band crawler & stainless steel band part number: 05-0116-009, 05

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WHERE THERE’S PIPE, THERE’S MATHEY

Band Crawler & Stainless Steel Band

Part Number: 05-0116-009, 05-0116-014

& 05-0116-M08

Parts and Operating Manual

______________Machine Model

_____________________Serial#

Revise: 1/18/12

P. O. Box 472110, Tulsa, OK 74147-2110 USA

Toll Free: 800-725-7311

918-447-1288 Office

918-447-0188 Fax

www.mathey.com

http://www.mathey.com/

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Table of Contents

Section Description Page 1.0 Safety 3 1.1 General Safety 3 1.2 Band Crawler Safety 3 2.0 General 4 Figure 1 Clearance around Pipe 4 3.0 Accessories 5 Table 1 Band Crawler and Accessories 6 Table 2 Band Selection Chart 7 4.0 Operation 7 4.1 Manual Band Crawler (description) 7 4.2 Motorized Band Crawler (description) 7 5.0 Set-up and Operation 8 5.1 Installation of Stainless Steel Band on Pipe 8 Figure 2 Stainless Steel Band Drawing 8 Table 3 Stainless Steel Band Parts List 8 Figure 3 Closing of Band Latch 9 5.2 Installation of the Manual Band Crawler on the Band 10 Figure 4 Relationship of Band Crawler Wheel to Stainless Steel Band 10 5.3 Installation of the Motorized Band Crawler on the Stainless Steel Band 10 Motor Control Box Nomenclature 11 Figure 5 Torch Tip Selection 11 5.4 Installation of the Torch in the Band Crawler 12 5.5 The Manual Band Crawler Cutting Process 12 5.6 Turning off the Torch off and dismounting the Manual Band Crawler 12 5.7 The Motorized Band Crawler Cutting Process 12 5.8 Turning off the Torch and dismounting the Motorized Band Crawler 13 Figure 6 Band Crawler Parts Breakdown 14 Table 4 Band Crawler Parts Breakdown 15 Figure 7 Band Crawler Motorizing Kit Parts Breakdown 16 Table 5 Band Crawler Motorizing Kit Parts Breakdown 17 Table 6 Suggest 1 Years Spare Parts for the Band Crawler 17 6.0 Maintenance 18 6.1 Band Crawler Maintenance 18 6.2 Installing and Replacing Flexible Drive Cable Assembly 18 6.3 Wheel Spring Tension Adjustment 18 6.4 Removing and Replacing the Drive Wheel Assembly 19 6.5 Removing and Replacing the Worm Gear Assembly Shaft 19 6.6 Installation of the Motorizing Kit 21 6.7 Replacing the Motorized Band Crawler Motor Shaft 21 6.8 Storage 23 6.9 Band Maintenance 23 7.0 Limitations 23 8.0 Machine Safety 23 Figure 12 Motor Control Box Schematic 24 9.0 Use Condition 25 9.1 Condition of Use 25 9.2 Use of Band and Band Crawler not allowed by Manufacturer 25 10.0 Disposal of the Band and Band Crawler 25 10.1 General Information 25 10.2 Composition of Major Components 25 Table 7 Trouble Shooting 26 11.0 Warranty 28

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Safety

Proper precautions should be taken when using this machine or any and all other heavy cutting and welding equipment. A little common sense goes a long way towards preventing accidents involving your Mathey Dearman Band Crawler.

1.1 General Safety

Eye protection must be worn to protect eyes from sparks, flying slag and the brilliant flame.

Protective clothing such as chaps, sleeves, steel toed shoes and gloves shall be worn to protect the operator from sparks or slag.

Make sure loose clothing, tools, belts, etc. do not become entangled between the wheel of the Band Crawler and the Band.

Clear the general area where the Band Crawler will be used of all trip hazards.

Use a Heat-Resistant Shield to protect nearby walls from sparks and hot material.

Adequate ventilation is required to prevent the concentration of oxygen/fuel, gas and/or other toxic fumes.

Do not store grease, gasoline or other flammable material in the area where the pipe is being cut.

Always have a fire extinguisher of the proper size and type in the work area.

Remove all smoldering materials from the work area when work has been completed.

The pipe must be secured to the table or pipe stand, prior to mounting the machine on the pipe.

Never wear loose clothing when operating the Band Crawler.

Fire is hot. Keep all flammable material, including hands and feet, as far from the path of the Cutting Torch as possible.

1.2 Band Crawler Safety

The operator and maintenance person shall read and understand the Band Crawler parts and operating manual prior to attempting operation of the equipment.

The operator and maintenance person shall read and understand the torch parts and operating manual prior to attempting operation or maintenance of the of the oxy/fuel torch.

The periodic maintenance instructions must be followed in the Band Crawler parts and operating manual.

Never use the Band Crawler for other than its intended purpose.

Never direct flame or debris associated with cutting process toward the oxygen or fuel gas cylinders.

Do not operate Band Crawler equipped with Oxy/fuel or plasma torch in an explosive environment.

Due to the risk of personnel injury never direct the flame or the fuel or plasma torch back toward the machine.

Discontinue the operation of the Band Crawler, if it is vibrating or operating erratically.

When using the Band Crawler, basic safety precautions must always be followed to reduce the risk of personal injury.

Always operate the tool in accordance with the operating instructions.

The Oxy/Fuel Torches or the Plasma Torches must be properly installed and fastened in the Torch Holder assembly to avoid injury to the operator.

There must be sufficient slack in the Oxy/Fuel or Plasma Hoses so the Band Crawler will be able to make a full circle around the pipe to complete cut.

Always follow the Oxy/fuel or plasma torch manufacturers operating instruction when using the Oxy/fuel or plasma torch Machine Torch.

The Band Crawler should only be used with a 1 3/8” diameter oxy/fuel or plasma torch having a barrel length not to exceed 10”.

The Band Crawler and Band must be free from all obstacles, especially hands and feet, before operating machine.

IN ADDITION TO THE ABOVE INSTRUCTION, 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 The Mathey Dearman Band Crawler is engineered and designed to hold and rotate a 12” long 1-3/8” / 35mm diameter oxy/fuel or plasma machine torch around 6” - 60” / 152 – 1524mm pipe to cut or to bevel pipe ends producing a bevel for the welding two (2) pipes together. The Band Crawler, both manual and motorized, fits all band sizes. Stainless Steel Bands are available with a standard latch for standard API line pipe sizes 6” to 60” / 152mm to 1520mm in 2” / 50mm increments. Special Stainless Steel Bands for odd size or larger pipes available on request.

Mathey Dearman Band Crawler consists of two (2) main assemblies:

1. The Flexible Stainless Steel Band installs around the outside diameter of the pipe to be cut or beveled. The Stainless Steel Band forms to the pipe outside diameter even under the most sever out-of-round conditions and acts as a guide to insure consistent cut or bevel.

2. The Band Crawler, which attaches the flexible Stainless Band, moves around the pipe by means of a 9’ or 14’ Flexible Drive Cable. A 230vac Motorized Band Crawler is also available to rotate plasma or oxy/fuel torch around the pipe.

