Wachs Trav-L-Cutter E User Manual Download Page 3

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Table of Contents

E.H. Wachs

Part No. 02-MAN-01, Rev. A i

Table of Contents

Chapter 1: Introduction to the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Purpose of This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

How to Use The Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Symbols and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Manual Updates and Revision Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Equipment Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Compact Design, Easy Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Standard Weld Prep Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Grooved, Mechanical Joint Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Offshore or Pipe Line Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Corrosion Resistant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Operates Anywhere . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Safe, Cold Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Fast, Reliable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Chapter 2: Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Safe Operating Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Safe Operating Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Operating and Maintenance Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Safety Alerts in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Protective Equipment Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Protective Clothing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Eye Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Hearing Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Chapter 3:

Machine Specifications

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Chapter 4:

Setup and Operating Procedures

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Wheel Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Chain Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Wheel Settings and Chain Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Chain Length Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Machine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Operating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Special Instructions for Assembling 2” Wide Drive Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Operating Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Chapter 5: Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Lubrication Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Summary of Contents for Trav-L-Cutter E

Page 1: ...04 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 E H Wachs 600 Knightsbridge Parkway Lincolnshire IL 6006...

Page 2: ...cal Standards Specifications Applied or Referenced EN ISO 12100 1 2003 A1 2009 EN ISO 12100 2 2003 A1 2009 EN 60201 1 2006 for electric machines EN ISO 13857 2008 EN 982 1996 A1 2008 E for hydrailic m...

Page 3: ...afe Cold Cutting 4 Fast Reliable 4 Chapter 2 Safety 5 Safe Operating Guidelines 5 Safe Operating Environment 6 Operating and Maintenance Safety 6 SafetyAlerts in This Manual 6 Protective Equipment Req...

Page 4: ...L Cutter ii Part No 02 MAN 01 Rev A E H Wachs Chapter 6 Consumable Select Chart 25 Data on Cutter Size 25 Cutters 27 Chapter 7 Troubleshooting Problems 29 Chapter 8 Parts Lists Exploded View Drawings...

Page 5: ...ns for set up operation and maintenance It also contains parts lists and diagrams and troubleshooting instructions to help you order replacement parts and perform user service able repairs How to Use...

Page 6: ...zardous situa tion that could result in seri ous injury or death CAUTION A CAUTION alert with the safety alert symbol indicates a potentially hazardous situa tion that could result in minor or moderat...

Page 7: ...w profile design needs only 10 to 12 of clearance and set up time is ten minutes or less Once the adjustable drive chain is pinned together and tensioned around the pipe the machine is ready to operat...

Page 8: ...ng to depths of 600 feet Safe Cold Cutting The Trav L Cutter can be used in explosive conditions onnatural gas crude product and fuel lines It has even been used to cut missile fuel cells Fast Reliabl...

Page 9: ...hazard READ THE OPERATING MANUAL Make sure you under stand all setup and operating instructions before you begin Keep this manual with the machine INSPECT MACHINE AND ACCESSORIES BEFORE USE Before st...

Page 10: ...e 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 se...

Page 11: ...is Chips can be very sharp and can cause serious cuts Do not wear gloves when the machine is operating Eye Protection Always wear impact resistant eye protection while operat ing or working near this...

Page 12: ...Trav L Cutter 8 Part No 02 MAN 01 Rev A E H Wachs...

Page 13: ...to 1829 mm pipe large diameter vessels All schedules Cutter Drive Pneumatic 4 H P GovernedAir Motor coupled with worm gearbox Hydraulic As above with hydraulic motor Cutter Speed Pneumatic 55 R P M I...

Page 14: ...8 lbs 190 kg Dimensions Length 24 61 cm Width 20 51 cm Height 10 3 4 28 cm Controls Pneumatic and Hydraulic Cutter on off feed on off with interlock to prevent machine feed unless cutter is turning Ad...

Page 15: ...69 246 6 75 171 5 10 31 262 29 72 REF 754 9 2 37 60 2 BLADE TRAVEL 3 13 79 4 MIN 6 25 158 8 MAX 15 00 381 19 76 502 25 30 642 6 50 12 7 66 TYP 16 8 15 12 384 2 16 56 CUT LINE 420 5 17 43 REF CUT LINE...

