Maintenance Manual GX 300 GX 480 GX 480 DT GX 480 APC GX 480 DT APC GX 510 GX 600 GX 800 GX 1000 GX/XR 1300 GX/XR 1600 Document Number 1902493 Issue F September 2008 Page 1
CONTENTS CHAPTER 1 INTRODUCTION & SAFETY Page 1.1 Foreword 4 1.2 Protection for Machine Operators 5 1.3 Signal Word Definition 6 1.4 The Importance of Regular Inspections 7 1.5 Cautions to be Observed by Technicians 8 1.6 Checking the Function of the Safety Circuit 10 CHAPTER 2 AIR SYSTEM 2.1 Air Control Assembly 12 2.2 Adjusting Procedure 12 2.3 Replace the Filter/Regulator Filter 13 2.4 Clean or Replace the Optical Scale Air Filters 14 2.5 Pneumatic Schematics 15 2.6 Pneumatic Drawings 22 CHAPTER - 3 COOLANT SYSTEM 3.1 Introduction 31 3.2 Chip Removal 32 3.3 Clean the Coolant Tank and Filters 33 3.4 Clean the Filter of Immersible pump 34 3.5 Clean the Coolant Screens 35 3.6 Coolant Directional Balls 37 3.7 Coolant Directional Pipes 37 3.8 Coolant/Chip Flush 38 3.9 Thru-Spindle Coolant [Option] 39 3.10 Replace the In-Line Spin-On Canister Filter 40 Page 2
CHAPTER 4 LUBRICATION Page 4.1 Axes Way Grease Lubrication 40 4.2 Tool Knockout Piston Lubrication 43 4.3 Tool Carousel Rail Lubrication 43 4.4 Fill the High-Speed Spindle Air-Oil Lubrication Tank 44 4.5 High Torque Gear Box Lubrication 45 4.6 Changing Oil in the ATC Cam Box Lubrication 47 4.7 Changing Oil in the APC Cam Box Lubrication 48 4.8 Changing Oil in the APC hydraulic Power Unit 48 4.9 Hydraulic Schematic 49 4.10 Hydraulic Drawing 49 CHAPTER 5 MISCALLANEOUS 5.1 Interlock Switch with Door Locking Device 50 5.2 Vision Window Guards 50 5.3 Spindle Belt Tension 51 5.4 Clean the Power Case Heat Exchanger Air Filter 53 5.5 Work Light Lamp Replacement 54 5.6 Adjusting APC Hydraulic Pressure 55 5.7 Cleaning the Optional Chip Conveyor or Auger When Blocked 56 5.8 Maintenance and Cleaning of Spindle Chiller 57 APPENDIX 1 Preventive Maintenance Schedule 59 Page 3
CHAPTER 1 INTRODUCTION & SAFETY 1.1 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 semipermanent 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 by only 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, cables 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
1.2 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 Waste Operation of the machine generates industrial waste such as chips, waste oil and coolant. Legal permission is required to dispose of such industrial waste. Disposal of the waste 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 waste. 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 waste or a service station with the appropriate facilities. Chips: Entrust the disposal of chips to a party qualified to dispose of industrial waste or a party capable of metallic waste recycling. Page 5
1.3 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
1.4 THE IMPORTANCE OF REGULAR INSPECTIONS. Scheduled regular inspection and proper repair of the machine operated by a maintenance person 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 the 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. Using such parts will make the machine warranty void. Page 7
1.5 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
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 loose 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
1.6 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. Below is a list of the Safety Circuit Components and their function Safety Component Main Isolator Located on the Electrical Cabinet. Emergency Stop There is an Emergency Stop device on the Control Panel Axes Limits Intended Function To isolate main power to the machine The Emergency Stop function is to disable the Servo Motors, Spindle Motor and ATC, thus disabling all the Axes, Automatic and Manual functions To stop over travel of the x, y and z axis 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 Place the machine in MANUAL MODE with all the doors closed. Use the Axes Jog Keys to run each Axes one at a time at MAXIMUM feedrate to the end of the Axes travel. NORMAL RESULT: The Axes will stop before hitting the Hard Stop If any of the Safety Devices are not functioning normally do not attempt to operate the machine. Page 10
