EP - 424 - End Prep Bevelers - Manual

EP 424 End Prep MachineUser’s ManualCopyright © 2010 E.H. Wachs. All rights reserved.This manual may not be reproduced in whole or in partwithout the written consent of E.H. Wachs.E.H. Wachs600 Knightsbridge ParkwayLincolnshire, IL 60069www.ehwachs.comE.H. Wachs Part No. 81-MAN-00Rev. 0-0610, June 2010Revision History:Original June 2010EP 424 End Prep MachinePart No. 81-MAN-00, Rev. 0-0610 E.H. Wachs Table of ContentsTable of ContentsChapter 1: About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Purpose of This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1How to Use The Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Symbols and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Manual Updates and Revision Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Chapter 2: Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Operator Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Protective Equipment Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Chapter 3: Introduction to the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Overview of the EP 424 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Form-Tool Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Single-Point Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12EP 424 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Drive Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Dimensions and Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Operating Envelope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Chapter 4: Assembly, Disassembly, and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Storage Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Chapter 5: Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Mounting the Mandrel on the Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Mounting the Universal (Standard) Mandrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Mounting the Independent Chuck Mandrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Using the Drive Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Mounting and Operating the Air Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Mounting and Operating the Hydraulic Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Form Tool Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Planning the Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Operating Envelope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Selecting Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Adjusting the Tool Holder Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Setting Up and Mounting the EP 424 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 1EP 424 End Prep MachineAssembling the Machine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Removing the Machine from the Workpiece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Single Point Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Installing the Single-Point Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Planning the Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Operating Envelope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Selecting Tool Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Beveling O.D. Set-Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Setting Up and Mounting the EP 424 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71Assembling the Machine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71Using the Speed Prep Autofeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75Compound Bevel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75Removing the Machine from the Workpiece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77Removing the Single-Point Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Chapter 6: Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Main Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Felt Wipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85Single-Point Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86Mandrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86Drive Motor Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87Chapter 7: Service and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89Adjusting the Single-Point Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89Tighten the Starwheel Stop Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89Adding/Removing Gib Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89Adjust the Push Plate Set Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90Calibrating the Speed Prep Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91Air Motor Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93Chapter 8: Parts Lists and Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95Chapter 9: Accessories and Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98Chapter 10: Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102Return Goods Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1022 Part No. 81-MAN-00, Rev. 0-0610 E.H. WachsChapter 1, About This ManualChapter 1About This ManualPURPOSE 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, AccessoriesIf 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.In This ChapterPURPOSE OF THIS MANUALHOW TO USE THE MANUALSYMBOLS AND WARNINGSMANUAL UPDATES AND REVISION TRACKINGE.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 1You will also want to refer to Chapter 8, Parts Lists and Drawings.EP 424 End Prep MachineHOW TO USE THE MANUALThroughout this manual, 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 WARNINGSThe 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.WARNINGThis 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.CAUTION2 Part No. 81-MAN-00, Rev. 0-0610 E.H. WachsChapter 1, About This Manual: Manual Updates and Revision TrackingA 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 TRACKINGCurrent versions of E.H. Wachs Company manuals are also available in PDF for-mat. You can request an electronic copy of this manual by emailing customer service at sales@wachsco.com.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. CAUTIONThis 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.IMPORTANTNOTENOTEThis symbol indicates a user note. Notes provide additional information to supple-ment the instructions, or tips for easier operation.E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 3EP 424 End Prep Machine4 Part No. 81-MAN-00, Rev. 0-0610 E.H. WachsChapter 2, SafetyChapter 2SafetyE.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 SAFETYFollow these guidelines for safe operation of the equip-ment.Look for this sym-bol throughout the manual. It indicates 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 In This ChapterOPERATOR SAFETYSAFETY LABELSE.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 5labels from E.H. Wachs Company.• KEEP CLEAR OF MOVING PARTS. Keep hands, arms, and fingers clear of all rotating or moving parts. EP 424 End Prep MachineAlways 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 SymbolsThis icon is displayed with any safety alert that indicates a personal injury hazard. WARNINGThis safety alert indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. CAUTIONThis 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. WachsChapter 2, Safety: Safety LabelsProtective Equipment RequirementsFor 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 LABELSThe 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.WARNINGCAUTIONPersonal hearing protection is recom-mended when operating or working near this tool.E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 7EP 424 End Prep MachineFigure 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).8 Part No. 81-MAN-00, Rev. 0-0610 E.H. WachsChapter 2, Safety: Safety LabelsFigure 2-5. Compressed air pressure safety label (part no. 90-401-02).Figure 2-6. Hydraulic pressure safety label (part no. 90-402-01).E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 9EP 424 End Prep Machine10 Part No. 81-MAN-00, Rev. 0-0610 E.H. WachsChapter 3, Introduction to the EquipmentChapter 3Introduction to the EquipmentOVERVIEW OF THE EP 424The 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 ConfigurationIn This ChapterOVERVIEW OF THE EP 424SPECIFICATIONSOPERATING ENVELOPEE.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 11The form tool configurations have a rotating tool head with 3 tool holders, for performing up to 3 simultaneous opera-EP 424 End Prep Machinetions. 