KAO FONG MACHINERY CO.

,LTD

Chapter 1 Safety precaution

Before operating the machine, read this manual and fully understand the contests of the manual to avoid personal accident or equipment damage. This operation guard of this machine is equipped with an electromagnetic lock switch for operational safety. Some workpiece are flammable. Do not machine such workpiece on this machine. Carefully handle the workpiece and cutters. The workpiece should be clamped correctly by the jigs. The tool holders should also be secured correctly on the Tool Magazine and the Spindle. During maintenance, turn off the main power. Unqualified operators are not allowed to operate the machine before they received a training course. Unauthorized and un-qualified personnel are not allow to access to areas such as electrical cabinet, motor, transformers, and relay boxes (Connectors) Read carefully the instruction and operation manual and know well each parts and commands during the training course. In case of any doubts, ask the instructor and must understand well each of the function of the machine. All operators shall know the locations, functions and regulations of the emergency stop buttons. Make sure the machine is properly grounded. Dont try to by pass all safety devices, guards and sensors and interlock devices. Dont try to maintain the machine when it is still running. Switch off the main power when carry out maintenance, repairing and/or cleaning. Operators shall wear safety shoes and gloves when loading / unloading materials etc. Never operate the machine if there is a possibility of potential explosion in the working zone. After maintenance and repair work for the equipment is completed, make sure that all parts that were removed during the operation have been restored to their original positions. Before starting the equipment, be sure to check that the covers and guards have been mounted at their original positions. Check that the fixed safety devices are operating. To avoid getting caught in the moving parts of the equipment, do not wear loose clothing, necklaces or bracelets.

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KAO FONG MACHINERY CO.,LTD

Chapter 2 Machine description

2-1 Intended use and machine life
The machine is designed only for cold metal and plastic material machining. Other purpose of working is prohibited. The materials, such as wood glass metal powderceramic and poisonous materials, etc. are not allowed being used on this machine. 10 years

Intended use

Machine life

2-2 Out-looking
HMC-400
2385

5410 4410

3820

1000

590

910

3290

3290 2385

590

560

485

1105

2020

367

652

2514

2-1

2830

KAO FONG MACHINERY CO.,LTD

HMC-500
3000

6385

4630

1000

1050
755

3910 3910 3740 328 3000

755

685

448

1788

1710

1285

508

703

2-2

3150

KAO FONG MACHINERY CO.,LTD

HMC-630

870.5

5687.5

1000

4550

2-3

KAO FONG MACHINERY CO.,LTD 2-3 Main parts and names

NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Name Built-in motor Work table B axis servo motor ATC Cam ATC Slowup Motor Hydraulic unit Air dryer Oil Cooler Electrical Cabinet Oil spray unit Oil infusion unit X axis servo motor Y axis servo motor Z axis servo motor Operation Cabinet Auto exchange table Coolant tank Chip conveyor Liquid-Chip Separator

Q`ty 1 2 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1
2-4

Remark 10000rpm/BT-50 FANUC-B160LL/13000i FMH-500P2(0.001) 22/3000i-4kw A505-ARM300 ATC-40T(BT-50) GF200-50-A2-1/4HP-1:90 DAT-10G HBO-2RPTSBM2 SHOWA-MOA-0 YET-C2-3L 30/3000i-5kw 30/3000i-5kw 22/3000i-4kw APC-T500 FCS-50L

KAO FONG MACHINERY CO.,LTD

2-4 Specification
AXES HORIZONTAL MACHINING CENTER X axis Y axis Z axis Rapid travel (X,Y,Z axis) Cutting speed Spindle nose to table Spindle nose to table center Table to floor X axis motor Y axis motor Z axis motor B axis motor Guide way Linear scale BALL SCREW(center coolant) Table working area Pallets Loading capacity Max. working area APC changing time Table index Linear scale Spindle speed Spindle transmission Spindle power Tool shank MAGAZINE Magazine capacity (ST) Magazine capacity (OP) Max. tool dia. Max. tool dia.(without adjacent tool) Max. tool length Max. tool weight Chip to Chip time Tool to Tool time CONTROLLER FANUC ACCESSORIES Tank capacity DIMENSIONS Floor areadth Machine Height Net Weight L mm mm kg 370 5410x3290 2830 9000 18i M standard option mm mm mm kg sec sec kw HMC-400 mm mm mm m/min m/min mm mm mm 630 560 560 24(40) 10 50-610 130-690 1100 4kw 4kw 4kw 3kw Linear option option 400x400 2 550 600/720 9 0.001 option 15000 Built-in 18.5/22 BT-40 40 60 75 150 300 8 9 3.5

Table

mm/mm kg mm/mm sec deg.

SPINDLE rpm

2-5

KAO FONG MACHINERY CO.,LTD

AXES HORIZONTAL MACHINING CENTER X axis Y axis Z axis Rapid travel (X,Y,Z axis) Cutting speed Spindle nose to table Spindle nose to table center Table to floor X axis motor Y axis motor Z axis motor B axis motor Guide way Linear scale BALL SCREW(center coolant) Table working area Pallets Loading capacity Max. working area APC changing time Table index Linear scale Spindle speed Spindle transmission Spindle power Tool shank MAGAZINE Magazine capacity (ST) Magazine capacity (OP) Max. tool dia. Max. tool dia.(without adjacent tool) Max. tool length Max. tool weight Chip to Chip time Tool to Tool time CONTROLLER FANUC ACCESSORIES Tank capacity DIMENSIONS Floor areadth Machine Height Net Weight L mm mm kg 400 7560x4550 3105 13000 18i M standard option mm mm mm kg sec sec kw HMC-500 mm mm mm m/min m/min mm mm mm 720 650 650 24(40) 10 100-750 150-800 1200 7kw 9kw 4kw 4kw Linear option option 500x500 2 1200 1050/1000 15 0.001 option 10000 Built-in 25/30 BT-50 40 60 125 240 400 20 9 3.5

Table

mm/mm kg mm/mm sec deg.

