M.S.K. MOTOR KOMPRESÖR MAKINA SAN. TIC. LTD. STI.

Nilufer Organize Sanayi Bolgesi 113. Sk. No: 23 Nilüfer Bursa Turkey 16140

Tel : +90 224 411 07 45 Fax : +90 224 411 07 49

PRODUCT AND MAINTENANCE MANUAL

COPY-MILLING MACHINE

Model No. OMRM 117

YOUR OZGENC DISTRIBUTOR IS:

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1 INTRODUCTION

TABLE OF CONTENTS

1. INTRODUCTION ............................................................................................................................... 3

2. SAFETY MEASURES .......................................................................................................................... 4

2.1 SYMBOLS USED IN THIS MANUAL ........................................................................................... 4

2.2 SAFETY INSTRUCTION .............................................................................................................. 5

3. MACHINE DESCRIPTION .................................................................................................................. 6

3.1 GENERAL VIEW ........................................................................................................................ 6

3.2 TECHNICAL DESCRIPTION ........................................................................................................ 8

3.3 TECHNICAL SPECIFICATIONS .................................................................................................... 8

4. INSTALLATION ................................................................................................................................. 9

4.1 TRANSPORTATION DIRECTIONS .............................................................................................. 9

4.2 WORKING CONDITIONS ......................................................................................................... 10

4.3 MACHINE MOUNTING AND INSTALLATION .......................................................................... 11

4.4 INITIAL CONNECTION ............................................................................................................ 12

5. OPERATING PRINCIPLE .................................................................................................................. 13

5.1 MACHINE CONTROLS............................................................................................................. 13

5.2 SWITCHING THE MACHINE ON .............................................................................................. 14

6. SERVICING AND LUBRICATING THE MACHINE .............................................................................. 15

6.1 MAINTENANCE TABLE ........................................................................................................... 16

6.2 REGULAR LUBRICATION POINTS............................................................................................ 16

6.2.1 OILS RECOMMENDED FOR REGULAR LUBRICATION ..................................................... 16

6.3 Change milling cutters of triple drilling motor ...................................................................... 17

6.4 REED SWITCH ADJUSTMENT ................................................................................................. 18

7. PNEUMATIC PARTS ........................................................................................................................ 19

7.1 VALVE AND CYLINDER INSPECTION ...................................................................................... 19

7.2 ADJUSTING THE PNEUMATIC CYLINDER TRAVEL SPEED ....................................................... 20

7.3 LUBRICATOR .......................................................................................................................... 20

7.4 WHAT LUBRICATOR IS NECESSARY FOR ................................................................................ 21

7.5 OILS APPROVED FOR LUBRICATOR USE................................................................................. 22

8. TROUBLESHOOTING ...................................................................................................................... 23

8.1 WHAT TO DO IF A MALFUNCTION IS PRESENT...................................................................... 23

8.2 PROBLEM – CAUSE – SOLUTION TABLE ................................................................................. 23

9. CIRCUIT DIAGRAMS ....................................................................................................................... 25

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2 INTRODUCTION

9.1 PNEUMATIC CIRCUIT ............................................................................................................. 25

9.2 ELECTRICAL CIRCUIT .............................................................................................................. 26

10. PARTS LIST ................................................................................................................................. 28

10.1 MECHANICAL COMPONENTS ................................................................................................ 28

10.1.1 TRIPLE DRILLING MOTOR ASSEMBLY ............................................................................ 28

10.1.2 PNEUMATIC CLAMP ASSEMBLY..................................................................................... 28

10.2 ELECTRICAL AND PNEUMATIC COMPONENTS ...................................................................... 29

11. WARRANTY ................................................................................................................................ 30

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3 INTRODUCTION

1. INTRODUCTION

Congratualtions! You have just purchased a high quality piece of equipment. No doubts, you have made a right and a reasonable choice, because our production is highly reliable and conforms to European quality standards. The equipment is easy to operate, has high consumer properties and will last for long.

This user manual covers the operation and usage of the machine. Each operator may work with this machine only after he or she had read this manual and understood it thoroughly.

The manufacturer guarantees the operability of the machine during the warranty period provided that it is operated properly and complies with all the requirements of this manual.

