Deta MR4AL User Manual

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Page 1

deta

#40 DISK TYPE TOOL CHANGER SYSTEM

INTERNATIONAL

USER MANUAL

This manual is applicable to model:

MR4AL

BT40/CAT40/DIN40/HSK50A/HSK63A

Revised date:2014/05/23

Page 2

Contents Page

1、Tool Changer System Mechanical Specification & Drawing

·······················································································

2、Power Supply Specification for Electrical Control ··························

3、Electrical Control ·········································································

4、Electrical Control Protection Programming ·································

5、Installation Procedure ··································································

6、Original Setting··············································································

7、Trouble Shooting···········································································

8、Maintenance ·················································································

Page 3

1、Tool Changer System Mechanical Specification &

Drawings :

1-1. Specification:

Item Model

Tool Capacity 24T

Maximum Tool Diameter 75mm

Max. Tool Length 300mm Max. Tool Weight 7Kgf

Total Tool Weight 120 Kgf

MR4AL

CAM BOX Speed (CAM BOX Only)

Magazine Speed 0.6 sec. / tool (60Hz)

Tool Selection Two Way Random Selection

1.5 sec. (60Hz)

Page 4

1-2. Maximum Tool Rotational Inertia Diagram:

Drawing:

MAX TOOL Weight D kgf

A B C D MOMENT=D*B(≦10.29N-m)

tool length tool median point(A/2) tool diameter tool weight

Page 5

1-3. Drawings:

Assembly drawing and part list for disk type tool magazine, CAM BOX and tool changing arm as per attached drawings and list.

Page 6

TITLE-CPART NO.ITEM NO

F F

4 5

MR4AK0001J02 MR4AK0002A002 MR4AK0004A003 MR4AK0025A04

MR4AK0005F01-T-10

MR4AK0010A066 MR4AK0018B01 MR4AK0006A068 MR4AK0026C019

R4KKV0009A0110 MR4AK0013A02 MR4AK0014Z0112

MR4AK028AB01-0113

MR4AK000003A02

本體

刀盤組

壓缸固定鈑組

倒刀定位座

倒刀壓缸

前蓋支撐桿

倒刀塊

固定鈑

刀套固定桿

渦輪減速機1:40

馬達

驅動軸

Cylinder Mounting Plate Moudule

Pocket Positioning Seat

TITLE-E

Bady

Tool Disk Module

Pneumatic Cylinder

Support Rod

Cover Plate倒刀蓋鈑

Tool Tilt Block

Sensor BlockSensor感應鈑

Sensor Lock BlockSensor

Shaft

Woem Gear

MOTOR

Tool Disk Driver

QTY.

1 1 4 1 1 1

1 1 1

MATERIAL

FC30

1 1

Nylon+40纖

市購品

SS41

SS41(2t)

S45C

SS41(3t)

SS411 S45C24

市購品

S45C

E E

EB000000CF6G MR4AK0036A0116 MR4AK0007A05 MR4AK0034A0318

MR4A-0019A0119

P40K-1250112-0120

SR400000000321 EB10AL201183-00A22 EB20AL201183-00A23

MR4AK0035A0224 WA000000000825

M8xP1.25x30L26

M827 M628

曲線滾輪

定位感應片

壓缸前蓋

刀庫前外罩

承靠塊

刀套

近接開關

電控盒

電控盒蓋

CAMBOX

內六角承窩頭螺栓

外罩

墊片

平墊圈

Roller

Positioning Sensor Block

Front Of Cover

MAG Front Cover

Positioning Key

PocketBT

Proximity Sensor

CE Electric Box

CE Electric Box COVER

COMBOX COVER

Washer Hexagon Socket Heard Screw Finshed Circular Plain Washer Finshed Circular Plain Washer

