Hyd-Mech S-20 User manual

1
S-20/23
395426
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
FOREWORD ....................................................................................................................................0.2
BASIC RULES .................................................................................................................................0.4
RESPONSIBILITIES OF THE OWNER ...........................................................................................0.5
RESPONSIBILITIES OF THE OPERATOR AND MAINTENANCE PERSONNEL .........................0.6
SECTION 1 - INSTALLATION
SAFETY PRECAUTIONS ................................................................................................................1.1
VISUAL INSPECTION .....................................................................................................................1.2
LIFTING THE S20/23 WITH A FORK LIFT......................................................................................1.3
WRAPPED FOR SHIPPING ............................................................................................................1.3
LEVELLING THE SAW ....................................................................................................................1.3
HYDRAULIC OIL .............................................................................................................................1.3
WIRING CONNECTIONS FOR S20/S23 .........................................................................................1.4
CUTTING FLUID..............................................................................................................................1.4
POWER CABLE ROUTING (S20/S23)............................................................................................1.4
WIRING CONNECTIONS ................................................................................................................1.4
WIRING CONNECTIONS FOR MACHINES WITH VFD OPTION...................................................1.5
SECTION 2 – OPERATING INSTRUCTIONS
HYDRAULIC CONTROLS ...............................................................................................................2.1
ELECTRICAL CONTROLS..............................................................................................................2.1
ELECTRICAL CONTROLS (S20 VFD / S23 VFD OPTION) ...........................................................2.2
ELECTRICAL CONTROLS (S20H VFD / S23H VFD OPTION)......................................................2.3
HYDRAULIC CONTROLS (S20H VFD / S23H VFD OPTION)........................................................2.3
BLADE BASICS...............................................................................................................................2.4
OPTIMUM BLADE PITCH ...............................................................................................................2.5
VISE OPERATION ...........................................................................................................................2.5
HEAD SWING AND BRAKE............................................................................................................2.6
COOLANT CONTROLS...................................................................................................................2.6
BLADE SPEED SELECTION (NOT APPLICABLE TO S-23).........................................................2.6
CHANGING BELT POSITION..........................................................................................................2.7
GUIDE ARM POSITIONING ............................................................................................................2.7

ii
SECTION 3 - MAINTENANCE & TROUBLESHOOTING
BLADE CHANGING PROCEDURE.................................................................................................3.2
BLADE GUIDE ADJUSTMENT .......................................................................................................3.3
BLADE BRUSH ADJUSTMENT......................................................................................................3.4
ANGLE BRAKE ADJUSTMENT......................................................................................................3.4
BELT TENSION ADJUSTMENT (NOT APPLICABLE TO S23)......................................................3.4
HEAD DOWN LIMIT SWITCH .........................................................................................................3.5
LUBRICATION .................................................................................................................................3.5
GEARBOX LUBRICATION S23 ......................................................................................................3.6
GEARBOX LUBRICATION S20 WITH VFD OPTION .....................................................................3.6
TROUBLE SHOOTING....................................................................................................................3.7
SECTION 4 - ELECTRICAL
S20 / S23 COMPONENT LAYOUT: VFD OPTION ..........................................................................4.1
S22H / S23H COMPONENT LOCATION: VFD OPTION ...............................................................4.4
FOR ELECTRICAL SCHEMATICS AND COMPONENT PARTS LIST SEE PDF ON ATTACHED
CD. ...................................................................................................................................................4.7
SECTION 5 - HYDRAULIC
FOR HYDRAULIC SCHEMATICS AND PLUMBING DIAGRAMS SEE PDF ON ATTACHED
CD. ...................................................................................................................................................5.1
SECTION 6 - MECHANICAL ASSEMBLIES
FOR MECHANICAL ASSEMBLY DRAWINGS SEE PDF ON ATTACHED CD ..............................6.1
SECTION 7 - OPTIONS
BLADE BREAKAGE SWITCH (STANDARD ON CE MACHINES) ................................................7.1
MIST COOLANT SYSTEM ..............................................................................................................7.1
HYDRAULIC POWER PACK (S20H / S23H): .................................................................................7.2
VARIABLE VISE PRESSURE OPTION (S20H / S23H): .................................................................7.2
OVERHEAD BUNDLING (HYDRAULIC S20H / S23H)...................................................................7.3
WORK LAMP ASSEMBLY...............................................................................................................7.4
MATERIAL STOP.............................................................................................................................7.4
FOR OPTIONAL ASSEMBLY DRAWINGS SEE PDF ON ATTACHED CD. ...................................7.4
SECTION 8 - SPECIFICATIONS
S20 CUTTING CAPACITY ...............................................................................................................8.2
S20 MACHINE LAYOUT (SHEET 1) ...............................................................................................8.3
S20 MACHINE LAYOUT (SHEET 2) ...............................................................................................8.4
S23 CUTTING CAPACITY ...............................................................................................................8.6
S23 MACHINE LAYOUT (SHEET 1) ...............................................................................................8.7
S23 MACHINE LAYOUT (SHEET 2) ...............................................................................................8.8
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.

