Wachs SDB 412 User manual

SDB 412 and FF 424
User’s Manual
Copyright © 2013 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. 66-MAN-01
Rev. A, March 2013

Chapter 1, About This Manual
E.H. Wachs Part No. 66-MAN-01, Rev. A 1
About This Manual
PURPOSE OF THIS MANUAL
This manual explains how to operate and maintain the
SDB-412 small diameter beveler (SDB) and FF 424 flange
facer. It includes instructions for set-up, operation, and
maintenance. It also contains parts lists, diagrams, and ser-
vice information to help you order replacement parts and
perform user-serviceable repairs.
Before operating the machine, read through this manual and
become familiar with all instructions.
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. Thislarge 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 defini-
tions. Refer to it for safety notes and other information.
In This Chapter
PURPOSE OF THIS MANUAL
HOW TO USE THE MANUAL
SYMBOLS AND WARNINGS
MANUAL UPDATES AND
REVISION TRACKING

SDB 412 and FF 424
2 Part No. 66-MAN-01, Rev. A E.H. Wachs
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.
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.
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
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

Chapter 1, About This Manual: Manual Updates and Revision Tracking
E.H. Wachs Part No. 66-MAN-01, Rev. A 3
A NOTE provides supple-
mentary information or oper-
ating tips.
MANUAL UPDATES AND REVISION TRACKING
Current versions of E.H.
Wachs manuals are also
available in PDF format. You
can request an electronic
copy of this manual by email-
ing customer service at
[email protected].
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.
NOTE
NOTE
This symbol indicates a user note. Notes
provide additional information to supple-
ment the instructions, or tips for easier
operation.

SDB 412 and FF 424
4 Part No. 66-MAN-01, Rev. A E.H. Wachs

Chapter 2, Safety
E.H. Wachs Part No. 66-MAN-01, Rev. A 5
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 SDB 412/
FF 424. It contains important safety instructions and rec-
ommendations.
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.
•KEEP CLEAR OF MOVING PARTS. Keep hands,
arms, and fingers clear of all rotating or moving parts.
In This Chapter
OPERATOR SAFETY
SAFETY LABELS

SDB 412 and FF 424
6 Part No. 66-MAN-01, Rev. A 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: Operator Safety
E.H. Wachs Part No. 66-MAN-01, Rev. A 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.
1. THIS MACHINE HAS BEEN DESIGNED WITH
VIBRATIONAL CONCERNS IN MIND.
2. IF EXCESSIVE VIBRATIONS OCCUR, RATE
MAY BE TOO FAST AND/OR NOT ENOUGH. THIS
CAN USUALLY BE CORRECTED BY TAKING
A DEEPER CUT.
3. CHECK THE POWER SUPPLY HOOKUP FOR ANY
LOOSE CONNECTIONS.
4. MAKE SURE THE CUTTING TOOL IS SEATED
PROPERLY AND TIGHTENED AS WELL.
5. BE SURE THAT THE WORKPIECE IS WITHIN
THE MACHINES OPERATIONAL CAPACITY
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.

SDB 412 and FF 424
8 Part No. 66-MAN-01, Rev. A E.H. Wachs
MACHINE NOISE LEVELS:
NOTE: NOISE LEVELS HAVE BEEN MEASURED AT 1 METER
HIGH AND 1.6 METERS AWAY.
CONTINUOUS W-WEIGHTED SOUND PRESSURE LEVEL AT
WORK STATION 62 DB (A)
PEAK “C’-WEIGHTED MAXIMUM SOUND PRESSURE 95 DB
(C)
SOUND POWER LEVEL EMMITED BY MACHINE 89 DB (A)
SAFETY LABELS
The following safety labels are on the SDB 412. If the stick-
ers are damaged or missing, replace them immediately. See
“Ordering Information” at the end of this manual.
Figure 2-1. The Warning sticker is on the SDB 412.
Do not put your hands near the rotating head while
the machine is running. (Part number 66-147-00.)
Figure 2-2. The Caution sticker is on the SDB 412 air
motor. Wear ear and eye protection while operating
the machine. (Part number 90-401-03.)

Chapter 2, Safety: Safety Labels
E.H. Wachs Part No. 66-MAN-01, Rev. A 9
Figure 2-3. The air pressure limit label is on the air
motor. (Part number 90-401-02.)
Figure 2-4. The eye injury warning label is on the
hydraulic drive. (Part number 90-401-01.)
Figure 2-5. The hydraulic pressure limit label is on
the hydraulic motor. (Part number 90-402-01.)
Figure 2-6. The hot surface warning label is on the
hydraulic drive. (Part number 90-403-00.)

