Hyd-Mech S-25A User Manual

Dear Customer, As a businessman you understand the necessity of keeping the cost of each step of production to an absolute

minimum without sacrificing quality. In the purchase of any new piece of equipment you are looking to increase your production and consequently reduce your cost, while maintaining or improving quality.

With these points clearly in mind we have designed the HYD-MECH S-25A. Our goal is to change stock cutoff from a "necessary evil" to a money making and time saving part of your operation.

Please use this manual to familiarize yourself and your employees on the proper operation and maintenance of the S-25A.

We appreciate the confidence you have shown in our product and wish you every success in its use. Sincerely,

HYD-MECH ENGINEERING LTD.

Stan Jasinski, P. Eng., President

HYD-MECH

P.O. BOX 1087 / WOODSTOCK, ONTARIO N4S 8P6 · PHONE (519) 539-6341 / FAX (519) 539-5126

PRINTED IN CANADA 1995

THIS PAGE INTENTIONALLY LEFT BLANK

TABLE OF CONTENTS

SECTION 1 - INSTALLATION

Safety......................................................................................................................................... 1.1

Lifting and Shipping.................................................................................................................... 1.1

Vise Cylinders............................................................................................................................. 1.2

Head Restraint Bar..................................................................................................................... 1.3

Leveling..................................................................................................................................... 1.3

Wiring Connections.................................................................................................................... 1.4

Hydraulic Oil and Cutting Fluid................................................................................................... 1.4

SECTION 2 - CONTROLS AND OPERATIONS

SUBSECTION 2A - The Control Console........................................................................................... 2.1

Start-up...................................................................................................................................... 2.1

S25 Manual Controls.................................................................................................................. 2.1

Shuttle Length Control................................................................................................................ 2.5

Conventional Length Control Set-up and Calibration................................................................... 2.5

S25 Automatic Controls (PLC 100)............................................................................................. 2.6

Blade Kerf......................................................................................................................... 2.6

PLC in Manual Mode ....................................................................................................... 2.7

PLC in Auto Mode - Single Job......................................................................................... 2.8

PLC in Auto Mode - Multi Job............................................................................................ 2.9

Important Notes With Respect To PLC Operation............................................................. 2.10

Interrupting the Auto Cycle...................................................................................... 2.10

Entering Blade Kerf................................................................................................. 2.11

Inch-Metric Input or Measuring................................................................................ 2.11

SUBSECTION 2B - Saw Cutting Controls........................................................................................... 2.12

Blade Basics............................................................................................................................... 2.12

Variable Speed Control............................................................................................................... 2.13

Hydraulic Feed Control............................................................................................................... 2.13

Using The Saw Cutting Parameters Door Chart........................................................................... 2.14

Step 1 Determine Effective MAterial Width....................................................................... 2.14

Step 2 Setting The Feed Force Limit................................................................................. 2.15

Step 3 Determine Optimum Blade Pitch............................................................................ 2.16

Step 4 Determine Optimum Blade Speed.......................................................................... 2.17

Step 5 Determine Feed Rate Setting................................................................................. 2.18

Cutting Control Set Up Examples................................................................................................ 2.20

SUBSECTION 2C - Mechanical Controls............................................................................................ 2.22

Head Up And Down Limit Setting................................................................................................ 2.22

Coolant Flow.............................................................................................................................. 2.23

Guide Arm Positioning................................................................................................................ 2.23

Blade Changing.......................................................................................................................... 2.24

SECTION 3 - MAINTENANCE AND TROUBLESHOOTING

Blade Brush................................................................................................................................ 3.1

Blade Guides.............................................................................................................................. 3.1

Lubrication............................................................................................................................... 3.2

Cleanliness................................................................................................................................. 3.3

Hydraulic Maintenance................................................................................................................ 3.3

Trouble Shooting......................................................................................................................... 3.4

SECTION 4 - ELECTRICAL SYSTEM

General Information.................................................................................................................... 4.1

Photos of Standard Electrical Components................................................................................. 4.1

Photos of Optional Electrical Components.................................................................................. 4.3

List of Electrical Components For An S-25A With the Optioanl PLC100.................................... 4.4

List of Electrical Components For A Standard S-25A.................................................................. 4.7

Standard Electrical Schematic S25-7-00-1.......................................................... 4.12

Standard Electrical Wiring Diagram S25-70-02 pg.1............................................... .... 4.13

Wiring Diagram S25-70-02 pg. 2 ................................................. 4.14

Wiring Diagram ( Contol Box) S25-70-02 pg.3.................................................... 4.15

Electrical Schematic (PLC Option) S25A-7-00-1A ..................................................... 4.16

Electrical Wiring Diagram PLC S25A-7-00-2A pg.1 ............................................. 4.17

Electical Wiring Diagram PLC (Control Box) S25A-7-00-2A2 pg.2 ........................................... 4.18

SECTION 5 - HYDRAULIC SYSTEM

General Information.................................................................................................................... 5.1

Parts List and Photos of Hydraulic Components.......................................................................... 5.1

Cylinder Components .................................................................................................................. 5.2

Positive Downfeed Valve Components ...................................................................................... 5.3

Hydraulic Schematic S25A-6-00-1 ...................................................... 5.4

Hydraulic Plumbing Diagram S25A-6-00-2 ....................................................... 5.5

Plumbing Diagram (VVP Option) S25A-6-00-2....................................................... 5.6

SECTION 6 - MECHANICAL ASSEMBLIES

Parts List and Photos:

Blade Guide Arm Assembly........................................................................................................ 6.1

Guide Arm Rack Assembly......................................................................................................... 6.2

Blade Brush Assembly................................................................................................................ 6.3

Drive Assembly.......................................................................................................................... 6.4

Idler Wheel Assembly................................................................................................................. 6.5

Vise Cylinder Mounting Assembly............................................................................................... 6.6

Front Table Assembly ................................................................................................................ 6.7

Gearbox Assembly.................................................................................................................... 6.8

Auxiliary Table Assembly............................................................................................................ 6.9

Shuttle Guide Assembly.............................................................................................................. 6.10

Infeed Conveyor assembly......................................................................................................... 6.11

Pivot Link Assembly.................................................................................................................. 6.12

Head Swing Assembly............................................................................................................... 6.13

Coolant System Assembly.......................................................................................................... 6.14

Outfeed Table Assembly............................................................................................................. 6.15

Length Control Assembly............................................................................................................ 6.16

SECTION 7 - OPTIONAL SAW EQUIPMENT

Overhead Bundling Attachment.................................................................................................. 7.1

Variable Vise Pressure................................................................................................................ 7.2

Blade Breakage Switch............................................................................................................... 7.3

Out of Stock Limit Switch............................................................................................................ 7.4

Remote Blade Speed Adjustment............................................................................................... 7.5

SECTION 8 - SPECIFICATIONS

Specification List........................................................................................................................ 8.1

Dimensional Drawings................................................................................................................ 8.2

SECTION 9 - WARRANTY

Warranty..................................................................................................................................... 9.1

SECTION 1 - INSTALLATION

SAFETY

All safety precautions must be observed during installation, operation, maintenance or repair work on the S-25A bandsaw machine.

-Inspect the machine throughout before power hook-up. Special attention should be paid to electrical and hydraulic systems keeping an eye out for any potential shipping damage.

-Power hook-up should be performed by qualified personnel.

-Machine should be used according to its specifications.

-Long hair, loose clothing, gloves, should not be worn while operating the machine.

-Stock must not be loaded while blade is running.

-Machine should not be operated unless all guards, covers and doors are in place and closed.

1.1

-Long and heavy stock should be supported in where it extends off the saw table.

-Area around the machine should be kept clean and tidy.

-Operator should keep a safe distance from all moving parts especially the blade and vises.

-If not performing properly the machine should be stopped immediately and repaired by a qualified person.

-No modifications to the machine are allowed without Hyd-Mech’s prior approval. Any approved modifications shall be performed by trained personnel.

LIFTING AND SHIPPING

To lift the S-25 bandsaw an overhead crane with a “T” shaped lifting harness should be used Fig. 1-1A and Fig. 1-2A. Hook the lifting harness to a chain shackle on the infeed base 'A' and to chain shackles on both sides of the saw base 'B'. An experianced rigger should select the rigging based on the 7300 LB. weight of the saw.

WARNING: Under no circumstances should the lifting harness be pushing against any part of the saw.

Fig. 1-2AFig. 1-1A

1.2

VISE CYLINDERS

To permit the S-25A to be shipped in a standard trailer, the three vise cylinders must be fully retracted, the hydraulic hoses disconnected, and the mounting brackets unbolted from the infeed table Fig. 1-3. The cylinder tube is then rotated around the cylinder rod so that the mounting bracket and tube are upside-down. This jaw is now pushed completely toward the fixed jaw letting the bracket rest on the infeed table. Before the initial start-up, reinstall the vise bracket and reconnect the vise cylinder hoses Fig. 1-4. TABLE 1 lists the hose reconnections, Fig 1-5 shows one of the junction blocks as it appears when machine is shipped. Fig. 1-6 shows a junction block after the vise cylinder hoses have been reconnected.

HOSE # HOSE TO CYLINDER CONNECTING HOSE

CON NECTI ON AT JUNCTION BLOCK

34 ROD END (FRONT VISE) 32 33 PISTON END 31 24 ROD END (SHUTTLE VISE) 22 23 PISTON END 21 34C ROD END (AUX. VISE) 32 C 33C PISTON 31C

TABLE 1

Fig. 1-3 Vises disassembled for shipping.

Fig. 1-5 Junction block plumed for shipping.

Fig. 1-4 Reassembled vises.

Fig. 1-6 Vise cylinder plumed to junction block.

HEAD RESTRAINT BAR

The S-25A bandsaw is shipped with the head secured at the 45° position by a restraint bar and is wired down to the base to ensure that the head can not move in any direction during shipping. After the saw has been lifted into position, the head restraint bar must be removed along with the wire.

Fig. 1-7 Head restraint member and tie down wire.

1.3

LEVELLING

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.

Machine should be levelled in both directions ie. across its table and along its infeed conveyor especially when machine is to be inserted into a large conveyor system.

Nine levelling screws are provided. Steel plates are to be placed under each screw to prevent their sinking into the concrete floor. In cases when machine is to be anchored permanently, anchoring holes are provided. They are located next to the levelling screws.

NOTE: In some cases levelling the saw infeed and auxiliary 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).

Fig. 1-8 Level the saw using a precision level.

1.4

WIRING CONNECTIONS

After the machine is levelled and anchored the necessary power hook-up needs to be performed. In order to provide safe operation as well as to prevent potential damage to the machine, only qualified personnel should make the connections.

BEFORE START-UP THE FOLLOWING TWO POINTS SHOULD BE CHECKED FOR

-signs of damage that may have occurred during shipping to the electrical cables and the hydraulic hoses.

-the hydraulic oil level is between the upper and lower lines on the level gauge (see SECTION 3 pg. 3.4). 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 L1, L2, L3 terminals at the junction block inside the control box Fig.1-9. 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 Fig. 1-10 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 the phase order.

ATTENTION: Running the hydraulics "backwards" can damage the hydraulic pump.

L1, L2, L3 Terminals

Ground Clamp

Fig. 1-10 System pressure gauge.

Fig. 1-9 Electrical junction block.

