Page 1 Maintenance Manual GS 42 GS 51 GS 150 SV 150 GS 200 SV 200 GS 250 SV 250 GS 250 L SV 250 L GS 200/66 SV 200/66 GS 200/66 L SV 200/66 L Original instructions Document Number GS 000950002 Issue J August 2011
Welcome message from author
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
Page 1
Maintenance Manual
GS 42 GS 51 GS 150 SV 150 GS 200 SV 200 GS 250 SV 250
GS 250 L SV 250 L GS 200/66 SV 200/66
GS 200/66 L SV 200/66 L
Original instructions Document Number GS 000950002
Issue J August 2011
Page 2
CONTENTS
Page
CHAPTER 1 – INTRODUCTION & SAFETY
1.1 Intended Use 4
1.2 Foreword 4
1.3 Protection for Machine Operators 5
1.4 Signal Word Definition 6
1.5 The Importance of Regular Inspections 7
1.6 Cautions to be Observed by Technicians 8
1.7 Checking the Function of the Safety Circuit 10
CHAPTER 2 – AIR AND ELECTRICAL LOCK-OUT PROCEDURES
2.1 Air Lock-out 13
2.2 Electrical Lock-out 13
CHAPTER - 3 – AIR SYSTEM
3.1 System Description 14
3.2 Setting the Air Pressure 15
3.3 Maintenance 15
3.4 Clean or Replace the Optical Scale Air Filter (OPT) 17
3.5 Pneumatic Schematics 18
3.6 Pneumatic Diagram 19
3.7 Tubing Safety Factor of Pneumatic System 21
CHAPTER - 4 – COOLANT SYSTEM
4.1 Introduction 22
4.2 Checking the Coolant Level 22
4.3 Chip Removal (Machines without Chip Conveyor) 24
4.4 Cleaning the Coolant Tank 25
4.5 Replacing the Coolant Pump 27
4.6 Coolant/Flush Piping Diagram 29
4.7 Cleaning the Filter of Coolant Thru-turret 30
Page 3
Page
CHAPTER 5 – HYDRAULIC SYSTEM
5.1 Introduction 31
5.2 Hydraulic Tank 31
5.3 Adjusting the Hydraulic System Pressure 33
5.4 Depressed Pressure for Emergency 34
5.5 Hydraulic Schematic 36
5.6 Hydraulic Diagram 38
5.7 Tubing Safety Factor of Hydraulic System 40
CHAPTER 6 – LUBRICATION
6.1 Introduction 41
6.2 Recommended Grease 41
6.3 Lubrication Alarm 42
6.4 Grease Volume 42
6.5 Axis Lubrication Procedures 42
6.6 Lubrication Line Replacement 46
6.7 Duplomatic Live Tool Drive Lubrication (Option) 47
6.7.1 Radial BMT-65 Turret 49
6.8 Chuck Lubrication 50
6.9 Clean and Lubrication on Working Area 50
CHAPTER 7 – MISCALLANEOUS
7.1 Battery Maintenance 51
7.2 Turret Zero Reference 53
7.3 Adjusting the Tailstock Bushing for Center 54
7.4 Cleaning the Linear Guideway of Tailstock for Chips 55
7.5 Cleaning the Power Case Heat Exchanger Air Filter 56
7.6 Cleaning the Power Case Plenum fan Air Filter 56
7.7 Guard Door Interlock Switch 57
7.8 Vision Panels 58
7.9 Maintenance and Cleaning of Spindle Chiller Oil (Option) 58
7.10 Spindle Chiller Tubing Diagram (Option) 60
7.11 Restart after chuck exchanged 61
7.12 Safety Warning for Top Jaw and T-Nut Placement 62
7.13 Operation of Steady Rest Feature 63
APPENDIX ONE – Preventive Maintenance Schedule 66
Page 4
CHAPTER 1 – INTRODUCTION & SAFETY 1.1 INTENDED USE
GS/SV Series CNC Lathes
1.2 FOREWORD
This maintenance manual describes inspection procedures. Since the daily and regular inspections to be carried out by machine operators are very important in maintaining machine accuracy, operators are required to carry out proper inspection and maintenance in accordance with the details given in this manual. The illustrations in this manual are used as examples. Depending on the machine, the shapes of systems may differ from the illustrations in this manual. Before carrying out any maintenance work, ensure that the machinery is switched off and disconnected from the main power supply. Also ensure that the necessary warning signs and /or locks are appointed to stop any unauthorized persons from switching the power on to the machine until the work is complete and the machinery is safe to operate. The above warning signs or indications should be secured by a semi-permanent means with the printing clearly visible. Only qualified and competent maintenance engineers should carry out machinery maintenance work. Working on live electrical equipment must be carried out only by suitably qualified electricians. Over travel limit switches, proximity switches and interlock mechanisms including all functional parts should not be removed or modified. Never use compressed air to clean dirt or chips from the machine. Air pressure could force dirt particles and other foreign material past seals and wipers. When working in high places, use steps or a ladder which are maintained daily for safety. Use only fuses, cable's etc. from reputable recognised manufacturers.
The maintenance person should check that the machine operates safety after the work is completed. Maintenance and inspection data should be recorded and kept for reference.
Page 5
1.3 PROTECTION FOR MACHINE OPERATORS
Machine operators are responsible for the following: Carry out machining operations, programming, maintenance and inspection work in accordance with the details in the instruction manuals supplied with the machine. Only operators who have received proper training and have sufficient understanding of the caution information are allowed to operate or program a machine tool, or carry out inspection and maintenance work on it. With regard to safety related measures, operators must receive training at least once a year. Develop a thorough understanding of, and strictly observe the local regulations relating to the prevention of accidents and environmental conservation. Disposing of Industrial Wastes
Operation of the machine generates various industrial wastes such as chips, waste oil and coolant. Legal permission is required to dispose of such industrial wastes. Disposal of these wastes at locations other than approved sites will pollute the environment, cause environmental destruction, and adversely affect the plant and animal life in the area. Follow the local regulations when disposing of industrial wastes. Examples of industrial waste processing methods are given below: Waste oil & coolant: Entrust the disposal of waste oil and coolant to a party
qualified to dispose of industrial wastes or a service station with the appropriate facilities.
Chips: Entrust the disposal of chips to a party qualified to
dispose of industrial wastes or a party capable of metallic waste recycling.
Page 6
1.4 SIGNAL WORD DEFINITION
Various symbols are used to indicate different types of warning information and advice. Learn the meanings of these symbols and read the explanation to ensure safe operation while using this manual.
SYMBOLS RELATED TO WARNINGS The warning information is classified into three groups “DANGER”, ”WARNING” and “CAUTION”. The following symbols are used to indicate the level of danger.
Other symbols:
Indicates an imminently hazardous situation which, if not avoided will result in death or serious injury. The information described in the DANGER frame must be strictly observed.
Indicates a potentially hazardous situation which, if not avoided will result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided could result in minor or moderate damage to the machine.
Indicates the items that must be taken into consideration
Page 7
1.5 THE IMPORTANCE OF REGULAR INSPECTIONS.
Scheduled regular inspection and proper repair of the machine, carried out by a maintenance technician, is the key to long lasting machine accuracy. Take proper action to obey the operators who are in charge of daily inspection. Feel free to contact your Hardinge representative if you have any questions on the instruction manual, circuit diagrams or maintenance manual.
Before beginning maintenance
Listen to the operator in charge of the machine operation to understand the problem accurately. Study the actual condition and plan the repair range and steps. Study the specification, construction and functions of the machine portion to be repaired If more than two maintenance technicians must work on the machine, or if cooperation with other people in other sections is necessary, discuss the repair procedure with these people so that everyone understands what to do. Prepare spare parts and consumables to be used.
When changing parts, be sure to use only genuine parts specified by the authorized distributor. The distributor cannot be responsible for any trouble arising from the use of parts not specified by the distributor. Using parts that are not specified may not only impair the performance of the machine, it could also make the machine unsafe and could cause accidents involving serious injuries or damage to the machine. The machine warranty will be void also.
Page 8
1.6 CAUTIONS TO BE OBSERVED BY TECHNICIANS
1) Electrical wiring work should only be done by qualified electrical engineers. If a person with no knowledge of safe practices during electrical work undertakes wiring work he/she could receive an electrical shock.
2) Always isolate the machine power before carrying out inspections, repairs or maintenance. In addition set the isolator switch on the Control Cabinet to the OFF position and lock it, and place “UNDER MAINTENANCE” signs around the machine. If inspection or maintenance work is carried out on the machine with the power on machine elements could be moved and the inspection, maintenance personnel could be seriously injured.
3) Never touch a switch, button or key with wet hands.
4) If it is not properly grounded or is leaking current, you could receive an electric shock.