MANUFACTURED BY:

M.S.K. MOTOR KOMPRESOR MAKINA SAN. TIC. LTD. STI.

Address : Nilufer Organize Sanayi Bolgesi 113. Sk. No: 23 Nilufer

Phone No. : +90 224 411 07 45 pbx

Fax : +90 224 411 07 49

Web : www.mskmakina.com.tr

E-mail : info@mskmakina.com.tr

Some operational characteristics of the machine are possibly not specified herein.

We performed surveillance to verify the information herein. However, presence of some inconsistency is possible and complete conformance is not guaranteed.

The producer reserves the right to modify and instructions.

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4 SAFETY MEASURES

2. SAFETY MEASURES

1. Operation of the machine will be performed only by the operator. 2. Start the operation only after you have made sure that you have thoroughly understood all

the designations and definitions pertaining to safety. 3. The operator, who did not read or understand this manual, may not work on or operate this

machine. 4. Knowledge and understanding of this manual is important to prevent injury to the operator

and damage to third parties, animals, environment and machine itself.

Do not operate the machine without observing all the provisions mentioned above because such operation is undoubtedly dangerous!

2.1 SYMBOLS USED IN THIS MANUAL

Indication of information necessary to familiarize the user with the machine.

Indication of necessity of consulting the manual before operating the machine.

Indication of the safety guidelines to be observed in order to prevent possible damage to the machine.

Warning of high voltage presence.

Warning of possible injury and any kinds of temporary damage.

Warning of possible emergencies causing injury or death.

Indication of necessity to wear protective clothing

Indication of necessity to wear hearing protection while operating the machine.

Indication of necessity to wear eye protection while operating the machine.

Indication of necessity to wear gloves while operating the machine.

Warning of possible hand injury when it is jammed.

Prohibitive sign. Do not touch. Dangerous.

Warning to perform certain measures before servicing the machine.

Warning of high temperature presence

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5 SAFETY MEASURES

2.2 SAFETY INSTRUCTION

ATTENTION! It is mandatory to read the manual and understand all rules and provisions.

Keep the manual in a safe place. The manual shall be within easy reach in order to be consulted while servicing the equipment.

The person performing the installation of the machine shall thoroughly read and understand this manual.

The operator is prohibited to perform repair in case of machine malfunction. The malfunction repair shall be performed by service professional only.

The machine and its parts shall be protected from any external actions. Check the lubricator regularly and top off the oil if necessary.

It is prohibited to be under the machine during the loading and unloading.

The machine shall be grounded. Operation without grounding is prohibited!

Eye protection shall be used while machine operation.

Hearing protection shall be used against the equipment noise.

Gloves shall be worn while changing the discs.

Only original spare parts shall be used.

Take care of the control panel. Make sure that it is protected from any mechanical damage.

Start-up of the equipment shall be performed only by the service professional. Start-up by any other person is prohibited.

Equipment repair shall be performed only by service professionals and only with genuine spare parts and consumables.

Usage of the equipment for purposes other than its intended use may cause dangerous situations.

Always pay attention and check what you do, do not start the machine operation without thinking. Operation of the machine is prohibited if you are tired or under influence of drugs, alcohol or medications. А minor inattention while operating the machine may cause major injuries.

Operation of the machine with damaged power cable is prohibited. The damaged cable shall be replaced as soon as possible.

Use special work clothes. Do not wear loose-fitting clothing or jewelry. Watch out for hair, clothing and gloves around moving parts. Loose-fitting clothing, jewelry or long hair may be caught with moving parts of the machine.

Power and air supply shall be switched off before performing any repairs or maintenance.

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6 MACHINE DESCRIPTION

Removal of protection components of the machine is prohibited. It shall be remembered that machine protection components are installed there to ensure the safe operation of the machine.

Avoid jamming your hands between profile fixing cylinders and moving parts of the equipment.

Do not open the protective covers until the machine is fully switched off.

Only one operator shall work with the machine.

The machine shall undergo regular maintenance and adjustment. Do not operate the machine if it is out of order.

Do not operate the machine in wet or damp environments.

Touching the heating plate of the machine in operation, as well as touching the plate when it is heated, is prohibited.

