Manual Hardinge Gx480

 

Maintenance Manual

GX GX 300 510 GX 480 GX 480 APC GX 710 GX 600 GX 1000 GX 1300 GX 1600

Original instructions Document Number 1902493 Issue G February 2009

 

Page 1

 

CONTENTS   CHAPTER 1 – INTRODUCTION & SAFETY

Page

1.1

Foreword

4

1.2 

Protection for Machine Operators

5

1.3 

Signal Word Definition

6

1.4 

The Importance of Regular Inspections

7

1.5 

Cautions to be Observed by Technicians

8

1.6 

Checking the Function of the Safety Circuit

10

CHAPTER 2 – AIR SYSTEM 2.1 

Air Control Assembly

13

2.2 

Adjusting Procedure

13

2.3 

Replace the Filter/Regulator Filter

14

2.4 

Clean or Replace the Optical Scale Air Filters

15

2.5 

Pneumatic Schematics

16

2.6 

Pneumatic Drawings

22

2.7 

Safety Factor of Pneumatic System

29

CHAPTER - 3 – COOLANT SYSTEM 3.1 

Introduction

30

3.2 

Chip Removal

31

3.3 

Clean the Coolant Tank and Filters

32

3.4 

Clean the Filter of Immersible pump

33

3.5 

Clean the Coolant Screens

34

3.6 

Coolant Directional Pipes

36

3.7  3.8 

Coolant Directional Balls Coolant/Chip Flush

36 37

3.9 

Thru-Spindle Coolant [Option]

38

3.10 

Replace the In-Line Spin-On Canister Filter

38

3.11 

Coolant Flushing & Piping Diagram

39

 

Page 2

 

CHAPTER 4 – LUBRICATION

Page

4.1 

Axes Way Grease Lubrication

42

4.2 

Tool Knockout Piston Lubrication

45

4.3 

Tool Carousel Rail Lubrication

45

4.4 

Fill the High-Speed Spindle Air-Oil Lubrication Tank

46

4.5 

High – Torque Gear Box Lubrication

47

4.6 

Changing Oil in the ATC Cam Box Lubrication

49

4.7 

Changing Oil in the APC Cam Box Lubrication

50

4.8 

Changing Oil in the APC hydraulic Power Unit

50

4.9 

Hydraulic Schematic

51

4.10 

Hydraulic Diagram

51

CHAPTER 5 – MISCALLANEOUS 5.1 

Interlock Switch with Door Locking Device

52

5.2 

Vision Window Guards

53

5.3  5.4 

Spindle Belt Tension Clean the Power Case Heat Exchanger Air Filter

54 56

5.5 

Work Light Lamp Replacement

57

5.6 

Adjusting APC Hydraulic Pressure

58

5.7 

Cleaning the Optional Chip Conveyor or Auger When Blocked

59

5.8 

Maintenance and Cleaning of Spindle Chiller

60

5.9 

Spindle Chiller Tubing Diagram

61

APPENDIX 1 – Preventive Maintenance Schedule

 

63

Page 3

 

CHAPTER 1 – INTRODUCTION & SAFETY 1.1

FOREWORD This maintenance manual describes inspection procedures. Since the daily and regular inspections to be carried out by machine operators are very important in maintaining machine accuracy, operators are required to carry out proper inspection and maintenance in accordance with the details given in this manual. The illustrations in this manual are used as examples. Depending on the machine, the shapes of systems may differ from the illustrations in this manual. Before carrying out any maintenance work, ensure that the machinery is switched off and disconnected from the main power supply. Also ensure that the necessary warning signs and /or locks are appointed to stop any unauthorized persons from switching the power on to the machine until the work is complete and the machinery is safe to operate. The above warning signs or indications should be secured by a semipermanent means with the printing clearly visible. Only qualified and competent maintenance engineers should carry out machinery maintenance work. Working on live electrical equipment must be carried out by only suitably qualified electricians. Over travel limit switches, proximity switches and interlock mechanisms including all functional parts should not be removed or modified. Never use compressed air to clean dirt or chips from the machine. Air pressure could force dirt particles and other foreign material past seals and wipers. When working in high places, use steps or a ladder which are maintained daily for safety. Use only fuses, cables etc. from reputable recognised manufacturers. The maintenance person should check that the machine operates safety after the work is completed. Maintenance and inspection data should be recorded and kept for reference.

 

Page 4

 

1.2

PROTECTION FOR MACHINE OPERATORS Machine operators are responsible for the following: Carry out machining operations, programming, maintenance and inspection work in accordance with the details in the instruction manuals supplied with the machine. Only operators who have received proper training and have sufficient understanding of the caution information are allowed to operate or program a machine tool, or carry out inspection and maintenance work on it. With regard to safety related measures, operators must receive training at least once a year. Develop a thorough understanding of, and strictly observe the local regulations relating to the prevention of accidents and environmental conservation. Disposing of Industrial Waste Operation of the machine generates industrial waste such as chips, waste oil and coolant. Legal permission is required to dispose of such industrial waste. Disposal of the waste at locations other than approved sites will pollute the environment, cause environmental destruction, and adversely affect the plant and animal life in the area. Follow the local regulations when disposing d isposing of industrial waste. Examples of industrial waste processing methods are given below:

 

Waste oil & coolant:

Entrust the disposal of waste oil and coolant to a party qualified to dispose of industrial waste or a service station with the appropriate facilities.

Chips:

Entrust the disposal of chips to a party qualified to dispose of industrial waste or a party capable of metallic waste recycling.

Page 5

 

1.3

SIGNAL WORD DEFINITION Various symbols are used to indicate different types of warning information and advice. Learn the meanings of these symbols and read the explanation to ensure safe operation while using this manual. SYMBOLS RELATED TO WARNINGS The warning information is classified into three groups  “  “DANGER  DANGER ”, ”, “WARNING “WARNING”” and “CAUTION “CAUTION”. ”. The following symbols are used to indicate the level of danger.

