KAKA Industrial DP-40 User manual

0
Vertical Drilling Machine
MODEL DP-40
OPERATION MANUAL

1
Foreword
WARNING: FAILURE TO FOLLOW THESE RULES MAY RESULT IN SERIOUS PERSONAL
INJURY.
This user manual has been prepared for those who use the machine or who are responsible for
maintenance and service of the machine. Keep this manual properly for future reference. Always
make this manual easily available for all those concerned.
Read through the manual carefully before transporting, installing and starting up the machine. The
machine is simple design and robustly built, but we can’t guarantee perfect function if it is
incorrectly handled.
Therefore, it is necessary to let yourself to be acquainted with the function thoroughly and to carry
out practical tests on the various parts in the control system and the machine settings. Once these are
mastered the excellent properties of the machine can be fully utilized and the component parts will be
given the maximum service life.
Each machine should be tested for accuracy and capacity in the factory. The experienced
personnel check both the mechanical and electrical functions according to a standardized
program, that means we can guarantee the highest workmanship and consistent quality.
By our following directions and your own good judgement, we convinced that your new machine will give
satisfaction to everyman. However, should any problems arise, please do not hesitate to contact
our dealers or ourselves.
Correctly use your machine is one of the best concerning design and safety. However, any
machine that is used incorrectly could be a safety risk. It is of vital importance, that those who use
the machine should be informed to know how to handle it correctly. They should read and
understand these instructions as well as all plates available on the machine.
0.1 Safety symbol
Rear the manual carefully before operation
and maintenance of the machine.
Wear safety glass when operating the
machine.
Wear ears protection when operating.
Cutting hazard. Do not touch the drill bit
when it is running.

2
1 SAFETY INSTRUCTIONS
1.1 SAFETY RULES FOR ALL MACHINES WEAR PROPER APPAREL.
(1.) Always wear eyes protection. Also use face or dust mask if cutting operation is
dusty.
(2.) Wear proper apparel. Do not wear loose clothing, gloves, rings, bracelet etc., there
is hazard of entanglement.
(3.) Wear protective hair covering to contain long hair.
(4.) Keep proper footing and balance at all times. Non-slip footwear is recommended.
(5.) Keep children away from the machine. Serious injury could occur if the tool is
tipped or if the cutting machine is accidentally contacted.
(6.) Don’t leave machine until it comes to a complete stop.
(7.) Do not operate machine while under the influence of alcohol or any medication.
(8.) Make sure the plug is disconnected from power supply while making maintenance,
adjustment or repair.
(9.) Always keep hands and fingers away from the aiguille.
(10.) Do not force the machine. It will do the job better and safer at the ratings for which it
was designed.
(11.) Use clamps to hold work piece when operating.
(12.) Consult the operator’s manual for recommended accessories. The use of improper
accessories may cause hazard.
(13.) Avoid accidental starting. Always make sure the low/high speed switch is in ‘0’
position before plugging in power cord.
(14.) Grounding the machines. Always make sure your machine is well connected to the
earth. It may reduce electric shock hazards.
(15.) Do not install & use the machine in flammable, explosible or damp environment.
(16.) For your hearing health, we advise the operator to wear hearing protection when
necessary.
(17.) Do not start the machine until all safeguards are located to their position.
Hazards may occur when running with safeguards opened.
(18.) Fix the machine to the floor for enough stability when machining long and heavy
workpiece. Proper lifting equipment is required for workpieces over 10 kg in weight.
Provision shall be provided by the end user for installation and operation of lifting
equipment.
(19.) The speed adjustment must be done only when the machine stops.
(20.) The machine tool must only be used for the purpose it has been designed for. Never
use the machine tool without the limits established by the technical data.
(21.) Do not neglect regular inspections in accordance with the instructions for use.
(22.) Operation, setting and maintenance including shall be achieved by the required skill
level of operators.
(23.) It should use certain tools in case avoid being scalded for the hot blade tools after
drilling.
(24.) Don’t put the fingers on drilled hole in case to protect the safety of finger.
(25.) The swarf is sharp after drilling, it should use certain tool to clean in order to avoid
fingers being hurt.
(26.) Pay attention to the spindle rotation direction when take the first trial run, the direction
should be the same with the direction which indicated on front of the machine. When the
rotation is not right, you can change the rotaion in the plug conveniently.
(27.) Pay attention to the relationship between the diameter of drill and spindle speed. The spindle
speed must decrease with the increasing of drill diameter. When the diameter of drill is Φ25mm, the
spindle speed shall be lower than 600rpm; Only when drill diameter is Φ3mm, the maximum
spindle speed can be selected.

