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SERIES VERTICAL DRILLING MACHINE

OPERATION MANUAL

Factory No.

NINGXIA DAHE NC MACHINE TOOL Co. LTD.


THE PEOPLES REPUBLIC OF CHINA

Contents

Introduction....3
Safety precautions......4
Technical data....6
Usage specification of the machine....8
1. Transportation and installation...8
2. Operation..13
3. Transmission system.18
4. Adjustment of the machine...29
5. Machine lubrication..29
6. Bearings used in the machine31
7. Machine electrical system.37
Machine maintenance and fault eliminating....63
1. Machine maintenance 63
2. Machine fault eliminating63
Machine damageable part list and drawing. 64
1. Damageable parts list64
2. Damageable part drawings65

Page 2 of 80

Introduction
The product series of vertical drilling machine tool in DAHE Co. includes
Z5125A, Z5132A, Z5140A, Z5150A, Z5163C, Z5180C etc. Among them, Z5125A,
Z5132A, Z5140A and Z5150A are universal general purpose machine with squarecolume, Z5163C and Z5180C are semi-automatic vertical drilling machine developed
by the company with square-colume and new structure avoiding disadvantages of old
type. Their drilling capacities were tested in steel with tensile strength b=500-600
MPa and shown in following table:
Type
Max
drilling
dia (mm)

Z5125A
25

Z5132A
32

Z5140A
40

Z5150A
50

Z5163C
63

Z5180C
80

All the machines can be used for drilling, counterboring, counter-sinking, spotfacing and tapping etc and also be used for boring with a fixture.
With advantages of high efficiency, large motive power, high accuracy, fine
rigidity, wide speed range, centralized controls, good looking appearance, easy
maintenance and operation, these machines are not only suitable for small batch
production shops but also suitable for volume batch production shops.
Machine appearance is shown in fig 1-1

Fig. 1-1

Page 3 of 80

Safety Precautions
1. When lifting the machine with a crane, a iron bar which diameter is not less than
30mm must be used and the bar length protruding from each side should not be
shorter than 300mm. And softwood or felt pad must be put between steel wire
rope and the machine surface.
2. Before elevating or dropping the spindle box, panel clamping screws 16 or 20
must be loosed (different machine type need to refer fig 3-6 or fig 3-7 ).
3. The speed changing operation is forbidden when the machine spindle is running,
otherwise transporting gears will be damaged.
4. To touch the spindle with hand is forbidden before it stopped completely, or else
operator will be injured.
5. Safety measure must be adopted to avoid the operator is injured by splashed scrap
iron when the machine is cutting.
6. The spindle must move to original position before to remove cutting tool with a
wedge.
7. The handle position is correct or not must be checked before turn on the machine.
8. The power must be turn off when to clean or to maintain the machine.
9. Let the machine to run unloading with a speed from lower, middle to higher for
several minutes if it is used for first time or reused after long time.
10. Cutting parameters can be selected according following table.

Table. 1-1 Z5125A Z5132A


Workpiece material
Process
Cutting parameters
Dia.(mm)

steelb =500-600MPa
Drilling

iron HB=200

Tapping

Drilling

Tapping

1250

0.11

315

2000

0.11

500

10

800

0.11

200

1250

0.16

315

20

315

0.224

125

500

0.224

125

25

200

0.315

315

0.315

32

125

0.16

200

0.315

Note: 1. n----spindle speed(r/min)


f----feed (mm/r)
2. Using a lesser parameter than that given in table 1-1 if the machine run under
a heavy load status.

Page 4 of 80

Table. 1-2 Z5140A Z5150A


Workpiece material

steelb =500-600MPa

Process

Drilling

Cutting parameters
Dia.(mm)

iron HB=200

Tapping

Drilling

Tapping

1400

0.11

355

1400

0.11

500

10

710

0.11

250

1000

0.224

355

20

355

0.224

125

500

0.315

180

25

250

0.315

125

355

0.45

125

32

180

0.224

90

250

0.315

90

40

180

0.224

180

0.315

50

125

0.11

125

0.224

Note: 1. n----spindle speed(r/min)


f----feed (mm/r)
2. Using a lesser parameter than that given in table 1-1 if the machine run under
a heavy load status.

Table. 1-3 Z5163C Z5180C


Workpiece material

Max dia.
(mm)

Iron

43

Steel b =520-700MPa

48

Steel b =700-900MPa

48

Steel

1100MPa

48

=1000-

Cutting
tool
material
High
speed
steel

Spindle
speed
(r/min)

Feed
(mm/r)

82

0.27

82

0.40

105

0.40

105

0.27

Note: The cutting tool must be knife-edged if drilling with the max diameter
according to parameters given in table 1-3, otherwise the machine will be
damaged easily.

Page 5 of 80

Technical data
Table 2-1
Unit

Z5125A

Z5132A

Z5140A

mm

25

32

40

9000

9000

16000

Max permissible
spindle toque

Nm

160

160

350

Power of main motor

KW

2.2

2.2

Tapper of spindle hole

MO

Distance between
spindle axis and guide
surface

mm

280

280

335

Spindle travel

mm

200

200

250

Spindle box travel

mm

200

200

200

Working table travel

mm

310

310

300

Working table area

mm

400550

400550

480560

Width of T-solt on the


working table

mm

14

14

18

Max distance between


spindle head face and
table face

mm

710

710

750

Power of cooling
pump

KW

0.09

0.09

0.09

L/min

25

25

25

Overall dimension
LWH

mm

9608002290

9608002290

10909002530

Machine net weight

Kg

950/1200

950/1200

1250/1500

Max drilling dia.


Max feed resistance

Flow rate of cooling


pump

Page 6 of 80

Spindle speed

r/min

50-2000 (9
steps

50-2000 (9
steps

31.5-1400
12 steps

mm/rev

0.056-1.80
9 steps

0.056-1.80
9 steps

0.056-1.80 9
steps

Unit

Z5150A

Z5163C

Z5180C

mm

50

63

80

16000

30000

30000

Max permissible
spindle toque

Nm

350

800

800

Power of main motor

KW

5.5

5.5

Tapper of spindle hole

MO

Distance between
spindle axis and guide
surface

mm

335

375

375

Spindle travel

mm

250

250

250

Spindle box travel

mm

200

250

250

Working table travel

mm

300

300

300

Working table area

mm

480560

650550

650550

Width of T-solt on the


working table

mm

18

22

22

Max distance between


spindle head face and
table face

mm

750

850

850

Power of cooling
pump

KW

0.09

0.12

0.12

L/min

25

50

50

Overall dimension
LWH

mm

10909002530

986014702800

986014702800

Machine net weight

Kg

1250/1500

2500/2800

2500/2800

r/min

31.5-1400
12 steps

40-570 (9
steps

40-570
(9
steps

Feed

Table 2-1 continued

Max drilling dia.


Max feed resistance

Flow rate of cooling


pump

Spindle speed

Page 7 of 80

Feed

mm/rev

0.056-1.80
9 steps

0.11-0.78 6
steps

0.11-0.78
6 steps

Usage specification of the machine


1. Transportation and installation
(1) Transportation
During transporting the machine, the ropes should be tied as position signed on the
packing case. Upside, sidewise positions and excessive inclination are forbidden.
Heavy impact and shock would not permit. By means of inclined plane for loading or
unloading, Max inclination angle should not be greater than 15.
Unpacking, firstly open top plate, then side ones. Be sure not to insert crowbar to
much in order to prevent the machine from hit.
After unpacking, the machine should be transported by swinging with iron bar
and steel wire according to fig. 3-1. The iron bars diameter is not less than 30mm and
the bars length protruding from each side should not be shorter than 300mm. And
softwood or felt pad must be put between steel wire rope and the machine surface.