Indicates an imminently hazardous situation which, if not avoided will result in death or serious injury. The information described in the DANGER frame must be strictly observed.

Indicates a potentially hazardous situation which, if not avoided will result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided could result in minor or moderate damage to the machine.

Other symbols:

 

Indicates the items that must be taken into consideration

Page 6

 

1.4

THE IMPORTANCE OF REGULAR INSPECTIONS. Scheduled regular inspection and proper repair of the machine operated by a maintenance person is the key to long lasting machine accuracy. Take proper action to obey the operators who are In charge of daily inspection. Feel free to contact the representative if you have any questions on the instruction manual, circuit diagrams or maintenance manual. Before beginning maintenance Listen to the operator in charge of the machine operation to understand the problem accurately. Study the actual condition and plan the repair range and steps. Study the specification, construction and functions of the machine portion to be repaired If more than two maintenance technicians must work on the machine, or if cooperation with other people in other sections is necessary, discuss the repair procedure with these people so that everyone understands what to do. Prepare spare parts and consumables to be used.

When changing parts, be sure to use only genuine parts specified by the authorized distributor. The distributor cannot be responsible for any trouble arising from the use of parts not specified by the distributor. Using parts that are not specified may not only impair the performance of the machine, it could also make the machine unsafe and could cause accidents involving serious injuries or damage to the machine. Using such parts will make the machine warranty void. void.   

 

Page 7

 

1.5

CAUTIONS TO BE OBSERVED BY TECHNICIANS

1) Electrical wiring work should only be done by qualified electrical engineers. If a person with no knowledge of safe practices during electrical work undertakes wiring work he/she could receive an electrical shock. 2) Always isolate the machine power before carrying out inspections, repairs or maintenance. In addition set the isolator switch on the Control Cabinet to the OFF position and lock it, and place “UNDER MAINTENANCE” signs around the machine. If inspection or maintenance work is carried out on the machine with the power on machine elements could be moved and the inspection, maintenance personnel could be seriously injured. 3) Never touch a switch, button or key with wet hands. 4) If it is not properly grounded or is leaking current, you could receive an electric shock.

1) Machine operators and authorized personnel working inside the plant and in the vicinity of the machine must put their clothing and hair in order so that there is no danger they will be entangled in the machine. If you have uncontrolled long hair or loose clothing and it gets caught in the machine, you will be seriously injured. Always wear safety shoes and eye protection. 2) The parameters are set on shipment in accordance with the machine specifications, do not change them without first consulting the machine distributor. If the parameters are changed without consultation, the machine may operate in an unexpected manner, causing accidents involving serious injuries or damage to the machine. 3) The machine specifications are set before shipping so that the machine can deliver it’s full performance. Changing the settings without consultation may lead to accidents involving serious injuries, impaired machine performance and a considerable shortening of the machine service life. If the settings and or specifications have been changed or the machine has to be modified to meet the new machining requirements or due to changes in the operating o perating conditions, consult the machine distributor.

 

Page 8

 

4) When two or more people are involved in Maintenance work, they must cooperate carefully and communicate as fully as possible. If one worker moves the machine without noticing another worker is inside or near the machine, they could be seriously injured. 5) When changing parts, be sure to use genuine parts specified by the distributor, the distributor cannot be responsible for any trouble arising from the use of such parts. Using parts that are not specified will not only impair the performance of the machine, it could also make the machine unsafe to operate and could lead to serious injuries or damage to the machine. 6) When using equipment such as wires, ropes and cranes, make sure that they can bear the mass to be hoisted.

1) Use service tools appropriate for the intended work. If the tools are not appropriate, parts could be broken or bolts not tightened properly, leading to machine failure. 2) Do not place service tools or parts directly on the slideways this could cause scratches or other damage to the slideways, adversely affecting the machines life. 3) Do not climb on top of the machine, if you loose your balance, you could fall off and injure yourself. Use a ladder or service platform when you have to work in high places 4) When moving a heavy object, always carry it with the help of at least one other person or use a crane. If you attempt to carry a heavy object by yourself, you could be injured.

 

Page 9

 

1.6

CHECKING THE FUNCTION OF THE SAFETY CIRCUIT The Function of the Safety Circuit components should be checked after the machine is turned on and in normal operating condition. The maintenance technician should check that the machine operates op erates safety (e.g. safety relay, interlocking switch or relevant components like timer in the interlocking or emergency stop circuits, etc) after the work is completed. Maintenance and inspection data should be recorded and kept for reference. Below is a list of the Safety Circuit Components and their function

Safety Component   Component Main Isolator Located on the Electrical Cabinet.

Intended Function  Function 

Test Procedure and Result  Result 

To isolate main power to the machine

With the machine in normal operating mode and worklight on, first press the Emergency Stop Switch on the Operating Panel and then shut down the machine by turning the main isolator anti clockwise. NORMAL RESULT: All power to the machine has been removed and the worklight is OFF.

Emergency Stop There are Emergency Stop devices on the Control Panel and remote handwheel

The Emergency Stop function is to disable the Servo Motors, Spindle Motor and ATC , thus disabling all the Axes, Automatic and Manual functions

With the machine in normal operating mode, press the Emergency Stop Device.

Axes Limits

To stop over travel of the x, y and z axis in both + and directions

Each axis is also protected by software limits which are active prior to the hard wired switches being reached. Therefore it is not normally possible to test the operation of these switches.

NORMAL RESULT: All Axes feeds will be disabled. The NC and VDU will still be ON. The message “ EMERGENCY STOP” will be displayed

If any of the Safety Devices are not functioning normally do not attempt to operate the machine.

 

Page 10

 

Door Interlocks (Front Sliding Doors, toolchanger door and APC checking door)

a) When an interlock is open (guard open) no axis movement is allowed when the mode selection switch is set to program. b) When an interlock is open (guard open) the maximum Axes speeds are limited when the mode selection switch is set to manual. c) When an interlock is open (guard open) the spindle is disabled. No rotation is allowed d) When an interlock is open (guard open) no automatic cycle can be started.

