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13.  Summart of the electrical 

13-1 

   

13.1 Electrical components and layout 

13-1 

   

13.2 Control panel, switches and symbols 

13-2 

   

13.3 Power circuit 

13-3 

   

13.3.1 Wiring diagram for standard electric box three phase 

13-3 

   

13.3.2 Wiring diagram for simple electric box three phase 

13-4 

  

13.3.3 

Power circuit (ce option)

 13-5 

   

13.4 Schedule of electrical equipment (ce option) 

13-7 

Summary of Contents for K5S

Page 1: ...OPERATING MANUAL HEALTH AND SAFETY GUIDANCE NOTES MODEL K5V DATE 2002 10 01 VERSION 6 ...

Page 2: ...stock lubrication 5 1 5 2 Machine table lubrication 5 2 6 Instruction in operations 6 1 6 1 Headstock 6 1 6 1 1 Spindle switch 6 1 6 1 2 Spindle brake 6 1 6 1 3 Chucking of tooling shank and dismantling 6 1 6 1 4 Manual feed 6 1 6 1 5 Manual micro motion feed 6 2 6 1 6 Automatic feed 6 2 6 1 7 Speed change of spindle 6 3 6 1 8 Headstock tilting 6 5 6 2 Machine body operations 6 6 6 2 1 Ram movemen...

Page 3: ...s 10 2 10 2 2 Adjustment of saddle gib 10 3 10 2 3 Adjustment of knee gib 10 4 10 2 4 Adjustment of ram gib 10 5 10 2 5 Adjustment of collect aligning screw 10 5 11 Maintenance 11 1 11 1 Daily maintenance 11 1 11 2 Monthly maintenance 11 1 11 3 Quarterly maintenance 11 1 12 Parts list 12 1 12 1 Head stock upside 1 12 1 12 2 Head stock upside 2 12 3 12 3 Head stock upside 3 12 5 12 4 Head stock inf...

Page 4: ...2 Control panel switches and symbols 13 2 13 3 Power circuit 13 3 13 3 1 Wiring diagram for standard electric box three phase 13 3 13 3 2 Wiring diagram for simple electric box three phase 13 4 13 3 3 Power circuit ce option 13 5 13 4 Schedule of electrical equipment ce option 13 7 ...

Page 5: ...Make sure power has been turned off when machine is unused for sometime n Be sure spindle is not running when using gauges on the machine o Never take depth of cuts beyond machine s capability 1 2 MACHINE OPERATORS PRECAUTIONS a The machine is to be started or operated by an authorized operator only b Immediate stop and repair are needed in case of troubles in operations c In installation the mach...

Page 6: ...1 2 ...

Page 7: ...FIG1 2 1 3 1 4 SAFETY DEVICES AND INSPECTION ...

Page 8: ...1 4 2 MACHINE SPECIFICATIONS SPINDLE GUARD CE OPTION CHIP TRAY FIG1 3 ...

Page 9: ...OTOR 5HP SPINDLE SPEED 50Hz L 58 360 H 500 3000 VARIABLE L 54 270 H 474 2392 4 STEP 60Hz L 70 425 H 600 3600 VARIABLE L 65 324 H 569 2807 4 STEP A OVERALL HEIGHT 2310mm 91 B OVERALL DEPTH 1795mm 70 5 8 C OVERALL WIDTH 1760mm 69 1 4 D MIN MAX DISTANCE 60 560mm 2 3 8 22 E MIN MAX DISTANCE 30 488mm 1 1 4 19 1 2 F MIN MAX DISTANCE 162 567mm 6 3 8 23 1 4 G MIN MAX DISTANCE 305 760mm 12 30 NET WEIGHT 16...

Page 10: ...1 Milling head stock 2 RAM 3 Turret 4 Culumn 5 Work table 6 Saddle 7 Knee 8 Operating plate 3 1 3 1 HEADSTOCK 1 4 7 3 8 6 2 5 FIG3 1 ...

Page 11: ...HINE BODY 1 COLUMN TURRET AND RAM HI LOW SPEED SELECTOR QUILL FEED LEVER MICROMETER ADJUSTING NUT QUILL LOCK FEED REVERSE KNOB HANDLEWHEEL FEED CONTROL LEVER QUILL FEED LEVER SPEED SELECTOR HANDLEEWHEEL FEED REVERSE KNOB ...

