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1. GaNDNOL 5 1 00 960 96 INNYOOT 00 560 98 0096098 6 18 1 00610968 d38WfN LdVd WALI 1 55 Part No 66 01 Rev A E H Wachs SDB 412 and FF 424 Bearing Housing Assembly 66 304 00 MAWASSVY ONISNOH NIVN 00 06 99 ZL 0046099 Ol 1 0078099 6 00 60 99 8 00186099 4 ONRVJS JNOO 0066099 9 0060099 S PNT WILL 0080099 p 0060099 ONNMV38 0007098 6 dVNS ONR 0066098 d3J8WfN LdVd E H Wachs Part No 66 01 Rev 56 Parts Lists and Drawings Feed Housing Assembly 66 305 00 18W3SSV 35001 03446 20 8 1 99 WW ONIY 0334 38 v1 l SALON pS dIQNVH 8900606 Sc 6X9L8 E SS 007 006 6 XOCY l SOHS v 0005006 v EXOCv l SOHS 2 14009006 20 8 9 XOTW L SOHS 8 9005006 IZ TAMOG 009 X 5281 Z 5097006 61 NMOHS LON WU ONIY 0334 T139v1 20 61 99 vl 108699 6 po dVMS 0066099 8 pA 2 00466199 9 ONISNOH 1 00 061
2. Wachs 600 Knightsbridge Parkway Lincolnshire IL 60069 www ehwachs com SDB 412 and FF 424 User s Manual E H Wachs Part No 66 MAN 01 Rev A March 2013 Copyright O 2013 E H Wachs All rights reserved This manual may not be reproduced in whole or in part without the written consent of E H Wachs EU DECLARATION OF CONFORMITY WITH COUNCIL DIRECTIVE 2006 42 EC Issue Details Date Place 1 1 2011 E H Wachs Lincolnshire IL USA Directives Machinery Safety Directive 2006 42 EC Conforming Machinery End Prep and Flange Facing Machines Model TSE FSE and TFS Tube and Fitting Squaring Machines Model SDB 103 SDB 206 and SDB 412 Small Diameter Bevelers Model FF 206 FF 313 and FF 424 Flange Facers Model SB LB and MB Plus Boiler Tube Bevelers EP 424 End Prep Flange Facer 18 000 XX TSE FSE 19 000 XX TFS 16 000 XX SDB 103 FF 206 56 000 XX SDB 206 FF313 66 000 XX SDB Model Number 412 FF 424 70 000 XX SB 71 000 XX MB Plus 72 000 XX LB 81 000 XX EP 424 Manufacturer E H Wachs 600 Knightsbridge Parkway Lincolnshire IL 60069 USA Responsible Representative Orbitalum Tools GmbH Josef Sch ttler Str 17 78224 Singen Germany Tel 49 0 7731 792 872 Fax 49 0 7731 792 566 EN ISO 12100 1 2003 A1 2009 EN ISO 12100 2 2003 A1 2009 EN 60204 1 2006 for electric machines EN ISO 13857 2008 EN 982 1996 A1 2008 for hydraulic machines
3. N E IN3W3OVON3 4 TYNAIAIGNI 00 6 17 99 33S 7 z9 1761 2 805 10020 167010 2 2 cz 8 6 Jl S JONV ONIdWY TO po E 0010 18511 __ 060 p m 16 6 _ 790 TAPA 0019 13348 3334 XvW Wda OZ oez 16 8 LZ 881 sree Z Lez 8161 21760 gt NOILQTOA33 JIGNVH 1334 aad 6176 80 0334 1 E H Wachs Part No 66 01 Rev 40 Operating Envelopes FF 424 Flange Facer Hydraulic Drive 66 000 FH 172811 10 9 34O3MIS TV1OL 181 add ce L 28007 31vX 0334 011 15 0051 amp uiw OE WdO 8 AAV AL SIN3W3IRn 8711 JOOL INASNI XVW 00 017 9S 1001 FJONVA E 0221 00 61 96 08 44 5 SJONVY 7 282 TYNGIAIANI 404 10 r1F 99 335 ZI 0 1 925121 67 80 296 67 0 9 JONVY S3ONV3 IWNGIAIGNI 404 10 17 99 33S d 1 66118210 2212 1780 8091 JONV v6S 5 R T340NYW NO IN3W3OVON3 QV33HL SJONVY c9 TWNGIAIGNI
4. 002 094 6 OnnvagdAH 805 diOJINVW 00 61 09 8 Z 31ON 335 JO8INOO AAW 00386009 4 144 1 45 1 00 9811 09 9 o 0 YOLOW CAAH NOLOW AOLdVaV YOLOW AOLdVAV 00 202 20 87 650 06 ASGWNN LalVd SHOVM H 3 LOVINOD SLN3W3OV 1d33l 404 SAWOD A33 GT 29 820 06 338WfN SHOVM LOVINOD SIN3W3OV 1d33 YOLOW S3WOO ONIR O Zll l 31ON CN CO UD NOLLdIH5S3d 5 d38WfN Ld Vd 65 Part No 66 01 Rev A E H Wachs SDB 412 and FF 424 66 Part No 66 01 Rev E H Wachs Chapter 6 Ordering Information Ordering Information In This Chapter To place an order request service or get more detailed information on any E H Wachs products call us at one of ORDERING REPLACEMENT the following numbers PARTS REPAIR INFORMATION U S 800 323 8185 WARRANTY INFORMATION International 847 537 8800 RETURN GOODS ADDRESS You can also visit our Web site at www ehwachs com ORDERING REPLACEMENT PARTS When ordering parts refer to the drawings and parts lists Please provide the part description and part number for all parts you are ordering REPAIR INFORMATION Please call us for an authorization number before returning any equipment for repair or factory service We will adv
5. NOTE Use 90 PSI maximum air pressure Higher air pressure increases the loads and stresses on the tool parts sockets and fasteners and may result in breakage Higher air pressure also increases the sound level of the tool E Form Tool Installation Procedure Setting Up The Form Tools Refer to tool selec tion chart Install the facing tool in beveling head All tool bits must be installed so the cutting edge will contact the pipe when rotating in a clockwise direction as seen from rear of machine The tool bits are locked into place with the set screws ad jacent to the slot CAUTION Do not allow tool to come in with mandrel or dam age will CAUTION Disconnect the air supply when ever changing or adjusting the form tool FF 424 FLANGE FACING SYSTEM SECTION V FF 424 SET UP AND OPERATING PROCEDURES 2 Start machine and turn feed nut in until of variables inherent in a portable machine of this cutting tool contacts the pipe Continue type Check tooling facing until pipe has a clean finish Retract e To high of an operating speed or to great of a the beveling head Turn off machine and radial feed rate for the material being machined insert O D beveling tool 5 INTERMITTENT CUTS When working on a rough 3 Start machine again and feed beveling tool cut end of a piece of pipe or a warped flange the into the pipe until facing tool touches again need to do an intermittent cut does exist In order Adjust O
6. 410 1334 aad 21 2 80 0314 gt 7 lt 86 SAONVA 911 NOISN31X3 4 10 40 99 33S 26 26 SJON SYUILIWITTIW 33V SLAAOVA NI SNOISNIWIG E H Wachs SDB 412 and FF 424 FF 424 Flange Facer Air Drive 66 000 FF 2 91 ISd 06 3ain SS3ad EN sns SYALAWITIIW 34V S139 VH9 SNOISNAWIG 1 72811 1079 37085 1V1OL 16 87 4 av 9 Z 28007 31v8 Q334 i 1 84111 1001 L33SNI XVW 00 012 95 1001 JONVA EM 107211 00 761 95 77 EUG 08 Clg rel ER v9 8 v 690 807213 SJONVY 931 TYNAIAIGNI 10 71 99 33S 2155 19 51216880 656 i 7612 JONVY ONIdWYT1O 2111 4694 609 a i 134 06706 SIONVY 00 vC 2 N IWNGIAICNI 3O4 10 17 99 335 169621 M leszel 18 910 1 61011880 4911 o N JONV3 ONIJWY 1O 6897 e 2 81 im _ 2 A I 1 i 99 E SJONV3 931 18
7. 5 18 2 00 101 99 I19VWISNFrAV 1 5 0096099 z TANGNVW 0 871 I 00426099 E H Wachs Part No 66 MAN 01 Rev A 62 Flange Facer Conversion Kit 66 421 00 ITEM PART NUMBER DESCRIPTION 66 404 00 SINGLE POINT FF TOOL SLIDE 3 8 THRU 24 66 415 00 66 01 EXTENSION ADAPTER ASSEMBLY MANUAL SDB 412 FF 424 NOTSHOWN 40400 I 41500 I 1 E H Wachs Part No 66 01 Rev A Parts Lists and Drawings 63 SDB 412 and FF 424 Pneumatic Drive 56 302 00 NOlD3lONd3A3 ava 13gV 1 0140F06 S 440554 4 avi I 0010060 edldvav 06 dHWIdNZ LXWIdNC I S996006 lOMINOO MOTH 0000099 6 93345 MOT3NDHOL NOIOW 104095 184 Wall 1 E H Wachs Part No 66 MAN 01 Rev A 64 Parts Lists and Drawings Hydraulic Drive 56 413 00 4 04 8088 Lx v 1 1 8745006 96 OZ H LINN 1 8099006 72 TION 82171 8 13 4 2 1992006 zz IZ 6 TION 8 5 X 8 1 134 11 41 MOH 81 491 6 44 5 SNIaldS ONINIV I33 1X3 WW9Z 1OHINOD GALVSNAdWOD 38055380 3ATVA E LL NOlV3ddO AMW dvO 1 006 09 OL NOILVIOsHINV AJW 1 14
8. be faced Figure 16 DEREN d Figure 13 NOTE Use 90 psi max air pressure Higher air pressure increases stresses and loads on the machine com ponents and fasteners which may result in break age Higher air pressure also increases the sound decibel level of the tool 15 Setthe throttle control valve The FF424 is equipped with a throttle control valve to meter the airflow to the motor Rotating the throttle clock wise will open the valve counter clockwise Figure 15 rotation will close the valve Figure 14 Figure 16 17 Rotate the axial feed handle assembly clockwise until the tool bit just touches the desired surface to be faced Figure 14 18 Again rotate the tool slide starwheel nut raising the bit just above the surface to be faced 32 FF 424 FLANGE FACING SYSTEM SECTION V FF 424 SET UP AND OPERATING PROCEDURES 19 Using the infeed indice guage rotate the NOTE axial feed handles clockwise until the de A general rule of thumb is to take light cuts sired depth of cut is attained Figure 17 to clean up the flange face To produce a 500 3 a RMS or record groove finish best results are achieved with a finish cut depth of 007 to 008 7 A Figure 17 20 Tighten the machine mandrel locking set screws with the provided hex key set Figure 18 Figure 19 IMPORTANT Tighten both locking set screws equally Apply ten
