5SA Saddle Machine Part Number: Parts & Operating Manual

Transcription

1 Machine Model Serial # Po Box , Tulsa, OK USA Toll Free: office fax 5SA Saddle Machine Part Number: Parts & Operating Manual REVISED: November 28, 2011 Mathey Dearman, Inc. 1

2 Table of Contents Item Subject Page# 1.0 Safety General Information Installation of Spacer Bolts 4 Picture 1 Spacer Bolt Installation 4 Spacer Bolt Calculation 4 Figure 1 Spacer Bolt Configuration for 20, 22, 24 & 26 5 Table 1 Spacer Bolt Part Identification Installation of Saddle Machine on Pipe 6 Picture 2 Closing Boomer Latch 6 Figure 2 Boomer Assembly Parts Configuration 6 Table 2 Boomer Assembly Parts Identification 6 Figure 3 Torch Arm & Torch Carrier Configuration 7 Table 3 Torch Arm & Torch Carrier Parts Identification Installation of Torch Arm, Torch Carrier Assembly and Torch 7 Picture 3 Installation of Torch Arm 7 Picture 4 Installation of Wing Nut The manual Cutting Process 8 A Note on Back Beveling 9 Figure 4 Manual Saddle Parts Configuration 10 Table 4 Manual Saddle Parts Identification 11 Figure 5 Single Bearing Bracket Configuration 12 Table 5 Single Bearing Bracket Parts Identification 12 Figure 6 Double Bearing Bracket Parts Configuration 13 Table 6 Double Bearing Bracket Parts Identification 13 Table 7 Trouble Shooting Maintenance Timing the Ring Gear to the Pinion Gear of the Manual Saddle Machine Installation of a new Drive Chains Repair of the Single and Double Bearing Bracket Storage Limitations Machine Safety Condition of use Condition of use Use of the Saddle Machine not allowed by the manufacturer Disposal of Saddle Machine General Information Composition of Major Components Warranty 20 Table 8 Commercial Pipe Sizes 20 2

3 1.0 Safety Proper precautions should be taken when using this machine or any and all other heavy cutting and welding equipment. A little common sense goes a long way towards preventing accidents involving your Mathey Dearman Saddle Machine. The operator and maintenance person shall read and understand the Saddle Machine parts and operating manual prior to attempting operation of the equipment. The operator and maintenance person shall read and understand the torch parts and operating manual prior to attempting operation or maintenance of the of the oxy/fuel torch. Eye protection must be worn to protect eyes from sparks, flying slag and the brilliant flame. Protective clothing such as chaps, sleeves, steel toed shoes and gloves shall be worn to protect the operator from sparks or slag. Make sure loose clothing, tools, belts, etc. do not become entangled on the Gear Teeth or Torch Arm. The periodic maintenance instructions must be followed in the Saddle Machine parts and operating manual. Never use the Saddle Machine for other than its intended purpose. Clear the general area where the Saddle Machine will be used of all trip hazards. Use a Heat-Resistant Shield to protect nearby walls from sparks and hot material. Adequate ventilation is required to prevent the concentration of oxygen/fuel, gas and/or other toxic fumes. Do not store grease, gasoline or other flammable material in the area where the pipe is being cut. Never direct flame or debris associated with cutting process toward the oxygen or fuel gas cylinders. Do not operate Saddle Machine equipped with Oxy/fuel or plasma torch in an explosive environment. Always have a fire extinguisher of the proper size and type in the work area. Remove all smoldering materials from the work area when work has been completed. Due to the risk of personnel injury never direct the flame or the fuel or plasma torch back toward the machine. Discontinue the operation of the Saddle Machine, if it is vibrating or operating erratically. When using the Saddle Machine, basic safety precautions must always be followed to reduce the risk of personal injury. Always operate the tool in accordance with the operating instructions. The Oxy/Fuel Torches or the Plasma Torches must be properly installed and fastened in the Torch Holder assembly to avoid injury to the operator. There must be sufficient slack in the Oxy/Fuel or Plasma Hoses so the Saddle Machine will be able to make a full circle around the pipe to complete cut. Always follow the Oxy/fuel or plasma torch manufacturers operating instruction when using the Oxy/fuel or plasma torch Machine Torch. The Saddle machine should only be used with a 1 3/8 diameter oxy/fuel or plasma torch having a barrel length not to exceed 10. The pipe must be secured to the table or pipe stand, prior to mounting the machine on the pipe. Never wear loose clothing when operating the Saddle Machine. The Ring Gear and Pinion Gears must be free from all obstacles, especially hands and feet, before operating machine. Fire is hot. Keep all flammable material, including hands and feet, as far from the path of the Cutting Torch as possible. IN ADDITION TO THE ABOVE PROCEDURES, ALL SHOP, NATIONAL AND MANUFACTURER S SAFETY INSTRUCTION CONCERNING THE FLAME CUTTING SYSTEM SHOULD BE FOLLOWED. ALL CUTTING OPERATIONS SHOULD BE CONDUCTED IN THE BEST OF SAFETY CONDITIONS. 3

