04975NEWLANDNTG15.01GRINDER.pdf

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NTG15.01 FOREWORD PAGE 0-1

Copyright: © 2009 by NEWLAND MACHINE TOOL GROUP INC.

Instruction Manual for Vertical Grinding, Turning, and Milling Center model NTG15.01

This manual contains information, drawings, and other documents that are supplied with the above-mentioned machine.

NEWLAND MACHINE TOOL GROUP INC. holds the copyright of this Instruction Manual, which was written for the installation, operating, supervisory, and maintenance personnel. All rights reserved.

Neither this Instruction Manual nor any part may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying and recording, or by any information storage or retrieval system, without prior permission in writing from NEWLAND

MACHINE TOOL GROUP INC.

The consent of NEWLAND MACHINE TOOL GROUP INC. does not extend for promotion or creating new products.

Direct all inquiries to:

NEWLAND MACHINE TOOL GROUP INC.

64 Jardin Drive, Suite 3E, Vaughan, Ontario Canada, L4K 3P3

Phone: 1 (905) 660-6667 ext. 101

Fax: 1 (905) 660-6678

E-mail: info@newlandmachines.com http://www.newlandmachines.com

Disclaimer

This manual contains basic information required for the correct installation and use, as well as for the adequate maintenance of the NEWLAND Vertical Grinding, Turning and Milling Center model NTG15.01.

The manual corresponds with the current technology and to the level of knowledge at the time of sale of the machine.

http://www.newlandmachines.com/

NTG15.01 FOREWORD PAGE 0-2

NEWLAND MACHINE TOOL GROUP INC. reserves the right to improve the design and manufacturing of the machine without any obligation to update previous products and/or manuals.

Foreword

This manual contains all the information required for the correct installation and use, as well as for the adequate maintenance of the NEWLAND Vertical Grinding, Turning, and Milling Center model NTG15.01.

The information provided in this manual should be read, understood, and observed in all points by all personnel responsible for the machine operation and maintenance.

Operating the machine within the limits of its designated use implies observing carefully the instructions contained in this manual, as well as complying with the required inspection and maintenance operations.

Never make any modifications to the machine without prior written approval of NEWLAND MACHINE TOOL GROUP INC.

NEWLAND MACHINE TOOL GROUP INC. declines any liability for property damages, personnel injuries and/or operating faults if insufficiently trained persons operate the machine or if the machine is used beyond its technical specifications.

Should any problems arise, please contact our Service Departments.

If you have queries (suggestions, corrections) in relation to this documentation, please email us.

This manual has one separate document “Electrical and operation manual”.

NTG15.01 FOREWORD PAGE 0-3

Table of Contents

Section 1. Safety precautions

Section 2. General information

Section 3. Transportation

Section 4. Installation

Section 5. Machine description

Section 6. Hydraulic, pneumatic and lubrication systems

Section 7. Maintenance and repair

Section 8. Major units

Machine Information

Name: Vertical grinding, turning and milling center

Model: NTG15.01

Serial No.: 150113021

Year of production: _____2013

Manufacturing Plant:__________________________

Shop where machine is installed:________________

Inventory No.:_______________________________

Date machine put into operation:________________

NTG15.01 – SAFETY PRECAUTIONS PAGE 1-1

Section 1. Safety precautions

Your machine was manufactured in conformity with the guidelines for the prevention of accidents. It must be stressed out that inappropriate operation or negligence to follow the safety regulations may cause serious accidents with injury to personnel and machine damage. A metal cutting machine tool can be a very safe machine or it can be a very dangerous one. The difference depends on the personnel who are required to perform duties relating to the machine tool operations and maintenance. It is imperative that all individuals involved in operating this machine read, understand, and follow safety recommendations listed in this section and comply with the safety rules of the owner of this machine.

These safety recommendations are just guidelines. They cannot include all of the situations that might arise in all companies in all types of operations.

By following these rules, you can prevent serious personal injury and costly damage to the equipment.

Machine safety features:

1) Belt transmissions have protective covers.

2) Machine operators are protected against chips and lubricant-coolant liquid by screens and protective guards.

3) Warning signs of danger are shown on the outside surfaces of enclosures.

4) Electrical equipment of the machine is connected to the power source via single input located at the bottom part of the machine control cabinet.

5) Main circuit breaker disconnects when the control cabinet door opens.

6) The machine is provided with 2 emergency buttons with red mushroom-shaped pusher of large size. These buttons are installed on the control panel and MPG.

7) Electrical equipment of the machine is provided with zero voltage protection using neutral trip incorporated in main circuit breaker.

8) Traverse of main movable units is restricted in two extreme positions in positive and negative directions by means of two limit switches. Prior to limit switches we have soft limits and then the emergency stop for the limit switches.

9) The machine is equipped with interlock system used for shutting off the main motion earlier than the feed motion.

10) Tool clamping device cannot be shut off during spindle rotation.

NTG15.01 – SAFETY PRECAUTIONS PAGE 1-2

11) The machine warning system involves the following signals:

- malfunction of hydraulic station

- programmable operation using CNC

- CNC is not ready for operation

- running into emergency limit switch

- lubricant-oil liquid level is lower than permissible

12) Display on the machine control panel helps to diagnose the machine malfunctions and shutdowns.

13) The machine has a build-in fixture with luminescent lamps at 24 VDC for local lighting of the machining area.

14) Electrical equipment insulation resistance between power wires and ground, between control circuit wires and power circuit, and between control circuit wires and ground should be not less than 1 Mohm, the insulation resistance of motor windings being not less than 0.5 Mohm at a voltage of not below 480 V.

Safety recommendations

The following safety regulations must be strictly observed.

- The machine must only be operated, serviced and maintained by authorized, skilled and instructed personnel. These individuals must have received a special instruction on the possible danger arising. Those not qualified shall not operate the machine.