3. MACHINE DESCRIPTION

3.1 GENERAL VIEW

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7 MACHINE DESCRIPTION

Fig. 3.1-1 General view

1. Power switch 2. Triple drilling motor control lever 3. Triple drilling motor push-button 4. Milling motor control lever 5. Milling motor push button 6. Horizontal pneumatic clamps 7. Motor to mill copying holes 8. Motor for triple drilling 9. Template

9

2

1

8

7

6

5

3

5

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8 MACHINE DESCRIPTION

3.2 TECHNICAL DESCRIPTION

- manual vertical milling motor feed for milling the fitting recess - manual horizontal low-rpm motor with triple drilling gearbox feed to drill the handle holes - easy angle adjustment and setting of milling depth for drain channels - the scale of copying is 1:1 - special fixture of milling cutter tip prevents bending while drilling reinforced sections - horizontal pneumatic clamps - power supply unit protects the system from power surges

3.3 TECHNICAL SPECIFICATIONS

Total output : 2.3kW Motor output (triple drilling) : 1.1kW Motor RPM : 2810 RPM Voltage : 380V Frequency : 50Hz Air pressure : 6-8 bar Air consumption : 9lpm Dimensions : 1530 x 1000 x 780mm Weight : 125kg Ød1 side milling cutter for triple drilling : 11mm

Ød2 central milling cutter for triple drilling : 12mm length of side milling cutter for triple drilling : 140mm length of central milling cutter for triple drilling : 140mm milling cutter length : 80mm ØD1 milling cutter : 5mm

ØD2 milling cutter : 8mm Milling cutter Х axis travel : 290mm

Milling cutter Y axis travel : 150mm Milling cutter Z axis travel : 110mm Max PVC profile width : 100mm Max PVC profile height : 110mm Min PVC profile height : 40mm

h

a

Fig. 3.3-1 Technical specifications

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9 INSTALLATION

4. INSTALLATION

►The equipment has passed factory operational tests of all mechanical and pneumatic assemblies. All materials and spare parts shipped from the factory were fully and thoroughly inspected before delivery to the transport operator.

►Please check and inspect the equipment on take-over for any damage taken in transit.

4.1 TRANSPORTATION DIRECTIONS

►The machine is shipped in a special packaging. Pay attention to the leveling of the machine’s position on the forklift’s forks.

►Positioning the forks as close to the ground as possible provides balance and ensures good field of view for the forklift operator. The forks shall be adjusted for maximum spacing width and the machine situated in the center.

1. Damage of the cables, cylinders, hoses, lubricator and control panel shall be avoided when loading the forklift.

2. Means of transport shall be appropriately sized for the machine. 3. Avoid hitting the machine while moving it. 4. The machine shall be moved by the forklift truck.

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10 INSTALLATION

4.2 WORKING CONDITIONS

Fig. 4.2-1 Required working area

►To ensure high performance of the machine, it is recommended to place the machine in the shop while observing the manufacturer recommended clearances. Minimum top clearance between the topmost machine part and the ceiling is 2m.

►The understructure shall support machine’s weight (design load bearing capacity - 1 ton per m2)

► The following ambient conditions are advised in order to ensure best operator performance:

Lighting : Sufficiently bright (approx. 500 lux)

Temperature : Room temperature (approx. 15 - 22°C)

Pressure : 6 – 8bar

Humidity : approx. 50-60 %

► Ground line shall be properly provided for the machine

► 380 VAC, 3-phase shall be supplied via fuse box

► Power supply shall be fitted with voltage stabilizer.

Warning: If the machine’s power supply has no voltage stabilizer, warranty on electrical and pneumatic components is null and void!

► 6-8 Bar air supply shall be routed to the machine and provide it with dry air. (A dehumidifier in air compressor outlet ensures dry air supply).

► Proper air hose is required for air supply.

Warning: If air supply has no dehumidifier, warranty on pneumatic valves is null and void!

1500 mm

1000 mm

500 mm

1500 mm

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11 INSTALLATION

4.3 MACHINE MOUNTING AND INSTALLATION

►Make sure the surface and base is even and endurable. Make sure there is enough space around the machine for safe operation, servicing and turn.

►Use level while installing the machine. When the machine is in balanced position then vibrations are decreased, it becomes more simple to operate, performance and performance quality are increased.

