Bakim Kilavuzu

8/14/2019 Bakim Kilavuzu

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4 REGULAR INSPECTION AND MAINTENANCE

4-4

4-3 Maintenance/Inspection Items

4-3-1 List of maintenance/inspection items

The following list explains the check items and intervals. Carry out the routine inspection on the

basis of this list.

Inspection positions and corresponding numbers are given further down the list in the illustration.

Refer to the list and the illustration together.

Table 4-1 List of maintenance/inspection items

Period of inspection

Number of months

of operationNo. Inspection point Inspection item

Reference

sections

in this

manualDaily Weekly

1 3 6 12 24

1 GeneralArranging the machine periphery in order, cleaning the

machine and its periphery (especially, the floor)!

Checking the chuck unit and its periphery to scan for chips !

Checking for secure mounting of the top jaws !

Checking for smooth chucking/unchucking !

Greasing the chuck unit (before operation) !

Disassembling and Cleaning the chuck !

Removing any chips from the coolant collector !

2 Headstock

Cleaning the draining holes underneath the spindle

front-end cover

5-1, 7-2-1,

7-2-2

!

Checking the tailstock spindle to scan for chips !

Checking the tailstock body for smooth forward/backward

movement

!

Greasing the linear guide blocks !

Greasing the ball screw !

3 Tailstock

Removing chips sticking to the sheet metal sections on the

periphery of the tailstock body

5-5, 7-2-7

!

Checking for secure mounting of the cutting tools and the

holder!

Checking the turret and the cutting tools to scan for chips !4 Turret

Checking for tension etc. of milling spindle belt

5-2, 5-4,

7-2-3,

7-2-5

!

Wiping away the grease stuck to the tip of the linear guide !5 X-axis, Z-axis

Checking the backlush of X- and Z-axis

5-4, 7-2-5,

7-2-6 !

Cleaning the sensor section and removing any chips !6

TOOL EYE

(Option) Checking for sounds of reaction during sensor contact5-3, 7-2-4

!

Checking the oil levels, and if necessary, refilling !7

Grease

lubrication unit Checking for oil leakage and for damaged piping

4-4, 5-7,

7-2-9 !

Checking the oil levels, and if necessary, refilling !

Cleaning the oil supply fitler !8Oil lubrication

unit

Checking for oil leakage and for damaged piping

4-4, 5-7,

7-2-10

!


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REGULAR INSPECTION AND MAINTENANCE 4

4-5


Number of months


Reference

sections

in this

manualDaily Weekly

1 3 6 12 24

Checking for appropriate pressure !

Checking the oil levels, and if necessary, refilling !

Cleaning the strainers !

Replacing the hydraulic oil !

Checking for oil leakage and for damaged piping !

9 Hydraulic unit

Checking the line filter element, and if necessary, replacing

4-4, 5-6,

7-2-8

!

Checking the coolant levels, and if necessary, refilling !

Cleaning the radiator !

Cleaning the radiator fan !10

Headstock

cooling unit

Replacing the coolant

4-4, 5-10,

7-2-13

!

Checking the coolant levels, and if necessary, refilling !

Checking the degree of dirtiness of the filters and cleaning !

Checking the degree of dirtiness of the coolant and if

necessary, replacing!11 Coolant unit

Cleaning up the chips

(Side-pullout chip conveyor specifications)

5-8,

7-2-11,

!

Checking the element and if necessary, replacing !12 Air unit

Checking the air pressure

5-9,

7-2-12 !

Checking if the door is fully closed !

Checking the electrical components for dirt and

discoloration and checking for loose terminal screws!

Cleaning inside and outside fans of the electrical control

cabinet

!

13Electrical control

cabinet

Checking the degree of dirtiness of the filters and cleaning

5-10-2,

5-16-2,

5-16-4

!

Checking for loose connector/terminals between units ! 14 Connectors

Checking the electric cables6-2-4, 6-3

!

15 Foundation Checking and adjusting the bed level using a level 6-2-4 !

16Grounding

resistance

Checking for a grounding resistance of 10 ohms or less

(use a 500 V megger)

6-1-2,

6-3-2!

Checking the wipers for abnormalities such as damage !

17Slideway and

covers Checking the front door safety glass for abnormalities such

as damage

5-12,

5-16-5,

5-16-6,

7-2-14!

18Machine internal

covers

Checking for the accumulation of chips, and if necessary,cleaning

(Operator door circumference, cover for the lower part of

the headstock, cover for the upper part of the turret, cover

for the lower part of the turret, Z axis way cover, tail axis

rear cover)

4-3, 5-5-5,

5-11-4,

5-12

!

Cleaning the chips on the steady-rest-roller and connect

pins!

Confirming whether the steady rest arm operates smoothly !

Cleaning the chips accumulated around the steady rest !

