Sawyer Excalibur Series User manual

Sawyer Manufacturing Company
7799 S. Regency Dr., Tulsa, OK 74131 USA
F918.834.0318
[e-mail]
We appreciate your business!
Congratulaons on your new SAWYER product. We are proud to
have you as our customer and will strive to provide you with the best
service and reliability in the industry. This product is backed by our
extensive warranty and world-wide service network. To locate your
nearest distributor or service agency, please contact us at the phone
number and address listed on the boom of each page.
You are in good company!
Sawyer Manufacturing Company is the world leader in the design
and manufacture of pipeline and welding equipment and has been
since 1948. Sawyer equipment has become a standard in the industry
and connues to set the benchmark for quality and durability.
This user operaon manual has been made to instruct you for the best
use and operaon of your Sawyer product. Your sasfacon with our
products is our main goal. Please read this enre manual carefully,
nong all ps, notes and warnings. Safety always comes rst.
About Us
Warranty
All products manufactured by or for Sawyer Manufacturing Company are
guaranteed against defects due to faulty workmanship or materials for twelve
months from the date of purchase.
This guarantee is limited to the repair or replacement of any parts found to be
defecve, and no other liability–expressed, implied, or conngent–is assumed.
Record the following informaon for warranty purposes:
Where purchased:________________________________________________
Purchase date:___________________________________________________
Equipment Serial #:_______________________________________________
P918.834.2550
sawyermfg.com
V1
AW
B
C
G
D
U
Excalibur Manual
Cold Cung Model 210
Parts Diagram - 210H
210H - Oil (Hydraulic Driven)
210E - Electric (Electric Driven)
210P -
Air (Pneumac Driven)
L
K
E
F
I
J
O
N
QT
Q
V
A. Blade Speed Control
B. Start/Stop Control
C. Machine Direconal Control
D. Machine Speed Control
E. Feed Screw
F. Liing Cables
G. Liing Spring Clips
H. Blade Lowering/Raising Handle (not shown)
I. Blade Safety Cover
J. Cuer Spindle
K. Blade Safety Device
L. Cuer Lock Nut & Cuer Collar Support
M. Milling Cuer (not shown)
N. Lubricator Nozzle
O. Mist Lubricaon System Hose
P. Coolant Container (not shown)
Q. Guide Wheels
R. Guide Wheel Tracks (not shown)
S. Socket Head Cap Screws (not shown)
T. Hydraulic Hose Connector
U. Drive Chain (not shown)
V. Drive Chain Sprockets
W. Chain Tensioning Screw
X. Single Chain Pin (not shown)

Sawyer Manufacturing Company
7799 S. Regency Dr., Tulsa, OK 74131 USA
F918.834.0318
[e-mail]
P918.834.2550
sawyermfg.com
V1
Installation
1. Connecons and Power Sources
A. Hydraulic Machine
1. Connect machine to hydraulic power supply (Fig. 1) with the capability of
minimum pressure of 110 bars at 72 L/min. with 25 micron lter and air-
cooled heat exchanger.
2. Ensure power supply is connected properly by checking for clockwise rotaon
of blades.
3. Connect the Mist Lubricaon System Hose (O, Fig. 2) to the Coolant
Container (P). Use a synthec coolant oil type BIO/42 EP or similar.
Note: A small air compressor is required to operate the Automac Double Mist Lubricaon system.
4. Turn the Start/Stop Control (B, Fig. 3) to the On posion to ensure clockwise
rotaon of blades. Turn O.
Tip: If hydraulic hose longer than 50 feet (15 meters) is required, the hose diameter should be
increased accordingly to ensure adequate pressure.
B. Pneumac Machine
1. Connect machine to compressor with a minimum capacity of
4000 liters and pressure of 116psi (8 bars). For the LP (Low Pressure) variant,
the minimum operang pressure is 6 bar, to a maximum of 10 bar.
2. The regulator of the air lter/lubricaon device should be set at
90psi (6 bar).
3. Connect the Cuer Lubricator System to the coolant container. Use
a synthec coolant oil type BIO/42 EP or similar.
4. Turn the Start/Stop Control to the On posion to ensure clockwise rotaon of
blades. Turn O.
Note: If an automac dual mist lubricaon system has been specied, refer to operang instrucons
with the supplied compressor.
