Hyd-Mech S-20H Installation guide

IN BANDSAW TECHNOLOGY
OPERATIONS &
MAINTENANCE
MANUAL

THANKYOU,
On behalf of everyone at HYD.MECH , I would like to thank and congratulate you on your decision to purchase a
HYD.MECH bandsaw.
Your new machine is now ready to play a key role in increasing the efficiency of your operation, helping you to
reduce cutting 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 familiarize yourself and your employees with the correct operation and maintenance procedures as outlined in this
manual.
Wesincerely appreciate the confidenceyou have demonstrated inpurchasing our product andlook forward to
buildinga long and mutuallybeneficialrelationship.
Thank-you.
HYD.MECH GROUP LIMITED
P.O. BOX 1030, 1079 Parkinson Road
Woodstock, Ontario Canada, N4S 8A4
Phone:[phone]
Service1-877-237-0914
Sales1-800-276-SAWS(7297)
Fax[phone]
e-mail, [email protected]
S-20H
2002, rev b, 393320

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i S22Hce2002a
S20H Series II Table of Contents
INSTALLATION and SPECIFICATIONS
SAFETYPRECAUTIONS ........................................................................................................................................ 1
SPECIFICATIONS ................................................................................................................................................... 2
LAYOUTDRAWINGS ............................................................................................................................................... 3
LIFTING THE S-20 SERIES II ................................................................................................................................. 5
WRAPPEDFORSHIPPING .................................................................................................................................... 5
REMOVINGTHESAWFROMSHIPPINGSKID ...................................................................................................... 5
CUTTINGFLUID ...................................................................................................................................................... 6
HYDRAULICOIL ...................................................................................................................................................... 6
LEVELLINGTHESAW............................................................................................................................................. 6
POWERWIRINGCONNECTIONS........................................................................................................................... 7
OPERATING INSTRUCTIONS
OPERATORCONTROLPANEL................................................................................................................................ 9
ELECTRICALCONTROLS.................................................................................................................................. 9
VISECONTROLS............................................................................................................................................... 9
HEADCONTROLS ............................................................................................................................................. 9
BLADE BASICS ................................................................................................................................................... 10
DETERMINEOPTIMUMBLADE PITCH........................................................................................................... 11
BLADE SPEED SELECTION................................................................................................................................. 12
CHANGINGBELTPOSITION ................................................................................................................................ 12
VARIABLESPEEDCONTROL .............................................................................................................................. 12
HEAD SWING and BREAK................................................................................................................................... 12
GUIDEARMPOSITIONING .................................................................................................................................. 13
COOLANTFLOW................................................................................................................................................... 13
OPTIONALCONTROLS ........................................................................................................................................ 14
WORKSTOP ......................................................................................................................................................... 14
HYDRAULICBUNDLING........................................................................................................................................ 14
VARIABLE VISE PRESSURE ............................................................................................................................... 14
MAINTENANCE and TROUBLESHOOTING
SAFETYLOCKOUTandPROCEDURE ................................................................................................................. 15
BLADECHANGINGPROCEDURE ........................................................................................................................ 16
BLADETRACKINGADJUSTMENT ....................................................................................................................... 17
IDLERWHEELADJUSTMENT ......................................................................................................................... 17
DRIVEWHEELADJUSTMENT......................................................................................................................... 17
BLADEBRUSHADJUSTMENT ............................................................................................................................. 18
ANGLEBRAKEADJUSTMENTandPROCEDURE............................................................................................... 18
BLADEGUIDEADJUSTMENT .............................................................................................................................. 18
HEADDOWNLIMITSWITCH................................................................................................................................ 19
BELT TENSIONADJUSTMENT............................................................................................................................ 19
LUBRICATION ....................................................................................................................................................... 19
TROUBLESHOOTINGGUIDE .............................................................................................................................. 21
SERVICERECORD&NOTES............................................................................................................................... 22
ELECTRICAL SYSTEM
CONTROLPANEL&COMPONENTS .................................................................................................................... 23
ELECTRICALCOMPONENTSLISTS.................................................................................................................... 24
ELECTRICALSCHEMATICandWIRINGDRAWINGS ........................................................................................... 27
---- Continued ----