HYDRAULIC OIL AND CUTTING FLUID

The S-25A bandsaw is supplied with Valvoline 150-46 hydraulic oil. If it is necessary to change the oil to a different brand see the HYDRAULIC SECTION for an equivalent grade oil.

No cutting fluid 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 the manufacturer.

SUB SECTION 2A - CONTROLS AND OPERATIONS

THE CONTROL CONSOLE

START-UP

The S-25A 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 remotely. (See Fig. 2A-1)

We can not overstress the importance of familiarizing yourself with the controls of the S-25A prior to starting the machine.

2.1

NOTE: WHEN STARTING THE S-25A FOR THE FIRST TIME

SWITCH IS IN IT'S

NEUTRAL

POSITION, THE BLADE IS RUNNING IN A DIRECTION, AND THAT THE HYDRAULIC PRESSURE IS pg. 3.4).

MAKE SURE

900 PSI

THAT THE MODE SELECTOR

COUNTER CLOCKWISE

± 25 PSI (see SECTION 3

Fig. 2A-1 Standard S-25A operation control panel.

S-25A MANUAL CONTROLS

HYDR AULI C STAR T B UTTO N: Starts hydraulic pump motor and energizes the BLADE START BUTTON

BLADE MO TOR This button is only operative when the hydraulic system has been STA RT BUTTO N: started. Momentarily depressing this button will start the blade

BLADE MOTOR Momentarily depressing this button will stop the blade motor. STOP BUTTON:

and the MODE SWITCH. The fixed vise will open or close according to its selector switch position. The actions of all other functions are dependent upon the MODE SWITCH position. (see MODE SWITCH)

motor.

2.2

EMERGENCY STOP

This button will stop both the hydraulic and blade motors and

BU TTO N: de-energizes the MODE SWITCH.

The head and shuttle motion will cease. The vises will remain as they are, but if closed, they will gradually lose gripping force. For this reason all long stock should be supported so that in this eventuality, it will not fall.

HYDRAULIC AND B LADE Both of the drive motors are protected by individual overload relays. MOTOR RES ET B UTTONS : If a motor draws excessive amperage, the corresponding relay will

open and the entire machine will shut down as if the EMERGENCY STOP button had been pressed. Depressing the corresponding RESET button will close the opened contactor overload and allow the machine to be restarted.

MODE SWITCH: Has three positions, MANUAL, NEUTRAL, and AUTO

MANUAL: in manual all the following functions except the HEAD

SWING CONTROLS and the AUTO CYCLE DIAL, are operative.

NEUTRAL:only the FIXED VISE SWITCH, the COOLANT SWITCH

and the HEAD SWING CONTROLS are operative.

AUTO: all of the functions are under the control of the AUTO

CYCLE DIAL, and the MANUAL CONTROL switches are inoperative.

HEAD CONTR OL S WITCH: Inoperative unless MODE SWITCH is in MANUAL.

UP: the head will rise until it reaches the HEAD UP LIMIT SWITCH SETTING. HOLD: the head will remain stationary. DOWN: the head will descend until it reaches the bottom. Descent

is controlled by the FEED RATE and FEED FORCE controls.

INDE X F ORWA RD BUTTON : Button is inoperative except when MODE SWITCH is in MANUAL.

Depressing this button fully will cause the shuttle table to quickly advance toward the saw table until the button is released or the shuttle reaches the forward limit of travel.

Depressing this button partially will cause the shuttle table to advance toward the saw table at a very slow rate until the button is released or the shuttle reaches the forward limit of travel. This control is intended to assist in the accurate positioning of heavy pieces of stock.

INDEX REV ERSE BUT TON: Button is inoperative except when MODE SWITCH is in MANUAL.

Depressing this button fully will cause the shuttle table to quickly retract away from the saw table until the button is released or the shuttle reaches the rearward limit of travel.

Depressing this button partially will cause the shuttle table to retract away from the saw table at a very slow rate until the button is released or the shuttle reaches the rearward limit of travel. This control is intended to assist in the accurate positioning of heavy pieces of stock.

INDEX VISE SWIT CH: This switch is only operative when the MODE SWITCH is in

MANUAL. It operates in the same manner as the FIXED VISE SWITCH but controls the vise mounted on the shuttle table.

2.3

FIXED VISE SWITCH:

This switch is operative as long as the machine is supplied with power. Unlike the other function switches it is active when the MODE SWITCH is in NEUTRAL. The FIXED VISE SWITCH is wired this way to insure that the fixed vise will not release the work piece when switching between AUTO and MANUAL, or if the saw should shut down during a cut due to a motor overload. This security is provided only if the FIXED VISE SWITCH is left in the CLOSE position during automatic operation; the AUTO CYCLE DIAL will open the front vise as required. The FIXED VISE SWITCH should be turned to OPEN when shutting the saw down for a prolonged period of time (i.e. overnight). When this switch is in the CLOSE position, the fixed vise will stay closed even when shutting the saw down with the EMERGENCY STOP button, but the vise pressure will quickly drop off and it should not be relied upon to hold unbalanced work pieces after shutdown.

FAST SWING SWITCH: This switch is only operative when the MODE SWITCH is in the

NEUTRAL position. Positioning this selector switch to 90° will swing the head fast towards the 90° position. Likewise positioning this selector switch to 30° will swing the head toward the 30° position. Leaving the switch on the lock position will restrain the head from further angular motion. The angle change can be observed on the angle scale located on the head swing drum Fig. 2A-2.

SLOW SWING SWITCH: Operates in the same manner as the FAST SWING SWITCH except it

swings the head at a slower rate making fine adjustment easier.

COOL AN T SWITC H: Has three positions ON, WASH, and OFF

MUL TI I NDE X CO UNT ER:The counter is operative only in the AUTO MODE. The number on

Fig. 2A-2 Angle scale.

ON: the coolant flows only when the head descends WASH: coolant flows any time the machine is under power, permitting wash-down with the hand line without running the machine OFF: no coolant flow

the manually set thumb wheel display, controls the number of shuttles made by the shuttle table between each saw cut Fig 2A-3. If the setting is changed during the shuttling portion of the AUTO CYCLE, the new setting will not be accepted until after the current cutting cycle.

2.4

AUTO CYCLE DIAL:

This knob rotates in a clockwise direction when the saw is running and the MODE SWITCH is in AUTO Fig. 2A-4. As it rotates it sends out control commands indicated on the dial. Whenever the head or shuttle motion is initiated, the dial will stop and wait for the motion to reach the end of its travel, and then it will resume its rotation. It is recommended that the AUTO MODE always be initiated with the AUTO CYCLE DIAL in the START position. This will result in the fixed vise closing, the index vise opening, the head lowering (unless it is already down), and the shuttle table retracting (unless it is already retracted). The head will then rise to the limit set by the HEAD UP LIMIT SWITCH and the cycle will

proceed in order, as on the dial. When manually positioning the AUTO CYCLE DIAL, it should always be turned in the clockwise direction. NEVER TURN THE AUTO CYCLE DIAL COUNTER CLOCKWISE.

PIECE COUNTER: The counter is operative in both AUTO and MANUAL Fig. 2A-5. It is manually

set to the number of cuts desired and counts down to zero at which point it turns the saw off. If the counter is set at zero it will not permit the saw to be started. If in the MANUAL MODE it is desired to have the saw shut down at the end of the cut, the PIECE COUNTER must be set to 1 (one) before the cut. The counter counts one half count when the head down signal begins and the other half count when the head down signal ends. Thus, if the AUTO CYCLE is interrupted during cutting, a false count will be recorded. In this event simply push the PIECE COUNTER back up one count.

Fig. 2A-3 Multi index counter.

BLADE SPEED SWITCH: This optional switch controls the blade speed which can be infinitely adjusted (OPTIONAL)

between 75 and 400 SFPM. The blade speed change can be observed on the blade speed digital display, located on the front control panel (Fig. 2A-6). On machines quipped with the optional PLC 100 controller the blade speed is displayed in the blade speed window located on the PLC controller (Fig. 2A-

7). Switch is active only when blade is running.

Fig. 2A-6 Blase speed digital readout.

Fig 2A-4 Auto cycle dial. Fig. 2A-5 Piece counter.

Fig. 2A-7 Blade speed display window on the PLC 100.

SHUTTLE LENGTH CONTROL

To adjust for desired stock for a production run,as shown in Fig. 2A-8, move the Adjusting block 'A' to the desired position along the scale. Fine adjustments can be made using the micrometer 'B'. The zero point on the micrometer is .250 inch. This gives you 1/4" in and 1/4" out for fine adjustment.

Fig. 2A-8 Length control block.

CONVENTIONAL LENGTH CONTROL SET-UP AND CALIBRATION

2.5

The calibration makes no allowance for kerf loss and this must be added by the operator. Although blade thickness is standard with relation to blade size, blade kerf may vary due to different pitch or manufacturer. We recommend that you measure the kerf of the blade which you are using by making a cut into a solid piece of steel and measuring the width of the cut. In the following examples we will use a blade kerf of .080". The procedure for setting and calibrating the conventional length control is as follows:

To obtain a desired piece length add the kerf allowance. If the resulting length is less then 40", fully advance the shuttle and set the adjusting block pointer to the resulting length. Set the Multi-Index Counter to "1". If the resulting length is greater than 40", divide it by the smallest number which will result in a dividend less than 40". Fully advance the shuttle and set the adjusting block pointer to the resulting dividend. Set the MULTI INDEX COUNTER to the divisor.

Example 1

Desired piece length 9 3/4"

+ Kerf aprox. 1/16"

= Total shuttle required 9 13/16"

The result is less than 40". Set the adjusting block pointer to 9 13/16" and the MULTI INDEX COUNTER to "1".

Example 2

Desired piece length 73 3/8" + Kerf 1/16"

= Total shuttle required 73 7/16"

The result is greater than 40". We must divide by 2 in order to get a dividend less than 40 inches.

Set the adjusting block to 36 23/32" and the MULTI INDEX COUNTER to "2".

73.4375 = 36.719

2.6

It is wise to make a trial cut in order to check the accuracy of the length setting. Start by being certain that the head up limit switch is correctly set up for the work piece. Using the manual mode raise the head fully and advance the stock about 1/16" - 1/8" beyond the blade for a trim cut. Make the required trim cut.

Set the PIECE COUNTER to "2" and the AUTO CYCLE KNOB to "START". Start the blade and switch the MODE SWITCH to "AUTO". The stock will advance and a cut will be made resulting in a trial piece.

Check the length of this piece. If it is not accurate enough, use the micrometer head to zero in on exactly the length you require. The general procedure for using the micrometer length adjustment is as follows:

NEW MICRO SETTING = OLD MICRO SETTING + (DESIRED LENGTH - ACTUAL LENGTH)

NUMBER OF INDEXES

If in example 1, the resulting piece was 9.775 inches rather than the disired 9.750" then:

NEW MICRO SETTING = .250 + 9.750 - 9.775

1 = .250 + (-.025) = .225

If in example 2, the resulting piece was 83.313" rather than the required 83.275" then:

NEW MICRO SETTING = .250 + 83.375 - 83.313

= .250 + .062

= .271

Increasing the micrometer setting increases the part length, while decreasing the micrometer setting decreases the part length.

NOTE: Remember to reset the micrometer to exactly midscale at the end of each run.

S-25A AUTOMATIC CONTROLS

BLADE KERF

Although blade thickness is standard with respect to blade size, blade kerf may vary due to different pitch or manufacturer. We recommend that you measure the kerf of the blade which you are using by making a cut into a solid piece of steel and measuring the width of the cut. In the following examples we will use a blade kerf of .080".