SDB 412 and FF 424
10 Part No. 66-MAN-01, Rev. A E.H. Wachs

SDB 412/2 SMALL DIAMETER BEVELER
VIBRATION REDUCTION
1. THIS MACHINE HAS BEEN DESIGNED WITH
VIBRATIONAL CONCERNS IN MIND.
2. IF EXCESSIVE VIBRATIONS OCCUR, RATE
MAY BE TOO FAST AND/OR NOT ENOUGH. THIS
CAN USUALLY BE CORRECTED BY TAKING
A DEEPER CUT.
3. CHECK THE POWER SUPPLY HOOKUP FOR ANY
LOOSE CONNECTIONS.
4. MAKE SURE THE CUTTING TOOL IS SEATED
PROPERLY AND TIGHTENED AS WELL.
5. BE SURE THAT THE WORKPIECE IS WITH-
IN THE MACHINES OPERATIONAL CAPACITY.
SECTION II B
SAFETY INSTRUCTIONS
MACHINE NOISE LEVELS:
NOTE: NOISE LEVELS HAVE BEEN MEASURED AT 1 METER HIGH AND 1.6 METERS AWAY.
CONTINUOUS W-WEIGHTED SOUND PRESSURE LEVEL AT WORK STATION 62 DB (A)
PEAK “C’-WEIGHTED MAXIMUM SOUND PRESSURE 95 DB (C)
SOUND POWER LEVEL EMMITED BY MACHINE 89 DB (A)
IMPORTANT:
ALWAYS WEAR HEARING PROTECTION WHEN OPERATING THIS OR OTHER WACHS MACHINERY.
11

SDB 412/2 SMALL DIAMETER BEVELER
1. Select proper leg extension for pipe l.D. (use
leg extension chart on pg 4). Secure legs to
mandrel by tightening two captivated shcs,
using provided hex key set.
NOTE: Each extension leg will be stamped with
it’s part number for easy identification.
( Fig. 1)
2. It is recommended to mount the mandrel by
itself and then install the machine onto the
mandrel to insure proper squaring of machine
and avoid operator injury.
3. lnsert the blade end of the mandrel into the
pipe l.D.
NOTE: Keep the machine-ward end of the legs as
close to the pipe edge as practical. Max
depth of penetration into pipe should be 3/4”
(19mm ) from the machine-ward end of the
legs to the edge of pipe.
( Fig. 2)
4. Mount the mandrel into the pipe by tightening
the draw bar nut to 90 ft. lbs. Move the man-
drel back and forth as well as up and down to
help assure a proper fit. Securely snug the
draw bar nut.
( Fig. 3)
NOTE: Place mandrel shaft keyways in relationship
to keys located in machine sothat appropri-
ate air motor location is achieved.
5. Prepare to mount beveling machine onto
mandrel. Inspect the bore of the beveling
head for dirt and metal chips. Clean the bore
with compressed air or solvent as necessary.
6. Wipe mandrel clean and apply a light coating
of oil.
7. Slide the machine body over the mandrel,
being careful not to scrape the head bushing.
( Fig. 4)
12

SDB 412/2 SMALL DIAMETER BEVELER
( Fig. 7)
( Fig. 8)
8. Align the keys in the machine with the key-
way slots in the mandrel. Push the machine
forward until the feed nut and the threaded
portion of the mandrel meet.
9. Rotate the feed handle assembly clockwise
to engage the feed nut and machine with the
mandrel. (Figure 5).
10. Tighten the machine/mandrel locking set screws
located on either side of the machine body using
the provided hex key set. Tighten both locking
screws equally. Apply tension in order to pre-load
the machine to the mast and remove any play.
(Fig 6.)
( Fig. 5)
( Fig. 6)
11. Connect a clean, dry 90 psi air supply to the
machine. It is recommended to use an Air
Treatment Device in the air line to filter air
and lubricate the motor. ( Fig. 7)
NOTE: Use 90 psi. max. air pressure. Higher air
pressure increases the loads and stresses
on parts and fasteners which may result in
breakage. Higher air pressure also increases
the sound level of the tool.
12. Setup the form tools. (Refer to the tool sel-
ection chart on page 17). Install the facing
tool in the beveling head. All tool bits must be
installed so that the cutting edge will contact
the pipe when rotating in a clockwise direc-
tion from the operators perspective. Tool bits
are locked into place with set screws ad-
jacent to the slot. (Fig. 8)
CAUTION: Do not allow tool bit to come into
contact with the mandrel or damage
will result.
13

