Hydra-Stop LD4120 User manual

4”–12” Operang Instrucons — Revised April 2021
Hydra-Stopper LD4120 Line Stopping Machine

Hydra-Stopper™ LD4120 Line Stopping Machine | Operating Instructions | 2
© 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.
Secon 1 — General Safety Precauons
1.0.0 General Safety Precautions ....................................................... 3
Secon 2 — Tapping for 4”–8” HSF 250 Line Stop Fing
2.1.0 Mount and Pressure Test Fitting Body on Pipe......................... 5
2.2.0 Installing the Temporary Gate Valve ......................................... 5
2.3.0 Setting up the Hydra-Tapper ..................................................... 5
2.4.0 Installing the Hydra-Tapper ....................................................... 6
2.5.0 Performing the Line Tap ............................................................ 6
2.6.0 Removing the Hydra-Tapper...................................................... 7
Secon 3 — Tapping for the 10”–12” HSF 250 Line Stop
Fing
3.1.0 Mount and Pressure Test Fitting Body on Pipe......................... 8
3.2.0 Installing the Temporary Gate Valve ......................................... 8
3.3.0 Setting up the Hydra-Tapper ..................................................... 8
3.4.0 Installing the Hydra-Tapper ....................................................... 9
3.5.0 Performing the Line Tap .......................................................... 10
3.6.0 Removing the Hydra-Tapper.................................................... 10
Secon 4 — Line Stopping with the Hydra-Stopper
4.1.0 Setting up the Hydra-Stopper for Line Stopping..................... 12
4.2.0 Installing the Hydra-Stopper ................................................... 12
4.3.0 Performing the Line Stop ........................................................ 13
4.4.0 Removing the Hydra-Stopper.................................................. 13
4.5.0 Completing the Line Stop Procedure ...................................... 13
4.6.0 Maintenance and Storage ....................................................... 13
4.6.1 Temporary Valves .................................................................... 13
4.6.2 Hydra-Tapper........................................................................... 13
4.6.3 Hydra-Stopping Unit................................................................ 14
4.6.4 Changing the Stop Housing..................................................... 14
4.6.5 General Maintenance.............................................................. 14
4.6.6 Cutter Care .............................................................................. 14
Secon 5 — Appendices
Appendix A — Hydra-Stopper Parts ID Chart................................... 16
Appendix B1 — Hydra-Tapper Parts ID Chart Without OS&Y
Rising Stem....................................................................................... 17
Appendix B2 — Hydra-Tapper Parts ID Chart With OS&Y
Rising Stem....................................................................................... 18
Appendix C — 4”–8” HSF 250 Line Stop Fitting Body Install
Instructions....................................................................................... 19
Appendix D — 10”–12” HSF 250 Line Stop Fitting Body Install
Instructions....................................................................................... 21
Appendix E — 4”–8” Completion Plug Installation Instructions ...... 23
Appendix F — 10”–12” Completion Plug Installation Instructions .. 25
Appendix G — Line Stopping and the Importance of Equalization.. 27
Appendix H — Line Stop Trouble Shooting Guide ........................... 28
Table of Contents

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© 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.
SECTION 1.0.0 — General Safety Warnings
These instrucons depict the use of the most up-to-date Hydra-
Stop line stop ngs, tapping equipment, and accessories.
Please be certain you are following the instrucons for your
equipment.
General Safety Precauons — Read and Follow Instrucons
Carefully read and understand all safety messages in this
manual before using the equipment. The manuals provided
with the equalizaon pump must also be read for safety.
The maintenance procedures are to be followed to keep the
equipment in good working condion.
Personal Protecon
Hydra-Stop recommends that installers wear required personal
protecve equipment including but not limited to:
• Hard Hat
• Safety Shoes
• Safety Glasses
• Ear Protecon
• Gloves
Avoid wearing jewelry, such as rings, wristwatches, necklaces,
or bracelets. If working near trac, select ear protecon that
allows you to hear the trac for safety.
