Operational Manual

for HLT80-8/12T NC
Hydraulic Tool Carrier

C h a n g z h o u Ya x i n g N C E q u i p m e n t C o . L t d
Changzhou Xinshu NC Machine Equipment Co. Ltd

Headquarter Add.: North Yanzhuang Bridge 161#, Qishuyan, Changzhou

Phone： 0519-8351985 8350255
Fax： 0519-8351985 8362511

New plant Add.: Qianjia Industrial Park, Yaoguan, Changzhou

Phone： 0519-8360168 8771358
Fax： 0519-8360168
 CONTENTS

1.Introduction .................................................................................................... 2
2.Main Parameter ........................................................................................................3
3.Overall dimensions (8 stations)................................................................................3
4.Timescale..................................................................................................................4
5.Operation Process.....................................................................................................6
6.Components and interface specification ..................................................................6
7.Mounting & Adjusting..............................................................................................9
8.Operation and Maintenance ...................................................................................11

9.Normal failure and troubleshooting .......................................................................11

10.Attention for (Dis)assembly of tool carrier ..........................................................12
11.Discard..................................................................................................................12

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1. Introduction

We very much appreciate your support to us for purchasing Yaxing Product.

Tool carrier Specialty:

z Hydraulic Motor driven, simple structure with reliable accurately movement;
z 2-way rotation tool carrier makes fast and smooth nearby tool selection;
z Photoelectric absolute encoder ensures rapid respond and precise cutter change sequence;
z Three-piece contrate gear achieves good cutter protection and change cutter without lifting.
z Hydraulic clamp methods can be apply for heavy cutting with reliable and powerful clamp;
z Compact structure with International standardization mounting dimension makes easy change.

This manual is guideline of installation, adjusting, operation, maintenance instruction for tool
carrier. In order to prevent potential inconvenience and let the product utilize its proper
performance, please carefully read this manual and operating by this manual, it will bring
advantage and benefit for your production.

Caution: Our company will not take any responsibility if there is any machine or component
damage as well personnel injury without comply with this manual.

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2. Main Parameter

Item Parameter Item Parameter

No. of cutter station N 8；12 Repetition accuracy mm <0.005
Central height mm 80 Graduation accuracy mm <0.050
Max, carriable rotary inertia Kgm2 2 Working Pressure MPa 3.5
Time for turn 45 º S 0.3 Work Flow rate L/min 20
Time for turn 45º & locked S 0.6 Max. Unbalanced moment Nm 20
Time for turn 180º S 1.2 Max. tangential torque KNm 2.1
Time for turn 180 º & Net weight (without
S 1.5 Kg 60
locked cutterhead)

3. Overall dimensions (8 stations)

常州亚兴数控设备有限公司
C h an g hz ou Ya x ni g C NC E q ui p me nt Co ., Lt d .

*: Special requirement on tool carrier order regard as technology contracts

3
4. Timescale

八工 位液压刀架
Control timescale for 8-station 1 号 刀 位 2号 刀 位 2号刀位 1号 刀 位 8号刀位
控 制时序图 Station 1 Station 2 Station 2 Station 1 Station 8
hydraulic tool carrier
Hydraulic Motor
液压马达 veer
顺 转rotate
液压马达
Hydraulic Motor 停转
stall
液压马达逆转
Hydraulic Motor reverse rotate
Release solenoid 1 1
刀 盘松 开valve
1为
1: 电 磁 阀 solenoid
Electrify 得 电 valve
电磁阀
0 0 为 电 磁 阀 失solenoid
电
of cutterhead 0 0:Disconnect valve

