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Diamond Wire Saw User’s Manual

Part No. 10-010-MAN, Rev. 1-0310

E.H. Wachs

Summary of Contents for WS-8460

Page 1: ...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 60069 www ehwachs com E H Wachs Part No 10...

Page 2: ...Diamond Wire Saw User s Manual Part No 10 010 MAN Rev 1 0310 E H Wachs...

Page 3: ...Lifting for Horizontal Cut 11 Rigging the WS 8460 12 Storing the Machine 12 Operating Envelope 13 Chapter 2 Safety 15 Operator Safety 15 Safety Symbols 16 Protective Equipment Requirements 17 Safety L...

Page 4: ...on the WS 8460 41 Replacing the Mounting Shoes 42 Replacing the Wheel Liners 42 Tension and Idler Wheels 43 Drive Wheel 46 Bleeding the Feed Tension Control 49 Chapter 5 Parts List and Ordering Infor...

Page 5: ...s manual refer to this column for warnings cautions and notices with supplementary information This manual is organized to help you quickly find the infor mation you need Each chapter describes a spec...

Page 6: ...l indicates a potentially hazardous situa tion that could result in minor or moderate injury A CAUTION alert with the damage alert symbol indi cates a situation that will result in damage to the equip...

Page 7: ...designed to cut submerged pipe of varying materials and thicknesses The machine operates on hydraulic power and is controlled remotely using the Wachs topside control panel TCP The saw uses a continuo...

Page 8: ...e and the second pair of digits is the smallest For example the WS 3616 saw will cut pipes from 16 to 36 406 to 914 mm O D Various wire saw models are available each designed to cut a range of pipe si...

Page 9: ...cutting wire The tension wheel is on a pivoting spring loaded fixture that maintains wire tension The other two idler wheels are fixed at the bottom of the bow where the cutting wire engages the pipe...

Page 10: ...along the center rail drives the bow Figure 1 3 The feed system components are shown The feed block is attached to the saw bow The top of the feed screw has a drive nut to allow the feed to be operat...

Page 11: ...re A hydraulic actuator on the tension wheel fixture measures the deflection of the wire as it cuts If the feed speed is too fast the increased wire deflection trips the actuator which slows down the...

Page 12: ...me When the cylinder rods are extended the clamps pivot inward to grip the underside of the pipe and hold the machine securely to it Figure 1 6 illustrates the clamping operation See Adjusting Clamp A...

Page 13: ...as clamp shoes attached that the machine rests upon when installed on the pipe These shoes are made of a compressible composite material that deforms slightly under pressure to create a secure slip fr...

Page 14: ...on label is attached to the top of the machine frame on WS 164 through WS 5230 models See the end of this section for information on rigging the WS 8460 model Figure 1 10 The rigging label is on top o...

Page 15: ...gth to hold the machine reasonably straight Figure 1 11 To position the machine vertically on the pipe attach to the two top lift hooks Lifting for Horizontal Cut With the machine positioned horizonta...

Page 16: ...ift points indicated to lift the machine horizontally or vertically Figure 1 14 To lift the machine horizontally from the other side use the three points indicated in the photo third point is out of v...

Page 17: ...age describe the operating envelope for all four diamond wire saw mod els The DIM column in the table refers to the labeled dimensions on the drawing Stroke is the feed distance of the saw bow Table 2...

Page 18: ...Diamond Wire Saw User s Manual 14 Part No 10 010 MAN Rev 1 0310 E H Wachs A B C...

Page 19: ...er ating the machine topside stay a safe distance from the machine or behind a protective barrier Divers should stay a safe distance from the machine when it is running Seri ous injury or death could...

Page 20: ...ure or remove loose fitting clothing and jewelry and securely bind long hair to prevent them from getting caught in moving parts of the machine KEEP WORK AREA CLEAR Keep all clutter and nonessential m...

Page 21: ...Hearing protectors are required in high noise areas 85 dBA or greater The operation of other tools and equipment in the area reflective surfaces process noises and resonant struc tures can increase t...

Page 22: ...Diamond Wire Saw User s Manual 18 Part No 10 010 MAN Rev 1 0310 E H Wachs...

Page 23: ...wheel fixture check the start lines on the feed control actuator When there is no tension on the wire the actuator rod will be retracted and the start lines will be offset Figure 3 1 With no tension...

Page 24: ...fixture to increase the tension on the wire Depending on the exact length of the wire about 3 4 of the screw will be visible when the tension is set correctly Figure 3 3 When the wire is properly tens...

Page 25: ...the frame Multiple sets of holes allow the arms to be mounted in various positions The hole pairs for each position are stamped with the size of the largest pipe for that position Refer to the followi...

