Hyd-Mech DM-1215 User manual

USE AND MAINTENANCE MANUAL
YEAR OF MANUFACTURE: ______________
DM−1215
EN

Translation of the original instructions EN
”CE” CONFORMITY DECLARATION
(according to EEC MACHINES DIRECTIVE 2006/42/CE annex II A)
The manufacturer:
MEP S.p.A.
Via Enzo Magnani, 1
61045 Pergola (PU) ITALIA
Tel. [phone]−Fax [phone]
Hereby declares that the bandsawing machine:
Machine Type: SAWING MACHINE
Machine model: DM- 1215
Serial number:
Year of manufacture:
is in specification with the following directives:
 EEC MACHINES DIRECTIVE 2006/42/CE
SEN 16093:2017
 DIRECTIVE 2014/30/UE ”EMC”
SEN 50370−1:2005 Emission
SEN 50370−2:2003 Immunity
Responsible of a Technical File
(Walter Di Giovanni) c/o MEP SPA
Via Enzo Magnani, 1
61045 −Pergola −PU −ITALY
Pergola, lì
Managing Director
(William Giacometti)

5
Introduction and technical specifications 1−1.............
Foreword 1−1......................................
Machine presentation 1−1.............................
Machine specification 1−2............................
Name plate 1−2.....................................
Dimensions 1−4....................................
Functional parts 2−1.................................
DM−1215 model 2−1................................
Cutting head 2−2....................................
Vice 2−2..........................................
Control Panel 2−3...................................
Fixed work table and turntable 2−3.....................
Base 2−4..........................................
Safety and accident prevention 3−1.....................
Use of the machine 3−1..............................
General recommendations 3−2.........................
Recommendations to the operator 3−3...................
Machine safety devices 3−5...........................
Reference standards 3−5..............................
Protection against accidental contact with the blade 3−6.....
Electrical equipment 3−6.............................
Emergency devices 3−7..............................
Noise level of the machine 3−8.........................
Noise level measurement 3−8..........................
Noise level values 3−8...............................
Vibration emission 3−9...............................
Electromagnetic compatibility 3−9......................
Machine installation 4−1..............................
Packaging and storage 4−1............................
Anchoring the machine 4−4...........................
Minimum requirements 4−4...........................
Check list 4−5......................................
Connection to the power supply 4−6....................
Description of machine operation 5−1...................
Description of the control panel 5−1....................
Basic instructions for carrying out a cutting operation cycle 5−3
Manoeuvring the cutting head 5−3......................

6
Clamping the work piece in the vice 5−3.................
Rapid vice positioning 5−4............................
Rapid vice translation 5−4............................
Width of cut 5−4....................................
Preliminary check list for cutting operation 5−5...........
Manual operating cycle 5−6...........................
Gravity−feed functioning cycle 5−8.....................
Angled cuts 5−9....................................
Angled cuts 45 to the left 5−9........................
Angled cuts 60 to the left 5−10........................
Angled cuts 45 to the right 5−12.......................
Diagrams, exploded views and replace−
ment parts 6−1...................................
How to read the wiring diagrams 6−2....................
D2−Letter codes used to designate the type of component 6−4
Standardised Wiring Diagrams 6−7.....................
Front flywheel assembly 6−25..........................
Motor flywheel assembly 6−28..........................
Cutting head cover 6−31...............................
Vice assembly 6−33..................................
Base assembly 6−35..................................
Control panel 6−37...................................
Fixed work table and turntable 6−39.....................
Cylinder unit 6−42...................................
Laser and lamp group 6−44............................
Adjustments 7−1....................................
Vice 7−1..........................................
Vice play adjustment 7−1.............................
Cutting head 7−3....................................
Blade tensioner slide play adjustment 7−3................
Adjusting operating head travel 7−4.....................
Blade guide parts 7−5................................
Blade guide heads 7−5...............................
Blade steady buttons 7−5.............................
Blade guide plates 7−5...............................
Blade 7−8.........................................
Tool change 7−8....................................
Blade perpendicularity 7−10............................

