/
Text
S M T С 1L
CAK50n SERIES
CAK61n SERIES
FTL50n SERIES
FTL61n SERIES
CNC LATHES
CNC LATHES
CNC LATHES
CNC LATHES
TABLE FOR CONTROL
PARAMETERS OF THE
MACHINE
CNC System: GSK980TDa
Serial No.:
SHENYANG NO.l LATHE WORKS
SHENYANG MACHINE TOOL CO., LTD
THE PEOPLE'S REPUBLIC OF CHINA
5On /6In SERIES
TABLE FOR CONTROL PARAMETERS OF THE MACHINE
Parameter of status
Prm. No. Prm. Value Remarks
00 J 00011000 Bit4 0/1 : Control of spindle speed switch amount/ control of simulation voltage Bit6 0/1 : Control of changing-frequency/servo of spindle
002 00100010
003 00110000
004 01000000 BitO 0/1 : Metric/Inch machine
005 00010001
006 00000000
007 10000000
008 00000011
009 00100011 Bit5 0/1 : High level/low level alarm of alarm signal of convertor
010 00000001
011 00010101 BitO 0/1 : Low level/high level valid of turret locking signal Bit 1 0/1 : High level/low level valid of turret signal Bit4 0/1 : Not measured/measured turret locking signal
012 10101011
013 00000000
014 00000011
164 11101000 BitO 0/1 : Invalid/valid of chuck control function Bitl 0/1 : Check/not check whether the chuck is clamped Bit2 0/1 : Invalid/valid of tailstock control function Bit3 0/1 : Invalid/valid of allowed signal of spindle rotating Bit7 0/1 : Invalid/valid of auto, changing-step function
168 11110011 BitO 0/1 : Control mode of extemal/intemal clamping of chuck Bit4 0/1 : Invalid/valid of pressure measuring function Bit5 0/1 : Alarm at high level/low level of pressure measuring signal Bit6 0/1 : Invalid/valid of protection door function Bit7 0/1 : protection door is closed when low level/high level of protection door switch
172 00000000 Bit7 0/1 : Hand unit is of no effecting/in effect
173 00000000 Bit5 0/1 : Not self-locked/self locked of rapid override button Bit6 0/1 : Protection door switch/ Protection door lock Bit7 0/1 : Invalid/valid of hydraulic function
174 00001000
175 01000000 Bit6 0/1 : Not check/check arrival signal of spindle speed before cutting
182 00000100 BitO,Bitl : For normal power-driven 4^6 station turret when it is set at 00 Bit2 0/1 : Not check/check turret position signal when changing tool is completed
184 00000000 BitO 0/1 : Display of Chinese/English
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5 On /61 n SERIES
TABLE FOR CONTROL PARAMETERS OF THE MACHINE
Data Parameter
Prm. No. Prm. Value Remarks
015 1
016 1
017 2
018 1
019 5
020 0
021 625 Compensation value of voltage offset for 10V of simulation output
022 4000 Max. moving speed for X-axis
023 8000 Max. moving speed for Z-axis
024 100
025 100
026 200
027 8000
028 500
029 100
030 10
031 0
032 400
033 200
034 4 Compensation rate of reversal clearance for X-axis
035 30 Compensation rate of reversal clearance for Z-axis
036 0 Compensation value of voltage offset for 0V of simulation output
037 240 Max. speed at step 1 of spindle
038 700 Max. speed at step 2 of spindle
039 2120 Max. speed at step 3 of spindle
Prm. No. Prm. Value Remarks
040 2120
041 100
042 10
043 100
044 115200 Baud rate of serial port communination
045 999999 Coordinate of soft limit for +X-axis
046 999999 Coordinate of soft limit for +Z-axis
047 -999999 Coordinate of soft limit for -X-axis
048 -999999 Coordinate of soft limit for -Z-axis
049 0
050 0
051 3500
052 500
053 1500
054 -2500
055 3
056 500
057 2
058 0
059 20
060 20
061 2
062 0
063 0
064 0
065 1
066 1
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50n /6In SERIES
TABLE FOR CONTROL PARAMETERS OF THE MACHINE
Prm. No. Prm. Value Remarks
067 250 Frequency voltage when changing step of spindle
068 200 Spindle rotating speed under manuai/wheel mode
069 0
070 1024 Wire no. of spindle encoder
071 32
072 0
073 0
074 0
075 2300
076 1000
077 0
078 15000
079 0
080 500
081 500
082 0
083 2000
084 4
085 2000
086 0
087 100
088 0
089 100,.
102 48000
103 80000
109 50
110 1
111 1
112 0
113 8000
119 5
140 9999 fc.
Note: Switch on the switch of setting system
parameter when setting the parameter and select
input mode.
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50n /6In SERIES
TABLE FOR CONTROL PARAMETERS OF THE MACHINE
Parameter for DT time
DC parameter table
Prm. No. Prm. Value Remarks
DT0019 3000 Checking time of alarm of low pressure of chuck
DT0020 3000 Checking time of alarm of low pressure of tailstock
DT0022 1000 Delay for starting changing step when changing step of spindle
DT0023 10000 Allowed time of changing step of spindle
DT0024 200 Delay time of power-off of YC1
DT0025 200 Delay time of power-off of YC2
DT0026 1000 Stop time of spindle delay after changing step of spindle
DT0028 10000 Control time of delayed closing protection door
DT0030 1000 Checking time of spindle stepless during auto, running
Prm. No. Prm. Value Remarks
DC020 5 Fluctuation revolution at zero speed
Servo parameter table
Prm. No. X-axis Z-axis
12 10 10
13 ft ft
Note: No 13 is leadscrew pitch of X-axis
and Z-axis.
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TABLE FOR CONTROL PARAMETERS OF THE MACHINE
Parameter of convertor SJ300:
Prm. Value Remarks
Prm. No. Before Delivery Setting Name Setting Scope
F002 30.00 4 Accelerating time 1 0.01-99.99
F003 30.00 4 Decelerating time 1 0.01-99.99
A001 1 1 Selection of frequency instruction 1: Terminal of control circuit
A002 1 1 Selection of running instruction 1: Terminal of control circuit
A003 50/60 33.3 Setting of fundamental frequency 30.00Hz-max. frequency
A 004 50 110 Setting of max. frequency 30.00Hz-400
A044 0 0 Characteristic curve 3: Vector control of non-speed sensor
A05] 00 00 Enable of DC braking 00: Invalid 01: Valid
A061 0 110 Setting of upper limit for frequency Start frequency-max. frequency
A062 0 0 Setting of lower limit for frequency Start frequency-max. frequency
A082 460 380 Voltage of motor Voltage grade: 400V
B012 Rated current 1.2 times of rated current of motor Electronic thermal protection-switch 0.20 rated current -1.2 rated current
B021 01 00 Operating mode of overload limit 0: Invalid 1: Valid while accelerating/ decelerating
B082 0.5 0.5 Start frequency 0.10-9.99
B083 5.0 5 Frequency of carrier wave 0.5-12.0KHz
B090 0 85 Use rate of braking resistor 0-100%
B095 0 2 Dynamic control of braking 00: Invalid 01: Used while running 02: Used while running or stop
C055 100 150 Checked standard I of over torque 0-200%
C008 1 1 Function selection of terminal 8 Reverse valid
C021 0 1 Function selection of terminal 11 Frequency arrival
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TABLE FOR CONTROL PARAMETERS OF THE MACHINE
Prm. No. Prm. Value Remarks
Before Delivery Setting Name Setting Scope
H005 1.59 10 Responding time of motor speed 8-15
Parameters of TOSHIBA Converter
Prm. No. Prm. Value Remarks
Delivery Setting
AU) 0 0 Automatic accelerating / decelerating
AD2 0 1 Automatic increase of torque
CNOD I 0 Selection for instruction mode
FNOD 2 1 Selection for setting mode of freq.
ACC 10 6.0 Time of accelerating
DEC 10 5.0 Time of decelerating
FH 80 110 Max. frequency
UL 80 110 Ppper limit frequency
LL 0 0 Lower limit frequency
uL 60 33.3 Basic frequency
Pt 0 3 Selection for V/F control mode
F204 no Frequency of VIA input point 2
F213 60 Frequency of VIB input point 2
F300 12 16.5 Frequency of carrier wave PWM
F304 0 1 Selection for electric braking
F306 200 220 Adjustment of output voltage
F308 75 15 Dynamic break resistance
F309 0.12 1 Dynamic break resistance capability
F710 0 1 Selection for display of standard monitor
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UK
S M T C IL
CAK50n SERIES
CAK50n SERIES
FTL50n SERIES
FTL61n SERIES
CNC LATHES
CNC LATHES
CNC LATHES
CNC LATHES
INSTRUCTION BOOK
(For Electrical Unit)
CNC System: GSKSSOTDa
SHENYANG NO.l LATHE WORKS
SHENYANG MACHINE TOOL CO., LTD
THE PEOPLE'S REPUBLIC OF CHINA
50n SERIES/61n SERIES
CONTENTS
CONTENTS
1 OVERVIEW OF ELECTRICAL SYSTEM.............................................3
1.1 Arrangement Diagram of Electrical Equipment...........................3
1.2 Table of Basic Performance of CNC System..............................4
1.3 List of Motors Used for the Machine...................................5
1.4 Operator's Panel of the Machine.......................................6
1.4.1 Table of Functions of Operation Keyboard........................7
1.4.2 Operating Panel of the Machine..................................8
1.5 Coordinate Axes and Setting of Coordinate System......................8
1.6 Code Table of G Commands...........................................11
1.7 Code Table of M Commands...........................................12
1.8 Code Table of T Commands...........................................12
2 FEEDING (POWER-ON) OF THE MACHINE........................................14
2.1 Major Technical Requirements of Electrical Unit of the Machine........14
2.2 Basic Requirements before Power-on of the Machines....................15
2.3 Check before Power-on of the Machines.................................15
2.4 Power-on of the Machine...............................................15
2.5 Power-on of CNC System................................................16
3 BASIC OPERATION OF THE MACHINES..........................................17
3.1 Selection of Operation Mode..........................................17
3.1.1 Edit Mode......................................................17
3.1.2Manual Data Input (MDI) Mode.....................................17
3.1.3 Auto Operation Mode............................................18
3.1.4Manual Operation Mode...........................................19
3.1.5 Mode of Reference Point Return.................................22
3.2 Cycle Start and Feed Hold............................................23
3.3 Operation of Trial-run (Dry Run).....................................23
3.4 Lock Operation of the Machine........................................24
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50n SERIES/61n SERIES
CONTENTS
3.5 Operation of Auxiliary Locking of Machine..............................24
3.6 Operation of Single Segment............................................24
3.7 Operation of Lubricating Guideways of the Machine.......................24
3.8 Limitation and Release of Overtravel of the Machine.....................25
3.8.1 Limitation of Store Travellimit (Software Limitation)............25
3.8.2 Hard Limitation Switch (Hardware Limitation).....................25
3.9 E-stop Operation.......................................................25
3.10 Door Lock..............................................................26
4 HYDRAULIC SYSTEM (OPTIONAL).................................................27
4.1 Start of Hydraulic System..............................................27
4.2 Operation of Hydraulic Chuck...........................................27
4.3 Operation of Hydraulic tailstock.......................................27
5 OPERATING FLOW DIAGRAM AND USER’S PARAMETERS................................28
5.1 Operating Flow Diagram.................................................28
5.2 User s Parameters......................................................29
6 ELECTRICAL MAINTENANCE AND ADJUSTMENT.......................................30
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50n SERIES/61n SERIES
INSTRUCTION OF PRODUCT TYPES
This is the instruction of product types mentioned in this «OPERATION MANUAL)) :
FTL 50n series include: FTL5060ni, FTL5085ni, FTL50135ni, FTL50186ni, FTL5085nj,
FTL50135nj, FTL50186nj
FTL61n series include: FTL6160ni, FTL6185ni, FTL61135ni, FTL61186ni, FTL6185nj,
FTL61135nj, FTL61186nj
CAK50n series include: CAK5060ni, CAK5085ni, CAK50135ni, CAK50186ni, CAK5085nj,
CAK50135nj, CAK50186nj
САК61П series include: CAK6160ni, CAK6185ni, CAK61135ni, CAK61186ni, CAK6185nj,
CAK61135nj, CAK61186nj
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50n SERIES/61n SERIES
OVERVIEW OF ELECTRICAL SYSTEM
1 OVERVIEW OF ELECTRICAL SYSTEM
1.1 Arrangement Diagram of Electrical Equipment
— Operator’s panel of the machine
CNC System Spindle encoder
Zero-point return and overtravel switch
AC /DC control board Clutch for changing speed of spindle
Electronic brake for spindle
Lubricating device for guideways
Hydraulic solenoid valve
Illuminating device
Spindle motor (universal)
. Motor for turret indexing
Motor for cooling pump
Motor for lubricating pump of headstock
\ Hydraulic motor
Servo driving unit Servomotor for X-axis
—
Servomotor for Z-axis
Speed-regulating unit for spindle Spindle motor
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50n SERIES/61n SERIES
OVERVIEW OF ELECTRICAL SYSTEM
1.2 Table of Basic Performance of CNC System
Main Performance Target
CNC system GSK980TDa
Min. command unit 0.001mm
Max. programming size 9999.999mm
Capacity of workpiece program 80m
Absolute/lncremental program X, z/u,w
Linear/Circular interpolation •
Metric thread •
Chamfering at the end of threads •
Canned cycle •
Combination cycle •
Subprogram call •
Conversion of Metric and Inch •
Tool compensation •
Tool tip radius compensation •
Feed/rev., feed/min. •
Control of constant linear speed
Clearance compensation •
Compensation of pitch error •
Parallel shift of work coordinate •
Return reference point •
Protection of software over-travel •
RS232C Communication
Feed drive device ST series AC servo motor
Stepless adjusting speed for spindle ★ available
Display device LCD 320x240
: Basic function ★: Optional function
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OVERVIEW OF ELECTRICAL SYSTEM
1.3 List of Motors Used for the Machine
No. Name Specification Remarks
1 Spindle motor YD132M-2/4, 6.5kW/8kW 1450r/2800r/min Available for step speed change
Spindle motor YL160M-4 7.5kW 1500r/min
2 4-station motor for turret indexing YLJ-1-4 INm 1500r/min
6-station motor for turret indexing YLJ-3-6 3Nm lOOOr/min
3 Motor for lubricating headstock AO-5624 120W 2800r /min
4 Motor for cooling pump AOB-25 90W 2800г/min Optional
5 Hydraulic motor Y90L-6 1.1 kw lOOOr/min
6 Servo motor for X-axis 130SJT-M050D 1.3kW 5NM 2500R/MIN
7 Servo motor for Z-axis 13OSJT-MO75D 1.88kW 7.5NM 2500R/MIN Available for 600/850
8 Servo motor for Z-axis 130SJT-M150B 2.3kW 15NM 1500R/MIN Available for 1350/1860
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OVERVIEW OF ELECTRICAL SYSTEM
1.4 Operator's Panel of the Machine
(2)
(1) Display and keyboard of CNC device
(2) Operator’s panel of the machine
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OVERVIEW OF ELECTRICAL SYSTEM
1.4.1 Table of Functions of Operation Keyboard
No. Symbol Name
1 ft- ч _L> Edit mode
2 'Ф V- I Auto, mode
3 mx MD1 data input
4 Mode of return reference point
5 Handwheel mode
6 1 X ? Manual feed mode
7 V / Mode of returning zero of program
8 Ф — < !> Single segment mode
9 MIS Mode of program skip
10 ft" T—к V. J Locking mode of machine
11 MSI •> am, Locking mode of auxiliary function
12 ф- Dry run mode
13 Гф O> Mode of optional stop of program
14 fb _П_ xi гцъ FQ Selection key of hand wheel increment and rapid override
15 J~~|_ X1O /VL 25% Selection key of handwheel increment and rapid override
16 • ф- _TL xioo 'VL 50% Selection key of handwheel increment and rapid override
17 J Lxiooo ПАЛ 00% I Selection key of hand wheel increment and rapid override
18 t 1№П Open of protection door
19 ft- О
20 > z> V . .. On/off of machine lubricating
No. Symbol Name
21 Ah 4^ Coolant on/off
22 (t) On/off of spindle jogging state
23 'I О Manual tool selection
24 I OX J -Jogging of X-axis
25 Щ I > + Jogging of X-axis
26 s Manual rapid speed
27 ft- <Xi -Jogging of Z-axis
28 EZ^> + Jogging of Z-axis
29 'i Manual spindle reverse
30 ft Q ' Manual spindle stop
31 ф"* Manual spindle forward
32 Increase of spindle override selection
33 ft/—x ' ,±^№00^ 100% of spindle override selection
34 • ф- Decrease of spindle override selection
35 ft Wv% + Increase of feed rate override selection
36 VW! 00% 100% of feed rate override selection
37 ft- VA% - Decrease of feed rate override selection
38 L Clamping/releasing of chuck
39 Advancing/withdrawing of tailstock
40 *"(£) Start/stop of hydraulic motor
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OVERVIEW OF ELECTRICAL SYSTEM
1.4.2 Operating Panel of the Machine
No. Symbol Name No. Symbol Name
41 1 Power-on of CNC system 47 ? • Overtravel release button
42 Power-off of CNC system 48 E-stop button
43 Cycle start button 49 N, Handwheel pulse generator
44 Feed hold button
1.5 Coordinate Axes and Setting of Coordinate System
The machine has two feed axes and adopts transmitting structure for AC servomotor to
drive ball leadscrew to obtain plane continuous path movement.
Longitudinal feed axis is in parallel with spindle and it is called Z-axis (feed), and the
direction pointing at tailstock is positive direction.
Traverse feed axis is perpendicular with X-axis and it is called X-axis (feed), direction of
away from workpiece is positive direction.
In order to describe moving position and moving path of tool tip, first, it is necessary to
establish a coordinate system on a certain point on workpiece which is chucked on the
machine, then, edit program for the workpiece to be turned according to certain rules and
on the basis of some points of tool movement path. The two axes of workpiece
coordinate system are separately parallel with two feed axes of the machine. The axis
parallel with longitudinal feed axis is called Z (coordinate) axis, and that parallel with
traverse axis is called X (coordinate) axis. Direction of coordinate axis is always in
keeping with that of feed axis. Point coordinate (X, Z) is referred to as absolute
coordinate.Using absolute coordinate to program is called absolute programming. To use
absolute programming, first, it is necessary to set coordinate system, that is, set the
origin of coordinate system to a specified position. In normal case, Z-axis is set on the
rotary center of spindle and X-axis is set to position on chuck endface, workpiece
endface,etc.
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OVERVIEW OF ELECTRICAL SYSTEM
Point S shown in the right figure on last page is an original position for turning.
Coordinate value set by G50 is the coordinate value of the point S. Point R is reference
point of the machine.
Programming mode of not using absolute coordinate and displacement amount of using
new position to present position is called incremental programming. In general, there are
two methods to obtain incremental programming. The standard method of the machine is
(U, W) address mode.
For this machine, both the absolute programming and the incremental programming can
be used, and combination programming is also used. Diameter programming is used in
the direction of X-axis of the machine, therefore, programmed value X (U) is two times
of practical coordinate value, coordinate value of X-axis displayed on screen is also two
times of practical value, but movement amount of tool is only half of programmed value.
Direction commanded by circular interpolation G02, G03 is shown by the above figure.
Setting method No. 1 of coordinate system:
If the value Xr and Zr are separately input in Prm49 and Prm50, the system will establish
a coordinate system automatically after returning reference point manually or
automatically. And the coordinate value of reference point “r” under this coordinate
system is (Xr, Zr). At the same time, the position display immediately displays absolute
coordinate as (Xr, Zr).
After a workpiece is chucked on the machine, if you want to take some point “O” on the
workpiece as origin of coordinate system, you can measure the distance from the point
“O” to the reference point “r”, then input the value into Prm49 and Prm50, and then the
coordinate system can be established automatically after reference point return.
Setting the distance from the point “O” to the reference point “r” can be obtained by
means of trial cutting, and the specific method is as follows:
1) Set Prm49 and Prm50 separately as 0, and then return reference point to make the
display of absolute coordinate be zero.
2) Manually move the carriage of the machine to the position which is close to the
workpiece to cut endface, and then move away from the workpiece along X-axis
direction. Record the displayed value of Z-axis absolute coordinate.
3) Manually cut outer diameter, and then move away from the workpiece along Z-axis
direction. Record the displayed value of X-axis absolute coordinate and the
measured value “d” of the O.D.
4) Input | X | + d into Prm49 and | Z | +L into Prm50.
Return to the reference point again, and the input values of Prm49 and Prm50 will be
separately displayed as the absolute coordinate, and at this moment, the coordinate
system taking point W as the origin will be automatically established.
After the coordinate system has be established by the means described, it is not
necessary to set the coordinate system by Command G50. As long as no power-off or
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50n SERIES/61n SERIES
OVERVIEW OF ELECTRICAL SYSTEM
trouble, anywhere the carriage moved to is in accordance with the positions displayed by
absolute coordinate. Therefore, as long as no interference, it is able to start the
machining program wherever the carriage is.
If coordinate system has been set again after it has been automatically set by means of
return of reference point, the priority will be given to the coordinate system by
Command G50.
Setting method No. 2 of mechanical coordinate system:
Edit command G50 in program.
Format: G50 X a Z Y .
Select reference tool (E.g. J#)
Move the tool 1 # to nearby workpiece manually to cut endface of workpiece, then move
it away from the workpiece along X-axis direction. Reset (clear) the position coordinate
W.
Turn O.D. of workpiece manually. Then, move the tool away from the workpiece along
Z-axis direction. Reset the position coordinate U and measure value D of 0. D. of
workpiece.
