Model Hbw 110R2 Horizontal Boring

MODEL HBW 110R2 HORIZONTAL BORING

& MILLING MACHINE

OPERATION MANUAL

(MECHANICAL SECTION)

SPINDLE DIA.Ф110mm

MODELHBW110 R2

NO.

KAAST Machine Tools, Inc.

CATALOG

1.INTRODUCTION

1.1CLASSIFICATION OFOPERATIONMANUALS

1.2FEATURES

1.3MAIN UTILIZATIONANDAPPLICATIONRANGE

2.STRUCTUREANDWORKINGPRINCIPLE

2.1MAINSTRUCTUREANDWORKINGPRINCIPLEANDFEATURES

2.2UTILIZATIONANDWORKINGPRINCIPLEOFMAIN COMPONENTSANDFUNCTIONALUNIT

3.TECHNICALCHARACTERISTIC

3.1MAIN CHARACTERISTIC

3.2MAINPARAMETERS

3.3OVERALLAND INSTALLATIONSIZES

3.4WEIGHT

4.LIFT,INSTALLATIONANDADJUSTMENT

4.1LIFT AND INSTALLATION PROCEDURE, METHOD AND PRECAUTION

4.2ADJUSTMENTPROCEDURE,METHODANDPRECAUTION

4.3TRIALRUN

5.OPERATION

5.1PREPARATIONANDCHECKINGBEFOREOPERATION AND SAFETYPROTECTION DURING OPERATION

5.2OPERATIONPROCEDUREANDMETHODDURING STARTINGANDRUNNING

6.TROUBLESHOOTING

7.SAFETYPROTECTIONDEVICEANDPRECAUTION

8.MAINTENANCEAND LUBRICATION

8.1PREVENTIVESERVICEAND MAINTENANCE

8.2SERVICEANDMAINTENANCEDURING RUNNING

9.TRANSPORTATIONAND STORAGE

9.1TRANSPORTING PRECAUTION

9.2STORING CONDITIONANDPRECAUTION

10.EXPLANATIONSFORACCESSORIESANDVULNERABLE PARTSAND SPECIFICATIONSOF ROLLING BEARINGS

10.1CUTTINGTHREAD

10.2EXPLANATIONS FORVULNERABLE PARTS

10.3LISTOF ROLLINGBEARINGS

FIGURES

FIG.2-1“OVERALLFIGURE”of HBW110R2FIG.2-2“OVERALLFIGURE”ofHBW110R2FIG.2-3 “OVERALLFIGURE”ofHBW110R2

FIG.2-4 DIAGRAMOF DRIVE SYSTEM

FIG.2-5DIAGRAMOF SPINDLESTRUCTUREFIG.2-6DIMENSIONOFTHESPINDLENOSEFIG.3-1 HBW110R2“FOUNDATION”

FIG.4-1 HOISTINGBED

FIG.4-2CHECKING INSTALLATIONLEVEL FIG.4-3HOISTINGAUXILIARYGUIDEWAYFIG.4-4 HOISTINGCOLUMN

FIG.4-5HOISTING WORKTABLEFIG.4-6HOISTINGHEADSTOCK

FIG.4-7ADJUSTMENTOFOVERLOADFEED SAFETYDEVICEFIG.4-8 ADJUSTMENTOFV-BELTDEVICEOFMAINMOTORFIG.4-9 ADJUSTMENTOFCLAMPING DEVICEOF HEADSTOCKFIG.4-10 ADJUSTMENT OF CLAMPING DEVICE OF ROTARY

WORKTABLE

FIG.4-11HOISTINGSMALLCOLUMNFIG.5-1MACHINECONTROL

FIG.5-2POSITIONINGDEVICEOF ROTARYWORKTABLEFIG.8-1 LUBRICATIONSYSTEM

FIG.10-1 FRICTIONDISK

FIG.10-2FRICTIONDISKOF GEARFIG.10-3PRESS PIECE

FIG.10-4ARRANGEMENTOFROLLINGBEARINGS

FIG.11-1DIMENSIONOFT-SLOTOFFACINGHEADANDDIMENSIONOFT-SLOTANDPOSITIONINGHOLESOFWORKTABLE

1.INTRODUCTION

1.1CLASSIFICATIONOFOPERATION MANUALS

HBW110R2operationmanualsarecomposedofoperationmanualformechanicalsection,operationmanualforelectricandoperationmanualfor DROunit.

1.1.1The mechanicalsectionisprovidedwith four-pointpositioning.

1.2FEATURES

ThespindlediameterofthiskindofmachineisФ110mm.Thespindlesystemfeaturesstrongrigidity,it’ssuitableforroughmachining,henceimprove machiningefficiency.

Themachinebed,column,upperandlowerslidecarriagesadoptrectangular guideway.Themachine featuresgoodstability.

isequippedwithsteel-insertedauxiliaryguideway,strengtheningrigidityoflowercarriage,enlargingtraversaltravelandmachine’soperatingrange.

Thismachineadoptselectronicopticaldigitaldisplayunittomakecoordinatemeasurement.AdoptingDROunitcanimproveefficiencyandlower cost.

Themachineconformstoaccuracystandardofhorizontalmillingboringmachine;the standardnumber isGB5289.1-2008.

1.3MAINUTILIZATIONANDAPPLICATIONRANGE

Themachineisdesignedformachiningvariousholesandplainsurfaces

ofmachinepartsbothinpieceworkandbatchproduction.Sinceit’sequippedwithfacinghead’sradialtoolholder,sobiggerholeandbiggerplainsurface canbemachined.

Inadditiontoavarietyofdrilling,enlarging,boringandreaming,it’salsosuitableformillingandthreadcutting(threadcuttingattachmenthastobe orderedseparately).

2.STRUCTUREANDWORKING PRINCIPLE

2.1MAINSTRUCTURE AND WORKINGPRINCIPLE ANDCHARACTERISTIC

2.1.1Overall figure(seeFig.2-1, 2-2, 2-3)

Asthefig.2-1,fig.2-2andfig.2-3shown,theHBW 110 & 110R2aremainlycomposedofmachinebed,headstock,frontcolumn,endcolumnwithrearsupport,upperslidecarriage,lowerslidecarriageandworktable,etc.

Toolislocatedonthespindleofheadstockorfacingheadinmachining.Everykindofspeedandfeedingamount canbeachievedfromtheheadstock.Theheadstockmovesupanddownalongtheguidewayoffrontcolumn.Theworkpieceislocatedontheworktable.Itcanmaketransversalandlongitudinalmovementwiththeworktablefollowingtheupperandlowerslidecarriages.Andtheworktablecanalsorotatea

certainangleinhorizontalplaneroundingthecircleguidewayofupperslidecarriage,soastomachineholeorplanewithacertainangle.Theboringtoolonthespindlecanmakeaxialmovementfollowingthespindletofinishaxialfeedoradjustaxialpositionoftool.Ifthespindleandtoolbarextendtoolonger,loaditsleftendwithbearingtostrengthenrigidofspindleandtoolbar.Whenthetoolislocatedontheradialtoolholderoffacinghead,theradialtoolholderdragsthetooltodoradialfeedingtoturnend.

2.1.2HBW110R2have7kindsofmovement:mainmovement,powerfeedmovementofspindleandradialtoolholderoffacingheadandmanualtrimmingofeverymovablecomponents.Manualfeedofspindleandradialtoolholderoffacinghead,feedingofheadstockandendcolumnsupport(upanddown),transversalandlongitudinalfeedingofworktableandrapidtraverse.

Heregivesoutdescriptionrespectivelyreferringtothediagramofdrivesystem.

2.1.2.1MAIN MOVEMENT

Atwo-speedmotor,whichislocatedontheheadstock,drivesthemachine.PoweristransmittedfromthemotortoshaftIIthroughV-belt.Gears6,5,4ofthetripleslidinggearonshaftIIareengagedwithfixedgears3,2,1 ontheshaftIII.Thenthrough the following gearsand shafts,

i.e.fixedgears61,62ontheshaftIII,gears60,59,58ofthetriple

slidinggear ontheshaftIV,fixedgears57,9ontheshaftVandgears10,11;powerisfinallytransmittedtothespindle.Besides,poweristransmittedtofacingheadthroughgears115,113.18stepsofspindlespeedand16stepsoffacingheadspeedarethereforederivedfromthetwo-speedmotoranddifferentpositionsofthetripleslidinggears.(Speed160rpmand180rpm areinhibited.)

