lathe am-1440bsl - smithy am-1440bs 20150921.pdf · clothing & safety 10 safety aspects related...

Thank You For Your Order

Congratulations on your purchase of an AutoMate CNC Lathe. With proper setup and care, your machine will provide many years of quality work and productivity.

This guide covers general instructions for set-up and maintenance for Automate CNC Lathes. Along with this guide you will also receive a machining operations and programming handbook for the Siemens 808D control system along with your machine. We recommend keeping this set-up guide with that manual when your machine arrives.

Enjoy your Automate CNC Lathe!

www.smithy.com | [email protected] | Ann Arbor, Michigan | USA 1

Index

Covered In This Document

This document covers basic information that you will need to prepare for delivery of the CNC Lathe and to begin setting up your machine. The topics in this document include:

www.smithy.com | [email protected] | Ann Arbor, Michigan | USA2

Index

Index

IndexThank You For Your Order 2Covered In This Document 1Index 2

Safety GuidelinesSafety Guidelines 5General Safety Guidelines - Safety First! 6Overview 6Danger Symbols 7Warning Symbols 8Basic Points Of Safety 9Clothing & Safety 10Safety Aspects Related To Tools & Work Holding 11Safety Aspects Related To Maintenance 12Safety Aspects Related To The Workplace 12Safety Equipment 13More Guidelines For Safe Machine Tool Operations 14General Personal Safety Rules 15Carrying Methods for Safety 18Risk Control 19Hazards 20Final Safety Note 21

Delivery & Set-upDelivery & Set-up 23Tracking Your Shipment 24Preparing For Delivery 25Set-Up Clearances & Conditions 25Power Requirements 26Taking Delivery 27Inspecting Your Shipment 27Loading the Machine 27Opening the Crate 28Removing Machine from Pallet 30Removing Shipping Support Braces 32Remove the brace 33Leveling Machine 35Mechanical Maintenance 37Maintenance Schedule 37Daily Maintenance 37Periodic Maintenance 38Perform these maintenance tasks as per the schedule below. 38Lubrication System & Machine Lubrication 39Ball Screws and Guide Ways 39Headstock & Spindle Bearings 39Periodic Maintenance Tasks 40Linear Motion Guide & Bearing Maintenance 40Machine Operation – Quick Start Guide 41Powering up the machine 41Powering down the machine 41Machine Home Position (808D basic only) 41


Index

Keyboard Layout 42Tool Mounting and Holding 43Tool Holding Options 44Installing the Tooling 44

Diagrams and partsDiagrams and Parts 47CJK6132-00 BED ASSEMBLY 48SADDLE&TOOLPOST ASSEMBLY 52HEADSTOCK ASSEMBLY 56TAILSTOCK ASSEMBLY 60


Safety Guidelines

Safety Guidelines


Safety Guidelines

General Safety Guidelines - Safety First!

General operational techniques and safety procedures will be outlined in these guidelines. Youwill note, for example, that all rotating parts, wherever feasible, are protected byspecially designed covers and shields. If the machine is operated in accordance with themanufacturer’s instructions, it will provide you with reliable service. However, withmachines of this nature, serious accidents may occur due to improper or carelessoperation. It is strongly recommended that you read this manual and accompanyingmanuals and understand thoroughly the contents of the manuals. Not every example ofimproper operation or unauthorized usage which may lead to malfunction or an accidentcan be anticipated. If a particular operation is not documented in this manual as an authorized usage of the equipment, it should be assumed that it is an unauthorized orimproper usage with potential danger and should be avoided or the manufacturer shouldbe consulted before the actual use.

Safety This machine is provided with various safety devices to protect the operator and themachine. However, these cannot cover all aspects of safety. Therefore, the operator must thoroughly read and understand the content of this manual before the machine is turned on and operated. The operator should also take into consideration these and other aspects of safety related to his/her particular environmental conditions, materials and tools.

Safety Symbols Used in this Manual Three categories of safety guidelines have been used throughout this manual. Please take note of these symbols and understand their meanings.

DANGERIf this action is not avoided, it will cause permanent harmto your health, such as death or serious injury, and it may also cause permanent damage to your machine.

WARNINGIf this action is not avoided, it can cause potential harm to your health, resulting serious injury, and has potential to cause serious harm to your machine.

CAUTIONIf this action is not avoided, it may cause potential harm to your health, such as minor to moderate injury, and may also cause moderate harm to your machine.

Always observe the safety instructions inscribed on the safety nameplate fixed to the machine.

DO NOT remove or damage these name plates.

DO NOT attempt to operate or turn on the machine until you have read and understood the manuals supplied with the machine.

Overview


Safety Guidelines

Danger Symbols


Safety Guidelines

Warning Symbols

WARNING

Electrocution hazardDeath by electric shock can occur.

Follow manufacturer’s material safety data warning.

Risk of serious physical injury.Machine cannot protect from toxins.

Moving parts can crush or cut.Automatic tool changer can cut and/or crush.

Ensure the machine is not in automatic operation before reaching inside.


Safety Guidelines

Basic Points Of Safety

• There are high voltage terminals on the electrical control panel, motors, junction boxes and other equipment. DO NOT touch any of these components under any circumstances, when the power supply is ON.

• Make sure that all safety covers are fitted and electrical boxes are closed and secured before the power is switched to ON.

• If any components or safety covers are to be removed, first switch off or disconnect the main plug.

• Memorize the position of the EMERGENCY STOP BUTTON on the machine so that you can press it immediately from any position in case of emergencies.

• DO NOT touch the tool holder while the machine is running. Under no circumstances, should you touch a rotating tool holder or work piece while the machine is in operation mode.

• To prevent incorrect operation of the machine, carefully check the position of the switches before operation.

• If in doubt, consult this manual or a Smithy technician for advise and suggestions.

• Always unplug the main plug when the machine is notv in use.

• If more than one person is operating the machine, DO NOT proceed to the next step without informing the other operator(s) that you are about to do so.

• DO NOT modify the machine in any way that will affect safety.


Safety Guidelines

Clothing & Safety

• Tie back long hair to prevent entangling with rotary tools.

• Wear safety equipment.

• Always wear a protective mask when machining Magnesium alloys.

• Never wear loose or baggy clothes.

• DO NOT operate the machine while under the influence of drugs or alcohol.

