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OPERATION MAI.[UAL
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 Contents

1 . Safety Instruction and Working Environment.................. ". " ".....3

2. Main Usage and Features of Machine .......8

3. Main Parameter of Machine ....... I 0

7. Electrical System of Machine ...........27

9. Transportation and Installation of Machine ........................3 6

10. Operation of the Machine ....38

 i . S afefy Instruction and Working Environment
. . GE\ER{L SAFETY RULES
Operator must read the instruction before operating the machine, and the manager
of safety department should assure the operator knows the requirem-
ents well.
WARNNG! NEVER CONTACT THE CUTTERS AND OT}IER DRTVING
PARTS WITH HA}{DS IF THEYARE STILL RLINNNG.
1.1"1 The operation, maintenance and repair of the machine must be done by qualified
person who have been trained to have the ability to forecast the potential risks. Only
safety-conscious persons who are fully aware of the risks can operate the machine.
1.1.2 To those people who assemble, operate, or maintain the machine must be
confirmed to have read and understood the operating instructions.
1.1.3 After stopping the machine, the tool will still run for a period of time due to
inertia, do not open the tool guard and touch the tool with your hand before it comes to
stop running.
1.1.4 Do not detach or modify any part of the safety guard. The machine should be
disconnected from the por.ver supply during maintenance or repair.
1.1.5 Assign special persons to operate, maintain and adjust the machine.
1.1.6 Operate the machine in technically perfect condition. Only the producer or
quaiified person can corxpletely repair the machine.
1 .1.7 Stop the machine immediately if abnormal phenomena appear, check and repair
the machine by specialized persons in time.
1.1.8 Disassembly and assembly the machine with the hoisting equipment, which is
of enough load capacity.
1.1.9 Observe all safety instructions and warnings attached to the machine, make sure
they are always complete and perfectly legible.
1.1.10 Do safety inspection before operating. Ensure the stroke limit switches, stop
block and emergency stop button safe and reliable.
1.1.1lReinstall the removed guards and safety devices in place after maintaining.
1.1.12 Do maintenance or adjustment only after switching the machine off and
disconnecting the machine from the power source.
1.1.13 Always keep children away from the machine. Operating personel age must be
 ': least 18 years.
-l4 Do not wear loose clothing, gloves, neckties or jewelry (rings, watches, etc).

^{eep the quills and the edges of the work uniform tight. Always be sure to wear
.afety goggles and wear safety shoes during operation.
: . 1.15 Put the long hair into a safety hat during operation no matter the operator is a
rtan or a woman.
i .1.16 It is recommended to wear suitable hearing protection equipment when
necessary to reduce the risk of hearing loss.
\ .1.17 Provide adequate light around the machine, and keep the perimeter around the
machine dry clean and in good order" In addition, do not place anything near the
machine; otherwise it becomes an obstactre during operation.
1" 1.1 8 Do not remove the guards from their working place during operation.
1 .1 . i 9 Disconnect the power supply before leaving the machine.
l.l.2O Restart the machine only after the guards and safety devices are replaced to
their position and in their good function.
t "l.21Do not place tools, work pieces, which is not in use on the machine, especiaily
on the moving parts.
t.1.22 Clamp r,vorkpiece and tools cornpletely and reliably, take off the wrench from
chuck before starting the spindle running.
1.1.23 Stop the machine before adjusting the position of the coolant nozzles.
1.1.24 Do not use compressed air to remove dust and chips etc. deposited on the
machine, switchboard, control unit etc.
| .1.25 Both operators and the iraintenance men should read the descriptions carefully

on the caution plate attached cn the machine" They should observe the OPERATION
MANUAL in their work. During operation and maintenance, care should be taken so

that the caution plate is not dirtiecl or damaged.

)p 1.1.26 Always bear in mind where the emergency stop button is so that you can

operate it without delay in case of an emergency.

1.1.27 Start the machine according to the starting procedures strictly.
nd 1 .1.28 Keep your hands away from the moving parts of the machine during operation.
', 1.29 When removing chip iron around the tooling system, avoid taking them out
be .rirectly by hand, there is cutting hazards. It is safer with proper tool when doing this.
Be sure to stop the machine when removing chip from the machine.
i.1,30 Prior to starting test operation, read this manual carefully so as to be familiar
rvith the machine.
1.1,31 Contact the manufacturer if for some reason about some of the OPERATION
MAI{UAL become unreadable.
1,1,32 Stop the spindle and the feed in each axis before installing a tool.
1.2 Additional Safety Rules Of Machine
1.2.1 Must read and understand the entire instruction manual before operating the
machine.
1.2.2 Always wear approved safety glasses/suit while operating machine tool.
1.2.3 Make sure the machine is properly grounded.
1.2.4Befare operating the machine, remove tie, rings, watches, other jewelry Keep
the quills and the edges of the work uniform tight. Always be sure to wear safety
goggles and wear safety shoes during operation. Do not wear gloves while
operating machine tool.
1.2.5 Keep the floor around the machine clean and away from scrap materials, oil and
::iase, etc.
i.1.6 Keep aii guards of the machine securely in place at all times when working. For
nairtenance purpose, use extreme caution and replace the guards immediately after
:-"intenance.
r i.- \{ake sure workpiece and cutter be fitted and clamped well, and make sure the
r"*::.r doesn't touch the workpiece before starting the machine.
- Mfust shut off power supply before adjusting or maintaining the machine.
o I . T:e operator must keep clear-minded when operating the machine and pay

