sharp SV 4328, SV 5127, SV 6332 Maintenance Manual
SV-4328ST
VERTICAL MACHINING CENTER
MAINTENANCE MANUAL
Ver 2.1
2
PRECISION MACHINE TOOLS Ver2.1 Maintenance Manual
Chapter 1 Routine Maintenance
1-1 Routine Maintenance Checklist 4
1-2 Routine Maintenance Instruction Diagram 5
1-3 Cautions for Machine Maintenance 9
Chapter 2 The Spindle Unit
2-1 Cautions for High Speed Processing 12
2-2 Tool Shank and Broach Bolts 13
2 - 3 S p i n d l e W a r m - u p 1 5
2- 4 Spi n dl e P re - O pe r at i on C h e ck 1 6
2- 5 Spi n dl e A l ar m H an d l in g 17
Chapter 3 The Air Compressor Unit
3-1 Air Comp ressor System Layout 19
3-2 Air Compressor System Circui t 20
3-3 The Air Compressor Unit 20
3-4 Ai r C om pr esso r D eta ile d Spe ci fi c ati o ns an d F un cti o ns 21
3-5 Air Compressor Unit Usage Instr uction 24
3-6 A i r C o m p r e s s o r T r o u b l e s h o o t i n g 2 5
Chapter 4 The Lubrication Unit
4-1 C ent ralize d L ub ric ati on Sys te m Di agram 2 7
4- 2 Spi n dl e B ea ri ng Lu br i ca ti o n 2 9
4 - 3 G u i d e wa y s a n d B a l l S c r e w L u b r i c a t i o n 2 9
4-4 Lubricati on of the Cam Box of Tool Magazine 34
4-5 Counterweight Chain a nd Spro cket Be aring Lubrication 34
4 - 6 C y l i n d e r L u b r i c a t i o n 3 5
4 - 7 L u b r i ca t i o n L o c a t i o n 3 5
Chapter 5 The Spindle Oil Cooling Unit
5-1 Oil Cooling Pipeline Diagram 37
5-2 The Spindle Oil Cooling Unit 38
Chapter 6 The Electrical Unit
6- 1 Th e El e c tr i c al Uni t 4 5
Chapter 7 Appendix
7- 1 Oi l S el e c t i on 4 9
7-2 Calibratio n of Spindl e Tool Change Locati on 50
7-3 Determination of the Z-axis Mechanical Reference Point 52
7 - 4 P r o g r a m a n d S e r v o A l a r ms D e s c r i p t i o n 5 5
7-5 List of the Machine Components 110
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PRECISION MACHINE TOOLS Ver2.1 Maintenance Manual
Chapter 1
Routine Maintenance
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PRECISION MACHINE TOOLS Ver2.1 Maintenance Manual
1-1 Routine Maintenance Checklist
Routine maintenance inspection can be classified into daily, weekly, monthly and annually. The
maintenance is given when the machine functions normally The actual frequency and the operation
frequency are different. When operating the both, pay attention to abnormal noises, oil volume, air
pressure and machine abnormalities during the processing.
○：Check ◎：Add oil ☉：Clean
A：Adjustment F: Function check G: Grease coasting R: Replace when necessary
No.
1
2
3
4
5
6
7
8
Spindle unit
Lubrication
unit
Spindle oil
coolant unit
Maintenance Daily Weekly Monthly Annually Note
Spindle operation
○
warm-up
Spindle nose
Lubrication pump
☉
☉
Depending
on the brand
of the lube oil
Lubrication pump
◎
oil volume
Spindle oil
○
☉
coolant unit
Temperature
○ -1°C
difference setup
Oil coolant unit filter
☉
Air compressor
○ 5.5~7 kgf/cm²
source pressure
Air compressor
9
Air
Compressor
Unit
10
cylinder and filter
drainage
Air compressor
○
◎
unit lube oil
Air leakage of the air
11
○
compressor system
12 Coolant capacity ○
Coolant
13
Coolant box filter
☉
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PRECISION MACHINE TOOLS Ver2.1 Maintenance Manual
No.
