Wachs EP 424 User Manual

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E.H. Wachs 600 Knightsbridge Parkway Lincolnshire, IL 60069 www.ehwachs.com

EP 424 End Prep Machine

User’s Manual

E.H. Wachs Part No. 81-MAN-00 Rev. 0-0610, June 2010

Revision History: Original June 2010

This manual may not be reproduced in whole or in part

without the written consent of E.H. Wachs.

EP 424 End Prep Machine

Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

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

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

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

Chapter 3: Introduction to the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Overview of the EP 424 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Form-Tool Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Single-Point Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

EP 424 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Drive Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Dimensions and Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Operating Envelope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Chapter 4: Assembly, Disassembly, and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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

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

Chapter 5: Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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

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

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

Using the Drive Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Mounting and Operating the Air Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Mounting and Operating the Hydraulic Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Form Tool Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Planning the Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Operating Envelope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Selecting Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Adjusting the Tool Holder Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Setting Up and Mounting the EP 424 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 1

EP 424 End Prep Machine

Assembling the Machine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Removing the Machine from the Workpiece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Single Point Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Installing the Single-Point Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Planning the Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Operating Envelope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Selecting Tool Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Beveling O.D. Set-Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Setting Up and Mounting the EP 424 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Assembling the Machine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Using the Speed Prep Autofeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Compound Bevel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Removing the Machine from the Workpiece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Removing the Single-Point Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Chapter 6: Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Main Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Felt Wipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Single-Point Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Mandrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Drive Motor Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Chapter 7: Service and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Adjusting the Single-Point Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Tighten the Starwheel Stop Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Adding/Removing Gib Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Adjust the Push Plate Set Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Calibrating the Speed Prep Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Air Motor Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Chapter 8: Parts Lists and Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Chapter 9: Accessories and Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Chapter 10: Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Return Goods Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

2 P art No. 81-MAN-00, Re v. 0-0610 E.H. Wachs

Chapter 1

About This Manual

PURPOSE OF THIS MANUAL

This manual explains how to operate and maintain the EP 424 end prep machine. It includes instructions for setup, operation, and maintenance. It also contains parts lists, diagrams, and service information to help you order replacement parts and perform user-serviceable repairs.

Chapter 1, About This Manual

In This Chapter

PURPOSE OF THIS MANUAL HOW TO USE THE MANUAL SYMBOLS AND WARNINGS MANUAL UPDATES AND

EVISION TRACKING

Before operating the EP 424, 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.

E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 1

EP 424 End Prep Machine

WARNING

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.

CAUTION

HOW TO USE THE MANUAL

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

This manual is organized to help you quickly find the information you need. Each chapter describes a specific topic on using or maintaining your equipment.

Each page is designed with two columns. This large column on the inside of the page contains instructions and illustrations. Use these instructions to operate and maintain the equipment.

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 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.

A WARNING alert with the safety alert symbol indicates a potentially hazardous situation that could result in seri- ous injury or death.

A CAUTION alert with the safety alert symbol indicates a potentially hazardous situation that could result in minor or moderate injury.

2 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

Chapter 1, About This Manual: Manual Updates and Revision Tracking

CAUTION

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.

IMPORTANT

NOTE

This symbol indicates a user note. Notes provide additional information to supplement the instructions, or tips for easier operation.

A CAUTION alert with the damage alert symbol indicates a situation that will result in damage to the equipment.

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

equipment.

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.

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.

A NOTE provides supplementary information or operating tips.

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 sales@wachsco.com

E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 3

EP 424 End Prep Machine

4 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

Chapter 2

Safety

E.H. Wachs 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.

Chapter 2, Safety

In This Chapter

OPERATOR SAFETY SAFETY LABELS

Read this chapter carefully before operating the EP 424 end prep machine. It contains important safety instructions and recommendations.

OPERATOR SAFETY

Follow these guidelines for safe operation of the equipment.

• 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, leaking lubricant, rusted components, and any other physical conditions that may affect operation. Properly maintaining the machine can greatly decrease the chances for injury.

• ALWAYS READ PLACARDS AND LABELS. Make

sure all placards, labels, and stickers are clearly legible and in good condition. You can purchase replacement labels from E.H. Wachs Company.

• KEEP CLEAR OF MOVING PARTS.

arms, and fingers clear of all rotating or moving parts.

Keep hands,

Look for this symbol throughout the manual. It indicates a personal injury hazard.

E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 5

EP 424 End Prep Machine

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.

6 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

Protective Equipment Requirements

Always wear impact resistant eye protection while operating or working near this equipment.

WARNING

CAUTION

Personal hearing protection is recommended when operating or working near this tool.

For additional information on eye and face protection, refer to Federal OSHA regulations, 29 Code of Federal Regulations, Section 1910.133., Eye and Face Protection and American National Standards Institute, ANSI Z87.1, Occupational and Educational Eye and Face Protection. Z87.1 is available from the American National Standards Institute, Inc., 1430 Broadway, New York, NY 10018.

Chapter 2, Safety: Safety Labels

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 structures can increase the noise level in the area. For additional information on hearing protection, refer to Federal OSHA regulations, 29 Code of Federal Regulations, Section

1910.95, Occupational Noise Exposure and ANSI S12.6 Hearing Protectors.

SAFETY LABELS

The following safety labels are on the EP 424 machine. If a label is lost or unreadable, order and attach a replacement. See ordering instructions in Chapter 10.

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EP 424 End Prep Machine

Figure 2-1. Crush hazard safety label (part no. 81165-00).

Figure 2-2. Crush and cut hazard safety label (part no. 90-401-04).

Figure 2-3. Loud noise hazard safety label, provided with air drive configurations (part no. 90-401-03).

Figure 2-4. Eye injury hazard label, provided with hydraulic drive configurations (part no. 90-401-01).

8 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

Figure 2-5. Compressed air pressure safety label (part no. 90-401-02).

Chapter 2, Safety: Safety Labels

Figure 2-6. Hydraulic pressure safety label (part no. 90-402-01).

E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 9

EP 424 End Prep Machine

10 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

Chapter 3

Introduction to the Equipment

OVERVIEW OF THE EP 424

Chapter 3, Introduction to the Equipment

In This Chapter

OVERVIEW OF THE EP 424 S

PECIFICATIONS

The EP 424 is an I.D. (inside diameter) mounted end prep machine for facing, beveling, counterboring, and J-prepping pipes and flanges. It can be used for pipes from 4-24 inches O.D., with wall thicknesses up to 1.6” (41 mm) using form tools, or 6.5” (165 mm) with single-point operation.

The EP 424 is provided in 4 configurations:

• Form tool machine with air drive, part no. 81-000-01

• Form tool machine with hydraulic drive, part no. 81000-02

• Single-point machine with air drive, part no. 81-000-03

• Single-point machine with hydraulic drive, part no. 81000-04.

Form tool operation is quick to set up and easy to perform on pipe walls up to schedule 160 (1.6” on 16” pipe). For heavier wall pipe up to 6.5” wall thickness, the single-point kit allows you to perform any bevel profile.

OPERATING ENVELOPE

Form-Tool Configuration

The form tool configurations have a rotating tool head with 3 tool holders, for performing up to 3 simultaneous opera-

E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 11

EP 424 End Prep Machine

tions. Tooling is available for facing, single-angle beveling, compound beveling, counterboring,

The form tool configuration will perform end prepping (facing, beveling, J-prepping, and counterboring), with the operator manually feeding the tool head.

Figure 3-1. The photo shows the form tool configuration of the machine with the standard self-centering mandrel.

Single-Point Configuration

The single-point machine is provided with a tool slide that feeds the tool radially across the face of the pipe or flange. The slide is driven by a starwheel that engages trips on a ring mounted to the machine housing. Bevels are performed using the Speed Prep auto-feed system, which automatically feeds the machine axially as it cuts.

The single-point machine will perform facing or beveling of thick-walled pipes and flanges.

12 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

Chapter 3, Introduction to the Equipment: Overview of the EP 424

Figure 3-2. The photo shows the single-point configuration of the EP 424.

EP 424 Components

The following components are provided with the form tool configuration of the EP 424:

• main drive assembly with lifting attachments

• feed assembly

• rotating tool head

• standard self-centering mandrel

• drive motor (air or hydraulic)

• hand tool set

The single-point configuration includes the following additional components:

E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 13

EP 424 End Prep Machine

StarwheelFeed screws

Male tool slide

Tool holder

Feed gauge

• single-point slide

Figure 3-3. The single-point slide feeds the tool radially across the pipe face. It is driven along a feed screw by a starwheel.

