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:
CautionsPrevention
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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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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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.
1) Value of the input source current has to be the same as the one on the plague.
2) The wiring has to follow the instructions on the plaque to avoid damaging the oil pump.
3) Ground the ground wire.
4) A filter is installed on the inlet of the oil tank. Do not contaminate the manifold block
components.
5) Wash the filter whenever it is contaminated to maintain its function.
6) Do not drop oil, water or other onto the control circuit, or the control circuit may be
damaged.
7) Pay attention to the oil level when filling up the oil.
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4-2 Spindle Bearing Lubrication
High quality lube oil is used for the spindle bearing, and it is good for high temperature and high
speed conditions. Its lubricating effect on the bearing is long-lasting without being too oily, and
therefore there is no need to add or to change the lube oil for a while. It is therefore cost-saving.
4-3 Guide way and Ball Screw Lubrication
The linear guide way of X, Y and Z axes and the ball screws are lubricated by a centralized
lubrication system which lubricates according to the set schedule.Machine operators must ensure
that the oiling machine has enough oil, as well as whether there is any abnormality.
1) Lead Screw Lubrication
The bearing of the lead screw can be divided into the motor end and the housing end. Lube oil is
applied onto both ends for oil sealing. If the oil goes bad, dissemble these parts to wash the bearing
and reassembling them. Please contact the Company to have professionals checkup and
modification for you.
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PRECISION MACHINE TOOLS Ver2.1 Maintenance Manual
2) Guide way Lubrication
Guide ways of the workbench (X-axis), the saddle (Y-axis), the head (Z-axis), ball screws of the three
axes (X, Y and Z axes) and the nuts are lubricated by the automatic centralized lubrication system in
which an oil pump is located at the back of the machine.
If the machine has not been operated for a long time, less lube oil will be available in the oil tube. For
the following cases:
1) A machine installed for the first time;
2) A machine has not been operated for a long time;
3) Before operating a machine (daily);
You should manually lubricate to ensure that sufficient lube oil has circulated the entire guide way.
Press the red button on the lube oil pump for about 40 sec before releasing the button. Wait for 10
sec to repeat the above procedure. Repeat this process until lube oil has leaked out from the guide
way.
Cautions:
The oil tank has a 6-L capacity. Add oil from the oil inlet each week (or when necessary). If the oil
level reaches the minimum oil level, the operation panel will issue an alarm message informing the
risk.
1) Add clean lube oil specified for the guide way through the oil inlet. Do not use other types of lube
oil.
The recommended oils are:
Mobil VACTRA 1
Shell TONNA T32
2) Lube oil level:
The level should be maintained between the maximum and the minimum oil level marked on the oil
tank. Once the level drops below the midpoint, add oil as soon as possible. Do not add oil only after
the alarm goes off, which can affect the operation of the machine.
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SPINDLE HEAD UNIT
Number Model Name Quantity
1. PA6 Pipe cape 1
2. PB6 Pipe 1
3. PQ101 Connector 1
4. PH601 Straight angle connector 1
5. HBL-3 Volume-based distributor 1
6. PAN4 nut 7
7. PB4 Pipe 14
8. PA4 Pipe cape 7
9. PH4-1 Straight angle flat
connector
10. PG01 Sealing plug 1
7
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WORK TABLE UNIT
Item Name Item Name
H Left front guide way surface A Right front guide way surface
G
E
F Left rear guide way surface D Right rear guide way surface
Left front reference surface
B
and pressure plate
Left rear reference surface
C
and pressure plate
Right front reference surface
and pressure plate
Right front reference surface
and pressure plate
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Number
10. PA4 Pipe cape 9
11. PD401 Connector 8
12. HBL-5 Volume-based distributor 1
Saddle unit
Model Name Quantity
1. PH4-1 Flat and straight-angle connector 1
2. PB6 Pipe 7
3. JD6 Fixed dual connector 1
4. PH601 Straight-angle connector 3
5. PKD6 3-way pipe 1
6. HBL-4 Volume-based distributor 1
7. PQ01 Sealing plug 2
8. PAN4 nut 9
9. PB4 Pipe 18
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Item
Name Item
A Left front embedded pressure plate I Right front embedded pressure plate
B Front left-right reference surface J Front right-right reference surface
C Front left-left reference surface K Front right-left reference surface
D Left front guide way surface L Right front guide way surface
E Left rear guide way surface M Right rear guide way surface
F Rear left-left reference surface N Rear right-left reference surface
G Rear left-right reference surface O Rear right-right reference surface
H Left front embedded pressure plate P Right front embedded pressure plate
Number Model Name Quantity
1. PKD6 3-way pipe 2
2. PB6 Pipe 8
3. PA6 Pipe cape 8
4. HBL-4 Volume-based distributor 1
Name
5. HBL-5 Volume-based distributor 2
6. PAN4 Nut 17
7. PB4 Pipe 34
8. PA4 Pipe cape 17
9. PH4-1 Flat and straight-angle connector
17
10. PH601 Straight-angle connector 2
11. HBL-3 Volume-based distributor 1
12. PQ101 Connector 2
13 PG01 Sealing plug 1
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PRECISION MACHINE TOOLS Ver2.1 Maintenance Manual
4-4 Lubrication of the Cam Box of Tool Magazine
Tool magazine’s rotation is driven by ACT cam box. To ensure a smooth rotation of the cam box, it
has to be routinely checked on whether there is enough oil for the oil lens. If not, add oil. After 2,400
hour of operation, replace the circulating oil in the cam box.
