OPERATIONS & MAINTENANCE

Transcription

1 OPERATIONS & MAINTENANCE M A N UA L I N B A N D S A W T E C H N O L O G Y

2 S-35P 2002, Rev a, THANK YOU, On behalf of everyone at HYD. MECH, I would like to thank and congratulate you on your decision to purchase a HYD. MECH band saw. 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: (519) Service Sales SAWS(7297) Fax (519) , info@hydmech.com

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4 S-35P Table of Contents SPECIFICATIONS and INSTALLATION SAFETY PRECAUTIONS... 1 WARRANTY... 2 SPECIFICATIONS... 3 S-35 LAYOUT DRAWING... 4 S-35P LIFTING INSTRUCTIONS... 5 FOUNDATION, LEVELLING AND ANCHORING... 6 GENERAL INFORMATION... 6 EARTH GROUNDING PROCEDURE... 6 POWER WIRING CONNECTIONS... 7 CUTTING FLUID... 8 HYDRAULIC OIL... 8 OPERATING INSTRUCTIONS BLADE BASICS... 9 VARIABLE SPEED CONTROL... 9 THE CONTROL CONSOLE START-UP OPERATOR PANEL SWITCHES KERF CORRECTION COOLANT FLOW CONTROL VARIABLE VISE PRESSURE OPTIONAL CUT LINE LASER SIGHT OPERATOR PLC INTERFACE HYDRAULIC FEED CONTROL CUTTING PARAMETERS and EXAMPLE STEP 1, DETERMINE EFFECTIVE MATERIAL WIDTH STEP 2, SET FEED FORCE LIMIT STEP 3, DETERMINE OPTIMUM BLADE PITCH STEP 4, DETERMINE OPTIMUM BLADE SPEED STEP 5, DETERMINE FEED RATE SETTING ADDITIONAL CUTTING SETUP EXAMPLES MAINTENANCE AND TROUBLE SHOOTING BLADE BRUSH ADJUSTMENT BLADE CHANGING PROCEDURE NEW BLADE BREAK-IN LUBRICATION REQUIREMENTS HYDRAULIC MAINTENANCE CLEANLINESS TROUBLE SHOOTING SERVICE RECORD & NOTES ELECTRICAL SYSTEM GENERAL INFORMATION INITIAL STARTUP ELECTRICAL COMPONENTS LISTS ELECTRICAL SCHEMATIC & WIRING DIAGRAMS i M16/ a

5 HYDRAULIC SYSTEM S-35P HYDRAULIC COMPONENTS LIST HYDRAULIC ASSEMBLIES CYLINDER ASSEMBLIES HYDRAULIC SERVICE KITS S36 HYDRAULIC SCHEMATIC and PLUMBING DIAGRAMS MECHANICAL ASSEMBLIES GUIDE BLOCK ASSEMBLIES GUIDE ARM ASSEMBLIES BLADE TENSION ASSEMBLY DRIVE ASSEMBLY HEAD PIVOT ASSEMBLY HYDRAULIC TANK ASSEMBLY( Less hoses.) HYDRAULIC PUMP ASSEMBLY (Less hoses.) HEAD CONTROL ASSEMBLY VISE ASSEMBLY BUNDLING ASSEMBLY ii M16/ a

6 SECTION 1 INSTALLATION SECTION 1 - INSTALLATION

7 SECTION 1 - INSTALLATION

8 SPECIFICATIONS and INSTALLATION Upon delivery of your new S-35P bandsaw, 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-35P 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-35P 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 : OPERATOR : OPERATOR : OPERATOR : OPERATOR : OPERATOR : OPERATOR: OPERATOR: OPERATOR: THE SAW SHOULD NEVER BE OPERATED UNLESS ALL GUARDS AND DOORS ARE IN PLACE AND CLOSED. KEEP A SAFE DISTANCE FROM ALL MOVING PARTS - ESPECIALLY THE BLADE AND VISES. LOOSE CLOTHING AND GLOVES SHOULD NEVER BE WORN WHILE OPERATING THE SAW. COVER LONG HAIR. 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. 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. MUST WEAR EYE PROTECTION. MAINTAIN PROPER ADJUSTMENT OF BLADE TENSION AND BLADE GUIDES DO NOT REMOVE JAMMED CUTOFF PIECES UNTIL BLADE HAS STOPPED. NO MODIFICATIONS TO THE MACHINE ARE PERMITTED WITHOUT PRIOR APPROVAL FROMHYD. MECH. ANY APPROVED MODIFICATIONS SHOULD ONLY BE UNDERTAKEN BFCY TRAINED PERSONNEL. Pg 1 S a

9 WARRANTY Hyd. Mech Group warrants each new S-35P bandsaw to be free from failure resulting from defective material and workmanship under proper use and service for a period of one year following the date of shipment to the user. Hyd. Mech's sole obligation under this warranty is limited to the repair or replacement without charge, at Hyd-Mech's factory, warehouse, or approved repair shop,of any part or parts which Hyd. Mech's inspection shall disclose to be defective. Return freight must be prepaid by the user. This warranty, in its entirety, does not cover maintenance items, including but not limited to lubricating grease and oils, filters, V-belts, saw blades, etc., nor any items therein which show signs of neglect, overloading, abuse, accident, inadequate maintenance, or unauthorized altering. MOTOR, GEARBOX, PUMP, ELECTRIC COMPONENTS, VALVES, HOSES, FITTINGS, and any other items used in the manufacture of the S-35P, but not originally manufactured by Hyd-Mech are subject to the original manufacturer's warranty. Hyd. Mech will provide such assistance and information as is necessary and available to facilitate the user's claim to such other manufacturer. Liability or obligation on the part of Hyd. Mech for damages, whether general, special or for negligence and expressly including any incidental and consequential damages is hereby disclaimed. Hyd. Mech's obligation to repair or replace shall be the limit of its liability under this warranty and the sole and exclusive right and remedy of the user. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, WRITTEN OR ORAL, INCLUDING WITHOUT LIMITATION ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. This warranty may not be changed, altered, or modified in any way except in writing by Hyd. Mech Group. HYD. MECH GROUP 1079 Parkinson Road P.O. BOX 1030 Woodstock, Ontario N4S 8A4 Phone: (519) Fax: (519) Toll Free (877) info@hydmech.com Pg 2 S a

10 SPECIFICATIONS Cutting Capacity rectangular 32" High x 42" Wide Blade length 29' 6" width 2" thickness.050" or 063" Blade speed 75 to 350 Surface Feet/Minute - Variable Blade guides Carbide Blade wheel diameter 32" Motors 5 Horsepower - Hydraulic 10 Horsepower - Variable Frequency Drive Coolant pump 16.6 Gallons Per Minute Coolant reservoir 6 Gallons Table height 36 " High Machine weight 15,000 pounds Overall Dimensions 214" Wide x 107" Long x 92" High with the head down and the console parallel. Pg 3 S a

11 S-35 LAYOUT DRAWING Pg 4 S a

12 S-35P LIFTING INSTRUCTIONS The S-35P weighs nearly 15,000 lbs. and its lifting and placement should be handled by qualified riggers. To lift the S-35P saw, use the following procedure. 1) Fix the head at 90 0 with a 3/4"NC x 2 1/2" hex bolt, jam nut & washer at the 90 0 stop adjustment as shown in the photo. 2) Anchor the head in the full down position with the lift strut and lift anchor weldment as shown in the photo. 3) Anchor the operator console to prevent it from swinging. The console shipping restraint shown in the photo should be used. 4) With the above steps completed and suitable equipment rated for 15,000lbs, the saw may be lifted as shown in the photo below When the machine is properly placed, the restraints must be removed before attempting to use the saw. They should all be kept in a safe place for future use. 1) The head fixed at 90 0 with ONE 3/4" bolt. 2) Lift strut & anchor weldment installed. The lifting lug on the top of the head is placed so that the machine is balanced when all of the shipping restraints are installed. 3) Operator console shipping restraint installed. Pg 5 S a

