Sharp SV-4328 User manual
SV-4328 / SV5128 / SV6332
MAINTENANCE MANUAL
2
PRECISIONMACHINETOOLS Ver 2 Maintenance Manual
Chapter 1 Routine Maintenance
1-1 Routine Maintenance Checklist 4
1-2 Routine Maintenance Instruction Diagram 5
1-3 Cautions for Machine Maintenance 9
Chapter 2 The Spindle Unit
2-1CautionsforHighSpeedProcessing 12
2-2 Tool Shank and Broach Bolts 13
2-3 Spindle Warm-up 15
2-4 Spindle Pre-Operation Check 16
2-5 Spindle Alarm Handling 17
Chapter 3 The Air Compressor Unit
3-1 Air Compressor System Layout 19
3-2 Air Compressor System Circuit 20
3-3 The Air Compressor Unit 20
3-4 Air Compressor Detailed Specifications and Functions 21
3-5 Air Compressor Unit Usage Instruction 24
3‐6Air Compressor Troubleshooting 25
Chapter 4 The Lubrication Unit
4-1 Centralized Lubrication System Diagram 27
4-2 Spindle Bearing Lubrication 29
4-3 Guide ways and Ball Screw Lubrication 29
4-4 Lubrication of the Cam Box of Tool Magazine 34
4-5 Counterweight Chain and Sprocket Bearing Lubrication 34
4-6 Cylinder Lubrication 35
4-7 Lubrication Location 35
Chapter 5 The Spindle Oil Cooling Unit
5-1 Oil Cooling Pipeline Diagram 37
5-2 The Spindle Oil Cooling Unit 38
Chapter 6 The Electrical Unit
6-1 The Electrical Unit 45
Chapter 7 Appendix
7-1 Oil Selection 49
7-2 Calibration of Spindle Tool Change Location 50
7-3 Determination of the Z-axis Mechanical Reference Point 52
7-4 Program and Servo Alarms Description 55
7-5 List of the Machine Components 110
3
PRECISIONMACHINETOOLS Ver 2 Maintenance Manual
Chapter 1
Routine Maintenance
4
PRECISIONMACHINETOOLS Ver 2 Maintenance Manual
1-1 Routine Maintenance Checklist
Routine maintenance inspection can be classified into daily, weekly, monthly and annually. The
maintenance is given when the machine functions normally The actual frequency and the operation
frequency are different. When operating the both, pay attention to abnormal noises, oil volume, air
pressure and machine abnormalities during the processing.
○：Check ◎：Addoil ☉：Clean
A：Adjustment F: Function check G: Grease coasting R: Replace when necessary
No. Maintenance Daily Weekly Monthly Annually Note
1 Spindle operation
warm-up ○
2
Spindle unit
Spindle nose ☉
3
Lubrication pump
☉
Depending
on the brand
of the lube oil
4
Lubrication
unit Lubrication pump
oil volume ◎
5 Spindle oil
coolant unit ○☉
6 Temperature
difference setup ○-1°C
7
Spindle oil
coolant unit
Oil coolant unit filter ☉
8 Air compressor
source pressure ○5.5~7 kgf/cm²
9
Air compressor
cylinder and filter
drainage
○
10 Air compressor
unit lube oil ◎
11
Air
Compressor
Unit
Air leakage of the air
compressor system ○
12 Coolant capacity ○
13 Coolant Coolant box filter ☉
5
PRECISIONMACHINETOOLS Ver 2 Maintenance Manual
No. Maintenance Daily Weekly Monthly Annually Note
14
Internal flow of
the tool change
machine
R/
1-year
Depending
on the brand
of the lube
oil
15
Tool magazine
automatic tool
change (ATC)
system Tool sleeve and
tool change claw ☉
16 CNC operation
panel
Emergency stop
button
○,F
17 Operation button ○,F
18 Spindle cooling fan ○/☉
19 Electric box CNC axial battery ○R
20 Machine static precision check ○,A
21 Machine position precision check ○,A Replace
22 Spindle cooling fan ○/☉
23 Oil skimmer ○,F ☉
Note: The schedule presented in table is for normal operation only. If the environment is not optimal
or if the usage frequency has exceeded the suggested basic standard, you may need to increase the
frequency of maintenance
Note 2: If there is any inconsistency between this table and instruction from elsewhere, use the
information provided on this table.