SPINDLE rpm

2-6

KAO FONG MACHINERY CO.,LTD

AXES HORIZONTAL MACHINING CENTER X axis Y axis Z axis Rapid travel (X,Y,Z axis) Cutting speed Spindle nose to table Spindle nose to table center Table to floor X axis motor Y axis motor Z axis motor B axis motor Guide way Linear scale BALL SCREW(center coolant) Table working area Pallets Loading capacity Max. working area APC changing time Table index Linear scale Spindle speed Spindle transmission Spindle power Tool shank MAGAZINE Magazine capacity (ST) Magazine capacity (OP) Max. tool dia. Max. tool dia.(without adjacent tool) Max. tool length Max. tool weight Chip to Chip time Tool to Tool time CONTROLLER FANUC ACCESSORIES Tank capacity DIMENSIONS Floor areadth Machine Height Net Weight L mm mm kg 400 7560x4550 3405 18000 18i M standard option mm mm mm kg sec sec kw HMC-630 mm mm mm m/min m/min mm mm mm 1050 800 880 24(40) 10 100-900 150-1030 1250 7kw 9kw 7kw 4kw Linear option option 630x630 2 1200 1050/1000 15 0.001 option 10000 Built-in 25/30 BT-50 40 60 125 240 400 20 9 3.5

Table

mm/mm kg mm/mm sec deg.

SPINDLE rpm

2-7

KAO FONG MACHINERY CO.,LTD 2-5AccessoriesStandard accessories STANDARDS

1 2 3 4 5 6 7 8 COOLANT UNIT FULL ENCLOSURE AUTO LUBRICATION SYSTEM SPINDLE AIR BLAST WORK LIGHT A.T.C. UNIT A.P.C UNIT ALARM LIGHT 9 10 11 12 13 14 15 16 LEVELING BOLTS & PADS SPINDLE OIL COOLER DUAL SCREW TYPE CHIP CONVEYOR M30 AUTO POWER OFF HEAT EXCHANGE ON CABINET Rs232 INTERFACE ADJUSTING TOOLS & BOX LIFT-UP CHIP CONVEYOR

OPTIONS
1 2 3 4 5 6 COOLING THROUGH TOOL & TOOL HOLDER AUTO TOOL LENGTH MEASUREMENT WORK PIECE MESUREMENT SYSTEM LINEAR SCALE TRANSFORMER COOLANT THROUGH SPINDLE 7 8 9 10 11 CE SPEC. CSA SPEC. EMC SPEC. ALARM BEEPER RAPID SPEED 40MT/MIN

2-8

KAO FONG MACHINERY CO.,LTD 2-6 Work table and fixing holes
HMC-400

A-A(1:1)

B-B(1:1)

HMC-500

A-A(1:1)

B-B(1:1)

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KAO FONG MACHINERY CO.,LTD

HMC-630

A-A(1:1)

B-B(1:1)

2-7

Tool shank and pull stud

HMC-400 BT-40

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KAO FONG MACHINERY CO.,LTD

HMC-400 CAT-40

HMC-500/630 BT-50

HMC-500/630

CAT-50

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KAO FONG MACHINERY CO.,LTD 2-8 Operation position and noise values
!

loading/unloading workpieces Operation areas Operation Cabinet

noise level : HMC-500:75.8dB(A)

!

Danger area

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KAO FONG MACHINERY CO.,LTD 2-9 Location of warning sign, label and nameplate

Warning sign

Significance Electrical hazards Warning sign

Stabbing or puncture hazards, when spindle running Warning sign

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KAO FONG MACHINERY CO.,LTD

Max.tool length L= 300 OD= 75 mm mm

(without adjacent tools)

Max.tool length L= 400 OD= 125 mm mm

(without adjacent tools)

OD= 150 W= 8

mm Kg

OD= 250 mm W= 20 Kg

Max.tool diameter Max.tool mass

Max.tool diameter Max.tool mass

Designation sign

OD

OD

Significance Movement or trice position Designation sign

Gloves Designation sign Use in cleaning

Safety shoes Designation sign Normal use

Read manual clearly

2-14

KAO FONG MACHINERY CO.,LTD

CE mark nameplate

L
OD

Max. tool scale limits Designation sign HMC-400

Max.tool length L= 300 OD= 75 mm mm

(without adjacent tools)

OD= 150 W= 8

mm Kg

Max.tool diameter Max.tool mass

L
OD

Max. tool scale limits Designation sign HMC-500/630

Max.tool length L= 400 OD= 125 mm mm

(without adjacent tools)

OD= 250 mm W= 20 Kg

Max.tool diameter Max.tool mass

3AC MAX

220 50 96

v
Hz A 22 KVA

RATED CAPACITY

OD

MAX. OD =
W
H

700

mm

MAX. H =

800

mm

MAX. W =

800

kg

HORIZONTAL MACHINING CENTER

MODEL NO: HMC500 DATE: SERIAL NO: KAO FONG MACHINERY CO., LTD.
NO.2 LANE 128, SECTION 1, CHUNG CHIN ROAD, TAYA, TAICHUNG, TAIWAN, R.O.C. P.O.BOX:2248 TAYA, TAIWAN, R.O.C. TEL: (04)25662116 FAX: (04)25671001