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 ConfigurationThe 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. WachsChapter 3, Introduction to the Equipment: Overview of the EP 424Figure 3-2. The photo shows the single-point configu-ration of the EP 424.EP 424 ComponentsThe 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 setThe single-point configuration includes the following addi-tional components:E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 13EP 424 End Prep Machine• single-point slideFigure 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 assemblyFigure 3-4. The photo shows the trip assembly mounted on the main drive housing.StarwheelFeed screwsMale tool slideTool holderFeed gauge14 Part No. 81-MAN-00, Rev. 0-0610 E.H. WachsChapter 3, Introduction to the Equipment: Overview of the EP 424The 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 moduleFigure 3-5. The speed prep module is installed on the main drive to operate the feed mechanism for single-point beveling.• independent chuck mandrelFigure 3-6. The independent chuck mandrel allows you to center the machine on the O.D. of the pipe.WARNINGSpeed Prep moduleE.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 15EP 424 End Prep Machine• extension leg kit for standard mandrelFigure 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 assemblyFigure 3-8. The dial indicator is provided for center-ing the independent chuck in the pipe.16 Part No. 81-MAN-00, Rev. 0-0610 E.H. WachsChapter 3, Introduction to the Equipment: Overview of the EP 424Drive MotorsTwo 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 17EP 424 End Prep MachineBoth motors include adapters for the EP 424. The motors are interchangeable, requiring no modifications to the EP 424 machine.AccessoriesThe following accessories are available for the EP 424:• Single-point upgrade kit, part no. 81-400-00 (for form-tool machine configuration); includes Speed Prep mod-ule, 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. (Pro-vided 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. WachsChapter 3, Introduction to the Equipment: SpecificationsSPECIFICATIONS CapacitiesDimensions and WeightsThe 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 1: EP 424 Operating CapacitiesAir 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 revolutionSingle-point slide radial feed 0.0052” (0.132 mm) per engaged trip; 6.5” (165 mm) maximum feedMax feed travel 3.50” (88.9 mm)Max. rotating speed (no load) 20 rpmMin. pipe wall thickness Schedule 40Max. pipe wall thickness (form tool)1.6” (40.5 mm), depending on mate-rialMax pipe wall thickness (sin-gle-point) 6.5” (165 mm)Lift hook capacity 1000 lb (454 kg)Table 2: Overall Dimensions and WeightsConfiguration Dimensions(L x W x H)Weight (Std. Mandrel/ Ind. Chuck Mandrel)81-000-01(Form tool/air drive) 28.8” x 36.2” x 16.1”(732 x 919 x 408 mm)154.5 lb (70.2 kg)/172 lb (78.2 kg)81-000-02(Form tool/hydraulic drive)28.8” x 25.3” x 16.1”(732 x 643 x 408 mm)162 lb (73.6 kg)/179.5 lb/81.6 kgE.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 19EP 424 End Prep MachineOPERATING ENVELOPEThe 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 com-ponents:• Standard mandrel with extension legs• Form tool rotating head• Independent chuck mandrel with extension legs• Single-point slide.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 case37” x 36.3” x 22.3”(940 x 922 x 566 mm)Table 2: Overall Dimensions and WeightsConfiguration Dimensions(L x W x H)Weight (Std. Mandrel/ Ind. Chuck Mandrel)20 Part No. 81-MAN-00, Rev. 0-0610 E.H. WachsITH GAGEMENTREL)13.6815.73tion8.19208.29(SHOWN W.50 [12.7] TREAD ENON MAND7.51.0225.93.5991.128.81731.610.47265.93.50MAX TRAVEL88.95.38136.556-198-02INSERT HOLDER& 56-711-01FACING/BEVELING TOOL29.31744.6AXIAL FEED: .071"[1.80] PER FEEDHANDLE REVOLUTION(CLOCKWISE)5.38136.5LEGS SHOWN FULLY EXTENDED4.20MAX106.6MAX2.7269.2 LEGS SHOWN FULLY RETRACTED3.25MIN82.6MIN47.5399.5MAX FREE SPEED20 RPMAIR REQUIREMENTSAIR CONSUMPTION 95 cfm [2690 l/min]PRESSURE 90 PSI [6.2 BAR]1/2 NPTNOTE:SEE 81-303-00 FOR ALLEXTENSION RANGESOperating EnvelopeEP 424 Air Drive Configura81-000-013EMENTMAX TRAVEL88.9LEGS SHOWN FULLY RETRACTEDNOTE:SEE 81-303-00 FOR ALLEXTENSION RANGESOperating EnvelopeEP 424 Hydraulic Drive Configuration81-000-02.29(SHOWN WITH .50"[12.7] THREAD ENGAGON MANDREL)7.58.1920828.81731.610.47265.93.0978.41.5238.63.505.38136.556-198-02INSERT HOLDER&56-711-01FACING/BEVELINGTOOL17.41442.37.66194.5AXIAL FEED: .071"[1.80] PER FEEDHANDLE REVOLUTION(CLOCKWISE)15.73399.513.68347.5MAX FREE SPEED20 RPMMAX FLOW 15 GPM [57 LPM]MAX PRESSURE 2000 PSI [138 BAR]5.38136.5LEGS SHOWN FULLY EXTENDED4.20MAX106.7MAX2.7269.23.25MIN82.6MIN50 NGAMENTANDREL2.76.84173.6.THREAD EON M125.35643.88.192083.50MAX TRAVEL88.956-205-01HOLDER&52-701-01INSERT TOOLFEED RATE: .0052" [.132]PER TRIP ENGAGEDTOTAL STROKE: 6.5" [165.1]29.31744.6AXIAL FEED: .071" [1.80] PER FEEDHANDLE REVOLUTION(CLOCKWISE)13.00330.227.15ROTATING 689.711.90(SEE 81-305-00R FULL LEG CHART)302.3AIR REQUIREMENTSAIR CONSUMPTION 95 cfm [2690 l/min]PRESSURE 90 PSI (6.2 bar)MAX FREE SPEED20 RPM1/2 NPTOperating EnvelopeEP 424 Air Drive ConfigurationSingle-Point Operation81-000-03FO25.35643.8Single-Point Operation81-000-048.19208.50THREAD ENGAMENTON MANDREL12.76.84173.63.50MAX TRAVEL88.956-205-01HOLDER&52-701-01INSERT TOOLFEED RATE: .0052" [.132]PER TRIP ENGAGEDTOTAL STROKE: 6.5" [165.1]17.41442.37.66194.5AXIAL FEED: .071" [1.80] PER FEEDHANDLE REVOLUTION(CLOCKWISE)13.00330.211.94SEE 81-305-00R FULL LEG CHART303.227.15689.7MAX FREE SPEED20 RPMMAX FLOW 15 GPM [57 LPM]MAX PRESSURE 2000 PSI [138 BAR]Operating EnvelopeEP 424 Hydraulic Drive ConfigurationFO4.20MAXMAX3.27MIN83.1MIN I.D. WITH MAX"B"MAX POSITIONMIN I.D. WITH MIN"A"MIN POSITION3.1580.1.5012.7Operating EnvelopeEP 424 Standard Mandrel and Extension Legs81-303-00MAX1.3834.913.68347.416.39416.2TOOL HOLDERSHOWN IN OUTER POSITION1.7945.31.1930.1Operating EnvelopeEP 424 Rotating Tool Head81-304-008.50MIN CLAMPING 215.91.7544.524.85631.125.28MAX CLAMPING 642.1INDEPENDENT CHUCK MANDRELLEG SETID RANGEINCHESMM23-313-008.50 - 10.50215.9 - 266.7WITH SPACER (23-221-00)9.50 - 11.50241.3 - 292.123-214-0111.18 - 13.15284.0 - 334.0WITH SPACER (23-221-00)12.18 - 14.15309.4 - 359.423-214-0214.43 - 16.50366.5 - 419.1WITH SPACER (23-221-00)15.43 - 17.50391.9 - 444.523-214-0316.87 - 18.81428.5 - 477.8WITH SPACER (23-221-00)17.87 - 19.81453.9 - 503.223-214-0419.31 - 21.30490.5 - 541.0WITH SPACER (23-221-00)20.31 - 22.30515.9 - 566.423-214-0522.28 - 24.28565.9 - 616.7WITH SPACER (23-221-00)23.28 - 25.28591.3 - 642.1Operating EnvelopeEP 424 Independent Chuck Mandrel and Extension Legs81-305-00MIN TOOL POSTIONSHOWN WITH HIGH RANGETOOL HOLDER 56-205-01& INSERT TOOL 52-701-01MIN TOOL POSTION SHOWN WITH LOW RANGE TOOL HOLDER 56-205-00& INSERT TOOL 52-701-01Operating EnvelopeEP 424 Single-Point Slide 81-306-0023.62599.8MAX TOOL POSTIONSHOWN WITH LOW RANGETOOL HOLDER 56-205-00& INSERT TOOL 52-701-0126.38670MAX TOOL POSTIONSHOWN WITH HIGH RANGETOOL HOLDER 56-205-01& INSERT TOOL 52-701-017.25184.14.25107.9R13.58344.82.5564.7SHOWN WITH .50"THREAD ENGAGMENT& 3 TOOL HOLDER SCREWSSLIDE TRAVEL: 6.5"Chapter 4, Assembly, Disassembly, and StorageChapter 4Assembly, Disassembly, and StoragePACKAGINGThe 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 compo-nents 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.In This ChapterPACKAGINGSTORAGE CHECKLISTE.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 29Figure 4-1. The photo shows the EP 424 in its case.EP 424 End Prep MachineFigure 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 CHECKLISTBefore storing the EP 424, perform the following mainte-nance steps. If you are using the machine in an especially dirty or corrosive environment, perform these steps fre-quently.• Clean the machine by wiping off dirt, debris, and accu-mulated 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. WachsChapter 5, Operating InstructionsChapter 5Operating InstructionsMOUNTING THE MANDREL ON THE PIPETypically, 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 man-drel and mount the machine. 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 man-drel, 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 In This ChapterMOUNTING THE MANDREL ON THE PIPEUSING THE DRIVE MOTORSFORM TOOL OPERATIONSINGLE POINT OPERATIONE.