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Hyd-Mech S-20DS Use And Maintenance Manual Download Page 4

How to read the wiring diagrams

6---2

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D2 --- Letter codes used to designate the type of component

6---4

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Standardised Wiring Diagrams (CENELEC Standard)

6---7

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Exploded views

6---16

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Base assembly

6---16

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Fixed worktable

6---18

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Front flywheel assembly

6---20

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Vice unit

6---22

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Driving pulley unit

6---24

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Cutting head cover

6---26

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Motor unit

6---28

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Cylinders

6---30

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Control panel

6---32

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Cylinders S---20DS

6---34

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Optional MA

6---36

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Optional Discharge side adaptor

6---38

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Optional Discharge side adaptor

6---40

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Adjustments

7---1

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Air treatment unit (MA version)

7---1

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Topping up and bleeding the cylinder

7---2

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Topping up the head cylinder

7---2

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Bleeding the head cylinder

7---3

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Working pressure of the hydraulic control unit (optional)

7---4

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Cutting head

7---5

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Blade tensioner slide play adjustment

7---5

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Adjusting operating head travel (CCS)

7---6

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Adjustment of the operating head course (with optional hydraulic control unit

for the raising of the cutting bow)

7---7

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Blade guide components

7---9

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Blade guide heads

7---9

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Blade steady buttons

7---9

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Blade guide plates

7---9

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Blade

7---12

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Tool changeover

7---12

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Blade perpendicularity

7---14

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Blade orthogonality

7---15

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Front flywheel

7---16

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Rear flywheel

7---16

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Maintenance and choice of consumables

8---1

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The role of the operator

8---1

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Maintenance requirements

8---2

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General maintenance

8---2

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Daily

8---2

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Weekly

8---2

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Monthly

8---3

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Maintenance of working parts

8---3

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Consumable materials

8---3

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Oils for oleopneumatic circuit

8---3

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Oil for lubricant/coolant fluid

8---4

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Cutting speed and choice of tools

9---1

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Cutting speed

9---1

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Standard machine

9---1

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Summary of Contents for S-20DS

Page 1: ...EN YEAR OF MANUFACTURE ______________ S 20DS USE AND MAINTENANCE MANUAL ...

Page 2: ......

Page 3: ...se level values 3 8 Electromagnetic compatibility 3 9 Machine installation 4 1 Packaging and storage 4 1 Anchoring the machine 4 4 Minimum requirements 4 4 Check list 4 5 Connection to the power supply 4 6 Description of machine operation 5 1 Control panel description 5 1 Basic instructions for carrying out a cutting operation cycle 5 3 Clamping the work piece in the vice 5 3 Rapid vice positionin...

Page 4: ...the hydraulic control unit optional 7 4 Cutting head 7 5 Blade tensioner slide play adjustment 7 5 Adjusting operating head travel CCS 7 6 Adjustment of the operating head course with optional hydraulic control unit for the raising of the cutting bow 7 7 Blade guide components 7 9 Blade guide heads 7 9 Blade steady buttons 7 9 Blade guide plates 7 9 Blade 7 12 Tool changeover 7 12 Blade perpendicu...

Page 5: ...s 9 6 Set 9 6 Standard or splayed set 9 6 Undulated set 9 7 Alternating grouped sets 9 7 Alternating set 9 7 Blade selection table relating to cutting speed and downstroke speed 9 8 Classification of steels 9 9 Classification of steels 9 10 Troubleshooting 10 1 Troubleshooting blade and cutting problems 10 1 Troubleshooting machine faults 10 8 Accessory Installation 11 1 Accessories that can be fi...

Page 6: ......

Page 7: ...arious materials such as stainless steel light alloys aluminium copper and bronze at high speed and with high precision Its high cutting capacity combined with the possibility of making inclined cuts from 60 left to 60 right make this model the ideal solution for satisfying the wide strange of cutting needs of machine shops turneries structural steel shops and engineering workshops We congratulate...

Page 8: ...in a new cutting cycle can be started by pressing the button on the control board In the AV version Automatic Vice a pneumatic cylinder applied to the vice blocks the material in the jaws the vice opening clos ing key is found on the control board Machine specification The anodised aluminium name plate is riveted on the side of the machine the same data are reproduced on the declaration of conform...

Page 9: ...Amps Power Kw rpm 4 400 3 7 1 5 1410 Stator wound with enamelled copper wire class H 200 C Class F insulation limit temperature TL 155 C IP 55 protection rating total against contact with live parts water sprayed from all directions with shaft oil seal Conforming to CEI norms publication IEC 34 of 01 07 1985 Example of class F insulation in air cooled machines at an ambient tempera ture of 40 C ac...

Page 10: ...tenance manual S 20DS CUTTING CAPACITY 60 a 210 200 200x250 45 320 300 300x300 60 210 200 200x250 CUTTING CAPACITY Section Ø lxl bxh 0 260 230 290 x 200 45 a 190 180 180 x 210 60 a 120 120 120 x 130 45 150 130 120 x 160 ...

Page 11: ...1 5 5 Introduction and technical specifications Dimensions MACHINE INSTALLED Work table height mm 880 Weight Kg 1080 2300 1880 70 1700 2450 3300 880 ...

Page 12: ...1 6 6 Use and maintenance manual S 20DS PACKED WEIGHT Wooden cage and pallet Kg 130 Wooden pallet Kg 70 2900 1800 1800 ...

Page 13: ...n order for the user to move towards a full understanding of how the machine works which is described in detail in the chapter 5 this chapter deals with the main units and their locations CUTTING HEAD CONTROL PANEL VICE TURNTABLE BASE 2 ...

Page 14: ...which the band the band guide elements the band tensioning unit and the mechanical speed variator are mounted The operating head is restricted in its movements by the articulated joint on the rotatng platform Motor Blade guide heads Belt tensioning wheel Transmission box Drive pulley Idle pulley Rear flywheel Speed variator Cutting head beam Front flywheel Blade casing ...

