Hyd-Mech H-40 Operation And Maintenance Manual Download Page 49

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Summary of Contents for H-40

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

Page 2: ...er 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 ...

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Page 4: ...ith SERVO VALVES 6 SAW SETUP EXAMPLE 7 STEP 1 effective material width 7 STEP 2 blade pitch 7 STEP 3 blade speed 8 STEP 4 feed rate 9 SECTION 2C MECHANICAL CONTROLS 11 HEAD DOWN LIMIT SETTING 11 VARIABLE CONVEYOR SPEED 11 GUIDE ARM POSITIONING 12 COOLANT CONTROLS 13 SECTION 3 MAINTENANCE AND TROUBLESHOOTING 1 BLADE BRUSH ADJUSTMENT 1 BLADE CHANGING 1 BLADE GUIDE ADJUSTMENT 2 HYDRAULIC MAINTENANCE ...

Page 5: ...EL ASSEMBLY 3 HYDRAULIC PUMP ASSEMBLY 4 HYDRAULIC TANK ASSEMBLY 5 DATUM LINE VISE JAW ASSEMBLIES 6 MOVABLE VISE JAW ASSEMBLIES 7 CHIP AUGER ASSEMBLY 8 ANTIVIBRATION ROLLERS AND TOP GUIDES 9 CONVEYOR ROLLER ASSEMBLY 10 CONVEYOR DRIVE ASSEMBLY 11 BLADE DRIVE ASSEMBLY 12 CONVEYOR DRIVE GEAR BOX ASSEMBLY 13 BLADE DRIVE GEAR BOX ASSEMBLY 14 SECTION 8 SPECIFICATIONS 1 MODEL H 40 40 SPECIFICATION LIST 1 ...

Page 6: ...SECTION 1 INSTALLATION SECTION 1 INSTALLATION ...

Page 7: ...SECTION 1 INSTALLATION ...

Page 8: ...A CLEAN AND TIDY CONDITION TO AVOID OBSTACLES OPERATORS COULD TRIP OVER THE H 40 SHOULD ONLY BE OPERATEDACCORDING 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 IMMEDIATELYAND REPAIRED OPERATOR THE SAW SHOULD NEVER BE OPERATED UNLESS ALL GUARDS AND DOORS ARE IN PLACE AND CLOSED OPERATOR KEEP A SAFE ...

Page 9: ...Pg 1 2 H40 LIFTING THE H 40 The machine wieght is 39 000lbs or 42 000lbs with the optional outboard vise ...

Page 10: ...ally when machine is to be inserted into a larger conveyor system The photo below shows the conveyor from the infeed side Four levelling screws are provided one in each corner of the machine base Steel plates are to be placed under each screw to prevent their sinking into the concrete floor Level saw front to rear NOTE In some cases levelling the saw infeed and auxiliary conveyor with a slight slo...

Page 11: ...cess for safe operation and maintenance 2 Cut strapping and remove conveyor drive chip bucket from saw rollers 3 Remove coolant tank position at the left side of the saw facing from front 4 Remove leveling pads from inside coolant tank place under saw base leveling bolts 5 Check machine level from side to side back to front A slight incline 1 8 1 4 rear of saw higher will assist coolant flow back ...

Page 12: ...de to FU2 fuses and ground connections inside the electrical panel as shown below During the initial hook up it is very important to check that the phase order is correct This is indicated by the hydraulic pressure gauge registering a pressure rise and the blade running in a counter clockwise direction If the hydraulics do not register an immediate pressure rise shut the hydraulics off and change ...

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Page 14: ...SECTION 2 OPERATING INSTRUCTIONS SECTION 2 OPERATING INSTRUCTIONS ...

Page 15: ...SECTION 2 OPERATING INSTRUCTIONS ...

Page 16: ...ol the main functions at all times The control panel is shown below We can not overstress the importance of familiarizing yourself with the controls of the H 40 prior to starting the machine NOTE WHEN STARTING THE H 40 FOR THE FIRST TIME MAKE SURE THAT THE BLADE IS MOVING IN A COUNTERCLOCKWISE DIRECTION AND THAT THE HYDRAULIC PRESSURE IS 110OPSI H 40 Operator Control Console ...