3
1.2 ADDITIONAL SAFETY RULES FOR THE AIGUILLE:
(1.) Make sure the rotating direction of the aiguille is right. The direction of the aiguille
should be in accordance with the direction mark on the machine.
(2.) Make sure aiguille speed is set correctly for the drill.
(3.) Check and use proper aiguille including aiguille size and type.
(4.) Always make sure the aiguille and workpiece are firmly clamped before starting
cutting.
(5.) Make all adjustments with the power off. In order to obtain precise and correct ways
of adjustment while assembling, the user should read the instruction detailed in this
manual.
(6.) Keep your work area clean. Cluttered areas and benches invite accidents.
(7.) DON’T USE IN DANGEROUS ENVIRONMENT. Don’t use running machine in damp or
wet locations, or expose them to rain. Lighting within the workzone shall be provided with
a minimum of 500lux at the tool tip when the guard is open.
(8.) KEEP CHILDREN AND VISITIORS AWAY. All children and visitors should be kept in
the safe distance from work area.
(9.) DISCONNECT the plug of the machine away from power source when making repairs.
(10.) CHECK DAMAGED PARTS. Before using the machine, guards or other parts that are
damaged should be carefully checked to ensure that they will operate properly. Guards
or other parts that are damaged should be immediately replaced.
(11.) STOP MACHINE before servicing and when changing accessories such as aiguille,etc.
2. INTRODUCTION OF THE MACHINE
2.1 Usage
This machine is used only for general metals drilling and tapping within the range of drilling capacity.
Cast iron, steel, copper, aluminum, stainless steel, etc. can be machined in the machine.
Forbidden cutting materials: 1) Non-metallic materials, e.g. graphite, stone, wood, plastics, etc. 2)
The materials having a rigidity that is lower than the rigidity of the materials to be clamped or fixed; 3)
Metals having low ignition points, e.g. magnesium alloy; 4) Toxic and inflammable materials.
2.2 Requirement of operating site
This machine is designed for operating on the site:
The height above sea level doesn’t exceed 1000m;
The temperature range of air doesn’t exceed 5℃～40℃.
The relative humidity doesn’t exceed 50% at a maximum temperature of +40 ℃.
Higher relative humidity may be permitted at lower temperature (e.g.90% at 20℃).
Lighting within the workzone shall be provided with a minimum of 500lux at the tool tip when
the guard is open.
Clean environment, good ventilation and enough space shall be kept to operate and maintain
the machine tool and electrical cabinet conveniently.

4
2.3 Requirement of power supply
The input power supply of the machine is AC400V, 50 Hz. 3/PE.
1) Fluctuating range:
-Voltage The steady-state AC power supply is 0.9～1.1 times of the rated value.
-Frequency 0.99～1.01 times of rated frequency (continuous working)
0.98～1.02 times of rated frequency(short period working)
-Harmonics The sum of 2nd-5th distorted harmonic must not exceed 10% of RMS of voltage,
maximum 2% of RMS of line voltage is allowed to add to the sum of 6th-30th harmonic.
2) Unbalanced voltage of 3-phase power supply
Negative sequence component are not allowed to exceed 2% of the positive sequence
component.
3) Short-circuited protection and incoming line
The machine tool shall have short-circuited protective device at the power supply end by the
end-user, the rated current of which must be as low as possible, but not be less than 5A. The
diameter of the incoming supply cords include PE conductor should not be less than 1.5mm2.
4) Overvoltage protection
Overvoltage protection device shall be provided in the power supply line by the end user.
2.5 Electrical connection
Electrical installations should be always performed by authorized electricians.
1)Make sure that the correct voltage is supplied to the machine.
2)Set up the electrical connections according to the attached electrical drawing.
3)Make sure that the drilling spindle has the correct rotation direction.
Warning: The machine must be grounded firmly!
2.6 Specification，THIS IS FOR TX530A
Drilling capacity(mm)
40
Tapping capacity(mm)
25
Swing(mm)
530
Spindle tapper
MT4
Spindle travel
150
Spindle speed
High speed 245-2000rpm,Low speed 65-540rpm
Spindle nose to table(mm)
605
Spindle nose to base(mm)
1150
Quill diameter (mm)
75
Column diameter (mm)
115
Motor power
2.2kw
Table size(mm)
560x475
Table slot(mm)
16
Base size(mm)
688x486
Machine size(cm)
95x58x200
Net weight
382kg