Warning: Warranty is Void if the Band Crawler or Motor Control Box is disassembled

by the distributor or end-user during Warranty Period

Manual Band Crawler with 9’/ 2.7m or 14’ / 4.3m Flex Drive Cable Shipping Dimensions (approx.) 23" x 23" x 12 1/2" (584 x 584 x 318mm)

110VAC Motorized Band Crawler Shipping Dimensions (approx.) 18" x 18" x 11 1/2" (457 x 457x 492mm)

230VAC Motorized Band Crawler Shipping Dimensions (approx.) 18" x 18" x 11 1/2" (457 x 457x 492mm)

Figure 1 – Clearance around the Pipe

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3.0 - ACCESSORIES

Torch Angle Head Adaptor (Part No. 05-0200-003)

This attachment allows the Torch to be adjusted to any bevel angle up to

90-degrees and permits adjustment for a lead or lag angle of the torch.

A 3/4” Button Tip (Victor Series 108 Cutting Tip) should be used when

cutting at 90 degree to pipe surface.

Right Angle Head Adaptor (Part No. 05-0117-030)

This attachment lets the Flexible Drive Cable Assembly swivel through

180 degrees. The feature decreases the amount of clearance needed

around the pipe to approximately 6” / 152mm for tight areas where

there is very little clearance.

Rack Adjustable Torch Holder (Part No. 05-0116-032) This attachment provides horizontal and vertical rack adjustment of

Plasma or Oxy-fuel Machine Torches. The torch must be equipped with

a rack for vertical adjustment

Double Torch Arm (Part No. 05-0117-039) The Double Torch Arm is a device used for mounting two standard oxy-fuel

or plasma torches to the Band Crawler.

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Table 1 – Band Crawler and Accessories

Description Part Number Shipping Weight

(lbs/kg)

Band Crawler with 9’ / 2.7m Flex Drive Cable 05-0116-009 26 / 12

Band Crawler with 14’/ 4.3m Flex Drive Cable 05-0116-014 30 / 14

Right Angle Drive Adaptor (for Flex Driver Cable) 05-0117-030 1 / .5

Motorized Band Crawler, 230VAC 05-0116-M08 27 / 12.4

Electric Motorizing Retrofit Kit (230VAC) 05-0116-A08 9 / 4

Rack Adjustable Torch Arm 05-0116-032 7 / 3.2

Double Torch Arm 05-0117-039 9 / 4.1

Victor MT210A Machine Torch 05-0200-002 4 / 1.8

Victor BHA Torch Angle Adaptor 05-0200-003 1.3 / 0.6

Victor 3”/76mm long Acetylene Cutting Tip, 3/4” / 19 cap. 05-0201-001 .2 / .1

Victor 3”/76mm long Acetylene Cutting Tip, 1”/25mm cap. 05-0201-002 .2 / .1

Victor 3/4”/19mm long Acetylene Cutting Button Tip, 3/4” / 19 Cap. 05-0201-003 .2 / .1

Victor 3/4”/19mm long. Acetylene Cutting Button Tip, 1”/ 25mm Cap 05-0201-003 .2 / .1

Victor 3”/76mm long Propane Cutting Tip, 3/4” / 19 cap. 05-0201-013 .2 / .1

Victor 3”/76mm long Propane 3”/76mm long Cutting Tip, 1”/25mm cap. 05-0201-014 .2 / .1

Note: The use of a machine torch with a torch barrel shorter than 10” / 254mm is not recommended.

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Table 2 – Stainless Steel Band Selector Chart

NOTE: Intermediate and larger size bands are available on special order.

4.0 - OPERATION

4.1 Manual Band Crawler Manual operation of the Band Crawler is controlled by rotating the Crank Handle of the 9’ / 2.7m or 14’/ 4.3m Flexible Drive Cable Assembly. It can be turned in either direction, for either clockwise or counterclockwise rotation of Band Crawler around the Stainless Steel Band that is mounted to the pipe.

4.2 Motorized Band Crawler The CE Motorized Band Crawler is available in a 230 vac model. Motorized operation is controlled with the European version of the Mathey Dearman Motor Control Box. Forward / Stop / Reverse Switch on Motor Control Box determines clockwise and counterclockwise rotation of Band Crawler around the pipe. The Speed Control Knob controls speed of rotation around the pipe. The Motor Control Box is equipped with Emergency Stop

Pipe Size Latch Type Standard Weight (approx.)

Inches mm lbs. kg.

6 152 05-0104-006 5 2

8 203 05-0104-008 6 3

10 254 05-0104-010 7 3

12 304 05-0104-012 7 3

14 356 05-0104-014 11 5

16 406 05-0104-016 12 5

18 457 05-0104-018 13 6

20 508 05-0104-020 14 6

22 559 05-0104-022 15 7

24 610 05-0104-024 24 11

26 660 05-0104-026 25 11

28 711 05-0104-028 25 11

30 762 05-0104-030 25 11

32 813 05-0104-032 26 12

34 864 05-0104-034 27 12

36 914 05-0104-036 29 13

38 965 05-0104-038 31 14

40 1016 05-0104-040 33 15

42 1067 05-0104-042 36 16

44 1118 05-0104-044 39 18

46 1168 05-0104-046 43 20

48 1219 05-0104-048 90 41

50 1270 05-0104-050 92 42

52 1321 05-0104-052 96 44

54 1372 05-0104-054 100 45

56 1422 05-0104-056 106 48

58 1473 05-0101-058 110 50

60 1524 05-0104-060 115 52

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5.0 – SET-UP AND OPERATION 5.1 Installation of Stainless Steel Band on Pipe

Figure 2 Table 3 – Band Parts List

Note 1: All Bands sizes are slightly different, contact Mathey Dearman, Inc. for parts information.

Note 2: Locating Pins and Upper or Lower Duckbills is an integral part of the Band and are not field-

replaceable. The Band must be returned to Mathey Dearman Inc. for replacement of these parts.

Note 3: Quantities vary with band size.

Item No. Part Description Part No. Qty. Req’d

1 Stainless Steel Band Material See Note 1 1

2 Locating Pins 05.0103.003 See Note 2

3 Anchor Block 05-0103-115 See Note 1

4 Upper and Lower Duck Bill 05-0103-118 See Note 2

5 Standard Band Latch Assembly, 6” – 12” pipe 05-0103-100 See Note 1

Standard Band Latch Assembly, 14” pipe & up 05-0103-102 See Note 1

6 Band Handle 05-0103-001 See Note 1

7 Band Stiffener 05-0103-007 See Note 3

8 Hex Head Cap Screw, 1/4-28NF x 1/2” long 10-14F0-012 See Note 3

9 Internal Locking Washer, 1/4” 12-0014-I00 See Note 3

10 Socket Head Cap Screw, 1/4"-20 x 5/8” long 11-14C0-058 2

11 1/4"-20 Lock Nut 1L-14C0-000 2

12 Socket Head Cap Screw, 1/4"-20 x 3/8” long 11-14C0-038 2

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5.1.1 Measure the pipe and select proper size Band for pipe size to be cut or beveled. The size of the Band is marked near the Duckbill of the Band. 5.1.2 Lift the Latch Handle of the Latch Handle Assembly (Figure 2 Item A) to open the Band.

Note: Sometimes it is necessary to push the Latch Handle over center in order to separate the Band Ends.

Figure 3

5.1.3 Lift the Latch Handle Assembly (Figure 2 Item A) out from the Latch Anchor (Figure 2 Item 4).

5.1.4 Pull the Band Handles (Figure 2 Item 6) outward spreading the ends of the Band apart and place it over the pipe.

5.1.5 Pull the Band Handles (Figure 2 Item 6) together and insert band end with the tangs into the Duckbill (Figure 2 Item 4).