Page 12: ...4 POSITION AND NOISE LEVEL 4 1 OPERATOR POSITION AND NOISE LEVER RAM RAM LOCK LEVER COULUMN RAMPINION TURRET GIBBOLT FIG3 3 HANDLE WHEEL SADDLE KNEE ELEVATING CRANK HANDLE WHEEL SADDLE LOCK LEVER WORK TABLE LOCK LEVER WORK TABLE FIG3 4 ...

Page 13: ...Noise Level Less Than 82 dB At a distance of 1 meter from the sun face of the machinery and at a height of 1 6 meter from floor FIG4 1 4 1 4 2 SPINDLE NOISE DETAIL Spindle Nose Detail ...

Page 14: ...FIG4 2 4 2 5 LUBRICATION 5 1 HEADSTOCK LUBRICATION ...

Page 15: ...8 ESSO FEBIS K53 FULL TWICE DAILY COUNTER SHAFT GEAR WORM GEAR CRADLE 2 COSMO CHASSIS GREASE NO 3 FULL ONCE WEEKLY BULL GEAR BEARING SLEEVE 3 COSMO CHASSIS GREASE NO 3 FULL ONCE WEEKLY HEAD STOCK MATCHING QUILL HOLES 5 1 5 2 MACHINE TABLE LUBRICATION 3 1 2 ...

Page 16: ...FECTUATED BY MEANS OF THE HAND CRANK PUMP ON THE LEFT SIDE OF KNEE METHOD 3 TO 5 TIME DAILY BY PULLING TWICE EACH TIME LUBRICANT KUO KUANG R 68 GULFWAY 52 VACTRA 2 ESSO FBIS K 53 SHELL TONNA 33 5 2 6 INSTRUCTIONS IN OPERATIONS 6 1 HEADSTOCK SLIDING SURFACE WORK TABLE KNEE SLIDING SURFACE ...

Page 17: ...f tooling shank and dismantling First the spindle must be raised up to its maximum height The screw of draw bar is right turn When the screw is turned clockwise is for locking of tooling shank and vice versa To take out the tooling shank the drawbar to allow the tooling shank to separate from the spindle Turn the drawbar until the tooling shank comes off totally NOTE According to spindle braking b...

Page 18: ...d inward FIG6 3 it is for downward feed and vice versa The middle position is neutral f As shown in FIG6 4 the working depth may be set by micrometer adjustments nuts K each graduation is 0 001 or 0 02 mm When the quill stop block I contacts the micrometer nut K the feed control lever F may simply jump from F2 back to F1 position owing to the connecting motion between the feed trip lever and feed ...

Page 19: ...k row gear to engage c To shift the low speed into the high one use the brake lever so as to put a stop to the spindle clutch Then turn the spindle slightly so that the clutch may be engaged feasibly A click sound of engagement may be sensed at this moment d The direction of low speed rotation is opposite to that of the high speed By the reversing switch the direction may changed to that high spee...

Page 20: ...fe of the internal mechanism d It takes roughly 10 to 15 minutes to change from low speed to the high one and viceversa 6 4 6 1 8 HEADSTOCK TILTING Cross tilting FIG6 6 Loosen evenly the four lock nuts and turn the worm shaft S until the desired angle is G J ...

Page 21: ...r than 30 degrees the safety pin T must be drawn out there is no need to pull the pin out for any angle less than that b Do not loosen the lock nuts R totally during the adjustment FIG6 6 6 5 6 2 MACHINE BODY OPERATIONS 6 2 1 Ram movement and swiveling see FIG6 7 1 Ram movement 52 S ...

Page 22: ...tion lock up A 2 Ram swiveling Loosen the four locking bolts C And force the cross srm to turn until the desired angle is obtained lock up C FIG6 7 6 6 6 2 2 Zero positioning as shown in FIG6 8 of dial ring of table feed 1 Loosen the nut D of dial ring 2 Turn the dial right E to zero position 3 Lock the nut d of dial ring C B A ...