Page 17: ...T VISE Three position switch when the CLOSE is selected the switch SWITCH will maintain this postion and the vise will close When OPEN is selected the vise will open until the switch is released from this position at which time the switch is spring returned to the center positon In center position the vise will not open or close although it will not resist a large force indefinitely without creepi...

Page 18: ...ction which would move material toward the back of the machine Releasing the pushbutton deactivates conveyor motor s and movement will stop CONVEYOR SPEED Allows for increase or decrease in speed of selected RHEOSTAT conveyor s when FORWARD or REVERSE pushbuttons are depressed BLADE SPEED Allows for increase or decrease of blade speed while RHEOSTAT blade motor is running DIGITALREADOUT Readout di...

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Page 20: ... by taking two or three cuts through solid four or five inch diameter mild steel at an extremely slow feed rate Utilizing a very slow blade speed is recommended 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 After break in the following s...

Page 21: ... blade life If the Feed Rate setting is too low time and blade life will be wasted If the setting is too high each tooth will get too big of a bite and tooth strippage will result Determining the correct Feed Rate to set is a 4 step process which includes setting the blade speed and choosing the correct blade pitch or compensating for the one you have to use These steps are explained in the follow...

Page 22: ...h of a cut taken by each tooth Allowance for the use of a non optimum blade is made in STEP 4 Optimum blade pitch teeth per Optimum blade pitch teeth per Optimum blade pitch teeth per Optimum blade pitch teeth per Optimum blade pitch teeth per inch T P I for effective material inch T P I for effective material inch T P I for effective material inch T P I for effective material inch T P I for effec...

Page 23: ... 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 structruals and bundles a lower blade speed may reduce vibration and prevent premature blade failure NOTE About Material Hardness The Graph Step 4 illustrates blade speed curves for m...

Page 24: ...ends through the workpiece FEED RATE Knob controls FEED RATE of the blade in the range 0 to 10 in min on the H 40 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 Setting 2 3 21 38 50 71 25 57 34 3 4 31 ...

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Page 26: ...be changed If changed it may cause the machine to malfunction in the automatic cycle VARIABLE CONVEYOR SPEED Both the infeed and out feed conveyors have a variable speed as well as forward and reverse directions controled from the operator control panel The three controls are shown as they appear on the control panel Head Down Limit Switch Head height encoder ...

Page 27: ... with the guide arm adjusted as close to the material as permitted In order to adjust the guide arm the remote guide arm adjustment switch located on the control console is used to hydraulically position the guide arm Turn the switch clockwise to move the guide arm toward the stock Turn the switch counterclockwise to move the guide arm away from the stock H 40 Guide Arm Position ...

Page 28: ...turn will carry it into the cutting area Additional coolant can be supplied with the coolant bars shown below which are controled by the two knobs labeled FLEX HOSE NOTE When cutting materials that do not need coolant cast iron some coolant flow is required to provide blade lubrication and prevent scoring of the blade by the carbides Coolant Bars can be placed on top of materials for extra coolant...

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Page 30: ...SECTION 3 MAINTENANCE AND TROUBLE SHOOTING SECTION 3 MAINTENANCE AND TROUBLE SHOOTING ...

Page 31: ...SECTION 3 MAINTENANCE AND TROUBLE SHOOTING ...

Page 32: ...switch to the RUN position 10 Turn the carbide tensioning levers clockwise until they rest on the stops Blade Tension Switch Guide Arm Lever Released BLADE BRUSH ADJUSTMENT The blade brush is properly set when the machine leaves the factory however it wears out during operation and needs to be adjusted periodically The blade brush assembly is shown in the photo In order to adjust it the nut on the...

Page 33: ...h the locking handle in the locked position use a large flat screw driver to turn the loader bolt 2 clockwise until tight and then loosen it approximately 1 8 of a turn Tighten the set screw 1 Blade guides seldom need replacement but they are available through your Hyd Mech dealer Shown are the 2 5 8 blade guides on the left and the 3 blade guides on the right Blade Guide Pads with Carbides Carbid...

Page 34: ...dd oil more often than at filter changes Add oil only to the top line on the level gauge The H 40 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 Texaco Rando HD 46 but to avoid any risk we suggest staying with Texaco Rando HD 46 If it is desired to change brands it is neces...