ii S22Hce 2002a
HYDRAULIC SYSTEM
HYDRAULICCOMPONENTS................................................................................................................................. 29
HYDRAULICCYLINDERASSEMBLIES ................................................................................................................ 30
HYDRAULICSERVICEKITS ................................................................................................................................. 30
S22HHYDRAULICSCHEMATIC............................................................................................................................ 31
S22HPLUMBINGDIAGRAM................................................................................................................................. 32
MECHANICAL ASSEMBLIES
GUIDE ARM & CARBIDE ASSEMBLIES .............................................................................................................. 33
BLADE DRIVEASSEMBLY ................................................................................................................................... 34
3HORSEPOWERDRIVEOPTION ...................................................................................................................... 36
IDLER WHEELASSEMBLY .................................................................................................................................. 38
BLADE BRUSHASSEMBLY .................................................................................................................................. 39
COUNTERBALANCESPRINGASSEMBLY.......................................................................................................... 40
PIVOTLINKASSEMBLY ....................................................................................................................................... 41
FRONT VISE ASSEMBLY .................................................................................................................................... 42
WORK STOPASSEMBLY ..................................................................................................................................... 43
COOLANT GROUP............................................................................................................................................... 44
DOORSandCOVERS ........................................................................................................................................... 45
BLADE BREAKAGE .............................................................................................................................................. 45

SECTION 1 - INSTALLATION
SECTION 1
INSTALLATION

SECTION 1 - INSTALLATION

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SPECIFICATIONS and INSTALLATION
Upon delivery of your new S-20 Series II 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 to check for damaged cords, hoses and fluid leaks. In the event of damage
caused during shipping, contact your carrier to file a damage claim. At the begining and through out this manual
there are precuationary indicators, these will inform you of areas which require special attention.
SAFETY PRECAUTIONS
The S-20 Series IIhas been designed to give years of reliable service. It is essential that operators be alerted to
the safe operation of this saw, and the practices to avoid that could lead to injury. The following safety rules are at
the minimum necessary for the safe installation, operation, and maintenance of the saw.Take every precaution for
theprotectionof operators and maintenance personnel.
ØPOWERHOOK-UPSANDREPAIRS SHOULD BEATTEMPTEDONLYBYQUALIFIEDTRADESMEN.
ØTHE SAW SHOULD BE LOCATED INANAREAWITH SUFFICIENTROOM TO SAFELY LOAD STOCK
INTOTHE SAW.SECURETHE SAWTOTHE FLOOR.
ØTHEAREAAROUND THE SAW SHOULD BE MAINTAINED INACLEANAND TIDY CONDITIONTOAVOID
OBSTACLESOPERATORSCOULDTRIPOVER.
ØTHES-20 SERIES II SHOULDONLYBEOPERATEDACCORDINGTOTHESPECIFICATIONS OFTHE
SAW.AVOID UNSAFE USAGEPRACTICES.
ØIFATANYTIMETHE SAW DOES NOTAPPEAR TO BE OPERATING PROPERLY IT SHOULD BE
STOPPEDIMMEDIATELYANDREPAIRED.
ØOPERATOR: THESAW SHOULD NEVER BEOPERATEDUNLESSALLGUARDSANDDOORS
ARE IN PLACEAND CLOSED.
ØOPERATOR: KEEPASAFE DISTANCE FROM ALLMOVING PARTS - ESPECIALLY THE BLADE
AND VISES.
ØOPERATOR: LOOSECLOTHINGAND GLOVES SHOULD NEVER BE WORN WHILE OPERATING
THESAW.COVERLONGHAIR.
ØOPERATOR: STOCKSHOULD NOTBELOADEDONTOTHESAWIFTHEBLADEIS RUNNING.
ØOPERATOR : LONGAND HEAVY STOCK SHOULDALWAYS BE PROPERLY SUPPORTED IN
FRONTOFANDBEHINDTHESAW.
ØOPERATOR: NEVERATTEMPTTO DISLODGE OR MOVESTOCKWHILE THE BLADE ISMOVING.
TAKETHETIMETOSTOPTHESAWBLADE,REMOVEOBSTRUCTIONS,AND
RESTARTBLADE.
ØOPERATOR: MUSTWEAREYEPROTECTION
ØOPERATOR: MAINTAIN PROPERADJUSTMENTOF BLADE TENSION, BLADE GUIDESAND
BEARINGSURFACES.
ØOPERATOR: HOLD WORKPIECE FIRMLYAGAINSTTABLE.
ØOPERATOR: DO NOT REMOVE JAMMEDCUTOFFPIECES UNTILBLADEHAS STOPPED.
NO MODIFICATIONS TO THE MACHINEARE PERMITTED WITHOUT PRIOR APPROVAL FROM HYD.MECH.
ANYAPPROVED MODIFICATIONS SHOULD ONLY BE UNDERTAKEN BY TRAINED PERSONNEL.

