Arsenal FU 321M Operating instructions

OPERATING AND MAINTENANCE MANUAL FU 321M 65
Operating and maintenance
manual
UNIVERSAL MILLING
MACHINE
FU 321M
Arsenal Company, 100 Rozova dolina Str., 6100 Bulgaria
tel: ++ 359/431/633 22, 634 31 telex 088 507 F ARS BG,
fax: ++ 359/431/633 32, 631 87
E-mail: [e-mail]
[email protected]

OPERATING AND MAINTENANCE MANUAL FU 321M 64
UNIVERSAL MILLING MACHINE
FU 321M
SET OF MANUALS:
UNIVERSAL MILLING MACHINE FU 321M
Operating and Maintenance Manual
FREQUENCY INVERTOR
Operatingand Maintenance Manual
VERTICAL MILLING HEAD VFG 281 / VFG 323
Operating and Maintenance Manual
UNIVERSAL DIVIDING UNIT UDA 125 / UDA 160
Operating and Maintenance Manual
INDEXING TABLE KDM 320
Operating and Maintenance Manual
SLOTING HEAD SG 251 / SG 321
Operating and Maintenance Manual
UNIVERSAL MILLING HEAD UFG 285 / UFG 325
Operating and Maintenance Manual
DIGITAL READING DEVICE
Operating and Maintenance Manual
SYSTEM FOR LUBRICATION
Operating and Maintenance Manual

OPERATING AND MAINTENANCE MANUAL FU 321M 63
C O N T E N T S
CERTIFICATE ................................................................................ 1
APPLICATION ............................................................................... 2
SAFETY PRECAUTIONS ............................................................. 3
SPECIFICATIONS ......................................................................... 6
TRANSPORTATION AND INSTALLATION ................................ 8
PACKING LIST ............................................................................. 11
TEST CERTIFICATE ..................................................................... 13
OPERATION .................................................................................. 15
DESCRIPTION OF THE MAIN MACHINE UNITS .................. 19
LUBRICATION .............................................................................. 21
COOLING SYSTEM ..................................................................... 22
MAINTENANCE ............................................................................ 23
LIST OF BEARINGS ................................................................... 25
ELECTRIC EQUIPMENT .............................................................. 26
DRAWINGS AND CHARTS ......................................................... 33

OPERATING AND MAINTENANCE MANUAL FU 321M 1
TYPE: UNIVERSALMILLING
MACHINE
MODEL: FU 321M
Modification:
normal
tropical
metric
inch
Mainmotor range:
standard
option
Main motor power:
standard
option
YEAR OF PRODUCTION: . . . . . . . . . . . . . . . . . .
SERIAL No: . . . . . . . . . . . . . . . . . .
INVENTORYNo: . . . . . . . . . . . . . . . . . .
C E R T I F I C A T E

OPERATING AND MAINTENANCE MANUAL FU 321M 2
APPLICATION
The Universal Milling Machine is meant to fulfil various milling operations for the
needs of general engineering, which are done through circular, disk-type, form end
milling, gear and other types of cutters.
Various planes, grooves, gear wheels can be machined, it is capable of boring in
steel, cast iron, nonferrous and plastic parts.
The machine can carry out automatic pendulous and semi-automatic linear cycles.
The processing possibilities of the machine can be expanded by using a vertical
milling head, an universal milling head, universal indexing device, rotary index
table, slotting head, rack toothing device and other accessories.