• DO NOT operate the machine if you suffer from dizziness.

• Always use gloves when loading or unloading work pieces or tools and when removing chips from the work area to protect your hands from sharp chips and burns caused by heat generated during machining.

• DO NOT subject the machine, control box, operator panel, or the electrical control panel to a high voltage surge.

• DO NOT change the parameters or electrical setting values without good reason. If it becomes necessary to change the parameters or settings, first check with a Smithy technician to assure that it is safe to do so. Be sure to note the original values so that the control can be reset to that value, if necessary.

• DO NOT paint, soil, damage, modify, or remove any of the safety nameplates.

• If the details become illegible or if the nameplate is lost, obtain a replacement from Smithy and mount it at the original location.

• DO NOT remove any safety covers while the machine is in automatic operation mode.

• STOP all machine operations before cleaning the machine or any of the peripheral equipment. After a job has been completed, set up each part of the machine so that it is ready to be used for the next series of operations.

• Close all covers and junction boxes before running the machine.

• Check all electrical cables for damage to prevent electrical shock.

• DO NOT handle coolant with bare hands to avoid irritation.

• Always use wire rope or slings as per standards, suitable for the load to be supported.

• DO NOT remove or adjust switches to increase axis travel beyond the machine specifications.

• DO NOT wipe the workpiece or clear away chips with your hand or with a rag while the spindle is in operation.


Safety Guidelines

• DO NOT allow chips to accumulate in the work envelope.

• Warm up the spindle and axis motion before running the machine in automatic mode.

• DO NOT operate the keyboard or operation panel switches when wearing gloves.

• DO NOT disconnect the main power cable without switching off the CNC and PC connections.

• Always use proper cutting tools and work holding clamps suitable for the work and within the specifications of the machine.

• DO NOT stall the machine during cutting due to improper feed and depth of cut suitable for the work piece material.

• DO NOT operate the spindle above the rated speed of the arbors/tool holders and cutting tools you expect to mount and use in any machining operation.

• Replace worn tools as soon as they are identified.

• Take care not to place any part of your body in possible pinch points on the machine.

• Make sure the tool length to diameter ratio is proper in order to minimize vibration due to excessive overhang conditions.

• Make sure the drawbar and the tool holders are tightened to the proper cutting conditions before actual cutting operations begin.

Safety Aspects Related To Tools & Work Holding


Safety Guidelines

• Always disconnect the power to the machine before carrying out any maintenance work.

• After the power has been switched off for a minimum of 60 minutes, check voltage with a multi-meter or equivalent meter to make sure there is no residual voltage.

• Maintenance of electrical and mechanical components should only be carried out by individuals with working knowledge of the machine tool.

• DO NOT remove or modify switches.

• Clean the machine areas after maintenance is completed.

• DO NOT use compressed air to clean the machines.

• Always provide sufficient work space around the machine and peripheral equipment.

• Protect all cables from being damaged by cutting chips.

Safety Aspects Related To Maintenance

Safety Aspects Related To The Workplace


Safety Guidelines

Safety Equipment

This machine is provided with various mechanical and electrical safety devices to protect the operator and the machine. The safety devices include interlock devices and emergency stop switches. However, it is absolutely necessary that the operator familiarizes himself with the instruction manual of the machine before operating the machine. The manufacturer emphasizes that it is the sole responsibility of the operator to ensure that all operations using the Automate CNC Lathe are carried out in a completely safe manner.

Neither the manufacturer nor its representative or dealers can assume responsibility for any mishaps, damage or personal injury which may occur as a result of improper operation or from failure to observe the safety precautions mentioned in this manual.


Safety Guidelines

More Guidelines For Safe Machine Tool OperationsThis machine is provided with various mechanical and electrical safety devices to protect the operator and the machine. The safety devices include interlock devices and emergency stop switches. However, it is absolutely necessary that the operator familiarizes himself with the instruction manual of the machine before operating the machine. The manufacturer emphasizes that it is the sole responsibility of the operator to ensure that all operations using

the Automate CNC Lathe are carried out in a completely safe manner.

Neither the manufacturer nor its representative or dealers can assume responsibility for any mishaps, damage or personal injury which may occur as a result of improper operation or from failure to observe the safety precautions mentioned in this manual.

CNC machine safety systemThe built-in safety system on a CNC machine includes guards and protective devices which shouldbe securely fitted and always kept in position while the machine is being used. It may include:

Emergency Stop ButtonUsed to shut down the machine immediately. It is located on the control panel and at other pointson the machine, for example the hand held unit.

Soundproof CasingReduces noise emission generated by the operating section and protects the operator from the riskof flying objects or tool fragments.

Curtain GuardsMade of PVC and designed to protect the operator from the risk of airborne chips or toolfragments.

Guard FenceThe fence marks the working area in which the machine moves. It protects the operator from therisk of interference with moving parts. The guard may be of an open type or made of mesh.

• Never operate a CNC machine without proper training or consulting the specific operator’s manual for that particular machine and control type.

• Never attempt to program a CNC machine without proper training or consulting the specific programmer’s manual for that particular machine and control type.


Safety Guidelines

General Personal Safety Rules

Below are some general personal safety rules that you can use as a guide only. You might like to add any other rules that apply to you.

DO: DON’T:

• Always wear safety glasses and hearing protection when operating CNC machines.

• Always wear safety glasses when closely observing cutting tools.

• Always wear safety boots or other suitable footwear.

• Always keep long hair covered when operating CNC machines.

• Always keep hands clear of moving parts during machining operations.

• Always stand clear of the machine while it is running and warn others of the dangers of being too close.

• Always avoid contact with cutting edges when handling tools or changing tools by hand.

• Always turn the CNC machine off completely and clean it up when you have finished using it.

• Never wear gloves.

• Never wear loose clothing or jewellery.

• Never reach into a CNC machine while it is running.

• Never place hands near a revolving spindle.

• Never leave the machine so that someone else is able to start it by pressing the cycle start button.


Safety Guidelines

DO: DON’T: • Always check that the machine is

not operating when loading a tool magazine.

• Always check that tools are in good condition, for example, sharp and free of cracks.

• Always check that tools are set correctly.

• Always check that the correct tool data is entered into the CNC program.

• Always test tools before use.

• Always check that the seating surfaces are clean before installing tools.