7
Orthogonality of the blade 7−11.........................
Rotation axis control 7−14.............................
Maintenance and choice of consumables 8−1..............
The role of the operator 8−1...........................
Maintenance requirements 8−2.........................
General maintenance 8−2.............................
Daily 8−2..........................................
Weekly 8−2........................................
Monthly 8−3.......................................
Maintenance of working parts 8−3......................
Consumable materials 8−3............................
Oil for transmission box 8−4..........................
Oil for lubricant/coolant fluid 8−4......................
Cutting speed and choice of tools 9−1...................
Cutting speed 9−1...................................
Standard machine 9−1................................
Choice of blade 9−3.................................
Saw tooth pitch 9−3.................................
Cutting speed and downstroke speed 9−4.................
Types of swarf: 9−4..................................
Lubricant/coolant fluid 9−5...........................
Blade structure 9−6..................................
Blade types 9−6.....................................
Conventional rake 9−7...............................
Positive rake 9−7....................................
Variable pitch 9−7...................................
Variable pitch blades with 0 cutting angle 9−8...........
Variable pitch with positive rake (from 9 to 10 degrees) 9−8.
Set: 9−8...........................................
Standard or splayed set 9−8...........................
Undulated set 9−9...................................
Alternating grouped sets 9−9..........................
Alternating set 9−9..................................
Blade selection table relating to cutting speed and downstroke speed .......
9−10
Classification of steels 9−11............................
Classification of steels 9−12............................
Troubleshooting 10−1.................................

8
Troubleshooting blade and cutting problems 10−1...........
Troubleshooting machine faults 10−8.....................
Accessory Installation 11−1............................
Blade 11−1.........................................
Roller table 11−1.....................................
Discharge side roller table adapter with support 11−2........

1−1
Introduction and
technical
specifications
Foreword
Hydmech, in response to modern production techniques, has developed the new
DM-1215.
This work tool has been designed to satisfy the wide range of cutting needs of a
modern workshop with simplicity and reliability, while at the same time comply
ing with all EEC safety standards.
The DM-1215 is structurally rigid, silent and safe: it produces a minimum of
waste (1.2 mm) while its great versatility makes it suitable for cutting various
materials such as stainless steel light alloys, aluminium, copper and bronze at
high speed and with high precision.
Its high cutting capacity, combined with the possibility of making inclined cuts
from 60° left to 45° right, make this model the ideal solution for satisfying the
wide strange of cutting needs of machine shops, turneries, structural steel shops
and engineering workshops.
We congratulate our clients on having chosen this product, which will give
effective and faithful service for many years, especially if the instructions
contained in this use and maintenance manual are carefully followed.
This cutting machine has been designed and made specifically for cutting
metallic materials.
Machine presentation
Functioning is Manual / Gravity-feed. After having checked the material in the
cutting vice, the operator must hold the cutting head control lever and press the
micro-switch to start-up the belt. The belt starts to move and the cuttting head
starts its descent. The speed is adjustable using the cutting head speed adjuster on
the control board.
The head cuts the material; after the cut, a limit switch stops the cutting cycle,
then the head lifts by the head lifting/lowering switch, and after having fed
material again a new cutting cycle is started with the push button from the control
board.
It is also equipped with MA (automatic vice), namely a pneumatic cylinder
applied on the vice that locks the material between the jaws: the vice opening/
closing button is on the control panel.
Warning
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1−210 Use and maintenance manual DM-1215
Machine specification
Name plate
The anodised aluminium name plate is riveted on the side of the machine; the
same data are reproduced on the declaration of conformity included with this use
and maintenance manual.
When communicating with the Technical Service department, the model, serial
number and year of manufacture of the machine must be quoted.
CUTTING SPEEDS
Speed mt/min 15÷115
BAND SAW
Rated size mm 3440 x 27 x 0,9
Max/min blade length mm 3420÷3460
Blade height mm 27
Blade width mm 0,9
Band saw tension bar/kg 70 / 900
When choosing the cutting tool, if its dimensions do not correspond to those
included in the “Rated size” section, check that the dimensions at least fall
within the admissible max/min specifications.
RATED ELECTRICAL POWER
Head spindle motor kW 2,2
Electric coolant pump motor kW 0,15 x 2
Max installed power kW 2,5
WORKING PRESSURE
Working pressure blade tensioning/detensioning kg 900/70
The “air consumption” value refers to standard conditions (temperature 0°and
pressure 1.013 bar, i.e. density 1.3 x 10−3Kg/l) where 1 Kg/min. = 772 Nl/min.
LUBRICANT/COOLANT FLUID AND OIL
Oil for transmission box capacità Kg 0,32
Oil for Cut Control System cylinder capacità Lt 0,7
Lubricant/coolant fluid (oil concentration 5-6%) capacità Lt 80
N.B.
Attention
N.B.