Page 8 of 80

Fig .3-1 machine swinging

(2) Installation
Before installing, the foundation should be prepared well according to fig.3-2,
fig.3-3 or fig.3-4. Neither gaps nor crack should appear in the foundation after
concrete solidification. During pouring cement mortar, corresponding to different
machine, 4 foundation bolt holes with sectional surface 100100mm and depth
240mm, or 150150mm and depth 350mm, and 1 pit with sectional diameter 80mm
and depth 80mm, or diameter 100mm and depth 80mm, or diameter 120mm and
depth 100mm should be provided according to the shown positions in fig.3-2, fig.3-3
or fig.3-4 respectively. The pit is prepared for stretching out the elevating lead-screw
from the base when the work-table is dropped to lowest position.
During installing, please put 4 iron wedges with width 60-80mm and an angle
less than 5 near foundation bolts and put the machine on iron wedges with
foundation bolt into bolt hole. Before pouring cement into foundation bolt holes, level
the machine lengthwise and crosswise by means of a level. After cement has been
Page 9 of 80

solidified, tighten the bolt nuts slowly and evenly sothat the machine leveling error is
not greater than 0.04/1000.
Connecting the electric power supply and the earth wire, wipe off the grease,
dust and other contaminations etc with a clean rag dipped in kerosene. Coat lubricant
on the machine surface. Fill machine oil No.20 into spindle box, then a trial run can
be made.

850

540
1150

determined by soil depth

205

base profile

905

100x100
iron pad

Fig. 3-2 Foundation plan for Z5125A and Z5125A

Page 10 of 80

determined by soil depth

iron pad

base profile
100x100

Fig. 3-3 Foundation plan for Z5140A and Z5150A

Page 11 of 80

determined by soil depth

iron pad

790

power supply wire hole 100

150x150

270

650
1100
1197
1740

505

55
base profile

Fig. 3-4 Foundation plan for Z5163C and Z5180C

Page 12 of 80

2. Operation
Before the machine is put into operation, the operator should be familiar with
application and location of controlling parts. Fig. 3-6 or Fig. 3-7 shows positions of
those parts, table 3-1 or table 3-2 lists their names and application accord with the
serial number in the corresponding fig.
2. 1 Operation of Z5125A, Z5132A, Z5140A and Z5150A
Please pay close attention to following item:
(1) Before the machine is put into work, the spindle box panel clamping screws
16 must be loosed firstly for adjusting the spindle box location, after adjustment,
tighten the screws 16.
(2) Checking whether all controls are in right positions before starting the
machine.
(3) Let the machine run unloading with a speed from lower, middle to higher
for several minutes if it is used for first time or reused after long time.
(4) During running, do not change the spindle speed or feed, and spindle
reversion is not permitted also. If speed change required, the machine must be
stopped.
(5) Power supply switch should be turned off when the machine is not used.
Start, stop and reverse of spindle
The start, stop and reverse of spindle are accomplished by push buttons. The
selective switch 3 should be turn to drilling position when performing drilling
operation or operating spindle reverse operation by means of push button.
When performing tapping operation by using tapping reverse mechanism , the
selective switch should be turn to tapping position.
Manual feed
Turn the control lever 7 anti-clockwise, in this case the manual feed can be
obtained.
Power feed and over-run feed
Pull out the end cover 8, turn lever 7 anti-clockwise by angle 20, thus power
feed is engaged. If turning lever 7 clockwise by angle 20, then power feed is
disengaged. During power feed if lever 7 is turned anti-clockwise at a speed higher
than that of power feed, thus spindle over-run feed can be obtained.
The automatic stopping of power feed
The dog 9 screwed up in the slot of dial 12 turns with the lever 7. When the
striking dog 9 strikes the pin 10, the feed clutch is disengaged. In this way the power
feed is stopped and depth-setting drilling is realized. The presetting of drilling depth
can be done though graduated dial 12 and graduation on scale. Disengaged clutch can
be reengaged by moving the lever 11 down.
Automatic tapping reversion

Page 13 of 80

The automatic tapping reversion device is mounted on left-side of the machine (see
fig.3-5). When this device is used, turn the drilling-tapping selective switch to
tapping position, then adjust stop dog 2 and 5
on dial 1 (see fig.3-5). Then automatic tapping
1
is accomplished by operating the lever 7. When
2
3
stop dog 2 turns clockwise to press the stylus 4,
4
5
the spindle automatic reverse is achieved so
tapping depth-setting isrealized. When spindle
turns back to its original position, the stop dog
5 presses stylus 3 to cause spindle rotation from Fig.3-5 Tapping Automatic
reversing device
reverse rotation (CCW) to forward rotation
(CW) for another operation. If this device is not
in use, the stop dogs should be moved to its limit position in order to prevent the
stylus from being pressed.
This forward and reverse tapping operation can also be done by means of buttons
but selective switch 3 should be turned to drilling position in order to keep away
interference of electric actions.
Due to limit of motor properties, the frequency of starting, changing direction of
spindle should not be too high. The operator should notice this point when using this
device for tapping.

Page 14 of 80

2
5

6
4

13

11
14
15
10
16
9
20

12
17

19
18
1

Fig.3-6 Control parts of the machine


(Z5125A, Z5132A, Z5140A , Z5150A)
Table 3-1 List of control parts of Z5125A, Z5132A, Z5140A , Z5150A
No.

Name and Applications

Machine power switch

Buttons of forward, reverse rotation, stop of spindle

Selective switch for tapping or drilling operation

On-off selective switch for cooling pump

Handle for spindle speed change

Handle for spindle feed change

Handle for spindle feed operation

End cover for controlling power feed

Stop dog for stroke setting cutting

10

Stop pin for feed clutch

11

Handle for resetting clutch to its original position

Page 15 of 80

12

Graduated dial for spindle feed

13

Knurled screw

14

Dial with stop dogs for automatic tapping reversion

15

Handle for spindle box elevation

16

Screw for spindle box clamping

17

Handle for worktable elevation

18

Cock for regulating cooling level

19

Lamp switch

20

Regulating screw of balancing spring

Change of spindle speed and feed rate


Both spindle speed and feed rate change are achieved by means of two single
handles. Left-side handle 5 is used for spindle speed change, and right-side handle 6
for feed rate change. Handle 6 has four positions i.e. forward, backward, right and left
positions. The third position counted from the left is 0 position during checking, it is
easy to rotate spindle manually if handle 6 is moved on 0 position. Handle for feed
rate change can be back and forth or right and left moved to three position. The
corresponding value of spindle speed and feed rate can be read on the speed and rare
plates.
On the plate there is a cutting speed chart recommended for drilling and tapping by
means of top quality, high speed steel drill and tap. Depending on the cutting speed
and machining diameter the corresponding spindle speed can be determined from
spindle speed chart.

2. 2 Operation of Z5163C and Z5180C


(1) Automatic-manual selective switch usage
This machine has two different work modes as manual and semiautomatic cycle.
Turn the automatic-manual selective switch to manual position, the machine can be
used to manually adjust by step or to adjust stop dogs position for semiautomatic
cycle, if the switch was turned to automatic position, the machine would run with
the way of semiautomatic cycle. In manual adjusting way, fast feed, fast backward,
forward rotation or reverse rotation of the spindle are all realized by pressing a button.
Button 5, 6, 8, 9 are used to control the spindle reverse rotation, forward rotation, fast
backward and fast feed respectively. Excepting forward rotation and reverse rotation,
the others are all in jog model that means the button was pressed, the spindle would
move, and the button was loosed, the spindle would stop to move mean while it would
be braked.