Keep Spectators Away from Installaon Area
Keep all spectators and other workers away from machines and
work area(s) while in operaon.
Clear Work Area
Clear the work area of all objects that might interfere with
the proper operaon of any tools. Avoid placing tools or other
objects where they can fall into the pit.
Do Not Work in an Unsupported Trench
Do not work in trench with unstable sides, which could cave in.
Specic requirements for shoring or sloping trench walls are
available from several sources including federal and state oces.
Be sure to contact suitable authories for these requirements
before working in the trench. A minimum 5’x 5’ excavaon is
recommended.
Locate the exisng pipe joints or ngs in the area and use the
appropriate restraint methods if necessary.
Check Laws and Regulaons
Know and obey all Federal, State, and local laws and regulaons
that apply to your work situaon.
Handling the Equipment
To avoid back injury, use proper liing techniques. Follow all
equipment instrucons when liing heavy loads.
Check Hardware and Equipment
Make sure that all air or hydraulic line couplings are ghtened
and secured to eliminate the chance of accidental uncoupling.
Use hose connecon retaining devices such as locking rings,
clips, pins, chains, or cables. Idenfy all equipment and tools
necessary for the size of HSF 250 you intend to install. Inspect
equipment to verify it is in good working condion and free of
wear and damage prior to use. Never start an operaon if the
equipment is not in proper working order. Contact Hydra-Stop if
equipment is not in working order.
Do Not Exceed Load Rang on Any Liing Equipment
This includes but is not limited to liing magnets, eye bolts and
straps. Liing magnets provided with Hydra-Stop equipment are
labeled with a load rang. 12” knife gate liing assists and 3/4”
eye bolts should ONLY be used for liing 12” and 8” temporary
gate valves respecvely.
WARNING: Failure to follow any of the above safety instrucons
or those that follow in this manual, could result in serious injury.
Any operaon involving work on pipe containing liquids or
gases under pressure is potenally hazardous. It is necessary,
therefore, that correct procedures be followed in the use and
maintenance of this equipment to maintain a safe working
environment.
No person should use this equipment who is not fully trained in
the procedures stated in this manual, and who is not fully aware
of the potenal hazards connected with work on pipe containing
liquids or gases under pressure.
The purchaser of this equipment is responsible for the manner
in which this equipment is used, maintained and the training,
competence and safety of the operators.
Should any diculty arise at any me in the use of this
equipment, please contact HYDRA-STOP at 708-389-5111
immediately.

Tapping Procedure for 4”–12” HSF Line Stop Installaon
Hydra-Stopper LD4120 Line Stopping Machine

Hydra-Stopper™ LD4120 Line Stopping Machine | Operating Instructions | 5
© 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.
Section 2 — Tapping for 4”–8” HSF 250 Line Stop
Fitting
2.1.0 Mount and Pressure Test Fing Body on Pipe
2.1.1) Select the proper HSF 250 for installaon. Idenfy the type
of pipe the HSF 250 will be installed on. Accurately measure the
outside diameter of the pipe.
2.1.2) Refer to Appendix C (page 19) to review the HSF 250 Line
Stop Fing Body Installaon Instrucons.
2.2.0 Installing the Temporary Gate Valve
2.2.1) Install the temporary gate valve. Use
the 8” temporary gate valve on 4”, 6”, and
8” HSF 250s. If using aluminum stopping
heads, posion the temporary gate valve at
the true 3, 6, 9, or 12 o’clock posion (see
Figure 1A). This will assist in the alignment
of an aluminum stopping head in the line
stopping procedure.
If using rubber stopping heads, you can
posion the temporary gate valve as shown
in Figure 1B.
NOTE: Temporary gate valves are single
direcon valves and must be posioned
top up. The 8” gate temporary valve must
be installed with the O-ring groove facing
up.
2.2.2) Bolt the temporary gate valve to
the top of the HSF 250 ange using the
bolts, nuts, and washers provided with the
installaon equipment. We recommend
using a cross-ghtening paern.