Page 35: ...ease In addition to the grease points shown vise jaw guides and infeed rollers require greasing HYD MECH recomends monthly lubrication Four linear bearings with a grease nipple Roller chains Apply grease to the four places indicated on the blade tension assembly Shown with the cover removed Apply grease to all four sides of the guide arm shaft with it fully extended With the vis s closed apply gre...

Page 36: ...Adjust accordingly 3a Blade tension is determined by system pressure Check that system pressure is as specified above 3b Set tracking 4a Blade tension is determined by system pressure Check that system pressure is as specified above 4b Reduce 5a Reduce 5b Adjust accordingly 5c Blade tension is determined by system pressure Check the system pressure is as specified above 6a Blade tension is determi...

Page 37: ... qualified to work on machine tool electrical systems 13a Select manual mode 14a Readjust head up limit switch bracket PROBLEM 9 Saw will not start 10 Saw starts but will not run after Start button has been released 11 Saw starts but no hydraulic functions 12 Individual functions will not respond to its manual control switch 13 Saw starts but only front vise functions 14 Head will not rise CAUSE 9...

Page 38: ...check operation of related limit switches Limit switch levers should operate freely and emit an audible click on both depress and release If not replace the switch nose Look for cause of switch damage ie debris or maladjustment of switch actuator To check the switch unit itself remove the switch lid and wire together the two terminals closest to the wiring port If function now responds to manual s...

Page 39: ...Pg 3 8 H40 DATE SERVICED BY COMMENTS SERVICE RECORD NOTES ...

Page 40: ...SECTION 4 ELECTRICAL SYSTEM SECTION 4 ELECTRICAL SYSTEM ...

Page 41: ...SECTION 4 ELECTRICAL SYSTEM ...

Page 42: ...and rated for 64 amps must be connected to the main power line At initial hook up it is important to check that the phase order is correct This is indicated by the hydraulic pressure gauge registering an IMMEDIATE pressure rise and the blade drive wheel revolving in a counter clockwise direction If thses are not observed SHUT THE MACHINE DOWN IMMEDIATELY and reverse any two of the phase lines NOTE...

Page 43: ... 4 2 H40 Inside control panel PLC 5FU2 5FU1 4FU ELECTRICAL PANEL LAYOUTS 1M 3M 4M 2M Line Rectifier Variable Frequency Drive Unit for all motors Transformer Motor overloads High voltage panel layout Fuses ...

Page 44: ...act block ZB2 BA2 ZB2 BZ102 Telemecanique Telemecanique 1SS Coolant Selector Switch Black 3 positions maintained selector switch Mounting base with 2 N O contact blocks ZB2 BD3 ZB2 BZ103 Telemecanique Telemecanique 2SS Rear Vise Selector Switch Black 1 position spring return from left to center 1 position maintained to right s s Mounting base with 2 N O contact blocks plus 1 N C contact ZB2 BD7 ZB...

Page 45: ...n 28316 Muffin Coolant Pump Coolant pump 1 Phase 120 VAC 5MSP Little Giant Coolant Pump Junction Box SCEJB442 Selectric Wire terminal 20 10 AWG WK4 U Wieland Wire terminal 20 8 AWG WK6 U Wieland Wire terminal 16 6 AWG WK10 U Wieland Double ground terminal 20 8 AWG WK4 D2 2SLU Wieland Ground terminal 16 6 AWG WK10 U Wieland Suppressor SSQUENCHO1 Selectric R C Suppressor Quenchark 504M02QA100 Quench...

Page 46: ...XELVKL 75 16 250 5 3 57 75 7 6TXDUH 35 0 5 86 86 3 57 86 2 5 3 57 8 8 DVW FWLQJ 70 860 RXOG 6 21 5 86 86 3 57 86 2 5 3 57 8 7 7 5 860 HUUD 8 8 3 57 86 2 5 3 57 7 7 5 8 8 3 57 86 2 5 3 57 8 8 3 57 86 2 5 3 57 6 211 7 3 57 9 7HOHPHFDQLTXH 1 5 725 3 57 07 5 07 RUSRUDWLRQ 32 5 20321 176 IRU 9 0 1 HVFULSWLRQ WHP RGH DV RQ VFKHPDWLF RPSRQHQW 0 DQXIDFWXUHU 21752 75 16 250 5 75 9 9 7 7 7 7 3 6 92 7 0 1 0 ...