With the moveable guard open and the feedrate override set to maximum, press one by one each of the axes jog keys NORMAL RESULT: The axes will not move. With the moveable guard open and the feedrate override set to maximum, press one by one each of the axes jog keys NORMAL RESULT: The Axes speed will be no more than 2000 mm/minute as displayed on the VDU With the moveable guard open, press the Spindle CW or CCW keys. NORMAL RESULT: The Spindle will not start. Attempt to run an automatic cycle including an MDI tool change with the guard open. NORMAL RESULT: There will be no machine movement Close the guard and start an automatic cycle. NORMAL RESULT: The interlock should be locked and it should not be possible to open the door until the program is stopped, and all axes motion (including spindle) has stopped.

e) When the guards are closed (interlock is closed) it is not possible to open the guard during an automatic cycle. After an automatic cycle is complete and the spindle comes to a complete halt it is possible to open the guard door. Note: Only the GX 480 DT, GX 480 APC & GX 480 DT APC have toolchanger load station doors.

Only the GX 480 APC & GX 480 DT APC have a checking door.

If any of the Safety Devices are not functioning normally do not attempt to operate the machine.

 

Page 11

 

Door Interlocks of Electrical cabinet (Cabinet Doors)

a) When door interlock switch is on the position “0” and the cabinet doors open, the machine power will remain ON.

b) When door interlock switch is on the position “1” and the cabinet doors open, the machine power will be turned OFF.

With the machine in normal operating mode, turn the door interlock switch of electrical cabinet to position “0” and open the cabinet doors. NORMAL RESULT: The machine power remind ON. (NOTE NOTE:: Only to be used for maintenance purposes by qualified and competent maintenance engineers.) With the machine in normal operating mode, turn the door interlock switch of electrical cabinet to position “1” and open the cabinet doors. NORMAL RESULT: The machine power will be turned OFF.

If any of the Safety Devices are not functioning normally do not attempt to operate the machine.

 

Page 12

 

CHAPTER 2 – AIR SYSTEM 2.1

AIR CONTROL ASSEMBLY The air control assembly is mounted at the rear of the machining centre, can be adjusted and must be set to a consistent air pressure between 59 psi and 73 psi [4.1 and 5 bars] or high-performance spindle machines near 90 psi [6.2 bars].

If the factory air has excessive moisture, a heavy-duty air dryer must be added to the incoming air line.

2.2 ADJUSTING PROCEDURE 1. Turn on the air supply. 2. Lift the adjusting k knob nob turn it clockwise clockwise to increase the pressure and anti-clockwise to decrease the pressure(direction when looking down) at the pressure regulator. 3. Push the adjusting adjusting knob down to click in position.

Air Filter/Regulator and Lubricator

 

Page 13

 

2.3

REPLACE THE FILTER/REGULATOR FILTER The filter/regulator filter bowl drains automatically. Check the air system bowls once a week for contaminates. 1.  Turn off the air supply. 2.  Twist ring “A” anti-clockwise to release the shell and bowl from the head. Drain any water and contaminants from the bowl. 3.  Clean the bowl with a lint-free cloth. 4.  To release the filter, unscrew the nylon fixture. Thread the new filter on the nipple until it is tight. 5.  Put the bowl into the shell; press the shell up into the head. Rotate the ring clockwise until the latches secure it. 6.  Unthread screw “B” and fill the lubricator with the recommended oil below.

 A

B

C

Air Filter/Regulator and Lubricator

 

Machine component

Filter/Regulator/Lubricator combination

Lubricant characteristic

1)  2)  3)  4) 

Lubrication method

Oil feeder

Lubrication frequency

As needed, 1/yr.

Tank capacity

0.3 Liters

Recommended grade of lubricant

1)  2)  3)  4) 

Viscosity: ISO VG32 Viscosity index: above 95 Anti-rust, anti-oxidation Good Stability

CPC Circulation Oil R32 Mobil DTE Light Daphne Super Multi Oil 32 Shell Turbo OilT32

Page 14

 

2.4

CLEAN OR REPLACE THE OPTICAL SCALE AIR FILTERS (OPTION) Optical scale is an option that enhances the accuracy of the control to make more consistent parts. The air pressure switch is set at the factory and should not be adjusted. When the outlet air pressure is below 10 psi [0.7 bar], the air filters must be cleaned or replaced. Clean or replace the filters as follows:  follows:  supply.  1.  Turn off the air supply.  2.  Unthread the outer shell from the head 3.  Drain any water and contaminants from the shell. 4.  Clean the shell with a lint-free cloth. 5.  Clean or replace the filter(s) as necessary. 6.  Install the shell on the head.

Optical Scale Filter/Regulator Air Module  Module 

 

Page 15

 

2.5

PNEUMATIC SCHEMATICS

2

0.3μFilter 5μFilter 2

40μ

  GX 300 & GX 510 Spindle with CTS

2

0.3μFilter 5μFilter

2

40μ

  GX 300 & GX 510 Swing Arm ATC

 

Page 16

 

2

0.3μFilter

5μFilter

2

40μ

  GX 300 & GX 510 Auto Front Door

2

0.3μFilter

5μFilter

2

40μ

  GX 300 & GX 510 Auto Magazine Door

 

Page 17

 

2

0.3μFilter

5μFilter

2

40μ

  GX 480 & GX 710 Swing Arm ATC

2

0.3μFilter

5μFilter

2

40μ

  GX 480 & GX 710 Carousel ATC

 

Page 18

 

2

0.3μFilter 5μFilter

2

40μ

  GX 600, GX 1000, GX 1300 & GX 1600 Carousel ATC

2

0.3μFilter 5μFilter

2

40μ

 

GX 600, GX 1000, GX 1300 & GX 1600 Swing Arm ATC

 

Page 19

 

