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Hyundai SKT 100/200 CNC TURNING CENTER. INSTALLATION MAINTENANCE MANUAL (VERSION No.: VOL1.0) - page 3

No.

Name and Number

Figure

Qty.

1676014040

3

(Leveling Seat)

6

4

Foundation Bolt

6

1676-09-301-0

5

(Level-Plate)

1

4-2. Foundation Work

CAUTION

Special attention should be paid o the foundation work since it have great influence on maintaining the

accuracy of working and initial installing for a long time.

a. To install the machine, it needs the concrete floor over 300mm in thickness. Put the! levelling

set under the levelling bolt.

b. To maintain machine accuracy, install new concreat ground at the place where has 1 less

than 300m in thickness (See Para. 4-5, Foundation Work).

4-8

IV. TRANSPORT & INSTALLATION

4-2-1.

Without using Foundation Bolt

a. Put the levelling seat at the place shown in foundation diagram.

b. After inserting the levelling bolt in the machine, put it above the levelling seat with about

10mm distance from the upper side of levelling seat.

c. Adjust the levelling bolt, set the level of machine correctly and then tighten the levelling

nut.

Fig. 4-4 Installation of Levelling Bolt

4-2-2.

Using Foundation Bolt (Optional)

a. Place the machine at the place to be installed and perform the 1st levelling work. If the

levelling seat is out its position or it is impossible to adjust it with the levelling bolt due to

poor foundation, use a wedge to do a levelling work.

b. After a completion on the first levelling work, insert the foundation bolt from the bottom of

machine and install it to the machine using nuts.

c. Fill the mortar up to the bottom and the side of levelling sear and stir it with a bar.

d. Adjust the levelling bolt, complete levelling work in all sides, and then engage the

foundation bolt tightly.

4-9

Foundation

Bolt

Seat

Mortar

Concrete

10 - 15 mm

Gravel

Fig. 4-5 Foundation Work

5.

Adjustment of Level

(1) The levelling method is one of the factors to determine the degree of machine.

(2) Levelling the machine is the most- basic work and has an influence on the degree of the

workpiece and the life of machine itself.

(3) Perform levelling in the following order.

a. Install the machine on the floor to be installed as shown in the chapter 4, "installation"

b. Attach the level plate to the turret as shown in Fig. 4-6.

c. Place the level above the level plate.

d. Move the level much as the full feed in 2-axis (430mm 16.93in) and then read the result.

At the time, adjust the level using the levelling bolt so that the difference from the

reading is ±0.04mm/m (±0.00157in/40in)

Level Tolerance

0.04 mm/m(0.00157in/40in)

Level Accuracy

1 scale = 0.02 mm/m(0.00079in/40in)

4-10

IV. TRANSPORT & INSTALLATION

Level

Level Plate

Fig. 4-6 Adjustment of Level

e. Handle the used level enable to maintain the same level in the same direction.

CAUTION

1.

Keep the contact face of level clean to prevent dust, etc. from penetrating the level in

measuring.

2.

Uncontrolled level of the machine may result in malfunction due to declination or worn at

the wet moving part of bed.

3.

When move the level, be careful not to be interfered with chuck and tail stock.

(4) In the last horizontal levelling, do a job with the foundation bolt and nut tightened firmly.

(5) After installing the machine, perform the levelling as follows.

Term

Period

for 2 - 3 days after installing the machine

Daily

for 6 months

Monthly

after 6 months

Quarterly

4-11

6.

Cleaning

(1)

When transporting the machine, there is a risk of mixing with sand or dust. Therefore

secure the saddle or cross slide before cleaning

(2)

Because each part of this machine has tightened at factory, loosen and then clean it.

(3)

When cleaning the machine, wipe out the anticorrosive paint using soft cotten clothes wet

with kerosene or benzene.

(4)

Remove the moisture all over the machine completely.

CAUTION

When cleaning, do not use compressed air. Otherwise, it may cause damage allowing foreign

matters to enter into the crevice by air pressure.

4-12

IV. TRANSPORT & INSTALLATION

7.

Lubrication and Oiling

(1)

Perform oiling at the positions as shown in Figs. 4-7, 4-8 and 4-9.

(2)

Table 4-1 shows the recommended lubrication and oiling.

7-1.

