Wachs SDB-103 User Manual
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Wachs SDB-103 User Manual

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E.H. Wachs
600 Knightsbridge Parkway
Lincolnshire, IL 60069
www.ehwachs.com
SDB-103 Small Diameter Beveler
and FF 206 Flange Facer
E.H. Wachs Part No. 16-MAN-01
Rev. 4-1109, November 2009
Revision History:
Original
April 1996
Copyright © 2009 E.H. Wachs. All rights reserved.
This manual may not be reproduced in whole or in part
User's Manual
without the written consent of E.H. Wachs.

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  • Page 1 E.H. Wachs Part No. 16-MAN-01 Rev. 4-1109, November 2009 Revision History: Original April 1996 Copyright © 2009 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.
  • Page 2 SDB-103 Small Diameter Beveler and FF 206 Flange Facer Part No. 16-MAN-01, Rev. 4-1109 E.H. Wachs...

  • Page 3: Table Of Contents

    Installing the Trip Collar ........... . 44 E.H. Wachs...
  • Page 4 SDB-103 Small Diameter Beveler and FF 206 Flange Facer FF 206 Independent Fitting Mandrel Setup ......... 45 Squaring the FF 206 on Squared Flange .

  • Page 5: Chapter 1: About This Manual

    ANUAL This manual explains how to operate and maintain the OW TO ANUAL SDB-103 small diameter beveler (SDB) and FF 206 flange facer. It includes instructions for set-up, operation, and YMBOLS AND ARNINGS maintenance. It also contains parts lists, diagrams, and ser-...

  • Page 6: Symbols And Warnings

    SDB-103 Small Diameter Beveler and FF 206 Flange Facer YMBOLS AND ARNINGS 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.

  • Page 7: Manual Updates And Revision Tracking

    RACKING Current versions of E.H. Occasionally, we will update manuals with improved opera- Wachs manuals are also tion or maintenance procedures, or with corrections if nec- available in PDF format. You essary. When a manual is revised, we will update the can request an electronic revision history on the title page.
  • Page 8 Directive: Machinery Directive on machinery safety, 98/37/EC Conforming Machinery: Pipe Beveling & Cut-Off Machines Model#:16, 56, 66, 70, 71, 72-000-XX Serial #: Manufacturer: E. H. Wachs Company 600 Knightsbridge Parkway Lincolnshire, IL 60069 USA Patrick Fuss Authorized Representative: Director of International Sales and Service...

  • Page 9: Chapter 2: Safety

    Chapter 2, Safety Chapter 2 Safety In This Chapter E.H. Wachs takes great pride in designing and manufactur- PERATOR AFETY ing safe, high-quality products. We make user safety a top priority in the design of all our products. AFETY ABELS Read this chapter carefully before operating the SDB 103/ FF 206.

  • Page 10: Safety Symbols

    SDB-103 Small Diameter Beveler and FF 206 Flange Facer 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.

  • Page 11: Protective Equipment Requirements

    1910.95, Occupational Noise Exposure and ANSI S12.6 Hearing Protectors. AFETY ABELS The following safety labels are on the SDB 103. If the stick- ers are damaged or missing, replace them immediately. See Chapter 10 for ordering information. E.H. Wachs Part No. 16-MAN-01, Rev. 4-1109...
  • Page 12 SDB-103 Small Diameter Beveler and FF 206 Flange Facer Figure 2-1. The Caution sticker is on the SDB 103 air motor. Wear ear and eye protection while operating the machine. (Part number 90-401-03.) Figure 2-2. The Warning sticker is on the SDB 103.

  • Page 13: Chapter 3: Introduction To The Equipment

    The tool head has three tools slots, allowing mul- tiple facing, beveling, and counterboring operations to be performed simultaneously. The machine includes all accessories and tools necessary for operation, and is shipped in a durable, waterproof stor- age case. E.H. Wachs Part No. 16-MAN-01, Rev. 4-1109...
  • Page 14 SDB-103 Small Diameter Beveler and FF 206 Flange Facer Tool head Machine body Clamp leg sets Mandrel Feed handle Air motor Drawbar Figure 3-1. The photo shows the SDB 103 compo- nents and accessories. 16-021-07 16-021-06 16-021-05 16-021-01 16-021-04 16-021-02 16-021-03 Figure 3-2.

