VERTICAL & HORIZONTAL MILLING MACHINE
NSM-T
INSTRUCTION & OPERATING MANUAL
NAMSUN MACHINERY CORPORATION
TEL.+82-42-6255561 FAX.+82-42-6229921
CONTENTS
1 General
1.1
Construction of this book ……… 41.2
Important manual precautions……….. 42 Safety Instructions
2.1 Machine operation……… 52.2 Maintenance……….………. 6
2.3 Electrical and control system………. 6
2.4
Report to the machine operator……….. 73 Specifications 3.1
Machine specifications……….. 83.2 Dimensions 3.2.1 Outline dimensions………..………….……9
3.2.2 Floor plan………..….……10
3.2.3 Table (dimensional drawing)……… 11
3.2.4 Tool (dimensional drawing)………. 11
3.3 Main parts of the machine …..……….……… 12
3.4 List of machine accessories………. 15
4 Machine transportation and foundation 4.1
Selection of installation site ….…..………. 164.2
Lifting and Transportation..……….. 164.3
Foundation………. 174.4
Installation of the machine………..……….. 174.5
Leveling ………. 185 Power source
5.1 Connection of power supply……… 196 Before running the machine 6.1 Loosening the clamps……….. 20
6.2 Supply of oil……….. 21
6.2.1 Supply of cutting oil………. 21
6.2.2 Automatic slideway surface lubrication unit ………21
6.3 Cleaning the machine……..………. 22
6.4 Movement confirmation………. 22
7 Construction
7.1 Main spindle speed change mechanism……….. 237.2 Drive mechanism………. 24
7.2.1 Table longitudinal feed……….. 24
7.2.2 Table cross feed.……… 25
7.2.3 Knee vertical feed ………. 26
7.3 Coolant lubrication mechanism ………. 27
8 Safety device 8.1 Emergency stop button
……… 288.2
Power source ……… 288.3
Table automatic feed ………..………… 298.4 Spindle feed
……….………..………… 298.5
Knee up/down handle……..……… 299 Machine operation
9.1 Turning-on the power supply
……… 309.2
Turning-off the power supply ……… 319.3 Vertical spindle start and stop
……… 329.4 Vertical spindle speed change
……….. 339.4.1 Shift change method of the V belt…………
……… 349.4.2
Change by pole number conversion (2/4P) of the main spindle motor9.4.3
Gear change with speed (High-Low) change knob……….
… 349.5 Horizontal spindle speed change
……….. 359.6 Spindle manual feed
………. 369.7 Automatic spindle feed
………. 379.8 Head swivel
………. 389.9 Ram traverse movement
………. 389.10 Table manual feed
………. 399.11 Automatic table feed
………. 419.12 Table rapid feed
………. 439.13 Mounting / Dismounting of the tool
………. 4510 Inspection and maintenance
10.1 Inspection and maintenance……….. 4710.2 Gib adjustment ……….. ……….. 47
10.3 Adjustment of the main spindle brake….………. 49
10.4 Brakes table/saddle……….. 51
10.5 Supply of oil 10.5.1 List of lubricating oil……….. 52
10.5.2 Slideway surface lubrication system………. 53
10.5.3 Quill slideway lubrication……….. 53
10.5.4 Table feed gear box lubrication……….. 54
10.5.5 Knee vertical screw lubrication……….. 54
10.5.6 Knee vertical screw inspection……….. 55
11 Electric box / maintenance 11.1 Major components of the right electric box………. 55
11.2 Return of breaker for the main power supply………..…….. 57
11.3 Return of Thermal relays………. 57
11.4 Fuse exchange ……….……… 58
12 Plate indication symbol………. 59
13 Maintenance & Inspection list………. 60
14 Guide to Trouble-shooting………. 61
15 Safety pin replacement………. 62
16 Spring Replacement (table feed transmission) ……… ………. 64
1. General
1.1. Construction of this book
This manual is a guidebook for safe machine transportation and operation of the NSM-T turret- type vertical and horizontal milling machine. Please read and understand this instruction manual carefully before operation. Always keep this manual in the operation area.
The major contents of this instruction book include (1) specification (2) installation (3) operation and (4) inspection/maintenance of the NSM-T vertical and horizontal milling machine.
This manual may be changed without prior notice due to the continuing developments and improvements of this machine. Therefore, details of the purchased product may be different from the specifications and the operations written in this manual.
If there are any questions regarding the contents of this instruction manual, please do not hesitate to contact your machine distributor or our company.
1.2. Important manual precautions
This manual shows cautionary signs/symbols to avoid any accidents, injuries, and machine damages. Please follow the instructions carefully to avoid any trouble while using this machine.
Serious injuries or lethal accidents may occur if this is neglected.
Injuries may occur if this is neglected.
The machine may be damaged and / or inoperable if this is neglected.
On the other hand, useful information for this machine is shown as “NOTE” in this manual For more convenient use of this machine
2. Safety Instructions
The prevention of any accidents involving human life and mechanical damage that may incur from improper machine operation is our main objective. Therefore, abiding by safety regulations when using the machine and executing daily adjustment and inspection of the machine are very important. Please read and understand the subsequent instructions thoroughly and follow them at all times.
2.1. Machine operation
The machine operator should fully understand this operation manual not only for operational information but also for its safety rules or regulations on machine operation.
a. Always keep the safety protective garments (e.g. safety spectacles, safety shoes, etc.) ready for use and wear them completely at all times.
b. Wear proper working clothes such as clothes with tight sleeves and cuffs, and a working cap before working at the site.
c. Smoking and placing one’s hands in his pockets shall be prohibited.
d. Do not operate the machine with gloved hands.
e. Know the respective function of switches, etc. as shown in the operation manual.
f. Do not use the machine beyond its capacity and limits.
g. Keep one’s hands away from the rotating components or driving parts of the machine at all times during its operation.
h. Turn-off the machine power before cleaning out the cutting chips dropped on the machine table or swarfs twined round cutting tools. Furthermore, do not touch the chips, the tool edges, etc. with bare hands.
i. Position the adjustment of the coolant nozzle after the machine has been turned-off.
j. Keep sufficient lighting around the machine and create a clean environment by keeping a dry atmosphere and by putting the things in order so as not to leave any obstacles lying around the site area.
k. Do not touch any switch with wet or oily hands.
l. In case of setting tools or work pieces, use the most appropriate tools such as spanners, wrenches etc., to suit the objects.
m. After the machining work, turn off the power source as shown in the procedure. Clean the machine and put some rust preventive oil around the major parts of the machine
such as slides etc. Be extra careful when using soluble coolants with the machine.
n. Avoid the use of compressed air for removing or cleaning dust or cutting chips around the main body, electric control panel, numerical control unit and surrounding floor area of the machine.