Page 23: ...achine body s rigidity The sliding surface setting levers as shown in FIG6 9 are clockwise for setting and counterclockwise for release FIG6 9 6 7 7 TRANSPORT UNPACKING AND FLOOR SPACE 7 1 METHODS OF TRANSPORT 1 Machine net weight approx 1010KGS 2 Prior to unpacking transport may be using a forklift FIG7 1 FIG6 8 WORK TABLE LOCK LEVER SADDLE LOCK LEVER ...

Page 24: ...o hoist the unpacked case by reinforced cable the motion shall observe strictly the instruction appeared on the side of the wooden case 5 Keep the work table and saddle in the proper positions so as to keep the machine balance 6 Do not hoist the machine too high The best position is to keep the machine base approximately 10 cm from the ground 7 Do not allow the machine to wobble in hoisting 8 Only...

Page 25: ...unpacking do not move the sliding surfaces and work table as long as the rustproof oil on them are not cleaned off and followed with the lubrication e Before the cleaning starts the sliding protective pieces must be dismantled and all sliding surface setting levers loosened When the rustproof oil is removed proper amount of lubricant should be injected onto various sliding surfaces Then move the s...

Page 26: ...7 3 8 PRECISION ALIGNMENT FIG7 3 ...

Page 27: ...uality Beside it may extend the machine service life For details of components to be aligned and precision requirements please vide the table of precision inspection NOTE To align the vertically of spindle to the table surface is necessary to loosen the three machine head bolts vide FIG6 6 p and the four machine head nuts However the bolts and nuts can not be loosened totally to prevent the compon...

Page 28: ...agonal concave bolts C that locked the bearing housing to insert into the two holes of the speed change spring pieces D Lock into the motor vari disc E and evenly lock up the two bolts C Push sown the speed change spring F so as to separate it from the retainer ring G d Take out the retainer ring G e Take off the two hexagonal bolts H that locked the motor The motor may be lifted up Motor vari dis...

Page 29: ...antle four hexagonal concave bolts N O and the two at the bottom P f Take off the two hexagonal concave bolts S speed change housing Q and gear housing R g Use a mallet and hit the upper belt housing T lightly so that it will break away from the fix pin U for dismantling of the upper belt housing h When the speed change belt is replaced accordingly restore the machine by reversing the orders NOTE ...

Page 30: ... hexagonal concave bolts V bottom belt housing T1 d Use a soft mallet and hit the bottom belt housing lightly to disengage it with the fix pin W to dismantle the bottom belt housing T1 as shown in FIG9 4 e Take off the hexagonal concave bolt X of the two setting bearing housing and remove the front vari disc assembly set E1 Brake block Y can be replaced then f Reverse the order to restore the mach...

Page 31: ...om belt housing and change the timing belt as shown in FIG9 4 c Refer to step C to D on p 28 replacement of brake block for the dismantling of bottom belt housing and change the timing belt as shown in FIG9 4 d Restore the machine structure by reversing the steps once the timing belt is replaced NOTE Belt to be replaced shall conform to the manufacture s specs FIG9 4 ...

Page 32: ...e crank F so that the bracket will be separated from the knee with a certain distance between them as shown in figure 30 the distance must be longer than the length of the adjusting tool d Insert the larger end of clearance adjusting tool into the knee and turn the locking nut J one round antic lock wise reverse the adjusting tool and insert the smaller end into the knee turn the nut K clockwise a...

Page 33: ...esult of long term operation between the sliding surface and gibs the worn out gibs will create a clearance Therefore the gibs must be adjusted to upkeep the precision of sliding surfaces 10 2 1 Adjustment of work table gibs vide FIG 10 3 The gibs are attached onto between the saddle seat and work table dovetail a Loosen the lock lever L b Clean the slide way and add the lubricant c Use a screwdri...

Page 34: ...ft side of saddle and knee dovetail a Loosen the saddle lock bolt A b Move the saddle to the front part of knee c Take off the wiper holder B of saddle d Clean the slide way and add the lubricant e Use a screw driver to adjust the gib screw D of the saddle f Employ the same methods to adjust the work table gib g lock up the wiper holder B on the saddle FIG10 3 ...

Page 35: ...e performed as follows a Loosen the knee clamp lever G vide FIG 10 6 b Take off the wiper holder Q c Clean the slide way and add the lubricant d Raise the knee to its up most position e Use a screw driver to adjust the gib screw R of the knee f Employ the same methods to adjust the work table gib g Restore and lock up the wiper holder Q FIG10 4 FIG10 5 ...

