Microsoft Word TPG FOLLOW 1100 1250 (falta indice) PARALLEL LATHE TPG 11005000 INSTRUCTION BOOK TPG 1100 1250 SERIES OPERATION MANUAL 2 MATTERS NEEDING ATTENTION TO OPERATION 1 It is necessary for yo.
INSTRUCTION BOOK PARALLEL LATHE TPG 1100/5000 TPG 1100-1250 SERIES OPERATION MANUAL MATTERS NEEDING ATTENTION TO OPERATION It is necessary for you to read this Instruction Book carefully and thoroughly and be acquainted with all details of the Instruction Book before operating the machine If the machine's structure and technical parameters have any change, please pardon for without notice TPG 1100-1250 SERIES OPERATION MANUAL CONTENTS INSTRUCTION BOOK ·············································································1 PART 1: MECHANICALUNIT ·····································································5 1.1 Application and Turning Range of the Machine ······················ 1.2 Noise of the Machine ··························································· 1.3 Requirements of Environment to the Machine························ 2.1 Transportation of the Machine ·············································· 2.2 Handling of the Machine ······················································ 2.3 Installation of the Machine ··················································· 3.1 Specifications of the machine (See Table and Table 2) ········ 11 4.1 Main Drive System ·····························································14 5.1 Arrangement drawing of handles (please see Fig 7) ·············19 5.2 Definition of Operating Directions of Handles and Hand wheel of the Machine ····································································20 5.3 Operating Procedures of the Machine ································20 6.1 Adjustment of Spindle ························································28 6.2 Adjustment of Braking························································28 6.3 Adjustment of Tool Post ·····················································29 6.4 Installation and Adjustment of Tool ······································29 6.5 Adjustment of Safety Clutch in the Apron ·····························30 6.6 Adjustment of Tension of V-belts of Main Transmission ·········31 7.1 Disposition of Necessary Safety Warning Labels···················31 7.2 Overload Safety Clutch·······················································31 7.3 Over-clutch with Single Direction ········································32 7.4 Interlock Protection of Feed Rod and Leadscrew ··················32 7.5 Prompt of Remnant Risks ···················································33 8.1 Maintenance of the Machine················································34 TPG 1100-1250 SERIES OPERATION MANUAL 8.2 Lubrication of the Machine ·················································35 10.1 Function of Hydraulic System············································40 10.2 Components and their function of Hydraulic System ···········40 10.3 Oil Lines of Hydraulic System ···········································41 10.4 Maintenance of Hydraulic System ······································42 11.1 Preparation before Pouring Cutting Fluid ····························42 11.2 Pouring of Cutting Fluid ····················································42 11.3 Use of Cutting Fluid ··························································42 12.1 Routine Inspection ···························································43 12.2 Periodic Inspection ··························································44 12.3 Overhauling of the Machine···············································45 PART 2: ELECTRICALUNIT ···································································· 49 15.1 Location Code Index ························································50 TPG 1100-1250 SERIES OPERATION MANUAL PART 1: Mechanical Unit TPG 1100-1250 SERIES OPERATION MANUAL GENERAL DESCRIPTION 1.1 Application and Turning Range of the Machine 1.1.1 Application of the Machine The machine can perform various turning work, such as end face, external cylindrical surface, turning inner holes, cutting of various threads in Metric, Whitworth, Module, Diametral threads etc of various workpieces Except those, by means of the compound rest, the machine can alone cut short taper by power and by means of the compound rest and through longitudinal feed motion it can also tum long taper by power The machine is also used for drilling, trepanning, boring, etc Owing to its powerful power and strong rigidity, the machine is suitable to tum various workpieces made from ferrous or non-ferrous metals 1.1.2 Turning Range of the Machine Turning range of the machine should be determined according to size and specification