E.H. Wachs EP 424, User Manual

Page 1: ... 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 ...

Page 2: ...ridge 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 hy...

Page 3: ...s 16 Dimensions and Weights 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 Cha...

Page 4: ...ol Holder 71 Beveling O D Set Back 72 Setting Up and Mounting the EP 424 74 Assembling the Machine Components 74 Using the Speed PrepAutofeed 79 Compound Bevel 79 Removing the Machine from the Workpiece 81 Removing the Single Point Kit 81 Chapter 6 Routine Maintenance 87 Lubrication 87 Main DriveAssembly 87 Felt Wipers 88 Single Point Slide 89 Mandrel 90 Drive Motor Lubrication 91 Chapter 7 Servic...

Page 5: ...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 Ho...

Page 6: ...EP 424 End Prep Machine iv Part No 81 MAN 00 Rev C E H Wachs ...

Page 7: ...ore 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 ch...

Page 8: ...s and notices with supplementary information WARNING A WARNING alert with the safety alert symbol indicates a potentially hazardous situation that could result in serious injury or death CAUTION A CAUTION 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 p...

Page 9: ...ill 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 sales wachsco com You may have factory service or upgrades...

Page 10: ...EP 424 End Prep Machine 4 Part No 81 MAN 00 Rev C E H Wachs ...

Page 11: ...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 Compa ny KEEP CLEAR OF MOVING PARTS...

Page 12: ...ace protection refer to Federal OSHAregulations 29 Code of Federal Regulations Section 1910 133 Eye and Face Protection andAmerican National Standards Institute ANSI Z87 1 Occupational and Educational Eye and Face Protection Z87 1 is available from theAmerican National Standards Institute Inc 1430 Broadway New York NY 10018 CAUTION Personal hearing protection is recommended when operating or worki...

Page 13: ...d attach a replacement See ordering instructions in Chapter 10 Figure 2 1 Crush hazard safety label part no 81 165 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 ...

Page 14: ...EP 424 End Prep Machine 8 Part No 81 MAN 00 Rev C E H Wachs Figure 2 5 Compressed air pressure safety label part no 90 401 02 Figure 2 6 Hydraulic pressure safety label part no 90 402 01 ...

Page 15: ...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 81 000 02 Single point machine with air drive part no 81 000 03 Single point machine with hydraulic drive part no 81 000 04 Form tool operation is quick to set up and easy to perform on pipe w...

Page 16: ...he 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 Be...

Page 17: ...e 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 ...

Page 18: ...al components single point slide Starwheel Feed screws Male tool slide Tool holder Feed gauge 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 ...

Page 19: ...main drive to operate the feed mecha nism for single point beveling WARNING 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 independent chuck mandrel Figure 3 6 The independent chuck mandrel allows you to center the machine on the O D of the pipe...

Page 20: ...hs 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 Figure 3 8 The dial indicator is provided for centering the independent chuck in the pipe ...

Page 21: ...or 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 Both motors include adapters for the EP 424 The motors are interchangeable requiring no modifi cations to the EP 42...

Page 22: ...hort 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 SPECIFICATIONS Capacities Table 1 EP424 Operating Capacities Air requirements 95 cfm at 90 psi 2690 l min at 6 2 bar Hydraulic requirements Min 10 gpm max 15 gpm at 2000 psi 38 57 l min at 138 bar Axial feed 0 071 per feed handle revolution Single point slid...

Page 23: ...408 mm 162 lb 73 6 kg 179 5 lb 81 6 kg 81 000 03 Single point air drive 25 5 x 42 3 x 21 2 648 x 1075 x 539 mm 176 lb 80 kg 193 5 lb 88 kg 81 000 04 Single point hydraulic drive 25 4 x 30 4 x 21 2 645 x 772 x 539 mm 183 5 lb 83 4 kg 201 lb 91 4 kg Shipping storage case 37 x 36 3 x 22 3 940 x 922 x 566 mm OPERATING ENVELOPE The drawings on the following pages illustrate the operating envelope for a...

Page 24: ...hs Standard Configuration with Air Drive 81 000 01 6 2 1 7 7 5 1 0 17 21 0 1 5 0 75 9 16 57 2 5 1 9 1 722 3 5 1 5 92 87 21 2 6 6 6 2 1 8 7 1 0 0 6 6 2 1 8 5 75 7 0 1 0 1 0 5 63 530 5 5 48 5 0 176 5 2168037 21 FIP O PLQ 35 6685 36 5 137 NOTE 6 25 7 16 21 5 1 6 ...