5.1.6 Place the Band at a distance approximately 5” – 7” to 127 – 178 mm from the cut line.

5.1.7 Insert end of the Latch Handle Assembly (Figure 2 Item 5) into the Latch Anchor (Figure 2 Item 3).

5.1.8 Close the Latch Handle Assembly (Figure 2 Item 5) by pushing the Latch Handle Figure 2 Item A) of the Latch Handle Assembly downward.

Note: The closure on the pipe can be adjust by rotating the Latch Handle clockwise to loosen or counterclockwise to tighten.

5.1.9 Make sure that all Rest Pins (Figure 2 Item 2) on both sides of the Band are making contact with the pipe. Note: If some of the Rest Pins (Figure 2 Item 2) of the Band are not making contact with the pipe it may be an indication that the Band is out of square with the pipe and the Band must repositioned and resquared to the pipe. Note: Never use a hard faced hammer to square the band on the pipe as the wheels of the Band Crawler may have difficulty crossing the damaged area.

5.1.10 The Band Crawler is ready to mount onto the Band.

Note: There is no need for an out-of-round coping device because of the flexibility of the band allows it to conform to the contour of the out- of-round pipe when locked into position on pipe.

Caution: Use caution when closing the band latch to insure the hand is not caught

between the latch handle and band surface

Caution: Use caution when closing the band latch to insure fingers or clothing is not

caught between the inner surface of the band or rest pins and the pipe surface.

Caution: Keep your finger clear of the area where the band end with the tangs will be inserted into the Duckbill.

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5.2 – Installation of the Manual Band Crawler on the Band

5.2.1 Turn the Hex Head Cap Screws (Figure 6 item 12) counterclockwise with a 7/16” Wrench until the rear and front Ball Leg Assemblies (Figure 6 items 8 & 10) rotate.

5.2.2 Place the Band Crawler over the band and move the rear and front Ball Leg Assemblies (Figure 6 items 8 &10) inward or outward until the groove in the Wheel of Drive Wheel Assembly (Figure 6 items 14) matches the radius of the Band.

5.2.3 Slowly close the two (2) latch handles (Figure 6 item 21B) of the rear and front Ball Leg Assemblies (Figure 6 items 8 & 10) while aligning the groove of the wheel assembly (Figure 6 item 14) on the edge of the band.

5.2.4 Adjust the rear Ball Leg Assembly (Figure 6 items 8) until the groove in the drive wheel assembly (Figure 6 item 14) matches the radius of the band.

5.2.5 Tighten the Hex Head Cap Screws (Figure 6 item 12) in the rear ball leg assembly (Figure 6 items 8) with a 7/16” wrench until the Ball Leg Assembly is difficult to move. Do tighten at this time.

5.2.6 Adjust the front Ball Leg Assembly (Figure 6 items 10) until the groove in the drive wheel assembly (Figure 6 item 14) matches the radius of the band

Figure 4

5.2.7 Tighten the Hex Head Cap Screws (Figure 6 item 12) in the rear ball leg assembly with a 7/16” Wrench until the Ball Leg Assembly is difficult to move. Do tighten at this time.

5.2.8 Recheck both the drive wheel assembly (Figure 6 item 14) in the rear and front Ball Leg Assemblies (Figure 6 items 8 & 10) matches the radius of the band and adjust if necessary.

5.2.9 Tighten all 4 of the Hex Head Cap Screws (Figure 6 item 12) clockwise with a 7/16” Wrench. Note: Over tightening of the Hex Head Cap Screws may strip the thread in the aluminum body (Figure 6 item 5).

5.2.10 Rotate the hand crank of the 9 or 14 foot Flexible Drive Shaft assembly (Figure 6 item 19A or 19B) to move the Band Crawler around the Band.

5.2.11 If the Band Crawler is slipping on the band or will not travel up hill, lift the Latch Handle (Figure 6 item 21B) of the rear Ball Leg Assembly (Figure 6 items 8) and rotate the tension nut clockwise 1/4 turn with the 7/16” Wrench.

5.2.12 Lift the Latch Handle (Figure 6 item 21B) of the front Ball Leg Assemblies (Figure 6 items 10) and rotate the tension nut counterclockwise 1/8 turn with the 7/16” Wrench.

5.2.13 Rotate the hand crank of the 9 or 14 foot Flexible Drive Shaft assembly (Figure 6 item 19A or 19B) to move the Band Crawler around the Band.

5.2.14 If the Band Crawler is still slipping on the pipe repeat steps 2.2.11, 2.2.12 and 2.2.13. Note: The Levers should lock the legs securely, but not so tightly that the Wheels bind against the Band.

5.2.15 Proceed to the instruction for mounting in the Band Crawler.

5.3 – Installation of the Motorized Band Crawler on the Band

Warning: Do not change direction of rotation of the Motorized Band Crawler while Gear Motor is running as the motor commentator or motor control box may suffer damage. Always move the Forward/Stop/Reverse switch to OFF position for at least 1 full second prior to moving the switch to the forward and reverse Position.

5.3.1 Follow steps 2.2.1 through 2.2.9 for the mounting the Mounting the Manual band Crawler on the Band. 5.3.2 Connect the Electrical Connector (Figure 7 item 33) to the Motor Control Box (Figure 7 item 35). 5.3.3 Depress the Emergency Stop Switch. 5.3.4 Move the Forward/Stop/ Reverse Switch of the motor control box is in the “STOP” position. 5.3.5 Rotate the Speed Rheostat Switch counterclockwise to the “0” position on the dial. 5.3.6 Plug the Motor Control Box (Figure 7 item 35) into the electrical power source.

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5.3.7 Twist to release the Emergency Stop Switch. 5.3.8 Move the Forward/Stop/ Reverse Switch of the motor control box is in the “FORWARD or Reverse” position. 5.3.9 Slowly rotate the Speed Rheostat Switch clockwise to the “3” position on the dial.

5.3.10 Follow steps 5.2.11 through 5.2.14 of the instructions for the mounting the Manual band Crawler on the Band. 5.3.11 Depress the Emergency Stop Switch. 5.3.12 Move the Forward/Stop/ Reverse Switch of the motor control box is in the “STOP” position. 5.3.13 Rotate the Speed Rheostat Switch counterclockwise to the “0” position on the dial. 5.3.14 Follow the instructions for mounting the torch in the Band Crawler.

Figure 5

Warning: Use extreme care when plugging the Motor Control Box as

there is a risk of electrical shock and death if handled improperly.

Warning: There is a risk of electrical shock if the electrical cord between the Motor

Control Box and Band Crawler is pinched between the Wheel Assembly and the Band.

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5.4 - Installation of the Torch in the Band Crawler 5.4.1 Turn the Set Screw (Figure 6 item 7) counterclockwise until the Torch Holder Eccentric (Figure 6 item 9) rotates. 5.4.2 Rotate the Torch Holder Eccentric (9) until the hole for the torch in the Torch Holder Eccentric (9) is at its

furthermost point from the band surface. 5.4.3 Install the machine torch through the bore of the Torch Holder Eccentric (Figure 6 item 9).

Note: This installation requires an Angle Head Adaptor for the Torch Tip (See Section 2 - Accessories).

Warning: A Machine Torch having a barrel length less than 10” / 254mm should never be used with the Band Crawler. If the Cutting Tip is too close to the Drive Wheel Assemblies (Figure 6 item 14), it will cause the grease to seep from the needle bearings of the Drive Wheel Assemblies causing the needle bearings to seize and may shear the Worm Gear Shaft Assembly (Figure 6 item 11).