Fig 2A-9 Optional PLC 100 programmable controler.

2.12

SUBSECTION 2B - SAW CUTTING CONTROLS

This section has been prepared to give the operator the ability to set up the saw for most cutting situations. The saw is equipped with variable speed control and hydraulic feed control, as well as an extensive door chart to guide the operator in the correct setting of these controls.

BLADE BASICS

Technology is rapidly changing all aspects of production machining. Metal cut-off 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 2/3 or 4/6 bi-metal blade supplied with the S-25A series saws) 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 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 six points must be closely monitored to ensure long blade life:

1. Proper blade tension should be maintained. (see SECTION 3 pg. 3.4 BLADE TENSION)

2. Generous coolant application is essential with almost all materials. A high quality and well mixed coolant will many times extend blade life, and also increase cutting rate quality. On those materials where c oolant is undes irable forcutting, 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 must be chosen.

5. The proper blade speed must be selected.

6. The proper feed rate must be applied.

2.13

VARIABLE SPEED CONTROL

Blade speed can be adjusted infinitely between 75 and 400 SFPM (Surface Feet/Minute). Adjustment should be made only when the blade is running. Clockwise rotation of handwheel “A” (Fig. 2B-1) increases the blade speed while counter clockwise rotation decreases the blade speed. Blade speed is displayed on an indicator located in the adjustment hand wheel. On machines equipped with the optional remote blade speed adjustment, adjustment is made using the BLADE SPEED selector switch Fig 2B-2 located on the control panel. Blade speed is displayed on the digital blade speed display Fig. 2B-3 or on the blade speed display window located on the optional PLC 100 controller Fig. 2B-4.

Fig. 2B-1 Blade speed adjustment.

Fig. 2B-2 Blade speed selector switch.

Fig. 2B-3 Digital blade speed display.

Fig. 2B-4 Blade speed display window.

HYDRAULIC FEED CONTROL

The hydraulic feed control is located on the control panel below the electrical control console. These controls allow independent control of Feed Force and Feed Rate. See Fig. 2B-5.

Feed Force Gauge

Fast Approach Lever Depress for fast head descent

Feed Force Knob Used to set Feed Force Limit (clockwise rotation to increse and counter clockwise rotation to decrease).

Fig 2B-5 Hydraulic feed control.

Feed Rate Knob with feed rate scale (calibrated in inches/minute) Used to set Feed Rate (counter clockwise rotation to increase and clockwise rotation to decrease

USING THE SAW CUTTING PARAMETERS ON CHART

2.14

A full size chart is mounted on the panel. The chart contains five steps for the operator to follow in order to achieve optimum performance of the saw.

Fig. 2B-6 Saw cutting parameter door chart.

As Example #1 we will use the CHART to set up the saw, for cutting 8" Diameter, 1045 Carbon Steel.

STEP 1

DETERMINE EFFECTIVE MATERIAL WIDTH, W (in.)

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 diractly measured. For bundles of tubes and structuals, measuring the effective width is difficult. For those cases effective width is 60% to 75% of the actual material width.

Fig. 2B-4

NOTE:

2.15

Both effective material width and guide arm width are used in setting the saw. Guide arm width is the distance between the guide arms and is used in STEP 2. 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 STEP 3 and 4.

In Example #1, for an 8" diameter solid, effective material width is 8".

STEP 2

SET FEED FORCE LIMIT The Feed Force Limit is the maximum amount of force with which the head is allowed to push the blade into the

workpiece. The controls for setting the Feed Force Limit consist of: Feed Force Gauge

Feed Force Knob

Feed Rate Knob

To set FEED

Fig. 2B-5 Hydraulic feed control.

FORCE LIMIT:

- With the Mode Switch in “manual” position, move the head fully down.

- After the head is down, open the feed rate valve, depress the yellow FEED FORCE SETTING button and adjust the FEED FORCE.

Example #1

Set the feed force at 250-300 psi. This will protect the blade from buckling. This amount of feed force will also prevent the blade from cutting out of square. If the cuts obtained are not square and the blade is not at fault, reduce the feed force pressure. Generally a higher feed force can be used when cutting solids. When cutting structuals or bundles a lower feed force should be used.

Fig. 2B-6 Feed Force pressure.

2.16

SIGNIFICANCE OF GAUGE READING: With the head down and yellow button depressed the (FEED FORCE “set” on manual control panel) FEED

FORCE gauge indicates the setting of the FEED FORCE LIMIT. During cutting the gauge shows the actual force being applied by the blade to the workpiece.

In typical cutting situations, the needle on the gauge will rise toward 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 the preset FEED FORCE LIMIT, which it will not exceed.

When cutting soft materials and or narrow cross sections, the gauge reaging may be low, but the FEED RATE will be maintained. Any changes during cutting, such as, material hardness or material cross section will influence the gauge readings. Therefore, in some cutting situations the gauge reading may rise and fall. A very low gauge reading is uaully observed when the blade is approaching the material to be cut, but not yeyt cutting.

STEP 3

DETERMINE OPTIMUM BLADE PITCH, TEETH PER INCH (T.P.I) Selecting a blade with proper tooth pitch is important in order to acheive optimal cutting rates and good blade

life. For cutting narrow or thin wall structual 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 (see Fig 2B-7 below).

It is impractical to change the blade to the proper pitch every time a different width of material is cut and it is not

Fig. 2B-7 Optimum blabe pitch, teeth per inch (T.P.I.) for effective material width, W (in.).

2.17

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.

In our Example #1, for an effective material width of 8" the optimum blade has 2/3 teeth per inch.

STEP 4

DETERMINE OPTIMUM BLADE SPEED, V (ft/min) The relationship between optimum blade speed and effective material width for various materials is represented

on the graph Fig. 2B-8. The graph shows that as effective material width gets wider or as material gets harder, lower blade speeds are

recomended. If material is narrower or soft, higher blades speeds should be selected.

Fig. 2B-8 Optimum blade speed curves.

In Example #1 8" Dia, 1045 Medium Carbon Steel solid bar is to be cut.

- On the graph above find the Medium Carbon Steel Curve which represents the optimum blade speeds for 1045 Carbon Steel.

- On the horizontal axis (effective material width axis) find number 8 which represent effective material width of an 8" diameter solid.

- Find the point where a vertical line from 8" 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”.

- Thus, for 8"diameter, 1045 Carbon Steel solid bar 200 ft/min is the optimum blade speed. NOTE: 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 structuals and bundles, a lower blade speed may reduce vibration and prevent premature blade failure.

The table below shows a few examples of optimum blade speed for different materials. TABLE 2B-1

NOTE: About Material Hardness The Graph - Step 4, Fig 2B-8, illustrates blade speed curves for material hardness 20 Rc (225 Bhn) or lower.

If the material is harder , use multipliers from the NOTE (near the bottom) of the Graph.

2.18

For example, if the 5 diameter, 1045 Carbon Steel material, from the table above, had been hardened to 35 Rc (325 Bhn) then we must multiply the blade speed of 225 ft/min by .60.

Thus 225 ft/min x .60 = 135 ft/min. (This is the optimum blade speed for 5" diameter, 1045 Carbon Steel, 35 Rc hard).

STEP 5

DETERMINE FEED RATE SETTING, FR (in/min) FEED RATE is the vertical speed at which the blade descends through the workpiece.

FEED RATE Knob controls FEED RATE of the blade in the range 0 to 25 in/min. The FEED RATE should be adjusted only in one direction (from “0” to required value). If you go too far, go back to “0” and come back up. To set FEED RATE for particular cutting situations use the Graph, Fig 2B-10, which represents the relationship between FEED RATE, blade speed and blade pitch.

Fig. 2B-9 Hydraulic feed control.

2.19

` For Example #1, it is known from Step

3 that otimum blade pitch is 2/3, and from Step 4 that blade speed ,200 ft/ min. From the graph, Fig. 2B-10 the FEED RATE is determined in the following way:

- On the horizontal axis (blade speed axis), find 200 ft/min.

- Find the point where a vertical line from 200 ft/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 FEED RATE. Thus 1.8 in/min is the FEED RATE for cutting 8" diameter, 1045 Carbon Steel when the optimum 2/3 pitch blade is used.

Fig. 2B-10

If the machine is fitted with a blade coarser than optimum (eg. 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 decresed to 1.3 in/min for this blade.

If however, the machine is fitted with a finer than optimum blade (eg. 3/4 TPI) we use the graph for the optimum blade as before, and then use a multiplier given by the table 2B-2.

2/3 .21 .25 .31 .50.38 .71

.57

.34

3/4

TABLE 2B-2

As a result we find that we must decrease our FEED RATE of 1.8 in/min by a factor of .71. In this case we should use FEED RATE of 1.8 in/min x .71 = 1.3 in/min.

CUTTING CONTROL SET UP EXAMPLES

FOR EXAMPLES #2 AND #3 PLEASE GO TO THE SAW AND FOLLOW STEPS 1-5 ON THE CHART:

Example #2

Material to be cut

-Round Steel Tube

SAE 4320 6" OD x 4" ID

-Hardened to 35 Rc (325 Bhn)

STEP 1

Effective Material Width: 4 1/2" (.75 x6)

STEP 2

Feed Force limit setting for 6" Diameter material 180 P.S.I.

STEP 3

Optimum blade pitch (TPI): 3/4 T.P.I. Actual blade pitch on the saw: 4/6 T.P.I.

2.20

STEP 4

Optimum blade speed for 4 1/2" effective 225 ft/min material width

Blade speed reduced by hardness factor: 225 ft/minx.60=135ft/min

STEP 5

Feed Rate for 3/4 TPI blade: 1.8 in/min Feed Rate for 4/6 TPI blade: 1.8 in/minx.70=1.3in/min

(reduced by finer than optimum blade pitch factor, Table 2B-2 - STEP 5)

2.21

Example #3

Material to be cut

-low carbon steel

-2" x 2" tube x 1/4" wall

-clamped in vises 12 pcs in a bundle (6" x 6")

STEP 1

Effective material width: 5" (6" x 8")

STEP 2

Feed Force limit for 8" wide material: 180 P.S.I.

STEP 3

Optimum blade pitch for 5" effective material width: 3/4 T.P.I.

STEP 4

Optimum blade speed for 5" effective material width: 320 ft/min

STEP 5

Feed Rate: 4.0 in/min

SUBSECTION 2C - MECHANICAL CONTROLS

HEAD UP AND HEAD DOWN LIMIT SETTING

Head Up Limit: In order to maximize production in the automatic cycle the HEAD UP LIMIT should be set

to match the height of the material. By adjusting the HEAD UP LIMIT SETTING KNOB the head can be set to rise just above the material eliminating unnecessary head travel in the cycle and therefore shortening the cycle time.

To Set Limit: As in Fig. 2C-1,for coarse adjustment depress button 'A' and slide knob 'B' up or down to

approximately the desired height. To finely adjust the height turn knob 'B'. Counter clock wise rotation of the knob raises the upper limit of head travel and clockwise to lower the limit of head travel. The head up limit should be set by starting with the head below the required height and the knob screwed in to the limit switch. MANUAL mode must then be selected and the HEAD CONTROL SWITCH rotated counter clockwise until the blade has at leas 1/ 2" clearance above the material and slightly more when cutting bundles.

