Use these instructions to operate and maintain the equipment. The narrower column on the outside contains additional information such as warnings, special notes, and defini- tions. Refer to it for safety notes and other information. E.H. Wachs Part No. 08-051-MAN, Rev. 1-0709...
IMPORTANT An IMPORTANT alert with the damage alert symbol indi- cates a situation that may result in damage to the equipment. Part No. 08-051-MAN, Rev. 1-0709 E.H. Wachs...
Feed drive: operates the bow holding the wire drive sys- tem, to feed the wire through the pipe and retract the bow when finished cutting. • Clamp drive: operates the clamping arms that secure the machine to the pipe during cutting. E.H. Wachs Part No. 08-051-MAN, Rev. 1-0709...
The wire is a custom-made loop for the size of the saw. Spare wires can be ordered from E.H. Wachs. Feed System A feed drive mechanism on the main frame of the machine drives the bow and cutting system up and down to perform the cut and retract the bow after cutting.
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Figure 1-4. Use the manual feed nut to move the saw bow if it cannot be operated using hydraulic power. Turn the nut clockwise to retract the bow away from the workpiece. Part No. 08-051-MAN, Rev. 1-0709 E.H. Wachs...
Figure 1-6 illustrates the clamping operation. See the end of this chapter for drawings that illustrate clamp position settings for the range of each wire saw model. E.H. Wachs Part No. 08-051-MAN, Rev. 1-0709...
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These shoes are made of a compressible composite material that deforms slightly under pressure to create a secure, slip-free grip on the pipe when the machine is clamped. Part No. 08-051-MAN, Rev. 1-0709 E.H. Wachs...
(shown open) under pressure) Figure 1-9. The photo shows the controls on the top- side control unit. (The fourth circuit, to the far right, is not used with the subsea wire saw.) E.H. Wachs Part No. 08-051-MAN, Rev. 1-0709...
IMPORTANT: Do not attach to this hook when lifting the machine vertically! Figure 1-11. To position the machine vertically on the pipe, attach to the two top lift hooks. Part No. 08-051-MAN, Rev. 1-0709 E.H. Wachs...
You can leave the wire installed on the machine during stor- age. Keep a normal amount of tension on the wire to hold it in place. E.H. Wachs Part No. 08-051-MAN, Rev. 1-0709...
Chapter 2, Safety Chapter 2 Safety In This Chapter The E.H. Wachs Company takes great pride in designing PERATOR AFETY and manufacturing safe, high-quality products. We make user safety a top priority in the design of all our products. AFETY...
CAUTION This safety alert, with the personal injury hazard symbol, indicates a potentially hazardous situation that, if not avoided, could result in minor or moderate injury. Part No. 08-051-MAN, Rev. 1-0709 E.H. Wachs...
Federal OSHA regulations, 29 Code of Federal Regulations, Section 1910.95, Occupational Noise Exposure and ANSI S12.6 Hearing Protectors. AFETY ABELS There is no safety labeling on the subsea wire saw. E.H. Wachs Part No. 08-051-MAN, Rev. 1-0709...
ERFORMING THE start lines will be offset. EMOVING THE ACHINE Figure 3-1. With no tension on the wire, the feed actuator start lines will be offset. E.H. Wachs Part No. 08-051-MAN, Rev. 1-0709...
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You should be able to deflect the wire fairly easily by pushing it up between the idler wheels. Push it in far enough to compress the tension spring, and make sure the actuator rod extends into the slot in the shaft. Part No. 08-051-MAN, Rev. 1-0709 E.H. Wachs...
Table 1 and Figure 3-5 describe the pipe size settings for the WS-3012 model. Table 1: Pipe Size Ranges for Clamping Arm Positions—WS-3012 Size Stamp Pipe Diameter Range 12” to 14” (305-356 mm) 14” to 18” (356-457 mm) 18” to 22” (457-559 mm) E.H. Wachs Part No. 08-051-MAN, Rev. 1-0709...
Figure 3-5. The photo shows the size stamps on the WS-3012 model. The pin is in the 26-30” position. WS-3616 Pipe Size Settings Table 2 and Figure 3-6 describe the pipe size settings for the WS-3616 model. Part No. 08-051-MAN, Rev. 1-0709 E.H. Wachs...
Slide the clamp arm assembly so that the mounting holes line up with the appropriate hole pair for the pipe size you are cutting. Part No. 08-051-MAN, Rev. 1-0709 E.H. Wachs...
