• Make sure the machine is adequately supported until you tighten the clamp feet securely on the
workpiece.
• Refer to the weight chart in Chapter 2 to determine if multiple operators or a lifting device are
needed to help support the machine.
• The LCSF is easier to handle in a horizontal position when the ring halves are assembled. If
possible, install it as an assembled ring.
• If you need to split the machine to install on in-line pipe, make sure each half is supported until
installation is complete. Two lifting devices may be required, one for each half of the machine.
• Use a scaffolding or other support structure(s) if avail­able. Make sure the LCSF rests stably on
the support.
• When performing a parting operation, make sure the workpiece is securely supported both
above and below the LCSF.
Positioning the Machine for the Cut
1.
With the frame halves securely tightened, move the machine to the cut line position marked
on the pipe.
2.
Using the scale, set your machine 2-1/4” (57 mm) back from the line or punch mark at the
position where you mount the tool slides. (See the cut line identified in the envelope drawings in Chapter 3.)
E.H. Wachs
Part No. 60-MAN-07, Rev. C67
Low Clearance Split Frame, Models 204-1420
Figure 5-21. Measure 2-1/4” back from the punch mark.
Clamp Pad Centering Procedure
NOTE
For easy visualization, we often refer to positions on the LCSF by numbers on a
clock.
1.
68
Starting with the clamp pad nearest the 12 o’clock position, tighten the clamping screw until
the gap at the top and the bottom of the machine are approxi­mately equal.
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Setting Up the LCSF
2.
Snug the clamp pad nearest the 6 o’clock position.
NOTE
Clamp legs are secured with Integrated Captivated Socket Head Cap Screws
(SHCS) to secure themselves to the sta­tionary ring.
Figure 5-22. Tighten the clamping screw until the leg is just snug on the pipe.
3.
Snug the clamping screws nearest the 3 and 9 o’clock positions. At this point the machine is
rough centered and you may begin making the final adjustments.
E.H. Wachs
Part No. 60-MAN-07, Rev. C69
Low Clearance Split Frame, Models 204-1420
NOTE
With the clamping screws snug, you should be able to nudge the LCSF on the pipe.
If necessary, SLIGHTLY loosen the clamp pads at the 6 and 12 o’clock position, or
the 3 and 9 o’clock positions. You can tap on the LCSF with the provided rubber
hammer to nudge it.
4.
Place the short end of the provided square on the pipe with the ruler side against the stationary ring at the 12 o’clock position. Check the LCSF’s squareness to the O.D. of the pipe. If
there is a gap, adjust the machine until the gap is closed.
Figure 5-23. Use the square to make sure the machine is perpendicular to the pipe.
5.
When the LCSF is square to the pipe, check the dis­tance from the slide mounting location on
the machine to the cut line. It should be 2-1/4” (57 mm). If neces­sary, nudge the machine to
adjust the position.
6.
When the LCSF is square and at the correct location, tighten the clamping screws.
7.
Start at the clamp leg nearest the 12 o’clock position. Using a scale, measure the distance
from the surface of the pipe to the inner surface of the LCSF at that location. Write the measurement down.
70
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Setting Up the LCSF
Figure 5-24. Measure the gap at the clamp leg near­est the 12 o-clock position.
8.
Move to the clamp leg 180° opposite the one in the previous step and measure the distance
between the pipe surface and the inner surface of the LCSF. Write this measurement down.
9.
Add the two measurements together. Divide the result by 2. This number is the distance the
LCSF should be from the pipe at both clamp pad locations.
EXAMPLE:
• The distance at the first location is 1.7 inches.
• The distance at the second location is 2.1 inches.
• Add 1.7 to 2.1, then divide by 2. The result is 1.9 inches, which is the desired distanced
between the pipe and LCSF at each location.
10. Using the scale as you make the adjustments, turn the clamp pad screws alternately until you
have the same pipe-to-LCSF distance at both locations.
11. Repeat this procedure at the two clamp leg locations 90° from the first two.
12. Measure at all four locations again. Re-adjust if neces­sary.
13. Remove the frame locking pins and manually rotate the machine a full 360°.
NOTE
You should make a final check for squareness after the clamp pads are tightened
E.H. Wachs
Part No. 60-MAN-07, Rev. C71
Low Clearance Split Frame, Models 204-1420
Figure 5-25. Remove the frame locking pins.
14. If you can’t turn the rotating frame by hand, the clamp legs may be too tight, binding the
machine. One at a time, loosen and then re-snug the clamping screws. Try to rotate the
machine again.
72
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Install Tool Slides and Tooling
Figure 5-26. Rotate the machine by hand.
15. If you still can’t turn the machine, see the section “Bearing Adjustment” in Chapter 7.
Install Tool Slides and Tooling
Standard Slides
The standard slides for LCSF models 1824 through 4248 are the “super extended” parting and
beveling slides (part nos. 60-437-00 and 60-438-00).
On the back of each of the tool slides are pairs of holes for three mounting positions, as shown in
Figure 5-27. Two mounting pins are provided to use in the appropriate hole pair. The hole pairs
represent the three possible mounting positions: high (farthest from machine I.D.), middle, and
low (closest to machine I.D.).
Choose the lowest slide position that will not collide with the pipe surface. (Refer to the operating
envelope drawings in Chapter 3.) This minimizes the extended length of the tool, increasing
rigidity of the cutting system.
1.
Insert the mounting pins in the required holes for the pipe size:
• Use the “high” position if the pipe diameter is less than 2” (25 mm) smaller than the machine
size (for instance, 34.5” pipe with 36 inch LCSF).
• Use the “middle” position if the pipe diameter is 2”-4” (25-51 mm) smaller than the machine
size (for instance, 33” pipe with 36 inch LCSF).
E.H. Wachs
Part No. 60-MAN-07, Rev. C73
Low Clearance Split Frame, Models 204-1420
• Use the “low” position if the pipe diameter is more than 4” (51 mm) smaller than the machine
size (for instance, 31” pipe with 36 inch LCSF).
Low
Middle
High
Figure 5-27. Insert the mounting pins in the slide.
2.
Mount the tool slide to the rotating frame by inserting the pins in the mounting holes at each
slide position. Tighten the four 5/16 -18 SHCS in each slide with the supplied hex key set.
Figure 5-28. Tighten the SHCS on each side of the tool slide.
3.
Using a 3/16” hex wrench, turn the starwheels on both slides clockwise to fully retract the
slides.
74
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Install Tool Slides and Tooling
Extended Slides
You can install the extended slides (60-415-00/60-416-00). When used on model 1824-4248
LCSFs, these slides have only one mounting position.
1.
Mount the tool slides to the rotating frame by inserting the pins in the mounting holes at each
slide position. Tighten the four 5/16 -18 SHCS in each slide with the supplied hex key set.
2.
Using a 3/16” hex wrench, turn the starwheels on both slides clockwise to fully retract the
slides.
Install the Tooling
For a straight cut-off operation, install a parting tool in both the parting and beveling slide. It is
important that you use two parting tools. The tools are offset to prevent binding and stalling of
the machine.
For a parting and bevel operation, install a parting tool and a beveling tool. See the information in
“Tool Selection” ear­lier in this chapter.
1.
To install parting tools, loosen the 2 tool set screws and the 4 tool cover screws. Insert the
tool as shown in Figure 5-29.
Tool set
screws
Tool
cover
screws
Cutting edge
Figure 5-29. Installing the parting tool with the cut­ting edge in the cutting direction as
shown.
2.
Snug all 4 tool cover screws, then tighten them.
3.
Tighten the 2 tool set screws.
4.
To install a beveling tool, loosen the 2 tool set screws in the tool cover plate, and the set
screw in the side of the tool holder.
E.H. Wachs
Part No. 60-MAN-07, Rev. C75
Low Clearance Split Frame, Models 204-1420
Set screws
Figure 5-30. There are three set screws for beveling tools.
5.
Insert the beveling tool with the cutting edge in the direction of rotation, as shown in Figure
5-31.
Cutting edge
Figure 5-31. Insert the bevel tool in the holder with the cutting edge in the direction of
rotation.
6.
Snug the set screw on the side of the tool holder, then tighten the 2 set screws on the tool
cover. Tighten the side set screw.
7.
Turn the rotating ring by hand to check the tooling clearances. Make sure the tools do not
touch the pipe, and that there is enough slide travel for the tooling to reach the I.D. Refer to
the slide envelope drawings in Chapter 3.
8.
Set the tooling. Bring the parting tool 1/8 inch away from the pipe and the bevel tool 1/8 inch
away from the pipe. Check tool extension and slide travel again, as in the previous step.
76
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Install Tool Slides and Tooling
Figure 5-32. The tip of the parting tool should be about 1/8” (3 mm) from the pipe surface.
Figure 5-33. The tip of the beveling tool should be about 1/8” (3 mm) from the pipe surface.
9.
Rotate the machine manually to make sure the tool clears all the way around the pipe.
E.H. Wachs
Part No. 60-MAN-07, Rev. C77
Low Clearance Split Frame, Models 204-1420
Figure 5-34. Rotate the machine to check tool clear­ances.
Dual Tooling Setup
You can “stack” parting and beveling tools in the beveling slide to prevent tool binding on heavywall pipe. This setup helps clear chips as the cutting groove deepens.
Figure 5-35. You can use a combination of parting and beveling tools in the beveling slide.
1.
78
Install the required parting tool in the parting slide tool holder. Set the cutting tip of the tool
1/16” from the surface of the pipe and tighten the screws in the tool cover.
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Install Tool Slides and Tooling
2.
Install the required beveling tool in the beveling slide tool holder. Set the cutting edge of the
beveling tool 1/16” from the surface of the pipe.
3.
Snug the screws on the beveling tool cover, then securely tighten the screw(s) on the tool
block holding the side of the tool. (Number of screws depends on the slide model.)
4.
Loosen the screws in the beveling tool cover and insert the parting tool on top of the beveling
tool.
Figure 5-36. Insert the tooling as shown with the off­set between the parting blades at 1/16
inch from each other.
5.
Adjust the position of the parting tool in the beveling slide for the desired land thickness. To
increase the land, set the parting tool beyond the tip of the beveling tool. The land thickness
will be 3/32” plus the distance the parting tool extends past the beveling tool.
NOTE
Example: For a 1/4” land, extend the parting tool 5/32” beyond the beveling tool
(3/32” + 5/32” = 1/4”).
6.
Start the tooling with a 1/16 to 1/8 inch gap from the pipe surface and proceed to the installation of the trip assembly.
E.H. Wachs
Part No. 60-MAN-07, Rev. C79
Low Clearance Split Frame, Models 204-1420
Figure 5-37. Set the tip of the parting tool 1/8” (3 mm) from the pipe surface.
Figure 5-38. The photo shows the parting tool 1/8” (3 mm) above the punch mark.
Install the Trip Assembly
Configure the trip assembly for the slide position on the LCSF (low, middle, or high position).
• Attach the trip directly (with no extension blocks) to the LCSF for slides in the low position.
• Attach the trip with one extension block for slides in the middle position.
• Attach the trip with two extension blocks for slides in the high position.
Different length screws are provided for each configuration.
80
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Install Tool Slides and Tooling
Figure 5-39. The trip assembly is provided with 2 extension blocks, and 3 sizes of screws for
the 3 con­figurations (no block, 1 block, or 2 blocks).
1.
Pull out the trip lever swivel pin and remove the lever from the trip assembly.
Figure 5-40. Pull out the pin and remove the trip lever.
2.
If extension blocks are required, align the block(s) with the bottom of the trip mount. Stack
the blocks so that the raised tabs on the top interlock with the slot on the bottom of the adjacent piece.
E.H. Wachs
Part No. 60-MAN-07, Rev. C81
Low Clearance Split Frame, Models 204-1420
Middle slide
position
High slide
position
Figure 5-41. Use the required number of extension blocks for the slide position.
3.
Insert the required screws through the base of the trip mount and the holes in the extension
block(s), as shown above.
4.
Put the trip assembly in place on the stationary ring and tighten the three screws.
Figure 5-42. The trip assembly is shown with 2 exten­sion blocks, corresponding to the slides
in the “high” position.
5.
Put the trip lever in place, with the “fork”in the lever engaged on the trip plunger. Insert the
swivel pin.
6.
Push the trip lever down to disengage the trip.
82
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Install Tool Slides and Tooling
Figure 5-43. Push the trip lever down to lift the trip pin into the disengaged position.
7.
Time the starwheel feed system and take all the backlash out of the feed mechansim.
NOTE
The feed rate for all tool slides is 0.0312” (0.79 mm) per revolution of the star­wheel.
This equals 0.0026” (0.066 mm) per revolution of machine.
• To take the backlash out, turn the starwheel counter-clockwise (direction of feed) until all
backlash is gone and you can feel a slight resistance.
• To time the starwheel, make sure a point of the star is aligned with the machined line
(usually marked in red) on the top of the tool block.
Figure 5-44. Time the starwheel. You can align any point of the wheel with the red line on the
tool block.
E.H. Wachs
Part No. 60-MAN-07, Rev. C83
Low Clearance Split Frame, Models 204-1420
8.
Repeat step 5 for the other slide.
9.
Engage the trip pin by pulling up on the trip lever.
Figure 5-45. Engage the trip pin by pulling up on the paddle lever.
Install the Drive Motor
The air and hydraulic drive motors are provided with adapt­ers to attach to the LCSF pinion housing. See the appropri­ate section below for the drive motor you are using.
NOTE
The drive motor may be placed in several different positions. The motor should be
mounted in a position that allows the operator the easi­est and safest access possi­
ble.
Air Motor
1.
Loosen the two 5/16-18” SHCS located on the back of the pinion housing.
2.
Align two of the bolt holes in the drive motor mount­ing flange with the two SHCSs in the
pinion housing and slip the flange over the SHCS. All air motors use the same style flange.
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Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Install Tool Slides and Tooling
Figure 5-46. Align the bolt holes in the motor flange with the two SHCS in the pinion housing.
NOTE
The square drive shaft on the motor must insert fully into the socket in the pinion
hous­ing. If necessary, turn the rotating frame slightly back and forth by hand until the
drive hex seats itself properly.
3.
Tighten the 2 motor mounting screws to secure the drive motor.
4.
Re-time the starwheel.
5.
Attach the power supply to the drive motor.
Hydraulic Motor
The hydraulic motor is supplied with an adapter to attach to the LCSF pinion housing. First attach
the adapter to the LCSF, then mount the motor on the adapter.
1.
The hydraulic motor is supplied with the adapter attached. Remove the two screws holding
the motor to the adapter.
E.H. Wachs
Part No. 60-MAN-07, Rev. C85
Low Clearance Split Frame, Models 204-1420
Figure 5-47. Remove the hydraulic drive screws to detach the drive motor from the adapter.