=::-=-.:---.l :t ri'hat he is doing. It is not allowed to operate the machine when the
.:e:.1::: :. .ired. after drinking or taking medicines.
- I :: l!*.: :::is properly. Don't force a tool or an attachment to do work which was
:l:: l.!-::;:. S:arp tools should be used. Deformed or dull tools should not be used.
i -: : - l.[=-!:- :;i:::r the motor switch is in oFF position before connecting the
m.::: :: ; -fr----: I :"-',-ef SUpply.
i l.:: ln'*'";: i::r:r,;::r operate or adjust the machine when the procedure is not
---i--*---
n- . -=^
t.Z.l3 be careful, the handle of the spindle quill rapidly rebound.
l.2.l4It is advised that the operator shouid change machining position on the table
frequently in order to prolong the life of the machine.
1.2.15 Lubricate the machine in time according to the lubricating demand.
1.2.16 Keep the electrical elements clean, do not clean the electrical elements with
kerosene or gas.
1.2.17 Be sure that the spindle rotation of the machine comes to rest before changing
spindle speed.
1.2.18 It is forbidden to process flammable and explosive rnetal, for example : pure
aluminum, magnesium and so on.
1.2.19 The machine should never be used in flammable, explosive or humid
environment
1.2.20 The machine should be disassembled and assembled supported by the lifting
mechanism with sufficient bearing capacity.
1.Z.zlAlways stop the machine before adjusting the position of the cooiing nozzle.
1.2.22 Make sure that the operating site should kept well ventilated. It is
recommended that ventilation equipment should be provided on the operating site"
1.2.23 Must use the special swinging rings, boits that manufacturer supplied to swing
the machine according to the swing figure.
L.2.24 Must make sure the each clamp part of the machine be in the clamp state and
adjust the machine well according to the demand.of swing.figwo, then may swing the
machine.
1.2.25 Must check whether every clamp part is reliable, every travel is reliable,
grounding wire is reliable, phase sequence of power supply is right, emergency stop
pushbutton is reliable.
1.2.26 Must clamp workpiece and cutter securely, but excessively cut workpiece.
1.2.27 Must clamp the arm, column, headstock securely, otherwise will result in
injury.
1"2.28 Select revolving speed and feed on the table of plate according to the
machining material and different diameter of drill, otherwise may cause injury to the
machine.
1.2.2g The spindle feed handle will turn r,vhen the spindle is automatibally feeding,
and keep away from the handle, otherwise may cause rnjury to operator. L
1.2.30 Keep others away from the work area during the run of machine. n-

1.2.31Carefully observe things around the machine before turning the arm, otherwise I
wiil result in serious injury. t
1.2.32 There are push points between the headstock and stop block, the arm and u
column, so operators will look to their own safety. ni
1.2.33 Shut off main supply before repairing the machine.
1.2.34 Shut off power supply of machine before eliminating the malfunction,
1.2.35 Must push the E-stop button on headstock panel when the machine has a fault,
then shut off main switch. Do not switch on main switch before eliminating the
malfunction.
1.2.36 The operation, maintenance and reparation of the machine must be done by I3.
qualified person who have been trained to have the ability to forecast the potential
risks. Put the long hair into a safety hat during operation no matter the operator is a 1-3-

man or a woman. 1.3.,

1"2.37 Operator must be familiar with the position of E-stop switch and working lJ;
method.
1.2.38 Eiectrical maintenance personnel work as working rules and wear insulated
shoes. Do not switch on main switch during the reparation, and hang electrical '_1

warning plate on the power switch.

