Wachs 06-030-MAN User manual

Window Cutter
User’s Manual
Copyright © 2009 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 60069
www.ehwachs.com
E.H. Wachs Part No. 06-030-MAN
Rev. 2-0709, July 2009
Revision History:
Version 1 June 2006

Window Cutter
Part No. 06-030-MAN, Rev. 2-0709 E.H. Wachs

Table of Contents
E.H. Wachs Part No. 06-030-MAN, Rev. 2-0709 1
Table of Contents
Chapter 1: About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Purpose of This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
How to Use The Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Symbols and Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Manual Updates and Revision Tracking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Chapter 2: Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Operator Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Safety Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Machine Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Chapter 3: Introduction to the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Usage and Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Window Cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hydraulic Power Unit (HPU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Chapter 4: Assembly, Disassembly, and Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Removing the Machine from the Shipping/Storage Crate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Environmental Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Long-Term Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Chapter 5: Operating Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Configuring the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Install the Tracking Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Setting the Chain Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installing the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Mounting on Horizontal Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Mounting on Vertical Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Mounting the Guide Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Mounting the Window Cutter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Connect Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Window Cutter
2 Part No. 06-030-MAN, Rev. 2-0709 E.H.Wachs
Cutting the Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Horizontal Pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Vertical Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Machine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Flow Control Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Radial Cut Stabilizing Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Rotating the Cutter Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Feeding the Cutter into the Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Chapter 6: Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Chapter 7: Service and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Chapter 8: Parts Lists and Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Chapter 9: Accessories and Spare Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Chapter 10: Ordering Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Ordering Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Warranty Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Return Goods Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Chapter 1, About This Manual
E.H. Wachs Part No. 06-030-MAN, Rev. 2-0709 1
Chapter 1
About This Manual
PURPOSE OF THIS MANUAL
This manual explains how to operate and maintain your
window cutter system. It includes instructions for set-up,
operation, and routine maintenance. It also contains parts
lists, assembly diagrams, and troubleshooting instructions
to help you order replacement parts and perform user-ser-
viceable repairs.
Before operating the window cutter, you should read
through this manual and become familiar with all instruc-
tions. At a minimum, make sure you read and understand
the following chapters:
• Chapter 1, About This Manual
• Chapter 2, Safety
• Chapter 3, Introduction
• Chapter 5, Operating Instructions.
If you will be performing service or repairs, make sure you
read and understand these chapters:
• Chapter 1, About This Manual
• Chapter 4, Assembly, Disassembly, and Storage
• Chapter 6, Routine Maintenance
• Chapter 7, Service and Repair.
You will also want to refer to Chapter 8, Parts Lists and
Drawings.
In This Chapter
PURPOSE OF THIS MANUAL
HOW TO USE THE MANUAL
SYMBOLS AND WARNINGS
MANUAL UPDATES AND
REVISION TRACKING

Window Cutter
2 Part No. 06-030-MAN, Rev. 2-0709 E.H. Wachs
HOW TO USE THE MANUAL
Throughoutthis 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 specific topic on
using or maintaining the window cutter.
Each page is designed with two columns. This large column
on the inside of the page contains instructions and illustra-
tions. Use these instructions to operate and maintain the
window cutter.
The narrower column on the outside contains additional
information such as warnings, special notes, and definitions.
Refer to it for safety notes and other information.
SYMBOLS AND WARNINGS
The following symbols are used throughout this manual to
indicate special notes and warnings. They appear in the out-
side 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. See Chapter 2 for more
detailed safety information.
NOTE
This symbol indicates a user notice.
Notices provide additional information to
supplement the instructions, or tips for
easier operation.

Chapter 1, About This Manual: Manual Updates and Revision Tracking
E.H. Wachs Part No. 06-030-MAN, Rev. 2-0709 3
MANUAL UPDATES AND REVISION TRACKING
Current versions of E.H.
Wachs Company manuals
are also available in PDF for-
mat. You can request an
electroniccopyofthis manual
by emailing customer service
at [email protected].
Occasionally, we will update manuals with improved opera-
tion or maintenance procedures, or with corrections if nec-
essary. Revised chapters will be available for customers. If
you receive revised chapters for your manual, remove the
old chapters from your binder and replace them with the
new chapters.
When a manual is revised, we will update the revision his-
tory on the title page and at the bottom of the pages in the
revised chapters. It is important to put the current title page
with the revision history in your manual. This will help you
make sure you have all current information.
You may have factory service or upgrades performed on
your equipment. If this service changes any technical data
or operation and maintenance procedures, we will include
revised sections of the manual when we return the equip-
ment to you. Remove the old chapters from your manual
and replace them with the revised chapters.