Move the carriage manually until U= a -D, W= y -L are displayed. (“L” is a distance
from coordinate's origin to trial-tuming endface of workpiece.)
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50n SERIES/61n SERIES
OVERVIEW OF ELECTRICAL SYSTEM
1.6 Code Table of G Commands
[Code Group Function Remark
Fboo 01 Positioning of rapid travel
G01 Linear interpolation
G02 Circular interpolation (CW)
G03 Circular interpolation (CCW)
G04 00 Dwell
G28 Reference point return
G32 01 Thread cutting
G50 00 Coordinate system setting/setting of spindle speed limitation
G65 00 Macro-program command
G70 00 Finishing cycle
G71 Roughing cycle of external cylinder surface
G72 Cycle of roughing end face
G73 Canned turning cycle
G74 Cycle of drilling deep-hole on end-face
G75 Grooving cycle of on OD, I D.
G76 Combination cycle for cutting thread
G90 01 Canned cycle for traverse cutting
G92 Canned cycle for cutting threads
G94 Canned cycle for cutting end-face
G96 02 Constant linear speed control
G97 Cancel of constant linear speed
FG98 05 Feed/min.
G99 Feed/rev.
G codes in Group 00 are non-model and they are only effective for the segments in which
they are specified.
Codes in a few different groups can be specified in the same block. The last code is valid if
codes in many different groups are specified.
The system is under this G code state when symbol“F” shows switch-on.
Under the control of constant linear speed, the max. speed of spindle can be set by Command
G50.
Whether it is in clockwise or counterclockwise for G02 and G 03, it is dependent on
direction of the coordinate system.
It is only allowed to use code M, S and T after the command G90, G92, G93 and G94 are
relieved by G codes except G04 and G65.
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OVERVIEW OF ELECTRICAL SYSTEM
1.7 Code Table of M Commands
Code Function Remarks
MOO Unconditional stop of program
M03 Spindle forward
M04 Spindle reverse
M05 Spindle stop
M08 Coolant ON
M09 Coolant OFF
M30 End of program and return to program beginning
M32 Lubricating ON
M33 Lubricating OFF
M41 Spindle step I
M42 Spindle step II
M43 Spindle step III
M44 Spindle step IV
MIO
Ml 1
M12
M13
M98 Subprogram call
M99 Subprogram return
1.8 Code Table of T Commands
T commands are comprehensive commands of tool selection and tool compensation, and
they consist of T+4 digits.
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OVERVIEW OF ELECTRICAL SYSTEM
Format: ТААФ*
▲ Tool No., from 01 to max. tool number of turret which shall not be exceeded.
• Unit No. of tool compensation, from 01 to 32 can be specified. 00 can be specified
to present cancel of tool compensation. Tool No. and tool compensation No. can be
freely combined. Each tool can use tool compensation unit of many groups.
Code Function Remarks
TO 100 Selection of tool No.l
T0200 Selection of tool No.2
T0300 Selection of tool No.3
T0400 Selection of tool No.4
T0500 Selection of tool No. 5 Available for 6-station turret
T0600 Selection of tool No.6
T0700 Selection of tool No.7 Available for 8-station turret
T0800 Selection of tool No. 8
For example, No.2 tool is selected and ready for using tool compensation unit of Group 3
to compensate No.2 tool, it is necessary to edit statement T0203 at proper position of
program.
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FEEDING (POWER-ON) OF THE MACHINE
2 FEEDING (POWER-ON) OF THE MACHINE
2.1 Major Technical Requirements of Electrical Unit of the Machine
No. Name of Equipment Specification Remarks
1 General power of the machine FTL50N/61N Series
15kW
2 General current of the machine Power supply of 380V 40A For more than 380V the electrified wire netting is the same as that of 380V
Power supply of 220V 60A
3 General fuse of user's power supply Power supply of 380V 50A For more than 380V the electrified wire netting is the same as that of 380V
Power supply of 220V 70A
4 Wire system 3-phase 4-wire
5 Voltage of electrified wire netting Basic 3-phase; 380V Optional voltage 20v/420v/440v/460v
6 Allowed fluctuating range of voltage of electrified wire netting Voltage: steady-state voltage is 0.9 — 1.1 times of rated voltage (continuous running)
Frequency: steady-state frequency is 0.9 — 1.1 times of rated frequency (continuous running)
7 Harmonious wave Summation of distortion harmonic wave for 2-5 times do not exceed 10% of mean square root of line voltage Summation of distortion harmonic wave for 6-30 times do not exceed 2% of mean square root of line voltage
8 Unbalanced voltage Constituent of negative sequence and zero sequence do not exceed 2% of constituent of positive sequence of 3-phase power supply voltage.
9 Voltage interruption Duration of power supply intermittent or zero voltage do not exceed 3MS, interval of phase sequence is over 1S.
10 t Voltage drop Voltage drop shall not be more than 20% of peak voltage of one period and dropping interval time of phase distance should be more than IS.
11 Frequency of electrified wire netting 50Hz 60Hz available
12 Allowed fluctuating range of frequency of electrified wire netting ±1%
Temperature of working environment 0°C~45°C
13 Relative humidity Less than 75%
14 Vibration (when operating) 0.5G F
15 Control i voltage xc AC U0V/190VA
DC DC 24V/6.5A
16 Illuminating voltage/capacity AC 220V/30W
17 Voltage and capacity of CNC system AC 200V/400VA
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FEEDING (POWER-ON) OF THE MACHINE
18 Voltage and capacity of servo amplifier AC 200V/2.2kVA
2.2 Basic Requirements before Power-on of the Machines
Feeding (power-on) of electrical system of the machine must employ 3-phase, 4-wire (3
phase wires and 1 PE wire) AC power supply. Section of feeder shall not be less than the
recommended, and the end must be connected pressing] у and firmly by cold pressing
terminal whose capacity is specified.
The special earthing bolt set on the bed body of the machine must be connected firmly
and reliably with earthing wire.
Welding machine, high frequency equipment, etc. are not allowed to be connected
nearby the machine.
2.3 Check before Power-on of the Machines
First switch-on:
It is necessary to confirm if the power supply of feeding of the machine conforms with
requirements of “section 2.1” and “section 2.2”.
It is necessary to confirm if protection ground wire is connected with earth bolt, firmly
and reliably, specified by the machine. And earthing resistor shall be less than 100 Q.
Check whether any of contactors, relays and connectors on the AC board and the DC
board is loose or flick off.
Check whether any of modules, insertion connectors of CNC system is loose or flick off.
Check whether the breakers on the AC distribution board in the electrical cabinet are all
closed.
Check whether any of electrical devices, cables and control pendant are loose, flick away
or damaged.
Check whether the belt cover door is well closed otherwise, the breaker QFO of the
genera] power supply of the machine cannot be well closed.
2.4 Power-on of the Machine
The machine has been provided with feeding conditions after al) checking jobs
mentioned above are completed and are confirmed no trouble. Feeding procedures are as
follows:
Switch on the breaker of general power supply. After the motor for headstock lubricating
pump of headstock starts, the working lamp lights on.
It is necessary to confirm the phase sequence of the power supply at the first time
feeding, wrong sequence of the power supply may result in a series of troubles which
should not occur, for example, turret does not index, cooling pump does not pump water,
headstock is not lubricated, hydraulic system has no pressure, etc. , even component(s)
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FEEDING (POWER-ON) OF THE MACHINE
may be damaged.
Simple method to judge the phase order:
Observe whether in the oil window on the front of headstock lubricating oil flows on. If
there is oil flow, it shows the phase order is correct, if there is no oil flow and the
lubricating motor runs on normally, it shows the phase order is often not correct in the
first time feeding. In this case you should switch off user’s switch of power supply
(Attention: Not the general switch of the machine) Correcting method is to change
positions of two phases at the terminal of leading wires of external power supply.
2.5 Power-on of CNC System
Press the NC start key on the Operator's Panel of the machine, a few seconds later, the
screen will be lighting and display concerned positions and command information; the
display of tool No. and the display of step position will be alternatively displaying,
Wherever as long as the button for power-off NC is pressed, the system will
immediately be power-off.
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BASIC OPERATION OF THE MACHINES
3 BASIC OPERATION OF THE MACHINES
3.1
Selection of Operation Mode
Six keys shown in above figure are selection keys of operation mode and they are used to
select six operation modes of the machine, in any case, only one mode can be selected.
3.1.1
Edit Mode
This mode is an operation mode to input, modify, cancel, inquiry and call turning
program of workpiece. Switch on the switch of program protection before inputting,
modification, cancel of work turning program. In this mode, work program does not
run.
For the operating procedures in detail of edit mode, refer to the «GSK980TD
OPERATION MANUAL» , please.
3.1.2
Manual Data Input (MDI) Mode
Under this mode, entry the segment of program by the keyboard of CNC system, then,
press the cycle start key to execute it. In general case, this mode is used to execute
operation of simple test. Please refer to the «GSK980TD OPERATION MANUAL» .
Operating steps are as follows:
(D Press ]g> key, coming into login mode of MDI operation mode (input mode).
(2) Press «PROGRAM» key on the CNC keyboard.
® Press «PAGE TURNING» key, displaying page with segment value on the left upper
on screen.
(4) Press the «IN» key through word character keyboard of CNC, displaying input
command words on the right half part of screen.
(5) Press the Cycle Start key В after all command words are input, the indicating
lamp of this key will light on. Programs come into executing status. The indicating
lamp goes out after the programs are completely executed.
(6) If it is required to execute the same segment of a program, it is required to input the
segment command again. In addition, for once, only once segment can be
executed.
(7) If displacement command is included in the program being executed, it is required
to execute the operation of return of reference point at first.
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3.1.3 Auto Operation Mode
Auto, operation mode is a mode which controls the machine to perform continuous and
automatic turning according to commands of programs.
This operation mode is also referred as stored program operation mode because the
programs executed by automatic operation (that is, work programs) are stored in the
storage of CNC system before cycle start.
It is necessary to measure compensation value of each tool accurately by help of correct
correcting tool method before starting automatic operation cycle, and then, set the
measured compensation value in tool compensation unit which is specified by program.
It is necessary to move the turret exactly to the original position specified by workpiece
program before starting automatic operation cycle.
If returning reference point operation is correctly executed before starting automatic
operation cycle (the lamp for reference point is not flashing), it is recommended that
operator record the machine coordinate at turning start point, this is very useful to deal
with possible emergency of sudden dump, tool insert damaged and rapidly back to
turning.
1. Basic operating procedures are as follows:
(1) Press f ] key to select Auto, operation mode
(2) Select program to be executed
(3) Press the Cycle Start key Я|, automatic turning cycle starts.
(4) After programs are executea completely, the indicating lamp of cycle start key
goes out, turning cycle ends, programs return to the beginning to prepare next
execution.
Automatic running of programs may stop under following cases:
(1) Executing command M30; (normal stop)
(2) Reset key on the CNC keys board is pressed;
(3) Emergency stop button has been pressed;
(4) Wrong alarm of program;
(5) Servo alarms.
Automatic running of programs maicdwell under following cases:
(1) The key of Feed Dwell key has been pressed, the indicating lamp of the
feed dwell key I lights on and the spindle keep the original state. In this time, as
long as the Cycle Start key is pressed, program recovers to automatic running.
(2) Operation mode is out of automatic operation mode. In this case, the machine
returns to automatic operation mode as soon as press the key of automatic operation
mode, then, press the Cycle Start key ЙЦ , program recovers to automatic running
immediately.
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(3) Program executed command MOO; Press the Cycle Start key
to automatic running immediately.
, program recovers
(4) Single-segment switch has been switched on. Press the Cycle Start кеуИИ ,
program runs continuously, but, only one segment is executed by pressing the Cycle
Start key as long as single-segment switch is not switched off.
3.1.4
Manual Operation Modi
Press the key fe) ], with the indicating lamp of this key lights on, the machine comes
into manual operation mode. Under this operation mode, all the operations of manual
functions as follows can all be executed.
3.1.4.1
Jog and Jog Rate of X-axis and Z-axis l_T
Ш 4
'<F. ~
Wv% -
wmoo%
Pressing ! 3 key, the carriage is moving to negative direction of X-axis, releasing
the key, the carriage stops moving.
key, the carriage is moving to positive direction of X-axis, releasing
Pressing! В
the key, the carriage stops moving.
fF
Pressing key, the carriage is moving to negative direction of Z-axis, releasing
the key, the carriage stops moving,
f------------
Pressing I key, the carriage is moving to positive direction of Z-axis, releasing the
key, the carriage stops moving.
Moving rate of feed axis is determined by pressing the up/down key of feed override
. The corresponding feedrate override is 0%-150%, the
the « GSK980Tda
*—
VAX -
switch w +
asftf a _______ ____
corresponding feedrate is l-1260r/min. Please refer to
Wvl00%
OPERATION MANUAL)) for details.
'
Ж
3.1.4.2
Rapid Jog and Rapid Override
JX X1
'VU FO
V_____
fF"—
JL xio
vu 25%
'
П X100
чтс 50%^
fEZ
J Lxiooo
44,100%
While the jog key of a certain direction and rapid override key are being pressed
together at the same time, the indicating lamp above the corresponding key lights on,
the feeding axis will move rapidly. Release the rapid selecting key, the indicating
lamp of the key goes out, and the movement of feeding shaft recovers to jog speed.
Rapid moving rate = rapid-override xrapid moving rate set by Prm022, 023.
There are four kinds of selections of rapid override: F0%, 25%, 50% and 100%,
which are selected by up and down selection key of rapid feed override selection
----
Л..М0
fr I
%% FO
\----J
key
Лхюо
ЧА50Х
V_____
J~l WOO
nJblOQgj
Rapid override is also effective for rapid instruction of programs (GOO, G28 and
rapid-movement segment of canned cycle). In addition, it is also valid for rapid
travel of manual return reference point.
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3.1.43
FWD, REV, Stop and Jog of Spindle
Select required changing-speed step and speed class of spindle by means of
changing-speed handle on headstock of the machine and speed-up or speed-down key
on the operator’s panel and according to Change-speed Chart of the Spindle.
Press the Spindle FWD key
Press the Spindle REV key
Press the Spindle Stop key *0
, the spindle will forward.
, the spindle will reverse.
, the spindle will stops rotating.
the key is released.
Keep pressing the key
, the spindle will forward, and the spindle will stop until
Every time when the spindle executes the operation of stop running, the time set for
spindle stop command to spindle braking command is set by parameter 087 and 088,
and the time for spindle braking output (braking time) will be determined by 089 and
090. if necessary, the user can adjust the time properly.
Under Auto mode or MDI mode:
After command (M03 ) of spindle forward is executed, the spindle will forward.
After command (M04) of spindle reverse is executed, the spindle will reverse.
If spindle stop command (M05) is executed, the spindle will stops rotating.
Do not starting Spindle at neutral step!
It is necessary to close the protection door well before start of spindle!
Do not start spindle at high speed in case of workpiece is not clamped for the
machine equipped with non-hydraulic chuck!
3.1.4.4
ON/OFF of Coolant
Press the “ON/OFF of coolant” key , the cooling pump will be powered on to
work. Open the cock of coolant, coolant is gushing. If press the key again, the cooling
pump is off and coolant stops gushing.
Under Auto. Mode or MDI mode, with the Command M08 is executed, it is able to
start the coolant, and with the Command M09, it is able to stop the coolant.
3.1.4.5
Manual Tool Selection
Pressing the Manual Tool Section ke>
, turret is automatically released, then,
it is counterclockwise indexing and searches required tool station by contactless
switch. After the Tool Selection key is released, the turret counter leans against the
seat automatically, then, it is locked on the adjacent position of low digits. The current
tool station number TXXXX will be displayed at the right lower comer of the display.
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Lightly press the Tool Selection key can realize pressing one time to select one tool
station.
Keep pressing the Tool Selection key, and do not release it until the turret index over
the required tool station, and in this way, it is able to select any tool station by
pressing the key once.
Insufficient delay of turret locking can affect locking rigidity of turret, but
overlong delay of turret locking can make the turret motor overheat, resulting in
damage. Delay time of turret locking is set by parameter 085 that has been well set
before delivery, and it should not be changed at will. If you find that locking of turret
is not enough and affecting machining accuracy, properly increase the setting value
for the time is allowed. Pay attention to temperature of turret motor when increasing
the value. Record the time data in the Parameter Table after adjustment.
Manual tool setting
1) Select a reference tool (for example, select tool 1#).
2) Move the tool 1 # close to the workpiece, cut endface and then move away from the
workpiece along X-axis direction, and then reset position coordinate W.
3) Cut outer diameter manually, and move away from the workpiece along Z-axis
direction, and then reset the position coordinate U.
4) Move the turret within the safety area to change for the second tool.
5) Make the tool tip of the second tool pointing at the endface, and then press key Z,
inputting Z-axis coordinate value, and the press the key IN.
6) Make the tool tip of the second tool pointing at the outer diameter, and then press
the key X, inputting X-axis coordinate value, and then press the key IN. Until now,
the tool compensation for the second tool will be automatically input as tool
compensation 2# UNIT.
7) Repeat the above process from 4) to 6) for other tools, completing the input of tool
compensation for all tools.
3.1.4.6 Feed Mode of Handwheel PulseFeed
й x
Press the key ® , with the indicating lamp of the key lighting, the machine will be
under feed mode of handwheel pulse generator. Operator can turn the handwheel of
handwheel pulse generator to make turret moving in directions of all sides (forwards,
backwards, left and right). Its speed can be adjusted at will. It is very available for
tool-setting operation in short distance, etc.
Operating procedures are as follows:_______
1. Select handwheel pulse overrit^o. ooi^
2. Handwheel pulse overrides have four: 0.001/0.01/0.1/lmm. You can select any
kind of them according to rapid, slow, finishing and roughing. The indicating
lamp of selected override lights on, thus, equivalent value per scale on the
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BASIC OPERATION OF THE MACHINES
handwheel can be determined.
3.
4.
r Z '•
Select the handwheel feed axis. Press the key ^,x
, it is able to select Z-axis.
, it is able to select X-axis, and
^z
Select any speed by means of feed override switch.
5. Turn the handwheel clockwise or counterclockwise.
Manual feed mode can execute manual spindle change speed, manual spindle start
and stop, manual coolant ON and OFF, manual tool selection.
3.1.5
Mode of Reference Point Return
Press the key , •>&-
return.
the machine will be under the operation mode of reference point
It is available for the operator to separately carry out the operation of reference point
return for X-axis and Z-axis by means of pressing the key $ 1Ф .At this moment,
the indicating light corresponding to the figure key will be on. After the operation of
reference point return has been completed for each axis, the coordinate system taking
the reference point as the origin will be established. And until now, the software
overtravel protection and pitch compensation can be only valid.
Specific operation steps are as follows:
2.
First, check if the carriage is presently in front of retarding stop block for reference
point return. If not, switch to the manual mode at first, to manually move the
carriage to be in front of the stop block for reference point return.
to switch to the mode of reference point return.
Press the key .
V__ ____
Keep pressing the key и , and don’t release the key until X-axis has moved into
retarding. And after a period, the indicating light above the figure key
corresponding to the key for reference point return for X-axis will be on, and
unit now, X-axis stops moving, and the operation of reference point return for
X-axis is completed.
Keep pressing the key I □>
will be on.
and don’t release the key until Z-axis has moved into
retarding. And after a period, the indicating light above „The figure key
corresponding to the key for reference point return for Z-axis
and unit now, Z-axis stops moving, and the operation of reference point return for
Z-axis is completed.
5. After the operation of reference point return for each axis has been completed, the
coordinate system taking the reference point as the origin will be automatically
established. And until now, the software overtravel protection and pitch
compensation can only be valid. If the coordinate value (XO, ZO) has been input
into Prm049 and Prm050, the coordinate system of workpiece machining which
takes reference point (-X0, -ZO) as origin will be established. All the workpiece
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BASIC OPERATION OF THE MACHINES
programs can be programmed relatively to this coordinate system, and it is not
needed to use command G50. However, if the command has been used in
establishment of coordinate system, the coordinate system established by Command
G50 will be valid. For the requirement of whether the coordinate system will be
automatically set after operation of reference point return, it is set by the user in the
Prm012.7. For details, refer to the List of parameters.
As long as the CNC system is required to restart after power off, the operation of
reference point return must be executed. The operation of reference point return can
be completed by Command G28 under Auto mode or MDI mode.
3.2
Cycle Start and Feed Hold
J
ilW
,^a| : Both Auto mode and MDI mode are used to start execution of the program. And
during the program being performed, the indicating lamp on the left-upper comer of the
key lights on.
injuring program being performed under Auto mode or MDI mode, press the Feed hold
key, the program being executed will be held. Whatever case, press the Cycle Start key
again, the program will be executed continuously.
3.3
Operation of Trial-run
(Dry Run)
Trial-run is also referred as dry run, it is a operation which is to test, check the newly
input programs of turning workpiece under non-turning condition. In order to shorten
debugging time, feed rate is forced to max. value by the system during trial - running.
Operating procedures are as follows:
1. Select Auto, mode to call out program to be tested.
2. Press the Trial-running key with its indicating lamp “ON” lights on, showing
that trial-running status is valid.
3. Press the Cycle Start key with its indicating lamp lights on, trial-running operation
begins.
4. Feed speed during operation of trial run is controlled by rapid speed button.
Status of RT rapid button Feed Rate under Various Program Commands
Rapid instruction GOO Cutting feed instruction G01, etc.
ON Rapid feedrate Max. cutting feedrate
OFF Rapid feedrate Manual feedrate
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3.4
Lock Operation of the Machine:
Press the key
with its indicating lamp lighting on, lock of the machine is valid.