5
2.7 .Noise information：
We evaluated the noise according to EN ISO 3746 under following condition: idle running with the
spindle maximum rotation speed.
The sound power level: 90.2dB(A);
The sound pressure level:77.6 dB(A).
The figures quoted are emission levels and are not necessarily safe working levels. Whilst there is a
correlation between the emission and exposure levels, this cannot be used reliably to determine
whether or not further precautions are required. Factors that Influence the actual level of exposure
of the workforce include characteristics of the work room, the other sources of noise, etc. i.e. the
number of machines and other adjacent processes. Also the permissible exposure level can vary
from country to country, This information, however, will enable the user of the machine to make a
better evaluation of the hazard and risk.
2.8 Residual risks
1) It should use certain tools in case avoid being scalded for the hot blade tools after drilling.
2) Don’t put the fingers on drilled hole in case to protect the safety of finger.
3) The swarf is sharp after drilling, it should use certain tool to clean in order to avoid fingers being hurt.
3 Packing and transportation
While transporting or handling the machine, be most careful and let the activity be done by
qualified personnel especially trained for this kind of activity.
While the machine is being loaded or unloaded, make sure that no person or subject gets
pressed by the machine !
Do not enter the area under the machine lifted by a crane or a high-lift trolley!
During transporting or storing the machine, means must be taken to protect the machine against
excessive vibrations and humidity.
It should be stored in a shelter at temperatures ranging from -25°C to 55°C.
As standard, the machine is wrapped up in a robust wooden box and is transported this way.
Transportation after unpacking, please use heavy duty fiber belt to lift up the machine in fig 1.

6
Warning: -Tighten all locks before operating.
-ALWAYS keep proper footing & balance while moving this machine, and only
use heavy-duty fibre belt to lift up the machine.
4 Cleaning
All bright parts of the machine are treated with rusty prevention. By removing this, be careful not to
use too strong cleaning compound. The paint might then get damaged.
5 Lubrication
All high –speed shafts and gears are journalled in ball bearings or roller bearings, so that the
machine needs very little lubrication, but shall ensure that at least one lubrication each year.
Fig2
Fig1

7
6.PART LIST

8
Part #
Drawing number/Code
name
Description
Size
Q’ty
1
TX530-1001
Base
1
2
GB/T5782
Hex Bolt
M12X65
6
3
GB/T93
Spring Washer
12
6
4
TX530-1002
Working Table
1
5
TX530-1020
Cover
1
6
GB/T70.1
Hex Screw
M6X12
4
7
GB/T95
Washer
6
4
8
Coolant Pump
45W2m
1
9
GB/T70.1
Hex Screw
M5X10
1
10
GB/T96.1
Bigger Washer
5
1
11
TX530-1019
Colum sleeve
1
12
TX530-1026
Copper block
2
13
GB/T77
Hex Bolt
M12X20
2
14
TX530-1018
Colum sleeve cover
1
15
GB/T96.1
Bigger washer
8
3
16
GB/T818
Cross screw
M8X16
3
17
GB/T95
Washer
4
2
18
GB/T70.1
Hex Bolt
M4X60
1
19
GB/T6170
Nut
M4
1
20
TX530-1005
Rack
1
21
TX530-1003
column
1
22
GB/T70.1
Hex Bolt
M6X12
1
23
GB/T96.1
Bigger washer
6
1
24
TX530-1004
Lower sleeve
1
25
TX530-1026
Copper block
2
26
GB/T77
Hex Bolt
M12X20
2
27
TX530-1022
Rock arm
1
28
TX530-1025
Cranking Bar
1
29
JB/T7270.5
Turning Handle
M10X80
1
30
TX530-1021
Rock Arm
1
31
TX530-1016
Front Sleeve
1
32
TX530-1023
Spring
1
33
TX530-1015
rear sleeve
1
34
TX530-1017
Wire Block
1
35
TX530- Photos 4
CoverΦ45
1
36
GB/T70.1
Hex Bolt
M6X25
1
37
GB/T879.1
Spring pin
5X16
2