Door Interlocks (Front Sliding Doors, toolchanger door and APCchecking door) a) When an interlock is open (guard open) the maximum Axes speeds are limited b) When an interlock is open (guard open) the spindle is disabled. No rotation is allowed c) When an interlock is open (guard open) no automatic cycle can be started. d) 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 it is possible to open the guard. 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 including an MDI tool change 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. Note: Only the GX 480 DT, GX 480 APC & GX 480 DT APC have toolchanger load station doors. Only the GX 480 APC & GX 480 DT APC have a checking door. If any of the Safety Devices are not functioning normally do not attempt to operate the machine. Page 11
CHAPTER 2 AIR SYSTEM 2.1 AIR CONTROL ASSEMBLY The air control assembly is mounted at the rear of the machining centre, can be adjusted and must be set to a consistent air pressure between 59 psi and 73 psi [4.1 and 5 bars] or high-performance spindle machines near 90 psi [6.2 bars]. If the factory air has excessive moisture, a heavy-duty air dryer must be added to the incoming air line. 2.2 ADJUSTING PROCEDURE 1. Turn on the air supply. 2. Lift the adjusting knob turn it clockwise to increase the pressure and anti-clockwise to decrease the pressure(direction when looking down) at the pressure regulator. 3. Push the adjusting knob down to click in position. Air Filter/Regulator and Lubricator Page 12
2.3 REPLACE THE FILTER/REGULATOR FILTER The filter/regulator filter bowl drains automatically. Check the air system bowls once a week for contaminates. 1. Turn off the air supply. 2. Twist ring A anti-clockwise to release the shell and bowl from the head. Drain any water and contaminants from the bowl. 3. Clean the bowl with a lint-free cloth. 4. To release the filter, unscrew the nylon fixture. Thread the new filter on the nipple until it is tight. 5. Put the bowl into the shell; press the shell up into the head. Rotate the ring clockwise until the latches secure it. 6. Unthread screw B and fill the lubricator with the recommended oil below. Air Filter/Regulator and Lubricator Machine component Filter/Regulator/Lubricator combination Lubricant characteristic Lubrication method Lubrication frequency Tank capacity 1) Viscosity: ISO VG32 2) Viscosity index: above 95 3) Anti-rust, anti-oxidation 4) Good Stability Oil feeder As needed, 1/yr. 0.3 Liters Recommended grade of lubricant 1) CPC Circulation Oil R32 2) Mobil DTE Light 3) Daphne Super Multi Oil 32 4) Shell Turbo OilT32 Page 13
2.4 CLEAN OR REPLACE THE OPTICAL SCALE AIR FILTERS 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 Page 14
2.5 PNEUMATIC SCHEMATICS 2 2 40μ GX 300/510 Spindle with CTS 2 2 40μ GX 300/510 Swing Arm ATC Page 15
2 2 40μ GX 300/510 Auto Front Door 2 2 40μ GX 300/510 Auto Magazine Door Page 16
2 2 40μ GX 480 DT Turret ATC 2 2 40μ GX 480 DT Swing Arm ATC Page 17
2 2 40μ GX 480 Swing Arm ATC 2 2 40μ GX 480 Carousel ATC Page 18
2 2 40μ GX 600/800/1000/1300/1600 & XR 1300/1600 Carousel ATC 2 2 40μ GX 600/800/1000/1300/1600 & XR 1300/1600 Swing Arm ATC Page 19
2 2 40μ GX 480 APC & GX 480 DT APC 2 2 40μ APC Standard Page 20
Air Blast for Tool Probe on GX 480/600/1000/1300/1600 (OPT) 2 GX Series Spindle with CTS/ATS (Air Through Spindle) - OPT Page 21
2.6 PNEUMATIC DIAGRAMS GX 300/510 Spindle with CTS GX 300/510 Swing Arm ATC Page 22
GX 300/510 Auto Front Door GX 300/510 Auto Magazine Door Page 23
GX 480 DT Turret ATC GX 480 DT Swing Arm ATC Page 24
GX 480 Swing Arm ATC GX 480 Swing Arm ATC (With CTS) Page 25
GX 480 Carousel ATC GX 600/800/1000 Carousel ATC Page 26
GX 600/800/1000 Swing Arm ATC GX 600/800/1000 Swing Arm ATC (With CTS) Page 27
GX 1300/1600 and XR 1300/1600 Carousel ATC GX 1300/1600 and XR 1300/1600 Swing Arm ATC Page 28
