Mathey Dearman 5SA User manual

WHERE THERE IS PIPE, THERE’S MATHEY
Po Box 472110, Tulsa, OK 74147 USA
Toll Free: 800-725-7311 / 918-447-1288 office
918-447-0188 fax
www.mathey.com
5SA SADDLE MACHINE PARTS &
OPERATING MANUAL
Part Number: 03-0105-000 / 03-0105-S01
REVISED: March 14, 2016
©Mathey Dearman, Inc.
For future reference, record your Saddle Machine model and serial numbers here:
Saddle Machine Model ________SA Serial #M_______________ Manual ____ Motorized ____
ENGLISH
LANGUAGE
ENGLISH
LANGUAGE
5SA SADDLE MACHINE
PARTS AND OPERATING MANUAL
PART NO: 03-0105-00 / 03-0105-SO1
JUNE 2022

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Table of Contents
Item Subject Page#
1.0 SAFETY …………………………………………………………………………………………………………………… 3
2.0 GENERAL INFORMATION ……………………………………………………………………………………………… 7
3.0 INSTALLATION OF SPACER BOLTS ……………………………………………………………………………… 7
Picture 1 Spacer Bolt Installation ………………………………………………………………………………………. 7
Spacer Bolt Calculation ………………………………………………………………………………………. 7
Figure 1 Spacer Bolt Configuration for 24”, 26”, 28” & 30” …………………………………………………. 8
Table 1 Spacer Bolt Part Identification ……………………………………………………………………………… 8
4.0 INSTALLATION OF THE SADDLE MACHINE ON THE PIPE ………………………………………… 8
Picture 2 Closing Boomer Latch ………………………………………………………………………………………. 9
Figure 2 Boomer Assembly Parts Configuration ……….……………………………………………………………. 9
Table 2 Boomer Assembly Parts Identification …………………………………………………………………….. 9
Figure 3Torch Arm & Torch Carrier Configuration ……………………………………………………………. 10
Table 3 Torch Arm & Torch Carrier Parts Identification …………………………………………………… 10
5.0 INSTALLATION OF THE TORCH ARM, TORCH CARRIER ASSEMBLY AND TORCH ……. 10
Picture 3 Installation of Torch Arm ……………………………………………………………………………………….. 10
Picture 4 Installation of Wing Nut ……………………………………………………………………………………….. 11
6.0 THE MANUAL CUTTING PROCESS ………………………………………………………………………………. 11
7.0 THE MOTORIZED CUTTING PROCESS ……………………………………………………………………… 12
Picture 5 Stepper Motor Control Box Face View ……………………………………………………………………… 12
Picture 6 Stepper Motor Control Box End View ……………………………………………………………………… 12
Picture 7 Cable, Motor (from Motor Control Box to Stepper Motor Assembly ……………………….. 13
A Note on Back Beveling ………………………………………………………………………………………… 14
Figure 4 Manual 5SA Saddle Parts Configuration ……………………………………………………………………… 15
Table 4 Manual 5SA Saddle Parts Identification ……………………………………………………………………… 15
Figure 5 Single Bearing Bracket Configuration ……………………………………………………………………… 16
Table 5 Single Bearing Bracket Parts Identification ……………………………………………………………. 16
Figure 6 Double Bearing Bracket Parts Configuration ……………………………………………………………. 17
Table 6 Double Bearing Bracket Parts Identification ……………………………………………………………. 17
Figure 7 Motorized 5SA Saddle Parts Configuration ……………………………………………………………. 18
Table 7 Motorized 5SA Saddle Parts Identification ……………………………………………………………. 19
Table 8 Trouble Shooting …………………………………………………………………………………………………. 20
8.0 MAINTENANCE …………………………………………………………………………………………………. 21
8.1 Timing the Ring Gear to the Pinion Gear of the Manual Saddle Machine ……………… 21
8.2 Installation of a new Drive Chains on the Manual Saddle Machine ……………………….. 22
8.3 Timing the Ring Gear to the Pinion Gear of the Motorized Saddle Machine ………………. 24
8.4 Installation of a new Drive Chains on the Motorized Saddle Machine ……………………….. 24
8.5 Installation of the Stepper Motor Kit ……………………………………………………………………… 25
8.6 Repair of the Single and Double Bearing Bracket …………………………………………………… 26
8.7 Storage ……………………………………………………………………………………………………………………. 26
9.0 LIMITATIONS …………………………………………………………………………………………………………… 26
10 .0 MACHINE SAFETY ………………………………………………………………………………………………….. 26
11.0 CONDITION OF USE ………………………………………………………………………………………………….. 26
11.1 Condition of use ………………………………………………………………………………………………….. 26
11.2 Use of the Saddle Machine not allowed by the manufacturer …………………………………. 27
12.0 DISPOSAL OF SADDLE MACHINE ……………………………………………………………………………….. 27
12.1 General Information ………………………………………………………………………………………………….. 27
12.2 Composition of Major Components ………………………………………………………………………. 27
13.0 Warranty …………………………………………………………………………………………………………………….. 27
Table 9 Commercial Pipe Sizes ………………………………………………………………………………………………….. 27
For the latest news, accessories and information about Mathey Dearman products visit:
www.mathey.com

