H-18/22 ASV

393115
November 2004, REV G

Thank you,

On behalf of everyone at HYD·MECH Group Limited, I would like to thank and congratulate you on your decision to pur-
chase 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 famil-
iarize yourself and your employees with the correct operation and maintenance procedures as outlined in this manual.

We sincerely appreciate the confidence you have demonstrated in purchasing our product and look forward to building a
long and mutually beneficial relationship.

Thank you

Hyd·Mech Group Limited

P.O. Box 1030, 1079 Parkinson Road
Woodstock, Ontario, N4S 8A4
Phone : (519) 539-6341
Service : 1-877-237-0914
Sales : 1-877-276-SAWS (7297)
Fax : (519) 539-5126
e-mail : [email protected]
 TABLE OF CONTENTS
SECTION 1, INSTALLATION
SAFETY PRECAUTIONS............................................................................................................................................ 1.1
H-18/22 SV LIFTING INSTRUCTIONS ....................................................................................................................... 1.2
FOUNDATION, LEVELLING AND ANCHORING ........................................................................................................ 1.3
WIRING CONNECTIONS............................................................................................................................................ 1.3
HYDRAULIC OIL AND CUTTING FLUID .................................................................................................................... 1.4

SECTION 2, OPERATION
BLADE BASICS .......................................................................................................................................................... 2.1
VARIABLE SPEED CONTROL ................................................................................................................................... 2.1
THE CONTROL PANEL .............................................................................................................................................. 2.1
MANUAL OPERATION................................................................................................................................................ 2.1
PLC 100 CONTROL SYSTEMS.................................................................................................................................. 2.4
OPERATION OVERVIEW ........................................................................................................................................... 2.4
ACTIVATING THE PLC ............................................................................................................................................... 2.5
FUNCTION KEY DESCRIPTIONS.............................................................................................................................. 2.5
SINGLE PART CYCLE OPERATION .......................................................................................................................... 2.6
KERF CORRECTION.................................................................................................................................................. 2.6
AUTOMATIC OPERATION.......................................................................................................................................... 2.7
PROCEDURE FOR EDITING OR STARTING A NEW JOB IN AUTO MODE............................................................. 2.7
JOB IN PROGRESS.................................................................................................................................................... 2.7
WORKING WITH A QUEUE ........................................................................................................................................ 2.8
HYDRAULIC FEED CONTROL................................................................................................................................... 2.9
CUTTING PARAMETERS CHART.............................................................................................................................. 2.10
CUTTING SOLIDS ...................................................................................................................................................... 2.10
CUTTING STRUCTURALS ......................................................................................................................................... 2.10
ADDITIONAL CONTROLS .......................................................................................................................................... 2.13
COOLANT FLOW........................................................................................................................................................ 2.13
HEAD UP AND DOWN LIMIT SETTING ..................................................................................................................... 2.14
VARIABLE VISE PRESSURE (OPTION) ................................................................................................................... 2.14
BUNDLING OPERATION (OPTION) .......................................................................................................................... 2.15

SECTION 3, MAINTENANCE & TROUBLESHOOTING

LOCK -OUT ................................................................................................................................................................. 3.1
LOCK OUT PROCEDURE .......................................................................................................................................... 3.1
BLADE CHANGING PROCEDURE ............................................................................................................................ 3.1
BLADE BRUSH ADJUSTMENT .................................................................................................................................. 3.2
BLADE TRACKING ADJUSTMENT ............................................................................................................................ 3.2
IDLER WHEEL TRACKING......................................................................................................................................... 3.2
DRIVE WHEEL TRACKING ........................................................................................................................................ 3.2
CAM FOLLOWER ADJUSTMENT .............................................................................................................................. 3.3
LUBRICATION............................................................................................................................................................. 3.3
GEARBOX LUBRICATION (H-18ASV WITH A503 GEARBOX) ................................................................................. 3.4
OUTPUT SHAFT LUBRICATION ................................................................................................................................ 3.5
HYDRAULIC MAINTENANCE..................................................................................................................................... 3.5
CLEANLINESS............................................................................................................................................................ 3.6
TROUBLE SHOOTING ............................................................................................................................................... 3.6
PROGAMMABLE LOGIC CONTROL.......................................................................................................................... 3.8
PLC PARAMETERS .................................................................................................................................................... 3.8
PLC TROUBLESHOTTING ......................................................................................................................................... 3.10
FUSES......................................................................................................................................................................... 3.15
MITSUBISHI FX2N 48MR INPUTS AND OUTPUTS .................................................................................................. 3.16
ENCODER & PROXIMITY SENSOR CONNECTIONS............................................................................................... 3.17
CALIBRATION PROCEDURE..................................................................................................................................... 3.18
HEAD HEIGHT CALIBRATION PROCEDURE ........................................................................................................... 3.19

TOC.1
SECTION 4, ELECTRICAL
GENERAL INFORMATION.......................................................................................................................................... 4.1
INITIAL HOOKUP........................................................................................................................................................ 4.1
H-18/22 SV ELECTRICAL SCHEMATIC, NO OPTIONS 208/240 VAC ...................................................................... 4.8
H-18/22 SV ELECTRICAL WIRING DIAGRAM, NO OPTIONS 208/240 VAC ............................................................ 4.12
H-18/22 SV ELECTRICAL WIRING DIAGRAM INPUTS & OUTPUTS, NO OPTIONS 208/240 VAC ........................ 4.18
H-18/22 SV ELECTRICAL SCHEMATIC, WITH OPTIONS, 208/240 VAC ................................................................. 4.20
H-18/22 SV ELECTRICAL WIRING DIAGRAM, WITH OPTIONS, 208/240 VAC ....................................................... 4.24
H-18/22 SV ELECTRICAL WIRING DIAGRAM INPUTS & OUTPUTS, WITH OPTIONS, 208/240 VAC ................... 4.30
H-18/22 SV ELECTRICAL SCHEMATIC, NO OPTIONS 480/575 VAC ...................................................................... 4.32
H-18/22 SV ELECTRICAL WIRING DIAGRAM, NO OPTIONS 480/575 VAC ............................................................ 4.36
H-18/22 SV ELECTRICAL WIRING DIAGRAM INPUTS & OUTPUTS, WITH NO OPTIONS, 480/575 VAC ............. 4.42
H-18/22 SV ELECTRICAL SCHEMATIC, WITH OPTIONS, 480/575 VAC ................................................................. 4.44
H-18/22 SV ELECTRICAL WIRING DIAGRAM, WITH OPTIONS, 480/575 VAC ....................................................... 4.48
H-18/22 SV ELECTRICAL WIRING DIAGRAM INPUTS & OUTPUTS, WITH OPTIONS, 480/575 VAC ................... 4.54

SECTION 5, HYDRAULIC SYSTEM

GLAND ASSEMBLIES ................................................................................................................................................ 5.2
PISTON ASSEMBLIES................................................................................................................................................ 5.2
H-18/22 SV HYDRAULIC SCHEMATIC ...................................................................................................................... 5.3
H-18/22 SV PLUMBING DIAGRAM ............................................................................................................................ 5.4

SECTION 6, MECHANICAL
H-18 SV BLADE BRUSH ASSEMBLY......................................................................................................................... 6.1
H-22 SV BLADE BRUSH ASSEMBLY......................................................................................................................... 6.2
H-18/22 SV GUIDE ARM ASSEMBLY......................................................................................................................... 6.3
H-18/22 SV CARBIDE GUIDE ASSEMBLY................................................................................................................ 6.4
H-18/22 SV ANTI-VIBRATION ROLLER ASSEMBLY ................................................................................................. 6.5
H-18 SV IDLER WHEEL ASSEMBLY.......................................................................................................................... 6.6
H-22 SV IDLER WHEEL ASSEMBLY.......................................................................................................................... 6.7
H-18/22 SV HYDRAULIC PUMP ASSEMBLY............................................................................................................. 6.8
H-18/22 SV HYDRAULIC TANK ASSEMBLY .............................................................................................................. 6.9
H-18/22 SV FRONT VISE ASSEMBLY ....................................................................................................................... 6.10
H-18/22 SV SHUTTLE VISE DATUM LINE JAW ASSEMBLY .................................................................................... 6.11
H-18/22 SV SHUTTLE VISE ASSEMBLY ................................................................................................................... 6.12
H-18/22 SV CHIP AUGER ASSEMBLY....................................................................................................................... 6.13
H-18 SV DRIVE ASSEMBLY ....................................................................................................................................... 6.14
H-22 SV DRIVE ASSEMBLY ....................................................................................................................................... 6.16

SECTION 7, OPTIONAL EQUIPMENT

H-18/22 SV BUNDLING ASSEMBLY .......................................................................................................................... 7.1
H-18/22 SV OUTBOARD BUNDLING ASSEMBLY ..................................................................................................... 7.2

SECTION 8, SPECIFICATIONS
H-18 SV LAYOUT........................................................................................................................................................ 8.2
H-22 SV LAYOUT........................................................................................................................................................ 8.3

SECTION 9, WARRANTY
WARRANTY ................................................................................................................................................................ 9.1

TOC.2
 SECTION 1, INSTALLATION
Upon delivery of your new H-18/22 SV saw, it is imperative that a thorough inspection be undertaken to check for any
damage that could have been sustained during shipping. Special attention should be paid to the electrical and hydraulic
systems to check for damaged cords, hoses and fluid leaks. In the event of damage caused during shipping, contact your
carrier to file a damage claim.

SAFETY PRECAUTIONS

The machine has been designed to give years of reliable service. It is essential that operators be alerted to the safe
operation of this saw, and the practices to avoid that could lead to injury. The following safety rules are at the minimum
necessary for the safe installation, operation, and maintenance of the saw. Take every precaution for the protection of
operators and maintenance personnel.

• POWER HOOK-UPS AND REPAIRS SHOULD BE ATTEMPTED ONLY BY QUALIFIED TRADESMEN.

• THE SAW SHOULD BE LOCATED IN AN AREA WITH SUFFICIENT ROOM TO SAFELY LOAD STOCK INTO
THE SAW. SECURE THE SAW TO THE FLOOR.

• THE AREA AROUND THE SAW SHOULD BE MAINTAINED IN A CLEAN AND TIDY CONDITION TO AVOID
OBSTACLES OPERATORS COULD TRIP OVER.

• THE H-18/22 SV SHOULD ONLY BE OPERATED ACCORDING TO THE SPECIFICATIONS OF THE SAW.
AVOID UNSAFE USAGE PRACTICES.

• IF AT ANY TIME THE SAW DOES NOT APPEAR TO BE OPERATING PROPERLY IT SHOULD BE
STOPPED IMMEDIATELY AND REPAIRED.

OPERATOR :
• THE SAW SHOULD NEVER BE OPERATED UNLESS ALL GUARDS AND DOORS ARE IN PLACE AND
CLOSED.

• KEEP A SAFE DISTANCE FROM ALL MOVING PARTS - ESPECIALLY THE BLADE AND VISES.

• LOOSE CLOTHING AND GLOVES SHOULD NEVER BE WORN WHILE OPERATING THE SAW. COVER LONG
HAIR.

• STOCK SHOULD NOT BE LOADED ONTO THE SAW IF THE BLADE IS RUNNING.

• LONG AND HEAVY STOCK SHOULD ALWAYS BE PROPERLY SUPPORTED IN FRONT OF AND BEHIND THE
SAW.

• NEVER ATTEMPT TO DISLODGE OR MOVE STOCK WHILE THE BLADE IS MOVING. TAKE THE TIME TO
STOP THE SAW BLADE, REMOVE OBSTRUCTIONS, AND START BLADE.

• MUST WEAR EYE PROTECTION.

• 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 FROM

HYD-MECH. ANY APPROVED MODIFICATIONS SHOULD ONLY BE UNDERTAKEN BY TRAINED PERSONNEL.

1.1
H-18/22 SV LIFTING INSTRUCTIONS

1.2
FOUNDATION, LEVELLING AND ANCHORING

Machine location should be carefully selected. A flat con-

crete 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 leveled in both directions i.e. along and

across its in-feed conveyor especially when machine is to be
inserted into a larger conveyor system.

Six leveling screws are provided, one in each corner of the

machine base plus on in the hydraulic cabinet. Steel plates
are to be placed under each screw to prevent their sinking
into the concrete floor. In cases where the machine is to be
anchored permanently, anchoring holes are provided. They
are located next to the leveling screws.

NOTE:
In some cases leveling the saw in-feed and auxiliary con-
veyor 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).

WIRING CONNECTIONS

After the machine is leveled 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:

1. Signs of damage that may have occurred during shipping to the electrical cables and the hydraulic hoses.
2. The hydraulic oil level is between the upper and lower lines on the level gauge.

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 and

Ground terminals in the main electrical box found beside the
conveyor on the drive side. For machines equipped with a variable
frequency drive unit, an earth ground is also recommended.

During the initial hook-up it is very important to check that the

phase order is correct. This is indicated by the hydraulic pres-
sure gauge registering a pressure rise and the blade running in
a counter clockwise direction. If the hydraulics do not register an
immediate pressure rise, shut the hydraulics off and change the
phase order.

ATTENTION: Running the hydraulics “backwards” can damage

the hydraulic pump.

1.3
HYDRAULIC OIL AND CUTTING FLUID

The H-18/22 SV bandsaw is supplied with Arco Duro 46 hydraulic oil. If it is necessary to change the oil to a different
brand see the HYDRAULIC SECTION for 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.

1.4
 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. The saw is equipped with a variable blade speed control and hydraulic feed control, as well as an extensive door
chart to guide the operator to the correct setting of these controls.

BLADE BASICS

Technology is rapidly changing all aspects of production machining. Metal cutoff 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 4/6 or 3/4 bi-metal blade supplied with the machine) 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. (It is also advisable to utilize a slow blade speed.)

These two or three slow cuts sufficiently lap (polish) the teeth on 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, Maintenance and Troubleshooting)
2. Generous coolant application is essential with most materials. A high quality and well mixed coolant will extend
blade life, and also increase cutting rate and quality. On those materials where coolant is undesirable for cutting,
a slight coolant flow or periodic oiling of the blade is necessary to prevent the blade from being scored by the
carbide guides.
3. The stock being cut must be securely clamped in the vises.
4. The proper feed force should be chosen. (see Saw Cutting Parameters: Step 2)
5. The proper blade speed must be selected. (see Saw Cutting parameters: Step 4)
6. The proper feed rate must be applied. (see Saw Cutting Parameters: Step 5)

VARIABLE SPEED CONTROL

Blade speed can be adjusted infinitely between 60 to 350 SFM (Surface Feet/Minute) (18 to 107m/min). Adjustment
should be made only when the blade is running. Clockwise rotation of the knob increases blade speed while counter
clockwise rotation decreases blade speed.

THE CONTROL PANEL

START-UP

The H-18/22 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. We can
not overstress the importance of familiarizing yourself with the controls of the H-18/22 prior to starting the
machine.

NOTE:
1. ALL SWITCHES MUST BE IN THE CENTER NEUTRAL POSITION TO START THE MACHINE!
2. WHEN STARTING THE MACHINE FOR THE FIRST TIME MAKE SURE THAT BLADE IS MOVING IN A COUN-
TERCLOCKWISE DIRECTION, AND THAT THE HYDRAULIC PRESSURE IS 1000 PSI (6890kP). IF THERE IS
NO IMMEDIATE PRESSURE, SHUT THE SAW DOWN AND CHANGE THE PHASE ORDER.

MANUAL OPERATION

Manual Operations can be performed when the PLC 100 controller is set to MAN (AUTO is active when a RED light is on
above the AUTO/MAN button). All functions are self-explanatory. Specific control button functions are described on the
following pages.

2.1
 FRONT VISE - This switch has three positions, OPEN, HOLD and CLOSE. With the switch held in the
OPEN position the vise will open all the way or until the switch is released. With the switch in the HOLD
position, the vise will stay where it is and will not move freely although it will not resist a large force
indefinitely without creeping. In CLOSE, the vise will close all the way, or until it encounters enough
resistance to stop it.

HEAD CONTROL - This switch has three positions: UP, HOLD and DOWN. The switch is inactive un-
less the PLC is in manual mode. In the UP position, the head will rise until it trips the head up limit which
is adjustable via the PLC. In the HOLD position the head will stay still. In the DOWN position the head
will descend until it reaches the bottom of the stroke. The speed of descent is controlled by the Head
Feed and Head Force Limit controls.

BLADE START - The blade can be started only when the hydraulics are running in either manual or auto
mode.
NOTE: In automatic Mode the head will not descend until the blade has been started, which the PLC will
prompt the operator to do so.

HYDRAULIC START - To start the hydraulic system, the switches for the head and both vises must be in
the “NEUTRAL” position. The “HYDRAULIC START” button must be depressed and held in momentarily
until the PLC display becomes active.

CYCLE START / PAUSE - This button starts the cutting cycles and will stay illuminated white until the
cycles are completed. The PLC control system will prompt you to start the blade if it is not running. The
machine will then begin the automatic cycle until completed when it will shut itself off. The current cycle
can be PAUSED by pressing this button at any time during a cycle and restarted by pressing it again.

COOLANT - This switch has three positions, AUTO, OFF, and ON. In the ON position, the coolant
system will operate when there is power to the machine; this allows using the wash gun to clean the
machine. In the OFF position, the coolant system is inactive. In the AUTO position the coolant system
will only run when the blade is on. The coolant system can be run when the blade is on and the head is
descending by selecting this option in the PLC parameters.

2.2
SHUTTLE VISE - This switch has three positions, OPEN, HOLD and CLOSE. With the switch held in
the OPEN position the vise will open all the way or until the switch is released. With the switch in the
HOLD position, the vise will stay where it is and will not move freely although it will not resist a large
force indefinitely without creeping. In CLOSE, the vise will close all the way, or until it encounters
enough resistance to stop it.

BLADE STOP BUTTON - Stops the blade. If the blade is stopped during a cycle, the cycle will continue
but will not let the head descend until the blade is started.

STOP - This mushroom button stops the blade and hydraulic motors. Both vises will hold their posi-
tion but, 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.

WORK LAMP - This option switch has two positions, OFF and ON.

LASER GUIDE - This option switch has two positions, OFF and ON.

2.3
PLC 100 CONTROL SYSTEMS

NOTE: This instruction manual is applicable to the H-18/22 SV equipped with a MITSUBISHI PLC manufactured after and
including the following serial numbers:

Machine Model Serial #

H-18S B1001099, B1001103

DISPLAY WINDOW

PLC FUNCTION KEYS

NUMERIC KEY PAD CURSOR KEYS

ENTER KEY

OPERATION OVERVIEW

The PLC is a programmable logic controller which allows the operator to run the machine in both manual and automatic
modes.

In manual mode, all functions can be operated by using a combination of selector switches on the control console and
the PLC function buttons. Also the operator has the ability to execute a single cut utilizing a preprogrammed “Single Part
Cycle”.

In automatic mode, the PLC has the capacity to program and store 99 jobs. Designated job numbers can be programmed
for quantity required (maximum of 999 pieces) and lengths from 0.1” to 220” (5588mm).

Jobs can be run individually or in a QUEUE which allows a maximum of 5 jobs to run consecutively and the queue can be
repeated automatically as well up to 99 times.

All machine operators should be familiar with the entire operation instructions prior to operating the machine.

NOTE: If an emergency situation arises during any operation, use the large red mushroom “STOP” button located on the
control panel to shut down the machine. To operate the machine, the “STOP” button must be pulled out.

2.4
ACTIVATING THE PLC

Position the head, fixed vise, and shuttle vise switches to the NEUTRAL (center) positions. If any of these switches are
not in the NEUTRAL position, the hydraulics will not start. The PLC control will become active when the HYDRAULIC
START button is depressed and “held in” momentarily. First, the HMI and PLC’s current revision number will be shown on
the display window and finally the MANUAL MODE display window will appear as shown below. The AUTO/MAN green
indicator light will be on and all MANUAL controls are enabled. The “LTH” value (shuttle vise position) will always display
zero at start up. The “LTH” value can be reset or cleared at any time in MANUAL mode by pressing the CLEAR function
button.

FUNCTION KEY DESCRIPTIONS

If a red indicator light above a function button is illuminated, it means that the function printed in red at the top of the but-
ton is enabled. No light indicates the function printed in black at the bottom of the function button is enabled.

The following are the function keys for AUTO and MAN modes:

AUTO / MAN MODE

- This key will toggle between MAN and AUTO modes. Auto mode cannot be accessed unless the front vise is
closed.
- Also used to stop an automatic job in progress by switching to MANUAL mode.

UNLABELLED
- The function of theses keys are displayed directly above them. The function will change as the PLC is
switched from one mode to another and as process of each mode is changed.

INCH/MM / CLEAR
- While depressed momentarily, it resets the displayed length value to zero. If held depressed for a few sec-
onds, the displayed length will toggle between millimeters and inches and the blade speed in either surface feet
per minute or meters per minute. It becomes disabled once any cycle is initiated.

MANUAL MODE FUNCTION KEY DESCRIPTIONS

While in manual mode, the display will show the current function of the unlabelled key. They are shown below.

REV

FWD S/F

FWD: FORWARD - This key will advance the shuttle vise toward the head (home position). If pressed simultaneously
with the REV key, (the front vise must be closed and a password is required) the parameters will be
displayed.

REV: REVERSE - This key will retract the shuttle vise away from the head (home position). If pressed simultaneously with
the FWD key, (the front vise must be closed and a password is required) the parameters will be dis-
played.

S/F : SLOW / FAST - This key will toggle between slow and fast shuttle speed.

2.5
SINGLE PART CYCLE OPERATION

In MAN mode, the PLC allows the operator to initiate a “Single Part Cycle” to cut one piece at a desired length. To accom-
plish this, follow the procedure below.

1. A trim cut should be made before initiating the “Single Part Cycle” operation.
2. Make sure the front vise switch is in the closed position and set the head up limit switch. The AUTO/MAN indicator
light will flash alternately green and red.
3. Make sure the head is set so that the blade is above the material and the head selector switch is in the HOLD
position.
4. The cursor will be flashing at the LENGTH position. Key in the desired value from 0” to 220” and press enter. If the
value is incorrect, re-enter the value and press enter again.
ENTER KEY
BLADE SPEED
LENGTH

5. If the blade is not running, you will be prompted by the word “BLADE” flashing on the display window. Start the
blade and adjust the blade speed as required.

FLASHING

6. When the blade is started, the word “BLADE” will change to the word “CYCLE” flashing on the display window.
Press CYCLE START and the cycle will begin.
7. When the cycle button is pressed, the shuttle vise will move forward to the home position before executing the
length movement. The head will descend and make the cut.
8. When the cut is completed, the head will rise to the head up limit switch, the blade will stop and the display win-
dow will reset for the next cut.
9. To cut another piece, repeat steps 2 through 6.

NOTES:
1. To “PAUSE” the “SINGLE CUT CYCLE”, press the “CYCLE START” button. The “CYCLE START” button will be-
gin to flash and the screen will indicate a paused condition. All movements will immediately cease. To continue the
cycle, press “CYCLE START” button again.
2. To cut multiple pieces, switch to AUTO MODE and follow the automatic procedures.

KERF CORRECTION

When making cuts, the PLC must account for an amount called the “KERF” which is the material removed by the blade.
This value must be entered into the PLC and must be checked and adjusted as required when the blade has been re-
placed. This is due to the fact that there is a variance in the kerf value from blade to blade. The original value entered is
for the blade installed at the time of manufacture. If the kerf value is to be adjusted its value can be accessed while in
Auto Mode. Press and hold the key below the word “KERF” on the display until the display appears as shown. Enter the
desired kerf value and press enter.

NOTE: Whenever a new job or new material is being loaded for production, the head up limit switch should be properly
set to clear the material, positioned for a trim cut and the front vise closed (in “MANUAL MODE”).

RETURNS TO RETURNS TO THE

AUTO MODE QUEUE

2.6
AUTOMATIC OPERATION

When the AUTO/MAN button is pressed, the red indicator light above it will come on, and the blade will stop if it has been
running. The screen will change to the JOB display window as shown below and be ready for editing or starting a new job.
All manual functions will be disabled.

JOB DISPLAY WINDOW

JOB NUMBER REQUIRED QTY
LENGTH CUT QTY

PROCEDURE FOR EDITING OR STARTING A NEW JOB IN AUTO MODE

1. In AUTO mode, key in a job number from 0 to 99 and press enter. The REQUIRED QUANTITY (RQ), LENGTH
(LTH) and QUANTITY (CT) will be displayed. The values displayed can be edited by pressing ENTER after each
new value, and the job will be stored in memory with the new values. To navigate through the values, use the
CURSOR keys.
2. After the values are entered, press the CYCLE START button, the switch will illuminate, the display window will
prompt you to start the blade for a trim cut (if the “Trim Cut” parameter has been selected).

CAUTION:
If the head is in its down position, it will rise to the head up limit so that no damage to the blade will occur.

3. After starting the blade, the head will descend for the cut and the machine will complete the required job.

JOB IN PROGRESS

4. At the completion of the job, the machine will shut down if “0” has been entered in the “POWER DWN TIMER”
parameter or continue running for the specified time up to a maximum of 180 minutes.

NOTES:
1. The “CT” value is the accumulated total number of parts that have been cut from the JOB number since it was last
reset. The machine will only cut the quantity which is the difference between REQUIRED QUANTITY and CUT
QUANTITY. When REQUIRED QUANTITY equals CUT QUANTITY, the machine AUTO CYCLE will stop and you
will be unable to restart the same job until the “CUT QUANTITY” value has been reset.
2. The AUTO cycle may be exited and stopped at any time by pressing the key.

NOTE: Before entering “AUTO MODE” and working with a “QUEUE”, follow the same procedures outlined on the previous
page for “AUTOMATIC OPERATION” with regards to setting up for an initial trim cut.

2.7
WORKING WITH A QUEUE

The purpose of a QUEUE is to allow the operator to run several jobs (max of 5) in series if they are of the same material
and shape.
In AUTO mode, press the key below the word “QUE” on the display and the display window will appear as shown.

If you choose to VIEW the QUEUE, press the key below the words “VIEW QUE” on the display. The display window will
show the jobs in the current QUEUE. Four jobs at a time are shown.
PROGRAMMED JOB
NUMBER

FIRST JOB LENGTH TO CUT

QUANITY TO CUT

Use the CURSOR buttons to view all the jobs. To run the QUEUE as it is displayed (jobs may be edited in this mode),

press the CYCLE START button on the control panel. The screen will now prompt you to start the blade for a trim cut.

If you choose to edit the QUEUE, press the key below the words “CLEAR QUE” on the display. This will clear any jobs
that are in the QUEUE and the display window will show an empty Queue. Jobs may be entered and edited in this mode.

VIEW QUE CLEAR QUE

To fill the QUEUE, follow these two steps.

1. Key in a job number and press ENTER. If that job number has previously been programmed, it’s values will be
displayed. The cursor will move to the next position in the QUEUE. Up to five jobs may be in the QUEUE at any
time. The job values can be edited in this mode.
2. When the desired jobs have been entered, you may press the CYCLE START button on the control panel to ex-
ecute the jobs in the QUEUE. (Follow the same procedures to initiate a cycle as in “AUTOMATIC OPERATION”)

The QUEUE may be exited to the previous screen at any time by pressing the key under JOB. At completion of the
“QUEUE”, the machine will shut down if “0” has been entered in the “POWER DWN TIMER” parameter or continue run-
ning for the specified time up to a maximum of 180 minutes.

2.8
HYDRAULIC FEED CONTROL

The Hydraulic Feed Control is located to the left of the control panel. These controls allow independent control of Feed
Force and Feed Rate.

FEED FORCE KNOB

USED TO SET FEED FORCE LIMIT
(COUNTERCLOCKWISE ROTATION
TO INCREASE AND CLOCKWISE
ROTATION TO DECREASE).

FAST APPROACH LEVER

DEPRESS FOR FAST HEAD DE-
SCENT

FEED RATE KNOB

USED TO SET FEED RATE (COUN-
TERCLOCKWISE ROTATION TO
INCREASE AND CLOCKWISE
ROTATION TO DECREASE).

2.9
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 perfor-
mance of the saw. These steps are detailed on the following pages.

CHART EXAMPLE #1

We will use the parameters chart to set up the saw for cutting 8” (200mm) Diameter
#1045 Carbon Steel.

STEP 1, DETERMINE EFFECTIVE MATERIAL WIDTH - W (inches) or (mm)

Effective material width, W (in.) for most common shapes of materials, is the widest
solid part of the material to be in contact with blade during cutting. For simple shapes,
as illustrated on the chart, this can be directly measured. For bundles of tubes and
structurals, measuring the effective width is difficult. Effective width is 60% to 75% of
the actual material width.

NOTES:
1. Both effective material width and guide arm width are used in setting the saw.
2. Guide arm width is the distance between the guide arms and is used in STEP
2.
3. 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 STEPS 3 and 4. In Example #1, for an 8” (200 mm) diameter solid, Effective Mate-
rial Width is 8” (200mm).

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 work-
piece. FEED FORCE LIMIT should be set with the head in the down mode, according to the label.

CUTTING SOLIDS

For cutting solids, the wider the section, the less FF should be
set, to avoid blade overloading. See the graph. % OF FF
SETTING
EXAMPLE: When cutting a solid which is 1/2 of machine
capacity using the graph, locate 50% on the horizontal line
and travel upwards to the plotted line and then travel directly
across to the vertical FF Setting line. The point that you have
arrived at shows a setting of 40% for a piece 50% of capacity.
MAT’L WIDTH AS %
OF CAPACITY
CUTTING STRUCTURALS

A reduced Feed Force Setting is used when cutting structurals:

For structurals, a blade finer than optimum can be used for more efficient cutting.

If a finer than optimum blade is going to be used, Feed Force Setting should be reduced even further.

STEP 3; DETERMINE OPTIMUM BLADE PITCH - TEETH PER

INCH (T.P.I.) BLADE FF SETTING
1 OPTIMUM PITCH 20%
Selecting a blade with proper tooth pitch is important in order to FROM STEP 3
achieve optimal cutting rates and good blade life. 2 PITCH FINER THAN 0%
For cutting narrow or thin wall structural materials a fine blade with OPTIMUM

2.10
many teeth per inch (T.P.I.) is recommended. For wide materials a blade with a coarse pitch should be used. The sketch
can be referenced for the blade pitch changes for differing effective material widths.

It is impractical to change the blade to the proper pitch every time a different
width of material is cut and it is not necessary, but remember that the optimum
blade will cut most efficiently. Too fine a blade must be fed slower on wide
material because the small gullets between the teeth will get packed with
chips before they get across and out of the cut. Too coarse 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: Effective material width of 8” (200 mm) & Optimum blade
has 2/3 teeth per inch.

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

In Example #1
1. 8” (200mm) diameter #1045 Medium
Carbon Steel solid bar is to be cut.
2. On the graph above find the Me-
dium Carbon Steel Curve which
represents the optimum blade
speeds for 1045 Carbon Steel.
3. On the horizontal axis (effective
material width axis) find number 8
which represents effective material
width of an 8” (200mm) diameter
solid.
4. Find the point where a vertical line
from 8” (200mm) intersects the
Medium Carbon Steel Curve.
5. From this intersection point run
horizontally left to the vertical axis
(optimum blade speed axis) and
find the point marked “200”.
6. For 8” (200mm) diameter, 1045 Carbon Steel solid bar 200 ft/min (60m/min) is the optimum blade speed.
NOTE:
1. Higher than optimum blade speed will cause rapid blade dulling. Lower than optimum blade speeds reduce
cutting rates proportionately and 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 structurals and bundles, a
lower blade speed may reduce vibration and prevent premature blade failure.
2. Material Hardness - The graph above illustrates blade speed curves for materials of hardness 20 RC (225 Bhn) or
lower. If the material is hardened then the multipliers need to be used. These multipliers are given in the NOTE at
the bottom right of the graph. As the hardness increases the optimum blade speed decreases.

STEP 5, DETERMINE FEED RATE SETTING, FR (in/min) (mm/min).

FEED RATE is the vertical speed at which the blade descends through the work-piece.

The FEED RATE Knob controls FEED RATE of the blade descent in the range 0 to 15 in/min (380mm/min). The FEED
RATE should be adjusted only in one direction (from “O” to required value). If you go too far, go back to “O” and come

2.11
back up. To set FEED RATE for particular cutting situations use the Graph below, which represents the relationship be-
tween FEED RATE, blade speed and blade pitch.

NO. MATERIALS OPTIMUM BLADE SPEED

ft/min m/min
1 5” (125mm) Dia Solid Carbon Steel 225 70
2 12” (300mm) I-Beam 290 90
3 4” x 4”(100 x 100mm) Rec Tube, 1/4” (6mm) Wall 350 110
4 4”(100) 400 Stainless Steel 140 45
5 2” x 2” (50 x 50mm) Rec Tube 1/4” (6mm) Wall
Bundle 5 x 5 pcs 10” x 10” (500 x 500mm) 325 100
6 3” x 3” (75 x 75mm) Inconel 60 20

For Example #1, it is known from Step 3 that optimum blade pitch is 2/3, and from Step 4 that blade speed is 200 ft/min
(60mm/min). From the Graph on the left, the FEED RATE is determined in the following way:
• On the horizontal axis (blade speed axis), find 200 ft/min (60mm/min).
• Find the point where a vertical line from 200 ft/min (60mm/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 (45mm/min) FEED RATE. Thus 1.8 in/min (45mm/min) is the FEED RATE
for cutting 8” (200mm) diameter 1045 Carbon Steel when the optimum 2/3 pitch blade is
used.

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.
3/4 TPI) we use the graph for the optimum blade as before, and then use a multiplier given by the
table below.

NOTE:
Use the following chart when cutting solids. For structurals, see “CUTTING STRUCTURALS” in STEP 2.

ADDITIONAL CUTTING SETUP EXAMPLES

EXAMPLE # 2

Material:
Round Steel Tube SAE 4320 - Hardened to 35 RC (325
Bhn )
Dimensions - 6” O.D. x 4” I.D. (150mm O.D. x 100mm
I.D.)

Step 1 Effective Material Width:4 1/2” (.75 X 6) 114mm

(19 x 6)
Step 2 Feed Force limit setting for 6” Diameter material
Refer to Feed Force Limit, Setting in Step 2
Step 3 Optimum blade pitch (TPI), 3/4 T. P. I.
Actual blade pitch on the saw: 4/6 T. P. I.
Step 4 Optimum blade speed for 4 1/2” effective 225
ft/min (70m/min) material width (70m/min x .60 =
42m/min)
Blade speed reduced by hardness factor: 225

2.12
 Optimum
Pitch
10/14 1.0
8/12 .83
6/10 0.67 .80
5/8 0.54 .65 .81
4/6 0.42 .50 .63 .77
3/4 0.29 .35 .44 .54 .70
2/3 0.21 .25 .31 .38 .50 .71
1.4/2.5 0.17 .20 .25 .31 .40 .57 .80
.85/1.5 0.1 .12 .15 .18 .24 .34 .48 .60 1.0
10/14 8/12 6/10 5/8 4/6 3/4 2/3 1.4/2.5 .85/1.5

If your blade is finer than optimum blade pitch,

multiply feed rate, FR, by above factors

ft/min X .60 = 135ft/min

Step 5 Feed Rate for 3/4 TPI blade: 1.8 in/min (45mm/min)
Feed Rate for 4/6 TPI blade: 1.8 in/min X .70 = 1.3in/min (reduced by finer than optimum blade pitch fac-
tor) (45mm/min x .70= 31.5mm/min)

EXAMPLE # 3

Material:
Bundle low carbon steel 2” x 2” Tube with 1/4” wall, 12 piece bundle (50mm x 50mm with 6mm wall)
Dimensions:
6” x 8” (150mm x 200mm)

Step 1 Effective Material Width: 5” ( .6 X 8” ) 120mm (.6 x 200)

Step 2 Feed Force limit setting for 8” Diameter material.
Step 3 Optimum blade pitch (TPI): 3/4 T. P. I.
Step 4 Optimum blade speed for 5 “ effective material width - 320 ft/min (100m/min)
Step 5 Feed Rate for 3/4 TPI blade: 4.0 in/min (100mm/min)

ADDITIONAL CONTROLS

COOLANT FLOW

The main coolant control is found on the control panel.

WASH: Coolant flows any time the machine is under power, permitting wash down with
spray nozzle without running machine.
OFF: No coolant flow.
ON: The coolant flows only when the blade is running or when the blade is running and the
head is descending. This is selectable via the PLC parameters.
The bandsaw is equipped with two independently controlled coolant spouts that are capable
of supplying a generous flow of coolant to the blade.
The left guide arm supplies a flow of coolant that should flood the blade as it moves through
the carbide pads into the material to be cut. The adjustable spout on the left guide arm should
be set with the blade speed to provide the flood of coolant necessary.
The right guide arm provides a coolant flow through the flexible hose that can be pointed directly where necessary. This
flexible hose should be used when cutting solid bars, bundles, or wide structurals. Set the flow of coolant directly into the
opening in the material where the blade is cutting.
NOTE:

2.13
When cutting materials that do not need constant coolant, such as Cast Iron, some coolant flow is required for blade lubri-
cation to prevent blade scoring by the carbide pads as the blade moves through them.

HEAD UP and DOWN LIMIT SETTING

The head up limit is used to restrict the distance the head travels for each stroke. It can be adjusted at any time by moving
the switch trip plate to any position on the vertical bar. The trip plate & switches are found behind the head on the drive
end near the gear box.

Head Up Limit: In order to maximize production in the automatic, cycle the Head Up Limit should be set to just clear the
height of the material.

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.

HEAD UP LIMIT SWITCH

HEAD DOWN LIMIT SWITCH

VARIABLE VISE PRESSURE (OPTION)

This option allows the operator to adjust the vise pressure. This can be valuable when cutting light structurals and tubes.
By reducing the vise pressure from the system (H18=1000, H22=1100psi) pressure, distortion of materials is prevented.
The controls are located at the drive end of the machine.

2.14
BUNDLING OPERATION (OPTION)

The bundling vises can be operated in direct conjunction with the front and shuttle vises or at a slower clamping speed.
Either bundling can be turned on or off at any time. The on / off valves are shown in the photos.
The speed at which the bundling jaws close can be adjusted as required by turning the flow control valves (shown in the
photos) for each bundling cylinder.

CLOSING SPEED
FRONT BUNDLING FLOW OPENING SPEED
CONTROL VALVES

CLOSING SPEED
OPENING SPEED
SHUTTLE
BUNDLING
ON/OFF VALVE

2.15
 SECTION 3, MAINTENANCE AND TROUBLE SHOOTING
LOCK -OUT

Purpose:
To prevent injury to workers caused by unexpected start-up of machines being worked on.
OR
Where the starting of a machine or device may endanger the safety of a worker

a. Control switches or other control mechanisms shall be locked out;

AND
b. Other effective precautions necessary to prevent such starting shall be taken

LOCK OUT PROCEDURE

Whenever work is to be performed on a machine, the person in charge should follow

Lockout procedures as is required by his organization. The main power disconnect box
is supplied with a suitable mechanism for this purpose as shown below. To place a lock
on the switch, turn the switch to OFF.

BLADE CHANGING PROCEDURE

NOTE:
Wear gloves, safety glasses and a long sleeve shirt for protection from the sharp blade.
The hydraulics should be OFF any time the operator has his/her hands in contact with
the blade.

1. Select MANUAL mode and raise the head so the drive door will clear the elec-
trical control panel.
2. Release the blade tension by turning the Blade Tension Switch to “-”.
3. Remove the blade guard.
4. Shut the machine off and open the idler and drive doors.
5. At the top of the head, the saw blade runs in a protective channel. Grip the blade at each
end of this channel and twist the blade teeth down past the channel and slide the blade
forward. Let the blade rest on the out feed table, then slide the blade down and out of the
carbide guides.
6. Before installing the new blade, check that it measures 1.615” wide including the teeth.
Some blade manufacturers supply blades that measure 1.5” including the teeth. The
same applies to 2” blades, they should measure 2.120”. In this case you may not be able
to adjust the head down limit to complete the cut.
7. Your new blade will be in a coil. While wearing gloves hold the blade away from you, twist the blade to uncoil it.
Do not let the blade teeth bounce on the concrete floor as some damage to the blade may be caused.
8. Place the new blade in the carbide guides and then slide the blade over the wheels. The teeth should be pointing
towards the drive side as they pass through the carbide guides.
9. Turn the machine on and the blade tension switch to the “+ RUN” position, turn the two carbide locking handles
clockwise to the locked position. Jog the blade a few rotations to check that the blade is not moving on or off the
wheels.

NOTE:
Whenever the blade is changed, the KERF value (1 1/4” blade = 0.060” - 0.065”, 1 1/2” blade = 0.076 - 0.082”) should be
checked and the new value entered into the PLC. See page 12 for entering instructions.

3.1
BLADE BRUSH ADJUSTMENT

The blade brush is properly set when machine leaves the factory, but it wears out during operation and needs to be read-
justed periodically. The blade brush assembly is found behind the drive side door and is shown below. To adjust the as-
sembly, loosen the hex nut, turn the set screw counterclockwise until the wires on the brush touch the bottom of the blade
gullets and tighten the hex nut.
The brush should be replaced as it becomes worn to approximately 70% of it’s original 3” diameter. Replacements can be
purchased through your Hyd·Mech Dealer.

H-22 SV Blade Brush

H-18 SV Blade Brush

BLADE TRACKING ADJUSTMENT

For an H-18, blade tracking is set so the teeth of the blade protrude .260±.01” (6.6±.25mm) from the face of the wheels.
For an H-22, blade tracking is set so the teeth of the blade protrude .310±.01” (6.6±.25mm) from the face of the wheels

IDLER WHEEL TRACKING C A C D B D

Release blade tension before adjusting. The tracking is adjusted by

regulating the “push” set screws and the “pull” hex bolts. Before mak-
ing any adjustments, bolts “A & B” should be loosened but remain
snug. This will allow easy movement for the slide assembly. It should
be noted that most adjustments can be made with the “B & D” bolts.
Loosening bolts “A” and turning in set screws “C” by equal amounts
will move the blade off the wheel. Loosening bolts “B” and turning
in set screws “D” by equal amounts will move the blade on to the
wheel. After each “C” or “D” adjustment, tighten bolts “A & B”, run the
blade and then check the tracking.

Note: Check the proximity sensor distance from the wheel targets and spokes before starting the blade drive. Failure to do
so may result in damage to the sensor.

DRIVE WHEEL TRACKING Refer to gearbox illustration

Release blade tension before adjusting. Loosening bolts “A” and turning in set screws “C” by equal amounts will move the
blade OFF the wheel. Loosening bolts “B” and turning in set screws “D” by equal amounts will move the blade ON to the
wheel. After each “C” or “D” set screw adjustment, tighten bolts “A” or “B”, turn tension switch to “+ RUN”, run the blade for
a moment and recheck the tracking.

3.2
 B
A
D C

C
A

D
B

CAM FOLLOWER ADJUSTMENT

There are two cam followers mounted on the head frame. The set of cam followers are shown on the following page(s).
One of them is fixed and the other is adjustable. The cam followers are factory set and usually do not require adjustment.
In a properly adjusted system of cam followers only one side should be in contact with the guide. The gap between the
other and the guide bar should not exceed .003” to .005”. If it exceeds .003” to .005” you should contact your dealer to
arrange for adjustment.

LUBRICATION

The design of the machine was intended to minimize maintenance, although periodically certain moving parts need lubri-
cation. We recommend that this periodic lubrication be done once a month using any general purpose grease. In addition

3.3
 IDLER WHEEL TENSIONER
(ONE AT BOTH ENDS) CAM FOLLOWER GREASE
NIPPLES

4 GUIDE ARM GREASE

POINTS

2 VISE SHUTTLE VISE GREASE 2 SHUTTLE SHAFT BEARING HOUS-

NIPPLES INGS

GEARBOX LUBRICATION (H-18ASV WITH A503 GEARBOX)

The Bonfiglioli A503 gearbox used on the H18 is supplied with 5.3 litres (1.35 US gallon) of Mobil SHC 630
synthetic oil. This oil has an ISO Viscosity Grade of 220 that is optimum for ambient temperatures from 20 – 40
Deg C [70 – 104 Deg F]. If the machine will be operated for prolonged periods at ambient temperatures below
20 Deg C [70 Deg F] an oil of ISO Viscosity Grade 150 should be substituted.

Because of the tilted orientation of the gearbox on the H18 saw, the correct oil level is about 1 inch below the
level plug, F, shown in the illustration.

The suggested oil change interval is given below:

Oil Temperature Mineral Oil Interval Synthetic Oil Interval

Deg C [deg F] [hours] [hours]
<65 [< 150 F ] 8000 25000
65 – 80 [150 F – 175 F] 4000 15000
80 – 95 [175 F – 200 F] 2000 12500

3.4
Oil can be changed by draining through plug, E, and filling at plug F. If
the type of oil is being changed, it is advisable to flush the old oil by filling
the box with the normal quantity of the new oil, running it briefly at mod-
erate speed, and then draining the box again, before re-filling it with a
fresh quantity of the new oil.

OUTPUT SHAFT LUBRICATION G

Always follow Lock-out Procedures before performing this lubrica-

tion.
Band tension load is carried by a grease lubricated spherical bearing.
A grease fitting is accessible through the spokes of the blade wheel, as
shown at point G in the accompanying illustration. Lubricate once per
year with 30 ml [1 fluid once] of NLGI Class 2 Lithium base mineral oil
grease. This quantity represents about 20 to 30 strokes of a typical hand
grease gun

to the grease points shown, vise jaw guides, in-feed rollers and bundling assemblies require greasing.

HYDRAULIC MAINTENANCE

1. OIL FILTER- Ten micron filtration of the oil is provided by a spin on type filter mounted on the tank return line. The
element should be changed after first 50 hours of operation and then every 500 working hours. See section 5 for
replacement filter element information.

2. HYDRAULIC OIL- Machine hydraulic reservoir is filled with mineral oil Texaco Rando HD46. In case of changing
the brand, hydraulic system should be drained and thoroughly flashed. Following is a list of recommended re-
placement oils:

• Texaco Rando HD 46
• CHEVRON ECO Hydraulic oil AW ISO 46
• MOBIL DTE 25
• ESSO NUTO H46
• SHELL TELLUS OIL 46

3. HYDRAULIC 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 if at all.

4. HYDAULIC OIL CHANGE - Oil visual inspection should be conducted with every filter change for following signs
of degradation:
• Milky or hazy oil color
• Burnt smell
• Varnish or sludge formation
• Increased viscosity
If one of the above is observed then oil should be changed. It is recommended to change oil after every
6000 hours of operation or every 2 years.

5. OIL TEMPERATURE - Oil temperature is indicated by a thermometer contained in the level gauge. Oil tempera-
ture during steady operation should stabilize at about 50-55F (28-31 deg C) above room temperature. Thus in a
70F (21 deg C) shop one might expect an oil temperature of about 120F (49 deg C). Oil temperature should never
exceed 155F (68 deg C).

6. HYDRAULIC PRESSURE - Hydraulic pressure is factory set and should not require any further attention. For
adjustment see hydraulic schematic.

3.5
 7. BLADE TENSION – Blade tension pressure is factory set and should not
require any farther attention. For adjustment see hydraulic schematic.

8. CARBIDE PRESSURE
Carbide lock pressure is factory preset:
• H-18SV 300 – 400 PSI
• H-22SV 150 – 200 PSI
The pressure gauge is not provided. There is a separate port to
hook up a gauge if setting needs to be verified or corrected.

CLEANLINESS Gauge Port

The heavy duty design should endure heavy operating conditions and provide the customer with flawless machine perfor-
mance. To extend good performance some care is required especially as cleanliness is concerned.

The following areas should be kept clean:

• Control console free of dirt and grease.
• Door charts free of dirt and grease.
• Wheel boxes free of chips.
• Blade guides free of chips.
• Out-feed table free of chips.
• A large chip build-up should be avoided in the base of the saw.

NOTE:
All parts must be cleaned before any repair service can be performed on them.

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 person-
nel who will be able to rectify the problem.

PROBLEM PROBABLE CAUSE SOLUTION

1a. Blade worn. 1a. Replace blade.

Saw is cutting out of 1b. Low blade tension. 1b. Reset blade tension.
1
square vertically. 1c. Blade guides. 1c. Check for worn guides.
1d. Excessive feed rate. 1d. Check for proper cutting parameters.

Saw is cutting out of

2 2 Stock not square in vises. 2 Adjust accordingly.
square horizontally.

Blade comes off 3a. Not enough blade tension. 3a. Reset blade tension.
3
wheels. 3b. Improper tracking. 3b. Set tracking.

4a. Not enough blade tension. 4a. Tension blade.

4 Blade stalls in cut. 4b. Excessive feed force. 4b. Reduce.
4c. Excessive feed rate. 4c. Reduce.

5a. Blade speed too fast. 5a. Reduce.

Blade vibrates ex-
5 5b. Guide arms too far apart. 5b. Adjust accordingly.
cessively.
5c. Not enough blade tension. 5c. Reset blade tension.

Excessive blade 6a. Excessive blade tension. 6a. Reduce blade tension.
6
breakage. 6b. Excessive feed rate. 6b. Reduce.

3.6
 7a. Blade pitch too fine. 7a. Select coarser pitch.
7b. Blade brush not cleaning. 7b. Adjust or replace blade brush.
7 Tooth strippage.
7c. Excessive feed rate. 7c. Reduce.
7d. Excessive feed force. 7d. Reduce.

8a. No coolant. 8a. Add coolant.

8 No coolant flow. 8b. Coolant line blocked. 8b. Blow out coolant line.
8c. Coolant pump inoperable. 8c. Check, replace if

Depress each of the over-load buttons

located in the electrical box. Depressing one
9a. Motor overload has tripped. 9a.
button at a time and trying to start the saw will
indicate which motor was overloaded.

9 Saw will not start.

Replace the fuse in the control panel. Ran-
9b. Control circuit fuse has blown. 9b. dom blowouts may occur but a quickly repeat-
ed blowout points to an internal wiring fault.

Vise or head selector switch not Turn all switches to the center (neutral) posi-
9c. 9c.
in the center (neutral) position. tion.

Saw starts but will Reload with stock or reset the blade. Hold the
On machines so equipped, the
not run after Start hydraulic start button and release the blade
10 10 out-of-stock or blade breakage 10
button has been tension or open vises far enough to deacti-
limit switch has been tripped.
released. vate the limit switch.

If blade wheels run clockwise,

Stop immediately; reverse any two of the
11a. wrong phase order in power 11a.
Saw starts but no three phase connections.
11 connection to saw.
hydraulic functions.
If pump is noisy cause may be Stop immediately, add hydraulic oil. (See
11b. 11b.
low hydraulic oil level. page 28 hydraulic maintenance.)
Pump-motor coupling has sepa-
In Manual Mode 11c. 11c. Adjust accordingly.
rated.

Observe pilot light(s) on relevant

This requires the attention of a qualified ser-
12a. valve. If pilot light fails to go on, 12a.
vice person.
No individual func- problem is electrical.
tion will respond to If pilot light related to inopera-
12 Disassembly of hydraulic valves should be
its manual control tive function does light, problem
switch. under taken only by qualified service person-
12b. may still be the coil . If problem 12b.
nel or those knowledgeable with hydraulic
remains it may result from dirt in
components.
the valve spool.

Feed Rate Valve is fully closed

Turn Feed Rate Knob in a counter clockwise
13a. - pointer is set on “0” or close to 13a.
to open valve.
Head will not de- “0” in/min.
13
scend. 13b. Feed Force Limit is set too low. 13b. Increase Feed Force Limit.
Check for physical interference
13c. 13c. Remove obstructions.
preventing the head from falling.

3.7
 In Automatic Mode

Auto cycle will not No job queue programmed to Enter job numbers(s) and job data as de-
14 14 14
start. run. scribed in Section 2.

PROGAMMABLE LOGIC CONTROL

Note:
The PLC is equipped with a lithium battery to keep the program stored while the power is shut down. The bat-
tery will need to be replaced every 3 to 5 years, depending on the usage. A visual warning will be displayed
on the interface when the battery drains to a certain level. Batteries can be purchased through your Hyd·Mech
distributor.

The programmable logic control uses signals from limit switches, control panel switches, encoders (rotary shaft
or linear) and information that is programmed into it to supply accurate automatic length control and sawing
functions.

The inputs used include:

• Head up limit switch
• Head down limit switch
• Machine function switches and push buttons
• A signal from the auto/manual push button (tells the PLC whether auto or manual operation has been
selected).

A proximity switch is mounted through the rear of th eilder wheel box. Targets for this switch are mounted on
the back of the idler wheel, or, all six spokes of the wheel may be targets.

The programmed information includes logic put into the PLC by the manufacturer, as well as information pro-
grammed into it, through the keypad during assembly. Information from the plant is referred to as the param-
eters. The parameters are important for the PLC to provide accurate sawing lengths and blade speed display.
Following is a description of each parameter and the procedure to access them.

To view the PLC parameters:

In manual mode, with the front vise switch in the “close” position press FWD and REV key simultaneously (not
more the 0.5 sec apart). The PLC will prompt you for a password that can be obtained from the Hyd·Mech
Group Limited Service Dept. If the password is correct a screen of parameters will appear. The display will
show four lines of parameters at a time. If the length control calibration is necessary, follow the calibration pro-
cedure in this section. To move through the parameters use the cursor keys to scroll up or down. To change a
parameter, cursor to that parameter line and using the number keys type in the new value and press enter. To
leave the parameters press the Auto/Man key.

PLC PARAMETERS

SPEED CONST
Blade speed adjustment number. If the actual blade speed is different than the displayed blade speed, a new
speed factor will need to be calculated (providing the wheel trgs is set correctly). Actual speed ÷ display + ad-

3.8
justment factor X existing speed factor = New Speed Factor

WHEEL TRGETS
Number of targets per revolution of the idler wheel. S20A, S23A, H10/14, M16/20 = 1 H18/22, H28/32 = 6.

HGT CLB (Press Enter)

This is to be used only if calibration is required. Call Hyd·Mech Service department for instruction.

ACTUAL HGT
Actual Height Value. Value entered after performing length calibration procedure (described later in this sec-
tion). This value represents the head full stroke height.

HGT CONST
Height constant. Specifies linear distance of head movement in inches per one pulse of head encoder.

LTH CLB (Press Enter)

Length calibration. This is to be used only if calibration is required. Call Hyd·Mech Service department for
instruction.

ACTUAL LTH
Actual Length Value. Value entered after performing length calibration procedure (described later in this sec-
tion). PLC uses this value to calculate its length encoder resolution and stroke parameter. Note: If Calibration
Procedure is activated and not completed, or activated and a value not entered for ACT LTH, this value will
reset to 00.000 and the PLC will not be able to count/display lengths.

LTH CONST
Length constant. Specifies linear distance of shuttle movement in inches per one pulse of shuttle encoder.

ACCEL DIST
Shuttle acceleration distance. Distance, in inches, the shuttle will travel slowly before reaching fast speed while
starting to move in either direction. (i.e. 1.000).

DECEL DIST
Shuttle deceleration distance. Distance, in inches, the shuttle will travel slowly reaching home or target posi-
tion. (i.e. 1.000)

MIN FST DIST

Minimum fast speed distance. If programmed length is smaller than this parameter override to slow speed.
(Shuttle)

TARGET WINDOW
Allowable +/- tolerance from programmed length.

FVO DWELL
Delay time for the opening of the fixed VISE in seconds.

SVO DWELL
Delay time for the opening of the shuttle VISE in seconds.

CLOSE TIME
Delay time for the closing of the shuttle or fixed VISE in seconds.

FEED RATE

3.9
Activates feed rate display. Not active on S20A, S23A and H10 machines.

ACTUAL POSITION
If this value is set to “YES” displays shuttle vise actual position.

HOLD SHT HOME

Hold shuttle VISE home and closed during cut.

BRKN PROX
Allows user to override signal from prox switch in case it is broken. (When set to “NO” machine will not run with
broken proximity sensor. Set to “YES” allows machine to run).

MIN BLD SPEED

Minimum blade speed on which the PLC will detect the that blade is running

SPD PROX DELAY

Speed proximity delay time between pulses read by the proximity switch on which the blade breakage function
will be activated.

POWER DWN TIMER

If “0” selected, then the machine will shut down after the job is completed. This will allow the machine to contin-
ue running for a specified time after the job (in Manual Mode) or the cycle (in Auto Mode) has been completed.
Range from “0” to “180” minutes.

BLADE CLEAR
If set to “YES”; When the AUTO cycle reaches the function of head up, the shuttle will retract the material
from the blade by 1/8” before the head will move up. When the head reaches the up position the next length of
material is shuttled into position.

TRIM CUT
If “YES” selected the machine will perform a facing cut of the material at the beginning of an automatic cycle.

OUT OF STOCK
Selecting “yes” activates the out of stock option which prevents the shuttle vise from closing if insufficient
length of material is available for the next length advance. Also stops the automatic cycle after completing the
last cut.

COOLANT
When “BLD” selected, coolant flows when the blade is running. When “BLD+ DWN” selected, coolant flows
when the blade is running and head is moving down.

QUEUE
The queue allows the operator to run several jobs (max 5) in series. If “REPEAT” is selected the above series
will be executed the selected number of times.

PLC TROUBLESHOTTING

Problem 1 (for automatic models with a shuttle)

PLC is not measuring lengths

Possible causes:

3.10
1. Encoder
a. Pinion gear is loose on the encoder shaft
b. A bad encoder
2. Encoder Cable
a. Bad connections at the encoder or the PLC
b. Open or shorted wire.
3. PLC Unit
a. Damaged hardware
4. Display unit
a. No power from the PLC unit
b. Damaged hardware
5. Actual Length (Actual LTH)
a. The parameter value is set to 00.000. Perform a self-calibration procedure and enter the value.

Diagnosis:
1. With the machine in MANUAL mode, bring the shuttle forward to the home position and clear the length
display so it reads “0.000”. Run the shuttle, in slow speed, to the rear of the machine and back to the
home position. Make sure you move in full complete strokes.
a. The length should accumulate on the display as a positive number when the shuttle is moving
away from the blade and should count back to 0 when coming back. If this is not the case then
reverse the green channel wire on the encoder with the white channel wire.
b. If the display alters between 0.000 and ± 0.001, then the encoder channel is not being recorded
correctly.
2. To determine the cause, first, check the encoder cable connections at both ends to be sure all four
wires are connected properly.
3. Measure the voltage:
a. At the encoder connector. Between 0 Volt pin and 24 Volt pin. This voltage should be a minimum
of 22 VDC and 26 VDC.
If the voltage is incorrect, check the encoder cable continuity. If it is ok, there is possible PLC prob-
lem.
If the voltage is correct then proceed to the next step.
b. At the encoder connector. Between 0 Volt pin and channel A pin, and, between 0 Volt pin and
channel B pin. This voltage should be slightly less then the supply voltage at each channel
If the voltage is incorrect at this point, check for proper continuity of these wires and repair as nec-
essary.

Note:
When checking the encoder cable for continuity, each wire should also be checked for shorting to
ground and or to each other. If the voltage to the encoder is correct, proceed to the next step.
4. At the encoder connection of the PLC, between the 0 volt and A&B channels, with the shuttle moving
slow, the voltage should be approx. 10 to 13 VDC. Input LED’s X0 and X1 should flicker or go dim with
the shuttle moving. If these LED’s show no change with the shuttle moving, the encoder is likely at fault.
Check that the pinion gear is securely fastened to the encoder shaft and that it can rotate along the
rack as the shuttle moves.

If all mechanical components are functioning correctly then the encoder is defective.
If all test check positive, the problem is in the PLC unit.

Problem # 2 (for automatic models with a shuttle)

Inaccurate Lengths in Auto Mode

3.11
Possible Causes:

1. Encoder
a. Pinion not engaging the rack all the way from front to back.
b. Mechanical interference.
c. Pinion loose on the encoder shaft.
2. Encoder Cable
a. Bad connection at encoder or at the PLC
b. Intermittent open in one or more signal wires
3. Improper programmed information
a. Existing parameter(s) incorrect
b. Incorrect blade kerf
4. PLC
a. Faulty PLC unit (not repairable in the field)

GENERAL RULES

Normally, three types of length inaccuracies may occur.

2. Inconsistent
a. Lengths cut are not consistent, error changes. It doesn’t matter how long the part required is the
error is never the same.
b. Cause: Most likely a defective electrical, hydraulic or mechanical component.
3. Consistent
a. Length cut are consistent and the error is also consistent. The error always stays the same
regardless of part length.
b. Cause: Kerf Value
4. Linear
a. Lengths cut are consistent but the error increases as the part length increases. The longer the
part the greater the error.
b. Cause: When the self-calibration is executed, an incorrect “ACT LTH” value was entered.

Diagnosis:
• Check and record the existing parameters. Also check for proper blade kerf. By making a cut part way
into a piece of material and measuring the width of the cut, the operator can check the blade kerf.

INCONSISTENT INACCURACY
• With the machine in Manual mode, move the shuttle all the way forward and clear (zero) the length
display. Move the shuttle in reverse, in slow speed, all the way to the end of its travel. Return the shuttle
forward to the home position, also in slow speed. The display should read 0.000” ± 0.005”. Do this test
several times to be sure the read-out is repeatable.

Diagnosis:
• Following the same procedure, run the shuttle alternating between fast and slow speed going back and
forth. Again the display should be able to read 0.000” ± .005” when returning to the home position.
• If the display does not read as specified:
o Check the encoder pinion gear to be sure it can run smoothly down the rack and that the gear
and rack teeth engage over the entire travel of the shuttle.
o Check that the pinion gear is tight on the encoder shaft.
o Check the encoders cable connections, a loose connection could easily cause this concern.
o Remove the encoder from the machine and check that the shaft can rotate freely. There should
be no binding or rough spots felt when spinning the shaft. Plug the encoder cable into the
encoder, clear the length display and rotate the shaft as closely as possible to one revolution.

3.12
 The display should ready 3.142” (positive or negative depending on the direction you rotated).
Repeat this test 3 or 4 times, spinning the shaft several times between tests.

CONSISTENT INACCURACY (make sure the blade kerf value is correct)

Change the “ACTUAL POS” parameter to 1. This will make the PLC show actual shuttle travel in AUTO

With no material in the machine:

1. Program JOB 1 for 2 pieces of 5” in length. JOB 2 for 2 pieces of 10” in length and JOB 3 for 2 pieces
of one complete shuttle stroke length.
2. Enter JOB’s 1 to 3 into the QUEUE.
3. Record measurements on the display each time the shuttle vise reaches the target length and closes. It
should equal the required length plus the programmed kerf. Check that this measurement is ± .002” for
each length. If the overshoot / undershoot is very inconsistent, it could be related to an incorrect shuttle
cushion period. This many be caused be “DECEL DIST” parameter being set to low, defective fast or
reverse output relays on the PLC, or the hydraulic cushion vale (located at the hydraulic manifold) may
be faulty.

LINEAR INACCURACY (not valid for machines with linear encoder)

Load machine with a piece of stock for test cutting

Open the parameters screen
Initiate the length calibration procedure
Re-enter the new “ACT LTH” (actual length) value
Re-cut test lengths and check if accuracy is satisfactory

Note:
Linear inaccuracy may be corrected in two ways, by using the length calibration as described or by adjusting
the LTH CONST as follows:

Load the machine with a piece of stock for test cutting

Program the PLC to cut two pieces of 1”, 12” and a length equal to a shuttle and a half of the machine being
checked.
Make the cuts and measure as accurately as possible.
Using the formula provided, calculate the new parameter “LTH CONST”

Formula for determining new parameter “LTH CONST”

Measured length ÷ programmed length x existing constant = new “LTH CONST”

i.e. Programmed length =1.00” Measured Length =.99” -.001”

=12.00” =11.988” -.012”
=60.00” =59.940” -.060”

Existing parameter for LTH CONST = 0.001256

11.988 ÷ 12.00 x .0012566 = 0.001255
The new parameter LTH CONST value would then be 0.001255. This value should be entered and the test
repeated. Adjust the parameter as necessary.

GENERAL RULE:
Lowering the parameter value = longer shuttle travel = longer parts
Increasing the value = shorter shuttle travel = shorter parts

Problem 3 (for P Models, disregard all references to a shuttle)

3.13
Auto Cycle Not Being Completed

In auto mode, the PLC controls the saw functions through output relays. For a certain function to be actuated,
the PLC must first see specific input(s). Like the output relays, the input relays are located on the PLC unit.
Directly beside the input and output terminals are red LED’s (Light Emitting Diode), which will light up when
the corresponding input is being received or output being actuated. Observation of these input/output LED’s
can help diagnose auto cycle problems. Refer to the PLC inputs and outputs in this section. When a problem
occurs in the auto mode, the lights should be checked to see if they are coming on at the proper time or if they
are coming on at all.

Input LED’s
If a specific input light does not come on when expected
• Check for a faulty/misadjusted limit switch, push button, encoder or faulty wiring or connections.
• Wiring for each limit switch should be connected from the VDC terminal connection to the particular
limit switch, and from the limit switch to the input connector of the PLC.
Note:
All inputs are denoted by and “X”
All inputs are denoted by a “Y”

Following is information on output diagnosis and the sequence of inputs and outputs during the auto cycle.

Auto Cycle Sequence:

After the mode push button is in the auto position and the job has been programmed into the PLC, and the
cycle start push button pressed:
1. Hydraulics running, the head should move to it’s up limit, if it is not already there. Shuttle vise should
open and come forward to the home position. HUP input light must come on for the cycle to continue.
a. Head Raise L/S input on – cycle should continue, if not check outputs per step 2.
b. Head Raise L/S input not on – Check that the head up limit switch is being activated. Check the
limit switch/limit switch wiring.
2. Front vise should be closed; the shuttle vise should stay open and move back to the programmed
length.
a. FVC output should be on and SVO output will light momentarily, SHUTTLE REVERSE output
and SHUTTLE FAST output should be on when the shuttle moves back fast.
3. As the shuttle approaches the target length the FST output should shut off and the shuttle should travel
slowly for the DEC DIST parameter, cushion distance. When the shuttle reaches the target length the
SVC output should light and the shuttle vise should close on the material.
4. FVO output light should momentarily turn on and the front vise should open.
5. FWD output should light as will the FST for the shuttle to move forward in fast speed. FST will turn off
when the shuttle home cushion period is reached and thee shuttle should slow down into the home
position.
6. FVC output should light and the front vise should close. FWD light should go out, HDN output should
come on and the head should start to descend for the cut. IF the blade is not running at this time, auto
cycle will hold until minimum SFM is reached. Depending on “HLD SHTL HM” parameter in the PLC,
the shuttle may stay home and closed during the cut or may move back to pick up the next length. HUP
input should go out as the head descends and HUP L/S deactivates.
7. After the cut is completed HDN input should light, HDN output should go out, the HUP output should
light and the head should move up. When the head reaches it’s up limit, HUP input should come on,
RHD output off and the cycle repeats with the next length being clamped on by the shuttle, front vise
opening and the light being brought forward to home position.

As mentioned, beside each input and output terminal there is a bank of red LED’s. Each light corresponds to
it input or output. An input LED will light when it’s specific input signal is being received at the PLC and output

3.14
LED’s will light when the PLC commands specific outputs. IF an output LED is present then either the output
relay is faulty/stuck or the output (3 amp) fuse is blown. IF a fuse is blown, a shorted directional valve coil,
shorted noise suppressor at the coil or shorted wiring could be the cause (a good coil will measure between
30 to 40 ohms). If the fuse is good and no output voltage condition still exists, with the output light on, then the
relay is defective. If this is the case the PLC will have to be returned to the manufacturer for repair.

FUSES

The PLC has five glass fuses in line with it.

Fuse “4FU” is a 2 amp instant blow fuse which feeds power to the input side of the PLC thorough input terminal
“L”
Fuses “5FU1” to “5FU4” are 3 amp time delay fuses which each supply power to a specific bank of output re-
lays through that bank of relays “COM” terminal:

5FU1 is wired to terminal “COM1” supplying outputs -Y0, Y1, Y2, Y3

5FU3 is wired to terminal “COM3” supplying outputs -Y10, Y11, T12, Y13
5FU4 is wired to terminal “COM4: supplying outputs -Y14, Y15, Y16, Y17
5FU5 is wired to terminal “COM5” supplying outputs -Y20, Y21, Y22, Y23

Problem 4

No Display

Possible Causes:
1. No power to the PLC
2. PLC unit failure
3. Faulty connection of cable between PLC and Interface

Diagnosis:
a. Check the power led. This light should be on when the PLC is switched on.
b. If the light is on, the PLC may have failed. Check for proper connection of the cable at the PLC
and at the interface. Also check the PLC fuse.
c. If the fuse is OK, ensure that power is being supplied to the fuse.

Problem 5

No blade speed display

Possible Causes:
1. Fault at the proximity sensor
a. Bad sensor, misadjusted sensor (the gap should be approx .030” - .040”)
b. Contamination on the end of the sensor.
2. Fault at the PLC
a. Bad connection of sensor wiring
b. Faulty PLC unit.

Diagnosis:
• Check for LED light on the sensor. The light indicates that the sensor has power and is activated. The
problem could be with the sensor, signal wire to the PLC or with the PLC itself. With the blade running,
the light on the back of the sensor should “pulse”. Likewise, the PLC input LED X2, should also be
“Pulsing”. If both LED’s are pulsing with the blade running, the PLC is the problem. If the sensor is puls-
ing but the input LED on the PLC is not, there is a problem between the sensor and the PLC unit.
• If the LED on the sensor is not on, the problem is with the sensor wiring or the sensor is at fault.

3.15
MITSUBISHI FX2N 48MR INPUTS AND OUTPUTS

Input and output terminal identification:

The top row of identification labels corresponds to the top row of terminals and the bottom row of labels to the
bottom row of terminals. Input and output LED numbers correspond to the input or output of the same number.
I.E. input LED #0 corresponds to input X0.

PLC status indicators:

Power LED turns on when power supply is on.
Run LED is on when PLC is in RUN mode. Note: If power LED is on then the run LED should be on.
If not, then check the run/stop switch. It should be in the run position.
Batt V Battery low voltage. If this LED is on then the PLC battery should be replaced.
Prog E Flashing LED indicates a program error.
CPU E LED on (Solid) indicates a CPU Error.

C B
Power
G Run
E Batt. V
F
Prog -E
CPU - E

D
A - Input Terminals
B - Input Indicating LED’s
C - Input Terminal Identification
D - Output Terminals
E - Output Indicating LED’s
F - Output Terminal Identification
G - PLC Status Indicator Lights

3.16
Input/Output Terminal Information

X0 Shuttle encoder, channel A X10 Shuttle vise close switch

X1 Shuttle encoder, channel B X11 Shuttle vise open switch
X2 Blade Speed X12 Front vise close switch
X3 Feed rate encoder A X13 Front vise open switch
Inputs X4 Feed rate encoder B X14 Head raise switch
X5 Head lower L/S X15 Head lower switch
X6 Coolant Switch X16 Blade start
X7 Coolant Switch X17 Cycle start
X20 Blade stop P/B
X21 Out of stock (option)
X22 Head Raise L/S

Y0 Machine latch Y10 Front vise close

Y1 Open Y11 Front vise open
Y2 Open Y12 Shuttle fast
Y3 Blade run pilot light Y13 Blade motor contactor
Y4 VFD start Y14 Shuttle reverse
Outputs

Y5 VFD stop / reset Y15 Shuttle forward

Y6 Open Y16 Head raise
Y7 Open Y17 Head lower
Y20 Shuttle vise close
Y21 Shuttle vise open
Y22 Coolant pump on / off
Y23 Cycle on pilot light

ENCODER & PROXIMITY SENSOR CONNECTIONS

3.17
CALIBRATION PROCEDURE

Length calibration may be achieved in two ways, by inputting the ACTUAL LTH or LTH CONST parameter.
To determine the ACTUAL LTH value, the LTH CLB (length calibration) procedure must be executed.
In manual mode, position a piece of material, which is longer that the shuttle full stroke length and close the
front vise. Simultaneously press the “FWD” and “REV” buttons on the PLC to access the parameter. A pass-
word is required at this point, which can be obtained from the Hyd·Mech Service Dept. The screen will then
display as follows:

With the cursor at the shown position press the enter button. The cycle start button will the start to flash and
the “Enter” will change to “On” indication self calibration modes. Start the blade and the trim cut will be made.
After the trim cut is made the head will rise, the shuttle will retract fully in slow speed, clamp the material and
come fully forward in slow speed to the home position and make a cut. After the cut is complete “On” will
change back to “Press Enter”. Measure the length of the cut part.
Move the cursor down to the “ACTUAL LTH” and enter the length of the cut part. Then exit the parameters by
pressing the AUTO/MAN key (the cycle start button will stop flashing). To determine if the encoder channels
are connected correctly, observe the actual length parameter for the sign only during shuttle retraction in cali-
bration mode. If the actual length value shows as a negative number, then the channels must be reversed and
the calibration procedure repeated.

To determine “LTH CONST” value, use this formula;

LTH CONST = ENCODER PINION CIRCUMFERENCE (TTd) ÷ ENCODER RESOLUTION
Example:
For a 1” pinion diameter and 2500 PPR encoder:

LTH CONST = TTD ÷ 2500PPR = 0.001257

NOTE:
When first entering the parameters screen if not running the self-calibration do not use the enter key but use
the cursor keys to scroll through the parameters.

To check length control consistency:

1. Perform test cuts of three different lengths (i.e. 1”, 12”, 20”) and measure as accurately as possible with
a Vernier or dial caliper.

2. If the measurements indicate a linear problem (measured length error increases as the programmed
length increases), the “ACTUAL LGTH” or “LTH CONST” value will have to be adjusted.

To adjust “ACTUAL LGTH” value The Length Calibration Procedure MUST be performed. This may be done
with material in the machine (cut and measure material length) or with no material in the machine (let machine
complete the calibration cycle, then enter new value).

If part length error gets longer as the programmed length increases; ACTUAL LTH value should be increased.

If part length error gets shorter as the programmed length increases; ACTUAL LTH value should be decreased.

Make small adjustments at a time (i.e. .020” - .030”) and check with test cuts.

3.18
To adjust “LTH CONST”, follow this procedure:

Cut length ÷ Programmed length x Existing “LTH CONST” = New “LTH CONST”

Example:
Cut length of 11.998”, Programmed length of 12”, Existing “LTH CONST” parameter of 0.001256.
11.988 ÷ 12.000 x 0.001256 = 0.001255

The new “LTH CONST” value of 0.001255 should be entered as the “LTH CONST” parameter and test cuts
repeated. Adjust the parameter again if necessary.

General rule:
Lowering the “LTH CONST” value = Longer shuttle travel = Longer parts.
Increasing the “LTH CONST” value = Shorter shuttle travel = Shorter parts.

HEAD HEIGHT CALIBRATION PROCEDURE

NOTE:
On “M” machines remove the head up limit switch target to prevent damage of the head up limit switch during
calibration.
Head calibration may be achieved in two ways: by inputting “ACTUAL HGT” (actual height) or “HGT CONST”
(height constant) parameter.
To determine “Actual HGT” value, the “HGT CLB” (height calibration) procedure must be executed.

1. Enter the PLC parameter screen as per Length Calibration Procedure above.
2. Using the arrow cursor keys scroll down until the screen displays:
3. With the cursor on the word “ENTER”, press the key. The cycle start button will begin to flash, the
“ENTER” will change to “ON” (indicating self calibration mode) and the head will move to it’s down limit
and then will move up to it’s full upper limit.
4. Measure the distance from the vise horizontal wear strips to the blade teeth tips, and enter this value
in the ACTUAL HGT parameter. Measurement must be made along the front vise datum jaw. Input
this measurement value & press the key. Press the key to finish the procedure & exit the parameters
screen.

NOTE:
To determine if the encoder channels are connected, observe the actual height value parameter for the sign
during head up movement while in calibration mode. If the actual height value shows as a negative number,
the channels must be reversed and the calibration procedure repeated.

To determine “HGH CONST” value, use this formula;

ACTUAL FEED RATE ÷ Displayed FEED RATE x HGT CONST = new HGT CONST.

5. Input new HGT CONST & press.

6. Press the AUTO/MAN key to exit the parameters screen.

3.19
 SECTION 4, ELECTRICAL SYSTEM
GENERAL INFORMATION

This machine has been built to the customers requirements, however, if any voltage changes are required, consult
Hyd·Mech service department before implementing any changes.

INITIAL HOOKUP

At initial hook-up it is important to check that the phase order is correct. This is indicated by the blade drive wheel revolv-
ing in a counter clockwise 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 and photos of electrical components.

NOTES:

1. The PLC is equipped with a lithium battery to keep the program stored while the power is shut down. The battery
will need to be replaced every 3 to 5 years, depending on usage. A visual warning will be displayed on the inter-
face when the battery drains to a certain level. Batteries can be purchased through your Hyd·Mech Distributor.
2. If the machine is equipped with an inverter, do not turn disconnect on for 3 three minutes after disconnect has
been shut off. Cycling power sooner than 3 minutes will result in damage to the Variable Frequency Drive.
3. All of the machines equipped with a Mitsubishi PLC have a snap on Ferrite core on the interface cable. This is
placed near the interface in order to reduce “noise”.

Hirschman connectors and directional control valve solenoids

3 HP Electric Motor

4.1
 Mitsubishi PLC

Electrical Disconnect and Fuses

Mitsubishi Inverter

Transformer

4.2
 LIST OF H18ASV & H22ASV ELECTRICAL COMPONENTS
Item Code as on
Component
H22ASV Description Part Number
Manufacturer
Schematic
1PB-Emergency Stop Red mushroom head, latching push button. ZB2 BT4 Telemecanique
Push Button Mounting base with 1 N/C contact block. ZB2 BZ102 Telemecanique

2PB-Hydraulic Start Green, illuminated, flush head push button. ZB2 BW33 Telemecanique
Push Button Light module with 1 N/O contact block plus ZB2 BW061 Telemecanique
130V (BA9s) light bulb. SP105 Spectro

3PB-Cycle Start White, illuminated, flush head push button. ZB2 BW31 Telemecanique
Push Button Light module with 1 N/O contact block & ZB2 BW061 Telemecanique
130V (BA9s) light bulb. SP105 Spectro
4PB-Blade Stop Black, non-illuminated, flush head push button. ZB2 BA2 Telemecanique
Push Button Mounting base with 1 N/C contact block. ZB2 BZ102 Telemecanique
5PB-Blade Start Green, illuminated, flush head push button. ZB2 BW33 Telemecanique
Push Button Light module with 1 N/O contact block plus ZB2 BW061 Telemecanique
130V (BA9s) light bulb. SP105 Spectro

1SS-Coolant Black, 3 positions, maintained selector switch. ZB2 BD3 Telemecanique

Selector Switch Mounting base with 2 N/O contact blocks. ZB2 BZ103 Telemecanique
2SS-Shuttle Vise Black, 1 position spring return from left to center &
Selector Switch 1 position maintained to right s/s. ZB2 BD7 Telemecanique
Mounting base with 2 N/O contact blocks plus ZB2 BZ103 Telemecanique
1 N/C contact. ZB2 BE102 Telemecanique
3SS-Front Vise Se- Black, 1 position spring return from left to center &
lector Switch 1 position maintained to right s/s. ZB2 BD7 Telemecanique
Mounting base with 2 N/O contact blocks plus ZB2 BZ103 Telemecanique
1 N/C contact. ZB2 BE102 Telemecanique
4SS-Head Black, 3 positions, maintained selector switch. ZB2 BD3 Telemecanique
Selector Switch Mounting base with 2 N/O contact blocks plus ZB2 BZ103 Telemecanique
2 N/C contact blocks. ZB2 BE102 Telemecanique
5SS-Blade Tension Black, 3 positions, maintained selector switch.
Selector Switch Mounting base with 2 N/O contact blocks and XALJ133 HMG
Mounted in plastic enclosure (black/yellow).
7SS-Work Lamp Black, 2 positions maintained selector switch. ZB2 BD2 Telemecanique
Selector Switch Mounting base with 1 N/O contact block. ZB2 BZ102 Telemecanique
1BS -Blade Speed 1 K ohm Potentiometer KU1021S20 HMG

LIST OF H18ASV & H22ASV ELECTRICAL COMPONENTS

Item Code as on Component

Description Part Number
H22A Schematic Manufacturer

FX2N-48MR Mitsubishi PLC. FX2N-48MR Mitsubishi

E200 Mitsubishi Interface E200 Mitsubishi
Interface communication cable H22-FX2N32-009 HMG
Ferrite core 444164951 Ferrite

4.3
Hydrualic
Hirschmann connector H/927811311 Hirschmann
Valve Connector

6CR Coolant pump relay G2R-2-S Omron

plus mounting base. P2RF-08-E
Fuse holder USM1
1FU Gould
5A Time-delay fuse ATDR5
Fuse holder for “power” into PLC WK10/Si Wieland
6FU
2A Instant glass fuse AGC-2 Buss
Fuse holder for PLC outputs WK10/Si Wieland
5FU1 - 5FU4
3A Time Delay glass fuse MDL-3 Buss
1 L/S
Limit switch with roller lever XCK L115H7 Telemecanique
Head up
2 L/S
Limit switch with roller lever XCK L115H7 Telemecanique
Head Down
4 L/S
Limit switch with roller lever XCK L115H7 Telemecanique
Out Of Stock
P1 -
Proximity switch c/w washer & nut (NPN - N0) DCA12/4608KS Burgess-Saia
Blade Speed
E1 Incremental encoder for length count (2500 PPR) H2098017 ETI
E4 Incremental encoder for feed rate count.(8192 PPR) 6-112225-00 Stegmann
Coolant Pump Coolant pump 1 Phase /120 VAC 3E-12NT Little Giant
Coolant Pump Junction Box SCEJB442 HMG
Wire terminal 20-10 AWG WK4/U Wieland
Wire terminal 20-8 AWG WK6/U Wieland
Wire terminal 16-6 AWG WK10/U Wieland
Double ground terminal 20-8 AWG WK4/D2/2SLU Wieland
Ground terminal 16-6 AWG WK10/U Wieland
Suppressor SSQUENCHO1 HMG
R-C Suppressor Quenchark 504M02QA100 Quenchark
Options

Item Code as on Component

Description Part Number
H22A Schematic Manufacturer

15SS-Laser Black, 2 positions maintained selector switch. ZB2 BD2 Telemecanique

Guide. Mounting base with 1 N/O contact block. ZB2 BZ102 Telemecanique
Selector Switch.
26SS-Oil Heater Black, 2 positions maintained selector switch. ZB2 BD2 Telemecanique
Selector Switch. Mounting base with 1 N/O contact block. ZB2 BZ102 Telemecanique
27SS-Mist. Black, 2 positions maintained selector switch. ZB2 BD2 Telemecanique
Selector Switch. Mounting base with 1 N/O & 1 N/C contact block. ZB2 BZ102 Telemecanique
ZB2BE101

4.4
4.5
 H18ASV POWER COMPONENTS for SPECIFIC VOLTAGES
Description &
Component
(Item Code) MACHINE VOLTAGE
Manufacturer
as on schematic

3ph 208V 3ph 240V 3ph 400V 3ph 480V 3ph 575V

3HP HYDRAULIC PUMP MOTOR (1M) Frame Size 182TC, 1800 R.P.M.
CONTACTOR (1M) LC1D1210G6 LC1D1210G6 LC1D1210G6 LC1D1210G6 LC1D1210G6 Telemecanique

THERMAL OVERLOAD
LR2D1314 LR2D1314 LR2D1310 LR2D1310 LR2D1308 Telemecanique
(1 O/L)
MOTOR F.L.A.
8.6 A 8.0 A 4.6 A 4.0 A 3.2 A
( 1750 RPM )

FUSE SIZE & 20A T.D 20A T.D 10A T.D 10A T.D 8A T.D
FUSE HOLDER PART # ATDR20 ATDR20 ATDR10 ATDR10 ATDR8 Gould
(3FU1, 3FU2, 3FU3) 30310 30310 USM3 30310 30310

10HP INVERTER & 10HP BLADE DRIVE MOTOR (2M) Frame Size 286TC, 1750 R.P.M.

INVERTER PART # & FR-E520-7.5K -NA FR-E520-7.5K-NA FR-E540-7.5K-NA FR-E540-7.5K-NA FR-A560-7.5K-NA

Mitsubishi
INPUT CURRENT 31.9A 28.8A 16.6A 14.4A 11.5A

2M CONTACTOR LC1D5011 LC1D5011 LC1D2510 LC1D1810 LC1D1210

50A T.D 45A T.D 30A T.D 30A T.D 20A T.D
FUSE SIZE & FUSE HOLDER PART #
AJT50 AJT45 ATDR30 ATDR30 ATDR20 Gould
(4FU1, 4FU2, 4FU3)
60608J 60608J USM3 30310 30310

4.6
CONTROL TRANSFORMER (TR) 750 VA

TRANSFORMER
9070 T750D3 9070 T750D1 9070 T750D33 9070 T750D1 9070 T750D5 Square-D
PART # (TR)

PRIMARY FUSE SIZE 12A Fast Acting 12A Fast Acting 10A Fast Acting 8A Fast Acting 8A Fast Acting
FUSE HOLDER PART # ATM12 ATM12 ATM10 ATM8 ATM8 Gould
(2FU1, 2FU2) 30310 30310 USM1 30310 30310

SECONDARY FUSE 8A T.D 8A T.D 8A T.D 8A T.D 8A T.D

FUSE HOLDER PART # ATDR8 ATDR8 ATDR8 ATDR8 ATDR8 Gould
(1FU) 30310 30310 USM1 30310 30310

LINE REACTOR PART# MTE

- - - MTE RL-01803 MTE RL-01203
( 480 & 575 VAC ONLY) Corporation

INVERTER FILTER
- - FR-E5NF-H7.5K - - Mitsubishi
(400 VAC ONLY)

MACHINE VOLTAGE

3ph 208V 3ph 240V 3ph 400V 3ph 480V 3ph 575V Component Manufacturer

60A 60A 30A 30A 30A

Sprecher +
DISCONNECT RATING (A) SPRECHER + SPRECHER + SPRECHER + SPRECHER + SPRECHER +
Schuh
SCHUH SCHUH SCHUH SCHUH SCHUH
 H22ASV POWER COMPONENTS for SPECIFIC VOLTAGES
Description &
Component
(Item Code) MACHINE VOLTAGE
Manufacturer
as on schematic

3ph 208V 3ph 240V 3ph 400V 3ph 480V 3ph 575V

3HP HYDRAULIC PUMP MOTOR (1M) Frame Size 182TC, 1800 R.P.M.
CONTACTOR (1M) LC1D1210G6 LC1D1210G6 LC1D1210G6 LC1D1210G6 LC1D1210G6 Telemecanique

THERMAL OVERLOAD
LR2D1314 LR2D1314 LR2D1310 LR2D1310 LR2D1308 Telemecanique
(1 O/L)
MOTOR F.L.A.
8.6 A 8.0 A 4.6 A 4.0 A 3.2 A
( 1750 RPM )

FUSE SIZE & 20A T.D 20A T.D 10A T.D 10A T.D 8A T.D
FUSE HOLDER PART # ATDR20 ATDR20 ATDR10 ATDR10 ATDR8 Gould
(3FU1, 3FU2, 3FU3) 30310 30310 USM3 30310 30310

10HP INVERTER & 10HP BLADE DRIVE MOTOR (2M) Frame Size 286TC, 1200 R.P.M.

INVERTER PART # & FR-E520-7.5K -NA FR-E520-7.5K-NA FR-E540-7.5K-NA FR-E540-7.5K-NA FR-A560-7.5K-NA

Mitsubishi
INPUT CURRENT 33.4A 30.1A 16.6A 15.1A 12.1A

2M CONTACTOR LC1D5011 LC1D5011 LC1D2510 LC1D1810 LC1D1210

FUSE SIZE & FUSE HOLDER 50A T.D 45A T.D 30A T.D 30A T.D 20A T.D
PART # AJT50 AJT45 ATDR30 ATDR30 ATDR20 Gould

4.7
(4FU1, 4FU2, 4FU3) 60608J 60608J USM3 30310 30310

CONTROL TRANSFORMER (TR) 750 VA

TRANSFORMER
9070 T750D3 9070 T750D1 9070 T750D33 9070 T750D1 9070 T750D5 Square-D
PART # (TR)

PRIMARY FUSE SIZE 12A Fast Acting 12A Fast Acting 10A Fast Acting 8A Fast Acting 8A Fast Acting
FUSE HOLDER PART # ATM12 ATM12 ATM10 ATM8 ATM8 Gould
(2FU1, 2FU2) 30310 30310 USM1 30310 30310

SECONDARY FUSE 8A T.D 8A T.D 8A T.D 8A T.D 8A T.D

FUSE HOLDER PART # ATDR8 ATDR8 ATDR8 ATDR8 ATDR8 Gould
(1FU) 30310 30310 USM1 30310 30310

LINE REACTOR PART# MTE

- - - MTE RL-01803 MTE RL-01203
( 480 & 575 VAC ONLY) Corporation

INVERTER FILTER
- - FR-E5NF-H7.5K - - Mitsubishi
(400 VAC ONLY)

MACHINE VOLTAGE
Component
3ph 208V 3ph 240V 3ph 400V 3ph 480V 3ph 575V
Manufacturer

60A 60A 30A 30A 30A Sprecher +

DISCONNECT RATING (A)
SPRECHER + SCHUH SPRECHER + SCHUH SPRECHER + SCHUH SPRECHER + SCHUH SPRECHER + SCHUH Schuh
H-18/22 SV ELECTRICAL SCHEMATIC, NO OPTIONS 208/240 VAC
Please note that the H-22 SV uses a Hydraulic Blade Brush

ENERGIZAR
BOBINA IM7B

IM7C ENERGIZAR PLC

IM7D Enclavamiento con Y0

4.8
4.9
4.10
4.11
H-18/22 SV ELECTRICAL WIRING DIAGRAM, NO OPTIONS 208/240 VAC

4.12
4.13
4.14
4.15
4.16
4.17
H-18/22 SV ELECTRICAL WIRING DIAGRAM INPUTS & OUTPUTS, NO OPTIONS 208/240 VAC

4.18
4.19
H-18/22 SV ELECTRICAL SCHEMATIC, WITH OPTIONS, 208/240 VAC

4.20
4.21
4.22
4.23
H-18/22 SV ELECTRICAL WIRING DIAGRAM, WITH OPTIONS, 208/240 VAC

4.24
4.25
4.26
4.27
4.28
4.29
H-18/22 SV ELECTRICAL WIRING DIAGRAM INPUTS & OUTPUTS, WITH OPTIONS, 208/240 VAC

4.30
4.31
H-18/22 SV ELECTRICAL SCHEMATIC, NO OPTIONS 480/575 VAC

4.32
4.33
4.34
4.35
H-18/22 SV ELECTRICAL WIRING DIAGRAM, NO OPTIONS 480/575 VAC

4.36
4.37
4.38
4.39
4.40
4.41
H-18/22 SV ELECTRICAL WIRING DIAGRAM INPUTS & OUTPUTS, WITH NO OPTIONS, 480/575 VAC

4.42
4.43
H-18/22 SV ELECTRICAL SCHEMATIC, WITH OPTIONS, 480/575 VAC

4.44
4.45
4.46
4.47
H-18/22 SV ELECTRICAL WIRING DIAGRAM, WITH OPTIONS, 480/575 VAC

4.48
4.49
4.50
4.51
4.52
4.53
H-18/22 SV ELECTRICAL WIRING DIAGRAM INPUTS & OUTPUTS, WITH OPTIONS, 480/575 VAC

4.54
4.55
 SECTION 5, HYDRAULIC SYSTEM
The H-18/22 SV hydraulic system does not require any special work on a new machine before its start-up. The hydrau-
lic tank is filled with Duro AW46 hydraulic oil and all machine functions have been tested at the factory to ensure proper
operation upon initial start-up.

ITEM QTY H-18 SV PART NUMBER H-22 SV PART NUMBER DESCRIPTION

1 1 H22-C41-00A H22-C41-00A MAIN HEAD CYLINDER
2 1 H22-C42-00 H22-C42-00 AUX HEAD CYLINDER
3 1 H14-C1-00A H14-C1-00A SHUTTLE CYLINDER
4 1 H14-C22-00 H14-C22-00 DATUM CYLINDER
5 1 H22SV-C31-00C H22SV-C31-00C FT VISE CYLINDER
6 1 H22-C31-00C H22-C31-00C SHT VISE CYLINDER
7 (2) H22SV-C23-00 H22SV-C23-00 BUNDLING CYLINDER
8 (1) H18SV-G531-00 H22SV-G531-00 OUTBOARD BUNDLING CYLINDER
9 1 S25-C5-00 H22-C5-00A BLADE TENSION CYLINDER
10 1 MB6P_A MB6P_A MANIFOLD BLOCK
11 1 DDF6-0-00 DDF6-0-00 DDF VALVE
12 2 DPCH-1 DPCH-1 DOUBLE PILOT CHECK VALVE
13 3 DCV3P-AB-T DCV3P-AB-T DIRECTIONAL VALVE
14 2 DCV3P-AB-C DCV3P-AB-C DIRECTIONAL VALVE
15 1 PV2P-A-C PV2P-A-C POPET VALVE
16 1 CHB-25 CHB-25 CUSHION BLOCK
17 1 HM-01 HM-01 CHIP AUGER MOTOR
18 1 PRV-2 PRV-2 PRESSURE REDUCING VALVE
19 1 HYP-1 HYP-1 HYDRAULIC PUMP
20 1 SF 6520 SF 6520 RETURN FILTER ELEMENT
21 1 PBDP OBN EZ1 PBDP OBN EZ1 PRESSURE REDUCING VALVE
22 (1) PRV1-10-K-4T-12 PRESSURE REDUCING VALVE VVP OPTION
23 (1) JB-02 DOUBLE JUNCTION BLOCK VVP OPTION
24 1 PRV1-10-S-0-6 HYDRAULIC CARBIDE LOCK CARTRIDGE
25 1 SPCH-1 SPCH-1 SINGLE PILOT CHECK VALVE

5.1
GLAND ASSEMBLIES

PISTON ASSEMBLIES

5.2
H-18/22 SV HYDRAULIC SCHEMATIC

5.3
H-18/22 SV PLUMBING DIAGRAM

5.4
5.5
H-18 SV BLADE BRUSH ASSEMBLY

ITEM QTY S-22 PART NUMBER DESCRIPTION

1 1 S20-922A-00 BRUSH MOUNTING WELDMENT
2 1 W6440-4 BEARING
3 1 S20-925-03A POLYURETHANE WHEEL
4 1 S20-925-02A SHAFT EXTENSION
5 1 5043 3” BLADE BRUSH
6 2 .5FLT FLAT WASHER
7 1 B1-.50x1.0 HEX HEAD CAP SCREW
8 2 TC 13 COMPRESSION SPRING
9 4 .375FLT FLAT WASHER
10 2 A1-.375X3.5 SOCKET HEAD CAP SCREW
11 1 S1-.375X2.5 SOCKET SET SCREW, FLAT POINT
12 1 S1-.25x.25-C SOCKET SET SCREW, CUP POINT
13 1 .375-16HXNUT HEX NUT
14 1 .50LOC LOCK WASHER

6.1
H-22 SV BLADE BRUSH ASSEMBLY

ITEM QTY H-22 PART NUMBER DESCRIPTION

1 1 129-0017 HYDRAULIC MOTOR
2 1 H22-48-01 MOTOR MOUNTING BRACKET
3 1 S20-926-02A EXTENSION
4 2 .5FLT FLAT WASHER
5 1 12290 4” BLADE BRUSH
6 1 .5HXNUT HEX NUT
7 5 B2-.25x.75 HEX HEAD CAP SCREW, NF
8 6 .375FLT FLAT WASHER
9 3 TC 13 COMPRESSION SPRING
10 2 A1-.375x3.75 SOCKET HEAD CAP SCREW
11 3 .375HXNUT HEX NUT
12 1 S1-.375x4 SOCKET SET SCREW

6.2
H-18/22 SV GUIDE ARM ASSEMBLY

ITEM QTY H-18 SV PART NUMBER H-22 SV PART NUMBER DESCRIPTION

1 1 H18SV-461-00 H22SV-461-00 FIXED GUIDE ARM
2 1 H18SV-471-01B H22SV-471-01A MOVABLE GUIDE ARM
3 3 A1-.5x3.5 A1-.5X4.5 SOCKET HEAD CAP SCREW
4 12 A3-8x40 A3-8x40 SOCKET HEAD CAP SCREW, METRIC
5 2 LGR25R780 LGR25R900 LINEAR BEARING RAIL
6 3 LGW25CA LGW25CA LINEAR BEARING BLOCK
7 24 A1-.25x1.25 A1-.25x1.25 SOCKET HEAD CAP SCREW

6.3
H-18/22 SV CARBIDE GUIDE ASSEMBLY

Fixed Guide Arm (H18SV-461-00C or H22SV-461-00)

or
Moveable Guide Arm (H18SV-471-00 or H22SV-471-00)

ITEM QTY (H-22 SV) H-18 SV PART NUMBER H-22 SV PART NUMBER DESCRIPTION
FLAT SOCKET HEAD CAP
1 1 F1-.312x.5 F1-.375 X .75 SCREW
2 2 CRB-150-22-00A CRB-200-22-00 CARBIDE PLATE
3 1 CRB-TL-770 H22-46/47 INFO_1 TOP CARBIDE
4 1 .25x1.25 .25x1.25 ROLL PIN
5 2 .156x1.75 .156x1.75 ROLL PIN
6 1 W-270 W-270 BOW WASHER
8 2 (1) 362868 2-022 O RING (1/16X5/8X3/4)
9 1 H14-47-04D H22SV-47-04 CARBIDE LOCKING PISTON
10 1 362868 2-024 O RING
11 1 H14-47-05a H22-47-05 COVER, carbide locking piston
FLAT SOCKET HEAD CAP
12 3 (4) A1-.19x.25 A1-.19x.25 SCREW

6.4
H-18/22 SV ANTI-VIBRATION ROLLER ASSEMBLY

ITEM QTY H18-22 PART NUMBER DESCRIPTION

1 1 AVR-471-01A BLOCK, IDLER SIDE
2 1 AVR-461A-01 BLOCK, DRIVE SIDE
3 4 A1-.375x2 SOCKET HEAD CAP SCREW
4 6 6200 2RS BALL BEARING
5 1 AVR-461-03 BACK ROLLER RACE
6 2 AVR-461-02A FRONT ROLLER RACE
7 3 B3-10x30S METRIC SOCKET HEAD SHOULDER SCREW
8 2 014 O-RING (.625x1/16)
9 4 AVR-471-02A BUSHING
10 1 6000 2RS BALL BEARING
11 1 B3-10x16 METRIC SOCKET HEAD SHOULDER SCREW

6.5
H-18 SV IDLER WHEEL ASSEMBLY

ITEM QTY H-18 PART NUMBER DESCRIPTION

1 1 S25-341-01A IDLER TRACK BASE PLATE
2 1 S25-3411-00B IDLER WHEEL CARRIER WELDMENT
3 2 S25-341-02A IDLER TRACK
4 15 .5LOC LOCK WASHER
5 4 .5FLT FLAT WASHER
6 11 B1-.5x1.5 HEX HEAD CAP SCREW
7 4 B1-.5x2.5 HEX HEAD CAP SCREW
8 4 S1-.5x.75C SOCKET SET SCREW, CUP POINT
9 3 1613-B STRAIGHT GREASE FITTING
10 1 B1-.625x2.5 HEX HEAD CAP SCREW
11 1 .625LOC LOCK WASHER
12 1 S1-.375x.375 SOCKET SET SCREW, CUP POINT
13 1 CM10 5/8 NF ROD END
14 1 .625-18HNUT 5/8-18 HEX NUT
15 1 S25-C5-00 TENSION CYLINDER
16 1 S25-3-02A IDLER WHEEL SHAFT
17 1 S25-3-06A IDLER WHEEL
18 2 6308-2RS BALL BEARING
19 1 S25-3-03B IDLER WHEEL BEARING SPACER
20 1 HO-0354-PA 3 9/16 INTERNAL RETAING RING
21 1 WP-1-01 IDLER WHEEL RETAINER
6.6
H-22 SV IDLER WHEEL ASSEMBLY

ITEM QTY H-22 PART NUMBER DESCRIPTION

1 1 H22-43-01A BACK PLATE
2 1 H22-431-00 SLIDER WELDMENT
3 1 S1-.5x1-C SOCKET SET SCREW, CUP POINT
4 2 H22-6-01 TENSION CYLINDER MOUNTING PIN
5 1 H22-C5-00A BLADE TENSION CYLINDER
6 2 H22-43-02 TENSION TRACK
7 4 A1-.875x3.25 SOCKET HEAD CAP SCREW
8 8 A1-.875x2.5 SOCKET HEAD CAP SCREW
9 4 S1-.875x1.5-F SOCKET SET SCREW, FLAT POINT
10 1 H22-43-03 SHAFT
11 1 W27-45-01A IDLER WHEEL
12 1 W32-45-02 SEAL ADAPTER
13 1 NU313NA ROLLER BEARING
14 1 W27-45-03 OD BEARING SPACER
15 2 W27-45-02 BEARING SPACER
16 1 63132RS BALL BEARING
17 1 H22-45-05 RETAINING CAP
18 1 B1-.75x2.5 HEX HEAD CAP SCREW
19 1 HO-550 5 1/2 INTERNAL RETAINING RING
20 1 .75LOC LOCK WASHER

6.7
H-18/22 SV HYDRAULIC PUMP ASSEMBLY

ITEM QTY H-18 PART NUMBER DESCRIPTION

1 1 182TC 3 HP, 1800RPM, SPECIFY VOLTAGE
2 1 5J - 1 1/8 SUREFLEX COUPLING FLANGE
3 1 5JEM SLEEVE
4 1 5J 3/4 SUREFLEX COUPLING FLANGE
5 1 1960 3 & 5HP BELL HOUSING
6 4 .5LOC LOCK WASHER
7 4 B1-.5x1.5 HEX HEAD CAP SCREW
8 1 PVQ-13-A2R-SE-15-10-CM7 HYDRAULIC PUMP
9 2 .375LOC LOCK WASHER
10 2 B1-.375x.75 HEX HEAD CAP SCREW
11 1 2501-6-4 90 deg ELBOW, 9/16NF/MJIC
12 1 0503-12-8 O RING FITTING, 1 1/16”NF/MJIC
13 1 3903-8-8 FITTING, 90 deg SWIVEL, F/MJIC
14 1 0502-12-12 FITTING, 1 1/16”NF/FNPT
15 1 0188-12-12 FITTING, MNPT/HOSE BARB

6.8
H-18/22 SV HYDRAULIC TANK ASSEMBLY

ITEM QTY PART NUMBER DESCRIPTION

1 1 H14-611-00A POWER PACK WELDMENT
2 1 S22A-61-01 OIL TANK LID
3 4 B1-.25x.75 HEX HEAD CAP SCREW
4 4 .25LOC LOCK WASHER
5 1 SES-3-40-S-80 FILLER CAP & BREATHER, 50micron
6 6 T1-.19x.5 TRUSS HEAD MACHINE SCREW
7 1 SNA2B LEVEL & TEMPERATURE GAUGE
8 1 TFS-100-0-P SUCTION STRAINER
9 1 MP-100-FE 90 deg ELBOW, FNPT/FNPT
10 1 0188-12-12 FITTING, MNPT/HOSE BARB
11 1 MP-116-E 90 deg ELBOW, FNPT/MNPT
12 1 SA-F07-25-0 FILTER HEAD
13 1 SF-6520 10 micron RETURN FILTER
14 1 30182B-12-8 FITTING, FNPT/HOSE BARB
15 1 2103-4-4 90 deg ELBOW, MNPT/MJIC

6.9
H-18/22 SV FRONT VISE ASSEMBLY

ITEM QTY H-18 PART NUMBER H-22 PART NUMBER DESCRIPTION

1 1 H22V-511-00 H22SV-511-00 FRONT VISE FRAME WELDMENT
2 1 H18SV-512-00 H22SV-512-00 FRONT VISE DATUM WELDMENT
3 3 H18SV-5-02 H22SV-5-02 WEAR STRIP
4 1 H18SV-5-03 H22SV-5-03 WEAR STRIP OUT FEED SIDE
5 1 H18SV-5-04 H18SV-5-04 MOVABLE JAW SLIDER
6 2 H22SV-51-01 H22SV-51-01 FRONT VISE WAY
7 3 H18SV-2-06 H18SV-2-06 TABLE INSERT
8 1 H18SV-513-00 H22SV-513-00 FRONT VISE MOVABLE JAW WELDMENT
9 1 H18SV-514-00 H18SV-514-00 TRACK ROLLER ASEMBLY
10 2 H18SV-5-01 H22SV-5-01 WEARSTRIP
11 1 H22SV-C31-00 H22SV-C31-00 VISE CYLINDER
12 1 H18SV-2-07 H18SV-2-07 OUT FEED PLATE
13 1 H18SV-2-08 H18SV-2-08 FIXED FENCE
14 1 H18SV-2-09 H18SV-2-09 ADJUSTABLE FENCE

6.10
H-18/22 SV SHUTTLE VISE DATUM LINE JAW ASSEMBLY

DATUM CYLINDER

ITEM QTY H-18 PART NUMBER H-22 PART NUMBER DESCRIPTION

1 1 H18SV-5221-00 H22SV-5221-00 DATUM LINE JAW
2 2 H18-5-02 H22-5-01 WEAR STRIP
3 12 F1-.312x.75 F1-.312x.75 FLAT SOCKET HEAD CAP SCREW
4 3 H14-5A-10 H14-5A-10 SMALL JAW MOUNTING PIN
5 1 H14-5A-12 H14-5A-12 SMALL DATUM JAW LINK
6 1 H14-5A-11 H14-5A-11 LARGE DATUM JAW LINK
7 2 H14-5-15 H14-5-15 LARGE JAW MOUNTING PIN
8 4 SH-0125-PA SH-0125-PA 1 1/8 EXTERNAL RETAINING RING
9 1 H14-C22-00 DATUM CYLINDER

6.11
H-18/22 SV SHUTTLE VISE ASSEMBLY

ITEM QTY PART NUMBER DESCRIPTION

1 1 H22SV-521-00 FRONT VISE FRAME
3 2 H22-5-03 MOVABLE JAW SHAFT
4 4 H3000 3” SHAFT WIPER
5 4 9.375x1x.125 WEAR RING (702 STRIP)
6 1 H22-C31-00 VISE CYLINDER
7 1 H22-5-05 CYLINDER MOUNTING PLATE
8 2 F1-.5x1 FLAT SOCKET HEAD CAP SCREW
9 1 SH-0287-PA 2 7/8 EXTERNAL RETAINING RING
10 1 H22SV-5-05 MOVABLE JAW PLATE
11 2 H22SV-5-01 WEAR STRIP
12 12 F1-.312x.5 FLAT SOCKET HEAD CAP SCREW
13 1 F1-.75x2 FLAT SOCKET HEAD CAP SCREW

6.12
H-18/22 SV CHIP AUGER ASSEMBLY

ITEM QTY H-18 PART NUMBER DESCRIPTION

1 1 MG.12.09.10 HYDRAULIC MOTOR
2 2 2503-6-4 O RING ADAPTOR, M STRT/FNPT
3 2 2103-4-4 90 deg ELBOW, MNPT/MJIC
4 1 S1-.312x.25C SOCKET SET SCREW, CUP POINT
5 4 F1-.375x1 FLAT SOCKET HEAD CAP SCREW
6 1 H18-12-00 AUGER WELDMENT

6.13
H-18 SV DRIVE ASSEMBLY

6.14
6.15
H-22 SV DRIVE ASSEMBLY

6.16
6.17
H-18/22 SV BUNDLING ASSEMBLY

SHUTTLE BUNDLING

FRONT BUNDLING

ITEM QTY PART NUMBER DESCRIPTION

1 2 H22SV-G5111-00 BUNDLING BRACKET
2 2 H22SV-C23-00 BUNDLING CYCLINDER
3 4 R3100-200 2” EXTERNAL RET. RING
4 2 H22SV-G511-02 COVER
5 2 H22SV-G511-01 BUNDLING SHAFT
6 1 H22SV-G5112-00 FRONT BUNDLING CLAMP
7 2 H18-G5111-03 BUNDLING WEAR STRIP
8 4 H2250 2 1//4” YELLOW SHAFT WIPER
9 4 7.260 X 1 X .125 2 1/4” WEAR RING, 702 STRIP
10 1 H22SV-G5121-00 SHUTLE BUNDLING CLAMP

7.1
H-18/22 SV OUTBOARD BUNDLING ASSEMBLY

7.2
 SECTION 8, SPECIFICATIONS

ITEM H-18 SV DIMENSIONS H-22 SV DIMENSIONS

Round: 18” Diameter Round: 22” Diameter
Capacity Square: 18” x 18” (Bundling to full capacity Square: 22” x 22” (Bundling to full capacity
optional) optional)

Length: 19’2” Length: 22”

Blade Width: 1 1/2”, 1 1/4” (Optional) Width: 2”
Thickness: .050” (.042”, 1 1/4 Blade) Thickness: .063”

Blade Speed 50-350 SFM 40-300 SFM

Blade Tension Hydraulic Hydraulic

Blade Guides Carbide Carbide

Blade Wheel Diameter 22” 27”

Blade Drive: 10 H.P Blade Drive: 10 H.P

Motors
Hydraulic Drive: 3 H.P Hydraulic Drive: 3 H.P

Hydraulic Pump: (Pressure Compensated) Hydraulic Pump: (Pressure Compensated)

Pumps Constant pressure variable flow: (6 1/2 Constant pressure variable flow: (6 1/2
G.P.M) G.P.M)
Coolant Pump: 3 1/2 G.P.M. (150W) Coolant Pump: 3 1/2 G.P.M. (150W)

Hydraulic Tank 9 U.S. Gallons 9 U.S. Gallons

Hydraulic System Pressure 1000 psi 1100 psi

Vise Control Hydraulic Hydraulic

Shuttle Stroke 0-34” Single stroke milti-indexing standard 0-34” Single stroke milti-indexing standard

Table Height 31” 31”

Control Panel Waist Height Waist Height

Machine Weight 8500 LBS 12500 LBS

Maximum Work Load 10000 LBS 15000 LBS

8.1
H-18 SV LAYOUT

8.2
H-22 SV LAYOUT

8.3
 WARRANTY

Hyd-Mech Group Limited warrants each new H-18/22 SV bandsaw to be free from failure resulting from defective material
and workmanship under proper use and service for a period of two years parts and one year labour by an authorized Hyd-
Mech dealer 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, fil-
ters, 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 H-18/22 SV, but not originally manufactured by Hyd·Mech are subject to the original manufacturer’s war-
ranty. 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 includ-
ing 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.

THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR

IMPLIED, WRITTEN OR ORAL, INCLUDING WITHOUT LIMITATION ANY IMPLIED WARRANTIES OF MERCHANT-
ABILITY 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. BOX 1030
Woodstock, Ontario
N4S 8P6
Phone: (519) 539-6341
Fax: (519) 539-5126
Toll Free: (877) 276-SAWS (7297)
E-mail: [email protected]

9.1
Speed Constant Wheel Targets Height CLB

(Press Enter)

Actual Height Height Constant Lth CLB

(Press Enter)

Actual Length Length Constant Accel Dist

Decel Distance Min Fast Dist Target Window

FVO Dwell SVO Dwell Close Time

Feed Rate Actual Position Hold SHT Home

Yes / No Yes / No Yes / No

Brkn Prox Min Bld Speed SPD Prox Delay

Yes / No
Power Dwn Timer Blade Clear Trim Cut

Yes / No Yes / No
Out of Stock Coolant Queue

Yes / No BLD / BLD& DOWN Single / Repeat

Kerf

9.2