Table of Contents
Advertisement
Quick Links
H4040, H4060, H4080
393139
THANK YOU,
On behalf of everyone at HYD·MECH Group Limited, we would like to thank and congratulate you on your decision to
purchase a HYD·MECH bandsaw.
Your new machine is now ready to play a key role in increasing the efficiency of your operation, helping you to reduce cost
while boosting quality and productivity.
To ensure you are maximizing the power and versatility of your new HYD·MECH bandsaw, please take the time to
familiarize yourself and your employees with the correct operation and maintenance procedures as outlined in this
manual. Please keep this instruction manual for future reference in a known location and easily accessible to all users of
the device.
HYD·MECH offers a great variety of options, components, and features for its various models. Therefore, some of the
equipment described in this manual (various illustrations and drawings) may not be applicable to your particular machine.
The information and specifications provided in this manual were accurate at the time of printing. HYD·MECH reserves the
right to discontinue or change specifications or design at any time without notice and without incurring any obligation.
Thank you.
Hyd·Mech Group Limited
P.O. Box 1659, 1079 Parkinson Road
Woodstock, Ontario, N4S 0A9
Phone : (519) 539-6341
Service : 1-877-237-0914
Sales : 1-877-276-SAWS (7297)
Fax : (519) 539-5126
e-mail : info@hydmech.com
PRINTED APRIL 2017
1
Advertisement
Table of Contents
Troubleshooting
Related Manuals for Hyd-Mech H4040
Summary of Contents for Hyd-Mech H4040
- Page 1 H4040, H4060, H4080 393139 THANK YOU, On behalf of everyone at HYD·MECH Group Limited, we would like to thank and congratulate you on your decision to purchase a HYD·MECH bandsaw. Your new machine is now ready to play a key role in increasing the efficiency of your operation, helping you to reduce cost while boosting quality and productivity.
-
Page 2: Table Of Contents
TABLE OF CONTENTS SECTION 0 - SAFETY INSTRUCTIONS SUMMARY ............................0.1 BASIC RULES ..........................0.3 RESPONSIBILITIES OF THE OWNER ....................0.3 RESPONSIBILITIES OF THE OPERATOR AND MAINTENANCE PERSONNEL ......0.4 SAFETY HAZARD LABELS ......................0.6 SECTION 1 - INSTALLATION SAFETY PRECAUTIONS .........................1.1 LIFTING THE H-40 ...........................1.2 MACHINE LAYOUT ..........................1.3 H-40 INSTALLATION PROCEDURE ....................1.4 FOUNDATION, LEVELING AND ANCHORING ................1.4... - Page 3 MECHANICAL ASSEMBLY DRAWINGS & PARTS LIST: SEE PDF ON ATTACHED CD ....6.1 SECTION 7 - OPTIONS OPTIONAL ASSEMBLY DRAWINGS: SEE PDF ON ATTACHED CD ..........7.1 BLADE DEVIATION MONITORING SYSTEM (K10) ................7.1 SECTION 8 - SPECIFICATIONS H4040 SPECIFICATIONS ........................8.1 H4060 SPECIFICATIONS ........................8.2 H4080 SPECIFICATIONS ........................8.3 LAYOUT DRAWING .........................8.4 SECTION 9 - WARRANTY...
-
Page 4: Summary
SECTION 0 - SAFETY INSTRUCTIONS SUMMARY All persons operating this machine must have read and understood all of the following sections of this Manual: Section 0 SAFETY Section 2 OPERATING INSTRUCTIONS However, as a memory aid, the following is a summary of the Safety Section. Put Safety First Mandatory Information –... - Page 5 FOREWORD Put Safety First! This Safety Section contains important information to help you work safely with your machine and describes the dangers inherent to bandsaws. Some of these dangers are obvious, while others are less evident. It really is important to PUT SAFETY FIRST. Make it a habit to consider the hazards associated with any action BEFORE you do it.
