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Atrump KL Series Operator's Manual & Parts List

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鼻
ATRLJMP
MAC HIN E R Y
KL
Operator's Manual
洹匣
KL-42
KL-50
& Parts List
Series
Series

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  • Page 1 鼻 ATRLJMP MAC HIN E R Y 洹匣 KL-42 Series KL-50 Series Operator's Manual & Parts List...

  • Page 2: Table Of Contents

    Content SAFETY INSTRUCTIONS …………………………………………………..………. P 1-1 1.1 General safety instructions for operating the machine …………………………… P 1.1.1 Safety instructions for work holding …………………………………………. P 1.2 Maintenance safety instruction ……………………………………………………………… P 1.3 Installation precautions ………………………………………………………………………... P 1.3.1 Wiring ………………………………………………………………………………………. 1.3.2 Grounding ………………………………………………………………………………… 1.3.3 Environmental conditions …………………………………………………………...
  • Page 3 Content 3.3.1 Checking for shortage ………………………………………………………………… P 3.3.2 Machine Lifting …………………………………………………………………………… 3.3.3 Machine Placing …………………………………………………………………………… P 3.3.4 Machine Clean & Lubrication ……………………………………………………… P 3.4 Machine Leveling …………………………………………………………………………………… 3.5 Lubrication ……………………………………………………………………………………………… P 3-10 3.5.1 Lubrication pump specification …………………………………………………… P 3-10 3.5.2 Lubrication System ……………………………………………………………………… P 3-11 3.5.3 Lubrication system on Headstock ………………………………………………...
  • Page 4 Content 5.5 Independent chuck……………………….…………………………………………………… PARTS LIST ………………………………………………………………………………………….………. P 6-1 6.1 Headstock ……………………………………………………………………………………………… 6.1.1 Parts list of headstock.………………………………………………………………… 6.2 X-axis Transs .…….…..………………………………….….…….…….………………………... P 6.2.1 Parts list of 42CS Saddle............6.3 Z-axis Transs. .…….…..………………………….…….………………………………………… 6-11 6.3.1 Parts list of 42CS BED....…………………………….…….……………… Tailstock Oil Motor.…….…..…………………….…….….…….…….……………………….. P 6-13 6.4.1 Parts list of 50CT tailstock (Oil Motor)…………………….…….…………..

  • Page 5: Safety Instructions

    SAFETY INSTRUCTIONS 1- 1...

  • Page 6: General Safety Instructions For Operating The Machine

    1. SAFETY INSTRUCTIONS WARNING Do not install, operate, or service this machine until: 1) You have read and understand the safety instructions on the pages that follow. 2) You have read and understand the operator’s manual, especially knowing the function and location of all machine controls and read manuals for any related accessories.
  • Page 7 * Spindle and chuck rotation * Indexing of turret and tools * Carriage and cross-slide movement * Tailstock movement, both quill and body 6) Keep machine and area around it clean and well lighted. Never allow chips , coolant or oil to remain on the floor. Do not leave loose objects on around machine.

  • Page 8: Safety Instructions For Work Holding

    off” or “power off” modes. 18) When restarting a machine after it has been shut down, always assume it has been tampered with. Recheck all phases of the job as though you were running the first piece. 19) Never touch spindle start or spindle jog control until hands, feet, and body are well clear of the work area.
  • Page 9 the chuck at the beginning of every shift. Use only the chuck manufacturer’s recommended lubricant. A. A weekly examination of the condition of chuck should be made. This examination should include the measurement of jaw clamping force with a jaw force gage to insure that the chuck is function , as it should. B.

  • Page 10: Maintenance Safety Instruction

    1.2 Maintenance safety instruction WARNING High voltage is used to power the machine; only authorized electricians should Correct any electrical component failure. Disconnect main power and lock in off position before attempting any repair. Tag disconnect switch “DO NOT START” 1) Read and understand safety instructions for machine operator before servicing this machine.
  • Page 11 Generally, the NC machine should be ground to a separate grounding rod. If an independent ground cannot be provided for the machine, prepare the ground connection as follow: 1) Connect a single conductor to it’s own grounding terminal. This will avoid possible serious accidents resulting from ground currents ,which might otherwise flow in the NC machine if a peripheral device , should malfunction.

