TV510 - Manual de Manutenção PDF

TV-510/ TV510A
MAINTENANCE MANUAL

FAI R FRI END ENT. GROUP- MACHI NE TOOLS DI VI SON
133
ADDRESS: NO.133, Gong 1st Road, Taichung
I ndustrial Park, Taichung City, Taiwan,
R.O.C.
TEL: (886) 4-3594075 (8 )
FAX: (886) 4-3590318

M1V105E2 2005/ 12/ 20

TV-510/ TV510A

MAINTENANCE MANUAL

HANGZHOU GOOD FRI END PRECI SI ON MACHI NERY
CO.,LTD.
ADDRESS: No.120, Shixin North Road, Xiaoshan
Economy& Technology Development
Zone .Zhejiang.P.R.C
TEL: (86) 571-82831393
FAX: (86) 571-82835069

M1V105E2 2005/ 12/ 20

Maintenance Manual

0-1
Content
Chapter 1 Setting, Adjustment and Maintenance
1. Daily Checkups-------------------------------------------------------------------------------1-1
2. Periodical Maintenance---------------------------------------------------------------------1-3
3. Lubrication------------------------------------------------------------------------------------1-6
4. Air-Pressure System-----------------------------------------------------------------------1-13
5. Replacement and Maintenance for Components----------------------------------------1-18
Go Next to Parts List

*Speci f i cati on are subj ect to change wi thout noti ce

Maintenance Manual

1-1

TV510 I NDEX
NO DWG. NO ASSEMBLY NAME PAGE
1 A82001

SHEET ASSY
P1
2 A82002
-
Spi ndl e Head Ass' y- Carousel Bel t type
P2
3 A82003
-
Spi ndl e Head Ass' y- Carousel Di rect type
P3
4 A82004
-
Spi ndl e Head Ass' y- AmBel t type
P4
5 A82005
-
Spi ndl e Head Ass' y- AmDi rect type
P5
6 A82006

Oi l Cool er Uni t
P6
7
A82007

Worki ng Tabl e Assy
P7
8
A82008
,
Base &Saddl e Assy
P8
9 A82009

Three AXI S TRANSMI SSI ON UNI T
P9
10 A82010
A. T. C- 14T
A. T. C Assy- Carousel Bel t type 14T
P10
11 A82011
A. T. C- 14T
A. T. C Assy- Carousel Di rect type 14T
P11
12 A82012
A. T. C- 20T
A. T. C Assy- AmBel t type 20T
P12
13 A82013
A. T. C- 20T
A. T. C Assy- AmDi rect type 20T
P13
14 A82014

Col umAssy
P14
15 A82015

El ectri cdl Cabi net Uni t Assy
P15
16 A82016
-
Spi ndel Assy- Di rect Type
P16
17 A82017
-
Spi ndel Assy - Bet Type
P17
18 A82018

Cool ant Uni t
P18
19 A82019
-
Ai r Pressure Uni t Assy- Carousel Type
P19
20 A17008A

Ai r Pressure Ci rcui t
P20

Maintenance Manual

2-1
21 A82020

Pl ate Uni t ASSY
P21
NO DWG. NO ASSEMBLY NAME PAGE
22 A82021

Shi pment Fi xed Uni t
P22
23 A82022
X
Lubri cati on Uni t Of X Axi s Assy
P23
24 A82023
Y
Lubri cati on Uni t Of Y Axi s Assy
P24
25 A82024
Z
Lubri cati on Uni t Of Z Axi s Assy
P25

