CIA 010M - 96

Serial N°.................

C.I.A. Mathey Italiana S.r.l. Via Isonzo, 26 - 20050 S. Damiano di Brugherio (MI)

Phone: +39 039 831019 • Fax: +39 039 2020079

Mathey Dearman, Inc. 4344 South Maybelle Ave. Tulsa, OK 74107

Phone: 800-725-7311 • 918-447-1288 • Fax: 918-447-0188

Maxi Chain Driven

Pipe Cutting and Beveling Machine Parts and Operating Manual

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Table of Contents Section Description Page

1.0 General Information 2 2.0 Specification 2 2.1 General Specification 2 2.2 Feature 2

Table 1 Chain Length Table 3 2.3 Cutting Tips 4

Table 2 Cutting Tips Table 4 2.4 Dimension and Weight 5

Figure 2 Machine Dimensions 5 3.0 Operating Instruction 6 3.1 Chain length 6 3.2 Lengthen & Shorten Drive Chain 6 3.3 Cutting 16” & Smaller Pipe Diameters 6 3.4 Cutting Pipe Under Certain Conditions 7

Table 3 Guide Strip Section Requirements 9 3.5 How to Fit Cutting Torch 9 3.6 Starting Manual Cutting Process 10 3.7 230 V ac Motorized Cutting Process 10 3.8 115 V ac Motorized Cutting Process 10 3.9 Disassembly of Manual Model After Use 11

3.10 Disassembly of 230 V ac Motorized Model 11 3.11 Disassembly of 115 V ac Motorized Model 11 4.0 Safety Devices 11 5.0 Conditions of Use 12 6.0 Maintenance 12 7.0 Warranty 12 7.1 General Conditions 12 7.2 Limitations 12

Warranty Certificate 13 8.0 Recommended Non-use Conditions 14 9.0 Material Composition of Components 14

Table 4 MAXI Chain Machine Trouble Shooting Guide 14 Figure 5 Parts Drawing of MAXI Chain Machine 15 Table 5 Parts List Table 16 Figure 6 Motorized Unit Parts Drawing 18 Table 6 Motorized MAXI Parts List 19 Figure 7 Accessories 20 Table 7 Accessories Parts List 20 Table 8 Chain Kits 21

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1.0- GENERAL INFORMATION If the manual should be lost or damage, it is possible to obtain a copy on our Internet site at www.mathey.com or from C.I.A. Mathey Italiana S.r.l. or Mathey Dearman, Inc. at the phone number or address mentioned on the front page of the manual. When requesting a manual, please provide the following information:

• Type of Machine and Model • Serial Number • Supplier • Name and Address of the User • Correct Address where to Deliver the Copy of the Manual.

If the machine is the property of anyone, who is not the original purchaser, please inform us so we can communicate with the new owner for any up dated information. At the time of sale, the manual represents the state of the art technology and should be considered inadequate if it is later updated due to improvements. C.I.A. Mathey Italiana S.r.l. and Mathey Dearman are not obligated to update the manual and/or the Maxi Chain Machine of the purchaser if improvements are made due to new technology.

This manual is supplied with the machine. • All operators, maintenance employees and other personnel should read the manual as it concerns

safe operation, spare parts and warranty. • The manual should be kept in a clean and humid free environment with easy reach of the operators. • All operators should read the manual prior to attempting to install, use, perform maintenance or dismantle

the Maxi Chain Machine. • The supervisor should make sure the operators understand the operation of the Maxi Chain Machine

and Oxygen/fuel Machine Cutting Torch. • Do not damage or remove any labels or the nameplate fitted on the machine. • Accidents can be prevented if the operators understand the operation of the machine and cutting torch.

2.0 - SPECIFICATION 2.1 - General Specification The Maxi Chain Driven Cutting and Bevelling Machine is designed to manually rotate an oxygen/fuel machine cutting torch around pipes 4” (102 mm.) and larger in diameter. The Maxi Chain Machine can be used with any gas cutting machine torch (acetylene, Butane, propylene, natural gas or propane gas) or machine having a diameter of 30 or 35 mm. Pricing for propane or acetylene machine cutting torch is available. If vertical adjustment of the Gas Cutting Torch is necessary a Rack can be added to the Gas Torch.

2.2. - Features The Maxi Chain Machine Frame, which is an alloy aluminium casting, is fitted with a Forwarding Device, Tensioning Cam Handles, Wheels and a Rack Holder-Floating Device to support the Torch. The Maxi Chain Machine is attached to the pipe being cut by means of a 3-Mesh Chain. The Forwarding Device rotates the machine around the pipe during the cutting operation. Two (2) Hand Cranks are used to move the Forwarding Device composed of a Worm Screw and a Bronze Toothed Rim that are joined to the Chain Pinion. Two Tensioning Cams provide tension to the chain to fix the machine to the pipe. The Forwarding Device moves upward on two ALUMINUM columns as tension is applied to the Chain. The Rack Holder Floating Device provides movement perpendicular to the machine line of travel and a Knob with Pinion Positions it.

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Figure 1 – Wheel Position

Table 1.

