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Instruction Handbook for ML/TL Series Lathes
Milltronics Manufacturing Company
1400 Mill Lane
Waconia, MN 55387 USA
Phone 952-442-1410 Fax 952-442-6457
www.milltronics.net
Rev 1 11-2-11

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Summary of Contents for Milltronics ML Series

  • Page 1 Instruction Handbook for ML/TL Series Lathes Milltronics Manufacturing Company 1400 Mill Lane Waconia, MN 55387 USA Phone 952-442-1410 Fax 952-442-6457 www.milltronics.net Rev 1 11-2-11...
  • Page 3: Table Of Contents

    NSTRUCTION ANDBOOK 1973 ERVING THE ETAL UTTING NDUSTRY INCE • W 1400 M , MN 55387 ACONIA : 952.442.6455 • F : 952.442.6457 Table Of Contents Chapter 1 - Safety ......................1 Safety Checklist......................2 Basic Points Of Safety....................2 Clothing and Personal Safety..................
  • Page 5 2-Speed Transmission Maintenance – ML35-40 Only..........48 Spindle Bearing Maintenance (some models)............49 Steady rest operation guidelines and maintenance............ 50 Chapter 7 – 7200 CNC Operation ................. 51 Milltronics 7200 CNC Front Panel ................51 Power ON........................51 Power OFF......................... 51 Diagram of Main Screen..................... 54 C-Axis and Live Tooling Operation (option)..............
  • Page 7: Chapter 1 - Safety

    Chapter 1 - Safety The general principles for safe operation of Milltronics machines are outlined in this manual. Every Milltronics machine is engineered for safety. You will note, for example, that all rotating parts are protected by specially designed covers. On some models, the...
  • Page 8: Safety Checklist

    Safety Checklist • Always observe the safety instructions inscribed on the safety lebeles fixed onto the machine. Do not remove or alter these labels. • Do not attempt to operate this machine until you have read the manuals supplied with the machine and understand each of the functions and operation methods. •...
  • Page 9: Clothing And Personal Safety

    • Do not subject the CNC control unit, the operator’s panel, or the electrical control panel to strong voltage fluctuations. • Do not change any machine parameter values without consulting Milltronics service department. If it becomes necessary to change a value, first check if it is safe to do so, then make a note of the original value so it can be reset if necessary.
  • Page 10 • Always use safety shoes with steel toecaps and oil resistant soles. • Do not operate the machine while wearing loose or baggy clothes. • Always completely fasten buttons and hooks on the arms of clothing to avoid danger of entanglement in machine mechanisms. •...
  • Page 11: Safety Related To Workpiece Machining And Tooling

    1 - S HAPTER AFETY Safety Related to Workpiece Machining And Tooling 1. DANGER • Never operate the spindle above the rated speed of accessories mounted on it (chucks, tooling, etc). • Do not extend stock out of a lathe headstock without an appropriate bar feed or support.
  • Page 12: Electrical Safety

    Electrical Safety Read and understand the following list of cautions before attempting to perform service on this equipment. Failure to observe these rules can result in death or serious injury. 1. DANGER • Only qualified personnel should attempt to take current and voltage readings or perform service.
  • Page 13: Machine Safety Labels

    1 - S HAPTER AFETY maintenance, such as cleaning the table or removing chips from the machining enclosure, the machine should be put in an emergency stop condition, de-energizing the axis servo motors and spindle motor. Following these precautions prevents someone from becoming trapped or entangled in the machine.
  • Page 14: Tl14-Ml16-Ml18 Safety And Maintenance Label Locations And Descriptions

    TL14-ML16-ML18 Safety and Maintenance Label Locations and Descriptions Item Description Page Danger and Safety Precaution Extended Material/Stock Danger Chip Auger/Conveyor Hazard Main Power Hazard and Notice Lathe Safety Operation Instructions Warmup and daily checks Hydraulic Oil Maintenance Notice Waylube maintenance Located on hydraulic tank (if equipped)
  • Page 15: Ml22-26 Safety And Maintenance Label Locations And Descriptions