Chapter 1 Setting, Adjustment, and Maintenance

1-1
1. Daily Checkups
When operating machine, user should notice the following situations. If anything is
abnormal, find out the cause or connect with our technical personnels for troubleshooting.
1. 1 Before Power ON
A. Check if any damage or poor connection to wires and plugs.
B. Check if gauges of gear box, tool changer unit and lubricant are normal.
C. Check the level of cutting fluid tank and see if its necessary to add cutting fluid.
D. If air pressure is normal.
E. Any leakage.
F. If each safety garde device is normal and nobody in danger zone.
1. 2 After Power ON
A. Spindle temperature rises too high or makes any inregular noise.
B. If automatic oil injector is qualified in the following situations
(1) Oil pressure should be 3~5kgf/cm
2
(0.3~0.5 Mpa or 3~5 Bar).
(2) If oil consumption is normal. If not, check up any damage on pipes or plugs.
(3) If running and stopping time is correct. (Recommand to add oil 15sec./6min.)
C. Check machining programs.
D. Check any lost or insufficient machining tools.
E. Check any damage to clamping/unclamping tools and if standard point is normal.
F. Keep machine and panel of operation cabinet clean and dry.
G. If transformer produces heat.
H. If spindle blast is normal.


1-2
1. 3 After Work
A. Clean spindle cones by cleaning stick daily.
B. Clean up chips on cover of three axes and water tank.
C. Clean up foreign chippings on tools eight hours once at least.
D. Clean motors of each axis daily.
E. Clean the external part once after work.
F. Move three axes to the center of travels to keep balance and precision of machine.
G. After clean up cutting chips, wipe table with anti rust oil.
H. Check each safety door is closed.
I . Check if power switch is off.
J . Check if switch of power source is off.


1-3
2. Periodical Maintenance
2.1 Maintenance
2.1.1 Notice
A. To ensure safety of maintenance work, never open each electric door and
guard cover unless for necessory maintenance work.
B. Dont use compressed air to clean up machine or other components. (If
environment is not clean, dust or metal chips may be blown into bearing or
slideways.)
2.1.2 Daily Maintenance
A. Clean up chips, dust, and other matters on table, base seat and device for
measuring tool length.
B. Clean up all stuffs on slideways (the parts without guard cover).
C. Clean guard each axis and slideway cover.
D. Clean spindle inner cone.
E. Clean limit switches and all electric components explosed outside.
F. Check level of centralized lubricant tank and spindle lubricant tank. Keep
oil level at recommanded height.
G. Make sure water in air filter is drained off.
H. Make sure pressure is correct.
Lubrication system35 kgf/cm
2
(0.3~0.5 Mpa or 3~5 Bar).
Air pressure unit over 6 kgf/cm
2
(0.6 Mpa or 6 Bar).
I. Check any leakage of machine or hydraulic unit; if so, deal with it properly.
J. Check pipe and tank for cutting fluid and clean up all foreign matters.
K. Check capacity of cutting fluid. Add it if necessary.
L. Check if all working lamps or warning lamps are normal.
M. Check and clean chippings on the unit of measuring tool length.
N. If screws of terminal table is loosened.
O. If too much carbon on relay.


1-4
2.1.3 Weekly Maintenance
A. Execute daily maintenance.
B. Check damage or irregular noise from spindle top, tool seat, or other
accessories. Clean the surrounding of spindle.
C. Check level of hydraulic unit (should be over the min. at least). If
insufficient, add it to the proper level. Check if mechanical reference point
of each axis is moved.
D. Check if any reference position is moved.
E. Wash filter of cutting fluid tank weekly.
F. Check if function of chip conveyor and motor lubricant is normal.
G. Clean and check oil tank of three point is normal.
H. Keep panel keys on operation cabinet dry and clean.
I. Keep limit switch clean.
2.1.4 Monthly Maintenance
A. Execute weekly maintenance.
B. Clean operation panel, inner parts of control cabinet, and filter of heat
exchanger.
C. Check level of table and base seat and make sure foundation bolts are lock.
D. Check if adjustment is necessary for slideway oblique wedge.
E. Clean air filter; replace a new one if necessary.
F. Check if electromagnetic valve, limit switch, and limit switch function are
normal.
G. Clean wipes on surface of slideway; replace it if necessary.
H. Clean oil filter of hydraulic unit.
I. Check any lossen situation or poor contact to plugs.
J. Check if interlock device and timer are normal. Check if relay generates
appropriate contact pressure. Clean the contact face of the relay.
K. Drain off cutting fluid; wash water tank and pipe. Then, fill in cutting fluid
again.


