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Hyd-Mech H4040, Manual

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Hyd-Mech H4040 Manual Download Page 12

1.2

LIFTING THE H-40

The machine weight for  a H40-40 is 39,000lbs (17690Kg) or 42,000lbs (19051Kg) with the optional outboard vise.

The machine weight for  a H40-60 is 42,000lbs (19051Kg) or 45,000lbs (20412Kg) with the optional outboard vise.

The machine weight for  a H40-80 is 46,000lbs (20865Kg) or 50,000lbs (22680Kg) with the optional outboard vise.

Pg 1.2

H40

LIFTING THE H-40

The machine wieght is 39,000lbs or 42,000lbs with the optional outboard vise.

Summary of Contents for H4040

Page 1: ... manual for future reference in a known location and easily accessible to all users of the device HYD MECH offers a great variety of options components and features for its various models Therefore some of the equipment described in this manual various illustrations and drawings may not be applicable to your particular machine The information and specifications provided in this manual were accurat...

Page 2: ...1 6 WIRING CONNECTIONS 1 6 SECTION 2 OPERATING INSTRUCTIONS BLADE BASICS 2 1 VARIABLE SPEED CONTROL 2 1 THE CONTROL PANEL 2 1 MANUAL OPERATION 2 1 HYDRAULIC FEED CONTROL 2 6 CUTTING PARAMETERS CHART 2 7 HEAD DOWN LIMIT SETTING 2 13 GUIDE ARM POSITIONING 2 14 COOLANT CONTROLS 2 15 SECTION 3 MAINTENANCE SAFETY DURING MAINTENANCE AND TROUBLESHOOTING 3 1 LOCK OUT PROCEDURE 3 1 BLADE CHANGE MODE PROCED...

Page 3: ...ANICAL ASSEMBLIES MECHANICAL ASSEMBLY DRAWINGS PARTS LIST SEE PDF ON ATTACHED CD 6 1 SECTION 7 OPTIONS OPTIONAL ASSEMBLY DRAWINGS SEE PDF ON ATTACHED CD 7 1 BLADE DEVIATION MONITORING SYSTEM K10 7 1 SECTION 8 SPECIFICATIONS H4040 SPECIFICATIONS 8 1 H4060 SPECIFICATIONS 8 2 H4080 SPECIFICATIONS 8 3 LAYOUT DRAWING 8 4 SECTION 9 WARRANTY WARRANTY 9 1 ...

Page 4: ... Materials are within designed specifications and are non hazardous Owner is responsible to Keep Manual accessible at the machine Ensure only reliable fully trained personnel work with the machine Clearly define responsibilities of all personnel working with the machine Keep the machine in good working order Operator and Maintenance Personnel are responsible to Keep all safety equipment in order c...

Page 5: ...azards 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 if you get hurt You owe it to yourself your family and your co workers to PUT SAFETY FIRST Mandatory Information All persons operating this machine must have read and understood all of the fol...

Page 6: ...nnot accept any liability for personal injury or property damage due to operator errors or non compliance with the Safety and Operating Instructions contained in this Manual RESPONSIBILITIES OF THE OWNER Organization of work This Operation and Maintenance Manual must always be kept near the machine so that it is accessible to all concerned The general statutory and other legal regulations on accid...

Page 7: ...t 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 shutdowns Emergency Stop Button E Stops Always be aware of the location of the Emergency Stop Button s Do not allow material or objects to block your access to an Emergency Stop Damage If any changes capable of impairing safety are observed in the mach...

Page 8: ... and duration of noise emission requiring hearing protection depends upon the national regulations in the country in which the machine is being used The actual level of noise emission by band sawing machines depends upon work piece size shape and material blade type blade speed and feed rate The only practical course of action is to measure the actual noise emission levels for the type of work tha...

Page 9: ...onal injury or death All supervisors operators and maintenance personnel must locate and understand the safety information associated with each hazard label prior to operating or servicing the machine The safety hazard labels shown below are located at various positions on the machine to indicate possible safety hazards The location and re order part number of all the safety labels associated with...

Page 10: ...Keep hands clear of vises and work piece when vises are opened or closed Be aware that vise closing or opening may result in potentially dangerous work piece movement Be aware also that the opening motion of a vise may create potential pinch points MOVING PARTS CAN CRUSH AND CUT Keep hands clear of chip auger Lock out power in accordance with your company s lock out procedures before attempting to...

Page 11: ... 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 H 40 SAW 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 O...

Page 12: ...tboard vise The machine weight for a H40 60 is 42 000lbs 19051Kg or 45 000lbs 20412Kg with the optional outboard vise The machine weight for a H40 80 is 46 000lbs 20865Kg or 50 000lbs 22680Kg with the optional outboard vise LIFTING THE H 40 The machine wieght is 39 000lbs or 42 000lbs with the optional outboard vise ...