1 1

5 1 1

CF6B2 SS41

ABS FRP1

S45C

市購品

ADC 12 ADC 12

SS411

市購品

4 4

D D

M8xP1.25x20L

M6xP1.0x10L30

M6xP1.0x12L31

M1032

M10xP1.5x30L33

M634

M6xP1.0 x12L35

M8xP1.25x12L36

M6xP1.0x10L37

M1238

BT000000002039

M6xP1.0x10L40

內六角承窩頭螺栓

圓頭內六角承窩頭螺絲

彈簧墊圈

內六角承窩頭螺栓

彈簧墊圈

內六角承窩頭螺栓

圓頭內六角承窩頭螺絲

六角螺帽

環首螺栓 M20

圓頭內六角承窩頭螺絲

Hexagon Socket Heard Screw Hexagon Socket Heard Screw

Hexagon Socket Button Heard Screw

Spring Lock Washer

Hexagon Socket Heard Screw

Spring Lock Washer Hexagon Socket Heard Screw Hexagon Socket Heard Screw

Hexagon Socket Button Heard Screw

4 4 4 4 5

4Nut 1 4

C C

B B

UNIT NO.

QUANTITY

MATERIAL

NO.

圖框更新版本

>0 ±0.1

A A

>6 ±0.2

2009/12/29

>30 ±0.3 >120 ±0.5 >350 ±0.8

>1000±1.2

deta INTERNATIONAL

TEL:886-4-25617722 FAX:886-4-25617177

NAME

DRAWING DESING CHECK APPROVE

ANGEL2014/5/26

PART NO.

MR4AL0001A01

SCALE

TITLE

NMR4AE(#40X24T) NMR4AE(#40X24T)

Page 7

QTY.PART NO.ITEM NO

4 5

D D

MR4AK0002B01-T

MR4AK0011A022

1 6 6BS 4168 - M6 x 163

6M10

MATERIAL

POM

CFV10B6BE0000CFV10B

TITLE-C

刀盤鋁

耐磨片

內六角皿頭螺栓

曲線滾輪軸承

六角螺帽

TITLE-E

Tool Disk

Wear Resistant Strip

Socket Countersunk Heard Screw

Roller

NOTE

Nut

C C

B B

A A

MATERIAL

UNIT NO.

deta INTERNATIONAL

TEL:886-4-25617722 FAX:886-4-25617177

NAME

DRAWING DESING CHECK APPROVE

wayne2014/3/4

PART NO.

MR4AK0002A00

QUANTITY

SCALE

TITLE

刀盤組

Tool Disk Module

NO.

圖框更新版本

2009/12/29

>0 ±0.1 >6 ±0.2 >30 ±0.3 >120 ±0.5 >350 ±0.8 >1000±1.2

Page 8

SS411MR4AK0004A101

UP2MR4AK0012A072

4BS 4168 - M6 x 163

壓缸固定鈑

內六角皿頭螺栓

Cylinder Mounting Plate

Wear Resis tant Strip(

Socket Countersunk Heard Screw

NOTETITLE-ETITLE-CMATERIALQTY.PART NO.ITEM NO

Ⅱ)耐磨片

D D

C C

B B

A A

MATERIAL

UNIT NO.

deta INTERNATIONAL

TEL:886-4-25617722 FAX:886-4-25617177

DRAWING DESING

NAME

wayne2014/3/4

CHECK APPROVE

PART NO.

MR4AK0004A00

QUANTITY

SCALE

TITLE

壓缸固定鈑組

Cylinder Mounting Plate Module

NO.

圖框更新版本

2009/12/29

>0 ±0.1 >6 ±0.2 >30 ±0.3 >120 ±0.5 >350 ±0.8 >1000±1.2

Page 9

J J

4 5

I I

11 12

H H

G G

A40C-2651AC011

A40C-0002A042 A40C-0028C043 A40C-0007A02 A40C-0004A03 00A40C-0020C6 A40C-0005A07 A40C-0013F048 A40C-0008A029 A40C-0006C0310 A40C-0009A03

OTTW00SER08V13

M5xP0.8x16L M5xP0.8X30L15

M616

M6xP1.0x16L

M818

M8xP1.25x16L19

8x25L20

M5xP0.8x10L21

M522 M523

TITLE-CPART NO.ITME NO.