  • Page 12: Environmental Conditions

    (Wrong Grounding) 1.3.3 Environmental conditions Generally, the machine will be installed on the following conditions. However, these may change over a period of time or in response to seasonal changes. 1) Supply voltage : 90% to 110% of nominal supply voltage 2) Source frequency : ±...
  • Page 13 shock will be sustained. 2) Do not touch a switch witch wet hands. This, too, can cause an electric shock. WARNING 1) The emergency stop push-button should be well known so that it can be operated at any time without having to look for it. 2) Before replacing a fuse, switch off the machine.

  • Page 14: Before Switching On

    1.4.1 Before switching on DANGER Cables, cords or electric wires whose insulation is damaged can cause current leaks and electric shocks. Before using these, check their condition. WARNING 1) Be sure the instruction manual and the programming manual are fully understood.

  • Page 15: Routine Inspections

    1.4.2 Routine inspections WARNING When checking belt tensions, do not get your fingers caught between the belt and pulley. CAUTION 1) Check pressure gages for proper readings. 2) Check motor, gearboxes and other parts for abnormal noises. 3) Check the motor lubrication, and sliding parts for evidence of proper lubrication 4) Check safety covers and safety devices for proper operation 5) Check belt tensions.

  • Page 16: Operation

    5) Tools or any items must not be place on the headstock, turret, cover and similar places. 6) If the center holes of heavy cylindrical work piece are too small, the work pieces can jump out when loaded. Be careful about center holes and angles. CAUTION 1) Tool lengths should be within specified tolerances to prevent interference.

  • Page 17: To Interrupt Machine

    1) The machine could not open under automatic operation. Also, the machine front guard can’t be opened under automatic operation model. 2) When performing heavy-duty machining, carefully prevent hips from being accumulated since hot chips can catch fire. 1.4.6 To interrupt machine WARNING 1) When leaving the machine temporarily after completing a job, turn off the power switch on the operation panel, and the main circuit breaker.

  • Page 18: Completing A Job

    1.4.7 Completing a job CAUTION 1) Always clean the machine or equipment. Remove and dispose of chips and clean cover, guard and windows, etc. 2) Do not clean the machine or equipment before it has been stopped. 3) Return each machine component to its initial condition. 4) Check wipers for breakage.

  • Page 19: Maintenance Operation

    1.4.10 Maintenance operation DANGER 1) Those not engaged in the maintenance work should not operate the main circuit breaker or the control power ON switch on the operating panel. For this purpose, “Do not touch the switch, maintenance operation in progress” or similar working should be indicated on such switches and at any other appropriates locations, such indication should be secured by a semi-permanent means in the reading direction.

  • Page 20: Unit Operation Is Begun After Maintenance

    1.4.11 Unit operation is begun after maintenance WARNING 1) Arrange things in order around the section to receive the maintenance, including working environments. Wipe water and oil off and provide safe working environments. 2) All parts and waste oil should be removed by the operator and placed far enough away from the machine to be safe.
  • Page 21 1- 17...
  • Page 22 1- 18...

  • Page 23: Hazard List And Solution

    1.6 Hazard List and Solution HAZARD LOCATION RISH DESCRIPTION SOLUTION Z axis leads screw When z-axis is moving, the Fit a protection cover above rotating Ball screw could cause The Ball screw to prevent hurt to operator if he touches it operator from touching it with unconsciously.

  • Page 24: Machine Specifications

    MACHINE SPECIFICATIONS...

  • Page 25: Dimensional Drawing

    2.1 Machine Specifications 2.1.1 Dimensional drawing Unit：mm...
  • Page 26 2.1.2 Main Unit Item Description Item Description SERVO MOTOR OF Z AXIS BALL SCREW OF X AXIS SPINDLE SERVO MOTOR OF X AXIS ELECTRIC POWER BOX AIR CONDITIONER HEAD STOCK TRANSFORMER CHUCK SPINDLE OIL COOLER SPLASH GUARD HYDRAULIC TANK CHIP CONVEYER BALL SCREW OF Z AXIS FOUNDATION BOLT CONTROL PANEL...