2.1.2.2POWERFEEDOFSPINDLEANDRADIALTOOLHOLDER

Feedpoweristransmittedfromgear57ontheshaftVtogear88ofthedoublegearontheshaftXII.Thentheothergear89ofthisdoublegeartransmitspowertotheshaftXIIIthroughgear87.Thengears86,85,84ofthistripleslidinggearonthatshaftdrivethefixedgears80,82,83ontheshaftXIV,andthefixedgears81,82ontheshaftXIVtransmitpowertogear78,79ontheshaftXVrespectively.Doubleslidinggears72,71onshaftXVareengagedwithgears70,69ontheshaftXVI.Whereasgears70,69areagainengagedwithgears68,67ontheshaftXVII,transmittingpowertogear73onsafetyclutchshaftXVIIIandthentoshaftXIXthroughgears77and76.Thenpoweristransmittedthroughbevelgears75and74toverticalfeedshaftXX.Theworm55onthefeedshaftis engagedwiththewormgear56todriveshaftVIIIonwhichdirectionchangegears21,18,20,19 areableto transmitpowertogear54ontheshaftIXinbothdirection.Thenthroughgear17onthat

shaft,gear16ontheshaftXandgears15and14thefeedmotionistransferredtoleadscrew12.Thusspindleaxialfeedisobtainedbytherotationofleadscrew12throughnut13.Throughgear110onshaftXXXII,poweristransmittedtogear107.Andanotherpoweristransmittedtogear111fromafixedgear113onthefacinghead,throughplanetarymechanismbothpowers aretransmittedtogear116onthefacingheadfromgears108,109ontheshaftXXXIII.Thenthroughgear119,worm118ontheshaftXXXIV,wormgear117andgear114 ontheshaftXXXV,finally,poweristransmittedtotherackonthe slidingblockofthefacinghead(whichisengagedwiththegear114),hencetheradialfeedingofthefacinghead’sradialtoolholdercanbeobtained.

Intheabovementioneddrivingsystem,18stepsofspindlefeedand18stepsoffacinghead’stoolholderfeedareobtainedbyonetriplegearandthree double gears(since two ofthem have thesame numberofteeth,thedouble-gearscangive3combinationsofspeedonly.).Highspeedandhighfeedrateshouldnotbeused simultaneously.

2.1.2.2.1The productofspindle speedbyfeedmust1.8m/min.

2.1.2.2.2The productoffacingheadspeedbyfeedmust0.6m/min.

2.1.2.3MANUALTRIMMINGOFMOVABLEPARTS

Manualtrimmingofallmovablepartsiseffectedbymeansofhandle(7)throughgears66,65andbevelgears64,63,finallytransmittingpower

tothe shaftXX(hereafterfollowspower feed).

2.1.2.4HANDFEEDOFSPINDLEANDFACINGHEAD’SRADIALTOOLHOLDER

Spindleandtoolholderhandfeedareeffectedbymeansofhandle(13)throughbevelgears51,52toshaftXXIandthenthrough24,53toshaftIX(hereafterfollowspower feed).

Readingsonscalediskareobtainedfromgears25,29,30,31,50and49whenusingspindle andtoolholder power feed.

2.1.2.5FEEDINGOFHEADSTOCKANDENDCOLUMNSUPPORT(UPANDDOWN)

Power istransmittedinthefollowingway:

Throughbevelgear36onshaftXXtogear37onshaftXXII;throughgear39and38toshaftXXIII;throughgears90,91,92ofthebi-directionalgeargrouptoshaftXXIV;throughgears45and44toshaftXXV;throughgears46,47toshaftXXVI.Finallythroughgears28and27passtoleadscrew23andnut22.Thustheheadstockupanddownfeedmovementonthefrontcolumn’s guideway isobtained.

Thereare18stepsofheadstockfeedsincethereare18differentspeedonshaftXX.Atthesametimegears99and98ontheotherendofshaftXXVItransmitpowertoleadscrew103ofendcolumnandnut105.Sothattheboringbarstayontheendcolumnobtainsthesame18stepsofupwardanddownwardfeed.

Theheightdifferencebetweenthesupportholepivotandthespindlepivotafterupanddownmovementcanbeadjustedthroughworm106andworm gear 104onthe endcolumn.

Manualfeedoftheheadstock(upanddown)iscarriedoutbymeansofgears26ontheshaftXXVIIand27ontheshaftXXVIII.Longitudinalmovementofendcolumnalongbedisrealizedmanuallybytransmittingtheforcefrombevelgear101ofshaftXXXIandbevelgear102ofshaftXXXVItoshaftXXXVI,thenthroughgear 100engagingwithrack40.PRECAUTION:Highspindlespeedandhighfeedrateshouldn’tbeused simultaneously.

Theproductof spindlespeedbyfeedmust≤1.8m/min.

2.1.2.6LONGITUDINALANDTRANSVERSALFEEDOFWORKTABLE

Bytransmittingpowerfromgear48onshaftXXIVandgear97onshaftXXIXtoleadscrew94andnut95,transversalpowerfeedofworktableisobtained. It alsohas18steps.

PRECAUTION:Highfeedrateandlargefeedshouldn’tbeusedsimultaneously.

Theproductof spindlespeedbyfeedmust1.8m/min.

Manualtransversalfeedis carriedoutthroughhandleverandclutch(20)rotatingleadscrew94andnut95.Longitudinalpowerfeedofworktableisrealizedbytransmittingpowerfromworm93onshaftXXIVand

wormgear42tobevelgear41andrack40.Manuallongitudinalfeedisobtainedbyahandlevel,clutch19,gear96and43,worm93,wormgear42,aswellasbevelgear41andrack40.Insuchcasefeeddistributionclutchhastobe disengaged.

2.1.2.7RAPIDTRAVERSE

Inordertoreducedowntime,rapidtraversedevicesareprovidedforallmovingparts.Poweris transmittedfromthebuilt-inmotorthroughgears33, 32, 34, 35toshaftXXII anddistributedtovariousmechanisms.

Attention:

Whentheheadstockgoesdownandthedistancebetweenspindleaxisandtablesurfacereaches5mm,atthattimethespindleshouldhavebeenwithdrawnpreviously.Sothatitshouldnotcomeintocollisionwiththetablesurface,itisnotallowedtogoanyfurther,otherwisetheleadscrewnutontheheadstockwillcomeintocontactwiththepartsofmachinebedandrasterruler.Becauseradialstrokeoffacinghead’sradialtoolholderisshorter,whenrapidmovingorpowerfeedisclosedtotheendofthestroke,youshouldchangepowerdriveintohandoperationtopreventaccidents.Ifithasexceededthetravellimit,thetoolholdermustn’tfeedcontinuously.Inthiscase,themachinemustbestoppedimmediately,andtoolholdershouldbereturnedtooriginalpositionbyhand.Themachinecanberestarteduntilhandfeedoftoolholdercanbeobtainedagainbyhandwheel13.