2

0.3μFilter

5μFilter

2

40μ

  GX 480 APC Standard

2

0.3μFilter

5μFilter

2

40μ

  Air Blast for Tool Probe on GX 480, GX 600, GX 1000, GX 1300 & GX 1600 (Option)

 

Page 20

 

2

2

40μ

  GX Series Spindle with CTS/ATS (Air Through Spindle) - Option

 

Page 21

 

2.6

PNEUMATIC DIAGRAMS

GX 300 & GX 510 Spindle with CTS

GX 300 & GX 510 Swing Arm ATC

 

Page 22

 

GX 300 & GX 510 Auto Front Door

GX 300 & GX 510 Auto Magazine Door

 

Page 23

 

GX 480 & GX 710 Swing Arm ATC

GX 480 & GX 710 Swing Arm ATC (With CTS)

 

Page 24

 

GX 480 & GX 710 Carousel ATC

GX 600, GX 1000, GX 1300 & GX 1600 Carousel ATC

 

Page 25

 

GX 600 & GX 1000 Swing Arm ATC

GX 600 & GX 1000 Swing Arm ATC (With CTS)

 

Page 26

 

GX 1300 & GX 1600 Swing Arm ATC

APC Pallet

 

Page 27

 

Air Blast for Tool Probe on GX Series - Option

GX Series Spindle with CTS/ATS (Air Through Spindle) - Option

 

Page 28

 

2.7

 

Safety Factor of Pneumatic System

PU

UM0640 UM0850 UM1065 UM1280

ODxID (mm) 6x4 8x5 10x6.5 12x8

Burst Pressure Min. (Mpa), 25°C 2.7 2.7 2.7 2.7

Working Pressure Max. (Mpa) 0.7 0.7 0.7 0.7

Safety Factor 3.9 3.9 3.9 3.9

Nylon

NB0640 NB0860 NB1075 NB1290

6x4 8x6 10x7.5 12x9

8 5.7 4 3

0.7 0.7 0.7 0.7

11.4 8.2 5.7 4.3

Material

Nominal

Page 29

 

CHAPTER 3 - COOLANT SYSTEM 3.1

INTRODUCTION CAUTION: Whenever water soluble coolants are used it is important to use the manufacturer’s recommended mix ratio (concentration). It is also important to maintain the coolant by keeping the proper concentration level when coolant solution is added to compensate for evaporation. Another important factor is coolant Ph (acidity). Typically, the coolant Ph range is between 8.5 and 9.2. Below 8.5 the rust inhibitors in the coolant start depleting, which can result in corrosion of machine components. Also, the quality of the water should be tested by the coolant manufacturer so that the proper coolant additives can be administered. Failure to follow these recommendations could result in damage to the machine, seals, and paint. If the coolant you have selected starts to react (cause material to rust, pit, swell, soften, crack, or blister) with any portion of the machine tool, Hardinge suggests that you discontinue use and contact your coolant representative for alternative coolants. It should also be noted that certain chemicals react with different d ifferent metals. Hardinge recommends that you consult with your coolant representative to assure that the material you are cutting does not react with the coolant you have selected. The two most popular types of cutting fluids are cutting oils and water-based coolants. Whenever cutting fluids are used, it is essential to follow the coolant manufacturer’s recommendations and maintenance. Fill the tank assembly with the approved coolant to the FULL line of the sight gauge “A”. Approximate coolant tank capacities are shown in the following chart: Coolant Tank Capacity Machine Model

liters

US gallons Imperial gallons

GX 300

125

33

28

GX 480, GX 710 & GX 480 APC

120

31.7

26.4

GX 510

158

42

35

GX 600

230

61

51

GX 1000 GX 1300

360 400

95 106

79 88

GX 1600

538

142

118

 A

Sight gauge of coolant tank  

Page 30

 

3.2

CHIP REMOVAL The tank assembly has chip trays that screen the metal chips and allows the coolant to drain through and recycle.

Use a rake and suitable container to remove metal chips from the chip trays. Dispose of the chips in an environmentally safe manner.   manner.

1.  Allow the coolant to drain back into the tank. 2.  Open the guard door; sweep metal chips from the table and way covers into the coolant tank. 3.  If the machine does not have a chip conveyor, carefully slide chip tray “A” and “B” out the side from the corners of the coolant tank to clean. 4.  If the machine does not have a chip conveyor, carefully rake or shovel the chips into a chip receptacle from the opening or draw the chip tray “A” and  “B” out from the both corners of the coolant tank to clean. 5.  If necessary, move the tank into an area that is convenient to remove the metal chips. 6.  Rake or dump the chips into a container and dispose them properly.

Tray   Left Side Chip Tray

Right Side Chip Tray Tray  

Chip Tray

B

GX 480 & GX 710

 

GX 600 & GX 1000

Page 31

 

A

A GX 1300 & GX 1600

3.3

GX 300 & GX 510

CLEAN THE COOLANT TANK AND FILTERS Clean the coolant tank at least once every six months or more frequently if the materials being cut contaminate the coolant. Clean the coolant tank whenever changing the type or brand of coolant. 1.  Roll the tank assembly out from under the machine. 2.  At both ends of the coolant tank, remove the pipe plug or use a pump to drain out the coolant from the tank. 3.  Lift the chip pans from the tank to clean.

Wear protection and be careful when removing coolant and metal chips from the coolant tank.   Dispose of the coolant, chips and cleaner in an environmentally safe manner.  manner. 

4.  5.  6.  7. 

Wipe the coolant tank clean. Lift the screens from the slots. Shake out the metal chips and wipe the filter screens clean. Wash the coolant tank assembly with a cleaner recommended by the coolant manufacturer to remove any bacterial contamination. 8.  Place the filter screens in their slots. 9.  Return the tank to the opening under the machine. 10. Pour the approved coolant directly into the work area to drain into the coolant tank. Fill the tank to the FULL line of the sight gauge. 11. Power up the machine to check for coolant leaks.