Connect the hydraulic hoses from the topside control panel clamp securely on the pipe. (TCP) to the hydraulic bulkhead on the machine, as indi- Damage to the machine cated in Figure 3-10. could result. E.H. Wachs Part No. 08-051-MAN, Rev. 1-0709...
(Clamp flow is preset to 4 gpm) • Clamp direction to ENGAGE The flow on the clamp circuit • Feed direction to FORWARD is set internally at 4 gpm. • (Cutter direction is preset to forward). Part No. 08-051-MAN, Rev. 1-0709 E.H. Wachs...
Figure 3-11. Push the feed flow lever down to supply power to the feed drive. Set the feed speed knob to 2.5 gpm. E.H. Wachs Part No. 08-051-MAN, Rev. 1-0709...
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Push the cutting drive flow lever down to open the This is because smaller pipes cutting drive circuit. fit closer between the mount- ing shoes. Figure 3-13. Push the cutting flow lever down to sup- ply power to the cutting drive. Part No. 08-051-MAN, Rev. 1-0709 E.H. Wachs...
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Continue until the wire has completely severed the NOTE pipe. The feed drive will travel Pull the feed flow lever up to turn off the feed drive. about 2 inches beyond the bottom of the largest pipe size. E.H. Wachs Part No. 08-051-MAN, Rev. 1-0709...
Pull the cutter flow lever up to turn off the cutter drive. Figure 3-16. Pull the cutter flow lever up to turn off the cutter. EMOVING THE ACHINE Set the feed direction knob on the TCP to REVERSE. Part No. 08-051-MAN, Rev. 1-0709 E.H. Wachs...
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Push the feed flow lever down to open the feed circuit. Figure 3-18. Push the feed flow lever down to supply power to the feed drive. Push the feed speed knob down to 6.5 gpm (maximum flow). E.H. Wachs Part No. 08-051-MAN, Rev. 1-0709...
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Figure 3-20. Pull the feed flow lever up to turn off the feed drive. Rig the shackles to the overhead lift. Lift just enough to put tension on the chains and secure the machine. Push the clamping direction knob to the RETRACT position. Part No. 08-051-MAN, Rev. 1-0709 E.H. Wachs...
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Pull the clamping flow levers back up. Lift the machine off the pipe. Move it to the next cut- ting location or bring it topside if you are finished. E.H. Wachs Part No. 08-051-MAN, Rev. 1-0709...
Figure 4-1. Each wheel hub has a grease fitting. Pump AquaLube into the grease fittings on the feed gears, feed motor, and feed block (4 fittings). CAUTION Do not directly apply lubricant to the feed screw. E.H. Wachs Part No. 08-051-MAN, Rev. 1-0709...
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Figure 4-3. Grease the fitting at the bottom of the feed screw. Pump AquaLube into the grease fittings on the cylin- der rod ends until grease is visible. Part No. 08-051-MAN, Rev. 1-0709 E.H. Wachs...
Figure 4-5. Turn the tensioning knob all the way down on the screw to loosen the wire. Slip the wire off the drive wheel, then remove it from the other wheels. E.H. Wachs Part No. 08-051-MAN, Rev. 1-0709...
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The drive wheel fixture is stamped with an arrow show- ing the direction of rotation. Figure 4-8. Install the wire so that the arrows point in the direction of travel, as shown. Part No. 08-051-MAN, Rev. 1-0709 E.H. Wachs...
Replace the nuts and tighten them securely. EPLACING THE HEEL INERS The liners on the cutting wire wheels are durable and long- lasting. They may wear out after extensive use, or be dam- E.H. Wachs Part No. 08-051-MAN, Rev. 1-0709...
Remove the 6 screws holding the side plate in place. something that supports the You only need to remove one side plate. side plate, with a gap for the hub shaft to keep it from sit- ting on the shaft. Part No. 08-051-MAN, Rev. 1-0709 E.H. Wachs...
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Remove the old wheel liner. You may have to pry it loose with a screwdriver. Figure 4-12. Pull the liner off the wheel. You may have to pry it with a screwdriver to get it loose. E.H. Wachs Part No. 08-051-MAN, Rev. 1-0709...