6
PRECISIONMACHINETOOLS Ver 2 Maintenance Manual
1-2 Routine Maintenance Instruction Diagram
( 14、15 )
Tool magazine / Automatic tool
change system
( 1、2 )
Spindle unit
( 17 )
Operation box
( 16 )
Emergency stop button
( 12、13 )
Coolant
7
PRECISIONMACHINETOOLS Ver 2 Maintenance Manual
Machine precision check (20 – 21)
8
PRECISIONMACHINETOOLS Ver 2 Maintenance Manual
( 18、19 )
Electrical box
( 22 )
Fans
( 23 )
Oil skimmer
9
PRECISIONMACHINETOOLS Ver 2 Maintenance Manual
( 5、6、7 )
Spindle oil temperature
controller
( 8、9、10、11 )
Aircompressorpreparationunit
( 3、4 )
Centrallubricationsystem
10
PRECISIONMACHINETOOLS Ver 2 Maintenance Manual
1-3 Cautions for Machine Maintenance
It is important to perform maintenance on each listed items in order to maintain machine precision
and extend machine lifespan.
Erroneous operation may damage the machine or lead to injury of the operator. Be cautious about
the following matters:
Cautions Prevention
Spindle operation warm-up
To extend the lifespan, follow the instructions given in Section
2-3 for machine warm-up before turning on the machine.
If the machine has been stopped for a long period, follow the
instructions given in Section 2-3 for machine warm-up before
turning on the machine in order to extend the life span.
Dynamic balance of the cutter
To extend the lifespan as well as to increase the precision,
please follow instructions given in Section 2-1 for usage as
well as achieving a dynamic balance for the cutter.
Standard broach bolts
Broach bolt is an important component jointing the spindle and
the tool shank. Using a wrong broach bolt is hazardous for the
operation. Make sure that only the standard one is used.
Spindle pre-operation check
Check the machine before spindle operation according to
instructions given in Section 2-4 in order to extend the lifespan
of the spindle.
Manually loosening the
spindle’s cutter
When loosening the cutter of the spindle, make sure that each
step is executed correctly or may lead to personnel injury.
Manual installing the cutter onto
the spindle
When changing the cutter, be cautious not to drop the cutter,
which may damage the workbench or tools. Manually change
the cutter only if necessary, and the procedures are written on
the operation panel at the front. Press and let go of the spindle
cutter loosening button to loosen up or to grasp the cutter.
Do not touch the spinning tool
magazine
The tool magazine is controlled by CNC and motor. After
turning on the machine, do not touch the tool magazine or may
be injured. Turn off the power for changing the cutter.
11
PRECISIONMACHINETOOLS Ver 2 Maintenance Manual
Cautions Prevention
Spindle nose cleaning Keep the taper of spindle nose and cutter shank clean at all
time to prevent dust or iron filings affecting the precision. The
spindle has an automatic dust removal function, but the
operator should wipe the parts with standard air-laid paper for
maintaining spindle precision.
Air quality inside the air
compressor
The function pressure of this air compressor is 5kgf/cm²( 71
psi ). Therefore the air pressure source has to be at least 5.5
kgf/cm²( 78 psi ) and stabilized.
This machine has an air filter that eliminates impurities and
water vapor from the air. Air for the air pressure source has to
be clean and dry. Check the filter constantly to extend the
lifespan of the filter.
To effectively eliminates water vapor by the filter, drain the
water from the air tank of the air compressor. (Water drainage
is more effective in the morning).
Lube oil from the lubricating
pump (automatic)
Lube oil is released by the lubricating pump to lubricate the
guide ways and the lead screws. Insufficient lubrication may
speed up the abrasion and affect machine precision.
Always make sure that there is enough oil in the tank. If the
amount of oil is below the lower limit of the oil-level gauge, the
operation panel as well as the screen will issue a warning
message. Please add more oil as early as possible.
Adding oil to the spindle oil
cooler and setting up the
temperature difference
Oil cooling circulation system was adopted for the spindle to
effectively suppress spindle temperature increase and thus
extend the lifespan of the spindle. Use the correct type of
circulation and add more oil when the level is too low.