4 2.0 General Information 2.1 The 5SA Saddle Machine is designed to rotate a 1 3/8 /35mm diameter 12 long oxy/fuel or plasma machine torch to cut and/or bevel 24 / 610mm, 26 / 660.4mm, 28 / 711.2mm and 30 / 762mm horizontal nominal size API line pipe. The machine comes with Spacer Bolts for the above list pipe sizes. Spacer bolts are available for other pipe or tubing sizes within the machine cutting range. 2.2 Operator Training The Operator requires no training providing they read and understand the parts and operating manual. The training mainly involves teaching the operator to smoothly and without hesitation rotate the crank handle so the oxy/fuel or plasma torch produces a smooth even cut around the pipe. 2.3 Maintenance Personnel Mathey Dearman offers a training course at its facility on the major machine repairs at no charge. The parts and operating manual contains information concerning the lubrication and minor repair. 3.0 Installation Spacer Bolts 3.1 Select the correct combination of Spacer Bolts and/or spacers for pipe being cut. 3.2 Install the four (4)combinations of Spacer Bolts and Spacers for the pipe to be cut in the four (4) holes in the Machined Saddle (Picture 2 or Figure 5 item 1), with the Spacer End of the Bolts on the Bore (I.D.) side of the saddle. 3.3 Place the spacer if require on the Spacer Bolt protruding through the top of the Saddle. Secure Spacer Bolts and Spacers to the Saddle by threading the Hex Nut onto the threaded portion on the topside of Saddle. The hex nut does not have to be tightened with a wrench as the purpose of the nut is to secure the spacer bolt to the saddle. 24 Pipe 26 Pipe 28 Pipe 30 Pipe Picture 1 Spacer Bolt Installation Spacer Bolt Length Calculation Bore (inside diameter) of 5SA Machine Saddle 30-1/2 (775mm) Subtract actual OD of pipe 28 (711mm) Difference 2-1/2 (63.5mm) Divide Difference by two (2) 2-1/2 2 = 1-1/4 (31.8mm The correct Spacer length (between outside diameter of pipe and inside diameter of saddle) is 1-1/4 (31.8mm). 4

5 Figure 1: Spacer Configuration for 24, 26, 28, & 30 pipe Table 1 Spacer Bolt Part Identification ITEM # PART DESCRIPTION PART # QUANTITY REQUIRED 1 Spacer Bolt for 24 / 610mm pipe Spacer Bolt 26 pipe Spacer 1 / 25.4mm Hex Nut, 1/2-13 1H-12C Spacer Bolt Kit (includes all of the above) 03-05SA-KIT Installation of Saddle Machine on Pipe 4.1 Place the Saddle Machine squarely on the pipe, as close as possible to the cut line. All 4 spacer bolts should make contact with the pipe. 4.2 Place the hook of the Boomer (Figure 2 item 1) into the Boomer Eye (Figure 4 Item 8) located on the Saddle (Figure 4 Item 1). 4.3 Place the Spring Snap (Figure 2 Item 4) into the Boomer Eye (Figure 4 Item 8) on the other side of the Saddle (Figure 4 Item 1). 4.4 In order to get a stable installation of the 5SA Saddle Machine, the Spring Snap (Figure 2 Item 4) of the Boomer Assembly (Figure 2) must be adjusted on the Chain (Figure 2 item 3) so that the spring (Figure 2 Item 2) is stretched approximately 1/2" -3/4 (12-19mm) when the Boomer is closed. Caution: Improper tensioning of the boomer assembly or failure to latch the boomer assembly may result in injury. 4.5 When the Chain is properly adjusted, close the Boomer (Figure 2 item 1). 5

6 Picture 2 Closing Boomer Caution: Be careful not to get finger caught between the latch handle and boomer frame. Figure 2: Boomer Assembly Part # Table 2 Boomer Assembly Parts Identification ITEM # PART DESCRIPTION PART # QUANTITY 1 Boomer Spring Chain Spring Snap

7 Figure 3: Torch Arm Part Number: Torch Carrier Assembly Part Number: Table 3 - Torch Arm and Torch Carrier Parts Identification ITEM # PART DESCRIPTION PART # QUANTITY A Torch Arm B Torch Carrier Assembly Torch Clamp Base Torch Clamp Clamp Screw Kit (includes 5, 6 & 7) Thumb Screw, 3/8-16 x 3/ TS Thumb Screw, 3/8-16 x TS Flat Washer, 3/ F Installation of Torch Arm, Torch Carrier Assembly and Torch 5.1 Install Torch Arm (Figure 3, Item A) over the two threaded studs (Figure 4 item 16) located on the face of the Ring Gear (Figure 4 Item 3). Picture 3 Installation of Torch Arm on the Threaded Stud 5.2 Secure the Torch Arm to the Ring Gear with the wing nuts (Figure 4 item 17) provided in the Spacer Bolt Box. 7