2.2. Maintenance
The person in charge of the maintenance and checking of the machine should thoroughly read this operation manual to fully understand the particulars of this machine’s potential and to get skills and knowledge of the machine’s vital components (such as its structure, function and capacity of accessories and appended systems) and to carry out necessary inspection and adjustment of these components.
a. Perform the check and maintenance diligently and regularly based on the given time interval per item (refer to the list of maintenance and checking)
b. Always start the check and maintenance only after the power source has been turned off. During some inevitable cases, always carry the task under the supervision of the machine operator. However, never come near or worse, touch the drive part of the machine.
c. Do not remove or modify the stroke limit switches of the traveling axes or any mechanism installed for safe maintenance.
d. Keep all the doors, covers, etc, closed except when the machine is being adjusted.
Pay special attention to the doors of the control system, electrical control panel, etc.
e. When replacement of parts is required, only use the spare parts that are specified by our company.
f. Never leave the machine dismantled after the daily inspection routine of checking and cleaning is done. Return any part that has been disconnected from the machine to its proper places.
g. Put a support pillar in between any vertically moving part of the machine during the maintenance check.
2.3. Electrical and control systems
An electric engineer is needed during the maintenance work of the electrical systems.
a. During maintenance checks for electrical appliances, remove the metallic eyeglasses, wristwatch, bracelets, etc. from the body and bring countermeasures in case of an electric shock accident.
b. In addition, turn off the main power source on the left hand side of the machine’s main body. Next, turn off the main power switch installed inside the factory, and start to work after careful inspection has been made. If possible, lock the power state or show an alarm indication with a handling tag. Do not allow anyone other than the personnel in charge to operate it.
c. Use the machine’s primary circuit wires as specified in the operation manual. Do not
use longer or thicker cords than what is required. If the primary cable line needs to be trained on the floor, cover it to avoid any damage that may be caused by cutting chips, etc.
d. Do not change the current rating value of the electric system’s thermal relays and the rating value of various volumes.
e. Handle the electrical appliances of the machine’s main body with utmost care. Keep them away from water or any wet materials.
f. Whenever replacement of parts for electrical appliances is required, only use the spare parts that are specified by the company. In particular, avoid using fuses that have larger capacity than what is specified.
g. Recheck the whole electrical system (e.g. looseness of connector parts) before turning on the power source. Make sure that all the covers and doors are securely closed before turning the power on.
2.4.
Report to the machine operatorWhen the work (such as maintenance checks, equipment completion and adjustment) has finished, make a report to the machine operator regarding the details and re-confirm again that everything is under normal control.
When the work (such as maintenance checks, equipment completion and adjustment) has finished, make a report to the machine operator regarding the details and re-confirm again that everything is under normal control
3. Specifications
3.1. Machine specifications
TABLE
Working surface 1100 x 280 mm
T-slots 16 mm x No3
Travel (X, Y, Z) 820 x 300 x 450 mm
Number of power feeds (X, Y) 12 steps
Range of power feeds (X, Y) 15 – 720 mm/min
Rapid traverse (X, Y) 3000 mm/min
Rapid traverse (Z) 800 mm/min
Table loading capacity 250 kg
SPINDLE
Taper of spindle bore (Vertical) NT 40 (Horizontal) NT 50 Number of spindle speeds (Vertical) 16 steps
(Horizontal) 9 steps Range of spindle speeds (Vertical) 75 – 3600 rpm
(Horizontal) 90 – 1400 rpm
Vertical traverse of spindle 140 mm
Power feed of spindle 0.035, 0.07, 0.14 mm/rev
Head Tilting Angle ± 90 degree
OVER ARM
Over Arm Max. Cross Travel 535 mm
Over Arm Swivel Angle 360 degrees
MOTOR
Main spindle motor (Vertical) 2/1 kW, 2/4 P (Horizontal) 3.7kW, 4P
Feed motor for X and Y axis 1.5 kW, 4P
Vertical rapid motor 0.9 kW, 6P
Coolant pump motor 60 W, 2P
Floor space 3000 x 2000
Machine Weight 2300 kg
3.2. Outline dimension 3.2.1. Outline dimensions
3.2.2. Floor plan
Legend: “*”—long table
3.2.3. Table (dimensional drawing)
3.2.4. Tool (dimensional drawing)
3.3. Main parts of the machine
<Head (Front)>
<Head (Right side)>
<Front>
<Left side>
<Right side>
<Rear>
3.4. List of machine accessories
The machine is equipped with the following accessories:
<Column relation>
Work lamp x 1
Rubber chip cover (Column) x 1 Crank handle & Knock pin puller x 1 1 inch milling arbor x 1
<Documents>
Instruction manual x 1
Parts list x 1
<Toolbox>
Screw driver (+, -) x each 1
L-wrenches set x 1 set
Single spanner (27 mm) x 1 Monkey spanner (300 mm) x 1
Base plate x 4
Knock pin x 1
4. Machine transportation and foundation
4.1. Selection of installation site
Select a site for installing the machine. Consider the following details to achieve the machine’s maximum performance.
4.2. Lifting and Transportation
Lift the machine by fixing the table on the center and by lowering the knee and moving the table to the column side. Then, stick an 80 to 120mm (3.1” to 4.7”) thick piece of wood between the saddle and the column slide way. Lastly, hook a steel device to the two bolts at the left and right sides of the column and the two hexes. If the steel device is not available, a forklift truck can be used.
Machine weight 2,300 kg
• The device to be used for lifting the machine must be strong and durable enough to endure the weight of this machine. Never use wire ropes that are twisted, out of shape and rusted. The machine may be dropped during its transportation and / or lifting, if coarse wire ropes are used. This may cause serious injuries or accidents.
4.3. Foundation
The machine should be installed on a solid and flat concrete floor. Check the quality and the structure of the floor’s foundation to insure the solidity of the ground.