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1.0 SAFETY
ELECTRIC SHOCK CAN KILL
Electric Shock can injure or kill. Saddle machine operation and many cutting processes use or produce high voltage
electrical energy. This electric energy can cause severe or fatal shock to the operator or others in the work place.
•Never touch any parts that are electrically “live” or “hot”
•Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the plasma cutting circuit.
•Repair or replace all worn or damaged parts.
•Extra care must be taken when work place is moist or damp.
•If installing a motorized saddle machine, install and maintain equipment according to NEC (National Electric Code),
refer to publications section in this manual.
•Disconnect power source before performing any service or repairs.
•Read and follow all the instructions in the operating manuals.
FIRE AND EXPLOSION
Hot slag, sparks, oxygen-fueled cutting flame or the plasma arc can cause fire and explosion.
•Be sure there are no combustible or flammable materials in the workplace. Any material that cannot be removed
must be protected.
•Ventilate all flammable or explosive vapors from the workplace.
•Do not cut or weld on containers that may have held combustibles.
•Provide a fire watch when working in an area where fire hazards may exist.
AUTOMATIC OPERATION
The 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/fuel torch cutting, and grinding can cause noise levels
that exceed safe limits. You must protect your ears from loud noise to prevent permanent loss of hearing.
•To protect your hearing from loud noise, wear protective earplugs and/or ear muffs. Protect others in the workplace.
•Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels.
•For information on how to test for noise refer to the publications section of this manual
GASES, DUST, AND FUMES
Gases and fumes produced during the cutting process can be dangerous to your health.
•Keep all fumes and gases away from the breathing area. Keep your head out of the cutting fume plume.
•Use an air-supplied respirator if ventilation is not adequate to remove all fumes and gases.
•The kinds of fumes and gases from cutting depend on the kind of metal being cut, coatings on the metal, and the
different processes. You must be very careful when cutting or welding any metals which may contain the following:
Antimony Cadmium Lead Selenium Arsenic Chromium Manganese Silver
Barium Cobalt Mercury Vanadium Beryllium Copper Nickel
•For information on how to test for fumes and gases in your workplace refer to publications section of this manual.
•Use special equipment, if needed, to capture fumes and gases.
•Do not use in an area where combustible or explosive gases or materials are located.
•Phosgene, a toxic gas, is generated from the vapors of chlorinated solvents and cleansers. Remove all sources of these
vapors.
•This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State
of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Sec. 25249.5 et seq.)

