Hyd-Mech S-23A User manual

IN BANDSAW TECHNOLOGY
OPERATIONS &
MAINTENANCE
MANUAL

S-23AS-23A
S-23AS-23A
S-23A
2001,revc,393365
THANKYOU,
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.
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.
We sincerely appreciate the confidence you have demonstrated in purchasing our product and look forward to
building a long and mutually beneficial relationship.
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 1-800-276-SAWS(7297)
Fax [phone]
e-mail, [e-mail]

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S23A Table of Contents
SECTION 1, INSTALLATION
SAFETY PRECAUTIONS ........................................................................................................................................ 1
OPERATOR SAFETY - VISUAL INSPECTION......................................................................................................... 2
LIFTING THE S-23A ................................................................................................................................................ 3
WRAPPED FOR SHIPPING .................................................................................................................................... 3
LEVELLING THE SAW ............................................................................................................................................. 4
CUTTING FLUID ...................................................................................................................................................... 4
SPEED ADJUSTOR INSTALLATION ........................................................................................................................ 4
HYDRAULIC OIL and TANK...................................................................................................................................... 4
POWER WIRING CONNECTIONS ........................................................................................................................... 5
POWER WIRING CONNECTIONS (for S-23A with the PLC option).......................................................................... 6
SECTION 2, OPERATING INSTRUCTIONS
BLADE BASICS ...................................................................................................................................................... 7
VARIABLE SPEED CONTROL ................................................................................................................................ 7
OPERATOR CONTROL CONSOLE .......................................................................................................................... 8
MANUAL CONTROLS ......................................................................................................................................... 9
SEQUENCER OPERATION GUIDE ........................................................................................................... 11
ORDER OF OPERATION........................................................................................................................ 11
BLADE SPEED INDICATOR ................................................................................................................... 12
SEQUENCER PARAMETER SETUP...................................................................................................... 12
PARAMETER OPTIONS ................................................................................................................... 13
PARAMETER OPTIONS SETTINGS ............................................................................................... 13
OPTIONAL PLC 100 OPERATION GUIDE ........................................................................................................ 14
MANUAL CONTROLS FOR PLC OPTION ................................................................................................... 14
PLC 100 CONTROL SYSTEM ..................................................................................................................... 16
OPERATION OVERVIEW ....................................................................................................................... 16
ACTIVATING THE PLC ........................................................................................................................... 17
PLC CONTROL PANEL ........................................................................................................................... 17
FUNCTION KEY DESCRIPTIONS.......................................................................................................... 18
MANUAL MODE FUNCTION KEY DESCRIPTIONS ............................................................................... 18
SINGLE PART CYCLE OPERATION ...................................................................................................... 19
AUTOMATIC OPERATION ...................................................................................................................... 20
PROCEDURE FOR EDITING OR STARTING A NEW JOB IN AUTO MODE ..................................... 20
WORKING WITH A QUEUE ............................................................................................................. 21
KERF CORRECTION for ANGLE CUTTING ..................................................................................................... 22
HEAD UP LIMIT SETTING ............................................................................................................................... 23
COOLANT FLOW ............................................................................................................................................. 23
MECHANICAL CONTROLS .............................................................................................................................. 23
HEAD SWING and BRAKE ......................................................................................................................... 23
GUIDE ARM POSITIONING ........................................................................................................................ 24
SHUTTLE LENGTH CONTROLS ................................................................................................................. 24
HYDRAULIC FEED CONTROL .................................................................................................................... 25
CUTTING PARAMETERS CHART ......................................................................................................................... 25
CHART EXAMPLE #1....................................................................................................................................... 26
STEP 1, DETERMINE EFFECTIVE MATERIAL WIDTH .............................................................................. 26
STEP 2, SET FEED FORCE LIMIT ............................................................................................................. 26
STEP 3, DETERMINE OPTIMUM BLADE PITCH ....................................................................................... 27
STEP 4, DETERMINE OPTIMUM BLADE SPEED...................................................................................... 27
STEP 5, DETERMINE FEED RATE SETTING ............................................................................................ 28
ADDITIONAL CUTTING SETUP EXAMPLES................................................................................................... 29
---- Continued ----