Tip: If air hose longer than 50 feet (15 meters) is required, the hose diameter should be increased
accordingly to ensure adequate pressure and volume of air.
C. Electric Machine
1. Connect machine to 3-phase, 380/440V power supply with N and E.
2. Connect the Double Mist Lubricaon System to the Coolant Container. Use
a synthec coolant oil type BIO/42 EP or similar.
Note: A small air compressor is required to operate the Automac Double Mist Lubricaon system.
4. Turn the Start/Stop Control to the On posion to ensure clockwise rotaon of
blades. Turn O.
Installaon
**Photos in this manual are of the Hydraulic Machine**
Fig. 1
Fig. 2
*Not Included
Tools Needed For Installaon and Operaon/Cung*
Liing Cables
& Clips
6mm
Socket
Hexagon
“T”
Handle
Torque Wrench
Elbow Wrench w/Bayonet
30-32 mm Wrench
Chip Brush* 12-13 mm Wrench
Blade
Blank
Blade
Lowering/Raising
Handle
Chain Block
Hex Keys
Wedges
Chain
Coupling
Screw
Synthec
Coolant*
Oiler*
Pin Driver
C Spanner
8 & 16 mm
hexagon
socket 4” Extension
O
P
Fig. 3
B

Sawyer Manufacturing Company
7799 S. Regency Dr., Tulsa, OK 74131 USA
F918.834.0318
[e-mail]
P918.834.2550
sawyermfg.com
V1
2. Seng Guide Wheels for the pipe diameter to be cut
A. Li machine and verify the wheel holders holding the Guide
Wheels (Q, Fig. 5) are aached in the correct Guide Wheel Tracks (R) for
the diameter of pipe to be cut.
Tip: If a posion change is required, remove the four Socket Head Cap Screws (S, Fig. 6), t wheel
supports in the proper slots for the diameter being cut and reinstall the screws.
3. Installing the Drive Chain
A. Thread the Drive Chain (U) through the machine and onto the Drive Chain
Sprockets (V, Fig. 6). Refer to Table 1, page 6
B. The required Drive Chain length is determined by the diameter of the
pipe to be cut.
C.Lengthen the Drive Chain.
1. Select the chain segments required to lengthen the chain
2. If the chain is unjoined, proceed to the next step. If chain is joined,
then remove a single chain pin (X, Fig. 7a).
Tip: Use a pin hammer
3. Add the required amount of addional chain to the ends and secure
(Fig. 7) using a Chain Link Kit (oponal).
D.Shorten the Drive Chain.
1. Select the chain segments required to shorten the length.
2. If the chain is unjoined, proceed to the next step. If chain is joined,
then remove a single chain pin (X, Fig. 7a).
Tip: Use a pin hammer
3. Measure from the unlinked chain point to the correct length and
remove the excess chain. Repeat previous step and secure (Fig. 7)
4. Installing the Excalibur on the pipe
A. Using the two liing cables (F, Fig. 8), li the Excalibur onto the pipe.
B. Release the liing mechanism, ensuring the machine is sll supported on
the pipe unl the chain is ghtened and secured.
C. Tighten the mesh chain by rotang the Chain Tensioning Screw (W, Fig. 9)
counterclockwise with the 16 mm Swivel T Handle.
D. Torque the Chain Tensioning Screw (W) to 96 ./lb. (130NM).
1. Release the tension on the two Liing Cables (F) and unhook the Liing
Spring Clips (G) from the machine.
E. Connect the supplied air/hydraulic hoses to the relevant connectors on the
Excalibur machine, and start the power source
Hose Connector (T, Fig. 10) on the Excalibur, and start the power source.
1. Turn the Start/Stop Control to the ON posion. (B, Fig. 10a)
Note: Hydraulic Model only – If this is the rst me the hydraulic power supply is being run, let the
hydraulic uid circulate through the machine 15-20 minutes to remove air bubbles from the uid.
2. Move the Machine Direconal Control (C, Fig. 10a) to the forward posion.
3. Turn the Machine Speed Control (D, Fig. 10a) valve counter-clockwise.
4. Rotate the Excalibur one full turn around the pipe to align the chain. (Fig. 11)
Note: Verify there is enough clearance for the machine to travel around the pipe.