SDB 412/2 SMALL DIAMETER BEVELER
CAUTION: Disconnect the air supply whenever
changing the form tools.
CAUTION: Be certain the there is adequate clear
ance between the mandrel legs and
the tooling
13. Start machine and turn feed nut in until the
cutting tool contacts the pipe. Continue facing
until pipe has a clean finish. Retract bevel head
and insert the O.D. beveling tool
14. Feed beveling head into the pipe until the facing
tool bit touches again. Adjust the O.D. beveling
tool in or out radially depending upon the land
thickness desired.
15. The last tool bit to install is the l.D. deburring
tool. It should be placed into the slot opposite
the beveling tool. This tool may also require
some adjustment.
NOTE: If only two tools are to be used, place them
in opposite slots to offset cutting load.
16. Once the cutting bits are in place, the machine
can be moved from one pipe to another of the
same size without resitting the tool bits.
Tips For Good Finish
1. Always place mandrel as close to pipe end as
possible.
2. Use a cutting oil or coolant generously. This will
also increase cutter life.
3. Adjust cutting head RPM for material. A good rule
of thumb is the harder the material, the slower the
speed.
4. Always keep a lot of pressure on the feed nut and
pull out of cut quickly when prep is finished.
14

SDB 412/2 SMALL DIAMETER BEVELER
BEVELING MACHINE TO FLANGE FACER CONVERSION PROCEDURE
4. Mount flange facing tool slide on macrune
rotating head. Align dowel pin holes in flange
facer with the dowel pins on the machine head.
(FIG. 3)
NOTE: Be sure to install the felt washer. Coat the
washer with a light amount of oil in the rear
of the flange facing module.
1. Remove the mandrel from the machine body.
Next, loosen and remove the four 3/8-16 x 1-1/4”
shcs securing the rotating tool holder plate
(Fig. 1).
2. Remove the rotating tool holder plate, (part # 66-
005-00) from the machine body by lifting it from
the two dowel pins pressed into the rotating
head. (Fig. 2)
Fig. 1
Fig. 2
3. Install the trip collar assembly onto the machine
housing by tightening the six locking socket set
screws located on the out diameter of the collar
assembly (Fig. 2).
NOTE: When installing the trip ring assembly, center
the cut out relief on trip ring over the air motor
housing for proper trip lever location. Be sure
that ring sits flush against housing all around.
Fig. 3
5. Secure with four 3/8-16 x 1-1/4” shcs.
Fig. 4
15

SDB 412/2 SMALL DIAMETER BEVELER
B. MANUAL BEVEL GENERATION USING
SINGLE POINT MODULE:
A bevel can be generated by feeding the cutting
tool into the work radially and axially simultaneously.
As the radial feed advances the tool automatically,
the operator must withdraw the tool by rotating the
axial feed handle counter-clockwise. The correct
amount of axial feed per machine revolution is given
in the following chart.
For example, to generate a 30 degree bevel with 6
trips engaged (the fastest tool feed setting), the
operator must withdraw the cutting tool .018” each
time the cutting tool completes a revolution. This
distance is represented by .018 (18 thousandths)
increments on the calibrated feed dial located on the
feed handle assembly.
MANUAL BEVEL GENERATION CHART
A. FLANGE SURFACE TRIP CHART
C. TIPS FOR A GOOD FINISH:
SINGLE POINT FLANGE FACING
BEVELING MODULE
1. Always place mandrel as close to pipe end as
possible.
2. Use the cutting coolant generously. This will
also increase cutter life.
3. The feed rate for each trip is .005 per revolution.
4. CHATTER: Tool chatter occurs when the tool
begins to vibrate during a cut. Excessive tool
chatter can cause poor quality surface finishes.
Chatter can be caused by any one of a number
of variables inherent in a portable machine of this
type. Check tooling: To high of an operating
speed or to great of a radial feed rate for the
material being machined.
5. INTERMITTENT CUTS: When working on a rough
cut end of a piece of pipe or a warped flange, the
need to do an intermittend cut does exist. In order
to prolong tool life and reduce shock loads on the
machine and inserts, intermittent cuts should be
done at a slower speed and feed rate. Once a full
cut is achieved, operating speeds can be increased
to normal machining procedures.
6. As you finish a pass, note your location on the
indiced axial feed guage. Then, to take your next
pass, rotate the feed handle backwards 1 full turn
to your noted location and retract your tool slide.
Once retracted, rotate the feed handle in the amount
you wish for the cut depth of your next pass. This
will allow you to retract the slide without damaging
the tooling, remove all backlash in the feed handle,
and give you an exact depth of cut on your next
pass.
7. To produce a 500 RMS or record groove finish, the
best results are achieved with a finish cut depth of
.007” to .008”.
16

