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Sharp V-1, General & Electrics Manual

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SHARP

V-1 KNEE MILL GENERAL MANUAL

CH2-4

KRDM24C0 V4.0S

2.2 LIFTING WITH THE MACHINE PACKED

2.2.1 SAFETY RULES FOR MACHINE LIFTING

The following safety rules must be absolutely followed when lifting and/or moving the

machine

1. Ensure all the parts of the machine are fully secured before lifting or moving it.

2. Use a forklift of sufficient capacity to raise or move the packed or machine.

3. Pay special attention to machine balance while lifting.

4. Have another person to help guide the way while lifting the machine.

5. Make sure the forks of the forklift protrude past the far edge of the machine bottom.

6. Do not raise the machine too high as this may cause a loss of stability.

7. The forklift should be driven by experience personnel.

Summary of Contents for V-1

Page 1: ...VERTICAL MILL GENERAL ELECTRICS MANUAL Manual Number KRDM24C0 Date NOV 2018 REV V4 0S ...

Page 2: ...stalled in a safe operating position with all service pipes and cables clear of the operation area so as not to cause a hazard Access must be allowed for safe maintenance swarf and oil disposal including safe stacking of machine and unmachined components WARNING The machine is equipped with safety devices Do not change any safety devices on the machines If changes to these safety devices are made ...

Page 3: ...DRO system Distance from spindle nose to working table 50 457 mm Distance from spindle center to main column 450 mm Spindle Taper ISO 40 Spindle speed LOW 60 540rpm HIGH 540 4000rpm 60Hz LOW 60 540rpm HIGH 540 4000rpm 50Hz Spindle motor 5 HP Quill Quill travel 127 mm Quill dimensions 105 mm Quill feeds 038 076 152mm Head tilt Overarm swivel 360 Front to back 45 0 45 Left to right 90 0 90 General s...

Page 4: ...und table 1 5 HP A C Rapid Vertical motor Electrics system Auto lubrication Coolant pump Power longitudinal feed X axis OPTIONAL EQUIPMENT Inverter head Air power drawbar DRO system 60 mm raised column X and Y axes ballscrews Power cross feed Y axis Working light Roller type Y axis up down chip guard Iron or Fiberglass coolant tray To keep improving and developing new functions the Specification i...

Page 5: ...SHARP V 1 KNEE MILL GENERAL MANUAL 4 KRDM24C0 V4 0S DIMENSION STANDARD A B C D E F G MIN MAX V 1 1480 2290 305 50 457 1720 1473 620 UNIT mm ...

Page 6: ...SHARP V 1 KNEE MILL GENERAL MANUAL 5 KRDM24C0 V4 0S ...

Page 7: ...DS CH1 3 1 5 VARIABLE SPEED DRIVE CH1 4 1 6 POTENTIAL DANGER AREAS CH1 4 1 7 OPERATING SAFETY PRECAUTIONS CH1 5 1 8 GENERAL PRINCIPLES CONCERNING OPERATOR SAFETY FOR THIS MACHINE CH1 6 1 9 SIGNS CH1 10 CHAPTER 2 SHIPPING AND HANDLING 2 1 SHIPPING AND HANDLING CH2 2 2 2 LIFTING WITH THE MACHINE PACKED CH2 4 2 3 FIX MACHINE DURING TRANSPORTATION CH2 7 2 4 REMOVE FIXTURE CH2 7 2 5 STORAGE CH2 7 ...

Page 8: ...ELECTRICAL REQUIREMENT CH3 7 3 5 LEVELING THE MACHINE CH3 12 3 6 INSPECTION CH3 14 CHAPTER 4 5 OPERATIONAL PROCEDURE MECHANISM 4 1 MACHINE CH4 2 4 2 SAFETY EQUIPMENT CH4 2 4 3 BEFORE START UP CH4 2 4 4 START AND STOP THE MACHINE CH4 4 4 5 PREPARATION CH4 5 4 6 OPERATION CH4 6 4 7 BREAK UP CH4 18 4 8 FINISH CH4 18 4 9 INSPECTION AFTER FINISHE CH4 18 4 10 LUBRICATOR CH4 20 ...

Page 9: ...ACKLASH CH6 5 CHAPTER 7 MACHINE MAINTENANCE 7 1 PREPARATION BEFORE MAINTENANCE CH7 2 7 2 LUBRICATION SYSTEM CH7 2 7 3 LUBRICATION CH7 4 7 4 OIL SYSTEM CH7 6 7 5 MOTOR REMOVEL CH7 8 7 6 COLLET ALIGNING SCREW REPLACEMENT CH7 9 7 7 BALANCE SPRING REPLACEMENT CH7 11 7 8 FEED TRIP ADJUSTMENT CH7 12 7 9 QUILL REMOVAL CH7 13 7 10 THE MACHINE MAINTENANCE CH7 14 7 11 PREVENTIVE MAINTENANCE CH7 15 7 12 HOW ...

Page 10: ...NG CH8 2 8 2 ISO METRIC THREAD DATA CH8 6 8 3 CUTTING SPEED CH8 6 8 4 CUTTING DEPTH CH8 8 8 5 FEED SPEED CH8 8 CHAPTER 9 PARTS LIST 9 1 HEAD DRAWING H01 1 9 2 VERTICAL MILLING HEAD DRAWING H02 1 9 3 UP DOWN LEFT RIGHT DRAWING H03 1 9 4 FRONT REAR DRAWING H04 1 CHAPTER 10 ELECTRICS DRAWINGS ...

Page 11: ...SHARP V 1 KNEE MILL GENERAL MANUAL 10 KRDM24C0 V4 0S This page is intentionally left blank ...

Page 12: ...SHARP V 1 KNEE MILL GENERAL MANUAL CH1 1 KRDM24C0 V4 0S CHAPTER 1 HEALTH AND SAFETY PLEASE READ CAREFULLY BEFORE OPERATION OF YOUR MACHINE ...

Page 13: ...ed has the requisite skill and is authorized to operate the machine or if undergoing training is under the close supervision of a skilled and authorized person Attentions are drawn to the importance of compliance with the various statutory regulations which may be applicable such as The Protection of Eyes Regulations It is further stressed that good established workshop practice is essential Adequ...