2.1.3LISTOFGEAR,WORM, GEARWORM,LEADSCREWAND NUT

No. / PartNo. / TeethHeads / Module
Pitch / Directionor HelicalAngle / DeflectionAmount / Material / HeatTreatment
1 / 3A322HBW110 / 49 / 3 / +0.93 / 40Cr / G48
2 / 3A323HBW110 / 41 / 3 / +0.94 / 40Cr / G48
3 / 3A312HBW110 / 57 / 3 / +0.79 / 40Cr / G48
4 / 3A320HBW110 / 28 / 3 / +1.32 / 40Cr / T250G48
5 / 3A321HBW110 / 36 / 3 / +1.31 / 40Cr / T250G48
6 / 3A314HBW110 / 20 / 3 / +1.46 / 40Cr / G48
7 / 3A315HBW110 / 24 / 2.5 / 45
8 / 3A316HBW110 / 24 / 2.5 / 45
9 / 3A306HBW110 / 48 / 4 / +1.27 / 40Cr / G48
10 / 3A324HBW110 / 32 / 4 / Left13013’ / +1.00 / 20Cr / S0.9-C59
11 / 3B312HBW110 / 69 / 4 / Right13013’ / -1.00 / 20Cr / S0.9-C59
12 / 3L302HBW110 / 3 / 8 / Right13026’ / 45
13 / 3L309HBW110 / 3 / 8 / Right13013’ / 15
ZQSn6-6-3
14 / 3L301HBW110 / 69 / 2.5 / -0.25 / 45 / G48
15 / 3L303HBW110 / 50 / 2.5 / 45 / G48
16 / 3F304HBW110 / 33 / 2.5 / +0.8 / 45 / G48
17 / 3F303HBW110 / 48 / 2.5 / +0.5 / 45 / G48
18 / 3F313HBW110 / 47 / 2.5 / 40Cr / G48
19 / 3F308HBW110 / 47 / 2.5 / 40Cr / G48
20 / 3F309HBW110 / 33 / 3.5 / +1.01 / 20Cr / S0.9-C59
21 / 3F310HBW110 / 47 / 2.5 / 40Cr / G48
No. / PartNo. / TeethHeads / Module
Pitch / Directionor HelicalAngle / DeflectionAmount / Material / HeatTreatment
22 / 3G306HBW110 / 2 / 3 / Right7016’ / 15
ZQSn6-6-3
23 / 1A303AHBW110 / 2 / 3 / Right7016’ / 45 / T235
24 / 3D313HBW110 / 34 / 3 / 40Cr / C42
25 / 3D313HBW110 / 36 / 2 / 40Cr / C42
26 / 1A319HBW110 / 18 / 3 / 45
27 / 1A320HBW110 / 48 / 3 / 45
28 / 1A321HBW110 / 18 / 3 / 45 / C48
29 / 3D314HBW110 / 46 / 2 / 45
30 / 3D314HBW110 / 17 / 2 / 45
31 / 3D317HBW110 / 30 / 2 / 45
32 / 1A337HBW110 / 58 / 2 / 45 / G48
33 / 1A330HBW110 / 31 / 2 / 40Cr / G48
34 / 1A337HBW110 / 38 / 2 / 45 / G48
35 / 1A339HBW110 / 58 / 2 / 45 / G48
36 / 1A341HBW110 / 19 / 3.5 / 45 / G48
37 / 1A340HBW110 / 27 / 3.5 / 45 / G48
38 / 1B362GHBW110 / 44 / 3 / 45 / G48
39 / 1B392GHBW110 / 22 / 3 / 40Cr / T235
40 / 1A311HBW110 / Rack / 5 / Left13056’ / 45
41 / 1B382HBW110 / 11 / 5 / Right13056’ / 0.88 / 40Cr / G48
42 / 1B384HBW110 / 52 / 3 / Right4018’ / 45
ZQSn6-6-3
No. / PartNo. / TeethHeads / Module
Pitch / Directionor HelicalAngle / DeflectionAmount / Material / HeatTreatment
43 / 1B316GHBW110 / 48 / 2 / 20Cr / S0.9-C59
44 / 1B390HBW110 / 36 / 3.5 / 40Cr / G48
45 / 1B308HBW110 / 36 / 3.5 / 40Cr / G48
46 / 1B363GHBW110 / 33 / 3 / 45 / G48
47 / 1B391GHBW110 / 29 / 3 / 40Cr / T235
48 / 1B304HBW110 / 35 / 3 / 20Cr / Z0.9-C59
49 / 3D304HBW110 / 99 / 2 / 45
50 / 3D320HBW110 / 16 / 2 / 45
51 / 3D306HBW110 / 57 / 2.5 / 45
52 / 3D309HBW110 / 49 / 2.5 / 45
53 / 3F307HBW110 / 40 / 3 / 45 / G48
54 / 1F307HBW110 / 24 / 3.5 / +2.00 / 45 / G48
55 / 3G311HBW110 / 4 / 3 / Right10047’ / 40Cr / G48
56 / 3F316HBW110 / 29 / 3 / Right10047’ / 45
ZQSn6-6-3
57 / 3A307HBW110 / 35 / 3 / +1.29 / 40Cr / G48
58 / 3A305-
3
HBW110 / 19 / 4 / +1.97 / 20Cr / S0.9-C59
59 / 3A305-
2
HBW110 / 55 / 3 / +0.82 / 20Cr / S0.9-C59
60 / 3A305-
1
HBW110 / 30 / 3 / 1.28 / 20Cr / S0.9-C59
61 / 3A302HBW110 / 22 / 3 / +1.434 / 20Cr / S0.9-C59
62 / 3A303HBW110 / 47 / 3 / +0.97 / 40Cr / G48
63 / 3G301HBW110 / 30 / 3 / 45
No. / PartNo. / TeethHeads / Module
Pitch / Directionor HelicalAngle / DeflectionAmount / Material / HeatTreatment
64 / 3I318HBW110 / 24 / 3 / 45
65 / 3I319HBW110 / 50 / 3 / 45 / G48
66 / 3I303HBW110 / 13 / 3 / +0.6 / 45 / G42
67 / 3E308HBW110 / 18 / 2.5 / +1.25 / 40Cr / G48
68 / 3E307HBW110 / 50 / 2.5 / +0.76 / 40Cr / G48
69 / 3E305HBW110 / 18 / 2.5 / +1.25 / 40Cr / G48
70 / 3E305HBW110 / 50 / 2.5 / +0.76 / 40Cr / G48
71 / 3E303HBW110 / 18 / 2.5 / +1.25 / 45 / G48
72 / 3E303HBW110 / 50 / 2.5 / +0.76 / 45 / T250G48
73 / 3E320HBW110 / 42 / 2.5 / +0.88 / 45 / G48
74 / 3E318HBW110 / 42 / 2.5 / 40Cr / G48
75 / 3E318HBW110 / 21 / 2.5 / 40Cr / G48
76 / 3E327HBW110 / 45 / 2.5 / +0.84 / 45 / G48
77 / 3E322HBW110 / 39 / 2.5 / +0.93 / 40Cr / T250G48
78 / 3E310HBW110 / 50 / 2.5 / +0.76 / 45 / G48
79 / 3E310HBW110 / 34 / 2.5 / +1.00 / 45 / G48
80 / 3E311HBW110 / 46 / 2.5 / 45
81 / 3E311HBW110 / 18 / 2.5 / +1.25 / 45
82 / 3E312HBW110 / 34 / 2.5 / +1.00 / 45 / G48
83 / 3E312HBW110 / 40 / 2.5 / +0.91 / 45 / G48
84 / 3E313HBW110 / 23 / 2.5 / +0.64 / 45 / G48
85 / 3E313HBW110 / 34 / 2.5 / +1.00 / 45 / G48
No. / PartNo. / TeethHeads / Module
Pitch / Directionor HelicalAngle / DeflectionAmount / Material / HeatTreatment
86 / 3E313HBW110 / 28 / 2.5 / +1.10 / 45 / G48
87 / 3E314HBW110 / 52 / 3 / +0.825 / 45 / G48
88 / 3B305HBW110 / 55 / 3 / +1.21 / 45 / G48
89 / 3B305HBW110 / 32 / 3 / +0.825 / 45 / G48
90 / 1B390HBW110 / 36 / 3.5 / 40Cr / G48
91 / 1B308HBW110 / 36 / 3.5 / 40Cr / G48
92 / 1B308HBW110 / 36 / 3.5 / 40Cr / G48
93 / 1B316GHBW110 / 2 / 3 / Right4018’ / 20Cr / S0.9-C59
94 / 1B308HBW110 / 1 / 6 / Left2058’ / 45
95 / 1B318HBW110 / 1 / 6 / Left2058’ / 45
ZQSn6-6-3
96 / 3B349GHBW110 / 42 / 2 / 45 / G48
97 / 1B310HBW110 / 41 / 3 / 45
98 / 2A304HBW110 / 44 / 3 / 45
99 / 2A305HBW110 / 22 / 3 / 45
100 / 2A306HBW110 / 11 / 5 / Right13056’ / 0.88 / 45
101 / 2A316HBW110 / 11 / 2.5 / Right500 / 45 / G48
102 / 2A308HBW110 / 34 / 2.5 / Right400 / 45 / G48
103 / 2A301HBW110 / 2 / 6 / Left6036’ / 45
104 / 2A601HBW110 / 44 / 1.5 / Right3027’ / ZQSn6-6-3
105 / 2A601HBW110 / 2 / 6 / Left6036’ / ZQSn6-6-3
106 / 2A328HBW110 / 1 / 1.5 / Right3027’ / 45
107 / 3N313BHBW110 / 18 / 2 / 40Cr / G52
No. / PartNo. / TeethHeads / Module
Pitch / Directionor HelicalAngle / DeflectionAmount / Material / HeatTreatment
108 / 3N312HBW110 / 25 / 2 / -0.8 / 45 / T235
TeethG48
109 / 3N301HBW110 / 27 / 2.5 / 0.484875 / 45 / T235
TeethG48
110 / 3F301BHBW110 / 20 / 2 / 40Cr / G48
111 / 3N311BHBW110 / 27 / 4 / 3.944 / 45 / T235
TeethG48
112 / 3N310BHBW110 / 14 / 2 / +0.8 / 40Cr / G52
113 / 3N309HBW110 / 90 / 4 / 2.728 / 45 / T235
114 / 3N307HBW110 / 15 / 2 / 45 / T235
115 / 3A302HBW110 / 14 / 4 / 2.228 / 40Cr / G48
116 / 3N302HBW110 / 162 / 2.5 / 1.524175 / 45 / T235
117 / 3N305HBW110 / 1 / 2 / Right4023’55″ / 45 / C42
118 / 3N601HBW110 / 24 / 2 / Right4023’55″ / ZQSn10
-1
119 / 3N306HBW110 / 15 / 2.5 / 45 / T235

Note:“HBW110”inthelistmeanthepartsborrowedfromtheModel“HBW110”.

2.2 USAGEANDWORKINGPRINCIPLEOFMAINCOMPONENTSANDFUNCTIONALUNIT

HBW110R2maincomponentsandfunctionalunitsinclude:

Machinebed,frontcolumn,worktable,endcolumnandheadstock.Theusageandworkingprinciplesareasshowninthe following.

2.2.1MACHINE BEDANDFRONTCOLUMN

Inordertoimprovewearresistance,theguidewaysofbedandfrontcolumnarehardened.Thereisasetofspindleweightbalanceunitinthefrontcolumn,theratiobetweentheheadstockandthebalanceweightis1:1.

2.2.2WORKTABLE

Theworktableiscomposedofthreeparts,i.e.rotaryworktable,upperslidecarriage andlower slide carriage.

Rotaryworktableissupportedbyasetofballsplacedonacircularraceonupperslidecarriage.Whenabigringisrotatedbyasectorgearwhichisdrivenbyaspecialtelescopiclever, forceistransmittedthroughfourcamblocksontheringtotherollersandleversets.Thustherotarytable islockedonthe upper slidecarriage.

Sincetherotarypivotisprovidedwithaconerollingbearingandthetableissupportedonballs,thereforethetablecanberotatedsmoothlyandeasily.

Clampingofupperslidecarriageiseffectedbymeansofaleverthroughalongshaftwitheccentricsleevewhosehigherpointspressthepinsthatactonlever.Incaseofheavycutting,tightenthenutsonleftslideasnecessary.