Page 36: ...t use a marking pencil to draw a line on quill A and its nose piece B b Loosen the setting screw C nose piece Use a hook spanner to take off the nose piece B c Use a hexagonal spanner of appropriate length to take off the collect aligning screw D for replacement d When the collect aligning screw is replaced set the nose piece B tightly until it is positioned on the marked line e Set the set screw ...

Page 37: ...FIG10 7 10 6 ...

Page 38: ...ach say work table shall be cleaned and the unfinished work piece must be removed a little bit of lubricant is recommended 5 At the close of each day all setting levers shall be loosened and all aliding parts shall be move to the proper position The cutter must be dismantied 6 At the close of each day the head stock must be restored to its normal position if it is tilted 11 2 MONTHLY MAINTENANCE 1...

Page 39: ...12 PARTS LSIT 12 1 12 1 HEAD STOCK UPSIDE 1 ...

Page 40: ... SPRING PIN 1 83 K 2 V 0 8 3 0 0 SPEED CHANGE CHAIN DRUM 1 84 K 2 V 0 8 4 0 0 SPEED CHANGE SPUR GEAR 1 85 3 x 3 x 8 KEY 1 86 5 x 1 0 SPRING PIN 1 87 5 1 6 NC HEX CAP NUT 1 88 K 2 V 0 8 8 0 0 CAUTION PLATE 1 88 1 M 5 x 6 L ROUND HEAD SCREW 2 92 K 2 V 0 9 2 0 0 SCREW 1 95 K 2 V 0 9 5 0 0 BRAKE SHOE ASSEMBLY 1 96 M 6 x 2 0 HEX HD SCREW 1 97 K 2 V 0 9 7 0 0 BRAKE SHOE PIVOT SLEEVE 1 98 K 2 V 0 9 8 0 0...

Page 41: ...12 3 12 2 HEAD STOCK UPSIDE 2 ...

Page 42: ...EARING SPACER 1 111 K 4 V 1 1 1 0 0 BEARING SPACER 1 112 R 7 2 SNAP RING 1 113 K 2 V 1 1 3 0 0 SPRING 3 114 K 2 V 1 1 4 0 0 BULL GEAR PINION COUNTER SHAFT 1 115 5 x 5 x 1 8 KEY 1 116 5 x 5 x 1 2 KEY 1 117 K 2 V 1 1 7 0 0 BULL GEAR PINION 1 117 1 M 8 x 8 SOCKET SET SCREW 1 118 6 2 0 3 Z Z BALL BEARING 2 119 K 5 V 1 1 9 0 0 PULLEY 1 120 5 8 NC HEX NUT 1 120 1 M 5 x 5 SOCKET SET SCREW 1 121 K 5 V 1 2...

Page 43: ...12 5 12 3 HEAD STOCK UPSIDE 3 ...

Page 44: ...RING 1 44 M 6 x 2 0 0SOCKET CAP SCREW 3 51 K 4 V 0 5 1 0 0 STATIONARY DRIVEN VARIDISC 1 53 S 5 0 SNAP RING 1 54 K 4 V 0 5 4 0 0 ADJUSTABLE DRIVEN VARIDISC 1 55 K 2 V 0 5 5 0 0 KEY 1 56 3 x 8 SPRING PIN 1 57 6 9 1 3 Z Z BALL BEARING 1 59 K 4 V 0 5 9 0 0 SPINDLE PULLEY BEARING SLIDING HOUSING 1 60 M 5 x 1 6 SOCKET CAP SCREW 2 61 K 2 V 0 6 1 0 0 PIVOT SLEEVE 2 62 K 2 V 0 6 2 0 0 SPEED CHANGE PLATE 1 ...

Page 45: ...12 7 12 4 HEAD STOCK INFRASTRUCTURE 1 ...

Page 46: ... N 1 97 1 4 x 3 4 SOCKET SET SCREW 1 97 1 1 4 NUT 1 176 K 2 A 1 7 6 0 0 QUILL PINION SHAFT BUSHING 1 176 1 K 4 A 1 7 6 A 0 SNAP RING S 32 1 177 K 2 A 1 7 7 0 0 PINION SHAFT WORM GEAR SPACER 1 178 K 2 A 1 7 8 0 0 OVERLOAD CLUTCH WORM GEAR 1 179 M4 x 1 6 S O CK E T CA P S CREW 3 180 K 2 A 1 8 0 0 0 OVERLOAD CLUTCH RING 1 181 K 2 A 1 8 1 0 0 OVERLOAD CLUTCH 1 183 K 2 A 1 8 3 0 0 SAFETY CLUTCH SPRING ...