Hydraulic Oil

1)

Fill up the quantity of oil to the degree higher than that of oil gage (After filled up, it is

recommended that the level is met with the standard level of oil gage).

2)

Quantity of oil is 15 liter(3.92 gal).

Fig. 4-7 Filling Hydraulic Oil

3)

After this, perform oiling as specified.

7-2.

Oiling Wet-Moving Parts in the X-and Z-axes

1)

Fill oil the lubrication tank in front of bed.

2)

The quantity about 1.8 liter(0.47 gal).

3)

If the oil is exhausted in the tank, the red lamp will be illuminated on the Operating Panel.

Then, fill it up.

Fig. 4-8 Filling Lubrication Oil

4-13

7-3.

Oiling Hydraulic Chuck

•

Fill up the chuck daily while opening and closing it by means of the grease gun.

Fig 4-9 Greasing Chuck

Table 4-1. Lubrication Oiling Table

Place

Method

Quantity

Period

ISO Spec.

Maker

Used Oil

CB32 or

SHELL TELLUS

SHELL

HL32

OIL C32

Hydraulic

ESSO

TERESSO 32

Half-Yearly

tank

MOBIL DTE OIL

MOBIL

LIGHT

CALTEX

FBK OIL RO32

SHELL TONA

SHELL

If the

OIL T68

Wet

lubrication

ESSO

FABIS K-68

moving

G68

lack lamp

MOBIL

part

illuminated

MOBIL

VACTORA OIL

No.2

SHELL

ALBANIA 2

Manual

Daily More

DOW

MOLY KOTE

Hydraulic

Oiling

fully

than one

CC460

CORNING

BR2-S

chuck

Grease

time

MOBILUS

Gun

MOBIL

GREASE 2

4-14

IV. TRANSPORT & INSTALLATION

8.

Coolant

There are several kinds of coolant such as soluble and insoluble ones. The methods of filling

coolant into the machine are as follows.

(1)

Fill coolant into its tank in the rear of machine.

(2)

Total quantity of coolant is 135 liter.

Name

Quantity

Total Quantity

Coolant main tank

92 liter(24 gal)

135 liter(35.23 gal)

Coolant auxiliary tank

43 liter (11.23 gal)

Coolant Main Tank

Coolant Auxiliary Tank

Fig. 4-10 Filling Coolant

(3)

When installing the machine, performing test operation or having not used for long-term,

use the spare sufficiently.

4-15

(4)

Notice When Using Soluble Coolant

1) When selecting soluble coolant, select one in consideration of the lubrication, settlement,

anticorrosive, foaming device, unfixing with oil, safety, and so on.

2) Before starting or after stopping the work, remove chips and clean up soluble coolant

attached on each wet moving part, tool post turning part, and cross slide.

After that, always apply lubrication oil lightly.

3) Exchange the soluable coolant if corroded.

CAUTION

1.

Because soluable coolant is anti-corrosive treated, it is good in wet condition but easy to be

corroded in a dry state. After a completion of work, do not forget to apply anticorrosive oil on

the wet moving part.

2.

The soluable coolant has an alkalis factor and may remove fat from the personal skin. So, be

careful of worker' s health.

3.

For the dilution method and agent of soluable coolant, follow the manufacturer's instruction

because they are different dependent on its kind.

4)

For the dilution method and agent of soluable coolant, follow the manufactures's instruction

because they are different dependent on its kind.

9.

Electric Power and Wiring

CAUTION

For the electric device (welder, high-frequency seasoning device, electric spark machine, and

etc.) occurring high-frequency noise, use the independent switchboard or install it away from over

20m.

Over 20m

4-16

IV. TRANSPORT & INSTALLATION

9-1.

Power Switch

Install other machines with the independent power switches at the place where easy to open and

close. See the following table for the capacity of fuse.

9-2.

Wiring To Machine Form Power Switch

Perform wiring to the 1st NFB1 through leading hole located in the lower left of the Electric Control

Panel. For the thickness of wire, see the following table and connect if so far the R.S.T not to be

changed.

Leading Hole

Model

Power Capacity

Available [mm*]

Fuse [A]

(kVA)

R, S, T

Grounding line

SKT100

11.4

14

14

75

SKT200

14.1

16

14

75

4-17

9-3.

Changing Electric Units According to Voltage and Frequency

CAUTION

If the voltage fluctuated seriously, it may cause misoperation of the machine and failure of the electric

and electronic parts. Therefore, set the fluctuating rate not to exceed ± 10%.