1-5
L. Make sure that NC controller works normally.
2.1.5 Maintenance every six months
A. Execute monthly maintenance.
B. Clean NC unit, control unit, and machine.
C. Change hydraulic oil in hydraulic system, lubricant in magazine gear box
spindle head table,. Clean the inner part of oil tank.
D. Clean all motors.
E. Check all eclectric components and relay disc visually.
F. Wash lubricant pump and fill in lubricant according to manufactorys
commands.
G. Check if test program execute smoothly.
H. Measure interval of NC servo axis. Adjust value if necessory.
I. Test machines movement and functions by test program.


1-6
3. Lubrication
3. 1 Lubrication on slideway surface
3.1.1 The surface of three slideways, including linear slideway and lubricant of their
ball screw are lubricated in set time/set amount by automatic oil injector.
3.1.2 Drawing of lubricant system:
The l ubri cant systemdrawi ng of the machi ne i s bel ow:

Fig. 1-1
A. The automatic oil injector is set at the rear side of column.
A type distributor is set at the rear side of column too.
B. As to the lubricant drawings for X, Y and Z axes, please refer to
A82022,A82023, A82024 in the Parts List.


1-7
Drawi ng of Y Z axi s l ubri cati on systerm
A6 di stri butor
A3 type di stri butor
Lubri cant Pump

Fig. 1-2

3.1.3 Lubrication explanations the lubrication of the machine is the coordination of
PLC time and the rate of flow, which is fixed forcibly.
A. While the oil is insufficient, the PLC will show the extraordinariness and


1-8
notify the operator to refill until the oil is sufficient.
B. If the working is executed by the program automatically and shows abnormal
phenomenon, the machine will stay at the present state.
After the problem is removed, to press the Start button can resume working
C. If some axis lacks oil and the machine does not show the phenomenon, users
can check the pipe or oil path to see whether there is a break on the pipe or
clog on the connector.
3.1.4 Injector explanations
A. Appearance

Fig. 1-3


1-9
B. Illustration for Oil Feed
(1) In oil capacity controller, floatable switch for oil amount. (automatic oil
detector).
(2) Adjust oil feed amount according to need by pump movements time.
(3) The methods of suppling oil includes continual force lubrication and
intermittent force lubrication. It is controlled by PLC.
(4) The oil injector is made of special aluminum alloy. It is durable and the
structure is very beautiful. The inlet entrance of oil tank is big enough
for installing a filter. Resin filter is set at entrance of pump, intake to
prevent foreign matters from being sucking in perfectly .
(5) Direct transmission between oil pump and motor adopts special alloy
steel materials with great durable and trustworthy. It also can decrease
friction and noise sufficiently.
(6) Motor with single phase is according to national stanard , precise mini
motor, safety loading and heat dissipation after continual running are
designed and counted by proficients. Nil breakdown is one of its
specail advantages.
(7) Wonderful result to be installed on your excellent products with its
beautiful form and precise structure.
(8) After wiring and installation, fill oil up in continual force way first; then
choose suitable lubricative type for increasing life of machine.
(9) Adopt PT1/8 pipe connector for outpour in 4 or 6 oil pipe.
(10) All automatic mechanical lubricative parts can use the machine for
automatic centralized lubricant feed device.
(11) The capacity of oil tank is 4000CC. with clear oil gage on the box to
check oil amount conveniently (visual oil detector).
Notice Items 1. Before using oil motor, please open it for air release. After
oil flowing out, start the continual or intermittent oil feed.
2. Dont work with used oil.