Page 26: ...e size settings for the WS 3012 model Figure 3 5 The photo shows the size stamps on the WS 3012 model The pin is in the 26 30 position Table 2 Pipe Size Ranges for Clamping Arm Positions WS 3012 Size...

Page 27: ...3 6 describe the pipe size settings for the WS 3616 model Figure 3 6 The photo shows the size stamps on the WS 3616 model The pin is in the 16 20 position Table 3 Pipe Size Ranges for Clamping Arm Pos...

Page 28: ...n the 46 52 position WS 8460 Pipe Size Settings Table 5 and Figure 3 8 describe the pipe size settings for the WS 8460 model Table 4 Pipe Size Ranges for Clamping Arm Positions WS 5230 Size Stamp Pipe...

Page 29: ...while the saw is in a vertical position The clamp arms may fall when the pins are removed resulting in personal injury and equipment damage Make sure the saw is sitting horizontally on a level surface...

Page 30: ...side 2 Slide the clamp arm assembly so that the mounting holes line up with the appropriate hole pair for the pipe size you are cutting 3 Insert the forked pin through the back of the machine Figure 3...

Page 31: ...t very high speed If the wire breaks segments of the wire can fragment and be thrown from the machine at danger ous speeds Stay a safe dis tance from the machine or behind a protective barrier when op...

Page 32: ...direction to FORWARD Cutter direction is preset to forward 1 Align the machine at the desired cut line perpendicu lar to the center axis of the pipe The clamping arms should extend around the pipe an...

Page 33: ...e at danger ous speeds Make sure all personnel are at a safe dis tance before starting the cut ting drive Serious injury or death could result from contact with the wire or as a result of the wire bre...

Page 34: ...wire as the bow feeds toward the pipe When the wire is within 1 4 of the pipe surface pull the feed flow lever up to turn off the feed drive 4 Push the cutting drive flow lever down to open the cuttin...

Page 35: ...re enters the cut increase the cutting speed by moving the cutting speed knob Do not go above 19 gpm 8 During cutting the feed control actuator on the ten sion wheel fixture adjusts the feed rate to k...

Page 36: ...Rev 1 0310 E H Wachs Figure 3 16 Push the feed flow lever up to 0 and pull the feed flow lever up to turn off the feed drive 11 Pull the cutter flow lever up to turn off the cutter drive Figure 3 17...

Page 37: ...THE MACHINE 1 Set the feed direction knob on the TCP to REVERSE Figure 3 18 Set the feed direction knob to REVERSE 2 Push the feed flow lever down to open the feed circuit Figure 3 19 Push the feed fl...

Page 38: ...act the feed drive on a 36 inch pipe 4 When the saw bow is back at its home position pull the feed flow lever up to stop the feed drive Figure 3 21 Pull the feed flow lever up to turn off the feed dri...

Page 39: ...tion knob to RETRACT 7 Push both clamping flow levers down simultaneously until the clamp arms are fully open The right return pressure gauge reading will equal the system pres sure Pull the clamping...

Page 40: ...Diamond Wire Saw User s Manual 36 Part No 10 010 MAN Rev 1 0310 E H Wachs...

Page 41: ...ease fittings on each of the 4 wheel hubs Do NOT use AquaLube on the wheel hubs Figure 4 1 Each wheel hub has a grease fitting Do not directly apply lubricant to the feed screw 2 Pump AquaLube into th...

Page 42: ...shown at the top of the feed system 3 Pump AquaLube into the grease fitting on the feed screw mount at the bottom of the screw Figure 4 3 Grease the fitting at the bottom of the feed screw 4 Pump Aqua...

Page 43: ...of the frame See special instructions at the end of this section for the WS 8460 model Wear gloves when handling the wire The abrasive sur faces are sharp and could cut your hands 1 Turn the tension k...

Page 44: ...re has arrowheads molded into the plastic coating The dark shoulder of the cutting bead should trail the bead as the wire cuts The drive wheel fixture is stamped with an arrow show ing the direction o...

Page 45: ...lace the cutting wire 1 If there is a wire on the saw turn the drive wheel ten sion knob to fully release the tension on the wire 2 Remove the nut from the idler wheel shaft and pull out the shaft 3 P...

Page 46: ...e nuts on the four screws holding the shoe in place 2 Remove the shoe 3 Put the new shoe in place and replace the screws 4 Replace the nuts and tighten them securely REPLACING THE WHEEL LINERS The lin...

Page 47: ...take the wheel out of the wheel mounting fixture Figure 4 11 Remove the hub bolt to take off the wheel The bolt head is on top in this view with the nut on the bottom of the fixture It may be easier t...