13 FOUNDATION, LEVELLING AND ANCHORING Machine location should be carefully selected. A flat concrete floor 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 levelled in both directions of the table, especially when the machine is to be inserted into a larger conveyor system. Six levelling screws and feet are provided. As built, the machine is stable without anchoring. If desired, lag bolts may be installed through the leveling bolts and pads. NOTE: In some cases, levelling the saw infeed and any infeed conveyors 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). Levelling screws and feet GENERAL INFORMATION This machine has been built to the customers rquirements, however, if any voltage changes are required, refer to the information in the Electrical System section and then consult Hyd. Mech Service department before implementing any changes. NOTE: 1)The PLC is equipped with a lithium battery to keep the program stored while the power is shut down. The battery will need to be replaced every 3 to 5 years, depending on usage. A visual warning will be displayed on the interface when the battery drains to a certain level. Battaries can be purchased through your Hyd. Mech Distibutor. 2) If the machine is equiped with an inverter, do not turn disconnect on for 3 three minutes after disconnect has been shut off. Cycling power sooner than 3 minuets will result in damage to the Variable Frequency Drive. EARTH GROUNDING PROCEDURE 1. Customer to provide and install a ground rod approx..60 (15mm) diameter, copper clad steel, to be driven no less than 8 (2.5m) into the ground, no more than 10 (3m) away from control enclosure. 2. Ground rod to be connected to customer s in plant ground system. This connection shall be made directly at the ground rod. (If applicable). 3. It is desirable that the overall resistance to ground measured at the ground rod does not exceed 3 ohms. Customer is advised to consult local power company for further information on grounding. 4. Ground rod to be connected to ground terminal in control enclosure using insulated, stranded copper wire. The correct wire size is shown below. Machine FLA 5A 10A 20A 30A 40A Wire Size AWG An additional point to check is ensuring continuity of ground within control enclosure. Start with main power entrance ground terminal where internal ground conductors should originate and connect to, DIN terminal strip, control transformer and the lid of control enclosure. Also PLC and Interface units should have their own ground conductors connected to one of the main ground terminals. 6. Properly functioning ground system will; - provide safety for personnel. - ensure correct operation of electrical/electronic devices. - prevent damage to electrical/electronic apparatus. - help dissipate lightning strikes. - divert stray radio frequency (RF) energy from electronic/control equipment. Pg 6 S a

14 POWER WIRING CONNECTIONS When the machine has been located and levelled the installation can be completed with the power hook-up. In order to provide safe operation and to prevent potential damage to the machine, only qualified personnel should make the electrical connections. The Supply Voltage and the Full Load Amperage of the machine is displayed on the serial plate. A Voltage Label is also affixed to the operator console. Connection from the Main supply is made to L1, L2, L3, and Ground of the Power Terminal Connection Block located inside the Operator panel. Hyd. Mech also recomends that an earth ground be installed on this machine. Because the console is designed to swing for service access, use flexible conduit passing close to the console pivot point. Check for signs of damage to the electrical cables from shipping or installation. Check for the CORRECT PHASE ORDER, hydraulic system pressure should start to rise almost immediately upon pressing the Hydraulic Start button. If there is no pressure registering, SHUT THE MACHINE DOWN IMMEDIATELY! Running the machine with the phases incorrect will cause damage to the systems. Any two of L1,L2 or L3 connections should be reversed from the main supply to correct. Ground & L1, L2, L3 terminals. Location of the main power line terminals inside the operator control console. Pg 7 S a

15 CUTTING FLUID The S-35P 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 on 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. The coolant used can be poured anywhere into the chip tray below the table. The coolant tank is shipped with the machine and must be p[laced under the lip at the idler end of the base tray. HYDRAULIC OIL As shipped, the saw oil tank is filled with Texaco Rando HD 46 hydraulic oil. If you want to change the hydraulic oil or the brand of oil, see HYDRAULIC MAINTE- NANCE. Oil Level Gauge and Filler Cap on the front of the operator console. Pg 8 S a

16 SECTION 2 OPERATING INSTRUCTIONS SECTION 2 - OPERATING INSTRUCTIONS

17 SECTION 2 - OPERATING INSTRUCTIONS

18 OPERATING INSTRUCTIONS This detailed description has been prepared to give the operator the ability to set up the saw for most cutting situations. The saw is equipped with 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 S-35P) 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 1/4 of the feed rate and increase gradually over 2 or 3 cuts. (It is also advisable to utilize a slow blade speed.) These two or three 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, 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 Blade Changing in the Maintenance section) 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. (Saw Cutting Parameters: Step 2) 5. The proper blade speed must be selected. (Saw Cutting parameters: Step 4) 6. The proper feed rate must be applied. (Saw Cutting Parameters: Step 5) VARIABLE SPEED CONTROL Blade speed can be adjusted infinitely between 75 to 350 SFM (23 to 122m/min) (Surface Feet/Minute). The blade speed is controlled with a dial on the control panel, and the actual speed in Feet/Minute is displayed on the PLC interface whenever the speed is changed or when Feed Rate/Blade Speed acreen is selected with + button on the interface. Blade speed dial on the control panel. Pg 9 S a

19 THE CONTROL CONSOLE START-UP The S-35P control console has been designed to simplify the operation of the saw, to give the operator the ability to stop any function at any time, and to be able to control all the functions from the control console. We can not overstress the importance of familiarizing yourself with the controls of the S-35P prior to starting the machine. The operation of the S-35P is completely handled at the operator control panel. All of the manual function operation switches, the hydraulic controls, the saw controller, and the coolant flow knobs are located on the control console. All of the controls are described in detail on the following pages. The console is hinged to allow the operator to set its position depending on the job requirements. To activate the controls, check that the EMERGENCY STOP button is pulled out, press the HYDRAULIC START button and hold it in until the PLC interface displays the software revision number. At this point, release the HYDRAULIC START button, the hydraulic system will be running and the control panel is activated. Operator Control Console. Pg 10 S a

20 OPERATOR PANEL SWITCHES EMERGENCY STOP - This mushroom button stops the blade and hydraulic motors. The vise will hold it's position but, pressure will begin to fall off. Long pieces of work should always be supported so they will not become loose over time and fall while the machine is shut down. BLADE STOP BUTTON - Stops the blade. TOP ROW BUNDLING VISE - This optional switch has three positions, CLOSE, OPEN, and HOLD (at the center & unlabeled). In CLOSE, the vise will close all the way, or until it encounters enough resistance to stop it. With the switch held in the OPEN position the vise will open all the way or until the switch is released. With the switch in the HOLD position, the vise will stay where it is and will not move freely although it will not resist a large force indefinitely without creeping. CONTROL FUSE - This 10amp normal acting fuse protects the control circuits and the coolant pump. If this fuse is blown, it will become illuminated. To replace the 10 amp fuse, press in and turn counter clockwise. The fuse and cap are spring loaded. CONTROL FUSE - This 2amp instant acting fuse protects the PLC. If this fuse is blown, it will become illuminated. To replace the 2 amp fuse, press in and turn counter clockwise. The fuse and cap are spring loaded. HYDRAULIC START - To activatye the hydraulic system, the switches for the head and vises must be in the "NEUTRAL" position. The "HYDRAULIC START" button must be depressed and held in momentarily until the PLC interface displays the software revision number. The button will become illuminated when the hydraulic system is activated. SECOND ROW BLADE START - The blade can be started only when the hydraulics are running. NOTE: In automatic Mode the head will not descend until the blade has been started. BLADE SPEED - This dial will increase or decrease the blade speed. The speed limits are 75 to 350 S.F.M. The blade speed is displayed on the PLC interface. THIRD ROW MAIN VISE - This switch has three positions, OPEN, CLOSE, and HOLD (at the center & unlabeled). With the switch held in the OPEN position the vise will open all the way or until the switch is released. With the switch in the HOLD position, the vise will stay where it is and will not move freely although it will not resist a large force indefinitely without creeping. In CLOSE, the vise will close all the way, or until it encounters enough resistance to stop it. See also HYDRAULIC FEED CONTROL for variable vise pressure. GUIDE ARM - This switch controls the position of the idler (left) guide arm. It is always advisable to have the distance between the guide arms as close as possible to the material width. Pg 11 S a

