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CKE6150 Horizontal CNC Lathe

Operating Manual (Mechanical, hydraulic part) Max. swing over bed Max. workpiece length

500mm(19.69 inch) 750mm(29.53 inch) 1000mm(39.37 inch) 1500mm(59.06 inch) 2000mm(78.74 inch)

Ser. No.

Dalian Machine Tool Group Corp. The people’s Republic of China


CKE6150-010

Contents 0. Preface … … … … … … … … … … … … … … … … … … … … … … … … … … … … … 2 1. Brief introduction… … … … … … … … … … … … … … … … … … … … … … … … 3 2. Safety instruction… … … … … … … … … … … … … … … … … … … … … … … … 3 3. Machine handle, installation, clean and run in… … … … … … … … … … 15 4. Main technical specifications … … … … … … … … … … … … … … … … … … 20 5. Transmission system … … … … … … … … … … … … … … … … … … … … … … … 24 6. Lubrication system… … … … … … … … … … … … … … … … … … … … … … … … 41 7. Cooling system… … … … … … … … … … … … … … … … … … … … … … … … … … 45 8. Hydraulic system… … … … … … … … … … … … … … … … … … … … … … … … … 47 9. Main structures and usage & adjustment… … … … … … … … … … … … … … 49 10.Diagram for cutting limit of tool post… … … … … … … … … … … … … … 55 11.Perishable parts… … … … … … … … … … … … … … … … … … … … … … … … … 55 12.Check and maintenance … … … … … … … … … … … … … … … … … … … … … … 60 13.Common mechanical faults check… … … … … … … … … … … … … … … … … … 62

N.B.:This Operating Manual consists of Mechanical, Hydraulic & Electric parts, please read the three parts together when operating this machine.

DALIAN MACHINE TOOL IMPORT &EXPORT CORPORATION Address: 38 ANSHAN ROAD DALIAN, CHINA Tel: 0411-83630767 83637554 83630422 Fax: 0411-83646795 Postcode: 116022

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CKE6150-010

Preface We would like to thank you for choosing our machine. CKE6150 series lathe can bring together the requirements for better machining, high precision, easy to operating, quick way from drawing to workpiece and special features for nowadays-modern workshop. With proper care, under the assisting of our Operating and Maintenance Manual, you will get satisfied productions from this machine. This manual is meant for the following staff, who before commencement of operating the machine, must thoroughly study and understand the contents: .Process engineer .Lathe operator .Head of maintenance and service .Head of operating machine tools in production shop To ensure full and proper utilization of the machine tool and extend its operation life, lower operational costs and obtain economic effects, the following should be observed: 1. Comply with industrial safety regulation. For this purpose, the operation instruction, lubrication instruction and work safety recommendation should be available in a visible and accessible place near the lathe. 2. Follow the requirements and directions of this manual in the scope of operation and maintenance. Keep the machine clean, perform continuous maintenance and immediately eliminate any defects and damages noticed. 3. Only the person, who have been trained and well acquainted with the information content of this manual, can operate the machine.

Note Due to the constant technical improvements, this reference manual relates only to the machine tool with which it is delivered. Illustrations and specifications are not binding in details in this manual. The designs are subject to modification without notice. Anything unclear or wrong is found; please contact the manufacturer in time. Otherwise, the manufacturers do not take any consequence for financial loss accordingly.

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CKE6150-010

1. Brief introduction 1.1 Main application and structure feature The horizontal machine can move X-axis and Z-axis to finish automatically turning of internal/external cylinder, taper, end face, grooving and chamfer of shaft and disc parts. Additionally, it can also cut metric and imperial thread as well as end face thread and taper thread. This machine adopts semi-closed CNC system having FANUC, DMTG, SIEMENS, Guangzhou CNC system or other required CNC system, corresponding AC servo motors as driving parts, and MPG as detecting elements. There are four types of headstock: a) dual speed motor and solenoid relay, can realize automatic speed changing within 3 manual ranges; b) frequency conversion motor and realize stepless change within 3 manual ranges; c) frequency conversion motor can realize stepless change within 3 automatic ranges; d) adopt AC main servo motor, realize stepless speed change. Tool post can be vertical 4-station or horizontal 6-station electric type. Chuck is a manual one or hydraulic one. And manual tailstock and hydraulic tailstock can be choosed. The mating faces between saddle and slide way are of Turcite-B. Forced lubrication is done to mating faces between ballscrew and guideway by centralized lubricator. All the above makes feed system to optimize the precision movement amount of the parts can be got, thus improving the positioning accuracies and service life of the guideway. This machine, according to man-machine engineering principle, has pleasant appearance and adopts full guards to protect operator against the splash of the chips and coolant. 2. Overview of the machine(see Fig.1)

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CKE6150-010

2. Safety instruction 2.1. Notice to operator: a. Only the operators, who thoroughly understand the safety instruction, operation and maintenance manual, can operate the lathe. The lathe operator should wear protective clothing and helmet, and avoid being damaged by the rotating workpiece. Never let the head and hand reach over rotating parts. Never operate the lathe after taking OTC medicine or much alcohol. b. The technological process person should be trained on preparing production of CNC machine tools. Ensure clamping of cutting tools and workpiece secure and reliable so as not to allow any tools or workpiece loose caused by cutting forces. A skilled and experienced operator is needed to start the lathe for the first time. Before starting the lathe, do close and lock all the doors and covers. And check for proper setting of operating elements (buttons, knobs, levers, switches, etc.). It is forbidden to utilize the lathe or internal unit after confirming damage to any electric, mechanical safeguards, interlocking and setting elements and equipments. Anything abnormal or breakdown should be reported to relevant person. c. It is forbidden to operate the lathe after confirming damage to safety elements. d. Before switching on or putting the lathe into motion, it should be checked that this task does not form a danger to another person. e. Not permit strangers to the lathe without the qualified supervisors. f. Keep work area clean and dry, remove chips, oil and other obstacle; in order to obtain optimal output and safe work condition, use cabinets or shelves to store the tools; furthermore, provide the suitable tools to operate and service units and platform. g. The stopped lathe should be protected against accidental switching on (in case of lubricating, cleaning, or other intervals in work switch off the mains). For large repairs and adjustments, flow of current to the electric cabinet should be completely cut off, and then wires L1,L2,L3 removed from terminal board and bare ends insulated. It is forbidden to switch off power supply by means of the main switch on electric cabinet or the external main switch while main drive is on or spindle is rotating. h. For the sake of transportation safety, the movable parts (such as guard door and console, etc.) should be fixed(see Fig. 2). The user should remove the fixing plate before coming into use the lathe, and keep them well for future use. i.Install the lathe on a proper foundation. Considering convenient and safe operation, leave enough room to open the guards and doors during adjustment, lubrication and inspection. And before proceeding to work, check the lathe earthing condition for safety. j. Ensure the lighting is well(200-500Lx). Only an operator, who has been trained and has -4-


CKE6150-010

good knowledge of this Manual, can independently operate the lathe. k. Every time restart the lathe after a long time idle, lubricate it by the manual pulling rod of the lubricating pump. l. Do not run the lathe unattended. m. When fixing the chuck or some attachments on spindle, the power should be cut off in spindle running. n. Never mount a fixture, which has not been verified for its compatibility. o. Check the load of all centers.