The drawing below shows the dimension of the machine bed.
4.4. Installation of the machine
Using leveling bolts
• Wipe off both faces of the base plate for installation to remove grease, dirt, or anything else that sticks to it.
• Set the base plate as shown in the figure below.
• Adjust the level using the leveling bolts (Refer to “4-5 Leveling”)
4.5. Leveling
Leveling should be carried out when the whole system, after wiring and piping, is ready to be moved. Even though the power is turned-off, it is still necessary to do the provisional leveling work in order to avoid any transfiguration in the machine.
The following should be carried out during the method of leveling.
a. Use a level gauge with an accuracy of about 0.02 mm per 1,000 mm.
b. Position the table, the saddle and the knee at the center of movement.
c. Put the level gauge on the center of the table at the right, left, front and rear positions respectively. Adjust the level using the four leveling bolts.
d. The level of the machine is already fixed. When the machine installation is finished, the load given to the holding point will initially change and then it will gradually stabilize. However, this should still be checked on certain intervals. It is recommended to check it at least once every six months.
5. Power source
The following power supply is necessary to drive this machine
Three phase AC power supply : 220V or 380 V 50Hz or 60 Hz Power supply for lighting : 220V 50Hz or 60 Hz
5.1. Connection of power supply
The hole for the power supply cable is at the lower rear side of the electric cabinet, which is located at the right side of the column.
① Socket (220V) for lighting
② The hole for power supply cable
<<Terminal block for three phase power supply>>
Connect the power supply cable in the hole, and connect a power supply to terminal R, S, and T. Connect terminal G to the ground. ]
<< Electric box door >>
• Be sure to use a 3.5 square mm or bigger dia. cable for power supply and connect it firmly on the terminal in the electric cabinet. Using a small dia.
cable is very dangerous for it may cause heat ignition. This may result to accidents caused by wire disconnection.
• Use pipes to protect the cable from cutting oil, cutting chips, or even dust that may go into the wire hole of the electric cabinet. If a gap occurs, these materials or substances may go into the cabinet and may cause electric trouble.
• Use an earth ground line to avoid shock-related accidents that are caused by over and / or leak current in the machine. The earth ground line’s size should be the same as the power supply’s size.
• The main breaker switch is on the electric cabinet of the machine. However, it is also necessary to install a power supply switch between the factory power supply and the machine for safety purposes.
• The power must be cut when the electricity engineer exchanges the power supply.
• Serious injuries or lethal accidents may occur if this is neglected.
6. Before running the machine
6.1. Loosening the clamps
The machine is well clamped to protect each of its parts against vibration during its transportation. Loosen the clamps on each axis (X, Y, Z) before running this machine to avoid its damage.
① Table longitudinal feed brake: Adjust the screw of the table longitudinal feed handle
② Table clamp: Use the two (2) levers in front of the saddle
③ Saddle clamp: Use the lever at the lower right side of the saddle
④ Knee clamp: Use the two (2) bolts at the rear right side of the knee
⑤ Transverse feed brake: Adjust the screw of the transverse feed handle.
6.2. Supply of oil
6.2.1. Supply of cutting oil
Supply the required amount of cutting oil in the base tank.
The cutting oil tank volume is 25 liters or 6.6 gallons.
6.2.2. Automatic slide way surface lubrication unit
The left side is equipped with a slide way surface lubrication unit.
Only use the recommended brands of lubrication oil, as specified below. The use of waste oil or other brands shall cause a defect on the machine’s precision.
(Make name) (Brand name)
• Idumitsu Kosan Daphne multiway 68C
• Showa Shell oil Tonna oil T68(XHVI)
• Mobil Oil Obil vactra oil No.2
• Nippon oil Nisseki mul-path 68
6.3. Cleaning the machine
The following are ways on how to clean the machine to prevent it from rusting.
• In case of grease, moisten a waste cloth with washing oil. Wipe the dirty area with it. Then, wipe it again using a dry waste cloth.
• In case of CRC, wipe it only with a waste cloth
• In case of colored varnish, use alcohol to moisten the waste cloth, and wipe the area with it. Wipe the rest using a clean waste cloth.
Re-apply a large amount of lubricating oil on the slide way.
The use of strong solvents like trichloroethylene, lacquer and thinner will destroy the synthetic resin (Turcite B) of the machine’s paint.
6.4. Movement confirmation
A trial running confirmation after the set up should be done to check any trouble caused by vibration during the machine’s transportation. A skilled person for this machine shall inspect the following:
[Fundamental movements]
1. Operation / cancellation of emergency stop 2. Main spindle start (CW, CCW)
3. Main spindle stop/brake 4. Main spindle speed change 5. Manual feed of each axis 6. Automatic feed of each axis 7. Feed speed change 8. Rapid feed of each axis 9. Coolant ON/OFF
[Safety device]
Re-start switch check
Up and down handle safety device
7. Construction
7.1. Vertical spindle speed change mechanism
Using a two speed three-phase motor with a pole change (2 steps), a V belt shift change (four steps) and an H/L gear change (2 steps), the main spindle speed change can be set up to16 steps with a 75 to 3600 min-1 range. This enables the machine to provide the most suitable spindle speed for all kinds of tools and materials.
H/L gear change L H
Pole change 1 2 1 2
V belt
Position 1 2 3 4
250 170 105 75
500 340 210 150
1800 1250 800 550
3600 2500 1600 1100
<< Main spindle transmission composition >>
2.0/1.0 kw(2/4p)
Since the gear change is included in the H/L operation, the H/L speed change should not be operated when the main spindle is running for this will damage the gear.
The belt that is used for the main spindle is expected to wear out in time. To replace an old one, please refer to the specification below.
Belt type:
V belt type by “MITSUBOSHI” 60Hz 8360B, 50Hz 8370B
7.2.1. Table longitudinal feed
< Manual feed >
When the “longitudinal feed direction change lever” is neutral (feed clutch comes off), push the Whole handle and engage it with the handle clutch. Next, turn the driving gear through the bevel gear. Then, turn the gear nut to enable the lead screw to turn and let the table move.
< Automatic feed >
Turn the feed gearbox that is mounted at the left side of the saddle to the driving gear R/L (a clutch was added through the bevel shaft and gear). Using the “ longitudinal feed direction change lever”, turn the driving gear. Then, turn the gear nut to enable the lead screw to turn and let the table move.