5.4.4 Adjust Torch Tip to desired bevel angle. 5.4.5 Adjust torch horizontally in Eccentric Torch Holder (Figure 6 item 9) for proper Tip alignment with cut line. 5.4.6 Rotate Eccentric in Band Crawler (Figure 6 item 5) to set Tip to the pipe distance per the torch manufacturer’s

instructions. 5.4.7 Turn the Set Screw (Figure 6 item 7) to lock Torch and Eccentric Torch Holder (Figure 6 item 9) in position in the

Band Crawler Body (Figure 6 item 5).

Note: A Rack Adjustable Torch Arm (Mathey Part No. 05-0116-032) is available to hold the Fuel or Plasma Machine Torch eliminating the need for the Torch Angle Head Adaptor.

Special Note: If the Torch Carrier Crawler is going to be used to create a back bevel, the distance between the Torch Tip and Drive Wheel Assemblies (Figure 6 item 14) should be as far as possible to minimize the heating of the Bearings of the Drive Wheel Assemblies (14).

5.5 - The Manual Band Crawler Cutting Process

5.5.1 Light the Torch per the torch manufacturer’s instructions. 5.5.2 Preheat the pipe per the torch manufacturer’s instructions. 5.5.3 Move the cutting oxygen valve of the torch to the cutting position per the torch manufacturer’s instructions. 5.5.4 Rotate the hand crank of the 9 or 14 foot Flexible Drive Shaft assembly (Figure 6 item 19A or 19B) in the desired

direction to move the Band Crawler around the pipe.

5.6 - Turning off the Torch and dismounting the Manual Band Crawler

5.6.1 Once the cut is complete move the cutting oxygen valve of the torch to the off position per the torch manufacturer’s instructions.

5.6.2 Close the Oxygen and fuel gas valves on the torch per the torch manufacturer’s instructions. 5.6.3 Lift the Latch Handles (Figure 6 item 21B) on the Rear and Front Ball Leg Assemblies (Figure 6 items 8 & 10) to

release the Band Crawler from the band. 5.6.4 Lift up on the Band Latch Handle (Figure 2 item A)

5.6.5 Remove end of the Latch Handle Assembly (Figure 2 Item 5) from the Latch Anchor (Figure 2 Item 3).

5.6.6 Pull the Band Handles (Figure 2 Item 6) outward spreading the ends of the Band apart and remove it from the pipe.




5.7 - The Motorized Band Crawler Cutting Process 5.7.1 Depress the Emergency Stop Switch. 5.7.2 Connect the Electrical Connector (Figure 7 item 33) to the Motor Control Box (Figure 7 item 35). 5.7.3 Connect the Motor Control Box (Figure 7 item 35) from the 230vac electrical power source


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5.7.4 Rotate the Speed Rheostat Switch clockwise to the “2” position on the dial. 5.7.5 Light the Torch per the torch manufacturer’s instructions. 5.7.6 Preheat the pipe per the torch manufacturer’s instructions. 5.7.7 Twist to release the Emergency Stop Switch. 5.7.8 Move the cutting oxygen valve of the torch to the cutting position per the torch manufacturer’s instructions. 5.7.9 Move the Forward/Stop/ Reverse Switch of the motor control box in the direction desired. 5.7.10 Slowly rotate the Speed Rheostat Switch clockwise until the desired cutting speed is achieved.

5.8 - Turning off the Torch and dismounting the Motorized Band Crawler

5.8.1 When the cut is complete move the cutting oxygen valve of the torch to the off position per the torch manufacturer’s instructions. 5.8.2 Depress the Emergency Stop Switch. 5.8.3 Close the Oxygen and fuel gas valves on the torch per the torch manufacturer’s instructions. 5.8.4 Disconnect the Motor Control Box (Figure 7 item 35) from the 230vac electrical power source 5.8.5 Disconnect the Electrical Connector (Figure 7 item 33) to the Motor Control Box (Figure 7 item 35).

5.8.6 Lift the Latch Handles (Figure 6 item 21B) on the Rear and Front Ball Leg Assemblies (Figure 6 items 8 & 10) to release the Band Crawler from the band.

5.8.7 Lift up on the Band Latch Handle (Figure 2 item A).

5.8.8 Remove end of the Latch Handle Assembly (Figure 2 Item 5) from the Latch Anchor (Figure 2 Item 3).

5.8.9 Pull the Band Handles (Figure 2 Item 6) outward spreading the ends of the Band apart and remove it from the pipe.





Warning: Use extreme care when plugging the Motor Control Box as there is a

risk of electrical shock and death if handled improperly.



Warning: There is a risk of electrical shock if the electrical cord between the Motor

Control Box and Band Crawler is pinched between the Wheel Assembly and the Band.

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Figure 6 – Band Crawler Parts Break Down

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Table 4 – Band Crawler Parts Breakdown

Item Description Part Number Qty.

1 End Plug 05-0116-021 1

2 Name Plate 01-0209-025 1

4 Grease Zerk 01-0469-003 1

5 Crawler Body 05-0116-013 1

6 Connector 05-0116-012 1

7 Set Screw 05-0116-011 1

8 Rear Ball Leg Assembly 05-0116-010 1

9 Eccentric Torch Holder 05-0116-008 1

10 Front Ball Leg Assembly 05-0116-020 1

11 Worm Shaft Assembly 05-0116-007 1

11A Bearing Housing 05-0116-117 1

12 Hex Head Cap Screw, 1/4-28NF x 2” Lg. 10-14F0-200 4

13 Flat Washer, 1/4” 12-0014-F00 4

14 Drive Wheel Assembly 05-0116-083 4

15 Rear Flange Leg Assembly 05-0116-001 1

16 Bearings, Worm Gear Shaft Assembly 05-0116-003 4

17 Worm Gear Assembly Shaft 05-0116-002 2

18 Front Flange Leg Assembly 05-0116-004 1

19A 9 Foot Flexible Drive Shaft Assembly 05-0116-022 1

19B 14 Foot Flexible Drive Shaft Assembly 05-0116-031 1

20 #8-32 SCK’T Set Screw x 1/4” 19-08C0-014 4

21 Latch Assembly 05-0116-040 2

21A Short Anchor Block 05-0116-061 1

21B Latch Handle 05-0116-016 1

21C Long Anchor Block 05-0116-046 1

21D Rivet 17-3160-100 2

21E Tension Nut 1H-14F0-000 1

21F Latch Spring 01-0183-013 1

21G Anchor Pin 05-0116-036 1

21H Long Latch Pin 1L-14FO-000 1

21I Anchor Pin 04-0106-023 1

22 Shim 05-0116-030 1

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Figure 7 – Band Crawler Motorizing Kit Parts Breakdown

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Table 5 - Crawler Motorizing Kit Parts List

Item # Part Description Part No. Quantity

Req.

~ 230VAC Motorized Crawler 05-0116-M11 ~

30 Motor Shaft 05-0116-081 1

31 Motor Connector 05-0116-080 1

32 Crawler Motor 03-0201-056 1

33 Electrical Coupling 03-0203-011 1

34 Machine Screw, 10-32unc x 1/2” long 14-01C0-012 4

35 230vac Motor Control Box 03-0203-006 1

36 #10 Flat Washer 10-0001-F00 4

37 10-30unc x 1/4" long 19.01C0.014 2

38 15 Foot Cord 03-0203-020 1

39 Motor Mounting Bracket 05-0116-082 1

Table 6 – Suggested 1Years Spare Parts per Band Crawler

Manual Crawler

Item # Part Description Part No. Suggested Qty.