- Wear eye protection at all times

- Wear safety shoes in proper condition to protect against falling objects, and accidentally kicking sharp-edged materials.

- Long hair, loose clothing, and necklaces present a hazard to the operator and should be avoided.

- The area around the machine should be free of oil or coolant spills and free from obstructions.

- Do not enter the working area while machine is running.

- Alcohol and other drugs impair judgment and slow reaction times. Do not operate this machine while under their influence.

- Be mentally alert on the job, and be serious about the job.

NTG15.01 – SAFETY PRECAUTIONS PAGE 1-3

- Know where all emergency stop buttons are located.

- Be aware of conditions that may be a fire hazard, such as volatile liquids and machining materials with low flash point.

- The work piece must be securely clamped in position prior to starting the machine.

- Tools, milling heads and other special equipment must be properly mounted prior to starting the machine working cycle.

- Maintain tooling in good condition. Use only properly sharpened tools.

- Any loose objects must be removed from the table prior to starting the machining operation.

- Manual handling of tools, fixture and special equipment weighting over 20 kg (45 lb) is not permitted. To transport those pieces, the appropriate lifting and transportation equipment must be used.

- Safety features on the machine (limit switches) must be operating. It is forbidden to bypass them.

- Machine fault conditions must be corrected by qualified personnel only. Power must be cut off from the machine prior to service.

- Protective equipment such as belt and chain guards must always be in proper condition.

- Damaged electrical cables must be replaced immediately.

- It is forbidden to disconnect plugs and sockets during machine operation.

- All hydraulic and pneumatic systems must be de-pressurized before carrying out any repair work.

- It is not permitted to carry out any work on moving machine members (table, saddle, etc.)

- Damaged devices shall not be used.

- Auxiliary devices, transport facilities, etc. must always be kept in a proper condition.

- Do not remove chips from the workpiece area with your hands or while the table is turning. Use a brush to remove chips after the table has stopped.

- Keeps hands off of the table and out of the path of moving units during machining operations.

- The machine cannot be restarted for the duration of the repair or maintenance work.

- The tool clamping system shall be subjected to a function test at regular intervals.

- Protective devices and covers shall only be removed for repair work and maintenance purposes. It is not permitted to operate the machine without such protective devices.

NTG15.01 – SAFETY PRECAUTIONS PAGE 1-4

- No person shall be within the danger zone of the machine. Danger zones are all those areas where machine units move, e.g. all rotary and linear drives, motors, pumps.

- The control cabinet doors shall only be opened with power shut off.

- The machine shall be inspected at regular intervals. During such inspections, special attention shall be paid to broken wires, cable connectors and strain relief connectors. Any faults shall be fixed immediately.

- Fuses shall only be replaced by using special tools. The new fuses shall not be inserted unless the machine main power disconnect is shut down.

- The machine shall be shut down when not in use. The control system shall be interlocked so that the machine cannot be powered up by any unauthorized person.

Safety Precautions to Be Followed when Installing the Machine on Site:

The installation site must be prepared as indicated in the Foundation Assignment Drawing (see Figure 4-1), the site area being cleaned from foreign objects and roped off. Special warning plates should be hung on the rope to keep unauthorized personal out.

Every person, involved in installation, must be familiar with Section 4 of this Manual and properly instructed on accident prevention techniques.

Safety Precautions to Be Followed when Preparing the Machine for Operation:

Do not work on the machine unless it is grounded, have guards installed, opening elements of guards and electrical cabinets (doors, shutters, etc.) closed and guard removable elements (covers, protective bellows, cases, etc.) mounted in their places.

Do not fail to ensure before the work that:

- jaws on the faceplate are installed and clamped, and that cutting tools or their arbors are clamped in tool holders;

- there are no loose foreign objects on the faceplate.

Safety Precautions to Be Followed when Working on the Machine:

Anyone allowed to operate the machine must be thoroughly instructed in accident prevention techniques and fully familiar with this Service Manual.

During work do not fail to fulfill the following:

- ensure that the jaws, fixtures, cutting tools and work piece are well secured;

- disconnect the machine from electric mains before cleaning jobs;

- do not remove chips from the machine unless the latter is stopped;

- take measurements on the work piece only after the faceplate has come to a full standstill;

NTG15.01 – SAFETY PRECAUTIONS PAGE 1-5

- never operate the machine if its electrical equipment is out of order, nor do any repair jobs unless the machine is turned off at the mains;

- do not leave foreign objects (wrenches, shims, etc.) on the faceplate;

- turn off the machine at electric mains if a long interval in operation is expected;

- be cautious when setting and adjusting the machine movable parts (tool heads, tools magazine, faceplate).

Safe operation

The following provisions ensure safe operation:

The main motion drive is protected with a plate or guard.

The faceplate and tool magazines have a stationary guard incorporating doors and a movable covers. All guard glasses are safe due to a special heat-treatment.

WARNING! Avoid starting the machine with the faceplate unguarded.

Safety Precautions to Be Followed when Checking the Machine General Conditions:

Such a check must be carried out by personnel who are familiar with the machine design and operation and underwent adequate training in accident prevention techniques. All these general requirements, related to machine tools operations, are mandatory to observe.

Safety Precautions to Be Followed when Troubleshooting the Machine:

After a problem has been detected in a running machine, it must be immediately stopped.

To resolve the problem: disconnect the machine, find out the cause of problem, and eliminate it. In doing this, all general requirements, related to machine tool operations, are obligatory to observe.

Safety Precautions to Be Followed when Storing and Transporting the Machine:

Before its installation, the machine must be stored in Factory packing in specially prepared area.