LENGTH OF CHAIN FOR DIFFERENT PIPE DIAMETER

Pipe Diameter*

In/mm

4 / 102 6 / 152 8 / 203 10 / 254 12 / 305 16 / 406 18 / 457

Wheel Position A B B B B B B

Chain Length (In/mm)

28 / 711 34 / 864 40 / 1016 46 / 1168 52 / 1321 62 / 1575 68 / 1727

Pipe

Diameter* In/mm

20 / 508 22 / 559 24 / 610 26 / 660 28 / 711 30 / 762 32 / 813

Wheel Position

B B B B B C C

Chain Length (In/mm)

74 / 1881 80 / 2032 86 / 2184 93 / 2362 99 / 2515 105 / 2667 111 / 2816

Pipe

Diameter* In/mm

36 / 914 38 / 965 40 / 1016 42 / 1067 48 / 1219 50 / 1270 52 / 1321

Wheel Position

C C C C C C C

Chain Length (In/mm)

123 / 3127 129 / 3283 136 / 3439 142 / 3607 161 / 4089 167 / 4242 173 / 4394

*The pipe diameter listed is the nominal pipe size; for the actual pipe outside diameters see a commercial pipe chart for actual outside diameter of the pipe. A Chain Calculation Formula for determining the length of chain needed can be found on the Internet at www.mathey.com under Product Formulas.

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2.3 - Cutting Tips: Tips are available for any torch and most types of gas and cutting capacities.

Table 2 - How to select the right cutting tip for different cutting thickness and gas.

Acetylene Gas

Tip Code Cutting Thickness (in/mm) Tip

Code Cutting Thickness (in/mm)

n. 1 5/16 - 5/8 / 8 - 15 n. 4 3 - 6 / 75 - 150

n. 2 5/8 - 1 3/8 / 15 - 35 n. 5 6” - 8 / 150 - 200

n. 3 1 3/8 - 3 / 35 - 75 n. 6 8 - 12 / 200 - 300

The above mentioned tips are sold through C.I.A. Mathey Italiana S.r.l. and Mathey Dearman Inc. for other torches and speciality gas tip contact same as above.

Propane Gas Tip

Code Cutting Thickness (in/mm) Tip Code Cutting Thickness (in/mm)

n. 1 1/2 - 3/4 / 12,5 - 20 n. 6 5 - 6 / 125 - 150

n. 2 3/4” - 1 3/8 / 20 - 35 n. 7 6 - 7 / 150 - 175

n. 3 1 3/8 - 2 3/8 / 35 - 60 n. 8 7 - 8 / 175 - 200

n. 4 2 3/8 - 3 / 60 - 75 n. 9 8 - 9 / 200 - 225

n. 5 3 - 5 / 75 - 125 n. 10 9 - 10 / 225 - 250

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2.4 - Dimension and Weight.

Figure 1 – Machine Dimensions

Net Weight Shipping Weight Machine Description (lbs/kg) (lbs/kg)

Manual Model 45 / 20.4 63 / 28.4 115vac Motorized Model 49 / 22.2 67 / 30.4 230vac Motorized Model 55 / 25 73 / 33 Shipping Dimensions CIA Mathey Mathey Dearman Manual Model 10” X 15” X 30” / 254 X 381 X 762mm 115vac Motorized Model 15” X 15” X 30” / 381 X 381 X 762mm 230vac Motorized Model 17 ¾” X 15 ¾” X 15 ¾” / 451 X 400 X 400mm

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3.0 - OPERATING INSTRUCTION 3.1 - Chain Length

Drive Chain Length required is determined by the diameter of pipe to be cut. Table 1 of Section 2.2 shows the chain length for various diameters of pipe. See the Calculation Formula on our web site at www.mathey.com or contact for other diameters of pipe other than those listed.

3.2 How to Lengthen/Shorten the Drive Chain.

From Table 1 of Section 2.2, select the Drive-Chain length required. If the chain length is incorrect, proceed as follows: - To Lengthen the Drive-Chain.

- Select the chain segments required to extend the chain to the length mentioned in Table 1 of Section 2.2. - Join the Chain Segments with Chain Junction Link (Item N° - 21D) or Joint Bolt (Item N° -21A) and Nut (Item

N° - 21B). In some instance it may be necessary to use the False Link (Item N° - 21C)

- Set the Chain Segment, which is the proper length in the Chain Unpinning Block (Item N°-20B) and remove the Chain Pin with the Pin Extractor (Item N° - 20A). If one pin is removed the chain is joined with the Joint Bolt (Item N° - 21B) and Nut (Item N° - 21A). If two pins are removed the chain is joined with the Chain Junction Link (Item N° - 21D).

- Check the Chain Ends to make sure that they meet your application requirement. For Male/female Chain Ends Joint Bolt (Item N° - 21B) and Nut (Item N° - 21A) and for Female to Female Chain Ends use Chain Junction Link (Item N° - 21D).

Note: In some instances it may be necessary to use False Link (Item N° - 21C) in order to obtain the proper chain length.

- To shorten the Drive Chain. - Select the Chain Segments required to shorten the chain to the length mentioned in Table 1 of the Section

2.2. - Set the Chain Segment, which is the proper length in the Chain Unpinning Block (Item N° - 20B) and remove

the Chain Pin with the Pin Extractor (Item N° - 20A). If one pin is removed the chain is joined with the Joint Bolt (Item N° - 21B) and Nut (Item N° - 21A). If the two pins are removed the chain is joined with the Chain Junction Link (Item N° - 21D).

- Check that the Chain Ends to make sure that they meet your application requirement. For Male/Female Chain Ends Joint bolt (Item N° - 21B) and Nut (Item N° - 21A) and for Female to female Chain Ends use Chain Junction Link (Item N° - 21B).