8 Picture 4 Installation of the Wing Nut 5.3 Remove the Clamp from the (Figure 3 Item 3) from the torch Carrier Assembly (Fig. 3, Item B). 5.4 Place the Torch Carrier Assembly (Figure 3 item B) on the Torch Arm (Figure 3 item A) with hole for Torch of the Torch Clamp (Figure 3 Item 2) nearest the Ring Gear (Figure 4 item 3). NOTE: For the squarest cut place the torch as close to the Ring Gear (Figure 4 item 3) as possible 5.5 Reinsert Thumbscrew (Figure 3 Item 6) through the hole in the base of the clamp base (Figure 3 item 1) and thread it into the Clamp (Figure 3 item 3) securing the Torch Carrier Assembly to the Torch Arm. 5.6 The Torch Clamp Base (Fig. 3 Item 1) is marked 0, 60, and 90. Use 0 Position for square cuts (no bevel). Positions 60 and 90 make the appropriate bevel to produce a V Groove of 60 and 90 degrees respectively when the two pipe ends are butted together. 5.7 Select the correct Cutting tip for the wall thickness and fuel gas per the torch manufactures instructions. 5.8 Insert 10 Long 1 3/8 diameter Machine Oxy/fuel or Plasma Machine Torch (not supplied) into Torch Clamp (Fig. 3, Item 2) and adjust torch tip to pipe height per the torch manufacturer instructions and tighten the Thumbscrew (Fig. 3, item 6) securing the Torch in the Torch Carrier Assembly. Note: A 10 long Oxy/fuel or Plasma machine torch is required for the Saddle Machine to cut all pipes within its range. 6.0 The Cutting Process 6.1 Rotate Torch one full turn around the pipe to be sure torch tip will maintain the same distance around the pipe. Note: If the torch tip contacts the pipe at any point during its rotation either the incorrect spacer bolts were selected or the pipe is oversize, undersize or out of round. If the distance of the torch tip is greater at the 6:00 o clock either the incorrect spacer bolts were selected or the pipe is undersize, oversize or out of round. 6.2 Connect the gas hose from the fuel regulator to the left hand thread port 10 long Oxy/fuel or Plasma Machine Torch per the manufacturer s instructions. 6.3 Connect the oxygen hose from the oxygen regulator to the right hand thread port 10 long Oxy/fuel or Plasma Machine Torch per the manufacturer s instructions. Caution: The oxygen and fuel hoses must be connected to the right port on the machine torch. Failure to do so may result in serious injury. Caution: The hose must not be drawn through the molten slag produced by the cutting process Caution: Goggles, gloves, mask and other appropriate safety attire must be worn during the cutting process. 8

9 6.4 Adjust the oxygen and fuel gas regulator per the regulator manufacturer s instructions. 6.5 Light the cutting torch per the torch manufacturer instructions. Note: If the pipe is coated with Polyurethane, Carbo-Zinc, and Epoxy or is heavily rusted it will require that the coating be burnt off or removed by some other method in order to achieve a quality cut. 6.6 Follow the torch manufacturer s instructions for preheating the pipe. 6.7 While rotating the machine torch around the pipe, move the cutting oxygen valve to the ON position to penetrate the pipe per the torch manufacturer s instructions. Note: If the torch penetrates the pipe without the machine being rotated it will create a notch in the bevel that is unacceptable to most welding codes. Caution: Keep hands and clothing away from the gearing as it will cause serious injury. 6.8 Rotate the torch around the pipe until the cut is complete. 6.9 Rotate the cutting oxygen valve of the cutting torch to the OFF position per the torch manufacturer s instructions Close the fuel and oxygen valve of the torch per the torch manufacturer s instructions Close the valve on the Oxygen and fuel gas bottles if no further cuts are to be made per the torch manufacturer s instructions. Caution: The pipe and debris from the cutting process are extremely hot and can cause serious injury. A Note on Back Beveling Remove the oxy/fuel or torch from the torch carrier assembly. Rotate the Torch Clamp Base and Torch 180 degrees on the Torch Arm and re-tighten with thumbscrew and clamp. Reinstall the oxy/fuel or torch from the torch carrier assembly. When back beveling, place Torch as close to Saddle as possible without placing flame directly on or near Saddle. The Torch is now positioned for back beveling. Caution: When back beveling, the cutting flame and hot zone of the pipe is directed toward the operator. 9

10 Figure 4: CE 5SA Manual Machine Configuration Part # CE Table 4: 5SA Machine Manual Item # Part Description Part # Qty. 1 Saddle Cap Ring Ring Gear (Not Shown) Single Bearing Bracket Assembly (left) Single Bearing Bracket Assembly (right) Double Bearing Bracket Assembly Handle Tie Rod Boomer Eye Cap Screw, hex head, 5/16, 18NC x 5/ C Cap Screw, hex head, 3/8, 16NC x 7/ C Cap Screw, hex head, 3/8, 16NC x 1-1/ C Washer, flat, 3/ F00 13 Items not Show in Figure 4 13 Spacer Bolt Kit 03-05SA-KIT 1 14 Boomer Assembly Drive Chain Threaded Stud (Ring Gear) Wing Nuts, 5/16 1W-56C

11 Figure 5: Right Single Bearing Bracket Assembly Part Number: Left Single Bearing Bracket Assembly Part Number: Table 5: Right and Left Single Bearing Bracket Assembly Item Part Description Part # Qty. # 1 Bracket Sprocket, Chain Drive Axle Pinion Gear Spacer Bearing Set Screw, 5/16, 18NC x 5/ C Set Screw, 1/4, 20NC x 1/ C Spiral Ring, 1/ Spring Pin, 3/16 x Spring Pin, 3/16 x 1-1/