• radial feed trip assembly

Figure 3-4. The photo shows the trip assembly mounted on the main drive housing.

14 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

• Speed Prep autofeed module

WARNING

Speed Prep module

Chapter 3, Introduction to the Equipment: Overview of the EP 424

The Speed Prep autofeed can feed the machine until it comes off the mandrel. Crushing or other serious injuries could occur. Use the autofeed stop plate (81-316-

00) to keep the machine from feeding too far.

Figure 3-5. The speed prep module is installed on the main drive to operate the feed mechanism for singlepoint beveling.

• independent chuck mandrel

Figure 3-6. The independent chuck mandrel allows you to center the machine on the O.D. of the pipe.

E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 15

EP 424 End Prep Machine

• extension leg kit for standard mandrel

Figure 3-7. Two sets of extension legs allow the standard mandrel to be mounted in pipes up to 23.64” I.D.

• dial indicator assembly

16 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

Figure 3-8. The dial indicator is provided for centering the independent chuck in the pipe.

Chapter 3, Introduction to the Equipment: Overview of the EP 424

Drive Motors

Two drive motors are available for the EP 424:

• a 3.5 HP air motor, part no. 81-311-00. The air motor requires 95 cfm air flow at 90 psi (2,700 l/min at 6.2 bar).

Figure 3-9. The photo shows the EP 424 air motor.

• a hydraulic motor, part no. 81-310-00. The hydraulic motor requires 10 gpm flow at 1500 psi (38 l/min @103 bar).

Figure 3-10. The hydraulic motor is interchangeable with the air motor.

E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 17

EP 424 End Prep Machine

Both motors include adapters for the EP 424. The motors are interchangeable, requiring no modifications to the EP 424 machine.

Accessories

The following accessories are available for the EP 424:

• Single-point upgrade kit, part no. 81-400-00 (for formtool machine configuration); includes Speed Prep module, single-point slide, trip ring, and independent chuck.

• Extension leg kit for standard mandrel, part no. 81-303-

01. Extends maximum clamping I.D. to 23.64” (600.5 mm).

• Independent chuck mandrel, part no. 81-305-00. (Provided with single-point machine or kit; available as option for form tool machine.)

• Short perch mandrel, part no. 81-315-00. Self-centering mandrel for pipes with bends or limited I.D. access.

• Air treatment module, part no. 26-407-00.

18 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

SPECIFICATIONS

Capacities

Table 1: EP 424 Operating Capacities

Chapter 3, Introduction to the Equipment: Specifications

Air requirements

Hydraulic requirements

Axial feed 0.071” per feed handle revolution

Single-point slide radial feed

Max feed travel 3.50” (88.9 mm) Max. rotating speed (no

load) Min. pipe wall thickness Schedule 40 Max. pipe wall thickness

(form tool) Max pipe wall thickness (sin-

gle-point) Lift hook capacity 1000 lb (454 kg)

95 cfm at 90 psi (2690 l/min at 6.2 bar)

Min 10 gpm/max 15 gpm at 2000 psi (38/57 l/min at 138 bar)

0.0052” (0.132 mm) per engaged trip;

6.5” (165 mm) maximum feed

20 rpm

1.6” (40.5 mm), depending on material

6.5” (165 mm)

Dimensions and Weights

The envelope drawings in the following section include the dimensions for each machine configuration, and the weight for each subassembly. Table 2 below includes overall dimensions and weights for each configuration.

Table 2: Overall Dimensions and Weights

Configuration

81-000-01 (Form tool/air drive)

81-000-02 (Form tool/ hydraulic drive)

Dimensions

(L x W x H)

28.8” x 36.2” x 16.1” (732 x 919 x 408 mm)

28.8” x 25.3” x 16.1” (732 x 643 x 408 mm)

154.5 lb (70.2 kg)/ 172 lb (78.2 kg)

162 lb (73.6 kg)/

179.5 lb/81.6 kg

E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 19

Weight

(Std. Mandrel/

Ind. Chuck Mandrel)

EP 424 End Prep Machine

Table 2: Overall Dimensions and Weights

Weight

(Std. Mandrel/

Ind. Chuck Mandrel)

Configuration

81-000-03 (Single-point/air drive)

81-000-04 (Single-point/ hydraulic drive)

Shipping/ storage case

Dimensions

(L x W x H)

25.5” x 42.3” x 21.2” (648 x 1075 x 539 mm)

25.4” x 30.4” x 21.2” (645 x 772 x 539 mm)

37” x 36.3” x 22.3” (940 x 922 x 566 mm)

176 lb (80 kg)/

193.5 lb (88 kg)

183.5 lb (83.4 kg)/ 201 lb (91.4 kg)

OPERATING ENVELOPE

The drawings on the following pages illustrate the operating envelope for all configurations of the EP 424:

• Standard machine with air drive (81-000-01)

• Standard machine with hydraulic drive (81-000-02)

• Single-point machine with air drive (81-000-03)

• Single-point machine with hydraulic drive (81-000-04).

There are also dimensional drawings for the following components:

• Standard mandrel with extension legs

• Form tool rotating head

• Independent chuck mandrel with extension legs

• Single-point slide.

20 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

29.31

744.6

AXIAL FEED: .071"[1.80] PER FEED

HANDLE REVOLUTION

(CLOCKWISE)

28.81

731.6

10.47

265.9

1.02

25.9

3.59

91.1

7.5

.29

(SHOWN WITH

ON MANDREL)

.50 [12.7] TREAD ENGAGEMENT

5.38

136.5

208

8.19

56-198-02

56-711-01

INSERT HOLDER

3.50

88.9

TOOL

FACING/BEVELING

Operating Envelope

EP 424 Air Drive Conguration

81-000-01

MAX TRAVEL

15.73

13.68

399.5

347.5

20 RPM

MAX FREE SPEED

5.38

136.5

AIR REQUIREMENTS

AIR CONSUMPTION 95 cfm [2690 l/min]

PRESSURE 90 PSI [6.2 BAR]

MAX

4.20

1/2 NPT

106.6

LEGS SHOWN FULLY EXTENDED

2.72

69.2

MIN

3.25

82.6

LEGS SHOWN FULLY RETRACTED

NOTE:

SEE 81-303-00 FOR ALL

EXTENSION RANGES

17.41

442.3

.29

7.5

(SHOWN WITH

ON MANDREL)

7.66

AXIAL FEED: .071"[1.80] PER FEED

HANDLE REVOLUTION

(CLOCKWISE)

194.5

28.81

731.6

10.47

265.9

1.52

3.09

38.6

78.4

5.38

.50"[12.7] THREAD ENGAGEMENT

136.5

208

8.19

56-711-01

56-198-02

INSERT HOLDER

FACING/BEVELING

TOOL

3.50

88.9

Operating Envelope

MAX TRAVEL

EP 424 Hydraulic Drive Conguration

81-000-02

15.73

13.68

399.5

347.5

20 RPM

MAX FREE SPEED

MAX FLOW 15 GPM [57 LPM]

MAX PRESSURE 2000 PSI [138 BAR]

5.38

136.5

MAX

4.20

MAX

106.7

LEGS SHOWN FULLY EXTENDED

2.72

69.2

MIN

3.25

82.6

LEGS SHOWN FULLY RETRACTED

NOTE:

SEE 81-303-00 FOR ALL

EXTENSION RANGES

29.31

744.6

.50

12.7 ON MANDREL

THREAD ENGAMENT

8.19

208

25.35

643.8

27.15

689.7 ROTATING

20 RPM

MAX FREE SPEED

AXIAL FEED: .071" [1.80] PER FEED

HANDLE REVOLUTION

(CLOCKWISE)

13.00

330.2

FEED RATE: .0052" [.132]

PER TRIP ENGAGED

TOTAL STROKE: 6.5" [165.1]

3.50

88.9 MAX TRAVEL

HOLDER

56-205-01

52-701-01

INSERT TOOL

6.84

173.6

Operating Envelope

EP 424 Air Drive Conguration

Single-Point Operation

81-000-03

11.90

302.3 (SEE 81-305-00

FOR FULL LEG CHART)