1.2.39 Appointed person is in charge of the key to electrical door and power switch.
1.2.4a switch off the main switch before opening the electrical door.
t.2.41User shall add guard according to the size and shape of the workpiece to avoid
causing danger that coolant and scrap iron splash.
1.2.42 Must not loosen the lifting rope when the machine is not installed and the
foundation bolts are tight. l.ITI
1.2.43 Must not wear loose clothing, gloves, neckties or jewelry (rings, watches, etc). Im,
Keep the quills and the edges of the work uniform tight. tfuc qp

1.2.44 Kerosene, gas and other flammable liquid are prohibited to clean the machine. 3_3 fl
compressed air device is prohibited to clean the machine. Tft
1-1.45 Unauthorized persons must not start, operate, maintain the machine and open fteri{x
the electrical dooq contact electrical components. Th
harffin
 . 1.46 Must not exceed + 180' when turning arm in the horizontal direction.
. ).17 Must fill lubricant oil into each gearbox and oil pocket according to
demand of operation manual before starting the machine for the first time!
\\-arning: Failure to comply with the instruction may cause serious injury.
1.3. Working environment and note of caution symbol

1.3.1 The machine is designed for operating on the site:

The height above sea level doesn't exceed 1000m.
The ambient temperature range doesn't exceed 5C
-40C.
The relative humidity doesn't exceed 50% within*4OC and90o/o within*2OC.
Transportation temperature range is within -25"C-*55"C
The light in the working environment should not be lower than 500 lux.
1.3.2Do not use the machine in an environment of electric dirt,
explosion, metal fretted, gas and steam which can destroy insulation .

1.3.3 Do not use the machine in an environment of impact and vibration.

i.3.4 The uoise of the machine S 85 dB (A).
1.3.5 Note of caution symbol:

:hazardous electrical voltage.

:Irnminent danger that will serious injury to

personnel or damage to machine.

2. Main Usage and Features of Machine

2.lThe machine is widely used in the every field of machining, it is used to bore,
ream, tapping, spot facing and so on. The machine is also used to bore a hole under
the special conditions of proper technological equipment,
2.2 Structure and features of the machine
The machine consists of base, column, table, main drive mechanism, coolant,
lubrication, electrical equipments and so on.
The appearance of the machine is elegant, the overail layout of the machine is
harmonious. Hydraulic preselect speed change can save auxiliary time. Clockwise
8
 and counterclockwise turn and brake, speed change, neutral of spindle is
aontrolled by only one handle. Mechanical and electrical linkage structure is adopted
to clamp headstock and colurnn. Harden main guideway surface to prolong life of the
m.ashine. The machine possesses protection set.

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3. Main Parameter of Machine

 Specification Parameter

Max. drilling diameter (mm) 32 (1.26")

Spindle bore taper (Morse) MS4

Spindle speed steps 16

32-2s0a (s0Hz)
38-3000 (60H2)
Spindle speed range (rpm) Warning: 1600, t920 2500,
3000 rpm speed of spindle
are forbidden.

Spindle feed steps I

Spindle feed range (mm/rev. ) 0. 10-1.25 (0.004,'-0.05")

1.27(s0HzX 50',;
Arm lifting speed (m/ min)
1.524 (60H2) (60")

Arm rotary angle f 180'

Max. spindle torque (N.m) 200

Max. spindle feed resisting force (N) 10000

Main motor power (kW) ))

Arm lifting motor power (kW) 0.75

Hydraulic clamping motor power (kW) 0.37

Cooling motor power (kW) 0.075

Net weight (approximately) (kg) 1600

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Machine tool each part size (mm)
!q
Code Parameter Code 32
Parameter
_q]
A 1000(39.37',) I 2050(90.7'') BO

B 300(1 1.81") L 315(12.4.)

C 700(27.56,,) M 1710(67.32")

D 1000(39.37") N t760(69.23,)

E 250(9.94") o 160(6.3'')

F 500(19.69") P 400(15.7s")

G 280(11") a 550(21.65")

H 2300(90.55,') 0 24A(9.45,)

11
 4. Drive System of Machine

4.1 Drive system chart

4B
s*,.
47 (h(,.
f:$: -rJ ,4
rr:
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46 t
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I

45
10
44
11
43r'
12
42
13
4l t4
-40-,-] 1E
3g
16
38
17
37 '\\18
36
35
\M 20
34 2t
J'J
22
32 2,3
31
24
30

dg ?8 \21

t2
i"aIn fnotof
W rpm
2500 (3000
4 )
i 430 rpm
]r ooo {1s20 }
{50t-iz} j rooo (1200 }
I s00 {e60}
1716 rpm .Jora G5r6i
(aoHei 1500 rc001
Ii+oo {480}
J315 (378)
{250 (300} zod
d200 (240) o'
I160 (1e2)
Jr25 (150)
J 100 (120) Aocul
'
iao lbol fiil.1)
1150
{60} fr.t

Spindle Speed Chart

32 t38)
50Flz {60U21
Heat t
H XI mmirev. {inchlrev.} and h
ot. es
{s.os'!}
0.,,80 {0.03"}
0. 50 {0,CI2,}
,0.40 t0.0161
0.32 {0,013"i
0. 25 {0.01'}
0, 16 (0"006")
0. 10 (0.004")