OPERATING AND MAINTENANCE MANUAL FU 321M 3
SAFETY PRECAUTIONS
Any type of incorrect use of the machine may result in serious personal injury for
the machine operator. We suggest therewore that the advice and information of-
fered should be througly digested and adhered to as closely as possible so as to
guarantee your saafety and for the operator's safety ass well as to prolong the life-
span of the machine.
GENERAL PRECAUTIONS
* Never leave the machine working without being watched by an operator.
* The operator must be trained to operate milling machines. Training should be
done by manufacturer's or supplier's expert.
* Do not operate this machine without having previously read and fully understood
the safety precautions in this chapter.
* Do not operate this machine without having previously read and fully understood
the Instructions Manual.
* Make sure a supervisor or instructor is present the first time you work this
machine.
* Never attempt to operate the milling machine while your senses are impaired by
medication, drugs, alcohol or other substances.
* Always use safety gear (safety glasses, shoes, etc.)
* Never use gloves which could become caught in the moving parts of the
machine i.e. gloves which are too big and/or are damaged. Only use gloves which
are in good condition and are the right size for the operator. Gloves should also
be used when handling tools / components because they may be sharp.
* Always keep the machine and equipment clean.
* Do not remove nor modify safety systems or their functioning.
* The handle for manual motion of the transversal and vertical feed is to be
removed from the machine before putting on the automatic feed and the rapid
traverse.
* Position yourself at a safe distance from machine so as to avoid getting caught
in the moving parts of the machine. Do not wear watches, rings, necklaces, ties,
etc. and roll up long sleeves to your elbows, long hair should be tied back.
* Provide an adequate light source. If additional lighting is needed do not hesitate
in asking for it.
* Make sure the network voltage corresponds with the voltage marked on the
machine by the manufacturer.

OPERATING AND MAINTENANCE MANUAL FU 321M 4
* Be aware of the position of the emergency stop.
* Protect your hands. Stop the main spindle before proceeding to change tools
or workpiece, adjusting a new workpiece, measuring, changing or adjusting belts,
puleys or gears, removing swarf or oil, etc.
* Before starting operation make sure that the workpiece and the cuttters are well
tightened.
* Loose objects on the table may be catapulted into the air. Before starting to
work remove all loose objects such as tools, mandrels, clothes, etc.
* Arrange all tools in order of use.
* Damaged or weakened tools break easily. Keep all tools sharp. Check tools and
toolholder on a regular basis. Insert the tool as far as possible into the toolholder.
* Avoid tool breakage.Use suitable machining feeds and speeds. Reduce speed and
feed when unusual noises are noticed. Avoid unnecessary damage to tool and/or
workpiece. Never start the machine when the tool is touching the workpiece. After
mounting the tool, carry out a trial run. Do not operate the machine in automatic
mode in the beginning.
* Do not use compressed air to clean or remove dust and swarff from the
machine and its surroundings. Use a brush or chip scraper.
* Certain materials, such as magnetisium are highly inflammable in powder or
chip form. Always consult a supervisor before working with these materials.
* Prevent fires. Keep inflamable material and liquid well away from the work area
and hot swarf.
* Make sure the machine is disconnected from the mains before procceding with
any type of repairs or maintenance.
* Maintenance should be carried out by qualified staff.
WARNING: All electrical connections must be performed by a qualified electri-
cian or service engineer.
THIS DOCUMENT IS A GUIDELINE FOR THE OPERATOR. HOWEVER,
"ARSENAL" Co. DOES NOT ASSUME ANY RESPONSIBILITY FOR ANY
ACCIDENTS NOR CAN WE GUARANTEE THE AVOIDANCE OF ANY
ACCIDENTS EVEN IF ALL SAFETY INSTRUCTIONS ARE STRICTLY
FOLLOWED AS THE TYPE OF WORK PERFORMED MAY REQUIRE
DIFFERENT SAFETY MEASURES.

OPERATING AND MAINTENANCE MANUAL FU 321M 5
NOISE OUTPUT LEVEL DETAILS
In accordance with paragraph (1.7.4.f) of APPENDIX I of the 98/37/EG
Directive we hereafter state the noise output values for the machine:
1) acoustic pressure level value at - ........ dB
idle running of main drive at max. speed
2) acoustic pressure level value when cutting - less than 82 dB
Fact gathering system:
Measuring of the acoustic pressure has taken place at 1 meter from the machine
and a height of 1.60 meter above the floor.