Wheneveritisnecessarytolocklowerslidecarriageonthebedguideway, simply tighten the bolts of press plate under the bed

guideway.

Tableisprovidedwithahand-pulledpumptolubricatevariousgears,bearingsandlongitudinalandtransversalguideways.

2.2.3ENDCOLUMN

Toolholdersupportofendcolumncangoupanddowninsynchronismwiththeheadstockthroughthedrivesystem.Thisisanadjustingdeviceonendcolumntocorrecttheliftingmisalignment.Rotateitshandwheeltoliftthetoolrodsupport.

Lockthe endcolumn onguidewaybytwoscrews.

2.2.4HEADSTOCK

Variousspeedandfeedofspindleandfacingheadcanbeobtainedto movethe gearsbyoperatingtherespectivespeciallevers.

Hollowspindle(1)is supportedby twoprecisionconerollerbearings(4).(See“Fig.2-5SpindleConstruction”)Therearethreebushes(3)insideofhollowspindle.Innerboresofthebushesarefine-finishedandhavefittingclearanceswiththespindle(2).Thespindleisnotonlyabletomoveaxiallyinthehollowspindle’sholebutalsoabletorotatetogetherwithit.Facinghead(8)issupportontwosetsofprecisionconerollerbearing.Bothbearingsaresupportedbyafixingsleeve(6)ontheheadstock.Ramonthefacingheadhasaradialtraveltomakebiggersurface machiningandboring.

The spindle in the headstock will influence the precision and

performanceofwholemachine;sothespindlenose’sdimensionandshapearespecifiednormally;seethefig.2-6fordetails.Thetaperholeofspindleadopts7:24.Thetaper-shankwhichinstalledinthespindleholemustfitISOBT50,therivetmustfitISOBT50standard.Whenreleasingtool,theoiltankshoulduse20#engineoilabout42L.Whenpressthereleasingbutton,theoilpumpmotorshouldstart,adjustfluidvalvewhichontheoiltank,letthepressureis4Mpa.(Tensionis12000N).Atthistime,hydraulicoilpushbar(1)tomakethejacket(2)release, thentoo-changecanbecarriedout.

3.MAINTECHNICALCHARACTERISTIC

3.1MAIN CHARACTERISTIC

Max. loadonworktable 5000kg

Max. permittedtorqueofspindle 1100N.m

Max. permittedtorqueoffacinghead 1100N.m

Max. axialfeedingforceonspindle 13000N

Stepsof spindlespeed 18steps

Stepsof facingheadspeed 16steps

Rangeofspindlespeed12~1000rpm(Thehighestspeedofreplacedbeltcanreach 1100rpm)

Rangeoffacingheadspeed4~160rpm

Feedingstepsofradialtoolholder

offacinghead perrev.18stepsFeedingrangeof radialtoolholder

offacinghead perrev.0.05-16 mmFeedingstepsofheadstockandworktable

per spindle rev.18steps

Feedingrangeof headstockandworktable

per spindle rev.0.025-8mm

Feedingstepsofheadstockandworktable

per facingheadrev.18steps

Feedingrangeof headstockandworktable

per facingheadrev.0.075-24 mmShiftamountofheadstock, longitudinal

handleoftable per rev. respectively6mmShiftamountofheadstock, transversal

handleoftable per rev. respectively8mm

Rapidtraverseofspindle3.6m/minRapidtraverse of facingheadradialtoolholder 1.12m/min

3.2MAINPARAMETERS

Spindledia.110 mm

Worktablearea(L×W)1250×1250mm

Max. differencefrom spindle center totable face1205 mmMin.differencefromspindlecenter totableface 5 mmVerticalstrokeofheadstock 1200 mm

Axialstrokeof spindle550 mm

Radialstroke of facingheadtoolholder160 mm

Longitudinalstroke of worktable1100mm

Transversal strokeofworktable1800 mm

Max. boringhole dia.240 mm

Max.machinedenddia.offacingheadtoolholder630 mmMax. drillingholedia. 50 mm

InnerholetaperofspindleBT50(7:24)Axialspindleshiftamountper handlerev. 25 mmAxialspindleshiftamountper trimminghandwheelrev. 1mm

Cuttingthread, Metric (pitch)1-10 mmInch(teeth/inch) 4-20

Mainmotorpower(A.C. threephases380V,60Hz)6.5/8kwPoleNo. 4/2

Rapidmotorpower(A.C.threephases380V,60Hz)3KWPoleNo. 4

Speedofheadstocklifting,worktable longitudinal1.8m/minandtransversalrapidmovement

3.3SIZES OFOVERALLAND INSTALLATION(L×W×H)

HBW110R24970×3005×3285mm

Asfor theinstallationsizes, seethe foundationfigure.

PRECAUTION:Thefoundationmustbemadeaccordingtothemachinemodel.

3.4WEIGHT

NETWEIGHTHBW110R214500Kg

4.LIFT,INSTALLATIONANDADJUSTMENT

4.1LIFTANDINSTALLATIONPROCEDURE,METHODANDPRECAUTION

4.1.1The machine is packed in three cases in order to transport itconveniently.

Whentransporttheunpackedmachine,eachpartofthemachineshouldbe hoisted from thepositionmarkedonthecase.Don’tinclinethemachine, forbidtoplace themachine upsidedown.

Afterunpackingthemachine,youshouldhoisteachpartofthemachineaccordingtothetransportationfigureofeachpart.Putsomewooden

padsorsoftmaterialsbetweensteelropesandmachinesurfaceinordertoprotectpaint(refertothe “Machine HoistingFigure”).

Theninstallthemachine infollowingway:

Wipeofftherust-inhibitoilontheguideway,liftingleadscrewandpulleysupport,andapplylubricationoil.

4.1.2INSTALLATIONMETHODANDPROCEDURES

4.1.2.1.Putthemachinebed,columnandendsupporton12piecesofparallellocatedonthefoundation(Refertothe“FoundationFigure”forparallelslayoutandfoundationpreparation.).

Installationlevelisadjustedthroughparallelsandindicatedwith0.02/1000levelerandbridge plate.

Placealeveler“a”onthebedguideway(see“MachineLevelingCheckIllustration”)inthedirectionofguidewayitself.Anotherleveler“b”isplaced on thebridgeplatein thedirectionperpendiculartotheguideway.Levelcheckshouldbedoneonbothendsofguideway.Itisnotallowablethatthereadingsonlevels“a”,“b”exceeding0.04/1000afterthemachine isleveled.

4.1.2.2.Puttwoauxiliaryguidewaysonthetenpiecesofparallelsofitselfattwosidesofmachinebed.(Referto“FoundationFigure”).Mounttheguidewaysaccordingtotheassemblyfigure.Thenchecktheauxiliaryguidewayslevelingandtheparallelismofbedguideway(Referto“InstallationLevelingCheckIllustration”)bymeansofleveler

of0.02/1000,dialgaugeandbridgeplate.TheD-valueofreadingsoflevelershouldn’texceed0.04/1000.Theparallelismbetweenauxiliaryguidewayandmainguidewayinverticalshouldbe0.03.

4.1.2.3.Hoist up the bigcolumn(referto fig4-4Hoistfigure)andput onthemachinebed,thenmountthepositioningpinsandlockwith14bolts(M24X100).Checkbiggersurfaceofcolumnguidewaydeflectstobackside(0.04-0.05),theorientedsurfaceofcolumnguidewaydeflectstoworktable(0.03-0.05),andthentestwithalevelerwhichreadingis0.02/1000andabridge-type(aspecialcheckingtool).Iffit,lockthe14bolts(M24)withwrenchwhichmomentis800Nm.Inordertoensureeachboltbearingmomentis740Nm,makesurethebigcolumnandmachinebedis firmandimperviousjoint.

4.1.2.4Hoistuptheworktablesectionandmountsupportateachendofworktable,thenmountonpositionofpinsandlockit.Thenremovetheclampingplateslocatedattwoendsofthelowestguidewayunderworktable.(Beforeremovingtheclampingplates,youshouldmakeamakerattheremovingpositioninordertomounttheplatesattheoriginposition.)Handletheworktableandputitonthebedguideway,andmountontheconnectingparts(smoothbar,clampingplates,gib,etc.)betweenbedandworktable.Afteradjustment,mountoncablesofdigitalreadout, wiresandrectangular flexiblepipes,etc.

4.1.2.5.Removetheclampingplateslocatedattwosidesofheadstock

guideway.Beforeremovingit,youshouldmakeamakeratitspositioninorder toremountitatthe originposition.

Hoistuptheheadstockandlettheguidewayofheadstockclosetoguidewayofcolumn.Locatetheclampingplatesandgibsattwosidesofguideway.Putthewoodenpadsatthebottomofheadstock.Mountonleadscrew,smoothbar,pads, bearingsupportandbearings.

4.1.2.6.Hoistupthesmallcolumn(refertofig4-11hoistfigure)putitonthebackslidecarriage,mountthepoisoningpinsandlockwith8bolts(M20X100).Ensureeachboltbearmomentis400Nm,andmakesurethesmallcolumnandbackslidecarriageisfirmandimperviousjoint.

4.1.2.7Remountonthe balancingsystemofheadstock

(a).Insertthebarforcounterweightintothecolumnandmountonthecounterweightandinsertthe woodenpads.