AIR REQUIREMENTS

AIR CONSUMPTION 95 cfm [2690 l/min]

PRESSURE 90 PSI (6.2 bar)

1/2 NPT

17.41

442.3

AXIAL FEED: .071" [1.80] PER FEED

HANDLE REVOLUTION

(CLOCKWISE)

7.66

194.5

FEED RATE: .0052" [.132]

PER TRIP ENGAGED

TOTAL STROKE: 6.5" [165.1]

3.50

88.9 MAX TRAVEL

HOLDER

56-205-01

.50

12.7

52-701-01

INSERT TOOL

ON MANDREL

THREAD ENGAMENT

8.19

208

25.35

643.8

6.84

173.6

27.15

689.7

20 RPM

MAX FREE SPEED

13.00

330.2

MAX FLOW 15 GPM [57 LPM]

MAX PRESSURE 2000 PSI [138 BAR]

Operating Envelope

EP 424 Hydraulic Drive Conguration

Single-Point Operation

81-000-04

11.94

303.2 SEE 81-305-00

FOR FULL LEG CHART

MIN

3.27

MIN

83.1 MIN I.D. WITH

3.15

80.1

.50

12.7

Operating Envelope

EP 424 Standard Mandrel and Extension Legs

81-303-00

MAX

4.20 MAX I.D. WITH

"A"

MIN

MIN POSITION

"B"

MAX POSITION

MAX

1.79

45.3

16.39

416.2

13.68

347.4

1.19

30.1

Operating Envelope

EP 424 Rotating Tool Head

81-304-00

TOOL HOLDER

SHOWN IN OUTER POSITION

1.38

34.9

ID RANGE

INCHES

8.50 - 10.50 215.9 - 266.7

9.50 - 11.50 241.3 - 292.1

11.18 - 13.15 284.0 - 334.0

INDEPENDENT CHUCK MANDREL

12.18 - 14.15 309.4 - 359.4

14.43 - 16.50 366.5 - 419.1

15.43 - 17.50 391.9 - 444.5

16.87 - 18.81 428.5 - 477.8

17.87 - 19.81 453.9 - 503.2

19.31 - 21.30 490.5 - 541.0

20.31 - 22.30 515.9 - 566.4

22.28 - 24.28 565.9 - 616.7

23.28 - 25.28 591.3 - 642.1

1.75

44.5

24.85

631.1

LEG SET

23-313-00

23-214-01

(23-221-00)

WITH SPACER

23-214-02

(23-221-00)

WITH SPACER

(23-221-00)

WITH SPACER

25.28

23-214-03

642.1

23-214-04

(23-221-00)

WITH SPACER

MAX CLAMPING

23-214-05

(23-221-00)

WITH SPACER

(23-221-00)

WITH SPACER

Operating Envelope

EP 424 Independent Chuck Mandrel

and Extension Legs

81-305-00

8.50

215.9

MIN CLAMPING

26.38

670

MAX TOOL POSTION

TOOL HOLDER 56-205-01

& INSERT TOOL 52-701-01

SHOWN WITH HIGH RANGE

13.58 R

344.8

7.25

184.1

2.55

64.7

Operating Envelope

EP 424 Single-Point Slide

81-306-00

23.62

599.8

MAX TOOL POSTION

TOOL HOLDER 56-205-00

& INSERT TOOL 52-701-01

SHOWN WITH LOW RANGE

SHOWN WITH .50"

THREAD ENGAGMENT

& 3 TOOL HOLDER SCREWS

SLIDE TRAVEL: 6.5"

4.25

107.9

MIN TOOL POSTION

TOOL HOLDER 56-205-01

& INSERT TOOL 52-701-01

SHOWN WITH HIGH RANGE

MIN TOOL POSTION

TOOL HOLDER 56-205-00

& INSERT TOOL 52-701-01

SHOWN WITH LOW RANGE

Chapter 4

Assembly, Disassembly, and Storage

Chapter 4, Assembly, Disassembly, and Storage

In This Chapter

PACKAGING

The EP 424 comes in a customized steel shipping/storage case. The case includes compartments for all standard and optional components, and is designed to hold all components securely to prevent damage in shipping.

Store the machine in its case at all times when it is not in use. Figure 4-1 shows the layout of the components in the case. There are lockdown pins for securing the EP 424 machine, as shown in Figure 4-2.

PACKAGING STORAGE CHECKLIST

Figure 4-1. The photo shows the EP 424 in its case.

E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 29

EP 424 End Prep Machine

Figure 4-2. Two lockdown pins are provided to secure the machine in the storage case. Always insert the pins through the case brackets and the EP 424 handle when storing the machine.

STORAGE CHECKLIST

Before storing the EP 424, perform the following maintenance steps. If you are using the machine in an especially dirty or corrosive environment, perform these steps frequently.

• Clean the machine by wiping off dirt, debris, and accumulated oil or grease.

• Put oil in the air motor oiler, and operate the motor for a few seconds to lubricate its internal components.

• Lubricate the machine according to the instructions in Chapter 6.

• Spray or wipe a light coating of anti-corrosion lubricant on non-finished, non-painted surfaces.

• Put the machine in its storage case, with all components stored in their compartments.

• If possible, keep the storage case indoors and away from moisture.

• If you will be storing the machine longer than 30 days, put desiccant packets in the case to prevent corrosion.

30 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

Chapter 5

Operating Instructions

MOUNTING THE MANDREL ON THE PIPE

Typically, you will install the mandrel (either the standard or independent chuck mandrel) in the pipe before mounting the EP 424 machine. This makes it easier to align the mandrel and mount the machine.

Chapter 5, Operating Instructions

In This Chapter

MOUNTING THE MANDREL ON

THE PIPE

USING THE DRIVE MOTORS FORM TOOL OPERATION SINGLE POINT OPERATION

The standard mandrel is recommended when it can be used on the pipe. It is self-centering, and is quicker and easier to mount than the independent chuck mandrel. The standard mandrel can be mounted in pipes with an I.D. range from

3.27” to 23.64” (83.1 to 600.5 mm).

The workpiece may not be suitable for the standard mandrel, such as in the following situations:

• the I.D. of the pipe is uneven or eroded

• the end of the pipe is on a bend

• the end surface of the pipe is not square

• you need to center the operation on the O.D. of the pipe.

In these cases, you will need to use the independent chuck mandrel. You can use the independent chuck mandrel for either form tool or single-point operation. The independent chuck mandrel can be mounted in pipes with an I.D. range from 8.50” to 25.28” (215.9 to 642.1 mm).

E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 31

EP 424 End Prep Machine

NOTE

If the pipe I.D. is larger than

15.96” (405.4 mm), you will need the extended leg kit.

Mounting the Universal (Standard) Mandrel

Measure the I.D. of the pipe.

See the envelope drawings in Chapter 3 for an illustration of the clamp leg configurations.

Figure 5-1. Measure the I.D. of the pipe to determine which leg set will be required.

Refer to the clamp leg chart in Table 1 to select the

correct combination of clamp legs. Find the I.D. you measured (inches or mm) in the appropriate column on the left, then select the leg extensions listed in the column on the right.