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2.2. Danger The following dangers should be aware: 2.2.1 Cutting fluid Cancer of the skin may be produced by continuous contact with oil; particularly with straight cutting oils, but also with soluble oils. The following precautions should be taken: a.Avoid unnecessary contact with oil. b.Wear protective clothing. c.Use protective shields and guards. d.Do not wear oil soaked or contaminated clothing. e.After work thoroughly wash all parts of the body that have come into contact with oils. f.Avoid mixing different types of oils. g.Change oils regularly. h.Dispose of oils correctly. 2.2.2 Safe operation of chucks -5-


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a.Used in sound condition. b.If the chuck has sustained damage, high speeds may be dangerous. This applies particularly to chucks with gray cast iron bodies wherein fractures may occur. c.The gripping power required is not known in advance. d.The strength of the component being gripped, the area of the grip, the balance of the workpiece, etc. will all have a major effect on the safe max. RPM that can be used. There is the possibility of the workpiece becoming insecurely gripped due to the influence of centrifugal force. The factors involved include: ·Speed is too high; ·Weight and type of gripping jaws is non-standard; ·Improper radius of gripping jaws are operating; ·Inadequate lubrication condition; ·State of balance; ·The gripping force applied to the workpiece in the static condition; ·Magnitude of the cutting forces involved. ·Whether the workpiece is gripping externally or internally. Careful attention must be paid to these factors. As they vary with each particular application, a manufacturer cannot provide specific parameters for general use, the factors involved being outside his control. 2.2.3 General principles concerning operator safety a. Do not grip a component with grease or oil on it; Grip all components firmly; Do not attempt to hold components that are too awkward or too difficult to hold; Do not hold components that are too heavy for the lathe; Know how to hold components properly when lifting. b. Be sure to clean oil or grease from hand tools and levers; Be sure there is enough texture on the surface of the hand tool or levers for proper safe hand contact; Always choose proper hand tool and appropriate grip position on the lever; Do not use hand tools or levers in an awkward position; Do not apply excessive force; Do not use broken, chipped or defective tools; Do not allow any unfixed hand tools or handles on the chuck; Do not use tools without handles. c. Be sure workpiece cannot move in chuck or other holding device. d. Beware of irregular shaped workpiece and large burrs on workpiece. e. Always select the correct tools for the job. f. Always support the workpiece as necessary using chucks, steadies and centers. g. Correctly locate tool in socket heads and screw slots. Ensure check screw is tight. h. Do not rush work. Never substitute the wrong size tools if the correct sized tool is -6-


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not available or cannot be located in the shop. Do not move guards or open guard doors while lathe is under power. i. Do not place hand or body in path of moving objects. Beware of moving lathe parts that can fall. Be aware of where you are moving your hand or body in relationship to the lathe. Beware of holding tools or other parts inserted in or attached to the chuck or workpiece. Beware of hands or other parts of body that may in position to be hit by a chuck or workpiece. Never place hand on chuck or workpiece to stop rotation of the spindle. j. Beware of accident occurring because of pulling levers, operating clutch or switching on power. Know the function of each and every control. On machines with clutch drive make sure clutch is completely disengaged on stopping. And kept proper adjusted. k. Make sure power has been turned off when lathe is unused for sometime. Allow chuck to stop before operating it. Always check chuck area for chuck keys and loose items. Never start spindle with chuck key in the chuck. Do not allow distractions to interfere with lathe operations. l. Beware of lathe dangers when attending to other aspects of lathe operation, eg. Whilst operating tailstock. Beware of chuck guard and other guards loosing. m. Beware of loose hair near the rotating parts of the lathe. Make sure wearing protections before operating the lathe. Always wear the proper protections. Beware of performing another operation while I close proximity to rotating parts on the lathe. n. Always attend to filling and deburring operations. Always pay attention to file or deburring tools close to the chuck. Files and deburring tools may catch on chuck. o. Be sure clutch (where applicable) is in the neutral position when using gauges on the lathe. Beware of spindle running/stopping position when hands are resting on clutch levers. p. Be sure lathe is in neutral position when placing gauges on components gripped in the chuck. Be sure motor is not running when using gauges on the chuck. q. Beware of material flying from the lathe. Keep protective guards at the point of operation. r. When the chuck and workpiece are in motion never reach over, under or around them to make an adjustment. Never reach over, under or around a chuck or workpiece to retrieve anything. Beware of where you leave your tools during set up. Never reach over, under or around workpiece to move hand tool/lathe to another position. Never reach over, under or around the workpiece to tighten a lathe part. Never reach over, under or around workpiece to remove swarf. s. Know the proper procedure for applying loads. Never apply force from an awkward position. -7-


CKE6150-010

Never mount a workpiece too large/heavy for the lathe. Never mount a workpiece too large/heavy for the operator. Use the equipment necessary for handling workpiece. Never apply undue force on the accessory or control lever. Secure all workpiece. Secure all jaws, nuts, blots and locks. Always use the correct equipment. Never take cuts beyond machine’s capability. t. Never use excessive force in polishing and deburring. Always use proper hand tools to remove swarf. Never hurry to remove swarf. Beware of swarf wrapped around the chuck or workpiece. Cut off the power, before replacing the change wheels. Beware of parts may falling during operating chuck/lathe. Make sure that max. RPM of chuck and permitting cutting speed of gripped component are up to the requirement of RPM of choosed spindle. Be sure the end guard door is closed before lathe running. u. On the end guard door, have two nameplates as shown, one means if spindle is running, do not touch; the other means do not touch the running pulley and belts.

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CKE6150-010

2.2.4 Accidents at Metalworking Lathes using Emery Cloth

A high proportion of all accidents at metalworking lathes involve the use of emery cloth and result in injuries such as broken and occasionally, amputated fingers. Emery cloth is used to deburr, polish or size a wide range of components while they are rotating in lathes. Most accidents happen when each end of a strip of emery cloth is held in separate hands and passed around the back of the component being linished. If the cloth is wrapped around the fingers or becomes snagged on the component while it is tightly gripped, then a serious injury may occur.

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Precautions Employs should assess the need to use emery cloth on components rotating in a lathe. Such operations may not be necessary if: the finish being sought is not demanding; a sizing operation can be successfully performed either by turning or by further operations in a dedicated polishing or grinding machine. If it is required in process using the emery cloth against rotating components, then emery cloth should be applied using either: a.A backing board of good quality wood; b.A tool post onto which the emery cloth may be placed;

c. A “nutcracker” consisting of two backing boards, which are lined with emery cloth and joined at end shaped so that they may pass the surface to be linished. - 10 -


CKE6150-010

d. Abrasive-impregnated wire brushes. Force should be applied by pulling both ends of the cloth upwards, never allowing the cloth to go slack or to wrap around either the operators’ finger or the component. Only very short lengths or pads of cloth should be used which are incapable of causing entanglements. Gloves should never be worn when polishing is being carried out.