  • Page 15: Optional Mandrels

    Collet-style mandrels are also on a bend or that has limited I.D. access, an independent available for pipe or tube. Call fitting mandrel (16-414-00) with dowel-style clamp legs is E.H. Wachs customer service available as an option. to discuss your application’s requirements.
  • Page 16 SDB-103 Small Diameter Beveler and FF 206 Flange Facer Figure 3-4. The independent fitting mandrel shown in the photo uses dowel-style clamp legs, shown at right. Figure 3-5. The squaring plate is used to square the SDB to the pipe face when using the independent fit- ting mandrel.

  • Page 17: Ff 206 Flange Facer

    Various finishes can be cut with the FF 206 by varying the number of engaged trips on the trip ring. Finish options include flange face, record groove, or RMS 63 finish. E.H. Wachs Part No. 16-MAN-01, Rev. 4-1109...
  • Page 18 SDB-103 Small Diameter Beveler and FF 206 Flange Facer Tool holder Feed screw Starwheel Feed direction SDB head mounting interface Figure 3-7. The flange facing slide mounts on the SDB 103 to face flanges. Figure 3-8. The single-point tool holder with tool inserts is used for flange facing.

  • Page 19: Performance Charts

    (a) = Limited by mandrel I.D. (b) = Small I.D. conversion kit required (c) = Carbon steel only Table 2: FF 206 Flange Surface Trip Chart Trips Engaged RMS Finish 63 RMS 125 RMS 250 RMS 500 RMS E.H. Wachs Part No. 16-MAN-01, Rev. 4-1109...

  • Page 20: Specifications

    SDB-103 Small Diameter Beveler and FF 206 Flange Facer PECIFICATIONS Machine capacity SDB 103: Pipe and tube 0.875” (22.2 mm) I.D. to 4.5” (114 mm) O.D. FF 206: Flange O.D. from 2.0” (51 mm) to 6.0” (152 mm). Machining functions Facing, O.D.

  • Page 25: Chapter 4: Assembly, Disassembly, And Storage

    Keep the machines in their cases when not in use. Figure 4-1 and Figure 4-2 show the machines in their cases. SDB 103 Clamp leg sets Hand tools Figure 4-1. The photo shows the SDB 103 in its case. E.H. Wachs Part No. 16-MAN-01, Rev. 4-1109...

  • Page 26: Storage Checklist

    SDB-103 Small Diameter Beveler and FF 206 Flange Facer Squaring plate FF 206 trip ring Hand tools Tool holder and inserts FF 206 slide SDB 103 machine with inde- Clamp leg sets pendent fitting mandrel Figure 4-2. The photo shows the components of the FF 206, including the SDB 103 machine, in its storage case.

  • Page 27: Chapter 5: Operating Instructions

    Clean the bore with compressed air or solvent UTTING THE as necessary. INGLE OINT EVELING Wipe the mandrel clean, and apply a light coating of oil. Figure 5-1. When cleaning the mandrel, inspect the threads for damage. E.H. Wachs Part No. 16-MAN-01, Rev. 4-1109...

  • Page 28: Setting Up The Sdb 103

    SDB-103 Small Diameter Beveler and FF 206 Flange Facer Lubricate the machine according to the guidelines in Chapter 6. SDB 103 ETTING P THE Installing the Standard Mandrel These instructions are for installing the standard mandrel on NOTE the SDB 103. For instructions on the optional mandrels, see “Installing the Small I.D.
  • Page 29 Figure 5-4. Tighten the collar nut with finger pressure to captivate the draw bar nut on the mandrel. E.H. Wachs Part No. 16-MAN-01, Rev. 4-1109...

  • Page 30: Installing The Extension Legs

    SDB-103 Small Diameter Beveler and FF 206 Flange Facer Installing the Extension Legs Install the appropriate leg set to fit the pipe you are machin- ing. Table 1 gives the I.D. range for each leg set provided with the SDB 103 standard mandrel.