The machine is allowed to be handled only by persons who have undergone special training in accident prevention techniques and who are familiar with general regulations related to handling weights and the operation requirements as stated in this Manual.

NTG15.01 GENERAL INFORMATION PAGE 2-1

Section 2. General Information

Application

Machine is designed for turning, milling, drilling, and grinding of large components.

It may be used either as a part of manufacturing system, automated workshop section or as a self-contained manufacturing unit.

Operating temperature range - 40°F to 95°F (5°С to 35°С). Machine accuracy standards are maintained at an operating temperature from 66°F to 70°F (19°С to 21°С). The speed of air temperature change should not exceed 2°F (1°C) per hour.

Machine should be isolated from air streams, heat radiation and exposure to direct sun. Relative air humidity should not exceed 80% at 77°F (25°С). Ambient atmosphere should not be explosive, dirty; aggressive gas and vapor content should be minimized. Machine should be installed on vibration-proof foundation.

Permissible amplitude velocity of foundation vibrations within the area of machine installation should not exceed 0.04”/sec. (0.00102 m/sec).

Description

GENERAL CONSTRUCTION: NTG15.01 machine is built on a cast iron base filled with polymer casting. The superior vibration dampening qualities of the polymer casting filling (10 times that of ordinary cast iron) allow improvement in cutting conditions, part finishes, and tool life. Two separate cast iron columns are installed on the base top surface. The cross rail is a box shaped casting, which is fixed to the column top surfaces.

The bearing surfaces of the machine are monorail type linear rollers. This system provides high accuracy, excellent rigidity, and speed.

The machine is equipped with the dresser.

The machine uses standard CAT 50 tool holders.

The cutting area of the machine is fully enclosed by steel covers.

SPINDLE: The spindle provides both grinding and milling/drilling operations. In the turning mode the spindle is blocked from rotation. The spindle saddle moves horizontally along the cross rail (X-axis). The spindle head moves vertically (Z-axis) along the spindle saddle.

TABLE: The table with T-slots is mounted to the main spindle axis. The table runs on a precision bearing, and is powered by the main drive. C-drive enables the table to be positioned accurately. The bearing assembly is designed to ensure smooth table rotation and its resistance to vibration.

TOOLCHANGER: The machine is equipped with a 10-position automatic tool changer. The tools are protected from chips and coolant while in the carousel by steel covers of the machine and a retractable door. A powerful air blast is provided while in the tool change cycle to provide further protection from chip intrusion.

NTG15.01 GENERAL INFORMATION PAGE 2-2

Figure 2-1. Machine General View.

NTG15.01 GENERAL INFORMATION PAGE 2-3

Machine overall dimensions:

Length 195.47” 4,965 mm

Width 235.55” 5,983 mm

Height 172” 4,370 mm

Total machine weight 46,400 lb 21,100 kg

Specification

Maximum swing 60” 1524 mm

Table diameter 51.6” 1310 mm

Maximum work piece weight 10,000 lb 4545 kg

Maximum distance from the table surface to the spindle nose 40.7” 1035 mm

Horizontal spindle travel (X-axis) 82.7” 2100 mm

Vertical spindle travel (Z-axis) 35.4” 900 mm

Maximum spindle speed 4000 rpm

Spindle power 29.5 HP 22 kW

Spindle taper ISO 50

Maximum spindle torque 372 ft.lb 505 Nm

Maximum table speed 200 rpm

Power of table drive motor 40.2 HP 30 kW

Maximum table speed in C-axis mode 3.6 rpm

Working feed rate 0-196.9 IPM 0-5000 mm/min

Rapid feed rate 393.7 IPM 10,000 mm/min

Number of tools in tool changer 10

Maximum tool diameter 15” 381 mm

Tool shank CAT 50

Maximum tool length 15.7” 400 mm

Maximum grinding wheel width 1.5” 38.1 mm

NTG15.01 GENERAL INFORMATION PAGE 2-4

MACHINE FEATURES:

FANUC 31i CNC control and AC feed motors with digital drives and high resolution encoders

Fixed cross rail

C-axis

Faceplate with T-slots

Preloaded ball screws on all linear axes

HEIDENHAIN linear scales for all axes feedback

10-position automatic tool changer

Grinding wheel dresser

Full enclosure with mist collector

Concertino (bellows) type way covers

Power tool clamping

Hydraulic system

Automatic lubrication system

Part probe

Coolant filtration system

Acoustic sensor gap elimination

Air gun

Special machine paint color

Full set of screw jacks and anchor bolts for machine installation

Full set of manuals for machine major systems including CD with all Fanuc manuals

NTG15.01 GENERAL INFORMATION PAGE 2-5

Figure 2-2. Machine Front View.

NTG15.01 GENERAL INFORMATION PAGE 2-6

Figure 2-3. Machine Top View

NTG15.01 GENERAL INFORMATION PAGE 2-7

Figure 2-4. Machine Side View

NTG15.01 GENERAL INFORMATION PAGE 2-8

Utilities required to operate the machine:

AIR:

air supply 45 CFM air pressure 90 PSI

LOW PRESSURE COOLANT:

coolant supply 8 GPM coolant pressure 55 PSI

HIGH PRESSURE COOLANT:

coolant supply 5 GPM coolant pressure 250 PSI

OIL:

Lubrication unit:

flow rate 1.6 GPM pressure 100 PSI reservoir capacity 35 GAL

Hydraulic power unit:

flow rate 5 GPM pressure 1150 PSI reservoir capacity 40 GAL

ELECTRICS:

working voltage 480 V full load current 145 A total power supply 120 KVA electrical current frequency 60 HZ

NTG15.01 GENERAL INFORMATION PAGE 2-9

Machine capacity diagrams

Figure 2-4. Table drive capacity diagram.

NTG15.01 GENERAL INFORMATION PAGE 2-10

Figure 2-5. Spindle capacity diagram.