►Air pressure shall be 6-8Bar. Thick hose prevents the pressure drop throughout the line. Moreover, moisture ingress shall be avoided to prevent pneumatic cylinders and valves breakage. ►Note: If air supply connection does not include dehumidifier then pneumatic valves are not subject to warranty service!

►The power mains connection shall be performed by the service professional or a certified electrician.

► Used fuse box shall comply with safety norms and electric standards. Power supply line shall be fitted with voltage stabilizer.

► The earthing network prevents damage to the operator from ground current, this is why the construction and reliability of the earth loop are paramount. ►Ground line shall be properly provided for the machine.

► Power surges, voltage spikes and drops are harmful and dangerous for the machine. Use a voltage stabilizer to prevent such events. Otherwise the manufacturer shall be not liable for possible malfunctions. ►Warning: If the machine’s power supply has no voltage stabilizer, then electrical and pneumatic components are not subject to warranty service!

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12 INSTALLATION

4.4 INITIAL CONNECTION

1. Remove the packaging. 2. Position the machine on even horizontal surface. 3. Connect the power (380 V). 4. Connect the air supply (6-8 Bar). 5. Check the lubricator oil level.

►The initial connection shall be performed by the technical support service. The manufacturer assumes no liability for the damage caused by connecting the machine by personnel other than service department personnel.

Initial connection by the service department personnel

Repair the malfunctions resulting from transport

Check the levelling of the installed machine

Check the electrical and air connections

Switch the machine on

Brief the operator

Give directions on safety and maintenance

Note: On initial start-up, milling cutters rotation direction needs to be checked.

Check the direction of the rotation! (Only for three-phase motor version without phase control relay):

►Sometimes, due to phase sequence in the three-phase electrical grid, machine’s motor rotates backwards. This may cause machine or workpiece damage. This is why motor’s direction of rotation shall be checked before each new machine start. To do this, briefly switch on the machine on and check if the milling cutter is rotating in the direction of an arrow mark.

►In case, if the milling cutters are rotating incorrectly, change the phase sequence in the socket connector, to which the machine power supply cable is connected. This shall be done by a qualified electrician!

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13 OPERATING PRINCIPLE

5. OPERATING PRINCIPLE

5.1 MACHINE CONTROLS

Fig. 5.1-1 Machine controls

1. Power switch 2. Milling motor push-button 3. Triple drilling motor push-button 4. Pneumatic clamps 5. Template

Fig. 5.1-2 Template

1. Hole for window handle

2. Holes for fitting recess

3. Holes for drain channels

4. Keyway

5. Holes for door handle

6. Hole for vertical lock

1

2 3

4

5

2 1 4 6 5 3

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14 OPERATING PRINCIPLE

5.2 SWITCHING THE MACHINE ON

►The following conditions shall be present in order to make the machine ready to start.

Set the power switch to the “1” position.

Set the power switch on the control panel to the “1” position.

Pneumatic clamps are open.

Triple drilling motor is in back position.

Profiling motor is in top position.

Before commencing the work make sure that there is no personnel present (service personnel, etc.) in the proximity of the machine, who may suffer injuries from the moving parts of the machine; the operator shall take care to ensure the safety of those who present nearby and around, who also should be warned for the operation of the machine.

OPERATION

1. Switch the power on. 2. Put the workpiece on the frame. 3. Use the clamping valve to fix the workpiece with pneumatic clamps.

Horizontal pneumatic clamps shall be used for profiling or triple drilling. Vertical pneumatic clamps shall be used for milling the drain channels.

4. For triple drilling, switch the motor on with a button and slowly pull the lever towards yourself.

5. For profiling, put the adjuster into the required groove, switch the motor on and pull the lever towards yourself – the motor will lower. Move the motor handle to mill the hole.

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15 SERVICING AND LUBRICATING THE MACHINE

6. SERVICING AND LUBRICATING THE MACHINE

1. Servicing shall be performed by the authorized personnel only. 2. Switch off the power and air supply completely before servicing the machine. 3. Put the power switch in the “0” position to switch off. 4. Disconnect the air supply hose from the machine to fully switch off the air supply. 5. Perform the daily cleanup of the machine regularly. Clean the machine from the cuttings

every day. Use air gun to clean up. 6. Use the types of oil recommended by the manufacturer. 7. Check the lubricator frequently. If it is empty or near empty, fill it with required quantity of

oil. 8. The fuse box shall be air blown from cuttings and dust not less than once a month. 9. The cutters shall be changed by authorized person only. 10. The pressure required for the machine is 6Bar. Check it frequently.