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If you removed the shaft, replace it through the center of the wheel. Figure 4-14. Replace the shaft through the center of the wheel. Replace the side plate, making sure that the keys in the shaft fit into the slots in plate. Part No. 08-051-MAN, Rev. 1-0709 E.H. Wachs...
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Figure 4-16. Replace the screws in the side plate. Replace the wheel into its mounting fixture. Put the bolt through the top of the fixture, and install the nut on the bottom. Tighten the nut securely. E.H. Wachs Part No. 08-051-MAN, Rev. 1-0709...
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. Part No. 08-051-MAN, Rev. 1-0709 E.H. Wachs...
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Replace the tension rod mounting bolt through the plates and tension rod end. Put the nut on the end of the bolt and tighten it securely. Tighten the spacer bolt and hub bolt securely. E.H. Wachs Part No. 08-051-MAN, Rev. 1-0709...
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Pivot pin Stop collars Set screw Figure 4-19. Make sure the pivot pin is through both plates, then position the stop collars and tighten the set screws. Part No. 08-051-MAN, Rev. 1-0709 E.H. Wachs...
ARTS ISTS AND AYOUT RAWINGS 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...
Warranty Infor mation 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.
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3/8 HOSE, SAE100R16 TYPE S 5/8 HOSE, SAE100R16 TYPE S RETAINING RING, EXTERNAL .781 SHAFT RETAINING RING, INTERNAL 1.850 HOUSING CLAMP COLLAR, 1/2" ID (316 SS) CLAMP COLLAR, 1‐1/4" ID BEARING, 20mm ID x 47mm OD x 14 mm 440 SS SINGLE SEALED WASHER, THRUST 30mm ID x 47mm OD x 1mm BUSHING, FLANGE 1" ID x 1‐1/8" OD x 1" LNG. BUSHING, FLANGE 1‐1/4" ID x 1.4 OD x 1" LNG. LINEAR BEARING SYSTEM (RAIL/CARRIAGE) DIE SPRING, 1/2" ID x 1" OD x 12" FREE LENGTH FITTING, TEE 3/8" JIC (F) x 3/8" JIC (M) x 3/8" JIC (M) COUPLING, FEMALE ‐08 NPT COUPLING, MALE ‐08 NPT COUPLING, MALE ‐12 NPT COUPLING, FEMALE ‐12 NPT FITTING, BULKHEAD 1/2" NPT x 1/2" JIC FITTING, BULKHEAD 3/4" NPT x 3/4" JIC NUT, BULKHEAD LOCK ‐08 NUT, BULKHEAD LOCK ‐12 ROD END, BALL JOINT EYEBOLT, 5/8‐11 KNOB, 1/2‐13 ZINC ANODE, 2" DIA. 5/8" ANCHOR SHACKLE, W/ SCREW PIN FEED SCREW ASSEMBLY HYDRAULIC MOTOR SNAP RING (3/4" O.D. SHAFT) SNAP RING (1‐5/8" I.D. BORE) CLAMP ON COLLAR, 3/4‐16 (303 SS) BEARING (.75 x 1.625 x .438) WASHER, BELLEVILLE SPRING 2" OD x 1" ID x .065 THICK Part No. 08-051-MAN, Rev. 1-0709 E.H. Wachs...
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FITTING, TEE 1/4" TUBE (F) x 1/4" TUBE (F) x 1/8" NPT (M) FITTING, TEE 1/8" NPT (F) x 1/8" NPT (F) x 1/8" NPT (M) BALL VALVE, 1/8" NPT (F) x 1/8" NPT (F) FITTING, 1/8" NPT (M) x 3/8" HOSE BARB 12" TUBING, 3/8" CLEAR PVC FITTING, 1/8" NPT (F) x 3/8" HOSE BARB FITTING, TEE 1/8" NPT (F) x 1/8" NPT (F) x 1/8" NPT (F) FITTING, 1/8" NPT (M) x 1/4" JIC (M) AIR VENT, 1/8" NPT (M) TUBE CLAMP, 5/8" CRIMP FITTING, ‐4 HOSE x ‐4 JIC (F) CRIMP FITTING, ‐4 HOSE x ‐4 JIC (F) x 45 DEG. CRIMP FITTING, ‐4 HOSE x ‐4 JIC (F) x 90 DEG. HOSE, 1/4" Check Valve, 3/8" FITTING, ‐4 SAE (M) x ‐6 JIC (M) 90 DEG. Fitting, 3/8" JIC (F) x 3/8" JIC (F) Fitting, Tee 3/8" JIC (M) x 3/8" JIC (M) x 1/4" ORB (M) Fitting, Tee 3/8" JIC (M) x 3/8" JIC (M) x 1/4" ORB (M) CRIMP FITTING, ‐6 HOSE x ‐8 JIC (F) CRIMP FITTING, ‐6 HOSE x ‐6 JIC (F) x 90 DEG. CRIMP FITTING, ‐6 HOSE x ‐6 JIC (F) HOSE, 3/8" SPRING, .72 OD, x .586 ID x 2" LNG. CYLINDER, 2.5" STROKE Fasteners Description MAIN FRAME ASSEMBLY 72 FHCS, 1/4‐20 x 5/8" LNG. 30 FHCS, 5/16‐18 x 3/4" LNG. E.H. Wachs Part No. 08-051-MAN, Rev. 1-0709...