Page 14: ...ith straight cutting oils but also with soluble oils The following precautions should be taken 1 Avoid unnecessary contact with oil 2 Wear protective clothing 3 Use protective shields and guards 4 Do not wear oil soaked or contaminated clothing 5 After work thoroughly wash all parts of the body that have come into contact with oils 6 Avoid mixing different types of oils 7 Change oils regularly 8 D...

Page 15: ...imum safe speed for any operation are not exceeded 1 6 POTENTIAL DANGER AREAS Keep away from those areas having moving or rotating machine parts Do not touch or reach over moving or rotating objects They cause a serious accident if not used properly Fully understand all the safety procedures before starting to use the machine Beware of potential dangerous area and warning and dangerous awareness t...

Page 16: ... where it may be fouled with rotating or moving parts 7 Do not touch or reach over moving or rotating machine parts 8 Do not touch any switch without care 9 Ensure you know the function of the switch and how to use it before using it 10 Do not operate the machine in excess of its rated capacity 11 Stop the machine immediately if anything unexpected happens 12 Ensure that you know how to stop the m...

Page 17: ...panel with wet hands this could result in electric shock 9 Do not grip a component with grease or oil on it a Grip all components firmly b Do not attempt to hold components that are too awkward or too difficult to hold c Do not hold components that are too heavy for the machine d Know how to hold components properly when lifting 10 Be sure to clean oil or grease from hand tools levers and handles ...

Page 18: ...re of moving machine parts that can fall b Be aware of where you are moving your hand or body in relationship to the machine c Be aware of hands or other parts of the body that may be in position to be hit by a spindle or workpiece 26 Know the function of each and every control 27 Never place hand on spindle or workpiece 28 Make sure power has been turned off when the machine is unused for some ti...

Page 19: ...Never use the wrong protective guard c Know how to select the proper guards 41 When the spindle and workpiece are in motion never reach over under or around a workpiece to make an adjustment 42 Never reach over under or around a workpiece to retrieve anything 43 Never reach over under or around the workpiece to tighten a machine part 44 Never reach over under or around a workpiece to move hand too...

Page 20: ...e or workpiece 58 Beware of tools or machine parts falling on controls 59 Do not change the original setting parameters unless it is necessary Always keep records of the original setting values before change 59 Do not blur block or take away any however according to set back afterward plate and sign for warning notice danger Please contact us or our local dealer or distributor to purchase a new pl...

Page 21: ...SHARP V 1 KNEE MILL GENERAL MANUAL CH1 10 KRDM24C0 V4 0S 1 9 SIGNS 7 8 9 13 2 6 3 4 5 6 11 12 ...

Page 22: ...SHARP V 1 KNEE MILL GENERAL MANUAL CH1 11 KRDM24C0 V4 0S 1 9 1 MACHINE SIGNS 1 1 1 2 1 3 2 Spindle air brake 3 S A1230 Speed selection change caution 4 S A1210 Speed selection ...

Page 23: ...LL GENERAL MANUAL CH1 12 KRDM24C0 V4 0S 5 Engage power feed warning 6 Lubrication added 7 S S2081 EYE Protection Warning 8 S S1060 Hit head warning 9 1 S S1101 AC220V Yellow Sticker 9 4 S S1105 AC440V Yellow Sticker 10 ...

Page 24: ...3 S S1071 Safety Warning NOTE On the MILL machine there are shipping brackets the hold the machine head ATC and axes in place during shipping These brackets must be removed before operating the machine Do not discard the shipping brackets The shipping brackets must be replaced if the machine is ever moved ...

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Page 26: ...SHARP V 1 KNEE MILL GENERAL MANUAL CH2 1 KRDM24C0 V4 0S CHAPTER 2 SHIPPING AND HANDLING PLEASE READ CAREFULLY BEFORE SHIPPING AND HANDLING OF THIS MACHINE ...

Page 27: ...e load capacity Don t try to do handling under unknown the load capacity of the handling equipment otherwise might happen accident that damaged handling equipment and machine even person injury Use only the sling frame provided by us to lift this machine Uses of any other sling frame are prohibited because might happen accident that damaged handling equipment and machine even person injury Ensure ...

Page 28: ...before proceed 2 Do not stop the lifting motions suddenly during the process Prevent sudden movement of the machine too quick and the machine could become unbalanced This might reault in a serious accident that causes the machine to drop 3 Only qualified people are allowed to operate the lifting equipment to handle this machinery package so that prevent accident happen NOTE The packing is subject ...

Page 29: ...e fully secured before lifting or moving it 2 Use a forklift of sufficient capacity to raise or move the packed or machine 3 Pay special attention to machine balance while lifting 4 Have another person to help guide the way while lifting the machine 5 Make sure the forks of the forklift protrude past the far edge of the machine bottom 6 Do not raise the machine too high as this may cause a loss of...

Page 30: ...t should be 4 tons at least 2 For V 1 machine if 2 machine package in one pallet the loading capacity of the lifting equipment should be 7 tons at least 3 Beware that the lifting truck might overturne because of an improper lifting height This might cause people injury and damage the machine 4 Always assign a person to guide the way to ensure safety ...

Page 31: ...acity below 4 tons is prohibited 2 Use only the sling frame provided to lift the machine Other fixture or rope is prohibited 3 Pay special attention to machine balance while lifting Please adjust the machine like the figure 4 Beware that the machine might overturn because of an improper lifting height This might cause people injury and damage the machine 5 Always assign a person to guide the way t...

Page 32: ...n all the loose parts and have an anti rust treatment of the machine 2 Ensure to fix the machine firmly inside the crate to prevent the machine move from falling 3 Ensure to enclose the machine with a waterproof cover to keep this machine from moisture or corrosive substance It prevents the mechanical and electrical parts from damage 4 Ensure to put an anti moisture substance inside the crate 5 Do...

Page 33: ...al and electrical parts damage 4 Ensure to put anti moisture substance inside the electric cabinet operating panel and any other enclosure of this machine 5 Do not place the machine directly under the sunlight or any other heat source Keep away from any corrosive substance or any equipment causing abnormal vibration The ambient temperature and moisture should be moderate and kept as constant and s...