9. 53 Part No 66 01 Rev E H Wachs SDB 412 and FF 424 Standard Mandrel Assembly 66 301 01 9 Tu E 9 2887 9 8990006 O 23 ann 005899 e Lc 09995 EJ 8 4 O 6 1 6 01 SOHT 06 00 20 99 Z Sr 008 1 0031099 9 INIWATIM 00 10 99 G3NDNOL 9 0 INNYOOT 1 00 98098 1 0096098 1 006 096 1 8 LYVd WALI 1 Wachs Part No 66 01 Rev 54 Parts Lists and Drawings Standard Mandrel Assembly with Legs 66 407 01 UWL SZE G G amp T 0801 6911 A18W3SSV O31 UUB 662 L OZT OS LL v9 OL ATAWASSV 6 8 OSOL v9 6 A1aW3SSV UWO r 616 086 798 AIGWASSV uwz EZ 1761 18 8 794 N1SW3SSV uuuue 861 7891 1982 799 ATaW3SSV WO l r Erl 199 Se S ATEWAISSV 19 7 17811 186 699 AIGWASSV O31 1X3 NOILLdIYIS3GA G4SN 80 580 99 L0 S80 99 90 S80 99 79 70 9 C0 890799 LO S80 99 ON LuVd W3L TIONS 7X8 l NId 9 86902006 aanv 1 0096099 OL GdIONSV ddS dB3HM 6 INN I 0076099 4 Bw XonHO AdOS 1 0091099 INAWATAM 1 0021099
10. 304 00 S 17 99 33S Z gt 8051 10066 I cel ez zl D 1761 ST JONV3 ONIJdWY TO GZ 00 19 6 G l 16 24 H 7 ST 00 10 0 22 TA 951 JIGNVH 1334 43d 121721 80 0334 gt 12 ONIMS 690 807213 7609 007720 is y 6967 69 11 N I 13346 3334 XVW uiw WdO 8 6 Wd EZ Su3 L3WITTIW 38V SL3340V88 NI SNOISNAWIC 4 Part No 66 01 Rev A E H Wachs SDB 412 and FF 424 Standard Mandrel Assembly 66 301 01 DIMENSIONS IN BRACKETS ARE MILLIMETERS 22 97 583 4 53 78 MIN LEGS SHOWN FULLY RETRACTED 21 50 546 1 04 95 __ 125 7 2 SHOWN FULLY EXTENDED 42 Part No 66 01 Rev E H Wachs SDB 412 Tooling Charts The following charts and diagrams specify tooling for bev eling deburring J prep and counterboring with the SDB 412 E H Wachs Part No 66 01 Rev A SDB 412 Tooling Charts 43 SDB 412 and FF 424 Beveling ANGLE Bevel Tool Chart MAX WALL Deburring Deburring Tool Chart PIPE I D DEBURRING TOOL MIN PIPE I D MAX PIPE I D 56 702
11. 424 4 Part No 66 MAN O1 Rev A E H Wachs Chapter 2 Safety Safety E H Wachs takes great pride in designing and manufactur ing safe high quality products We make user safety a top priority in the design of all our products Read this chapter carefully before operating the SDB 412 FF 424 It contains important safety instructions and rec ommendations OPERATOR SAFETY Follow these guidelines for safe operation of the equip ment READ THE OPERATING MANUAL Make sure you understand all setup and operating instructions before you begin INSPECT MACHINE AND ACCESSORIES Before starting the machine look for loose bolts or nuts leaking lubricant rusted components and any other physical conditions that may affect operation Properly maintaining the machine can greatly decrease the chances for injury ALWAYS READ PLACARDS AND LABELS Make sure all placards labels and stickers are clearly legible and in good condition You can purchase replacement labels from E H Wachs KEEP CLEAR OF MOVING PARTS Keep hands arms and fingers clear of all rotating or moving parts E H Wachs Part No 66 01 Rev A In This Chapter OPERATOR SAFETY SAFETY LABELS Look for this sym N bol throughout the manual It indicates a personal injury hazard SDB 412 and FF 424 Always turn machine off before doing any adjustments Or service SECURE LOOSE CLOTHING AND JEWELRY Secure or remove lo
12. 66 000 FH 1HOI3H 81 X uuuse9 X HLON31 Uturelll ZY SNOISN3WIG DNIddIHS I X 06 7 1 SOHS 00 80 99 6 Ga1vAlLdvO 8 6 X 1 06 SOHS 00 80 99 1 1134 00 70 99 2 v 6 ANIHOVW 35001 d3ddlHS 1 SALON NMOHS LON 1 6 91 6 HON34M 29 008 06 OG NMOHS LON 135 8 6 91 6 07 008 06 61 NMOHS LON 8 1 1 62 008 06 8 NMOHS LON 135 7 1 9 6 90 008 06 21 6 1 XOcv l SOHS 2 21 050 06 91 9 2 00 152 0 7 9009006 91 NMOHS LON 44 219 846 TYNNYN 1 LO NVW 99 Fl A18W3SSV 331dVGV NOISNALX3 00 18 99 21 5931 TANGNVW 1 10 17 99 6 76 NAHL 86 IANS 1001 dd INIOd 31ONIS I 007099 LL A18W3SSV ONISNOH Q334J 0050699 01 A18W3SSv ONISNOH I 00270699 6 NMOHS LON GALVAILdVO LXOc v L SOHS 2 008099 8 NMOHS LON G3lVAlldvO 8 6 X 00 9 1 SOHS 0098099 2 NMOHSION 3OV3NOIS 3SVO 0057099 9 NMOHS LON 1134 4 2 00 70 99 S NMOHS ION 4354 104198 ATAWASSV 1 6061 9095 NMOHS LON X3OL HON3NM 0016 98 z NMOHS LON 4 35 2 38vl 00000198 1 1 194253 LdVd W3ll
13. 99 ANNONS ONINIVI3J O19809 MJHSVM 00 0099 LAN 0334 00 10 99 z pI WNL 00497098 NOILdIYIS3G Y39WNN LuVd WALI 57 Part No 66 01 Rev E H Wachs SDB 412 and FF 424 Main Housing Assembly 66 303 00 ITEM PART NUMBER DESCRIPTION 66 001 00 HOUSING BEARING 66 030 00 66 032 00 ITEM PART NUMBER DESCRIPTION 1 6600500 1 MHEAD ROTATNG NOTES 1 ONE FELT WIPER 66 043 00 SHIPPED LOOSE WITH ASSEMBLY 58 Part No 66 01 Rev A E H Wachs e Parts Lists and Drawings Flange Facer Slide 66 404 00 4 5 Er 6 9 9 SN i N 5 4 4 SNIHOVW 3SOO1 5 00 014 96 IN3SNI 1001 1 SALON VARE d 18 v X 26 01 JONA NMOHS LON 14 9 v X 8 6 133205 NMOHS LON 13HO1V3 3AING 9 6 HON3NM NMOHS LON 31 331 8 1 HON33M 1015 06 6 1 LAN 29 006 06 85 008 06 Sy 008 06 6 008 06 01 560 06 Nid 8 6 01 1 1 X91 8 SOHS 01 940 06 21 020 06 v X 81 91 S SOH8 80790706 2 1 1 WYT 1 06 LAN v X Oc v l SSS 99 90 06 70 VS0 06 80 090 06 20 050 06 90 090 06 90 970 06 06 6 8 6 X 66 01 SOH8 TION v X 8 1 70 070 06 00 811 99 0
14. After 40 hours of operation flush the air motor with a solution of three parts cleaning solvent and one part air motor oil After flushing add oz 30 cc air motor oil into air line and run air motor for one minute It is very important that the components of the mandrel assembly remain clean and free from corrosion The legs and machine surfaces should be cleaned and oiled on a daily basis MANDREL STRESS INSPECTION PROCEDURE 1 The mandrel should be removed from the machine body and inspected after every twenty hours of operation 2 Remove the drawbar nut 66 025 00 and the collar nut 66 024 00 3 Remove the mandrel from the machine body by rotating the feed handles counter clockwise 4 Physically examine the mandrel and threads look for any signs of wear or damage 5 Measure the length of the threaded drawbar If the draw bar length is 21 1 2 the drawbar may remain in use If the length of the drawbar is equal to or exceeds 22W in length the drawbar is no longer safe and should be replaced 18 SDB 412 2 SMALL DIAMETER BEVELER INSERT TOOLING CHART HSS OR CARDBIDE FACE BEVEL INSERT HSS OR CARDBIDE J PREP INSERT INSERT TOOL HOLDER KIT INCLUDES 20 BEVEL HOLDER 37 1 2 BEVEL HOLDER 2 SCREWS 1 WRENCH 1 HOLDER LOW RANGE FACING HOLDER SHOWN CONVERSION CHART ORIGINAL REPLACEMENT REPLACEMENT TOOL INSERTS TOOL STANDARD JPREP HOLDER Facing low range 56 708 01 56 701 01 Fa
15. by holder and insert combinations and are now available only by special order contract manufacturer for pricing and availability 20 SDB 412 2 SMALL DIAMETER BEVELER SDB 412 EXTENSION LEG CHART Captivated Screw Keg Design Extensions Required Pipe I D Range 66 085 01 4 67 5 83 66 085 02 5 67 6 83 66 085 03 6 67 7 83 66 085 04 7 66 8 83 66 085 05 6 66 9 83 66 085 06 9 66 10 82 66 085 07 10 66 11 82 66 085 08 11 66 12 82 NEW LEG DESIGN OCTOBER 1992 21 22 FF 424 FLANGE FACING SYSTEM SECTION FF 424 INTRODUCTION The following is a listing of individual controls and components that are important to the successful operation of the FF 424 Prior to attempting to set up and operate the FF424 it is recommended that you become familiar with these items A POWER HEAD K AIRMOTOR B FLANGE FACING MODULE AIRINLET C TRIP RING AND TRIPS M ADJUSTABLE SPEED CONTROL D LIFTING HANDLE N ON OFFLEVER E AXIALINFEED HANDLES F TOOL HOLDER SLOT 0 MANDREL G TOOL HIGH amp LOW RANGE MANDREL ADAPTOR CONE 8 5 12 8 RANGE H MACHINE LOCKING SCREWS 0 MANDREL ADAPTOR CONE 12 7 20 0 AXIAL INFEED INDICE DIAL RANGE J STARWHEEL MANDREL EXPANSION NUT S ADAPTOR CONE MOUNTING SCREWS 3 EACH LEG SETS PER SET WITH 1 ADJUSTABLE U ALIGNMENT FIXTURE 23 FF 424 FLANGE FACING SYSTEM SECTION VI FF 424 MAINTENANCE Under normal operating conditions