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•Some dust created by cutting, grinding, drilling, and other construction activities contains chemicals known to cause
cancer, birth defects or other reproductive harm. Some examples of these chemicals are:
•Lead from lead-based paint.
•Crystalline silica from bricks and cement and other masonry products.
•Arsenic and chromium from chemically-treated lumber (CCA).
•Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to
these chemicals: work in a well-ventilated area, and work with approved safety equipment, such as those dust masks
that are specially designed to filter out microscopic particles.
•Avoid prolonged contact 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 vicinity of Saddle Machine operations should be aware of debris and take necessary precautions. Consult
the publications section of this manual for further information.
PLASMA ARC RAYS
Plasma Arc Rays can injure your eyes and burn your skin. The plasma arc process produces very bright ultraviolet and
infrared light. These arc rays will damage your eyes and burn your skin if you are not properly protected.
•To protect your eyes, always wear a welding helmet or shield. Also, always wear safety glasses with side shields,
goggles or other protective eye wear.
•Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks.
•Keep helmet and safety glasses in good condition. Replace lenses when cracked, chipped or dirty.
•Protect others in the work area from the arc rays. Use protective booths, screens or shields.
•Use the shade of lens as suggested in the following per ANSI/ASC Z49.1:
HEAVY COMPONENTS
Use caution when lifting or moving the saddle machine. Use team lifting when necessary to avoid personal injury. When
using a mechanical device to move a machine follow all manufacturers’ safety guidelines. Pipe being operated on with the
machine may be heavy. Use all lifting guidelines outlined in Occupational Safety & Health Administration technical manual
Sect. 7, Ch. 1.5. See publications section for additional information.
ELECTRIC AND MAGNETIC FIELDS
Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding and plasma
cutting current creates EMF fields around cables and machines. EMF fields may interfere with some pacemakers, and
operators and observers having a pacemaker should consult their physician before operation. Exposure to EMF fields may
also have other health effects which are now not known.
PINCH AND CRUSH POINTS
Mathey Dearman Saddle Machines in motion can create pinch points in normal operation. Be aware of all areas that may
potentially be a hazard when the Saddle Machine is in motion. Avoid working on the machine while the control electronics
are energized. Do not allow hoses, cords or other nearby items to come in contact with the machine.

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HOT MATERIALS
The process of plasma cutting creates 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 to allow material to cool completely
before handling.
MECHANICAL DRIVES
Mechanical drives are in use while the Saddle Machine is in operation. These drives use gears, chains, and drive screws.
These components can move at high speed. Do not attempt to service, adjust, or otherwise touch these components while
the machine is on. Secure loose articles of clothing and cables to prevent entanglement.
AIR LINES UNDER PRESSURE
Certain tools and equipment use compressed air lines to operate. These air lines are under pressure. Hot sparks or flying
debris may cause damage to these lines. Ensure that the air lines are kept free of punctures, burns, or other damage or
defects that could cause failure. Inspect air lines periodically and repair or replace damaged lines.

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PUBLICATIONS
Refer to the following standards or their latest revisions for more information:
• OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910, obtainable from the Superintendent of Documents, U.S. Government
Printing Office, Washington, D.C. 20402
• ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING, obtainable from the American Welding Society, 550 N.W. Lejeune
Rd, Miami, FL 33126
• NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING, obtainable from the Superintendent of
Documents, U.S. Government Printing Office, Washington, D.C. 20402
• ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION, obtainable from
American National Standards Institute, 1430 Broadway, New York, NY 10018
• ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES, obtainable from American
National Standards Institute, 1430 Broadway, New York, NY 10018
• AWS Standard A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES, 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 Standard 51B, CUTTING AND WELDING PROCESSES, obtainable from the National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269
• CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, obtainable from the Compressed Gas
Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202
• CSA Standard W117.2, CODE FOR SAFETY IN WELDING AND CUTTING, obtainable from the Canadian Standards Association,
Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3
• NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Association, 1900 Arch
Street, Philadelphia, PA 19103
• ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PROTECTION, obtainable from American National Standards Institute,
1430 Broadway, New York, NY 10018
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.

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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 OF 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 1 or Figure 4 item 1), with the Spacer End of the Bolts on the Bore (I.D.) side of the saddle.
3.3 If required place the spacer 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
The correct Spacer length (between outside diameter of pipe and inside diameter of saddle) is 1-1/4” (31.8mm).
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)

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Figure 1: Spacer Configuration for 24”, 26”, 28”, & 30” pipe
Table 1 – Spacer Bolt Part Identification
4.0 INSTALLATION OF THE SADDLE MACHINE ON THE 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.
4.5 When the Chain is properly adjusted, close the Boomer (Figure 2 item 1).
ITEM # PART DESCRIPTION PART # QUANTITY REQUIRED
1 Spacer Bolt for 24” / 610mm pipe 03-0110-008 4
2 Spacer 1” / 25.4mm 04-0106-018 8
3 Spacer Bolt 03-0110-011 4
4 Hex Nut, 1/2 - 13 1H-12C0-000 4
5 Spacer Bolt Kit (includes all of the above) 03-05SA-KIT 1
WARNING: Improper tensioning of the boomer assembly or failure to latch the boomer assembly
may result in injury.

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Picture 2 – Closing Boomer Latch
Figure 2: Boomer Assembly Part # 03-0105-017
Table 2 – Boomer Assembly Parts Identification
ITEM # PART DESCRIPTION PART # QUANTITY
1 Boomer 01-0258-001 1
2 Spring 01-0184-003 1
3 Chain 01-0577-006 1
4 Spring Snap 01-0258-003 1
WARNING: Be careful not to get finger caught between the latch handle and boomer
frame.