1-10
D. Illustration of Movement Oil pump is turned round by motor drive.
Lubricant in oil box is suck in through oil filter and sent to outpour through no
return valve and flew to each lubricant pipe through main pipe. Pressure inner
pipe is set at 0kgf/cm
2
~12kgf/cm
2
(0 Mpa ~1.2 Mpa). If pressure inner pipe is
over the standard when pressure adjusting valve is at 3.5kgf/cm
2
(0.35 Mpa),
pressure adjusting valve start to return the over pressured oil back to oil box to
keep set pressure, 3.5kgf/cm
2
(0.35 Mpa), in oil pipe.
Z03164
Fig. 1-4
Notice items for operation
(1) The sticking of oil must be between 8cst~200cst (at 38), equal to
spindle oil #60~turbine oil #140.
(2) Oil temperature must be in the range of 5~60.
(3) Please use clean lubricant.
(4) Specially notice that to install magnetic oil filter in circulating force oil
feed. Clean it periodically to ensure lubricant effect.


1-11
3.1.5 Specificaiton for lubrication
A. Pressure of oil feed is 3~5kgf/cm
2
(0.3~0.5 Mpa or 3~5 Bar).
B. Capacity of oil box is 4 L.
C. Amount of oil feed That to run 8 minutes with oil feed 10 seconds is
recommended.
3.1.6 Oil replenishment Loosen oil cover to replenish oil to set amount (observe
from the oil gauge).
3.1.7 Adjustment of the oil supply intermission and running.
A. Please refer to our companys suggestion, which suggests the intermission 8
minutes and the running 10 seconds.
3. 2 Lubrication for spindle
A. Adopt oblique ball bearing in high precision and lubricated by yellow oil
which is able to endure temperature rise to reach the effect of high precision
and low temperatue rise.
B. The correct using way and suitable amount of yellow oil for bearing inner
spindle will affect spindles temperature rise and the pre-pressure from bearing
also affects spindles precision. Hence, if necessary to add yellow oil, please
connect with our company or agents.
3. 3 Lubrication for other parts
A. Keep the same amount for oil of three point set and drain water at suitable time.
B. Coolant capacity is135L check it up every week.


1-
12
4. Air pressure system
4. 1 Illustration
4. 1. 1 Items Adopt air pressure system to control the following movement.
(A) Pot moves up and down. Magazine moves left and right in armless type.
(B) Spindle clamping and unclamping.
(C) Spidle dustproof blasting.
(D) Spindle blast from inner cones.
4. 1. 2 Range
(A) Normal pressure is set at 6~7 kgf/cm
2
(0.6~0.7 Mpa or 6~7 Bar).
(B) When pressure is lower than 5kgf/cm
2
(0.5 Mpa or 5 Bar), control system will
send warning message and stop machine.
(C) The min. flow is 200L/min.
4. 2 Tube system
Refer to the air pressure wiring drawing in parts list.


1-
13
4.2.2 Illustration for magnetic valve control

Fig. 1-5 040825B


1-
14
4. 3 Pressure Adjustment
4. 3. 1 In normal pressure, three points set is adjustable pull switch of pressure
valve upward. Turn right for increasing pressure; left, decreasing. The range
must be in 6~7kgf/cm
2
(0.6~0.7 Mpa or 6~7 Bar). After adjustment, push
down and set switch in its origional place.
See details on Fig. 1-6.
A. Rotate in this direction to increase pressure
B. Rotate in this direction to decrease pressure
4. 3. 2 The min. working pressure can be adjusted by pressure adjustor If
abnormal pressure often occur and adjustor is not set at 5kgf/cm
2
(0.5 Mpa
or 5 Bar) or sensor at 1.5bar, please adjust according to the following drawing.
A. Use type screwdriver to loosen and take off flat screws on the top
cover. Details are as fig. 1-7.
B. Take off set piece. See details as fig. 1-10.
C. Move vernier to 5kgf/cm
2

(0.5 Mpa or 5 Bar) by a cross type screwdriver
or 6mm open spanner. Details are as fig. 1-8.
D. Move vernier to 1.5bar by a screwdriver or 6mm open spanner. See
details in fig. 1-9.
E. Replace and lock the set piece as fig. 1-10.
F. Lock the top cover as fig. 1-7.


