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Mazak VTC-160A Maintenance Manual Download Page 5

5-3 ATC Magazine

5-5

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5-3-1 Troubleshooting

5-5

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5-3-2 Construction of the ATC Magazine

5-5

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5-4 Hydraulic System

5-6

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5-4-1 Troubleshooting

5-6

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5-4-2 Maintenance of the Hydraulic Unit

5-6

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5-4-3 Hydraulic Circuit Diagram

5-7

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5-5 Pneumatic System

5-8

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5-5-1 Troubleshooting

5-8

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5-5-2 Maintenance of the Air Unit

5-8

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5-5-3 Pneumatic Circuit Diagram

5-10

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5-6 Centralized Lubrication Unit

5-12

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5-6-1 Troubleshooting

5-12

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5-6-2 Maintenance of the Centralized Lubrication Unit

5-12

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5-6-3 Spindle, Linear Guide and Ball Screw Lubrication

5-12

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5-7 Spindle Cooling Unit

5-13

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5-7-1 Troubleshooting

5-13

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5-7-2 Construction of the Spindle Cooling Unit

5-13

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5-7-3 Spindle Cooling Circuit Diagram

5-14

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5-8 Coolant System

5-15

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5-8-1 Troubleshooting

5-15

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5-8-2 Construction of the Coolant System

5-15

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5-9 Covers

5-16

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5-9-1 Troubleshooting

5-16

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5-9-2 Machine Covers

5-16

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5-9-3 Changing the Reed Switch

5-17

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5-10 NC Unit and Electric Control Cabinet

5-18

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5-10-1 Troubleshooting

5-18

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5-10-2 Resetting the thermal relay

5-18

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5-10-3 Changing the Proximity Sensor

5-19

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6 INSTALLATION

6-1

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6-1 Precautions on Installing the Machine

6-1

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Return to Library

Summary of Contents for VTC-160A

Page 1: ...llowing documentation thoroughly Do not attempt to operate or perform maintenance repair on the machine without a thorough understanding of the actions about to be taken If any question exists contact...

Page 2: ...Notes Return to Library...

Page 3: ...Basic Safety Items 2 1 2 3 Clothing and Personal Safety 2 3 2 4 Operational Safety 2 3 2 5 Safety Considerations Relating to Holding Workpieces and Tooling 2 4 2 6 Maintenance Safety 2 5 2 7 Workplace...

Page 4: ...ng Oils 4 8 4 5 2 Around the Machine 4 8 4 6 Every Six Month Inspection and Maintenance 4 9 4 6 1 Changing or Replenishing Oils 4 9 4 6 2 Around the Machine 4 10 4 7 Every One and Two year Inspection...

Page 5: ...nit 5 12 5 6 3 Spindle Linear Guide and Ball Screw Lubrication 5 12 5 7 Spindle Cooling Unit 5 13 5 7 1 Troubleshooting 5 13 5 7 2 Construction of the Spindle Cooling Unit 5 13 5 7 3 Spindle Cooling C...

Page 6: ...Installing the Machine 6 11 6 4 Connecting to the Power and Air Sources 6 13 6 4 1 Connecting to the Power Source 6 13 6 4 2 Grounding 6 15 6 4 3 Connecting to the Air Source 6 16 6 5 Test Run 6 17 6...

Page 7: ...electrical settings If changes are unavoidable record the values prior to the change so that they can be returned to their original settings if necessary 6 Do not deface scratch or remove any caution...

Page 8: ...ols and other items around the machine or equipment should be stored to ensure good footing and clear aisles 5 Do not place tools or any other items on the headstock turret covers and similar places F...

Page 9: ...programs CAUTION 1 Thoroughly read and understand the safety precautions in the instruction manual 2 Thoroughly read the whole maintenance manual and fully understand the principles construction and...

Page 10: ...UT OFF MACHINE POWER USING NORMAL SHUT DOWN PROCEDURES 4 TURN OFF THE MACHINE AND INDIVIDUAL BUILDING CIRCUIT BREAKERS MAKE SURE ALL STORED ELECTRICAL ENERGY IS RELIEVED EG SPINDLE AXIS SERVO CONTROLL...

Page 11: ...t should be put all around the concrete pad 3 Form a cone in the foundation for J bolt anchors or use expansion anchors 4 With the foundation anchor bolt holes open pour the primary concrete at a mini...

