ANUAL This manual explains how to operate and maintain the OW TO ANUAL EP 424 end prep machine. It includes instructions for set- up, operation, and maintenance. It also contains parts lists, YMBOLS AND ARNINGS diagrams, and service information to help you order...
EP 424 End Prep Machine OW TO ANUAL Throughout this manual, refer This manual is organized to help you quickly find the infor- to this column for warnings, mation you need. Each chapter describes a specific topic on cautions, and notices with using or maintaining your equipment.
RACKING Current versions of E.H. Occasionally, we will update manuals with improved opera- Wachs Company manuals tion or maintenance procedures, or with corrections if nec- are also available in PDF for- essary. When a manual is revised, we will update the mat.
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EP 424 End Prep Machine Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs...
We make user safety a top priority in the design of all our products. AFETY ABELS Read this chapter carefully before operating the EP 424 end prep machine. It contains important safety instructions and recommendations. PERATOR...
EP 424 End Prep Machine Always turn machine off before doing any adjustments or service. • SECURE LOOSE CLOTHING AND JEWELRY. Secure or remove loose-fitting clothing and jewelry, and securely bind long hair, to prevent them from getting caught in moving parts of the machine.
1910.95, Occupational Noise Exposure and ANSI S12.6 Hearing Protectors. AFETY ABELS The following safety labels are on the EP 424 machine. If a label is lost or unreadable, order and attach a replacement. See ordering instructions in Chapter 10. E.H. Wachs...
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EP 424 End Prep Machine Figure 2-1. Crush hazard safety label (part no. 81- 165-00). Figure 2-2. Crush and cut hazard safety label (part no. 90-401-04). Figure 2-3. Loud noise hazard safety label, provided with air drive configurations (part no. 90-401-03).
PECIFICATIONS PERATING NVELOPE The EP 424 is an I.D. (inside diameter) mounted end prep machine for facing, beveling, counterboring, and J-prep- ping pipes and flanges. It can be used for pipes from 4-24 inches O.D., with wall thicknesses up to 1.6” (41 mm) using form tools, or 6.5”...
EP 424 End Prep Machine tions. Tooling is available for facing, single-angle beveling, compound beveling, counterboring, The form tool configuration will perform end prepping (fac- ing, beveling, J-prepping, and counterboring), with the operator manually feeding the tool head. Figure 3-1. The photo shows the form tool configura- tion of the machine with the standard self-centering mandrel.
Chapter 3, Introduction to the Equipment: Overview of the EP 424 Figure 3-2. The photo shows the single-point configu- ration of the EP 424. EP 424 Components The following components are provided with the form tool configuration of the EP 424: •...
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EP 424 End Prep Machine • single-point slide Feed gauge Tool holder Feed screws Starwheel Male tool slide Figure 3-3. The single-point slide feeds the tool radi- ally across the pipe face. It is driven along a feed screw by a starwheel.
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Chapter 3, Introduction to the Equipment: Overview of the EP 424 • Speed Prep autofeed module WARNING Speed Prep module The Speed Prep autofeed can feed the machine until it comes off the mandrel. Crushing or other serious injuries could occur. Use the...
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EP 424 End Prep Machine • extension leg kit for standard mandrel Figure 3-7. Two sets of extension legs allow the stan- dard mandrel to be mounted in pipes up to 23.64” I.D. • dial indicator assembly Figure 3-8. The dial indicator is provided for center- ing the independent chuck in the pipe.
Chapter 3, Introduction to the Equipment: Overview of the EP 424 Drive Motors Two 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).
EP 424 End Prep Machine Both motors include adapters for the EP 424. The motors are interchangeable, requiring no modifications to the EP 424 machine. Accessories The following accessories are available for the EP 424: • Single-point upgrade kit, part no. 81-400-00 (for form- tool machine configuration);...