Page 34: ...SHARP V 1 KNEE MILL GENERAL MANUAL CH3 1 KRDM24C0 V4 0S CHAPTER 3 INSTALLATION PLEASE READ CAREFULLY BEFORE INSTALLATION THIS MACHINE ...

Page 35: ...rking days before the arrival of this machine If short of space please inform local agent or us as soon as possible we will provide a suggestion and information service for you Please clear the space in advance for the machine to move in and install WARNING Ensure to reserve space for optional equipment Please contact local agent or us if you have any problem in installing this machine ...

Page 36: ...C0 V4 0S 3 1 1 SPACE REQUIREMENT A distance of at least 500 mm is required from machine to wall end objects or between machines to ensure easy repair cleaning and maintenance of machine Recommended site space for the machine with standard equipment ...

Page 37: ...es etc 3 2 1 ENVIRONMENTAL REQUIREMENT This machine should be installed under the right environments as following 1 Supply voltage 90 to 110 of the rated voltage 2 Source frequency Rated frequency 1 Hz 3 Ambient temperature 5 C to 40 C 4 Altitude shall be at altitudes up to 1000m above mean sea level 5 Relative humidity less than 90 and not exceed 50 at 40 C The moisture condense to water drop due...

Page 38: ...t 12 days prior to the arrivalof the machine Refer to the following foundation construction diagrams for details The construction procedures are listed as follows Dig the foundation site Pave the site bottom with a layer of pebble stone 2 Ensure to reserve 6 spaces for installing the L shape fixing studs and foundation pads before filling up the foundation site with concrete Ensure those 6 surface...

Page 39: ... Ensure the ground is rigid enough to place the machine Place the leveling blocks on the ground then place the machine upon the leveling blocks Level the machine accordingly see 3 3 3 3 3 3 FOUNDATION CONSTRUCTION WARNING After Leveling the machine base you need to lock 8 reserved spaces as well ...

Page 40: ...nsure all the associated connections and wiring are appropriate that is connections and wiring should conform with the local safety rules at least 2 Ensure to install a adequate current fault breaker see 3 4 5 prior to the power supply switch or transformer of this machine 3 Thread the power supply cable through the cable inlet positioned at the lower right side of the machine rest the cable upon ...

Page 41: ...nel of this machine 4 Do not connect the power cable of this machine to any power source or power panel that might cause an abrupt voltage drop 5 Remove all the anti moisture substances placed inside the cabinets or panels 6 Ensure to turn off all the power supplies and place Under Installation High Voltage Equipment Do not turn on the Power warning signs in front of the main power supply switch b...

Page 42: ...ually This kind of arrangement could prevent external grounding current overflow into this machine This overflow current might result in a serious damage on this machine and is prohibited 2 The reinforced concrete steel rod is usually used as a grounding terminal because of its low resistance to ground less than 100 ohms In doing so please make connections according to the following instructions T...

Page 43: ...SHARP V 1 KNEE MILL GENERAL MANUAL CH3 10 KRDM24C0 V4 0S 3 4 4 ELECTRICAL CONNECTION ...

Page 44: ...UIREMENT 220V No Machine Rated Capacity Wire Current fault breaker 1 V 1 33 A 8 0 m 40 A 2 3 4 440V No Machine Rated Capacity Wire Current fault breaker 1 V 1 19 A 5 5 m 20 A 2 3 4 WARNING Ensure the electrical cables have the same or better power rating as prescribed in the electrical document ...

Page 45: ...e between the base bed and foundation pad is 5 mm approx long 4 Place two horizontal levels on the working table orthogonal level the machine until differences between levels in both directions are within 0 05mm m 5 Fasten the setup nuts for the foundation pads and L shape fixing studs 6 Fill up the foundation with concrete 7 Wait for about seven days until the concrete is dry and solid 8 Place tw...

Page 46: ...machine perfectly square with table is necessary Use gauge to check the square within 0 02mm Please check square of machine following instructions 1 Loosen the binding bolts see the figure 2 Mount the gauge on the spindle nose and check the square within 0 02mm 300mm 3 Tight the bolts 4 Check the precision again after tight all bolts ...

Page 47: ...ing table 7 Ensure there is no loose part on the folding guard 8 Ensure all the fixing studs are fastened properly 9 Secure nuts bolts locks and other parts needed to be secured 10 Ensure the hydraulic pneumatic and cutting coolant systems are connected properly 11 Ensure safety guarding shields and doors are in a good condition 12 Ensure the hydraulic oil lubricant and cutting coolant are filled ...

Page 48: ...e pressure indication is abnormal Check the power supply wiring connection if necessary 3 Ensure the emergency stop switch 4 Ensure the lubrication pump work and all the machine parts are lubricated properly 5 Ensure over travel limit switch work 6 A time interval of more than 30 seconds is required between power switch off and on at the mains isolator to allow the machine interval self checking c...

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Page 50: ...SHARP V 1 KNEE MILL GENERAL MANUAL CH4 1 KRDM24C0 V4 0S CHAPTER 4 5 OPERATIONAL PROCEDURE MECHANISM PLEASE READ CAREFULLY BEFORE STARTING TO OPERATE AND ADJUSTMENT THIS MACHINE ...

Page 51: ...START UP Ensure all the wires and cables are insulated properly before starting up this machine otherwise might happen electric leakage and shock 4 3 1 INSPECTION BEFORE TURNING ON THE POWER 1 Ensure you know how to use this machine before starting it 2 Ensure the power supply of this machine is enough to run all the units of this machine easily before starting up the machine 3 Ensure there is no ...

Page 52: ... Ensure turn off the ON OFF switch on the power feed before press the power feed on button on the operating panel 13 Ensure the standby signal light is luminous after switching on the main power supply 14 Ensure the electrical cabinet door of operating panel and other safety guarding are closed 15 Always clean and lubricate all the sliding surfaces before starting up the machine if the machine is ...

