UNIVERSAL MACHINE TOOL

OPERATING INSTRUCTION

(^Mr^^ MODEL: SWING OVER BED: DRILLING CAPACITY: STROKE OF RAM: WORKING AREA: MACHINE NO: oi^o^l

420mm 38mm 275mm 200mmx600mm

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NANTONG SANDE MACHINERY CO., LTD.

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CONTENTS

1. GENERAL INSTRUCTION 1 1-A MODEL,NAME, PATENT NUMBER OF MACHINE TOOL 1 1 -B OUTLINE 1 1-C FEATURES AND APPLICATION 2

2. MAIN SPECIFICATION AND DESIGN PARAMENTERS 2

3. CONSTRUCTION AND WORK PRINCIPLE 4 3-1 CONSTRUCTION- - 4 3-2 WORKING PRINCIPLE 7

4. LIFTING AND MAINTENANCE 15

5. INSTALLATION, ADJUSTMENT AND TRIAL 18

6. LUBRICATION- 20

7. LIST OF ROLLER BEARINGS 21

8. OPERATING 23

9. MAINTENANCE 30

10. BREAK DOWN AND REPARATION 31

1. General instruction 1-A. Model,name and patent number of machine tool.

Model: Name: Universal Machine TOOL

1-B. Outline

Fig. 1 Outline of The Universal Machine Tool

1. Lathe 2. Drill & mill part 3. Horizontal mill part 4. Shaper

1-C. Features and applications The universal machine tool has flmctions of lathe, drill, shaper and mill (longitudinal,

horizontal). Each function can be operated separately from other accessories. This machine tool is good at geometric precision, high at working altitude and higher in

productivity. Through the medium of slideway made from the high quality wear-resisting cast-iron which produced with supersonic quench and finish grinding, the all gears of headstock were also quenched and finish grinded. For reduce the noise, some handwheel were used the nonmetal gears, so the machine tool is long-lasting and lower at noise. For the cutting, drilling and milling, the machine tool set up a special "ON", "OFF" safety interlocking mechanism, the overload safety device fixed in the apron. The machine tool is reliable to use, easy to operate. The construction of the machine tool is compact, the color of the external form is pleasant and using ground to fix is small. The users also can order the machine tool at the function you choosed.

The machine tool is mainly using to cutting, planning, milling and drilling, to machining the various rotational surface, such as external surface of cylinder, surface of taper of forming rotational surfaces; planning the various planes, flutes, etc; drilling and boring the various holes; and also processing the metric thread, British thread, modulus thread and diametral pitch thread etc.

The Universal Machine Tool is applied to the maintenance departments of ships, outdoor working groups, industrial and mining enterprises, etc.

2. Main specifications and design parameters 2-A. Lathe Unit (mm)

Swing over bed 420 Swing over carriage 250 Swing in gap 650 Valid width in gap 100 Max.lathing length 1000 (QN6004) /1500 (QN6004/2) Taper of main spindle MT N0.5 Dia. Of spindle thru. Hole 35 Taper of tailstock spindle MT N0.4 Section dimension of cutter arbor 20 X 20 Spindle speed 12steps 22.4-1000 r/min Longitudinal feed 31 steps 0.129-2.056 mm/r Cross feed 3Isteps 0.063-1 mm/r Metric threading 23kinds 0.25-6 Inch threading 24kinds 2-32 t.p.i. Travelling distance of tailstock spindle 100

2-B. Shaper Max. stroke of ram 275 Max. horizontal travel of table 150 Max. distance from table to ram 205 Working area of table (W X L) 200X600 Max. vertical travel of carriage 50 Width of T -slot in table 12 Center distance and number of T-slot 63mm, 3 Ram speed 3 steps 25-50 r/min Longitudinal mechanical feed of table 5kinds 0.15-0.76

2-C. Milling, drilling Max. drilling capacity 38 Span 200 Distance between spindle nose and table MAX 650 Size of table (W X L) 200 X 600 Taper of spindle hole MT N0.4 Max. bearing capacity of table (kg ) 120 Dia. of spindle thru. Hole 15 Spindle speed 6sLeps 140-600 r/min Travel of spindle 100 Horizontal travel of table 150 Vertical travel of table 275 Travel of knee 500 Max. Dia. of milling cutter tool face mill:63

end mill: 16 2-D. Horizontal milling

Taper of spindle MT N0.3 Dia. of cutter arbor 25.4; 22 Distance between main spindle and overarai 131 Cross travel of table 150 Longitudinal travel of table 275 Vertical travel of table 500 Spindle speed (r/min) 6steps 90-500