17 Worm Gear Shaft Assembly 05-0116-002 4



20 #8-32x1/4 Sck’t Set Screw 19-08C0-014 4

Motorized Crawler

17 Worm Gear Shaft Assembly 05-0116-002 4



20 #8-32x1/4 Sck’t Set Screw 19-08C0-014 4

30 Motor Shaft 05-0116-081 1

32 Crawler Motor 03-0201-056 1

35 230vac Motor Control Box 03-0203-003 1

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6.0 – Maintenance Mathey Band Machines require only minimal maintenance. However, they are precision machines and in order to

achieve precision results with them, they should be used and handled with reasonable care, and be kept clean and

lubricated.

6.1 – Band Crawler Maintenance

The Ball Legs, Flanged Legs, Drive Wheels and Torch Holder Eccentric should be kept clear of slag and other trapped abrasives, particularly sand and dirt. Use a soft rag and non-flammable solvent to clean the machine.

The Grease Zerk on top of the Band Crawler Body should be greased once a month if used periodically and once a week if used heavily, and before storing. The Crawler Body should be lubricated with gun grease (example: Lubriplate™ 130AA).

During transportation, or when not in use, the Band Crawler should be stored in a protective container such as a Carrying Case or the original factory shipping carton. Flexible Drive Cable on the Manual Band Crawler, and the Electrical Cords and Connections on the Motorized Band Crawler, should be kept clean and protected from kinking as well as from sharp objects that could cause cuts or punctures.

Warning: Do not use air when cleaning the machine.

6.2 – Installing or Replacing Flexible Drive Cable Assembly

The Manual Band Crawler is shipped with the Flexible Drive Cable Assembly installed; however, if there is a need to change the Drive Cable, follow this re-installation procedure.

6.2.1 The Flexible Shaft inside the Flexible Drive Cable Assembly (19A or 19B) extends approximately 1 ½ inches beyond the Swivel Nut (E), and is inserted into the Torch Carrier Crawler through the Connector (Figure 6 item 6)

Figure 8

6.2.2 The Flexible Shaft inside the Flexible Drive Cable Assembly (19A or 19B) must be turned so the Keyway (Groove) of the exposed end of the Flexible Drive Cable Assembly aligns with the Key of the Worm Shaft (Figure 6 item 11) located inside the Connector (Figure 6 item 6).

6.2.3 When the Key of the Worm Shaft (Figure 6 item 11) and the Keyway (Groove) of the exposed end of the Flexible Drive Cable Assembly are aligned, the Swivel Nut (E) of the Drive Cable will be in position to be screwed onto the Connector (Figure 6 item 6).

6.2.4 Tighten the Swivel Nut (E) by hand until it stops turning.

6.3 - Wheel Spring Tension Adjustment 6.3.1 Lift up the Lever (Figure 6 item 21B) of the Rear or Front Ball Leg Assemblies (Figure 6 items 8 & 10) to expose the

tension nut. 6.3.2 Turn the Tension Nut (Figure 6 item 21E) clockwise 2 turns to release the spring tension. 6.3.3 Adjust the spring tension until the groove of the Wheel Assembly (Figure 6 item 14) of the Front and Rear Ball Leg

Assemblies (Figure 6 items 8 & 10) make contact with Stainless Steel Band. 6.3.4 Mount the Torch and any Accessories that will be used on the Band Crawler. 6.3.5 Adjust the Spring Tension Nut (Figure 6 item 21E) Counterclockwise in 1/8 turn increments until the Crawler goes

around the Band without slipping with all Accessories attached.

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Note: Do not tighten the Spring Tension Nut more than is necessary to stop the Band Crawler from slipping on the band as this may cause damage to the wheels.

6.4 - Removing & Replacing the Drive Wheel Assembly (14). If there is uneven wear in the Groove of the Drive Wheel Assembly (Figure 6 item 14) or the wear in the Groove is more than 1/32” / .8mm deep, the Drive Wheel Assembly should be replaced.

6.4.1 With a 5/64” Hex Key turn the 8-32 x 1/4" long set screw (Figure 6 item 20) in the Drive Wheel Assembly (Figure 6 item 14) counterclockwise 1 full turn.

6.4.2 Heat the Ball Legs or Flange Leg Assembly (Figure 6 Item 8, 10, 15 or 18) with a Propane Torch on low flame momentarily just enough to remove the Drive Wheel Assembly.

6.4.3 Grab the Drive Wheel Assembly (Figure 6 item 14) with a pair of pliers and remove it from the Ball Leg or Flange Leg Assembly (Figure 6 Item 8, 10, 15 or 18). If the Drive Wheel comes off by itself, grab the inner bearing race and remove the inner bearing race and bearing from the Ball Leg or Flange Leg Assembly.

6.4.4 Place the Inner race of the Drive Wheel Assembly (Figure 6 item 14) into the hole of the Ball Leg or Flange Leg Assembly (Figure 6 Item 8, 10, 15 or 18) and onto Worm Gear Assembly Shaft (Figure 6 item 17).

6.4.5 Push the Drive Wheel Assembly (Figure 6 item 14) into the Ball Leg or Flange Leg Assembly (Figure 6 Item 8, 10, 15 or 18)

Note: It may be necessary to warm Ball Legs or Flange Leg Assembly (Figure 6 Items 8, 10, 15 or 18) just enough to slide the Drive Wheel Assembly into the Band Crawler Leg over the Worm Gear Assembly Shaft (Figure 6 item 17).

Note: If the bearing of the Drive Wheel Assembly (Figure 6 item 14) slides freely into the Ball Leg or Flange Leg Assembly (Figure 6 Item 8, 10, 15 or 18), place the leg in a vice and apply just enough pressure to slightly egg the bore of the Ball Leg or Flange Leg Assembly so the bearing will some pressure to fit into the leg assembly

Note: It is helpful to use a strong Magnet, such as a rare earth magnet, to draw the Worm Gear Assembly Shaft (Figure 6 item 17) through the Drive wheel Assembly.

6.4.6 With a 5/64” Hex Key tighten the 8-32 x 1/4" long set screw (Figure 6 item 20) in the Drive Wheel Assembly (Figure 6 item 14) against the Worm Gear Assembly Shaft (Figure 6 item 17).

6.4.7 Apply Lithium grease to the Grease Zerks (Figure 6 item 4) at the top of the Band Crawler Body (Figure 6 item 5) until it starts to seep between the Ball Leg or Flange Leg Assembly (Figure 6 Item 8, 10, 15 or 18) and the Drive Wheel of the Drive Wheel Assembly (Figure 6 item 14). The grease should be slowly applied slowly and do not over apply.

6.4.8 Rotate the Crank Handle Assembly (26) to make sure all wheels are turning.

6.4.9 Follow the instructions for the Adjustment of the Wheel Spring Tension in section 3.3.

6.5 - Removing & Replacing the Worm Gears Assembly Shaft (17)

If one of the Drive Wheel Assemblies (Figure 6 item 14) in the Ball Leg or Flange Assemblies (Figure 6 items 8, 10, 15 or 18) is not turning, it is an indication that the Worm Gear Assembly Shaft (Figure 6 item 17) is sheared. The Worm Gear Assembly Shaft (Figure 6 item 17) should be replaced.