Page 53: ...e Machine optional Release the EMERGENCY STOP button Press POWER ON button 4 4 2 EMERGENCY STOP PROCEDURE If any emergency conditions are happened push down the emergency stop button on the operation panel to stop the machine immediately Pull upward to release the emergency stop button 4 4 3 NORMAL STOP PROCEDURE 1 Push the EMERGENCY STOP button of NC equipment 2 Turn off the main power supply swi...

Page 54: ...ng area clean and orderly 5 Do not lay anything upon the working surfaces including the guideways saddle safety guards etc 4 5 2 NOTICES 1 Check the hydraulic oil level of the hydraulic tank regularly Please use the recommended oil as described in the oil guide table of the maintenance manual 3 Use the standard cutting tools and tool length 4 Always try a light load machining before doing a heavy ...

Page 55: ...ng the coolant nozzles 8 Do not touch or reach over rotating or moving objects 9 Do not remove any safety equipment 10 Always use the proper tools instead of using your hand to remove the chip from the cutting tool 11 Do not install or remove the cutting tool and other tool holding equipment unless the machine is fully stopped 12 Always wear appropriate protective equipment while working in a dust...

Page 56: ...SHARP V 1 KNEE MILL GENERAL MANUAL CH4 7 KRDM24C0 V4 0S 4 6 2 MAIN PARTS 1 Bed base 2 Turret 3 Ram 4 Spindle motor 5 Variable head 6 Spindle 7 Saddle 8 Knee 9 Table 10 Control panel ...

Page 57: ...t be following 1 Use spanner to unlock the 4 bolts 2 Swivel the turret to the required location that you need an 3 Lock the 4 bolts 4 6 4 MOVE RAM SLIDE To move ram slide the procedures below must be following 1 Release the two setting screws A and B 2 Use spanner C to move ram slide 3 Lock the setting screws B and A ...

Page 58: ...the front of saddle Ensure to use asequately clamping pressure to set it otherwise excessive pressure will broke the clamping parts 4 6 6 CLAMPING SADDLE If operator don t use saddle feed it can be clamped to add rigidity This can decrease vibration when doing heavy cut The clamping saddle locking lever is located on the left side of saddle Ensure to use adequately clamping pressure to set it othe...

Page 59: ...tor don t use knee feed it can be clamped to add rigidity This can decrease vibration when doing heavy cut The clamping lnee locking lever is located on the left side of knee Ensure to use adequately clamping pressure to set it otherwise excessive pressure will broke the clamping parts ...

Page 60: ...werful and fast please uses this equipment carefully Before using these power feed please read the operation manual first Do not try to use this equipment unless you understand how to operate and stop it WARNING Ensure to turn off the ON OFF switch on the power feed before press on the power feed on button on the operating panel ...

Page 61: ... 4 6 9 CONTROL PANEL 4 6 9 1 CONTROL PANEL WITH INVERTER HEAD 1 SPINDLE REV FWD SWITCH 2 SPINDLE ON BUTTON 3 POWER FEED ON BUTTON 4 POWER ON LAMP 5 SPINDLE OVERRIDE SWITCH 6 KNEE UP DOWN SWITCH 7 COOLANT ON OFF SWITCH 8 EMERGENCY STOP BUTTON 1 2 3 5 6 8 4 7 ...

Page 62: ...2 Adjustable micrometer depth stop 3 Indicator mounting rod 4 5 Spindle brake 6 Quill feed speed selector lever 7 Quill feed reversing knob 8 Quill feed clutch control lever 9 Quill 10 Draw bar 11 Spindle override 12 Speed range select lever 13 Power feed transmission lever 14 Quill feed handle 15 Quill stop 16 Quill lock ...

Page 63: ...ve speed range select lever 12 to change the speed range rotate the spindle by hand until the clutch engages fully 50Hz 60 LOW HIGH LOW HIGH V 1 60 390 rpm 420 3000 rpm 70 460 rpm 460 3600 rpm NOTE Due to gear construction when machine is running in low speed range spindle rotation is opposite to the high speed range Therfore ensure the rotation direction before machining WARNING Do not change the...

Page 64: ...he spindle speed 4 6 13 SPINDLE BRAKE Move the spindle brake lever 5 front or back can stop spindle WARNING Do not change the spindle speed when the spindle is stationary WARNING Do not use the spindle brake unless turn off the spindle motor Also ensure that the spindle brake is released before starting the motor Otherwise might cause serious accident ...

Page 65: ...ill feed reversing knob 7 to select the feed direction engage quill feed control lever 8 4 6 15 HAND QUILL FEED ONE There are 6 parts NO 1 7 8 13 15 16 necessary to adjust when use hand feed To use hand quill feed the procedures below must be following Ensure the spindle is full stop and the quill lock 16 is off use the micrometer dial 15 to set travel set the power feed transmission lever 13 at O...

Page 66: ... 20NF R8 M16 P2 0 ISO40 5 8 11NC ISO40 When tightening or loosing the drawbar it is necessary to lock the spindle Use the spindle brake 5 to lock the spindle 1 To tight the tool the procedures below must be following Use spindle brake to lock the spindle use spanner to turn the drawbar clockwise until tighttening tool 2 To loose the tool the procedures below must be following Use spindle brake to ...

Page 67: ...nd the machine is left unattended 4 8 FINISH Ensure to turn off the machine power when finish work the procedures below must be following Push down the emergency stop button Switch off the main power switch of the machine optional Turn off the factory s main power supply 4 9 INSPECTION AFTER FINISH 1 Ensure all the machine parts are in good conditions 2 Check the centralized lubrication system Fil...

Page 68: ...achining job is done Ensure to put anti rust oil on the machine bed and all the moving parts to keep them from rust and dirt 3 The machine moving parts should be returned to the adequate location 4 Check and replace the broken wipers 5 Check and replace the lubricant or hydraulic oil if they are dirty or emulsify 6 Check and replace the coolant if they are dirty 7 Check and refill the lubricant hy...

Page 69: ... LUBRICATOR 1 Electrical control box cover 9 Alarm beeper 2 YET D1 control box 10 Pressure gauge 3 Oil tank cap 11 One way elbow adapter 4 Upper lid 12 Lifting rod 5 Inlet filter 13 Shaft set 6 Oil tank 14 Pressure release valve 7 Folat switch 15 Gear Pump 8 Electrical control box housing ...

