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

Transcription

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 Issue J August 2011 Page 1

2 CONTENTS Page CHAPTER 1 INTRODUCTION & SAFETY 1.1 Intended Use Foreword Protection for Machine Operators Signal Word Definition The Importance of Regular Inspections Cautions to be Observed by Technicians Checking the Function of the Safety Circuit 10 CHAPTER 2 AIR AND ELECTRICAL LOCK-OUT PROCEDURES 2.1 Air Lock-out Electrical Lock-out 13 CHAPTER - 3 AIR SYSTEM 3.1 System Description Setting the Air Pressure Maintenance Clean or Replace the Optical Scale Air Filter (OPT) Pneumatic Schematics Pneumatic Diagram Tubing Safety Factor of Pneumatic System 21 CHAPTER - 4 COOLANT SYSTEM 4.1 Introduction Checking the Coolant Level Chip Removal (Machines without Chip Conveyor) Cleaning the Coolant Tank Replacing the Coolant Pump Coolant/Flush Piping Diagram Cleaning the Filter of Coolant Thru-turret 30 Page 2

3 Page CHAPTER 5 HYDRAULIC SYSTEM 5.1 Introduction Hydraulic Tank Adjusting the Hydraulic System Pressure Depressed Pressure for Emergency Hydraulic Schematic Hydraulic Diagram Tubing Safety Factor of Hydraulic System 40 CHAPTER 6 LUBRICATION 6.1 Introduction Recommended Grease Lubrication Alarm Grease Volume Axis Lubrication Procedures Lubrication Line Replacement Duplomatic Live Tool Drive Lubrication (Option) Radial BMT-65 Turret Chuck Lubrication Clean and Lubrication on Working Area 50 CHAPTER 7 MISCALLANEOUS 7.1 Battery Maintenance Turret Zero Reference Adjusting the Tailstock Bushing for Center Cleaning the Linear Guideway of Tailstock for Chips Cleaning the Power Case Heat Exchanger Air Filter Cleaning the Power Case Plenum fan Air Filter Guard Door Interlock Switch Vision Panels Maintenance and Cleaning of Spindle Chiller Oil (Option) Spindle Chiller Tubing Diagram (Option) Restart after chuck exchanged Safety Warning for Top Jaw and T-Nut Placement Operation of Steady Rest Feature 63 APPENDIX ONE Preventive Maintenance Schedule 66 Page 3

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 4

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: Chips: 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. Entrust the disposal of chips to a party qualified to dispose of industrial wastes or a party capable of metallic waste recycling. Page 5

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. 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. Other symbols: Indicates the items that must be taken into consideration Page 6

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 7

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 8

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 9

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 Main Isolator Located on the Electrical Cabinet. Emergency Stop There are Emergency Stop devices on the Control Panel and remote handwheel (if fitted) Axes Limits Intended Function To isolate main power to the machine The Emergency Stop function is to disable the Servo Motors, Spindle Motor, thus disabling all the Axes, Automatic and Manual functions To stop over travel of the x, and z axes in both + and - directions Test Procedure and Result 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: All Axes feeds will be disabled. The NC and VDU will still be ON. The message EMERGENCY STOP will be displayed 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 10

11 Door Interlocks (Front Door) a) When an interlock is open (guard open) no axis movement is allowed when the mode selection switch is set to program. b) When an interlock is open (guard open) the maximum Axes speeds are limited when the mode selection switch is set to manual. c) When an interlock is open (guard open) the spindle is disabled. No rotation is allowed d) When an interlock is open (guard open) no automatic cycle can be started. 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. 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. 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 With the moveable guard open, press the Spindle CW or CCW keys. NORMAL RESULT: The Spindle will not start. Attempt to run an automatic cycle with the guard open. NORMAL RESULT: There will be no machine movement 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 11

12 Door Interlocks of Electrical cabinet (Cabinet Doors) a) When door interlock switch is on the position 0 and the cabinet doors open, the machine power will remain ON. 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 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.) 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 12

13 CHAPTER 2 - AIR AND ELECTRICAL LOCK-OUT PROCEDURES 2.1 AIR LOCK-OUT The air lock-out procedure applies only to machines equipped with the optional parts catcher. 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. A Figure Main Disconnect Switch Figure 2.2 Air Filter Regulator for Optional Parts Catcher Page 13

