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Chapter 6, Routine Maintenance

E.H. Wachs

Part No. 16-MAN-01, Rev. 4-1109

Chapter 6

Routine Maintenance

REAK

-I

ERIOD

After the first 10 hours of operation, you should check the
pre-load on the main shaft bearings of the SDB 103, and
adjust if necessary.

Remove the drive motor from the machine.

Remove the mandrel and drawbar.

Remove the 4 screws holding the feed housing assem-
bly (16-302-00) and remove the assembly.

Figure 6-1. Remove the 4 screws attaching the feed
housing assembly.

Feed housing ass’y
screws (3 shown)

In This Chapter

Summary of Contents for SDB-103

Page 1: ...H Wachs All rights reserved This manual may not be reproduced in whole or in part without the written consent of E H Wachs E H Wachs 600 Knightsbridge Parkway Lincolnshire IL 60069 www ehwachs com E H...

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: ...5 Specifications 16 Operating Envelope 16 Chapter 4 Assembly Disassembly and Storage 21 Storage Checklist 22 Chapter 5 Operating Instructions 23 Pre Operation Checklist 23 Setting Up the SDB 103 24 In...

Page 4: ...outine Maintenance 55 Break In Period 55 Periodic Inspection Checklist 56 Lubrication 57 Chapter 7 Service and Repair 59 SDB 103 Service 59 Replacing the Front Bushing 59 FF 206 Service 59 Castle Nut...

Page 5: ...MANUAL Throughout this manual refer to this column for warnings cautions and notices with supplementary information This manual is organized to help you quickly find the infor mation you need Each cha...

Page 6: ...alert symbol indicates a potentially hazardous situa tion that could result in minor or moderate injury A CAUTION alert with the damage alert symbol indi cates a situation that will result in damage t...

Page 7: ...chs com Occasionally we will update manuals with improved opera tion or maintenance procedures or with corrections if nec essary When a manual is revised we will update the revision history on the tit...

Page 8: ...l Estate Sandbach Chesire CW11 3JA United Kingdom Harmonized Standards Referenced or Applied BS EN 292 1 1991 BS EN 292 2 1991 BS EN 294 1992 BS EN 349 1998 BS EN 418 1992 BS EN 60204 1 1998 BS EN 982...

Page 9: ...ersonal injury hazard READ THE OPERATING MANUAL Make sure you understand all setup and operating instructions before you begin INSPECT MACHINE AND ACCESSORIES Before starting the machine look for loos...

Page 10: ...AR Keep all clutter and nonessential materials out of the work area Only people directly involved with the work being performed should have access to the area Safety Symbols This icon is displayed wit...

Page 11: ...s 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 informati...

Page 12: ...Wachs 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 Do not...

Page 13: ...ized clamp leg sets are provided to cover the full range of operation Select and install the appropriate leg set for the pipe you are machining install the tooling and mount the machine on the pipe us...

Page 14: ...accessories Figure 3 2 The standard clamp leg sets identified by part number fit the standard mandrel to a range of pipe and tube sizes See the tables in Chapter 5 for the clamping range for each leg...

Page 15: ...our application s requirements The standard and small I D mandrels automatically center the machine on the I D and squares it to the centerline of the pipe If you need to mount the machine in a pipe t...

Page 16: ...4 1109 E H Wachs 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...

Page 17: ...purchased as a fully integrated machine or as a kit to upgrade the SDB 103 Figure 3 6 The photo shows the components of the FF 206 including the SDB 103 machine The FF 206 uses a radial feed tool sli...

Page 18: ...16 MAN 01 Rev 4 1109 E H Wachs 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 Starwheel F...

Page 19: ...well as exotic materials such as HK40 and incalloys Effective prepping range 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...

Page 20: ...Mounting mechanism I D mounted mandrel with adjustable clamping legs and multiple legs sets to cover full I D range Standard diameter small I D and independent fitting short clearance mandrels availa...

Page 21: ...5 LEGS SHOWN FULLY RETRACTED SEE DETAIL A 6 26 159 0 4 75 120 7 1 28 32 6 LEGS SHOWN FULLY RETRACTED 1 16 MIN 29 6 2 46 62 5 LEGS SHOWN FULLY EXTENDED 1 57 MAX 39 9 DIMENSIONS IN BRACKETS ARE MILLIMET...

