Sharp 1840TC-FC User manual

CNC HIGH SPEED PRECISION LATHE
INSTRUCTION MANUAL AND PARTS LIST
1840TC-FC/ 1840TC-F
2060TC-F
2460TC-F

CONTENT
1.Safety Instruction .......................................................................................2
1.1 General Safety Instruction For Operating The Machine ..................... 3-6
1.2 Safety Instructions For Workholding ...................................................6-7
1.3 Maintenance Safety Instructions ..........................................................7-8
1.4 Installation Safety Instructions ................................................................8
1.5 Installation Precautions ..................................................................... 8-11
1.6 Safety Precautions ............................................................................11-15
1.7 Warning Signs Plate On The Machine ...................................................16
2. Specification ............................................................................................17
2.1 General Layout Of Lathe........................................................................18
2.2 Dimensional Drawing ............................................................................19
2.3 Machine Specification .................................:....................................19-20
2.4 Hardware & Operation ............................................…………...............21
2.5 Control Panel Function Keys .................................................................21
2.6 Standard Accessories..............................................................................22
2.7 Optional Accessories..............................................................................22
2.8 Check List .............................................................................................23
3. Maintenance.............................................................................................24
3.1 General Preparation & Selecting Location...........................................25
3.2 Connection Of Power Line ....................................................................26
3.3 Unpacking .............................................................................................27
3.4 Lifting Machine ... .................................................................................28
3.5 Placing The Machine .............................................................................28
3.6 Clean & Lubricating Machine ...............................................................29
3.7 Leveling Machine ..................................................................................29
3.8 Electrical Equipments ............................................................................30
3.9 Lubrication .......................................................................................31-37
3.10 Machine Body ................................................................................37-42
3.11 Electric Equipment .........................................................................43-45

4. Operation...................................................................................................46
4.1 Moving Direction ...................................................................................47
4.2 Machine Operation .................................................................................48
4.3 Operator Panel ..................................................................................49-50
4.4 Selection Of Spindle Speeds .............................................................51-54
4.5 Machine Data ...................................................................................55-57
5. Parts List ………………………………………………………………....58
5.1 Parts List Content ………………………………………........................59
Headstock ..............................................................................................60 - 79
Tool Post ................................................................................................80 - 81
X- Axis ...................................................................................................82 - 84
Z -Axis ...................................................................................................85 - 86
Manual Pulse Generator Assembly ..........................................................87-88
Tailstock ...................................................................................................89-95
X,Z Axis Cover.........................................................................................96-98
Electrical Control Box............................................................................99-100
Bed & Chip Tray .................................................................................101- 102
Operation Box & Door Assembly........................................................103-105
Splash Guard & Cover Assembly..........................................................106-108

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SAFETY INSTRUCTIONS
FOR
TURNING CENTERS
WARNING
Please read this manual before operation or maintaining the machine,
everyone working on the machine must know how to operate it safety and
correctly to avoid possible injury.

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1.SAFETY INSTRUCTIONS

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WARNlNG:
Do not install, operate, or service this machine unless:
(1) You have to read and understand the safety instructions on the pages that
follow.
(2) You have to read and understand the MlCROWEILY operator’s manual,
especially knowing the function and locations of all machine controls and
read manuals for any related accessories.
(3) You have to read and understand all safety and instruction plates attached to
the machine and its related accessories.
(4) Prior to installing or servicing the machine read and understand the
MICROWEILY maintenance manual, servicing the machine must be done only
by competent and trained personnel.
NOTE:
The MlCROWElLY’s operation manual and maintenance manual, each
containing a copy of these safety instructions, should be keep in the vicinity of
the machine so they are accessible to the operator and maintenance personel.
The following safety instructions are general recommendations for most common
operations on a turning machine.
Additional safety measures may be required for your particular application,
MlCROWEILY therefore, makes no warranty or representation as to the absolute
correctness or sufficiency of the instructions.
1. 1GENERAL SAFETY INSTRUCTIONS FOR OPERATING THE MACHINE
(1) The best defense against injuries on a turning machine is to be alert, never
initiate a machine function unless you completely understand what the
function will cause the machine to do.
(2) Never operate the machine with any cover or shield open or removed.
(3) Never reach into the work area when the spindle is turning or if the machine is
in automatic mode.
(4) Put the machine in manual mode and be sure last programmed function has be
completed before reaching inside of the work area