2-E. Power of main motor 3Kw 50Hz 1440r/min 60Hz 1720r/min

Motor power of cooling pump 40W

3

2-F. Mass of machine tool(kg) Overall dimention of machine tool

~2500(QN6004) 2653x1228x1680

~2700(QN6004/2) 3153x1228x1680

(LxWxH)

2-G. The machine tool's colour:

2-H. Power source: V Control power source:

phase_ _V sigle-phase_

.Hz AC Hz

2-J. Grade of motor's insulation

2-K. Main motor protection:IP_

3. Construction and working principle 3.1 Construction

The Universal Machine Tool is mainly composed of the following units, its overall view is shown as Fig.2.

3.1.1 Turning unit 3.1.1.1 The gear-box 13, which is located at the back-left side of the bed 1, is the prepositive

gearshift for the turning, drilling and milling movements, it is also the gearshift mechanism for the planning movement of the ram 10.

3.1.1.2 Headstock 2, at the left side of bed, it has one turning spindle and one horizontal milling spindle which can rotate in a required speed. In addition,it also has the function to transmit the torque to milling head for drilling and milling operation.

3.1.1.3 Saddle and carriage 5, located at the middle of the bed. The saddle can move along the bed in longitudinal direction, while the carriage can move on the saddle in different directions such as in longitudinal, cross and oblique directions.

3.1.1.4 Tailstock 6, located on the guideway at the end of the bed, it can move to and for to the desired position to support the workpiece. In addition, the tailstock can hold the drilling tool or other kinds of tools for hole processing.

3.1.1.5 Feed box 3, installed at the front-left side of the bed. It's a main gearshift mechanism for tool to get the designed feeding and to process the desired thread piicli.

3.1.1.6 Apron 4, fixed at the bottom of the saddle 5. It can transmit the action from the feed box 3 to the carriage to realize its different operations such as longitudinal feeding, cross feeding, rapid moving or thread processing.

3.1.1.7 Bed 1, all main functioning elements should keep exact relative position on the bed when operating.

3.1.2 Planing unit

1. Bed 2. Heads took 3. Feed box 4. Apron 5. Saddle & Carriage 6. Tail stock 7. Planing nachine columi 8. Feeding box of the planing nachine 9. V(5rking t ibl e uni t 10. Ram 11. Ifcrizontal 14. Elec. box 15. M)t or 12. n- i l l ing & MUing head 13. Csar box 14. H ^^ c. box 15,M)tor

Fi e. 2 CVerall view of The Universal Mchi ne Tool

3.1.2.1 Planing machine column 7, as the first part of the completed machine, which is mounted on the foudation. It has a pair of fixed ratio gears 13 anH a rocker mechanism. At its front end, there is a vertical dovetail guideway matched with the knee. Some movable and fixed gibs are provided between its up surface and the matched part. At its front right side, a gearshift box 13, speed changing knob and start, stop control handle of plarming unit, as well as a safty interlock mechanism are equipped.

3.1.2.2 Rocker mechanism, when the bigger gear in column 7 rotating, it will make the ram move back and forth through the crank and rocker mechanism. When adjust the distance between the crank pin hole and the center line of hollow spindle, you can get the desired stroke of ram.

3.1.2.3 Ram 10, It is a hollow casting with a dovetail guideway at its bottom and a groove on its top surface. A lead screw is provided to connect the ram anf the crand ricker mechanism, so adjust the leadscrew, the desired relative position of ram to table can be obtained.

3.1.2.4 Working table unit 9. This unit indues working table, saddle and knee, etc.The saddle with worktable can move in cross direction along the guideway of knee.The longitudinal movement of the table can be controlled by hand or power. Through a leadscrew set and a leadscrew set and a pair of fixed ratio gears which are transmitted by apair of bevel wheels and a universal rocker driven by the feeding box of the planning machine to realize the longitudinal power feed. After releasing the lock screw at the left side of the column, the knee can move up and down by rotating the handle. When planning workpiece, the interlock will function to limit the knee's position.