• Always check that spindle direction is correct for right-hand or left-hand operation.

• Only use tools within the limits specified by the manufacturer.

• Only tighten tools to recommended torque values.

• Never use blunt tools.

• Never use cracked or chipped tools.

• Never use tools with damaged tungsten tips.


Safety Guidelines

DO: DON’T: • Always keep the area around the

machine clear of obstacles.

• Always stack material where you can reach it but where it is clear of the moving parts of the machine.

• Always check that tools are sharp and set correctly.

• Always check that the correct tool data is entered into the CNC program.

• Always make sure that all guards are in position while the machine is in operation.

• Always make sure that all work and fixtures are clamped securely before starting machine.

• Always make sure spindle direction is correct for right-hand or left-hand operation.

• Always conduct a dry run to ensure the program is correct.

• Always follow company policy on correct procedures when handling or lifting parts or tooling.

• Do not use the machine table as a workbench.

• Do not use compressed air to blow chips from the parts of the machine, machine surfaces, cabinets, controls or floor around the machine.


Safety Guidelines

Carrying Methods for Safety

Personnal Protective Equiptment (PPE)

Hearing protection

Footwear

Clothing

• 1. Never twist your body Change direction by moving your feet.

• 2. Always have clear vision Shouldn’t trip over or bump into anything.

• 3. Slide the load It’s a lot easier than lifting.

• 4. To place the load on the benchPut it on the edge and slide it forward.

Before entering a machine shop you must wear personal protective equipment at all times. Theseshould include:Eye protection it is necessary to wear safety glasses, goggles or face shields at all times in areas where small flying fragments or dust can be encountered when working in the machine shop.

Hearing protection must be worn at all times. The type of hearing protection chosen will depend on: Personal choice by the operator for comfort and fit noise reduction required (ear muffs will give better noise reduction than ear plugs).

Suitable footwear must be worn. A closed shoe with leather uppers or safety boots would beappropriate.

It is important to remember that while you are working in the machine shop you should notbe wearing loose clothing or jewellery, which may get caught in revolving cutters. The movingparts of a machine revolve at high speeds and if any loose clothing or jewellery is caught in therevolving cutters you will be dragged into the machine causing serious injury or death.


Safety Guidelines

Risk Control

Long Hair:Keep long hair covered.Tie hair back.Wear a hair net.

Noise:Wear earmuffs.Wear ear plugs. Eyes:Wear safety glasses.Wear safety shield. Footwear:Wear closed shoe with non-skid sole.

Never dust yourself or a workmate down with an air hose. (Compressed air)

Dust: Wear dust mask. Chemicals:Wear gloves or protective clothing.Wear face mask. Guards: Guards on machines must be used at all times.


Safety Guidelines

Hazard Control• Hierarchy of Control.• How to control a hazard and minimise

the risk of an injury.• Example of hazard. • What to do. • How to do it.• Electrical hazards: Eliminate Install

electric droppers instead of using extension cords.

• Toxic chemicals: Substitute Introduce less toxic materials (polishes, adhesives etc.).

• Noise: Enclose Install canopies to the noisiest machines.

• Flying particles: Isolation Set aside specific areas for grinding.

• Machining dust Engineer controls Install and use dust extraction equipment.

• Slip / trip hazards Work practices Adopt better housekeeping procedures.

• Fatigue Administrate Rotate job tasks amongst workers.

• New equipment Training Staff development programs.

• Dust / noise, etc PPE Use personal protective equipment.

1. Spot the hazardA hazard is anything that could hurt you or someone else, is unsafe, or could cause an accident.Use all your senses to spot hazards – look around, listen, notice any strange smells (like smoke or chemicals) and use your knowledge about things that might be dangerous.

2. Assess the riskWork out how likely is it that the hazard will hurt someone, and how badly they could be hurt.Always tell someone about hazards you can’t fix yourself, and remember it is more urgent to make the changes if the hazard is likely to cause serious injury.

3. Minimize the riskFix the hazard yourself if you can, or tell someone who is able to fix it. The best way to fix the hazard is to get rid of it, but as this is not always possible there are some ways you can make the hazard less dangerous:• Substitute it for a less hazardous material or item.• Isolate it to an area where it’s more out of harm’s way, such as a locked room.• Add safeguards – for example, put clear guards around cutting or slicing equipment or warning signs for people to see.• Use personal protective equipment and clothing any time you are working with hazardous materials and/or equipment.

Here are the three steps involved in dealing with hazards:

Hazards


Safety Guidelines

Final Safety Note

AutoMate CNC machines have been proven to be safe and reliable. However, if abused or operated improperly, any machine can cause injury to you or others. Please read

this guide and the machine manual carefully before you start machining. Proper use will create a safe working environment and prolong the life of your machine.


Delivery & Set-Up

Delivery & Set-up


Delivery & Set-Up

Delivery & Set-Up

Tracking Your ShipmentThe best way to be prepared is to know exactly when your machine will arrive. Your “Pro Number” in the cover letter serves as your tracking number for your machine. You have several options available to track your Automate CNC System as it makes its way to you.

By Phone

ESTES – 1-800-755-2728 – Press 3 and you will be directed to a live customer service representative who can help you.

UPS – 1-800-PICKUPS – Select #1 and state our tracking number.

U.S. Mail – 1-800-275-8777 – Select desired language and select #5.

On The Web

ESTES – Go to www.estes.com. Click on Tools, then click on Tracking, and enter your pro number using the format 103-123456.

ESTES – If we are given your e-mail address at the time of ordering, we will enter it when we complete your shipping paperwork. CCX will send you automatic updates as your shipment travels to its final destination.

UPS – Go to www.ups.com. Select United States from the drop down field. Click on the blue arrow. Click on the “Tracking” tab at the top of the screen.

U.S. Mail – Go to www.usps.com. Click on “Track and Confirm”.

We make every effort to ship your complete order at one time. If you ordered a 4th axis rotary table at the time of order, the rotary table will be shipped with the machine. If ordered at a separate time, it will be shipped via Estes as well. If you ordered the fourth axis with an Automate 808D Advanced control system with 4th axis option on your CNC Lathe, the board is pre-installed into the control box.