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 31from 8.50” to 25.28” (215.9 to 642.1 mm).EP 424 End Prep MachineMounting the Universal (Standard) Mandrel1. Measure the I.D. of the pipe.If the pipe I.D. is larger than 15.96” (405.4 mm), you will need the extended leg kit.Figure 5-1. Measure the I.D. of the pipe to determine which leg set will be required.See the envelope drawings in Chapter 3 for an illustration of the clamp leg configurations.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.NOTENOTE32 Part No. 81-MAN-00, Rev. 0-0610 E.H. WachsChapter 5, Operating Instructions: Mounting the Mandrel on the Pipe3. 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 Table 1: Standard Mandrel Clamping Leg ChartI.D. Inches I.D. mmLeg Extensions UsedMin Max Min Max3.27 4.20 83.1 106.7 None4.07 4.99 103.4 126.8 #14.86 5.79 123.4 147.1 #25.64 6.56 143.3 166.6 #3 & #16.46 7.39 164.1 187.7 #3 & #27.22 8.15 183.4 207.1 #3, #2, & #17.94 8.87 201.7 225.3 #4 & #18.77 9.71 222.8 246.6 #4 & #29.53 10.46 242.1 265.7 #4, #3, & #110.24 11.18 260.1 284.0 #5 & #111.09 12.02 281.7 305.3 #5 & #211.84 12.77 300.7 324.4 #5, #3, & #112.69 13.62 322.3 346.0 #5, #3, & #212.58 13.51 319.5 343.2 #6 & #113.43 14.36 341.1 364.7 #6 & #214.17 15.11 359.9 383.8 #6, #3, & #115.03 15.96 381.8 405.4 #6, #3, & #2With 81-303-01 Extended Leg Kit14.87 15.80 377.7 401.3 #7 & #115.73 16.66 399.5 423.2 #7 & #216.47 17.40 418.3 442.0 #7, #3, & #117.33 18.26 440.2 463.8 #7, #3, & #217.19 18.12 436.6 460.3 #8 & #118.05 18.98 458.5 482.1 #8 & #218.78 19.72 477.0 500.9 #8, #3, & #119.65 20.58 499.1 522.7 #8, #3, & #220.38 21.32 517.7 541.5 #8, #3, #2, & #121.10 22.04 535.9 559.8 #8, #4, & #121.97 22.90 558.0 581.7 #8, #4, & #222.70 23.64 576.6 600.5 #8, #4, #3, & #1E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 33EP 424 End Prep Machineleg first, then “stack” them in size order. Make sure the legs seat squarely, then securely tighten the screws.Extension leg #1 does not have threaded holes to install other legs on top of it.Figure 5-2. Screw the captivated screws into the man-drel to secure the legs.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.NOTE34 Part No. 81-MAN-00, Rev. 0-0610 E.H. WachsChapter 5, Operating Instructions: Mounting the Mandrel on the PipeA socket wrench and 1-1/16” socket are provided with the EP 424.5. 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.For stability, the clamp legs should be as close as possi-ble 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.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.Figure 5-5. Insert the clamping legs into the pipe.7. Turn the drawbar nut clockwise to clamp the legs inside the pipe until they are snug enough to hold the mandrel.NOTENOTEE.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 35EP 424 End Prep MachineFigure 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.Figure 5-7. Measure the distance from the pipe end to the clamping legs to make sure there is enough clear-ance 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.36 Part No. 81-MAN-00, Rev. 0-0610 E.H. WachsChapter 5, Operating Instructions: Mounting the Mandrel on the PipeMounting the Independent Chuck MandrelStart 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.See the envelope drawings in Chapter 3 for an illustration of the clamp leg configurations.2. 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.NOTEE.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 37EP 424 End Prep Machine3. Screw the 4 chuck legs into 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.Table 2: Independent Chuck Clamping Leg ChartI.D. Inches I.D. mmLeg Set Used Spacer (23-221-00) UsedMin Max Min Max8.50 10.50 215.9 266.7 23-313-00 No9.50 11.50 241.3 292.1 23-313-00 Yes11.18 13.15 284.0 334.0 23-214-01 No12.18 14.15 309.4 359.4 23-214-01 Yes14.43 16.50 366.5 419.1 23-214-02 No15.43 17.50 391.9 444.5 23-214-02 Yes16.87 18.81 428.5 477.8 23-214-03 No17.87 19.81 453.9 503.2 23-214-03 Yes19.31 21.30 490.5 541.0 23-214-04 No20.31 22.30 515.9 566.4 23-214-04 Yes22.28 24.28 565.9 616.7 23-214-05 No23.28 25.28 591.3 642.1 23-214-05 Yes38 Part No. 81-MAN-00, Rev. 0-0610 E.H. WachsChapter 5, Operating Instructions: Mounting the Mandrel on the PipeFigure 5-10. Put on the jam nut as shown, with the shoulder of the nut toward the chuck.5. 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.6. Insert a button into the end of each chuck leg. The but-tons are fitted with o-rings to hold them in the leg.ShoulderE.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 39EP 424 End Prep MachineFigure 5-12. Put buttons on the end of each chuck leg.7. Place the chuck body inside the I.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.40 Part No. 81-MAN-00, Rev. 0-0610 E.H. WachsChapter 5, Operating Instructions: Mounting the Mandrel on the PipeFigure 5-14. Mount the alignment gauge to the studs in the chuck.9. 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.10. Loosen the clamp legs slightly, and push the chuck body into the pipe until all four ends of the alignment E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 41EP 424 End Prep Machinegauge 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 are against the pipe surface.You will roughly center the chuck body in the pipe (to the precision of the alignment gauge scales). You will pre-cisely center the mandrel later in this procedure.11. To center the 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 dis-tance 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.NOTE42 Part No. 81-MAN-00, Rev. 0-0610 E.H. WachsChapter 5, Operating Instructions: Mounting the Mandrel on the PipeFigure 5-18. When the chuck is rough centered, snug the jam nuts to hold the clamping legs in place.13. Remove the alignment gauge from the studs. Make 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 43EP 424 End Prep MachineIf the chuck does not need any further centering adjust-ment, install a spacer (23-203-00) over each stud before mounting the mandrel.14. Mount the mandrel onto the chuck.Figure 5-20. Mount the mandrel on the independent chuck.15. Replace the 2 washers (female washer first) and the nut onto each stud to hold the mandrel 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.NOTE44 Part No. 81-MAN-00, Rev. 0-0610 E.H. WachsChapter 5, Operating Instructions: Mounting the Mandrel on the Pipe17. 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.18. Assemble the indicator and set the magnetic mount onto the indicator mounting collar. Turn 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 mag-net.19. Position the tip of the indicator to touch the pipe sur-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 45EP 424 End Prep MachineFigure 5-24. Set the tip of the indicator to touch the pipe, perpendicular to the surface.Do not adjust the mandrel centering screws if stud spac-ers (23-203-00) are installed. The mandrel position cannot be adjusted with the spacers.20. Move the indicator around the pipe end by rotating the mounting collar. Check the reading on the indicator dial to measure how far the mandrel is off center.Figure 5-25. Sweep the indicator around the pipe sur-face 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.NOTE46 Part No. 81-MAN-00, Rev. 0-0610 E.H. WachsChapter 5, Operating Instructions: Using the Drive Motors21. To center the mandrel, adjust the mandrel centering screws in the face plate.Figure 5-26. Turn the mandrel centering screws to adjust the position of the mandrel.22. When you have the mandrel centered, tighten down the nuts on the mandrel mounting studs.23. Remove the indicator and the indicator mounting col-lar.USING THE DRIVE MOTORSRefer 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 Drive1. To 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 47EP 424 End Prep MachineFigure 5-27. Put the air motor flange over the screws in the motor adapter.2. 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.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.The air supply must provide 95 cfm at 90 psi (2700 l/min at 6.2 bar).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.NOTE48 Part No. 81-MAN-00, Rev. 0-0610 E.H. WachsChapter 5, Operating Instructions: Using the Drive MotorsFigure 5-29. Squeeze the air motor trigger to start the machine.6. Adjust the motor speed by turning the speed control-ler.Figure 5-30. Turn the speed control collar to adjust the rotation speed of the machine.The use of coolant or cutting lubricant is recommended. This will improve the cutting performance and increase the life of the tooling.7. While 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 nec-essary to reduce chatter and achieve the appropriate end prep finish.9. When the prep is complete, release the air motor trig-ger to stop the machine.NOTEE.