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SPECIFICATIONS
IMPERIAL DIMENSIONS METRIC DIMENSIONS
CuttingCapacity
rectangular 13" High x 18" Wide 325mmx450mm
round 12" dia @ 45 deg 300mmdia @45deg
Blade length 13' 6" 4115mm
width 1 " (1.075" including teeth) 25mm (27.3mmincluding teeth)
thickness .032" 0.8mm
Bladespeed (with 50Hz, 1450RPMmotor)
Standardsteppulley 90/140/220/310SFM 22/34/58/90 m/min
Variablespeed option 65 to 330 SFM - Variable 22 to 122 m/min - Variable
Bladeguides CarbideInserts
Bladewheeldiameter 16" 400 mm
Motors Standard 2 HP 1.5 kW
Variable SpeedOption 3 HP 2.2 kW
HydraulicDrive 1/4 HP 0.2 kW
Hydraulic Optional -MicroPowerpack gear pump
Coolantpump 2.4 US Gal/min 9 L/min
Coolant reservoir 6 Gallons 23 Litre
Table height 30 " High 762 mm
Machine weight 1800 pounds 810 kg
OverallDimensions 80" W x 80.5" L x 55.5" H 2037mm W x 2046mm Lx 1408mm H

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LAYOUT DRAWINGS

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LIFTING THE S-20 SERIES II
The S-20 is shipped with a shipping pallet attached
to the saw. When lifting the pallet with a forklift truck
make sure that the load is firmly balanced. The
following photo shows a lift truck lifting the saw and
palletfrom the correct side. The pallet lengthdimension
is87” (213cm). Minimumforklength of 72”(182cm) is
recommended to safely lift the pallet.
WRAPPED FOR SHIPPING
TheS-20 Series II is shrink-wrappedfor shipping
fromourplant. Remove the wrapping fromaroundthe
saw.Complete the inspectionfor signs ofdamage. The
photo shows the floor mounting plates located at the
corners of the saw. Undo the bolts that hold the saw to the pallet. Retain
these bolts to use for levelling. The larger diameter hole is used for
retainingduringshipping and for usewithconcrete floor anchors. The
smallerdiameter,threaded holes ateach corner are usedfor levelling the
sawproperly.
REMOVING THE SAW FROM SHIPPING SKID
Lift the right (drive) side of the saw as shown with a lift truck and
place two blocks under the saw as shown. With a lift truck (fork
length60” (150cm) and ratedfor1800lb (810kg) minimum), liftthe
saw from the skid at the FRONT of the machine as shown and place
itwhererequired.
Lifting the packaged S-20 Series II with a lift truck.
Bolt holding the saw to the skid (4
places).
Blocks placed under the saw.
Lifting the machine with a lift truck from the front
of machine.

