YAMAZAKI YAMAZAKI MACHINERY WORKS, LTD. x 1, Norifune} Oguchi-cho, Niwa-gun, Aichi-pref., Japan Phone: Oguchi (05879) 5—1131 Telex: J59777 Ir Cable: “MAZAK” NAGOYA YAMAZAKI MACHINERY CORPORATION, LTD. 8025 Production Drive, Florence, Kentucky 41042 U.S.A LJ Phone: (606) 7275700 Western Union Telex 214674 YAMAZAKI MACHINERY EUROPE N.V. Research Park Grauwmeer 7 3030 Leuven, Belgium Telephone: (016) 230902 = Telex: 62552 MAZAK B Created with @ nitro’ professional dowload thefre tril online at sttepdfzonprfessional“MAINTENANCE MANUAL & PARTS LIST = FOR Quick im | CHUCKER « UNIVERSALryN EN OY OS, A: CONTENTS GENERAL DESCRIPTION ..... 1-1 Introduction .. 1-2 Instructions for Safety Maintenance Operations 1-3 Name of Machine Parts FROM MACHINE INSTALLATION TO TRIAL OPERATION 2-1 Environment 2-2 Air Source 2-3. Foundation Plan .... 2-4 Installation Procedure .... LUBRICANT AND COOLANT 3-1. Oiling and Greasing Points .. 3-2 Lubrication of Slideways and Ball Screws 3-3 Construction and Inspection of Coolant Equipment 3-4 Pneumatics .. 3-5 Power Chuck «. 3-6 Turret. TAIL STOCK 4-1 Tailstock Body 4-2 Switches on Machine . 4-3. Adjustment of Limit Switch .... 4-4 Zero Return 4-5 How to Determine Home Position . 4-6 How to Fix Home Position 4-7 Replacing Shear Pin ADJUSTMENT OF MACHINE UNITS 5-1 Alignment of Headstock .. 5-2. Inspection of Belt... : 5-3 Inspection and Adjustment of Gibs and Wipers 5-4 Adjustment of Backlash 5-5 Aligning Tailstock 5-6 Trouble and Troubleshooting 9 ST. A DF’ é-] BLECTRICAC , lwsTA CCA TERRI. “Rratess! AdSALSWATD Page 14 or] 1-2 1-4 24 24 2-2 23 2-5,1. GENERAL DESCRIPTION 1-1 Introduction This manual describes the following items for the machine operators and maintenance engineers to consult it when necessary so that QUICK-TURN can provide its performance consistently with less down time. 1) Necessary items from machine installation to trial operation. 2) Necessary items to maintain QUICK-TURN at its best conditions. 3) Necessary items for replacing spare parts. 4) Necessary items to pinpoint the cause of the encountered troubles and those to restore the machine functions. Since it is very difficult to list up all possible troubles and defects of the machine which are traceable to a variety of causes, and virtually impossible to cover all of those troubleshooting and repair procedures, please directly contact us or local servcice stations if you cannot find apporpriate instructions in this manual for the encountered trouble. . Created with 0 ni tro? professio nal Sn ero ne a j | | | | | |Instructions for Safety Maintenance Operations Carefully read the following instructions before starting maintenance and repair jobs and be sure to strictly observe them to assure safety of the service engineers and to accomplish necessary work efficiently. (1) Preliminary Items 1) Check the machine to be serviced by yourself at the machine installation place. 2) Plan the followings according to the checked results ‘* Range of maintenance * Maintenance sequence © Maintenance time ‘* Necessary number of maintenance engineers © Costs 3) If necessary, contact the engineers of other sections for co-operative maintenance. 4) Prepare replacement parts and consumable parts necessary for the intended maintenance, such as packings, seals, O rings, bearings and lubricant. 5) Before starting maintenance, be sure to get well acquainted with the specifications, construction and functions of the machine. 6) Keep all measuring instruments and service tools in a good, ready-to-use condition. Discard the excessively worn tools and use new ones. 7) Keep the records of all preventive and corrective maintenance jobs that have . been carried out. (2) Safety Maintenance Mechanical Maintenance 1) The maintenance engineers should dress suitable for safe maintenance job. (Clothes, shoes, safety cap and safety glasses) 2) Hang a tag which informs other operators that the machine is now under repair or inspection 3) Keep sufficient servicing area so that maintenance job can be carried out without obstructed, 4) Use the instruments and tools that suit the individual job requirements. 5) When handling heavy objects (20 kg or more), be sure to handle them by two or more operators or using a crane. Created with nitro professional dowrloadthefre trl online a stepafcom professional 42Operation of the fork lift truck or crane, or hoisting work can be done only by an authorized personnel. Use wire or nylon slings with sufficient strength enough to withstand the weight of the machine unit to be lifted. When more than two or more operators are engaged in the maintenance job, be sure to communicate each other to safely proceed the maintenance job step by step. Use a ladder or bench when maintenance job is to ber done at a high place. The servicing area should be lighted properly. Use the recommended brand of hydraulic oil, lubricant and grease, or equivalent ones. Electrical Maintenance 4) Electrical maintenance should be carried out only by an authorized electrical engineer. 2) Be sure to turn off the main power disconnect if the live parts will cause hazards to the maintenance engineer. i 8) When the maintenance job is to be done with power removed, be sure to hang the tag telling "DO NOT TURN POWER ON’ on the main power disconnect, 4) Never touch electrical wiring or controls with wet hands. 5) Never try to tamper with the controls used to set macine controls data unless required. 6) Use the fuses and wires of the specified rating. (3) After-Maintenance Instructions 1) Check the serviced points again for normal operation. 2) Discard the defective and worn out parts, and used oil according to the regulations of your company 8) Turn over the machine to the section in charge after cleaning the machine and service floor. Take the records of the maintenance job and inspection results. Submit the relevant records to the sections concerned , it necessary. Created with @ nitro™ professional 1 dowload thefre rl online at aitepdicon professional1-3 Name of Machine Parts (1) Electrical contro! panel (7) Oil pan (2) Headstock (8) Chip conveyor (3) Operator's control console (9) Power chuck (4) Turret (10) side cover (8) Tailstock (11) Transformer (6) Front cover @ nitro” professional ve dowload thefre trl online a stpafcom professional a2. FROM MACHINE INSTALLATION TO TRIAL OPERATION 2-1 Environment Avoid the following places to install the machine. 1) The place exposed to direct sunlight, near heat source, or subjected to large temperature change. 2) Humid place 3) Dusty place 4) Place near a vibration generating equipment 5) Weak soil Notes: 1. If the machine is to be installed at a place near a vibration generating equipment provide vibration insulation pit around the machine foundation or other suitable measures to protect the machine from the vibration. 