    1 - S HAPTER AFETY ML22-26 Safety and Maintenance Label Locations and Descriptions -26 Safety and Maintenance Label Locations and Descriptions Item Item Description Description Page Page Danger and Safety Precaution Extended Material/Stock Danger Chip Auger/Conveyor Hazard Main Power Hazard and Notice Lathe Safety Operation Instructions Warmup and daily checks Hydraulic Oil Maintenance Notice...
  • Page 16: Ml30-40 Safety And Maintenance Label Locations And Descriptions

    ML30-40 Safety and Maintenance Label Locations and Descriptions Item Description Page Danger and Safety Precaution Extended Material/Stock Danger Chip Auger/Conveyor Hazard Main Power Hazard and Notice Lathe Safety Operation Instructions Warmup and daily checks Hydraulic Oil Maintenance Notice Waylube maintenance Located on hydraulic tank (if equipped)
  • Page 17 1 - S HAPTER AFETY Read and understand all Safety, Operation, and Maintenance labels affixed to the machine to ensure safety and reliability. Located at headstock end near spindle through hole. Located around hazard areas on models equipped with chip conveyor.
  • Page 18 Located near main power disconnect switch on all models. Located at front of lathe near operator station where it is clearly visible. Important safety guidelines that must be observed. All models, located near operator station. Perform all checks to prevent damage and ensure reliable operation.
  • Page 19 1 - S HAPTER AFETY Perform maintenance to prevent damage and ensure reliable operation. (If equipped with air filter/regulator)
  • Page 21: Chapter 2 - Specification

    Chapter 2 - Specification Machine Weights TL14 ML16 ML18 ML22 ML26 ML35 ML40 Lbs. 4000 6000 7500 9000 9500 23,500 24,500 1800 2730 3400 4100 4300 10,500 11,000 Weights listed above are for standard bed length only. Consult specifications at the back of this manual for optional bed lengths.
  • Page 22: Tooling Specifications

    Tooling Specifications Milltronics lathes come equipped for various tooling sizes depending on machine model and turret size selected, if any. Please refer to your machine order or dealer to find out what tooling is required for your particular machine.
  • Page 23: Ml14-26 Series Machine Layout

    2 - S HAPTER PECIFICATION ML14-26 Series Machine Layout...
  • Page 24: Ml35-40 Series Machine Layouts

    ML35-40 Series Machine Layouts ML35 Series ML40 Series...
  • Page 25 2 - S HAPTER PECIFICATION Item Identification Item Description Item Description 1 Speed change device, if equipped 11 Turret (option) 2 Electric box 12 Cross slide 3 Headstock 13 Tail stock 4 Z axis servo motor 14 Bearing bracket (rear ) 5 Bearing bracket (front) 15 Spindle servo motor 6 Spindle...
  • Page 26: Leveling Bolt And Pad

    Spindle Nose and chuck guard Operator panels Tool Turret Tailstock Coolant pump Waylube unit Conveyor Chute (option) Shift cylinder (if equipped) Air system (if equipped) Leveling bolt and pad...
  • Page 27: Chapter 3 - Site Preparation

    1. At least 4” thick concrete slab free of cracks and not crossing any expansion joints for ML/TL14-26, and 6” thick for ML35 and 40”. 2. Milltronics will not guarantee machine geometry unless this is adhered to. 3. Ample ceiling height, and clearance behind the machine to fully open the door of the electrical cabinet at the rear of the machine.
  • Page 28: Power And Ground Requirements

    4. Milltronics does not allow the use of a separate grounding rod. 5. Milltronics does not allow conduit or wire raceways be used as a ground. 6. If a transformer is used to step the voltage down to 220 refer to the transformer grounding procedures immediately following this page.
  • Page 29: Connecting A Transformer