1-
15

Fig. 1-6 Fig. 1-8 Fig. 1-9
Z03173
Fig. 1-7 Fig. 1-10


1-
16
5. Replacement and Maintenance for Components
5.1 Generality
5.1.1 Before takeing off components, record the following information
A. The model of machine.
B. Specification and brand of the replaced component.
C. Relative position of up/down connection to avoid mistakes for replacement.
5.1.2 After installaion of new component and before checking that its function is
normal, dont throw the origional one.
5.1.3 Notice items for maintenance
A. Operator should understand the steps for stopping machine. To maintain
machine after machine stops.
B. Maintain interior
(1) Turn off power.
(2) If it is necessary to turn on power, maintenance should be done after
lock machine (refer to operation manual).
(3) Clean the place for cutting fluid or lubricant where is possible to be
stepped in the internal part to prevent from skipping.
(4) Clean the place of chips where is possible to be stepped or touched in
the internal part to avoid danger.
5.1.4 Clean chips right away during running.
A. Push pause first, then lock machine, last clean chips.
B. Use a brush or other tools to clean chips instead of hands to prevent
from hurt.


1-
17
5.2 Responsibilities for Maintenance
5.2.1 Allow operators to handle the situation by themselves
A. No influence to screw, plate, etc. for machine precision.
B. Simple component, such as fuses, switches, oil pipe connection, and so on.
C. If unable to constitute components, connect with our company for
maintenance.
D. Because maintenance staffs may not service at limited time, please learn
maintenance by phone or fax.
5.2.2 The following items must be maintained by qualified staffs.
A. Traverse of spindle is too serious.
B. Noise of spindle.
C. Noise of gear.
D. Leakage of spindle head.
E. Maintenance of lead screw.
F. Magazine and arm.
G. Dropping tools.


1-
18
5.3 Replacement of lamp bulb
5.3.1 Replacement procedure of panel indicator lamp
A. Turn power off.
B. Take apart cover of keys.
C. Take off broken bulb and replace a new one.
D. Lock the cover of keys.
5.3.2 Replacement procedure of LED indicator lamp
A. Turn off power.
B. Take apart panel.
C. Take off welding points by welding gun.
D. Take off LED and replace a new one.
E. Weld LED points anew. Notice the and poles
F. Lock panel.


1-
19
5.4 Replacement for limit switches
5.4.1 Drawing of detector switch Please refer to electrical manual.
5.4.2 Replacement procedure
A. Turn off power.
B. Before replacement, measure the original position. Record relative position for
a, b, c and d as fig. 1-11.
(1) Length that limit switch extends outside the set plate. (a)
(2) Length that limit switch stays inside set plate. (b)
(3) Max. upward length for adjusting limit switch at set plate. (c)
(4) Max. downward length for adjusting limit switch at set plate. (d)

Fig. 1-11
C. After confirming connection method, replace it according to measurement of
former section (B).


1-
20
5.4.3 Adjustment
Setting and Adjustment for Traverse
a. Positive setting value
Value
Controller Parameter
axis axis axis
700 5.000
701 5.000 FANUC
702 5.000
MITSUBISHI #14OT+ 5.000 5.000 5.000
b. Negative setting value
Value
Controller Parameter
axis axis axis
704 -510.000
705 -400.000
FANUC
706 -400.000
(-300.000)
MITSUBISHI #13OT- -510.000 -400.000 -400.000
(-300.000)


1-
21
B. Adjustment for spindle clamping/unclamping and limit switch(for arm
and belt type)
1 Drawing
Fig. 1-12
2 Method for Adjustment
a. When block touches limit switch A, it is clamping. Limit switch
should move toward the inner 2.4mm.
b. When block touches limit switch B, it is unclamping. Limit switch
also should move toward the inner 2.4mm.


1-
22
C. Limit switch adjustment for pocket up and down
1 Drawing
Fig. 1-13
2 Method for Adjustment
a. When dog meet limit switch A, pocket is down and limit switch
moves inward 2.4mm.
b. When dog meet limit switch B, pocket is up and limit switch moves
inward 2.4mm.
5.5 The replacement of fuse and relay, please refer to the electrical manual.
5.6 The protecting PC board for the front door should be changed
annually or when its unable to see through it.

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