E.H. Wachs EP 424 User manual

EP 424 End Prep Machine

User’s Manual

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. 81-MAN-00

Rev. C, January 2016

Revision History:

Original June 2010

Rev.A April 2013

Rev. B May 2014

EU DECLARATION OF CONFORMITY

WITH

COUNCIL DIRECTIVE 2006/42/EC

Issue Details: DATE:

1/1/2011 Place:

E.H.Wachs, Lincolnshire, IL USA

Directives: Machinery Safety Directive 2006/42/EC

Conforming Machinery: End Prep and Flange Facing Machines:

Model TSE, FSE, and TFS Tube and Fitting Squaring Machines.

Model SDB 103, SDB 206, and SDB 412 Small Diameter

Bevelers; Model FF 206; FF 313, and FF 424 Flange Facers.

Model SB, LB, and MB Plus Boiler Tube Bevelers.

EP 424 End Prep/Flange Facer.

Model Number: 18-000-XX (TSE, FSE); 19-000-XX (TFS); 16-000-XX (SDB-

103/FF-206); 56-000-XX (SDB-206/FF313); 66-000-XX (SDB-

412/FF-424); 70-000-XX (SB); 71-000-XX (MB Plus); 72-000-XX

(LB); 81-000-XX (EP 424)

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 &

Other Technical

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 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

Conformity is Declared: Essential Health and Safety Requirements of Annex 1 of the

Machinery Directive

WeherebycertifythatthemachinerydescrivedaboveconformstotheprovisionsofCouncilDirective

2006/42/EContheapproximationofthelawsoftheMemberStatesrelatingtothesafetyofmachinery.

Signed:

Signatory: Pete Mullally

Quality Manager

E.H. Wachs

Table of Contents

E.H. Wachs Part No. 81-MAN-00, Rev. C i

Table of Contents

Chapter1: AboutThis Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Purpose ofThis Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

How to Use The Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Symbols andWarnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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

Chapter2: Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Operator Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Protective Equipment Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Safety Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Chapter3: Introduction tothe Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Overview of the EP424. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Form-Tool Conﬁguration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Single-Point Conﬁguration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

EP424 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Drive Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Speciﬁcations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Dimensions andWeights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Operating Envelope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Standard Conﬁguration withAir Drive (81-000-01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Standard Conﬁg. with Hydraulic Drive (81-000-02). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Single-Point Conﬁguration withAir Drive (81-000-03) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Single-Point Conﬁg. with Hydraulic Drive (81-000-04). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Single-Point with Speed Prep,Air Drive (81-000-05). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Single-Point with Speed Prep, Hyd. Drive (81-000-06) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Standard Mandrel Dimensions/Leg Chart (81-303-00). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Rotating HeadAssembly (81-304-00). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Independent Chuck Dims/Leg Chart (81-305-00). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Single-Point Slide (81-306-00) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Chapter4: Assembly, Disassembly, andStorage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Storage Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Chapter5: Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Mounting the Mandrel on the Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Mounting the Universal (Standard) Mandrel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

EP424 End Prep Machine

ii Part No. 81-MAN-00, Rev. C E.H. Wachs

Mounting the Independent Chuck Mandrel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Using the Drive Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Mounting and Operating theAir Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Mounting and Operating the Hydraulic Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

FormTool Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Planning the Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Operating Envelope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

SelectingTooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Adjusting theTool Holder Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Setting Up and Mounting the EP424. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Assembling the Machine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Removing the Machine from theWorkpiece. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Single Point Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Installing the Single-Point Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Planning the Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Operating Envelope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

SelectingTool Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Beveling O.D. Set-Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Setting Up and Mounting the EP424. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Assembling the Machine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Using the Speed PrepAutofeed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Compound Bevel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Removing the Machine from theWorkpiece. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Removing the Single-Point Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Chapter6: Routine Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Main DriveAssembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

FeltWipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Single-Point Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Mandrel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Drive Motor Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Chapter7: Service andRepair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Adjusting the Single-Point Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Tighten the Starwheel Stop Collar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Adding/Removing Gib Shims. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Adjust the Push Plate Set Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Calibrating the Speed Prep Scale. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Chapter8: Parts Listsand Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Standard Conﬁg.,Air Drive (81-000-01). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Standard Conﬁg., Hydraulic Drive (81-000-02) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Single-Point with Independent Chuck,Air Drive (81-000-03) . . . . . . . . . . . . . . . . . . . . . . . 100