SDB 412/2 SMALL DIAMETER BEVELER
BEVELINGAND FACING, USINGTHE FLANGE
FACER MANDRELFOR CENTERING ONELBOWS
ANDBENDS.
1. Measure the pipe I. D. Select the extension leg
set required. Refer to flange facer mandrel leg
extension chart.
NOTE: Set up the flange facing mandrel with
machine body removed.
2. Insert the legs into the mandrel head.
NOTE: Adjustable leg adjustment screw must be
completely tightened against leg face.
3. Place the mandrel assembly into pipe. Position
the adjustable leg at the “short radius bend”
portion of pipe,(FIG. 12) and snug the draw bar
nut.
NOTE: Legs should be kept as close as pos-
sible to the pipe edge, yet back far enough to
perform the desired operation.
4. CHECK MANDREL CENTERING!
Measure the distance over the adjustable leg
from the pipe l.D. to the mandrel shaft. Then
measure the same distance 1800 from the
adjustable leg. When the mandrel is centered,
these two measurements will be approximately
equal.
NOTE:If additional centering is required and man-
drel removal is necessary, utilize the alignment
fixture to insure returning the legs to the original
set up location. Place the alignment fixture on the
mandrel shaft, push it forward to meet the pipe
face, and snug the fixture in place. Remove the
mandrel; make the leg adjustment needed. Re-
insert the mandrel and alignment fixture. Make sure
(Fig. 12)
the adjustable leg is located at the ”short radius bend“.
Push the assembly tight against the pipe face and
tighten the mandrel. The legs should be at the origi
nal set up location. If the pipe end is square the align
ment fixture will square the mandrel shaft to the pipe.
5. If additional centering is required, loosen the
mandrel and adjustable leg.
NOTE: One complete revolution of the adjustment
screw is equal to 0.050 thousandths (1.19 mm) of
travel on the small legs and .056 thousandths on
the large leg sets.
EXAMPLE: If the distance over the adjustable leg,
between the mandrel shaft and pipe I. D. is one inch
(1”) and the distance 180° from the adjustable leg ,
between the mandrel shaft and the pipe I. D.,
is 1-1/8” divide the difference in half.
1/8” (.125) + 2 =.0625 (1/16”)
Rotate the adjustable leg out approximately one
and 1/8 turns.
6. Re-insert the mandrel after making the centering
adjustments, Measure for centering again. Repeat
if necessary.
7. If the elbow or bend has a square end, utilize the
alignment fixture to square the mandrel shaft. Place
the fixture on the mandrel shaft and push it forward
to meet the pipe face; snug the fixture in place.
Loosen the mandrel assembly slightly push the
fixture forward until it rests firmly against the pipe
face, and retighten the mandrel.
8. If the elbow or bend has been cut and is not square,
a reference point for squaring should be established.
9. Once established, install the alignment fixture on
the mandrel, pushing it firmly against the pipe face.
Position the three legs so that one of the three
jacking set screws in each leg is positioned over the
pipe face. Screw in the jacking set screws until the
back side of the fixture plate is square to the ref-
erence point.
17

SDB 412/2 SMALL DIAMETER BEVELER
SECTIONVI
MAINTENANCE
Under normal operating conditions, the bevel gear sets and roller bearing should be inspected every 100
hours of operation and lubricated as needed. If exceptionally difficult work has been performed or if excessive
coolant used, inspection and lubrication should be done much more frequently.
The bore of the cutting head, feed nut and mandrel must be kept cleaned and oiled.
After the first ten hours of operation, the mainshaft bearing preload should be checked. Remove the air motor.
Remove the 6, 1/4-20x 7/8 SHCS to remove feed nut housing (66-002-00). Bend the Iockwasher (66-034-00) tab
clear from the locknut (66-033-00). Insert and tighten an old, used tool bit into one of the slots on the cutting head.
Clamp machine into a bench vise. Using the lock nut tool and a torque wrench, tighten locknutto 150ft lbs. while
rotating the main housing. Once tight, secure lock washer tang into the closest locknut slot. Replace feed nut
housing and fasteners. Replace and secure air motor.
After every ten hours of operation, inspect the mandrel guide bushing for wear. Replace as necessary.
NOTE: Excessive chatter may indicate a worn mandrel guide bushing
After 40 hours of operation, flush the air motor with a solution of three parts cleaning solvent and one part air
motor oil. After flushing, add I oz. (30 cc) air motor oil into air line and run air motor for one minute. It is very
important that the components of the mandrel assembly remain clean and free from corrosion. The legs and
machine surfaces should be cleaned and oiled on a daily basis.
MANDRELSTRESS INSPECTION PROCEDURE:
1. The mandrel should be removed from the machine body and inspected after every twenty hours of
operation.
2. Remove the drawbar nut (#66-025-00) and the collar nut (# 66-024-00).
3. Remove the mandrel from the machine body by rotating the feed handles counter clockwise.
4. Physically examine the mandrel and threads, look for any signs of wear or damage.
5. Measure the length of the threaded drawbar. If the draw bar length is 21-1/2”, the drawbar may remain
in use. If the length of the drawbar is equal to or exceeds 22W in length the drawbar is no longer safe
and should be replaced.
18