J* i-* r

Spindle speed / feed chart -

l3 -
 -.2 Drive parts list
No. 1 2 3 4 5 6 7 8 I 10 11 12

Teeth or number
:f starter of thread 53 50 18 55 37 25 ;57, 1B 42 JO 24 31

' Module 2 2.5 2 2.5 2

Helix anole
and direcfion
of turning

Accuracy grade 7-7C 6-6C 7-7C 6-6C 7-7C 8-8C

r Material 45 40Cr 20Cr-

MnT
40Cr 40Cr 40Cr 45

Heat treatment
G52
s0.5 G52
and hardness -G58

13 t4 15 r6 t7 18 19 20 21 22 23 24

25 38 40 t6 24 23 38 37 38 1 32 2

2 1.5 2 1.5 '2 1.5

Z',\',51', 8"07',48',
right right ,

8-8C 7-7C 8-8C

40Cr 45 40Cr 45 2ACr 45 40Cr 40Cr 45 40Cr

s0.7- G52 C4B G52

G52 c58 T235 T235

14
l5 26 27 28 29 30 31 32 JJ 34 35 36 37

2i 18 13 90 58 46 28 32 36 J 20 43 28

2 2.5 1.5 2 J 2
r,

lr
209'51" 8007'48" 14002'10"
right right right -,1

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8-8C 7-7C 8-8C 7*7C 'i'il..-
t.)
HT .ID
45 40Cr 40Cr 45 45 40Cr HTro-s+ 45 40Cr 4
30-54 ()
i1
u-L
T235
.rd
T235 Teeth i{
G48 T235 G52 352 G52
D0.3 +6i part
c42

38 39 40 41 42 43 44 45 46 47 48
O11
4l ,1 n
JJ 21 43 JJ 42 32 37 22 38 i
2 1.5 I iI !

40 05' 0g' -!
L],

/-
/-_

right -a-

7-7C 8-8C
ZQSn
-
45 40Cr 45 4OCr 40Cr
6-6-3
Gs2
Gs2
Claw
Claw
G52 meas- G52 Gs2 T235
measurement
urement
H42
}{42
1. Remark: Meaning of the heat treatment as followino
S: Carbonization. G: High-frequency quench. C: Quench.
H: Flame Hardening. D: Nitride. T: Hardening and tempering
Values after the codes are hardness and depth of carbonization.
2. Hardness of the heat treatment is hardness of teeth of gear and thread of worm.

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11
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32

Bearing list

a
No. I 2 -l 4 5 6 7 I o

Model 609 626 6000 6AA2 6004 6005 6007 6007 6008

9X24 6x 19 10x26 15x32 20x40 25x'47 35X62 35x62 40x 68

Specification
x7 X6 X8 X9 x12 x12 x14 x14 x15

Accuracy
grade
G D (P5) \_l

Quantity 1 7 1 2 6 5 J 2 2

t6
 10 t1 t2 13 l4 15 l6 t7 18 19 20

6010 6013 6014 601 3 6202 6204 6205 6206 6209 6209 6301

50x 65x 70x 65X l5x 20x 25x 30x 45X 45X
80 100 110 100 35 47
tzx37
52 62 85 85
xi6 x18 x20 x18 x11 x14 x15 x16 x19 x19
xt2
G

2 1 2 I I I 4 2 I 1 I

i 2l 22 23 24 25 26 27 78 29 30 31
i

$44 6306 6203 62A5 6208 51106 51107 5111i 5ttt2 51113 5LIT7

2AX 30x 17x 25X 4AX. 35x 55X 60x 65X 85X
<, 30x47
52 72 40 80 52
x15 x19 xt2 x15 x18
xll xt2
78
x16
85
xt7
90
xt8
110
x19
G D (P5) G

2 I 2 4 1 I 2 1 I 1 2

5t205
 5. Main Structure and ACjustment of Machine
5.1 Main speed change mechanism

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18
5.2 Feed and speed change mechanism

1-:

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=H--7'--1 ; I

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 5.3 worm shaft mechanism

s\
Adjustment of steel ball safety clutch:
Turn nut 3 to adjust the feed resisting force.
Dismantle steel ball safety clutch:
Remove the pin I in the splined sleeve 2, steel ball safety ciutch subassembly may
be dismantled.
Dismantle wonn shaft:
Remove the pin 5 in the inner teeth sleeve 4, unscrew the screw on the supporting
sleeve 6, supporting sleeve and worm shaft may be dismantled.

Specification Feed resisting force (N) Clutch condition

< I 1200 Normal

2s
11200-13200 Detachment

< 14000 Normal

32
1400G-17150 Detachment

< 17150 Normal \

40 . ::,,;:tllii1,l .
l,'iiri:
.:::i':1 r.
ririir.'i
i.;;;lr;i- l

1715V-20210 ,,,r
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Detachment a
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20
5.-1 Horizontal shaft mechanism

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Installation and dismantling of the horizontal shaft

Loosen nut 1, dismantle handwheel 5, the horizontal shaft subassembly may be
dismantled.
Caution: Must lift
the spindle in the highest position before dismantling the
horizontal shaft, loosen the spindle balance spring, and put the supporting wood
biock under the spindie to prevent the spindle from falling down.
Must lift the spindle in the highest position before installing the horizontal shaft,
*-
-:i
spindie balance cam must accord with the specified position, otherwise spindle can't
keep balance.
Adjustment of ciutch:
Adjust the clutch during the clutch is engaged, put handle 4 in the power position,
tighten the nut 3 to make the teeth mesh well, tighten the screw 2 andtighten nut 3 on
the horizontal spindle 6 after ensuring handle 4 is operated well.