7.2.2. Table cross feed
< Manual feed >
Push the ‘Whole’ handle to connect with the handle clutch and turn the ball screw directly.
The nut, which is connected to the saddle, enables the table to move.
< Automatic feed >
Turn the feed gearbox that is mounted at the left side of the saddle to the driving gear R/L using different gears. Knock down the “ Cross feed direction change lever ” using the clutch. Then, turn the drive shaft. The lead screw turns through the Driving gear that is installed in the Drive shaft, enabling the table to cross.
7.2.3. Knee vertical feed
< Manual feed >
Push the vertical handle and engage it with the handle clutch. While turning it, a vertical screw turns through the spiral pinion installed on the vertical screw. The nut that is connected to the stand enables the knee to move up and down.
< Automatic rapid feed >
A motor for vertical movement is installed to the vertical axial central part of the machine.
Using the vertical rapid feed button, the motor turns in the direction of CW or CCW and the vertical screw turns through the spiral gear that is installed to the vertical drive shaft. Then, the nut, which is connected to the stand lets the knee move up and down.
When the clutch of the vertical handle is engaged, the rapid feed operation is not completed due to the operation of the safety limit switch.
7.3. Coolant lubrication mechanism
The rear of the base is used as the coolant tank. Its capacity is approximately 25 liters. A circulation system passes through the coolant oil between the column and the rear of the knee, through the gutter at the rear of the saddle from the rear of the table. It then returns to the tank through the base filter cup after it is sucked up from the tank by a coolant pump that is installed inside the column, and passed through a pipe at the front left side of the head, from the rear side of the column. The flow amount is adjusted depending on the work that is being done.
The coolant pump can be operated with the selector switch on the electric box. When the switch is set to the ON position, the green pilot lamp will light up to show that the coolant pump is running.
The coolant pump is 100W, with an ability of 8m and a capacity of 10 lit/min at 60Hz. Using clean water, it has an ability of 2m and a capacity of 10 lit/min at 50Hz. However, since its capacity changes depending on the viscosity of the used coolant, high viscosity coolant should be avoided.
When selecting the cutting oil
Aside from its cutting performance, tool life, and finishing surface, also consider the following characteristics:
• It should not cause the work piece to rust.
• It should have a high ignition point.
• It should not harm the skin or the human body, as a whole.
• It should not emit any bad smell.
• It should not corrode the machine’s paint.
8. Safety device
8.1. Emergency stop button
The mushroom shaped push-button on the front operation panel is the machine’s emergency stop button. After removing the cause of the emergency, set the main spindle lever switch to a position of “ Stop ( ) ” or “ Brake ( )”. Then, press the next green push-button to restart.
8.2. Power source
When the electrical parts, operation circuit, motor, etc., are shorted or grounded, the circuit breaker that is installed at the back side of the electric box turns off (Trip condition) to protect the machine against an over current. After troubleshooting is done, first press down the switch of the breaker to OFF before setting it to ON.
(Trip) (OFF) (ON)
8.3. Table automatic feed
The table automatic feed safety device is inside the safety pin cover in front of the feed gearbox. Each of its two couplings is connected to a 4 mm safety pin. When an overload is encountered, this safety pin is shorn off, and the automatic feed stops at the same time as the interception of the motion from the motor. Thus, it protects the gearbox and the gears in the saddle. To replace the shorn-off pin, see “ 15. Safety pin replacement” for instructions.
The safety pin uses low carbon steel of Ø 4 mm.
Using a pin that is made up of other materials or shapes may damage the machine.
8.4. Spindle feed
When the automatic spindle feed and the find feed handle encounter an overload, the clutch of the pinion shaft that is meshed with the quill rack trips, and the damage of the feed system parts is prevented. The spindle thrust force (propulsion) that trips the clutch is set at 250 to 300 kgf (550 to 660 lbs)
8.5. Knee up/down handle
It is very dangerous if the handle engages and rotates during the rapid traverse. Thus, this machine employs a safety device that operates the limit switch to disable the knee rapid traverse if the handle is engaged.
(Rapid traverse possible) (Rapid traverse impossible)
9. Machine operation
9.1. Turning-on the power supply
Confirm the following details before turning-on the power supply. (All answers should be
“Yes”)
① Is the door of the electric box completely closed?
② Is there certainly nothing around the machine to obstruct its operation?
③ Is the main spindle lever switch at a position of Stop “ ” or Brake “ ”?
The main power supply breaker is at the rear side of the electric box, which is located at the right side of the column. Turn this switch up to turn the main power on.
The Pilot lamp (POWER) on the electric box lights up to show that the power is being supplied.
Be sure that the main spindle lever switch is at a position of Stop “ ” or Brake “ ”.
Then, press the restart button.
The safety circuit works when the main spindle’s lever switch and the power are switched “ON”. Press the “RESTART” button only when the switch of the main spindle is set to the “OFF ( ) or “Brakes “( ) position.
.
9.2. Turning-off the power supply
Confirm the following details before turning-off the power supply. (All answers should be
“Yes”)
• Are all operation levers in the “OFF” or “Neutral” position?
• Does each axis of the machine stop around the central side? Do the other moving parts stop entirely?
• Is there enough distance between the work piece and the cutting tool?
Push the “OFF” button of the main power supply switches to turn-off the power supply.
Be sure to turn-off the main power supply breaker in the electric box during blackouts. When the power returns, restart the power supply from (9-1).
9.3. Vertical spindle start and stop
The spindle motor’s rotation (clockwise / counter clockwise) and speed (high / low) can be controlled using the selector switch at the front right side of the head. When starting the spindle, select the right side (clockwise rotation) or the left side (counter clockwise rotation) and 1 (low speed) or 2 (high speed) after settling the position of the belt. The motor will not run using the “0” position since this is an OFF position.
When the arrowhead of the spindle lever switch at the front top of the head is set to the “▌”
position, the spindle rotates. The “ ” position is the neutral position. The “ ” applies the brake to the spindle.
When the spindle does not start even when the lever switch is set to the “▌” position, the emergency stop interlock may be actuated. If this happens, return the switch to the “ ” or
“ ” position and press the green push button switch on the front operating panel. Then, operate the lever switch.