Page 15: ...eres The vice is manually neared to the material to be cut using a hand wheel and blocking is performed using a hydraulic cylinder in the AV version Slideway Handwheel Vice support lead nut Control Panel The control panel has a protection rating of IP 54 and contains the electronic equipment Access to the control panel is protected by a safety panel mounted on hinges and fastened with screws speci...

Page 16: ...d platform It is made up of two parts upper and lower which close the rotating and platform and support the cutting surface in interchangeable steel The lower part is the resting base of the rotating platform cutting surface and vice It is free to run transversely on linear guides and slides with re circulation of pre loaded spheres It is integral to the base and the rear part has the reference st...

Page 17: ...tor reducer unit Rotation of the band is performed by a system made up of a motor connected to a variator and a mechanical speed reducer This unit allows rotation of the band in a continuous adjustment range that goes from 20 to 100 m min ...

Page 18: ... surface which conveys the coolant to the rear tank via the tank cover and a swarf collection drawer An electric pump is housed inside the tank which draws the clean fluid from the filter system Lubricant coolant tank Electric pump housing Swarf collection drawer Hydraulic single box housing ...

Page 19: ...ll the machine s controls The instructions warnings and accident prevention standards in this manual must be respected without question by all those concerned The following definitions are those provided for by EEC MACHINES DIRECTIVE 98 37 CE H Danger zone any zone in and or around a machine in which the presence of a person constitutes a risk for the safety and health of that person H Person expo...

Page 20: ...o avoiding any blinding light concentrations Reference standard ISO 8995 89 Lighting in work environments CONNECTIONS Check that the power supply cables and pneumatic feed systems comply with the maximum machine absorption values listed in the Machine Specification tables replace if necessary EARTHING The installation of the earthing system must comply with the requirements set out in IEC STANDARD...

Page 21: ...he case of abnormal operation of the machine Before starting cutting operations support the material at both ends of the machine using the support arm standard or OPTIONAL acces sories such as the feed and discharge roller tables shown in the diagram below Before removing the devices supporting and moving the material fasten the latter in place using the machine s clamping devices or other suitabl...

Page 22: ...port shoulder where they could jam in the blade When using the pneumatic vice MA version check that the jaws move right up to and effectively clamp the workpiece as the maximum travel is only 8 mm and check that the clamping procedure is correct When working on the band saw wear gloves only when handling mate rials and for tool changing or adjustment operations Only perform one operation at a time...

Page 23: ...vements in health and safety at work H EEC Directive No 90 394 for the protection of workers against risks deriving from exposure at work to carcinogenic substances H EEC Directive No 77 576 and No 79 640 on safety signs at work PERSONAL PROTECTION H EEC Directive No 89 656 and No 89 686 on the use of personal protection de vices ENVIRONMENTAL PROTECTION H EEC Directive No 75 442 on waste disposal...

Page 24: ...l lock device allowing panel to be opened only after the electricity supply has been turned off H 24 Vac Control voltage for actuators in accordance with chapter 6 or Euro pean Standard Control and indication circuits paragraph 2 Control Cir cuits sub section 1 Preferential voltage values for control circuits H plant short circuit protection by means of rapid fuses earthing of all plant parts conn...

Page 25: ...r must be rotated 45 After the emergency situ ation has been resolved the machine must be reset 2 Automatic thermal magnetic cutout switch with thermal magnetic relay The machine s automatic switch positioned on the left hand side of the base has two protective systems against the lack of voltage In fact if there is a lack of voltage it disconnects all electrical devices blocking the machine immed...

Page 26: ...as that actually fluctuating over the same period of time This calculation is made automatically by the integrator noise meter The measurements are taken every 60 seconds in order to obtain a stabilised value The reading stays on the display for a sufficient time to enable a reading to be taken by the operator Measurements are taken by holding the instrument at approximately 1 metre from the machi...

Page 27: ...llowing text contains a list of the applied standards and the results of the electromagnetic compatibility testing of machine model S 20DS Test report no 140201 Emissions H EN 50081 2 1994 Electromagnetic Compatibility Generic standard regarding emissions Part 2 Industrial Environment H EN 55011 1999 Industrial scientific and medical radio frequency appliances ISM Characteristics of radio frequenc...

Page 28: ...nsients bursts immunity tests Basic publication H EN 61000 4 6 1995 Electromagnetic Compatibility EMC Part 4 Test and measurement techniques Section 6 Immunity to conducted interference induced by radio frequency fields H ENV 50204 1996 Electromagnetic field irradiated from digital wireless telepho nes IMMUNITY TO ELECTROSTATIC DISCHARGES Gate Test levels Evaluation criterion Result Enclosure cont...

Page 29: ... following ways 1 on a pallet with straps and heat shrink plastic 2 on a pallet with straps heat shrink plastic and a wooden crate In both cases for correct balancing the machine must be handled using a fork lift truck inserting the tines at the points indicated by the arrows using the reference marks on the crate itself Before carrying out lifting operations make sure that the weight of the ma ch...

Page 30: ... wrapped must not be stacked two high and machines pallettized and crated must not be stacked three high To install the machine first remove the packing paying particular attention not to cut any electric wires or hydraulic hoses if necessary use pliers a hammer and a cutter Open crate in the illustrated order Attention Attention ...

Page 31: ...shrink covering 4 remove the straps 5 remove nails from pallet securing planks and remove planks 6 remove the front panel and insert fork tines 3 4 5 6 To locate the machine in the workplace the machine dimensions and necessary operator working space including the spaces laid down in safety standards must be taken into account ...

Page 32: ...g the machine BASE 1138 1296 Minimum requirements For the machine to function correctly the room in which it is to be installed must satisfy the following requirements H power supply voltage frequency refer to the values on the rating plate H pneumatic operating pressure not less than 6 Bar and not more than 8 Bar H temperature of machine location from 10 to 50 C H relative humidity not more than ...