Note: In some instances it may be necessary to use False Link (Item N° - 21C) in order to obtain the proper chain length.

3.3 Cutting 16” Pipe Diameters and Smaller with the Maxi Chain Machine.

Check the area where the Maxi Chain Machine Wheel and Chain will be placed on the pipe for concave or convex areas on the pipe surface, before placing the machine on the pipe -remove as much of the deformity that is allowed by the welding specification.

Set the machine on the portion of the pipe that is to remain on the Pipe Stand, with the Wheels of the Torch Arm side of the machine about 6” - 8” (152- 203mm) away from the cut line. The distant from cut line to the Wheels is dependent on the Torch Bevel Angle.

Warning: Unrepairable damage to the Maxi Chain Machine will occur if the machine is placed on the portion of the pipe to be cut off.

- Pull the Drive Chain through the cavity between the Sliding Core (3M) and the Sprocket (Item N° - 4A) until 12” – 18” of the Chain is protruding out of the other side.

- Lay the Chain to rest on the Sprocket (Item N° - 4A). - Connect the Chain Ends. - Rotate the Tensioning Levers simultaneously applying tension to the Chain. - For a square cut, rotate the Maxi Chain Machine one (1) full turn around the pipe to insure the chain is

perpendicular to the outside diameter of the pipe. - The Chain Machine is now ready for the

installation of the Fuel Torch.

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Note: If the pipe is spiral welded, excessively out of round or is in the vertical or oblique position, see instructions for the Installation of the Guide Strip.

3.4 The Maxi Chain Machine Guide Strip is recommended when cutting pipe under the following conditions. If the pipe to be cut is spiral welded, severely out of round, in the vertical position or oblique position, when cutting pipes larger than 18” (457mm), it will be necessary to use a Guide Strip to fit the Guide Belt.

- Check the area 8” - 18” (203 - 457mm) away from the cut line where the Maxi Guide Strip

will be placed on the pipe for concave or convex areas in the pipe surface. Remove as much of the deformity that is allowed by the welding specification.

Warning: Placing the machine on the portion of the pipe that is being cut off will result in unrepairable damage to the Maxi Chain Machine.

- Form all sections of the Guide Strip as close as possible so that they fit the pipe diameter to be cut. The better the sections of the Guide Strip fit the diameter of the pipe; the easier it will be to latch the ends of the Guide Strip together.

- Attach the sections of the Guide Strips together as shown in Figure 3 with the Washer

(Item N° - C1) in between the Band End Pivot Points and insert the Pins (Item N° - C2). When assembled, the section containing the Latch Handle Assemblies (Item N° - B) should be at one end of the assembled Guide Strip and the section containing the Latch Receiver (Item N° - A) should be at the other end. Repeat this step for each section to be assembled.

FIGURE 3

- It may be necessary to move the Latch Handle Assemblies in order for the Guide Strip to fit tightly around the Pipe. To move the Latch Handle Assemblies (Item N° - B) to their proper location, remove the Countersunk Screws and Domed Nuts (D) from the Latch Handle Assemblies (Item N° - B) shown in Figure 4 and remove the Latch Assemblies from the Guide Strip.

- Place the section (Item N° - G) containing the Latch Handle Assemblies (Item N° - B) over the section containing the Latch End (Item N° - A).

- Fold the Latch Handles (Item N° - E) of the Assemblies over until it touches the Screws (Item N° - F) of the Latch Adjustment.

- Place the end of the Latch Adjustment Screws (Item N° - F) of the Latch Handle Assemblies (Item N° - B) into the curved portion of the Latch Receiver (Item N° - A).

- Locate the nearest holes in Section G of the Guide Strip and mark them.

- Place the Latch Handle Assemblies (Item N° - B) Base over the marked holes and insert

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- Countersunk Screws and Nuts (Item N° - D) in the Latch Handle Assembly Base. Tighten the Domed Nuts on the Screws. - Again place the section containing the Latch Handle Assemblies (Item N° - B) over the section containing the Latch End (Item N° - F). - Place the end of the Latch Adjustment Screws (Item N° - F) of the Latch Handle Assemblies into the curved portion of the Latch Receiver (Item N° - A). - Adjust the end of the Latch Adjustment Screws (Item N° - F) until the Handle of Latch Handle Assembly Locks in position.

Note: A large amount of pressure should not be used to close the Latch.

Figure 4 Warning: The Latch should not be forced closed as this will cause damage to the Latch or deform the end of the Receiver Section.

- Place the Wheels (Item N° - 11D) of Maxi Chain Machine over the Guide Strip. - Pull the Drive Chain through the cavity and over the Sprocket (Item N° - 4A), until 12” – 18” of the Chain is protruding out the other side of the Cavity. - Lay the Chain (Item N° - 21) to rest on the Sprocket (Item N° - 4A) - Place the Chain between the Dome Nuts located near the center of the Guide Strip. - Connect the chain ends. - Rotate the Tensioning Levers (Item N° - 8E) simultaneously applying tension to the Chain. - Cut the Chain to length and insert the Conn-link. - The Maxi Chain Machine is now ready for installation of the Fuel Torch.