2t
 Caution: Engagement and disengagement of clutch are controlled by 36 pieces of
steel balls (specification: gVIb). Prevent steel balls from scattering during
disassembly; the quantity of steel bail is indispensable, and other kind of steel ball
can not take the place of the steel ball (specification: gVIb) during installation,
otherwise it will damage the clutch.

5.5 Headstock clamping mechanism

Adjustment of headstock ctrarnping force:

e Loosen the screw 1, move the part 2, which may adjust the headstock clamping
d force, and adjust the clamping force until headstock does not loosen when exerting
peripheral force (300N) on the headstock moving handwheel edge.
ft, Adjustment ofjunction surface of headstock and rocker arm:
rt Loosen screw 4, turn eccentric shaft 3, which may adjust the clearance between
the headstock and rocker arm. Depth of insertion of feeler gauge (specification:
thickness is 0.04mm) doesn't exceed 20mm when moving the headstock,
t0,
exerting peripheral force on handwheel edge doesn't exceed 40N.
sn

22
5.5 Spindle and balance mechanism
- !t-[
(mi
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hon:
*or.

the
Suur

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li
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Sc.rer
columr
clampi
u"hen e
thrust (
tighten
23
 Must remove the horizontal spindle first (see horizontal shaft mechanism), then
remove the location pin 3 behind the headstock before dismantling the spindle"
Spindle balance cmr, 2 must accord with the graphic position when installing the
horizontal spindle.
Adjustment of spindle balance force:
Turn the screw lclockwise to reduce the balance force, otherwise it will increase
the balance force.
Structure and characteristics of spindle:
Semicircle hole on the spindle head is used to insert the tool-drop wrench, which
can unload the tool easily to maintain spindle accuracy chronically.

5.7 Column clamping mechanism

\
\,,

Screw 1 is used to adjust the conical surface clearance between inside and outside
columns, six screws are given force evenly. Nut 2 is used to adjust the column
clamping force, and adjust the clamping force until outside column does not turn
when exerting horizontal thrust (300N) on the rocker arm end. Exerting horizontal
thrust (30N) on the rocker arm end to turn the column after the column is loosened,
tighten the screw 3, tighten the nut 2 on the column top 4.
1A
5.8 Lifting and clamping mechanism of rocker arn

l'r

I
i.

Tighten nuts 1, 2 slightly when the rocker arn is loose, then make handle 5 loose,
make the handle 5 be in clamping position after turning the nuts 3, 4, feeler gauge
(thickness: 0.04mm) can not be inserted into the two ends clearance of rocker arm.

6. Hydraulic System

speed
change
hydraulic principle diagram

25
 Pipe No.
1 2 3 4 5 6
Spindle actio
FWD + +

REV + +

Speed change + + + +

Neutral + +

Stop

Oil ways state table

Remark: The sign "+" denotes high pressure oil; the sign "-" denotes low
pressure oil.
O rWn oi1 cylindeq @ REV oil cylinder, @ Preselector valve,
@ neutral oil cylinder, @ oil pump exit, @ oil return port,
@oil suction pipe
Operating valve and preselector valve are at the top of headstock. Spindle speed
preselector valve and feed preselector valve are respectively 16-position 6-way rotary
valve and 8-position 5-way rotary valve. Every rotary valve respectiveiy controls four
oil cylinders and three differential motion oil cylinders, which can realize the main
spindle 16-step speed change and 8-step feed speed.
High pressure oil enters preseiector valve to drive every speed change oil
cylinder, which can drive sliding gear to change speed during speed change; high
pressure oil enters clockwise and counterrotating oil cylinders through small holes
simultaneously, for the clockwise and counterrotating oil cylinders' arca is
different( clockwise cylinder's area is greater than counterrotating oii cylinder,s area.
)
which make shifting fork that presses the friction disc press the ciockwise rotating
Ira friction disc with a little force, then start the swivel chain slowly.
rEv
o
,t
When the control valve is in stop position, oil way @ directly connects with the
a
oil pool oil gallery @, so the whole system is in low pressure state, at the same time,
op
the spring that brake oil cylinder will be loosened to press the friction disc due to
lost pressure of oil *ay
@, which make driving chain brake, so spindle stops.
Please connect the oil pipe according to the number of pipe, and make the end of
oil pipe @ into oil net when inserting oil pipe @ and cleaning the oil net, or else,
26
u'hich make the hydraulic pressure system will possibly be destroyed, and the
hydraulic pressure system can't ensure work for a long time.
Hydraulic pressure system force is controlled by the spring in relief valve on the i r-t
oil pump, the working pressure force is 1.6-2MPa.