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 49EP 424 End Prep MachineMounting and Operating the Hydraulic Drive1. 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.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.50 Part No. 81-MAN-00, Rev. 0-0610 E.H. WachsChapter 5, Operating Instructions: Using the Drive Motors3. Connect the hydraulic hoses to the ports on the motor as described in Figure 5-33.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. Tank (return) connectorPressure connectorE.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 51EP 424 End Prep MachineFigure 5-34. Turn the hydraulic lever to the ON posi-tion as shown. The form tool head has arrows indicating the correct direction of rotation.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.Figure 5-35. Use the speed dial on the hydraulic man-ifold to adjust the machine rotation speed.NOTE52 Part No. 81-MAN-00, Rev. 0-0610 E.H. WachsChapter 5, Operating Instructions: Form Tool OperationThe use of coolant or cutting lubricant is recommended. This will improve the cutting performance and increase the life of the tooling.8. While holding the hydraulic drive lever on, operate the machine as described in the appropriate 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 appro-priate end prep finish.10. When the prep is complete, release the hydraulic drive lever to stop the machine.FORM TOOL OPERATIONThe 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:• 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.)Setting the feed selector to 0° will reduce wear on the Speed Prep components when you are not using the autofeed.• If your EP 424 is equipped with the Speed Prep autofeed module, set the axial feed selector to 0° when doing form tool operations. Figure 5-36. Set the Speed Prep selector to 0° before doing form tool operations.NOTENOTEE.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 53EP 424 End Prep MachinePlanning the OperationOperating EnvelopeMake sure you have adequate clearance around the work-piece. See the operating envelope drawings in Chapter 3 for reference. Selecting ToolingUse the following charts to select the appropriate tooling for the operation.Figure 5-37. The chart describes the tooling used for facing/beveling operations.54 Part No. 81-MAN-00, Rev. 0-0610 E.H. WachsChapter 5, Operating Instructions: Form Tool OperationFigure 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 55EP 424 End Prep MachineFigure 5-40. The chart describes the tooling used for J-prep operations.Adjusting the Tool Holder PositionsYou 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.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.)56 Part No. 81-MAN-00, Rev. 0-0610 E.H. WachsChapter 5, Operating Instructions: Form Tool OperationFigure 5-41. The photo shows the tool holder moved to the “outer” position for larger diameter pipes.2. 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 424You will probably find it easiest to assemble the main com-ponents of the EP 424 as you install the machine. The fol-lowing 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 ComponentsThe 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 57EP 424 End Prep MachineIt is recommended that you using a lifting device to pick up the EP 424. If you are lift-ing it manually, have two operators lift it.1. 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.2. 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.Figure 5-43. Position the machine to mount it on the mandrel.NOTE58 Part No. 81-MAN-00, Rev. 0-0610 E.H. WachsChapter 5, Operating Instructions: Form Tool Operation3. Slide the machine forward on the mandrel. Turn the machine back and forth while pushing to engage it all the way onto the spline.Figure 5-44. Push the machine forward onto the man-drel. Push the machine forward while turning the feed handle to start the threads.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.Figure 5-45. Turn the feed handle clockwise to engage the mandrel threads in the feed nut.NOTEMandrel threadsFeed nutE.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 59EP 424 End Prep Machine6. 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.Figure 5-47. Insert the tool in the tool holder and tighten the set screws holding it. Make sure the cutting edge of the tool is toward the direction of rotation, as shown.8. Install any other tools required for the operation in the other tool holders. You can perform up to 3 operations Direction of rotation60 Part No. 81-MAN-00, Rev. 0-0610 E.H. WachsChapter 5, Operating Instructions: Form Tool Operationsimultaneously—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 described earlier in this chapter.11. Turn on the power source (air or hydraulic). Keep hands clear of the rotat-ing head while the machine is operating. Contact with the head or tooling could result in serious injury.12. Turn on the drive motor. The machine will start to rotate. Adjust the motor speed using the speed control-ler on the drive.13. Turn the feed handle clockwise to feed the tooling into the pipe face. Check the radial position of the tooling. Stop the machine if you need to adjust the tool posi-tion.The use of coolant or cutting lubricant is recommended. This will improve the cutting performance and increase the life of the tooling.14. Continue feeding the tooling into the pipe. Adjust the drive motor speed if necessary to reduce chatter and achieve the appropriate end prep finish.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.WARNINGNOTEE.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 61EP 424 End Prep MachineFigure 5-49. Use the scale on the feed housing to measure axial feed distance.16. When the prep is complete, turn the feed handle coun-ter-clockwise to retract the tooling from the pipe end. Release the air motor trigger to stop the machine.Removing the Machine from the Workpiece1. Turn the feed handle counter-clockwise to retract the tooling away from the pipe end.2. 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.3. Disconnect the power source (air or hydraulic) from the drive motor.4. Loosen the 4 motor mounting screws and remove the drive motor.5. Connect the lifting device to the lifting eye on the machine. Raise the lift enough to put slight tension on the chain or strap.6. Turn the feed handle counter-clockwise until the threads on the mandrel disengage from the feed nut.7. 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.8. If the standard mandrel is installed, use a 1-1/16” wrench or socket to turn the drawbar nut counter-clockwise to loosen the clamp legs.62 Part No. 81-MAN-00, Rev. 0-0610 E.H. WachsChapter 5, Operating Instructions: Single Point Operation9. 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 OPERATIONInstalling the Single-Point KitIf 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.1. Set the machine on a stable work surface that can sup-port its weight. Use a lifting device to lift the EP 424.2. 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.3. Pull the mandrel out through the front of the machine.E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 63EP 424 End Prep MachineFigure 5-51. Pull the mandrel out of the machine.4. 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 rotat-ing head to the main shaft.5. Remove the rotating head from the main shaft.64 Part No. 81-MAN-00, Rev. 0-0610 E.H. WachsChapter 5, Operating Instructions: Single Point OperationFigure 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.Figure 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.E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 65EP 424 End Prep MachineThe 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 sin-gle-point slide. 8. 