Maintenance Daily Weekly Monthly Annually
Note
Depending
Internal flow of
Tool magazine
14
automatic tool
the tool change
R/
1-year
on the brand
of the lube
machine
change (ATC)
system
15
Tool sleeve and
☉
oil
tool change claw
16 CNC operation
panel
Emergency stop
button
○,F
17 Operation button ○,F
18 Spindle cooling fan
○/☉
Electric box
19
CNC axial battery ○ R
20 Machine static precision check ○,A
21 Machine position precision check ○,A Replace
22 Spindle cooling fan
23 Oil skimmer ○,F
○/☉
☉
Note: The schedule presented in table is for normal operation only. If the environment is not optimal
or if the usage frequency has exceeded the suggested basic standard, you may need to increase the
frequency of maintenance
Note 2: If there is any inconsistency between this table and instruction from elsewhere, use the
information provided on this table.
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PRECISION MACHINE TOOLS Ver2.1 Maintenance Manual
1-2 Routine Maintenance Instruction Diagram
( 14、15 ) Tool magazine / Automatic tool change system
( 1、2 ) Spindle unit
( 17 ) Operation box
( 12、13 ) Coolant
( 16 ) Emergency stop button
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PRECISION MACHINE TOOLS Ver2.1 Maintenance Manual
Machine precision check (20 – 21)
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PRECISION MACHINE TOOLS Ver2.1 Maintenance Manual
( 22 )
Fans
( 18、19 )
Electrical box
( 23 )
Oil skimmer
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PRECISION MACHINE TOOLS Ver2.1 Maintenance Manual
( 5、6、7 )
Spindle oil temperature
controller
( 8、9、10、11 )
Air compressor preparation unit
( 3、4 )
Central lubrication system
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PRECISION MACHINE TOOLS Ver2.1 Maintenance Manual
1-3 Cautions for Machine Maintenance
It is important to perform maintenance on each listed items in order to maintain machine precision
and extend machine lifespan.
Erroneous operation may damage the machine or lead to injury of the operator. Be cautious about
the following matters:
Cautions Prevention
To extend the lifespan, follow the instructions given in Section
2-3 for machine warm-up before turning on the machine.
Spindle operation warm-up
Dynamic balance of the cutter
Standard broach bolts
Spindle pre-operation check
Manually loosening the
spindle’s cutter
If the machine has been stopped for a long period, follow the
instructions given in Section 2-3 for machine warm-up before
turning on the machine in order to extend the life span.
To extend the lifespan as well as to increase the precision,
please follow instructions given in Section 2-1 for usage as
well as achieving a dynamic balance for the cutter.
Broach bolt is an important component jointing the spindle and
the tool shank. Using a wrong broach bolt is hazardous for the
operation. Make sure that only the standard one is used.
Check the machine before spindle operation according to
instructions given in Section 2-4 in order to extend the lifespan
of the spindle.
When loosening the cutter of the spindle, make sure that each
step is executed correctly or may lead to personnel injury.
When changing the cutter, be cautious not to drop the cutter,
Manual installing the cutter onto
which may damage the workbench or tools. Manually change
the cutter only if necessary, and the procedures are written on
the spindle
the operation panel at the front. Press and let go of the spindle
cutter loosening button to loosen up or to grasp the cutter.
The tool magazine is controlled by CNC and motor. After
Do not touch the spinning tool
turning on the machine, do not touch the tool magazine or may
magazine
be injured. Turn off the power for changing the cutter.
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PRECISION MACHINE TOOLS Ver2.1 Maintenance Manual
Cautions Prevention
Spindle nose cleaning Keep the taper of spindle nose and cutter shank clean at all
time to prevent dust or iron filings affecting the precision. The
spindle has an automatic dust removal function, but the
operator should wipe the parts with standard air-laid paper for
maintaining spindle precision.