2.
Remove the 2 motor mounting screws from the pinion housing and set them aside. The
hydraulic motor adapter includes screws for mounting to the pinion housing.
Figure 5-48. Remove the pinion housing motor mounting screws and store them in a secure
place.
3.
Attach the hydraulic motor adapter to the pinion hous­ing and securely tighten the 2 screws.
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Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Install Tool Slides and Tooling
Figure 5-49. Attach the hydraulic drive adapter to the pinion housing.
Figure 5-50. Tighten the 2 screws holding the hydrau­lic drive adapter to the pinion housing.
4.
Insert the hydraulic motor shaft through the adapter so that the square shaft fits into the
pinion. Turn the motor as required to align the shaft and fully seat the motor flange on the
adapter.
NOTE
The drive shaft fits snugly into the socket in the pinion. You may have to “wiggle” the
drive to insert the shaft into the socket.
E.H. Wachs
Part No. 60-MAN-07, Rev. C87
Low Clearance Split Frame, Models 204-1420
Figure 5-51. Insert the hydraulic drive shaft through the adapter so that the square drive fits
into the pinion socket.
5.
Attach the motor to the adapter using the 2 screws pro­vided. Tighten the screws securely.
Figure 5-52. Tighten the 2 screws holding the drive to the adapter.
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Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Cutting Operation
6.
Connect the hydraulic hoses to the motor as shown. Make sure the pressure and return (tank)
lines are con­nected to the correct fittings.
IMPORTANT
The standard hydraulic hose fittings are female for the pressure side and male for the
return side. Make sure the fittings and connections are correct. Operating the LCSF in
the reverse direction can damage the machine.
Pressure connector
Return connector
Figure 5-53. Connect the hydraulic hoses to the drive as shown.
Cutting Operation
Set up the LCSF, tool slides, and drive motor as described in the previous sections.
WARNING
Failure to support the work­piece and the fall-off piece could result in serious injury and/or
damage to the machine.
If you are doing a severing operation, make sure the work­piece is adequately supported on boths
sides of the cut line. If necessary, use a catch device for the fall-off piece.
1.
Check that power connections (air or hydraulic) to the LCSF are securely attached.
2.
Make sure that tooling is installed correctly and securely.
E.H. Wachs
Part No. 60-MAN-07, Rev. C89
Low Clearance Split Frame, Models 204-1420
3.
Turn on the power (air or hydraulic) at the source.
4.
Set the speed control on the drive motor to the lowest setting. Engage the drive motor on/off
lever to start the machine. If the machine does not start, increase the speed control slightly.
WARNING
Keep clear of moving parts while operating the LCSF.
Faster
Slower
Slower
Faster
Air motor
Hydraulic motor
Figure 5-54. The photos show the speed adjustment controls on the drive motors. Set the
speed control to the minimum before starting the LCSF on a new setup.
NOTE
If the starwheel does not con­tact the trip pin smoothly, stop the machine immediately
and follow starwheel timing proce­dures.
5.
Engage the trip and operate the machine slowly (3-4 RPM) to verify that the trip is turning
the starwheel.
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Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Cutting Operation
Figure 5-55. Pull the trip lever up to engage the trip.
6.
Set the speed control to increase the speed to the desired RPM. Continue machine operation.
The tool slides will advance until the tools begin to cut the workpiece.
Faster
Figure 5-56. Turn the air motor throttle to increase the speed.
7.
Once the tool bits begin to remove material from the workpiece, be sure to apply liberal
amounts of coolant for the duration of the machining process.
E.H. Wachs
Part No. 60-MAN-07, Rev. C91
Low Clearance Split Frame, Models 204-1420
8.
You may need to disengage the trip occasionally to adjust the feed rate or to let chips clear
out of the cut. Push the trip lever down as the machine is rotating, and operate the machine
for 2-3 rotations. Pull the trip lever up to re-engage the trip and continue cutting.
NOTE
Using coolant is strongly rec­ommended to enhance cut­ting and increase tool life. If
worksite requirements pre­vent you from using coolant, you may need to adjust
oper­ating speed, feed rate (using the trip), or tooling.
Figure 5-57. Push the trip lever down to disengage the trip.
9.
If you need to manually clear chips from the cut or the machine, disengage the trip as described above. Then stop the machine before clearing chips.
WARNING
Use a wire brush or a pliers to avoid touching the chips, which can be hot and very sharp.
Wear appropriate gloves for cleaning up chips.
10. When you have finished clearing chips, start the machine without the trip engaged. Operate it
for at least one rotation before engaging the trip.
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Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Counterboring
11. Continue operating the LCSF until the machining operation is complete.
CAUTION
When cutting, never extend the male tool holder of the tool beyond the red line scribed on the tool
slide body.
12. Release the on/off lever to stop the LCSF.
Counterboring
If a counterbore is to be performed, be sure to leave an over­sized land. This will allow for material
removal without vio­lating the land thickness.
Planning the Operation
1.
Determine the amount of material that needs to be machined from the I.D. of the pipe.
Measure the existing pipe I.D. and subtract this value from the “planned” I.D. The difference is the
amount of material that needs to be machined from the existing pipe I.D.
E.H. Wachs
Part No. 60-MAN-07, Rev. C93
Low Clearance Split Frame, Models 204-1420
Figure 5-58. Measure the I.D. of the pipe.
Example:
Figure 5-59. The width of the counterbore is ½ of the difference between the existing I.D.
and planned I.D.
94
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Counterboring
Planned I.D. dimension
16.85”
Existing I.D. dimension
16.55”
Difference0.30”
Divide by 2
0.15” Per side
Thus, the existing diameter needs to be counterbored to increase the existing I.D. by 0.30”, or
0.15” per side.
2.
Determine the thickness that can be removed with each pass.
As a rule of thumb, you can cut about 0.060” on most pipe materials without causing excess
machine vibration, damag­ing the tooling, or stalling the machine. Depending on the material you
are cutting, you may need to decrease this thickness. On some materials, you may be able to cut a
thicker pass, but in general you should not exceed more than about half the width of the tool taper.
3.
Determine the depth for the first counterbore pass.
Because the counterbore tool is tapered, you must start out making longer passes than the desired
counterbore depth. Each pass is shorter than the previous one, until the final pass completes the
I.D. of the required straight bore to the desired depth.
Figure 5-60. In this example, three passes with the counterbore tool are required to achieve
the desired straight counterbore depth.
In Figure 5-61, the planned counterbore depth is 0.375” of straight bore. (This is a value that is
specified in the weld prep detail.) A general rule of thumb is the counterbore depth is just deep
enough to locate the transition of the straight bore/taper intersection out of the weld x-ray zone, or
behind the end of the weld prep as shown in Figure 5-61.
E.H. Wachs
Part No. 60-MAN-07, Rev. C95
Low Clearance Split Frame, Models 204-1420
Figure 5-61. Counterbore depth
From Step 1, 0.15” needs to be removed from the wall thickness. If the taper on the counterbore
tool bit is 4:1, we can determine the depth of the first counterbore pass:
Figure 5-62. The depth of the tapered part of the bore is a function of the tool taper and the
counterbore thickness.
0.15” x 4 (taper ratio) = 0.60” (length of the tapered portion)
+ 0.375” (length of straight bore)
= 0.975” (Total counterbore depth including the lead out angle)
COUNTERBORE PLANNING FORMULA
The knowns:
Angle = 14 1/2° or 4 to 1 taper ratio
Material per pass .050
Total material removed of .150
96
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Counterboring
Need to find how deep to bore, or c of our angle:
Side b = .150
Angle B = 14 1/2°
Formula to find Side c:
c = b x cot. B
(cot. B = 3.8667)
c = .150 x 3.8667 is .580
To calculate desired amount to be removed:
c = .050 x 3.8667
c = .193
First Pass Depth
.580 - .193 = .387 + .375 = .762
Second Pass Depth
.762 - .193 = .569
Third Pass Depth
.569 - .193 = .376
E.H. Wachs
Part No. 60-MAN-07, Rev. C97
Low Clearance Split Frame, Models 204-1420
Counterbore Set-up
1.
Remove the tooling from the slides. Clean, then place the tooling in a secure location
2.
Remove the front cap from the bevel slide only.
3.
Attach the counterbore slide using the four 5/16” SHCS to the bevel slide.
Figure 5-63. Attach the counterbore slide.
4.
Secure the final 5/16” SHCS on the side of the bevel slide to complete installation.
Figure 5-64. Secure the SCHS on the side of the bevel slide.
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Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Counterboring
5.
Install the counterbore bit into the tool slot and secure with screws.
Figure 5-65. Install the counterbore tool into the slot.
Cutting the Counterbore
1.
Feed the cutting tool into the pipe by turning the axial feed handle counter clockwise until the
flat of the tool is inside the pipe face.
Figure 5-66. Turn the feed handle counter clockwise.
E.H. Wachs
Part No. 60-MAN-07, Rev. C99
Low Clearance Split Frame, Models 204-1420
2.
Turn the radial feed handle counterclockwise until the cutting tool lightly touches the pipe
wall.
Figure 5-67. Turn the radial feed handle until the tool lightly touches the pipe.
3.
Adjust the counterbore slide for the first cut by turning the radial toolslide feed screw clockwise (each revolu­tion is .0312”).
NOTE
Turn the axial feed knob clockwise to move the tool away from the pipe face.
Figure 5-68. Adjust the counterbore slide by turning the radial feed screw clockwise.
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Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Counterboring
Figure 5-69. Axial (.0312) and radial (.0784) adjust­ment per revolution.
Figure 5-70. First pass of the counterbore tool
4.
Engage air motor and set the speed at approximately 6 - 8 rpm.
NOTE
The incremental decal on the radial feed handle is not the radial feed depth indica­tor.
Each line on the decal irepresents a .020” cut on the overall I.D.
5.
Hold the axial feed handle as the machine rotates. This feeds the tool into the pipe.
E.H. Wachs
Part No. 60-MAN-07, Rev. C101
Low Clearance Split Frame, Models 204-1420
6.
Once the tool begins to cut, release the axial feed han­dle. Holding the feed handle for approximately 1/4 turn per revolution, will feed the tool into the pipe gradually. The longer the
handle is held, the greater the feed rate.
7.
Use the depth gauge on the support block monitor to observe the depth of the counterboring
operation. As soon as the desired depth is reached, stop the machine.
CAUTION
Cutting chips are VERY sharp. DO NOT touch them with bare hands. Serious injury could
result.
Figure 5-71. Depth gauge on the support block.
8.
Measure the I.D. of the pipe. If the desired I.D. has been attained, remove the counterbore
assembly. If the I.D. measurement required has not been achieved, repeat steps 3 - 9.
LCSF Cutting Accessories
The following LCSF accessories are provided with their own user’s manuals for setup and operation:
• Bridge Slide Accessory for Low Clearance Split Frame (manual part no. 60-MAN-03).
• Large LCSF O.D. Tracking Slide —for LCSF models 1824 to 4248 (manual part no. 60-MAN04).
• External-Internal Casing Cutter (EICC) (manual part no. 60-MAN-05).
102
Part No. 60-MAN-07, 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 5-72. 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. 60-MAN-07, Rev. C103
Low Clearance Split Frame, Models 204-1420
Control Panel Reference
Figure 5-73 illustrates and describes the features of the ACM control panel.
Reset button (required
at startup, after emer­
gency stop, or after loss
of input pressure)
ON/OFF lockout
(shown in unlocked
position)
Pendant enable switch
(shown in ON position)
ON/OFF valve
(shown in OFF
position)
Emergency off switch
Output pressure gauge
Pressure regulator
Figure 5-73. The photo illustrates the ACM controls.
104
Part No. 60-MAN-07, 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 5-74. Position the ACM at a convenient dis­tance from the split frame machine.
E.H. Wachs
Part No. 60-MAN-07, Rev. C105
Low Clearance Split Frame, Models 204-1420
Operating the ACM
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 118.
Before connecting the ACM, the control panel should be in the pre-operation state, as shown in
Figure 5-75.
NOTE
An instruction sticker for set­ting up and operating the ACM is attached to the inside
of the case lid.
ACM Operation Sticker (part no. 60-1296-00).
106
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Remote Operation with the SF ACM
Figure 5-75. The ACM controls should be in the pre-operation state, as shown, before
connecting the air lines.
1.
Make sure the air supply is turned off at the source.
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.
2.
Attach the air supply line to the input connector of the ACM.
Figure 5-76. 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.
E.H. Wachs
Part No. 60-MAN-07, Rev. C107
Low Clearance Split Frame, Models 204-1420
CAUTION
Do not allow the hoses to contact moving parts. This could damage the hoses or components of the split frame.
Figure 5-77. Route the hoses so they do not touch moving parts of the 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).
108
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Remote Operation with the SF ACM
Figure 5-78. 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 5-79. Press in the lock-out tab to enable the ON/OFF valve.
8.
Turn the ON/OFF valve counter-clockwise to the ON position.
E.H. Wachs
Part No. 60-MAN-07, Rev. C109
Low Clearance Split Frame, Models 204-1420
Figure 5-80. Turn the ON/OFF valve counter-clock­wise to the ON position (shown in OFF
position).
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.
9.
Press the Reset button on the control panel.
Figure 5-81. 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.
110
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Remote Operation with the SF ACM
Figure 5-82. Turn the Remote Enable switch on to allow operation using the handheld
pendant.
11. The handheld pendant will now operate the split frame machine.
CAUTION
Keep the pendant and its hoses away from moving parts. Allowing hoses to con­tact the
equipment could damage them.
Figure 5-83. Squeeze the trigger on the handheld pen­dant to operate the machine.
E.H. Wachs
Part No. 60-MAN-07, Rev. C111
Low Clearance Split Frame, Models 204-1420
Adjusting the Output Pressure
Use the pressure regulator on the control panel to adjust the output pressure to 90 psi (6.2 bar).
NOTE
The maximum output pres­sure is 116 psi (8.0 bar).
1.
Pull the knob up and turn it to adjust the pressure.
• To increase pressure, turn it clockwise.
• To decrease pressure, turn it counter-clockwise.
DECREASE
PRESSURE
INCREASE
PRESSURE
Figure 5-84. Pull up on the pressure knob and turn it to adjust the pressure.
2.
112
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.
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Remote Operation with the SF ACM
Figure 5-85. 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.
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.
E.H. Wachs
Part No. 60-MAN-07, Rev. C113
Low Clearance Split Frame, Models 204-1420
Figure 5-86. Push the air line disconnect onto the air drive fitting until it locks in place.
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.
114
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Remote Operation with the SF ACM
Figure 5-87. 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 5-88. Push the collar forward and pull the dis­connect to remove it from the fitting.
