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Hyundai SKT 100/200 CNC TURNING CENTER. INSTALLATION MAINTENANCE MANUAL (VERSION No.: VOL1.0) - page 4

V. REPAIR AND PRESERVATION

3) X-axis Dog and Limit Switch

P = 24grid (in diameter)

+OT Dog

Reference Point Dog

0.08

Reduction

range

Reference Point

Limit Switch

16.45

Reduction

OFF

+OT Dog

0.08

+OT Limit Switch

+OT Limit Switch

Fig. 5-5 X-axis Dog and Limit Switch Attached Position

5-11

4) Z-axis

Standard Soft Jaw

Paper

Tab le 5-1. Chuck Dimensions

mm (in)

Type

Chuck

CAUTION

For SKT100/200, the reference point of Z-axis is different in diameter as shown in the above table, so

adjust it after checking the specification of Chuck.

5-12

V. REPAIR AND PRESERVATION

a. To approach the outer diameter bite tool to chuck and protect the blade end, use a thin

piece of paper, feed the handle and approach the tip end of bite tool to the jaw section

until the paper is not moved.

b. Set the "EXTERNAL" coordinate "Z" to "0" (see X-axis).

c. Set the mode to Handle X, move the head stock in the + direction of X-axis, and make

it not to be interfered with Tail Stock.

5-13

d. Using the handle, determine the position at reference point.

CAUTION

1.

Perform only in Z-axis.

2.

Position X-axis at a distance from reference point.

e. This time, move the current position to be "C" value of Table 5-1, set "EXTERNAL"

coordinate to "0" and then move it about 1/2 (6,000) of ball screw pitch in the opposite

direction to Reference Point Return.

f.

Move the reference point return dog to the position where reference point reduction signal

is turned ON.

g. Reference point return the Z-axis.

h. Using the handle, confirm the

distance from reference point to

reduction signal OFF is within the

specified range. If out of the

specified, readjust the dog.

i.

Perform para. 2 and 3 again and

write the differences between

"MACHINE" coordinate value and

"C" value of Table 5-1 at parameter

1850 as the grid shift amount.

j.

Turn off and then re-apply the

power.

5-14

V. REPAIR AND PRESERVATION

CAUTION

If the para. j being not performed, it will not be operated properly.

1-3-3. Z-axis Dog and Limit Switch Attached Position

-OT Limit Switch

Reference Point

Limit Switch

+OT Limit Switch

-OT Dog

Reference Point Dog

+OT Dog

Fig. 5-6 Z-axis Dog and Limit Switch Attached Position

5-15

1-4. X- and Z-axes Backlash Adjusting Method

1) Delete the compensation entered.

a. Select the setting screen and make the parameter change valid.

b. Select the parameter screen and delete the backlash compensation.

2) Measuring Backlash

a. Fit the dial indicator to the head stock from turret or Sub-spindle side.

b. Measure the backlash using X- or Z-axis handle (See the following Fig.)

Dial indicator

0.002 mm

Turn the handle to the left and set

the Handle Indicator mode to "0".

Turn again the handle to the right of

20 ~ 30°.

Backlash in Z

Turn the handle to the right and

Backlash in X

set the pointer to "0". This time,

the difference of indicator

becomes the backlash.

5-16

1-5. Q-Setter Position Adjustment

After the machine collided or repaired, check the position of Q-setter is misaligned.

CAUTION

If the Q-setter used with misaligned, it requires the compensation as being misaligned.

1) Check the distance parameter to the position of sensor.

Reference Point

#5016

#5018

#5015

#5017

Set #5016 “1”

Key in 5015

Press SYSTEM key

Press the Key, and "5015" will be

displayed.

For the inside of X-axis

For the outside of X-axis

For the opposite direction of Z-axis

For Z-axis

5-18

V. REPAIR AND PRESERVATION

2) Check the offset of tool to be used in measuring.

1: Outside Tool

2: Inside Tool

3) Measure the compensation according to Q-setter.

a. Check the reference point return lamp is illuminated.

If not illuminated, perform the reference point return manually.

b. Set the mode to manual (JOG, handle feed) and pull out the Q-setter to the position to be

measured.

c. Call the tool to be used in measuring.

5-19

d. Approach the tool nose to Q-setter. If contacted to the sensor in the manual mode, the

tool offset will be input automatically.

4) Calculate new parameter to the position of center.

New parameter = old parameter + (new offset - old offset) x 1000

para. 1)

para. 3

para. 2)

para. 5)

new #5015)

new #5016)

new #5017)

new #5018)

5) Set the parameter at #5015.

Key in the

data

Press [SYSTEM] Key

5-20

V. REPAIR AND PRESERVATION

CAUTION

After changing the data, always press the RESET key, turn off and then re-apply the power.