21 PECK CYCLE - Pressing this button once enables the PECK CYCLE and becomes illuminated. Pressing it again disables the cycle. This function is usefull when cutting large i beams where internal stresses in the work piece may cause the cut to close up and grab the blade. When the PECK CYCLE is enabled, it will sense when the blade is about to jam and move the head up about 3/4" and then continue with the cut. LASER GUIDE - This optional switch will turn the laser sight guide on and off. BOTTOM ROW THIRD ROW SQUARE VISE - This optional switch has three positions, OPEN, CLOSE, and HOLD (at the center & unlabeled). With the switch held in the OPEN position the vise will open all the way or until the switch is released. With the switch in the HOLD position, the vise will stay where it is and will not move freely although it will not resist a large force indefinitely without creeping. In CLOSE, the vise will close all the way, or until it encounters enough resistance to stop it. COOLANT - This switch has three positions, WASH, ON and OFF. Set to WASH, there is a constant flow of coolant, set to OFF, there is no coolant flow. Set to ON, the coolant will flow only when the head is descending. The coolant flow adjustment knobs are located on the side of the operator control panel, see page 2.9. The Wash gun and hose have a hanger beside the three adjustment knobs. FEED FORCE LIMIT - The Feed Force Limit SETTING button is to be held depressed while adjusting the Feed Force Limit. Refer to "HYDRAULIC FEED CONTROL" on the following page. HEAD - This switch has three positions: UP, HOLD and DOWN. In the UP position, the head will rise until it reaches the head up limit if the limit has been set or the maximum height. In the HOLD position the head will stay still but there may be some creeping down over time. In the DOWN position the head will descend until it reaches the bottom of the stroke. The speed of descent is controlled by the Feed Rate and Feed Force Limit controls. HEAD SWING 90 o - This is a two position push button. By pressing the button in partially, the head will SLOWLY swing towards the 90 o position until it reaches 90 o or the button is released. This allows for a fine adjustment in the cut angle. If pressed fully in, the head will swing at a FAST rate. NOTE: The HEAD switch must be in the "HOLD" position for this button to operate. HEAD SWING 30 o - This is a two position push button. By pressing the button in partially, the head will SLOWLY swing towards the 30 o position until it reaches 30 o or the button is released. This allows for a fine adjustment in the cut angle. If pressed fully in, the head will swing at a FAST rate. NOTE: The HEAD CONTROL switch must be in the "HOLD" position for this button to operate. FAST APPROACH - By depressing this button, the head will descend at an accelerated rate when the head is moving down. This button is inactive except when the HEAD switch is in "DOWN". HEAD UP LIMIT - Turning this switch clockwise will illuminate it and activate the head height limit at the current head height. Refer to the Operator Interface Instructions. Pg 12 S a

22 KERF CORRECTION When making mitred cuts, the part length must be set longer than the desired length by an amount we will call the "KERF CORRECTION". This is due to the fact that the PLC does not account for a difference in the kerf value at various angles. The standard kerf and corrected values are as follows: STD 90DEG " BLADE COOLANT FLOW CONTROL The S-35P has been designed to ensure that adequate coolant can be applied to the cutting surfaces. The adjustible guide arm has an integral coolant flow design that delivers coolant to the blade at the point where the blade contacts the stock. The coolant flow adjustment knobs are located on the side of the Operator control panel. The Wash gun and hose have a hanger beside the three adjustment knobs. The S-35P is equipped with a portable coolant nozzle that can be attached to metal surfaces. It is shown mounted on the head cylinder in the photo but can be moved to the most convenient location as different materials are being cut. The magnetic force can be turned On and Off with the lever on the base of the unit. Shown below are two addition coolant bars for placement on top of materials to be cut. Coolant Bars can be placed on top of materials for extra coolant coverage. Flow is controled with the dials labeld "FLEX HOSE". Pg 13 S a

23 VARIABLE VISE PRESSURE The variable vise pressure option allows the vise clamping pressure to be adjusted to protect some weaker material that might be deformed at full system pressure. OPTIONAL CUT LINE LASER SIGHT This laser is used to show where the blade will fall on the material to be cut. This is done with a red laser beam which is approximately.030" wide that can be placed on either the infeed or out feed side of the blade. This is particularly useful when cutting angles on structural materials. There will be a control switch on the operator panel. Laser Unit 1049 LASER RADIATION DO NOT STARE INTO BEAM LASER DIODE 1.0 MILLIWATT MAXIMUM OUTPUT CLASS II LASER PRODUCT Warning label found on front of head and on laser cover at rear. Laser Information: - Wave length is 635nm (+ 5nm). - Voltage is supplied by an adaptor at 6VDC, 100mA nominal. The laser mounted above the drive guide arm. NOTE: In order to lengthen the life of the light, this unit should be shut off when not actually aligning a cut line. Pg 14 S a

24 OPERATOR PLC INTERFACE The Operator Interface is a small panel with LCD display and a membrane keypad. As supplied, only the + key and & keys are functional. A small PLC ( programmable logic control ) is contained within the operator console. Its purpose is to control head up limit setting, the peck cycle, and to process information about the saw s operation for display to the operator. The PLC attempts to always show the most appropriate screen. The default screen, and the one which appears after hydraulic power is first turned on, shows blade height and mitre angle. When either the blade motor is started or head down is selected, the screen showing feed rate and blade speed appears. When the head reaches the full down position, the elapsed time is displayed. When head up is selected, the head height and angle re-appears. If a preset Head Up Limit is reached, it is displayed. The automatic screen selection can be over-ridden by scrolling through the 4 different screens using the + key. 1. HT - Displays Height of blade above the table, at the datum vise jaw,in inches & a = Displays Head angle (mitre angle) in degrees. 2. FR- Displays Feed Rate in inches per minute. Shows rate for a point on the blade 20" out from the datum vise jaw. Datum end rate is 20% lower. Outer end rate is 20% higher & SFM- Displays blade speed in Feet/Minute. 3. A - TIME ELP Displays elapsed time in minutes, since the Head started descending with the blade running. B - Time REM Displays predicted time until the end of the cut, in minutes. 4. Hd UP LIM Displays the current setting for the Head Up Limit, in inches, at the Datum Vise jaw. 0.0 indicates that no limit has been set, and the Head can rise to full capacity. 5. Constant XXXX This is a parameters screen which is factory set and machine specific. This should not be changed. Call Hyd. Mech Service for assistance in changing. Count This displays the head angle position in encoder pulses. 0 should be displayed when the head is at 90 O. If any other number is displayed, call Hyd. Mech service for assistance. 6. BLADE STALL This indicates that the blade has stopped due to excessive resistance. This cannot happen during a Peck Cycle. In other modes, if this occures, raise the head and reduce the Feed Force before continuing the cut. When the stall conditions have been removed, the display defaults to the height & angle screen. BLADE STALL Pg 15 S a

25 HYDRAULIC FEED CONTROL The Hydraulic Feed Control of the S35P requires the operator to make two settings; the Feed Force Limit, and the Feed Rate ( which would be better called Feed Rate Limit ). The Feed Rate Setting controls the maximum rate at which the blade will descend. This is the actual rate when the blade is descending through air, or is cutting fairly narrow cross-sections (for example, the flanges of even very large beams).the Feed Rate Setting is controlled by a black plastic valve knob on the control console. Although the knob has graduations from 0 to 10, setting is best achieved by increasing slowly from 0, with the Head Selector Switch set to Down while observing the resulting feed rate displayed on the Operator Interface in the format FR = x.x. Determining the correct Feed Rate to set is covered in the section How To Cut. The Feed Force Limit controls, or limits, the maximum amount of force that the guide arms can exert on the blade. Imagine the saw blade descending towards an I - beam workpiece. Until the blade contacts the work, there is practically no force applied to it by the guide arms. When the blade starts to cut the beam flanges there will be some resistance, but the feed force required to maintain the set Feed Rate Limit will still be fairly low because the cross-section of metal being cut is small. However, as the blade descends to the level of the web, the amount of metal being cut increases dramatically, and the Feed Force required to maintain the set Feed Rate increases proportionately. A correctly set Feed Force Limit will prevent the crooked cuts which result from excessive feed force, by slowing the actual feed rate whenever the blade meets too much resistance. The Feed Force Limit on the S-35P is set somewhat differently than on other Hyd. Mech machines. The head is raised above the saw table, and the Head Selector Switch set to Hold. Then, with the yellow Feed Force Limit Setting button depressed, the Feed Pressure Gauge will display the actual limit setting, which can be adjusted by the brass coloured valve knob. Determining the correct Feed Force Limit to set is covered in the section How To Cut. CUTTING PARAMETERS There are five steps for the operator to follow in order to achieve optimum performance of the saw. PARAMETERS EXAMPLE #1 We will use the chart to set up the saw for cutting 8" (200mm) Diameter #1045 Carbon Steel. STEP 1 DETERMINE EFFECTIVE MATERIAL WIDTH - W ( inches ) or (mm) The hydraulic controls as described above. Effective material width, W (in.) for most common shapes of materials, is the widest solid part of the material to be in contact with blade during cutting. For simple shapes, this can be directly measured. For bundles of tubes and structurals, measuring the effective width is difficult. Effective width is 60% to 75% of the actual material width. Material Width Chart NOTES: 1) Both effective material width and guide arm width are used in setting the saw. 2) Guide arm width is the distance between the guide arms and is used in STEP 2. 3) Effective material width, as determined here in STEP 1, can be thought of as the average width of material seen by each tooth, and it is used in STEPS 3 and 4. In Example #1, for an 8" (200 mm) diameter solid, Effective Material Width is 8" (200mm). Pg 16 S a