Page 33: ...gles n n n n Electronic transducer of the stretching of the band with display on the con sole n n n n Blade cleaning device with rotating brushes with movement transmitted from the pulley engine n n n n Designed for transpallet handling systems n n n n Mobile console to operate while maintaining visual control n n n n Manual vice with screws with rapid nearing and transfer on the linear guides and...

Page 34: ...hich matches the socket to be used EN 60204 1 par 5 3 2 CONNECTION FOR 5 CORE WIRE SYSTEMS WITH NEUTRAL R L1 S L2 T L3 PE GND N NEUTRAL CONNECTION FOR 4 CORE WIRE SYSTEMS WITH NEUTRAL S L2 T L3 PE GND R L1 When using systems with a neutral wire special care must be taken when con necting the blue neutral wire in that if it is connected to a phase wire it will dis charge the phase voltage to the eq...

Page 35: ...this check the following operations must be carried out set the blade tension to 1200 BAR make sure the cover is properly closed at the back of the cutting head there is a bayonet limiter for correct cover closure make sure that the machine is not in an emergency condition red mush room head pushbutton released after having applied voltage to the machine set the selector for permission of motor st...

Page 36: ...motor will start up and the blade will start rotating Ensure that the blade moves in the correct direction as shown in the abo ve figure If it does not simply reverse two of the phase wires on the machine power supply input The sawing machine is now ready to start the work for which it was designed Chapter 5 provides a detailed description of the various functions of the machine and its operating ...

Page 37: ...he pushbuttons and other components on the control panel Control panel description The figure below shows the control panel of the S 20DS FAST APPROACH BLADE SPEED Ft min BLADE OFF ON FEED RATE BLADE TENSION BLADE START HEAD FEED COOLANT 0N AUTO 0FF EMERGENCY STOP FIXED VISE CLOSE OPEN 276 92 184 230 46 328 138 1888 5 ...

Page 38: ... only present in the AV version Selector for the opening and closing of the cutting vice 4 START BUTTON The cutting cycle is allowed to start if the blade motor selector has been activated 5 HEAD DOWNSTROKE SPEED REGULATOR The hydraulic circuit flow regulator can be used to set the cutting head down stroke speed 6 BLADE MOTOR SELECTOR During normal operation of the machine this enables or disables...

Page 39: ...to ensure that the workpiece is securely clamped in the vice proceed as follows make sure the workpiece dimensions do not exceed the machine s cutting ca pacity make sure the piece is correctly supported on both sides of the machine move the vice to within 2 3 mm of the workpiece using the handwheel 2 3 mm Turn the selector for the closure of the vice make sure the workpiece is securely clamped in...

Page 40: ... free to slide back and forth to the required position On ce positioned release the lever to lock the vice in place Finally position the vice to within 2 3 mm of the workpiece using the han dwheel Rapid vice translation The vice can be moved to the left or to the right in order to carry out angled cuts by sliding it along the straight guides Release the blocking ball grip indicated in the figure P...

Page 41: ... cut is determined by the longitudinal section of the workpiece so that only the part of the blade required to make the cut is actually exposed Position the workpiece on the work table in proximity to the blade downstro ke trajectory and clamp it in the vice release the lever to allow the blade guide small head rod to run inside the bow position the mobile front guide head near the workpiece so th...

Page 42: ...peed selected is right for the kind of piece to be cut that all protections are in place and correctly locked the level of lubricant coolant and that the electropump is activated That the blade descent speed is correct CCS Cut Control System functioning cycle Semi automatic cutting sequence power up the machine by turning the main switch position the workpiece in the vice During this programming p...

Page 43: ...orm the working and calculate the length of the cuts with the rod for measured cuts Close the vice or near it to the material to be cut leaving a minimum distance of 2 3 mm if the au tomatic vice option is present AV Start up the cutting cycle using the button on the console select the cutting speed adequate for the type of material Turn the knob to vary the speed of the band only when the band is...

Page 44: ...ted out that the bar support rollerway located on the loading side of the machine to the left of the cutting table has two pre set positions one for straight cuts or cuts with an inclination of up to 30 left or right the other for cuts with an inclination of 60 right Loading side rollerway position For 0 or 30 left right cuts check that the rollerway is positioned as shown in the drawing below For...

Page 45: ...ot slacken the turntable lock release lever The 0 45 and reference stops for cuts to the right and the 45 reference stop for cuts to the left facilitate rapid head positioning during turntable rotation However the eccentric pin is only correctly positioned if the initial rotation of the turntable when released is corrected Warning ...

Page 46: ...ition to avoid blade collision with the moving jaw on the clamp Relock the turntable lock release lever Perform the cut keeping in mind the preliminary safety instructions noted in this chapter Angled cuts 60 to the left Ensure that the vice is positioned on the left of the cutting slit at 05 see the previous paragraph Release the the block unblock head rotating surface lever remove the pre set st...

Page 47: ...is displayed on the graduation noted on the rotating surface Always rotate the head when it is in the upper position to avoid blade collision with the moving jaw on the clamp Tighten the block unblock rotating surface lever Perform the cut keeping in mind the preliminary safety instructions noted in this chapter Attention ...

Page 48: ...ce to the left or right make sure the moving jaw is be yond the 0 cutting slot to avoid any risk of collision with the blade downstroke slacken the turntable lock release lever remove the 0 stop swing the head from left to right until it is positioned at the required angle as indicated by the graduated scale on the turntable relock the turntable lock release lever Perform the cut keeping in mind t...

Page 49: ...e vice to the right of the cutting slit Remove the pre set stroke to 45 right When positioning the vice on the left or on the right pay attention that the mo bile jaw does not exceed the cutting slit at 05 In this way it will not interfere with the band during descent Attention ...

Page 50: ...lease lever swing the head from left to right until it is positioned at the required angle as indicated by the graduated scale on the turntable relock the turntable lock release lever Perform the cut keeping in mind the preliminary safety instructions noted in this chapter ...

