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Chapter 9 

 

Preventive Maintenance 

                                     

                                 
 
                 
 

 
 
 
 
 

Summary of Contents for AL52

Page 1: ...AL52 AM52...

Page 2: ...ipment Specification 2 5 2 5 Machine Accessories 2 6 2 6 Machine Accuracy 2 7 2 7 Dimensions 2 7 2 8 Main Part 2 9 2 9 Power Performance Diagrams 2 10 2 10 Working Range and Workpiece Weight 2 11 2 11...

Page 3: ...Splash Guarding Enclosure 7 15 7 5 Mechanism Adjustment 7 16 Chapter 8 Pneumatic coolant systems 8 1 Schematic Diagram of the Pneumatic System 8 1 8 2 Schematic Diagram of the Pneumatic Piping System...

Page 4: ......

Page 5: ...Chapter 1 Machine Safety Regulation...

Page 6: ...imensional accuracy or further details It provides extremely high machining accuracy Be careful of rigidity of working material setting operation maintenance and troubleshooting please reference speci...

Page 7: ...against unsafe practices Black lettering on Yellow Background Safety Alert Symbol Black triangle Yellow exclamation point 1 1 1 Danger 1 1 1 1 Do not touch Control Panel Transformer Motor Connection...

Page 8: ...12 Don t use machines in damp or wet locations or near potentially explosive environment Keep working area well lighted and ventilation 1 1 2 13 The workshop of user shall be equipped with the fire ex...

Page 9: ...s machine and its safety devices to the operator prior to his her operating the machine Use demonstration as a positive means of instruction and be certain that the operator fully understands the mach...

Page 10: ...bey the local regulation and be deeply careful 1 1 3 8 Only competent well trained personnel should be permitted to operate or perform maintenance on this machine 1 1 3 9 Before operating this machine...

Page 11: ...section carefully before handling the package 1 2 1 Danger 1 2 1 1 This machine weight is gross weight of 9 tons for AL52 AM52 the safety load of the handling equipment must be greater than10 tons for...

Page 12: ...and car go up around the machine also prohibited people to climb the crowfoot and wire ropes to avoid accidental condition of people happen to fall 1 2 3 Caution 1 2 3 1 When lifting and moving machi...

Page 13: ...o ground of less than 100 Gnerally the NC machine should be grounded to a separately grounding rod If an independent ground can not be provided for the machine Please ground as follows 1 3 2 1 Connect...

Page 14: ...Machine Safety Regulation 1 9 Grounding resistance Smaller than 100 Common grounding Grounding as figure 2 Grounding resistance 100 NOTE Never ground equipments as figure 3...

Page 15: ...1 3 3 5 Altitude shall be at altitudes up to 1000m above mean sea level 1 3 3 6 Atmosphere Free from excessive dust acid fume corrosive gases and salt 1 3 3 7 Avoid exposing the machine directly to s...

Page 16: ...4 1 3 3 When machine is unpacked or has not been used for a period of time a few days or longer every sliding part must be cleaned and lubricated and turn on lubricant pump for a while until lubricat...

Page 17: ...on Otherwise might result in squeeze to wounded and disabled 1 4 2 2Caution 1 4 2 2 1 Check the pressure readings regularly to make sure all the system pressures setting are normal 1 4 2 2 2 Observe...

Page 18: ...g is normal or not when warming up the machine in the mean time 1 4 3 1 3 The door and safety guards must be closed when spindle speed is over to avoid any accident When spindle starts working please...

Page 19: ...nded grease as described in the oil guide table please refer to operator s manual recommended oil on chapter 6 3 1 4 4 2 2 Use the recommended cutting tools and tool length as described in Chapter Two...

Page 20: ...g cutting 1 4 5 2 2When heavy cutting please note and prevent from chips piling up too high that chips temperature will be high and cause fire 1 4 6 Cutting Interruption 1 4 6 1 Warning When leaving m...

Page 21: ...1 4 7 1 7Check quantity of coolant lubricant oil and hydraulic oil fill it if it is not sufficient 1 4 7 1 8Clean filter of coolant lubricant and hydraulic oil 1 4 7 1 9Be sure that operator s power s...