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Page 58: ...SECTION 5 HYDRAULIC SYSTEM SECTION 5 HYDRAULIC SYSTEM ...

Page 59: ...SECTION 5 HYDRAULIC SYSTEM ...

Page 60: ... require any special work on a new machine before its start up The hydraulic tank is filled with Texaco Rando 46 hydraulic oil and all machine functions have been tested at the factory to ensure proper operation upon initial start up Hydraulic Manifold and Motor Assemblies ...

Page 61: ...e DCV3P AB T 17 1 Single Solenoid Two Way Valve PV2P A C 18 1 Relief Valve RV7 19 1 Feed Rate Valve DF7 0 00 20 1 Pump HYP 1 21 1 Suction Strainer TFS 100 0 P 22 1 Return Filter SF6520 23 1 Cooler AO 10 24 2 Needle Valve N10B 25 1 Check Valve CHV H 40 DDF SETUP INSTRUCTIONS July 19 1999 FEED FORCE V SETUP 1 Turn Feed Force valve counter clockwise till it stops use ALLAN HEX key 3 16 2 Move machine...

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Page 68: ...SECTION 6 MECHANICAL ASSEMBLIES SECTION 6 MECHANICAL ASSEMBLIES ...

Page 69: ...SECTION 6 MECHANICAL ASSEMBLIES ...

Page 70: ...Pg 6 1 H40 SECTION 6 MECHANICAL ASSEMBLIES BLADE BRUSH ASSEMBLY 7 0 47 3 57 180 5 6 5 37 21 200 5 8 02725 02725 3725 2 2 6 5 187 187 0 75 3 6 5 6 6 7 7 16 21 7 7 6 5 586 187 187 ...

Page 71: ...47 3 57 180 5 6 5 37 21 5 9 8 50 867 5 8 50 62 7 3 6 5 7 62 7 3 6 5 6 635 1 5 2 5 8 5 03 2 7 1 3 67 78 1 7 5 6 62 7 6 28 5 6 5 723 5 3 6 5 86 1 5 5 1 5 5 5 5 3 5 5217 5 3 22 17 12 2 5 1 7 62 7 3 6 5 GUIDE ARM ASSEMBLY ...

Page 72: ...5 37 21 5 55 5 7 16 21 1 5 3 1 6 7 2 5 7 62 7 3 6 5 7 16 21 1 5 7 16 21 1 5 3 1 3 7 3 6 5 2 2 6 5 6 62 7 6 7 6 5 7 32 17 3 6 5 2 2 6 5 5 6 7 5 56 5 1 5 5 1 63 5 2 3 17 51 5 7 1 1 5 1 5 2 5 5 1 3 1 3 7 5 1 3 1 3 7 IDLER WHEEL ASSEMBLY ...

Page 73: ... 6 4 H40 HYDRAULIC PUMP ASSEMBLY 7 0 47 3 57 180 5 6 5 37 21 7 3 530 9 7 3 283 1 1 1 7 3 16 57 7 3 283 1 1 3 286 1 2 2 6 5 3 6 5 3 5 8 3803 2 2 6 5 3 6 5 GHJ 1 0 675 7 1 0 GHJ 6 9 0 675 7 1 137 0137 26 5 ...

Page 74: ...EMBLY 7 0 47 3 57 180 5 6 5 37 21 5 8 7 1 0 17 7 6 3 68 7 21 675 1 5 61 9 7 03 5 785 8 03 GHJ 0 0 2 0137 26 5 5 8 7 1 62 7 3 6 5 6 6 6 PLFURQ 5 5 7 5 3 7 75866 3 36 0 1 6 5 6 PLFURQ 5 7851 7 5 6 7 5 03 GHJ 0 2 0137 137 675 7 0137 0 ...

Page 75: ...Pg 6 6 H40 DATUM LINE VISE JAW ASSEMBLIES 7 0 47 3 57 180 5 6 5 37 21 1 287 RSWLRQ 3 6 5 2 2 6 5 5675 3 7 62 7 3 6 5 9 57 52 5 86 1 9 57 52 5 3 1 ...

