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V-30/40

VER:IM-V051800 NO:P20ABEV34A

LEADWELL
CONTENT
PAGES

PREFACE, INTRODUCTION, COPYRIGHT....................................... I, II, III 1. SAFETY PRECAUTIONS


1-1 SAFETY RULES............................................................................................... 1-2 GENERAL SAFETY INSTRUCTIONS............................................................ 1-3 THE DIAGRAMS AND DRAWINGS OF SAFETY......................................... 1-4 DANGER AREAS............................................................................................. 1-1 1-3 1-5 1-9

2. MACHINE FEATURE
2-1 NOMENCLATURE .......................................................................................... 2-2 MACHINE OUTLINE DIMENSION...................................... 2-3 SPECIFICATION............................................................................................... 2-1 2-3 2-7

3. TRANSPORTATION
3-1 PRECAUTION................................................................................................... 3-2 TRANSPORTATION DRAWING................................................. 3-3 TRANSPORTATION-FLOOR DRAWING....................................................... 3-1 3-2 3-4

4. INSTALLATION
4-1 PRECAUTION.................................................................................................. 4-2 ENVIRONMENTAL REQUIREMENT............................................................ 4-3 THE PROCEDURE OF INSTALLATION MACHINE .................................... 4-1 4-1 4-3

5. KEY PARTS FEATURES


5-1 PNEUMATIC SYSTEM ................................................................................. 5-1-1 FRL UNIT .................................. 5-1-2 TECHNICAL DATA AND OUTLINE DIMENSION.................................. 5-1-3 THE SETTING METHOD OF FRL UNIT .................................................. 5-1-4 THE LOOP SKETCH OF PNEUMATIC SYSTEM................................. 5-1-5 THE ROUTE SKETCH OF PNEUMATIC SYSTEM............................... 5-2 COOLANT SYSTEM ..................................................................................... 5-2-1 OUTLINE DIMENSION OF COOLANT PUMP......................................... 5-2-2 TECHNICAL DATA.................................................................................... 5-2-3 POSITION OF TERMINAL BOX................................................................ 5-2-4 PIPE WORK................................................................................................. 5-2-5 ELECTRICAL CONNECTION.................................................................... 5-2-6 PHASE OF THE PUMP............................................................................... 5-2-7 TROUBLESHOOTING................................................................................ 5-1 5-1 5-2 5-3 5-4 5-5 5-7 5-7 5-7 5-7 5-7 5-8 5-8 5-8

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5-3 SPINDLE OIL COOLER SYSTEM ..................................................... 5-3-1 OUTLINE DIMENSION.............................................................................. 5-3-2 CIRCUIT DIAGRAM................................................................................... 5-3-3 WIRE CONNECTION.................................................................................. 5-3-4 GENERAL CAUTION................................................................................. 5-3-5 MAINTENANCE.......................................................................................... 5-3-6 TROUBLESHOOTING................................................................................ 5-4 LUBRICATION SYSTEM ............................................................................. 5-4-1 OUTLINE DIMENSION............................................................................... 5-4-2 FULL UP LUBRICATION OIL ................................................................... 5-4-3 THE LUBRICATION SYSTEM SKETCHES OF AXES ............................. 5-4-4 THE LUBRICATION SYSTEM SKETCHES OF AXES............................. 5-5 HEAT EXCHANGER SYSTEM .................................................................... 5-5-1 OUTLINE DIMENSION OF HEAT EXCHANGER.................................... 5-5-2 GENERAL CAUTION................................................................................. 5-5-3 SPECIFICATION AND TECHNICAL DATA.. 5-5-4 BASIC MAINTENANCE.. 5-9 5-9 5-9 5-10 5-10 5-11 5-12 5-13 5-13 5-13 5-15 5-16 5-17 5-17 5-17 5-17 5-18 6-1 6-1 6-1 6-1 6-2 6-2 6-3 6-5 6-7 6-9 6-16

6 OPERATION
6-1 MISCELLANEOUS FUNCTION (M FUNCTION/M CODE) ......................... 6-2 SPECIFYING THE SPINDLE SPEED (S FUNCTION/S CODE) ................ 6-3 TOOL NUMBER CODE (T FUNCTION/T CODE) ......................................... 6-4 SPECIFYING THE FEED RATE (F FUNCTION) ........................................... 6-5 PREPARATORY FUNCTION (G FUNCTION) .............................................. 6-6 PROGRAM ...................................................................................................... 6-7 COORDINATION SYSTEM ............................................................................ 6-8 MDI KEYBOARD & PANEL ....................................................................... 6-9 MDI KEYBOARD FUNCTIONS ..................................................................... 6-10 FUNCTIONAL BUTTONS DESCRIPTION................................................... 6-11 FUNCTION OPERATION..........................................................................

7 CLEAN AND MAINTENANCE


7-1 DAILY MAINTENANCE................................................................................. 7-1 7-2 WEEKLY MAINTENCE................................................................................... 7-2 7-3 SEMIANNUAL MAINTENANCE.................................................................... 7-2 7-4 ANNUAL MAINTENANCE............................................................................. 7-3 7-5 ENVIRONMENTAL CLAIMS.......................................................................... 7-3 7-6 OUR GOAL....................................................................................................... 7-3 7-7 WASTE TREATMENT..................................................................................... 7-4 APPENDEXI-M CODEAPPENDEX II-G CODE -Caution: Spindle Operation

LEADWELL
PREFACE
Thank you for purchasing the CNC MACHINE TOOL CENTER. We at Leadwell are confident your purchase will greatly expand your work capacity and efficiency. This issue has been prepared to assist you on ordering replacement, servicing parts, technical problem for the type of V-40. Due to constant improvement in design, you may find slight variations from the machine delivered to you. This merely indicates that equipment improvements have been made to better meet your requirements. If you have any question on your machine or this publication, please contact your Leadwell dealer or local agent.

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BRIEF INTRODUCTION OF LEADWELL
Founded in 1980, Leadwell CNC Machines Mfg., Corp., is now the largest CNC machine tool maker in Taiwan. Leadwell is constantly searching for perfection by upgrading the performance, product quality and reliability of its products which range from CNC Vertical /Horizontal Machining Centers, Turning Centers, Plastic Injection Molding Machines, Grinders, Tapping/Drilling Machines to Laser Cutting Machines, 5-face Machining Centers and Flexible Manufacturing Systems (FMS). In 1993 Leadwell received the Outstanding Product Award --SYMBOL OF EXCELLENCE and its quality passed ISO recognition. Hence, Leadwell products are recognized as highly reliable. In October, 1997 Leadwell has received the National Quality Award by the Executive Yuan, R.O.C. We have developed our products total quality management with outstanding result. January of 1999, the grate month, Leadwell passed a certification of ISO-14001 from the Bureau of Commodity Inspection And Quarantine (BCIQ) Ministry of Economic Affairs Taiwan.

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CHANGES AND COPYING
Leadwell reserves the right to make any change or modification to this manual without giving previous notice and without incurring any obligation. You may not reproduce or transmit in any form or by any means without the written permission of Leadwell.

Copyright 2005 LEADWELL CNC Machines Mfg., Corp. All rights reserved.

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1 SAFETY PRECAUTIONS
This machine is provided with a number of safety devices to protect personnel and equipment from injury and damage. Operators should not, however, rely solely upon these safety devices but should operate the machine after fully understanding what special precautions to take by reading the following statements thoroughly.

1-1 SAFETY RULES


However, safe operation cannot be ensured if operators use a CNC Machine Center improperly or do not follow safety rules properly. Failure to comply with these rules may result in death, injury, or damage to the machine and/or products. In addition to the safety information in this manual, common sense tells us there are many "Don'ts" when operating a machine. Unless an operation is specifically stated in this instruction manual, consider that operation a "Don't". 1-1-1 The basic conditions given below must always be strictly followed. Only qualified personnel are permitted to maintain and/or operate this machine. Read the instruction manual thoroughly and make sure the contents are completely understood in order to operate a machine efficiently and safely. Always keep this safety paragraph and the instruction manual at a designated place near the machine so that they can be easily accessed whenever required. Use safety shoes which are not damaged by oil, safety goggles with side covers, safety clothes and other safety protection. Keys must be kept by a senior qualified person. Be sure there are no articles around the machine. Turn off the power source before leaving, checking and daily work. All persons concerned with operation and maintenance of this machine must be aware of the emergency stop buttons and switches' location, functions and operation. In the event of power failure, turn off the main circuit breaker immediately. Use the recommended hydraulic oils, lubricants and grease or acceptable equivalents. 1-1

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Replacement fuses should have the proper current ratings. Protect the NC unit, operating panel, electric control panel, etc., from shocks, since this could cause a failure or malfunction. Do not change parameters, volumes and other electrical settings unnecessarily. If such changes are unavoidable, record the values prior the change so that they can be returned to their original settings if necessary. Do not soil, scratch or remove the caution plate. Should it become illegible or be missing, order another caution plate from the supplier. Whenever operating a forklift truck, over-crane similar equipment, special care should be taken to prevent collisions and damage to surroundings.

