Daily maintenance 2

Periodical maintenance 4
Every week 4
Every month 5
Every 3 months 6
Every 6 months 7
Every 12 months 9
Lubrication 7 7
Major operation faults 73
Fuses & motor breaker 74
Registration of custom macros 15

Turn off the machine. circuit breaker switch before

inspecting or sewicing the machine unless
power is required for the inspection or sewicing.
DAILY MAINTENANCE

A AWARNING
Turn off the machine circuit breaker switch before
inspecting or servicing the machine unless
power is required for the inspection or servicing.

inspect and maintain machine parts as described below before starting

the day’s operation, or as required when the operation is interrupted.

Cleaning
Clean the following parts - and the other parts as required:
Upper and lower X-axis guide bars.
Front and rear Y-axis guide bars.
Index pins and their holes.
Upper turret and punch heads.
Lower turret (Be sure to remove chips.)
Brush table

Lubrication
Lubricate the following parts - see “Lubrication” for lubricating
locations and recommended oils:
Workclamps.
Index pin holes.
Turret slides.
Punches and dies (Check to ensure that they are firmly mounted.)

Air systems
PRESSURE: Check and adjust the main air pressure, valve lubrica-
tion and the striker blowing air pressure - both are required to be 5
kg/cm* (71 psi). Drain the water accumulated in the air filters of the
press air systems and the air compressor. Check the level of oil in
the lubricators and replenish the oil as required. Refer to Part II, .
Installation, for procedures.
PIPING: Check to ensure that the air system piping is free of leakage
or damage.
Hydraulic system
PRESSURE: Inspect the main oil pressure on their pressure gauges
by opening their stop valves - with the hydraulic pump motor
running and the press stopped. Be sure to close the valves after the
inspection.
Required main oil pressure: high 2QQ+5 kg/cm*
low 1 QQ_+5 kg/cm*
EXTERMAL 65&5 kg/cm*
Contact AMADA if either pressure is outside of the required range.

OIL LEVEL: Check the level of oil in the hydraulic oil tank and
replenish the oil as required - the level should be between the high
and low level marks on the level gauge when punching is being
performed.
PIPING: Check to ensure that the hydraulic and cooling water system
piping is free of leakage or damage.
COOLING WATER UNIT: Check the amount of water in the cooling
water unit and replenish water as required. Also check and adjust
the amount of water flow.

Others . I - -
TAPE READER: Clean the
stlrfaces of the tape guide
f . ‘0. , . .
and reading head of the tape
reader by using cotton gauze
or swabs dampened with
absolute alcohol. 1
TOOLS: Inspect the tools for wear or damage -the condition may
be determined by burrs on punched holes. Regrind the worn tools as
required.
PERIODICAL MAINTENANCE

I A WARNING
Turn off the machine circuit breaker switch before
inspecting or servicing the machine unless
power is required for the inspection or servicing.

Every week
Inspect and maintain machine parts as described below every week in
addition to other periodical maintenance programs
LUBRICATION
Lubricate the upper and lower X-axis guide bars and the front and rear
Y-axis guide bars - see “Lubrication” for their locations and
recommended oils.
TAPE READER
l Clean the light source lamp and lens by using cotton gauze or
swabs, and absolute alcohol if necessary.
l Clean the bottom of the tape box by using a piece of cloth, brush, or
vacuum cleaner.
l Clean the tape retainer magnet by using cotton gauze dampened
with absolute alcohol. If the magnet has attracted metal dust,
uncover the magnet by removing the screw on the tape passage
side, and remove the dust by using a piece of adhesive tape.
l Clean the tape retainer, stop shoe, capstan roller, and pinch roller
by using cotton gauze or swabs dampened with absolute alcohol.
AIR LUBRICATOR
Check the air lubricators of the main air pressure system and the
striker blowing air pressure system for the frequency of oil drops and
regulate the frequency as required:
Main air pressure system:
One drop per 5 in-and-out operations of the turret index pins.
Striker blowing air pressure system:
One drop per 5 to 10 hits (large punches).
 Turn the lubricator adjustment screw clockwise to decrease the
frequency or counterclockwise to increase it.