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CUTTING FLUID
The S20 uses a pump and reservoir to circulate the necessary cutting fluid to the blade for maximum blade life.
Your saw blade supplier will be able to provide information to the cutting fluid products that are available for your
needs.
No cutting fluid (coolant) is supplied with the machine. There are two types of coolant available:
- oil based; dilute 1:10 ratio (one part concentrated coolant to 10 parts water)
- synthetic; dilute as recommended by manufacturer.
LEVELLING THE SAW
Use a machinist's level across the vise table
to level the saw. Adjust the level with the
levellingboltssupplied. Consideration should be
given to the flow of the coolant as it returns to
the coolant trough at the vise end of the saw.
Levelling to give a small incline towards this
area helps to ensure the coolant supply returns
tothe container.
HYDRAULIC OIL
TheS-20Hoption is supplied withTexacoRandoHD46
hydraulic oil. Substitutes should be a #46 hydraulic oil. The
power pack and tank is mounted on the inside of the door
found at the idler side of the infeed table. The tank should
be at least 3/4 full at all times.
The power pack with the
door opened.
Hydraulictank
filler cap is
found
near the pump
& motor
assembly.
Coolant components (Shown with tank removed).
WashDown
Hose
Coolant
Tank & Pump
Coolantfilter,
S25-1-03&
screen,S22-1-11

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POWER WIRING CONNECTIONS
When the machine has been anchored and levelled the power hook-up is the last installation step. In order to
providesafe operation andtoprevent potential damageto the machine,onlyqualified personnel shouldmake the
electricalconnections.
As supplied your new S-20 Series II is set to run on three phase voltage or single phase. The supply voltage of
the machine is displayed on the Serial # Plate and the Voltage Label.
Connection from the Main supply is made to L1, L2, L3, (or L1 & L2 for single phase) and Ground terminals
betweenthe contactor & transformer.
Supply conductors should be rated for the current supplied and should be protected by time delay fusing rated for
theamperage stated onthe machine serialplate
CHECKFOR: - Signs of damage to the electrical cables from shipping or installation.
-Correct phase order.The bladeshouldberunningcounter clockwise.
(If the blade direction is wrong, two lines should be reversed to correct)
POWER CABLE ROUTING
The main power cable can be routed up through the bottom of the
head frame to the access holes in the end of the control panel. Cable
liquide 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.
The S-20, with "H" option control panel, opened.L3, L2, L1 and Ground

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SECTION 2 - OPERATING INSTRUCTIONS
SECTION 2
OPERATING INSTRUCTIONS

SECTION 2 - OPERATING INSTRUCTIONS

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OPERATING INSTRUCTIONS
OPERATOR CONTROL PANEL
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 are operated
from the control panel. The Vise and Feed Rate setting are both controled with the hydraulic controls shown on the
nextpage.
ELECTRICAL CONTROLS
HYDRAULICBUTTON
This button will start the hydraulic
START Button, system. It will
illuminate when pressed and held
momentarily.
EMERGENCYSTOPBUTTON
Pressingthe red EMERGENCY STOP
Button STOP Button will turn OFF all
machine functions with the exception of
the coolant if the selector switch is in
theWASH position.
BLADE SWITCH
This selector switch starts and
stops the saw blade. The blade will
not start with the Head in the down
position.
COOLANTSWITCH
ON : Coolantflow when
bladeisrunning.
OFF : Nocoolantflow.
WASH : Constantflow.
HEAD CONTROLS
UP The head will rise as long as the
lever is pushed up.
HOLD The head will stay at it's
current position when the lever is in this
position.
DOWN The Head will descend at set
Feed Rate.
FEED RATE DIAL The speed at which
the head will descend can be set on the
scale of 1 to 10. As the number
increases so does feed rate.
VISE CONTROL
OPEN The vise will open when
the lever is pushed up.
HOLD The vise will hold it's
position when the lever is in the
center position.
CLOSE The vise will close when
the lever is pushed down.
NOTE: Seepage14 if the bundling
option is present.