Oil inlet
Oil lens
4-5 Counterweight Chain and Sprocket Bearing Lubrication
Apply lube oil onto the sprocket of the counterweight chain. There is an oil inlet at the center of the
sprocket bearing. Add oil at least once a year. Lubricate the counterweight chain, too.
入油口
(oil in)
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PRECISION MACHINE TOOLS Ver2.1 Maintenance Manual
4-6 Cylinder Lubrication
1. Normally, oil in the oil cup will be depleted eventually. The oil will be used up after about 500,000
times.
2. Normally, it is recommended to remove the remaining oil from the oil cup each year and add new
one when doing the machine maintenance (dot not disassemble the oil cup, or it may be
damaged).
3. The color of the oil will be darkened if it has not been replaced for a long time. It will affect the air
pressure and lifespan of the machine. Check it routinely or monthly.
4. It is abnormal is the oil is depleted within 2 to 3 days. Check whether there is leakage at the oil cup
or the cup is broken. If so, replace the oil cup. If the depletion is abnormal, the boosting cylinder
may need to be replaced immediately to protect the spindle.
4-7 Lubrication Location
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PRECISION MACHINE TOOLS Ver2.1 Maintenance Manual
Chapter 5
The Spindle Oil Cooling Unit
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PRECISION MACHINE TOOLS Ver2.1 Maintenance Manual
5-1 Oil Cooling Pipeline Diagram
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PRECISION MACHINE TOOLS Ver2.1 Maintenance Manual
5-2 Spindle Oil Cooling Unit
a) Add the correct type of oil according to the instructions presented on the plaque.
b) The air filter of the cooling unit should be kept clean. It can be taken out for cleaning.
c) The cooling unit also has a oil filter, which has to be cleaned routinely.
Names and operation of functions on the small panel
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PRECISION MACHINE TOOLS Ver2.1 Maintenance Manual
The spindle has already been appropriately adjusted prior to the installation. It is normal to have a
slight increase of temperature. Spindle oil temperature is supplementary only; do not set the
temperature too high or too low. The temperature control mechanism for the cooler is base on
tracking temperature differences between the oil temperature and the room temperature (or the
machine temperature) to make sure that the difference is well maintained.
The cooling unit is turn on and off automatically based on the temperature of the machine. The
control key of the oil temperature is on the control panel of the cooling unit. When the SV is set to 0℃,
the oil temperature and the machine temperature are the same. When the SV is set to +℃,
temperature of the oil will be greater than of machine. When the SV is set to -℃, temperature of the
oil will be less than of the machine. In general, these two temperatures are set to be equal. If the oil
temperature is set to be lower than the machine temperature, temperature of the oil tank will be
smaller than that of the machine. In this case, condensation may occur, which could contaminate the
oil. Moreover, the external guide way of the bearing may shrink during the operation because the
level of fraction and temperature will be increased, which can damage the spindle.
Do not arbitrarily modify the default value.
Note: This machine has automatic fault detection. When any fault detected, the panel will flash and
display the fault signal. Troubleshooting is required. Then, turn off the machine for at least 10 sec
before turning it on again. For operation quality, double-check that all the problems have been
resolved and the system is at a good condition.
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PRECISION MACHINE TOOLS Ver2.1 Maintenance Manual
The oil filter shall be installed at the return oil ( inlet ) of the cooler to filter impurity efficiently and
protect the spindle.
Oil cooler uses hydraulic oil and lubrication oil. The directed oil for WEXTEN cooler is 2-300 CST.
The oil below are prohibited.
(1 ) Hydraulic oil of phosphoric ester and chlorinated hydrocarbon types, water, water/ glycol
hydraulic oil
( 2 ) Cutting oil, grinding oil and water-soluble liquid.
( 3 ) Medicine and corrosion liquid.
( 4 ) Gasoline , kerosene and EDM oil.
Check points before operation
1. When the power source is turned on, check to see if power lamp is lighted up.( see figure 1 )
2. Check that electrical resistance of compressor and pump is above 500 ohms.
3. Check that the oil level is at least at 80% level of the oil tank ( see figure 2 )
4. Check that the outlet of the oil tank is tightly secured.
5. Check that the overload switch is at “on “position.
6. Check that value is set at 5 kg/cm² for the pump pressure ( 5kg/cm² indicates 12 L/min, 20L/min,