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1-2 GENERAL SAFETY INSTRUCTIONS
1-2-1 CAUTIONS OF OPERATING MACHINE:
Only well-trained personnel may operate this machine. Always wear helmet, protecting glasses, safety shoes and other protecting equipment as required while operating this machine. Do not wear loose clothing or jewelry that can be caught by moving parts of machine. Do not touch the chip and blade tip of the cutter with naked hands or the moving parts with gloves. During operating, do not take the chip away or touch the rotating portion parts with naked hands and other tools. When performing heavy-duty machining, carefulley prevent chips from being accumulated since hot chips can catch fire.

Do not touch any switches with wet fingers. Always remember the position of the emergency stop button, so that you can press the button immediately if accident occurred. Never operate the machine, unless everything is completely set down. Do not use fuses other than those are specified. Pay attention to the high voltage devices and keep away from them as possible as you can. When the machine is operating, do not put your hands into the rotating and moving objects. Stop the machine before adjusting the position of coolant nozzle or disposing the chips. Always turn off the power before performing maintenance or inspection. Cables, cords or electric wires whose insulation is damaged can produce current leaks and electric shocks. Before using, please check their condition. Do not operate switches with gloves. This could cause malfunctions, damage, etc.. Do not cut the kind of material which are easy to cause fire on this machine, such as magnesium, magnesian ally or other material with lower melting point. During automatic operating, never open the machine door occasionally. During the time of worming, do not touch or operate the machine parts.

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1-2-2 ROUTINE INSPECTIONS:
Check pressure gauges for proper reading Check motors and other parts for abnormal noises. Check the motor lubrication, sliding parts for evidence of proper lubrication. Check safety covers and safety devices for proper operation. Before the first time to use, each sliding parts must be freshly lubricated after unpacking or keeping the machine idle for a period. For the lubricant and so on, keep the lubricating oil pump working until oil oozes out from wiper. Contact our service station or agents in connection with what procedure should be taken since it depends on the type of machine. Clean the tank so that any abnormalities can be found easily. Make sure that the gauges for hydraulic pressure, air pressure, lubricating oil pressure indicated the correct values. Make sure that lubricating oil and hydraulic oil are properly supplied to the correct places. Oil reserviors should be filled to indicated levels. Check and fill it up, if necessary. Check the coolant level on the tank, and fill it with coolant, if necessary. All parts and waste oils should be removed by the operator and placed far enough away from the machine set.

1-2-3 WARM UP AND PREPARATION:


The power cable from the factory feeder switch to the machine main circuit breaker must check if there is a sufficient sectional area to handle the electric power usage. Warm up the machine, especially the spindle and feed shaft by running them for ten to twenty minutes with about half or one-third the maximum speed in the automatic operation mode. Wire ropes or slings should be strong enough to handle the loads and should conform to the mandatory provisions. Tools should conform to the machine specifications, dimensions and type. After installing a tool, make a trial run.

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1-3 THE DIAGRAMS AND DRAWINGS OF SAFETY
1-3-1 WARNING SIGNS AND LABELS:

There are several specific safety signs and labels on your machine. These signs and labels are attached to the machine at easy-to-see locations. DANGER: Indicated an imminently hazardous situation, which if not avoided, could result in death or serious injury. WARNING: Indicated a potentially hazardous situation, which if not avoided, could result in death or serious injury. CAUTION: Indicated a potentially hazardous situation, which if not avoided, might result moderate danger to the machine and death or serious injury. LABELS: Indicated some special purpose or production examined by Q.C. DEP.. Make sure that you can read all warning and instruction labels. Clean or replace these labels if you can not read clearly. By using a cloth, water and soap clean surface of them. Do not use solvent, gasoline or unknown solution. You must replace new labels if they are broke, missing or can not be recognized. In addition to the information given on safety labels, there is a variety of other cautionary information which must be observed by operators during machine installation, operating and maintenance. Read all safety-related information carefully. Failure to observe the danger of caution information can lead operators a serious injury or damage to the machine. Always observe this information during machine installation, operation and maintenance. Those warning and sign labels as shown as following pages.

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1-3-2 WARNING SIGNS AND LABELS: (Drum type ATC)

CAUTION
A.Please check cylinder oil level regularly.(specification R32) B.To ensure smooth running and prolonged life of the spindle,Please warm up to the recommended procedure below. (1) Only run the spindle with correct tool loaded.Never run the spindle without tool. Please give close attention to the dynamic balancing requirement of tooling before running at high speed.

(O)
(2) Check list of spindle warming up procedure. Situation Spindle speed Time (Max.speed=100%rpm) (Minute) 30% 15 15 15 15 15 15 15 15

(X)

Check item 1.Any noise

Daily running

2.Any abnormal vibration 3.Temperature rise less than 20C

Spindle has been idled over 72hrs Spindle has been idled over two weeks

1.30% 2.60% 1.25% 2.50% 3.65% 4.80% 5.100%

1.Any noise
2.Any abnormal vibration 3.Temperature rise less than 20C

1.Any noise
2.Any abnormal vibration 3.Temperature rise less than 20C

Please notice every step of the process, if the temperature rise exceeds 20C,please decrease the speed to 1000rpm;after the temperature is higher than environmental temperature about 5C,keep on warming up according to the list above. The definition of 20C is that the temperature difference between spindle and environment should be less than 20C. If not resolvable abnormal situations happen during operation,please contact with agents. If speed exceeds 8000rpm, the dynamical balance of the tool must below 2.5u.

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1-3-3 WARNING SIGNS AND LABELS:

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1-3-4 WARNING SIGNS AND LABELS:

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1-4 DANGER AREAS
1-4-1 THE AREA WITH MOVING PARTS: When no safety guarding, the inside of machine is an extremely dangerous area due to High-speed spindles rotation, tool X, Y and Z axes movements, tool magazine rotation, tool arm rotation, swin arm of pallet rotation and quill motions. In addition to chips and coolant are constantly bouncing and splashing in a wet, very hot environment. In electric controlling cabinet, it is touched, can produce current leak and electric shock without protection or insulation acrylics. So we had not stuck labels on the cabinet but also warning statements in the instruction manual. (Refer to the following drawings)

All areas inside the body cover are Danger area.

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1-4-1 COMPONENTS HIGH VOLTAGE:

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2 MACHINE FEATURE:
2-1 NOMENCLATURE: V-30

ITEM
1 2 3 4 5 6 7 8 9 10 11 12 COLUMN UNIT

DESCRIPTION
SPINDLE HEADSTOCK UNIT SPINDLE UNIT TABLE UNIT SADDLE UNIT BASE UNIT DUAL COIL TYPE CHIP CONVEYOR SHEET METAL ENCLOSURE GUARDS UNIT OPERATION CABINET UNIT THREE AXES TRANSMISSION UNIT & TELESCOPIC COVERS POWER CABINET UNIT COOLANT TANK UNIT

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V-40

ITEM
1 2 3 4 5 6 7 8 9 10 11 12 BASE UNIT SADDLE UNIT TABLE UNIT

DESCRIPTION
AUTOMATIC TOOL CHANGER UNIT

SPINDLE HEADSTOCK UNIT SPINDLE UNIT SHEET METAL ENCLOSURE GUARDS UNIT OPERATION CABINET UNIT THREE AXES TRANSMISSION UNIT & TELESCOPIC COVERS COLUMN AND BALANCE WEIGHT UNIT POWER CABINET UNIT COOLANT TANK UNIT

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2-2 MACHINE OUTLINE DIMENSION:

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MACHINE OUTLINE DIMENSION (OPTION)

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2-3 SPECIFICATION OF MACHINE: V-30
Capacity
X-axis travel Y-axis travel Z-axis travel Distance from table(pallet) top to spindle end Distance from column front to spindle center mm(in) mm(in) mm(in) mm(in) mm(in)

760(30) 410(16) 410 (16) 130-540(5.1-21.3) 438(17)

Table
Size of working surface Permissible mass of workpiece Table working surface configuratin Height from floor to table top mm(in)xmm(in) kg(lb) mm(in) mm(in)

890x400(35x15.7) 300(660) 18Tx125x3 830(32.6)

Spindle
Spindle speeds Number of spindle speed ranges Spindle nose(nominal size,NO.) Spindle bearing inner diameter Ratios Max. spindle torque Transmission Tool clamping force Kg(lb) N.M(ft.lbf) mm(in) min-1

8000 1 7/24 Taper,NO40 70 (2.75) 1:1 95.5(70.4) H.T.D Belt 800 (1760) 20/20/15(66/66/50) 5(16.6) 1260(49.6)

Feedrate
Rapid traverse Feedrate Jog feedrate m/min(IPM) m/min(IPM) mm/min(IPM)

A.T.C
Tool shank(nominal size,NO.) Retention knob(nominal size,NO.) Tool storage capacity Max. tool diameter(with adjacent tools) Max. tool diameter(without adjacent tools) Max. tool mass Max. tool length Tool change time tool to tool Tool change time chip to chip Tool selection mm(in) mm(in) kg(lb) mm(in) sec sec

Drum type
BT-40

Arm type

MAS-P40T-IJIS-B-6339 20 95(3.7) 150(5.9) 7(15.4) 250(9.8) 7.5 13 Random 24 80(3.15) 110(4.3) 7(15.4) 250(9.8) 3 10