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.Figure 5-56. There are three dowel pins in the back of the single-point slide to mount it to the main shaft.9. Using a 5/16” hex wrench, tighten the 6 captivated screws in the single-point slide to secure it to the main shaft.NOTENOTE66 Part No. 81-MAN-00, Rev. 0-0610 E.H. WachsChapter 5, Operating Instructions: Single Point OperationFigure 5-57. Tighten the captivated screws in the 6 holes to attach the single-point slide to the main 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 the handle until E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 67EP 424 End Prep Machinethe 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 OperationOperating EnvelopeMake sure you have adequate clearance around the work-piece. See the operating envelope drawings in Chapter 3 for reference. Selecting Tool HolderTwo 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.Beveling O.D. Set-BackThe O.D. set-back is the distance from the end of the pipe where you will start the beveling operation. It is determined 68 Part No. 81-MAN-00, Rev. 0-0610 E.H. WachsChapter 5, Operating Instructions: Single Point Operationby 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 fol-lowing 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”LRREAWS = Set-BackR = Root RadiusL = LandE = Land ExtensionA = Bevel AngleW = Wall Thickness (After Counterbore)SS = R + E + [tan(A) x (W - L - R)]E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 69EP 424 End Prep MachineFor a compound bevel, use the following formula: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”LRREA1WS = Set-BackR = Root RadiusL = LandE = Land ExtensionA1 = Inner Bevel AngleA2 = Outer Bevel AngleT = Transition (from I.D.)W = Wall Thickness (After Counterbore)S = R + E + [tan(A2) x (W - T)] + [tan(A1) x (T - L - R)] A2ST70 Part No. 81-MAN-00, Rev. 0-0610 E.H. WachsChapter 5, Operating Instructions: Single Point OperationSetting Up and Mounting the EP 424You will probably find it easiest to assemble the main com-ponents of the EP 424 as you install the machine. The fol-lowing 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 ComponentsThe following procedure assumes that the mandrel has been mounted in the pipe, as described earlier in this chapter.It is recommended that you using a lifting device to pick up the EP 424. If you are lift-ing it manually, have two operators lift it.1. Attach a crane or other lifting device to the lift hook on the machine body. Figure 5-62. Attach the lifting device to the lift ring.2. 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.NOTEE.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 71EP 424 End Prep MachineFigure 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.Figure 5-64. Push the machine forward on the man-drel until you can engage the mandrel threads in the feed nut.72 Part No. 81-MAN-00, Rev. 0-0610 E.H. WachsChapter 5, Operating Instructions: Single Point OperationPush the machine forward while turning the feed handle to start the threads.4. When the machine is fully engaged on the spline, lower the lifting device slightly to take the tension off it.5. 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.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 man-drel. The stop plate prevents the machine from auto-feeding all the way off the mandrel.8. 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.NOTEE.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 73EP 424 End Prep MachineFigure 5-66. Install the tool holder in the slide.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.74 Part No. 81-MAN-00, Rev. 0-0610 E.H. WachsChapter 5, Operating Instructions: Single Point OperationUsing the Speed Prep AutofeedThe 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.1. 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.2. Engage the required number of trips. For multiple trips, engage them on opposite sides of the trip assem-bly.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 han-dle back toward you. You will feel it “snap” into place. Immediately let go of the feed handle.5. As the machine rotates, the autofeed will turn the feed handle counter-clockwise.6. To disengage the autofeed, push the feed handle in.Compound BevelUse the knob stops to set the angles.1. 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.2. Move the left knob stop up against the knob and tighten it.WARNINGE.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 75EP 424 End Prep MachineFigure 5-68. Set the left knob stop against the Speed Prep knob.3. Loosen the Speed Prep knob and set it to the location of the transition angle. Lock the knob in place.4. Move the right knob stop up against the 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.76 Part No. 81-MAN-00, Rev. 0-0610 E.H. WachsChapter 5, Operating Instructions: Single Point Operation7. 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 Prep knob and move it over against the right knob stop. Tighten the knob.9. Continue until the bevel is complete.Removing the Machine from the Workpiece1. Using a 5/16” hex wrench, turn the starwheel on the slide clockwise to retract the tool away from the pipe.2. Turn the feed handle counter-clockwise to retract the single-point slide away from the pipe end.3. It is recommended that you remove the tool holder from the slide before removing the machine. This pre-vents accidental damage to the tooling, or damage or injury caused by the tooling in case of a collision while moving the machine.4. Disconnect the power source (air or hydraulic) from the drive motor.5. Loosen the 4 motor mounting screws and remove the drive motor.6. Connect the lifting device to the lifting eye on the 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 drawbar nut counter-clockwise to loosen the clamp legs.10. If the independent chuck mandrel is installed, loosen the jam nuts and then loosen the clamp legs.11. Pull the mandrel out of the pipe.E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 77EP 424 End Prep Machine12. 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.Removing the Single-Point Kit1. Set the machine on a stable work surface that can sup-port its weight. Use a lifting device to lift the EP 424.2. 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.3. Pull the mandrel out through the front of the machine.78 Part No. 81-MAN-00, Rev. 0-0610 E.H. WachsChapter 5, Operating Instructions: Single Point OperationFigure 5-71. Pull the mandrel out of the machine.4. 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 single-point slide. 5. Remove the single-point slide from the main shaft.E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 79EP 424 End Prep MachineFigure 5-73. Remove the single-point slide.6. Using a 1/8” hex wrench, loosen the 4 set screws in the trip assembly.Figure 5-74. Loosen the set screws holding the trip assembly to the housing.7. Remove the trip assembly from the main housing.80 Part No. 81-MAN-00, Rev. 0-0610 E.H. WachsChapter 5, Operating Instructions: Single Point OperationFigure 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.Figure 5-76. 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.E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 81EP 424 End Prep MachineFigure 5-77. Tighten the 6 screws holding on the rotating head.82 Part No. 81-MAN-00, Rev. 0-0610 E.H. WachsChapter 6, Routine MaintenanceChapter 6Routine MaintenanceLUBRICATIONMain Drive AssemblyThere 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 In This ChapterLUBRICATIONDRIVE MOTOR LUBRICATIONE.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 83through the fitting. 1. Using a 3/16” hex wrench, remove the plug in the top of the main drive housing.EP 424 End Prep MachineFigure 6-2. Remove the grease plug before putting grease into the main drive assembly.2. 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.Felt WipersBoth 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 84 Part No. 81-MAN-00, Rev. 0-0610 E.H. WachsChapter 6, Routine Maintenance: Lubricationmandrel getting dry, remove the rotating head or single-point slide to lubricate the wiper.Inspect the condition of the wiper. Replace it if it is dam-aged, deformed from wear, or very dirty.