Max.spindle speed

10000 mm

-1

2-15

KAO FONG MACHINERY CO.,LTD

Designation sign
3AC MAX 220 50 96

v
Hz A 22 KVA

Significance Power reqired Designation sign

RATED CAPACITY

Max. workpiece limits Designation sign

OD

MAX. OD =
W
H

700

mm

MAX. H =

800

mm

MAX. W =

800

kg

HMC-400 MAX D = 600 mm MAX H = 720 mm MAX W = 550kg HMC-500 MAX D = 700 mm MAX H = 800 mm MAX W = 800kg HMC-630 MAX D = 1050 mm MAX H = 1000 mm MAX W =1200kg

Manufacture nameplate
HORIZONTAL MACHINING CENTER
MODEL NO: HMC500 DATE: SERIAL NO: KAO FONG MACHINERY CO., LTD.
NO.2 LANE 128, SECTION 1, CHUNG CHIN ROAD, TAYA, TAICHUNG, TAIWAN, R.O.C. P.O.BOX:2248 TAYA, TAIWAN, R.O.C. TEL: (04)25662116 FAX: (04)25671001

Correct spindle tool to clamp or unclamp Designation sign

Max.spindle speed

10000 mm

-1

Max.spindle speed 10000 HMC-500/630 Max.spindle speed 15000 HMC-400

Designation sign Designation sign

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KAO FONG MACHINERY CO.,LTD

PE

Pneumatic required 5~7 Kg/cm2 Hydraulic required

Spindle Tool APC A AXIS B AXIS ATC 35 60 50 50 Kg/cm 2 Kg/cm 2 Kg/cm 2 Kg/cm 2 Kg/cm 2

Designation sign
Hydraulic required
Spindle Tool APC A AXIS B AXIS ATC 35 60 50 50 Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2

Significance Hydrulic required

Pneumatic required
Pneumatic required 5~7 Kg/cm2

Lubrication inlet

An outlet

Earthed point

Isolator

2-17

KAO FONG MACHINERY CO.,LTD

Spindle Running-in Procedures Case 1 Ordinary operation 2 Spindle rests over 72 hours Spindle speed (Percentage of max. speed) 20% 1. 25% 2. 50% 1. 2. 3. 4. 20% 40% 60% 80% Max. speed Warning Time (min) 10 10 10 15 15 *30 *30 *40 Check points 1.Temperature-rise Within 20C 2.Vibration 3.Noise 1.Temperature-rise Within 20C 2.Vibration 3.Noise 1.Temperature-rise Within 20C 2.Vibration 3.Noise 4.Proceed to next stage after temperature stabilizes

Spindle rests over 2 weeks

(1)Start the spindle after a tool is clamped in spindle

(2)If temperature-rise is over 20C , reduce spindle speed to 800rpm , then restart the procedure after the spindle temperature has cooled off to within 5C above the ambient temperature

Usually, there are some chips under rotary table and on APC plate. Thus, please use air gun to clean the chips on daily shift or clean them regularly.
Z

(1) Cutting oil check from time to time. (check the level through meter) (2) Clean chips and dirt remained in the tank as well as the filter plate. (3) Clean chips on the filter plate cyclically.be careful to wear safety gloves and use tools like clamp to do this work.

2-18

KAO FONG MACHINERY CO.,LTD

Chapter 3 Transportation, movement and installation

3-1 Transportationpackage
B (cm) A (cm)

Main machine Unit Item HMC-400 HMC-500 HMC-630 A(cm) 4340 515 620 B(cm) 2885 350 342 C(cm) 3080 340 360 Weight (kgw) 11000 17500 22000 Forks(m) 2 2.4 3

Option equipment Unit Item HMC-400 HMC-500 HMC-630 A(cm) 273 303 410 B(cm) 224 224 300 C(cm) 215 215 220 Weight (kgw) 1800 2100 3000 Forks(m) 2 2.4 3

C (cm)

3-19

KAO FONG MACHINERY CO.,LTD

Transportationunpackage Unit Item HMC-400 HMC-500 HMC-630 D(m) 2 2.4 3 E(cm) 1200 1500 1800 F(cm) 300 500 700 Weight (kgw) 9000 13000 18000

Transportationunpackage

The distance between each fork1.5m

Machines hang up
1. Hang machine on positions shown drawing below. 2. Ensure all hang up wires and cables are qualified in duty. 3. Carefully with all machines pipes, cables, wires, units during hanging up. 4. Check & locking all hydraulic & lubrication units to preventing oil leaking. Required cables:A:25L3200mm;B:25L3300mm;C:25L3600mm

3-20

KAO FONG MACHINERY CO.,LTD Disposal instructionsAccording to the local law

HMC-500 safety installation of machine floor condition HMC-400

HMC-500

Concrete

Broken stone

3-21

KAO FONG MACHINERY CO.,LTD

HMC-630

3-2 Environment requirement

1.Do not install the machine at a place subject to direct sunshine and/or adjacent to a heat generation source such as a furnace/oven. 2.Do not install the machine at a place subject to rapid temperature changes. The temperature should be 20~ 35 3.Do not install the machine at a place where there is a lot of dust and dirt, or a location affected by chemical gases, sea breeze etc. 4.Do not install the machine at a place subject to excessive moisture. The humidity should be 30 ~ 80

5.Do not install the machine on a slope or unstable place. 6.Please connect the electric power and make sure the ground wire is connected correctly