6) Adjusting Method according to Cutting. [(fine adjustment following data 5)]

a. Call the tool to be used in cutting.

b. When the desired value is assumed

at

50 mm by chucking the

workpiece, cut it with the work

coordinate set to 50.0.

c. Measure the workpiece has been

cut.

d. Calculate new parameter.

New parameter = (old parameter) + (measured value - desired value) x 1000

Ex. 1:

#5015 = (-60482) + (49.8-50.0) x 1000 = (-60482) + (-200) =-60682

Ex. 2:

#5015 = (-140657) + (50.25-50.0)x1000=(-140657)+250 = 140407

2.

General Check and Repair

2-1. General

1) General check and repair are essential to maintain the high integriy for a long time. So,

general check and repair take precedence of any other job.

CAUTION

1.

When doing the general check and repair, open the necessary cover or door and the door of electric

control panel remains closed.

2.

Never use compressed air. It may result in penetration of foreign matters into the spindle bearing

and guide-way.

WARNING

Prior to performing the general check and repair, place the main break of electric control panel to OFF as

shown in Fig. 5-7.

5-21

Fig. 5-7 Main Break Switch OFF Position

2) Always record the operation and check/repairing works.

Recording and Maintaining the operation is necessary for the operation of machine. Record

the check and repairing works independently from the operation.

3) Check and repair will be performed in short time. This short-term work is important to avoid

the unexpected accident or problem. And it is one of the important works to use the machine

effectively for a long time.

4) Oiling

WARNING

If the recommended oil didn't supplied, it may occur damage in the machine.

This machine has many places to be lubricated. When lubricating, "Avoid over-filling"

important. When oiling, follow this manual.

5) Check and repair can be performed daily, weekly, monthly and yearly. Check, fill oil an| clean

the machine as instructed in this manual.

5-22

V. REPAIR AND PRESERVATION

2-2. Check and Repair Items

Note:

{

Checking Period,

z CRT display

Checking and Repairing period

Reference

Period

Item

Daily

Weekly

Monthly

Six-

Yearly

Biennially

Reference

monthly

1. Remove chips inside the

{

2-3-1

machine

2. Remove chips above the

{

2-3-1

tool post

3. Remove chips above the tail

{

2-3-1

stock

4. Remove chips from each

{

2-3-1

slider cover

5. Clean coolant nozzle

{

3-6-3

(if clogged)

6. Treatment of chip

{

2-3-1

7. Clean coolant tank

{

3-6-2

8. Coolant filter

{

3-6-2

9. Check the hydraulic oil flow

{

2-3-3

10. Check the coolant flow

z

2-3-3

11. Check the lubricating flow

{

2-3-3

12. Hydraulic oil pressure 35

{

2-3-4

kgf/cm²

13. Check the lubricating oil

z

3-5-1

supply

14. Check the coolant supply

{

3-6-1

15. Hydraulic oil strainer

{

3-4-2

16. Lubricating pump filter

{

3-5-2

17. Clean around the machine

{

2-3-1

18. Oil leakage

{

2-3-3

19. Remove the tool chip and

{

2-4-2

check if damaged and

broken

20. Loosen bolt

{

21. Turret tool sank

{

2-4-2

22. Check Operating Panel

{

23. Clean the Electric Panel

{

24. Operation of emergency

{

stop switch

25. Vibration, noise and

{

increased temperature

26. Check the operation of

z

safety device

27. Check the tension of spindle

({ )

{

2-6-2

belt

one month after

installation

5-23

Check and Repair Items (Continued)

Note:

{

Checking Period,

z CRT display

Period

Checking and Repairing period

Reference

Item

Daily

Weekly

monthly

Six-

Yearly

Biennially

Monthly

28. Check the multi

{

2-6-2

cover of X-axis

29. Operation of the

{

2-6-2

wiper in X-and

Z-axes

30. Clean inside of the

{

3-6-2

coolant tank and

change oil

31. Moving hose

{

2-6-1

32. Clean the OSRAM

{

2-7-1

lamp

33. Relay in the

{

Electric Box

34. Machine level

{

35. Check backlash

{

1-4

36 Clean the fan

{

2-5-3

37. Clean the front

{

3-1-2

cover of spindle

38. Applying chuck

{

2-3-1

grease

2-3.

Daily Check and Repair

2-3-1. Inside of the Machine

DANGER

Before cleaning inside of the machine, always turn OFF the power.

CAUTION

Never use compressed air. It may result in the machine failure.

1) Use the tool such as brush, damp cloth, etc.

2) Remove chips and collect them in the chip box of machine.

5-24

V. REPAIR AND PRESERVATION

CAUTION

1.