Page 16: ...ND PLUG 16 02 212 00 1 FLOW CONTROL VALVE 1 4 17 90 044 53 4 SSS 10 32 X 5 16 CP NOT SHOWN 18 90 058 02 1 NIPPLE 1 4 X 5 GALV LP 19 90 058 04 1 COUPLING 1 4 GALV LP 20 90 058 05 3 1 4 NPT F X 1 4 NPT...

Page 17: ...2 6 13 155 6 9 69 246 6 75 171 5 10 31 262 BLADE TRAVEL 3 13 79 4 MIN 6 25 158 8 MAX 15 00 381 26 07 662 1 1 35 REF 34 2 19 76 502 12 49 317 2 66 TYP 16 8 15 12 384 2 16 56 CUT LINE 420 5 18 28 REF C...

Page 18: ...218 00 1 MANIFOLD 17 02 298 00 1 LABEL TRAV L CUTTER HYD NOT SHOWN 18 90 029 44 1 KEY 1 8 X 1 2 3 WOODRUFF 404 NOT SHOWN 19 90 058 51 1 ADAPTER 1 4 NPT M X 1 4 NPT F SWIVEL 45 20 90 058 52 2 ADAPTER...

Page 19: ...R A V E L M A C H I N E T R A V E L M A C H I N E T R A V E L M A C H I N E T R A V E L M A C H I N E T R A V E L PIP E 6 00 13 99 152 355mm PIP E 20 00 35 99 508 914mm PIP E 48 00 72 00 1219 1829mm W...

Page 20: ...0 D 83 2108mm 02 450 20 D 24 S 24 00 610mm 13 330mm 02 457 24 91 2312mm 02 450 24 Di 25 80 655mm 96 2438mm 30 S 30 00 762mm 20 508mm 02 457 30 111 2819mm 02 450 30 Di 32 00 813mm 116 2946mm 36 S 36 00...

Page 21: ...1194 55 1397 61 1549 63 1600 69 1752 76 1930 83 2108 96 2438 116 2946 133 3378 152 3861 173 4394 194 4928 207 5258 X PIPE DIAMETER 6 8 10 12 14 16 18 20 24 30 36 42 48 54 60 72 Chain Length Calculatio...

Page 22: ...17 shown in figure 1 should be removed and the wheel assemblies taken from the carriage Place the wheel assemblies in the proper slots in the carriage Make sure the protruding dowel pins Part No 90 07...

Page 23: ...tting and Chain Length inside cover Leave six inches protruding on valve end of machine balance of chain on other end 6 Place the machine on the pipe and join the open ends of the chain with a connect...

Page 24: ...owly feed the rotating cutter down until it extends through the wall of the pipe by approximately 1 4 This is done by turning the feed screw Part No 02 001 00 in a clockwise direction One complete tur...

Page 25: ...Start with the basic length marked 6 and add to it in sequence the pieces marked 8 10 12 If this chain is correctly assembled it will be the proper length to be threaded through the Trav LCutter and w...

Page 26: ...90 psi and volume of approximately 100 cu ft per minute 4 Cut cast iron and ductile iron pipe dry Use a thread cutting oil or a water soluble cutting oil on steel and stainless steel pipe to lubricat...

Page 27: ...8 324 6 14 78 375 4 02 207 14 02 428 14 14 03 356 4 16 03 407 2 02 207 16 02 428 16 16 03 407 2 18 03 458 0 02 207 18 02 428 18 18 03 458 0 20 03 508 8 02 207 20 02 428 20 20 03 508 8 22 03 559 6 02 2...

Page 28: ...Trav L Cutter 24 Part No 02 MAN 01 Rev A E H Wachs...

Page 29: ...and require no further lubrication The bronze bushings are composed of Sintered Bronze and are oil impregnated and should require no further lubrication under normal conditions Under severe condition...

Page 30: ...ing out of hole add Heavy Duty Worm Gear Oil p n 02 401 00 with an oil can until oil is running out of hole Replace plug To check oil level in Drive Gear Box p n 02 194 00 B remove Trav L Cutter cover...