刀臂本體

扣刀爪

頂刀爪

頂刀爪彈簧

定位銷

銅套組

安全頂銷

頂刀爪限位鈑

安全頂銷彈簧

彈簧蓋鈑

迫緊環蓋

迫緊環CX0000d40D45

內六角承窩頭螺栓

彈簧墊圈

內六角承窩頭螺栓

彈簧墊圈

內六角承窩頭螺栓

彈簧銷

內六角皿頭螺栓

彈簧墊圈

TITLE-E

Main Body

Finger Spring

Key

Safety Cover

Position Limited Plate

Safety Spring Pin

Cox Cover

Seal

Ⅱ刮刷環Ⅱ

Hxagon Socket Heard Screw Hxagon Socket Heard Screw

Spring Lock Washer

Hxagon Socket Heard Screw

Spring Pin

Socket Countersunk Heard Screw

Spring Lock Washer Spring Lock Washer

QTY.

MATERIAL

AL70751

C50C2Gripper S50C2Finger

2COPPER COVER

1 2Taper Snap Ring 2

8Hxagon Socket Heard Screw 8 8

SWPB

S45C2

SMF50302

SWPB2

SS412Spring Cover

SCM4

4 6

F F

E E

D D

C C

B B

A A

DRAWING DESING CHECK APPROVE

wayne2014/3/5

NAME

deta INTERNATIONAL

TEL:886-4-256177 22 FAX:886-4-25617177

UNIT NO.

PART NO.

A40C-A2650111-01

MATERIAL

QUANTITY

SCALE

TITLE

#40刀臂組(R265)

Arm Assembly

NO.

圖框更新版本

2009/12/29

>0 ±0.1 >6 ±0.2 >30 ±0.3 >120 ±0.5 >350 ±0.8 >1000±1.2

Page 10

項目

A40C-0020A06

D D

OR00000P18VT2 OT000SER18VT3

零件表

銅套

型環 P18

刮刷環 SER18

O-RING P18 SER18

青銅(銅鋁合金)

數量材質英文名稱中文名稱零件號碼

1 1NBR 1

C C

B B

MATERIAL

A A

deta INTERNATIONAL

TEL:886-4-25617722 FAX:886-4-25617177

NAME

DRAWING DESING CHECK APPROVE

doris2010/12/16

UNIT NO.

PART NO.

QUANTITY

SCALE

TITLE

銅套組

COPPER COVER00A40C-0020C

NO.

圖框更新版本

2009/12/29

>0 ±0.1 >6 ±0.2 >30 ±0.3 >120 ±0.5 >350 ±0.8 >1000±1.2

Page 11

2、Power Supply Specification for Electrical Control:

2-1. Follow the table listed below if disk type tool-changing

system’s power supply is not specified:

Power Supply

Category

Electrical Power Supply: 3

Specification

Signal Power Supply: DC 24V

Electrical Pneumatic

Phase

220V (50/60Hz)

5 BAR (Filtered

through three- points

assembly)

2-2. Specification of Sensor Used In disk Type Tool

Changer System Are as Followed:

Sensor

Specification

Tool Magazine Positioning

and Counting

M12 PNP 24V

Normal Open

Shielded Distance = 0.6mm

Tool-Changing Mechanism

Φ4 PNP DC24V

Normal Open

Shielded Distance =

0.8mm

Page 12

3、Electrical Control:

Configuration Drawing for Electronic Control

Components·····························································

Sequence Drawing of Tool-Changing System··········

Standard Wiring Diagram·········································

Motor Wiring Diagram for Tool Magazine·················

Motor Wiring Diagram for CAM BOX························

Pneumatic Circuit Diagram······································

DMR4L0009A01

DMR4L0010A01

DMR4L0011A01

DMR4L0012A01

DMR4L0013A01

DMR4L0014A01

Page 13

Page 14

Page 15

Page 16

Page 17

Page 18

4、Electrical Control Protection Programming:

(1) As Cam box and the tool magazine move extremely fast, the control

program for all motor relays, sensors, and the I/O port of electromagnetic valves should be written on PLC Level 1 of the controller (where SCAN TIME reacts faster). This is to prevent the electronic control from having over slow reactions and causing the machine to make wrong movements.