-
Page 6: Basic Rules
Manual, and When all operations and procedures are in compliance with this Manual. Hyd-Mech Group cannot accept any liability for personal injury or property damage due to operator errors or non-compliance with the Safety and Operating Instructions contained in this Manual. -
Page 7: Responsibilities Of The Operator And Maintenance Personnel
Define responsibilities Clearly define exactly who is responsible for operating, setting-up, servicing and repairing the machine. Define the responsibilities of the machine operator and authorize him to refuse any instructions by third parties if they run contrary to the machine’s safety. Persons being trained on the machine may only work on or with the machine under the constant supervision of an experienced operator. - Page 8 Clothing, jewellery, protective equipment Personnel operating or working on the machine must not wear un-restrained long hair, loose-fitting clothes and dangling jewellery. When operating or working on the machine, always wear suitable, officially tested personal protective equipment such as safety glasses and safety boots and any other equipment required by workplace regulations.
-
Page 9: Safety Hazard Labels
On Hyd-Mech machines the Master Disconnect Switch will be of one of four types: • Rotary switch mounted in electrical control cabinet door and inter-locked with door. • Rotary switch mounted on the side of the operator interface console. Lever switch mounted in separate box on the machine. - Page 10 MOVING BANDSAW BLADE WILL CUT Do NOT operate with guard removed. Do NOT place hands or fingers near moving bandsaw blade. For blade changing, always follow the proper Blade Changing Procedure, as given in Section 3 of this manual. PINCH POINT Machine parts may move without warning, either because the machine is operating automatically, or because another person initiates the motion.
-
Page 11: Section 1 - Installation
MAINTAIN PROPER ADJUSTMENT OF BLADE TENSION, BLADE GUIDES, AND BEARINGS. • HOLD WORKPIECE FIRMLY AGAINST TABLE. • DO NOT REMOVE JAMMED CUTOFF PIECES UNTIL BLADE HAS STOPPED. NO MODIFICATIONS TO THE MACHINE ARE PERMITTED WITHOUT PRIOR APPROVAL FRO HYD-MECH. ANY APPROVED MODIFICATIONS SHOULD ONLY BE UNDERTAKEN BY TRAINED PERSONNEL. -
Page 12: Lifting The
LIFTING THE H-40 LIFTING THE H-40 The machine weight for a H40-40 is 39,000lbs (17690Kg) or 42,000lbs (19051Kg) with the optional outboard vise. The machine wieght is 39,000lbs or 42,000lbs with the optional outboard vise. The machine weight for a H40-60 is 42,000lbs (19051Kg) or 45,000lbs (20412Kg) with the optional outboard vise. The machine weight for a H40-80 is 46,000lbs (20865Kg) or 50,000lbs (22680Kg) with the optional outboard vise. -
Page 13: Machine Layout
MACHINE LAYOUT... -
Page 14: H-40 Installation Procedure
FOUNDATION, LEVELING AND ANCHORING Machine location should be carefully selected. A flat concrete floor area should be chosen. It should have enough free space surrounding the machine to enable free access for safe operation and maintenance. The machine should be leveled in both directions, i.e. along and across its infeed conveyor especially when machine is to be inserted into a larger conveyor system. - Page 15 For machine shipping purposes the following items have been removed from the saw. • Infeed conveyor gearbox and motor • Bearing housing support • Chain guard H40 ADDENDUM: SECTION 1 – INSTALLATION Once the machine has been installed, levelled and anchored the above three items are to be installed as follows: 1.
-
Page 16: Hydraulic Oil And Cutting Fluid
HYDRAULIC OIL AND CUTTING FLUID The H-40 bandsaw is supplied with Texaco 46 hydraulic oil. If it in necessary to change the oil to different brand see the HYDRAULIC SECTION for equivalent grade oil. No cutting fluid is supplied with machine. There are two types of coolant available: -Oil based;... - Page 17 Ground connection L1 L2 L3 Electrical panel located behind the head on the drive side...
-
Page 18: Section 2 - Operating Instructions
SECTION 2 - OPERATING INSTRUCTIONS This section has been prepared to give the operator the ability to set up the saw for most cutting situations. Before cutting any material, the operator should be familiar with all operations and controls as well as the basic cutting theory described below. - Page 19 EMERGENCY STOP Stops blade and hydraulic motors. Head motion will stop and vise clamping pressure will begin to fall off. Long pieces of work should always be supported so they will not become loose over time and fall while the machine is shut down. This is a latched button and must be pulled out to start the machine.