Veer electromagnet
刀 盘转 位 电for
磁 阀rotary
1 1 1为
1: 电 磁 阀 solenoid
Electrify 得 电 valve
之 顺转
solenoid valve of电cutterhead
磁铁 0 0 0 为 电 磁 阀 失solenoid
电
0:Disconnect valve
Reverse electromagnet 1 for
刀 盘转 位 电 磁 阀 1为
1: 电 磁 阀 solenoid
Electrify 得 电 valve
rotary solenoid
之 逆转 电 valve
磁铁 of0 1
0 为 电 磁 阀 失solenoid
0:Disconnect 电 valve
cutterhead 0
Stall/locking proximity 1 1 11:为High
高电平 level NC
常 负
刀 盘 停 转 锁紧 接 近 开 关 0: Low level contact,
switch of cutterhead 0 0 0为低电平 闭 逻
Nega-
触 辑
Station 刀release 1 1 11:为High
高电平 level
盘 松 开 转位proximity
tive
接近开关 点 ！
0 0: Low
0为低电平 level logic
switch of cutterhead 0
1 1:高High
电 平 level
2 0 01
1为
0 为 低 电 平 level
0: Low
刀 20 0
1
Tool 架 2 1 10 必Must
须 使 用use
选 通Gating
(TP) Signal
21 0 （ T P ） 信号 。
编
1
Carrier 1
码 222 0
2 0
器 11
Encoder
233 0
2 0
Gating 1
选通（T P） 10
(TP) 0
 十二 工位 液压 刀架
Control timescale for 8-station 1号 刀位 2号刀位 2号刀 位 1号刀位 12号刀 位
控制 时序 图
hydraulic tool carrier Station 1 Station 2 Station 2 Station 1 Station 8
Hydraulic 液压马
Motor达顺
veer
转 rotate
Hydraulic 液压马
Motor达停
stall
转
Hydraulic 液压马
Motor达逆 转 rotate
reverse

Release solenoid valve 1 1 1:1为 电磁阀solenoid

Electrify 得电 valve
刀盘 松开 电磁阀
0 0为 电磁阀 solenoid
失电 valve
of cutterhead 0 0:Disconnect

Veer electromagnet
刀盘 转位 电磁阀 1 1
for rotary 1:1为 电磁阀solenoid
Electrify 得电 valve
之顺 转电 磁铁 0 0为 电磁阀 solenoid
失电 valve
solenoid valve of cutterhead 0 0:Disconnect
Reverse electromagnet for
刀盘 转位 电磁阀 1 1:1为 电磁阀solenoid
Electrify 得电 valve
rotary solenoid valve of 1
之逆 转电 磁铁 0 0为 电磁阀 失电
cutterhead 0 0:Disconnect solenoid valve

Stall/locking proximity 1 1 1: High

1为 高电平 level NC
常 负
刀 盘停转 锁紧 接近开 关 0: Low level contact,
0 0为 低电平 闭 逻
switch of cutterhead 0 Nega-
触 辑
1 1
Station release proximity 1为 高电平
1: High level tive
刀 盘松开 转位 接近开 关 点 ！
logic
0 0: Low
0为 低电平 level
switch of cutterhead 0
11 1: 高电平
High level
1为
2 00 0 0: 低电平
Low level
2 0 0为
刀
Tool 11 Must use Gating
架 2 11 0 必 须使用 选通
(TP) Signal
2 0 （ TP）信 号。
编
Carrier 11
码 2 22 0
2 0
Encoder 器 11
2 33 0
2 0
Gating 11
选通 （TP） 0
(TP) 0

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5. Operation Process

6. Components and interface specification

 6.1 Location of components and interfaces

1 2 3 4

7
Water inlet

Oil drainage outlet

8

3 6 5 9 10

Spill port 23/8"

Oil inlet

11 7
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6.2 Component description and type
No. Description Type Remarks
1 Hydraulic motor BMP（H)-100
2 Release solenoid valve of cutterhead DSG-01-2B2-D24-N1 Yuci Youyan
Veer electromagnet for rotary solenoid valve of
3 SD1-24-50
cutterhead
4 Graduation solenoid valve of cutterhead DSG-01-3C4-D24-N1 Yuci Youyan
5 Lockable speed adjustment rod
6 Rotary buffer adjusting knob
7 Junction Box
8 Photoelectric absolute encoder XWJ-1-8/12 8/12 stations
9 Station release proximity switch of cutterhead GA30-0224PB
10 Stall/locking proximity switch of cutterhead GA30-0224PB
Reverse electromagnet for rotary solenoid valve of
11 SD1-24-50
cutterhead