MAIN AIR PRESSURE SYSTEM STRIKER BLOWlNG AIR PRESSURE SYSTEM

Every month
Inspect and maintain machine parts as described below every month
in addition to other periodical maintenance programs.
LUBRICATION
Lubricate the following machine parts - see “Lubrication” for their
locations and recommended oils.
Turret drive gears Y-axis bearings
Upper turret tensioner bearing Y-axis ball-nut
Lower turret tensioner bearing d X-axis bearings
Upper turret disk beating X-axis ball-nut
Lower turret disk bearing C-axis driven points
Striker C-axis wormgear housings
Ram C-axis index pin holes
NC AIR FILTER
Detach the air filter from the back
of the cabinet by removing the
two screws and clean the filter by
blowing compressed air on its
inside surface. If the filter is
heavily covered with dust,
immerse it in the water mixed
with synthetic detergent (2 to 4 g
per liter of water) for several
minutes, wash it by rubbing,
rinse it, and dry it in the shade.

COOLING WATER UNIT

Drain the water and clean the tank, sprinkler, strainer, and outside.
Refill the tank with clean water.
Every 3 months
Inspect and maintain machine parts as described below every 3
months in addition to other periodical maintenance programs.

LUBRICATION
Lubricate the following machine parts - see “Lubrication” for their
locations and recommended oils.
T-axis gearbox Y-axis gearbox
Turret drive chains C-axis gearbox

HYDRAULIC OIL CHANGE

Change the hydraulic oil and line filter elements as described below
after the initial 3 months of operation - and every one year or 2QOO
hours of operation, whichever comes first, thereafter.
Recommended hydraulic oil: AMADA Hydraulic Press TV-1 1 OX
Required amount of hydraulic oil: 200 liters (53.3 U.S. gal)
Low pressure line filter element: P-GC-12-5-I 0~ (TAISEI)
High pressure line filter element: P-GF-A-03-3-10~ (TAISEI)

7 Confirm that the machine and the NC are turned off.

2 Check that the temperature of the oil in the tank is below 40°C.
3 Open the pressure stop valves and confirm that the main and
pilot pressure gauges indicate zero.

4 Open the drain stop valve located below the oil level gauge to
drain the tank.
5 Detach the side cover by removing their screws.
 6 Detach the filter hqusings by
removing the fixing bolts and
change the elements.
Prepave the oil container,
because little amount of oil
will drain out of the filter
housing at this time.

. 7 Attach the filter housings.

8 Close the drain stop valve.
9 Fill the tank with the new hydraulic oil.
9 0 Attach the side cover.
7 I Turn on the machine and the NC.

72 Change the operation mode to MDI and perform a warm-up

operation repeatedly for five times.
13 Confirm that the required pressures are indicated on the pressure
gauges and that there is no leakage from the two plugs. Then
replace the side cover.

Every 6 months
Inspect and maintain required pressures for the hydraulic accumulators
as described belo,w every 6 months in addition to other periodical
maintenance programs.
NOTE :
The procedure requires a pressure gauge, a 3-way valve, and
nitrogen gas. The pressure in the pilot line accumulator may drop .
during the inspection procedure since the accumulator has a small
capacity.

A WARNING
The following procedure is hazardous.
Have a qualified serviceman carry out the work.
7 Remove the machine top cover to expose the main line and servo-
valve pilot line accumulators.
2 Remove the fuse protection nut from each accumulator and attach
the 3-way valve (see note) in place of the nut.
N O T E: Be sure that the 3-way valve’s relief valve is closed, valve
handle is Ioosened,.and intake is capped at this time.
High pressure & Low pressure LINE ACCMULaTORS