APC Pallet Air Blast for Tool Probe on GX 480/600/800/1000/1300/1600 (opt) Page 29
GX Series Spindle with CTS/ATS (Air Through Spindle) - OPT Page 30
CHAPTER 3 - COOLANT SYSTEM 3.1 INTRODUCTION The two most popular types of cutting fluids are cutting oils and water-based coolants. Whenever cutting fluids are used, it is essential to follow the coolant manufacturer s recommendations and maintenance. Fill the tank assembly with the approved coolant to the FULL line of the sight gauge. Approximate coolant tank capacities are shown in the following chart: Coolant Tank Capacity Machine Model liters US gallons Imperial gallons GX 300 125 33 28 GX 480/480 APC GX 480 DT/480 DT APC 100 27 22 GX 510 158 42 35 GX 600 230 61 51 GX 800 & GX 1000 360 95 79 GX 1300 & XR 1300 400 106 88 GX 1600 & XR 1600 538 142 118 Page 31
3.2 CHIP REMOVAL The tank assembly has chip trays that screen the metal chips and allows the coolant to drain through and recycle. Use a rake and suitable container to remove metal chips from the chip trays. Dispose of the chips in an environmentally safe manner. 1. Allow the coolant to drain back into the tank. 2. Open the guard door; sweep metal chips from the table and way covers into the coolant tank. 3. If the machine does not have a chip conveyor, carefully slide chip tray A and B out the side from the corners of the coolant tank to clean. 4. If necessary, move the tank into an area that is convenient to remove the metal chips. 5. Rake or dump the chips into a container and dispose them properly. Left Side Chip Tray Right Side Chip Tray Chip Tray B For GX 480 For GX 600/800/1000 Page 32
A A For GX 1300/1600 and XR 1300/1600 For GX 300/510 3.3 CLEAN THE COOLANT TANK AND FILTERS Clean the coolant tank at least once every six months or more frequently if the materials being cut contaminate the coolant. Clean the coolant tank whenever changing the type or brand of coolant. 1. Roll the tank assembly out from under the machine. 2. At both ends of the coolant tank, remove the pipe plug or use a pump to drain out the coolant from the tank. 3. Lift the chip pans from the tank to clean. Wear protection and be careful when removing coolant and metal chips from the coolant tank. Dispose of the coolant, chips and cleaner in an environmentally safe manner. 4. Wipe the coolant tank clean. 5. Lift the screens from the slots. 6. Shake out the metal chips and wipe the filter screens clean. 7. Wash the coolant tank assembly with a cleaner recommended by the coolant manufacturer to remove any bacterial contamination. 8. Place the filter screens in their slots. 9. Return the tank to the opening under the machine. 10. Pour the approved coolant directly into the work area to drain into the coolant tank. Fill the tank to the FULL line of the sight gauge. 11. Power up the machine to check for coolant leaks. Page 33
3.4 CLEAN THE FILTER OF IMMERSIBLE PUMP The pump filter should be cleaned at regular intervals to ensure a correct flow of coolant and whenever there appears to be a drop in coolant pressure. 1. Disconnected the hose from the pump. 2. Take apart the pump from the mounting and placed upside down. 3. Loose the screw B of filter screen and remove it. 4. Blow the pressure air to sweep chips away and re-assemble the unit. 5. Power up the machine to check for coolant leaks. Periodic checks At regular intervals, depending on the conditions and time of operation, the following checks should be made: - Check the quantity of liquid and operating pressure. - Check the motor is not overheating. - Check that there are no leaks. A For GX 1300/1600 & XR 1300/1600 For GX 600/800/1000 B For GX 480/480 APC/480 DT/ 480 DT APC Clean the pump filter Page 34
For GX 300/510 3.5 CLEAN THE COOLANT SCREENS GX 600/800/1000/1300/1600, XR 1300/1600 & GX 480/480 DT The coolant screens should be cleaned every 500 hours or whenever there appears to be a reduction in coolant flow. 1. Power down the machine, wait to allow the coolant to drain into the tank. 2. Carefully roll the coolant tank out, so the coolant inside will not splash onto the ground. 3. Remove the filter screen of 2mm, shake out the chips and wipe the screen clean. 4. Put the screen back in the slot, BUT behind the filter screen of 1mm, so that chips can still be blocked when lifting up the 1mm screen to clean. 5. Remove the filter screen of 1mm, shake out the chips and wipe the screen clean, then place behind where it was, that s behind 2mm screen. Remove 2mm Screen (For GX 480 & GX 480 DT) Replace 2mm Screen (For GX 480 & GX 480 DT) Page 35
Replace 1mm Screen (For GX 480 & GX 480 DT) Coolant Screen (For GX 600/800/1000) Coolant Screen (For GX 1300/1600 & XR 1300/1600) Coolant Screen (For GX 300/510) Page 36
3.6 COOLANT DIRECTIONAL BALLS Five coolant directional balls are located on the spindle face, equally spaced around the tool. The directional balls are mounted in Nylon cups; to adjust the directional position of the coolant balls, put a hex wrench or dowel up into the coolant ball orifice and move the ball. Move the direction of the other balls as necessary. Spindle Face 3.7 COOLANT DIRECTIONAL PIPES GX 480/480 DT, GX 1300/1600 & XR 1300/1600 Two/three coolant directional lock line pipes are located on the right hand side of the spindle face/guard; these are freely adjustable to suit direction and length. For GX 480/480 DT For GX 1300/1600 & XR 1300/1600 Page 37
3.8 COOLANT/CHIP FLUSH The adjustable hoses can be set at any length or angle to flush chips toward the chip recovery screens. Separate any ball link, remove or add links as necessary and re-attach the separated links by snapping them together. Coolant/Chip Flush Adjustable Hoses Chip Flush For GX 1300/1600 & XR 1300/1600 Page 38
3.9 THRU-SPINDLE COOLANT [Option] The thru-spindle coolant option must be factory installed. The spindle can be run even though the coolant is not active. There are three coolant filters on machines equipped with the thru-spindle coolant option: two in-coolant-line filters and the filter screens in the coolant tank. The in-line filter is a blue filter mounted on the back of the coolant tank in the coolant return line. The in-line blue filter must be cleaned whenever there appears to be a drop in the thru-spindle coolant pressure. Refer to Section 3.4 for information on cleaning the in-line blue filter. Spin-on canister filter is mounted near the coolant pump on the right side of the tower (facing the rear of the machine). The spin-on canister filter must be replaced whenever there appears to be a drop in the thru-spindle coolant pressure. 3.10 REPLACE THE IN-LINE SPIN-ON CANISTER FILTER 1. Allow the coolant to drain back into the tank. 2. Wrap the filter head with a rag to catch coolant as filter canister is removed. Unthread the filter from its mounting nipple. 3. Wipe the mounting nipple with a lint free cloth. 4. Remove the filter seal from the mounting surface. 5. Fill the filter replacement one-half full with fresh coolant and apply a light coat of oil around the seal on top of the filter. 6. Thread the replacement filter on one-quarter to one-half of a turn further. 7. Power up the machine to check for coolant leaks. Thru-Spindle Spin-On Canister Filter Page 39
CHAPTER 4 - LUBRICATION 4.1 AXES WAY GREASE LUBRICATION GX 480 & GX 480 DT Grease is used to lubricate axes guideways and axes ballscrew nuts. Recommended lubrication is every 600 hours of operation. Use only Kluber ISOFLEX NBU 15 or NCA 15 grease. Never mix the grease from different manufacturers. The system cannot be over greased. Lubricate all the sliding surfaces by jogging the axes several times before resuming automatic operation. Grease the Z axes linear guildeways 1. Open the cover and apply the grease to each nipple until the resistance is felt. Z AXIS GREASE Z Axis Grease Fittings at Front of Tower (For GX 480 & GX 480 DT) Z Axis Grease Fittings at Front of Tower (For GX 300/510) Page 40
Grease the X & Y axes linear guildeways 1. Jog the X axis until the Y axis grease fittings are uncovered. The X axis grease fittings are attached and move with the X axis jog. 2. Apply the correct amount of grease. X AXIS GREASE Y AXIS GREASE X and Y Axes Grease Fittings at Front of Way Cover (FOR GX 480 & GX 480 DT) Y AXIS GREASE X AXIS GREASE X and Y Axes Grease Fittings at Front of Way Cover (FOR GX 300/510) If grease was added because there was an alarm fault ( 600 hour lube alarm ), clear the alarm after the control has been powered up. Fanuc Control: Siemens Control: Heidenhain: Press the Reset and Feed Hold push buttons at the same time to clear the alarm. Press and hold the Reset push button for 5 seconds or until the alarm is cleared. Press NC stop. Then press the CE and Power Enable together. Page 41
GX 600/800/1000/1300/1600 and XR 1300/1600 Central manual grease supplier for the X, Y & Z axes linear guildeways and ballscrew Grease is used to lubricate axes guideways and axes ballscrew nuts. Recommended lubrication is every 400 hours of operation. Recommended grade of grease 1) Castrol Spheerol L-EP1 2) BP Energrease LS1 3) Mobil US EP1 1. Open the door at the rear of machine. 2. Pull the lever of the central manual grease supplier 18 times. Central Manual Grease Lubrication System At rear of the machine (For GX 600/800/1000) Central Manual Grease Lubrication System At rear of the machine (For GX 1300/1600 and XR 1300/1600) Page 42
4.2 TOOL KNOCKOUT PISTON LUBRICATION Add oil to the air/oil tool-knockout piston oil cup A at least once every month. Remove the oil cap. Use recommended oil as below and then replace the cap. Mobil DTE 24 Shell Tellus 32 Tool Knockout Lubricator Cup 4.3 TOOL CAROUSEL RAIL LUBRICATION Tool carousel grease fitting B is in a seam on top of the carousel. The grease fitting can best be seen when the tool carousel is at the retract position (furthest from the spindle). Refill the oil every 600 hours. 1. Wipe the fitting(s) clean of dirt or contaminants. 2. Apply Kluber ISOFLEX NCA 15 grease to the nipple until resistance is felt. 3. Wipe the nipple(s) clean of excess grease. Carousel Grease Fitting Page 43
4.4 FILL THE HIGH-SPEED SPINDLE AIR-OIL LUBRICATOR TANK The air-oil lubrication system is located at the rear of the machine between the power case and the column. It supplies oil to the spindle bearings. The run time for one full spindle lubricator tank is approximately 5230 hours. The pump cycle time is preset at the factory to pump oil every 48 minutes. 1. Locate the lubricator tank and tank filler cap. 2. Wipe the tank cover and filler cap. 3. Remove the filler cap and slowly fill the tank with pre-filtered Mobil DTE-797 oil pre-filtered through a 3 micron or better filter. Wait a full 5 minutes to allow any air in the oil to escape. 4. Install the filler cap. High-Speed Spindle Lubrication System Air and Lubricator Check and correct the air-oil lubricator components as follows: 1. Open two latches and lift off front cover D. The mixing block (metering unit) is mounted in the lower left corner with the air-oil feeder lines and air line connected to the bottom. The main air line is the larger diameter line. The smaller line supplies oil to the mixing block. 2. Check the oil lines and oil pressure. 3. Check the air pressure from the main air panel to the controller and mixing block. 4. Check the air pressure from the mixing block to spindle. SPINDLE LABYRINTH AIR SEAL The air pressure must be left ON for 15 minutes after the spindle has stopped to allow the spindle interior to cool to room temperature without drawing in coolant and contaminants. Page 44
4.5 HIGH-TORQUE GEAR BOX LUBRICATION The gearbox on the high-torque spindle machines requires a closed-loop circulation of lubrication. This system consists of a tank, pump, heat exchanger (radiator and fan) and the gearbox. The heat exchanger helps stabilize and keep the gearbox at a constant operating temperature. The oil level must be checked each 2000 hours of operation and the oil must be changed every two years. Select the oil from the table on the next page. Adding Oil to the High-Torque Gear Box Tank 1. Make sure the spindle is down to its lowest point (-Z position). 2. Remove the sheet metal cover above and around the spindle column to expose the spindle drive and high-torque mechanisms. 3. Open the right side door and locate gearbox tank F. High-Torque Gear Box Tank Select the oil from the table below. Some tanks may have a filler cap. If there is a filler cap, clean the cap and area around the cap Open the cap and add oil until the tank is full. 5. Unthread tank vent G, and add oil until the tank is full. 6. Thread the vent on until it is snug. 7. Check the hoses for any kinks or leaks and correct any problems as necessary. 8. Mount the spindle sheet metal cover and tighten the screws. 9. Power up the machine and continue with machine operation or maintenance. Page 45
Machine Component Lubricant characteristic Lubrication method Lubrication frequency Tank capacity Recommended grade of lubricant High-Torque Gear Box Tank 1) Viscosity: ISO VG32 2) Viscosity index: above 95 3) Anti-rust, anti-oxidation 4) Good Stability Oil circulation As needed, 1/yr..95 qt. [1.0 Liter] 1) CPC Circulation Oil R32 2) Mobil D.T.E Heavy Medium 3) Daphne Super Multi Oil 68 4) Shell Turbo Oil T68 5) Esso Teresstic T68 Changing the Oil in the High-Torque Gear Box Tank The oil in the high-torque gearbox must be replaced every two years. 1. Make sure the spindle is down to its lowest point (-Z position). 2. Unthread the screws and lift off the sheet metal cover above and around the spindle column to expose the spindle drive and high-torque mechanisms. 3. Open the right side door and locate gearbox tank F, Figure 4.7. 4. Unthread the screws that fasten the tank top to the tank. The tank top has the lubricator pump mounted on it. 5. Carefully pry the top from the tank and set it aside. 6. Pump or wipe the oil from the tank until it is empty. Wipe the tank clean with a lint-free cloth. 7. Install the tank top and tighten the screws that fasten the top to the tank. Select the oil from the table on the previous page. Some tanks may have a filler cap; if there is a filler cap, clean the cap and area around the cap, open the cap and add oil until the tank is full. 8. Unthread tank vent G, and add oil until the tank is full. The tank will hold approximately 1 litre of fluid. 9. Thread the vent on until it is snug. 10. Check the hoses for any kinks or leaks and correct any problems as necessary. 11. Mount the spindle sheet metal cover and tighten the screws. 12. Power up the machine and continue with machine operation or maintenance. Page 46
4.6 CHANGING OIL IN THE ATC CAM BOX LUBRICATION The oil in the ATC CAM BOX must be changed every 2500 hours. Use the oil MOBIL Mobilgear 630. 1. Make sure the spindle is down to its lowest point (-Z position). 2. Open the left side door and locate ATC. 3. Unthread screw A to drain the oil from the tank until it is empty. 4. Install screw A. 5. Unthread screw B and fill the tank to the HALF line of the sight gauge. The spindle motor B A The bottom of the ATC CAM BOX The top of the ATC CAM BOX ATC CAM Oil Level Sight Gauge Page 47
4.7 CHANGING OIL IN THE APC CAM BOX LUBRICATION The APC CAM BOX is located at the middle of the APC hinge arm. Change the oil every 2 years. Use the recommended oils as below: SHELL Omala EP320 MOBIL Mobilgear EP320 CASTROL Alpha EP320 TOTAL EP320 1. Unthread the screw A to drain the oil from the tank until it is empty. 2. Tighten the screws that fasten the button to the tank. 3. Unthread the screw B and fill the tank to the HALF line of the sight gauge. B APC CAM Oil Level Sight Gauge A 4.8 CHANGING OIL IN THE APC HYDRAULIC POWER UNIT The APC hydraulic power unit is usually place rear-right side of the machine. Changing the hydraulic oil every 2000 hours. Use the recommended oils as below: MOBIL HYDRAULIC AW32 ESSO HYDRAULIC AW32 HYSPIN AWS32 Approximate hydraulic tank capacity is shown in the following chart: Machine Models GX 480 APC, GX 480 DT APC Hydraulic Tank Capacity 40 liters 10.6 US gallons 8.8 Imperial gallons Page 48
4.9 HYDRAULIC SCHEMATIC APC Pallet 4.10 HYDRAULIC DRAWING APC Pallet Page 49
CHAPTER 5 - MISCELLANEOUS 5.1 INTERLOCK SWITCH WITH GUARD DOOR LOCKING Both the front doors and the side toolchanger access door are equipped with an interlock switch with a door locking device. The doors must be shut completely before the machine can be started, and are 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. 5.2 VISION WINDOW GUARDS The GX range of machines is equipped with transparent window guards to allow the operator to observe the machining process, whilst protecting him from potential hazards. These windows are made from polycarbonate plate. Due to the aging phenomenon of polycarbonate it is necessary to REPLACE THE WINDOW GUARDS PERIODICALLY, as specified in the Operators Safety Manual Section 1.7. Page 50
5.3 SPINDLE BELT TENSION Check the drive belt tension frequently across all belts approximately at the midpoint between pulleys, as shown. Spindle Belt Deflection SPINDLE BELT TENSION SPECIFICATION Standard Spindle Drive GX 300/510/600/800/1000 GX 1300/1600 & XR 1300/1600 Belt Type Force Deflection Frequency Timing Belt 4.4 lb-f [2 kg-f] GX 480.157 in. [4 mm] 76±2 Hz Belt Type Force Deflection Frequency Timing Belt 4.9 lb-f [2.2 kg-f].142 in. [3.6 mm] 52±2 Hz High Speed Spindle Drive [Option] GX 600/800/1000 GX 1300/1600 & XR 1300/1600 Belt Configuration Belt Type Force Deflection Frequency 3 Strand Belt V Belt 5.1 lb-f [2.3 kg-f].165 in. [4.2 mm] 150±2 Hz Page 51
ADJUSTMENT PROCEDURE 1. Wait for the cycle to end and make certain that the spindle is stopped. 2. Power down the machine. 3. Loosen four mounting screws G, on the motor plate and two nuts of adjusting screw F. 4. Adjust the belt tension by tightening or loosening adjusting screw F. 5. Lock the adjusting bolt by tightening the two nuts together. 6. Tighten the four mounting screws on the motor plate. Spindle Belt Tension Adjustment (GX Machines Not Equipped with High Torque Option) Page 52
5.4 CLEAN THE POWER CASE HEAT EXCHANGER AIR FILTER The heat exchanger provides the cooling and environmental protection necessary for proper operation. The cleaning interval depends largely on the shop environment, the more dirt and dust particles in the air, the more frequently the filter will require cleaning. Clean the power case heat exchanger air filter as follows: 1. Lift up the tab on the filter, slide the bottom out and pull it down to remove. 2. Clean the air filter clean in soapy water. 3. Dry it with compressed air or allow it to air dry. Air Filter on Heat Exchanger GX-XR 1300/1600 Range (Heidenhain & Siemens) The filter is accessed using a step ladder. Care should be taken to ensure the step ladder is safety positioned, so it will not topple over and does not require excessive reaching. Any local guidance/legislation on the use of ladders must be followed. The cleaning interval depends largely on the shop environment, the more dirt and dust particles in the air, the more frequently the filter will require cleaning. Clean the power case heat exchanger air filter as follows: Air Filter of Heat Exchanger on 1. Lift up the tab on the filter, slide the bottom the top of electrical cabinet out and pull it down to remove. 2. Clean the air filter clean in soapy water. 3. Dry it with compressed air or allow it to air dry. Page 53
5.5 WORK LIGHT LAMP REPLACEMENT Lamp compartment and lamp may be hot. Allow them to cool down before handling. 1. Unlatch and open the right side access door to access the lamp. 2. Unthread the screws and lift the rear cover off. 3. Pinch together the wire retaining clip and unfasten it from the bracket; swing it back. Lift halogen bulb E from the socket. Disconnect the bulb wire. 4. Connect the new bulb wire and install the halogen bulb (or fluorescent lamp) in the socket by fastening the retaining clip. 5. Be sure that the O-ring is in place; mount the cover and thread in the screws. Work Light (Rear Cover Removed) Page 54
5.6 ADJUSTING APC HYDRAULIC UNIT 1. Loosen the nut to turn adjusting screw to 30kg/cm 2. Turn it clockwise to increase the pressure and anti-clockwise to decrease the pressure (direction when looking down) at the gauge. 2. Rotate the pressure switch cap to achieve 20 bar. APC Hydraulic Unit Pressure Switch Hydraulic Unit Pressure Gauge Page 55
5.7 CLEANING THE OPTIONAL CHIP CONVEYOR OR AUGER WHEN BLOCKED The chip conveyor or auger can became blocked for a number of reasons too much swarf, a large piece of excess stock material etc. When this occurs take the following steps: 1. Stop the swarf conveyor or auger by pressing the chip Conveyor ON/OFF key or issuing the stop M-code. 2. Reverse the conveyor or auger with the hold-to-run key or switch. 3. Open the guard door to see if the blockage can now be manually removed. Use the correct personal protective equipment. 4. Run the conveyor forward (with the guard door close). 5. Repeat process 2 to 4 until the blockage is removed. Do not use your bare hands to remove swarf. Page 56
MAINTENANCE AND CLEANING OF SPINDLE CHILLER A) Turn the operation switch and main power source OFF before proceeding with installation or maintenance. B) Please avoid a naked flame (from welding etc) near any oil (gas or liquid form) from the chiller. Components that required cleaning regularly are the chiller body, condenser, air filter, oil filter and oil tank. Please refer to the chiller instruction manual for details. Cleaning the Air Filter 1. To remove the filter, lift up and draw out the filter 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 is heavy stained. Cleaning the Air Filter Page 57
Change the Oil for Chiller Use the correct recommend oil for the spindle chiller, in order to keep the spindle at a suitable temperature. Recommended oil for Chiller Capacity (litres) Viscosity: ISO VG6 VG32 12 Mobil Velocite oil No. 3 12 1. Removed the plug M, Figure below, on the bottom of oil tank to drain out the oil after 2000 hours operation. 2. Open the cap L, Figure as below, to refill the oil tank. 3. If the chiller is located in humid climate zone, eventually water will condense within the tank and sink at the bottom. Please drain out the water from the tank at least once a month. L M Change the Oil for Chiller Cleaning the Oil Filter 1. Clean the filter once a day when the machine is new, or when parts of the spindle chiller circuit have been replaced. 2. Clean the filter every week during normal operation. Page 58
APPENDIX 1 - PREVENTIVE MAINTENANCE SCHEDULE The following maintenance times are approximate and components may need attention more frequently if excessive environmental pollution is present. 8 Hours Check air line filter bowls Check coolant level and thru-spindle coolant pressure Check cutting fluid (coolant) concentration and Ph Clean thru-spindle coolant tank screens Check coolant filters 40 Hours Remove chips from coolant tank (as necessary) Check heat exchanger air filter. Clean as necessary Wash machine and wipe clean 160 Hours Check and clean air line filter Check tool knockout piston lubrication Check power case for contaminants 400 Hours Add X, Y, and Z axes way grease (with the central manual grease supplier) 500 Hours Clean the coolant screens 600 Hours Add X, Y, and Z axes way grease (with grease fittings) Add tool carousel rail grease Check tool knockout lubrication cup for oil Check spindle drive belt for wear and adjust tension 1000 Hours Clean and flush coolant system and change coolant Check coolant hoses for cracks, bad fittings, and kinks Check spindle drive belt for wear and tension Check and tighten all electrical plugs and connections 2000 Hours Tool knockout piston oil Check high-torque spindle gear box lubrication Check spindle oil-air lubricator oil Check ATC CAM BOX lubrication Check spindle drive belt for wear and tension Check all push buttons and switches 4000 Hours Change oil in high-torque gear box ONE YEAR Change hydraulic oil Check oil hoses for cracks, bad fittings, and kinks TWO YEARS Change APC cam box oil Page 59