Page 51: ...aking up the machine giving information useful in carrying out repair and maintenance operations This chapter will also enable the user to order replacement parts with no risk of misunderstanding as all parts are given codes Pneumatic diagram MA version CMT GTA VIA Pneumatic components key VIA Air inlet valve VP Pedal valve CMT Cutter vice cy linder GTA Air treatment unit VM Manual valve CPT Head ...

Page 52: ...ay in which they have been drawn up Each sheet of the project contains a box which gives the following information The numbers indicate the columns into which the entire drawing is divided Indications of the date production started Identification of the designer Identification of the Reference Standard Indications of the model of machine Indication of the page number MARIO ROSSI ...

Page 53: ...er the dot identifies the column on that page example 11 8 indicates that the wire continues on page no 11 in column 8 This symbol identifies the wire with its relative number and co lour The pages following the wiring diagrams contain the following lists 1 components list list of all components and terminals list list of all the ter minals with the following information n in house article code n ...

Page 54: ... EN 60204 1 D2 Letter codes used to designate the type of component LETTER TYPE OF COMPONENT EXAMPLES IDENTIFICATION OF THE APPLIANCE A Complex units Laser Maser Regulator A B Transducers converting a non electrical signal to an electrical signal and vice versa Transistor amplifier IC amplifier Magnetic amplifier Valve amplifier Printed circuit board Drawer Rack AD AJ AM AV AP AT AR C Capacitors C...

Page 55: ...ll or nothing timed relays timers KA KL KM KP KR KT L Inductors reactors Inductor Stop coil Reactor L M Motors M N Analogue intgrated circuits Operational amplifiers Hybrid analog digital ap pliances N P Measurement equipment test de vices Indicator recorder and inte grator measurement devices Signal generators P Q Power circuit switching appliances Automatic switch Engine saver switch Knife switc...

Page 56: ...pipes semiconductors Electronic pipe Gas discharge pipe Diode Transistor Thyristor V W Transmission lines wave guides antennas Conductor Cable Bar Wave guide Wave guide directional coupler Dipole Parabolic antenna W X Terminals sockets plugs Connector bar Test plug Plug Socket Terminal connector band XB XJ XP XS XT Y Electrically operated mechanical appliances Electromagnet Electromagnetic brake E...

Page 57: ...6 7 51 Diagrams exploded views and replace Standardised Wiring Diagrams CENELEC Standard ...

Page 58: ...6 8 52 Use and maintenance manual S 20DS ...

Page 59: ...6 9 53 Diagrams exploded views and replace ...

Page 60: ...6 10 54 Use and maintenance manual S 20DS ...

Page 61: ...6 11 55 Diagrams exploded views and replace ...

Page 62: ...W97 Q0 4 X110 L2 AWG16 6 BLACK Q0 4 X110 L2 022 0314B W98 Q0 6 X110 L3 AWG16 7 BLACK Q0 6 X110 L3 022 0134Y G W99 X1 PE X110 PE AWG16 YELLOW GREEN X1 PE X110 PE 022 0134Y G W100 PE PE Switch plate AWG16 YELLOW GREEN PLATE PE X1 PE 022 0134Y G W101 PE T1 0 Vac 0 24 AWG16 YELLOW GREEN T1 0 PE 022 0134Y G W102 Q0 1 K0 1 AWG16 1 BLACK Q0 1 K0 D1 022 0134Y G W103 Q0 2 K0 2 AWG16 2 BLACK Q0 3 K0 D2 022 ...

Page 63: ...EI K4 3 5 CONTACTOR MOELLER K16 5 8 LOK VALVE RELAY TECNAIR 022 0412 K16 5 8 CONNECTOR LOK VALVE TECNAIR 044 1258 K16 5 8 LOK VALVE TECNAIR K23 5 6 LOK VALVE RELAY TECNAIR 022 0412 K23 5 6 CONNECTOR LOK VALVE TECNAIR 044 1258 K23 5 6 LOK VALVE TECNAIR K40 5 3 LOK VALVE RELAY TECNAIR 022 0412 K40 5 3 CONNECTOR LOK VALVE TECNAIR 044 1258 K40 5 3 LOK VALVE TECNAIR 019 1722 M1 2 5 BLADE MOTOR CARPANEL...

Page 64: ...FF ON PUSH BUTTON MOELLER S50 3 4 FIXING ADAPTER MOELLER S50 3 4 BLOK NO MOELLER List of terminals CODE ID RIF DESCRIPTION MANUFACTURER 022 2247 X1 1 2 QUADRUPLE GROUND TERMINAL PHOENIX CONTACT 022 2247 X1 1 2 QUADRUPLE GROUND TERMINAL PHOENIX CONTACT X100 3 0 BLADE TENSION DATA 022 0715 X110 2 2 INVERTER TELEMACANIQUE ...

Page 65: ......

Page 66: ...6 16 59 Use and maintenance manual S 20DS Exploded views This part of the manual contains detailed exploded views of the machine which can help to gain a deeper knowledge of how it is made Base assembly ...

Page 67: ...NC M M 2 5 NR 2 000 028 0010 COOLANT PISTOL NR 1 000 028 0081 MALE FEMALE REDUCTION 1 2 3 8 CL 2531 NR 1 000 028 0121 JOINT 3 8 17 CL 2601 NR 2 000 028 0236 3 PH ELECTROPUMP PA150 120 NR 1 000 028 0391 LOOC LINE HOSE SPD ART 69540 3 4 MT 1 000 028 0396 NOZZLE 0 20 SPD FP50 11B50 NR 1 000 028 0401 FITTING 3 4 SPD FP50 17A20 NR 1 000 034 0901 1 2 GAS OIL LEVEL CAP NR 1 000 034 0905 TAO 3 1 2 BLACK O...

Page 68: ...6 18 61 Use and maintenance manual S 20DS Fixed worktable ...