(2) In the proceeding of tool changing, each movement has to be

confirmed for its completion before continuing with the next movement. (Refer to the tool-changing flowchart diagram)

(3) Do not topple the tool if the sensor for the positioning of the tool

magazine is not confirmed (i.e. LS4 is ON).

(4) Do not start the motor of the tool magazine or rotate the tool palette

if LS2 is OFF in the proceeding of tool tilt and LS1 is ON before confirming the completion of tool tilt.

(5) Do not change the tool if tool tilt is not confirmed (i.e. LS1 is ON).

(6) Do not change the tool if the spindle of the machine has not returned

to the tool changing position.

(7) Do not change the tool if the spindle orientation has not been

completed.

(8) Do not move the spindle head if the arm has not return to its home

position.

(9) Overload protection relay should be activated when overloading, so

that the motor will not be burn off.

(10) The amperage of the motor’s current has to be below the motor’s

full load current.

1/4 Hp: 1.2 A; 1/2 Hp: 2 A; 3/4Hp:2.8 A;1 Hp: 3 A (at 60Hz)

Page 19

Page 20

5、Installation Procedure:

Before installing our disk type tool-changing system, you should read this section carefully and understand it completely before proceeding with the installation procedure.

Adjustment of the arm and the tool magazine was done before the product left our factory, users do not have to spend time to work on it. Hence, users could treat the tool magazine, the tool-changing mechanism and the tool arm as a complete unit without having to do any adjustment when installing our Disk Type Tool Changing System. But the tool-changing point of the spindle and the tool-changing point of the arm have to be accurately adjusted.

The tool-changing point of the spindle and the tool-changing point of the arm have to be accurately overlapped, so that tool-changing movements will be smoothly carried out under normal usage without any collision noise. If the adjustment is inaccurate, not only toolchanging movements will not be smooth but it will also produce collision noises, which will have harmful effect on the life span of the tool. Hence, the only important point for installing our Disk Type Tool Changing System is “to overlap the tool-changing point of the spindle and the toolchanging point of the arm accurately”. We recommend users to follow the installation procedures below:

(1) Make an interfacing bracket as we have suggested, and lock it onto

the vertical column after confirming the bilateral perpendicularity geometrical tolerance between the vertical column interface and the tool magazine interface.

(2) Make a three-stages tool-calibration fixture as we have suggested.

(As per attached drawing)

(3) Lock the disk type tool-changing system onto the interfacing bracket.

Put the two rest blocks closely on the top of the interfacing bracket and ensure the horizontal accuracy is kept.

(4) Move the Z-direction of the spindle to the highest point.

(5) Put adjustment fixture A into the spindle for the spindle to grip and

let the tool-changing arm grip adjustment fixture B. Press and release the brake, which is on top of the tool-changing mechanism motor. Then use a hexagonal spanner to turn the screw, which is

Page 21

located at the top center of the motor, until the tool-changing mechanism reaches the tool-clipping position. (Keep turning the screw on top of the tool-changing mechanism motor, and the toolchanging arm will remain fixed for a period of time. This will ensure that the tool-clipping position has been reached).

(6) Use a level to adjust the interfacing bracket so that the tool-changing

arm is perpendicular to the spindle.

(7) Move the Z-direction of the spindle to about 2mm from the top of the

predicted tool-changing point.

(8) Adjust the X- and Y-direction of the tool-changing system so that the

X- and Y-coordinate of the tool-changing points for the tool-changing arm and the spindle overlap. If adjusting the Fixture C allow it to pass through the Fixture B and entering the internal hole of the Fixture A that means the X and Y direction adjustment is completed.

(9) Measure the Z-direction coordinate for the tool-changing point of the

down to approximately 0.3~0.5mm above the Z-direction coordinate of the tool-changing point for the tool-changing arm (the ideal distance would be 1/2 of the spindle clamp distance). And set this point as the coordinate for the tool-changing point. Again, use the hexagonal spanner to turn the screw on the top center of the motor in the opposite direction, until the tool-changing mechanism returns to its home position.