Page 16 of 80

(2) Feed under manual adjustment


When the automatic-manual selective switch is on manual position, press button 9,
the spindle quickly moves downward to a certain position and stopped if the button 9
be loosened. With the main handle 14, can adjust position of stop dog. pressing button
8, the spindle quickly moves backward.
(3) Semiautomatic cycle
Dog adjustment
Turning the automatic-manual selective switch to manual position, to adjust
positions of striking dog 16, 17, 18 according to the required dimensions of fast feed
and working feed with being machined workpiece, fasten these striking dogs on origin
position of spindle travel, adjusting these striking dogs position with the scale plate
and checking if these striking dogs position are right with a example workpiece by
operating the main operation handle 14, the corresponding indication light will be turn
on when a striking dog pressed a travel switch. The working feed striking dog 18
controls spindle feed rate changing from fast feed to working feed, fast back striking
dog 17 controls spindle travel direction changing from working feed to fast moving
backward and cycle stop striking dog controls spindle rotation stop when it moved
back on origin position. Must pay attention that need to leave 3-5mm overrun distance
when adjusting the working feed striking dog 18( that means the actual fast feed travel
distance lessen 3-5mm than that of theoretic) for preventing the drill overrun to strike
workpiece.
Cycle starting
Turning the automatic-manual selective switch to automatic position, pressing
Cycle starting button 4, the spindle will accomplish following semiautomatic cycle
according to positions of striking dog 16, 17, 18:
Spindle fast feeds to approach workpiece.
Spindle rotates when working feed started.
Spindle fast moves backward to original position.
Spindle stops rotation. Cycle ends.
(4) Spindle box elevating or dropping
Spindle box elevating or dropping can be accomplished by inserting handle 21
into square shank 15 at left-side of spindle box and turning the handle after loosening
screw 20 ( altogether 6 pieces, referring fig. 3-7 ). Tighten the screws 20 when
adjustment finished.
(5) Change of spindle speed and feed rate
Both spindle speed and feed rate change are achieved by means of two single
handles. Left-side handle 11 is used for spindle speed change, and right-side handle
10 for feed rate change. Handle 11 can be turned 3 positions in front-back direction
and 4 positions in left-right direction. The third position counted from the left is 0
position, it is easy to rotate spindle manually if handle 11 is moved on 0 position
during checking and cutting tool changing. Handle for feed rate change can be turned
2 positions in front-back direction and 3 positions in left-right direction. The
corresponding value of spindle speed and feed rate can be read on the speed and rare
plates.
Page 17 of 80

On the plate there is a cutting speed chart recommended for drilling by means of top
quality with high speed steel drill. Depending on the cutting speed and machining
diameter, the corresponding spindle speed can be determined from spindle speed
chart.

20
11
10
9
8

19
18

7
2
3
4
5
6

17
16
1
15
14
13
12

21

Fig. 3-7 Control parts of the machine


(Z5163C, Z5180C)

Table 3-2 List of control parts of Z5125A, Z5132A, Z5140A , Z5150A


No.

Name

Applications

Power switch

Turn on or off the machine power

Emergency button

Turn off power and braking spindle

Automatic-manual selective switch

For selecting operation mode of manual


or semiautomatic cycle

Cycle starting button

starting machine semiautomatic cycle


mode

Button of spindle reverse rotation

Turn on or off spindle reverse rotation

Button of spindle forward rotation

Turn on or off spindle forward rotation

On-off selective switch for cooling pump

Turn on or off the cooling pump

Page 18 of 80

Button of spindle fast backward

Turn on or off spindle fast backward

Button of spindle fast feed,

Turn on or off spindle fast feed

10

Handle for spindle feed change

For changing spindle feed rate

11

Handle for spindle speed change

For changing spindle speed

12

Regulating of spindle balance force

Regulating balancing spring by a screw

13

Regulating cooling level

Regulating the flow of cooling liquid

14

Main handle

For performing manual feed or power


feed

15

Worm shaft for spindle box elevation

To elevate spindle box manually

16

Stop dog for automatic cycle end

Switching spindle from fast backward


to stop state

17

Stop dog for fast backward

Switching spindle from working feed to


fast backward state

18

Stop dog for working feed

Switching spindle from fast feed to


working feed state

19

Knurled screw

Screwing out the knurled screw, the


safety resistance of the clutch can be
adjusted.

20

Screw for spindle box clamping

For spindle box clamping or loosing

21

Handle for worktable elevation

For worktable position adjusting on


vertical direction

3. Transmission system
3.1 Transmission system of Z5125A, Z5132A, Z5140A, Z5150A
All these machines have same motions as follows. The transmission system chart
is shown in fig. 3-8 and components listed in table 3-3 or table 3-4.
(1) Spindle rotation
The rotation is transferred from the main motor on the top of the spindle box to
the shaftvia spring coupling and gears 1,2 and then through four-slinding gears 3, 4,
5, 6 on shiftto the fixed gears 7, 8, 9, 10 on shaft. Afterwards the motion is
transmitted from gears 9, 10 on shaft and then via gears 12, 13 to the fixed gears
16, 17 on shaft which transfers the motion to spindle through the spindle hole thus
twelve steps speed can be obtained.

Page 19 of 80

There is difference with above in Z5125A and Z5132A, that there are three
slinding gears on shift(gear 6 on shiftand gear 7 on shaft are take away) and the
spindle can obtain nine steps speed.

Fig.3-8 Transmission system of Z5125A, Z5132A, Z5140A, Z5150A

(2) Spindle feed


The feed motion is transferred from gear 15 on shaft via gears 18, 19 on shaft
to the fixed gear 20 on shaft and then triple-slinding gears 21, 22, 23 on shaft
to fixed gears 24, 27, 28 on shaft . After that the motion is transferred from fixed
gears 25, 26, 28 on shaft to triple-slinding gears 29, 30, 31 on shaft and
through gears 32, 33, worm 34, worm gears 35 horizontal shaft 36 to spindle quill
rack 37, then nine steps of spindle feed per revolution are available.
(3) adjusting movement and others
The spindle box elevation movement is accomplished by turning a handle to
cause gear 45 rotating on rack 46 fixed on vertical column via worm 44, worm
gears 43.
The worktable elevation movement is realized by turning a handle to cause the
Page 20 of 80

leadscrew 49 to rotate in abutment 50 through bevel gears 47 and 48.


The gear 40 mounted on the horizontal shaft end connects with the cam
cylindrical spring mechanism via gear 41 so as to balance the weight of spindle.
Drilling depth is controlled by the graduated dial with inner gear 39 driven by
gear 38 on the horizontal shaft. The automatic tapping reversion is controlled by
stop dog mounted on the plate driven by gear 40 via inner gear 42.
Table 3-3 Components list of Z5125A and Z5132A according with fig. 3-8
Unit

Spindle speed change

No. in Fig3-8

10

11

12

Module

2.5

2.5

No. of teeth

25

43

28

22

16

28

16

35

40

19

Coefficient of
displacement

-0.381
5

+0.258 +0. 265

+0.265

Screw angle
Width of rim

14

12

11

12

13

11

49

11

12

15

Material

45

45

45

45

45

45

45

45

45

45

Heat treatment

G48

G48

G48

G48

G48

G48

G48

G48

G48

G48

Workpiece No.

Table 3-3 continued


Unit

Spindle speed change

Feed change

No. in Fig3-8

13

14

16

17

15

18

19

20

21

22

Module

No. of teeth

25

43

28

22

16

28

16

35

40

19

Coefficient of
displacement

-0.243

Screw angle
Width of rim

14

13

15

40

12

10

10

10

10

10

Material

45

45

45

45

45

45

45

45

45

45

Heat
treatment

G48

G48

G48

G48

G48

G48

G48

G48

G48

G48

Workpiece
No.