Page 31: ...pe may require the use of the next larger size cutter If the wall thickness of the pipe is unknown feed the cutter into the pipe as far as possible and then retract it so that the cut can be inspected...

Page 32: ...e 5 RH Bevel One 6 Cutter for steel pipe One 5 LH Bevel All mounted on drive collars 8 for Steel Pipe H S S 7 for Steel Pipe H S S 6 for Steel Pipe H S S 8 for Cast Iron and Cement Lined Pipe Carbide...

Page 33: ...L CARBIDE TIPPED SAW PART NO SIZE APPLICATION 02 605 00 6 X 3 16 FOR CAST IRON AND CEMENT LINED PIPE UP TO 1 WALL 02 606 00 7 X 3 16 FOR CAST IRON AND CEMENT LINED PIPE UP TO 1 1 2 WALL 02 607 00 8 X...

Page 34: ...Trav L Cutter 30 Part No 02 MAN 01 Rev A E H Wachs...

Page 35: ...oil and check for leaks 2 Chain drive sprocket breakage 1 Damaged chain Replace 2 Chain connected incorrectly Check connection points and correct 3 Connection pin not fully inserted Insert completely...

Page 36: ...bration 1 Feed too fast Slow feed 2 Cutter too deep Raise cutter 3 Dull cutter Replace cutter 4 Drive chain loose Check tension per instructions 5 Cutter installed backwards Replace cutter and install...

Page 37: ...Chapter 8 Parts Lists Exploded View Drawings E H Wachs Part No 02 MAN 01 Rev A 33 Chapter 8 Parts Lists Exploded View Drawings...

Page 38: ...1 LINE UP PIN NOT SHOWN 9 02 162 00 1 WRENCH TORQUE NOT SHOWN 10 02 175 00 3 STEEL WEDGE NOT SHOWN 11 02 176 00 1 STORAGE CASE NOT SHOWN 12 02 177 00 1 CASE DIVIDER FOR BLADES NOT SHOWN 13 02 287 00 1...

Page 39: ...ESCRIPTION 1 02 163 00 1 BODY AIR FILTER 2 02 164 00 1 FILTER ELEMENT 3 02 166 00 1 AIR LINE LUBRICATOR 4 02 171 00 1 INLET AIR HOSE WHIP 3 4 X 2 5 02 192 00 1 END PLUG 6 90 218 01 1 NIPPLE 3 4 CLOSE...

Page 40: ...MOTOR AND FRAME ASSEMBLY 18 02 500 03 1 KIT CUTTER SPACERS 3 16 11 16 3 4 18 1 02 290 03 2 SPACER TRAV L CUTTER 18 2 02 290 17 1 SPACER TRAV L CUTTER 18 3 02 290 20 1 SPACER TRAV L CUTTER 19 90 048 0...

Page 41: ...2 307 00 1 SPROCKET ASSEMBLY 8 02 308 00 1 MANIFOLD ASSEMBLY 9 02 309 00 1 AIR MOTOR AND SPINDLE ASSEMBLY 10 02 310 00 1 CARRIAGE DRIVE AND FRAME ASSEMBLY 11 90 098 57 1 ADAPTER 1 2 NPT F X 1 2 NPT F...

Page 42: ...058 04 1 COUPLING 1 4 GALV LP 4 90 058 05 1 1 4 NPT F X 1 4 NPT M BRASS LP 90 5 90 058 51 1 ADAPTER 1 4 NPT M X 1 4 NPT F SWIVEL 45 6 90 098 01 1 NIPPLE 1 2 CLOSE LP BLACK 7 90 098 04 1 ELBOW 1 2 45 S...

Page 43: ...Chapter 8 Parts Lists Exploded View Drawings 39 ITEM PART NUMBER QTY DESCRIPTION...

Page 44: ...TEN SCREW 6 02 131 00 1 SHAFT GUIDE ROLLER INSIDE 7 02 132 01 1 ROLLER CHAIN GUIDE 8 02 133 00 2 BUSHING 9 02 137 02 1 CARRIAGE UNIVERSAL 10 02 191 00 1 SHIM GEAR BOX 11 02 301 00 1 CARRIAGE DRIVE AS...

