tornos DECO 7 Manual
DECO Internal RP
TORNOS SA - CH-2740 MOUTIER - http://www.tornos.ch Printed in Switzerland Copyright E1999-2003
DECO 7 Headstock Revision ref. 305001
DESCRIPTION - PROCEDURES en TT5500
TT5500 - DECO 7 Headstock Revision
Chap. / 2 TT5500 en - 12/04
Differentiationof degrees of risk
These instructions indicate a number of safety measure symbols which appear also on the machine and are
intended to protect the user, his/her effects and the environment from injuries and damage as applicable.
Below, you will find the safety symbols, their headings and definitions. Please, read these first before you con-
tinue.
∆Danger !
indicates a direct danger of death or serious injury.
∆Warning !
indicates an object or action which may cause death or serious injury.
∆Caution !
indicates an object or action which may cause injury or serious damage.
∆Attention !
indicates incorrect actions or such that may cause damage.
⊗Prohibition !
indicates an action or operation prohibited because of evident or alleged hazards.
⇒Info :
Gives information or comment related to safety.
⇒Note :
Gives information unrelated to safety
Important Safety Indications
∆Warning !
Read the instruction before operating the machine.
Should the user disregard the instructions of this manual, TORNOS SA declines any liability what-
soever.
∆Attention !
Certain maintenance works are absolutely necessary to ensure good operation of the machine. They
are given in the MAINTENANCE SCHEDULE on the machine
(or see Instructions: OPERATION-MAINTENANCE).
∆Caution!
TORNOS SA disclaims all responsibility for any modifications carried out by the customer to the
machine, and to its related equipment and software, without agreement ratified by
TORNOS SA.
TT5500 - DECO 7 Headstock Revision
3TT5500 en - 12/04
TABLE OF CONTENTS
1. EQUIPMENT 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. DISMOUNTING THE HEADSTOCK 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. CHECKING THE PARTS 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. MOUNTING 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 PREPARING THE PARTS 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 MOUNTING THE PARTS 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. REFILLING THE HEADSTOCK 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. CHECKING THE HEADSTOCK 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7. BREAKING IN THE HEADSTOCK 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8. ASSEMBLY DRAWINGS 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9. APPENDIX - DECO 7 BREAK-IN SHEET 17. . . . . . . . . . . . . . . . . . . . . . . . . . . .
TT5500 - DECO 7 Headstock Revision
Chap. 2. / 5TT5500 en - 12/04
1. EQUIPMENT
Assembly drawing ref. 305001
Tools ref. 758 444
Press travel ~450mm
Grease Mobile 28
Kubler NBU15
Molykote DX
Headstock filling oil ISO GV 220
Screw locking product Loctite 222
2. DISMOUNTING THE HEADSTOCK
Actions Notes
1. After dismounting the headstock from the
machine, remove : the plastic plugs (510),
the 3 screws (470) (see section E-E),
the window (020), the tubing (190) using an M6
screw, the 2 gaskets (see section G-G).
2. Loosen the 2 screws (520), the plug (210), the
pivot axis (200), the gaskets.
3. Loosen the 4 clamping screws (400) section J-J
a 1/2 turn and tighten the 4 screws (050) 4 to 5
turns to release the springs (610).
4. On the headstock front side, loosen the 6 screws
(410), ”screws locked” section A-A.
5. Push the flange (130) to remove the thrust ring
(600).
6. Loosen the 4 screws (430) section H-H.
7. Remove the spindle from the rear making sure to
recover the 4 springs (610) section J-J.
8. Remove the cover (030) section A-A.
⇒Note :
Refer to the assembly drawing, ref 305001.
TT5500 - DECO 7 Headstock Revision
Chap. 2. / 6 TT5500 en - 12/04
Actions Notes
9. Floating solenoid valve (180).
10.Cylinder (220), gasket (530)
11. Thrust ring (160)
12.2 bleed screws (140) of the primary piston (230).
2 bleed screws (140) of the spindle.
13.Remove the gaskets from the bleed screws (660).
14.Refill plug (150) section C-C and remove the gas-
ket.
15.Primary piston (230) section A-A.
16.Cut the gaskets from the primary piston.
17.Remove the rear case (040).
18.Lock ring (170) and gasket (550) from the ring.
19. Remove the roller bearings (650) using appropri-
ate tools. ⇒Note :
To facilitate dismounting, the outer cage can be
removed from the roller bearings or the FACOM
bearing remover can be used.
20.Place the spindle front on the press plate.
21.Using the tool (ref. 10), press on the case (090) to
compress the spring (270).
Then release the Seeger ring (590) and remove
it.
22.Remove the case (090), the spring (270) and the
secondary piston (070) using the thrust tube
(250).
23.Loosen the nut (080).
24.Remove the inner and outer gaskets from the sec-
ondary piston.
∆Caution !
The nut is locked with loctite ; the thread is a
right-hand threading.
25.Using a rod, remove the front roller bearings (640)
of the headstock from inside the body through the
passage holes.
26.Using a press and tools (see image to right),
remove the collet (260).
TT5500 - DECO 7 Headstock Revision
Chap. 3. / 7TT5500 en - 12/04
3. CHECKING THE PARTS
∆Caution !
