[rx8pilot]

I am in the process of repairing a 2000SY Doosan and almost have it ready for work.

The final challenge is diagnosing and repairing the live tool drive. When running free, it is quiet. After engaging a tool, it rattles loud enough to have you lunge full speed for the reset button. I have pulled the turret cover off (separate thread - it was not easy) and found that a couple of o-rings were damaged and allowing coolant into the turret . It is a bit rusty and mucky but It cleaned up well. I don't see that any critical surfaces are damaged yet. Special thanks to @dhardt for the assistance getting this far.

With the cover off, it is easy to pinpoint the source of the rattle from the drive shaft interfacing the live tool holder. Visually, it appears that there may be a minor alignment issue. I ended up pulling the drive out before I thought to measure the gap at the coupling. The gears visually look good, the assembly rotates smoothly, and does not have any play that I can detect with my hands. The shaft has about .001" runout when measured out of the machine which is more than I expected but perhaps not enough to make it rattle like it is. Before removal - the runout was closer to .004" while engaged with a toolholder. The drive slot shows considerable wear - which allows for a lot of slop when a live tool is engaged.

Initially, I was going to replace the shaft just because I already had it apart until I realized it costs $650. I better make sure I am making a sound decision.

Attachment 409538

Coupling wear.....
Attachment 409540

[dhardt]

The actual live tooling has "play room" and can not be used for alignment. The "fixing tool" from the manual for a Puma 240M has a tighter tolerance for setting all three "center points" needed for proper alignment.

Link to manual: https://www.cnczone.com/forums/daewo...ml#post1691268

The manual is on page 2 of the thread and I think the turret section starts around page 80 or 85ish of said manual.

[rx8pilot]

Thank you for the link.... your manual posts are amazing.

Studying the 240M which is considerably different than the 2000SY but I guess the alignment concepts are very similar. I have the parts manual for the 2000SY which is helpful, but the service procedures depicted in the linked 240M manual are better.

Do you think the visible wear on the drive shaft (in the photo) would be significant enough to make the noise? If the rattling noise can be solved by an alignment - that would be amazing.



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[dhardt]

In your original post, you had said when running free it is quiet", if so there is no issue with grinding of the live tool Drive. The only noise you mentioned occurring was when the tool itself was engaging with the live tool Drive.
That would be an alignment issue.

[rx8pilot]

In your original post, you had said when running free it is quiet", if so there is no issue with grinding of the live tool Drive. The only noise you mentioned occurring was when the tool itself was engaging with the live tool Drive.
That would be an alignment issue.

True -

I have been (as time permits) been studying the alignment procedures you linked for the 240M which I also have in the shop. I will be back on the machine in two days and hoping I can formulate a plan of attack ahead of time. I do not have the alignment tools so I will have to use alternate methods or make something. @dhardt - in your experience, is the wear on the drive dog looking excessive? For drilling and milling, I would think it is too sensitive, but for tapping, the backlash could be a problem. I really don't mind replacing the shaft if it is needed, but obivously prefer to make an educated decision before spending the $675 on the part plus the bearings and installation.

One thing I don't recall seeing in the manual is lubrication for the bevel gear. In my experience, I don't think I should be guessing. Some sort of high-pressure grease perhaps on the base?

While I have the parts off the machine - I am going to order and replace all soft seals. Some are already broken so there is not any choice on those, but replacing all of them seems like the quality approach.

[dhardt]

Spec sheet for the grease for the REAR mounted Live Tool Drive is attached.

Maintenance procedure for the REAR mounted Live Tool Drive is attached.

(Please note: Anyone reading this...If your unit is a FRONT mount style...it is AIR/OIL lube and totally different from this posted information)

[rx8pilot]

After some consideration and discovering that the preferred grease is hard to find in affordable quantities - I called in the specialists to do the final assembly, alignment, and testing. It was a good call.
The technician came from ProTek and I am able to learn so much while being nearly guaranteed success.

Doing the initial legwork saved a TON of money too. Thank you to dhardt for all the help. I was able to pull the turret apart, inspect, clean, and replace all the seals ahead of the tech arrival. Now that I was able to watch the tech, I have a new skill and deeper understanding of the machine.