E.H. Wachs
Part No. 60-MAN-07, Rev. C115
Low Clearance Split Frame, Models 204-1420
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 5-89. 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.
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.
116
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 5, Operating Instructions: Remote Operation with the SF ACM
Figure 5-90. 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 5-91. Attach the open throttle plate with the trigger pin.
4.
With the hammer and punch, drive in the pin until it is flush
E.H. Wachs
Part No. 60-MAN-07, Rev. C117
Low Clearance Split Frame, Models 204-1420
Figure 5-92. Drive in the pin to secure the open throt­tle plate.
CAUTION
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.
5.
The open throttle plate holds the air valve open on the motor.
Figure 5-93. The photo shows the correct installation of the open throttle plate.
118
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 6, Routine Maintenance
Chapter 6
Routine Maintenance
Daily Maintenance
After each use, clean debris from all moving parts, includ­ing the rotating ring and slide components. This will pro­long the life of the machine, and prevent contamination of the storage/shipping
case.
1.
Use a brush or compressed air to remove loose debris from all sliding and rotating surfaces.
2.
Neutralize any corrosive fluids that the machine may have come into contact with during
operation, by wip­ing surfaces with a clean cloth sprayed with a house­hold cleaning solvent.
Lubrication
Tool Slides
Lubricate all moving parts every 10 hours of operation. Use Mobil-lith AW-2 or equivalent.
Air Motor
An in-line oiler lubricates the air motor. You can adjust the drip rate of the oiler by turning the
needle valve in the oiler using a flat screwdriver. Turn the screw counter-clockwise to increase the
drip rate.
NOTE
The numbers on the dial do not indicate the number of drips per minute.
E.H. Wachs Part No. 60-MAN-07, Rev. C119
Low Clearance Split Frame, Models 204-1420
Figure 6-1. Use the needle valve screw to adjust the drip rate of the air motor oiler.
To check the drip rate of the oiler, run the air motor for one minute while holding a sheet of paper in
front of the air out­let port. The paper should become stained with oil. If the paper is not oily,
increase the drip rate on the oiler. If the paper becomes saturated or gets oily within a few seconds,
decrease the drip rate.
As a general guideline, the standard LCSF air motor (1.5 HP) should use about 6-10 drops of oil
per minute. The heavy-duty and reversible air motors (2.5 HP) should use about 8-12 drips per
minute.
Recommended Air Motor Lubricants
Air Motor Grease
Standard duty: NLGI Grade 2 grease (such as Chevron Black Pearl,
CPS 24591)
High temperature: Amsoil Synthetic GVC or equivalent
Air Motor Oil
Wachs air motor oil:
Pint (p/n 02-407-00)
Gallon (p/n 02-402-00)
Felt Wipers
Felt wipers are installed in the stationary ring to clean and lubricate the raceway as the LCSF
rotates. All LCSF models have two felt wipers, one in each section of the stationary ring. There are
3 sizes of wipers, used with the range of LCSF models:
• LCSF model 204 (4”) uses wiper 60-1176-00.
• LCSF models 206-1420 (6”-20”) use wiper 60-1178-00.
• LCSF models 1824-4248 (24”-48”) use wiper 60-1181-00.
120
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 6, Routine Maintenance: Servicing the SF ACM
60-1176-00
60-1178-00
60-1181-00
Figure 6-2. The photo shows the LCSF felt wipers.
Use the following procedure to access and service the felt wipers. Apply oil to the wipers every
time you use the LCSF. Inspect them to see if they are worn, damaged, or excessively dirty, and
replace them if necessary.
Note: Current LCSF machines have spring-loaded wiper brackets to keep the wiper in contact with
the raceway. Some machines were supplied without spring-loaded brackets; if your LCSF does not
have springs, you will need to adjust the wiper position when re-assembling the machine. See
notes in the instructions below.
3.
Lay the LCSF on a workbench with the rotating ring up.
4.
Remove the slides and the pinion housing.
5.
Rotate the machine to align the split lines on the stationary and rotating rings. Insert the
frame locking pins.
6.
Separate the machine at the split lines. Refer to the instructions in the LCSF User’s Manual.
7.
To access the felt wipers, remove the frame locking pins and turn the rotating ring out of the
stationary ring until you can see the wiper.
E.H. Wachs
Part No. 60-MAN-07, Rev. C121
Low Clearance Split Frame, Models 204-1420
Figure 6-3. Turn the rotating ring out of the stationary ring far enough to access the wipers.
8.
Remove the wiper from the bracket and inspect it for wear, damage or buildup of debris.
Figure 6-4. Inspect the wiper for wear, damage, or debris.
• You can clean debris from the wiper with compressed air. If there is debris such as metal
chips embedded in the wiper, replace it.
122
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 6, Routine Maintenance: Servicing the SF ACM
9.
• Check the contact edge of the wiper for wear. If the corners are worn off or the wiper is
deformed, replace it.
• Some dirt and discoloration on the wiper is normal. If it is extremely dirty, and the dirt
affects the consistency of the fabric, replace the wiper.
Replace the wiper in the bracket. Make sure the notched edge of the wiper is down (toward
the stationary ring).
Notched edge (60-1178-00
and 60-1181-00)
Figure 6-5. Replace the wiper in the bracket, with the notched edge down.
10. Apply two drops of way oil directly to the wiper. (Way oil available from E.H. Wachs, part
no. 60-1184-00.)
11. Turn the rotating ring back, pushing the wiper into the bracket to fit inside the raceway.
E.H. Wachs
Part No. 60-MAN-07, Rev. C123
Low Clearance Split Frame, Models 204-1420
Figure 6-6. Push the wiper into the bracket and turn the rotating ring into position.
12. NOTE: If your LCSF does not have spring-loaded wiper brackets, adjust the position of the
wiper so that it is in firm contact with the raceway when you turn the rotating ring back into
the stationary ring.
Adjust wiper position to
contact raceway
Figure 6-7. For machines without spring-loaded wiper brackets, make sure the wiper is in
contact with the raceway. Adjust the wiper position if necessary.
124
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 6, Routine Maintenance: Servicing the SF ACM
Servicing the SF ACM
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.
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.
NOTE
Remove the output hose and control pendant before lifting the control panel out of
the case.
Figure 6-8. Lift the control panel out of the case for service or to drain out accumulated
water.
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.
NOTE
The 5 micron filter element is available from E.H. Wachs or from the manufacturer
(Rexroth, part no. 1829207068).
E.H. Wachs
Part No. 60-MAN-07, Rev. C125
Low Clearance Split Frame, Models 204-1420
Figure 6-9. To remove the filter, pull the locking tab down with your thumb and turn the filter
to the left.
126
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 7, Service and Repair
Chapter 7
Service and Repair
Troubleshooting
Trouble
Machine won’t run
Machine runs slowly
Tool slide does not feed
Possible Cause
Detent pins not removed
Remove pins
Power supply not on
Check power supply
Improper bearing preload
Refer to maintenance for adjustment
Improper speed or gear box setting Turn throttle on the motor
p.s.i. not correct
Needs 80 - 100 p.s.i.
Trip pin not engaged
Engage trip pin
Trip pin assembly in wrong position Add or remove spacers
Stripped feed screw or nut
Replace part or add dovetail
Improper tool slide adjustment
Readjust tool slide
Tool penetration causes tool to bind Worn feed screw / feed nut
Tool bit is dull
Machine moves during cut
Machine chatters during cut
Poor cutting quality
E.H. Wachs
Remedy
Replace feed screw / feed nut
Replace bit
Loose clamp pads
Tighten clamp pads
Speed control too fast
Reduce speed
Tool bit is dull
Replace bit
Improper ring adjustment
Readjust ring
Tool bit is dull
Replace bit
Improper tool installation
Reinstall bit
Part No. 60-MAN-07, Rev. C127
Low Clearance Split Frame, Models 204-1420
Adjusting the Bearings
LCSF Machines with Fixed Bearings (2009 and Later)
LCSF machines manufactured since 2009 have fixed reference bearings for improved bearing
adjustment. (Machines manufactured before 2009 have a different bearing adjustment procedure;
see the instructions in the LCSF User Manual.)
If you are not sure if your machine has fixed bearings, take off the bearing cap at one of the fixed
bearing positions. Fixed bearings do not have a hex end for turning the eccentric. The figures
below shows the positions of the fixed bearings on the LCSF models noted in the captions.
Fixed position
bearings
Figure 7-1. The drawing shows the positions of the fixed bearings for LCSF models 18244248 (24” through 48”).
128
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 7, Service and Repair: Adjusting the Bearings
Fixed bearing
(no hex end)
Adjustable bearings
(with hex end)
Figure 7-2. To check if your LCSF machine has the fixed-bearing design, remove the bearing
caps at the fixed bearing positions. If the shaft has no hex in it, as shown, it is a fixed bearing.
NOTE
Remove the pinion housing assembly and tool slides before beginning bearing
adjustment.
Required tools:
• 3/16” hex wrench
• 9/16” socket wrench
• Alignment pins (60-098-00)
• Bearing adjustment wrench (60-089-00)
NOTE
If you are installing new guide wheel bearings, assemble the bearings, eccentric
shafts, and bearing spacers to the stationary ring.Tighten the 3/8-16 nylock hex nut
enough to allow eccentric shafts to rotate smoothly.
1.
To prepare existing guide wheel bearings for adjustment procedure, loosen the 3/8-16
Nylock hex nut only enough to allow eccentric shafts to rotate smoothly. Make a mark on the
edge of each bearing with a permanent marker. These marks will help you check that the
bearings are turning later in this proce­dure.
E.H. Wachs
Part No. 60-MAN-07, Rev. C129
Low Clearance Split Frame, Models 204-1420
Figure 7-3. Mark the edge of each bearing.
2.
Rotate all eccentric shafts to position the guide wheel bearings toward the inside of the
stationary ring.
Figure 7-4. Rotate the eccentric shafts so that the high point of each bearing faces the inside
of the ring.
3.
130
Slide the rotating ring into the stationary ring, then repeat with the other half of the machine.
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 7, Service and Repair: Adjusting the Bearings
Figure 7-5. Slide rotating ring into stationary ring.
4.
Assemble the ring halves, tightening the captivated screws of the stationary ring first.
Figure 7-6. Assemble the ring halves and tighten the captivated screws.
CAUTION
Use a crane or other lifting device to lift the LCSF. There is a risk of injury from lifting the
machine, or from setting or dropping it on hands or feet.
5.
Position the machine with the rotating ring face down on the workbench and check for free
play between the rotating and stationary rings. (The stationary ring should “wobble” on the
rotating ring.) Disassemble the machine and repeat Step 2 if play is not felt.
E.H. Wachs
Part No. 60-MAN-07, Rev. C131
Low Clearance Split Frame, Models 204-1420
Figure 7-7. Check for play between the rotating and stationary rings.
6.
Do not insert the alignment pins.
7.
Starting at position #1 shown in the figures below, turn the eccentric shaft counter-clockwise
until you feel the bearing just touch the groove. Tighten the 9/16 nylock hex nut.
Pos. #2
Pos. #4
Pos. #1
Pos. #3
Figure 7-8. Adjust the bearings in the order shown, then work around the machine toward
the pinion, alternating side to side. (Models 1824-4248.)
8.
Adjust the bearing at position #2 in the same way.
9.
Continue to adjust the bearings around the ring, alternating side to side. Finish with the
bearings below the pinion, between the fixed bearings.
132
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 7, Service and Repair: Extended Slide Adjustment
10. Rotate the machine through at least one full revo­lution, looking through an alignment pin
hole to check that all guide wheel bearings turn with the machine. (The marks you made
earlier will help you see if the bearings are turning.)
• You should be able to rotate the machine by hand. If you cannot, repeat the entire adjustment
procedure.
• The machine should rotate smoothly, with no sticking points. If it sticks or catches at any point,
try to re-adjust the bearings at the split lines where the machine catches. If you cannot get it to
operate smoothly with a slight adjustment, repeat the entire adjustment procedure.
• If any adjustable bearing is not turning, try to adjust it again. If you cannot get it to turn with a
slight adjustment, repeat the entire adjustment procedure.
• If either of the fixed bearings is not turning, repeat the entire adjustment proce­dure.
Pre-2009 Machine (Without Fixed Reference Bearings)
The following procedure is for LCSFs with a serial number starting with 08 or less (08-XXXX),
manufactured before 2009.
11. Remove any tool slides installed on the rotating ring.
12. Using a 1/4” hex wrench, split the LCSF. Remove the rotating ring from the stationary frame.
Figure 7-9. Separate the stationary and rotating rings.
13. Clean out the area around the guide wheel bearings (37-005-00) in the stationary frame and
the “V” groove area of the rotating ring.
E.H. Wachs
Part No. 60-MAN-07, Rev. C133
Low Clearance Split Frame, Models 204-1420
Figure 7-10. Clean debris from the stationary ring.
14. Inspect the “V” groove area of the rotating ring for deformation, cracking, and/or pitting. If
the ring is damaged, you will need to replace it.
Figure 7-11. Inspect the “V” groove of the rotating ring for wear or damage.
15. Check to make sure each bearing spins freely by hand.
16. Remove the plastic caps on the back of the stationary ring and inspect the bearing assemblies.
Replace any worn or broken components.
NOTE
134
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 7, Service and Repair: Extended Slide Adjustment
Each bearing assembly con­sists of a bearing, a spacer, an eccentric shaft, a washer,
and a lock nut). See assem­bly drawings in Chapter 8 for specific part numbers for
your LCSF model.
Figure 7-12. Remove the plastic caps to inspect the bearing assemblies.
17. Using a 1/2” socket wrench, break loose the 5/16”-18 lock nuts (90-065-03).
E.H. Wachs
Part No. 60-MAN-07, Rev. C135
Low Clearance Split Frame, Models 204-1420
Figure 7-13. Loosen the lock nuts.
18. Turn the eccentric shafts so that the lines on top of them point toward the frame center.
Figure 7-14. Set the marks on the eccentric shafts toward the center of the ring.
19. Insert the rotating ring halves back into the stationary ring halves.
20. Reassemble the machine halves using a 1/4” hex wrench.
21. An optional bearing fixture plate (60-205-00) is available to make adjusting the bearings
easier. Install the plate on the rotating ring at one of the slide mount­ing positions, using two
(2) 5/16”-18 x 7/8” SHCS and a 1/4” hex wrench.
136
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 7, Service and Repair: Extended Slide Adjustment
NOTE
The bearing fixture plate keeps the eccentric shafts from turning as you tighten the
bearing lock nuts. This keeps the guide wheel bear­ings within the “V” groove preload
of 10-15 in-lb.