- Page 20 HYDRAULIC START To start the hydraulic system, the switches for the head and vises must be in the “NEUTRAL” position. The “HYDRAULIC START” button must be depressed and held in momentarily until the PLC display becomes active. BLADE START Starts the blade when depressed. Only active with hydraulics running and saw head up, off of lower limit switch.
- Page 21 SAFETY LOCK This lock is provided for the safety of the operator during the blade changing procedure. When the lock is in the “ON” position, the door interlocks are disabled and the only functions that are active are the HEAD and BLADE TENSION controls. All other controls are inactive. After the blade has been changed the lock must be switched to “OFF”...
- Page 22 When the machine is initially powered the LCD will show company logo and software version. On activation of a push button or selector switch the LCD display will show the head height. Depressing the button under B RUN will change the screen to show FEED RATE and BLADE SPEED. Depressing the button under TIME will change the screen to show CUTTING TIMES.
-
Page 23: Hydraulic Feed Control
HYDRAULIC FEED CONTROL The Hydraulic Feed Control is located to the left of the control panel. These controls allow independent control of Feed Force (FF) and Feed Rate (FR) FEED FORCE IS FACTORY PRESET AND CANNOT BE ADJUSTED ON ANY H40 MODEL. -
Page 24: Cutting Parameters Chart
CUTTING PARAMETERS CHART A full size CUTTING PARAMETERS CHART is mounted on the front of the saw. The chart contains five steps for the operator to follow in order to achieve optimum performance of the saw. These steps are detailed on the following pages. Saw Cutting Parameters Chart CHART EXAMPLE #1 We will use the parameters chart to set up the saw for cutting 8”... - Page 25 STEP 2: SET FEED FORCE LIMIT (DOES NOT APPLY TO H40 MACHINES AS FEED FORCE IS FACTORY PRESET) The Feed Force Limit is the maximum amount of force with which the head is allowed to push the blade into the work-piece.
- Page 26 STEP 3: DETERMINE OPTIMUM BLADE PITCH - TEETH PER INCH (T.P.I.) Selecting a blade with proper tooth pitch is important in order to achieve optimal cutting rates and good blade life. For cutting narrow or thin wall structural materials a fine blade with many teeth per inch (T.P.I.) is recommended. For wide materials a blade with a coarse pitch should be used.
- Page 27 STEP 4: DETERMINE OPTIMUM BLADE SPEED, V (ft/min) (m/min) The relationship between optimum blade speed and effective material width for various materials is represented on the graph shown. The graph shows that as effective material width gets wider or as material gets harder, lower blade speeds are recom- mended.
- Page 28 The following table gives examples of the optimum blade speeds for different materials. MATERIALS OPTIMUM BLADE SPEED (ft/min) (m/min) 5” (125mm) Diameter Solid Carbon Steel 12” (300mm) I-Beam 4” x 4” (100mm x 100mm) Rect. Tube 1/4” (6mm) Wall 4” (100mm) 400 Stainless Steel 2”...
- Page 29 FEED RATE, continued If the saw is fitted with a blade coarser than optimum (e.g.: 1.4/2.5 TPI) we can still use the graph, but we go to the 1.4/2.5 curve. As a result we find that the FEED RATE is decreased to 1.3 in/min (133mm/min) for this blade. If however, the machine is fitted with a finer than optimum blade (e.g.