7. Electrical System of Machine

Power source of the machine tool: 380V1220Y1440Y 50H2, 3-phase. Special demand
,-eai.
is according to special order. Control circuit, illuminance circuit, indicator light are
.. .,'
controlled by control transformer, and voltage is 24Y.It fits to all kinds of voltages
-I

- -r'-t
and frequency electrical parts. Motors are installed on the machine tool as following:
Ml-Main motor; Mz-lifting motor; M3-column clamping motor
M4-cooling pump motor
Power supply switchboard is at the front-bottom of column, cooling pump motor is
:---
installed on the base, column clamping motor is installed on the top of the column,
the other eiectrical equipments are set on the headstock and rocker arm. Operator
must not always turn the rocker arrn in the same direction to avoid twisting off the
wire that is through the inner column during the operation.
7.1 Preparation work before trial run
Close the door of the electrical box of rocker arm and column before switching on the
power supply. The power supply indicator light HL1 and pushbuttons indicator lights
will light after switching on the main switch QF1,
7.2 Rotation of main motor
Press the start pushbutton SB3, AC contactor KMI sucks and seif-locks, main motor
Ml turns, indicator light HL2 goes out. Press the stop pushbutton SB2, contactor
KMl releases, main rnotor M1 stops, indicator light HL2 lights.
Set thermal relay FR in circuit in order to avoid a longtime overland run of main
motor, set value of thermal relay according to the rated current of main motor
7.3 Rocker arm lift
Loosen rocker arm clamping handle 3, micro switch SQ1 presses cbntact to close,
press lifting button SB4 ( or falling buttons SB5 ), AC contactor KM2(or KM3) sucks,
lifting motor M2 turns to drive the rocker arm to rise (or fall ).
Release the button SB4 (or SB5) when the rocker arm is lifted( or iowered) in proper
position, AC contactor KM2 (or KM3) releases, lifting motor M2 stops.
27
 Limit switches SQ2, SQ3 are used to lirnit the vertical travel of rocker arm, lifting
motor stops when rocker arm lifts in limit position, contacts of limit switches SQ2,
SQ3 break off, AC contactors KM2 (or KM3) go off, lifting motor stop.
7.4 looseness (or clamping ) of column and headstock
Turn change-over switch 14 in loose or clamp position of column right first, contact
of change-over switch 14 connects, put up (press) clamping handle 4 of column and
headstock, contact of micro switch SQ4 closes (open), which make AC contactors
KM4, KM5 sucks or disconnects, and make column clamping motor M3 clockwise or
counterclockwise turn to loosen or clamp the colurnn.
Put up (press) clamping handle 4 of column and headstock, mechanical clamping
plate on the headstock also can loosen (or clamp ) headstock with the action of the
handle 4.
1S
Clamping motor M3 drives cam to press the micro switch SQ5, SQ6 respectively,
[,
which make contacts of micro switch SQ5, SQ6 disconnect, motor stops when micro
or
switch SQ5, SQ6 are in clamping position (or loose position).
he
It will damage the clamping motor when clamping motor is in a overland state for a
long time if column clamp motor is in place and cam can not make the switch off.
7.4.1 Release or clamp headstock alone
be
Turn change-over switch 14 in loose or clamp position of column left first,
hts
contact of change-over switch 14 disconnects, then put up (press) clamping handle 4
of headstock, which realizes alone looseness (or clamping ) of headstock
'7.5'Siart and stop of cooling pump
Eor
Tum on or shut off auto switch QF2 to switch on or off the power supply to
;tor
realize start or stop of cooling pump.
7.6 Check the phase sequence of power supply
rain
Switch on the main power source after installing the machine tool. Press the spindle
start pushbutton SB3, then main motor start, indicator light goes out. Turn the handie
l6 in forward or reyerse position, spindle can clockwise or counterclockwise tum,
ose,
which shows right, otherwise change the any two positions of power supply wires.
rcks
7 .7 Maintenance of electrical equipment
Keep electrical equipment clean, must clean dust, dirty and oil dirty periodically.
Dust may be cleaned by air blower, gasoline and kerosene are forbidden to ciean
rr
r:
i
!

wlres.
Check the motor once a year and clean the bearing, change oil (calcium-base
grease) in the bearing of motor once a year.
Clean all the dirty on the contacts carefully, change the wearing part with the new,
there must not be oil on the contact. Repair the burning or oxidation contact slightly
with file.
Voltage deviation ofpower supply does not exceed *70% of rated power supply.