Figure 7-15. Install the bearing fixture plate on the rotating ring at the slide mounting position.
Figure 7-16. The fixture plate will hold the eccentric shaft as you set the bearing wheel
against the “V” groove.
22. If you do not have the bearing fixture plate, you will need to use a 3/16” hex wrench to
hold the eccen­tric shaft. Since this is done while tightening the 5/16”-18 lock nut, you must
be careful to keep adequate “V” groove preload (10-15 in-lb) on the eccentric shaft.
E.H. Wachs
Part No. 60-MAN-07, Rev. C137
Low Clearance Split Frame, Models 204-1420
23. Refer to the Figure 7-9 for your LCSF model, and locate the #1 position eccentric shaft.
Figure 7-17. Bearing Adjustment Sequence Chart
24. Turn the eccentric shaft counter-clockwise until the guide wheel bearing touches the rotating
ring “V” groove. Torque 10-15 in-lb.
25. Secure the eccentric shaft using the bearing fixture plate and tighten the lock nut to 150 in-lb.
138
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 7, Service and Repair: Super Extended Slide Adjustment
Figure 7-18. Secure the eccentric shaft.
26. Repeat Steps 14 and 15 for the #2, #3, and #4 posi­tions.
27. Check that the rotating ring is centered to the station­ary frame using the supplied square. If
not centered, repeat Steps 14 and 15.
Figure 7-19. Center the rotating ring to the stationary frame.
28. Turn the rotating ring by hand around the stationary frame. The machine should turn smooth-
ly and consis­tently. Check the backlash between the rotating ring and the pinion gear.
29. Repeat Steps 14 and 15 for the remaining bearings.
30. Check that all guide wheel bearings rotate while the machine turns. Look through the holes in
the rotating ring while turning the machine.
E.H. Wachs
Part No. 60-MAN-07, Rev. C139
Low Clearance Split Frame, Models 204-1420
Figure 7-20. Check for bearing rotation as you turn the rotating ring.
31. Turn the rotating ring by hand around the stationary ring. The machine should turn smoothly
and consis­tently, and should stop immediately when you stop turning it. If it doesn’t operate
this way, repeat the bearing adjustment procedure.
Extended Slide Adjustment
To check the tension on the tool slide, attempt to turn the starwheel at the front of the slide. It
should be very difficult to turn with your bare hand, but you should be able to turn it by hand with a
rag or some form of cushion.
NOTE
The star wheel should require approximately 15-17 in-lbs of torque to turn.
The slide tension is adjusted using four (4) set screws on the dovetail on one side of the slide. The
dovetail “clamps” the male tool slide, and the screws adjust how tightly the dove­tail holds the male
slide.
Use the following procedure to completely reset the slide tension.
1.
140
Loosen the four (4) 1/4-20 jam nuts and set screws on the side of the slide.
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 7, Service and Repair: Air Motor Maintenance
Figure 7-21. Loosen the jam nuts (top), then loosen the set screws (bottom).
2.
Remove the four (4) 1/4-20 x 7/8” socket head cap screws from the adjustable dovetail.
3.
Remove the four (4) 1/4-20” cap screws from the star­wheel plate.
4.
Clean the slide as best you can and apply a thin layer of grease on the face of the adjustable
dovetail.
E.H. Wachs
Part No. 60-MAN-07, Rev. C141
Low Clearance Split Frame, Models 204-1420
Figure 7-22. Remove the dovetail and clean the slide.
5.
Turn the starwheel until the tool slide is in the central position.
6.
Replace the adjustable dovetail and the four (4) 1/4-20 x 7/8” socket head cap screws.
Figure 7-23. Replace the dovetail and SHCS.
7.
Position the adjustable dovetail so that there is no gap between it and the slide base.
8.
Tighten the 1/4-20 x 7/8” socket head cap screws so they are “snug”. You do not want them to
be fully tightened or the tension will not be set correctly.
142
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 7, Service and Repair: Air Motor Maintenance
Figure 7-24. Tighten the SHCS until snug.
9.
Replace the center two (2) 1/4-20 set screws and tighten them until the adjustable dovetail is
touching the tool slide.
Figure 7-25. Replace the set screws and tighten.
10. Make sure the dovetail stays as straight as possible.
11. Tighten the 1/4-20 set screws and turn the star wheel at the same time until you feel tension in
the star wheel. Try to keep the tension on the set screws as even as possible.
E.H. Wachs
Part No. 60-MAN-07, Rev. C143
Low Clearance Split Frame, Models 204-1420
Figure 7-26. Tighten set screws while turning the star
wheel.
12. Move the tool slide to the top and adjust the 1/4-20 set
screw until you feel the same amountof tension as in
the middle.
13. Repeat the process for the bottom of the slide.
14. Fully tighten the four (4) 1/4-20 x 7/8” socket head cap
screws on the adjustable dovetail.
Figure 7-27. Tighten SHCS on dovetail.
15. Tighten the four (4) 1/4-20” socket cap screws on the
starwheel plate.
144
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 7, Service and Repair: Air Motor Maintenance
16. Check the tension on the full range of the slide. It should be the same.
Figure 7-28. Check the tension on the slide by driving it to both ends of the feed screw.
17. If you can still turn the starwheel with your bare hand, you need to slightly tighten the four
(4) set screws once again so that the tension is the same throughout the travel of the tool slide.
18. If a torque wrench is available, attach to the feed screw while turning the star wheel. Turning
the star­wheel should require 15-17 in/lb of torque.
Figure 7-29. Adjust the feed screw with the torque wrench.
E.H. Wachs
Part No. 60-MAN-07, Rev. C145
Low Clearance Split Frame, Models 204-1420
Super Extended Slide Adjustment
Use the following procedure to completely reset the tension on the slide.
1.
Remove the three (3) 1/4-20 x 7/8” socket head cap screws from both dovetails on either side
of the tool slide and remove both dovetails.
Figure 7-30. Remove the SHCS from both dovetails.
2.
Keep track of the position and order of the shims that are under one or both of the dovetails.
Figure 7-31. Keep track of the position and order of the shims.
3.
146
Clean the slide, dovetails, and shims. The slides will not adjust correctly if they are dirty.
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 7, Service and Repair: Air Motor Maintenance
Figure 7-32. Clean the slide, dovetails, and shims.
4.
Lightly grease the face of the dovetails.
5.
Replace the shims in the same order and position in which you removed them.
6.
Replace one of the dovetails and tighten down the three 1/4-20 x 7/8” socket head cap
screws.
.
Figure 7-33. Replace the dovetail and the SCHS.
E.H. Wachs
Part No. 60-MAN-07, Rev. C147
Low Clearance Split Frame, Models 204-1420
7.
If you can turn the starwheel by hand you will need to remove the first full shim and check
the tension.
Figure 7-34. Check the tension by turning the star­wheel.
8.
If the tension is still incorrect, you will need to add or remove shims as required to obtain
proper adjustment of the slide.
• Adding a shim decreases the tension.
• Removing a shim increases the tension.
Figure 7-35. Adjust tension until correct.
148
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 7, Service and Repair: Air Motor Maintenance
9.
The slide should have even tension throughout the travel of the tool slide. With the torque
wrench, it should read 15-17 in/lbs.
If you cannot move the starwheel easily with your bare hand when you have the two dovetails off
the slide, there may be a problem with the feed screw or feed nut. Clean them as well as you can. If
you still cannot turn the starwheel with your bare hand, you may need a replacement part or to send
the slide in for service.
Air Motor Maintenance
See the exploded view drawings for air motors in the “Parts Lists and Drawing” section of this
manual.
1.
Clamp the flats of the handle in a vise with the tool in a vertical position.
2.
Using a suitable wrench, loosen (left hand threads) the clamp nut and remove the angle head
assembly. Unscrew and remove the clutch housing and gear case assemblies. Clamp the gear
case in the vise and unscrew the clutch housing.
3.
Slip the motor unit out the front of the handle. It may be necessary to bump the handle on the
work bench to loosen the motor.
Disassembling Air Motor Subassemblies
Right Angle Head
1.
Remove the bearing cap lock screw (1/16 hex) and unscrew (left hand threads) the bearing
cap. Clamp the square drive in the vise and use a soft mallet to drive the angle head off. Press
the spindle out of the driven gear and then press the spindle out of the ball bearing.
2.
Unscrew and remove the bearing retainer and grease plug. Use a suitable driver to drive the
pinion gear out of the housing.
Gear Case
1.
Slip the entire gear train out the rear of the gear case. The 2nd reduction idler gears may be
removed for inspection by driving the idler gear pins out the rear of the spider.
Motor
1.
Use a soft faced mallet to drive the rotor out of the front rotor bearing. This will allow the
removal of the front bearing plate, cylinder, and five (5) rotor blades from the rotor.
2.
Clamp the rotor lightly in the vise and unscrew the rotor lock nut.
E.H. Wachs
Part No. 60-MAN-07, Rev. C149
Low Clearance Split Frame, Models 204-1420
3.
Rest the rear bearing plate on the vise jaws and use a soft faced mallet to drive the rotor out of
the rear rotor bearing.
Handle
1.
Unscrew the inlet bushing for inspection of the throttle components. Wash the air inlet screen
in a solvent and blow it out in the reverse direction of normal airflow. Replace if damaged or
clogged.
Reassembly
The tool is reassembled in the reverse order of disassembly.
1.
Clean all parts thoroughly in a solvent and inspect for damage or wear.
2.
Check all bearings for wear which can be detected by excessive end play and/or roughness
that would indi­cate a brinelled condition.
3.
The rotor blades should be replaced if they measure less than 3/8” (9.5 mm) at either end.
4.
All gear teeth, bearings, and pins should receive a close inspection and be replaced if necessary. All gears and open bearings should receive a generous amount of No. 2 Moly grease
during reassembly.
Motor
1.
Install the rear rotor bearing into the rear bearing plate. Make sure the outer bearing race is
firmly seated in the bearing plate.
IMPORTANT: During reas­sembly of the complete tool, it is important that the motor be free. After
the tool is com­pletely assembled, the right angle square drive spindle should turn freely using a
small hand wrench. If the spindle does not turn freely, the motor should be checked for proper
spacing. Do not run the tool until the spindle turns freely. Failure to do this could result in damage
to motor components.
2.
Clamp the rotor body lightly in the vise with the threaded end up and slip the rear bearing
plate assem­bly onto the rotor shaft far enough for the bearing lock nut to start.
3.
Tighten the lock nut until there is approximately .0015” clearance between the rotor and
bearing plate. The outer bearing race should be firmly seated and the rotor bumped forward
when checking this clearance.
4.
Pack both rotor bearings with a good grade of No. 2 Moly grease after assembly of the motor
unit.
150
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 7, Service and Repair: Air Motor Maintenance
Air Motor Vanes
Before installing new rotor vanes, you may need to grind them to ensure precise sizing according
to the following chart.
Air Motor
Part No.
Description
Rotor Blade
Part No.
Min. Length
Max. Length
60-329-00
2-1/2 HP
899927
2.745”
2.748”
60-211-00
1-1/2 HP
869569
2.244”
2.247”
Right Angle Head
When installing needle bearings, press only on the bearing’s stamped end. The pinion needle
bearing should be slipped on the pinion gear and pressed into the housing to the fol­lowing depth:
• 3- 3/16” (81 mm).
1. Tighten the pinion bearing retainer to 35 to 40 lb-ft (47.5 to 54.2 Nm) ensure proper gear
make-up.
2.
Torque the driven gear bearing cap to 100/110 lb-ft (135/149 Nm).
NOTE
When assembling the angle head to the complete tool, the clamp nut (left hand
threads) must be torqued to 100/110 lb-ft (135/149 Nm).
E.H. Wachs
Part No. 60-MAN-07, Rev. C151
Low Clearance Split Frame, Models 204-1420
152
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 8, Parts Lists and Drawings
Chapter 8
Parts Lists and Drawings
This chapter contains exploded view drawings with parts lists for all LCSF models, including
sub-assemblies. To identify and order parts, locate the assembly for your LCSF model. Sub-assemblies are called out by part number on top-level assemblies.
E.H. Wachs
Part No. 60-MAN-07, Rev. C153
Low Clearance Split Frame, Models 204-1420
Model 1824-4248 (24”-48” inch LCSF)
ITEM NO.
PART NUMBER
QTY
TABLE
DESCRIPTION
LCSF MODEL
60-000-24
60-000-28
60-000-32
60-000-36
60-000-39
60-000-42
60-000-48
STATIONARY
ROTATING
FRAME ASSEMBLY FRAME ASSEMBLY
60-1250-24
60-1271-24
60-1250-28
60-1271-28
60-1250-32
60-1271-32
60-1250-36
60-1271-36
60-1271-39
60-1250-39
60-1250-42
60-1271-42
60-1250-48
60-1271-48
SEE TABLE
SEE TABLE
154
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 8, Parts Lists and Drawings:
Stationary Ring Assembly (Models 1824 through 4248)
ITEM
NO.
1
2
3
4
5
6
7
8
9
PART NUMBER
QTY.
DESCRIPTION
SEE TABLE
SEE TABLE
60-259-00
60-262-00
90-069-13
90-096-10
90-099-13
90-219-11
90-219-19
1
1
2
2
4
2
2
2
8
RING, STATIONARY-UPPER
RING, STATIONARY-LOWER
SCREW, CAPTIVATED
DRILL BUSHING
INSERT, 5/16-18 X 2D (.62 LG.) HELICAL
PIN, 1/2 x 1.00 DOWEL
INSERT, 1/2-13 X 1.5D (.75 LG.) HELICAL
INSERT, 3/4-10 X 1.5D (1.12 LG) HELICAL
INSERT, 3/4-10 X 2.5D (1.19 LG) HELICAL
TABLE
STATIONARY
RING ASSEMBLY
60-249-24
60-249-28
60-249-32
60-249-36
60-249-42
60-249-48
STATIONARY
RING, UPPER
60-250-24
60-250-28
60-250-32
60-250-36
60-250-42
60-250-48
STATIONARY
RING, LOWER
60-251-24
60-251-28
60-251-32
60-251-36
60-251-42
60-251-48
8
9
6
3
9
1
4
7
2
5
4
7
6
3
8
E.H. Wachs
Part No. 60-MAN-07, Rev. C155
Low Clearance Split Frame, Models 204-1420
Wiper Kit Assembly, 60-552-03
ITEM
PART NUMBER
QTY.
1
2
3
60-1181-00
60-1182-00
60-1183-00
2
2
2
DESCRIPTION
WIPER, 24-50 LCSF
SPACER, 24-50 LCSF WIPER
BRACKET, 24-50 LCSF WIPER
Wiper Kit, 60-552-03.
