Wachs EP 424 User manual

EP 424 End Prep Machine
User’s Manual
Copyright © 2010 E.H. Wachs. All rights reserved.
This manual may not be reproduced in whole or in part
without the written consent of E.H. Wachs.
E.H. Wachs
600 Knightsbridge Parkway
Lincolnshire, IL 60069
www.ehwachs.com
E.H. Wachs Part No. 81-MAN-00
Rev. 0-0610, June 2010
Revision History:
Original June 2010

EP 424 End Prep Machine
Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

Table of Contents
E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 1
Table of Contents
Chapter 1: About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Purpose of This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
How to Use The Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Symbols and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Manual Updates and Revision Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Chapter 2: Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Operator Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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

EP 424 End Prep Machine
2 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs
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

Chapter 1, About This Manual
E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 1
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 set-
up, operation, and maintenance. It also contains parts lists,
diagrams, and service information to help you order
replacement parts and perform user-serviceable repairs.
Before operating the EP 424, you should read through this
manual and become familiar with all instructions. At a min-
imum, 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.
In This Chapter
PURPOSE OF THIS MANUAL
HOW TO USE THE MANUAL
SYMBOLS AND WARNINGS
MANUAL UPDATES AND
REVISION TRACKING

EP 424 End Prep Machine
2 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs
HOW TO USE THE MANUAL
Throughoutthismanual, refer
to this column for warnings,
cautions, and notices with
supplementary information.
This manual is organized to help you quickly find the infor-
mation you need. Each chapter describes a specific topic on
using or maintaining your equipment.
Each page is designed with two columns. This large column
on the inside of the page contains instructions and illustra-
tions. Use these instructions to operate and maintain the
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 out-
side column of the page, next to the section they refer to.
Make sure you understand what each symbol means, and
follow all instructions for cautions and warnings.
A WARNING alert with the
safety alert symbol indicates
a potentially hazardous situa-
tion that could result in seri-
ous injury or death.
A CAUTION alert with the
safety alert symbol indicates
a potentially hazardous situa-
tion that could result in
minor or moderate injury.
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

Chapter 1, About This Manual: Manual Updates and Revision Tracking
E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 3
A CAUTION alert with the
damage alert symbol indi-
cates a situation that will
result in damage to the
equipment.
An IMPORTANT alert with
the damage alert symbol indi-
cates a situation that may
result in damage to the
equipment.
A NOTE provides supple-
mentary information or oper-
ating tips.
MANUAL UPDATES AND REVISION TRACKING
Current versions of E.H.
Wachs Company manuals
are also available in PDF for-
mat. You can request an
electroniccopyof this manual
by emailing customer service
at [email protected]m.
Occasionally, we will update manuals with improved opera-
tion or maintenance procedures, or with corrections if nec-
essary. 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.
CAUTION
This is the equipment damage alert
symbol. It is used to alert you to poten-
tial equipment damage situations.
Obey all messages that follow this sym-
bol to avoid damaging the equipment or
workpiece on which it is operating.
IMPORTANT
NOTE
NOTE
This symbol indicates a user note. Notes
provide additional information to supple-
ment the instructions, or tips for easier
operation.

EP 424 End Prep Machine
4 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

Chapter 2, Safety
E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 5
Chapter 2
Safety
E.H. Wachs takes great pride in designing and manufactur-
ing safe, high-quality products. We make user safety a top
priority in the design of all our products.
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 equip-
ment.
Look for this sym-
bol throughout the
manual.Itindicates
a personal injury
hazard.
•READ THE OPERATING MANUAL. Make sure
you understand all setup and operating instructions
before you begin.
•INSPECT MACHINE AND ACCESSORIES.
Before starting the machine, look for loose bolts or
nuts, 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. Keep hands,
arms, and fingers clear of all rotating or moving parts.
In This Chapter
OPERATOR SAFETY
SAFETY LABELS

EP 424 End Prep Machine
6 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs
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.

Chapter 2, Safety: Safety Labels
E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 7
Protective Equipment Requirements
For additional information on eye and face protection, refer
to Federal OSHA regulations, 29 Code of Federal Regula-
tions, Section 1910.133., Eye and Face Protection and
American National Standards Institute, ANSI Z87.1, Occu-
pational and Educational Eye and Face Protection. Z87.1 is
available from the American National Standards Institute,
Inc., 1430 Broadway, New York, NY 10018.
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 struc-
tures 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.
Always wear impact resistant eye pro-
tection while operating or working near
this equipment.
WARNING
CAUTION
Personal hearing protection is recom-
mended when operating or working near
this tool.

EP 424 End Prep Machine
8 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs
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).

Chapter 2, Safety: Safety Labels
E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 9
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).

EP 424 End Prep Machine
10 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs

Chapter 3, Introduction to the Equipment
E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 11
Chapter 3
Introduction to the
Equipment
OVERVIEW OF THE EP 424
The EP 424 is an I.D. (inside diameter) mounted end prep
machine for facing, beveling, counterboring, and J-prep-
ping 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 opera-
tion.
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 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.
Form-Tool Configuration
The form tool configurations have a rotating tool head with
3 tool holders, for performing up to 3 simultaneous opera-
In This Chapter
OVERVIEW OF THE EP 424
SPECIFICATIONS
OPERATING ENVELOPE

EP 424 End Prep Machine
12 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs
tions. Tooling is available for facing, single-angle beveling,
compound beveling, counterboring,
The form tool configuration will perform end prepping (fac-
ing, beveling, J-prepping, and counterboring), with the
operator manually feeding the tool head.
Figure 3-1. The photo shows the form tool configura-
tion 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.

Chapter 3, Introduction to the Equipment: Overview of the EP 424
E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 13
Figure 3-2. The photo shows the single-point configu-
ration 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 addi-
tional components:

EP 424 End Prep Machine
14 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs
• single-point slide
Figure 3-3. The single-point slide feeds the tool radi-
ally 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.
StarwheelFeed screws
Male tool slide
Tool holder
Feed gauge

Chapter 3, Introduction to the Equipment: Overview of the EP 424
E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 15
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.
• Speed Prep autofeed module
Figure 3-5. The speed prep module is installed on the
main drive to operate the feed mechanism for single-
point beveling.
• independent chuck mandrel
Figure 3-6. The independent chuck mandrel allows
you to center the machine on the O.D. of the pipe.
WARNING
Speed Prep
module

EP 424 End Prep Machine
16 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs
• extension leg kit for standard mandrel
Figure 3-7. Two sets of extension legs allow the stan-
dard mandrel to be mounted in pipes up to 23.64” I.D.
• dial indicator assembly
Figure 3-8. The dial indicator is provided for center-
ing the independent chuck in the pipe.