of the machine Operation of the machine over the specification is forbidden Otherwise, it will result in personal injury or death caused by accidents 1.2 Noise of the Machine Sound pressure level of idle running noise of the machine is 83dB (A) 1.3 Requirements of Environment to the Machine Themachine is to be used in environment available following specified practical environment conditions and running conditions Environmental temperature: Within the range of 5℃ - 40 ℃ and the average temperature shall not be more than 35℃ for 24 hours TRANSPORTATION, HANDLING AND INSTALLATION 2.1 Transportation of the Machine We have vibration and taken some measures such as moisture-proof, anti- anti-shock during packing the machine, therefore, the machine can bear transport and storage under temperature from -25°-55°C and also transport and storage in short time within 24 hours under status of temperature of 70°C TPG 1100-1250 SERIES OPERATION MANUAL 2.2 Handling of the Machine To lift the machine packed in wooden case by a crane, strong steel wire rope should be looped in the rope marks pointed lateral sides of the case, when transporting and unloading the case, bumping and shocking should be avoided In any case, not over incline the case If rolls are used for the transport of the case, it is important that the inclination of condition or the slope should not exceed 15°, the diameter of the rolls used must not be over 70 mm Never place the case on a prismatic body or upside down When lifting the unpacked machine with a crane (the lifting capacity more than 20 tons), use strong steel bars with Φ80-90 mm,1500~1800 mm long, and made them insert into the elliptical hanging holes of bed Then unite the steel rope to the steel stick and keep balance with carriage The wooden blocks should be padded between the strong steel wire ropes and the position touched with the wire ropes of the machine avoiding damages to the machine 2.3 Installation of the Machine 2.1.1 Preparation Work before Installation Installation of the machine should be in accordance with the stipulations given in the Chapter 1.5 Besides, pay attention to the following: ● The machine shall be installed in workshop with arrester And please refer to the Fig for the installation ● The floor for installing the machine should not be soft and not strong enough If the machine needs to be installed on this kind of soft soil floor, it is necessary to use the pile way or similar measures to increase the supporting force of the soil so that the machine will not sink or incline ● If the machine needs to be installed near the position with vibration resource, it is necessary to dig a canal around the machine or make similar measures for anti-vibration 2.1.2 Power Interface The terminal block of power supply is located on the switchboard in the electric cabinet TPG 1100-1250 SERIES OPERATION MANUAL 2.1.3 Installation of the machine The performance of a machine is greatly influenced by an installing way If the guide ways of a machine is precisely machined, the original accuracy cannot be obtained due to the reason of bad installation of the machine So, the required machining accuracy cannot be obtained easily And most troubles of the machine are caused by this reason 2.1.4 Foundation of the Machine Comprehensive check and test of the machine had been carried out before consignment of the machine from the factory Incorrect installing may affect the accuracy and the performance of the machine Note: For the machine installation, a plane installation place should be first found, then, build the foundation according to specified ambient requirements and the Foundation plan Fig Install the adjusting vertical iron at two sides of bed legs (the vertical adjusting iron and the screws should be made by the customer according to Fig and Fig.4) and return oil pipeline according to Fig 1, Fig 2, Fig and Fig.4 The floor space of the machines not only includes the space required by operating machine but also the space required for maintenance (distance for water tank and for maintenance), the foundation plan shows the space for machine itself and maintenance 2.1.5 Installing Steps ● Put the iron plate of 60mm ×60mm ×10mm same to the foundation bolts (Part should be made by t l1e user) under every adjusting screw in the vertical direction of bed TPG 1100-1250 SERIES OPERATION MANUAL ● Roughly adjust installing accuracy of the machine The accuracy of installation tested by a level that is placed respectively at two ends of bed ways The reading of the level should not be over 0.02/1000 in both longitudinal and transverse direction If not so, adjust the adjusting screw in the vertical direction of bed ● After doing this, pour cement mortar into the