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 SlideEach 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 85EP 424 End Prep MachineFigure 6-6. Lubricate the feed screw with a light coat-ing of oil.Mandrel1. Oil the spline on the mandrel (standard or independent chuck) each time you use it. Apply a light coating of oil.2. Each time you use the standard mandrel, oil the chuck legs where they engage in the mandrel slots. Apply a light coating of oil.Figure 6-7. Lubricate the mandrels at the points shown. Wipe on a light coating of oil.Feed screwSplineMandrel leg slots86 Part No. 81-MAN-00, Rev. 0-0610 E.H. WachsChapter 6, Routine Maintenance: Drive Motor LubricationDRIVE MOTOR LUBRICATIONThe hydraulic motor is self-lubricating and requires no routine maintenance.See the air motor manufacturer’s manual for full mainte-nance 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. Grease the air motor fitting once a month.E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 87EP 424 End Prep Machine88 Part No. 81-MAN-00, Rev. 0-0610 E.H. WachsChapter 7, Service and RepairChapter 7Service and RepairADJUSTMENTSAdjusting the Single-Point Slide You can adjust the feed tension on the single-point slide. The slide should be adjusted so that you can turn the star-wheel 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 follow-ing procedure to adjust the tension on the slide.Tighten the Starwheel Stop Collar1. 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 ShimsIn This ChapterADJUSTMENTSAIR MOTOR MANUALE.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 89Shims are used under the gibs to set the vertical tension on the male slide. Shims are “stacked” to achieve the desired tension.EP 424 End Prep Machine• 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 verti-cal wobble. If you can move the slide, you will need to remove a shim on each side.If the slide is too tight, you may need to add a shim. The procedure for adding shims is the same.1. Using a 5/16” hex wrench, securely tighten down all 4 screws holding each gib. Check the male slide for ver-tical wobble. Move the slide to both ends of travel, checking it as you go.2. If you can move the slide vertically at any position, remove all 4 screws from each gib and take the gibs off.3. Remove one shim from each side. Stack the remaining shim(s) and the wear plate to line up the holes in the base plate.4. Replace the gibs and the screws. Tighten the screws down securely.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.5. Move the slide through the full range of travel, check-ing the tension as you go. Adjust the Push Plate Set ScrewsSet 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.1. 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.2. Using the 5/16” hex wrench, crack loose the 4 screws on each gib.3. Using a 5/32” hex wrench, remove the jam screws from all 4 set screw holes.NOTENOTE90 Part No. 81-MAN-00, Rev. 0-0610 E.H. WachsChapter 7, Service and Repair: Adjustments4. With the 5/32” hex wrench, snug down the 2 set screws on the ends. Slightly loosen the 2 set screws in the middle.5. Turn the feed screw to move the male slide through the full range of travel. Check for appropriate resis-tance as you turn the screw, and loosen or tighten the 2 end screws as necessary to adjust the tightness.6. When the tension is equal along the full length of travel, snug down the 2 middle set screws.7. Move the slide along the length of travel and adjust the screws as necessary.8. Replace and tighten the jam screws on all 4 set screws.Calibrating the Speed Prep ScaleIf necessary, you can move the Speed Prep scale to make sure the bevel angle settings are accurate. You should peri-odically check the calibration, especially if your beveling operation requires very accurate angles.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 cali-bration depends on a realistic cutting process. See the detailed instructions in Chapter 5 for setting up and per-forming 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 operation.4. Attach power to the drive motor and operate the machine until it starts to cut the workpiece.5. Turn off the drive motor.6. Engage one trip on the trip assembly.7. Loosen the Speed Prep knob and set it so that the gauge is at 30°. Tighten the knob to lock it in place.E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 91EP 424 End Prep Machine8. Turn the feed handle to set the axial feed scale to 0 (or to any reference reading). Make a note of the reading on the axial feed scale.9. Start the drive motor. The single-point slide will start to rotate.10. When the slide reaches the top of rotation, pull out the feed handle to start the autofeed.11. Count the rotations as the machine operates. When it reaches 10 rotations, push in the feed handle to stop the autofeed. Turn off the drive motor.12. Note the reading on the axial feed scale. Subtract the original reading at the start from the current reading to determine the measured axial feed.13. Find the measured axial feed in Table 1 below, and read across for the actual bevel angle. Make a note of the angle.* 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 set the Speed Prep gauge to 29°.15. Re-tighten the button head cap screws on the scale.Table 1: Speed Prep CalibrationMeasured Axial Feed* Actual Bevel Angle (rounded to 0.5°).027” 26.5°.028” 27.5°.029” 29°.030” 30°.031” 31°.032” 32.5°.033” 33.5°92 Part No. 81-MAN-00, Rev. 0-0610 E.H. WachsChapter 7, Service and Repair: Air Motor ManualAIR MOTOR MANUALThe air motor manufacturer’s operating and maintenance manual is included following this page. Refer to it for detailed maintenance and repair instructions.E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 93EP 424 End Prep Machine94 Part No. 81-MAN-00, Rev. 0-0610 E.H. WachsChapter 8, Parts Lists and DrawingsChapter 8Parts Lists and DrawingsRefer to the following drawings for parts identification and ordering. Each drawing includes a parts list for the assem-bly.E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 95EP 424 End Prep Machine96 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs785693ITEMPART NUMBER QTY. DESCRIPTION156-710-011SDB INSERT HOLDER KIT (NOT SHOWN)256-711-011TOOL, INSERT (NOT SHOWN)381-035-001COVER, REAR HOUSING481-166-001LABEL, UNIVERSAL LEG CHART (NOT SHOWN)581-300-001ASSEMBLY, MAIN DRIVE681-301-001ASSEMBLY, REAR FEED781-303-001ASSEMBLY, STANDARD MANDREL881-304-001ROTATING HEAD ASSEMBLY981-311-001ASSEMBLY, AIR DRIVE1081-312-001STORAGE CASE, EP-424 (NOT SHOWN)1181-312-120QUICK PIN, 3/8 (NOT SHOWN)1281-MAN-001EP-424 MANUAL (NOT SHOWN)1390-800-281WRENCH, 1/4 HEX LONG ARM (NOT SHOWN)1490-800-401WRENCH, 3/16-3/8 HEX SET (NOT SHOWN)1590-800-471SOCKET, 1/2 DRV x 5/16 HEX DRIVER LG. (NOT SHOWN)1690-800-621WRENCH, 3/16 HEX 9" T-HANDLE (NOT SHOWN)1790-800-631WRENCH, 1/2 RATCHET (NOT SHOWN)1890-800-881SOCKET, 1/2 X 1-1/16 6-PT (NOT SHOWN)EP 424 Air Drive Configuration81-000-01785693ITEMPART NUMBER QTY. DESCRIPTION156-710-011SDB INSERT HOLDER KIT (NOT SHOWN)256-711-011TOOL, INSERT (NOT SHOWN)381-035-001COVER, REAR HOUSING481-166-001LABEL, UNIVERSAL LEG CHART (NOT SHOWN)581-300-001ASSEMBLY, MAIN DRIVE681-301-001ASSEMBLY, REAR FEED781-303-001ASSEMBLY, STANDARD MANDREL881-304-001ROTATING HEAD ASSEMBLY981-310-001ASSEMBLY, HYD. DRIVE1081-312-001STORAGE CASE, EP-424 (NOT SHOWN)1181-312-120QUICK PIN, 3/8 (NOT SHOWN)1281-MAN-001EP-424 MANUAL (NOT SHOWN)1390-800-281WRENCH, 1/4 HEX LONG ARM (NOT SHOWN)1490-800-401WRENCH, 3/16 - 3/8 HEX SET (NOT SHOWN)1590-800-471SOCKET, 1/2 DRV X 5/16 HEX DRIVER LG. (NOT SHOWN)1690-800-621WRENCH, 3/16 HEX 9" T-HANDLE (NOT SHOWN)1790-800-631WRENCH, 1/2 RATCHET (NOT SHOWN)1890-800-881SOCKET, 1/2 X 1-1/16 6PT. (NOT SHOWN)EP 424 Hydraulic Drive Configuration81-000-021516179111910ITEMPART NUMBER QTY. DESCRIPTION156-424-011TOOL HOLDER ASSEMBLY-HIGH RANGE (NOT SHOWN)256-710-011SDB INSERT HOLDER KIT (NOT SHOWN)356-711-011TOOL, INSERT (NOT SHOWN)481-162-001LABEL, INDEPENDENT LEG CHART (NOT SHOWN)581-163-001LABEL, AUTO FEED (NOT SHOWN)681-164-001LABEL, MANUAL FEED (NOT SHOWN)781-166-001LABEL, UNIVERSAL LEG CHART (NOT SHOWN)881-167-002LABEL, INDEP LEG HOLDER CHART (NOT SHOWN)981-300-001ASSEMBLY, MAIN DRIVE1081-301-001ASSEMBLY, REAR FEED1181-302-001ASSEMBLY, AUTO FEED1281-303-001ASSEMBLY, STANDARD MANDREL (NOT SHOWN)1381-303-011LEG EXTENSION EXTENDED KIT (NOT SHOWN)1481-304-001ROTATING HEAD ASSEMBLY (NOT SHOWN)1581-305-001CHUCK, 10"-24" INDEPENDENT1681-306-001SINGLE POINT SLIDE ASSY.1781-307-001TRIP ASSEMBLY1881-309-001KIT, INDICATOR (NOT SHOWN)1981-311-001ASSEMBLY, AIR DRIVE2081-312-001STORAGE CASE, EP-424 (NOT SHOWN)2181-312-120QUICK PIN, 3/8 (NOT SHOWN)2281-313-002CHUCK LEG TRAY (NOT SHOWN)2381-316-001SAFETY STOP ASSEMBLY2481-MAN-001EP-424 MANUAL (NOT SHOWN)2590-800-251WRENCH, 2-1/4 PUMP (NOT SHOWN)2690-800-261WRENCH, 7/8 COMBINATION (NOT SHOWN)2790-800-281WRENCH, 1/4 HEX LONG ARM (NOT SHOWN)2890-800-291WRENCH, 1-1/8 COMBINATION (NOT SHOWN)2990-800-311WRENCH, 9/16 COMBINATION (NOT SHOWN)3090-800-381WRENCH, 7/16 COMBINATION (NOT SHOWN)3190-800-391WRENCH, 