12 Figure 6: Double Bearing Bracket Assembly, Part # Table 6 Double Bearing Bracket Assembly Part Identification Item Part Description Part # Qty. # 1 Bracket Crank Handle Assembly Crank Pinion Crank Gear and Double Sprocket Axle Bearings Spacer Spacer Set Collar, 1/ Set Screw, 1/4, 20NC x 1/ C Screw, round head 1/4, 20NC x 1/ C Washer, flat, 1/ F Spring Pin, 3/16 x 1-1/ Spiral Ring, 1/

13 Table 7 TROUBLESHOOTING MANUAL MACHINE Symptom Possible Cause(s) Corrective Action Machine is cutting out of square Machine hesitates or stops as the Pinion Gear enters the Ring Gear. 7.0 Maintenance Incorrect Spacer Bolts Washer is installed between the Saddle and the Spacer Bolt. Pipe is over size, under size or outof-round. Customer is cutting tubing. Customer is back beveling the pipe. All four (4) Spacer Bolts are not in contact with pipe. Torch, Torch Arm or Torch Carrier is loose. Hoses are binding. Machine has been dropped. Torch is at end of Torch Arm. The Pinion Gears too shallow in the large Ring Gear. The timing of the Pinion Gears to the Ring Gear is out of adjustment. The Drive Chain is stretched. Use only Mathey Spacer Bolts. Remove Washer Use the PRO-Model to compensate for over or under size and out-of-round pipe. Contact Mathey Dearman Sales Department for Spacer Bolts for tubing. Use of the Double Torch Arm Attachment is strongly recommended. Save time and money by making both bevels simultaneously. Reposition machine so that all four (4) Spacer Bolts contact the pipe and re-latch Boomer. Tighten Wing Nuts or Thumbscrews. Wrap the Hose one (1) full turn around the pipe. Rotate the Ring Gear of the machine so the Hoses unwrap during the cutting process. Send the machine to a certified repair station for resizing Cap Ring, Ring Gear and Saddle. Move the Torch closer to the Ring Gear. Readjust the Bearing Brackets so the Pinion Gear per the repair instructions. Readjust the timing per the repair instructions. Readjust the Bearing Brackets to eliminate the slack in the Chain per the repair instructions. If the slack cannot be eliminated replace the Drive Chain. In order to the maximum life of the Saddle machine, the maintenance should be performed by an authorized Mathey Dearman Certified Repair Center. The Mathey Dearman Saddle Machines require only minimal maintenance. In order to achieve proper results, make sure the Saddle machine is handled with reasonable care and it is kept clean and lubricated. The machine should be stored in a protective container such as a Mathey Dearman Machine Storage Box or the original factory shipping crate during transporting or when not in use. The Ring Gear, Pinion Gears, and Drive Chains should be kept clear of slag and other trapped abrasives, especially sand and dirt. The Saddle, Ring Gear, and Cap Ring should be cleaned weekly and the Ring Gear track surfaces should be coated with Lubriplate 130-AA or equal lubricant weekly under heavy use and before storing. The Drive Chains and Sprockets should be cleaned regularly and coated with a film of a light oil or lubricant such as WD-40 or equal. The bearings (Figure 5 item 5) in the Single Bearing Brackets (Figure 5) and the bearings (Figure 6 item 7) in the Double Bearing Bracket (Figure 6) are sealed lubricated bearings and should never require replacement. There is 1 thread hole in the side of the Single Bearing Bracket (Figure 5 item 1) containing a set screw (Figure 5 item 8) and 2 thread holes in the side of the Double Bearing Bracket (Figure 6 item 1) containing a set screw (Figure 6 item 10). These Set Screws should never be loosened or removed except to replace the bearings (Figure 5 item 6) and (Figure 6 item 6). Contact Mathey Dearman at , should any questions arise that are not covered in the manual 13