foundation bolt holes When the mortar has fully dried out, make finish adjustment ● For fining adjustment of the accuracy of the machine On one hand, adjust the adjusting screw in tl1e vertical direction; on the other hand, adjust the screws on the adjusting vertical iron at two sides until the machine accuracy meets the requirement ● After the accuracy meets the requirement, cover the upper entrance of cooling tank by a wooden plate，fill cement mortar around the bed leg smoothly to prevent ingress of lubricating oil TPG 1100-1250 SERIES OPERATION MANUAL 10 TPG 1100-1250 SERIES OPERATION MANUAL 54 TPG 1100-1250 SERIES OPERATION MANUAL 55 TPG 1100-1250 SERIES OPERATION MANUAL 56 TPG 1100-1250 SERIES OPERATION MANUAL 16 INSTRUCTION OF ELECTRIC SYSTEM OF THE LATHE Regarding the instruction of the electric system, please see the principle diagram, connecting diagram and assembly diagram The standard power supply of the lathe is 3N-50HZ AC380V The control voltage of the lathe is AC ll0 V, and the voltage of the signal lamp and illumination lamp is AC24V 17 INSTALLATION 17.1 The cable for power supply should be supplied by user according to cross section and color shown in the Circuit Diagrams The cross section of protecting grounding wire should be more than or equal to that of the phase wires 17.2 User should supply suitable fuse on its power supply Power from the power supply is led into the machine through the general power supply switch The general current value is 80A when the main motor is 22KW 17.3 After the machine is installed, turn the handle of the general switch QFl of power supply right to the position ON to switch on the power supply The main motor will start when pressing the button SB1 on the headstock The green spindle forward button on the headstock or on the apron is used to start the main motor If the spindle forward, it shows that the phase sequence is right Otherwise, it is necessary to exchange positions of any two wires of the line of power supply 17.4 800 mm away from the outside of the machine should be kept for maintenance of electric equipment; too small space may cause difficulty in maintenance of the electric equipment 57 TPG 1100-1250 SERIES OPERATION MANUAL 18 ELECTRIC SYSTEM, OPERATION AND OTHERS OF THE MACHINE 18.1 Before starting the machine, open the door of electric cabinet by a key to check whether the overheat relay, QF2 , QF3 and the air-switches QF1, QF5, QF6,QF7, QF8 are switched or not, whether every connecting terminal and the earthling terminal is reliable connection or not, then close the door of the electric cabinet after completion of inspection Close the front protecting cover and the pulley cover well 18.2 Shift the general switch QFI of power supply to the position ON to switch the power supply with illuminating for indicating light HL2 on the panel of headstock 18.3 Start and stop of the main motor Shift the joystick lever for rapid feed to required direction, then pressing on the rapid button SB3 (see Fig 3) on the top of the rapid feed joystick lever, having KM2 electrifying and sucking -on, the rapid motor will run, thus, the rapid moving of required direction can be obtained Release the button SB3, having KM2 un-electrifying and being released, 58 TPG 1100-1250 SERIES OPERATION MANUAL the rapid motor M2 will stop running, and rapid moving stop For this lathe, in order to prevent the main motor, coolant pump and rapid motor overload running, the electric circuit is provided overheat relay RFI and breaker QF2, QF3, its regulated value had been regulated according to the current values given by the label of the motor for the coolant pump and that given by the data plate of the lubricating motor In general case, this value should not be regulated If in special case, it may be microregulated by authorized special person The green signal lamp on the button panel on the headstock is indicator lamp for power supply, and the red signal lamp is the indicator lamp of forward and reverse of the spindle When the handle on the spindle box is on the location of forward accelerate, the long linkage bar with the handle opens the normally closed contact of the travel switch SQ2, at the time, press SB9 or SBI to realize shifting speed during running The lathe should be equipped with well ground connection 18.4 Work lamp of the machine In normal, the work lamp of the machine is 40W or 50W If change high-power bulb to use, the transformer will be in overload status for long time, and transformer will be burned out All at own risk 18.5 Miscellaneous need attention After the emergency stop button is pushed, some electric elements in the machine have still electricity Only after switch off the general switch of power supply QFl, the connecting