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  1. #1
    Join Date
    Nov 2017
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    Geelong, Australia
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    Default The joy of having a TOS.... ( FNGJ32 mill )

    Thought I'd start a new project thread for ongoing updates/adventures/frustrations on my newly arrived TOS FNGJ32 universal mill....

    A couple of weeks ago we made the trip from the workshop at work, to home. Can't say it was the most relaxing trip I've had, but we made it safely.
    Here we are all loaded up ready to leave



    Unloading in my shed with the gantry and chain block.



    Steve

  2. #2
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    Default The joy of having a TOS.... ( FNGJ32 mill )

    Safely on the ground


    And the cleaning begins. I haven't bothered unhooking it from the gantry as it needs to be lifted again when it moves to its final position:



    The obligatory coolant sump snot to be cleaned out



    Steve

  3. #3
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    Default The joy of having a TOS.... ( FNGJ32 mill )

    With it up on the timber bearers it was easy to drain the spindle and knee oil reservoirs. The drain plugs are only about 50mm off the floor level normally, but easy to get a container under when they are 100mm higher.

    Spindle oil was pretty good, just many years of grey wear/sludge sitting in the bottom, but wiped out easily.
    Knee oil was slightly contaminated with coolant, so not quite as nice.

    The spindle lube pump had been leaking at the outlet connection (30 year old clear hose gets a bit hard!!) so it and the coolant pump were having an oil bath



    I replaced that main lube supply hose with some rubber fuel hose.
    The “green” hoses were clear when it left the factory...

    Steve

  4. #4
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    Nov 2017
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    Default The joy of having a TOS.... ( FNGJ32 mill )

    Some new ISO46 hydraulic oil for the spindle, and some ISO68 way oil for the knee and we're ready to give the lube pumps a run.

    Lubrication happens automatically when its running, but there is also an intermittent push button switch for manually running the pumps before use if its been sitting for a while.



    It has the usual windows so you can see the oil is flowing, one in the spindle, one in the knee.



    Power it up, push the button and I can hear the pump running but no oil in either window
    Simple fix - phase rotation issue so swapping two power wires in the plug and we have oil !!!!

    Only in the spindle though.....nothing in the knee....

    Steve

  5. #5
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    Default

    Just a side photo for some context:



    Steve

  6. #6
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    Default The joy of having a TOS.... ( FNGJ32 mill )

    The knee has a separate pump, sitting in the LH end behind the way covers, but you can eyeball it through an access cover in the end of the knee without taking the way covers off.
    Its a motor with a belt drive to a piston pump.






    I got my lovely assistant (AKA SWMBO) out in the cold to push the button while I look at the belt. A brief twitch, but doesn't turn.
    Hmmmm...

    First time SWMBO has seen it up close so I proudly go to demo the power feeds. Hit the feed button for a particular axis, it starts to move then slows down and stops, but the feed motor is still running. As though the feed clutch is slipping...

    Its about now that I recall PDW's warning a while back to the effect of "beware the electrics on the eastern block machines"

    A photo of under the knee since I was down there. The green coil is the pickup hose for the lube pump.



    Steve

  7. #7
    Join Date
    Oct 2011
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    Norwood-ish, Adelaide
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    Default

    Nice looking machine. The only thing wrong is that you can not sing the 'Maho Man' song
    https://youtu.be/xa5M19pck5E?t=104

    Michael

  8. #8
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    Thanks Michael. For the sake of mankind, me not being able to sing at all is a positive anyway!!

    Steve

  9. #9
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    Default The joy of having a TOS.... ( FNGJ32 mill )

    Luckily I have the wiring diagrams and manuals for the machine. I reckon you'd have to be VERY keen to take one on without the diagrams and operational description.

    The electrical cabinet is a double layer affair. First layer contains mainly low voltage wiring for various microswitches and also houses the LV transformers. This is the second layer with all the contactors, timers and rectifiers etc.



    Last time I know 100% that the feeds were running was about 6 months ago. I've never confirmed that the knee oiler worked.
    Only thing different between then and now is 6 months, and its now running on my phase converter instead of mains 3 phase.

    My first thought was that I might be running into the common issue of the control circuits being run from the phantom(generated) phase on the converter.
    I had this with my lathe previously - the voltage drop on motor start is enough to cause the control circuit to drop out. Easily solved by making sure the control circuit is getting its power from the "real" 2 phases.
    Without tracing the wiring, I tried the shotgun approach of just testing the 3 different input wiring options. No change in behaviour.

    Time for some proper troubleshooting I think......

    Steve

  10. #10
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    Default

    Congratulations on a nice looking mill Steve, there won't be many things you can't do with a machine like that in your workshop.
    The covers on the Z ways are an interesting arrangement, is there a horizontal spindle hidden somewhere?
    Cheers,
    Greg.

  11. #11
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    Quote Originally Posted by kwijibo99 View Post
    Congratulations on a nice looking mill Steve, there won't be many things you can't do with a machine like that in your workshop.
    The covers on the Z ways are an interesting arrangement, is there a horizontal spindle hidden somewhere?
    Cheers,
    Greg.
    Thanks Greg.
    The horizontal spindle is behind the vertical head (and what drives the vertical) - ie you unbolt the head, swing it around to the side on its support arm and you are left with the horizontal spindle. The drawbar for the horizontal is to the spindle housing and has a 90deg drive arrangement so you tighten it by the square drive on the RH side of the housing.
    Both spindles are 40 taper.
    There's a support arm for horizontal milling that bolts on in place of the vertical head.

    Steve

  12. #12
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    Oct 2011
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    Your mill (like mine) takes what are called 'milk bottle' fuses. They are not easy to come by, so I would suggest working out what sizes you need and contacting a local electrical wholesaler to get spares now, rather than waiting weeks for them to arrive...

    Been there, done that.

    Michael

  13. #13
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    Default

    Good tip. There's actually a couple of boxes of them in the bottom of the cabinet, but I'll check to make sure all the sizes are covered.
    I've got a single one on my lathe. Damn thing led me on a merry chase a couple of times as it got slightly loose from vibration and I'd get intermittent stuttering on startup.

    Steve

  14. #14
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    Apr 2018
    Location
    Drouin Vic
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    Default

    Looks like a great bit of kit Steve, with a very respectable work envelope.

  15. #15
    Join Date
    Oct 2016
    Location
    Melbourne
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    Default

    Nice mill mate I got fuses for my rambaudi mill from this mob https://www.swe-check.com.au/ they will post out.

    Cheers,
    Mark.

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