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(5) The function of the machine make it impossible to eliminate all pinch points,
bc particularly aware of the following pinch points:
-Spindlc and chuck rotation
-Indexing of turret and tools
-Carriage and cross slide movement
-Tailstock movement, both quill and body
(6) Never allow chips, coolant or oil remain on the floor, do not leave loose object
on or around machine.
(7) Clothing:
*Wear safety glasses with eye shields all times.
*Never use a compressed air hose to remove chips from a machine
*Do not wear rings, watches, tie or loose sleeve clothing.
*Gloves are easily caught in moving parts, take them off before
turning machine .
*Always wear safety shoes with steel toes and oil resistance soles.
*Never remove protection for even a short time when operating the
machine.
*Know the correct way to wear protective devices.
If operator has long hair, hair should always be tucked under a cap
or tied back and up, beware of loose hair near the rotating parts of lathe.
(8) Turning machines are designed to be ran by one person, persons other than the
designed operator should stay out of the machine area during operation.
(9) Take care not to bump or accidentally touch any machine control.
(10) Do not paint, alter, deface or remove any warning plates from the machine,
replacement plates are available from MICROWEILY.
(11) Do not operate machine while talking.
(12) Never operate the machine after taking strong medication, using non-
prescription drugs or consuming alcoholic beverages. Persons with illnesses
which might cause dizziness or fainting should never operate this machine.
(13) The electric components arc protected from normal moisture resulting from
humidity use of water base solubles as coolant, etc., DO NOT use water
clean the machine or the are around it.

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(14) Never touch a machine control device or electrical component when your
hand is wet.
(I5) Keep flammable liquids and materials away from the work area and hot chips.
(16) Never clean up clips while the machine is running or is in automatic mode.
(17) Do not file work pieces being rotated under power.
(18) At the end of work day, the machine should be placed in either
"CONTROL OFF" or "POWER OFF" modes.
(19) When restarting 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.
(20) Never touch spindle start or spindle job control until hands, feet body are
well clear of the work area.
(21) Do not stand on any parts of machine while coolant and oil make surface on
the machine slippery which present electrical hazard under machine has
power on.
(22) Never extend an unsupported bar out of the rear of the spindle or hydraulic
cylinder a distance from a concentric support more than 10 times its diameter.
Doing so can cause the bar to bend or break. When any bar is extended a
large sign should be placed to warn people to stay away from the area.
(23) If you work turning machine with bar feeder together, please keep away from
the exit end of the bar feeder when the machine is running.
1.2 SAFETY INSTRUCTIONS FOR WORKHOLDING:
(1) Never running machine until your workpiece was held 100% sure.
(2) A chuck is the most common workholding device used on this machine, some
of the factors which affect the holding ability of a chuck are:
*Clamping force of jaws
*Rotational speed of the spindle
*Type of jaw surface (serrated, smooth,etc.,)
*Area of chuck jaws in contact with the workpiece
* Type of chuck
*Configuration of the workpiece ...shape, weight and balance
*Jaw weight and location

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(3) Before running machine, make sure the workpiece is gripping internally or
internally, since low chuck pressure will diminish jaw gripping force which
may allow the workpiece to come out of the jaws. Excessive pressure can
damage a power chuck which could cause a loss of jaw force. The gripping
force of a power chuck can be ordiminished as much as 50% because of lack
of lubrication or lack of periodic cleaning, components of the chuck are
subject to wear and damage which also can lessen gripping power. Need
support workpiece by steady rest or tailstock center while workpiece length
over 200mm.
A. Grease the chuck at the beginning of every shift, use only the chuck
manufacturer’s recommended lubricant.
B. A weekly examination of the condition of the chuck, this examination should
include the measurement of jaw clamping force with a jaw force gage to insure
that chuck is functioning as it should.
C. With reference to manufacturer’s manual for chuck and cylinder to any other
maintenance requirements. As the spindle r.p.m. increase the gripping force
of the jaw decreases, various types of top jaws are used on chucks for different
applications, the best workholding conditions that need use serrated contact
surfaces on work gripping surfaces and use the maximum area of contact
between the jaws and the workpiece, improper use cause injury.
(4) If chuck or accessory was not supplied by MICROWEILY with machine
together, verify the safe operating speed by their manufacturer.
(5) Always be sure the chuck or acccssory is located correctly on the spindle nose
and it is securely bolted to the face of spindle.
(6) Be sure any item bolted or clamped to a chuck or fixture is securely fastened
before starting the spindle.
(7) The spindle speed could not be high speed during the workpiece too long.
(8) Always be aware that closing chuck jaws can trap fingers or hands.
(9) The same safety instructions apply to power chucks and manual operated
chucks, the following additional precautions for manual chuck when you use
it.