2. If the machine is to be installed on a weak soil, reinforce the subsoil by driving piles to prevent settling or tilting of machine installation™ foundation. Created with @ nitro” professional a download the free trial online at nitropdficom/professional2-2 Air Source Since the clamp mechanisms of the machine are actuated pneumatically, ari source as specified below is necessary: Pressure 5 kg/cm? or higher Delivery 100 Ni/min or more Use a compressor of 1 HP output. Note: If the supply air contains water content or if air temperature is very hign, it will cause the pneumatic equipment to be damaged. In these cases, it is necessary to provide auxiliary equipment such as an air drier in the pneumatic circuit. As will be detailed later, the air to be suppplied should be filtered by a mist separator of 0.3 filtration capability. Created with | i @ nitro” professional A dowload thefre trl online a stp com professionaldownload the fre trl onine at sitrepdicon professional @ nitro” professional creatdPaith 23 d wae jonuoe 8.194 (METRIC SYSTEM) UNIVERSAL qweudinbe On| eued ronuo9 \eoui0913} 2-3 Foundation Plan VnCHUCKER (METRIC SYSTEM) paces 2 ened a Loar i & ‘oor ffi 2 i a | 3 M16 x 920 150 x 150 x 16 Y Chip bucket 1185 an ‘Chip conveyor 3 anne | Hh 58 1 B oF : om war we | ~ 09ve a } an ne ae a. @ nitro’ professional dowload thefre trl online a stop com professionalvou! aun S i 2 & 2 a = & € 2 2 o © & = Z 5 1109 vonepuno} Jo 12190 punoi® oar uP WSO X GOTT K SOS # vexanq duo TeUIaES ju 1aMog Tor@AUe® dig ear oF Suz eg LH ~ croatSRBh ie ued 10 oF se), % ‘wozti ras wa [we ST) @ nitro” professional dowload thefre trl online a step com professional 25 ‘iu ay| CHUCKER (INCH SYSTEM) foundation 307 g | 3 z 3 5 2 5 8 é 8] seettasr] |e * 6 9.045) 9.845, I 7.845] } Trans a , ll pan 20.348 20.725 Operating 95 <3) iene at iy 3 Tee" si Neetroee| fl oe r our 7a"| croncta ed @ nitro” professional dowload thefre trl online a attend com /professonal 2624-1 2-4-2 Installation Procedure As a machine tool builder, itis our prime concern that the machine can maintain its accuracy for a long time and that the machine can provideits designed performance consistently. Machine installation has a great influence on these two points and even the QUICK-TURN finished extremely accurately cannot provide the required performance if installed poorly. Please carefully read the following installation instructions to install your machine in the same conditions as it was built so that it can provide the disigned performance consistently. Packing ‘The machine is disassembled into the following units for transportation’ a) Machine proper b) Covers ©) Tool holders, accessories, etc, ) Chip conveyor and chip guard (option) Transportation When transporting the machine, great care should be exercised so that machine proper, NC equipment, electrical control panel and other units are not subjected to shock load. Before lifting the machine, be sure to check that each unit is fixed properly and that there is no object on the machin. The machine may be lifted only in the manner indicated below: The machine is provided one eye bolt and two lifting bosses. Hook the wire slings of 20 mm dia. or larger around them andlift the machine using acranewitha capacity of 5 tons or larger. Be sure to place wooden blocks or rags between the wire slings and the machine where the wire slings directly contact. Created with 0 ni itro”F professional dowload thefre trl online a sttopdfcom professional4) Crane with minimum 7.5 tons capacity 2) Wire sling with minimum 20 mm diameter 3) Lifting boss wa = 4) How to Fift the Machine Notes: 1. The machine should be well balanced when lifted. Before lifting the machine, check tobe sure that itis in well balanced by lifting it slightly. 2. The angle between the wire slings should be less than 60° when lifting the machine, 3. When lifting the machine with two or more operators, be sure to confirm safety of the intended operation by exchanging signs each other. Created with nitro” professional p dowload thefre trl online a step com professional 282-4-3 After bringing the machine to a place where it is installed, place the foundation bolt and foundation plate on the leveling holes of the machine while the machine is lifted. Lower the machine then so that the foundation bolts are properiy installed in the pits made according to the foundation plan. Since the leveling bolts are not used in this step, place them above the lower surface of the bed. As the machine is first leveled using wedges, place the wedges near the foundation pits. Cleaning After placing the machine on the wedges, remove the rust-preventive coating from the Isideways and other metallic surfaces with rags soaked with cleaning oll. After removing rust-preventive coating, apply the specified lubricant to the slideways Since the rust-preventive coating is apt to be contaminated with grits or dust while transportation, never try to move the machine units until the coating is completely wiped off. Note: When cleaning the machine, great care should be exercised so that cleaning oil may not flow through the wiper. Created with 0 ni tro? professional dowload thefre trl online a stp com professionalMaAzAK AATAL oO 3. LUBRICANT AND COOLANT 3-1 Oiling and Grea: g Points Supply only the specified lubricant to the proper lefvel of the tanks. When replenishing or changing the lubricant, refer to the table provided below. ‘The lubrication period is based upon eight hours operation a day be + J a No. Part Name Lubricating Point ity Recommended Oil Remarks Air fiter ‘Teresso 32 (ESSO) Check every § or 7 days 1 Regulator Air instrument 0.11 D.7.E oll light (MOBIL) and refill clean the filter Lubricator (0.03 gal.) Tellus 32 (SHELL) every year. Air hydro ‘Teresso 92 (ESSO) Check every 6 months 2 booster Tail stock 0.05/ D-T.E. oil light (MOBIL) and refill (oly universal) (0.01 gal.) Tellus 32 (SHELL) 3 Line titer Febis K68 (ESSO) Check every § or 7 days 4 Olltank Slide way 1.81 Vactra No.2 (MOBIL) and refill clean the (3.14 gal.) Tonna oil T68 (SHELL) filter every year. Created with ie @ nitro” professional dowload thefre trl online a stop com professionalMAZBK Lathe Greasing Points List —Spindle NN Bearing Spec. — Spindle front bearing Mobilux No. 2 (Mobil) 129 Spindle rear bearing Multemp LRL-3 (Kyodo Yushi) 6g/bearing Other bearing Multemp LRL-3 (Kyodo Yushi) Proper amount (80% af space volume) Oring groove Multemp LRL-3 (Kyodo Yushi) Proper amount Gear teeth of high if maaien coupling Multemp LRL-3 (Kyodo Yushi) Proper amount Created with zl @ nitro” professional dowrload the fre trl online a stp com professionalMazak kathe 3-2 Lubrication of Slideways and Ball Screws Slideways of the bed and cross slide (X-axis and Z-axis) and ball screws are lubricated by the Automatic Lube Unit. Lubricant amount fed to each lubricating point is maintained at a predetermined amount by means of the flow unit. Ifatrouble takes place in the lubrication system causing the lubrication pressure to drop below 0.3 kg/om? (4.3 PSI), the pressure switch is activated, warning indication (LUBRICATION ALARM) appears on the CRT, and the machine is brought to a single block state intermittent lubrication pump, “aie | Created with a @ nitro” professional dowload thefre trl online a stop com professional1) Lubrication System Diagram — Slideways and Ball Screws — Te Fels Tee woo] I} [oor ponerse © Leaps © >sidenay @ =} © woo] =] {wes} __— Sirona wa} pevewy © i=} wear 6 [en] |—ssiiemy © + ‘ortsa’ © eo} ogune @ cross sie © 6 [ie] =} a] ot} 923 eco Os ca a? 8am © car 1 Jp Doers @ Created with @ nitro” professional dowload thefre trl online a stp com professional 34Sprocket 252) goa ps Tailstock @ a] eon} Te 6021 | soo] 9) Slidewey © Created with @ nitro” professional = dowrload thefre trl online a std com professionalMAZAK LATHE 2) Inspection of lube unit for slideways and ball screws a) Cleaning of filter Be sure to clean the oil filter in the oil tank every year. Remove the plastics lube oil tank by pulling it downward, and you can find the filter. The blue line filter at the side of the lube oil tank is a consumable part. Replace it every year under normal service conditions, or if delivery of the lube oil is reduced excessively. b) Inspection of lubricating points Before starting daily operation, be sure to check if each lubricating point is, properly lubricated. If any of the lubricating points is not lubricated, it is caused by clogged flow unit or leakage through lubrication piping runs. c) Clogged flow unit When coolant or impurities enter into the flow unit, check valve seat of the flow unit is clogged, causing it to fail to operate correctly. If the flow unit is, clogged, replace it with new one. Created with v @ nitro” professional dowload thefre trl online a stop com professional3) Troubleshooting of Automatic Intermittent Lubrication Pump Cause ¢ Then no lubricant is fed from the pump. Wrong pump drive motor rotating direction (except MMXL) Low oil level