Used with these LCSF models:
60-000-24, 60-000-28, 60-000-32,
60-000-36, 60-000-42, 60-000-48.
2
3
1
156
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 8, Parts Lists and Drawings:
Pinion Housing, 60-409-00
ITEM
PART NUMBER
QTY.
DESCRIPTION
1
60-1231-00
1
GEAR, PINION
2
3
60-1232-00
60-1233-00
1
1
HOUSING, PINION
PINION COVER
4
60-1234-00
1
BEARING, DBL ROW ANG CONTACT
5
6
60-1235-00
60-1236-00
1
1
BEARING, DEEP GROOVE BALL
RING, RETAINING
7
8
9
10
60-181-00
90-050-11
90-060-07
90-060-27
1
2
2
4
LABEL, STARWHEEL
SHCS, 1/4-20 x 1-1/8
SHCS, 5/16-18 X 3/4
SHCS, 5/16-18 X 2-3/4
11
90-076-05
2
PIN, 3/8 X 1/2 DOWEL
NOTES: WEIGHT = 4.9lb [10.8kg]
10
9
7
5
6
4
1
2
3
11
8
E.H. Wachs
Part No. 60-MAN-07, Rev. C157
Low Clearance Split Frame, Models 204-1420
Front Drive Pinion Housing, 60-425-04
ITEM
PART NUMBER
QTY.
1
2
3
4
5
6
7
8
9
10
11
12
60-125-00
60-341-01
60-342-01
60-343-01
60-344-01
60-345-00
90-060-07
90-060-10
90-060-20
90-069-12
90-076-07
90-076-10
3
1
1
1
1
1
2
4
2
2
2
2
DESCRIPTION
HOUSING, PINION-FRONT 24"-48" LCSF
HOUSING, PINION-REAR 24"-48" LCSF
GEAR, PINION-FRONT DRIVE 24"-48" LCSF
GEAR, IDLER-FRONT DRIVE LCSF 24"-48"
SHCS, 5/16-18 X 1
SHCS, 5/16-18 X 2
INSERT, 5/16-18 X 1.5 D (.47 LG) HELICAL
7
10
2
1
5
6
1
12
4
11
1
8
9
3
158
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 8, Parts Lists and Drawings:
Clamp Legs, 60-127-XX
ITEM
PART NUMBER
QTY.
1
2
3
WHERE USED
90-060-05
90-065-09
1
2
2
DESCRIPTION
EXTENSIONS, CLAMP PAD
SHCS, 5/16-18 X 1/2
NUT, 5/16 PUSH
-WHERE USEDITEM
PART NUMBER
1
60-027-05
60-027-07
60-027-10
60-027-15
60-027-20
60-027-25
60-027-28
60-027-30
60-027-31
60-027-35
60-027-40
QTY.
1
ORDERING NUMBERS
DESCRIPTION
ASSEMBLY
NUMBER
INDIVIDUAL
CLAMP PADS
EXTENSIONS, CLAMP LEG
60-127-05
60-127-07
60-127-10
60-127-15
60-127-20
60-127-25
60-127-28
60-127-30
60-127-31
60-127-35
60-127-40
60-127-05
60-127-07
60-127-10
60-127-15
60-127-20
60-127-25
60-127-28
60-127-30
60-127-31
60-127-35
60-127-40
SIZE
0.5”
0.75”
1.0”
1.5”
2.0”
2.5”
2.8”
3.0”
3.1”
3.5”
4.0”
CLAMP PAD
SETS (QTY. 4)
60-408-05
60-408-07
60-408-10
60-408-15
60-408-20
60-408-25
60-408-28
60-408-30
60-408-31
60-408-35
60-408-40
NOTE: LCSF models 204 through 1420 have 4 clamp legs.
See clamp leg charts in Chapter 5 for pipe size configurations.
3
1
2
E.H. Wachs
Part No. 60-MAN-07, Rev. C159
Low Clearance Split Frame, Models 204-1420
Trip Assembly, 60-434-00
ITEM
PART NUMBER
QTY.
1
2
3
4
5
6
7
8
9
43-067-00
60-068-00
60-1048-00
60-1049-00
60-1050-00
60-266-00
60-338-00
90-026-55
90-059-08
2
2
1
1
1
1
1
1
1
DESCRIPTION
SCREW, CAPTIVATED
SHIM, TRIP SCREW
SPOOL
LEVER
QUICK PIN
HOUSING, TRIP
PIN, TRIP
1/8" X 1/2" PIN
SPRING PLUNGER
WEIGHT = 1lb. [.5kg]
4
3
1
7
2
6
8
5
9
160
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 8, Parts Lists and Drawings:
Extended Parting Slide, 60-415-00
ITEM
PART NUMBER
QTY.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
60-119-00
60-188-01
60-189-00
60-190-00
60-191-00
60-192-00
60-194-00
60-195-00
60-196-00
60-229-00
90-050-05
90-050-08
90-054-08
90-055-04
90-056-12
90-059-05
90-060-12
90-065-09
90-060-08
1
1
1
1
1
1
1
1
2
1
2
8
4
4
2
2
4
4
6
DESCRIPTION
PLATE ASSEMBLY, FEED SCREW
SUPPORT, TOOL SLIDE
PLATE, WEAR (H.D.)
DOVETAIL, ADJUSTABLE (H.D.)
DOVETAIL, FIXED (H.D.)
SLIDE, MALE-PARTING (H.D.)
COVER, TOOL SLIDE (H.D.)
SCREW, FEED (H.D.)
PIN, ALIGNMENT
NUT, FEED (H.D. STAR-FEED)
SHCS, 1/4-20 X 1/2
SHCS, 1/4-20 X 7/8
SSS, 1/4-20 X 7/8
NUT, 1/4-20 JAM
PIN, 1/4 X 1-1/4 DOWEL
LH SHCS, 1/4-20 X 1/2
SHCS, 5/16-18 X 1-1/4
NUT, 5/16 PUSH
SHCS, 5/16-18 X 7/8
11
1
16
8
5
3
2
9
17
17
15
12
17
13
4
18
7
19
E.H. Wachs
6
14
10
12
17
Part No. 60-MAN-07, Rev. C161
Low Clearance Split Frame, Models 204-1420
Extended Beveling Slide, 60-416-00
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
60-119-00
60-188-01
60-189-00
60-190-00
60-191-00
60-193-00
60-194-00
60-195-00
60-196-00
60-214-00
60-229-00
90-050-05
90-050-08
90-054-08
90-055-04
90-056-12
90-059-05
90-060-12
90-060-17
90-065-09
90-060-08
1
1
1
1
1
1
1
1
2
1
1
2
8
4
4
2
2
5
4
8
8
DESCRIPTION
PLATE ASSEMBLY, FEED SCREW
SUPPORT, TOOL SLIDE
PLATE, WEAR (H.D.)
DOVETAIL, ADJUSTABLE (H.D.)
DOVETAIL, FIXED (H.D.)
SLIDE, MALE FORM TOOL (H.D.)
COVER, TOOL SLIDE (H.D.)
SCREW, FEED (H.D.)
PIN, ALIGNMENT
COVER, H.D. DBL. BEVEL
NUT, FEED (H.D. STAR-FEED)
SHCS, 1/4-20 X 1/2
SHCS, 1/4-20 X 7/8
SSS, 1/4-20 X 7/8
NUT, 1/4-20 JAM
PIN, 1/4 X 1-1/4 DOWEL
LH SHCS, 1/4-20 X 1/2
SHCS, 5/16-18 X 1-1/4
SHCS, 5/16-18 X 1-3/4
NUT, 5/16 PUSH
SHCS, 5/16-18 X 7/8
12
1
17
8
5
3
2
9
18
4
18
16
13
18
14
4
20
6
11
7
13
21
18
18
20
10
21
19
162
Part No. 60-MAN-07, Rev. C
E.H. Wachs
15
Chapter 8, Parts Lists and Drawings:
Super Extended Parting Slide, 60-437-00
ITEM
PART NUMBER
QTY.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
43-043-00
43-064-00
60-192-00
60-194-00
60-196-00
60-229-00
60-315-00
60-319-00
60-320-00
60-322-00
60-335-00
60-339-00
60-340-00
90-016-55
90-019-43
90-050-08
90-060-12
90-065-05
90-065-09
90-060-08
4
2
1
1
2
1
1
1
1
1
2
2
1
1
1
6
4
1
4
10
DESCRIPTION
THRUST WASHER
BEARING, THRUST
SLIDE, MALE-PARTING (H.D.)
COVER, TOOL SLIDE (H.D.)
PIN, ALIGNMENT
NUT, FEED (H.D. STAR-FEED)
SUPPORT, TOOL SLIDE
SCREW, FEED
WHEEL, STAR
SHIM, DOVETAIL
DOVETAIL
BUSHING, FEED SCREW
BLOCK, FEED SCREW
PIN, 5/64 X 1/2 ROLL
KEY, 3/32 X 3/8 WOODRUFF
SHCS, 1/4-20 X 7/8
SHCS, 5/16-18 X 1-1/4
NUT, 5/16-24 SLOTTED
NUT, 5/16 PUSH
SHCS, 5/16-18 X 7/8
14
1
20
13
12
1
2
9
11
16
17
4
15
8
20
12
1
2
1
7
19
3
6
5
16
11
10
E.H. Wachs
17
Part No. 60-MAN-07, Rev. C163
18
Low Clearance Split Frame, Models 204-1420
Super Extended Beveling Slide, 60-438-00
ITEM
PART NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
43-043-00
43-064-00
60-193-00
60-194-00
60-196-00
60-214-00
60-229-00
60-315-00
60-319-00
60-320-00
60-322-00
60-335-00
60-339-00
60-340-00
90-016-55
90-019-43
90-050-08
90-060-12
90-060-17
90-065-05
90-065-09
90-060-08
QTY.
4
2
1
1
2
1
1
1
1
1
1
2
2
1
1
1
6
5
4
1
8
12
DESCRIPTION
THRUST WASHER
BEARING, THRUST
SLIDE, MALE FORM TOOL (H.D.)
COVER, TOOL SLIDE (H.D.)
PIN, ALIGNMENT
COVER, H.D. DBL. BEVEL
NUT, FEED (H.D. STAR-FEED)
SUPPORT, TOOL SLIDE
SCREW, FEED
WHEEL, STAR
SHIM, DOVETAIL
DOVETAIL
BUSHING, FEED SCREW
BLOCK, FEED SCREW
PIN, 5/64 X 1/2 ROLL
KEY, 3/32 X 3/8 WOODRUFF
SHCS, 1/4-20 X 7/8
SHCS, 5/16-18 X 1-1/4
SHCS, 5/16-18 X 1-3/4
NUT, 5/16-24 SLOTTED
NUT, 5/16 PUSH
SHCS, 5/16-18 X 7/8
19
15
6
1
22
22
14
21
13
1
2
10
12
17
22
16
4
18
9
13
1
2
1
8
21
3
7
5
18
17
12
11
164
18
Part No. 60-MAN-07, Rev. C
E.H. Wachs
20
Chapter 8, Parts Lists and Drawings:
Universal Counterbore Slide, 60-405-UC
12
16
17
9
ITEM
PART NUMBER
QTY.
1
2
3
4
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
60-134-04
60-140-10
60-145-00
60-146-00
60-146-01
60-147-01
60-148-00
60-149-00
60-150-00
60-151-00
60-152-02
60-157-00
60-236-10
90-036-52
90-046-51
90-050-30
90-060-06
90-060-12
90-065-09
90-065-53
90-074-06
90-075-00
60-135-00
1
2
1
1
1
1
1
1
1
1
1
1
1
2
1
4
2
4
4
4
2
2
1
DESCRIPTION
BAR-BORING-C'BORE
KEY, BORING BAR
INSERT, KEYLOCKING
LABEL, C'BORE DEPTH
LABEL, RADIAL FEED
SCREW, FEED
BLOCK, SUPPORT LC1-12
PLATE, THRUST LC1-12
BUSHING, LC1-12
WASHER, SPRING
KNOB, FEED
BUSHING LC1-3
WELDMENT, C'BORE FRAME
PIN, 5/32 X 1/4 ROLL
PIN, 3/16 X 1 ROLL
SHCS, 1/4-20 X 3
SHCS, 5/16-18 X 5/8
SHCS, 5/16-18 X 1-1/4
NUT, 5/16 PUSH
WASHER, 5/16 AN
SSS, 3/8-16 X 5/8
NUT, 3/8-16 JAM
INDICATOR LC1-12
WEIGHT = 10lb. [4.5kg]
13
7
15
8
6
10
11
3
19
21
4
14
24
1
18
20
23
E.H. Wachs
22
2
Part No. 60-MAN-07, Rev. C165
Low Clearance Split Frame, Models 204-1420
Worm Gear Parting Slide, 60-430-01
ITEM
PART NUMBER
QTY.
DESCRIPTION
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
43-067-00
53-087-00
60-235-00
60-288-00
60-290-00
60-291-00
60-292-00
60-293-00
60-294-00
60-295-00
60-296-00
60-296-01
60-306-00
60-307-00
60-308-00
60-309-00
60-310-00
60-311-00
60-313-02
60-314-00
90-024-04
4
1
1
2
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
2
22
90-029-43
1
23
24
25
26
27
28
29
30
31
32
33
34
35
36
90-044-07
90-045-04
90-046-57
90-050-07
90-056-07
90-056-12
90-060-07
90-060-10
90-064-15
90-065-04
90-070-12
90-095-07
90-205-09
90-500-05
1
1
1
2
2
4
4
10
4
4
4
1
1
1
SCREW, CAPTIVATED
NUT, FEED
KEY, MODIFIED
BEARING, SHOULDER
BLOCK, FEED
STAR WHEEL
SPACER
GEAR, WORM
WORM
BEARING
WORM GEAR COVER
WORM SLIDE FRICTION BUSHING
SCREW, FEED
SLIDE, MALE
PLATE, MOUNTING
GIB
DOVETAIL-LEFT
DOVETAIL-RIGHT
HOLDER, PARTING TOOL-LOW
COVER, PARTING TOOL
SSS, 8-32 X 1/8
KEY, 1/8 X 1/2 8630 ALLOY STL
WOODRUFF
SSS, 10-24 X 3/4
NUT, 10-24 NYLOCK
PIN, 3/16 X 3/4 ROLL
SHCS, 1/4-20 X 3/4
PIN, 1/4 X 3/4 DOWEL
PIN, 1/4 X 1-1/4 DOWEL
SHCS, 5/16-18 X 3/4
SHCS, 5/16-18 X 1
SSS, 5/16-18 X 1-1/2
NUT, 5/16-18 JAM
SHCS, 3/8-16 X 1-1/4
NUT, 1/2-20 NYLK THN
NUT, 5/8-18 CASTLE
1/4-28 GREASE ZERK
1
WEIGHT = 23.2lb. [10.5kg]
20
30
17
30
26
25
19
35
10
33
9
12
22
4
29
21
34
8
7
28
36
3
11
27
2
28
29
4
14
13
5
16
15
23
10
24
6
30
33
18
31
32
166
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 8, Parts Lists and Drawings:
Worm Gear Beveling Slide, 60-430-02
ITEM
PART NUMBER
QTY.