  • Page 27: Specification

    2.1.3 Specifications KL-4260 KL-4280 KL-42120 KL-42160 KL-42200 KL-42240 Model \ Description Working Capacity Φ1070 Swing over bed (mm) Center height (mm) Φ744 Swing over cross slide (mm) Dist. between centers (mm) 1700 2200 3200 4200 5200 6200 Width of bed (mm) Headstock H: 161-800 H: 111-560...
  • Page 28 KL-5060 KL-5080 KL-50120 KL-50160 KL-50200 KL-50240 Model \ Description Working Capacity Φ1270 Swing over bed (mm) Center height (mm) Φ944 Swing over cross slide (mm) Dist. between centers (mm) 1700 2200 3200 4200 5200 6200 Width of bed (mm) Headstock H: 161-800 H: 111-560 H: 54-270...
  • Page 29 2.1.4 Interrupted diagram of tool rack Unit : mm TURRET MODEL L max. KL-42/5060 1500 KL-42/5080 2000 KL-42/50120 3000 4 WAY Toolpost KL-42/50160 4000 KL-42/50200 5000 KL-42/50240 6000 KL-42/5060 1430 KL-42/5080 1930 KL-42/50120 2930 8 Station Toolpost KL-42/50160 3930 KL-42/50200 4930 KL-42/50240 5930...

  • Page 30: Interrupted Diagram Of Tool Rack

    Interrupted diagram of tool rack Unit : mm TURRET MODEL Dt max. D max. KL-4200 Dia.1060 Dia.740 4 WAY Toolpost KL-5000 8 Station Toolpost Dia.1260 Dia.940...

  • Page 31: Check List

    2.2 Check list 2.2.1 Check list for operation Item Description No Read through operating manual thoroughly Read through all instruction manual thoroughly Lifting moving machine Installing machine Leveling machine Lubricating instruction Checking electrical circuit connection Main switch and button ‘’ON’’ Press emergency stop button to stop machine Learn safety rules...

  • Page 32: Installation

    INSTALLATION...

  • Page 33: Foundation

    3. INSTALLATION N O T I C E When the machine is settled, please remove the red block from the machine. 3.1 Foundation To upgrade the operation efficiency and accuracy of precision machining, a proper foundation is required. It is recommended to locate the machine in a place away and without the influence of damping, chemical gas or trembling.
  • Page 34 Install the machine on the first or second floor. Take the stress of ceiling and foundation into careful consideration to see if machine load can be offset. 3.1.1 Foundation Layout Please dig holes in places as big as shown in Figure for setting foundation bolts. Place the bolts in the holes then fill the holes with cement.

  • Page 35: Foundation Layout

    Foundation Layout 間隔數 總長 MODEL KL-42/5060 3925 KL-42/5080 4425 KL-42/50120 5425 KL-42/50160 6425 KL-42/50200 7425 KL-42/50240 8425...

  • Page 36: Layout & Floor Plan

    3.1.2 Layout & Floor Plan Following is a top view drawing.

  • Page 37: Connection Of Power Line

    3.2 Connection of power line 1) Make sure the voltage of incoming power supply is the right type that the machine requires or as marked on the unit. 2) Connect the power wires per electrical code in your area. 3) Power wires, grounding and over-voltage protector should comply with the local electricity regulations.

  • Page 38: Machine Lifting

    3.3.2 Machine Lifting Please use the following equipment to lift the machine. 1) A crane which the safety loading weight required must more than the machine at least. 2) Some tools for lifting machine. Wrap the straps under the ribs as shown in Figure and then lift the machine in the slowest speed of crane.

  • Page 39: Machine Placing

    Machine Lifting 3.3.3 Machine Placing Before placing the machine, fix the adjusting screws on the base, make the machine as close as possible to the floor, and position the leveling pads in their most suitable place, so as to increase the stability of machine. 3.3.4 Machine Clean &...

  • Page 40: Machine Leveling

    3.4 Machine Leveling It is necessary to level the machine before starting to operate the machine. Please prepare the following tools to adjust machine leveling: 1) Accurate spirit leveling gauge (spec. 0.02mm/1000mm or 0.01in/4ft) 2) Two adjustable wrench Clean the table surface thoroughly, set one of the spirit leveling gauge on the longitudinal direction and the other on the cross direction of the slide.