The function pressure of this air compressor is 5kgf/cm²( 71
psi ). Therefore the air pressure source has to be at least 5.5
kgf/cm²( 78 psi ) and stabilized.
This machine has an air filter that eliminates impurities and
Air quality inside the air
compressor
Lube oil from the lubricating
pump (automatic)
Adding oil to the spindle oil
cooler and setting up the
water vapor from the air. Air for the air pressure source has to
be clean and dry. Check the filter constantly to extend the
lifespan of the filter.
To effectively eliminates water vapor by the filter, drain the
water from the air tank of the air compressor. (Water drainage
is more effective in the morning).
Lube oil is released by the lubricating pump to lubricate the
guide ways and the lead screws. Insufficient lubrication may
speed up the abrasion and affect machine precision.
Always make sure that there is enough oil in the tank. If the
amount of oil is below the lower limit of the oil-level gauge, the
operation panel as well as the screen will issue a warning
message. Please add more oil as early as possible.
Oil cooling circulation system was adopted for the spindle to
effectively suppress spindle temperature increase and thus
extend the lifespan of the spindle. Use the correct type of
circulation and add more oil when the level is too low.
temperature difference
The machine adopts synchronous machine temperature
adjustment Temperature difference is set to 0 to prevent big
temperature difference, which can damage spindle bearing.
Do not change the value arbitrarily.
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PRECISION MACHINE TOOLS Ver2.1 Maintenance Manual
Cautions Prevention
Constantly check the guide ways of the three
axes (X, Y & Z). Check whether there are iron
Guide way check
Correctly locking the work pieces
Correctly locking the doors
filings or other types of grains attached to the
guide ways. To extend the lifespan, remove the
dust or they may scratch the slide.
When placing work pieces onto the workbench,
make sure that they are well locked or they may
spin out and cause personnel injury.
Make sure the operation door and the two side
doors are well locked to prevent the cutter from
bursting apart or iron filings from flying out,
which is dangerous.
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PRECISION MACHINE TOOLS Ver2.1 Maintenance Manual
Chapter 2
The Spindle Unit
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PRECISION MACHINE TOOLS Ver2.1 Maintenance Manual
2-1 Cautions for High Speed Processing
During high-speed processing (S = 8000 rpm or above; F = 300 mm/min or above), the shank and
the style of the cutter has a critical impact on spindle lifespan and processing precision. Matters that
need more attention are:
1). Grasp the cutter before running the spindle to avoid damaging the spindle.
2). During high-speeding chipping (8000rpm or above), use only G2.5 level cutters and shanks that
have been calibrated for dynamic balance. The reason is that vibration generated from centrifugal
force may damage the spindle bearing and rapidly wear out the cutter.
3) Balance tolerance for the shank and the cutter combination is affected by the following three
factors: rotation speed of the cutter, balance tolerance of the spindle, and weight of the shank.
Therefore, using a shorter cutter with a smaller diameter for high-speed chipping is advantageous in
terms of spindle vibration, temperature increase, thermal deformation, and processing precision.
4) The geometric shape of the cutter blade has an effect on cutter abrasion. Increase the angular
backlash of the blade can reduce abrasion due to scratches. Suitable cutter materials can also
minimize abrasion during high-speed processing; for example, cermet, tin or tic coated carbide
cutters have longer lifespan than conventional cutters. Ceramic (Si3N4) cutters are better than cermet
cutters.
5) Perform another dynamic balance calibration after combining the cutter and the shank together.
The dynamic balance standard should be G2.5 or above.