Daily maintenance

► Clean the machine and adjacent surfaces with compressed air.

► Clean the dust and other contaminants with a clean rag.

► Check the cutters. Chipped or broken milling cutters shall be replaced.

► Check the lubricator for condensate. Refer to p. 21

Weekly maintenance

► Check the lubricator oil level.

► Check the lubricator oil supply.

Monthly maintenance

► Lubricate the lubrication points.

► Monitor the weekly maintenance.

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16 SERVICING AND LUBRICATING THE MACHINE

6.1 MAINTENANCE TABLE

DAILY WEEKLY MONTHLY

Clean the working surface from oil, dust etc

Х

Check the milling cutters

Х

Check the lubricator condensate level

Х

Check the lubricator oil level

Х

Check the lubricator oil supply

Х

Lubricate regularly Х

Motor carbon brushes Х

6.2 REGULAR LUBRICATION POINTS

Fig. 6.2-1 Regular lubrication points

6.2.1 OILS RECOMMENDED FOR REGULAR

LUBRICATION

1. Shell: Alvania 3, R3, Cyprina 3, RA 2. Mobil: Mobilux 2, 3, EP2, EP3; Mobilgrease MP 3. British Petroleum: Energrease L2, LS3 4. Exxon: Beacon 3 5. Castrol: Castrol LM, LMX 6. Agip: Agip F1 CR MU3; Agip F1 CP FC3 7. Teboil: Multi-Purpose Grease 8. Texaco: Hytex EP-2 9. Unocal 76: Multiplex Red Grease 2 10. Valvoline: General Multi Purpose Grease

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17 SERVICING AND LUBRICATING THE MACHINE

6.3 Change milling cutters of triple drilling motor

Fig. 6.3-1 Change of milling cutters of triple drilling motor

1. Switch off all air and power supply to the machine. 2. Remove the grease nipple (1). 3. Remove the protective motor cover (2). 4. Remove front milling cutters fixture (3). 5. Hold the milling cutter seat. Use another wrench to loosen the right-handed rotating side milling cutter in the direction specified by arrow mark (counter-clockwise). The central left-handed rotating milling cutter is loosened clockwise. Replace the milling cutter. 6. Reverse the operations after milling cutters are replaced.

Wear gloves when changing the milling cutters.

1

2

3

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18 SERVICING AND LUBRICATING THE MACHINE

6.4 REED SWITCH ADJUSTMENT

►Reed switch is an electromechanical device consisting of a pair of ferromagnetic contacts in a sealed glass balloon. When a permanent magnet is close or an electric magnet is turned on, then the reed switch makes contact. Reed switches are used as no-contact switches, proximity sensors, etc.

►The pneumatic cylinder has an internal magnet. The magnet moves with the piston. The cylinder surface has a reed switch attached, which trip the contact when activated by magnet. If the position of the reed switch is altered, it won’t interact with the magnet, what means that the reed switch won’t be able to send the signal to the system and no action will be performed. In such case the reed switch needs to be moved along the arrow marks, left or right. When the reed switch interacts with the magnet, the LED on the reed switch lights up. This is the position to fix it.

Fig. 6.4-1 Reed switch adjustment

1. Reed switch 2. Piston and magnet

1

2

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19 PNEUMATIC PARTS

7. PNEUMATIC PARTS

7.1 VALVE AND CYLINDER INSPECTION

Fig. 7.1-1 Valve and cylinder inspection

1. Piston cup 2. Ring seal

If the machine does not perform certain operations or if the valve exhaust holes constantly leak air, the following needed to be done:

1. To find the cylinder corresponding to the valve, refer to the pneumatics diagram. If no such diagram is present, follow the cylinder hoses to find the valve.

2. Disconnect the hoses from the А and В ports of the cylinder. Supply air into port А, check the port В. If air leaks through port В, then piston cup is malfunctioning. Likewise introduce air to port В and check the port А.