2.22

Fig. 2C-1 Head limit adustment.

Head Down The coolant pumpshuts off when the cut has been completed. Limit Switch: The exact instant it shuts off the power supply can be set by the adjustment bolt 'A' as

shown in Fig. 2C-2 NOTE: 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 auto cycle.

Fig 2C-2 Head down limit switch

2.23

GUIDE ARM POSITIONING

It is desirable, in order to maintain maximum beam strength in the blade, to keep the guides as close together as possible. This span is obviously determined by stock size. As shown in Fig. 2C-3 ,in order to increase or decrease the span between the guide arms, simply undo the guide arm lock handle A and move the guide arm closer to or further away from the other guide via the rack-and-pinion crank B. We cannot overstress the importance to performance of keeping blade span to a minimum.

Fig. 2C-3

COOLANT FLOW

A generous flow of coolant should be applied in order to increase production and blade life.

Machine is provided with two independently controlled coolant spouts.

- One from the adjustable guide arm nozzle. This one should always flood the blade with coolant. Slight readjustment may be required when changing the blade speed. A properly adjusted flow of coolant should cover the blade which in turn will carry it into the cutting area. Flow adjusting tap is shown in Fig. 2C-4.

- The coolant hose on the fixed guide arm should be used in cases when cutting solid bars, bundles or wide structurals. The flow of coolant should be directed into the opening created by the blade. Flow adjusting tap is shown Fig. 2C-4.

NOTE: When cutting materials that do not need coolant (cast iron) some coolant flow is required to provide blade lubrication to prevent blade scoring by carbides.

Coolant Flow Adjusting Taps

Fig. 2C-4

BLADE CHANGING

1. Select manual mode and raise the head slightly (about two inches at the drive side guide arm).

2. Open the idler and drive doors.

3. Remove the blade guard Fig. 2C-5.

4. Release the carbide guides Fig. 2C-6.

5. Release the blade tension by positioning the blade tension selector switch to '-' Fig. 2C-7.

TURN THE HYDRAULICS OFF.

6. Push the blade out from between the carbide guides.

7. Remove the blade.

8. Install a new blade. The teeth should be facing away from the head of the saw. The teeth on the part of the blade between the two guide blocks should point towards the drive side of the head.

9. Turn the hydraulics on and tension the blade by positioning the blade tension selector switch to '+'.

2.24

10. Start the blade for a few rotations in order for the blade to seat in the carbide guides and to track itself on the wheels.

11. Replace the blade guard.

12. Close the carbide guides Fig. 2C-8.

13. Close the idler and drive doors.

Fig. 2C-5 Blade guard.

Fig 2C-6 Carbide handles (released).

Fig. 2C-7 Blade tension switch.

Fig. 2C-8 Carbide handles (locked).

THIS PAGE INTENTIONALLY LEFT BLANK

3.1

SECTION 3 - MAINTENANCE AND TROUBLESHOOTING

BLADE BRUSH

The blade brush is properly set when machine leaves the factory but it wears out during operation and needs to be readjusted periodically. The blade brush assembly is shown in Fig. 3-1. In order to readjust it, the nut on the adjusting screw needs to be loosened and the screw turned counter clockwise until wires from the brush touch the bottom of the blade gullets Fig. 3-2.

NOTE: Proper adjustment and operation of the blade brush is essential to the correct operation of the bandsaw and the longegivity of the blade. Therefore periodic maintenance and inspection of the machine should not be neglected.

If the brush gets worn to approximately 70% of its original diameter 3 " OD it should be replaced. A brush may be purchased through a HYD-MECH dealer in your area.

Adjusting screw

Fig. 3-1 Blade brush assembly

Fig. 3-2 Properly adjusted blade brush

BLADE GUIDES

Each guide arm is provided with a set of blade guides. Both sets are identical, except for the top carbides. Each set consists of: top carbide, fixed carbide and adjustable carbide pad. Guide blocks fitted with blade guides are shown in Fig. 3-3.

Fig. 3-3 Assembled blade guides.

Adjustable carbide pad

Fixed carbide pad

Fig. 3-4 Disassembled blade guides.

Top servo carbide

Top carbide

3.2

LUBRICATION

The design of the S-25A was intended to minimize maintenance, although periodically certain moving parts need lubrication. We recommend that this periodic lubrication be done once a month using any general purpose grease at the points indicated G.

Fig. 3-5 Vertical Pivot.

Fig. 3-6 Horizontal Pivot.

Fig. 3-7 90 Degree Shaft.

Fig. 3-9 Idler Wheel Slider.

Fig. 3-8 Vise Ways.

Fig. 3-10 Guide Arm Positioning Shaft.

3.3

Fig. 3-11 Counterbal-

Fig. 3-12 Shuttle Bearing Housing.

ance Shaft.

CLEANLINESS

The S-25A series design should endure heavy operating conditions and provide the customer with flawless machine performance. To extend good performance some care is required, especially cleanliness.

The following areas should be kept clean of dirt, grease and chips:

-CONTROL CONSOLE -OUT FEED TABLE

-DOOR CHARTS -LARGE BUILD UP OF CHIPS IN THE SAW BASE

-WHEEL BOXES -VISE WAYS

-BLADE GUIDES

NOTE: All parts should be cleaned before any repair or service is performed on them.

A wash gun is supplied for washing chips off the table and vise ways Fig. 3-14.

Oil filter

Level gauge Oil fill cap

Fig. 3-13 Oil tank.

HYDRAULIC MAINTENANCE

There are only four 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 every 1000 working hours or once per year. Suitable replacement elements are:

Fig. 3-14 Wash down hose.

CANFLO RSE-30-10 GRESEN K-23018 LHA SPE-15-10 ZINGA AE-10

3.4

2. 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-25A is shipped from the factory with Valvoline 150-46 hydraulic oil. Generally any brand of recognized mineral hydraulic oil with the same properties should be compatible with Valvoline 150-46, but to avoid any risk we suggest staying with Valvoline 150-46. 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 automatic cycles with the index set to full stroke and head to full rise, drain the tank again, and finally fill the tank with the new brand.

Hydraulic tank capacity is approximately 17 US gallons.

Recommended replacement oils: Chevron AW Hydraulic Oil 46

Esso - NUTO H46 Mobil - Mobil DEC 25 Petro Canada - Harmony AW 46 Texaco - Rando HD 46 Shell Tellus 46

3. OIL TEMPERATURE - Oil temperature is indicated by a thermometer contained in the level gauge Fig 3-13. Oil temperature during steady operation should stabilize at about 50 - 55 F° above room temperature. Thus in a 70 F° shop one might expect an oil temperature of about 120 F°. Oil temperature should never exceed 160 F°.

4. SYSTEM PRESSURE - System pressure is factory set to 900 ± 25 psi and should not require further attention except precautionary observation at start-up and occassionally thereafter.

5. BLADE TENSION - Is controlled by system pressure.

6. VISE PRESSURE - Is controlled by system pressure. If machine is equipped with the optional variable vise pressure; vise pressure is operator adjustable.

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 people 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.

PROBABLE CAUSE

1a. Blade worn. 1b. Carbide guides loose.

2a. Angle not set correctly. 2b. Angle pointer has moved.

2c. Stock not square in vise.

SOLUTION

1a. Change blade. 1b. Adjust

2a. Adjust accordingly. 2b. The scale is accurate. Adjust

and tighten the pointer.

2c. Adjust accordingly.

3. Blade comes off wheels.

3a. Not enough blade tension.

3b. Improper tracking.

3a. Blade tension is determined

by system pressure. Check that system pressure is as specified earlier in this section.

3b. Adjust accordingly

3.5

PROBLEM

4. Blade stalls in cut.

5. Blade vibrating excessively.

6. Excessive blade breakage.

PROBABLE CAUSE

4a. Not enough blade tension.

4b. Excessive feed force.

5a. Blade speed too fast. 5b. Guide arms too far apart. 5c. Not enough blade tension.

6a. Excessive blade tension.

6b. Excessive feed rate.

SOLUTION

4a. Blade tension is determined

by system pressure. Check that system pressure is as specified earlier in this section..

4b. Reduce.

5a. Reduce. 5b. Adjust accordingly. 5c. Blade tension is determined

by system pressure. Check that system pressure is as specified earlier in this section.

NOTE: New blades tend to vibrate

until they are "broken in".

6a. Blade tension is determined

by system pressure. Check that system pressure is as specified in this section.

6b. Reduce.

7. No coolant flow.

8. Saw will not start.

9. Saw starts but will not run after

Start Button has been released.

10. Saw starts but no hydraulic

functions.

7a. No coolant. 7b. Coolant line blockage. 7c. Coolant pump inoperable.

8a. Piece counter set at "0". 8b. Motor overload has tripped.

8c. Control circuit fuse has

blown.

9a. On machines so equipped,

the out-of-stock or blade breakage limit switch has been tripped.

10a.If blade wheels run clock

wise, wrong phase order in power connection to saw.

10b.If pump is noisy, low hydrau-

lic oil.

7a. Add coolant. 7b. Blow out coolant lines. 7c. Check and replace if it is

necessary.

8a. Reset Piece Counter. 8b. Depress each of the reset

buttons on the main control box. Depressing one reset at a time and trying to start the saw will indicate which motor was overloaded.

8c. Replace the fuse with a 5

Amp 250 Volt AG1 type fuse. Random blowouts may occur but a quickly repeated blow out indicates an internal wiring fault.

9a. Reload with stock or remount

blade.

10a. Stop immediately; reverse

any two of the three line phase connections.

10b. Stop immediately; add

hydraulic oil (see hydraulic maintenance earlier in this section).

3.6

11. Saw starts but only front vise

functions.

IN MANUAL MODE

12. Head will not rise.

13. Head will not descend.

14. Head still will not rise or fall,

or any individual function will

PROBABLE CAUSE

11a.Mode Selector Switch is in

"Neutral".

Head up limit switch is set

12a.

fully down.

13a. Feed Rate valve is fully

closed (pointer is set on "0" or close to "0" in/min).

13b.Feed Force Limit is set too

low.

13c. Pointer is adjusted incor-

rectly.

14a.Observe pilot light(s) on

relevant valve, visible by removing the side panel on infeed base. If pilot light related to inoperable function fails to light, problem is electrical.

14b.If pilot light related to inoper

able function does light, problem may still be the coil (see 14a. SOLUTION). If problem remains it probably results from dirt in the valve spool. If the problem is related to index forward or retract, or head swing it may also be dirt in the cushion valve mounted near the manifold.

SOLUTION PROBLEM

11a. Select "manual" mode.

Readjust head up limit

12a.

switch.

13a. Turn Feed Rate Knob count-

er clockwise to open valve.

13b. Increase Feed Force limit to

at least 150 psi.

13c. Loosen pointer, turn knob

clockwise until it bottoms; tighten pointer at "0".

14a.In case of head and index

functions check operation of related limit switches. Limit switch buttons should operate freely and emit an audible click on both depress and release. If not replace the switch. Look for cause of switch damage. 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 switch replace the switch. If function still does not respond then... Remove the side panel on the infeed to gain access to the valves. Re move coil retaining nut and withdraw problem related coil, replace it with any other coil from the group. If the problem remain it requires the attention of a qualified service person.

14b.Disassembly of hydraulic

valves should be undertaken only by qualified service personnel or those knowledg able with hydraulic components.