Press the key again, having the indicating light off, lock status of the machine is
released.
Under locking status of the machine, moving operation (jog, handwheel feed) of each
axis under manual mode can only change displayed values of position and not move
every axis of the machine, but, spindle, coolant and turret work normally (it is able to
execute M, S and T).
Under locking status of the machine, the programs under the auto mode and MDI mode
will run normally, the displaying value for position will be displayed, but without
movement of any axis. Howevre, spindle, coolant and turret work normally.
This function is used for checking out the programs.
3.5
Operation of Auxiliary Locking of Machine
^MST '
K^T
»j. vith the indicating lamp above the figure key lighting, the function
Press the key
of locking the machine is valid. Press the key again, the indicating light will be off, and
the locking status of the machine will be released. And in this case, it is not able to
execute M, S,T.
»—к '
Operation of Single Segment _!=!/
w
under Auto, mode or MDI mode with the indicating lamp over the
Press the key '* □)
figure key lights on, single-segment function is valid. Press the key again, the indicating
lamp goes off, single segment function is canceled. The Single-segment Function key is
allowed to be switched over while program is continuously running.
During valid period of single-segment function under Auto, mode, pressing the Cycle
Start key once, only one segment will be executed; Press the key again, the next segment
will be executed.
Functional application: Mainly, it is used to test programs, and according to the practical
requirements, it can also be combined with the functions of trial-run, lock of the machine
and segment-skip.
Note: In the diagnosis page, press the “DIAGNOSIS” key to switch Diagnosis/Machine
Panel Display Page, in the Machine Panel Display Page, by means of the key
1,2,3,4 and 5, it is able to switch to lock operation of machine, operation of
locking auxiliary function, operation of single segment, operation of dry run, and
switch for optional-skip of program.
Operation of Lubricating Guideways of the Machine <
ваяя»,
The machine has been provided with lubricating function for guideways.
The machine comes into lubricating state after you press the key for lubricating
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BASIC OPERATION OF THE MACHINES
guideways undwer manual mode after power-on of it (“NC start”). If you press the key
again, the lubricating will stop. The operator may start and stop the lubricating for
guideways accotding to the demand.
It is required to pump oil for the guideways and saddle for at least twice per day(one
time in the morning, and the other in the afternoon), and during the oiling, it is necessary
to have reciprocating movement of the two axes of the machine.
Under the Auto mode or MDI mode, the command M32 is used to execute lubricating
ON, and the command M33 to execute lubricating OFF. if you press the key again, the
lubricating will be off.
3.8 Limitation and Release of Overtravel of the Machine
3.8.1 Limitation of Store Travellimit (Software Limitation)
During operation, the carriage of the machine may move out of safe area set by Prm045,
046, 047 or 048 in some direction due to some reasons (operation fault, programming
data error, etc.), CNC system will alarm, and the carriage will stop moving. Move the
carriage out of forbidden area in opposite direction, then, you can do normal operation.
The software limitation is only valid after the coordinate system has been
established by means of completing execution of manual return of reference point after
the machine is power on.
3.8.2 Hard Limitation Switch (Hardware Limitation)
The machine is provided with overtravel limitation switches both in positive directions
and negative directions of X-axis and Z-axis. Positions of the dogs of the switches can
be adjusted by operator. If movement of the carriage in a certain direction has
overwhelmed the limitation switch due to some reasons (operation fault, programming
data error, servo trouble, etc.), CNC system will immediately come into emergency
stop status, giving alarm and stops moving of the carriage. In this case, keep pressing
the overtravel-release key, as well as make the carriage moving out of forbidden area in
the opposite direction, then release the limitation switch which has been overwhelmed,
thus, emergency status is released.
Safe area specified by hard limitation should be more than that specified by soft
limitation, therefore, soft limitation should be used as much as possible to extend
serving life of hard switch.
Hard limitation switch is very important safe device of the machine, user should
periodically check its validity to avoid accidents ! ! 1
3.9 E-stop Operation
A red mushroom emergency stop button is on the left-lower comer on the Operator’s
panel. If any emergency case occurs, all actions of the machine stop immediately as soon
as the emergency stop button is pressed and the button will be self-locked automatically.
Turning the button for a certain angle clockwise can make it be recovered after
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emergency-shooting or trouble-shooting. After the emergency stop button is pressed,
spindle may run for 3-5 seconds due to inertia. The carriage can slide a little.
3.10 Door Lock
In case the machine is provided with door lock, the door lock is locked automatically
after the protection door of the machine is closed, the machine can work. Press release
button under manual mode or input M8 command under auto, mode when the machine is
at non-working status, the door lock can be released, at this time, the protection door can
be released.
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HYDRAULIC SYSTEM
4
4.1
of hydraulic system, the indicating lamp above the key lights
4.2
HYDRAULIC SYSTEM (OPTIONAL)
Start of Hydraulic System ®
J J jgs)
Close the automatic air switch QF5 in the electric cabinet.
Press start/stop kev<$>
on, the hydraulic pump starts. Press it once, the indicating lamp goes off, the hydraulic
pump stops. The hydraulic pump stops after E-stop operation, and the hydraulic pump
should be started again.
Adjust the pressure and the pressure relay of the hydraulic system to obtain the pressure
required by clamping a workpiece.
Operation of Hydraulic Chuck
It is also available to complete clamping and releasing hydraulic chuck by К or by the
foot-pedal switch. Press the key (or step the foot-pedal switch) one time, chuck will be
clamped, with the indicating lamp of the key lights on. Pressing the key (or stepping the
pedal switch) again can make the chuck released, and the indicating lamp of the key goes
out. The min. clamping force of hydraulic chuck is indicated by pressure relay, the user
can regulate clamping force according to practical situation. Travel switch can be
selected for indication.
4.3
/гЕ\ In order to avoid accidents, operating the chuck is not allowed when the spindle
is running. It is only available for you to operate the hydraulic chuck while the spindle
speed is retarded to zero.
Operation of Hydraulic tailstock
It is also available to complete advancing and withdrawing the hydraulic tailstock by
or by the foot-pedal switch. Press the key (or step the foot-pedal switch) one time, the
tailstock will advance, with the indicating lamp of the key lights on. Pressing the key (or
stepping the pedal switch) again can make the tailstock withdraw, and the indicating
lamp of the key goes out. The min. tightening force of hydraulic tailstock sleeve is
indicated by pressure relay, the user can regulate the tightening force according to
practical situation. Travel switch can be selected for indication.
In order to avoid accidents, operating the tailstock is not allowed when the
spindle is running. It is only available for you to operate the tailstock while the spindle
speed is retarded to zero.
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OPERATING FLOW DIAGRAM AND USER’S PARAMETERS
5 OPERATING FLOW DIAGRAM AND USER’S PARAMETERS
5.1 Operating Flow Diagram
Close the general power supply breaker, and then the machine gets normal
power-on
~... .... ..... ' I ~ .............................
Switch on the push-button, CNC system gets power.
— I
Select the mode of return reference point to return reference-point for Z-axis and
X-axis respectively.
Input turning programs, check and confirm their correctness.
” , .......I ----------
Lock the machine, and then execute the dry-run program. Then check the
correctness of the program, especially the correctness of the coordinate size of each
program segment. After the check, it is necessary to cancel the dry-run operation.
Release the machine and load the workpiece for trial-running, and select every
tool manually, and then measure the tool compensation of every tool in method of
trial-running and input the tool compensation unit specified by the program. At
last, pay attention to the positive and negative sign and decimal point.
I ...............• ~ .....
Taking the trial-turned workpiece as reference, move the carriage manually to
coordinate position set by command G50. Unload the workpiece for trial-turning
Call out program of current turning workpiece, and select Auto, operation mode
and proper feed overridde as well as rapid override. Press the Cycle Start key to
start the automatic cycle turning. For turning first workpiece, it is better to select
lower rapid override and using single block function can reduce troubles resulting
from program and error from tool setting.
After first workpiece is completed, measure sizes of each turning position and
modify tool compensation value of each tool. Then, turn the second workpiece.
Recover rapid override of 100% to turn all of workpieces after confirming all
sizes are correct.
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OPERATING FLOW DIAGRAM AND USER’S PARAMETERS
5.2 User’s Parameters
Prm. No. Meaning of Prm. Prm. Value Remarks
022 Rapid movement of X-axis 4000mm/min It is only allowed for the user to decrease this value.
023 Rapid movement of Z-axis 8000mm/min It is only allowed for the user to decrease this value.
034 Clearance compensation of X-axis 0-255 P The parameter of the machine should be adjusted after the machine is used for a certain period.
035 Clearance compensation of X-axis 0- 255P The parameter of the machine should be adjusted after the machine is used for a certain period.
047 Negative protection zone of X-axis
048 Negative protection zone of Z-axis -
045 Positive protection zone of X-axis *
044 Positive protection zone of Z-axis -
049 Coordinate of X-axis reference point
050 Coordinate of Z-axis reference point
051 G71/g72 Cut depth ]-9999999 P
052 G71/G72 Relief 1-9999999 P
053 G73 Total cut amount of X-axis 1-9999999 P
054 G73 Total cut amount of Z-axis 1-9999999 P
055 G73 Cutting number
056 G74/G75 Relief 1-9999999 P
057 G76 Repeated number
058 G76 Angle of tool tip 0/29/30/55/60/80
059 G76 Min. cut depth
060 G76 Permissible error for finish turning
-
Note: Before modify the parameters, it is necessary to set the parameter switch at the
position ON. For details, please refer to (<GSK980TDa OPERATION MANUAL)) .
SHENYANG MACHINE TOOL CO.,LTD
29
CAK50n/61n SERIES
ELECTRICAL MAINTENANCE AND ADJUSTMENT
6 ELECTRICAL MAINTENANCE AND ADJUSTMENT
During electric maintenance, if it is required to open the belt cover to carry out the
inspection, please pull out the feeler lever of power-off switch for door open. Otherwise, it
is unable to switch on the switch of power supply.
When alarm information is displayed on the display screen during the electric maintenance,
please do trouble-shooting for the system alarms according to remedy of relative alarm
given by «GSK980TDa OPERATION MANUAL)) .
While the machine is powered off, the parameters and turning programs of CNC system
are protected by the batteries. The screen displays alarm warn when energy of the batteries
is not enough, in this case, it is necessary for user to change them immediately under status
of power-on of CNC system, otherwise, the parameters and the programs may be lost.
It is necessary for you to carefully and thoroughly read (<GSK980TDa OPERATION
MANUAL)), before operating the machine to avoid operation failure resulting in accidents.
SHENYANG MACHINE TOOL CO.,LTD
30
НК
S М Т С L
CAK50n SERIES
САК61П SERIES
FTL50n SERIES
FTL61n SERIES
CNC LATHES
CNC LATHES
CNC LATHES
CNC LATHES
CIRCUIT DIAGRAMS
CNC System: GSK980TDa
SHENYANG NO.l LATHE WORKS
SHENYANG MACHINE TOOL CO., LTD
THE PEOPLE'S REPUBLIC OF CHINA
50n/61n SERIES
CONTROL STATION
CONTENTS
1 COMMON CIRCUITS..........................................1
2 CIRCUIT FOR PANEL........................................8
3 SPINDLE (DOUBLE-SPEED MOTOR)............................10
4 SPINDLE (HITACHI MOTOR WITH CONVERTER)..................14
5 SPINDLE (TOSHIBA MOTOR WITH CONVERTER)..................17
6 CIRCUIT FOR SERVO.......................................20
7 CIRCUIT FOR TURRET......................................22
8 CIRCUITS FOR HYDRAULIC CHUCK............................25
9 DOOR LOCK...............................................28
SHENYANG MACHINE TOOL CO.,LTD
1
I 2
Outer power supply and
protection of mdcnine
50A. 10mm2is recommended ।
for user of over 3 ~380V ।
2
н
General switch of power supply and protection circuit Lubricating motor for headstock Motor for coolant pump
LI
XTO
iPE
J-O-
I
Гт
' L3
QFO
Refer to table
6mm2 (10mm2
110A
-o—
XT1
70A- 16mm2is recommended I
for user of over 3~220V ।
a?
cn
01 VT1
<?X11
^--rSOO
L11 VT1
<? XI1
L31
X-L31_______.-------------------
102 ПГ
4k >«. Й
110 U31V31W3
нм
F3 ГЛ-Л E8
Drawing 001F,
110
XT1
М2
AO-5624
0.12kW
1500r/min
j QF2
S_1,5mm2 (2.5mm2)
j
f j Refer to table
XT1
М3
AOB-25
0.09kW
3000r/min
KM3
3ower supply voltage QFO QF2 QF3
220V 60A 1A 1A
380V 40A 0.63A 0.63A
400V
420V
. 440V
Note: Wire diameter in the bracket is for power supply voltage of 220V.
Z
4
Coolant ON/OFF
0.5mm2
В
FX-G
A XT2
XT2
KA8
XT1 KM3
06
06
06
180QQF/1
I 10
50n/61n SERIES
ELECTRIC UNIT OF THE MACHINE
SHENYANG MACHINE TOOL CO.,LTD
2
50n/61 n SERIES ELECTRIC UNIT OF THE MACHINE
50n/61n SERIES
ELECTRIC UNIT OF THE MACHINE
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SHENYANG MACHINE TOOL CO.,LTD
4
50n/6In SERIES
ELECTRIC UNIT OF THE MACHINE
SHENYANG MACHINE TOOL CO.,LTD
5
50n/61n SERIES ELECTRIC UNIT OF THE MACHINE
z
п02 ,
+24V| "1
SQ5
i
5
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Entrance for
user's power supply
104
105
+24V
| ^SQ6 pQ7 pQ8'
105
+24V
DECZ
W007
W009 Wiring box of carriage
XT3
В
Switchboard
XT1
wool
W008
Electic cabinet
2
M1B
W002
W003
1 U2V2W2 ® ' 1 U3V3W3 ® !
М2
motor
Centralization
lubricating device
Motor for I
|_for headstock | pooling pump |
Earthing plate
W006
W005
---------------6-----------------
! Illuminating light of the machine’
220A ,
E
5
ELI
F
7
5On/61 n SERIES ELECTRIC UNIT OF THE MACHINE
18000F/7
SHENYANG MACHINE TOOL CO.,LTD
A
В
D
E
F
OO
2 I
Power ON/OFF
+24M
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XT4
?XT5 _
I \ KA17
! \ E2
Power ON/OFF for CNC system
110A <о 1f— Y3.3
XT1 DV
XT2
KA17 j
E2
ФХТ2
FX-G
ФХТ2
0.5mm
XT5
I- 7SB14
120
100
A XT5
Б5
C5
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XT4 VI7 KAI 7
XT1 F30 KM30
003F/1/B5 000F/4/E7
003F/1/B5
003F/1/B5
z
2
Light of cycle start Light of intermittent
Intermittent
E-stop
Cycle start
Y3.2
DV
D
X f 1.1 ?v X 1.4 RV X0.5 RV
(XS^ ,J) s >p) XS40 k J8) > >(7) J'Olj
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XT4
XT4
_ 0.5mm2
XT5
5
18001F/1
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F
tart •
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50n/61n SERIES ELECTRIC UNIT OF THE MACHINE
А
в
Е
F
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N С
z
ш
SB10
А
XS39R
XS40R
XS41R
XS42R
W106
W107
W108
W109
W103
MPG
+24Mt
3 XS39A 120 >—
100 < к—
< XS40A ^2 102 < r —
+24V< >—
.< XS41A 110
ESP >-
< XS42A ST >—
SP >—
STD H-
SPD )—
FX-G OM >™
W102
220В'
+24V
ST
SP
+24М
100
120
102
XS30R
XS31R
W104
W105
W100
W101
SB13
SB12
SB15
SB14
< CN1 X-axis servo model
< CN1 Z-axis servo model
ХТ1
Electic cabinet
+24V
SB11
ОМ
STD
SPD
HL13
HL12
Е
XS38
1 HA
2.4 +5V
5 HB
6.9 ov
F
z
50n/61n SERIES ELECTRIC UNIT OF THE MACHINE
СЛ
гл
сл
гл
гл
2
Control of spindle motor
YC1
3
YC2
Ш
Е
YB
Clutch 1 for spindle changing steps Clutch 2 for spindle changing steps Braking signal for system
Forward
Reverse
YY-Type run
A-Type run
Electronic brake
+24M
+247
271
\s
273
3/06
/ KM1Z
/ D2
JC2
1/09
7 KM1F
/ D3
7 KM1F
/ D3
210
211
KA2
3/04
RR
7 KM1Z
/ 02
216 ,
7 KMiB
/ D5
218
7 KM1A
/ 04
212
П4
+24V)
Brake
YB
KM1Z
KM1F
E
V51 YC2
П8 V50 YC1
110A____
Txfi
Ц KM7
/ 05
I 7KA3
kmiz i „7 Vos
KM8 Bl 1/E9 Brake J Bl JZ П4 FX-G —
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4> ХГ2 i b
XII
217
7 Kill
/ 04
274
L KM8
/ i/Ь
213
KM1A
KM18 FIO KM7
YC1
YC2
233
234
П4
Z
s
SHENYANG MACHINE TOOL CO.,LTD
9
Spindle encoder
OOOF/6/D4
201
203
206
204
0.5mm
SAR
2/C2| 2/B9 2/C3 2/B9 2/C9|2/B2 Ж
Ж
2/B7
2/B8
5
H
2
KAI VI KA2 V2 KA3 V3 KA4 V4 KA5 V5 KA6 V6 KA7 V7
+24V
XT4
SPCW SPCCW SSTP S1 S2 S3 S4
Spindle motor forward Spindle motor reverse Spindle motor stop Con trol relay for changing speed of spindle
Response of spindle running
GSK980TD Y1.2 Y0.4 Y0.7 Y1.0 YO.O Y0.1 Y1.3
DV DV DV DV DV pv pv
XS39
~~r~~.....to.......
permission signal for
changing step of spindle
X2.‘ RV X0.1 RV
4XT4
i XT4
1XS32A
\ KM1Z \ KM1F\ KM8
\2/D2 \ 2/D3V/E9
5On/61 n SERIES ELECTRIC UNIT OF THE MACHINE
50n/61n SERIES ELECTRIC UNIT OF THE MACHINE
11 1 -----|itoin motor ond convertor | ' Д
motor
L11L21L31
-I QF1
J J2A
R20
—QZF
ДО11М
Bl B2
VII
W11
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7.5kW/11k*
1460r/min
3
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18012F/1
1 I 2 I 3 I 4 I 5 I 6 I 7 I 8 I 9 I 10
m
n
X
2
m
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„ ftrnng-sfen switch fnr snjndle
Switch 1 ISwitch? И Ilitch4 BwitcnS
Input of spindle s?
ipindle rvse.
GSK980TD
RV
'(12) _Y(13)
+24V
СМ2
,XS41
207
FLT
GR1
DA3
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IFX-G
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E4
Drawing OOOF/6/D5
KA2 V2 KA6 V6 KA7 V7
SAR
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. XT4 KAI VI
OM
1+24V
SQ21 SQ22 SQ23 SQ24 SQ25 XT4
X2.2 X2.1
RV RV
X3.6 X3.3
RV RV
X2.5 X2.3
RV RV
GR3
GR4
GR5
—
ov
AL2 11
SJ300-075HF
CM1
—о----
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FW
Schematic of switch position
0 о ООО
GR1 GR2 GR3GR4GR5 '
2K0R for 1~R5,
I 2
Ж GR1 GR2 GR3 GR4 GR5
— + — + —
M41 + + — —
M42 — + — — +
M43 + — — — +
GSK980TD -
Y1.2 Y0.4 Y0.1 Y1.3
DV DV DV DV
FXS39A О
201
s
18012F/2
I 10
F
50n/61 n SERIES ELECTRIC UNIT OF THE MACHINE
50n/61n SERIES ELECTRIC UNIT OF THE MACHINE
z
Main motor and frequency
convertor_________________
L11 L21 L31
________, Brnkiqg rssirtnnce.
Motor for blowing mom motor
;6 , ,i ,—~
Clutch for step-chongini
I QF1
J 40A
R20
.№1000*
W11
VFS11-2075P
W
6mm2
Bl
B2
“6------6-
PA PB
220A 0
1------Jxti
MIO
YVP132M-4
75Hf/11kW
Spindle encoder
Drawing 000F/6/D4
a
ев
3
o
ев
ев
18022F/1
1 (T
E
F
<Z>
tn
<Z>
tn
tn
m
tn
50n/6In SERIES
ELECTRIC UNIT OF THE MACHINE
SHENYANG MACHINE TOOL CO.,LTD
18
50n/61 n SERIES ELECTRIC UNIT OF THE MACHINE
SHENYANG MACHINE TOOL CO.,LTD
50n/61n SERIES ELECTRIC UNIT OF THE MACHINE
(Z>
tn
SHENYANG MACHINE TOOL CO.,LTD
D
Power circuit for tuuret motor Control contactor for turret motor (Control relay for turret motor
Forward Reverse Forward Reverse | Forward Reverse
L11
L21
L31
U41
V41W41
\--\A
A
F4
W4
1.5mm2 (2.5mm2)
' JF4
J Refer to table
KM4Z
KM4F
XT1
M4
YU-1-4
0.12kW
1400r/min
110A
XT4 КАЮ VI0
+24V
о---
GSKS 80TD Y1.6 OV Y C 1.7 )V
XS40 XS40> 4 10 d A — 2) 2? 4 11 A A 5ZI
KA11 V11
B5
B6
c
E
Note: Wire dio. in the bracket is available
for power supply votalge 220V.