Page 22: ...Before operation and maintenance must carefully read and understand all the instructions given in this manual 1 4 9 1 5Maintain as instruction and establish maintenance record 1 4 10 Maintenance 1 4 1...

Page 23: ...components and discard oils out of the machine to suitable place 1 4 11 2 Caution 1 4 11 2 1Maintenance people must inspect whether machine operation is safe or not 1 4 11 2 2Keep record of maintenan...

Page 24: ...05 and choose the reverse direction of Fig 06 which the operator was trapped then rotate the handwheel 1 4 12 2Procedure by without resuming power supply 1 4 12 2 1 When the operator was twisted by th...

Page 25: ...been designed to be protected by guards or covers as possible to avoid user s directly contact with these parts However it can not avoid dangers caused by user s abnormal operation So users and maint...

Page 26: ...Safety Regulation 1 21 1 5 1 2 The parts with mark as drawings shown below are all high voltage parts Please be attention that only qualified engineers are allowed to open the box to avoid electrical...

Page 27: ...before removing parts or servicing 1 6 4 Exposed moving parts can cause Severe injury LOCK OUT POWER before removing guard 1 6 5 Hazardous voltage will cause severe Injury or death LOCK OUT POWER bef...

Page 28: ...y LOCK OUT POWER before removing guard or servicing 1 6 9 Exposed gripping parts or area can cause Severe injury LOCK OUT POWER Before removing cover or servicing 1 6 10 Riskof accidents caused by ele...

Page 29: ...Chapter 2 Machine Specification...

Page 30: ...de the safety and efficiency of the working process could be increased tremendously Nevertheless read all the manuals we provided thoroughly Do not try to use this machine unless you understand how to...

Page 31: ...min 1 OPT 12000 min 1 Feedrate Feedrate of X Y Z axis 1 12000 M min 0 04 472 4 ipm Slideways of X Y Z axis Linear Guideway Rapid traverse of X Y Z axis 36 M min Tool Magazine Tool capacity STD 24 pcs...

Page 32: ...12000 min 1 Feedrate Feedrate of X Y Z axis 1 12000 M min 0 04 472 4 ipm Slideways of X Y Z axis Linear Guideway Rapid traverse of X Y Z axis 36 M min Tool Magazine Tool capacity STD 24 pcs OPT 30pcs...

Page 33: ...T 12000 min 1 Feedrate Feedrate of X Y Z axis 1 12000 M min 0 04 472 4 ipm Slideways of X Y Z axis Boxway Rapid traverse of X Y Z axis 18 M min Tool Magazine Tool capacity STD 24 pcs OPT 30pcs Tool se...

Page 34: ...temperature 0 45 C 32 F to 113 F 2 4 2 8 Ambient relative humidity less than 90 with no condensation occurred 2 4 2 9 Other environment requirements are listed below 2 7 1 1 A constant and smooth ambi...

Page 35: ...Cooling System for Spindle 5 Spindle Taper Cleaner 6 Arm Type A T C 24 Tools 7 T Slot Type Table 8 Heat Exchanger for Electrical Cabinet 9 Fully Enclosed Splash Guard 10 Grease Lubrication System 11...

Page 36: ...Machine Specification 2 7 2 6 Machining Accuracy 2 7 Dimensions AL52 AM52 ITEM MODLE X Y Z axis Positioning Repeatability AL52 AM52 0 004 0 005 0 003 0 004...

Page 37: ...2 8 Machine Specification AL52 Column height...

Page 38: ...fication 2 9 2 8 Main Parts Item Nomenclature 1 Shield cover 2 Electrical cabinet 3 Operation panel 4 Coolant tank 5 Headstock 6 Main column 7 Bed base 8 Working table 9 Saddle 10 Tool magazine 11 Pne...

Page 39: ...2 10 Machine Specification 2 9Working Range and Workpiece Weight Maximum weight of workpiece AL52 AM52 1200 KG MODEL A B C D E F G H AL52 AM52 1300 100 1500 680 15 650 680 150 AL52 Column height 353...