1) Machine operators and authorized personnel working inside the plant and in the vicinity of the machine must put their clothing and hair in order so that there is no danger they will be entangled in the machine. If you have uncontrolled long hair or loose clothing and it gets caught in the machine, you will be seriously injured. Always wear safety shoes and eye protection.
2) The parameters are set on shipment in accordance with the machine specifications, do not change them without first consulting the machine distributor. If the parameters are changed without consultation, the machine may operate in an unexpected manner, causing accidents involving serious injuries or damage to the machine.
3) The machine specifications are set before shipping so that the machine can deliver it’s full performance. Changing the settings without consultation may lead to accidents involving serious injuries, impaired machine performance and a considerable shortening of the machine service life. If the settings and or specifications have been changed or the machine has to be modified to meet the new machining requirements or due to changes in the operating conditions, consult the machine distributor.
Page 9
4) When two or more people are involved in Maintenance work, they must cooperate carefully and communicate as fully as possible. If one worker moves the machine without noticing another worker is inside or near the machine, they could be seriously injured.
5) When changing parts, be sure to use genuine parts specified by the distributor, the distributor cannot be responsible for any trouble arising from the use of such parts. Using parts that are not specified will not only impair the performance of the machine, it could also make the machine unsafe to operate and could lead to serious injuries or damage to the machine.
6) When using equipment such as wires, ropes and cranes, make sure that they can bear the mass to be hoisted.
1) Use service tools appropriate for the intended work. If the tools are not appropriate, parts could be broken or bolts not tightened properly, leading to machine failure.
2) Do not place service tools or parts directly on the slideways this could cause scratches or other damage to the slideways, adversely affecting the machines life.
3) Do not climb on top of the machine, if you lose your balance, you could fall off and injure yourself. Use a ladder or service platform when you have to work in high places
4) When moving a heavy object, always carry it with the help of at least one other person or use a crane. If you attempt to carry a heavy object by yourself, you could be injured.
Page 10
1.7 CHECKING THE FUNCTION OF THE SAFETY CIRCUIT
The Function of the Safety Circuit components should be checked after the machine is turned on and in normal operating condition. The maintenance technician should check that the machine operates safety (e.g. safety relay, interlocking switch or safety relevant components like timer in the interlocking or emergency stop circuits, etc) after the work is completed. Maintenance and inspection data should be recorded and kept for reference. Below is a list of the Safety Circuit Components and their function
Safety Component
Intended Function Test Procedure and Result
Main Isolator Located on the Electrical Cabinet.
To isolate main power to the machine
With the machine in normal operating mode and worklight on, first press the Emergency Stop Switch on the Operating Panel and then shut down the machine by turning the main isolator anti clockwise.
NORMAL RESULT: All power to the machine has been
removed and the worklight is OFF. With the machine in normal operating mode, press the Emergency Stop Device.
NORMAL RESULT:
Emergency Stop There are Emergency Stop devices on the Control Panel and remote handwheel (if fitted)
The Emergency Stop function is to disable the Servo Motors, Spindle Motor, thus disabling all the Axes, Automatic and Manual functions
All Axes feeds will be disabled. The NC and VDU will still be ON. The message “ EMERGENCY STOP” will be displayed
Axes Limits To stop over travel of the x, and z axes in both + and -directions
Each axis is also protected by software limits which are active prior to the hards wired switches being reached. Therefore it is not normally possible to test the operation of these switches.
If any of the Safety Devices are not functioning normally do not attempt to operate the machine.
Page 11
a) When an interlock is open (guard open) no axis movement is allowed when the mode selection switch is set to program.
With the moveable guard open and the feedrate override set to maximum, press one by one each of the axes jog keys NORMAL RESULT: The axes will not move.
b) When an interlock is open (guard open) the maximum Axes speeds are limited when the mode selection switch is set to manual.
With the moveable guard open and the feedrate override set to maximum, press one by one each of the axes jog keys NORMAL RESULT: The Axes speed will be no more than 2000 mm/minute as displayed on the VDU
c) When an interlock is open (guard open) the spindle is disabled. No rotation is allowed
With the moveable guard open, press the Spindle CW or CCW keys. NORMAL RESULT: The Spindle will not start.
d) When an interlock is open (guard open) no automatic cycle can be started.
Attempt to run an automatic cycle with the guard open. NORMAL RESULT: There will be no machine movement
Door Interlocks (Front Door)
e) When the guards are closed (interlocks closed), it is not possible to open the guard during an automatic cycle. After an automatic cycle is complete and the spindle comes to a complete halt it is possible to open the guard door.
Close the guard and start an automatic cycle. NORMAL RESULT: The interlock should be locked and it should not be possible to open the door until the program is stopped, and all axes motion (including spindle) has stopped.
If any of the Safety Devices are not functioning normally do not attempt to operate the machine.
Page 12
a) When door interlock switch is on the position “0” and the cabinet doors open, the machine power will remain ON.
With the machine in normal operating mode, turn the door interlock switch of electrical cabinet to position “0” and open the cabinet doors.
NORMAL RESULT: The machine power remains ON. (NOTE: Only to be used for maintenance purposes by qualified and competent maintenance engineers.)
Door Interlocks of Electrical cabinet (Cabinet Doors)
b) When door interlock switch is on the position “1” and the cabinet doors open, the machine power will be turned OFF.
With the machine in normal operating mode, turn the door interlock switch of electrical cabinet to position “1” and open the cabinet doors.
NORMAL RESULT: The machine power will be turned OFF.
If any of the Safety Devices are not functioning normally do not attempt to operate the machine.
Page 13
CHAPTER 2 - AIR AND ELECTRICAL LOCK-OUT PROCEDURES 2.1 AIR LOCK-OUT 1. Turn main air valve “C”, Figure 2.2, OFF. 2. Place a lock on the main air valve to prevent the valve from being turned ON. 2.2 ELECTRICAL LOCK-OUT 1. Turn main disconnect switch “A”, Figure 2.1, OFF. 2. Pull lock out tab out. 3. Lock out the main disconnect handle through tab.
The air lock-out procedure applies only to machines equipped with the optional parts catcher.
A
Figure 2.1 - Main Disconnect Switch Figure 2.2 – Air Filter Regulator for Optional Parts Catcher
Page 14
CHAPTER 3 – AIR SYSTEM 3.1 SYSTEM DESCRIPTION The air connection is located at the rear of the machine near the lower left corner. It is mounted on the side of the hydraulic tank, as shown in Figure 3.1 or 3.2. The incoming air line should have a minimum inside diameter of 3/8 inch [9.5 mm]. Air is supplied to the following: • The air nozzle, if fitted, is located on the front of the machine below the operator
control panel • The optional parts catcher Machines without Optional Part Catcher Machines are equipped with a quick disconnect fitting, as shown in Figure 3.1. Machines with Optional Part Catcher Machines equipped with the optional parts catcher are equipped with a quick-disconnect fitting, ON-OFF air valve, air filter/regulator, and air line lubricator, as shown in Figure 3.2. An air dryer may have to be added in the air line if the factory air has excessive moisture. When a machine equipped with the optional parts catcher is powered up, turn ON the air source and set regulator knob “A”, Figure 3.2, at a constant pressure from 70 psi to 90 psi [4.9 to 6.2 bars].
Figure 3.1 - Air Connection (Machine without Optional Part Catcher)
Figure 3.2 - Air Connection (Machine with Optional Part Catcher)
The air filter/regulator is equipped with an automatic drain.
Page 15
3.2 SETTING THE AIR PRESSURE 1. Turn main air valve “B”, Figure 3.2, ON. 2. Lift knob “A” up to unlock. 3. Rotate the knob in the appropriate direction to increase or decrease pressure as
needed. 4. Press knob “A” down to secure the pressure setting. 3.3 MAINTENANCE Air system maintenance consists of the following: • Cleaning the air system bowls • Replacing the air filter • Replacing the air lubrication oil Air Filter/Regulator 1. Turn main air valve “B”, Figure 3.2, OFF and lock out. 2. Twist filter bowl “C” 1/8 turn in either direction to release the bowl from the
filter/regulator head. 3. Clean the bowl with a lint-free cloth. 4. Unthread filter retainer “F” and remove air filter “E”, Figure 3.3. 5. Install the replacement air filter and the filter retainer. 6. Insert the bowl into the filter/regulator head and twist the bowl 1/8 turn in either
direction to lock the bowl in position. 7. Pull the bowl downward to confirm that the bowl is in place.
This information applies only to machines equipped with the optional part catcher.
Turn the air valve OFF and lock out before performing air system maintenance.
Notice the orientation of the locking lugs on the filter bowl when it releases from the filter/regulator head.