Page 12: ...LECTRICAL CODE BEFORE SIZING AND INSTALLING THE INCOMING POWER WIRING PLEASE SEE THE ADDITIONAL CAUTIONS ON THE FOLLOWING PAGE GROUNDING 1 An isolated earth ground with a resistance to ground of less...

Page 13: ...g NOTE Step down or voltage regulating transformers are external peripheral to the machine tool and are considered the primary input line source for the machine Local electrical code or practice may r...

Page 14: ...TO CHANGE FAILURE TO COMPLY WITH THESE INSTRUCTIONS COULD RESULT IN DAMAGE TO THE MACHINE SERIOUS INJURY OR DEATH IF ANY QUESTIONS EXIST CONTACT THE NEAREST MAZAK SERVICE CENTER FOR ASSISTANCE S 8 MA...

Page 15: ...CIFIC TOOL HOLDER ITSELF WHICHEVER IS LESS THIS RESTRICTION APPLIES TO DIAMETER WEIGHT MAXIMUM SPINDLE RPM MAXIMUM CUTTING TOOL ROTATION SPEED ETC FOR COMPLETE SPECIFICATIONS MAKE SURE TO REFERENCE OP...

Page 16: ...GESTED TO BE USED BY THE MACHINING NAVAGATION FUNCTION FAILURE TO COMPLY WITH THESE INSTRUCTIONS COULD RESULT IN DAMAGE TO THE MACHINE SERIOUS INJURY OR DEATH IF ANY QUESTIONS EXIST CONTACT THE NEARES...

Page 17: ...the all motion Chip spiral conveyor would stop Prohibit cycle start Chip spiral conveyor would stop MANUAL No Limitation No Limitation CLOSE AUTO No Limitation Can not run auto operation TURNING CENT...

Page 18: ...CENGDB0551E APPENDIX SWITCH PANEL for M640M Machining Center SWITCH PANEL for M640MT T Turning Center DOOR UNLOCK SWITCH MACHINE SET UP SWITCH PED EDS 001 S 12 Return to Library...

Page 19: ...tion easily How well are the manuals organized How easy are the manuals to understand Are the illustrations helpful Overall how do you rate the documentation What did you like about the documentation...

Page 20: ...Notes Return to Library...

Page 21: ...details of alarms Parts list Describes the details of parts and the procedure for purchasing the necessary parts Electric circuit diagrams Shows the wiring diagrams Instruction manuals for optional eq...

Page 22: ...title as indicated by the denominator and that this is the first of those figures as indicated by the numerator 2 Table numbers Table numbers consist of the word Table followed by two numerals joined...

Page 23: ...The meanings of our safety precautions to DANGER WARNING and CAUTION are as follows DANGER Failure to follow these instructions could result in loss of life WARNING Failure to observe these instructio...

Page 24: ...h as pressing the EMERGENCY STOP button that disable machine operation CAUTION l If there is a power failure switch off the main power breaker immediately l Do not subject the NC unit the operation pa...

Page 25: ...due to current leakage or electric shock l Do not handle coolant with bare hands since it is liable to cause irritation Operators with allergies should take special precautions l Do not operate the ma...

Page 26: ...lace tools promptly since badly worn tools can cause accidents and injuries l Before starting operation check that the workpiece is securely mounted and cannot become detached by the cutting forces ap...

Page 27: ...f the covers removed for maintenance have been refitted l Wipe up any water or oil spills immediately and keep the maintenance area and the workplace clean and tidy at all times CAUTION l Maintenance...

Page 28: ...ol post or covers For lathes l Make sure that the nominal cross sectional area of the power supply cable between the factory power supply switch and the machine main power breaker is such as to enable...

Page 29: ...d 2 While the operator s door is open spindle speed is restricted by the preset safety speed 2 Magazine door interlock 1 If the magazine door is opened while the magazine is operating the magazine sto...

Page 30: ...Cutting conditions suggested by the Machining Navigation Function Cutting conditions for tools that are suggested to be used by the Machining Navigation Function Confirm that every necessary precauti...

Page 31: ...driven by an AC servo motor and a ball screw An encoder used for position detection is built in the servo motor Linear guides are used as the guide for the column to move on the saddle 4 Z axis The s...