9
38
TX530-1006
Gear box
1
39
TX530-1012
Connecting sleeve
1
40
GB/T95
Flat washer
6
2
41
GB/T6170
nut
M6
1
42
GB/T5781
screw
M6X30
1
43
GB/T879.1
Spring pin
4X26
1
44
TX530-1013
Gear 1
1
45
GB/T276
bearing
6202-2z
2
46
TX530-1011
Bearing base
1
47
GB/T70.1
Hex Screw
M6X20
2
48
GB/T93
Spring washer
6
2
49
GB/T70.1
Hex bolt
M8X50
3
50
GB/T77
Hex bolt
M5X8
2
51
TX530-1007
Connecting sleeve
1
52
GB/T77
Hex Bolt
M6X10
2
53
GB/T894.1
Ring
25
2
54
GB/T276
bearing
6005-2z
1
55
GB/T77
Hex Bolt
M6X10
1
56
TX530-1014
Gear 2
1
57
GB/T301
Bearing
51102
1
58
TX530-1008
Worm
1
59
GB/T1095
Key
5X20
1
60
TX530-1009
Gear
1
61
TX530-1010
Gear shaft
1
62
TX530-1010-1
Copper sleeve
2
63
Slub Head
G3/8"
2
64
Pipe
Φ12Xφ8
2m
65
Vlave
G3/8"
1
66
Pipe
G3/8"
1
67
TX530A-6001
Joint
1
68
Pipe Clamp
φ25
2
69
Pipe
φ25Xφ21
1.5m
70
Pipe Clamp
φ12
2

10

11
1
TX530-2001
Head assembly
1
2
TX530- Photos 3
Blank cover
6
3
GB/T6170
Hex nut
M12
4
4
TX530-2039
Locking block
4
5
TX530-2040
Locking lever
2
6
TX530-2010
Feed Handle
3
7
GB/T7271.5
Long handle sleeve
M12X60
3
8
TX530-2008
Seat for feed handle
1
9
GB/T1095
Key
6X20
1
10
GB/T77
Set screw
M5X10
1
11
GB/T894.1
Circlips
25
1
12
GB/T70.1
Hex socket cap screw
M8X20
3
13
TX530-2009
Shaft sleeve
1
14
TX530-2029
Cooling pipe bracket
1
15
GB/T70.1
Hex socket cap screw
M8X20
1
16
GB/T95
Flat washer
8
1
17
LX12-108
Data lable
1
18
JB/TZQ4444
Drain plug
G1/4
1
19
GB/T812
Round nut
M30X1.5
1
20
GB/T297
Taper roller bearing
30206
1
21
TX530-2017
Spindle
1
22
GB/T3452.1
O rubber sealing ring
75X5.3
1
23
TX530-2016
Sleeve
1
24
GB/T297
Taper roller bearing
30207
1
25
GB/T13871.1
Oil seal
B53
1
26
TX530-2018
Lower bush
1
27
GB/T70.1
Hex socket cap screw
M6X50
2
28
TB36-2021
Small bush
1
29
GB/T77
Hexagon socket set
screws
M4X6
1
30
JB/T6659
O ring
10X1.5
1
31
TX530-2045
Anti-rotation block
1
32
TB36-2023
Screw rod
1
33
TB36-2024-1
Screw jacket
1
34
TB36-2024
Small bush
1
35
TB36-2025
Turn handle
1
36
GB/T78
Hexagon set screws with
cone
M5X8
1
37
GB/T77
Hexagon socket set
screws
M5X10
1

12
38
TB36-3013
Lable
1
39
TB36
Digital tachometer
display
1
40
T28Ⅳ-2001
Digital seat
1
41
GB/T70.1
Hex socket cap screw
M5X20
2
42
Digital scale
1
43
TX530-2019
Micro switch top bracket
1
44
GB/T70.1
Hex socket cap screw
M5X20
4
45
TX530-2020
Micro switch lower
bracket
1
46
Micro switch
2
47
TX530-2002
Inner sleeve
1
48
TX530-2003
Fixed seat
1
49
GB/T818
Cross recess head screw
M4X25
2
50
JB/T7274.4
Star handle
M8X32
1
51
TX530-2046
Copper block
1
52
JB/T7270.12
Ajustable fixing handle
M6
1
53
GB/T70.1
Hex socket cap screw
M8X20
2
54
GB/T95
Flat washer
8
2
55
GB/T894.1
Circlips
30
1
56
TX530-2004
Vertical square bar
1
57
GB/T879.1
Spring pin
3X14
1
58
TX530-2005
Horizontal square bar
1
59
GB/T6170
Hex nut
M10
2
60
GB/T93
Spring washer
10
2
61
TX530-2006
Fixed strip
1
62
GB/T70.2
Hexagon flat head
screws
M8X12
2
63
TX530-2007
Safety guard
1
64
TX530-2031
Panel
1
65
GB/T70.2
Hexagon flat head
screws
M5X10
4
66
GB/T96.1
Washer
5
4
67
TX530-2026
Front bracket
1
68
GB/T70.1
Hex socket cap screw
M8X35
2
69
GB/T96.1
Washer
8
2
70
TX530-2030
Head box panel
1
71
GB/T9074.5
Flat washer combination
M4X10
4
72
GB/T77
Hexagon socket set
screws
M8X16
1
73
TX530-2015
Sleeve guide pin
1