    3 – S HAPTER REPARATION Connecting a Transformer It is important that proper grounding procedures be followed when hooking up machines to power. Please review the following pages. They explain proper transformer connections and checks to ensure proper connections. Refer to the autotransformer diagram provided to verify that your connections are suitable.
  • Page 30: Autotransformer Connection Diagram

    Autotransformer Connection Diagram If your machine was ordered from Milltronics with a transformer option an autotransformer is supplied. The diagram below illustrates the various input voltage selections and proper ground wire connections. Always call the factory if in doubt concerning transformer connections as serious...
  • Page 31: Air Supply System (If Equipped)

    HAPTER REPARATION Air Supply System (if equipped) Depending on options (air collet, pneumatic gear shift mechanism), some Milltronics lathes require a constant supply of quality air pressure in order to perform optimally. 90- 110 PSI at 10 CFM is required.
  • Page 32: Lifting

    Lifting The preferred method of lifting Milltronics ML series lathes is by forklift. By Crane or Hoist If a crane or hoist must be used, the machine must be lifted by the bed with the use of a special lifting bracket and eye bolt, along with straps rated to handle the weight of the machine.
  • Page 33: Ml22-Ml26 Lifting Device Drawing

    3 – S HAPTER REPARATION ML22-ML26 Lifting device drawing...
  • Page 35: Chapter 4 - Installation

    Startup checklist The enclosed startup checklist guides the process of the machine installation and checkout. The startup checklist forms must be completed and sent to Milltronics Mfg. to activate the machine warranty. Use the startup checklist in conjunction with the following outline when installing and setting up the machine.
  • Page 36 Install the handwheel panel. Connect the 37-pin plug onto the back side of the panel assembly. Be sure the connector locks in place when the locking ring is turned. Fasten the panel using the hardware provided. Connect all remaining cables to their respective plugs on the machine. Once the machine is in place and assembled this far, have the power and air supplies connected by qualified personnel as described in chapter 1.
  • Page 37: Level The Machine

    ML Lathe Head Stock Taper Specification (Refer to this text while leveling the machine in the startup checklist) Milltronics ML lathe products have a .0002 inch per foot (.005mm per 300mm) specification for head stock taper. In almost all cases action will be required at the time of setup to adjust the lathe into tolerance.
  • Page 38 By inserting a ground bar into the spindle with the chuck removed. This requires a bar that has the morse taper of the spindle ground into its end. Typically there is a spindle taper adapter plug shipped with the machine to be used with a center, and this taper can be used as well.
  • Page 39: Initial Checks Of The Machine, Its Guards And Safety Systems

    4 - I HAPTER NSTALLATION Initial Checks of the Machine, its Guards and Safety Systems General Checks 1. Check for missing parts. Do not operate the machine if parts are missing. 2. Visually check for damage outside of machine and inside. Do not operate the machine if there has been shipping damage.
  • Page 40: Visually Check That Guards Are In Place

    WARNING: DANGEROUS VOLTAGES EXIST FOR THE VOLTAGE LEVEL CHECKS! 2. Check voltage levels. As stated in the Electrical Safety Rules, only qualified personnel should attempt to take these measurements. With the electrical cabinet door open, turn on the main power at the disconnect switch. Do not reset the drives, i.e.
  • Page 41: Safety Checks

    On Milltronics lathes, the Z axis homes in the center of travel. Turn main power on. Press the green ENABLE button to power up the servos. Note: If the machine does not ENABLE, check all emergency stop switches: conveyor, remote hand controller, etc.
  • Page 42: Test The Emergency Stop Circuit

    Test the Emergency Stop Circuit Having followed the steps outlined above for resetting the machine and starting the spindle, then Press the red EMERGENCY STOP button. Spindle rotation should stop. The emergency stop button is the most important safety switch on the machine. It stops and then de-energizes the spindle motor. (At the same time, it stops and de-energizes the axis servo motors, although they are not running for this test.) When the red emergency stop button is pushed, the spindle should brake to a...
  • Page 43: Chapter 5 - Failure Modes, Detection And Prevention