(10) Change the tool manually first, to check that the movements of tool

pot toppling, the tool-changing mechanism performing the toolchange, the spindle catching and releasing tools, … etc coordinate well together without any error, then proceed with CNC automatic sequence program control. After trial tool-changing several times and making sure that no bad phenomena appear, the positioning pins can be fix into positions between the tool-changing system and the interfacing bracket, and between the interfacing bracket and the vertical column, respectively.

(11) Connect the circuit for electronic control, pneumatic valves, and

pneumatic source according to the wiring diagram.

(12) Pour the hi-grade of circulation oil into the tool-changing

mechanism until the surface of the oil can be seen from the oilviewing window

Page 22

6、Original Setting:

(1) The gap between the tool magazine orientation and the counter

sensor (M12) and the sensor block should be adjusted to between

0.8~1.0 mm.

(2) The gap of tool magazine motor’s brake pad should be adjusted to

between 0.2~0.35 mm.

(3) The gap between the sensor (Φ4) on Cam box tool-changing

mechanism and the sensing block should be adjusted to between

0.4~0.5 mm.

(4) The gap of Cam box motor’s brake pad should be adjusted to

between 0.3~0.35 mm.

Page 23

7、Troubleshooting:

7-1. Unstable tool tilting:

We have made the best adjustment to the disk type tool-changing system before our product left our factory, and we would suggest users not to do any random adjustment. If tool tilt is unstable due to the transportation or human error, please follow the procedures below to check and make adjustment:

(1) Check whether the pneumatic source conform to the power

supplying specification (refer to the section on the electrical control’s power supply specification).

(2) Check whether the tool tilting mechanism has any damage to it. If

so, please contact us and we will send someone over to repair it.

※

Note: Be sure not to set the speed too fast, otherwise there is a

possible danger of dropping the tool.

Page 24

7-2. Tool Calibration Procedure

Please adjust the arm as following procedure when need:

(1) Use an overhead crane to lift the Cam box and inspect it externally

for any flaw.

(2) Use M12×50L + spring washer + flat washer to fasten the Cam box

onto the datum surface of the tool magazine’s main structure, and pull the Cam box to the elongated holes on the outside.

(3) Open the power distribution box of the Cam box and connect it to

the power supply of the electronic control box. Check to see if there is any abnormal phenomenon in the operation of the Cam box.

(4) Tighten the nut and sun washer on the Cam box shaft。(as

illustrated in Diagram 1).

(5)Use M5×35L bolt + spring washer to fasten the packing rings on the

tool-changing arm, but do not tighten it temporarily.

(6) Sequentially insert the separation ring for the tool-changing arm

and put the tool-changing arm into the Cam box axis, and fasten M12×35L bolt + spring washer onto the tool-changing arm with a bit tightness around the axis and without any gaps.

(7) Supply electrical power to Cam box to allow the Cam box axis to

rotate to the tool-clipping angle.

(8) Use the three-point tool calibration fixtures to adjust the position of

the tool-changing arm. The adjustment method is to insert Fixture

Page 25

A into the tool pot, and Fixture B is placed at the tool clipper and coupled with the protuberance, but the tool pusher clip has to be placed into the arm first. Then, re-adjust the Cam box position, so that Fixture C can go through Fixture A and Fixture B and reach the arm at the position of the tool-clipping point, and line up with the center of the tool pot.

(9) Tighten the Cam box on the magazine with 4.M12X12L screws。 (10) Check the clearance between the flange of the clip and tool

flange ,if the toper cleanses is equal to lower cleame are the same。(the cleame is 0.8mm for BT and that is 0.2mm for CAT and

DIN Tool shank)if the toper cleame is not equal to lower clew , one nut move the above set of Cam box and arm up or down。(as

illustrated in Diagram 2).

(11) In the process of tightening, use magnetic holder to hold the leveler

on the Cam box. The pointer of the leveler should touch the tool clipper near the outer rim. Repeat the height measurement for both ends of the tool clipper, where the height at both ends should be within 0.1mm of difference.