16. operate and maintain the equipment The narrower column on the outside contains additional information such as warnings special notes and defini tions Refer to it for safety notes and other information E H Wachs Part No 66 01 Rev A Chapter 1 About This Manual In This Chapter PURPOSE OF THIS MANUAL How TO UsE THE MANUAL SYMBOLS AND WARNINGS MANUAL UPDATES AND REVISION TRACKING Throughout this manual refer to this column for warnings cautions and notices with supplementary information SDB 412 and FF 424 WARNING gt A WARNING alert with the safety alert symbol indicates a potentially hazardous situa tion that could result in seri ous injury or death CAUTION gt A CAUTION alert with the safety alert symbol indicates a potentially hazardous situa tion that could result in minor or moderate injury CAUTION A CAUTION alert with the damage alert symbol indi cates a situation that will result in damage to the equipment IMPORTANT IMPORTANT alert with the damage alert symbol indi cates a situation that may result in damage to the equipment N SYMBOLS AND WARNINGS The following symbols are used throughout this manual to indicate special notes and warnings They appear in the out side column of the page next to the section they refer to Make sure you understand what each symbol means and follow all instructions for cautions and warnings T
17. or other coolant generously This will also increase cutter life 3 Adjust cutting head RPM for material A good rule of thumb is the harder the material the slower the speed 4 Always keep a lot of pressure on the feed nut and pull out of cut quickly when prep is finished Tips for a good finish SINGLE POINT FLANGE FACING BEVELING MODULE 1 Always place mandrel as close to pipe end as possible 2 Use a cutting coolant generously This will also increase cutter life 3 The feed rate for each trip is 005 per revolution 4 CHATTER Tool chatter occurs when the tool begins to vibrate during a cut Excessive tool chatter can cause poor quality surface finishes Chatter can be caused by any one of a number 36 Operating Envelopes Operating Envelopes The following pages illustrate the dimensions and operating envelopes for all configurations of the SDB 412 and FF 424 E H Wachs Part No 66 01 Rev A 37 SDB 412 and FF 424 SDB 412 Air Drive 66 000 01 Sy lt 9 154 06 4 uitu 668711 WD 56 INOILdWNSNOD SIN3W33IQO33 1 C 4S6 v6 LT TaAVaL ZOOL 66 1001 ONIT3A38 ONIO V 10 11 96 CNV 133SNI 20 86 1 95 lt 82 29 eS 57 338 GILOWALIM ATINA NMOHS 5911 391M32019 NOILQTOA33 JIGNVH 1334 43d 101 2
18. plate with the dowel pins on the machine head and insert plate Figure 4 FF 424 FLANGE FACING SYSTEM SECTION V FF 424 SET UP AND OPERATING PROCEDURES C BEVELING MACHINE OPTION SET UP AND OPERATION INSTRUCTIONS Extension Leg Selection 1 The FF 424 BEVELER uses one mandrel assem bly with the addition of eight leg extension sets to cover its entire operating range 3 780 to 12 82 l D 2 The mandrel itself has three permanently mounted chuck legs which expand or contract to the inside wall of the pipe with or without extension legs when the draw bar nut is rotated 3 To determine which extension leg set is required measure the work piece pipe 1 0 Refer to the extension leg selection chart Each extension leg will be stamped with its part number for easy identification 4 Select the required extension leg set The exten sion legs fasten to the permanently mounted chuck legs with two captivated socket head cap screws in each leg Mounting the Mandrel Assembly Into the Pipe NOTE It is recommended to mount the mandrel by itself and then install the machine onto the mandrel to Insure proper squaring of machine and avoid operator injury 1 Insert the blade end of mandrel into the pipe For best results keep the end of the blades as close to the pipe edge as practical The maximum depth of penetration into the pipe should be 3 4 19mm from the tapered ends of the leg to the end of the pipe Be cert
19. the bevel gear 4 Physically examine the mandrel and threads look for sets and roller bearing should be inspected every 100 any signs of wear or damage hours of operation and lubricated as needed If exceptionally difficult work has been performed or if 5 Measure the length of the threaded drawbar If the excessive coolant has contaminated the gear sets and drawbar length is 21 1 2 the drawbar may remain in use roller bearings inspection and lubrication should be If the length of the drawbar is equal to or exceeds 22 in done much more frequently length the drawbar is no longer safe and should be re placed The bore of the cutting head feed nut and mandrel must be kept cleaned and oiled MAIN SHAFT BEARING PRE LOAD Lock nut tool required wachs part 66 141 00 After the first ten hours of operation the mainshaft bearing preload should be checked Remove the air motor Remove the 6 1 4 20 x 7 8 SHCS to remove feed nut housing 66 002 00 Bend the lock washer 66 034 00 tab clear from the locknut 66 033 00 In sert and tighten an old used tool bit into one of the slots on the cutting head Clamp machine into a bench vise Using the lock nut tool and a torque wrench tighten locknut to 150 ft lbs while rotating the main housing Once tight re secure lock washer tang into the closest locknut slot Replace feed nut housing and fasteners Replace and secure air motor After every ten hours of operations inspect the man d
20. 0 211 29 LS 970 06 66 v 610 06 CC 11 99 00 00 11 99 4 gt 5 9935 32018 00 21 1 99 00 11 1 99 30115 31 14 180ddNS 00 01 1 99 00 601 99 JOA 5 1431 3 34415 00 801 99 00 90 1 99 3Svg I31V 1d 00 501 99 00 990 99 SNI dS 43ONN 1d 00 70 99 00 6 10 99 334 NMOHS LON MOT 103 33q1OH 00 S 10 29 607 12 95 JONVA HOIH ONIOV JONV 14 4 1 3110901 7 M3N2S 0 14 99 00 40 96 1435 TOOL 6 00 01 96 6 6 TIVE ASONN Id 00 07 1 06 NOILdIYIS3G Ld Vd 59 Part No 66 01 Rev A E H Wachs Leg Replacement Set 66 411 00 SDB 412 and FF 424 A18W3SSV O3INOISN3IX3 80 580 09 6 AIGWASSV O31NOISN3IX3 7058099 8 AIGWASSV Od31NOISN3IX3 90 58099 4 AIGWASSV O31NOISN3IX3 lt 50 58099 9 AIGWASSV O31NOISN3IX3 058099 S A18W3SSV O3I1NOISN3IX3 lt 058099 v AIGWASSV Od31NOISN3IX3 27058099 MAWASSV O3INOISN3IX3 10 58099 6 NOILdIYDS3G LdVd WALI Wachs Part No 66 01 Rev A 60 e Parts Lists and Drawings Fitting Mandrel 66 414 01 lesze 18 21 172061 60701 18 8821 LI 18 0 21 89701 6 6 186601 166 976121678 88611 68 2281
21. 01 3 78 96 0mm 11 25 285 7mm 56 702 02 3 78 96 0mm 11 84 300 1mm 56 702 03 4 03 102 4mm 12 47 316 7 44 0 Part No 66 MANOLRev A EH Wachs SDB 412 Tooling Charts J Prep J Prep Tool Chart 15 LAND EXTENSION 3 8 NOTE 1 TOOL RETAINED WITH AT LEAST 2 SCREWS BEVEL TOOL FACING TOOL 56 709 01 56 708 01 1 68 42 7mm 3 78 96 0mm 10 72 272 3mm 14 03 356 4mm 56 709 05 56 708 01 1 68 42 7mm 3 78 96 0mm 12 23 310 6mm 15 56 395 2mm Counterbore Counterbore Tool Chart 149 COUNTERBORE PIPE I D DEPTH NOTE 1 TOOL RETAINED WITH AT LEAST 2 SCREWS C BORETOOL MINPIPELD MIN C BORELD C BOREI D 1 MAX DEPTH MAS DEPTH og 56 05 01 3 78 96 0mm 3 78 96 0mm 11 83 300 5mm 0 63 16 0mm 0 48 12 2mm 56 705 02 4 27 108 5mm 4 52 114 8mm 12 95 328 9mm 0 63 16 0mm 0 48 12 2mm 56 705 03 5 27 133 9mm 5 52 140 2mm 13 95 354 3mm 0 63 16 0mm 0 48 12 2mm E H Wachs Part No 66 01 Rev A 45 SDB 412 and FF 424 46 Part No 66 01 Rev E H Wachs Parts Lists and Drawings The following pages illustrate the components for the SDB 412 and FF 424 Use the parts list on each drawing to order replacement parts E H Wachs Part No 66 01 Rev A Parts Lists and Drawings 49 SDB 412 and FF 424 SDB 412 Air Drive 66 000 01