Pow. suo. voltaae 0F4
220V 4A
380V 1.6A
400V
420V
440V
18004F/1
50n/61 n SERIES ELECTRIC UNIT OF THE MACHINE
SHENYANG MACHINE TOOL CO.,LTD
to
UJ
X2.6 X3.2
RV RV
XS41 ч '(5) | '(4) s -(з) V (2) '"l ' (22) (21) < [ (20) 5 p(H.23)_j
— * • 11 ' — - ___ —’ . » — —’ — * - * ‘ 1 - »I -1 * - • 1 • — _ .. •« ——
]XS41A >(5) v ’(4) ч 1 (3) V (2) 5 > (22) | • (21) < f(20> 1 ✓ (11,23)
, M1B /17) | ,(16) J , (15) (14) < > (13) Y (12) < ДИ) S > (22-25) |
tim' T2M° T3M T4M T5M T6M° TCP +24V* 0.5mm2 > XT3
X41 (3f ^Сгееп)(4)л' '(PurpleX5)^ '(Blue) (6)r '(Yellow) (7f "“(Grey) (8Г '(White) (9)^ '(Pink) (2)' '(Red)
- - -
50n/61n SERIES ELECTRIC UNIT OF THE MACHINE
50n/61n SERIES ELECTRIC UNIT OF THE MACHINE
1
121
L31
Note:
Hydraulic motor
1.5mm2 (2.5mm2)
П QF5
J Refer to table
V51
W51
U51
U5 V5
«5
LX501l)>fl®)j
XT80
U5
M5
Y90L-6
1.1KW
lOOOr/min
8 19 1
Relay control for hydraulic Toilstock
„ . . , . . , j i- Relay control for hydraulic chuck
onro con actor or У rqu IC ^y^huck closing | Chuck releasing |Ta3rfock sleere odwmcinq j Tqfctod sleeve ff'thdnwnnq
110A
XT1
KAI 6
XT2
517
o---------------—
XT1 KM5 F15
C2
C2
C2
Wire dia. in the bracket is available for power supply 220V.
2
+24M
XT4 —„— . , —<_ 11 " * 1 v ' ‘ ‘ - — —
KJO
Ч- KA13
/ 0/Г7
A-----
KJ
KSO
WJO
Ч- KA12
/ 9/Г7
-----A------
KS
2/E8
WTO
KA15
-----A-----
WJ
WT
2/E9
KA14
OM
В
Y(9) y(1,2)|
Q
A--------------6------
V51 YV1
YV2 V52 V53 YV3
Row. sup. voltaqe 0F5
220V 6A
380V 4A
400V
420V
440V
2
D
YV4 V54
E
50n/61n SERIES
ELECTRIC UNIT OF THE MACHINE
SHENYANG MACHINE TOOL CO.,LTD
26
50n/61n SERIES
ELECTRIC UNIT OF THE MACHINE
SHENYANG MACHINE TOOL CO.,LTD
27
SHENYANG MACHINE TOOL CO.,LTD
XS40
XS40
|XS42A
ФХТ4
BY1
42
KA90 V90
Safety loop
Lock of protection door j
Switch of protection door
18009F/1
5
S
+24V
dia. 0.5mm2
....1....
LOCK Solenoid
SQ90
\ SQ2
02
Door lock of protection door DOOR
Power supply for door lock Releosinq of door lock Control relay of door lock Switch of protection door
A
GSK980TD X1.0 RV Y3.0 DV
XS42
GSK980TD X1 R .0 IV
B:
XS40A 20
OM
v KA90
\ E6
|xti
LOCK
ад
+24M
E2(~)
D2 I+24V
s-
E3
:XS40A
< DI > XT4
D
E
50n/61n SERIES ELECTRIC UNIT OF THE MACHINE
SHENYANG MACHINE TOOL CO.,LTD
2
2
£
2
Ш
A
В
E
2
2
2
50n/61n SERIES ELECTRIC UNIT OF THE MACHINE
ПК
S М Т (С JL
САК50 SERIES CNC LATHES
САК61 SERIES CNC LATHES
INSTRUCTION BOOK
(For Mechanical Unit)
SHENYANG NO. 1 LATHE WORKS
SHENYANG MACHINE TOOL CO., LTD
THE PEOPLE' S REPUBLIC OF CHINA
САК50/САК61 SERIES
INSTRUCTION BOOK
IT IS NECESSARY FOR YOU TO READ THIS BOOK CAREFULLY AND
THOROUGHLY BEFORE OPERATING THE MACHINE.
THE CHINESE VERSION OF THIS TECHNICAL DOCUMENT IN ENGLISH IS
REGARDED AS FINAL.
SHENYANG MACHINE TOOL CO., LTD
I
САК50/САК61 SERIES
MATTERS NEEDING ATTENTION TO OPERATION
MATTERS NEEDING ATTENTION TO OPERATION
It is necessary for you to read this Instruction Book carefully and thoroughly and be acquainted
with all details of the Instruction Book before operating the machine, only for doing this you
can make the machine completely run safely.
Although this Instruction Book has been checked carefully, if you find there is still a few
questionable points, incorrect explanation or omission in it, please make contact with our
factory.
For explaining concrete details of the machine, some graphs in this Book were drawn without
doors, safe guards, cover, etc. Therefore, before the operation of the machine, put on all these
covers, safe guards or close the doors according to this Instruction Book, otherwise, some
troubles may occur, resulting in the machine’s major assembly or other attachments being
damaged.
In order to transport the machine safely, safe-guard doors, etc. are fixed. Users must dismount
all these fixtures before operation of the machine to avoid damage to the machine.
The coolant shall be filled through the oil pan, and then flow into the water tank. It is
prohibited to fill the coolant on the top of the cooling pump to prevent the motor for cooling
pump from being burnt.
SHENYANG MACHINE TOOL CO., LTD
2
САК50/САК61 SERIES
MATTERS NEEDING ATTENTION TO INSTALLATION
MATTERS NEEDING ATTENTION TO INSTALLATION
In order to ensure the machine run normally, the following items during installation of the
machine must be paid attention:
1 Wiring
1.1 The performance values of wire used for connecting the electrical parts should be
equal to or more than the specified values.
1.2 Never connect the power cable like electrical welder, high-freq. Quencher, etc. which
may cause interference to the switchboard.
1.3 Power cable should be connected by skilled electriciano
2 Earthing
For cross section of the used earthing wire, earthing resistor, and matters needing attention
to earthing, please refer to standard GB5226.1-2002.
The earthing wire should be connected as shown by figures given below.
Separate earthing wire
Common earthing wire
Never connect several equipment to one earthing rod as the figure shown below:
SHENYANG MACHINE TOOL CO., LTD
САК50/САК61 SERIES
NOTICE TO ENVIRONMENTAL PROTECTION
NOTICE TO ENVIRONMENTAL PROTECTION
The following stipulations have to be followed when the machine is finally scrapped:
• It is necessary to deliver some harmful or non-degradable castoffs, including used batteries,
electrical elements, rubber components, etc., which cannot be recovered or re-utilized and
designated local recovering unit.
• The waste liquid leading to environment pollution, such as lubricating oil, coolant, etc.,
which cannot be recovered or re-utilized have to be drained off at designated local place.
SHENYANG MACHINE TOOL CO., LTD
4
САК6150/САК6161 SERIES
CONTENTS
CONTENTS
1 GENERAL DESCRIPTION.........................................................I
1.1 Application Scope and Purpose of the Instruction Book..................1
1.2 Identification Marking of Model....................................... 1
1.3 Major Application of the Machine.......................................2
1.4 Accuracy of the Machine................................................2
1.5 Working Environment of the Machine.....................................2
1.6 Effect of the Machine to the Environment...............................2
2 MATTERS NEEDING ATTENTION TO SAFE GUARD....................................3
2.1 Requirements for Operator and Maintainer...............................3
2.2 Basic Requirements of Operation........................................3
2.3 Requirement Prior to Switching on the Power Supply.....................4
2.4 Requirement after Switching on the Power Supply........................5
2.5 Normal Inspection......................................................5
2.6 Temperature Raising....................................................5
2.7 Preparation before Starting the Machine................................6
2.8 Matters Needing Attention during Operation.............................6
2.9 Machining Interruption.................................................7
2.10 After Turning.........................................................7
2.11 Safeguard Devices.....................................................8
2.12 Preparation before Maintenance........................................8
2.13 Maintenance Operation.................................................8
2.14 Handling after Maintenance............................................9
2.15 Miscellaneous.........................................................9
3 HANDLING AND INSTALLATION.................................................11
3.1 Transportation and Storage of the Machine.............................11
3.2 Preparation before Installation.......................................11
3.2.1 Ambient Requirement (for Machine)...............................11
3.2.2 Ambient Requirement (for NC)....................................11
3.2.3 Power Interface.................................................11
3.2.4 General Power Supply............................................11
3.3 Handling..............................................................11
3.4 How to Install the Machine............................................14
3.4.1 Foundation......................................................15
3.4.2 Temporary Leveling..............................................15
3.5 Inspection of Inner Devices Connection................................15
3.6 Inspection before Operation...........................................15
3.7 Final Adjustment of Bed Level........................................ 16
3.8 Maintenance and Inspection of Inner Devices Connection after Installation.16
SHENYANG MACHINE TOOL CO., LTD I
САК6150/САК6161 SERIES
CONTENTS
3.8.1 Maintenance of Primary Period after Installation...............16
3.8.2 Check the Connection of Inner Devices..........................17
3.8.3 Check Electric Control Panel...................................17
3.9 Occupied Floor Space and Foundation Plan of the Machine..............17
4 SPECIFICATIONS OF THE MACHINE............................................18
4.1 Explanation to the Specification.....................................18
4.2 Table of Technical Specifications....................................18
4.3 Torque Vs Power Drawing of Spindle (Freq.-chnaing)...................20
4.3.1 Manual Speed Change............................................28
4.3.2 Hydraulic and Power-driven Speed Change........................20
5 CONSTRUCTION OF THE MACHINE..............................................21
5.1 Layout of the Machine................................................21
5.2 Brief Introduction to Parts of Machine...............................21
5.2.1 Headstock......................................................21
5.2.2 Chuck..........................................................29
5.2.3 X-axis and Z-axis..............................................30
5.2.4 Turret.........................................................30
5.2.5 Tailstock......................................................31
5.2.6 Hydraulic System...............................................31
5.2.7 Pneumatic System...............................................41
5.2.8 Lubricating System.............................................48
6 OPERATION AND SAFEGUARD OF THE MACHINE...................................50
6.1 Safe Guard...........................................................50
6.2 Set Necessary Warn Labels for Safety.................................51
7 INSPECTION AND MAINTENANCE...............................................52
7.1 Routine Inspection...................................................52
7.2 Periodic Inspection..................................................53
7.3 Lubrication and Cooling..............................................54
7.3.1 Hydraulic Device...............................................54
7.3.2 Lubricating Device.............................................54
7.3.3 Cooling Device.................................................54
7.4 Adjustment and Maintenance of the Machine............................55
7.4.1 Adjustment of V- belts....................................... 55
7.4.2 Adjustment of Spindle..........................................55
7.4.3 Chuck..........................................................57
7.4.4 Clearance......................................................57
7.4.5 Electric Maintenance...........................................57
7.5 Common Trouble-shooting..............................................58
7.5.1 Common Troubles and the Causes of Troubles.....................58
7.5.2 Check for 1/0 Diagnosis Display................................61
8 TOOL DISPOSITION.........................................................62
9 ACCESSORIES AND WEARING PARTS................................67
9.1 Standard Accessories Provided with the Machine.......................67
9.2 Optional Accessories Provided with the Machine.......................67
9.3 Wearing Parts........................................................67
SHENYANG MACHINE TOOL CO., LTD II
САК50/САК61 SERIES
GENERAL DESCRIPTION
1 GENERAL DESCRIPTION
1.1 Application Scope and Purpose of the Instruction Book
The Instruction Book is edited for the CNC lathes provided with FANUC Oi-Mate-TC,
SMTCL-NC100, DASEN-3g, GUANGZHOU NC System, CHENGDU GUANGTAI NC
System, FAGOR 805 5T, SIEMENS 802D, WUHAN HU AZHONG CENTURY STAR
HNC-22T,GJ-201T, etc.
The Chapter 2 of the Instruction Book—“Matters Needing Attention to Safety Protection”
can be taken as routine inspection items of operators.
The Chapter 3 of the Instruction Book—Handling and Installation of the Machine,
explains matters needing attention and the methods for installing the machine.
The Chapter 4 of the Instruction Book—Specifications of the Machine”, and Chapter 5—
“Construction of the Machine”, describe the content needing pre-comprehension before
operation.
The Chapter 7 of the Instruction Book—Inspection and Maintenance, is the knowledge
needed for operation and maintenance for operators.
In Chapter 8 of the Instruction Book— “Tool Disposition” submits machining range of the
machine, tool interference, etc.
If any trouble that is not mentioned in the Instruction Book occurs, please make contact
with the Market Department of our factory.
1.2 Identification Marking of Model
The model identification markings of model of the machines consist of Code of
construction character, 1/10 of max. swing diameter over bed, 1/10 of max. turning length,
model of control system and safeguard type and max. length of workpiece to be turned.
For the machines provided with FANUC Oi-Mate-TC, SMTCL-NC100, DASEN-3g,
GUANGZHOU NC System, CHENGDU GUANGTAI NC System, FAGOR 8055T,
SIEMENS 802D, WUHAN HU AZHONG CENTURY STAR HNC-22T, GJ-20lT,etc., the
code of the system are separately d, b, bgj, n, t, f, g, e, s. In addition, the machines can be
divided into four kinds according to max. turning length—600, 850,1350 and 1860, two
series—i and j , according to safeguard types and four size according to the max length of
workpiece to be turned—640, 890, 1390 and 1900.
CAK50 85di X 890
Max, length of workpiece to be turned
Model of control system and safeguard type
1/10 of max, turning length
1/10 of max. swing diameter over bed
NC
Code of construction character
Lathe
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GENERAL DESCRIPTION
1.3 Major Applications of the Machine
The machine is mainly used for turning various shaft-type workpieces and disc workpieces,
cutting all kinds of threads, arcs, cones and internal and external curvic surfaces of
gyro-rotors, and it can meet the need of speed while cutting ferrous and non-ferrous metals
at high speed. Therefore, the machine is suitable for of gyro-rotor workpieces in
high-efficiency, large-batch and high-accuracy machining in the fields of automobile,
motorcycle, electronic, aerospace, war industry, etc. The workpieces produced on the
machine can be up to the working accuracy of Grade IT6~IT7 and Cp can be up to 1.6
1.4 Accuracy of the Machine
Accuracy of the machine is in accordance with Standard JB/T8324.1-1996 «Testing of the
Accuracy for Horizontal NC Turning Machines» .
1.5 Working Environment of the Machine
The machine is to be used in following environment and operating conditions:
• Environmental temperature: 5° C ~ 40°C.
• Humidity: When under the max. temperature of 40°C, the relative humidity shall not
be over the range of 50%, and the principle of humidity change is that no
condensation results in.
• Height above sea level: Lower than 1000 m.
• Atmosphere: There is no excessive dust, acid gas, corrosive gas and salt
component.
• Radiation: It is necessary to avoid temperature rising of environment due to direct
lighting up of the sun for the machine or heat radiation.
• Location for installation of the machine should be far away from vibrating source,
flammable and hazard articles.
1.6 Effect of the Machine to the Environment
The sound-pressure grade of noise from the machine is < 83dB(A). The machine is
provided with full guard and does not drain harmful gas or liquid. Therefore, there is no
bad affection from the machine to the environment.
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MATTERS NEEDING ATTENTION TO SAFE GUARD
2 MATTERS NEEDING ATTENTION TO SAFE GUARD
The machine is provided with some safeguards to prevent operator from injury or
machine from damage. So, before operation of the machine it is necessary for the
operator to be acquainted with details on the all safety labels and the following
regulations.
2.1 Requirements for Operator and Maintainer
• The operator of the machine shall be the personnel who was trained and has skill
certificate. Before operating the machine, it is necessary to read the Instruction
Book carefully and comprehend the content in the Instruction Book thoroughly.
It is only permissible to operate the machine after the operator possesses the
required ability for operating the machine.
• To avoid accidents, personnel to do the maintenance for the machine shall be
qualified or possess maintaining capability.
2.2 Basic Requirements of Operation
A Danger:
• Never touch some devices such as control board, transformer, terminal block and
other places with high-voltage terminals; otherwise, it may cause shock.
• Never touch any switch with wet hand; otherwise, short circuit will result in to
cause personnel injury.
Warn:
• Be familiar with the position of emergency stop button so that it can be touched
immediately whenever necessary.
• It is necessary to power off the machine before replacing fuse.
• Whenever troubles occur in power supply, it is necessary to switch off the switch
of main circuit.
• When two persons have to do a job, a coordinate signal for every operating step
should be set for coordination, and the next step cannot be done unless the signal
specified is given.
Notices:
• Recommended hydraulic oil, lubrication oil and grease or the oil having same
functions as the recommend ones that are allowed should be used.
• The fuse, which has satisfied rated current value, should be used.
• It is necessary to prevent the NC devices, operator’s panel and electric control
board from being attacked, otherwise, troubles resulting in the abnormal work of
SHENYANG MACHINE TOOL CO., LTD
САК50/САК61 SERIES
MATTERS NEEDING ATTENTION TO SAFE GUARD
the machine will occur.
• Don’t change parameters or other electric devices at will. If it must be changed,
you should register the original value before change, so that it can recover to the
original value when needed.
• Do not dirty nick or get down any caution label. If the words on it are not clear or
lost, order a new one from our Works.
• Enough working space should be given to avoid accident.
• Oil or water can make the floor slipping to cause danger. So, always keep the
floor clean and dry to avoid accidents.
• Confirm the switch that you are going to use, don’t mistake.
• Never touch switches at will.
• The worktable near the machine should be very strong and stable to prevent
something from sliding down from it.
2.3 Requirement Prior to Switching on the Power Supply
/f\ Danger:
All cables, wires or patch cord whose insulating covers are damaged will cause
current leakage or shock, so it is necessary to check them carefully before use.
Warn:
• It is necessary to understand all the details specified in the Instruction Book and
Programming Manual, and make clear for every function and operation
procedure.
• Wear the insulating shoes, overalls and other articles for safeguard.
• Close the doors and covers of NC unit, operation panel and electric control panel.
Notices:
• The cables used from electrifying switch to the switch for general power supply
of the machine should have enough section to meet the requirements of electric
power.
• The cables set on the floor must have the ability of chip proof to avoid short
circuits.
• Before starting the machine for the first time after unpacking the wooden cases
or start the machine after a long-time stop of the machine, it is necessary to oil
the sliding parts with new lubrication oil, the lubrication pump should
continuously work until the oil seeps from chip scraper.
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• The oil tank of the machine should be filled to the oil level, and check it, refill it if
necessary.
• For lubricating point, the kind of oil and relative oil position, please refer to their
concerned labels.
• Every switch and operating lever should be nimble, smooth and the actions
should be checked.
• When you supply power to the machine, switch on the factory electrifying switch,
main circuit switch and power supply switch (make them at Positions “ON”) on
the operator’s panel in turn.
• Check the amount of coolant; and add it when necessary.
2.4 Requirement after Switching on the Power Supply
When the switch of power supply on the operator’s panel is set to ON, check if the
indicating lamp READY is light or not.
2.5 Normal Inspection
Warn:
Never insert your finger in-between the pulley and belts when you check the tension
of the belts.
Notice:
• Check if the reading on the pressure meter is correct.
• Check if there is any abnormal noise coming from motor, gearbox or other parts.
• Check the lubrication state of sliding parts.
• Check if the safeguard device or protective cover is under good status.
• Check the tension of the belts. If they are too loose, replace them with new
matchable ones.
2.6 Temperature Raising
Notices:
• When you raise the temperature of the machine, especially for spindle and feed
shafts, the machine should run at half or one-third of max. speed for 10-20
minutes under automatic mode so that the stable temperature required for the
machine can be reached.
• Under the automatic mode, every action of the part should be carried out
according to the program. At the same time, the action status of each part shall
be checked.
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MATTERS NEEDING ATTENTION TO SAFE GUARD
• If the machine has been stopped for a long time, you’d better not start the
machine with actual machining otherwise which may damage the sliding parts
because of the lubrication is not sufficient. For this reason the machine parts may
get heat expansion to affect the machining accuracy. In order to avoid this
situation the machine temperature should be raised.
2.7 Preparation before Starting the Machine
Warn:
• Tooling should be in accordance with the technical parameters, size and type of
the machine.
• Excessive wear or damage of tools will influence the working accuracy directly or
damage the machine, so new ones should replace excessive worn tools
beforehand.
• For the convenience of safe check, the working area should have good
illumination.
• Tools or other things around the machine or equipment should be arranged in
perfect order and keep the environment tidy and the path unlocked.
• Tools and other things cannot be put on the headstock, turret, covers or other
similar positions.
• If the center hole of a heavy cylindrical workpiece is too small, the workpiece
may skip out of the center when it is loaded, so, pay attention to the size and
angle of the center hole.
Notice:
• The length of workpiece should be limited within the specified range to avoid
interference.
• After the tools are set, trail run should be performed first.
2.8 Matters Needing Attention during Operation
Danger :
• Long hair should be covered with cap when operating the machine.
• Workpiece must be chucked tightly.
• The adjustment of the nozzle of the coolant is permissible only when the machine
is under stop status.
• During machining, it is forbidden to touch workpiece or spindle by hand or
under other modes.
• Do not open the door of machine during automatic machining.