PROBLEM PROBABLE CAUSE SOLUTION

not respond to its manual control switch.

15a. Pointer of Feed Rate valve is

15a.Readjust pointer as in 13c.

stopped by stop bolt but not

15. Head descends when Feed

fully closing the valve. Rate valve pointer is set to "0" on the scale and Feed Force limit gauge is more than 150 psi.

16a Cushion limit switch is

stuck or damaged.

16a.As in 14a check and repair or

replace.

16. Index retracts but only very slowly.

3.7

IN AUTOMATIC MODE

17. Auto cycle stops.

17a.If cycle seems to stop be

cause of a particular function is inactive, switch to manual and see it that function is still inactive. If so see previous section "IN MANUAL MODE".

17b.If the function is active in

"manual" mode.

17c. If the cycle does not respond

to limit switch prodding. check for a damaged limit switch as outlined in 14a. SOLUTION, above. In this case wire together the two switch terminals furthest from the wiring port.

17a.Readjust limit switch actua-

tor.

17b. Begin auto cycle over again

from start position on Auto Cycle Dial. Note last function motion before the cycle stops and check related limit switch function. For example, if the head comes down and then the cycle stops, check that the head down limit switch is being actuated by prodding it with a screwdriver. If the auto cycle resumes, the limit switch actuating bolt must be readjusted. Similarly if the shuttle advances and then the cycle stops, check that the shuttle forward limit switch is being actuated.

17c. Check for cause of damage

and replace limit switch as needed.

18. Piece length gradually in

18a.Length adjustment block not

tight.

18b.Micrometer adjustment is

creeping.

18a. Tighten the knob.

18b.Very slightly tighten the set

screw which retains the micrometer in the adjusting block. This will increase the stiffness of the micrometer threads.

3.8

PROBLEM PROBABLE CAUSE

creases during production run.

19a.Stock is slipping in rear vise

during advance or in front

19. Piece length shows large

vise during retraction. erratic decreases from set value.

IN AUTO MODE (Optional) PLC

20a.No job or job que pro

grammed to run.

20. Auto cycle will not start.

21a. Headup, head down, or

shuttle home limit switch not

21. Auto cycle stops before

being contacted. completion.

SOLUTION

19a. Apply oil to front and rear

vise jaws.

20a.Enter job number(s) and job

data as in SECTION 2A CONTROL CONSOLE.

21a.Run saw in auto cycle. Note

last function motion before the cycle stops and check related limit switch function. For example, if the head comes down and then the cycle stops, check that the head down limit switch is being actuated by prodding it with a screwdriver. If the auto cycle resumes, the limit switch actuating bolt must be readjusted. Similarly if the shuttle advances and then the cycle stops, check that the shuttle forward limit switch is being actuated.

SECTION 4 - ELECTRICAL SYSTEM

GENERAL INFORMATION

The power connection to the machine is made to the L1, L2 and L3 terminals of the contactor located in the main control box. As supplied, the machine is set to run on three phase voltage as indicated on the serial plate and the voltage label.

In order to use the machine on a different supply voltage the following changes must be made:

1. Change the blade motor (or if equipped with a dual voltage motor, rewire it)

2. Change the hydraulic pump motor (or if equipped with a dual voltage motor, rewire it)

3. Change the control transformer (or if equipped with a dual voltage unit, rewire it)

4. Change the blade and pump motor overloads, located adjacent to the contactor, to suit the full load current of the new or rewired motor.

All other components are supplied from the control transformer and operate on 115V, single phase. They do not need altering.

4.1

The machine is supplied for use on a 60HZ supply. For use on a 50HZ supply consult the factory.

WHEN CHANGING THE SUPPLY VOLTAGE, CAREFULLY OBSERVE THE ABOVE STEPS. THESE STEPS ARE ESSENTIAL TO AVOID SEVERE DAMAGE TO THE MOTOR AND CONTROLS.

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 and the hydraulic pressure gauge registering a pressure rise.On the following pages are the electrical schematics and physical wiring diagrams along with a list of electrical components.

PHOTOS OF STANDARD ELECTRICAL COMPONENTS

L 1

L 2

L 3

GND

TR 1CR 2C R 1M

Fig. 4-1 Inside of the standard electrical control box.

4.2

9SS 1PB8SS4SS7SS 4PB

6SS 3SS 5SS 5PB 2PB 4PB

2SS

Fig. 4-2 Back of the control panel.

1SS

1CNT

Fig. 4-3 Blade Tension selector switch 6SS, 10SS.

Fig. 4-5 Head Down limit switch 2LS.

Fig. 4-4 Head Up limit switch 1LS.

4LS

6LS

Fig. 4-6 Shuttle control limit switches.

3LS

5LS

4.3

Fig. 4-7 Blade motor 2MTR.

Fig. 4-8 Hydraulic pump motor 1MTR.

Fig. 4-9 Coolant pump motor 3MTR.

PHOTOS OF OPTIONAL ELECTRICAL COMPONENTS

Fig. 4-10 Hirschman connectors and directional valve solenoids.

1PB

3PB

Fig. 4-11 Back of the control panel with the optional PLC 100 controler.

5PB 7PB 5SS 8SS 7SS

2SS

6PB

3SS

4SS

1SS

9SS

2PB

4PB

PLC100

4.4

Fig. 4-12 Encoder.

Fig. 4-13 Shuttle hohe limit switch 3LS.

Fig. 4-14 Blade speed pickup PROX.

LIST OF ELECTRICAL COMPONENTS FOR AN S-25A WITH THE OPTIONAL PLC100

Item Cose Function Description Component Component as on Manufacturer Number S-25A Sch.

1PB Emergency Stop Operating head (red mushroom) Telemecanique ZB2BC4

push button 1 NC contact block Telemecanique ZB2BE102

2PB Hydraulic Start Operating head (green illuminated, Telemecanique ZB2BW33

push button flush style)

Light block Telemecanique ZB2BW061 130 V Lamp Telemecanique SP106 1 NO contact block Telemecanique ZB2BE101

3PB Blase Stop Operating head (black flush style) Telemecanique ZB2BA2

push button 1 NC contact block Telemecanique ZB2BE102

4PB Blade Start Operating head (green illuminated, Telemecanique ZB2BW33

push button flush style)

Lamp block Telemecanique ZB2BW061 130V Lam p Telemecanique SP105 1 NO contact block Telemecanique ZB2BE101

Item Cose Function Description Component Component as on Manufacturer Number S-25A Sch.

5PB Feed Force Limit Operating heaf (yellow flush Telemecanique ZB2BA5

setting push style) button 1 NO contact block Telemecanique ZB2BE101

6PB Index Forward Booted push button operator Telemecanique XACB9212

push button 2 speed 2 contact block assembly

1 NO, 1 NO early close Telemecanique XENB1181

7PB Index Reverse Booted push button operator Telemecanique XACB9212

push button 2 speed 2 contact block assembly

1 NO, 1NO early close Telemecanique XENB1181

1SS Mode Operation head (3position Telemecanique ZB2BJ3

Man/Off/Auto maintained, long) selector switch 1 NO early close Telemecanique ZB2BE201

1 NC late open Telemecanique ZB2BE202 1 NO Telemecanique ZB2BE101 2 NC Telemecanique ZB2BE102

4.5

2SS Head Operating head (3 position Telemecanique ZB2BJ3

Up/Hold/Down maintained, long) selector switch 2 NO contact blocks Telemecanique ZB2BE101

3SS Coolant Operating head (3 position Telemecanique ZB2BD3

selector switch maintained)

2 NO contact blocks Telemecanique ZB2BE101

4SS Fixed Vise Operating head (3 position, one Telemecanique ZB2BJ7

selector switch maintained, one spring return to

center, long) 2 NO contact blocks Telemecanique ZB2BE101

5SS Shuttle Vise Operating head (3 position, one Telemecanique ZB2BJ7

selector switch maintained, one spring return to

center, long) 2 NO contact blocks Telemecanique ZB2BE101

6SS Blade Tension Selector switch and housing Telemecanique XALJ133

selector switch assembly (3 position maintained)

2 NO contact blocks Telemecanique ZB2BE101

7SS Slow Head Operating Head (3 position with Telemecanique ZB2BD5

Swing selector spring return to center) switch 2 NO contact blocks Telemecanique AB2BE101

8SS Fast Head Operating Head (3 position with Telemecanique ZB2BD5

Swing selector spring return to center) switch 2 NO contact blocks Telemecanique AB2BE101

9SS PLC on/off Operating head (standard 2 position Telemecanique ZB2BJ2

selector switch maintained)

1 NO contact blocks Telemecanique ZB2BE101

4.6

Item Cose Function Description Component Component as on Manufacturer Number S-25A Sch.

1LS Head Up R od Plung er Telemecanique XCKL110H7

limit switch

2LS Head Dow n Rod Plun ger Telemecanique XCKL110H7

limit switch

3LS Shuttle Home Rod Plunger Telemecanique XCKL110H7

limit switch

TR Transformer Open Style 500VA

60Hz single phase Prim. V. - Sec. V. 240V-120V Hammond HT97838 480V-120V Hammond HT97818 600V-120V Hammond HT96808

1M Motor Contactor Open Style

(hydr aulics) 240V Telemecanique LC1D5811G6

480/600V Telemecanique LC1D1810G6

2M Motor Contactor OPen Style

(blade) 240V Telemecanique LC1D5811G6

480/600V Telemecanique LC1D1810G6

1AC Auxiliary Contact 2 NO contacts Telemecanique LA1DN20

Block

1CR Auto-Manual 4 NO contacts Telemecanique CA2DN40G6

relay

2CR Head Down 2 NO, 2 NC contacts Telemecanique CA2DN22G6

relay

1OL Motor Overload Triple Pole Thermal

(hydr aulics) 3HP 208/24 0V Telemecanique LR2D1314

3HP 480V Telemecanique LR2D1310 3HP 600V Telemecanique LR2D1308

2OL Motor Overload Triple Pole Thermal

(blade) 10HP 208/240V Telemecanique LR2D3353

10H P 480V Telemecanique LR2D1316 10H P 600V Telemecanique LR2D1316

1MTR El. Motor 182TC/3PH/3HP US Motors 2HP182TC

(hydraulics) 208/240V

480V 600V

2MTR El. Motor 215TC/3PH/10HP US Motors 5HP215TC

(blade) 208/240V

480V 600V

Item Cose Function Description Component Component as on Manufacturer Number S-25A Sch.

3MTR El. Motor 1PHZ 120VAC Little Giant 2E-NT502186

(coolant pump)

(with pump assembly)

PLC Length Programable logic control Hyd-Mech PLC100

Controller

FH Fuse holder Standard for 1 1/4" x 1/4" Little Fuse H342-858

Fuse 5A 250V BUSS MDL-5

PROX Blade speed Inductive proximity switch Omron TL-X2C1-E

pickup

Hirschman Female connector with light GDM 927811-011 connectors indicator GDM 2011

Encoder Incremental shaft encoder Deem MBE-3122-1000-QWCY

Directional Vickers Y(120 VAC) valve solenoid

4.7

LIST OF ELECTRICAL COMONENTS FOR A STANDARD S-25A

Item Cose Function Description Component Component as on Manufacturer Number S-25A Sch.