Page 13: ...E TO USE OR RIGHT OR LICENSE TO DISCLOSE IT TO OTHERS FOR ANY PURPOSE WHATSOEVER ALL RIGHTS RESERVED ECN NUMBER REV DATE BY REVISIONS STANDARD HYDMECH TOLERANCES UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES THIRD ANGLE PROJECTION TITLE DRWN BY A CHKED BY MAT L DATE SCALE SHEET REV DRAWING NUMBER H40 0 00 EngCoop Jan 21 2016 1 66 1 B C D E F G H I J A J I H G F E D C B 0 1 2 3 4 5 6 7 8 0 8 ...

Page 14: ...hen cutting tubing or bun dles H 40 INSTALLATION PROCEDURE 1 Machine location should be carefully selected A flat concrete floor area should be chosen and have enough free space surrounding the machine to enable free access 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...

Page 15: ...3 Install the bearing housing support 2 4 Install the chain guard 3 H40 ADDENDUM SECTION 1 INSTALLATION IN ADDITION TO SECTION 1 INSTALLATION For machine shipping purposes the the following items have been removed from the H40 saw 1 Infeed conveyor gearbox and motor 2 Bearing housing support 3 Chain guard 1 3 2 Once the machine has been installed levelled and anchored the above three items are to ...

Page 16: ...etween the upper and lower lines on the level gauge on the front of the control panel base As supplied the machine is set to run on three phase voltage as indicated on the serial plate and voltage label Power connection to the machine is made to machine disconnect and ground connections inside the electrical panel as shown below During the initial hook up it is very important to check that the pha...

Page 17: ...1 7 L1 L2 L3 Electrical panel located behind the head on the drive side Ground connection ...

Page 18: ...on 3 Maintenance and Troubleshooting 2 Generous coolant application is essential with most materials A high quality and well mixed coolant will extend blade life and also increase cutting rate and quality On those materials where coolant is undesirable for cutting a slight coolant flow or periodic oiling of the blade is necessary to prevent the blade from being scored by the carbide guides 3 The s...

Page 19: ...In the DOWN position the head will descend until it reaches the lower limit switch The speed or rate of descent is controlled by the FEED RATE VALVE CONVEYOR FORWARD When depressed the selected conveyor s rollers rotate in a direction which would move material forward from behind the saw head toward the front of the machine Releasing the push button deactivates conveyor motor s and movement will s...

Page 20: ...op REAR VISE This switch has three positions OPEN NEUTRAL and CLOSE 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 NEUTRAL 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 encoun...

Page 21: ...and OUTFEED Selects the conveyor s to move when the CONVEYOR FORWARD or REVERSE PUSH BUTTONS are used BLADE TENSION Located in the idler wheel box is a three position maintained switch Normal running position is RUN This position will keep constant tension on the blade In the center HOLD position the idler wheel is held in position with not tension applied to the blade The position retracts the id...

Page 22: ...h button or selector switch the LCD display will show the head height Depressing the button under TIME will change the screen to show CUTTING TIMES Depressing the button under EXIT will change the display to the previous screen Depressing the button under B RUN will change the screen to show FEED RATE and BLADE SPEED ...

Page 23: ...OCKWISE ROTATION TO INCREASE AND CLOCKWISE ROTATION TO DECREASE HYDRAULIC FEED CONTROL The Hydraulic Feed Control is located to the left of the control panel These controls allow independent control of Feed Force FF and Feed Rate FR FEED FORCE IS FACTORY PRESET AND CANNOT BE ADJUSTED ON ANY H40 MODEL ...

Page 24: ... W inches or mm 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 as illustrated on the chart 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 ...

Page 25: ... set to avoid blade overloading See the graph below EXAMPLE When cutting a solid which is 1 2 of machine capacity using the graph locate 50 on the horizontal line and travel upwards to the plotted line and then travel directly across to the vertical FF Setting line The point that you have arrived at shows a setting of 40 for a piece 50 of capacity OF FF SETTING MAT L WIDTH AS OF SAW CAPACITY CUTTI...

Page 26: ...T P I for Material Width Inches 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...

Page 27: ...the Medium Carbon Steel Curve 5 From this intersection point run horizontally left to the vertical axis optimum blade speed axis and find the point marked 200 6 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 d...

Page 28: ...irec tion 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 Example 1 It is known from Step 3 that optimum blade pitch is 2 3 and from Step 4 that blade speed is 200 ft min 60mm min From the Graph on the left the FEED RATE is ...

Page 29: ...l Tube SAE 4320 Hardened to 35 RC 325 Bhn Dimensions 6 O D x 4 I D 150mm O D x 100mm I D Step 1 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 materi...