26 STEP 2 SET FEED FORCE LIMIT The Feed Force Limit is the maximum amount of force withwhich the head is allowed to push the blade into the workpiece. The purpose of this limit is to protect the blade from deflecting laterally and causing a crooked cut. The maximum feed force that a blade can accept without lateral deflection depends upon blade width, thickness, and tension, and upon guide arm spacing. The S-35 uses only 2 inch blades, and is set up for the more popular.062 blade thickness* and blade tension is factory preset for these blades. Thus, from the operator s point of view, the correct Feed Force Limit depends only upon guide arm spacing. The chart gives the relationship between guide arm spacing and Feed Force Limit. Note that the Limit is given in psi because this is what the Feed Pressure Gauge displays. The formula used is: Feed Force Limit [psi] = / Guide Arm Spacing [ in.] Note that it is possible to use.050 thick blades but it requires that the blade guides be adjusted, see Section 3, Maintenance. For occasional use no other adjustments are required, but for optimum blade life a 20% reduction in band tension, and Feed Force Limits would be required. The actual setting of the Feed Force Limit is covered in the preceding Operation Section. SIGNIFICANCE OF GAUGE READING With the head raised and the yellow Feed Force Setting button *8,'(Ã$50Ã63$&,1*Ã>ÃLQ@ depressed, the Feed Pressure Gauge will show the current setting of the Feed Force Limit. During cutting, the gauge shows the sum of the hydraulic pressures being exerted on the top blade guides in the two guide arms. The total force exerted on the blade, in pounds, is about 1/2 the gauge pressure in psi. In typical cutting situations, the needle on the gauge will rise towards the preset FEED FORCE LIMIT and stabilize, usually at a lower level. If the material being cut is very hard or wide, the needle may rise all the way to, but will not exceed the preset FEED FORCE LIMIT. When cutting soft materials and or narrow cross sections, the gauge reading may be low, but the FEED RATE will be maintained. Any changes during cutting, such as, material hardness or material cross sections will influence the gauge readings. Therefore, in some cutting situations the gauge reading may rise and fall. A very low gauge reading is usually observed when the blade is approaching the material to be cut, but not yet cutting. L@ V S Ã>,7,0 Ã/ ( & 5 2 Ã) ' ( ( ) STEP 3, 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. The sketch can be referenced for the blade pitch changes for differing effective 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. Allowance for the use of a non-optimum blade is made in STEP 5. Optimum Blade Pitch ( T.P.I. ) In our Example #1 : Effective material width of 8" (200 mm) & Optimum blade has 2/3 teeth per inch Continued ---- Pg 17 S a

27 STEP 4, DETERMINE OPTIMUM BLADE SPEED, V (ft/min) (m/min) The relationship between optimum blade speed and effective material width for various materials is represented on the graph shown. The graph shows that as effective material width gets wider or as material gets harder, lower blade speeds are recommended. If material is narrow or soft, higher blades speeds should be selected. In Example #1-8" (200mm) diameter #1045 Medium Carbon Steel solid bar is to be cut. - On the graph above find the Medium Carbon Steel Curve which Optimum Blade Speed Curves represents the optimum blade speeds for 1045 Carbon Steel. - On the horizontal axis (effective material width axis) find number 8 which represents effective material width of an 8" (200mm) diameter solid. - Find the point where a vertical line from 8" (200mm) intersects the Medium Carbon Steel Curve. - From this intersection point run horizontally left to the vertical axis (optimum blade speed axis) and find the point marked 200. For 8" (200mm) diameter, 1045 Carbon Steel solid bar 200 ft/min (60m/min) is the optimum blade speed. NOTE: 1) Higher than optimum blade speed will cause rapid blade dulling. Lower than optimum blade speeds reduce cutting rates proportionately and do not result in significantly longer blade life except where there is a vibration problem. If the blade vibrates appreciably at optimum speed as most often occurs with structurals and bundles, a lower blade speed may reduce vibration and prevent premature blade failure. 2) Material Hardness - The graph above illustrates blade speed curves for materials of hardness 20 RC (225 Bhn) or lower. If the material is hardened then the multipliers need to be used. These multipliers are given in the NOTE at the bottom right of the graph. As the hardness increases the optimum blade speed decreases. The following table gives examples of the optimum blade speeds for different materials. NO. MATERIALS OPTIMUM BLADE SPEED ft/min m/min 1 5" (125mm) Dia Solid Carbon Steel " (300mm) I-Beam " x 4" (100 x 100mm) Rec Tube, 1/4" (6mm) Wall "(100) 400 Stainless Steel " x 2" (50 x 50mm) Rec Tube 1/4" (6mm) Wall Bundle 5 x 5pcs 10" x 10" (500 x 500mm) " x 3" (75 x 75mm) Inconel Materials and Blade Speed Pg 18 S a

28 STEP 5, DETERMINE FEED RATE SETTING, FR (in/min) (mm/min). FEED RATE is the vertical speed at which the blade descends through the work piece. The FEED RATE Knob controls FEED RATE of the blade descent in the range 0 to 15 in/ min (380mm/min). The FEED RATE should be adjusted only in one direction (from O to required value). If you go too far, go back to O and come back up. To set FEED RATE for particular cutting situations use the Graph below, which represents the relationship between FEED RATE, blade speed and blade pitch. Feed Rate Calculation For Example #1, it is known from Step 3 that optimum blade pitch is 2/ 3, and from Step 4 that blade speed, Feed Rate Knob is 200 ft/min (60mm/min). From the Graph on the left, the FEED RATE is determined in the following way: - On the horizontal axis (blade speed axis), find 200 ft/ min(60mm/min). - Find the point where a vertical line from 200 ft/min (60mm/min) would intersect the 2/3 blade pitch curve. - From this intersection point run horizontally left to the vertical (FEED RATE) axis, to arrive at 1.8 in/min (45mm/ min) FEED RATE. Thus 1.8 in/min (45mm/min) is the FEED RATE for cutting 8" (200mm) diameter 1045 Carbon Steel when the optimum 2/3 pitch blade is used. If the saw is fitted with a blade coarser than optimum (e.g.. 1.4/2.5 TPI) we can still use the graph, but we go to the 1.4/2.5 curve. As a result we find that the FEED RATE is decreased to 1.3 in/min (133mm/min) for this blade. If however, the machine is fitted with a finer than optimum blade (e.g. 3/4 TPI) we use the graph for the optimum blade as before, and then use a multiplier given by the table below. NOTE: Use the following chart when cutting solids. For structurals, see "CUTTING STRUCTURALS" in STEP 2. Optimum versus Actual Blade Pitch ---- Continued ---- Pg 19 S a

29 ADDITIONAL CUTTING SETUP EXAMPLES EXAMPLE # 2 Material Round Steel Tube SAE Hardened to 35 RC ( 325 Bhn ) Dimensions - 6" O.D. x 4" I.D. (150mm O.D. x 100mm I.D.) STEP I Effective Material Width: 4 1/2" (.75 X 6) 114mm (19 x 6) STEP 2 Feed Force limit setting for 6" Diameter material Refer to Feed Force Limit, Setting in Step 2 STEP 3 Optimum blade pitch (TPI): 3/4 T. P. I. Actual blade pitch on the saw: 4/6 T. P. I. STEP 4 Optimum blade speed for 4 1/2" effective 225 ft/min (70m/min) material width Blade speed reduced by hardness factor : 225 ft/min X.60 = 135ft/min (70m/min x.60 = 42m/min) STEP 5 Feed Rate for 3/4 TPI blade: 1.8 in/min (45mm/min) Feed Rate for 4/6 TPI blade: 1.8 in/min X.70 = 1.3in/min (reduced by finer than optimum blade pitch factor) (45mm/min x.70= 31.5mm/min) EXAMPLE # 3 Material Bundle - Low carbon steel 2" x 2" Tube with 1/4" wall, 12 piece bundle (50mm x 50mm with 6mm wall) Dimensions - 6" x 8" (150mm x 200mm) STEP I Effective Material Width: 5" (.6 X 8" ) 120mm (.6 x 200) STEP 2 Feed Force limit setting for 8" Diameter material. Refer to Feed Force Limit, Setting in Step 2 STEP 3 Optimum blade pitch (TPI): 3/4 T. P. I. STEP 4 Optimum blade speed for 5 " effective material width ft/min (100m/min) STEP 5 Feed Rate for 3/4 TPI blade: 4.0 in/min (100mm/min) Pg 20 S a