3.1.2.5 Feeding box 8 of the planning machine, located at the front left side of the column. It has a driving gear, a big gear with arocker, and a cam centi-elined on a hollow shaft. When the hollow shaft rotates, the cam will drive the driven wheel rotating, through a pair of cross bevel gears and agear screw set, the power feeding of worktable can be realized. Adjust the relative positions of the two cams, the different feeds i^nn be obtained.

3.1.3 Drilling & milling unit 3.1.3.1 Drilling and milling head 12. It is mounted at the back side of the headstock, the head

is a support part and action transmitter of the spindle. When drilling, the spindle gets its main action from power, and its feeding from manual operation. When milling, replace the drilling tool and its collet by milling tool and its collet. Operating the milling handle instead of the drilling handle to control the spindle feeding. The speed of the spindle is controlled by the knob A at the left side of the column of planning machine and knob C on headstock.

6

3.1.3.2 Work table 9. When drilling or milling, because of the action of interlock rr^ccliaism, the feed of the worktable can be obtained only by manual operation.

3.1.4 Horizontal milling unit 11. 3.1.4.1 Ram and hanger. The ram is a round shaft, one of its ends is fixed at the support

position of the drilling and milling head, and the other is equiped a hanger to support cutter arbor. When processing, the milling tool performs the main action, the worktable with the workpiece performs its feeding. Action. If necessary, you can install the taper handle tool in the spindle directly.

3.1.4.2 Worktable fescribled in 1.3.2. Its feeds in X,Y,Z axises are controlled by hand. 3.2 Working principle

This machine consists of two systems: the electric system and the mechanical transmitting system which includes main driving unit and feed driving unit.

3.2.1 Mechanism transmitting system 3.2.1.1 Main transmission chain of the machine transmission process describled as following

and its corresponding transmission structure shown on Fig.3.

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Fig.VA Way of the lifting of machine body

Fig.7A Way of the lifting of machine body (without public base)

14

The machine tool is set with 2 motors and 2 push button controls. M2 is the main motor(Y100L2-4; Y100L2-4H, for shipping 3 kw). Ml is the cooling gump motor (AB-12, 40W). Emergency stop switchs are to be provided, one at lathe operators position and one at the drill/shaper/miller position. For keeping the all electrical system functioning normally, ther machine tool's main return circuit is set 3 fuses(FUl). The controlling, lighting and DC. Return circuit set fuses separately (FU2,FU3,FU4). When it operates, close the switch(QS) at first, then push the button SB3(SB4), the spindle of the machine tool rotates noraially. If push the button SB5 (SB6), the spindle rotates reversally and push the SBl (SB2), the spindle will be stopped. Brake of the machine tool adopts the energy controllation. When push the button SBl (SB2), the spindle motor turn off, and at the same time, that is in contact with DC. Return circuit, the winding of spindle motor turn on DC. The function of brake is start. Through delay DC. Return circuit, the machine tool is stop. The braking time is adjusted by timing relay(KT). "ON" or "OFF" the cooling pump are controlled by the button SB8 or SB7. Pushes the button SB8, The cooling pump will be operated, and pushes SB7, it is stop. The cross section of electrical wire should be 4mm ,^ and the grounding conductor's cross section should be 2.5mm , which should use the multi-ply copper wires. This machine tool has the good grounding safeguard. The electrical components of metal are connected witli yellow and green to busbar from grounding.

4. Lifting and maintenance 4.1 Lifting

Before lifting, remove all protective covers first, then place the ropes according to the Fig.7 indication. Use some lissome material between the rope and some bulge or machined part to prevent them from their directly contacting. Balance the machine by moving the saddle and tailstock, then lift it carefully, when put it down, more attention should be paid.

4.2 Maintenance 1) Before packing, grease all machined parts for rust-proof. When installation, clean all

surfaces first, then oil them with machine-oil after they are dried up. Any scraping or abrading is not allowed.

2) Don't change the position of operation handle at random. 3 ) The attachments of the machine are placed in the tool box and the back column chest.

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5. Installation, adjustment and trial 5.1 Installation

Fig. 8 shows its assembly diagram on ship or engineering truck. 5.2 Adjustment

Move the worktable of the planning machine to the center position, where a level(acscuracy: 0.02/1000) is placed on. The readings both in long, and cross should not be more than 0.04/1000. Then moving the slide to the middle position of its guideway travel, place a level there, the readings both in longitudinal and cross direction should not be more than 0.04/1000.