Page 22: ...LEGS SHOWN FULLY RETRACTED SEE DETAIL A 4 75 120 7 6 26 159 0 1 28 32 6 LEGS SHOWN FULLY RETRACTED 1 16 MIN 29 6 2 46 62 5 LEGS SHOWN FULLY EXTENDED 1 57 MAX 39 9 DETAIL A NOTE SEE 16 409 00 FOR EXTE...

Page 23: ...16 070 01 87 MIN 22 1 3 13 REF 79 4 1 11 MAX 28 3 2 70 MAX TRAVEL 68 6 LEGS 16 068 00 SHOWN FULLY RETRACTED AND WITHOUT O RING 16 070 02 97 MIN 24 7 1 25MAX 31 7 CLAMPING RANGE DIMENSIONS IN BRACKETS...

Page 24: ...L 6 4 33 8 3 3 14 79 9 4 23 MAX TRAVEL 107 3 60 702 00 INSERT TOOL 16 042 00 TOOL HOLDER 6 19 157 1 1 77 REF 45 0 R6 63 SWING 168 3 3 19 81 0 14 07 357 3 6 26 159 0 DIMENSIONS IN BRACKETS ARE MILLIMET...

Page 25: ...p legs mandrels and tool heads for various applications Instructions are also provided for converting the SDB 103 to the FF 206 flange facer The SDB 103 and FF 206 are shipped in custom configured sto...

Page 26: ...e the motor for a few seconds to lubricate its internal components Apply grease to the grease fitting on the SDB machine body Rub a coating of light oil on the drawbar and mandrel Rub a coating of oil...

Page 27: ...ect the bore of the rotating 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 Figure 5 1 When cleaning...

Page 28: ...instructions on the optional mandrels see Installing the Small I D Conversion Kit and Installing the Independent Fitting Mandrel later in this section 1 Insert the threaded end of the mandrel through...

Page 29: ...all the draw bar nut and then install and tighten the collar nut The collar nut captivates the draw bar nut so the draw bar nut can be turned to expand and contract the mandrel legs Figure 5 4 Tighten...

Page 30: ...ece pipe I D and refer to the extension leg chart in Table 1 Figure 5 5 Use a scale to measure the I D of the pipe Table 1 Standard Mandrel Extension Legs Leg Set Thickness I D Range None N A 1 16 1 5...

Page 31: ...fasten them to the mandrel legs 3 Tighten the captivated screws on the extension legs to attach the extension legs to the mandrel legs Figure 5 7 Attach the clamp legs to the mandrel and tighten the 2...

Page 32: ...asure the pipe I D and select the appropriate leg set and o ring to fit Make sure to use the correct o ring for the leg set you are using Refer to Table 2 below 9 Install the legs onto the drawbar chu...

Page 33: ...required Refer to the extension leg chart in Table 3 below 4 Insert the legs into the mandrel head The adjustment screw in the adjustable leg must be completely screwed in Table 3 Independent Fitting...

Page 34: ...eveler and FF 206 Flange Facer 30 Part No 16 MAN 01 Rev 4 1109 E H Wachs 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 inde...

Page 35: ...and still keep the machine body and rotating head stable 1 Insert the mandrel chuck into the pipe For best results keep the end of the chuck legs close to the pipe edge Figure 5 10 Insert the mandrel...

Page 36: ...the drawbar nut Independent Fitting Mandrel You can install the indepen dent fitting mandrel in the pipe before putting it on the SDB 103 or FF 206 machine The mandrel may be easier to square without...

Page 37: ...the shaft of the mandrel and slide it against the head Pull the mandrel back in the pipe if necessary Figure 5 13 Put the squaring plate onto the mandrel 3 Tighten the set screws in the squaring plate...

Page 38: ...ation of the legs in the pipe Figure 5 15 The mandrel legs should be close to the edge of the pipe 6 If you need to install the SDB 103 or FF 206 on the mandrel slide the tool head over the mandrel an...

Page 39: ...his number down as measurement A 4 At the position 180 across from the adjustable leg measure the distance from the pipe I D to the mandrel shaft Write this number down as measurement B If the two mea...