2.3. General practical operation knowledge Danger: ---(1)Never touch any Hi-Vo connector of control panel, transformer, motor, distributing box, and never make them short circuit. (2)Never touch these locations with wet hands to avoid short circuit. Warning: ---(1)Any operation is forbidden before ESB is release. (2)Isolate the machine before replacing fuse. (3)Allow sufficient working area for safe operation. (4)Always keep the floor dry and clean. (5)Check the connecting condition for correctness before starting the machine. Notice: ---(1)Cut off the main control switch immediately the wiring is disconnected. (2)Use the specified hydraulic oil and lubricant. - 11 -


CKE6150-010

(3)Replace the fuse with the rated one. (4)Any element in the electric cabinet shouldn’t be short, otherwise, accident or malfunction will occur. (5)Never alter the data capacity or other pre-set electric data. 2.4. Set-up before starting: Danger: ---Check carefully the insulating layer of cable, wire and conductor, which can cause electric shock and break. Warning: ---(1)Understand thoroughly the mechanism diagram and programming to aware of all the functions and operation sequences. (2)Wear protection, such as oil-proof shoes and clothes. (3)Ensure all NC units, control panel and door to the electric cabinet are closed. Notice: ---(1)The distributing board, connected with the factory power, must be installed in a distant position from the machine. The distributing box installed on the floor should be with guard to avoid short by iron chip. (2)For the first use of the machine after unpacking or use after a long time idle, every lubrication location must be filled with lubricant. Lubricate the guideway by the manual pulling rod of the lubricating pump. (3)Check the lubrication oil tank, hydraulic oil tank and coolant tank to ensure. (4)Check the action flexibility of each switch. The machine should be started sequentially, i.e. the factory power switch, machine mains and start switch on the control panel. 2.5. Regular inspection: Warning: ---Never reach your hand into the gap between belt and pulley when checking the belt tension. Notice: ---(1)Check the value of pipe pressure gauge. (2)Check the lubrication condition of every lubrication location. (3)Check the statue of every pilot lamp. (4)Check belt tension. 2.6. Warm-up - 12 -


CKE6150-010

Notice: ---Warm up of the machine, especially for spindle and feed shaft, they should be carried out at 1/2~1/3 of the max. speed for 10~20 minutes in automatic mode. And check the running condition of every part. 2.7. Set-up Warning: ---(1)The tools should meet requirements of machine (in length and diameter). (2)Check the wear condition of tools and replace with new one in time. (3)Never lay tool or anything on the cover, where it may fall down for vibrating. (4)The escape way should be built in the operation area, where enough brightness is required. Notice: ---(1)The length and installation location of the tools should be dependent on the workpiece to avoid danger. (2)Trial run is needed after the installation of the tool. 2.8. Operation Warning: ---(1)Never operate machine with long loose hair but you can have your hair curved and put on hat. (2)Never manipulate switch with gloves on, otherwise malfunction will happen. (3)The lathe should be stopped while adjusting the direction of cooling nozzle. (4)Never touch the moving workpiece or rotating spindle. Notice: ---(1)Be sure to avoid squeezing fingers when closing guard doors of the lathe. (2)Never open the guard door of the lathe during its normal running.. (3)When powerful cutting is carried out, take care of the chips and exposed body. 2.9. Interruption working Warning: ---Make sure power for the control panel and mains has been turned off when lathe is unused for some time after finishing a task of work. 2.10. Safety unit (1)Guard covers for guideways (2)Overtravel limit switch for X, Z-axis. - 13 -


CKE6150-010

(3)Soft limit switch. (4)Emergency button (5)Interlock switch Instructions to overload protection of main drive parts: Solenoid clutch is mounted on I axis of universal headstock. When spindle overloaded because of unexpected reason, friction disc of solenoid clutch on I axis will slip against damaging of main drive system elements. Instructions to overload protection of X, Z-axis drive parts: X, Z-axis driving parts overload protection can be realized by electric system control. The instant current to X, Z-axis servo motor may too large caused by malfunction of saddle and cross slide, which collide with workpiece or chuck; or caused by saddle and cross slide overtravel for the damage of X, Z-axis overtravel switch. If the current is larger than set value of the system, alarm will occur on the display. Two servo motors will stop at once. 2.11. Maintenance Danger: ---Any operation is forbidden before the power for mains and control panel is turned off. Warning: ---(1)The electric system should be maintained only by professional technicians and two more technicians are better. (2)Never change the position of overtravel switch and stop at will, otherwise fault will follow. (3)Record should be kept for maintenance. (4)Only after reading carefully the Maintenance Manual and Operation Manual, can the operator commence maintenance. 2.12. Application condition (1)Power:Rated voltage ±10% (2)Frequency:50Hz±0.5Hz (3)relative humidity:Lower than 75% (4)Ambient temperature:5°C~40°C, average temperature is no more than 35°C

within 24h.

(5)No condensation. (6)Atmosphere:No extra dust, acid rain, corrosive gas and salinity. (7)Avoid temperature growing because of lathe exposed to the sun directly or heat radiation. (8)Avoid abnormal vibration of the lathe. Warning:Provided the lathe is used to machine cast iron, dust collector should be used to ensure normal running of the lathe! 2.13. Max. permitting load of the lathe - 14 -


CKE6150-010

Universal type

Inverter type

Servo type

Power

8Kw

7.5Kw

11Kw

Torque

1100N.M

1300N.M

135N.M

Cutting force

10000N

12000N

2700N

Max. permitting weight for workpiece gripped in chuck:500Kg 2.14. Other declaration Warning: ---Never change the spindle speed when it is rotating! The workpiece must be gripped by the chuck whilst it is running at high speed to protect the chuck jaws from flying! 2.15. The following industrial safety recommendations should be placed on the machine tool or a notable position near the machine a) Only a worker, who has been trained and is familiar with the manual’s content, may have the right to independently operate the machine tool. b) Before starting the machine, check the proper setting of operating elements and selection of parameters. The operator should wear proper protective clothing. c) Before switching on the machine, check that this task dose not form a accident hazard to another person. d) Do not let hands or head reach over rotating or moving parts. e) In case of incorrect operation occurs, switch off the machine and report to the superior. f) Secure the workpiece and tools gripping. So it is not allow any fastener loose caused by cutting forces. g) Maximum speed of spindle. The operator has to verify the max. allowed speed of the chuck (indicated on the chuck) and has to limit the speed of the spindle accordingly. If the workpiece, which the operator is working with, is beyond rear of spindle, consequently the spindle speed has to be limited. h) The tailstock should be used according to this Manual and be well clamped before working. Cannot unclamp or lift it during working. i) Only the responsible and authorized service technicians, who have technical knowledge of the machine and relevant technical documents, can motor protector. After opening, it should be good closed and well fixed with the previous screws. 2.16. Noise level - 15 -


CKE6150-010

According to GB/T16769-1997Metal Cutting Machine Tool-Noise Level Measuring, measure at 6 positions 1 meter away from the machine (height is 1 meter). Maximum noise level is less than 83dB (A); Note: The measuring condition is that the spindle with standard chuck is running at top speed.

3. Machine handling, installation and run in 3.1. Handling Transfer the machine as follows: Fix the guard door during transportation (Lock tight the fastening screws of fixing parts both sides under the guard door). The machine packing case should be lifted by steel cable according to the lifting marks outside the package. Additionally, lessen kinds of impact and vibration. Especially, when handling and lowering the machine, never make the bottom and sides of the packing case be impacted and vibrated fiercely, and never make the packing case over-slant, otherwise the machine’s accuracies can be affected or the machine can be damaged. When moving the machine package with rolling bar on inclination floor, it is required that the inclination angle not be more than 15°and the diameter of the rolling bar not more than 70mm. Moreover, the machine package is not allowed to be put on any edged things or put upside down, and all the measures are to keep the machine’s accuracies. When unpacking the machine, first to inspect the appearance of the machine, then check the accessories and tools according to the Packing List. When lifting the unpacked machine with crane, steel cable should be inserted into the bed web of No.1 and No.3 holes, as shown in Fig. 3. At the same time, saddle and tailstock should also be used to keep balance. When hoisting, wood pads should be put in the area where steel cable - 16 -


CKE6150-010

touches the machine and protect plate; or put the steel cable inside one rubber tubing, as can protect the machine and protect plate.