5. Re-torque the Chain Tensioning Screw (W, Fig. 9) to 96 ./lb. (130NM).
6. Turn o the air/hydraulic power source.
Tip: Open pressure bypass valve before turning o power to the Excalibur.
Fig. 10
Fig. 5
Fig. 9
Fig. 6
Fig. 11
Installation
Fig. 7
X
T
Q
R
S
U
V
Fig. 8
Fig. 7a
F
Fig. 10a
D
C
B
X
W

Sawyer Manufacturing Company
7799 S. Regency Dr., Tulsa, OK 74131 USA
F918.834.0318
[e-mail]
P918.834.2550
sawyermfg.com
V1
Installation
Operation
Fig. 13
Fig. 14
Fig. 12
Fig. 13
Fig. 15
5. Installing Center and Beveling Cuers
A. With the aid of the Blade Lowering/Raising Handle, turn the Feed Screw
(E, Fig. 9) clockwise unl the cuer spindle is raised to its highest posion.
B. Open the Blade Safety Cover (I, Fig. 12a) and loosen the Cuer Lock Nut (L)
by rotang it clockwise. Remove the Cuer Lock Nut, washer and Cuer
Support Collar (L).
Note: Remove all metal chips and debris from the wheel supports and slots in the boom of the chassis.
C. Place the Milling Cuer (M, Fig. 12a) on the Cuer Spindle (J) so the cung
edge is facing downward.
Note: All teeth must face clockwise, as indicated by the arrow on the Cuer Safety Cover
D. Align the holes in the Milling Cuer (M) with the two hardened pins and
push the Milling Cuer forward unl it contacts the face of the male
cuer drive collar. Follow the same procedure to install the center
Milling Cuer and the second Milling Cuer.
E. Install the Cuer Support Collar, washer and Cuer Lock Nut. (L, Fig. 13)
F. Lower the Cuer Safety Cover (I) and latch the Blade Safety Device
to the cover.
Note: The machine will not funcon if blade safety cover is not latched to the blade safety device.
1. Preparaon for the cung process
A. With the Blade Lowering/Raising Handle, (H, Fig. 13) turn the Feed
Screw (E) unl the Cuer Spindle (J) is raised to its highest posion.
B. Turn the Start/Stop Control (B, Fig. 14) to the O posion.
C. Turn the Machine Direconal Control (C, Fig. 14) to the Stop posion.
D. Turn the Machine Speed Control (D, Fig. 14) clockwise to the 0 or fully
closed posion.
E. Turn the Blade Speed control (A, Fig. 14) clockwise to the 0 or fully
closed posion.
Note: Ensure the safety cuer cover is closed and the blade shut-o device is latched to the cover.
F. Turn o the air/hydraulic power source and bleed the pressure from the
supply hoses.
G. Connect and secure the air/hydraulic hose quick disconnects to the
Excalibur.
Note: Air lter/lubricaon device must be placed in the center of the two air hoses. Make sure the
blow of the lubricator assembly is lled with pneumac oil.
H. Start the power supply.
I. Verify correct air/hydraulic output pressure and ow rate.
2. Using the Excalibur for the cung process
A. Turn the air valve of the Mist Lubricaon System device On.
B. Adjust the Lubricator Nozzle (N) as needed to provide a steady ow of
coolant on the blades.
C. With the Blade Lowering/Raising Handle, (H, Fig. 15) turn the Feed
Screw (E) counter-clockwise unl the Milling Cuers (M) are through the
thickness of the pipe at desired depth.
I
I
J
H
H
MN
J
B
ADC
M
Fig. 12a
L
E

Sawyer Manufacturing Company
7799 S. Regency Dr., Tulsa, OK 74131 USA
F918.834.0318
[e-mail]
P918.834.2550
sawyermfg.com
V1
Operation
Fig. 21
Fig. 20
Fig. 19
Fig. 17
D. Remove the Blade Lowering/Raising Handle (H) from the Feed Screw (E)
E. Turn the Machine Direconal Control (C, Fig. 16) to the Feed posion.
Note: Never aempt to cut pipe by placing the forward control knob in the REVERSE posion.
F. Slowly open the Machine Speed Control (D, Fig. 16) unl the desired
forward (feed) speed is achieved.
Note: Check to see if the desired cut and bevel depth are being achieved.