0.7
Gloves
Experience has shown that careless use of gloves around machinery is a major factor in serious
hand injuries.
Gloves should not be worn when operating or adjusting the machine, except:
Wear protective gloves when handling bandsaw blades at blade changes.
Gloves may be worn when handling work pieces, only if the machine is in Manual Mode
and the bandsaw blade is not running.
If the machine is running in Auto Mode, and only if the cut parts are greater than 24
inches long, it may be possible to safely wear gloves for handling the cut parts, but the
wearer of the gloves must never put his hands near the blade for any reason. If the cut
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parts bucket or other suitable arrangement to avoid the necessity to pick them off the
machine by hand.
Hearing protection
Ear protection must be worn whenever necessary.
The level and duration of noise emission requiring hearing protection depends upon the national
regulations in the country in which the machine is being used.
The actual level of noise emission by band sawing machines depends upon work piece size,
shape and material, blade type, blade speed and feed rate.
The only practical course of action is to measure the actual noise emission levels for the type
of work that is typically done. With reference to national standards, decide upon the necessary
hearing protection required.
In the absence of such measurements, it is advisable for anyone exposed to long periods of
moderate to loud noise to wear hearing protection. It is important to understand that hearing loss
is gradual and easily goes un-noticed until it is serious and irreversible.
Workplace
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must be level and clean, without any build-up of chips, off-cuts, coolant, or hydraulic oil.
The workplace must be well lit, and protected from the elements, such as rain, snow, abrasive dust, and
extremes of temperature
Nothing may ever be placed on, or leaned against the machine, with the obvious exception of the work
piece on the table and conveyor of the machine.

0.8
Master Disconnect
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off the master electrical disconnect switch, and locking it out so that it cannot be switched on again
without authorization.
On Hyd-Mech machines the Master Disconnect Switch will be of one of three types:
x Rotary switch mounted in electrical control cabinet door and inter-locked with door
x Lever switch mounted in separate box mounted on the machine
x Supply disconnect switch supplied by user at installation and usually wall-mounted within sight of
the machine, depending upon local regulations.
In almost all jurisdictions, it is required that owners of industrial equipment establish and post lock-out pro-
cedures. Know and use the lock-out procedures of your company or organization.
Residual Risks
The machine is still not completely de-energized if an electrical cabinet door type switch is
locked-out.
The line side of the disconnect switch itself remains energized.
Variable speed blade drives store dangerous voltage in their capacitors, and this requires time to
dissipate. After locking out power, wait 3 minutes before beginning to work on machine electrical
circuits.
If compressed air is supplied to the machine to power a mist lubrication system or other devices,
it should be disconnected, and any stored air pressure released before working on the machine.
The weight of individual machine components represents stored potential energy that can be
released if they fall when disconnected. Secure these components with adequate hoisting gear
before disassembly.