Page 40: ...ber of turns you calculated above 7 With the squaring plate still on the mandrel re install the mandrel on the pipe and tighten the drawbar nut 8 Remove the squaring plate and repeat the A and B measu...

Page 41: ...n the screws holding the motor in place 2 Connect power air or electric to the drive motor 3 Start the machine and turn the manual feed handle clockwise until the cutting tools contact the pipe IMPORT...

Page 42: ...s a clean finish 5 When the desired finish is complete turn the feed han dle counter clockwise to retract the tool away from the pipe face Turn off the drive motor 6 Retract the tool head fully by tur...

Page 43: ...I D 1 Loosen the tool bit wedge screw and remove the fac ing tool 2 Insert the counterbore tool Figure 5 21 Insert the counterbore tool but do not snug the tool bit wedge screws 3 Measure the desired...

Page 44: ...ntil the desired coun terbore is cut 10 Operate the machine until the counterbore is com plete Tips for a Good Finish 1 Set the mandrel legs as close to the pipe end as possi ble while leaving enough...

Page 45: ...ds for optimum performance 4 Adjust cutting head RPM depending on the material The harder the material the slower the speed should be Figure 5 24 Turn the air motor throttle clockwise to increase RPM...

Page 46: ...er 42 Part No 16 MAN 01 Rev 4 1109 E H Wachs Figure 5 25 Turn the feed handle counter clockwise as shown to retract the tool bits 7 Use the calibrated feed handle for precise cuts Figure 5 26 The cali...

Page 47: ...feed handle counter clockwise until the man drel shaft disengages from the feed nut Figure 5 27 Remove the drawbar nut before remov ing the mandrel Take care not to damage the mandrel bushing when re...

Page 48: ...lling the Trip Collar 1 Install the trip collar assembly The locking screw must be located close to the air motor housing Instal lation at this position will ensure access to each trip Figure 5 30 The...

Page 49: ...washer must be installed on the back of the module Figure 5 31 Align the mounting screws with the rotating head holes 4 Tighten the four mounting screws with the provided hex key set 5 Insert the man...

Page 50: ...sure the I D of the flange 2 Insert legs into mandrel head The leg adjustment screw must be completely tightened against the leg face Figure 5 33 Attach the leg adjustment screw to the adjustable leg...

Page 51: ...e alignment fixture over the mandrel shaft 2 Slide the alignment fixture firmly against the flange face 3 Tighten the two brass tipped screws to lock the align ment fixture in place Figure 5 34 The sq...

Page 52: ...ng 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 Mounting the F...

Page 53: ...of the flange 2 Install the single point tool holder and cutting tool Tighten the tool positioning screws Figure 5 38 Position the single point cutting tool with the cutting surface in the direction o...

Page 54: ...rface Trip Chart Figure 5 39 Flip the trip lever up to engage the trip 5 Turn the flange facer by hand until the starwheel reaches an engaged trip Ensure that the starwheel will strike the trip as the...

Page 55: ...feed handle clockwise to set the tool bit depth 7 Gently snug the set screw on the back of the feed han dle to prevent the machine from feeding radially dur ing operation Figure 5 41 Snug the feed ha...

Page 56: ...to the O D of the flange surface Once the tool has cut a full 360 degrees regulate the speed and feed for best perfor mance Different materials will require different feed speeds for optimum performa...

Page 57: ...are performing and refer to the drawing in Figure 5 43 EXAMPLE T 0 75 A 20 D tangent 20 x 0 75 0 364 x 0 75 0 273 Figure 5 43 Use the pipe thickness and the bevel angle to calculate the starting depth...

Page 58: ...t is past the O D of the pipe face 7 Turn the feed handle clockwise to advance the tool bit to the desired cutting depth If you are cutting multiple passes advance it to the position of the first pass...

Page 59: ...n shaft bearings of the SDB 103 and adjust if necessary 1 Remove the drive motor from the machine 2 Remove the mandrel and drawbar 3 Remove the 4 screws holding the feed housing assem bly 16 302 00 an...

Page 60: ...ndrel into the machine and turn the feed handle clockwise to engage the feed screw through the feed nut housing This will ensure proper feed nut housing alignment with the mandrel 11 Tighten the 4 scr...