3.2 Unpacking and transportation Using iron pallet or wooden board for packing, and depend on transportation means and order to choose one. After receiving the lathe, its external state and equipment should be checked. It is need carefully check the condition of all the hoisting equipments and replace anything unreliable. In no case should operating or moving parts (such as, guards, saddles, tailstock, etc.), when lift the machine. It is recommended to locate the lathe far from vibration, chemical gas, and without the influence of electrical interference. Keep the balance, when lift and unload the machine. To avoid damaging of paint coating, cushion blocks should be used in all places where lings touch the machine housing. 3.3 When lifting the machine, the following items should be paid enough attention toďźš a.

Never impact the NC system and HI-VO switch plate. Before hoisting the machine, first to inspect whether all parts are fixed and if any excess thing is laid on the machine.

b.

Keep the machine balanced both in longitudinal and cross direction, thus, keep it balanced once it leaves the floor.

c.

The lifting angle of the steel cable should not be more than 60°.

d.

Whenever lifting the machine, if more than one person operates, they must send out information mutually to guarantee their safety.

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CKE6150-010

WARNING The minimum capacity of hoisting equipments (crane, sling, etc)must more than weight of the machine! 3.4. Required space and the surroundings Allow sufficient area around the machine to ensure easy operation and reparation, e.g. work loading, chips removal, coolant tank cleaning and access to the electric cabinet. Since these machines are constructed with higher lever of accuracy, it is therefore necessary that they are installed in work shops having better conditions than average. Recommended operating conditions: ◎Relative humidity of air 50% to 70%, at the temperature of 20°C; ◎Temperature in work shop is 18°C to 22°C, and temperature gradient should be 0.5°C /h; ◎Away from all sources of vibrations. Otherwise build vibration-proof ditch around the lathe; ◎The noise level around the lathe is no more than 78dB. The level of vibration of the foundation defined by an acceleration of up to 0.5m/s2; ◎Lighting of the work shop should be uniform and shadow-free; ◎The working area should free from condensed water, dust and chemical gas; ◎Do not expose the lathe to the sun directly; ◎Separate the power wire and other high-power devices. 3.5. Requirements to foundation Build the foundation according to the Foundation Installation Diagram (Fig.4) before installing the machine. Place wedges around every foundation bolt hole, then put the machine onto the wedges. Leveling the machine, and make the readings of the level not exceed 0.06/1000mm both in longitudinal and cross direction. Then fix the foundation bolts with concrete, simultaneously check the setting of the machine with level again. Check the accuracy when concrete is fully dry and finish cleaning. At last, fix the wedges with concrete. Inspect it as the method shown in Certificate of Quality.

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大连机床集团

CKE6150-010

3.6. Cleaning In the period of set-up of the lathe, clean all anti-rust coating with cleaning agent. Coat the gliding surface and all the exposed surfaces with oil against rust. After cleaning the machine thoroughly, fill adequate lubricant according to the machine lubrication chart. 3.7 Run in Before run-in, remove the guards and fixing parts for the NC system during transportation (see Fig. 2), and keep them well for future use. Before power on the machine, check whether the electric system is in good condition and whether the motor is damp; then switch on the mains and simultaneously check the following items: Pull the selector lever of headstock to the neutral position, then start the main motor. Provided oil can be observed in the sight glass located in front of the headstock, make the spindle run for some time at the lowest speed, afterwards increase the spindle speed step by step to drive the tool post moving in X- and Z-axis. And then do rapid moving to test the function of limit switch. Manual operation is adopted. After verifying every motion is normal by manual operation, do the dry run under manual input mode and check if CNC device is stable and reliable. Finally, input the program to carry out automatic cycle test.

SUGGEST To keep high precision, for newly installed machine, check its level every week. When the foundation is rigid enough, you may level the machine once per 1-3 month(s). 3.8 Connecting up to mains supply - 19 -


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The lathe should be connected to the electric mains according to the Electric Manual. The voltage should be same with the lathe. The coolant pump and spindle motor have the phases separately. If the motor runs reversibly, please adjust the phase of the main power supply.

WARNING Only the professional can connect the mains. Please do not switch on the machine if the voltage of the machine is different from the supplied power, and please contact the electric engineer to modify.

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4. Main technical specification and parameters(universal, inverter, servo type) Ser

Specification and parameters Item

Unit

No.

750

1000

1500

Max. swing dia. Over bed

Mm

φ500

Max. swing dia. Over slide

Mm

φ280

Max. turning diameter

Mm

Max. length of workpiece

Mm

φ500(4-station) 680

2000

φ400(6-station)

930

1430

1930

1435

1935

1 Distance from spindle center to bed Mm

250

Mm

1130

X-axis

Mm

280

Z-axis

Mm

guideway surface Distance from spindle center line to

4

X-axis Z-axis

Feed speed

3

Spindle

2

Travel

floor

685

935

Work feed

Mm/min

0.01~3000

Rapid feed

Mm/min

4000

Work feed

Mm/min

0.01~6000

0.01~4000

Rapid feed

Mm/min

8000

6000

Spindle speed(universal)

R/min

45~2000

Spindle speed(inverter)

R/min

7~2200

Spindle speed(servo)

R/min

30~3000

Spindle nose type(universal, D8 inverter)

7

Tailstock

6

Motor

5

Tool post

Spindle nose type(servo)

A28 φ82

Spindle bore dia.

Mm

Tool station

Station

4

6

Tool shank

Mm

25x25

25x25

Tool change time(1 station)

S

2.4

2.0

Tool change time(full stations)

S

4.3 Manual

Hydraulic

Pneumatic

Max. travel

Mm

150

120

120

Quill diameter

Mm

φ75

φ75

φ75

Taper of tailstock quill

Morse

5

5

5

Universal

Inverter

Servo

Power

Kw

6.5/8

7.5

11

Speed

R/min

1440/2880

570~2940

0~6000

Main motor - 21 -


CKE6150-010

Classification

Fanuc-0i-mate

SIEMENS

X-axis servo

Power

Kw

1.2

0.94

motor

Speed

R/min

3000

3000

Z-axis servo

Power

Kw

1.2

1.88

motor

Speed

R/min

3000

3000

Cooling pump

Power

Kw

0.12

motor

Flow

L/min

25

Centralized

Power

W

3

Displacement

Ml/time

5.5

lubricator motor

8

9

X-axis

Z-axis

Ballscrew dia.

Mm

φ20

φ40(2000,φ50)

Ballscrew thread pitch

Mm

4

6

Chuck type

Universal, inverter:K11250C;D8

Ser

servo:K11254C/A28G

Specification Item

Unit

No.