2.2.3) Install the O-ring in the groove of the
8” temporary gate valve (see Figure 1B).
2.2.4) Fully open the temporary gate valve.
NOTE: If you own an aluminum temporary
gate valve, fully close the temporary gate
valve and count the number of turns to
open. This is important to know in order to
check clearance issues later.
2.3.0 Seng up the Hydra-Tapper
2.3.1) Select proper size saw mandrel. Tapping of the 4”-8” HSF
250 requires the 27” long saw mandrel.
2.3.2) Select proper size shell cuer. Hydra-Stop shell cuers are
shipped painted black. If you repaint shell cuers in the future,
Hydra-Stop recommends painng them black.
• Installaon of 4” HSF 250 requires 3.8” cuer.
• Installaon of 6” HSF 250 requires 5.8” cuer.
• Installaon of 8” HSF 250 requires 7.9” cuer.
NOTE: Do not use red painted shell cuers to install the HSF
250. Hydra-Stop side tap shell cuers are shipped painted red.
Red painted side tap shell cuers are 1/2” undersized for side
tapping.
2.3.3) Select proper size pilot drill.
• Installaon of the 4” and the 6” HSF 250 ngs require the
1/2” X 6” long pilot drill.
• Installaon of the 8” HSF 250 ng requires the 1/2” X
7-1/4” length pilot drill.
NOTE: Tapping PVC or steel pipe will require a twist-style pilot
drill.
NOTE: Failure to use the proper sized or type of pilot drill will
result in a failed installaon.
2.3.4) Loosen and remove the Allen-head pilot drill retaining set
screw located on the side of the saw mandrel ange base.
2.3.5) Visually locate the tapered relief on the base of the pilot
drill. Noce the stop or ledge at the base of the taper (see Figure
2).
2.3.6) Mark the at of the taper with a visible marking agent (see
Figure 3).
2.3.7) Align the pilot drill at with the Allen-head set screw and
insert the pilot drill through the center of the saw mandrel stud
(see Figure 4).
2.3.8) Conrm you have completely inserted the pilot drill
and engaged the tapered at. Look into set screw hole for the
marking on the pilot drill. Adjust the pilot drill unl you can see
the marking (see Figure 5 on next page).
Figure 1A
Figure 3
Figure 2
Figure 1B
Figure 4

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2.3.9) Once aligned, insert and ghten the set screw. Test pull
the pilot drill to ensure the set screw is properly locked in place
against the pilot drill ledge. Check the coupon retaining clips so
they move freely (see Figure 6).
NOTE: Wear gloves when pulling on the pilot drill. Edges may be
sharp.
2.3.10) Loosen and back out the 2 Allen-head cap screws on the
ange of the saw mandrel unl ush with the face of the ange.
2.3.11) Thread the appropriate shell cuer all the way onto the
threaded stud of the saw mandrel’s anged end.
2.3.12) Back o to align the holes in the base of the shell cuer
with the Allen-head cap screws and thread them through the
holes. Tighten Allen-head cap screws.
2.3.13) Make sure the saw mandrel is clean and free of rust or
grime (steel wool can be used to clean and smooth the surface).
2.3.14) Lubricate the end of the saw mandrel with a dab of the
food-grade lubricant provided with the equipment to help it slide
freely through the packing nut assembly.
2.3.15) Slide the assembled shell cuer and saw mandrel into
the Hydra-Tapper unl the saw mandrel ange booms out in
the Hydra-Tapper.
2.3.17) Hand ghten the clamp lever on the packing nut
assembly to keep the assembled shell cuer and saw mandrel in
place.
NOTE: Do not use tools to ghten the clamp lever.
2.4.0 Installing the Hydra-Tapper
2.4.1) Using a strap or sling install the assembled Hydra-Tapper
onto the 8” temporary gate valve and align the bolt slots.
NOTE: Use extreme cauon not to damage the shell cuer or
pilot drill as the unit is raised and posioned on to the temporary
valve. Note the posion of the fully retracted cung assembly.