14 7.1 Timing the Ring Gear to the Pinion Gears Adjusting of the timing requires the purchase of the Axle (Figure 5 item 4). Note: Redrilling of the old Axle will severely weaken the axle Remove both Tie Rod Handles (Figure 4 item 7) from the Single and Double Bearing Bracket Assemblies (Figure 4 items 4, 5 & 6) by removing Hex Head Cap Screws (Figure 5 item 10 ) and Washers (Figure 5 item 12) using a 6/16" wrench. NOTE: Save Hex Head Cap Screws (Figure 5 item 10) and Washers (Figure 5 item 12) Remove 3/8-16 x 7/8 Hex Head Cap Screws (Figure 4 item 10) and 3/8 Washer (Figure 4 item 12) from the Left Single Bearing Bracket (Figure 4 item 4) with a 9/16 wrench. Note: Do not loosen the 3/8-16 x 3/4" & 1 1/4" Hex Head Cap Screws (Figure 4 Items 11 & 12) hold the Right Single Bearing Bracket (Figure 4 item 5) and Double Bearing Bracket Assembly (Figure 4 item 6) to the Saddle (Figure 4 item 1) Remove the Drive Chain (Figure 4 item 15) from the Sprocket (Figure 5 item 2) of the Left Single Bearing Bracket Assembly (Figure 4 item 4) Place the Left Single Bearing Bracket Assembly (Figure 4 item 4) in a vise With a 5/32 / 4mm diameter drift punch remove 3/16 x 1 ¼ long Spring Pin (Figure 5 item 11) and 3/16 x 1 long Spring Pin (Figure 5 item 10). NOTE: Save 3/16 x 1 ¼ long Spring Pin (Figure 5 item 11) and 3/16 x 1 long Spring Pin (Figure 5 item 10) for reuse at a later time With a 5/32 allen wrench loosen the Socket Set Screw (Figure 5 item 6) in the Sprocket (Figure 5 item 2) of the Right Single Bearing Bracket Assembly (Figure 5) Remove the Sprocket (Figure 5 item 2) from the axle (Figure 5 item 4) of the Single Bearing Bracket Assembly (Figure 5) With a 1/4" / 6mm drift punch drive the Axle (Figure 5 item 3) / Pinion Gear (Figure 5 item 4) assembly out of the Left Single Bearing Bracket Assembly (Figure 4 item 4) With a 1/4" / 6mm drift punch drive Axle (Figure 5 item 3) out of Pinion Gear (Figure 5 item 4) Press the new Axle (Figure 5 item 3) into Pinion Gear (Figure 5 item 4). Warning: Redrilling of the old Axle will severely weaken the axle Drill a 3/16 / 4.7mm hole completely through the center of the flange of the Pinion Gear (Figure 5 item 4) Install the 3/16 x 1 long Spring Pin (Figure 5 item 10) in the 3/16 / 4.7mm hole Install the Axle (Figure 5 item 3) / Pinion Gear (Figure 5 item 4) assembly into the Left Single Bearing Bracket Assembly (Figure 4 item 4) Place the Sprocket (Figure 5 item 2) on the Axle (Figure 5 item 3) with the hub of the Sprocket facing outward Place the Drive Chain (Figure 4 item 15) on the Sprocket (Figure 5 item 2) of the Left Single Bearing Bracket Assembly (Figure 4 item 4) and the Double Sprocket (Figure 6 item 3) of the Double Bearing Bracket Assembly (Figure 4 item 6) When placing the Left Single Bearing Bracket Assembly (Figure 4 item 4) in position, rotate the Pinion Gear (Figure 5 item 3) so teeth mesh in the teeth of Ring Gear (Figure 4 item 3) Install the 3/8-16 x 7/8 Hex Head Cap Screws (Figure 4 item 10) and 3/8 Washer (Figure 4 item 12) through the Left Single Bearing Bracket (Figure 4 item 4) and screw into the Saddle (Figure 4 item 1) The should be a.005 to.007 gap between the Pinion Gear (Figure 5 item 4) and the teeth of Ring Gear (Figure 4 item 3) Snug the 3/8-16 x 7/8 Hex Head Cap Screws (Figure 4 item 10) with a 9/16 wrench Tighten the Socket Set Screw (Figure 5 item 6) in the Sprocket (Figure 5 item 2) of the left Single Bearing Bracket (Figure 4 Item 4) with a 5/32 allen wrench. 14

15 Rotate the Ring Gear (Figure 4 item 3) clockwise (as viewed from the front of the machine) check the entry of the Pinion Gear (Figure 5 item3) of the Right and Left Single Bearing Bracket Assemblies (Figure 4 items 4 & 5) into the Ring Gear (Figure 4 item 3) Adjust the Pinion Gear (Figure 6 item 3) of the left Single Bearing Brackets (Figure 4 item 4) as needed so that it enters the Ring Gear (Figure 5 item 3) without hesitation. Note: When the Pinion Gears (Figure 5 item 3) of the Right and Left Single Bearing Bracket (Figure 5 item 4 & 5) enters the Ring Gear (Figure 4 item 3) it should not suddenly pull the Ring Gear. As the Pinion Gear (Figure 5 item 4) of the Right and Left Single Bearing Bracket (Figure 5 item 4 & 5) leaves the Ring Gear (Figure 5 item 3) it should not suddenly push the Ring Gear Make sure the Pinion Gears (Figure 5 item 3) of the Right and Left Single Bearing Bracket (Figure 5 item 4&5) are evenly spaced in the teeth of the Ring Gear (Figure 4 item 3) Tighten all Hex Head Cap Screws (Figure 4 item 10) in the Left Single Bearing Bracket Assembly(Figure 4 item 4) using a 9/16 wrench Rotate the Ring Gear (Figure 4 item 3) one (1) full revolution in the clockwise and counterclockwise direction checking the entry of the Ring Gear (Figure 4 item 3) into the Pinion Gears (Figure 5 item 3) of the Right & Left Single Bearing Bracket (Figure 4 items 4 & 5). Note: The entry of the Pinion Gears into the Ring Gear should be smooth and without hesitation. Note: When the Pinion Gears (Figure 5 item 3) of the Right and Left Single Bearing Bracket (Figure 5 item 3) enters the Ring Gear (Figure 4 item 3) it should not suddenly pull the Ring Gear. As the Pinion Gear (Figure 5 item 4) of the Right & Left Single Bearing Bracket (Figure 4 items 4 & 5) leaves the Ring Gear (Figure 4 item 3) it should not suddenly push the Ring Gear Reattach both Tie Rod Handles (Figure 4 item 7) to the Single and Double Bearing Bracket Assemblies (Figure 4 items 4, 5 & 6) with the Hex Head Cap Screws (Figure 4 item 11) and Washers (Figure 4 item 12) and tighten with a 9/16" wrench Rotate the Ring Gear (Figure 4 item 3) one (1) full revolution in the clockwise and counterclockwise direction checking the entry of the Ring Gear into the Pinion (Figure 5 item 3) of the Right & Left Single Bearing Bracket Assembly (Figure 4 items 4 & 5) to insure the entry of the Pinion Gears into the Ring Gear is smooth and without hesitation Drill through Sprocket (Figure 5 item 2) and Axle (Figure 5 item 3) of the Left Single Bearing Bracket Assembly with a 3/16 drill Install 3/16 x 1-1/4 long Spring Pin (Figure 8 item 11) in the (Figure 5 item 2) The saddle machine is now ready for the cutting operation. 7.2 Installation of a New Drive Chains Installation of a new Drive Chains (Figure 4 item 15) will also require the purchase of an Axle (Figure 5 item 4). Note: Redrilling of the old Axle will severely weaken the axle Remove both Tie Rod Handles (Figure 4 item 7) from the Single and Double Bearing Bracket Assemblies (Figure 4 items 4, 5 & 6) by removing Hex Head Cap Screws (Figure 5 item 10 ) and Washer (Figure 4 item 12) using a 9/16" wrench. NOTE: Save Hex Head Cap Screws (Figure 5 item 10) and Washer (Figure 4 item 12) Remove all 3/8-16 x 7/8 Hex Head Cap Screws (Figure 4 item 10) and 3/8 Washer (Figure 4 item 12) from the Left Single Bearing Bracket Assembly (Figure 4 item 4) with a 9/16 wrench Remove the Drive Chain (Figure 4 item 15) from the Sprocket (Figure 4 item 2) of Left Single Bearing Bracket Assembly (Figure 4 item 4) and the Double Sprocket (Figure 6 item 4) of the Double Bearing Bracket Assembly (Figure 4 item 6) Place the Left Single Bearing Bracket Assembly (Figure 4 item 4) on the table. 15

