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Hyundai SKT 100/200 CNC TURNING CENTER. INSTALLATION MAINTENANCE MANUAL (VERSION No.: VOL1.0) - page 5

a. Disassemble the cover at the

rear of machine and check

hoses for damage in the Z-axis

direction and two hoses in the

X-axis direction.

b. Attach the cover.

Fig. 5-30 Checking Moving Hose

4) Cleaning Front Cover of Spindle

For detailed information, see chap. 3-1-2 "Cleaning Front Cover of Spindle".

2-6-2. Around the Machine

1) Checking the operation of Safety device

Check the limit switch and dog installed on the door for operation.

Limit Switch

Dog

Applicable only to the C.E.

Fig. 5-31 Door Interlock

WARNING

Never change the positions of limit switch and dog installed on the door.

Also, using during stopping operation may cause personal severe injury.

5-40

V. REPAIR AND PRESERVATION

2) Adjustment of Belt Tensions

a. Adjusting the tension of spindle belt.

The spindle belt should

Set Screw

Bracket

F (load)

Displacement

Fig. 5-32 Spindle Belt Tension

Table 5-2. Belt Tension

Unit : mm (in)

Model

Belt Displacement

Load

SKT100

10.8mm(0.43)

15.4kgf(154N)

SKT200

10.9mm(0.43)

17kgf(170N)

Used tool: wrench (6mm and 12mm)

b. Unscrew bolts, turn setscrews under bracket and then adjust the tension.

c. After adjustment of tension, secure bolts and engage the above set screws.

CAUTION

When adjusting the tension belt, tighten both of setscrews in bracket to equally to allot the bracket to

move horizontally.

5-41

3) Adjustment of position coder timing belt tension

The timing belt should be checked first after one month of installation. Thereafter, check it every

6 months.

Bolt

Load

Displace-

ment

Fig. 5-33 SKT100 Timing Belt Tension

Unscrew a bolt, adjust the tension as in Table 5-3, and engage it again.

Bolt

Load

Displace-

ment

Fig. 5-34 SKT200 Timing Belt Tension

Table 5-2. Belt Tension

unit : mm (in)I

Model

Belt Displacement

Load

SKT100

2.8(0.11)

0.4kgf(4N))

SKT200

3.1mm(0.12)

0.4kgf(4N)

Used tool : Wrench (10mm)

5-42

V. REPAIR AND PRESERVATION

4) Checking and Changing Wiper

DANGER

Always turn OFF the power before repairing the machine. Otherwise, it may cause personal severe

injury.

Check the wipe for operation and if damaged or broken, exchange it with reference to the

following diagram.

Used tool : Wrench (4mm)

Fig. 5-35 Wiper location diagram

5-43

5) Checking and Exchanging X-axis Multicover

DANGER

Always turn OFF the power before repairing the machine. Otherwise, it may cause personal severe

injury.

Used tool : wrench(5mm) and brush

a. Check the multicover for operation in the manual feed of X-axis.

b. Raise the stainless plate of multicover, check the inside neoprensheet for damage and then

remove chips.

Fig. 5-36 X-axis Multicover

5-44

V. REPAIR AND PRESERVATION

2-7.

Yearly Check and Repair

2-7-1. Around the machine

1) Work light

Follow the orders as below when cleaning a glass of work light or changing a bulb.

WARNING

When exchanging a bulb, always turn OFF the power. Otherwise, it may cause personal injury.

WARNING

1.

When exchanging a bulb, always wear clean gloves. Otherwise, this can result in contamination

on the bulb and affect on its brightness.

2.

Never grasp a bulb with bare hands.

Used tools: wrench (5 mm), damp clothes

a. Unscrew bolts and disassemble the front cover.

b. Remove a bulb by hands and insert new one.

c. Reassemble the front cover.

Fig. 5-37 Changing a Bulb of Work Light

5-45

2) Checking and Repairing Levelling bolt

Used tool:

spanner (24 mm)

a. Check the levelling bolt and nut for looseness.

b. For the adjustment of level, see chapter 4 "Transport and Installation".