50 – 6000 rpm Level G6.3 Balance level
6000 – 18000 rpm Level G2.5
Spindle Rotation Speed (rpm) Cutter Diameter (mm) Cutter Length (mm)
6000 – 8000 125 250
8000 – 10000 100 250
10000 – 12000 80 250
12000 – 15000 65 200
15000 – 18000 50 200
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PRECISION MACHINE TOOLS Ver2.1 Maintenance Manual
2-2 Tool Shank and Broach Bolts
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PRECISION MACHINE TOOLS Ver2.1 Maintenance Manual
CAT 40 STUD
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PRECISION MACHINE TOOLS Ver2.1 Maintenance Manual
2-3 Spindle Warm-up
This is an aerosol lubrication design, and so before turning on the machine, follow the warm-up steps
below to extend the lifespan of the spindle and to avoid damaging the bearing by letting the oil
aerosol getting into the bearing ahead.
Spindle warm-up time
Item
1 Routine operation Max Rpm 20% 10
If the spindle has been
stopped for more than two
2
hours, warm-up is
compulsive.
Spindle stopped for more
3
than 72 hours
Condition
Spindle RPM
(Maximum RPM %)
20% 10
1. 20%
2. 50%
Rotation Time
( min )
Check Contents
1. Less than 10°C
increase of
temperature
2. Shocks
3. Noises
1. Less than 10°C
increase of
temperature
Shocks
2. Noises
1. Less than 10°C
increase of
10
temperature
10
2. Shocks
3. Noises
1. 500 RPM
2. 20%
3. 40%
Spindle stopped for more
4
than 2 weeks
4. 60%
5. 80%
6. Maximum RPM
60
10
10
*10
*10
*10
Less than 10°C
increase of
temperatureShocks
Noises
4. Do not go onto the
next step until the
temperature has
become stable.
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PRECISION MACHINE TOOLS Ver2.1 Maintenance Manual
Cautions
1) If the shank is not installed onto the spindle, do not operate the spindle. See the figure below.
If the temperature of the bearing has increased for more than 10%, reduce the rotation speed of the
spindle to 500 and do not carry out the warm-up until the temperature is about 5°C higher than the
room temperature.
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PRECISION MACHINE TOOLS Ver2.1 Maintenance Manual
2-4 Spindle Pre-Operation Check
1) Check whether the air pressure source is normal.
2) Check No.7 electric oil pump tank (Refer to the diagram in Section 3-1) for whether there is
enough oil.
3) Run the spindle at 100 rpm to check whether the oil pump is functioning normally.
4) If everything is okay, carry out the warm-up according to the spindle warm-up procedures
presented in Section 2-3.
Caution
1. The oil volume and air supply volume of this aerosol lubrication unit has already been set at the
factory. Do not adjust the values arbitrarily.
2. During the maintenance, do not disassemble, bend, or flatten the output oil pipe, which may
damage the oil pipe.
3. Timely fill up the oil tank.
4. If the spindle has been stopped for more than 2 hours, run the spindle system, including the
aerosol lubrication system, at a speed that is 20% of the maximum speed.
The machine has to have a forced warm-up for 10 minutes before starting the actual work.
5. Do not adjust the oil/air mixing valve. Use the factory-set default value for lubrication interval.
Do not change the values arbitrarily or the bearing may be damaged.
6. For this unit, if the screen displays “ALARM 1002, 1056, 2004,” check and turn off the alarm
before continuing the operation.
7. Do not turn on and off the spindle repeatedly in a short period of time during the processing.
The inside of the spindle may be over-lubricated, which can cause the spindle overheated.
8. If the spindle alarm went off when starting the operation, it is due to overheated bearing. Stop
the operation. Wait until the temperature returns to normal. Check if there is any problem before
starting the warm-up and the operation.
9. It is normal to have oil dropped onto the workbench or the processing item when running the
machine. This comes from the exhausted oil aerosol. Do not block the outlet or the back pressure
may lead to temperature increase, thereby damaging the spindle bearing.