2.4.2) Install and cross ghten the bolts, nuts, and washers
to secure the assembly. Thread the 1/4” nipple and ball valve
into the tap housing and wrench ghten. Teon tape or thread
sealant can be used.
2.4.3) Hold and control the exposed saw mandrel, loosen the
packing nut assembly clamp lever, and slowly lower the saw
mandrel down unl the pilot drill is resng on the center top
of the pipe. Ensure the shell cuer spins freely in a clockwise
direcon.
2.4.4) Slide the stop collar over the saw mandrel.
2.4.5) Set the cung depth by measuring from the top of the
packing nut assembly to the lower side of the stop collar.
• 4” pipe = 3” cung depth
• 6” pipe = 4” cung depth
• 8” pipe = 5” cung depth
2.4.6) Tighten the stop collar to the correct
measurement (see Figure 7).
2.4.7) Install the drive unit by liing it above
the saw mandrel and slide it into the three
guide bars.
2.4.8) Lower the drive unit onto the
machined hex of the saw mandrel. Conrm
the drive unit is fully seated onto the
machined hex of the saw mandrel (see
Figure 8).
2.4.9) Install feed screw by
threading it through the top plate
of the Hydra-Tapper unl the
opening covers the spindle on the
drive unit.
NOTE: Do not apply downward force as it can damage the pilot
drill.
2.4.10) When the feed screw makes contact with the top of the
drive unit, back o one full turn.
2.4.11) If using a non-OS&Y tapping machine, assemble the
handle assembly and install over the ats at the top of the feed
screw and ghten the handles.
2.5.0 Performing the Line Tap
2.5.1) Ensure ball valve on the Hydra-Tapper P2 housing is open.
2.5.2) Connect the drive unit power source to the drive unit. The
air drive unit requires 90 CFM at 90 PSI. The hydraulic drive unit
Figure 7
(Measurement shown
for reference only)
Figure 5
Figure 6
Figure 8

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© 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.
requires 9 GPM at 1800 PSI.
2.5.3) Ensure the drive unit lever control is in the neutral
posion. Always run the power unit in the clockwise direcon.
NOTE: Avoid reversing as this will damage the carbide on the
pilot drill and carbide teeth on the shell cuer.
2.5.4) Engage the drive unit and conrm the saw mandrel is
rotang in the clockwise direcon. Slowly turn the feed screw
handle assembly in a clockwise direcon keeping slight, constant
pressure unl the tap is complete.
2.5.5) Close the ball valve on the P2 housing of the Hydra-Tapper
as water lls the housing and ows from the valve.
2.5.6) The tap is complete when the boom of the stop collar
makes contact with the top of the packing nut assembly.
NOTE: Do not overfeed the tap. Overfeeding the tap will cause
the shell cuer to jam.
2.5.7) Return the drive unit lever control to the neutral posion.
2.5.8) Loosen stop collar and connue to advance the feed
screw an addional two complete revoluons to ensure the
cut is complete. The shell cuer should spin freely. If it does,
disconnect the drive unit power source from the drive unit. If the
shell cuer does not spin freely, pull the drive unit lever control
down and conrm the saw mandrel is rotang in a clockwise
direcon. Slowly turn the handle assembly in a clockwise
direcon an addional two complete revoluons. Repeat steps
2.5.6 and 2.5.7
2.5.9) Slowly turn the handle assembly in a counterclockwise
direcon unl the stop collar has reached the starng
measurement.
• 4” pipe = 3” cung depth
• 6” pipe = 4” cung depth
• 8” pipe = 5” cung depth
2.5.10) Tighten the packing nut assembly clamp lever to lock the
saw mandrel in place. Remove feed screw. Remove drive unit.
2.5.11) Place a box end wrench over the hex
on the saw mandrel and use the wrench as
a lever brake to hold in place (see Figure 9).
2.5.12) Loosen the packing nut assembly
clamp lever and allow the pressure to
slowly raise the cuer assembly fully into
the tapping housing.