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A.P.C
Number of pallets Method of pallet change Pallet changing time MAG drive method sec

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Motors
Spindle motor 30min/cont X-axis feed motor Const torque Thrust force Ball screw Goo-G Y-axis feed motor Const torque Thrust force Ball screw Goo-G Z-axis feed motor Const torque Thrust force Ball screw Goo-G Hydraulic pump motor Lubricant pump motor Coolant pump motor KW(HP) KW(HP) Nm Kgf mm G KW(HP) Nm Kgf mm G KW(HP) Nm Kgf mm G KW(HP) W KW(HP)

FANUC
7.5(10) 1.2(1.6) 8 410

Motor type
p12/8000i c8/2000i

36xP10x1248L 0.23 1.2(1.6) c8/2000i 8 410 40xP10x888L 0.23 1.8(2.4) c12/2000i 12 610 40xP10x1120L 0.175 --4 50HZ-0.5(0.67) / 60HZ-0.76(1)

Guide way
X guide way Width Guide distance Y guide way Width Guide distance Z guide way Width Guide distance mm(in) mm(in) mm(in) mm(in) mm(in) mm(in)

LG24-35-1640L-2 334 (13.1) 472 (18.5) LG24-35-1000L-2 694 (27.3) 445.5 (17.5) LG24-35-1080L-2 434 (17) 464 (18.2)

Power sources
Electrical power supply KVA

25

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Compressed air pressure Compressed air flow rate Mpa psi L/min

0.6(87) 400

Capacity
Hydraulic oil tank Lubricant tank Coolant tank L L L

--2 200/300 (OPT)

Machine size
Height of machine Floor space Mass of machine mm(in) mmxmm(in) Kg(lb)

FANUC
2430(95.6) 2100(82.6)x2721(107) 4500(9000) 0.01/FULL +/-0.005

Miscellaneous
Positioning accuracy Repeatability mm mm

Cutting capacity
Milling Drilling Tapping c.c mm

210 38 M30

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2-3 SPECIFICATION OF MACHINE: V-40
Capacity
X-axis travel Y-axis travel Z-axis travel Distance from table(pallet) top to spindle end Distance from column front to spindle center mm(in) mm(in) mm(in) mm(in) mm(in)

1020(40.2) 510(20.1) 510 (20.1) 160-670(6.3-26.4) 515(20)

Table
Size of working surface Permissible mass of workpiece Table working surface configuratin Height from floor to table top mm(in)xmm(in) kg(lb) mm(in) mm(in)

1200x510(4721x19.7) 500(1100) 18Tx100x5 830(32.6)

Spindle
Spindle speeds Number of spindle speed ranges Spindle nose(nominal size,NO.) Spindle bearing inner diameter Ratios Max. spindle torque Transmission Tool clamping force Kg(lb) N.M(ft.lbf) mm(in) min-1

8000 1 7/24 Taper,NO40 70 (2.75) 1:1 114.6(84.5) H.T.D Belt 850 (1870) 20/20/15(66/66/50) 5(16.6) 1260(49.6)

Feedrate
Rapid traverse Feedrate Jog feedrate m/min(IPM) m/min(IPM) mm/min(IPM)

A.T.C
Tool shank(nominal size,NO.) Retention knob(nominal size,NO.) Tool storage capacity Max. tool diameter(with adjacent tools) Max. tool diameter(without adjacent tools) Max. tool mass Max. tool length Tool change time tool to tool Tool change time chip to chip Tool selection mm(in) mm(in) kg(lb) mm(in) sec sec

Drum type
BT-40

Arm type

MAS-P40T-IJIS-B-6339 20 95(3.7) 150(5.9) 7(15.4) 250(9.8) 7.5 13 Random 24 80(3.15) 110(4.3) 7(15.4) 250(9.8) 3 10

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A.P.C
Number of pallets Method of pallet change Pallet changing time MAG drive method sec

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Motors
Spindle motor 30min/cont X-axis feed motor Const torque Thrust force Ball screw Goo-G Y-axis feed motor Const torque Thrust force Ball screw Goo-G Z-axis feed motor Const torque Thrust force Ball screw Goo-G Hydraulic pump motor Lubricant pump motor Coolant pump motor KW(HP) KW(HP) Nm Kgf mm G KW(HP) Nm Kgf mm G KW(HP) Nm Kgf mm G KW(HP) W KW(HP)

FANUC
9(11.7) 1.2(1.6) 8 410

Motor type
p15/8000i c8/2000i

40xP12x1580L 0.23 1.2(1.6) c8/2000i 8 410 40xP10x1248L 0.23 1.8(2.4) c12/2000i 12 610 40xP10x1120L 0.175 --4 50HZ-0.5(0.67) / 60HZ-0.76(1)

Guide way
X guide way Width Guide distance Y guide way Width Guide distance Z guide way Width Guide distance mm(in) mm(in) mm(in) mm(in) mm(in) mm(in)

LG24-35-2040L-2 409 (16.1) 774 (30.4) LG24-35-1240L-2 928 (36.5) 434 (17) LG24-35-1200L-2 434 (17) 437 (17.2)

Power sources
Electrical power supply KVA

25

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Compressed air pressure Compressed air flow rate Mpa psi L/min

0.6(87) 400

Capacity
Hydraulic oil tank Lubricant tank Coolant tank L L L

--2 200/300 (OP)

Machine size
Height of machine Floor space Mass of machine mm(in) mmxmm(in) Kg(lb)

FANUC
2585(101) 2990(117.7)x2929(115) 5400(11880) 0.01/FULL +/-0.005

Miscellaneous
Positioning accuracy Repeatability mm mm

Cutting capacity
Milling Drilling Tapping c.c mm

210 38 M30

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3. TRANSPORTATION:
3-1 PRECAUTION:
1. Only trained, qualified workers should operate forklift trucks, cranes or similar equipments and apply slings. 2. The wires used to lift should be checked that they are strong enough for the weight of machine center and in good condition. The dimensions of wire ropes specified in manual. (Refer to drawings) 3. Be sure that the wires will not come into contact with any delicate parts of machine center. Preotect machine by placing cloths or wooden blocks. 4. Before hoisting the machine, make sure all moving units are fixed in place. 5. Be careful and avoid the hoisting wires contacting with any piping, unit, parts, electric cables. 6. Check around the site of machine and make it clean, proper to be installed, that is, User may keep machine away from jolts during move or transport machine. 7. Always inspect slings, chains, hoists or other lifting devices prior to us and never work on a component while it is hanging from a crane or other lifting mechanism. 8. The floor of machine located must be firm, in order to ensure vibration free and secure fastening. Should the floor not be firm, a concrete foundation is recommended. 9. Keep the machines center of gravity at the center of the forks. Refer to the next page drawings for hoisting.

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3-2. TRANSPOTATION DRAWING

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3-3. TRANSPORATION-FLOOR DRAWING

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4. INSTALLATION AND PREPARTION:
4-1 PRECATION:
1. Only trained, qualified workers should operate forklift trucks, cranes or similar equipment and apply slings. 2. Use only wires of dimensions specified in the manual. They must be strong enough to support the weight of the machine. 3. Before hoisting the machine, make sure that each of the units is fixed securely. 4. Be careful during remove the machine to proper site and install it. 5. Keep clean around the machine and floor. 6. be sure electrical cables and wire will not be damaged during installing machine. 7. After installation and clean, connect the wire to the power source and ensure the requirement of power capacity is proper. 8. Before using, remove the anti-rusty oil by rags with paraffin or fueloil. Toluene compounds must not be used.

4-2. ENVIRONMENTAL REQUIREMENT:


1. Where the machine avoid exposing to the direct sunlight and/or near to a heat source, etc.. Ambient temperature during operation should be 0 thru 40. 2. Avoid a location where the humidity is considerable fluctuating and/or it is highly humid, normally 75 and below in relative humidity. 3. Avoid using the machine under such invironments as to be specially dustful and/or to have a vaporous. organic corrosive gas highly concentrated. 4. Where there is no vibration source in the surroundings. 5. Flat and smooth ground without dust or other particles. The required bearing pressure of the floor is at least 5000kg/. 6. The machine must be protected from electrical noise sources, such as electric welders and an electric discharge machines. 7. Always ground machine independently, the ground resistance is 100 ohms or less and the length of ground cable is as short as possible. 8. The sound pressure level at the operators position is under 85 dbA. 9. Foundation should be constructed of either, reinforced or non-reinforced concrete with thickness and consistency compatible to industry standards for machine weight.

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4-3 THE PRECEDURE OF INSTALLATION MACHINE:
1. Position the machine after settling down the machine to the adequate place. 2. Put the foundation pads under the foundation bolts and according to the drawing of foundation to position machine.

RIGHT SIDE VIEW FOUNDATION DRAWING NO.VW02001800

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3. Remove all the fixed blocks and screws: a. Take away the fixed screws of counter balance in column. b. Remove the fixed blocks between saddle and base. c. Remove the fixed blocks between saddle and transmission bracket of Y-axis. d. Remove the fixed block under ATC. e. After power on, let headstock upward a little bit to remove the supported block under spindle. f. Use MPG and let spindle headstock downward a little bit, then take away the rod of counter balance in column. g. Put on the 2 parts on the machine for column.(Refer to the next page following drawing.) Refer to the following drawings.