Clogged suction filter Plugged piping runs (collapsed, twisted, disconnected, etc.) No lubricant suction due to high viscosity Seized inlet check valve at open position Seized outlet check valve at open position ‘* No pressure bilding-up No oil delivered from the pump due to any of the causes indicated above Defective check seat packing Worn V ring in the piston cylinder * No plunger operation Broken reducing mechanism due to reversal operation while initial ‘operation Defective cam Defective motor Worn worm wheel gear 37 Measures Reverse motor rotating direction Replenish the specified lubricant to the specified level (up to flange surface of the pump). Clean or replace the suction filter. ‘Change the lubricant, if necessary. Replace them Use the lubricant of the specified viscosity. Clean the check valve. Clean the check valve. Follow the instructions above Replace it with new one. . Replace it with new one. Replace, Replace the cam. 7 Replace the motor. Replace the worm wheel gear. Created with @ nitro” professional dowload thefre trl online a attend com professionalMNAZAK Lathe 3-3. Construction and Inspection of Coolant Equipment 1. Construction of Coolant Equipment The coolant reserved in the oil pan at the front lower part of the machine is pumped through the strainer and is supplied to the workpiece from the coolant nozzle above the spindle. 2. Inspection of Coolant Equipment 1) 2) 3) 4) 5) Coolant tank capacity Chucker type... . 67 / Universal type... 93 / Cleaning of strainer The strainer can be removed by turning it in the counterclockwise direction. Clean the strainer when delivery amount of the coolant becomes small Replenishing coolant If no coolant if supplied or the strainer in the coolant tank is exposed, replenish the coolant > Priming When starting the coolant pump after long machine shut down, be sure to prime the pump. Supply the priming water by removing the nipple at the delivery side until the coolant flows through the piping run. Coolant pump Type NP-180J of Mitsubishi Electric make is used. For the details of coolant pump operation, refer to the instructions attached to this manual POF Srofessional dowrloadthefre trl online a step com professionalPneumatics ing Supply Air Shown in the following page are the air purifying systems. The compressed air usually contains water, dust, deteriorated oil, carbon particles and other foreign matter, and if the “dirty air” is used, various types of troubles of the pneumatic circuits and equipment will be resulted. Nine of ten troubles of the pneumatic equipment are caused by the “quality” of the air being used. And once a trouble takes place, it not only lowers production efficiency, but also requires the machine to stop for maintenance. For the system to operate without troubles, itis, of vital importance to supply clean air to the system. QUICK-TURN is equipped with the air control unit as indicated in the following page. Please select the proper air supply system meeting the quality of the air available in your shop. Created with 32 @ nitro” professional dowload thefre trl online a sttopdfcom professional2. Air purifying system Ponowes 6q uED ue s31e79, 99 UBD Tt 14 uBjo104 are Aiddns eu ‘99215 uoyepuowwosoy (rs) Mun jones ay (*¢0) 94% Bu oyeredas si ell (s) oreo! urn yonuos ary | sorezedas ysi¥y ‘- acm f (19) Wun jonu0s aly = (7 §1 01) 207 1 pavedesd oq a1) }Ok 0 a01n08 sy aq @ nitro” professional download thefre tl onine at sitepdicon professional 3-403. Pneumatic Circuit Diagram No. Part Name Maker Qty ‘Type 1 Solenoid valve Shoketsu 1 V4920-031VU 2 Silencer Shoketsu 2 AN-300 3 Air regulator Shoketsu 1 AR200-038 4 Lube unit Shoketsu 1 AUSI1-0981 i 3 Solenoid vaive Shoketsu 1 v410-021U 6 Silencer Shoketsu 1 AN-200 7 Pressure SW. ‘Shokeisu 1 1SG120-030 8 Speed controller Shoketsu 1 AS3100-02 ® Air regulator Shoketsu 1 ARI11-02 10 Solenoid valve Shoketsu 1 VS4310-0210 11 Silencer Shoketsu 1 AN210-02 12 Speed controller Shoketsu 1 AS2100-01 18 Air hydro booster ___Shoketsu 1 CAB63-01-10902 14 Solenoid vaive Shoketsu 1 4320-0210 : Tall stock chuck Turret lamp 5 aetna Body clamp = i 1 ae! LEI ® a eS io le | egos | aa @ © 4 al UF | be | Pte fi etal ro Be. (LD ~s an @ nitro’ professional dowrloadthefre trl online a stp com professionalAir inlet Regulator Filter \ Regulator Oller As stated before, 90% of the troubles of the pneumatic system is caused by inadequate “quality” of the supply air. The best way to prevent troubles of the pneumatic system is to supply clean air to the system. 5. Air Filter The filter adopts auto-drain system which automatically discharges the drained water from the bowl when it is accumulated to the certain level of the bowl. Connect vinyl hose to the drain port at bottom of the bowl to lead the drain water to the drain pit. It is necessary to check to every day if the drain water is properly discharged. Created with a2 @ nitro” professional dowload thefre trl online a stp com professionalDAZAK LATHE. @ 6, Reducing Valve Main line pressure of the pneumatic system should be set higher than 5 kg/cm The higher the pressure is, the more positively the pneumatic actuators can operate. The machine is equipped with the pressure switch to detect drop of supply air pressure. The pressure switch is factory-set to actuate at 4.5 kg/cm? and if the source pressure drops lower than 4.5 kg/cm? due to trouble of the compressor or other causes, it is actuated to stop the machine instantaneously. 7. Oiler The oiler serves to add a slight amount of lubricant to the air, thereby lubricating the actuators. Recommended lubricant and amount of lubricant consumption are shown below: Lubricant Teresso 32 (Esso) grade DTE Oil Light (Mobil) Tellus 32 (Shell) Oil drop of oil per 5 liter of air. consumption © 1 drop per 2 cycles of standard chuck cylinder operation © 1 drop per 30 steps of turret index * 1 drop per 5 cycles of tailstock spindle movement Adjust oll consumption amount to meet the instructions indicated above. Description of each unit element is provided in the following pages. Created with an @ nitro” professional dowrload the fre trl online a stp com professional8. Chuck Operation Control Pneum: Circuit Pragsure switch x oA | @—-fiPh | i> The chuck operating cylinder equipped as a standard accessory is actuated pneumatically. The pressure of supply air is limited to 5.5 kgf/cm? from the capacities of the cylinder and chuck | Standard chuck and cylinder | Chuck HO1MAB-A6-J Cylinder . .... HO6CB255-R196 Maximum set pressure . .. 5.5 kgf/cm? Created with @ nitro” professional dowrloadthefre trl online a stopdfcom professional 3149. Turret Clamp Pneumatic Circuit TT Hy Turret index is done by an induction motor and cimap of itis secured penumatically. No special adjustment is required for this circuit. Created with @ nitro” professional dowload thefre trl online a stp com /profssonal 3-1510. Tailstock Spindle Control Pneumatic Circuit Inside the tailstock body are the valves to control the tailstock spindle operation. The black knob at the center is used to adjust the tailstock spindle thrust which is indicated on the thrust meter, and the two smaller knobs on both sides are used to adjust spindle advance speed. 