13
74
TX530-2011
Feed gear shaft
1
75
GB/T1095
Key
6X20
1
76
GB/T818
Cross recess head screw
M5X8
1
77
GB/T879.1
Spring pin
3X5
2
78
TX530-2012
Connecting disc
1
79
GB/T818
Screw
M5X20
3
80
TX530-2013
Coil Spring
1
81
TX530-2014
Coil Spring box
1
82
JB/T7274.4
Knob
M6X25
1
83
TX530-2035
Left rear cover
1
84
GB/T9074.5
Pain washer assembly
M5X12
2
85
GB/T70.1
Bolt
M8X12
1
86
GB/T96.1
Washer
8
2
87
TX530-2033
Speed display card board
1
88
TX530-2034
Speed display bracket
1
89
GB/T70.1
Bolt
M5X12
2
90
GB/T93
Spring washer
5
2
91
GB/T818
Bolt
M4X20
2
92
GB/T862.2
Locking washer
4
2
93
GB/T6170
Nut
M4
2
94
GB/T77
Screw
M8X16
1
95
TX530-2027
Belt Wheel
1
96
GB/T6170
Hex Nut
M5
1
97
GB/T70.1
Screw
M5X20
1
98
GB/T276
Bearing
6009-2z
2
99
TX530-2038
Sleeve
1
100
GB/T894.1
external circlip
45
1
101
JB/T7941.2
Oil Leveler A20
M27X1.5
1
102
Motor
1
103
TX530-2044
Motor Flange
1
104
TX530-2032
Board
2
105
GB/T96.1
Washer
5
4
106
GB/T70.2
Screw
M5X10
8
107
GB/T96.1
Washer
5
6
108
GB/T70.2
Screw
M5X10
6
109
Lightning label
1
110
TX530-2042
Speed label
1
111
TX530-2021
Cover
1
112
TX530-2043
Oil label
1

14
113
GB/T9074.5
Pain washer assembly
M5X12
2
114
GB/T70.1
Screw
M10X16
4
115
TX530-2041-1
Motor support seating
1
116
TX530-2028
Middle Belt wheel
1
117
GB/T77
Screw
M8X8
2
118
GB/T70.1
Screw
M8X35
4
119
GB/T93
Spring Washer
8
4
120
GB/T70.1
Screw
M8X35
4
121
GB/T118
Pin
6X40
2
122
GB/T13871.1
Oil seal
B46
1
123
GB/T893.1
Internal Circlip
62
1
124
GB/T276
Bearing
6007-2z
1
125
TX530-2041-2
Shaft
1
126
GB/T1095
Flat Key
8X7X20
1
127
TX530-2041-8
Gear
1
128
GB/T894.1
external circlip
32
1
129
GB/T276
Bearing
6202-2z
1
130
GB/T1095
Flat Key
8X7X56
1
131
TX530-2041-3
Back shaft
1
132
GB/T1095
Flat Key
8X7X36
1
133
GB/T276
Bearing
6005-2z
2
134
GB/T893.1
Internal Circlip
47
2
135
GB/T13871.1
Oil Seal
B36
1
136
TX530-2041-6
Round Rack
1
137
TX530-2041-4
Yoke Bar
1
138
TX530-2041-5
Copper shift fork
1
139
GB/T93
elastic collar
10
1
140
GB/T6170
Nut
M10
1
141
GB/T77
Screw
M6X10
1
142
TX530-2041-7
Fork Rack
1
143
GB/T13871.1
Oil Seal
B13
1
144
GB/T893.1
Internal Circlip
30
1
145
TX530-2036
Speed handle seat
1
146
TX530-2037
Speed handle
1
147
GB/T77
Screw
M10X12
1
148
Arc synchronous belt
720-8M
1
149
GB/T894.1
external circlip
25
2
150
TX530-2041-9
Upper Gear
1
151
GB/T1095
Flat Key
6X6X16
1

15
152
TX530-2041-10
Lower Gear
1
153
Steel Ball
SΦ8
2
154
TX530-2041-11
Spring
2
155
GB/T77
Screw
M10X10
2
156
GB/T894.1
external circlip
48
1
157
GB/T894.1
external circlip
25
1
158
GB/T276
Bearing
6202-2z
1

16
7. Electrical drawing
Note: This manual is only for your reference. Owing to continuous
improvement of the machines, Changes may be made at any time without
obligation on notice. Please note the local voltage for operating this kind
of electric machine