(b).Mountonthepulleyyokeandinsertthesteelropesintothegrooveof pulley.

(c).Raisetheheadstockbymeansofcrankingbar.Mountthesteelropescorrectly.Thenremovethewoodenpadsundertheheadstockandwoodenpadsforfasteningthe counterweight.

(d).Lowertheheadstockbythecrankingbarandtightenthesteelrope,thenraisethecounterweightanddragthebarforcounterweightoutofthecolumn.

4.1.2.8.Coverthetopcoverofcolumn.Mountonthepartsdismountedfrom thedigitalreadoutandother dismountedpartsandelectricwires.

4.1.2.9.Releasethefixturesbetweeneachmovablepart.Checkthemachinelevelagainaccordingtotheinstallationlevelingcheckillustration.Readjustthemachinelevelifnecessary. Afterreadjustment,accordingtotheaccuracyvaluespecifiedintheitem24oftheINSPECTIONCERTIFICATE“verticalityofheadstockverticalmotion toworktablesurface”,adjusttheverticalityofcolumntoworktablebyparallelsunderthemachinebed,buttheinstallationlevelofthemachineshouldnot beeffected.Thenadjusttheauxiliaryguideway.Atlast,adjustthepart1B341finelyanddrillholesforpins,theninsertpinsandpositionthepart.

4.1.2.10.Fastenthefoundationscrewsandpaycloseattentiontothereadingsofleveler;thereadings ofthelevelermustnotexceedthespecifiedvalues.Otherwisetheguidewaywillbedeformedandthemachine’slifewillbeshortened.

Afterthemachineisleveled,fillthegapbetweenmachineandfoundationaroundthebedwithsomecementmortar.Checkthemachinelevelaftercementmortarhashardened.

4.22ADJUSTMENTMETHODANDPROCEDURES

4.2.1Installationlevelisadjustedthroughparallelsandindicatedwith0.02/1000leveler andbridge plate.

Placealeveler“a”onthebedguideway(see“MachineLevelingCheckIllustration”)inthedirectionofguidewayitself.Anotherleveler“b”isplaced onthebridgeplateinthedirectionperpendiculartotheguideway.Levelcheckshouldbedoneonbothendsofguideway.Itisnotallowablethatthereadingsonlevels“a”,“b”exceeding0.04/1000afterthemachineisleveled.Theparallelismbetweenauxiliaryguidewayandmainguidewayshouldbe 0.03.

Afterthemachineisleveled,accordingtotheaccuracyvaluespecifiedintheINSPECTIONCERTIFICATE“verticalityofheadstockvertical motiontoworktablesurface”,adjusttheverticalityofcolumntoworktablebyparallelsunderthemachinebed,buttheinstallationlevelofthe machineshouldnot beeffected.

Fastenthefoundationscrewsandpaycloseattentiontothereadingsofleveler;thereadingsofthelevelermustnotexceedthespecifiedvalues.Otherwisetheguidewaywillbedeformedandthemachine’slifewillbeshortened.

Afterthemachineisleveled,fillthegapbetweenmachineandfoundationaroundthebedwithsomecementmortar.Checkthemachinelevelafter cementmortar hashardened.

4.2.2Themachinehasbeenproperlyadjustedbeforedelivery.Normallyreadjustmentisn’tneeded.Butincasereadjustmentsarerequiredbecauseofvibrationoftransportation,long-termserviceorsomeother

reasons, thefollowinginstructionsshouldbe observed.

4.2.2.1FEED OVERLOAD SAFETYDEVICE

Inthefigure4-6,removethethinplatecircularcoveroverthespindle.Turnthehexscrewwithhexwrenchinclockwisedirection,thenthefeedingforcewillbeincreasedandviceversa.Adjustmentischeckedasfollowing:

Drillacastironpiecewitha50mmdiameterdrill.Select50rpmforspindlespeed,0.52mm/revforfeedrateand100mmfordepth ofhole.Insuchcasesafetydeviceshouldbeingoodworkingconditionwithoutdisengagement.Butwhenthefeedis increased to1.03mm/rev,thesafetydevice shoulddisengage automatically.

4.2.2.2ADJUSTING V-BELTTENSIONFORMAIN MOTORLoosenthenutsonmainmotor’sbase(seefigure4-8“AdjustmentofV-beltofMainMotor”)androtatethebaserounditssupportingaxis.Thenthecenterdistancebetweentwopulleysischanged.InsuchawaythetensionofV-beltisadjusted.Takecaretotightenthenutsagainafteradjustment(Notice:Spindle speed of 1100rpm can only be achieved by using the 50Hz belt (30104,3A116)instead ofthe60Hzbelt(30109, 3A117).Warning:thespindleshould not run formorethan15minsat 1100rpmmode.)

4.2.2.3CLAMPINGFORCE OFHEADSTOCK

Therearetwoclampingdevicesforheadstockonthebackofthefrontguideway ofcolumn.Turnadjustingscrews by hexwrench to change theinitialpositionofpressblocks.Thusthemagnitudeofclampingforcecanbeadjusted.Besuretogettheclampingforcesonbothclampingdevicesasequal aspossible. RefertoFig.4-9.

4.2.2.4CLAMPINGFORCE OFUPPERSLIDECARRIAGE

Theclampingmechanismofupperslidecarriageissimilartothatofheadstock.As toitsadjustingmethodseethe previousitem.

4.2.2.5CLAMPINGFORCE OFROTARYWORKTABLE

Turntheadjustingscrewsofclampingdeviceunderthetablesoastochangetheinitialpositionofpressblocks(seefigure“Adjustmentofrotaryworktableclampingdevice”).Thusthemagnitudeofclampingforceisadjusted.

Takecarethattheclampingforcesofthefourclampingdevicesshouldbeasequalas possible.

4.2.2.6CLEARANCEOFSPINDLE ROLLING BEARING

Inthespindleconstructionfigure,findthewasherbetweentwolockingnuts(5)attherearpartofhollowspindleandgetitsbentteethstraight.Theclearanceofthetwospindlerollingbearingscanbechangedbythenuts.Afteradjustment,moveoutthespindletoadistanceof300mmfromthefacingheadtoitsfrontendandcheckthespindlerunoutbya

dialindicator.Makethecontactonthefurthestoutercircularfacefromthespindle,rotatewiththelowestspeed,andthedialindicatorjumpingshouldn’texceed0.025mm.

PRECAUTION:(1).thisaccuracyonlycanbeobtainedwhenthebearingsstillkeeptheiroriginalaccuracy.Otherwisethisaccuracyshouldbereducedaccordingly.

(2).Itisrecommendednottotightenbearingsexcessively,otherwisethebearingswouldbeoverheatedduringoperationandtheirserviceliveswouldbe shortened.

4.2.2.7SAFETYOFRAPIDMOTOR

Loosenthewasherattheendoftheshaftofthemotorforrapidtraverseandturnthenuttochangethepressureofspring.Checkhastobeproceededasfollows:

Load5000kgontheworktableandstarttherapidtraverse.Inthiscase,thetableshouldmovesmoothly.Whenitmovesandstrikesagainstalimitblock,thesafetydeviceshouldslipandthemotorshouldstopimmediatelywithrapidhandle (6).

Itshouldbepointedoutthatthisisonlyasafetymeasuretopreventmachinedamagewhenunexpectedaccidentstakeplace.Thereforeitisnotallowedtodrivethetabletostrikeagainstlimitblocksinnormaloperation.

4.3 TRIALRUN

Havingremovedanti-corrosivegreasefromthemachineandfilleditupwithlubricationoil,adjustthemachinepartsinconformitywithOperationManual,whichtheoperatormusthavethoroughlystudiedandhasgotagoodunderstandingaboutthemachineconstructionandinstruction.Thenturneachhandleandhandwheelmanuallytomoverelevantpartsinordertochecksmoothnessofmotionandnormality.Ifthereisanyfailure, getridofit.

Whenallpartshavebeencheckedmanuallyandareallincorrectconditions,pushmotorjogrotationbuttonandcheckwhetherpowermotionisallrightornot.Thenstartmainmotorandincreasethespindleorfacingheadspeedfromthelowesttothehighestprogressively.Itshould runatleast for5minutes ateach stepofspeed andrunforhalfanhouratthehighestspeed.Whilespindleisrunning,moveitbackwardoccasionallytopreventthevariationofclearancebetweenspindleandspindlebushingsduetotemperaturerise,whichmighthaveeffectonmachineperformance.

Themachinecanbeputintooperationonlyafterhaspassedtheabovetestsandchecks.

(Note:Placeanoilplugattheconnectionbetweentailstockandheadstock.Whenputtingintooperation,itcanbeallowedtodraintheoilone time.)

5.OPERATION

5.1Preparation andcheckbeforeoperation,safetyprotectionduringoperation.

5.1.1Checkifeverymechanismisnormalbeforeoperation.Thenmaketrialrunat lowspeed.Check ifhas anyabnormalnoise,ifhas any, repairit.

5.1.2Puttheworkpieces,chucksandmachineaccessoriesgently,preventfromscratchingthetableface.Forbidtoolsandworkpiecesonthe guideway.

5.1.3Wipeandcleanbeforefittingchuckandmachineaccessories.