G. Cut the pipe (Fig. 17), machine will travel full rotaon around the pipe.
H. Cuer stoppage
1. If a cuer block occurs, quickly turn the Machine Direconal Control
(C, Fig. 18) to the Return posion and leave it in that posion unl the cuers
start rotang.
2. When the cuers begin rotang, move the Machine Direconal Control
(C, Fig. 18a) to the Stop posion.
3. Close the Machine Speed Control (D, Fig 18) a small amount.
4. Turn the Machine Direconal Control (C, Fig. 16) to the Feed posion.
I. When the cut is complete, move the Machine Direconal Control
(C, Fig. 20) to the Stop posion.
1. Using the Blade Lowering/Raising Handle, (H, Fig. 21), rotate the Feed
Screw (E) unl the Milling Cuers (M) are raised to their highest posion.
2. Turn the Start/Stop Control (B, Fig. 20) to the O posion.
3. Turn the air valve of the Mist Lubricaon System to the O posion.
4. Turn o the air/hydraulic power supply.
5. Bleed all air/hydraulic pressure from the hoses, and disconnect the hoses from
Hydraulic Hose Connector (T) on the Excalibur.
3. Disconnecng the power source
A. Hydraulic Machine
1. Turn o the hydraulic power supply.
2. Bleed all hydraulic pressure from the hoses by rotang the cuer control knob
back and forward to the OFF and ON posion several mes.
3. Disconnect the hydraulic hose from the Excalibur.
B. Pneumac Machine
1. Turn o air supply.
2. Bleed all air pressure from the hoses by rotang the cuer control knob back
and forward to the OFF and ON posion several mes.
3. Disconnect the air hose from the Excalibur.
C. Electric Machine
1. Turn o the power supply.
Fig. 16
Fig. 18
D
D
C
C
Fig. 18a
H
C
C
D

Roune Maintenance
Tip: Plan all roune maintenance when the machine is not in operaon.
When the machine is cung “heavy wall or high strength alloy pipes”, it
is recommended the machine be thoroughly checked aer each cut.
General
1. Inspect the Cuer Blades for wear and the integrity of
the edge aer each cut.
2. Check the Mist Lubricaon System on a regular basis
during the cung process. (if applicable)
A. Check nozzles for obstrucon aer each use.
Clean as necessary.
Note: Always keep the synthec coolant plasc bole clean to avoid debris
or dirt that may obstruct the Lubricaon Nozzle (M).
Pneumac Machine
1. Check the Air Filter / Lubricaon Device and periodically
check the assembly to be certain it is funconing properly
when using the Air Drive Excalibur.
A. Drain the water from the water separator of the Air Filter/
Lubricaon Device on a regular basis.
B. Replenish the oil in the inline Lubricator of the Air Filter/
Lubricaon Device with pneumac oil as needed.
Note: Periodically check the Air or Hydraulic Power Supply.
Hydraulic Machine
Tip: To obtain the best performance, it is important to use a hydraulic
uid with the best viscosity index for the ambient temperature in which
the machine will be working. Under extreme condions, use synthec
addive oil with a high degree of stability.
Note: for applicatons with vegetable biodegradable oil and special mixture,
contact Sawyer prior to use.
A. Filter hydraulic uid through a 25 micro lter when
adding oil to the Hydraulic Power Supply reservoir
Note: Failure to lter the uid may cause damage to the hydraulic blade
and forward motors. Use the same hydraulic oil that was originally in the
reservoir.
Maintenance
Lubricaon Guide
1. The following parts must be oiled once
weekly.
with Lubricang Oil Specicaon: ISA VG 68,
Viscosity 68 & Density 0.887
A. Upper and Lower Gibs
B. Chain Tension Screw.
C. Bronze Bushings.
D. Axle.
E. Depth Control Assembly.
2. The following part must be oiled every 2
weeks.
A. Bronze Wheel Bearing.
3. The following part must be oiled daily.
A. Guide Rod.
B. Install torch inside torch holder.
C. Tighten adjustment knob.
4. The Main Transmission Unit and the Feed
Transmission Unit must be greased using
Lithium based high melng point grease
aer every 10-15 hours of usage.
5. Regarding the chain, this must be inspected,
cleaned and oiled at least once every week.
Table 2. Posioning of the wheels for various pipe diameters and
cung depths