To stop the spindle motor, revert the lever switch to the stop position. Then, move it to the“ ” position to stop the spindle mechanical brakes from working.
The Safe circuit works as soon as the power is turned on and after an emergency stop has been done. The main spindle doesn’t turn around even if the lever switch is operated. Press the “RESTART” button after reverting the lever to the
“ ” position
9.4. Vertical spindle speed change
The spindle speed can be set up to16 steps within the 75 to 3,600 rpm range using the following changes.
• Shift change of the V belt (four steps)
• Change by pole number conversion (2/4p) of the main spindle motor
• Gear change with speed (High-Low) change knob
H/L gear change L H
Pole change 1 2 1 2
V belt
Position 1 2 3 4
250 170 105 75
500 340 210 150
1800 1250 800 550
3600 2500 1600 1100
9.4.1. Shift change method of V belt
Shift the V belt of the main spindle using the following procedure:
i. Set the main spindle lever switch on “ ”, and press the “Emergency stop”
switch. Put the selector switch of the spindle motor to “0”
ii. Loosen the main spindle motor clamp lever, and move the V belt adjustment lever on the front side. Loosen the V belt.
iii. Set the V belt to the desired position Tighten the main spindle motor clamp lever by pushing the adjustment lever backward.
9.4.2. Change by pole number conversion (2/4p) of the main spindle motor
Set the selection switch to the desired position after making sure that the main spindle is switched-off.
9.4.3. Gear change with speed (High-Low) change knob
Set the selection switch to the desired position after making sure that the main spindle is switched-off.
Before shifting the belt or operating the main spindle motor pole number conversion, make sure that the main spindle is not turning by first checking the main spindle lever switch operation. Operating it while the spindle is still turning may cause motor trouble. Never change the spindle speed (Hi-Low) change knob while the spindle is rotating for it will damage or destroy the gear.
9.5. Horizontal spindle speed change
The spindle speed ranges from 90 rpm to 1400 rpm, within (9) steps, as shown on the spindle speed round table on the right side of the machine column
.
See the figure below.
The horizontal spindle ready to run by pressing the “ON” push button ( ) on the operation panel. The spindle speed change lever is used for changing the speed of the spindle rotation. Never move the lever during a spindle rotation for this will damage the gear.
SpindleⅠ& Ⅱ on the panel indicate the direction of the spindle rotation. When a knob is turned towards Spindle I, the spindle rotates clockwise. When a knob is turned towards Spindle II, the spindle rotates counterclockwise. The belt for the spindle wears- off in time. For replacement, the 'Mitsuboshi V belt should be used.
9.6. Spindle manual feed
There are two ways to manually move the spindle upward or downward.
[By the quill vertical feed lever]
Loosen the quill clamp lever at the lower front of the head and move the quill vertical manual feed lever while engaging the internal clutch.
[By the fine feed handle]
Loosen the quill clamp lever at the lower front of the head and set the automatic feed change knob at the left side of the head to the neutral position (between the feed rate number “▌”).
Then, set the automatic (or manual) feed lever at the lower front left of the head to the left.
Turn the fine feed handle clockwise to move the quill. When the automatic (or manual) feed release lever at the lower front of the head is pushed down, the automatic feed lever is released and the fine feed handle reverts to a free state.
9.7. Automatic spindle feed knob
Loosen the quill clamp lever at the lower front of the head and set the automatic feed change knob to the desired feed rate position (0.035, 0.07, 0.14 mm/rev [0.0014, 0.0028, 0.056 inch/rev]) in the 3-step feed rate. Then, start the automatic spindle feed by setting the automatic feed lever to the left.
To forcefully stop the automatic feed, push down the automatic feed release lever.
Since the ‘automatic stop’ is performed by pushing down the ‘automatic feed stop adjusting nut’ using the automatic feed stop dog at the center front of the head, set the two adjusting nuts to the stop position. The adjusting nuts can be locked using the bolts. The automatic feed stroke is 140 mm (5-1/2”).
First, set the Automatic feed clutch knob to the desired position. When this selection knob sets to the position shown on the right, the gears are engaged and it enables to move the quill upward or downward.
When the spindle is rotating counterclockwise, the automatic feed is applied in the upward direction. There is no automatic stop system for this direction. It should be stopped manually for this will damage the quill and gear case.
Accordingly, pay attention to the automatic feed when the main spindle tends to rotate towards the counter clockwise direction.
9.8. Head swivel
First, remove the knock pin at the front right side of the head using the accessory knock pin puller. Next, loosen the two head swivel clamp bolts. Do not pull them out. Then, insert the accessory crank handle into the front hexagonal head (head swivel shaft) and swivel the head in accordance with the swivel angle dial.
After swiveling the head to the desired angle, clamp it by tightening both head swivel clamp bolts equally at the top and at the bottom.
Since the head stock pin alone cannot ensure precision, always check the angle using the swing check on the table. The head swivel should revert to 00.
9.9. Ram transverse movement
The ram can be moved transversely (535 mm [21”]) by hand. First, loosen the two ram clamp bolts at the right side of the swivel base. In this state, the ram can be moved transversely by inserting the accessory crank handle into the hexagonal head of the ‘ram transverse movement pinion shaft’ while operating the handle.
After moving the ram to the desired position, be sure to clamp it using the two ram clamp bolts.
9.10. Table manual feed
The table can be moved in three directions using the manual handle.
The table can be moved longitudinally using the handle at the front left side of the saddle.
The saddle can be moved transversely using the handle at the front right side of the knee.
The knee can be moved vertically using the crank at the front left side of the knee.
[Table longitudinal feed]
Loosen the two table clamp levers at the front of the saddle. Next, set the ‘table longitudinal feed direction change lever’ to the neutral position. Then, engage the table longitudinal handle clutch and turn the handle.
• When the feed handle is turned counter-clockwise, the table moves to the left.
• When the feed handle is turned clockwise, the table moves to the right.
The ‘table feed gauge’ should have an accuracy of 0.02 mm per division on the feed speed dial and the table should move at 4 mm per revolution.
[Table transverse feed]
Loosen the saddle clamp lever at the lower right side of the saddle, engage the transverse feed handle clutch, and turn the handle.
• When the feed handle is turned counterclockwise, the saddle moves forward.
• When the feed handle is turned clockwise, the saddle moves backward.