  • Page 31: Installing The Small I.d. Conversion Kit

    SDB 103 on pipe I.D.s down to 0.875” (22.2 mm). The kit includes a thinner mandrel and a tool head with a smaller bore. Use the following procedure to replace the standard mandrel and tool head. E.H. Wachs Part No. 16-MAN-01, Rev. 4-1109...

  • Page 32: Installing The Independent Fitting Mandrel

    SDB-103 Small Diameter Beveler and FF 206 Flange Facer Loosen and remove the collar nut and drawbar nut on the standard mandrel. Turn the feed handle counter-clockwise until you can remove the standard mandrel through the tool head of the SDB 103.
  • Page 33 16-053-07/ 1.694” (43.0 mm) 3.75” 4.11” 16-054-07 1.574” (39.9 mm) (95.2 mm) (104.3 mm) Insert the legs into the mandrel head. The adjustment screw in the adjustable leg must be completely screwed in. E.H. Wachs Part No. 16-MAN-01, Rev. 4-1109...
  • Page 34 SDB-103 Small Diameter Beveler and FF 206 Flange Facer Figure 5-8. Attach the leg adjustment screw to the adjustable leg and screw it in fully. Figure 5-9. Insert the legs into the independent fitting mandrel. Part No. 16-MAN-01, Rev. 4-1109...

  • Page 35: Mounting The Sdb 103

    Rotate the draw bar nut with the supplied wrench to NOTE expand the mandrel legs into the I.D. of the pipe. The Torque the draw- chuck legs will automatically center the machine to bar nut to 25 lb-ft. the pipe. E.H. Wachs Part No. 16-MAN-01, Rev. 4-1109...

  • Page 36: Independent Fitting Mandrel

    SDB-103 Small Diameter Beveler and FF 206 Flange Facer Figure 5-11. Hold the machine in place and tighten the drawbar nut. Independent Fitting Mandrel Set the mandrel assembly, with the required leg set NOTE installed, into the pipe. You can install the indepen-...
  • Page 37 Figure 5-13. Put the squaring plate onto the mandrel. Tighten the set screws in the squaring plate to secure it to the mandrel. Figure 5-14. Tighten both set screws in the squaring plate to secure and center it to the mandrel. E.H. Wachs Part No. 16-MAN-01, Rev. 4-1109...

  • Page 38: Installing And Centering On Elbows And Bends

    SDB-103 Small Diameter Beveler and FF 206 Flange Facer Push the mandrel into the pipe so that the squaring plate is pressed tight against the pipe face. Tighten the drawbar nut while holding the mandrel in this posi- tion. Loosen the set screws in the squaring plate and remove the plate from the mandrel.
  • Page 39 “C”. – ------------ - • One turn of the adjustment screw extends the screw by 0.035” (0.89 mm). Divide “C” by this amount to deter- mine how many turns to adjust the screw. E.H. Wachs Part No. 16-MAN-01, Rev. 4-1109...

  • Page 40: Installing Tooling

    SDB-103 Small Diameter Beveler and FF 206 Flange Facer --------------- - Turns 0.035 Before removing the mandrel, attach the squaring plate to it with the plate firmly against the pipe face. Loosen the drawbar nut to remove the mandrel. Turn the adjustment screw the number of turns you NOTE calculated above.

  • Page 41: Cutting The O.d

    SDB air motor. Machine life can be shortened and the warranty can be voided if an ATM is not used. An ATM can be purchased from E.H. Wachs or a third party. E.H. Wachs Part No. 16-MAN-01, Rev. 4-1109...
  • Page 42 SDB-103 Small Diameter Beveler and FF 206 Flange Facer Figure 5-19. To face the pipe, turn the feed handle clockwise. Continue operating the machine until the pipe has a clean finish. When the desired finish is complete, turn the feed han- dle counter-clockwise to retract the tool away from the pipe face.

  • Page 43: Cutting The I.d

    Figure 5-21. Insert the counterbore tool but do not snug the tool bit wedge screws. Measure the desired counterbore radius and land thickness. Figure 5-22. Use a scale to properly position the counterbore tool. E.H. Wachs Part No. 16-MAN-01, Rev. 4-1109...