V-40 THE FIXBLOCKS OF MANCHINE

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Right side and left side each way put on a part.

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4. Install the accessaries: a. Lock up the front telescopic cover of y-axis. b. Mount on the front cover of table. c. Lock up the left side cover of enclosure. d. Mount the protecting cover on ATC. e. Pipe coolant pump and coolant tank after settling down the coolant tank. 5. Replace the z-axis motor on transmission housing, if is removed: a. Tighten the screw S1 on the coupling of z-axis. b. Tighten the screw S2 on the motor side of z-axis. (Refer to the following drawing) c. Make 3 axes return to home position after power on.

V-40 MOUNTING DRAWING OF Z AXIS MOTOR

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6. THE PROCEDURE OF ADJUSTING LEVEL : 1. Let three axes return to the home position. 2. Clean the table surface and put the levels gauge on just as the drawing shown. 3. Adjust the foundation bolts and nuts to make the foundation bolts locate within the slot of pad.

4. Move X axis to 510mm and Y axis to -255mm . Adjust the foundation bolts and ensure the bubbles of level gauges in the middle position or keep the deviation within 0.01 mm. 5. Move Y axis to the zero position and -510mm(for V-40) by adjusting the bolts and nuts to make the difference between the two points within 0.01 mm(V1) /0.04 mm(V2). 6. After returning Y axis to -255mm, move X axis to zero position and1020mm. The difference value between two points should be within 0.05 mm(V1)/0.04mm(V2). 7. Tighten the foundation bolts and nuts.

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7. Correct the drum type tool changing position: a. Z axis returns to home position by manual. b. Put a tool into spindle by the switch of clamp or unclamp and make sure the distance between spindle nose and tool edge is within 0.6-0.8 mm.(As drawing shown)

c. Turn off the air source, then orientate spindle by M19. d. Push the tool magazine toward spindle by hand and check if the tool key match with tool keyway. e. Reconnect the air source system. f. Ensure the movement of tool magazine is smoothly by M21, M22 under manual mode. g. Adjust the screws of the air cylinders located on top of tool magazine, if the movement is stagnant. h. If there is a distance along Z-axis between tool magazine and tool in spindle, adjust to match with tool key of tool magazine by parameter no. 1850(Z) for 21MB/18MC, FANUC. i. If there is an offset between the changing tool pocket of tool magazine and tool key on spindle, adjust by the orientation pad mounted on orientation wheel of spindle. j. Make sure everything is smoothly, then from beginning to operate.

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7-1. Correct the arm type tool changing position:

a. Z axis returns to home position by manual. b. Put a tool into spindle by the switch of the clamp or unclamp and make sure the distance between spindle nose and tool edge is within 0.6-0.8 mm.(As drawing shown)

ARM
c. Then press the d. Press the e. Press the MPG button. SPDL ORIEN DGONS PARAM button.

f. (Look CRT) Press the button below the (PARAM). g. (Look below PAGE) Press the h. Press the MDI i. Press the 1 button. button.(page down)

button. [When (PWO=0 (Can not change date), PWO=1 (can change date)]

j. Press the INPUT button.(showing 100 alarm)

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k. Press the DGONS PARAM button l. (Looking CRT) Press the button below the (DGNOS) L l. press the NO. Q P m. Press the n. Press the 5 button.

5 button.

buttons.(normal D0525 10000000)

INPUT 0

o. Press the 1

1 1

0 0 0

bottons. 10000000) then press the

p. Press the INPUT

buttons.(after finish change it back to D0525 MPG

q. (Make sure the spindle nose higher than arms top) Press the

SP

buttons. button the arm will be move, so take care of you fingers)

r. (When you press the CYCLE

s. Make sure the distance between spindle nose and arms top is within (BT type 5.90 0.05mm. (for CAT type is 3.30.05mm) (If you want to arm to reverse, change the D0526 00100000 to D0526 00100001 then press CYCLE the START fingers.) button .(before you press the cycle start button take care of your

t. Change the DGNOS D0525 10000000 and D0526 00100000 and PARAM PWO=0 BACK u. Press the MDI M 6 /.# EOB buttons.(for test auto tool change)

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5. KEY PARTS FEATURES
5-1 PNEUMATIC SYSTEM :
5-1-1. FRL UNIT :

Filter Regulator

Lubricator

NO. 1 2 3 4 5 6 7 8 9 10 11 12 13

NAME Body Bonnet Valve Assembly Filter Element Baffle Diaphragm Assembly Deflector Bowl Spring O Ring(Valve) MY seal O Ring

NO. 1 2 3 4 5 6 7 8

NAME Body Sight Dome Filter Cup Damper Guide Needle Valve Bowl O Ring Damper

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5-1-2. TECHNICAL DATA AND OUTLINE DIMENSION :
a. TECHNICAL DATA :

TYPE Max. operating pressure Min. operating pressure Regulating range Ambient and media temperature Pressure gauge indicated Filter rating Filter bowl capacity Max. flow rate Lubricator bowl capacity Recommanded oil Range of lubricator function

AC3010 FILTER REGULATOR LUBRICATOR 9.9 kgf/c 1 kgf/c

0.58.5 kgf/ c 560 10 kgf/c 5 m 20 cm3 1700 l/min 50 c m3 ISO VG 32 (20) 5 drops/min, PIN=5 kgf/ c, 40l/min

NOTE : 1. Polycarbonate bowls may be damaged and possibly fail if exposed to synthetic oils, thinner solvents, trichlorethylene, kerosene or other aromatic hydrocarbons. used in above atmosphere, please use a metal bowl. 2. Unsuitable for flow is below 100 normal l/min. 3. The drain line should be 8 mm or more and overall line should be less than 5 M. When

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b. OUTLINE DIMENSION :

5-1-3. THE SETTING METHOD OF FRL UNIT :


a. Check pressure supply before adjusting system pressure. b. The adjustment knob is a locking type. Pull the knob upward from the bodyuntil an orange band is visible. (Show on the drawing)

c. Adjust as necessary, that with watch of the pressure gauge and clockwise rotaton of the knob results in a increasing pressure or counterclockwise turn will reduce the pressure. d. Then push the knob back into locking position after adjusting. e. Adjust oil droplet by turning a knob of needle valve, clockwise turn will increase oil capacity and counterclockwise turn(fully open) will stop the oil droplet.

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5-1-4. THE LOOP SKETCH OF PNEUMATIC SYSTEM :

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5-1-5 THE ROUTE SKETCH OF PENUMATIC SYSTEM(STANDARD)

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5-1-6 OPTION FOR AUTOMATIC TOOL LENGTH MESUREMENT

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5-2 COOLANT SYSTEM:
5-2-1 OUTLINE DIMENTION OF COOLANT PUMP:

5-2-2 TECHNICAL DATA : TYPE Max. operating pressure Min. inlet pressure Liquid temperature range Max. ambient temperature

GRUNDFOS CH4-20 10 bars (0 - +40) 6 bars (+41 - +90) 0.75 bar (20/ 50Hz) 0.68 bar (20/ 60Hz) 0 - +90 +55

5-2-3 POSITION OF TERMINAL BOX : a. The terminal box can be changed to any one of 0, 90, 180. It is not allowed to be changed by user or owner of this machine. 5-2-4 PIPEWORK : a. The pipe should be fitted so that any tension caused by variations in temperature does not affect the pump. A strainer is recommended in cases where solids could enter the suction pipe and block the pump. b. The pump suction port must be below the lowest coolant level, for the pump is not self-priming. c. If a hose is used as suction pipe, it must be non-collapsible and every joint of the suction pipe should be completely tight. d. The discharge pipe should be at least the same diameter as the discharge port of the pump to minimize pressure drop, high flow velocities and noise. 5-7

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5-2-5 ELECTRICAL CONNECTIONS : a. The electrical connections should be carried out in accordance with local regulations. b. The operating voltage and frequency are marked on the nameplate mounted on pump. c. The pump must be connected to an external on/off switch. NOTE : Never make any connections in the pump terminal box unless the electricity supply has been switched off. 5-2-6 PHASE OF THE PUMP : a. Signal- phase motor (1x110/220V, 60Hz), do not incorprate motor protection and must be connected to an approved motor starter. The other incorporate a thermal overload switch and require no additional motor protection. b. Three-Phases motor must be connected to a motor starter, the set nominal current of which must correspond to the electrical data on the nameplate. NOTE : 1. Do not start the pump at first time using until it has been filled with coolant. 2. Every connection are made as shown on the inside of the terminal box cover. 3. The pump should rotate counter0clockwise when viewed from the motor end and arrows on the motor fans cover indicated the correct direction of rotation. 4. To reverse the direction of rotation, switch off the power supply and interchange any two of inputing supply wire. 5-2-7 TROUBLE SHOOTING : FAULT CAUSE Pump does not start. Supply failure. Control circuit has cut out or is defective. Motor is defective. Pump is blocked by impurities. Pump runs but gives no coolant. Pump is not filled with coolant. Suction or discharge pipe is blocked by impurities. Leakage in suction pipe. Foot or check valve is blocked. Pump runs at reduced capacity. Wrong direction of rotation(three-phase). Suction lift is too great. Suction or discharge pipe is blocked. Pump is blocked by impurities. Foot or check valve is partly blocked. Pumpstops during operation. Thermal overload switch in motor or external motor protection cuts out. Control circuit has cut out. 5-8

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5-3 SPINDLE OIL COOLER SYSTEM
5-3-1 OUTLINE DIMENSION: TYPE CO-4PT (L050250t20)

5-3-2 CIRCUIT DIAGRAM:

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5-3-3 WIRE CONNECTION: 1. Be sure R.S.T are in phase after turning on. 2. Check insulation of compressor and pump before running. 3. 23C temperature meter must set at 25. 4. Operation switch should be ON position. 5. When the negative phase relay is triggered, reconnect two of R.S.T three lines of power wire. 5-3-4 GENERAL CAUTION: 1. The oil cooler is designed for reducing heat and cooling spindle of CNC machinery. It can not be used out of the range as following illustration.

