1100M Maintenance
- Sam Bollen
Machine Maintenance
In This Section, You'll Learn:
About the required maintenance procedures that you must do so that this machine operates as designed.
Before operating the machine in any way, you must read and understand this section.
Maintenance Safety
Read and understand the following safety messages before beginning any maintenance procedures.
All Maintenance Procedures
Understand that the machine is automatically controlled and can start at any time.
Power off the machine and disconnect the pneumatic supply before doing any maintenance procedures.
When appropriate, lockout/tagout the Main Disconnect switch and the pneumatic supply line before doing any maintenance procedures.
Wear safety eye protection rated for ANSI Z87+.
Swarf Maintenance Procedures
Wear work gloves.
Coolant Maintenance Procedures
Wear rubber gloves.
Maintenance Schedules
To keep your machine running as smoothly as possible, you must regularly do the following maintenance procedures.
NOTE:Â Before you begin any maintenance procedures, read and understand "Maintenance Safety".
If you disassemble any components, refer to the machine's reference drawings when you've completed the maintenance procedure. For information, see Diagrams and Parts Lists. For any additional support, we can help. Create a support ticket with Tormach Technical Support at tormach.com/how-to-submit-a-support-ticket for guidance on how to proceed.
NOTE:Â For information on completing the following maintenance procedures, see the operator's manual for your machine.
Daily
Clean the way covers of chips.
Clean the chip baskets on the coolant tank.
Examine the coolant level and condition.
Examine the way oil level and refill as necessary.
Retract the plunger on the manual oiler, hold it in the retracted position for two seconds, and then release it.
NOTE:Â The plunger should move slowly from the retracted position. If it doesn't, it could indicate a malfunctioning oiler.
If you have pneumatic accessories installed (like a Power Drawbar), verify that the regulator has at least 90 psi compressed air.
Verify that the door switches are properly functioning.
Weekly
Clean all exterior surfaces with a clean rag.
Verify that the machine's lubrication points (sliding surfaces and ball screw nuts) are receiving way oil.
Examine the enclosure and other guards for damage.
Examine the drawbar for wear.
Examine the Tormach Tooling System (TTS) collet for wear.
Remove vises, fixture plates, rotary tables, and other accessories, and then examine them for rust.
If needed, reapply rust inhibitor before reinstalling workholding and accessories.Check coolant concentration.
Monthly
Clean the electrical cabinet vents of dust with a clean cloth or compressed air.
Clean fine swarf from the coolant tank.
Examine all axes' slideway surfaces and ball screws to determine if an oil film is present.
Examine the air tool oil level in the FRLÂ Filter-Regulator-Lubricator and refill as necessary.
Semi-Annually
NOTE:Â After the first 90 days of operation, complete the items on this list. After that, complete the items every six months.
Examine the spindle belt for wear.
Examine the way covers for wear.
Examine the X-axis flex conduit for wear.
Annually
Verify that the limit switches are properly functioning.
Remove the way covers and examine them for wear. Clean any chips or oil underneath the way covers.
Examine the windows and replace them if necessary.
Check the machine's backlash.
Regular Maintenance
Clean the Way Covers
To extend the service life of the machine, you must make sure that the way covers are protecting the machine's slideways. Regularly do the following:
Examine the way covers for signs of wear or damage. If the way covers are damaged, you must replace them.
Use a chip brush to clean the way covers of chips and other swarf.
Clean the Coolant System
To extend the service life of the coolant and the coolant pump, you must make sure that both are free of contaminants.
Regularly do the following:
Use a chip brush to clean the machine, chip trays, and enclosure of chips and other swarf.
Empty the chip strainer on the coolant tank.
Measure the coolant concentration, pH, and volume, and then compare your findings to the material's safety data sheet (SDS).
Coolant Level Too Low Fill the coolant tank with fresh coolant, making sure that it is the appropriate concentration.
Coolant pH Outside of Manufacturer's Recommended Coolant Limits Adjust the pH according to the manufacturer's recommendation.
NOTE:Â You must only use coolant that is recommended for machining. See "Cutting Fluid Reference".
Examine the coolant pump's impeller for blockages.
To remove tramp way oil from the coolant tank, use one of the following:
Periodically do the following:
Remove the coolant tank covers and the chip strainer, and then clean the fine swarf from the coolant tank.
If you're using a filter to prevent small particles from entering the coolant tank, replace it when it's saturated with chips, swarf, or tramp oil.
Examine the coolant for contamination, and determine if the coolant's oil-water emulsion has broken.
Drain and thoroughly clean the coolant tank, and then replace with fresh coolant.
NOTICE! Hazardous Waste:Â Only dispose of coolant as advised by local environmental protection authorities. You must not dispose of coolant in a septic system or a sewer.
About Cutting Fluid
Clean and well maintained coolant has increased performance, prevents rust, and smells better than contaminated coolant.
Coolant becomes contaminated when:
Swarf accumulates in the chip pans, the chip strainer, or the coolant tank.
Tramp oil isn't regularly removed from the coolant tank.
The concentration or pH aren't maintained to the manufacture’s specifications.
Using flood coolant provides the following benefits:
Cools the cutting zone
Flushes away swarf
Lubricates the cutting tool
Provides some degree of rust inhibition
You must only use flood coolant that is recommended for CNC machining applications, like:
Soluble oils
Semi-synthetic coolants
Synthetic coolants
You must never use:
Coolant without rust inhibitors
Flammable coolants such as alcohols, diesel fuel, or kerosene
WARNING! Fire Hazard:Â The machine and its enclosure are not designed to contain fire or explosions. Only use materials and coolants that are intended for the specific machining operation. Never use flammable or explosive items.