750

1000

1500

2000

Mm

2577x1749x1620

2827x1749x1620

3327x1749x1620

3827x1749x1620

Mm

2760x1910x2180

3010x1910x1970

3510x1910x2180

4010x1910x2180

Mm

2760x1970x1970

3010x1970x1970

3510x1970x1970

4010x1970x1970

Net weight

Kg

2550

2600

2700

2800

Gross weight

Kg

3150

3300

3450

3600

Overall dimension(L×W×H) Packing case dimension (domestic) (L×W×H) 10

Packing case dimension (export) (L×W×H)

5. Machine transmission system There are two kinds of transmission system, i.e. automatic step speed change and automatic stepless speed change. 5.1. Automatic step speed change (Double-speed motor & solenoid clutch) (universal) Transmission system assembly of machine(See Fig. 5) Double motor+ two solenoid clutch+ 3-step manual speed change lever make the spindle get 12 steps of speed. Transmission of spindle at lowest speed: 1440×112/224×45/65×19/56×17/68=45/min Transmission of spindle at some middle speed: 1440×112/224×55/55×44/32×17/68=250/min Transmission of spindle at highest speed: - 22 -


CKE6150-010

2880×112/224×55/55×44/32×50/50=2000/min For the other transmission, see the Transmission System Assembly. The spindle speed range is listed in the following table(r/min) L

45

63

90

125

M

180

250

355

500

H

710

1000

1400

2000

There are 3 steps of manually-operated speed change---(L),(M),(H)and 4 steps speed change can be realized in each manual step.

- 23 -


CKE6150-010

Bearing List

- 24 -


CKE6150-010

Ser. Description

Model

1

Bearing

2

Bearing

Accuracy

Dimension

Qty

Position

302

15×42×13

1

Headstock Ⅴaxis

105

25×47×12

1

HeadstockⅤaxis

7020ACTA/P5DBB

100×150×48

1set

HeadstockⅣaxis

D107

35×62×14

1

HeadstockⅢ axis

No.

Angular contact

3 4

bearing Bearing

5

Bearing

D208

40×80×18

1

HeadstockⅡaxis

6

Bearing

D308

40×90×23

2

HeadstockⅠaxis

7

Bearing

D108

40×68×15

4

HeadstockⅠaxis

8

Bearing

D207

35×72×17

1

HeadstockⅠaxis

9

Bearing

D106

30×55×13

1

HeadstockⅡaxis

D2007108E

40×68×19

1

HeadstockⅢ axis

D7507E

35×72×23

1

HeadstockⅢ axis

C3182124K

120×180×46

1

HeadstockⅣaxis

Conic roller

10

bearing Conic roller

11

bearing Dual-row cylinder

12 roller bearing 13

Bearing

D102

15×32×9

1

X-axis leadscrew

14

Thrust bearing

8205

25×47×15

1

Tailstock

15

Bearing

D206

30×62×16

1

Z-axis leadscrew

16

Bearing

ZARN2052

20×52×46

1

X-axis leadscrew

17

Bearing

ZARN3570TN

35×70×54

1

Z-axis leadscrew

Gear List

- 25 -


CKE6150-010

Ser.

Deflection Position

Teeth

Modulus

Heat Material

coefficient

No.

Part No.

Remarks

treatment Special

1

HeadstockⅤaxis

66

2

-0.5

20501A nylon

2

HeadstockⅣaxis

66

2

3

HeadstockⅡaxis

55

4

HeadstockⅠaxis

5

-0.4

45

G48

20705

2.5

45

G52

20719

55

2.5

45

G52

20716

HeadstockⅡaxis

65

2.5

45

G52

20713

6

HeadstockⅠaxis

45

2.5

45

G52

20715

7

HeadstockⅡaxis

44

2.5

45

G52

20712

8

HeadstockⅢaxis

32

2.5

45

G52

20709

9

HeadstockⅡaxis

19

2.5

45

G52

20711

10

HeadstockⅢaxis

56

2.5

45

G52

20710

11

HeadstockⅢaxis

50

3

40Cr

G52

20707A

12

HeadstockⅢaxis

17

3.5

40Cr

G52

20720

13

HeadstockⅣaxis

50

3

45

G52

20703

14

HeadstockⅣaxis

68

3.5

45

G52

20702

5.2. Automatic or manual stepless speed change(inverter) Machine transmission system diagram(see Fig. 6) Change the speed of motor through the inverter, and spindle can realize 3-step stepless speed change by 3-step manual or automatic speed change. Constant linear speed cutting can be achieved in every step. The motor speed changing range is 5~99Hz, below 33.3Hz is the area of constant torque; Above 33.3Hz is the area of - 26 -


CKE6150-010

constant power, and for speed regulating characteristic graph see Fig.7. The spindle speed range is listed in the following table(r/min)

L

7~135

M

30~550

H

110~2200

There are 3 steps of manually-operated speed change--(L),(M)and(H)

- 27 -


CKE6150-010

- 28 -


CKE6150-010

Bearing List for inverter type main transmission(See the following table)

Ser.No.

Description

Model

Dimension

Qty

Position

1

Bearing

302

15×42×13

1

HeadstockⅤaxis

2

Bearing

105

25×47×12

1

HeadstockⅤaxis

7020ACTA/P5DBB

100×150×48

1 set

HeadstockⅣaxis

D209

45×85×19

2

HeadstockⅡaxis

Accuracy

Angular contact 3 bearing 4

Bearing

- 29 -


CKE6150-010

5

Bearing

D107

35×62×14

1

HeadstockⅢaxis

6

Bearing

D106

30×55×13

1

HeadstockⅡaxis

D2007108E

40×68×19

1

HeadstockⅢ axis

D7507E

35×72×23

1

HeadstockⅢ axis

C3182124K

120×180×46

1

HeadstockⅣ axis

Conic roller 7 bearing Conic roller 8 bearing Dual-row cylinder 9 roller bearing 10

Bearing

D102

15×32×9

1

X-axis leadscrew

11

Thrust bearing

8205

25×47×15

1

Tailstock

12

Bearing

D206

30×62×16

1

Z-axis leadscrew

13

Bearing

ZARN2052

20×52×46

1

X-axis leadscrew

14

Bearing

ZARN3570TN

35×70×54

1

Z-axis leadscrew

Gear List for inverter type main transmission(see the following table)

Ser.

Defection Position

Teeth

Modulus

No.

Heat Material

coefficient

Part No. treatment

Special 1

HeadstockⅤaxis

66

2

-0.5

20501A nylon

2

HeadstockⅣaxis

66

2

3

HeadstockⅢaxis

32

4

HeadstockⅡaxis

5

HeadstockⅡaxis

-0.4

45

G48

20705

2.5

45

G52

20709

44

2.5

45

G52

20712

19

2.5

40Cr

G52

A20701

+0.525 - 30 -

Remarks


CKE6150-010

6

HeadstockⅢ axis

56

2.5

45

G52

20710

7

HeadstockⅢ axis

50

3

40Cr

G52

20707A

8

HeadstockⅢ axis

17

3.5

40Cr

G52

20720

9

HeadstockⅣaxis

50

3

45

G52

20703

10

HeadstockⅣaxis

68

3.5

45

G52

20702

5.3. Full stepless speed change(servo type) Machine transmission system diagram

The main transmission of the machine is driven by FANUC β12/7000i

AC spindle motor. Pass to the

spindle through multi-V belt by ratio 1:2, which make spindle max. speed to be 3000r/min, constant power 750-3000r/min. The spindle is running synchronous with encoder driven by a group of timing belt. The encoder exchanges spindle angle displacement to photoelectric pulse signal, and then transfer to CNC system to realize controlling spindle speed. See the figure for characteristic graph of spindle output power and torque.