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16 HHCS, 5/8‐11 x 1‐1/2" LNG. HHCS, 5/8‐11 x 1‐3/4" LNG. HHCS, 5/8‐11 x 2‐1/4" LNG. HHCS, 5/8‐11 x 2‐3/4" LNG. HHCS, 5/8‐11 x 6" LNG. HHCS, 3/4‐10 x 2" LNG. 12 HHCS, M10 x 45 LNG. SHCS, 1/4‐20 x 3/4" LNG. SHCS, 1/4‐20 x 7/8" LNG. 24 SHCS, 1/4‐20 x 1‐1/4" LNG. 12 SHCS, 1/4‐20 x 5/8" LNG. SHCS, 5/16‐18 x 5/8 LNG. 42 SHCS, 5/16‐18 x 1‐1/4" LNG. SHCS, 7/16‐14 x 1" LNG. SSS, CUP POINT 1/4‐20 x 7/8" LNG. NUT, NYLOCK 1/4‐20 54 NUT, NYLOCK 5/16‐18 107 NUT, NYLOCK 3/8‐16 16 NUT, NYLOCK 7/16‐14 NUT, NYLOCK 1/2‐13 NUT, NYLOCK 5/8‐11 35 PIN, DOWEL 1/4" DIA. X 5/8" LNG. PIN, DOWEL 1/4" DIA. X 7/8" LNG. PIN, DOWEL 5/16" DIA. X 1" LNG. Part No. 08-051-MAN, Rev. 1-0709 E.H. Wachs...
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12 WASHER, 10 MM ZERK, GREASE (303 SS) ZERK, GREASE 1/4‐28 (303 SS) FEED SCREW ASSEMBLY FASTENERS HHCS, 3/8‐16 x 1" LNG. HHCS, 3/8‐16 x 1‐1/8" LNG. SHCS, 8‐32 x 3" LNG. SHCS, 10‐24 x 1‐1/2" LNG. SHCS, 1/4‐28 x 5/8" LNG. HHCS, 5/16‐18 X 5/8" LNG. SSS, 1/4‐20 x 3/4" LNG. SSS, CUP POINT 5/16‐18 x 1/4" LNG. SSS, CUP POINT 5/16‐18 x 1" LNG. PLUG, PIPE 1/8" NPT (316 SS) NUT, NYLOCK 1/4‐20 NUT, NYLOCK 3/8‐16 PIN, SPRING 3/32" DIA x 3/8" LNG (420 SS) PIN, CLEVIS 1/4" OD x 1‐1/2" LNG. (316SS) PIN, DOWEL 1/4" DIA. X 5/8" LNG. PIN, DOWEL 1/4" DIA. X 1‐3/8" LNG. ZERK, GREASE 1/4‐28 (303 SS) 14 WASHER, 3/8" AN FEED RELIEF ASSEMBLY FASTENERS SHCS, 8‐32 x 5/8" LNG. SHCS, 1/4‐28 x 1" LNG. SHCS, 1/4‐28 x 1‐1/2" LNG. SHCS, 1/4‐28 x 5/8" LNG. WASHER, 1/2" 18‐8 SS SHOULDER BOLT, 1/2" DIA. X 1" LNG. SHCS, 10‐24 x 5/8" LNG. FHCS, 1/4‐28 x 1" LNG. PIN, DOWEL 3/16" DIA. X 1‐1/4" LNG. E.H. Wachs Part No. 08-051-MAN, Rev. 1-0709...