Victor Taichung Machinery Troubleshooting and Maintenance Manual

Victor Taichung Machinery
Troubleshooting and Maintenance Manual
(E)
MAINTENANCE
and
TROUBLESHOOTING
MANUAL
E-1
1) MAINTENANCE
E-2
1.1
Daily Check List
1.1.1
Before power on:
Inspect the outside of the machine.
Check if there is any interference within the moving range of the machine.
If there is any damage on slideway, if yes, grind it with an oil stone.
Check the lubricating oil level, add if necessary.
Check coolant volume, add if necessary.
Check Hydraulic Pressure (35 kg/sq. cm) and also the chucking and tailstock pressure.
Add yellow grease onto the chuck oil dispenser, each hole 3 times.
This is concerned
with the life of the chuck and accuracy of the 3 jaws slideway.
Check the level of the lubricating oil, if its not enough, then Alarm 3 will illuminate and
automatic perform can not be started. Before operation of the machine, fill the tank, and
check the level of the lubricating oil after processing.
hours use 1 barrel (2 liters).
In normal operation about 8 - 12
If its being used too fast, its possibly a disorder or leakage
in the dispenser or the lubricating oil pipe.
If the usage of oil is too slow, its possibly the
oil absorber of the lubricating pump is stuck, or the viscosity of the oil is to high.
Check the oil volume in the hydraulic tank, if it is not enough, add hydraulic oil, otherwise
check if it is leaking.
Check the coolant, from the indicating meter of the coolant tank and see if it is in need of
more oil.
Too much coolant will spill out onto the ground, and too little will create noise
as the coolant motor catches the air, furthermore, it will shorten the motor life.
Check belt, spindle belt, gearbox belt, and speed checker belt.
broken, it can display the spindle speed and drilling.
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If speed checker belt is
1.1.2
After power on:
Check the main pressure gauge if it is nearby 45 kg/sq. cm, then it is OK.
If too low, check
the phase of power is correct.

Check to see if the cooling fan is operating normally.
If not, find out the reason.
Press the button on the lubricating pump and check if the pressure can rise to 15kgs/sq.
If it
is too high or too low check the lubricating pump, proportion dispensor, oil dispensor and
connector.
Check the pressure of the chuck and the tailstock and see if they can meet the pressure for
cutting the workpiece.
1.1.3
If necessary, adjust this.
The end of daily operation:
Take off workpiece, do not leave the workpiece on the chuck.

Clean the chips on the turret, chuck, tailstock, slideway, chip collector and at the back of the
hydraulic cylinder away.
Spray antirusting oil on the turret, chuck and slideway.
Checking if the useage of lubrication oil is abnormal.
Normally, it takes 1 barrel (2 liters)
for 8 - 12 working hours.

Make sure the power is off.
1.2 Machine lubrication

1.2.1 Lubrication method:
Lubrication is for maintaining the life and accuracy of the machine.
Defective lubrication can
effect a smooth operation, especially for a lathe which is running for a long time.
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1.2.2 Lubrication Pump:

There are 2 ways the lubrication pump can be activated, manual
for lubrication according to the setting at DGN.
and automatic performance
After power on, the lubricating pump will start
every 5 minutes by manual performance, or will start every 3 minutes by automatic performance.
It will discharge a volume of 5cc at a pressure of 15kg/sq.cm for around 2 seconds
About 8 - 12 hours use 1 barrel (2 liters).
at a time.
Parts for lubrication including carriage of X, Z axis,
tailstock carriage, and tailstock quill.
1.3 Recommended Machine Way Lubricants for Victor Machines

Manufacturer
Description
Kin. Viscosity
40C 100C
VI
Index
Number
Flash Point
(C.O.C.)
ELF
MOGLIA 68
68
8.9
103
246
BP
MACCURAT D 68
65
8.9
109
216
CALUBE
WAY OIL 68
65.3
9.2
110
215
70.9
9.1
102
226
64.6
7.7
---
190
63
8.7
115
166
68
9.2
115
236
64.7
8.80
110
230
66.6
9.2
113
212
CPC
ESSO
FEBISK 68
MOBIL
Vactra Sevies 68
NIPPON GREASE WAY LOBE OILH-68

NISSEKI
UNIWAY 68
PRTRO-CANADA ACCUFLO 68
PHILLIPS
WAYLUBE 68
61
7.9
95
224
SHELL
TONNA OILST 68
68
9.3
---
232
SHOWA
A-R OIL 68
68
8.8
106
240
SPECIALTY
MACHINE WAY
65
7.2
---
201
LUBRICANTS 68X
SUNOCO
WAYLUBE 1180
68
9.1
110
216
TOTAL
DROSERA MS 68
68
9.3
108
230
46
6.74
110
215
VIP
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1.4 Recommended Hydraulic Oils for Victor Machines