 

Page 32

 

3.4

CLEAN THE FILTER OF IMMERSIBLE PUMP The pump filter should be cleaned at regular intervals to ensure a correct flow of coolant and whenever there appears to be a drop in coolant pressure. 1.  2.  3.  4.  5. 

Disconnected the hose from the pump. Take apart the pump from the mounting and placed upside down. Loose the screw “B” of filter screen and remove it. Blow the pressure air to sweep chips away and re-assemble the unit. Power up the machine to check for coolant leaks.

Periodic checks At regular intervals, depending on the conditions and time of operation, the following checks should be made: - Check the quantity of liquid and operating pressure. - Check the motor is not overheating. - Check that there are no leaks.

A

GX 1300 & GX 1600

GX 600 & GX 1000

B

GX 480 & GX 710

 

Clean the pump filter

Page 33

 

GX 300 & GX 510

3.5

CLEAN THE COOLANT SCREENS – GX 600 GX 1000 GX 1300 GX 1600 GX 480 & GX 710

The coolant screens should be cleaned every 500 hours or whenever there appears to be a reduction in coolant flow. 1.  Power down the machine, wait to allow the coolant to drain into the tank. 2.  Carefully roll the coolant tank out, so the coolant inside will not splash onto the ground. 3.  Remove the filter screen of 2mm, shake out the chips and wipe the screen clean. 4.  Put the screen back in the slot, BUT behind the filter screen of 1mm (only for GX 480 & GX 710), so that chips can still be blocked when lifting up the 1mm screen to clean. 5.  Remove the filter screen of 1mm, shake out the chips and wipe the screen clean, then place behind where it was, that’s behind 2mm screen  screen 

Remove 2mm Screen GX 480

 

Replace 2mm Screen GX 480

Page 34

 

Replace 1mm Screen GX 480

Coolant Screen GX 1300 & GX 1600

 

Coolant Screen GX 600 & GX 1000

Coolant GX 300 &Screen GX 510

Page 35

 

3.6

COOLANT DIRECTIONAL PIPES – GX 480, GX 710, GX 1300 & GX 1600 Two/three coolant directional lock line pipes are located on the right hand side of the spindle face/guard; these are freely adjustable to suit direction and length.

GX 480

3.7

GX 1300 & GX 1600

COOLANT DIRECTIONAL BALLS Five coolant directional balls are located on the spindle face, equally spaced around the tool. The directional balls are mounted in Nylon cups; to adjust the directional position of the coolant balls, put a hex wrench or dowel up into the coolant ball orifice and move the ball. Move the direction of the other balls as necessary.

Spindle Face

 

Page 36

 

3.8

COOLANT/CHIP FLUSH The adjustable hoses can be set at any length or angle to flush chips toward the chip recovery screens. Separate any ball link, remove or add links as necessary and re-attach the separated links by snapping them together.

Coolant/Chip Flush Adjustable Hoses

Chip Flush

GX 1300 & GX 1600

 

Page 37

 

3.9

THRU-SPINDLE COOLANT [Option] The thru-spindle coolant option must be factory installed. The spindle can be run even though the coolant is not active. There are three coolant filters on machines equipped with the thru-spindle coolant option: two in-coolant-line filters and the filter screens in the coolant tank. The in-line filter is a blue filter mounted on the back of the coolant tank in the coolant return line. The in-line blue filter must be cleaned whenever there appears to be a drop in the thru-spindle coolant pressure. Spin-on canister filter is mounted near the coolant pump on the right side of the tower (facing the rear of the machine). The spin-on canister filter must be replaced whenever there appears to be a drop in the thru-spindle coolant pressure.

3.10

REPLACE THE IN-LINE SPIN-ON CANISTER FILTER 1.  Allow the coolant to drain back into the tank. 2.  Wrap the filter head with a rag to catch coolant as filter canister is removed. Unthread the filter from its mounting nipple. 3.  Wipe the mounting nipple with a lint free cloth. 4.  Remove the filter seal from the mounting surface. 5.  Fill the filter replacement one-half full with fresh coolant and apply a light coat of oil around the seal on top of the filter. 6.  Thread the replacement filter on one-quarter to one-half of a turn further. 7.  Power up the machine to check for coolant leaks.

Thru-Spindle Spin-On Canister Filter  Filter 

 

Page 38

 

3.11

COOLANT FLUSHING & PIPING DIAGRAM

COOLANT TANK

  Standard - Chip Flushing GX 480, GX 710, GX 600 & GX 1000

40 PSI

COOLANT TANK

  Standard - Coolant Flushing GX 480, GX 710, GX 600, GX 1000, GX 1300 & GX 1600

 

Page 39

 

280 PSI

COOLANT TANK

  Option - Coolant Through Spindle GX 480, GX 710, GX 600 & GX 1000

280 PSI

COOLANT TANK

  Option - Coolant Through Spindle GX 1300 & GX 1600

 

Page 40

 

Standard - Chip Flushing GX 1300 & GX 1600

 

Page 41

 

CHAPTER 4 - LUBRICATION 4.1 

AXES WAY GREASE LUBRICATION GX 480, GX 480 APC & GX 710 Grease is used to lubricate axes guideways and axes ballscrew nuts. Recommended lubrication is every 600 hours of operation.

Use only Kluber ISOFLEX® NBU 15 or NCA 15 grease. Never mix the grease from different manufacturers. The system cannot be over greased.

Lubricate all the sliding surfaces by jogging the axes several times before resuming automatic operation.

Grease the Z axes linear guildeways 1.  Open the cover and apply the grease to each nipple until the resistance is felt. Z AXIS GREASE

Z Axis Grease Fittings at Front of Tower GX 480, GX 480 APC & GX 710

 

Z Axis Grease Fittings at Front of Tower GX 300 & GX 510

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Grease the X & Y axes linear guildeways 1.  Jog the X axis until the Y axis grease fittings are uncovered. The X axis grease fittings are attached and move with the X axis jog. 2.  Apply the correct amount of grease.