The machine adopts synchronous machine temperature
adjustment Temperature difference is set to 0 to prevent big
temperature difference, which can damage spindle bearing.
Do not change the value arbitrarily.
12
PRECISIONMACHINETOOLS Ver 2 Maintenance Manual
Cautions Prevention
Guide way check
Constantly check the guide ways of the three
axes (X, Y & Z). Check whether there are iron
filings or other types of grains attached to the
guide ways. To extend the lifespan, remove the
dust or they may scratch the slide.
Correctly locking the work pieces
When placing work pieces onto the workbench,
make sure that they are well locked or they may
spin out and cause personnel injury.
Correctly locking the doors
Make sure the operation door and the two side
doors are well locked to prevent the cutter from
bursting apart or iron filings from flying out,
which is dangerous.
13
PRECISIONMACHINETOOLS Ver 2 Maintenance Manual
Chapter 2
The Spindle Unit
14
PRECISIONMACHINETOOLS Ver 2 Maintenance Manual
2-1 Cautions for High Speed Processing
During high-speed processing (S = 8000 rpm or above; F = 300 mm/min or above), the shank and
the style of the cutter has a critical impact on spindle lifespan and processing precision. Matters that
need more attention are:
1). Grasp the cutter before running the spindle to avoid damaging the spindle.
2). During high-speeding chipping (8000rpm or above), use only G2.5 level cutters and shanks that
have been calibrated for dynamic balance. The reason is that vibration generated from centrifugal
force may damage the spindle bearing and rapidly wear out the cutter.
3) Balance tolerance for the shank and the cutter combination is affected by the following three
factors: rotation speed of the cutter, balance tolerance of the spindle, and weight of the shank.
Therefore, using a shorter cutter with a smaller diameter for high-speed chipping is advantageous in
terms of spindle vibration, temperature increase, thermal deformation, and processing precision.
4) The geometric shape of the cutter blade has an effect on cutter abrasion. Increase the angular
backlash of the blade can reduce abrasion due to scratches. Suitable cutter materials can also
minimize abrasion during high-speed processing; for example, cermet, tin or tic coated carbide
cutters have longer lifespan than conventional cutters. Ceramic (Si3N4) cutters are better than cermet
cutters.
5) Perform another dynamic balance calibration after combining the cutter and the shank together.
The dynamic balance standard should be G2.5 or above.
50 – 6000 rpm Level G6.3
Balance level
6000 – 18000 rpm Level G2.5
Spindle Rotation Speed (rpm) Cutter Diameter (mm) Cutter Length (mm)
6000 – 8000 125 250
8000 – 10000 100 250
10000 – 12000 80 250
12000 – 15000 65 200
15000 – 18000 50 200
15
PRECISIONMACHINETOOLS Ver 2 Maintenance Manual
2-2 Tool Shank and Broach Bolts
16
PRECISIONMACHINETOOLS Ver 2 Maintenance Manual
CAT 40 STUD
17
PRECISIONMACHINETOOLS Ver 2 Maintenance Manual
2-3 Spindle Warm-up
This is an aerosol lubrication design, and so before turning on the machine, follow the warm-up steps
below to extend the lifespan of the spindle and to avoid damaging the bearing by letting the oil
aerosol getting into the bearing ahead.
Spindle warm-up time
Item Condition Spindle RPM
(Maximum RPM %)
Rotation Time
( min ) Check Contents
1 Routine operation Max Rpm 20% 10
1. Less than 10°C
increase of
temperature
2. Shocks
3. Noises
2
If the spindle has been
stopped for more than two
hours, warm-up is
compulsive.
20% 10
1. Less than 10°C
increase of
temperature
Shocks
2. Noises
3 Spindle stopped for more
than 72 hours
1. 20%
2. 50% 10
10
1. Less than 10°C
increase of
temperature
2. Shocks
3. Noises
4 Spindle stopped for more
than 2 weeks
1. 500 RPM
2. 20%
3. 40%
4. 60%
5. 80%
6. Maximum RPM
60
10
10
*10
*10
*10
Less than 10°C
increase of
temperatureShocks
Noises
4. Do not go onto the
next step until the
temperature has
become stable.