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Table 3 - Guide Strip Section Required for a Given Diameter

Pipe Diameter In / mm

Head Section

05-0520-013B

Tail Section

05-0520-013D

Short Center Section

05-0520-013C

Long Center Section

05-0520-013A 18 / 458 1 1 **** **** 20 / 508 1 1 **** **** 24 / 610 1 1 **** **** 28 / 711 1 1 1 **** 30 / 762 1 1 1 **** 32 / 813 1 1 1 **** 34 / 864 1 1 **** 1

36 / 914 1 1 **** 1

42 / 1067 1 1 2 **** 48 / 1219 1 1 1 1

52 / 1321 1 1 **** 2

54 / 1372 1 1 2 1

58 / 1473 1 1 2 1

60 / 1524 1 1 1 2

3.5 How to Fit the Cutting Torch. The 1 3/8” (35mm) Torch Holder (Item N° - 17) is offered with a Knob for 32 pitch or metric pinion (Item N° - 17A) to adjust the Gas Torch Tip to pipe height.

- The shop manager and equipment operators should read the Torch Manufacturer’s Instructions for proper use of the gas cutting torch. - Use the correct the gas for the type of torch purchased. - Verify the Torch Cutting Tip is the correct tip for the type of gas and pipe thickness.

See Table 2 on Section 2.3 for torch tip cutting capacities.

- A Plasma Cutting System with Machine Cutting Torch can be used with the Maxi Chain Machine to cut stainless steel and non-ferrous pipes. - Set Gas and Oxygen Regulators to the pressure specified by the manufacturer for the type of gas that is being used. - Move the knob (Item N° - 13A) to check the Torch Arm Tension and adjust as needed. - Install the Torch into the Torch Holder (Item N° - 17) and rotate the Knob with Pinion (Item N° - 17A) to adjust the Gas Torch Tip to the correct pipe height. - Tighten Screw (Item N° - 17C) so that the Torch moves up and down with some friction.

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3.6 STARTING THE MANUAL CUTTING PROCESS - Light the gas torch per the manufacturer’s instructions. - Preheat the pipe to the desired temperature. - Rotate the Crank Handle (Item N° - 24A/24C) while applying the Cutting Oxygen to the Gas Torch to minimize

notching of the pipe. - Rotate the Crank Handle (Item N° - 24A/24C) until the torch has completed the cut. - Turn off the Cutting Oxygen Valve as soon as the cut is complete. - Turn off the gas and oxygen to the Gas Torch.

3.7 STARTING THE 230VAC MOTORIZED CUTTING PROCESS - Connect the Power Supply (Item N° - 28 or 28A) to the Right Angle Drive Motor (Item N° - 22/B). - Connect the Remote Control Pendant Cord (Item N° - 27A) to the Power Supply (Item N° - 28 or 28A) - Connect the Power Supply (Item N° - 28 or 28A) to the 230vac electrical source. - Move the Main Power Switch (Item N° - 28/D) located on the Power Supply to the “On” Position. - Move the Pendant Power Switch (Item N° - 28/D) to the “ON” Position. - Move the Pendant Forward/Reverse Switch (Item N° - 27/D) on to the Forward or Reverse Position to check

functionality of the equipment. Increase the Speed Regulator as needed. - Move the Pendant Power Switch (Item N° - 28/D) to the “OFF” Position, - Light the Gas Torch per the manufacturer’s instructions. - Preheat the pipe to the desired temperature. - Move the Pendant Power Switch (Item N° - 28/D) to the “ON” Position. - Move the Pendant Forward/Reverse Switch (Item N° - 27/D) to the Forward or Reverse Position. - Start the rotation of the Maxi Chain Machine around the pipe, while applying the cutting oxygen to the Gas

Torch to minimize notching of the pipe. - Increase the Speed Regulator (Item N° - 27/E) as needed to achieve the desired cut quality. - Continue to rotate the Maxi Chain Machine around the pipe until the cut is complete. - Turn off the Cutting Oxygen Valve as soon as the cut is complete. - Move the Pendant Power Switch (Item N° - 27/C) to the “OFF” Position. - Turn off the gas and oxygen to the Gas Torch.

3.8 STARTING THE 115VAC MOTORIZED CUTTING PROCESS - Connect the Motor Control Box (Item N° - 27/A1) to the Right Angle Drive Motor (Item N° - 22/B1). - Make sure the Motor Control Box (Item N° - 27/A1) Forward/Reverse Switch is in the “Center” or “Off”

Position. - Connect the Motor Control Box (Item N° - 27/A1) to the 115vac Electrical Source. - Move the Forward/Reverse Switch to the Forward or Reverse Position to check functionality of the

equipment. Increase the Speed Regulator Clockwise as needed. - Move the Motor Control Box (Item N° - 27/A1) Forward/Reverse Switch to the “Center” or “Off” Position. - Light the Gas Torch per the manufacturer’s instructions. - Preheat the pipe to the desired temperature. - Move the Motor Control Box (Item N° - 27/A1) Forward/Reverse Switch to the desired direction, while

applying the Cutting Oxygen to the Gas Torch to minimize notching of the pipe. - Increase the Speed Regulator clockwise as needed to achieve the desired cut quality. - Rotate the machine around the pipe until the cut is complete. - Turn off the Cutting Oxygen Valve as soon as the cut is complete - Move the Forward/Reverse Switch on the Motor Control Box (Item N° - 27/A1) to the “Off” Position. - Turn off the gas and oxygen to the Gas Torch.