CLEAN THE PARTS TO CHECK FOR CONDITION.
Actions Notes
1. Change all the damaged parts with contact rust or
wear.
2. Change the roller bearings.
3. Change the gaskets.
4. For the old spindles and the retainer spring, have
them checked for balance.
5. For the bleed screws, mount new screws (060)
with gaskets (610).
TT5500 - DECO 7 Headstock Revision
Chap. 4.2 / 8 TT5500 en - 12/04
4. MOUNTING
∆Caution !
Check the parts before mounting to make sure they are not defective.
4.1 PREPARING THE PARTS
Actions Notes
1. Lightly grease the gaskets and the mechanical
surfaces in contact.
⇒Note :
Use the grease Kubler NBU15
4.2 MOUNTING THE PARTS
Actions Notes
1. Lightly grease inside the case (040).
2. Mount the 2 rear roller bearings (650) in the case
(040) by aligning the marks.
3. Lightly grease the spindle and mount the assem-
bly in the case ”with roller bearings”.
⇒Note :
Case number aligned with the spindle screwed
key.
4. Mount the lock ring (170) with gasket (550).
650
040
TT5500 - DECO 7 Headstock Revision
Chap. 4.2 / 9TT5500 en - 12/04
5. Insert the guidebush on the spindle, lightly grease
with the grease Mobil 28 and then mount the pri-
mary piston (230).
⇒Note :
To mount the inner gaskets, see the drawing
”Mounting in closed grooves”.
∆Caution !
Pay particular attention to the mounting
direction of the gaskets.
⇒Note :
To facilitate the mounting of the piston, use the
press ”without forcing”.
230
6. Mount the thrust ring (160) on the spindle with the
offset holes against the spindle front side.
7. Mount the gasket (530) on the spindle and then
lightly grease.
⇒Note :
Use the grease Molykote DX.
8. Lightly grease the large inner diameter of the cyl-
inder (220) and mount it on the spindle.
⇒Note :
Use the grease Mobil 28.
9. Degrease the part of the cylinder (220) receiving
the solenoid valve.
10.Insert the ”dry and clean” solenoid valve (180) on
the cylinder.
11. Grease the rear roller bearing of the body and the
case on the spindle.
⇒Note :
Use the grease Molykote DX.
12.Insert the springs after greasing them with the
grease Mobil 28.
13.Lightly grease the front roller bearing of the body
and position the numbers upward.
⇒Note :
Use the grease Kubler NBU15.
14.Grease the screwed key of the spindle.
220
180
15.Mount the front roller bearings (640), align the
marks and orient them to the screwed key side.
16.If necessary, mount with the press and special tool
ref.60.
∆Caution !
Do not strike or hit the roller bearings!
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Chap. 4.2 / 10 TT5500 en - 12/04
17.Mount the cover (030) ; lightly grease the 2 holes. ⇒Note:
Use the grease Kubler NBU15.
⇒Note :
Offset holes on thread and bore side of the
body.
18.Tighten and apply some locking product to the 4
screws (430). ⇒Note :
Use the locking product Loctite 222.
19.Mount the baffle plate (120) and the flange (130) ;
push against the front side using the collet.
20.Install the thrust ring (600) in place.
⇒Note :
Gap in the middle on screwed key side of the
spindle. See auxiliary drawing 11A.
21.Alternately tighten the 6 screws (410) diagonally
and torque using the torque wrench.
Position the gap Abetween 2 threads in the
middle of the thrust ring.
⇒Note :
Torque with the torque wrench to the value 1.3
N.
Use some Loctite 222 to lock the screws.
A
22.Lightly grease the rear inner side of the spindle B.
Grease the inside and outside of the secondary
piston between the gasket and the threading, and
”hand mount” it in the spindle.
⇒Note:
Use the grease Mobil 28.
23.Grease the spring (270) and mount it in the
spindle. (Mark point on the spring front side
aligned with the refill plug).
24.Grease the case (090) and insert it in the spindle.
B
270
090
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Chap. 4.2 / 11TT5500 en - 12/04
25.Place the headstock on the press with the tool ref.
40 to mount the ”Seeger” ring (590), with the gap
of the ring in the middle of the refill plug.
∆Caution !
Install in place without forcing to prevent
damaging the secondary piston’s gaskets.
590
26.Adjust the clearance of the spindle by loosening
the 4 adjusting screws (050) section J-J until at
the stop without forcing by ”alternately tightening
the screws diagonally”.
27.Tap on the body with a nylon mallet to install the
assembly.
28.Tighten 1/4 turn and reloosen 1/8 turn.
29.Tighten the 4 clamping screws with brass wire.
30.Tap on the body with a nylon mallet and check.
∆Attention !
The spindle must turn freely without binding
or wobbling.
31.Mount the tubing (190) and the pivot axis (200)
”lightly greased” section G-G.
32.Using the nylon mallet, tap softly to not damage
the solenoid valve.
33.Tighten the sealing plug (210) with its gasket
using the 2 screws (520).
34.Place the thrust tube (250), grease the threads
and tighten it in the headstock. ⇒Note:
Use the grease Mobil 28.
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