rih

aE

I
l

--j
s
i

_ sB-
s,

m
-
H
.t--..B.
sqr,

SQ2,I
- SQs,I

29
 Code Name Specification Qtv

M1 motor Y100L1-4 2.2.KW VI I

M2 motor Y802-4 0.75KWV1 I

M3 motor LO27r24-4 370WV1 1

M4 Coolingpump DB-6 75W I

JBK5-160 160VA
TC Control transformer 1
I:0-220Y 1380Y I 4AAY I 415V I 440Y O:0-24V

KMl AC contactor CJX-I-12172 (AC 24V 50Hz) I

KM2.KM5 AC contactor CtX^l-9122 (AC 24Y 50Hz) 4

QSl .Power switch JFDl1-25/31 red I ' :-

QS2 Cooling switch JFDl1-25/31 black I

QFl breaker DZ47-63 (3P 16A) I

QF2 breaker DZ47-63 (3P 1A) 1

QF3-QF4 breaker DZ47-63 (lP 3A) 2

FR Thermal relay JRSs-25IF (4.s-6.sA) '1;

SB1 Emergency stop LAYT-01ZS/red 1

SB2 button LAYT-O18N/red 1

SB3 button LAYT-lODS/green (AC 24Y) 1

SB4-SB5 button LAYT-I0BN/tlack 2

SA knob LAYT-10)#2i01 I

HL1 Indicator light XDl white (AC 24Y) 1

EL light lc25 (AC24V 40U/) I

sQl, SQ4 Limit switch YAL2 2

sQ2, SQ3 Limit switch LX5-1lN 2

sQ5, SQ6 Limit switch KW-1 2

30
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8. Lubrication System of Machine

"i t1,
.::

!-t'*.- r*\ z'';*

i-i"j \U {8J t61
,t
't:

l!
il
f::
\:
t\
t'
1,

I.
I

Open the plastic cover with oiler sign when operator wants to fill oil into oil hole
@. Oit surface can not be higher than center red pot 5 mm of oil mark, otherwise it
wili leak oil.'

No. Oil site Oil no. Cycle No. Oil site Oil no. Cycle Remark
40# 20# Add oil th
Guideway Keep oil on Worm
1 Machine 5 Machine once per
of column the machine wheel it
oil oil shift.
a! P1,
The'lower )tf Change oil Guideway 40# Keep oil
2 part of Calcium-base once half a 6 ofrocker Machine on the rvi
headstock grease vear. arTn oil machine 5ttr
20# Change oil Clamping 20# Add oil Mr
Oil hole of
J Machine once three set of Machine once per
headstock.
oi1. months. headstock oil shift.
eie
Lifting
Upper and a! Do not bel
)# Add oil lead 40# Add oil
lower fill too
4 Calcium-base once per 8 screw of Machine once per of:
bearings of much
grease shift. rocker oil. shift. Put
spindle. oil.
afin.
mal
insr
the
35
 9. Transportation and Installation of Machine

:rllr ,r :r: l Lifting chart

"i:'''
Must load,or.unload
9'[*@ machiine according to outer sign the packing box. Do not tilt
the packing caSe during lifting. Must open the packing container carefully, ot
it will scratch the paint on the machine surface. then convey the machine wlth forklift.
.- sry.ffi
Please set a steei wire rope according to lifting chart when convoying the machine
with crane, and insert some pads or soft cloth between the machine surface and the
steel wire rope.
Must not connect the power supply to the machine during the lifting and instaltatiBrll,
Keep the balance of the machine ciuring lifting'the machine, and do not press the
electrical door. Each part of machine must be in clamping state during lifting and
before installation. Forbid anybody (except operator) to stand within the +180o'range
of rocker arm rotation.
Put the sizing block under the machine according to the following figure in order to
make machine run steadily and keep high machining accuracy, the machine must be
installed on the concrete foundation. Check the ievei of the cross and longitudinal of
the base and make sure the level of the cross and longitudinal of the base does not
36
 exceed 0.1/1000. Fix the foundation bolts after adjusting the accuracy of the machine
according to accuracy test list in the operation manual. Recheck the accuracy of the
machine according to the accuracy test list in the operation manual after the concrete
is dry and fixing the foundation bolts.