Fig. 5-38 Checking Levelling Bolt

3) Adjustment of Backlash in Each Axis

See para. 1-4 "Adjustment of backlash in X- and Z-axes".

2-8. Check and Repair Before Long-term Storage

Check and repair if the machine is stopped for more than 2 weeks as follows:

(1) Apply rust-proof oil.

(2) Remove coolant.

(3) Save the NC data.

1) Rust-proof

DANGER

Before applying rust-proof oil, turn OFF the main power of machine. Otherwise, it may cause personal

injury.

5-46

5) Warm up of Machine

A. Warm up of Spindle

Before operating since stopped for a long time, idle the machine in the following orders.

a. Clamp the rotation speed of

spindle to

1.000 rpm for a

safety.

b. Rotate the spindle with

500

rpm for half an hour.

c. Rotate the spindle with 1.000

rpm for half an hour.

d. Stop the spindle.

WARNING

If rotating the spindle in a high speed suddenly since stopped for a long time, it may result in a failure of

the spindle bearing or chuck cylinder.

B. Warm up each axis (X- and Z-axes) and Tail Stock

Idle X- and Z-axes for half an hour before operation since stopped for a long time.

Fig. 5-49 Warm up Each Axis and Tail Stock

5-48

V. REPAIR AND PRESERVATION

3.

Maintenance of Major Units

3-1.

Spindle

3-1-1. Adjustment of Degree in Spindle

If the spindle changed its position or disassembled for maintenance, adjust as follows:

Pad mounting bolt

Position

Position

Spindle Bolt

Calculation formula

(measured length)

Fig. 5-40 Adjustment of Spindle Accuracy

Used tools: spanner (24 mm), dial gage (0.002 mm)

Material:

∅ 50x250 (∅ 2x10) aluminium or cast-iron

1) Loosen spindle bolt and disassemble into the bolt of A and B pads. Re-assemble A and B pads

and engage spindle bolt.

2) Measure the material for testing (length: 250 mm).

3) Cut the material for testing (fine cut).

4) Measure the roundness of workpiece (For example).

If the difference (overhall length of 250 mm (10)) of cylindricity is 0,015 (0.0006) mm, the

current sum of pad will be 0,030 (0.0012) by the above calculation formula:

c

If the configuration of manufacturing material is

,

polish the grinded surf ace (attached to head stock) of A pad as 0.030 (0.0012).

d If the configuration of manufacturing material is

,

polish the grinded surf ace (attached to head stock) of B pad as 0,030 (0.0012).

5-49

5) Engage bolts for engaging head stock.

6) Fine cut the material for testing.

Adjust the difference of roundness to be less than 0,015 (0.0006) mm.

7) Repeat between 2) and 6) until the roundness reaches to the desired value.

3-1-2. Cleaning Front Cover of Spindle

DANGER

Turn OFF the power when entering the machine for cleaning the front cover of spindle. Otherwise, it

may cause personal injury.

Clean the drain hole located under the front cover of spindle to prevent from being clogged. Drill the

drain hole, using a wire.

Used tool: ∅ 3 wire

Fig. 5-41 Cleaning Front Cover of Spindle

CAUTION

Never use compressed air. It may cause machine failure.

5-50

V. REPAIR AND PRESERVATION

3-2.

X- and Z-axes

3-2-1. X-and Z-axes Constructions

X-axis Servo Motor

Torque Limiter

Torque Limiter

X-axis Ball Screw

Z-axis Servo Motor

Cross Slide

Z-axis Ball Screw

Saddle

Fig. 5-42 X- and Z-axes Constructions

1) X- and Z-axes are driven by ball screws and AC servo motor.

2) The positions of X- and Z-axes are verified by the encoder installed in AC servo motor.

3) X- and Z-axes servo control units are located in the Electrical Box.

5-51

3-3.

Tool Post

3-3-1. Tool Post Construction

Servo motor

Cylinder

Dog

Clamp Limit Switch

Unclamp Limit Switch

Fig. 5-43 Tool Post Construction

3-3-2. Tool Post Home Position Setting

1) Period of Home Position Setting

Because the absolute position detector is used as the position detection system of tool post

servo, the home position setting of Tool Post should be performed in the following cases. If

indexing the tool post without home position setting, alarm no. “A90” will be displayed on the

servo amp.

c

If have disassembled or reassembled the servo motor

d

If exchanging the servo amp

e

If exchanging the battery

f

If disconnecting the detector connector of servo motor

g

If the absolute position data has been missed by other causes.

