Hyd-Mech S-20 A User manual

1
S-20/23 A
395427
January 2006 Revision A
THANK YOU,
On behalf of everyone at HYD.MECH, I would like to thank and congratulate you on your decision to purchase a HYD.
MECH band saw.
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ting costs while boosting quality and productivity.
To ensure you are maximizing the power and versatility of your new HYD.MECH band saw, please take the time to famil-
iarize yourself and your employees with the correct operation and maintenance procedures as outlined in this manual.
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Thank-you.
HYD.MECH GROUP LIMITED
P.O. BOX 1030, 1079 Parkinson Road
Woodstock, Ontario Canada, N4S 8A4
Phone: [phone]
Service 1-877-237-0914
Sales 1-877-276-SAWS(7297)
Fax [phone]
e-mail: [email protected]

i
TABLE OF CONTENTS
SECTION 0 - SAFETY INSTRUCTIONS
SUMMARY .......................................................................................................................................0.1
BASIC RULES .................................................................................................................................0.4
RESPONSIBILITIES OF THE OWNER ...........................................................................................0.5
RESPONSIBILITIES OF THE OPERATOR AND MAINTENANCE PERSONNEL .........................0.6
SECTION 1 - INSTALLATION
INSTALLATION................................................................................................................................1.1
SAFETY PRECAUTIONS ................................................................................................................1.1
LIFTING THE S-20/23A WITH A FORK LIFT ..................................................................................1.2
WRAPPED FOR SHIPPING ............................................................................................................1.2
REMOVING THE SAW FROM THE SKID .......................................................................................1.2
LEVELLING THE SAW ....................................................................................................................1.3
HYDRAULIC OIL .............................................................................................................................1.3
CUTTING FLUID..............................................................................................................................1.3
POWER WIRING CONNECTIONS..................................................................................................1.3
SECTION 2 – OPERATING INSTRUCTIONS
BLADE BASICS...............................................................................................................................2.1
SEQUENCER CONTROL................................................................................................................2.1
HMI KEYS ........................................................................................................................................2.3
DISPLAY ..........................................................................................................................................2.4
PLC 100 CONTROL SYSTEM.........................................................................................................2.8
MECHANICAL CONTROLS ..........................................................................................................2.14
SECTION 3 – MAINTENANCE AND TROUBLESHOOTING
SAFETY DURING MAINTENANCE AND TROUBLESHOOTING ..................................................3.1
LOCK OUT PROCEDURE...............................................................................................................3.1
RESTORING MACHINE TO USE ....................................................................................................3.1
BLADE CHANGING PROCEDURE.................................................................................................3.2
BLADE GUIDE ADJUSTMENT .......................................................................................................3.3
BLADE BRUSH ADJUSTMENT......................................................................................................3.4
ANGLE BRAKE ADJUSTMENT......................................................................................................3.4
HEAD DOWN LIMIT SWITCH .........................................................................................................3.4
LUBRICATION .................................................................................................................................3.5
GEARBOX LUBRICATION S-20A ..................................................................................................3.6
GEARBOX LUBRICATION S-23A...................................................................................................3.6
HYDRAULIC MAINTENANCE.........................................................................................................3.7
PLC 100 TROUBLESHOOTING......................................................................................................3.9
FUSES.............................................................................................................................................3.12
MITSUBISHI 100 INPUTS AND OUTPUTS....................................................................................3.13
CALIBRATION PROCEDURE ........................................................................................................3.14

ii
SECTION 4 - ELECTRICAL
MAIN PANEL: COMPONENT LAYOUT ..........................................................................................4.1
PCB BOARD: FUSE LOCATION ....................................................................................................4.2
MAIN PANEL: COMPONENT LAYOUT ..........................................................................................4.3
MAIN PANEL: COMPONENT LAYOUT ..........................................................................................4.4
MAIN PANEL: COMPONENT LAYOUT ..........................................................................................4.5
ELECTRICAL SCHEMATIC DRAWING NUMBERS .......................................................................4.6
FOR ELECTRICAL SCHEMATICS AND COMPONENTS PARTS LIST SEE PDF ON ATTACHED
CD. ...................................................................................................................................................4.6
SECTION 5 - HYDRAULIC
HYDRAULIC COMPONENT LIST ...................................................................................................5.1
FILLER CAP AND FILTER ELEMENT LOCATION.........................................................................5.2
OIL LEVEL GAUGE AND DRAIN PLUG.........................................................................................5.2
FOR HYDRAULIC SCHEMATICS AND PLUMBING DIAGRAMS SEE PDF ON ATTACHED CD.5.3
SECTION 6 - MECHANICAL ASSEMBLIES
FOR MECHANICAL ASSEMBLY DRAWINGS SEE PDF ON ATTACHED CD ..............................6.1
SECTION 7 - OPTIONAL EQUIPMENT
OUT OF STOCK SWITCH ...............................................................................................................7.1
MIST COOLANT SYSTEM ..............................................................................................................7.1
VARIABLE VISE PRESSURE OPTION...........................................................................................7.2
OVERHEAD BUNDLING .................................................................................................................7.2
WORK STOP ASSEMBLY...............................................................................................................7.3
WORK LAMP ASSEMBLY...............................................................................................................7.3
FOR OPTIONAL ASSEMBLIES SEE PDF ON ATTACHED CD .....................................................7.3
SECTION 8 - SPECIFICATIONS
S-20A BANDSAW SPECIFICATION LIST.......................................................................................8.1
S-23A BANDSAW SPECIFICATION LIST.......................................................................................8.5
SECTION 9 - WARRANTY
WARRANTY.....................................................................................................................................9.1