32 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

Chapter 5, Operating Instructions: Mounting the Mandrel on the Pipe

Table 1: Standard Mandrel Clamping Leg Chart

I.D. Inches I.D. mm

Min Max Min Max

3.27 4.20 83.1 106.7 None

4.07 4.99 103.4 126.8 #1

4.86 5.79 123.4 147.1 #2

5.64 6.56 143.3 166.6 #3 & #1

6.46 7.39 164.1 187.7 #3 & #2

7.22 8.15 183.4 207.1 #3, #2, & #1

7.94 8.87 201.7 225.3 #4 & #1

8.77 9.71 222.8 246.6 #4 & #2

9.53 10.46 242.1 265.7 #4, #3, & #1

10.24 11.18 260.1 284.0 #5 & #1

11.09 12.02 281.7 305.3 #5 & #2

11.84 12.77 300.7 324.4 #5, #3, & #1

12.69 13.62 322.3 346.0 #5, #3, & #2

12.58 1 3.51 319.5 343.2 #6 & #1

13.43 1 4.36 341.1 364.7 #6 & #2

14.17 15.11 359.9 383.8 #6, #3, & #1

15.03 15.96 381.8 405.4 #6, #3, & #2

Leg Extensions Used

With 81-303-01 Extended Leg Kit

14.87 1 5.80 377.7 401.3 #7 & #1

15.73 1 6.66 399.5 423.2 #7 & #2

16.47 17.40 418.3 442.0 #7, #3, & #1

17.33 18.26 440.2 463.8 #7, #3, & #2

17.19 1 8.12 436.6 460.3 #8 & #1

18.05 1 8.98 458.5 482.1 #8 & #2

18.78 19.72 477.0 500.9 #8, #3, & #1

19.65 20.58 499.1 522.7 #8, #3, & #2

20.38 2 1.32 517.7 541.5 #8, #3, #2, & #1

21.10 22.04 535.9 559.8 #8, #4, & #1

21.97 22.90 558.0 581.7 #8, #4, & #2

22.70 2 3.64 576.6 600.5 #8, #4, #3, & #1

Using a 3/16” hex wrench, attach the clamping legs to

the mandrel chuck legs with the captivated screws. If you are using more than one leg set, install the largest

E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 33

EP 424 End Prep Machine

NOTE

Extension leg #1 does not have threaded holes to install other legs on top of it.

leg first, then “stack” them in size order. Make sure the legs seat squarely, then securely tighten the screws.

Figure 5-2. Screw the captivated scr ews into the mandrel to secure the legs.

Always install extension leg #1 or #2 last, on top of

the others. These legs are steel for greater durability.

34 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

Figure 5-3. Use the steel extension legs (#1 or #2) on top when installing multiple legs.

Chapter 5, Operating Instructions: Mounting the Mandrel on the Pipe

NOTE

Using a 1-1/16” wrench or socket, turn the drawbar

nut counter-clockwise to retract the clamping legs.

Figure 5-4. Turn the drawbar nut counter-clockwise to retract the clamping legs.

Insert the clamping legs into the I.D. of the pipe. Hold

the mandrel so that the legs are far enough inside the end of the pipe to be out of the way of the machining operation.

A socket wrench and 1-1/16” socket are provided with the EP 424.

For stability, the clamp legs should be as close as possible to the end of the pipe. However, make sure they are far enough into the pipe to avoid being damaged during the operation. This is espe-

cially critical if you are counterboring.

Figure 5-5. Insert the clamping legs into the pipe.

Turn the drawbar nut clockwise to clamp the legs

inside the pipe until they are snug enough to hold the mandrel.

E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 35

EP 424 End Prep Machine

Figure 5-6. Turn the drawbar nut clockwise until the clamping legs are snug in the I.D. of the pipe.

Check that the legs are square on the pipe I.D., and are

far enough from the pipe end for the operation.

Figure 5-7. Measur e the distance from the pipe end to the clamping legs to make sure there is enough clearance for the operation.

If necessary, adjust the position of the clamping legs.

Then turn the drawbar nut clockwise to clamp the legs securely in the pipe.

36 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

Chapter 5, Operating Instructions: Mounting the Mandrel on the Pipe

NOTE

Mounting the Independent Chuck Mandrel

Start with the chuck body separated from the mandrel.

Measure the I.D. of the pipe.

Figure 5-8. Measure the I.D. of the pipe to determine which leg set will be required.

Refer to the clamp leg chart in Table 2 to select the

correct clamp legs. Find the I.D. you measured (inches or mm) in the appropriate column on the left, then select the leg set listed in the column on the right.

See the envelope drawings in Chapter 3 for an illustration of the clamp leg configurations.

E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 37

EP 424 End Prep Machine

Table 2: Independent Chuck Clamping Leg Chart

I.D. Inches I.D. mm

MinMaxMinMax

8.50 10.50 215.9 266.7 23-313-00 No

9.50 11.50 241.3 292.1 23-313-00 Yes

1 1.18 13.15 284.0 334.0 23-214-01 No

12.18 14.15 309.4 359.4 23-214-01 Yes

14.43 16.50 366.5 419.1 23-214-02 No

15.43 17.50 391.9 444.5 23-214-02 Yes

16.87 18.81 428.5 477.8 23-214-03 No

17.87 19.81 453.9 503.2 23-214-03 Yes

19.31 21.30 490.5 541.0 23-214-04 No

20.31 22.30 515.9 566.4 23-214-04 Yes

22.28 24.28 565.9 616.7 23-214-05 No

23.28 25.28 591.3 642.1 23-214-05 Yes

Screw the 4 chuck legs into the chuck body. Leave

Leg Set Used

Spacer (23-221-

00) Used

about 1/2” of threads exposed for the jam nut.

38 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

Figure 5-9. Screw the chuck legs into the chuck.

Put a jam nut over each leg, with the “shoulder” side

of it toward the chuck body . Thread it a few turns onto the chuck leg.

Chapter 5, Operating Instructions: Mounting the Mandrel on the Pipe

Shoulder

Figure 5-10. Put on the jam nut as shown, with the shoulder of the nut toward the chuck.

If chuck leg spacers (23-221-00) are required, install a

spacer over each of the 4 independent chuck buttons.

Figure 5-11. If required, put a chuck leg spacer on each chuck button end.

Insert a button into the end of each chuck leg. The but-

tons are fitted with o-rings to hold them in the leg.

E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 39

EP 424 End Prep Machine

Figure 5-12. Put buttons on the end of each chuck leg.

Place the chuck body inside the I.D. of the pipe and

screw the legs out to snug them against the I.D.

40 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

Figure 5-13. Screw the legs out to snug the chuck inside the pipe.

Remove the nuts from the 4 threaded studs, and put

the interlocking pieces of the alignment gauge over the studs with the scale sides facing you.

Chapter 5, Operating Instructions: Mounting the Mandrel on the Pipe

Figure 5-14. Mount the alignment gauge to the studs in the chuck.

Screw the nuts onto the studs to secure the alignment

gauge. The gauge pieces should be tight against the face plate. You may have to move the chuck out to tighten the gauge against the face plate.

Figure 5-15. The alignment gauge must be flush against the face plate surface.

Loosen the clamp legs slightly, and push the chuck

10.

body into the pipe until all four ends of the alignment

E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 41

EP 424 End Prep Machine

NOTE

gauge are touching the end of the pipe. Re-tighten the legs to hold the chuck body in place.

You will roughly center the chuck body in the pipe (to the precision of the alignment gauge scales). You will precisely center the mandrel later in this procedure.

Figure 5-16. Push the chuck body into the pipe until all four arms of the alignment gauge are against the pipe surface.

To center the chuck body, refer to the scales on the

11.

alignment gauges. Using a 1-1/8” end wrench on the flats of the chuck legs, turn opposite legs in or out until the scale touches the pipe I.D. at the same distance on both sides.

Figure 5-17. Alternately adjust opposite legs to center the chuck in the pipe.

42 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

When the chuck body is centered, use a 2-1/4” wrench

12.

to snug the jam nuts against the chuck body.

Chapter 5, Operating Instructions: Mounting the Mandrel on the Pipe

Figure 5-18. When the chuck is rough centered, snug the jam nuts to hold the clamping legs in place.

Remove the alignment gauge from the studs. Make

13.

sure you have the nut and both washers removed from each stud.

Figure 5-19. Remove the alignment gauge and the nuts and washers from the chuck studs.

E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 43

EP 424 End Prep Machine

NOTE

If the chuck does not need any further centering adjustment, install a spacer (23203-00) over each stud before mounting the mandrel.

Mount the mandrel onto the chuck.

14.

Figure 5-20. Mount the mandrel on the independent chuck.

Replace the 2 washers (female washer first) and the

15.

nut onto each stud to hold the mandrel in place. Snug the nuts to finger tightness.

Place the indicator mounting collar over the mandrel

16.

and slide it close to the pipe.

44 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

Figure 5-21. Slide the indicator collar over the end of the mandrel.

Chapter 5, Operating Instructions: Mounting the Mandrel on the Pipe

Tighten the set screws in the indicator collar to hold it

17.

in place on the mandrel.

Figure 5-22. Position the collar near the pipe surface and tighten the set screws to hold it in place.