3. If air leaks around piston rod when air is introduced into В port, then С seal is malfunctioning. 4. If the cylinder has been checked and no air leaks found in А, В and С, but the valve exhaust

still leaks air, then the valve itself needs to be checked. 5. To find if the fault is in the valve or the coil, do the following: coil valves have a button, if the

button is pressed, but nothing happens to the cylinder, then the coil has burnt out and needs to be replaced. The electric signal does not reach the coil. (When current is supplied to the coil, the magnets make audible click)

1 2

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20 PNEUMATIC PARTS

7.2 ADJUSTING THE PNEUMATIC CYLINDER TRAVEL SPEED

Fig. 7.2-1 Adjusting the pneumatic cylinder

►Turn the adjusting wheel (1). Screw to be tighten or loosen (2). This is the way to adjust the pressure of the piston (6) of the cylinder (5) defining the travel speed of the pneumatic cylinder. Turn damper (3) to adjust the air cushion.

►Note: These settings are the same for all types of adjustable pneumatic cylinders.

►The damper provides smooth conversion and removes jolts and bumps.

7.3 LUBRICATOR

►First thing needed for reliable pneumatic system operation is sufficient quantity of clean dry compressed air.

►Lubricator is the element which cleans the compressed air from pollutants, extracts water from it, regulates its pressure and saturates it with oil, which helps to prevent wear on pneumatic cylinders and valves.

► Oil consumption of the lubricator with air supplied is approximately 1 drop per 2 minutes. In case of different oil consumption, adjustments shall be made to the oil feed in pressure regulator.

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21 PNEUMATIC PARTS

7.4 WHAT LUBRICATOR IS NECESSARY FOR

1. The pollutants of the compressor and pneumatic circuit affect the sensitive elements such as pneumatic valves. The lubricator prevents these pollutants from getting into the machine.

2. Water vapor, which is normally present in compressed air, turns into condensate under high pressure. The pneumatic elements may be affected by the condensate, which can cause swelling of the felt seal of the valve or corrosion of the cylinders inner surfaces. Most pneumatic malfunctions are caused by water getting into the system. Centrifugal force traps large water particles in the condensate flask. In case of excessive quantities of condensate in the pneumatic circuit, the system shall be fitted with a dehumidifier.

3. Changes in air pressure may also affect system’s operation. For example, increase or decrease in cylinder travel speed, malfunction of some systems or even system failure at high pressures. The pressure regulator installed on the lubricator keeps the air pressure in the specific range.

4. Most pneumatic system malfunctions are caused by lack of oil in the system. Non-lubricated systems wear out quickly. Also, non-lubricated systems are more affected by the condensate. The pneumatic oil, which is in the lubricator oil spray flask, provides the necessary system lubrication.

USAGE

1. Fill the lubricator oil spray flask with a certain type of oil. 2. If the machine does not consume oil, unscrew the oil supply screw on the oil spray flask,

switch on the machine and adjust the feed rate on the basis of one drop in two minutes while air supplied.

3. Lubricator shall be filled with recommended oil only. Do not use oils of other types such as hydraulic, brake, vegetable or other oils. Usage of such oil types is a definite cause of the system malfunctions and failures.

4. The oil spray flask may be contaminated over time. Empty it, wash the inside with soap and water and fill with fresh oil.

5. Do not forget to drain the water from the condensate flask.

WARNING! The following malfunctions are not covered by warranty:

1. Malfunctions caused by lack of oil in the machines where all the oil was consumed. 2. Malfunctions caused by condensate, overflowing from the condensate flask. 3. Malfunctions caused by using non-approved pneumatic oil, non-approved lubricants or

greases including such as hydraulic, brake, vegetable or other oils.

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22 PNEUMATIC PARTS

Fig. 7.4-1 Lubricator

1. Pressure regulator knob 2. Air pressure gauge 3. Condensate flask 4. Condensate drain valve 5. Oil flow adjusting screw 6. Oil spray flask

ADJUSTMENTS

Pressure adjustment: Pull the regulator knob “1”upwards. Turn clockwise to increase the outgoing air pressure, turn counterclockwise to decrease air pressure.

Condensate removal: Drain the water by pressing on the condensate drain valve “4”.