Table of Contents

E.H. Wachs Part No. 81-MAN-00, Rev. C iii

Single-Point with Independent Chuck, Hydraulic Drive (81-000-04). . . . . . . . . . . . . . . . . . 101

Single-Point with Standard Mandrel,Air Drive (81-000-05) . . . . . . . . . . . . . . . . . . . . . . . . 102

Single-Point with Standard Mandrel,Air Drive (81-000-06) . . . . . . . . . . . . . . . . . . . . . . . . 103

Standard Conﬁg. with Electric DriveAdapter (81-000-07). . . . . . . . . . . . . . . . . . . . . . . . . . 104

Main DriveAssembly (81-300-00) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Rear FeedAssembly (81-301-00) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Speed PrepAuto Feed (81-302-00) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

EPD Electric DriveAdapter Kit (81-500-00) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Standard MandrelAssembly (81-303-00) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Rotating HeadAssembly (81-304-00). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Independent ChuckAssembly (81-305-00). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Single-Point SlideAssembly (81-306-00). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

TripAssembly (81-307-00). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Safety StopAssembly (81-316-00) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Hydraulic DriveAssembly (81-310-00) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Optional Remote-Operated Hydraulic DriveAssembly (81-310-01) . . . . . . . . . . . . . . . . . . 114

Air DriveAssembly (81-311-00). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Feed Lock (81-317-00) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Single-Point Holder Kit (81-702-00). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Chapter9: Accessories andSpareParts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Chapter10: Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Return GoodsAddress. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

EP424 End Prep Machine

iv Part No. 81-MAN-00, Rev. C E.H. Wachs

Chapter 1, About This Manual

E.H. Wachs Part No. 81-MAN-00, Rev. C 1

Chapter1

About This Manual

PURPOSE OF THIS MANUAL

This manual explains how to operate and maintain the EP424 end prep machine. 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.

Before operating the EP424, you should read through this manual and become familiar with all

instructions.At a minimum, make sure you read and understand the following chapters:

• Chapter 1,About This Manual

• Chapter 2, Safety

• Chapter 3, Introduction to the Equipment

• Chapter 5, Operating Instructions

• Chapter 9,Accessories

If you will be performing service or repairs, make sure you read and understand these chapters:

• Chapter 1,About This Manual

• Chapter 4,Assembly and Disassembly

• Chapter 6, Routine Maintenance

• Chapter 7, Service and Repair.

You will also want to refer to Chapter 8, Parts Lists and Drawings.

EP 424 End Prep Machine

2 Part No. 81-MAN-00, Rev. C E.H. Wachs

HOW TO USE THE MANUAL

This manual is organized to help you quicklyﬁnd the information you need. Each chapter de-

scribes a speciﬁc topic on using or maintaining your equipment.

Use these instructions to operate and maintain the equipment.

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.

Throughout this manual, refer to warnings, cautions, and notices with supplementary information.

WARNING

AWARNING alert with the safety alert symbol indicates a potentially hazardous situation that could

result in serious injury or death.

CAUTION

ACAUTION alert with the safety alert symbol indicates a potentially hazardous situation that could result

in minor or moderate injury.

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.

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.

CAUTION

ACAUTION alert with the damage alert symbol indicates a situation that will result in damage to the

equipment.

Chapter 1, About This Manual:

E.H. Wachs Part No. 81-MAN-00, Rev. C 3

IMPORTANT

An IMPORTANT alert with the damage alert symbol indicates a situation that may result in damage

to the equipment.

NOTE

This symbol indicates a user note. Notes provide additional information to supple-

ment the instructions, or tips for easier operation.

MANUAL UPDATES AND REVISION TRACKING

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.

Current versions of E.H. Wachs Company manuals are also available in PDF format. You can

request an electronic copy of this manual by emailing customer service at [email protected].

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.

EP 424 End Prep Machine

4 Part No. 81-MAN-00, Rev. C E.H. Wachs

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