Page 69: ...MIT SWITCH NR 1 000 010 1688 ROTATING TABLE NR 1 000 010 2803 SLIDE GUIDE LGW25HC 1 R0520 Z3H NR 2 000 010 3164 HEAD HEAD STROKE STOP NR 1 000 010 7221 M16 LOW SCREW NUT NR 1 000 010 7488 10 X 45 FLAT POINT VCE GRUB SCREW NR 4 000 010 7602 0 5 WASHER NR 2 000 010 7603 0 6 WASHER NR 2 000 010 7605 0 10 WASHER NR 4 000 010 7831 5 X 12 BUTON SCREW NR 2 000 010 7860 TCEI 5 X 15 SCREW NR 2 000 010 7870...

Page 70: ...6 20 63 Use and maintenance manual S 20DS Front flywheel assembly ...

Page 71: ...0640 Z3H NR 1 000 010 4021 GIB SLIDE ADJUSTMENT PLATE NR 2 000 010 7226 M6 SELF LOCKING SCREW NUT NR 1 000 010 7229 M8 SELF LOCKING SCREW NUT NR 2 000 010 7461 6 X 25 FLAT POINT VCE GRUB SCREW NR 6 000 010 7604 0 8 WASHER NR 4 000 010 7831 5 X 12 BUTON SCREW NR 5 000 010 7870 TCEI 6 X 16 SCREW NR 10 000 010 7871 TCEI 6 X 20 SCREW NR 2 000 010 7872 TCEI 6 X 25 SCREW NR 1 000 010 7890 TCEI 8 X 12 SC...

Page 72: ...6 22 65 Use and maintenance manual S 20DS Vice unit ...

Page 73: ...00 010 1554 CLAMPING BRACKET NR 1 000 010 2372 SCREW NUT 60 NR 1 000 010 2810 LGW25HC 1 R580 Z3H LINEAR GUIDE NR 2 000 010 7413 8 X 30 CYLIND POINT VCE GRUB SCREW NR 2 000 010 7454 8 X 8 CONICAL POINT VCE GRUB SCREW NR 1 000 010 7461 6 X 25 FLAT POINT VCE GRUB SCREW NR 2 000 010 7475 8 X 8 FLAT POINT VCE GRUB SCREW NR 1 000 010 7870 TCEI 6 X 16 SCREW NR 8 000 010 7872 TCEI 6 X 25 SCREW NR 27 000 0...

Page 74: ...6 24 67 Use and maintenance manual S 20DS Driving pulley unit ...

Page 75: ...HER SH NR 1 000 010 7230 M10 SELF LOCKING SCREW NUT NR 1 000 010 7402 6 X 12 CYLIND POINT VCE GRUB SCREW NR 5 000 010 7831 5 X 12 BUTON SCREW NR 5 000 010 7852 TCEI 4 X 12 SCREW NR 2 000 010 7859 TCEI 5 X 12 SCREW NR 3 000 010 7873 TCEI 6 X 30 SCREW NR 2 000 010 7877 TCEI 6 X 45 SCREW NR 2 000 010 7890 TCEI 8 X 12 SCREW NR 2 000 010 7893 TCEI 8 X 20 SCREW NR 4 000 010 7899 TCEI 8 X 60 SCREW NR 4 0...

Page 76: ...6 26 69 Use and maintenance manual S 20DS Cutting head cover ...

Page 77: ...0 12 WASHER NR 10 000 010 7831 5 X 12 BUTON SCREW NR 8 000 010 7945 TCEI 12 X 80 SCREW NR 10 000 016 0142 CENTRAL BLADE COVER NR 1 000 016 0191 BOW WATER COLLECTOR NR 1 000 016 0927 BLADE COVER SHARK NR 1 000 016 1223 BOW SAFETY SWITCH FIX PLATE NR 1 000 016 1224 COVER SAFETY SWITCH FIX PLATE NR 1 000 022 0037 FR 690 SAFETY SWITCH NR 1 000 022 0234 CORD PRESSER NR 1 000 028 0121 JOINT 3 8 17 CL 26...

Page 78: ...6 28 71 Use and maintenance manual S 20DS Motor unit ...

Page 79: ...UT NR 1 000 010 1201 SCREWS AND BOLTS NR 4 000 010 2067 SPECIAL BUSHING DIA 16X8 NR 1 000 010 7111 8 X 7 X 32 KEY NR 2 000 010 7893 TCEI 8 X 20 SCREW NR 4 000 010 7976 TE 10 X 30 SCREW NR 4 000 019 3604 3 PH MOTOR 90L4P KW1 5 B5 V 230 400 50 NR 1 000 025 0766 VF72 F15 P90 V6 GEARBOX NR 1 000 025 0851 MECHANICAL VARIATOR V1FP90 V51 2 VG NR 1 000 025 0863 CONNECTOR TLK 130 50X80 NR 1 000 025 0923 BE...

Page 80: ...6 30 73 Use and maintenance manual S 20DS Cylinders ...

Page 81: ...103 16 X 1 5 FORK NR 1 000 010 7221 M16 LOW SCREW NUT NR 1 000 022 0378 CONNECTOR F REGENERATOR VALVE COIL NR 1 000 022 0615 COIL X CYLINDER VALVE NR 1 000 043 0055 HEAD DOWN FEED CYLINDER NR 1 000 044 1251 CYLINDER REGENERATING VALVE NR 1 000 044 1257 CYLINDER LOADING VALVE NR 1 000 ...

Page 82: ...6 32 75 Use and maintenance manual S 20DS Control panel ...

Page 83: ...ON SCREW NR 8 000 010 7870 TCEI 6 X 16 SCREW NR 4 000 010 7887 TCEI 5 X 40 SCREW NR 6 000 010 7954 TE 6 X 30 SCREW NR 2 000 016 0236 CONSOLLE MOVING ROD NR 1 000 016 0307 CONTROL PANEL NR 1 000 016 1484 CONSOLLE FIX BRACKET NR 1 000 022 0209 RAPID JOINT SEM 29 NR 1 000 022 0247 POLYAMIDE HUMMEL NUT NR 1 000 025 0073 BEARING 63001 2RS NR 2 000 031 3235 KEYPAD SH 452 CCS NR 1 000 034 1166 KNOB 22 MM...