-
Page 30: Head Down Limit Setting
HEAD DOWN LIMIT SETTING Head Down Limit: This limit is factory set and under ordinary cutting requirements should not be changed. If changed, it HEAD DOWN LIMIT SETTING may cause the machine to malfunction in the automatic cycle. Head Down Limit: This limit is factory set and under ordinary cutting requirements should not be changed. If changed, it may cause the machine to malfunction in the automatic cycle. -
Page 31: Guide Arm Positioning
GUIDE ARM POSITIONING The adjustable guide arm should always be adjusted with respect to the material width. It will optimize cutting conditions and increase blade life with the guide arm adjusted as close to the material as permitted. In order to adjust the guide arm, the remote guide arm adjustment switch, located on the control console is used to hydraulically position the guide arm. -
Page 32: Coolant Controls
COOLANT CONTROLS COOLANT CONTROLS COOLANT CONTROLS A generous flow of coolant should be applied in order to increase production and blade life. The machine is provided with A generous flow of coolant should be applied in order to increase production and blade life. The machine is provided with A generous flow of coolant should be applied in order to increase production and blade life. -
Page 33: Section 3 - Maintenance
SECTION 3 – MAINTENANCE SAFETY DURING MAINTENANCE AND TROUBLESHOOTING “Lock-out”, or “Lock-out Tag-out” are terms that refer to procedures taken to prevent the unexpected start-up, or other re- lease of energy, by a machine, whenever anyone is required to remove or bypass safety guards or devices, or whenever anyone is required to place part of his body in a hazard area. -
Page 34: Blade Change Mode Procedure
RESTORING MACHINE TO USE After completion of all repairs or maintenance to the locked-out machine, it shall be restored to use as follows: The person(s) who performed the work shall verify that all areas around the machine are safe, before the machine is re-energized. - Page 35 BLADE REMOVAL 1. With the blade change mode key switch in ‘OFF’, the blade stopped and the hydraulics ON, raise the saw head until the drive door will clear the electrical control panel. 2. Move the guide arm out to provide room between the two guide arms to easily grasp the blade with two hands, BUT DO NOT TOUCH THE BLADE UNTIL THE BLADE CHANGE MODE SWITCH IS TURNED TO THE ‘ON’...
-
Page 36: Blade Brush Adjustment
If the brush gets worn to approximately 70% of its original diameter, it should be replaced. A brush may be purchased through a Hyd-Mech Group Limited dealer in your area. -
Page 37: Lubrication
We recommend that this periodic lubrication be done once a month using any general purpose grease. In addition to the grease points shown, vise jaw guides and infeed rollers require greasing. Hyd-Mech Group Limited recommends monthly lubrication. HYD-MECH recomends monthly lubrication. -
Page 38: Hydraulic Maintenance
HYDRAULIC MAINTENANCE There are only FIVE items of routine maintenance associated with the hydraulic system: 1. OIL FILTER – Ten-micron filtration of the hydraulic oil is provided by a spin-on type filter mounted on the tank return line. The element should be changed after the first 50 Hours of operation and then every 500 working hours. Suitable replacement elements are: CANFLO RSE-30-10... -
Page 39: Trouble Shooting Guide
Most problems which may occur have relatively simple solutions which appear in this section. If the solution is not found here, contact the Hyd-Mech Distributor from whom you purchased your bandsaw. They have trained field service personnel who will be able to rectify the problem. - Page 40 Excessive blade break- 6a. Excessive blade tension 6a.Blade tension is age. determined by system pressure. Check that system pressure is as specified above. 6b. Excessive feed rate. 6b. Reduce. Tooth Strippage 7a. Blade pitch too fine 7a.Select coarser pitch. 7b. Blade brush not cleaning 7b.
- Page 41 Saw starts but no hydrau- 11a. If blade wheels run 11a. Stop immediately; functions. clockwise, wrong phase reverse any two of the three order in power connection phase connections. to saw. 11b. If pump is noisy cause 11b. Stop immediately; add may be low hydraulic oil level.
- Page 42 Head still will not rise or 15a. Observe pilot light (s) 15a. In case of head function fall, or any individual function on relevant valve. If pilot check operation of related will not respond to its manual light related to inoperative limit switches.
- Page 43 Head will not descend. 16a. Feed Rate Valve is 16a. Turn Feed Rate Knob fully closed-pointer is set on counter clockwise to open “0” or close to “0” in/min. valve. 16b. Feed Force Limit is set 16b. Increase Feed Force too low.
