Hyd Mech Model S-20M Manual - Westway Machinery
S20 SERIES III393289REV BThank you,On behalf of everyone at HYD·MECH Group Limited, 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 costwhile boosting quality and productivity.To ensure you are maximizing the power and versatility of your new HYD·MECH bandsaw, 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 along and mutually beneficial relationship.Thank youHyd·Mech Group LimitedP.O. Box 1030, 1079 Parkinson RoadWoodstock, Ontario, N4S 8A4Phone : (519) 539-6341Service : 1-877-237-0914Sales : 1-877-276-SAWS (7297)Fax : (519) 539-5126e-mail : info@hydmech.com
TABLE OF CONTENTSSECTION 0 - SAFETY INSTRUCTIONSSUMMARY.0.1BASIC RULES.0.4RESPONSIBILITIES OF THE OWNER.0.5RESPONSIBILITIES OF THE OPERATOR AND MAINTENANCE PERSONNEL.0.6SECTION 1 INSTALLATIONLIFTING MACHINE.1.1FOUNDATION, LEVELLING AND ANCHORING.1.2WIRING CONNECTIONS.1.2HYDRAULIC OIL .1.3CUTTING FLUID.1.3SECTION 2 – OPERATING INSTRUCTIONSOPERATOR CONTROL PANEL.2.1OPERATOR PANEL CONTROLS.2.2VISE CONTROL.2.3HEAD UP.2.3GUIDE ARM POSITIONING.2.4COOLANT FLOW.2.4HEAD SWING AND BREAK . .2.4BLADE BASICS.2.5MIST COOLANT.2.6WORK STOP.2.7WORK LAMP.2.7SECTION 3 - MAINTENANCE AND TROUBLESHOOTINGBLADE CHANGING PROCEDURE.3.1BLADE TRACKING ADUSTMENT.3.3BLADE GUIDE ADJUSTMENT.3.4CARBIDE REPLACEMENT.3.5BLADE PERPENDICULARITY.3.5HEAD DOWN LIMIT SWITCH.3.8LUBRICATION.3.8BLADE TENSION SLIDE ADJUSTMENT.3.890 AND 30 DEGREE STOP ADJUSTMENT.3.9GEARBOX LUBRICATION.3.9TROUBLE SHOOTING GUIDE.3.10
SECTION 4 - ELECTRICALFOR ELECTRICAL SCHEMATICS AND COMPONENTS PARTS LISTS SEE PDF ON ATTACHEDCD.4.1SECTION 5 - HYDRAULICFOR HYDRAULIC SCHEMATICS AND PLUMBING DIAGRAMS SEE PDF ON ATTACHED CD.5.1SECTION 6 - MECHANICAL ASSEMBLIESFOR MECHANICAL ASSEMBLY DRAWINGS SEE PDF ON ATTACHED CD.6.1SECTION - 7 OPTIONSFOR OPTIONAL ASSEMBLY DRAWINGS SEE PDF ON ATTACHED CD.7.1SECTION 8 - SPECIFICATIONSS20 SERIES III BANDSAW SPECIFICATION LIST.8.1S20 SERIES III LAYOUT.8.2SECTION 9 - WARRANTYWARRANTY.9.1ii
SECTION 0 - SAFETY INSTRUCTIONSSUMMARYAll persons operating this machine must have read and understood all of the following sections of this Manual:Section 0SAFETYSection 2OPERATING INSTRUCTIONSHowever, as a memory aid, the following is a summary of the Safety Section.Put Safety FirstMandatory Information – What operators and maintenance people must have read and understood.Signatures – Everyone involved with this machine must sign to confirm they have read and understood mandatory information.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 specifications and are non-hazardousOwner is responsible to keep Manual accessible at the machine ensure only reliable, fully trained personnel work with the machine clearly define responsibilities of all personnel working with the machine keep the machine in good working orderOperator 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.0.1
FOREWORDPut Safety First!This Safety Section contains important information to help you work safely with your machine and describes the dangersinherent 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 BEFOREyou do it. If you feel any uncertainty, stop and find a safer approach to the action. If you’re still uncertain, ask for advicefrom your supervisor.The SAFETY FIRST approach is particularly necessary when you do something new, or different, and most people instinctively 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 usinto unthinking, automatic repetition. Be alert for this, and when you feel it happening, stop and take stock of your situation. 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 first, think how much production you’ll lose ifyou get hurt.You owe it to yourself, your family, and your co-workers to PUT SAFETY FIRST.Mandatory InformationAll persons operating this machine must have read and understood all of the following sections of this Manual:Section 0SAFETYSection 2OPERATING INSTRUCTIONSPersonnel involved in installation and maintenance of the machine must have read and understood all sections of themanualPersons who have difficulty reading, or for whom English is not their first language, must receive particularly thoroughinstruction.0.2
SignaturesEveryone involved in operation of this machine must sign below to confirm that:I have read and understood all parts of Section 0 – Safety, and Section 2 – Operating Instructions.NameDateSignatureEveryone involved in the installation, inspection, maintenance, and repair of this machine must sign below to confirm that:I have read and understood all parts of this Operation and Maintenance Manual.NameDateSignature0.3
BASIC RULESIntended UseOur machines are designed and built in line with the state of the art, and specifically in accordance withAmerican 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 specified capacity, or forpurposes other than those specified in this Manual.Exclusion of MisuseMisuse includes, for example:Sawing hazardous materials such as magnesium or leadSawing work pieces which exceed the maximum workload appearing in the SpecificationsOperating the machine without all original safety equipment and guardsLiabilityThe machine may only be operated:when it is in good working order, andwhen the operator has read and understood the Safety and Operating Instructions Sections of the Manual, andwhen 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 errorsor non-compliance with the Safety and Operating Instructions contained in this Manual.0.4