Page 25: ... H Wachs Part No 81 MAN 00 Rev C 19 Standard Config with Hydraulic Drive 81 000 02 6 2 1 7 7 5 1 0 17 21 0 1 5 0 75 9 16 57 2 5 1 9 1 722 3 5 1 5 92 87 21 2 6 0 5 63 530 0 2 30 30 0 35 6685 36 5 6 6 2 1 8 7 1 0 0 6 6 2 1 8 5 75 7 0 1 0 1 NOTE 6 25 7 16 21 5 1 6 ...

Page 26: ...s Single Point Configuration with Air Drive 81 000 03 7 5 1 0 17 21 0 1 5 0 75 9 2 5 16 57 722 5 7 3 5 75 3 1 727 6752 3 5 1 5 92 87 21 2 6 527 7 1 6 25 8 57 5 5 48 5 0 176 5 2168037 21 FIP O PLQ 35 6685 36 0 5 63 530 137 DIMENSIONS IN BRACKETS ARE MILLIMETERS ...

Page 27: ... E H Wachs Part No 81 MAN 00 Rev C 21 Single Point Config with Hydraulic Drive 81 000 04 7 5 1 0 17 21 0 1 5 0 75 9 2 5 16 57 722 5 7 3 5 75 3 1 727 6752 3 5 1 5 92 87 21 2 6 6 25 8 57 0 5 63 530 0 2 30 30 0 35 6685 36 5 DIMENSIONS IN BRACKETS ARE MILLIMETERS ...

Page 28: ...t with Speed Prep Air Drive 81 000 05 7 5 1 0 17 21 0 1 5 0 75 9 2 5 16 57 722 5 7 3 5 75 3 1 727 6752 5 3 5 1 5 92 87 21 2 6 527 7 1 6 25 8 57 5 5 48 5 0 176 5 2168037 21 FIP O PLQ 35 6685 36 0 5 63 530 137 6 6 2 1 8 7 1 0 0 6 6 2 1 8 5 75 7 0 1 0 1 NOTE 6 25 7 16 21 5 1 6 ...

Page 29: ...rt No 81 MAN 00 Rev C 23 Single Point with Speed Prep Hyd Drive 81 000 06 7 5 1 0 17 21 0 1 5 0 75 9 2 5 16 57 722 5 7 3 5 75 3 1 727 6752 3 5 1 5 92 87 21 2 6 6 25 8 57 0 5 63 530 0 2 30 30 0 35 6685 36 5 6 6 2 1 8 7 1 0 0 6 6 2 1 8 5 75 7 0 1 0 1 NOTE 6 25 7 16 21 5 1 6 ...

Page 30: ...EP 424 End Prep Machine 24 Part No 81 MAN 00 Rev C E H Wachs Standard Mandrel Dimensions Leg Chart 81 303 00 ...

Page 31: ...Chapter 3 Introduction to the Equipment Operating Envelope E H Wachs Part No 81 MAN 00 Rev C 25 Rotating Head Assembly 81 304 00 722 2 5 6 2 1 1 287 5 326 7 21 ...

Page 32: ... End Prep Machine 26 Part No 81 MAN 00 Rev C E H Wachs Independent Chuck Dims Leg Chart 81 305 00 0 1 03 1 0 03 1 INDEPENDENT CHUCK MANDREL LEG SET ID RANGE INCHES MM 7 63 5 7 63 5 7 63 5 7 63 5 7 63 5 7 63 5 ...

Page 33: ...No 81 MAN 00 Rev C 27 Single Point Slide 81 306 00 0 722 3267 21 6 2 1 7 2 5 1 722 2 5 16 57 722 0 722 3267 21 6 2 1 7 5 1 722 2 5 16 57 722 0 1 722 3267 21 6 2 1 7 5 1 722 2 5 16 57 722 0 1 722 3267 21 6 2 1 7 2 5 1 722 2 5 16 57 722 5 6 2 1 7 7 5 1 0 17 722 2 5 6 5 6 6 75 9 ...

Page 34: ...EP 424 End Prep Machine 28 Part No 81 MAN 00 Rev C E H Wachs ...

Page 35: ... 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 Figure 4 1 The photo shows the EP 424 in its case ...

Page 36: ...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 ...

Page 37: ...han 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 I...

Page 38: ... NOTE If the pipe I D is larger than 15 96 405 4 mm you will need the extended leg kit 2 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 NOTE See the envelope drawings in Chapter 3 for an illustration of the clamp leg ...

Page 39: ...51 319 5 343 2 6 1 13 43 14 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 With 81 303 01 Extended Leg Kit 14 87 15 80 377 7 401 3 7 1 15 73 16 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 18 12 436 6 460 3 8 1 18 05 18 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 21 32 517 7 541 5 8 3 2...

Page 40: ...the mandrel to secure the legs NOTE Extension leg 1 does not have threaded holes to install other legs on top of it 4 Always install extension leg 1 or 2 last on top of the others These legs are steel for greater durability Figure 5 3 Use the steel extension legs 1 or 2 on top when installing multiple legs ...