According to the voltage and frequency of the power of factory, it is needed to change the setting

of electric applications. Prior to changing, check its voltage and frequency.

1) Power voltage 200/220V ± 10%

2) Power frequency 50/60Hz ± 1Hz

9-3-1. Tab Changing for Controlling Transformer

Open the door of the Electric Control Panel, remove the plastic cover of Transformer and then

change the wiring as shown in the following table.

Voltage

R2

T,

191-210 V

200 V

0 V

211-240 V

220 V

0 V

4-18

IV. TRANSPORT & INSTALLATION

9-3-2. External Transformer

CAUTION

Transformer for 220V power supplier

The transformer should be installed by the customer' s direct purchase. This company

can't provide any external transformer for the 220V power supplier.

But the specific feature of a transformer should follow as below.

1)

Available only to EN 60742 (Please use authorized products)

2)

Feature

- Capacity : Above 25(KVA)

- Voltage - Primary : 380~440(V)

- Secondary : 200~220(V)

OUTPUT

INPUT

Power Supply Switch

External Transformer

Electric Box

9-4.

Grounding

WARNING

Only authorized engineer can do earth working. Failure to comply may result in personal severe injury,

death, or accident.

1)

All electric devices should be grounded to prevent personal injury and misoperation of

the machine according to the specification, after installed.

2)

Select the grounding point as close to the machine as possible and perform wiring

independently.

4-19

3)

Do the third-Class grounding only by the authorized engineer,

a.

The third-Class grounding

-

Thickness of wire : under 100 Ω

-

Thickness of wire : 1.5 times as that of power supply in thickness.

At least 14mm2

-

Measuring device : 500V Megger

4).

Grounding Method

The machine should be grounded by one of the following methods,

a.

Individual grounding

b.

Common grounding

* The grounding line of each machine should be grounded at its ground terminal

directly.(Only one line to one terminal)

* Grounding resistance =

100

[Ω]

number of machine

c.

Never ground in the following methods.

4-20

IV. TRANSPORT & INSTALLATION

10.

Disassembling and Cleaning Shipment Fixture

When shipped, each axis is fixed by shipment fixture for a safety.

WARNING

NEVER operate the machine before disassembling the shipment fixture.

After disassembling the shipment fixture, unless otherwise stated, clean the applied anticorrosive

agents with light or cleaning oils and apply the cleaned part with lubricating oil for sliding.

CAUTION

Do not use oil or kinds of chemicals which may affect the painting of body. Be careful of a fire.

The location of the shipment fixture is shown in the following figure (yellow painting).

Shipment Fixture(Yellow)

4-21

11.

Checking Before Test Working

Before test working, make sure the followings.

(1)

Check all the fixtures for transport or shipment are removed.

(2)

Check any part or accessory is omitted.

(3)

Check the lubricating, operating oil, and coolants are supplied properly.

(4)

Check the coolant tank is located properly.

12.

Required Dimension In Working 12-1. Tool Moving Range

•

Variable array tool post stroke

mm

Type

Tool Post

A

B

C

D

E

F

G

H

I

J

SKT100

12 angle spec.

169

91

32

35.2

91

185

18

35

190

20

SKT200

12 angle spec.

210

114

38

42.1

120

190

47

68

157

53

4-22

IV. TRANSPORT & INSTALLATION

12-2. Tod Interference Diagram

1)

SKT100 Interference Diagram

Unit: mm

4-23

2)

SKT200 Interference Diagram

Unit: mm

4-24

V. REPAIR AND PRESERVATION

1.

Mechanical Overview

1-1. Mechanical Construction

X-axis Motor

X-axis Motor

Turret

Saddle

Tool Post

Z-axis

Head Stock

Bed

Z-axis Motor

Rotary Cylinder

Coolant Tank

Spindle Motor

Hydraulic Manifold

Hydraulic Motor

Fig. 5-1 Mechanical Construction - Major Unit

5-1

1-2. Moving Range of Axis

X-Axis Up/Down direction vertically with the center of spindle

X-Axis

+: in tool post upward

-: in Tool post downward

Z-axis Up/Downward direction horizontally with the center spindle

Z-axis

+: in the right direction of tool post movement

-: in the left direction of tool post movement

CAUTION

It is based when the operator spindle stands in front of the machine.