Assemble the indicator and set the magnetic mount

18.

onto the indicator mounting collar. T urn the magnet on to hold the indicator in place.

Figure 5-23. Set the magnetic base of the indicator on the collar, and turn the switch on to engage the magnet.

Position the tip of the indicator to touch the pipe sur-

19.

face. You can indicate on either the O.D. or the I.D. of the pipe, depending on where the operation needs to be centered.

E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 45

EP 424 End Prep Machine

NOTE

Do not adjust the mandrel centering screws if stud spacers (23-203-00) are installed. The mandrel position cannot be adjusted with the spacers.

Figure 5-24. Set the tip of the indicator to touch the pipe, perpendicular to the surface.

Move the indicator around the pipe end by rotating the

20.

mounting collar. Check the reading on the indicator dial to measure how far the mandrel is off center.

46 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

Figure 5-25. Sweep the indicator around the pipe surface to check centering of the mandrel. You can center on either the O.D. or the I.D. of the pipe, as required for the operation.

To center the mandrel, adjust the mandrel centering

21.

screws in the face plate.

Chapter 5, Operating Instructions: Using the Drive Motors

Figure 5-26. Turn the mandrel centering screws to adjust the position of the mandrel.

When you have the mandrel centered, tighten down

22.

the nuts on the mandrel mounting studs. Remove the indicator and the indicator mounting col-

23.

lar.

USING THE DRIVE MOTORS

Refer to the instructions in this section for the drive motor (air or hydraulic) provided with your EP 424 machine. The motors are installed and operated the same way for either form tool or single-point operation.

Mounting and Operating the Air Drive

T o install the air motor , put the motor flange over the 4

motor mounting screws on the EP 424 motor adapter. You may have to rotate the motor slightly to engage the spline in the shaft.

E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 47

EP 424 End Prep Machine

NOTE

Figure 5-27. Put the air motor flange over the screws in the motor adapter.

Rotate the air motor to secure the screw heads in the

slotted holes of the flange. Using a 1/4” hex wrench, tighten the screws securely.

The air supply must provide 95 cfm at 90 psi (2700 l/min at 6.2 bar).

48 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

Figure 5-28. Turn the flange to seat the screws in the slots, then tighten the screws.

Make sure the air supply is turned off at the source.

Connect the air line to the connector on the air motor. Turn on the air supply at the source.

To operate the EP 424, squeeze the trigger on the air

motor. The machine (form tool head or single-point slide) will start to rotate.

Figure 5-29. Squeeze the air motor trigger to start the

NOTE

machine.

Adjust the motor speed by turning the speed control-

ler.

Chapter 5, Operating Instructions: Using the Drive Motors

Figure 5-30. Turn the speed control collar to adjust the rotation speed of the machine.

While holding the air motor trigger, operate the

machine as described in the appropriate section below (form tool or single-point operation).

As the machine cuts, adjust the air motor speed if nec-

essary to reduce chatter and achieve the appropriate end prep finish.

When the prep is complete, release the air motor trig-

ger to stop the machine.

E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 49

The use of coolant or cutting lubricant is recommended. This will improve the cutting performance and increase the life of the tooling.

EP 424 End Prep Machine

Mounting and Operating the Hydraulic Drive

To install the hydraulic motor, put the motor flange

over the 4 motor mounting screws on the EP 424 motor adapter. You may have to rotate the motor slightly to engage the spline in the shaft.

Figure 5-31. Mount the hydraulic motor flange onto the screws in the motor adapter.

Turn the flange to engage the screw heads in the slots,

then tighten the screws using a 1/4” hex wrench.

50 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

Figure 5-32. Turn the flange to seat the screws in the slots, then tighten the screws.

Connect the hydraulic hoses to the ports on the motor

Tank (return) connector

Pressure connector

as described in Figure 5-33.

Chapter 5, Operating Instructions: Using the Drive Motors

Figure 5-33. Connect the hydraulic hoses to the motor as shown.

Turn on the hydraulic power supply. Set it to 10 gpm

at 1500 psi (38 l/min at 103 bar). Push the hydraulic drive lever toward the main body

of the machine. The machine will start to rotate.

E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 51

EP 424 End Prep Machine

NOTE

The form tool head has arrows indicating the correct direction of rotation.

Figure 5-34. Turn the hydraulic lever to the ON position as shown.

Make sure the machine is turning clockwise. If it is

turning the wrong way, the hydraulic hoses are reversed. Turn off the HPU and switch the hoses.

Adjust the drive motor speed by turning the speed dial

on the hydraulic motor.

52 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

Figure 5-35. Use the speed dial on the hydraulic manifold to adjust the machine rotation speed.

Chapter 5, Operating Instructions: Form Tool Operation

NOTE

While holding the hydraulic drive lever on, operate

the machine as described in the appropriate section below (form tool or single-point operation).

As the machine cuts, adjust the hydraulic motor speed

if necessary to reduce chatter and achieve the appropriate end prep finish.

When the prep is complete, release the hydraulic drive

10.

lever to stop the machine.

FORM TOOL OPERATION

The EP 424 has three tool holders, which can each hold a different tool. This allows you to perform any combination of facing, beveling, and counterboring simultaneously.

Make sure the EP 424 is set up as follows for form tool operation:

The use of coolant or cutting lubricant is recommended. This will improve the cutting performance and increase the life of the tooling.

• Use the standard mandrel, if possible for the workpiece.

• Have the single-point slide removed and the rotating tool head installed. (See “Removing the Single-Point Kit” in the next section.)

• If your EP 424 is equipped with the Speed Prep autofeed module, set the axial feed selector to 0° when doing form tool operations.

Setting the feed selector to 0° will reduce wear on the Speed Prep components when you are not using the autofeed.

Figure 5-36. Set the Speed Prep selector to 0° before doing form tool operations.

E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 53

EP 424 End Prep Machine

Planning the Operation

Operating Envelope

Make sure you have adequate clearance around the workpiece. See the operating envelope drawings in Chapter 3 for reference.

Selecting Tooling

Use the following charts to select the appropriate tooling for the operation.

54 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

Figure 5-37. The chart describes the tooling used for facing/beveling operations.

Chapter 5, Operating Instructions: Form Tool Operation

Figure 5-38. The chart describes the tooling used for counterboring.

Figure 5-39. The chart describes the tooling used for deburring.

E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 55

EP 424 End Prep Machine

Figure 5-40. The chart describes the tooling used for J-prep operations.

Adjusting the Tool Holder Positions

You may need to change the positions of the tool holders in the rotating head, depending on the pipe diameter . Each tool holder can be set to an “inner” (small diameter) or “outer” (large diameter) position.

Using a 1/4” hex wrench, remove the 8 screws holding

the tool holder to the rotating head. (Note: if the tool holder is already in the outer position, it will have 6 screws holding it.)

56 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

Chapter 5, Operating Instructions: Form Tool Operation

Figure 5-41. The photo shows the tool holder moved to the “outer” position for larger diameter pipes.

Move the tool holder to the other position. Line up the

holes and re-insert the screws. Use 6 screws if setting the holder to the outer position.

Setting Up and Mounting the EP 424

You will probably find it easiest to assemble the main components of the EP 424 as you install the machine. The following is the recommended sequence for installation:

• Configure and mount the mandrel in the workpiece, as described at the beginning of this chapter.

• Install the machine body onto the mandrel.

• Install the tooling in the rotating tool head.

• Install the drive motor.

If desired, you can assemble the machine and then mount it on the workpiece. You will need a lifting device to support the machine as you mount it.

Assembling the Machine Components

The following procedure assumes that the mandrel has been mounted in the pipe, as described earlier in this chapter.

E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 57

EP 424 End Prep Machine

NOTE

It is recommended that you using a lifting device to pick up the EP 424. If you are lifting it manually, have two operators lift it.

Attach a crane or other lifting device to the lift hook

on the machine body.

Figure 5-42. Attach the lifting device to the lift hook.

Use the lifting device to pick up the EP 424 and posi-

tion it for mounting on the mandrel. If you do not have a lifting device, two people can lift the machine into place using the handles.

58 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

Figure 5-43. Position the machine to mount it on the mandrel.

Slide the machine forward on the mandrel. Turn the

NOTE

Mandrel threads

Feed nut

machine back and forth while pushing to engage it all the way onto the spline.