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 The air filter/regulator is equipped with an automatic drain. Machines equipped with the optional parts catcher are equipped with a quickdisconnect 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 Air Connection (Machine without Optional Part Catcher) Figure Air Connection (Machine with Optional Part Catcher) Page 14

15 3.2 SETTING THE AIR PRESSURE This information applies only to machines equipped with the optional part catcher. 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 Turn the air valve OFF and lock out before performing air system 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. Notice the orientation of the locking lugs on the filter bowl when it releases from the filter/regulator head. 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 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. Page 15

16 Figure Air Filter and Filter Retainer Air Line Lubricator 1. Turn main air valve B, Figure 3.2, OFF and lock out. Use care not to spill the oil in the lubricator bowl. 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 Page 16

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 17

18 3.5 PNEUMATIC SCHEMATIC Chute rotation (Part catcher)(opt) Sliding Cover (Part catcher)(opt) Auto Door(OPT) Air blast(opt) Air purge for Duplomatic live tooling turret(opt) GS/SV 150/200 & 200/66 / 250 series machines Air Purge (SPINDLE) Optical Scale (X & Z axis) Chute rotation (Part catcher) (OPT) Sliding Cover (PART CATCHER) (OPT) Auto door(opt) Air blast(opt) Switching the Coolant or Air through the turret Air purge for Duplomatic live tooling turret(opt) Air gun coolant air GS 42/51 machines Page 18

19 3.6 PNEUMATIC DIAGRAM Switching the Coolant or Air through the turret Turret AIR PURGE (LIVE TOOLING TURRET) Z AXIS OPTICAL SCALE AUTO DOOR Chute rotation (Part catcher) Air blast (Headwall) X AXIS OPTICAL SCALE Air gun GS/SV 150/200 series machines Sliding cover (Part catcher) L0085 GS/SV 200/66 / 250 series machines Page 19

20 AIR PURGE (HEAD STOCK) Switching the Coolant or Air through the turret Turret Air purge (LIVE TOOLING TURRET) Z AXIS Optical scale Autor door(option) Chute rotation (Option) (Part catcher) X AXIS Optical scale Air gun Sliding cover (Option) (Part catcher) GS 42/51 machines Page 20

21 3.7 Tubing Safety Factor of Pneumatic System Material PU Nylon Nominal ODxID (mm) Burst Pressure Min. (bar), 25 Working Pressure Max. (bar) Safety Factor UM0640 6x UM0850 8x UM x UM x NB0640 6x NB0860 8x NB x NB x Page 21

22 CHAPTER 4 - COOLANT SYSTEM 4.1 INTRODUCTION When coolant system maintenance is required, the machine must be powered down. 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. A properly selected and maintained coolant, either oil or water based, will ensure the best performance from the coolant and machine. 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. Page 22

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 GS/SV 200 & GS GS 200/66 & SV 200/ GS 200/66 L & SV 200/66 L GS/SV GS/SV 250 L CHECKING THE COOLANT LEVEL Check the coolant level through sight gauge A, Figure 4.1 or B, Figure 4.2. Figure Coolant Sight Gauge Figure Coolant Sight Gauge Page 23

24 4.3 CHIP REMOVAL (MACHINES WITHOUT CHIP CONVEYOR) Do not remove chips with your bare hands. 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 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 Rake the chips from chip pan "E" into a suitable container. 6. Align the tank with the machine and roll it into place. C D E Figure Chip Tray Cover Figure Chip Pan Mounting Bolt and Chip Pan Page 24

25 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. Figure Coolant Pump Assembly Figure Coolant Tank Screen and Filter 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 25

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 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. F G K G H Figure Coolant Pump Assembly Figure Chip Pan Mounting Bolts 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 Chip Pan and Coolant Tank Figure Coolant Tank Screen Page 26

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. O N O N Figure Coolant Hoses Connected to pump Figure Coolant Hoses Connected to pump 7. Remove the cover from electrical junction box H, Figure 4.5 or Record the electrical connections in the junction box. Refer to Figure 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 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. Page 27

28 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. Figure Electrical Junction Box, Page 28

29 4.6 Coolant/Flush Piping Diagram Turret 280 psi Head Wall Filter 40 psi L0080 COOLANT TANK GS/SV 150/200 & GS 42/51 series machines Turret 280 psi Head Wall Filter COOLANT TANK 40 psi L0084 GS/SV 200/66 / 250 series machines Page 29

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 hours. Cleaning Procedure as below: 1. Unthread 4 screws A on the both side of filter, Figure 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. 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 A B Figure 4.15 Filter of Coolant Thru-turret Page 30

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 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. 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. 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/ Page 31

32 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 Figure Rear Access Cover Draining and Filling the Hydraulic Tank 1. Power down the machine. 2. Remove access cover A, Figure Place a drain pan capable of holding a minimum of 16 gallons [60 litres] of oil under drain plug D, Figure 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 Hydraulic System Figure Hydraulic Tank Drain Plug Figure Strainer for Filler Neck Page 32

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. 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. 1. Remove access cover A, Figure 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. Figure 5.5 Hydraulic System Pressure Adjustment GS Series Equipments Table Ⅰ: The hydraulic system pressure (bar, Max.) for various machines and equipments Main Hydraulic Pressure Turret Type Hydraulic Pressure Tailstock Body (opt) Quill Chuck Chuck (A) Pressure Switch setting Chuck (B) GS 150/ * 8* SV 150/200 VDI 30 Live Vertical Tooling GS 42 (40) 20 5* 5* GS * 5* VDI Vertical 40 Note: * use on CE machines only. GS/SV 200/66 & 200/66 L GS/SV 250 & 250 L Live Tooling 50 Main Hydraulic Tailstock 25* ~27 8* 8* 50* 17.5 Page 33

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 E D A B Figure 5.6 Control Valve Cabinet at left-side of GS-SV 150/200 & GS 42/51 series. Figure 5.7 Control Valve Cabinet at left-side of GS-SV 200/66 /250 series. Page 34

35 F G H Figure 5.8 Control Valve Cabinet at right-side for GS-SV 150/200 & GS 42/51 series. Figure 5.9 Control Valve Assembly at Rear of GS-SV 200/66 /250 series. J K Figure 5.10 Control Valve Cabinet at right-side for GS-SV 200/66 /250 series. Figure 5.11 Control Valve Assembly at Rear for GS-SV machines. Page 35

36 5.5 HYDRAULIC SCHEMATIC Standard Standard with C-axis Servo Turning Chuck Dynamic Turning Oil tank for hydraulic turret Space Cover TAILSTOCK CE TAILSTOCK GS-SV 150/200 & GS 42/51 Lathes Servo turret Standard Standard with C- axis Chuck C axis Tailstock clamping Oil tank for hydraulic turret Programe Tailstock without CE Clamping Moving Programe tailstock with CE Clamping Moving GS-SV 200/66 /250 Lathes Page 36

37 L0068 Standard Standard with C axis Servo Turret Chuck C axis Drain Steady rest and program tailstock without CE Tailstock clamping Steady rest Breaking Moving Program tailstock without CE Breaking Moving Cover Steady rest and program tailstock with CE Steady rest Moving Breaking Program tailstock with CE Moving Breaking Cover GS-SV 200/66 L /250 L Lathes Page 37

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 38

39 Tailstock cartridge L0087 GS-SV 200/66 / 200/66 L /250/250 L for Hydralic/Servo Turret, Chuck and Tailstock 尾座鎖緊尾座移動 中心架 Tailstock cartridge L0086 GS-SV 200/66 / 200/66 L /250/250 L for Live Tooling, Chuck and Tailstock Page 39

40 5.7 TUBING SAFETY FACTOR OF HYDRAULIC SYSTEM Material Nominal ODxID Burst Pressure Working Pressure Safety (mm) Min. (bar) Max. (bar) Factor NBR R x (1) 18.4 Compound R x (2) 10.5 HR M-6 9.5x (1) 11.4 Synthetic HR M-6 9.5X (2) 9.2 Rubber HR x (1) 14.3 HR M X (2) 8.2 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. Page 40

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. 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. 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 KLÜBER Isoflex NCA 15 KLÜBER Isoflex NBU 15 Hardinge Grease Cartridge Part Number TT NCA HS SL Other greases may not contain certain additive packages needed for proper lubrication and performance. Page 41

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 grease gun supplied with the machine delivers 3 cc per full stroke. 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 Grease should be added when the linear guides are still warm from operation. 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 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. Page 42

43 2. Wipe the fittings clean of excess grease. 3. Install cover A, Figure 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. B A C Figure Rear Access Cover Figure Grease Manifolds Figure Z Axis Grease Fitting Figure X Axis Grease Fitting Page 43

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. A Figure 6.2a Access door on left-rear side of machine Figure 6.2b - Central Manual Grease Lubrication System Recommended grade of grease 1) Castrol Spheerol L-EP 1 2) BP Energrease LS-EP 1 3) Mobilux EP 1 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 Power down the machine. 4. Remove cover F, Figure 6.5, to gain access to the fittings on grease manifold G, Figure 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 Power up the machine. Page 44

45 10. Move the tailstock to the Home position. Figure Grease Manifold Access Cover on Tailstock Figure Tailstock Grease Manifold 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 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. Figure Tailstock Grease Fitting 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. Page 45

46 6.6 LUBRICATION LINE REPLACEMENT Replacement Part Numbers Grease Manifold TT Tubing TT 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. 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. 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 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. Page 46

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 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 47

48 Size Ref. Description Code Plug 1/16 NPTF Plug 1/8 NPTF Plug 1/8 NPTF If it is necessary to add grease, use KLUBERSYNTH UH (Cod ) max. 40 cm 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. I Figure 6.8 Live tool grease plug Figure 6.9 Remove grease plug 6. Rotate gear while replenishing grease with the recommended lubricant. Amount Type Manufacturers 30~40cm 3 KLÜBERSYNTH UH (Cod ) KLÜBER LUBRICATION 7. Replace the plug. 8. Power up the machine. Figure 6.10 Replenish grease Page 48

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 BMT-65 Turret Page 49

50 6.8 CHUCK LUBRICATION Don t miss any lubrication point! And supply the grease everyday. Clamp force will reduce, because of no 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. Recommended Greases for Chuck (Containing disulphide molybdenum) 1) Mobil Mobiltemp SHC32 2) ESSO Beacon Q2 3) KITAGAWA Chuck Grease Nipples Figure 6.11 Grease nipples on the chuck Suggested amount to be used for grease: Chuck Type TF3B-6A5 TF3B-8A6 Grease amount (3 Places), ml 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. Page 50

51 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. Make certain that the replacement battery is like the battery being removed. Check the battery voltage and receptacle. Turret Controller Battery (Non-Live Tooling Machines Only) 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. 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 Verify the new battery pack matches the battery pack being replaced. 6. Disconnect the old battery from receptacle B, Figure Connect the new battery. 8. Install the battery and close the cover. 9. Close the power case door. Figure Turret Controller (Non-Live Tooling Machines) Figure Turret Controller Battery Page 51

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 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. C Figure CNC Control Unit Figure 7.4 CNC Control Battery CNC Control Battery For Siemens Control only NOTE: Data will be held for 15 minutes with battery being removed. Battery Specifications: Ordering Code: 6FC AA18-0AA0 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 Connect the new battery. 6. Insert the CCU3 module and tighten the fixing screws. Page 52

53 C Figure 7.5 CNC Control Unit Figure CNC Control Battery 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 Keep Relay Screen Page 53

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 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 The concentricity of the tailstock centerline and the spindle centerline must be within.0006 inches [0.015 mm]. 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 Tailstock Center Sleeve Page 54

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. A B Figure 7.7 way-covers for GS 150 Page 55

56 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 Figure 7.8 Heat Exchanger Air Filter on the Power Case Door 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. Figure Plenum Fan and Air Filter Page 56

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. 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. Special key to unlock the door when no power is available. 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. Page 57

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) 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. 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 Page 58

59 Change the Oil for Chiller Using the recommended spindle chiller oil will maintain spindle temperatures at a suitable level. Recommended oil for Chiller Capacity (litres) Mobil Velocite oil No 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. L M K Figure Change the Oil for Chiller 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. Page 59

60 7.10 SPINDLE CHILLER TUBING DIADRAM (OPTION) GS 150/200/250 & 200/66 L0116 Page 60

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 61

62 7.12 SAFETY WARNING FOR TOP JAW AND T-NUT PLACEMENT. 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. 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. 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. Page 62

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. Lockdown Bolt A1 X Axis Tram Alignment Bock A Adjustment Bolt B Steady Rest Viewed From Main Spindle - View A Page 63

64 Lockdown Bolt A2 Z Axis Tram Alignment Blocks (3 Blocks Total) X Axis Tram Alignment Bock A Steady Rest Viewed From Tailstock - View B Y Axis Tram Alignment Bocks (2 Blocks Total) Steady Rest Viewed From Below - View C Tailstock Forward Trip Dog D1 Tailstock Forward Trip Dog - View D Page 64

65 Tailstock Adjustable Home Trip Dog D2 Tailstock Adjustable Home Forward Trip Dog - View E Page 65