6.3 Component description

6.3.1 Encoder: DC24V PNP8421 code output; output voltage of 24V; load capacity of 30mA.
Interface mode Line color table
+24V
Color Red
线色 红 Black 黑 White
白 Green
绿0
Signal +24V 0V Gating 2
PNP型
PNP
输出
Output 信号 +24V Pink
Color Purple
0V 选通 2
0
Yellow Gray
Type
(blue)
编码器
Encoder
线色 紫1 粉（兰） 黄 灰
负载
Load
Signal
2 3
2 2 2
Chec
king
信号 2 1 2
2 2 校验
3

0V
Encoder truth table
Position 1 2 3 4 5 6 7 8 9 10 11 12
0
2 1 0 1 0 1 0 1 0 1 0 1 0
21 0 1 1 0 0 1 1 0 0 1 1 0
22 0 0 0 1 1 1 1 0 0 0 0 1
23 0 0 0 0 0 0 0 1` 1 1 1 1
Gating 1 1 1 1 1 1 1 1 1 1 1 1
Checking 1 1 0 1 0 0 1 1 0 0 1 0

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6.3.2 Proximity Switch: DC24V PNP NC type; output current 300mA.
Interface mode line color table

+24V

Color
PNP型
PNP Type 线色Brown
棕 兰Blue 黑Black
Proximity
输出
Output
Signal +24V 0V Output
接近 开关
Switch
Load 信号 +24V 0V 输出
负载

0V
6.3.3 Solenoid Valves:
6.3.3.1 Functional Symbol: Station release solenoid of cutterhead Static locking solenoid of cutterhead

6.3.3.2 Voltage DC24V, operation range 21.6-26.4V; Power: 26W; holding current: 1.1A

6.4 Attention :
6.4.1 Encoder, and proximity switches connectable load is: relays and programmable logic controllers, etc.

6.4.2 Encoder does not allow power cord reverse connection; and the absolute forbids live (un)load; its not
allowed to short-circuit between the various signals; at the same time when the power supply cathode is
open, strictly prohibited to switch on load circuit.

6.4.3 Hydraulic oil: ISO VG32 or VG46 hydraulic oil is recommended; viscosity :15-300cSt; oil
temperature :0-60 ℃; contamination: NSA 12, oil duct filter under 25μm is recommended to use.

7. Mounting & Adjusting

7.1 Mounting
Tool carrier bottom must ensure that clean during installation, if necessary, pad plate can be added under
the tool carrier bottom to adjust the center height. Place tool carrier in proper position of tool carriage
pad in machine, calibration cutterhead side surface (mounting surfaces of boring seat ), tighten the
mounting screws (M10: 70Nm).

7.2 Electical wiring

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 Please wiring according tocomponent requirement and following wiring table.

Wiring Table
Color Signal Color Signal
Red Encoders, proximity switches +24 v Orange Station release proximity switch of cutterhead
Black Encoder, proximity switches 0v Blue Stall/locking proximity switch of cutterhead
(Thin)
Green Encoder 1 bit Black 1 Cutterhead release solenoid valve +24 V
(Thick)
Purple Encoder 2 bit Black 2 Veer electromagnet for rotary solenoid valve of
(Thick) cutterhead +24V
Pink Encoder 4 bit Black 3 Reverse electromagnet for rotary solenoid
(Thick) valve of cutterhead +24V
Yellow Encoder 8 bit Yellow& Solenoid valve common cathode
green
White Encoder gating Brown Spare
Gray Encoder parity checking

7.3 Tubing
Please match each pipe by drawing 6.1 "Location of components and interfaces", connected oil line and
cooling water pipe, this tool carrier give 2 C-M18X1.5 pipe joints free of charge; if drainage outlet need
to connect drainage pipe, then the highest point of the pipe must be lower than the drainage outlet,
otherwise please connect orthogonal pipe to drainage outlet and put pipe nozzle downwards.