Smaller items such as end Lathe adapters, end Lathes and general machine accessories are sent via UPS Ground or US Mail. It is possible that you may see your machine arrive before your UPS shipment. Please give any items shipped UPS or US Mail 7-10 days for delivery. If we were given your e-mail address at the time of order a detailed list of the items you ordered, along with information on how they were shipped will be emailed to you. The associated tracking numbers for your shipment will be e-mailed to you along with this Set-Up Guide.

We handle complex Automate CNC orders every day – orders usually consist of at least one crate and several boxes of varying sizes and weights. We work closely with Estes and UPS or USPS to make sure you are getting fast, convenient delivery of your ordered items at a reasonable shipping cost.

Your order may arrive in several installments, over a period of 7-10 days after you receive this letter.


Delivery & Set-Up

Preparing For Delivery

There are a number of things you can do to prepare your shop or work space for your new Automate CNC Lathe.

You will need a designated area with a level floor that is capable of supporting your Automate CNC Lathe, plus the maximum allowable work piece weight for your

specific model of CNC Lathe. (Please refer to the specification chart for the Lathe you ordered to obtain this specification.)

As a rule, the supporting structure should be able to hold 5-6 times the weight of the machine without any appreciable, permanent deformation.

Set up the Lathe in a location where you have plenty of working space. Leave at least 3 to 4 feet of clearance on the operating side of the machine. Note the suggested clearances for the other sides of the ma-chine.

Please take the following points into con-sideration when placing your machine in its new home.

The chosen location for your CNC Lathe should be a permanent location for the machine. Transporting machines is hard on the machine, and the people involved.Make sure the ground is as level as possible.

It will make leveling the machine simpler.The maximum temperature of your shop or working environment should not exceed 125ºF.Humidity levels should not exceed 80%.

Lathe Model A Dimension B Dimension C Dimension D DimensionAM-1340SL 78 in 20 in 60 in 77 in

1970 mm 500 mm 1570 mm 1950 mm

Set-Up Clearances & Conditions


Delivery & Set-Up

Set up the Lathe in a location where you have plenty of working space. Leave at least 3 to 4 feet of clearance on the operating side of the machine. Note the suggested clearances for the other sides of the

machine.Please take the following points into consideration when placing your machine in its new home.

Three phase machines are supplied without a plug as there are numerous connections for 3 phase circuits. The power cord/plug that is supplied with

the Automate CNC single phase system is 220 volt NEMA 6-15P plug. This plug will fit into a 220 volt NEMA 6-15R or 6-20R receptacle.

Lathe Model Voltage Amps PhaseAM-1340SL 220 15 Single/3phase

Power Requirements

220 Plug Configuration


Delivery & Set-Up

Taking Delivery

Here are some recommendations for taking delivery of your AutoMate machine. In some cases, you will pick up the crated machine at a trucking terminal or depot. Before picking up your machine, contact the designated terminal, ask about the loading arrangements, and arrange for timely pick-up. You may also arrange to have the machine delivered to your shop location if you have not already done so.

On arrival of the machine thoroughly check each crate and carton for signs of loss or damage.

While a shipping company employee is present, open any crate or carton that shows signs of loss or damage.

Examine the contents with the shipping company employee.

If any damage is present, record an exact, detailed description of the results of the examination on both the shipper’s and your delivery receipt. Be specific. If damage is present, it is best to document the damage even if you deem the damage as minor. Undocumented and unnoted damage will result in a denied claim.

After you have inspected the crate and signed for the machine, a shipping company employee will load your machine into your vehicle. The loading procedure depends upon your vehicle and the facilities at the terminal.

If the shipping company’s forklift is not restricted to the loading dock, you can have the crate loaded directly into the truck or trailer bed with the forklift.

Regardless of how you load the machine, always be sure to tie the load down securely so that it does not shift during transport.

NOTE: The crate is intended to protect the machine; damage to the crate does not necessarily mean that your Automate CNC machine has been damaged. However, noting any damage to the crate on the delivery receipt will make it much easier to substantiate a claim if there actually is damage.

Inspecting Your Shipment

Loading the Machine


Delivery & Set-Up

Step 5: Set the crate aside, out of the immediate work area. It’s advisable to keep the crate in the event you ever to return the machine for repair. Take note, the chip tray for your machine is packaged inside the machine’s crate cover. Remove the crate carefully in order to avoid damaging your machine or the chip tray.

*NOTE: Check the machine carefully for signs of damage, especially if you noted damage to the crate earlier. If concealed damage is found, please call Smithy at 1-800-476-4849 immediately.

*Note: Crate Top is Heavy. Ask for assistance when sliding the crate cover off the pallet, as it is quite heavy. Crate covers can weigh up to 100 pounds.

• Step 1: Cut the metal bands encircling the crate with tin snips. (Depending on the machine, there may not be metals bands encircling the crate.)

• Step 2: Using a hammer and claw remove the nails from the bottom crate cover which secure the crate cover to the pallet.

• Step 3: Once all the nails from the crate cover, have been removed. Remove the nails from one side of the crate in order to pull the side off of the crate cover.

• Step 4: After the side has been removed, and with help from an associate, tilt the crate top back off of the pallet.

Before opening the crate remove the packing list from the plastic bag attached to the crate and put the document in a safe place.

Wear leather work gloves and safety glasses for this operation, especially when cutting the metal bands, if present. These bands encircle the crate and are under tension.

Opening the Crate


Delivery & Set-Up


Delivery & Set-Up

Removing Machine from Pallet

You should use a forklift to remove the Automate CNC Lathe from the pallet. If you do not own a forklift you can rent one by the hour. Renting a forklift to handle such a heavy machine is highly recommended. It will be money well spent – both in terms of safety and efficiency. Any other lifting device you might use will create a situation where the Lathe and crate are unstable. Accidents are more likely to happen in this type of situation and this machine is very heavy. A tipped or dropped machine will

result in significant damage to the machine and to any individual located in its vicinity.

There are four bolts securing the machine to the pallet, use an adjustable wrench to remove nuts located on the machine (see picture below.) Once the nuts have been removed, the attached bolts will likely fall through. If the bolts do not fall through just tap the screws through the casting and pallet.


Delivery & Set-Up

The machine can be picked up from either the front or back. Shop floor layout will determine which method is best for your situation. Molded into the base casting are slots for forklift forks. Insert forks into base as far as they will go without hitting the electrical box or chip guard enclosure. Lift the machine only high enough to slide pallet out from underneath. As always be cautious, and try to keep sudden movements to a minimum.