Page 47: ...12 9 12 5 HEAD STOCK INFRASTRUCTURE 2 ...

Page 48: ...R 1 176 1 K 4 A 1 7 6 1 0 SHAFT BUSHING 1 182 K 4 A 1 8 2 0 0 QUILL PINION SHAFT 1 182 1 K 2 A 1 8 2 A 0 PIN 1 191 M 6 x 1 2 ROUND HEAD SCREW 1 192 K 2 A 1 9 2 0 0 BEVEL PINION WASHER 1 193 K 4 A 1 9 3 0 0 FEED BEVEL PINION 1 195 M 6 x 6 SOCKET SET SCREW 1 196 K 4 A 1 9 6 0 0 FEED WORM GEAR SHAFT SLEEVE 1 197 K 4 A 1 9 7 0 0 WORM CRADLE BUSHING 1 198 K 4 A 1 9 8 0 0 WORM GEAR SPACER 1 199 K 4 A 1 ...

Page 49: ...12 11 12 6 HEAD STOCK INFRASTRUCTURE 3 ...

Page 50: ... K 5 A 1 0 4 0 0 OIL BAFFLE 1 106 K 5 A 1 0 6 0 0 BEARING SPACER 1 107 K 5 A 1 0 7 0 0 BEARING SPACER 1 108 6 0 0 8 Z Z BEARING 1 108 1 S 3 0 SNAP RING 1 109 K 5 A 1 0 9 0 0 SLEEVE 1 110 K 5 A 1 1 0 0 0 SPINDLE R8 1 114 K 5 A 1 1 4 0 0 NUT 1 114 H1 K 5 A 1 1 4 1 0 SET SCREW 1 114 H2 K 5 A 1 1 4 2 0 PLATE 1 154 K 2 A 1 5 4 0 0 WORM GEAR 1 155 3 x 3 x 1 5 KEY 1 156 K 4 A 1 5 6 0 0 WORM SHAFT 1 156 1...

Page 51: ...12 13 12 7 HEAD STOCK INFRASTRUCTURE 4 ...

Page 52: ... A 0 8 5 0 0 FEED TRIP PLUNGER BUSHING 1 86 3 x 1 1 2 SPRING PIN 1 87 K 4 A 0 8 7 0 0 CAM ROD 1 89 K 2 A 0 8 9 0 0 TRIP HANDLE 1 89 1 1 4 BLACK PLASTIC BALL HANDLE 1 90 K 2 A 0 9 0 0 0 TRIP HANDLE PIN 1 92 K 2 A 0 9 2 0 0 FEED TRIP BRACKET 1 92H K 5 A 0 9 2 0 0 1 224 K 2 A 2 2 4 0 0 HANDWHEEL HANDLE 1 225 K 2 A 2 2 5 0 0 HANDWHEEL 1 226 K 2 A 2 2 6 0 0 FEED REVERSE KNOB STUD 1 227 K 2 A 2 2 7 0 0 ...

Page 53: ...12 15 12 8 COLUMN ASSEMBLY ...

Page 54: ... RAM PINION 1 21 P M D E 1 2 0 0 ZERO PLATE 3 22 K 2 C 0 4 1 0 0 GIB ADJ SCREW 2 23 M 1 2 x 4 0 SOCKET CAP SCREW 10 24 M 5 x 6 ROUND HEAD SCREW 5 25 K 5 C 1 3 5 0 0 COOLANT PUMP COVER 1 26 K 5 C 1 1 3 0 0 SLIDING RAIL 1 27 3 4 x 3 HEX BOLD 4 28 3 4 U N C NUT 4 29 K 5 C 0 9 9 0 0 ADJUST BRACK 4 30 K 5 C 0 5 5 0 0 KNEE COLUMN GIB 2 31 K 2 C 1 3 0 0 0 INFILTRATION NET 1 32 M 1 0 x 3 0 SOCKET CAP SCRE...