Responsibilities of the ownerOrganization of workThis Operation and Maintenance Manual must always be kept near the machine so that it is accessible toall concerned.The general, statutory and other legal regulations on accident prevention and environmental protectionmust also be observed, in addition to the Manual material. The operators and maintenance personnelmust be instructed accordingly. This obligation also includes the handling of dangerous substances andthe provision and use of personal protective equipment.Choice and qualification of personnelEnsure that work on the machine is only carried out by reliable persons who have been appropriatelytrained for such work.TrainingEveryone working on or with the machine must be duly trained with regard to the correct use of the machine, the correct use of safety equipment, the foreseeable dangers that may arise during operation of themachine, and the safety precautions to be taken.In addition, the personnel must be instructed to check all safety devices at regular intervals.Define responsibilitiesClearly define exactly who is responsible for operating, setting-up, servicing and repairing the machine.Define the responsibilities of the machine operator and authorize him to refuse any instructions by thirdparties 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 supervision of an experienced operator. Observe the minimum age limits required by law.Condition of Machine and WorkplaceEnsure 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 sufficient clearance around it for the safe loading and unloadingof work pieces.0.5
Responsibilities of the operator and maintenance personnelSafety equipmentAll 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 first time, and after prolonged shutdownsEmergency Stop Button ( E-Stops)Always be aware of the location of the Emergency Stop Button(s). Do not allow material or objects toblock your access to an Emergency Stop.DamageIf 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 switchedoff, locked-out, and the fault reported to the responsible person.Safe operationThe machine may only be operated when in good working order and when all protective equipment is inplace and operational.Keep a safe distance from all moving parts – especially the blade and visesStock should not be loaded onto the saw if the blade is runningLong and heavy stock should always be properly supported in front of and behind the saw.FaultsThe machine must be switched off and locked-out before starting to remedy any faults.Safety hazard labelsSafety hazard labels, and other instructional labels on the machine must be observed. They must beclearly visible and legible at all times. If they become damaged they must be replaced.Clothing, jewellery, protective equipmentPersonnel operating or working on the machine must not wear un-restrained long hair, loosefitting clothes and dangling jewellery.When operating or working on the machine, always wear suitable, officially tested personal protective equipment such as safety glasses and safety boots and any other equipment required byplant regulations.0.6
GlovesExperience has shown that careless use of gloves around machinery is a major factor in serioushand 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 Modeand the bandsaw blade is not running.If the machine is running in Auto Mode, and only if the cut parts are greater than 24inches long, it may be possible to safely wear gloves for handling the cut parts, but thewearer of the gloves must never put his hands near the blade for any reason. If the cutparts are less than 24 inches long, it is required to arrange their automatic flow into aparts bucket or other suitable arrangement to avoid the necessity to pick them off themachine by hand.Hearing protectionEar protection must be worn whenever necessary.The level and duration of noise emission requiring hearing protection depends upon the nationalregulations 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 typeof work that is typically done. With reference to national standards, decide upon the necessaryhearing protection required.In the absence of such measurements, it is advisable for anyone exposed to long periods ofmoderate to loud noise to wear hearing protection. It is important to understand that hearing lossis gradual and easily goes un-noticed until it is serious and irreversible.WorkplaceA clear working area without any obstructions is essential for safe operation of the machine. The floormust 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, andextremes of temperatureNothing may ever be placed on, or leaned against the machine, with the obvious exception of the workpiece on the table and conveyor of the machine.0.7