Y AXIS GREASE

X AXIS GREASE

X and Y Axes Grease Fittings at Front of Way Cover GX 480, GX 480 APC & GX 710

Y AXIS GREASE

X AXIS GREASE

X and Y Axes Grease Fittings at Front of Way Cover GX 300 & GX 510  510  

If grease was added because there was an alarm fault (“600 hour lube alarm”), clear the alarm after the control has been powered up.

 

Fanuc Control:

Press the Reset and Feed |Hold push buttons at the same time to clear the alarm.

Siemens Control:

Press and hold the Reset push button for 5 seconds or until the alarm is cleared.

Heidenhain:

Press NC stop. Then press the CE and Power Enable together.

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GX 600, GX 1000, GX 1300 & GX 1600 Central manual grease supplier for the X, Y & Z axes linear guildeways and ballscrew Grease is used to lubricate axes guideways and axes ballscrew nuts. Recommended lubrication is every 400 hours of operation. Recommended grade of grease

1) Castrol Spheerol L-EP 1 2) BP Energrease LS-EP 1 3) Mobil UX EP 1

1.  Open the door at the rear of machine. 2.  Pull the lever of the central manual grease supplier 18 times.

Central Manual Grease Lubrication System At rear of the machine GX 600 & GX 1000

 

Central Manual Grease Lubrication System At rear of the machine GX 1300 & GX 1600

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4.2

TOOL KNOCKOUT PISTON LUBRICATION

Add oil to the air/oil tool-knockout piston oil cup “A” at least once every month. Remove the oil cap. Use recommended oil as below and then replace the cap. Mobil DTE 24 Shell Tellus 32

Cup   Tool Knockout Lubricator Cup 4.3

TOOL CAROUSEL RAIL LUBRICATION Tool carousel grease fitting “B” is in a seam on top of the carousel. The grease fitting can best be seen when the tool carousel is at the retract position (furthest from the spindle). Refill the oil every 600 hours. 1.  Wipe the fitting(s) clean of dirt or contaminants. 2.  Apply Kluber ISOFLEX® NCA 15 grease to the nipple until resistance is felt. 3.  Wipe the nipple(s) clean of excess grease.

Carousel Grease Fitting  Fitting 

 

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4.4

FILL THE HIGH-SPEED SPINDLE AIR-OIL LUBRICATOR TANK The air-oil lubrication system is located at the rear of the machine between the power case and the column. It supplies oil to the spindle bearings. The time for one full spindle lubricator tankrun is approximately 5230 hours. The pump cycle time is preset at the factory to pump oil every 48 minutes. 1.  Locate the lubricator tank and tank filler cap. 2.  Wipe the tank cover and filler cap. 3. Remove the filler cap cap and slowly fill the tank with pre-filtered Mobil DTE-797 oil pre-filtered through a 3 micron or better filter. filter. Wait a full 5 minutes to allow any air in the oil to escape. 4.  Install the filler cap. cap.   High-Speed Spindle Lubrication System Air and Lubricator  Lubricator  Check and correct the air-oil lubricator components as follows:  1.  Open two latches and lift off front cover “D”. The mixing block (metering unit) is mounted in the lower left corner with the air-oil feeder lines and air line connected to the bottom. The main air line is the larger diameter line. The smaller line supplies oil to the mixing block. 2. Check the oil lines and oil pressure. 3. Check the air pressure from the main air air panel to the controller controller and mixing block. 4. Check the air pressure from the mixing block to spindle. SPINDLE LABYRINTH AIR SEAL

The air pressure must be left ON for 15 minutes after the spindle has stopped to allow the spindle interior to cool to room temperature without drawing in coolant and contaminants.

 

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4.5

HIGH-TORQUE GEAR BOX LUBRICATION The gearbox on the high-torque spindle machines requires a closed-loop circulation of lubrication. This system consists of a tank, pump, heat exchanger (radiator and fan) and the gearbox. The heat exchanger helps stabilize and keep the gearbox at a constant operating temperature. The oil level must be checked each 2000 hours of operation and the oil must be changed every two years. Select the oil from the table on the next page.  page.   Adding Oil to the High-Torque Gear Box Tank 1.  Make sure the spindle is down to its lowest point (-Z position). 2.  Remove the sheet metal cover above and around the spindle column to expose the spindle drive and high-torque mechanisms. 3.  Open the right side door and locate gearbox tank “F”.

High-Torque Gear Box Tank

Select the oil from the table below. Some tanks may have a filler cap. If there is a filler cap, clean the cap and area around the cap Open the cap and add oil until the tank is full.

5. Unthread tank vent “G”, “G”, and add oil until the tank is full. 6. Thread the vent on until it is snug. 7. Check the hoses for any kinks or leaks leaks and correct any any problems as necessary. 8. Mount the spindle sheet metal cover and tighten the screws. 9. Power up the machine and continue continue with machine operation or maintenance.

 

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Machine Component

High-Torque Gear Box Tank

Lubricant characteristic

1)  2)  3)  4) 

Viscosity: ISO VG32 Viscosity index: above 95 Anti-rust, anti-oxidation Good Stability

Lubrication method

Oil circulation

Lubrication frequency

As needed, 1/yr.

Tank capacity

.95 qt. [1.0 Liter]

Recommended grade of lubricant

1)  2)  3)  4)  5) 

CPC Circulation Oil R32 Mobil D.T.E Heavy Medium Daphne Super Multi Oil 68 Shell Turbo Oil T68 Esso Teresstic T68

Changing the Oil in the High-Torque Gear Box Tank The oil in the high-torque gearbox must be replaced every two years.

1.  Make sure the spindle is down to its lowest point (-Z position). 2.  Unthread the screws and lift off the sheet metal cover above and around the spindle column to expose the spindle drive and high-torque mechanisms. 3.  Open the right side door and locate gearbox tank “F”, Figure 4.7. 4.  Unthread the screws that fasten the tank top to the tank. The tank top has the lubricator pump mounted on it. 5.  Carefully pry the top from the tank and set it aside. 6.  Pump or wipe the oil from the tank until it is empty. Wipe the tank clean with a lint-free cloth. 7.  Install the tank top and tighten the screws that fasten the top to the tank.