2.5.13) Conrm the shell cuer and saw
mandrel assembly is fully retracted and lock
the saw mandrel in place by ghtening the
packing nut assembly clamp lever.
2.5.14) Close the temporary gate valve. If
using an aluminum gate valve, make sure
you get the same number of turns to close as you counted in
step 2.2.4.
2.6.0 Removing the Hydra-Tapper
2.6.1) Relieve the pressure from the Hydra-Tapper by opening
the ball valve and discharging the pressure.
2.6.2) Connect the slings or straps to the Hydra-Tapper. Unbolt
and remove the Hydra-Tapper from the temporary gate valve.
Place the Hydra-Tapper in a dry and safe work area.
2.6.3) Remove stop collar.
2.6.4) Remove cuer and saw mandrel assembly.
2.6.5) Remove the coupon by loosening the Allen-head pilot drill
retaining set screw. Remove the pilot drill from the saw mandrel
stud.
2.6.6) Flip the pilot drill and insert it point end through the
hole in the coupon past the retaining clips and use it to pull the
coupon out of the cuer.
NOTE: Wear gloves when removing the coupon. Coupon edges
may be sharp.
2.6.7) Inspect the coupon for pipe thickness and condion.
2.6.8) Remove cuer from saw mandrel.
Figure 9

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© 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.
Section 3 —Tapping for 10”-12” HSF 250 Line Stop
Fitting
3.1.0 Mount and Pressure Test Valve Body on Pipe
3.1.1) Select the proper HSF 250 for installaon. Idenfy the type
of pipe the HSF 250 will be installed on. Accurately measure the
outside diameter of the pipe.
3.1.2) Refer to Appendix D (page 21) to review the HSF 250 Line
Stop Fing Body Installaon Instrucons.
3.2.0 Installing the Temporary Gate Valve
3.2.1) Install the temporary gate valve. Use
the 12” temporary gate valve for 10” and
12” HSF 250s. If using aluminum stopping
heads, posion the temporary gate valve at
the true 3, 6, 9, or 12 o’clock posion (see
Figure 10A). This will assist in the alignment
of an aluminum stopping head in the line
stopping procedure.
If using rubber stopping heads, you can
posion the temporary gate valve as shown
in Figure 10B.
NOTE: Temporary gate valves are single
direcon valves and must be posioned
top up. The 12” gate temporary valve must
be installed with the red bar facing up (see
Figure 10A or 10B).
3.2.2) Install the ange O-ring in the O-ring
channel on the HSF 250. Carefully lower
the 12” temporary gate valve into posion.
Ensure the temporary gate valve is centered
on the valve ange.
NOTE: Failure to center temporary
valve could cause mis-alignment
resulng in a failed installaon.
3.2.3) Bolt the temporary gate valve
to the top of the HSF 250 ange
using the nuts and washers provided
with the installaon equipment.
3.2.4) Install green ber gasket
(without holes) on the top side of
temporary gate valve (see Figure
10B).
3.2.5) Fully open the temporary
valve and re-check that temporary
valve is centered.
3.3.0 Seng up the Hydra-Tapper
3.3.1) Bolt Hydra-Tapper to the P-20 component using the
bolts and nuts included with Hydra-Tapper
equipment (see Figure 11).
3.3.2) Select proper size saw mandrel. Tapping
of 10” and 12” HSF 250s requires the 40” long
saw mandrel.
3.3.3) Select proper size shell cuer. Hydra-
Stop shell cuers are shipped painted black. If
you repaint shell cuers in the future, Hydra-
Stop recommends painng them black.
 Installaon of 10” HSF 250 requires a 9.8”
cuer.
 Installaon of 12” HSF 250 requires 11.8”
cuer.
NOTE: Do not use red painted shell cuers to install HSF 250.
Hydra-Stop side tap shell cuers are shipped painted red.
Red painted side tap shell cuers are 1/2” undersized for side
tapping.