Page 41: ... 4 Turn the drawbar nut counter clockwise to retract the clamping legs 6 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 NOTE 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 bein...

Page 42: ... Turn the drawbar nut clockwise to clamp the legs inside the pipe until they are snug enough to hold the mandrel Figure 5 6 Turn the drawbar nut clockwise until the clamping legs are snug in the I D of the pipe 8 Check that the legs are square on the pipe I D and are far enough from the pipe end for the operation ...

Page 43: ...sure there is enough clearance for the operation 9 If necessary adjust the position of the clamping legs Then turn the drawbar nut clockwise to clamp the legs securely in the pipe Mounting the Independent Chuck Mandrel Start with the chuck body separated from the mandrel 1 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 ...

Page 44: ...ons Table 2 Independent Chuck Clamping Leg Chart I D Inches I D mm Leg Set Used Spacer 23 221 00 Used Min Max Min Max 8 50 10 50 215 9 266 7 23 213 00 No 9 50 11 50 241 3 292 1 23 213 00 Yes 11 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 ...

Page 45: ...to the chuck body Leave about 1 2 of threads exposed for the jam nut Figure 5 9 Screw the chuck legs into the chuck 4 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 Shoulder Figure 5 10 Put on the jam nut as shown with the shoulder of the nut toward the chuck ...

Page 46: ...quired 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 6 Insert a button into the end of each chuck leg The buttons are fitted with o rings to hold them in the leg Figure 5 12 Put buttons on the end of each chuck leg ...

Page 47: ...D of the pipe and screw the legs out to snug them against the I D Figure 5 13 Screw the legs out to snug the chuck inside the pipe 8 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 Figure 5 14 Mount the alignment gauge to the studs in the chuck ...

Page 48: ...the gauge against the face plate Figure 5 15 The alignment gauge must be flush against the face plate surface 10 Loosen the clamp legs slightly and push the chuck body into the pipe until all four ends of the alignment gauge are touching the end of the pipe Re tighten the legs to hold the chuck body in place Figure 5 16 Push the chuck body into the pipe until all four arms of the alignment gauge a...

Page 49: ... chuck body refer to the scales on the 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 12 When the chuck body is centered use a 2 1 4 wrench to snug the jam nuts against the chuck body Figure 5 18 ...

Page 50: ... washers removed from each stud Figure 5 19 Remove the alignment gauge and the nuts and washers from the chuck studs 14 Mount the mandrel onto the chuck NOTE If the chuck does not need any further centering adjustment install a spacer 23 203 00 over each stud before mounting the mandrel Figure 5 20 Mount the mandrel on the independent chuck ...

Page 51: ...andrel in place Snug the nuts to finger tightness 16 Place the indicator mounting collar over the mandrel and slide it close to the pipe Figure 5 21 Slide the indicator collar over the end of the mandrel 17 Tighten the set screws in the indicator collar to hold it 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 ...

Page 52: ...cator in place Figure 5 23 Set the magnetic base of the indicator on the collar and turn the switch on to engage the magnet 19 Position the tip of the indicator to touch the pipe surface You can indicate on either the O D or the I D of the pipe depending on where the operation needs to be centered Figure 5 24 Set the tip of the indicator to touch the pipe perpendicular to the surface ...

Page 53: ...ding on the indicator dial to measure how far the mandrel is off center 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 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 ...

Page 54: ... 23 Remove the indicator and the indicator mounting collar 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 sin gle point operation Mounting and Operating the Air Drive 1 To install the air motor put the motor flange over the 4 motor moun...

Page 55: ...rench tighten the screws securely Figure 5 28 Turn the flange to seat the screws in the slots then tighten the screws 3 Make sure the air supply is turned off at the source Connect the air line to the connector on the air motor 4 Turn on the air supply at the source 5 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 NO...

Page 56: ...e holding the air motor trigger operate the machine as described in the appropriate section below form tool or single point operation 8 As the machine cuts adjust the air motor speed if necessary to reduce chatter and achieve the appropriate end prep finish 9 When the prep is complete release the air motor trigger to stop the machine NOTE The use of coolant or cutting lubricant is recommended This...

Page 57: ...e 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 2 Turn the flange to engage the screw heads in the slots then tighten the screws using a 1 4 hex wrench Figure 5 32 Turn the flange to seat the screws in the slots then tighten the screws ...

Page 58: ...as described in Figure 5 33 Tank return connector Pressure connector Figure 5 33 Connect the hydraulic hoses to the motor as shown 4 Turn on the hydraulic power supply Set it to 10 gpm at 1500 psi 38 l min at 103 bar 5 Push the hydraulic drive lever toward the main body of the machine The machine will start to rotate ...