Page 84: ...6 34 77 Use and maintenance manual S 20DS Cylinders S 20DS ...

Page 85: ...20 SCREW NR 2 000 016 0360 LIMIT SWITCH FIX BRACKET SH 330 HH NR 1 000 016 0361 LIMIT SWITCH BRACKET PLATE NR 1 000 016 2082 HYDRAULIC UNIT FIXING BRACKET NR 1 000 022 0378 CONNECTOR F REGENERATOR VALVE COIL NR 1 000 022 0501 LIMIT SWITCH SHLW 155 NR 2 000 022 0592 COIL X CYLINDER VALVE SH 320 SXI AXI NR 1 000 034 1001 LEVER 8 MA PK55 NR 2 000 043 0219 MFF 1 4 CL 2070 310I T JOINT NR 1 000 043 025...

Page 86: ...6 36 79 Use and maintenance manual S 20DS Optional MA ...

Page 87: ...R 1 000 043 0206 4X1 8 CL 6511 HEXAGONAL COUPLING NR 2 000 043 0228 1 4 1 8 CL 2531 REDUCTION NR 1 000 043 0251 M F ELBOW RLA 8 1 8 CL 2020 NR 1 000 043 0264 6 4 1 8 ELBOW JOINT NR 1 000 043 0276 1 8 8 8 CONICAL NIPPLE NR 1 000 043 0290 1 4 QUICK COUPLING NR 1 000 043 0473 1 8 CL 2921 BRASS SILENCER NR 2 000 043 0552 MANOMETER 0 40 NR 0 000 043 0564 FR 1 4 20 08 NR 1 000 043 0601 VMS 114 1 4 08 VA...

Page 88: ...6 38 81 Use and maintenance manual S 20DS Optional Discharge side adaptor ...

Page 89: ...U of M Quantity 010 7205 M10 NUT NR 4 000 010 7605 WASHER DIAM 10 NR 8 000 010 7911 TCEI SCREW 10 X 20 NR 4 000 016 0829 K210 LOWER EXTENDABLE NR 1 000 016 0830 K210 UPPER EXTENDABLE NR 1 000 034 0844 NUT COMPLETE FEET NR 2 000 ...

Page 90: ...6 40 83 Use and maintenance manual S 20DS Optional Discharge side adaptor ...

Page 91: ...IDE 01 20 L 460 NR 1 000 010 7202 M5 SCREW NUT NR 2 000 010 7221 M16 LOW SCREW NUT NR 3 000 010 7861 TCEI 5 X 20 SCREW NR 8 000 010 7863 TCEI 5 X 30 SCREW NR 2 000 010 7872 TCEI 6 X 25 SCREW NR 4 000 010 7890 TCEI 8 X 12 SCREW NR 1 000 010 7972 TE 16 X 60 SCREW NR 3 000 016 1039 INFEED ROLLER BRACKET SUPPORT NR 1 000 025 0921 BEARING 6003 2Z NR 2 000 025 1181 DRY LINTTW CARRIAGE 01 20 NR 1 000 ...

Page 92: ......

Page 93: ...ory circuit The pressure can in any case be set should the workpiece be subject to deforming stress or is unstable during the cutting process the vice should be positioned at 2 3 mm from the piece before final clamping The user is requested to have available in the workshop a plant having the characteristics described in CHAPTER 4 The diagram below shows an exploded view of the air treatment unit ...

Page 94: ...linder head is brought to the FCTI Head Up Limiter position so that the oil level in the compensation tank see photograph below can be checked using the rod If the rod upper ring location is not visible the oil level is insufficient To top up the oil in the tank the instructions are as follows keep the head in the FCTI position fully up by closing the head descent reg ulator unscrew the filler val...

Page 95: ... the hydraulic circuit cause the head to stutter in down phase When this happens bleed the circuit as follows position the head at FCTI using a 10 mm open wrench slacken the bleed valve until oil exits close the valve and perform a number of empty work cycles if necessary top up the compensation tank The oil which spills out during the above operation can be collected using a pipe inserted on the ...

Page 96: ...ing of the head are described in this section M1 Head cylinder Open the base door and remove the mono control unit to be adjusted Loosen the hex locknut on the maximum pressure regulator valve and using a socket wrench increase clockwise or decrease anti clockwise thepressure displayed on the pressure gauge This done tighten the lock nut and return the hydraulic power pack back in side the base ...

Page 97: ...ows open the cutting head cover un tension the band with the relevant hand wheel remove the blade from the flywheels remove the plug connecting the slideway to the cylinder rod move the slide back and forwards to locate any friction or excessive play slacken the nuts using a tubular nut driver to hold the grub screws firm finally tighten the grub screws to take up any play or otherwise slacken the...

Page 98: ...F screws as indicated in the diagram An electric end run exists that determines the FCTA point End Run Head Forward and that can be adjusted to stop cutting as follows Release the fixing screws of the end run support and run it forward and back ward on the slits to near or distance it from the contact point Tighten the screws when the best position has been reached ...

Page 99: ...nd Run Head Backward and End Run Head Forward points block the piece manually in the vice using the hand wheel or using the vice opening closing button in the AV version completely close the head descent speed adjuster set the blade motor selector at 1 BLADE OFF ON press the start button on the control board Slowly open the head descent speed adjuster and allow the blade to descend to about 10mm f...

Page 100: ...the end run lever Start up the blade motor using the button and open the head descent adjuster to perform the cut At the end of cutting close the head descent adjuster again and near the FCTA end run to the end run control rod The closure of the end run contact determines the automatic re ascent of the head as it is pushed by the hydraulic control unit ...