3.3.4) Select proper size pilot drill. Installaon of 10” and 12”
HSF 250s requires the 3/4” X 10 5/16” long pilot drill.
NOTE: Tapping PVC or steel pipe will require a twist-style pilot
drill.
NOTE: Failure to use the proper sized or type of pilot drill will
result in a failed installaon.
3.3.5) Loosen and remove the Allen-head pilot drill retaining set
screw located on the side of the saw mandrel ange base.
3.3.6) Visually locate the tapered relief on the base of the pilot
drill. Noce the stop or ledge at the base of the taper (see Figure
12).
3.3.7) Mark the at of the taper with a visible marking agent (see
Figure 13).
3.3.8) Align the pilot drill at with the Allen-head set screw and
insert the pilot drill through the center of saw mandrel stud (see
Figure 14).
Figure 10A
Figure 13
Figure 12
Figure 11
Figure 10B
Figure 14

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3.3.9) Conrm you have completely inserted the pilot drill
and engaged the tapered at. Look into set screw hole for the
marking on the pilot bit. Adjust the pilot drill unl you can see
the marking (see Figure 15).
3.3.10) Once aligned, insert and ghten the set screw. Test pull
the pilot drill to ensure the set screw is properly locked in place
against the pilot drill ledge. Check the coupon retaining clips so
they move freely (see Figure 16).
NOTE: Wear gloves when pulling on the pilot bit. Edges may be
sharp.
3.3.11) Thread the appropriate shell cuer all the way onto the
threaded stud of the saw mandrel anged end.
3.3.12) Back o cuer to align
the holes in the base of the shell
cuer with the Allen-head cap
screw holes in the saw mandrel.
Thread screws from inside the
shell cuers and then into the
saw mandrel holes (see Figure
17).
3.3.13) Thread nylon lock nuts
onto Allen-head cap screws and
ghten (see Figure 18).
3.3.14) Make sure the saw
mandrel is clean and free of
rust or grime (steel wool can be
used to clean and smooth the
surface).
3.3.15) Lubricate the end of the
saw mandrel with a dab of the
food-grade lubricant provided
with the equipment to help it slide freely through the packing
nut assembly.
3.3.16) Slide the assembled shell cuer and saw mandrel into
the Hydra-Tapper unl the saw mandrel ange booms out in
the P-20 component.
3.3.17) Hand ghten the clamp lever on the packing nut
assembly to keep the assembled shell cuer and saw mandrel in
place.
NOTE: Do not use tools to ghten the clamp lever.
3.4.0 Installing the Hydra-Tapper
3.4.1) Using a strap or sling install the assembled Hydra-Tapper
on to the 12” temporary gate valve and align the bolt slots.
NOTE: Use extreme cauon not to damage the shell cuer or pi-
lot drill as the unit is raised and posioned on to the temporary
valve. Note the posion of the fully retracted cung assembly.
3.4.2) Cross ghten the bolts, nuts and washers to secure the
assembly. Thread the 1/4” nipple and ball valve into the tap
housing and wrench ghten. Teon tape or thread sealant can
be used.
3.4.3) Hold and control the exposed saw mandrel, loosen the
clamp lever, and slowly lower the saw mandrel unl the pilot
drill is resng on the top of the pipe. Ensure the shell cuer spins
freely in a clockwise direcon.
3.4.4) Slide the stop collar over the saw mandrel.
3.4.5) Set the cung depth by measuring from the top of the
packing nut assembly to the lower side of the stop collar.
3.4.6) Tighten the stop collar to the correct
measurement (see Figure 19).
• 10” pipe = 6” cung depth
• 12” pipe = 7” cung depth
3.4.7) Install the drive unit by liing it above
the saw mandrel and slide it into the three
guide bars.
3.4.8) Lower the drive unit onto the machined
hex of the saw mandrel. Conrm the drive unit
is fully seated onto the machined hex of the
saw mandrel (see Figure 20).
3.4.9) Install feed screw by threading it through
the top plate of the Hydra-Tapper
unl the opening covers the spin-
dle on the drive unit.
