Hyd-Mech S20 SERIES III User manual

1
Thank you,
On behalf of everyone at HYD·MECH Group Limited, I would like to thank and congratulate you on your decision to pur-
chase a HYD·MECH bandsaw.
Your new machine is now ready to play a key role in increasing the efciency of your operation, helping you to reduce cost
while boosting quality and productivity.
To ensure you are maximizing the power and versatility of your new HYD·MECH bandsaw, please take the time to famil-
iarize yourself and your employees with the correct operation and maintenance procedures as outlined in this manual.
We sincerely appreciate the condence you have demonstrated in purchasing our product and look forward to building a
long and mutually benecial relationship.
Thank you
Hyd·Mech Group Limited
P.O. Box 1030, 1079 Parkinson Road
Woodstock, Ontario, N4S 8A4
Phone : [phone]
Service : 1-877-237-0914
Sales : 1-877-276-SAWS (7297)
Fax : [phone]
e-mail : [email protected]
S20 SERIES III
393289
REV B

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
LIFTING MACHINE..........................................................................................................................1.1
FOUNDATION, LEVELLING AND ANCHORING............................................................................1.2
WIRING CONNECTIONS.................................................................................................................1.2
HYDRAULIC OIL ............................................................................................................................1.3
CUTTING FLUID..............................................................................................................................1.3
SECTION 2 – OPERATING INSTRUCTIONS
OPERATOR CONTROL PANEL......................................................................................................2.1
OPERATOR PANEL CONTROLS ...................................................................................................2.2
VISE CONTROL...............................................................................................................................2.3
HEAD UP .........................................................................................................................................2.3
GUIDE ARM POSITIONING ............................................................................................................2.4
COOLANT FLOW ............................................................................................................................2.4
HEAD SWING AND BREAK ...........................................................................................................2.4
BLADE BASICS...............................................................................................................................2.5
MIST COOLANT ..............................................................................................................................2.6
WORK STOP ...................................................................................................................................2.7
WORK LAMP...................................................................................................................................2.7
SECTION 3 - MAINTENANCE AND TROUBLESHOOTING
BLADE CHANGING PROCEDURE.................................................................................................3.1
BLADE TRACKING ADUSTMENT..................................................................................................3.3
BLADE GUIDE ADJUSTMENT .......................................................................................................3.4
CARBIDE REPLACEMENT.............................................................................................................3.5
BLADE PERPENDICULARITY........................................................................................................3.5
HEAD DOWN LIMIT SWITCH .........................................................................................................3.8
LUBRICATION .................................................................................................................................3.8
BLADE TENSION SLIDE ADJUSTMENT .......................................................................................3.8
90 AND 30 DEGREE STOP ADJUSTMENT....................................................................................3.9
GEARBOX LUBRICATION..............................................................................................................3.9
TROUBLE SHOOTING GUIDE.......................................................................................................3.10

ii
SECTION 4 - ELECTRICAL
FOR ELECTRICAL SCHEMATICS AND COMPONENTS PARTS LISTS SEE PDF ON ATTACHED
CD ....................................................................................................................................................4.1
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
FOR OPTIONAL ASSEMBLY DRAWINGS SEE PDF ON ATTACHED CD ....................................7.1
SECTION 8 - SPECIFICATIONS
S20 SERIES III BANDSAW SPECIFICATION LIST ........................................................................8.1
S20 SERIES III LAYOUT .................................................................................................................8.2
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.
Signatures – Everyone involved with this machine must sign to conrm they have read and understood mandatory infor-
mation.
Basic Rules – only use this machine when
• it is in good working order
• all safety equipment is in place and functional
• operations are in compliance with this manual
• materials are within designed specications and are non-hazardous
Owner is responsible to
• keep Manual accessible at the machine
• ensure only reliable, fully trained personnel work with the machine
• clearly dene responsibilities of all personnel working with the machine
• keep the machine in good working order
Operator and Maintenance Personnel are responsible to:
• keep all safety equipment in order, check its function at the beginning of each shift, and report any shortcomings
• shut-down machine and report any faults or malfunctions which could impair safety
• understand and obey safety hazard labels
• not to wear un-restrained long hair, loose clothing or jewellery
• wear all required personal protective equipment
• not to wear gloves within 24 inches of moving blade
• maintain a clean working area and machine
• 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
you do it. If you feel any uncertainty, stop and nd a safer approach to the action. If you’re still uncertain, ask for advice
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.
Certainly production is important, but if you think you’re too busy to put safety rst, think how much production you’ll lose if
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
Persons who have difculty reading, or for whom English is not their rst language, must receive particularly thorough
instruction.