Page 59: ...o the ON position as shown 6 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 7 Adjust the drive motor speed by turning the speed dial on the hydraulic motor NOTE The form tool head has arrows indicating the correct direction of rotation ...

Page 60: ...cribed in the appropri ate section below form tool or single point operation 9 As the machine cuts adjust the hydraulic motor speed if necessary to reduce chatter and achieve the appropriate end prep finish 10 When the prep is complete release the hydraulic drive lever to stop the machine NOTE The use of coolant or cutting lubricant is recommended This will improve the cutting performance and incr...

Page 61: ...orm tool operation 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 NOTE Setting the feed selector to 0 will reduce wear on the Speed Prep ...

Page 62: ...ope Make sure you have adequate clearance around the workpiece See the operating envelope draw ings in Chapter 3 for reference Selecting Tooling Use the following charts to select the appropriate tooling for the operation Figure 5 37 The chart describes the tooling used for facing beveling operations ...

Page 63: ... Operating Instructions Form Tool Operation E H Wachs Part No 81 MAN 00 Rev C 57 Figure 5 38 The chart describes the tooling used for counterboring Figure 5 39 The chart describes the tooling used for deburring ...

Page 64: ...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 diame ter position 1 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 ...

Page 65: ...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 suppo...

Page 66: ...lifting it manually have two operators lift it Figure 5 42 Attach the lifting device to the lift hook 2 Use the lifting device to pick up the EP 424 and position 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 Figure 5 43 Position the machine to mount it on the mandrel ...

Page 67: ...pushing to engage it all the way onto the spline Figure 5 44 Push the machine forward onto the mandrel 4 When the machine is fully engaged on the spline lower the lifting device slightly to take the tension off it 5 Turn the feed handle clockwise to engage the mandrel threads in the feed nut NOTE Push the machine forward while turning the feed handle to start the threads ...

Page 68: ... the mandrel threads in the feed nut 6 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 7 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 ...

Page 69: ...ons simultaneously for example facing beveling and counterboring 9 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 Figure 5 48 Turn the feed handle to position the tools near the cutting surface Adjust the tool position if necessary 10 Install and connect the drive motor as describe...

Page 70: ...h 15 You can use the scale on the feed housing to measure the axial depth of cut Each line on the the scale is 0 001 0 025 mm of feed Figure 5 49 Use the scale on the feed housing to measure axial feed distance 16 When the prep is complete turn the feed handle counter clockwise to retract the tooling from the pipe end Release the air motor trigger to stop the machine Removing the Machine from the ...

Page 71: ... If the independent chuck mandrel is installed loosen the jam nuts and then loosen the clamp legs Pull the mandrel out of the pipe 10 If you are finished with the machine or are going to 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 in...

Page 72: ...Turn the feed handle counter clockwise to thread the mandrel out of the feed nut 3 Pull the mandrel out through the front of the machine Figure 5 51 Pull the mandrel out of the machine 4 Using a 5 16 hex wrench remove the 6 screws holding the rotating head to the main shaft ...

Page 73: ...g head to the main shaft 5 Remove the rotating head from the main shaft Figure 5 53 Remove the rotating head 6 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 ...

Page 74: ...gure 5 54 Mount the trip assembly on the housing 7 Using a 1 8 hex wrench tighten the 4 set screws in the trip assembly 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 ...

Page 75: ... 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 NOTE Make sure the felt wiper is in place on the back of the single point slide Figure 5 56 There are three dowel pins in the back of the single point slide to mount it to the main shaft ...

Page 76: ...in shaft 10 If you want to install the mandrel before mounting the 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 single point slide 11 Turn the feed handle clockwise to engage the threads of the mandrel into the feed nut Turn th...

Page 77: ...clearance around the workpiece See the operating envelope draw ings 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 rang...

Page 78: ...le 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 L R R E A W S Set Back R Root Radius L Land E Land Extension A Bevel Angle W Wall Thickness After Counterbore S S R E tan A x W L R Figure 5 60 The diagram illustrates how to compute the O D set back when performing a sin...

Page 79: ...0 100 0 125 0 250 0 364 x 0 575 0 459 For a compound bevel use the following formula L R R E A1 W 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 A2 S T Figure 5 61 The diagram illustrates how to compute the O D set back when performing a compound bevel ...

Page 80: ... 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 t...

Page 81: ...ting device to pick up the EP 424 and position 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 Figure 5 63 Position the EP 424 to mount it on the mandrel 3 Slide the machine forward on the mandrel Turn the machine back and forth while pushing to engage it all the way onto the spline ...

Page 82: ...EP 424 End Prep Machine 76 Part No 81 MAN 00 Rev C E H Wachs Figure 5 64 Push the machine forward on the mandrel until you can engage the mandrel threads in the feed nut ...