3-22

KAO FONG MACHINERY CO.,LTD 3-3 Space requirement

E
Opreation areas

1000

Dimension
Type

HMC-400 HMC-500 HMC-630

A(mm) 6480 7460 8630

B(mm) 4535 5225 5625

C(mm) 600 600 600

D(mm) 1150 1150 1150

E(mm) 1000 1000 1000

F(mm) 470 470 470

3-4 Supplies preparation

1. Power & ground wire: Voltage:3P/AC220V Frequency: 6010% Hz ( 400V& 380V transformer if require). Power wires connecting: Connecting terminal positions RST through bottom side of cabinet. (position G for ground wire=16mm) ATTENTION: RE-CHECK ALL WIRES CONNECTING POSITIONS BEFORE POWER ON. 2. Hydraulic& Pneumatic pressure: Min. Hydraulic required: 0.59Mpa Min. pneumatic required: 0.29~0.68 Mpa 3. Lubrication oil: As recommended. ( refer to table as attached) 4. Cutting oil: Oil tank capacity 350 liters , keep PH around 9 as recommended. ATTENTION: DO NOT USING LOW FLASH POINT OIL FOR SAFETY CONCERN. 5. Spindle coolant oil: R10 spindle oil as preferred. 6. Spindle lubrication oil: Spindle oil R22 Mobil Velocitie no.10 as preferred.
3-23

KAO FONG MACHINERY CO.,LTD 3-5 Instruction for how the initial test and examination of the machine 3-5.1 Fixing frames remove
1. Remove the fixing frames when machine positioned (located as drawing shows) Attention: Make sure the frames removed before test running start.
Fixing Frame Fixing Frame Fixing Frame

Fixing Frame

Fixing Frame

3-5.2 Greases Removal

1. Remove the greases coated on axes protection covers. (Might use the coal oil with cloth for greases cleaning and sprays lubrication oil upon). Attention: Avoid cleaning solution flowing into guide way scraper.

3-5.3 Leveling adjustment

1. Leveling adjust until within standard 1mm/m .
Leveling Adjust Seat Leveling Gauge

2. Steps of positions adjustment: firstly positions1234, and secondly positions 5678. (refer to drawing below)

3-24

KAO FONG MACHINERY CO.,LTD

Lifting Block(Up) Adjust Bolt Lifting Seat Lifing Block(Down) Foundation Block

Base Blot

3. Set the work table into position and precise leveling adjust through axes moving.

3-5.4 Final check before machine running

1. Check the voltage into 220V, 60HZ, 3P. 2. Check the ground wire & all wires connecting. 3. Connecting air pipe with dryer entry (pressure 7kg/ 2) 4. Check all alarm lights working. 5. Check feed rate in manual function. 6. Check all fixing frames to be removed. 7. Check anti-rust oil removed & spray lubrication oil upon. 8. Installing cutting oil pump with pipes. 9. Check quantity & tank position of cutting oil. 10. Check tools type, weight, length, diameter. 11. Closing all doors & windows. 12. Check all safety & warning mark plates in exact positions.
3-25

KAO FONG MACHINERY CO.,LTD 3-5.5 Spindle warming running

Attention: Follow the steps as below before spindle warming running. 1. Starting spindles lubrication& coolant system. 2. Maintain spindle speed in 3000rpm continuing at least 5 mins. (To make sure bearing lubricated then up to speed 10000rpm) ATTENTION ! DO NOT TRY TO RUN THE SPINDLE WITHOUT TOOL STUD.

(O)

(X)

3. Slow down rpm into 800 when if temperature over 20.

3-5.6 Standard steps of spindle warming running and check

States Spindle RPM ( max. rpm%) 20% Time (mins) 10 Item of check 1. Temperature should be lower than 20. 2. Vibration. 3. Noise. 1. Temperature should be lower than 20. 2. Vibration. 3. Noise 1. Temperature should be lower than 20. 2. Vibration. 3. Noise 4. Programs running until temp. in stable

Normal daily running

Spindle without running over 72 hours

1.25% 2.50% 1.20% 2.40% 3.60% 4.80% 5. max. rpm

10 10 15 15 30 30 40

Spindle without running over 2 weeks

3-26

KAO FONG MACHINERY CO.,LTD 3-5.7 Operation of spindle clamp/unclamp clamp/unclamp button in spindle This is only used in probe or small tools, do not put on normal tools hear.

The method of clamp/unclamp (1)Step the tool to right position when it stopput on with two hands Be careful: it is very dangerous when you put on the tools by one handplease put on the tools with two hands because the tools can reach 20 Max mass

(2)Unload toolUsing tool remover to make it unclamp , then put it away

3-27

KAO FONG MACHINERY CO.,LTD 3-5.8 External extraction equipment

External extraction equipment extract harmful fine mists and vapour

3-28

KAO FONG MACHINERY CO.,LTD 3-5.9 External joint of Electrical Section

Separator

Oil Cooler

Hydraulic

Air Dryer

EA EC EB

Electric Box

EF

ED

EE

EI

EH EG

EL EK EJ

Coolant Pump Separator

Item 1 2 3 4 5 6 7 8 9 10 11 12

No
EA EB EC ED EE EF EG EH EI EJ EK EL

Name Air Dryer Hydraulic Motor Oil Cooler Separator Moter C.T.S Coolant Pump(Type:CRK2-180) Separator Interlock Front Ceiling shower coolant Rear Ceiling shower coolant Suction pump Chip conveyor Separator Moter Spindle coolant

Chip conveyor

3-29

KAO FONG MACHINERY CO.,LTD

3-5.10 External joint of HydraulicOilCoolant Section

Separator

Oil Cooler

Hydraulic

Air Dryer

OA OB OC OD OE OF OG OH

OJ(DOWN)