0.3
Signatures
Everyone involved in operation of this machine must sign below to conrm that:
I have read and understood all parts of Section 0 – Safety, and Section 2 – Operating Instructions.
Name Date Signature
Everyone involved in the installation, inspection, maintenance, and repair of this machine must sign below to conrm that:
I have read and understood all parts of this Operation and Maintenance Manual.
Name Date Signature

0.4
BASIC RULES
Intended Use
Our machines are designed and built in line with the state of the art, and specically in accordance with
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,
or damage other property, if they are operated incorrectly, used beyond their specied capacity, or for
purposes other than those specied in this Manual.
Exclusion of Misuse
Misuse includes, for example:
Sawing hazardous materials such as magnesium or lead
Sawing work pieces which exceed the maximum workload appearing in the Specications
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.
Choice and qualication of personnel
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.
Dene responsibilities
Clearly dene exactly who is responsible for operating, setting-up, servicing and repairing the machine.
Dene the responsibilities of the machine operator and authorize him to refuse any instructions by third
parties if they run contrary to the machine’s safety.
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.
Ensure that the machine is installed with sufcient clearance around it for the safe loading and unloading
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:
• at the start of every shift.
• after maintenance and repair work
• when starting for the rst time, and after prolonged shutdowns
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-
tting clothes and dangling jewellery.
When operating or working on the machine, always wear suitable, ofcially tested personal pro-
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
parts are less than 24 inches long, it is required to arrange their automatic ow into a
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
A clear working area without any obstructions is essential for safe operation of the machine. The oor
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
Lock-out the machine before undertaking any maintenance or repair work on it. ‘Lock-out’ refers switching
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:
• Rotary switch mounted in electrical control cabinet door and inter-locked with door
• Lever switch mounted in separate box mounted on the machine
• 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 S20 Series III 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 and hoses, or for uid leaks. In the event of damage caused during shipping, contact
your carrier to le for a damage claim.
LIFTING MACHINE
This machine is to be lifted in one, fully assembled piece. In order to lift the machine it needs to be in the following
condition:
• Saw head in the down position
• Coolant tank emptied
The S20 Series III may be lifted from the FRONT with a forklift, which has a minimum capacity of 4500 lbs (2040 kg) and a
fork length of 72” (1830mm).
The S20 Series III is shrink-wrapped for shipping from our plant. Remove wrapping from the saw and dispose safely.
Complete the inspection for signs of damage. Undo the bolts that hold the saw to the pallet. Retain these bolts to use for
machine leveling.

1.2
FOUNDATION, LEVELLING AND ANCHORING
Machine location should be carefully selected. A at concrete oor area should be chosen. It should have enough free
space surrounding the machine to enable free access for safe operation and maintenance. The machine should be lev-
eled in both directions (from side to side & from front to back), using a level on the machine out-feed table. Six leveling
screws used for securing machine to the pallet during transport, should be installed, one in each corner of the machine
base, as shown below. It might be required to place steel plates under leveling bolts to prevent their sinking into the
concrete oor. In cases when the machine is to be anchored permanently, anchoring holes are provided. They are located
next to the leveling screw holes. The larger diameter hole is used for retaining during shipping and for use with concrete
oor anchors. The smaller diameter threaded hole at each corner, are used for leveling the saw.
Using a level on the machine out-feed table, level machine front to back and side to side.
NOTE: In some cases leveling the saw infeed with a slight slope towards the blade is recommended. This will prevent
coolant from running down the raw stock. (This is especially true when cutting tubing or bundles).
WIRING CONNECTIONS
After the machine is leveled and anchored the necessary power hook-up needs to be performed.
Check that there is no sign of shipping damage to the electrical conduits, cords or hydraulic hoses.
As supplied, the S20 Series III is built to run on three phase AC Voltage, as indicated on the machine serial plate and volt-
age label. Machine voltage is customer specic and should be indicated while ordering the machine. If machine voltage
does not match available power source contact factory.
Power connection to the machine is made in the junction box, located at the side of the machine. The power cable can be
routed through the supplied hole in the junction box, and connections made to L1, L2, L3, and ground terminals. Proper
strain relief should be used on the incoming power cable.
240V & 480V Junction Box
208V & 600V Junction Box

1.3
HYDRAULIC OIL
As shipped the saw hydraulic circuit is lled with Texaco Rando HDZ 22 hydraulic oil. In
general any mineral hydraulic oil ISO viscosity grade 22 is suitable as a replacement.
The head cylinder contains oil that should be topped up to the level of ller plug A. Add oil
to the cylinder only with head in the down position. The head is a self air-bleeding cylinder
with a small port in the top plate. It is normal for excess of oil to be displaced from this port.
A
CUTTING FLUID
The S20 series III uses pump and reservoir to circulate necessary cutting uid to the blade for maximum blade life. Your
blade supplier will be able to provide information about cutting uid products that are available for your needs.
No cutting uid is supplied with the machine. There are two types of coolant available:
• Oil based; dilute in 1:10 ratio (one part of concentrated coolant and 10 parts of water).
• Synthetic; dilute as recommended by manufacturer

2.1
SECTION 2 – 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 and Feed Rate setting are oper-
ated from the control panel. For all the functions to work machine has to be powered up. The Main Disconnect switch,
which is located on the side of control box, has to be in ON position. Emergency Switch has to be released (turn Emer-
gency Knob clockwise to release). For the blade to operate the blade door has to be completely shut and blade tensioned
to minimum tension of 1000 kg.
Main Disconnect switch is located on the side on the machine control box.