Page 30: ...hanged If changed it may cause the machine to malfunction in the automatic cycle 2 13 HEAD DOWN LIMIT SETTING Head Down Limit This limit is factory set and under ordinary cutting requirements should not be changed If changed it may cause the machine to malfunction in the automatic cycle LIMIT SWITCH HEAD DOWN ADJUSTMENT BLOCK ...

Page 31: ... 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 counter clockwise to move the guide arm away from the stock ENSURE CLEARANCE BETWEEN GUIDE ARM AND VISES AT AL...

Page 32: ...ith adjustable coolant on the left side of the operator panel as shown below A properly adjusted flow of coolant should cover the blade from the adjustable guide arm which in turn will carry it into the cutting area Additional coolant can be supplied with the coolant bars shown below which are controlled by the knob labeled FLEX HOSE NOTE When cutting materials that do not need coolant cast iron s...

Page 33: ...machine via the Power Junction Box see picture below must be turned OFF and locked in the OFF 0 position by means of a padlock The key for this padlock must be kept by the person performing the work on the machine If more than one person is performing work on the machine then a multiple lock hasp shall be used and each person shall apply his or her own lock to the hasp 4 The Machine Power Disconne...

Page 34: ...her employees who use the machine shall be informed that the lock out has been removed After notification is made the machine may be re started BLADE CHANGE MODE PROCEDURE Wear safety glasses gloves and a long sleeve shirt for protection when handling band saw blades during blade change NOTE THAT GLOVES SHOULD NEVER BE WORN NEAR A RUNNING BANDSAW BLADE When handling new blades or ones that will be...

Page 35: ... must be installed with the teeth facing towards the rear of the saw where it passes around the wheels and with the teeth in the cutting area pointing away the drive wheel This may require that the blade be turned inside out before installation 1 With the blade change mode key switch remaining in the ON position turn the blade tension switch to the position for several seconds until the idler whee...

Page 36: ... in the photo In order to adjust it the nut on the adjusting bolt needs to be loosened and the brush mounting bracket turned until the wires from the brush touch the bottom of the blade gullets as shown and then tighten the adjusting nut If the brush gets worn to approximately 70 of its original diameter it should be replaced A brush may be purchased through a Hyd Mech Group Limited dealer in your...

Page 37: ...ains 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 grease to all four sides of the vise shaft LUBRICATION The design of the H 40 was intended to minimize maintenance although periodically certain moving parts need lubrication We recommend t...

Page 38: ... it is necessary to drain the tank and to fill to 1 3 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 Recommended replacement oils Chevron AW Hydraulic Oil 46 ESSO NUTO H46 Mobil Mobil DTE 25 Shell Tellus 46 Petro Canada Harmony AW 46 3 OIL TEMPERATURE Oil temperature is indicated by a thermometer contained in...

Page 39: ...ock not square in vises 2 Adjust accordingly 3 Blade comes off wheels 3a Not enough blade tension 3a Blade tension is determined by system pressure Check that system pressure is as specified above 3b Improper tracking 3b Set tracking 4 Blade stalls in cut 4a Not enough blade tension 4a Blade tension is determined by system pressure Check that system pressure is as specified above 4b Excessive feed...

Page 40: ...cessary 9 Saw will not start 9a Motor overload has 9a Depress each of the tripped overload buttons located in the electrical box Depressing one button at a time and trying to start the saw will indicate which motor was overloaded 9b Control circuit fuse has 9b Replace the fuse with a blown 5 Amp 250 Volt AG1 type fuse Random blowouts may occur but a quickly repeated blow out indicates an internal ...

Page 41: ... control console control switch related to inoperative function and should be left to some fails to light problem is one qualified to work on electrical machine tool electrical systems 12b If pilot light related to 12b Solution usually requires inoperative function does opening the control console light problem may be the and should be left to some coil If problem remains after one qualified to wo...

Page 42: ...lf remove the switch lid and wire together the two terminals closest to the wiring port If function now responds to manual switch replace internal limit switch unit If function still does not respond then Open panel door to gain access to valves Remove coil retaining nut and withdraw problem related coil replace it with any other coil from the group If the problem remains it requires the attention...

Page 43: ...Increase Feed Force too low Limit to at least 150 psi 16c Pointer is not adjusted 16c Loosen printer turn knob clockwise until it bottoms tighten pointer at 0 17 Head descends when Feed 17a Pointer of Feed Rate 17a Re adjust pointer As in Rate Valve pointer is set to valve is stopped by stop 16c 0 on the scale and Feed bolt but not fully closing the Force Limit gauge is more valve than 150 psi ...

Page 44: ...4 1 ELECTRICAL SCHEMATICS SEE PDF ON ATTACHED CD SECTION 4 ELECTRICAL ...