Once the pallet is removed, gently lower the machine until it is a few inches off the ground. Locate the leveling screws and pads

that were shipped with the machine. Insert each screw into the base casting where you removed the nuts in previous steps. Screw each one down until the cone of the screw protrudes from the bottom of the casting. You will notice on the leveling pads that there is a machined cup used to locate the cone portion of the screw. Gently lower the machine until all four of the screws are located in the cups of the leveling pads.


Delivery & Set-Up

Several braces are installed on the machine to help keep machine stable during shipping. All braces must be removed prior to using machine.

Remove the control arm extension brace. Typically this consists of removing shrink wrap and zip ties from the piece around the control arm itself. See picture below:

Removing Shipping Support Braces


Delivery & Set-Up

There is one more brace to remove, which is located in the back of the column. This brace is a Z shaped bracket and it’s used to keep the Z axis counter weight from swinging during shipping. Remove the two SHCS that are screwed in to the counterweight itself. Take precaution not to

get anything in the way of the roller chains when counterweight is freed. Remove the remaining two SHCS from the angle bracket. Use a long T-handle allen wrench or a ratchet with long extension for removal is preferred. See photo below:

Next remove the brace that is zip tied to the ATC guide rails. See picture below:


Delivery & Set-Up

There is one more brace to remove, which is located in the back of the column. This brace is a Z shaped bracket and it’s used to keep the Z axis counter weight from swinging during shipping. Remove the two SHCS that are screwed in to the counterweight itself. Take precaution not to get anything in the way of the roller chains when counterweight is freed. Remove the remaining two SHCS from the angle bracket. Use a long T-handle allen wrench or a ratchet with long extension for removal is preferred. See photo below:

DO NOT power up your machine until you completely read and understood your machine’s safety and operations manual. If you have questions regarding safety or operation of your machine, call an Automate CNC Technician at 1-800-476-4849 or e-mail at [email protected]

This is a birds-eye view standing on a ladder. Z bracket has already been removed, but remaining screw holes can still be pictured.


Delivery & Set-Up

Leveling Machine

Adjusting machine tools so they are level is very important and have benefits that aren’t often considered. Vertical machining centers not only produce more accurate parts when properly leveled, that last longer as well. A machine tool that isn’t properly leveled isn’t lubricated evenly throughout the machine, and parts wear unevenly.

The Automate CNC Lathes are supplied with 4 leveling screws, and with leveling pads, as previously discussed. At this point we will discuss precision leveling of the CNC Lathe. When leveling machines, a few items are needed:

Machinist level (we recommend a .0005 over 10” Starett level)123 Blocks (optional)Flat polishing stone (optional)

New machines have a newly machined table surface, but these instructions apply any time you level the machine. On used machines, remove all items from table, and stone any nicks with a flat polishing stone. Position the X/Y axis and mid travel. Face the Lathe, and place the precision level parallel to the X axis (left to right).


Delivery & Set-Up

Lift one side of the level or the other until the bubble is in the middle. Note which end of the told is shown to be higher. This is the side you start on.Adjust the screws down on the side that needs to be raised. Keep equal pressure on the screws on that side. After you make an adjustment to one screw you should adjust the other so there is constant pressure on both screws. Check the level often - it doesn’t take much for the bubble to bypass the middle of the level.When the bubble is in the middle on the X

axis, rotate the level 90 degrees and adjust the Y axis in the same method as step 4.When Y axis is leveled properly, rotate the level 90 degrees again,and see if the X axis is still level. If the X axis is now out of level repeat steps 2 through 4.Check Y axis one more time and adjust accordingly.

Note: We are using 123 blocks in the pictures, but the steps are identical.


Delivery & Set-Up

Mechanical Maintenance

Maintenance Schedule Daily MaintenanceMaintaining your machine as per the schedule documented in this manual will help prolong the life of the machine and aid in the production of precision work pieces. It should be noted that the maintenance schedules listed herein, are intended to be used as a guide. The environment and working conditions of your shop should be taken into consideration.

Perform these maintenance tasks at the beginning and at the end of work.

Area Of Maintenance Maintenance Task How OftenLubrication System Check for proper oil level

Check for distribution film of oil on all sliding surfaces Check for leaks

At the start of work

Coolant Level (Optional)

Check for proper coolant level At the start of work

Machine Work Area Check for leakage and cleanliness At the start & end of work

Cleaning Clean the work holding devicesClean guardsClean machineClean trays

At the start & end of work

External Wiring & Cables

Check fit of cable connectionsCheck for damaged cable


Machine General Condition

Check entire machine for loose or miss-ing fasteners


Spindle Clean the spindle taper At the start of work


Delivery & Set-Up

Periodic Maintenance

Perform these maintenance tasks as per the schedule below.

Mechanical Mainte-nance

Maintenance Task How Often

Axes Backlash Check and compensate of neces-sary

6 months

Ball Screw Guards Check condition 6 months or replace as necessary

Drive Belt Check conditionCheck tension

6 months or replace as necessary

Machine Base/Table Check for level & mounting bolt loosening

6 months

Electrical Mainte-nance

Maintenance Task How Often

Electrical Cabinets Check for cleanlinessCheck & secure any loose connec-tions

3 months

Electrical Elements Check for proper working of push button switches

3 months

Proximity Switches Check for proper operations 3 months

Motors Check for condition & testing 1 month

*Additional instructions given.


Delivery & Set-Up

Lubrication System & Machine Lubrication

Ball Screws and Guide Ways Headstock & Spindle Bearings

This section covers the lubrication of your machine. There are two primary areas of lubrication: areas lubricated by the automatic lube system and the life greased bearings.

Remember, proper lubrication is very important. It greatly affects the performance and longevity of your machine. If the machine is operated without supplying the lubricating oil, it will cause seizure of the

sliding surfaces. Before operating, visually inspect the oil on the actual machine surfaces.

Use only recommended lubrication oils which are clean and free from foreign matter. Periodically clean the tank and strainers/filters, if provided, inspect the equipment’s functioning or lube supply pipes for damaged to ensure optimum machine operation.