2.2
SWITCH FUNCTION
EMERGENCY STOP
BUTTON
Pressing the red EMERGENCY STOP button will turn OFF all machine functions.
To operate machine after emergency stop the EMERGENCY STOP knob has to be released.
To release EMERGENCY STOP turn knob clockwise.
COOLANT SWITCH
This switch has three positions: AUTO, OFF, and ON.
In the ON position, the coolant system will operate when there is power to the machine. This
allows use of the wash gun to clean the machine.
In the OFF position, the coolant system is inactive.
In the AUTO position the coolant system will only run when the blade is on.
BLADE START The BLADE START button will start the blade with BLADE SWITCH in ON position. The
blade will not start if there is not sufcient blade tension or head door is not closed properly.
BLADE SWITCH
This switch has two positions: ON and OFF.
The ON position enables the operator to start the blade by depressing the BLADE START
button.
The OFF position shuts off the blade if it is running. The blade will not start if the BLADE
SWITCH is in this position.
BLADE SPEED DIAL Sets the blade speed innitely from 46 ft/min - 330 ft/min.
FEED RATE DIAL The speed at which the head will descend can be set on the scale from 0 to 10. As the
number increases so does the feed rate.
HEAD FEED
Works only when the blade is running.
Depressing the HEAD FEED button results in head continous descent proportionally to the
FEED RATE DIAL setting. To stop head movement move the BLADE SWITCH to the OFF
position.
FAST APPROACH
Works only when the blade is not running.
The BLADE SWITCH can be at an arbitrary position.
Depressing and holding the FAST APPROACH button advances the head with fast down
speed. Releasing the FAST APPROACH button will stop the head from descending.
BLADE TENSION DISPLAY
Shows the blade tension force in kg.
Recommended blade tension is between 1000 - 1200 kg. If blade tension is below 550 kg
the blade will not start.
Operator Panel Controls

2.3
MECHANICAL CONTROLS
VISE CONTROL
The material clamping vise is a cam operated, double handle locking vise. The saw operator can push the vise handle to
close the jaw on the material and then lock it from either side of the saw. The handles have two positions, forward toward
the stock to unlock the vise and away from the stock to lock. The following photo’s show vise handles in locked and un-
locked position.
HEAD UP
After nishing a cut the operator needs to manually lift the head to the required height by pushing on the provided handle
below the blade tension wheel. Required lifting force is factory set using counterbalance springs to approximately 35 lbs at
point of effort.
Locked Position Unlocked Position
Lift here

2.4
GUIDE ARM POSITIONING
The S20 Series III idler side guide arm is adjustable to accommodate varying material widths. The guide arm should be
adjusted as close to the material as possible while still allowing it to pass. This process of matching the guide arm spacing
to the material size is important to optimize blade life and ensure straightness of the cut.
COOLANT FLOW
The S20 Series III bandsaw is equipped with a coolant pump supplying coolant ow to four coolant outlets.
• The wash gun is provided for clearing chip accumulations.
• Guide arm coolant nozzles, one at each guide arm, are equipped with a ow control shut-off valve. The guide arm
nozzles should be adjusted to apply an even covering of coolant to the blade.
• The exible nozzle can be pointed directly where necessary. It should be used when cutting wide work pieces,
bundles, or structurals. Set extra coolant into the saw kerf at about mid span of the cut. The exible nozzle has a
ow control shut-off valve.
NOTE: When cutting materials that do not need constant coolant, such as cast iron, some coolant ow is still required for
blade lubrication to prevent blade scoring by carbide pads as the blade moves through them.
HEAD SWING and BREAK
An integral function of the S20 Series III is the ability to make mitered
cuts at angles between 90 and 30 degrees. The Head swing of the
S20 Series III is easily changed to set a different cutting angle by rst
releasing the Angle Brake lever, and then manually moving the Head
to the cutting angle desired. An angle scale with a pointer in clear view
of the saw operator allows for accurate setting of the cutting angle.
The Angle Brake lever is then locked in position by forcing it into the
down position. It should be noted that the angle brake should be
locked into position whenever cutting with the saw. The photo illus-
trates the Angle Brake in the locked position at 65 degrees. To set the
saw to the 90 degree position, the Head (in the fully down position) is
moved until the frame meets the 90 degree stop bolt, which is located
in the coolant tray at the drive end of the head.
To adjust the guide arm location pull down the
locking handle and slide the guide arm to the
required position, and then release the locking
handle. The locking handle is spring energized
and will self return to the locking position.
Locking handle
Head swing scale and angle brake locked