Page 83: ... mandrel threads in the feed nut 6 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 Figure 5 65 Engage the mandrel threads fully in the feed nut for stable operation 7 Install the autofeed stop plate on the end of the mandrel The stop plate prevents the machine from autof...

Page 84: ...e 9 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 10 Turn the feed handle clockwise to advance the tool to the starting position above the O D of the pipe ...

Page 85: ...stop plate 81 316 00 to keep the machine from feeding too far 2 Engage the required number of trips For multiple trips engage them on opposite sides of the trip assembly 3 Start the drive motor to operate the machine Ensure that the starwheel is turning when it strikes the engaged trips 4 To engage the Speed Prep autofeed pull the feed handle back toward you You will feel it snap into place Immedi...

Page 86: ...knob and tighten it Figure 5 69 Set the right knob stop 5 Set the Speed Prep knob back to the starting angle position and lock it in place 6 Measure and mark the transition point on the pipe face surface 7 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 8 When the tool reaches the transition point loosen the Speed ...

Page 87: ...he machine Raise the lift enough to put slight tension on the chain or strap 7 Turn the feed handle counter clockwise until the threads on the mandrel disengage from the feed nut 8 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 9 If the standard mandrel is installed use a 1 1 16 wrench or socket to turn the drawba...

Page 88: ...ounter clockwise until the mandrel is threaded out of the feed nut 3 Pull the mandrel out through the front of the machine Figure 5 71 Pull the mandrel out of the machine 4 Using a 5 16 hex wrench completely loosen the 6 captivated screws holding the sin gle point slide to the main drive assembly ...

Page 89: ... Wachs Part No 81 MAN 00 Rev C 83 Figure 5 72 Loosen the 6 screws holding the single point slide 5 Remove the single point slide from the main shaft Figure 5 73 Remove the single point slide 6 Using a 1 8 hex wrench loosen the 4 set screws in the trip assembly ...

Page 90: ...e set screws holding the trip assembly to the housing 7 Remove the trip assembly from the main housing Figure 5 75 Remove the trip assembly 8 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 ...

Page 91: ...76 Align the dowel pins in the rotating head indicated by arrows with the holes in the main shaft and press the head onto the shaft 9 Using a 5 16 hex wrench tighten the 6 captivated screws in the rotating head to secure it to the main shaft Figure 5 77 Tighten the 6 screws holding on the rotating head ...

Page 92: ...EP 424 End Prep Machine 86 Part No 81 MAN 00 Rev C E H Wachs ...

Page 93: ... Main Drive Assembly 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 1 Using a 3 16 hex wrench remove the plug in the top of the main drive housing ...

Page 94: ...Figure 6 3 Insert the plug and screw it in until it is flush with the top of the housing 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 single point slide to lubricate the wiper Inspect the condition of the wiper ...

Page 95: ...art No 81 MAN 00 Rev C 89 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 ...

Page 96: ...ine on the mandrel standard or independent chuck each time you use it Apply a light coating of oil 4 Each time you use the standard mandrel oil the chuck legs where they engage in the mandrel slots Apply a light coating of oil Spline Mandrel leg slots Figure 6 7 Lubricate the mandrels at the points shown Wipe on a light coating of oil Feed Screw ...

Page 97: ...aintenance information The manual is includ ed 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...

Page 98: ...EP 424 End Prep Machine 92 Part No 81 MAN 00 Rev C E H Wachs ...

Page 99: ...top Collar 1 Using a 5 32 hex wrench loosen the screw in the stop collar adjacent to the starwheel 2 Using the hex wrench in the head of the screw rotate the stop collar so that it is tight against the starwheel 3 Re tighten the screw to secure the stop collar 4 Check the tension on the starwheel If it is acceptable no further adjustment is necessary Adding Removing Gib Shims Shims are used under ...

Page 100: ...e 4 Replace the gibs and the screws Tighten the screws down securely 5 Move the slide through the full range of travel checking the tension as you go NOTE 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 Adjust the Push Plate Set Screws Set the final tension of the slide using the set...

Page 101: ... the detailed instructions in Chapter 5 for setting up and performing a single point bevel 1 Configure the EP 424 for single point operation 2 Mount the machine on a pipe or sample workpiece suitable for single point beveling 3 Install a single point tool in the slide and configure the machine to start the beveling opera tion 4 Attach power to the drive motor and operate the machine until it start...

Page 102: ... 029 29 030 30 031 31 032 32 5 033 33 5 10 rotations 1 trip engaged Speed Prep set to 30 14 Using a 5 64 hex wrench loosen the 2 button head 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 se...

Page 103: ...ts Lists and Drawings E H Wachs Part No 81 MAN 00 Rev C 97 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 ...