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A. Always use spring-loaded, self-ejecting type safety wrenches.
B. Never put an extension bar on chuck wrench or hit it hammer.
C. Centrifugal force can cause the scroll to unwind if the chuck is empty.
the jaws may come out of the chuck while the spindle is turning.
(10) If a workpiece is extend from the chuck, the distance of 3 to 4 times it
diameter, without being supported by the tailstock, poor cutting conditions
will normally occur, check load capacity of revolving centres for application
in hand.
1.3 MAINTENANCE SAFETY INSTRUCTIONS,
(1) WARNING:Only authorized electricians can install or modify any electrical
component failure. Disconnect main power and lock in “OFF” position
beforeattempting any repair, tag disconnect switch “DO NOT START”.
(2) Read and understand safety instructions before servicing this machine.
(3) Know all points were voltages are present on this machine and in electrical
boxes.
(4) Residual voltages can exist in the electrical cabinets for a period of time after
power has been turned off. Check any component inside cabinet by meter
before touching.
1.4 INSTALLATION SAFETY INSTRUCTIONS:
(1) Verify machine weight and make sure lifting equipment, cables, etc., are
sufficient capacity, refer to follow MICROWEILY’s maintenance manual to
lift and move machine.
(2) MICROWEILY machine has transformer tapes for various voltages and power
cycles, if machine subsequently moved by user, the transformer taps must be
checked and be sure which are wired correctly for new location.
(3) A copper (5/8” minimum diameter) rod must be sunk through
foundation into the earth at the machine, length should be sufficient
to provide less than 80 ohms resistance between the end of the rod
and earth ground, a large copper wire must directly connect this
earth ground to the ground connection provided on the machine.

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1.5 INSTALLATION PRECAUTIONS
To ensure the safe operation of the NC machine, note the following
during installation:
1.5.1 Wiring
Be sure to use electrical conductors with performance ratings(1)
equivalent or superior to those described in the maintenance manual.
Do not connect to the power distribution panel any power cables for(2)
devices which can cause line noise, such as are welders and high
frequency quenching machines.
Arrange for qualified engineer to connect the power lines.(3)
1.5.2 Grounding
Use a grounding wire with a cross section of more than 14mm², for protective
earth conditions, please follow the law of each country.
This wire size should be greater than AWG (American Wire Gauge)
No.5 and SWG (British Legal Standard Wire Gauge) No.6
Generally, the NC machine should be grounded to a separate grounding rod,
if an independent ground can not be provided for the machine, prepare the
ground connection as follows:
(1)Connect a single conductor to its 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.
(2)Be careful when using concrete reinforcing rods as grounding points,
these reinforcing rods often are used to ground equipment because
they usually offer a resistance to ground of less than 100 ohms,
in doing so, makes the connection as following:
This also applies to connecting ground wires to regular grounding
terminals.
Do not use the same grounding reinforcing rod or grounding terminala.
for the devices since this could lead to line noise such as produced
electric welders and high frequency quenching machines.
Use a grounding terminal with an adequate electrical performanceb.
rating and which is durable.

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(3) A separate grounding wire should be used, one whose length is as
short as possible.
(4) Check the resistance to ground by actual measurement. This should
measure less than 100 ohms if the single device is connect to its own
grounding rod.
DESIRABLE INDEPENDENT GROUNDING:
Earth resistance:
Less than 100 ohms
COMMON GROUNDS:
Resistance to ground=100/
the number of devices
connected to the ground (Ω)
NEVER GROUND EQUIPMENT AS SHOWN IN THE FOLLOWING FIGURE:

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1.5.3 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 reason changes.
Supply voltage :90% to 110% of supply voltage(1)
Source frequency :±2 HZ frequency(2)
Ambient temperature :0°C to 45°C (32°F to 113°F)(3)
Relative humidity :Less than 80%(4)
Temperature changes should not cause
condensation.
Atmosphere(5) : Free from excessive dust, acid fumes corrosive gase
and salt.
It should be avoided to expose the machine to direct sunlight or heat(6)
rays which can change the environmental temperature.
Avoid exposing the NC machine to abnormal vibration, if it is(7)
different to observe meet these conditions contact us immediately.
1.6 SAFETY PRECAUTIONS
The operator should not rely solely the safety devices, operator must understand
special precautions as following before operate machine.
1.6.1 Basic Operating Practices
DANGER:
Some control panels, transformers, motors, junction boxes and other(1)
parts have high voltage terminals, these should not be touched or a
severe electric shock will be sustained.
Do not touch switch by wet hands.(2)
WARNING:
The emergency stop push button switch location should be well know(1)
and it can be operated at any time without having to look for it.
After switch off machine one minute, the replacing fuse.(2)
Provide sufficient working space to avoid hazardous falls.(3)
Keep the machine and work area neat, clean and orderly.(4)
Before operating switches, always check that they are the right ones.(5)
Never touch a switch accidentally.(6)
Never lay anything on the working surface of the machine, where it may foul(7)
with rotating or moving parts.

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(8) If job to be done by two or more persons, coordinating signals should
be given at each step of the operation, unless a signal is given and
acknowledges, the next step should not be taken.
CAUTION:
When power failure, turn off the main circuit breaker immediately.(1)
Dispose of oils CORRECTLY.(2)
Replacement fuses should have the proper current ratings.(3)
Protect the NC unit, operating panel, electric control panel, etc., from shocks,(4)
since this could cause a failure or malfunction.
Do not change parameters, values and other electrical settings, if change are(5)
un-avoidable, record the values prior that they can be returned to their original
settings if necessary.
Do not soil, scratch or remove the caution plate, should it become illegible or(6)
be missing, order another caution plate from the supplier shown on machine
and suitable place.
1.6.2 Before Switching On:
DANGER:
When cables, cords or electric wire whose insulation is damaged that will cause
current leaking and electric shocks, check above before switch on,
WARNING:
Be sure the instruction manual and the programming manual are fully(1)
understood, every function and operating procedure should completely clear.
Do not wear oil soaked or contaminated clothing, always wear safety(2)
shoes, safety goggles with side covers, safety clothes and other safety
protection correctly.
Close all NC unit, operating panel and electric control panel doors and(3)
cover.
CAUTION:
The power cable from the factory feeder switch to the machine main(1)
circuit breaker should have a sufficient sectional area to handle the
electric power used.
Cables which must be laid on the floor must be protected against(2)
chips so that short circuits will not occur.

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(3) Before first operating the machine after un-packing or keeping the
machine idle for a long period (several or more), each sliding parts
must be freshly lubricated, keep lubricating oil pump working until
oil oozes out from wiper.
(4) Oil reservoirs should be filled to indicated levels, check and add oil,
if necessary.
(5) For lubricating points, oil brands and appropriate levels, see the
various instruction plates.
(6) Switches And levers should operate smoothly.
(7) When switching machine on, put the factory feeder switch, the
machine main circuit breaker and the power switch on the operating
panel to the “ON” position in the order.
(8) Check the coolant level, and add coolant, if necessary.
1.6.3 After Control Power Switch Has Been Turned On
CAUTION:
When the power switch on, the operating panel is “ON” position as described is
7 above, the READY lamp should be also be check.
1.6.4 Routine Inspections
WARNING:
When checking belt tensions, keep your fingers away between belt and pulley.
CAUTION:
Check pressure gages for proper readings.(1)
Check motors, headstock and other parts for abnormal noises.(2)
Check the motor lubrication and sliding parts for evidence of proper(3)
lubrication.
Check safety covers and safety devices for proper operation.(4)
Check belt tensions, replace any set of belts that has become stretched with a(5)
fresh matching set.

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1.6.5 Warm Up
CAUTION:
Warm up the machine, especially the spindle and feed shaft by(1)
running for 10 to 20 minutes at about half or one third the maximum
speed in the automatic operation mode.
This automatic operation program should cause each machine(2)
component operate, at the same time, check their operations.
Be particularly careful to warm up the spindle which over maximum(3)
speed running.
If the machine is used for actual machining immediately after being
started; following a long idle period, sliding parts may be worn due to
lack of oil, thermal expansion of the machine components can
jeopardize machining accuracy to avoid above condition, always
warm machine up.
1.6.6 Preparations
WARNING:
Tooling should conform to the machine specifications, dimensions(1)
and types.
Seriously worn tools can cause injuries, replace all such tools with(2)
new ones beforehand.
The work area should be adequately lighted to facilitate safety checks.(3)
Tools and other items around machine or equipment should be stored to ensure(4)
good footing and clear aisles.
Tools or any items must not be place on the headstock, turret, cover and similar(5)
places.
If the center holes of heavy cylindrical workpiece are too small, the workpieces(6)
will jump out when loaded, be careful the center holes and angles.
CAUTION:
Too lengths should be within specified tolerances to prevent interference.(1)
(2) Make trail running after installed tool .
1.6.7 Operation
WARNING:
(1) Do not work with long hair that can be caught by machine.
(2) Do not operate switches with gloves on that could cause malfunctions, etc.
(3) Whenever a heavy workpiece must be moved, two or more persons
should always work together of there is any risk involved.