OI(UP)

Oil Cooler-IN

Oil Cooler-OUT

B-Axis OUT B-Axis IN ATC OUT ATC IN Spindle OUT Spindle IN APC OUT APC IN

C.T.S Coolant Pump (Type:CRK2-180)

CE

Suction pump Front Ceiling shower coolant

(Type:MTA-4) (TYPE:MTA-3) CA CB CC CD

Rear Ceiling shower coolant

(Type:MTA-4)

Spindle coolant
(Type:SPK2-3/5)

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

No
OA OB OC OD OE OF OG OH OI OJ CA CB CC CD CE

Name B-Axis OUT B-Axis IN ATC OUT ATC IN Spindle OUT Spindle IN APC OUT APC IN Oil Cooler-OUT Oil Cooler-IN Front Ceiling shower coolant Rear Ceiling shower coolant Suction pump Spindle coolant C.T.S Coolant Pump(Type:CRK2-180)

3-30

KAO FONG MACHINERY CO.,LTD 3-5.11 Chip conveyor installation method

(1) Lays aside the coolant tank front of the machine position. (2) Hang up the chip conveyor and put down inside of the coolant tank.

Front Pedestal

Chip conveyor Coolant tank

Cover

(3) Hang up Front Pedestalput it down on top of the chip conveyor and the coolant tank. (4) Connect Electrical joint of the chip conveyor and test its function.

3-31

KAO FONG MACHINERY CO.,LTD

Chapter 4 Maintenance and adjustment

4-1 Ally inspection

Attention: Units daily inspection as drawings below.

Hydraulic Unit meter Cooler Oil tep.Controller Oil Level

Electric Cabinet ON/OFF

Air Pressure Meter Tools Clamp/UnClamp(manual switch)

Alarm Lights

Operator Panel

Cutting Oil Leveler

Oiler

Oil-Air Spindle Lub.

4-32

KAO FONG MACHINERY CO.,LTD 4-2 Maintenance and Inspection areas

Make sure available spaces in all units are enough. (as drawings below) 1. Chip remove cyclically & keep cutting oil in as standard position always.
Oiler Slowup Motor Oil-Air Spindle Lub X-axis Linear way Auto Pallet Change Pallet(B-axis) Z-axis Linear way

Air Dryer

Hydraulic Unit

Cooler

Filter Y-axis Linear way

Dimension
Type

HMC-400 HMC-500 HMC-630

A(mm) 6480 7460 8630

B(mm) 4535 5225 5625

4-3 Items of inspection

Based on machine high performance and duty extending reason, please must ensure all indicated items as table below before operation. ITEMS CYCLE Check the quantity of lubrication oil Every 2~3 days ( Add oil immediately when alarm ) Tank3 litres Check ball screws lubrication fountioain especially when machine stop running during long period. Daily Check air pressure setting on 0.49~0.68kg/cm2 Daily Check no air leaking. Daily & any times Check hydraulic pressure on 5.8Mpabefore operation start. Daily Cutting oil check from time to time. (check the level through meter) Cyclically Tank350 litres Keep dust free on both tool shank& spindle aperture. Daily Keep guide ways without chips as less as possible. Cyclically Low speed running before operation (daily10~20 mins) Daily Check oil quantity of spindle cooler & lubrication units. Daily
4-33

KAO FONG MACHINERY CO.,LTD 4-4 Special attentions

Items Air condition into air compressor Auto lubrication ball screws Tool shank released Pull stud Tool replace by manual Max. tool dia. & work piece Description Due to air pressure set on 0.49Mpa, therefore the pressure of air compressor should maintain upon 0.58 Mpa. Make sure always cleared on filter & water drain unit working. Check lubrication oil recycle tank and add oil immediately when alarm. Carefully when duty of tool shank release Check the pull stud before installation. ( For safety reason please ensure that tool shank application as indicated only) Handle with care when tool replace by manual (Do not loading or unloading tool inclined.) Distance between tools are127mm. Max. tool dia.125mm. Max. work piece loading 800Kg. Max. work piece dimension700x800L(mm) Since tool magazine control by NC & hydraulic cylinder. Therefore, keep hands away from it when machine running start.

Tool magazine

4-5 Sindle coolant system

1. Oil cooler required capacity : 6000 kcal/hr 2. Oil flow & oil pipes: 13.5 L/min will be preferred, i.d. upon 10mm as preferred. 3. Spindle oil recommend: Low viscosity spindle oil R10. 4. Starting lubrication & oil coolant system before spindle running. 5. Maintain spindle speed at 3000rpm at least 5mins then turning up to 10000rpm. ITEMS CYCLE CONTENTS DESCRIPTION Pneumatic unit daily 0.29~0.49Mpa Filter of pneumatic unit daily Water eliminate Filter of pneumatic unit 2000hrs Cleaning or replace Cleaning by water (5) Filter of pneumatic unit 2000hrs Filter replace (0.5) Oil quantity of daily Check level upon lubrication unit line as often Lubrication unit 200hrs Add. oil Spindle oil R22 Mobil Velocite no.10 Filter of lubrication unit 2000hrs Cleaning or replace Cleaning by oil Spindle cooler oil Spindle cooler oil Filter of spindle cooler daily 2000hrs 50hrs Check level upon line as often Oil replace cleaning
4-34

1 2 3 4 5 6 7 8 9 10

Spindle oil R10 Mobil Velocite no.6 Spindle oil (R10) Mobil Velocite no.6 By neutral agent or water