  • Page 41: Lubrication

    3.5 Lubrication 3.5.1 Lubrication pump specification Auto, manual pump tank capacity :3.0 Effective capacity :4.0 Motor : (110V) / 220V DIRECTIONS * Note the oil quantity will reduce gradually under normal application. * Note whether motor is running or not. 1) Fill clean lubricant into the oil tank up to the “MAX”...

  • Page 42: Lubrication System

    2) The standard of CESH type, operation time is 10 sec fixed, and interval time is 1-60 min optional. 3) The electronic box has operation indicator and interval indicator. Two types of this CESH series, CESH Turn On-Feeding Type and CESH Turn On-Interval Type, both could automatically save the original operation and interval time.
  • Page 43 Still, please check the fluid level before operation. Add the following recommended Lubricant to the reservoir. A. Chinese petroleum Corp. 68 B. Shell Tonna 68 C. Mobil vactra #2 D. Esso H68 3-12...

  • Page 44: Lubrication System On Headstock

    3.5.3 Lubrication system on Headstock The Gear construction in headstock is lubricated by mechanical type of pump. Spindle rotation On either direction will activate the pump to supply lubricant. 3.5.4 Lubrication on Tailstock Bed width 770mm there are two oil ball on the tailstock. Please add 10 drops of recommended lubricant to them.

  • Page 45: Chucks And Chuck Mounting

    3.6 Chucks and chuck mounting NOTICE Use only high-speed chucks which are capable of min. rpm with these machines. 3.6.1 Chuck fitting on A2-11 spindle nose When fit a A2-11 type chuck , it is necessary to fit a Back plate for chuck. Fitting the Back plate first, then fit the chuck on.

  • Page 46: Maintenance

    MAINTENANCE...

  • Page 47: Lubrication System

    4 MAINTENANCE 4.1 Lubrication System Check all the fitting of lubrication system under normal operation temperature. If oil leaking is founds, tighten the fittings. Inspect oil level daily. 4.1.1 Replacing headstock Oil It is necessary to replace the oil for a new machine after one month. of operation.

  • Page 48: Fittings

    Figure 4-1 4.1.2 Fittings Check all fittings after 500 hours of operation especially their tightness between tubes. After that, do the regular check every 200 hours. 4.2 Machine body In order to maximize the machine performance, the accuracy on headstock and all slides have to be re-adjust after three months of operation.

  • Page 49: Cross-Slide

    2) If the pointer of the in indicator swings drastically, release the headstock fixing screws and adjusting the adjusting to fine the paralleled of spindle and Z axis 3) After adjustment, tighten the fixing screws and move the saddle to observe the pointer of the indicator.

  • Page 50: Saddle

    4.2.3 Saddle lf the gibs between saddle and bed become loose, it will affect the accuracy of saddle travel. Check and adjust them every six months according to the following steps. 1) Use flat head screw driver to loosen the adjust screw 1 & 2 as shown as Fig. about 1/2 circle CCW.

  • Page 51: Aligning Tailstock To Spindle

    4.2.4 Aligning tailstock to spindle If there is taper appearing on work piece while machining it by using tailstock. Follow the following steps to re-align tailstock to the spindle. 1) Insert a gauge bar between the spindle and tailstock, attach the base of a test indicator to the saddle, and apply the stylus of the indicator to the surface of the bar, of its maximal difference for later adjustment.

  • Page 52: Electric Equipment

    4.3 Electric equipment 4.3.1 Motor Spindle motor is equipped with IP. Therefore, no special care in required. Have qualified technician check and clean it every six months is OK. Other motors should be checked annually. 4.3.2 Control units No special care is required. Cleaning CRT or TFT display and key board by using a clean cloth.

  • Page 53: Remove Chip And Renew Coolant

    4.5 Remove chip and renew coolant 1) There is too much chip deposited in the machine or before the end of work everyday. It is necessary to take a little time for removing the chip from the machine. First should turn off the power on the operate panel, and then opening the safety doors.

