Welcome to the SYIL 5 Series Maintenance and Service Manual
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Maintaining the SYIL 5 Series machine requires a complete understanding of its structure and performance, as well as a good command of its components functions and operating principles.
Performing regular repairs and maintenance is critical ensuring to the machine’s sustained precision and service life. Along with the daily checks and inspections that should occur before starting the machine, proper maintenance of the machine requires observing its Maintenance and Service Cycles at the specified intervals.
A clean, orderly working environment is a crucial precondition for repair and maintenance work. Exposure to dirt, debris, dust, oil contaminants, and humidity can accelerate the deterioration of mechanical equipment and electrical contacts, affecting the functionality, precision and service life of the machine and its components.
It is important to make a detailed plan before carrying out maintenance and service procedures. Throughout the process, records should be kept of how long components have been in use for. Under normal usage conditions, components will eventually reach the limits of their service life after extended periods of use. Failure to replace expired components may result in a loss of precision or complete failure of the machine, and worksites should maintain an inventory of components that can be used to replace old components when necessary.
To minimize the risks of injury or equipment damage, always observe the following precautions when working on the machine:
Ensure that the doors of all electrical cabinets, operation boxes, and protective shields remain closed except as required to carry out scheduled maintenance procedures.
- Avoid using compressed air or other pressure tools to clean the machine equipment, as dirt and debris such as dust, oil contaminants, and metal scraps can enter the bearings, ball screws, and other components when airborne, shortening these components’ service life.
Ensure the power switches in the machine’s control panel and electrical control box are completely shut off before beginning repairs or maintenance inside the moving range of the machine’s worktable.
- Ensure that any slippery surfaces on the floor around the machine are covered with cardboard or wooden boards to prevent maintenance and service personnel from slipping and falling.
In addition, maintenance and service personnel should be familiar with the SYIL 5 Series Safety Rules before beginning work on the machine.
Maintenance and Service Cycles
Effective maintenance of the SYIL 5 Series machine and its components involves procedures that should be scheduled for daily, weekly, monthly, semiannual, and annual service cycles.
Maintenance and service personnel should be familiar with the procedures specified for each of the cycles in this section and ensure they are carried out at the specified intervals.
Daily Maintenance and Service
The following procedures should be conducted at least once each day:
- Wipe away any metal scraps or oil residues that have accumulated on the worktable, machine interior, or extendable protective shields (which cover the three spindles). Apply rust preventive oil to each component after cleaning it.
- After finishing work, wipe clean the main spindle taper hole.
- Clean the tool storeroom, storeroom chassis, and connection rod group, then apply lubricant oil as needed.
- Clean the rail for the tool holding finger on the main spindle head and apply lubricant oil as needed.
- Check that there is sufficient oil in the three-point combined oil reservoir and release the moisture from the three-point combination moisture filter and oil reservoir dim spot.
- Check whether the three-axis automatic lubricating pump is able to start when the power supply is connected. (The automatic lubricating pump works at 15-minute intervals with a feeding volume of 3-6 cc).
- Check the oil level in the three-axis automatic lubricator and add oil if necessary.
- Check for leakage in the oil hose of the hydraulic oil unit.
- Remove metal scraps from the supporting filter mesh.
- Check the cutting fluid level and add fluid as needed. Check for cutting fluid leakage in the chip flushing pipe.
- Check the machine’s signal lamps for indicators of abnormal conditions and confirm that all lamps are working correctly.
Weekly Maintenance and Service
The following procedures should be conducted at least once each week:
- Confirm that the tool pulling plugs are secure and ensure the tool holder is in clean condition.
- Inspect the inner hole of the main spindle and clean as needed. Check the taper’s grinding surface for scratches or scuff marks that could indicate dirt or debris on the tools or in the main spindle’s inner hole.
- Check the oil level in the oil tank.
- Check the oil in the circulating oil feeder and worktable feeding pumps.
- Check whether the three-axis mechanism has become displaced from its original position.