1.1
SECTION 1 - INSTALLATION
Upon delivery of your new S-20/23 saw, it is imperative that a thorough inspection be undertaken to check for any damage
that could have been sustained during shipping. Special attention should be paid to the electrical and hydraulic systems
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SAFETY PRECAUTIONS
The S-20/23 has been designed to give years of reliable service. It is essential that operators be alerted to the safe opera-
tion of this saw, and the practices to avoid that could lead to injury. The following safety rules are at the minimum neces-
sary for the safe installation, operation, and maintenance of the saw. Take every precaution for the protection of operators
and maintenance personnel.
x POWER HOOK-UPS AND REPAIRS SHOULD BE ATTEMPTED ONLY BY QUALIFIED TRADESMEN.
x THE SAW SHOULD BE LOCATED IN AN AREA WITH SUFFICIENT ROOM TO SAFELY LOAD STOCK INTO
THE SAW. SECURE THE SAW TO THE FLOOR.
x THE AREA AROUND THE SAW SHOULD BE MAINTAINED IN A CLEAN AND TIDY CONDITION TO AVOID
OBSTACLES OPERATORS COULD TRIP OVER.
x THE S-20/23 SHOULD ONLY BE OPERATED ACCORDING TO THE SPECIFICATIONS OF THE SAW. AVOID
UNSAFE USAGE PRACTICES.
x IF AT ANY TIME THE SAW DOES NOT APPEAR TO BE OPERATING PROPERLY IT SHOULD BE STOPPED
IMMEDIATELY AND REPAIRED.
OPERATOR:
x THE SAW SHOULD NEVER BE OPERATED UNLESS ALL GUARDS AND DOORS ARE IN PLACE AND
CLOSED.
x KEEP A SAFE DISTANCE FROM ALL MOVING PARTS - ESPECIALLY THE BLADE AND VISES.
x LOOSE CLOTHING AND GLOVES SHOULD NEVER BE WORN WHILE OPERATING THE SAW. COVER LONG
HAIR.
x STOCK SHOULD NOT BE LOADED ONTO THE SAW IF THE BLADE IS RUNNING.
x LONG AND HEAVY STOCK SHOULD ALWAYS BE PROPERLY SUPPORTED IN FRONT OF AND BEHIND THE
SAW.
x NEVER ATTEMPT TO DISLODGE OR MOVE STOCK WHILE THE BLADE IS MOVING. TAKE THE TIME TO
STOP THE SAW BLADE, REMOVE OBSTRUCTIONS, AND RESTART BLADE.
x MUST WEAR EYE PROTECTION
x MAINTAIN PROPER ADJUSTMENT OF BLADE TENSION, BLADE GUIDES, AND THRUST BEARINGS
x HOLD WORK PIECE FIRMLY AGAINST TABLE
x DO NOT REMOVE JAMMED CUTOFF PIECES UNTIL BLADE HAS STOPPED
NO MODIFICATIONS TO THE MACHINE ARE PERMITTED WITHOUT PRIOR APPROVAL FROM HYD-MECH. ANY AP-
PROVED MODIFICATIONS SHOULD ONLY BE UNDERTAKEN BY TRAINED PERSONNEL.

1.2
1
2
3
1. Head - keep away from moving blade
2. Vise - never load stock with the blade moving
3. Head - watch for head descending to the table
4. Pivot - check for head movement blockage
5. Drive - secure pulley cover when running
VISUAL INSPECTION
4
5

1.3
LIFTING THE S20/23 WITH A FORK LIFT
The S-20/23 is shipped with a shipping pallet
attached to the saw. When lifting the pallet with a
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anced. The pallet length dimension is 84” (2132
mm). Minimum fork length of 72” (1827 mm) is
recommended to safely lift the pallet.
WRAPPED FOR SHIPPING
The S-20/23 is shrink-wrapped for shipping from
our plant. Remove the wrapping from around
the saw. Complete the inspection for signs of
damage. Undo the bolts that hold the saw to
the pallet. Retain these bolts to use for leveling.
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ing plates located at the corners of the saw. The larger diameter hole is used for retaining during shipping and for use with
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LEVELLING THE SAW
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give a small incline towards this area helps to ensure the coolant supply returns to the container.
HYDRAULIC OIL
The S-20/23 is supplied with ISO VG22 hydraulic oil. Substitutes must be of the same vis-
cosity in order for the system to work properly.
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the cylinder only with the head in the down position. The head cylinder is a self air-bleeding
cylinder with a small port in the top plate. If excess oil is displaced from this port, the cylinder
is working normally.