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Figure 3: Torch Arm Part Number: 03-0101-001
Torch Carrier Assembly Part Number: 03-0100-002
Table 3 - Torch Arm and Torch Carrier Parts Identification
ITEM #
PART DESCRIPTION
PART #
QUANTITY
A
Torch Arm
03-0101-001
1
B
Torch Carrier Assembly
03-0100-002
1
1
Torch Clamp Base
03-0100-003
1
2
Torch Clamp
03-0100-005
1
3
Clamp
03-0100-004
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
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5.0 INSTALLATION OF THE TORCH ARM, TORCH CARRIER ASSEMBLY AND TORCH
5.1 Install Torch Arm (Figure 3, Item A) over the two threaded studs (Picture 3) 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 (Picture 4) provided in the Spacer Bolt Box.

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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 MANUAL 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 or out of round. If the distance of the torch tip is greater at the 6:00 position, either
the incorrect spacer bolts were selected or the pipe is undersize or out of round.
If using the Plasma Machine Torch, skip to step 6.7 after completing 6.1
6.2 Connect the gas hose from the fuel regulator to the left hand thread port 10” long Oxy/fuel 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 per the
manufacturer’s instructions.
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.
WARNING: The hose must not be drawn through the molten slag produced by the cutting
process.
WARNING: 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.
WARNING: Goggles, gloves, mask and other appropriate safety attire must be worn during the
cutting process.

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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 (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.
6.8 Rotate the torch around the pipe until the cut is complete.
6.9 If using a Plasma torch, turn off per the torch manufacturer instructions. If using an Oxy/fuel torch, proceed to
steps 6.10-6.12.
6.10 Rotate the cutting oxygen valve of the cutting torch to the OFF position per the torch manufacturer’s instructions.
6.11 Close the fuel and oxygen valve of the torch per the torch manufacturer’s instructions.
6.12 Close the valve on the Oxygen and fuel gas bottles if no further cuts are to be made per the torch
manufacturer’s instructions.
7.0 THE MOTORIZED CUTTING PROCESS
7.1 Installation of Torch Arm, Torch Carrier Assembly and Oxy/fuel or Plasma Torch per instruction in 5.0
7.2 Depress the Emergency Stop Switch.
7.3 Connect the Motor Cable to surface mount connector of the Motor Control Box.
7.4 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 6 – Motor Control Box End View
Picture 5 – 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.

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NOTE: If using a plasma torch system, connect the plasma cable between the Motor Control Box and the plasma
torch system in the same manner. Verify the cable lock feature is engaged at both ends.
Make sure the Plasma Switch is in the “Off” position.
7.5 Connect the Motor Control Box power cable to the AC electrical receptacle.
7.6 Twist to release the Emergency Stop Switch.
7.7 The digital screen will light with the following.
991 – Indicates that a NEMA 23 motor is in use.
992 – Indicates that a NEMA 34 motor is in use.
993 – Indicates that a heavy-duty NEMA 34 motor is in use.
994 & 995 – Check cable connection at Motor Control Box and Motor.
999 – Indicates the Directional Control Switch is in the “Forward” or “Reverse” position. Move to the “Off” position.
7.8 If no faults are present after the motor number appears, the percent of maximum speed will be displayed in
the window.
7.9 Move the Directional Control Switch to the “Forward” or “Reverse” direction.
7.10 Depress the Speed Control Switch until the percent of motor speed reads about 32% or machine speed or
control of the machine can be maintained should an emergency arise.
7.11 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 or is further away from
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.
7.12 Depress the Emergency Stop Switch.
7.13 Disconnect the Motor Control Box power cable from the AC electrical receptacle. If
using a Plasma Torch, skip to step 7.17.
7.14 Connect the gas hose from the fuel regulator to the left hand thread port 10” long
Oxy/fuel per the manufacturer’s instructions.
7.15 Connect the oxygen hose from the oxygen regulator to the right hand thread port
10” long Oxy/fuel per the manufacturer’s instructions.
7.16 Adjust the oxygen and fuel gas regulator per the regulator manufacturer’s instructions.
7.17 Connect the Motor Control Box power cable to the AC electrical receptacle.
7.18 Twist to release the Emergency Stop Switch.
7.19 Verify the percent of maximum speed is displayed in the window.
7.20 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.
7.21 Move the Directional Control Switch to the “Forward” or “Reverse” direction. If using a Plasma Torch, skip to
step 7.24
7.22 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.
7.23 Follow the torch manufacturer’s instructions for preheating the pipe.
7.24 While the machine is rotating around the pipe, move the cutting oxygen valve to the ON position to penetrate the
pipe per the torch manufacturer’s instructions.
NOTE: If using a plasma torch in conjunction with the Motor Control Box, depress the Plasma On / Off button on the
Motor Control Boxes at this time to turn the plasma torch on. (The plasma cable is designed for use with a Hypertherm,
Thermal Dynamics, Victor or new ESAB plasma system.)
WARNING: The Oxygen and fuel gas hoses must not be drawn through the molten slag produced by
the cutting process
WARNING: 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.
WARNING: Goggles, gloves, mask and other appropriate safety attire must be worn during the
cutting process.
Picture 7 – Motor Cable
Part Number: 03-0203-200