5.1.4Operatorshouldn’tleavethemachineduringoperation.Iffindinganyabnormalconditions,suchasworkpieceshocking,biggercuttingload,tablefacejumpingandabnormalmachinenoise,stoptocheckimmediatelyandgetridofthem.

5.1.5Whenrapidtraverse,stopthetoolattheposition30-50mmawayfromtheworkpiece,thenfeedbyhand.Makethetoolapproachtheworkpiece slowly,avoidthetooltoshockworkpiece.

5.1.6Therearelimitdevicesatthelimitpositionsoflongitudinalandtransversaltravelofworktable.Thetravellimitmustn’texceedthespecifiedrange.Don’tremovethelimit,preventfromexceedingtravellimitanddamagingmachineparts.

5.2OPERATIONPROCEDURESANDMETHODDURINGRUNNING

5.2.1Button(14)is usedfor machinestartandstop.See figure 5-1.

Speedandfeedchangesofspindleandfacingheadarecarriedoutbylever(9)and(8)respectively.Sincethesetwoleversarelinkedwithlimitswitches,assoonaseitheroftheleversispulledout,themotorstopsrunning.Buttheengagedchangeovergearshavenotdisengagedyet.Whentheleveristurnedthrough1800,rotateituntilitreachestherequiredposition.Thenputbacktheleverintheoppositedirection.Atthattimespeedrelayisaffectedandthemotorbeginstorotateatlowspeedimpulsivelysothattheslidinggearsmightbeengagedsmoothly.Thusnewspeedor feedisobtained.

Lever (13) is usedfor controllingspindlefeedand toolholder radialfeed.(Whenthoseleversareplacedintheirendpositions,apowermotioncanbeobtained.Whenthatinmiddleposition,amanualmotioncanbeeffected.)

Thefeeddistributionanddirectionchangeoftableandheadstockarecontrolledbyareversiblelever(18).Powerfeed andrapidtraverseofallmovingpartsiscontrolledbylever(6).Whenlever(18)or(13)isputintherequiredposition,bypressinglever(6)downwardfromitsmiddleposition,youwillgetthe powerfeedforeach movingpart.Whenlever6ispulledoutorpulledin,rapidtraverseofeachmovingpartinboth

directionscanbeobtainedwithoutconsideringthepositionsofdirectionchangegearssincethebi-directionalswitchofthemotorforrapidtraverseisdirectlyoperationinthiscase.

Whenfeedingdevicemeetsobstaclesorthemovingpartcomestostrikeagainstitstravelendstopper,notonlythefeedstopsbutlevercomesbacktotheoriginalpositionautomatically.Inordertoprotectthemachineagainstanysuddenaccident,allfeeddevicesareprovidedwithanelectricalinterlocksystem.Sospindlefeedortoolholderfeed,feedof tableorheadstockcannot beaffectedsimultaneously.Ifboth feedsareputintoactionatthe same timebymistake, motor stops immediately.

Handoperationdevicesforthefollowingpartsareprovidedtofacilitateoperation:

Lever(13)isformanualfeedofspindleandfacinghead’sradialtoolholder.Device(19)forlongitudinalmovementoftable;device(20)fortransversalmovementoftable;device(12)forheadstockupwardanddownwardmovement;device(21)forlongitudinalmovementofendcolumnalongbedandhandwheel(1)foradjustment oftheverticalpositionofboringbar stayonthe endguideway.

Manualtrimmingofallmovingpartsiscontrolledbyhandwheel(7).Becauseofmechanicalinterlockwhenanymovingpartisinpowerfeedorrapidtraverse,handwheel(7)isautomaticallywithdrawntopreventaccidents.

RefertoFig.5-2.Whenthetableistoberotated,releasepositioningpinbyhandle(15).Whentableistobepositionedat00,900,1800,2700,maketheworktablepositioningpinsetintopositioningsleeve.(Seethefigure.)

Lockingofspindle,facingheadram,headstock,rotarytable,upperslidecarriage,endcolumntoolholderandholdercoverisrealizedbyoneoftheclampingdevices(10), (24), (5),(11), (4), (3),(2) respectively.

Lockingofheadstockiseffectedattwopointsthroughalinkagesystembydevice (11).

Inordertoreleasecertainclampedpart,clampingblocksorpressplatesshouldbereleasedaccordingly.Clampingdeviceshouldbereleasedtoitspositionlimit(except24,becauseithasstopper)toensureallofitslockedpartsarereleased completely.

Whenlever(22)isplacedon“ON”position,arotarymotionoffacingheadcanbeobtained,assoonasitisplacedontheir“OFF”position,therotarymotionisstopped.

Whenlever(23)isplacedon“Feedingoffacinghead’sradialtoolholder”position,toolholderfeedingcanbeobtained.Whenplaceon“Axialfeedingofspindle”position,spindleaxialfeedingcanbeobtained. Lockthehandle(10) whenusingfacinghead.

PRECAUTION:

1).Thelevers(22),(23)permittochangetheirpositiononlywhenthe

machineisstopped.When(22)ison“ON”position,(23)isonthe“Feedingofradialtoolholderoffacinghead”position;otherwise,toolholder willslipawayautomaticallywhenfacingheadrotates.

2).Whentheworktablelongitudinaltravellimitisvalid,theworktablelengthmustbeinthetransversaldirection,andtheworktablecan’tberotate900or2700;otherwisetheworktablewillcomeintocollisionwiththecolumn andendsupport.

3).Whenusingradialtoolholderoffacingheadforradialfeeding,thespindlemustbereturnedtothelimitposition,otherwisewillshockthespindle.

5.2.2OPERATIONINSTRUCTION(seeFig.5-1)

NO. / NAME
1 / Adjustinghandwheelofendcolumn’stoolholdersupport
2 / Clampingdeviceoftoolholdersupport’scover
3 / Clampingdeviceof endcolumn toolholdersupport
4 / Clamping device of worktable upper slide carriage (in twoplaces, usedforheavycutting)
5 / Clampingdeviceof rotarytable
6 / Leverforfeedandrapidtraverse
7 / Manualtrimminghandwheelforfineadjustmentsofspindle,facinghead, headstockandworktable
8 / Feedingchangeoverhandleforspindle,facinghead,headstockandworktable
9 / Speedchanginghandlefor spindle andfacinghead
10 / Spindleclampingdevice
11 / Headstockclampingdevice
12 / Manualdevicefor headstockmovement
13 / Handleforchanging feedingdirection ofspindleand facinghead
14 / Switchesforspindlestarting,stoppingandjogging
15 / Positioningdevice of rotaryworktable
16 / Clampingdeviceofworktable’s upperslidecarriage
17 / Mainpowerswitch(right) andlightingswitch(left)
18 / Feeddistributinganddirectionchangingleverforheadstockandtable
19 / Manualdevicefor table longitudinalmovement
20 / Manualdevicefor table transversalmovement
21 / Manualdevicefor endcolumnmovement
22 / Leverfor rotarymotionof facinghead
23 / Leverforspindlefeedingandfacinghead’stoolholderfeeding
24 / Clampingdeviceoframoffacinghead

6.TROUBLESHOOTING

NO. / TROUBLE / REMEDY
1 / Spindlespeeddoesn’tcoincidewithindicatedspeed. / Checkspeedchangedevice.Pointthespeedpointeratgear9.Insuchcasemakesurethateachholestampedwith“9”onthediskwithholesisinsertedbythepin-headofarack bar,and thescalemarks on gear,gearsectorandspeedchangingstandcoincidewithone another.
2 / Spindlespeedistwiceorhalfasmuchasindicatedspeed. / CorrectspeedvariableswitchSQ5,whenspeedpointerispointedatthefirststep,SQ5shouldbedisengagedandmainmotormustrunatlowspeed.
3 / Whenthehandleforspindlespeedchangingispulledout,mainmotorfailstohavejogging;orwhenthehandleispushedbackandspeed-changingoperationisfinished,mainmotorfailstostartautomatically. / Correctthedeviceatthebackendofspeedchanginghandleshaft.Makesurethatlimitswitches(SQ3,SQ7)areintherequiredconditionwhenspeedchanginghandleisinitsinoroutposition.
4 / Actualfeeddoesn’tcoincidewithindicatedfeed. / Checkfeedchangingdevice.Pointfeedpointeratgear9.Insuchcase,makesurethatallthattheholesstampedwith“9”ontheholediskareinsertedbypin-headsofrackbars,andscalemarksofgear,gearsectorandfeedchangedevicebodycoincidewithone another.
5 / Whenthehandleforfeedchangingispulledout,mainmotorfailstohavejogging;orwhenthehandleispushedbackandfeedchangingoperationisfinished,mainmotorfailstostart automatically. / Correctthedeviceatthebackendoffeedchanginghandle.Makesurethatthelimitswitches(SQ4,SQ6)areintherequiredconditionwhenhandleisinitsinor outposition.
6 / Oilpumpforheadstocklubricationfailstosuckoil. / 1.Checkwhetherthereisairleakageinoilsuctionpiping.
2.Check and seewhethertheslidevalvelocatedhorizontallyinthepumpisabletomovefreelyornotbecauseofdirtyoilorsomeothercauses.Undernormalcondition,whentheslidevalveinpump isplacedvertically,itshouldbeabletogodownwardsbyitsownweight.