- Clean the machining oil tank’s filter screen.
- Check that all cooling fans are working correctly.
- Check that the tool changing arm is able to operate smoothly.
- Check whether the cutting tool head in the tool storeroom is able to revolve smoothly.
Monthly Maintenance and Service
The following procedures should be conducted at least once each month:
- Clean the control panel, electrical box, and thermal exchanger net.
- Confirm that the machine is horizontally leveled within the specified range, confirm the proper horizontal adjustment of all screws, and check that the fixing screw cap has not become loosened.
- Inspect the angle between the main spindle and the worktable and ensure the two are perpendicular to each other.
- Inspect the three-axis limits and check that the micro switch is operating normally.
- Rinse the cutting fluid tank and clean the cutting fluid and flushing pump.
- Check whether there is any oil, dirt, or dust in the electrical cabinet. After removing any such debris, investigate its origin.
Semiannual Maintenance and Service
The following procedures should be conducted at least once each six months:
- Clean the CNC control unit and control panel.
- Remove the protective shields from the three spindles and clean the oil pipe connectors of the three spindles, ball screws, three-axis limits, and micro switch in their original positions. After cleaning, confirm each of these components is functioning properly.
- Clean all of the machine’s motors.
- Replace the oil in the oil pressure units and in the ATC’s reducer.
- Test whether the machine’s motors produce any abnormal sounds or noises during startup.
- Test all electrical components, units, relays, and high voltage distributors.
- Clean the lubricating pump and oil tank and inspect the connection points of all internal circuits.
- Test the back clearance of each spindle and adjust their correction values and wedge gaps as needed.
- Inspect and clean the cooling fans and confirm they are functioning correctly.
- Clean the inner side of the electrical cabinet and operation cabinet.
- Write a test program to evaluate whether the machine’s relative functions are operating correctly.
- Confirm that main spindle runout does not reach an excessive amplitude and check whether the gaps between bearings in the main spindle have changed in size.
- Check whether any bolts or screw caps have become loose and secure them as needed.
- Check that there is sufficient lubricating grease on each of the sliding rails.
- Perform a thorough check of the machine’s connection points, connectors, sockets, and controls to ensure they are functioning correctly.
- Perform a comprehensive inspection of the insulation’s resistance and make a clear record of the values measured.
Annual Maintenance and Service
The following procedures should be conducted at least once each year:
- Check the sensitivity of the controls on the control panel.
- Use a cleaning cloth and alcohol to wipe away any carbon deposition that has accumulated on the contacts of the relays in the relay cabinet and the operation cabinet.
- Clean the cutting fluid tank and replace the old machining oil with new oil of the same type.
- Clean and replace the oil in the oil pressure unit. Check that the adjustment pressure settings are normal.
Daily Precision Maintenance
To ensure its sustained precision during machining work, operators and maintenance personnel should coordinate to ensure proper day-to-day care of the machine.
Ensure that the following procedures are carried out before, during, and after daily operation of the machine as needed:
Before beginning operation, warm up the machine and check whether oil needs to be added to each of its oil supply points.
- Check that the oil line is unblocked and clear any debris as needed.
After shutting down the machine, apply protective sleeves to the equipment and ensure the saddle seat is placed in the center of the machining area (with the three spindles at the center positions of their respective strokes).
Clean and arrange all tools and appliances in the working area after completing work.
- Maintain the machine in a clean condition.
Keep the machine away from any potential sources of vibration and ensure that the worksite where it is installed is built on firm foundations.
Electrical Cabinet Upkeep
Ensuring correct maintenance of the electrical cabinet and its components is essential to ensuring the machine’s performance and safety during use.
This section introduces the key component areas and procedures involved in maintaining the electrical cabinet in sound working condition.
- The electrical cabinet’s filtering screen should be cleaned and maintained on a monthly basis. Compressed air can be used to clean the filtering screen. Be sure to dismount the filter screen before cleaning.
- The cutting fluid tank’s metal scrap filter screen should be cleaned at least once each week.