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SECTION 3, MAINTENANCE and TROUBLESHOOTING
BLADE CHANGING PROCEDURE ........................................................................................................................ 31
BLADE TRACKING ADJUSTMENT ....................................................................................................................... 32
IDLER WHEEL ADJUSTMENT ......................................................................................................................... 32
DRIVE WHEEL ADJUSTMENT......................................................................................................................... 32
BLADE BRUSH ADJUSTMENT ............................................................................................................................. 33
ANGLE BRAKE ADJUSTMENT and PROCEDURE ............................................................................................... 33
DRIVE BELT REPLACEMENT .............................................................................................................................. 33
BLADE GUIDE ADJUSTMENT .............................................................................................................................. 33
HEAD DOWN LIMIT SWITCH ................................................................................................................................ 34
LUBRICATION ....................................................................................................................................................... 34
HYDRAULIC MAINTENANCE ................................................................................................................................ 35
CLEANLINESS ...................................................................................................................................................... 35
TROUBLE SHOOTING GUIDE .............................................................................................................................. 36
TROUBLESHOOTING THE SEQUENCER ........................................................................................................ 38
PROGRAMMABLE LENGTH CONTROL DESCRIPTION ................................................................................. 39
PLC 100E PARAMETERS ........................................................................................................................... 40
PLC 100 TROUBLESHOOTING ................................................................................................................... 41
PLC IS NOT MEASURING LENGTHS. ................................................................................................... 41
INACCURATE LENGTHS IN AUTO MODE ............................................................................................. 42
INCONSISTENT INACCURACY ........................................................................................................ 42
CONSISTENT INACCURACY............................................................................................................ 43
LINEAR INACCURACY ..................................................................................................................... 43
AUTO CYCLE NOT BEING COMPLETED. .............................................................................................. 43
NO DISPLAY .......................................................................................................................................... 45
NO BLADE SPEED DISPLAY ................................................................................................................ 45
MITSUBISHI 100 INPUTS & OUTPUTS ..................................................................................................... 46
INPUT / OUTPUT TERMINAL INFORMATION ....................................................................................... 47
ENCODER & PROXIMITY SENSOR CONNECTIONS ............................................................................ 47
CALIBRATION PROCEDURE FOR PLC 100L .............................................................................................. 48
SERVICE RECORD & NOTES ..................................................................................................................... 49
SECTION 4, ELECTRICAL SYSTEM
INITIAL START-UP ................................................................................................................................................. 51
SEQUENCER CONTROL BOX LAYOUT. ............................................................................................................... 52
OPTIONAL PLC CONTROL BOX LAYOUT ............................................................................................................ 53
SEQUENCER ELECTRICAL PARTS LISTS .......................................................................................................... 54
OPTIONAL PLC ELECTRICAL PARTS LISTS ....................................................................................................... 57
SEQUENCER ELECTRICAL SCHEMATIC &WIRING DRAWINGS ........................................................................ 61
OPTIONAL PLC ELECTRICAL SCHEMATIC &WIRING DRAWINGS ..................................................................... 63
SECTION 5, HYDRAULIC SYSTEM
HYDRAULIC COMPONENTS LIST and LOCATIONS ............................................................................................. 67
CYLINDER ASSEMBLIES ................................................................................................................................ 68
GLAND ASSEMBLIES ..................................................................................................................................... 68
PISTON ASSemblies ............................................................................................................................................. 68
HYDRAULIC SCHEMATIC & PLUMBING DRAWINGS ........................................................................................... 69
SECTION 6, MECHANICAL ASSEMBLIES
GUIDE ARM & CARBIDE ASSEMBLIES .............................................................................................................. 73
BLADE DRIVE ASSEMBLY ................................................................................................................................... 74
HM4A GEAR BOX ASSEMBLY ............................................................................................................................. 76
IDLER WHEEL ASSEMBLY ................................................................................................................................... 77
BLADE BRUSH ASSEMBLY .................................................................................................................................. 78
COUNTER BALANCE SPRING ASSEMBLY.......................................................................................................... 79