(12) Place the tool pusher clip spring onto the end of the tool pusher clip,

and after smearing some lubricating oil, fit it into the tool-changing arm. Fix M8 anti-revolving bolt + spring washer to the arm (as illustrated in Diagram 3).

(13) Turn the manual bolt behind the Cam box motor, so that the tool-

changing arm descends about 50mm. Apply lubricant on the safety pusher pin of the tool-changing arm and then insert it into the lubricated spring of safety pusher pin. Then, insert the safety pusher pin into the tool-changing arm and fasten it with M5×35L bolt + spring washer (as illustrated in Diagram 1).

(14) After fastening the parts for the tool-changing arm, try several times

to make sure that the safety pusher pin can spring upwards freely, and test to see if tool-changing movement is working properly by putting a tool into the tool pot.

Page 26

7-3. When the tool palette not turning smoothly:

(1) Please check to see if there is any foreign object got stuck to the

Geneva wheel or drive shaft (refer to the assembly drawing and part list). Please eliminate it.

(2) Please dismantle the motor and then electrify the motor, so it

operates independently. Check to see if it rotates smoothly without any noise.

(3) If after going through above inspections without eliminating the

breakdown, please contact our company.

7-4. When the tool arm motion not smooth:

(1) Please check to see if there is any damage to the tool-changing

arm. If there is, please contact our company to have the parts replaced.

(2) Please check the tool-changing mechanism and main structure of

the tool magazine to see if there is any change to the locking position (Check to see whether there is any damage to the positioning pin or it has already been shear off. If there is, please contact our company to have the parts replaced.

(3) Please check whether there is any loose movement between the

tool-changing arm and axis of the tool-changing mechanism. If there is, please stop the machine and cut off the power supply and loosen the screw on top center of the motor with a hexagonal spanner until the tool-changing mechanism reach the tool clipping position. Push the tool-changing arm upward to the end and clip on the tool that has toppled down, then calibrate both end of the toolchanging arm so they are within (0.1mm) in height, (Refer to tool calibration procedure)

(4) Be sure not to self dismantle the tool-changing mechanism, if

there is any breakdown, please contact our company.

7-5 When the tool-changing speed is too slow:

(1) Please check whether the motor produces any strange noise

(2) Please check whether the power supply conform to the

specification.

Page 27

(3) Please check whether the speed of spindle clamping and

unclamping complies with the requirement.

(4) There is any other breakdown, please contact us.

7-6. Sudden power failure during the course of tool change by the tool-changing arm

(1) For short period of power failure, please re-start the machine, and

manually return the tool-changing arm to its original position.

(2) For long period of power failure, please release the motor brake,

rotating the tool-changing arm to its original point location by using a spanner to turn the spindle on top of the Cam box motor, and ensure the safety of the machinery by forcing the tool pot to return the tool.

Page 28

8、Maintenance:

(1) The circulation oil inside the tool-changing mechanism should be

changed after 2400 hours of continuous usage. And the oil level has to be checked non-periodically. A refill is in order if the oil falls below the required level.

(2) Tool disk and cylinder mounting plate’s surface need to cheek

grease everymonth

(3) Check and see if there is still some lubricating oil in the bearing

every three-month.

Page 29

Thank you for using our products. Please inform us if there is any defect so that we can make improvements and offer you more stable and better quality products.

deta

INTERNATIONAL

No. 47-5, Zunqian Rd., Shengang Shiang,Taichung County 42952 Taiwan(R.O.C)

Tel: (886-4) 2561-7722

Fax: (886-4) 2561-7177 Sales department e-mail [email protected] Design department e-mail [email protected]

Page 30

Automatic Tool Changer

S402

<< Manual >>

Sun-Train Cam Industrial Co., Ltd.