Select the oil from the table on the previous page. Some tanks may have a filler cap; if there is a filler cap, clean the cap and area around the cap, open the cap and add oil until the tank is full.

8.  Unthread tank vent “G”, and add oil until the tank is full. The tank will hold approximately 1 litre of fluid. 9.  Thread the vent on until it is snug. 10. Check the hoses for any kinks or leaks and correct any problems as necessary. 11. Mount the spindle sheet metal cover and tighten the screws. 12. Power up the machine and continue with machine operation or maintenance.

 

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4.6

CHANGING OIL IN THE ATC CAM BOX LUBRICATION The oil in the ATC CAM BOX must be changed every 2500 hours. Use the oil MOBIL Mobilgear 630. 1.  Make sure the spindle is down to its lowest point (-Z position). 2.  Open the left side door and locate ATC. 3.  Unthread screw “A” to drain the oil from the tank until it is empty.  

4. screw “A”.“B” and fill the tank to the HALF line of the sight gauge. 5.  Install Unthread screw

The spindle motor

B

A

The bottom of the ATC CAM BOX

The top of the ATC CAM BOX

ATC CAM Oil Level Sight Gauge

 

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4.7

CHANGING OIL IN THE APC CAM BOX LUBRICATION The APC CAM BOX is located at the middle of the APC hinge arm. arm.  Change the oil every 2 years. Use the recommended oils as below: SHELL Omala EP320 MOBIL Mobilgear Mobilgear EP320  EP320 CASTROL Alpha EP320

B

TOTAL EP320  EP320  1.  Unthread the screw “A” to drain the oil from the tank until it is empty. 2.  Tighten the screws that fasten the button to the tank. 3.  Unthread the screw “B” and fill the tank to the HALF line of the sight gauge.

4.8

A

APC CAM Oil Level Sight Gauge

CHANGING OIL IN THE THE APC APC HYDRAULIC HYDRAULIC P POWER OWER UNIT The APC hydraulic power unit is usually place rear-right side of the machine. Changing the hydraulic oil every 2000 hours. Use the recommended oils as below: MOBIL DTE-24 ESSO Nuto H-32 HYSPIN AWS32 Approximate hydraulic tank capacity is shown in the following chart: Machine Models

GX 480 APC

 

 

Hydraulic Tank Capacity 40 liters 10.6 US gallons 8.8 Imperial gallons

Page 50

 

4.9

HYDRAULIC SCHEMATIC

 APC Pallet 

4.10

HYDRAULIC DIAGRAM

 APC Pallet

 

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CHAPTER 5 - MISCELLANEOUS  5.1

INTERLOCK SWITCH WITH GUARD DOOR LOCKING Both the front doors and the side toolchanger access door are equipped with an interlock switch with a door locking device. The doors must be shut completely before the machine can be started, and are locked shut during machine operation. A special key is attached with this machine located in the power cabinet.

This key is for AUTHORISED PERSONNEL ONLY and for MAINTENANCE PURPOSES ONLY. The key must only be used to release the door lock when the doors are locked and no power is available to the machine. It must not be used for any other purpose. Return the switch to the ‘LOCK’ position and remove the key before applying power to the machine.

Special key to unlock the door when no power is available. Door Interlock of Electrical Cabinet Safety Circuit When door interlock switch is on the position “0” and the cabinet doors are open, the power of machine will be kept ON. When door interlock switch is on the position “1” and the cabinet doors are open, the power of machine will be turned OFF.

 

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5.2

VISION WINDOW GUARDS

The GX range of machines is equipped with transparent window guards to allow the operator to observe the machining process, whilst protecting him from potential hazards. These windows are made from polycarbonate plate. Due to the aging phenomenon of polycarbonate it is necessary to REPLACE THE WINDOW GUARDS PERIODICALLY, as specified in the Operators Safety Manual – Section 1.7. 1.7.

 

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5.3

SPINDLE BELT TENSION 

Check the drive belt tension frequently across all belts approximately at the midpoint between pulleys, as shown.

S indle indle Belt Belt Defl Deflect ection ion SPINDLE BELT TENSION SPECIFICATION Standard Spindle Drive GX 300, GX 510, GX 600, GX 1000, GX 1300 & GX 1600 Belt Type Type  

Force   Force

Timing Belt

4.4 lb-f [2 kg-f]

Deflection   Frequency Deflection Frequency   .157 in. [4 mm]

76±2 Hz

GX 480 & GX 710 Belt Type

Force   Force

Timing Belt

4.9 lb-f [2.2 kg-f]

Deflection   Frequency Deflection Frequency   .142 in. [3.6 mm]

52±2 Hz

High Speed Spindle Drive [Option] 1600   GX 600, GX 1000, GX 1300 & GX 1600  Belt Configuration

Belt Type

Force

Deflection

Frequency   Frequency

3 Strand Belt

V Belt

5.1 lb-f [2.3 kg-f]

.165 in. [4.2 mm]

150±2 Hz

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ADJUSTMENT PROCEDURE  1. Wait for the cycle cycle to end and make certain that the spindle is stopped. 2. Power down the machine. 3. Loosen four mounting screws “G”, on the motor plate and two nuts of adjusting screw “F”. 4. Adjust the belt tension by tightening tightening or loosening adjusting screw “F”. 5. Lock the adjusting adjusting bolt by tightening the two nuts together. 6. Tighten the four mounting screws on the motor plate.