2. Oil cooler usse mineral hydraulic oil or lubrication oil and the viscosity is 22-32 Cst. Phosphoric ester, chlorinated, hydrocarbon type fluids, cutting oil, grinding oil, medicine or corrosion liquids, gasoline, kerosene fuel and water-soluble liquid can not use on this unit. 3. Do not fall it flat and strike it as moving and put it on a level and solid floor. 4. Locate the oil cooler at well ventilation place where is free from fire hazard and from direct sunlight or heat. 5. Be sure the pressure of oil pump is set from 4 to 8 kg/cm2. 6. The pressure loss of outlet pipe should be below 3 kg/cm2. 5-10

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7. Be sure the installation place of oil cooler unit where exhausting and air suction can be well performed. (Refer to the following sketches)

8. Fit a suction strainer to the suction end of oil piping which is of 100 to 150 mesh (10-15mm metal net), therefore, it will be free from damage of compressor and drop of cooling capacity. Both suction and discharge pipes outside must be designed that the size larger than the size of outlet and inlet of oil cooler. 9. Before removing the air filter must wait for more 10 minutes after turning off switch. 10. When the refrigerator once stops, wait for more 3 minutes. If not necessary, do not ON-OFF of the refrigerator. 5-3-5 MAINTENANCE : 1. Be sure to turn off the main power switch when the oil cooler is checked or maintained. 2. Do not brush or use polishing powder, acid, solvent, benzine and hot water to clean the surface of case. It is necessary, clean with dry cloths and neutral detergent. 3. Clean the suction strainer at the suction end of the oil cooler, oil pipes after work. 4. Wash the air filter once a week. 5. Clean up the dirt on radiator of oil cooler with compressive air once half year. 5-11

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5-3-6 TROUBLE SHOOTING: SITUATION CAUSE REMEDY Main power turned on, but Negative phase relay is Reconnect the wiring. the indicate lamp is not lit. triggered. Control circuit Replace the fuse. protector is blown. Pump runs but no oil flow Joint of oil piping is Check the joint of oil pipe and lower oil circulation rate loosened from suction side. at suction side and tighten of air. the loose joint. Clean the suction strainer. Change the oil of oil tank if the oil is contaminated. The oil level in tank is too Trace and refill up oil. low. undue pressure loss in oil Enlarge the oil pipe pipe cause actuation of diameter or trim shortly the relief valve. piping. Oil viscosity too high. Choose the appropriate oil. Pump runs but the Thermostat is OFF. Shift the thermostat setting refrigerator does not work. to the lower side until the refrigerator starts. Both pump and refrigerator Control circuit protector Replace the fuse. Check the power source. stop. failed. Power failure. Buzzer comes out while Air filter clogged. Clean the air filter. Obstacle block the suction Remove the obstacle. refrigerator runs. or exhausting port. High pressure switch Ambient temperature is too Move the machine to the actuated. high. lower temperature or far Thermostat is OFF. from heat source. Compressor motor overload Compressor out of order. Replace the compreessor. relay actuated. NOTE : 1. If alarm does not display, motor still runs but oil is not cool, please record the situation and ask technical service or local agent right away. 2. Damage from cleaning air filter irregularly is not included quarantee period. 5-12 Suction strainer clogged.

LEADWELL
5-4 LUBRICATION SYSTEM
5-4-1. OUTLINE DIMENSION:

5-4-2. FILL UP LUBRICATION OIL: a. After opening the cap of oil inlet, fill up the clean fresh oil till to the top line of high level. b. The oil tank should always preserve clean lubricant. c. In case of impurity remains in the oil tank, please take the oil away and wash the tank, oil net immediately. Then refill up new oil or it will fail the oil feeding. d. Adjust oil discharge by taking off the plastic cup and three E type retainers first. e. Pull the rod up or down till the requirement volumn of discharge is up to the scale on rod, then fix with the E type retainers. f. It is necessary to refill up lubricant oil if oil level is below the lower line during operating. NOTE : 1. The oil quantity will reduce gradually under normal application. 2. Be careful whether the motor is running normally or abnormally, if not, contact to the local agent or Leadwell service department. 3. The lubrication please use MOBIL VACTRA OIL NO.2 or SHELL OIL T68 or ESSO FEBISK68 or another brand of equivalence oil. PS: Normality each 1000 hours make to once protection. 5-13

LEADWELL
5-4-2-1 OIL RECOMMENDATION :
The following drawing is a plate of oil usage recommendation .

OIL USAGE RECOMMENDATION


BRAND ITEM LUBRICATOR OF PNEUMATIC AUTO LUBRICATOR SYSTEM APINDLE OIL COOLER SYSTEM HYDRAULIC SYSTEM GEAR OF ROTARY TABLE SPINDLE MOTOR GEAR BOC RARUS 424 CORENA S32 TERESSO 32 HYSPIN VG32 PERFECTO T32 VACTRA 2 VELOCITE 12 DTE LIGHT MOBILGARD DTE HEAVY MEDIUM TONNA T68 TURBO T32 TELLUS 32 OMALA 150 TELLUS 68 FEBIS K68 SPINESSO 22 NUTO H32 SPARTAN EP 150 NUTO H68 MAGNA BD68 HYSPIN VG32 PERFECTO T32 HYSPIN AWS32 ALPHA SP150 ALPHA SP68

MOBIL

SHELL

ESSO

CASTROL

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5-4-3 THE LUBRICATION SYSTEM SKETCHES OF AXES :

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5-4-4 THE LUBRICATION SYSTEM SKETCHES OF AXES :

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5-5 HEAT EXCHANGER SYSTEM :
5-5-1 OUTLINE DIMENSION OF HEAT EXCHANGER :

5-5-2 GENERAL CAUTION :


1. For using in an ambient with high moisture or oil mist content, calk it with sealing material around. 2. Keep the air inlet portion of heat exchanger open to fresh air. 3. Every month clean the fan net with clean water and reinstall in after completely dry. 4. Replace the filter once a year.

5-5-3 SPECIFICATION AND TECHNICAL DATA :


TYPE Cooling Capacity (w/k) Voltage Current Ambient temperature EA-5AR 25 AC 220V 0.6 A 35 below

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5-5-4 BASIC MAINTENANCE :
1. Check and ensure that hot air exhausted from the heat exchanger every day. 2. If no hot air exhausted, check top and lower fans on heat exchanger if they can rotate normally. 3. If one of them did not operate, check if the wire connection is correct. 4. If wire connected correctly, that means, the motor is out of order and contact with our service person to replace. 5. If both of fans stop to operate, check the circuit breaker if it is short. (CP4)

6. If the circuit breaker is normal condition, check the fans again after resetting. 7. If it still can not operate, please contact our service person to replace.

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6 OPERATION:
6-1 MISCELLANEOUS FUNCTION (M FUNCTION/M CODE) :
In operating this machine, specify on/off controls on the operation panel such as spindle start/stop, coolant on/off, mirror image, table indexing, tool change, etc.. Within 2 digits the address M. Two or more M codes other than specially approved combination are not allowed in the same block.

6-2 SPECIFYING THE SPINDLE SPEED (S FUNCTION/S CODE) :


Specify directly a spindle speed with 4 digits numerical values following the address S. S45 45 rpm S4000 4000 rpm Program example : S500 Specify the spindle speed M03 Spindle start S3500 Changing the speed at runing condition M05 Spindle stop M04 Reverse rotation at 300 rpm NOTE 1 : During spindle rotation, if the S command is given the spindle will run and change its speed. NOTE 2 : If an axis movement command is specified simultaneously with M03 or M04, spindle rotation and axis movement will start at the same time. If the axis movement command is specified simultaneously with M05, the spindle will stop after completing an axis movement.

6-3 TOOL NUMBER CODE (T FUNCTION/T CODE) :


Specify within a 2 digits numerical values following the address rang from 0 to 99. Program example : M06 T02 Change tool to No.2

NOTE : If only a T command is given, it is for NC memorized no action. However, if T command is specified simultaneously with M06, the tool changing fuction will be performed.

6-4 SPECIFYING THE FEED RATE (F FUNCTION) :


a. With a numerical value of 1 to 5000 following the address F, specify a speed at which the tool moves over a distance between two fixed points by linear or circular interpolation.