Page 48: ...achs Figure 4 12 Remove the screws from the side plate to take it off 4 Remove the side plate 5 Remove the old wheel liner You may have to pry it loose with a screwdriver Figure 4 13 Pull the liner of...

Page 49: ...ner on the wheel and press it down into place Figure 4 14 Put the new wheel liner on the wheel 7 If you removed the shaft replace it through the center of the wheel Figure 4 15 Replace the shaft throu...

Page 50: ...and install the nut on the bottom Tighten the nut securely Drive Wheel Remove the cutting wire before taking off any of the wheels To replace the drive wheel liner you must first remove the wheel and...

Page 51: ...the pivot pin 3 Remove the nut from the bolt holding the wheel assembly to the tension rod then remove the bolt The wheel and motor assembly will be free from the saw bow Figure 4 18 Remove the nut o...

Page 52: ...g sure the correct side is toward the motor 9 Replace the top plate Insert the spacer bolt through the spacer and snug it down 10 Replace the hub bolt and snug it 11 Replace the tension rod mounting b...

Page 53: ...ON CONTROL If the feed tension control mechanism is not working prop erly you will need to bleed the system Typically the prob lem will be that the system overfeeds putting too much tension on the wir...

Page 54: ...under neath it to avoid damaging the grease fittings The full assembly drawings with parts lists are included in Chapter 5 2 Remove the cylinder from the spring assembly by removing 28 SHCS and 1 1 4...

Page 55: ...awing illustrates the components of the tension control mechanism Item 1 is the tension control mechanism cylinder 4 If sight tube has no green fluid visible remove end plug and fill with 50 50 antifr...

Page 56: ...cylinder Figure 4 21 back and forth 10 times 13 If required fill the sight tube with 50 50 antifreeze 14 Open the frame bypass ball valve Item 10 in Figure 4 22 15 Close the sight tube ball valve Ite...

Page 57: ...r Web site at www ehwachs com Ordering Replacement Parts When ordering parts refer to the parts lists in this chapter Please provide the part description and part number for all parts you are ordering...

Page 58: ...urn 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 Par...

Page 59: ...g Wheel Assembly 10 010 00 434 Idler Wheel Assembly 10 010 00 435 Spring Tension Assembly Table 2 WS 164 Assembly Drawings Drawing Number Description 10 010 16 411 Feed Frame 10 010 16 413 Lifting Tub...

Page 60: ...table Clamp with Actuator 10 010 36 430 Bow Frame 10 010 36 224B Bulkhead Plate Table 5 WS 5230 Assembly Drawings Drawing Number Description 10 010 52 410 Frame Assembly 10 010 52 411 Feed Frame 10 01...

Page 61: ...NG BALL 75 x 1 625 x 438 1 14 P06 150 036 GEARBOX PRIMARY 2 15 P06 150 037 SPACER GEARBOX 2 16 P06 150 038 MOTOR FEED 1 17 Truarc 5100 75 H RETAINING RING SS 1 18 Truarc N5000 162 H RETAINING RING SS...

Page 62: ...1A535 SET SCREW 1 4 20 x 3 8 LG SS 1 23 9595K34 COMPRESSION SPRING 1 24 Brennan 2404 04 02 SS FITTING 1 8 NPT TO 1 4 JIC 2 25 Brennan 5408 04 O PLUG 1 26 Brennan 6565 06 06 FJS FJS STRAIGHT 2 27 Brenn...

Page 63: ...PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF E H WACHS ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF E H WACHS IS PROHIBITE...

Page 64: ...A580 SHCS 5 16 18 x 5 8 LG SS 6 24 92210A582 FSHCS 5 16 18 x 1 125 LG SS 6 25 92240A714 HHCS 1 2 13 x 1 25 LG 4 26 93286A030 5 16 WASHER AL 6 27 9452K134 45 O RING BUNA N 70 1 28 98017A209 1 2 WASHER...

Page 65: ...SIZE C REV DWG NO 10 010 00 432 DRAWN BY APPROVED BY DATE DATE SCALE SHEET 1 2 1 OF 1 TITLE PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF E H WACHS ANY...

Page 66: ...A539 FHSCS 1 4 20x5 8 LG SS 30 16 CLAMP COLLAR 1 2 ID 316 SS 2 17 GARLOCK 08FDU06 2 18 P08 018 123 1 4 28 GREASE ZERK SS 1 19 Spirolox RRT 185 RETAINING RING 2 20 SS 6204 1RS BALL BEARING SS 2 21 TIMK...