Chapter 5, Operating Instructions: Form Tool Operation

Figure 5-44. Push the machine forwar d onto the mandrel.

When the machine is fully engaged on the spline,

lower the lifting device slightly to take the tension off it.

Turn the feed handle clockwise to engage the mandrel

threads in the feed nut.

Push the machine forward while turning the feed handle to start the threads.

Figure 5-45. Turn the feed handle clockwise to engage the mandrel threads in the feed nut.

E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 59

EP 424 End Prep Machine

Direction of rotation

Turn the feed handle clockwise until the drawbar nut

emerges from the back of the machine.

Figure 5-46. Engage the mandrel threads fully in the feed nut for stable operation.

Using a 3/16” hex wrench, loosen the tooling set

screws in the tool holder and put the tool in the holder . Tighten the set screws.

Figure 5-47. Insert the tool in the tool holder and tighten the set screws holding it. Make sur e the cutting edge of the tool is toward the direction of rotation, as shown.

60 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

Install any other tools required for the operation in the

other tool holders. You can perform up to 3 operations

simultaneously—for example, facing, beveling, and

WARNING

NOTE

counterboring. Turn the feed handle clockwise until the tools are

close to the pipe end. If necessary, loosen the set screws and adjust the tool positions for the required operation.

Chapter 5, Operating Instructions: Form Tool Operation

Figure 5-48. T urn the feed handle to position the tools near the cutting surface. Adjust the tool position if necessary.

Install and connect the drive motor as described earlier

10.

in this chapter. Turn on the power source (air or hydraulic).

11.

Turn on the drive motor. The machine will start to

12.

rotate. Adjust the motor speed using the speed controller on the drive.

Turn the feed handle clockwise to feed the tooling into

13.

the pipe face. Check the radial position of the tooling. Stop the machine if you need to adjust the tool position.

Continue feeding the tooling into the pipe. Adjust the

14.

drive motor speed if necessary to reduce chatter and achieve the appropriate end prep finish.

You can use the scale on the feed housing to measure

15.

the axial depth of cut. Each line on the the scale is

0.001” (0.025 mm) of feed.

Keep hands clear of the rotating head while the machine is operating. Contact with the head or tooling could result in serious injury.

The use of coolant or cutting lubricant is recommended. This will improve the cutting performance and increase the life of the tooling.

E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 61

EP 424 End Prep Machine

Figure 5-49. Use the scale on the feed housing to measure axial feed distance.

When the prep is complete, turn the feed handle coun-

16.

ter-clockwise to retract the tooling from the pipe end. Release the air motor trigger to stop the machine.

Removing the Machine from the Workpiece

Turn the feed handle counter-clockwise to retract the

tooling away from the pipe end. It is recommended that you remove the tooling from

the tool holders before removing the machine. This prevents accidental damage to the tooling, or damage or injury caused by the tooling in case of a collision while moving the machine.

Disconnect the power source (air or hydraulic) from

the drive motor. Loosen the 4 motor mounting screws and remove the

drive motor. Connect the lifting device to the lifting eye on the

machine. Raise the lift enough to put slight tension on the chain or strap.

Turn the feed handle counter-clockwise until the

threads on the mandrel disengage from the feed nut. Make sure the lift is supporting the machine. Pull the

machine back off the mandrel, and set it on the floor or a stable work surface.

62 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

If the standard mandrel is installed, use a 1-1/16”

wrench or socket to turn the drawbar nut counterclockwise to loosen the clamp legs.

Chapter 5, Operating Instructions: Single Point Operation

If the independent chuck mandrel is installed, loosen

the jam nuts and then loosen the clamp legs.Pull the mandrel out of the pipe.

If you are finished with the machine, or are going to

10.

work on a different sized pipe, remove the clamp leg extensions from the mandrel.

SINGLE POINT OPERATION

Installing the Single-Point Kit

If your EP 424 machine is equipped with the single-point option kit, it will include the single-point slide, trip ring, and independent chuck as additional components. Set up the machine as described below for single-point operation.

Set the machine on a stable work surface that can sup-

port its weight. Use a lifting device to lift the EP 424. If the mandrel is installed, remove it by turning the

feed handle counter-clockwise until the mandrel is threaded out of the feed nut.

Figure 5-50. Turn the feed handle counter-clockwise to thread the mandrel out of the feed nut.

Pull the mandrel out through the front of the machine.

E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 63

EP 424 End Prep Machine

Figure 5-51. Pull the mandrel out of the machine.

Using a 5/16” hex wrench, remove the 6 screws hold-

ing the rotating head to the main shaft.

Figure 5-52. Remove the 6 screws holding the rotating head to the main shaft.

Remove the rotating head from the main shaft.

64 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

Figure 5-53. Remove the rotating head.

Chapter 5, Operating Instructions: Single Point Operation

Install the trip assembly onto the front of the machine,

with the trip knobs toward the feed handle side. Fit the ring of the trip assembly around the the rim of the main housing, with the set screws aligned with the flats in the housing.

Figure 5-54. Mount the trip assembly on the housing.

Using a 1/8” hex wrench, tighten the 4 set screws in

the trip assembly.

E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 65

EP 424 End Prep Machine

NOTE

The trip assembly screws are on the back of the ring.

Figure 5-55. Tighten down the 4 set screws while holding the trip ring assembly in place.

Make sure the felt wiper is in place on the back of the single-point slide.

Put the single-point slide into place on the main shaft.

Align the 3 dowel pins in the slide with the holes in the shaft, and press the slide into place.

66 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

Figure 5-56. Ther e are three dowel pins in the back of the single-point slide to mount it to the main shaft.

Using a 5/16” hex wrench, tighten the 6 captivated

screws in the single-point slide to secure it to the main shaft.

Chapter 5, Operating Instructions: Single Point Operation

Figure 5-57. Tighten the captivated screws in the 6 holes to attach the single-point slide to the main shaft.

If you want to install the mandrel before mounting the

10.

machine on the workpiece, insert the threaded end of the mandrel through the single-point slide. You may have to turn the mandrel slightly while pushing it to engage the spline.

Figure 5-58. Insert the mandrel through the singlepoint slide.

Turn the feed handle clockwise to engage the threads

11.

of the mandrel into the feed nut. Turn the handle until

E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 67

EP 424 End Prep Machine

the threads emerge through the back of the rear feed assembly.

Figure 5-59. Turn the feed handle clockwise to engage the mandrel threads in the feed nut.

Planning the Operation

Operating Envelope

Make sure you have adequate clearance around the workpiece. See the operating envelope drawings in Chapter 3 for reference.

Selecting Tool Holder

Two tool holders are provided with the single-point slide:

• low-range (part no. 56-424-00), for pipe O.D. range

4.24”-23.62” (108-600 mm)

• high-range (part no. 56-424-01), for pipe O.D. range

7.25”-24” (184-610 mm).

For most applications, you can use either tool holder. Make sure you select one with a range that includes the O.D. of the pipe you are machining.

68 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

Beveling O.D. Set-Back

The O.D. set-back is the distance from the end of the pipe where you will start the beveling operation. It is determined

Chapter 5, Operating Instructions: Single Point Operation

S = Set-Back R = Root Radius L = Land E = Land Extension A = Bevel Angle W = Wall Thickness (After Counterbore)

S = R + E + [tan(A) x (W - L - R)]

by the angle(s) of the bevel, the pipe wall thickness, the land thickness, the land root radius, and the land extension.

For a single-angle bevel, compute the set-back using the following formula:

Figure 5-60. The diagram illustrates how to compute the O.D. set-back when performing a single-angle bevel.

SINGLE-ANGLE BEVEL EXAMPLE:

R = 0.125” L = 0.100” E = 0.125” A = 20° W = 0.800”

S = 0.125” + 0.125” + [tan(20°) x (0.800” - 0.100” - 0.125”]

= 0.250” + [0.364 x 0.575”]

= 0.459”

E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 69

EP 424 End Prep Machine

S = Set-Back R = Root Radius L = Land E = Land Extension A1 = Inner Bevel Angle A2 = Outer Bevel Angle T = Transition (from I.D.) W = Wall Thickness (After Counterbore)

S = R + E + [tan(A2) x (W - T)] + [tan(A1) x (T - L - R)]

For a compound bevel, use the following formula:

70 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

Figure 5-61. The diagram illustrates how to compute the O.D. set-back when performing a compound bevel.