6.5.1 If disassembling manual Band Crawler, unscrew the Connector (Figure 8 item E) to remove the 9 or 14 foot Flexible drive shaft (Figure 6 item 19A or 19B) from the Connector (Figure 6 item 6).

6.5.2 If disassembling manual Band Crawler, remove Connector (Figure 6 item 6) from the Crawler Body (Figure 6 item 5). In the case of the motorized crawler unscrew the Motor Connector (Figure 8 item E) from the Crawler Body (Figure 6 item 5).

6.5.3 Rotate the Worm Shaft Assembly (Figure 6 item 11) counterclockwise to remove it from the Body (Figure 6 item 5).

6.5.4 With a 5/64” Hex Key turn the 8-32 x 1/4" long set screw (Figure 6 item 20) in the Drive Wheel Assembly (Figure 6 item 14) counterclockwise 1 full turn.

6.5.5 Heat the Ball Legs or Flange Leg Assembly (Figure 6 Item 8, 10, 15 or 18) with a Propane Torch on low flame momentarily just enough to remove the Drive Wheel Assembly.

6.5.6 Grab the Drive Wheel Assembly (Figure 6 item 14) with a pair of pliers and remove it from the Ball Leg or Flange Leg Assembly (Figure 6 Item 8, 10, 15 or 18). If the Drive Wheel comes off by itself, grab the inner bearing race and remove the inner bearing race and bearing from the Ball Leg or Flange Leg Assembly.

6.5.7 With a 7/16” wrench remove Hex Head Cap Screws (Figure 6 item 12) from the Ball Leg and Flange Assembly (Figure 6 items 8, 10, 15 or 18) that is not turning.

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6.5.8 Remove the Front or Rear Flange Leg Assembly (Figure 6 item 15 or 18) from the Band Crawler Body (Figure 6 item 5).

6.5.9 Remove the Front or Rear Ball Leg Assembly (Figure 6 item 8 or 10) from the Band Crawler Body (Figure 6 item 5). The Worm Gear Assembly Shaft (Figure 6 Item 17) should remain the Front or Rear Ball Leg Assembly.

6.5.10 Remove the Worm Gear Assembly Shaft (Figure 6 Item 17) from the Front or Rear Ball Leg Assembly

6.5.11 Place the Crawler Body with Grease Zerk (Figure 6 item 4) facing downward in a soft jaw vice.

Figure 9

6.5.12 Place the end of the Worm Gear Assembly Shaft (Figure 9 item 17) having the shoulder of the Gear thru the recessed Bearing (Figure 9 item 16) in the Rear or Front Flange leg (Figure 9 item 15 or 18) until it comes out the flange leg as shown above.

6.5.13 Place the end of the Worm Gear Assembly Shaft (Figure 9 item 17) protruding out Crawler Body (Figure 9 item 5) into the bore of the Rear or Front Ball Leg Assembly (Figure 9 item 8 or 10).

6.5.14 Push the Worm Gear Assembly Shaft (Figure 9 item 17) thru the bearing Crawler Body (Figure 9 item 5) until it protrudes out the leg.

6.5.15 Place the Inner race of the Drive Wheel Assembly (Figure 6 item 14) into the hole of the Ball Leg or Flange Leg Assembly (Figure 6 Item 8, 10, 15 or 18) and onto Worm Gear Assembly Shaft (Figure 6 item 17).

6.5.16 Push the Drive Wheel Assembly (Figure 6 item 14) into the Ball Leg or Flange Leg Assembly (Figure 6 Item 8, 10, 15 or 18)

Note: It may be necessary to warm Ball Legs or Flange Leg Assembly (Figure 6 Items 8, 10, 15 or 18) just enough to slide the Drive Wheel Assembly into the Crawler Leg over the Worm Gear Assembly Shaft (Figure 6 item 17).

Note: If the bearing of the Drive Wheel Assembly (Figure 6 item 14) slides freely into the Ball Leg or Flange Leg Assembly (Figure 6 Item 8, 10, 15 or 18), place the leg in a vice and apply just enough pressure to slightly egg the bore of the Ball Leg or Flange Leg Assembly so the bearing will some pressure to fit into the leg assembly

Note: It is helpful to use a strong Magnet, such as a rare earth magnet, to draw the Worm Gear Assembly Shaft (Figure 6 item 17) through the Drive wheel Assembly.

6.5.17 With a 5/64” Hex Key tighten the 8-32 x 1/4" long set screw (Figure 6 item 20) in the Drive Wheel Assembly (Figure 6 item 14) against the Worm Gear Assembly Shaft (Figure 6 item 17).

6.5.18 Install the Worm Shaft Assembly (Figure 6 item 11) into the hole in the end of the Band Crawler body and rotate clockwise to install it from the Body (Figure 6 item 5).

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6.5.19 If assembling manual Band Crawler, thread Connector (Figure 6 item 6) into the Crawler Body (Figure 6 item 5) and tighten. In the case of the motorized crawler screw the Motor Connector (Figure 8 item E) into the Crawler Body (Figure 6 item 5).

6.5.20 Follow the instructions for the installation of the 9 or 14 foot Flexible Drive Shaft Assembly (Figure 6 item 19A or 19B) in Section 3.2

6.5.21 Rotate the Crank Handle Assembly of the 9 or 14 foot Flexible Drive Shaft Assembly (Figure 6 item 19A or 19B) to make sure all Drive Wheel Assemblies (Figure 6 item 14) are turning.

6.5.22 Apply Lithium grease to the Grease Zerks (Figure 6 item 4) at the top of the Crawler Body (Figure 6 item 5) until it starts to seep between the Ball Leg or Flange Leg Assembly (Figure 6 Item 8, 10, 15 or 18) and the Drive Wheel of the Drive Wheel Assembly (Figure 6 item 14). The grease should be slowly applied slowly so it is not over applied.

6.5.23 The Band Crawler is now ready for the cutting operation

6.6 - Installation of Motorizing Kit (03-0116-A08) 6.6.1 Unscrew the Connector (Figure 8 item E) to remove the 9 or 14 foot Flexible drive shaft (Figure 6 item 19A or 19B)

from the Connector (Figure 6 item 6). 6.6.2 Remove Connector (Figure 6 item 6) from the Band Crawler Body (Figure 6 item 5). In the case of the motorized

crawler unscrew the Motor Connector (Figure 8 item E) from the Crawler Body (Figure 6 item 5). 6.6.3 Align Slot in Motor Shaft (Figure 7 item 30) with the Tang in the bore of the Worm Shaft Assembly (Figure 6

item11). 6.6.4 Align bar at the bottom of the Motor Mounting bracket (Figure 7 item 39) with the bottom of the Band Crawler

Body (Figure 7 item 5). 6.6.5 Screw the Motorizing Kit Crawler Connector (Figure 7 item 31) of the motorizing kit into the Band Crawler Body

and tighten. 6.6.6 Depress the Red Emergency Stop Switch located on the Motor Control Box. 6.6.7 Connect the Motor Control Box (Figure 7 item 35) to Electrical Coupling (Figure 7 item 33). 6.6.8 Move the Forward/Stop/Reverse to the STOP position. 6.6.9 Turn the Rheostat counterclockwise to the “0” position. 6.6.10 Connect the Motor Control Box (Figure 7 item 35) to the 230vac power source.