Page 16
Air Line Lubricator 1. Turn main air valve “B”, Figure 3.2, OFF and lock out. NOTE: Notice the orientation of the locking lugs on the filter bowl when it releases
from the lubricator head. 2. Twist filter bowl “D” 1/8 turn in either direction to release the bowl from the
lubricator head. 3. Properly dispose of the oil in the lubricator bowl. 4. Clean the bowl with a lint-free cloth. 5. Fill the lubricator bowl with the appropriate oil. Refer the list of approved air
system oils. 6. Insert the bowl into the lubricator head and twist the bowl 1/8 turn in either
direction to lock the bowl in position. 7. Pull the bowl downward to confirm that the bowl is in place. Approved Air System Oils CPC Circulation Oil R32 Mobil DTE® Oil Light Daphne Super Multi Oil 32 Shell Tellus® Oil 32 Esso Teresso 32 Castrol HYSPIN AWS 32
Figure 3.3 - Air Filter and Filter Retainer
Use care not to spill the oil in the lubricator bowl.
Page 17
3.4 CLEAN OR REPLACE THE OPTICAL SCALE AIR FILTERS (OPT)
Optical scale is an option that enhances the accuracy of the control to make more consistent parts. The air pressure switch is set at the factory and should not be adjusted. When the outlet air pressure is below 10 psi [0.7 bar], the air filters must be cleaned or replaced.
Clean or replace the filters as follows: 1. Turn off the air supply. 2. Unthread the outer shell from the head 3. Drain any water and contaminants from the shell. 4. Clean the shell with a lint-free cloth. 5. Clean or replace the filter(s) as necessary. 6. Install the shell on the head.
Optical Scale, Filter/Regulator Air Module (GS 150 L)
Page 18
3.5 PNEUMATIC SCHEMATIC
Auto Door(OPT)
Air blast(OPT)Air purge for Duplomaticlive tooling turret(OPT)
Chute rotation (Part catcher)(OPT) Sliding Cover
(Part catcher)(OPT)
GS/SV 150/200 & 200/66 / 250 series machines
Chute rotation (Part catcher)
(OPT)
Sliding Cover (PART CATCHER)
(OPT) Auto door(OPT)
Air blast(OPT)Air purge for Duplomaticlive tooling turret(OPT) Air gun
Air Purge(SPINDLE)
Optical Scale(X & Z axis)
coolant air
Switching the Coolant or Airthrough the turret
GS 42/51 machines
Page 19
3.6 PNEUMATIC DIAGRAM
Turret
Z AXISOPTICAL SCALE
X AXISOPTICAL SCALE
AIR PURGE(LIVE TOOLING TURRET)
AUTO DOOR
Chute rotation (Part catcher)
Sliding cover (Part catcher)
Air gun
Switching the Coolant or Airthrough the turret
Air blast (Headwall)
GS/SV 150/200 series machines
L0085
GS/SV 200/66 / 250 series machines
Page 20
Turret
Z AXISOptical scale
X AXISOptical scale
AIR PURGE(HEAD STOCK)
Air purge(LIVE TOOLING TURRET)
Autor door(Option)Chute rotation (Option)
(Part catcher)
Sliding cover(Option)
(Part catcher)Air gun
Switching the Coolant or Airthrough the turret
GS 42/51 machines
Page 21
3.7 Tubing Safety Factor of Pneumatic System
Material Nominal ODxID (mm)
Burst Pressure Min. (bar), 25℃
Working Pressure Max. (bar)
Safety Factor
UM0640 6x4 27 7 3.9 UM0850 8x5 27 7 3.9 UM1065 10x6.5 27 7 3.9
PU
UM1280 12x8 27 7 3.9 NB0640 6x4 80 7 11.4 NB0860 8x6 57 7 8.2 NB1075 10x7.5 40 7 5.7
Nylon
NB1290 12x9 30 7 4.3
Page 22
CHAPTER 4 - COOLANT SYSTEM 4.1 INTRODUCTION Hardinge machine tools are designed using the latest technology and highest quality materials available. However, due to the ever increasing number of coolant selections available, it is impossible to test material compatibility with each and every coolant. CAUTION: Whenever water soluble coolants are used it is important to use the manufacturer’s recommended mix ratio (concentration). It is also important to maintain the coolant by keeping the proper concentration level when coolant solution is added to compensate for evaporation. Another important factor is coolant Ph (acidity). Typically, the coolant Ph range is between 8.5 and 9.2. Below 8.5 the rust inhibitors in the coolant start depleting, which can result in corrosion of machine components. Also, the quality of the water should be tested by the coolant manufacturer so that the proper coolant additives can be administered. Failure to follow these recommendations could result in damage to the machine, seals, and paint. If the coolant you have selected starts to react (cause material to rust, pit, swell, soften, crack, or blister) with any portion of the machine tool, Hardinge suggests that you discontinue use and contact your coolant representative for alternative coolants. It should also be noted that certain chemicals react with different metals. Hardinge recommends that you consult with your coolant representative to assure that the material you are cutting does not react with the coolant you have selected.
System Description GS/SV Series CNC lathes have a coolant recirculation system for either oil-based or water-based coolant. The system consists of a coolant tank with filters, an electric pump, directional nozzles on the head wall and turret and a coolant catcher at the left end of the spindle. Most of the fluid drains down into the tank through the chip pan; however, some liquid returns to the tank through the hoses from the coolant catcher. The coolant system is ready when the machine is powered up. The Coolant ON/OFF push button alternately activates and deactivates the flow of coolant.
When coolant system maintenance is required, the machine must be powered down.
A properly selected and maintained coolant, either oil or water based, will ensure the best performance from the coolant and machine.
Page 23
The approximate coolant tank capacity is listed below in gallons [litres]:
Coolant tank capacity
Machine Model Liters US gallons Imperial gallons GS /SV 150 & GS 42 156 41 34 GS/SV 200 & GS 51 156 41 34
GS 200/66 & SV 200/66 290 77 64 GS 200/66 L & SV 200/66 L 360 95 79
GS/SV 250 290 77 64 GS/SV 250 L 360 95 79
4.2 CHECKING THE COOLANT LEVEL Check the coolant level through sight gauge “A”, Figure 4.1 or “B”, Figure 4.2.
Figure 4.1 - Coolant Sight Gauge
Figure 4.2 - Coolant Sight Gauge
Page 24
4.3 CHIP REMOVAL (MACHINES WITHOUT CHIP CONVEYOR)
GS/SV 150/200 & GS 42/51 Lathes 1. Power down the machine. 2. If coolant was ON, wait a few minutes to allow any coolant that was in use to
drain back into the tank. 3. Open or remove chip tray cover “C”, Figure 4.3. 4. Rake the chips into a suitable container. 5. Close or replace chip tray cover “C”. GS/SV 200/66 Series and 250 Series Lathes 1. Power down and lock out the machine. 2. If coolant was ON, wait a few minutes to allow any coolant that was in use to
drain back into the tank. 3. Roll the coolant tank from the front of the machine. 4. Remove two mounting bolts "D", Figure 4.4. 5. Rake the chips from chip pan "E" into a suitable container. 6. Align the tank with the machine and roll it into place.
C
Figure 4.3 - Chip Tray Cover
E
D
Figure 4.4 - Chip Pan Mounting Bolt and Chip Pan
Do not remove chips with your bare hands.
Page 25
Figure 4.5 - Coolant Pump Assembly
Figure 4.6 - Coolant Tank Screen and Filter
4.4 CLEANING THE COOLANT TANK GS/SV 150/200 & GS 42/51 Lathes Clean the coolant tank at least once every six months or more frequently if the coolant becomes contaminated by material being cut. Clean the coolant tank whenever changing the type or brand of coolant.
1. Power down the machine. 2. If coolant was ON, wait a few minutes to allow any coolant that was in use to
drain back into the tank. 3. At the right end of the machine, loosen wing bolts “G” to allow coolant pump “F”,
Figure 4.5, to be removed from the tank. 4. Pull the coolant pump from the tank and place in a bucket or other container to
catch any coolant which may drain from the pump. 5. Roll the coolant tank from the front of the machine. 6. Place a shallow pan under the drain plug at them end of the tank. 7. Remove the pipe plug to drain the coolant from the tank. 8. Remove filter “I” and screen “J”, Figure 4.6, from the tank. 9. Remove any coolant remaining in the tank and wipe the tank clean. 10. Wash the filter, screen, and coolant tank with a cleaner recommended by the
coolant manufacturer to remove any bacterial contamination. 11. Flush the cleaner from the coolant tank and clean it as necessary. 12. Apply pipe sealant to the pipe plug and thread it into the tank drain. 13. Replace the filter in the tank. 14. Mount the screen in the tank. 15. Align the tank with the opening and roll it into place. 16. Mount the coolant pump and secure with the wing bolts. 17. Fill the tank with approved coolant to the FULL line of the sight gauge. 18. Power up the machine. 19. Check for any coolant leaks and correct them as necessary.