0.1
SECTION 0 - SAFETY INSTRUCTIONS
SUMMARY
All persons operating this machine must have read and understood all of the following sections of this Manual:
Section 0 SAFETY
Section 2 OPERATING INSTRUCTIONS
However, as a memory aid, the following is a summary of the Safety Section.
Put Safety First
Mandatory Information – What operators and maintenance people must have read and understood.
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mation.
Basic Rules – only use this machine when
x it is in good working order
x all safety equipment is in place and functional
x operations are in compliance with this manual
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Owner is responsible to
x keep Manual accessible at the machine
x ensure only reliable, fully trained personnel work with the machine
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x keep the machine in good working order
Operator and Maintenance Personnel are responsible to:
x keep all safety equipment in order, check its function at the beginning of each shift, and report any shortcomings
x shut-down machine and report any faults or malfunctions which could impair safety
x understand and obey safety hazard labels
x not to wear un-restrained long hair, loose clothing or jewellery
x wear all required personal protective equipment
x not to wear gloves within 24 inches of moving blade
x maintain a clean working area and machine
x always use Lock-out when performing maintenance or repairs.

0.2
FOREWORD
Put Safety First!
This Safety Section contains important information to help you work safely with your machine and describes the dangers
inherent in our machines. Some of these dangers are obvious, while others are less evident.
It really is important to PUT SAFETY FIRST. Make it a habit to consider the hazards associated with any action BEFORE
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from your supervisor.
The SAFETY FIRST approach is particularly necessary when you do something new, or different, and most people in-
stinctively recognize this, although impatience may still cause them to take unnecessary risks.
Danger also lurks in the routine task that we have done over and over. Here, familiarity, boredom, or tiredness may lull us
into unthinking, automatic repetition. Be alert for this, and when you feel it happening, stop and take stock of your situa-
tion. Review the safety hazards associated with what you are doing. That should get your brain working again.
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you get hurt.
You owe it to yourself, your family, and your co-workers to PUT SAFETY FIRST.
Mandatory Information
All persons operating this machine must have read and understood all of the following sections of this Manual:
Section 0 SAFETY
Section 2 OPERATING INSTRUCTIONS
Personnel involved in installation and maintenance of the machine must have read and understood all sections of the
manual
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instruction.

0.3
Signatures
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I have read and understood all parts of Section 0 – Safety, and Section 2 – Operating Instructions.
Name Date Signature
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I have read and understood all parts of this Operation and Maintenance Manual.
Name Date Signature

0.4
BASIC RULES
Intended Use
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American National Standards Institute Standard B11.10 Safety Requirements for Metal Sawing Machines.
However, all machines may endanger the safety of their users and/or third parties, and be damaged,
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Exclusion of Misuse
Misuse includes, for example:
Sawing hazardous materials such as magnesium or lead
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Operating the machine without all original safety equipment and guards
Liability
The machine may only be operated:
when it is in good working order, and
when the operator has read and understood the Safety and Operating Instructions Sections of the Manu-
al, and
when all operations and procedures are in compliance with this Manual.
Hyd-Mech Group cannot accept any liability for personal injury or property damage due to operator errors
or non-compliance with the Safety and Operating Instructions contained in this Manual.

0.5
Responsibilities of the owner
Organization of work
This Operation and Maintenance Manual must always be kept near the machine so that it is accessible to
all concerned.
The general, statutory and other legal regulations on accident prevention and environmental protection
must also be observed, in addition to the Manual material. The operators and maintenance personnel
must be instructed accordingly. This obligation also includes the handling of dangerous substances and
the provision and use of personal protective equipment.
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Ensure that work on the machine is only carried out by reliable persons who have been appropriately
trained for such work.
Training
Everyone working on or with the machine must be duly trained with regard to the correct use of the ma-
chine, the correct use of safety equipment, the foreseeable dangers that may arise during operation of the
machine, and the safety precautions to be taken.
In addition, the personnel must be instructed to check all safety devices at regular intervals.
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Persons being trained on the machine may only work on or with the machine under the constant supervi-
sion of an experienced operator. Observe the minimum age limits required by law.
Condition of Machine and Workplace
Ensure that the machine and its safety equipment is kept in good working order.
Ensure that the work area is well lit, and protected from the elements, such as rain, snow, abrasive dust,
and extremes of temperature.
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of work pieces.

0.6
Responsibilities of the operator and maintenance personnel
Safety equipment
All machines are delivered with safety equipment that must not be removed or bypassed during operation.
The correct functioning of safety equipment on the machine must be checked:
x at the start of every shift.
x after maintenance and repair work
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Emergency Stop Button ( E-Stops)
Always be aware of the location of the Emergency Stop Button(s). Do not allow material or objects to
block your access to an Emergency Stop.
Damage
If any changes capable of impairing safety are observed in the machine or its operation, such as damage,
malfunctions, or irregularities, then appropriate steps must be taken immediately, the machine switched
off, locked-out, and the fault reported to the responsible person.
Safe operation
The machine may only be operated when in good working order and when all protective equipment is in
place and operational.
Keep a safe distance from all moving parts – especially the blade and vises
Stock should not be loaded onto the saw if the blade is running
Long and heavy stock should always be properly supported in front of and behind the saw.
Faults
The machine must be switched off and locked-out before starting to remedy any faults.
Safety hazard labels
Safety hazard labels, and other instructional labels on the machine must be observed. They must be
clearly visible and legible at all times. If they become damaged they must be replaced.
Clothing, jewellery, protective equipment
Personnel operating or working on the machine must not wear un-restrained long hair, loose-
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tective equipment such as safety glasses and safety boots and any other equipment required by
plant regulations.