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3.9 DISASSEMBLY MANUAL MODEL AFTER USE - Remove the Cutting Torch from the Torch Holder (Item N° - 17). Check the functionality of the Gas Torch and Cutting Tip. - Rotate the Tensioning Levers (Item N° - 8E) simultaneously releasing the chain tension. - Remove the Joint Bolt (Item N° - 21A) and Nut (21B) or Junction Link (Item N° - 21D) from

the Chain. - Remove the Chain Machine from the pipe by releasing both Latch Handle Assemblies. - If the Guide Strip is used, remove from pipe by releasing both Latch Handle Assemblies

(Item N° - B).

3.10 DISASSEMBLY 230VAC MOTORIZED MODEL AFTER USE - Move the Power Switch (Item N° - 27/C) to the “OFF” Position. - Disconnect the Power Supply (Item N° - 28 or 28A) to the 230vac Electrical Source. - Disconnect the Power Supply (Item N° - 28 or 28A) to the Right Angle Drive Motor (Item N° - 22/B).

Disconnect the Remote Control Pendent (Item N° - 27A) to the Power Supply (Item N° - 28 or 28A).

- Remove the Cutting Torch form the Torch Holder (Item N° - 17). Check the functionality of the Gas Cutting Torch and Cutting Tip. - Rotate the Tensioning Levers (Item N° - 8E) simultaneously releasing the chain tension. - Remove the Joint Bolt (Item N° - 21A) and Nut (Item N° - 21B) or Junction Link

(Item N° - 21C) from the chain. - Remove the Maxi Chain Machine from the pipe. - Remove the Guide Strip from the pipe by releasing the both Latches if used.

3.11 DISASSEMBLY 115VAC MOTORIZED MODEL AFTER USE - Move the Motor Control Box (27/A1) Forward/Reverse Switch to the “Off” Position. - Disconnect the Motor Control Box (27/A1) from the 115vac Electrical Source. - Disconnect the Motor Control Box (27/A1) from the Right Angle Drive Motor (22/B1). - Remove the Cutting Torch from the Torch Holder (17). Check the functionality of the Gas

Cutting Torch and Cutting Tip. - Rotate the Tensioning Levers (8E) simultaneously releasing the chain tension. - Remove the Joint Bolt and Nut (21A) or Junction Link (21B) from the Chain. - Remove the Joint Bolt (Item N° - 21A) and Nut (Item N° - 21B) or Junction Link

(Item N° - 21C) from the Chain. - Remove the Chain Machine from the pipe. - Remove the Guide Strip from the pipe by releasing the both Latches if used.

4.0. - SAFETY DEVICES 4.1 Accident Prevention Rules. The operator should follow all shop, national, and manufacturer standard Safety Procedures for the safety of the operator using the Maxi Chain Cutting Machine such as: - During the cutting process, all the personnel not associated with the process, should stay at safe distance. - Persons in the work area should always wear safety equipment such as gloves, safety shoes and clothing

suitable for the work environment and the ambient temperature. - While the Maxi Machine is in operation, all personnel working in the vicinity of the machine should wear safety

glasses or other eye protection. - Before starting the cutting operation, check all connections to the torch on oxygen and gas regulators to make

sure they are tight. - Considering the thickness of the pipe to cut, the cutting speed must be properly selected. - Keep the work area clear of all flammable material. - Always wear safety glasses or face shield when removing slag, grinding dust and other debris from the work

area.

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1. Make sure the Maxi Chain Machine, torch, regulators and hose are properly maintained.

IN ADDITION TO THE ABOVE PROCEDURES, ALL SHOP, NATIONAL AND MANUFACTURER’S SAFETY INSTRUCTIONS CONCERNING FLAME CUTTING SYSTEM SHOULD BE FOLLOWED. ALL CUTTING OPERATIONS SHOULD BE CONDUCTED IN THE BEST OF SAFETY CONDITIONS.

5.0 – CONDITIONS OF USE 5.1 Provided Use Condition The Maxi Chain Machine is designed to cut pipe having a minimum nominal pipe diameter of 4” (102mm). It is not recommended to fit the Guide Belt and the Drive Chain on heavily crushed pipe or pipe having weld crown in excess of 3/8” (9.5mm) in order to avoid disfigurement of the Guide Strip and overloading of the Drive Chain. Cutting of vertical pipe should not be attempted without the use the Maxi Guide Strip.

6.0. - MAINTENANCE 6.1 Routine Maintenance - Routine maintenance should be planned in advance to avoid down time. - The period between routine maintenance checks should be shortened if the machine is in constant use. - Check the machine to make sure it has not been dropped. - Replace all worn parts during the routine maintenance inspection,. - Maintain the gas torch and the oxygen and gas regulators per the manufacturer’s instructions. - Check daily all oxygen and gas hoses for burns and abrasions. - Oxygen and gas bottles should be checked in accordance to the safety standard.

6.2 Extraordinary Maintenance The machine does not require specific maintenance under normal conditions. Please contact C.I.A. Mathey Italiana S.r.l. or Mathey Dearman Inc. for assistance and suggestions to obtain best machine performance or prior to disassembly of the Maxi Machine. Please inform manufacturer of any problems that occur or any suggestions to improve the performance of the cutting machine. Your suggestions will aid in updating future machines.

7.0 - WARRANTY 7.1 - General Conditions

C.I.A. Italiana S.r.l. and Mathey Dearman Inc. warrant the product mentioned in this manual for a period of 1 (one) year from the date of deliver. The warranty is valid for the above mentioned period and only for the parts that will have defect of design or defective material. Complaints must be sent directly to C.I.A. Italiana S.r.l. or Mathey Dearman Inc. with an explanation of the defects. C.I.A. Italiana S.r.l. or Mathey Dearman Inc. will provide full instructions for repair or replacement, free of charge of the complained parts. Any transport expenses or/and service will be covered by the customer.