- The main spindle motor’s cooling fan should be cleaned at least once every six months. Maintenance personnel should dismount the blades of the cooling fan, wipe them clean, and then reinstall them securely.
Interior Maintenance and Cleaning of the Electrical Cabinet and Operation Cabinet
- Confirm that the air switches are working correctly.
- Confirm that the fixing screws of circuit connectors are securely anchored.
- Check the transformer for any signs of overheating.
- Periodically remove any accumulated dust from the electrical cabinet. (Never use compressed air to clean the electrical cabinet or any interior components of the machine.)
- Check the relay’s contact points for any accumulated dirt or dust.
Due to the presence of moving parts that can generate high levels of friction and heat, regular maintenance of the SYIL 5 Series machine’s lubrication system is essential to ensuring the precision and service life of the machine and its components.
This section introduces the correct procedures for inspecting and maintaining the lubrication mechanism for each of the machine’s components.
Equipment Lubrication Methods
- The three-axis ball screw rod should lubricate automatically at 75-minute intervals, with an oil feeding volume of 3-6 cc. An alarm will activate when the oil in the lubricant tank is insufficient to supply it. This alarm will stop once a sufficient volume of lubricant oil has been added.
- When the lubricant alarm activates while a program is being executed in auto mode, the program will come to a pause after completing the section of the program already underway. After lubricant levels have been restored and the alarm has stopped, press the auto execute key (CYCLE START) to resume execution of the next section of the program.
- Adjust the oil volume according to the needle valve of the three-point combined oil cup and add spindle oil as needed (i.e., oil with low viscosity). Periodically mix the oil with water vapor until a sufficient level of lubrication is reached.
- Use only hydraulic circulation oil with the correct specifications in the APC oil tank. The oil should be replaced at least once every six months.
- The ATC reducer must be lubricated with an oil manufactured specifically for use in reducers. This oil should be replaced at least once every three years.
- The rail lubricating oil tank has a capacity of 1.6 liters. Be sure to check the oil level in the tank at least once every three days and add oil as needed to maintain adequate levels during operation.
- The cutting fluid tank’s capacity is between 873 and 1048 liters, and that of the gear drive is between 1700 to 2200 liters. Be sure to check the cutting fluid level each week and add fluid as needed.
- When performing semiannual maintenance and service, dismount the protective shields of the spindles, clean their ball screw rods, and check the ball screw oil feeding mechanism to ensure it can provide automatic lubrication to the spindles. It is also recommended that you clean the spindles’ lubrication positions, run each spindle through a full stroke, and run each spindle at high speed to assess the effectiveness of automatic lubrication system.
Lubricant Level Maintenance
Please follow all the requirements introduced in this section when using lubricants.
Pneumatic System (Three-point Combination) Lubricant
Check the oil level in the pneumatic system and add oil to the tank as needed.
Check the three-point combined moisture filter’s water cup (located in the pneumatic system) and remove any accumulated water.
Use only lubricating oil with the correct specifications and ensure that any oil used to replace it meets the same specifications.
Automatic Lubrication Injector (Rail Oil) Lubricant
Periodically check the oil level of the automatic lubricant oil injector (at least once every two to three days).
Use only lubricant oil with the correct specifications and ensure that any oil used to replace it meets the same specifications.
Hydraulic System (Oil Pressure Unit) Lubricant
Periodically check the oil level in the oil pressure tank.
Always use hydraulic oil meeting the correct specifications to refill the oil supply.
- Completely replace all hydraulic oil in the system at least once every six months.
ATC Reducer Lubricant
Replace the oil for the reducing unit at least once every two years.
- Use only oil with the correct specifications.
|Point of Application||Oil Feeding Volume (cc)||Oil Type||Oil Feeding Time|
|Rail Oil||20||R68||Applied once every 75 minutes|
|Three-Point Combination||3～5||R10||Injected in combination with blowing air|
|Main Spindle||7.21/min||R10||Circulated oil feeding|