- 31 -


CKE6150-010

Bearing List for servo type main transmission(see the following table)

Ser. Description

Model

Bearing

NN3022TKRCC1P5

Accuracy

Dimension

Qty

Position

Remarks

110×170×45

1

Spindle

NSK

No. 1

- 32 -


CKE6150-010

Encoder 2

Bearing

D80304

20×52×15

2 shaft

Angular contact 3

130×200×33 7026A5TDBDC8P4

1 set

×3

bearing

Spindle

NSK

X-axis 4

Bearing

D102

15×32×9

1 leadscrew

5

Thrust bearing

8205

25×47×15

1

6

Bearing

D206

30×62×16

1

Tailstock Z-axis leadscrew X-axis

7

Bearing

ZARN2052

20×52×46

1 leadscrew Z-axis

8

Bearing

ZARN3570TN

35×70×54

1 leadscrew

Gear List for servo type main transmission(see the following table) Ser.

Deflection Position

Teeth

No.

Modulus

Heat Material

coefficient

1

Spindle pulley

2

Encoder pulley

50

Part No.

Remarks

treatment HT200

B20105

45

B20706

6. Lubrication system Proper lubrication will enhance machine performance and prolong its work life. Fill up is according to the schedule strictly. Every time before start, preparation should be checked, and lubrication condition should be checked regularly. The machine has two sets of lubrication system: first one is for lubricating guideway, on - 33 -


CKE6150-010

right side guard; the second is for headstock, at the outside of left plinth. In order to ensure the machine work normally, all the friction surface of the machine should be lubricated fully. 6.1 Headstock(see Fig.10) The lubrication oil tank and oil pump are located in the front plinth. The lube, through the wired oil filter, is pumped by the oil pump to the oil distributor, then every driving parts and spindle front/rear bearings in the headstock can be lubricated, after which, the lube will return to the oil tank through the oil return pipe located in the bottom part of headstock. The oil supply condition can be observed in the oil sight glass. For the first oiling the machine, the following items should be paid attention to: (1)Lube is filled into the oil tank through the headstock; (2)10 L of oil is demanded to be filled. If excessive oil is filled, overflow will occur. In order to guarantee the normal running of the machine, it is suggested that the headstock oil tank (including oil filter) should be cleaned every 3~4 months. 6.2. Saddle, slide and X, Z-axis ball screws The lubrication for the saddle, slide and X, Z-axis ball screws will be finished by the centralized lubricator, mounted on the tailstock, to supply lube. 5.5 ml of lube from the centralized lubricator will flow at the interval of 15 minutes to every lubrication location through pipes and metrical units. There are 6 lubrication points: (1)2 off cross slide guideway (2)1 off X-axis leadscrew (3)2 off saddle guideway (4)1 off Z-axis leadscrew For the first starting of the machine, the centralized lubricator should be started firstly; only after every oil circuit is filled with lube and every lubrication location gets lube, can the machine be started, afterwards, it is unnecessary to start the centralized lubricator before starting the machine. Lubricant can be supplied manually as necessary, and the oil supplying method is as follows: pull the manual pulling rod of the lubricator to the upper limit, then release it to make the piston reset of itself, up to now, one act of oil supplying is finished. Never discharge oil by force with manual pulling rod to avoid damaging the parts inside the pump. Alarm will occur when the lube in the lubricator is in low level and lube should be refilled in time. The following reasons can cause the fault: 1) Dirty oil, broken sieve and lubricating units incorrect closing will stop lubrication system; 2) Pipe is damaged, or connector is leaking; 3) Control device or protective device is damaged; 4) Parameters in control device are set wrong; 5) The ingredient in the lubricant may damage the seal; 6) The sealing function of lubricating pump has been damaged; - 34 -


CKE6150-010

Clean the oil tank and sieve, etc. devices as follows: remove the metering unit from oil distributor, and then clean it in kerosene (or other proper cleanser), after which blow the bottom (with thread). If pressure pipe is broken, replace it and connect it well. 6.3. X, Z-axis bearing X, Z-axis bearings are lubricated by NBU long-lasting grease. Only renew it at the time of overhaul, and do not need to fill up any of other time. 6.4. Tool post According to Tool Post Operating Manual to lubricated the tool post. 6.5. Tailstock Fill the oil cup every shift. 6.6. Machine lubrication indication to oil condition ďźˆsee Fig. 11

- 35 -


CKE6150-010

7. Cooling systemďźˆsee Fig. 12 The cooling system is mounted in the coolant tank. The coolant, through the pipe circuit, is pumped by the cooling pump to the saddle, and then through pipe circuit to slide, finally it blows out from the nozzle, located in the tool post. The 4-starion tool post of the machine is internal cooling. The nozzle direction can be adjusted if not appropriate. Beware that the nozzle direction must be adjusted when the machine is in stop state. When the machine adopts horizontal 6-station turret, the cooling system shall be external cycle, i.e. the coolant should be sent to the cutting locations by the cooling hose on the rear of the saddle. The coolant flow can be adjusted by the taper valve on the top of the cooling strut. The used coolant flows back to the chip cart and through the small filter hole at the bottom of the cart back to coolant tank. The coolant tank should be cleaned at regular intervals. 3-phase electric pump, model AYB-25 is equipped with this machine and the coolant is a kind of emulsion. According to the different requirements of the workpiece, the customer can make up by himself or select different trademark of emulsion.

Notice Never close the regulating valve while coolant pump is running, or overload to the pump will occur.

- 36 -


CKE6150-010

8. Hydraulic system 8.1. Function of hydraulic system 8.1.1 Clamping and releasing of power chuck 8.1.2 Clamping and releasing of tailstock 8.2. Composition of hydraulic system 8.2.1 Oil pump and oil tank unit The hydraulic oil tank of the machine is located on the base behind the machine bed, which is connected by bolts. The oil tank has a capacity of about 75L(L—HM32;GB11119)of hydraulic oil. And oil pump motor set (YBDZ—C20(V3)—CY) is mounted on the top surface of the oil tank. Outlet pressure of the pump is P1=3.0Mpa. 8.2.2 Chuck clamping system unit Clamping and releasing actions of the power chuck are controlled by 2-position,4-way solenoid change valve (24EO—F10B—W),a check valve(A—F10D3—P)and a pressure reducing valve(J1—Fa10D3—P). Clamping force may be adjusted with the pressure reducing valve according to working requirements, with pressure P2=0.7-2.5Mpa. To ensure that the machine starts to cut workpiece only when the workpiece is clamped firmly, 2 pressure relays(PD—Fa10D—B)and(PD—Fa10D3—A)are fitted to the oil inlet and outlet circuits respectively, with set pressure: SP1=SP2=P2. So the machine begins to cut workpiece after the - 37 -


