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Mathey Dearman 03-0102-00, Parts And Operating Manual

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Mathey Dearman 03-0102-00 Parts And Operating Manual Download Page 13

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7.6 

Follow the torch manufacturer’s instructions for preheating the pipe. 

7.7   

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 (if using the Plasma Machine torch, activate per the torch manufacturer 

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. 

7.8 

Rotate the torch around the pipe until the cut is complete. 

7.9 

If using a Plasma torch, turn off per the torch manufacturer instructions. If using an Oxy/fuel torch, proceed to steps 

7.10-7.12. 

7.10 

Rotate the cutting oxygen valve of the cutting torch to the OFF position per the torch manufacturer’s instructions.  

7.11 

Close the fuel and oxygen valve of the torch per the torch manufacturer’s instructions. 

7.12 

Close the valve on the Oxygen and fuel gas bottles if no further cuts are to be made per the torch manufacturers   

                  instructions.  

 
8.0    THE MOTORIZED CUTTING PROCESS 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

8.1 

Installation of Torch Arm, Torch Carrier Assembly and Oxy/fuel or Plasma Torch per instruction in 6.0 

8.2 

Depress the Emergency Stop Switch. 

8.3 

Connect the Motor Cable to surface mount connector of the Motor Control Box.  

8.4 

Connect the other end of the motor cable to the motor assembly.   

NOTE:  Verify the cable lock feature is engage at both ends of the motor cable. 

WARNING

  

         

 

  

      

 

 

 

 

WARNING:  The pipe and debris from the cutting process are extremely hot and can cause  

 

 

WARNING: Keep hands and clothing away from the gearing as it will cause serious injury. 

Picture 8 – Motor Control Box End View 

Picture 7 – Motor Control Box Face View 

Part Number: 03-0203-008 

WARNING: Motor Control Box is designed for use with single phase 90 -240 volts alternating  

current (AC). Use of a higher current will result in serious injury or death 

WARNING:  Motor Control Box is 

not

 designed for use with direct current (DC).  Connection of the  

Motor Control Box to direct current will result in serious injury or death. 

WARNING: The pipe and debris from the cutting process are extremely hot and cause serious  

injury or death. 

Summary of Contents for 03-0102-00

Page 1: ...4107 USA Toll Free 1 800 725 7311 1 918 447 1288 Fax 1 918 447 0188 sales mathey com www mathey com 2SA Saddle Machine Parts Operating Manual Part Number 03 0102 000 03 0102 S01 REVISED February 18 2016 Mathey Dearman Inc For future reference record your Saddle Machine model and serial numbers here Saddle Machine Model ________ SA Serial M___________________ Manual ____ Motorized ____ ...

Page 2: ...re 8 End of the Motor Control Box 13 Picture 9 Cable Motor Control Box to Stepper Motor 14 Figure 5 2SA Saddle Machine Parts Configuration 16 Table 5 2SA Saddle Machine Parts Identification 16 Figure 6 Single Bearing Bracket Configuration 17 Table 6 Single Bearing Bracket Parts Identification 17 Figure 7 Double Bearing Bracket Parts Configuration 17 Table 7 Double Bearing Bracket Parts Identificat...

Page 3: ... Saddle Machine may operate automatically without warning Keep the immediate area around the Saddle Machine clear of materials that may cause interference Keep area clear of bystanders All untrained persons should not work on or near a saddle machine Do not leave the saddle machine unattended while power is on to any electronics NOISE Noise can cause permanent hearing loss Plasma arc cutting oxy f...

Page 4: ...t with dust from cutting grinding drilling and other construction activities Wear protective clothing and wash exposed areas with soap and water Allowing dust to get into your mouth eyes or lay on the skin may promote absorption of harmful chemicals FLYING DEBRIS Metal cutting operations can create debris Use proper eye protection pursuant to ANSI Z87 1 requirements All persons operating in the vi...

Page 5: ...s an arc of electricity that can be up to 45 000 F 25 000 C Oxygen fuel cutting flame can be up to 6 330 F 3 500 C As a result cut materials will be very hot after cutting Use extreme care when handling recently cut materials Proper protective apparel such as protective gloves should be worn when handling recently cut material Material handling devices should also be considered It is recommended t...

Page 6: ...TIBLES obtainable from American Welding Society 550 N W LeJeune Rd Miami FL 33126 NFPA Standard 51 OXYGEN FUEL GAS SYSTEMS FOR WELDING CUTTING AND ALLIED PROCESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 NFPA Standard 70 NATIONAL ELECTRICAL CODE obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 NFPA Standar...

Page 7: ...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 OF THE SPACER BOLTS 3 1 Select the correct Spacer Bolt for pipe being cut The top of the spacer bolt storage box will help with the selection of th...