KAO FONG MACHINERY CO.,LTD 4-6 Spindle lubrication system

Spindle

0.03CC 0.03CC 0.03CC 0.03CC 0.01CC

HO6

HO6

name plate

HO6

HO6 HO6

3~5kgf/cm

Air unit

HO6

Vent

Remarks: 1. Pump set up: times/16 min 2. Lubrication oil : Mobil Velocite no. 10(R22) 3. Oil filter before spray mixing: within 30 4. Air supply dryer: as required & with filter within 0.5 5. Air pressure: 0.29~0.49Mpa (pump pressure & oil quantity as connected) 6. Spray oil quantity of distributor: 0.03cc (0.01cc as marked 1)
4-35

Lubrication Unit Curcle time(once/16min)

R22

Filter (30) LF0101

Oil-Air Distributor

HO6

HO6

HO6

KAO FONG MACHINERY CO.,LTD 4-7 Hydraulic system (spindle tool B axis APC)

4-36

KAO FONG MACHINERY CO.,LTD 4-8 Hydraulic unit of tool magazine system

4-37

KAO FONG MACHINERY CO.,LTD 4-9 Table of lubricants

ISO3498
Nach FC10 CL10 Mobil Velocite Oil No.6 SPINESSO 10 Shell Teilus Ol C 10 Castrol Hyspin AWS10 BP Energol HL 10 AVILUB RL 10-C Aral Sumurol CM 10 FC22 CL22 Mobil Velocite Oil No.10 SPINESSO 22 Shell Teilus Oil C 22 Castrol Hyspin AWS22 BP Energol HL 22 AVILUB RL 22-C Aral Sumurol CM 22 CB32 CL32 Mobil Vactra Oil Light TERESSO 32 Shell Teilus Oil C 32 Castrol Hyspin AWS32 BP Energol HL 32 AVILUB RL 32-C Aral Sumurol CM 32 CC100 GLP100 Mobiigear 627 SPARTAN EP 100 Shell Omaia Ol C 100 Castrol Hyspin AWS100 BP Energol GX-XP 100 AVILUB RSX 100 Aral Degol BG 100 CC150 GLP 150 Mobiigear 629 SPARTAN EP 150 Shell Omaia Ol C 150 Castrol Alpna SP 150 BP Energol GX-XP 150 AVILUB RSX 150 Aral Degol BG 150 GLP68 CGLP68

Kennzeichnung

Name of COMP.

DIN51502

Mobil ESSO Shell Castrol BP AVIA ARAL

Bettbannoei 68 FEBIS K 68 Shell Tonna Ol TX 68 Castrol Magna BTH68 BP Maccurat 68 D BP Energol HP-C 68 D AVILUB RSL 68-SU Aral Deganit BW 68

4-38

KAO FONG MACHINERY CO.,LTD 4-10 Exchange table operation and maintenance

Profile and units lacation

Preparing unit

Adjustment of exchange table

1 .Make sure table in upon position before rotary exchange. 2 .Adjustable rotation speed: The final step of rotary would be adjustable. ( through releasing adjust nut & turning to increasing or decreasing rotation speed.)
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KAO FONG MACHINERY CO.,LTD

3 .Check pallet in the exact position when after exchange. 4 .Adjust nuts when if table not in the right position (refer to drawing as below) 5 .Table rotating by manually : Through Foot Switch allow to rotate table manually.(Manually when positioning and 0 position confirm) 6.Gaps between exchange tables: Normally between1~3 mm.

Foot Switch Seat

Foot Switch

Adjust nuts on table

switch seat sensor adjust block lock nut withanti water gel M5 bolt sensor adjust block

Questions and Solutions When proximity switch has no action which might caused: 1 . Proximity switch damaged. 2 . Distance between proximity switch& sensor are to far.(The ideal distance are1.5~2mm) AttentionDischarge the oil before proximity switch take out and add. oil when mounted.
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KAO FONG MACHINERY CO.,LTD 4-11 B Axis operation and maintenance

Lubrication & hydraulic oils 1. Lubrication oil: Highly rust against and anti-oxidized as required. Viscosity classes ISO-VG around 100~150. Recommend as: JoMo - LATHUS 100 (or 150) Mobil- Gear 629 Shell- Omela Oil 100 (or 150) Esso - Spartan 100 (or 150) 2. Lubrication Oil addition: Make sure without any chips get in when during oil addition to ensure the mechanical parts running out of risk. 3. Lubrication Oil exchange: Exchange whole oil per 6 months. 4. Locking unit of hydraulic oil: Safety data as preferred 3.43Mpa . (max. 4.9Mpa ) AttentionHigh quality oil pipes as recommend. STEPS: Discharge air when first oil infusion time: first, oil pressure set up 1.96Mpa and performer order LOCK from controller. Secondly, releasing exhaust until no more oil foam coming out and lock again to re-exhaust couple times. Finally, pressure set up around 3.43~4.9Mpa as required. 5. Running test Before tilting rotary table operation please follow steps as below: a. Check no more load on tilting rotary table before motor getting start. b. Process confirm, check N/C signal as exact and re-operating lock & release. c. Make sure clamping unit in release function when motor running. AttentionDo not make titting rotary table clamped during rotation. d. 0 point return set up: Signal from N/C & position as arranged.(first, disk rotary with high speed and slow down when touch lamina switch and signal return from pulse coder when stop on 0 position. Attention Change the parameter of parallel within 0.02mm when parallel out of standard. (The parameters excluding minus and please replace block if still not in standard.)