Page 32: ...hen circulated to the tank Refer to 5 7 3 Spindle Cooling Circuit Diagram 12 Coolant system A coolant pump is used to feed coolant pumped from the coolant tank to coolant nozzles Coolant has two funct...

Page 33: ...Air unit Centralized lubrication unit Main power disconnect switch ATC unit Magazine Magazine operation panel Magazine door Hydraulic unit Coolant system Colum Spindle cooling unit Control panel Fig 3...

Page 34: ...and left direction Positive direction Saddle movement to the right Negative direction Saddle movement to the left Y axis Column movements in the back and forth direction Positive direction Column mov...

Page 35: ...ter the bearings and slideways causing the failure of the machine l Before carrying out maintenance or repair work on the machine lock the main power disconnect in the OFF position with a padlock so t...

Page 36: ...n the coolant tank 4 3 2 3 Cleaning the filer of the spindle cooling unit 4 4 1 Checking Oil Levels 1 Checking the hydraulic oil level 4 3 3 2 Checking the spindle cooling fluid level 4 3 3 3 Checking...

Page 37: ...t 4 4 1 5 Cleaning the tool shank 4 4 1 6 Checking the emergency stop buttons for correct operation 4 5 2 7 Checking the indicator lamps on the operation panels 4 4 1 8 Checking the safety devices for...

Page 38: ...the machine Clear the inside of the machine particularly those parts indicated below of accumulated chips dirt and dust Around the magazine Table and its periphery Around the ATC cover Over the Y axi...

Page 39: ...operating conditions 2 Cleaning the filter standard specification machine After removing chips from the chip bucket clean the filter by using an air gun Note Do not use the air gun around the machine...

Page 40: ...ing coolant Do not handle coolant with bare hands 2 If the coolant level is low replenish with the stipulated coolant to the upper limit level of the oil level gauge If the coolant goes over the upper...

Page 41: ...looseness and tighten it if loose 3 Cleaning the tool shank Clean the tool shank with clean cloth 4 Cleaning the filter of the spindle cooling unit Pull the filter upward to remove it then clean the...

Page 42: ...ting oil consumption amount 5 2 cc per hour Recommended oil Refer to 7 1 2 List of Oiling Points Note When replenishing oil use only the oil specified by Yamazaki Mazak Otherwise machine trouble and o...

Page 43: ...8 Remove the tank Remove the M5 12L hexagon socket head cap screws 8 pcs and the tank can be removed 9 Clean the tank Carefully wipe stains and deposits off the inside and outside of the tank with a...

Page 44: ...g Points 4 6 2 Around the Machine 1 Checking the safety devices for correct operation l Since the machine may move unexpectedly leading to a hazardous situation if a safety device is faulty do not res...

Page 45: ...cases A Air is always leaking through the drain port Corrective action Turn the drain port in the S direction for closing If the air still leaks refer to 5 5 Pneumatic System for the corrective actio...

Page 46: ...loth and dry the floor immediately If the floor remains wet with spilled fluid personnel could slip over and be injured Procedure 1 Pull out the tank to the machine front side 2 Remove the filters buc...

Page 47: ...oses for damage such as cracks abnormal bulge and deterioration If any damage is found contact your local Mazak Technical Center 6 Cleaning the spindle lubricating unit filters Procedure 1 Take out th...

Page 48: ...ng fluid collecting pan under the drain port and loosen the drain plug Cooling fluid is discharged Max 20 L 5 28 gal US 3 Loosen the bolts clamping the suction port cover and pull the cover up Drain O...

Page 49: ...ake out the lubrication unit Pipe Lubrication unit Tank Suction filter MC111 01190 Take out Bolts Fig 4 9 Cleaning the Suction Filter 1 2 Note Do not disconnect the pipes Otherwise air will enter the...

Page 50: ...lter Filter clamp 4 places Fig 4 10 Cleaning the Suction Filter 2 2 7 Clean the suction filter Use washing oil kerosene etc to clean the suction filter At the same time clean the inside of the tank wi...

Page 51: ...e rusted and the function of them will be deteriorated Therefore apply rust preventive oil to these parts if the machine will not be operated for a long time Linear guide rails X Y Z axis Ball screws...

Page 52: ...nish coolant to the coolant tank For details refer to 4 6 2 Around the Machine 3 Usual inspection before starting the operation Perform the inspection which are required before starting daily operatio...