22. 1 680 0334 lt vegg XVW 16722 GJANALX3 ATINA 5 5941 25211 560 NMOHS 931 196 NIW 8L E s 13346 3344 XV W SAONVA ONIJWY O 911 NOISN3LX3 10 20 29 445 ALON S4313WNITIIW 33V SLAWOVA NI SNOISNAWIG E H Wachs Part No 66 01 Rev 38 Operating Envelopes SDB 412 Hydraulic Drive 66 000 03 2011 ISd 0051 SINAWIAAINO AS r 3 86 LlLl 39 07 62 uiu OE WdO 8 Ol vadAH 13AVAL 120011 BE GJANALX3 ATINS NMOHS 8911 L Vom XVW S6 v 9 1001 NIBA38 ONIOVJ 2 _ 10 112 95 ov 5 CNV mL LASNI 20 861 95 o lt 5 196 _ 2 NMOHS S931 NIW 8260 2 rd 1112 99 DE 29 211 cS c 2 841 gt 806 i Ne 2 esiz 878 13346 Z uiu OE Wd 8 6 Wd EZ d m 335 ATINI NMOHS 5931 L LEZ 8 96 2160 06610
23. 12174 187991 169 9 87 65876 18 1611 619 176117 eS v 17506 10721 8987 60 11 897 lt 01 c OSZ 58 6 LET 6176 16121188 5611 697 18 8 11 804 81911769 057 129 e871 5079 191111 v VIC 561 5 76 VIG NOISN3WIG NOI Ldld2S3G SYSLAWITTIW 38V S130 V88 NI SNOISN3WIG 90 v60 99 SO 60 99 YO 60 99 Jl8visnfav wl 09099 70909 109099 2090099 909 099 508099 608099 770809 Jig visnrav G4SN 383HM 90 60 99 50 660 99 70 60 99 20 260 99 20 660 99 0 260 99 20 220 99 020599 9 70 210 99 60 220 99 20 220 99 779 1uVd NOILdld2S3G 4 J19VISNFAV vid 041 wl J19VISNrAV 931 951 333HA 951 v 1 02 6 1 SOHS 11 8 6 1 81 91 6 13MOQ v X 91 6 v X 81 91 S SOHd 6 X 81 91 S SOHS dil 5588 7 6 X 00 1 SSS G3SN 45 060 06 90 690 06 20 990 06 6 0 090 06 8 690 06 11 8 ON83dS AAH 6 1 X 06 1v 1 83HSVM 8 2 X OG H 1 5 AlaWASSV GOY 81 640 06 6 06 00 98 1 99 OO GE 1 99 7 9 JOV4 S1V1d NMOHS LON 3ONVY 931 139 1 NMOHS LON 3ONV 931 38 V1 1 99 00 92 0 660 99 00 660
24. 1HOI3H 81 X HIGIM 184448691 480 HION31 Zr SNOISN3WIG ONIddIHS gt GI31vAlldvO I X 06 7 SOHS 00 80 99 2 2 8 6 X 02 7 1 SOHS 00 980 99 1 NIHOVW 3SOO1Q3ddlHS 11 S3LON NMOHS LON 3IGNVH L 6 91 6 HON3N4M 29 008 06 61 NMOHS LON 135 8 6 91 6 HON3HM _ 008 06 81 NMOHS LON NOILVNISGWOO 8 l L HON34M 60008 06 41 NMOHS LON 13 1 79 6 90 008 06 91 81 91 6 SOHS 6 21 090 06 91 y XOTH L SOHS 141 050 006 8 4 1 v 8005004 NMOHS LON b r 61 805 1 LONYW 99 zi A18W3SSV TANGNVW Q3vQONVIS 1 10 0599 11 A18W3SSV ONILVLOYN AYVANVLIS 1 00 90 99 OL 18 1355 ONISNOH 0050699 6 A18W3SSV ONISNOH 00 708 99 8 NMOHS LON G31lVAlldvO LX Oc v L SOHS Z 00 8099 4 NMOHS LON d31VAlldvO 8 6 XOc v L SOHS 0099099 9 NMOHS LON JOVAOIS 35 I 00 97099 NMOHS LON 4354 4 ONIIOOI 10 01595 A18W3SSV lv 1 00 08 95 5 ION 18871 00 660 95 z MJOVdS ONM 1 000109 NOILdIYIS3G Y39WNN Ld Vd Wall E H Wachs Part No 66 MAN 01 Rev A 50 Parts Lists and Drawings SDB 412 Hydraulic Drive 66 000 03 I X HIG
25. 22 Now time the starwheel In order to prevent sion in order to pre load machine to mast allow damage to machine the star wheel must be axial feed handles to rotate while also under ten timed prior to engaging any trips Figure 20 sion Figure 18 Figure 20 21 Engage the desired number of trips on the 2 trip collar assembly to achieve the surface finish 23 The machine is now ready to cut Press the required Figure 19 Refer to flange surface trip alr motor lever to begin cutting chart 33 FF 424 FLANGE FACING SYSTEM SECTION V FF 424 SET UP AND OPERATING PROCEDURES B FLANGE FACER TO BEVELING MACHINE CONVERSION PROCEDURE 1 Remove the flange facer mandrel from the machine body Figure 1 Figure 1 2 Remove the flange facer tool slide module by removing the four 3 8 16 x 1 1 4 SHCS using the provided hex key set Figure 2 Figure 2 3 Remove the trip collar assembly from the flange facer machine housing by loosen ing the six locking socket set screws Figure 3 34 NOTE When reinstalling the trip ring assembly center cut out relief on trip ring over the air motor housing for proper trip lever location Be sure that ring sits flush against housing all around Figure 3 4 Mountrotating tool holder plate on machine rotating NOTE Be sure to install the felt washer Coat the washer with light oil Place into recessed hole in rear of tool holder plate Align dowel pin holes in
26. 66 094 09 66 094 10 66 094 11 66 094 12 66 094 13 66 094 14 66 094 15 66 094 16 NOTE SOLID LEGS 66 077 01 MUST BE INSERTED INTO MANDREL 66 414 00 PRIOR TO NUMBER 66 090 00 OR 66 092 00 MANDREL ADAPTOR NIETHER MANDREL ADAPTOR THREE SOLID LEGS ARE NOT IN THE MANDREL BODY NOTE ALWAYS INSERT LEGS WITH POINTED END INTO MANDREL DAMAGE WILL RESULT IF INCORRECTLY INSTALLED 26 FF 424 FLANGE FACING SYSTEM SECTION VIII FF 424 CONSUMABLE SELECTION GRAPHS BEVELING MACHINE LEG EXTENSION CHART Captivated Screw Leg Design Extensions Required Pipe D Range NONE 3 78 4 90 66 085 01 4 67 5 83 66 085 02 5 67 6 83 66 085 03 6 67 7 83 66 085 04 66 8 83 66 085 05 8 66 9 83 66 085 06 9 66 10 82 66 085 07 10 66 11 82 66 085 08 11 66 12 82 NEW LEG DESIGN OCTOBER 1992 27 FF 424 FLANGE FACING SYSTEM SECTION VIII FF 424 CONSUMABLE SELECTION GRAPHS BEVELING AND MACHINE TOOLING SELECTION CHART TOOL BIT CUTTING EDGE 15 10 1 0 Deburring 56 702 01 For low range 1 0 pipe or tube 10 1 0 Deburring 56 702 02 For mid range 1 0 pipe or tube N N A 10 1 0 Deburring 56 702 03 For high range 1 0 pipe ortube N A 20 J Bevel 56 703 00 For low range O D pipe or tube 1 50 38 1 mm 20 J Bevel 56 702 02 For high range O D pipe or tube 1 50 38 1 mm Small 4 1 Taper Medium 4 1 Taper Large 4 1 Taper Counterbore 56 705 03 For high range O D p
27. 99 NMOHS LON 3558018 18 NMOHS LON 3OV3OIS 18 318v1Snf QV VIG 1 5 1IHANVYW MOJI 8761 88 AALdVaV 318v1Snf Qv MANOS AdOS GINDNOL 5 2NIMV38 LANYOOT aVEMVAC LNN NOILdld2S3G 007860799 00 60 99 00 9 60 99 00 060 99 0076 0799 0078 0799 00 700 99 00 9 0 9S 00 SE0 9S 00 520 95 d38WfN 4 61 Part No 66 01 Rev A E H Wachs SDB 412 and FF 424 Leg Extension Adapter 66 415 00 c 808 10702 6 6871 62 61 1971 91 28 81 leest 58 1 loser 61 11 8 917 179 78661 69 S 1 0861 Z6 v1 6 19 SZ v1 9 69 61 648v 12 61 96971 6781 le 157 2771 locer S071 8 717 66791 879661 19 81 27822 68 71 6 6S 17 9 Lr 1 62616 01 VIG NOISN3WIQ Sd3L3WITTIW 38V 1330 V88 NI SNOISN3WIC 9 1 760 99 9 prem 06099 414 16 wl 80 7 60 99 80 660 99 10 7 60 99 20 660 99 NOILdld2S3Q un Ld Vd Wall NOILdIYIS3G un 1d Vd WALI ITAVISNFAV dasn 333HA 6 VIG ut OF a y aasn 8 v L TXOTT L SOHS 28 060 06 Z TIVE 2 1 81 91 6 114 S 069006 9 NMOHSION 3ONYV3 10 001 99 S NMOHS LON SONVA 00 01 99 f NMOHS LON
28. ALL DIAMETER BEVELER BEVELING AND FACING USING THE FLANGE FACER MANDREL FOR CENTERING ON ELBOWS AND BENDS 1 Measure the pipe D Select the extension leg set required Refer to flange facer mandrel leg extension chart NOTE Set up the flange facing mandrel with machine body removed Insert the legs into the mandrel head NOTE Adjustable leg adjustment screw must be completely tightened against leg face Place the mandrel assembly into pipe Position the adjustable leg at the short radius bend portion of pipe FIG 12 and snug the draw bar nut NOTE Legs should be kept as close as pos sible to the pipe edge yet back far enough to perform the desired operation Short Radius Band Fig 42 8 CHECK MANDREL CENTERING Measure the distance over the adjustable leg from the pipe I D to the mandrel shaft Then measure the same distance 1800 from the adjustable leg When the mandrel is centered these two measurements will be approximately equal NOTE If additional centering is required and man drel removal is necessary utilize the alignment fixture to insure returning the legs to the original set up location Place the alignment fixture on the mandrel shaft push it forward to meet the pipe face and snug the fixture in place Remove the mandrel make the leg adjustment needed Re insert the mandrel and alignment fixture Make sure 17 the adjustable leg is located at the s