Page 40: ...Machine Specification 2 11 2 10 Dimensions of the Working Table AL52 AM52...

Page 41: ...2 12 Machine Specification 2 11 Dimensions of the Tool Holder 2 11 1 BT 40 JIS Specification...

Page 42: ...Machine Specification 2 13 2 11 2 V40 ANSI Specification...

Page 43: ...2 14 Machine Specification 2 11 3 V40 CT Specification...

Page 44: ...Machine Specification 2 15 2 11 4 CAT 40 Specification Unit inch...

Page 45: ...2 16 Machine Specification 2 12 Specifications of the Tool...

Page 46: ...Machine Specification 2 17 2 13 Stroke Limits for Axes and ATC MODEL A B C D E F G H AL52 AM52 1300 100 1500 680 15 650 680 150 AL52 Column height 353...

Page 47: ...sm for Tool Clamping and Unclamping The tool clamping and unclamping are accomplished through the use of disk spring drawing bar and a pneumatic system as shown below The tool clamping force applied b...

Page 48: ......

Page 49: ...Chapter 3 Shipping Handling and Installation...

Page 50: ...B C D E F AL52 AM52 6380 5250 3380 2250 763 789 3 1 1 1 Ensure to reserve space for optional equipment Please contact us if you have any problem in installing this machine 3 1 1 2 Ensure the site spac...

Page 51: ...the arrival of the machine Refer to the following foundation construction diagrams for details The construction procedures are listed as follows 3 1 2 1 1 1 Dig the foundation site Pave the site bott...

Page 52: ...Shipping Handling and Installation 3 3 AL52 AM52...

Page 53: ...1 1 Ensure that strength of the cables can sustain the weight of the machine 3 2 1 2 Ensure the lifted machinery package is in balance before starting to move it 3 2 1 3 Abrupt changes in lifting low...

Page 54: ...Shipping Handling and Installation 3 5...

Page 55: ...L52 AM52 3 2 2 2 2 The AL52 AM52 packed machine is 438 cm in length 270 cm in width and 301 cm in height Ensure nobody is in the way and the path is not blocked before moving the packed machine It cou...

Page 56: ...wise might cause people injury and damage the machine 3 2 3 1 3 Ensure lifting forks are in an appropriate position and the object is in balance before proceeding Keep any part of the machine at least...

Page 57: ...3 Use only the sling frame provided to lift the machine Other fixture or rope is prohibited 3 2 3 2 4 AL52 AM52 is 338 cm in length 267 cm in width and 267 cm in height 338x231x255 cm for AL42 Ensure...

Page 58: ...nd move the saddle to the main column as close as possible Place a wooden block on top of the table then lower the headstock slowly until it rests on the wooden block 3 2 4 1 3 Tool Magazine Place woo...

Page 59: ...Installation 3 2 4 2 How to move work piece Using sling to move work piece is necessary for any work piece heavy than 10 Kgs Operation procedure description is below Work piece must has fix point for...

Page 60: ...Shipping Handling and Installation 3 11 Move work piece to table Lock the bolt and positioning block...

Page 61: ...remove all the fixtures listed below before operating the machine 3 2 5 1 Remove the fixed block 1 under the headstock 3 2 5 2 Remove the fixed plate 2 on the working table 3 2 5 3 Remove the fixed pl...

Page 62: ...ons fork lift is necessary 2 240 Fork length must longer than 240 cm 1 3 Step 1 Pull the iron base by hawser Step 2 Fork lift on the position as the picture Step 3 Move the base and machine on the woo...

Page 63: ...3 14 Shipping Handling and Installation...

Page 64: ...sible 3 3 2 Storage of the Bare Machine 3 3 2 1 Ensure to fasten all the loose parts and have an anti rust treatment of the machine 3 3 2 2 Ensure to fasten all the sliding guards and doors to prevent...

Page 65: ...4 Connect the connector marked with PE inside the electric cabinet to the external grounding conductor If it is no PE wiring on the external power supply system please prepare one ground wire and set...