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САК50/САК61 SERIES MATTERS NEEDING ATTENTION TO SAFE GUARD
• During heavy cutting, hot chips may cause fire, so preventing chips from
congestion is necessary.
Warn:
• When operating the machine, operate the switches without gloves to avoid
mis-operation.
• Workpiece can be unloaded only when the tool and spindle are under stop status.
• Cleaning chips is forbidden during cutting.
* It is forbidden to open the safeguard door when the machine is running.
Notice:
* When moving heavy workpiece, more than two people must work together to
ensure safety.
• The operators who use fork-type lifter, crane or other similar equipment must
have been professionally trained and have been granted concerned certificate.
• Whenever operating the fork type lifter, crane or other similar equipment, great
attention should be paid to avoid collide with other devices around.
• The steel wire or hook being used for handling must have enough strength to
satisfy the requirement of loading, and they must be limited within the safe rules.
• Do not clean chips on the cutter by bare hand, but use brush to clean it.
* Mounting and dismounting tools should be done only when the machine is under
stop status.
* Operator should wear anti-gas mask when machining the workpieces made from
magnesium alloy.
2.9 Machining Interruption
Notices:
After machining, before leaving from the machine, the operator have to turn off the
switch of power supply on the operator’s panel as well as the switch of main circuit.
2.10 After Turning
Notices:
• Cleaning is forbidden before stopping the machine.
• When the machining is ending, remove the chip and clean the door, window and
cover. The iron chip should be cleaned by special hook or other implement,and it
should not be cleaned by hands directly.
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MATTERS NEEDING ATTENTION TO SAFE GUARD
• Back all parts of the machine to their original positions.
• Check the chip scraper to see if it is damaged, and replace it with a new one if
it’s damaged.
• Check if the coolant, hydraulic oil and lubricating oil are dirty, and if the
pollution is serious, change it with the new.
• Check the amount of coolant, hydraulic oil and lubricating oil, and add them
when necessary.
• Clean the filter of the water tank.
• Before leaving from the machine, turn off the switch of power supply on
operating pendant as well as the switch of main circuit and main switch of the
machine.
2.11 Safeguard Devices
• Front and back protection devices and coolant protection device.
• Overtravel limitation switch
• Protection device for chuck, tailstock and tool (NC software is set by user
parameters).
• Store travel limit (NC software)
• Emergency stop button
2.12 Preparation before Maintenance
Warn:
• Any maintenance cannot be done without authorization.
• Replacement of parts, wearing parts (seal, oil seal, О-type ring, bearing, grease
and oil) should be made according to preplan.
• Prepare record, preventive measures and correct maintenance method.
Notices:
• Carefully read and be acquainted with the safeguard measures specified in the
INSTRUCTION BOOK.
• Read the INSTRUCTION BOOK carefully and thoroughly and be acquainted
with the relative principle, structure and notices included in the Book.
2.13 Maintenance Operation
A Danger:
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MATTERS NEEDING ATTENTION TO SAFE GUARD
• During the period of maintenance, anyone who has no relationship with the
maintenance should not operate the main circuit switch or the power ON switch
on the pendant, therefore a sign plate with “The machine is under maintaining,
don’t touch the switch” or with words similar to the above meaning should be
hung on the switch or other suitable places. This plate should be easy to see and
to pick off but uneasy to fall down.
• It’s dangerous to maintain the machine with power on, principally the switch of
main circuit should be turn off during maintenance.
Warn:
• A professional maintainer should carry out the electric maintenance and the
maintainer should always be in contact with the chief, and never make any
decision by himself.
• Travel limit device, approach switch or interlock devices cannot be dismounted
or modified.
* In order to ensure the safety, the ladder or the lifter used for high-altitude work
must be maintained and controlled every day.
• Fuses and cables used for the machine should be certificated products.
2.14 Handling after Maintenance
Warn:
• After maintenance is finished, the working place should be cleaned and
re-arranged, and the oil, water on every part should be cleared away to get a
good working ambience.
• Take the dismounted parts and dirty oil far away from the machine to keep
safety.
Notice:
• Maintainer should check if the operation of the machine is safe.
• Register and keep all the data of maintenance and inspection for further
reference.
2.15 Miscellaneous
• Max. allowed loading of the machine (standard configuration):
For FANUC Oi control system
Power: 8 kW 7.5 kW (frequency-changing motor)
Torque: 1318 Nm 840 Nm (frequency-changing motor)
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MATTERS NEEDING ATTENTION TO SAFE GUARD
Cutting force:
9000 N (for horizontal turret is provided, the value is 5000
N)
• When the chuck is running at high speed, the jaws must clamp a workpiece to
avoid being thrown off from the chuck! While the spindle is running, it is
forbidden to shift the speed-changing handle.
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HANDLING AND INSTALLATION
3 HANDLING AND INSTALLATION
3.1 Transportation and Storage of the Machine
Measures for corresponding anti-damp, anti-vibration and anti-impact had been taken
during the packing of the machine, guaranteeing the machine can be transported and
stored under the temperature of -25°C~+55°C, and the highest resistible temperature is up
to 70°C during the short-period transportation and storage within 24h.
3.2 Preparation before Installation
3.2.1 Ambient Requirement (for Machine)
The machine shouldn’t be installed in the positions listed below:
• The ambient temperature can obviously change. For example, the machine’s installing
position has direct heat resource or is close to the heat resource.
• Over-wet place.
• Too dust, too dirty place.
• Near the vibration resource.
• The floor for installing the machine is not strong enough or soft.
Notice:
• If the machine has to be installed near the position with vibration resource, dig a canal
around the machine or make similar measures for anti-vibration.
• If the machine has to be installed on the soft soil, it is necessary to use the pile way or
similar measures to increase the force of the soil support, so that the machine will not
sink or incline.
3.2.2 Ambient Requirement (for NC)
• Ambient temperature: 5 ~ 40°C (under working condition)
• Relative humidity in normal case: Lower than 75%
3.2.3 Power Interface
Terminal block is located at side of the front leg of the machine.
3.2.4 General Power Supply
Prepare the power supply cable and earthing wire according to main power supply
specified by the Table for Control Parameters of the Machine. For the details, please
refer to «INSTRUCTION BOOK for Electric Unit)) .
3.3 Handling
For handling plan, please refer to Fig. 1 - 1, 1-2
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HANDLING AND INSTALLATION
Max. length of workpiece to be turned i > j series
A В c
640 2575 1370 1700
890 2825 1620 1700
139O 3325 2120 1700
1900 3825 1700
Floor space for maintenance
1000
570
160
Normal working location of operator
Fig- 1-1
Inlet hole of
pwr.-sup.cable
RI/21
1620
Adjust pad iron 8-П8С
8.10
970
360
520
Handling plan and foundation schematic for the machine
of i, j series (max. length of workpiece: 640, 890, 1390)
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HANDLING AND INSTALLATION
Fig. 1-2 Handling plan and foundation schematic for machine
of ij series(max. length of workpiece: 1900)
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HANDLING AND INSTALLATION
• During handling, a great attention should be paid to avoid the NC system and
high-pressure switchboard to be shocked. Before handling the machine, check if every
part is stable or movable, whether there is an article that is not allowed to be put on the
machine.
The requirements mentioned below should be followed during handling the
machine:
The protection door should be first fixed when the machine is transported. On both sides
under the protection door there are two screw holes of M6. Make the screws of МбхЗО of
the dog on the guideways be fixed with the protection door. And the pieces, on the edge
of the protection door, used for transportation make the door be connected and fixed with
the rear protection position. To lift the machine packed in wooden case by a crane, strong
steel wire rope should be looped in the rope marks pointed lateral side of the case. When
transporting and unloading the case, bumping and shocking should be avoided. Over
inclination of packing case is prohibited, otherwise, the accuracy of the machine will be
badly affected even damaged. If rolls are used for the transport of the case, it is important
that the inclination of condition of the slips should not exceed 15° and the diameter of the
rolling rod should not be more than 70 mm. Never place the case on a prismatic body or
upside down to avoid accuracy of the machine to be affected.
When the machine is unpacked, first inspect its exterior condition and check attachments
according to the “Packing List”.
When using a crane lifts the unpacked machine, make the steel wire rope pass through
the first and the third (for L=l900, it should be the fourth) rib holes on the front of the
bed (see Fig. 1-1) and by the help of the carriage and the tailstock to balance the machine
to be lifted. Before the machine is lifted, wooden blocks should be padded between the
strong steel wire rope and the machine or the steel wire ropes are slipped with rubber
pipes to prevent the machine and the protection plate from scratching.
• The machine should be kept balance in both horizontal and vertical during handling,
so, at the very beginning when the machine being handled up the machine should be
kept balance.
• The angle of the handling rope is no more than 60°.
• Whenever more than one person carries out the handling work, signals should be used
between each other for coordination.
3.4 How to Install the Machine
The performance of a machine is greatly influenced by the installation way. If the
guideways of a machine are finishing machined, but the original accuracy cannot be
reached due to the reason of bad installation of the machine. And most troubles of the
machine were caused by this reason.
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HANDLING AND INSTALLATION
Read the installing procedure carefully, and install the machine according to the
requirements specified, so that the machine can perform high-precision machining.
3.4.1 Foundation
For installing the machine, a plane installation place should be first found, then arrange
the environment according to the specifications and determine the installation space
according to the foundation plan.
The floor space of machine includes the machine itself and maintenance space, which
has been specified in Foundation Plan.
3.4.2 Temporary Leveling
• Lift up the machine and set the foundation bolts and wedges into the boltholes for
leveling.
• Put down the machine slowly to make the foundation bolts come into the
foundation holes according to the stipulations given by the Foundation plan.
• Insert the wedges into the bottom of the bed for temporary leveling to obtain rough
adjustment.
• Fix the foundation bolts with cement after rough adjustment.
• If the anti-vibration wedges are used, they can be directly put on the plane cement
made floor.
3.5 Inspection of Inner Devices Connection
After the leveling, before switching on the machine, the following preparation work
should be done:
• Be sure that grounding wire connected correctly (resistor is lower than 10Q).
• Tighten the screws on terminals.
• Re-check whether couplings are connected tightly.
• Make sure the printed-circuit boards inside NC devices are not moveable.
• Make sure that input power supply is in correct phase, and otherwise NC device or
AC converting control board may have troubles.
3.6 Inspection before Operation
After connection of inside devices, check the mechanical system and electrical system of
the machine according to the following rules.
• Cleaning
Sliding surfaces and metal parts surfaces of the machine were covered with a film
of antirust for rust proof. Some dust, sand or other dirty things may come into the
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HANDLING AND INSTALLATION
anti-rust coating during transportation, so, before starting the machine, clean out
this rust preventive with cloth dipped with cleaning oil. After cleaning, cover them
with a film of lubrication oil.
• Inspection of machine:
♦ Check if any part of the machine has been damaged.
♦ Check if any part or attachment has been lost.
♦ Check if every part has been lubricated well.
♦ Check if all the hydraulic pipes have been connected well.
• Check electrical system before I after switching on power supply (Refer to
Instruction Book for Electrical Unit).
• Matters needing attention when the machine is under the condition of stopped for a
long term:
When the machines is started first time after installation or after a long-term stop,
start it with lubrication to make the slide surfaces have enough lubrication oil.
3.7 Final Adjustment of Bed Level
When the cement in the foundation holes is solidified, adjust the level by leveling bolt
and arrange the leveler according to the rule of “temporary level adjustment”. For the
steps and tolerances of leveling, refer to the “Test Certificate”.
3.8 Maintenance and Inspection of Inner Devices Connection after Installation
3.8 .1 Maintenance of Primary Period after Installation
For the primary period after the installation of machine, the level of the machine bed will
change obviously for reasons of unstable solidifying of the surface and the solidification
of foundation are not steady, so that the accuracy of the machine will be greatly affected.
On the other hand, because of the primary wear, the machine is very easy to be polluted,
which will result in machine trouble easily.
Measures that should be taken for maintenance during the primary period of installation
are as follows:
• Trial-run
For first time trial-running, it should be carried out with great care, the time of
trial-run is about 1 hours, and heavy load cannot be used during trial-run.
• Check the bed level of the primary period
Check the bed level after the machine is installed for six months; check the situation
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HANDLING AND INSTALLATION
of foundation once a month at least. If any un-normal phenomenon was found, correct
it to reach the specified requirement so that the accuracy of the bed level can be
ensured.
• After six months, the checking period can be extended according to the situation
of practical change. When it reaches a certain steady extent, the checking period can
be set for once or twice a year periodically.
3.8.2 Check the Connection of Inner Devices
Check NC device, main machine, hydraulic device, control panel and other devices to
make sure that their electric connection is correct.
• Check if connectors are connected tightly.
Check if the electric connection of devices is right. Inspect if the electric connectors
between devices are tight, and tighten them when necessary.
• Check if the screws of terminals are connected well
Check if interface of the machine and the screws on terminals of electric equipment
on control panel are loose, and if any of them is loose, tighten them according to the
requirements.
• Check if the screws on terminals and installing screws of micro-switch are loose,
tight them when needed.
3.8.3 Cheek Electric Control Panel
Before checking the electric control panel, switch off the power supply of the machine is
necessary.
• Terminal screws and weld elements
Check every terminal screw on electric equipment, tighten them when they are loose,
and softly pull the weld element on relay board to make sure they are welded well.
• Arc-deflector
Check every arc-deflector, and replace them when their colors change.
• Cleaning
When some dust, chip or other dirty things were inside the electric control panel,
clean them out carefully; otherwise, they may cause troubles.
• When the air filter become black that means it was polluted, dismount it and clean
softly with water.
3.9 Occupied Floor Space and Foundation Plan of the Machine
Please refer to Fig. 1-1,1-2, 1-3 and 1-4.
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SPECIFICATIONS OF THE MACHINE
4 SPECIFICATIONS OF THE MACHINE
4.1 Explanation to the Specification
This machine has some different sizes and types. Before read the manual, make sure the
type of your machine.
Note: The parameters not specially stated in this operation manual are parameters of
standard configuration of the machine.
4.2 Table of Technical Specifications
Item Unit Specification
Max. swing dia. over bed mm 500 610
Max. length of workpiece to be turned mm 640. 890, 1390, 1900
Max. turning dia. mm 500 610
Max. turning length mm 600, 850, 1350, I860
Max. turning dia. over carriage mm 300 370
Type and code of spindle nose D8, A,8
Front taper hole of the spindle 1: 20
Dia. of spindle bore mm 70
Range of spindle speed (common) r/min 40-1800
Range of spindle speed (manual speed changing and frequency changing) r/min 72-370; 300-900; 800-2200
Range of spindle speed (auto speed changing and frequency changing) r/min 22-220; 71-710; 215-2200
Steps of spindle speed (common) 12 steps
Steps of spindle speed (freq.-changing) 3 steps, stepless
Output power of mtr. for spdl. (Common) kW 6.5/8
(Freq.-changing) kW 11 (manual ) 7.5/11 (auto)
Center height From the bed mm 250 305
From the floor mm 1130 1185
Rapid speed of X-axis m/min 4
Rapid speed of Z-axis m/min 8 6
X-axis travel mm 250 305
Z-axis travel mm 640 890 1390 1900
Dia. of tailstock sleeve mm 75
Travel of tailstock sleeve mm 150
Taper of tailstock sleeve Morse No. 5 (hydraulic tailstock: Morse No. 4)
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САК5О/САК61 SERIES
SPECIFICATIONS OF THE MACHINE
Item Unit Specification
Type of turret 4-station 6-station (vertical) 6-station (vertical)
Indexing time of turret s 3 3.5 5
Size of tool shank Inner circle mm 25X25
Inner hole mm Ф25 Ф32
Machine weight Swing dia. mm Ф500 Ф610
Workpiece length mm 640 890 1390 1900 640 890 1390 1900
Weight kg 2100 2300 2600 2900 2200 2500 2700 3000
Overall dimensions of the machine LxWxH (full protection) i series e s 2535 X 1600 X 1650 2785 X 1600X 1650 3285X1600X 1650 3785X 1600X 1650 2535X 1600X 1650 2785X1600X1650 3285X1600X1650 Г 3785X 1600X 1650
LxWxH (semi protection) j series E S 2385 X 1600X 1650 2630X 1600X 1650 313OX 1600X 1650 3630 X 1600X 1650 2385X1600X 1650 2630X 1600X 1650 3130X 1600X 1650 3630X1600X1650
SHENYANG MACHINE TOOL CO., LTD
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САК50/САК61 SERIES
SPECIFICATIONS OF THE MACHINE
4.3 Torque Vs Power Drawing of Spindle (Frequency-changing)
4.3.1 Manual Speed Change
330 3300
Speed drawing of stepless speed-spindle
Characteristic of spindle torque (power)
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САК50/САК61 SERIES
CONSTRUCTION OF THE MACHINE
5 CONSTRUCTION OF THE MACHINE
5.1 Layout of the Machine
Refer to Fig. 2, please.
Headstock Turret Safeguard Carriage Tailstock
Fig. 2 Layout of the machine
5.2 Brief Introduction to Farts of Machine
5.2.1 Headstock
• Common (refer to Fig. 3-1).
The main driving system separately engages the two electromagnetic clutches on
Shaft I to make the gears 2, 3 engaging when the electromagnetic clutches on the
left is sucked on and when the electromagnetic clutches on the right is sucked on,
gearl engages with 4. If through the speed-changing lever of spindle (see Fig. 4) to
make the gears 9, 10 engaging, spindle is under high-speed status. If by means of
the changing lever to make gear 5 engages wifti 6, 7 engages with 8. 11 engages
with 12 first and through the sliding gear 13 on Shaft V engaging with big gear of
the spindle 14, the transmission of the spindle is low-speed state, and the spindle
van obtain low speed.
The machine is of 12-step stepless changing speed. The driving calculations of
various revolution speeds of each step are calculated as follows:
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21
САК50/САК61 SERIES
CONSTRUCTION OF THE MACHINE
116 49 24 34 29 ,л , .
a: 1460 x x — x — x — x — =40 r/min 230 71 78 58 69
b: 116 59 24 34 29 , . 1460 x x x x x =56 r/min 230 61 78 58 69 116 49 24 34 29 .
C: 2880 x x x — x x 80 r/min 230 71 78 58 69
d: ooon 116 59 24 34 29 11O , . 2880 x x — x — x — x — =112 r/min 230 61 78 58 69 ,л^ 116 49 57 34 29 л , .
e: 1460 x x — x — x — x — = 170 r/min 230 71 44 58 69
f: 116 59 57 34 29 , . 1460 x x — x — x — x — =z,36 r/min 230 61 44 58 69 116 49 57 34 29 w , .
g: 2880 x x — x — x — x — =335 r/min 230 71 44 58 69
h: noon 116 59 57 34 29 лпс . . 2880 x x — x — x — x — =475 r/min 230 61 44 58 69
i: I/irn 116 49 63 , . 1460 x x — x — =640 r/min 230 71 50
к : 1460 x---x — x — =900 r/min
230 61 50
। noon 49 63 .
1 : 2880 x---x — x — = 1320 r/min
230 71 50
noon 116 59 63 .
m: 2880 x----x — x—=1800r/min
230 61 50
• Manual freq-conversion (Refer to Fig. 3-4)
The main driving system separately engages with gear 1 on Shaft I and with gear 2
on Shaft III, then through the speed-changing lever of spindle (Fig. 4) to make gear
7 and spindle gear 8 engaging, spindle is under high-speed state, thus, high speed
can be obtained. If by means of the changing lever to make gear 5 engage with 6,
and gear 9 engage with gear 10, and through the sliding gear 11 on Shaft V
engaging with big gear 12 of spindle, the spindle is of middle speed chain, thus
middle speed can be obtained. If through the changing lever to make gears 3
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22
САК50/САК61 SERIES
CONSTRUCTION OF THE MACHINE
engage with 4, and gear 9 engage with 10, and through the sliding gear 1 Ion Shaft
V engaging with big gear 12 of spindle, the spindle is low speed chain, thus, low
speed can be obtained.
• Power-driven freq.-conversion (See Fig.3-2)
Main transmission is transmitted from the gear 1 on Shaft 1 to the gear 3 on Shaft III and
to gear 6 on shaft VI through the gear 5, this transmitting chain is high speed.
Main transmission is transmitted from the gear 2 on Shaft I to the gear 4 on Shaft III and
to the gear 6 on Shaft VI through the gear 5, and this transmitting chain is middle speed.
Main transmission is transmitted from the gear 2 on Shaft I to the gear 4 on Shaft III and
to the gear 8 on shaft VI through the gear 7, and this transmitting chain is low speed.
The driving calculations of various revolution speeds of each step are calculated as
follows:
115 56 47 „„„„ , .
a: jjOOx-----x — x — =2200 r/mm
230 52 38
, пплл 115 28 47 .
b: jjOOx-----x — x-—=714r/min
230 80 38
c: 3300 x----x — x — =243 r/min
230 80 69
• Hydraulic freq.-conversion (See Fig.3-5)
Main transmission is transmitted from the gear I on Shaft I to the gear 3 on Shaft III and
to the gear 6 on Shaft VI through the gear 5, and this transmitting chain is high speed.
Main transmission is transmitted from the gear 2 on Shaft I to the gear 4 on Shaft III and
to the gear 6 on Shaft VI through the gear 5, and this transmitting chain is middle speed.
Main transmission is transmitted from the gear 2 on Shaft I to the gear 4 on Shaft HI and
to the gear 8 on shaft VI through the gear 7, and this transmitting chain is low speed.