Spindle Belt Tension Adjustment (GX Machines Not Equipped with High Torque Option)

 

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5.4

CLEAN THE THE POWER POWER CASE CASE H HEAT EAT EXCHANGER AIR FILTER  FILTER   The heat exchanger provides the cooling and environmental protection necessary for proper operation. The cleaning interval depends largely on the shop environment, the more dirt and dust particles in the air, the more frequently the filter will require cleaning. Clean the power case heat exchanger air filter as follows: 1.  Lift up the tab on the filter, slide the bottom out and pull it down to remove. 2.  Clean the air filter clean in soapy water. 3.  Dry it with compressed air or allow it to air dry. Air Filter on Heat Exchanger

GX-XR 1300/1600 Range (Heidenhain ( Heidenhain & Siemens) The filter is accessed using a step ladder. Care should be taken to ensure the step ladder is safety positioned, so it will not topple over and does not require excessive reaching. Any local guidance/legislation on the use of ladders must be followed. The cleaning interval depends largely on the shop environment, the more dirt and dust particles in the air, the more frequently the filter will require cleaning. Clean the power case heat exchanger air filter Air Filter of Heat Exchanger on as follows: 1.  Lift up the tab on the filter, slide the bottom the top of electrical cabinet out and pull it down to remove. 2.  Clean the air filter clean in soapy water. 3.  Dry it with compressed air or allow it to air dry.

 

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5.5

WORK LIGHT LAMP REPLACEMENT 

Lamp compartment and lamp may be hot. Allow them to cool down before handling.

1.  Unlatch and open the right side access door to access the lamp. 2.  Unthread the screws and lift the rear cover off. 3.  Pinch together the wire retaining clip and unfasten it from the bracket; swing it back. Lift halogen bulb “E” from the socket. Disconnect the bulb wire. 4.  Connect the new bulb wire and install the halogen bulb (or fluorescent lamp) in the socket by fastening the retaining clip. 5.  Be sure that the O-ring is in place; mount the cover and thread in the screws.

Work Light (Rear Cover Removed)

 

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5.6

ADJUSTING APC HYDRAULIC UNIT 1. Loosen the nut to turn adjusting screw to 30kg/cm2. Turn it clockwise to increase the pressure and anti-clockwise to decrease the pressure (direction when looking down) at the gauge. 2. Rotate the pressure switch cap to achieve 20 bar.

APC Hydraulic Unit

Hydraulic Unit Pressure Gauge

Pressure Switch

 

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5.7

CLEANING THE OPTIONAL OPTIONAL CHIP CHIP CONVEYOR CONVEYOR OR AUGER WHEN WHEN BLOCKED

The chip conveyor or auger can became blocked for a number of reasons – too much swarf, a large piece of excess stock material etc. When this occurs take the following steps: 1.  Stop the swarf conveyor or auger by pressing the chip Conveyor ON/OFF key or issuing the stop M-code. 2.  Reverse the conveyor or auger with the hold-to-run key or switch. 3.  Open the guard door to see if the blockage can now be manually removed. Use the correct personal protective equipment. 4.  Run the conveyor forward (with the guard door close). 5.  Repeat process 2 to 4 until the blockage is removed. Do not use your bare hands to remove swarf.

 

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5.8

MAINTENANCE AND CLEANING OF SPINDLE CHILLER

A) Turn the operation switch and main power source OFF before proceeding with installation or maintenance. B) Please avoid a naked flame (from welding etc) near any oil (gas or liquid form) from the chiller. Components that required cleaning regularly are the chiller body, condenser, air filter, oil filter and oil tank. Please refer to the chiller instruction manual for details. Cleaning the Air Filter 1.  To remove the filter, lift up and draw out the filter as shown below. 2.  Use a vacuum cleaner, compressed air, water and brush to clean the filter. 3.  Allow the filter to dry after cleaning before installing back onto the machine. 4.  Clean the filter regularly at least once every week and it is recommended to clean the filter whenever it is heavy stained.

Cleaning the Air Filter

 

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Change the Oil for Chiller  Use the correct recommend oil for the spindle chiller, in order to keep the spindle at a suitable temperature.

Recommended oil for Chiller

Capacity (litres)

Viscosity: ISO VG6～VG32 VG32  

12

Mobil Velocite oil No. 3

12

1.  Removed the plug “M”, Figure below, on the bottom of oil tank to drain out the oil after 2000 hours operation. 2.  Open the cap “L”, Figure as below, to refill the oil tank. 3.  If the chiller is located in humid climate zone, eventually water will condense within the tank and sink at the bottom. Please drain out the water from the tank at least once a month.

L

M

Change the Oil for Chiller

Cleaning the Oil Filter  1.  Clean the filter once a day when the machine is new, or when parts of the spindle chiller circuit have been replaced. 2.  Clean the filter every week during normal operation.

 

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5.9

Spindle Chiller Tubing Diagram

 

Page 62

 

APPENDIX 1 - PREVENTIVE MAINTENANCE SCHEDULE The following maintenance times are approximate and components may need attention more frequently if excessive environmental pollution is present. 8 Hours Check air line filter bowls Check coolant level and thru-spindle coolant pressure Check cutting fluid (coolant) concentration and Ph Clean thru-spindle coolant tank screens Check coolant filters /screens  /screens   40 Hours Remove chips from coolant tank (as necessary) Check heat exchanger air filter. Clean as necessary Wash machine and wipe clean 160 Hours Check and clean air line filter Check tool knockout piston lubrication Check power case for contaminants 400 Hours Add X, Y, and Z axes way grease (with the central manual grease supplier) 500 Hours Clean the coolant screens 600 Hours Add X, Y, and Z axes way grease (with grease fittings) Add tool carousel rail grease Check tool knockout lubrication cup for oil Check spindle drive belt for wear and adjust tension 1000 Hours Clean and flush coolant system and change coolant Check coolant hoses for cracks, bad fittings, and kinks Check spindle drive belt for wear and tension Check and tighten all electrical plugs and connections 2000 Hours Tool knockout piston oil Check high-torque spindle gear box lubrication Check spindle oil-air lubricator oil Check ATC CAM BOX lubrication Check spindle drive belt for wear and tension Check all push buttons and switches 4000 Hours Change oil in high-torque gear box ONE YEAR Change hydraulic oil Check oil hoses for cracks, bad fittings, and kinks TWO YEARS Change APC cam box oil