    Chapter 5 - Failure Modes, Detection and Prevention Minimizing Wear and Tear • The effects of everyday wear and tear may be minimized by good maintenance practice. Items high on the maintenance list include keeping the machine clean, providing clean dry compressed air with the correct oil drip into the air stream, and continuous application of the correct way oil through the automatic oiler.
  • Page 44: Diagnosing Mechanical Faults

    Diagnosing Mechanical Faults • Eyes, ears and hands are the best tools for detecting mechanical failure modes. As is the case for electrical faults, an accidental crash between tool and workpiece is a likely way to cause mechanical damage. A wide variety of mechanical failure modes also are possible even without a crash.
  • Page 45: Chapter 6 - Maintenance

    Chapter 6 – Maintenance Periodic Maintenance; Verification Of Safety Systems Note: Before performing any of the procedures in this section, please read and follow the directions in this manual covering safe practices for operation, setting and maintenance. Maintenance operations should only be performed by qualified personnel as described in chapter 1.
  • Page 46: Monthly

    • Inspect the coolant collector at the rear of the spindle to ensure it is draining properly and is not blocked by chips. If cutting chips accumulate in the collector, install a plug in the spindle/chuck bore to prevent this. – Also see “hydraulic chuck”...
  • Page 47: Safety Checks, To Be Carried Out Monthly And After Maintenance Operations

    6 - M HAPTER AINTENANCE • Change turret gear oil (if equipped). Safety Checks, to be carried out monthly and after maintenance operations • Repeat the checks for correct operation of the emergency stop circuit and of the safety enclosure circuit outlined in Chapter 4 of this manual. •...
  • Page 48: Air System Maintenance (If Equipped)

    Air System Maintenance (if equipped) • Ensure the air lubrication unit dispenses oil, and that the oil reservoir fill level is maintained. (Use Marvel No. 085, Mobil Velocite No. 10 or equivalent oil, further details about lubrication type can be found in the mechanical manual) •...
  • Page 49: Way Lube Maintenance

    6 - M HAPTER AINTENANCE Way Lube Maintenance • Ensure the way lube reservoir level is maintained (if equipped). (Use Mobil Vactra No. 02, Amoco Waytec No 68, Sunoco Sunwaylube No1180, or equivalent oil, further details about this lubricant can be found in the mechanical manual).
  • Page 50: Tool Turret Maintenance - Pragati

    Tool Turret Maintenance - Pragati Add 85W140 gear oil here, until level is at center of sight window Replace gear oil annually. Monitor sight glass to ensure fluid level remains topped off. Drain plug Sight window Tool Turret Maintenance - Baruffaldi Baruffaldi live tool turret Consult Buraffauldi turret...
  • Page 51: Hydraulic System Maintenance

    6 - M HAPTER AINTENANCE Hydraulic System Maintenance Check oil level in the hydraulic tank weekly and top off with Mobil DTE24 or equivalent if necessary. Replace the hydraulic oil annually with Mobil DTE24 or equivalent. Tank capacity is 18 Gallons or 68 Liters Filler/vent cap A maintenance label on the...
  • Page 52 Top View Chuck o Pressure switch and digital gauge. o Manual actuators o Pressure adjustment knob. Tailstock o Pressure adjustment knob. o Manual actuator o Pressure switch and digital gauge. Hydraulic Pressure The pressure regulators are factory set to 200psi. Each regulator should be adjusted according to specific job requirements.
  • Page 53: Hydraulic Tailstock Speed Adjustment

    6 - M HAPTER AINTENANCE Hydraulic Tailstock Speed Adjustment Adjust the flow valve Flow valve to vary the speed of the tailstock quill in/out motion.
  • Page 54: 2-Speed Transmission Maintenance - Ml35-40 Only