Page 104: ...7 2 5 7 127 6 2 1 722 16 57 127 6 2 1 7 722 1 57 1 35 3 127 6 2 1 29 5 5 5 286 1 6 3 127 6 2 1 81 9 56 57 127 6 2 1 66 0 0 1 5 9 66 0 5 5 66 0 67 1 5 0 1 5 527 7 1 66 0 66 0 5 5 9 6725 6 3 127 6 2 1 0 1 3 0 18 127 6 2 1 5 1 21 50 127 6 2 1 5 1 6 7 127 6 2 1 62 7 59 5 9 5 127 6 2 1 5 1 7 1 127 6 2 1 5 1 5 7 7 127 6 2 1 62 7 37 127 6 2 1 ...

Page 105: ...ION 6 16 57 2 5 7 127 6 2 1 722 16 57 127 6 2 1 7 722 1 57 1 35 3 127 6 2 1 29 5 5 5 286 1 6 3 127 6 2 1 81 9 56 57 127 6 2 1 66 0 0 1 5 9 66 0 5 5 66 0 67 1 5 0 1 5 527 7 1 66 0 66 0 5 9 6725 6 3 127 6 2 1 0 1 3 0 18 127 6 2 1 5 1 21 50 127 6 2 1 5 1 6 7 127 6 2 1 62 7 59 5 9 5 127 6 2 1 5 1 7 1 127 6 2 1 5 1 5 7 7 127 6 2 1 62 7 37 127 6 2 1 ...

Page 106: ... 2 1 81 9 56 57 127 6 2 1 66 0 0 1 5 9 66 0 5 5 66 0 872 66 0 67 1 5 0 1 5 127 6 2 1 7 16 21 7 1 7 127 6 2 1 527 7 1 66 0 127 6 2 1 8 1 3 1 17 6 1 32 17 6 66 75 3 66 0 7 1 725 127 6 2 1 66 0 5 5 9 6725 6 3 127 6 2 1 6 7 6723 66 0 127 6 2 1 2 66 0 127 6 2 1 16 57 3 1 66 127 6 2 1 2 5 7 6 1 32 17 127 6 2 1 0 1 3 0 18 127 6 2 1 5 1 21 50 127 6 2 1 5 1 7 1 127 6 2 1 5 1 6 7 127 6 2 1 62 7 59 5 9 21 12...

Page 107: ... 6 3 127 6 2 1 81 9 56 57 127 6 2 1 66 0 0 1 5 9 66 0 5 5 66 0 872 66 0 67 1 5 0 1 5 127 6 2 1 7 16 21 7 1 7 127 6 2 1 527 7 1 66 0 127 6 2 1 8 1 3 1 17 6 1 32 17 6 66 75 3 66 0 7 1 725 127 6 2 1 66 0 5 9 6725 6 3 127 6 2 1 6 7 6723 66 0 127 6 2 1 2 66 0 127 6 2 1 16 57 3 1 66 127 6 2 1 2 5 7 6 1 32 17 127 6 2 1 0 1 3 0 18 127 6 2 1 5 1 21 50 127 6 2 1 5 1 7 1 127 6 2 1 5 1 6 7 127 6 2 1 62 7 59 5...

Page 108: ...27 6 2 1 6 3 127 6 2 1 81 9 56 57 127 6 2 1 66 0 0 1 5 9 66 0 5 5 66 0 872 66 0 67 1 5 0 1 5 7 16 21 7 1 7 127 6 2 1 527 7 1 66 0 127 6 2 1 6 1 32 17 6 66 75 3 66 0 66 0 5 5 9 6725 6 3 127 6 2 1 6 7 6723 66 0 127 6 2 1 2 66 0 127 6 2 1 16 57 3 1 66 127 6 2 1 2 5 7 6 1 32 17 127 6 2 1 0 1 3 0 18 127 6 2 1 5 1 21 50 127 6 2 1 5 1 7 1 127 6 2 1 5 1 6 7 127 6 2 1 62 7 59 5 9 5 21 127 6 2 1 5 1 7 1 127...

Page 109: ...22 25 127 6 2 1 6 3 127 6 2 1 81 9 56 57 127 6 2 1 66 0 0 1 5 9 66 0 5 5 66 0 872 66 0 67 1 5 0 1 5 7 16 21 7 1 7 127 6 2 1 527 7 1 66 0 127 6 2 1 6 1 32 17 6 66 75 3 66 0 66 0 5 9 6725 6 3 127 6 2 1 6 7 6723 66 0 127 6 2 1 2 66 0 127 6 2 1 16 57 3 1 66 127 6 2 1 2 5 7 6 1 32 17 127 6 2 1 0 1 3 0 18 127 6 2 1 5 1 21 50 127 6 2 1 5 1 7 1 127 6 2 1 5 1 6 7 127 6 2 1 62 7 59 5 9 5 21 127 6 2 1 5 1 7 ...