The driving calculations of various revolution speeds of each step are calculated as follows:
a: 2880 x 130 X 230 56 47 — x — 52 38 =2165 r/min
b: 2880 x 130 X 230 28 47 80X 38 =700 r/min
C: 2880 x 130 X 230 28 29 80X69 =235 r/min
SHENYANG MACHINE TOOL CO., LTD
23
SHENYANG MACHINE TOOL CO., LTD
40X80X 18; 208
1 (m2. 25, 249)
6 (m2.5,2.78,0.2)
5 (m2.5,224,0.2)
9(m3, Z63)
2 (m2.25,259)
4-40X68X15; 108
__________Ф 230
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A02 6314TH 85
120W 1500r/rain
TO132M 4/2
(double-speed
8 (m2.5, 244, 0.2)
Servo motor 1FK7060
20X52X46;ZARN2052TN
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'35X80X21; 36307
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6.-5/8KW
1460/288'Or/tnin c
Servo motor
6 8is/3000i(L-640,890) I
3 12 i s/2000i (1^1390, 1900)
HC102-A47(L^64C\ 890)
HC1.52-A47 (1390; 1900)
) 1FK7O6O(64Q, 890)
1FK7063(1390,1900)
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25X52X15; 205
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2-35X72.X 17;D207
Fig. 3-1 Drawing of main transmission of manual changing step (Bj, Dj, Gj)
CAK50/CAK61 SERIES CONSTRUCTION OF THE MACHINE
SHENYANG MACHINE TOOL CO., LTD
40X80X 18:208
2 (m2. 5, Z28)
1 (m2.5, Z56)
6(m4, Z38,0.166)
6 (m2, Z89)
5(m2, Z52)
35X62X 14;E107
40X68X 15; E108
20X52X46;ZARN2052TiN
5(m4Z47, 0. 2)
25X47X15;8205
2-70X90X10; 1000814.
Ф130
120W 1500г7ш1п
А02 6314ТН В5
40X80X18:4620.8
Servo motor 130ACM07730H
Servomotor ₽8is/30001
Servo motor HC52-A47
Servo motor 1FK7.060
. 2-20X42 X12 ;E104
35X72X 17:3620.7
7 (m3. 5,Z29,) ~0. 078)
ip.i
1:01
3(m2. 5, Z52, -0.16)
35X80X21; 46307 IH
2X95X 145X24;D4611-9f
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Ф230
2-55X90X 18:111
40X90X23:308
4 (m2.5, Z80, -0.16)
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... HC102~A47(L-640,890)
2-35X72X17:0207
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motor)
Servo motor
7 5/11KW 8is/30.00i (L-640,890)
©
0
о
c
25X52X15:205
HC152-A47(L-1390,1900)
1FK7060(640,890)
130ACM07730H (640,890)
130ACM10025H(1390,1900)
g oioiioi
2-35X62X 18'08207
Fig. 3-2 Drawing of main transmission of power changing step
Гг28Х5,9 left
110X170 X 45 ;P3Q2»R
FFZD40X6T-3
CAK50/CAK61 SERIES CONSTRUCTION OF THE MACHINE
SHENYANG MACHINE TOOL CO., LTD
40X80X 18:208
1 (m2.25, Z49)__
2(ш2.25, Z59)
4-40 X 68 X 15; 108
6(ш2, 5, Z78, 0.2)
5 (m2.5, Z24, 0.2)
9 (m3, Z63)______
7 (m2. 5, Z57,0.1)
8(ш2.5, Z44,0. 2)
Servo motor
13QST-M05025H
130АСМ06025Н
to
Ch
.. Ф 230
2-55X90X 18:111
40X90X23:308
30Х62Х 16;Е36206
4 (m2. 25, Z71, -Q. 16)
3(ш2. 25,^61,-0.16)
35X80X21; 46307
35Х72Х 17;Е207
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2-95 X 145X24; 046119 Г~
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2-70х90Х10;1000814 Q
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120W 1500r/min
Л02 6314TH B5
130ACM0773GH
20 X 52X46 ;ZARN2052TN
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35X80X21; 36307'
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11 (m2.75, Z34, -0. 182)
14 (m4, Z69)
6. 5/8KW 146Q/2880r/min
Serv.o motor
L1L20X4-3,5-D left
25X52X15:205
| | О О IOIIOI
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30Х62Х16;Е36Ж
110X170X45;W022MBKR
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YD132M
4/2 (double-speed
motor)
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1308Т-М07720НШ0,890)
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130АСМ10025Н(640,890)
130АСМ07730Н.(640,890)
130АСМ10025Н(1390,1900)
2-35X72X 17;D207
Drawing of main transmission of manual changing step (Nj, Tj, Pj)
СAK5O/CAK61 SERIES CONSTRUCTION OF THE MACHINE
SHENYANG MACHINE TOOL CO., LTD
40X8M;208
Ф214
2-55X90X18;Elll
40X90X23;E308
30X62X16;E36206
2(m2.25r261. И.16)
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CAK50/CAK61 SERIES CONSTRUCTION OF THE MACHINE
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20 X 52 X 46; ZARN2.052TN
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Fig. 3-4 Drawing of main transmission of manual changing step
Тг28Х5,9 left
SHENYANG MACHINE TOOL CO., LTD
40X80X18;208
.ШШ1__
1 (1112.5,256, f -0.143)
Ф230..................
2-55X90X 18;Elll
40X90X23;®
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7.50 2880r/iuin
Ф130
120W 1500r/aiin
A02 6314TH B5
Servo motor оC6/2000
Servo motor P 6/2000
(1=890,640,1390)
б O 1OIIOI
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25X52X 15:205
FFZD40X6T-3E3
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2-35X72X 17:0207
Fig. 3-5 Drawing of main transmission (hydraulic changing step)
CAK50/CAK61 SERIES CONSTRUCTION OF THE MACHINE
СЛК50/САК61 SERBS
CONSTRUCTION OF THE MACHINE
Speed-changing
Handle for
Handle for
Lever for locking
Fig. 4 Control handles of machine
5.2.2 Chuck
Standaid chuck of this machine is manual chuck, and we can offer hydraulic chuck and
electric chuck according to the requirements from the user.
Hydraulic chuck is connected with rotary oil-cylinder by link rod, the piston inside
hydraulic cylinder moves to the direction of chuck and to make the jaws of the chuck
release through the wedge type structure, and the jaws will close when the piston returns
back. The rotary oil-cylinder consists of cylinder body, single-way valve and rotary
conjunction. The single-way valve will keep the constant pressure inside the cylinder
when the oil pressure goes down unusually because of the trouble of pressure resource.
The structure of the jaws must suit the shape of the workpiece to be chucked. Some
limitations and matters needing attention were specified for ensuring the safety, high
accuracy and serving life of the chuck, therefore, it is necessary to operate according to
the specifications in "Operation Manual of Chuck”.
For working principle and matters needing attention to power chuck, please refer to
Operation Manual for power chuck.
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САК50/САК61 SERIES
CONSTRUCTION OF THE MACHINE
5.2.3 X-axis and Z-axis
The carriage is driven to move along Z direction by Z-axis motor through ball screw rod,
the turret on the carriage is driven to move along X direction of the carriage by X-axis
motor through ball screw rod.
Principle of zero point reset: the machine of this series can be equipped with absolute
encoder and incremental encoder according to different control system provided.
5.2.3.1 Zero-Return for the Machine with Absolute Encoder
Within the moving area of carriage, there is a reference position called zero point of the
machine. The coordinate system of the machine set by NC device takes this zero point
as a reference point to realize the control of carriage motion. The two axes of the
machine have adopted the absolute encoders which possess memory function for the
servo system, and before the delivery of the machine, reference-point return has been
carried out and the mechanical coordinate system has been established, therefore, when <
power off, the set coordinate system will be kept and memorized by the encoder.
Hereby, it is not necessary for the user to do reference-point return every time after
power on while operating the machine. Even if the system doesn’t alarm white the
reference-point is lost due to the energy loss of the battery or the reference-point
position of the machine has been changed due to the relative-position change of
servo-motor axis (X-axis and Z-axis) to the leadscrew (X-axis and Z-axis) while
maintaining, it is still necessary to reset the reference point. For the specific method of
reference-point setting, please refer to «Instruction Book of Electric Unit» .
5.2.3.2 Zero-return for the Machine with Incremental Encoder
Within the moving area of carriage, there is a reference position called zero point of the
machine (usually named as reference point). The coordinate system of the machine set
by NC device takes this zero point as a reference point to realize the control of carriage
motion. While the NC device is powered on, the zero point of the machine may change,
so it is necessary to carry out the zero-point return before the auto operation. For the
specific operation, please refer to «Instruction Book of Electric Unit» .
5.2.4 Turret
The turret of the machine is series SLD150A vertical turret which is designed by our
factory.
It doesn't need to be lifted. It adopts inner type cooling.
And the turret is up for indexing, the time for indexing is very short and positioning is
very accurate, available with both 4-station and 6-station. For details of operation and
04
maintenance, please refer to INSTRUCTION BOOK for SLD150A—
06
According to the user’s requirement, horizontal 6-station turret can be provided also.
SHENYANG MACHINE TOOL CO., LTD
30
САК5О/САК61 SERIES
CONSTRUCTION OF THE MACHINE
5.2.5 Tailstock
The machine can be provided with three types of tailstock, i.e. manual tailstock,
hydraulic tailstock and pneumatic tailstock.
The manual tailstock is the same as the one used for the universal lathes, it is locked to
the bed by the principle of eccentricity, and by help of turning handwheel by hand to
make the leadscrew drive the tailstock can obtain tailstock spindle advancing and
backing.
Advancing and backing of the hydraulic tailstock and pneumatic tailstock are realized
according to the hydraulic principle and pneumatic principle. The limit switch used by
the tailstock base body can prevent the carriage from bumping with the tailstock.
5.2.6 Hydraulic System
5.2.6.1 Hydraulic Chuck and Tailstock
The machine can be provided with hydraulic chuck with changeable-clamping-force
and hydraulic tailstock to increase automation of the machine. The hydraulic tank is set
on the side of the headstock, and all hydraulic elements are produced by Taiwan
Northman Company. The hydraulic control valves with overlad type are mounted in
front of the oil tank, having compact in structure and convenient for installation.
• Major specifications of hydraulic system
Hydraulic motor: Y90L-4 (B5) 1.5 kW 1450 r/min
Hydraulic pump: VPVC-F-20-A-2-02
Rated pressure: 1.5~3.5 Mpa
Delivery flow: 11.1 ml/r
Volume of oil tank: 90 L
Pressure of hydraulic system: 2.5 MPa
Overall dimension of oil tank: 600 mm X 460 mm X 800 mm
For hydraulic transmission principle, please refer to Fig. 5: Drawing of hydraulic
principle.
Hydraulic system of the machine is divided into two kinds: one is hydraulic chuck
with changeable-clamping-force and hydraulic tailstock, and the other is hydraulic
chuck with unchange-clamping-force and hydraulic tailstock. Users can select any
of them according to their own requirements. For the machine without hydraulic
tailstock, all other parts are the same with the machine that has the hydraulic
tailstock, except the overlad return of tailstock that should be got rid of
accordingly.
♦ Oil resource
The hydraulic system adopts VP VC variable blade pump made by Taiwan
SHENYANG MACHINE TOOL CO., LTD
31
САК50/САК61 SERIES
CONSTRUCTION OF THE MACHINE
Northman. This kind of pump is characterized by low noise, stable performance,
rated draining flow of ll.Iml/r, rated pressure 7 MPa, the working pressure of
1.5~3.5 Mpa, and its real flow quantity can be adjusted according to the speed of
chuck movement.
♦ Return for Chuck with Changeable-clamping-force (refer to Fig.5, Diagram of
hydraulic principle)
During the machining, according to different conditions, we have designed chucks for
internal clamping and external clamping. It is needed to change the clamping force
during the machining some special parts, so we have designed hydraulic chuck with
changeable-clamping-force.
On the return of hydraulic system there is a high pressure clamping and a low
pressure clamping, and they are separately controlled by pressure relays SP1 and SP2.
WhenYVl (electrification) andYV5, it’s high pressure clamping. SP2 sends out a '
signal. At this time SP1 has the same pressure as that of the system and the adjusting
pressure is 2.0~2.5Mpa.
WhenYVl (electrification) andYV6, it is low pressure clamping. SP2 sends out a
signal. At this time the adjusting pressure of SP2 is the same as that of pressure-relief
valve, and the adjusting range is 0.4~0.8Mpa.
Description for adjustment of MEPS superimposed electro pressure relay
1. Clockwise adjust the potentiometer for return difference to minimum (in fact, adjust
the return difference to zero).
2. Adjust the pressure to P (1-8), in general, take 8 =5%. P is a working pressure, P
(1-8) is an alarm pressure; the alarm pressure takes 3.8 kgf/cm when P = 4 kgf/
2 ,
cm ).
3. Adjust the upper-limitation potentiometer to make the indicating light just lighting
on (in fact that the upper-limitation potentiometer is regulated at alarm pressure P
(1-8).
4. Turn the potentiometer of return difference by 4-5 turns counter-clockwise (in fact
that the return difference should be regulated more than 5%, at this time, the
indicating light is still lighting on).
5. Adjust the pressure to P (in this time, the indicator still lights on).
6. Adjust the potentiometer of return difference slowly and clockwise to make the
indicating light just goes out (in fact, adjust the surplus to 5%).
7. If working pressure is needed to rise, it is necessary to readjust it according to the
regulations given by steps 1-6.
When YV2, YV5 are electrified, the chuck is released.
After the workpiece is clamped, the pressure relay PS~~70 sends signal for clamping
ready. During machining, if the pressure goes down due to the troubles of the system.
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32
САК50/САК61 SERIES
CONSTRUCTION OF THE MACHINE
SP 1 and SP2 will alarm and the machine will stop.
♦ Tailstock Return
The tailstock return consists of relief valve, two-way and single-way throttles,
electromagnetic reversing valve and pressure relay. The relief valve MPR—02A is
used to adjust the withstanding pressure of tailstock, the adjusting range of pressure is
1.0 —2.0Mpa and the tightening speed is adjusted by MT — 02W. With the
electromagnet YV3with electricity, the tailstock is withstood, as the electromagnet
YV3 electrified, the tailstock will be withstanding and with electromagnet YV4
electrified, the tailstock will withdraw.
The pressure relay PS —70 (SP3) will send out ready signal of tightening. During
machining, if the pressure goes down due to troubles of the system, SP3 will alarm
and the machine will stop. If the machine is without hydraulic tailstock, the return
will not be available.
• Maintenance of the hydraulic system
1) It is necessary to apply YA-HL46 hydraulic oil or the hydraulic system, and the oil
shall be changed according to the using status regularly.
2) It is necessary to check the oil level in the oil tank often, and if the oil level is
lower than the lowest level, add oil in time.
3) It is necessary to add oil to the oil tank through the air filter.
4) The oil-suction filter shall be checked and changed periodically.
5) If there is abnormal noise or vibration from the hydraulic system, check and
maintenance must be carried out immediately.
• Adjusting value of hydraulic system parameter
Name Adjusted Element Adjusted Value
System pressure Pump VPVC-F-20-A-2-02 2.0MPa (2.0—2.5MPa)
Pressure of chuck clamping Relief valve MPR-02A-K-0-20 l.5MPa (1.2—2.5MPa)
Clamping signal Pressure relay PS-70 (SP1 ) ( SP2 ) Same as the pressure of relief valve of the chuck
Withstanding pressure of the tailstock Relief valve MPR-02A-K-0-20 1.2MPa (1.0—2.0MPa)
Withstanding signal Pressure relay PS—70 (SP3) Same as the relief valve of the tailstock
Chuck speed Max. flow of the pump Depending on requirement
Tailstock speed Throttle MJ-02W-K—20 Depending on requirement
Note:The value in the ( ) is the adjustment range which depends on the state of the
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CONSTRUCTION OF THE MACHINE
workpieces to be cut.
• List of hydraulic elements
Name Type Qty- Manufacturer
Hydraulic pump VPVC-F-20-A-20-02 1
Single-way valve CI—T—03—05 — 10 1 Taiwan Northman or Janus of Taiwan /
Single-way valve MC-02P-05-20 I
Relief valve MPR-02A-K-0-20 2
Restrictor MT-02W-K-20 1
Electromagnetic reversing valve S WH - G02 - D2 - D24 - 20 2
Pressure relay PS-70 1
Air filter AB-1163 I
Pressure gauge Y—60—Z type III 3
Pressure relay MPS-02P-1-10 1 Taiwan Northman Company
• Hydraulic system of hydraulic chuck with unchanged-clamping-force and hydraulic
tailstock
When the machine is provided with the hydraulic chuck with unchanged pressure
according to the user’s requirement, please refer to Fig 6 Principle diagram of
hydraulic system.
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CONSTRUCTION OF THE MACHINE
SWH-G02-D2-D24-20 SWH-G02-D2-D24-20 SWH-G02-D2-D24-20
Fig. 5 Principle diagram of hydraulic system
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SHENYANG MACHINE TOOL CO., LTD
Fig.6 Principle diagram of hydralic system
С AK50/C AK61 SERIES CONSTRUCTION OF THE MACHINE
САК50/САК61 SERIES
CONSTRUCTION OF THE MACHINE
This machine can be provided with two kinds of hydraulic system for user to select: One
is to have hydraulic chuck and hydraulic tailstock, and the other one is only to have
hydraulic chuck. For the machine without hydraulic tailstock, the overlad return of
tailstock has been removed, and all the other parts are remained the same.
This section only explains the circuit and principle of the hydraulic chuck, and all the
other parts are the same as the description above.
♦ Chuck return
The chuck return consists of single-way valve, relief valve, electromagnetic reversing
valve and pressure relay. Single-way valve MC—02P prevents interference of
clamping return with the other returns, relief valve MPR—02A is used to adjust
clamping pressure of the chuck and the adjusting range of the clamping force is 1.2—
2.5 Mpa according to the need of the workpiece to be turned. When the electromagnet
YVlis electrifying, the chuck will clamp, when the electromagnet YV2 is electrifying,
the chuck will release.
After the workpiece is clamped, the pressure relay PS—70 (SP1) sends out a ready
signal, during machining if the pressure goes down due to system’s trouble, SP1 will
send out an alarm signal, the machine stops.
5.2.6.2 Hydraulic-spindle Change Speed and Hydraulic Chuck
The machine employs hydraulic-spindle change speed to improve the automation of the
machine, besides, the machine is provided with hydraulic chuck. The hydraulic oil tank
is located on the side of the headstock, and all the hydraulic control components are
from Taiwan Janus Co. The hydraulic control valves are mounted in the front of the oil
tank under overlad-mode, which provided the machine with compact construction and
convenient installation.
• The major parameters of the hydraulic system
Hydraulic motor: Y90L-4 (B5), 1.5kW, 1450r/min
Hydraulic pump: VP-20-F-A2
Adjusting range of pressure: 1.5-3.6Mpa
Max. flow capacity: 11.1 ml/r
Volume of oil tank: 90L
Pressure of hydraulic system: 2.5Mpa
Overall dimensions of oil tank: 600 mm X 460 mm X 800mm
• Oil resource
The hydraulic system adopts VP variable vane-type pump made by Taiwan Janus
Co., and the noise of this kind of pump is low and the performance stable. Its rate
delivery capacity is 11.1 ml/r and actual flow of the pump can be adjusted
according to the speed of chuck movement. There is a pressure adjusting
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САК50/САК61 SERIES
CONSTRUCTION OF THE MACHINE
mechanism inside the pump and the working pressure of the pump is of 1.5-3.5
Mpa.
In order to ensure cleanness of hydraulic oil of the hydraulic system, WU-63 X
80-J oil filter for sucking oil is mounted on the oil sucking mouth of the oil pump
for preventing dirt or foreign substance from entering to prolong the serving life of
the pump and decrease troubles. The air-filter mounted on the oil tank is used for
keeping air-flowing in the oil tank and preventing foreign substance in air outside
the tank from entering, also it is used for filling oil. The dis-assembly filtering net
can be cleaned and changed conveniently.
• Hydraulic return (Refer to Fig. 6-1 the Principle Diagram of Hydraulic System)
♦ Chuck return
The chuck return consists of single-way valve, relief valve, pressure relay and
electromagnetic reversing valve. The single-way valve CYP-02-A prevents
interference of clamping return with the other returns. The relief valve
BRVP-02-L-A is used to adjust clamping pressure of the chuck according to the
required clamping force of workpiece to be turned, in general, the adjusting range
of the clamping force is of 1.2-2.5Mpa. When the electromagnet YV1 is
electrifying, the chuck will clamp, the electromagnet YV2 is electrifying, the chuck
will release.
After the workpiece is clamped, the pressure relay MJCS-02-P-L-L (SP1) sends out
a ready signal, during machining if the pressure gets down due to reason of
system’s trouble, SP1 will send an alarm signal, and the machine will stop.
♦ Return of hydraulic speed-change
The return of hydraulic speed-change of spindle mainly consists of throttle valve,
relief valve, spill valve and electromagnetic reversing valve. The relief valve
BRVP-02-L-A is used to adjust pressure of three oil cylinders. The spill valve
RVA-02-L-B keeps certain back pressure in chamber of oil cylinder AO separately
for preventing mis-action. The throttle valves TVCW-02-L-X, TVCA-02-L-X and
TVCW-02-L-Y can adjust flowing quantity of the hydraulic oil cylinder to realize
speed control, and also they can decrease hydraulic impulse. Combining action of
the magnetic reversing valves D5-02-3C4-D2 and D5-02-2N2-D2 can realize
different actions of the hydraulic oil cylinder to make spindle obtain automatic
change speed of 4 steps of idling step, low speed, middle speed and high speed to
increase automation of the machine.
♦ List of Hydraulic Components of the Machine
Name Type Qty- Manufacturer
Hydraulic pump VP-20-F-A2 1 Taiwan Janus Co.