Chapter 3, Introduction to the Equipment: Specifications PECIFICATIONS Capacities Table 1: EP 424 Operating Capacities 95 cfm at 90 psi Air requirements (2690 l/min at 6.2 bar) Min 10 gpm/max 15 gpm at 2000 psi Hydraulic requirements (38/57 l/min at 138 bar) Axial feed 0.071”...
(940 x 922 x 566 mm) PERATING NVELOPE The 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) •...
Figure 4-1 shows the layout of the components in the case. There are lockdown pins for securing the EP 424 machine, as shown in Figure 4-2. Figure 4-1. The photo shows the EP 424 in its case. E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610...
EP 424 End Prep Machine Figure 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. TORAGE HECKLIST Before storing the EP 424, perform the following mainte- nance steps.
OTORS Typically, you will install the mandrel (either the standard PERATION or independent chuck mandrel) in the pipe before mounting the EP 424 machine. This makes it easier to align the man- INGLE OINT PERATION drel and mount the machine.
EP 424 End Prep Machine Mounting the Universal (Standard) Mandrel Measure the I.D. of the pipe. NOTE 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.
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#8, #4, #3, & #1 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 E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610...
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EP 424 End Prep Machine leg first, then “stack” them in size order. Make sure the legs seat squarely, then securely tighten the screws. NOTE Extension leg #1 does not have threaded holes to install other legs on top of it.
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A socket wrench and 1-1/16” socket are provided with the EP 424. Figure 5-4. Turn the drawbar nut counter-clockwise to retract the clamping legs. Insert the clamping legs into the I.D. of the pipe. Hold...
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EP 424 End Prep Machine Figure 5-6. Turn the drawbar nut clockwise until the clamping legs are snug in the I.D. of the pipe. Check that the legs are square on the pipe I.D., and are far enough from the pipe end for the operation.
See the envelope drawings in select the leg set listed in the column on the right. Chapter 3 for an illustration of the clamp leg configurations. E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610...
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EP 424 End Prep Machine Table 2: Independent Chuck Clamping Leg Chart I.D. Inches I.D. mm Spacer (23-221- Leg Set Used 00) Used 8.50 10.50 215.9 266.7 23-313-00 9.50 11.50 241.3 292.1 23-313-00 11.18 13.15 284.0 334.0 23-214-01 12.18 14.15 309.4...
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Figure 5-11. If required, put a chuck leg spacer on each chuck button end. Insert a button into the end of each chuck leg. The but- tons are fitted with o-rings to hold them in the leg. E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610...
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EP 424 End Prep Machine Figure 5-12. Put buttons on the end of each chuck leg. 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.
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Figure 5-15. The alignment gauge must be flush against the face plate surface. 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...
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EP 424 End Prep Machine gauge are touching the end of the pipe. Re-tighten the legs to hold the chuck body in place. Figure 5-16. Push the chuck body into the pipe until all four arms of the alignment gauge are against the pipe surface.
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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...
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EP 424 End Prep Machine Mount the mandrel onto the chuck. NOTE If the chuck does not need any further centering adjust- ment, install a spacer (23- 203-00) over each stud before mounting the mandrel. Figure 5-20. Mount the mandrel on the independent chuck.
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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...
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EP 424 End Prep Machine Figure 5-24. Set the tip of the indicator to touch the pipe, perpendicular to the surface. Move the indicator around the pipe end by rotating the NOTE mounting collar. Check the reading on the indicator dial to measure how far the mandrel is off center.
RIVE OTORS Refer to the instructions in this section for the drive motor (air or hydraulic) provided with your EP 424 machine. The motors are installed and operated the same way for either form tool or single-point operation. Mounting and Operating the Air Drive To install the air motor, put the motor flange over the 4 motor mounting screws on the EP 424 motor adapter.
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Connect the air line to the connector on the air motor. Turn on the air supply at the source. NOTE To operate the EP 424, squeeze the trigger on the air The air supply must provide motor. The machine (form tool head or single-point 95 cfm at 90 psi (2700 l/min slide) will start to rotate.
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When the prep is complete, release the air motor trig- ger to stop the machine. E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610...