  • Page 54: Notice For Maintenance And Inspection

    Notice for maintenance and inspection Execute an emergency stop or switch off the main power supply before carrying out maintenance and inspection work. If the machine is still in an operable condition during this work and for example, a sensor is inadvertently touched, the machine may move due care is therefore required.
  • Page 55 ↓ Service Request Call to our Representative 1. Lubricating Oil and Supplying Coolant Always use the types of oil specified. Do not mix the oil of different brands even if they are indicated as the “equivalent oil”. Original maker will not be responsible for any problem arising from the use of oil not specified by + -.
  • Page 56 6. Supplying Coolant to the Coolant tank a) Press the coolant off switch to stop coolant supply. b) Check the coolant tank volume with the oil level gage. c) Supply coolant from the top of coolant tank. 7. Greasing the Chuck Master Jaws a) Stop the spindle b) Supply grease from the three grease cups around the chuck.

  • Page 57: Maintenance And Inspection List

    Maintenance and Inspection List Cycle Inspection 1. Remove chip, dust and other foreign matter around the table base, saddle, tool length measuring device, etc. 2. Wipe off lubrication, coolant and chip from the machine surface. 3.Wipe off all foreign matter from the slide ways not protected by the cover(base slide ways) 4.
  • Page 58 Cycle Inspection 4. Clean the air filter. Replace it, if necessary. Never use thinner or similar agents in cleaning the air filter. 5. Clean the slide ways wipers. Replace them, if necessary. 6. Check to be sure that the solenoids and limits switch can correctly function.

  • Page 59: Chuck

    CHUCK...

  • Page 60: Instruction Manual

    5.1 INSTRUCTION MANUAL INTRODUCTION To ensure safe operation of your chuck Please read this instruction Manual and pay particular attentions marked with , including IMPORTANT instructions concerning chuck performance 5.1.1 SAFETY PRECAUTIONS Please read this manual and following indications carefully. DANGER 1.
  • Page 61 Function reduces! 3. When clamping the work, take care not to pinch your hand. 4. After clamping the work with regulated torque, be sure to remove the Handle. Danger by discharge of handle. CAUTION 1. Never attempt to hammer the chuck, jaws or clamped workpieces. Never strike a work piece, which is kept on the chuck, by a hammer or the likes, The accuracy and function of the chuck will be damaged, and its life span shortened remarkably as well.
  • Page 62 IMPORTANT 1. Frequently clean the chuck. 2. When repeat accuracy is required, it is desired to tighten with the same Pinion if it is the same diameter. 5.2 INSTALLATIION 1. Adapter mounting accuracy is influenced to the chuck. Accordingly, finish the adapter run-out and face run-out within 0.005mm after mounting to spindle.

  • Page 63: Maintenance And Inspection

    5.3 MAINTENANCE AND INSPECTION 1. Clean engagement part in the chuck body and jaw 2. Lubricate in ball cap and the engagement part in the chuck body and jaw 1 or 2 times a day. 3. If sward or foreign matter is caught inside chuck(scroll, gear part), remove the chuck immediately and disassemble and clean it.

  • Page 64: Independent Chuck

    5.5 Independent chuck 1. Note whether the clamping chuck is tight or not. 2. Reduce speed to machine irregular work pieces, in order to avoid the machine shaken.

  • Page 65: Parts List

    PARTS LIST...

  • Page 66: Headstock

    6.1 Headstock 6.1.1 42HB, Spindle bore 155mm (6’’)
  • Page 67 42HB, Spindle bore 155mm (6’’)
  • Page 68 6.1.2 PARTS LIST OF 42HB(6”) HEADSTOCK Rev.2016.01.25 PART’S NO. DESCRIPTION REMARK Q'TY 48HB-601 HEAD STOCK 42HA-602 COVER 42HA-603A SPINDLE 42HB-604 INPUT SHAFT 004-1 42HA-604-1 SPACER RING FOR PULLEY 004-2 42HA-604-2 WASHER 42HA-605 V-PULLEY 42HA-606 COVER 42HB-605 GEAR 42HA-616 SHATT 42HA-618 GEAR 42HA-619 SHAFT...
  • Page 69 PARTS LIST OF 42HB(6”) HEADSTOCK Rev.2016.01.25 PART’S NO. DESCRIPTION REMARK Q'TY 42HA-645 COVER 045-1 42HA-645-1 COVER 42HA-646 COVER 50HB-047 BEVEL GEAR 42HA-648 SHAFT OF FIXED 42HB-649 CAMSHAFT 42HB-650 42HB-651-1 SPEED CHANGE FORK 42HB-652 RING 2014.11.21 BEARING 6006 BEARING 6208 BEARING 6010 BEARING 6909 BEARING 32040 BEARING 6038...
  • Page 70 PARTS LIST OF 42HB(6”) HEADSTOCK Rev.2016.01.25 PART’S NO. DESCRIPTION REMARK Q'TY O RING G75 O RING G55 O RING G85 O RING G65 OIL SEAL 47*30*10 OIL SEAL 68*45*12 OIL SEAL 38*25*8 OIL SEAL 55*30*11 MOTOR OIL PUMP SENSOR NUT M12 SCREW M8*35 SCREW M6*35 SCREW M10*30...
  • Page 71 6.2 X-axis Tarns. 6.2.1 Parts List of 42CS SADDLE...
  • Page 72 Parts List of 42CS SADDLE...