Page 67: ...RUARC 5108 78 RETAINING RING 2 15 92210A539 FHSCS 1 4 20x5 8 LG SS 24 16 91950A033 1 2 WASHER SS 2 17 91831A137 LOCKNUT 1 2 13 SS 1 SIZE B REV DWG NO 10 010 00 434 DRAWN BY APPROVED BY DATE DATE SCALE...

Page 68: ...SS 1 17 98125A443 1 2 WASHER 1 06 OD 17 THK SS 1 18 BRENNAN 2404 04 02 SS FITTING 1 8 NPT TO 1 4 JIC 2 19 EATON 705 2 A A B B C C D D E E F F 8 8 7 7 6 6 5 5 4 4 3 3 2 2 1 1 SIZE C REV DWG NO 10 010...

Page 69: ...IN 15T 3 8 PITCH 1 21 9713K94 DISC CLUTCH 4 22 6438K56 CLAMP ON SHAFT COLLAR 1 23 92240A585 HHCS 5 16 18 x 1 25 LG 1 24 92320A231 STANDOFF 4 25 90145A539 1 4 x 5 8 LG DOWEL PIN 2 26 92311A534 CUP POIN...

Page 70: ...AWN BY APPROVED BY DATE DATE SCALE SHEET 1 6 1 OF 1 TITLE PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF E H WACHS ANY REPRODUCTION IN PART OR AS A WHOL...

Page 71: ...A542 SHCS 1 4 20 x 1 LG SS 2 23 92311A535 SET SCREW 1 4 20 x 3 8 LG SS 1 24 9595K34 COMPRESSION SPRING 1 25 Brennan 2404 04 02 SS FITTING 1 8 NPT TO 1 4 JIC 2 26 Brennan 5408 04 O PLUG 1 27 Brennan 65...

Page 72: ...PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF E H WACHS ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF E H WACHS IS PROHIBIT...

Page 73: ...F 2 TITLE PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF E H WACHS ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF E H WACHS IS...

Page 74: ...SS 56 33 98017A209 1 2 WASHER SS 4 34 98017A215 5 8 WASHER SS 17 35 98017A220 3 4 WASHER SS 2 36 98017A655 1 4 WASHER SS 16 37 98017A689 5 16 WASHER SS 42 38 92240A622 HHSC 3 8 16 x 3 4 LG SS 2 A A B...

Page 75: ...4 21 92240A585 HHCS 5 16 18 x 1 25 LG 1 22 92311A534 CUP POINT SET SCREW 1 4 20 x 5 16 LG 2 23 92311A541 SET SCREW 1 4 20 x 7 8 LG SS 1 24 92320A231 STANDOFF 4 25 9389A580 CLEVIS PIN 1 26 9713K94 DIS...

Page 76: ...ATE DATE SCALE SHEET 1 8 1 OF 1 TITLE PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF E H WACHS ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTE...

Page 77: ...16 x 2 LG 12 25 92240A583 HHCS 5 16 18 x 1 lg 6 26 92240A626 HHCS 3 8 16x1 5 LG SS 7 27 92240A714 HHCS 1 2 13 x 1 25 LG 4 28 92240A798 HHCS 5 8 11 x 1 5 LG SS 14 29 95412A804 5 8 11 x 1 5 LG STUD 2 30...

Page 78: ...HCS 1 4 20 x 1 25 LG 2 18 92198A818 HHCS 5 8 11 x 6 LG SS 1 19 92210A796 FHCS 5 8 11x 1 25 LG 16 20 98017A215 5 8 WASHER SS 2 21 Garlock 16FDU16 BUSHING 2 22 Garlock 20FDU16 BUSHING 2 23 Parker 6 10_c...

Page 79: ...2 90298A712 SHOULDER SCREW 3 8 16 x 1 LG SS 2 23 91287A375 HHCS M10 x 1 5 45mm LG SS 12 24 91831A127 LOCKNUT 3 8 16 SS 47 25 91831A137 LOCKNUT 1 2 13 SS 2 26 92196A541 SHCS 1 4 20 x 7 8 LG SS 1 27 921...

Page 80: ...ROVED BY DATE DATE SCALE SHEET 1 3 1 OF 1 TITLE PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF E H WACHS ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT...

Page 81: ...31A030 LOCKNUT 5 16 18 SS 45 21 91831A127 LOCKNUT 3 8 16 SS 32 22 92196A539 SHCS 1 4 20 x 5 8 LG SS 4 23 92196A585 SHCS 5 16 18x1 25 LG SS 45 24 92198A803 HHCS 5 8 11 x 2 25 LG SS 4 25 92210A626 FSHCS...