Mounting and Operating the Hydraulic Drive 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.
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Turn on the hydraulic power supply. Set it to 10 gpm at 1500 psi (38 l/min at 103 bar). Push the hydraulic drive lever toward the main body of the machine. The machine will start to rotate. E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610...
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EP 424 End Prep Machine Figure 5-34. Turn the hydraulic lever to the ON posi- tion as shown. Make sure the machine is turning clockwise. If it is NOTE turning the wrong way, the hydraulic hoses are reversed. Turn off the HPU and switch the hoses.
The 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: •...
EP 424 End Prep Machine Planning the Operation Operating Envelope Make sure you have adequate clearance around the work- piece. See the operating envelope drawings in Chapter 3 for reference. Selecting Tooling Use the following charts to select the appropriate tooling for the operation.
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Chapter 5, Operating Instructions: Form Tool Operation Figure 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...
EP 424 End Prep Machine Figure 5-40. The chart describes the tooling used for J-prep operations. Adjusting the Tool Holder Positions You 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”...
Setting Up and Mounting the EP 424 You 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: •...
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Figure 5-42. Attach the lifting device to the lift hook. 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.
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Turn the feed handle clockwise to engage the mandrel to start the threads. threads in the feed nut. Feed nut Mandrel threads Figure 5-45. Turn the feed handle clockwise to engage the mandrel threads in the feed nut. E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610...
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EP 424 End Prep Machine 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. Using a 3/16” hex wrench, loosen the tooling set screws in the tool holder and put the tool in the holder.
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You can use the scale on the feed housing to measure This will improve the cutting the axial depth of cut. Each line on the the scale is performance and increase 0.001” (0.025 mm) of feed. the life of the tooling. E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610...
EP 424 End Prep Machine Figure 5-49. Use the scale on the feed housing to measure axial feed distance. 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.
Set the machine on a stable work surface that can sup- port its weight. Use a lifting device to lift the EP 424. If the mandrel is installed, remove it by turning the feed handle counter-clockwise until the mandrel is threaded out of the feed nut.
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EP 424 End Prep Machine Figure 5-51. Pull the mandrel out of the machine. 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.
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Figure 5-54. Mount the trip assembly on the housing. 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...
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EP 424 End Prep Machine NOTE The trip assembly screws are on the back of the ring. Figure 5-55. Tighten down the 4 set screws while holding the trip ring assembly in place. Put the single-point slide into place on the main shaft.
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Figure 5-58. Insert the mandrel through the single- point slide. 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...
EP 424 End Prep Machine the 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 Operation Operating Envelope Make sure you have adequate clearance around the work- piece.
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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” E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610...
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EP 424 End Prep Machine For a compound bevel, use the following formula: S = Set-Back R = Root Radius L = Land E = Land Extension A1 = Inner Bevel Angle A2 = Outer Bevel Angle T = Transition (from I.D.)
Chapter 5, Operating Instructions: Single Point Operation Setting Up and Mounting the EP 424 You 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: •...
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EP 424 End Prep Machine Figure 5-63. Position the EP 424 to mount it on the mandrel. Slide the machine forward on the mandrel. Turn the machine back and forth while pushing to engage it all the way onto the spline.
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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. E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610...
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EP 424 End Prep Machine Figure 5-66. Install the tool holder in the slide. 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.
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. Move the left knob stop up against the knob and tighten it. E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610...
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EP 424 End Prep Machine Figure 5-68. Set the left knob stop against the Speed Prep knob. Loosen the Speed Prep knob and set it to the location of the transition angle. Lock the knob in place. Move the right knob stop up against the knob and tighten it.
If the independent chuck mandrel is installed, loosen the jam nuts and then loosen the clamp legs. Pull the mandrel out of the pipe. E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610...
Removing the Single-Point Kit Set the machine on a stable work surface that can sup- port its weight. Use a lifting device to lift the EP 424. If the mandrel is installed, remove it by turning the feed handle counter-clockwise until the mandrel is threaded out of the feed nut.