The ball screws, linear guide ways and dovetail slides are lubricated by the automatic lubrication system. Follow the lubrication schedule in table 6.1. Follow the lube pump instructions on setting the timing. The amount of oil required will depend on your shop environment.

A thin layer of lubrication should be present on the slides at all times.

The bearings are of a precision class of accuracy. The spindle bearings are lubricated for life with high grade grease, such as Kluber Isoflex NBU-15. This grease maintains its lubrication properties at both low and high temperatures (-70ºF to 120ºF). There is no necessary lubrication to these bearings.

If the spindle starts making abnormal noises or gets very warm above (120ºF), check for damage of the spindle bearings after stopping the machine completely. The spindle should be warmed up for approximately 15-20 minutes when the machine has been stopped for a long period (for example 5 or more days).

Lubricating Points Lubricating System & Recommended Oil Grade

Quantity

Headstock Bearings GreaseKluber Isoflex BU-15

Life Grease

Ballscrews & Guide ways

Automatic lube systemMobil-1-Vactra #2

1 Liter

Ball screwBearings

GreaseKluber Isoflex NBU-15

Life Grease


Delivery & Set-Up

Axis Bearing Adjustment/Axis Backlash

Linear Motion Guide & Bearing Maintenance

Backlash is the amount of movement the screw makes before the table engages. There are a number of signs that may indicate that there is excessive backlash with your system:

• Rough/uneven surface finishes• Dimension inaccuracies• Table shakes under machining force

Even if none of these signs are present, it is recommended to check for backlash compensation every 3-6 months depending on your usage of the machine. Please note: Siemens 808d software has provisions for compensating for backlash within the program. This section of the manual is addressing mechanical backlash compensation. There are three main

mechanical reasons for backlash:

1. Pre-loaded ball nut is damaged and is causing axial play between the nut and the screw. If the ball nut is damage, the only solution to this is to replace the balls crew and ball nut assembly.

2. The end support bearings are damaged. If you find that the end bearings are damaged, follow the procedure below for replacing the bearings.

3. The ball nut mounting screws are loose. Tighten the bolts and make sure the bolts or housing threads are not damaged before tightening.

4. The end bearing tightening nut is loose.

Unlike dovetail guide ways, linear motion guides are free from wear. It requires neither adjustment of the gibs due to uneven wear nor maintenance to restore the original accuracy. Linear guides use a forced lubrication system to provide and maintain a uniform film over moving parts. This not only prevents smoother motion, it assures less maintenance than other systems. Linear guide ways require constant lubrication in a very small quantity, all handled effortlessly through the automatic oiler. There are no adjustments required for such bearings and guides.

Make sure the linear bearings are not splashed with coolant directly since the lubricant may be contaminated and compromised if it comes in contact with coolant. Coolant may wash off or emulsify the lubricant; thereby, significantly degrading lubrication’s performance. One sign of such case is the increased noise when the Z-Axis slide moves up and down at high speed. Make sure lubrication supply is present by checking the ends of the lubrication supply pippin for the proper oil flow.

Periodic Maintenance Tasks


Delivery & Set-Up

Powering up the machine

Powering down the machine

Machine Home Position (808D basic only)

1. Once power has been hooked up by a qualified technician, close the door on the electrical box located at the rear of the machine. This will prevent metal swarf, water, oil, and dust from contaminating electrical components.

2. Turn on the power switch, which is located on the back of control/electrical box on the rear of machine.

3. Turn the key to “Lock” on the front of the operators control unit.

4. Make sure the emergency switches located on the front of the control unit are not depressed.

5. Push the start button on the front of the control unit.

You should hear relays pull in the back of the machine as well as see the Siemens control unit start up. If you do not see activity on the display, check for proper power being fed into the electrical box.

1. Release the “Emergency Stop” button located on the front of the control unit

2. Press the “Power” button on the control unit

3. Turn the switch on the back of machine to off

When a machine home position is requested, axis(s) are moved in the positive direction until home limit switches are reached. The machine needs to reference itself from a known point on the machine, in our case, the limit switches. This allows

work and tool offsets possible. To home the machine, make sure the control has “Ref. Point” select, and push the directional button for the axis you would like to move. See picture below:

Machine Operation – Quick Start Guide


Delivery & Set-Up

Keyboard Layout

A. Horizontal Soft KeysB. Vertical Soft KeysC. Alpha Keypad D. Numeric KeypadE. Navigation/Help keypadF. Programming keypad


Delivery & Set-Up

Tool Mounting and HoldingDuring machining operations cutters are mounted in a tool holder which is drawn into the spindle by an automatic drawbar system. The Automate CNC Lathes use industry standard BT-30 tool holders, shown below:


Delivery & Set-Up

Tool Holding Options

Installing the Tooling

There is an enormous variety of BT30 tooling available on the market. Being as its one of the most popular tapers on the market, tooling can be sourced at most machine tool accessory suppliers . Below are just a few examples.

Arbors come in different sizes and lengths with one end tapered to suit the inside spindle taper, in the case of the Automate CNC Lathe, an BT-30 taper is required. The term arbor is used for a general work holding device. Arbors can mount drill chucks, slitting saws, gear cutters and shell end Lathes. An arbor is secured in place with the drawbar system.

Collets (Spring Collets) are the most commonly used work holding device. They come in a variety of styles and sizes. They are bored to hold a specific diameter. As the collet is drawn into the spindle of the machine, the spring collet “closes” or “clamps” down on the tool securing it in place.

End Lathe Adapters are made specifically to hold end Lathes. Like arbors they come in different sizes with one end tapered to fit the inside spindle taper. End Lathe adapters are bored to a specific size to hold end Lathes with a corresponding shank size. End Lathes are secured in the adapter by friction and a set screw clamps down on the flat of the end Lathe for extra security.

Once you have determined the appropriate tooling for your operation, you will need to secure it in the Lathe spindle and eventually the ATC changer via the automatic drawbar system.

Step 1: Press the K11 button on the control panel. (K11 is a safety relay that allows the power drawbar to operate.)

Step 2. Press the “Machine” button on the operator control panel, then press the “TSM” horizontal soft key.

Step 2: Hold the tool with the pull stud as high as it will go into the spindle.

Step 3: Press and hold the tool release button on the front of the spindle. You will feel the tool advance further into the

spindle as well as here the power drawbar actuating.

Step 4: Line up the slots in the tool holder with the tangs on the spindle nose.