OPERATING AND MAINTENANCE MANUAL FU 321M 6
SPECIFICATIONS
Basic dimensions
Distance from spindle center to table top
minimum ........................................................ mm 30
maximum ....................................................... mm 490
Distance between body guides and table center
minimum ............................................................ mm 280
maximum ............................................................ mm 640
Distance from spindle center to yoke ................... mm 150
Distance from floor to spindle center ................... mm 1430
Table
Working table size ................................................... mm 320 x 1350
Table swing to left and right ................................. degrees x45
Table travel:
- longitudinal
manual ................................................. mm 1000
automatic .............................................. mm 980
- cross
manual ................................................. mm 360
automatic .............................................. mm 340
- vertical
manual ................................................. mm 460
automatic ............................................. mm 440
T-slots ...................................................................... No 5
T-slot width ............................................................. mm 18
Distance between T-slots ........................................ mm 63
Table feeds .............................................................. No stepless
Feed range
longitudinal .................................................... mm/min 10 - 1000
cross ............................................................... mm/min 10 - 1000
vertical ........................................................... mm/min 4- 415

OPERATING AND MAINTENANCE MANUAL FU 321M 7
rapid traverse
longitudinal ........................................ mm/min 2500
cross .................................................. mm/min 2500
vertical ............................................... mm/min 1040
Spindle
Spindle nose ......................................................... ISO 50
Spindle bore ......................................................... mm 29
Spindle dia at front bearing ................................ mm 110
No. of spindle speeds .......................................... No 18
Spindle speed range
standard ....................................................... min-1 32 - 1600
option .......................................................... min-1 40 - 2000
Drive
Main motor power:
standart ........................................................ kW 7,5
option .......................................................... kW 5,5
Feed motor power ................................................ kW 2,2
Overall dimensions:
Length .......................................................... mm 2620
Width ........................................................... mm 2090
Height .......................................................... mm 1780
Machine weight ........................................... kg 2850

OPERATING AND MAINTENANCE MANUAL FU 321M 8
TRANSPORTATION AND INSTALLATION
LIFTING, MOVING AND TRANSPORTATION
When the machine is in packed condition, it should be lifted and moved to the
transport vehicle by means of a lifting equipment of more than 4 t capacity, being
gripped at the place indicated on the packing / Fig.23 /.
When the machine is in unpacked condition or is in a packing, suitable for truck
transportation (just on a pallet), it should be lifted and moved as slings are fixed
on the yoke. Protection pads 10 / Fig.1 / are put under the slings to protect the
finished surfaces. The yoke should be locked.
UNPACKING
During unpacking the availability of all parts and accessories should be established
according to the packing list. Claims, related to shortages and condition of the
machine and its accessories, made after putting it into operation, are not accepted.
CLEANING
Before machine installation, it should be cleaned from the rust - preventing oil
with pure diesel oil. For removal of protective oil film, do not use solid objects
and diluents that can damage the metal surfaces, paint and label marking. The
following water-soluble alkaline degreasing materials are recommended:
- Flexiclean and Techniclean, manufactured by CASTROL;
- Cimclean PC 410 and Cimclean PC 430, manufactured by CIMCOOL
Unpainted surfaces should be dried with rags and then lubricated with "Mobil
Vactra oil No.2". The machine mechanisms shall be lubricated after installation and
foundation as specified in section "Lubrication".
FOUNDATION
The location of the machine must be picked carefully. A minimum distance of
500 mm must be left between the machine and any other machine and/or struc-
tures. Do not place the machine in a humid, dirty and badly illuminated enviroment.
While foundation is being done, check regularly the longitudinal and cross level-
ling of the work table. The tolerance is 0.03 mm per 1000 mm. Levelling accuracy
can be achieved with the help of wedges positioned near the foundation bolts.

OPERATING AND MAINTENANCE MANUAL FU 321M 9
Install the machine on stable and flat concrete floor and if necessary use addi-
tional pads including vibroinsulating pads, or place concrete. If the floor is un-
stable, install the machine on a concrete foundation / Fig.2 /. Machine base has
holes for the foundation bolts, by which machine can be fixed at special situa-
tions. The dimension H depends on the bearing capacity of the soil, but it should
be minimum 350 mm.
After final curing of the concrete, tight the nuts of foundation bolts (if used), as
continuously observe and keep not to disturb the horizontal leveling of the ma-
chine. Then fill the space between the machine and the foundation with a mixture
of sand and cement.
Fondation bolts, nuts and the leveling plates are not delivered by the producer.
NOTE: The use of vibration insulating supports is allowed if the soil is hard
enough. Foundation bolts, nuts and wedges are not supplied by the manufacturer.
MACHINE DIMENSIONS
3150
2450
1300
360 320
500
720
2090 500
1635 1455
500 500
2665
3310
45
45
30406940
1078
1080
306
Еl. conection point

