General Mainrenance

In pursuit of excellence
Presentation On
1. TELESCOPIC COVER.
2. SPINDLE.
3. HYDRAULIC.
4. COOLANT / CUTTING OIL.
5. LUBRICATION.
6. PNEUMATIC.
7. FRONT DOOR PANEL.
1. TELESCOPIC COVER In pursuit of excellence
Check point Method Remarks
Noise Abnormal Noise

Chips or Replace if
Dents Clean by Brush required
Wiper
Condition Visual Servo way 68
Lubrication Manual Smear Oil
Telescopic Cover Telescopic Cover

2. SPINDLE In pursuit of excellence
Spindle Bore Clean the Check the

& Taper current at
Tool Holder ( By dry maximum
cloth) RPM
To be < 25%
at no load
Tool Holder
At Machine Spindle Bore
3. HYDRAULIC In pursuit of excellence
Power Pack Use Servo

Oil level / Temp/ Touch & Feel system 32 oil
Leakage/pressur Visual
e
4. COOLANT / CUTTING OIL In pursuit of excellence
Coolant Level Visual To be at green level

check Ph = 8.5 ; 6-8%
Water soluble coolant
Float
5. LUBRICATION In pursuit of excellence
Oil level & Visual Servo way -68

Pressure 15 Bar (1.5MPa)
when inched on Gauge
6. PNEUMATIC In pursuit of excellence

Filter Drain water – Servo – Spin 12
Regulator Auto 5 Bar on Gauge
Lubricator Oil Level
Pressure Visual
7. FRONT/SIDE DOOR PANEL In pursuit of excellence
Clean ( By Dry cloth) Manual

• 1. Panel Cooler Filter

• 2. Tool Posts
1. PANEL COOLER FILTER In pursuit of excellence

Mesh Clean
Manually
2. TOOL POST In pursuit of excellence
Chip Clean ATC Magazine

accumulation manually is isolated
from chips
1. Hydraulic
2. Brake ( ATC arm & MAG Motor)
3. Tool ejection
4. CTS suction strainer
5. Rotary joint CTS Deublin
6. CTS Gasket
7. Coolant Tank
8. Split collet
1. HYDRAULIC In pursuit of excellence

Suction Clean manually &
stainer & check clog
Return line indicator
filter
2. BRAKE
( ATC ARM & MAG MOTOR)

Actuation Sound during Check gap =
actuation 0.2mm in
released
condition
Feeler 0.2 mm
3. TOOL EJECTION In pursuit of excellence

Ejection in Auto - By As per
( 0.7 - 0.8 ) Ejection Design
gauge
4. CTS SUCTION STAINER In pursuit of excellence

At the inlet of Clean manually by
the Pump diesel and air
5. ROTARY JOINT CTS DEUBLIN In pursuit of excellence

Leakage Visual Replace if Req
6. CTS GASKET In pursuit of excellence

Leakage Visual Replace pin Locator
7. COOLANT TANK In pursuit of excellence

Change Manually Check
coolant after concentration 6-8%
cleaning the Ph – 8.5 Preferably
tank Yushiro
8. SPLIT COLLET In pursuit of excellence
Tightness / Visual – Check Replace if

Wear out Run out as std wear out
test
1. Tool clamping force

2. Heat sink Fan
3. ATC Side & front mounted
4. Ball screw & Guide way
1.Tool Clamping Force In pursuit of excellence

At Spindle By clamp rite As per Manual
gauge
2.Heat Sink Fan

Visual Clean
clogging manually
3.ATC Side mounted

Alignment 3 Piece alignment As per

gauge ( while tool Manual
changing)
4.BALL SCREW & GUIDEWAYS In pursuit of excellence

Metering Manually Open
cartridges & observe the telescopic
lub hoses oil flow cover and
check replace
if required
1. ATC Gearbox oil

2. Hydraulic
1.ATC Gearbox oil In pursuit of excellence

Oil Change Servo system 150
SIDE ATC
FRONT ATC
2.Hydraulic

Oil Change Servo system 32
1. Disc Spring
1. Disc Spring

Message Change / Replace Disc
Message Spring set
1. Spindle – Indirect Drive

2. Drive & system Fan
1.Spindle – Indirect Driv In pursuit of excellence

Belt tension Adjust Ref Maint manual
2.Drive Fan
Drive Fan Clean manually
1. Hydraulic accumulator
1.Hydraulic Accumulator In pursuit of excellence
Accumulator Check shutoff value

tightness & gas
charge / leakage
MACHINE HEALTH CHECKUP POINTS
BASE BUILD ASSEMBLY:
1. Check for smooth movement of the axis and for

current percentage.
2. Check for lubrication of all three axis (metering

cartridges and hoses etc).
3. Check for telescopic cover wipers.
4. Check guide ways condition.
5. Check for telescopic cover lip condition and for gap.

6. Check for X & Y axis drain hole for size and blockage.
7. Check for ball screw support bearings condition and ball screw
condition.
8. Check all three axis coupling for proper tightness.
9. Check for axis backlash & repeatability.
10. Check for telescopic cover scissors lock nut, replace if

damaged.
11. Check for lubrication On/ Off timing and alarms.
12. Check for X axis motor condition and its connection.