5.3 trial 5.3.1 Before trial, check the following items:

1) Check if the main power of machine is in good condition. 2 ) Before switch on the power, check its insulation (its resistance should be more than

2 M Q with the 550MV testing vohage.) 3) Filling the oil into the headstock and feeding box to their marked position.

Lubricating periodically all points according to the Lubrication Point. 4 ) ense the V-belt to its normal working position. 5 ) Check if all handles are in their proper positions or not. 6) Check if all protective covers are installed properly. When the machine running,

covers should not contact with all movable parts. 7 ) Idle running. Set all handles to their corresponding mode, then start the motor. 8) Before beginning the planning operation, check the safty interlock device to ensure

the worktable at its correct relative position to the ram. When the motor is running, don't shift the handle B.

5.3.2 Start Two interlocked button panels are equipped. The main button panel is used for controlling the starting and stopping of the spindle, controlling the spindle rotating directions(clockwise or counter clockwise) and controlling the cooling pump on or off. The assistant button panel used for controlling the spindle's movement, and linking with main button.

5.3.3 When trial, run the machine at idle mode first, then from low speed to higher speed. Don't shift the handle for gearshift until the machine stops. Users should be familiar with the properties of this machine before operating it, and more attentions should be paid for you safety.

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Fig.9 Lubricating Points :Ar Hiind lubricator

Lubrication You can apply lubrication oil on machine as mentioned below. Table 1. Oiling schedule

Code

A

B

C

D

E F

G

H

I

J

K

L

M

N

Area to be Oiled

Tailstock

Headstock

Driving box

Carriage & saddle

Apron Lathe feed box

Bracket at the right side of guide Shaft of horizontal milling Slide way of ram and swing lever Feed box of shaper Table feed conversion box Table, saddle slide way Chang gear box

Shaper column interior

Oiling method

Hand oiling

Open cover & supply oil

II

Hand oiling

Hand oiling Open cover & Supply o i l

Hand oiling

n

II

II

II

II

II

II

Name of specified oil

Engler recosity2.6-3.31 E50

II

II

II

II

II

II

II

II

II

II

II

II

II

Reoiling interval

Once a day

Anytime to keep oil up to the middle of oil gauge

II

Once a day

Once a day

Once a day

//

II

II

II

II

II

If

Replacin-g cycle

Twice a year

Twice a year

Twice a year

20

7. List of roller bearing ( Table 2 ) How to assembly roller bearing, please refer to the drawing 3 for transmission system and the drawing 11 for operation and table 2.

Assembhng part

Headstock

Feed box

Shaft

IX

VII

IV

V

VI

XI

Illb

IVb lib VIb

Vllb

Model

7210

8110

206

206 305 206 207 110

50205

205 103 206 211

HR30-215 J 104

46102

60105

203

105 205 204 204

D7205

DB105

Name Single-row taper roller bearing Single thrust axial contact ball bearing Single row annular ball bearing ;/ // // II

II

Single row annular ball bearing with snap ring groove Single row annular ball bearing ;/ //

Single row taper Roller beraing Single row annular ball bearing Single row annular Contact bearing Single row annular ball bearing with shield Single row annular Ball bearing II

II

II

Single row taper roller bearing Single thrust Axial contact bearing

Specification

50x90x20

50x70x14

30x62x16

30x62x16 25x62x17 30x62x16 35x72x17 50x80x16

25x52x15

25x52x15 40x68x15 30x62x16 55x110x21 75x130x25

20x42x12

15x32x9

25x47x12

17x40x12

25x47x12 25x52x15 20x47x14

25x52x16

25x42x11

QTY.

2

2

2

Remark

GB297-84

GB301-84

GB276-89 // It

tf

II

It

If

If

If

If

tf

NSK

GB270-89

G292-83

GB278-89

GB276-89 II

II

II

GB297-84

GB301-84

21

Assembling part

Driving box

Shaper

Head of Driller &

miller

Feed mechanism

of miller

Shaft

I

II

III

XIV

XV

lie

lie

Ic

Handle 18

Model

46305

46306

110

46305

46306 46306

110

46306

46206

7307

7208

46109

D7206

D7208

7207

60103

60103

60202

Name

Single row annular contact bearing tr

Single row aimular Ball bearing

Single row annular Contact bearing ;/ /;

Single row annular ball bearing

Single row annular contact bearing //

Single row taper Roller bearing II

Single row annular contact bearing

Single row taper roller bearing //

II

Single row annular Ball bearing with shields

Single row annular ball bearing with shields

Single-row annular ball bearing with shields

Specification

25x62x17

30x72x19

50x80x16

25x62x17

30x72x19 30x72x19

50x80x16

30x72x19

30x62x16

35x80x21

40x80x18

45x75x16

30x62x17

40x80x20

35x72x18

17x35x10

17x35x10

15x35x11

QTY.