GS/SV 200/66 Series and 250 Series Lathes 1. Power down and lock out the machine. 2. If coolant was ON, wait a few minutes to allow any coolant that was in use to
drain back into the tank. 3. At the rear of the machine, loosen wing bolts “G” to allow coolant pump “F”,
Figure 4.7, to be removed from the tank. 4. Pull the coolant pump from the tank and place in a bucket or other container to
catch any coolant which may drain from the pump.
Page 26
5. Roll the coolant tank from the front of the machine. 6. Remove the coolant from the tank by pumping it out into an appropriate container.
or – Remove the pipe plug and allow the coolant to drain from the tank into an appropriate container.
7. Remove two mounting bolts "K", Figure 4.8. 8. Remove chip pan "L", Figure 4.9, from the coolant tank. 9. Clean chip pan. 10. Remove three coolant tank screens “M”, Figure 4.10, from the tank. 11. Remove any coolant remaining in the tank and wipe the tank clean. 12. Wash the screens and coolant tank with a cleaner recommended by the coolant
manufacturer to remove any bacterial contamination. 13. Flush the cleaner from the coolant tank and clean it as necessary. 14. If the pipe plug was removed in order to drain the coolant tank, apply pipe sealant
to the pipe plug and thread it into the tank drain. 15. Install the screens in the tank. 16. Fasten the chip pan to the coolant tank with the chip pan mounting bolts. 17. Align the tank with the machine and roll it into place. 18. Mount the coolant pump and secure with the wing bolts. 19. Fill the tank with approved coolant to the FULL line of the sight gauge. 20. Power up the machine. 21. Check for any coolant leaks and correct them as necessary.
Figure 4.9 - Chip Pan and Coolant Tank
Figure 4.10 - Coolant Tank Screen
F
G
Figure 4.7 - Coolant Pump Assembly
H
G
Figure 4.8 - Chip Pan Mounting Bolts
K
Page 27
4.5 REPLACING THE COOLANT PUMP The coolant pump supplies coolant to the headwall and turret. The coolant pump assembly for GS/SV 150, 200 and GS 42/51 series lathes is located on the coolant tank at the rear of the machine. The coolant pump assembly for GS/SV 200/66 series and 250 series lathes is located on the coolant tank on the side of the machine. 1. Power down and lock out the machine. 2. If coolant was ON, wait a few minutes to allow any coolant that was in use to
drain back into the tank. 3. Disconnect the coolant pump cable from the machine. 4. Disconnect coolant hoses “N” and “O”, Figure 4.11 or 4.12, from the fittings on the
coolant pump assembly. 5. Loosen wing bolts “G” to allow coolant pump assembly “F”, Figure 4.5, or "F",
Figure 4.7, to be removed from the tank. 6. Allow any coolant present in the pump to drain back into the tank. 7. Remove the cover from electrical junction box “H”, Figure 4.5 or 4.7. 8. Record the electrical connections in the junction box. Refer to Figure 4.13. 9. Disconnect the three power wires and the ground wire. 10. Remove the retaining nut from the conduit fitting and remove the conduit
assembly from the junction box. 11. Remove the cover from the electrical junction box on the replacement pump
assembly. 12. Install the conduit assembly on the junction box on the replacement pump
assembly. 13. Connect the ground wire and three power wires as recorded in Step 8. 14. Mount the cover on the electrical junction box. 15. If necessary, remove the mounting flange from the old coolant pump assembly
and mount it on the replacement assembly.
Figure 4.11 - Coolant Hoses Connected to pump
N
O
Figure 4.12 - Coolant Hoses Connected to pump
O
N
Page 28
Figure 4.13 - Electrical Junction Box,
NOTE: Apply pipe thread sealant to the threads on the fittings. 16. If necessary, remove the fittings from the old coolant pump assembly and mount
them on the replacement assembly. 17. Mount the coolant pump assembly on the tank and secure using the two wing
bolts. 18. Connect the coolant hoses to the fittings on the coolant pump assembly. 19. Connect the coolant pump cable to the power case. 20. Power up the machine. 21. Check if the pump is functional.
Page 29
4.6 Coolant/Flush Piping Diagram
280 psi
40 psi
Head Wall
Turret
COOLANT TANK
Filter
L0080
GS/SV 150/200 & GS 42/51 series machines
280 psi
40 psi
Head Wall
Turret
COOLANT TANKL0084
Filter
GS/SV 200/66 / 250 series machines
Page 30
4.7 Cleaning the Filter of Coolant Thru-turret (OPT) The filter is equipped for filtering chips contains on the piping for Thru-turret coolant and mounted on the right or back of machine. The filter must be cleaned whenever there appears to be a drop in the thru-turret coolant pressure. The oil filter must be cleaned up periodically. In general the cleaning period is 400-450 hours. Cleaning Procedure as below: 1. Unthread 4 screws “A” on the both side of filter, Figure 4.15. 2. Take apart the bottom cup “B” of filter. 3. Take out the galvanized oil screen which contains the cup inside. 4. Blow off the oil sticks on the oil screen with high pressure air. If the oil sticks can
not be clean up, then using the diesel or oil remover. 5. Install the screen of filter after cleaned.
A
B
Figure 4.15 – Filter of Coolant Thru-turret
Figure 4.14a – Rear view for GS-SV 150/200/42/51 Machine
Figure 4.14b – Right-side view for GS-SV 200/66 / 250 Series Machine
Page 31
CHAPTER 5 - HYDRAULIC SYSTEM 5.1 INTRODUCTION The hydraulic unit is located at the rear of the machine. The hydraulic pump, which is driven by a 2 horsepower motor, provides a maximum of 580 psi [40 bar] operating pressure to the collet closer, spindle brake, turret, and tailstock. A 6-micron filter unit cleans the hydraulic fluid before it enters the distribution manifold. The following maintenance procedures have the greatest effect on the hydraulic system’s performance, efficiency, and life:
Replacing the hydraulic oil on a regular schedule. Maintaining a sufficient quantity of hydraulic fluid of the proper type and viscosity. Changing the filter on a regular schedule. Keeping air contamination out of the system. Keeping all connections leak free.
5.2 HYDRAULIC TANK The oil level should be maintained at or near FULL to ensure good system cooling, good air dissipation, and overall system performance. Verify the hydraulic fluid level with sight gauge “C”, Figure 5.2. Filling the Hydraulic Tank 1. Power down and lock out the machine. 2. Remove access cover “A”, Figure 5.1. 3. Wipe filler cap “B”, Figure 5.2, and the area around the filler cap clean. 4. Remove the filler cap and slowly fill the tank with approved hydraulic oil. Refer to
the list of approved hydraulic system oils. 5. Replace the filler cap. 6. Replace access cover “A”, Figure 5.1.
Hydraulic Tank Capacity
Hydraulic Tank Capacity
Machine Models Liters US gallons Imperial gallons
GS 150/200/250/250 L/ 200/66 /200/66 L
SV 150/200/250/250 L / 200/66 L / 200/66 L
GS 42/51
60 15.9 13.2
It is recommended that the machine not be powered up for at least 10 minutes after oil has been added to the hydraulic tank. This will allow any air bubbles present in the oil to dissipate.
Page 32
Figure 4.1 - Rear Access Cover
Figure 5.2 - Hydraulic System
Approved Hydraulic System Oils Mobil DTE®-13M Oil Nisseki SuperHyrando 32 Oil Philapak Caydol HVI32 Oil Shell Tellus Oil IS 32 Esso Univis N 32 Freedom High VI ISO32 CPC 32AW Caltex Rando Oil HD 32 Draining and Filling the Hydraulic Tank 1. Power down the machine. 2. Remove access cover “A”, Figure 5.1. 3. Place a drain pan capable of holding a minimum of
16 gallons [60 litres] of oil under drain plug “D”, Figure 5.3.
4. Remove the drain plug to empty the hydraulic tank. 5. Apply pipe sealant to the drain plug and install the
drain plug in the tank. 6. Clean and remove filler cap “B”. 7. Clean strainer “E”, Figure 5.4, with a solvent
recommended by the hydraulic oil manufacturer and let the strainer air dry.
8. Replace the strainer in the filler neck of the hydraulic tank.
9. Slowly fill the tank with approved hydraulic oil. Refer to the list of approved hydraulic system oils on the previous page.
10. Replace the filler cap. 11. Replace access cover “A”, Figure 5.1.
Figure 5.3 - Hydraulic Tank Drain Plug Figure 5.4 - Strainer for Filler Neck
Page 33
5.3 ADJUSTING THE HYDRAULIC SYSTEM PRESSURE The machine’s hydraulic system pressure can be adjusted by threading pressure adjustment screw “F”, Figure 5.5, IN or OUT. The hydraulic system main pressure gauge is located on the front of the machine. The main system hydraulic pressure should be set as below, Table Ⅰ.
1. Remove access cover “A”, Figure 5.1. 2. Loosen the adjustment screw lock nut. 3. Turn adjustment screw “F” as needed to increase or decrease system pressure. 4. Hold the adjustment screw while tightening the lock nut. Confirm that the system
pressure setting is correct or adjust as necessary. 5. Replace access cover “A”, Figure 5.1.
Table Ⅰ： The hydraulic system pressure (bar, Max.) for various machines and equipments
Note: “*” use on CE machines only.
Tailstock Pressure Switch setting Equipments
GS Series
Main Hydraulic Pressure
Turret Type Hydraulic Pressure Body
(opt) Quill Chuck
Chuck (A)
Chuck (B)
Main Hydraulic Tailstock
GS 150/200 SV 150/200
27 8* 8*
GS 42 20 5* 5*
GS 51
40 VDI 30 Vertical
35
Live Tooling
40
25 (40)
15 5* 5*
25* 12
GS/SV 200/66 & 200/66 L GS/SV 250 & 250 L
70 VDI 40 Vertical
40
Live Tooling
50 70 20 26~27 8* 8* 50* 17.5
Figure 5.5 – Hydraulic System Pressure Adjustment
The hydraulic system pressure adjustment is performed with the hydraulic pump motor ON. DO NOT allow machine operation while access cover “A”, Figure 5.1 is removed from the machine.
Page 34
5.4 DEPRESSED PRESSURE FOR EMERGENCY Means are provided at relevant danger zone and where residual risk exists for the movement of machine axes for emergency purposes (e.g. the release of trapped person). Drives power is OFF when emergency stop button has been pushed. If emergency hydraulic pressure release is needed, proceed as below:
1. Press at least 5 second on the manual active button of workholding solenoid “A” and “B”, Figure 5.6 and Figure 5.7, on both side for the chuck closer.
2. Press at least 5 second on the manual active button of solenoid “C”, “D” and solenoid “E”, Figure 5.6 and Figure 5.7, (2-speed ratio) on both side for the spindle brake.
3. Press at least 5 second on the manual active button of hydraulic cylinder/motor solenoid “F” and “G”, Figure 5.8 and Figure 5.9, on both sides for the tailstock body.
4. Press at least 5 second on the manual active button of solenoid “H”, Figure 5.9, on both sides for the tailstock clamp.
5. Press at least 5 second on the manual active button of solenoid “J”, Figure 5.10, on both sides for the tailstock quill.
6. Press at least 5 second on the manual active button of tool index clamping solenoid “K”, Figure 5.11, on both sides for the turret clamp.
C
A
Figure 5.6 – Control Valve Cabinet at left-side of GS-SV 150/200 & GS 42/51 series.
B
D E
Figure 5.7 – Control Valve Cabinet at left-side of GS-SV 200/66 /250 series.
Page 35
Figure 5.10 –Control Valve Cabinet at right-side for GS-SV 200/66 /250 series.
J
Figure 5.11 – Control Valve Assembly at Rear for GS-SV machines.
K
Figure 5.8 –Control Valve Cabinet at right-side for GS-SV
150/200 & GS 42/51 series.
F
Figure 5.9 – Control Valve Assembly at Rear of GS-SV 200/66 /250 series.
G
H
Page 36
5.5 HYDRAULIC SCHEMATIC
Dynamic Turning
Space Cover
Servo Turning Chuck
Standard Standard with C-axis
CE TAILSTOCKOil tank for hydraulic turretTAILSTOCK
GS-SV 150/200 & GS 42/51 Lathes
Servo turret ChuckC axis
Programe Tailstockwithout CE
Clamping Moving
Standard Standard with C- axis
Programe tailstockwith CE
Tailstock clamping
Clamping
MovingOil tank for hydraulic turret
GS-SV 200/66 /250 Lathes
Page 37
Dra
in
Ser
vo T
urre
tC
huck
C a
xis
Sta
ndar
dS
tand
ard
with
C a
xis
Tails
tock
cla
mpi
ng
Bre
akin
g
Cov
er
Mov
ing
Pro
gram
tails
tock
with
out C
E
Ste
ady
rest
and
pro
gram
tails
tock
with
CE
Pro
gram
tails
tock
with
CE
Bre
akin
g
Cov
er
Mov
ing
Ste
ady
rest
and
pro
gram
tails
tock
with
out C
E
Ste
ady
rest
Ste
ady
rest
Bre
akin
gB
reak
ing
Mov
ing
Mov
ing
L006
8
GS-SV 200/66 L /250 L Lathes
Page 38
5.6 HYDRAULIC DIAGRAM
L0083
GS-SV 150/200 & GS 42/51 for Hydraulic/Servo Turret, Chuck and Tailstock
L0082
GS-SV 150/200 & GS 42/51 for Live Tooling, Chuck and Tailstock
Page 39
Tailstock cartridge
L0087
GS-SV 200/66 / 200/66 L /250/250 L for Hydralic/Servo Turret, Chuck and Tailstock
Tailstock cartridge
中心架尾座移動
尾座鎖緊
L0086
GS-SV 200/66 / 200/66 L /250/250 L for Live Tooling, Chuck and Tailstock
Page 40
5.7 TUBING SAFETY FACTOR OF HYDRAULIC SYSTEM
Note: (1) These figures are available for GX/SV 150, 200 series Lathes.
(2) These figures are available for GX/SV 200/66, 250 series Lathes.
Material Nominal ODxID (mm)
Burst Pressure Min. (bar)
Working Pressure Max. (bar)
Safety Factor
R200-02 3.6x8.3 735 40 (1) 18.4 NBR Compound R200-02 3.6x8.3 735 70 (2) 10.5
HR10300000M-6 9.5x17.4 643 40 (1) 11.4 HR10300000M-6 9.5X17.4 643 70 (2) 9.2 HR10400000-8 12.7x20.7 571 40 (1) 14.3
Synthetic Rubber
HR10400000M-8 12.7X20.7 571 70 (2) 8.2
Page 41
CHAPTER 6 - LUBRICATION 6.1 INTRODUCTION We recommend that the machine is “Warmed up” prior to first operation by running all axes for 3 to 5 minutes at about half or one third the maximum speed and full travel (as condition possible) in the automatic operation mode before actual cutting. GS/SV 150/200, GS 42/51 series and SV 200/66, SV 250 series CNC lathe axes are grease lubricated at grease blocks mounted on the right side of the carriage. The grease system lubricates the ball screws and truck bearings on the linear guideways. Fresh grease should be added every 600 hours of machine operation or more frequently under severe operating conditions. The NSK K1 Seal® linear guideway used on the axes of GS 200/66 and GS 250 lathes are greased for life and require no further lubrication. Please contact your supplier if any abnormality is found.
Importance of Lubrication Running conditions of the machine, workholding systems, and equipment used on the machine, depend heavily upon the lubrication management. Make certain that the lubrication system is checked frequently under severe operating conditions to keep the machine in proper working condition. Lubricate workholding and ancillary equipment in accordance with the manufacturer’s instructions. 6.2 RECOMMENDED GREASE The following greases are recommended by Hardinge Inc. for use on the GS/SV series CNC lathe.
Grease Hardinge Grease Cartridge
Part Number
KLÜBER® Isoflex NCA 15 TT 0010994NCA
KLÜBER® Isoflex NBU 15 HS 00010994SL
Other greases may not contain certain additive packages needed for proper lubrication and performance.
When the grease lubrication system requires maintenance, the machine must be powered down.
Workholding and additional equipment must be lubricated and maintained in accordance with the manufacturers instructions.
Page 42
6.3 LUBRICATION ALARM The control issues an alarm message after 600 hours of operation. The lubrication alarm does not stop the machine, but will inhibit Cycle Start. Press the Reset and Feed Hold push buttons at the same time to clear the alarm. 6.4 GREASE VOLUME The grease volume presented is dependent upon the grease gun being used. Carefully measure the amount of grease or count the grease gun strokes necessary to lubricate the guides and ball screws. Be certain that all air is purged from any grease gun before use. The required amount of grease is:
Linear Guides: 3½ cc Ball Screws: 11 cc
Make certain that all the sliding surfaces are lubricated well by jogging the axes at 50% of the maximum rapid traverse for a full 30 minutes before resuming automatic operation. 6.5 AXIS LUBRICATION PROCEDURES X and Z Axis Lubrication 1. Wait for the cycle to end and that the spindles and slides are stationary. 2. Move the X and Z axes to the reference position. 3. Power down and lock out the machine. 4. Remove cover “A”, Figure 6.1, to gain access to the fittings on grease manifolds
“B” and “C”, Figure 6.2. 5. Clean the grease fittings.
NOTE: Only use a manually operated grease gun. GS/SV 150 & 200 Series and GS 42/51 Series Lathes Fitting “B” supplies grease to the X axis. Fitting “C” supplies grease to the Z axis. GS/SV 200/66 Series and 250 Series Lathes Fitting “D” supplies grease to the Z axis. Fitting “E” supplies grease to the X axis. 1. Attach the grease gun nozzle to each grease fitting; slowly and evenly pump in
the specified amount of grease.
The grease gun supplied with the machine delivers 3 cc per full stroke.
Grease should be added when the linear guides are still warm from operation.
Page 43
2. Wipe the fittings clean of excess grease. 3. Install cover “A”, Figure 6.1. 4. Power up the machine. 5. Jog the axes at 50% of the maximum rapid traverse for a full 30 minutes before
resuming automatic machine operation.
Figure 6.3 - Z Axis Grease Fitting
Figure 6.4 - X Axis Grease Fitting
A
Figure 6.1 - Rear Access Cover
Figure 6.2 - Grease Manifolds
B
C
Page 44
CENTRAL MANUAL GREASE SUPPLIER (OPT.) Central manual grease supplier “A”, Figure 6.2b, supplies grease to the X & Z axes linear guildeways and ballscrew which located on the left-rear side of machine. Recommended lubrication is every 400 hours of operation.
1. Open the door at the rear of machine. 2. Pull the lever of the central manual grease supplier 18 times.
Tailstock Lubrication on GS/SV 150 & 200 Series and GS 42/51 Series Lathes 1. Wait for the cycle to end and that the spindles and slides are stationary. 2. Move the tailstock toward the guard door opening to gain access to cover “F”,
Figure 6.5. 3. Power down the machine. 4. Remove cover “F”, Figure 6.5, to gain access to the fittings on grease manifold “G”,
Figure 6.6. 5. Clean the grease fittings.
NOTE: Only use a manually operated grease gun. 6. Attach the grease gun nozzle to each grease fitting; slowly and evenly pump in
the specified amount of grease. 7. Wipe the fittings clean of excess grease. 8. Replace cover “F”, Figure 6.5. 9. Power up the machine.
Recommended grade of grease
1) Castrol Spheerol L-EP 1 2) BP Energrease LS-EP 1 3) Mobilux EP 1
A
Figure 6.2b - Central Manual Grease Lubrication System
Figure 6.2a – Access door on left-rear side of machine
Page 45
Figure 6.7 - Tailstock Grease Fitting
10. Move the tailstock to the Home position. Tailstock Lubrication on GS/SV 200/66 Series and 250 Series Lathes 1. Wait for the cycle to end and that the spindles
and slides are stationary. 2. Move the tailstock toward the guard door
opening to gain access to grease fitting “H”, Figure 6.7.
3. Power down and lock out the machine. 4. Clean the grease fitting. NOTE: Only use a manually operated grease gun. 5. Attach the grease gun nozzle to the grease
fitting; slowly and evenly pump in the specified amount of grease.
6. Wipe the fitting clean of excess grease. 7. Power up the machine. 8. Move the tailstock to the fixed Home position. 9. If necessary, clear the 600 hour alarm by pressing the Reset and Feed Hold push
buttons at the same time.
Figure 6.5 - Grease Manifold Access Cover on Tailstock
Figure 6.6 - Tailstock Grease Manifold
Page 46
6.6 LUBRICATION LINE REPLACEMENT Replacement Part Numbers
Grease Manifold TT 0010234
Tubing TT 0007007
Replacing a Lubrication Line 1. Wait for the cycle to end and make certain that the spindle is stopped. 2. Remove cover “A”, Figure 6.1, to gain access to the grease manifolds and grease
lines. 3. Jog each axis until the grease/lubrication lines are accessible.
4. Power down and lock out the machine. 5. Check each lubrication line for damage. Before disconnecting the line being
replaced, measure the length and check the route from the grease manifold to either the linear guide or ball screw.
6. Disconnect the lubrication line and compare the length of the old lubrication line and the replacement lubrication line.
7. Before installing the replacement line, fill the line with KLÜBER® Isoflex NCA 15 or NBU 15 grease.
8. Install the replacement lubrication line: A) Connect one end of the replacement lubrication line at the grease manifold. B) Add the specified grease through its fitting until grease appears at the other
end of the lubrication line. C) Connect that end of the lubrication line.
9. Wipe the fittings clean of excess grease. 10. Install cover “A”, Figure 6.1. 11. Power up the machine. 12. Jog the axes at 50% of the maximum rapid traverse for a full 30 minutes before
resuming automatic machine operation.
Replace the lubrication lines one line at a time. The ball screw lubrication lines connect to the middle fitting (marked “BS”) on each grease manifold.
Page 47
6.7 DUPLOMATIC LIVE TOOL DRIVE LUBRICATION (OPTION)
Warning According to instruction Manual M.I.6486, Lubrication depends on working conditions, at least after 2000 – 2500 working hours. For adding or replacing of the lubricant, use proper hole on the top of MDT housing. Lubrication Alarm An alarm message appears after 2400 hours of operation. The alarm will inhibit Cycle Start. Press Reset and Feedhold simultaneously and holding 2 seconds minimum to clear the message. Procedure 1. Start the check after some tool rotation cycles 2. Stop tool rotation and remove plug P/N 126 on the top of MDT housing. 3. Introduce inside the hole a sharp tool and touch the gear below the hole. 4. Check the status of the tool tip:
4.1 No grease / Add new grease 4.2 Dark grease / Don’t Act 4.3 Grease-metallic dust mixture / Call Duplomatic Service Center 4.4 Grease-coolant mixture / Call Duplomatic Service Center 4.5 Grease-oil mixture / Call Duplomatic Service Center
Page 48
Size Ref. Description Code 12 126 Plug 1/16 “ NPTF 0570167 16 126 Plug 1/8 “ NPTF 0570168 20 126 Plug 1/8 “ NPTF 0570168
5. If it is necessary to add grease, use KLUBERSYNTH UH1 14-1600 (Cod. 0897155)
max. 40 cm3. 6. Close plug P/N 126 on the top of MDT housing. Adding Oil to the Duplomatic MDT System 1. Wait for the cycle to end, and for the spindles and slides to be stationary. 2. Jog each axis until the MDT system is accessible. 3. Remove the turret protection cover for replenishment when necessary. 4. Power down the machine. 5. Remove plug “I”, Figure 6.9. 6. Rotate gear while replenishing grease with the recommended lubricant.
Amount Type Manufacturers
30~40cm3 KLÜBERSYNTH UH1 14-1600 (Cod. 0897155) KLÜBER LUBRICATION
7. Replace the plug. 8. Power up the machine. Figure 6.10 – Replenish grease
Figure 6.9 – Remove grease plug Figure 6.8 – Live tool grease plug
I
Page 49
6.7.1 Radial BMT-65 Turret The drive lubrication of Radial BMT-65 turret is same as the live tooling turret as above.
Figure 6.10.1 – BMT-65 Turret
Page 50
6.8 CHUCK LUBRICATION
The chuck is designed to hold the workpiece at high rotational speed. Proper lubrication of the chuck is required for safe operation and maximum life of the chuck. Apply the grease to the grease nipple at the periphery end of each master jaw with a grease gun, Figure 6.11, a minimum of once a day. However, when the machine is operated at high speed rotation or a large amount of water soluble coolant is used, more of lubrication is needed according to service condition.
Suggested amount to be used for grease:
Chuck Type TF3B-6A5 TF3B-8A6 Grease amount (3 Places), ml
15 18
6.9 CLEAN AND LUBRICATION ON WORKING AREA Clean the machine and its accessories shall be taking after completed the work. Clean up the chips and wipe up the waycovers, vision panels and inside enclosure. Finally, wipe a coating of lubricant on the surface of movable parts (such as the table, waycover … etc), to prevent moving part get rust from the moisture of air.
1) Mobil Mobiltemp SHC32 2) ESSO Beacon Q2
Recommended Greases for Chuck (Containing disulphide molybdenum)
3) KITAGAWA Chuck Grease
Don’t miss any lubrication point! And supply the grease everyday. Clamp force will reduce, because of no lubrication.
Figure 6.11 – Grease nipples on the chuck
Nipples
Page 51
Figure 7.1 - Turret Controller (Non-Live Tooling Machines)
Figure 7.2 - Turret Controller Battery
CHAPTER 7 - MISCELLANEOUS 7.1 BATTERY MAINTENANCE The recommended replacement interval for the turret controller and CNC control batteries is once a year. Check the age of the batteries. Replace the batteries if they will expire before the machine is to be put back into service. The turret controller and CNC control batteries are located in the power case.
Turret Controller Battery (Non-Live Tooling Machines Only)
The turret controller can temporarily maintain memory for approximately 20 minutes without the battery backup. Battery Specifications: Manufacturer: Mitsubishi Battery Number: ER17330V Voltage Rating: 3.6 volt Battery Type: Lithium Use the following procedure to check or replace the control battery. 1. Power up the machine. 2. After approximately 30 seconds, power down the
machine. 3. Turn the main disconnect switch to the OPEN position
and open the power case door. 4. Open battery cover “A”, Figure 7.1. 5. Verify the new battery pack matches the battery pack
being replaced. 6. Disconnect the old battery from receptacle “B”, Figure
7.2. 7. Connect the new battery. 8. Install the battery and close the cover. 9. Close the power case door.
Make certain that the replacement battery is like the battery being removed. Check the battery voltage and receptacle.
Battery replacement can be done with the control turned ON or OFF. If the power is OFF, the change MUST be done within 20 minutes of when the power was turned OFF.
Page 52
CNC Control Battery – For Fanuc Control only
NOTE: Data will be held for 30 minutes with battery being removed. Battery Specifications: Ordering Code: A02B-0200-K102 FANUC Specification: A98L-0031-0012 Battery Type: Lithium Use the following procedure to check or replace the control battery. 1. Power up the machine. 2. After approximately 30 seconds, power down and lock out the machine. 3. Turn the main disconnect switch to the OPEN position and open the power case
door. 4. Verify the new battery matches the battery being replaced. 5. Disconnect the old battery from receptacle “C”, Figure 7.4 and take the battery
out of its case. 6. Connect the new battery. 7. Close the power case door. CNC Control Battery – For Siemens Control only
NOTE: Data will be held for 15 minutes with battery being removed. Battery Specifications: Ordering Code: 6FC5-247-0AA18-0AA0 SIEMENS Specification: SINUMERIK 810D Battery Type: Lithium Use the following procedure to check or replace the control battery. 1. Power down the machine. Refer to the appropriate power-down procedure. 2. Undo the four fixing screws on the CCU3 module and remove the module. 3. Verify the new battery matches the battery being replaced. 4. Disconnect the old battery from receptacle “C”, Figure 7.6. 5. Connect the new battery. 6. Insert the CCU3 module and tighten the fixing screws.
Figure 7.3 - CNC Control Unit
C
Figure 7.4 – CNC Control Battery
Page 53
Figure 7.5 - Keep Relay Screen
Figure 7.6 - CNC Control Battery
C
SIEMENS Specification: SINUMERIK 828D Battery Type: No battery request 7.2 TURRET ZERO REFERENCE
NOTE: This procedure applies only to non-live tooling machines The turret zero reference will need to be reset if any of the following events occur: The turret controller is replaced. The turret index motor is replaced. The turret index motor feedback cable is disconnected. The turret indexes to the wrong station. The turret controller backup battery has expired and the machine has been
powered down for more than 20 minutes. Alarm "A 90" is displayed on the turret controller.
1. Power up the machine. 2. Set the Mode Select switch to Manual Data Input mode. 3. Set Parameter Write Enable (PWE) to "1":
A) Press the Offset Setting key. B) Press the Setting soft key. C) If necessary, use the Page Up/Down keys to display the Setting page that
contains the Parameter Write field. D) If necessary, use the cursor keys to
move the cursor to the Parameter Write field.
E) Press the Operator soft key. F) Press the ON:1 soft key.
4. Set K00, bit 6 to "1": A) Press the System key. B) Press the PMCPRM soft key. C) Press the KEEPRL (Keep Relay) soft key. D) Move the cursor to K00, bit 6. Refer to
Figure 7.5. E) Key in "1" and press the Input key.
Alarm message 2002 will be displayed
Figure 7.5 – CNC Control Unit
Page 54
5. Set the Mode Select switch to Reference mode. 6. Set the Turret Station selector switch "12". 7. Press and hold the Turret Index push button for 2 seconds. The turret will not
index. 8. Set K00, bit 6 to "0". The alarm message will be cleared from the display. 9. Press the Turret Index push button. The turret will index to station 12. 10. Test the turret by setting the Turret Station selector switch to other turret stations
and pressing the Turret Index push button. 11. Set the Mode Select switch to Manual Data Input mode. 12. Set Parameter Write Enable (PWE) to "0".
A) Press the Offset Setting key. The Setting page that contains the Parameter Write field will be displayed.
B) Press the Operator soft key C) Press the OFF: 0 soft key.
13. Press the control Reset key. 7.3 ADJUSTING THE TAILSTOCK BUSHING FOR CENTER Adjusting the Bushing 1. Loosen four bolts “E”, Figure 7.6; then, hand tightens. 2. Tighten two upper bolts “G” to move center sleeve “F” downward or tighten two
lower bolts “H” to move center sleeve “F” upward. 3. Torque four bolts “E” to 12.5 lb-ft [17 N•m] 4. Torque upper bolts “G” and lower bolts “H” to 11 lb-ft [15 N•m] 5. Check the concentricity between the tailstock centerline and the spindle centerline
and adjust as necessary
Figure 7.6 - Tailstock Center Sleeve
The concentricity of the tailstock centerline and the spindle centerline must be within .0006 inches [0.015 mm].
Page 55
7.4 CLEANING THE LINEAR GUIDEWAYS OF TAILSTOCK FOR CHIPS (GS 150/200, GS 42/51, SV 150/200 only) The linear guideways of the tailstock are underneath the tailstock and its way-covers. The linear guideways provide steady load capacity and smooth motion. They must be kept clean and free from chips. 1. Set the Mode Select switch to Jog mode. 2. Perform both the X and Z axes to Reference Home. (Based on the Reference Home
Procedure on the Operator’s Manual) 3. Operated the tailstock Jog switch: manually position the tailstock to the left which
is the middle of the guideway approximately, then take apart the front way-cover by loosening 5 screws, Figure 7.7 “A”, cleaning with the brush to sweep away the chips which pile up around of the guideways.
4. Operating the tailstock Jog switch again, move left to the end of travel of the tailstock, then take apart the rear way-cover, Figure 7.7 “B”, by loosening 7 screws, cleaning again.
5. Wipe a coating of grease over all guideway surfaces with a lint-free cloth. 6. Install both covers.
Figure 7.7 way-covers for GS 150
A B
Page 56
Figure 7.9 - Plenum Fan and Air Filter
Figure 7.8 – Heat Exchanger Air Filter on the Power Case Door
7.5 CLEANING THE POWER CASE HEAT EXCHANGER AIR FILTER The power case is cooled by a heat exchange system. The heat exchanger provides the cooling and environmental protection necessary for proper operation of the printed circuit boards. This air unit employs a closed loop design which circulates air inside the power case while sealing out potentially contaminated, external air. The heat exchanger is located either on the door exterior or near the top of the power case. Air is moved inside the power case while external air is drawn across the corrugated metal (heat exchange) plate. It is recommended that air filter “I”, Figure 7.8, be cleaned once a week. 1. Power down the machine. 2. Clean the power case heat exchanger air filter as
follows: A) Use the tab on the filter to lift the air filter up, slide
the bottom out and pull it down to remove the air filter from its frame.
B) Wash the air filter clean in detergent and water. Blow it out with compressed air and allow it to air dry.
C) Be sure that the air filter is dry; put the filter, with tab down, up into the top of its frame, press it in and drop it into the bottom of the frame
7.6 CLEANING THE POWER CASE PLENUM FAN AIR FILTER The plenum fan is located on the side of the power case. It is recommended that the plenum air filter “J”, Figure 7.9, be cleaned once a week. 1. Power down the machine. 2. Clean the plenum fan air filter as follows: A) Apply even pressure to sides of plenum fan cover
and unsnap from plenum fan. Remove the air filter from the interior of the fan cover.
B) Wash the air filter clean in detergent and water. Blow it out with compressed air and allow it to air dry.
C) Make certain that the air filter is dry; lay the filter inside the fan cover, and snap the cover on the plenum fan.
Page 57
7.7 GUARD DOOR INTERLOCK SWITCH The front door is equipped with an interlock switch with a door locking device. The door must be shut completely before the machine can be started, and is locked shut during machine operation. A special key is attached with this machine, located in the power cabinet.
Door Interlock of Electrical Cabinet Safety Circuit When the door interlock switch is set to the “0” position and the cabinet doors are open, the machine power will remain ON. When door interlock switch is set to the “1” position and the cabinet doors are open, the machine power will be turned OFF.
Special key to unlock the door when no power is available.
This key is for AUTHORISED PERSONNEL ONLY and for MAINTENANCE PURPOSES ONLY. The key must only be used to release the door lock when the doors are locked and no power is available to the machine. It must not be used for any other purpose. Return the switch to the ‘LOCK’ position and remove the key before applying power to the machine.
Page 58
7.8 VISION PANELS
The GS-SV Series range of machines is equipped with transparent vision panels to allow the operator to observe the machining process, whilst protecting from potential hazards. These vision panels are made from sealed composite units of toughened glass and polycarbonate compound. Due to the aging phenomenon of polycarbonate it is necessary to REPLACE THE VISION PANELS PERIODICALLY, as specified in the Operators Safety Manual.
7.9 MAINTENANCE AND CLEANING OF SPINDLE CHILLER (OPTION)
Lists of components that required cleaning regularly, which are chiller body, condenser, air filter, oil filter and oil tank. Please reference the instruction manual of chiller for detail. Cleaning the Air Filter 1. To remove the filter, lift the filter up and draw out, as shown below. 2. Use a vacuum cleaner, compressed air, water and brush to clean the filter. 3. Allow the filter to dry after cleaning before installing back onto the machine. 4. Clean the filter regularly at least once every week and it is recommended to clean
the filter whenever it’s heavy stained.
Figure 7.10 – Cleaning the Air Filter
A) Turn the operation switch and main power source OFF before proceeding with any installation or maintenance.
B) If there is flame welding while repairing, please avoid flame near any oil (gas or liquid form) area.
Page 59
Change the Oil for Chiller
1. Check the level of oil tank via the level gauge “K”, Figure 7.11, every day. 2. Remove plug “M”, Figure 7.11, on the bottom of oil tank to drain out the oil after
2000 hours operation. 3. Open cap “L”, Figure 7.11, to add oil to the chiller unit. 4. If the chiller is located in humid climate zone, eventually water will form within the
tank and sink at the bottom. Please drain out the water from the tank at least once a month.
Cleaning the Oil Filter 1. Clean the filter once a day in the early stage after piping. 2. Clean the filter every week after normal operation.
Recommended oil for Chiller Capacity (litres)
Mobil Velocite oil No.3 7
Using the recommended spindle chiller oil will maintain spindle temperatures at a suitable level.
Figure 7.11 - Change the Oil for Chiller
K
L
M
Page 60
7.10 SPINDLE CHILLER TUBING DIADRAM (OPTION)
L0116 GS 150/200/250 & 200/66
Page 61
7.11 RESTART AFTER CHUCK EXCHANGED If the chuck has been exchanged for any reason, a maintenance technician should restart the machine and verify correct chuck operation. Warning: DO NOT exceed the maximum specified spindle speed, as indicated on the chuck body. Personal injury or damage to the chuck can result 1. Before powering ON the machine. Check the maximum rotational speed of the
chuck, which is stamped on the chuck. 2. Start the machine spindle at a low rotation speed. 3. Carefully set-up the spindle from low rang to high range. 4. Repeat steps 2 and 3 with the spindle rotating in the opposite direction. 5. Note if any abnormal noise and vibration occurs. If any abnormal noise and
vibration is observed, inspect and correct it.
Page 62
7.12 SAFETY WARNING FOR TOP JAW AND T-NUT PLACEMENT. Notices on use: When changing the top jaw, clean the serration part of the master jaw and the fit-in part of T-nut. Otherwise, this may cause errors in accuracy.
T-nut does not protrude from master jaw, refer to the “CORRECT” way as below. In case of using on condition of “NOT CORRECT”, it will be cause the damage of master jaw or T-nut, the error of accuracy and may accident occur.
Using properly tighten torque for the jaw mounting bolts as shown in the chuck instruction manual. To prevent the jaw or workpiece flight. Make jaw to clamp the workpieces in correct ways. Accuracy and function may reduce, because of clamping in uncorrected ways.
Page 63
7.13 OPERATION OF STEADY REST FEATURE For GS 200/66 L & GS 250 L Only
General Notes: 1. Prior to using the steady rest feature remove the following alignment blocks
to minimize damage in the event of a crash. a. X axis tram alignment block (see view “A”). b. Y axis tram alignment blocks (see view “C”).
2. Program commands are as follows: a. M94 open steady rest. b. M95 close steady rest.
3. To utilize the steady rest push button on the operator panel JOG MODE is required. Single button push to close or to open.
4. There is a telescoping rod which connects the tailstock to the steady rest which may require the operator to adjust the steady rest and tailstock trip dog blocks.
5. Should machine not activate cycle start in AUTO MODE due to repositioning, see step 5 in “Procedure for Adjustment” section below.
6. Refer to SMW documentation for steady rest unit supplied with machine for further information.
7. There is a telescoping rod which connects the tailstock to the steady rest Procedure for Adjustment of “Z Axis” Position for Steady Rest Unit 1. Loosen the (2) lockdown bolts “A1” in view “A” and “A2” in view B. 2. Reposition the steady rest turning adjustment bolt “B” in view A to position
desired. Note: This may also be repositioned by hand with some effort. The tailstock body assembly may need to be jogged forward (towards the main spindle) to allow full travel of the steady rest.
3. Tighten the (2) lockdown bolts “A1” in view A and “A2” in view B and torque to 180 Nm/133 ft/lbs.
4. Should tailstock engagement be desired set tailstock forward trip dog “D1” in view D to desired position for tailstock body positioning. This switch can be verified by viewing diagnostic X17 bit 6 on the PMC diagnostics page.
5. Reposition tailstock adjustable home position trip dog “D2” in view E as required to signaling that the tailstock is in its home position to machine control. The switch can be verified by viewing diagnostic X17 bit 7 on the PMC diagnostics page.
Steady Rest Viewed From Main Spindle - View “A”
Lockdown Bolt “A1”
Adjustment Bolt “B”
X Axis Tram Alignment Bock A
Page 64
Steady Rest Viewed From Tailstock - View “B”
Steady Rest Viewed From Below - View “C”
Tailstock Forward Trip Dog - View “D”
Lockdown Bolt “A2”
Z Axis Tram Alignment Blocks (3 Blocks Total)
X Axis Tram Alignment Bock A
Y Axis Tram Alignment Bocks (2 Blocks Total)
Tailstock Forward Trip Dog “D1”
Page 65
Tailstock Adjustable Home Forward Trip Dog - View “E”
Tailstock Adjustable Home Trip Dog “D2”
Page 66
APPENDIX ONE – PREVENTIVE MAINTENANCE SCHEDULE CAUTION: Do not use caustic or abrasive cleaners on this machine.
Never use compressed air to clean dirt or chips from the machine. Air pressure could force dirt particles and other foreign material past seals and wipers.
CLEANING THE MACHINE Maintaining a clean machine is part of any good maintenance program. Machines should be periodically wiped with lint-free cloths soaked with a good grade of petroleum-based grease solvent. If the machine is operated in an atmosphere that causes surfaces to rust quickly, wipe these surfaces with a lint-free cloth soaked in mineral oil. MAINTENANCE SCHEDULE The following maintenance times are approximate and components may need attention more frequently if excessive environmental pollution is present. Preventive maintenance frequency is for single shifts and should be increased proportionally when work is for two or three shifts per day. 8 HOURS Check coolant level ------------------------------------------------------------- Chapter 4 Check coolant concentration --------------------------------------------------- Chapter 4 Measure coolant PH ------------------------------------------------------------ Chapter 4 Check chips in coolant reservoir; remove as necessary ---------------------- Chapter 4 Check hydraulic pressure gauges ---------------------------------------------- Chapter 5 Check hydraulic fluid level in the tank ---------------------------------------- Chapter 5 Check for hydraulic fluid leaks ------------------------------------------------- Chapter 5 40 HOURS Clean or replace machine air filters ------------------------------------------- Chapter 7 Wash the machine and wipe clean -------------------------------------------- See above Clean spindle chiller filter and check oil-----------------------------------------Chapter 7 Clean air filter of spindle chiller -------------------------------------------------Chapter 7 400 HOURS Clean the filter of coolant thru-turret ------------------------------------------ Chapter 4 600 HOURS Clean the linear guideways of tailstock for chips ----------------------------- Chapter 7 600 HOURS Apply axes way grease lubrication -------------------------------------------- Chapter 6 1000 HOURS Drain and refill the hydraulic oil tank ------------------------------------------ Chapter 5 Replace the hydraulic oil filter ------------------------------------------------- Chapter 5 Replace the cutting coolant ---------------------------------------------------- Chapter 4 2000 HOURS Install a fresh control battery -------------------------------------------------- Chapter 7 Replace the spindle chiller oil ---------------------------------------------------Chapter 7
Related Documents