- direction X-axis

+ direction

- direction Z-axis

+ direction

Fig. 5-2 Moving Range of Axis

5-2

V. REPAIR AND PRESERVATION

1-3.

Reference Point Adjustment of Each Axis

Reference point may be changed and resetted for repairing and checking or due to the collision

of tool post. This time, the reference point should be adjusted in the following orders.

CAUTION

Reference point is the unique position determined by the parameter of NC device and the dog & limit

switch of machine.

1-3-1. Reference Point Adjusting Method 1

In case that "[MACHINE(ABSOLUTE)]" coordinate value is less than reference point, adjust it in

the following method.

1) Initiate running distance

Initiate the Reference Point Return Running Distance entered.

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

Press [SETTING] key

PARAMETER WRITE

5-3

b. Initiate the Reference Point Return Distance by selecting parameter screen.

c. Make parameter change invalid, turn off and then re-apply the power.

2) X-Axis Reference Point Adjustment

a. Attach Dial Gauge(1/100) at holder and then secure in chuck.

CAUTION

If using Magnet Stand instead of Fixture, it may be curved over 0.1 mm.

b. Put the indicator near to I.D base holder using feed handle and set the motion to "0" in

the X direction.

Xy direction

c. Select the package position screen.

5-4

V. REPAIR AND PRESERVATION

d. Set the mode to Handle Z, move the Head Stock in the + direction of Z-axis

e. The differences between reference point position in X-axis and the coordinate value of

MACHINE become a running distance.

3) X-Axis Reference Point Adjustment

a. To approach the outer diameter

bite tool to chuck and protect the

blade end, use a thin piece of

paper, feed the handle and

approach the tip end of bite tool

to the jaw section until the paper

is not moved.

b. Select the package position screen.

5-5

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

it not to disturbed in Tail Stock (Special Accessory).

d. The differences between reference point position in Z-axis and the coordinate value of

MACHINE become the grid shift amount.

4) Input Running Distance

a. Make the parameter change valid according to para. 1).

b. Calculate the running distance

If the [MACHINE] coordinate is set to 377.268 and 332.754 for 380.000 in the X-axis

and 330.000 in the Z-axis, the running distance of each axis will be calculated as

follows.

• X-axis distance = initial value + (380.000-377.268) X1000

= 1000+2732 = 3732

• Z-axis distance = initial value + (330.000-322.754) x 1000

= 1000+7246 = 8246

CAUTION

In case that "MACHINE" coordinate value is more than the reference point distance, it is required to

adjust the deceleration dog.

c. Change the parameter.

5-6

V. REPAIR AND PRESERVATION

1-3-2. Reference Point Adjusting Method 2

In case that "MACHINE (ABSOLUTE)" coordinate value is more than the reference point

distance, adjust in the following method.

1) Initialize running distance

Initialize the running distance as in "Zero Adjusting Method 1", turn off and then re-apply

the power.

2) X-axis

mm(in)

Fig. 5-3 Moving Range of X-axis

Set the distance to the center of spindle from that of I.D. Base holder from that of spindle at

380.000 (SKT100) and 314.000 (SKT200) in the + direction.

a. Attach Dial Gauge (1/100) at holder and then secure in chuck.

CAUTION

If using Magnet Stand instead of Fixture, it may be curved over 0.1 mm.

b. Make I.D. base holder in

proximity to indicator using

feed handle and set the motion

in X direction to "0".

Xy direc-

tion

5-7

c. Set the coordinate "X" to "0

d. Set the mode to Handle Z, move the turret head in the + direction of Z-axis and make

it not to be interfered with Tail Stock.

e. Move the X-axis to reference point by means of handle.

5-8

V. REPAIR AND PRESERVATION

CAUTION

1.

Perform only in X-axis.

2.

Place Z-axis at a distance from reference point.

f.

This time, move the current position "EXTERNAL" coordinate to be 380.000 (SKT100) and

314.000 (SKT200), set the coordinate X at "0" and then move it about 1/2 (6,000) of ball

screw pitch in the opposite direction from Reference Point Return.

g. Move the reference point return dog to the position where the reference point reduction

signal is turned ON.

Fig. 5-4 Reference Point Return Dog Movement

h. Reference point return the X-axis.

5-9

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