    2-Speed Transmission Maintenance – ML35-40 Only Speed Transmission Maintenance – ML35-40 Only Oil drain Sight window 2-Speed Transmission 2-Speed Transmission Periodically inspect the oil level by eriodically inspect the oil level by checking the sight window. hecking the sight window. Replace gearbox oil after first three eplace gearbox oil after first three months, then every six months...
  • Page 55: Spindle Bearing Maintenance (Some Models)

    6 - M HAPTER AINTENANCE Spindle Bearing Maintenance (some models) Maintenance of the Spindle Bearing Grease for Large Spindle Bore Lathes (Applies to all 10” bore and above, and 6” bore w/ tapered roller bearings) • Use only Kluber STABURAGS NBU 8 EP grease or equivalent. •...
  • Page 56: Steady Rest Operation Guidelines And Maintenance

    Steady rest operation guidelines and maintenance Steady rest options supplied by Milltronics are designed for toolroom use or limited production applications only. High speed, high production applications extend beyond the scope of a simple steady rest. When using the steady rest, adhere to the following guidelines: 1.
  • Page 57: Chapter 7 - 7200 Cnc Operation

    Chapter 7 – 7200 CNC Operation Milltronics 7200 CNC Front Panel 3 4 5 Power ON The main power switch is located on the electrical cabinet at the back of the machine. When main power is switched on, the power to the CNC is also applied.
  • Page 58 1) Manual Pulse Generator (HANDWHEEL) - rotate this wheel to control axis feed while in HDW mode. 2) FEEDRATE override rotary switch - labeled in percentages. Controls the feedrate and rapid traverse (Exception - see #3) of the machine axes. Also affects handwheel rate.
  • Page 59 7 – 7200 CNC O HAPTER PERATION 8) SPINDLE CW/STOP/CCW (Use along with #10 ENABLE on lathe controls) o Spindle CW button – starts spindle in clockwise direction provided there is a programmed spindle rpm. o Spindle CCW button – starts spindle in counter-clockwise direction provided there is a programmed spindle rpm.
  • Page 60: Diagram Of Main Screen

    Diagram of Main Screen RunTime When you are verifying a program the runtime displays the calculated time to make the parts. When you are running a program it shows the elapsed time since the program was started. The total of all program run times are kept in the “Job Time”...
  • Page 61 7 – 7200 CNC O HAPTER PERATION The Function Keys Highlighted Function Keys are active or available. Status Window Status Window displays detailed information on the state of the control. A detailed description is given below. Diagram of Status Window The \ changes back and forth to / and \ each time the status window is updated.
  • Page 62 Spindle override and direction: The position of the spindle override and the resulting rpm (if there is no spindle encoder) or the actual rpm (if there is a spindle encoder). This line also displays whether the spindle is off or running CW or CCW.
  • Page 63: C-Axis And Live Tooling Operation (Option)

    7 – 7200 CNC O HAPTER PERATION C-Axis and Live Tooling Operation (option) Spindle Selection Commands G24, G25 o G24 - Select main spindle o G25 - Select live tooling spindle After power up, a spindle must be selected before executing any other spindle commands.
  • Page 64 Spindle Jog Function The spindle jog button (when the door is open) will jog the main spindle (if in G24). If in G25 (live tooling spindle) the jog button (when the door is open) will jog the live tooling spindle. Drilling/Tapping Notes It is possible to drill (or tap) 3 different ways.
  • Page 65: Chapter 8 Machine Specifications

    Chapter 8 Machine Specifications TL14 & TL15 Specifications Effective Sept. 1, 2007 Configuration – Flat Bed Lathe Version C Version H Control Type Centurion 7 Centurion 7 Number of Axes Spindle RPM CNC Auto Programmable RPM Dual Handwheel, Handwheel Teach, Conversational G / M Code, Functions Manual or Automatic Operation of Spindle RPM and Coolant CAPACITY...
  • Page 66 Notes: Measurements performed with Renishaw laser. Measurements are linear over entire travel, and temperature changes and loading may affect tolerances. Centurion features covered under separate literature. Additional Centurion 7 features and additional options covered under separate literature. Milltronics reserves the right to change specifications at any time without incurring obligation.
  • Page 67: Ml16-Ml26 Specifications