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(4) Only trained, qualified workers should operate forklift trucks.
(5) Whenever operating a forklift truck, special care should be taken to
prevent collisions and damage any surroundings.
(6) Wire ropes or slings should be strong enough to load and lifting
should conform to the mandatory previsions.
(7) Grip workpieces securely.
(8) Stop machine before adjusting the coolant nozzle at the tip.
(9) Never touch a turning workpiece, spindle by hands or by any other
way.
(10) While a workpiece is turning, do not wipe it off or remove chips by
cloth or hand, always stop machine first and then use a brush and
sweeper.
(11) Keep all guards and cover plates in place and all machine cabinet
doors closed.
(12) Stop the machine whenever installing or removing a tool.
(13) Whenever machining magnesium alloy parts, wear a protective
mask.
CAUTION:
During automatic operation, never open the machine door.(1)
When performing heavy duty machining, carefully prevent chips from being(2)
accumulate since hot chips can catch fire.
1.6.8 To Interrupt Machining
WARNING:
When leaving the machine temporarily after completing a job, turn off the power
switch on the operation panel and the main circuit breaker.
1.6.9 Completing A Job
CAUTION:
Always clean the machine or equipment, remove and dispose of chips(1)
and clean cover windows, etc.,
Do not clean the machine or equipment before it had stopped.(2)
Return each machine component to its initial condition.(3)
Check wipers does any breakage, replace broken wipers.(4)
Check coolant, hydraulic oil and lubricant does any contaminate.(5)
Check coolant, hydraulic oil and lubricant levels, add, if necessary.(6)
(7) Clean the oil pan filter.
(8) Before leaving the machine at the end of the shift, turn off the power switch on
the operating panel, machine main circuit breaker and factory feeder switch in
that order.

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1.6.10 Safety Devices
(1) Front cover, rear cover and coolant cover.
(2) Over travel limit switches.
(3) Chuck barrier, tail barrier and tool barrier (NC software).
(4) Stored stroke limit (NC software).
(5) Emergency stop push button switch.
1.6.11 Maintenance Operation Preparations
(1) Do not proceed any maintenance operation unless instructed to do by
specialist.
(2) Replacement parts, consumables (packing, oil seals, o-rings, bearing,
oil and grease etc.,) should be arranged in advance.
(3) Prepare to record preventive and corrective maintenance operations.
CAUTION:
(1) Thoroughly read and understand the safety precautions from the instruction
manual.
(2) Thoroughly read the whole maintenance manual and fully understand the
principles, construction and precautions involved.
1.6.12 Maintenance Operation
DANGER:
(1) During maintenance working 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 during maintenance operating in progress”.or
similar wording should be indicated on such switches and at any other
appropriates locations, such indication should be secured by a semi-
premanent means in the reading direction.
(2) With the machine turned on, any maintenance operation can be
dangerous, in principle, the main circuit breaker should be turned off
throughout the operation.
WARNING:
(1) The electrical maintenance should be done by a qualified person or by others
competent person, keep close contact with the responsible person, do not
decide byyour-selves.
(2) Overtravel limit and proximity switches and interlock mechanism including
functional parts should not be removed or modified.
(3) When maintenance should be use steps or ladders, the safety is very important.
(4) Fuses, cables, etc., made by qualified manufacturers should be employed.
1.6.13 Until Operation Is Begun After Maintenance
WARNING:
All parts and waste oil should be removed by the operator and placed far enough
away from the machine to be safe.
CAUTION:
(1) The maintenance person should check that the machine operates safely.
(2) Maintenance and inspection data should be recorded and kept for reference.

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1.7 WARNING SIGNS PLATE ON THE MACHINE
Safety related informatino, with must be strictly ovserved by all machine
operators, is given on warning signs plate, these warning signs plate are
attached to the machine.

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2. SPECIFICATION