Filling the lubricator with oil: Turn the oil spray flask clockwise and remove it. Refill with pneumatic oil.

Adjusting the lubrication rate: Turn the adjusting screw “5” clockwise to decrease the flow, turn counterclockwise to increase.

7.5 OILS APPROVED FOR LUBRICATOR USE

1. ESSO NUTO H32 2. MOBIL DTE24SHELL TELLUS C10 3. SHELL TELLUS C10 4. FESTO SPECIAL OIL 5. PETROL OFISI SPINDURA 10 6. ARAL VITAM GF32 7. MOBIL DHE LIGHT

1

4

2

6

5

3

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23 TROUBLESHOOTING

8. TROUBLESHOOTING

8.1 WHAT TO DO IF A MALFUNCTION IS PRESENT

1. Check the power supply 3-phase voltage yourself or have it checked by a certified electrician. 2. The machine needs 6Bar of air pressure to operate. Check that on the lubricator pressure

gauge. 3. Open the valve panel cover. Check for leaks in hoses, fittings and valves. If a leak is present,

try to sort it out. 4. Switch the power off and open the fuse box. Check the circuit breakers. If there are cable

breakage or loose terminal screws, sort that out.

8.2 PROBLEM – CAUSE – SOLUTION TABLE

No movement at all Electric fault Power supply fault Incorrect connection Pneumatic system malfunction

Check the power switch Check the fuses Check the power supply Check lubricator air pressure

Motors do not turn Electric system malfunction Check the power switch Check the fuses Check the contactors and thermal relay Check the motors

Triple drilling motor does not work. No fore-aft movement

Electric malfunction Shock absorber malfunction

Check the phases. Replace the shock absorber

Pneumatic clamps do not work Pneumatic cylinder or valve malfunction Pneumatic connection malfunction Lubricator malfunction

Refer to p. 19 Check pneumatic connections Replace the lubricator

The button does not work Dust in button contacts Loose wire ends Button fused due to fault

Clean with air Fasten wire ends Replace the button

Valve damage Valve coil dislocated Valve coil wires loose or burnt No lubricant in the valve

Replace the coil Fasten or replace the wires Lubricate the valve

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24 TROUBLESHOOTING

Central shaft glands damaged. Dirt in the limiters Air hose damaged

Replace the glands Clean the limiters Check the hose. Try to repair the mentioned valve malfunctions. If this does not help – replace the valve

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25 CIRCUIT DIAGRAMS

9. CIRCUIT DIAGRAMS

9.1 PNEUMATIC CIRCUIT

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26 CIRCUIT DIAGRAMS

9.2 ELECTRICAL CIRCUIT

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27 CIRCUIT DIAGRAMS

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28 PARTS LIST

10. PARTS LIST

10.1 MECHANICAL COMPONENTS

10.1.1 TRIPLE DRILLING MOTOR ASSEMBLY

10.1.2 PNEUMATIC CLAMP ASSEMBLY

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29 PARTS LIST

10.2 ELECTRICAL AND PNEUMATIC COMPONENTS

Fig. 10.2-1 Fuse box

12

12

15

4

8

20

11

10

9

14

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30 WARRANTY

11. WARRANTY

1. The manufacturer guarantees the product to be free from defects in material and workmanship for 1 (one) year.

The warranty does not cover:

1. Malfunctions resulting from disregarding the guidelines of the user manual. 2. The consumables (milling cutters, drill bits, cutting wheels, Teflon etc). 3. Damage caused by transportation. 4. Damage caused by non-genuine parts. Damage caused by careless or unqualified user. 5. Equipment with the start-up performed by unauthorized technicians. 6. Attempts to repair the machine by personnel without manufacturer authorization. 7. Damage caused by improper transportation, use and service, and also cases of alterations

made to the machine’s serial number. 8. Damage caused by lubricant shortage or use of unsuitable lubricant and the like. 9. Damage caused by absence of air dehumidifier in the air supply. 10. Damage caused by power supply surges, specifically:

a. Phase shortage b. Damage caused by wrong phase sequence c. Overvoltage d. Undervoltage e. Power overload

The manufacturer reserves the right to modify the process and the manual.

16

27

26

28

1

31

17