5-52

V. REPAIR AND PRESERVATION

2) Home Position Setting Method

a. Unclamp

the

turret

by

simultaneously

pressing

“[SPINDLE

STOP]”

and

“[SELECT]”, “[FEED HOLD]” on

the Operating Panel.

The Message,

“2067 TURRET

COMPULSORY UNCLAMP” will

be displayed on the alarm screen.

Parameter K0#3="1"

Unclamp

the

turret

by

Simultaneously

pressing

[TURRET INDEX],

[ROTATING

TOOL STOP] on the operating

panel.

b. Press the Emergency Stop switch.

Emergency Stop

c. Turn the turret by hand and set the

No.

1 tool. Turn the turret and

remain it on the position where the

arrows of turret and tool post body

are aligned.

d. Release the Emergency Stop state

and press the "STAND-BY" switch.

5-53

e. Press the “CALL LIGHT OFF” switch.

The turret is clamped and ALARM

“2067” disappears on the alarm

screen.

f.

Verify that bit "7" of X1000 has been

changed to "1" in the diagnostic

screen.

g. With the Emergency stop switch

pressed, press the Spindle

“STOP”

Mode "SELECT”, and “FEED HOLD”

switches simultaneously.

h. Reset the Emergency Stop switch.

Now the home position setting of tool

post is completed and enables the

turret index.

5-54

V. REPAIR AND PRESERVATION

3-3-3. Adjustment and Exchange of Clamp, Unclamp and Limit Switches.

If clamp and unclamp operations are not satisfied or the limit switch requires to be exchanged,

adjust as follows:

WARNING

Prior to implementing the actions, turn OFF the power. Otherwise, it may cause personal severe injury.

Used tools: wrench (5 mm), spanner

1) Disassemble the cover.

2) Adjust the dog bolt.

3) If exchanging the limit switch, disassemble engaging bolts, replace and then engage the limit

switch (Adjust the dog bolt).

4) Attach the cover.

Cover

Dog

Bolt

Bolt

Clamp Limit Switch

Unclamp Limit Switch

Fig. 5-44 Adjustment and Change of Proximity Switch

5-55

3-3-4. Restoration in Collision of Turret

If the turret is collided by crash, misoperation or program error while turning, correct it in the

following orders.

WARNING

If the power required, always install the safety guard and then work inside of the machine. Otherwise, it

may cause personal severe injury.

Under Repairing

Fig. 5-45 Installation of Safety Guard in Repairing.

Used tools: dial gage (0,002 mm)

∅ 9.8 drill

wrench (8 and 10 mm)

∅ 10 reamer

1) Perform the Home Position Setting of

turret as shown in param.

3-3-2

"Turret Home Position Setting".

Pin

Plug

2) Install the dial gage on the surface

No. 1 of turret and check the X-axis

Bolt

Plug

for flat.

3)If the flatness of turret is more than 0.02

mm, disassemble the plug and pin in

front of turret and loosen the bolt

properly.

4) Adjust the turret so far the flatness is

within 0.02 mm and engage the bolt.

Fig. 5-46 Repairing Turret

5-56

V. REPAIR AND PRESERVATION

5) After engaged, check again for the flatness.

6) Engage the pin to be deviated as 90° from the position of pulled out.

7) Close the plug after pin works.

8) Check for the flatness.

If the turret has been collided

during rotation

Motor

Spare Gear

Verify 1) and 2) and if the flatness is

within the desired value, follow the

Bolt

instructions given below.

Retainer

a. Loosen the bolt and remove a

bundle of motor.

b. Disassemble

the

gear

engaged with motor shaft and

reengage it not to be slided.

Fig.5-47 Repairing Turret

3-4. Hydraulic

3-4-1. Hydraulic Circuit Diagram

Fig.5-48

Hydraulic Circuit Diagram

5-57

3-4-2. Repairing Hydraulic Tank

If there is an abnormal noise or high temperature in the hydraulic tank, check, repair and replace the

pump and motor, if necessary.