1−3
11 Introduction and technical specifications
VICE
Vice max. opening mm 385
SPINDLE MOTOR
No.of poles Current (Volts) Absorption
(Amps)
Power (Kw) rpm Band saw
speed
4 139-240 14,8/8,6 2,20 1720 15/115 mt/min
Stator wound with enamelled copper wire, class H 200°C.
Class F insulation (limit temperature TL 155°C).
IP 55 protection rating (total against contact with live parts, water sprayed from all directions, with shaft oil
seal).
Conforming to CEI norms, publication: IEC 34 of 01/07/1985.
Example of class F insulation: in air−cooled machines at an ambient tempera-
ture of 40° C (according to CEI 2−3 and IEC 85), the allowable overtempera-
ture is 100° C (where 100 C represents the allowable DT).
The machine is supplied with a 2/4 pole three phase motor giving 2 band saw
speeds:
−1ª speed (4 poles) = 40 mt/min
-2ªspeed (2 poles)= 80 mt/min;
The OPTIONAL 4/8 pole motor gives speeds of 36/18 mt./min.
CUTTING CAPACITY
Section
0° 280 260 380 x 260
45° 260 250 300 x 200
60° 180 170 200 x 170
45° 200 180 230 x 160
N.B.
Warning

1−412 Use and maintenance manual DM-1215
Dimensions
MACHINE INSTALLED
Work table height mm 870
Weight Kg 695
1300
2000
2000
PACKED WEIGHT
Wooden cage and pallet Kg 100
Wooden pallet Kg 30

2−1
Functional parts
DM−1215 model
In order for the user to move towards a full understanding of how the machine
works, which is described in detail in the chapter 5, this chapter deals with the
main units and their locations.
CUTTING HEAD
CONTROL PANEL
VICE
TURNTABLE
BASE
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2−214 Use and maintenance manual DM-1215
Cutting head
The cutting head is the unit that cuts the material. It consists of a cast iron head
on which the following are mounted: the band saw, the blade guide components,
the blade tensioner components, the transmission box and the spindle motor.
The cutting head is restrained in its movements by the articulated joint on the
surface to be cut, and performs a cutting sequence controlled by the cutting head
recall spring and the hydraulic brake.
Motor
Head joint pivot
Blade guide heads
Blade guide head plate
Handwheel
Transmission box
Vice
The vice is the unit that clamps the workpiece in place during cutting; it consists
of a vice support, commonly known as a lead nut, fixed to the work table, and a
lead screw with a slideway on which the mobile jaw is mounted.
The vice is approached to the cutting material manually by handwheel and the
locking is by pneumatic cylinder.
Turntable
Slideway
Handwheel
Fixed platform
Vice support (lead nut)

2−3
15 Functional parts
Control Panel
The control panel has a protection rating of IP 54 and contains the electrical
equipment. Access is gained by removing the screws fastening a safety panel,
while the operator's safety is guaranteed by a key-operated safety switch,
designed to prevent any intentional interference with the unit. In order to remove
the panel from its mounting, the main switch has to be shifted to 0 (OFF), which
automatically cuts off the electrical supply.
Control panel
Main switch
Panel fastened by
screws
Fixed work table and turntable
Both the fixed work table and turntable are made from cast-iron. The turntable
constitutes the fulcrum of the cutting head and the machine's cutting surface,
while the fixed table supports the turntable by means of a 420 mm diameter roller
bearing, preloaded with a thrust bearing. A lubrication circuit inside the bearing
guarantees a long service life and facilitates rotation of the head from right to left
for angled cuts.
Turntable
Lubricator
Fixed work table

2−416 Use and maintenance manual DM-1215
Base
This unit features a large coolant collection surface which conveys the coolant to
a rear tank via the tank cover, and a swarf collection drawer. An electric pump is
housed inside the tank which draws the clean fluid from the filter system.
Tank cover
Swarf collection drawer
Electric pump housing
Lubricant/coolant tank
Coolant spray gun
On the right side there is the refrigerant fluid gun and the removable shaving
collector drawer.