29. AlLdvO I X OZ v 1 SOHS 00 90 99 2 G3a1vAlldvO 8 S X 00 9 1 SOHS 00 980 99 1 134 83dIM 00 670 99 Z dNIHOVW 35007 5 S31 1 NMOHS LON 37ANWH 1 6 91 6 HONISM 29 008 06 NMOHS LON 136 9 6 91 6 HON33M 008 06 IZ NMOHS ION 8 1 1 60 08 06 OG NMOHS LON 136 7 1 F9 S 90 008 06 61 1 1 81 91 9 SOHS 21 090 06 91 1 XOTH L SOHS 2 21 050 06 21 8 XOCv l SOHS 8005006 91 NMOHS LON 6 6 845 TYNNYN 1 LONVYW99 SL A18W3SSV NOISN3IX3 0091 99 vl 5041 TANGNVW 1 10 10 99 70 NAHL 8 2 JANS TOOL 44 INIOd FIONIS 1 00 07 99 21 A18W3SSV ONISNOH d33d 00 906 99 LL A18W3SSV ONISNOH 00 06 99 OL NMOHS LON dilVAlldvO Oc r L SoOHS 2 00478099 6 NMOHS LON Ga1WAlldWO 8 6 XOc vy L SOHS 0099099 8 NMOHSION 3OV3OIS 3 VO 00 50 09 NMOHS LON 1134 2 00 00 99 9 NMOHS LON 1 10195 S A18W3SSV NOLOW 0000696 v NMOHS ION XNHOL HON3N3M 00 161 95 NMOHSION d43SVO 38 1 0000198 z NOlILdIlH2S3Q d38WfN LuVd E H Wachs Part No 66 01 Rev 52 Parts Lists and Drawings FF 424 Flange Facer Hydraulic Drive
30. An adjustable leg has been provided to compen sated centering on slip over or butt welded flanges when mandrel placement must be inside the pipe I D Figure 4 FF 424 FLANGE FACING SYSTEM SECTION V FF 424 SET UP AND OPERATING PROCEDURES 6 Insert the leg set into the adapter Figure 5 8 Slide the flange alignment fixture over the mandrel shaft Figure 7 Figure 5 Figure 7 7 Place the mandrel assembly into the flange D with one leg at the 6 o clock position 9 Extend the alignment arms if necessary with The legs should be kept as close as possible the supplied hex key set Figure 8 to the flange 1 0 edge yet back far enough to perform the desired operation Snug the man drel into place by tightening the draw bar nut Figure 6 with the supplied 1 1 8 wrench NOTE Observe the mandrel keyway slots When the slots are at the nine o clock and three o clock position the flange facer motor position can be placed at the six o clock or twelve o clock location Position the mandrel slots at the desired location for air motor clearance or operation Figure 8 10 Loosen the mandrel assembly using the draw bar nut and push the alignment fixture firmly against the flange face Retighten the draw bar nut with the supplied 1 1 8 wrench Figure 9 Figure 6 30 FF 424 FLANGE FACING SYSTEM SECTION V FF 424 SET UP AND OPERATING PROCEDURES Figure 9 11 Install the flange facing m
31. D beveling tool in or out radially to prolong tool life and reduce shock loads on the depending on the land thickness desired machine and inserts intermittent cuts should be done at a slower speed and feed rate Once a full 4 The last tool bit to install is the 1 0 deburring cut is achieved operating speeds can be in tool It should be placed in the slot opposite the creased to normal machining procedures beveling tool It may also require adjustment in or out to produce the desired height and depth 6 As you finish a pass note your location on the indiced axial feed gauge Then to take your NOTE If only two tools are to be used place next pass rotate the feed handle backwards 1 full them in opposite slots to offset cutting load turn to your noted location and retract your tool slide Once retracted rotate the feed handle in Continuous Operation Once the cutting tools are the amount you wish for the cut depth of your in place the machine can be moved from one pipe to next pass This will allow you to retract the slide another of the same size without resetting the tool with out damaging the tooling remove all back bits lash in the feed handle and give you an exact depth of cut on your next pass F Tips For a Good Finish 7 To produce a 500 RMS or record groove finish the 1 Always place mandrel as close to pipe end as best results are achieved with a finish cut depth of possible 007 to 008 2 Use a cutting oil
32. E CONNECTIONS 4 MAKESURE THE CUTTING TOOL IS SEATED PROPERLY AND TIGHTENED AS WELL 5 BE SURE THAT THE WORKPIECE IS WITH IN THE MACHINES OPERATIONAL CAPACITY IN THE HAZARDOUS ZONE THERE 15 A HIGH RISK OF ENTANGLEMENT MAGHINE NOISE LEVELS NOTE NOISE LEVELS HAVE BEEN MEASURED AT 1 METER HIGH AND 1 6 METERS AWAY CONTINUOUS W WEIGHTED SOUND PRESSURE LEVEL AT WORK STATION 62 DB A PEAK C WEIGHTED MAXIMUM SOUND PRESSURE 95 DB C SOUND POWER LEVEL EMMITED BY MACHINE 89 DB A IMPORTANT ALWAYS WEAR HEARING PROTECTION WHEN OPERATING THIS OR OTHER WACHS MACHINERY 11 SDB 412 2 SMALL DIAMETER BEVELER 1 Select proper leg extension for pipe 1 0 use 4 Mount the mandrel into the pipe by tightening leg extension chart on pg 4 Secure legs to the draw bar nut to 90 ft lbs Move the man mandrel by tightening two captivated shcs drel back and forth as well as up and down to using provided hex key set help assure a proper fit Securely snug the draw bar nut Fig 3 NOTE Each extension leg will be stamped with it s part number for easy identification NOTE Place mandrel shaft keyways in relationship to keys located in machine sothat appropri 2 It is recommended to mount the mandrel by U ate air motor location is achieved itself and then install the machine onto the mandrel to insure proper squaring of machine and avoid operator injury 5 Prepare to mount beveling machine ont
33. EN 983 1996 for pneumatic machines EN 13732 1 2006 EN ISO 14121 1 2007 EN ISO 13850 2008 for pneumatic machines Provisions with which Essential Health and Safety Requirements of Annex 1 of the Conformity is Declared Machinery Directive We hereby certify that the machinery described above conforms to the provisions of Council Directive 2006 42 EC on the approximation of the laws of the Member States relating to the safety of machinery VAM Signatory Pete Mullally Quality Manager E H Wachs Harmonised Standards amp Other Technical Standards Specifications Applied or Referenced About This Manual PURPOSE THIS MANUAL This manual explains how to operate and maintain the SDB 412 small diameter beveler SDB and FF 424 flange facer It includes instructions for set up operation and maintenance It also contains parts lists diagrams and ser vice information to help you order replacement parts and perform user serviceable repairs Before operating the machine read through this manual and become familiar with all instructions How TO USE THE MANUAL 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
34. IM uuusgeo X HLONAT L SNOISNJWIO ONIddIHS 7 81 57 Qa1vAlldvO I 02 1 SOHS 00 80 99 6 Q31vAlldvO 8 6 X 02 7 1 SOHS 00 980 99 1 JQNIHOVW 3S001G3ddIHS l NMOHS LON 410 1 6 91 6 29 008 06 21 NMOHS LON 135 8 6 91 6 HON34M 07 008 06 9l NMOHS LON NOILVNISWOO 8 1 1 60 008 06 Sl NMOHS LON 136 79 S HONISM 9000806 vl 6 XOTH L SOHS 2 21 050 06 ZI 8005006 5208 007 8 4 NMOHS LON 4 017 805 IWANVW IONVW 99 LL A18W3SSV TANGNVW QalVQNVIS 100099 0 A18W3SSV ONILVION Q3VQONVIS 00 006 99 6 AldW3SSv 0050699 8 A18W3SSV 00 06 09 Z NMOHS LON d lVAlldvO I 06 1 5 5 Z 00478099 9 NMOHS LON G31vAlldvO 8 6 XOc v L SOHS 00 98099 S 5 1 358018 3570 00 97099 f NMOHS LON 4354 10 01 95 A18W3SSV JAINA OFINVAGAH 1 60 10 98 6 NMOHS LON 1391 00 660 95 NOILdld 5S3G 1 4 WALI 51 Part No 66 01 Rev A E H Wachs SDB 412 and FF 424 FF 424 Flange Facer Air Drive 66 000 FF 1HOI3H Sr 81 X HIGIM uuuse9 ST X HION31 18444 6 1 SNOISN3WIG ONIddlHS Q31v