4-12

Sensor blocks adjustment

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KAO FONG MACHINERY CO.,LTD

0 point set up Using proximity switch when block touch caused decelerate and positioning fount ion. Proximity switch height adjustment: Clock way turning is the way back to 0 point. Release fixing nuts & turn tilting rotary table to sensory area till light up. (normal gap1~2mm) And lock nuts, switch fixing set. Blacks adjustment: Release nuts on block & adjust it.
table speed

distance of grid shift

table movement micro switch on micro switch off origin (stop point desired) table stop point

0 position return

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1. 2.

Work piece loading

Check the surface of disc has no score or dent. Prevent un-flat or steeply work piece surface contact with disc directly.

moving angle table center line

work center line

start point

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KAO FONG MACHINERY CO.,LTD

division tolerance

start moving angle

Attention Seriously when lock work piece on and make sure lock thghtly enough.

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Screw and Screw Wheel gaps adjustment

Gaps adjustment: Turning both right & left side screws close to screw wheel.(ideal condition around 0.005~0.008mm) Attention When gap sets on 0.005mm , must turm rocker arm manually for make sure titting rotary table rotation. Normallythe gaps have already set up when machine finished and please refer to Steps following when adjust requied. Gap Measurement Fixing measurement meter on position as drawing shown below.

First , insert steel bar as drawing shown ( keep 100 mm over as shown too) and forwarding it as clock way. (note the data of meter). Secondly, reversing it as against clock way again(note the data of meter). Plus both data = gap AttentionMake sure no more rotate on both screw and screw bearing otherwise the gap are unable to measure.
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KAO FONG MACHINERY CO.,LTD

Take off cover as drawing below and put meter on posttion A and turn adjust ring until data lower then 0.01mm.

Steps of gap adjustment

a. Discharge oil totally from screw. b. Take out the side cover c. Release fixing bolts & take out motor. d. Release bolts from motor & take cover out. e. Release fixing bolts on screw f. Adjust screw gear slowly as shown below.

g. Lock bolts slowly& sequentially as drawing below when adjust finishing.

Attention: The final tight force as

1.18 N.m
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KAO FONG MACHINERY CO.,LTD 4-15 Intendance

Check daily before operation start a. Check oil level as normal. b. Check tilting rotary table under capacity. (work piece weight & driving torque) c. Whether noise when tilting rotary table rotation.

4-16 Replacement of oil of Hydraulic unit

1 2

5 6

1.pressure control screw 2. pressure gage 3.Filter cap

4.oil level gage 5.Oil tank 6.drain

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KAO FONG MACHINERY CO.,LTD 4-17 Clean coolant method

(1) lift the front pedestal up and move it away. (2) pull out the chip conveyor and coolant tank.

Chip conveyor

Front Pedestal

Coolant tank

(3) lift the conveyor out of the coolant tank, and then move it away.

Cover

(4) unscrew the fasteners, then open the cover plate of the coolant tank and pump. (5) sluice out the coolant in the tank completely. (6) clean chips and dirt remained in the tank as well as the filter plate. be careful to wear safety gloves and use tools like shovels to do this work.

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(7) restore the conveyor, tank and pedestal in backward procedures as described above. (8) refill clean coolant to accomplish the coolant replacement.

4-18 Clearing away the chip

1. Uses the tool (broom, , dont use the air-gun) to collect chips to waste recycling. 2. Dump rubbish into waste recovery yard. 3. Return the oil tank above the water tank. 4. lay up the water tank under filing exportation wearing gloves.

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KAO FONG MACHINERY CO.,LTD

4-19 PC plates depends method

For the safety of the operators, the pc plates on the guards should be free from breakage. the necessity of the replacement of the pc plates depends on the events of cracks or rupture. generally the period is about 2 to 3 years. (1) use genuine PC plates from the machine supplier. (2) unscrew the screws on the edges of the plates. (3) remove the setting plates and PC plates out of the guards. (4) apply leakproof glue to PC plates on the contacting portion with the guards. then fit them back in position. (5) restore the setting plates and fasten the screws to accomplish the replacement.

Hex. Scoket Bolt

Operated Door

Pressure Plate PC Plate

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KAO FONG MACHINERY CO.,LTD 4-20 Release of person trapped in the machine

When the machine is in the condition of power disconnection or maintenances status The inter lock in the status of (CLAMP) in case the maintenance person is closed in The interior of the machine and can not open the safety door to get out as the power Can not be operated to discharge the circuit of inter lock of the door. The way to get out is by usmg hand tools to open the door by force. As shown in the picture please Find the component near by the inter lock and then turn the LOCK position to UNLOCK. After the person left safely. Please remember to restore the inter lock to LOCK position on Account of to prevent any person is endangered when the power is on because after the safety Door was opened by force. It would stay at unlocked status.

How to relax interlock

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Chapter 5 The troubleshooting

When malfunction happened, please use this chapter trying to fix the basic problem. And gather the information as following items. We will do our best to recover the machine as soon as possible. 1. 2. Machine serial number, Mode, Control system and delivery date? The responded massage of machine: what is the alarm message and alarm number of servo? Does fuse fail? Is over load escaped? What happens: In which mode? If it happens constantly? If it happens during executing some G code or M.S.T. code? If it happen at the particular machine coordinate? Are there any signs abnormally? Check the frequency of occurrence: what is the frequency? When did the problem first occur? What did you do after malfunction? Outline of environment: Is the voltage stable? Have you updated the program ? Have you changed the operator? Have you updated the tools and clampers? Is the temperature and quake of environment normal? Before malfunction happened: have you edited program or changed auxiliary equipment? Do you adjust or remove the machine?