7.SAFETYPROTECTIONDEVICEANDPRECAUTION

7.1OVERLOAD SAFETYDEVICE

Wheneverymovingpartisinpowerfeed,andexceedingthespecifiedvalueduetosomeobstaclesorsuddenaccidents,thesafetyclutchinfeedingboxisimmediatelydisengagedandpowerfeedingstops.Whenthecauseforoverloadhasbeeneliminated,startfeedingagainbylever(6). (See figure“MachineControlsDescription”.)

Theresistingforcethatsafetyclutchcanbearisadjustedbycompressedspring.Safetyclutchmustbedisengagedassoonasresistingforceexceeds13000N.

7.2SAFETYDEVICE OFRAPIDTRAVERSE

Thissafetydeviceismountedonthemachinebed.Whenmovingpartsmeetobstaclesorsuddenaccidents,thefrictiondiskswillslipimmediatelyandnolongertransmitpower,sothattherapidtraversemaybestopped.Undernormalcondition(withclampingdevicereleasesandwithoutanyobstacles),ifrapidtraversefails,thepressurebetweenfrictiondisksmustbereadjusted.

8.MAINTENANCEANDLUBRICATION

8.1PREVENTIVE SERVICEANDMAINTENANCE

8.1.1Maintenanceofboringmillingmachinewillinfluenceitsprecisionandlifelargely.Especiallythespindle,worktable,leadscrewsofupperandlowerslidecarriageandguidewaysurfacemustbeofteninlubricatingstate.Lubricatethemachineinnerpartbesidestheouterpartof guideway.

See thelubricationsystem figure8-1,fillingoilperiodicallyaccording tothefigure.Oftencheckifeverymovingpartissmoothduringoperation.Filloiltothespecifiedscale,lubricateoilpumpandpiping,serviceintime ifoccurringtrouble.

8.1.2DETAILLUBRICATINGMETHOD

Theamountoflubricationoilneededforheadstockisabout12litres.Theoilispouredthroughthesquareholewithafilterscreenontheuppersideandtailpartof headstock.

Machinedrivesystemandvariouscomponentsandfeeddeviceinsideheadstockarelubricatedbylubricationoildeliveredbyagearpump,whichismountedonthepulley’sstand.

Oilissuckedthroughfilterbyagearpumpandthenpumpedthroughfeedingboxtotheoilgroovesontheupperwallofheadstock.Thenoilisdistributed toeachlubricationpointthroughpiping.

Tocheckandrepairthepump,itisnecessarytodismountthebackcoverofheadstockandthenremovethepumpfromstandwithoutdismountingthepiping.

Afterdismountingthebottomcoverofheadstock,oilfiltercanbecleaned.

Lubricationofotherpartsofmachinehastobeproceededaccordingtotheinstructionsonthelubricationchart.

ChangetheCalcium-basegreaseforthebearingsoftwomotorseveryyear.Bearingsshouldbe thoroughlycleanedinadvanceof oilchanging.Oildrainplug isattachedunderneaththetail-boxandthecoveroffacinghead. Remove the plug to drain oil timely to prevent oil fromoverflowingtothe floor.

Lubricatethefrontcolumnguidewaybycentralizedlubricationstationat

thebackoftailstockwithhydraulicguidewayoil(GB/T7631.11-94).Forbidusinglubeoilwithwateroranti-abrasive(lubeoilwithwatermayleadtocomponentsrust,lubeoilwithanti-abrasivemayleadtofilter clog).

LubricatetherearcolumnguidewayandbedguidewaywithG100(No.70precisionmachineguidewayoil)everyshift,lubricatetheleadscrewandspindle withA68(No.40engine oil) everyshift.

8.1.3LISTOFLUBRICATIONSYSTEM

NO / PART / TYPE / OILTYPE / PERIOD / 400CVISCOSITY
A / Boringbarslidebearings / Tooilpool / A68(No.40
engineoil) / 3timeseveryshift / 61.2-74.8
B / Headstockmechanism / Toheadstocktail / A32(No.20
engineoil) / Asrequired / 28.8-35.2
Worktable / Centralizedlubricationstation / 00below: CN32guidewayoil
00above:
N68
guidewayoil / Asrequired / 28.8-35.2
61.2-74.8
C / Upperbearingoftoolholderleadscrew / Tooilcup / A68(No.40
engine oil) / Everyweek / 61.2-74.8
D / Endcolumnmechanism / Todistributingoil pool
E / Pulleybearingof
counterweight / Tooilcup / No.1
Calcium-basegrease / Everyhalfan year / 750C
Centerbearingofrotary
worktable / Tobearing
Bearingoffeedrod / Tobearing
Facingheadmechanism / Dismountingthedifferentialbox to fill inbearing / Heat-resistantgrease
F / Steelballofrotary
worktable / Hoisting tableto filloil / No.1
Calcium-basegrease / Everyyear / 750C
Backbearingofleadscrewoftablecrossmovement / Tobearing
Slavepulleybearing / Tobearing
G / Bearingoffacinghead / Dismountthefacingheadtofillin bearing / Heat-resistantgrease / Every5year / 750C
H / Facingheadmechanism / Tooilcupandoil pool / A68(No.40
engineoil) / Every
shiftinusing / 61.2-74.8

8.2SERVICEANDMAINTENANCEDURINGRUNNING

Removechipsanddustduringrunningtokeepmachineclean.Especiallyshouldcleantheworktable,upperandlowerslidecarriages,bedguideway,frontandendcolumnguidewaysandleadscrewnuts,avoid toscratchtheguideway faceand wear,so asto increasethemachinelife.Forbidtoblowchipsanddustwithcompressedairincleaning.Preventtinychipsinthemachinemovingpartsfromoccurring“slow” machineincident.

9.TRANSPORTATIONANDSTORAGE

9.1PRECAUTIONS OFHOSTINGANDTRANSPORTING

Seethehoistingfigure.Hoistthemachineaccordingtothemarksonthecrate;inclinationshouldbe avoided.

Usestandardpackingcrateinlongtransportation.Fixthemachineonthetruckfirstbeforetransportingandkeepthemachinestableintransportation.Forbidtoswaythemachine,otherwisewillinfluencethemachineprecisionandperformance largely.

9.2STORAGECONDITIONANDPRECAUTION

9.2.1Applyenoughlubricationoilonkeypartsbefore storage.

9.2.2Storageplaceshouldbewithoutshock;otherwisewillinfluencemachineperformance.

9.2.3Store atadryplace andavoidhumid.

9.2.4Storingplaceshouldbelessdustandash,avoiddusttoenterintothemachine todamageparts.

9.2.5Themachineshouldbeplacedinnormaltemperature;preventtoohighortoolowtemperaturefromoccurringdeformation,soastoinfluence machiningaccuracy.

10.EXPLANATIONSOFMACHINEACCESSORIES,VULNERABLEPARTSANDROLLINGBEARINGSPECIFICATIONS

10.1CUTTINGTHREAD

Whenusershaveorderedtheoptionalthreadcuttingattachment,threadcuttingoperation canbe done onthemachine.

Bothmetricandinchthreadscanbecutbyutilizingchangegearsandspindle feedonthe machine.

Inthecaseofthreadcutting,spindlefeedpointershouldbesetto2.9mm/revonlyduetotherequirementofcorrectdriveratiofordrive

systeminthreadcutting.

Changegear table forthreadcutting:

Seethe followinglistfor the relationshipbetweenactualcuttings.

Change gear formula /
Metric thread
A·C
t=4 ————
D·B
Inchthread
DB
—·—
213
P= 400————
A·C
Teeth of changegears
Metricthread / Inchthread
t / A / B / C / D / P / A / B / C / D
Pitchmm / 1 / 18 / 30 / 20 / 48 / Teethper inch / 20 / 18 / 27 / 20 / 42
1.25 / 20 / 48 / 27 / 36 / 19 / 20 / 57 / 40 / 42
1.5 / 20 / 40 / 36 / 48 / 18 / 20 / 27 / 20 / 42
2 / 18 / 27 / 36 / 48 / 16 / 20 / 27 / 20 / 42
2.5 / 20 / 24 / 36 / 48 / 14 / 20 / 24 / 20 / 42
3 / 20 / 40 / 36 / 24 / 12 / 30 / 21 / 20 / 42
3.5 / 42 / 36 / 30 / 40 / 11 / 20 / 27 / 40 / 42
4 / 24 / 18 / 36 / 48 / 10 / 20 / 33 / 40 / 42
4.5 / 27 / 18 / 36 / 48 / 9 / 20 / 30 / 40 / 42
5 / 40 / 24 / 36 / 48 / 8 / 20 / 27 / 40 / 42
5.5 / 33 / 18 / 36 / 48 / 7 / 20 / 21 / 40 / 42
6 / 40 / 20 / 36 / 48 / 6 / 30 / 27 / 40 / 42
7 / 30 / 36 / 42 / 20 / 5 / 24 / 18 / 40 / 42
8 / 40 / 30 / 42 / 28 / 4 / 30 / 18 / 40 / 42
9 / 36 / 24 / 42 / 28 / Spindlefeedpointershouldbepointedat2.9mm/revwhilecuttingthread.
10 / 40 / 24 / 42 / 28

10.2EXPLANATIONS OFVULNERABLEPARTS

10.2.1Thefollowingtableliststhevulnerablepartsandfigure.Thesearespecialorderedparts.ThepartsnumbersinthelistareborrowedfromHBW110.