16 7.2.5 Remove the center and outermost 3/8-16 x 7/8 Hex Head Cap Screws (Figure 4 item 10) and 3/8 Washer (Figure 4 item 14) from the Right Single Bearing Bracket Assembly (Figure 4 item 5) with a 9/16 wrench. Note: Do not loosen the 3/8-16 x 7/8 Hex Head Cap Screws (Figure 4 item 10) that hold the Double Bearing Bracket (Figure 4 item 6) to the Saddle (Figure 4 item 12) Tilt the Right Single Bearing Bracket Assembly (Figure 4 item 5) inward toward the Double Bearing Bracket Assembly (Figure 4 item 6) Remove the Drive Chain (Figure 4 item 15) from the Sprocket (Figure 4 item 2) of the Right Single Bearing Bracket Assemblies (Figure 4 item 5) and the Double Sprocket (Figure 6 item 3) of the Double Bearing Bracket Assembly (Figure 4 item 6) Install the new Drive Chain (Figure 4 item 15) onto the Sprocket (Figure 5 item 2) of the Right Single Bearing Bracket Assemblies (Figure 4 item 5) and the Double Sprocket (Figure 6 item 4) of the Double Bearing Bracket Assembly (Figure 4 item 6) Move the Right Single Bearing Bracket (Figure 4 item 5) into position on the backside of Saddle (Figure 4 item 1), while moving Ring Gear (Figure 4 item 3) as needed so the teeth of the Pinion Gear (Figure 5 item 4) of the Right Single Bearing Bracket Assembly (Figure 4 item 5) mesh with the teeth of the Ring Gear (Figure 4 item 3) Reinstall the center and outermost 3/8-16 x 7/8 Hex Head Cap Screws (Figure 4 item 10) and 3/8 Washer (Figure 4 item 12) into the Right Single Bearing Bracket Assembly (Figure 4 item 5) and thread into Saddle (Figure 4 item 3) finger tight Adjust the Pinion Gear (Figure 5 item 4) of the Right Single Bearing Bracket Assembly (Figure 4 item 5) so there is.005 to.007 gap between the Pinion Gear and the teeth of Ring Gear (Figure 4 item 3) Tighten all 3/8-16 x 7/8 Hex Head Cap Screws (Figure 4 item 10) that hold the Right Single Bearing Bracket Assembly (Figure 4 item 5) in position on the Saddle (Figure 4 item 1) with a 9/16 wrench Place the Left Single Bearing Bracket Assembly (Figure 4 item 4) in a vise With a 5/32 / 4mm diameter drift punch remove 3/16 x 1 1/4 long Spring Pin (Figure 5 item 11) from the sprocket (Figure 5 item 2) and 3/16 x 1 long Spring Pin (Figure 5 item 10) from the Pinion Gear (Figure 5 item 4). NOTE: Save 3/16 x 1 ¼ long Spring Pin (Figure 5 item 11) and 3/16 x 1 long Spring Pin (Figure 5 item 10) for reuse at a later time With a 5/32 allen wrench loosen the Socket Set Screw (Figure 5 item 6) in the Sprocket (Figure 5 item 2) of the Left Single Bearing Bracket Assembly (Figure 4 item 4) Remove the Sprocket (Figure 5 item 2) and axle (Figure 5 item) from the Left Single Bearing Bracket Assembly (Figure 4 item 4) With a 1/4" / 6mm drift punch drive the Axle (Figure 5 item 3) / Pinion Gear (Figure 5 item 4) assembly out of the Left Single Bearing Bracket Assembly (Figure 4 item 4) With a 1/4" / 6mm drift punch drive Axle (Figure 5 item 3) out of Pinion Gear (Figure 5 item 4) Press the new Axle (Figure 5 item 3) into Pinion Gear (Figure 5 item 4). Warning: Redrilling of the old Axle will severely weaken the axle Place a 3/16 / 4.7mm drill in the 3/16 / 4.7mm hole locate in the flange of the Pinion Gear (Figure 5 item 4) and drill completely through axle (Figure 5 item 3) and Pinion Gear (Figure 5 item 4) Install the 3/16 x 1 1/4 long Spring Pin (Figure 5 item 11) in the 3/16 / 4.7mm hole in the flange of the Pinion Gear (Figure 5 item 3) Install the Axle (Figure 5 item 3) / Pinion Gear (Figure 5 item 4) assembly into the Left Single Bearing Bracket Assembly (Figure 4 item 4) Place the Sprocket (Figure 5 item 2) on the Axle (Figure 5 item 3) with the hub of the Sprocket facing outward Place the Drive Chain (Figure 4 item 15) on the Sprocket (Figure 5 item 2) of the Left Single Bearing Bracket Assembly (Figure 4 item 4) and the Double Sprocket (Figure 6 item 3) of the Double Bearing Bracket Assembly (Figure 4 item 6). 16