NUT

PRESSURE
GAUGE
CONNECTOR

3 Attach the pressure gauge to the 3-way valve, tighten the valve
handle, and read the pressure.
4 If the reading is below the required pressure, supply nitrogen gas
through the intake of the 3-way valve. The required pressure for
each accumulator when the hydraulic pump is stopped is as
follows:
Low pressure line accumulator: 68+3.4 kg/cm* (967248 psi)
High pressure line accumulator: 135+_8 kg/cm* (1920+,113 psi)
Every 12 months .
Inspect and maintain machine parts as described below every 12
months in addition to other periodical maintenance programs.
HYDWAUL%C Q%L CHANGE
change the hydraulic oil and line filter elements every one year or
2000 hours of operation, whichever comes first. See page 6 for the
procedure.
BACKUP BATTERIES
change the backup batteries which are installed in the NC and the
PHNC as described below. These batteries are used to maintain the
programs and parameters in the memory when the NC or the PHNC is
turned off. If they are consumed, the programs and parameters in the
memory will be lost entirely. In addition to the change every year, the
batteries must also be changed whenever a battery alarm has been
caused.
NC BACKUP BATPERIES
(3 AMI alkaline-manganese dry batteries)
NOTE: Be sure to turn on the NC during the following procedure. The
programs and parameters in the memory will be lost if the NC is turned
Off.

1 Loosen the two set screws to

detach the cover of the battery
storage.
2 Remove the old batteries and
set the new batteries with their
plus and minus terminals
correctly placed as shown on
the storage.
3 Replace and clamp the cover.
A battery alarm will be identified by
the message “2007 BATTERY” and the
word “BAT” displayed on the CRT
screen when the NC is turned on. In
this case, change the batteries in the
same manner as described above,
then press the RESET key, and con-
firm that the alarm display has disap-
peared. If the alarm display is still on,
the batteries may be set incorrectly or
they are defective - check the
setting or change the batteries.

9
 PI-MC BACKUP BATTERIES
(3 AMY alkaline-manganese dry batteries)
NOTE: Be sure to turn on the PHNC during.‘the following procedure.
The parameters in the memory will be lost if the PHNC is turned off.

WARNING
a
The following procedure is hazardous.
Have a qualified serviceman carry out the work.

Open the electrical control cabi-

net and then turn on the circuit
breaker switch.
Open the battery storage, remove’
the old batteries, and set the new
batteries with their plus and
minus terminals correctly placed
as shown on the storage.
Confirm that the LED (LD3: BAT)
on the PHMPU board on the back
of the battery storage is unlighted.
If the LED is lighted, the batteries
may be set incorrectly or they are
defective - check the setting or
change the batteries.

Close the battery storage and turn off the circuit breaker switch.
Close the electrical control cabinet.
A battery alarm will be identified by the message “BATTERY WARN”
shown on PHNC display when the power is turned on. In this case,
change the batteries in the manner as described above, then contact
AMADA immediately to reset this alarm.

10
\ - LUBRICATION
Lubricate machine parts, replenish oils, or change oils as described
below during the daily and periodical maintenance operations. See
next page for identification of the machine parts.
RECOMMENDED OILS
A: MOBIL DTE Oil Light, SHELL Tellus-32, ESSO Teresso 32
B: MOBIL DTE Oil Extra Heavy, SHELL Tellus Oil Cl50, ESSO Teresso 150
C: MOBIL Mobil Grease 22, SHELL Alvania Grease RA, ESSO Beacon 325
0: ESSO Hydraulic Fluid TV-1 10X

NQb JvlACHINF PART Q!l FREQUENCY

Lower turret disk’s bearng (grease nipple) C Every month
2 Index pin [lower] (grease nipple) C Every month
3 Index pin [upper] (grease nipple) C Every month
4 T-axis bearing (grease nipple) C Every month
5 Upper turret disk’s bearing (grease nipple) C Every month
6 T-axis gearbox (oil bath) A Every 3 months
7 Striker (grease nipple) C Every month
a X-axis bearing (grease nipple) C Every month
9 X-axis ball-nut (grease nipple) C Every month
10 Y-axis bearing (grease nipple) C Every month
11 Y-axis ball-nut (grease nipple) C Every month
12 X-axis guide bar (grease nipple) C Every week
13 Y-axis guide bar (grease nipple) C Every week
14 Ram (grease nipple) C Every week
15 Cramp (oiler) A Daily
16 Tools (oiler) A Daily
17 Air lubricator (oiler) A Replenish
ia Upper, lower chain (oiler) A Every 3 months
19 Upper, lower wormgear (grease nipple) C Every month
20 Hydraulic unit (oil tank) . D Change after initial 3
months and every 1
year or 2000 hours
thereafter.

11
 TOP VIEW

REAR VIEW

12
MAJOR OPERATION FAULTS
The causes of major operation faults and their remedies are as
follows:

@ The NC cannot be turned on.