7.4 Adjusting
Open the oil pump, connected to pressure oil and return oil, adjust the working pressure to 3.5-3.7Mpa;
electrifies release solenoid valve of the cutterhead (2) Power (or hand presses the corresponding
solenoid control lever) to make cutterhead release, do not disconnect power (or loose hand); and then
switch on the power of veer electromagnet for cutterhead rotary solenoid valve (3)(or hand presses the
corresponding solenoid control lever), let the cutterhead continuous rotating, adjust pressure oil flow to
make cutterhead rotational speed stays 35 rpm, rotational speed should be decreased appropriately if the
oil temp. low and increased appropriately if the oil temp. High. After the setting, disconnect release
solenoid valve of the cutterhead (2) Power (or looses the corresponding solenoid control lever), after
cutterhead return station and locked, then disconnect the power of veer electromagnet for cutterhead
rotary solenoid valve (3)(or looses the corresponding solenoid control lever) .

If necessary, adjust the buffer control knob to buffer the rotary impact to the minimum, but not too small

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 so as not bring the cutterhead in position, tighten the nut after adjustment.

8. Operation and Maintenance

8.1 Each components relative positions have been set during ex-works. It's not suggested to adjust
casually during operation.

8.2 Maintenance
8.2.1 After each day's working finished, it's strongly recommended to clean up the cooling fluid, iron filings
and etc on tool carrier, then coating anti-rust oil on cutterhead.

8.2.2 Under normal workload situation, every two years should disassemble the tool carrier, cleaning all parts,
then coating right amount of lithium grease in all bearings, gears and the ring groove of external
contrate gear, reassemble and reset the tool carrier in the end.

8.2.3 Under full-day workload situation, each year should disassemble the tool carrier, cleaning all parts, then
coating right amount of lithium grease in all bearings, gears and the ring groove of external contrate gear,
reassemble and reset the tool carrier in the end.

9. Normal failure and troubleshooting

Failure phenomenon Cause Troubleshooting

Cutterhead don't Release solenoid valve of cutterhead haven't Check the solenoid valve
1
release electrified or failure is normal working or not
Release solenoid valve of cutterhead haven't Check the solenoid valve
2 Cutterhead don't lock
disconnect power or failure is normal working or not
Wrong position or failure of Station release Adjusting position or
1)
Cutterhead don't proximity switch of cutterhead change
3
rotate Rotary solenoid valve of cutterhead haven't Check the solenoid valve
2)
electrified or failure is normal working or not
Heavy impact during
4 Rotary buffer adjusting knob openning too big Decrease the openning
cutterhead rotation
Not in position
5 during cutterhead Rotary buffer adjusting knob openning too small Increase the openning
rotation
Reverse rotation, The veer and reverse electromagnet anode is reverse
6 Exchange Anode
wrong cutter position connected
Wrong position or failure of Stall/locking proximity Adjusting position or
7 No locking signal
switch of cutterhead change
Failure phenomenon Cause Troubleshooting

11
 1) Incorrect program Adjustment program
2) The encoder connection is not properly Connected to correct
Out of order or
8 3) Encoder is damaged Replace the encoder
continuous rotation
Release solenoid valve of cutterhead haven't Check the solenoid valve
4)
disconnect power or failure is normal working or not
Disassemble drainage
Low Cutting Fluid or
9 Cutting Fluid orifice jammed valve, check the cutting
blocked
fluid tube and clean stem
Collision
1) Tool carrier not in Re-adjust the tool carrier
position to proper position
10 2) The body or the Replacement of damaged
cutterhead broken parts
Note: After Collision recovered, please double check the tool carrier central height and relative precision
of the cutterhead in order to ensure the original accuracy restored.

10. Attention for (Dis)assembly of tool carrier

10.1 Make records for the relative position of parts during disassemble tool carrier, pay attention don't
damage the seals and so on.

10.2 Strictly keep each parts clean during reassembly and prevent to bring in any foreign matter or dust.

10.3 Cam can be mounted when cutterhead in locking position with side pin inserted.

10.4 Hydraulic block is over-positioning mounting method, the screws should be gradually tightened.

10.5 Encoder should be adjusted after cutterhead locked, check the corresponding cutter station No. with the
output signal, and the output signal should be presented Symmetrical State at encoder's fixed position
(take gating signal as standard).

11. Discard

11.1 Disassemble the tool carrier into parts, clean the greasy dirt of all parts.

11.2 Remove all the seals in the tool carrier .

11.3 Sorting each part.

11.4 Dispose or reuse in accordance with the local resources recycling or disposal regulation.

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