Page 8: ...ct actual OD of pipe 8 5 8 219mm Difference 4 3 8 111mm Divide Difference by two 2 4 3 8 2 2 3 16 55 5mm ITEM PART DESCRIPTION PART QUANTITY REQUIRED 1 Spacer for 6 152mm pipe 03 0110 022 4 2 Spacer for 8 203mm pipe 03 0110 003 4 3 Spacer for 10 254mm pipe 03 0110 002 4 4 Spacer for 12 304mm pipe 03 0110 001 4 5 Spacer Bolt Kit includes all of the above 03 02SA KIT 1 PART DESCRIPTION Part QUANTITY...

Page 9: ...pacer bolt 6 Pipe 8 Pipe 10 Pipe 12 Pipe Picture 3 Step Spacer Installation 5 0 INSTALLATION OF THE 2SA SADDLE MACHINE ON THE PIPE 5 1 Place the 2SA Machine Saddle squarely on the pipe as close as possible to the cut line All 4 spacer bolts or step spacers should contact the pipe 5 2 Place the hook of the Boomer Figure 3 item 1 into the Boomer Eye Figure 5 Item 7 on the Saddle Figure 5 Item 1 5 3 ...

Page 10: ...omer Assembly Parts Identification ITEM PART DESCRIPTION PART QUANTITY 1 Boomer 01 0258 001 1 2 Spring 01 0184 002 1 3 Chain 01 0577 003 1 4 Spring Snap 01 0258 003 1 WARNING Be careful not to get finger caught between the latch handle and boomer frame WARNING Improper tensioning of the boomer assembly or failure to latch the boomer assembly may result in injury ...

Page 11: ...004 1 4 Screw Kit includes 5 6 7 03 0100 029 1 5 Thumb Screw 3 8 16 x 3 4 22 38TS 034 2 6 Thumb Screw 3 8 16 x 1 22 38TS 100 2 7 Flat Washer 3 8 12 0038 F00 2 6 0 INSTALLATION OF THE TORCH ARM TORCH CARRIER ASSEMBLY AND TORCH 6 1 Install Torch Arm Figure 4 Item A over the two threaded studs Figure 5 item 14 in the face of the 2SA Machine Ring Gear Figure 5 Item 3 Picture 5 Installation of Torch Ar...

Page 12: ...t all pipes within its range 7 0 THE MANUAL CUTTING PROCESS 7 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 or out of round If the distance of the torch tip is greater at the 6 00 positio...

Page 13: ... to be made per the torch manufacturers instructions 8 0 THE MOTORIZED CUTTING PROCESS 8 1 Installation of Torch Arm Torch Carrier Assembly and Oxy fuel or Plasma Torch per instruction in 6 0 8 2 Depress the Emergency Stop Switch 8 3 Connect the Motor Cable to surface mount connector of the Motor Control Box 8 4 Connect the other end of the motor cable to the motor assembly NOTE Verify the cable l...

Page 14: ...nufacturer s instructions 8 15 Connect the oxygen hose from the oxygen regulator to the right hand thread port 10 long Oxy fuel per the manufacturer s instructions 8 16 Adjust the oxygen and fuel gas regulator per the regulator manufacturer s instructions 8 17 Connect the Motor Control Box power cable to the AC electrical receptacle 8 18 Twist to release the Emergency Stop Switch 8 19 Verify the p...

Page 15: ...nufacturer s instructions 8 31 Close the Oxygen and fuel valve on the gas bottles per the torch manufacturer s instructions 8 32 Disconnect the Motor Control Box power cable from the electrical receptacle 8 33 Move the Directional Control Switch to the Off position A NOTE ON BACK BEVELING Remove the torch from the torch carrier assembly Rotate the Torch Clamp Base and Torch 180 degrees on the Torc...

Page 16: ...ie Rod Handle 03 0102 010 1 7 Boomer Eye 03 0101 017 2 8 Cap Screw Hex Head 5 16 18NC x 10 56C0 012 2 9 Cap Screw Hex Head 5 16 18NC x 3 4 10 56C0 034 4 10 Cap Screw Hex Head 5 16 18NC x 7 8 10 56C0 078 2 11 Cap Screw Hex Head 5 16 18NC x 1 10 56C0 100 2 12 Nut Hex 5 16 18NC 1H 56C0 000 2 13 Nut Hex 3 8 16NC 1H 38C0 000 2 14 Threaded Stud not shown in Ring Gear 01 0194 003 2 15 Wing Nut 5 16 18NC ...