Page 76: ... 1 5 1 3 1 3 7 5 1 3 1 3 7 5217 9 6 1 5 3 1 2 3 17 51 5 7 1 1 5 1 6 9 6 1 5 5 5 9 6 1 5 3 1 6 62 7 6 7 6 5 1 29 5 7 62 7 3 6 5 27720 29 5 MOVABLE VISE JAW ASSEMBLIES NOTE Only one vise jaw is shown If there is an optional outfeed vise installed on the machine then all quantities must be multiplied by 2 except item 3 ...

Page 77: ...Pg 6 8 H40 7 0 47 3 57 180 5 6 5 37 21 3 8 5 7528 3 8 5 7528 3 8 5 7528 0 5 8 02725 7 62 7 3 6 5 3725 0137 137 GJ 2 0137 0 8 5 8 5 8 5 6 62 7 6 7 6 5 21 2 21 2 CHIP AUGER ASSEMBLY ...

Page 78: ...ide arms TOP GUIDES There is one assembly found behind each of the blade wheel doors at the top of the head ANTIVIBRATION ROLLERS AND TOP GUIDES 7 0 47 3 57 180 5 6 5 37 21 52 5 2 5 5 1 52 5 56 5 1 1 3 7 62 7 3 6 5 6 62 7 6 7 6 5 5 5 02817 1 5 7 3 6 5 2 2 6 5 7 7 6 5 6 62 7 6 7 6 5 02817 1 5 7 723 5 2 6 5 86 1 3 1 ...

Page 79: ...Pg 6 10 H40 CONVEYOR ROLLER ASSEMBLY 7 0 47 3 57 180 5 6 5 37 21 52 5 52 5 52 5 56 5 1 52 5 6 7 0 17 5675 3 5 675 3 7 62 7 3 6 5 723 5675 3 7 62 7 3 6 5 7 62 7 3 6 5 2 21 21 ...

Page 80: ... ASSEMBLY 7 0 47 3 57 180 5 6 5 37 21 7 3 530 9 5 2 2 5 0 75 3 6 5 0 2 0 75 2 6 5 2 2 6 5 3 6 5 283 1 1 283 1 6 9 283 1 1 0 5 2 6 7 0 17 6 7 286 1 0 75 3 6 5 56 5 1 2 3 17 51 5 7 1 1 5 1 63 5 6352 7 3 3 6 5 5217 29 5 62 7 3 6 5 ...

Page 81: ...6 12 H40 BLADE DRIVE ASSEMBLY 7 0 47 3 57 180 5 6 5 37 21 30 5 2 7 3 530 9 5 2 7 33 1 3 7 5 2 3 927 3 7 3 6 5 2 2 6 5 187 187 5 9 5 9 5 7 1 5 0 75 3 6 5 0 2 0 75 2 6 5 3 6 5 2 2 6 5 6 62 7 6 7 6 5 7 32 17 ...

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Page 88: ...SECTION 8 SPECIFICATIONS SECTION 8 SPECIFICATIONS ...

Page 89: ...SECTION 8 SPECIFICATIONS ...

Page 90: ...heel Diameter 45 Motors Blade Drive 20 H P 1800RPM Hydraulic Drive 5 H P 1800RPM Pumps Hydraulic Pump Pressure Compensated Constant pressure variable flow 6 5 GPM Coolant Pump 16 6 GPM Hydraulic Tank 17 U S Gallons 46 oil Coolant Tank 27 U S Gallons Hydraulic System Pressure 1200 psi Vise Control Hydraulic Table Height 27 Control Panel Waist Height Machine Weight 39 000 LBS 42 000 LBS With optiona...

Page 91: ...Pg 8 2 H4040 2000 LAYOUT DRAWING ...

Page 92: ...SECTION 9 WARRANTY SECTION 9 WARRANTY ...

Page 93: ...SECTION 9 WARRANTY ...

Page 94: ...sed in the manufacture of the H 40 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 a...

Page 95: ...NCE 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 www hydmech com HYD MECH GROUP LIMITED HYD MECH CORPORATION P O Box 1030 1079 Parki...

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