Table 3-3 continued


Unit

Feed change

No. in Fig3-8

23

24

25

26

27

28

29

30

31

32

Module

No. of teeth

18

38

32

17

27

48

32

48

17

18

Page 21 of 80

+0.254

Coefficient of

+0.254

displacement

Screw angle
Width of rim

10

10

10

10

10

10

10

10

10

15

Material

45

45

45

45

45

45

45

45

45

45

Heat
treatment

G48

G48

G48

G48

G48

G48

G48

G48

G48

G48

Workpiece
No.

Table 3-3 continued


Unit

Feed change

No. in Fig38

33

34

35

36

37

38

39

40

41

42

Module

1.5

1.5

1.5

No. of teeth

47

47

14

24

28

56

28

30

48

349

349

left

left

16

11

14

10

40Cr

HT300

45

45

45

T235

T235

T235

Coefficient of
displacement

Screw angle
Width of
rim

10

51*

32

79

Material

45

45

HT300

40Cr

45

Heat
treatment

G48

T23

G52

T235

G48

Workpiece
No.

Table 3-3 continued


Unit

Spindle box elevation

worktable elevation

No. in Fig38

43

44

45

46

47

48

49

50

Module

2.5

2.5

2.5

2.5

No. of teeth

47

47

14

56

28

30

48

+0.10

Coefficient of
displacement

Screw angle

445

445

49

49

Page 22 of 80

Width of
rim

34.8*

26

13.5

16

22

22

32*

32*

Material

45

HT300

45

45

45

45

45

HT200

Heat
treatment

T235

Workpiece
No.
Note: *means that number expressions major diameter of screw, lead screw or nut.

Table 3-4 Components list of Z5140A and Z5150A according with fig. 3-8
Unit

Spindle speed change

No. in Fig3-8

10

11

12

Module

No. of teeth

21

39

16

30

25

20

45

30

16

35

40

18

Coefficient of
displacement

0.467
5

+0.
258

Screw angle
Width of rim

14

11

13

11

11

13.5

12

11

49

13

12

15

Material

45

45

45

45

45

45

45

45

45

45

45

40Cr

Heat treatment

G48

G48

G48

G48

G48

G48

G48

G48

G48

G48

G48

G48

Workpiece No.

Table 3-4 continued


Unit

Spindle speed change

Feed change

No. in Fig3-8

13

14

16

17

15

18

19

20

21

22

Module

No. of teeth

42

23

58

34

44

41

34

40

27

38

Width of rim

14.5

12.5

15

41

12

10

12

10

10

10

Material

40Cr

40Cr

45

45

45

45

45

45

45

45

Heat
treatment

G48

G48

G48

G48

G48

G48

G48

G48

G48

G48

Coefficient of
displacement
Screw angle

Workpiece
No.

Page 23 of 80

Table 3-4 continued


Unit

Feed change

No. in Fig3-8

23

24

25

26

27

28

29

30

31

32

Module

No. of teeth

17

38

32

17

27

48

32

48

17

18

+0.254

Coefficient of

+0.254

displacement

Screw angle
Width of rim

10

10

10

10

10

10

10

10

10

15

Material

45

45

45

45

45

45

45

45

45

45

Heat
treatment

G48

G48

G48

G48

G48

G48

G48

G48

G48

G48

Workpiece
No.

Table 3-4 continued


Unit

Feed change

No. in Fig38

33

34

35

36

37

38

39

40

41

42

Module

1.5

1.5

1.5

No. of teeth

47

52

14

29

28

56

28

79

60

16

11

14

10

10

40Cr

HT200

45

45

45

T235

T235

T235

Coefficient of

+0.187

displacement

Screw angle

349

349

left

left

Width of
rim

10

51*

32

75

Material

45

45

HT300

40Cr

Heat
treatment

G48

T235

45

G52

Workpiece
No.

Table 3-4 continued


Unit

Spindle box elevation

worktable elevation

No. in Fig38

43

44

45

46

47

48

49

50

Module

2.5

2.5

2.5

2.5

3.5

3.5

3.5

3.5

No. of teeth

42

16

34

16

40

+0.10

Coefficient of
displacement

Screw angle

445

445

Page 24 of 80

49

49

Width of
rim

34.8*

26

13.5

16

26

26

50*

50*

Material

45

HT300

45

45

45

45

45

HT200

Heat
treatment

T235

Workpiece
No.
Note: *means that number expressions major diameter of screw, lead screw or nut.

3.2 Transmission system of Z5163C, Z5180C


All these machines have same motions as follows. The transmission system chart
is shown in fig. 3-9 and components listed in table 3-4.
(1) Spindle rotation
The rotation is transferred from the main motor on the top of the spindle box to
gear 1 via friction coupling to make the gear 2 rotating which was fixed on shaft.
And then motion is transmitted from shaftto shaft through two pairs tripleslinding gears between them. Afterwards the motion is transmitted from shaft via
gears 11, 16 to the shaft , which transfers the motion to spindle through the spindle
hole, thus the spindle can obtain nine steps speed.
(2) Spindle feed
The feed motion is transferred from gear 15 on shaft via gears 21,17 on shaft
and gears 19,18 on shaft to the fixed gear 20 on shaft , and then the motion is
transmitted from shaft to shaft via a pair of triple-slinding gears on shaft
and a pair of twin-slinding gears on shaft . After that the motion is transferred from
fixed gear 31 on shaft to fixed gear 46 on shaft ,when the electromagnetic
coupling is turn-on, the motion is transferred via worm 34, worm gears 33, horizontal
shaft 37 and a gear fixed on the shaft 37 to spindle quill rack 32, then six steps of
spindle feed per revolution are available.
(3) Semiautomatic cycle
The machine has a fast transmission chain for realizing machining semiautomatic
cycle which including the fast feed to workpiece, working feed, fast moving backward
and stop functions. The fast feed motion was supplied by a 0.55KW motor, and
transferred via gears 47, 48, 49 to gear 45. When the electromagnetic coupling is turnon, the motion is transferred via worm 34, worm gears 33, horizontal shaft 37 and a
gear fixed on the shaft 37 to spindle quill rack 32, then the spindle feed can obtain a
fast feed rate of 3m/min. through to control the fast motor rotation direction and turn
the electromagnetic coupling on or off, the movement needed in semiauto- matic
cycle machining can be obtained.
(4) adjusting movement and others
The spindle box elevation movement is accomplished by turning a handle to
cause gear 42 rotating on rack 43 fixed on vertical column via worm 40, worm

Page 25 of 80

gears 41.
The worktable elevation movement is realized by turning a handle to cause the
lead-screw 52 to rotate in abutment 53 through bevel gears 50 and 51.
The gear 35 mounted on the horizontal shaft drives inner gear 36 to cause the
graduated dial and striking dog rotating, through the cooperating of dogs and
switches, to realize the semiautomatic cycle. Mean while, the gear 38 mounted on
the horizontal shaft drives inner gear 39, which connects with the cam cylindrical
spring mechanism, so as to balance the weight of spindle.

20

45
44
43
42
41
40
39
38

Fig.3-9 Transmission system of Z5163C, Z5180C

Table 3-5 Components list of Z5163C and Z5180C according with fig. 3-9
Unit

Spindle speed change

No. in Fig3-9

Module

3.5

3.5

No. of teeth

22

38

29

23

18

17

47

+0.30

+0.40

Coefficient of

Page 26 of 80

displacement
Screw angle
Width of rim

17

15

Material

40Cr

45

Heat treatment

G48

Workpiece No.