1

1

2

1

1 2

2

1

1

1

1

2

1

1

2

2

2

2

Remark

GB292-83

GB292-83

GB276-89

GB292-83

// //

GB276-89

GB292-83

//

GB297-84

II

GB292-83

GB297-84

II

GB278-89

GB278-89

GB278-89

22

AssembUng part

Table

Knee

Carriage

Shaft

Lead screw

Cross reed

handle 14

Socket Head Crank

24

Lead screw

of knee

Handle 10

Handle 9

Model

36204

204

8204

105

206

8102

8104

Name

Single-row annular contact bearing

Single-row annular ball bearing

Single thrust axial contact bearing

Single row annular ball bearing

//

Single row axial contact bearing

//

Specification

20x47x14

20x47x14

20x40x14

25x47x12

40x62x16

15x28x9

20x35x10

QTY.

2

1

2

2

1

2

2

Remark

GB292-83

GB276-89

GB301-84

GB276-89

GB276-89

GN301-84

GN301-84

8. Operating 8.1 Preparation and inspection

1) Lubricating all points indicated on Lubrication Points before operating. 2) Check if the handle is at its proper speed mode, and the other functions are in their

invalid state. 3) hen the machine running, the operator should not go away. 4) Don't put the tools, workpieces etc. on the guideway or movable parts. 5) Checkif the workpiece is tightened. 6) Check if the tool is tightened. 7 ) Before feeding the tool, release the braking device. 8) Operartion rules such as: wearing cap, glasses, not wearing gloves etc. should be

obeved. 9) After finishing the work, clean the maching, put all tools, attachments in the tool

box or the bottom of back column.

23

1 o) Tum off the power switch. 8.2 Machine operation

Figure 10 shows the locations of all handles, the machine should be stopped first. 8.2.1 Turning operation

1) Headstock By changing the positions of handle A,D,C, the spindle in the headstock can get 12 steps of steps of speed: Set handle C at its L mode, then change handle A, handle D to different positions, the spindle can obtain 6 steps of speed: 22.4, 31.5, 45, 63, 90, 125 r/min. If set handle C at its H mode, Change handle A, Handle D position, another six steps of speed can be realized:180,25f^,355,500, 710, 1000 r/min. When turning operation, the handle 1 should be set at its idle mode, stop the machine when do the machine when do the gear shift.

2) Feeding system This part consists of apron (including a change gear unit),saddle, slide and tool carrier etc. Its longitudinal feeding is controlled by handlewheel 8 which marked a scale of 0.25mm per measure, and when the handlewheel 8 turns a round, the saddle will have a 27.5mm travel. The cross feeding is realized by rotating the handle 9, which marked a scale of 0.1mm per measure, turn the handle 9 a round, the slide will move a travel of 20mm. When feeding manually, the handle 7 should be set at its neutral mode (marked position), the halfnut should be disengaged from the leadscrew by moving the knob 5 to its upposition, while by moving knob 6 to its downposition to disengaged the woim-gear. When power feeding, push the handle 7 onti-clockwise in(cross feeding) or pull it clockwise out(for Long, feeding) first, then turn up knob 6. After work, reset the knob 6 and handle 7 to their original positions in the reverse order. When turning thread, set handle 7 to its neutral mode(idle position), and turn knob 6 to its down-position, then engage the halfnut with leadscrew by turning down the knob 5. The interlock mechanism in the apron is equipped for ensuring the safty of the operator. Adjust the change-gear unit to the desired mode indicated on the table on the cover of feeding box according to the thread pitch(Metric or Imperial) or federate. Move knob 4 to -Pmode for bare bar turning, and to ^^ mode for thread direction selection. Handle 12 is to choose the thread's kinds. When turning the metric threads on metric lathe with different pitchs except 0.25, 0.3, 0.4, 0.5, 0.6, 0.75, 1.0,1.2, 1.5, 2, 3, 6rmTi pitches, it is necessary to mount a index dial indicator at the left side of the apron to avoid "thread missina" From