First, pull the collected chips out of the machine and collect them into the chip box.

2.

Using coolant, clean the inside of machine.

3.

If chips not removed, it may cause a failure of the machine.

3) Inject the grease into the Chuck

and clean it. Use the specified

grease.

grease

Fig. 5-8 Checking the inside of Machine

5-25

2-3-2. Outside of the Machine

1) Remove the collected chips into the separated chip box.

WARNING

If there are coolant, grease or water on the floor, immediately wipe it out using damp clothes or papers.

Otherwise, it can cause personal injury from slipping.

Used tool: shovel, brush

A. If the machine hasn't equipped with

chip conveyor

a. Remove chips from the front of

the machine. Pull out the coolant

tank in front of the machine, pick

out chips from the chip box in

coolant tank and put them into a

separate container and return its

original position.

Fig. 5-9 Removing chips from the chip box(1/2)]

b. Remove chips from the rear of the machine

Disassemble the cover from a separate chip container, remove chips, put them int. the

chip box and then reassemble the cover.

Fig. 5-9 Removing chips from the chip box (2/2)

5-26

V. REPAIR AND PRESERVATION

B. If the machine equipped with chip conveyor

Position the chip box just under the chip conveyor and remove the collected chips.

Chip conveyor

Fig. 5-10 Removing Chips out of the Chip Box

2-3-3. Checking Oil Flow

Oil flow can be checked by means of flow level gage in the tank. If filling oil, use the

recommended oil.

1) Check the flow of hydraulic oil

2) Check the flow of lubricating oil

3) Check the flow of coolant

Hydraulic oil

Lubricating

Coolant

Fig. 5-111 Checking Oil Flow

5-27

2-3-4. Checking Pressure

Check the pressures in Hydraulic unit, Chuck, Sub-chuck and Tail Stock.

1) Hydraulic unit: 35 kgf/cm² (3.5 MPa)

2) Chuck: 5 ~ 27 kgf/cm² (0.5 ~ 2.7 MPa)

3) Tail Stock: 1 ~ 20 kgf/cm² (0.1 ~ 2 MPa)

WARNING

If being set above the specified pressure, it can cause machine failure.

Tail Stock pressure

Chuck Pressure

Hydraulic Unit Gage

Fig. 5-12 Checking Pressure

5-28

V. REPAIR AND PRESERVATION

2-3-5. Filling and Changing Oil

CAUTION

• If using soluble coolant

1.

Choose it in consideration of its characteristics such as rustproof, security, cooling, and etc.

2.

It should not include the contents dangerous to human body.

3.

It should not be deteriorated during the storage.

4.

It should not include corrosive or risk elements to the painting.

5.

It should not include elements melting to rubber products used in the machine.

6.

It should not include the contents which may degrade machine accuracy.

7.

Add a little rustproof oil when mixing coolant with soluble coolant. Otherwise, it may be rusted as

coolant dried.

8.

When completing work, wipe out the part contacted with coolant. Apply it with rustproof oil after

cleaning.

9.

Take care not to touch coolant with skin. Be sure you should be informed of its user's .instruction

for your health.

10. The mixing method of soluble coolant with water depends on the kinds of coolant and follow the

instructions of the manufacturer.

WARNING

Make sure the problem occurred by coolant, and etc. is not warranted.

1) Filling Oil (if necessary)

WARNING

If there is coolant, grease, or water on the floor, immediately wipe it out with damp clothes or papers.

Otherwise, it may cause personal injury.

5-29

A. Filling coolant is possible in front or rear of the machine, but generally supplied at the rear.

a. Oiling in the front box of the machine

Pull out the coolant tank and fill it.

Fig. 5-13 Oiling in front of the machine

b. Oiling in the rear of machine

Disassemble the cover at the rear of machine, remove multi-hole iron plate from sub

tank, and then fill coolant.

Fig. 5-14 Oiling at the rear of machine.

WARNING

1.

Never touch coolant with bare hands.

2.

Coolant may damage the skin seriously:

5-30

V. REPAIR AND PRESERVATION

2-3-6. Around the Machine

1) Clean the outside of machine.

Wipe out oil and remove coolant, chip, and etc.

Clean CRT screen and operating panel with soft clothes dampened in cleaning solution.

2) Check there is an evidence of oil leakage outside of the machine.

3) Check if chips are removed, broken or damaged from the tool (insert),

2-4.

Weekly Check and Repair 2-4-1. Inside of the machine

2-4-1 Inside of the machine

1) Cleaning the filter of coolant tank.

WARNING

When using compressed air, always wear protective goggles.

a. Use brush and air gun.

b. Remove the filter and clean it with brush.

Fig. 5-15 Cleaning the Filter of Coolant Tank

CAUTION

The use of air gun in the vicinity of the machine may cause the machine failure.