    ML16-ML26 Specifications Machine Model ML16 ML18 ML22 ML26 Control Type Centurion 7T Centurion 7T Centurion 7T Centurion 7T Dual Handwheel, Handwheel Teach, Conversational G/M Functions Code, Manual or Automatic Operation of Spindle RPM and Coolant CAPACITY Swing Over Bed 17.5" 440 mm (dia.) 19"...
  • Page 68 SPINDLE ML16 ML18 ML22 ML26 12/10 HP 18/12 HP 24/15 HP 24/15 HP Horsepower 1 minute / 30 minutes 9/7.5 kw 13/9 kw 18/11 kw 18/11 kw Optional Horsepower 18/12 HP 24/15 HP 24/15 HP 18/11 kw 24/15 HP 18/11 kw 1 minute / 30 minutes (Performance Package 13/9 kw 18/11 kw...
  • Page 69 Tolerances are guaranteed over 10" sq. area. Centurion features covered under separate literature. For machine duty rating, see "Truth in Specifications" on www.milltronics.net. Milltronics reserves the right to change specifications at any time without incurring obligation.
  • Page 70: Ml30-Ml45 Specifications

    ML30-ML45 Specifications Effective March 1, 2006 Machine Model ML35/80 ML40/80 Control Type Centurion 7T Centurion 7T Dual Handwheel, Handwheel Teach, Conversational Functions G/M Code, Manual or Automatic Operation of Spindle RPM and Coolant CAPACITY Swing Over Bed 36.2" 920 mm 39.7"...
  • Page 71 Machine Model ML35/80 ML40/80 10 - 750 10 - 750 Spindle Range 2 – 10" Spindle Bore Spindle Speed 14" Spindle Bore *See note above 10 - 500 10 - 500 Spindle Range 1 – 14" Spindle Bore 10 - 375 10 - 375 Spindle Range 2 –...
  • Page 72 Tolerances are guaranteed over 10" sq. area. Centurion features covered under separate literature. For machine duty rating, see "Truth in Specifications" on www.milltronics.net. Milltronics reserves the right to change specifications at any time without incurring obligation.
  • Page 73: Chapter 9 Startup Checklist For Ml/Tl Series Lathes

    Air ran to machine for transmission, some models (80-120 psi 10 CFM) Checked By Hydraulic (chuck option) oil supplied (17-18 Gal. DTE24, ISO VG32) Checked By Milltronics Representative Responsibility (Initial or write n/a if does not apply) Check for missing parts Visually check for damage outside of machine and inside.
  • Page 75 Make sure the machine is wired to the GND line from the plant AC distribution system by a copper wire equal to or greater in size than the power feed wires. Milltronics does not allow the use of a separate ground rod, conduit, or wire raceways to be used as a ground source.
  • Page 77 ACONIA : 952.442.6455 • F : 952.442.6457 www.milltronics.net ENABLE MACHINE AND BE READY TO E-STOP IN CASE OF AXIS RUNAWAY. Home the machine (machine must be ENABLED). Check for smooth motion. Check the flood pump rotation and verify lubricator function.
  • Page 79 • MN 55387 1400 M ACONIA : 952.442.6455 • F : 952.442.6457 www.milltronics.net Turret (optional) Check for proper home position and rotation direction MDI - tool change tool # 1 (M6 T0101) Check the turret position (it should be #1) Advance the turret from pocket #1 to #2 (MDI M6 T02 T02) Switch phasing of input power if direction is incorrect.
  • Page 81 I / we accept this machine, its installation, and the terms of the warranty. Customer Signature Print Date Milltronics Rep. Print Date When this form is complete forward it to Milltronics for warranty activation commencing on the date of initial delivery to the first customer.

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