Page 110: ...N 6 16 57 2 5 7 127 6 2 1 722 16 57 127 6 2 1 7 722 1 57 1 35 3 127 6 2 1 29 5 5 5 286 1 6 3 127 6 2 1 81 9 56 57 127 6 2 1 66 0 0 1 5 9 66 0 5 5 66 0 67 1 5 0 1 5 527 7 1 66 0 6725 6 3 127 6 2 1 7 37 5 3 72 3 0 1 3 0 18 127 6 2 1 5 1 21 50 127 6 2 1 5 1 6 7 127 6 2 1 62 7 59 5 9 5 127 6 2 1 5 1 7 1 127 6 2 1 5 1 5 7 7 127 6 2 1 62 7 37 127 6 2 1 ...

Page 111: ... 03 3 250 1 3 250 1387 1 3 5217 5 1 55 5 6 7 6 6 0 1 6 7 6833257 66 0 2 6833257 02817 1 7 0 1 21 7 0 1 83 7 0 1 21 7 0 1 83 7 0 1 21 7 0 1 83 5 1 0 1 5 5 1 286 1 5 7 1 1 250 5 2 5 1 6 0 250 86 6 5 48 5 7 66 0 6 0 250 86 6 5 48 5 7 66 0 6 0 250 86 6 5 48 5 7 66 0 6 0 250 86 6 5 48 5 7 66 0 6 1387 250 6 7 3 5 5 5 1 6 9 2 67 5 1 2 5 1 3 1 52 633 137 5 6 6 6 5 8 5 9 6 6 6 6 6 3 1 2 6 6 6 6 5 6 77 1 13...

Page 112: ... 81 301 00 7 OEV NJ ITEM PART NUMBER QTY DESCRIPTION 286 1 5 5 5 7 187 5 9 187 1 283 1 63 1 37 5 187 5 9 3 1 6 7 5 6 6 5 5 5 1 7 3 5 0 685 6 00 127 6 2 1 02 5 1 63 5 5 7 1 1 7 17 5 1 5 9 5 5 1 187 5 1 63 5 5 7 1 1 3 1 52 6 6 6 6 6 6 6 6 187 3 1 2 3 81 5 9 6351 6 6 3 1 2 3 1 2 6 6 1 ...

Page 113: ...ev C 107 Speed Prep Auto Feed 81 302 00 7 OEV NJ EP 424 Auto Feed Assembly 81 302 00 Contact E H Wachs for repair part information EPD Electric Drive Adapter Kit 81 500 00 ITEM PART NUMBER QTY DESCRIPTION 283 1 02725 37 5 286 1 3 02725 37 5 63 1 7 02 72 6 7 37 5 64 ...

Page 114: ...EP 424 End Prep Machine 108 Part No 81 MAN 00 Rev C E H Wachs Standard Mandrel Assembly 81 303 00 127 6 ITEM PART NUMBER QTY DESCRIPTION ...

Page 115: ...Chapter 8 Parts Lists and Drawings E H Wachs Part No 81 MAN 00 Rev C 109 Rotating Head Assembly 81 304 00 7 OEV NJ ITEM PART NUMBER QTY DESCRIPTION 3 5 7 527 7 1 722 2 5 527 7 1 6 6 37 9 7 6 6 3 1 2 ...

Page 116: ...8 1 3 1 17 8 127 6 2 1 127 6 2 1 127 6 2 1 127 6 2 1 127 6 2 1 0 187 02 63 5 8 ITEM PART NUMBER QTY DESCRIPTION 187 5 5 6 5 5 5 7 5867 5217 8 8 5 1 63 5 5 7 1 1 6 5 5 5 7 5867 0 1 5 1 3 1 17 8 3 7 1 57 127 6 2 1 2 5 57 127 6 2 1 8 75 127 6 2 1 6 6 16 57 ITEM PART NUMBER QTY DESCRIPTION 6 1 5 187 5 1 6 5 6 1 0 6 5 6 1 0 16 57 678 666 6 9 3 5 1 3803 127 6 2 1 5 1 20 127 6 2 1 5 1 20 127 6 2 1 5 1 20...

Page 117: ... MAN 00 Rev C 111 Single Point Slide Assembly 81 306 00 6 2 1 25 5 2 2 7 21 2 7 0 7 OEV NJ ITEM PART NUMBER QTY DESCRIPTION 3 5 7 58 5 6 3 7 6 6 37 9 7 0 6 722 6 63 5 187 86 1 6 5 6 5 4 6 0 386 3 7 5 75 9 3 7 5 03 2 5 87 21 7 3 64 6 666 666 6 6 6 3 1 2 67 5 ...