NOTE: Do not apply downward
force as it can damage the pilot
drill.
3.4.10) When the feed screw
makes contact with the top of the
drive unit, back o one full turn.
3.4.11) Assemble the handle
assembly and install over the ats
at the top of the feed screw and
ghten the handles.
Figure 15
Figure 16
Figure 17
Figure 18
Figure 19
(Measurement
shown for
reference only)
Figure 20

Hydra-Stopper™ LD4120 Line Stopping Machine | Operating Instructions | 10
© 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.
3.5.0 Performing the Line Tap
3.5.1) Ensure ball valves on the Hydra-Tapper P2 housing and the
P20 housing are open.
3.5.2) Connect the drive unit power source to the drive unit. The
air drive unit requires 90 CFM at 90 PSI. The hydraulic drive unit
requires 9 GPM at 1800 PSI.
3.5.3) Ensure the drive unit lever control is in the neutral
posion. Always run the power unit in the clockwise direcon.
NOTE: Avoid reversing as this will damage the carbide on the
pilot drill and carbide teeth on the shell cuer.
3.5.4) Engage the drive unit and conrm the saw mandrel is
rotang in the clockwise direcon. Slowly turn the handle
assembly in a clockwise direcon keeping slight, constant
pressure unl the tap is complete.
3.5.5) Close the ball valves on the P20 housing and the P2
housing of the Hydra-Tapper as water lls the housings and ows
from the valves.
3.5.6) The tap is complete when the boom of the stop collar
makes contact with the top of the packing nut assembly.
NOTE: Do not overfeed the tap. Overfeeding the tap will cause
the shell cuer to jam.
3.5.7) Return the drive unit lever control to the neutral posion.
3.5.8) Loosen the stop collar and connue to advance the feed
screw an addional two complete revoluons to ensure the
cut is complete. The shell cuer should spin freely. If it does,
disconnect the drive unit power source from the drive unit. If
the shell cuer does not spin freely, engage the drive unit and
conrm the saw mandrel is rotang in a clockwise direcon.
Slowly turn the handle assembly in a clockwise direcon an
addional two complete revoluons. Repeat steps 3.5.6 and
3.5.7.
3.5.9) Slowly turn the handle assembly in a counter-clockwise
direcon unl the stop collar has reached the starng
measurement.
• 10” pipe = 6” cung depth
• 12” pipe = 7” cung depth
3.5.10) Tighten the packing nut assembly clamp lever to lock the
saw mandrel in place. Remove feed screw. Remove drive unit.
3.5.11) Place a box end wrench over the hex
on the saw mandrel and use the wrench as a
lever brake to hold in place.
3.5.12) Loosen the packing nut assembly
clamp lever and allow the pressure to slowly
raise the cuer assembly fully into the
tapping housing (see Figure 21).
3.5.13) Conrm the shell cuer and saw
mandrel is fully retracted and lock the saw
mandrel in place by ghtening the packing
nut assembly clamp lever.
3.5.14) Close the temporary gate valve.
3.6.0 Removing the Hydra-Tapper
3.6.1) Relieve the pressure from the Hydra-Tapper by opening
the ball valve and discharging the pressure.
3.6.2) Connect the slings or straps to the Hydra-Tapper. Unbolt
and remove the Hydra-Tapper / P-20 assembly from the
temporary gate valve. Place the assembly in a dry and safe work
area.
3.6.3) Remove stop collar.
3.6.4) Remove cuer and saw mandrel assembly.
3.6.5) Remove the coupon by loosening the Allen-head pilot drill
retaining set screw. Remove the pilot drill from the saw mandrel
stud.
3.6.6) Flip the pilot drill and insert it point end through the
hole in the coupon past the retaining clips and use it to pull the
coupon out of the cuer.
NOTE: Wear gloves when removing the coupon. Coupon edges
may be sharp.
3.6.7) Inspect the coupon for pipe thickness and condion.
3.6.8) Remove cuer from saw mandrel.
Figure 21