631129C

15

15

15

20

15

40Cr

40Cr

45

G48

G48

G48

G48

631128C

631150C

631102A

631107C

Table 3-5 continued


Unit

Spindle speed change

No. in Fig3-9

10

11

12

13

14

Module

No. of teeth

52

33

41

24

46

61

27

Coefficient of
displacement

-0.30

+0.124

Screw angle
Width of rim

15

15

15

18

15

20

15

Material

45

45

45

45

45

45

40Cr

Heat treatment

G48

G48

G48

G48

G48

G48

G48

Workpiece No.

631108C

631122C

631103C

631118C

631115C 631114A

631110C

Table 3-5 continued


Unit

Spindle speed change

Feed change

No. in Fig3-9

15

16

17

18

19

20

21

Module

No. of teeth

56

48

21

35

42

33

54

Width of rim

10

18

10

10

10

10

Material

45

45

45

40Cr

45

45

G48

G48

G48

G48

G48

G48

631117C

631116C

632109A

632108A

632101A

632115A

Coefficient
of
displacement
Screw angle

Heat
treatment
WorkpieceNo
.

Table 3-5 continued


Unit
No. in Fig3-9

Feed change
22

23

24

Page 27 of 80

25

26

27

Module

No. of teeth

47

27

22

44

33

33

Width of rim

11

11

11

11

11

Material

45

45

45

40Cr

45

Heat treatment

G48

G48

G48

G48

G48

WorkpieceNo.

632105A

632106A

632108 C

632107C

632109C

Coefficient of
displacement
Screw angle

Table 3-5 continued


Unit

Feed change

No. in Fig3-9

28

29

30

31

32

33

34

Module

2.5

No. of teeth

18

38

32

18

20

60

348 52

348 52

42

90

Coefficient of
displacement
Screw angle
Width of rim

11

11

11

12

Material

45

45

45

40Cr

45

HT300

40Cr

Heat treatment

G48

G48

G48

G48

T235 G48

G48

T235

633124C

636102C

633013C

633116A

WorkpieceNo.

632113A

Table 3-5 continued


Unit

Feed mechanism

No. in Fig3-9

35

36

37

44

45

46

47

Module

2.5

No. of teeth

19

39

14

60

22

52

34

Width of rim

12

12

133

13

12

12

12

Material

45

45

40Cr

45

45

45

45

Heat treatment

G48

T235

T235 C52

G48

G48

G48

G48

WorkpieceNo.

633137C

633101A

633105A

633115A

633118C

633114A

633123C

Coefficient of
displacement
Screw angle

Table 3-5 continued


Unit

Spindle speed change


Page 28 of 80

Feed change

No. in Fig3-9

48

49

38

39

Module

No. of teeth

34

34

18

54

Width of rim

12

12

37

10

Material

45

45

45

45

Heat treatment

G48

G48

G48

G48

WorkpieceNo.

633129C

633121C

633104A

636113A

Coefficient of
displacement
Screw angle

Table 3-5 continued


Unit

Spindle box elevation

No. in Fig3-9

40

41

42

43

Module

2.5

2.5

No. of teeth

62

18

33

Screw angle

310 47

310 47

Width of rim

80

35

15

315

Material

45

HT300

45

45

Heat treatment

T235

T235

T235

WorkpieceNo.

633107C

633101C

637103C

Coefficient of
displacement

633014C

Table 3-5 continued


Unit

Spindle box elevation

No. in Fig3-9

50

51

52

53

Module

3.5

3.5

No. of teeth

12

42

Width of rim

23

23

385

100

Material

45

45

45

HT300

Z5163-7102

Z5163-7103

Z5163-7104

Z5163-7014A

Coefficient of
displacement
Screw angle

Heat treatment
WorkpieceNo.

4. Adjustment of the machine


Adjustment of safety clutch
Page 29 of 80

When adjusting feed worm clutch, screwing out the knurled screw plug on the
right cover of the spindle box, in the hole, the screw-nut on upper part of the worm
shaft can be found, rotating the nut, the safety resistance of the clutch can be adjusted.
Before dispatch, the safety resistance of the feed worm clutch has already been
adjusted. It should be readjusted only after major overhaul. For machines Z5140A and
Z5150A, worm clutch must be disengaged when the feed resistance of spindle has
reached 20000N, if it is less than 16000N, the machine should perform normal work.
For machines Z5125A and Z5132A, worm clutch must be disengaged when the
spindle feed resistance has reached 11000N, if it is less than 9000N, the machine
should perform normal work. But for machine Z5163C and Z5180C, the machine
should perform normal work when the feed resistance of spindle has reached 30000N,
if it is over 25% than rated resistance value, the worm clutch must be disengaged.
For different machine type, the adjustment must be strictly operated according to
table 3-4 and 3-5.
Adjustment of balance spring
The initial force of spindle balance spring can be adjusted by turning the screw at
the lower part of the balance sleeve (its position was shown in fig.3-6 or 3-7 by
number 20 or 12 indicated respectively). Clockwise rotation tension the spring while
anticlockwise rotation loosen the spring.
5. Machine lubrication
Lubrication points, oil kinds and period of machine lubrication are given in fig.310 and table 3-6.
Machine lubricant used must be pure and non-acidic and should not contain any
other impurities and water. For lubricating the spindle box, the lubricant is sucked up
by piston pump, then ejected out to various lubricating points through a lubricant pipe
and splashed onto all working surfaces due to the gear rotating action at high speed.
Lubricant filling hole is provided on the top cover of the spindle box. Lubricant
can be poured in after screwing out screw plug in case of machine stopped. The
lubricant amount filled is half height of lubricant level which is on right down side of
spindle box. The lubricating state can be observed through the oil glass on left side of
spindle box top cover. When the used lubricant is required to change, screw out the
plug in drainage hole at bottom of the spindle box.
The first lubricant change should be made after machine has been run for 10-15
days, and the second change should be made after machine running for 20-25 days
since the first lubricant change. Therefore the lubricant should be changed once every
three months. Before change, discharge the used lubricant completely and wash the
box with pure kerosene, then fill in the clean lubricant.
Spindle quill surface and column guiding ways should be lubricated everyday.
There are lubrication holes on spindle quill at upper and lower spindle bearings
position, through which grease can be filled in by grease gun. When lubricating this
position, turn off the electric supply switch, carefully move away the panel in front of
the box, the bearing lubricating holes can be found through a hole in inner wall of the
Page 30 of 80

box.
Frequently observe whether the lubricant goes through the glass during
machining operation in order to ensure proper working condition of lubricating
system.
Note that 6, 7 lubricating points in table 3-6 are only suitable for Z5163C and
Z5180C.

lubrication watch

oil filling

2
3
6

oil drain

5
4
7

Fig.3-10 lubricating points

Table 3-6
No.

Lubricating
positions

Main motor
bearing

Spindle box

Lubricating
mode

Lubricant type

Lubricating
position count

Lubricating cycle

manual

1#
calcium
-base grease

1/6(month)

pump

20# machine oil

often

Spindle
bearing

manual

1#
calcium
-base grease

1/6(month)

Cooling
pump bearing

manual

1#
calcium
-base grease

1/6(month)

Worktable

manual

20# machine oil

1/1(week)

Page 31 of 80

lead screw
6

Fast
motor
bearing

manual

1#
calcium
-base grease

1/6(month)

Worktable
bevel gears
and bearing

manual

20# machine oil

1/1(week)

6. Bearings used in the machine


Bearings distributed in the machine are shown in fig. 3-11, 3-12, 3-13, and their
detail information are listed in table 3-6, 3-7, 3-8 respectively.

209 206

305

206 205
3 pieces
203
50204

109
105
2 pieces
E107
E8107

8107

303
3 pieces
203
2 pieces
204
D8107
D107
2 pieces

101
8101
8104
105
2 pieces
108
2 pieces
8206

206
207

Fig.3-11 Bearings distribution in machine Z5125A, Z5132A

Table 3-7 List of bearings of Z5125A,Z5132A

Page 32 of 80

No
.

name

Bearing
No.