5-31

2-4-2. Outside of the Machine

1) Turret Tool Holder and Shank

Check the chips are removed from the tool holder or shank and engaging bolt is attached.

Fig. 5-16 Turret Tool Holder and Shank

2) Engaged State of Bolt

WARNING

1.

This check is for preventing a failure in advance.

2.

If neglecting this, it may cause the machine failure.

3) Check the Operating Panel is illuminated.

Petrol Lamp (Option)

Main Operating Panel

Fig. 5-17 Operating Position

5-32

V. REPAIR AND PRESERVATION

2-5.

Monthly Check and Repair

2-5-1. Inside of the Machine

1) Cleaning the nozzle of coolant

Used tool: - and + screwdrivers

Remove chips around the coolant nozzle attached at turret.

Fig. 5-18 Removing Turret Nozzle Chip

Fig. 5-19 Coolant Supplying Route

5-33

2-5-2. Filling and Changing Oil

1) Filling lubrication Oil

WARNING

When filling lubricating oil, always use the recommended oil by KIA.

Otherwise, it may cause the machine failures.

a. tank capacity:

-1.8 l (0.47 gal)

b. Lubricating oil supply:

-33dd/h

Recommended oil:

See chap. 3-5-2 “Place to be

Lubricated”.

Lubricating Oil

Filling Position

Fig. 5-20 Lubricating Oil Filling Position

Oil Filter Plug

Oil Level Gage

Fig. 5-21 Filling Lubricating oil

5-34

V. REPAIR AND PRESERVATION

c. Open the plug of oil filter.

d. Fill the recommended lubricating oil up to the upper limit of level gage.

e. Plug the oil filter.

WARNING

When filling lubricating oil, wipe out dropped oil on the floor with damp clothes or papers. Otherwise, it

may cause personal injury.

2) Whenever filling lubricating oil, always clean the waste oil tank.

Fig. 5-22 Cleaning Waste Oil Tank

WARNING

Unless the waste oil tank cleaned, it may cause personal injury due to overflow oil.

5-35

2-5-3. Outside of the Machine

1) Cleaning Cooling Fan

• Used tool: Wrench (3, 4, 5mm), damp clothes

WARNING

Before cleaning the fan, turn OFF the Main Power switch. Otherwise, it may cause personal injury.

a. Remove the door from the Electric

control panel and the fan filter from

the left side and then clean them

using air gun.

2-6.

Six-Monthly Check and Repair

2-6-1. Filling and Changing Oil

1) Exchanging Hydraulic Oil

WARNING

1.

Before exchanging the hydraulic oil, always turn OFF the power.

2.

When filling hydraulic oil, always use the recommended one by KIA.

Otherwise, it may cause the machine failures.

The hydraulic oil should be changed after the first 3 months of installation. Thereafter, change

it every 6 months.

Used tool:

Wrench (5 and 10 mm)

Oil capacity:

15 l (3.92 gal)

5-36

V. REPAIR AND PRESERVATION

a. Turn OFF the main power switch in the electric control panel at the rear of machine.

b. Disassemble the bolt in the left lower cover and place the collection container under the

drain plug installed at the rear of hydraulic unit.

c. Loosen the drain plug and collect hydraulic oil.

Fig. 5-23 Collecting Oil of Hydraulic Unit

d. When completed, close the drain

plug.

e. Open the door for repairing in

front of the machine and the oil

filter cap and then supply the

hydraulic oil.

Fig. 5-24 Supplying Hydraulic Oil

2) Changing Coolant

Clean chips in coolant tank and perform in the following orders.

WARNING

When changing coolant, wipe out dropped oil on the floor with damp clothes or papers. Otherwise, it

may cause personal injury.

5-37

• Used tools: Coolant collecting box, damp clothes, shovel, wrench (17 mm),

+ screwdriver, coolant capacity 135 l (35.25 gal)

a. Lock the ball valve before disconnecting hoses between the main and sub tanks.

Fig. 5-25 Disconnecting Coolant Tank

Fig. 5-26 Main Tank

Fig. 5-27 Sub Tank

5-38

V. REPAIR AND PRESERVATION

d. Position coolant collecting box

under the drain plug in main and

sub tanks, loosen the plug and

allow all coolant to drain.

Fig. 5-28 Collecting Coolant

e. Clean inside of the coolant tank

thoroughly.

f.

Clean the filter.

g. Slide coolant tank into the bed and

connect it with the main or sub tank.

h. Supply new coolant.

Fig. 5-29 Supplying Coolant

3) Checking Moving Hose

DANGER

Always turn OFF the power and then check moving hoses for damage.

Otherwise, it may cause personal injury.

5-39

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