DESCRIPTION
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
43-067-00
53-087-00
60-235-00
60-288-00
60-290-00
60-291-00
60-292-00
60-293-00
60-294-00
60-295-00
60-296-00
60-296-01
60-306-00
60-307-00
60-308-00
60-309-00
60-310-00
60-311-00
60-312-00
60-313-03
60-314-00
90-024-04
4
1
1
2
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
2
23
90-029-43
1
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
90-044-07
90-045-04
90-046-57
90-050-07
90-054-08
90-056-07
90-056-12
90-060-07
90-060-10
90-064-15
90-065-04
90-070-12
90-095-07
90-205-09
90-500-05
1
1
1
4
2
4
4
4
14
4
4
4
1
1
1
SCREW, CAPTIVATED
NUT, FEED
KEY, MODIFIED
BEARING, SHOULDER
BLOCK, FEED
STAR WHEEL
SPACER
GEAR, WORM
WORM
BEARING
WORM GEAR COVER
WORM SLIDE FRICTION BUSHING
SCREW, FEED
SLIDE, MALE
PLATE, MOUNTING
GIB
DOVETAIL-LEFT
DOVETAIL-RIGHT
HOLDER, BEVEL TOOL
HOLDER, PARTING TOOL-HIGH
COVER, PARTING TOOL
SSS, 8-32 X 1/8
KEY, 1/8 X 1/2 8630 ALLOY STL
WOODRUFF
SSS, 10-24 X 3/4
NUT, 10-24 NYLOCK
PIN, 3/16 X 3/4 ROLL
SHCS, 1/4-20 X 3/4
SSS, 1/4-20 X 7/8
PIN, 1/4 X 3/4 DOWEL
PIN, 1/4 X 1-1/4 DOWEL
SHCS, 5/16-18 X 3/4
SHCS, 5/16-18 X 1
SSS, 5/16-18 X 1-1/2
NUT, 5/16-18 JAM
SHCS, 3/8-16 X 1-1/4
NUT, 1/2-20 NYLK THN
NUT, 5/8-18 CASTLE
1/4-28 GREASE ZERK
1
32
19
27
29
21
28
32
27
32
26
17
20
?
10
35
9
12
23
4
31
22
36
8
22
7
30
38
3
11
29
2
30
31
4
14
13
5
16
15
24
10
25
6
32
35
18
33
34
E.H. Wachs
Part No. 60-MAN-07, Rev. C167
Low Clearance Split Frame, Models 204-1420
Worm Gear Slide Trip Assembly, 60-431-00
ITEM
PART NUMBER
QTY.
1
2
3
4
5
6
52-113-00
60-267-00
60-268-00
90-026-55
90-059-08
90-900-52
2
1
1
1
1
1
DESCRIPTION
SCREW, CAPTIVATED
HOUSING, TRIP
TRIP
1/8" X 1/2" PIN
SPRING PLUNGER
KNOB, 1/4-20 X 10D PUSH
WEIGHT = .4lb. [.2kg]
1
1
4
2
3
6
5
LOCTITE 262
168
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 8, Parts Lists and Drawings:
Heavy Wall Parting Tool Holders, 60-433-00
ITEM
PART NUMBER
QTY.
DESCRIPTION
1
2
3
4
5
6
43-067-00
60-034-01
60-034-02
60-314-00
90-050-07
90-056-07
8
1
1
2
4
4
SCREW, CAPTIVATED
LOW HEAVY WALL PARTING TOOL HOLDER
HIGH HEAVY WALL PARTING TOOL HOLDER
COVER, PARTING TOOL
SHCS, 1/4-20 X 3/4
PIN, 1/4 X 3/4 DOWEL
5
1
5
1
4
2
6
4
6
60-034-01
(LOW HEAVY WALL PARTING TOOL HOLDER)
E.H. Wachs
3
60-034-02
(HIGH HEAVY WALL PARTING TOOL HOLDER)
Part No. 60-MAN-07, Rev. C169
Low Clearance Split Frame, Models 204-1420
Heavy Wall Carbide Tool Kit, 60-712-00
ITEM
PART NUMBER
QTY.
DESCRIPTION
1
2
3
60-712-01
60-712-02
60-713-00
1
1
1
HOLDER, HEAVY WALL CARBIDE
INSERT EXTRACTOR
.313 INSERT (60-712-00)
NOTES:
1. THE PURCHASE OF A HOLDER (60-712-01) ALSO
INCLUDES THE INSERT EXTRACTOR TOOL (60-712-02).
1.77 REF.
45.0
1
3
2
170
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 8, Parts Lists and Drawings:
1.5 HP Air Drive, 60-423-00
ITEM NO.
PART NUMBER
1
2
3
3.1
3.1.1
3.1.2
3.1.3
3.1.4
3.1.5
3.1.6
3.1.7
3.1.8
3.1.9
3.1.10
3.1.11
3.1.12
3.1.13
3.1.14
3.1.15
3.1.16
3.1.17
3.1.18
3.1.19
3.1.19.1
3.1.19.2
3.1.19.3
3.1.19.4
3.2
3.2.1
3.2.1.1
3.2.1.2
3.2.1.3
3.2.1.3.1
3.2.1.3.2
3.2.2
05-082-00
60-210-00
60-211-00
CLE-201812
CLE-202632
CLE-203109
CLE-202481
CLE-202011
CLE-617754
CLE-202626
CLE-202055
CLE-202508
CLE-864195
CLE-869933
CLE-843656
CLE-864973
CLE-622062
CLE-869931
CLE-622881
CLE-203111
CLE-832079
CLE-203203
CLE-201638
CLE-204178
CLE-202105
CLE-845409
CLE-869855
CLE-201311
CLE-201308
CLE-203105
CLE-204809
CLE-203107
CLE-203062
CLE-846659
CLE-861485
DESCRIPTION
ITEM NO.
QTY.
OILER, AIR LINE
FLANGE, 1.5 HP CLECO-AIR
CLECO AIR MOTOR (55NL-3T-960)
SUBASSY; HANDLE
PAD; MUFFLER
PAD; MUFFLER
PIN; VALVE
SEAL RING
O-RING
DEFLECTOR; EXHAUST
THROTTLE VALVE
INLET SPACER
PIN; LEVER
BUSHING; INLET
SCREEN
SPRING; THROTTLE VALVE
O-RING
SEAT; THROTTLE VALVE
O-RING
HANDLE - REVERSIBLE
SPRING
NUT, METERING
SUBASSY; LOCKOFF LEVER
LEVER; LOCKOFF
TOGGLE
PIN; SPRING
SPRING; TOGGLE
SUBASSY, GEAR TRAIN
GEAR SPIDER
2ND RED GEAR SPIDER
2ND GEAR PIN (3/16 DOWEL)
IDLER GEAR; 2ND RED.
BUSHING
GEAR 20T, IDLER GEAR
SPIDER; OPEN
PART NUMBER
3.2.2.1
3.2.2.2
3.2.3
3.2.3.1
3.2.4
3.3
3.3.1
3.4
3.5
3.6
3.6.1
3.6.2
3.6.3
3.6.4
3.6.5
3.6.6
3.6.7
3.6.8
3.6.9
3.7
3.8
3.9
3.10
3.11
3.12
3.13
3.14
3.15
3.16
3.17
4
5
6
7
8
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
3
2
1
1
DESCRIPTION
CLE-832125
CLE-867532
CLE-867526
CLE-844774
CLE-867544
CLE-203101
CLE-863887
CLE-203102
CLE-843444
CLE-861496
CLE-867507
CLE-842517
CLE-867511
CLE-867512
CLE-867546
CLE-867547
CLE-867548
CLE-882661
CLE-207288
CLE-865352
CLE-867520
CLE-867521
CLE-867522
CLE-867528
CLE-867536
CLE-869569
CLE-869572
CLE-203989
CLE-619377
CLE-382633
66-100-00
90-098-01
90-403-00
90-401-02
90-401-03
QTY.
IDLE GEAR PIN
GEAR SPIDER
GEAR; IDLER
BEARING; NEEDLE (B-36)
GEAR CASE (50T)
CYLINDER
PIN; SLOTTED SPRING
ROTOR
BEARING; BALL
HEAD, ANGLE (T-4)
ANGLE HEAD; LONG HEAVY DUTY
BALL BEARING
PINION
GEAR
PLUG, PIPE
BALL BEARING
BEARING
NEEDLE BEARING
SPINDLE, 1/2" SQ. DRIVE
ROTOR LOCK NUT
PLATE, MAKE-UP
LOCK NUT
SNAP RING
MOTOR MAKE UP PLATE
PLATE; FRONT BEARING
ROTOR BLADE
PLATE; REAR BEARING
BEARING CAP
BEARING
PROTECTOR, SPLINE
VALVE; SPEED CONTROL
NIPPLE, 1/2 CLOSE LP BLACK
LABEL, BURN HAZARD/HOT SURFACE
LABEL, PRESSURE-AIR
LABEL, EAR AND EYE PROTECTION
3
1
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
5
1
1
1
1
1
2
1
1
1
3.1.7
3.1.4
3.6.5
3.1.12
3.11
3.6.8
3.1.6
3.2.4
3.6.4 (SEE NOTE-2)
3.1.13
3.16
3.6.9
3.12
3.2.1.3.2
6
3.6.6
3.1.11
3.13
3.2.1.1
3.1.14
8
3.1.1
3.1.8
3.6.1
3.1.2
3.2.1.2
3.1.15
3.17
3.4
3.2.1.3.1
3.1.5
2
3.2.2.1
3.6.3
3.1.10
3.2.2.2
3.3.1
(SEE NOTE-2)
3.6.7
3.14
7
3.5
3.7
3.9
5
3.15
3.1.9
3.8
3.1.16
1
3.1.19.1
3.1.19.3
3.1.19.4
WEIGHT = 8.6 LB. [ 3.9 kg]
GEARS CAN BE PURCHASED AS SET, PART NO.: CLE-861478
E.H. Wachs
3.1.18
3.1.19.2
3.6.2
3.10
3.1.17
3.1.3
3.2.3.1
5
4
Part No. 60-MAN-07, Rev. C171
Low Clearance Split Frame, Models 204-1420
1.5 HP Air Drive, Ported Exhaust, 60-407-00
ITEM NO.
1
1.1
1.1.1
1.1.2
1.1.3
1.1.4
1.1.5
1.1.7
1.1.8
1.1.9
1.1.10
1.1.11
1.1.12
1.1.13
1.1.14
1.1.15
1.1.16
1.1.17
1.1.17.1
1.1.17.2
1.1.17.3
1.1.17.4
1.1.18
1.1.19
1.2
1.2.1
1.2.1.1
1.2.1.2
1.2.1.3
1.2.1.3.1
1.2.1.3.2
1.2.2
1.2.2.1
1.2.2.2
1.2.3
1.2.3.1
1.2.4
1.3
1.3.1
1.4
1.5
1.6
1.6.1
1.6.2
1.6.3
1.6.4
1.6.5
1.6.6
1.6.7
1.6.8
1.6.9
1.7
1.8
1.9
1.10
1.11
1.12
1.13
1.14
1.15
1.16
1.17
2
3
4
5
6
PART NUMBER
60-211-00
CLE-201812
CLE-202632
CLE-203109
CLE-202481
CLE-202011
CLE-617754
CLE-202055
CLE-202508
CLE-864195
CLE-869933
CLE-843656
CLE-864973
CLE-622062
CLE-869931
CLE-622881
CLE-203111
CLE-201638
CLE-204178
CLE-202105
CLE-845409
CLE-869855
CLE-832079
CLE-203203
CLE-201311
CLE-201308
CLE-203105
CLE-204809
CLE-203107
CLE-203062
CLE-846659
CLE-861485
CLE-832125
CLE-867532
CLE-867526
CLE-844774
CLE-867544
CLE-203101
CLE-863887
CLE-203102
CLE-843444
CLE-861496
CLE-867507
CLE-842517
CLE-867511
CLE-867512
CLE-867546
CLE-867547
CLE-867548
CLE-882661
CLE-207288
CLE-865352
CLE-867520
CLE-867521
CLE-867522
CLE-867528
CLE-867536
CLE-869569
CLE-869572
CLE-203989
CLE-619377
CLE-382633
60-210-00
66-100-00
90-098-01
60-215-00
05-082-00
DESCRIPTION
QTY.
CLECO AIR MOTOR (55NL-3T-960)
SUBASSY; HANDLE
PAD; MUFFLER
PAD; MUFFLER
PIN; VALVE
SEAL RING
O-RING
THROTTLE VALVE
INLET SPACER
PIN; LEVER
BUSHING; INLET
SCREEN
SPRING; THROTTLE VALVE
O-RING
SEAT; THROTTLE VALVE
O-RING
HANDLE - REVERSIBLE
SUBASSY; LOCKOFF LEVER
LEVER; LOCKOFF
TOGGLE
PIN; SPRING
SPRING; TOGGLE
SPRING
NUT, METERING
SUBASSY, GEAR TRAIN
GEAR SPIDER
2ND RED GEAR SPIDER
2ND GEAR PIN (3/16 DOWEL)
IDLER GEAR; 2ND RED.
BUSHING
GEAR 20T, IDLER GEAR
SPIDER; OPEN
IDLE GEAR PIN
GEAR SPIDER
GEAR; IDLER
BEARING; NEEDLE (B-36)
GEAR CASE (50T)
CYLINDER
PIN; SLOTTED SPRING
ROTOR
BEARING; BALL
HEAD, ANGLE (T-4)
ANGLE HEAD; LONG HEAVY DUTY
BALL BEARING
PINION
GEAR
PLUG, PIPE
BALL BEARING
BEARING
NEEDLE BEARING
SPINDLE, 1/2" SQ. DRIVE
ROTOR LOCK NUT
PLATE, MAKE-UP
LOCK NUT
SNAP RING
MOTOR MAKE UP PLATE
PLATE; FRONT BEARING
ROTOR BLADE
PLATE; REAR BEARING
BEARING CAP
BEARING
PROTECTOR, SPLINE
FLANGE, 1.5 HP CLECO-AIR
VALVE; SPEED CONTROL
NIPPLE, 1/2 CLOSE LP BLACK
COLLECTOR, EXHAUST
OILER, AIR LINE
1.6.5
1.6.8
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
3
2
1
1
3
1
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
5
1
1
1
1
1
1
2
1
1
1.1.7
1.1.12
1.1.4
1.11
1.1.13
1.2.4
1.16
1.1.14
1.12
1.6.9
1.2.1.3.2
1.6.6
2
5
1.1.11
1.6.4
1.13
1.1.1
1.1.8
1.2.1.3.1
1.6.1
1.2.1.1
1.2.1.2
1.6.3
1.2.2.2
1.6.7
1.1.15
1.1.5
4
1.4
1.3.1
1.14
1.1.3
1.5
1.2.2.1
1.1.2
1.7
6
1.1.17.2
1.6.2
1.15
1.2.3.1
1.9
1.8
4
1.10
3
1.1.9
1.1.17.1
1.1.16
WEIGHT: 9 LB. [4.1 kg.]