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PRECISION MACHINE TOOLS Ver2.1 Maintenance Manual
2-5 Spindle Alarm Handling
1) For this unit, if the screen displays “ALARM 1002, 1056, 2004,” check whether the temperature of
the protective device of the bearing is 50°C. After checking the temperature, check whether the
pipelines are abnormal, squeezed or broken. Check whether the oil cooler and the air compressor
are normal. Wait for the temperature to drop before turning on the spindle for warm-up. This is the
first line of protection for the spindle.
2) The second spindle protection is the oil pump. The oil pump has liquid level detection, and when
the level is too low, ALARM will be issued. If the oil pipeline is blocked, the screen will display
ALARM 1002.
3) The third spindle protection is the pressure switch for air pressure supply. If there is insufficient air
pressure, the mixing valve will be incapable of emitting the oil aerosol. If this ALARM goes off, check
whether the oil pipeline is broken and whether air pressure supply is sufficient.
4) If the clients still cannot turn off the alarm after checking relevant pipelines, contact the service
department of the Company. Do not modify the setting arbitrarily.
5) Messages of the ALARM signals:
1. 1002 LUBE PRESSURE FAULT：Insufficient pressure from the automatic lubrication pump
2. 1056 SPINDLE COOLER ALARM：Abnormal spindle oil cooling function
3. 2004 LUBE LEVEL ALARM：Under the standard liquid level of the oil tank of the automatic
lubrication pump
6) For relevant settings, please refer to the electrical instructions.
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PRECISION MACHINE TOOLS Ver2.1 Maintenance Manual
Chapter 3
The Air Compressor Unit
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PRECISION MACHINE TOOLS Ver2.1 Maintenance Manual
3-1 Air Compressor System Layout
ATC
Rotary disk type tool magazine
Air gun
Machine front
Air pressure source
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PRECISION MACHINE TOOLS Ver2.1 Maintenance Manual
3-2 Air Compressor System Circuit Diagram
3-3 Air Compressor Unit
Connect to the air
pressure source
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PRECISION MACHINE TOOLS Ver2.1 Maintenance Manual
3-4 Air Compressor Detailed Specifications and Functions
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PRECISION MACHINE TOOLS Ver2.1 Maintenance Manual
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PRECISION MACHINE TOOLS Ver2.1 Maintenance Manual
Item
Name Size Qty.
L-shape extended
1
10mm_1/4" 1
brass connector
L-shape brass
2
10mm_1/4" 1
connector
1/4" 5/2-way_double
3 Solenoid valve
solenoid operated
4 Pressure detector 1/4" 1
5 Brass bushing 1/4"x3/8" 3
Copper female
6
thread four-way
3/8" 1
connector
Copper double
7
male thread
3/8" 1
connector
8 Solenoid valve 1/4" 2/2-way 1
1
9 Copper street elbow 1/4" 1
0
1/4" 2
10
Copper 90
double-male thread
connector
MACP300 T10
11 Connecting block
1
Quick straight
12
10mm_3/8" 1
connector
13 Straight connector 1/4"T*3/8"T 1
14 Air distribution block 1/4” * 2 1
MUSC-220-4E1-DC24
15 Solenoid valve
1
with lamp
Copper female
16
thread four-way
3/8" 1
connector
17 Quick connector 12mm_3/8" 1
Pressure regulating
18
MACP300-12A 1
valve
19 Water filtering cup MACP300-12A 1
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PRECISION MACHINE TOOLS Ver2.1 Maintenance Manual
20 Pressure gauge 1.5" 10KG/PSI 1
21 Solenoid valve
1
solenoid operated
L-shape
3/8" 3/2-way_single
22
8mm_3/8" 1
compressor fitting
23 Throttle valve 8mm_1/4" 1
Lubrication pump oil
24
55cc MACP300-12A 1
cup
L-shape
25
10mm_3/8" 1
compressor fitting
Quick nylon-tube
26
10mm_1/4"*90° 1
connector
27 Hex head plug 1/4" 4
0
3/8" 1
28
Copper 90
double-male thread
connector
29 Muffler (flat) 1/4" 3
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PRECISION MACHINE TOOLS Ver2.1 Maintenance Manual
3-5 Air Compressor Unit Usage Instruction
1) The pressure source of this machine’s pressure pipeline goes through the air pressure preparation
unit, and the pressure is set to 6kg/cm2. When the pressure source is less than 5kg/cm2, and the
duration lasts more than 2 – 3 sec, NC will turn on the alarm, and CRT will display 1011 AIR
PRESSURE LOW. In this case, check the pressure source and then press the RESET button to
continue the operation.