1) Turn OFF the power

2) Disassemble the bolt installed in the pump.

3) Disassemble the bolt connected the motor with pump.

4) Disconnect the pump from motor.

5) Apply the power and check the motor for rotation sound.

6) If the rotation sound of motor is high, change the motor.

7) If the motor is normal, change the pump.

CAUTION

Before applying the power since the pump has been changed, fill the filler hole installed on the pump

with hydraulic oil. Otherwise, it may cause the pump burnout.

Fig. 5-49

Hydraulic Tank Disassembly Diagram

5-58

V. REPAIR AND PRESERVATION

Fig. 5-50 Oiling After Changing Pump

Fig.5-51

Hydraulic Tank

5-59

Table 5-4. Hydraulic Tank Parts List

No.

Nomenclature

Qty.

Type

Remark

1

Motor

1

0,4Kw x 4P

2

Vane pump

1

MFG.S-2993

3

Oil Tank

1

10 liter

4

Oil Level Gage

1

VA-01

5

Air Bleed

1

6

T-chuck valve

1

CT-T03-0-4044A

7

Strainer

1

8

Pressure Gage

1

PT1/4 Ø 60 x 70 kgf/cm²

9

Socket

3

PT3/8

10

Nipple

1

PT3/8XPF1/4

11

Separator

1

40x25x10 mm

12

Nipple

2

13

Nut

1

M8

3-4-3. Pressure And Flow Adjustment

The pressure and flow of hydraulic unit have been adjusted at factory and need not to be done

specially. However, for the hydraulic chuck or tail stock it requires to be adjusted. If adjusting it, follow

the instructions given below.

1) Adjustment of Main Pressure

Increment

Decrement

Fig. 5-52

Adjustment of Main Pressure

5-60

V. REPAIR AND PRESERVATION

Used tools:

wrench (5 mm) and spanner (17 mm)

a. Loosen the nut using spanner.

b. If turning clockwise, the pressure is increased and if anticlockwise, it is decreased.

c. After adjusting, engage the nut using spanner.

WARNING

The main pressure is specified to 35 kgf/cm². If used over the specified value, it may cause machine

failure.

2) Adjusting the pressure of chuck and tail stock

Chuck Pressure Control

Valve

Chuck Pressure

Tail Stock

Gage

Pressure Gage

Tail Stock Pressure Control Valve

Fig. 5-53 Adjustment of Chuck and Tail Stock Pressure

If turning the pressure regulating valve knob clockwise, the pressure is increased and if anticlockwise, it

is decreased.

WARNING

The pressures of chuck and tail stock are specified to 27 kgf/cm² and 20 kgf/cm². If used over the

specified value, it may cause machine failure.

5-61

3-4-4. Repairing Manifold

A high level unit composed level the solenoid valve (direction converting valve),

hydraulic control valve, check valve, and etc..

1) Manifold construction

Fig. 5-54 Manifold Construction Diagram

Fig. 5-55 Manifold Disassembly Diagram

5-62

V. REPAIR AND PRESERVATION

2) Exchanging solenoid valve

In case of failures due to the broken internal spool or poor spring, disassemble, clean or

change the damaged solenoid valve in the following orders.

CAUTION

After stopping operation, the solenoid will be hot and cause burns in disassembled and exchanged.

Turn off the power, cool sufficiently and then replace it.

Plate

Screw

Terminal Box

Body

Spool

Cartridge

Coil

O-ring

Resin Nut

Fig. 5-56

Solenoid Valve Disassembly Diagram

Used tools:

+ screwdriver, wrench (4 mm)

5-63

A. Exchanging solenoid coil

a. Loosen and disassemble resin nut from solenoid coil.

b. Disassemble the washer and O-ring.

c. Pull out the coil in the axis direction and disassemble it from the body. Reassemble it in

the reverse order.

CAUTION

Torque the resin nut to 40-50 kgf • cm (4 ~ 5 N • m).