1SS Mode selector Operating head (3 position Telemecanique ZB2BJ3

switch maintained, long)

1 NO contact block Telemecanique ZB2BE101 1 NC contact block Telemecanique ZB2BE102

2SS Coolant selector Operating head (3 position Telemecanique ZB2BD3

swi tch maintained)

2 NO contact blocks Telemecanique ZB2BE101

3SS Fixed Vise Operating head (3 position, Telemecanique ZB2BJ7

selector switch one maintained, one spring return

to center, long) 2 NO contact blocks Telemecanique ZB2BE101

4SS Shuttle Vise Operating head (3 position, Telemecanique ZB2BJ7

selector switch one maintained, one spring return

to center, long) 2 NO contact blocks Telemecanique ZB2BE101

5SS Head Up/Hold/ Operating head (3 position Telemecanique ZB2BJ3

Down selector maintained, long) switch 2 NO contact blocks Telemecanique ZB2BE101

6SS Fast shuttle Operating Head (spring return Telemecanique ZB2BD5

selector switch to center, short)

4 NO contact block Telemecanique ZB2BE101

4.8

Item Cose Function Description Component Component as on Manufacturer Number S-25A Sch.

7SS Slow shuttle Operating head (spring return Telemecanique ZB2BD5

selector switch to center, short)

2 NO contact block Telemecanique ZB2BE101

8SS Fast head swing Operating head (3 position with Telemecanique ZB2BD5

selector switch spring return to center)

4 NO contact blocks Telemecanique ZB2BE101

9SS Slow head swing Operating head (3 position with Telemecanique ZB2BD5

selector switch spring return to center)

2 NO contact blocks Telemecanique ZB2BE101

10SS Blade Tension Selector switch and housing ass'y Telemecanique XALJ133

selector switch (3 position maintained)

2 NO contact blocks Telemecanique ZB2BE101

1PB Emergency Stop Operating head (red mushroom) Telemecanique ZB2BC4

push button 1 NC contact block Telemecanique ZB2BE102

2PB Hydraulic Start Operating head (green illuminated, Telemecanique ZB2BW33

push button flush style)

Light block Telemecanique ZB2BW061 130 V Lamp Telemecanique SP105 1 NO contact block Telemecanique ZB2BE101

3PB Blade Start Operating head (green illuminated, Telemecanique ZB2BW33

push button flush style)

Lamp block Telemecanique ZB2BW061 130V Lam p Telemecanique SP105 1 NO contact block Telemecanique ZB2BE101

4PB Blade Stop Operating head (black flush style) Telemecanique ZB2BA2

push button 1 NC contact block Telemecanique ZB2BE102

5PB Feed Force Limit Operating heaf (yellow flush Telemecanique ZB2BA5

setting push style) button 1 NO contact block Telemecanique ZB2BE101

1LS Head Up R od Plung er Telemecanique XCKL110H7

limit switch

2LS Head Dow n Rod Plun ger Telemecanique XCKL110H7

limit switch

3LS Shuttle forward Rod Plunger Telemecanique XCKL110H7

limit switch

4LS Shuttle back Rod Plunger Telemecanique XCKL110H7

limit switch

5LS Shuttle forward Roller Arm Telemecanique XCKL115H7

cushion L.S.

Item Cose Function Description Component Component as on Manufacturer Number S-25A Sch.

6LS Shuttle back Roller Arm Telemecanique XCKL115H7

cushionlimit switch

FU Fuse holder Standard for 1 1/4" x 1/4" Little Fuse H342-858

Fuse 5A 250V BUSS MDL-5

TR Transformer Open Style 500VA

60Hz single phase Prim. V. - Sec. V. 240V-120V Hammond HT97838 480V-120V Hammond HT97818 600V-120V Hammond HT96808

1M Motor Contactor Open Style

(hydr aulics) 240V Telemecanique LC1D5811G6

480/600V Telemecanique LC1D1810G6

4.9

2M Motor Contactor OPen Style

(blade) 2 40V Telemecanique LC1D5811G6

480/600V Telemecanique LC1D1810G6

1M5,6 Auxiliary Contact 2 NO contacts Telemecanique LA1DN20

Block

1CR Auto-Manual 4 NO contacts Telemecanique CA2DN40G6

relay

1CR5-8 Auxiliary Contact Telemecanique LA1DN13

on 1CR

2CR Head Down 2 NO, 2 NC contacts Telemecanique CA2DN22G6

relay

1OL Motor Overload Triple Pole Thermal

(hydr aulics) 3HP 208/24 0V Telemecanique LR2D1314

3HP 480V Telemecanique LR2D1310 3HP 600V Telemecanique LR2D1308

2OL Motor Overload Triple Pole Thermal

(blade) 1 0HP 208/240 V Telemecanique LR2D3353

10H P 480V Telemecanique LR2D1316 10H P 600V Telemecanique LR2D1316

1MTR El. Motor 182TC/3PH/3HP US Motors 2HP182TC

(hydraulics) 208/240V

480V 600V

4.10

Item Cose Function Description Component Component as on Manufacturer Number S-25A Sch.

2MTR El. Motor 215TC/3PH/10HP US Motors 5HP215TC

(blade) 208/240V

480V 600V

3MTR El. Motor 1PHZ 120VAC Little Giant 2E-NT502186

(coolant pump) (with pump assembly)

TM Timing motorSequencer SAIA KKB50-6-5-105-120/60 CW

& KNOB 4 268 4904 0

1CNT Piece counter Durant 34-11564 115VAC

MI(RE) MI(CNT) Multi Index Eagle Signal D2101 A3 115VAC

Counter

LMP Work Lamp Moffat 0618-3-AS

Hirschman Female connector with light GDM 927811-011 connectors indicator GDM 2011

Directional Vickers Y(120 VAC) valve solenoid

SECTION 5 - HYDRAULIC SYSTEM

The S-25A hydraulic system does not require any special work on a new machine before its start-up. The hydraulic tank is filled with Valvoline 150-46 hydraulic oil and all machine functions have been tested at the factory to ensure proper operation upon initial start-up.

PARTS LIST AND PHOTOS OF HYDRAULIC COMPONENTS

ITEM QTY DESCRIPTION OF PART PART NUMBER

1 1 Head Cylinder S25-C4-00 2 1 Shuttle Cylinder S25-C1-00 3 1 Blade Tension Cylinder S25-C5-00 4 3 Vice Cylinders S25-C3-00 5 1 Head Swing Cylinder S25-C9-00 6 3 Bundling Cylinder (Optional) S25-C23-00 7 1 Remote Blade Speed Cylinder (Optional) VSL-C9-00 8 1 Head Force Servo Valve T25-325-00 9 1 Positive Downfeed Valve DF2-0-00 10 1 Extension Block 2 position (Optional) EB-01 11 1 Manifold Block MB6P 12 3 Double Pilot Check DPCH-1 13 2 Pressure Gauge (1000 psi) PG-10 14 2 Pressure Gauge (500 psi) PG-5 15 2 Vice Valves DCV3P-AB-C 16 1 Remote Blade Speed Adjustment Valve (Optional) DCV3P-AB-T 17 1 Head Lift Valve DCV3P-AB-T 18 1 Head Swing Valve DCV3P-AB-T 19 1 Blade Tension Valve DCV3P-AB-C 20 1 Shuttle Valve DCV3P-AB-T 21 1 Relief Valve RV22-00 22 2 Poppet Valve PV2P-A-C 23 1 Swing Cushion Block CHB-15 24 1 Shuttle Cushion Block CHB-35 25 3 "o" Ring Plate MH-01 26 1 Pump HYP-1 27 1 Suction Strainer ZINGA SS-100-00 28 1 Return Filter ZINGA AE-10

or GRESEN K-2201

5.1

Fig. 5-2 Pump Motor AssemblyFig. 5-1 Hydraulic Manifold

Spring DF-2-03

'O' Ring Plug DF-2-04

Pusher DF-3-01

Spring DF-3-02

Screw DF-3-03

Shaft DF-3-04

Pushing Finger DF-3-05A

Spring Bushing DF-3-09

Spool DF-4-01

Spring DF-4-03

Spring Guide DF-4-04

Spring Guide DF-4-02

'O' Ring 1/2"OD x 3/8" ID x 1/ 16"

Spool DF3-1-01A

Needle DF1-1-01A

Pointer DF-1-02

Hex Jam Nut 5/8"-18

Black Knob 5/8-18 x 5/8

Plug 1/8" NPT

Spool DF-2-01

'O' Ring 3/8" OD x 1/4" ID x 1/16"

Plug 1/8" NPT

Spring DF-1-03

Spring Guide DF-2-02

Snap Ring Ext. 3/8" DIA

Lever

- DF-3-07 Tube

- 3/8" ID x 1.625"

Spring DF-1-03

2 of Snap Ring Ext 3/8" DIA

'O' Ring 1/4" OD x 1/8" ID x 1/16

Bolt 10-24 x 1/2"

Snap Ring 1/8" DIA

Plastic Ball

- 1" DIA x 1/4" NC

Spring DF-3-08

Ball 1/4" DIA

Roll Pin 1/8" DIA x 2"

Plug 1/8" NPT

2 of Back-Up Ring for 'O' Ring 1/2" OD x 3/8" ID x 1/ 16"

Plug 1/8" NPT

Orfice .013"

Back -Up Ring for 'O' Ring 1/2" OD x 3/8" ID x 1/16"

'O' Ring 1/2" OD x 3/8" ID x 1/16"

Valve Body DF-0-01

Needle DF-4-05B

Knob DF-4-06

Collar DF-3-06

POSITIVE DOWNFEED VALVE COMPONENTS

5.2

THIS PAGE INTENTIONALLY LEFT BLANK

GUIDE ARM ASSEMBLY

GUIDE ARMS ASSEMBLED

6 of Socket Head Cap Screws 3/8"NC x 1" LG

Guide Bar S25-32-01A

12 Set Screws 5/16"NC x 3.4" LG

Drive Side Guide Arm

S25-321-00A Idler Side Guide Arm S25-322-00A

Guide Block Pivot Pin S25-323-03A

Servo Valve Cap S25-324-01

Servo Valve Spool S25-323-05

Servo Needle S25-324-03 'O' Ring 3/4"x1/2"x1/8"

Idler Side Guide Block S25-3241-00A

Guide Arm Handle Hub S25-327-01 PLastic Tub 1/2"ID x 3 1/4"LG Rod 1/2"NC x 4 1/2"LG Ball 1 3/8"DIA x 1/2"NC Roll Pin 3/16"DIA x 1 1/4"LG Rod 5/8NF x 3 2/8"LG Flat Washer 1/2"ID x 1 3/4"OD

Coolant Nozzle Cool-02

'O' Ring 1/2"ODx1/4"ID

2 of Flat HEad Cap Screw 10-24 x 1"LG

Carbide Lock

Carbide Loader Hub H16-461-01 Rod HAndle S20-326-03 Plastic Tube 1/4" IDx 2 1/4"LG Set Screw 1/4"NC x 1/4"LG

Carbide Loader Bolt

S25-323-01A 3 of Disc Springs 1"OD x 1/2"ID x 0.35"