  • Page 73: Parts List Of 42Cs Saddle

    6.2.2 PARTS LIST OF 42CS SADDLE Rev.2018.05.07 PART’S NO. DESCRIPTION Q'TY REMARK 42CS-001 CARRIAGE 42CS-002 CROSS SLIDE 50CS-003 BALL SCREW 42S-004 GIB PLATE 50CS-005 WASHER 42S-006 42S-007 50CS-008 PULLEY 50CS-009 LOCKING COVER 50CS-010 BEARING COVER 42S-011 GIB PLATE 50CS-004 DUST COVER 25CB-014 BEARING COVER 42CS-015-1...
  • Page 74 PARTS LIST OF 42CS SADDLE Rev.2018.04.17 PART’S NO. DESCRIPTION Q'TY REMARK SCREW M12*40 SCREW M8*30 SCREW M12*50 SCREW M8*25 SCREW M12*55 SCREW M12*30 SCREW M12*35 SCREW M8*75 SCREW M6*20 SCREW NUT M35*P1.5 SCREW NUT M30*P1.5 LOCK Φ6 LOCKING RING 25*30 MOTOR FLUSH BOLT 6-10...

  • Page 75: Z-Axis Transs

    6.3 Z-axis Trans 6.3.1 Parts list of 42CB BED 6-11...
  • Page 76 6.3.2 PARTS LIST OF 42CB BED Rev.2018.04.25 PART’S NO. DESCRIPTION Q'TY REMARK 42CB-001 42B-001-1 50CB-002 BALL SCREW 50CB-003 BEARING BASE 50CB-004 BEARING COVER 42CB-005 LEADSCREW BASE 50CB-006 SPACER 50CB-008 SPACER 50CB-012 MOTOR BRACKET 50CB-030-1 DECELERATOR CONNECTION PLATE 50CB-031-1 DECELERATOR BASE 42CB-040 X-AXIS MOTOR PLATE 25B-050...

  • Page 77: Tailstock Oil Motor

    6.4 Tailstock ( Oil Motor 6.4.1 Parts list of tailstock (Oil Motor) 2015.01.07 6-13...
  • Page 78 Parts list of 42T tailstock (Oil Motor) 2015.01.07 6-14...
  • Page 79 6.4.2 PARTS LIST OF 42T TAILSTOCK OIL MOTOR Rev.2015.01.07 PART’S NO. DESCRIPTION Q'TY REMARK 42T-001 TAIL STOCK 42/48/58T-002 TAIL STOCK BASE 42T-603 QUILL 42T-004 SCREW 42T-005 42T-006 DUST COVER 42T-607 TAILSTOCK SHAFT 42T-008 FRONT SPACER 42T-609 COVER 18HA-069 HANDLE FOR SPEED CHANGE 51CT-013 SPACER 42/48/58T-014...
  • Page 80 PARTS LIST OF 42T TAILSTOCK OIL MOTOR Rev.2015.01.07 PART’S NO. DESCRIPTION Q'TY REMARK CAP SCREW M6*15 WASHER Ø 24* Ø 40*3 CAP SCREW M8*25 CAP SCREW M10*25 KEY 12*8*55 KEY 6*6*25 O RING P115 WASHER Ø 12* Ø 34*3 WASHER Ø 40* Ø 80*5 WASHER Ø16* Ø...

  • Page 81: Hydraulic Circuit Diagram

    6.5 Hydraulic circuit diagram 6-17...

This manual is also suitable for:

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