17 When placing the Left Single Bearing Bracket Assembly (Figure 4 item 4) in position on the Saddle (Figure 4 item 1), rotate the Pinion Gear (Figure 5 item 4) so the teeth mesh in the teeth of Ring Gear (Figure 4 item 3) Install the 3/8-16 x 7/8 Hex Head Cap Screws (Figure 4 item 10) and 3/8 Washers (Figure 4 item 12) through the Left Single Bearing Bracket (Figure 4 item 4) and screw them into the Saddle (Figure 4 item 1) finger tight There should be a.005 to.007 gap between the Pinion Gear (Figure 5 item 4) and the teeth of Ring Gear (Figure 4 item 3). Make sure the Pinion Gears (Figure 5 item 4) of the Single Bearing Brackets (Figure 4 items 4 & 5) are evenly spaced in the teeth of the Ring Gear (Figure 4 item 3) Snug the 3/8-16 x 7/8 Hex Head Cap Screws (Figure 4 item 10) with a 9/16 wrench Tighten the Socket Set Screw (Figure 5 item 11) in the Sprocket (Figure 5 item 2) of the left Single Bearing Bracket (Figure 4 item 4) with a 5/32 allen wrench Rotate the Ring Gear (Figure 4 item 3) clockwise (as viewed from the front of the machine) check the entry of the Pinion Gear (Figure 5 item 4) of the Right and Left Single Bearing Bracket Assemblies (Figure 4 items 4 & 5) into the Ring Gear (Figure 4 item 3) Adjust the Pinion Gear (Figure 5 item 4) of the Left Single Bearing Brackets (Figure 4 item 4) as needed so that it enters the Ring Gear (Figure 4 item 3) without hesitation. Note: When the Pinion Gears (Figure 5 item 4) of the Left and Right Single Bearing Bracket (Figure 4 item 4 & 5) enters the Ring Gear (Figure 4 item 3) it should not suddenly pull the Ring Gear. As the Pinion Gear (Figure 5 item 3) of the Left and Right Single Bearing Bracket (Figure 4 item 4 & 5) leaves the Ring Gear (Figure 4 item 3) it should not suddenly push the Ring Gear Tighten the Hex Head Cap Screws (Figure 4 item 11) on both sides of the Left Single Bearing Bracket Assembly (Figure 4 item 4) with a 9/16 wrench Rotate the Ring Gear (Figure 4 item 3) one (1) full revolution in the clockwise and counterclockwise direction checking the entry of the Ring Gear (Figure 4 item 3) into the Pinion Gears (Figure 5 item 4) of the Left and Right Single Bearing Bracket (Figure 4 item 4 & 5). Note: The entry of the Pinion Gears into the Ring Gear should be smooth and without hesitation Reattach both Tie Rod Handles (Figure 4 item 7) to the Single and Double Bearing Bracket Assemblies (Figure 4 items 4, 5 & 6) with the Hex Head Cap Screws (Figure 4 item 10) and Washer (Figure 4 item 12) and tighten with a 9/16 wrench Rotate the Ring Gear (Figure 4 item 3) one (1) full revolution in the clockwise and counterclockwise direction checking the entry of the Ring Gear (Figure 4 item 3) into the Pinion (Figure 5 item 4) of the Left & Right Single Bearing Bracket Assembly (Figure 4 item 4 & 5) to insure the entry of the Pinion Gears into the Ring Gear is smooth and without hesitation Drill through Sprocket (Figure 5 item 2) and Axle (Figure 5 item 3) of the Left Single Bearing Bracket Assembly with a 3/16 drill Install 3/16 x 1-1/4 long Spring Pin (Figure 8 item 11) in the (Figure 5 item 2) The saddle machine is now ready for the cutting operation. 7.3 Disassembly and Repair of the Single and Double Bearing Bracket Assemblies. Contact Mathey Dearman for instructions, if disassembly and repair of the Single and Double Bearing Bracket Assemblies is required 7.4 Storage If the machine will not be used for a period of the time, the machine should be cleaned and regreased with Lubriplate 130-AA. The machine should be stored in a clean and dry place protected from damage. 8.0 Limitations Mathey Dearman is not and will not be responsible for Improper use of the Saddle Machine. Use of the Saddle Machine in violation of any national and/or international electrical and safety regulations in force. 17