The ‘table feed gauge’ should have an accuracy of 0.02 mm per division on the feed speed dial and the table should move at 4 mm per revolution.
[Table vertical feed]
Loosen the two knee clamp bolts at the rear right side of the knee, engage the vertical feed crank handle clutch and turn the handle.
• When the feed handle is turned counterclockwise, the table moves downward.
• When the feed handle is turned clockwise, the table moves upward.
The ‘table feed gauge’ should have an accuracy of 0.02 mm per division on the feed speed dial and the table should move at 2 mm per revolution.
The ‘limit switch’ under the ‘table vertical feed handle’ secures the machine against damages caused by collision when the manual operation is being carried out. For safety, the lower and upper parts of knee are equipped with ‘stoppers’.
9.11. Automatic table feed
The table can be moved in longitudinal directions through the automatic feed operation.
Loosen the table clamp lever before operating the ‘table automatic longitudinal feed’. Press the “ON” push button ( ) at the top left side of the front operation panel to start the table feed motor. If the ‘longitudinal feed direction change lever’ at the center of the saddle is set to the right, the table will move to the right.
As for the automatic stop, a ‘stop dog’ is located on the front side of the table. When the ‘stop dog’ hits the rack that is connected with the ‘longitudinal feed direction change lever’, revert the lever to a neutral position to stop the table automatically. The table feed motor can be stopped by pressing the “OFF” push button ( ) that is located at the left side of the front operation panel.
[Setting of automatic feed speed]
To set the feed rate, 12 steps of speed change can be done through the ‘speed change wheel handle’ on the feed gear box at the lower left side of a saddle, and through the High / Low change knob operation.
[Mm / min]
No. 1 2 3 4 5 6
[60 Hz] H 720 507 342 267 187 127
L 87 61 41 32 22 15
H 600 420 283 221 155 105
[50 Hz]
L 72 50 34 26 18 12
[Feed rate list]
Set the feed change lever in the neutral position. Then, change the speed when the feed
motor turns. Push the knob in for low speed and pull it out for high speed.
<Feed speed dial handle>
<High-low change knob>
Change the ‘feed speed’ after setting the ‘longitudinal feed direction change lever’ to the neutral position. Changing the feed speed during an automatic feed adds an overload to the gear, and may cause its damage.
Operate the high-low change only in a low speed area (No. 1~3)
For the speed change wheel handle operation: Change from one level at a time. Extreme direct change (e.g. from the maximum speed (No.6) to the minimum speed (No.1) and vice-versa) cannot be performed.
9.12. Table rapid feed
The Table rapid feed is applied in the longitudinal, cross and vertical direction.
Longitudinal direction
When the table rapid feed lever on the feed gearbox is pulled up during an automatic feed, the table is fed at a rapid feed in the feed direction. The table transverse feed direction switch lever controls the feed direction. If this lever is pushed to the left, the table will move to the left. When released, the rapid lever gets lowered automatically and the feed returns to the cutting feed rate.
Cross Direction
The ‘table power cross feed operation’ is the same as the ‘longitudinal automatic feed operation’. If the transverse feed direction change lever is pushed lower, the table will move to the column side.
As for the automatic stop, the ‘stop dog’ is located on the side of the knee. When the ‘stop dog’ hits the lever of the ‘transverse feed direction change lever’, revert the lever to the neutral position to stop the table.
Vertical direction
Operating the push-button on the front operation panel performs this. While the upper “UP”
(/lower “DOWN”) push-button switch is being pressed, the rapid feed is applied in the table in the upward (/downward) direction. When the switch is released, the rapid feed stops at the place.
The ‘limit dog’ for upper or lower is installed at the right side of the knee. When the column side limit switch is operated, the motor power turns-off.
When performing the rapid feed, disengage the handle clutch by pulling the handle to disable the manual handle from turning.
There is a ‘clutch position detection’ limit switch for the knee vertical feed handle. When the handle clutch is engaged, the handle operates the limit switch so that the vertical rapid transverse cannot function.
9.13. Mounting / Dismounting of tool
< Mounting >
To mount a tool to the main spindle, follow the procedure below:
1. Be sure that the main spindle is turned-off. Move the quill to the upper end position and fix its position using the clamp lever.
2. Press the emergency stop button, and set cam switch to “0”
3. Set the spindle lever switch to brake “ ” position.
4. Match the driving key using the flange ditch. Press the “IN” button to mount it to main spindle.
• Always use standard tools.
• Never hold the edge of the cutting tool when mounting a tool.
• Before setting the tool in the main spindle, clean up the spindle taper and tool taper shank surface with a clean cloth to remove chips and dirt.
• Don’t operate the main spindle during work.
• Only use a right-sized spanner or wrench when mounting a tool to the spindle.
< Dismounting >
1. Be sure that the main spindle is turned-off. Move the quill to the upper end position and fix its position using a clamp lever.
2. Press the emergency stop button and set the cam switch to “0”
3. Set the spindle lever switch to the brake ( ) position.
4. Press the OUT button on the Auto draw bar panel and take out the tool carefully.
When the tool’s tapered part loosens-off from the main spindle, lock the nut with a bigger torque.
10. Inspection and maintenance
10.1. Inspection and maintenance
The operator shall perform the inspection and maintenance as described below.
Daily inspection and maintenance (Preoperational checks)
• Check the oil level of the slide way lubrication tank.
• Move each axis (table), and check if they strike properly.
• Check the brake operation of the main spindle.
Monthly inspection and maintenance
• Machine level check
• Gib looseness check
10.2. Gib adjustment
The gib of each part is already adjusted at the factory. However, when a loose gib is found during monthly inspection, then it is important to perform the adjustments as described below.
The gib adjustment may differ depending on the cutting conditions. Thus, please contact our serviceman to perform the adjustment.
① Longitudinal Gib (1 piece)
② Cross Gib (3 pieces)
③ Vertical Gib (3 pieces)
① Table and saddle (Longitudinal slide way, 1 piece)
A taper gib is installed at the table and the saddle slide way as shown below.