24

"ON" "OFF" button

Fig. 10 Operating handles and buttons diagram

the index indicating plate select a dial and worn gear with desired pitch and install. Then at the upper and lower part of the index dial indicator respectively. From the second threading onwards, the threading can be performed by moving down the knob 5 when the dial reading coincides with the mark line. When turning the inch scew threads on inch lathe with different threads except 32, 28, 24, 20, 16, 12, 8, 4, 2, it is also necessary to mount a index dial indicator at the left side of the apron to avoid "thread missing". When turning the meric thread on inch lathe and turning inch screw thr'^ ad on metric lathe, you can avoid missing thread by reversing machine, that means: retracting the tool to its initial position without moving up the halfnut knob 5 then go on turning processing.

3 ) Tailstock, steady rest, follower rest Tailstock, used for supporting the round workpiece by its center, is matched with the dovetail of the column. Its cross position can be adjusted by the adjusting screw to keep the center at a relative position to the center line of the spindle. For ordinary work, coincide the tailstock body and the base with mark line of the scale. When turning cone workpiece, have the center deviate from the center line of the spindle. During the process, oiling the center periodically to prevent it from overbake. As the support of the workpiece, the steady rest with some adjusting protrusive parts is fixed on the column while the follower rest as asupport can move with the slide.

4) Backlash adjustment of the spindle bearings. Proper backlash can keep the spindle good quality and prolong its working life. Figure 11 is the backlash adjustment of the spindle bearings. The sequence described as following: a. Remove the cover of the headstock. b. Seperate the overlap of the thrust ring 1 from the slot of nut2. c. Tighten nut 2 to decrease the backlash. d. Release the nut to increase the backlash. e. After adjustment, reset the overlap to its original position.

NOTE: This adjustment had been finished before the delivery. Adjustment is not permitted in general situation. Gib adjustment: Gib 3 is used for adjusting the backlash between compound rest and guideway (See Fig. 12a). Release screw 1 and tighten screw 2 to increase the backlash, and on the contrary, the backlash will be decreased.

26

The adjustment of the rise and fall worm's overload safety device: Worm bracket 1 makes the makes the worm be working, the safety device's power can be adjusted by screw 4 (See Fig. 12b). When the worm down by draw spring, which power can be adjusted by scew 3.

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Fig. 11 The adjustment of spindle bearings backlash

r S -

a. Adjustment of gib b. Adjustment of worm

Fig. 12

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8.2.2 Planing operating Before start the motor for planning process, turn knob B to the left to have safty interlock lock the knee to avoid the striking of the ram. Meanwhile, the gears connecting the shaping parts engages; the gears connecting the cutting, drilling and milling parts take apart to prevent their spindles form rotating, and vice verse. After planning, turn knob B to the right; recover safty interlock "Z"; insert click 1 to the slot of bar "2" (Fig. 13). Don't move knob B when the motor is running! By changing the position of knob A, you can get the different reciprocation frequency of the ram:25, 35 or 50 thnes/minute. The stroke of the ram is 275mm and it can be adjusted by square head shaft 13. Adjustment of stroke. Through the hole at the back side of the colunm, loosen the adjust nut l(See Fig. 13), then adjust the clamp 2. If move the clamp 2 backward, the stroke becomes forward, and vice verse. After finishing the adjustment, tighten the nut 1. The cross manual feed of the table is controlled by knob 14(See Fig.lO), and the longitudinal manual feed is controlled by knob 25, whose left side is positive and the right side is negative. Only under the condition of the planning process, can you use the power feed. The feed of the table is determined by knob 17, when drilling or milling process knob 25 should be at its neutral position, so no power feed presents. By rotating the handwheel 16, the feed of carrier can be realized, its travel is 50mm. To plan inclined surface, the carrier angle should be adjusted (from -20 to + 20). Tool is tightened on the arbor by screw 3(See Fig. 13) to avoid loose during the processing when install the tool or adjust travel of the ram, keep the earner not touch the column

8.2.3 Drilling and vertical milling Set knob 1 to the right side to present the drilling and milling processing. When drilling, the spindle feed is realized by turning knob 19; When vertical milling, push down the knob 19 first, then move around knob 18. The spindle speed is controlled by the knob D and knob A, and at the different position of knobs, can get different speed as following: 140, 280, 400, 560, 800r/min. Release screw at the left of the knee, tum knob 24 and put knob C at neutral position, you can obtain vertical feed of table.