  • Page 44: Tips For A Good Finish

    SDB-103 Small Diameter Beveler and FF 206 Flange Facer Adjust the counterbore tool appropriately. Loosen the opposite tool bit wedge screw. Insert the I.D. deburring tool into the slot opposite the NOTE beveling tool. Adjust the tool to produce the desired Once the cutting I.D.
  • Page 45 RPM and counter-clockwise to decrease RPM. Keep uniform pressure on the feed handle until the prep is complete. Retract the tool bits quickly by turning the feed handle counterclockwise when the prep is finished. E.H. Wachs Part No. 16-MAN-01, Rev. 4-1109...
  • Page 46 SDB-103 Small Diameter Beveler and FF 206 Flange Facer Figure 5-25. Turn the feed handle counter-clockwise as shown to retract the tool bits. Use the calibrated feed handle for precise cuts. Figure 5-26. The calibrated feed handle is graduated in 1/1000” increments.

  • Page 47: Ff 206 Flange Facing Setup

    Take care not to damage the mandrel bushing when removing the mandrel. Figure 5-28. Pull the mandrel out through the tool head. Remove the four screws retaining the rotating tool head, and remove the rotating head. E.H. Wachs Part No. 16-MAN-01, Rev. 4-1109...

  • Page 48: Installing The Trip Collar

    SDB-103 Small Diameter Beveler and FF 206 Flange Facer Figure 5-29. Remove the rotating head screws using a 3/16” hex wrench. Installing the Trip Collar Install the trip collar assembly. The locking screw NOTE must be located close to the air motor housing. Instal- Do not remove lation at this position will ensure access to each trip.

  • Page 49: Ff 206 Independent Fitting Mandrel Setup

    Insert the mandrel assembly into the machine body. Attach the drawbar nut and the collar nut to the end of the mandrel shaft. FF 206 I NDEPENDENT ITTING ANDREL ETUP Measure the flange I.D., and select extension leg set required. E.H. Wachs Part No. 16-MAN-01, Rev. 4-1109...
  • Page 50 SDB-103 Small Diameter Beveler and FF 206 Flange Facer Figure 5-32. Measure the I.D. of the flange. Insert legs into mandrel head. The leg adjustment NOTE screw must be completely tightened against the leg Set up the inde- face. pendent fitting mandrel with the machine body removed.

  • Page 51: Squaring The Ff 206 On Squared Flange

    Figure 5-34. The squaring plate automatically squares the FF 206 to the pipe face. Tighten the drawbar nut. Figure 5-35. Tighten the drawbar nut to clamp the mandrel in the flange I.D. E.H. Wachs Part No. 16-MAN-01, Rev. 4-1109...

  • Page 52: Squaring The Ff 206 On Unsquare Flange

    SDB-103 Small Diameter Beveler and FF 206 Flange Facer Remove the alignment fixture. The mandrel and machine are now square to the flange face. Squaring the FF 206 on Unsquare Flange If the elbow or bend is not square, establish a reference point for squaring, and then square the machine to that point using the procedure detailed above.

  • Page 53: Ff 206 Flange Facing Operating Procedure

    Figure 5-38. Position the single point cutting tool with the cutting surface in the direction of rotation. Time the starwheel by setting it so that one of its points is perpendicular to the flange face. E.H. Wachs Part No. 16-MAN-01, Rev. 4-1109...
  • Page 54 SDB-103 Small Diameter Beveler and FF 206 Flange Facer Engage the number of trips required for the desired surface finish, as described in Table 4. Table 4: FF 206 Flange Surface Trip Chart Trips Engaged RMS Finish 63 RMS 125 RMS...
  • Page 55 Figure 5-41. Snug the feed handle set screw to keep the machine from moving radially when flange facing. Connect the power supply (air or electric) to the drive motor. E.H. Wachs Part No. 16-MAN-01, Rev. 4-1109...
  • Page 56 SDB-103 Small Diameter Beveler and FF 206 Flange Facer Engage the power switch on the motor and operate the machine slowly, making sure the starwheel strikes each engaged trip. Operate the machine until the tool feeds in to the O.D.