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HYDRAULIC TANK ASSEMBLY (Less hoses) ........................................................................................................ 80
HYDRAULIC PUMP ASSEMBLY (Less hoses) ...................................................................................................... 81
PIVOT LINK ASSEMBLY ....................................................................................................................................... 82
FRONT VISE ASSEMBLY ..................................................................................................................................... 84
SHUTTLE VISE ASSEMBLY ................................................................................................................................. 85
INFEED CONEYOR ASSEMBLY ........................................................................................................................... 86
COOLANT GROUP ............................................................................................................................................... 86
LENGTH CONTROL ASSEMBLY ........................................................................................................................... 88
DOORS and COVERS ........................................................................................................................................... 89
SECTION 7, OPTIONS
WORK STOP ......................................................................................................................................................... 91
OVER HEAD BUNDLING ....................................................................................................................................... 92
MITSUBISHI PLC 100 ........................................................................................................................................... 93
PLC LENGTH ENCODER ASSEMBLY .................................................................................................................. 94
BLADE BREAKAGE .............................................................................................................................................. 95
WORK LAMP ASSEMBLY ..................................................................................................................................... 95
OUT OF STOCK SWITCH ..................................................................................................................................... 96
VARIABLE VISE PRESSURE ............................................................................................................................... 96
SECTION 8, SPECIFICATIONS
SPECIFICATION LIST .......................................................................................................................................... 97
LAYOUT DRAWINGS ............................................................................................................................................. 98
SECTION 9, WARRANTY
WARRANTY ..........................................................................................................................................................101
MITSUBISHI PLC PARAMETERS ........................................................................................................................102
SEQUENCER PARAMETERS ..............................................................................................................................102

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SECTION 1 - INSTALLATION
SECTION 1
INSTALLATION

SECTION 1 - INSTALLATION

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SECTION 1, INSTALLATION
Upon delivery of your new S-23A 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.
SAFETY PRECAUTIONS
The S-23A has 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 the
protection of operators and maintenance personnel.
POWER HOOK-UPS AND REPAIRS SHOULD BE ATTEMPTED ONLY BY QUALIFIED TRADESMEN.
THE SAW SHOULD BE LOCATED IN AN AREA WITH SUFFICIENT ROOM TO SAFELY LOAD STOCK
INTO THE SAW. SECURE THE SAW TO THE FLOOR.
THE AREA AROUND THE SAW SHOULD BE MAINTAINED IN A CLEAN AND TIDY CONDITION TO AVOID
OBSTACLES OPERATORS COULD TRIP OVER.
THE S-20A SERIES II SHOULD ONLY BE OPERATED ACCORDING TO THE SPECIFICATIONS OF THE
SAW. AVOID UNSAFE USAGE PRACTICES.
IF AT ANY TIME THE SAW DOES NOT APPEAR TO BE OPERATING PROPERLY IT SHOULD BE
STOPPED IMMEDIATELY AND REPAIRED.
OPERATOR : THE SAW SHOULD NEVER BE OPERATED UNLESS ALL GUARDS AND DOORS ARE
IN PLACE AND CLOSED.
OPERATOR : KEEP A SAFE DISTANCE FROM ALL MOVING PARTS - ESPECIALLY THE BLADE
AND VISES.
OPERATOR : LOOSE CLOTHING AND GLOVES SHOULD NEVER BE WORN WHILE OPERATING
THE SAW. COVER LONG HAIR.
OPERATOR : STOCK SHOULD NOT BE LOADED ONTO THE SAW IF THE BLADE IS RUNNING.
OPERATOR : LONG AND HEAVY STOCK SHOULD ALWAYS BE PROPERLY SUPPORTED IN
FRONT OF AND BEHIND THE SAW.
OPERATOR : 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.
OPERATOR: MUST WEAR EYE PROTECTION.
OPERATOR: MAINTAIN PROPER ADJUSTMENT OF BLADE TENSION, BLADE GUIDES, AND
BEARINGS
OPERATOR: HOLD WORKPIECE FIRMLY AGAINST TABLE.
OPERATOR: DO NOT REMOVE JAMMED CUTOFF PIECES UNTIL BLADE HAS STOPPED.
NO MODIFICATIONS TO THE MACHINE ARE PERMITTED WITHOUT PRIOR APPROVAL FROM HYD-MECH.
ANY APPROVED MODIFICATIONS SHOULD ONLY BE UNDERTAKEN BY TRAINED PERSONNEL.