Page 70: ...EL Name Plate Danger Front side of the electrical control box Outside of the electrical control box top cover Wiring Diageam Operation Notice Inside of the electrical control box Time Index Table Inside of the electrical control box top cover Left side of the oil tank ...

Page 71: ...4 10 4 1 THE SPECIFICATION OF THE FUSE 1 TYPE 350204 glass tube fuse slow blow type 5 2 20 2 Availabe range For protecting instruments power supplies computers the related equipment of computers and telephone sets 3 Shape Size as following illustrations Unit mm a Structure shape As shown in above figure Body size of fuse Dia 5 2 mm L 20mm b Rated Voltage 250 V AC c Rated Currentl 2A NOTE Viscosity...

Page 72: ...e is below 70 by way of Thermocouple Method while it keeps below 50 by way of Thermocouple Method c Fuse current character Rated Current 1 35 In 1 5 In 2 In 100mA 10A MAX MAX MIN MAX 60 MINUTE NON 3 S 120 S 4 10 4 2 FUSE REPLACEMENT Make sure the power cable is disconnected before the fuse replacement Remove the electrical control box cover and find the fuse Fig 7 Remove the fuse protection cover ...

Page 73: ...se clean periodically the oil tank of iSHAN centralized lubrications If the user wants to clean the bottom of the tank please TURN OFF the system first and remove the bolts on the tank to separate the tank for cleaning After cleaning the tank please fasten the bolts to fix the tank Please follow below requirements a ALWAYS Turn ON the power after more than 20 seconds of turning OFF to protect the ...

Page 74: ...SHARP V 1 KNEE MILL GENERAL MANUAL CH6 1 KRDM24C0 V4 0S CHAPTER 6 ADJUSTMENT PLEASE READ CAREFULLY BEFORE ADJUSTMENT OF THIS MACHINE ...

Page 75: ...might result in squeeze to wounded and disabled 6 1 1 NOTICES 1 Check the pressure readings regularly to make sure all the system pressures setting are normal 2 Observe regularly if there is any abnormal noise arising inside the rotating motors and other moving or rotating parts 3 Moving or rotating parts are lubricated properly 4 Ensure all the safety guards and safety equipments are installed pr...

Page 76: ...rclockwise to loose the gib a littile then turn the screw clockwise to adjust the gib until the table move smooth and precisely 6 3 ADJUSTMENT OF SADDLE GIB The taper gib A is used for adjusting precision of saddle moving The screw B is used for setting the gib When adjust the gib turn the screw counterclockwise to loose the gib a little then turn the screw clockwise to adjust the gib until the sa...

Page 77: ...ng precision of knee moving The screw B is used for setting the gib When adjust the gib turn the screw counterclockwise to loose the gib a little then turn the screw clockwise to adjust the gib until the knee move smooth and precisely WARNING Ensure to check gib every month Otherwise might result the machine out of accuracy ...

Page 78: ...cklash the procedures below must be following 1 Move the table or saddle to middle position 2 Withdraw handwheel C and 3 screw D 3 Move table or saddle to the location that you can see screws A 4 Loosen the screw A 5 Tighten the nut B unit 0 08 0 12mm 6 Tighten the screw A 7 Install the all parts ...

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Page 80: ...SHARP V 1 KNEE MILL GENERAL MANUAL CH7 1 KRDM24C0 V4 0S CHAPTER 7 MACHINE MAINTENANCE PLEASE READ CAREFULLY BEFORE MAINTENANCE ON THIS MACHINE ...

Page 81: ...res written in the maintenance manual 5 Follow the maintenance procedures and be sure to establish the maintenance records after work 7 2 LUBRICATION SYSTEM Running conditions of this machine depend heavily on the lubrication management Ensure to check the lubrication system frequently to keep this machine in a good service condition The following describe how to lubricate various machine parts pr...

Page 82: ...rections THE GUIDE TABLE LUBRICANT POSITION LUBRICANT CHARACTERISTIC FREQUENCY QUANTITY 1 4 HI LOW speed gear mechanism Grease Every month Suitable amount 2 Quill Light oil Twice a day 5 10 drops 3 HI LOW change Light oil Once a day 5 10 drops WARNING Ensure to lubricate the parts according to this guide table Otherwise might result in parts damage ...

Page 83: ...t conduction Good lubricant performance Lubrication Method Centralized Lub Circulating Lub Replace add Period Daily As needed As needed Tank Capacity 3 Liters 100 Liters Depend on Model Recommended Grade of Oil BP Macurrat D 68 Mobil Vactra No 2 Shell Tonna S2 M68 BECHEM Staroil CGLP 68 MF CPC Cutting Oil 31C Shell Dromus B or Macron 32 BECHEM AVANTIN This is recommended that use ISO68 grade of oi...

Page 84: ...evron Hydraulic Oil AW32 BECHEM Staroil NR 32 7 3 2 AUTO CENTRALIZED LUBRICATOR OPTIONAL A warning system is designed to notify users of checking and filling up the slideway lubricator Please fill up the tank immediately when the warning alarm message is shown The warning alarm will be continuing if the warning status is not released Ensure to check the centralized lubricator weekiy at least and f...

Page 85: ...SHARP V 1 KNEE MILL GENERAL MANUAL CH7 6 KRDM24C0 V4 0S 7 4 OIL SYSTEM 7 4 1 V 1 OIL SYSTEM UP DOWN OIL SYSTEM ...

Page 86: ...SHARP V 1 KNEE MILL GENERAL MANUAL CH7 7 KRDM24C0 V4 0S SADDLE OIL SYSTEM ...

Page 87: ... adjust lowest speed 2 Remove 3 screws B and cover A 3 Make a fixture comprised of C E F G H 4 Tighten 2 belts C on pulley D and work with fixture Rotate H clockwise and move spring F up by 10mm 5 Remove C type retaining ring I and fixture 6 Remove pulley D and 4 screws M 7 Remove motor N ...