Page 45: ...L AIR 3 02 037 00 1 CLAMP AIR MOTOR 4 02 043 00 1 OVERLOAD SAFETY COUPLING 5 02 108 00 1 SPROCKET DRIVE 6 02 194 00 1 GEAR BOX CARRIAGE DRIVE 7 02 212 00 1 FLOW CONTROL VALVE 1 4 8 90 027 12 1 KEY 1 8...

Page 46: ...02 203 00 1 MOTOR COUPLING CUTTER SPINDLE 4 02 252 00 1 ADAPTER MOTOR TRV L CUTTER I R 4800P 5 23 181 00 1 MUFFLER 6 90 057 13 1 KEY 1 4 SQ X 1 3 8 7 90 098 05 1 ELBOW 1 2 90 STREET 8 90 098 75 1 BUS...

Page 47: ...Chapter 8 Parts Lists Exploded View Drawings 43 ITEM PART NUMBER QTY DESCRIPTION...

Page 48: ...Trav L Cutter 44 ITEM PART NUMBER QTY DESCRIPTION Trav L Cutter Assembly Hydraulic Drive 02 000 02...

Page 49: ...ASSEMBLY 15 02 317 00 1 HYD MOTOR AND FRAME ASSEMBLY 16 02 500 03 1 KIT CUTTER SPACERS 3 16 11 16 3 4 16 1 02 290 03 2 SPACER TRAV L CUTTER 16 2 02 290 17 1 SPACER TRAV L CUTTER 16 3 02 290 20 1 SPAC...

Page 50: ...INK 6 02 178 01 4 COMPRESSION SPRING 7 02 307 00 1 SPROCKET ASSEMBLY 8 02 314 00 1 HYD CARRIAGE DRIVE AND FRAME ASSEMBLY 9 02 315 00 1 HYD MANIFOLD ASSEMBLY 10 02 316 00 1 HYD MOTOR AND SPINDLE ASSEMB...

Page 51: ...IN TEN SCREW 6 02 131 00 1 SHAFT GUIDE ROLLER INSIDE 7 02 132 01 1 ROLLER CHAIN GUIDE 8 02 133 00 2 BUSHING 9 02 137 02 1 CARRIAGE UNIVERSAL 10 02 206 01 1 SHIM HYDRAULIC GEAR BOX 11 02 306 00 1 SLIDE...

Page 52: ...1 MANIFOLD 7 90 058 51 1 ADAPTER 1 4 NPT M X 1 4 NPT F SWIVEL 45 8 90 058 52 2 ADAPTER 1 4 NPT M X 1 4 NPT F SWIVEL 90 9 90 058 58 2 NIPPLE 1 4 HEX H P 10 90 098 55 4 ADAPTER 1 2 NPT M X 1 2 NPT F SWI...

Page 53: ...SEMBLY 2 02 027 01 2 HOSE 1 2 HP X 30 LONG 3 02 199 00 1 MOTOR COUPLING DRIVE PIN 4 02 201 00 1 HYDRAULIC MOTOR CUTTER SPINDLE 5 02 202 00 1 ADAPTER CUTTER SPINDLE MOTOR 6 02 203 00 1 ADAPTOR DRIVE MO...

Page 54: ...RAULIC MOTOR CARRIAGE DRIVE 5 02 204 00 1 ADAPTER DRIVE MOTOR 6 02 205 00 1 BRACKET MOUNTING DRIVE MOTOR 7 02 214 01 2 1 4 HP HOSE ASSEMBLY 8 90 027 12 1 KEY 1 8 SQ X 1 1 4 9 90 029 44 1 KEY 1 8 X 1 2...

Page 55: ...RING RETAINING 2 02 132 01 1 ROLLER CHAIN GUIDE 3 02 133 00 2 BUSHING 4 02 144 00 1 AXLE 5 02 148 00 2 BRACKET AXLE 6 02 151 00 2 BEARING BALL 7 02 152 01 2 WHEEL 8 90 076 15 1 PIN 3 8 X 1 1 2 DOWEL 9...