B. Disassembling and cleaning the solenoid valve

If the solenoid valve clogged with foreign matters, disassemble and clean the body as follows:

a. Turn off the power.

b. Disconnect the coil.

c. Remove four bolts from the terminal box.

d. Disconnect the base plate.

e. Loosen and disconnect cartridge.

f.

Disconnect internal parts from the body.

g. Pull out the spool from body without forced power.

h. Clean body and each parts.

i.

Check each parts such as O-ring and then reassemble them.

CAUTION

1.

When assembling the spool in the body of solenoid valve, never push it with a force.

2.

Make sure there are no foreign matters in the valve.

3.

Torque the cartridge to 390-420 kgf • cm (39 ~ 42 N • m).

j.

Attach the base plate.

CAUTION

Torque the plate to 5.5 ~ 8.2 kgf • cm (0,55 - 0,82 N • m).

5-64

V. REPAIR AND PRESERVATION

k. Install the terminal box

l.

Install the solenoid coil

m. Connect wires and turn ON the power

n. Check the hydraulic units for operation.

C. Exchanging the solenoid valve

CAUTION

Solenoid valve is in the high temperature, therefore be careful not to be burned.

a. Turn OFF the power.

b. Remove four screws attached with the terminal box.

c. Disconnect wires.

d. Loosen the bolt securing valve.

CAUTION

When disconnecting bolts, make sure the reduction valve, check valve, and etc. are not

disconnected.

e. Install new solenoid valve.

f.

Torque the bolt to 40 - 50 kgf • cm(4 ~ 5 N • m).

CAUTION

1.

Make sure O-ring between each blocks is not disconnected.

2.

Avoid overtorque. It may cause a failure.

g. Connect the wire of terminal box.

h. Apply the power.

i.

Check for oil leakage.

j.

Check the hydraulic units for operation.

5-65

3-5. Lubrication Device

3-5-1. Place to be Lubricated

1)

4 places of bearing in the linear movement of X-axis.

2)

4 places of bearing in the linear movement of Z-axis.

3)

1 place of X-axis ballscrew and 2 places of support bearing.

4)

1 place of Z-axis ballscrew and 2 places of support bearing.

5)

2 places of tool post.

Fig. 5-57 Place to be Lubricated

5-66

V. REPAIR AND PRESERVATION

3-5-2. Cleaning Lubrication Unit

1) Construction

Fig. 5-58 Lubrication Unit construction

Table 5-5. Lubrication Unit Parts List

No.

Nomenclature

Qty

Model

Remark

1

Oil cap

1

2

Shaft guide

1

3

Filter

1

4

Hose

1

Ø 6(Ø 0.024)

mm(in)

5

Pressure switch

1

6

Oil tank

1

1800cc(0.47 gal)

7

Relief valve

1

8

Gear pump

1

See next page.

9

Float switch

1

10

Motor

1

15W(0.02HP) 2P

5-67

2) Using Lubrication Oil Pump and Motor

A. Pump

Item

Specification

Discharge

100cc/min (0.02 gal/min)

50/60Hz

Maximum Discharge pressure

8 kgf/cm²(0.8MPa)

Voltage

AC 110V(10)

Frequency

50/60Hz

B. Motor

Item

Specification

Power

15W (0.02HP)

Polarity

2P

Voltage

110V

Frequency

50/60Hz

Rated current

1.0/1.2 A

Revolution number

3000/3600 rpm

C. Cleaning Lubrication Unit

Used tools

:

wrench(5mm), + driver

a. Turn OFF the power.

b. Loosen bolts and disconnect the unit.

c. Disconnect the tank using + driver.

d. Clean the inside of tank.

e. Remove the filter from the suction port.

f.

Clean the filter using kerosene.

g. Remove foreign matters from the filter using compressed air.

h. Mount the filter.

i.

Mount the tank.

5-68

V. REPAIR AND PRESERVATION

j.

Install the unit.

k. Supply lubricating oil.

1.

Turn ON the power.

m. Check the wet moving part are being supplied with lubricating oil.

Fig. 5-59 Cleaning Lubrication Pump

WARNING

When cleaning the pump, remove oil dropped on the floor. Otherwise, it may cause personal injury.

5-69

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