Page 61: ...or oil or anti freeze motor oil Figure 6 2 Apply air motor oil to the air motor daily 3 Every 40 hours of operation flush the air motor with a solution of three parts cleaning solvent and one part air...

Page 62: ...SDB 103 Small Diameter Beveler and FF 206 Flange Facer 58 Part No 16 MAN 01 Rev 4 1109 E H Wachs Figure 6 3 When cleaning the mandrel inspect the threads for damage...

Page 63: ...olding the tool head and remove the head from the machine 3 Insert a 1 25 diameter drift pin from the rear of the main shaft and use it drive out the old bushing 4 Place the new bushing on a bushing d...

Page 64: ...ut by hand clockwise to snug it against the starwheel 3 Replace the pin in the feed screw holding the castle nut at the tightest location at which you can put the pin through it Tap the pin in with a...

Page 65: ...signs of wear Replace either or both if necessary 8 To re assemble the slide reverse this procedure Make sure the castle nut is snug against the starwheel before re installing the pin through the fee...

Page 66: ...turn the starwheel to check the slide tension If necessary loosen the cen ter gib screw and re adjust the center adjustment screw until the slide tension is correct 6 Loosen the center gib screw again...

Page 67: ...H Wachs Part No 16 MAN 01 Rev 4 1109 63 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 identi...

Page 68: ...SDB 103 Small Diameter Beveler and FF 206 Flange Facer 64 Part No 16 MAN 01 Rev 4 1109 E H Wachs...

Page 69: ...1 AIR MOTOR ASSEMBLY 6 16 302 00 1 FEED HOUSING ASSEMBLY 7 16 304 00 1 BEARING HOUSING ASSEMBLY 8 16 409 00 1 STD MANDREL ASSEMBLY 1 16 4 18 I D 9 16 MAN 01 1 MANUAL NOT SHOWN 10 56 099 00 1 LABEL NOT...

Page 70: ...1 LABEL WARNING 8 90 050 07 8 SHCS 1 4 20 X 3 4 9 16 MAN 01 1 MANUAL NOT SHOWN 10 16 082 00 1 CASE NOT SHOWN 11 16 087 00 1 INSERT FOAM NOT SHOWN 12 56 099 00 1 LABEL NOT SHOWN 13 90 800 02 1 WRENCH...

Page 71: ...NG FEED NUT 6 16 012 00 1 WASHER 7 16 013 10 1 RETAINING RING GROUND 8 WHERE USED 1 LABEL FEED NUT 9 90 040 05 4 SHCS 10 24 X 1 2 10 90 040 10 4 SHCS 10 24 X 1 11 90 054 08 4 SSS 1 4 20 X 7 8 12 90 07...

Page 72: ...RING 4 16 007 00 1 GEAR PINION 5 16 027 00 2 CUP BEARING 6 16 028 00 1 CONE BEARING 7 16 029 00 1 CONE W SEAL BEARING 8 16 030 00 1 BUSHING 9 16 031 00 1 LOCKNUT 10 26 047 00 1 PLATE NAME 11 26 096 00...

Page 73: ...RE USED ITEM PART NO DESCRIPTION 5 16 021 01 16 021 02 16 021 03 16 021 04 16 021 05 16 021 06 16 021 07 EXTENSION CHUCK LEG 1 53 1 94 38 9 49 3mm EXTENSION CHUCK LEG 1 90 2 32 48 3 58 9mm EXTENSION C...

Page 74: ...3 125 3 1 2 ITEM PART NUMBER QTY DESCRIPTION 1 16 004 00 1 HEAD ROTATING 2 16 025 00 1 WIPER FELT 3 90 050 07 4 SHCS 1 4 20 X 3 4 16 400 00 Standard Tool Head...

Page 75: ...0 90 800 68 1 WRENCH 3 4 X 5 8 BOX RATCHET NOT SHOWN 11 90 904 03 3 SSS 6 32 X 3 8 NYLON 12 WHERE USED 2 LEG 13 WHERE USED 1 LEG ADJUSTABLE LEG 1 694 LEG 1 544 LEG 1 394 LEG 1 244 LEG 1 094 LEG 944 LE...