Page 17: ...r 04 0106 010 1 7 Screw Socket Set 20NC x 1 4 19 14C0 014 1 8 Spring Pin 3 16 x 1 18 3160 100 1 9 Spiral Ring 01 0179 014 1 ITEM DESCRIPTION PART QTY 1 Bracket 03 0102 008 1 2 Pinion Gear 03 0102 006 1 3 Axle 03 0101 009 1 4 Crank Gear and Sprocket 03 0101 012 1 5 Crank Pinion 03 0101 013 1 6 Crank handle Assembly 03 0101 014 1 7 Bearing 01 0196 012 4 8 Spacer 04 0106 010 2 9 Screw socket set 20NC...

Page 18: ...18 18 Figure 8 Motorized 2SA Saddle Machine Configuration ...

Page 19: ... Cap Screw 8 32 unc x 1 2 lg 11 08C0 012 3 5 Socket Head Set Screw 8 32 unc x 3 16 19 08C0 316 1 6 Button Head Socket Cap Screw 10 24 unc x 3 4 lg 26 10C0 034 4 7 Motor Adaptor 03 0100 064 1 8 Motor Control Box complete with motor and plasma cable See page 13 03 0203 008 1 9 Cable Stepper Motor to Stepper Motor Control Box See page 14 03 0203 200 1 10 Cable Plasma Stepper Motor Control Box Not sho...

Page 20: ...the Ring Gear The Pinion Gears are too shallow in the large Ring Gear Readjust the Pinion Gear so it is at the proper depth in Ring Gear Machine hesitates or stops as the Pinion Gear enters the Ring Gear The timing of the Pinion Gears to the Ring Gear is out of adjustment Readjust the timing of the Pinion Gear to the Ring Gear per the repair instructions Readjust the Bearing Brackets to eliminate ...

Page 21: ... the front of the machine until the gap in the Ring Gear is at the 11 00 Position and off the Pinion Gear Figure 6 item 3 of the Single Bearing Bracket Figure 6 or until the Pinion Gear does not make contact with the Ring Gear 9 1 4 Rotate the Sprocket Figure 6 item 2 on the axle Figure 6 item 4 of the Single Bearing Brackets Figure 6 to make sure it is loose on the axle 9 1 5 Rotate the Ring Gear...

Page 22: ...ssembly Figure 7 item 4 of the Double Bearing Bracket Assembly Figure 7 9 2 7 Place the chain Figure 5 item 16 over the sprocket Figure 6 item 2 of the Single Bearing Bracket Assembly Figure 6 9 2 8 Rotate the Single Bearing Bracket Assembly Figure 6 clockwise while rotating the Pinion Gear Figure 6 item 3 so that it meshes into the Ring Gear Figure 5 item 3 9 2 9 Insert the Hex Head Cap Screw Fig...

Page 23: ... be displayed in the window 9 3 16 Move the Directional Control Switch to the Forward or Reverse direction 9 3 17 Depress the Speed Control Switch until the percent of motor speed reads about 32 so control of the machine can be maintained should an emergency arise 9 3 18 If the motorized unit is operating improperly see the trouble shooting in Table 9 9 4 Replacement of Drive Chain of the Machine ...

Page 24: ...Motor Control Box into a wall outlet having an output of 90 to 240 volts 9 5 15 Twist to release the Emergency Stop Switch 9 5 16 The Digital Screen will light up showing the following 991 Indicates the stepper motor is NEMA 23 992 Indicates the Stepper Motor is NEMA 34 993 Indicates the Stepper Motor is a heavy duty NEMA 994 995 Check cable connection at motor and motor control box 999 Indicates ...

Page 25: ...on 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 12 2 Use of the Saddle Machine not allowed by the Manufacturer Tampering with the electrical ...

Page 26: ...Sizes and Wall Thickness Pipe Size OD inches Nominal Wall Thickness for Schedule 10 20 40 Extra Strong 80 120 140 160 XX Strong 6 6 5 8 134 280 432 432 562 718 864 8 8 5 8 148 250 322 500 500 718 812 906 875 10 10 165 250 365 500 594 843 1 000 1 125 12 12 180 250 406 500 688 1 000 1 125 1 312 ...

Page 27: ...development as well as add on acquisitions to enhance its portfolio and to fulfil increasing industries demands With offices and warehousing on 4 continents 120 employees and more than 250 partnerships and distributors worldwide S F E Group prides itself in consistently offering the highest standard of both product quality and service to all its customers S F E Group looks forward to welcoming you...

Page 28: ...in guk South Korea Tel 82 32 624 2870 E mail sales asia sfe brands com SFE MIDDLE EAST SPECIALIZED FABRICATION EQUIPMENT GROUP Shams Freezone Sharjah United Arab Emirates Tel 971 0 50 217 1376 E mail sales me sfe brands com SFE INDIA SPECIALIZED FABRICATION EQUIPMENT GROUP Plot No PAP 3 D 3 Block Chinchwad Pune 411 019 Mob 91 90 1102 4332 Mob 91 95 5258 4361 E mail sales india sfe brands com SFE L...

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