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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. Remove the single-point slide from the main shaft. E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610...
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EP 424 End Prep Machine Figure 5-73. Remove the single-point slide. 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. Remove the trip assembly from the main housing.
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(indicated by arrows) with the holes in the main shaft, and press the head onto the shaft. 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...
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EP 424 End Prep Machine Figure 5-77. Tighten the 6 screws holding on the rotating head. Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs...
Every 30 days (more often with heavy use), apply grease through the fitting. Using a 3/16” hex wrench, remove the plug in the top of the main drive housing. E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610...
EP 424 End Prep Machine Figure 6-2. Remove the grease plug before putting grease into the main drive assembly. 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 6-4. Apply oil to the felt wiper in the rotating head. Figure 6-5. Replace felt wipers when they become worn or dirty. Single-Point Slide Each time you use the single-point slide, oil the feed screw. Apply a light coating of oil. E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610...
EP 424 End Prep Machine Feed screw Figure 6-6. Lubricate the feed screw with a light coat- ing of oil. Mandrel Oil the spline on the mandrel (standard or independent chuck) each time you use it. Apply a light coating of oil.
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...
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EP 424 End Prep Machine Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs...
Check the tension on the starwheel. If it is acceptable, no further adjustment is necessary. Adding/Removing Gib Shims Shims are used under the gibs to set the vertical tension on the male slide. Shims are “stacked” to achieve the desired tension. E.H. Wachs Part No. 81-MAN-00, Rev. 0-0610...
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.
See the detailed instructions in Chapter 5 for setting up and per- forming a single-point bevel. Configure the EP 424 for single-point operation. Mount the machine on a pipe or sample workpiece suitable for single-point beveling.
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EP 424 End Prep Machine 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. Start the drive motor. The single-point slide will start to rotate.
Chapter 7, Service and Repair: Air Motor Manual OTOR ANUAL The 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...
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EP 424 End Prep Machine Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs...
Chapter 8, Parts Lists and Drawings Chapter 8 Parts Lists and Drawings Refer 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...
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EP 424 End Prep Machine Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs...
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WEIGHT: 7.5 lbs / 3.4 kg EP 424 Auto Feed Assembly 81-302-00 Contact E.H. Wachs for repair part information.
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MOTOR DIRECTIONAL CONTROL VALVE FLOW CONTROL VALVE PRESSURE RELIEF VALVE: DEFAULT SETTING 2000 PSI Hydraulic Schematic EP 424 Hydraulic Drive Assembly 81-310-00...
Spare Parts In This Chapter CCESSORIES CCESSORIES OOLING The following accessories and options are available for the EP 424: Table 1: EP 424 Accessories and Options Part Number Description Single-point upgrade kit for form tool EP-424 con- 81-400-00 figurations (81-000-01/81-000-02) 81-303-01...
EP 424 End Prep Machine OOLING The following tooling is available for the EP-424. Table 2: EP 424 Facing Tooling Part Number Description Low-range facing tool insert holder kit, including 56-708-01 holder, insert screws, and wrench High-range facing tool insert holder kit, including...
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Custom HSS compound angle J bevel tool bit, 56-SPT-05 ground to customer specification. (Specific part no. assigned on order.) Table 4: EP 424 Counterbore and I.D. Tooling Part Number Description 10° I.D. deburring tool (0.150” required between 56-702-01 mandrel and I.D.)
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EP 424 End Prep Machine Table 5: EP 424 Tooling Accessories Part Number Description 56-190-00 Insert screw, used with all EP 424 insert holders. 56-191-00 Insert screw Torx wrench. Part No. 81-MAN-00, Rev. 0-0610 E.H. Wachs...
Chapter 10, Ordering Information Chapter 10 Ordering Information In This Chapter To place an order, request service, or get more detailed RDERING EPLACEMENT information on any E.H. Wachs products, call us at one of ARTS the following numbers: EPAIR NFORMATION U.S. 800-323-8185...
ARRANTY NFORMATION 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. ETURN...
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