Page 88: ...CEMENT 7 6 1 FOR 30 1 Use felt pen mark reference line on quill and nose cap B 2 Remove set screw A 3 Unscrew nose cap B 4 Replace nose cap B check felt pen markings for correct alignment 5 Replace set screw A Caution do not overtighten as this will cause distortion 6 Check gap E 003 08mm ...

Page 89: ...ose cap B 4 Remove lock screw C and collet aligning screw 5 Replace C insert R 8 collet and check that the dog on the end of the screw does not foul on the bottom of the guide slot 6 Replace lock screw C 7 Replace nose cap B check felt pen markings for correct alignment 8 Replace set screw A Caution do not overtighten as this will cause distortion 9 Check gap E ...

Page 90: ...rew A hub B and key C 3 Remove screws D allowing housing to rotate slowly releasing spring tension 4 Lift end of spring from peg on the pinion shaft 5 Rotate housing E anti clockwise from head casting 6 Remove spring from housing and replace 7 Refit spring to main housing casting turning housing clockwise until spring locates no peg in pinion shaft ...

Page 91: ...24C0 V4 0S 7 8 FEED TRIP ADJUSTMENT 1 Release locknut A 2 Engage trip handle C 3 Adjust micro nuts against quill stop B 4 Slowly turn adjusting screw D until lever C trips 5 At this point secure locknut A 6 Check that smart trip action is obtained ...

Page 92: ...rse lever E 2 Remove circlip F screw G and arm H 3 Thread shaft J through micro nuts and remove 4 Remove screw K and stop L 5 Remove quill 6 Clean all areas oil liberally and reassemble 7 Check correct operation of feed trip linkage See instruction on sketch 30 Re assembly of spline alignment See sketch 31 ...

Page 93: ...ANING RULE 1 Ensure to clean up the anti rust treatment with the kerosene or the diesel on the contact surfaces of the moving machine parts Don t clean up the anti rust solvent on other places than where mentioned above 2 Do not clean the machine with organic solvent 3 Do not use compressed air to remove the dust on the machine which might damage surfaces among sliding parts 4 Remove all the anti ...

Page 94: ... 4 Turn the power source switch off after job is finished 5 Release the water accumulated in the air filter cap 6 Remove chips from the machine every day after job is finished 7 Check the spindle taper bore after finishing the machining Clean up the spindle taper bore with the spindle taper bore cleaner as illustrated in the following chapter 8 Stop the machine immediately and find out sources of ...

Page 95: ...lubrication oil pipes 3 Clean up the cutting oil tank and then fill up the tank with recommended oil 4 Check ball screws and clean them 5 Ensure any nuts and screws are locked 7 11 4 HALF YEARLY MAINTENANCE 1 Ensure the spindle run out and bearing clearance are within the specified precision s 2 Ensure there are no loose nuts and screws 3 Ensure all the electrical parts such as connectors switches...

Page 96: ...tank Ensure all the setting pressure are normal 5 Check the machine leveling and adjust if necessary 6 Check all electric wire connections for looseness 7 Replace oil of the spindle cooler system if you have this equipment 7 12 HOW TO ORDER REPLACEMENT PARTS 1 Quote components part number and description against each part s illustration for all component parts required 2 Some parts are standard it...

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Page 98: ...SHARP V 1 KNEE MILL GENERAL MANUAL CH8 1 KRDM24C0 V4 0S CHAPTER 8 APPENDIX ...

Page 99: ...y tripped 1 Replace 2 Correct it 3 Reset INSUFFICIENT POWER OR MOTOR OVERHEATING 1 Less phase running 2 Overload cutting 3 Poor magnetic contractor 1 Correct 2 Reduce load 3 Replace TOOL CHATTERING 1 Workpiece not clamped securely 2 Improper tool type or material 1 Clamp it securely 2 Use correct tool only NO LUBRICANT DELIVERY 1 Lubrication pump failed 2 Lack of oil 3 Filter clogged 1 Check and c...

Page 100: ...ing force variation is close to machine natural frequency Using cutter with less teeth Loose of End milling cutter Axial force acts toward the direction away from spindle Selecting proper oblique and rotational to change the direction of axial force Deformation of workpiece Workpiece is not clamped properly Change clamping style and do not put excessive clamping force during finishing cutting Dama...

Page 101: ...ne by authorized personnel Motor fails to work Replace with a new motor The repair needs to be done by authorized personnel Incorrect input power at low voltage Ensure the input power Oil suction set is blocked Clean the suction set Impermissible lubricant Revised to the lubricant of suitable viscosity 30 150cSt Leaking at the connection of the pipe and the lubricator Incorrect installation The pi...

Page 102: ... dirty lubricant The repair needs to be done by authorized personnel 3 The motor runs but not in normal condition Replace with a new motor The repair needs to be done by authorized personnel Working on products that have not been disconnected from the power supply can cause serious injury or death to persons Installation maintenance and repair work may only be carried out by qualified experts on p...

Page 103: ...5 30 0 25 7060 3 5 2 147 0 4375 27 727 26 5 30 5 8 3 CUTTING SPEED The cutting speed of milling cutter can be expressed by v Dn 1000 Where V cutting speed D diameter of cutter n revolution per minute of the spindle Cutting speed varies between wide limits which are determined by the material being cut the material used in the cutter and other conditions which are determined by the specific operati...

Page 104: ...0 75 75 108 90 150 150 225 225 325 Low carbon steel ductile free cutting 152 197 150 180 28 46 35 46 35 140 110 140 90 130 108 130 270 400 325 400 Cast iron hard medium soft 220 300 180 220 150 180 15 23 23 33 35 46 45 70 70 100 110 140 50 75 75 108 108 130 150 225 225 325 325 400 Brasses and bronzes hard medium free cutting 150 250 100 150 80 100 21 46 46 83 83 116 64 140 140 250 250 350 63 130 1...

Page 105: ...EED Feed speed is determined by S N s Z Where S table feed speed N revolution per minute of cutter s feed per tooth Z NO of teeth of cutter The feed per tooth is used in most cases Table 2 gives suggested values of different types of milling cutters and kinds of work material in general conditions Machining type Cutting depth finishing 0 3 0 5 medium 0 4 1 4 rough 3 5 ...