NTG15.01 GENERAL INFORMATION PAGE 2-11

Kinematic Diagram

Figure 2-6. Kinematic diagram.

NTG15.01 GENERAL INFORMATION PAGE 2-12

POS. DESCRIPTION NUMBER OF

TEETH

MODUL

mm

PITCH

WIDTH

HELICAL

ANGLE

1 Sprocket 28 14

2 Belt O-2100 14

3 Sprocket 40 14

4 Gear 20 4 55 15˚ R

5 Gear 210 4 60 15˚ L

6 Sprocket 40 14

7 Gearbox (u=100)

8 Belt B-1960 14

9 Sprocket 75 8

10 Sprocket 30 8

11 Belt W-1000 8

12 Ball Screw Nut 10

13 Ball screw DIA=50 10

14 Ball Screw DIA=50 10

15 Gear 18 3 30

16 Gear 144 3 30

NTG15.01 GENERAL INFORMATION PAGE 2-13

Bearings Layout

Figure 2-6. Bearings layout.

NTG15.01 GENERAL INFORMATION PAGE 2-14

POS. DESIGNATION Q-TY NOTES

1 7214C-P4-DB 2 Set of 2 bearings

2 32220 2

3 6216 DDU 1 Set of 2 bearings

4 6311 1

5 YRTS 460 1 INA

6 ZARN 4075 LTN 3 INA

7 6905 DDU 1

8 MSR55E 4 PMI

9 MSR45E 4 PMI

NTG15.01 – TRANSPORTATION Page 3-1

Section 3. Transportation

Following the test run, the machine is prepared for shipment. The size prevents shipment of the machine fully assembled; therefore it has been carefully dismantled.

The transportation to the site has to be executed carefully, in order not to affect the accuracy of the machine by sharp shocks or pushes. Arrange the transportation with extra care in order to preventt damages through careless loading and unloading.

Eyebolts, transport bars, chains, or lifting slings of the appropriate capacity should be used as transport equipment.

Prepare machine for transportation in the following manner:

Disconnect freestanding equipment (control panel on arm, tool changer, etc.) and secure the cable to machine column.

Dismantle the head.

Dismantle the cross rail with the saddle.

Spray all bare metal surfaces with Houghton Rust Veto No.34 protection lubricant.

Pack some parts and components (control panel, tool holders, electrical cable, and technical documentation) in wooden crate or frame.

Load all packed pieces into containers as per the shipping specification.

Most of the pieces are packed in wooden crates. Large pieces are secured on wooden pallets and covered by thick plastic film with moisture absorbing bags spread around the unit.

When removing the machine units from the truck, or lifting during assembly, heavy wood blocks should be placed at all points where lifting cables or chains could contact finished surfaces. Extra care is required to protect scraped surfaces and machine components.

NTG15.01 – TRANSPORTATION Page 3-2

Handling Diagram

Figure 3-1 Base and Column Lifting Diagram

NTG15.01 – TRANSPORTATION Page 3-3

Figure 3-2 Cross Rail Lifting Diagram

NTG15.01 – INSTALLATION PAGE 4-1

Section 4. Installation

Installation and Assembly

1) First, according to the anchor bolts location drawing, mark and drill the pits with correct position and depth. We do not recommend using anchor bolts with diameter less than ¾” (20mm).

2) Clean all materials such as wood, stones, and debris found in and around the pit area.

3) Unpack the machine parts and remove rust protection spray. Use clean pieces of cloth dipped in mineral oil. Finally, apply light machine oil on clean surfaces.

4) The order of machine assembling should be as follows:

- Place the enclosure pan on the floor.

- Place the base with columns. Level the unit roughly using screw jacks.

- Install cross rail.

- Install head.

5) Level machine using screw jacks.

6) After leveling, all anchor bolts should be locked by locknuts.

7) Install hydraulic, electrical, and supplementary equipment.

8) Install enclosure and guards. The enclosure is sealed with silicone rubber sealant or polyurethane sealant. After sealing, test coolant system, check for leaks, and reseal as required.

NTG15.01 – INSTALLATION PAGE 4-2

Figure 4-1 Screw Jack

NTG15.01 – INSTALLATION PAGE 4-3

Initial start-up

Machine can be prepared for initial start-up after it has been installed and finally aligned on the floor. All auxiliary electrical and hydraulic units should be installed in position and connected to the machine.

Proceed as follows:

Turn on power supply to the electric cabinet.

Switch on the hydraulic station.

Make sure that signal lamps on control panel function properly.

Switch on and move all the mobile units of the machine.

It is advisable that the initial test run of the machine should last no less than two hours and be controlled by the CNC test program.

After initial start-up, machine may be put in operation.

NTG15.01 – INSTALLATION PAGE 4-4

Figure 4-2 Anchor bolts location

NTG15.01 – MACHINE DESCRIPTION PAGE 5-1

Section 5. Machine Description

GENERAL CONSTRUCTION

The base of the machine is made from polymer casting to provide maximum vibration damping, increased tool life, and improved surface finish. The base has configuration related to the columns to minimize thermal deflection. The machine frame consists of the base, two columns, and fixed cross rail. Fixed position cast cross rail incorporates the head, which travels horizontally along the cross rail ways. The spindle head is traveling vertically. The bearing surfaces of the machine are monorail type linear rollers. This system provides high accuracy, excellent rigidity and speed.

TABLE UNIT

The table runs in INA axial/radial roller, double direction bearing designed for high speed. Power is transmitted from the Fanuc AC motor via belt transmission with u=1.42 ratio and gearing with u=10.5 ratio. C-drive enables the table to be positioned accurately, and is driven by an AC motor via reducer (u=100), clutch, belt transmission with u=1 and the same helical gears with backlash compensation. The bearing assembly is designed to allow the adjustment of axial and radial clearances;

the bearing is pre-loaded to ensure smooth table rotation and vibration dampening.