Front Carbide Pad 1 1/4" BLADE CRB-125-41-00

1 1/2" BLADE CRB-150-21-00 Exterior Retaining Ring 1/4" DIA

Top Carbide S25-324 Roll Pin

5.16"DIA x 5/8"LG

Rear Carbide Pad 1 1/4"BLADE CRB-150-42-00 1 1/2" BLADE CRB-150-22-00

Flat Head Cap Screw 3/8"NC x 3/4"LG

4 of Hex Head Bolt 1/4"NC x 3/4" LG

Head Nut 1/2" NF

Drive Side Guide Block Assembly

Carbide Loader Bolt S25-323-01A Block Pivot Shaft S25-323-03A Carbide Loader Hub H16-461-01 Rod Handle S20-328-03 Knob 1"DIA x 1/4"NC 3 of Disc Springs 1"ODx1.2"IDx.035 Retaining Ring Exterior 1/4"DIA Plastic Tube 1/4"IDx2 1/4" LG Roll Pin 5/16"DIAx2"LG Flat Head Socket Head Cap Screw 3/8"NC x 3/4"LG Top Carbide CRB-TL-770

FOR 1 1/4" BLADE

Front Carbide Pad CRB125-41-00 Rear Carbide Pad CRB125-42-00

FOR 1 1/2" BLADE

Front Carbide Pad CRB150-21-00B Rear Carbide Pad CRB150-22-00B

6.1

Guide Arm Clamp Block S25-32-02

GEAR BOX ASSEMBLY

- Cover S25-33-01

-Roll Pin 1/8"DIA x 7/8"LG

- Spur Gear Boston NA20B-1/2"

- Snap Ring Spae Naur R3100-100

- Spacer Sleeve S25-33-04

- 2 of Bushing Boston 1620-8 1" ID x 1 1/4" OD x 1" LG

- Gear Box Weldment S25-331-00

- 2 of Bushing Fiberglide CJS-1812

- 1" Shaft Collar Ring Ball

- Crank Shaft S25-3302 -02

- Roll Pin 5/16" DIA x 1 3/4" LG

- Crank Weldment S25-333-00

- Hex Bolt 1/2" NC x 1" LG

3 of Set Scw. 3/8" NC x 1/2" LG

3 of Sc. Hd. Cap. Scw. 3/8" NC x 1" LG

3 of L/Washer 3/8"

-Rack Shaft Assembly S25-332-00

- Gear Rack S25-332-03

Guide Arm Bracket S25-33-03

4 of Hex Bolt 1/2" NC x 1 1/2" LG

2 of Nex Nut 1/2" NC

2 of 1/2" F/Washer

Hex Jam Nut 3/8" NC

Handle Jergens 32114

Sc. Hd. Cap Scw. 3/8" NC x 3 1/2" LG

4 of 1/2" L/Washer

GUIDE ARM RACK ASSEMBLED

GUIDE ARM RACK ASSEMBLY

6.2

Shaft Extension S20-025-02

Bearing FAG W6433-2

Set Screw 3/8" NC x 2 1/2" LG

Hex Nut 3/8" NC

Set Screw 1/4" NC x 1/4" LG

Bearing Plate S20-922A-00

Friction Wheel S20-925-03

4 of 3/8" Flat Washer

2 of Spring Trakar MW 123

2 of Threaded Rod 3/8" NC x 5" LG 2 of 3/8" NC Hex Huts

BLADE BRUSH ASSEMBLY

BLADE BRUSH ASSEMBLED

Hex Nut 1/2" NC

2 of 1/2" Flat Washer

2 of Blade Brush 1/2" ID x 3 1/2" OD M311 1/2

6.3

Pulley Spacer S25-371-01

Pulley Shim 371-04-060 Thick 371-05-020 Thick As Required

Key 5/16" x 5/16" x 2 3/8" LG

Key Retainier Waldes 5015-137

Speed Indicator Lenze HA1524:1 Ratio with Hyd-Mech label S25-95-30A

4 of Hex Bolt 3/8" NC x 3/4 LG

Speed Adjuster Lenze 11.430.25.931

6 of Hex Bolt 3/8" NC x 5/8" LG

Drive Housing Outer S25-3712-00

Hex Bolt M12 x 130

Key 8mm x 10mm x 60 mm

Drive Pulley Lenze 11.213.25.920 38mm Bore

Drive Belt Lenze 47x1060mm

Key 10mm x 16mm x 100mm

Gear Box HM5

4 of Hex Bolt M16 x 70 or 75mm

Gear Box Mounting Bracket S25-312-04

Blade Drive Wheel S25-3-07

Blade Motor US Motors 10HP 1800 RPM 215 TC Frame TEFC

Drive Housing, Inner S25-3711-00

2 of Hex Bolt M16 x 50mm

DRIVE ASSEMBLED

Drive Wheel Keeper H16-4-02

Hex Bolt M20 x 60mm

2 of Socket Head Cap Screw 1/2" NC x 1 1/2" LG

2 of Set Screw 1/2" NF x 1 1/4" LG

Mechanical Pulley Lenze 11.213.25.911 1 3/8" Bore.

Drive Wheel Cap Spacer H16-4-03

DRIVE ASSEMBLY

Adjuster Handwheel HA 15 x 15

6.4

Spacer S25-3-03B

2 of Bearing 6308 2RS

Snap Ring N5000-354

Retainer S25-3-04

1/2" L/Washer

Hex Bolt 1/2" NC x 1 1/2" LG

Hex Bolt 5/8" NC x 6" LG

5/8" L/Washer

Hex Nut

5/8" NC Blade Tension Cylinder S25-C5-00

Hex Nut 5/8" NF

Rod End 5/8" DIA CM-10 RH

Hex Bolt 5/8" NC x 2 1/4" LG

Socket Set Scw. 3/8" NC x 1/2" LG

Carrier Weldment S25-3411-00

Idler Wheel Shaft S25-3-02

10 of Hex Bolt 1/2" NC x 1 3/4" LG

4 of Hex Bolt 1/2" NC x 2 1/2" LG

Base Plate S25-341-01

4of Soc. Hd. Set Scw. 1/2" NC x 1 1/2" LG

2 of Idler Track S25-341-02

2 of Grease Nipple 1/8" NPT

Idler Wheel S25-3-06

14 of 1/2" L/Washer

IDLER WHEEL ASSEMBLED

IDLER WHEEL ASSEMBLY

6.5

2 of Snap Ring N5100-237

Cylinder Mount S25-533-00A

VISE CYLINDER ASSEMBLED

Hex Nut 3/4" NC

3/4" L/Washer

Hex Bolt 3/4" NC x 5 LG

Vise Cylinder S25-C3-00

Vise Hose JCT Block S25-6-05

6 of 1/2" L/Washer

6 of Hex Bolt 1/2 NC x 2 LG

'O' Ring 2 1/4" ID x 2 5/8"OD

VISE CYLINDER MOUNTING ASSEMBLY

2 of

6.6

VISE ASSEMBLED

Front Vise S25-534-00

2 of Hex Bolt 1/2" NC x 3" LG

3 of 1/2" L/Washer

2 of Washer S25-32-05

Hex Bolt 1/2" NC x 2 3/4" LG

Vertical Wear Strip S25-2-04

Vertical Wear Strip S25-53-06

Vise Key S25-53-02

1/2" x 3/4" Arbor Shim ( # of shims depends on clearance needed)

Vise Gib S25-53-03

2 of Wear Sptrip S25-2-01

Fixed Vise Jaw S25-2-06

2 of Roll Pin 3/8" DIA x 2 1/2" LG

8 of Hex Bolt 1/2" NC x 2 1/2" LG 8 of 1/2" Spring Washer

2 of Vertical Wear Strip S25-2-05

32 of Flat Head Hex Cap Screws 5/16" NC x 1/2" LG

FRONT TABLE ASSEMBLY

6.7

ITRM # QTY. DESCRIPTION

1 1 GEARCASE 2 1 WORMSHAFT CAP 3 1 WORMSHAF COVER 4 1 WHEELSHAFT CAP 5 1 WHEELSHAFT COVER 6 1 WORMSHAFT SINGLE START 7 1 WORMWHEEL 53 TEETH 8 1 WHEELSHAFT 9 1 WHEELSHAFT SPACER 10 VAR WORMSHAFT SHIMS 11 VAR WHEELSHAFT SHIMS 12 2 TAPER ROLLER BEARING REF:31309 13 1 TAPER ROLLER BEARING REF:30312 14 1 TAPER ROLLER BEARING REF:30314 15 1 OILSEAL 42X62X7 SEMI DUAL 16 1 OILSEAL 65X90X8 SEMI DUAL 17 1 WORMWHEEL KEY 0.625"X0.625"X3.75" R.B.E. 18 12 LOW HEAD SOCKET CAP SCREWS M10X25 19 12 LOW HEAD SOCKET CAP SCREWS M10X20 20 3.5 L MOBIL SHC 632 OIL (NOT SHOWN) 22 1 NAMEPLATE SIZE4 23 1 LUBRICATION PLATE SIZE 4 26 1 1/2" BSPT TAPER PLUG 27 1 3/8" BSPT TAPER PLUG

S-25 GEARBOX ASSEMBLY

6.8

Drip Trough S25-82-00

SHUTTLE TABLE ASSEMBLED

2 of Wear Strip S25-2-01

Table Weldment S25A-211-00

2 of Vertical Wear sptrip S25-2-05

Fixed Vise Jaw S25-A22-06

8 of 1/2" L/Washer

7 of Hex Bolt 1/2" NC x 2 1/4" LG 31of 1/2" NC x 1 1/2" LG

2 of Roll Pin 3/8" DIA x 2 1/2" LG

2 of Retainer S25-A22-02A

2 of Mounting Key S25-A22-01A

4 of 1/2" L/Washer

4 of Hex Bolt 1/2"NC x 1 3/4"LG

2 of Table Mounting Key S25-A22-04

4 of Hex Bolt 1/2"NC x 1 1/2" LG

4 of Hex Bolt 1/2"NC x 1 3/4"LG

4 of 1/2" L/Washeer

Shim 1/2" x 3/4" Arbon ( # of shims depends on clearance needed)

70 of Fl. Hd. Soc. Scw. 5/16" NC x 1/2" LG

Vise Gib S25-53-03

Vise Key S25-53-02

Vertical Wear Strip S25-2-04

Hex Bolt 1/2" NC x 2 3/4" LG

Rear Vise S25-532-00

3 of 1/2" L/Washer

2 of Washer T25-32-07

2 of Hex Bolt 1/2" NC x 3" LG

2 of Soc. Set Scw. 5/16" NC x 3/4" LG

2 of Soc. Hd. Cap Scw. 5/16" NC x 3/4" LG

SHUTTLE TABLE ASSEMBLY

6.9

Auxillary Roller S25-312-00

SHUTTLE GUIDE ASSEMBLY

4 of Set Scw. 1/2" NC x 1/2" LG

4 of Hex Bolt 3/8" NC x 3" LG

2 of Mounting Block S25-24-01

2 of Bushing S25A-312-02

2 of Bearing 2RS-630707

Roller Shaft S25A-24-03

2 of Set Scw. 5/16" NC x 1/2" LG

4 of 3/8" L/Washer

Rear Shaft Mounting Plate S25A-252-00A

Roller Tray S25A-242-00A

8 of Wiper CUSTOM SEAL H2250

Rear Cylinder Pin S25-676-00

Hydraulic Hose Hyd-Mech #12

Hydraulic Hose Hyd-Mech #11

Cylinder Rod Pin S25-675-00

8 of Wear Ring 7"x1"x1/8" 702 Strip

Shuttle Cylinder S25-C1-00

2 of Shuttle Shaft S25-A25-01

Front Shaft Mounting Plate S25A-251-00A

Shuttle Vise Carriage S25A-231-00A 2 of Bearing Housing H12-231-00

Infeed Shuttle Track

S25A-2-01 Shuttle Slider S25A-233-01A Shuttle Slider Carrier Weldment S25A-2331-00A