35. achine on the mandrel shaft Be sure to wipe the mandrel clean NOTE Align the internal machine keys with the mandrel keyway slots Engage the internal machine keys on the mandrel keyway slots Push the machine forward Rotate the handle assembly clockwise engaging the machine feed nut into the threaded portion of the mandrel shaft Figure 10 Figure 10 12 Install the tooling onto the flange facer tool slide slot Refer to the tool holder tool bit diagram Figure 11 31 NOTE Machine rotates clockwise as viewed from the rear of the machine Cutting bit must face clockwise Figure 11 13 Tighten the tool bit locking set screws with Figure 12 Figure 12 14 Attach the air supply Press the air motor lever and rotate the machine slowly to verify clearance Figure 13 IMPORTANT E H Wachs Co recommends the use of an ATM air treatment module P N 26 407 00 to filter air and lubricate the air motor The air motor warranty will be void if an ATM is not used FF 424 FLANGE FACING SYSTEM SECTION V FF 424 SET UP AND OPERATING PROCEDURES NOTE Adjust the cutting head RPM with the throttle control for flange size being machined Rule of thumb 3 to 4 RPM s recommended for 20 to 24 flange O D Increase 5 as flange sizes become smaller 16 Rotate the starwheel nut with the supplied 3 4 socket and ratchet Figure 15 until the tool bit tip is flush with the desired surface to
36. ain that there is adequate clearance between the blades and the 1 0 tooling This will allow for a normal prep and still keep the beveling head rigid 2 Move the mandrel back and forth and up and down while tightening the draw bar nut The chuck legs will automatically help center the machine Torque the draw bar nut to 90 ft Ibs Important Place mandrel shaft keyways in re lationship to locating keys in machine to select air motor operating location 35 D Mounting Machine Assembly On Mandrel 1 Inspect the bore of the beveling head for dirt and metal chips Clean the bore with compressed air or solvent as necessary 2 Wipe the mandrel clean and apply a light coating of oil 3 Insert the machine body over the mandrel being careful not to scrape the head bushing 4 Align the keys in the machine with the keyway slots in the mandrel Push the machine forward until the feed nut and threaded portion of mandrel shaft meet 5 Rotate feed handle assembly clockwise engag ing feed nut and machine with mandrel 6 Next tighten the machine mandrel locking set screws located on either side of the machine body using the provided hex key set Tighten both locking screws equally Applytension in order to pre load the machine to the mast and remove any play 7 Connect a clean dry 90 PSI air supply to machine It is recommended to use an ATM air treatment module in the air line to filter the air and lubricate the air motor
37. cing high range 56 708 02 56 709 01 56 709 02 56 709 03 56 711 01 56 712 01 56 711 02 56 712 02 56 700 02 37 1 2 beveling 45 beveling 56 709 04 LOW HIGH RANGE FACING HOLDER USAGE CHART 2 5 8 thru 13 37 low range 56 708 01 3 82 97 mm 11 16 283 mm eae 66 005 00 low range 856 708 01 4 80 122 mm 12 14 308 mm INSERT BEVELING HOLDERS ARE DESIGNED FOR USE WITH EITHER LOW RANGE OR HIGH RANGE FACING TOOLS ON ALL APPLICATIONS LOW RANGE FACING HOLDER 56 708 01 HEIGHT 1 25 HIGH RANGE FACING HOLDER 56 708 02 HEIGHT 1 50 19 SDB 412 2 SMALL DIAMETER BEVELER TOOL BELT DESCRIPTION MAXIMUM NUMBER see note WALL sme NA Small 4 1 Taper For low range O D Med 4 1 Taper nk For mid range O D Large 4 1 Taper For high range O D NOTE Tool bit ranges listed are to be used as guides when performing simultaneous prepping Individual tool usage will expand the cutting range 20 J Bevel 56 704 00 Z 2 0 150 38 1 mm T 15 HSS A Tungsten type high speed steel very high hardness recommended for difficult to machine materials Alayerof Titanium Nitride to increase cutting life and performance Super hard composite steel material offering maximum edge strength coated carbide N A Not Applicable Available NOTICE Effective June 1995 Single piece tool bits shown on this page have been replaced
38. e in place the machine can be moved from one pipe to another of the same size without resitting the tool bits Tips For Good Finish 1 Always place mandrel as close to pipe end as possible 2 Use cutting oil or coolant generously This will also increase cutter life 3 Adjust cutting head RPM for material A good rule of thumb is the harder the material the slower the speed 4 Always keep a lot of pressure on the feed nut and pull out of cut quickly when prep is finished 14 SDB 412 2 SMALL DIAMETER BEVELER BEVELING MACHINE TO FLANGE FACER CONVERSION PROCEDURE 1 Remove the mandrel from the machine body Next loosen and remove the four 3 8 16 x 1 1 4 shcs securing the rotating tool holder plate Fig 1 Fig 3 4 Mountflange facing tool slide on macrune rotating head Align dowel pin holes in flange facer with the dowel pins on the machine head Fig 1 9 9 NOTE sure to install the felt washer Coat the washer with a light amount of oil in the rear of the flange facing module 2 Remove the rotating tool holder plate part 66 005 00 from the machine body by lifting it from the two dowel pins pressed into the rotating head Fig 2 Fig 2 3 Install the trip collar assembly onto the machine Fig 4 housing by tightening the six locking socket set screws located on the out diameter of the collar 5 Secure with four 3 8 16 x 1 1 4 shcs assembly Fig 2 NOTE When
39. h 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 512 6 Hearing Protectors 1 THIS MACHINE HAS BEEN DESIGNED WITH VIBRATIONAL CONCERNS IN MIND 2 IF EXCESSIVE VIBRATIONS OCCUR RATE MAY BE TOO FAST AND OR NOT ENOUGH THIS CAN USUALLY BE CORRECTED BY TAKING A DEEPER CUT 3 CHECK THE POWER SUPPLY HOOKUP FOR ANY LOOSE CONNECTIONS 4 MAKE SURE THE CUTTING TOOL IS SEATED PROPERLY AND TIGHTENED AS WELL 5 BE SURE THAT THE WORKPIECE IS WITHIN THE MACHINES OPERATIONAL CAPACITY E H Wachs Part No 66 01 Rev A Chapter 2 Safety Operator Safety SDB 412 and FF 424 MACHINE NOISE LEVELS NOTE NOISE LEVELS HAVE BEEN MEASURED AT 1 METER HIGH AND 1 6 METERS AWAY CONTINUOUS W WEIGHTED SOUND PRESSURE LEVEL AT WORK STATION 62 DB A PEAK C WEIGHTED MAXIMUM SOUND PRESSURE 95 DB C SOUND POWER LEVEL EMMITED BY MACHINE 89 DB A SAFETY LABELS The following safety labels are on the SDB 412 If the stick ers are damaged or missing replace them immediately See Ordering Information at the end of this manual Keep Hands Clear Figure 2 1 The Warning sticker is on the SDB 412 Do not pu
40. his 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 This is the equipment damage alert symbol It is used to alert you to poten tial equipment damage situations Obey all messages that follow this sym bol to avoid damaging the equipment or workpiece on which it is operating Part No 66 MAN O1 Rev A E H Wachs Chapter 1 About This Manual Manual Updates and Revision Tracking NOTE This symbol indicates a user note Notes provide additional information to supple ment the instructions or tips for easier operation MANUAL UPDATES AND REVISION TRACKING Occasionally we will update manuals with improved opera tion or maintenance procedures or with corrections if nec essary When a manual 18 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 E H Wachs Part No 66 01 Rev A A NOTE provides supple mentary information or oper ating tips Current versions of E H Wachs manuals are also available in PDF format You can request an electronic copy of this manual by email ing customer service at sales ehwachs com SDB 412 and FF