172
1.1.17.3
Part No. 60-MAN-07, Rev. C
1.1.17.4
E.H. Wachs
Chapter 8, Parts Lists and Drawings:
2.5 HP Air Drive, 60-423-01
ITEM NO.
1
2
3
3.1
3.1.1
3.1.2
3.1.3
3.1.4
3.1.5
3.1.6
3.1.7
3.1.8
3.1.9
3.1.10
3.1.11
3.1.12
3.1.13
3.1.14
3.1.15
3.1.16
3.1.16.1
3.1.16.2
3.1.16.3
3.1.16.4
3.2
3.3
3.3.1
3.3.2
3.4
3.5
3.6
3.7
3.7.1
PART NUMBER
05-082-00
60-328-00
60-329-00
CLE-201811
CLE-H203150
CLE-864195
CLE-202481
CLE-869943
CLE-615018
CLE-202050
CLE-202051
CLE-869933
CLE-622881
CLE-202508
CLE-843656
CLE-864973
CLE-202055
CLE-622062
CLE-869931
CLE-201638
CLE-204178
CLE-202105
CLE-845409
CLE-869855
CLE-203147
CLE-203149
CLE-848809
CLE-812918
CLE-869927
CLE-869925
CLE-865352
CLE-861914
CLE-869906
DESCRIPTION
OILER, AIR LINE
FLANGE, H.D. CLECO-MOTOR
CLECO AIR MOTOR - 75-NL-3V-959
SUB ASSY; HANDLE - 230959
HANDLE
PIN; LEVER
PIN; VALVE
MUFFLER
O-RING
SPACER, EXHAUST DEFLECTOR
DEFLECTER, EXHAUST
BUSHING; INLET
O-RING
INLET SPACER
SCREEN
SPRING; THROTTLE VALVE
THROTTLE VALVE
O-RING
SEAT; THROTTLE VALVE
SUBASSY; LOCKOFF LEVER
LEVER; LOCKOFF
TOGGLE
PIN; SPRING
SPRING; TOGGLE
ROTOR
CYLINDER
CYLINDER CASTING
PIN, CYLINDER
ROTOR BLADE
REAR BRG PLT
ROTOR LOCK NUT
SUBASSY; GEAR TRAIN (75-3)
GEAR CASE 50T
ITEM NO.
QTY.
3.7.2
3.7.3
3.7.4
3.7.5
3.7.6
3.7.6.1
3.7.6.2
3.7.7
3.7.7.1
3.7.7.2
3.8
3.9
3.10
3.10.1
3.10.2
3.10.3
3.10.4
3.10.5
3.10.6
3.10.7
3.10.8
3.10.9
3.10.10
3.11
3.12
3.13
3.14
4
5
3.6
7
8
9
1
1
1
1
1
1
1
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
5
1
1
1
1
PART NUMBER
CLE-869905
CLE-869908
CLE-869907
CLE-869903
CLE-869898
CLE-869898-X
CLE-832125
CLE-869900
CLE-866160
CLE-844774
CLE-869923
CLE-869929
CLE-861904
CLE-869874
CLE-861903B
CLE-861903A
CLE-207289
CLE-869882
CLE-867546
CLE-869881
CLE-869880
CLE-869877
CLE-847659
CLE-869878
CLE-869879
CLE-847528
CLE-847960
66-100-00
90-098-01
CLE-203989
90-403-00
90-401-02
90-401-03
DESCRIPTION
SPIDER; CAGE
GEAR SHAFT
NEEDLE ROLLER
2ND RED IDGEAR
OPEN SPIDER
OPEN SPIDER CAST
IDLE GEAR PIN
IDLER GEAR 1ST RED IDL GR
SEMI; IDLER GEAR
BEARING; NEEDLE (B-36)
FRONT BRG PLT
SPACER, MOTOR
SUBASM; RA HEAD (V-1/2 SQ)
ANGLE HEAD
GEAR SET*
GEAR SET*
1/2 S.D. SPINDLE
BEARING
PLUG, PIPE
SPINDLE BEARING
THRUST BRG
BEARING RETAIN
BEARING
CLAMP NUT
CLAMP RING
BALL BEARING
SET SCREW
VALVE; SPEED CONTROL
NIPPLE, 1/2 CLOSE LP BLACK
BEARING CAP
LABEL, BURN HAZARD/HOT SURFACE
LABEL, PRESSURE-AIR
LABEL, EAR AND EYE PROTECTION
QTY.
1
3
39
3
1
1
6
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
2
1
1
1
1
2
3.10.7
3.10.4
3.10.3
3.7.1
8
3.1.14
3.10.6
3.13
3.1.15
3.10.1
3.1.1
3.1.13
3.9
3.8
3.7.2
3.7.4
3.10.5
3.1.12
3.7.6.1
7
3.7.5
3.7.3
3.1.11
3.1.16.4
3.1.10
3.1.16.1
3.1.3
3.3.1
3.11
3.7.6.2
3.7.7.1
3.7.7.2
3.1.9
3.1.8
3.3.2
3.1.16.2
3.4
3.1.2
5
3.12
3.10.2
3.2
3.1.16.3
3.5
3.10.8
3.13
1
3.6
3.1.4
5
3.6
3.1.7
3.10.10
3.14
3.10.9
4
3.1.6
3.1.5
9
WEIGHT = 13.4 lb. [6.1 kg]
E.H. Wachs
Part No. 60-MAN-07, Rev. C173
Low Clearance Split Frame, Models 204-1420
2.5 HP Reversible Air Drive, 60-4010-00
ITEM NO. PART NUMBER
1
1.1
1.1.1
1.1.2
1.1.3
1.1.4
1.1.5
1.1.6
1.1.7
1.1.8
1.1.9
1.1.10
1.1.11
1.1.12
1.1.13
1.1.14
1.1.15
1.1.16
1.1.17
1.1.18
1.1.19
1.1.20
1.1.21
1.1.22
1.2
1.2.1
1.2.2
1.3
1.4
1.4.1
1.4.2
1.4.3
60-329-01
CLE-201330
CLE-203151
CLE-202050
CLE-202051
CLE-615018
CLE-869943
CLE-202055
CLE-202508
CLE-622062
CLE-843656
CLE-864973
CLE-869931
CLE-869933
CLE-202481
CLE-864195
CLE-865063
CLE-869942
CLE-847234
CLE-867554
CLE-869939
CLE-869940
CLE-617510
CLE-622881
CLE-203148
CLE-848810
CLE-812918
CLE-203147
CLE-861913
CLE-869906
CLE-869904
CLE-869902
DESCRIPTION
CLECO AIR MOTOR - 75RNL-4V-4
SUBASSY; HANDLE
HANDLE
SPACER, EXHAUST DEFLECTOR
DEFLECTER, EXHAUST
O-RING
MUFFLER
THROTTLE VALVE
INLET SPACER
O-RING
SCREEN
SPRING; THROTTLE VALVE
SEAT; THROTTLE VALVE
BUSHING; INLET
PIN; VALVE
PIN; LEVER
LEVER, THROTTLE
REVERSE RING
O-RING
SCREW, REVERSING VALVE
SPACER
VALVE, REVERSING
O-RING
O-RING
CYLINDER
CYLINDER CASTING
PIN, CYLINDER
ROTOR
SUBASM; GEAR TRAIN
GEAR CASE 50T
2ND RED SPIDER
IDLER GEAR 2ND RED IDL GR
QTY.
1
1
1
1
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1.1.17
ITEM NO. PART NUMBER
1.4.4
1.4.5
1.4.6
1.4.6.1
1.4.6.2
1.4.7
1.4.7.1
1.4.7.2
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.11.1
1.11.2
1.11.3
1.11.4
1.11.5
1.11.6
1.11.7
1.11.8
1.11.9
1.11.10
1.12
1.13
1.14
2
3
4
5
6
CLE-869907
CLE-869908
CLE-869897
CLE-832125
CLE-869897-X
CLE-869899
CLE-844774
CLE-869899-X
CLE-865352
CLE-869901
CLE-869923
CLE-869928
CLE-869929
CLE-869927
CLE-861904
CLE-869874
CLE-861903B
CLE-861903A
CLE-207289
CLE-869882
CLE-867546
CLE-869881
CLE-869880
CLE-869877
CLE-847659
CLE-869879
CLE-869878
CLE-847528
05-082-00
60-328-00
66-100-00
90-098-01
90-403-00
1.1.21
4
1.11.10
1.1.3
1.4.7.2
1.1.20
5
1.1.5
2
1.5
1.1.4
5
1.1.12
1.1.16
1.1.22
1.8
1.3
1.4.4
1.1.6
1.1.11
1.1.8
1.9
1.1.18
1.11.1
1.2.1
1.11.3
6
1.7
1.1.15
1.13
1.4.5
1.4.3
1.10
1.1.10
1.12
1.4.6.2
1.4.2
1.2.2
1.1.9
1.11.2
1.4.6.1
1.1.13
1.1.7
1.11.8
1.4.7.1
1.14
1.1.2
NEEDLE ROLLER
GEAR SHAFT
1ST RED SPIDER
IDLE GEAR PIN
OPEN SPIDER CAST
1ST RED IDLER GEAR (A&B)
BEARING; NEEDLE (B-36)
SEMI; IDLER GEAR
ROTOR LOCK NUT
1ST RED. PINION (A&B)
FRONT BRG PLT
REAR BRG PLATE
SPACER, MOTOR
ROTOR BLADE
SUBASM; RA HEAD (V-1/2 SQ)
ANGLE HEAD
GEAR SET*
GEAR SET*
1/2 S.D. SPINDLE
BEARING
PLUG, PIPE
SPINDLE BEARING
THRUST BRG
BEARING RETAIN
BEARING
CLAMP RING
CLAMP NUT
BALL BEARING
OILER, AIR LINE
FLANGE, H.D. CLECO-MOTOR
VALVE; SPEED CONTROL
NIPPLE, 1/2 CLOSE LP BLACK
LABEL, BURN HAZARD/HOT SURFACE
1.11.9
1.1.19
1.1.4
DESCRIPTION
1.4.1
1.14
1.1.14
1.6
1.11.5
1.11.6
1.11.4
1.1.1
1.11.7
WEIGHT = 14 lb. [6.4 kg]
174
Part No. 60-MAN-07, Rev. C
3
E.H. Wachs
QTY.
39
3
1
6
1
3
1
1
1
1
1
1
1
5
1
1
1
1
1
1
1
1
1
1
1
2
1
2
1
1
1
2
1
Chapter 8, Parts Lists and Drawings:
36
35
SEE NOTE 2
3
25
12
32
23
1
2
29
26
SEE NOTE 1
33
7
19
ITEM
PART NUMBER
QTY.
DESCRIPTION
1
02-199-00
1
MOTOR COUPLING, DRIVE PIN
2
02-203-00
1
ADAPTOR, DRIVE MOTOR
3
53-073-00
1
HYDRAULIC MOTOR
4
60-1186-00
1
LCSF FLOW DIRECTION LABEL
5
60-198-00
1
VALVE, MRV DIRECTIONAL CONTROL
6
60-199-00
1
MANIFOLD, SDB HYDRAULIC
7
60-213-00
1
HYD. MOTOR MOUNT
8
76-072-00
1
PLATE, MRV ANTI-ROTATION
CAP, MRV OPERATOR
9
76-073-00
1
10
76-074-00
1
SPRING, TORSION
11
76-075-00
1
PLATE, SPRING COVER
12
76-175-00
1
RETAINING RING, 43/64
13
76-176-00
1
VALVE, PRESSURE RELIEF
14
76-177-00
1
VALVE, PRESSURE COMPENSATED FLOW CONTROL
15
76-180-00
1
RING, 26MM EXT RETAINING
16
76-181-00
1
DETENT SPRING
17
76-182-00
1
SPACER
18
76-183-00
1
HANDLE, 5/16"-18
FLOW CONTROL LABEL
19
76-185-00
1
20
90-026-56
1
PIN, 1/8 x 5/8 ROLL
21
90-026-58
2
PIN, 1/8 X 7/8 ROLL
PIN, 1/8 X 1.125 ROLL
22
90-026-61
2
23
90-054-02
1
SSS, 1/4-20 x 1/4
24
90-055-18
1
NUT, 1/4-20 ACORN
1/4 x 1 WOODDRUFF KEY
25
90-059-48
0
26
90-060-12
2
SHCS, 5/16-18 X 1-1/4
27
90-061-34
4
HHCS, 5/16-18 X 3-1/2"
28
90-065-52
4
WASHER, 5/16 FLAT
29
90-078-67
0
O-RING -112
30
90-088-84
2
PLUG, -04 ZERO-LEAK ORB
PLUG, -06 ZERO-LEAK ORB
31
90-088-86
8
32
90-090-15
2
SHCS, 1/2-13 X 1-1/2
33
90-098-79
1
ADAPTER, 1/2 NPT M X 1/2 ORB M - STRAIGHT
34
90-098-89
1
ADAPTER, 1/2 ORB M X 1/2 NPT M - 90
35
90-401-01
1
LABEL, EYE PROTECTION
36
90-402-01
1
LABEL, PRESSURE-HYD.
37
90-403-02
1
LABEL, BURN HAZARD/HOT SURFACE
13
14
34
31
6
4
5
20
28
8
21
10
30
37
27
11
15
18
16
17
NOTE :
1.
2.
-112 (BUNA-N) O-RING COMES WITH HYDRAULIC MOTOR FOR
REPLACEMENTS CONTACT E.H. WACHS PART NUMBER #90-078-67
WOODRUFF KEY SUPPLIED WITH MOTOR E.H. WACHS PART MUMBER #90-059-48
E.H. Wachs
22
9
24
Part No. 60-MAN-07, Rev. C175
Low Clearance Split Frame, Models 204-1420
Hydraulic Drive, 60-424-02
176
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 8, Parts Lists and Drawings:
Hydraulic Drive, 60-424-01 (OBSOLETE)
FLOW OUT
WEIGHT: 25.4 lbs [11.5 kg]
MUST ATTACH MOTOR MOUNT TO PINION HOUSING
PRIOR TO MOUNTING HYDRAULIC MOTOR.