OPERATING AND MAINTENANCE MANUAL FU 321M 66
FITTING OF THE TABLE GUARDS
The purpose of this safety system is to protect the operator when the machine
is performing any kind of operation and at same time to give the opportunity of
safety observation of the working proccess.
Polymethil-methacrylate (CRYSTACRYL 4 mm) is used for transparent parts of
this device. If any transparent part (a door or a panel) become scratched or
damaged in any way it should be replaced for safety reasons. This parts should
be cleaned regularly to avoid the operator's view obstruction.
The safety guard consists of 2 front doors and 2 side panels. Before proceeding
with any kind of operation the both front doors should be closed.
The fitting of the table guards is done by M8 bolts on both sides of the working
table keyways as shown below. First close both doors and then tighten the bolts
fully.
NOTE: The machines are being delivered with mounted safety guards.
OPTIONAL: Aninterlock system can be fitted to table guards. To fit the interlock
guard switch to the electrical cabinet, connect the two cables from the interlock
switch to slots 28 and 36 on the connector block. Remember to remove the link
between slots 28 and 36 before connecting the cables from the interlock swich.
WARNING: Any of these connections should be performed by a qualified elec-
trician or service engineer.
10

OPERATING AND MAINTENANCE MANUAL FU 321M 11
No Name Designation
Q’ty Delivered Note
1 2 3 4 5 6
1
ACESSORIES MOUNTED
ON THE MACHINE
1.1 Main electric motor . . . . . . . . . . . . 1
No: . . . . . . . . . . . . . . . . . .
. . . . . . . . kW . . . . . . . . . V
. . . . . . . . min-1 . . . . . . Hz
1.2 Feed electric motor . . . . . . . . . . . . 1
No: . . . . . . . . . . . . . . . . . .
. . . . . . . . kW . . . . . . . . . V
. . . . . . . . min-1 . . . . . . Hz
1.3 Frequence invertor 1
ACSM1-04AS-09A5-4
1.4 Encoder Е40S8-2500-6-L-5 1
1.5 Electric panel – complete: 1
No . . . . . . . . . . . . . . . . . . . .
. . . . . . . V; . . . . . . . . Hz
1.6 Cooling system in a set with 3041.70.00.00 1
pump type . . . . . . .
. . . . . . Hz . . . . . . V
. . . . . . . . . . min-1
1.7 Lubrication system with drive motor 1
type . . . . . . . . . . . . . . . . .
No: . . . . . . . . . . . . . . . . . .
. . . . . . . . kW . . . . . . . . . V
. . . . . . . . min-1 . . . . . . Hz
1.8 Lubrication unit with dosed feeding . . . . . . . . . . . . 1
No: . . . . . . . . . . . . . . . . . .
. . . . . . . . kW . . . . . . . . . V
. . . . . . . . min-1 . . . . . . Hz
1.9 Lighting for milling machines 1
2 STANDARD ACCESSORIES
2.1 Clamping rod – set 3041.91.00.00 1
2.2 Handle for manual movement 3021.91.00.00 1
2.3 Spanners
12 х14 1
24 х27 1
30 х32 1
32 х36 1
41 х46 1
2.4 Hexagon socket wrench
5 1
8 1
10 1
12 1
PACKING LIST
Type: ................................ Serial No:...............................
The accessories marked with “X” are included in the delivery