Single row radial ball bearing

101

12288

Single row radial ball bearing

105

254712

Single row radial ball bearing

107

356214

Single row radial ball bearing

107

356214

Single row radial ball bearing

108

406815

Single row radial ball bearing

109

457516

Single row radial ball bearing

203

174012

Single row radial ball bearing

204

204714

Single row radial ball bearing

205

255215

10

Single row radial ball bearing

206

306216

11

Single row radial ball bearing

207

357217

12

Single row radial ball bearing

209

458519

13

Single row radial ball bearing

303

144714

14

Single row radial ball bearing

305

256217

15

Single row radial ball bearing

50204

204714

16 Single row thrust radial ball bearing

8101

12269

17 Single row thrust radial ball bearing

8104

203510

18 Single row thrust radial ball bearing

8107

355212

19 Single row thrust radial ball bearing

8107

355212

20 Single row thrust radial ball bearing

8107

355212

21 Single row thrust radial ball bearing

8206

305216

Page 33 of 80

specification

amount

class

211 206

305

206 205
3 pieces
203
50204

210
105
2 pieces
E109
E8109

8107

303
3 pieces
203
2 pieces
204

8101

D8209

105
2 pieces

D109
2 pieces

101

8104

108
2 pieces
8206

206
207

Fig.3-12 Bearings distribution in machine Z5140A, Z5150A

Page 34 of 80

Table 3-8 List of bearings of Z5140A, Z5150A


N
o

name

Bearing
No.

specification

Single row radial ball bearing

101

12288

Single row radial ball bearing

105

254712

Single row radial ball bearing

108

406815

Single row radial ball bearing

109

457516

Single row radial ball bearing

109

457516

Single row radial ball bearing

203

174012

Single row radial ball bearing

204

204714

Single row radial ball bearing

205

255215

Single row radial ball bearing

206

306216

10

Single row radial ball bearing

207

357217

11

Single row radial ball bearing

210

509020

12

Single row radial ball bearing

211

5510021

13

Single row radial ball bearing

303

144714

14

Single row radial ball bearing

305

256217

15

Single row radial ball bearing

50204

204714

16 Single row thrust radial ball bearing

8101

12269

17 Single row thrust radial ball bearing

8104

203510

18 Single row thrust radial ball bearing

8107

355212

19 Single row thrust radial ball bearing

8109

456514

20 Single row thrust radial ball bearing

8206

305216

21 Single row thrust radial ball bearing

8209

457320

Page 35 of 80

amount

class

12 11 10 9 8 7

3
2

14

13

15

16

25
24

18
17

27
20

26
28

19

29

21

30
31
32
33

23
22
34

Fig.3-13 Bearings distribution in machine Z5163C, Z5180C

Page 36 of 80

Table 3-9 List of bearings of Z5163C, Z5180C


No
.

name

Deep Groove Ball Bearing

specification

amount

6206

306216

Deep Groove Ball Bearing

6306

307219

Deep Groove Ball Bearing

6307

358021

Deep Groove Ball Bearing

6207

357217

Deep Groove Ball Bearing

6304

205215

Deep Groove Ball Bearing

6209

458519

Deep Groove Ball Bearing

6016

8012522

P5

Deep Groove Ball Bearing

6015

7511520

P5

Needle bearing

KM281/20

284220

10

Deep Groove Ball Bearing

6004

204212

11

Deep Groove Ball Bearing

6205

255215

12

Deep Groove Ball Bearing

6003

173510

13

Deep Groove Ball Bearing

6004

204212

14

Deep Groove Ball Bearing

6303

205215

15

Deep Groove Ball Bearing

6205

255215

16

Thrust radial ball bearing

51205

254715

17

Thrust radial ball bearing

51113

659018

P6

18

Deep Groove Ball Bearing

6013

6510018

P6

D3182117K

8513034

D
P5

19

Double row cylindrical roller bearing

Bearing
No.

20

Thrust radial ball bearing

51116

8010519

21

Deep Groove Ball Bearing

6203

174012

22

Deep Groove Ball Bearing

6209

458519

23

Deep Groove Ball Bearing

6211

5510021

24

Deep Groove Ball Bearing

6004

204212

25

Deep Groove Ball Bearing

6003

173510

26

Deep Groove Ball Bearing

6204

204714

27

Tapered roller bearing

32007

352618

Page 37 of 80

class

28

Deep Groove Ball Bearing

6306

307219

29

Thrust radial ball bearing

51306

306021

30

Deep Groove Ball Bearing

6206

306216

31

Deep Groove Ball Bearing

6004

204212

32

Thrust radial ball bearing

51305

255828

33

Radial ball bearing

62205-2S

251258

34

Thrust radial ball bearing

51207

356218

7. Machine electrical system


7.1 Electrical system of Z5125A, Z5132A
Note: This machine has a touching switch on speed changing handle. The
speed changing operation is forbidden when the machine spindle is running,
otherwise transporting gears will be damaged. If speed changing is operated with
the handle, the spindle would be braking and stopped peremptorily. Only
operators hand leave the speed changing handle, the spindle clockwise anticlockwise rotation can be realized by pressing SB2, SB3.
The machine uses three phases, 380V and 50Hz AC power supply, the spindle
rotation and feed are all driven by main motor M1 and cooling pump is driven by
motor M2.
The controlling voltage of the machine is 110V, 24V. The main electric control
parts are mounted inside compartment at back of the column. For the electric
components, please refer to table 3-10. The controlling push buttons are centralized at
lower side of the spindle box, please refer to electrical assembly diagram 3-14.
As refer to the electrical principle diagram 3-15, when drilling-tapping selective
switch SA1 is turned to drilling position, the switch SA1between terminals 6-7 and
terminals 24-13 are turned on and switch between 11-12 is turned off thus the tapping
switch SQ1 and SQ2 are functionless. At this moment, the clockwise and anticlockwise rotation and braking of spindle can be controlled respectively by pressing
SB2, SB3 and SB1.
When drilling-tapping selective switch SA1 is turned to tapping position,
switch between 11-12 is turned on, but the switch SA1 between terminals 6-7 and
terminals 24-13 are turned off thus realizing the automatic changes of clockwise and
anti- clockwise rotation and braking of spindle by means of switch SQ1 and SQ2
which are controlled by stop dogs on the automatic tap reverse device.
When the cooling selective switch SA2 is turn on, the motor of cooling pump is
controlled by relay KA1 and it will be stopped or started along with stopping and
starting of spindle motor.