41. hort radius bend Push the assembly tight against the pipe face and tighten the mandrel The legs should be at the origi nal set up location If the pipe end is square the align ment fixture will square the mandrel shaft to the pipe If additional centering is required loosen the mandrel and adjustable leg NOTE One complete revolution of the adjustment screw is equal to 0 050 thousandths 1 19 mm of travel on the small legs and 056 thousandths on the large leg sets EXAMPLE If the distance over the adjustable leg between the mandrel shaft and pipe l D is one inch 1 and the distance 180 from the adjustable leg between the mandrel shaft and the pipe I D is 1 1 8 divide the difference in half 1 8 125 2 2 0625 1 167 Rotate the adjustable leg out approximately one and 1 8 turns Re insert the mandrel after making the centering adjustments Measure for centering again Repeat if necessary If the elbow or bend has a square end utilize the alignment fixture to square the mandrel shaft Place the fixture on the mandrel shaft and push it forward to meet the pipe face snug the fixture in place Loosen the mandrel assembly slightly push the fixture forward until it rests firmly against the pipe face and retighten the mandrel If the elbow or bend has been cut and is not square a reference point for squaring should be established Once established install the alignment fixture on the mandrel pushing it fi
42. installing the trip ring assembly center the cut out relief on trip ring over the air motor housing for proper trip lever location Be sure that ring sits flush against housing all around 15 SDB 412 2 SMALL DIAMETER BEVELER A FLANGE SURFACE TRIP CHART TRIP ENGAGEMENT 1 TRIP 2 TRIP 4 TRIP 6 TRIP 500 RMS B MANUAL BEVEL GENERATION USING SINGLE POINT MODULE A bevel can be generated by feeding the cutting tool into the work radially and axially simultaneously As the radial feed advances the tool automatically the operator must withdraw the tool by rotating the axial feed handle counter clockwise The correct amount of axial feed per machine revolution is given in the following chart For example to generate a 30 degree bevel with 6 trips engaged the fastest tool feed setting the operator must withdraw the cutting tool 018 each time the cutting tool completes a revolution This distance is represented by 018 18 thousandths increments on the calibrated feed dial located on the feed handle assembly MANUAL BEVEL GENERATION CHART TRIPS AXIAL FEED RATE REQUIRED PER MACHINE REVOLUTION Engaged 40 Bevel 20 Bevel 30 Bevel 37 1 2 Bevel _ er ww me 4 oe wr 3 wr we ww m _ 3 jr wr ww C TIPS FOR A GOOD FINISH SINGLE POINT FLANGE FACING BEVELING MODULE 1 Always place mandrel as close to pipe end as possible 2 Usethe cut
43. ipe or tube T 15 HSS A Tungsten type high speed steel very high hardness recommended for difficult to machine materials A layer of Titanium Nitride to increase cutting life and performance Super hard composite steel material offering maximum edge strength X X X X X X X X X X coated carbide N A Not Applicable Available NOTICE Effective June 1995 Single piece tool bits shown on this page have been replaced by holder and insert combinations and are now available only by special order contract manufacturer for pricing and availability 28 gt SECTION V FF 424 SET UP Measure the flange I D Refer to mandrel leg extension chart See page 13 To select the mandrel adaptor and leg Set required to mount in flange Insert the solid leg set 66 077 01 in the mandrel head POINT SIDE DOWN Figure 1 NOTE 66 077 01 solid leg set is required when installing the 66 090 00 adaptor or the 66 092 00 adaptor onto the mandrel head Figure 1 3 Mount the selected adaptor over the mandrel head and secure with the provided 3 SHCS Figure 2 29 FF 424 SET UP AND OPERATING PROCEDURES 4 Select extension leg set required Refer to the I D range chart decal provided on the leg extension box or on page 13 in this manual Figure 3 5 Install the adjustment screw into the adjust able leg and tighten completely Figure 4 ABOUT THE ADJUSTABLE LEG
44. ise you of shipping and handling When you send the equip ment please include the following information Your name company name Your address Your phone number A description of the problem or the work to be done E H Wachs Part No 66 01 Rev A 65 SDB 412 and FF 424 Before we perform any repair we will estimate the work and inform you of the cost and the time to complete it WARRANTY INFORMATION Enclosed with the manual is a warranty card Please fill out the registration card and return to E H Wachs Retain the owner s registration record and warranty card for your information RETURN GOODS ADDRESS Return equipment for repair to the following address E H Wachs 600 Knightsbridge Parkway Lincolnshire Illinois 60069 USA 66 Part No 66 01 Rev E H Wachs 5 Superior Equipment Complete Support 600 Knightsbridge Parkway Lincolnshire IL 60069 847 537 8800 www ehwachs com
45. o mandrel Inspect the bore of the beveling 3 Insert the blade end of the mandrel into the head for dirt and metal chips Clean the bore pipe 1 0 with compressed air or solvent as necessary NOTE Keep the machine ward end of the legs as 6 Wipe mandrel clean and apply a light coating close to the pipe edge as practical Max of oil depth of penetration into pipe should be 3 4 19mm from the machine ward end of the Slide the machine body over the mandrel legs to the edge of pipe being careful not to scrape the head bushing SDB 412 2 SMALL DIAMETER BEVELER 8 Align the keys in the machine with the key way slots in the mandrel Push the machine forward until the feed nut and the threaded portion of the mandrel meet 9 Rotate the feed handle assembly clockwise to engage the feed nut and machine with the mandrel Figure 5 Fig 5 12 10 Tighten the machine mandrel locking set screws located on either side of the machine body using the provided hex key set Tighten both locking screws equally Apply tension in order to pre load the machine to the mast and remove any play Fig 6 Fig 6 Fig 8 11 Connect a clean dry 90 psi air supply to the Fig 7 NOTE Use 90 psi max air pressure Higher air pressure increases the loads and stresses on parts and fasteners which may result in breakage Higher air pressure also increa
46. ose fitting clothing and jewelry and securely bind long hair to prevent them from getting caught in moving parts of the machine KEEP WORK AREA CLEAR Keep all clutter and nonessential materials out of the work area Only people directly involved with the work being performed should have access to the area Safety Symbols A This icon is displayed with any safety alert that indicates a personal injury hazard N WARNING This safety alert indicates a potentially hazardous situation that if not avoided could result in death or serious injury N CAUTION This safety alert with the personal injury hazard symbol indicates a potentially hazardous situation that if not avoided could result in minor or moderate injury Part No 66 MAN O1 Rev A E H Wachs Protective Equipment Requirements WARNING Always wear impact resistant eye pro tection while operating or working near this equipment For additional information on eye and face protection refer to Federal OSHA regulations 29 Code of Federal Regula tions Section 1910 133 Eye and Face Protection and American National Standards Institute ANSI Z87 1 Occu pational and Educational Eye and Face Protection Z87 1 is available from the American National Standards Institute Inc 1430 Broadway New York NY 10018 CAUTION Personal hearing protection is recom mended when operating or working near this tool Hearing protectors are required in hig