Master DisconnectLock-out the machine before undertaking any maintenance or repair work on it. ‘Lock-out’ refers switchingoff the master electrical disconnect switch, and locking it out so that it cannot be switched on againwithout 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 ofthe machine, depending upon local regulations.In almost all jurisdictions, it is required that owners of industrial equipment establish and post lock-out procedures. Know and use the lock-out procedures of your company or organization.Residual RisksThe machine is still not completely de-energized if an electrical cabinet door type switch islocked-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 todissipate. After locking out power, wait 3 minutes before beginning to work on machine electricalcircuits.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 bereleased if they fall when disconnected. Secure these components with adequate hoisting gearbefore disassembly.0.8
SECTION 1 INSTALLATIONUpon delivery of your new S20 Series III saw, it is imperative that a thorough inspection be undertaken to check for anydamage that could have been sustained during shipping. Special attention should be paid to the electrical and hydraulicsystems to check for damaged cords and hoses, or for fluid leaks. In the event of damage caused during shipping, contactyour carrier to file for a damage claim.LIFTING MACHINEThis machine is to be lifted in one, fully assembled piece. In order to lift the machine it needs to be in the followingcondition: Saw head in the down position Coolant tank emptiedThe S20 Series III may be lifted from the FRONT with a forklift, which has a minimum capacity of 4500 lbs (2040 kg) and afork 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 formachine leveling.1.1
FOUNDATION, LEVELLING AND ANCHORINGMachine location should be carefully selected. A flat concrete floor area should be chosen. It should have enough freespace surrounding the machine to enable free access for safe operation and maintenance. The machine should be leveled in both directions (from side to side & from front to back), using a level on the machine out-feed table. Six levelingscrews used for securing machine to the pallet during transport, should be installed, one in each corner of the machinebase, as shown below. It might be required to place steel plates under leveling bolts to prevent their sinking into theconcrete floor. In cases when the machine is to be anchored permanently, anchoring holes are provided. They are locatednext to the leveling screw holes. The larger diameter hole is used for retaining during shipping and for use with concretefloor 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 preventcoolant from running down the raw stock. (This is especially true when cutting tubing or bundles).WIRING CONNECTIONSAfter 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 voltage label. Machine voltage is customer specific and should be indicated while ordering the machine. If machine voltagedoes 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 berouted through the supplied hole in the junction box, and connections made to L1, L2, L3, and ground terminals. Properstrain relief should be used on the incoming power cable.240V & 480V Junction Box208V & 600V Junction Box1.2
HYDRAULIC OILAs shipped the saw hydraulic circuit is filled with Texaco Rando HDZ 22 hydraulic oil. Ingeneral 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 filler plug A. Add oilto the cylinder only with head in the down position. The head is a self air-bleeding cylinderwith a small port in the top plate. It is normal for excess of oil to be displaced from this port.ACUTTING FLUIDThe S20 series III uses pump and reservoir to circulate necessary cutting fluid to the blade for maximum blade life. Yourblade supplier will be able to provide information about cutting fluid products that are available for your needs.No cutting fluid 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 manufacturer1.3
SECTION 2 – OPERATING INSTRUCTIONSOPERATOR CONTROL PANELThe operator control panel provides the operator with all the controls necessary to operate the saw after the cutting anglehas been set and the stock has been loaded and secured. All of the electrical functions and Feed Rate setting are operated 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 Emergency Knob clockwise to release). For the blade to operate the blade door has to be completely shut and blade tensionedto minimum tension of 1000 kg.Main Disconnect switch is located on the side on the machine control box.2.1
Operator Panel ControlsSWITCHFUNCTIONEMERGENCY STOPBUTTONPressing 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 SWITCHThis switch has three positions: AUTO, OFF, and ON.In the ON position, the coolant system will operate when there is power to the machine. Thisallows 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 STARTThe BLADE START button will start the blade with BLADE SWITCH in ON position. Theblade will not start if there is not sufficient blade tension or head door is not closed properly.BLADE SWITCHThis switch has two positions: ON and OFF.The ON position enables the operator to start the blade by depressing the BLADE STARTbutton.The OFF position shuts off the blade if it is running. The blade will not start if the BLADESWITCH is in this position.BLADE SPEED DIALSets the blade speed infinitely from 46 ft/min - 330 ft/min.FEED RATE DIALThe speed at which the head will descend can be set on the scale from 0 to 10. As thenumber increases so does the feed rate.HEAD FEEDWorks only when the blade is running.Depressing the HEAD FEED button results in head continous descent proportionally to theFEED RATE DIAL setting. To stop head movement move the BLADE SWITCH to the OFFposition.FAST APPROACHWorks 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 downspeed. Releasing the FAST APPROACH button will stop the head from descending.Shows the blade tension force in kg.BLADE TENSION DISPLAY Recommended blade tension is between 1000 - 1200 kg. If blade tension is below 550 kgthe blade will not start.2.2