Page 118: ...MAN 00 Rev C E H Wachs Trip Assembly 81 307 00 7 OEV NJ ITEM PART NUMBER QTY DESCRIPTION 3 81 5 6 5 72 9 5 75 3 75 3 2 5 0 17 6 187 0 187 0 6 6 12 Safety Stop Assembly 81 316 00 ITEM PART NUMBER QTY DESCRIPTION 6723 52 5 3 1 2 6 6 5 7 187 9 ...

Page 119: ...c Drive Assembly 81 310 00 6 127 6 127 NOTE 81 1 2 5 1 20 6 7 5 8 02725 25 5 3 0 176 217 7 6 3 57 180 5 22 58 6833 7 02725 6 3 57 080 5 ITEM PART NUMBER QTY DESCRIPTION 5 8 0 1 2 68 66 0 283 1 02725 37 5 37 5 5 8 02725 63 5 0 1 2 5 8 02725 3 1 52 666 22 58 6 6 5 7 2 5 1 6 6 35 6685 ...

Page 120: ... 5 0 187 30 30 0 217 18286 35 6685 36 5 0 17 50 77 17 35 6685 2 9 5 0 187 36 5 2 5 1 6 81 1 1 8 7 5 02725 22 58 1 8 7 02725 62 6 203 17 48 6 211 76 PERFORMANCE DATA FLOW GPM LPM RPM 1000PSI 69 BAR ITEM PART NUMBER QTY DESCRIPTION 48 6 211 7 0 48 211 7 0 867 3 0 48 6 211 7 867 3 0 48 6 211 7 0 1 2 283 1 02725 37 5 37 5 5 8 02725 63 5 0 1 2 5 8 02725 3 1 52 666 22 58 6 6 5 1 2 5 1 3 8 52 25 6 6 37 5...

Page 121: ...Chapter 8 Parts Lists and Drawings E H Wachs Part No 81 MAN 00 Rev C 115 Air Drive Assembly 81 311 00 ITEM PART NUMBER QTY DESCRIPTION ...

Page 122: ...116 Part No 81 MAN 00 Rev C E H Wachs Feed Lock 81 317 00 ITEM PART NUMBER QTY DESCRIPTION 187 7 5 2 666 12 Single Point Holder Kit 81 702 00 ITEM PART NUMBER QTY DESCRIPTION 5 1 725 217 1 5 6 5 16 57 2 5 81 9 56 6 1 32 17 722 ...

Page 123: ... the EP 424 Table 1 EP424Accessories and Options Part Number Description 81 400 00 Single point upgrade kit for form tool EP 424 configurations 81 000 01 81 000 02 81 303 01 Extension leg kit for standard mandrel 81 305 00 Independent chuck mandrel 81 315 00 Short perch centering mandrel 81 310 00 Hydraulic drive assembly 81 311 00 Air drive assembly 26 407 00 Air treatment module ...

Page 124: ...d on order Table 3 EP424 Beveling Tooling Part Number Description 56 709 02 30 bevel tool insert holder kit including holder insert screws and wrench 56 709 03 37 5 bevel tool insert holder kit including holder insert screws and wrench 56 709 01 20 J bevel low range insert holder kit including holder insert screws and wrench Use with 56 708 01 facing insert holder for 0 040 land extension 56 709 0...

Page 125: ... D Tooling Part Number Description 56 702 01 10 I D deburring tool 0 150 required between mandrel and I D 56 702 02 10 I D deburring tool 0 449 required between mandrel and I D 56 702 03 10 I D deburring tool 0 762 required between mandrel and I D 56 705 01 4 1 taper counterbore tool 0 315 required between mandrel and I D 56 705 02 4 1 taper counterbore tool 0 875 required between mandrel and I D ...

Page 126: ...EP 424 End Prep Machine 120 Part No 81 MAN 00 Rev C E H Wachs ...

Page 127: ...wachs com ORDERING REPLACEMENT PARTS When ordering parts refer to the parts lists in this chapter Please provide the part description and part number for all parts you are ordering REPAIR INFORMATION Please call us for an authorization number before returning any equipment for repair or factory service We will advise you of shipping and handling When you send the equipment please include the follo...

Page 128: ...o complete it WARRANTY INFORMATION Enclosed with the manual is a warranty card Please fill out the registration card and return to E H Wachs Retain the owner s registration record and warranty card for your information RETURN GOODS ADDRESS Return equipment for repair to the following address E H Wachs 600 Knightsbridge Parkway Lincolnshire Illinois 60069 USA ...

Page 129: ... ...

Page 130: ...600 Knightsbridge Parkway Lincolnshire IL 60069 847 537 8800 www ehwachs com ...