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BLADE BASICS
Technology is rapidly changing all aspects of production machining. Metal cutoff is no exception. The
advances made in the bandsaw blade industry have definitely brought down the cost per cut, despite the three fold
higherprice of the newertechnology blades. Variable pitch(followingpage), bi-metal blades(likethe 3/4 or4/6bi-
metal blade supplied with the machine) last much longer, cut faster, and more accurately than the conventional
carbon steel blades. In order to take advantage of the superiority of bi-metal blades, it is critical to property “break-
in” a new blade. This is accomplished by taking two or three cuts through solid four or five inch diameter mild steel
at an extremely slow feed rate. These two or three slow cuts sufficiently lap (polish) the new blade so that it does
not snag the material being cut. Proper break-in will alleviate blade vibration, improve surface finish and accuracy,
andimprove expected bladelife.
1. A new blade must be properly "broken-in". Proper break-in will alleviate blade vibration, improve surface
finish and accuracy, and extend blade life. The most convenient way to do this is to cut the intended work-piece,
at the standard recommended blade speed for that material, but with the feed rate reduced to about 25% of
normal. Near the end of the first cut, increase the feed rate again, and once again when the blade approaches
the end of the second cut. Keep increasing feed rate in this fashion, so that normal feed rate is reached after
300 to 500 sq. cm of cutting.
2. Generous coolant application is essential with almost all materials. Ahigh quality and well mixed
coolant will dramatically extend blade life, and will increase cutting rate and surface finish. On those few
materials where coolant is undesirable, a slight coolant flow or periodic oiling of the blade is necessary to
prevent the blade from being scored by the carbide guides.
3. The stock being cut must be securely clamped in the vises. Stock movement during cutting will strip
blade teeth. Noticeable stock vibration reduces cutting performance and blade life - consideration should be
given to reorientation of the stock, or additional clamping measures (e.g. wood between vise jaws and work-
piece).
4. The proper blade speed for the work-piece material must be selected.
Use the following chart as a starting point.
- Blade speeds higher than recommended will quickly dull the blade. Blue chips are evidence of excessive
bladespeed.
- Lower than recommended speeds will not prolong blade life, and will require reduced feed rate - but
reduced speeds may be helpful in reducing vibration, and will increase blade life in that case.
5. The proper feed rate must be applied. Feed Rate is the speed which the head "free-falls", and is set with
the feed rate control knob. The head will descend more slowly when the blade encounters the work-piece but
the force of the blade on the work will not be changed unless the setting is changed. Verification of proper feed
rate is provided by the appearance of the cut chips which ideally form nicely curled "clock springs". (Note that
cast irons, and interrupted cuts result in short, broken chips even at ideal feed rates).
- Excessive feed rate will result in short blade life and/or crooked cuts.

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Optimum Blade Pitch ( T.P.I. ) for Material Width ( Inches )
DETERMINE OPTIMUM BLADE PITCH - TEETH PER INCH (T.P.I.)
Selecting a blade with proper tooth pitch is important in order to achieve optimal cutting rates and good blade
life.For cutting narrow or thin wall structural materials a fine, blade with many teeth per inch (T.P.I.)is recommended.
For wide materials a blade with a coarse pitch should be used. See the sketch below for the blade pitch changes
fordifferingeffective material widths.
It is impractical to change the blade to the proper pitch every time a different width of material is cut and it is not
necessary, but remember that the optimum blade will cut most efficiently. Too fine a blade must be fed slower on
wide material because the small gullets between the teeth will get packed with chips before they get across and out
of the cut. Too coarse a blade must be fed slower because it has fewer teeth cutting and there is a limit to the depth
of a cut taken by each tooth.
(
140, 220140, 220
140, 220140, 220
140, 220
140, 220140, 220
140, 220140, 220
140, 220
90, 14090, 140
90, 14090, 140
90, 140
140, 220140, 220
140, 220140, 220
140, 220
90, 14090, 140
90, 14090, 140
90, 140
140, 220140, 220
140, 220140, 220
140, 220
140, 220140, 220
140, 220140, 220
140, 220
140, 220140, 220
140, 220140, 220
140, 220
310310
310310
310
220220
220220
220
( in SFM )( in SFM )
( in SFM )( in SFM )
( in SFM )