Window Cutter
4 Part No. 06-030-MAN, Rev. 2-0709 E.H. Wachs

Chapter 2, Safety
E.H. Wachs Part No. 06-030-MAN, Rev. 2-0709 5
Chapter 2
Safety
The E.H. Wachs Company 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.
WARNING
Read this chapter carefully before operating the window
cutter system. Serious injury or death could result from
improper repair or service of this equipment.
Repair and/or service to this equipment must only be done
by an authorized and certified dealer.
OPERATOR SAFETY
Follow these guidelines for safe operation of any mechani-
cal equipment associated with the data logger.
Look for this sym-
bol throughout the
manual.Itindicates
a personal injury
hazard.
•READ THE OPERATING MANUAL. Make sure you
understand all setup and operating instructions before
you begin.
•INSPECT MACHINE AND ACCESSORIES. Before
starting the machine, look for loose bolts or nuts, leak-
ing lubricant, rusted components, and any other physical
conditions that may affect operation. Properly maintain-
ing the machine can greatly decrease the chances for
injury.
•ALWAYS READ PLACARDS AND LABELS. Make
sure all placards, labels, and stickers are clearly legible
In This Chapter
OPERATOR SAFETY
SAFETY LABELS
SAFETY PRECAUTIONS
MACHINE SAFETY

Window Cutter
6 Part No. 06-030-MAN, Rev. 2-0709 E.H. Wachs
and in good condition. You can purchase replacement
labels from E.H. Wachs Company.
•KEEP CLEAR OF MOVING PARTS. Keep hands,
arms, and fingers clear of all rotating or moving parts.
Always turn machine off 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.
•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.
Safety Symbols
This icon is displayed with any safety alert that indicates a
personal injury hazard.
WARNING
This safety alert 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.
NOTICE
This alert indicates a situation that, if not avoided, will
result in damage to the equipment.
IMPORTANT
This alert indicates a situation that, if not avoided, may
result in damage to the equipment.

Chapter 2, Safety: Safety Labels
E.H. Wachs Part No. 06-030-MAN, Rev. 2-0709 7
SAFETY LABELS
There is no safety labeling on the window cutter.
SAFETY PRECAUTIONS
WARNING
Failuretofollowthe
instructions for
safe operation
could result in operator injury.
• Perform all setup and configuration of the machine with
the power supply disconnected. Connect the power sup-
ply when you are ready to start cutting.
MACHINE SAFETY
NOTICE
Failure to follow the instruc-
tions for machine safety
could result in damage to the
equipment.
• Do not feed the cutter into the pipe too quickly. If the
machine chatters, slow down your feed rate.
• Use the auxiliary clamp when feeding the cutter into the
pipe when the cutter head is not at one end of the
machine.

Window Cutter
8 Part No. 06-030-MAN, Rev. 2-0709 E.H. Wachs

Chapter 3, Introduction to the Equipment
E.H. Wachs Part No. 06-030-MAN, Rev. 2-0709 9
Chapter 3
Introduction to the
Equipment
Read this chapter carefully to become familiar with the
components and features of your window cutter.
USAGE AND APPLICATIONS
The window cutter is designed to cut access windows in
pipes ranging from 6” to 48” diameter, up to 1-1/4” thick.
An adjustable-depth milling mechanism allows you to pre-
cisely cut through the thickness of the pipe without damag-
ing any internal structures.
The window cutter is mounted directly on a horizontal pipe.
For a vertical pipe, a guide ring the size of the pipe is
installed on the pipe at the top of the machine. Rings are
available for 16”, 18”, and 20” pipes; other sizes can be
made to order.
The machine can cut windows up to 36” in length axially
and from 10° to a full 360° radially.
SYSTEM COMPONENTS
Window Cutter
Figure 3-1 illustrates the components of the window cutter.
In This Chapter
USAGE AND APPLICATIONS
SYSTEM COMPONENTS
REQUIREMENTS
SPECIFICATIONS
ACCESSORIES

Window Cutter
10 Part No. 06-030-MAN, Rev. 2-0709 E.H. Wachs
Figure 3-1. Window cutter components
Radial gearbox Drive control lever
Chain tensioning
Feed select
gearbox
nut
Spindle
motor
Stabilizing
wedges
Manifold
Cutter
feed nut
Spindle
assembly
Spindle
assembly
Axial
drive
lock nut
screw
End support
plate
Radial drive
sprocket
End support
plate
Radial drive
sprocket