Page 106: ... 100 0 225 0 35 0 55 0 225 0 35 0 55 0 13 0 2 0 325 0 125 0 175 0 27 0 075 0 1 0 175 0 05 0 075 0 125 Magnesium and alloys 0 55 0 45 0 325 0 27 0 175 0 125 Aluminum and alloys 0 55 0 45 0 325 0 27 0 175 0 125 Plastics 0 375 0 3 0 225 0 175 0 125 0 1 Sintered carbide Special alloys hard tough annealed 300 400 220 300 180 220 0 25 0 3 0 35 0 2 0 25 0 27 0 13 0 175 0 2 0 125 0 13 0 175 0 075 0 1 0 1 ...

Page 107: ...SHARP V 1 KNEE MILL GENERAL MANUAL CH8 10 KRDM24C0 V4 0S This page is intentionally left blank ...

Page 108: ...SHARP V 1 KNEE MILL GENERAL MANUAL CH9 1 KRDM24C0 V4 0S CHAPTER 9 PARTS LIST ...

Page 109: ......

Page 110: ...7C MAIN SPINDLE SLIDING PULLEY 1 14 709 7A MOTOR SLIDING PULLEY 1 15 715 3 SPINDLE BRAKE 1 16 721 7 WASHER 1 17 723 7A BEARING COVER 1 18 725 3 TOP COVER 1 19 726 3 BRAKE SHAFT 1 20 727 7 BRAKE CAMS 2 21 729 BRAKE SUPPORTER 1 22 731 3 BRAKE SHAFT SLEVE 1 23 732 3 DRAWBAR 1 24 740 3 THREE ADMISSION CLUTCH 1 25 741 3 SLIDING BEARING BOX 1 26 742 3 SPACER SMALL 1 27 743 3 SPACER LARGE 1 28 744 HIGH L...

Page 111: ... AB6303 BEARING 6303ZZ 1 57 ABE0300720 BELT HTD 8M 720 25W 1 58 ABE0300600 BELT HTD 8M 600 32 1 59 AK050518 KEY 5x5x18 1 60 AK050520 KEY 5x5x20 1 61 AK080714 KEY 8x7x14 1 62 AK080780 KEY 8x7x50 1 63 AK100850 KEY 10x8x50 1 64 AKP10612 PIN 6x12L 1 65 ANII12012 NUT 1 2 12NC 3 66 ANI118058 NUT 5 8 18NF 1 67 ANI116038 NUT 3 8 16NC 1 68 ANI118516 NUT 5 16 18NC 1 69 ARS125080 RING R80x2 5 1 70 ASI231638 ...

Page 112: ...4 80 ASM305012 SCREW M5x0 8x12L 4 81 ASM306020 SCREW M6x1 0x20L 6 82 AWIH0112 WASHER 1 2 4 83 AWIS0112 WASHER 1 2 3 84 AWIS01516 WASHER 5 16 1 85 AWIS0158 WASHER 5 8 1 86 AWMF01050 WASHER 50 2 87 ANM215050 NUT M50 1 5 1 88 786 7 NAME PLATE 1 89 792 3 SPEED DISK 1 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 ...

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Page 114: ...047 3 CAM ROD SLEEVE ASSEMBLY 1 15 J 048 3 CAM ROD 1 16 J 051 SPRING PLUNGER 1 17 J 052 OVERLOAD CLUTCH WASHER 1 18 J 053 PINION SHAFT HUB SLEEVE 1 19 J 054 OVERLOAD CLUTCH SLEEVE 1 20 J 054 3 PINION SHAFT HUB HANDLE 1 21 J 055 3 PINION SHAFT HUB 1 22 J 057 KEY 1 23 J 058 OVERLOAD CLUTCH 1 24 J 059 OVERLOAD CLUTCH RING 1 25 J 060 3 OVERLOAD CLUTCH WORM GEAR 1 26 F 061 QUILL PINION OVERLOAD 1 CLUTC...

Page 115: ... 3 NOSEPIECE 1 50 J 250 SOCKET SET SCREW 1 51 J 256 COMPRESSION SPRING 1 52 J 260 DOWEL PIN 1 53 J 264 CAP SCREW 2 54 J 268 SOCKET SET SCREW 1 55 J 269 NUT 1 56 J 270 3 STELL PLATE 2 57 J 272 3 LOCK NUT 1 58 J 273 3 RING 1 59 J 275 SOCKET SET SCREW 1 60 J 276 3 SCREW 2 61 J 278 SCREW 1 62 J 281 PIN 1 63 J 282 PIN 1 64 J 288 SNAP SPRING 1 65 J 289 3 QUILLL HANDLE LOCK NUT 1 66 J 310 STEEL BALL 1 67...

Page 116: ...o Part Number Description Q ty Remarks 76 J 350 LOCKSCREW 1 77 J 355 3 HEX NUT 4 78 J 356 NUT 2 79 J 356 5 SET SCREW 1 80 J 373 SPRING 1 81 J 330 COMPRESSIVE SPRING 1 82 897 OIL CUP 1 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 ...

Page 117: ......

Page 118: ...CK HANDLE 1 15 M 051 INDICATOR ROD SCREW 1 16 M 052 INDICATOR ROD 1 17 J 065 QUILL LOCK SLEEVE 1 18 J 066 QUILL LOCK SLEEVE 1 19 J 070 3 BOLT 3 20 J 071 3 SPRING WASHER 3 21 J 097 GEAR SHIFT PLUNGER 2 22 J 098 CLUSTER GEAR SHIFT CRANK 1 23 J 099 FEED DRIVE CLUSTER GEAR 1 24 J 100 FEED DRIVE CLUSTER GEAR 1 25 J 101 FEED DRIVE CLUSTER GEAR 1 26 J 102 SET PIN 1 27 J 103 FEED DRIVE GEAR 1 28 J 104 DRI...