Page 45: ...equire 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 ASSEMBLY ...

Page 46: ...RE GAUGE 1000 PSI PG 10 8 1 PRESSURE GAUGE 2000 PSI PG 15 9 1 CHIP CONVEYOR DRIVE MOTOR HM 01 MG12 10 1 BRUSH MOTOR HM 02 11 0 1 REAR VISE VALVE DCV3P AB T 12 1 FRONT VISE VALVE DCV3P AB T 13 1 HEAD VALVE DCV3P AB T 14 1 BLADE TENSION VALVE DCV3P AB C 15 1 PRESSURE REDUCING VALVE PRV 2 16 1 GUIDE ARM VALVE DCV3P AB T 17 1 SINGLE SOLENOID TWO WAY VALVE PV2P A C 18 1 RELIEF VALVE RV7 19 1 FEED RATE ...

Page 47: ...6 1 MECHANICAL ASSEMBLY DRAWINGS PARTS LIST SEE PDF ON ATTACHED CD SECTION 6 MECHANICAL ASSEMBLIES ...

Page 48: ...layed on the operator interface in a form of bar graphs One bar graph for the transducer mounted on the idler guide arm and the second bar graph for the transducer mounted on the drive side guide arm The bar graphs appears in both Manual Mode and Automatic Mode Screens It is only active when the blade is running and head is descending The length of the bar graph is proportional to the blade deflec...

Page 49: ...parameter to ON by moving the cursor using the navigation keys to ON OFF and pressing ENTER The value of Blade Monitor parameter will change to ON Exit parameter screen by pressing function key F5 Repeating the above steps will disable the blade monitor option Warning and shutdown limits adjustments To adjust the warning and shutdown limits enter MONITOR LIMIT SETTING screen by pressing Press F2 B...

Page 50: ... limit if blade is cutting towards the part Increasing this value decreases sensitivity which will result in a larger deviation from nominal straight before shutdown sequence is initialized Cut in maximum limit in cutting towards infeed range 100 0 This parameter will adjust shutdown limit if blade is cutting towards the stock Decreasing this value decreases sensitivity which will result in a larg...

Page 51: ...g range of the proximity transducer At 0 the blade is exactly centered within the sensing range The display assists adjustment with the prompts SETTING or SET The prompt SET appears when the adjustment is within the acceptable range of 100 100 See sensor adjustment procedure section BLADE DEVIATION MONITOR ON OFF This parameter will activate or deactivate response of the blade deviation monitoring...

Page 52: ...25 Liters min pressure compensated Coolant 16 6 U S Gal min 63 Liters min Hydraulic Tank Coolant Tank System Pressure Vise Control Table Height Control Panel Maximum Workload Overall Dimensions 42000 lbs 19051 Kg 221 5613mm Wide 119 3023mm Long 148 3759mm High 27 686mm Waist Height Machine Weight 39 000 lbs 19051 Kg 42 000 lbs 20412 Kg with optional outboard vise 1200 PSI 8274 kPa hydraulic Pumps ...

Page 53: ... Liters min pressure compensated Coolant 16 6 U S Gal min 63 Liters min Hydraulic Tank Coolant Tank System Pressure Vise Control Table Height Control Panel Maximum Workload Overall Dimensions 50000 lbs 22680 Kg 241 6121mm Wide 119 3023mm Long 148 3759mm High Waist Height Machine Weight 42 000 lbs 19051 Kg 45 000 lbs 20412 Kg with optional outboard vise 1200 PSI 8274 kPa hydraulic 27 686mm 17 U S G...

Page 54: ...ic 6 1 2 U S Gal min 25 Liters min pressure compensated Coolant 16 6 U S Gal min 63 Liters min Hydraulic Tank System Pressure Vise Control Table Height Control Panel Maximum Workload Overall Dimensions 50000 lbs 22680 Kg 261 6629mm Wide 119 3023mm Long 148 3759mm High Machine Weight 46 000 lbs 20865 Kg 50 000 lbs 22680 Kg with optional outboard vise hydraulic 27 686mm Waist Height 17 U S Gallons 6...

Page 55: ...NFERS NO LICENSE TO USE OR RIGHT OR LICENSE TO DISCLOSE IT TO OTHERS FOR ANY PURPOSE WHATSOEVER ALL RIGHTS RESERVED ECN NUMBER REV DATE BY REVISIONS STANDARD HYDMECH TOLERANCES UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES THIRD ANGLE PROJECTION TITLE DRWN BY A CHKED BY MAT L DATE SCALE SHEET REV DRAWING NUMBER H40 0 00 EngCoop Jan 21 2016 1 66 1 B C D E F G H I J A J I H G F E D C B 0 1 2 3...

Page 56: ...acture of the saw 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...

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