COMPOUND BEVEL EXAMPLE:

R = 0.125” L = 0.100” E = 0.125” A1 = 30° A2 = 10° T = 0.750” W = 1.875”

S = 0.125” + 0.125” + [tan(10°) x (1.875” - 0.750”] + [tan(30°) x (0.750” - 0.125” - 0.125”]

= 0.250” + [0.176 x 1.125”] + [0.577 x 0.500]

= 0.250” + 0.198 + 0.289”

= 0.737”

Chapter 5, Operating Instructions: Single Point Operation

NOTE

Setting Up and Mounting the EP 424

You will probably find it easiest to assemble the main components of the EP 424 as you install the machine. The following is the recommended sequence for installation:

• Configure and mount the mandrel in the workpiece, as described in the previous section.

• Install the machine body onto the mandrel.

• Install the tool holder and tooling in the single-point slide.

• Install the drive motor.

If desired, you can assemble the machine and then mount it on the workpiece. You will need a lifting device to support the machine as you mount it.

Assembling the Machine Components

The following procedure assumes that the mandrel has been mounted in the pipe, as described earlier in this chapter.

Attach a crane or other lifting device to the lift hook

on the machine body.

It is recommended that you using a lifting device to pick up the EP 424. If you are lifting it manually, have two operators lift it.

Figure 5-62. Attach the lifting device to the lift ring.

Use the lifting device to pick up the EP 424 and posi-

tion it for mounting on the mandrel. If you do not have a lifting device, two people can lift the machine into place using the handles.

E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 71

EP 424 End Prep Machine

Figure 5-63. Position the EP 424 to mount it on the mandrel.

Slide the machine forward on the mandrel. Turn the

machine back and forth while pushing to engage it all the way onto the spline.

72 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

Figure 5-64. Push the machine forward on the mandrel until you can engage the mandrel threads in the feed nut.

When the machine is fully engaged on the spline,

NOTE

lower the lifting device slightly to take the tension off it.

When the machine is as far forward as it will go, turn

the feed handle clockwise to engage the mandrel threads in the feed nut.

Turn the feed handle clockwise until the end of the

mandrel emerges from the back of the machine. Feed the machine until at least 1/2” (13 mm) of threads on the mandrel are visible.

Chapter 5, Operating Instructions: Single Point Operation

Push the machine forward while turning the feed handle to start the threads.

Figure 5-65. Engage the mandrel threads fully in the feed nut for stable operation.

Install the autofeed stop plate on the end of the man-

drel. The stop plate prevents the machine from autofeeding all the way off the mandrel.

Using a 3/16” hex wrench, loosen the tooling set

screws in the male slide and put the tool holder with the tool in the slide. Tighten the set screws.

E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 73

EP 424 End Prep Machine

Figure 5-66. Install the tool holder in the slide.

Using a 5/16” hex wrench, turn the starwheel on the

slide to position the tool just beyond the O.D. of the pipe.

Figure 5-67. Turn the starwheel until the tool bit is positioned at the required start point.

74 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

Turn the feed handle clockwise to advance the tool to

10.

the starting position above the O.D. of the pipe.

Using the Speed Prep Autofeed

WARNING

Loosen the knob on the Speed Prep module, and slide

the gauge to the desired angle on the scale. Refer to the appropriate scale for using 1 trip or 2 trips. Tighten the knob.

Engage the required number of trips. For multiple

trips, engage them on opposite sides of the trip assembly.

Start the drive motor to operate the machine. Ensure

that the starwheel is turning when it strikes the engaged trips.

To engage the Speed Prep autofeed, pull the feed han-

dle back toward you. Y ou will f eel it “snap” into place. Immediately let go of the feed handle.

As the machine rotates, the autofeed will turn the feed

handle counter-clockwise.

Chapter 5, Operating Instructions: Single Point Operation

The Speed Prep autofeed can feed the machine until it comes off the mandrel. Crushing or other serious injuries could occur. Use the autofeed stop plate (81-316-

00) to keep the machine from feeding too far.

To disengage the autofeed, push the feed handle in.

Compound Bevel

Use the knob stops to set the angles.

Set the Speed Prep knob to the location for the starting

angle (the angle at the O.D. of the pipe). Lock the knob in place.

Move the left knob stop up against the knob and

tighten it.

E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 75

EP 424 End Prep Machine

Figure 5-68. Set the left knob stop against the Speed Prep knob.

Loosen the Speed Prep knob and set it to the location

of the transition angle. Lock the knob in place. Move the right knob stop up against the knob and

tighten it.

Figure 5-69. Set the right knob stop.

76 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

Set the Speed Prep knob back to the starting angle

position and lock it in place. Measure and mark the transition point on the pipe face

surface.

Chapter 5, Operating Instructions: Single Point Operation

Start the cutting operation on the O.D. of the pipe. Pull

the feed handle to engage the autofeed when the tool begins to cut the pipe.

When the tool reaches the transition point, loosen the

Speed Prep knob and move it over against the right knob stop. Tighten the knob.

Continue until the bevel is complete.

Removing the Machine from the Workpiece

Using a 5/16” hex wrench, turn the starwheel on the

slide clockwise to retract the tool away from the pipe. Turn the feed handle counter-clockwise to retract the

single-point slide away from the pipe end. It is recommended that you remove the tool holder

from the slide before removing the machine. This prevents accidental damage to the tooling, or damage or injury caused by the tooling in case of a collision while moving the machine.

Disconnect the power source (air or hydraulic) from

the drive motor. Loosen the 4 motor mounting screws and remove the

drive motor. Connect the lifting device to the lifting eye on the

machine. Raise the lift enough to put slight tension on the chain or strap.

Turn the feed handle counter-clockwise until the

threads on the mandrel disengage from the feed nut. Make sure the lift is supporting the machine. Pull the

machine back off the mandrel, and set it on the floor or a stable work surface.

If the standard mandrel is installed, use a 1-1/16”

wrench or socket to turn the drawbar nut counterclockwise to loosen the clamp legs.

If the independent chuck mandrel is installed, loosen

10.

the jam nuts and then loosen the clamp legs. Pull the mandrel out of the pipe.

11.

E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 77

EP 424 End Prep Machine

If you are finished with the machine, or are going to

12.

work on a different sized pipe, remove the clamp leg extensions from the mandrel.

Removing the Single-Point Kit

Set the machine on a stable work surface that can sup-

port its weight. Use a lifting device to lift the EP 424. If the mandrel is installed, remove it by turning the

feed handle counter-clockwise until the mandrel is threaded out of the feed nut.

Figure 5-70. Turn the feed handle counter-clockwise until the mandrel is threaded out of the feed nut.

Pull the mandrel out through the front of the machine.

78 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

Chapter 5, Operating Instructions: Single Point Operation

Figure 5-71. Pull the mandrel out of the machine.

Using a 5/16” hex wrench, completely loosen the 6

captivated screws holding the single-point slide to the main drive assembly.

Figure 5-72. Loosen the 6 screws holding the singlepoint slide.

Remove the single-point slide from the main shaft.

E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 79

EP 424 End Prep Machine

Figure 5-73. Remove the single-point slide.

Using a 1/8” hex wrench, loosen the 4 set screws in

the trip assembly.

80 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

Figure 5-74. Loosen the set screws holding the trip assembly to the housing.

Remove the trip assembly from the main housing.

Chapter 5, Operating Instructions: Single Point Operation

Figure 5-75. Remove the trip assembly.

Replace the rotating tool head on the main shaft. Align

the 3 dowel pins in the head with the holes in the shaft, and press the head into place.

Figure 5-76. Align the dowel pins in the r otating head (indicated by arrows) with the holes in the main s haft, and press the head onto the shaft.

Using a 5/16” hex wrench, tighten the 6 captivated

screws in the rotating head to secure it to the main shaft.

E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 81

EP 424 End Prep Machine

Figure 5-77. Tighten the 6 screws holding on the rotating head.

82 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

Chapter 6

Routine Maintenance

LUBRICATION

Main Drive Assembly

Chapter 6, Routine Maintenance

In This Chapter

LUBRICATION DRIVE MOTOR LUBRICATION

There is one grease fitting on the main drive assembly.