Manufacturer
Description
Kin. Viscosity
40C 100C
VI
Index
Number
Flash
Point
(C.O.C.)
ELF
ELFLNA DS 32
32
5.5
103
200
BP
BARTRAN 32
32
6.3
153
200
CALTEX
RANDO OIL HD 32
31.8
5.5
110
210
CALUBE
HYDRAULIC AW
30.4
5.3
102
212
OIL ISO 32
ESSO
UNIVIS N 32
30
151
212
FREEDOM
HIGH VI ISO 32
32
6.28
150
201
IDEMITSU
DAPHNE SUPER
33.31
6.22
138
196
HYDRO WR 32
NISSEKI
SUPER HYRANDO 32
32.5
5.68
115
228
PRTRO-CANADA
PREMIUM AW 32
30.8
5.23
104
212
PHILAPAK
CAYDOL HVI 32
30.4
5.3
102
212
PHILIPAK
CAYDOL AWI 32
32.6
6.5
150
182
SHELL
TELLUE OILS ISO 32
32.0
5.1
103
198
SHELL
TELLUS OILS ISO 32
32.0
5.4
104
216
SINO
S.O. HYDROIL HVI-S 32
33
6.9
170
180
Note:
For a new machine, the hydraulic oil should be changed after first 1000
hours/6 months and then every 2000 hours/1 year thereafter.
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1.5 Regular Check and Clean List

1.5.1 Cleaning hydraulic unit
1.5.2 Cleaning of lubricating pump:

Cleaning every 2 - 3 months. While the lubricating oil is used up, take off the fixed spring, which
at 2 sides of the lubricating pump with a screwdriver, move out the transparent oil tank, empty the
remaining oil and clean it. Meanwhile, clean the oil absorber filter mesh, which is at the bottom
of the lubricating pump. Then move back the oil tank, fix it with a spring and add lubricating oil.
1.5.3 Cleaning of oil dispenser:

If the using period of lubricating oil is abnormal, check the oil dispenser. Take off the fixed
screws on the plate at the back of the machine, 2 persons should take the plate down, and take off
the proportion dispenser and oil dispenser with an open wrench and a hexagon wrench.
Dismantle the oil dispenser in a clean environment place, note the order of assembly, assemble it
after cleaning with fuel oil and air.
1.5.4 Cleaning of splash cover of chuck:

Cleaning every 2 - 3 months. Take off soft jaws or hard jaws from chuck, and step on the foot
switch making the chuck open, take off 3 bolts at the center of the chuck with a hexagon wrench,
and take off the splash cover with a screw driver. Clean up the grease which is stuck on the slide
block. After cleaning the oil and dust, fit the splash cover back and fix it with 3 bolts. It is
prohibited to touch foot switch during the procedure of taking-off and fitting.
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1.5.5 Cleaning of chip conveyor tank:

Clean every 6 months, but clean every 3 months if its for cast iron processing. Take off the power
supply for the chip conveyor and cutting oil from the back of the machine, and take off the cutting
pump pipe with a screw driver; drag the conveyor to the right until the cutting pump is away from
the machine, then move out the conveyor. Take apart the conveyor and tank by hoist or manually,
clean out the cutting oil and chips in the tank. After cleaning, assemble the conveyor and tank
and fit them back to the machine. And then connect the power supply for the chip conveyor and
cutting pump, and fit in the cutting oil pipe.
1.5.6 Cleaning of chips collecting trough under the cylinder:

Clean once a month, but if there is no pad used in the hole of the chuck during processing, then it
needs cleaning once a week. Open the plate at the back of the spindle, located at the left side of
the machine, take off the mesh type chips collecting through under the cylinder, clean the chips
away and put it back.
1.5.7 Cleaning of chips collecting trough under Z axis anti-rusting plate:

Clean once a month.
Open the plate at the back of the spindle, located at the left side of the
machine, clean out the chips and cutting oil in the oblong chips collecting trough at the bottom of
the Z axis anti-rusting plate. If there is too much cutting oil, it will drop onto the servo motor and
therefore it will cause a short circuit.
1.5.8 Cleaning and replacement of filter mesh:

Do it once a month. Use cross driver to take down the trellis shape plate located at the right
bottom of the main power switch, take off the mesh, and replace a new mesh, then fit the plate back.
The mesh can be used again after washing and dry out, or use new sponge, which can be bought
from a store.
1.5.9 Cleaning of coolant filter:

Clean once a month. Lift the plastic bag of coolant filter on the electric box by hand, and take out
the filter, use air blower to clean the dust and oil on the filter, if necessary, clean it by water and fit
it back after it dries out.
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1.5.10 Replacement of battery:

About every 2 years. Based on the different using period, if the screen appears Alarm 2, and the
bottom of screen shows "BAT" letters, buy 3 pcs No. 1 alkaline battery, at power on condition, take
off the battery set cover with a philips screw driver, and replace with a new alkaline battery (watch
out the phase position), then fit the battery cover back.
1.5.11 Replacement of bulb:

If you have to replace a new bulb for a blown bulb.
Before replacement of bulb, turn off the main
power switch, then turn the black plastic button in front of working light in a counterclockwise
direction, and take it down, move out the condensing cover and bulb, take out the blown bulb and
replace a new one, fit the condensing cover and bulb back, and turn the black plastic button
clockwise direction to the original position.
1.5.12 Replacement of fuse:

For blown fuse, the transparent part will change to a black colour if its blown. Replace the fuse
with another of the same specification manually. If it immediately blows again after power on
call a technician to solve the problem.
1.5.13 Replacement of drier:

Every six months.
Take out the drier, which is inside the electric box, under sunshine for about 6
hours, then put it back into the electric box.

which can be bought from a drugstore.
If the drier is unusable, then replace it with a new one
1.5.14 Replacement of limit switch:

If the limit switch breaksdown, replace with a new one with the same specification.
Turn off the
power before replacement. The machine has to make adjustment after replacing some limit
switches, so call up service department for confirmation before replacement. If necessary, the
replacement should be taken care by a technician.
1.5.15 Replacement of sensor:

Same as above point.
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Troubleshooting and Maintenance Manual