terminals L 1, L2 and L3 on the input terminal of the general switch of power supply of the machine are poweron and the others are power-off In order to guarantee the person safety and equipment safety, it is necessary to switch off the general switch QFl of power supply 19 MAINTENANCE AND OF THE MACHINE ADJUSTMENT OF ELECTRIC EQUIPMENT In order to ensure person and equipment safety, the electric part of the equipment should be checked once a year and checking record should be written If finding any problem, you should take measures to solve it immediately The main electric circuit and the control circuit should be 59 TPG 1100-1250 SERIES OPERATION MANUAL measured with earthometer of 500V and their insulating resistance should more than megohm All the motors, the button board of the headstock, the button board of the carriage, the connecting wires boards are provided with earthing wire protection Whether the earthing wire is continuous or not is to be check and the earthing screws must be firmly tightened 19.1 Electric troubles should be inquired according to the electric drawing, the electric connecting wires drawing of the machine, and the drawing of installing switchboard of the machine 19.2 You may refer to following steps to inquire troubles: ● Check if the power supply lacks phase or not ● Check if the overheat relay RF1 trips or not ● Check if the normally opened contact of the switch SQI of the protecting door is normal or not ● Check if the normally opened contact of the start button SB6,7 is normal or not, the connecting wires are correct or not, also check if the normally closed contact of the stop button SB9, 10 are normal or not and the connecting wires are correctly connected or not ● Check if the contact of the contactor is correct or not ● Check if the connecting terminals in the electric circuit are loose or not 19.3 Coolant Pump Does Not Rotate: Please refer to following steps to inquire troubles: ， ● Check if the power supply lacks phase or not ● Check if the breaker QF3 trips or not ● Check if the contact of the buttons SA2 is normal or not and the connecting wires are correct or not ● Check if the contact of the contactor is normal or not 60 TPG 1100-1250 SERIES OPERATION MANUAL ● Check if the connecting terminals in the electric circuit are loose or not 19.4 Rapid Motor Does Not Run: Please refer to following steps to inquire troubles: ● Check if the power supply lacks phase or not ● Check if the breaker QF2 trips or not ● Check if the normally opened contact of the button SB3 is normal r not and the connecting wires are correct or not ● Check if the contact of the contactor is normal or not ● Check if the connecting terminals in the electric circuit are loose or not 61 TPG 1100-1250 SERIES OPERATION MANUAL 62 TPG 1100-1250 SERIES OPERATION MANUAL 63 TPG 1100-1250 SERIES OPERATION MANUAL 64 TPG 1100-1250 SERIES OPERATION MANUAL 65 TPG 1100-1250 SERIES OPERATION MANUAL 66 TPG 1100-1250 SERIES OPERATION MANUAL 67 TPG 1100-1250 SERIES OPERATION MANUAL Press the start button SB7 for spindle forward on the button panel of the headstock or the start button SB6 for spindle forward on the saddle, having KAI electrifying and sucking-on to make the solenoid YV sucking-on for obtaining spindle forward; If press the buttons SB10 or SB9 for spindle reverse on the button panel of the headstock, the relay KA2 will be electrifying and sucking-on to make the solenoid YV2 sucking-on for obtaining spindle reverse; If press the buttons SB5 on the button panel of the headstock for stop of spindle forward, or SB4 on the saddle for stop of spindle forward, the spindle braking solenoid YV3 sucking-on for obtaining spindle stop; Press the button SB8 o the button panel for spindle forward, having YV electrifying and sucking-on to make the spindle forward and jogging, and press the button SB1 to make main motor start Y-Δ；Press the red E-stop button SB2, KM3, KM4 and KM5 will unelectrify, main motor and coolant motor will stop SA1 is the braking selection knob for spindle stop, SA2 is the start-stop button for cooling pump, and SA3 is the ON-OFF knob for working lamp 68 ... Number of threads to be cut 15 TPG 1100- 1250 SERIES OPERATION MANUAL 16 TPG 1100- 1250 SERIES OPERATION MANUAL 17 TPG 1100- 1250 SERIES OPERATION MANUAL 18 TPG 1100- 1250 SERIES OPERATION MANUAL CONTROL... 45 TPG 1100- 1250 SERIES OPERATION MANUAL 13 COMMON TROUBLES AND TROUBLE-SHOOTING 46 TPG 1100- 1250 SERIES OPERATION MANUAL 47 TPG 1100- 1250 SERIES OPERATION MANUAL 14 LIST OF WEARING PARTS 48 TPG. .. brake, fill oil once every shift 37 TPG 1100- 1250 SERIES OPERATION MANUAL 38 TPG 1100- 1250 SERIES OPERATION MANUAL ARRANGEMENT OF ROLLING BEARINGS 39 TPG 1100- 1250 SERIES OPERATION MANUAL 10 DESCRIPTION