3.

4.

5.

6.

We hope to solve the problem immediately and completely. The above question is very helpful for us to find the problem. Any answer may be the key point to recover the machine. If during the telephone contact step, you could tell us the detail situation of machine. It will be more easier to find the reason of malfunction and recover it as soon as possible.

ALARM NUMBER E1

DESCRIPTION

STEP OF RECOVER

REMARKS
Better waiting 2-3 minutes, usually it happens because of too much chips in chip -conveyor through.

E2

MOL ALARM 1.Turn power OFF Motor for outside part 2.Open the door of electric have overload cabinet and check the situation OVERLOAD. 3.Push the RESET BUTTON which is on overload. OIL ALARM Spindle 1.Is filter too dirty? Use water, coolant pressure neutral cleaner or compressed detect alarm air to clean up and air-dry in overcast. 2.if not work, please call the cooler maker
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the TEL of the cooler maker is on the cooler unit plate and the manuals of cooler unit.

KAO FONG MACHINERY CO.,LTD

E3 SPINDLE ALARM heck it the feed rate and spindle speed are correct. 1.If not, turn power OFF and RESET. 2. If yes, use a screwdriver to open the door of electric cabinet (do not turn power OFF) and check the alarm number on the 7-segment decoder of spindle driver (at upper row, the second from the right side),and contact with the agent or FANUC. Please check the follow items:

E4

LUB ALARM LUB oil not enough

1.Is the oil enough? 2.If yes, maybe the oil detector is
broken. please check in according to electric circuit manual.

1002

1003

SPINDLE DRIVER ALARM spindle driver overload alarm EMERGENCY STOP ALARM

same as E3

1.Overtravel: press the EMG

RELEASE button on control panel. In EMG RELEASE mode: Switch to handle mode, use hand wheel to return original point, and RESET.

2.Motor overload(MOL. ALARM):

the same as E1(RESET) EMG not release the same as E2 Please follows the chapter 5 or ATC stand-by instruction of electric circuit manual

1004 1005

SPINDLE GEAR OIL ALARM ATC STAND-BY LS ATC not at stand by situation

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1007 SPINDLE CLAMP LS Please check the following items: 1.Is spindle unclamping? 2.Does spindle clamp limit switch touch the dog. 3.If yes, check if it have touched exactly and stable.

2002 2003

TOOL SEARCH ERROR ARM 60 M/C LOCK

1.Are T code all right. 2.Check the tool registration. 1.RESET NC. 2.Turn ON manual operation of ATC. (D500.1=0.1 D503.3=1 D503.4=1) 3.In MDI mode, used M code to return ATC to stand-by situation step by step. 4.Turn manual operation of ATC. 5.Return Z-axis to ZERO 1.Close safety door 2.If not works, please check if it is a problem of fuse. 1. During ATC tool change, Z-axis does not return to original point . Please return Z-axis back to original position. Check whether the air pressure is miss? 2.If the pressure is enough, check if the pressure switch is broken. 1.Is spindle on clamp? Is ARM on 0 ? 2.Check if LIMIT switch are stable that we mentioned before. 1.Are feed-rate and spindle rate OK? 2.RESET NC The same as E4 1.Is pressure of LUB enough? If yes, please delay the time of pressure D330= 15000
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2004 2007

SAFE DOOR INTERLOCK CHECK ZPZ POSITION

2006

AIR PRESSURE MISS

2008

CHECK SPINDLE OK LIST

2009 2010 2011

SPINDLE LOAD TOO MUCH LUB OIL MISS LUB PRESSURE MISS

KAO FONG MACHINERY CO.,LTD

2012 WAIT FOR RIGHT TOOL 1. May be the tool are not STAND BY 2.If the magazine keeping rotation, please call agent. XY-axes must back to second reference points. 1. Check count A and count B Sensor Only 10000rpm High speed sp

2013 2014 2015 2016 2017

GO G30 X0 Y0 FIRST MAGAZINE PARITY ERROR

For VMC-650800

SP NO TOOL CANT Please install tool then can start ROTATION spindle OIL/AIR LUB. ALARM SP WARM UP FOR 3000RPM PLEASE CHECK TOOL AND HIT CYCLE START P.B TO CONTINUE THEN WAIT 5MIN WHEN FIRST START SP SP WARM UP FOR 3000RPM PLEASE CHECK TOOL AND HIT CYCLE START P.B TO CONTINUE THEN WAIT 5MIN WHEN SP STOP OVER 2 HOUR 2020 ADMONISH!THE Z AXIS LOCK P.B IS ON.ARE YOU SURE?YES,PLEASE HIT CYCLE START P.B TO CONTINUE.NO,PLE ASE CHECK THE Z AXIS LOCK P.B. 2021 PLEASE PUSH OP2 P.B TO ENABLE JOG/RAP/ZRN MODE 2022 PLEASE PUSH M19 P.B 2023 APC ALARM OIL/AIR LUB SIGNAL NO OK CHECK OIL/AIR LUB. UNIT Please check sp tool,if ok press CYCLE START P.B to start sp warm up.

2018

SP stop over 2 hour please check sp tool,if ok press CYCLE START P.B to start sp warm up.

2020

Please check Z lock P.B in auto mode

2021

Push OP2 P.B to enable JOG/RAP/ZRN mode

2022 2023

Push M19 P.B to enable SPINDLE UNCLAMP mode Please check APC LS
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2024 2025 2021 APC AIR PRESSURE MISS 2025 Y,-Z PROTECT AREA Please check APC AIR PRESSURE LS Please check Y,-Z POINTS

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