1/8 HEX T-HANDLE (NOT SHOWN)3290-800-401WRENCH, 3/16 - 3/8 HEX SET (NOT SHOWN)3390-800-471SOCKET, 1/2 DRV X 5/16 HEX DRIVER LONG (NOT SHOWN)3490-800-621WRENCH, 3/16 HEX 9" T-HANDLE (NOT SHOWN)3590-800-631WRENCH, 1/2 DRV RATCHET (NOT SHOWN)3690-800-881SOCKET, 1/2 DRV X 1-1/16 6 PT. (NOT SHOWN)EP 424 Single Point Air Drive Configuration81-000-031516179111019ITEMPART NUMBER QTY. DESCRIPTION156-424-011TOOL HOLDER ASSEMBLY-HIGH RANGE (NOT SHOWN)256-710-011SDB INSERT HOLDER KIT (NOT SHOWN)356-711-011TOOL, INSERT(NOT SHOWN)481-162-001LABEL, INDEPENDENT LEG CHART (NOT SHOWN)581-163-001LABEL, AUTO FEED (NOT SHOWN)681-164-001LABEL, MANUAL FEED (NOT SHOWN)781-166-001LABEL, UNIVERSAL LEG CHART (NOT SHOWN)881-167-002LABEL, INDEP LEG HOLDER CHART (NOT SHOWN)981-300-001ASSEMBLY, MAIN DRIVE1081-301-001ASSEMBLY, REAR FEED1181-302-001ASSEMBLY, AUTO FEED1281-303-001ASSEMBLY, STANDARD MANDREL (NOT SHOWN)1381-303-011LEG EXTENSION EXTENDED KIT (NOT SHOWN)1481-304-001ROTATING HEAD ASSEMBLY (NOT SHOWN)1581-305-001CHUCK, 10"-24" INDEPENDENT1681-306-001SINGLE POINT SLIDE ASSY.1781-307-001TRIP ASSEMBLY1881-309-001KIT, INDICATOR (NOT SHOWN)1981-310-001ASSEMBLY, HYD. DRIVE2081-312-001STORAGE CASE, EP-424 (NOT SHOWN)2181-312-120QUICK PIN, 3/8 (NOT SHOWN)2281-313-002CHUCK LEG TRY (NOT SHOWN)2381-316-001SAFETY STOP ASSEMBLY2481-MAN-001EP-424 MANUAL (NOT SHOWN)2590-800-251WRENCH, 2-1/4 PUMP (NOT SHOWN)2690-800-261WRENCH, 7/8 COMBINATION (NOT SHOWN)2790-800-281WRENCH, 1/4 HEX LONG ARM (NOT SHOWN)2890-800-291WRENCH, 1-1/8 COMBINATION (NOT SHOWN)2990-800-311WRENCH, 9/16 COMBINATION (NOT SHOWN)3090-800-381WRENCH, 7/16 COMBINATION (NOT SHOWN)3190-800-391WRENCH, 1/8 HEX T-HANDLE (NOT SHOWN)3290-800-401WRENCH, 3/16 - 3/8 HEX SET (NOT SHOWN)3390-800-471SOCKET, 1/2 DRV X 5/16 HEX DRIVER LONG (NOT SHOWN)3490-800-621WRENCH, 3/16 HEX 9" T-HANDLE (NOT SHOWN)3590-800-631WRENCH, 1/2 DRV RATCHET (NOT SHOWN)3690-800-881SOCKET, 1/2 DRV X 1-1/16 6 PT. (NOT SHOWN)EP 424 Single Point Hydraulic Configuration81-000-043518723191115142125203322091819232483317161056313529223812133712262432736362834301WEIGHT: 55 lbs / 24.9 kg ITEMPART NUMBER QTY. DESCRIPTION180-0080-001NAME PLATE281-001-001MAIN HOUSING381-002-001SHAFT, MAIN481-005-001WORM SHAFT AND GEAR SET581-018-001NUT, BEARING681-019-001PLATE, BEARING NUT CLAMP781-020-001CAP, WORM END881-021-001CAP, WORM INPUT END981-022-001CAP, FRONT BEARING1081-024-001CARRIER, SHAFT SEAL1181-059-001SEAL, MAIN SHAFT1281-060-002SUPPORT ASSEMBLY1381-061-002BLOCK, SUPPORT MOUNTING1481-100-001TIMKEN CONE1581-100-011TIMKEN CUP1681-101-001TIMKEN CONE1781-101-011TIMKEN CUP1881-102-002TIMKEN CONE1981-102-012TIMKEN CUP2081-103-002BEARING, MANDREL2181-104-001RING, 3.25" HOUSING RETAINING2281-105-001KEY, WORM GEAR2381-106-002O-RING, -0382481-108-001SEAL, INPUT/WORM SHAFT2581-109-001CAP, REAR BEARING2681-152-001SWIVEL HOIST RING, 1000 LB2781-153-001O-RING, -257 2890-028-011SPP, 1/8 NPT DRYSEAL2990-039-056LHCS, 10-24 X 1/23090-049-064SCREW, #2-3/16 U-DRIVE3190-050-076SHCS, 1/4-20 X 3/43290-050-156SHCS, 1/4-20 X 1-1/23390-060-084SHCS, 5/16-18 X 7/83490-066-104PIN, 5/16 X 1.0 DOWEL3590-070-078SHCS, 3/8-16 X 3/43690-072-158BHCS, 3/8-16 X 1-1/23790-072-254BHCS, 3/8-16 X 2-1/23890-500-021GREASE FITTING, 1/8 NPT STRAIGHTEP 424 Main Drive Assembly81-300-0020231525261681426131529104271871931712924222128WEIGHT: 22.5 lbs / 10.2 kgITEMPART NUMBER QTY. DESCRIPTION181-012-001HOUSING, REAR281-013-001GEAR, 61T FEED NUT DRIVE381-014-001NUT, FEED481-015-001HANDLE, FEED581-016-001COUPLING, SPLINED681-041-001ADAPTER, FEED NUT DRIVE781-042-006PIN, SHIFTER881-110-001SHIELD981-111-001SHEILD, REAR BEARING1081-112-001TAPER MEASURE1181-112-011SCALE, AXIAL FEED (MM) (NOT SHOWN)1281-113-001RING, SPIRAL RETAINING1381-114-006DETENT, BALL1481-115-001BEARING, DRIVE GEAR1581-116-001BEARING, FEED NUT1681-117-001RING, SPIRAL RETAINING1790-026-572PIN, 1/8 X 3/4 ROLL1890-040-076SHCS, 10-24 X 3/41990-040-104SHCS, 10-24 X 12090-050-064SHCS, 1/4-20 X 5/82190-050-257SHCS 1/4-20 X 2.52290-055-016NUT, 1/4-20 HEX2390-056-062PIN, 1/4 X 5/8 DOWEL2490-059-086SPRING PLUNGER2590-060-074SHCS, 5/16-18 X 3/42690-066-104PIN, 5/16 X 1.0 DOWEL2790-066-156PIN, 5/16 X 1-1/2 DOWEL2890-077-532SHSB, 3/8 X 3/82990-900-674HANDLE, FEEDEP 424 Rear Feed Assembly81-301-00WEIGHT: 7.5 lbs / 3.4 kg EP 424 Auto Feed Assembly81-302-00Contact E.H. Wachs for repair part information.5153218467141312.111109.112.29.2SEE NOTE 3SEE NOTE 3NOTES: SEE OPERATING ENVELOPE DRAWING FOR LEG CHART1.NOT ALL LEGS AND FASTENERS SHOWN2.ITEMS #9.2 & 12.2 SHOWN FOR REFERENCE3.WEIGHT: 35 lbs / 15.8 kg - WITH OUT LEGS 51 lbs / 23.1 Kg - WITH LEGS SET #28ITEMPART NUMBER QTY.DESCRIPTION181-006-001MANDREL, SPLINED281-007-001BODY, CHUCK381-008-003LEG, CHUCK481-009-001DRAW BAR & NUT ASSY.581-017-001PLATE, DRAW BAR END681-025-001WASHER, DRAW BAR THRUST781-120-001RING, SPIRAL RETAINING881-143-001WASHER, DRAW BAR THRUST981-314-013LEG EXTENSION #1 ASSY.9.1 81-026-001LEG EXTENSION #19.2 66-087-002SCREW, CAPTIVE1081-314-023LEG EXTENSION #2 ASSY.1181-314-033LEG EXTENSION #3 ASSY.1281-314-043LEG EXTENSION #4 ASSY.12.1 81-027-021LEG EXTENSIONS #412.2 66-087-002SCREW, CAPTIVE1381-314-053LEG EXTENSION #5 ASSY.1481-314-063LEG EXTENSION #6 ASSY.1590-052-053BHCS 1/4-20 X .50 LG EP 424 Standard Mandrel Assembly81-303-002356714WEIGHT: 17.5 lbs / 7.9 kgITEMPART NUMBER QTY. DESCRIPTION166-043-001WIPER, FELT281-003-001HEAD, ROTATING381-030-003TOOL HOLDER, ROTATING HEAD481-064-006SHCS, 3/8-16 X 1-1/4 CAPTIVATED590-060-0724SHCS, 5/16-18 X 3/4690-074-0530SSS, 3/8-16 X 1/2790-076-103PIN, 3/8 X 1.0 DOWELEP 424 Rotating Head Assembly81-304-00261816123471352417202223212141511925INSTALLATION WITHALIGNMENT GAUGEWEIGHT: 52.5 lbs / 23.8 kgITEMPART NUMBER QTY.DESCRIPTION119-087-004O-RING -015223-203-004SPACER323-209-001BODY, INDEPENDANT CHUCK423-211-014BUSHING, CHUCK BODY523-212-004BUTTON, INDEPENDANT CHUCK623-213-004LEG, INDEPENDANT CHUCK (NOT SHOWN)723-214-014LEG, 11.18 - 13.15823-214-024LEG, 14.43 -16.50 (NOT SHOWN)923-214-034LEG, 16.87 -18.81 (NOT SHOWN)1023-214-044LEG, 19.31 -21.30 (NOT SHOWN)1123-214-054LEG, 22.28 -24.28 (NOT SHOWN)1223-215-004JAM NUT, MODIFIED1323-221-004SPACER, CHUCK LEG1481-079-002GAUGE1581-080-004SCALE, GAUGE1681-149-001MANDREL, INDEPENDENT CHUCK1781-151-001FACE PLATE1890-060-072SHCS, 5/16-18 X 3/41990-069-122INSERT, 5/16-18 X 1.5 D (.47 LG) HELICAL2090-071-114HHCS, 3/8-16 X 1 INCH GRADE 82190-095-054NUT, 1/2-13 HARDENED2290-095-564WASHER, 1/2 SELF ALIGN FEMALE2390-095-574WASHER, 1/2 SELF ALIGN MALE2490-099-134INSERT, 1/2-13 X 1.5D (.75 LG.) HELICAL2590-099-304STUD, 1/2-13 x 42690-209-014SSS, 5/8-11 x 1 SWIVEL PADEP 424 10”-24” Independent Chuck81-305-002122113131411194810151732311689202265718SHOWN FOR REF OF LOCATIONOF ITEM #16WEIGHT: 26.5 lbs / 12.0 kg ITEMPART NUMBERQTYDESCRIPTION166-043-001WIPER, FELT276-170-001RULER LABEL381-062-001BASE PLATE481-064-006SHCS, 3/8-16 X 1-1/4 CAPTIVATED581-065-001MALE SLIDE681-066-001TOOL SLIDE SPACER781-067-001FEED NUT881-068-002BUSHING981-069-001FEED SCREW1081-070-001STAR WHEEL1181-071-002SHIM1281-072-001PUSH PLATE1381-154-002GIB1481-155-002PLATE, WEAR1581-156-001CLAMP, 5/8-18 COLLAR1681-157-001CAUTION TAPE1790-027-031KEY, 1/8 SQ X 3/81890-052-053BHCS 1/4-20 X .50 LG 1990-064-038SSS, 5/16-18 X 3/82090-064-057SSS, 5/16-18 X 1/22190-070-108SHCS, 3/8-16 X 12290-072-072BHCS, 3/8-16 X 3/42390-076-103PIN, 3/8 X 1.0 DOWELEP 424 Single Point Slide Assembly81-306-00429835761WEIGHT: 5 lbs / 2.2 kgITEMPART NUMBER QTY. DESCRIPTION152-140-006PLUNGER, BALL256-073-004SCREW, 1/4 TOGGLE366-117-006LEVER, TRIP481-074-001TRIP COLLAR WELDMENT590-042-046BHCS, 10-32 X 3/8690-045-016NUT, 10-32 JAM790-045-026NUT, 10-24 JAM890-057-556SHSB, 1/4 X 1/2990-900-626KNOB, 10-32 X 3/4 BLACKEP 424 Trip Assembly81-307-00183128171425231516930328293319242067101324521121112627335223436WEIGHT: 32 lbs / 14.5 kgITEMPART NUMBERQTYDESCRIPTION160-1186-001LCSF FLOW DIRECTION LABEL260-198-001VALVE, MRV DIRECTIONAL CONTROL360-199-001MANIFOLD, SDB HYDRAULIC476-072-001PLATE, MRV ANTI-ROTATION576-073-001CAP, MRV OPERATOR676-074-001SPRING, TORSION776-075-001PLATE, SPRING COVER876-176-001VALVE, PRESSURE RELIEF976-177-001VALVE, PRESSURE COMPENSATED FLOW CONTROL1076-180-001RING, 26MM EXT RETAINING1176-181-001DETENT SPRING1276-182-001SPACER1376-183-001HANDLE, 5/16"-181476-185-001FLOW CONTROL LABEL1581-032-001COUPLING, MOTOR ADAPTER1681-058-001ADAPTER, HYDRAULIC MOTOR1781-063-001SPACER, MANIFOLD1881-146-001HYDRAULIC MOTOR1990-026-561PIN, 1/8 x 5/8 ROLL2090-026-582PIN, 