8.2.4 Horizontal milling Set knob 1 to the left position for horizontal milling. The spindle speed is still controlled by knob D and knob A, and get the following speeds: 90, 125, 180, 250, 355, 500 r/min. The spindle is supported by a single row taper roller bearing 3 and a single row thrust ball bearing 4 at its front end, and a single row annular ball

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1-. ^-..I_

a. Location of safty interlock b. Adjustment of ram travel

Fig.l3

Fig. 14 The adjustment for backlash of the horizontal spindle bearings

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bearing 5 at its back end. When do the adjustment of the spindle, remove the cover 6, separate the overlap of thrust ring 2 from the nut slot 1, then adjust the nutl. After finish the adjustment, reset the overlap of the ring and the cover 6 in the reverse order NOTE: Handle C should be at the neutral position.

9. Maintenance 9.1 Before starting

1) Before starting the machine, clean all guideways and worked surfaces, then oil them.

2 ) Lubricating the points shown on the lubricating point, 3 )Tum all knobs or handles to see if they are in good condition. If not, remove them

as soon as possible. 4) Set all handles to the proper position, then idle ruing the machine for 5 minutes

to see if it is in nomial state. 5 ) Adjust the speed, feed and cutting depth as required, tighten the workpiece and

tool. 6) After finish the above preparations, you can start the machine.

9.2 Running 1) Operator cannot go away fi-om the machine while the machine is running. 2) Any work such as: replace workpieces and tools, adjust the speed or travel,

lubricate all surfaces, etc. should be done after stop the machine. 3) Any abnormal situations such as overheat of rotating part, abnormal noise etc.

occurred, stop the machine instantly. Don't restart it until remove all troubles. 4) Under no circumstance, can change the speed while the spindle is rotating. Don't

move the handle B while the motor is running. 5) Don't adjust the workpiece on centers or on guideway surface, or, it will damage

the machine and affect the processing accuracy. 6) Check if the tailstock or center sleeve is fixed or not when processing workpiece

between centers, oil them periodically. 7) The worn or damaged centers caimot be used. If the overheat or abnormal noise

happened to the center, stop the machine immediately. 9.3 After stop the machine

1) Turn off the main power switch, set speed change knob at the neutral position. 2) Clean all oil stains and dust, clean the external surface of the machine oil for

rust-proof if it will be used soon. 3) If the machine will be stored or used long period lather, brush it a coat of rust

resisting oil.

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10. Breakdown and reparation

No.

1

2

3

Breakdown

The external diamerter of cylinder which is cut, caused taper

At the finish cutting the external diameter the surface appears fixed ripple

After cutting, the cylinder's external diameter changed into elliptic or prismoidal and after finishing cutting, the end of the workpiece shakes is more than the tolerance. When use notch cutter notches, it cause vibration

Part and cause

Parallelism of the center line of headstock spindle to the shifting slideway of carriage exceed the tolerance limit.

Slideway of body gradient is more than tolerance limit or after assembled, it caued out of shape.

The two centers is caused taper by cutting material.

The bad of cutting edge's wear-resisting caused by cutting tool.

The headstock's temperature increased and caused hot deformation of machine tool.

There are some scar or tracks on the slideway.

Protrusion in surface of racks is not well connecting.

Large clearance at the bearings of spindle.

Wear and tear of spindle bearing.

Large clearance at the toward bearing of tlie spindle.

Run-out of the center line of the spindle is too large.

Reparation

Correct the center lione of headstock spindle

Correct the slideway of body with adjustable wedge iron.

Adjust the crosswise screw of the flank of tailstok.

Correct the cutting tool and select the suitable spindle speed and feed.

Reduce the temperature of oil and reoil periodically.

Repair the scars or tracks or clean the protrusions

Correct the racks carefully.

Adjust the clearance between bearings of spindle.

Grind the bearing and spindle, or change roller bearing.

Adjust the clearance for spindle's toward bearing.

Adjust run-out of spindle to minimum.

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No.

4

5

6

7

Breakdown

When finish cutting, there are ripples nonregular on the surface of cylinder.

Protrusion appeared in the end of finished workpiece.

After threading, the threaad pitch is not even and there are some ripples on the surface of thread.

The tighten lever of tool post be pushed, the small one can't be turn.