  • Page 57: Single-Point Beveling

    Cut multiple passes if D is too thick to cut in one Figure 5-44. Cut multiple passes if necessary. E.H. Wachs Part No. 16-MAN-01, Rev. 4-1109...
  • Page 58 SDB-103 Small Diameter Beveler and FF 206 Flange Facer Engage the number of trips required for the surface finish desired. Refer to Table 4 earlier in this chapter. Refer to Table 5 for the required axial feed rate for the number of trips you are using.

  • Page 59: Chapter 6: Routine Maintenance

    Remove the mandrel and drawbar. Remove the 4 screws holding the feed housing assem- bly (16-302-00) and remove the assembly. Feed housing ass’y screws (3 shown) Figure 6-1. Remove the 4 screws attaching the feed housing assembly. E.H. Wachs Part No. 16-MAN-01, Rev. 4-1109...

  • Page 60: Periodic Inspection Checklist

    SDB-103 Small Diameter Beveler and FF 206 Flange Facer Insert and tighten an old tool bit in one slot of the cut- ting head. Set the tool head down onto a bench vise and clamp the tool bit in it to secure the machine body.

  • Page 61: Lubrication

    The components of the mandrel, including the draw- bar and clamp legs, should be cleaned and oiled every day of use. E.H. Wachs Part No. 16-MAN-01, Rev. 4-1109...
  • Page 62 SDB-103 Small Diameter Beveler and FF 206 Flange Facer Figure 6-3. When cleaning the mandrel, inspect the threads for damage. Part No. 16-MAN-01, Rev. 4-1109 E.H. Wachs...

  • Page 63: Chapter 7: Service And Repair

    Place the new bushing on a bushing driver (part # 16- 033-00 available from E.H. Wachs), and press it into the main shaft until the edge of the bushing is flush with the front of the shaft.

  • Page 64: Castle Nut Adjustment

    SDB-103 Small Diameter Beveler and FF 206 Flange Facer Castle Nut Adjustment If there is excess backlash in the feed screw, adjust it by adjusting the castle nut tight against the starwheel. Using a punch, drive out the pin holding the castle nut on the feed screw.

  • Page 65: Feed Tension Adjustment

    Adjustment screws (3) Gib screws (3) Figure 7-2. Adjust the adjustable gib to set the FF 206 slide tension. Turn the starwheel to move the male tool slide to about the center of the gibs. E.H. Wachs Part No. 16-MAN-01, Rev. 4-1109...
  • Page 66 SDB-103 Small Diameter Beveler and FF 206 Flange Facer On the adjustable gib, loosen the gib screws. Turn them just enough to crack them loose. To increase the slide tension, turn the middle adjust- ment screw in (clockwise). Turn the screw by a small amount—no more than 1/4 turn at a time.