CROSS RAIL

Cross rail is a box shaped, well ribbed casting. The left side of the cross rail houses the X-axis servo drive motor which drives the 2” diameter, pre-loaded ball screw via a timing belt with 2.5:1 ratio.

RAM HEAD

The ram head moves along the cross rail on liner roller guide ways. The ram motion is performed by a 2” diameter, pre-loaded ball screw driven by a FANUC AC servo motor via a timing belt with a 2.5:1 ratio. The tools are mechanically clamped.

Detailed description of spindle is enclosed in a separate spindle manual.

DRIVES

The machine incorporates the following drives for major motions:

Table rotation: AC variable speed spindle motor, belt transmission, helical gears

C-Drive: AC servomotor, reducer, clutch, belt transmission, helical gears

NTG15.01 – MACHINE DESCRIPTION PAGE 5-2

Ram head horizontal travel: AC servomotor, belt transmission, recirculation ball screw

Ram vertical travel: AC servomotor, belt transmission, recirculation ball screw

Spindle: AC direct drive

Enclosure door opening/closing for tool changer: Pneumatic cylinder

Main enclosure door: Hydraulic motor

Tool changer carrousel rotation: Hydraulic motor

Tool Clamping Mechanism

The tool clamping device enables the tools to be changed quickly and easily.

The tool clamping device is installed inside the spindle.

For detailed information about tool clamping device see a separate manual for spindle.

Feed Drives (X, Z – Axes)

All feed drives are of the same design.

Power is transmitted from FANUC AC motor. Each motor drives through a timing belt transmission (ratio 2.5:1) on to a ball screw, which rotates in the ball nut mounted on the machine unit to be moved. Ball nuts are preloaded to ensure “zero” backlash.

The speed of the motors is infinitely variable within the entire speed range.

Emergency switches are installed behind the travel limit. The activation of these switches causes ALL DRIVES to be cut off from power supply. The machine can only be rendered operative again when the drive that activated the emergency switch has been moved back into working range of travel. This is done by activating the hard limit override key switch.

Grinding Wheel Dresser

The dresser is an accessory for the shaping of abrasive disc. The dresser is installed on the right column and has high-speed spindle with diamond wheel.

Enclosure

The machine is equipped with full enclosure with hydraulically operated main door and mist extraction unit.

NTG15.01 – MACHINE DESCRIPTION PAGE 5-3

Tool changer

Tool changer is located on the right side of the machine. Tool carousel can hold 10 standard CAT 50 live tools. Tool carousel is driven by hydraulic motor and has location pin, which holds the disk in proper position.

Figure 5-1 Machine Front View

NTG15.01 – MACHINE DESCRIPTION PAGE 5-4

Figure 5-2 Machine Back View

NTG15.01 – MACHINE DESCRIPTION PAGE 5-5

Figure 5-3 Cutting area

NTG15.01 – MACHINE DESCRIPTION PAGE 5-6

Figure 5-4 Tool changer

NTG15.01 – HYDRAULIC, PNEUMATIC AND LUBRIICATION SYSTEM PAGE 6-1

Section 6. Hydraulic, Pneumatic and Lubrication System

General Description of Hydraulic / Pneumatic System

Hydraulic / Pneumatic system of the machine comprises:

Circulation lubrication system

Drop lubrication system

Hydraulic system

Pneumatic system

Coolant system

Chiller for spindle

Circulation lubrication system

As the machine is running, the main drive is lubricated continuously. The pump directs oil through the filter, flow switch, needle valves, and flow meter into the main drive. Control of flow is provided by switch S8. Nominal pressure in the system 100 psi.

If pressure more than 170 psi – change the filter element # 5.

Recommended oil grades:

Shell Mobil BP ESSO

Vitera 22 Velocite 10 Enegol CS22 Nuray 22

Tellus 22 Velocite В Energol SHP22 Spinesso 22

Tellus R22 DTE 21 Energol HLP22 Nuto H22

Tellus C22

Tellus S22

NTG15.01 – HYDRAULIC, PNEUMATIC AND LUBRIICATION SYSTEM PAGE 6-2

Figure 6-1 Circulation Lubrication System Diagram and Component List

NTG15.01 – HYDRAULIC, PNEUMATIC AND LUBRIICATION SYSTEM PAGE 6-3

Drop Lubrication System

LUBE system is used for oil automatic lubrication. This system ensures impulse-controlled delivery of lubricant to guide ways of the cross rail, head, and to the ball screws.

An impulse delivered during machine start is intended to fill oil into pipes through which it is admitted to the lubrication points.

Recommended oil – Way lube # 68 (Febis K 68). Oil reservoir capacity is 4 liters (1 galon).

Figure 6-2 Drop Lubrication System Diagram and Component List

NTG15.01 – HYDRAULIC, PNEUMATIC AND LUBRIICATION SYSTEM PAGE 6-4

Hydraulic System

The machine features the following systems and mechanisms which belong to the hydraulic equipment of the machine:

Backlash compensation

Spindle clamp

Tool clamp

Tool changer rotation

Tool changer clamp

Enclosure door

Figure 6-3 Hydraulic System Diagram

NTG15.01 – HYDRAULIC, PNEUMATIC AND LUBRIICATION SYSTEM PAGE 6-5

Figure 6-4 Hydraulic System Component List

Recommended oil grades:

Shell Mobil BP ESSO

Vitera 22 Velocite 10 Enegol CS22 Nuray 22

Tellus 22 Velocite В Energol SHP22 Spinesso 22

Tellus R22 DTE 21 Energol HLP22 Nuto H22

Tellus C22

Tellus S22

NTG15.01 – HYDRAULIC, PNEUMATIC AND LUBRIICATION SYSTEM PAGE 6-6

Pneumatic System

Pneumatic system has air regulator with filter 1 , regulator 3C with solenoid valve 2B to provide air for the transfer pump, solenoid valve 2A to provide air for cleaning spindle taper during the tool change, directional control valve 4 to operate tool changer door by pneumatic cylinder. Speed control provides by valves 6. Solenoid valve 2C provides air to spindle and dresser air seals, air regulator with filter 9 provides air to pressurize linear scales.