Power source incoming

Depth according to the
line tube is 100-200mm
high dbove floor, and condition of the soil
diame{er of tube is 25mm.

ii

ii

'i

Foundation drawing

,!l
37
I

it
 10. Operation of the machine

{-
0,_

t
T

ir
?
I.4
1

ls_
l7
f8

No. Name of operation parts

I Main power switch

2 Cooling pump switch

J Rocker arm clamp handle

4 Headstock, column, electromechanical interlocks cramp handle

5 Headstock moving lever

6 Headstock moving lever

7 spindle feed preselecting knob

38
 9 Dial fine-tuning handle

10 Cutting limit handle

11 Main motor start pushbutton

l2 Main motor stop pushbutton

13 Rocker arm lifting pushbutton

14 Column, headstock clamping/loose knob

15 Rocker arm falling pushbutton

16 Spindle speed change; FWD or REV, neratra{ handle.

t7 Lighting switch

18 Switch on, switch off power feed handle

19 Micro feed handwheel

2A Cooling switch

2t Tota'l stop button

10.1 Star,t of spindle

Switch on the rnain poriler sWitch, po\ilr€r ,sr{}Bly i,fidicator lan'rp lights, and
prishbutton lamp 11 lights. Press brutton 11, main rnotoristants;and pushbutton lamp
tl goes out. Adjust handle 16 in FWD or REV pos,ition,:spirrdle will clockwise turn
or counterclockwise turn.
10.2 Neutral of spindle:
tr
Put up the handle 16, which enable to trrn the spindle slightly by harlds. Press the
F
hatrdle 15 first, then start the spindle again.
10.3 Change of spindle spreed and fsed: I
Turn the preselecting knobs 7, B in required speed and feed position, press the I
handle 16 to change spee,l. @erator may preselect the speed during rotation. s1

0.4mm/rev and above 0.4mm/rev feed is not allowed to adopt during the
400-2500ryrn of spindle speed.
3e
 neutral

speed change

reverse

foreward
10.4 Spindle feed'
Power feed: Press the handle 18 down, then pull out the handle 5.
Manual feed: Push the handle 5, and turn the handle 5, which can drive the spindle to
feed up or down.
Micro feed: Make the handle 18 be in the horizontal position, then pull the*handle 5
out, turn the handwheel 19 to realize micro feed.

-tr
T

10.5 Cuttrng of setting travel:

Pull out the handle 10, tum the handle 9 in the Figure I position, then turn the dial
to make required cutting depth aim at "0" line on the box, then turn handle 9 in the
Figure II position, ffid make fine adjustment to aim at the "0" line, tighten the handle
9 with the other end locking knob, push the handle 10, pull out the handle 5, handle
18 automatically uplift when reaching the setting cutting depth. Must not exceed the
set travel, or it is easy to injure the horizontal shaft.

40
 1 1. Accuracy Test List

Geometry, Accuracy .J691

1.'t : r: ll :
r:lrl:::r ,, :1
,Accuracy
No. :ltem lnspebtion iketch'map,
Allowance Measurr

i Ai
Flatness of base working
Al-_:l
1
surface
.-r_l:
rr-/:
il\1".---_..---]--]i ,,,0.1011000
flai'or concave
O,o J

-::--l cl

Parallelism between
2
headstock movement and 0.30t1000 0.1?.
working face of base.

Parallelism between
3 working fice of ba5e',, 0.05/300 lz
and running of rocker arm 0r0 \

Radial runout of spindle

taper hole alig ,,:; ':::,,
4
i 0.0 25 <1.'ll
I. near spindle nose :

il .o,o5 ,'01
nQ$e ,,.:,,,' ,,, ,,i.
:: : :. ] ]
.,

4T
 lnspceti*n skolch map

e.0.?0llS0St o,lL
Perpendicularity
b" o.ts/t000* a tla
hetwesn spindle
txis tnd working tr
faco uf $ase, dislanue hgtween
tuo eonta*s ef
lndicatar gauge iead

Perpandicularity
betwaen *plndtre
a. 0"101300 6.dB
and wcrking face
of bare, b, 0.&5t3$0 OroT

Displacemrnt of
splndle axis *hen
otol
clampiog tlre
column and 0,or
headstock.

ilsrk f;ccurasy F6st

lcad value{feed

The change of
roslslanre): g lff
a. 3ltf}00-
porpendicularity
b. $ltsf0-
betresn spindlo
axis rnd tabls
';distaace betfleen tuo
surfacs under conta*ts of indicalor,
axfal frrcs.

42
 12. Packing List

No. I.{ame Specification Qtv Remark

I Machine 1

1
2 Table On the machine
pieces

8 There are 4 pieces on

J Hexagon nut M20
pieces the machine.

4
4 Foundation bolts M20x400
pieces

4
5 T-slot bolts M16x65 In the packing case.
pieces

4
6 T:siot bolts M20x400
pieces

8 There are 4 pieces on

7 Flat washer 2A
pieces the machine.

Checker: date:

Spare accessories (To follow the machine)

No. Name Specification Qtv Remark

2A
1 washer SZSGgi-2 6
pieces

8
2 washer SZSG9l-2 6 pieces

a G5t-2 20
O - ring
9x 1.9 pieces

8
4 O - ring G51-2 11 x 1.9
pieces

43
Special accessories (to pay extra charge)

No. Name Specification Qtv Remark

1 Retract wedge t, 2, J Each one

2 Reducing sleeve MT4l2;413;311 Each one

J spanner 200301c 1 piece

44