11. Adjusting Spindle Advance Speed (Flow Control Valve) Main control valve (®) Under normal operation conditions, this knob is used to adjust the spindle advance speed. Sub control valve (®) When very low thrust or very slow spindle advance speed is required, use this knob in addition to the main control valve adjust knob. Created with ae @ nitro” professional dowrload the fre trl online a stop com professional12. Tailstock Base To obtain higher clamp force of the tailstock base, the machine is equipped with the air-hydro booster. With the air supplied to one side of the cylinder, output of the cylinder at the opposite side having the section area of about one sixth of the one supplied with air is increased. Above the air-hydro cylinder is the oil pot. If the oil in ‘this potis used up, the air is sucked instead of the oil thereby decreasing the tailstock base clamp force remarkably. Be sureto replenish the oil to the pot every six months. If the booster sucks the air, push the both pins of the solenoid valve on the air-hydro booster. This unclamps the tailstock base allowing the’oil to be replenished. e Created with : ar @ nitro” professional dowrloadthefre trl online a sttopdfcom professionalRefer to the instructionmanual for the air-hydro booster prepared by the maker, which is attached to this manual Created with nitro” professional p dowrloadthefre trl online a sitpdicom professional 318The machine is equipped with a power chuck as a standard chuck and an air oylinder. Instructions for the power chuck and air cylinder are given in this section 3-5 Power Chuck ‘on the models indicated below: Power chuck . HO1MAB-AB-J (HOWA) nee Air sylinder . . . -. HOO6CB2550R196 (HOWA) Maximum speed . 4000 rpm 5.5 kgf/em? 6900 kg (while stationary with a pressure of 5.5 kgf/em’) Maximum pressure Maximum chucking force * Chucking force decreases as chuck speed increases and at 4000 rpm, it is about 1/2 of the maximum chucking force. Croated with | ae @ nitro” professional dowload thefre trl online a step com profes3-5-1 Inspection and Maintenance of Power Chuck ‘ aw nut g @ ~ [bee jaw (Chuck body ~ YL ataster jaw fe eect ‘Dust prooter Nut —weage plunger Draw tube Pilot bushing Mount screws Detail fo Power Chuck * Grease weekly through the grease nipple on the master jaw, * After finishing a daily work, be sure to clean the chuck surface. * Clean and grease each component part with removing the master jaws every three months at least. ‘* Disassemble and clean the chuck every six months. Replace the parts if worn Disassembling Procedure 1) Remove the top jaw. 2) Remove the dust prooter. 8) Remove the pilot bushing. 4) Unscrew the stop machine screw at the back of the master jaw, 5) Pull out the plunger from the chuck body by tapping it with a wooden hammer. 6) Remove the master jaw from the chuck body. Reverse the procedure above when assmebliriattetattbck. @ nitro” professional dowload thefre trl online a sttepdfcom professional 3-203-5-2 Maintenance and Inspection of Air Cylinder Since the air cylinder has a built-in check valve, inspect the pressure inside the cylinder every three months. To measure the inside pressure, supply the compressed air to the pressure measuring side and then shut off air supply after mounting the pressure gage to the two pressure detecting ports on the periphery of the cylinder. The same procedure applies when measuring the pressure of the opposite side. The allowable pressure drop is 30% of the setting pressure in 12 hours. After completing a daily work, discharge the drain from the air control unit. The drain accumulated inside the cylinder should be discharged from time to time by supplying low pressure air (about 0.5 kgf/cm) with removing the PT1/8 plug on the cylinder periphery. If the temperature of the distributor gets higher than “ambient temperature +25°C”, or if noise is generated from the distributor, replace the bearing of the distributor. Before starting a daily work, check to be sure that the cylinder can work normally by manually operating the valve two to three times. Created with an @ nitro” professional dowrloadthefre trl online a stp com professional3-5-3 Trouble and Troubleshooting Trouble Probable Cause Measures Piston motion is slow. Pressure of the air is lower Ithan the setting pressure Check the air control unit and source pressure. Piston stroke is short [The nut is going to be disengaged. Secure the nut tight and then tighten the set screw. Thrust is lower than the specified value. Pressure of the air is lower Ithan the setting pressure, ‘Setting pressure is not reached die to worn packings. Check the air control unit and source pressure. Check air leakage through the cylinder and the internal pressure of the cylinder. If leakage is, found replace the packing(s). Check vaive fails to work normally. ‘There is dust on the built-in icheck valve. Check the internal pressure and clean the check valve if leakage is found. ‘Temperature of the dis- tributor is abnormally high or} noise is generated from Insufficient bearing lubricant. the distributor. 3-22 Replace the bearing. Created with @ nitro” professional dowrload thefre trl online a stp com professional1) Extract the air through the pressure detecting ports by removing the plugs in them. 3-5-4 Disassembly Procedure CAUTION: Compressed air spouts from the ports. 2) Loosen sixteen mount bolts (M8 x 30) on the rod cover and remove it. 3) Remove the nut fixing the piston body and piston rod. Before removing the nut, loosen the set screw. 4) Remove the piston rod by pulling it rightward. This completes disassembly of the cylinder. 5) With removing four socket head screws on the distributor shaft, disconnect the piston rod and distributor. 6) Hook the wire through the air bleed holes at the projection of the valve and, then, pull out the check valve body from the piston rod, 7) After removing the snap ring, pull out the valve and valve seat from the check valve body. When removing the snap ring care should be exercised not to lose it. 8) Loosen three cross-recessed pan head screws (M4 x 10) on the cover (B), andthe distributor can be removed. After that remove the snap ring and the remove the distributor body with the bearing. This completes disassembly. Cautions on Disassembly | When disassembling the cylinder, be sure to leave match marks on each component part. s Cautions on Assembly Be sure to keep the component parts away from foreign matter. Coat them with enough grease. Created with an @ nitro” professional dowload thefre trl online a sttopdfcom professional3-6 Turret Construction of Turret Turret is rotated by the induction motor. 1. Turret Index Rotation of the motor shaft (|-shaft) is transmitted to Il-and II|-shaft, and then to IV shaft to index the turret. \ lsat isha ea Ba a 2. Clamp/Unclamp of Turret | Rotation of the motor shaft (I-shaft) is changed into vertical motion of the IV- shaft via the cam under Il-shaft and the lever (13). 4) [-shatt I-shatt leo anand é \, \ & fessional ioe area 3:24 dlowtioad there hl online S wiropdicom/profesinsl3. Aseries of turret index cycle, thatis, unclamp, index and clmap, is accomplished by the combination of turret index operation explained in item 1 and turret clamp/unclamp operation in 2. After turret index is completed, the air is supplied to the cylinders at parts A and B to clamp the turret firmly. c - D a A © =) ce a eg ay A Pg ad sey / A/S | // x ee I-shatt J / /\ashatt D shat 4, Confirmation of Turret Index Position of the turret is confirmed by the proximity switches PRS-1 and PRS-2 (21 and 218). Confirmation of turret clamp is made by the proximity switch PRS-4 (20) Motor rotation stop command is given by the proximity switch PRS-e (23). The respective proximity switches must be located at the center of the notches of the two dogs under the IV shaft when T4 command is provided. (Timing chart will be given later.) Dog position shown above corresponds to T1 command Created with an @ nitro” professional download thefre trl online a stop com professional6 As stated before, turret unclamp is made by the lever (13) andits vertical stroke is 5 mm at the position of pin (10). 5. Adjustment of Turret Unclamp. However, the lever stroke for turret unclamp shoud be set to 4.5 mm so that excessive force will not be applied to the lever (13) when turret is clamped. When the name plate and cap at the center of the turret is removed, socket head set screw inserted with split pin is shown at part C. To adjust the turret unclamp stroke, rotate the set screw at the center after removing the split pin with the turret clamped. After screwing in the set screw lightly up to the end of screwing- in stroke, loosen it about one fourth turns from such point. Rotate the turret two to three turns then to check to be sure that the set screw remains as adjusted without being secured, After that insert the split pin. This sets the turret unclamp stroke to about 4.5 mm Others To release the turret clamp force, turn the TURRET CLAMP switch at the back of the electrical control panel door to the OFF position. This releases the air and ‘clamp force. When removing the turret, use this switch. If the turret is tried to remove while the switch is placed in the ON position, the parts clamping the turret might be broken Created with co @ ni tro? professional dowload thefre trl online a stp com professional7. Replacing Turret When replacing the turret or when adjusting the turret if it is misaligned due to collision, follow the steps indicated below: 4) Index 71-1 position. (incase of turretreplacing) 2) After placing the SAFETY FREE switch on the door of the electrical control panel ON, turn the TURRET CLAMP switch at the back of the electrical control panel door OFF 3). Remove the name plate, cap and packing at the center of the turret. Turret clamp switen 4) Unscrew the set screw on the slotted round nut and then remove the nut using the special tool. Created with oe @ nitro” professional dowrload the fre trl online a stp com /profssgnal5) Screw in the flange of the specifal tool until the upper face of the flange comes to be flush with the upper face of the threaded shaft. After that screw in two M6 x 35 mm long camp screws into the turret to removeit from the center shatt. 6) After removing the flange of the special tool, remove the turret. This completes turret removal. When installing the turret, first set the turret on the center shaft with directing the T1-* face to the chuck side. Engage the teeth of the high index coupling positively and then follow the above indicated steps in the order of 4), 3) and 2). Created with PDF", f se @ nitro” professional dowload thefre trl online a stop com professionalAfter completing the intended work, be sure to return the TURREET CLAMP switch to ON. Turret index Is done with highly accurate high index coupling which should be kept away from dust and foreign matter. Clean around the turret before and after turret replacing and replace the turret carefully. Four boring bar holders fixed onto the turret are all self-bored on the machine. When drilling or reaming a hole which requires strict ity with respect to the spindle center, use these four concentric holders. Created with nitro” professional p dowload thefre trl online a stp com professional 3.298, Flow Chart — Turret Index Cycle Turret index commang aia | | Airsupply for turret SoL-1 Motor rotation BA" | | Clamauis shut off ON Turret unclamp ‘Turret rotation v ‘I | Indexed position | Completion of consistent signal Timer turret rotation pase Motor roation stop| at Clamp contirmation| signal PRS-3 Turrat clamp gene Air supply for turret Motor roattion stop| M14 OFF glam fe hurmed on [Completion of tur ret index Position confirmat Th 72 toe PRS1 ON ON OFF OFF PRSqoated@Ah OFF ON OFF @ nitro” professional dowload thefre trl online a stop com /profssgnal 3-30 joa] se oe sz ab oz gt ML on so a 9. Timing Chart — Turret Index 449 NO. | ago NO. a0} WO] 0] ao NO NO} WO] 0} Ho NO, 449 NO. HO NO. (No -Sua “G40 I-sua) puEWWoD EL xepuy youn yo (E44) weUD Bur ao NO (dors so1ou) Sud tro? professional dowrloadthefre trl online a stop com professional (uonewsyu0s vongod?y 2S (woreuuyuos vonts. isu @ prousjes 20100 3-31E uejoun, auseio xepuy 10114 puewica ON4, Tailstock 4-1. Tailstock Body Since the tailstock spindle is operated pneumatically, and as the air leaks through the valve slightly, the tailstock spindle gradually advances while it is located at a neutral position. It will cause hazardous conditions if chuck work cutting is done with the tailstock spindle focated at a neutral position for a long time. Be sure to locate the tailstock spindle at the retracted position by specifying a proper command when the tailstock spindle is not used for a long time, therefore. While MANUAL mode of operation, the tailstock spindle is located at the retract end positon when the tailstock spindle retract commands given. In AUTO mode operation, the tailstock spindle will not advance while the limit switch at the spindle retract end positon is turned on with the tailstock spindle retract command provided Note that the tailstock spindle will advance gradually if power supply is kept off for a long time. This is not a trouble, however. 1. Tailstock Base + Remove the front cover of the tailstock base, and you will see the hydro-booster provided at the rear of the cover. This hydro-booster is used to boost the tallstock base clamp force and if the oil of the booster is used up, it will result in very dangerous conditons as stated before. Therefore, be sure to check the oll amount of the hydro-booster periodically. Designed clamp piston stroke in the base is 0.5 mm. If piston stroke in unclamping gets large, it is because the oil amount is insufficient causing weak clamp force Adjustment of the piston stroke is made with the hex. nut at the center of the piston. Loosen the set screw first and then press ther two pins of the valve on the hydro-booster to unclamp the tailstock base. Rotate the nut clockwise fully after that. Then rotate it in the counterclockwise direction over 0°, and then return the nut clockwise to the position 50° to the fully closed point. With this setting, the piston stroke is set to 0.5 mm. Created with nitro’ professional dowload thefre trl online a stpdfcom professionalSet positon [Set ot this positon in clockwise rotation) et screw Created with @ nitro” professional ba dloweload the fre il online strand com/profesinsl2. Positioning Tailstock The tailstock is moved by the induction motor provided at the right end of the bed via the chains. Although the chains with minimum elongation are used, adjust them by pulling the sprocket of the headstock side leftward if the tailstock cannot be moved smoothly due to elongation of the chains. Proper amount of chains deflection is 2.4 mm as shown below when measured at the center of the two sprockets. When this adjustment is to be made, be sure to positon the tailstock at the retract positon. (At the center of the two sprockets) Deflection of 2.4 mm Fai) stock Created with @ nitro” professional dowrloadthefre trl online a step com professional a4-2 Switches on Machine — Arrangment and numbers of switches, motors and valves — — pet WB, | 8] Wz |[SOU-BA)[PAS-5][0-7] (eas) [ea] [ss SOL-36)|PRS-6 15:25; ts-21 Ma Spindle Drive Motor 5.57.5kW 2636370 Drives the spindle. (Mitsubishi) Ma ‘Coolant Pump Drive Motor 180 W NP-180J Vacuum type pump to deliver coolant (Mitusbishiy M7 Slideway Lubrication Pump Drive Motor aw MMXL Drives lube pump. (Lube) M14 Turrret Index Motor ‘20 W 0024-464 Unclamps, indexes and clamps the turret. (Oriental) M15 Tailstock Body Positioning Motor cow S1K-60GS-AF Moves the tailstock body in Z-axis direction. (Oriental) Mx X-Axis Drive Motor 0.8 kW H0-80-118 Servo motor to drive the cross slide (Mitsubishi) MZ Z-Axis drive Motor 08 KW HD-80-118 Servo motor to drive the carriage (Mitsubishi) M5 Chip Conveyor Drive Motor O41 KW. Used to drive the chip conveyor (Mitsubishi) SOL1 Turret Clamp 4110-0210 Controls air flow for turret clamp. (Shoketsu) SOL-8A Chuck Open V4320-031UN Created with (Shoketsu) @ nitro” professional . dowload thefre trl online a staf com professionalSOL-38 Chuck Close v4320-031UN Controls air flow to chuck operating cylinder (Shoketsu) SOL-23 Tailstock Body Unclamp \v4320-021U. Controls air flow for clamping the tailstock body (Shoketsu) against bed, SOL-24A— Tailstock Spindle Advance \vs4310-021U. (Shoketsu) SOL-248 Tailstock Spindle Retract vs4310-021U Controls air flow for tailstock spindle operation. (Shoketsu) Ls-15 Home Position — X-Axis SLI-EK Used for zeroing X-Axis. (Yamatake) isa7 Overtravel in Positive Direction — X-Axis| SLI-EK Protects X-axis move from overtraveling in the (Yamatake} positive direction. Ls-19 Overtravel in Negative Direction — X-Axis SLT-EK Protects X-axis move from overtraveling in the (Yamatake) negative direction Ls-21 Home Position — Z-Axis SLI-EK Used for zeroing Z-axis, (Yamatake) LS-23 _Overtravel in Positive Direction — Z-Axis SLI-EK Portects Z-axis move from overtraveling (Yamatake) —~ in the positive direction LS-25 _Overtravel in Negative Direction — Z-Axis, SLI-EK Protects Z-axis move from ovetraveling in the (Yamatake) negative direction Tailstock Body Advance End SLI-EK Limits tailstock body advance end position. (Yamatake) LS-32Tailstock Body Retract End SL1-EK Limits tailstock body retract end positon. (Yamatake) LS-33_Tallstock Spindle Advnace Confirmation SLI-EK : ‘ Detects tailstock spindle advance position. (Yamatake) LS-34 _Tallstock Spindle Retract Confirmation SLI-EK Detects tailstock spindle retract positon (Yamatake) PRS-1 Turret Position Confirmation BES 516-128, (Ballutt) PRS-2 Turret Positon Confirmation BES 516-128 | Turret indexed position is detected by the (Ballutt) combination of ON/OFF state of these two proximity switches. PRS-3 ‘Turret Index «BES 516-128 Controls ON/OFF of the turret index induction motor. (Ballutt PAS-4 Turret Clamp BES 516-128 Contirms turret clamp. (Ballutt) PRS-5 Spindle Drive Gear L Range BES 516-128 (Ballutf) PRS-6 Spindle Drive Gear H Range Created wth BES 516-128 Confirms presently selected gear range. i) sional 45 owrload the free tral online at sitropdf.com/professional4-3 Adjustment of 1. Micro Switch 2 8, somos obser) ge ut ze & oo \ se eat y\ EY \\ \A \\ Indicator line \ ina Upper surace of suten body Set the roller pressing-in stroke (roller stroke from actuated position to fully pressed-in position) to 1.8mm. Observe the indicator lines at the side of the roller when the micro switch reaches the most projected position of the dog: the upper surface of the switch doby (blue) should be at the center of the two indicator lines. 2. Proximity Switeh Adjust the position of the proximity switch until the clearance between the dog and the proximity switch is set to 0.5 mm = crested wth @ nitro” professional s dowload thefre trl online a step com professional4-4 Zero Return Zero Returen Sequence 1. Press the Zero return switch on the operator's contorl console. 2. Zero return the desired axis from a point more than 30 mm away from the home position by turning the monolever switch in the positive direction. | 3, The carriage (Z-axis) or cross slide (X-axis) moves ata rapid feedrate toward the home position. When the home position limit switch of that axis is actuated by the dog, deceleration for zero return signal is transmitted and axis traverse rate is decelerated. After that the axis moves at the decelerated speed. 4, When the grid point signal from the resolver is turned on after the home position limit switch is turned off, axis move stops and the axis is positioned to the home position. The home positioned indicator light goes on at the same time. Zora retun mode signal ann —I Ls/on LS/OFF Dex Deceleration signal for zero return (2 aes . Rapid Teedrate Oana > J Axis traverse rate | -0.8~ 12mm I Jf LS et se posi Created with @ nitro” professional oe dowrload thefres ial online a strepdfcom/prfesional@ 4-5 How to Determine Home Position X-Axis Z-Axis After carrying out OD turning on the test piece (round bar) clamped in the chuck, measure the finished diameter precisely (measured diameter = D). Bring the turret near the finished surface of the test piece and then measure the clearance between the turret front face and the test piece. Provided the measured clearance be Lx, present position of the turret can be calcualted in the following equation, a 125 i (125 + Lx D2) ‘As known from the program diagram, home position of X-axis is taken at a point 280 mm from the spindle center, move X-axis as much as [280- (125 + Lx +D/2)] observing the position display. Then the reached point is the home position on X- axis. Home position of Z-axis can be determined in the same manner a determining X- axis home position. Home position of: Chucker . 545 mm Universal . ... . 790 mm (from end face of the spindle) End face of ey the spindle | (L + Lz + 125) Created with 0 ni tro? professional dowrload thefre trl online a sttopdfcom professionalHow to Fix Home Position 1. Adjust the limit switch actuating stroke (1.8 mm). Axis stroke for limit switch kept ON (ON ~ OFF) X-axis.....31~ 32 mm Zeaxis 19 ~ 20 mm 2. Locate the turret at the home position in the manner as explained before. After resetting the position display to zero (0), set the dial indicator in the axis move direction. Press the dial indicator as much as 4 to 5 mm and set the pointer indication to zero by rotating the outer ring. 4. Adjust the position of the dog so that the limit switch is turned off ata point 2.5t0 3 mm to the home position. Carry out zero return operation. Enter the remaining distance to the home position following parameter ZPX(Z) After turning off power supply once, turn it on again and then carry out zero return operation. This positions the axis to the home position. 8. Adjust the dog position finally so that the limit switch is turned off at a point “value known in step 6 + 0.8 ~ 1.2 mm to the home position. * This adjustment is required only when the relative position of the resolver connected to the end of the ball screw with respect to the ball screw is mismatched when flexible coupling is disconnected, for instance. When the shear pin is broken or motor is detached, this adjustment is not necessary. 4-7 Replacing Shear Pin If the turret is sturck against a workpiece during axis move, the shear pin is broken thereby stopping axis move. Follow the steps indicated below to replace the broken shear pin X-Axis The shear pin is set in the timing belt pulley on the motor shaft. 1, Remove the cover fixed to the upper part of the carriage at the rear of the machine. 2. Align the match marks on the bushing and timing belt pulley by rotating the bushing using the manual pulse generator. 3. After inserting a screw of M4 x 20 mm long into the 4.5 mm dia. hole, rotate the bushing pulse by pulse until the set screw is positioned top. 4, Remove the screw. Created with 0 ni tro’ professional dowrloadthefre trl online a stpdfcom professional5. With loosening the set screw, rotate the bushing counterclockwise as much as 45° using the manual pulse generator. At this position tap the broken shear pin out of the bushing toward the motor shaft side. 6. Further rotate the bushing 45° counterclockwise and then tap the broken shear pin out of the pulley, 7. Align the match marks again. 8. Tap the shear pin painted yellow into the shear pin hole unitl the end face of it ‘comes to be flush with the bushing surface. 9. Fix the shear pin in position with the set screw. This ends replacement of the shear pin. Before starting machine operation, be sure to remove the cause of shear pin breakage. *Even when the shear pin is broken, the motor shaft can be rotated in manual mode operation “Use only the shear pin painted yellow for X-axis. *If one of the two shear pin holes is damaged, use another hole. “although there are two shear pin holes, use only one shear pin hole. . “A spare shear pin is supplied in the service tool kit box. | | Set screw ee a ra ‘Shear pin Match mark Bushing Extracting hole / Spare hole for shear pin_-~ \ Timing bett pulley Created with @ nitro” professional ea dowload thefre trl online a stp com professionalZ-Axis ‘The shear pin is set in the timing belt pulley on the motor shatt. Remove the machine side cover (main motor side). 2. Align the match marks on the nut and timing belt pulley by rotating the timing belt pulley using the manual pulse generator. 3. After inserting a screw of #5 x 30 mm long into the 6 mm dia. hole, (without M3 thread for set screw), move Z-axis (carriage) in the positive direction manually to ease replacement of the shear pin. Locate the shear pin hole top. Remove the bar. 5. Rotating the pulley as much as 60° in the convenient direction from the aligned position, tap the broken shear pins out of the nut and pulley through the larger holes on the pulley and nut, respectively. Align the match marks again. Tap the shear pin painted red into the shear pin hole unitl the end face of it comes to be flush with the periphery of the pulley. 8. Fix the shear pin in position with the set screw. This ends replacement of the shear pin. Before starting machine operation, be sure to remove the cause of shear pin breakage. “Even when the shear pin is broken, the motor shaft can be rotated in manual mode operation | “Use only the shear pin painted red for Z-axis “If one of the two shear pin holes is damaged, use another hole “Although there are two shear pin holes, use only one shear pin hole. A spare shear pin is supplied in the service tool kit box Created with @ nitro” professional & dowrloadthefre trl online a stp com /professonalShear pin ‘set screw Maten mark Extracting hole [16 mm cia.) =e Created with @ nitro” professional ace dowrlood thefres ial onlne a strepdfcom/profesional5. Adjustment of Machine Units 5-1 Alignment of headstock Since the headstock alignment is correctly adjusted before delivery, no adjustment is usually required after installation. However, if itis misaligned due to collision with the turret or other causes, adjust the alignment in the follwing steps. 5-5-1 Adjustment Procedure a) After setting a round test piece (650 x 300 mm long) in the chuck, carry out OD turning, b) Measure the cylindricity of the cut test piece using a micrometer to check if the front end of the test piece is thicker or thinner. ©) With placing the stem of the dial indicator at the front end of the test piece, set the Pointer reading to zero. d) Loosen the five headstock mount bolts. ©) Headstock alignment is done with one of the two adjust bolts on either side of the adjust block. Loosening one adjust bolt, tighten another bolt to correct the misalignment. When the front end of the test piece is thicker, shift the headstock toward the turret, and shift it away from the turret ifthe front end of the test piece is thinner. f) Secure the headstock mount bolts firmly. After that tighten the two adjust bolts evenly. Read the dial indicator to check to be sure that the headstock is shifted in the desired direction by a required amount. The reading will vary as the bolts are secured. 9) Cutthe test piece again as per item a). Ifthe result of the measurementstill fails to fall within the allowable limit, repeat the steps b) through g) again. Created with «= @ nitro” professional dowrload the fre trl online a step com professional5-1-2 Adjustment and Inspection fo Spindle Drive V Belts Tension If tension of the spindle drive V belt is adjusted too tight, service lives of the belt and bearings will be shortened. To the contrary, if adjusted weak slippage will result causing the rated motor output not to be transmitted. Adjust belt tension in the following procedure in the first three months after machine installation and then every six months after that. Adjusting Procedure a) Adjust the tension of V belt between the spindle and transmission gearbox. ') Adjust the tension of V belt between the transmission gearbox and motor. Notes: 1. Horizontally set the transmission gearbox and motor as accurate as. possible so that the shafts of them can be places parallel to the spindle. 2, Measure the tension of V belt at the center of the two pulleys. 3. Load should be applied to the V belt in right angle direction. Created with a @ ni tro? professional dowload thefre trl online at sitropdicon professionalProper Tension 2600 rpm Spec. Motor ~ Transmission gearbox 8V—875 5 pos. 4.2 mm/1.9 kgf Transmission gearbox ~ Spindle (L) 3V—S30 4 pcs. 6.7 mm/2.9 kgf Transmission gearbox ~ Spindle (H) 3V—530 4 pes. 6.7 mm/2.8 kgf 3600 rpm Spec. Motor ~ Transmission gearbox 3V—400 3 pos. 4.2 mm/2.2 kgf Transmission gearbox ~ Spindle (L) 3V—-530 3 pes. 6.7 mm/2.7 kgf Transmission gearbox ~ Spindle (H) 3V—530 3 pes. 6.7 mm/3.0 kgf ex) 6.7 mm kgt 1 For the pulleys of 3600 rpm spec., two V belt grooves between the motor and transmission gearbox and one between the transmission gearbox and spindle (both for Hand L) are not used. Set the V belt in the grooves near the rear side of the headstock and leave those away from the headstock rear side without belt. i Created with <2 @ nitro? professional dowrload the fre trl online a step com /professonal5-2. Inspection of V Belt The V belts used on this machine features good thermal resistance, oil resistance property, static-electricity-proof and longer service life. However, replace the belts when they reached the limitation of service life or wore out. 1) Service Life of V bvelt Standard service life of the V belt is about 10,000 hours of operation (about three years with ten hours operation per day). However, even within such limitation, replace the V belt if the following takes place: a) When the rubber lining is peeled off b) Only one or two belts are extremely slackened. c) When the belt is cracked at its side. 2) Precautions for Prolonging Service Life sat To ensure longer belt life, observe the fallowing points: a) Replace all pieces of V belts with new ones at a time. Replace all pieces of V belts with new ones even when only one or two belts are cut off, The combined use of new and used ones will reduce their total durability because their lengths and elasticity are unbalanced. b) When setting the belts on the pulleys, be sure to return the them along the adjust slide as near as possible each other. If set forcibly, the belts might be damaged. 3 : ¢) Cleaning of Pulley Gooves Oil ro dust adhered on the pulley grooves causes the belt to slip, thereby resulting in shorter life of it. 4 4) When placing an order for the V belts, be sure to specify “in matched set” in q addition to the type and number of them. (If the lengths of the belts being used are not equal, vibration and noise will be resulted. Therefore, it is necessary to use the lets of the same length so far as possible.) V belts between the transmission gearbox nd spindle should be used in matched set both for L and H range. §-2-1 Adjustment of Timing Belt 4. Timing Belt Use at Position Coder in Headstock Type of Timing Belt tao 2. Timing Belt Used at Axis Drive Unit Type of Timing Belt Tension * Tension adjustment procedure is the same, ag, Ta belt. PDF’ * ic @ nitro” professional dowrload thefre trl online a step com professional5-3 Inspection and Adjustment of Gibs and Wipers The clearance for the slideways on the carriage and cross slide can be adjusted with the gibs. Since the gib adjustment has great influence on lost motion, sensitivity for given pulses, and positioning accuracy, and further on out surfac roughness, adjust them carefully, Carriage (Z-Axis) 1. Remove the wiper. 2. Loosen all the bolts to allow the gib to move smoothly Merasure the backlash on Z-axis move and enter corresponding compensation data to the control. 4. Adjust the front gib first, and then the rear gib. Tighten the front bolt fully with the bolt at the opposite side left loose. After that return the front bolt about a halfturn and then turn the bolt at the opposite side counterclockwise fully to secure the gib in position with these two bolts. 5. Measure the lost motion, When the measured value is less than 0.01 mm, the adjustment is complete. If itis larger than 0.01 mm, readjust the gib. Created with © ni chem: - tro? professional dowload thefre trl online a stp com professionalGross slide (X-Axis) 1. Remove the wiper. 2. After loosening the upper bolt, press the gib upward to release the gib. Measure the backlash of X-axis move and enter corresponding compensation data to the control. With loosening the lower bolt, tighten the upper bolt fully. Return the upper bolt about a half turn from the fully tightened position. After that tighten the lower bolt fully to secure the gib in position. 6. Measure the lost motion. When, the measured value is less than 0.005 mm, the adjustment is complete, If it is larger than 0.005 mm, readjust the gib. Measurement of Lost Motion 1. Move the axis in the negative direction at a rapid feedrate as much as 60.000 mm. 2. Place the stem of the dial indicator onto the side face of the cross slide at the positive direction of axis move and then set the reading to zero. 3. Move the axis in the negative direction at a rapid feedrate as much as 50.000 mm. 4. Return the axis in the positive direction at a rapid feedrate by 50.000 mm. 5. Read the dial indicator. The read value indicates “lost motion” which expresses total accuracy of axis drive system Created with 56 nitro” professional pi al dowload thefre trl online a stop com professional4H 1) Dial indicator (set to zero) - a ae - 2) Backlash | | uy al + “ —— 3) Dial indicator indication 4) Set to zero i he 5) Read dial indicator indication Created with @ nitro” professional a download the free trial online at nitropdficom/professionalAdjustment of Backlash The resolver serving as a position detector of X- and Z-axisis directly coupled tothe axis drive ball screw. Therefore, difference between the actual turret position and resolver indication will result due to the following reasons. a) Backlash between ball screw and nut mount surface and other driving elements ‘engaging part of the axis drive system b) Improper gib adjustment c) Twisted ball screw The machine is equippped with backlash compensation function to electrically compensate for the mechanical difference. If the backlash is too large, shock load when starting axis move becomes excessively large, while too small backlash overloads bearings and gears causing shorter service life and noise. Although the backlash compensation amount is factory-set to a proper amount, re-setit when the set compensation amount becomes improper during long operation. Required backlash compensation amount can be set as a parameter data to the control. Created with @ nitro” professional oe dowrlood the fre ial onlne a strepdfcom/profesions5-5 Aligning Tailstock When a workpiece turned using the tailstock is tapered, align the tailstock spindle following the steps indicated below: 1) Clamp a test piece (round bar) in the chuck and then hold it with the taiistock spindle. The test piece should be clamped in the chuck as much as 20 to 30 mm. 2) Cut the test piece. 3) Measure the cylindricity of the cut test piece with micrometer by measuring the diameters ad A and B. 4) Placing the stem of the dial indicator onto the cut workpiece OD at tailstock side, set the reading to zero. 5) Loosen the bolts clamping the tailstock top to the tailstock body. 8) Alignment of the tailstock spindle can be done with the alinging bolts at the rear of the tailstock. Secure the aligning bolt (clocksiwe turning) with observing the dial indicator indication. This moves the tailstock body toward the secured direction. The amount to be moved is about two thirds of the measrued difference (a—b). . 7) After securing the tailstock body clamp bolts, cut the test piece again. 8) If the test piece is still tapered, repeat the steps 4) through 7) ag Th 9 35~ 20mm Created with 0 ni tro? professional dowload thefre trl online a stp com professional5-6 Trouble and Troubleshooting Coolant is not Supplied. Inspection Item Remarks 1 | Check the COOLANT switch on the operator's control console if itis set correctly. 2 | Check the strainer for coolant ifitis completely immersed inthe coolant. 3. | Check the strainer filter if itis clogged 4 | The coolant pump drive motor fails to start 5 _| Check the thermal relay of the coolant pump drive motor in the | electrical contro! pane! it itis tripped. Headstock is unusually hot. Inspection tem Remarks 1_| Check to see if the headstock is properly lubricated. 2 | lf preload of the spindle bearings is not properly adjusted, itwill : cause heat building-up of the headstock. Home position of X- or Z-axis fluctuates. Inspection ltem [Remarks 4 | Check the home position confirmation limit switch if it is . | secured in correct position. 2. | Is fluctuation amount 2 mm on position display reading? 3__| Check the resolver of the related axis ifit is mounted correctly Repeatability in positioning is poor Inspection Item Remarks 1_| Check the gibs if they are adjusted properly. 2_ | Check the slideway lubricated conditions it proper. Check the bolts and taper pins connecting component parts it | they are secure, 4 _| Check the resolvers if they are mounted properly. ‘Check the shear pins if they are broken. created with 5-10 @ nitro” professional download the fre tril online at sitrepdicon professionalE. Operation cannot be resumed atter collision Inspection Item Remarks [1 [1s the control in NOT READY state? 2_| Check the CRT if alarm no. is displayed. 3. | Check the shear pins if broken F. Chuck jaws fail to move. Inspection Item Remarks 1_| Check the setting pressure of pneumatic circuit if itis correct. 2 | Check the chuck operation pressure adjusting reducing valveif it Is set to correct value. +g. | heck the chuck jaws operation control solenoid valve if it works properly. 4. | Check the foot switch if normal 'g__| Check the relays operated by the foot switch operation if they operate normally. 6 | Check the wedge plunger and master jaws if they are seized up. E G. Jaw operation stroke is short. Inspection Item Remarks Check the position of the wedge plunger if itis set in a correct, . position. (Checkif the wedge plunger is struck against the cover 1 | or back plate. ‘Adjust the position of the wedge plunger by rotating the draw screw using an Allen wrench 2 _| Check the wedge plunger and master jaws if they are seized up H. Workpiece is tapered. Inspection Item z Remarks 7 | Ts he headstock correctly aligned? {in case of chuck work) 2 | sthe tailstock spindle correctly aligned? (in case of between centers work) Created with eat @ nitro” professional dowload thefre trl online a stop com professionalTailstock spindle cannot be moved. inspection Item Remarks 1 | Check the tallstock spindle thrust indication gage iit indicates proper value. > | Check the solenoid valve controling tailstock spindle operation if itis working properly. 43 | Check the relays actuated by the tailstock spindle operation commands if they can work normally. 14. | Check the tailstock spindle operation speed adjust valve if itis clogged. 5 | Check the lubricated conditions of the talstock spindle. I not properly lubricated, the spindle will be seized. Abnormality of the center of the rotating center. Inspection Item Remarks 1_| Check the tailstock spindle thrust if it is excessively high Check the bearing if it Is seized up due to excessively high 2 | thrust, which in turn results in braking, damage or other % trousles | . Tailstock body cannot be moved I Inspection Item Remarks + | Check the thermal relay of the tailstock body actuating motor | "i if itis tripped | 9 | Check the tailstock body actuating motor if it gets extraordinarily hot (80°C) | _ 3 Check the clamp cylinder iit unclamps the talstock basewhen | moving it. 4_|_Gheck the clamp solenoid if it works normally. [ '5 | Check the relays which are to be actuated by the move commands if they operate correctly. | & | Check the lubricated conditions of the tailstock base if itis- | seized due to poor lubrication | 7_| Check the tailstock drive chains if they are correct. | Created with 512 @ nitro” professional dowload thefre trl online at sitropdicon professional