3−1
Safety and accident
prevention
The DM-1215 has been designed and produced in accordance with European
standards. For the correct use of the machine we recommend that the instruc
tions contained in this chapter are carefully followed.
Use of the machine
The DM-1215 band saw cutting machine is intended exclusively for cutting
metallic materials, ferrous or non-ferrous, in section or solid.
Other types of material and machining are not compatible with the specific
characteristics of the saw.
The employer is responsible for instructing the personnel who, in turn, are
obliged to inform the operator of any accident risks, safety devices, noise
emission and accident prevention regulations provided for by international
standards and national laws regarding the use of the machine. The operator must
be perfectly aware of the position and function of all the machine's controls.The
instructions, warnings and accident prevention standards in this manual must be
respected without question by all those concerned.The following definitions are
those provided for by EEC MACHINES DIRECTIVE 2006/42/CE :
“Danger zone”: any zone in and/or around a machine in which the presence of a
person constitutes a risk for the safety and health of that person.
“Person exposed”: any person finding himself either completely or partly in a dan-
ger zone.
“Operator”: the person or persons given the responsibility of installing, operating,
adjusting, maintaining, cleaning, repairing or transporting the machine.
The manufacturer declines any responsibility whatsoever, either civil or crimi-
nal, should there be unauthorised interference or replacement of one or more
parts or assemblies on the machine, or if accessories, tools and consumable
materials are used that are different from those recommended by the manu-
facturer itself or if the machine is employed in a plant system and its proper
function is thereby altered.
Attention
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3−218 Use and maintenance manual DM-1215
General recommendations
LIGHTING
Insufficient lighting for the types of operation envisaged could constitute a safety
hazard for the persons concerned. For this reason, the machine user must provide
lighting in the working area sufficient to eliminate all shadowy areas while also
avoiding any blinding light concentrations. (Reference standard ISO 8995-89
“Lighting in work environments”).
CONNECTIONS
Check that the power supply cables and pneumatic feed systems comply with the
maximum machine absorption values listed in the “Machine Specification” tables;
replace if necessary.
EARTHING
The installation of the earthing system must comply with the requirements set out
in EN STANDARD 60204-1:2010.
OPERATOR POSITION
The position of the operator controlling machine operations must be as shown in
the diagram below.

3−3
19 Safety and accident prevention
Recommendations to the operator
Always wear proper goggles or protective glasses.
Do not use the machine without the guards in position. Replace the poly
carbonate windows , if subject to corrosion
Do not allow hands or arms to encroach on the cutting zone while the
machine is in operation.
Do not wear oversize clothing with long sleeves, oversize gloves,
bracelets, necklaces or any other object that may become entangled in
the machine during working; long hair must be tied back and bunched.
Always disconnect the power supply to the machine before carrying out
any maintenance work whatsoever, including in the case of abnormal op
eration of the machine.
Before starting cutting operations, support the material at both ends of
the machine using the support arm - standard, or OPTIONAL acces
sories such as the feed and discharge roller tables shown in the diagram
below. Before removing the devices supporting and moving the material,
fasten the latter in place using the machine's clamping devices or other
suitable equipment.
mm. 1500 mm. 1500
FEED ROLLER TABLE DISCHARGE ROLLER TABLE
Any maintenance work on the hydraulic or pneumatic systems must be
carried out only after the pressure in the system has been released.

3−420 Use and maintenance manual DM-1215
The operator must not perform any risky operations or operations not
required for the machining operation under way (e.g. remove swarf or
metal shavings from the machine while cutting).
Remove equipment, tools or any other objects from the cutting zone; al
ways keep the working area as clean as possible.
Before starting any cutting operations, ensure that the workpiece is se
curely held in the vice and the machine has been set correctly. A number
of examples of how to clamp different profiles correctly in our machines
are shown below.
Do not use the machine to cut pieces that exceed the capacity of the ma
chine as listed in the machine specifications.
Never move the machine while it is cutting.
Do not use blades of different sizes to those recommended in the ma
chine specifications.
When cutting very short pieces, make sure that they are not dragged be
hind the support shoulder, where they could jam in the blade.
When using the pneumatic vice check that the jaws move right up to and
effectively clamp the workpiece, as the maximum travel is only 6 mm, and
check that the clamping procedure is correct.
When working on the band saw, wear gloves only when handling materi
als and for tool changing or adjustment operations. Only perform one
operation at a time and do not hold more than one item or operate more
than one device simultaneously. Keep hands as clean as possible.
Warning: if the blade jams in the cut, press the emergency stop push-
button immediately. If this does not free the blade, slowly loosen the
vice, remove the piece and check the blade or blade teeth for breakage.
Replace the blade if necessary.