CKE6150-010

pressure relay sends a signal. 8.2.3 Tailstock clamping unit Clamping and returning actions of the tailstock are controlled by 3-position 4-way solenoid change valve (34EO—F6B), a check valve(A—F6D—P)and a pressure reducing valve(J—Fa6D—P—1). Clamping force may be adjusted with the pressure reducing valve according to working requirements, with pressure P3=0.6-1.6Mpa. To ensure that the machine starts to cut a workpiece only when the workpiece is clamped firmly, a pressure relay(PD—Fa6D—B)is fitted to the oil inlet circuit, with set pressure SP3=P3. So the machine begins to cut workpieces after the pressure relay sends a signal. 8.2.4 Hydraulic overlapped valve set Overlapped valve sets are overlapped directly by means of bolts, so the hydraulic system required is formed. Each overlapped valve serves functions of control and passage. 8.2.5 Main hydraulic piping The main hydraulic piping consists of the oil tank, hydraulic overlapped valve set and executive units, which are connected by seamless steel pipes and oil resistant rubber hoses, so as to realize transmission of hydraulic energy and finish the function of hydraulic transmission system further. 8.3 Adjustment and maintenance of hydraulic system 8.3.1 Exhausting air within hydraulic system After mounting of machine and hydraulic piping, fill the oil tank with clear hydraulic oil 75L, L-HM32; GB11119. When the machine is started initially or does not be used for a long period of time and the oil pump is started, should preloosen the adjustable bolt of pump, and then repeat starting of oil pump until the air within the oil pump is exhausted out completely so that the pump can run without noise. When starting drive parts, should make the oil cylinder have whole stroke reciprocating action several times and open the air exhausting hole of oil cylinder to exhaust air until the drive parts can run steady. 8.3.2 Pressure adjustment of system After starting the machine, check the pressure of each part according to requirements of system pressure. When the pressures are adjusted ready, other works may be done on the machine. Pressure values may be got from the pressure gages. Without use of pressure gages, turn the switch of pressure gages to zero to make the gages be in non-work state so as to protect them. 8.3.3 Maintenance for hydraulic parts Clean the filter and check oil level of oil tank every three months, and clean the oil tank every 6 months; when machine repairing, wear condition of hydraulic overlapped valve set and O-rings between connecting parts need to be checked, and replace them in time. 8.4. Common troubles and trouble shoot 8.4.1 Oil pump does not supply oil and oil transmission amount is reduced obviously. Cause:a. Counter-rotation of oil pump motor; b. Oil in oil tank is not enough; c. Block of oil suction pipe; - 38 -


CKE6150-010

d. Damage of oil pump. Removal methods:Change motor wire of oil pump; check oil level; remove dirt; check and repair oil pump. 8.4.2 System pressure is not enough Cause:a. Large leakage at pipe joints of oil cylinder; b. Block of valve core; c. Damage of oil distribution disc of oil pump; d. Damage of O-ring; e. Block of damp hole of pressure reducing valve. Removal methods:Check and repair oil pump and pressure reducing valve; tighten the pipe joints. 8.4.3 Noise in system Cause:a. Vanes of oil pump are blocked, not flexible; b. Have air in oil pump; c. Oil suction pipe and oil filter are blocked; d. Vibration of valve. Removal methods:Exhaust air; clean oil suction pipe and oil filter; check and repair oil pump and valve. 8.4.4 Motion speed of hydraulic drive parts is not uniform or too slow Cause:a. With air in system b. Damage of oil pump, supply of oil is not uniform; c. Oil in oil tank is not enough; d. Leakage of piping. Removal methods:Exhaust air; check and repair oil pump and piping; fill oil into oil tank. 8.4.5 Possible error actions in run of machine Cause:It is mainly caused by solenoid slide valve because electromagnet cannot be suction-closed or released. Removal methods:Check and repair electromagnet slide valve, change spring or electromagnet on the base of checking and repairing of circuit. 8.5. Circuit diagram of hydraulic system(see Fig. 13) The normal mounting of the machine hydraulic system includes hydraulic chuck, oil cylinder and hydraulic tailstock; if no hydraulic tailstock is equipped with the machine as demanded, we can only remove the circuit of the overlapped valves of the tailstock, and the rest shall be kept as what they are.

- 39 -


CKE6150-010

9. Main structures of machine and their usage & adjustment 9.1. Bed The bed is made of high-grade cast iron HT300. The induction-hardened surfaces of guideways have good - 40 -


CKE6150-010

wear-resistance. The main motor is mounted in the front leg and coolant is stored in the rear leg. The whole machine is compact in design and requires a small floor space. 9.2. Headstock The headstock adopts gear transmission. All the gears are made of high-quality steel and the surfaces of teeth are induction-hardened, so they are wear-resistant. The drive is directly transmitted to the gears in headstock by pulley from the main motor. Adjustment of spindle bearing: In general, the spindle accuracies have been adjusted ready. It is not necessary to do any adjustment. But if there is some unexpected thing happens, such as carriage strike or spindle accuracy is affected by other reasons during use of machine, spindle adjustment must be made. Do adjustment according to the following steps: (see Fig.14)Unscrew nut 1 or locking screw on nut 2; Then adjust nut1 or 2. When adjustment is done properly(spindle may be rotated with 1-2 revolutions by hand),tighten the locking screw. If not reaching the requirement, repeat the actions mentioned above. Dry run should be done for an hour after finishing adjustment. Temperature of spindle bearing is not allowed to exceed 70°. Otherwise, should loosen the nut a bit.

9.3. Saddle(see Fig. 15) The cross slide of carriage is driven by AC motor 1, through a pair of teeth pulleys 2 and 3, to transmit power to ball screw 5, and screw nut base 4 is fixed with cross slide 6 so as to drive the cross slide of carriage.

- 41 -


CKE6150-010

9.4. Tool post For the details of tool post structure and adjustment, refer to Tool Post Operating Manual. 9.5. Longitudinal drive unit (see Fig. 16) Longitudinal motion is controlled by AC servo motor 1, through a pair of teeth pulleys 2 & 3, to transmit power to the ball screw 4, and the screw nut base 5 is fixed on the connecting support in the front of the saddle so as to drive the saddle to move longitudinally.

9.6. Tailstock 9.6.1 Manual tailstock(see Fig. 17) Tailstock can be quick clamped on bed guideway by operating locking lever(19). This can be adopted in finish turning and semi-finish turning to avoid tailstock moving while turning. Under coarse turning or other heavy-load cutting, the locking nut(24)should be lock tight as well. Lock the quill by the lever(18). When machining taper parts with tailstock, adjust two sides of screws(C)to move the tailstock body to a appropriate - 42 -


CKE6150-010

position firstly,then lock lever(19)and screws(C).

9.6.2 Hydraulic tailstock(see Fig. 18) The movement of the quill is realized, through hydraulic drive, by control of pedal switch. Pre-clamp force of tailstock may be adjusted by adjustment of the pressure-reducing valve. For details see hydraulic circuit diagram and description. N.B.: (1)Pressure relay should signal spindle to rotate only after clamping the tailstock. (2)The tailstock should start to clamp only in the conditions of clamping of chuck and the electromagnets being in their places. (3)Only when the tailstock does not clamp any workpiece, pressure of hydraulic system may be adjusted.