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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.
7.25 Adjust the torch travel speed with Speed Control Switch until a quality cut is achieved.
7.26 Rotate the torch around the pipe until the cut is complete.
7.27 If using an Oxy/fuel torch, rotate the cutting oxygen valve of the cutting torch to the OFF position per the
torch manufacturer’s instructions. If using a Plasma torch, it will be necessary to depress the Plasma On / Off button
on the Motor Control Box to turn the torch off.
7.28 Depress the Emergency Stop Switch.
7.29 If using a Plasma torch, skip to step 7.32.
7.30 Close the fuel and oxygen valve of the torch per the torch manufacturer’s instructions.
7.31 Close the Oxygen and fuel valve on the gas bottles per the torch manufacturer’s instructions.
7.32 Disconnect the Motor Control Box power cable from the electrical receptacle.
7.33 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 Torch Arm and
re-tighten with thumbscrew and clamp. Reinstall the torch into 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.
WARNING: When back beveling, the cutting flame and “hot” zone of the pipe is directed toward
the operator.
WARNING: The pipe and debris from the cutting process are extremely hot and can cause serious
injury.
WARNING: Keep hands and clothing away from the gearing as it will cause serious injury.

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Figure 4: Manual 5SA Saddle Machine Configuration Part #03-0105-000
Table 4: 5SA Machine – Manual
Item #
Part Description
Part #
Qty.
1 Saddle 03-0105-001 1
2 Cap Ring 03-0105-003 1
3 Ring Gear (Not Shown) 03-0105-002 1
4 Single Bearing Bracket Assembly (left) 03-0105-004 1
5 Single Bearing Bracket Assembly (right) 03-0105-005 1
6 Double Bearing Bracket Assembly 03-0105-010 1
7 Handle Tie Rod 03-0105-016 2
8 Boomer Eye 03-0101-017 2
9 Cap Screw, hex head, 5/16”- 18NC x 5/8” 10-56C0-058 11
10 Cap Screw, hex head, 3/8”- 16NC x 7/8” 10-38C0-078 9
11 Cap Screw, hex head, 3/8”- 16NC x 1-1/4” 10-38C0-114 4
12 Washer, flat, 3/8” 12-0038-F00 13
18 Hex Nut, 3/8”-16 1H-38C0-000 4
Items not Show in Figure 4
13 Spacer Bolt Kit 03-05SA-KIT 1
14 Boomer Assembly 03-0105-017 1
15 Drive Chain 03-0105-015 2
16 Threaded Stud (Ring Gear) 01-0194-003 2
17 Wing Nuts, 5/16” 1W-56C0-000 2
18
18
18
18

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Figure 5: Right Single Bearing Bracket Assembly Part Number: 03-0105-005
Left Single Bearing Bracket Assembly Part Number: 03-0105-004
Table 5: Right and Left Single Bearing Bracket Assembly
Item #
Part Description
Part #
Qty.
1 Bracket 03-0105-006 1
2 Sprocket, Chain Drive 03-0105-008 1
3 Axle 03-0105-009 1
4 Pinion Gear 03-0105-007 1
5 Spacer 04-0106-013 1
6 Bearing 01-0196-012 2
7
Set Screw, 5/16”, 18NC x 5/16
19-56C0-056
2
8
Set Screw, 1/4”, 20NC x 1/4”
19-14C0-014
1
9 Spiral Ring, 1/2”
01-0179-014
1
10 Spring Pin, 3/16” x 1” 18-3160-100
1
11 Spring Pin, 3/16” x 1-1/4” 18-3160-114 1