6.6.11 Twist to release the Red Emergency Stop Switch located on the Motor Control Box 6.6.12 Move the Forward/Stop/Reverse to the FOWARD or REVERSE position. 6.6.13 Slowly rotate the Rheostat Clockwise. 6.6.14 Check the Band Crawler in both the forward and reverse direction. 6.6.15 Adjust the Speed Rheostat clockwise and counter clock to make sure the motor speeds up and slows down. 6.6.16 Move the Forward/Stop/Reverse to the STOP position. 6.6.17 Depress the Red Emergency Stop Switch located on the Motor Control Box. 6.6.18 Disconnect the Motor Control Box (Figure 7 item 35) to the 230vac power source.

6.6.19 See Section 2.3 for instructions for mounting the Band Crawler on the Band.

6.7 - Replacing the Motorized Band Crawler Motor Shaft (30). 6.7.1 Depress the Red Emergency Stop Switch located on the Motor Control Box. 6.7.2 Disconnect the Motor Control Box (Figure 7 item 35) from the 230vac power source.







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6.7.3 Disconnect the Motor Control Box (Figure 7 item 35) from Electrical Coupling (Figure 7 item 33). 6.7.4 Unscrew Connector (Figure 7 item 31) to remove the Band Crawler Motorizing kit. 6.7.5 With 2 each 7/16” wrenches unscrew 1/4"-20 Self Lock Nut (Figure 7 item 37) from the 1/4"-20 X 1” Hex Head Cap

Screws (Figure 7 item 34). 6.7.6 Remove the 90vdc Motor (Figure 7 item 32) from the Motor Mounting Bracket (Figure 7 items 39). 6.7.7 Remove Screws A & B from the transmission Plate (Figure 10 item C) from the 90vdc Motor (Figure 7 item 32).

Figure 10 6.7.8 Remove Transmission plate (Figure 10 item C) Shaft (Figure 7 item 30) with Worm Gear (Figure 7 item B) from

motor transmission. 6.7.9 At this time note the location of all shims and bearings on the Motor shaft (Figure 7 item 30) as they will need to

be placed back on the New Motor Shaft in the same order. 6.7.10 Remove all shims and bearings on the shaft. 6.7.11 With a 3/32 hex key loosen the two (2) Setscrews (Figure 7 item C) in the worm gear (Figure 7 item B). 6.7.12 Slide the worm gear (Figure 7 item B) off the Motor Shaft (Figure 7 item 30). 6.7.13 Slide the worm gear (Figure 7 item B) on to the new Motor Shaft (30). 6.7.14 Place the shims and bearings on the new Motor Shaft (Figure 7 item B) in the same order as they were on the old

Motor Shaft 6.7.15 Insert the small end of the motor shaft (Figure 7 item B) through Transmission plate (Figure 10 item C) until 1-1/4”

/32mm of the shaft protrudes the transmission plate. See Figure 11

Figure 11

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6.7.16 With a 3/32 hex key tighten the two (2) Setscrews (Figure 7 item C) in the worm gear (Figure 7 item B). 6.7.17 Install Transmission plate (Figure 10 item C) Shaft (Figure 7 item 30) with Worm Gear (Figure 7 item B) into motor

transmission. 6.7.18 Install Screws A & B in the Transmission plate (Figure 10 item C). 6.7.19 Place the Motorized kit Connector (Figure 7 item 31) into the hole of the Motor Mounting Bracket (Figure 7 item

39). 6.7.20 Place the Motor Shaft (Figure 7 item 30) into the Connector (Figure 7 item 31) and align holes in Motor Mounting

Bracket (Figure 7 item 39) with holes in the base of 90vdc Motor (Figure 7 item 32). 6.7.21 Fasten the 90vdc Motor (Figure 7 item 32) to the Mounting Bracket (Figure 7 item 39) with the washers (Figure 7

item 36) and 1/4 -20 x 3/4” Long Machine Screws (Figure 7 item 34). 6.7.22 Depress the Red Emergency Stop Switch located on the Motor Control Box. 6.7.23 Connect the Motor Control Box (Figure 7 item 35) to Electrical Coupling (Figure 7 item 33). 6.7.24 Move the Forward/Stop/Reverse to the STOP position. 6.7.25 Turn the Rheostat counterclockwise to the “0” position. 6.7.26 Connect the Motor Control Box (Figure 7 item 35) to the 230vac power source.

6.7.27 Twist to release the Red Emergency Stop Switch located on the Motor Control Box 6.7.28 Move the Forward/Stop/Reverse to the FOWARD or REVERSE position. 6.7.29 Slowly rotate the Rheostat Clockwise. 6.7.30 Check the Band Crawler in both the forward and reverse direction. 6.7.31 Adjust the Speed Rheostat clockwise and counter clock to make sure the motor speeds up and slows down. 6.7.32 Move the Forward/Stop/Reverse to the STOP position. 6.7.33 Depress the Red Emergency Stop Switch located on the Motor Control Box. 6.7.34 Disconnect the Motor Control Box (Figure 7 item 35) to the 230vac power source. 6.7.35 The machine is now ready for the cutting process.

6.8 Storage

If the Band Crawler will not be used for a period of the time, the machine should be cleaned and regreased with Lubriplate 130-AA. The machine should be stored in a clean and dry place protected from damage.

6.9 Stainless Steel Band Maintenance The Stainless Steel Bands should be kept clean. The Latch Assembly, Latch Handle Assemblies and the slot between the Upper and Lower Duckbills should be kept clear of trapped slag, abrasives, particularly sand and dirt. Bands should be laid on their sides rather than hanging or standing during transportation, or when not in use.

7.0 Limitations Mathey Dearman is not and will not be responsible for

Improper use of the Stainless Steel Band or Band Crawler.

Use of the Stainless Steel Band or Band Crawler in violation of any national and/or international electrical and safety regulations in force.

Connection of the Motorized Band Crawler to an improper or wrong power source.

Faulty maintenance.

Unauthorized modification and/or service of the Stainless Steel Band or Band Crawler.

Use of non-original spare parts or non-specific components.

Lack of observance or partial observance of the operating and maintenance instructions.

Unusual events such as natural disasters, wars, strikes or similar events.



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8.0 Machine Safety Users should follow these standard safety procedures in order to observe and prevent the safety of all employees:

Operators must use the wear safety goggles and shoes and should be suitably dressed for the working environment.

Operators and maintenance personnel should read and understand the Parts and Operating Manual prior to attempting any

type of function.

Check the electrical connections prior to operating the Motorized Band Crawler.

Turn off the electrical power source prior to disconnecting the electrical connector from the power source.

Observe all health warnings listed in the Parts and Operating Manual.

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Figure 12 – Motor Control Box Schematic

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9.0 Use Condition 9.1 Condition of use

The purpose of the Band Crawler is indicated on section 2.1. Any other use, different from what is listed in section 2.1,

could be hazardous to the operator.

The Band Crawler should be placed in a safe place protected from rain, extreme humidity, mud or accidental impact.

The Band Crawler should never be operated in an extremely humid environment such as fog or rain.

Adopt all the safety devices supplied or suggested by the manufacturer.

No modification to the Saddle Machine or its accessories should be done without the previous written approval by the

manufacturer.

Remember the Motor Control Box is attached to the power source current is applied to the motor control box. The Motor

Control Box should be disconnected from the power source when not in use.