Page 76: ...L 7 8 3 16 064 00 1 WELDMENT DRAW BAR 4 16 067 00 3 LEG 88 1 11 5 16 069 00 1 BUSHING 6 16 070 01 1 O RING 114 URETHANE SHORE 90 7 16 084 00 1 NUT DRAW BAR 8 90 050 12 4 SHCS 1 4 20 X 1 1 4 9 16 068 0...

Page 77: ...103 ELB MANDREL ASSEMBLY 6 66 147 00 1 LABEL WARNING 7 90 050 07 7 SHCS 1 4 20 X 3 4 8 16 MAN 01 1 MANUAL NOT SHOWN 9 16 025 00 2 WIPER FELT NOT SHOWN SHIPPED LOOSE 10 16 082 00 1 CASE NOT SHOWN 11 1...

Page 78: ...3 022 00 2 BEARING FEED SCREW 11 52 140 00 6 PLUNGER BALL 12 56 066 00 2 GIB 13 56 067 00 1 WHEEL STAR 14 56 190 00 2 SCREW INSERT 15 60 702 00 1 INSERT TOOL 16 90 019 43 1 KEY 3 32 X 3 8 WOODRUFF 17...

Page 79: ...2 ITEM PART NUMBER QTY DESCRIPTION 1 16 005 00 1 HEAD ROTATING 2 16 025 00 1 WIPER FELT 3 16 409 00 1 STD MANDREL ASSEMBLY 1 16 4 18 I D 4 90 050 07 4 SHCS 1 4 20 X 3 4 16 420 00 FF 206 to SDB 103 Con...

Page 80: ...1 16 026 00 1 MOTOR AIR 2 16 060 00 1 VALVE SPEED CONTROL 3 90 029 43 1 KEY 1 8 X 1 2 8630 ALLOY STL WOODRUFF 4 90 058 58 1 NIPPLE 1 4 HEX H P 5 90 401 02 1 LABEL PRESSURE 6 90 401 03 1 LABEL EAR AND...

Page 81: ...ING 8 WHERE USED 1 MOTOR METABO 9 26 126 01 1 COUPLING INPUT 10 90 020 15 7 SHCS 8 32 x 1 375 11 90 027 07 1 KEY 1 8 SQ X 3 4 12 90 050 08 3 SHCS 1 4 20 X 7 8 13 90 060 12 1 SHCS 5 16 18 X 1 1 4 14 90...

Page 82: ...1 2 DIA 2 26 080 00 1 WELDMENT A T M 3 26 083 00 1 FILTER REGULATOR LUBRICATOR FRL 4 90 050 07 2 SHCS 1 4 20 X 3 4 5 90 055 01 2 NUT 1 4 20 HEX 6 90 055 52 2 WASHER 1 4 SPLIT RING 7 90 055 56 4 WASHER...

Page 83: ...kit 16 414 00 Independent fitting mandrel 16 411 00 Collet mandrel for pipe special order 16 412 00 Collet mandrel for tube special order 16 421 00 FF 206 conversion kit for SDB 103 16 420 00 SDB 103...

Page 84: ...ium range bevel tool 26 411 03 37 5 high range bevel tool 26 411 04 37 5 carbide bevel tool 26 713 00 20 3 32 radius J bevel tool for 1 35 to 4 00 I D use with 26 410 02 facing tool for 0 030 land ext...

Page 85: ...PT 03 Custom high speed steel I D deburring tool cus tomer specifications required 26 SPT 05 Custom high speed steel counterboring tool cus tomer specifications required Table 5 FF 206 Single Point To...

Page 86: ...ange Facer 82 Part No 16 MAN 01 Rev 4 1109 E H Wachs 1 4 2 ITEM PART NUMBER QTY DESCRIPTION 1 16 042 00 1 HOLDER TOOL 2 56 190 00 2 SCREW INSERT 3 56 191 00 1 WRENCH TORX NOT SHOWN 4 60 702 00 5 INSER...

Page 87: ...refer to the drawings and parts lists in Chapter 8 Please provide the part description and part number for all parts you are ordering REPAIR INFORMATION Please call us for an authorization number befo...

Page 88: ...t 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...

Page 89: ......

Page 90: ...600 Knightsbridge Parkway Lincolnshire IL 60069 847 537 8800 www ehwachs com...

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