Page 53: ...4 19 7 Uploading the NC data Before starting the operation upload the NC data having been saved to the micro disk before stopping the machine Return to Library...

Page 54: ...4 20 MEMO Return to Library...

Page 55: ...ALARM screen refer to the Operating Manual of NC provided separately 2 Check the trouble and alarm if it recurs 3 Check the ambient temperature if it is within the specified range 4 Check if momentar...

Page 56: ...chnical Center There is abnormal noise or abnormal vibration during spindle rotation 1 The spindle is rotating at a high speed with an unbalanced tool mounted in it Change the tool with a balanced too...

Page 57: ...Contact Mazak Technical Center 5 1 2 Construction of the Spindle head Tool clamp unclamp valve Spindle through air valve Spindle through coolant valve Flood coolant valve Tool unclamp sensor Tool cla...

Page 58: ...ntrol unit is higher than 40 C 104 F Lower the ambient temperature 6 2 1 An axis stops due to alarm 3 The servo control unit in the electrical control cabinet is defective Contact Mazak Technical Cent...

Page 59: ...RT 2 4 1 in the Operating Manual 2 The magazine drive unit is defective Contact Mazak Technical Center The magazine does not rotate The magazine stop position is shifted from the correct index positio...

Page 60: ...t Contact Mazak Technical Center 1 The hydraulic unit filter is clogged Clean the filter 4 6 1 2 Insufficient oil amount in the hydraulic unit tank Replenish the specified oil 4 6 1 3 Bolts used in th...

Page 61: ...5 7 5 4 3 Hydraulic Circuit Diagram Return to Library...

Page 62: ...Air is constantly leaking through the drain port of the air unit 1 Automatic drain of the mist separator is defective Change the mist separator 4 6 2 5 5 2 5 5 2 Maintenance of the Air Unit 1 Changing...

Page 63: ...nging the Filter Element Procedure 1 Loose the four bolts and detach the body from the housing 2 Fit a new O ring to the body 3 Fit a new gasket to the body 4 Insert a new filter element into the hous...

Page 64: ...Circuit Diagram AIR BLAST OPTION TOOL CLAMP UNCLAMP SPINDLE AIR BLAST MAGAZINE DOOR OPEN CLOSE ROTARY TABLE OPTION OIL AIR LUBRICATION FOR SPINDLE Drawing No 1557ACD0011 Fig 5 5 Pneumatic Circuit Diag...

Page 65: ...0 Speed controller AS3001F 08 SMC Through air 1 YV22 G50SV006070 Solenoid valve VFS2220 1D 02 SMC Magazine cover OPEN 1 YV23 G50SV006070 Solenoid valve VFS2220 1D 02 SMC Magazine cover CLOSE 1 101F G5...

Page 66: ...t For the information on centralized lubrication unit maintenance refer to the following sections 4 5 Monthly Inspection and Maintenance 4 7 Every One and Two year Inspection and Maintenance 5 6 3 Spi...

Page 67: ...ler unit is directly subject to hot air take measures so that the chiller unit will not be subjected to the hot air Spindle cooling fluid is consumed abnormally quickly 1 Leak in the spindle cooling c...

Page 68: ...5 14 5 7 3 Spindle Cooling Circuit Diagram Fan cooler Spindle cartridge cooling fluid tank Fig 5 8 Spindle Cooling Circuit Diagram Return to Library...

Page 69: ...n the nozzle Due to interlock ATC cover open Operator s door open Coolant stop menu key ON Special tool selected Remove the cause of interlock 2 The coolant pump is defective There are no problems wit...

Page 70: ...nnect the air source meeting the specifications given in 6 2 3 Air Source Requirements 2 Reed switch is defective Although air cylinder has operated correctly the reed switch is not turned ON Change t...

Page 71: ...tch mounting bolt Reed switch mounting bracket Fig 5 11 Changing the Reed Switch Procedure 1 Mark the position of the reed switch mounting bracket on the cylinder 2 Unscrew the reed switch mounting bo...

Page 72: ...low the maintenance instructions for the individual units 5 1 to 5 9 The following alarm message is displayed on the screen 217 THERMAL TRIP 219 MAIN TRANSFORMER OVERHEAT The unit which uses the motor...