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Figure 6: Double Bearing Bracket Assembly, Part # 03-0105-010
Table 6 – Double Bearing Bracket Assembly Part Identification
Item #
Part Description
Part #
Qty.
1 Bracket 03-0105-011 1
2 Crank Handle Assembly 03-0103-012 1
3 Crank Pinion 03-0105-012 1
4 Crank Gear and Double Sprocket 03-0105-014 1
5 Axle 03-0105-013 1
6 Bearings
01-0196-012
4
7
Spacer 04-0106-056 1
8
Spacer 04-0106-013 1
9 Set Collar, 1/2”
01-0185-005
1
10 Set Screw, 1/4”, 20NC x 1/4” 19-14C0-014
4
11 Screw, round head 1/4”, 20NC x 1/2” 14-14C0-012 1
12 Washer, flat, 1/4” 12-0014-F00 1
13 Spring Pin, 3/16” x 1-1/2” 18-3160-112 1
14 Spiral Ring, 1/2” 01-0179-014 1

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Figure 7: Motorized 5SA Saddle Machine Configuration

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19
Table 7 – Motorized 5SA Saddle Machine Parts Identification
ITEM
DESCRIPTION PART# QTY.
1 5SA Saddle Machine 03-0105-000 1
Stepper Motor Kit (components included below) 03-0105-SA1 1
2 Threaded Stud, 5/16-18unc x 2” lg. 01.0194.007 1
3 Motor Adaptor 03-0103-031 1
4 Motor Support 03-0105-031 1
5 Motor Coupling 03-0105-032 1
6 Motor Spacer 03-0105-033 1
7 NEMA 34 High Torque Stepper Motor Assembly 03-0201-059 1
8 Socket Head Cap Screw, #8-32 unc x 1/2" lg. 11-08C0-012 3
9 Socket Head Set Screw, #8-32 unc x 3/16" lg. 19-08C0-316 1
10 Button Head Socket Cap Screw, 1/4-20 unc x 1" lg. 26-14C0-100 4
11 Hex Nut, 5/16 1H-56C0-000 2
12 Threaded Stud, 3/8-16unc x 1 7/8” lg. 01-0194-006 1
13 Flat Washer, 5/16 12-0056-F00 2
14 Motor Control Box complete with motor and plasma cable (See page 13) 03-0203-008 1
15 Cable, Stepper Motor to Stepper Motor Control box (See page 14) 03-0203-200 1
16 Cable, Plasma Stepper Motor Control Box (Not shown) 03-0203-201 1
17 Connector, NEMA 34 High Torque Stepper Motor Assembly (included in item 7) 03-0203-115 1

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Table 8 – TROUBLESHOOTING
MANUAL
Symptom Possible Cause(s) Corrective Action
Machine is cutting
out of square
Incorrect Spacers are used Use only Mathey Spacer Bolts.
Customer is cutting tubing.
Contact Mathey Dearman Sales Department for
Spacers for tubing.
The Spacer Bolts are not in contact with Pipe.
Reposition machine so that both Spacer Bolts
contact the pipe and re-tighten Boomer.
Torch, Torch Arm or Torch Carrier is loose. Tighten Wing Nuts or Thumbscrews.
Hoses are binding.
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.
Machine has been dropped.
Send the machine to a Certified Repair Station for
resizing Cap Ring, Ring Gear and Saddle.
Torch is at end of Torch Arm. Move the Torch closer to 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.
The Drive Chain is stretched.
Readjust the both Bearing Brackets to eliminate
the slack in the Chain per the repair instructions.
Replace the Drive Chain
MOTORIZED
Machine does not
rotate
Bad Motor Control Box or Motor Cable Replace Motor Control Box or Motor Cable
No DC output from motor control box Reset circuit breaker on motor control box
No electrical power at AC wall receptacle Reset circuit breaker at power panel
Emergency stop is depressed Rotate to release Emergency Stop Switch
Directional Control Switch is bad Contact Mathey Dearman
6 pin connector on motor assembly is bad Contact Mathey Dearman
Motor turns and
machine does not
rotate
Setscrew Motor Coupling is loose Retighten Setscrew in Motor Coupling