Single-way valve CIT-03-A1 1 Taiwan Janus Co.
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CONSTRUCTION OF THE MACHINE
Name Type Qty- Manufacturer
Overlay single-way valve CVP-02-A 1 Taiwan Janus Co.
Overlay relief valves BRVP-02-L-A 4 Taiwan Janus Co.
Overlay throttle valve TVCW-02-L-X 1 Taiwan Janus Co.
Overlay throttle valve TVCA-02-L-X 1 Taiwan Janus Co.
Overlay throttle valve TVCW-02-L-Y 1 Taiwan Janus Co.
Electromagnetic reversing valve D5-02-3C2-D2 1 Taiwan Janus Co.
Electromagnetic reversing valve D5-02-3C4-D2 1 Taiwan Janus Co.
Electromagnetic reversing valve D5-02-2N2-D2 1 Taiwan Janus Co.
Pressure relay MJCS-02-P-L-L 1 Taiwan Janus Co.
Overlay spill valve RVA-02-L-B 1 Taiwan Janus Co.
Air-fi Iter HS-1163 1 Taiwan Janus Co.
Pressure meters I-21/2-35-PTl/4-MPa 4 Taiwan Janus Co.
Pressure meter I-21/2-50-PTl/4-MPa 1 Taiwan Janus Co.
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САК50/САК61 SERIES CONSTRUCTION OF THE MACHINE
Table of Action Order of Elec tromagnet
^^^^._Electromagnet Change speecl'^^ YV11 YV12 YV13 YVI4
M40 (Idling) - - -
M41(Low) - +
M42 (Middle) - + + -
M42 (High) + - + —
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CONSTRUCTION OF THE MACHINE
• Adjusting value of parameters of hydraulic system
Name Adjusted Element Adjusted Value
Pressure of system Pump VP-20-F-A2 2.0Mpa (2.0~2.5MPa)
Clamping pressure of chuck Pressure-relief valve BRVP-02-L-A 1.5Mpa (1.2-2.5MPa)
Clamping signal Pressure relay MJCS-02-P-L-L (SP1) The same as the pressure of pressure-relief valve of chuck
Pressure of change speed Pressure-relief valve BRVP-O2-L-A(P1, P3) Depending on requirement
Pressure of change speed Relief valve BRVP-02-L-A (P2)
Chuck speed Max. flow of pump
Speed of change speed Throttle valve TVCW-02-L-X
Speed of change speed Throttle valve TVCA-02-L-X
Speed of change speed Throttle valve TVCW-02-L-Y
Note: The items in the ( ) of column Adjusted Value shall be determined according to
the status of the workpiece to be turned.
• Maintenance of hydraulic system
♦ It is necessary to apply YA-N46 hydraulic oil for hydraulic system, and the
hydraulic shall be changed according to the using status regularly.
♦ Check the oil level in the oil tank, and add it when it’s lower than the lowest oil
level.
♦ When adding the oil into the oil tank, the oil must go through the air filter.
♦ Check and change the oil suction filter inside the oil tank periodically.
♦ If there is abnormal noise or vibration from the hydraulic system, inspection and
maintenance must be done at once.
5.2.7 Pneumatic System
5.2.7.1 Pneumatic Tailstock
(Refer to Fig 7: Principle diagram of pneumatic tailstock, Fig. 8 and Fig.9: Assembly
drawings)
• Instruction of operating the pneumatic system
The pneumatic tailstock is composed by triple-assy XFRU403 of air resource,
manual valve XQ340661, single-way throttle valve 77101013 and deafener
XQ140600. The air resource triple-assy XFRU403 is mounted on the rear leg of the
machine, and all the others are all mounted on the tailstock.
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CONSTRUCTION OF THE MACHINE
The air resource triple-assy XFRU403 is composed by filter, pressure release, oil
atomizing as shown by A, B> C in the assembly drawing.
A- Adjusting screw is used to adjust the oil amount
B- Filling aperture bolt. When oiling, cut off the air source first, then screw off the B, after
oil adding, tighten the B, and ensure the seal.
C- For handwheel of pressure adjustment, normal stepless adjusting range is of
0.1-0.6. When adjusting the pressure, first, push the C upward vertically to the required
pressure, then press down it directly to lock the handwheel C in order to keep the
pressure stable. Manual reversing valve P is connected with air source triple-assy,
chamber A is connected with the inlet hole of single-way throttle, chamber В
connected with the small control cave of the cylinder, and R is connected with the
deafener.
Compressed air comes into the manual reversing valve through the triple-assy, then goes
into the single-way throttle through chamber A to push the cylinder tightening the
workpiece slowly, and the tightening speed is adjusted by the single-way throttle. The air
in the small cylinder goes into the deafener through the manual reversing valve, then
exhausted out.
When the position of the manual reversing valve is changed over, the air comes into the
small cave of the cylinder through the manual valve Chamber B, the cylinder moves to the
right quickly to release the tailstock.
The air in the big chamber comes into the manual reversing valve through the single-way
valve of the single-way throttle, and exhausted out through the deafener to finish the
action of tightening and releasing.
• Matters needing attention
The oil used for oil atomizer (the air-source element) must be very clean and be added
in time.
The convenience of adding oil should be considered when fitting the pipe.
The oil shouldn’t be filled too much, and otherwise, the effect of air pressure will be
lost.
The nylon pipe without burr should be inserted into the rabbet and put it to the end to
reach the requirement of connection and seal.
When the air pipe is removed, press in the connecting clip set with the thumb, and then
push out the air pipe slightly.
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CONSTRUCTION OF THE MACHINE
Tailstock tightening
77101013
XFRU403
Fig. 7 Principle diagram of pneumatic tailstock
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CONSTRUCTION OF THE MACHINE
Notes: 1. Manual conversing valve is installed on the tailstock, P is the inlet hole, R is for air
exhaust, Chamber A is connected with inlet hole of single-way throttle and Chamber
В will be directly screwed into the cylinder.
2. Single-way throttle 77101013 is pipe-type throttle to adjust the tightening speed of the
tailstock, and when the tailstock is withdrawing, the single-way valve will be opened
by the air, withdrawing the cylinder rapidly.
Fig. 8 Assembly drawing I of pneumatic tailstock
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T"
CTO
sO
r-<
С/Г
Note: The air source triple connector is mounted on the rear leg of the bed, the functions of A,B,Cof the element are as follow:
A - Adjusting screw, it is used to adjust the oil quantity.
В Oil hole screw. When oiling, cut off the air source first, then screw off the B, after oil adding, screw on the B, and ensure the seal.
C Handwheel of pressure adjustment. When adjusting the pressure, first push the C upward vertically to the needed pressure, then press
down it vertically to lock the handwheel C in order to keep the pressure stable.
CAK50/CAK61 SERIES CONSTRUCTION OF THE MACHINE
САК50/САК61 SERIES
CONSTRUCTION OF THE MACHINE
5.2.7.2 Pneumatic Chuck
5.2.7.2.1 Composition of Pneumatic System
The pneumatic system of the machine consists of air resource, triple-assy
FRC-1/4-D/MINI-KB-A (FESTO) of air resource, electromagnetic conversing valve
JMFH-5-1/4-B/24VDC (FESTO), etc. the pneumatic clamping action of the
pneumatic can be realized by the system. For the working principle of pneumatic
system, refer to Fig. 10, please.
Pneumatic chuck
Fig. 10 Diagram of pneumatic principle
5.2.7.2.1.1 Air Source
The function of the air resource of the machine: the air source shall be supplied by
the user, and the pressure of the air source shall not be less than 0.8Mpa. By means
of the pressure gauge, the system pressure can be observed, and the system
pressure can be adjusted by spill valve on the triple-connector of air resource.
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САК50/САК61 SERIES
CONSTRUCTION OF THE MACHINE
Whenever the system pressure is lower than 0.7Mpa, the pressure relay will send
signal.
5.2.7.2.1.2 Pneumatic Chuck
The machine employs pneumatic chuck, and when the electromagnet YV1 of the
electromagnetic conversing valve is electrifying, the chuck will clamp. When the
electromagnet YV2 of the electromagnetic conversing valve is electrifying, the
chuck will release. The clamping pressure of pneumatic chuck is determined by
the system pressure.
5.2.7.2.2 Operation and Maintenance of Pneumatic System
5.2.7.2.2.1 Element Installation
It is necessary to install the triple-connector of air resource vertically, and the
installation shall be carried out according to the direction shown by the arrow on
the bracket: let the compressed air enter into the filter, pressure-adjust section and
oil atomizer in turn.
5.2.7.2.2.2 Pressure Adjustment
Before switch on the air, it is necessary counter-clockwise to turn the handle of
triple-connector until the pressure-adjust spring is under the free status. Then turn
on the inlet valve on the pipeline to let air in, turn pressure-adjust handle clockwise
until the reading on the pressure gauge is up to the required.
5.2.7.2.2.3 Adjustment of Oil Drop
The required oil-drop amount can be obtained through adjusting the needle-type
valve of the triple-connector.
5.2.7.2.2.4 Maintenance
Connect the drainpipe under the filter into the specified container. And clean the
filtering net, the water cup and the oil cup according the practical working
condition.
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CAK5Q/CAK61 SEMES
CONSTRUCT»» OF THE MACHINE
5.2.8 Lubricating System
Refer to Fig. 11 and Fig. HA, please.
HL46
15
fHL46i
^”50“'-
grease (mge once a year)
OILWINDOW
ZZE
OIL ИВА
OILPAN
4HL46V-
ШШШМ CBRT
- ADD ANS® OIL PERIODICALLY
А1ЙШИЛ
,HL4^~ OIL NO.
OILNO./LUBRICATING INTERVALS (№S)
Fig. 11 Lubrication chart
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CONSTRUCTION OF THE MACHINE
ИМИ (Ж
--------------------ADD AND CHANGE OIL PERIODICALLY------------
--------------------ADD.OILOH:A W -----------------------------
------------- NO. 3 LI-BASED GR»(®NGE WHEN MAINTENANCE) ---
---------- СИ (СИСИН А YEAR)-------------
ПП.
(HH6 I------OIL NO. _ — да. 3 ы-в grease
। — H—OIL NO./LUBRICATING INTERVALS (DAYS) □ ___________________g®E
Fig. HA Lubrication chart
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OPERATION AND SAFEGUARD OF THE MACHINE
6 OPERATION AND SAFEGUARD OF THE MACHINE
6.1 Use of the Machine
For the starting and operating program, stop program, operating method, matters needing
attention to operation, fault operation occurring often, the countermeasures, etc. of the
machine during the period of machine running, please refer to the Instruction Book for
Electric Unit of the machine.
6.2 Safe Guard
♦ Full-close guard
The machine is provided with full-close shroud by means of protection cover, and a
series of safe guard measures have been taken into consideration. Only after the
protection doors are well closed, the machine can be started. During the operation of
the machine, the protection doors lock automatically. If the doors are opened, the
spindle stops ad the coolant off. In addition, the strengthened glass of the protection
doors can guarantee the safety of equipments and the personnel.
♦ Imported steel-band is applied to X-axis for protection, and telescoping protection
cover to Z-axis for protection. And with the slanting-back design, it is convenient for
chip removal and coolant collection.
♦ X-axis and Z-axis are separately provided with overtravel limit switches. If the limit
switches are pressed through the movement of carriage along a certain direction due
to some reason (fault operation, error of data input, servo troubles, etc.), the CNC
system will enter into the status of emergency stop immediately, alarming to stop the
movement of the carriage.
♦ Because the coolant device is provided with multi-layer filtration to make the
coolant be purified sufficiently, the return passage of coolant cannot be blocked.
♦ The electric design of the machine is in accordance with the Electric Standard
GB5226.1. Power circuits of the machine are all provided with protection for
over-current and short circuit. In addition, to guarantee the safety of the equipments
and personnel, the relative actions of the machine are all provided with interlock.
♦ The electric system of the machine possess the function of self-diagnosis, therefore,
the operator and the maintainer can observe the running status of each part of the
machine at any time through the indicating light and the display.
♦ Electric cabinet
The standard electric cabinet adapts full-close protection and air-conditioner for heat
emission, and within the electric cabinet, a certain space is left for function
expanding.
♦ The protection while power off resulted in by accident or self-troubles of the
machine occur.
While the power-off by accident or self-troubles of the machine occur, the movable
feed-shafts, the coolant motor, etc. under the “starting” status will enter stop status
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OPERATION AND SAFEGUARD OF THE MACHINE
due to the special design of control circuits; and those which are under the “stop”
status will not enter into the “starting” status, guaranteeing the safety of the machine.
In addition, the control programs in the computer of the machine are solidified in the
chip, and the machining programs are protected by the power supply of the battery,
therefore, the program menu stored in the computer will not lose while power off by
accident or self-troubles occur.
♦ The alarm device and E-stop button provided with the machine can prevent the
machine from damages resulting from sudden troubles. Because of the reasonable
design of softwares, alarms can be displayed in the form of letters or alarm signals,
and indicated by indicating light on the operator’s panel. According to different
conditions, the treatment of the machine to the alarms can be divided into three
forms: “E-stop” to emergency alarm; “feed hold” for common alarm; only “prompt”
for fault operation.
6.3 Set Necessary Warn Labels for Safety
Although a series of protection measures have been taken for the machine, some
potential, unobvious dangers still exist. Therefore, in order to prompt the operator, the
machine is provided with necessary warn labels for safety. The warn labels for safety as
follows:
Labels of safety explanation, safety warn, tailstock schematic, spindle safety, turret
safety, limit speed of spindle and electric shock.
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INSPECTION AND MAINTENANCE
7 INSPECTION AN© MAINTENANCE
7.1 Routine Inspection
Routine Inspection
No. Inspected Position Inspected Item Remarks
1 Oil gauge for lubricating position • Check if the oil is enough. • Check if the oil is polluted obviously. Add oil when it is not enough
2 Level of coolant • Check if level of the coolant is proper. • Check if the coolant is polluted obviously. • Check if the filter of the oil pan is blocked. Add coolant when necessary
3 Guideways • Check if the lubricant is enough. • Check if the chip scraper is damaged.
4 Pressure gauge • Check if the pressure is sufficient. Refer to section 5.2.6.
5 V-belt • Check if the tension is suitable. • Check if the surface of belt has any break or scratch.
6 Pipe, appearance of the machine • Check if there is any oil leakage. • Check if there is any coolant leakage.
7 Movable parts • Check if there is any noise or vibration. • Check if the movement is smooth and normal.
8 Operator’s panel • Check if the functions of the levers and switches are normal. • Check if there is any alarm.
9 Safety devices • Check if they work normally.
10 Cooling fan • Check if the fans on the cabinet and the bed work normally.
11 Outside wires and cables • Check if there is any wire broken. • Check if any insulated cover has been damaged.
12 Motors, gear box and other rotary devices • Check if there is any noise or vibration. • Check if there is any abnormal heat up.
13 Cleaning • Clean the surface of chuck, cover of the carriage guideways and chip guard screen and clean out the chips. Clean them after work
14 Lubrication of the chuck • Lubricate main jaws by grease. Once a week
15 Machining operation of the machine • Check whether the machining accuracy of the machine is kept within the specifications.
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7.2 Periodic Inspection
No. Inspected position Maintained Object Period
1 Hydraulic system Hydraulic devices Pipe joint • Change the hydraulic oil, and clean the filter. • Check for oil leakage. 6 months 6 months
2 Lubrication system Lubricating devices Pipe line • Clean oil filter. • Check for leakage, blockage or breakage on the pipeline. 1 year 6 months
3 Cooling devices Filter Chip pan • Clean the chip pan. • Change coolant, clean the filter and water tank. When it’s necessary
4 Air Air filter • Clean the air filter or change it when necessary. 1 year
5 V-belt Belt Pulley • Appearance inspection and the tension check of the belts. • Clean the pulley. 6 months
6 Motor of spindle Noise, vibration temperature raising, insulation resistor • Check the abnormal noise of the bearings and other places. • Clean the pulley. 6 months
7 Servo motors of X-axis and Z-axis Noise, temperature raising • Check the abnormal noise and temperature raise of the bearings and other places. I month
8 Chuck Chuck Rotary oil cylinder • Remove it and clean out the chips inside it. • Turn the cylinder to check leakage. 1 year 3 months
9 Operator’s panel Electric unit and wiring screw • Check if there is any abnormal smell or color, as well as if the contact surfaces had worn or the screw has been loosen. • Check for the dirt and clean them out. 6 months 1 month
10 Connection of inside units Electric connections between of cabinet and connections among the units of the machine • Check and tighten the wiring screws of relays, etc. • Check and tighten the screws of terminals of relays, etc. 6 months
11 Electric devices Limit switch Sensors Solenoid valve • Check and tighten the installing screws and wiring screws. • Check their functions and actions by proper operation. 6 months 1 month
12 X-axis and Z-axis Clearance • Measure the clearance with micrometer. 6 months
13 Base Bed level • Check the level of the bed with level, and adjust it when necessary. I year
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7.3 Lubrication and Cooling
7.3.1 Hydraulic Device
The maintenance of the hydraulic device consists of: change and supply of hydraulic oil,
check and clean oil filter.
• Change of hydraulic oil
The change of hydraulic oil depends on the frequency of using oil of the machine.
Generally, the oil change of the first time shall be carried out while the machine has
been used for three months, and all the used oil shall be changed. Later on, the oil
shall be changed once six months.
• Clean of oil filter
The oil filter must be checked and cleaned while changing hydraulic oil. The process
is: open the cover of oil tank to dismount the oil-suction-pipe, and get down the oil
filter. According to the practical using conditions, the oil filter shall be changed once
a year.
7.3.2 Lubricating Device
The maintenance of the lubricating device consists of:
7.3.2.1 Oiling
Oiling shall be carried out according to the regulations.
7.3.2.2 Clean or Change the Oil Filter
♦ Clean of oil filter
The clean or change of oil filter in the carriage shall be carried out once a year.
When getting out the oil pump from the carriage, you can see the oil filter. After
getting out the oil pump, remember to clean the inside of the carriage.
♦ Clean and change
The oil filter of the headstock shall be checked once for every 6 months. Dismount
the oil filter and the copper net together from the upper of the left endface of the
headstock, and if necessary, change the copper net.
♦ Check the lubrication for the lubricating parts
Ensure that the lubricating oil gets every part needing lubrication. The reason for
some lubricating part without required oil may be the leakage of oil line or the block
of the pipe joint. And if the pipe joint is blocked, it is necessary to change it by a
new one.
7.3.3 Cooling Device
Inspection and repair items of cooling device are as follows.
• Check if the cooling pump is normal.
9 Change coolant.
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INSPECTION AND MAINTENANCE
You should check coolant level in the coolant tank (chip plate) as soon as coolant is
being jetted from the coolant jet decreases. If coolant is not enough, add more and
make its level be over the sucking mouth of the cooling pump. If coolant is too dirty,
change the coolant in the coolant tank with the new completely. At the same time, also
clean inside of the chip pan.
• Cleaning of coolant filter
Take down the coolant filter and clean or change it.
7.4 Adjustment and Maintenance of the Machine
7.4.1 Adjustment of V- belts
The serving life of V-belts and bearings may be reduces if tension of V-belts is more than
allowable value. On the contrary, if the tension of the V-belts is too small, the V-belts
have not enough force to transfer rated power.
It is available to adjust the tension of the V-belts through moving the motor base upward
and downward. Proper tension of the V-belts should be determined by swag resulting
from loading the V-belts.
Adjust tension of the V-belts according to steps given below.
The belts shall be adjusted after the belts have been used for 3 months for the first time,
and later on, adjust them once every six months.
Adjusting steps:
• Pull the belt up at the direction vertical to the belt by hand. Applied force must be at
middle of the two pulleys.
• Screw up the four installing bolts on the motor base
• Screw the adjusting bolts to move the motor base, providing the belts with proper
tension.
• Cleaning grooves of the pulleys
The oil, dirty matter, dust or similar foreign matter in the grooves of the pulleys will
make the belts slip, shortening the serving life of the belts.
7.4.2 Adjustment of Spindle
Too large or too small clearance of spindle bearings can directly affect machining
accuracy of the machine. Rotating accuracy of spindle includes two items: radial run-out
and axial slip. The radial run-out is guaranteed by the double-row centripetal short
cylinder roller bearings in front of spindle and centripetal thrust ball bearings at the rear
of spindle. Axial slip is guaranteed by centripetal thrust bearings at the rear of spindle.
This accuracy has been well adjusted before delivery of the machine, so you needn’t
adjust it in general case. If it is necessary to do adjustment due to turret’s impact or other
reasons, please adjust it according to following steps:
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INSPECTION AND MAINTENANCE
Loosen the nut 1 (as shown by Fig. 12) or locking screw on the nut 2 for adjusting, after
adjustment, re-screw up the locking nut. If still, the requirement hasn’t been satisfied,
repeat the steps mentioned above.
After completing the adjustment, do dry run for the machine for one hour. And the
temperature of the spindle bearings shah not exceed 70°C, and otherwise, loosen the
locking nut a little. Note: when adj usting the nuts I and 2, it is necessary first to loosen
the locking screws on the nuts 1 and 2, then, re-screw up the screws.
The front bearings and the rear bearings of the spindle all employ 3# high-speed
spindle-bearing grease for lubrication.
Fig. 12-1 Spindle structure
Fig. 12-2 Spindle structure
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INSPECTION AND MAINTENANCE
7.4.3 Chuck
When the hydraulic chuck has been used for a long time, there may be fine chips
accumulate inside the chuck, which can result in troubles, so the chuck should be
dismounted and cleaned once every six months.