MAXIMUM FLOW: 15 GPM [57 LPM]
PRESSURE: UP TO 2000 PSI [138 BAR]
FLOW IN
1/2 NPT
1/2 NPT
PERFORMANCE DATA
FLOW
GPM [LPM]
2 [7.6]
4 [15.1]
6 [22.7]
8 [30.3]
10 [37.9]
12 [45.4]
14 [ 53.0]
15 [56.8]
11.631
295.4
8.231
209.1
3.934
99.9
RPM
47
94
141
188
235
282
330
353
4.022
102.2
3.125
79.4
ROTATION
1.838
46.7
.423
10.7
.500
12.7
6.688
169.9
INCREASE &
DECREASE FLOW KNOB
7.956
202.1
E.H. Wachs
R3.705
94.1
SPRING RETURN OPERATOR
Part No. 60-MAN-07, Rev. C177
Low Clearance Split Frame, Models 204-1420
Split Frame Air Control Module Schematic (60-375-00)
B
178
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 8, Parts Lists and Drawings:
Remote Control Hand Pendant (60-373-00)
ITEM
PART NUMBER
QTY.
1
2
3
4
5
6
7
56-206-00
60-1280-00
60-1281-00
60-1282-00
90-038-02
90-046-51
90-902-02
1
1
1
1
2
1
6 FT
DESCRIPTION
LEVER, LOCKOFF
HANDLE, SF REMOTE CONTROL
VALVE, CARTRIDGE
RING, SNAP .375 INTERNAL
ADAPTER, 1/8 NPTM X 1/4 PTC BRASS
PIN, 3/16 X 1 ROLL
HOSE, 1/4" OD x 1/8" ID TWIN-LINE PU
1
4
2
3
5
7
E.H. Wachs
6
Part No. 60-MAN-07, Rev. C179
Low Clearance Split Frame, Models 204-1420
180
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 9, Accessories and Spare Parts
Chapter 9
Accessories and Spare Parts
Accessories
The following equipment accessories expand the operating capabilities of the low clearance split
frame.
Table 1: Tool Slide Assemblies
Accessory
Description
Part No.
Parting slide
60-415-00
Beveling slide
60-416-00
Slide kit (parting slide, bev­eling slide, trip, extension blocks)
60-422-01
O.D. Tracking Slides (spring-loaded
slides to track the surface of out-ofround pipe) for 1824 through 4248
models
Parting slide
60-446-01
Beveling slide
60-446-02
Trip
60-446-03
Counterbore slide
Mounts to bevel slide for I.D. counterboring
60-405-UC
Single point beveling and counterboring applications with
LCSF models 1824 through 4248
60-428-24
60-428-28
60-428-32
60-428-36
60-428-39
60-428-42
60-428-28
Extended Tool Slides
Bridge slides
E.H. Wachs
Part No. 60-MAN-07, Rev. C181
Low Clearance Split Frame, Models 204-1420
Table 2: Drive Motors and Components
Description
Part No.
1.5 HP right angle air drive
60-423-00
1.5 HP right angle air drive with ported exhaust col­lector
60-407-00
Heavy duty 2.5 HP right angle air motor
60-423-01
2.5 HP right angle reversible air motor
60-4010-01
Hydraulic drive
60-424-01
Front drive pinion housing for 18”-48” LCSF
60-425-04
Air treatment module (for all air motors)
26-407-00
182
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 9, Accessories and Spare Parts: Tooling
Tooling
Table 3: LCSF Parting Tools
Part No.
Description
43-711-00
43-711-00P
3/16” x 3-7/16” (4.76 x 87 mm) HSS
parting tool
43-711-01
43-711-01P
3/16” x 5” (4.76 x 127 mm) HSS
parting tool
60-711-00
60-711-00P
1/4” x 6” (6.35 x 152 mm) HSS
parting tool
60-716-00
4.3” (110 mm) carbide insert holder
kit for 3/16” (4.76 mm) parting insert
60-717-00
3/16” (4.76 mm) car­bide insert
60-714-00
4.3” (110 mm) carbide insert holder
kit for 1/4” (6.35 mm) parting insert
60-715-00
1/4” (6.35 mm) carbide insert
60-SPT-11
3/16” wide special order
60-SPT-12
1/4” wide special order
60-SPT-13
1/2” wide special order
Design depends on application
HSS = High Speed Steel
60-SPT-XX are made to customer specifications; call for quotation.
Part numbers with “P” suffix are Premium Wachs tooling for high-alloy materials.
E.H. Wachs
Part No. 60-MAN-07, Rev. C183
Low Clearance Split Frame, Models 204-1420
Table 4: LCSF Beveling and Counterbore Tools
Description
Part No.
Application
HSS Inside Bevel Tool
30° x 3-1/8” (79 mm)
43-702-05
37.5° x 3-1/8” (79 mm)
43-703-05
Short bevel tool for most
materials. 30° - 1”
(25 mm) and 37.5° - 3/4”
(19 mm) maximum wall.
53-701-01
53-703-01P
53-701-00
53-703-00P
Long bevel tool for most
materials. 30° - 1”
(25 mm) and 37.5° - 3/4”
(19 mm) maximum wall.
30° x 3-1/8” (79 mm)
43-707-05
30° x 5” (127 mm)
43-707-06
37.5° x 3-1/8” (79 mm)
43-708-05
Outside bevel tool for
most materials. 30° - 1”
(25 mm) and 37.5° - 3/4”
(19 mm) maximum wall.
37.5° x 5” (127 mm)
43-708-06
30° x 5” (127 mm)
37.5° x 5” (127 mm)
HSS Outside Bevel Tool
HSS Double Bevel Tool
30° x 3-1/8” (79 mm)
43-709-05
30° x 5” (127 mm)
43-709-06
37.5° x 3-1/8” (79 mm)
43-710-05
37.5° x 5” (127 mm)
43-710-06
Double bevel tool for
most materials. 3/4”
(19 mm) maxi­mum wall.
HSS Compound Bevel Tool
10° x 37.5° x 4” (102 mm)
43-712-01
inside
10° x 37.5° x 4” (102 mm)
43-712-02
outside
10° x 37.5° x 5” (127 mm)
53-705-00
inside
10° x 30° x 5” (127 mm)
inside
HSS Counterbore Tool
Compound bevel tool for
most materials. 1-1/4”
(32 mm) maximum wall
for both tools.
53-704-00
60-700-04
4:1 taper; counterbores
most materials. Requires 60-405-US
universal counterbore
slide or 60-420-XX
bridge slide.
HSS = High Speed Steel
Part numbers with “P” suffix are Premium Wachs tooling for high-alloy materials.
Special Application Tooling
184
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 9, Accessories and Spare Parts: Tooling
Table 4: LCSF Beveling and Counterbore Tools
Description
Part No.
3/4” wide x 3-1/8” HSS
single angle bevel
1-1/2” wide x 3-1/8” HSS
single angle outside
bevel
1-1/2” wide x 3-1/8” HSS
double bevel
3/4” wide x 5” HSS single
angle bevel
Application
60-SPT-02
60-SPT-03
60-SPT-05
60-SPT-02
1-1/2” wide x 5” HSS
sin­gle angle outside
bevel
60-SPT-04
1-1/2” wide x 5” HSS
double bevel
60-SPT-06
Design depends on application
60-SPT-XX are made to customer specifications; call for quotation.
Table 5: LCSF Compound Angle Beveling Tools
Part No.
Description
43-712-01
10° x 37.5° inside bevel
53-704-00
10° x 30° inside bevel
53-705-00
10° x 37.5° inside bevel
43-712-02
10° x 37.5° outside bevel
60-SPT-07
60-SPT-08
60-SPT-09
Custom HSS compound
bevel tool
Custom single-angle
HSS J-Prep bevel tool
Design depends on application
Custom compound-angle
HSS J-Prep bevel tool
HSS = High Speed Steel
60-SPT-XX are made to customer specifications; call for quotation.
E.H. Wachs
Part No. 60-MAN-07, Rev. C185
Low Clearance Split Frame, Models 204-1420
Table 6: Single Point Tooling (Used with Bridge Slide)
Part No.
52-701-01
52-701-00P
52-711-01
52-711-02
Description
HSS tool bit for single
point facing and bevel­
ing. Standard 3/8” x 3/8”
(9.53 x 9.53 mm).
HSS 3/32” (2.38 mm)
radius tool bit for J-prep
HSS 1/8” (3.18 mm)
radius tool bit for J-prep
52-711-03
HSS 3/16” (4.76 mm)
radius tool bit for J-prep
60-707-00
Tool holder for HSS tool
bits
HSS = High Speed Steel
Part numbers with “P” suffix are Premium Wachs tooling for high-alloy materials.
186
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 9, Accessories and Spare Parts: Recommended Spares
Hydraulic Power Units
The following Wachs hydraulic power units (HPUs) are designed to operate low clearance split
frames and similar tools.
Table 7: Hydraulic Power Units for LCSF
Power Unit
Part No.
HCM-1G gas powered, 8 gpm @ 1500 psi (30 l/min @ 103 bar)
14-000-01
HCM-2E2 electric powered, 8 gpm @ 1500 psi
(30 l/min @ 103 bar)
14-000-06
HCM-2E4 electric powered, 8 gpm @ 1500 psi
(30 l/min @ 103 bar)
14-000-07
HCM-2G gas powered, 10 gpm @ 1500 psi
(38 l/min @ 103 bar)
14-000-08
HCM-3D diesel powered, 10 gpm @ 1500 psi
(38 l/min @ 103 bar)
14-000-09
HCM-3G gas powered, 14 gpm @ 1500 psi
(53 l/min @ 103 bar)
14-000-25
HCM-4D diesel powered, 14 gpm @ 1500 psi
(53 l/min @ 103 bar)
14-000-26
HPU-15 electric powered, 0-15 gpm @ 1500 psi
(0-57 l/min @ 103 bar)
14-000-20
HSM-5D diesel powered (skid mount), 14 gpm @ 1500 psi (53 l/min @ 103 bar)
14-000-31
HTM-5D diesel powered (trailer mount), 14 gpm @ 1500 psi (53 l/min @ 103 bar)
14-000-32
Tandem Pump Offshore diesel powered, 15 gpm @ 2000 psi (57 l/min @ 140 bar)
14-000-12
Recommended Spares
Spare parts and fastener kits are available for the LCSF. Select the kit(s) appropriate for your LCSF
model. Separate kits are provided for the base LCSF machine and for the tool slides.
(Note that the spare parts kits include fastener kits. Fastener kits can also be purchased separately.)
E.H. Wachs
Part No. 60-MAN-07, Rev. C187
Low Clearance Split Frame, Models 204-1420
Table 8: LCSF Spare Parts Kits
Kit No.
60-551-02
60-551-04
60-551-05
188
Description
Part Description
Spare Parts Kit for LCSF, 24”
through 48”
(models 1824 through 4248)
Spare Parts Kit for Extended
Slide Set (60-422-01)
Spare Parts Kit for Super
Extended Slide Set (60-440-00)
Part No.
Qty
Rear Pinion Bearing
60-125-00
1
SHCS, 1/2-13 x 2-1/2 Captivated
60-207-00
2
Bearing Eccentric
60-256-00
6
Bearing Spacer
60-257-00
6
SHCS, 3/4-10 x 3 Captivated
60-259-00
2
Bearing, Guide Wheel
60-260-00
6
Swing Bolt
60-263-00
2
Detent Pin
60-264-00
2
SHSB, 1/2 X 1-1/2
90-097-65
1
1/2” Eye Bolt
90-099-01
1
Kit, LCSF 24”-48” Fasteners
60-550-02
1
Feed Screw
60-195-00
1
Alignment Pin
60-196-00
2
Feed Nut
60-229-00
2
Shim Kit
60-232-00
1
Trip Pin
60-338-00
2
Kit, LC Slide Fasteners
60-550-03
1
Spring Plunger, 1/4-20 x 1/2
90-059-08
1
Alignment Pin
60-196-00
2
Feed Nut
60-229-00
2
Feed Screw
60-319-00
1
Shim, 0.002”
60-322-00
5
Trip Pin
60-338-00
2
Feed Screw Bushing
60-339-00
2
Kit, Extended Slide Fasteners
60-550-05
1
Spring Plunger, 1/4-20 x 1/2
90-059-08
1
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 9, Accessories and Spare Parts: Recommended Spares
Table 8: LCSF Spare Parts Kits
Kit No.
60-551-06
60-551-07
E.H. Wachs
Description
Part Description
Spare Parts Kit for Worm Slide
Set (60-430-00)
Spare Parts Kit for Universal
Counterbore Slide
Part No.
Qty
SHCS, 1/4-20 x 3/4 Captivated
43-067-00
1
Feed Nut
53-087-00
2
Modified Key
60-235-00
1
Trip Pin
60-268-00
1
Shoulder Bearing
60-288-00
2
Starwheel
60-291-00
1
Worm Gear
60-293-00
1
Feed Screw
60-306-00
1
Kit, Worm Slide Fasteners
60-550-06
1
Spring Plunger, 1/4-20 x 1/2
90-059-08
1
Feed Screw
60-147-00
1
Bushing LC1-12
60-150-00
1
Bushing LC1-3
60-157-00
1
Rev. 1 to Rev 2 Upgrade Kit
60-370-00
1
Kit, Universal Counterbore Slide
Fasteners
60-550-07
1
Part No. 60-MAN-07, Rev. C189
Low Clearance Split Frame, Models 204-1420
190
Part No. 60-MAN-07, Rev. C
E.H. Wachs
Chapter 10, Ordering Information
Chapter 10
Ordering Information
To place an order, request service, or get more detailed information on any E.H. Wachs products,
call us at one of the following numbers:
U.S.800-323-8185
International:847-537-8800
You can also visit our Web site at:
www.ehwachs.com
Ordering Replacement Parts
When ordering parts, refer to the drawings and parts lists in Chapter 8. Please provide the part
description and part number for all parts you are ordering.
Repair Information
Please call us for an authorization number before returning any equipment for repair or factory
service. We will advise you of shipping and handling. When you send the 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.
Before we perform any repair, we will estimate the work and inform you of the cost and the time to
complete it.
E.H. Wachs
Part No. 60-MAN-07, Rev. C191
Low Clearance Split Frame, Models 204-1420
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
192
Part No. 60-MAN-07, Rev. C
E.H. Wachs
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