Figure 6-5 Pneumatic System Diagram and Component List

NTG15.01 – HYDRAULIC, PNEUMATIC AND LUBRIICATION SYSTEM PAGE 6-7

Coolant System

Coolant system provides coolant through the spindle (pump 4), around the spindle and for big diameter wheel to the right and to the left side (pump 2), to the hydrophone (pump 5). Manual for disposable media filter enclosed.

Figure 6-6 Coolant System Diagram and Component List

NTG15.01 – HYDRAULIC, PNEUMATIC AND LUBRIICATION SYSTEM PAGE 6-8

Chiller for Spindle

Chiller provides chilled oil to remove heat from spindle motor.

Figure 6-7 Spindle Chiller Diagram

NTG15.01 – HYDRAULIC, PNEUMATIC AND LUBRIICATION SYSTEM PAGE 6-9

Components Location

Figure 6-8 Drop Lubrication Unit

NTG15.01 – HYDRAULIC, PNEUMATIC AND LUBRIICATION SYSTEM PAGE 6-10

Figure 6-9 Circulation Lubrication Unit

NTG15.01 – HYDRAULIC, PNEUMATIC AND LUBRIICATION SYSTEM PAGE 6-11

Figure 6-10 Right column. Pneumatic valves and manifold for tool changer and enclosure door.

NTG15.01 – HYDRAULIC, PNEUMATIC AND LUBRIICATION SYSTEM PAGE 6-12

Figure 6-11 Left column. Manifold for tool clamp, spindle clamp and backlash compensation.

NTG15.01 – HYDRAULIC, PNEUMATIC AND LUBRIICATION SYSTEM PAGE 6-13

Figure 6-12 Hydraulic power unit

NTG15.01 – HYDRAULIC, PNEUMATIC AND LUBRIICATION SYSTEM PAGE 6-14

Figure 6-13 Coolant System

NTG15.01 – HYDRAULIC, PNEUMATIC AND LUBRIICATION SYSTEM PAGE 6-15

Figure 6-14 Coolant system gages

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Figure 6-15 Chiller for spindle, hydraulic power unit, and coolant filtration station

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General Maintenance

Electric Motors – Lubricate as recommended by the motor manufacturer.

Filters – Change or clean as required or as indicated on filters supplied with visual indicators. Make sure to check indicators shortly after start-up.

Reservoirs – Maintain oil level at all times. The oil should be checked after the first 100 hours and verify that the class of oil meets the requirements of the pump being used. Change the oil every 1000 to 2000 hours depending on the application and operation environment.

Comments – See component literature in appendices.

Recommended Spare Parts Spare filter elements should be purchased with the power unit, and be available during the start-up operation. Other spare parts may be required, and are a function of the duty cycle of the hydraulic system, operation environment, and the acceptable down time of the equipment.

Preventative Maintenance

Filter Service

Filters must be maintained. The key to good filtration is filter maintenance. A machine may be equipped with the best filters available and they may be positioned in the system where they do the most good; but, if the filters are serviced and cleaned when dirty, the money spent for the filters and their installation has been wasted.

A filter which gets dirty after one day of service and is cleaned 29 days later gives 29 days of non-filtered fluid. A filter can be no better than the maintenance provided.

Maintenance Suggestions

1. Set up a filter maintenance schedule and follow it diligently.

2. Inspect filter elements that have been removed from the system for signs of failure which may indicate that the service interval should be shortened and of impending system problems.

3. Never return to the system any fluid, which has leaked out.

4. Always keep the supply of fresh fluid covered tightly.

5. Use clean containers, hoses, and funnels when filling the reservoir. Use of filter cart when adding oil is highly recommended.

6. Use common sense precautions to prevent entry of dirt into components that have been temporarily removed from the circuit.

7. Make sure that all clean-out holes, filter caps, and breather cap filters on the reservoir are properly fastened.

8. Do not run the system unless all normally provided filtration devices are in place.

9. Make certain that the fluid used in the system is of a type recommended by the manufacturers of the system of components.

10. Before changing from one type of fluid to another (e.g., from petroleum base oil to a fire resistant fluid), consult component and filter manufacturers in selection of the fluid and the filters that should be used. Also consult the publication “Recommended Practice for the use of Fire Resistant Fluids for Fluid Power Systems: published by the National Fluid Power Association.

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Maintaining Proper Oil Temperature Hot oil in your equipment’s hydraulic system is one of the primary causes of poor operation, component failure and downtime. Here are some pointers on maintaining proper oil temperature.

The oil in your hydraulic system was designed for operation within a specified temperature range. You may be able to run it at hotter temperatures for short periods of time, intermittently, without adverse effects. If you run continuously with oil that’s too hot, your equipment will operate poorly causing key component failure and machine downtime.

“Hot Oil” is a relative term. In most cases, 120 degrees F at the reservoir is considered an ideal operating temperature. Always take an oil temperature reading at the reservoir, not at a component or any of the piping.

Some hydraulic systems are designed to operate at 130 degrees F or higher. If you don’t know the maximum operating temperature for your equipment, check your component manual for temperature and viscosity limitations.

How can you keep your equipment’s hydraulic system from running too hot?