7.2 - Limitations C.I.A. Italiana S.r.l. and Mathey Dearman Inc. are not responsible for the following: - Improper use of the machine. - Use against the national and/or international regulation in force. - Improper or wrong connection. - Improper maintenance. - Unauthorized modifications and/or services. - Use of non-original spare parts or specific components not called for in this operating Manual. - Failure to observe the operating instruction. - Unusual events such as natural disasters.

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Warranty C.I.A. Italiana S.r.l. Mathey Dearman, Inc. Via Isonzo 26 4344 South Maybelle Ave. 2050 San Damiano di Brugherio Tulsa, OK 74107 Milano

Flame Pipe Cutting Machine Version Manual Motorized

Serial No: ………………………………………………….. Purchase Date: ………………………………………..….. Dealer: ……………………………………………….…….. Customer Name: ……………………………………….... Address: …………………………………………….……..

This machine is warranted for a period of 6 (six) months from the Date of Delivery.

Registered on: ……………….. by C.I.A. Mathey Italiana

__________________________________ (Signature and Stamp) For more information please call: C.I.A. Mathey Italiana - Phone: 0039-39-831019 – Fax: 0039-39-2020079 Mathey Dearman Inc. – Phone: 918-447-1288 - Fax: 918-447-0188

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8.0- MAXI CHAIN CUTTING MACHINE IS NOT RECOMMENDED FOR USE UNDER THE FOLLOWING CONDITIONS

Maxi Chain Machine is specially designed to cut and bevel pipes. Should never to be used in the presence of gas or flammable liquid or solid. All obstacles must be removed before operation to insure proper clearance around the pipe. The flame of the cutting torch should never be positioned in direction of the operator or other people. Never use the Cutting Torch with an improper gas. For Proper use of the Cutting Torch and Tip refer to the specific Manual for the Torch. Switch “OFF” the Cutting Machine and Torch prior to any type machine for maintenance.

9.0 – Material Composition of the Components The components of the MAXI Chain Machine are made from the following materials:

Table 4 - Maxi Chain Machine Trouble Shooting Guide

Carbon Steel Worm Screw, Bolts, Floating Device, Wheels, Shaft, Spring.

Aluminium Main body unit, “U” Body Unit, Torch Holder. Brass Pinion, Torch Holder Support, Slide, Toothed Rim Plastic Crank, Knob, Handle.

Symptom Probable Cause Corrective Action

Machine slips on the pipe

1. Drive Chain (Item N° 21) is too long. 1. Shorten Chain as necessary.

2. Pipe surface is too smooth. 2. Rough up surface of pipe so the chain will grip on the pipe.

3. Weld bead is too tall. 3. Grind down weld bead flush with pipe surface.

Machine is cutting the pipe out of

square

1. The Machine has not been taken one (1) full turn around the pipe prior to cutting.

1. When the machine is used without Guide Strip, rotate the machine 1 full rotation around the pipe prior to cutting the pipe.

2. A Guide Strip was not used to cutting pipe larger than 18”.

2. Install the Guide Strip on pipe.

3. A Guide Strip was not used when cutting spiral weld pipe.

3. Install the Guide Strip on pipe.

4. A Guide Strip was not used when cutting pipe on a angle.

4. Install the Guide Strip on pipe.

5. A Guide Strip was not used when cutting vertical pipe.

5. Install the Guide Strip on pipe.

6. A large plasma torch is being used with the machine.

6. Install the Guide Strip on pipe.

7. There is too much play between Rack Holder (12) and Sliding Support (14)

7. Tighten Screws in Sliding Support.

8. The Tracer Point (13C) is not Always in contact with the pipe during machine’s rotation around the pipe.

8. Adjust the Tracer Point so that it is always contacting the pipe through the machines’ entire rotation.

Motorized Machines Only

Machine does not operate in forward

or reverse

1. No voltage at Power Source. 1. Restore power at source.

2. Fuse is blown 2. Replace Fuse.

3. Connection between Motor Control Box and machine loose or disconnected.

3. Reconnect wiring

4. Set Screw (22C or 22D) in Coupling Sleeve (22A or 22A1) is not engaging Motor Shaft

4. Make sure Set Screw is above flat on Motor Shaft and tighten

Machine will not climb uphill when cutting thick wall pipe

1. Motor is operating below its curve power. 1. Use a cutting tip 1 to 2 sizes larger

15

Figure 4 – Exploded Parts Drawing of the MAXI Chain Machine

16

Table 5 - MAXI Chain Machine Parts LIST

ITEM DESCRIPTION PART NUMBER

ITEM DESCRIPTION PART NUMBER

1 Aluminum Main Body

05-0510-101 8C Lower Spring (2) 05-0510-108C

1A Socket Set Screw, M8 x 12 05-0510-101A 8D Traction Pin (2) 05-0510-108D 2B Double Sliding Block 05-0510-102B 8E Handle (2) 05-0510-108E 2A Bearing 05-0510-111C 8F Lock Nut, M10 05-0510-108F 3 Black, Worm Gear

Housing 05-0510-103 8G Pin, 8mm Dia. x 30mm 05-0510-108G

3A Flange 05-0510-103A 9A Pin, Floating Device Holder

05-0510-109A

3B Bearing (2) 05-0510-103B 9B Washer Pin Locking 05-0510-109B 3C Flange, Worm Gear