Page 119: ...1 51 J 135 CLUSTER GEAR KEY 1 52 J 136 3 WORM CRADLE BUSHING 1 53 J 138 PIN 1 54 J 145 FEED SHIFT ROD 1 55 J 146 FEED REVERSE BEVEL GEAR PINION 1 56 J 147 SLEEVE 1 57 J 151 TRIP LEVEL PIN 1 58 J 156 FEED REVERSE KNOB STUD 1 59 J 192 WASHER 1 60 J 251 SOCKET SET CAP SCREW 1 61 J 255 R HEAD SCREW 1 62 J 261 ROLL PIN 2 63 J 262 COMPRESSION SPRING 2 64 J 263 SET SCREW 4 65 J 265 CAP SCREW 2 66 J 266 R...

Page 120: ...y Remarks 79 J 324 FEED REVERSE BEVEL GEAR 1 80 J 327 STEEL PINION 1 81 J 330 COMPRESSION SPRING 1 82 J 336 SNAP RING 1 83 J 352 DOWEL PINS 1 84 J 369 3 SHAFT 1 85 J 410 LOCKING NUT 1 86 J 411 LOCKING NUT 1 87 J 412 LOCKING NUT 1 88 J 413 GREASE TUBE 1 89 J 414 CLIP 1 90 J 415 SCREW 1 91 J 416 HANDLE 1 92 896 GREASE NOZZLE 1 ...

Page 121: ......

Page 122: ...R 4 16 H 067 ELEVATING DIAL 1 17 H 068 DIAL HOLDER 1 18 H 069 DIAL LOCK NUT 2 19 H 070 GEAR SHAFT CLUTCH INSERT 1 20 H 071 3 ELEVATING CRANK 1 21 H 076 BEARING 6204ZZ 8 22 H 078 CROSS FEED DIAL 1 23 H 079 DIAL HOLDER 1 24 H 081 NUT 1 2 20NF 1 25 H 088 3 ADJUSTING SCREW 2 26 H 088 A ADJUSTING SCREW 3 27 H 088 B ADJUSTING SCREW 2 28 H 103 SCREW 3 8 16NC 1 1 4 L 11 29 H 105 7 SADDLE 2 30 H 110 6 LONG...

Page 123: ...C 1 4 L 4 52 H 402 6 FIXED PLATE R 1 53 H 403 6 FIXED PLATE L 1 54 H 404 3 CROSS GIB 2 55 H 405 3 SCREW 1 2 12NC 2 L 8 56 H 408 6 TIMING PULLEY 1 57 H 409 6 ELEVATING DRIVE SHAFT 1 58 H 410 3 KEY 5 5 30L 1 59 H 411 6A TIMING BELT PROTECTED COVER 1 60 H 413 6 ELEVATING MOTOR 1 61 H 414 3 TIMING BELT 225L 1 62 H 415 6 ELEVATING TIMING PULLEY 1 63 H 416 3 WASHER 1 4 6 64 H 418 SPRING WASHER 1 2 1 65 ...

Page 124: ... 1 89 H 531 HANDLE 1 90 H 532 6A CROSS SCREW BRACKET 1 91 H 546 WASHER AW04 1 92 H 556 BEARING TA1715 1 93 H 579 7 FIXED HOLDER OF MICRO SWITCH 1 94 H 579 7A COVER 1 95 H 580 7 MICRO SWITCH 1 96 H 581 7 SCREW 5 16 18NC 2 1 4 L 2 97 H 582 7 PROTECTIVE COVER 1 98 H 583 7 SCREW 3 16 24NC 3 4 L 4 99 H 584 6 STOP BLOCK 2 100 H 586 7 FIXED BLOCK 4 101 H 587 7 OIL SEAL 1 102 H 122 422 423 589 7 FREE LOCK...

Page 125: ......

Page 126: ... 510 WASHER AW05 2 16 H 059 6 BEVEL GEAR LARGE 1 17 H 062 BEARING 6204 Z 2 18 H 065 BEARING COVER 1 19 H 069 DIAL LOCK NUT 1 20 H 075 3 CROSS LEADSCREW 1 21 H 077 CROSS FEED BEARING BRACKET 1 22 H 078 CROSS FEED DIAL 1 23 H 079 DIAL HOLDER 1 24 H 080 6 BALL CRANK HANDLE 1 Automatic feed 25 H 081 NUT 2 26 H 098 SCREW 4 27 H 101 CROSS LEADSCREW FIXED NUT 1 28 H 102 PIN 4 29 H 103 SCREW 5 30 H 105 7 ...

Page 127: ...IP GUARD COVER PLATES MIDDLE 1 52 H 271 6 MACHINE BODY 1 53 H 275 RIVET 5 54 H 279 REFERENCE POINT PLATE 1 55 H 282 SCREW 2 56 H 283 PIN 2 57 H 284 PIN 1 58 H 285 3 HOISTING RING M33 3 5 1 59 H 286 OIL NETWORK 2 60 H 287 COOLANT NOZZLE ADAPTOR 1 61 H 288 90 TUBE 1 62 H 289 HOSE 1 63 H 292 3 PIPE TUBE 1 64 H 293 CLIPER 1 65 H 294 VALVE 1 66 H 295 COOLANT NOZZLE 1 67 H 418 SPRING WASHER 1 68 H 431 C...

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Page 129: ... ADAPTER PIVOT STUD 1 11 H 231 RAM PINION 1 12 H 236 3 ANGLE PLATE 1 13 H 239 SET SCREW 1 14 H 240 6 ADAPTER LOCKING BOLT 8 15 H 254 3 TURRET 1 16 H 270 6 TURRET CLAMP BOLT 1 17 H 271 6 MACHINE BODY 1 18 H 272 WASHER 5 8 1 19 H 273 RAM GIB SET SCREW 1 20 H 274 SCALE 1 21 H 275 RIVET 8 22 H 290 3 ADAPTER PIVOT STUD NUT 1 23 H 405 3 SCREW 10 24 H 426 3 ELEVATING FIXED PLATE R 1 25 H 427 3 ELEVATING ...

Page 130: ...SHARP V 1 KNEE MILL GENERAL MANUAL CH10 1 KRDM24C0 V4 0S CHAPTER 10 ELECTRICAL DRAWINGS ...

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