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F COMMAND F0001 F1 F0010 F0100 F5000 FEED RATE (mm/min.) FEED RATE (inch/min.) 1.0 1.0 10.0 100.0 5000.0 0.01 0.01 0.1 1.0 50.0

b. ACTUAL PROGRAM (METRIC UNIT) : G01 X150.0 F80 G02 X200.0 Y300.0 R400 G03 X250.0 Y50.0 R100.0 F300 NOTE : Be sure to use FXXXX together with G01, G02 and G03. c. FXXXX is not required for G00 (rapid traverse). NOTE 1 : The unit for F is either mm/min. or inch/min., indicating feed per minute. NOTE 2 : You may omit 0 in the upper digit of a numerical value.

6-5 PREPARATORY FUNCTION (G FUNCTION) :


GXX two-digit values following the address G shows what a program command means. This function prepares for spindle tool movement.

6-6 PROGRAM
6-6-1 SEARCHING OR CALLING PROGRAMS :
Classification Function Key switch Program number search Sequence number search SEARCH Address word search Address search Offset number Setting Mode switch PWE=1 button Function button Operation

[O]Program No. EDIT/AUTO PROGRAM [](Cursor) Program No. PROGRAM search[N] sequence No.[](Cursor) Search address PROGRAM and data input [](Cursor) PROGRAM Search address [](Cursor) [P/Q]Offset No.[INPUT]

AUTO

EDIT

EDIT

OFFSET

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6-6-2 PROGRAM EDITING:
Classification Function Key switch Program memory used Deletion of all program Deletion of a program Deletion of several PROGRAM blocks EDITING Deletion of a block Deletion of a word Alternation of a word Insertion of a word Setting Mode switch Function PWE=1 button button EDIT 0 0 0 0 0 EDIT EDIT EDIT EDIT EDIT Operation

PRGRM [P] [ INPUT] [O]9999 [DELET] [O]Program PRGRM No.[DELET] PRGRM [N]Sequence PRGRM No.[INPUT] PRGRM [EOB][DELET] Search the word to PRGRM be deleted [DELET] Search the word to PRGRM be alteredNew date[ALTER] Search the word to PRGRM be insertedNew date[insert]

EDIT

EDIT/AUTO

6-7 COORDINATION SYSTEM :


6-7-1 PROGRAMMING ZERO POINT :
When execute a program, it must be determined a program zero point at first. The programmer determines the zero point after viewing the machine drawing. The value of coordination determines a graphic position with 3 perpendicular lines mutually crossing at a point as shown as following drawing.

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6-7-2 COORDINATION SYSTEM :
The coordination system contains of 3 axes and 3 swivel axes as following sketch.

6-7-3 THE FLOWCHART OF ATC OPERATION :


Power on Return to the reference point on three axes Prepare the workpiece Call a proper program Locate all tools to tool pocket Mount tool onto the tool magazine Measure tool length and set tool compensation data Set work coordination system and zero point Prepare for automatic operation Dry run for testing program Machine program executing

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6-8 MDI KEYBOARD & PANEL

6-5

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OPERATION PANEL

SMALL

PANEL

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6-9 MDI KEYBOARD FUNCTIONS :
Address or numeric keys used to enter letters and numbers.

Cursor keys used to move cursor to expecting direction.

Page-up and page-down keys used to move screen on the CRT.

Help key used to get help with operations when operator does not know what to do next.

Reset key used to reset the CNC to release alarm or other setting.

Shift key pressed to input the lower right letter on the address/numberic keys.

Cancel key pressed to delete the input of letters or numbers on the key input buffer.

Input key pressed to input any address or numberic key in the key input buffer, then display on the CRT.

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Alter key pressed to alternate the characters of the input value and letters under program edit mode.

Under program edit mode, this key can insert the alphabet and numbers.

Under program edit mode, this key can delete the alphabet and numbers.

This key is pressed to display the current position.

This key is pressed to display and edit a program stored in memory.

Offset and setting key is used to display the offset value of workpiece, setting the variable parameter data.

System key is used to display and set the parameter, compensation value of pitch error or self-diagonostic data.

Message key is used to display alarm message, external operators message or alarm history.

Custom graph key is used to display dynamic graphic data.

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6-10 FUNCTIONAL BUTTONS DESCRIPTION :
CRT power on and off.

Selection mode to reference point

Start returning to the reference point

Jog feeding

Jog mode with incremental feedrate

Manual mode selection

Program teach Compensate the difference value between standard tool and tool wear position, working coordination system offset value. (For vertical machine, horizontal machine are not available function) Automatic operation

Program edit

Manual data input

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Incremental feed rate

Spindle orientation mode

Spindle revolution decreasement

Spindle movement with whole speed

Spindle revoluttion increasement

Spindle rotation with the direction of clockwise

Spindle stop

Spindle rotation counterclockwise Coolant A power on

with

the

direction

of

Coolant A power off

Automatic operation of coolant A

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OPERATION SELECTION :
Single block After executing one block of program, machine will stop. Block deletion A block include / in a program will be neglected

Optional stop After executing block, machine stops and include M01 code. Dry run Machine will move with jog feed rate in cycle operation and the F value will be neglected. Program test The M, S, T and B functions are neglected in automatic operation. Axis inhibit In cycle or manual operation, the position display as specified and M, S, T, B functions will be executed. Manual absolutely After executing this function, machine moves amount is not counted to present position on the work coordinate system by manual operation. Spare function button for spare function

Z axis cancel Cancel the movement of Z axis

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Cycle start Start automatic operation or cycle command

Cycle stop Stop feeding temporarily in automatic operation

Program stop Axes movement are locked and M, S, T functions can not be executed.

Axes traverse selection The direction of axes select during traverse.

Program protection Protect NC programs with key switch.

Tape plug Extension computer tape plug. (Optional selection)

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Override traverse selection Override traverse feeds with knob.

Emergency stop button Use for emergency situation occuring to stop machine operation.

FUNCTIONS OF SMALL PANEL :

DOOR OPEN

Door Open and Close Under MPG mode, Spindle stop rotating, the enclosure door can be opened and closed by hand. Or it is not opened under auto mode, until stopping program and spindle stop operating. (For CE type only) Spindle Reset Stop the rotation of spindle after press Feedhold button , under auto mode.

Program Restart Restart the programming commands that was interrupted.

TOOL UNCLAMP Tool Clamp and Unclamp Under MPG mode, when tool clamp and unclamp by pressing this button.

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Tool Magazine Rotation Tool magazine rotate with the direction of CW or CCW.

Emergency Release When over travers occured, presss this button, the axes can be moved again by MPG. One press moves one step.

Rapid Travers Feedrate The feedrate of rapid travers selectby turning the knob.

MPG Manual pulse generator turns by the handle bar.

INDICATE LAMP :

ATC Ready When the ATC is ready to change tool and reach to the home position or finish completely, the lamp will light on.

Axes Ready Axes movement are ready to home position, the lamp will light on.

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ALARM LAMP :
Coolant Alarm When coolant supply is not smooth or shortage, the lamp will light on and the message show on the screen. Spindle Orientation Alarm Spindle revolution or operation is abnormal, the lamp will light on and leave message on the screen.

Lubrication Alarm Lubrication supply is not abnormal, the lamp will light on and leave message on screen.

Emergency Alarm When emergency stop occure, the warning will be shown on the screen and the lamp will be light on.

Air Pressure Alarm Air pressure lose or below normal level, the lamp will be light on.

AIR

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6-11 FUNCTION OPERATION :
6-11-1 POWER ON AND OFF :
(1) Turn on the power source and switch on the lever near the top of electric controlling cabinet, then press the button to power on as well as watch on the CRT. Everthing is all right, press home mode and axes selection buttons to execute home command for being ready to run.

(2) Move X and Y axes to the center position or home position, then press power off button and turn off the main switch of power cabinet.

6-11-2 MANUAL FEED :


Press MPG button as mode selection

Select the direction of axis by pressing the axisal movement buttons at one time

Select the feed rate

Rotate the MPG to start manual feed and the feed rate is proportion to the speed of turning handle by hand.

6-11-3 RETURN TO REFERENCE POINT : 6-16

LEADWELL
Press the HOME button as mode selection.

Select the direction of desired axis and press the button. (The built-in lamp will light on)

Select the proper feedrate by turning the knob.

Press the Home Start button to start the movement at rapid traverse.

The indicate lamp will light till the reference point reach completely.

6-11-4 SPINDLE START :


Select the one of mode buttons of HOME, JOG, INCREASE JOG, MPG and TEACH.

Under MDI mode, Input the revolution value of spindle(S function) Press either the spindle rotation buttons.

Select the spindle speed and press either the spindle speed decreased or increased buttons. (NOTE : Be sure to confirm the S value when the manual spindle speed is used.)

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6-11-5 INCREASE JOG FEED :
Press the INC JOG button as mode selection.

Select the feedrate amount.

Select the direction of axes and release the button, the movement will be stopped.

X1 Metric input Inch input 0.001 mm 0.0001

X10 0.01 mm 0.001

X100 0.1 mm 0.01

X1K 1 mm 0.1

6-11-6 JOG FEED :


Press the JOG button as mode selection

Select the direction of designation axis to start the movement of axes. Release the button and the movement will stop.