No / Part No / Name / Material / Position / Pcs
1 / HBW110-1A331 / Frictiondisk / 38CrMoAIA / Bedandfrontcolumn / 4
2 / HBW110-1A332 / Gearfrictiondisk / 38CrMoAIA / Bedandfrontcolumn / 5
3 / HBW110-1A333 / Presspiece / 38CrMoAIA / Bedandfrontcolumn / 2

10.3LISTOFROLLING BEARINGS

Seefigure10-4“RollingBearingLayout”.Seethefollowinglistforrollingbearings:

No / Model / Name / Spec. / PrecisionClass / Qty
1 / 212 / One rowcenteringballbearing / 60×110×22 / G / 1
2 / 212 / One rowcenteringballbearing / 60×110×22 / G / 1
3 / 206 / One rowcenteringballbearing / 30×62×16 / G / 1
4 / 206 / One rowcenteringballbearing / 30×62×16 / G / 1
5 / 210 / One rowcenteringballbearing / 50×90×20 / G / 1
6 / 304 / One rowcenteringballbearing / 20×52×15 / G / 1
7 / 304 / One rowcenteringballbearing / 20×52×15 / G / 1
8 / 304 / One rowcenteringballbearing / 25×52×15 / G / 1
9 / 304 / One rowcenteringballbearing / 25×52×15 / G / 1
10 / 206 / One rowcenteringballbearing / 30×62×16 / G / 1
11 / 206 / One rowcenteringballbearing / 30×62×16 / G / 1
12 / 202 / One rowcenteringballbearing / 15×35×11 / G / 1
13 / 202 / One rowcenteringballbearing / 15×35×11 / G / 1
14 / 206 / One rowcenteringballbearing / 30×62×16 / G / 1
15 / 206 / One rowcenteringballbearing / 30×62×16 / G / 1
16 / 211 / One rowcenteringballbearing / 55×100×21 / G / 1
17 / 211 / One rowcenteringballbearing / 55×100×21 / G / 1
18 / 1306 / Doublerowcenteringballbearing / 30×72×19 / G / 1
19 / 307 / One rowcenteringballbearing / 35×80×21 / G / 1
20 / 7508 / One rowconeroller bearing / 40×80×23 / G / 1
21 / 7508 / One rowconeroller bearing / 40×80×23 / G / 1
22 / 7311 / One rowconeroller bearing / 55×120×32 / G / 1
23 / 205 / One rowcenteringballbearing / 25×52×15 / G / 1
24 / 2007132 / One rowconeroller bearing / 160×240×48 / D / 1
25 / 8120 / One waythrustballbearing / 100×135×25 / E / 1
26 / 8312 / One waythrustballbearing / 60×110×35 / E / 1
27 / 7606 / One rowconeroller bearing / 30×72×27 / G / 1
28 / 7606 / One rowconeroller bearing / 30×72×27 / G / 1
29 / 210 / One rowcenteringballbearing / 50×90×20 / G / 1
30 / 210 / One rowcenteringballbearing / 50×90×20 / G / 1
31 / 205 / One rowcenteringballbearing / 25×52×15 / G / 1
32 / 206 / One rowcenteringballbearing / 30×62×16 / G / 1
33 / 206 / One rowcenteringballbearing / 30×62×16 / G / 1
34 / 206 / One rowcenteringballbearing / 30×62×16 / G / 1
No / Model / Name / Spec. / PrecisionClass / Qty
35 / 207 / One rowcenteringballbearing / 35×72×17 / G / 1
36 / 208 / One rowcenteringballbearing / 40×80×18 / G / 1
37 / 203 / One rowcenteringballbearing / 17×40×12 / G / 1
38 / 7307 / One rowconeroller bearing / 35×80×21 / G / 1
39 / 7307 / One rowconeroller bearing / 35×80×21 / G / 1
40 / 208 / One rowcenteringballbearing / 40×80×18 / G / 2
41 / 208 / One rowcenteringballbearing / 40×80×18 / G / 2
42 / 206 / One rowcenteringballbearing / 30×62×16 / G / 1
43 / 206 / One rowcenteringballbearing / 30×62×16 / G / 1
44 / 206 / One rowcenteringballbearing / 30×62×16 / G / 1
45 / 209 / One rowcenteringballbearing / 45×85×19 / G / 1
46 / 206 / One rowcenteringballbearing / 30×62×16 / G / 1
47 / 8207 / One waythrustballbearing / 35×62×18 / G / 1
48 / 8207 / One waythrustballbearing / 35×62×18 / G / 1
49 / 203 / One rowcenteringballbearing / 17×40×12 / G / 1
50 / 203 / One rowcenteringballbearing / 17×40×12 / G / 1
51 / 217 / One rowcenteringballbearing / 85×150×28 / G / 1
52 / 8308 / One waythrustballbearing / 40×78×26 / D / 1
53 / 8109 / One waythrustballbearing / 45×65×14 / G / 1
54 / 208 / One rowcenteringballbearing / 40×80×18 / D / 1
55 / 8109 / One waythrustballbearing / 45×65×14 / G / 1
56 / 217 / One rowcenteringballbearing / 85×150×28 / G / 1
57 / 203 / One rowcenteringballbearing / 17×40×12 / G / 1
58 / 208 / One rowcenteringballbearing / 40×80×18 / G / 1
59 / 211 / One rowcenteringballbearing / 55×100×21 / G / 1
60 / 105 / One rowcenteringballbearing / 25×47×12 / G / 1
61 / 106 / One rowcenteringballbearing / 30×55×13 / G / 1
62 / 101 / One rowcenteringballbearing / 12×28×8 / G / 1
63 / 7515 / One wayconerollerbearing / 75 ×130 ×
33.5 / G / 1
64 / 2007132 / One wayconerollerbearing / 160×240×48 / G / 1
65 / 207 / One rowcenteringballbearing / 35×72×17 / G / 1
66 / 7609 / One wayconerollerbearing / 45×100×35 / G / 1
67 / 117 / One rowcenteringballbearing / 85×130×22 / G / 1
68 / 7308 / One wayconerollerbearing / 40×90×23 / G / 1
69 / 308 / One rowcenteringballbearing / 40×90×23 / G / 1
70 / 207 / One rowcenteringballbearing / 35×72×17 / G / 1
71 / 207 / One rowcenteringballbearing / 35×72×17 / G / 1
72 / 206 / One rowcenteringballbearing / 30×62×16 / G / 1
73 / 205 / One rowcenteringballbearing / 25×52×15 / G / 1
74 / 207 / One rowcenteringballbearing / 35×72×17 / G / 1
No / Model / Name / Spec. / PrecisionClass / Qty
75 / 304 / One rowcenteringballbearing / 20×52×15 / G / 1
76 / 304 / One rowcenteringballbearing / 20×52×15 / G / 1
77 / 304 / One rowcenteringballbearing / 20×52×15 / G / 1
78 / 304 / One rowcenteringballbearing / 20×52×15 / G / 1
79 / 304 / One rowcenteringballbearing / 20×52×15 / G / 1
80 / 211 / One rowcenteringballbearing / 55×100×21 / G / 1
81 / 46204 / One way centering thrust ballbearing / 20×47×14 / G / 1
82 / 46203 / One way centering thrust ballbearing / 17×40×12 / G / 1
83 / 46203 / One way centering thrust ballbearing / 17×40×12 / G / 1
84 / 46204 / One way centering thrust ballbearing / 20×47×14 / G / 1
85 / 117 / One rowcenteringballbearing / 85×130×22 / G / 1
86 / 2007948 / One wayconerollerbearing / 240×320×18 / D / 1
87 / 2007948 / One wayconerollerbearing / 240×320×18 / D / 1
88 / 1000801 / One rowcenteringballbearing / 12×21×5 / G / 1
89 / 104 / One rowcenteringballbearing / 20×42×12 / G / 1
90 / 104 / One rowcenteringballbearing / 20×42×12 / G / 1
91 / 1000801 / One rowcenteringballbearing / 12×21×5 / G / 1
92 / 7210 / One wayconerollerbearing / 50×90×20 / G / 1
93 / 7213 / One wayconerollerbearing / 65×120×23 / D / 1
94 / 7213 / One wayconerollerbearing / 65×120×23 / D / 1
95 / 7210 / One wayconerollerbearing / 50×90×20 / G / 1
96 / 310 / One rowcenteringballbearing / 50×110×27 / E / 1
97 / 310 / One rowcenteringballbearing / 50×110×27 / G / 1
98 / 8207 / One waythrustballbearing / 35×62×16 / G / 1
*99 / 7206 / One wayconerollerbearing / 30×62×16 / G / 1
*100 / 7206 / One wayconerollerbearing / 30×62×16 / G / 1
101 / 110 / One rowcenteringballbearing / 50×80×16 / G / 1
102 / 310 / One rowcenteringballbearing / 50×110×27 / E / 1
103 / 310 / One rowcenteringballbearing / 50×110×27 / G / 1
104 / 8308 / One waythrustballbearing / 40×78×26 / D / 1
105 / 208 / One rowcenteringballbearing / 40×80×18 / D / 1