Step 5: Release the drawbar button, tool should now be tight in the spindle with tool properly oriented and ready for operation.


Delivery & Set-Up


Diagram & Parts

Diagrams and Parts


Diagram & Parts

CJK6132-00 BED ASSEMBLY


Diagram & Parts

CJK6132-00 BED ASSEMBLY

Ref.No Manufactuer’s No. Description Qty1 CK6132-02-000 Headstock assembly 12 CK0632-06-001 Carriage assembly3 CK0632-06-000 Tailstock assembly 14 CK6132-00-027 Adjusting pad 15 GB/T95-85 Gacket 8 36 GB/T93-87 Spring washer 8 37 GB/T70-85 Socket head cap screw M8*35 78 CK6132-00-056 Groove plate B 19 CK6132-00-060 Groove plate A 110 GB/T70-85 Socket head cap screw M5*20 411 GB/T77-2000 Socket head cap headless set screw M4*10 812 CK6132-00-017 Locking block 313 CK6132-00-059 Position limiting block B 114 CK6132-00-065 Position limiting block A 215 GB/T70-85 Socket head cap screw M5*10 316 CK6132-00-002 Supporting seat of Z axis motor Z 117 GB/T70-85 Socket head cap screw M6*25 818 GB/T70-85 Socket head cap screw M8*30 419 CK6132-00-003 Cover board 120 GB/T818-2000 Cross recessed pan head screws M4*6 421 CK6132-00-043 Lead-screw seat of Z axis Z 122 GB/T70-85 Socket head cap screw M8*25 223 GB/T117-2000 Taper pin 6*40 224 CK6132-00-008 Balls-crew of Z axis( set) Z 125 GB/T1096-79 Round head normal flat key(A type) 6*20 126 ROTEX-GS None backlash elastic coupling L66 127 GB/T 292-94 Angular contact ball bearing 7205AC 228 CK6132-00-006 Spacer A(inside) 129 CK6132-00-007 Spacer A(outside) 130 CK6132-00-004 End cover A 131 GB/T70-85 Socket head cap screw M6*16 332 CK6132-00-005 Spacer A 133 GB/T810-86 Small round nut M24*1.5 234 GB/T 276-94 Bearing 6004-2Z(Double sided with dust-proof

cover) 1

35 CK6132-00-019 Spacer B 136 CK6132-00-047 Sleeve 137 GB/T819-85 Cross recessed countersunk head screw fixed

M5*83

38 GB/T810-86 Small round nut M20*1.5 2


Diagram & Parts

Ref.No Manufactuer’s No. Description Qty39 CK6132-00-009 Bed 140 CZ1340G-01T06-005 Sealing gaske(front stand) 141 CZ1340G-01T06-016 Sealing gaske(back stand) 142 GB/T5780-2000 hexagon bolt M12*65 643 GB/T95-85 Washer 12 644 GB/T93-87 Spring washer 12 645 GB/T41-2000 Hexagon nut M12 646 CK6132-00-014 Stand 147 CK6132-00-045 Supporting board for motor seat 148 GB/T95-85 Washer 6 449 GB/T93-87 Spring washer 6 450 GB/T70-85 Socket head cap screw M8*20 1551 CK6132-00-073 Seat of motor shaft 152 CZ1340G-01T07-006 Motor seat 153 CK6132-00-050 Shaft 254 CZ1340G-01T07-007 Adjusting screw arbor 155 GB/T70-85 Socket head cap screw M8*14 456 GB/T5287-85 Super big washer 12 257 GB/T41-2000 Hexagon nut M12 258 CK6132-00-001 Motor pulley 159 B3 机机100# Frequency main motor 2.2KW 1


Diagram & Parts


Diagram & Parts

SADDLE&TOOLPOST ASSEMBLY


Diagram & Parts

Ref.No Manufactuer’s No. Description Qty1 LDB4-51机0625机 4 electric stations 12 CK6132-00-058 Height adjusting block for tool-post 13 CK6132-00-011 Upper saddle 14 GB/T833-88 Slotted large cheese head screws M5*24 25 CZ1340G-05-031 Gib of big saddle 16 GB/T70-85 Socket head cap screw M5*22 107 GB/T117-2000 Taper pin 5*30 28 CK6132-00-035 Washer 19 CK6132-00-034 Leadscrew nut seat of X axis 110 GB/T70-85 Socket head cap screw M5*16 311 CK6132-00-012 End cover B 112 GB/T 276-94 Deep groove ball bearing 6201-2Z 113 CK6132-00-032 Ball-screw of X axis 114 GB/T1096-79 Normal flat key(A type) 4*16 115 GB/T 292-94 Angular contact ball bearing 7002AC 216 CK6132-00-030 Separating ring B(outside) 117 CK6132-00-029 Separating ring B(inside) 118 CK6132-00-025 End cover 119 GB/T70-85 Socket head cap screw M5*16 320 CK6132-00-033 Separating ring 121 CK6132-00-024 Timing pulley B 122 GB/T78-2000 Socket head cap screw M4*10 423 GB/T810-86 Small round nut M12*1.25 224 CK6132-00-013 Big saddle 125 GB/T70-85 Socket head cap screw M18*25 926 GB/T117-2000 Taper pin 6*30 427 CK6132-00-031 Lead-screw seat of X axis 128 CK6132-00-044 Motor seat of X axis 129 CK6132-00-023 Timing pulley A 130 L285-5M-19 Timing belt 131 CK6132-00-061 Groove plate 132 CK6132-00-065 Position limiting block A 233 CK6132-00-059 Position limiting block B 134 CK6132-00-017 Locking block 335 GB/T70-85 Socket head cap screw M5*12 236 GB/T70-85 Socket head cap screw M5*10 337 CZ1340G-05-006 Scrape A 238 CZ1340G-05-007 Scrape B 239 CZ1340G-05-012 Scrape C 2

SADDLE&TOOLPOST ASSEMBLY


Diagram & Parts

Ref.No Manufactuer’s No. Description Qty40 CZ1340G-05-014 Scrape D 241 GB/T823-85 Socket head cap screw M4*12 842 CZ1340G-05-005 Gib 243 CZ1340G-05-004 Pressing strip 144 GB/T78-2000 Socket head cap screw M6*16 445 GB/T41-2000 Hexagon nut M6 446 GB/T5781-86 Hexagon bolt M8*25 347 CZ1340G-05-013 Pressing block 248 GB/T5781-86 Hexagon bolt M8*20 449 CK6132-00-010 Connecting seat for saddle 150 CK6132-00-037 Nut seat of Z axis 1