Page 101: ...he blade steady buttons prevent upward blade flexure caused by the vertical action of the cutting force These buttons are fitted on both the front and rear heads and need no adjustment Blade guide plates The plate contact points feature widia inserts which guide the blade longitudinal ly A small amount of play must exist between the plates and blade to ensure that the blade runs smoothly and perpe...

Page 102: ... it as illus trated in the figure below wear protective gloves when making this adjustment make sure there is a small amount of play between the blade and guide plate inserts if the amount of play is not sufficient for the blade to run smoothly adjust the locking torque of the two grub screws with an Allen key ...

Page 103: ...djustments replace any worn plates by removing the plate fixing screw repeat the above sequence of steps on the rear blade guide head refit the front blade guard tension the blade and power up the machine again ...

Page 104: ... as follows In case of machine in emergency or simply to lower the cutting head without starting up belt rotation close the cutting head descent regulator completely and press the START button then gradually open the cutting head descent regulator If the machine has version HH perform the same operations by pressing the mushroom shaped EMERGENCY button and the START button at the same time disconn...

Page 105: ...ade into the front blade guide head make sure the back of the blade is facing the flywheel stop and that the teeth along the lower part of the blade are inclined towards the head pivot Make sure there is a small amount of play between the blade and guide plate inserts repeat the above sequence of steps on the rear blade guide head fit the blade on the flywheels and remount the front and rear blade...

Page 106: ...cutting vice position the square on the cleaned work surface and rest it against the blade close to the right hand vice jaw at a point where the blade teeth do not pre vent contact Slacken the head fixing screw A and adjust the two grub screws B if the blade touches the square at the bottom If the contact point is instead located at the top of the square slacken screw A and tighten grubs screws B ...

Page 107: ...uare Operation sequence place the head in the lowest position Position the goniometer or square against the fixed vice jaw adjacent to the blade If an error in orthogonality is found realign the blade guide heads as follows loosen the TCEI head locking screws A A and uniformly adjust grub screws B B until blade orthogonality in relation to workpiece rest shoulder is obtained After adjusting check ...

Page 108: ... Open the cutting head cover release tension in the belt using the handwheel provided Slacken the grub screw and using a mallet tap the shaft in or out restore the machine and turn the blade Check the distance between the blade and and edge of the wheels if necessary repeat the above operation until a gap od 1 mm is obtained be tween the back of the blade and the edge of the wheels Rear flywheel R...

Page 109: ...king screws on the wheel and manually move it in or out until the blade is correctly distanced from the edge of the wheel Re tighten the screws and check alignment by rotating the blade a few times If necessary make any further adjustments ...

Page 110: ......

Page 111: ...n safety as well as for the safety of other personnel and in the interests of machine productivity H check that his own work and that of the other operators of the machine always complies with the relevant safety standards Therefore check that the safety devices are in position and work perfectly and that personal safety requirements are complied with H Ensure that the working cycle is efficient a...

Page 112: ... the instructions for use and maintenance of the ma chine and those on the product itself General maintenance Daily The daily maintenance operations to carry out on the machine are as follows remove all swarf from the machine preferably with a non fibrous cloth empty the swarf drawer this is located on the right side of the base top up the lubricant coolant level check state of blade wear and repl...

Page 113: ...f necessary see Chapter 7 thoroughly clean the bottom of the water tank and the electropump filter Maintenance of working parts Maintenance personnel working on the S 20DS must pay particular attention to operating components such as the blade tensioning cylinder already dealt with in Chapter 7 loading the air treatment unit and the pneumatic vice No mainte nance is required for the worm screw red...

Page 114: ...ese types of oils Hyd Mech considers that the above product has the best price quality rapport The following oils can also be said to have similar characteristics and are therefore compatible AGIP NB 200 SHELL Lutem TT IP Utens Fluid F Finally a lubricant coolant guaranteed and distributed by a band saw manufactu rer LENOX is BAND ADE SAWING FLUID LENOX tank capacity Lt 80 oil concentration 5 6 ...

Page 115: ... this speed is performed using the mechanical variator according to the values noted in the following diagram The mechanical speed adjuster is an instrument that applied to the S 20DS allows to vary the number of revolutions of the motor spindle This instrument eases the task of whoever must perform particular works adapting the rotation speed of the band to the specific material The advantage is ...

Page 116: ... large dimensions require coarse teeth while small dimensions require finer teeth Whatever the case ensure that there are always at least six teeth engaged in the cut with reference to the thinnest vertical walls positioned transversally to the blade Cutting speed and downstroke speed The cutting speed m min and the downstroke speed cm2 min are limited by the heat generated around the points of th...

Page 117: ...ls Types of swarf H Very fine or fragmented swarf indicates that the downstroke speed and or cutting pressure is too low H Thick and or blue swarf indicates that the blade is overloaded H Long coils of swarf indicate ideal cutting conditions ...

Page 118: ...ed with a silicon steel body and having a high fatigue strength and super high speed steel teeth the two parts are welded by electronic or laser welding Standardised teeth types are termed M2 and M42 the difference being that M42 teeth are harder due to the addition of cobalt to the steel used to make the teeth Key Mo Molyb denum Ni Nickel Si Silicon V Vanadium W Tungsten Al Aluminium C Carbon Co ...

Page 119: ...lled materials for straight or angled cuts Positive rake Positive cutting angle 9 10 constant pitch Can be used for cutting all types of materials and is particularly suited to low carbon and non ferrous steels Used for cutting very large sections and diameters Variable pitch These blades have groups of teeth having different pitches and as a consequence have various tooth dimensions and differing...

Page 120: ...ing type is the most suitable for cutting large dimension pipes and profiles including large sections as well as for cutting solid sections up to the machine capacity limit Pitches available 3 4 4 6 Set The term set refers to the section of material removed by the blade during the cutting operation i e relating to width of cut and the offset position of the teeth with respect to the blade back Sta...