Page 38 of 80

For the machine electric wiring, please refer to fig. 3-16

Page 39 of 80

Page 40 of 80

Page 41 of 80

Page 42 of 80

Page 43 of 80

Page 44 of 80

7.2 Electrical system of Z5140A, Z5150A


There two modes of electrical control with machine Z5140A, Z5150A such as
modularization multifunctional relay control mode and traditional separated relay
control mode. User can select the control when order the machine.
7.2.1 Electrical system of Z5140A, Z5150A with modularization multifunctional
relay control mode
Note: This machine has a touching switch on speed changing handle. The
speed changing operation is forbidden when the machine spindle is running,
otherwise transporting gears will be damaged. If speed changing is operated with
the handle, the spindle would be braking and stopped peremptorily. Only
operators hand leave the speed changing handle, the spindle clockwise anticlockwise rotation can be realized by pressing SB2, SB3.
The machine uses three phases, 380V and 50Hz AC power supply, and a
modularization multifunctional relay is used for its controling. Otherwise, a foot pedal
is added for emergency switch, and a touch switch is used on spindle speed change
handle for emergency switch, so that this machine strengthens protection for operator
and machine from dangerous case.
The spindle rotation and feed are all driven by main motor M1 and cooling pump
is driven by motor M2 and all supplied by 380V and 50Hz AC power.
The machine controlling voltage is 110V, 50Hz. The main electric control parts
are mounted inside compartment at back of the column. For the electric components,
please refer to table 3-11. The controlling push buttons are centralized at lower side of
the spindle box, please refer to electrical assembly diagram 3-14.
As refer to the electrical principle diagram 3-19, when drilling-tapping selective
switch SA1 is turned to drilling position, the terminals COM and 251 of switch SA1
is turn-on and terminals COM and 252 is turn-off thus the tapping switch SQ1 and
SQ2 are functionless. At this moment, the clockwise and anti-clockwise rotation and
braking of spindle can be controlled respectively by pressing SB2, SB3 and SB1.
When drilling-tapping selective switch SA1 is turned to tapping position, the
terminals COM and 252 of switch SA1 is turn-on and terminals COM and 252 is turnoff thus realizing the automatic changes of clockwise and anti-clockwise rotation of
spindle by means of switch SQ1 and SQ2 which are controlled by stop dogs on the
automatic tap reverse device.
When the cooling selective switch SA2 is turn on, the motor of cooling pump is
controlled by relay KM4 and it will be stopped or started along with spindle motor
stopping and starting.
For the machine electric wiring, please refer to fig. 3-20

Page 45 of 80

Page 46 of 80

Page 47 of 80

Page 48 of 80

Page 49 of 80

Page 50 of 80

7.2.2 Electrical system of Z5140A, Z5150A with traditional separated relay


control mode
Note: This machine has a touching switch on speed changing handle. The speed
changing operation is forbidden when the machine spindle is running, otherwise
transporting gears will be damaged. If speed changing is operated with the
handle, the spindle would be braking and stopped peremptorily. Only operators
hand leave the speed changing handle, the spindle clockwise anti-clockwise
rotation can be realized by pressing SB2, SB3.
The machine uses three phases, 380V and 50Hz AC power supply, the spindle
rotation and feed are all driven by main motor M1 and cooling pump is driven by
motor M2.
The controlling voltage of the machine is 110V, 50Hz. The main electric control
parts are mounted inside compartment at back of the column. For the electric
components, please refer to table 3-12. The controlling push buttons are centralized at
lower side of the spindle box, please refer to electrical assembly diagram 3-14.
As refer to the electrical principle diagram 3-22, when drilling-tapping selective
switch SA1 is turned to drilling position, the switch SA1 between terminals 6-7 and
terminals 13-24 are turn-on and switch between 11-12 is turn-off thus the tapping
switch SQ1 and SQ2 are functionless. At this moment, the clockwise and anticlockwise rotation and braking of spindle can be controlled respectively by pressing
SB2, SB3 and SB1.
When drilling-tapping selective switch SA1 is turned to tapping position,
switch between 11-12 is turn-on, but the switch SA1 between terminals 6-7 and
terminals 13-24 are turn-off thus realizing the automatic changes of clockwise and
anti- clockwise rotation and braking of spindle by means of switch SQ1 and SQ2
which are controlled by stop dogs on the automatic tap reverse device.
When the cooling selective switch SA2 is turn on, the motor of cooling pump is
controlled by relay KA1 and it will be stopped or started along with stopping and
starting of spindle motor.
For the machine electric wiring, please refer to fig. 3-23

Page 51 of 80

Page 52 of 80

Page 53 of 80

Page 54 of 80

Table3-12
Amount

Electric components of Z5140A, Z5150A with traditional


separated relay control mode
Symbol

Type and technical data

Use

Note

M1

Y100L2-4B5 3KW; 380V 1420


6.8A RDM

Spindle motor

M2

AB-25C 90W; 0.31A 380V

Cooling pump motor

KM1

GSC1(CJX4-D)-1201ND /110V
F3-22D

Spindle CW contactor

KM2

GSC1(CJX4-D)-1201ND /110V
F3-22D

Spindle CCW contactor

KM3

GSC1(CJX4-D)-1201 /110V F322D

Spindle brake contactor

KA1

GSC1(CJX4-D)-0910 /110V F322D

Cooling pump motor contactor

KT1

GSC1(CJX4-D)- 0901 /110V


SK4-320D

Time contactor of brake

QF1

BJM1-125 12.5A

Spindle motor safeguard


switch

air

QF2

3VE1015-2DU00 0.4A

Cooling pump safeguard


switch

air

FA2

DZ47-63 10A

Braking safeguard air switch

FA3

DZ47-63 3A

Lamp safeguard air switch

FA1
FA4

DZ47-63 1A

Control safeguard air switch

VC1

2PQ1V-2 10A

rectifier diode

EL1

JC11-1 40W24V lamp

Machine lighting

User
prepare

SA1

YW1S-2E12

Selective knob of drilling or


tapping

SA2

YW1S-2E01

Cooling control knob

TC1

JBK3-250 380V/110V 30V 26V 24V

Control,
light,
Transformer

SB2 SB3

YW1B-M1E11G green

Spindle motor CW or CCW


button

SB1

YW1B-VE01R red

Emergency stop button

SQ1 SQ2

JW-11K

Tapping CW or CCW jiggle


switch

SQ3

FS-2

Foot pedal

SQ4

CMKG-001

Touching switch

Page 55 of 80

brake

7.3 Electrical system of Z5163C, Z5180C


Note: This machine has a touching switch on speed changing handle. The
speed changing operation is forbidden when the machine spindle is running,
otherwise transporting gears will be damaged. If speed changing is operated with
the handle, the spindle would be braking and stopped peremptorily. Only
operators hand leave the speed changing handle, the spindle clockwise anticlockwise rotation can be realized by pressing SB2, SB3.
The machine uses three phases, 380V and 50Hz AC power supply, and a
modularization multifunctional relay is used for its controlling. Otherwise, a touch
switch is used on spindle speed change handle for emergency switch, so that this
machine strengthens protection for operator and machine from dangerous case. The
machine uses three phases, 380V and 50Hz AC power supply, the spindle rotation and
feed are all driven by motor M1, the spindle fast move upwards and downwards is
driven by motor M2 and cooling pump is driven by motor M3.
The main electric control parts are mounted inside compartment at back of the
column. The controlling push buttons are centralized at lower side of the spindle box.
Stroke switches are all mounted beside the spindle box. Please refer to electrical
assembly diagram fig.3-25 and fig.3-29. For the electric components, please refer to
table 3-13.
Operation in automatic mode
As refer to the electrical principle diagram fig.3-26 and fig.3-27, when the
manual-semiautomatic selective switch SA2 is turned to automatic position, and the
origin switch SQ3 is pressed to turn-on, origin indicator lamp HL3 would be turn-on,
then pressing cycle start button SB4, the KM4 would be turn-on, the spindle fast
moves downward, SQ1 will be pressed to turn-on before the tool approached to
workpiece surface, meanwhile the working feed indicator lamp HL1 would be turnon, the KM4 would be turn-off, then KM1 and YC1would be turn-on, the spindle
rotated in CW and moved in working feed rate, the SQ2 will be pressed to turn-on
when the tool feed to certain position, meanwhile the fast backward indicator lamp
HL2 would be turn-on, then KM5 would be turn-on and YC1 turn-off, the fast motor
start rotating to make the spindle fast move backward, when SQ1 is pressed to turnon, KM1 would be turn-off , and KM3 turn-on causing spindle been braked, KM5
would be turn-off when spindle move back to origin, meanwhile the HL3 turn-on and
KM6 turn-on, fast motor been braked, the semiautomatic cycle ends. During
semiautomatic cycle, the cooling control knob should be in right position, thus the
cooling automatically turn on when spindle rotating and turn off spindle stop rotating.
Operation in manual mode
Turning the manual-semiautomatic selective switch SA2 to manual position,
following action can be operated. Pressing SB2, KM1 is turn-on and spindle rotating
Page 56 of 80