Diagram & Parts


Diagram & Parts

HEADSTOCK ASSEMBLY


Diagram & Parts

HEADSTOCK ASSEMBLYRef.No Manufactuer’s No. Description Qty1 CK6132-02A-002 Spindle pulley 12 GB/T1096 Key 8*56 13 A Tri-angle belt A1895 34 CK6132-02A-004 Timing pulley A 15 CK6132-02A-005 Rear cover 16 GB819-85 Cross recessed countersunk head

screw fixed M6*12 4

7 CK6132-02A-006 Rubber pad A 18 CK6132-02A-007A Spacer A 19 GB/T297 Circular cone roller bearings 30211/

P5 1

10 CK6132-02A-008 Bearing seat 111 CM-1224C-03-034 Oil hole cover 112 GB/T 301-199 Ball thrust bearing 113 CK6132-02A-009 Stop ring 114 CK6132-02A-010 Oil thrower 115 GB/T71-85 Set screw M6*10 116 GB/T1096 Key 8*28 117 CZ1340G-02-007 Headstock cover 118 GB70-85 Socket head cap screw M6*20 419 CZ1340G-02-008 Rubber pad 120 GB/T810 Round nut M68*2 221 GB893.1-86 Internal stop ring 110 122 CK6132-02A-011 Sapcer B 123 GB/T 285-94 Double row cylindrical roller bearing

NN3014K/P5 1

24 CK6132-02A-012 Front cover 125 GB70-85 Socket head cap screw M6*35 426 CK6132-02A-013 Rubber washer 127 GB70-85 Socket head cap screw M8*25 428 CK6132-02A-014 Headstock 129 CK6132-02A-015A Spindle 130 GB/T41 Hexagon nut M8 231 GB/T5781 Hexagon bolt M8*40 232 CZ1340G-02-056 Adjusting pad 133 GB/T70 Socket head cap screw M10*25 434 GB/T70 Socket head cap screw M10*40 435 GB/T93 Spring gasket 436 GB/T97.1 Flat washer 10 437 GB/T5780 Hexagon screw M12*20 1


Diagram & Parts

Ref.No Manufactuer’s No. Description Qty38 GB3452.1 O ring 11.8*2.65 139 CK6132-02A-019 Supporting column 240 CK6132-02A-017 Timing pulley B 141 GB/T77-85 Socket head cap set screw M6*12 242 A Timing belt L570-5M(wide 9) 143 GB/T70 Socket head cap screw M5*16 444 CK6132-02A-020 Supporting board 145 GB/T97.1 Flat washer 10 246 GB/T70 Socket head cap screw M10*70 247 CK6132-02A-022 Axle shaft 148 GB/T 276-94 Deep groove ball bearing 249 CK6132-02A-023 Spacer 150 CK6132B-20-023 Spacer 151 GB894.1-86 Stop ring 30 152 CK6132-02A-021 Bearing seat 153 GB893.1-86 Stop ring 47 154 GB/T1160.2 Screw-in oil cup A20 1


Diagram & Parts


Diagram & Parts

TAILSTOCK ASSEMBLY


Diagram & Parts

Ref.No Manufactuer’s No. Description Qty1 CK6132-06A-001 Tailstock 12 GB1155-75 Oil cup 8 33 CK6132-06A-002 Tailstock quill 14 CK6132-06A-004 Tailstock lead-screw 15 CZ1340G-06-017 Locking shaft 16 CZ1340G-06-018 Eccentric bushing 17 CZ1340G-06-004A Lead-screw nuts 18 GB/T70-85 M4*12 Socket head cap screw M4*12 39 GB/T301-1995 Bearing 51102 110 CK6132-06A-003 Lead-screw seat 111 GB/T70-85 M6*16 Socket head cap screw M6*6 412 CZ1340G-06-006 Graduation ring 机机机 113 GB/T77-2000 M6*10 Socket head cap headless set screw M6*10 114 GB/T1096-1979 Flat key 4*16 115 CZ1340G-06-008 Gasket 116 CZ1340G-06-009 Adjusting screw 117 GB/T78-2000 M5*20 Socket head cap taper set screw M5*20 118 CZ1340G-06-007 Handle wheel 119 CZ1340G-06-010 Handle sleeve 120 CZ1340G-06-011 Bolt of handle 121 CZ1340G-06-012 Long handle 122 JB/T7271.5-1994 Long handle sleeve BM10*50 123 CZ1340G-06-013 Handle 124 JB/T7271.5-1994 Handle sleeve BM8*40 125 CZ1340G-06-014 Stop pin 226 CK6132-06A-007 Locking bolt 127 CZ1340G-06-019 Fixing shaft 128 GB/T879-1986 Spring 129 CK6132-06A-006 Locking block 130 GB/T95-1985 Flat washer 12 131 GB/T41-1986 Hexagon nut M12 132 CZ1340G-06-021 Tailstock fixing block 133 GB/T79-2000 M10*40 Screw M10*40 334 GB/T79-2000 M8*14 Screw M8*14 135 CK6132-06A-005 Tailstock base plate 1

TAILSTOCK ASSEMBLY


Circuits


Circuits

Circuit Diagrams


Circuits

Transformer Circuit


Circuits

Strong Return Circuit


Circuits

Simple Frequency Conversion Circuit


Circuits

Servo Driver Circuit


Circuits

F. Servo Driver Circuit


Circuits

I/O Input Circuit


CircuitsHandwheel Connection Circuit


CircuitsCNC Circuit


Circuits

I/O Output Circuit


Circuits

I/O Celerity Input And Output Circuit


Circuits

AC Control Circuit


Circuits

6 Position Electrical Toolpost


Circuits

4 Position Electrical Toolpost


Circuits

System Return Circuit


Circuits

AC Control Return Circuit


Circuits

Transformer Circuit


Circuits

Strong Electrical Circuit


Circuits

www.automateCNC.com | 800-476-4849 | 170 Aprill Drive | Ann Arbor, Michigan 48103 | USA

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