30 SECTION 3 MAINTENANCE AND TROUBLE SHOOTING SECTION 3 - MAINTENANCE AND TROUBLE SHOOTING

31 SECTION 3 - MAINTENANCE AND TROUBLE SHOOTING

32 MAINTENANCE AND TROUBLE SHOOTING BLADE BRUSH ADJUSTMENT The blade brush, located behind the drive wheel door, is properly set when the machine leaves the factory, but it wears out during operation and needs to be readjusted periodically. The plastic drive wheel that is driven by the drive wheel face should be held against the blade face with the minimum force that is necessary. As the blade brush wears it is necessary to periodically adjust it closer to the blade or if a new brush is installed, further away from the blade. As shown, there are two springs on socket head screws holding the brush assembly gainst the blade. There is also an adjusting socket set screw with a hex nut on it. Loosen the hex nut with a 9/16" wrench and turn the set screw counter clockwise with a 3/16" allen key. This will move the brush closer to the blade. Adjust the set screw so that the brush cleans to the bottom of the blade gullets and tighten the hex nut.blade WHEEL TIRES The S-35P has a polyester belt on the idler blwheel. This is intended to reduce vibration in the machine while cutting. As it must be replaced occasionally, there should always be a spare on hand. Refer to page 6.9 for the idler wheel assembly and part numbers. Adjusting setscrew and hex nut. BLADE CHANGING PROCEDURE 1. Stop the blade. 2. Raise the Head so that the Idler wheel door clears the vise cylinder. 3. Open the Idler and Drive doors. 4. Lift the upper blade guard (found between the two wheel doors). The lifting handle is shown in the photo. 5. Lower the Idler wheel box bottom (found on the front of the saw) by loosening the grip handle shown below. The grip handle is shown in the photo. 6. Turn the blade tension switch (found behind the idler wheel door) to "OFF". 7. Turn the blade guide locking handle on both guide arms counter clockwise as shown. 8. Pull the blade off of the Ilder and Drive wheels. 9. Push the blade down and out from between the carbide blade guides in the guide blocks. 10. Remove the blade Continued ---- Pg 21 S a

33 11. Prepare to install the new blade. Observe that the blade teeth point in the direction of the wheel rotation. ( Clockwise when viewed from the rear of the saw ) NOTE: 1) Always wear gloves! 2) It may be necessary to "turn" the blade inside out. 12. Install the new blade loosely over the two wheels - using the "ON" and "HOLD" positions of the blade tension switch to put just enough tension on the blade to hold it. 13. Twist the blade and insert it into the two guide blocks. 14. Using a block of wood against the blade teeth, push the blade onto the wheels so that the blade teeth project fully out from the wheel faces. 15. Switch the blade tension switch to the "ON" position. 16. Close the upper blade guard. 17. Close the Idler wheel box bottom to its normal position and tighten the grip handle. 18. Shut both the Idler and Drive doors. 19. Turn both blade guide locking handles to the vertical position. NEW BLADE BREAK-IN 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 1/4 feed rate and increasing gradually over the two or three cuts. (It is also advisable to utilize a slow blade speed.) 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, accuracy, and blade life. LUBRICATION REQUIREMENTS The S -35P was designed to minimize the maintenance requirements and service downtime. In addition to grease points shown, the vise(s), infeed rollers & chain (if the machine is equipped with them) should be greased monthly. Vertical pivot grease nipple. The head must be swung away from Horizontal pivot grease Two grease nipples on the blade tension slide Pg 22 S a

34 HYDRAULIC MAINTENANCE There are only FIVE items of routine maintenance associated with the hydraulic system. 1. OIL FILTER - Ten micron filtration of the hydraulic oil is provided by a spin on type filter mounted on the tank return line. The element should be changed after the first 50 Hours of operation and then every 500 working hours. Suitable replacement elements are: CANFLO RSE GRESEN K PARKER ZINGA AE OIL LEVEL - Oil level should be maintained in the upper half of the level gauge. Normally the rate of oil consumption will be very low and it should be unnecessary to add oil more often than at filter changes. Add oil only to the top line on level gauge. The S-35P is shipped from the factory with Texaco Rando HD 46 hydraulic oil. Generally any brand of recognized mineral hydraulic oil with the same properties should be compatible with Rando HD46, but to avoid any risk we suggest staying with Rando HD 46. If it is desired to change brands, it is necessary to drain the tank and 1/ 3 refill it with the new oil, operate through several full strokes of each cylinder, drain the tank again, and finally fill the tank with the new brand. Hydraulic tank capacity is approximately 11 US gallons (42 L). Recommended replacement oils for Texaco Rando HD 46: Chevron AW Hydraulic Oil 46 Esso NUTO H46 Mobil Mobil DTE 25 Shell Tellus OIL TEMPERATURE - Oil temperature is indicated by a thermometer contained in the level gauge. Oil temperature during steady operation should stabilize at about F ( C ) above room temperature. Thus in a 70 F (20 C) shop one might expect an oil temperature of about 120 F (50 C) Oil temperature should never exceed 160 F (70 C) 4. OIL PRESSURE - Oil pressure is factory set to 1100 PSI and should not require further attention except precautionary observation at start-up and every few days thereafter. 5. BLADE TENSION - Is preset (1050psi) at the factory and should under normal conditions not require attention. CLEANLINESS The S-35P heavy duty design should endure heavy operating conditions and provide the customer with flawless machine performance. To extend good performance some care is required especially as cleanliness is concerned. The following areas should be kept clean: - Control console free of dirt and grease. - Encoder wheel areas. - Door charts free of dirt and grease. - Wheel boxes free of chips. - Blade guides free of chips. - Outfeed table free of chips. - A large chip build-up should be avoided in the base of the saw. NOTE: All parts must be cleaned before any repair service can be performed on them. Pg 23 S a

35 TROUBLE SHOOTING Most problems which may occur have relatively simple solutions which appear in this section. If the solution is not found here, contact the Hyd-Mech Distributor from whom you purchased your bandsaw. They have trained field service personnel who will be able to rectify the problem. PROBLEM 1. Saw is cutting out of square vertically. 2. Saw is cutting out of square horizontally. 3. Blade comes off wheels. 4. Blade stalls in cut. 5. Blade vibrates excessively. 6. Excessive blade breakage. 7. Tooth strippage 8. No coolant flow. PROBABLE CAUSE 1a. Blade dull. 1b. Tension off 1c. Blade guides lose or worn. 1d. Excessive feed rate 2. Stock not square in vises. 3a. Not enough blade tension. 3b. Improper tracking. 4a. Not enough blade tension. 4b. Excessive feed force. 4c. Excessive feed rate. 5a. Blade speed too fast. 5b. Guide arms too far apart. 5c. Not enough blade tension. 6a. Excessive blade tension. 6b. Excessive feed rate. 7a. Blade pitch too fine. 7b. Blade brush not cleaning. 7c. Excessive feed rate. 7d. Excessive feed force. 8a. No coolant. 8b. Coolant line blocked. 8c. Coolant pump inoperable. SOLUTION 1a. Change blade. 1b. Turn blade tension switch to ON. 1c. Turn guide handles fully clockwise. 1d. Check for proper cutting parameters 2. Adjust accordingly. 3a. Tension blade. 3b. Set tracking. 4a. Tension blade. 4b. Reduce. 4c. Reduce. 5a. Reduce. 5b. Adjust accordingly. 5c. Tension blade. 6a. Reduce blade tension. 6b. Reduce. 7a. Install a coarser pitch blade. 7b. Adjust or replace blade brush. 7c. Reduce. 7d. Reduce. 8a. Add coolant. 8b. Blow out coolant line. 8c. Check, replace if necessary. Pg 24 S a

36 PROBLEM 9. Saw will not start. 10. Saw starts but will not run after Start button has been released. PROBABLE CAUSE 9a. Control circuit fuse has blown. 9b. Vise or head selector switch not in the center (neutral) position. 10. On machines so equipped, the out-of-stock or blade breakage limit switch has been tripped. SOLUTION 9a. Replace the fuse on the control panel. Random blowouts may occur but a quickly repeated blowout points to an internal wiring fault. 9b. Turn all switches to the center (neutral) position 10. Reload with stock or re-mount blade. Hold the hydraulic start button and release the blade tension or open vises far enough to deactivate the limit switch. 11. Saw starts but no hydraulic functions. 11a. If blade wheels run clock wise, wrong phase order in power connection to saw. 11b. If pump is noisy cause may be low hydraulic oil level. 11c. Pump-motor coupling has separated. 11a. Stop immediately; reverse any two of the three phase connections. 11b. Stop immediately, add hydraulic oil. 11c. Adjust accordingly. Pg 25 S a