1. Set up a regular schedule for checking the oil temperature, appearance, smell and feel. Change oil as recommended by the equipment manufacturer.

2. Be prompt about removing, checking and repairing or replacing valves, pumps or other components that are running hot.

3. If relief or flow-control valves are running hot, check and adjust their settings. Follow your equipment owner’s manual.

4. Break in new components gradually. New, close fitting parts expand at different rates, and are especially prone to seize when they get too hot.

5. Start a cold pump motor on hot oil by jogging just enough to draw the hot oil into the component.

Then wait a few minutes to allow the temperature to equalize in all the pump’s parts. Repeat until the temperature on the outside of the pump is the same as that on the piping.

6. Keep your equipment clean. A thick layer of dirt acts as insulation. It will prevent the hydraulic system from getting rid of heat.

7. On hot days, and in hot climates, check and change the oil more frequently. Be sure to use oil recommended for hot weather operation by the equipment manufacturer or oil supplier.

Measuring Oil Temperature There are several ways to check the temperature of the oil. The best, most accurate method is by means of a thermometer. On some machines, this is mounted on the reservoir. Make it a habit to check the thermometer periodically, after the equipment has been running for more than an hour.

If your machine doesn’t have a reservoir thermometer, use the “palm test”. First check the tank with your fingertip; if it’s not too hot to touch, place your palm on the tank. You’ll be able to hold it there without discomfort if the oil temperature is about 130 degrees F or below.

Isolating Trouble-Spots To determine which components are “running hot” and overheating the oil, feel the outlet fittings and lines at the valves, pumps and motors. If the oil temperature is normal going into a component but hot coming out, that could be one of the potential problem areas.

A sticking valve can cause excessive heat. If a spool does not return promptly to the neutral position, the pump flow will be dumping continuously. This builds up heat rapidly.

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If a relief valve is set too low, part of the oil will be dumped across the valve with every cycle. This too, generates excessive heat. Even when all valves are set properly, they may not be operating well because of worn orifices or seals.

Always remove and check the hot components first.

Check Oil Samples Periodically Checking oil temperature periodically is good preventive maintenance. So too is the practice of periodically siphoning an oil sample from the reservoir, and comparing it with a sample of clean, new oil.

Oil that has been running too hot will look darker and feel thinner than new oil. It will also smell burned.

Normally it will contain more contaminants, because hot oil leads to an accelerated wear of component parts.

Trouble Shooting

Probably the greatest aid to troubleshooting is the confidence that comes with knowing the system.

Since every component has a purpose in the system, the construction and operating characteristics of each one should be clearly understood. For example, knowing that a solenoid controlled directional valve can be manually actuated will save considerable time in isolating a defective solenoid.

It is also important to know the capabilities of the system. Each component is the system has a maximum rated speed torque, or pressure. If the system is loaded beyond the specifications, the possibility of failure is greatly increased.

The correct operating pressures of a system must be known and always checked and set with a pressure gauge. The hydraulic schematic should have the correct pressures. If not, assume that the correct operating pressure is the lowest pressure that will allow adequate performance of the system function and still remain below the maximum rating of the components and machine. Once the correct pressures have been established, note them on the hydraulic schematic for future reference.

Understanding the system also includes knowing the proper signal and feedback level, as well as dither and gain settings in servo control systems.

Occasionally, a seemingly uncomplicated procedure such as relocating a system or changing a component part can cause problems. The points discussed below will aid in avoiding unnecessary complications.

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Each component in the system must be compatible with, and form an integral part of, the system.

As an example, placing the wrong size filter on the inlet of a pump can cause cavitations and subsequent damage to the pump.

All lines should be the correct size and free of restrictive bends. An undersized or restricted line results in a pressure drop in that line.

Some components are meant to be mounted in a specific position, relative to the other components or lines. The housing of an in-line pump, for example, must remain filled with fluid to provide lubrication.

Although they are not essential for system operation, having adequate test points for pressure readings will also expedite troubleshooting.

The ability to recognize trouble indicators in a specific system is usually acquired with experience. To help this process, analyze the system and develop a logical sequence for setting valves, mechanical stops, interlocks, and electrical controls. Tracing the flow paths can often be accomplished by listening for flow in the lines or feeling them for excessive warmth.

By working regularly with the system, a cause-and-effect troubleshooting guide, similar to the charts found in this appendix, can be developed. The initial time spent on such a project could save many hours of system down time later on.

Although troubleshooting and repair are a normal part of an operating a system, downtime can be minimized by keeping up on simple system maintenance. Regularly performing the three tasks noted here, the performance, efficiency, and life of the system would be greatly improved.

Maintain a sufficient quantity of hydraulic fluid that is clean and is the correct type and viscosity.

Change the filters and clean strainers often.

Keep all connections tight enough so that air is kept out of the system but no distortion is present.

Whenever system troubleshooting is being carried out, the most important consideration is always safety. Although much of practicing good safety habits is common sense, the stress of a breakdown situation may mean that a potential hazard gets overlooked. For this reason, it is a good idea to establish a regular shutdown procedure, like the one shown in Figure 1, which is carried out before beginning any work on a system.

These same safety considerations call for a restart procedure, which is followed when the repairs have been made, and the system is ready to run again.

Troubleshooting Charts The following troubleshooting charts are arranged in five main categories. The heading of each is a symptom that indicates some malfunction in the system. For example, if a pump is excessively noisy, refer to Chart I (Excessive Noise). The noisy pump is referenced in Column A below the main heading.

Underneath, listed in order of likelihood of occurrence or ease of checking, there are four probable causes for a noisy pump, each cause references a remedy that can be found at the bottom of the page. If cavitations are occurring I the system, perform the procedure(s) listed under Remedy A. If not, move to the next cause, continuing until the cause of the problem is determined and eliminated.