9.2 Use of the Band Crawler not allowed by the Manufacturer

Tampering with the electrical circuit of the Motorized Band Crawler. Operation of the Band Crawler without the appropriate safety devices. Perform maintenance with electrical current applied to the Band Crawler. Use of a liquid or foam fire extinguisher to extinguish a fire in or near the Band Crawler.

9.0 Disposal of the Band and Band Crawler 9.1 General Information

Do not dispose of any components recklessly without regard for the environment. Separate the components by category for a

possible reuse. All national and state regulations should be followed when disposing of waste.

9.2 Composition of the Major Components

Component Description Material

Crawler Body, Rear Ball Leg, Front Ball Leg, Rear Flange Leg Assembly Aluminum

Front Flange Leg Assembly

End Plug, Connector, Worm Shaft Assembly, Drive Wheel Assembly Carbon Steel

Bearings, Latch Spring, Latch Anchor, Long Anchor Block

Motor Mounting Bracket

Motor Control Box Cover Stainless Steel

Electrical Cords Rubber coated copper

Cord Retention Holder Plastic

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Table 7 – Trouble Shooting the Band Crawler

Symptom Probable Cause Corrective Action

Crawler Legs rotate and

Crawler will not move

1. Tension Springs (23) have improper adjusted. 1. Adjust Spring Tension. See Instruction “A”.

2. Wheel is heavily grooved 2. Replace Wheel Assembly (14) See Instruction “B”.

3. Crawler is trying to carry to much weight

around the pipe.

3. Use a 1 3/8” diameter machine torch with a 10”

long barrel.

4. Edges of Band are rounded or Uneven. 4. File band to a sharp Edge or replace Band.

The Wheel(s) will not

Rotate When Turning the

Crank Handle

1. Swivel Nut is loose. 1. Tighten Swivel Nut on Crank Handle Assembly (26).

2. Tip in side bore of Coupling on the Worm

Gear Shaft Assembly (11).

2. Replace the Worm Shaft Assembly (11).

See Instruction “D”.

3. The Cables of Worm Gear Shaft

Assembly(S) (17) is sheared.

3. Replace Worm Shaft Assembly (11) See Instruction “D”.

4. The Setscrew in Brass Gear of the Worm

Shaft Assembly(S) is sheared.

4. Tighten Setscrew in Brass Gear.

See Instruction “B”.

5. Spring Pin connecting the Worm to the Worm

Shaft Assembly (11) is sheared.

5. Replace the Worm Shaft Assembly.

See Instruction “D”.

6. The inner Cable of the 9’ or 14’ Flexible Drive

Cable is not connected correctly to the handle

end or the Crawler Body.

6. Disconnect the Flexible Drive Cable from the

Crawler Body. See Instruction “E”.

7. Torch is too close to the wheel(s) causing the

bearing to seize because of too much heat.

7. Replace the Worm Gear Shaft Assembly(s) (17).

See Instruction “B”.

Wheels are heavily

Grooved 1. To much Spring (23) tension on the legs

1. Use only enough spring tension to rotate the Crawler around the Band. See Instruction “A”

2. Replace Wheel Assemblies (14). See Instruction “A”

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Table 7 – Trouble Shooting the Band Crawler (cont.)

Motorized Only

Symptom Probable Cause Corrective Action

Motor rotates and Wheels do

not turn

1. Tip in side bore of Coupling on the Worm Gear Shaft Assembly (11).

1. Replace the Worm Shaft Assembly. See Instruction “D”.

2. The Cables of Worm Gear Shaft Assemblies (17) are sheared.

2. Replace the Worm Shaft Assembly(s). See Instruction “C”.

3. The Setscrews in Brass Gear of the Worm Shaft Assemblies (17) are sheared.

3. Tighten Setscrew in Brass Gear. See Instruction “C”.

4. Spring Pin connecting the Worm Gear to the Worm Shaft Assembly (11) is sheared.

4. Replace the Worm Shaft Assembly. See Instruction “D”.

5. Torch is too close to the wheel(s) causing the bearing to seize because of too much heat.

5. Replace the Worm Gear Shaft Assembly(s) (17). See Instruction “D”.

6. Motor Shaft is sheared. 6. Replace Motor Shaft (PN: 05-0116-017)

Motor does not rotate

1. No Power at electrical connect. 1. Use another electrical source

2. Fuse is Blown 2. Replace fuse (PN: 01-0427-008)

3. AC Power cord is cut 3. Return Motor Control Box to Mathey Dearman for Repair.

4. DC Cord between Motor Control Box and Crawler has open circuit

4. Return Motor Control Box to Mathey Dearman for Repair.

5. Forward – Stop – Reverse switch is broken

5. Return Motor Control Box to Mathey Dearman for Repair.

Machine will only rotate

in one direction

1. Forward/Stop/Reverse Switch is broken 1. Return Motor Control Box to Mathey Dearman for Repair

Note: Circuit Board of the Motor Control Box is extremely thin and excessive heat will severely damage the circuit board.

Note: Individual electrical components of the Motor Control Box circuit are not available from Mathey Dearman, Inc.

Warning: The WARRANTY IS VOID if any attempt is made to repair the Motor Control Box. If under warranty, Please send to factory for any needed repairs.

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11.0 Warranty

If any merchandise sold hereunder (except merchandise manufactured by other persons or firms) by Mathey Dearman, Inc. (the “Company”) is not in accordance with specifications shown on the order within customarily accepted tolerances, or is defective on account of workmanship or material, and if such merchandise is returned at the customer’s expense and rise, to the Company’s manufacturing facility (or at the Company’s option, is returned to a repair facility authorized by the Company), within one (1) year after the Company’s date of shipment thereof, the Company will, at its option, replace or repair the merchandise. This agreement, however, is upon the conditions: (A) that the customer promptly notifies the Company in writing of any claim under this agreement, setting forth in details any such claimed defect. (B) That the Company be afforded a reasonable opportunity to examine the merchandise and to investigate the claimed defect at the Company’s manufacturing facility or at an authorized repair facility, the Company shall not be, in any event, liable for damages beyond the price paid by the customer for such defective merchandise; specifically but without limitation, the Company may fulfill its obligations under this Agreement by tendering such purchase price at any time. THE COMPANY SHALL NOT BE LIABLE FOR CONSEQUENTIAL, INCIDENTAL, PUNITITVE, OR EXEMPLARY DAMAGES. This agreement does not obligate the Company to bear any transportation charges in connection with the replacement or the repair of defective merchandise. As to any item manufactured by other persons or firms, the Company agrees to present a request for adjustment for repair to such manufacturer, and the customer agrees that the liability of the Company shall not exceed any adjustment with respect to which such manufacturer accepts responsibility. THE ABOVE AGREEMENT IS IN LIEU OF ALL WARRANTIES, EXPRESSED OR IMPLIED AND IT IS AGREED THAT THERE IS NO EXPRESSED OR IMPLIED WARRANTY BY THE COMPANY AS TO THE FITNESS, MERCHANTABILITY CAPACITY, OR EFFICIENCY OF ANY MERCHANDISE SOLD, AND THAT THERE ARE NO ORAL OR WRITTEN EXPRESSED OR IMPLIED WARRANTIES MADE IN CONNECTION WITH ANY SALE BY THE COMPANY. No modification or addition to this agreement, either before or after the contract of sale, shall be made except on written authority of the President or Vice President of the Company.

band crawler & stainless steel band part number: 05-0116-009, 05

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