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1. BLADE - KEEP AWAY FROM MOVING BLADE!
2. VISE - NEVER LOAD STOCK WITH BLADE MOVING!
3. HEAD - WATCH FOR HEAD DESCENDING TO TABLE!
4. PIVOT - CHECK FOR HEAD MOVEMENT BLOCKAGE!
5. SHUTTLE - STAY CLEAR OF MOVING SHUTTLE & VISE!
OPERATOR SAFETY - VISUAL INSPECTION
The operator should always make a visual inspection of the saw before operating. The following areas should be
checked.
5 (BEHIND HEAD)
4
3
1
2
Safety Inspection Points for Operators

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WRAPPED FOR SHIPPING
The S-23A is wrapped for shipping from our plant. Remove the wrapping from around the saw. Complete the
inspection for signs of shipping damage. Undo the bolts that hold the saw to the pallet. Retain these bolts to use for
levelling. The following photo illustrates the floor mounting plates located at the corners of the saw. The larger
diameter hole is used for retaining during shipping and for use with concrete floor anchors. The smaller diameter,
threaded holes at each corner are used for levelling the saw properly.
LIFTING THE S-23A
The S-23A 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 pallet from the correct
side. The pallet length dimension is 120". Minimum fork length of 72" is recommended to safely lift the pallet.
Lifting the S-23A with a Forklift Truck
S-23A Mounted to Shipping Pallet

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CUTTING FLUID
The S-23A 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 levelling bolts supplied.
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 to the container.
HYDRAULIC OIL and TANK
The S-23A is supplied with a Texaco 46 hydraulic oil
in the oil tank. Substitutes should be a 46 grade of
hydraulic oil. See Section 3 for instructions on changing
brands of oil. The oil tank should be topped up to the
top line on the gauge . The oil pressure gauge indicates
system pressure.
SPEED ADJUSTOR INSTALLATION
The speed adjustor is packaged seperately for shipping purposes and must be installed prior to connecting the
power supply. Failure to do so will cause a safety hazard. Refer to page 74 for installation instructions.
Hydraulic Oil Tank
Oil Filler Cap
& Breather
Oil Level &
Temperature
Gauge
Oil Pressure
Gauge
Wash Down
Hose
Coolant
Trough
Inlet Screen

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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
provide safe operation and to prevent potential damage to the machine, only qualified personnel should make the
electrical connections. If the hydraulics do not register an immediate pressure rise,
- SHUT THE HYDRAULICS OFF -
and change the phase order. As supplied your new S-23A is set to run on three phase voltage. The supply
voltage of the machine is shown on the serial plate attached to the front of the machine. Connection from the Main
supply is made to L1, L2, L3, and ground terminals in the electrical control box as shown below.
If equiped with the PLC option, these connections are made in the power disconnect switch as shown in the
photographs on the next page.
Supply conductors should be rated for the current supplied and should be protected by time delay fusing rated
for the amperage 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 counterclockwise.
( If the blade direction is wrong, any two lines should be reversed to correct)
L1
L2
L3
GROUND
Main power connections found
inside the control box.
The power cable should be routed
through the two holes found at the
left end of the control box beside
the motor power cable. A suitable
strain relief should be used.

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POWER WIRING CONNECTIONS (for S-23A with the PLC option)
After the machine is levelled 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 machine, only qualified
personnel should be allowed to do the work.
The first two areas that need to be checked are:
- There is no signs of shipping damage to electrical conduits, cords or hydraulic hoses.
- Hydraulic oil level is between the upper and lower lines on the level gauge.
During the initial hook-up it is very important to check that the phase order is correct. This is indicated by the
hydraulic pressure gauge registering a pressure rise and the blade running in a counter clockwise direction. If the
hydraulics do not register an immediate pressure rise,
- SHUT THE POWER OFF -
And change the phase order. As supplied, the machine is set to run on the three phase voltage as indicated on
the serial plate and voltage label. Power connection to the machine is made to the main disconnect switch and the
Ll, L2, L3 and Ground terminals. The disconnect switch box is located on right side of the infeed.
To gain access to the disconnect box, follow these steps:
1) Ensure the switch is in the OFF position and power is diconnected.
2) Push the lockout tab to the right and pull the door open.
To close the door properly, reverse the above steps.
Disconnect box found on
the rear of the main base
at the drive end.
GROUNDGROUND
GROUNDGROUND
GROUND
Main Power Connections.
L1 L2 L3