Greasing the linear guide blocks !

19 Steady rest

Checking the wipers in the duct for abnormalities such as

damage

5-11

!


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4-6


Number of months


Reference

sections

in this

manualDaily Weekly

1 3 6 12 24

Checking for secure mounting of cutting tools and milling

holders

5-13-1 !

Checking the turret, milling holders and the cutting tools to

scan for chips5-13-2 !

Checking for entry of coolant into milling holder 5-13-3 !

20 Milling holder

Checking for looseness of eccentric pin mounting bolts5-13-4,

5-13-5!

Belt tension adjustment 5-14-1 !

21

Automatic

operator door

opening/closing Checking the safety switch and if necessary, replacing 5-14-4 !

Checking the degree of dirtiness of the oil pan filter and

cleaning!

22

Coolant

temperature

control Checking and cleaning the chiller unit air filter

5-15-2

!

23 Battery unit Replacing the batteries in the battery unit 5-16-2 !

Note 1: Maintenance check intervals are determined on the basis of eight hours operation a

day.

Note 2: Actual inspection intervals differ according to the particular operating conditions of the

machine and frequency of use. Understand that the listed values are for reference

only.


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4-7

4-3-2 Points of inspection items

Fig. 4-2 Inspection point of machine (1/3)


11 13

7

12

8 9

2

3

410

6

19


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4-8


21


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4-9

Fig. 4-5 Cleaning sections of the machine internal covers

Cover to fillthe gap

When cleaning this part, remove the coverused to fill the gap (Refer to the figure above)and while the door is closed, shove the chips tothe inner side of the machine with a brush.


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4-10

4-4 Supplying Oil and Coolant

1. Lubrication points

CAUTION

! When supplying or exchanging coolant, hydraulic oil and lubricating oil, use only oil

brands recommended by MAZAK. Use of another brand of oil will cause machine

malfunction and will damage the machine.

Use the appropriate amount of the recommended brand of oil when adding or changing oil.

A. Hydraulic unit

Fig. 4-6 Lubrication points (1/7)


1

3 24 5

6

5


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4-11

B. Headstock cooling unit/Chuck


C. Ball screw & Slideway (Tailstock) grease lubrication unit


10

9

11

8 7

7


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4-12

D. Slideway (Steady Rest: Option)


E. Grease lubrication unit


8

6


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4-13

F. Oil lubrication unit


2. List of oil and water supply

Table 4-2 Oil and water supply

No. Part name Lubrication point Qty Recommended oil Remarks Refer to

1 Oil filler port

2 Level gauge

3 Strainer

4 Drain plug

5 Line filter

Hydraulic unit 20 L" MOBIL DTE 24

" SHELL TELLUS OIL 32

Exchange oil every

6 months, then

clean the strainer.

Replace the line

filter element every

6 months.

5-6

6 Cartridge Ball screw &slideway

400 mLCartridge

Automatic

lubrication.

Supply occasionally.

7Grease

supply nipple

Ball screw &

Slideway

(Tailstock)

28 mL

8Grease

supply nipple

Slideway

(Steady Rest)12 mL

" Citrax EP No. 1

(Kyodo Yushi) Manual Lubrication

Supply every 6

months.

5-7

9 Tank

10 Oil filler port

Headstock cooling

unit5.0 L

" Distilled water or ion

exchanged water: 50%

LONG LIFE COOLANT

YZ (MOBIL)*: 50%

" MACHINE TOOL LONG

LIFE COOLANT

(MOBIL)

Exchange coolant

every 2 years.

Follow the

procedure outlined

in the Maintenance

Manual.

5-10

11Grease

supply nippleChuck 1 to 2 mL

" Klueberpaste ME 31-52

(KLUEBER

LUBRICATION)

Every day 5-1-2

12 Oil filler port

13 Level gauge

14 Suction filter

C-axis brake

(Milling machine)

Turret index gear

(Oil lubrication

unit)

1.8 L

" MOBIL VACTRA OIL

No. 2

" SHELL TONNA OIL

S68

Automatic

lubrication.

Supply occasionally.

Clean the filter

every year.

5-7-3,

7-2-10

* LONG LIFE COOLANT YZ is a special brand for Yamazaki Mazak.

Note: The replacement period is determined on the basis of eight hours operation a day.Delayed replacement or use of any product other than recommended oil may damage

the machine.

14

1213


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4-14

4-5 Processing of the Lubricant Collection Tube

After lubrication of the turret rotation gear and the C-axis brake, the oil accumulates in the oil

sump in the center of this machine on its rear side and is discharged through the tube.

Waste oil is collected in the attached waste oil can.

Fig. 4-13 Processing of the lubricant collection tube

Waste oil collectiontube

Waste oil can(Standard accessories)

E

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