Straight cutting oil
Water
If you use a coolant concentrate, you must mix it with water to the dilution ratio recommended by the coolant manufacturer. Use an optical refractometer to measure coolant concentration.
Examine the Drawbar
To extend the service life of the drawbar, you must make sure that the drawbar isn't damaged, and that it's properly lubricated.
Regularly do the following:
Examine the drawbar for signs of wear or damage.
Use Anti-Seize (PN 31273) to lubricate the following items:
Drawbar threads
Thrust shoulder of the drawbar
Drawbar's thrust washer
If you have an (optional) Power Drawbar, regularly do the following:
Use Anti-Seize to lubricate the Power Drawbar disc springs (the Belleville washers) and clamping mechanism.
Tighten the drawbar until it is as tight as possible while still releasing a Tormach Tooling System (TTS) tool holder using 90 psi (620 kPa) compressed air.
Examine the Enclosure Windows
Regularly examine the enclosure windows, and all other guarding, for signs of wear or damage.
When required, replace the windows with the following parts:
Window, 1100, Side (PN 37648)
Window, 1100, Left Door (PN 37649)
Window, 1100, Right Door (PN 37650)
Lubricate the Machine
To keep the machine operating properly, and to extend the service life of the machine, you must verify that the slideway surfaces and ball screws are receiving lubrication.
Regularly do the following:
Clean the oil reservoir's cover and all exposed surfaces surrounding the oil reservoir. Swarf or debris that enters the oil reservoir can plug the small, internal passages of the lubrication system.
NOTE:Â The strainer at the top of the oil reservoir isn't a filter, and can't remove all types of debris that may cause blockages.
Examine all axes' slideway surfaces and ball screws to determine if an oil film is present.
If there's not an oil film, examine the lubrication system for blockages, broken fittings, or pinched oil lines.
Examine the amount of available oil and, if necessary, refill with new, high-quality ISOÂ VG 68 grade Machine Oil (PNÂ 31386).
About the Manual Oiler
The manual oiler operates with a plunger:
On the Pull Stroke The oiler pulls machine oil from the oil reservoir.
On the Retract Stroke The oiler pushes machine oil through the lubrication system.
The plunger is spring-loaded, and creates a light hydraulic pressure sufficient to distribute the oil through the machine. Do not push the plunger after you retract it.
When the machine is first powered on (and then after every four hours of operation), retract the oiler's plunger and hold it in the retracted position for two seconds. Then, release the oiler's plunger.
NOTE:Â The plunger should move slowly from the retracted position. If it doesn't, it could indicate a malfunctioning oiler.
About the Automatic Oiler
The automatic oiler is powered whenever the machine is powered on, and has the following default settings:
Lubrication interval: 480 minutes (8 hours)
Actuation time: 12 seconds
Lubrication System Reference
The machine's lubrication system distributes oil to the following 15 points:
12 slideways bearing surfaces
Four on the X-axis
Four on the Y-axis
Four on the Z-axis
Three ball screw nuts
Examine the Spindle Belt
To extend the service life of the spindle belt, you must regularly examine it for signs of damage or wear.
If the spindle belt is damaged, you must replace it with Spindle Belt, 1100M (PN 37956).
Examine the Tormach Tooling System (TTS) Collet
To extend the service life of the Tormach Tooling System (TTS) collet, you must regularly do the following:
Examine the Tormach Tooling System (TTS) collet for signs of wear or damage.
Make sure the inside of the Tormach Tooling System (TTS) collet is clean and dry.
Use Anti-Seize (PN 31273) to lubricate the outside of the Tormach Tooling System (TTS) collet and the inside of the spindle taper.
Use a mild degreaser to clean the shank of all tool holders.
Prevent Rust
Take proper care to protect all exposed iron and steel surfaces on your machine. To reduce the possibility of rust, you must regularly do the following:
Clean the machine, chip pans, and enclosure of chips and other swarf with a chip brush.
Clean all exterior surfaces with a mild cleaner.
Only use flood coolant that is recommended for machining (see "Cutting Fluid Reference" (page 5)).
Periodically test the coolant concentration, and adjust (if necessary) to meet coolant manufacturer's recommended concentration.
Put LPS 3® (or similar rust inhibitor) on the machine before installing any workholding or accessories.
Only operate the machine in a temperature- and humidity-controlled environment. Extreme changes in temperature or humidity can create condensation on the machine.
Put LPS 3® (or similar rust inhibitor) on all exposed, non-painted metal surfaces before leaving the machine unused.
Remove all workholding and accessories, and then check for rust.
If needed, reapply rust inhibitor before reinstalling workholding or accessories.
If you find rust on the machine table, go to "Remove Rust".
Use a fine machinist's stone to remove light surface rust on the machine table: use light, even pressure, and move the stone in a random motion to avoid changing the flatness of the machine table.
If you find a lot of rust, or if there is rust on the machine's slideways or ball screws, take photos of all rust-covered areas. Create a support ticket with Tormach Technical Support at tormach.com/how-to-submit-a-support-ticket for guidance on how to proceed.
Looking for more information?
This is a section of the 1100M operator's manual. To view the whole manual, go to Tormach document UM10540.
If you have additional questions, we can help. Create a support ticket with Tormach Technical Support at tormach.com/how-to-submit-a-support-ticket for guidance on how to proceed.