OPERATING AND MAINTENANCE MANUAL FU 321M 12
1 2 3 4 5 6
2.5 Screw driver А1 260 х7 1
3 ADDITIONAL
ACCESSORIES
3.1 Horizontal swivel vice . . . . . . . . . . . . . . . . 1
3.2 Cutter arbor dia 22 - long 3041.92.00.00 1 a set
3.3 Cutter arbor dia 27 - long 3041.93.00.00 1 a set
3.4 Cutter arbor dia 32 - long 3041.94.00.00 1 a set
3.5 Cutter arbor dia 40 - long 3041.95.00.00 1 a set
3.6 Universal indexing device UDA 170 1 Separate
Ser. No . . . . . . . . . partlist
3.7 Rotary index table KDM 320 1 Separate
Ser. No . . . . . . . . . partlist
3.8 Slotting head SG 321 1 Separate
Ser. No . . . . . . . . . partlist
3.9 Vertical milling head VFG 323 1 Separate
Ser. No . . . . . . . . . partlist
3.10 Universal milling head UFG 325 1 Separate
Ser. No . . . . . . . . . partlist
3.11 Working area protection 3048.02.00.00 1
3.12 Digital reading device SIZO 1 Separate
Ser. No . . . . . . . . . partlist
3.13 Collet-chuck (set of collets 1
and clamping tool)
3.14 Clamping accessories - a set 1
3.15 Automatic cycle for longitudinal 1
traverse
4 SPARE PARTS
4.1 Rubber spider 3021.30.50.03 1
5 SPARE PARTS LIST 1
Date: .................................. Packed by: .....................................
QC: .................................................
160

OPERATING AND MAINTENANCE MANUAL FU 321M 13

TEST CERTIFICATE
Figure Tolerance
Measured
Standard
Inspection Item
1 2 3 4 5
0.03mm
per
1000mm
0.03mm
per
1000mm
0.02mm
per
300mm
0.03mm
per
1000mm
0.025mm
per
300mm
0.025mm
per
300mm
Dx90 °
0.010mm
0.018mm
No
1
2
3
4
5
6
7
8
2.1. Straightness onTable
Top /concavity is allowed/
2.2. Parallelism of the Table
Longitudinal Movement
to Table Reference T-Slot Side
2.3. Squareness between
Cross and Longitudinal
Table Movement
2.4. Parallelism of the
Longitudinal Table
Movement to Table Top
2.5. Parallelism of the Cross
Table Movement to
Table Top
2.6. Squareness between the
Vertical Table Movement and
the Table Top
2.7. SpindleAxial Runout
2.8. Spindle nose Runout

OPERATING AND MAINTENANCE MANUAL FU 321M 14


2.9. Radial runout of the spindle
nose outer diameter
2.10. Radial runout of spindle
female taper hole
2.11. Parallelism of the
horizontal spindle axis of
rotation to the table top
2.12. Parallelism of yoke
guideways to spindle axis
of rotation in horizontal
and vertical plane
2.13. Coaxiality of knee hole
and horizontal spindle in
vertical and horizontal
plane
2.14. For machines with
fixing element
2.15. For vertical milling
machines
3.4. Straightnes of plane 1
and plane 2 (side and top)
3.5. Parallelism of sample
workpiece planes in
longitudinal and cross
section
3.6. Squareness between sample
workpiece plane 1 to planes
2 and 4 and between plane 2
to planes 3 and 4
9
10
11
12
13
14
15
16
17
18
0.010 mm
0.010 mm
to the Nose
0.02 mm
per 300
0.025 mm
per 300 mm
0.02 mm
per 300 mm
0.03 mm
per
300 mm
0.025 mm
per
300 mm
0.025 mm
per
300 mm
0.020 mm
per
100 mm
1 2 3 4 5
Date: ............ QC: ................ QC Dept.Chief: ..............

OPERATING AND MAINTENANCE MANUAL FU 321M 15
OPERATION
DESCRIPTION OF MACHINE CONTROLS AND PARTS
/ Fig.3 and Fig.3a /
1. Index handle for vertical and cross table traverse
2. Saddle locking screw
3. Handwheel for longitudinal table travel
4. Handle for table longitudinal feed on/off
5. Limit switch for the longitudinal travel
6. Mechanism for yoke movement
7. Speed switch - over handle
8. Speed switch - over handle
9. Speed switch - over handle
10. Yoke tightening nut
11. Knee tightening nut
12. Table - to - saddle tightening screws
13. Longitudinal travel stop cams
14. Slide - to - knee tightening handle
15. Handle for cross feed on/off
16. Handle for longitudinal screw backlash elimination
17. Handle for vertical feed on/off
21. Handwheel for longitudinal table travel
22. Back cover
23. Cover
24. Vertical travel stop cams
25. Saddle locking screw
26. Knee - to - body tightening handle
27. Limit switch for the vertical travel
28. Cross travel stop cams
29. Limit switch for the cross travel
30. Safety clutch cover
41. Main breaker
42. Working light on/off switch
43. The operating mode selector
44. Coolant on/off switch
45. Emergency stop
46. Spindle start pulse button
47. Spindle on/off & direction of rotation switch
48. Rapid traverse button
49. Start button
50. Spindle stop button
51. Emergency stop
52. Signal lamp "Include tension"
53. Handle for feed reference potentiometer