1/8 X 7/8 ROLL2190-026-612PIN, 1/8 X 1.125 ROLL2290-046-501PIN, 3/16 X 1/2 ROLL2390-054-021SSS, 1/4-20 x 1/42490-055-181NUT, 1/4-20 ACORN2590-059-4811/4 x 1 WOODDRUFF KEY2690-061-404HHCS, 5/16-18 X 4"2790-065-524WASHER, 5/16 FLAT2890-078-674O-RING -1122990-088-842PLUG, -04 ZERO-LEAK ORB3090-088-868PLUG, -06 ZERO-LEAK ORB3190-090-152SHCS, 1/2-13 X 1-1/23290-098-791ADAPTER, 1/2 NPT M X 1/2 ORB M - STRAIGHT3390-098-891ADAPTER, 1/2 ORB M X 1/2 NPT M - 903490-401-011LABEL, EYE PROTECTION3590-401-041LABEL, CRUSH AND CUT3690-402-011LABEL, PRESSURE-HYD.EP 424 Hydraulic Drive Assembly81-310-00MOTORDIRECTIONALCONTROLVALVEFLOWCONTROLVALVEPRESSURERELIEFVALVE:DEFAULTSETTING2000 PSI Hydraulic SchematicEP 424 Hydraulic Drive Assembly81-310-004910311625181271413WEIGHT: 24.5 lbs / 11.1 kgITEMPART NUMBER QTY. DESCRIPTION166-100-001VALVE; SPEED CONTROL271-032-001O-RING, (-124)381-031-001HOUSING, AIR MOTOR ADAPTER481-032-001COUPLING, MOTOR ADAPTER581-073-001ADAPTER, THROTTLE LEVER681-141-001AIR MOTOR781-158-001THROTTLE881-159-00191SSS, 1/4-20 x 1/4100SQUARE KEY, 1/4 x 1-3/4 116SHCS, 5/16-18 X 3/4122SHCS, 5/16-18 X 1.0131NIPPLE, 1/2 CLOSE LP BLACK141LABEL, CRUSH AND CUTEP 424 Air Drive Assembly81-311-00321546ITEMPART NUMBER QTY. DESCRIPTION181-160-001STOP, AXIAL FEED281-161-002ROLLER390-056-102PIN, 1/4 X 1.00 DOWEL490-201-111HXCS, 5/8-11 X 1-1/4590-205-591WASHER, 5/8 FLAT690-205-031NUT, 5/8-11 HEAVY HEXEP 424 Safety Stop Assembly81-316-00Chapter 9, Accessories and Spare PartsChapter 9Accessories and Spare PartsACCESSORIESThe following accessories and options are available for the EP 424:Table 1: EP 424 Accessories and OptionsPart Number Description81-400-00 Single-point upgrade kit for form tool EP-424 con-figurations (81-000-01/81-000-02)81-303-01 Extension leg kit for standard mandrel81-305-00 Independent chuck mandrel81-315-00 Short perch centering mandrel81-310-00 Hydraulic drive assembly81-311-00 Air drive assembly26-407-00 Air treatment moduleIn This ChapterACCESSORIESTOOLINGE.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 97EP 424 End Prep MachineTOOLINGThe following tooling is available for the EP-424. Table 2: EP 424 Facing ToolingPart Number Description56-708-01 Low-range facing tool insert holder kit, including holder, insert screws, and wrench56-708-02 High-range facing tool insert holder kit, including holder, insert screws, and wrench56-711-01 Premium grade HSS 2 sided insert for facing and beveling.56-712-01 Carbide 2 sided insert for facing and beveling.56-710-01Insert holder kit. Includes low-range holder kit (56-708-01), high-range holder kit (56-708-02), and 37.5° bevel insert holder (56-709-03).56-SPT-02 Custom HSS facing tool bit, ground to customer specification. (Specific part no. assigned on order.)56-SPT-10Custom form tool or single-point insert holder, ground to customer specification. (Specific part no. assigned on order.)Table 3: EP 424 Beveling ToolingPart Number Description56-709-02 30° bevel tool insert holder kit, including holder, insert screws, and wrench56-709-03 37.5° bevel tool insert holder kit, including holder, insert screws, and wrench56-709-0120° 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 exten-sion.56-709-0520° J bevel high-range insert holder kit, including holder, insert screws, and wrench. Use with 56-708-01 facing insert holder for 0.040” land exten-sion.56-711-01 Premium grade HSS 2 sided insert for facing and beveling.56-712-01 Carbide 2 sided insert for facing and beveling.56-711-02 Premium grade HSS 2 sided 3/32” J bevel insert. Used with 56-709-01 and 56-709-05 holders.98 Part No. 81-MAN-00, Rev. 0-0610 E.H. WachsChapter 9, Accessories and Spare Parts: Tooling56-712-02 Carbide 2 sided 3/32” J bevel insert. Used with 56-709-01 and 56-709-05 holders.56-707-00 10° x 37.5° compound bevel form tool.56-710-01Insert holder kit. Includes low-range holder kit (56-708-01), high-range holder kit (56-708-02), and 37.5° bevel insert holder (56-709-03).56-SPT-01Custom HSS single angle bevel tool bit, ground to customer specification. (Specific part no. assigned on order.)56-SPT-03Custom HSS compound angle bevel tool bit, ground to customer specification. (Specific part no. assigned on order.)56-SPT-04Custom HSS single angle J bevel tool bit, ground to customer specification. (Specific part no. assigned on order.)56-SPT-05Custom HSS compound angle J bevel tool bit, ground to customer specification. (Specific part no. assigned on order.)Table 4: EP 424 Counterbore and I.D. ToolingPart Number Description56-702-01 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.)56-705-03 4:1 taper counterbore tool (1.375 required between mandrel and I.D.)56-SPT-06Custom HSS I.D. deburring tool bit, ground to cus-tomer specification. (Specific part no. assigned on order.)56-SPT-07Custom HSS counterbore tool bit, ground to cus-tomer specification. (Specific part no. assigned on order.)Table 3: EP 424 Beveling ToolingPart Number DescriptionE.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 99EP 424 End Prep MachineTable 5: EP 424 Tooling AccessoriesPart Number Description56-190-00 Insert screw, used with all EP 424 insert holders.56-191-00 Insert screw Torx wrench.100 Part No. 81-MAN-00, Rev. 0-0610 E.H. WachsChapter 10, Ordering InformationChapter 10Ordering InformationTo place an order, request service, or get more detailed information on any E.H. Wachs products, call us at one of the following numbers:U.S. 800-323-8185International: 847-537-8800You can also visit our Web site at:www.ehwachs.comORDERING REPLACEMENT PARTSWhen 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 INFORMATIONPlease 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 equip-ment, please include the following information:In This ChapterORDERING REPLACEMENT PARTSREPAIR INFORMATIONWARRANTY INFORMATIONRETURN GOODS ADDRESSE.H. Wachs Part No. 81-MAN-00, Rev. 0-0610 101• Your name/company name• Your address• Your phone number• A description of the problem or the work to be done.EP 424 End Prep MachineBefore we perform any repair, we will estimate the work and inform you of the cost and the time to complete it.WARRANTY INFORMATIONEnclosed 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 ADDRESSReturn equipment for repair to the following address. E.H. Wachs600 Knightsbridge ParkwayLincolnshire, Illinois 60069 USA102 Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs About This Manual Purpose of This Manual How to Use The Manual Symbols and Warnings Manual Updates and Revision Tracking Safety Operator Safety Safety Symbols Protective Equipment Requirements Safety Labels Introduction to the Equipment Overview of the EP 424 Form-Tool Configuration Single-Point Configuration EP 424 Components Drive Motors Accessories Specifications Capacities Dimensions and Weights Operating Envelope Assembly, Disassembly, and Storage Packaging Storage Checklist Operating Instructions Mounting the Mandrel on the Pipe Mounting the Universal (Standard) Mandrel Mounting the Independent Chuck Mandrel Using the Drive Motors Mounting and Operating the Air Drive Mounting and Operating the Hydraulic Drive Form Tool Operation Planning the Operation Operating Envelope Selecting Tooling Adjusting the Tool Holder Positions Setting Up and Mounting the EP 424 Assembling the Machine Components Removing the Machine from the Workpiece Single Point Operation Installing the Single-Point Kit Planning the Operation Operating Envelope Selecting Tool Holder Beveling O.D. Set-Back Setting Up and Mounting the EP 424 Assembling the Machine Components Using the Speed Prep Autofeed Compound Bevel Removing the Machine from the Workpiece Removing the Single-Point Kit Routine Maintenance Lubrication Main Drive Assembly Felt Wipers Single-Point Slide Mandrel Drive Motor Lubrication Service and Repair Adjustments Adjusting the Single-Point Slide Tighten the Starwheel Stop Collar Adding/Removing Gib Shims Adjust the Push Plate Set Screws Calibrating the Speed Prep Scale Air Motor Manual Parts Lists and Drawings Accessories and Spare Parts Accessories Tooling Ordering Information Ordering Replacement Parts Repair Information Warranty Information Return Goods Address assembly drawings R0 release.pdf 81-000-01 page1 81-000-02 page1 81-000-03 page1 81-000-04 page1 81-300-00 cropped 81-301-00 cropped 81-302-00 cropped 81-303-00 page1 81-304-00 page1 81-305-00 page1 81-306-00 page1 81-307-00 cropped 81-310-00 page1 81-310-00 page2 schematic 81-311-00 page1 81-316-00 cropped