Housing (2) 05-0510-103C 9C Bronze Bushing,

Floating Device 05-0510-109C

3D Bronze Toothed Rim 05-0510-103D 9D Socket Head Cap Screw, M8 x 16

05-0510-009D

3E Worm Screw 05-0510-103E 10A Spring Guide, Pressure Regulation

05-0510-110A

3F Bearing (2) 05-0510-103F 10B Spring 05-0510-110B 3G Socket Head Cap Screw,

M4 x12 05-0510-103G 10C Spring Holder,

Floating 05-0510-110C

3H Socket Head Flat Screw, M4 x 12

05-0510-103H 10D Knob, Pressure Regulation

05-0510-110D

3I Key, Bronze Toothed Rim 05-0510-103I 10E Socket Head Cap Screw, M4 x 12

05-0510-110E

4A Pinion 05-0510-104A 11 Wheel Complete, Bearing and Seeger (4)

05-0510-111

4B Locking Pin, Pinion 4mm x 50mm

05-0510-104B 11A Socket Head Cap Screw, M8 x 16 (4)

05-0510-11A

4C Pinion Holder Shaft 05-0510-104C 11B Snap Ring, (4) 05-0510-11B 5 Upper Locking Plate 05-0510-105 11C Bearing, (4) 05-0510-101C 6 Socket Head Cap Screw,

M5 x 20 (8) 05-0510-106 11D Wheel 05-0510-111D

7 Bronze Ram 05-0510-107 11E Washer, 8MM 05-0510-111E 7A Socket Set Screw, M5 x 40

(8) 05-0510-107A 11F Washer, 6MM 05-0510-111F

7B Socket Set Screw, M5 x 16 (8)

05-0510-107B 11G Socket Head Screw, M6 x 10

05-0510-111G

8 Can Mechanism 05-0510-108 12 Rack Holder, Floating Device with Bronze Rack

05-0510-112

8A Washer, M10 (2) 05-0510-108A 12A Bronze Rack 05-0510-112A

8B Upper Spring 05-0510-108B

17

ITEM DESCRIPTION PART NUMBER ITEM DESCRIPTION PART NUMBER

12C Socket Head Flat Screw, M3 x 8

05-0510-112C 20B Chain Pin Extractor Block

05-0510-120B

12D Socket Head Cap Screw, M6 x 10

05-0510-111G 21 1/2" - Three Mesh Chain 05-0510-005E

13 Sliding Support, Tracer Point, Complete

05-0510-113 21A Chain Coupling Bolt 05-0510-071

13A Handle with Toothed Pinion 05-0510-113A 21B Chain Coupling Nut 05-0510-062

13B Brass Slide 05-0510-113B 21C Chain False Link (1/2 link)

05-0510-121C

13C Tracer Point 05-0510-103C 21D Chain Junction Link 05-0510-006E

13D Handle, Tracer Point Locking 05-0510-113D 24 Crank Handle Assembly, Complete

05-0510-124

13E Socket Set Screw, M4 x 30 05-0510-103E 24A Revolving Handle 05-0510-124A

13F Hex Nut, M4 05-0510-113F 24B Allen Head Set Screw, M3 x 8

05-0510-112C

13G Socket Set Screw, M6 x 16 05-0510-013G 24C Crank Arm 05-0510-124C

14 Sliding Support, Complete 05-0510-114 25 Hose Support 05-0510-125

14B Socket Head Set Screw, M10 x 05-0510-114B 25A Bolt, M4 x 20 05-0510-125A

14C Socket Head Set Screw, M6 x 05-0510-114C 25B Hex Nut, M4 05-0510-113F

17 Torch Holder Support with 32 05-0510-117 26 Coping Devise 05-0510-126

17E Torch Holder Support with 05-0510-117E 26A Return Spring 05-0510-126A

17A Knob with 32 Toothed Pinion 05-0510-117A 26B Sprint Retainer 05-0510-126B

17A/1 Knob with Metric Toothed 05-0510-113A 26C Sliding Block 05-0510-126C

17B Locking Knob 05-0510-117B 26D Tracer Point 05-0510-126D

17C Allen Head Cap Screw, M5 x 05-0510-117C 26E Bronze Bushing, 05-0510-126E

17D Allen Head Set Screw, M4 x 05-0510-117D 26F End Bar 05-0510-126F

18 Cutting Torch less Rack 05-0510-005 26G Hex Nut (Description) 05-0510-126G

18A Locking Nut for Tip 05-0300-118A 26H Torch Support 05-0510-126H

18B Tip, Cutting Torch See Chart. 26I Washer, (Description) 05-0510-126I

19 Cutting Torch with Rack 05-0300-008 26J Socket Head Cap Screw, M8 x 16

05-0510-111A

19B Tip Cutting Torch See Chart. Allen Head Set Screw, M6 x 14

05-0510-126K

20 Chain Pin Extractor Block with Pin Extractor

05-0510-009

20A Pin Extractor 05-0510-120A

Table 5 - MAXI Chain Machine Parts LIST

18

19

TABLE 6 - MOTORIZED MAXI PARTS LIST

ITEM DESCRIPTION PART NUMBER

IITEM DESCRIPTION PART NUMBER

NOT SHOWN

230Vac Motorizing Kit with two (2) Sockets

05-0510-A02 28/B Socket Inc Female 50CC 05-0510-137

NOT SHOWN

230Vac Motorizing Kit with three (3) Sockets

05-0510-A03 28/C Socket Inc Male, 230vac 05-0510-138

NOT SHOWN

110vac Motorizing Kit 05-0510-A01 28D Main Power Switch 05-0510-142

22 Motor Mounting Flange. 230 vac Model

05-0510-122E 28E Lamp, 230vac 0810-00-080

22/I Motor Mounting Flange. 150 vac Model

05-0510-014 82 Green Cap 0810-00-082

22A Coupling Sleeve, 230vac Model

05-0510-122A 28/F Restraint, Electrical Cord

05-0510-136

22/A1 Coupling Sleeve, 115vac

05-0510-015 28/F1 Electrical Cord, 230vac (Not Shown)