SPINDLE & DRAWBAR ASSEMBLY:
1. Check for spindle run out, axial play, radial play, bearing condition etc.
2. Check for spindle orientation position and proximity setting.
3. Check tool clamping force and record.
4. Check for draw bar stroke for tool ejection.
5. Check for disc spring and split collet condition.
6. Replace all the O rings of draw bar once dismantled.
7. Check for belt, pulley tightness & belt resting ring condition etc in ID machines
and rotary table.
8. Check for rotary joint (Deublin / RIX) condition for leakages, run out, tightness
etc.
9. check coolant leakage from the rotary joint in the spindle motor and check any
blockages in drain hose.
10. Check whether proper pull studs are used as per our standard.
ATC:
1. Check for second reference position for height & set stoke w.r.t table.
2. Check for arm play and plunger actuation.
3. Check for V grove match.
4. Check arm alignment with the help of three piece gauge.
5. Check for pocket ball and springs, pocket gripper spring.
6. Check for pocket up / down and sliding cylinder for proper functioning.
7. Check for brake actuation of both arm and magazine torque motors.
8. Check for smooth movement of magazine.
9. Check for magazine chain tension (Horizontal).

APC :
1. Check for proper functioning of pallet clamp/ de clamp

cylinders, solenoids and its pressure switch setting.
2. Check for third reference position for the alignment
3. Check for chips accumulation near loading station side.
4. Check for chips accumulation near cup & cone seating area.
5. Check for chips accumulation in between pallet & arm.
6. Check for pull stud condition of cone clamping.
7. Check for proper back pressure build up in pallet clamp seat

sensor unit after pallet clamp.
HYD. POWER PACK:
1. Check pump condition for temperature, noise
2. Check oil cooler condition and fan mesh cleaning.
3. Check return line filter & suction strainer.
4. Check for any leakages from the valves etc.
5. Check for any loose connection in connectors for solenoid , pressure switch etc.
6. Hydraulic float switch & clog indicator checking.

COOLANT SYSTEM:
1. Check for proper usage of coolant and its management viz.

water usage, concentration, PH value, hardness, foaming,
coolant type and make etc
2. Check for all pump condition, motor direction and MPCB setting
as per motor ratings.
3. Check for coolant effectiveness of gun, chip push, side flush

etc.
4. In CTS machines, check for condition of float switch, suction

strainer, flow switch and for any leakages.
5. Check for CTS gasket and HP air blast.
6. Check for coolant low level proximity proper setting.

Problem solving
Step1: Observation
1. Observation is the first step- Never switch off power when there is an
alarm. (You may press emergency button in some cases)
2. Don't get panic , take some time before you act.
3. Record your observations , talk to the operator.
Step 2: Find the problem

1. Start from the Machine elements that can cause the problem.
2. Next check the external conditions like In put power ,

temperature , vibration .. And physical conditions like coolant
entry , Moisture deposit, etc.
3. Next check the cables / loose connections , connectors, etc.

Problem solving
4. By now you should be able to identify the cause of the
problem.
5. Then check if any hardware failed due to the above cause .
6. Study the cause and implement corrective measures.
Step 3: Corrective Action
1. Never replace the hardware until you are sure that the cause
of the problem is identified and corrective action is taken.
2. Always consult MMT/AMS in case you would like to change

any hardware.

General Mainrenance

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In pursuit of excellence

Check point Method Remarks

Noise Abnormal Noise

Telescopic Cover Telescopic Cover

Check point Method Remarks

Spindle Bore Clean the Check the

Check point Method Remarks

Power Pack Use Servo

Check point Method Remarks

Coolant Level Visual To be at green level

Check point Method Remarks

Oil level & Visual Servo way -68

Check point Method Remarks

Check point Method Remarks

Clean ( By Dry cloth) Manual

• 1. Panel Cooler Filter

Check point Method Remarks

Check point Method Remarks

Chip Clean ATC Magazine

Check point Method Remarks

Check point Method Remarks

Check point Method Remarks

Check point Method Remarks

Check point Method Remarks

Check point Method Remarks

Check point Method Remarks

Check point Method Remarks

Tightness / Visual – Check Replace if

1. Tool clamping force

Check point Method Remarks

Check point Method Remarks

3.ATC Side mounted

Alignment 3 Piece alignment As per

Check point Method Remarks

1. ATC Gearbox oil

Check point Method Remarks

Check point Method Remarks

Check point Method Remarks

1. Spindle – Indirect Drive

Check point Method Remarks

Check point Method Remarks

Accumulator Check shutoff value

1. Check for smooth movement of the axis and for

2. Check for lubrication of all three axis (metering

3. Check for telescopic cover wipers.

4. Check guide ways condition.

5. Check for telescopic cover lip condition and for gap.

8. Check all three axis coupling for proper tightness.

9. Check for axis backlash & repeatability.

10. Check for telescopic cover scissors lock nut, replace if

11. Check for lubrication On/ Off timing and alarms.

12. Check for X axis motor condition and its connection.

2. Check for spindle orientation position and proximity setting.

3. Check tool clamping force and record.

4. Check for draw bar stroke for tool ejection.

5. Check for disc spring and split collet condition.

6. Replace all the O rings of draw bar once dismantled.

2. Check for arm play and plunger actuation.

3. Check for V grove match.