Page 31

Catalog

1. external dimension diagram-------------3 6. signal wiring methods -------------------13

2. articles list-------------------------4 7. the installation direction of eccentric cap------14

3. exploded diagram 8. adjustment method of cam and bearing pre-load -15

3-1. input shaft part-------------------6 9. adjustment method of tool arm-------------16

3-2. output shaft part------------------7 10. specification of lubricant oil ---------------17

3-3. swing arm part -------------------8 11. ATC brake motors----------------------18

3-4. signal part ----------------------9

4. dismantling steps-------------------10

5. timing diagram---------------------11

２

Page 32

Page 33

Article List

items dash number name dash number items dash number name dash number items dash number name dash number

01 S402A01ST-01

02 S402A01ST-02

03 S402A01ST-03

04 S402A01ST-04

05 S402B01ST-01

06 S402B01ST-02

07 S402B01ST-03

08 S402B01ST-04

09 S402B01ST-05

10 S402B01ST-06

11 S402B01ST-07

12 S402B01ST-08

13 S402C01-65L-L-P3

S402C02-80L-L-P3

14 S402D01ST-01

15 S402D01ST-02

cam axis eccentric cap eccentric cap nut chain gear 6-spline shaft 6-groove tube beads driving wheel front bracket bracket of tube beads tube beads fixity cover spacer of tube beads spacer cam65 degrees cam80 degrees swing arm swing axis

1 24 S402E01ST-01

2 25 S402E01ST-01

2 26 S402F01ST-01

1 27 S402F01ST-02

1 28 S402F01ST-03

1 29 S402F01ST-04

1 30 S402J01ST-01

1 31 S402J01ST-02

1 32 S402J01ST-03

1 33 S402K01ST-01

1 34 DA20X28X13

1 35 DA22X34X11

1 36 DB24X45X13

37 B0080305 6202ZZ/deep groove ball bearing 2 61 68010019

1 38 B1150102 HR30206/滾錐軸承 2 62 68010020

1 39 B1170102 HR32008/滾錐軸承 2 63 68010021

signal standard film dust cover motor fixity bevel bevel pinion eccentric sleeve of motor chain gear (ideal gear) hain wheel axis chain wheel outer cover bulk box needle roller bearing∮20 needle roller bearing∮22

needle roller bearing (powerful type)∮24

1 48 68010005

1 49 68010007

1 50 68010008

1 51 68010009

1 52 68010010

1 53 68010011

1 54 68010012

1 55 68010013

1 56 68010014

1 57 68010015

6 58 68010016

1 59 68010017

1 60 68010018

55*2/

O-ring

G50/

O-ring

G75/

O-ring

G80/

O-ring

G95/

O-ring

AN08

locknuts

AW08

lock washer

AN11

locknuts

AW11

lock washer

M4*8L/hex socket head cap screws

M4*10L/ hex socket head cap screws

M4*12L/ hex socket head cap screws

M5*16L/ hex socket head cap screws

M6*14L/ hex socket head cap screws

M6*16L/ hex socket head cap screws

M6*25L/ hex socket head cap screws

16 S402D01ST-03

17 S402E01ST-01

18 S402E01ST-02

19 S402E01ST-01

20 S402E01ST-01

21 Na Na 45 Na Na

22 S402E01ST-06

23 S402E01ST-01

swing arm fixing base brake signals wheel cam signals wheel signals fixity signals wheel axis

signal box side cover signal axis chain wheel

1 40 B1190102 HR32011/滾錐軸承 2 64 68010022

1 41 CBC80012 1 42 CBC81012 AS4065/needle bearing spacer 4 66 68010024 M8*35L/ hex socket head cap screws 2

1 43 68010001

1 44 S402L01ST-01

1 46 68010003

1 47 68010004

NTB4065/

HK3516/

needle bearing

self-lubricated bearing

40*52*8/

UHS50/

TC grease seal

U- grease seal

2 65 68010023

４

M8*20L/ hex socket head cap screws

M8*25L/ hex socket head cap screws

Page 34

Article List

items dash number name dash number items dash number name dash number items dash number name dash number