05-0510-139

22/B Motor, 230vac Model 05-0510-122B 28G RE 2321 Main PC Board 0936-00-100

22/B1 Motor, 110vac Model 03-0201-056 28H 16A Fuse, 230vac Model 05-0510-135

22C Socket Hex Screw, M6 x 6 05-0510-122C 28/H1 1A Fuse, 115vac Model 01-427-008

22/C1 Socket Head Cap Screw, #8-24 x 1

11-08C0-100 28I Transformer - 500VA 0936-00-080

22D Socket Head Cap Screw,. M4 x 15

05-0510-122D 28J Transformer - 1000VA 0936-00-0087

22/D1 Socket Set Screw, 1/4-20NC x 1/4

19-14C0-014 28K Male Connection INC 50CC

05-0510-143

27 Remote Control Pendent, 230vac

05-0510-134 28/L Male Connection INC 230vac

05-0510-144

27/A1 Cord Pendent, 230vac 05-0510-325 NOT SHOWN

Drop Resistor 0820-00-013

27B Pilot Lamp, 230vac 0810-00-013 NOT SHOWN

Small Ferrite 05-0510-100

27C Pendent Power Switch, 230vac

05-0510-141 NOT SHOWN

Big Ferrite 05-0510-201

27D Forward Control Switch, 230vac

05-0510-127D NOT SHOWN

Rectifier Bridge 05-0510-140

27E Speed Regulator, 230vac 05-0510-101 NOT SHOWN

Filter AR 25 0936-00-020

27F Motor Box Control, 150vac Model

03-203-009 NOT SHOWN

230-110vac Step Down Transformer

01-0759-008

28 Power Supply Control Box, 2 outlets (Complete)

05-0510-127 NOT SHOWN

230vac, Power Cord 05-0510-139

28A Power Supply Control Box, three (3) outlets (Complete)

05-0510-128

20

TABLE 5 - MOTORIZED UNIT PARTS LIST

Table 7 – ACCESSORIES PARTS LIST

DRAWING NUMBER. DESCRIPTION PART NUMBER

37 48Vac Grinding Tool Kit (includes Grinder and Grinder Adaptor

05-0510-148K

37/A 230Vac Grinding Tool Kit (includes Grinder and Grinder Adaptor)

05-0510-220K

37/B Grinder (Adaptor) 48 & 230vac Grinder Only 05-0510-137B

37/C 48Vac Right Angle Grinder 05-0510-137C

37D Grinder Adaptor for US Grinder 05-0510-148

38/C 230vac Right Angle Grinder 05-0510-138C

39/A Guide Strip Head Section 05-0510-138B

39/B Guide Strip Tail Section 05-0510-013D

39/C Guide Strip Short Center Section 03-0201-013C

39/D Guide Strip Long Center Section 05-0510-013A

39/E Guide Strip Fasting Pin 05-0510-013E

40/A 9 Foot Flexible Drive Cable 05-0510-FDC

40/B 14 Foot Flexible Drive Cable 19-14C0-FD14

21

DESCRIPTION WHEEL POSITION PART NUMBER NET WEIGHT LBS./KG

Chain Block with Pin Driver -- 05-0510-009 3 / 1.4

Chain Kit for 4" Pipe 1 01-0510-004 3 / 1.4

Chain Kit for 6" Pipe 2 01-0510-006 4 / 2

Chain Kit for 8" Pipe 2 01-0510-008 5 / 2.3

Chain Kit for 10" Pipe 2 01-0510-010 5 / 2.3

Chain Kit for 12" Pipe 2 01-0510-012 6 / 2.7

Chain Kit for 16" Pipe 2 01-0510-016 7 / 3

Chain Kit for 18" Pipe 2 01-0510-018 8 / 3.6

Chain Kit for 20" Pipe 2 01-0510-020 8 / 3.6

Chain Kit for 24" Pipe 2 01-0510-024 10 / 4.5

Chain Kit for 28" Pipe 2 01-0510-028 11 / 5

Chain Kit for 30" Pipe 2 01-0510-030 12 / 5.4

Chain Kit for 32" Pipe 2 01-0510-032 13 / 5.9

Chain Kit for 38" Pipe 2 01-0510-038 15 / 6.8

Chain Kit for 40" Pipe 3 01-0510-040 15 / 6.8

Chain Kit for 42" Pipe 3 01-0510-042 16 / 7.3

Chain Kit for 48" Pipe 3 01-0510-048 18 / 8.2

Chain Kit for 52" Pipe 3 01-0510-052 18 / 8.2

Chain Kit for 60" Pipe 3 01-0510-60 22/ 10

Table 8 – CHAIN KITS

22