  • Page 67: Chapter 8: Parts Lists And Drawings

    Chapter 8, Parts Lists and Drawings Chapter 8 Parts Lists and Drawings The drawings on the following pages include parts lists for all components. Refer to the drawings and part numbers for identifying and ordering replacement parts. E.H. Wachs Part No. 16-MAN-01, Rev. 4-1109...
  • Page 68 SDB-103 Small Diameter Beveler and FF 206 Flange Facer Part No. 16-MAN-01, Rev. 4-1109 E.H. Wachs...
  • Page 69 ITEM PART NUMBER QTY. DESCRIPTION 16-005-00 HEAD, ROTATING 16-025-00 WIPER, FELT 16-082-00 CASE (NOT SHOWN) 16-087-00 INSERT, FOAM (NOT SHOWN) 16-301-00 AIR MOTOR ASSEMBLY 16-302-00 FEED HOUSING ASSEMBLY 16-304-00 BEARING HOUSING ASSEMBLY 16-409-00 STD. MANDREL ASSEMBLY, 1.16"-4.18" I.D. 16-MAN-01 MANUAL (NOT SHOWN) 56-099-00 LABEL (NOT SHOWN) 66-147-00...
  • Page 70 -WHERE USED- ITEM PART NUMBER QTY. DESCRIPTION 16-005-00 HEAD, ROTATING ITEM PART NO. DESCRIPTION USED ON 16-025-00 WIPER, FELT 16-416-00 SDB 103/3 ELECT. DRIVE ASSEMBLY-110V 16-000-02 16-302-00 FEED HOUSING ASSEMBLY 16-304-00 BEARING HOUSING ASSEMBLY 16-416-01 SDB 103/3 ELECT. DRIVE ASSEMBLY-220V 16-000-03 16-409-00 STD.
  • Page 77 ITEM PART NUMBER QTY. DESCRIPTION 16-301-00 AIR MOTOR ASSEMBLY 16-302-00 FEED HOUSING ASSEMBLY 16-304-00 BEARING HOUSING ASSEMBLY 16-404-00 SLIDE ASSEMBLY, SINGLE POINT 16-414-00 SDB 103 ELB. MANDREL ASSEMBLY 66-147-00 LABEL, WARNING 90-050-07 SHCS, 1/4-20 X 3/4 16-MAN-01 MANUAL (NOT SHOWN) 16-025-00 WIPER, FELT (NOT SHOWN-SHIPPED LOOSE) 16-082-00...
  • Page 78 ITEM PART NUMBER QTY. DESCRIPTION 16-025-00 WIPER, FELT 16-037-00 PLATE, MOUNTING 16-038-00 SLIDE, MALE 16-039-00 PLATE, BACKING 16-040-00 SCREW, FEED 16-041-00 BLOCK, FEED SCREW 16-042-00 HOLDER, TOOL 16-044-00 TRIP 16-045-00 WELDMENT, TRIP COLLAR 43-022-00 BEARING, FEED SCREW 52-140-00 PLUNGER, BALL 56-066-00 56-067-00 WHEEL, STAR...
  • Page 80 ITEM PART NUMBER QTY. DESCRIPTION 16-026-00 MOTOR, AIR 16-060-00 VALVE, SPEED CONTROL 90-029-43 KEY, 1/8 X 1/2 8630 ALLOY STL WOODRUFF 90-058-58 NIPPLE, 1/4 HEX H.P. 90-401-02 LABEL, PRESSURE 90-401-03 LABEL, EAR AND EYE PROTECTION 16-301-00, Air Motor Assembly...

  • Page 83: Chapter 9: Accessories And Spare Parts

    FF 206 tool slide 72-405-01 3.25” diameter wedgelock tool head 72-405-00 4.25” diameter wedgelock tool head 16-301-00 Air drive 16-416-00 110 V electric drive 16-416-01 220 V electric drive 26-407-00 Air treatment module E.H. Wachs Part No. 16-MAN-01, Rev. 4-1109...

  • Page 84: Tooling

    SDB-103 Small Diameter Beveler and FF 206 Flange Facer OOLING The following tables list tooling for the SDB 103 and FF 206. Table 2: SDB 103 Facing Tools Part Number Description 26-410-02 Standard facing tool 26-410-03 High-range facing tool 26-410-04 Carbide-tipped facing tool Custom high-speed steel facing tool—customer...
  • Page 85 Flange facing carbide insert tool holder kit (includes 16-701-00 tool wrench and 5 tool inserts) 60-702-00 Carbide insert for beveling and flange facing See the drawing on the next page for the single-point tool holder. E.H. Wachs Part No. 16-MAN-01, Rev. 4-1109...
  • Page 86 SDB-103 Small Diameter Beveler and FF 206 Flange Facer ITEM PART NUMBER QTY. DESCRIPTION 16-042-00 HOLDER, TOOL 56-190-00 SCREW, INSERT 56-191-00 WRENCH, TORX (NOT SHOWN) 60-702-00 INSERT, TOOL 16-701-00, Flange Facing Insert Holder Part No. 16-MAN-01, Rev. 4-1109 E.H. Wachs...

  • Page 87: Chapter 10: Ordering Information

    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...

  • Page 88: Warranty Information

    SDB-103 Small Diameter Beveler and FF 206 Flange Facer Before we perform any repair, we will estimate the work and inform you of the cost and the time to complete it. ARRANTY NFORMATION Enclosed with the manual is a warranty card. Please fill out the registration card and return to E.H.
  • Page 90 600 Knightsbridge Parkway • Lincolnshire, IL 60069 847-537-8800 • www.ehwachs.com...

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