Page 66: ...own in the foundation construction diagrams 3 6 3 Place two horizontal levels on the working table orthogonally level the machine until differences between levels in both directions are within 0 02 mm...

Page 67: ...squareness between the spindle centerline and the working table surface 3 6 7 1 Hold the dial gauge set directly under the spindle 3 6 7 2 Ensure the distance between the dial gauge probe and spindle...

Page 68: ...rking table along some distances then level the machine until readings at both ends are the same 3 6 8 5 Ensure moving or rotating parts do not interfere with the sheet metal construction 3 6 8 6 Ensu...

Page 69: ...Key driver This will prevent the control panel from rotation 3 7 1 12 Ensure safety guarding shields and doors are in a good condition 3 7 1 13 Ensure the hydraulic oil lubricant and cutting coolant a...

Page 70: ...Shipping Handling and Installation 3 21 3 8 Polycarbonate panes Note We recommend making a replacement the polycarbonate panes every three years...

Page 71: ...ollector is highly recommended This device usually is installed prior to shipment Just start this device during operation to have clean air in the environment and offer no harm to health During operat...

Page 72: ...Chapter 6 Lubrication...

Page 73: ...er is standard equipment 6 1 1 6 Instead of using the fan type cooler a refrigerator type cooler will be used to cool the cooling or lubrication oil of the spindle system upon request This refrigerato...

Page 74: ...e power is off 6 1 3 3 The warning alarm will be continuing if the warning status is not released even though the power is turned off on 6 1 3 4 Press the FEED HOLD and RESET keys together to release...

Page 75: ...Lubrication 6 3 Operation s Maintenance Manual EV 860 1050 6 2 Lubrication System Diagram 6 2 1 Grease Lubrication System Diagram AL52...

Page 76: ...6 4 Lubrication EV 860 1050 Operation s Maintenance Manual AM52...

Page 77: ...Lubrication 6 5 Operation s Maintenance Manual EV 860 1050 6 2 2 Oil lubrication Cooling Diagram...

Page 78: ...ease Lubrication Points 6 2 3 1 Fill the R68 lubricate from oil orifice if the optional centralized lubrication system is used instead 6 2 3 2 Move the headstock down to the end point Fill the R68 lub...

Page 79: ...2 Viscosity index above 95 3 Anti rust anti oxidation 4 Good Stability 1 Viscosity ISO VG32 2 Anti rust anti oxidation 3 Good Stability LubricationMethod Circulating Lub Oil feeder Oil Change Period...

Page 80: ...Chapter 7 Mechanism...

Page 81: ...indle motor through belts and pulleys The maximum spindle rotating speed is 10000 min The tool clamping and unclasping are accomplished through the use of disk spring draw bar and a pneumatic system a...

Page 82: ...holder the draw bar will be pulled up by the disk spring set to close the collet chuck To release the tool holder the collet chuck is pushed off by the pneumatic piston through the draw bar A stream...

Page 83: ...echanism 7 1 3 Spindle Positioning Mechanism The sensor tracks the spindle rotation motion and feeds the positioning signal to the spindle drive motor s controller to control the spindle position prec...

Page 84: ...spindle rotation pressured air comes through circuit A and pushes cylinder s piston and shifter downward to mach low speed gears In high gear spindle rotation pressured air comes through circuit B an...

Page 85: ...chanism 7 2 1 1 1 The working table is seated on guide rails of the saddle and driven by the AC servomotor via the connection of a coupling and a ballscrew 7 2 1 1 2 Because the AC servomotor is direc...

Page 86: ...trol loop 7 2 1 2 2 The maximum traveling range in the X direction is AL52 AM52 A safety mechanism is used to prevent the saddle from over traveling as described below 7 2 1 2 3 When the working table...

Page 87: ...The saddle is seated on guide rails of the bed base and driven by the AC servomotor via the connection of a coupling and a ballscrew 7 2 2 1 2 Because the AC servomotor is directly connected to the b...