Page 55: ...12 17 12 9 KNEE ASSEMBLY ...

Page 56: ... 0 8 4 0 0 ELEVATING CRANK 1 20 K 5 C 0 8 3 0 0 HANDLE 1 21 K 5 C 0 5 9 0 1 CHIP GUARD UPPER 1 22 K 5 C 0 6 0 0 1 CHIP GUARD MIDDLE 1 23 K 5 C 0 6 1 0 1 CHIP GUARD LOWER 1 24 K 5 C 0 4 9 0 0 SADDLE KNEE GIB 1 25 K 2 C 0 4 1 0 0 GIB ADJ SCREW 2 26 M 5 x 6 ROUND HEAD SCREW 12 27 K 5 C 1 3 4 0 0 KNEE COVER 2 28 1 2 N F HEX NUT 2 29 K 2 C 0 4 1 A 0 GIB ADJ SCREW 2 30 K 5 C 1 0 6 I 0 ELEVATING SCREW AS...

Page 57: ...12 19 12 10 TABLE SADDLE ASSEMBLY ...

Page 58: ...L BEARING 5 26 K 2 D 0 1 8 0 0 A D JUSTING WASHER 3 27 K 5 D 0 1 7 I 2 L O NGITUDINAL FEED SCREW INCH TABLE 52 1 K 5 D 0 1 7 M 2 L O NGITUDINAL FEED SCREW METRIC TABLE 52 1 K 5 D 0 1 7 I 8 L O NGITUDINAL FEED SCREW INCH TABLE 58 1 K 5 D 0 1 7 M 8 L O NGITUDINAL FEED SCREW METRIC TABLE 58 1 28 M 5 x 1 0 R O UND HEAD SCREW 16 29 K 2 D 0 2 8 0 0 C R OSS FEED BEARING BRACKET 1 30 K 5 D 0 3 0 I 1 C R O...

Page 59: ...12 11 SPINDLE GUARD CE OPTION 12 21 ...

Page 60: ...13 SUMMART OF THE ELECTRICAL 13 1 ELECTRICAL COMPONENTS AND LAYOUT 13 1 ...

Page 61: ...OL PANEL SWITCHES AND SYMBOLS CE OPTION 1 Spindle forward 2 Spindle stop 3 Spindle reverse 4 Emergency stop 5 X Y axis auto feed 6 Z axis rapid to up 7 Z axis rapid to down 8 Coolant pump switch 9 Pilot lamp 13 2 ...

Page 62: ...13 3 POWER CIRCUIT 13 3 1 WIRING DIAGRAM FOR STAND ARD ELECTRIC BOX THREE PHASE 13 3 ...

Page 63: ...13 3 2 WIRING DIAGRAM FOR SIMPLE ELECTRIC BOX THREE PHASE 13 4 ...

Page 64: ...13 3 3 POWER CIRCUIT CE OPTION 13 5 ...

Page 65: ...13 6 ...

Page 66: ... 1 BS 4794 VDE 0660 KM5 CONTACTOR RELAY RES 5A 240VAC 5A 30CDC GEN GA 240VAC USE 0 2A 100VDC 1 5A 30VDC 1 IDEC RY4S U AC 240 EN 60947 5 1 TB1 TB2 CASSETTE TERMINAL BLOCK AC 600V MAX 15A 12 30 SHINING TD 15H ULE121562 HL1 HL2 HL3 HL4 WORK LAMP SPINDLE FOR PILOT LAMP SPINDLE REV PILOT LAMP POWER FEED PILOT LAMP AC 24V 70W AC 24V 2W 1 1 JARREF YIAN KUANG TW 55L YK IP65 IEC 144 ZP65 SQ1 SQ2 SQ3 MANU L...

Page 67: ...õC 60õC MAX 600V 1 TONG WU CNS 3301 4398 JIS C3342 3401 M1 SPINDLE MOTOR M2 Z AXIS MOTOR M3 PUMP MOTOR U1 U2 U3 X AXIS POWER FEED Y AXIS POWER FEED Z AXIS POWER FEED AC 110V 50 60HZ 1 1 1 ALIGN ALIGN ALIGN CE 235 CE 250 U4 LUBRICATION AC 110 220V 50 60HZ 1 CHEN YING CES A 13 8 ...

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