SECTION 2 - OPERATING INSTRUCTIONS
SECTION 2
OPERATING INSTRUCTIONS

SECTION 2 - OPERATING INSTRUCTIONS

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SECTION 2, OPERATING INSTRUCTIONS
This section has been prepared to give the operator the ability to set up the saw for most cutting situations.
Before cutting any material, the operator should be familiar with all operations and controls as well as the basic
cutting theory described below.The saw is equipped with a variable blade speed control and hydraulic feed control,
as well as an extensive door chart to guide the operator to the correct setting of these controls.
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 higher
price of high technology blades.Variable pitch, bi-metal blades (like the 4/6 or 3/4 bi-metal blade supplied with the
machine) last much longer, cut faster, and more accurately than conventional carbon steel blades. In order to take
advantage of the superiority of bi-metal blades, it is critical to properly “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. (It is
also advisable to utilize a slow blade speed.)
These two or three slow cuts sufficiently lap (polish) the teeth on the new blade so that it does not snag the
material being cut. Proper break-in will alleviate blade vibration, improve surface finish, accuracy, and blade life.
After “break-in”, the following six points must be closely monitored to ensure long blade life:
1. Proper blade tension should be maintained. (see Section 3, Maintenance and Troubleshooting)
2. Generous coolant application is essential with most materials. A high quality and well mixed coolant will
extend blade life, and also increase cutting rate and quality. On those materials where coolant is
undesirable for cutting, 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.
4. The proper feed force should be chosen. (see Saw Cutting Parameters: Step 2)
5. The proper blade speed must be selected. (see Saw Cutting parameters: Step 4)
6. The proper feed rate must be applied. (see Saw Cutting Parameters: Step 5)
VARIABLE SPEED CONTROL
Blade speed can be adjusted infinitely between 75 to 350 SFM (Surface Feet/Minute)
(23 to 106 m/min). Adjustment should be made only when the blade is running. Clockwise
rotation of the knob increases blade speed while counter clockwise rotation decreases
blade speed.
It is recommended to occasionally run the speed adjustor through it’s full range. This
will help in maintaining the pulley system. It is also recommended that if the same speed
is used for long periods, then a minor adjustment should be made,eg; 200 SFM should be
run at 190 or 210 SFM for part of the time. This will help in reducing wear grooves and
keep the speed adjustment smooth.
Speed adjuster

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OPERATOR CONTROL CONSOLE
The operator control console 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 control functions
of the S-20A Series II or S-23A saw are provided to the operator from the control console which incorporates
the manual control switches, the Sequencer controller, and the Head Up Limit setting knob. The hydraulic
functions of the S-20A Series II / S-23A are controlled from the Hydraulic Feed Control unit. This unit is covered in
detail later in this section, see “Hydraulic Feed Control” on page 25.
The manual control switches allow the operator to raise and lower the Head of the saw, turn the blade on and
off, open and close the vises, move the shuttle, and turn the coolant supply on and off. The control switches are
described by function on the following three pages.
The Sequencer controller provides the
operator with the ability to operate the saw in
automatic mode. Starting on page 11, this
controller is described in detail.
An optional PLC controller can be supplied
for your S Series saw which has fully automatic
capabilities. Starting on page 14, this controller
is described in detail.
E200 PLC interface.
Sequencer Controller
Manual Control Switches for Sequencer

Pg 9 S22A/S23A 2001b 2100 v1.0
PLC SWITCH The PLC On/Off switch controls the power supply to the Sequencer
controller. When the switch is ON, the controller is active for display in Manual Mode, and to
set the saw operation cycles in Automatic Mode.
FIXED VISE SWITCH This switch has three positions, OPEN, HOLD, and CLOSE. It
is disabled when the SEQUENCER is in AUTO. The FIXED VISE switch is active while the
MODE switch is in MANUAL or NEUTRAL
OPEN: Opens the vise as long as it is held at OPEN.
HOLD: Holds the vise jaw in it's current position, however a large force will cause some
creeping over time.
CLOSE: Closes the vise.
HEAD POSITION SWITCH The HEAD switch is a three position switch and is
active only when the PLC switch is in MANUAL. When the switch is set to HOLD the Head will
remain stationary. In the UP position the Head will rise until the UPPER LIMIT is met. In the
DOWN position the Head will descend only if the Feed Rate control is set to a value greater than
zero.
FEED FORCE PUSH-BUTTON The FEED FORCE switch is used ONLY for the
hydraulic setup. Service personnel should contact the Hyd.Mech dealer for information and
procedures.
COOLANT SWITCH Has three positions WASH, OFF and ON.
ON: The coolant flows only when the Head descends.
WASH: Coolant flows any time the machine is under power, permitting wash-down with
hand line without running machine.
OFF: No coolant flow.
Manual Controls
TOP ROW
INDEX VISE (FORWARD) BUTTON The INDEX VISE button is a two position push
button. When partially depressed, the INDEX VISE will move forward slowly. When pressed in
fully, the INDEX VISE will move at a fast rate.