in CW, and clutch YC1 is turn-off. Pressing SB3, KM2 is turn-on and spindle rotating
in CCW, and clutch YC1 is turn-off. Pressing SB5, KM4 is turn-on, the spindle fast
moves downwards and would stop when SQ1 pressed. Pressing SB6, KM5 is turn-on,
the spindle fast moves upward and would stop when SQ3 pressed. When pressing
SB1, all motors would stop rotation.
Operation in tapping mode
Turning the manual-semiautomatic selective switch SA2 to tapping position,
following action can be operated. Turning the main handle downwards, the spindle
moves downwards, when SQ1 is pressed, KM1 would be turn-on and spindle rotating
in CW. Spindle continue moves downwards, when SQ2 is pressed, KM1 would be
turn-off, KM2 would be time-lapse turn-on and spindle rotating in CCW. Turning the
main handle upwards, the spindle moves upwards, when SQ1 is pressed, the spindle
stop, tapping ends.
Cooling control
Turning the cooling control knob SA1 to right position, the cooling
automatically turn on when spindle rotating in CW in manual mode, and the cooling
automatically turn off when pressed SB1 to stop spindle rotating. In automatic mode,
the cooling automatically turn on when SQ1 is pressed, and would be automatically
turn off when SQ3 is pressed during spindle move backwards to origin position. The
cooling would be always turn-on when turning the cooling control knob SA1 to left
position.
Indicator lamp state on operation board
HL1 turn-on means the machine is in working feed state. HL2 turn-on means the
machine working feed is end and the spindle is fast moving backward. HL3 turn-on
means the spindle is in origin position, cycle can be started.

Page 57 of 80

Fig.3-25 Electric installation diagram for Z5163C, Z5180C

Page 58 of 80

Page 59 of 80

Fig. 3-26 Electric principle of Z5163C, Z5180C

Page 60 of 80

Fig. 3-27 Multifunctional relay principle of Z5163C, Z5180C

Page 61 of 80

Fig. 3-28 Wiring diagram of Z5163C, Z5180C


Page 62 of 80

Fig. 3-29 Components disposing diagram of Z5163C, Z5180C

Page 63 of 80

Table3-13
Amo
unt

Electric components of Z5163C, Z5180C


Symbol

Type and technical data

Use

Not
e

M1

Y132-4B5 V1 5.5KW; 380V


11.6A RDM

Spindle motor

M2

A027122,B5 380V 550W 1.5A

Fast motor

M3

AB-50C 120W; 0.32A 380V

Cooling pump motor

KM1

GSC1-1201ND /110V

Spindle CW contactor

KM2

GSC1-1201ND /110V

Spindle CCW contactor

KM3

GSC1-1201 /110V

Spindle brake contactor

KM4
KM5

GSC1-0901ND /110V

Fast motor contactor

KM6

GSC1-0901ND /110V

Fast motor braking contactor

KM7

GSC1-0910 /110V

Cooling pump motor contactor

QF1

BLM1-125 20A

General power safeguard


switch

QF2

3VE1005-2DU00 4-6A

Main control circuit safeguard


air switch

FA1

DZ47-63 C3/1P 3A

110V power safeguard air switch

FA2

DZ47-63 C3/1P 3A

Lamp safeguard air switch

FA3

DZ47-63 C2/1P 2A

24V power safeguard air switch

FA4

DZ47-63 C2/1P 2A

Clutch power safeguard air switch

FA5

DZ47-63 C5/1P 5A

Clutch power safeguard air switch

FA6

DZ47-63 C5/1P 5A

Braking safeguard air switch

FA7

DZ47-63 C15/1P 15A

Braking safeguard air switch

FR1

JRS4-32316 11.6A

Spindle motor overheating relay

FR2

JRS4-32307 1.6A

Fast motor overheating relay

FR3

JRS4-32303 0.37A

Cooling motor overheating relay

SB1

YW1B-VE02R

Emergency stop button

SB2 SB3

YW1B-M1E10G

Buttons of spindle motor CW


or CCW and cycle start.

SB4

air

SB5 SB6

YW1B-M1E11G

Buttons of fast motor

SA1

YW1S-2E20

Cooling control knob

SA2

YW1S-3E20

Selective knob of work mode

HL1~
HL3

AL6M-P4GC

Work state indicator lamp

EL1

JC11-1 40W 24V lamp

Machine lighting

User
prepa
re

Page 64 of 80

VC1

2PQ1V-2

Rectifier bridge

SQ1 SQ2

JW2-11Z

Compages stroke switches

SQ3

YC1

DLM5-10

Electromagnetic clutch

PLC1

WJ1-20/12

Multifunctional relay

BJM1-A

Mechanical catenation outfit

JBK3-250 380V/110V 60V 26V 24V

Transformer

1
1

TC1

110V 100VA
60V 300VA
26V 100VA
24V 50VA

Page 65 of 80

Machine maintenance and fault eliminating


1.

Machine maintenance

(1) In order to prolong service life of the machine, attention should be paid to
cleaning the machine and lubricating it strictly according to lubrication requirement of
the machine. Ensure to clean the machine once a week.
(2) Connection of electric equipment shoud be tightened up. The electric equipment
shoud not be oxidized and it should be checked at least once a month.
(3) The coolant should be updated termly, espacially in south area, ehe coolant
should be often updated.
(4) Lubricating oil should be observed at every turn. Lubricating oil should be
added in time if it height is lower than requirement. Keeping the oil window clean and
often checking the oil window if the lubricating oil flow or not.
(5) When machining cast iron, must keep the spindle sleeve cleaning, otherwise the
spindle sleeve would be wear and tear.
2.

Machine fault eliminating

(1) If the depth of processed hole changed, please check if the striking dog in left
side of spindle box become flexible.
(2) Observing the spindle rotation direction when turn on machine power, if the
rotation direction is not right, please shift main motor wiring.
(3) If the spindle appears position descending or rebounding, please adjustment the
spindle balance machanism(please refer to machine adjustment).
(4) After used a period time, the machine may be appearing phenomena of
lubricating oil not circulating, please open the left side cover of spindle box and take
down oil pump, adjusting it to good state for flow oil.
(5) For different drilling machine, if the aiguille diameter less or equal to the the
certain maching required standard dimension but the machine can not work normally,
please check the aiguille knife-edge angle is right or not and tool edge is sharp or not.

Page 66 of 80

Machine damageable part list and drawing


1. Damageable parts list
1.1 Damageable part list of Z5125AZ5132A
Part No.

Name

Material

Amount

141401

rubber ring

oil-proof rubber

123011

Worm wheel

HT300

143171

Claw

45

144017

Slide block

HT200

145012

Sleeve

HT200

126011

Guide sleeve

HT300

Note

1.2 Damageable part list of Z5140AZ5150A


Part No.

Name

Material

Amount

141401

rubber ring

oil-proof rubber

143011

Worm wheel

HT300

143171

Claw

45

144017

Slide block

HT200

144013A

Fork catch

HT200

144109A

Slide block

45

145012

Sleeve

HT200

146011

Guide sleeve

HT300

Note

1.3 Damageable part list of Z5163CZ5180C


Part No.

Name

Material

Amount

634110C

Pin shaft

45

634111C

Pin shaft

45

634114C

Slide block

45

634117C

Fork tong

45

634118C

Fork tong

45

634019C

Slide block

HT200

631127C

centrifugation-block

45

631401C

Brake belt

Asbestos colophony

Page 67 of 80

Note

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