Select the override feeding rate by the knob of switch.

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6-11-7 RAPID TRAVERSE :

Press the JOG button as mode as selection.

Turn the knob of override feeding for rapid traverse.

Press the TRAVERSE button and the appointed axis button at the same time. If release them, the movement will be stopped.

RAPID TRAVERSE (IN 100) X axis Y axis Z axis 20 M/min 20 M/min 15 M/min

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7 CLEAN AND MAINTENANCE
CAUTION : 1. Shut off the power before doing any maintenance or cleaning job and obey the instruction or you might be hurt. 2. Any clean or maintenance concerned with removing must be careful and only well-trained personnel can do it.

7-1 DAILY MAINTENANCE :


7-1-1 BEFORE POWER ON :
a. Inspect if the power cable and external cable are normally connected and the voltage capacity is matched as machine required. b. Check if there is oil or coolant leakage on the hydraulic or coolant pipes. c. Check if there are enough oil for the hydraulic unit, lubrication unit and coolant unit. d. Check if the pressure gauges of hydraulic unit and pneumatic unit were indicated to zero position. e. Check if the auto tool changer unit is at the normal position.

7-1-2 AFTER POWER ON :


a. Check if there is alarm message after NC power on. b. NC should be ready to execute the program. c. All the running components should be run at normal condition without noise. d. The pressure gauge for pneumatic system should be at 6 kg/cm2. e. Auto lubricator should be actuated to pump oil with flow setting to 3-6 c.c./cycle. f. The lubricant should flow out to the slideways. g. The wipers on the telescopic covers should be cleaned from the chips. h. Test tool changing unit and make sure the unit can work smoothly.

7-1-3 AFTER FINISHING DAILY WORK :


a. Inspect the oil level of auto lubricator tank to refill up, if it is necessary and is consumed. b. If there is water or dirt in the tank, relieve and change fresh oil.

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c. Check the level of coolant to refill up and flush the coolant pump through with clean water if there is impurities after use. d. Clean the chips on the chip tank, conveyor, tool tip and tool magazine. e. Remove and centralize the chips on the chip bucket out side of the shop. f. The coolant pump which is not being used during periods frost should be drained (shown as the following sketch) or it will be harmful for pipe and pump. Take off the primiing plug P and drain plug V for draining.

g. Turn off working light, power supplier and draw out the connector of power cable whenever finishing work.

7-2 WEEKLY MAINTENANCE :


a. Clean fan net of heat exchanger on electrical cabinet. b. Clean fan net of spindle oil cooler. c. Clean fan net of motor on the hydraulic tank. d. Clean the motor fan of chip conveyor . e. Clean the filter net inside of coolant tank. f. Clean ATC motor fan and the brake of surrounding motor. g. Fill the grease for the warm gear of ATC transmission unit.

7-3 SEMIANNUAL MAINTENANCE :


a. Check and re-adjust the machine level and static accuracy. b. Inspect the home position and reset, if necessary. c. Ensure there is enough of lubricant on the slideway, gear of reducer and change or refill the fresh oil, such as lubricant, hydraulic oil, oil cooler tank, etc.

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d. Inspect the backlash of ball screw on three axes. e. Inspect the repeatitive accuracy and geometric accuracy of machine. f. Replace the fan net of heat exchanger on electrical cabinet. g. Replace the element of filter on hydraulic tank or other accessary parts. h. Clean the electrical motor outside and turn off the power at first. i. Before cleaning the chip or dirt on the conduction block of sensor and magnetic switch, turn off the power. j. Check the smooth function of all limit switches for axes and clean the dirt or re-adjust the position, if necessary.

7-4 ANNUAL MAINTENANCE :


a. Follow the same procedures as mentioned above semiannual maintenance. b. Replace the hydraulic oil and oil filter according to the oil recommandation. c. Replace the filter for auto lubricator and clean the lubrication tank, coolant tank. d. Do not pour out the wasting oil or coolant liquid casually. Itd better remain in oil bucket periodically and send to the authorities concerned of shop to do with it. e. Check and correct the geometric accuracy of machine.

7-5 ENVIRONMENTAL CLAIMS :


God creates this world and gives humanbeing the rights to rule over the earth. Leadwell, a part of this family shall have responsibility and duty to keep the earth away from damage or pollution during producting. We all obey the laws and regulations through our policy of quality control management and concept of environmental protection issue. We have been devoted ourselves on the environmental management system no matter at work or in life. It is our final destination that to make a sustainable development business and to provid a pure clean environment to the generations.

7-6 OUR GOAL :


1. RESOURCES RECOVERY : Not only check devices periodically and save the resources but reuse the recyclable resources and develop new less-polluted resources. 2. REDUCING WASTE : Specify and recycle the waste and reduce the quantity of waste.

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3. WATER CONTROL : Inspec the water, wastewater drained off to the sewage treatment plant through our sanitary sewer. 4. AIR CONTROL : Reduce air pollutants, obey the laws about emissions standard of air pollution. remain a high quaility and all devices are in good condition.

7-7 WASTE TREATMENT :


1. DURING OPERATION :
a. Waste Oil : There is any leakage of oil or liquid during operating machine, stop and check machine. Meanwhile report to your supervisor or manager to solve. The waste oil, solution or liquid must pour into the stored bucket at plant or follow the rules and procedures of waste treatment of your own control measures. It can not be poured out at random and not be allowed draining down through sewer. b. Cutting Chips : Some of the cutting chips are able to recycle, after machining, the chips must seperate and restore by material. It is must be placed and treat according to the environmental regulations of local plant. c. Toxic gas : Check the concentration of exhaust emissions and the emission equipments. Control the value to standard request every cyclic inspection.

2. AFTER OPERATION :
Waste Machine : When machine is out of order can not be fixed, do not throw away directly and sepreat the machine to pieces by material. Some of the material can be recycled such as casting iron, steel, metal, etc.. Some of them can not be reused such as cables, electrical parts, motors, PCB board, etc.. Store the same parts according to their material to do with local dealer or the procedures of waste treatment on your own.

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L E A DW E L L
APPENDEX I
CODE M00 M01 M02 M03 M04 M05 M06 M07 M08 M09 M10 M11 M12 M13 M14 M15 M16 M17 M18 M19 M20 M21 M22 M23 M24 M25 M26 M27 M28 M29 M30

M CODE
DESCRIPTION OPERATION CAN BE RESTART BY START BUTTON ON/OFF OF M01 CAN BE CONTROL BY SWITCH ON THE PANEL NCUNIT IS RESET & STOPPING ALL OPERATIONS OF MACHINE

M CODE LIST FOR DRUM TYPE ATC


FUNCTION PROGRAM STOP OPTION STOP PROGRAM END SPINDLE FORWARD SPINDLE REVERSE SPINDLE STOP

VIEWED FROM Z AXIS HOME AND ATC AUTOMATIC TOOL CHANG READY CHIP CLEAN CUTTING OIL SUPPLY SPINDLE MUST BE RUN IN AUTO MODE CUTTING OIL STOP & OIL MIST OFF FLOOD COOLANT B ON FOR A.P.C. MACHINE ONLY

SPINDLE CW & COOLANT ON SPINDLE CCW & COOLANT ON

SPINDLE ORIENTATION TOOL MAGAZINE RIGHT TOOL MAGAZINE LEFT

TOOL CLAMP TOOL UNCLAMP

RIGID TAPPING PROGRAM REWIND

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L E A DW E L L
M CODE LIST FOR DRUM TYPE ATC
CODE M31 M32 M33 M34 M35 M36 M37 M38 M39 M40 M41 M42 M43 M44 M45 M46 M47 M48 M49 M50 M51 M52 M53 M54 M55 M56 M57 M58 M59 M60 M61 M62 M63 M64 M65 M66 M67 FUNCTION DESCRIPTION

4 AXIS CLAMP 4 AXIS UNCLAMP INDEXER CYCLE

FOR 4 AXIS WITH 4TH AXIS SPARE FUNCTION FOR 4 AXIS WITH 4TH AXIS SPARE FUNCTION FOR 4 AXIS WITH INDEX FUNCTION

CHIP CONVEYOR ON CHIP CONVEYOR OFF

MIRROR IMAGE X OFF MIRROR IMAGE Y OFF MIRROR IMAGE 4 OFF DURING OF TOOL CHANG CANCAL M66

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L E A DW E L L
M CODE LIST FOR DRUM TYPE ATC
CODE M68 M69 M70 M71 M72 M73 M74 M75 M76 M77 M78 M79 M80 M81 M82 M83 M84 M85 M86 M87 M88 M89 M90 M91 M92 M93 M94 M95 M96 M97 M98 M99 CALL SUB-PROGRAM END SUB-PROGRAM SPARE FUNCTION SPARE FUNCTION SPARE FUNCTION SPARE FUNCTION SPARE FUNCTION SPARE FUNCTION SPARE FUNCTION SPARE FUNCTION SPARE FUNCTION ON/OFF MOMENTARY ON/OFF MOMENTARY M83:ON M84:OFF M84:ON M83:OFF ON-FIN-OFF PUSE OUTPUT TYPE ON-FIN-OFF PUSE OUTPUT TYPE ON-FIN-OFF PUSE OUTPUT TYPE ON-FIN-OFF PUSE OUTPUT TYPE ON-FIN-OFF PUSE OUTPUT TYPE MIRROR IMAGE OFF MIRROR IMAGE X ON MIRROR IMAGE Y ON MIRROR IMAGE Z ON MIRROR IMAGE 4 ON FUNCTION DESCRIPTION