18
PRECISIONMACHINETOOLS Ver 2 Maintenance Manual
Cautions
1) If the shank is not installed onto the spindle, do not operate the spindle. See the figure below.
If the temperature of the bearing has increased for more than 10%, reduce the rotation speed of the
spindle to 500 and do not carry out the warm-up until the temperature is about 5°C higher than the
room temperature.
19
PRECISIONMACHINETOOLS Ver 2 Maintenance Manual
2-4 Spindle Pre-Operation Check
1) Check whether the air pressure source is normal.
2) Check No.7 electric oil pump tank (Refer to the diagram in Section 3-1) for whether there is
enough oil.
3) Run the spindle at 100 rpm to check whether the oil pump is functioning normally.
4) If everything is okay, carry out the warm-up according to the spindle warm-up procedures
presented in Section 2-3.
Caution
1. The oil volume and air supply volume of this aerosol lubrication unit has already been set at the
factory. Do not adjust the values arbitrarily.
2. During the maintenance, do not disassemble, bend, or flatten the output oil pipe, which may
damage the oil pipe.
3. Timely fill up the oil tank.
4. If the spindle has been stopped for more than 2 hours, run the spindle system, including the
aerosol lubrication system, at a speed that is 20% of the maximum speed.
The machine has to have a forced warm-up for 10 minutes before starting the actual work.
5. Do not adjust the oil/air mixing valve. Use the factory-set default value for lubrication interval.
Do not change the values arbitrarily or the bearing may be damaged.
6. For this unit, if the screen displays “ALARM 1002, 1056, 2004,” check and turn off the alarm
before continuing the operation.
7. Do not turn on and off the spindle repeatedly in a short period of time during the processing.
The inside of the spindle may be over-lubricated, which can cause the spindle overheated.
8. If the spindle alarm went off when starting the operation, it is due to overheated bearing. Stop
the operation. Wait until the temperature returns to normal. Check if there is any problem before
starting the warm-up and the operation.
9. It is normal to have oil dropped onto the workbench or the processing item when running the
machine. This comes from the exhausted oil aerosol. Do not block the outlet or the back pressure
may lead to temperature increase, thereby damaging the spindle bearing.
20
PRECISIONMACHINETOOLS Ver 2 Maintenance Manual
2-5 Spindle Alarm Handling
1) For this unit, if the screen displays “ALARM 1002, 1056, 2004,” check whether the temperature of
the protective device of the bearing is 50°C. After checking the temperature, check whether the
pipelines are abnormal, squeezed or broken. Check whether the oil cooler and the air compressor
are normal. Wait for the temperature to drop before turning on the spindle for warm-up. This is the
first line of protection for the spindle.
2) The second spindle protection is the oil pump. The oil pump has liquid level detection, and when
the level is too low, ALARM will be issued. If the oil pipeline is blocked, the screen will display
ALARM 1002.
3) The third spindle protection is the pressure switch for air pressure supply. If there is insufficient air
pressure, the mixing valve will be incapable of emitting the oil aerosol. If this ALARM goes off, check
whether the oil pipeline is broken and whether air pressure supply is sufficient.
4) If the clients still cannot turn off the alarm after checking relevant pipelines, contact the service
department of the Company. Do not modify the setting arbitrarily.
5) Messages of the ALARM signals:
1. 1002 LUBE PRESSURE FAULT：Insufficient pressure from the automatic lubrication pump
2. 1056 SPINDLE COOLER ALARM：Abnormal spindle oil cooling function
3. 2004 LUBE LEVEL ALARM：Under the standard liquid level of the oil tank of the automatic
lubrication pump
6) For relevant settings, please refer to the electrical instructions.
This manual suits for next models
2
Table of contents
Other Sharp Industrial Equipment manuals
Popular Industrial Equipment manuals by other brands
monofil
monofil Aerosol-Abfullgerat D-2014 operating instructions
Freedom
Freedom HP6 Setup, operating, maintenance instructions
Haufftechnik
Haufftechnik HSI 150-K-AF Series Assembly instructions
THERMA
THERMA Trapzilla TZ-1826 Installation & maintenance instructions
System air
System air SAVE VTR 150/K installation instructions
Haufftechnik
Haufftechnik HSD manual