2) Maximum pressure: 10kgf/cm²
3) Adjustment range: 0.5 ~8.7 Kg f/ cm²
4 ) Filter size：5μ
5 ) Recommended lube oil：ISO VG32
6) The pressure source should not be lower than: 5.5kgf/cm²
7) Although the air compressor preparation unit of the water filter has an automatically water
drainage, the machine operator should check whether there is any water accumulation at the shift or
at the end of the day. If the water drainage function is abnormal, water vapor may get into the air
compressor component, thereby reducing the lifespan. For the water drainage function of the filter to
be more effective, water in the air tank of the air compressor should fully drained out. It is also
recommended to install a dehumidifier at the pressure source to make sure that the air is dry.
8) The machine operator should pay attention to whether the pressure pipeline is making a bz kind of
noise. This may be due to gas leakage at the connector. Check the machine by tracing the noise.
The pipeline of this machine is connected by connectors, and the disassembling method is
described below: The nylon tube can be directly inserted into the connector. Use the finger or a flat
screw driver to secure the connector when pulling out the nylon tube.
Use a screwdriver or fingers to press down the fixing ring.
Fixing ring
tube
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PRECISION MACHINE TOOLS Ver2.1 Maintenance Manual
3-6 Air Compressor Unit Troubleshooting
Problem Cause Correction
Reduced pressure source
output
Gas leakage
Disfunctional pressure
regulator
Output side air pressure low
Gas leakage at the screw cap
No oil dripped from the oil cup
The oil volume cannot be
adjusted
Oil leadkage at the adjustment
needle
Blocked filter Clean the filter
1. Loosened nut
2. Broken O-ring
3. Broken tube
Broken pressure regulator
1. Broken spring of the
pressure regulator
2. Broken spring of the valve
3. Dust or dirts on the base of
the valve
1. Tighten the nut
2. Replace the o-ring
3. Replace the tube
1. Replace the spring
2. Replace the spring
3. Clean the valve and the
base
4. Replace the valve
5. Replace the film
4. Broken lining of the valve
5. Broken film
1. Dust on the valve base
2. Broken inner lining rubber
3. Broken valve spring
1. Clean the valve and the
valve base
2. Replace the valve
3. Replace the spring
1. Loosened cap nut
2. Broken film
1. The adjusting needle being
too tight
2. The adjusting needle
cannot be closed or there
are dirts on the needle. The
adjustment needle cannot
bear the pressure
3. Broken or damaged
adjusting needle or needle
1. Tighten the cap nut
2. Replace the film
1. Loosen up the needle
2. Reduce the oil volume until
the level reaches the
maximum oil level
3. Add more oil until the level
reaches between the
maximum and the
minimum level
4. Clean up the blockage
base
1. The adjustment needle is
too loose
2. The adjustment needle
cannot be closed or dirt on
the needle. The adjusting
1. Tighteen the needle and
gradually loosen it for
adjustment
2. Remove the dirt
3. Partial replacement
needle cannot bear the
pressure
3. Broken or damaged
adjustment needle or
needle base
1. The needle is too loose
2. Broken O-ring
1. Tighten up the adjustment
needle
2. Replace the O-ring
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PRECISION MACHINE TOOLS Ver2.1 Maintenance Manual
Chapter 4
The Lubrication Unit
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