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L E A DW E L L
M CODE LIST FOR ARM TYPE ATC
O:OPTION CODE M00 M01 M02 M03 M04 M05 M06 M07 M08 M09 M10 M11 M12 M13 M14 M15 M16 M17 M18 M19 M20 M21 M22 M23 M24 M25 M26 M27 M28 M29 M30 M31 M32 M33 M34 M35 FUNCTION PROGRAM STOP PROGRAM OPTIONAL STOP END OF PROGRAM SPINDLE C.W. SPINDLE C.C.W. SPINDLE STOP AUTOMATIC TOOL CHANG C.T.S. COOLANT ON COOLANT ON COOLANT OFF CHIP CLEAN B:BASIC CLASSIFICATION B B B B B B B B B B O

SPINDLE C.W. & COOLANT ON SPINDLE C.C.W. & COOLANT ON

O O

SPINDLE ORIENTATION

SWING POCKET UP SWING POCKET DOWN TOOL CLAMP TOOL UNCLAMP RENISHOW ON RENISHOW OFF RIGID TAPPING PROGRAM REWIND

B B B B O O O B

CLAMP UNCLAMP

O O

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L E A DW E L L
M CODE LIST FOR ARM TYPE ATC
O:OPTION CODE M36 M37 M38 M39 M40 M41 M42 M43 M44 M45 M46 M47 M48 M49 M50 M51 M52 M53 M54 M55 M56 M57 M58 M59 M60 M61 M62 M63 M64 M65 M66 M67 M68 M69 M70 FUNCTION B:BASIC CLASSIFICATION

COOLANT THROUGH TOOL 4 AXIS CLAMP 4 AXIS UNCLAMP 5 AXIS CLAMP 5 AXIS UNCLAMP CHIP CONVEYOR ON CHIP CONVEYOR OFF

O O O O O O O

Z AXIS LOAD UP ON Z AXIS LOAD OFF

O O

ATLM AIR BLAST ON ATLM AIR BLAST OFF

O O

MIRROR IMAGE X OFF MIRROR IMAGE Y OFF MIRROR IMAGE 4 OFF MIRROR IMAGE 5 OFF

B B B O

MIRROR IMAGE OFF

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L E A DW E L L
M CODE LIST FOR ARM TYPE ATC
O:OPTION CODE M71 M72 M73 M74 M75 M76 M77 M78 M79 M80 M81 M82 M83 M84 M85 M86 M87 M88 M89 M90 M91 M92 M93 M94 M95 M96 M97 M98 M99 CALLING OF SUB-PROGRAM MAIN PROGRAM RETURN B B PART COUNTER B ON/OFF MOMENTARY ON/OFF MOMENTARY M83:ON M84:ON M84:OFF M83:OFF O O O O O O O SPINDLE LOAD UP ON SPINDLE LOAD DELECT OFF SPINDLE LOAD DOWN ON O O O MIRROR IMAGE 4 ON MIRROR IMAGE 5 ON B O FUNCTION MIRROR IMAGE X ON MIRROR IMAGE Y ON B B B:BASIC CLASSIFICATION

ONFIN--OFF ONFIN--OFF ONFIN--OFF

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L E A DW E L L
APPENDEX II G CODE
G CODE LIST
G code Group Function Positioning G00 01 Linear interpolation G01 G02 Circular interpolation / Helical interpolation CW G03 Circular interpolation / Helical interpolation CCW G04 Dwell, Exact stop G08 Lock-ahead control G09 00 Exact stop G10 Data setting G11 Data setting mode cancel 17 Polar coordinates command cancel G15 G16 Polar coordinates command XpYp plane selection Xp: X axis or its parallel axis G17 02 ZpXp plane selection Yp: Y axis or its parallel axis G18 YpZp plane selection Zp: Z axis or its parallel axis G19 G20 06 Input in inch Input in mm G21 04 Stored stroke check function on G22 Stored stroke check function off G23 Reference position return check G27 G28 Return to reference position G29 00 Return from reference position G30 2nd reference position return G31 Skip function Cutter compensation cancel G40 G41 07 Cutter compensation left G42 Cutter compensation right G43 Tool length compensation + direction G44 08 Tool length compensation - direction Tool length compensation cancel G49 11 Scaling cancel G50 G51 Scaling G52 00 Local coordinate system setting G53 Machine coordinate system selection Workpiece coordinate system 1 selection G54 G55 Workpiece coordinate system 2 selection G56 14 Workpiece coordinate system 3 selection G57 Workpiece coordinate system 4 selection Workpiece coordinate system 5 selection G58 Workpiece coordinate system 6 selection G59

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L E A DW E L L
G CODE LIST
Function G code Group G60 00 Single direction positioning G61 Exact stop mode G62 15 Automatic corner override G63 Tapping mode Cutting mode G64 G65 00 Macro call G66 12 Macro model call Macro model call cancel G67 G68 16 Coordinate rotation Coordinate rotation cancel G69 G73 09 Peck drilling cycle Counter tapping cycle G74 G76 09 Fine boring cycle Canned cycle cancel / external operation function cancel G80 G81 Drilling cycle, spot boring cycle or external operation function Drilling cycle or counter boring cycle G82 G83 Peck drilling cycle G84 Tapping cycle G85 Boring cycle G86 Boring cycle G87 09 Back boring cycle G88 Boring cycle G89 Boring cycle 03 Absolute command G90 Increment command G91 G92 00 Setting for work coordinate system or clamp at maximum spindle speed 05 Feed per minute G94 10 Return to initial canned cycle G98 G99 Return to R point in canned cycle (NOTE 1) G codes marked are initial G codes when turning power on (NOTE 2) G codes of group 00 are not modal . They are only effective in the block in which they are specified. (NODE 3) If a G code not list on the table of G code is inputted. Or optional G code not specified in the system is commanded, an command (No. 010) is displayed. (NOTE 4) A number of G code can be specified in the same block when more than one G code of the same group if specified. The G code specified later is effective. (NOTE 5) If any code of group 01 is specified in a canned cycle mode. The canned cycle is automatically cancelled and the G80 condition is entered. However a G code of group 01 is not affected by any of the canned cycle G codes. (NOTE 6) A G code is displayed from each group.
8-MGCODE

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APPENDIX

Caution: Spindle Operation


A. SPINDLE AIR PURGE 1.Set spindle air purge pressure at 1.2kg/cm21.5kg/cm2. Caution At power on for turning, check spindle air purge is functioning correctly. Caution Do not turn off spindle air purge or adjust pressure, it will lead to spindle defected or damage of spindle. B. SPINDLE OIL COOLER 1. Spindle shaft and quill with temperature difference may lead to spindle bearing burns. Spindle oil cooler temperature set up have to 2C higher than room temperature. 2. Rotary type of spindle oil cooler temperature is 25C at initial. Pls. adjust according to machine site. 3. Digital spindle oil cooler will detect spindle room temperature, no more adjustment is required. Caution At power on for turning, check spindle oil cooler is functioning correctly. C. SPINDLE WARM UP To ensure spindle smooth rotation in long term and long lifetime, at machine, installation or daily turn on, follows spindle warm up operation. D. SPINDLE TEMPERATURE INCREASE 1. This machine spindle was build up with high accuracy of spindle angular ball bearing of which add with high temperature endurable grease lubricator effective for maintain its accuracy with low temperature increasing at rotation. 2. If spindle temperature increased higher than 20C of room temperature, this indicates abnormal of the spindle. Contact machine builder immediately for authorized engineer delicate for maintenance will be required. Caution None authorized personnel disassembling spindle is prohibited. In case this accident happened, any failure to the spindle is subject to customers obligation. E. SPINDLE HIGH SPEED ROTATION TIME MANAGEMENTRef. table 1 1. Extreme speed of spindle rotation do not exceeds 1/4 of daily working hours. 2. Spindle speed stay less than normal rotation speed85% of extreme spindle speedfor machining. 3. Spindle run at normal continuous rotation speed do not exceed 8 hours a day. Otherwise, lower normal rotation speed to 70% of spindle speed, or reduce spindle speed to minimum speed for 1 hour will be required.
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4. Spindle speed less than minimum speed is not allowed. Table 1 Spindle specification 8000rpm 10000rpm 12000rpm 15000rpm Extreme speed of Spindle rotation 8000rpm 10000rpm 12000rpm 15000rpm Normal spindle rotation speed at 85% of Spindle peak 7000rpm 8500rpm 10000rpm 12000rpm Minimum speed 3000rpm 5000rpm 6000rpm

F. SPINDLE GUARANTEE 1. Spindle of normal operation, general spare parts will be guaranteed for 1 year. 2. Spindle bearing guaranteed for 2000hrs of rotation.

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