37 SERVICE RECORD & NOTES DATE SERVICED BY COMMENTS Pg 26 S a

38 SECTION 4 ELECTRICAL SYSTEM SECTION 4 - ELECTRICAL SYSTEM

39 SECTION 4 - ELECTRICAL SYSTEM

40 ELECTRICAL SYSTEM Electrical shock / electrocution. Contact with high voltage will cause death. Never perform any maintenance on or near electrical components until the machine s power source has been disconnected. Lock out power before servicing. The only way to be sure the machine s electrical circuits are safe is to turn off the machine s power supply at your facility s circuit panel and lock it out. The All Stop push-button does not disconnect the machine s power supply. Hazardous electricity is still present in the machine s electrical circuits. The machine s main electrical disconnect switch will remove electricity from the machine s circuits, however, deadly voltage is still present inside the main electrical panel at the infeed (line) side of the main fuses. Keep hands and tools away from the top of the electrical panel s main fuses. Never spray coolant directly at electrical components or junction boxes. GENERAL INFORMATION The power connection to the machine is made to the L1, L2 and L3 terminals of the junction block located in the main control box. The S-35P is set to run on three phase voltage as indicated on the serial plate and the voltage label. INITIAL STARTUP At initial hook-up it is important to check that the phase order is correct. This is indicated by the blade drive wheel revolving in a counterclockwise direction when viewed from the front of the machine and the hydraulic pressure gauge registering an immediate pressure rise. NOTES: Ø The PLC is equipped with a lithium battery to keep the program stored while the power is shut down. The battery will need to be replaced every 3 to 5 years, depending on usage. A visual warning will be displayed on the interface when the battery drains to a certain level. Batteries can be purchased through your Hyd. Mech Distributor. Ø If the machine is equipped with an inverter, do not turn disconnect on for 3 three minutes after disconnect has been shut off. Cycling power sooner than 3 minutes will result in damage to the Variable Frequency Drive. Ø All of the machines equipped with a Mitsubushi PLC have a snap on Ferrite core on the interface cable. This is placed near the interface in order to reduce "noise". Ø Hyd. Mech also recommends that an earth ground be installed on this machine. Pg 27 S a

41 ELECTRICAL COMPONENTS LISTS LIST OF S-36P ELECTRICAL COMPONENTS Item Code as on S36P Schematic Description Part Number Component Manufacturer 1PB-Emergency Stop Push Button 2PB-Hydraulic Start Push Button 3PB-Blade Stop Push Button 4PB-Blade Start Push Button 5PB-Feed Force Setting, Push Button 6PB-Selector Switch Head Up Limit Setting 7PB-Head Fast Approach Yellow Push Button 8PB-Peck Cycle, Push Button 9PB-Head Swing 30 Push Button 10PB-Head Swing 30 Push Button 1SS-Head Selector Switch 3SS-Main Vise Selector Switch Red mushroom head, latching push button. Mounting base with 1 N/C contact block. Green, illuminated, flush head push button. Light module with 1 N/O contact block plus 1 additional N/O contact block and 130V (BA9s) light bulb. Black, non-illuminated, flush head push button. Mounting base with 1 N/O contact block. Green, illuminated, flush head push button Light module with 1 N/O contact block and 130V (BA9s) light bulb. Yellow, lfush push button Contact body c/w 1N/O & 1N/C blocks Amber, illuminated, 2 positions Spring return,c/w 1 N/O block 130V (BA9s) light bulb. Yellow, flush pushbutton c/w1 N/O contact block. Amber, illuminated, pushbutton with illuminated body c/w 1 N/O contact block Light bulb - BA9S 130V. Pendant ( 2 step ) pushbutton with 2 speed contact block. Pendant ( 2 step ) pushbutton with 2 speed contact block. Black, 3 position maintainedselector switch with 1 N/O contact block Contact body-c/w 2N/O blocks Black, 3 position spring return from left to center & 1 position maintained to right s/s. Mounting base with 1 N/O contact block plus 1 4SS-Guide Arm Black, 3 positions, spring return l/r selector Selector Switch switch. Mounting base with 2 N/O 5SS-Coolant Selector Black, 3 positions, maintained selector switch. Switch Mounting base with 2 N/O contact blocks. 6SS-Blade Tension Black, 3 positions, maintained selector switch. Selector Switch Mounting base with 2 N/O contact blocks and Mounted in plastic enclosure (black/yellow). 11SS-Bundling Vise Selector Switch 12SS-Aux. Vise Selector Switch 13SS-Laser Guide Selector Switch OPTIONS Black, 2 position maintained selector switch Contact body-c/w collar and 2 N/O blocks Black, 2 position maintained selector switch Contact body-c/w collar and 2 N/O blocks Black, 2 position maintained selector switch Contact body-c/w collar and 2 N/O blocks Pg 28 S a ZB2 BT4 ZB2 BZ102 ZB2 BW33 ZB2 BW061 ZB2BE101 SP105 ZB2 BA2 ZB2 BZ1021 ZB2 BW33 ZB2 BW061 SP105 ZB2 BA5 ZB2 BZ105 ZB2 BK125 ZB2 BW061 SP105 ZB2 BA5 ZB2 BZ101 ZB2 BW35 ZB2 BW061 SP105 XAC B9212 XEN B1181 XAC B9212 XEN B1181 ZB2 BD3 ZB2 BE101 ZB2 BZ103 ZB2 BD7 ZB2 BZ103 ZB2 BE102 ZB2 BD3 ZB2 BZ103 ZB2 BD3 ZB2 BZ103 XALJ133 ZB2 BD7 ZB2 BZ103 ZB2 BD7 ZB2 BZ103 ZB2 BD7 ZB2 BZ103 Telemecanique Telemecanique Telemecanique Telemecanique Telemecanique Haskelite Telemecanique Telemecanique Telemecanique Telemecanique Haskelite Telemecanique Telemecanique Telemecanique Telemecanique Haskelite Telemecanique Telemecanique Telemecanique Telemecanique Haskelite Telemecanique Telemecanique Telemecanique Telemecanique Telemecanique Telemecanique Telemecanique Telemecanique Telemecanique Telemecanique Telemecanique Telemecanique Telemecanique Telemecanique Selectric Systems Telemecanique Telemecanique Telemecanique Telemecanique Telemecanique Telemecanique

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44 Description & (Item Code) as on schematic S35P POWER COMPONENTS for SPECIFIC VOLTAGES MACHINE VOLTAGE 3ph 208V 3ph 240V 3ph 380 3ph 415V 3ph 480V 3ph 575V Component Manufacturer Pg 31 S a 5HP HYDRAULIC PUMP MOTOR (1M) Frame Size 184TC, 1800 R.P.M. CONTACTOR (1M) LC1D1810G6 LC1D1810G6 LC1D1210G6 LC1D1210G6 LC1D1210G6 LC1D1210G6 AUX. CONTACT BLOCK (1M) LA1 DN20 LA1 DN20 LA1 DN20 LA1 DN20 LA1 DN20 LA1 DN20 THERMAL OVERLOAD (1 O/L) LR2D1321 LR2D1321 LR2D1312 LR2D1312 LR2D1312 LR2D1310 MOTOR F.L.A. ( 1750 RPM ) 14.1 A 12.8 A 8A 6.7 A 6.4A 5.1 A FUSE SIZE & FUSE HOLDER PART # (3FU1, 3FU2, 3FU3) INVERTER PART # & INPUT CURRENT FUSE SIZE & FUSE HOLDER PART # 30A T.D 6CC30S FR-A120E-7.5K-UL 37A 30A T.D 6CC30S FR-A120E-7.5K-UL 32A 15A T.D 6CC15S HP BLADE DRIVE MOTOR (2M) Frame Size WDA256T, 1200 R.P.M. (4FU1, 4FU2, 4FU3) 70A T.D AJT J 60A T.D AJT J FR-A140E-7.5K-UL 20.2A 40A T.D AJT J 15A T.D 6CC15S FR-A140E-7.5K-UL 18.5A 35A T.D AJT J 15A T.D 6CC15S FR-A140E-7.5K-UL 16A 30A T.D 6CC30S A T.D 6CC15S FR-A260E-7.5K- UL 11.4A 25A T.D 6CC25S Telemecanique Telemecanique Telemecanique Ferraz Mitsubishi Gould / Ferraz CONTROL TRANSFORMER (TR) 1000VA TRANSFORMER PART # (1TR) 9070 T1000D T1000D T1000D T1000D T1000D T1000D5 Square-D PRIMARY FUSE SIZE & FUSE HOLDER PART # (2FU1, 2FU2) 15A Fast Acting 6JX A Fast Acting 6JX A Fast Acting 6JX A Fast Acting 6JX A Fast Acting 6JX A Fast Acting 6JX Gould / Ferraz SECONDARY FUSE SIZE & FUSE HOLDER PART # (5FU) 10A T.D MDL 10 HKL 10A T.D MDL 10 HKL 10A T.D MDL 10 HKL 10A T.D MDL 10 HKL 10A T.D MDL 10 HKL 10A T.D MDL 10 HKL Buss LINE REACTOR PART # (480 & 575 VAC ONLY) MTE RL MTE RL MTE Corporation