NTG15.01 – HYDRAULIC, PNEUMATIC AND LUBRIICATION SYSTEM PAGE 6-21

LOWER OR

MECHANICALLY

SECURE

ALL SUSPENDED

LOADS

EXHAUST ANY

PRESSURE

LOCKED IN

THE SYSTEM

DRAIN DOWN

ALL

ACCUMULATORS

DISCHARGE

BOTH ENDS OF

INTENSIFIER

ISOLATE THE

ELECTRICAL

CONTROL

SYSTEM

ISOLATE THE

ELECTRICAL

POWER

SUPPLY

NTG15.01 – HYDRAULIC, PNEUMATIC AND LUBRIICATION SYSTEM PAGE 6-22

REMEDIES:

A. Any or all of the following:

Replace dirty filters

Wash strainers in solvent compatible with system fluid

Clean clogged inlet line

Clean reservoir breather vent

Change system fluid

Change to proper pump drive motor speed

Overhaul or replace supercharge pump

Check fluid temperature B. Any or all of the following:

Tighten leaky inlet connections

Fill reservoir to proper level with few exceptions, all return lines should be below fluid level in the reservoir

Bleed air from system

Replace pump shaft seal, also replace shaft if it worn at seal journal C. All of the following:

Align unit

Check condition of seals, bearing, and coupling D. Install and adjust pressure gauge E. Overhaul or replace defective part(s)

ABNORMAL NOISE

(deviating from usual)

PUMP NOISY MOTOR NOISY RELIEF VALVE

NOISY

Cavitations Remedy: A

Air in Fluid Remedy: B

Coupling Misaligned

Remedy: C

Setting too low or too close to another valve setting

Remedy: D Motor or Coupling Worn or Damaged

Remedy: E

Worn poppet and seat

Coupling Misaligned

Remedy: C

Pump Worn or Damaged

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Section 7. Maintenance and Repair

Maintenance

To provide normal operation of the machine and its components, the Customer should regularly perform inspection, repair and routine maintenance, and promptly eliminate any troubles or malfunctions. Care and maintenance are of the utmost importance to maintain the accuracy and efficiency of the machine. Operating troubles which are caused by insufficient or improper servicing can be very costly and can cause long periods of down-Time for the machine. Therefore, regular servicing is indispensable.

The supervisor of the factory must establish a good facility for maintenance and systematic organization to support maintenance for the machine. Then the operator and maintenance man must understand Maintenance manual completely and make effort not to down the machine with preventive maintenance. The maintenance man must be trained to repair the down machine quickly.

The preventive maintenance consists mainly of the daily maintenance and the periodic maintenance. For new machines it is important to have also the initial maintenance after installation.

Daily maintenance.

The first thing to do in daily maintenance is cleaning the machine. Basically, the machine should be cleaned at the end of each working day, and once a week the machine shall be cleaned thoroughly.

The machine is equipped with protective covers against chips and dust. However, if chips and dust piles on the covers without being removed, one of them may enter into the guide way and cause machine failure to function properly.

For cleaning the machine, do not use inflammable or corrosive liquids. It is not advisable to clean the machine by using compressed air, since this may cause the fine chips to enter into the machine.

Prior to operating the machine, check:

- Oil level in hydraulic system, and if necessary replenish or replace when oil is below required level or when oil is deteriorated. Oil of different makes must not be mixed even if they are of the same classification.

- Source air pressure.

- Tool mounting tapered hole for any kind of dirt remaining inside.

Periodic maintenance

Lubrication – Hydraulic System

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For frequency of lubrication and for intervals at which checks are to be made, refer to the section 6, which also contains information on the types of lubricants to be used.

- Oil change. Prior to filling in the lubricant, thoroughly clean the filler neck and its surrounding area to prevent contamination of fresh oil with dirt.

It is essential to ensure that only clean, fresh and water free oil is filled in.

The oil is to be changed whenever the condition of oil does no longer meet the requirements.

Oil-suitability checks should be carried out initially after 500 operating hours and later on every 2000 operating hours or 12 months.

For taking an oil sample, the pump must be started, since with the oil flowing the solid foreign particles cannot settle on the bottom of the reservoir, thus allowing the condition of the oil to be checked more closely. Samples must be passed to the oil manufacturer for analysis. As long as the lubrication properties are not impaired and the aging limit has not been exceeded, the oil remains suitable for further use after a cleaning and micro filtration. The oil manufacturer will advise on the necessary steps to be taken.

When cleaning the oil or when undertaking oil changes, properly clean the containers with suitable solvents.

All lubricating points are to be replenished with the amount of lubricant specified. Do not apply an excessive amount of lubricant to the lubrication points, since this would not increase the lubrication efficiency.

Do not mix oils of different kinds because this will hasten the deterioration of oil

The oil must be filled in such a manner that the formation of air bubbles is avoided.

- Return line filter. When the red indicator pops up, replace the filter element.

Mechanical checks.

At regular intervals of 3 months, the machine should be inspected. The following items require special attention during these inspections:

Noise development and temperature check on drives and bearing seats

Wipers and guide ways for scoring

Way covers for damage

Ball screw backlash

Belt drives

Machine geometry

Electrical motors

The electrical motors are equipped with motor protection switches, which cut power from the motors in case of overload.

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The motor protection switches are installed in the control cabinet. Whenever power is cut by the switch, the cause of malfunction must be determined, and the problem must be fixed. Thereafter, the motor protection switch can be activated again.

There are several reasons for activating those switches. They may be of mechanical or electrical nature.

Check the drive unit for evidence of short circuit, defective cables, seized ball screws, bearings, etc.

Initial Maintenance after Installation.

For some time after installation the machine is subject to initial wear and interior contamination which may lead to high possibility of machine damage.