Since the gib is inserted from the right side of the table at the back of the saddle, adjust the slide way gap by loosening the slotted head screw at the left side of the saddle (thin side) and tightening the bolt at the right side (thick side). Then, re-tighten the left side bolt so that the left and right bolts push the gib equally
② Saddle and knee (Cross slide way, 3 pieces)
Three taper gibs are installed at the saddle and the knee slide way as shown below. Adjust all three gibs by loosening the column side of the slotted head bolt and tightening the front bolt. Then, tighten the column side bolt again so that the front and rear bolts push the gibs equally
③ Knee and Column (Vertical way, 3 pieces)
Three taper gibs are installed at the knee and column slide way as shown below.
Adjust all three gibs by loosening the slotted head bolt at the bottom of the knee and tightening the top bolt. Then, tighten the bottom bolt again so that the top and bottom bolts push the gibs equally.
10.3. Adjustment of the main spindle brake
< Structure of the main spindle brake >
< Operation mechanism of the main spindle brake >
1. The brake axis (3) connects to the handle boss (1) and turns around when the main spindle lever in the brake side of the upper figure is pulled.
2. When the brake axis turns around, the operation piece (4) moves to the left direction. The tension pin (5) and the chain (6) connect to the expansion pin (7).
Turn the expansion pin.
3. When the expansion pin turns around, the brake shoe (8) expands. Then, it contracts inside the main spindle pulley and main spindle is braked.
<Adjustment method of the main spindle brake>
The brake shoe (8) wears out in time. The effect of the main spindle brake decreases due to the abrasion of the brake shoe. Thus, adjust it using the following procedure.
1. Turn-off the main power supply of the machine.
2. Match the main spindle H/L change knob to “H” side.
3. Set the main spindle lever to the brake position “ ”
4. Insert a screwdriver (-) in the brake-adjusting nut (2). A brake is effective when it
is turned clockwise. Adjust it while turning the main spindle by hand.
5. Match the main spindle lever with a neutral position “ ”, and check if the main spindle turns around easily by hand.
10.4. Brakes of table / saddle
This machine uses lead screws for the feed axis of the table (longitudinal) and the saddle.
There is a very little frictional resistance and there may be reverse turned by cutting resistance. For protection, feed brakes are installed to the machine.
[Brake for longitudinal and transverse]
In the longitudinal and transverse handle brake mechanism, the brakes’ lining piece holds the handle clutch boss. The brakes work by tightening them with adjusting screw.
10.5. Supply of oil
Lubrication is an important factor for executing and maintaining the machine’s accuracy.
Lubricate properly and carefully. Use the lubrication oil as shown below.
10.5.1. List of lubricating oil
Lubrication point
1.Feed gear box
2.Quill slide way
3.Knee vertical screw
/ nut
4.Feed slide way
Oil supply method Replenish Point
Oil cup (Saddle)
Oil cup (Head)
Grease nipple
Lubrication tank Replenish
Interval
Twice a week Daily Daily Daily
Replenish Amount
1.5 L (Change) (0.4 gal)
Suitable amount
Suitable amount
2 L
Recommended oil
Mobil oil Mobil DTE oil
24
Mobil Vactra Oil No.2
Mobilax EPO Mobil Vactra Oil No.
2
Shell oil Tona oil 68 Tona oil T68 Alvania
EP grease RO
Tona oil T68
Castrol oil Hyspin AW68 Magna BD 68 Sheerol AP 2 Magna BD 68
10.5.2. Slide way surface lubrication system
The left side of the column is equipped with a slide way surface lubrication unit (Oil pump).
This automatic lubrication does not function when the machine power is shut down.
Whenever the lubrication pump motor has run for a long time, the most appropriate volume of oil should be checked if the oil level reaches the upper limit of the oil gauge.
Maker: Hansung Precision Co., Ltd, Korea Model: HALS LUBE HMGP-105M
Voltage: 1Ø220V
Dis. Pressure: 8kg per square cm Discharge: 4~45 CC
Interval: 30~120 min
10.5.3. Quill slide way lubrication
The quill and the head slide ways are lubricated by the natural dripping of the lubrication oil from the oil cups installed at both sides of the head. The capacity of the oil cups is small.
Thus, more care is needed during daily lubrication.
10.5.4. Table feed gear box lubrication
Fill the inlet of the gearbox (up to the center of the oil gauge) using the recommended amount of lubrication oil. Always use new oil and prevent any foreign substance to get mixed with it, such as dust when filling. At first, change the oil after two months and then, change the oil twice a week. To drain the oil, remove the plug at the lower part of the bracket.
10.5.5. Knee vertical screw lubrication
The table longitudinal and transverse feed screws are lead screws with greased sealed in the nut. To lubricate the vertical screw, first raise the knee and slide the ‘vertical screw stand cover’ upward. Then, grease the vertical screw using the grease nipple that is on the nut. If the vertical screw runs out of grease, an abnormal noise will be generated and the vertical screw nut will wear abnormally. Therefore, move the stand cover upward and check the condition of the grease once a week.
10.5.6. Knee vertical screw inspection
The wear of the ‘knee vertical screw’ should be inspected at least once a week using the following method.
• Clamp the knee by tightening the two clamp bolts at the rear side of the knee using the accessory hex wrench.
• Turn the knee up/down handle CW and CCW. Check the range. The handle should be turned freely with a dial indicator.
11. Electric box / maintenance
11.1. Major components of the right electric box
< Electric box >
MS1 Magnet switch for horizontal spindle MS2 Magnet switch for horizontal spindle MS3 Magnet switch for gear box
MS4 Magnet switch for knee up MS5 Magnet switch for knee down MS6 Magnet switch for coolant and power MS7 Magnet switch for head motor MS8 Magnet switch for tool in MS9 Magnet switch for tool out OCR2 Thermal relays
OCR3 Thermal relays OCR4 Thermal relays OCR5 Thermal relays
EOCR Electronic thermal relays F1 Fuse & holder for circuit F2 Fuse & holder
F3 Fuse & holder for 220V outlet
TB1 Terminal block for 220V three-phase power supply connection TB2 Terminal block for circuit connection
TB3 Terminal block for circuit connection
< Operation panel >
< Electric box door >
Push button switch “UP” (for vertical rapid feed_UP)
Push button switch “DOWN” (for vertical rapid feed_DOWN)
Push button switch “ON” (for feed motor_ON) Push button switch “OFF” (for feed motor_OFF)
Push button switch “ON” (for horizontal spindle on) Push button switch “OFF” (for horizontal spindle off) Auto draw bar
Push button switch “IN” (for tool_IN) Push button switch “OUT” (for tool_OUT) Pilot Lamp Left (for Main power supply)
Pilot Lamp Right (for coolant pump)
< Selector switch for main spindle >
11.2. Return of breaker for the main power supply
When the operation circuit, motor, etc. that are installed to the machine are shorted or grounded, the circuit breaker inside the electric box at the right side of the column is turned OFF and the machine is protected against an over current. After troubleshooting or fixing the problem, reset the circuit breaker by turning it ON.