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58 SECTION 5 HYDRAULIC SYSTEM SECTION 5 - HYDRAULIC SYSTEM

59 SECTION 5 - HYDRAULIC SYSTEM

60 HYDRAULIC SYSTEM The S-35P hydraulic system does not require any special work on a new machine before its start up. The hydraulic tank is filled with Texaco Rando HD46 hydraulic oil and all machine functions have been tested at the factory to ensure proper operation upon initial start-up. S-35P HYDRAULIC COMPONENTS LIST ITEM QTY S-35P PART NUMBER DESCRIPTION 1 2 S35-C31-00 VISE / GUIDE ARM CYLINDER 2 1 S35-C31-00 SQUARING VISE (OPTION) 3 1 S35-C4-00 HEAD CYLINDER 4 1 H20-C5-00 BLADE TENSION CYLINDER 5 1 S35-C7-00 SWING CYLINDER 6 1 S35-C23-00 BUNDLING CYLINDER (OPTION) 7 1 DU16D06PA2 FEED RATE VALVE 8 1 S A SUBPLATE BLK FOR FEED RATE V. 9 1 PRV1-10-K-6T-6 FEED FORCE VALVE 10 1 PRV1-10-K-6T-6 HEAD PRESSURE V 11 1 PRV1-10-K-6T-12 VISE PRESSURE 12 1 SV2-10-C-6T-115A HEAD HOLD V SV2-10-C-6T-115A HEAD FAST APPROACH V EPV16-A-04-A-10H-24D-UVALVISTOR 15 1 EHH-AMP-702-D-20 VALVISTOR POWER PLUG 16 1 AOC OIL COOLER 17 1 HYP-1 PUMP 18 1 DCV3P-AB-T HEAD VALVE 19 1 DCV3P-AB-T GUIDE ARM VALVE 20 1 DCV3P-AB-T SWING VALVE 21 3 DPCH-1 DOUBLE PILOT CHECK VALVE 22 1 DCV3P-AB-C BLADE TENSION VALVE 23 1 DCV3P-AB-C SQUARING VISE VALVE (OPTION) 24 1 DCV3P-AB-C VISE VALVE 25 1 DCV3P-AB-C BUNDLING VALVE (OPTION) 26 1(2) PRV2 PRESSURE REDUCING V. SUBPLATE 27 1 JB-01 OR JB-02 JUNCTION BLK 28 4 PG15 PRESSURE GAUGE 1500 PSI 29 1 SF6520 RETURN FILTER ELEMENT 10 MICRON 30 1 MB6P_A 6-POSITION MANIFOLD 31 1 MB4P_A 4-POSITION MANIFOLD Hydraulic Manifold, Pump/Motor Assembly. Pg 39 S a

61 HYDRAULIC ASSEMBLIES CYLINDER ASSEMBLIES HYDRAULIC SERVICE KITS HYDRAULIC VALVES & KITS ITEM PDF AND DDF (feed rate only) (for feed force, contact Service Dept.) Kit number Kit # 661A-00SK S-35 HYDRAULIC CYLINDER SEAL KITS (kits do not include pistons or glands) Inside diameter Kit number 2.5" 2.5CSK 3" 3CSK 3.5" 3.5CSK Pg 40 S a

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68 SECTION 6 MECHANICAL ASSEMBLIES SECTION 6 - MECHANICAL ASSEMBLIES

69 SECTION 6 - MECHANICAL ASSEMBLIES

70 GUIDE BLOCK ASSEMBLIES MECHANICAL ASSEMBLiES ITEM QTY S35 PART NUMBER DESCRIPTION 1 1 S IDLER GUIDE BLOCK 2 2 S SERVO CAP 3 1 S A DRIVE GUIDE BLOCK x1.625 ROLL PIN CARBIDE 6 2 S SERVO SPOOL O RING JNUT JAM NUT, nf 9 2 S SERVO VALVE NEEDLE 10 4 A1-.312x.5 SOCKET HEAD CAP SCREW 11 2 F1-.5x.75 FLAT SOCKET HEAD CAP SCREW 12 4 CRB CARBIDE PAD 13 2 CRBL-01A CARBIDE SUPPORT 14 2 CRBL-02A CARBIDE SCREW 15 2 CRBL-03A HANDLE HOLDER 16 2 CRBL-04 CARBIDE LOCK HANDLE 17 2 CRBL-05 LEVER SLEEVE /8 BALL, 1/2-13 Pg 43 S a

71 GUIDE ARM ASSEMBLIES See previous page for complete assy of these guide blocks. ITEM QTY S35 PART NUMBER DESCRIPTION 1 1 S GUIDE BAR 2 11 A1-.625x1.5 SOCKET HEAD CAP SCREW 3 22 S1-.5x1F SOCKET SET SCREW, FLAT POINT 4 1 S DRIVE GUIDE ARM WELDMENT 5 1 S A DRIVE GUIDE BLOCK ASSEMBLY 6 1 S IDLER GUIDE BLOCK ASSEMBLY 7 2 A1-.312x1 SOCKET HEAD CAP SCREW 8 2 A1-.312x1.5 SOCKET HEAD CAP SCREW 9 2 S HEAVY WASHER LOC LOCK WASHER 11 2 B1-.5x2 HEX HEAD CAP SCREW 12 1 S IDLER GUIDE ARM WELDMENT 13 2 S GUIDE ARM SLIDER (see note below) LOC LOCK WASHER 15 8 B1-.75x2.5 HEX HEAD CAP SCREW 16 2 S1-.5x2.25C SOCKET SET SCREW, CUP POINT 17 2 S SPRING CARRIER K DISC SPRING 19 2 S PISTON 20 4 A1-.25x1.75 SOCKET HEAD CAP SCREW 21 2 B1-.625x5 HEX HEAD CAP SCREW LOC LOCK WASHER 23 2 S HEAVY WASHER 24 as req. S A GUIDE SLIDER SHIM Pg 44 S a

72 BLADE TENSION ASSEMBLY ITEM QTY S-35P PART NUMBER DESCRIPTION 1 1 H A BACK PLATE 2 1 S SLIDER WELDMENT 3 1 S1-.5x1C SOCKET SET SCREW, CUP POINT 4 1 B1-.75x3 HEX HEAD CAP SCREW 5 1 S35-C7-00 BLADE TENSION CYLINDER 6 1 CM-12 3/4 ROD END JNUT 3/4 NF JAM NUT 8 2 S BLADE TENSION ROD END SPACER 9 1 B1-.75x4 HEX HEAD CAP SCREW 10 2 H TENSION RACK 11 4 A1-.875x3.25 SOCKET HEAD CAP SCREW 12 8 A1-.875x2.5 SOCKET HEAD CAP SCREW 13 4 S1-.875x1.5C SOCKET SET SCREW, CUP POINT 14 1 S IDLER WHEEL PIN 15 1 SH-0356-PA 3 9/16" EXTERNAL RETAINING RIN RS BALL BEARING 17 1 S B IDLER WHEEL 18 1 S TIRE 19 1 HO-0550-PA 5 1/2" INTERNAL RETAINING RING RS BALL BEARING 21 1 S IDLER WHEEL RETAINER LOC LOCK WASHER 23 1 B1-.625x2.5 HEX HEAD CAP SCREW Pg 45 S a

73 DRIVE ASSEMBLY ITEM QTY PART NUMBER DESCRIPTION 1 1 PM70 GEAR BOX, 41: TC 10HP, 1200RPM, SPECIFY VOLTAGE 3 2 S GEAR BOX MOUNTING STUD 4 1 S GEAR BOX PIVOT PLATE 5 2 S ADJUSTING NUT 6 2 S /4-16nf STUD 7 2 S WASHER LNUT LOCK NUT, nf FLT FLAT WASHER FLT FLAT WASHER LNUT LOCK NUT, nf 12 1 S A DRIVE WHEEL 13 1 S DRIVE WHEEL CAP 14 1 M24LOC METRIC LOCK WASHER 15 1 B3-24x70 METRIC HEX HEAD CAP SCREW 16 4 S1-.875x1C SOCKET SET SCREW, CUP POINT 17 4 A1-.625x1.75 SOCKET HEAD CAP SCREW Pg 46 S a