1.4
CUTTING FLUID
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-Oil based; dilute 1:10 ratio (one part concentrated coolant to 10 parts water)
- Synthetic; dilute as recommended by manufacturer.
POWER CABLE ROUTING (S20/S23)
The main power cable can be routed up through the bottom of the head frame to the
access hole in the end of the control panel. Cable liquid tight reliefs should be used
to secure the cable into the control panel to ensure there is no movement of the
cable when the machine is operated.
WIRING CONNECTIONS
After the machine is leveled and anchored the necessary power hook-up needs to be
performed.
In order to provide a safe operation as well as to prevent potential damage to the
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As supplied your new S-20/23 is set to run on three phase voltage or single phase.
The supply voltage of the machine displayed on the Serial # Plate and the voltage
label.
Connection from the main power supply is made to the L1, L2, L3 (L1 and L2 for single phase) and ground terminals be-
tween the contactor and the transformer.
Supply conductor should be rated for the current supplied and should be protected by time delay fusing rated for the am-
perage stated on the machine serial plate.
Check for •Signs of damage to the electrical cables from shipping or installation.
•Correct phase order. The blade should be running in the counter clockwise direction. If the blade direc-
tion is wrong, two lines should be reversed.
Contactor
L1, L2, L3 and Ground
L1 L2 and Ground for
Single Phase Voltages
Contactor
Wiring connections for S20/S23

1.5
Wiring Connections for machines with VFD option
The power cable should be routed
through the hole found at the bottom
right of the box. A suitable strain relief
should be used.
L1, L2, L3, and ground terminals
found inside of the box

2.1
SECTION 2 – OPERATING INSTRUCTIONS
The operator control panel provides the operator with all the controls necessary to operate the saw after the
cutting angle has been set and the stock has been loaded and secured. All of the electrical functions and the
Feed Rate setting are operated from the control panel.
HYDRAULIC CONTROLS
FEED RATE KNOB - Controls feed rate of the head. This
rate can be set on the scale of 1
to 10. As the number increases so
does the feed rate.
HEAD CONTROL LEVER
HOLD - Stops and holds the Head at the current
position.
FEED - The Head will descend at the rate set by
the Feed Rate knob.
DOWN - Allows for rapid approach of the blade to
the workpiece.
ELECTRICAL CONTROLS
FUSE- Check if power fails. Twist & pull to remove the
fuse.
COOLANT Switch -
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START Button - This button starts the saw blade. The
blade will not start with the Head in the
down position or if any safety interlock
switches (if equipped) are not closed.
STOP Button - Pressing the RED mushroom button will
STOP the blade.

2.2
ELECTRICAL CONTROLS (S20 VFD / S23 VFD OPTION)
Blade Speed (1BS) – %ODGHVSHHGFDQEHDGMXVWHGLQ¿QLWHO\EHWZHHQWR6)0³6XUIDFH)HHW0LQXWH´WR
m/min). Adjustment should be made only when the blade is running.
Coolant Switch (1SS) – ON: &RQVWDQWÀRZ
OFF:1RFRRODQWÀRZ
AUTO: Blade running.
Blade Start (5PB) – A green push button. The blade will not start with the head in the down position, if any safety switch-
es are not closed, or if the emergency stop is depressed.
Emergency Stop (1PB) – This red mushroom head push button will stop the blade.
NOTE: Hydraulic controls are the same as the S20/S23 machine.