SHUTTLE GUIDE ASSEMBLED

6.10

Conveyor Frame S25A-311-00

4 of Hex Bolt 3/8" NC x 5/8" LG

4 of Hex Bolt 1/2" NC x 2 1/2" LG

8 of Sec. Set Scw. 1/2" NC x 1 1/2" LG

2 of Roll Off Guard S25A-31-01

4 of Roller Assembly S25-A312-00

- 1 of Roller Tube S25-A312-01

- 2 of Bearing 6307-2RS

- 2 of Bushing S25-A312-02

4 of Shaft Weldment S25-A313-00

4 of Hex Bolt 3/8" NC x 5/8" LG

4 of 3/8" L/Washer

INFEED CONVEYOR ASSEMBLY

6.11

Head Cylinder S25-C4-00

- Thrust Washer Torrington TRF-3648

- Thrust Washer Torrington TRB-3648

- 2 of Bushing S25-4-04

- Horizontal Pivot Shaft S25-3-01

- 3 of Hex Jam Nut 3/8" NF

- 3 of Soc. Set Scw. 3/8" NF x 1 1/4" LG

Pivot Link Weldment S25-41-00

- Spring Shaft Weldment S25-3421-00

- 2 of Springs Dieco MH81

Angle Pointer S25-9-01

Angle Scale S25-9-21

Grease Fitting 1/8" NPT Straight

- Damping Plate S25-4-02

- 2 of Support Washer S25-4-03

- 2 of Bushing S25-4-04

Vertical Pivot Shaft S25-4-01

PIVOT LINK ASSEMBLY

6.12

2 of Shaft Collar 1 1/8" DIA 1 PC Split

Head Swing Cylinder S25-C7-00

2 of Rod Wiper Custom Seal D1125

Washer S20-3-10

Hex Bolt 1/2" NC x 1 1/4" LG

2 of Cylinder Pin S25-625-00

2 of Fl. Hd. Soc. Cap Scw 3/8" NC x 3/4" LG

Hex Head Bolt 1/2" NC x 1 3/4" LG 1/2" NC Hex Head Nut

Rod End 1/2" DIA 1/2" NF Hex Nut

Angle Stop Shaft S25-43-01

HEAD SWING ASSEMBLY

6.13

Hose Adapter 1/4"NPT to 3/8" DIA Hose Versa 125-6B

Elbow Adapter 1/4"NPT Male to 1/4" NPT Female Versa 139-6B

Needle Valve 1/4"NPT Male to 1/4" NPT Female Versa 3120-B

1/4 NPT adapter Lock-Line

Hose 12" LG Lock-Line 36401

Nozzle Lock-Line 36403

Coolant Hose 3/8" DIA x 18" LG

Check "Y" S20A-82-02

Coolant Pump Little Giant 502186 2E-NT

Wash Gun Continental

22.CB

Connector Versa 193-6

Coolant Hose 3/8" DIA x 23' LG

Coolant Hose 3/8" DIA x 16' LG

NOTE: Coolant tank not shown S25-81-00

COOLANT SYSTEM ASSEMBLED

COOLANT SYSTEM ASSEMBLY

Hose Adapter 1/4"NPT to 3/8"DIA Hose Versa 125-6B

Elbow Adapter 1/4"NPT Male to 1/4" NPT Female Versa 139-6B

Needle Valve 1/4"NPT Male to 1/4" NPT Female Versa 3120-B

Hose clamp at each hose end SPAE- NAUR 080-035

Coolant Hose 3/8" DIA x 6' LG

- Junction Block S20-8-01

- 2 of Elbow Adapter 1/4"NPT to 3/8" DIA Hose Versa 139-6B

- Hose Adapter 1/4"NPT to 3/8"DIA Hose

6.14

OUTFEED TABLE ASSEMBLY

6.15

Material Stop Flag S20-01122-00

- Knob Assembly S20-914-00

- Clamp S20-912-00

Material Stop Bracket S20-911-00

Knob S20-912-02

Material Stop Shaft S25-0112B-01

Material Stop Frame S25-01121B-00

Fence S25-0112B-02

Outfeed Table S25-0111B-01

Outfeed Tray Weldment S25-01111B-00

Arm Weldment S25-7221-00

Hex Bolt 1/2" NC x 2 1/2" LG

Mounting Lever S25-722-03

Hex Bolt 1/2" NC x 1 1/2" LG 1/2" L/Washer

Mounting Clamp S25-722-04

Bushing Fiberglide CJS-1812

2 of Hex Nut 3/8" NC

3/8" L/Washer

Guide Arm S25-72-03

2 of Hex Bolt 3/8" NC x 1 1/2" LG

Forward Limit Switch Finger S25-72-02

2 of Jam Nut 5/16" NC

Contact Bolt S25-72-06

Contact Finger S25-72-05

Shaft S25-72-01

Contact Bolt S25-72-05

Pointer S25-724-07

Adjusting Block S25-724-01

3 of Soc Hd. Scw. 10-24 NC x 3/4" LG

Back L/S Finger S25-724-02A

Nex Nut 1/2" NC

1/2" L/Washer

Hex Bolt 1/2" NC x 1 1/2" LG

2 of Hex Bolt 3/8" NC x 3" LG

Hex Bolt 3/8" NC x 2" LG

3/8" L/Washer

LENGTH CONTROL ASSEMBLED

LENGTH CONTROL ASSEMBLY

Knob Dimco Gr 1-2311-006

NOTE: Length control box weldmwnt not shown S25A-7211B-00.

Limit switches listed in SECTION 4 ELECTRICAL.

Micrometer, Mitutoyo Metric 149-131 Imperial 149-147

Knob Dimco GR 1-2311-006

6.16

Bundling Cylinder S25-c-23-00

Cylinder clamp S25-555-00

Cylinder Rod Extension A20-55-02

Jaw Carrier A20-55-01

Clamp Bolt Assembly S25-556-00

NOTE: The hydraulic hose lengths used fot the shuttle vises are 39" and 40" long. The hydraulic hose lengths used for the fixed vise are 59" and 60" long. The hydraulic hose is SAE 100R1Female 1/4" JIC at both ends.

BUNDLING ASSEMBLY

Idler End Mounting Post S25-553-01B for short vises S25-55C-01 for tall 17" vises

1/2" L/Washer

Q/C Pin 4" LG S25-5573-00

Hex Bolt 1/2" NC x 6" LG

1/2" Nc Hex Head

2 of Q/C Pin 2" LG S25-5571-00

2 of Soc. Hd. Cap. Scw. 3/8" NC x 3/4" LG

Jaw Plate S25-55-03

Bundling Beam Rail S25-551C-01

Bundling Beam Rail S25-551C-02

Bundling Beam Spacer S25-551C-03

2 of Socket Head Cap Screw 1/2" NC x 2: LG

7.1

1/4" JIC to 1/4" NPT Elbow

Pressure Gauge 1000psi

Junction Block JB-02

2 Elbow 1/8"NPT x 1/4" JIC

2 of 'O' Ring Plate MH-01

8 of Rod 10-24 x 3 1/2" LG 8 of 10-24 Hex Nut 8 of Flat Washer

Pressure Raducing Valve PRV1

3 of Elbow SAE 6 to 1/4" JIC

2 of Hex Head Bolt 1/4" NC x 1 3/4" LG 2 of 1/4" Spring Washer 2 of 1/4"NC Nut

2 of Philips Head Screw 1/4"NC x 1/2" LG

2 of 1/4" NC Nut

Mounting Plate S25-6-04

NOTE: Hoses Not Shown Hose #20 - 48" Long Hose #30 - 48" Long Hose #33T - 48" Long Hose #35 - 13" Long

7.2

VARIABLE VISE PRESSURE ASSEMBLY

VARIABLE VISE PRESSURE

Lever S25-77-01 2 of Socket Head Cap Screw 5/16"NC x 3/4"LG

Blade Breakage Limit Switch Roller Arm Telemecanique XCKL115H7

7.3

For customers who plan to cut in automatic cycle with limited supervision a "Blade Breakage" switch is available. It will stop the machine operation as soon as the blade breaks. It will also provide an additional feature. The machine will not start until the blade is tensioned properly.

BLADE BREAKAGE LIMIT SWITCH ASSEMBLY

OUT OF STOCK LIMIT SWITCH ASSEMBLY

7.4

Collar S25-76-01 2 of 'O' Ring 13/32 ID x 5/8" OD

Rod S25-761-01

Out of Stock Limit Switch Roller Arm Telemecanique XCKL115H7

For customers who plan to cut in the automatic cycle with limited supervision an "Out of Stock" Limit Switch is available. It will stop the machine as soon as there is not enough material for the next cut in a cycle.

S-25A OPTIONAL REMOTE CONTROL VARIABLE SPEED DRIVE ADJUSTMENT

Hydraulic Hose

2 of Cords and Hirschman Connectors

7.5

Hydraulic Hose

External Snap Ring 1" SH-100

Adjuster Cup VS25-32-00

2 of Adjuster Nut VS25-3-01

Housing VS16-31-00

Directional Control Valve DCV3P-AB-T

'O' Ring Plate HYM-01

2 Position Junction Block JB-02

4 of Hex Bolt 5/16" NC x 3/4" LG

4 of 5/16" Spring Washer

Speed Changer Cylinder VSL-C9-00

-Electrical Switch Operating Head (3 position,spring return to centre) Telemecanique ZB2BJ5

- 1 NO Contact Telemecanique ZB2BZ103

-Designation Lable

THIS PAGE INTENTIONALLY LEFT BLANK

SECTION 8 - SPECIFICATIONS

SPACIFICATION LIST

MODEL S-25A DIMENSIONS ( IMPERIAL)

Capacity: Round 18" Diameter

Rectangular 18" high, 27" wide At 45° angle Round 18" Diameter At 30° angle Round 12" Diameter

Blade:Length 18' 10"

Width 1 1/2", 1 1/4" (optional) Thickness .050" (.042", 1/14" blade)

Blade s peed 75-400 SFM (infinitely variable)

Blade tension Hydraulic

Blade guides Carbide (coolant lubricated)

Blade wheel diameter 22"

8.1

Motors Blade drive 10 HP

Hydraulic drive 3 HP

Pumps Hydraulic pump Pressure compensated

constant pressure variable flow (6.5 GPM)

Coolant pump 3.5 GPM (150W)

Hydraulic tank 17 US Gal.

Hydraulic system pressure 900 p.s.i.

Vise control Hydraulic

Shuttle stroke 0-40" single stroke

Multi shuttle capability of up to 99 strokes

Table height 36"

Control panel Waist height

Outfeed table 32" L x 22" W

Machine weight 7300 lbs.

Maximum work load 8000 lbs.

Overall dimensions 111 " wide

160" long 72" high

8.2

S-25A OVERALL DIMENSIONS

160"

SECTION 9 - WARRANTY

Hyd-Mech Engineering Ltd. warrants each new S-25A 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 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-25A, 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.

9.1

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.

HYD-MECH ENGINEERING LTD. 239 Beards Lane P.O. BOX 1030 Woodstock, Ontario N4S 8A4 Phone: (519) 539-6341

Hyd-Mech S-25A User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual