V-60 i/80i MCV-1500i+ MCV-2000i - leadwell cnc machines mfg.,corp.

V-60 i/80i
MCV-1500i+
MCV-2000i
VER:IM-V060300
NO:P20ABEV60I
LEADWELL
V-60i/V-80i/MCV-1500i+/MCV-2000i
INSTRUCTION
MANUAL
P20ABEV60I
CONTENT
PAGES
PREFACE, INTRODUCTION, COPYRIGHT...................................
I, II, III
1. SAFETY PRECAUTIONS
1-1 SAFETY RULES...............................................................................................
1-1
1-2 GENERAL SAFETY INSTRUCTIONS............................................................
1-3
1-3 THE DIAGRAMS AND DRAWINGS OF SAFETY.........................................
1-5
1-4 DANGER AREAS.............................................................................................
1-8
2. MACHINE FEATURE
2-1 NOMENCLATURE ..........................................................................................
2-1
2-2 SPECIFICATION...............................................................................................
2-2
3. TRANSPORTATION
3-1 PRECAUTION...................................................................................................
3-1
3-2 TRANSPORTATION DRAWING …………….................................................
3-2
3-3 TRANSPORTATION-FLOOR DRAWING.......................................................
3-3
4. INSTALLATION
4-1 PRECAUTION..................................................................................................
4-1
4-2 ENVIRONMENTAL REQUIREMENT............................................................
4-1
4-3 THE PROCEDURE OF INSTALLATION MACHINE ....................................
4-2
4-4 THE PROCEDURE OF ADJUSTING LEVEL………......................................
4-8
5. KEY PARTS FEATURES
5-1 PNEUMATIC SYSTEM .................................................................................
5-1-1 FRL UNIT ……………………………………………..................................
5-1-2 TECHNICAL DATA AND OUTLINE DIMENSION..................................
5-1-3 THE SETTING METHOD OF FRL UNIT ..................................................
5-1-4 THE LOOP SKETCH OF PNEUMATIC SYSTEM...........…......................
5-1
5-1
5-2
5-3
5-4
5-2 COOLANT SYSTEM .....................................................................................
5-5
5-2-1 OUTLINE DIMENSION OF COOLANT PUMP.........................................
5-2-2 TECHNICAL DATA....................................................................................
5-2-3 POSITION OF TERMINAL BOX................................................................
5-2-4 PIPE WORK.................................................................................................
5-2-5 ELECTRICAL CONNECTIONS .................................................................
5-2-6 PHASE OF THE PUMP...............................................................................
5-2-7 TROUBLESHOOTING................................................................................
5-5
5-5
5-5
5-5
5-6
5-6
5-6
5-3 SPINDLE OIL CHILLER SYSTEM ...........................................……..........
5-3-1 OUTLINE DIMENSION..............................................................................
5-3-2 CIRCUIT DIAGRAM...................................................................................
5-3-3 WIRE CONNECTION..................................................................................
5-3-4 GENERAL CAUTION.................................................................................
5-3-5 MAINTENANCE..........................................................................................
5-3-6 TROUBLESHOOTING................................................................................
5-7
5-7
5-7
5-8
5-8
5-9
5-10
5-4 LUBRICATION SYSTEM .............................................................................
5-4-1 OUTLINE DIMENSION...............................................................................
5-4-2 FULL UP LUBRICATION OIL ...................................................................
5-4-2-1 OIL RECOMMENDATION ..............................................................
5-4-3 THE LUBRICATION SYSTEM SKETCHES OF AXES………………….
5-4-4 THE LUBRICATION SYSTEM SKETCHES OF AXES………………….
5-11
5-11
5-11
5-12
5-13
5-14
6. OPERATION
6-1 MISCELLANEOUS FUNCTION (M FUNCTION/M CODE) .........................
6-2 SPECIFYING THE SPINDLE SPEED (S FUNCTION/S CODE) ..........…......
6-3 TOOL NUMBER CODE (T FUNCTION/T CODE) .........................................
6-4 SPECIFYING THE FEED RATE (F FUNCTION) ...........................................
6-5 PREPARATORY FUNCTION (G FUNCTION) ..............................................
6-6 PROGRAM
6-6-1 Searching or calling programs ....................................................................
6-6-2 Program editing ............................................................................................
6-7 COORDINATION SYSTEM
6-7-1 Programming zero point …….......................................................................
6-7-2 Coordination system ………….....................................................................
6-7-3 The flowchart of ATC operation…………....................................................
6-1
6-1
6-1
6-2
6-2
6-2
6-3
6-4
6-4
6-5
7. CLEAN AND MAINTENANCE
7-1 DAILY MAINTENANCE
7.1.1 Before power on …………………………………………………………
7.1.2 After power on ……………………………………………………….……
7.1.3 After finishing daily work ……………………………………………...…
7-2 WEEKLY MAINTENCE...................................................................................
7-3 SEMIANNUAL MAINTENANCE....................................................................
7-4 ANNUAL MAINTENANCE.............................................................................
7-5 ENVIRONMENTAL CLAIMS..........................................................................
7-6 OUR GOAL.......................................................................................................
7-7 WASTE TREATMENT.....................................................................................
【APPENDIX】Caution：Spindle operation
7-1
7-1
7-1
7-2
7-2
7-3
7-3
7-3
7-4
PREFACE
Thank you for purchasing the CNC MACHINE TOOL CENTER. We at
Leadwell are confident your purchase will greatly expand your work
capacity and efficiency. This issue has been prepared to assist you on
ordering replacement, servicing parts, technical problem for the type of
V-60. Due to constant improvement in design, you may find slight
variations from the machine delivered to you. This merely indicates that
equipment
improvements
have
been
made
to
better
meet
your
requirements. If you have any question on your machine or this
publication, please contact your Leadwell dealer or local agent.
I
BRIEF INTRODUCTION OF LEADWELL
Founded in 1980, Leadwell CNC Machines Mfg., Corp., is now the largest CNC
machine tool maker in Taiwan. Leadwell is constantly searching for perfection by
upgrading the performance, product quality and reliability of its products which
range from CNC Vertical /Horizontal Machining Centers, Turning Centers, Plastic
Injection Molding Machines, Grinders, Tapping/Drilling Machines to Laser Cutting
Machines, 5-face Machining Centers and Flexible Manufacturing Systems (FMS).
In 1993 Leadwell received the Outstanding Product Award --SYMBOL OF
EXCELLENCE and its quality passed ISO recognition. Hence, Leadwell products
are recognized as highly reliable. In October, 1997 Leadwell has received the
National Quality Award by the Executive Yuan, R.O.C. We have developed our
products total quality management with outstanding result. January of 1999, the
grate month, Leadwell passed a certification of ISO-14001 from the Bureau of
Commodity Inspection And Quarantine (BCIQ) Ministry of Economic Affairs
Taiwan.
II
CHANGES AND COPYING
Leadwell reserves the right to make any change or modification to this manual
without giving previous notice and without incurring any obligation. You may not
reproduce or transmit in any form or by any means without the written permission
of Leadwell.
◎Copyright 2000 LEADWELL CNC Machines Mfg., Corp. All rights reserved.
III
Safety Precautions
Contents
1. SAFETY PRECAUTIONS
1.1 SAFETY RULES
1.1.1 The basic conditions given below must always be strictly followed …………… 1-1
1.2 GENERAL SAFETY INSTRUCTIONS
1.2.1 Cautions of operating machine …………………………………………………. 1-3
1.2.2 Routine inspections ……………………………………………………………... 1-4
1.2.3 Warm up and preparation ……………………………………………………….. 1-5
1.3 THE DIAGRAMS AND DRAWINGS OF SAFETY
1.3.1 Warning signs and labels ………………………………………………………... 1-5
1.4 DANGER AREAS
1.4.1 The area with moving parts ……………………………………………………... 1-8
1 SAFETY PRECAUTIONS
This machine is provided with a number of safety devices to protect personnel and
equipment from injury and damage. Operators should not, however, rely solely
upon these safety devices but should operate the machine after fully understanding
what special precautions to take by reading the following statements thoroughly.
1-1 SAFETY RULES
However, safe operation cannot be ensured if operators use a CNC
Machine Center improperly or do not follow safety rules properly.
Failure to comply with these rules may result in death, injury, or damage
to the machine and/or products. In addition to the safety information in
this manual, common sense tells us there are many "Don'ts" when
operating a machine. Unless an operation is specifically stated in this
instruction manual, consider that operation a "Don't".
1-1-1 The basic conditions given below must always be strictly followed.
‧ Only qualified personnel are permitted to maintain and/or operate this
machine.
‧ Read the instruction manual thoroughly and make sure the contents are
completely understood in order to operate a machine efficiently and safely.
‧ Always keep this safety paragraph and the instruction manual at a designated
place near the machine so that they can be easily accessed whenever required.
‧ Use safety shoes which are not damaged by oil, safety goggles with side
covers, safety clothes and other safety protection.
‧ Keys must be kept by a senior qualified person.
‧ Be sure there are no articles around the machine.
‧ Turn off the power source before leaving, checking and daily work.
‧ All persons concerned with operation and maintenance of this machine must
be aware of the emergency stop buttons and switches' location, functions and
operation.
‧ In the event of power failure, turn off the main circuit breaker immediately.
‧ Use the recommended hydraulic oils, lubricants and grease or acceptable
equivalents.
‧ Replacement fuses should have the proper current ratings.
1-1
‧ Protect the NC unit, operating panel, electric control panel, etc., from shocks,
since this could cause a failure or malfunction.
‧ Do not change parameters, volumes and other electrical settings
unnecessarily. If such changes are unavoidable, record the values prior the
change so that they can be returned to their original settings if necessary.
‧ Do not soil, scratch or remove the caution plate. Should it become illegible or
be missing, order another caution plate from the supplier.
‧ Whenever operating a forklift truck, over-crane similar equipment, special
care should be taken to prevent collisions and damage to surroundings.
1-2
1-2 GENERAL SAFETY INSTRUCTIONS
1-2-1 CAUTIONS OF OPERATING MACHINE:
‧ Only well-trained personnel may operate this machine.
‧ Always wear helmet, protecting glasses, safety shoes and other protecting equipment as
required while operating this machine.
‧ Do not wear loose clothing or jewelry that can be caught by moving parts of machine.
‧ Do not touch the chip and blade tip of the cutter with naked hands or the moving parts with
gloves.
‧ During operating, do not take the chip away or touch the rotating portion parts with naked
hands and other tools.
‧ When performing heavy-duty machining, carefulley prevent chips from being accumulated
since hot chips can catch fire.
‧ Do not touch any switches with wet fingers.
‧ Always remember the position of the emergency stop button, so that you can press the
button immediately if accident occurred.
‧ Never operate the machine, unless everything is completely set down.
‧ Do not use fuses other than those are specified.
‧ Pay attention to the high voltage devices and keep away from them as possible as you can.
‧ When the machine is operating, do not put your hands into the rotating and moving objects.
‧ Stop the machine before adjusting the position of coolant nozzle or disposing the chips.
‧ Always turn off the power before performing maintenance or inspection.
‧ Cables, cords or electric wires whose insulation is damaged can produce current leaks and
electric shocks. Before using, please check their condition.
‧ Do not operate switches with gloves. This could cause malfunctions, damage, etc..
‧ Do not cut the kind of material which are easy to cause fire on this machine, such as
magnesium, magnesian ally or other material with lower melting point.
‧ During automatic operating, never open the machine door occasionally.
‧ During the time of worming, do not touch or operate the machine parts.
1-3
1-2-2 ROUTINE INSPECTIONS:
‧ Check pressure gauges for proper reading
‧ Check motors and other parts for abnormal noises.
‧ Check the motor lubrication, sliding parts for evidence of proper lubrication.
‧ Check safety covers and safety devices for proper operation.
‧ Before the first time to use, each sliding parts must be freshly lubricated after unpacking or
keeping the machine idle for a period. For the lubricant and so on, keep the lubricating oil
pump working until oil oozes out from wiper. Contact our service station or agents in
connection with what procedure should be taken since it depends on the type of machine.
‧ Clean the tank so that any abnormalities can be found easily.
‧ Make sure that the gauges for hydraulic pressure, air pressure, lubricating oil pressure
indicated the correct values.
‧ Make sure that lubricating oil and hydraulic oil are properly supplied to the correct places.
‧ Oil reserviors should be filled to indicated levels. Check and fill it up, if necessary.
‧ Check the coolant level on the tank, and fill it with coolant, if necessary.
‧ All parts and waste oils should be removed by the operator and placed far enough away
from the machine set.
1-2-3 WARM UP AND PREPARATION:
‧ The power cable from the factory feeder switch to the machine main circuit breaker must
check if there is a sufficient sectional area to handle the electric power usage.
‧ Warm up the machine, especially the spindle and feed shaft by running them for ten to
twenty minutes with about half or one-third the maximum speed in the automatic operation
mode.
‧ Wire ropes or slings should be strong enough to handle the loads and should conform to the
mandatory provisions.
‧ Tools should conform to the machine specifications, dimensions and type.
‧ After installing a tool, make a trial run.
1-4
1-3 THE DIAGRAMS AND DRAWINGS OF SAFETY
1-3-1 WARNING SIGNS AND LABELS:
There are several specific safety signs and labels on your machine. These signs and labels are
attached to the machine at easy-to-see locations.
DANGER: Indicated an imminently hazardous situation, which if not avoided, could result in
death or serious injury.
WARNING: Indicated a potentially hazardous situation, which if not avoided, could result in
death or serious injury.
CAUTION: Indicated a potentially hazardous situation, which if not avoided, might result
moderate danger to the machine and death or serious injury.
LABELS: Indicated some special purpose or production examined by Q.C. DEP..
Make sure that you can read all warning and instruction labels. Clean or replace these labels
if you can not read clearly. By using a cloth, water and soap clean surface of them. Do not
use solvent, gasoline or unknown solution. You must replace new labels if they are broke,
missing or can not be recognized. In addition to the information given on safety labels, there
is a variety of other cautionary information which must be observed by operators during
machine installation, operating and maintenance. Read all safety-related information
carefully.
Failure to observe the danger of caution information can lead operators a serious injury or
damage to the machine. Always observe this information during machine installation,
operation and maintenance.
Those warning and sign labels as shown as following pages.
1-5
1-6
1-7
1-4 DANGER AREAS
1-4-1 THE AREA WITH MOVING PARTS:
When no safety guarding, the inside of machine is an extremely dangerous
area due to High-speed spindle‘s rotation, tool X, Y and Z axes movements,
tool magazine rotation, tool arm rotation, swin arm of pallet rotation and quill
motions. In addition to chips and coolant are constantly bouncing and
splashing in a wet, very hot environment. In electric controlling cabinet, it is
touched, can produce current leak and electric shock without protection or
insulation acrylics. So we had not stuck labels on the cabinet but also
warning statements in the instruction manual.
All areas inside the body cover are Danger area.
+Z
-Z
-x
+x
-Y
1-8
+Y
Machine Feature
Contents
2. MACHINE FEATURE
2.1 NOMENCLATURE ……………………………………………………………….. 2-1
2.2 SPECIFICATION OF MACHINE V-60(for Fanuc and Meldas) ………………. 2-2
2 MACHINE FEATURE :
2-1 NOMENCLATURE :
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
DESCRIPTION
AUTOMATIC TOOL CHANGER UINT
BASE UINT
SADDLE UNIT
TABLE UNIT
SPINDLE HEADSTOCK UNIT
SPINDLE UNIT
SHEET METAL ENCLOSURE GUARDS UNIT
OPERATION CABINET UNIT
COLUMN AND BALANCE WEIGHT UNIT
COLUMN AND BALANCE WEIGHT UINT
POWER CABINET UINT
COOLANT TANK UINT
HORN-COIL TYPE CHIP CONVEYOR
2-1
2-2 SPECIFICATION OF MACHINE V-60i
規
V-60 i
項
目
格
/
表
類別
S
SPECIFICATIONS
工作範圍
P
機型代碼
-
V
6
0
N
規
年份
版本
9
i 2
4
格
Capacity
X 軸行程
X-axis travel
mm(in)
1520(59.8)
Y 軸行程
Y-axis travel
mm(in)
650(25.6)
Z 軸行程
Z-axis travel
mm(in)
720(28.3)
mm(in)
100-820(4-32.3)
Distance from table(pallet) top to
工作台面至主軸端面
spindle end
Distance
from
column
front
to
立柱最前端至主軸中心
760(30)
(Full Stroke)mm(in)
spindle center
工 作 台
Table
工作台面積
Size of working surface
最大荷重
Permissible mass of workpiece
主
軸
mm(in)xmm(in)
1550x750 (61x29.5)
1200 (2640)
kg(lb)
Spindle
主軸轉速
Spindle speeds
min
鼻端型式
Spindle nose(nominal size,NO.)
主軸前軸承內徑
Spindle bearing inner diameter
速比/最大扭力
Ratios / Max. spindle torque
進 給 率
8000
-1
7/24 Taper, NO40
70 (2.75)
mm(in)
N M(ft lbf)
1:1/140 (103)
.
.
Feedrate
快速位移
Rapid traverse
m/min(IPM)
24/24/20 (944/944/786)
切削進給率
Feedrate
m/min(IPM)
5 (196.8)
自動換刀系統
A.T.C
Drum type
Arm type
24
刀具數
Tool storage capacity
刀具最大外徑(相鄰刀)
Max. tool diameter(with adjacent tools)
mm(in)
95(3.7)
80(3.15)
刀具最大外徑(非相鄰刀) Max. tool diameter(without adjacent tools)
mm(in)
150(5.9)
110(4.3)
刀具最大重量
Max. tool mass
kg(lb)
7(15.4)
7(15.4)
刀具最大長度
Max. tool length
mm(in)
250(9.8)
250(9.8)
換刀時間(tool to tool) Tool change time（tool to tool）
sec
8
3.5
換刀時間(chip to chip) Tool change time（chip to chip）
sec
14
12
馬達
Motors
主軸馬達
Spindle motor（30min/cont）
KW(HP)
11/15(15/20)αp22/8000i
X 軸伺服馬達
X-axis feed motor
KW(HP)
4(5.4)α22i/3000
Y 軸伺服馬達
Y-axis feed motors
KW (HP)
4(5.4)α22i/3000
Z 軸伺服馬達
Z-axis feed motors
KW (HP)
4(5.4)α22i/3000
機台尺寸
Machine size
機台總高
Height of machine
佔地空間（寬＊深）
Floor space
機台重量
Mass of machine
mm(in)
mmxmm(in)
Kg(lb)
2-2
3300(130)
4620x3500(182x125.5)
10500(23100)
Transportation
Contents
3. TRANSPORTATION
3.1 PRECAUTION……………………………………………………………………… 3-1
3.2 TRANSPORTATION DRAWING…………………………………………………. 3-2
3.3 TRANSPORTATION FLOOR DRAWING………………………………………. 3-3
3. TRANSPORTATION :
3-1. PRECAUTION :
1. Only trained, qualified workers should operate forklift trucks, cranes or similar
equipments and apply slings.
2. The wires used to lift should be checked that they are strong enough for the
weight of machine center and in good condition. The dimensions of wire ropes
specified in manual. (Refer to drawings)
3. Be sure that the wires will not come into contact with any delicate parts of
machine center. Preotect machine by placing cloths or wooden blocks.
4. Before hoisting the machine, make sure all moving units are fixed in place.
5. Be careful and avoid the hoisting wires contacting with any piping, unit, parts,
electric cables.
6. Check around the site of machine and make it clean, proper to be installed,
that is, can keep machine away from jolts during move or transport machine.
7. Always inspect slings, chains, hoists or other lifting devices prior to us and
never work on a component while it is hanging from a crane or other lifting
mechanism.
8. The floor of machine located must be firm, in order to ensure vibration free
and secure fastening. Should the floor not be firm, a concrete foundation is
recommended.
9. Keep the machine‘s center of gravity at the center of the forks.
Refer to the next pages drawings for hoisting.
3-1
3-2 TRANSPORTATION DRAWING
12 tons
3-2
3-3 TRANSPORTATION-FLOOR DRAWING
OUTLING DRAWING
3-3
Installation
And
Preparation
Contents
4. INSTALLATION AND PREPARTION
4.1 PRECATION ……………………………………………………………………….. 4-1
4.2 ENVIRONMENTAL REQUIREMENT …………………………………………. 4-1
4.3 THE PRECEDURE OF INSTALLATION MACHINE …………………………. 4-2
4.4 THE PRECEDURE OF ADJUTING LEVEL ………………………... ……... …. 4-8
4 INSTALLATION AND PREPARTION :
4-1 PRECATION :
1. Only trained, qualified workers should operate forklift trucks, cranes or similar equipment
and apply slings.
2. Use only wires of dimensions specified in the manual. They must be strong enough to
support the weight of the machine.
3. Before hoisting the machine, make sure that each of the units is fixed securely.
4. Be careful during remove the machine to proper site and install it.
5. Keep clean around the machine and floor.
6. be sure electrical cables and wire will not be damaged during installing machine.
7. After installation and clean, connect the wire to the power source and ensure the requirement
of power capacity is proper.
8. Before using, remove the anti-rusty oil by rags with paraffin or fueloil. Toluene compounds
must not be used.
4-2. ENVIRONMENTAL REQUIREMENT :
1. Where the machine avoid exposing to the direct sunlight and/or near to a heat source, etc..
Ambient temperature during operation should be 0 thru 40℃.
2. Avoid a location where the humidity is considerable fluctuating and/or it is highly humid,
normally 75﹪ and below in relative humidity.
3. Avoid using the machine under such invironments as to be specially dustful and/or to have a
vaporous. organic corrosive gas highly concentrated.
4. Where there is no vibration source in the surroundings.
5. Flat and smooth ground without dust or other particles. The required bearing pressure of the
floor is at least 5000kg/㎡.
6. The machine must be protected from electrical noise sources, such as electric welders and an
electric discharge machines.
7. Always ground machine independently, the ground resistance is 100 ohms or less and the
length of ground cable is as short as possible.
8. The sound pressure level at the operator‘s position is under 85 dbA.
9. Foundation should be constructed of either, reinforced or non-reinforced concrete with
thickness and consistency compatible to industry standards for machine weight.
4-1
4-3 THE PRECEDURE OF INSTALLATION MACHINE :
1. Position the machine after settling down the machine to the adequate place.
2. Put the foundation pads under the foundation bolts and according to the drawing
of foundation to position machine.
4-2
3. Replace the z-axis motor on transmission housing, if is removed:
a. Tighten the screw S2 on the coupling of z-axis.
b. Tighten the screw S1 on the motor side of z-axis. (Refer to the following drawing)
c. Make 3 axes return to home position after power on.
S2
S1
4-3
4. Correct the tool changing position:
a. Z axis returns to home position by manual.
b. Put a tool into spindle by the switch of clamp or unclamp and make sure the distance
between spindle nose and tool edge is within 0.6-0.8 mm.(As drawing shown)
c. Turn off the air source, then orientate spindle by M19.
d. Push the tool magazine toward spindle by hand and check if the tool key match with tool
keyway.
e. Reconnect the air source system.
f. Ensure the movement of tool magazine is smoothly by M21, M22 under manual mode.
g. Adjust the screws of the air cylinders located on top of tool magazine,if the movement is
stagnant.
h. If there is a distance along Z axis between tool magazine and tool in spindle, adjust to match
with tool key of tool magazine by parameter no. 1850 (Z) for 21MB/18MC, Fanuc.
i. If there is an offset between the changing tool pocket of tool magazine and tool key on
spindle, adjust by the orientation pad mounted on orientation wheel of spindle.
j. Make sure everything is smoothly, then from beginning to operate.
4-4
5. Correct the drum type tool changing position (for Fanuc and Mitsubishi):
a. Z axis returns to home position by manual.
b. Put a tool into spindle by the switch of clamp or unclamp and make sure the distance
between spindle nose and tool edge is within 0.6-0.8 mm.(As drawing shown)
c. Turn off the air source, then orientate spindle by M19.
d. Push the tool magazine toward spindle by hand and check if the tool key match with tool
keyway.
e. Reconnect the air source system.
f. Ensure the movement of tool magazine is smoothly by M21, M22 under manual mode.
g. Adjust the screws of the air cylinders located on top of tool magazine, if the movement is
stagnant.
h. If there is a distance along Z-axis between tool magazine and tool in spindle, adjust to match
with tool key of tool magazine by parameter no. 1850(Z) for 21MB/18MC, FANUC.
i. If there is an offset between the changing tool pocket of tool magazine and tool key on
spindle, adjust by the orientation pad mounted on orientation wheel of spindle.
j. Make sure everything is smoothly, then from beginning to operate.
4-5
5-1. Correct the arm type tool changing position(for Fanuc):
a. Z axis returns to home position by manual.
b. Put a tool into spindle by the switch of the clamp or unclamp and make sure
the distance between spindle nose and tool edge is within 0.6-0.8 mm.(As
drawing shown)
A
ARM
c. Then press the
d. Press the
MPG
SPDL
ORIEN
button.
button.
DGONS
e. Press the PARAM
f. (Look CRT) Press the button below the (PARAM).
g. (Look below “PAGE”) Press the
h. Press the MDI
i. Press the 1
Ð button.(page down)
button.
button. [When (PWO=0 (Can not change date), PWO=1 (can change date)]
j. Press the INPUT button.(showing 100 alarm)
k. Press the
DGNOS
PARTS
button
4-6
l. (Looking CRT) Press the button below the (DGNOS)
L
l. press the NO. Q button.
P
m. Press the 5
n. Press the
2
INPUT
o. Press the 1
0
5
buttons.(normal D0525 10000000)
button.
1 1
0 0 0 0 bottons.
p. Press the INPUT buttons.(after finish change it back to D0525
q. (Make sure the spindle nose higher than arm‘s top) Press the
10000000)
MPG
then press the
SPDL buttons.
ORIEN
r. (When you press the
CYCLE
button the arm will be move, so take care of you fingers)
START
s. Make sure the distance between spindle nose and arm‘s top is within (BT type 5.90±0.05mm.
(for CAT type is 3.3±0.05mm)
(If you want to arm to reverse, change the D0526 00100000 to D0526 00100001 then press
the CYCLE button .(before you press the “cycle start ” button take care of your fingers.)
START
t. Change the DGNOS “D0525 10000000” and “D0526 00100000” and PARAM “PWO=0”
BACK
u. Press the MDI
M
6
/.#
EOB
buttons.(for test auto tool change)
4-7
4-4. THE PROCEDURE OF ADJUSTING LEVEL :
1. Let three axes return to the home position.
2. Clean the table surface and put the levels gauge on just as the drawing shown.
3. Adjust the foundation bolts and nuts to make the foundation bolts locate within the slot of
pad.
A
B
4. Move X axis to 760mm(for V-60) and Y axis to -380mm(for V-60). Adjust the foundation
bolts and ensure the bubbles of level gauges in the middle position or keep the deviation
within 0.01 mm(A and B).
5. Move Y axis to zero and -760mm(for V-60). The difference value between two points should
be within 0.02 mm(A) and 0.04 mm(B).
6. After returning Y axis to -380mm(for V-60) Move X axis to the zero position and
1520mm(for V-60), by adjusting the bolts and nuts to make the difference between the two
points within 0.04 mm(A) and 0.05 mm(B).
7. Tighten the foundation bolts and nuts.
8. Check again.
4-8
metal plate Joins the place
with the foundation All must
spread guards against leaks
the rubber
9
4
metal plate Joins the
place with the foundation
All must spread guards
against leaks the rubber
0
1
4
metal plate Joins the place all
to need Spreads guards
against leaks the rubbe
metal plate Joins the place all
to need Spreads guards
against leaks the rubbe
metal plate Joins the place all
to need Spreads guards
against leaks the rubbe
Key parts features
Contents
5. KEY PARTS FEATURES
5.1 PNEUMATIC SYSTEM
5.1.1 FRL UNIT ……………………………………………………………………… 5-1
5.1.2 TECHNICAL DATA AND OUTLINE DIMENSION …………………………. 5-2
5.1.3 THE SETTING METHOD OF FRL UNIT …………………………………….. 5-3
5.1.4. THE LOOP SKETCH OF PNEUMATIC SYSTEM ………………………….. 5-4
5.2 COOLANT SYSTEM
5.2.1 OUTLINE DIMENSION OF COOLANT PUMP ……………………………… 5-5
5.2.2 TECHNICAL DATA …………………………………………………………… 5-5
5.2.3 POSITION OF TERMINAL BOX …………………………………………….. 5-5
5.2.4 PIPE WORK …………………………………………………………………… 5-5
5.2.5 ELECTRICAL CONNECTION ……………………………………………….
5-6
5.2.6 PHASE OF THE PUMP ……………………………………………………….. 5-6
5.2.7 TROUBLE SHOOTING ………………………………………………………. 5-6
5.3 SPINDLE OIL CHILLER SYSTEM
5.3.1 OUTLINE DIMENSION ………………………………………………………. 5-7
5.3.2 CIRCUIT DIAGRAM …………………………………………………………. 5-7
5.3.3 WIRE CONNECTION ………………………………………………………….. 5-8
5.3.4 GENERAL CAUTION ………………………………………………………… 5-8
5.3.5 MAINTENANCE ……………………………………………………………… 5-9
5.3.6 TROUBLE SHOOTING ………………………………………………………... 5-10
5.4 LUBRICATION SYSTEM
5.4.1 OUTLINE DIMENSION ………………………………………………………. 5-11
5.4.2 FILL UP LUBRICATION OIL ………………………………………………… 5-11
5.4.2-1 OIL RECOMMENDATION
..............................................................
5-12
5.4.3 THE LUBRICATION SYSTEM SKETCHES OF AXES………………….
5-13
5.4.4 THE LUBRICATION SYSTEM SKETCHES OF AXES………………….
5-14
5. KEY PARTS FEATURES
5-1 PNEUMATIC SYSTEM :
5-1-1. FRL UNIT :
Filter Regulator
Lubricator
NO.
NAME
NO.
NAME
1
Body
1
Body
2
Bonnet
2
Sight Dome
3
Valve Assembly
3
Filter Cup
4
Filter Element
4
Damper Guide
5
Baffle
5
Needle Valve
6
Diaphragm Assembly
6
Bowl
7
Deflector
7
O Ring
8
Bowl
8
Damper
9
Spring
10
O Ring(Case)
11
O Ring(Valve)
12
MY seal
13
O Ring
5-1
5-1-2. TECHNICAL DATA AND OUTLINE DIMENSION :
a. TECHNICAL DATA :
TYPE
AC3010 FILTER REGULATOR LUBRICATOR
Max. operating pressure
9.9 kgf/c ㎡
Min. operating pressure
1
Regulating range
0.5～8.5 kgf/ c ㎡
Ambient and media temperature
5～60℃
Pressure gauge indicated
10 kgf/c ㎡
Filter rating
5 μm
Filter bowl capacity
20 cm3
Max. flow rate
1700 l/min
Lubricator bowl capacity
50 c m3
Recommanded oil
ISO VG 32 (20℃)
Range of lubricator function
5 drops/min, PIN=5 kgf/ c ㎡, 40l/min
kgf/c ㎡
NOTE : 1. Polycarbonate bowls may be damaged and possibly fail if exposed to synthetic oils,
thinner solvents, trichlorethylene, kerosene or other aromatic hydrocarbons.
When
used in above atmosphere, please use a metal bowl.
2. Unsuitable for flow is below 100 normal l/min.
3. The drain
line should be 8 mm or more and overall line should be less than 5 M.
5-2
b. OUTLINE DIMENSION :
5-1-3. THE SETTING METHOD OF FRL UNIT :
a. Check pressure supply before adjusting system pressure.
b. The adjustment knob is a locking type. Pull the knob upward from the bodyuntil an orange
band is visible. (Show on the drawing)
c. Adjust as necessary, that with watch of the pressure gauge and clockwise rotaton of the knob
results in a increasing pressure or counterclockwise turn will reduce the pressure.
d. Then push the knob back into locking position after adjusting.
e. Adjust oil droplet by turning a knob of needle valve, clockwise turn will increase oil capacity
and counterclockwise turn(fully open) will stop the oil droplet.
5-3
5-1-4. THE LOOP SKETCH OF PNEUMATIC SYSTEM :
5-4
5-2 COOLANT SYSTEM:
5-2-1 OUTLINE DIMENTION OF COOLANT PUMP:
5-2-2 TECHNICAL DATA :
TYPE
Max. operating pressure
GRUNDFOS CH4-20
10 bars (0℃ - +40℃)
6 bars (+41℃ - +90℃)
Min. inlet pressure
0.75 bar (20℃/ 50Hz)
0.68 bar (20℃/ 60Hz)
Liquid temperature range
0℃ - +90℃
Max. ambient temperature
+55℃
5-2-3 POSITION OF TERMINAL BOX :
a. The terminal box can be changed to any one of 0°, 90°, 180°. It is not allowed
to be changed by user or owner of this machine.
5-2-4 PIPEWORK :
a. The pipe should be fitted so that any tension caused by variations in
temperature does not affect the pump. A strainer is recommended in cases
where solids could enter the suction pipe and block the pump.
b. The pump suction port must be below the lowest coolant level, for the pump is
not self-priming.
c. If a hose is used as suction pipe, it must be non-collapsible and every joint of
the suction pipe should be completely tight.
d. The discharge pipe should be at least the same diameter as the discharge port of
the pump to minimize pressure drop, high flow velocities and noise.
5-5
5-2-5 ELECTRICAL CONNECTIONS :
a. The electrical connections should be carried out in accordance with local
regulations.
b. The operating voltage and frequency are marked on the nameplate mounted on
pump.
c. The pump must be connected to an external on/off switch.
NOTE : Never make any connections in the pump terminal box unless the
electricity supply has been switched off.
5-2-6 PHASE OF THE PUMP :
a. Signal- phase motor (1x110/220V, 60Hz), do not incorprate motor protection
and must be connected to an approved motor starter. The other incorporate a
thermal overload switch and require no additional motor protection.
b. Three-Phases motor must be connected to a motor starter, the set nominal
current of which must correspond to the electrical data on the nameplate.
NOTE : 1. Do not start the pump at first time using until it has been filled with
coolant.
2. Every connection are made as shown on the inside of the terminal box
cover.
3. The pump should rotate counter0clockwise when viewed from the motor
end and arrows on the motor fan‘s cover indicated the correct direction of
rotation.
4. To reverse the direction of rotation, switch off the power supply and
interchange any two of inputing supply wire.
5-2-7 TROUBLE SHOOTING :
FAULT
Pump does not start.
CAUSE
Supply failure.
Control circuit has cut out or is defective.
Motor is defective.
Pump is blocked by impurities.
Pump runs but gives no coolant. Pump is not filled with coolant.
Suction or discharge pipe is blocked
impurities.
Leakage in suction pipe.
Foot or check valve is blocked.
Pump runs at reduced capacity. Wrong direction of rotation(three-phase).
Suction lift is too great.
Suction or discharge pipe is blocked.
Pump is blocked by impurities.
Foot or check valve is partly blocked.
Pumpstops during operation.
Thermal overload switch in motor or external
motor protection cuts out.
Control circuit has cut out.
5-6
by
5-3 SPINDLE OIL COOLER SYSTEM
5-3-1 OUTLINE DIMENSION:
TYPE CO-4PT
(L050250t20)
5-3-2 CIRCUIT DIAGRAM:
5-7
5-3-3 WIRE CONNECTION:
1. Be sure R.S.T are in phase after turning on.
2. Check insulation of compressor and pump before running.
3. 23C temperature meter must set at 25℃.
4. Operation switch should be “ON” position.
5. When the negative phase relay is triggered, reconnect two of R.S.T three lines
of power wire.
5-3-4 GENERAL CAUTION:
1. The oil cooler is designed for reducing heat and cooling spindle of CNC
machinery. It can not be used out of the range as following illustration.
2. Oil cooler usse mineral hydraulic oil or lubrication oil and the viscosity is
22-32 Cst. Phosphoric ester, chlorinated, hydrocarbon type fluids, cutting oil,
grinding oil, medicine or corrosion liquids, gasoline, kerosene fuel and
water-soluble liquid can not use on this unit.
3. Do not fall it flat and strike it as moving and put it on a level and solid floor.
4. Locate the oil cooler at well ventilation place where is free from fire hazard
and from direct sunlight or heat.
5. Be sure the pressure of oil pump is set from 4 to 8 kg/cm2.
6. The pressure loss of outlet pipe should be below 3 kg/cm2.
5-8
7. Be sure the installation place of oil cooler unit where exhausting and air
suction can be well performed. (Refer to the following sketches)
8. Fit a suction strainer to the suction end of oil piping which is of 100 to 150
mesh (10-15mm metal net), therefore, it will be free from damage of
compressor and drop of cooling capacity. Both suction and discharge pipes
outside must be designed that the size larger than the size of outlet and inlet of
oil cooler.
9. Before removing the air filter must wait for more 10 minutes after turning off
switch.
10. When the refrigerator once stops, wait for more 3 minutes. If not necessary,
do not ON-OFF of the refrigerator.
5-3-5 MAINTENANCE :
1. Be sure to turn off the main power switch when the oil cooler is checked or
maintained.
2. Do not brush or use polishing powder, acid, solvent, benzine and hot water to
clean the surface of case. It is necessary, clean with dry cloths and neutral
detergent.
3. Clean the suction strainer at the suction end of the oil cooler, oil pipes after
work.
4. Wash the air filter once a week.
5. Clean up the dirt on radiator of oil cooler with compressive air once half year.
5-9
5-3-6 TROUBLE SHOOTING:
SITUATION
CAUSE
REMEDY
Main power turned on, but Negative phase relay is Reconnect the wiring.
the indicate lamp is not lit.
triggered. Control circuit Replace the fuse.
protector is blown.
Pump runs but no oil flow Joint of oil piping is Check the joint of oil pipe
and lower oil circulation rate loosened from suction side. at suction side and tighten
of air.
the loose joint.
Suction strainer clogged.
Clean the suction strainer.
Change the oil of oil tank if
the oil is contaminated.
The oil level in tank is too Trace and refill up oil.
low.
undue pressure loss in oil Enlarge the oil pipe
pipe cause actuation of diameter or trim shortly the
relief valve.
piping.
Oil viscosity too high.
Choose the appropriate oil.
Pump
runs
but
the Thermostat is OFF.
Shift the thermostat setting
refrigerator does not work.
to the lower side until the
refrigerator starts.
Both pump and refrigerator Control circuit protector Replace the fuse.
stop.
failed. Power failure.
Check the power source.
Buzzer comes out while Air filter clogged.
Clean the air filter.
refrigerator runs.
Obstacle block the suction Remove the obstacle.
or exhausting port.
High
pressure
switch Ambient temperature is too Move the machine to the
actuated.
high.
lower temperature or far
Thermostat is OFF.
from heat source.
Compressor motor overload Compressor out of order. Replace the compreessor.
relay actuated.
NOTE :
1. If alarm does not display, motor still runs but oil is not cool, please record the
situation and ask technical service or local agent right away.
2. Damage from cleaning air filter irregularly is not included quarantee period.
5-10
5-4 LUBRICATION SYSTEM
5-4-1. OUTLINE DIMENSION:
5-4-2. FILL UP LUBRICATION OIL:
a. After opening the cap of oil inlet, fill up the clean fresh oil till to the top line
of high level.
b. The oil tank should always preserve clean lubricant.
c. In case of impurity remains in the oil tank, please take the oil away and wash
the tank, oil net immediately. Then refill up new oil or it will fail the oil
feeding.
d. Adjust oil discharge by taking off the plastic cup and three E type retainers
first.
e. Pull the rod up or down till the requirement volumn of discharge is up to the
scale on rod, then fix with the E type retainers.
f. It is necessary to refill up lubricant oil if oil level is below the lower line
during operating.
NOTE : 1. The oil quantity will reduce gradually under normal application.
2. Be careful whether the motor is running normally or abnormally, if not,
contact to the local agent or Leadwell service department.
3. The lubrication please use MOBIL VACTRA OIL NO.2 or SHELL
OIL T68 or ESSO FEBISK68 or another brand of equivalence oil.
PS: Normality each 1000 hours make to once protection.
5-11
5-4-2-1 OIL RECOMMENDATION :
The following drawing is a plate of oil usage recommendation .
OIL USAGE RECOMMENDATION
BRAND
MOBIL
SHELL
ESSO
CASTROL
RARUS 424
CORENA S32
TERESSO 32
HYSPIN VG32
ITEM
LUBRICATOR OF
PNEUMATIC
PERFECTO T32
AUTO LUBRICATOR
SYSTEM
VACTRA 2
TONNA T68
FEBIS K68
MAGNA BD68
APINDLE OIL
COOLER SYSTEM
VELOCITE 12
TURBO T32
SPINESSO 22
HYSPIN VG32
PERFECTO T32
HYDRAULIC SYSTEM
DTE LIGHT
TELLUS 32
NUTO H32
HYSPIN AWS32
GEAR OF ROTARY
TABLE
MOBILGARD
OMALA 150
SPARTAN EP
150
ALPHA SP150
SPINDLE MOTOR
GEAR BOC
DTE HEAVY
MEDIUM
TELLUS 68
NUTO H68
ALPHA SP68
5-12
5-4-3 THE LUBRICATION SYSTEM SKETCHES OF AXES :
5-13
5-4-4 THE LUBRICATION SYSTEM SKETCHES OF AXES :
5-14
Operation
Contents
6. OPERATION
6.1 MISCELLANEOUS FUNCTION (M FUNCTION/M CODE) …………………. 6-1
6.2 SPECIFYING THE SPINDLE SPEED (S FUNCTION/S CODE) ……………… 6-1
6.3 TOOL NUMBER CODE (T FUNCTION/T CODE) …………………………….. 6-1
6.4 SPECIFYING THE FEED RATE (F FUNCTION) ……………………………… 6-2
6.5 PREPARATORY FUNCTION (G FUNCTION) ………………………………… 6-2
6.6 PROGRAM
6.6.1 Searching or calling programs ………………………………………………….. 6-2
6.6.2 Program editing ………………………………………………………………… 6-3
6.7 COORDINATION SYSTEM
6.7.1 Programming zero point ………………………………………………………… 6-4
6.7.2 Coordination system ……………………………………………………………. 6-4
6.7.3 The flowchart of ATC operation ………………………………………………… 6-5
6 OPERATION:
6-1 MISCELLANEOUS FUNCTION (M FUNCTION/M CODE) :
In operating this machine, specify on/off controls on the operation panel such as spindle
start/stop, coolant on/off, mirror image, table indexing, tool change, etc.. , Within a 2 digits
the address M codes. Two or more M codes other than specially approved combination are
not allowed in the same block.
6-2 SPECIFYING THE SPINDLE SPEED (S FUNCTION/S CODE) :
Specify directly a spindle speed with 4 digits numerical values following the address S.
S45
S4000
45 rpm
4000 rpm
Program example :
S500＊
Specify the spindle speed
M03＊
Spindle start
S3500＊
Changing the speed at running condition
M05＊
Spindle stop
M04＊
Reverse rotation at 300 rpm
NOTE 1 : During spindle rotation, if the S command is given the spindle will run and
change its speed.
NOTE 2 : If an axis movement command is specified simultaneously with M03 or M04,
spindle rotation and axis movement will start at the same time. If the axis
movement command is specified simultaneously with M05, the spindle will stop
after completing an axis movement.
6-3 TOOL NUMBER CODE (T FUNCTION/T CODE) :
Specify within a 2 digits numerical values following the address rang from 0 to 99.
Program example :
M06 T02＊
Change tool to No.2
NOTE : If only a T command is given, it is for NC memorized no action. However, if T
command is specified simultaneously with M06, the tool changing function will be
performed.
6-1
6-4 SPECIFYING THE FEED RATE (F FUNCTION) :
a. With a numerical value of 1 to 5000 following the address F, specify a speed at which the
tool moves over a distance between two fixed points by linear or circular interpolation.
F COMMAND
FEED RATE (mm/min.) FEED RATE (inch/min.)
F0001
1.0
0.01
F1
1.0
0.01
F0010
10.0
0.1
F5000
5000.0
50.0
b. ACTUAL PROGRAM (METRIC UNIT) :
G01 X150.0 F80＊
G02 X200.0 Y300.0 R400＊
NOTE : Be sure to use “FXXXX” together with G01, G02 and G03.
c. “FXXXX” is not required for G00 (rapid traverse).
NOTE 1 : The unit for F is either mm/min. or inch/min., indicating feed per minute.
NOTE 2 : You may omit “0” in the upper digit of a numerical value.
6-5 PREPARATORY FUNCTION (G FUNCTION) :
“GXX” two-digit values following the address G shows what a program command means.
This function prepares for spindle tool movement.
6-6 PROGRAM
6-6-1 SEARCHING OR CALLING PROGRAMS :
Classification Function Key switch
Setting Mode switch
PWE=1
button
Program
number
search
SEARCH
Function
button
Operation
[O]Program No.
EDIT/AUTO PROGRAM [↓](Cursor)
Sequence
number
search
AUTO
Address
word search
EDIT
Address
search
Offset
number
EDIT
－
6-2
Program No.
PROGRAM search→[N]→
sequence
No.[↓](Cursor)
Search address→
PROGRAM and data input→
[↓](Cursor)
PROGRAM
OFFSET
Search address→
[↓](Cursor)
[P/Q]→Offset
No.→[INPUT]
6-6-2 PROGRAM EDITING:
Classification Function Key switch
Program
memory
used
Deletion of
all program
Deletion of
a program
Deletion of
several
PROGRAM
blocks
EDITING Deletion of
a block
Setting Mode switch Function
PWE=1
button
button
EDIT
PRGRM [P] [ INPUT]
0
EDIT
PRGRM
0
EDIT
0
EDIT
[N]Sequence
PRGRM No.[INPUT]
0
EDIT
PRGRM [EOB]→[DELET]
Deletion of
a word
0
EDIT
Alternation
of a word
0
EDIT
Insertion of
a word
Operation
EDIT/AUTO
0
6-3
[O]9999
[DELET]
[O]Program
PRGRM
No.[DELET]
Search the word to
PRGRM be deleted→
[DELET]
Search the word to
PRGRM be alteredNew
date[ALTER]
Search the word to
PRGRM be insertedNew
date[insert]
6-7 COORDINATION SYSTEM :
6-7-1 PROGRAMMING ZERO POINT :
When execute a program, it must be determined a program zero point at first. The
programmer determines the zero point after viewing the machine drawing. The value of
coordination determines a graphic position with 3 perpendicular lines mutually crossing at a
point as shown as following drawing.
6-7-2 COORDINATION SYSTEM :
The coordination system contains of 3 axes and 3 swivel axes as following sketch.
6-4
6-7-3 THE FLOWCHART OF ATC OPERATION :
Power on
↓
Return to the reference point on three axes
↓
Prepare the workbench
↓
Call a proper program
↓
Locate all tools to tool pocket
↓
Mount tool onto the tool magazine
↓
Measure tool length and set tool compensation data
↓
Set work coordination system and zero point
↓
Prepare for automatic operation
↓
Dry run for testing program
↓
Machine program executing
6-5
Cleaning
Maintenance &
Contents
7. CLEAN AND MAINTENANCE
7.1 DAILY MAINTENANCE
7.1.1 Before power on ………………………………………………………………… 7-1
7.1.2 After power on ………………………………………………………………….. 7-1
7.1.3 After finishing daily work ……………………………………………………… 7-1
7.2 WEEKLY MAINTENCE …………………………………………………………. 7-2
7.3 SEMIANNUAL MAINTENANCE ………………………………………………... 7-2
7.4 ANNUAL MAINTENANCE ……………………………………………………… 7-3
7.5 ENVIRONMENTAL CLAIMS …………………………………………………… 7-3
7.6 OUR GOAL ………………………………………………………………………… 7-3
7.7 WASTE TREATMENT ……………………………………………………………. 7-4
7. CLEAN AND MAINTENANCE
CAUTION : 1. Shut off the power before doing any maintenance or cleaning job and obey the
instruction or you might be hurt.
2. Any clean or maintenance concerned with removing must be careful and only
well-trained personnel can do it.
7-1 DAILY MAINTENANCE :
7-1-1 BEFORE POWER ON :
a. Inspect if the power cable and external cable are normally connected and the voltage
capacity is matched as machine required.
b. Check if there is oil or coolant leakage on the hydraulic or coolant pipes.
c. Check if there are enough oil for the hydraulic unit, lubrication unit and coolant unit.
d. Check if the pressure gauges of hydraulic unit and pneumatic unit were indicated to zero
position.
e. Check if the auto tool changer unit is at the normal position.
7-1-2 AFTER POWER ON :
a. Check if there is alarm message after NC power on.
b. NC should be ready to execute the program.
c. All the running components should be run at normal condition without noise.
d. The pressure gauge for pneumatic system should be at 6 kg/cm2.
e. Auto lubricator should be actuated to pump oil with flow setting to 3-6 c.c./cycle.
f. The lubricant should flow out to the sideways.
g. The wipers on the telescopic covers should be cleaned from the chips.
h. Test tool changing unit and make sure the unit can work smoothly.
7-1-3 AFTER FINISHING DAILY WORK :
a. Inspect the oil level of auto lubricator tank to refill up, if it is necessary and is consumed.
b. If there is water or dirt in the tank, relieve and change fresh oil.
c. Check the level of coolant to refill up and flush the coolant pump through with clean water
if there is impurities after use.
7-1
d. Clean the chips on the chip tank, conveyor, tool tip and tool magazine.
e. Remove and centralize the chips on the chip bucket out side of the shop.
f. The coolant pump which is not being used during periods frost should be drained (shown as
the following sketch) or it will be harmful for pipe and pump. Take off the priming plug P
and drain plug V for draining.
g. Turn off working light, power supplier and draw out the connector of power cable whenever
finishing work.
7-2 WEEKLY MAINTENANCE :
a. Clean fan net of heat exchanger on electrical cabinet.
b. Clean fan net of spindle oil cooler.
c. Clean fan net of motor on the hydraulic tank.
d. Clean the motor fan of chip conveyor .
e. Clean the filter net inside of coolant tank.
f. Clean ATC motor fan and the brake of surrounding motor.
g. Fill the grease for the warm gear of ATC transmission unit.
7-3 SEMIANNUAL MAINTENANCE :
a. Check and re-adjust the machine level and static accuracy.
b. Inspect the home position and reset, if necessary.
c. Ensure there is enough of lubricant on the line-way, gear of reducer and change or refill the
fresh oil, such as lubricant, hydraulic oil, oil cooler tank, etc.
d. Inspect the backlash of ball screw on three axes.
e. Inspect the repeating accuracy and geometric accuracy of machine.
f. Replace the fan net of heat exchanger on electrical cabinet.
7-2
g. Replace the element of filter on hydraulic tank or other accessory parts.
h. Clean the electrical motor outside and turn off the power at first.
i. Before cleaning the chip or dirt on the conduction block of sensor and magnetic switch, turn
off the power.
j. Check the smooth function of all limit switches for axes and clean the dirt or re-adjust the
position, if necessary.
7-4 ANNUAL MAINTENANCE :
a. Follow the same procedures as mentioned above semiannual maintenance.
b. Replace the hydraulic oil and oil filter according to the oil recommendation.
c. Replace the filter for auto lubricator and clean the lubrication tank, coolant tank.
d. Do not pour out the wasting oil or coolant liquid casually. It‘d better remain in oil bucket
periodically and send to the authorities concerned of shop to do with it.
e. Check and correct the geometric accuracy of machine.
7-5 ENVIRONMENTAL CLAIMS :
God creates this world and gives humanization the rights to rule over the earth. LEADWELL, a
part of this family shall have responsibility and duty to keep the earth away from damage or
pollution during producting. We all obey the laws and regulations through our policy of quality
control management and concept of environmental protection issue. We have been devoted
ourselves on the environmental management system no matter at work or in life. It is our final
destination that to make a sustainable development business and to provid a pure clean
environment to the generations.
7-6 OUR GOAL :
1. RESOURCES RECOVERY : Not only check devices periodically and save the resources but
reuse the recyclable resources and develop new less-polluted
resources.
2. REDUCING WASTE : Specify and recycle the waste and reduce the quantity of waste.
3. WATER CONTROL : Inspec the water, wastewater drained off to the sewage treatment plant
through our sanitary sewer.
4. AIR CONTROL : Reduce air pollutants, obey the laws about emissions standard of air
pollution. remain a high quaility and all devices are in good condition.
7-3
7-7 WASTE TREATMENT :
1. DURING OPERATION :
a. Waste Oil : There is any leakage of oil or liquid during operating machine, stop and check
machine. Meanwhile report to your supervisor or manager to solve. The
waste oil, solution or liquid must pour into the stored bucket at plant or follow
the rules and procedures of waste treatment of your own control measures. It
can not be poured out at random and not be allowed draining down through
sewer.
b. Cutting Chips : Some of the cutting chips are able to recycle, after machining, the chips must
seperate and restore by material. It is must be placed and treat according to
the environmental regulations of local plant.
c. Toxic gas : Check the concentration of exhaust emissions and the emission equipments.
Control the value to standard request every cyclic inspection.
2. AFTER OPERATION :
Waste Machine : When machine is out of order can not be fixed, do not throw away directly
and sepreat the machine to pieces by material. Some of the material can be
recycled such as casting iron, steel, metal, etc.. Some of them can not be
reused such as cables, electrical parts, motors, PCB board, etc.. Store the
same parts according to their material to do with local dealer or the
procedures of waste treatment on your own.
7-4
APPENDIX
Caution: Spindle Operation
A. SPINDLE AIR PURGE：
1.Set spindle air purge pressure at 1.2kg/cm2～1.5kg/cm2.
Caution At power on for turning, check spindle air purge is functioning correctly.
Caution Do not turn off spindle air purge or adjust pressure, it will lead to spindle
defected or damage of spindle.
B. SPINDLE OIL COOLER：
1. Spindle shaft and quill with temperature difference may lead to spindle bearing
burns. Spindle oil cooler temperature set up have to 2°C higher than room
temperature.
2. Rotary type of spindle oil cooler temperature is 25°C at initial. Pls. adjust according
to machine site.
3. Digital spindle oil cooler will detect spindle room temperature, no more adjustment
is required.
Caution At power on for turning, check spindle oil cooler is functioning correctly.
C. SPINDLE WARM UP：
To ensure spindle smooth rotation in long term and long lifetime, at machine,
installation or daily turn on, follows spindle warm up operation.
D. SPINDLE TEMPERATURE INCREASE：
1. This machine spindle was build up with high accuracy of spindle angular ball
bearing of which add with high temperature endurable grease lubricator effective for
maintain its accuracy with low temperature increasing at rotation.
2. If spindle temperature increased higher than 20°C of room temperature, this
indicates abnormal of the spindle. Contact machine builder immediately for
authorized engineer delicate for maintenance will be required.
Caution None authorized personnel disassembling spindle is prohibited. In case this
accident happened, any failure to the spindle is subject to customer’s obligation.
E. SPINDLE HIGH SPEED ROTATION TIME MANAGEMENT：Ref. table 1
1. Extreme speed of spindle rotation do not exceeds 1/4 of daily working hours.
2. Spindle speed stay less than normal rotation speed（85% of extreme spindle
speed）for machining.
3. Spindle run at normal continuous rotation speed do not exceed 8 hours a day.
Otherwise, lower normal rotation speed to 70% of spindle speed, or reduce
spindle speed to minimum speed for 1 hour will be required.
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01
4. Spindle speed less than minimum speed is not allowed.
Table 1
Spindle
specification
Extreme speed
of
Spindle rotation
Normal spindle rotation
speed at
85% of Spindle peak
Minimum
speed
8000rpm
8000rpm
7000rpm
-
10000rpm
10000rpm
8500rpm
3000rpm
12000rpm
12000rpm
10000rpm
5000rpm
15000rpm
15000rpm
12000rpm
6000rpm
F. SPINDLE GUARANTEE：
1. Spindle of normal operation, general spare parts will be guaranteed for 1 year.
2. Spindle bearing guaranteed for 2000hrs of rotation.
2
01
MEMO