Page 82: ...A249 SHCS 10 24 x 1 25 LG 4 21 92240A581 HHCS 5 16 18 x 3 4 LG 4 22 92240A585 HHCS 5 16 18 x 1 25 LG 1 23 92311A534 CUP POINT SET SCREW 1 4 20 x 5 16 LG 2 24 92311A541 SET SCREW 1 4 20 x 7 8 LG SS 1 2...

Page 83: ...CALE SHEET 1 12 1 OF 1 TITLE PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF E H WACHS ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISS...

Page 84: ...36 220 PLATE 220 2 11 10 010 36 221 SHOE 221 4 12 10 010 36 222 PLATE 222 1 13 10 010 36 223 ROD 223 2 14 10 010 36 224B BULKHEAD 1 15 10 010 36 413 LIFTING TUBE 1 16 10 010 36 421 ADJUSTABLE CLAMP WI...

Page 85: ...5 8 11 SS 1 18 92198A544 HHCS 1 4 20 x 1 25 LG 2 19 92198A818 HHCS 5 8 11 x 6 LG SS 1 20 92210A796 FHCS 5 8 11x 1 25 LG 16 21 98017A215 5 8 WASHER SS 2 22 Garlock 16FDU16 BUSHING 2 23 Garlock 20FDU16...

Page 86: ...2 22 1860A032 WASHER 1 2 PH 17 4 1 23 59915K486 BALL JOINT ROD END 1 24 90145A539 1 4 x 5 8 LG DOWEL PIN 36 25 90298A712 SHOULDER SCREW 3 8 16 x 1 LG SS 2 26 91287A375 HHCS M10 x 1 5 45mm LG SS 12 27...

Page 87: ...BY APPROVED BY DATE DATE SCALE SHEET 1 4 1 OF 1 TITLE PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF E H WACHS ANY REPRODUCTION IN PART OR AS A WHOLE W...

Page 88: ...PLATE 028 1 9 10 010 00 029 PLATE 029 2 10 10 010 52 242 ROD 242 1 11 10 010 00 243 PLATE 243 1 12 10 010 52 247 BAR LIFTING 2 13 10 010 00 251 ROD 251 1 14 10 010 52 246 PLATE 246 1 15 10 010 52 246...

Page 89: ...91847A029 JAM NUT 1 4 20 SS 1 20 92185A249 SHCS 10 24 x 1 25 LG 4 21 92240A581 HHCS 5 16 18 x 3 4 LG 4 22 92240A585 HHCS 5 16 18 x 1 25 LG 1 23 92311A534 CUP POINT SET SCREW 1 4 20 x 5 16 LG 2 24 923...

Page 90: ...VED BY DATE DATE SCALE SHEET 1 12 1 OF 1 TITLE PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF E H WACHS ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT T...

Page 91: ...10 010 52 220 PLATE 220 2 13 10 010 52 222 PLATE 222 1 14 10 010 52 223 ROD 223 2 15 10 010 52 224B WELDMENT BULKHEAD PLATE 1 16 10 010 52 413 LIFTING TUBE 1 17 10 010 52 421 ADJUSTABLE CLAMP WITH AC...

Page 92: ...LOCKNUT 5 8 11 SS 1 18 92198A544 HHCS 1 4 20 x 1 25 LG 2 19 92198A818 HHCS 5 8 11 x 6 LG SS 1 20 92210A796 FHCS 5 8 11x 1 25 LG 20 21 98017A215 5 8 WASHER SS 2 22 Garlock 16FDU16 BUSHING 2 23 Garlock...

Page 93: ...ASHER 1 2 PH 17 4 1 24 59915K486 BALL JOINT ROD END 1 25 90145A539 1 4 x 5 8 LG DOWEL PIN 44 26 90298A712 SHOULDER SCREW 3 8 16 x 1 LG SS 2 27 91287A375 HHCS M10 x 1 5 45mm LG SS 12 28 91831A127 LOCKN...

Page 94: ...PROVED BY DATE DATE SCALE SHEET 1 8 1 OF 1 TITLE PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF E H WACHS ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT...

Page 95: ...ride lever 15 Feed overload clutch 16 Lightweight planetary feed drive 17 Lift interface for vertical cut deployment 18 Lift interface for horizontal cut deployment 19 Hydraulic interface fittings 20...

Page 96: ...RT OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF E H WACHS IS PROHIBITED UNLESS OTHERWISE SPECIFIED TOLERANCES FRACTIONS 1 32 ONE PLACE DECIMAL 015 TWO PLACE DECIMAL 010 THREE PLACE DECIMAL 005 ANGU...

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