- 43 -


CKE6150-010

9.7. Chuck 9.7.1 Manual chuck 3-jaw manual chuck is of the standard chuck fitted for the machine; hydraulic chuck may also be fitted according to user's requirements. Operator should pay attention to that: not allow spindle idle run when the chuck does not clamp workpiece, or the jaws are easy to drop off to injure some person. The max. speed of φ250 manual chuck is 3000r/min. N.B.: When 4-jaw chuckφ400 or face plate is used, the spindle speed is required not more than 800r/min. 9.7.2 Hydraulic chuck The max. speed of φ250 hydraulic chuck is 2500r/min. Clamping and releasing of hydraulic chuck are controlled by the duplex pedal switch. Clamping force may change within a certain range (according to thickness of workpiece) by adjusting the pressure-reducing valve. See hydraulic circuit diagram and description about details. N.B.: (1)Pressure relay should signal spindle to rotate only after clamping the tailstock. (2)Only when the tailstock does not clamp any workpiece, pressure of hydraulic system may be adjusted. 9.7.3 Electric chuck The max. speed of φ250 electric chuck is 1500r/min. The chuck is controlled by the pedal switch. It may serve functions of inner or outer clamping. Only in case of chuck clamping, the spindle may be rotated. And when the spindle stops, chuck may be released. See operating - 44 -


CKE6150-010

manual of electric chuck and electric operating manual about details. 9.8. Spindle basic dimensions Universal and inverter types adopt D8 spindle nose. For basic dimensions see the following diagram.

Servo type adopts A28 spindle nose, the following diagram shows basic dimensions

9.9. Motor unitďźˆsee Fig. 19

- 45 -


CKE6150-010

The main motor is mounted on the motor base 2 in the front plinth of the machine, and power is transmitted to the headstock through the belt 1. V-belt should be tensioned properly to ensure enough power transmission. But, should pay attention to that tension force should not be larger than allowed value for belt. If larger, service life of V-belt and bearing will be affected; if tension is too small, V-belt cannot be enabled to transmit power rated. Should adjust tension of V-belt regularly. Adjustment should be made when the machine is put into use for 3 months. Then adjust tension each half a year. See the following about adjustment steps: (1)Pull V-belt in the direction vertical to the belt by hand, and acting force must be in the middle of two pulleys. (2)Turn the adjustable nut 3 to change the position of motor base 2 upper or lower so that the belt 1 has a proper tension. 10. Cutting limit size diagram for tool post(see Fig. 20 and 21) Note:(1)When max. cutting diameter is φ500(vertical 4-station tool post);φ400(horizontal 6-station turret)length of workpiece to be cut depends on extension length L of tool and system rigidity. (2)When using special tool holder or tool with super length, must pay attention: select a proper change tool position so as to prevent that the tool impacts the front guard door of the machine during tool changing. (see Fig.22) 11. Perishable parts

Ser. No.

Part No. & model

Name

Qty

- 46 -

Manufacturer


CKE6150-010

Tianjin machine tool

Wet type 1

DLM9-10

2 solenoid clutch

Tel:022-26352207 Liaoning Pulandian machine

Electromagnet 2

electrical equipment plant

LL10-16DB

1 brake

accessory factor Tel:13942874943

- 47 -


CKE6150-010

- 48 -


CKE6150-010

12. Check and maintenance Routine check Ser.

Position

Item

Remarks

No. 1

Are the functions of the switches and lever normal? Control panel Can alarms be indicated?

2

Cooling fan

Can the funs for control box and control panel rotate?

3

Safety unit

Can the unit serve its functions normally?

4

Oil indicator for H/stock oil tank

Is there enough oil? Oil low and add

Oil

indicator

for

Is oil polluted obviously?

centralized lubricator 5

Is lubricating oil enough? Guideway Is scraper damaged?

6

Are there any noise and vibration? Movable parts Is moving smooth and normal?

7

Is there any wire break? Outer wire, cable Is there any damage of insulation coat?

8

Is there any oil leakage? Piping Is there any coolant leakage?

9

Add as necessary Is coolant level proper? Change as Coolant level

Is coolant polluted obviously? necessary Is oil disk filter blocked? Clean as necessary.

10

Motor, gearbox, other rotating parts

11

Chuck lubrication

12

Is there any noise or vibration? Is there any abnormal heat? Lubricate circumference of jaws with lubrication oil

Once a week

Clean surface of chuck, carriage, slide plate and rear

Do this after

Clean guard cover and remove chips.

Regular check (see the following table) - 49 -

work.


CKE6150-010

Ser. Position

Item

Period

No. Check if there is peculiar smell and color change for Control

Electric unit and

1 panel

electric units, and wear of touch-surfaces and check

6 months

tightening of tough-bolt.

wiring bolt

Check if there is any dirt and clean it if necessary.

1 month

Electric Connection

connection

of

units

for Check and tighten wiring bolts. Check and retighten

2

inner

such

6 months

as bolts of terminals of relays, etc.

units

control

box,

machine etc. Limit 3

Electric unit

X, Z-axis

switch

Check and retighten mounting and wiring bolts.

6 months

Solenoid valve

Check functions and actions by concrete operating.

1 month

Sound,

Check if there is any abnormal sound or temperature

temperature rise

rise at bearing, etc.

Sensor

4

1 month servo motor

Sound, vibration, 5

Main motor

Check abnormal sound at bearing, etc.

6 months

Check appearance and tension. Clean pulley.

6 months

temperature rise, insulation Belt 6

V-belt Pulley Chuck

7

1 year

Chuck Rotary oil

8

Dismount and clean chips in chuck.

X & Z axes

Check oil leakage of rotary oil cylinder.

3 months

Clearance

Clearance measurement with micrometer.

6 months

Lubricating unit

Clean suction-filter

1year

Lubricating piping

9 system

Check if there is any oil leakage, block and break of 6 months piping

Filter Cooling 10

Do it at Change cooling liquid; clean filter, electromagnet

Chip tray unit

proper and coolant tank. Clean chip tray.

Electromagnet

time - 50 -


CKE6150-010

11

Foundation

Bed level

Check and adjust bed level with level-meter.

13.

Common mechanical faults and their removal methods

1 year

Ser. Item

Check methods

No. 1. Check whether repositioning of middle slide plate is accurate a. Check if fixing bolt of nut of middle slide plate leadscrew is loose. b. Check if lock nut of middle slide plate leadscrew is loose. c. Check if bearings at two ends of middle slide plate Repositioning in X-direction 1

leadscrew are worn. is not accurate d. Check if tooth belt of servo motor of X-axis is worn. e. Check if gib of middle slide plate is loose. 2. Check if repositioning of tool post is accurate. 3. Check if center height of tool nose conforms to axial line of spindle 1. If a platform appears when passing through quadrant, should check if leadscrew clearance in X direction is tool large. If large, adjust the clearance and make compensation With trace, in cutting arc to

in data.

2 pass through quadrant.

2. If protruding phenomenon appears when passing through quadrant, should check if leadscrew clearance compensation value in X direction is larger than actual clearance. If too large, should modify the compensation value in data.

With taper in cutting of

With wrong level of machine; should check installation level of

3 workpiece

machine again. 1. Check repositioning of saddle. a. Check if press-plate of saddle is loose

Repositioning in Z direction

b. Check if tooth belt is worn

4 is not accurate

c. Check if bearings at two ends of leadscrew are worn 2. Check repositioning of tool post. 3. Check axial displacement of spindle.

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CKE6150-010

With large change of sizes 1. Check if zero-return stop is loose. when starting program after 5

2. Check if zero-return switch is loose. returning back to reference 3. Check if zero-return switch is damaged. point

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CKE6150 - Operation Manual