Page 56: ...ITEM PART NUMBER QTY DESCRIPTION 1 02 001 00 1 SCREW FEED 2 02 002 00 1 RING RETAINING 3 02 003 00 1 BEARING BALL 4 02 005 00 1 BEARING HOUSING FEED SCREW 5 02 006 00 1 LOCK NUT FEED SCREW BEARING Fee...

Page 57: ...TEM PART NUMBER QTY DESCRIPTION 1 02 004 00 1 BOLT MODIFIED 1 2 13 X 1 00 SS 2 02 084 00 1 SLIDE CHAIN TENSION SPROCKET 3 02 086 00 1 SPROCKET 4 02 087 00 1 BUSHING TENSIONING SPROCKET 5 90 195 52 1 W...

Page 58: ...EARING 2 02 078 00 1 LOCKNUT BEARING 3 02 090 00 1 SHAFT CARRIAGE DRIVE 4 02 092 00 1 RING RETAINING 5 02 093 00 2 BEARING BALL 6 02 095 00 1 HOUSING FRONT BEARING 7 02 096 01 1 SPACER 8 02 096 02 1 S...

Page 59: ...1 BEARING NEEDLE 9 02 065 00 2 SEAL 10 02 070 00 1 LARGE OIL PLUG 11 02 073 01 1 SPINDLE CUTTER 12 02 074 00 2 BEARING BALL 13 02 075 00 1 GEAR WORM BRONZE 14 02 076 00 1 BEARING BALL 15 02 077 00 1...

Page 60: ...ITEM PART NUMBER QTY DESCRIPTION 1 02 001 00 1 SCREW FEED 2 02 002 00 1 RING RETAINING 3 02 003 00 1 BEARING BALL 4 02 005 00 1 BEARING HOUSING FEED SCREW 5 02 006 00 1 LOCK NUT FEED SCREW BEARING Fee...

Page 61: ...ings 57 4 5 3 2 1 ITEM PART NUMBER QTY DESCRIPTION 1 02 002 00 2 RING RETAINING 2 02 151 00 2 BEARING BALL 3 02 197 01 2 WHEEL GUIDE TRACK 4 90 190 10 2 SHCS 1 2 13 X 1 0 SS18 8 5 90 195 52 2 WASHER 1...

Page 62: ...PART No 02 405 00 COOLANT HOSE REF PART NO QTY DESCRIPTION 031 172 190 1 2 3 4 02 031 00 02 172 00 02 190 00 90 058 51 90 058 57 90 098 01 90 098 12 1 1 1 2 1 1 1 HOSE TRAVEL MOTOR PLATE MOUNTING ATT...

Page 63: ...Spray Mist System PART No 02 430 00 REF PART NO QTY DESCRIPTION 280 281 282 283 071 051 055 02 280 00 02 281 00 02 282 00 02 283 00 56 071 00 90 051 07 90 055 01 1 1 2 1 1 1 2 TANK PRESSURE NOZZLE VAL...

Page 64: ...229 4 102 34 864 11 54 STEEL PIPE 279 20 54 DUCTILE PIPE 508 29 60 STEEL PIPE 737 33 60 DUCTILE PIPE 838 67 72 STEEL PIPE 1702 2 1 ITEM PART NUMBER QTY DESCRIPTION 1 02 157 00 67 SILENT CHAIN 2 02 15...

Page 65: ...ing ordered REPAIR INFORMATION Please call E H Wachs Company prior to returning any equipment for repair We will advise you of shipping and handling Please enclose with equipment to be repaired your n...

Page 66: ...s RETURN GOODS ADDRESS E H Wachs Company 600 Knightsbridge Parkway Lincolnshire Illinois 60069 Call or Write E H Wachs Company 600 Knightsbridge Parkway Lincolnshire Illinois 60069 847 537 8800 FAX 84...

Page 67: ......

Page 68: ...E H WACHS Superior Equipment Complete Support 600 Knightsbridge Parkway Lincolnshire IL 60069 847 537 8800 www wachsco com...

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