OPERATING AND MAINTENANCE MANUAL FU 321M 16
PREPARATION FOR START - UP
Before initial operation of the machine after unpacking, or keeping the machine
idle for a long period, make a close examination and cleaning of all mechanisms,
fill the tanks with oil / Fig.8a / and coolant and connect the machine to the mains
as prescribed in the section "Electric Equipment".
The locking mechanism for the longitudinal travel 12, cross travel mechanism 14
and vertical travel mechanism 26 / Fig.3 / should be disengaged. All mechanisms
should operate smoothly and trouble - free. Check that they do that by hand.
Check the proper functioning of the gear boxes by switching from lowest to
highest gear speeds and feeds during idle running. At the same time constantly
observe the lubrication system operation through the oil level indicators.
Warm up the machine by running it for 30 minutes at idle running mode.
Proir to initial use of machine, Emergency Stop functions should be checked. To
check it start the spindle at max speed. After 10 seconds press one of the
"Emergency Stop" buttons 45 or 51 / Fig.3a / and make a note of how long it
tooks for spindle to stop. The function of each button should be checked sepa-
rately.
Then start the machine in exactly the same way and after 10 seconds use the main
breaker 41 / Fig. 3a / to stop the spindle. Measure the time for spindle stopping.
It should take longer for spindle to stop when use the main breaker.
If the time of spindle stop is the same for both tests a qualified electrician should
be called and the problem should be eliminated immediatly before the machine is
used.
CAUTION:
1. Remember: During a power failure the dynamic spindle stop will not be
available.
2. When a vertical milling head, a slotting head or a universal milling head are
used, the vertical stroke is limited. To prevent the danger of shock move the lower
cam into the additionally machined screw hole to fix it.
3. The table swing towards the electric cabinet is limited in order to avoid the
smash of the electric cabinet due to operator's carelessness. To swing the table
to bigger angle remove the stopper placed to the outlet of support's T-slot and
look out for not smaching the electric cabinet during table traverse on axis.
See and read carefully sections "Safety precautions" and "Maitenance".

OPERATING AND MAINTENANCE MANUAL FU 321M 17
SELECTION OF SPINDLE ROTATION SPEED
Each one of 18 speeds is selected by relevant to the desired speed combination
positioning of handles 1, 2 and 4 which are shown on the graphic panel scheme
/ Fig.9 /.
To facilitate the selection of desired speed, press the push - button 3 / Fig.9 /
as you have the handle shiften from its fixed position and slight turning the handle.
Do not change the spindle speed during machine operation.
SELECTION OF FEED RATE
Choise of desired feed is achieved by handle for feed reference potentiometer 53
/ Fig.3a /.
SELECTION OF LONGITUDINAL FEED
The manual longitudinal feeds are effected by handwheels 3 and 21 / Fig.3 / and
the automatic ones - by the handle 4 / Fig.3 /.
SELECTION OF CROSS AND VERTICAL FEEDS
Manual feed in cross and vertical direction is accomplished by handle 1
/ Fig.3 /. Remove the handle from the machine before putting on the automatic
feed and the rapid traverse.
The automatic table feed in cross direction is realized by handle 15 and in vertical
- by handle 17 / Fig.3 /.
COOLING OF THE TOOLS
Turn the switch "Coolant On/Off" /Pos.44, Fig.3a / in position "ON".
DRIVE UNITS ACTIVATING
The feed drive operation in cutting mode or at rapid traverse can be performed
with or without spindle rotation. The direction of spindle rotation is chosen by
"Spindle Off/Fwd/Rew" Switch 47 / Fig.3a /. Position "FWD" corresponds to the
spindle rotation counter-clockwise, facing the spindle. "REW" means clockwise
spindle rotation.
Main drive is activated by pressing of button "Start" / Pos.49, Fig.3a /, thus the
circuits for feed motion and coolant pump are prepared for work.