Page 121: ...f set is used with very fine teeth for cutting thin pipe walls and small section profiles from 1 to 3 mm Alternating grouped sets These are groups of teeth angled to the right one straight tooth then a further group angled to the left This set is used for very fine teeth for cutting very thin sections less than 1 mm Alternating set This set is one tooth to the right followed by one to the left Thi...

Page 122: ...4 6 3 4 3 4 3 4 3 4 3 4 3 4 3 4 3 4 3 4 3 4 3 4 3 4 3 4 3 4 60 70 50 60 15 20 15 20 75 90 80 90 25 40 70 80 80 90 S 10 10 S 30 30 S 50 50 S 80 80 S 120 120 S 230 Dimensions of the cutting section S mm Cutting speed mt min Cutting material Blade pitch Number of teeth per inch Lubrication sq mt min cut Structural steel Casehardened steel Steel for turning Mild steel High duty cast iron Rolled steel ...

Page 123: ... 845 En 58 E En 56 A En 58 G A 1 A 2 En 36 4360 50 A 3706 1 2 3 En 20 A En 31 1022 1035 1040 1010 1015 1060 1065 5135 5145 4135 3135 4315 8645 W 1 L 6 T 1 1310 316 304 410 309 S D 3 M 13 3310 3315 ASTMA 36 68 52100 Brinell HB HRB Kg mmq 160 170 160 180 150 175 160 180 160 180 180 205 180 200 200 230 190 230 200 225 190 220 150 190 190 230 217 248 217 248 160 200 130 170 150 200 215 240 200 230 160...

Page 124: ... 19 150 M 28 060 A 40 060 A 96 070 M 55 080 A 40 080 A 62 1717 CDS 110 708 A 37 708 M 40 735 A 50 534 A 99 817 M 40 311 tipo 6 e 7 BD 2 BD 3 BS 1 304 S 15 304 C 12 316 S 16 317 S 16 XC 18 XC 38 H 1 20 M 5 XC 60 XC 75 40 M 5 XC 42 H 1 25 CD 4 35 NCD 6 50 CV 4 100 C 6 Z 160 CVD 12 Z 200 C 12 55 NCVD 7 Z 2 CN 18 10 Z 6 CN 18 09 Z 3 CN 19 10 Z 12 CNS 25 20 Z 6 CND 17 12 304 S 12 C 15 C 35 C 22 Mn C 28...

Page 125: ...ble you to follow a methodical procedure for solving any problem Troubleshooting blade and cutting problems PROBLEM PROBABLE CAUSE SOLUTION Blade scored or scratched Widia inserts chipped or worn Replace Widia inserts loose or tight Adjust Widia inserts dirty Clean and re adjust correctly Cutting surfaces scored Blade teeth worn Replace blade Head downstroke speed too fast Reduce downstroke speed ...

Page 126: ... stroke speeds or clean surfa ce Cutting speed too high The teeth slide on the mate rial without cutting reduce cutting speed Head downstroke speed too slow The band saw runs over the material without removing it increase downstroke speed Insufficient coolant Check coolant level and clean pipes and jets Incorrect fluid concentration Check and use the correct concentration New blade inserted into a...

Page 127: ... 45 right and left by means of the appropriate screws Perpendicularity of the blade to the work surface Check and realign the blade guide heads then adjust the blade using the appropriate screws so that it is perpendi cular to the work surface Blade tension incorrect Bring pressure up to 60 Bar Blade worn Replace blade Tooth pitch unsuitable Probably a blade with too many teeth per inch is being u...

Page 128: ...e al tered surface areas such as oxides or sand or subcooled inclusions in the section These areas are much harder than the blade and will cause the teeth to break scrap or clean these ma terials Workpiece not clamped The blade may break if the workpiece moves during cut ting check the vice jaws and clamping pressure The blade stops in the cut Cutting pressure too high check and restore to rated p...

Page 129: ...peed must be chosen to suit the most critical part of the cut Teeth angled in the wrong direction Fit blade so that teeth point in the right direction Blade run in wrongly When using a new blade the cutting and downstroke speeds must be reduced to half the normal operating speed After the blade has been worn in about 300 cm2 for hard materials and about 1000 cm2 for soft materials the cutting and ...

Page 130: ...rom the back towards the te eth Position of blade on flywhe els incorrect The blade may be scraping on the edges of the flywhe els this problem is generally caused by blades which are deformed or wrongly welded conical Adjust the position of the front flywheel by mo ving the pin or change the blade Blade tension incorrect If the blade tension is too high or too low the blade will be subjected to a...

Page 131: ...d the material Replace or adjust Insufficient coolant Check coolant fluid level clean pipes and jets Incorrect fluid concentration Check and use the correct concentration The blade stops in the cut Cutting pressure too high check pressure and reset to rated pressure Head downstroke speed too fast reduce Head downstroke speed too slow increase The blade slips on the flyw heels incorrect or low blad...

Page 132: ... machine is in EMERGENCY state Blade protection cover Check that the closure is cor rect and the limit stop pres sed Current drop Check connections on the handgrip switch the blade protection limiter and the pressure gauge on the blade tensioner group BMT not energised Minimum Tension Coil Electrical power supply Check the phases the cables the plug the socket BMT Reset switch Make sure that the m...

Page 133: ... is not kinked or blocked Remove the obstruction Air treatment unit Check that the air treatment group is supplying the pres sure shown on the gauge The CCS optional is not working Minimum voltage relay Check that it is correctly sup plied and not burnt out Selector switch Check connections Replace if defective Lock valve Check for impurities preven ting correct functioning Re place if defective R...

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Page 135: ...to eliminate the chips from the chip collection drawer for installation proceed as follows disconnect the machine from the power supply extract and remove the chip collection drawer fit the lower part of the discharger unit in the place of the drawer making the holes coincide for the screws adjust the discharger unit feet so that the conveyor belt is slightly tilted connect the machine to the powe...

Page 136: ...ign of neglect overloading abuse accident inadequate maintenance or unauthorized altering 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 repla ce shall be the limit of its liability under this warranty and the sole and exclu...

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