18 Connection of the Motorized Saddle Machine to an improper or wrong power source. Faulty maintenance. Unauthorized modification and/or service of the Saddle Machine. Use of non-original spare parts or non-specific components. Lack of observance or partial observance of the operating and maintenance instructions. Unusual events such as natural disasters, wars, strikes or similar events. 9.0 Machine Safety Users should follow these standard safety procedures in order to observe and prevent the safety of all employees using the Oven: Operators must use the wear safety goggles and shoes and should be suitably dressed for the working environment. Operators and maintenance personnel should read and understand the Parts and Operating Manual prior to attempting any type of function. Check the electrical connections prior to operating the Motorized Saddle Machine. Turn off the electrical power source prior to disconnecting the electrical connector from the power source. Observe all health warnings listed in the Parts and Operating Manual Condition of use 10.1 Condition of use The purpose of the Saddle Machine is indicated on section 2.1. Any other use, different from what is listed in section 2.1, could be hazardous to the operator. The Saddle Machine should be placed in a safe place protected from rain, extreme humidity, mud or accidental impact. The Saddle Machine should never be operated in an extremely humid environment such as fog or rain. Adopt all the safety devices supplied or suggested by the manufacturer. No modification to the Saddle Machine or its accessories should be done without the previous written approval by the manufacturer. Remember the Motor Control Box is attached to the power source current is applied to the motor control box. The Motor Control Box should be disconnected from the power source when not in use Use of the Saddle Machine not allowed by the Manufacturer Tampering with the electrical circuit of the Motorized Saddle Machine. Operation of the Saddle without the appropriate safety devices. Perform maintenance with electrical current applied to the Saddle Machine. Use of a liquid or foam fire extinguisher to extinguish a fire in or near the Saddle Machine Disposal of the Saddle Machine 11.1 General Information Do not dispose of any components recklessly without regard for the environment. Separate the components by category for a possible reuse. All national and state regulations should be followed when disposing of waste Composition of the Major Components Component Description Saddle, Cap Ring, Ring Gear, Single & Double Bearing Bracket Step Spacers, Pinion Gear, Boomer, Boomer Chain, Spring, Spring Snap, Drive Chain, Crank Gear and Sprocket, Spacer Bolts, Bearings, Motor Mounting Bracket/Chain Guard and axles Cord Retention Holder Material Aluminum Steel Plastic 18

19 12.0 Warranty If any merchandise sold hereunder (except merchandise manufactured by other persons or firms) by Mathey Dearman, Inc. (the Company ) is not in accordance with specifications shown on the order within customarily accepted tolerances, or is defective on account of workmanship or material, and if such merchandise is returned at the customer s expense and rise, to the Company s manufacturing facility (or at the Company s option, is returned to a repair facility authorized by the Company), within 1 year after the Company s date of shipment thereof, the Company will, at its option, replace or repair the merchandise. This agreement, however, is upon the conditions: (A) that the customer promptly notifies the Company in writing of any claim under this agreement, setting forth in detail any such claimed defect. (B) That the Company be afforded a reasonable opportunity to examine the merchandise and to investigate the claimed defect at the Company s manufacturing facility or at an authorized repair facility, the Company shall not be, in any event, liable for damages beyond the price paid by the customer for such defective merchandise; specifically but without limitation, the Company may fulfill its obligations under this Agreement by tendering such purchase price at any time. THE COMPANY SHALL NOT BE LIABLE FOR CONSEQUENTIAL, INCIDENTAL, PUNITITVE, OR EXEMPLARY DAMAGES. This agreement does not obligate the Company to bear any transportation charges in connection with the replacement or the repair of defective merchandise. As to any item manufactured by other persons or firms, the Company agrees to present a request for adjustment for repair to such manufacturer, and the customer agrees that the liability of the Company shall not exceed any adjustment with respect to which such manufacturer accepts responsibility. THE ABOVE AGREEMENT IS IN LIEU OF ALL WARRANTIES, EXPRESSED OR IMPLIED AND IT IS AGREED THAT THERE IS NO EXPRESSED OR IMPLIED WARRANTY BY THE COMPANY AS TO THE FITNESS, MERCHANTABILITY CAPACITY, OR EFFICIENCY OF ANY MERCHANDISE SOLD, AND THAT THERE ARE NO ORAL OR WRITTEN EXPRESSED OR IMPLIED WARRANTIES MADE IN CONNECTION WITH ANY SALE BY THE COMPANY. No modification or addition to this agreement, either before or after the contract of sale, shall be made except on written authority of the President or Vice President of the Company. Pipe Size OD in inches Nominal Wall Thickness for Schedule Extra Strong XX Strong Table 8 Commercial Pipe Sizes and Wall Thickness 19

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