Page 73: ...5 mm 0 01 to 0 02 in Since the thread pitch of the sensor is 1 mm 0 039 in one turn of the nut moves the sensor 1 mm 0 039 in 6 Tighten nuts A and B at the same torque 7 After adjusting the sensor ope...

Page 74: ...5 20 MEMO Return to Library...

Page 75: ...the external air source requirements l Prepare a power source that meets the external power source requirements l When connecting the main power disconnect to the power source carry out piping work s...

Page 76: ...where there is high concentration of organic or corrosive gas if the machine must be operated under such environment consult Mazak for appropriate measures D Vibration Allowable maximum vibration duri...

Page 77: ...ermissible voltage fluctuation 10 2 Frequency 50 60 Hz 1 3 Total power requirements When installing the machine the machine may malfunction if the power capacity is insufficient and the service life o...

Page 78: ...s 3 4 03 3 08 Note 3 Through spindle coolant pump 1 36 1 04 Other motors option Chip conveyor 0 13 0 1 Total power requirements 4 1 49 1 14 Control circuit etc 5 Note 4 1 0 1 0 Grand total power requi...

Page 79: ...damaged In such cases use an air dryer or similar equipment 6 2 4 Items to Be Confirmed when Carrying the Machine 1 Machine dimensions In order to carry this standard machine into your plant the entra...

Page 80: ...humid places and places near vibration generation equipment Although required foundation work will vary according to soil conditions it is necessary to compact the ground well or pour concrete to avo...

Page 81: ...d to a lower position and the column and saddle to an almost center position with respective shipping brackets 2 Use a dedicated lifting attachment as shown in Fig 6 1 3 Use sufficiently thick wire ro...

Page 82: ...6 8 Machine body Fig 6 1 Lifting the Machine Return to Library...

Page 83: ...all of shipping brackets Store the removed shipping brackets and bolts in a suitable place to allow for reuse during movement or transport of the machine in the future 2 Installing the cover and other...

Page 84: ...machine at two locations with fittings and apply a wooden block to between the spindle and the table as shown in the following illustration Tool to be used Allen wrench 10 mm 0 394 in Wooden block Sa...

Page 85: ...to the leveling bolt holes in the machine 4 Set the set screws attached to the collars so that the foundation plates do not drop 5 Lower the machine gently so that the foundation bolts are correctly i...

Page 86: ...g class 3 grounding work Class D formerly class 3 grounding requirements Screws at terminals must be tight Connection of cannon connectors and other connectors Relays must be fitted and connected corr...

Page 87: ...allation work has been completed Procedure 1 Unscrew the bolts holding the main power disconnect box cover in place turn the switch to the OPEN RESET position and remove the cover Fig 6 1 Connecting t...

Page 88: ...6 14 3 Connect the wires to the R S and T terminals and the ground terminal of the N F B no fuse breaker MC111 01337 Fig 6 1 Connecting the Power Supply Cable 2 2 Return to Library...

Page 89: ...g resistance 100 max Power supply cable Refer to the List of Total Power Requirements Measuring instrument 500 V megger l The grounding work must be entrusted to an officially authorized electrical en...

Page 90: ...ctors are connected in the manner shown in the illustration above a faulty connection at one of the terminals could cause grounding current to be fed back to the machine resulting in serious accidents...

Page 91: ...ses and cables of the circuits for hydraulic pneumatic and coolant circuits are correctly connected 7 Make sure that the coolant tank is correctly placed 8 Make sure that the connection to the air sou...

Page 92: ...by referring to the parameter table in the electrical control cabinet 6 5 4 Checking the Machine in Manual Operation Operate the machine manually to make sure that the following operations are execut...

Page 93: ...7 1 7 APPENDIX 7 1 List of Sensors Limit Switches and Oiling Points 7 1 1 List of Sensors and Limit Switches Fig 7 1 Return to Library...

Page 94: ...necessary Clean the filter every year 2 Hydraulic power unit 10 L 2 64 gal UNI POWER 32 TELLUS OIL 32 DTE 24 ESSO SHELL MOBIL Change oil every 6 months When changing oil clean the filter at the same t...

Page 95: ...ilter G30TP002170 SFG 04 100W Taisei 3 years Centralized lubrication unit Filter set G06LAP00140 489011 Lube 3 years Slideway cover X axis slideway cover right Z33MBB90091 Z33MBB90040 VTC 200B VTC 300...

Page 96: ...7 4 MEMO Return to Library...

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