7.4.4 Clearance
The longitudinal, traverse feed systems of the machine all employ servo motor for drive:
power from the servo motor is transferred to the ball leadscrew through the gear whose
clearance is eliminated, then, through the leadscrew to drive slide, carriage and apron to
realize longitudinal and traverse movement.
In longitudinal, traverse feed boxes there are gears whose clearance is eliminated.
Backlash of teeth should be adjusted to be small, if it is found that the backlash is too
large, it is necessary to adjust it in time. When adjusting transmitting clearance of the
gears, please refer to Fig. 13. At first, loosen all screws 1 on the gear, by help of spring 2
(it is better to apply a certain external force along spring force direction.) to eliminate
teeth backlash, then, lock the screws. Until now, adjusting working has been finished.
Fig. 13 Adjustment of clearance
7.4.5 Electric Maintenance
7.4.5.1 Check of Main Motor
Check the main motor and the controller periodically.
7.4.5.2 Check the X-axis Servomotor and Z-axis Servomotor
The check and maintenance shall be carried out periodically.
7.4.5.3 Check the Electric Connection of the Machine
Check if the electric connections of NC device, main machine, hydraulic device and
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INSPECTION AND MAINTENANCE
electric cabinet, etc. are loose.
• Connector
Check if the connection of each connector is loose and re-screw it if there is.
• Screws of terminals
Check if the screws of relays and the terminals of electric elements on each
operating panel are loose, if there is, please re-tighten it (them).
• Limitation switch
Check if the wiring screws and the installation screws of the limitation switch are
loose. If there is tighten it (them).
7.4.5.4 Inspection of Control Box
Switch off the power supply before the inspection.
• Screws of wiring terminal and welding points
Check if wiring screws of electrical elements are loose, if there is, re-tighten it
(them). Lightly pull the welded part on the relay board and check if they are firmly
welded.
• Air-switch
Check if the air-switch is invalid.
• Arc quencher
Check if the arc quencher changes color. Change it with a new one if there is.
• Cleaning
Clean the dust and the fine chips that may result in troubles.
• Air-filter net
Lightly clear out the dust and dirty thing on the air-filter net with water.
7.5 Common Trouble-shooting
7.5.1 Common Troubles and the Causes of Troubles
7.5.1.1 Coolant Does Not Flow Out
• Check if setting of coolant switch on the Operator’s panel is normal, and whether
code M is correct.
• Check if the sucking hole of the coolant pump is fully dipped into coolant.
• Check if the filter of chip pan and the filter of sucking pump are blocked.
• Check if the motor for coolant pump works normally.
• Check if the connecting wires on the control panel of thermo-relay for coolant
pump are trip-off.
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INSPECTION AND MAINTENANCE
7.5.1.2 Abnormal Temperature Rising in the Headstock
• Lubricating inside the headstock is bad.
• Pre-tightening force of spindle bearings is not proper.
7.5.1.3 Zero Points of X-axis and Z-axis Disappear
• The switch for zero point is loose.
7.5.1.4 Bad Accuracy of Repeatability
• Adjustment of the gib is not proper.
• Lubrication of the guide ways is not proper.
• The screws of the couple and the expansion sleeve are loosened.
7.5.1.5 The machine does not work
• NC device displays alarm signal.
• There may be damage on some part.
7.5.1.6 The Jaws of Chuck Do not Work
• The value set by pressure-relief valve for adjusting chucking force is not correct.
• Open /close solenoid of the jaws does not normally work.
• Function of the foot-brake is abnormal.
• Relay corresponding to action of the foot-brake works abnormally.
• The wedges and the jaws are not firmly clamped.
7.5.1.7 Travel of the hydraulic jaws is short.
• Check if there are a lot of chips inside.
• Check if the rotary oil cylinder and the connecting rod are loose.
7.5.1.8 Taper on the Finished Workpiece Appears
• (When plate-type workpiece is turned)
Centering of headstock is not proper.
• (When shaft workpiece is turned).
Centering of tailstock is not proper.
• Check if it has got good installing accuracy.
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7.5.1.9 Tailstock Spindle Does Not Move
• Check the thrust of the tailstock spindle and inspect if the reading shown by
pressure meter is correct.
• Check if the solenoid for advancing /withdrawing the tailstock spindle works
normally.
• Check if the function of the auxiliary relay which works according to the
commands of advancing /withdrawing the tailstock is normal.
• Check if the adjusting speed valve to control advancing /withdrawing the tailstock
spindle is blocked.
• The tailstock spindle is jammed due to bad lubrication of the tailstock spindle.
7.5.1.10 Rocking of the Tailstock Center is Too Big
• Thrust of the tailstock spindle is too big.
• The bearings of the tailstock spindle may be damaged due to too big thrust of the
tailstock spindle.
7.5.1.11 The Tailstock Body Does Not Move Normally.
• Check if the eccentric locking has locked the tailstock body on the guideways.
• Lubrication of moving part of the tailstock body is not good, resulting in jam.
7.5.1.12 Invalid of Tool Disc Locking and Releasing
• Check if the hydraulic pressure is normal.
• Check if the solenoid for locking /releasing the tool disc works normally.
• Check if the relay working correspondingly with the instruction is normal or not.
7.5.1.13 Tool Disc Available with Release, but without Indexing
• Check if the hydraulic pipeline of the motor is connected correctly.
• Invalid of “Turret Release”.
• Check whether there is interference among teeth of the end-tooth-disc occurs.
7.5.1.14 Tool Disc Rotates Continuously, No Index Positioning
• Check if the position encoder works normally.
• Check if the relay working correspondingly with the instruction is normal or not.
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INSPECTION AND MAINTENANCE
7.5.1.15 Tool Disc Available with Rotation, but Its Stop does not Reach the Pre-set
Position
• The end-tooth-disc is mutual interference.
• Locking solenoid is abnormal.
7.5.1.16 Tool Disc Can Rotate and Stop, but the Index Position is Incorrect
• The engagement of the end-tooth disc is incorrect.
• The installing position of the tool disc is wrong.
• The installation of tools and the auxiliary implements is in serious imbalance.
• The backlash between the transmitting gears is too much.
7.5.1.17 “OVERDELAY OF SERVO” Alarm Displayed during Movement of X-axis and
Z-axis.
• The coupling is loose.
• The gibs on x-axis and z-axis are too tight.
• Lubrication of sliding faces is not good (oil pipeline is blocked).
7.5.1.18 Lubricating System
Lubricating system has no oil or there is no oil on some lubricating points.
• Check if the alarm of the oil pipeline is normal.
• The oil amount in the oil tank is not enough.
• The measuring part at the end of lubricating point is invalid, and it is necessary to
change it with a new one.
7.5.2 Inspection of I/O Diagnosis Display
While setting zero point of the machine or shooting troubles for the machine, it is
available to carry out the check of DIAGNOSIS display for the signals input via the
machine, for example, check the DIAGNOSIS-display for ON/OFF signal of the limit
switch. In addition, it is also available to check the DIAGNOSIS-display of signal output
from the NC device into the machine.
The steps of checking I/O (Input/Output) are as follows:
• Display the DIAGNOSIS-display.
• At the position of the cursor, input the address to be diagnosed, and then press the
key “ENTER” to input. '
• In order to check and manage some specific limit switch, for example, check whether
the limit switch is OFF or ON at present, call the address according to the steps
mentioned above, and the input signal of the limit switch will be displayed. Then,
check and confirm which relative digit “1” or “0” has been displayed.
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TOOL DWOKTION
8
Max length of workpiece of the machine: means the distance between the two centers.
When 6-station turret is used in tailstock, the distance from turret center to the chuck
endface: 890 mm size < 900 mm.
Tool rods and tool holders shown by Fig. 15 are only the part of tool rods and holders
supplied by our factory for users without special order. These tool rods and holders may
not meet the needs for special turning of workpieces and we have not considered tool
interference while turning workpieces in practice, so some sizes given by Fig. 15 are only
reference for users.
User should design required tool rods and tool holders while turning specific workpieces
according to the sizes given by Fig. 15. For details of tool interference diagram and related
limitation sizes, refer to Figi 4-1, Fig. 14, Fig. 15 and Fig. 16, please.
*4—<
О
I
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Allowed max, swing diameter when turret
is swinging at Spindle center
Table of Power Parameter for 6-station Turret
Item Value
Max. inertia loaded externally 2 kgm2
Max. axial resisting force 7000 N
Max. drilling diameter(steel piece) 025 mm
Max. main turning force 10000 N
Max. drilling length 230 mm
Specification"— D E
Max. swing dia. over bed 610 305 104
500 250 93
400 250 93
Center position of turret
I
сл
p
o’
p
Table of Max. main Turning Force Change of Turret
Overhang length of tools (mm) 150 200 300 400 500
Main turning force(N) 10000 7500 5000 3750 3000
Note: L is the distance from the cutting edge
to the swing centre of turret.
Length must be shorter than 420mmdue to the limitation
of the rear protection plate when a station is under
drilling status and core drill or reamer is set on every
other station.
Shown in dot-and-dash line
270
Cooling pipe 021,5
Rear protection
door of the machineL
Front protection door of the machine
when max. travel
Center Ime of turret
Spindle center
CAK50/CAK61 SERIES TOOL DISPOSITION
САК5О/САК61 SERIES
TOOL DISPOSITION
^Turning Size Specification Tool holder 1 Tool holder 2 A
В c
Max. swing dia. over bed 610 360 560
500 360 480
Center distance 890 650
640 400
1390 1150
1900 1660
The enter distance are the ones while the tailstock is available.
Explanation: The tool holder for 6-station turret shall be selected according to the specific
workpiece to be machined, and the parameters specified in the above table is only for the
standard tool holders (as shown in Fig. 15).
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TOOL DISPOSITION
Max. turningength В
Fig. 16 Drawing for limitation-turning-size of horizontal 6-station turret
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TOOL DISPOSITION
Fig. 17 Interference Diagram of tool sizes
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ACCESSORIES AND WEARING PARTS
9 ACCESSORIES AND WEARING PARTS
9.1 Standard Accessories Provided for the Machine
• Standard tool disc and tool holders
• Standard chuck
• A set of standard implements (refer to the packing list of the machine)
9.2 Optional Accessories Provided with the Machine
No. Name Model Qty- Remarks
1 Steady rest Iset For the machine with max. swing dia. over bed of Ф 500, the spanner for the steady rest shall be supplied.
2 Steady rest Iset For the machine with max. swing dia. over bed of Ф 610, the spanner for the steady rest shall be supplied.
T 3 Follower rest Iset
4 Hydraulic chuck Iset
5 Hydraulic tailstock Iset
6 Power-driven chuck Iset
7 Pneumatic chuck Iset
8 Drive plate Iset For manual chuck
9 RS232 Interface Iset Mounted on the electric cabinet
10 Communication cable I pee
1 1 Disc of communication software Ipce
9.3 Wearing Parts
Fig. No.l Part Name Part No. and Model Matl Qty Remarks
1 Center sleeve 80/5 S25-10 40Cr 1 Refer to Fig. 18
2 Center II5, S25-2 T8A 2 Refer to Fig. 18
3 Chip-scraping plate A15-03019L 2 Refer to Fig. 19
4 Chip-scraping plate A15-03020L 2 Refer to Fig. 20
5 Chip-scraping plate A15-05020L1 1 Refer to Fig. 21
6 Chip-scraping plate A15*05021 LI 1 Refer to Fig. 22
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ACCESSORIES AND WEARING PARTS
7 Chip-scraping plate A15-05022L1 1 Refer to Fig. 23
8 Chip-scraping plate A15-05023 LI 1 Refer to Fig. 24
9 Illuminating lamp of the machine. 1
10 Electromagnetic clutch DLM9-I0 2 Tianjin Electromagnetic Clutch Factory (for headstock with manual speed change)
11 Electromagnetic clutch DDL3-1.0 2 Tianjin Electromagnetic Clutch Factory (for headstock with lelectric speed change)
12 Braking device for motor LL10-16A 1 Jiangsu Binhai Petrochemical Industry Machinery Works (for the former construction of manual speed-changing)
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Fig. 18 Center sleeve (№5825-10)
Technical requirement: While do check with the gauge under the method of painting, the contacting part
shall be close to the end of larger diaand not be more than 65% of the working length.
Scale 1:2
Mali 40Cr
H.T. C48
200 Scale 1:2
Fig. 19 Center (П 5825-2) Mail T8 A
H.T. Local C)2
No. Technical Requirements Permissible Error (mm)
bn out of 60’ connoid to the center line of No. 5 cone 0.005
2 hgleof60° cone ± ia
While check |he Morse taper, the dyeing point shallbe uniformly arranged m the connoid, and the contact face shall be dose to the end of arger dia.Besid.es, the contact part shall not be less han the 60% of me working leogth.
Fig. 18
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ACCESSORIES AND WEARING PARTS
Fig. 20
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ACCESSORIES AND WEARING PARTS
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ACCESSORIES AND WEARING PARTS
Fig. 23
Fig. 24
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Шк
S М Т С L
SLD SERIES TURRET
OPERATION MANUAL
(MECHANICALAND ELECTRICAL PARTS)
SHENYANG MACHINE TOOL (GROUP) CO.,LTD
(NC TURRET BRANCH)
THE PEOPLE'S REPUBLIC OF CHINA
INDEX
1 Identification code----------------------------------------1
2 Technical data---------------------------------------------2
3 Turret placing on the machine----------------------------- 3
4 Periodic checks---------------------------------------------5
5 Coolant setting--------------------------------------------5
6 Wiring diagram---------------------------------------------5
7 Diagram and description of function------------------------6
8 Lubrication----------------------------------------------- 7
9 Assembly drawing-------------------------------------------7
10 Components list-------------------------------------------8
11 Break down search and repair —
-9
SLD SERIES TURRETS
Operating Instructions
IDENTIFICATION CODE
SLDJK — 5K— (Ю
SIZE COD.
102 102
130 130
146 150A
165 165
170 170/170A
210 210
260 260/260A
OPTIONALS
COD. FREQUENCY AND INERTIA
50 50HZ Standard
60 60HZ Standard
POSITIONS COD.
4 4
6 6
COD. MOTOR VOLT AND FREQUENCY
220-380 220-380V-50/60HZ
400-440 400-440V-50/60HZ
NC Turret Branch
1
SLD SERES TURRETS
Operating Instructions
1 INSTRUCTION TURRET
The turret is suitable for the CNC lathe, which can be selected four or six positions for use according
to the need. Four position Turrets can load with lathing cutter, baring cutter, etc., six positions turret can
load with various kinds of lathing cutter, boring cutter.
The turret has high indexing precision, kind rigidity, lifting inside, and reliable structure through
three gears precision. Utilizing die Location sensor to send the signals, die turret is reliable, sensitive, long
use life. The turret is divided into cooling inside and cooling outside according to different needs.
2 TECHNICAL DATA
Size SLD102 SLD106 SLD130 SLD 150A SLD165 SLD170 SLD 170A SLD210 SLD 260A
Stations 4 6 4 6 4 6 4 6 4 6 4 6 4 6 4 4
Center height (mm) 102 106 130 146 165 170 170 210 260
Max tangential torque 1650 1800 2000 2000 3200 3200 5000 5000 5000
Max tilting torque 750 750 800 800 1250 1250 2000 2000 2250
Inertia of transportable masses(Kgm) 0.8 0.8 1.1 1.1 1.7 1.7 4 4 4
Repeatability accuracy(") ±1.5 ±1.5 ±1.5 ±1.5 ±1.8 ±1.8 ±1.8 ±2 ±2
Indexing accuracy(") ±4 ±4 ±4 ±4 *h5 ±6 ±6 ±6 ±6
Rotating time only (s) 22 20 24 21 24 22 24 22 3.9 3.6 39 36 56 4.9 56 5.6
The motor i . „ . Torque (N.m) 3 3 3 3 5 5 5 5 5
Frequency (Hz) 50 50 50 50 50 50 50 50 50
Capacity (KVA) 0.76 0.76 0.75 1.14 1.14 1.71 1.71 1.71 1.71
Voltage(V) 380 380 380 380 380 380 380 380 380
Current (A) 2 2 2 2 3 3 4.5 4.5 4.5
NC Turret Branch
2
SLD SERIES TURRETS
Operating Instructions
3 PERFORMANCES DATA
NC Turret Branch
SLDSERIES TURRETS
Operating Instructions
4 PERIODIC CHECKS
The turret is life-lubricated so no replacement or filling lubricant is required.
Check the conditions of gasket, every 4,000 working hours of the machine, at least. If an excessive wear
is noted, it’s advisable to replace the gasket.
5 COOLANT OPERATION
Interior hole Cutter is used, firstly peg in cutter carrying is released, then the copper managing followed
with turret for cooling is loaded, original outlet is transferred to a position and can not spray water, set the
copper and is in charge of spraying water in the position.
—continuous supply: Max Ibar;
—by pressure cut-off during turret rotion:Max 2bar.
6 WIRING DIAGRAM
COMPONENT CHARACTERISTICS WIRING NUMBER COLOUR SIGNAL
Motor (3 phase) 380-400V 50/60HZ z—'A/— u C3))—v — W |.PE Black
Location sensor 10-30VD.C (RIPPLE) 10% 50шА/exit(load) OUTPUT-PNP 6 - 1 2 3 4 5 6 7 8 Green Purple Blue Yellow Gray Pink White Red TIM T2M T3M T4M T5M T6M TCP +24V
Notes: 1. For 90 series turret, the white signal line (9) is invalid.
2. For four-location turret, the gray signal line (5) and pink signal line (6) are invalid.
3. The length of the cable and length of metal hose are offered according to user's enquiry.
4. The output voltage is normal 24V, the low level outputs needs special order.
Cables Metal hose cone, electrical case NC control unit
NC Turret Branch
4
SLD SERIES TURRETS
Operating Instructions
7 DIAGRAM AND DESCRIPTION OF FUNCTION
The structure drawing picture of turret is on page 6. After the turret is ordered for selecting one cutter, the
motor clockwise rotation,then,taking worm (06), worm gear( 04),screw shaft(02) rotate following motor ,
locking plate (10) is lifted, Rotating plate (08) will be released, driving plate (15) puts on cutter stand (12)
reverse rotation. When cutter stand (12) is rotated to goal position, the motor is counterclockwise rotating,
the indexing pin(9) goes into slot on the indexing plate(21) by spring, driving plate (15) is not rotated,
locking plate (10) declines, the turret is locked, accurate localization. Then, the indicating locking of turret
occurs, die motor is de-eneigized, process finishes.
Notes: For 90 series turret, the locking signal is invalid.
Position 1
Position 6
Locking
Motor CW
Stop
Motor CCW
1
0
1
0
1
0
1
0
1
Position 1
Position 6
SLD SLD SLD SLD SLD SLD SLD SLD SLD
Type 102 106 130 1 50A 165 170 170A 210 260A
t2(ms) 500 500 500 500 500 500 800 800 800
8 LUBRICATION
The mechanical part of the turret is supplied with permanent lubrication and therefore it does not requin
periodical refilling or lubricant changes. The lubricant is to be changes only in case of complet
disassembly of the turret. The lubricant is to be filled before assembling the solenoid and the pin pouring
it through the hole of the pin. It is to be changed only in case of complete disassembly of the turret.
NC Turret Branch
5
SLD SERIES TURRETS
Operating Instructions
9 ASSEMBLY DRAWING
NC Turret Branch
6
SLD SERIES TURRETS
Operating Instructions
10 COMPONMENT LIST
COMPONMENT REE QTY CODE
Bottom plate 1 1
Screw shaft 2 1
Locking screw 3 1
Worm gear 4 1
Base 5 1
Worm 6 1
Immobile plate 7 1
Rotating plate 8 1
Index pin 9 2
Locking plate 10 1
Square nut 11 1
Cutter stand 12 1
Disk 13 1
Transfer plate 14 1
Driving plate 15 1
Ring 16 1
Locking screw 17 1
Disk 18 1
Micro switch Spring 19 1
Location sensor 20 1
Index plate 21 1
NC Turret Branch
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SLD SERIES TURRETS
Operating Instructions
11 BREAK DOWN RESEARCH AND REPAIR
Any kinds of maintenance or disassembly must take place with locked gears, cold surfaces, and
de-energized motor
Anomalies Probable causes Remedies
The turret doesn’t start the rotation The three-phase connection of motor is Probable error Three-phase of motor is Probable absent. The connections between the turret and NC control unit is error Correct connections Correct connections or replace motor Correct connections
There is a breakdown in the motor Replace the motor
The latch is not restored. Replace electromagnet latch, or restore spring
в The turret doesn’t reach the position 1. The thermic probes of location sensor is Probable out of order 2. The location signal line is Probable unreal, Broken, short circuit with earth. Replace thermic or location sensor Check on location signal line
c CNC system alarm, too long changing cutter time Disk (18) can not make micro switches (19) shut. Micro switches(19) is error Apply the locking glue on the nut, make disk (18) on the horizontal level, and guarantee micro switches shut correctly. Replace micro switches(19)
D In taiget work location , cutter stand swings the angle too big Location sensor and the accepting component deviate from too big The turret is locked, counterclockwise to adjust Location sensor (12), make system turret diagnose parameter random cutter yard turn from “0” into “1”, the turret is swung minimally, then fasten the screw (14).
E Indexing pin is nipped The cutter is over lengthy, overweight, when changing location, the turret rotate inertia is too big, the indexing latch is nipped. The first indexing latch slipped lubricated is bad.. The spring does not work 1. Rotate the turret to locking position by hands, restart. Forbid using the overlengthy cutter overweight. 2. The lubricating grease lubricates the first indexing latch, 3. Replace the spring.
NC Turret Branch
8