MECHANICAL CONTROLSVISE CONTROLThe material clamping vise is a cam operated, double handle locking vise. The saw operator can push the vise handle toclose the jaw on the material and then lock it from either side of the saw. The handles have two positions, forward towardthe stock to unlock the vise and away from the stock to lock. The following photo’s show vise handles in locked and unlocked position.Unlocked PositionLocked PositionHEAD UPAfter finishing a cut the operator needs to manually lift the head to the required height by pushing on the provided handlebelow the blade tension wheel. Required lifting force is factory set using counterbalance springs to approximately 35 lbs atpoint of effort.Lift here2.3
GUIDE ARM POSITIONINGThe S20 Series III idler side guide arm is adjustable to accommodate varying material widths. The guide arm should beadjusted as close to the material as possible while still allowing it to pass. This process of matching the guide arm spacingto the material size is important to optimize blade life and ensure straightness of the cut.To adjust the guide arm location pull down thelocking handle and slide the guide arm to therequired position, and then release the lockinghandle. The locking handle is spring energizedand will self return to the locking position.Locking handleCOOLANT FLOWThe S20 Series III bandsaw is equipped with a coolant pump supplying coolant flow 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 flow control shut-off valve. The guide armnozzles should be adjusted to apply an even covering of coolant to the blade.The flexible 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 flexible nozzle has aflow control shut-off valve.NOTE: When cutting materials that do not need constant coolant, such as cast iron, some coolant flow is still required forblade lubrication to prevent blade scoring by carbide pads as the blade moves through them.HEAD SWING and BREAKAn integral function of the S20 Series III is the ability to make miteredcuts at angles between 90 and 30 degrees. The Head swing of theS20 Series III is easily changed to set a different cutting angle by firstreleasing the Angle Brake lever, and then manually moving the Headto the cutting angle desired. An angle scale with a pointer in clear viewof the saw operator allows for accurate setting of the cutting angle.The Angle Brake lever is then locked in position by forcing it into thedown position. It should be noted that the angle brake should belocked into position whenever cutting with the saw. The photo illustrates the Angle Brake in the locked position at 65 degrees. To set thesaw to the 90 degree position, the Head (in the fully down position) ismoved until the frame meets the 90 degree stop bolt, which is locatedin the coolant tray at the drive end of the head.2.4Head swing scale and angle brake locked
BLADE BASICSTechnology is rapidly changing all aspects of production machining. Metal cutoff is no exception. The advances made inthe bandsaw industry have definitely brought down the cost per cut, despite the three-fold increase in the price of newertechnology blades. Variable pitch (following pages), bi-metal blades (like the ¾ or 4/6 bi-metal blade supplied with theHyd-Mech machine) last much longer, cut faster and more accurately than the conventional carbon steel blades. In orderto take advantage of the superiority of bi-metal blades, it is critical to properly “break in” a new blade. This is accomplishedby taking two or three cuts through solid four or five-inch diameter mild steel at an extremely slow feed rate. These two orthree slow cuts sufficiently lap (polish) the new blade so that it does not snag the material being cut. Proper break-in willalleviate blade vibration, improve surface finish and accuracy, and improve expected blade life.1. A new blade must be properly “broken-in”. Proper break-in will alleviate blade vibration, improve surface finishand accuracy, and improve expected blade life. The most convenient way to do this is to cut the intended workpiece, at the standard recommended blade speed for that material, but with the feed rate reduced to about 25% ofnormal. Near the en
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
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The information and speciications provided in this manual were accurate at the time of printing. HYD·MECH reserves the right to discontinue or change speciications or design at any time without notice and without incurring any obligation. Thank you. Hyd·Mech Group Limited P.O.
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