67 68010025

68 68010026

69 68010027

70 68010028

71 68010029

72 68010030

73 68010031

74 68010032

75 68010033

76 68010034

77 68010035

78 68010036

79 68010037

80 68010038

81 68010039

82 68010040 4*4*10/ double head round keys 1

M10*20L/ hex socket head cap screws

M10*30L/ hex socket head cap screws

M4*8L/

flat head screw

M5*8L/

flat head screw

PT1/8＂*8/

PT1/2＂*12/

M5*5L/

M5*10L/

M6*8L/

∮6/

∮10/

M10*P1.25/

M12/

ST-W12/

25H*92L

oil dam

socket set screws

spring washer

slip-on lock nut

galvanized nut

axis tab chain

4 90 FM2207508220 motor_3/4HP_1:8_AC220V 1

4 91 FM2207508380 motor_3/4HP_1:8_AC380V 1

83 68010041 5*5*20/ double head round keys 1

84 68010042 10*8*55/ double head round keys 1

85 68010043 8*30L/pin 2

86 68010044

87 68010045

88 68010046 Proximity switch

89 68010047

8*40L(1/50)/牙 M6

28mm

oil lens

PNP-3/E2E-CR8B1

MG16A-10B/

angle pin

cable fixed head

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８

Page 38

９

Page 39

Dismantling Steps:

First: The steps to replace 6-spline shaft:

1 Rotate to origin point and dismantle taper pin 【86】and M8 nut【65】 in which located above bulk cover. Next, remove the bulk cover. 2 Loosen the M6 bolts【63】and dismantle former fixing set【08】 3 Remove the 6-spline shaft 【08】 and dismantle driving wheel 【07】、locknuts AN08【53】and locknuts spacer AW08【54】and replace with a brand-new 6-spline shaft. ★Reverse the steps for assembly and restoration.

Second: The steps to replace the bearing in which located above 6- grooves tube beads:

1 Rotate to origin point and remove taper pin【86】and M8 nut【65】in which located above bulk cover. Next, remove the bulk cover. 2 Turn around the 6-groove tube beads【06】and remove former fixity【08】 3 Loosen and replace M6 socket head cap screws in which located inside the bearing 【75】 4 With a special dismantling tool to remove needle roller bearingφ20【34】and install the new articles, and then fix M6 allen screw with

anaerobic adhesive.

★Reverse the steps for assembly and restoration

Third: The Steps to Replace Swing Arm Bearing

1 Rotate to origin point and remove taper pin【86】and M8 nut【65】 in which located above bulk cover. Next, remove the bulk cover. 2 Remove allen screw【61】from swing arm fixity. 3 Use dismantling tools to twist swing-arm fixed axis【15】and then take it out. 4 Remove needle bearing axis NTB4060【41】, needle bearing spacer AS4060【42】and needle bearing HK3516【43】. 5 Remove needle roller bearingφ22【35】and needle roller bearingφ24【36】and replace all needed articles.

★Reverse the steps for assembly and restoration.

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Page 45

The speculation of lubricant oil

brand viscosity index ISO VG

SHEEL Omala EP 150~220 TOTAL Garter EP 150~220 MOBIL Mobilgerar 150~220 ESSO Spartan EP 150~220 CAST-OL Alpha SP-EP 150~220 CPC Pleiotropic gear oil 85w/95

A. Note:

1.Do not use recycled oil inside the machine, you must add lubricant oil to clean it.

2.The lubricant oil must add up to at least half of oil immersion lens, roughly 4200cc fuel.

B. Operating hours:

You must replace lubricating oil after the machine runs repeatedly 2400 hours.

C. Maintenance:

1.You muck check the oil level before you turn it on and add sufficient oil.

2.The lubricating oil should keep appropriate viscosity.

3. The voltage wiring used for motor should be correct.

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Page 46

ATC motor:

A. The checking points before you use it: (1) Check if the power cord is properly installed. (2) When a motor starts, please pay attention to its braking action

B. Checking troubleshooting steps: (1) Check if the power cable fully furnished, whether the voltage is stable or not and check the electromagnetic switches too. (2) When a motor starts, check if the braking action reacts to it. If the braking action fails, it will cause motor overload or burning. (3) Check whether the motor burned or not. (4) Check the brakes: (a) Check if the rectifier is burned (b) Check if the brake coil is burned.

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