Page 88: ...ar scales option which are a closed control loop 7 2 2 2 2 The maximum traveling range in the Y direction is 680mm AL52 AM52 A safety mechanism is used to prevent the saddle from over traveling as des...

Page 89: ...eadstock is seated on guide rails of the main column and driven by the AC servomotor via the connection of a coupling and a ballscrew 7 2 3 1 2 Because the AC servomotor is directly connected to the b...

Page 90: ...7 2 3 2 2 The maximum traveling range in the Z direction is 680mm AL52 AM52 A safety mechanism is used to prevent the headstock from over traveling as described below 7 2 3 2 3 When the headstock tra...

Page 91: ...onnectors on the base bed pass through the base bed to the Y axis cable carrier then connect to connectors located on the saddle And all the electrical wires air hoses and oil hoses connecting between...

Page 92: ...tool exchange command is issued the swivel disk will be rotated to the selected tool position according to NC or manual commands A proximity switch is used with the electrical motor to control the mag...

Page 93: ...the cylinder activates the draw bar and shifter to make the tool shank adapter rotate 90 then tool changing is possible After the tool changing process the cylinder activates the tool shank adapter t...

Page 94: ...es 65 at CCW direction to clamp tools 3 After spindle release the tool holder the tool arm moves downward for 115mm to pullout tools 4 Tool arm rotates 180 at CCW direction to change tools 5 Tool arm...

Page 95: ...ant filters to the coolant distributors Ensure to clean the coolant filters frequently The sheet metal enclosure is designed to have a 2 pieces front door so that you can inspect the machine or instal...

Page 96: ...r box and the nut of adjust bolt 2 Adjust the belt tension by tightening the adjust belt 3 Tighten the nut of adjust bolt 4 Tighten the fastening screws on the gear box or motor stand Note Ensure to h...

Page 97: ...7 17 Mechanism...

Page 98: ...Chapter 8 Pneumatic Coolant Systems...

Page 99: ...ressure Controls combination F R L Schematic Diagram of the Pneumatic Air Gun Tool Adapter Rotation 90 Horizontal 90 Spindle Tool Clamp Unclamp Clamp Unclamp SPINDLE AIR SEAL TAPER Tool holder cleanin...

Page 100: ...ination F R L Schematic Diagram of the Pneumatic Air Gun Tool Adapter Rotation 90 Horizontal 90 Spindle Tool Clamp Unclamp Clamp Unclamp SPINDLE AIR SEAL TAPER Tool holder cleaning Taper hole B MV 106...

Page 101: ...8 3 Pneumatic Coolant Systems 8 2 Schematic Diagram of the Pneumatic Piping System...

Page 102: ...of the tool holder so that all foreign matter adheres to the V groove could be blown away Meanwhile the spindle is rotating slowly to the tool exchange position The solenoid valve will be turned off...

Page 103: ...control the cylinder of column when the spindle head up and down It is operated by the air pressure from compressed air tank 8 4 2 Pressure value The main pressure meter for all pneumatic system is so...

Page 104: ...Pneumatic Coolant Systems 8 6 AL52 AM52 Behind on the machine lower and right side near the transformer and cooler oil The cylinder of column The cylinder of column Release pressure valve...

Page 105: ...8 7 Pneumatic Coolant Systems 8 5 Schematic Diagram of the Coolant System...

Page 106: ...Chapter 9 Preventive Maintenance...

Page 107: ...s before resuming the machine if any electrical part such as the connector switch electrical socket and electrical wire is out of order 9 2 Weekly Maintenance 9 2 1 Clean up the air filter with soap w...

Page 108: ...OTE Pour in coolant water up to the upper index mark H L Do not allow the water level to fall below the lower index mark L The cleaning procedures of coolant tank are described as below 1 Turn the bal...

Page 109: ...listed in the oil guide table 9 6 2 Do not power on the machine if the PCBs of the NC equipment have been taken out for maintenance 9 6 3 High parts of the machine which must be accessible for mainte...

Page 110: ...PARTS NO MM0100030A Mar 2019...

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