11.3. Return of thermal relays
The breaker and the thermal relays are in the circuit to protect the motor and the circuit from an overload and a short circuit. When the thermal relays works, the notch of the lower side of the setting dial comes out. After troubleshooting, push the notch back.
< Return of thermal relays >
11.4. Fuse exchange
The glass cartridge fuse is in the circuit for its protection.
< glass cartridge fuse >
[Confirmation]
The glass cartridge fuse is installed with the fuse holder. Pull the holder knob of the fuse holder, remove it, and check the fuse.
12. Plate indication symbol
The following indication symbols are used in this machine.
Symbol Meaning
Main spindle
▌
Start (ON)Stop (OFF) (Brake)
Feed
Rapid feed
Table
Feed per revolution
Graduation
Allow change speed only in stopped position
Clamp / Unclamp
Coolant pump
Safety pin position
Change direction R/L, H/L
Allow engage gears for quill feed
13. Maintenance & inspection list
Inspection point Inspection item Period Judgment standard Measure 1 Lubrication
system
Quantity of oil Every day Upper minimum line A quantity of oil doesn’t decrease or abnormally decrease
Supplying of designated oil Contact to service engineer
2 Quill slide way Oil film Every day Inspect it every day Supply of designated oil 3 Feed gear box Quantity of oil
Quality of oil
1 week Every 6 months Exchange of designated oil
4 Knee elevating screw
Quantity of oil Check wear
1 week 1 month
Inspect it every 1 week Check: A gap is greater than 1.5 mm
Grease to the knee elevating screw
Contact to our service engineer
5 Vertical feed handle
Safety device operation
Every day In the insertion of a vertical handle, the operation check of limit switch
Inspect switch
6 Machine body Level Loose gib 1 year 1 month
Is there not variation of forward, backward and both sides?
Readjustment of level Gib adjustment
7 Main spindle brake
Operation of brake
Every day Check acting condition of brakes
Adjust brake
8 Cutting oil
device
Delivery state Quality of oil
Every day 1 month
State of delivery is bad.
Contamination is big
Fill oil, Exchange of oil Exchange of oil Period Every day : Inspect it every day 1 week : Inspect it every 1 week
1 month : Inspect it every 1 month 1 year : Inspect it every 1 year
14. Guide to troubleshooting
Condition Cause Remedy
1 Start switch (RESTART) is not available.
All switches are not effective
Main spindle lever switch is ON.
Wire disconnection by a fuse cut or operation of thermal relays.
Set it to a position of OFF or brake, and press start switch.
Confirm a fuse and thermal relays.
2 Main spindle motor doesn’t turn Selector switch for main spindle is set in “0”
Set it to the desired position
3 Main spindle motor turns, but spindle doesn’t turn
Main spindle high/low speed change knob is locating at a position of neutral.
V belt is damaged, or loosens
Set it to the desired turn position. (H or L)
Exchange of belt / Adjustment of tension 4 High-speed side (H) turns, but
low speed side (L) doesn’t turn
Gear of main spindle low speed side is damaged
Contact to our service engineer
5 Main spindle brake isn’t effective
Abrasion of brake pad Adjustment of brakes
6 Table longitudinal rapid feed is possible, but cutting feed isn’t effective
Safety pin breaks.
Speed change wheel handle or high/low speed change knob isn’t set surely
Exchange of the safety pin.
Confirmation of change knob or handle
7 Longitudinal feed is uneven Safety pin breaks Exchange of the safety pin 8 Longitudinal feed is possible,
but cross feed isn’t effective in a machine of table power cross feed.
Safety pin breaks Exchange of the safety pin
9 Vertical rapid feed doesn’t move.
So that a vertical handle is locating with the clutch side, the safety device operation.
Move a vertical handle away from a clutch
Clean a safety device 10 Rapid feed of one direction of
rise or down doesn’t move
Safety device works by dust or cutting chips. (Limit switch for upper limit / lower limit works)
Clean limit switch
11 Coolant oil doesn’t come out Coolant pump doesn’t work Coolant oil is short
Confirm fuse for a pump.
Supply coolant oil 12 Electricity doesn’t come to a
socket for 100V of electric box
A power supply (100V) isn’t connected to terminal block for 100V.
Wire disconnection of a fuse for 100V
Connect 100V power supply.
Exchange a fuse
15. Safety pin replacement
[Confirmation of break]
When a safety pin is broken, the front coupling stops, and only the rear coupling turns.
(See lower figure)
[Safety pin replacement procedure]
When the gearbox gets overload, the safety pin is cut off to prevent gear damage. At this time, the table rapid feed is effective, but the cutting feed is ineffective.
Replace the safety pin in the following order.
1. Press the “OFF” switch of the feed in the operation box and stop the feed motor.
2. Remove the safety pin cover (4), the taper pin (6) and the front coupling (3).
3. Loosen the set bolt (1), and pull out the rear coupling.
4. Remove the broken safety pins from each coupling (2) (3), and change them using the attached safety pins.
5. Even out the taper hole of the drive shaft (5) using the shaft key (8) and insert the coupling. At this time, pay attention to the direction of the taper hole.
6. Punch in the taper pin (6), and fix the rear coupling (2) using the set bolt (1) by not leaving any space between the couplings.
7. Install the safety pin cover (4)
Three spare safety pins (shear pin) are attached for replacement. If a safety pin is broken or lost, a pin of the same size, made of low carbon steel (Ø4 x 20) should be used. Never use a pin that is made of hard materials, or a quenching pin, since this will cause a machine trouble.
Be sure that the power supply is turned-off. First, drain the oil from the spindle gearbox and dismantle the feed speed change unit. Second, replace the spring and make sure that the spindle rotation works at all the speed rates. Third, set the speed rates at the 4th rate from the lowest speed rate clockwise and place a spindle speed change gear like the picture below.