-
Page 44: Section 4 - Electrical
SECTION 4 - ELECTRICAL ELECTRICAL SCHEMATICS: SEE PDF ON ATTACHED CD... -
Page 45: Section 5 - Hydraulic System
SECTION 5 - HYDRAULIC SYSTEM The H-40 hydraulic system does not require any special work on a new machine before its start-up. The hydraulic tank is filled with Texaco Rando 46 hydraulic oil and all machine functions have been tested at the factory to ensure proper operation upon initial start-up. -
Page 46: Hydraulic Schematics & Plumbing Diagrams: See Pdf On Attached
LIST OF H-40 HYDRAULIC COMPONENTS ITEM QUANTITY DESCRIPTION PART NUMBER HEAD CYLINDER H40-C4-00B 1(2) VISE CYLINDER V18A-C1-00A BLADE TENSION CYLINDER H40-C5-00A GUIDE ARM POSITIONING CYLINDER H40-C6-00 MANIFOLD BLOCK MB1 MB6P 3(4) DOUBLE PILOT CHECK DPCH-1 PRESSURE GAUGE (1000 PSI) PG-10 PRESSURE GAUGE (2000 PSI) PG-15 CHIP CONVEYOR DRIVE MOTOR... -
Page 47: Section 6 - Mechanical Assemblies
SECTION 6 - MECHANICAL ASSEMBLIES MECHANICAL ASSEMBLY DRAWINGS & PARTS LIST: SEE PDF ON ATTACHED CD... -
Page 48: Section 7 - Options
SECTION 7 - OPTIONS OPTIONAL ASSEMBLY DRAWINGS: SEE PDF ON ATTACHED CD BLADE DEVIATION MONITORING SYSTEM (K10) BLADE DEVIATION MONITORING SYSTEM (K10) General description of the blade deviation monitoring system. This system monitors lateral blade deviation during cutting. If blade deflection increases beyond the pre-set warning limit, then the monitoring device sends a warning signal by means of flashing beacon mounted on the top of machine head. - Page 49 Procedure to access blade deviation parameters - To adjust the warning and shutdown limits, enter MONITOR LIMIT SETTING screen by pressing F2 (BLD. LIMITS) access blade deviation limit settings (Figure 1). The MONITOR LIMIT SETTING screen will be displayed (Fig. 2) Enter parameters screen by pressing function key F3.(Labeled: PARMTR) The PARAMETER SETTING screen will be displayed (Fig.
- Page 50 The MONITOR LIMIT SETTING screen will be displayed Figure 2. There are two scales, the upper one showing the preset right and left shutdown limits, and the lower scale showing the preset right and left warning limits. All four limits (right and left warning and right and left shutdown) are set independently.
- Page 51 To return from the MONITOR LIMIT SETTING screen to Auto or Manual screens, press EXIT F5 function key To access the parameters screen (Figure 3), press PARMTR (F3) function key. WARNING RESPONSE TIME MAX LIMIT RESPONSE TIME XXXX SENSOR BLADE DEVIATION MONITOR DISPLAY REFRESH RATE Figure 3 Parameter screen.
-
Page 52: Section 8 - Specifications
SECTION 8 - SPECIFICATIONS H4040 SPECIFICATIONS H-40-40 BANDSAW SPECIFICATIONS Capacity round 41" (1042mm) rectangular 41"x 41"(1042mm x 1042mm) Length 37'-0" (11278mm) Width 3" or 2 5/8" (76mm or 67mm) thickness .063" (1.6mm) Blade Blade Tension Hydraulic Blade Speed 45 - 225 sf/min (14 - 68 m/min) -
Page 53: H4060 Specifications
H4060 SPECIFICATIONS H-40-60 BANDSAW SPECIFICATIONS Capacity round 41" (1042mm) rectangular 41"x 61"(1042mm x 1550mm) Length 40'-4" (12294mm) Width 3" or 2 5/8" (76mm or 67mm) thickness .063" (1.6mm) Blade Blade Tension Hydraulic Blade Speed 45 - 225 sf/min (14 - 68 m/min) Blade Guides carbide inserts Blade Wheel Dia. -
Page 54: H4080 Specifications
H4080 SPECIFICATIONS H-40-80 BANDSAW SPECIFICATIONS Capacity round 41" (1042mm) rectangular 41"x 81"(1042mm x 2058mm) Length 43'-10" (13361mm) Width 3" or 2 5/8" (76mm or 67mm) thickness .063" (1.6mm) Blade Blade Tension Hydraulic Blade Speed 45 - 225 sf/min (13.5 - 67.5 m/min) Blade Guides carbide inserts Blade Wheel Dia. -
Page 55: Layout Drawing
LAYOUT DRAWING... -
Page 56: Section 9 - Warranty
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, WRITTEN OR ORAL, INCLUDING WITHOUT LIMITATION ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. This warranty may not be changed, altered, or modified in any way except in writing by Hyd-Mech Group Limited HYD·MECH GROUP LIMITED 1079 Parkinson Road P.O.
Need help?
Do you have a question about the H4040 and is the answer not in the manual?
Questions and answers