Figure 6-1. The grease fitting is at the bottom of the main drive assembly housing.

Every 30 days (more often with heavy use), apply grease through the fitting.

Using a 3/16” hex wrench, remove the plug in the top

of the main drive housing.

E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 83

EP 424 End Prep Machine

Figure 6-2. Remove the grease plug before putting grease into the main drive assembly.

Re-install the plug in the top of the house. Screw the

plug in until it is flush; do not screw it in all the way.

Figure 6-3. Insert the plug and screw it in until it is flush with the top of the housing.

84 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

Felt Wipers

Both the rotating head and single-point slide have a felt wiper to lubricate the mandrel. Apply oil directly to the wiper each time you disassemble the machine. If you see the

mandrel getting dry, remove the rotating head or singlepoint slide to lubricate the wiper.

Inspect the condition of the wiper. Replace it if it is damaged, deformed from wear, or very dirty.

Chapter 6, Routine Maintenance: Lubrication

Figure 6-4. Apply oil to the felt wiper in the rotating head.

Figure 6-5. Replace felt wipers when they become worn or dirty.

Single-Point Slide

Each time you use the single-point slide, oil the feed screw. Apply a light coating of oil.

E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 85

EP 424 End Prep Machine

Feed screw

Spline

Mandrel leg slots

Figure 6-6. Lubricate the feed screw with a light coating of oil.

Mandrel

Oil the spline on the mandrel (standard or independent

chuck) each time you use it. Apply a light coating of oil.

Each time you use the standard mandrel, oil the chuck

legs where they engage in the mandrel slots. Apply a light coating of oil.

86 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

Figure 6-7. Lubricate the mandrels at the points shown. Wipe on a light coating of oil.

Chapter 6, Routine Maintenance: Drive Motor Lubrication

DRIVE MOTOR LUBRICATION

The hydraulic motor is self-lubricating and requires no routine maintenance.

See the air motor manufacturer’s manual for full maintenance information. The manual is included at the end of Chapter 7 of this manual. Air motor lubrication guidelines are the following:

• An air line lubricator is recommended with the air motor. Use Ingersoll-Rand No. 50 air motor oil or equivalent.

• Every month, grease the air motor through the grease fitting on the motor. Use Ingersoll-Rand No. 28 grease or equivalent. Inject 1.5 cc of grease.

Figure 6-8. Gr ease the air motor fitting once a month.

E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 87

EP 424 End Prep Machine

88 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

Chapter 7

Service and Repair

ADJUSTMENTS

Adjusting the Single-Point Slide

Chapter 7, Service and Repair

In This Chapter

ADJUSTMENTS AIR MOTOR MANUAL

You can adjust the feed tension on the single-point slide. The slide should be adjusted so that you can turn the starwheel by hand using a tight grip. The starwheel should not wobble or turn easily.

If the starwheel is loose or turns too easily, use the following procedure to adjust the tension on the slide.

Tighten the Starwheel Stop Collar

Using a 5/32” hex wrench, loosen the screw in the

stop collar adjacent to the starwheel. Using the hex wrench in the head of the screw, rotate

the stop collar so that it is tight against the starwheel. Re-tighten the screw to secure the stop collar.

Check the tension on the starwheel. If it is acceptable,

no further adjustment is necessary.

Adding/Removing Gib Shims

Shims are used under the gibs to set the vertical tension on the male slide. Shims are “stacked” to achieve the desired tension.

E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 89

EP 424 End Prep Machine

NOTE

If the slide is too tight, you may need to add a shim. The procedure for adding shims is the same.

• Adding shims will loosen the tension on the slide.

• Removing shims will tighten the tension on the slide.

There should always be the same number of shims under both gibs.

As the slide wears, you may have to remove a shim to reset the tension. Check the male slide to see if there is any vertical wobble. If you can move the slide, you will need to remove a shim on each side.

Using a 5/16” hex wrench, securely tighten down all 4

screws holding each gib. Check the male slide for vertical wobble. Move the slide to both ends of travel, checking it as you go.

If you can move the slide vertically at any position,

remove all 4 screws from each gib and take the gibs off.

If the slide is too tight after you remove a shim, replace the shim and then adjust the tension using the push plate set screws. See instructions in the next section.

Remove one shim from each side. Stack the remaining

shim(s) and the wear plate to line up the holes in the base plate.

Replace the gibs and the screws. Tighten the screws

down securely. Move the slide through the full range of travel, check-

ing the tension as you go.

Adjust the Push Plate Set Screws

Set the final tension of the slide using the set screws on the side push plate.

There are four set screw holes in the side of the slide. Each hole has a screw for adjusting the push plate, and a second screw inserted as a jam screw.

Using a 5/16” hex wrench in the end of the feed screw ,

turn the screw until the male slide is all the way to the inner end of the screw.

90 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

Using the 5/16” hex wrench, crack loose the 4 screws

on each gib. Using a 5/32” hex wrench, remove the jam screws

from all 4 set screw holes.

With the 5/32” hex wrench, snug down the 2 set

screws on the ends. Slightly loosen the 2 set screws in the middle.

Turn the feed screw to move the male slide through

the full range of travel. Check for appropriate resistance as you turn the screw , and loosen or tighten the 2 end screws as necessary to adjust the tightness.

When the tension is equal along the full length of

travel, snug down the 2 middle set screws. Move the slide along the length of travel and adjust

the screws as necessary. Replace and tighten the jam screws on all 4 set screws.

Calibrating the Speed Prep Scale

If necessary, you can move the Speed Prep scale to make sure the bevel angle settings are accurate. You should periodically check the calibration, especially if your beveling operation requires very accurate angles.

Chapter 7, Service and Repair: Adjustments

Use the following procedure to check the calibration and adjust the scale. The procedure includes performing the beveling operation on an actual workpiece, since the calibration depends on a realistic cutting process. See the detailed instructions in Chapter 5 for setting up and performing a single-point bevel.

Configure the EP 424 for single-point operation.

Mount the machine on a pipe or sample workpiece

suitable for single-point beveling. Install a single-point tool in the slide and configure the

machine to start the beveling operation. Attach power to the drive motor and operate the

machine until it starts to cut the workpiece. Turn off the drive motor.

Engage one trip on the trip assembly.

Loosen the Speed Prep knob and set it so that the

gauge is at 30°. Tighten the knob to lock it in place.

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EP 424 End Prep Machine

Turn the feed handle to se t the axial feed scale to 0 (or

to any reference reading). Make a note of the reading on the axial feed scale.

Start the drive motor. The single-point slide will start

to rotate. When the slide reaches the top of rotation, pull out the

10.

feed handle to start the autofeed. Count the rotations as the machine operates. When it

11.

reaches 10 rotations, push in the feed handle to stop the autofeed. Turn off the drive motor.

Note the reading on the axial feed scale. Subtract the

12.

original reading at the start from the current reading to determine the measured axial feed.

Find the measured axial feed in Table 1 below, and

13.

read across for the actual bevel angle. Make a note of the angle.

Table 1: Speed Prep Calibration

Measured Axial Feed*

.027” 26.5° .028” 27.5° .029” 29° .030” 30° .031” 31° .032” 32.5° .033” 33.5°

* 10 rotations, 1 trip engaged, Speed Prep set to 30°.

Using a 5/64” hex wrench, loosen the 2 button head

14.

Actual Bevel Angle

(rounded to 0.5°)

cap screws on the Speed Prep scale, and slide the scale so that the angle you found in the previous step is aligned with the gauge on the Speed Prep knob. EXAMPLE: If you set the axial feed scale to 0 at the start, and it was at .029” after 10 rotations, you will set the Speed Prep gauge to 29°.

92 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

Re-tighten the button head cap screws on the scale.

15.

Chapter 7, Service and Repair: Air Motor Manual

AIR MOTOR MANUAL

The air motor manufacturer’s operating and maintenance manual is included following this page. Refer to it for detailed maintenance and repair instructions.

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Chapter 8

Parts Lists and Drawings

Refer to the following drawings for parts identification and ordering. Each drawing includes a parts list for the assembly.

Chapter 8, Parts Lists and Drawings

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Wachs EP 424 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual