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

Dear Customer,

As a businessman you understand the necessity of keeping the cost of each step of production to an absoluteminimum without sacrificing quality. In the purchase of any new piece of equipment you are looking to in-crease your production and consequently reduce your cost, while maintaining or improving quality.

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

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

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

Sincerely,HYD-MECH ENGINEERING LTD.

Stan Jasinski, P. Eng.,President

PRINTED IN CANADA 1995

THIS PAGE INTENTIONALLY LEFT BLANK

TABLE OF CONTENTSSECTION 1 - INSTALLATION

Safety......................................................................................................................................... 1.1Lifting and Shipping.................................................................................................................... 1.1Vise Cylinders............................................................................................................................. 1.2Head Restraint Bar..................................................................................................................... 1.3Leveling..................................................................................................................................... 1.3Wiring Connections.................................................................................................................... 1.4Hydraulic Oil and Cutting Fluid................................................................................................... 1.4

SECTION 2 - CONTROLS AND OPERATIONS SUBSECTION 2A - The Control Console........................................................................................... 2.1

Start-up...................................................................................................................................... 2.1S25 Manual Controls.................................................................................................................. 2.1Shuttle Length Control................................................................................................................ 2.5Conventional Length Control Set-up and Calibration................................................................... 2.5S25 Automatic Controls (PLC 100)............................................................................................. 2.6

Blade Kerf......................................................................................................................... 2.6PLC in Manual Mode ....................................................................................................... 2.7PLC in Auto Mode - Single Job......................................................................................... 2.8PLC in Auto Mode - Multi Job............................................................................................ 2.9Important Notes With Respect To PLC Operation............................................................. 2.10

Interrupting the Auto Cycle...................................................................................... 2.10Entering Blade Kerf................................................................................................. 2.11Inch-Metric Input or Measuring................................................................................ 2.11

SUBSECTION 2B - Saw Cutting Controls........................................................................................... 2.12Blade Basics............................................................................................................................... 2.12Variable Speed Control............................................................................................................... 2.13Hydraulic Feed Control............................................................................................................... 2.13Using The Saw Cutting Parameters Door Chart........................................................................... 2.14

Step 1 Determine Effective MAterial Width....................................................................... 2.14Step 2 Setting The Feed Force Limit................................................................................. 2.15Step 3 Determine Optimum Blade Pitch............................................................................ 2.16Step 4 Determine Optimum Blade Speed.......................................................................... 2.17Step 5 Determine Feed Rate Setting................................................................................. 2.18

Cutting Control Set Up Examples................................................................................................ 2.20 SUBSECTION 2C - Mechanical Controls............................................................................................ 2.22

Head Up And Down Limit Setting................................................................................................ 2.22Guide Arm Positioning................................................................................................................ 2.23Coolant Flow.............................................................................................................................. 2.23Blade Changing.......................................................................................................................... 2.24

SECTION 3 - MAINTENANCE AND TROUBLESHOOTINGBlade Brush................................................................................................................................ 3.1Blade Guides.............................................................................................................................. 3.1Lubrication............................................................................................................................... 3.2Cleanliness................................................................................................................................. 3.3Hydraulic Maintenance................................................................................................................ 3.3Trouble Shooting......................................................................................................................... 3.4

SECTION 4 - ELECTRICAL SYSTEMGeneral Information.................................................................................................................... 4.1Photos of Standard Electrical Components................................................................................. 4.1Photos of Optional Electrical Components.................................................................................. 4.3List of Electrical Components For An S-25A With the Optioanl PLC100.................................... 4.4List of Electrical Components For A Standard S-25A.................................................................. 4.7Standard Electrical Schematic S25-7-00-1.......................................................... 4.12Standard Electrical Wiring Diagram S25-70-02 pg.1............................................... .... 4.13Wiring Diagram S25-70-02 pg. 2 ................................................. 4.14Wiring Diagram ( Contol Box) S25-70-02 pg.3.................................................... 4.15Electrical Schematic (PLC Option) S25A-7-00-1A ..................................................... 4.16Electrical Wiring Diagram PLC S25A-7-00-2A pg.1 ............................................. 4.17Electical Wiring Diagram PLC (Control Box) S25A-7-00-2A2 pg.2 ........................................... 4.18

SECTION 5 - HYDRAULIC SYSTEMGeneral Information.................................................................................................................... 5.1Parts List and Photos of Hydraulic Components.......................................................................... 5.1Cylinder Components .................................................................................................................. 5.2Positive Downfeed Valve Components ...................................................................................... 5.3Hydraulic Schematic S25A-6-00-1 ...................................................... 5.4Hydraulic Plumbing Diagram S25A-6-00-2 ....................................................... 5.5Plumbing Diagram (VVP Option) S25A-6-00-2....................................................... 5.6

SECTION 6 - MECHANICAL ASSEMBLIESParts List and Photos:Blade Guide Arm Assembly........................................................................................................ 6.1Guide Arm Rack Assembly......................................................................................................... 6.2Blade Brush Assembly................................................................................................................ 6.3Drive Assembly.......................................................................................................................... 6.4Idler Wheel Assembly................................................................................................................. 6.5Vise Cylinder Mounting Assembly............................................................................................... 6.6Front Table Assembly ................................................................................................................ 6.7Gearbox Assembly.................................................................................................................... 6.8Auxiliary Table Assembly............................................................................................................ 6.9Shuttle Guide Assembly.............................................................................................................. 6.10Infeed Conveyor assembly......................................................................................................... 6.11Pivot Link Assembly.................................................................................................................. 6.12Head Swing Assembly............................................................................................................... 6.13Coolant System Assembly.......................................................................................................... 6.14Outfeed Table Assembly............................................................................................................. 6.15Length Control Assembly............................................................................................................ 6.16

SECTION 7 - OPTIONAL SAW EQUIPMENT Overhead Bundling Attachment.................................................................................................. 7.1Variable Vise Pressure................................................................................................................ 7.2Blade Breakage Switch............................................................................................................... 7.3Out of Stock Limit Switch............................................................................................................ 7.4Remote Blade Speed Adjustment............................................................................................... 7.5

SECTION 8 - SPECIFICATIONSSpecification List........................................................................................................................ 8.1Dimensional Drawings................................................................................................................ 8.2

SECTION 9 - WARRANTYWarranty..................................................................................................................................... 9.1

SECTION 1 - INSTALLATION

SAFETY

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

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

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

-Machine should be used according to its specifications.

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

-Stock must not be loaded while blade is running.

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

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

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

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

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

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

LIFTING AND SHIPPING

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

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

BB

AFig. 1-2AFig. 1-1A

1.1

HOSE # HOSE TO CYLINDER CONNECTING HOSECONNECTION AT JUNCTION BLOCK

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

TABLE 1

1.2

Fig. 1-4 Reassembled vises.Fig. 1-3 Vises disassembled for shipping.

Fig. 1-5 Junction block plumed for shipping. Fig. 1-6 Vise cylinder plumed to junction block.

VISE CYLINDERS

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

HEAD RESTRAINT BAR

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

1.3

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

Machine location should be carefully selected. A flat concrete floor area should be chosen. It should haveenough free space surrounding the machine to enable free access for safe operation and maintenance.

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

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

NOTE: In some cases levelling the saw infeed and auxiliary conveyors with a slight slope towards the blade isrecommended. This will prevent coolant from running down the raw stock. (This is especially true when cuttingtubing or bundles).

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

HYDRAULIC OIL AND CUTTING FLUID

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

No cutting fluid is supplied with the machine. There are two types of coolant available:- oil based; dilute 1:10 ratio (one part concentrated coolant to 10 parts water)- synthetic; dilute as recommended by the manufacturer.

WIRING CONNECTIONS

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

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

-signs of damage that may have occurred during shipping to the electrical cables and the hydraulic hoses.-the hydraulic oil level is between the upper and lower lines on the level gauge (see SECTION 3 pg. 3.4).

As supplied, the machine is set to run on three phase voltage as indicated on the serial plate and voltagelabel.Power connection to the machine is made to L1, L2, L3 terminals at the junction block inside the control boxFig.1-9. During the initial hook-up it is very important to check that the phase order is correct. This is indicatedby the hydraulic pressure gauge registering a pressure rise Fig. 1-10 and the blade running in a counterclockwise direction. If the hydraulics do not register an immediate pressure rise, shut the hydraulics off andchange the phase order.

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

1.4

Fig. 1-9 Electrical junction block.

L1, L2, L3Terminals

Ground Clamp

Fig. 1-10 System pressure gauge.

SUB SECTION 2A - CONTROLS AND OPERATIONS

THE CONTROL CONSOLE

START-UP

The S-25A control console has been designed to simplify the operation of the saw, to give the operator theability to stop any function at any time, and to be able to control all the functions remotely. (See Fig. 2A-1)

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

NOTE: WHEN STARTING THE S-25A FOR THE FIRST TIME MAKE SURE THAT THE MODE SELECTOR SWITCH IS IN IT'S NEUTRAL POSITION, THE BLADE IS RUNNING IN A COUNTER CLOCKWISE DIRECTION, AND THAT THE HYDRAULIC PRESSURE IS 900 PSI 25 PSI (see SECTION 3 pg. 3.4).

Fig. 2A-1 Standard S-25A operation control panel.S-25A MANUAL CONTROLSHYDRAULIC START BUTTON: Starts hydraulic pump motor and energizes the BLADE START BUTTON

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

BLADE MOTOR This button is only operative when the hydraulic system has beenSTART BUTTON: started. Momentarily depressing this button will start the blade

motor.

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

2.1

EMERGENCY STOP This button will stop both the hydraulic and blade motors andBUTTON: de-energizes the MODE SWITCH.

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

HYDRAULIC AND BLADE Both of the drive motors are protected by individual overload relays.MOTOR RESET BUTTONS: If a motor draws excessive amperage, the corresponding relay will

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

MODE SWITCH: Has three positions, MANUAL, NEUTRAL, and AUTOMANUAL: in manual all the following functions except the HEAD

SWING CONTROLS and the AUTO CYCLE DIAL, are operative.

NEUTRAL:only the FIXED VISE SWITCH, the COOLANT SWITCH and the HEAD SWING CONTROLS are operative.

AUTO: all of the functions are under the control of the AUTO CYCLE DIAL, and the MANUAL CONTROL switches are inoperative.

HEAD CONTROL SWITCH: Inoperative unless MODE SWITCH is in MANUAL.UP: the head will rise until it reaches the HEAD UP LIMIT SWITCH SETTING.HOLD: the head will remain stationary.DOWN: the head will descend until it reaches the bottom. Descent

is controlled by the FEED RATE and FEED FORCE controls.

INDEX FORWARD BUTTON: Button is inoperative except when MODE SWITCH is in MANUAL.Depressing this button fully will cause the shuttle table to quicklyadvance toward the saw table until the button is released or theshuttle reaches the forward limit of travel.

Depressing this button partially will cause the shuttle table toadvance toward the saw table at a very slow rate until the button isreleased or the shuttle reaches the forward limit of travel. Thiscontrol is intended to assist in the accurate positioning of heavypieces of stock.

INDEX REVERSE BUTTON: Button is inoperative except when MODE SWITCH is in MANUAL.Depressing this button fully will cause the shuttle table to quicklyretract away from the saw table until the button is released or theshuttle reaches the rearward limit of travel.

Depressing this button partially will cause the shuttle table to retractaway from the saw table at a very slow rate until the button isreleased or the shuttle reaches the rearward limit of travel. Thiscontrol is intended to assist in the accurate positioning of heavypieces of stock.

INDEX VISE SWITCH: This switch is only operative when the MODE SWITCH is inMANUAL. It operates in the same manner as the FIXED VISESWITCH but controls the vise mounted on the shuttle table.

2.2

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

FAST SWING SWITCH: This switch is only operative when the MODE SWITCH is in theNEUTRAL position.Positioning this selector switch to 90 will swing the head fast towards the 90position. Likewise positioning this selector switch to 30 will swing the headtoward the 30 position. Leaving the switch on the lock position will restrainthe head from further angular motion. The angle change can be observed onthe angle scale located on the head swing drum Fig. 2A-2.

COOLANT SWITCH: Has three positions ON, WASH, and OFFON: the coolant flows only when the head descendsWASH: coolant flows any time the machine is under power, permittingwash-down with the hand line without running the machineOFF: no coolant flow

MULTI INDEX COUNTER: The counter is operative only in the AUTO MODE. The number onthe manually set thumb wheel display, controls the number ofshuttles made by the shuttle table between each saw cut Fig 2A-3. If thesetting is changed during the shuttling portion of the AUTO CYCLE,the new setting will not be accepted until after the current cuttingcycle.

2.3

SLOW SWING SWITCH: Operates in the same manner as the FAST SWING SWITCH except itswings the head at a slower rate making fine adjustment easier.

Fig. 2A-2 Angle scale.

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

Fig. 2A-6 Blase speed digital readout. Fig. 2A-7 Blade speed displaywindow on the PLC 100.

BLADE SPEED SWITCH: This optional switch controls the blade speed which can be infinitely adjustedbetween 75 and 400 SFPM. The blade speed change can be observed on theblade speed digital display, located on the front control panel (Fig. 2A-6). Onmachines quipped with the optional PLC 100 controller the blade speed isdisplayed in the blade speed window located on the PLC controller (Fig. 2A-

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

PIECE COUNTER: The counter is operative in both AUTO and MANUAL Fig. 2A-5. It is manuallyset to the number of cuts desired and counts down to zero at which point itturns the saw off. If the counter is set at zero it will not permit the saw to bestarted. If in the MANUAL MODE it is desired to have the saw shut down atthe end of the cut, the PIECE COUNTER must be set to 1 (one) before thecut. The counter counts one half count when the head down signal begins andthe other half count when the head down signal ends. Thus, if the AUTOCYCLE is interrupted during cutting, a false count will be recorded. In thisevent simply push the PIECE COUNTER back up one count.

Fig. 2A-3 Multi indexcounter.

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

2.4

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

(OPTIONAL)

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

The result is less than 40". Set the adjusting block pointer to 9 13/16" and the MULTI INDEX COUNTER to "1".Example 2Desired piece length 73 3/8"+ Kerf 1/16"= Total shuttle required 73 7/16"The result is greater than 40". We must divide by 2 in order to get a dividend less than 40 inches.

73.4375 = 36.719

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

+ Kerf aprox. 1/16"= Total shuttle required 9 13/16"

Example 1Desired piece length 9 3/4"

CONVENTIONAL LENGTH CONTROL SET-UP AND CALIBRATIONThe calibration makes no allowance for kerf loss and this must be added by the operator. Although bladethickness is standard with relation to blade size, blade kerf may vary due to different pitch or manufacturer. Werecommend that you measure the kerf of the blade which you are using by making a cut into a solid piece ofsteel and measuring the width of the cut. In the following examples we will use a blade kerf of .080". Theprocedure for setting and calibrating the conventional length control is as follows:To obtain a desired piece length add the kerf allowance. If the resulting length is less then 40", fully advancethe shuttle and set the adjusting block pointer to the resulting length. Set the Multi-Index Counter to "1".If the resulting length is greater than 40", divide it by the smallest number which will result in a dividend lessthan 40". Fully advance the shuttle and set the adjusting block pointer to the resulting dividend. Set the MULTIINDEX COUNTER to the divisor.

Fig. 2A-8 Length control block.

A

B

2.5

Set the PIECE COUNTER to "2" and the AUTO CYCLE KNOB to "START". Start the blade and switch theMODE SWITCH to "AUTO". The stock will advance and a cut will be made resulting in a trial piece.Check the length of this piece. If it is not accurate enough, use the micrometer head to zero in on exactly thelength you require. The general procedure for using the micrometer length adjustment is as follows:NEW MICRO SETTING = OLD MICRO SETTING + (DESIRED LENGTH - ACTUAL LENGTH)

NUMBER OF INDEXESIf in example 1, the resulting piece was 9.775 inches rather than the disired 9.750" then:NEW MICRO SETTING = .250 + 9.750 - 9.775

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

If in example 2, the resulting piece was 83.313" rather than the required 83.275" then:NEW MICRO SETTING = .250 + 83.375 - 83.313

3= .250 + .062

3= .271

Increasing the micrometer setting increases the part length, while decreasing the micrometer setting de-creases the part length.NOTE: Remember to reset the micrometer to exactly midscale at the end of each run.

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

S-25A AUTOMATIC CONTROLSBLADE KERFAlthough blade thickness is stand-ard with respect to blade size, bladekerf may vary due to different pitchor manufacturer. We recommendthat you measure the kerf of theblade which you are using by mak-ing a cut into a solid piece of steeland measuring the width of the cut.In the following examples we willuse a blade kerf of .080".

Fig 2A-9 Optional PLC 100 programmable controler.

2.6

SUBSECTION 2B - SAW CUTTING CONTROLS

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

BLADE BASICS

Technology is rapidly changing all aspects of production machining. Metal cut-off is no exception. Theadvances made in the bandsaw blade industry have definitely brought down the cost per cut, despite the threefold higher price of high technology blades.

Variable pitch, bi-metal blades (like the 2/3 or 4/6 bi-metal blade supplied with the S-25A series saws) lastmuch 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 anextremely slow feed rate. (utilizing a very slow blade speed is recommended)

These two or three slow cuts sufficiently lap (polish) the new blade so that it does not snag the material beingcut. Proper break-in will alleviate blade vibration, improve surface finish, accuracy, and blade life.

After break-in the following six points must be closely monitored to ensure long blade life:

1. Proper blade tension should be maintained. (see SECTION 3 pg. 3.4 BLADE TENSION)2. Generous coolant application is essential with almost all materials. A high quality and well mixed

coolant will many times extend blade life, and also increase cutting rate quality. On those materialswhere coolant is undesirable forcutting, a slight coolant flow or periodic oiling of the blade is necessaryto prevent the blade from being scored by the carbide guides.

3. The stock being cut must be securely clamped in the vises.

4. The proper feed force must be chosen.

5. The proper blade speed must be selected.

6. The proper feed rate must be applied.

2.12

VARIABLE SPEED CONTROL

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

HYDRAULIC FEED CONTROL

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

Fig. 2B-1 Blade speed adjust-ment.

Fig. 2B-2 Blade speed selectorswitch.

Fig. 2B-3 Digital blade speeddisplay.

Fig. 2B-4 Blade speed display window.

Fast Approach LeverDepress for fast head descent

Feed Force KnobUsed to set Feed Force Limit(clockwise rotation to increseand counter clockwise rotationto decrease).

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

Feed Force Gauge

Fig 2B-5 Hydraulic feed control.

2.13

A

USING THE SAW CUTTING PARAMETERS ON CHART

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

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

STEP 1DETERMINE EFFECTIVE MATERIAL WIDTH, W (in.)

Effective material width, W (in.) for mostcommon shapes of materials, is the widestsolid part of the material to be in contact withblade during cutting. For simple shapes, asillustrated on the chart, this can be diractlymeasured. For bundles of tubes andstructuals, measuring the effective width isdifficult. For those cases effective width is60% to 75% of the actual material width.

NOTE:Fig. 2B-4

A full size chart is mounted on thepanel. The chart contains five steps forthe operator to follow in order to achieveoptimum performance of the saw.

2.14

Both effective material width and guide arm width are used in setting the saw. Guide arm width is the distancebetween the guide arms and is used in STEP 2. Effective material width, as determined here in STEP 1, can bethought of as the average width of material seen by each tooth, and it is used in STEP 3 and 4.

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

STEP 2SET FEED FORCE LIMIT

The Feed Force Limit is the maximum amount of force with which the head is allowed to push the blade into theworkpiece. The controls for setting the Feed Force Limit consist of:

Feed Force Gauge

- With the Mode Switch in manual position, move the head fully down.- After the head is down, open the feed rate valve, depress the yellow FEED FORCE SETTING button and adjust the FEED FORCE.

Example #1

Fig. 2B-6 Feed Force pressure.

Fig. 2B-5 Hydraulic feed control.

Feed Force Knob

Feed Rate Knob

To set FEEDFORCE LIMIT:

2.15

Set the feed force at 250-300 psi. This will protectthe blade from buckling. This amount of feed forcewill also prevent the blade from cutting out of square.If the cuts obtained are not square and the blade isnot at fault, reduce the feed force pressure. Gener-ally a higher feed force can be used when cuttingsolids. When cutting structuals or bundles a lowerfeed force should be used.

2.16

SIGNIFICANCE OF GAUGE READING:

With the head down and yellow button depressed the (FEED FORCE set on manual control panel) FEEDFORCE gauge indicates the setting of the FEED FORCE LIMIT. During cutting the gauge shows the actualforce being applied by the blade to the workpiece.

In typical cutting situations, the needle on the gauge will rise toward the preset FEED FORCE LIMIT andstabilize, usually at a lower level. If the material being cut is very hard or wide, the needle may rise all the wayto the preset FEED FORCE LIMIT, which it will not exceed.

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

STEP 3

DETERMINE OPTIMUM BLADE PITCH, TEETH PER INCH (T.P.I)

Selecting a blade with proper tooth pitch is important in order to acheive optimal cutting rates and good bladelife.

For cutting narrow or thin wall structual materials a fine blade with many teeth per inch (T.P.I) is recommended.For wide materials a blade with a coarse pitch should be used (see Fig 2B-7 below).

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

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

necessary, but remember that the optimum blade will cut most efficiently. Too fine a blade must be fed sloweron wide material because the small gullets between the teeth will get packed with chips before they get acrossand out of the cut. Too coarse a blade must be fed slower because it has fewer teeth cutting and there is a limitto the depth of a cut taken by each tooth. Allowance for the use of a non-optimum blade is made in STEP 5.

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

STEP 4

DETERMINE OPTIMUM BLADE SPEED, V (ft/min)The relationship between optimum blade speed and effective material width for various materials is representedon the graph Fig. 2B-8.

The graph shows that as effective material width gets wider or as material gets harder, lower blade speeds arerecomended. If material is narrower or soft, higher blades speeds should be selected.

Fig. 2B-8 Optimum blade speed curves.

In Example #1 8" Dia, 1045 Medium Carbon Steel solid bar is to be cut.- On the graph above find the Medium Carbon Steel Curve which represents the optimum blade speeds for 1045 Carbon Steel.- On the horizontal axis (effective material width axis) find number 8 which represent effective material width of an 8" diameter solid.- Find the point where a vertical line from 8" intersects the Medium Carbon Steel Curve.- From this intersection point run horizontally left to the vertical axis (optimum blade speed axis) and find the point marked 200.- Thus, for 8"diameter, 1045 Carbon Steel solid bar 200 ft/min is the optimum blade speed.

NOTE: Higher than optimum blade speed will cause rapid blade dulling. Lower than optimum blade speedsreduce cutting rates proportionately and do not result in significantly longer blade life except where there is avibration problem. If the blade vibrates appreciably at optimum speed as most often occurs with structuals andbundles, a lower blade speed may reduce vibration and prevent premature blade failure.

The table below shows a few examples of optimum blade speed for different materials.

TABLE 2B-1

2.17

NOTE: About Material Hardness

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

FEED RATE Knob controls FEED RATE of theblade in the range 0 to 25 in/min.The FEED RATE should be adjusted only in onedirection (from 0 to required value). If you go toofar, go back to 0 and come back up.To set FEED RATE for particular cutting situationsuse the Graph, Fig 2B-10, which represents therelationship between FEED RATE, blade speedand blade pitch.

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

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

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

STEP 5

DETERMINE FEED RATE SETTING, FR (in/min)

FEED RATE is the vertical speed at which the blade descends through the workpiece.

Fig. 2B-9 Hydraulic feed control.

2.18

Fig. 2B-10

If the machine is fitted with a blade coarser than optimum (eg. 1.4/2.5 TPI) we can still use the graph, but we goto the 1.4/2.5 curve. As a result we find that the FEED RATE is decresed to 1.3 in/min for this blade.

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

2.19

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

TABLE 2B-2

3/4.34.57

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

- Find the point where a vertical linefrom 200 ft/min would intersect the

` For Example #1, it is known from Step3 that otimum blade pitch is 2/3, andfrom Step 4 that blade speed ,200 ft/min. From the graph, Fig. 2B-10 theFEED RATE is determined in thefollowing way:- On the horizontal axis (blade speedaxis), find 200 ft/min.

2/3 blade pitch curve.- From this intersection point runhorizontally left to the vertical (FEEDRATE) axis, to arrive at 1.8 in/minFEED RATE. Thus 1.8 in/min is theFEED RATE for cutting 8" diameter,1045 Carbon Steel when the optimum2/3 pitch blade is used.

2.20

CUTTING CONTROL SET UP EXAMPLES

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

Example #2Material to be cut

-Round Steel Tube SAE 4320 6" OD x 4" ID-Hardened to 35 Rc (325 Bhn)

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

STEP 2Feed Force limit setting for 6" Diameter material 180 P.S.I.

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

STEP 4Optimum blade speed for 4 1/2" effective 225 ft/minmaterial width

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

STEP 5

Feed Rate for 3/4 TPI blade: 1.8 in/min

Feed Rate for 4/6 TPI blade: 1.8 in/minx.70=1.3in/min(reduced by finer than optimum blade pitch factor,Table 2B-2 - STEP 5)

Example #3

Material to be cut

-low carbon steel-2" x 2" tube x 1/4" wall

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

STEP 1Effective material width: 5" (6" x 8")

STEP 2Feed Force limit for 8" wide material: 180 P.S.I.

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

STEP 4Optimum blade speed for 5" effective material width: 320 ft/min

STEP 5Feed Rate: 4.0 in/min

2.21

SUBSECTION 2C - MECHANICAL CONTROLSHEAD UP AND HEAD DOWN LIMIT SETTINGHead Up Limit: In order to maximize production in the automatic cycle the HEAD UP LIMIT should be set

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

To Set Limit: As in Fig. 2C-1,for coarse adjustment depress button 'A' and slide knob 'B' up or down toapproximately the desired height. To finely adjust the height turn knob 'B'. Counter clockwise rotation of the knob raises the upper limit of head travel and clockwise to lower the limitof head travel. The head up limit should be set by starting with the head below the requiredheight and the knob screwed in to the limit switch. MANUAL mode must then be selectedand the HEAD CONTROL SWITCH rotated counter clockwise until the blade has at leas 1/2" clearance above the material and slightly more when cutting bundles.

Fig. 2C-1 Head limit adustment.

B

A

Head Down The coolant pumpshuts off when the cut has been completed.Limit Switch: The exact instant it shuts off the power supply can be set by the adjustment bolt 'A' asshown in Fig. 2C-2NOTE: This limit is factory set and under ordinary cutting requirements should not bechanged. If changed it may cause the machine to malfunction in the auto cycle.

Fig 2C-2 Head down limit switch

A

2.22

COOLANT FLOWA generous flow of coolant should be applied in order to increase production and blade life.Machine is provided with two independently controlled coolant spouts.- One from the adjustable guide arm nozzle. This one should always flood the blade with coolant. Slightreadjustment may be required when changing the blade speed. A properly adjusted flow of coolant should coverthe blade which in turn will carry it into the cutting area. Flow adjusting tap is shown in Fig. 2C-4.- The coolant hose on the fixed guide arm should be used in cases when cutting solid bars, bundles or widestructurals. The flow of coolant should be directed into the opening created by the blade. Flow adjusting tap isshown Fig. 2C-4.NOTE: When cutting materials that do not need coolant (cast iron) some coolant flow is required to provideblade lubrication to prevent blade scoring by carbides.

Fig. 2C-4

Coolant FlowAdjusting Taps

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

Fig. 2C-3

B

A

2.23

BLADE CHANGING1. Select manual mode and raise the head slightly (about two inches at the drive side guide arm).2. Open the idler and drive doors.3. Remove the blade guard Fig. 2C-5.4. Release the carbide guides Fig. 2C-6.5. Release the blade tension by positioning the blade tension selector switch to '-' Fig. 2C-7.

TURN THE HYDRAULICS OFF.6. Push the blade out from between the carbide guides.7. Remove the blade.8. Install a new blade. The teeth should be facing away from the head of the saw. The teeth on the part of

the blade between the two guide blocks should point towards the drive side of the head.9. Turn the hydraulics on and tension the blade by positioning the blade tension selector switch to '+'.10. Start the blade for a few rotations in order for the blade to seat in the carbide guides and to track itself on

the wheels.11. Replace the blade guard.12. Close the carbide guides Fig. 2C-8.13. Close the idler and drive doors.

Fig. 2C-5 Blade guard. Fig 2C-6 Carbide handles (released).

Fig. 2C-7 Blade tension switch. Fig. 2C-8 Carbide handles (locked).

2.24

THIS PAGE INTENTIONALLY LEFT BLANK

BLADE BRUSHThe blade brush is properly set when machine leaves the factory but it wears out during operation and needs tobe readjusted periodically. The blade brush assembly is shown in Fig. 3-1. In order to readjust it, the nut on theadjusting screw needs to be loosened and the screw turned counter clockwise until wires from the brush touchthe bottom of the blade gullets Fig. 3-2.NOTE: Proper adjustment and operation of the blade brush is essential to the correct operation of the bandsawand the longegivity of the blade. Therefore periodic maintenance and inspection of the machine should not beneglected.If the brush gets worn to approximately 70% of its original diameter 3 " OD it should be replaced. A brush maybe purchased through a HYD-MECH dealer in your area.

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

Adjustablecarbide pad

Top servo carbide Top carbide

Fixed carbide pad

Fig. 3-2 Properly adjusted blade brushFig. 3-1 Blade brush assembly

Adjusting screw

Fig. 3-4 Disassembled blade guides.

SECTION 3 - MAINTENANCE AND TROUBLESHOOTING

3.1

Fig. 3-3 Assembled blade guides.

LUBRICATIONThe design of the S-25A was intended to minimize maintenance, although periodically certain moving partsneed lubrication. We recommend that this periodic lubrication be done once a month using any general purposegrease at the points indicated G.

Fig. 3-5 Vertical Pivot.

G G

Fig. 3-6 Horizontal Pivot.

Fig. 3-7 90 Degree Shaft.

GG

Fig. 3-8 Vise Ways.

Fig. 3-9 Idler Wheel Slider.

G

GFig. 3-10 Guide Arm Positioning Shaft.

G

3.2

Oil filter Level gauge Oil fill cap Fig. 3-14 Wash down hose.Fig. 3-13 Oil tank.HYDRAULIC MAINTENANCEThere are only four items of routine maintenance associated with the hydraulic system.1. OIL FILTER - Ten micron filtration of the hydraulic oil is provided by a spin on type filter mounted on thetank return line. The element should be changed every 1000 working hours or once per year. Suitablereplacement elements are:

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

CLEANLINESSThe S-25A series design should endure heavy operating conditions and provide the customer with flawlessmachine performance. To extend good performance some care is required, especially cleanliness.The following areas should be kept clean of dirt, grease and chips:-CONTROL CONSOLE -OUTFEED TABLE-DOOR CHARTS -LARGE BUILD UP OF CHIPS IN THE SAW BASE-WHEEL BOXES -VISE WAYS-BLADE GUIDESNOTE: All parts should be cleaned before any repair or service is performed on them.A wash gun is supplied for washing chips off the table and vise ways Fig. 3-14.

Fig. 3-11 Counterbal-ance Shaft.

Fig. 3-12 Shuttle Bearing Housing.

G

3.3

G

2. OIL LEVEL - Oil level should be maintained in the upper half of the level gauge. Normally the rate of oilconsumption will be very low and it should be unnecessary to add oil more often than at filter changes. Add oilonly to the top line on level gauge.The S-25A is shipped from the factory with Valvoline 150-46 hydraulic oil. Generally any brand of recognizedmineral hydraulic oil with the same properties should be compatible with Valvoline 150-46, but to avoid any riskwe suggest staying with Valvoline 150-46. If it is desired to change brands, it is necessary to drain the tank and1/3 refill it with the new oil, operate through several automatic cycles with the index set to full stroke and headto full rise, drain the tank again, and finally fill the tank with the new brand.Hydraulic tank capacity is approximately 17 US gallons.Recommended replacement oils: Chevron AW Hydraulic Oil 46

Esso - NUTO H46Mobil - Mobil DEC 25Petro Canada - Harmony AW 46Texaco - Rando HD 46Shell Tellus 46

3. OIL TEMPERATURE - Oil temperature is indicated by a thermometer contained in the level gauge Fig 3-13.Oil temperature during steady operation should stabilize at about 50 - 55 F above room temperature. Thus in a70 F shop one might expect an oil temperature of about 120 F. Oil temperature should never exceed 160 F.4. SYSTEM PRESSURE - System pressure is factory set to 900 25 psi and should not require furtherattention except precautionary observation at start-up and occassionally thereafter.5. BLADE TENSION - Is controlled by system pressure.6. VISE PRESSURE - Is controlled by system pressure. If machine is equipped with the optional variable visepressure; vise pressure is operator adjustable.

3.4

TROUBLE SHOOTINGMost problems which may occur have relatively simple solutions which appear in this section. If the solution isnot found here, contact the Hyd-Mech Distributor from whom you purchased your bandsaw. They have trainedfield service people who will be able to rectify the problem. PROBLEM PROBABLE CAUSE SOLUTION1. Saw is cutting out of square

vertically.2. Saw is cutting out of square

horizontally.

3. Blade comes off wheels.

1a. Blade worn.1b. Carbide guides loose.2a. Angle not set correctly.2b. Angle pointer has moved.2c. Stock not square in vise.3a. Not enough blade tension.

3b. Improper tracking.

1a. Change blade.1b. Adjust2a. Adjust accordingly.2b. The scale is accurate. Adjust

and tighten the pointer.2c. Adjust accordingly.3a. Blade tension is determined

by system pressure. Checkthat system pressure is asspecified earlier in thissection.

3b. Adjust accordingly

PROBLEM PROBABLE CAUSE SOLUTION

3.5

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

6a. Excessive blade tension.

6b. Excessive feed rate.

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

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

8c. Control circuit fuse hasblown.

9a. On machines so equipped,the out-of-stock or bladebreakage limit switch hasbeen tripped.

10a. If blade wheels run clockwise, wrong phase order inpower connection to saw.

10b. If pump is noisy, low hydrau-lic oil.

4b. Reduce.5a. Reduce.5b. Adjust accordingly.5c. Blade tension is determined

by system pressure. Checkthat system pressure is asspecified earlier in thissection.NOTE: New blades tend to vibrateuntil they are "broken in".

6a. Blade tension is determinedby system pressure. Checkthat system pressure is asspecified in this section.

6b. Reduce.

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

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

buttons on the main controlbox. Depressing one reset ata time and trying to start thesaw will indicate which motorwas overloaded.

8c. Replace the fuse with a 5Amp 250 Volt AG1 type fuse.Random blowouts may occurbut a quickly repeated blowout indicates an internalwiring fault.

9a. Reload with stock or remountblade.

10a. Stop immediately; reverseany two of the three linephase connections.

10b. Stop immediately; addhydraulic oil (see hydraulicmaintenance earlier in thissection).

7. No coolant flow.

8. Saw will not start.

9. Saw starts but will not run afterStart Button has been re-leased.

10. Saw starts but no hydraulicfunctions.

6. Excessive blade breakage.

5. Blade vibrating excessively.

4a. Blade tension is determinedby system pressure. Checkthat system pressure is asspecified earlier in thissection..

4b. Excessive feed force.

4a. Not enough blade tension.4. Blade stalls in cut.

PROBABLE CAUSE SOLUTION PROBLEM11. Saw starts but only front vise

functions.IN MANUAL MODE12. Head will not rise.

13. Head will not descend.

3.6

11a. Mode Selector Switch is in"Neutral".

12a. Head up limit switch is setfully down.

13a. Feed Rate valve is fullyclosed (pointer is set on "0"or close to "0" in/min).

13b. Feed Force Limit is set too

11a. Select "manual" mode.

12a. Readjust head up limitswitch.

13a. Turn Feed Rate Knob count-er clockwise to open valve.

13b. Increase Feed Force limit toat least 150 psi.

13c. Loosen pointer, turn knobclockwise until it bottoms;tighten pointer at "0".

low.13c. Pointer is adjusted incor-

rectly.14a. Observe pilot light(s) on

relevant valve, visible byremoving the side panel oninfeed base. If pilot lightrelated to inoperable functionfails to light, problem iselectrical.

14b. If pilot light related to inoperable function does light,problem may still be the coil(see 14a. SOLUTION). Ifproblem remains it probablyresults from dirt in the valvespool. If the problem isrelated to index forward orretract, or head swing it mayalso be dirt in the cushionvalve mounted near themanifold.

14. Head still will not rise or fall,or any individual function will 14a. In case of head and indexfunctions check operation of

related limit switches. Limitswitch buttons should oper-ate freely and emit an audi-ble click on both depress andrelease. If not replace theswitch. Look for cause ofswitch damage. To checkthe switch unit itself, removethe switch lid and wiretogether the two terminalsclosest to the wiring port. Iffunction now responds tomanual switch replace theswitch. If function stilldoes not respond then...Remove the sidepanel on the infeed to gainaccess to the valves. Remove coil retaining nut andwithdraw problem relatedcoil, replace it with any othercoil from the group. If theproblem remain it requiresthe attention of a qualifiedservice person.

14b. Disassembly of hydraulicvalves should be undertakenonly by qualified servicepersonnel or those knowledgable with hydraulic compo-nents.

PROBLEM PROBABLE CAUSE SOLUTIONnot respond to its manualcontrol switch.

15. Head descends when FeedRate valve pointer is set to"0" on the scale and FeedForce limit gauge is morethan 150 psi.

16. Index retracts but only veryslowly.

IN AUTOMATIC MODE17. Auto cycle stops.

18. Piece length gradually in

15a. Readjust pointer as in 13c.

16a. As in 14a check and repair orreplace.

17a. Readjust limit switch actua-tor.

17b. Begin auto cycle over againfrom start position on AutoCycle Dial. Note last functionmotion before the cycle stopsand check related limit switchfunction. For example, if thehead comes down and thenthe cycle stops, check thatthe head down limit switch isbeing actuated by prodding itwith a screwdriver. If theauto cycle resumes, the limitswitch actuating bolt must bereadjusted. Similarly if theshuttle advances and thenthe cycle stops, check thatthe shuttle forward limitswitch is being actuated.

15a. Pointer of Feed Rate valve isstopped by stop bolt but notfully closing the valve.

16a Cushion limit switch isstuck or damaged.

17a. If cycle seems to stop because of a particular functionis inactive, switch to manualand see it that function is stillinactive. If so see previoussection "IN MANUALMODE".

17b. If the function is active in"manual" mode.

17c. If the cycle does not respondto limit switch prodding.check for a damaged limitswitch as outlined in 14a.SOLUTION, above. In thiscase wire together the twoswitch terminals furthest fromthe wiring port.

18a. Length adjustment block nottight.

18b. Micrometer adjustment iscreeping.

17c. Check for cause of damageand replace limit switch as needed.

18a. Tighten the knob.18b. Very slightly tighten the set

screw which retains themicrometer in the adjustingblock. This will increase thestiffness of the micrometerthreads.

3.7

PROBLEM PROBABLE CAUSE SOLUTIONcreases during productionrun.

19. Piece length shows largeerratic decreases from setvalue.

IN AUTO MODE (Optional) PLC20. Auto cycle will not start.

21. Auto cycle stops beforecompletion.

19a. Stock is slipping in rear viseduring advance or in frontvise during retraction.

20a. No job or job que programmed to run.

21a. Headup, head down, orshuttle home limit switch notbeing contacted.

19a. Apply oil to front and rearvise jaws.

20a. Enter job number(s) and jobdata as in SECTION 2ACONTROL CONSOLE.

21a. Run saw in auto cycle. Notelast function motion beforethe cycle stops and checkrelated limit switch function.For example, if the headcomes down and then thecycle stops, check that thehead down limit switch isbeing actuated by prodding itwith a screwdriver. If the autocycle resumes, the limitswitch actuating bolt must bereadjusted. Similarly if theshuttle advances and thenthe cycle stops, check thatthe shuttle forward limitswitch is being actuated.

3.8

SECTION 4 - ELECTRICAL SYSTEMGENERAL INFORMATIONThe power connection to the machine is made to the L1, L2 and L3 terminals of the contactor located in themain control box. As supplied, the machine is set to run on three phase voltage as indicated on the serial plateand the voltage label.In order to use the machine on a different supply voltage the following changes must be made:1. Change the blade motor (or if equipped with a dual voltage motor, rewire it)2. Change the hydraulic pump motor (or if equipped with a dual voltage motor, rewire it)3. Change the control transformer (or if equipped with a dual voltage unit, rewire it)4. Change the blade and pump motor overloads, located adjacent to the contactor, to suit the full loadcurrent of the new or rewired motor.All other components are supplied from the control transformer and operate on 115V, single phase. They do notneed altering.The machine is supplied for use on a 60HZ supply. For use on a 50HZ supply consult the factory.WHEN CHANGING THE SUPPLY VOLTAGE, CAREFULLY OBSERVE THE ABOVE STEPS. THESE STEPSARE ESSENTIAL TO AVOID SEVERE DAMAGE TO THE MOTOR AND CONTROLS.At initial hook-up it is important to check that the phase order is correct. This is indicated by the blade drivewheel revolving in a counterclockwise direction and the hydraulic pressure gauge registering a pressure rise.Onthe following pages are the electrical schematics and physical wiring diagrams along with a list of electricalcomponents.

4.1

PHOTOS OF STANDARD ELECTRICAL COMPONENTS

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

2MTR 1CR 2CR 1M

L 1L 2L 3GND

4.2

Fig. 4-2 Back of the control panel.

1CNT

MITM

9SS 1PB8SS4SS7SS 4PB

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

2SS FU 1SS

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

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

Fig. 4-5 Head Down limit switch 2LS. Fig. 4-6 Shuttle control limit switches.

6LS4LS

5LS3LS

4.3

PHOTOS OF OPTIONAL ELECTRICAL COMPONENTS

Fig. 4-7 Blade motor 2MTR. Fig. 4-8 Hydraulic pump motor 1MTR.

Fig. 4-10 Hirschman connectors and directionalvalve solenoids.Fig. 4-9 Coolant pump motor 3MTR.

1PB 3PB

6PB

FE 1SS3SS

PLC100

5PB 7PB 5SS 8SS 7SS

4SS 2SS 4PB2PB

9SS

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

4.4

LIST OF ELECTRICAL COMPONENTS FOR AN S-25A WITH THE OPTIONAL PLC100Item Cose Function Description Component Componentas on Manufacturer NumberS-25A Sch.1PB Emergency Stop Operating head (red mushroom) Telemecanique ZB2BC4

push button 1 NC contact block Telemecanique ZB2BE1022PB Hydraulic Start Operating head (green illuminated, Telemecanique ZB2BW33

push button flush style)Light block Telemecanique ZB2BW061130 V Lamp Telemecanique SP1061 NO contact block Telemecanique ZB2BE101

3PB Blase Stop Operating head (black flush style) Telemecanique ZB2BA2push button 1 NC contact block Telemecanique ZB2BE102

4PB Blade Start Operating head (green illuminated, Telemecanique ZB2BW33push button flush style)

Lamp block Telemecanique ZB2BW061130V Lamp Telemecanique SP1051 NO contact block Telemecanique ZB2BE101

Fig. 4-12 Encoder. Fig. 4-13 Shuttle hohe limit switch 3LS.

Fig. 4-14 Blade speed pickup PROX.

4.5

Item Cose Function Description Component Componentas on Manufacturer NumberS-25A Sch.5PB Feed Force Limit Operating heaf (yellow flush Telemecanique ZB2BA5

setting push style)button 1 NO contact block Telemecanique ZB2BE101

6PB Index Forward Booted push button operator Telemecanique XACB9212push button 2 speed 2 contact block assembly

1 NO, 1 NO early close Telemecanique XENB11817PB Index Reverse Booted push button operator Telemecanique XACB9212

push button 2 speed 2 contact block assembly1 NO, 1NO early close Telemecanique XENB1181

1SS Mode Operation head (3position Telemecanique ZB2BJ3Man/Off/Auto maintained, long)selector switch 1 NO early close Telemecanique ZB2BE201

1 NC late open Telemecanique ZB2BE2021 NO Telemecanique ZB2BE1012 NC Telemecanique ZB2BE102

2SS Head Operating head (3 position Telemecanique ZB2BJ3Up/Hold/Down maintained, long)selector switch 2 NO contact blocks Telemecanique ZB2BE101

3SS Coolant Operating head (3 position Telemecanique ZB2BD3selector switch maintained)

2 NO contact blocks Telemecanique ZB2BE1014SS Fixed Vise Operating head (3 position, one Telemecanique ZB2BJ7

selector switch maintained, one spring return tocenter, long)2 NO contact blocks Telemecanique ZB2BE101

5SS Shuttle Vise Operating head (3 position, one Telemecanique ZB2BJ7selector switch maintained, one spring return to

center, long)2 NO contact blocks Telemecanique ZB2BE101

6SS Blade Tension Selector switch and housing Telemecanique XALJ133selector switch assembly (3 position maintained)

2 NO contact blocks Telemecanique ZB2BE1017SS Slow Head Operating Head (3 position with Telemecanique ZB2BD5

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

8SS Fast Head Operating Head (3 position with Telemecanique ZB2BD5Swing selector spring return to center)switch 2 NO contact blocks Telemecanique AB2BE101

9SS PLC on/off Operating head (standard 2 position Telemecanique ZB2BJ2selector switch maintained)

1 NO contact blocks Telemecanique ZB2BE101

4.6

Item Cose Function Description Component Componentas on Manufacturer NumberS-25A Sch.1LS Head Up Rod Plunger Telemecanique XCKL110H7

limit switch2LS Head Down Rod Plunger Telemecanique XCKL110H7

limit switch3LS Shuttle Home Rod Plunger Telemecanique XCKL110H7

limit switchTR Transformer Open Style 500VA

60Hz single phasePrim. V. - Sec. V.240V-120V Hammond HT97838480V-120V Hammond HT97818600V-120V Hammond HT96808

1M Motor Contactor Open Style(hydraulics) 240V Telemecanique LC1D5811G6

480/600V Telemecanique LC1D1810G62M Motor Contactor OPen Style

(blade) 240V Telemecanique LC1D5811G6480/600V Telemecanique LC1D1810G6

1AC Auxiliary Contact 2 NO contacts Telemecanique LA1DN20Block

1CR Auto-Manual 4 NO contacts Telemecanique CA2DN40G6relay

2CR Head Down 2 NO, 2 NC contacts Telemecanique CA2DN22G6relay

1OL Motor Overload Triple Pole Thermal(hydraulics) 3HP 208/240V Telemecanique LR2D1314

3HP 480V Telemecanique LR2D13103HP 600V Telemecanique LR2D1308

2OL Motor Overload Triple Pole Thermal(blade) 10HP 208/240V Telemecanique LR2D3353

10HP 480V Telemecanique LR2D131610HP 600V Telemecanique LR2D1316

1MTR El. Motor 182TC/3PH/3HP US Motors 2HP182TC(hydraulics) 208/240V

480V600V

2MTR El. Motor 215TC/3PH/10HP US Motors 5HP215TC(blade) 208/240V

480V600V

4.7

Item Cose Function Description Component Componentas on Manufacturer NumberS-25A Sch.3MTR El. Motor 1PHZ 120VAC Little Giant 2E-NT502186

(coolant pump) (with pump assembly)PLC Length Programable logic control Hyd-Mech PLC100

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

Fuse 5A 250V BUSS MDL-5PROX Blade speed Inductive proximity switch Omron TL-X2C1-E

pickupHirschman Female connector with light GDM 927811-011connectors indicator GDM 2011Encoder Incremental shaft encoder Deem MBE-3122-1000-QWCYDirectional Vickers Y(120 VAC)valvesolenoid

LIST OF ELECTRICAL COMONENTS FOR A STANDARD S-25AItem Cose Function Description Component Componentas on Manufacturer NumberS-25A Sch.1SS Mode selector Operating head (3 position Telemecanique ZB2BJ3

switch maintained, long)1 NO contact block Telemecanique ZB2BE1011 NC contact block Telemecanique ZB2BE102

2SS Coolant selector Operating head (3 position Telemecanique ZB2BD3switch maintained)

2 NO contact blocks Telemecanique ZB2BE1013SS Fixed Vise Operating head (3 position, Telemecanique ZB2BJ7

selector switch one maintained, one spring returnto center, long)2 NO contact blocks Telemecanique ZB2BE101

4SS Shuttle Vise Operating head (3 position, Telemecanique ZB2BJ7selector switch one maintained, one spring return

to center, long)2 NO contact blocks Telemecanique ZB2BE101

5SS Head Up/Hold/ Operating head (3 position Telemecanique ZB2BJ3Down selector maintained, long)switch 2 NO contact blocks Telemecanique ZB2BE101

6SS Fast shuttle Operating Head (spring return Telemecanique ZB2BD5selector switch to center, short)

4 NO contact block Telemecanique ZB2BE101

4.8

Item Cose Function Description Component Componentas on Manufacturer NumberS-25A Sch.7SS Slow shuttle Operating head (spring return Telemecanique ZB2BD5

selector switch to center, short)2 NO contact block Telemecanique ZB2BE101

8SS Fast head swing Operating head (3 position with Telemecanique ZB2BD5selector switch spring return to center)

4 NO contact blocks Telemecanique ZB2BE1019SS Slow head swing Operating head (3 position with Telemecanique ZB2BD5

selector switch spring return to center)2 NO contact blocks Telemecanique ZB2BE101

10SS Blade Tension Selector switch and housing ass'y Telemecanique XALJ133selector switch (3 position maintained)

2 NO contact blocks Telemecanique ZB2BE1011PB Emergency Stop Operating head (red mushroom) Telemecanique ZB2BC4

push button 1 NC contact block Telemecanique ZB2BE1022PB Hydraulic Start Operating head (green illuminated, Telemecanique ZB2BW33

push button flush style)Light block Telemecanique ZB2BW061130 V Lamp Telemecanique SP1051 NO contact block Telemecanique ZB2BE101

3PB Blade Start Operating head (green illuminated, Telemecanique ZB2BW33push button flush style)

Lamp block Telemecanique ZB2BW061130V Lamp Telemecanique SP1051 NO contact block Telemecanique ZB2BE101

4PB Blade Stop Operating head (black flush style) Telemecanique ZB2BA2push button 1 NC contact block Telemecanique ZB2BE102

5PB Feed Force Limit Operating heaf (yellow flush Telemecanique ZB2BA5setting push style)button 1 NO contact block Telemecanique ZB2BE101

1LS Head Up Rod Plunger Telemecanique XCKL110H7limit switch

2LS Head Down Rod Plunger Telemecanique XCKL110H7limit switch

3LS Shuttle forward Rod Plunger Telemecanique XCKL110H7limit switch

4LS Shuttle back Rod Plunger Telemecanique XCKL110H7limit switch

5LS Shuttle forward Roller Arm Telemecanique XCKL115H7cushion L.S.

Item Cose Function Description Component Componentas on Manufacturer NumberS-25A Sch.6LS Shuttle back Roller Arm Telemecanique XCKL115H7

cushionlimitswitch

FU Fuse holder Standard for 1 1/4" x 1/4" Little Fuse H342-858Fuse 5A 250V BUSS MDL-5

TR Transformer Open Style 500VA60Hz single phasePrim. V. - Sec. V.240V-120V Hammond HT97838480V-120V Hammond HT97818600V-120V Hammond HT96808

1M Motor Contactor Open Style(hydraulics) 240V Telemecanique LC1D5811G6

480/600V Telemecanique LC1D1810G62M Motor Contactor OPen Style

(blade) 240V Telemecanique LC1D5811G6480/600V Telemecanique LC1D1810G6

1M5,6 Auxiliary Contact 2 NO contacts Telemecanique LA1DN20Block

1CR Auto-Manual 4 NO contacts Telemecanique CA2DN40G6relay

1CR5-8 Auxiliary Contact Telemecanique LA1DN13on 1CR

2CR Head Down 2 NO, 2 NC contacts Telemecanique CA2DN22G6relay

1OL Motor Overload Triple Pole Thermal(hydraulics) 3HP 208/240V Telemecanique LR2D1314

3HP 480V Telemecanique LR2D13103HP 600V Telemecanique LR2D1308

2OL Motor Overload Triple Pole Thermal(blade) 10HP 208/240V Telemecanique LR2D3353

10HP 480V Telemecanique LR2D131610HP 600V Telemecanique LR2D1316

1MTR El. Motor 182TC/3PH/3HP US Motors 2HP182TC(hydraulics) 208/240V

480V600V

4.9

Item Cose Function Description Component Componentas on Manufacturer NumberS-25A Sch.2MTR El. Motor 215TC/3PH/10HP US Motors 5HP215TC

(blade) 208/240V480V600V

3MTR El. Motor 1PHZ 120VAC Little Giant 2E-NT502186(coolant pump) (with pump assembly)

TM Timing motorSequencer SAIA KKB50-6-5-105-120/60 CW & KNOB 4 268 4904 0

1CNT Piece counter Durant 34-11564 115VACMI(RE)MI(CNT) Multi Index Eagle Signal D2101 A3 115VAC

CounterLMP Work Lamp Moffat 0618-3-AS

Hirschman Female connector with light GDM 927811-011connectors indicator GDM 2011Directional Vickers Y(120 VAC)valvesolenoid

4.10

SECTION 5 - HYDRAULIC SYSTEMThe S-25A hydraulic system does not require any special work on a new machine before its start-up. Thehydraulic tank is filled with Valvoline 150-46 hydraulic oil and all machine functions have been tested at thefactory to ensure proper operation upon initial start-up.

PARTS LIST AND PHOTOS OF HYDRAULIC COMPONENTSITEM QTY DESCRIPTION OF PART PART NUMBER1 1 Head Cylinder S25-C4-002 1 Shuttle Cylinder S25-C1-003 1 Blade Tension Cylinder S25-C5-004 3 Vice Cylinders S25-C3-005 1 Head Swing Cylinder S25-C9-006 3 Bundling Cylinder (Optional) S25-C23-007 1 Remote Blade Speed Cylinder (Optional) VSL-C9-008 1 Head Force Servo Valve T25-325-009 1 Positive Downfeed Valve DF2-0-0010 1 Extension Block 2 position (Optional) EB-0111 1 Manifold Block MB6P12 3 Double Pilot Check DPCH-113 2 Pressure Gauge (1000 psi) PG-1014 2 Pressure Gauge (500 psi) PG-515 2 Vice Valves DCV3P-AB-C16 1 Remote Blade Speed Adjustment Valve (Optional) DCV3P-AB-T17 1 Head Lift Valve DCV3P-AB-T18 1 Head Swing Valve DCV3P-AB-T19 1 Blade Tension Valve DCV3P-AB-C20 1 Shuttle Valve DCV3P-AB-T21 1 Relief Valve RV22-0022 2 Poppet Valve PV2P-A-C23 1 Swing Cushion Block CHB-1524 1 Shuttle Cushion Block CHB-3525 3 "o" Ring Plate MH-0126 1 Pump HYP-127 1 Suction Strainer ZINGA SS-100-0028 1 Return Filter ZINGA AE-10

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

or GRESEN K-2201

5.1

SpringDF-2-03

'O' Ring PlugDF-2-04

PusherDF-3-01

SpringDF-3-02

ScrewDF-3-03

ShaftDF-3-04

Pushing FingerDF-3-05A

SpringBushingDF-3-09

SpoolDF-4-01

SpringDF-4-03

Spring GuideDF-4-04

SpringGuideDF-4-02

'O' Ring1/2"OD x 3/8" ID x 1/16"

SpoolDF3-1-01ANeedle

DF1-1-01APointerDF-1-02

Hex Jam Nut5/8"-18

Black Knob5/8-18 x 5/8

Plug1/8" NPT

SpoolDF-2-01

'O' Ring3/8" OD x 1/4" ID x 1/16"

Plug1/8" NPT

SpringDF-1-03

Spring GuideDF-2-02

Snap Ring Ext.3/8" DIA

Lever- DF-3-07Tube- 3/8" ID x 1.625"

SpringDF-1-03

2 of Snap Ring Ext3/8" DIA

'O' Ring1/4" OD x 1/8" ID x 1/16

Bolt10-24 x 1/2" Snap Ring1/8" DIA

Plastic Ball- 1" DIA x 1/4" NC

SpringDF-3-08

Ball1/4" DIA

Roll Pin1/8" DIA x 2"

Plug1/8" NPT

2 of Back-Up Ringfor 'O' Ring1/2" OD x 3/8" ID x 1/16"

Plug1/8" NPT

Orfice .013"

Back -Up Ringfor 'O' Ring1/2" OD x 3/8" ID x 1/16"

'O' Ring1/2" OD x 3/8" ID x 1/16"

Valve BodyDF-0-01

NeedleDF-4-05B

KnobDF-4-06

CollarDF-3-06

POSITIVE DOWNFEED VALVE COMPONENTS

5

.

2

THIS PAGE INTENTIONALLY LEFT BLANK

GUIDE ARM ASSEMBLY

GUIDE ARMS ASSEMBLED

6 of Socket Head Cap Screws3/8"NC x 1" LGGuide Bar

S25-32-01A12 Set Screws5/16"NC x 3.4" LG

Drive Side Guide ArmS25-321-00A

Idler Side Guide ArmS25-322-00A

Guide Block Pivot PinS25-323-03A

Servo Valve CapS25-324-01

Servo Valve SpoolS25-323-05

Servo NeedleS25-324-03'O' Ring 3/4"x1/2"x1/8"

Idler Side Guide BlockS25-3241-00A

Guide Arm Handle HubS25-327-01PLastic Tub 1/2"ID x 3 1/4"LGRod 1/2"NC x 4 1/2"LGBall 1 3/8"DIA x 1/2"NCRoll Pin 3/16"DIA x 1 1/4"LGRod 5/8NF x 3 2/8"LGFlat Washer 1/2"ID x 1 3/4"OD

Coolant NozzleCool-02

'O' Ring 1/2"ODx1/4"ID2 of Flat HEad Cap Screw10-24 x 1"LG

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

Carbide Loader BoltS25-323-01A

3 of Disc Springs1"OD x 1/2"ID x 0.35"

Front Carbide Pad1 1/4" BLADE CRB-125-41-001 1/2" BLADE CRB-150-21-00

Exterior Retaining Ring1/4" DIATop CarbideS25-324

Roll Pin5.16"DIA x 5/8"LG

Rear Carbide Pad1 1/4"BLADE CRB-150-42-001 1/2" BLADE CRB-150-22-00

Flat Head Cap Screw3/8"NC x 3/4"LG

4 of Hex Head Bolt1/4"NC x 3/4" LG

Head Nut1/2" NF

Drive Side Guide Block AssemblyCarbide Loader Bolt S25-323-01ABlock Pivot Shaft S25-323-03ACarbide Loader Hub H16-461-01Rod Handle S20-328-03Knob 1"DIA x 1/4"NC3 of Disc Springs 1"ODx1.2"IDx.035Retaining Ring Exterior 1/4"DIAPlastic Tube 1/4"IDx2 1/4" LGRoll Pin 5/16"DIAx2"LGFlat Head Socket Head Cap Screw 3/8"NC x3/4"LGTop Carbide CRB-TL-770FOR 1 1/4" BLADEFront Carbide Pad CRB125-41-00Rear Carbide Pad CRB125-42-00FOR 1 1/2" BLADEFront Carbide Pad CRB150-21-00BRear Carbide Pad CRB150-22-00B

6

.

1

Guide Arm Clamp BlockS25-32-02

GEAR BOX ASSEMBLY- Cover S25-33-01-Roll Pin1/8"DIA x 7/8"LG- Spur Gear Boston NA20B-1/2"- Snap Ring Spae Naur R3100-100- Spacer Sleeve S25-33-04- 2 of Bushing Boston 1620-8 1" ID x 1 1/4" OD x 1" LG- Gear Box Weldment S25-331-00- 2 of Bushing Fiberglide CJS-1812- 1" Shaft Collar Ring Ball- Crank Shaft S25-3302 -02- Roll Pin 5/16" DIA x 1 3/4" LG- Crank Weldment S25-333-00- Hex Bolt 1/2" NC x 1" LG

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

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

3 of L/Washer3 /8"

-Rack Shaft Assembly S25-332-00- Gear Rack S25-332-03

Guide Arm BracketS25-33-03

4 of Hex Bolt1/2" NC x 1 1/2" LG

2 of Nex Nut1/2" NC

2 of 1/2" F/Washer

Hex Jam Nut3/8" NC

HandleJergens 32114

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

4 of 1/2" L/Washer

GUIDE ARM RACK ASSEMBLED

GUIDE ARM RACK ASSEMBLY 6 . 2

Shaft ExtensionS20-025-02

BearingFAG W6433-2

Set Screw3/8" NC x 2 1/2" LG

Hex Nut3/8" NC

Set Screw1/4" NC x 1/4" LG

Bearing PlateS20-922A-00

Friction WheelS20-925-03

4 of 3/8" Flat Washer2 of SpringTrakar MW 123

2 of Threaded Rod3/8" NC x 5" LG2 of 3/8" NC Hex Huts

BLADE BRUSH ASSEMBLY

BLADE BRUSH ASSEMBLED

Hex Nut1/2" NC

2 of 1/2" Flat Washer

2 of Blade Brush1/2" ID x 3 1/2" OD M311 1/2

6

.

3

Pulley SpacerS25-371-01

Pulley Shim371-04-060 Thick371-05-020 ThickAs Required

Key5/16" x 5/16" x 2 3/8" LG

Key Retainier Waldes5015-137

Speed IndicatorLenze HA1524:1 Ratiowith Hyd-Mech labelS25-95-30A

4 of Hex Bolt3/8" NC x 3/4 LG

Speed AdjusterLenze 11.430.25.931

6 of Hex Bolt3/8" NC x 5/8" LG

Drive Housing OuterS25-3712-00

Hex BoltM12 x 130

Key8mm x 10mm x 60 mm

Drive PulleyLenze 11.213.25.92038mm Bore

Drive BeltLenze47x1060mm

Key10mm x 16mm x 100mm

Gear BoxHM5

4 of Hex BoltM16 x 70 or 75mm

Gear Box Mounting BracketS25-312-04

Blade Drive WheelS25-3-07

Blade MotorUS Motors10HP 1800 RPM215 TC Frame TEFC

Drive Housing, InnerS25-3711-00

2 of Hex BoltM16 x 50mm

DRIVE ASSEMBLED

Drive Wheel KeeperH16-4-02

Hex BoltM20 x 60mm

2 of Socket Head Cap Screw1/2" NC x 1 1/2" LG

2 of Set Screw1/2" NF x 1 1/4" LG

Mechanical PulleyLenze 11.213.25.9111 3/8" Bore.

Drive Wheel Cap SpacerH16-4-03

DRIVE ASSEMBLY

Adjuster Handwheel HA 15 x 15

6

.

4

SpacerS25-3-03B

2 of Bearing6308 2RS

Snap RingN5000-354

RetainerS25-3-04

1/2" L/Washer

Hex Bolt1/2" NC x 1 1/2" LG

Hex Bolt5/8" NC x 6" LG

5/8" L/Washer

Hex Nut5/8" NC

Blade Tension CylinderS25-C5-00

Hex Nut5/8" NF

Rod End5/8" DIA CM-10 RH

Hex Bolt5/8" NC x 2 1/4" LG

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

Carrier WeldmentS25-3411-00

Idler Wheel ShaftS25-3-02

10 of Hex Bolt1/2" NC x 1 3/4" LG4 of Hex Bolt

1/2" NC x 2 1/2" LG

Base PlateS25-341-01

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

2 of Idler TrackS25-341-02

2 of Grease Nipple1/8" NPT

Idler WheelS25-3-06

14 of 1/2" L/Washer

IDLER WHEEL ASSEMBLED

IDLER WHEEL ASSEMBLY6

.

5

2 of Snap RingN5100-237 Cylinder Mount

S25-533-00A

VISE CYLINDER ASSEMBLED

Hex Nut3/4" NC

3/4" L/Washer

Hex Bolt3/4" NC x 5 LG

Vise CylinderS25-C3-00

Vise Hose JCT BlockS25-6-05

6 of 1/2" L/Washer6 of Hex Bolt1/2 NC x 2 LG

'O' Ring2 1/4" ID x 2 5/8"OD

VISE CYLINDER MOUNTING ASSEMBLY

2 of

6

.

6

VISE ASSEMBLED

Front ViseS25-534-00

2 of Hex Bolt1/2" NC x 3" LG

3 of 1/2" L/Washer

2 of WasherS25-32-05

Hex Bolt1/2" NC x 2 3/4" LG

Vertical Wear StripS25-2-04

Vertical Wear StripS25-53-06

Vise KeyS25-53-02

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

Vise GibS25-53-03

2 of Wear SptripS25-2-01

Fixed Vise JawS25-2-06

2 of Roll Pin3/8" DIA x 2 1/2" LG

8 of Hex Bolt1/2" NC x 2 1/2" LG8 of 1/2" Spring Washer

2 of Vertical Wear StripS25-2-0532 of Flat Head Hex Cap Screws5/16" NC x 1/2" LG

FRONT TABLE ASSEMBLY6

.

7

ITRM # QTY. DESCRIPTION1 1 GEARCASE2 1 WORMSHAFT CAP3 1 WORMSHAF COVER4 1 WHEELSHAFT CAP5 1 WHEELSHAFT COVER6 1 WORMSHAFT SINGLE START7 1 WORMWHEEL 53 TEETH8 1 WHEELSHAFT9 1 WHEELSHAFT SPACER10 VAR WORMSHAFT SHIMS11 VAR WHEELSHAFT SHIMS12 2 TAPER ROLLER BEARING REF:3130913 1 TAPER ROLLER BEARING REF:3031214 1 TAPER ROLLER BEARING REF:3031415 1 OILSEAL 42X62X7 SEMI DUAL16 1 OILSEAL 65X90X8 SEMI DUAL17 1 WORMWHEEL KEY 0.625"X0.625"X3.75" R.B.E.18 12 LOW HEAD SOCKET CAP SCREWS M10X2519 12 LOW HEAD SOCKET CAP SCREWS M10X2020 3.5 L MOBIL SHC 632 OIL (NOT SHOWN)22 1 NAMEPLATE SIZE423 1 LUBRICATION PLATE SIZE 426 1 1/2" BSPT TAPER PLUG27 1 3/8" BSPT TAPER PLUG

S-25 GEARBOX ASSEMBLY 6 . 8

Drip TroughS25-82-00

SHUTTLE TABLE ASSEMBLED2 of Wear StripS25-2-01

Table WeldmentS25A-211-00

2 of Vertical Wear sptripS25-2-05

Fixed Vise JawS25-A22-06

8 of 1/2" L/Washer

7 of Hex Bolt1/2" NC x 2 1/4" LG31of 1/2" NC x 1 1/2" LG

2 of Roll Pin3/8" DIA x 2 1/2" LG

2 of RetainerS25-A22-02A

2 of Mounting KeyS25-A22-01A

4 of 1/2" L/Washer

4 of Hex Bolt1/2"NC x 1 3/4"LG

2 of Table Mounting KeyS25-A22-04

4 of Hex Bolt1/2"NC x 1 1/2" LG

4 of Hex Bolt1/2"NC x 1 3/4"LG

4 of 1/2" L/Washeer

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

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

Vise GibS25-53-03 Vise KeyS25-53-02

Vertical Wear StripS25-2-04

Hex Bolt1/2" NC x 2 3/4" LG

Rear ViseS25-532-00

3 of 1/2" L/Washer

2 of WasherT25-32-07

2 of Hex Bolt1/2" NC x 3" LG

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

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

SHUTTLE TABLE ASSEMBLY6

.

9

Auxillary RollerS25-312-00

SHUTTLE GUIDE ASSEMBLY4 of Set Scw.1/2" NC x 1/2" LG

4 of Hex Bolt3/8" NC x 3" LG

2 of Mounting BlockS25-24-012 of BushingS25A-312-022 of Bearing2RS-630707

Roller ShaftS25A-24-03

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

4 of 3/8" L/Washer

Rear Shaft Mounting PlateS25A-252-00A

Roller TrayS25A-242-00A

8 of WiperCUSTOM SEALH2250

Rear Cylinder PinS25-676-00

Hydraulic HoseHyd-Mech #12

Hydraulic HoseHyd-Mech #11

Cylinder Rod PinS25-675-00

8 of Wear Ring7"x1"x1/8" 702 Strip

Shuttle CylinderS25-C1-00

2 of Shuttle ShaftS25-A25-01

Front Shaft Mounting PlateS25A-251-00A

Shuttle Vise CarriageS25A-231-00A2 of Bearing HousingH12-231-00 Infeed Shuttle Track

S25A-2-01Shuttle SliderS25A-233-01AShuttle Slider Carrier WeldmentS25A-2331-00A

SHUTTLE GUIDE ASSEMBLED

6

.

1

0

Conveyor FrameS25A-311-00

4 of Hex Bolt3/8" NC x 5/8" LG

4 of Hex Bolt1/2" NC x 2 1/2" LG

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

2 of Roll Off GuardS25A-31-01

4 of Roller AssemblyS25-A312-00- 1 of Roller Tube S25-A312-01- 2 of Bearing 6307-2RS- 2 of Bushing S25-A312-02

4 of Shaft WeldmentS25-A313-00

4 of Hex Bolt3/8" NC x 5/8" LG4 of 3/8" L/Washer

INFEED CONVEYOR ASSEMBLY6

.

1

1

Head CylinderS25-C4-00

- Thrust Washer Torrington TRF-3648- Thrust Washer Torrington TRB-3648- 2 of Bushing S25-4-04- Horizontal Pivot Shaft S25-3-01- 3 of Hex Jam Nut 3/8" NF- 3 of Soc. Set Scw. 3/8" NF x 1 1/4" LG

Pivot Link WeldmentS25-41-00

- Spring Shaft Weldment S25-3421-00- 2 of Springs Dieco MH81

Angle PointerS25-9-01

Angle ScaleS25-9-21

Grease Fitting1/8" NPT Straight

- Damping Plate S25-4-02- 2 of Support Washer S25-4-03- 2 of Bushing S25-4-04

Vertical Pivot ShaftS25-4-01

PIVOT LINK ASSEMBLY 6 . 1 2

2 of Shaft Collar1 1/8" DIA 1 PC Split

Head Swing CylinderS25-C7-00 2 of Rod Wiper

Custom Seal D1125

WasherS20-3-10 Hex Bolt1/2" NC x 1 1/4" LG

2 of Cylinder PinS25-625-00

2 of Fl. Hd. Soc. Cap Scw3/8" NC x 3/4" LG

Hex Head Bolt1/2" NC x 1 3/4" LG1/2" NC Hex Head Nut

Rod End1/2" DIA1/2" NF Hex Nut Angle Stop ShaftS25-43-01

HEAD SWING ASSEMBLY6

.

1

3

Hose Adapter1/4"NPT to 3/8" DIA HoseVersa 125-6B

Elbow Adapter1/4"NPT Male to 1/4" NPT FemaleVersa 139-6B

Needle Valve1/4"NPT Male to 1/4" NPT FemaleVersa 3120-B

1/4 NPT adapterLock-LineHose 12" LGLock-Line36401

NozzleLock-Line36403

Coolant Hose3/8" DIA x 18" LG

Check "Y"S20A-82-02

Coolant PumpLittle Giant 502186 2E-NT

Wash GunContinental22.CB

ConnectorVersa 193-6

Coolant Hose3/8" DIA x 23' LG

Coolant Hose3/8" DIA x 16' LG

NOTE: Coolant tank not shown S25-81-00

COOLANT SYSTEM ASSEMBLED

COOLANT SYSTEM ASSEMBLY

Hose Adapter1/4"NPT to 3/8"DIA HoseVersa 125-6B Elbow Adapter1/4"NPT Male to 1/4" NPT Female

Versa 139-6B

Needle Valve1/4"NPT Male to 1/4" NPT FemaleVersa 3120-B

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

Coolant Hose3/8" DIA x 6' LG

- Junction Block S20-8-01- 2 of Elbow Adapter1/4"NPT to 3/8" DIAHoseVersa 139-6B- Hose Adapter1/4"NPT to 3/8"DIAHose

6

.

1

4

Material Stop FlagS20-01122-00 Material Stop BracketS20-911-00

KnobS20-912-02

Material Stop ShaftS25-0112B-01

FenceS25-0112B-02

Outfeed TableS25-0111B-01

Outfeed Tray WeldmentS25-01111B-00

- Knob Assembly S20-914-00- Clamp S20-912-00

OUTFEED TABLE ASSEMBLY

Material Stop FrameS25-01121B-00

6.15

Arm WeldmentS25-7221-00

Hex Bolt1/2" NC x 2 1/2" LG

Mounting LeverS25-722-03

Hex Bolt1/2" NC x 1 1/2" LG 1/2" L/Washer

Mounting ClampS25-722-04

B