74 HEAD PIVOT ASSEMBLY ITEM QTY S35 PART NUMBER DESCRIPTION 1 1 S PIVOT LINK WELDMENT 2 2 S PIVOT SUPPORT WASHER 3 2 AA BUSHING, 2 5/8x2 1/4x2 4 1 S PIVOT LINK DAMPING PLATE 5 1 S VERTICAL PIVOT SHAFT 6 1 S VERTICAL PIVOT PIN LOCK 7 4 A1-.75x3.5 SOCKET HEAD CAP SCREW 8 1 S HORIZONTAL PIVOT SHAFT 9 1 S ADJUSTABLE WASHER 10 1 S ADJUSTABLE SLEEVE /4x.010 SHIM 12 1 S ADJUSTABLE CAP LOC LOCK WASHER 14 1 B1-.5x1.25 HEX HEAD CAP SCREW 15 2 S BEARING BACK UP OIL SEAL S BEARING CONE ASSEMBLY S BEARING CUP 19 1 SH-O225-PA 2 1/4 EXTERNAL RETAINING RING Pg 47 S a

75 HYDRAULIC TANK ASSEMBLY( Less hoses.) ITEM QTY PART NUMBER DESCRIPTION 1 1 H HYDRAULIC TANK WELDMENT 2 1 TFS P SUCTION STRAINER 3 1 SNA2B LEVEL & TEMPERATURE GAUGE 4 1 MP100-FE 90deg BMI FEMALE ELBOW MNPT-HOSE BARB 6 1 H HYDRAULIC TANK LID 7 12 A1-.19x.5 SOCKET HEAD CAP SCREW 8 1 SES-3-40-S micron FILLER & BREATHER CAP 9 6 T1-.19x.5 TRUSS HEAD PHILLIPS MACHINE SCREW 10 1 SF micron RETURN FILTER 11 1 SAF FILTER HEAD 12 2 MP116-E 90deg BMI ELBOW MNPT-FNPT STRAIGHT MNPT-MJIC Pg 48 S a

76 HYDRAULIC PUMP ASSEMBLY (Less hoses.) ITEM QTY PART NUMBER DESCRIPTION TC 5HP, 1800RPM, 480V 2 1 L095x1 1/8 JAW TYPE COUPLING FLANGE 3 1 LN095 JAW TYPE INSERT 4 1 L095x3/4 JAW TYPE COUPLING FLANGE HP BELL HOUSING 6 4.5LOC LOCK WASHER 7 4 B1-.5x1 HEX HEAD CAP SCREW 8 1 HYP-1 HYDRAULIC PUMP LOC LOCK WASHER 10 2 B1-.375x1 HEX HEAD CAP SCREW deg 9/16NF-MJIC STRAIGHT 1 1/16NF-MJIC deg SWIVEL FJIC-MJIC STRAIGHT 1 1/16NF-FNPT MNPT-HOSE BARB Pg 49 S a

77 HEAD CONTROL ASSEMBLY ITEM QTY S-35 PART NUMBER DESCRIPTION 1 1 S HEAD CONTROL BOX 2 2 CJS-1812 FIBERGLIDE BUSHING 3 1 S HEAD CONTROL SHAFT JNUT HEX JAM NUT, nf 5 1 CM-12 3/4" ROD END 6 5 RB-169 GROMMET 7 1 S B ENCODER BRACKET 8 2 A1-.312x1.25 SOCKET HEAD CAP SCREW 9 1 B1-.312x.75 HEX HEAD CAP SCREW STEGMAN ENCODER 11 4 P-.138x.5 PHILLIPS PAN HEAD MACHINE SCREW 12 4 K-LK 6-32 KEEPS NUT 13 1 S ENCODER DRIVE WHEEL O RING 15 1 XCKL-115 LIMIT SWITCH, ROLLER ARM 16 1 A1-.625x.75S SOCKET HEAD SHOULDER SCREW 17 1 S COVER 18 4 B1-.312x.5 HEX HEAD CAP SCREW Pg 50 S a

78 VISE ASSEMBLY ITEM QTY PART NUMBER DESCRIPTION 1 1 S TABLE WELDMENT 2 2 S WEAR STRIP, DRIVE END 3 1 S WEAR STRIP, IDLER END REAR 4 1 S WEAR STRIP IDLER END FRONT 5 56 F1-.312x.5 FLAT SOCKET HEAD CAP SCREW 6 1 S FRONT FIXED VISE JAW WELDMENT 7 4 S VISE WEAR STRIP LOC LOCK WASHER 9 6 B1-.625x1.75 HEX HEAD CAP SCREW 10 4 B1-.625x8 HEX HEAD CAP SCREW 11 1 S A VISE POST WELDMENT 12 1 S MOVABLE JAW WELDMENT 13 1 S VISE KEY 14 1 S VISE GIB 15 1 B1-.75x.5 HEX HEAD CAP SCREW HXNUT HEX NUT LOC LOCK WASHER 18 3 B1-.625x3.5 HEX HEAD CAP SCREW 19 1 S35-C31-00 VISE CYLINDER 20 1 S VISE CYLINDER RETAINING CAP 21 1 SH-0300-PA 3" EXTERNAL RETAINING RING LOC LOCK WASHER 23 4 B1-.5x1.25 HEX HEAD CAP SCREW Pg 51 S a

79 BUNDLING ASSEMBLY Pg 52 S a

80 ITEM QTY S35 PART NUMBER DESCRIPTION 1 1 S35-1G54-00 BUNDLING VISE POST 2 1 S35-1G53-00 UPPER BUNDLING ARM WELDMENT 3 1 S35-1G52A-00 LOWER BUNDLING ARM WELDMENT 4 1 S35-1G MAIN BUNDLING JAW WELDMENT 5 4 AA OILLITE BUSHING, 1.5x1.75x STRAIGHT GREASE FITTING 7 1 SH-0150-PA 1 1/2 EXTERNAL RETAINING RING 8 1 F1-.5x1 FLAT SOCKET HEAD CAP SCREW 9 1 S35-1G5-03A LOWER SHOULDER CAP 10 2 TRB-4860 THRUST WASHER 11 2 AA OILLITE BUSHING, 3x3.25x F1-1x2.5 FLAT SOCKET HEAD CAP SCREW 13 1 S35-1G5-01 LOWER WRIST PIN 14 2 S1-.312x.625 SOCKET SET SCREW, CUP POINT 15 1 S35-1G5-02 UPPER WRIST PIN 16 2 TRB-2435 THRUST WASHER 17 1 S35-1G5-04 POLYURETHANE WEAR STRIP, A S1-.375x.375 SOCKET SET SCREW, CUP POINT 19 1 S35-C23-00 BUNDLING CYLINDER 20 1 B1-.625x2 HEX HEAD CAP SCREW 21 1,625LOC LOCK WASHER 22 4 B1-.5x1.5 HEX HEAD CAP SCREW 23 1 S35-1G EXTENDED JAW WELDMENT, 4" 24 1 S35-1G EXTENDED JAW WELDMENT, 6" 25 1 S35-1G EXTENDED JAW WELDMENT, 8" 26 1 S35-1G EXTENDED JAW WELDMENT, 10" 27 1 S35-1G5-05 POLYURETHANE WEAR STRIP, A60, 4" 28 1 S35-1G5-06 POLYURETHANE WEAR STRIP, A60, 6" 29 1 S35-1G5-07 POLYURETHANE WEAR STRIP, A60, 8" 30 1 S35-1G5-08 POLYURETHANE WEAR STRIP, A60, 10" Pg 53 S a

81 OPERATIONS OPERATIONS OPERATIONS OPERATIONS OPERATIONS OPERATIONS OPERATIONS OPERATIONS OPERATIONS OPERATIONS OPERATIONS OPERATIONS OPERATIONS OPERATIONS & & & & & & & & & & & & & & MAINTENANCE MAINTENANCE MAINTENANCE MAINTENANCE MAINTENANCE MAINTENANCE MAINTENANCE MAINTENANCE MAINTENANCE MAINTENANCE MAINTENANCE MAINTENANCE MAINTENANCE MAINTENANCE MANUAL MANUAL MANUAL MANUAL MANUAL MANUAL MANUAL MANUAL MANUAL MANUAL MANUAL MANUAL MANUAL MANUAL Through its twinned distribution channel of authorized dealers and factory representatives, HYD MECH services a worldwide network of customers from its two state-of-the-art manufacturing facilities in Houston,Texas, USA and Woodstock, Ontario, Canada. Check out the full range of Rock Solid Sawing Solutions at HYD MECH GROUP LIMITED P.O. Box 1030, 1079 Parkinson Road Woodstock, Ontario Canada N4S 8A4 phone: (519) fax: (519) sales: SAWS(7297) parts: HYD MECH CORPORATION 6901 Avenue V., Houston,Texas USA website: info@hydmech.com