- The circuit breaker switch is not turned to ON. Turn the switch to
ON.
- A fuse on the back of the NC unit is blown. Change the fuse.
l The hydraulic pump motor does not start.
- The overload relay has been actuated. Press the reset button
for the motor magnet switch.
- The HYD MOTOR switch in the electrical control cabinet is not
turned to ON. Turn the switch to ON.
- The AIR PRESSURE indicator light is lighted. See below.

* The indicator light is lighted.

AIR PRESSURE

- The operating air pressure has been reduced. Normalize the

pressure to 5.0 kg/cm2 (71 psi).
- Pressure switch PSI is faulty. Adjust or replace the switch.

l Punching cannot be performed.

- The machine is in a stop condition. Reset the condition.
- The index pins are not inserted into the turrets. insert the pins.
- The operation mode is not properly selected. Change to the
proper mode.
- The PRESS SELECTION switch is turned to OFF . Turn the switch to
CYCLE or INCHING.

e The TOP indicator light does not light.

DEAD CENTER

- The ram is not at the top dead center. Change the operation
mode to a mode other than MEMORY and TAPE.
* The X/Y-axis does not operate.
- The x-gauge block is notlowered. Lower the block.
- The tool change door is open. Close the door.
- The workclamps are open. Close the workclamps.
- The pressed STOP button has not been reset. Reset the button.

13
FUSES & MOTOR BREAKER
FUSES
Both circuit protectors and ordinary
fuses are used. A circuit protector will
be turned off if an overcurrent is
supplied to the circuit and can be reset
to the ON position after removing the .
cause of the overcurrent. A blown fuse
can be identified through the hole in
the back of the fuse block. Change the
blown fuse with the spare fuse after
removing the cause of the overcurrent.

MOTOR BREAKER
An overloading of the hydraulic pump motor is protected by a thermal
relay, which will actuate the motor breaker to stop the motor when an
overcurrent is supplied to the motor. The motor breaker can be reset
as follows:
Turn off the NC and then the
machine.
Remove the cause of the
overload.
Reset the lever of the motor
breaker.
Turn the power on for the
machine and then for the NC.

14
REGISTRATION OF CUSTOM MACROS
If the punching programs registered in the memory are erroneously
erased, the custom macroprogram will also be erased. The erased
macroprogram must a%so be replaced by registering the contents of
the custom macroprogram tape* in the memory in addition to the
restoration of the erased punching program.
* stored in the pocket on the inside of the back door of the electrical control cabinet.
7 First, change the data for parameter 0318 (from 10100110 to 00000000)
in the following manner:
1) change the operation mode to MDI and turn the EDIT PROTECT
switch to OFF.
2) Press the &SET key together 7
with the FUNC key, showing 01234 Nf234

the SETTING (SET DATA) display.

3) Press the L/SET key to show
the “PARAMETER SET” prompt.
Then key-in “P* and wow and
press the-INPUT key to seleot
“ENABLE” to permit Setting Of a
parameter. (The NC will be
placed under an alarm con-
dition at this time.)
0 1 2 3 4 N1234
4) Press the PARAMETER-defined /-
soft key, showing a list of
parameter numbers and data.
5) Move the cursor to parameter
number 0318, or key-in “~318”
and press the INPUT key.
NOTICE
8e sure to place the cursor under no
other parameter numbers but “0318”.
I
6) With the cursor placed under - 0 1 2 3 4 N1234
the parameter 0318, key-i.n “P”
and “0 (qro)", and press the
INPUT key, resetting the data for
the parameter to zeros.
7)’ Press the & ET key together
with the FUNC key to show the
“PARAMETER SET” prompt
again. Then key-in “P” and
“0” and press the INPUT key to
Sekt “DISABLE”.
8) Press the RESET key to reset
the NC alarm.

15
 Set the custom macroprogram tape in the tape reader and
register the program in the memory in the normal manner. If
there is a program with the same program number as the custom
macro in the memory, erase the program or change the program
number before registering the custom macro.
Now that the custom r

macroprogram is
-
0 1 2 3 4 N1234
registered in the
memory, the data for :
P

parameter 0318 must be :

Pyzi :
changed back to l
0

Bbzt :P 1

lOlOO in the same :

a

manner described in :
step 1. llli

16