Part and cause

The channel of the spindle's roller bearing wear and tear.

Axial oscillation of spindle is too large.

When hold workpiece by tailstock, the center sleeve is not steady.

Parallelism of slideway of carriage to the center line of headstock spindle is tool large.

Squareness of up slideway to under slideway of the carriage exceed the tolerance limit.

The leading screw wear and tear or twisted.

Adjust the axle clearance for leading screw.

The tool post connected badly with the base plate of up tool post.

The basal plane of tool post is not smooth.

After holding the tool the tool post out of shape.

Reparation

Change the rcUci bearing.

Adjust clearance for spindle's toward thrust ball bearing.

Check if the holder and tailstock's center sleeve is suitable to axle-hole. If axle-hole large or causing loose and the holder lost function. At first, mend axle-hole's size select the center sellve.

Correct the center line of headstock spindle.

After overhaul, if the machine tool appears error, it must be scraped the surface of the low slide plane. If not overhaul, the machine tool appears error, it must be scraped up slide plane.

Repair the leading screw, change nut, adjust clearance for lead-screw and "open-close" nut.

Adjuust the axle clearance for leading screw.

Correct basal plane of tool post by scraping.

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No.

8

9

10

11

Breakdown

At finish cutting the external diameter, the surface appears ripple regularly.

When planning fineness of the workpiece is not good or ripple on the workpiece.

The temperature of the ram increase.

When cutting, the cutter tool is dropped.

Part and cause

Serious vibration of machine tool is caused by large amplitude from pulley and rotational parts, etc.

Vibration of machine tool is caused by the grounding of workshop.

Vibration caused between the tool and workpiece.

The moving direction of the ram is not parallel with the swing direction of rocker.

Large clearance between fixer plates.

Mesh of the big gear is not well.

Tool post is loose or contact is not well. Contact rigidity of wortable, knee, and the guideway of the knee is not well.

Backlash between the taper hole of folded plate and the pin is exceed.

The fixer plate is not good contact with guide surface of ram or the fixer plate pressed more tightly.

Fixed screw of the carriage is loosing.

Large clearance between leading screw and nut of tool post.

Reparation

Correct the amphtude of the pulley, rotational parts. Grind external diameter and belt triangular ditch If in case, the serious vibration of other machine should be moved away for a distance. Grind the cutting tool, correct the location of tool's edge and length of the arbor.

The rocker hole is not concentric with the up supporting bearing's hole Scrape the surface of the up supporting hp?si:-.g.

Scrape the surface of rocker, parallel to the hole of rocker, adjust the backlash of fixer plates.

Grind the big gear.

Scrape each part of tool post.

Adjust the contact rigidity of the three parts.

Ream and adjust the clearance of the taper hole of folded plate and the pin. Scrape the surface of the up supporting bearing, ensure that the up supporting bearing is concentric with the rocker, ensure that is parallel with the hole.

Change the fixed screw.

Change the nut according to leading screw.

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No.

12

13

14

15

16

17

Breakdown

When change the direction of the ram, it appears the sound of lash.

Bad in the cutting precision.

When the table moving crossly, the feed is not ever.

The folded plate is checked.

The spindle in the head can't be moved up and down lightly.

The crank of the worktable move heavily.

Part and cause

The rocker is not concentric with the up supporting bearing.

The hole of the rocker is not parallel with the surface. Large clearance in the each shafts and holes of the rocker and each moving surface. Large tolerance between the fixer plate and the ram, that caused the ram move toward, and the ram is bad contact to column.

Large backlash between the connecting rod's hole of the feed mechanism and shaft.

The ratchet and pawl are wear and tear.

The tapered pin of the folded plate is tightened with the taper hole.

The surface between the folded plate and its supporting is not vertical to the taper hole.

The spline of spindle is partly twist.

The external diameter of the spindle sleeve is out of the shape.

The feeding lead screw is not coaxial with nut.

Repar^ticn

Scrape the surface of the up supporting bearing. Scrape the surface of the rocker.

Mend the hole and change the shaft.

Adjust the fixer plate, mend and scrape the surface of the ram and fixer plate.

Mend the hole, inset the sleeve and change the shaft.

Mend and change the ratchet and pawl.

Adjust the tapered pin.

Ream the tapered hole once more and match the tapered pin.

Correct the twist part.

Correct the sleeve of spindle.

Adjust the clearance between the leading screw and nut.

34