47. rel guide bushing for wear Replace as necessary NOTE Excessive chatter may indicate a worn man drel guide bushing After 40 hours of operation flush the air motor with a solution of three parts cleaning solvent and one part air motor oil After flushing add 1 oz 30 cc air motor oil into air line and run air motor for one minute It is very important that the components of the mandrel assem bly remain clean and free from corrosion The legs and machine surfaces should be cleaned and oiled on a daily basis MANDREL STRESS INSPECTION PROCEDURE 1 The mandrel should be removed from the machine body and inspected after every twenty hours of operation 2 Remove the drawbar nut 66 025 00 and the collar nut 66 024 00 3 Remove the mandrel from the machine body by rotating the feed handles counter clockwise 24 FF 424 FLANGE FACING SYSTEM SECTION VII FF 424 CHARTS AND GRAPHS A FLANGE SURFACE TRIP CHART C FLANGE FACING MODULE TOOL HOLDER TOOL BIT DIAGRAM TRIP ENGAGEMENT RMS FINISH 1TRIP 63RMS LOW RANGE TOOL HOLDER PART 56 193 00 RANGE 4 THROUGH 21 5 2TRIP 125 RMS 4TRIP 250 RMS 6TRIP 500 RMS B MANUAL BEVEL GENERATION USING SINGLE POINT MODULE A bevel can be generated by feeding the cutting tool into the work radially and axially simulta HIGH RANGE neously As the radial feed advances the tool TOOL HOLDER automatically the operator must withdraw the tool PART 56 192 00 by rotating
48. rmly against the pipe face Position the three legs so that one of the three jacking set screws in each leg is positioned over the pipe face Screw in the jacking set screws until the back side of the fixture plate is square to the ref erence point SDB 412 2 SMALL DIAMETER BEVELER SECTION VI MAINTENANCE Under normal operating conditions the bevel gear sets and roller bearing should be inspected every 100 hours of operation and lubricated as needed If exceptionally difficult work has been performed or if excessive coolant used inspection and lubrication should be done much more frequently The bore of the cutting head feed nut and mandrel must be kept cleaned and oiled After the first ten hours of operation the mainshaft bearing preload should be checked Remove the air motor Remove the 6 1 4 20x 7 8 SHCS to remove feed nut housing 66 002 00 Bend the lockwasher 66 034 00 tab clear from the locknut 66 033 00 Insert and tighten an old used tool bit into one of the slots on the cutting head Clamp machine into a bench vise Using the lock nut tool and a torque wrench tighten locknutto 150ft Ibs while rotating the main housing Once tight secure lock washer tang into the closest locknut slot Replace feed nut housing and fasteners Replace and secure air motor After every ten hours of operation inspect the mandrel guide bushing for wear Replace as necessary NOTE Excessive chatter may indicate a worn mandrel guide bushing
49. ses the sound level of the tool Setup the form tools Refer to the tool sel ection chart on page 17 Install the facing tool in the beveling head All tool bits must be installed so that the cutting edge will contact the pipe when rotating in a clockwise direc tion from the operators perspective Tool bits are locked into place with set screws ad jacent to the slot Fig 8 machine It is recommended to use an Air CAUTION Do not allow tool bit to come into Treatment Device in the air line to filter air and lubricate the motor Fig 7 13 contact with the mandrel or damage will result SDB 412 2 SMALL DIAMETER BEVELER CAUTION Disconnect the air supply whenever changing the form tools CAUTION Becertain the there is adequate clear ance between the mandrel legs and the tooling 13 Start machine and turn feed nut in until the cutting tool contacts the pipe Continue facing until pipe has a clean finish Retract bevel head and insert the O D beveling tool 14 Feed beveling head into the pipe until the facing tool bit touches again Adjust the O D beveling tool in or out radially depending upon the land thickness desired 15 The last tool bit to install is the 1 0 deburring tool It should be placed into the slot opposite the beveling tool This tool may also require some adjustment NOTE If only two tools are to be used place them in opposite slots to offset cutting load 16 Once the cutting bits ar
50. t your hands near the rotating head while the machine is running Part number 66 147 00 CAUTION Loud noise hazard and risk of eye injury Ear and eye protection must be worn Figure 2 2 The Caution sticker is on the SDB 412 air motor Wear ear and eye protection while operating the machine Part number 90 401 03 Part No 66 MAN O1 Rev A E H Wachs Chapter 2 Safety Safety Labels N CAUTION Figure 2 3 The air pressure limit label is on the air motor Part number 90 401 02 A CAUTION CAUTION Risk of eye Injury Eye protection must be worn Figure 2 4 The eye injury warning label is on the hydraulic drive Part number 90 401 01 2000 PSI 138 bar Figure 2 5 The hydraulic pressure limit label is on the hydraulic motor Part number 90 402 01 Figure 2 6 The hot surface warning label is on the hydraulic drive Part number 90 403 00 E H Wachs Part No 66 01 Rev A 9 SDB 412 and FF 424 10 Part No 66 MAN 01 Rev E H Wachs SDB 412 2 SMALL DIAMETER BEVELER SECTION II B SAFETY INSTRUCTIONS VIBRATION REDUCTION KEEP HANDS AWAY FROM 1 THIS MACHINE HAS BEEN DESIGNED WITH ROTATING CUTTING TOOLS VIBRATIONAL CONCERNS IN MIND 2 IF EXCESSIVE VIBRATIONS OCCUR RATE MAY BE TOO FAST AND OR NOT ENOUGH THIS CAN USUALLY BE CORRECTED BY TAKING A DEEPER CUT 3 CHECK THE POWER SUPPLY HOOKUP FOR ANY LOOS
51. the axial feed handle counterclock RANGE 6 25 wise The correct amount of axial feed per ma 8 chine revolution is given on the following chart THROUGH 24 0 For example to generate a degree bevel with 6 trips engaged the fastest tool feed setting the operator must withdraw the cutting tool 0181 each time the cutting tool completes a revolu TOOL HOLDER tion This distance is represented by 018 18 TOOL BIT thousandths increments on the calibrated feed dial located on the feed handle assembly PART 56 709 00 RANGE N A MANUAL BEVEL GENERATION CHART Engaged 10 Bevel 20 Bevel 30 Bevel 37 1 2 Bevel evo a w wr wr w w 25 FF 424 FLANGE FACING SYSTEM SECTION VIII FF 424 CONSUMABLE SELECTION GRAPHS ASSEMBLY SOLID LEG 2 PCS ADJ LEG 1 PC CHUCKING RANGE LEG SET PART LENGTH PART LENGH MIN DIA MAX DIA 66 414 00 manrel no adapter 3 75 8 5 range 66 414 00 mandrel 66 090 00 mandrel adaptor 8 4 12 8 range 66 414 00 mandrel 66 092 00 mandrel adaptor 12 7 20 0 range 66 077 01 66 077 02 66 077 03 66 077 04 66 077 05 66 077 06 66 077 07 66 093 01 66 093 02 66 093 03 66 093 04 66 093 05 66 093 06 66 093 07 66 093 08 66 093 09 66 093 10 66 093 11 66 093 12 66 093 13 66 093 14 66 093 15 66 093 16 66 078 07 66 094 01 66 094 02 66 094 03 66 094 04 66 094 05 66 094 06 66 094 07 66 094 08
52. ting coolant generously This will also increase cutter life 3 Thefeed rate for each trip is 005 per revolution 4 CHATTER Tool chatter occurs when the tool begins to vibrate during a cut Excessive tool 16 chatter can cause poor quality surface finishes Chatter can be caused by any one of a number of variables inherent in a portable machine of this type Check tooling To high of an operating speed or to great of a radial feed rate for the material being machined INTERMITTENT CUTS When working on a rough cut end of a piece of pipe or a warped flange the need to do an intermittend cut does exist In order to prolong tool life and reduce shock loads on the machine and inserts intermittent cuts should be done at a slower speed and feed rate Once a full cut is achieved operating speeds can be increased to normal machining procedures As you finish a pass note your location on the indiced axial feed guage Then to take your next pass rotate the feed handle backwards 1 full turn to your noted location and retract your tool slide Once retracted rotate the feed handle in the amount you wish for the cut depth of your next pass This will allow you to retract the slide without damaging the tooling remove all backlash in the feed handle and give you an exact depth of cut on your next pass To produce a 500 RMS or record groove finish the best results are achieved with a finish cut depth of 007 to 008 SDB 412 2 SM

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