Chapter 3, Introduction to the Equipment: Requirements
E.H. Wachs Part No. 06-030-MAN, Rev. 2-0709 11
Hydraulic Power Unit (HPU)
Figure 3-2 illustrates the hydraulic power unit (HPU) pro-
vided with the window cutter.
Figure 3-2. Hydraulic power unit provided with the
window cutter.
REQUIREMENTS
Handling
CAUTION
Do not attempt to lift or move
the window cutter by hand.
Use a hoist or crane.
The window cutter weighs approximately 400 lbs (182 kg).
You will need a hoist or crane to move it and position it on
the pipe for cutting.
The machine has four removable lift hooks installed on its
frame. To position the machine horizontally, use all four
hooks. To position the machine vertically, use the two hooks
at the top end of the frame.
Starter box
Filter housing
Fluid reservoir Tank heater
Motor

Window Cutter
12 Part No. 06-030-MAN, Rev. 2-0709 E.H. Wachs
Figure 3-3. Two lift hooks are provided at each end of
the frame for lifting the window cutter. The hooks are
in threaded holes and can be removed.
Power Source
The hydraulic power unit for the window cutter provides 10
gpm (38 lpm) flow at 2,000 psi. The HPU operates on 230
V electric power at 28.4 amps.
SPECIFICATIONS
Length: 63” (160 cm)
Width: 31” (79 cm)
Height: 13” (33 cm)
Radial Clearance: 16.5” (42 cm)
Weight: approx. 400 lbs (180 kg)
Max. Axial Feed: 36”
Axial Feed Rate: 6 inches per minute
Max. Radial Feed:360°
Radial Feed Rate:6 inches per minute
Blade RPM: 40-160 rpm
Tooling: 6” diameter slitting blade
5” diameter beveling blade

Chapter 3, Introduction to the Equipment: Accessories
E.H. Wachs Part No. 06-030-MAN, Rev. 2-0709 13
ACCESSORIES
• Guide rings for vertical pipe—16”, 18”, and 20”
Figure 3-4. Guide ring for cutting on vertical pipe
• Radial cut support clamp
Figure 3-5. Support clamp for reducing vibration dur-
ing radial cuts

Window Cutter
14 Part No. 06-030-MAN, Rev. 2-0709 E.H. Wachs

Chapter 4, Assembly, Disassembly, and Storage
E.H. Wachs Part No. 06-030-MAN, Rev. 2-0709 15
Chapter 4
Assembly,
Disassembly, and
Storage
The window cutter is shipped fully assembled from the fac-
tory in a shipping/storage crate.
REMOVING THE MACHINE FROM THE
SHIPPING/STORAGE CRATE
You will need to use a crane to pick up the window cutter.
1. Screw the lift hooks into the window cutter frame if
they are not already in place.
2. Position the crane above the crate.
Always lift the machine out of
the case using all four hooks.
If you will be mounting it on a
vertical pipe, set it down on a
flat surface first and lift it from
there with the two top hooks.
3. Attach a chain or cable to each of the four lift hooks
on the machine, and attach the other ends to the crane.
Make sure the crane hook is
centered over the window
cutter before lifting it.
4. Raise the crane until the cables or chains are taut, then
slowly lift the machine. Make sure that the machine is
fairly level and that it does not catch against the side
of the crate.
5. You can mount the machine directly on a horizontal
pipe as described in Chapter 5. If you are mounting it
on a vertical pipe, first set it down on a level surface
and detach the hooks from the bottom end of the
machine.
In This Chapter
REMOVING THE MACHINE FROM
THE SHIPPING/STORAGE CRATE
ENVIRONMENTAL
REQUIREMENTS
LONG-TERM STORAGE

Window Cutter
16 Part No. 06-030-MAN, Rev. 2-0709 E.H. Wachs
ENVIRONMENTAL REQUIREMENTS
The window cutter can be operated in any environment,
including undersea. If used underwater, it is especially
important that you keep it well lubricated, and that you
clean and oil it after each use.
The hydraulic power unit can get wet without damage but
should not be operated in standing water.
LONG-TERM STORAGE
Clean the machine thoroughly before storage. If it has been
used undersea, spray it with fresh water to remove salt resi-
due. Remove the cutting blade from the machine.
Oil all machined surfaces and grease the machine according
to the instructions in Chapter 6.
Secure the machine in its crate. If possible, store it in a non-
corrosive atmosphere away from salt water.